PYROLYSIS OF HDPE TO PRODUCE BENZENE AS

FUEL (Individual report)

Table Of Contents
1. Introduction.....................................................................................................................................3
2. Literature Review..........................................................................................................................3
CHAPTER 3 – MASS AND ENERGY BALANCE...............................................................................4

3.1 Process flow diagram...................................................................................................................4

3.2 Computer Aided Simulation (Aspen HYSYS)..........................................................................4
3.3 Mass Balance................................................................................................................................5
3.4 Energy balance.............................................................................................................................8
CHAPTER 4 – PROCESS DESIGN.....................................................................................................10

4.1 Minor Equipment......................................................................................................................10

4.1.1 Compressor.........................................................................................................................10
First Step: Determine the Volume Flow Rate,...................................................................................11
4.1.2 Heat Exchanger (E-102).......................................................................................................16
4.2 Major Equipment......................................................................................................................25
4.2.1 Fischer-Tropsch reactor......................................................................................................25
CHAPTER 5 – MECHANICAL DESIGN............................................................................................28

CHAPTER 6 – PIPING AND INSTRUMENTATION DIAGRAM (P&ID) DEVELOPMENT.........29

6.2 Process Control and Instrumentation......................................................................................31

CHAPTER 7 – PLANT SAFETY CONSIDERATION........................................................................31

CHAPTER 8 – PLANT OPERATING, START-UP AND SHUTDOWN PHILOSOPHY AND

PROCEDURES.....................................................................................................................................32

CHAPTER 9 – COSTING AND ECONOMIC EVALUATION..........................................................33

9.1 Cost of Fischer-Tropsch reactor...............................................................................................33

References.............................................................................................................................................34

Appendix...............................................................................................................................................35

.............................................................................................................................................................. 36
CHAPTER 1 & 2 – INTRODUCTION & LITERATURE REVIEW

1. Introduction
2. Literature Review
CHAPTER 3 – MASS AND ENERGY BALANCE
3.1 Process flow diagram

Figure 3.1: PFD for HDPE Pyrolysis to Produce Benzen as Fuel

3.2 Computer Aided Simulation (Aspen HYSYS)

Figure 3.2: Overall HYSYS Simulation

3.3 Mass Balance

Figure 3: Heater (E-102)

Table 3.1: Heater (E-102)

Input Output
Stream Stream 7 Stream 8
Temperature [℃] -17.11 125
Pressure [kPa] 152 152
Heater (E-102)

Component Molar − − −
mass[kg/kmol]
Butane 58.12 − 3.063725 3.063725
Benzene 78.11 −
232.8431 232.8431
Toluene 92.14 − 12.2549 12.2549
Methane 16.04 −
232.8431 232.8431

Ethane 30.07 − 3.063725 3.063725

Propane 44.1 − 3.063725 3.063725
Pentane 72.15 − 3.063725 3.063725
HDPE − − − −
Char / Coke − − − −
Total mass flowrate by stream
− 490.1961 490.1961
Total mass flowrate 3170 3170
−

Figure 3.4: Gas to Liquid Phase Changer (Fischer-Tropsch Reaction)

Table 3.2: Gas to Liquid Phase Changer (Fischer-Tropsch Reaction)

Input Output
Stream Stream 7 Stream 8
Temperature [℃] -17.11 125
Pressure [kPa] 152 152

Fischer-Tropsch Reactor
Component Molar − − −
mass[kg/kmol]
Butane 58.12 − 3.063725 3.063725
Benzene 78.11 −
232.8431 232.8431
Toluene 92.14 − 12.2549 12.2549

Methane 16.04 −
232.8431 232.8431

Ethane 30.07 − 3.063725 3.063725

Propane 44.1 − 3.063725 3.063725
Pentane 72.15 − 3.063725 3.063725
HDPE − − − −
Char / Coke − − − −
Total mass flowrate by stream
− 490.1961 490.1961
Total mass flowrate 3170 3170
−

Figure 3.5:Compressor (COMP-101)

Table 3.3:Compressor (COMP-101)

