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e POH Inc.

e POH Inc. . Consultants: Hope Baumgarner Tyler Gibson Wes Hudkins Joseph Nick Josh Stephens. e POH Inc. . Addition of a Cylcohexane Production Process to Independent Refineries Inc. Overview: Based on our findings for project 3, the addition of the cyclohexane unit is not profitable

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e POH Inc.

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  1. ePOH Inc. Consultants: Hope Baumgarner Tyler Gibson Wes Hudkins Joseph Nick Josh Stephens

  2. ePOH Inc. Addition of a Cylcohexane Production Process to Independent Refineries Inc. • Overview: • Based on our findings for project 3, the addition of the cyclohexane unit is not profitable • Large price increase in cyclohexane would be required to make process profitable • Current market value Cyclohexane: $4.10/gal • For process to be profitable price would have to be 5 times the current market value Project 3

  3. ePOH Inc. Addition of a Cylcohexane Production Process to Independent Refineries Inc • Economic Analysis: • Total Capital Investment: TCI = FCI + WC =$4,690,000 • Fixed Capital Investment: FCI = DC + IC = $3,640,000 • Annual Product Cost: $243 MM to $357 MM when a 4% inflation rate is taken into account • Process considered profitable when ROR > 8% • Annual Cash Flow: CF = (S-C) x (1-Φ)+dΦ Project 3

  4. ePOH Inc. Addition of a Cylcohexane Production Process to Independent Refineries Inc • Economic Analysis: • Annual Cash Flow: Project 3

  5. ePOH Inc. Addition of a Cylcohexane Production Process to Independent Refineries Inc • Economic Analysis: • Net Present Worth: Criterion used to determine profitability • Payout Time: Time required to recover investment • Positive values indicate that investment will be recovered • Negative values indicate investment will not be recovered • Return on Investment: Describes how much money is earned per dollar invested • When ROI>ROR the process is profitable Project 3

  6. ePOH Inc. Addition of a Cylcohexane Production Process to Independent Refineries Inc Economic Analysis: Project 3

  7. ePOH Inc. Addition of a Cylcohexane Production Process to Independent Refineries Inc • Equipment Cost & Specifications • Mixer & Splitter: • Diameter = 4.9 ft • Height = 19.6 ft • Volume = 185 ft3 • Material: Carbon Steel • Cost included in the piping cost • Heat Exchangers: • Shell & Tube • Carbon Steel tubes and shell Project 3

  8. ePOH Inc. Addition of a Cylcohexane Production Process to Independent Refineries Inc Equipment Cost & Specifications: Project 3

  9. ePOH Inc. Addition of a Cylcohexane Production Process to Independent Refineries Inc • Equipment Cost & Specifications: • Flash Tank: • Vertical liquid gas gravity settling separator • Cross sectional area: 57 ft2 • Tank Diameter: 9 ft • Cost: $81,000 Project 3

  10. ePOH Inc. Addition of a Cylcohexane Production Process to Independent Refineries Inc • Equipment Cost & Specifications: • Reactor: • Tubular reactor • 30 tubes • L= 20 ft • OD = 3 inches • 40% of the cross sectional area dedicated to tubes • Cost: $9,000 • Compressor: • Power Requirement: 53 kW • Adiabatic Efficiency: 80% • Type: Centrifugal • Cost: $80,000 Project 3

  11. ePOH Inc. Addition of a Cylcohexane Production Process to Independent Refineries Inc • Equipment Cost & Specifications: • Distillation Column, Condenser & Reboiler: • Size based on estimated superficial velocity for flooding to occur • Operation 80% of vapor speed • Based on Perry’s Chemical Engineer’s Handbook it suggest that about 15% of total cross sectional area be devoted to downcomer envelope • Number of Trays: 28 • Reboiler: Specified as a kettle Project 3

  12. ePOH Inc. Addition of a Cylcohexane Production Process to Independent Refineries Inc • Equipment Cost & Specifications: • Distillation Column, Condenser & Reboiler: • Column Cost: $140,000 • Condenser Cost: $40,300 • Reboiler Cost: $515,600 • Total Cost: $781,400 Project 3

