Technological Selection

The catalytic reforming technique, coal gas method, and dehydrogenation of ethylbenzene
method are the three primary industrial production technologies for toluene. All three
technologies are in-situ production; the precursor chemicals are synthesized on-site and then
directed into a processing facility where they are converted to toluene. The costs of equipment,
manufacturing, process efficiency, and production rate differ amongst processes and are used
to determine the type of technique to be utilised.

Catalytic reforming

As depicted schematically in Figure 1, hydro-treating is a technique that enhances the quality

of liquid hydrocarbon streams used in catalytic reforming by exposing them to high or low
hydrogen pressure conditions with the aid of a catalyst.

Figure 1

Toluene's main component is catalytic reformate, which accounts for around 94.5% of
production capacity feedstock and approximately 87% of domestic toluene manufacture. The
catalytic dehydrogenation of light straight run naphtha in the presence of hydrogen produces
an aromatic hydrocarbon mixture comprising toluene, xylene, and benzene, known as catalytic
reforming. Figure 2 depicts the catalytic reforming process. Light naphtha, which comprises
the three primary toluene synthesis products ethylcyclopentane, methylcyclohexane, and
dimethylcyclopentane, is hydro-treated prior to reforming to eliminate chemicals that might
function as catalyst poisons in the reforming process. The first step is to mix naphtha with
recycled hydrogen; the second step is to preheat the naphtha; in the third step, naphtha is heated
in a fired heater before being transferred to a series of catalyst-containing reactors in the fourth
step.

Figure 2

Hydrogen is recovered from the liquid reformate using a flash drum after the final reactor's
effluent has been cooled. While the reformate is sent to a stabiliser fractionator for further
processing, the hydrogen gas is compressed and returned to the reactors. To obtain a stable
reformate, the fractionator eliminates C4 and lighter hydrocarbons. The stabilised reformate is
fed into the toluene recovery process as a feedstock.

Coal gas

Coal gas is an alternative to the catalytic reforming approach in the synthesis of toluene.
Despite the fact that coal is no longer a substantial source of toluene, toluene may be recovered
from coal products. Carbon dioxide and volatile substances such as tar and water are formed
when coal is carbonised by heating in the absence of air in horizontal retort or coke oven.
Toluene is present in small amounts in both coal tar and coal gas, which may be separated using
extraction procedures. Typically, coal gas is cleaned with a coal tar or petroleum-derived oil.
The hydrocarbons entrained in coal gas are absorbed by these oils. The aromatics may then be
recovered as crude benzene by distilling the oil. Several innovative ways for producing toluene
from coal have been developed. Many of these innovative methods are derived from coal
liquification and are still in the early phases of development.

Dehydrogenation of ethylbenzene

The dehydrogenation methods used to make styrene from ethylbenzene yield toluene as a
byproduct. Trace amounts of toluene are created as a by-product of the isothermal styrene
synthesis process. Step 1 involves heating pure ethylbenzene in a heat exchanger, and the
resulting vapour is continually mixed with steam at 710°C in Step 2, which contains one of
several catalysts. A condenser condenses water and crude styrene vapours after the reaction
product exits the heat exchanger. Step 4 involves collecting and utilising the hydrogen-rich
process gas as fuel, while Step 5 involves cleaning the process water in a stripper and returning
it to the boiler. Step 6 involves the storage of the remaining crude liquid styrene in a tank.
Toluene, styrene, benzene, ethylbenzene and tars are the liquid's major ingredients. A
toluene/benzene column is used to separate benzene and toluene from crude styrene in Step 7.
Distillation is then used to separate them. Toluene is normally sold, while benzene is recycled
or sold in the region that generates ethylbenzene. At step 6, the crude styrene is separated from
an ethylbenzene, benzene and toluene stream and treated separately in different facilities.
 Process Setup
Criteria Weightage Catalytic Coal Gas Dehydrogenation
Reforming of Ethylene

Equipment Costs 20 3 2 2

Manufacturing Costs 25 3 2 1

Process Efficiency 15 3 2 1

Process Production Rate 15 3 2 1

Theoretical Yield 15 3 2 1

Scalability 10 3 1 1

Total 2.6 2.2 1.35

Rank 1 2 3

Based on the previously established criteria. It is obvious that the catalytic reforming technique
is the best way to produce toluene.
 HAZOP form for Reactor (CRV-100)

Figure 3: Reactor, CRV-100

Guide Word Deviation Causes Consequences Action

Less Reactor inlet Pipeline leakage of The unreacted reactant Pipeline stream
stream flow rate process fluid. ratio will be greater should be checked
is less than the reacted weekly or on a
reactant ratio, regular basis to
resulting in a poor ensure that it is in
conversion rate and a good working order.
low product yield.
More Liquid level in The output stream Overflow of the Installation of the
the reactor valve is reactor vessel, which liquid level indicator
vessel is too malfunctioning, might cause the in the reactor.
high. preventing the reactor to fail.
liquid product from
flowing into the
next machine or
equipment.
More of The reactor is Process fluid valve The vessel reactor Restoring normal
under extreme failure. exploded as a result of pressure by installing
pressure. excessive pressure. a pressure relief
valve.
Reverse or Backflow of The pressure in the No reaction occur. Installation of a
No, Not inlet stream of inlet reactor is high pump at the process
process fluid in comparison to fluid inlet stream to
the pressure in the ensure that the
process fluid in the reactor pressure is
pipeline's inlet always lower than
stream. the process fluid inlet
stream pressure.
Other than Unwanted The pipeline stream Product contamination Pipeline coating
material in the has corroded. leads to decreased using the proper
process fluid product quality. coating material to
flow reduce corrosion rate