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Blue-OX Energy Management

Blue-OX Energy Management. TJ Chancellor Paul Cole Sara Habib Mira Kim Claudio Ramos Vicente Rosas. Benzene Hydrogenation Process . Project 3: Benzene Hydrogenation Process . Purpose - provide an economic analysis for the benzene hydrogenation process. Objectives -

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Blue-OX Energy Management

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  1. Blue-OX Energy Management TJ Chancellor Paul Cole Sara Habib Mira Kim Claudio Ramos Vicente Rosas

  2. Benzene Hydrogenation Process

  3. Project 3: Benzene Hydrogenation Process Purpose - provide an economic analysis for the benzene hydrogenation process. Objectives - • Estimate the total fixed capital investment • Estimate the annual product cost. • Estimate the annual cash flow for the life of the project. • Report profitability based on ROI, discounted cash flow, (NPW), and POT. • NPW if products were sold at half or three times the price of cyclohexane.

  4. Process Flow Diagram

  5. Results

  6. Annual Cash Flow

  7. Annual Total Product Cost

  8. Profitability

  9. Recommendations • If market value of cyclohexane falls below $2.32/gallon the process should be discontinued.

  10. Hydrogenation Process Fluid Flow Economics

  11. Purpose • Perform sensitivity analysis for the quantification of risk • Determine the minimum price difference between the product and raw material • Select material types for different piping section • Determine pressure drops through the pipe network in order to determine if more pumps are needed • Perform safety analysis for the suggested pipes • Suggest insulation material and thickness • Estimate the Fixed Capital Investment

  12. Results

  13. FindingsOptimized Pipe Network Insulation Total Cost

  14. FindingsOptimized Pipe Network Insulation Total Cost Percentage less than the Non-optimized

  15. Results • For Non-optimized pipes the minimum price is $1.44 • For the Optimized pipes network the minimum price drop 4 cents to $1.40 • Pressure Drop around the entire network was found negligible

  16. Pressure Drops for Each Stream

  17. Recommendations • By using the nominal diameter suggested the company will save about $200,000 in the capital investment for the pipes • Blue Ox determine that 2 inches thick rock wool insulation is the economical optimum • Based on the simulation and calculation the pressure drop is negligible throughout the pipe network thus no new pump or compressor is necessary at this time

  18. Heat and Material Balances and Pump Analysis

  19. Heat and Material Balances and Pump Analysis Objectives: solve heat and material balances for the process from Project 3 select an appropriate material for the reactor determine the work needed at the pump for the pumping section of the process suggest a pump type create NPSHA vs. flow rate diagram system head vs. flow rate diagram   estimate the Fixed Capital Investment for the pumping section.

  20. Results: Material Balance Heat Balance

  21. Material • Stainless Steel • Reactor contains Hydrogen at high T and P • Resistant to corrosion • Ensures reactor safety & longevity Pump • Work Needed: 5.06 kW • Pressure Drop: 38 psia • Discharge Pressure: 593 psia • Type: regenerative pump (turbine pump )

  22. NPSHA and System Head vs. Flow Rate

  23. Fixed Capital Investment for the pumping section

  24. Heat Transport Equipment

  25. Objectives • Design heat exchanger E1 by hand (using Excel) and by simulation (using Pro/II). • Choose materials for construction of the heat exchangers. • Generate T-Q diagrams for each of the heat exchangers. • Design a distillation column for the process.

  26. Hand Design • Double pass heat exchanger. • Nominal Tube Size: ½ inch • Tube Length: 16 feet • Total Area: 2117 ft2 • Fluid Flow Rate: 4.73 m3/s • Tube Side Pressure Drop: 1.71 psi

  27. Simulator Design • Front End Stationary Head: Channel and Removable Cover • Shell Type: Double Pass with Longitudinal Baffle • Rear End Head: U-Tube Bundle • Shell Inside Diameter: 8 inches • Tubes per Shell: 24 • Area: 588ft2

  28. Heat Exchanger Materials • 304 Stainless Steel was chosen as the material for construction. • Stainless steel was chosen because of the corrosive properties of methane and benzene.

  29. Economics • Price of a single heat exchanger: $12,155 • Purchased Equipment (3 heat exchangers): $36,465 • Fixed Capital Investment: $190,530

  30. Distillation Column • 28 Trays. 2 feet between trays. 5 feet for the top and bottom trays. • Column Height: 66 feet • Tray Diameter: 93 inches • Condenser • Reboiler • Reflux Ratio: 24

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