Oligomer Production Plant Design
Designed and optimized an industrial oligomer production facility using Aspen Plus simulation, process controls, heat integration, and economic analysis.
Louisiana State University — Senior Capstone Design Project
Led the design and economic evaluation of a 45 kta oligomer production facility that converts propylene into higher-value hydrocarbon products through catalytic condensation and multi-stage separation processes. The project combined process simulation, equipment design, heat integration, process controls, and financial analysis to develop an economically optimized industrial-scale chemical plant.
Using Aspen Plus, our team developed a complete process flowsheet incorporating:
an adiabatic plug-flow reactor,
multiple distillation columns,
recycle systems,
heat exchangers,
and utility integration strategies.
The design emphasized maximizing production of high-value C9 oligomers while reducing utility consumption and improving overall plant profitability. Through iterative optimization of reactor pressure, recycle ratios, heat recovery, and equipment configuration, the project achieved a final estimated Net Present Value (NPV) of approximately $187 million with a projected internal rate of return exceeding 100%.
A major component of the project focused on process optimization and energy efficiency. Our team implemented cross-exchange heat recovery and steam generation strategies that reduced utility demand and improved process economics through internal energy integration.
The project also included process safety analysis and advanced control strategy development. We evaluated overpressure and flammability scenarios using hazard analysis methodologies and designed cascade and inferential control loops to maintain product quality, stabilize operation, and optimize separation efficiency within the distillation system.
Key Engineering Concepts
Aspen Plus process simulation
Distillation column design
Heat integration and utility optimization
Reactor design and recycle systems
Process controls and instrumentation
Pressure-corrected temperature control
Economic analysis (DCF, NPV, IRR)
Process safety and hazard mitigation
Industrial-scale process optimization
Tools & Methods
Aspen Plus
Economic modeling
Heat exchanger network analysis
Process control strategy development
Distillation and separation modeling
Hazard analysis and risk mitigation
Technical presentations and reporting
Key Outcomes
Designed a fully integrated oligomer production facility processing 45 kta of propylene feed
Increased process profitability through reactor optimization and recycle improvements
Reduced utility costs through heat integration and steam generation strategies
Developed advanced process control strategies to maintain product purity and operational stability
Presented technical, economic, and safety findings to engineering faculty and industry reviewers