  13. ePOH Inc. Fluid Transport and Economic Analysis • Design of the pipe network • Stainless Steel • Currently operating at unsafe pressures • Pipes need to be increased to schedule 80 • Piping dimensions proposed by IRI found to be less than optimal • ePOH’s recommendations could save $500,000 • Adding fiberglass insulation will decrease NPW by $1 million Project 4

  14. ePOH Inc. • Two-phase flow • Pro II was used to determine what flow regimes are inside the two-phase flow pipes in the process • The Reynolds number was calculated for single phase flow from the thermodynamic parameters given by Pro II, and then the flow regimes for the two-phase streams were taken from the simulation report • All the single-phase streams are in the turbulent flow regime, and all the two-phase flow streams are in the stratified wavy flow regime Fluid Transport and Economic Analysis Project 4

  15. ePOH Inc. • Pressure Drop in Streams • Pressure drops in the pipes are much smaller than the overall pressure gradient in the system • Current compressor pushes the stream up to 500 psia while they exit the system at atmospheric pressure • There is no need to add additional pumps and compressors to overcome the pressure drop in the pipes Fluid Transport and Economic Analysis Project 4

  16. ePOH Inc. Fluid Transport and Economic Analysis • Performed risk analysis on the cyclohexane unit • High risk, very low return • Less than 20% chance of breaking even • The difference between cyclohexane (product) and benzene (raw material) would need to increase to $1.51/gallon • ePOH does NOT recommend constructing the cylcohexane unit • Could use Diels Alder reaction as an alternative way to produce cylcohexane Project 4

  17. ePOH Inc. NPSHA vs. Flow Rate Project 5

  18. ePOH Inc. Project 5 System Head vs. Flow Rate

  19. ePOH Inc. Project 5 Pumping section PFD

  20. ePOH Inc. • Reactor Material Chosen: Type 304 Stainless Steel • Advantages of material: • resist to corrosion • high alloy metal • very high tensile strength Project 5 Reactor Specifications

  21. ePOH Inc. Project 5 Piping and Insulation Specifications

  22. ePOH Inc. Pump Specifications Project 5

  23. ePOH Inc. Pumping Section: Fixed Capital Investment Project 5

  24. ePOH Inc. CH-Plant:Heat Exchanger Study E2 E1 E3 Project 6

  25. ePOH Inc. Heat Exchanger: Hand Design • Exchanger E1 designed for two cases: • Single-Pass Tubes • Double-Pass Tubes • Equipment cost determined for each design • T-Q Diagram compared Project 6

  26. ePOH Inc. • Single-Pass Tubes • Double-Pass Tubes Project 6

  27. ePOH Inc. T-Q Diagrams: E1 • Single-Pass Tubes • Double-Pass Tubes Project 6

  28. ePOH Inc. Heat Exchanger: Rigorous Model • Rigorous heat exchanger model used for exchanger E1 • Tube length and diameter and shell diameter were varied to produce the smallest heat transfer area • Designed using Pro II Process Simulator * Minimize heat transfer area to Minimize cost! Project 6

  29. ePOH Inc. Heat Exchanger: Rigorous Model Square Pitch 236 tubes, each 16 feet long 1275 ft2 heat transfer area 11,600,000 Btu/hr heat duty Project 6

  30. ePOH Inc. Heat Exchanger 2 and 3 Designed using the simple heat exchanger models with Pro II Project 6

  31. ePOH Inc. Cost of Heat Exchangers Project 6

  32. ePOH Inc. Cyclohexane Tower Dimensions • 7 feet in diameter, 56 feet tall • 28 trays inside column • 2 foot spacing between column • Condenser duty: -3,300 Btu/sec • Reboiler duty: 3,700 Btu/sec • Column sized assuming vapor velocity is 80% of that required for flooding from the following correlation: Project 6

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