EB Plant EQUATE Petrochemical Company

1. EB Plant EQUATE Petrochemical Company

2. Agenda • EB Unit Description • EB Plant Overview -Basic chemistry -Design of EB plant - Catalyst -Operating conditions

3. EB Unit Description • The Ethylbenzene Unit consists of three main sections: • Alkylation Reactor Section • Transalkylation Reactor Section • Distillation Section.

4. EB Unit Overview

5. EB Block Flow Diagram

6. EB simple flow

7. EB Plant Overview -Basic chemistry • The chemistry of EB reactions is centered on Benzene molecules and Ethylene molecules. The chemistry is fundamentally based on carbon and hydrogen atoms arranged in various combinations. • Benzene feed to the process is a six carbon ring compound with three double bonds alternating between the carbons, C6H6 • Ethylene feed to the process is a two carbon molecule with double bonds between the carbons, C2H2 C = C

8. In the EB Process there are two types of reactions: 1- Alkylation Reaction. 2-Transalkylation Reaction. The reaction will produce Ethyl Benzene (EB) in the presence of Zeolite catalyst

9. Alkylation Reaction • Alkylation reaction is the main reaction in EB process where one ethyl group is supplied by Ethylene molecules is being attached to one Benzene ring to produce Ethyl Benzene (EB) C6H6 + C2H4  C8H10 BZ Ethylene EB • The Alkylation reaction is an exothermic reaction, it’s an irreversible reaction and essentially all the ethylene is reacted

10. Poly Ethyl Benzene (PEB’s) are also produced while producing EB PEB reactions as shown below: C6H5-C2H5 + C2H4  C6H4-(C2H5)2 Ethyl Benzene Ethylene Diethyl Benzene C6H4-(C2H5)2 + C2H4  C6H3-(C2H5)3 Diethyl Benzene Ethylene Triethyl Benzene

11. C6H3-(C2H5)3 + C2H4  C6H2-(C2H5)4 Triethyl Benzene Ethylene Tetraethyl Benzene • Other minor by product are caused by : 1-Ethylene attached at the end of an ethyl group of EB C6H5-C2H5 + C2H4  C6H5-C4H9 Ethyl Benzene Ethylene Butyl Benzene (BB) 2-Benzene reacts with Propylene C6H6 + C3H6  C6H5-C3H7 Benzene Propylene normalpropylbenzene (NPB)

12. 3-Benzene reacts with Propylene C6H6 + C3H6  C6H5-C3H7 Benzene Cumene (CUM) 4-Ethylene reacts with Toluene C6H5-CH3 + C2H4  C6H5-C3H7 Toluene Ethylene Ethyl Toluene Propylene

13. At the design ratio of Benzene to Ethylene feeds is 2.5 molar basis and seven catalyst beds, the alkylation reaction creates: • Diethyl Benzene 9.7% • Triethyl Benzene 0.6% • Tetraethyl Benzene 0.03% • Butyl Benzene 0.02%

14. Transalkylation (TA) Reaction The purpose of TA Reactor is to reacts recycle PEB with Benzene to produce EB. C6H4-(C2H5)2 + C6H6  2C6H5-C2H5 Diethyl Benzene Benzene Ethyl Benzene C6H3-(C2H5)3 + C6H6  C6H4-(C2H5)2 + C6H5-C2H5 Triethyl Benzene Benzene DiethyBenzene EthylBenzene

15. C6H5-C4H9 + C6H6  2 C6H5-C2H5 Butyl Benzene (BB) Benzene Ethyl Benzene

16. Design of EB Plant

17. Ethylene specification Page 17

18. Benzene specification

19. EB Specification

20. Ethylene feed system Control Ethylene feed rate to the Alkylation reactor Control Plant EB Capacity Ensure B/E ratio is acceptable

21. Benzene feed system Remove catalyst poisons from benzene Take regular samples to track guard bed performance Replace BZ treater4 mol-sieve as needed Use freshest mol-sieve in “downstream” treater

22. Alkylation system • React ethylene with benzene to make Ethylbenzene • Control reaction parameters for optimum selectivity and catalyst life • B/E ratio at 2.5 (molar) or 7.04 (weight) • Inlet temperature • Water concentration

23. Alkylator Reactor Reactive Guard Bed Alkylator Intercooler Ethylene mixers

24. Reactive Guard Bed Separate vessel containing catalyst Allows replacement while keeping unit in operation Catalyst aging typically only in first bed

