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PROJECT REPORTS

CUMENE

PROJECT REPORT Submitted by ➢ Patel Rutvik

166450305543

➢ Patel Shreyas

166450305545

➢ Patel Tirth.

166450305546

➢ Prajapati Nikul.

166450305548

➢ Rajput Komal.

166450305550

➢ Savaliya Divyam.

166450305552

IN FULFILLMENT FOR THE AWARD OF THE DEGREE OF DIPLOMA IN CHEMICAL ENGINEERING.

SHREE KJ POLYTECHNIC, BHARUCH

CERTIFICATE

This is to certify that SAVALIYA DIVYAM B., PATEL TIRTH., PATEL SHREYAS., PATEL RUTVIK., PRAJAPATI NIKUL., RAJPUT KOMAL. of Diploma in chemical Engineering have successfully completed the Term-work in the Subject PROJECT (360501) offered during the academic term 2018-2019.

GUIDE.

HEAD OF DEPARTMENT.

PREFACE

•

Teaching is the important knowledge, but training develops habits. It assures that technical skills cannot be perfect without practical training. Hence, the practical training is grate valuable for engineering student the actual aim of in plant training is to get all operation and process which are carried out in the industries and more about the chemical equipment.

•

Practical makes a man perfect in practical training a person deals with many technical problems. In real operation and process another aim of I plant training is to learn industrial management and discipline.

•

This project describes the manufacture of “ISOPROPYL ALCOHOL” is prepared fulfillment in chemical engineering. It is purely academic in nature though attempts have been made to incorporate faculty data available from journals, books and other sources. Reasonable assumption have been made for data those were not available .

•

This report includes the information based on theoretical backgrounds. So this report cannot applicable to industrial scale to tally . but for actual setting up of a new chemical plant and expansion or revision of existing one requires the use of design report as a preliminary estimate.

•

The report provides preliminary information and gives an idea and in sign into the process design aspects.

•

The report also includes safety consideration, instrumentation, and process control. The reference section at the end lists the source of information. A detailed market surveys and plant set up design factor has to be studied before setting up a plant end. A number of pilot trials should be conducted before starting. No such trails were conducted

ACKNOWLEDGEMENT

We extend our sincere gratitude to our guide Shri K .J Panchal sir and Head of department in Chemical Engineering Prof. Shri. sir in SHREE KJ POLYTECHNIC, BHARUCH for sharing his knowledge and resources and also for his availability. We are also thankful to Shri K.J . Panchal sir our project group guider in Chemical Engineering Department. For extending his help in the course, we are also thanks to all the authors and editors of various reference books, research paper that helped us through his report.

Thanking you sir …..

INDEX Topic

SR.no

Page no. From.

1

Introduction

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8

Introduction Structural formula Market analysis List manufacturers of cumene Properties Uses & Application Raw materials Catalyst used

2

Manufacturing process with flow diagrams.

2.1 2.2 2.3 2.4

Various process of manufacturing Selection of most suitable process Detail description of selected process Process equipment flow diagrams

3

List major equipmen & instrumentation required

3.1 3.3

Equipment Instrumentation

4

Material balance

4.1 4.2

Material balance for various equipment Overall material balance

5

Plant design basis

5.1 5.2

Plant design Plant size

6

Plant location

6.1 6.2

Plant location & site selection Schematic plant layout

7

Economic evaluation

7.1

Capital cost estimation

To.

7.2

Estimation of capital investment costs

8

Important aspects of safety & Pollution control

8.1 8.2

Safety Pollution

9

MSDS of raw material and product

10

Conclusion

11

Preference

Chapter 1

INTRODUCTION

1.1 INTRODUCTION Cumene (isopropyl benzene) is an organic compound that is based on an aromatic hydrocarbon with an aliphatic substitution. It is a constituent of crude oil and refined fuels. It is a flammable colorless liquid that has a boiling point of 152 °C. Nearly all the cumene that is produced as a pure compound on an industrial scale is converted to cumene hydroperoxide, which is an intermediate in the synthesis of other industrially important chemicals, primarily phenol and acetone. •

The alkylation of benzene with propylene gives CUMENE a very important petrochemical C3 compound.

•

The cumene molecular have can be visualize as straight chain propylene group have benzene ring attached at the middle carbon form cumene (C6H5CH(CH3)2

•

The cumene production capacity of the world is about 7 million Ton/day distribute over 40 plant.

