Part 1 Part 2 Part 3 Part 4 Part 5

Introduction & Flow sheeting

Detailed design Economic analysis HAZOP Conclusion

Objective
To design an MTBE plant that produces 100,000 tons of MTBE per year. MTBE is a gasoline additive. The reaction is between isobutene and methanol as follows: (CH3)2C=CH2 + CH3OH (CH3)3C-O-CH3

Process Description

process flow diagram of step 4 by Visio program

Site Selection
Comparison Factor Utilities: Fuel supply Electric power Water supply Plant location: Raw material availability Energy availability Transportation Facilities Plant location: Water supply Labor supply Site characteristics Waste disposal facilities Score (out of 9) Site (1) Salalah Site (2) Rusail Site (3) Sohar

Part 2 Detailed design

Heat Exchanger
Purpose Description Sizing Data

OverallBasic sizing data of model ofheat heatexchanger exchanger

Detailed model of heat exchanger

Reactor

Purposes CH3OH + (CH3)2C=CH2 Conditions Sizing Data & analysis

(CH3)3C-O-CH3

Mole fractions of methanol, i-butene and MTBE

Molar Flow of the components

Distillation

Purposes of second distillation Condition Sizing Data & analysis

Condenser and re-boiler performances

Engineering Economic Analysis of MTBE production

Economic evaluations:
Total cost

Fixed Capital Investment (FCL)

Cost of Manufacture

Bare Module

Working Capital

Manufacture Cost

General Expenses

Direct

Indirect

Calculations:
To calculate the Cost of Operating Labor (COL):
N=4 vessel + 3 tower + 5 heat exchanger + 4 pumps = 16 NOL = (6.9 +1.71P2 +0.23Nnp)0.5 = (6.29 +31.7*0 +0.23*16)0.5 = 3.16 op/shift NOP = (4.5) shift/day * NOL =4.5 * 3.16= 14.22 14op/day 52900$ = cost of labor (per operator/year) COL = NOP * cost of labor = 14 * 52900$ = $740600/year

To calculate the Cost of Manufacture (COM) without depreciation: COMd= 1.23(CRM + CWT + CUT) +2.73 COL + 0.180 FCI
= 1.23(74932776 + 0 + 15222900) +2.73*740600 +0.180*619000 =$113* 10^6

To calculate the production cost of MTBE:

Cost of MTBE = COMd/ production rate = $113* 10^6 / 1*10^8kg/year =1.13 $/kg

Con.start

start up

FCl Shut down WC Project Life

HAZOP
What is it Its purpose Concept Key words

procedure offering potential to improve the safety, reliability and operability of process plants by recognizing and eliminating potential problems when designing

An identifying technique leading methodically to most potential and detectable deviations which could conceivably arise in the course of normal operating routine

1. Taking description of a process, questioning every part of it to establish the deviations 2. Assessment is made. 3. Action is then taken.

Primary

Secondary

P&ID for MTBE Plant with Control Loops

Process water Waste Butylenes

FIC

E-901 T-902 lps P-901 A/B E-905

V-901
R-901 Methanol E-903

T-903 V-903

cw
LI C

FIC

P-904 A/B cw

Butylenes feed
FIC

V-902

LI C

P-903 A/B P-902 A/B

LIC

T-901

E-904 mps Waste water

LIC

E-902

hps

MTBE

P&ID for Distillation Colum (for HAZOP Study Case)

SIZE
PSV 105

4" x 6" 120 PSIG 6"-P-105 TO FLARE UCD-AB1

PSV 107

SET

D
TI 128

CSO CSO

V 3"-P-102
PI 104

SIZE x 1" SET 100 PSIG COOLING WATER RETURN 6"-CW-102 UCD-BA2

2"-P-119

4"-P-104

8"-P-103

2"-P-110

EX-101 FEED/BOTTOM EXCH 1/P COOLEDBOTTOMS TO STORAGE PCD-AA3 2"-P-119 FC 1/P COLUMN FEED FROM FEED DRUM V-101 PCD-AA1 FC
TT 126 LAH 120 FE 101 FT 101 FRC 101 FY 101 FV 101 TI 102 LV 119 LY 119 LIC 119 TR 103

Node: Overhead line 8-P-103 Type: Line EX-102 LIGHT ENDS CONDENCER C-101 Design Conditions: 427.75 kmole/hr at FO LIGHT ENDS STRIPPER 500 kpa & 56.27 C
FY 116

PT 106

N.C.

3"-P-104

FY 116

D D

COOLING WATER SUPPLY 6"-CW-101 UCD-BA2 PAH PAL

PIC 106 PY 106 PY 106

1/P

2"-P-101

6"-P-113 1/P FROM M.P. STEAM HEADER 3"-S-101 UCD-AC1 FC EX-103 REBOILER TO CONDENSATE RETURN HEADER UCD-AC1 3"-S-102
ST LAL 121 LSL 121 LT 119 TV 126 TY 12 TRC 126

21

Deviation: High pressure Guide Word: High Parameter: Pressure Design Inlet: 500 kpa
TI 117 FRC 116 FT 116 FE 116 LSLL 116 LALL 116 LG 118

1-P-105

UCD-AB1 FO TO FLARE

V-102 REFLUX DRUM

LT 107

TAL
LSH 120

LAH LAL
LIC 107

PUMP STOP (P-102 & S) 4"-P-112

FD 127 PSLL 125

1.5"-P-118

1.5"-P-118 2"-P-116 3"-P-115 2"-P-117

ZO 122 ZC 122 PI 124 XA 122 MS 122

MS 122

2"-P-109

Cause: Blocked discharge AUTO START SPARE Consequences: Over 2"-P-106 pressuring of PUMP (P-101S) stripper Safeguards: 1. PVS-105 relieving to flare D 2. Check valve. 3. Isolation valve actuated on reverse flow condition
PSLL 109

PUMP STOP (P-101 &S)

PALL 109

FR 106 FE 106

LY 107

1/P
LV 107

FT 106

DISTILLATE 1-P-111 PCD-AA2

FO TO LIGHT ENDS STORAGE TANKEX-101

3"-P-106

MOV 122

CLOSE

3"-P-107

2"-P-116

3"-P-106

2"-P-106

V
PI 123

AUTOSTART

XI 128

XI 129

RUN

STOP

P-102S BOTTOMS PUMP (SPARE)

XI 126

XI 127

3"-P-106

PI 110

PI 111

RUN

STOP

P-102 BOTTOMS PUMP

XI 113

XI 112

XI 115

XI 114

RUN

STOP

P-101 REFLUX PUMP

RUN STOP

P-101S REFLUX PUMP (SPARE)

3"-P-107