Executive Summary This report illustrates the process of Propane Dehydrogenation (PDH). It is required to 400 KT/year of Propylene with purity of 99.5% and selectivity of Propylene not below 80%. In PDH process three main reactions are maintained and they are endothermic reactions. The main reaction is an equilibrium reaction of Propane to produce Propylene and Hydrogen. The side reactions are the reaction of Propane to produce Methane and Ethylene, and the reaction of Ethylene and Hydrogen to produce Ethane, where Platinum (Pt) is being used in PDH process as a catalyst. In chapter one (Literature Review), alternative processes of producing Propylene and major differences between them are listed such as Propane Dehydrogenation, Methanol to Olefins, and Olefin Metathesis. Furthermore, properties of each material are being listed in this chapter. Additionally, safety part and environment of the process has been mentioned and illustrated in this chapter such as operational safety, accidents response, and workers education. Finally, Bow-Tie diagrams of the toxicity, health risks, and flammability of the materials and National Fire Protection Association (NFPA) has been listed for each component. In chapter two (Mass and Energy Balance), mass and energy balance calculation has been applied to all equipment in the system. These calculations were done based on the law of conservation of mass and energy by applying allowable assumptions. In chapter three (Simulation), Aspen HYSYS V11 has been used to simulate the process of Propane Dehydrogenation (PDH). Process Flow Diagram (PFD) of PDH process has been mentioned in this chapter and detailed comparison between mass and energy balance calculations and Aspen HYSYS simulation has been listed with their percentage error difference for each equipment. Additionally, three case studies have been applied to reactors which are the effect of changing temperature of the reactors on selectivity and conversion, the effect of changing pressure of the reactors on selectivity and conversion, and the effect of changing volume of the reactors on selectivity and conversion. In chapter four (Equipment Design), detailed design of plug flow reactors (PFR), distillation columns, flash drum, heat exchangers, compressors, fired heaters, condensers, reboilers, and pippin have been shown in this chapter. It has been found that the volume of each reactor to be equal to 3.2072. Furthermore, Depropanizer has 24 stages, Deethanizer has 26 trays, and Propane/Propylene splitter has 145 trays. Finally, a plant layout of the PDH process has been listed at the end of this chapter. In chapter five (Economics and Heat Integration), economic analysis of PDH process has been done on many aspects including capital cost, total bare module cost, grassroot costs, water operation cost, waste treatment cost, operating labor cost, utility cost, raw material cost, and fixed capital cost. For heat integration part, heat integration has been applied to the system to find if there are possibilities of reducing utilities. In this part (βTmin) has been assumed to be 10 oC
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