80,000 MTPY Cyclohexane Plant, Part of Complete Caprolactum Plant (IPP Stock #600883)
The Cyclohexane Plant is part of a Caprolactam Facility which includes all intermediate and byproduct plants. The facility starts with benzene and finishes with caprolactam and ammonium sulfate byproduct:
• Cyclohexane Plant – 80,000 MTPY
• Cyclohexanone Plant – 55,000 MTPY
• Oximation Plant – 62,000 MTPY
• Caprolactam Plant – 60,000 MTPY
• Ammonium Sulfate – 108,000 MTPY
• Incinerator – 5 m3/hr liquid waste
Documentation is complete and well-organized. Much of it is electronic and has already been shared with IPP. The plant has been well-maintained and is still being kept up with a staff of four employees. There is a nitrogen pad on the process and they are turning the rotating equipment monthly. The 15.1 hectares of land can be purchased with the facility. There are abundant spare parts available with the facility.
The Cyclohexane Plant uses 73,000 MTPY of benzene to produce 80,000 MTPY of pure cyclohexane. It can also produce a small heptane byproduct and has a small effluent stream that is mostly water from the benzene drying column overheads. The plant was the last plant running when it shut down in August, 2013.
The incoming benzene is heated to 60°C by cross-exchanging with the benzene drying columns bottoms stream. The benzene is then dried in the drying column to less than 100 ppm water and pumped from the bottom of the column. The drying column has 20 sieve trays, a reboiler, and an overhead condenser system. The carbon steel column is 0.7 meters diameter by 12.5 meters tall and is rated for 2.6 bar at 115°C. There is an azeotropic mixture going overhead in the column at 15,000 ppm water. This stream is used for reflux in the drying column.
The dry benzene is now pumped up to high-pressure using two Sundyne pumps and is then heated with hot oil and evaporated at 130°C. The benzene is mixed with hydrogen which is compressed with a Demag compressor rated for 41.6 bar. The compressor is driven with a steam turbine.
The benzene/hydrogen mixture is then sent to the hydrogenation reactor which operates at 30 bar and 340°C with 0.3% platinum catalyst on aluminum oxide substrate. Hydrogen with purity as low as 74% can be used in this process. The carbon steel reactor is 1.8 meters diameter by 6.1 meters tall. It is rated for 34 bar at 315°C.
The hydrogenation reactor products then flow to the after-reactor which is filled with zinc oxide catalyst in the first bed and platinum catalyst on aluminum oxide substrate in the second bed. The after-reactor is 2.2 meters diameter by 5.2 meters tall. It is rated for 34 bar at 315°C. All catalysts have been removed from the reactors. The cyclohexane product is then cooled with a steam-generating boiler and some other cross-exchangers for energy efficiency. The carbon steel boiler is 2.4 meters diameter by 5.8 meters long and is rated for 21 bar at 226°C. The condensed product is sent to the heptane column where n-heptane and other high-boiling compounds are removed. Pure cyclohexane exits the top of the heptane column. The pure cyclohexane product is then condensed and pumped to storage. The heptane column has been removed because it was not necessary.
There are two incoming electrical feeders with automatic switching gear which is included in the plant sale. There are 13 transformers in the 1,000 to 2,000 kva range. The frequency for all electrical equipment in this facility is 60 Hz. There are three cooling tower cells with three Worthington cooling tower water pumps. The cooling tower is in poor condition, but the pumps are in good condition. There are four Trane chillers which appear to be about 300 tons of refrigeration capacity each. There is a 500 kW emergency generator driven with a diesel motor. There are two Centac instrument air compressors. The compressor is missing from one of the units. There are two diesel-driven fire water pumps capable of 18 bar discharge pressure. The flare is said to be 55 meters tall, but it appears to be much taller. There are about 17 major tanks in the tank farms. They are a mix of carbon steel and 304 stainless steel construction.
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