1. ChEn 4501 Process Design HDA process Alternative Design Economics Report
Section 5 – Group 7 – Yellow
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2. Our Alternative Design PFD

3. This added millions to our yearly cash flows.
What’s New?
We installed a heat exchanger using the reactor inlet and outlet as the cold and hot streams.
This added millions to our yearly cash flows.
For our alternative design, the purge stream was treated in a high pressure flash tank with the goal of benzene recovery.
A few auxiliary process units were required to bring the purge stream to the temperature and pressure required for an acceptable separation.

4. All costs and revenues ($/yr)
New Material Flows
Stream
Flow (lb/hr)
Cost ($/100 lb)
Materials Cost ($/yr)
Fuel Values ($/yr)
All costs and revenues ($/yr)
Feed Toluene
26,260
-27.27
-58,370,000 #
Feed Gas
1,291
-50.33
-5,030,000
Benzene Product
20,870
40.86
69,500,000
Purge Gas
5,229
9,586,000
Purge Diphenyl
1,105
941,100
Total yearly profit from materials bought, sold and purged: $16.62 M/yr

5. New Energy Flows
Energy Streams for:
Duty (BTU/hr)
Utility
Energy Cost ($/yr)
Reactor Cooling
527,800
Cooling Water
7,349
Compressor 1
1,185,000
Electricity
169,800
Compressor 2
75,640
Pump 1
28,830
4,132
Pump 2
64,090
9,185
Stabilizer Column Condenser
3,096
3.906
Stabilizer Column Reboiler
4,140,000
Steam at 450 psig
184,800
Benzene Column Condenser
10,920,000
13,780
Benzene Column Reboiler
8,034,000
358,600
Toluene Column Condenser
1,719,000
2,169
Toluene Column Reboiler
1,645,000
235,800
Turbine Generator
979,800
-140,400
Total yearly operating costs from utilities $920,900/yr