BlueOX Energy Management

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Blue-OX Energy Management

• TJ Chancellor
• Paul Cole
• Sara Habib
• Mira Kim
• Claudio Ramos
• Vicente Rosas

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Benzene Hydrogenation Process
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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.

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Process Flow Diagram
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Results
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Annual Cash Flow
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Annual Total Product Cost
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Profitability
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Recommendations

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

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Hydrogenation Process Fluid Flow Economics
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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

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

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Pressure Drops for Each Stream
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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

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Heat and Material Balances and Pump Analysis
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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.

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Results

• Material Balance

Heat Balance
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• 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 )

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NPSHA and System Head vs. Flow Rate
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Fixed Capital Investment for the pumping section

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Heat Transport Equipment
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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.

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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

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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

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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.

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Economics

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

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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