•

The catalyst for such a process is phosphoric acid supposed. Silica Kieselguhr(skpa).

•

Only few plants are based on the MONSANTO TECHNOLOGY, which uses aluminum trichloride (ALCL3) as catalyst .

•

Cumene producers account for approximately 20% of the global demand for benzene.

1.2 STRUCTURE

2 dimension structure of cumene.

3 dimension structure of cumene

1.3 PRESENT STATUS AND MARKET ANALYSIS. Essentially, all world cumene is consumed for the production of phenol and acetone. As a result, demand for cumene is strongly tied to the phenol market. Trade In cumene accounts for only 4% of world production. The largest exporter of cumene are the United States & Japan. Taiwan also import large volume of cumene for phenol production. As of early 2011, the U.S. cumene market was tight-primarily as a result of a shortage of feedstock propylene. Schedule plant maintenance by several large cumene manufacturer was also planned for early to mid 2011. Because of the cumene shortage, phenol and acetone plant operations rate have been reduced significantly, which in turn has restricted phenol export to Europe and higher demand region such as Asia & South America.

Increased demand for bisphenol A and phenolic resin will result in strong Demand for phenol, particularly in Asia (excluding Japan). As a result, consumption of cumene for phenol is forecast to grow at approximately 8% per year in the region China alone is expected to add a million metric ton of cumene capacity during stream in 2013) to supply its phenol/ acetone plants

that are slated to come on stream during that period. Overall, world wide cumene consumption for the production of phenol/acetone is forecast to grow at an average annual rate of about 4.5% during 2010–2015.

1.4 LIST PRODUCE OF CUMENE.

1.4.1. list cumene manufacturers in India SR. No 1

2

3

4

List of cumene manufacturing industry

Capacity

Herdillia chemicals Ltd.

2000 TPA

Air India building, 13thfloor,narimanpoint, Bombay400021(Maharashtra) Si group India ltd. Ballarpur road Opp. juinagar railway station Turbhethane, NaviMumbai(Maharashtra) Hindustan organic chemicals Industry, 81,Maharishi karvemarg, Harchandri house, Mumbai (400002) Global polychemllc. N-2, sector 11, Noida-201301, Uttar Pradesh.

1470 TPA

40000 TPA 10301 TPA

Table 1, list producer of cumene and capacity of cumen .

1.4.2 LIST GLOBAL MANUFACTURER 1

Hangzhou Tianlong Co., Ltd Zhejiang, China.

300000 TPA

2

A.M. FOOD chemical co., Ltd Shandong, China.

10000 TPA

3

TS CHEMICAL PVT. LTD Texas, American

20000 TPA

4

JLM CHEMICAL .PVT .LTD Blue Island, IL, USA

1120 TPQ

5

EniChem , ENI. CO.LTD. San Donato Milanese, Italy

1980 TPQ

Table 2, Global manufacturer of cumene and capacity of cumene

1.5 PROPERTIES

➢ PHYSICAL PROPERTIES OF CUMEN. •

Color

•

Odour.

:- odourless

•

Molecular weight.

:-

120.19

•

Purity

:-

99%

•

Melting point.

:-

-96.9°C

•

Boiling point.

:-

152.5°C

•

Density

:-

0.862 gm/cc

•

Flash point.

:-

39°C

•

Vapour pressure

:-

4.5 mmHg at 25°C

•

Ignition point.

:-

138°C

•

Freezing point

:-

-96°C

•

Thermal conductivity.

:-

0.124 w×m/k

•

Surface tension.

:-

0.791 N/M

•

Flammable limit in air. :-

:- colorless

lower – 0.9% volume,

:-. Higher – 6.5% volume •

Toxicity limit.

:-

200 PPM

•

Soluble

:-

Water, and more solvent.

•

Insoluble in.

:- Alcohol, Ether, Carbotetrachloride & etc.

➢ CHEMICAL PROPERTIES OF CUMENE

•

Cumene under goes oxidation to give cumene hydroperoxide by means of air or oxygen. ✓ C6H5CH(CH3)2 + O2 = C6H5(CH3)2COOH.

