Chemical Reactor Designing
Semester Project
Styrene Production
Group Members:
Baleegha Afzal (15)
Ammara Shehzadi (18)
Fatima Zahid (21)
Ateeqa Arif (39)
Submitted To:
Engr. khaqan Javaid
Styrene
Styrene, also known as ethenylbenzene, vinyl-benzene, and phenylethene, is an organic compound with the
chemical formula C6H5CH=CH2.
This derivative of benzene is a colorless
oily liquid that evaporates easily and has a
sweet smell, although high concentrations
have a less pleasant odor.
Styrene is the precursor to polystyrene and
several copolymers.
Industrial production from
ethylbenzene
The modern method for production of styrene by
dehydrogenation of ethylbenzene was first achieved in the 1930s.
The production of styrene increased dramatically during the
1940s, when it was popularized as a feedstock for
synthetic rubber.
Because it is produced on such a large scale, ethylbenzene in turn
prepared on a prodigious scale (by alkylation of benzene with
ethylene).
Ethylbenzene is mixed in the gas phase with 1015 times its
volume in high-temperature steam, and passed over a solid
catalyst bed.
Most ethylbenzene dehydrogenation catalysts are based on
iron(III) oxide, promoted by several percent potassium oxide or
potassium carbonate.
Reaction and their
structure:
Phisiochemical data:
Property
Physical Form
Common Usage
International System
Value & Unit
Value & Unit
Colourless, oily liquid
Colour (acc. ASTM D 1209 / DIN 6271) 10 max. / Pt-Co scale
Odour
Unpleasant, aromatic
Odour threshold
0.1 ppm
Relative molecular mass
Density at 20C (acc. ASTM D 4052
0.43 mg/m3
104.14
0.906 kg/l
906 kg/m3
Boiling point
145C
Melting point/Freezing point
-31C
Reaction system
Styrene is highly endothermic.
The superheated steam also provides
energy to drive the reaction.
Decompostion of ethyle benzene to
benzene and ethylene,and hydrodealkylation to give methane and
toulene are unwanted side reactions.
Products are cooled, producing steam
from high temperature reactor effluent.
Process flow diagram
Reactions
+
Ethylebenzene styrene hydrogen
Reaction kinetics
lnK = 15.5408 = 4.24*
Procedure:
This
reaction is highly endothermic
so select high temperature range.Its
operating temperature is 632(.As we
assume from 273K-2033K.
Calculate K from equation
lnK = 15.5408- 14852.6/T
Procedure:
Assume
0.1 rate to determine the
partial pressure from 1st rate
equation at different temperatures.
r1=4.24*10^6
For partial pressure eq. becomes
peb=r1/4.24*10^6
Procedure:
Styrene is in gas form ,ideal gas
equation use:
PV=nRT
P=n/V(R*T)
C=peb/RT
P= CRT
Procedure:
Calculate concentration from 1st rate
equation by applying ideal gas
equation:
r1=4.24*10^6
P=CRT
Equation becomes r1=4.24*10^6
C=1-[r1/4.24*10^6*RT]
Procedure
Calculate
equillibrium conversion.
Xe =
Calculate conversion at different
assumed rate by equation:
X=
Caf=Cao(1-X)
PROCEDURE
rate from range ( 0.01-0.1).
Assume
This is the material balance .
Initial conc. Will be taken from given steam
table w.r.t their inlet stream in reactor.
(=512.7)
Energy balance equation:
T=T
PROCEDURE
Now
at this point,calculate conversion
from energy balance equation at
different temperatures.
X=( T-T)*
T starts from 800K because before
this temperature , conversion will be
ve. And for energy balance lines T
varies with the difference of 40 K.