Input Output
Stream Stream 6 Stream 7
Temperature [℃] 125 125
Pressure [kPa] 101.3 152

Compressor (COMP-101)
Component Molar mass[kg/kmol] − − −
Butane 58.12 − 3.063725 3.063725
Benzene 78.11 −
232.8431 232.8431
Toluene 92.14 − 12.2549 12.2549
 Methane 16.04 −
232.8431 232.8431

Ethane 30.07 − 3.063725 3.063725

Propane 44.1 − 3.063725 3.063725
Pentane 72.15 − 3.063725 3.063725
HDPE − − − −
Char / Coke − − − −
Total mass flowrate by stream
− 490.1961 490.1961
Total mass flowrate 3170 3170
−

3.4 Energy balance

 Table 3.4: Energy balance (Heater (E-102)

Inlet Outlet
T=- P= T= P=
17.11 152kpa 125 152kpa
℃ ℃
Stream 6 7
Heater Components n H Q (kJ/hr)
(kmol/hr)
H1 H2 H3 H (total)
Methane 6.8953 -0.0241 -24.1000 -
166.1765
Ethane 0.0006 -0.0347 -34.7000 -0.0221
Propane 0.0004 -0.0479 -47.9000 -0.0208
Butane 0.0003 -0.0649 -64.9000 -0.0214
Pentane 0.0003 -0.0807 -80.7000 -0.0214

Benzene 1.3346 -0.0522 -52.2000 -69.6640

Toluene 0.0033 -0.0663 -66.3000 -0.2204
Total -236.1466
Enegy Q

Table 3.5: Energy balance (Fischer-Tropsch Reaction)

Inlet Outlet

T=- P= T= P=
17.11℃ 152kpa 125℃ 152kpa
Stream 6 7

Water-Gas Shift Components n H Q (kJ/hr)

Reaction (WGSR) (kmol/hr)
H1 H2 H3 H (total)

Methane 6.8953 -0.0241 -24.1000 -

166.1765
Ethane 0.0006 -0.0347 -34.7000 -0.0221
Propane 0.0004 -0.0479 -47.9000 -0.0208
Butane 0.0003 -0.0649 -64.9000 -0.0214
Pentane 0.0003 -0.0807 -80.7000 -0.0214

Benzene 1.3346 -0.0522 -52.2000 -69.6640

Toluene 0.0033 -0.0663 -66.3000 -0.2204
Total Enegy Q -236.1466

Table 3.6: Energy balance (Compressor 101)

Inlet Outlet
T=125℃ P= T= P=
 101.3kpa 125 152kpa
℃
Stream 6 7
Compressor Components n H Q
101 (kmol/hr) (kJ/hr)
H1 H2 H3 H (total)
Methane 6.8953 0.0069 6.9000 47.5775
Ethane 0.0006 0.0099 9.9000 0.0063
Propane 0.0004 0.0137 13.7000 0.0059
Butane 0.0003 0.0185 18.5000 0.0061
Pentane 0.0003 0.0231 23.1000 0.0061

Benzene 1.3346 0.0149 14.9000 19.8849

Toluene 0.0033 0.0190 19.0000 0.0632
Total Enegy 67.5501
Q

CHAPTER 4 – PROCESS DESIGN

4.1 Detailed Design Major Equipment

4.1.1 Detailed Design Gas to Liquid Phase Changer (Fischer-Tropsch Reaction)

In this paper, we build a reactor for 90% conversion of synthesis gas into benzene in a
Fischer-Tropsch reactor with an optimum reactor size of 6.8 m3 and an iron-based catalyst
with a volume of catalyst of 7.4 m3 (Multi-Tubular Fixed Bed Reactor). The operating
pressure is 0.152 MPa, and the temperature is 429 degrees Celsius. Below is the
specification sheet shown after the calculation for the FTR is done in the excel sheet
attached in the report.