•

By catalytic actions of dilute sulphuric acid, cumene hydroperoxide is Split into phenol & acetone. ✓ C6H5(CH3)2COOH = C6H5OH + CH3COCH3

1.6 USES OF CUMENE

1. Cumene is a natural component of coal tar and crude oil, and also can be used as Blanding component in gasoline. 2. A building-block chemical, almost all cumene approximately 98% of cumene is consumed as a chemical intermediate in the production of phenol & acetone, two chemicals that are widely use plastic . 3. Additional, cumene I’m minor amounts is used as a solvent during the manufacturing of paints, lacquer & enamel. 4. Cumene is also used as a solvent for fats and raisins. 5. Cumene by itself is not generally sold by producers for consumers used

1.7 RAW MATERIALS USED. Raw materials for cumene manufacturing are; ➢ 1.Benzene ➢ 2.Propane ➢ 3.Propylene.

1.8

CATALYST USED. ➢ QZ-2000™

& ➢

QZ-2001™

2000catalyst is a solid, regenerable, zeolitecatalyst used to produce c umene (isopropylbenzene) via alkylation of benzene with QZ_2001 catalyst is based on a proprietary betazeolite formulation developed b y UOP

Chapter :- 2

Manufacturing Processes Of Cumene With Flow Diagrams.

2.1 Various process of manufacturing.

1) Q-max™ Manufacturing process. 2) CD -TECH manufacturing process. 3) Monsanto – Lummus Crest Cumene Process. 4) UOP cumene process .

5) Badger cumene process .

1) Q-MAX™ CUMENE manufacturing process flow diagram.

Fig.2 Q-MAX™ cumene manufacturing process.

2)CD-TECH CUMENE manufacturing process flow diagram.

Fig.3 CD-TECH CUMENE manufacturing process.

3) MONSANTO – LUMMUS crest cumene process.

Fig.4 MONSANTO LUMMUS cumene manufacturing process

4) UOP cumene manufacturing process .

Fig.5

UOP cumene manufacturing process.

5) Badger Cumene Manufacturing Process.

Fig.6 MOBILE BADGER cumene manufacturing process.

2.3 SELECTION OF CUMENE MANUFACTURING PROCESS

✓ Q-MAX ™ Manufacturing process is most convenient process for CUMENE manufacturing.

Justification of selection of cumene:o Product yield is 99.7 weight%. o High activity and selective with minimum by product formation. o Typical cumene productive yield is 95.5% pure. o Extremely tolerant to poison. o Proven run-length of up to 5 years. o Low catalyst cost . o Low in investments as compare to other process. o Reduce in solid waste. o Corrosion free environment.

2.4 Process description on Q-MAX ™ cumene manufacturing process.

1. Raw material propylene and benzene are used for the production of cumene. 2. These are stored in the respective storage tanks of 500MT capacity in the storage yard pumped to the unit by the centrifugal pumps. 3. Benzene pumped to the feed vessel which mixes with the recycled benzene. Benzene stream is pumped through the vaporizer with 25 atmospheric pressure and vaporized to the temperature of 243℃, mixed with the propylene which is of same and temperature and pressure of benzene stream. 4. This reactant mixture passed through a fired super heater where reaction temperature 350℃ is obtained. 5. The vapor mixture is sent to the reactor tube side which is packed with the solid phosphoric acid catalyst supported on the the exothermal heat is removed by the pressurized water which is used for steam production and the effluent from the reactor i.e. cumene, p-DIPB, unreacted benzene, propylene and propane with temperature 350℃ is used as the heating media in the vaporizer which used for the benzene vaporizing and cooled to 40℃ in a water cooler, propylene and propane are separated from the liquid mixture of cumene, p-DIPB, benzene in a separator operating slightly above atmospheric and the pressure is controlled by the vapor control value of the separator, the fuel gas is used as fuel for the furnace also. 6. The liquid mixture is sent to the benzene distillation column which operates at 1 atmospheric pressure, 98.1% of benzene is obtained as the distillate and used as recycle

and the bottom liquid mixture is pumped at bubble point to the cumene distillation column where distillate 99.9% cumene and bottom pure p-DIPB is obtained. 7. The heat of bottom product p-DIPB is used for preheating the benzene column feed, All the utility as cooling water, electricity, steam from the boiler, pneumatic air are supplied from the utility section. 8. The typical reactor effluent yield contains 94.8 Wt. % cumene and 3.1 Wt. % of diiso propyl benzene. The remaining 2.1 % is primarily heavy aromatics. 9. This high yield of cumene is achieved without of diiso propyl benzene and is unique to the solid phosphoric acid catalyst process. 10. The cumene product is 99.9 Wt. % pure and the heavy aromatics, which have an octane number of 109, can either be used as high octane gasoline blending components or combined with additional benzene and sent to a trans alkylation section of the plant where diiso propyl benzene is converted to cumene. 11. The overall yields of cumene for this process are typically 97-98 Wt. % with trans alkylation and 94-96 Wt. % without trans alkylation.

