1. Styrene Production by Catalytic
Dehydrogenation of Ethylbenzene
Proposed By:
Michelle Otutu, CAS
DeMarioDunkley
Chika Oluku
Kevon Smith

2. Overview
• What is Styrene ? Uses?
• Reaction Kinetics
• Production Routes
• Feed Preparation & Reacting the Feed
• Separation & Recycles
• Heat Integration
• Capital Cost Estimates
• Conclusion

3. Styrene Uses

4. Reaction Kinetics

5. Production Routes
Main reaction:
By Products reactions :

6. FEED PREPARATION & REACTION
Feed contains : 98% E-Benzene Benzene, 1% and 1% Toluene
Temperature = 25 C
Pressure = 101.3 kPa
Mass Flow = 14857.8569 kg/h

9. REACTION RESULTS
• Overall Single Pass Conversion was 72.92%
• Selectivity of Styrene was found to be 97.91%

10. SEPARATION &RECYCLES
• Three Phase Separator

11. • Inlet Stream: Liquid-Liquid mixture (two
immiscible liquids)
• Outlet Stream:
• Light gases – Methane, Ethene, Hydrogen, etc
• Intermediate oil (API ~ 24.7degree)
• Waste water
• Inlet Diverter
• Weir
• Mist extractor.

12. • From literature review, we found that these are in general more
economical
• Promotes gravity separation (flow velocity perpendicular to settling
velocity)
• Enhances phase equilibrium (greater interface area)
• They require more plan area compared to a vertical with similar
dimensions.
• Poor handling of solid sediments in mixture
PROS & CONS

13. • S.Gavg = 0.906
• APIavg =24.7 degrees
• Residence time = 8 – 10mins
• Volumetric flow of liquid (organic) = 19.37m3/h
• Volumetric flow of water = 28.02m3/h
• Total = 47.39m3/h = 0.7898m3/min
• Volume of Total liquid = 7.2m3
• Total volume of tank = Total liquid volume +
clearance = 15m3
SIZING

14. Tank Specifications
• Diameter – 5ft = 1.524m3 and,
• Seam to Seam – 15ft = 4.572m3
• Volume = 8.34m3/tank.

16. HEAT INTERGRATION
Flow sheet Stream Flowrate (kg/s) Cp (kJ/KgK) mCp(kJ/s K) Tin(C) Tout(C) Q(kW)
5a->5b H1 13.08256475 2.40082008 31.4088841 550 50 15704.44
4a->4b H2 13.08253618 2.62694634 34.36712059 830 600 7904.44
4a1-> 4a2 C1 13.08253618 2.38988138 31.26570965 550 600 -1563.29
1a-> 1b C2 5.165433535 1.77118872 9.148957588 40 140 -914.90
Total 5426.26
Stage Delta T Stage Q's Qculmative
A 230 7904.437736 7904.43774
B 50 -1563.285482 6341.15225
C 400 12563.55364 18904.7059
D 100 2225.992651 21130.6985
30
130
230
330
430
530
630
40
140
240
340
440
540
640
740
840
0 1 2 3 4 5
ColdStreams
HotStreams
Temperature Interval Diagram
H1
H2
C1
C2

17. Basic Heat Exchanger Network
Cold Utility
Basic HEN 13226.2608
H1 H1
15704.44 7904.44
1563.29 914.90
C1 C2
-1563.29 -914.90
CASCADE DIAGRAM
A
7904.438
7904.437736
B
-1563.29
6341.152254
C
12563.55
18904.70589
D
2225.993
21130.69855 Cold Utility

18. Waste Streams
• Green House Gases – Carbon Dioxide, Nitrous
Oxide
• Particulate Matter - PM2.5 penetrates deeper
into the lungs and interfere with gas exchange.
• Respiratory problems- asthma, lung
disease, changes in heart rhythms, and heart
attacks.
• Reduce Fossil fuel usage.
• Detailed recycle stream analysis.

19. Storage
• Ethylbenzene, Benzene, Toluene, Styrene
• Safety Issues – All highly flammable, explosive
vapours.
• Storage conditions – 30 deg.C, light resistant
containers, well ventilated room, tightly
sealed containers.
• Handling – Beware mechanical impact or
static discharge.

20. Production Development
• “For a conventional dehydrogenation catalyst,
capable of providing a yield of about 69% with
the injection of air, the yield is only about 58%
after 24 hours and scarcely exceeds 50% after
an operation lasting 2 days.”
-U.S. Patent Sources

21. CAPTIAL COST ESTIMATE
• Direct costs
- Equipment purchase, delivery, installation,
piping
 Indirect costs
- Contractor fees, legal expenses, supervision

22. Specific Equipment Costs
Compressors Compressor Type Power (kilowatts) # Spares MOC Purchased Equipment Cost Bare Module Cost
C-101 Centrifugal 9080 0 Stainless Steel $ 2,000,000 $ 11,500,000
Fired Heaters Type Heat Duty (MJ/h) Steam Superheat (°C) MOC Pressure (kPag) Purchased Equipment Cost Bare Module Cost
H-101 Process Heater 0.008 Stainless Steel 101.3 $ 472,000 $ 1,330,000
H-102 Molten Salt Heater 900 $ 39,600 $ 86,000
Mixers Type Power (kilowatts) # Spares Purchased Equipment Cost Bare Module Cost
M-101 Impeller 5 4 $ 110,000 $ 151,000
Pumps (with drives) Pump Type Power (kilowatts) # Spares MOC Discharge Pressure (kPag) Purchased Equipment Cost Bare Module Cost
P-101 Centrifugal 0.107 0 Carbon Steel 61.3 $ 2,450 $ 9,760
Reactors Type Volume (cubic meters) Purchased Equipment Cost Bare Module Cost
R-101 Jacketed Agitated 25 $ 70,500 $ 282,000
R-102 Jacketed Agitated 25 $ 70,500 $ 282,000
Towers Tower Description Height (meters) Diameter (meters) Tower MOC Demister MOC Pressure (kPag) Purchased Equipment Cost Bare Module Cost
T-101 9 Stainless Steel Sieve Trays 1.79 1.2 Stainless Steel Stainless Steel 40 $ 19,300 $ 70,500
T-102 98 Stainless Steel Sieve Trays 1.79 1.19 Stainless Steel Stainless Steel 40 $ 112,000 $ 227,000
User Added
Equipment Description BMF0 Actual BMF Purchased Equipment Cost Bare Module Cost
Z-101 Cooler 1 2.17 $ 39,600 $ 86,000
Z-102 Cooler 1 2.17 $ 39,600 $ 86,000
Z-103 3-phase Separator 1 3.33 $ 22,500 $ 75,000
Z-104 Relief Valve 1 1.29 $ 700 $ 900
Total Bare Module Cost $ 13,938,260

23. Totals
• Annual operating cost: $16.5 M
• Grass roots/Capital cost: $20.1 M

24. CONCLUSION