25. Transalkylator React PEB with benzene to make EB No Temperature increase Preheater to control reactor temperature

26. Benzene column Recover benzene from reactor product Furnace reboiler Condenser generates MP steam 0.5% EB in overhead 700 ppm Bz in bottom product

27. EB column Separate EB product from PEB and heavies Steam reboiler Condenser generates LP steam 1 ppm DEB in EB product 1 wt% EB in bottom product

28. PEB column Separate PEB product from heavies Steam reboiler Condenser preheats condensate (BFW) 50 ppm dicyclics in PEB product 5 wt% TEB in bottom product

29. Lights Column Dry fresh benzene (<25 ppm in bottoms) Remove non-aromatics and lights components Heat input by vapour stream from Bz column Condenser preheats fresh benzene Portion condensed by Cooling Water

30. Benzene treaters Remove organic N-components from benzene Mol-sieve operating at elevated temperature (115°C) Benzene Treaterscontains two types of molecular sieve, which has function:1. As water adsorber 4A molecular sieve 2. As benzene impurities adsorber 13X molecular sieveVolume ratio between water adsorber and benzene impurities adsorber 1 : 3

31. Benzene Treater contains of two types of molecular sieve, which has function:1. As water adsorber  4A molecular sieve 2. As benzene impurities adsorber 13X molecular sieveVolume ratio between water adsorber and benzene impurities adsorber  1 : 3Basic chemistry in the Benzene Treater: C6H6 + B + A  C6H6 + BABenzene Basic compound Active site on Benzene without Basic compound attached dissolved in Benzene Molecular sieve Basic compound to molecularsieve

32. EB Plant

33. Catalyst: • Zeolite catalyst. • Type : 1- EM – 3300 (Alkylation Reactor) 2- EM – 3700 (TA Reactor)

34. Catalyst poisons: • Nitrogen compounds will deactivate the catalyst by neutralizing acid sites. Maximum 1 ppm in Benzene feed and 0.025 ppm out of the RGB. • Chloride will interact and weaken the catalyst binder. Maximum 1 ppm in Benzene. • Water, will deactivate the catalyst. • Metals, will permanently deactivate the catalyst.

35. Operating Condition

36. 1. BZ to C2 ratio : 7.04 wt/wt or 2.5mol/mol 2. C2 conversion is nearly 100% 3. Effluent Pressure : 34.1 kg/cm2 4. Inlet bed temperature : 195 °C 5. Outlet bed temperature : 257 °C 6. Catalyst : EM-3300 Alkylation Reactor

37. TA Reactor : • BZ to PEB ratio : 2.0 wt/wt • DEB Conversion : 62% • Effluent pressure : 31.1 kg/cm2 • Operating temperature : 200°C • Catalyst : EM-3700

38. Light Column • Operating pressure : 1.5 kg/cm2 • Overhead temperature : 111 °C • Bottom temperature : 115 °C • Number of tray : 20 trays • Water content at bottom : 25 ppm (design)

39. BENZENE TREATER • Operating pressure : 18.2 kg/cm2 • Inlet bed temperature : 110 °C • Delta pressure : 0.35 • N2 compound at outlet: 30 ppb (0.03 ppm) • Adsorbing media : Molecular sieve (4A and 13X)

40. BENZENE COLUMN • Operating pressure : 13.2 kg.cm2 • Key component temperature : 269 °C (tray 11) • Reflux ratio : 1.62 • Overhead temperature : 200 °C • Bottom temperature : 280 °C • Number of tray : 40 trays • BZ content at bottom : less than 700 ppm • EB content at overhead : 0.5 % wt

41. EB COLUMN • Operating pressure : 1.1 kg/cm2 • Key component temperature : 221 °C (tray 5) • Overhead temperature : 169 °C • Bottom temperature : 231 °C • Reflux ratio : 1.3 • Number of tray : 54 trays • EB content in the bottom : < 1% wt • DEB content in the overhead : < 1 ppm

42. PEB COLUMN • Operating pressure : -0.8 kg/cm2 • Key component temperature : 176 °C (tray 4) • Overhead temperature : 141 °C • Bottom temperature : 229 °C • Reflux ratio : 0.2 • Number of tray : 20 trays • TEB content in bottom : < 5 %wt • Heavies content in overhead : < 50 ppm

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