2.5 Manufacturing process description of Cumene.

A representative Q-Max flow diagram is shown. The alkylation reactor is typically divided into four catalyst beds contained in a single reactor shell. The fresh benzene is routed through the upper midsection of the depropanizer column to remove excess water and then sent to the alkylation reactor via a side draw. The recycle benzene to both the alkylation and trans alkylation reactors comes from the overhead of the benzene column. A mixture of fresh and recycle benzene is charged down flow through the alkylation reactor. The fresh propylene feed is split between the four catalyst beds. An excess of benzene is used to avoid polyalkylation and to help minimize olefin oligomerization. Because the reaction is exothermic, the temperature rise in the reactor is controlled by recycling a portion of the reactor effluent to the reactor inlet, which acts as a heat sink. In addition, the inlet temperature of each downstream bed is reduced to the same temperature as that of the first bed inlet by injecting a portion of cooled reactor effluent between the beds. Effluent from the alkylation reactor is sent to the depropanizer column, which removes any propane and water that may have entered with the propylene feed. The bottoms from the depropanizer column are sent to the benzene column, where excess benzene is collected overhead and recycled. Benzene column bottoms are sent to the cumene column, where the cumene product is recovered overhead. The Cumene column bottom which contains most d-isopropyl benzene is send to the DIPB stream leaves the column by way of a side cut and is recycled to the Tran alkylation reactor. The DIPB column bottom consist of heavy aromatic by-product, which are normally blended into fuel oil. Steam or hot oil provide the heat for the product, fractionation section.

A portion of the recycle benzene from the top of the benzene column is combined with the recycle DIPB from the side cut of the DIPB column and sent to the trans alkylation reactor. In the trans alkylation reactor, DIPB and benzene are converted to additional cumene. The effluent from the trans alkylation reactor is then sent to the benzene column. The QZ-2000 catalyst utilized in both the alkylation and trans alkylation reactors is regenerable. At the end of each cycle, the catalyst is typically regenerated ex-situ via a simple carbon burn by a certified regeneration contractor. However, the unit can also be designed for in-situ catalyst regeneration. Mild operating conditions and a corrosion-free process environment permit the use of carbon-steel construction and conventional process equipment.

2.4 PROCESS FLOW DIAGRAM WITH INSTRUMENTATION AND EQUIPMENT OF Q-MAX ™ PROCESS FOR CUMENE MANUFACTURING

Figure 7, PFD. of Cumene manufacturing process with all instrumentation and fittings with feed locations, heat exchanger, pumps, coolers etc.

Chapter:- 3

List major equipment and instrumentation required in manufacturing of Cumene

.

3.1 MAJOR EQUIPMENT

Major equipment required in Q-MAX ™ CUMENE MANUFACTURING are follow:1. Alkylation reactors. 2. Trans alkylation reactor 3. Depropanizer column. 4. Benzene column. 5. Cumen column. 6. DIPB column. Other general equipment used in cumene manufacturing process.

1.

Feed drum.

2. Feed pump. 3. Feed vaporizer. 4. Feed heater. 5. Effluent coolers. 6. Phase separator. 7.

Condenser.

8.

Reflux pump.

9. Reboiler. 10. Cumene Reflux drum.

1. Alkylation reactors. The alkylation reactor is typically divided into four catalyst beds contained in a single reactor shell. The fresh benzene is routed through the upper midsection of the depropanizer column to remove excess water and then sent to the alkylation reactor via a side draw. The recycle benzene to both the alkylation and trans alkylation reactors comes from the overhead of the benzene column.

A mixture of fresh and recycle benzene is charged down flow through the alkylation reactor. The fresh propylene feed is split between the four catalyst beds. An excess of benzene is used to avoid polyalkylation and to help minimize olefin oligomerization. Because the reaction is exothermic, the temperature rise in the reactor is controlled by recycling a portion of the reactor effluent to the reactor inlet, which acts as a heat sink. In addition, the inlet temperature of each downstream bed is reduced to the same temperature as that of the first bed inlet by injecting a portion of cooled reactor effluent between the beds. Effluent from the alkylation reactor is sent to the depropanizer column, which removes any propane and water that may have entered with the propylene feed.

