Progress Report for Week 1 of Design of Cumene Production Facility

Team #: 13

Goals for Week 1:

1. Researched alternative technologies for process, and market analysis

2. Calculation of Gross Annual Profit for Process

3. Hand calculations for reactor sizing and comparison to Aspen Plus simulation

4. Development of preliminary PFD

5. Examine environmentally friendly processes and waste treatment.

Summary of Accomplishments for Week 1:

1. The gross annual profit was found to be $49,725,183.41. This is the maximum amount of profit expected at 90% conversion under ideal conditions neglecting such factors as startup cost and equipment.

2. Calculations were completed by hand to obtain molar flow rates. However, the volume and conversion need to be calculated.

Team Activities in Week 1

Member (s)	Task	Time spent (h)
Mia Barrington	Background research.	9
Robert Duncanson and Jessica Blanding	Preliminary reactor sizing and gross profit calculations.	10
Total (h)		19

Goals for Week 2:

1. Evaluate alternate separation sequences.
2. Carry out flash and distillation column (shortcut and rigorous) simulations.
3. Optimize process units and include recycle.

The overall objective of this project is to create a process to generate 100,000 metric tons per year of cumene using benzene and propylene. The target design is achieving a 99% purity of cumene. We start by analyzing the kinetics of the problem.

Based on the given rate law and rate constant. We can begin to deduce information about the specifications of our reactor. The second reaction proceeds faster than the first reaction because the pre-exponential factor A is higher than the first reaction. It could be difficult to optimize the two equations but because the activation energy has a similar relationship we can optimize the reactions by operating at a low temperature. At low temperatures, the reaction favors the alkylation reaction. A short residence time or short reactor will also help maximize the selectivity of reaction A. We would also have excess benzene fed into the reactor at a high flow rate in order to minimize the amount of propylene that reacts with cumene to form an undesired product. Moderate pressures will be used.

However, when using lower temperatures, a larger reactor becomes necessary. Therefore, the temperature and reactor size must be optimized. We would not use high temperatures or high pressures because the reaction would then favor the undesired product.

The alkylation reaction is highly exothermic. Therefore, we would like to utilize that heat to minimize utility costs and equipment.

Hand Calculations

To find the flow rates

For a ration of fresh feed to recycle feed of 1:3

Problems

1. Calculating the design specifications (volume at a specified conversion with initial guesses for the molar flows of benzene and propylene) for a PBR with multiple reactions.

2. We are still optimizing the temperatures and pressures used throughout the process and would like further guidance as to how we can more efficiently find the best operating conditions.

~Mia B.
~Jessica B.
~RSD