Table 4.1: Specification Sheet for Fischer-Tropsch Reactor

FTR SPECIFICATION SHEET

Equipment FTR Date
Prepared
Tag No. FTR by
Function To convert synthesis gas into benzene
Type Sieve Plate
Operation Continuous
Position reactor
Process Condition
Stream Inlet Outlet
Stream No. S1 S3
Temperature (℃) 429 429
Pressure (kPa) 152 152
Molar Flowrate
(kmol/hr) 68.61 68.61
 Mass Flowrate (kg/hr) 3170 3170

4.2 Detailed Design Minor Equipment

4.2.1 Detailed Design Compressor (COMP 101)
A compressor is used to boost the pressure in the gas state. Centrifugal and reciprocating
compressors are the two types of compressors. COMP-101 raises the pressure in stream 6
containing liquid oil and light hydrocarbon gas from 101.3 kPa to 152 kPa. In general,
centrifugal compressors are appropriate for compression ratios ranging from 1 to 4, whereas
reciprocating compressors are appropriate for compression ratios more than 5. COMP-101
operates on the isentropic principle, which means that there is no flow of heat energy in the
operation, making it adiabatic. COMP-101 has two stages, according to the calculations. The
speed was calculated to be 8833.87 rpm using the fan law. After accounting for piston leakage
(2%) and losses of 35 kW due to the assumption of an iso-carbon seal, the final power of the
K-100 is predicted to be 78.93kW. 85.6497% is the volumetric efficiency. The only parameter
considered for process control is pressure, as the compressor's primary duty is to increase
pressure.
Below is the specification sheet shown after the calculation for the compressor is done in the
excel sheet attached in the report.

Table 4.3: Specification Sheet of COMP-101

COMPRESSOR (COMP-101) SPECIFICATION SHEETS

Equipment Pump Date
TAG no. COMP-101 Prepared by
Function To increase pressure of HDPE stream for downstream
Type Centrifugal Pump Position Horizontal
Operation Continuous
Operating Condition INLET OUTLET
Stream S6 S7
Temperature C 25 25
Pressure kPa 101.3 152
Mass Flowrate kg/hr 7325.038 7325.038
Volumetric Flowrate m3/h 8.4592 8.4592
Density kg/m3 794 794
Viscosity cP 2.2866 2.2866
Pa s 2.29E-03 2.29E-03
SPECIFICATION
Material of Construction Stainless Steel
Relative Roughness 0.00057
Pump Efficiency % 78%
Energy J/kg 35116.8
Power kW 78.93
NPSH m -174.5978815

4.2.2 Detailed Design Heat Exchanger (E-102)

 The design of heat exchanger control system is made as to ensure the heat exchanger
operate at the optimum condition and safe to be used throughout the process. Heat exchanger
involves in changing of temperature and the flow rates of at the inlet of heat exchanger will
affect the temperature changes. Thus, flow rates become the control variable in this unit
operation. Heat exchanger is a part of heat and energy integration process. The process
mentioned is to reducing energy consumption and at the same time maximizing the heat
recovery in this plant. Flow is the main controlled variable here and control system is located
at inlet stream of both heat exchangers.

After the deodorization process, the equipment of E-102 oversees cooling the hot HDPE
stream as it exits the distillation column. Reduce the temperature of the stream from -
17.11°C to 85°C as a process requirement for cooling it. The temperature of the water is
believed to be 125°C before being reduced to 25°C.

Below is the specification sheet shown after the calculation for the heat exchanger is done in
the excel sheet attached in the report.

Table 4.4: Process condition of Heat Exchanger (E-102)

Operating Condition E-102

Parameter Units Shell Shell Tube Tube
o
Temperature C 30 46.0610 55.3020 45.5655
Pressure kPa 1 1 1 1
Mass Flowrate kg/hr 88856.4847 88856.4847 45032.7760 45032.7760
Volumetric Flowrate m3/h
Density kg/m3 1003.5666 991.2941 753.4602 764.1547
Viscosity cP 0.7972 0.5827 0.3672 0.4141
Pa s 7.972E-03 5.827E-03 3.672E-03 4.141E-03
Thermal conductivity W/mK 0.6182 0.6388 0.1669 0.1711