2. Trans alkylation reactor. In the trans alkylation reactor, DIPB and benzene are converted to additional cumene. The effluent from the trans alkylation reactor is then sent to the benzene column. The QZ-2000 catalyst utilized in both the alkylation and trans alkylation reactors is regenerable. At the end of each cycle, the catalyst is typically regenerated ex-situ via a simple carbon burn by a certified regeneration contractor. However, the unit can also be designed for in-situ catalyst regeneration. Mild operating conditions and a corrosion-free process environment permit the use of carbonsteel construction and conventional process equipment.

3. Depropanizer Reactors. Depropanizer Reactors is reactors which removes propane, water, and other impurities present in the propylene feed. The depropanizer has a total condenser, partial reboiler, 20 equilibrium stages , and operates at 17 bar. The feed streams, a saturated liquid at 101.6°C, enter at stage 11 at a flow rate of 100Kmol/hr.

4. Benzene column. The bottoms from the depropanizer column are sent to the benzene column, where excess benzene is collected overhead and recycled. Benzene column bottoms are sent to the cumene column, where the cumene product is recovered overhead.

5. Cumene Column. Benzene column bottoms are sent to the cumene column, where the cumene product is recovered overhead. The Cumene column bottom which contains most d-isopropyl benzene is send to the DIPB stream leaves the column by way of a side cut and is recycled to the Tran alkylation reactor. The bottom liquid mixture is pumped at bubble point to the cumene distillation column where distillate 99.9% cumene and bottom pure p-DIPB is obtained.

6. DIPB COLUMN. The Cumene column bottom which contains most d-isopropyl benzene is send to the DIPB stream leaves the column by way of a side cut and is recycled to the Tran alkylation reactor. The DIPB column bottom consist of heavy aromatic by-product, which are normally blended into fuel oil. Steam or hot oil provide the heat for the product, fractionation section.

.

3.2 Instrumentation Required In Cumene Manufacturing Process. Major instrumentation required in cumene manufacturing process are:1. Pressure measuring instruments. ✓ Diaphragm pressure valve. ✓ Border tube pressure gauge 2. Flow measuring devices. •

Turbine flow metre.

•

Vortex flowmeters.

•

Coriolis flowmeter.

3. Temperature measuring devices. •

Electro pyrometer.

•

Helix bimetallic element thermometer.

4. Level measuring instrument. •

Radar level measuring transmitter.

•

Buoyancy level measurement device.

5. Valve control and regulations. 6. Ph measuring instruments. •

Ph meter.

•

Ph indicator.

Chapter :- 4

MATERIAL BALANCE

4.1 Overall Material Balance.

Reaction’s in the Alkylation Reactor: C3H6 + C6H6 = C6H5 - C3H7 (Cumene, IPB) C3H6 + C6H5-C3H7 = C3H7–C6H4C3H7(diisopropylbenzene;DIPB;C6H4[CH(CH3)2]) Reaction’s in the Trans-Alkylation Reactor: C3H7–C6H4-C3H7+C6H6 2(C6H5-C3H7) Conversion of Propylene in Alkylation reactor :%100 Reactor Conversion for Trans-Alkylation reactor :%50

Basis: Per hour of operation Amount of cumene to be obtained = 1 M ton of cumene per annum. =106/330 tons per day of cumene. = 106/(330 x 24) tons of cumene per hr. = 126.26 x 103 kg of cumene per hr. =(126.26 x 103)/120.19 kmoles of cumene per hr. = 1050.50 Kgmole/hr

Assuming 97% conversion and 2% loss. ∴ Cumene required = 1050.50/ .98 =1071.94 Kgmoles/hr = 128836.32 Kg/hr

Hence 128836.32 kg of cumene is required to be produced per hr. Propylene required =1071.94/.97 = 1105.09 Kgmole = 1105.09 x 42 Kg/hr of propylene = 46413.78 Kg/hr of propylene

Assuming benzene required is 25% extra = 1105.09 x 1.25 Kmoles of benzene = 1381.3625 Kgmole/hr = 107746.27 Kg/hr

Propane acts as an inert in the whole process . It is used for quenching purpose in the reactor. It does not take part in the chemical reaction . Also It is inevitably associated with the propylene as an impurity as their molecular weight is very close. We assume propylene to propane ratio as 3:1. Being an inert we are neglecting propane balance in the material balance to avoid complexity.

