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Simulation and Optimization of Ethyl Benzene Production Using Aspen Plus Platform

Conference Paper · November 2014

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Utkarsh Maheshwari Kalyanee Ambatkar

D. Y. Patil Institute of Engineering, Management & Research, Akurdi, Pune Birla Institute of Technology and Science Pilani
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Prathyusha Naini
Birla Institute of Technology and Science Pilani
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 ASPEN SIMULATION AND OPTIMIZATION OF ETHYLBENZENE PRODUCTION
Kalyanee Ambatkar1, Prathyusha Naini2
1
Teaching Assistant at Birala Institute Of Technology And Science, Pilani, BITS Pilani Campus, Pilani, Rajasthan, Pin code:
333031
2
Teaching Assistant at Birala Institute Of Technology And Science, Pilani, BITS Pilani Campus, Pilani, Rajasthan, Pin code:
333031

E-mail addresses: 2013024@pilani.bits-pilani.ac.in, 2013023@pilani.bits-pilani.ac.in

Abstract: The work deals with optimization of the process of production of ethylbenzene by liquid-phase benzene alkylation.
This process involves the reaction of benzene with ethylene to form ethylbenzene. Ethylene reacts with ethylbenzene to form
undesired product di-ethyl benzene, if the temperatures of reactor or concentrations of ethylene are high. Di-ethyl benzene reacts
with benzene to form ethylbenzene. Di-ethyl benzene is the highest-boiling component in the system; it comes out the bottom of
two distillation columns. The recycling benzene is more expensive. The economic optimum steady-state design is developed
that minimizes total annual cost. Thus it provides a classic example of an engineering design and optimization of a process. The
purpose of this project is to develop an optimum design for the ethylbenzene process considering reactor size, benzene recycled.

Keywords: ethylbenzene, 1,4-diethyl benzene, Aspen simulation, Optimization

1. Introduction:

Ethylbenzene is an organic compound with the formula C6H5CH2CH3. The aromatic hydrocarbon is important in the
petrochemical industry and as an intermediate in the production of styrene, which is used for making polystyrene, it is a
common plastic material. Also present in small amounts in crude oil, ethylbenzene is produced by combining benzene and
ethylene in an acid-catalysed chemical reaction.
It is used as a solvent for aluminium bromide in anhydrous electro deposition of aluminium. Ethylbenzene is an ingredient in
some paints and solvent grade xylene is nearly always contaminated with a few per cent of ethylbenzene.
2. Material and Methods:
In this process we used two reactors in series, two distillation columns and two liquid recycle streams. It is a nice example of a
multiunit complex process that is typical of many chemical plants found in industry.
The ethylbenzene process involves gaseous ethylene into the liquid phase of the first of two CSTR reactors in series. Both the
reactors operate at high pressure to maintain liquid in the reactor at high temperatures required for reasonable reaction rates. A
large liquid benzene stream is fed to the first reactor. The heat of exothermic reaction is removed by generating steam in this
reactor [1].
Effluent from first reactor is fed into second reactor along with recycle stream of Di-ethyl benzene. This reactor is adiabatic.
Effluent from second reactor is fed to a distillation column that produces a distillate that is mostly benzene, which is recycled to
first reactor along with fresh feed of make-up benzene. Bottom stream is a mixture of ethylbenzene and Di-ethyl benzene. It is
fed to a second distillation column that produces ethylbenzene distillate and Di-ethyl benzene bottoms, which is recycled back
to second reactor [2]
2.1 Aspen simulation and optimization
Process has been simulated in Aspen Plus and the results obtained are shown in the form of snapshots in figures below.
3. Results and Discussion
Simulation of the process flow diagram of ethylbenzene process has been done using Aspen Plus. After optimization it has been
found that the yield of ethylbenzene could only be increased by 0.8832%. The results are shown in the figure given below.

3.1 Figures and Tables

1
 Figure 1: Process flow chart of ethylbenzene production plant[4]

Figure 2: Aspen simulated flowchart of ethylbenzene production plant

2
 Figure 3: Reflux ratio plot for benzene column

Figure 4: Reflux ratio plot for ethylbenzene column

3
 Figure 5: Composition of all streams

Figure 6: Composition of all streams after optimization

4
 Figure 7:Summery of Benzene column

4. Conclusions:
By studying simulation of the process flow diagram of ethylbenzene production process using Aspen Plus it has been found that
the yield of ethylbenzene could only be increased by 0.1832% after optimization. It can be because of economic constrains as
well as the reaction conditions which can give maximum possible conversion which is 35 % in case of ethylbenzene production.

References
[1] Dimian A. C., Integrated Design and Simulation of Chemical Processes, Elsevier (2003).
[2] Douglas JM. Conceptual Design of Chemical Processes. New York: McGraw-Hill, (1988).
[3] Luyben W. L., Distillation Design and Control Using Aspen Simulation, Wiley, New York (2006).
[4] Luyben W. L., Design and control of the ethyl benzene process, Wiley, AIChE JournalVolume 57, Issue 3, pages 655–670,
(2010).

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