Table 4.5: Heater (E-102) Specification Sheet

HEAT EXCHANGER (E-102) SPECIFICATION SHEET

Service Unit Process Cooling Date
Tag No. E-102 Prepared by
Description Cooling Down HDPE for Downstream Process
Type Shell and Tube Heat Exchanger
Flow Arrangement Counter-Current Position Horizontal
Operating Condition
Exchanger Side Shell Side Tube Side
Parameter Inlet Oulet Inlet Outlet
Stream S7 S8 S123* S123**
Cooling Water Cooling Water
Fluid Name HDPE HDPE In Out
Operating Temperature
(°C) 120 25 20 90
Operating Pressure
(kPa) 1 1 1 1
 Mass Flowrate (kg/hr) 7325.0380 7325.0380 3663.7990 3663.7990
Mass Density (kg/m³) 794 794 997 997
Viscosity (cP) 2.8230 2.8230 0.8904 0.8904
Thermal Conductivity
(W/mK) 0.1045 0.1045 0.6071 0.6071
Specificit Heat (kJ/kgC) 1.8254 1.8254 4.2000 4.2000
Heat Transfer Rate (kW) 352.8487
No. of Tube
No. of Shell Passes 1 passes 2
ΔT(LMTD) 10.4646

Overall Heat Transfer 350

Coefficient (W/m²°C)
Heat Transfer Area (m²) 81.6934
Shell and Tube Construction
Material of Construction Stainless Steel 304L
Tube Outer Diameter Length of
(mm) 8.43871 Tube (m) 7.3200
Tube Inner Diameter Wall thickness
(mm) 6.71171 (m) 1.727
Area of one
No. of Tubes 12 Tube (m²) 0.000
Tube arrangement Triangular
Shell Bundle Clearence Split-ring Floating Head
Bundle Diameter Shell diameter
Clearence (m) 0.2579 (m) 0.3109
Baffle spacing
Baffle Diameter (m) 0.3093 (m) 0.5000
Shell Side Tube Side
Heat Transfer
Coefficient (W/m²°C) 482.0554 842.0392
Pressure Drop (kPa) 3.9746 2.3895

4.3 Mechanical Design of Gas to Liquid Phase Changer (Fischer-Tropsch Reaction)

Figure 4.6 Mechanical Drawing for the Side View, Front View and Cross Section view of Fischer –
Tropsch Reactor)

CHAPTER 5 – MECHANICAL DESIGN

 Figure 5.2: Detailed design of major equipment

CHAPTER 6 – PIPING AND INSTRUMENTATION DIAGRAM

(P&ID) DEVELOPMENT.
6.1 Pipe Sizing for Reactor (Fischer-Tropsch Reaction), Compressor COMP-101, heat
exchanger (E-102)

Table 6.1: Pipe sizing

Volumetric 48.16 48.16 48.16

Flowrate m3/hr
25.00 25.00 25.00
Assumed Velocity m/hr
1.93 1.93 1.93
Pipe Area m2
1.57 1.57 1.57
Pipe OD m
2 2 2
Actual Pipe Size m
6.2 Process Control and Instrumentation

Figure 6.2: Process Control and Instrumentation

CHAPTER 7 – PLANT SAFETY CONSIDERATION

CHAPTER 8 – PLANT OPERATING, START-UP AND SHUTDOWN PHILOSOPHY

AND PROCEDURES

CHAPTER 9 – COSTING AND ECONOMIC EVALUATION

9.1 Cost of Fischer-Tropsch reactor
References

Maitlis, P. M., & De Klerk, A. (2013). What is Fischer–Tropsch. Greener Fischer-Tropsch

Processes for Fuels and Feedstocks. Weinheim: Wiley-VCH Verlag GmbH & Co. KGaA.

Sinnott, R. K., & Coulson, J. M. (2005). Coulson & Richardson's Chemical Engineering
Design. Elsevier Butterworth-Heinemann, .

Towle, W., & Sinnott, R. K. (2008). Chemical Engineering Design: Principles, practice and
economics of plant and Process Design. Elsevier/Butterworth-Heinemann.
Appendix