1.) Material balance around reactor :

Propylene = 46413.78 Kg/hr Benzene = 107746.27 Kg/hr

Products:

Alkylation

Type equation here. Cumene = 128836.32

Reactor

Kg/hr Propylene = 1105.09-1071.94

=33.15 Kmoles/hr is reacted to give DIPB

Benzene required to give DIPB = 33.15/2 kmoles/hr = 16.575 kmoles/hr DIPB produced= 16.575 x 162 = 2685.15 Kg/hr Benzene in product = 1381.3625 – 1071.94 -16.575 = 292.85 kmoles/hr = 22820.85 kg/hr Input = 46413.78 + 107746.27 = 154160.05 Kg/hr Output = 128836.32 + 2685.15 + 22820.85= 154342 Kg/hr Input = output

2) Depropanasing column Assuming almost all the propane is removed in depropanising column and sent to reactor for quenching. Hence material balance for depropanasing column is not considered.

3.) Distilation colume 1: (Benzene column)

Feed, F= Benzene + cumene + DIPB = 154160 Kg/hr XF= 22820.85/154160 = 0.1480

D = Benzene = 15969.41Kg/hr

Benzene Column

F=D+W 154160 = D +W F XF = DXD +WX w Taking XF = 0.9999 , XD = 0.05 154160 x 0.1480 = D x 0.9999 +W x 0.05 3023.5 =0.9999 D + (20374 – D) x 0.05

W= Cumene + DIPB = 138190 kJ/KG

D = 15969.41 Kg/hr = Benzene W = 154160 – 15969.41 = 138190.5 Kg/hr = cumene + DIPB Input = 154160 kg/hr Output = 15969.41 + 138190.5 = 154160 kg/hr Input = Output

Assuming all the Benzene present in benzene column is recycled to the feed . Hence considering negligible amount of benzene to be part of residue. This will avoid the complexity of multicomponent distillation in Cumene column. Therefore amount of benzene recycled

= 15969.5 Kg/hr.

Therefore feed actually given to the system = 154160 + 15969.5 = 170129.5 Kg/hr.

4.).Distilation column 3: (Cumene column)

F = Cumene + DIPB = 138190.5 Kg/hr XF = 128836.3/138190.5 = 0.932

Cumene = D = 17065.2Kg/hr

Cumene Column

F = D +W 138190.6 = D +W FXF = DXD + WXW Taking XD = 0.995 XW = 0.01 138190.5 x 0.932 = D x 0 .995 + W x 0.01 128793.54 = 0.995D + (138190.5 – D) 0.01 D = 129051 kg/hr W = 138190.5 – 129 = 9139.5 Kg/hr Input = 138190.5 Kg/hr Output = 129051 + 9139.5 = 138190.5 Kg/hr. Input = output

DIPB = W = 371.79Kg/hr = 2%.

Chapter: 5

Plant Design Basis

5.1 Design Basis. Capacity,(kmol/h),110 Alkylation reactor type catalytic distillation reactor Catalyst, Zeolite -Y Catalystregenerationfrequency,years2 Catalystlife,years6 Temperature,°C (top-bottom) 198-249 Pressure,bar14 B/P feed ratio, mole/mole1.64 Conversion,%: Propylene%100 Benzene%55 Trans alkylation reactor type: Single catalyst bed Catalyst Zeolite-Y Catalystlife,years6 Temperature,°C140-150 Benzene/DIPB feed ratio, mole/mole 5.2 ConversionofDIPB,%50 Overall yields, mol% Separations Units: •

Benzene column:

Type :Distillation column Purity of Top product :%100Benzene Purity of Bottom Product :%78.5Cumene

Operational Conditions :Tin:1030C Tbottom :1240C Ttop:45 Operational pressure:0.3bar •

Cumene column:

Type :Distillation column Purity of Top Product :%100Cumene Purity of Bottom Product :%100DIPB, Operational Conditions :Tin:1240C Tbottom:1720C Ttop:1100C Operational pressure :0.3

Chapter 6

Utility Required For Selected Process

6.1 Utilities. Utilities: The word utilities is not generally used for the ancillary services needed in the operation of any production process. These services will normally be supplied from a central site facility, and will include: (1) Electricity. (2) Steam for process heating. (3) Cooling water. (4) Water for general use. (5) Demineralised water. (6) Compressed air. (7) Inert gas supplies. (8) Refrigeration. (9) Effluent disposal facilities.

