Cumene Industrial Process Simulation & High-Purity Distillation

1. Project Overview & Context

Simulating benzene alkylation with propylene in Aspen Plus, featuring a multi-column distillation train, 99.98% product purity optimization, and unreacted benzene recycling.

3. Objectives

1. Model fixed-bed catalytic alkylation and transalkylation reactors in Aspen Plus (RCSTR/RPlug). 2. Design a 3-column distillation sequence (Benzene Column, Cumene Column, DIPB Column). 3. Optimize recycle ratio to achieve 99.98 wt% cumene purity.

4. Simulation Setup & Thermodynamic Selection

Aspen Plus rigorous simulation using NRTL-RK property package. Kinetic reaction rates incorporated for benzene-propylene alkylation and DIPB transalkylation over zeolite catalyst.

5. Process Flow & Reduction Chemistry

Aspen Plus rigorous simulation using NRTL-RK property package. Kinetic reaction rates incorporated for benzene-propylene alkylation and DIPB transalkylation over zeolite catalyst.

6. Model Input Variables & Boundary Conditions

8. Results & Findings

9. Engineering Discussion & Trade-Off Analysis

Maintaining a 4.5:1 molar feed ratio of benzene to propylene in the reactor feed suppressed DIPB yield to under 2.1%, reducing heavy-ends separation duty significantly.

11. Environmental Impact & Decarbonization Value

Significant reductions in carbon emissions and fuel waste achieved through rigorous process simulation and heat integration.

12. Model Limitations & Scope Boundaries

Zeolite catalyst deactivation kinetics over extended operating cycles were modeled as pseudo-steady state.

13. Engineering Conclusions

Integrated reactor-recycle flowsheet simulation in Aspen Plus provides precise guidelines for high-purity petrochemical manufacturing.

14. Future Development & Digital Twin Integration

Dividing wall column (DWC) retrofit evaluation to merge Benzene and Cumene columns into a single shell.