GRAPH BETWEEN TEMP. AND CONVERSION
energy balance lines
CA0 =
512
mole/
liter
equilibrium
line
0.9
0.8
material balance
lines
r=
0.01
0.7
r=
0.05
r = 0.06
r = 0.07
r=
0.02
0.6
r=
0.08
r = 0.09
0.5
CONVERSION
X
r = 0.1
r=
0.03
0.4
r=
0.04
0.3
0.2
0.1
0
200
400
600
800
1000
1200
1400
TEMPERATURE IN K
1600
1800
2000
PROCEDURE
This
reaction is highly endothermic
so conversion decrease with increase
in rate and vice versa.
X=
At 0.1 rate ,conversion will be
decrease.
Sizing curves
Sizing curve plot b/w conversion And
1/rate.
Here we discuss three cases:
isothermal
Adiabatic
Multistage reactor
Isothermal sizing curve:
Draw isothermal
line at any
temperature.
Note the
conversion and
rate that touching
the isothermal line.
Take inverse of rate
nd draw sizing
curve.
1/r
120
100
80
60
40
20
0.2
0.4
0.6
0.8
1.2
Adiabatic sizing curve
GRAPH BETWEEN CONVERSION AND RATE
120
100
V/ Fa0
80
60
1/ RATE
40
20
0.2
0.4
0.6
CONVERSION
0.8
1.2
MULTISTAGE REACTOR
graph between conversion and 1/rate
Graph between conversion and 1/rate
120
30
100
25
80
20
1/rate 15
60
1/RATE
10
40
5
20
0
0.74
0
0.76
0.78
0.8
0.82
0.84
0.86
0.88
0.05
0.1
0.15
0.2
0.25
0.3
0.35
conversion x
0.9
CONVERSION X
graph between conversion and 1/rate
35
30
25
20
1/rate
15
10
5
0
0.35
0.4
0.45
0.5
converasion x
0.55
0.6
0.65
0.4
COST
ESTIMATION
FOR THE
REACTOR
MATERIAL TO BE USED
FOR THE REACTOR WE ARE CONDIDERING
TWO TYPES OF STAINLESS STEEL SHEETS
1. SS304
2. SS316
. BOTH OF THEM HAVE THE SAME PROPERTIES
1. CORROSION RESISTANCE
2. 10% NICKEL , 18 % CHROMIUM
CONTINUED
THE MAJOR DIFFERENCE IS THE AMOUNT OF
MOLYBDENUM (2%) USED IN SS316.
MOLYBDENUM CONTENT TO INCREASE ITS
RESISTANCE TO CORROSION WHEN COMPARED
TO OTHER 300 SERIES ALLOYS
BUT IT IS WAY MORE EXPENSIVE THEN SS304.
SO THIS MATERIAL IS MAINY USED.
INLESS STEEL SHEETS PRIC
Stainless Steel
Plate
Size
1.2mm 5WL
4.0 mm
6.0 mm
8.0 mm
10.0 mm
304
$ per metre
316
$ per
metre
350 / 130
225 p/m
470 p/m
650 p/m
694 p/m
2
2
2
2
650 p/m
CALCULATIONS
SS316=$3500/ton
SS304=$2200/ton
RATE OF STAINLESS
SHEETS BASED ON THE
COST OF NICKEL PRICE.
(LME)
CALCULATIONS
TOTAL VOLUME=8861.3648m
AS THE COST IS=$650p/m
VOLUME OF ONE SHEET=0.008m
VOLUME FOR THE REACTOR
USED=2215.3412m
TAKING THE ESTIMATED VALUE=2300m
TAKING THE HEIGHT AS =12m
AND THE DIAMETER =16m
CALCULATIONS
COST OF ONE REACTOR=650 x 2300
=$1495000
WEIGHT OF THE REACTOR=$1495000/$2200p/TON
=679.545TONWEIGHT
OF SHEETS USED=679545kg/63.44kg
=10711.611kg
=10.7116 TON
CALCULATIONS
AS THE COST FOR SS304=$2200p/TON
=2200 X 10.7116
=$23565
AS RATE OF DOLLAR TODAY IS
105.35RUPPEES
=2482631 RUPPEES
AS THE COST OF FOUR REACTORS WOUL BE
=9930526.144 RUPPEES
THANK
YOU