Electricity: .The power required for electrochemical processes, motor drives, lighting, and general use maybe generated on site, but will more usually be purchased from the local supply company. The voltage at which the supply is taken or generated will depend on the demand. For a large site the supply will be taken at a very high voltage, typically 11,000 or 33,000 V. Transformers will be used to step down the supply voltage to the voltages used on the site. In the United Kingdom a three phase 415V system is used for general industrial purposes, and 240V single phase for

lighting and other low power requirements. If a number of large motors is used, a supply at an intermediate high voltage will also be provided, typically 6000 or 11,000V.

Steam: The steam for heating is usually generated in water tube boilers using the most economical fuel level available. The process temperatures required can usually be obtained with low temperature steam typically 2.5 bar and steam distributed at a relatively low pressure, typically around 8 bar (100 psig). Higher steam pressures, or proprietary heat transfer fluids, such as dowtherm will be needed for high process temperatures.

Combined Heat and Power (Co-generation): The energy costs on a large site can be reduced if the electrical power required is generated on the site and the exhaust steam from the turbines used for process heating. The overall thermal efficiency of such systems can be in the range 70-80 %, compared with the 3040 % obtained from a conventional power station, where the heat in the exhaust steam is wasted in the condenser. Whether a combined heat and power system scheme is worth considering for a particular site will depend on the size of the site, the cost of fuel, the balance between the power and heating demands, and particularly on the availability of and cost of, stand by supplies and the price paid for any surplus power electricity generated.

Cooling Water:

Natural and forced draft cooling towers are generally used to provide the cooling water required in a site; unless water can be drawn from a convenient river or lake in sufficient quantity.

Water for General Use: The water required for general purposes on a site will usually be taken from the local mains supply, unless a cheaper source of suitable quantity water is available from a river, lake or well.

Demineralized Water: Demineralized water from which all the minerals have been removed by ion exchange, is used where pure water is needed for process use, and as boiler feed water. Mixed and multiple bed ion exchange units are used, one resin converting the cations to hydrogen and the other removing the acid radicals. Water with less than one ppm of dissolved solids can be produced.

Refrigeration: It will be needed for processes that require temperatures below those that can be economically obtained with cooling water. For temperatures down to around 10 o C chilled water can be used. For lower temperatures, down to -30oC, salt brines are used to distribute the “refrigeration” round the site from a central refrigeration machine.

Compressed Air:

It will be needed for general use, and for the pneumatic controllers that are usually used for chemical process plant control.

Inert Gases: Where large quantities of inert gas are required for the inert blanketing of tanks and for purging is usually supplied from a central facility. Nitrogen is normally used and is manufactured on site in an air liquefaction plant, or purchased as liquid in tankers.

Chapter: 6

Plant locations, Plant layout & site selection.

6.1 Plant

location and site selection:

The location of the plant can have a crucial effect on the profitability of a project and the scope for future expansion. Many factors must be considered when selecting a suitable site. The factors to be considered are: 1. Location with respect to the marketing area 2. Raw material supply. 3. Transport facilities. 4. Availability of labour. 5. Availability of utilities: water, fuel, power. 6. Availability of suitable land. 7. Environmental impact, and effluent disposal. 8. Local community considerations. 9. Climate. 10. Political and strategic considerations.

1. Marketing Area: For materials that are produced in bulk quantities such as cement, mineral acids and fertilizers where the cost of the product per ton is relatively low and the cost of transport a significant fraction of the sales price, the plant should be located close to the primary market. This consideration will be less important for low volume production, high-priced products, such as pharmaceuticals.

2. Raw Materials:

The availability and price of suitable raw materials will often determine the plant location. Plant producing bulk chemicals are best located close to the source of the major raw material: where this is also close to the marketing area.

3. Transport: The transport of materials & products to & from the plant will be an overriding consideration in site selection. If practicable, site should be selected that is close to at least two major forms of transport road, rail, waterway (canal or river) or a sea port. Road transport is being increasingly efficient for the movement of personnel &essential equipment & supplies & the proximity of the site airport should be considered.

4. Availability of labour: Labour will be needed for construction of the plant & its operation. Skilled construction workers will usually be brought in from outside the site area, but there should be an adequate pool of unskilled labour available locally ; & labour suitable for training to operate the plant. Skilled tradesmen will be needed for plant maintenance. Local trade union customs & restrictive practices will have to be considered when assessing the availability & suitability of the local labour for recruitment & training.

5. Utilities(Services) Chemical processes invariably require large quantities of water for cooling & general process use, & the plant must be located near a source of water of suitable quantity. Process water may be drawn from a river, from wells, or purchased from a local authority.

At some sites the cooling water required can be taken from a river or lake , or from the sea; at other locations cooling tower will be needed. Electrical power will be needed at all sites. Electrochemical processes that require large quantities of power; for example, aluminium smelters need to be located close to a cheap source of power. A competitive priced fuel must be available on site for steam & power generation.

6. Environment impact,& disposal: All industrial processes produce waste products & full consideration must be given to the difficulties & cost of their disposal. The disposal of toxic & harmful effluents will be coverd by local regulations & the appropriate authorities must be consulted during the initial site survey to determine the standards that must be met. An environmental impact assessment should be made for each new project or major modification or addition to an existing process.

7. Local community considerations: The proposed plant must fit in with & be acceptable to the local community. Full consideration must be given to the safe location of the plant so that it does not impose a significant additional risk to the community. On a new site, the local community must be able to provide adequate facilities for the plant personnel: school, banks, housing & recreational & cultural facilities

8. Land (site selection)

Sufficient suitable land must be available for the proposed plant & for future expansion. The land should ideally be flat, well drained & have suitable load bearing characteristics. A full site evaluation should be made to determine the need of piling or other special formations.

9. Climate: Adverse climate conditions at a site will increase cost. Abnormally low temperatures will require the provisition of additional insulation & special heating for equipment & pipe runs. Stronger structures will be needed at locations subject to high winds (cyclone hurricane areas) or earthquakes.

10. Political & Stratergic Considerations: Capital grants tax concessions & other inducements are often given by the government to direct renew investments to preferred locations, such as areas of high unemployment. The availability of such grants can be the overriding consideration in site selection.

6.2 plant layout The economic construction & efficient operation of a process unit will depend on how well he plant & equipment specified on the process flow-sheet is laid out. The principal factors to be considered are:

1. Economic consideration: construction & operating cost 2. The process requirements 3. Convenience of operation 4. Convenience of maintenance 5. Safety 6. Future expansion 7. Modular construction

1. Costs: The cost of construction can be minimized by adopting a layout that gives the shortest run of connecting pipe between equipment & the least amount of structural steel work. However this will not necessarily be the best arrangement for operation & maintenance. Process Requirements: An example of the need to take into account process considerations is the need to clevate the base of columns to provide the necessary net positive suction head to a pump or the operating head for a thermosyphon reboiler. 2. Process Requirements: Equipment that needs to have frequent operator attention should be located convenient to the control room. Valves, sample points, and instruments should be located at convenient positions and heights. Sufficient working space and head room must be provided to allow easy access to equipment. 3. Maintenance:

Heat exchangers need to be cited so that the tube bundles can be easily withdrawn for cleaning and tube replacement. Vessels that require frequent replacement of catalyst or packing should be located on the outside of buildings. Equipment that requires dismantling for maintenance, such as compressors and large pumps, should be placed under cover. 4. Safety: Blast walls maybe needed to isolate potentially hazardous equipment, and confine the effects of an explosion. At least two escape routes for operators must be provided from each level in the process buildings. 5. Plant Expansion: Equipments should be located so that it can be conveniently tied in with any future expansion of the process. Space should be left on pipe alleys for future needs, and services pipes over-sized to allow for future requirements. 6. Modular Constructions: In resent years there has been a move to assemble sections of plant at the plant manufacturers site. These modules will include the equipment, structural steel, piping and instrumentation. The modules are then transported to the plant site, by road or sea.

6.3 Plant layout.

Chapter:7

Economic Evaluation of Project.

7.1 Estimation of Total capital cost investments. The most important aspect of plant process design is the economics behind the plant’s construction and the future value. The initial year for the plant is 2013, and all prices and discounts will reference to 2013 dollars. All equations used in economic analysis are included in appendix C. The economics will be displayed in four categories: fixed capital investment, working capital investment, capital costs, depreciation, and discounted cash flow.

7.1.1 Fixed capital investment.