Beruflich Dokumente
Kultur Dokumente
SUBMITTED TO:
DR. JAGANNATHAN KRISHNAN
DECEMBER 2O14
ID NO
2013873332
2013280436
2013805264
2013659008
2013210046
2013895434
2013837186
2013467628
2013801798
DATE SUBMITTED:
18TH
CONTENT
1.0
INTRODUCTION...........................................................................................
.............. 1
1.1
Background
Literature.................................................................................. 1
1.2
History.................................................................................................
.......... 2
1.3
Property of
Formaldehyde......................................................................... 3-5
1.4
Applications.........................................................................................
...... 6-7
1.5
Selection of the production of
Formaldehyde.......................................... 8-9
1.6
Health and
Safety.................................................................................. 10-11
2.0
PROCESS
DESCRIPTION..........................................................................................
12
2.1
Process Flow
Diagram(PFD).......................................................................12-14
2.2
Process
Description................................................................................... 15
2.3
Stream
Summary.................................................................................. 16-19
3.0
EQUIPMENT
SIZING............................................................................................... 20
3.1
Pump...................................................................................................
...... 20-21
3.2
Absorber..............................................................................................
..... 21-22
3.3
Compressor.........................................................................................
..... 22-23
3.4
Distillation Column.............................................................................
23-24
3.5
Reactor................................................................................................
25-26
3.6
Heater E1................................................................................................ 26-27
3.7
Heater E2................................................................................................ 27-28
3.8
Cooler E4................................................................................................ 28
3.9
Cooler E-3...........................................................................................
28-30
4.0
ECONOMIC
ANALYSIS.......................................................................................... 31
4.1
Estimation of Capital.........................................................................
32-35
2
4.2
4.3
4.4
5.0
PINCH
ANALYSIS............................................................................................ 5159
6.0
ENVIRONMENTAL
CONSIDERATION................................................................. 60
6.1
Methanol.............................................................................................
... 61
6.2
Formalin..............................................................................................
61-64
7.0
PLANT
LAYOUT................................................................................................ 65
7.1
Plant Site
Suggested................................................................................ 67-70
7.2
Map of Site
Location............................................................................... 71-72
7.3
Site
Layout........................................................................................... 7375
7.4
Plant
Layout......................................................................................... 7678
SUMMARY&
CONCLUSION.............................................................................. 79-80
8.0
1.0
INTRODUCTION
1.1
Background Literature
Methanol,
CH 3 OH
most important chemical raw materials. 85% of the methanol produced is used in the
chemical industry as a starting material or solvent for synthesis. The by-product is
used in the fuel and energy sector and increasing throughout the years. Worldwide
production capacity in 1989 was around
21 10
22.4 10
keeps mounting in 2011, which was the consumption of pure methanol reached
almost
Methanol
CH 3 OH
1.2
History
Ancient Egyptians used a mixture of substances that included methanol in
their embalming process. They obtained the methanol from pyrolysis of wood.
Pyrolysis is the chemical decomposition of condensed organic substances by
heating. However, pure methanol wasnt isolated until 1661 by Robert Boyle, who
produced the chemical through the distillation of boxwood. The chemical later
became known as pyroxylic spirit. The French chemists Jean-Baptiste Dumas and
Eugene Peligot determined its elemental composition in 1834.
4
The term methyl was derived from the word methylene, which was coined
by Dumas and Peligot in 1840. It was then applied to describe methyl alcohol. The
International Conference on Chemical Nomenclature shortened this to methanol in
1892. When German chemists Alwin Mittasch and Mathias Pier developed a means
to convert synthesis gas into methanol, a patent was filed on Jan. 12, 1926. In 2006
astronomers at Jodrell Bank Observatory using the Merlin array of radio telescopes,
discovered a large cloud of methanol in space, 300 billion miles across.
Formaldehyde is the simplest aldehyde with the chemical formula HCHO.
Since its accidental production by Alexander Mikhailovich Butlerov in 1859 and
subsequent discovery by A. W. Hofmann in 1868, formaldehyde has become a major
industrial product. Hofmann passed a mixture of methanol and air over a heated
platinum spiral and then identified formaldehyde as the product. This method lead to
the major way in which formaldehyde is manufactured today, the oxidation of
methanol with air using a metal catalyst.
Formaldehyde is normally found in pressed wood products such as particle
board, plywood, panelling and fibreboard, glues and adhesives, durable press fabrics
like drapes, furniture, cabinets and building materials made from particleboard,
medium density fibreboard and certain moulded plastics. Products containing
formaldehyde also "off-gas" which means the formaldehyde will evaporate into the air
slowly at a low rate. Products that pose this risk including some latex paints,
wallpapers, cardboard and paper products, dishwashing liquids, fabric softeners,
shoe-care agents, carpet cleaners, lacquers and some cosmetics, such as nail polish
and nail hardener. Formaldehyde is widely produced around the world for use as a
disinfectant and preservative. It is also used in textile finishing and in the production
of resins that act as adhesives and binders for wood products.
1.3
Properties of Formaldehyde
1.3.1
Chemical Properties
1.3.2
Physical Properties
The chemical formula for formaldehyde is CH2O and the molecular weight is 30.03 g/mol.
The vapour pressure for formaldehyde is 10 mm Hg at -88 EC, and its log octanol/water
partition coefficient (Log Kow) is -0.65. Formaldehyde is a colourless gas with a pungent,
suffocating odour at room temperature; the odour threshold for formaldehyde is 0.83 ppm.
Formaldehyde is readily soluble in water at room temperature. Commercial formaldehyde is
produced and sold as an aqueous solution containing 37 to 50 percent formaldehyde by
weight.
1.4
Applications
8
derivatives,
including
pentaerythritol,
hexamethylenetetramine,
and
butanediol. Two percent is used in textile treating and small amounts of formaldehyde
are present as preservatives or bactericides in consumer and industrial products,
such as cosmetics, shampoos and glues.
Some products prepared from formaldehyde contain unreacted formaldehyde
residues which may be released from the product over its useful life. One example is
urea-formaldehyde resin. Urea-formaldehyde resin is a generic name that actually
represents an entire class of related formulations. Over 60 percent of ureaformaldehyde resin production in 1977 was consumed by particleboard and plywood
manufacturing, where the resin is used as a glue. Urea-formaldehyde resins are also
used in decorative laminates, textiles, paper, and foundry sand moulds.
Formaldehyde resins are used to treat textiles to impart wrinkle-resistance to
clothing. About 60-85 percent of all apparel fabric is finished with formaldehydecontaining resins. As apparel manufacture is the sixth largest industry sector in the
United States, this use is the major source of widespread exposure to formaldehyde
because of the large number of workers potentially exposed. In addition, the natural
gas and petroleum industries use formaldehyde-based resins in drilling operations, to
increase oil and gas well yield and to improve service life. Formaldehyde-based
glues help paint to adhere to surfaces, and veneer and paper overlays to adhere to
particleboard.
Formaldehyde destroys bacteria, fungi, moulds, and yeast. Its commercial
importance as a fungicide is probably its greatest use as a disinfectant. Because of
its bactericidal properties, formaldehyde is used in numerous cosmetic preparations.
Formaldehyde's uses can lead to widespread exposure in downstream
industries.
For
example,
when
formaldehyde
is
present
in
disinfectants,
10
1.5
Criterions
Old
Oxidation of
Formalin
Tail
traditional
hydrocarbo
production
Circulation
method
-
n gases
-
unit 800
+
Method
0
Consumption of energy
-2
-1
Low
inhibitor
distillation
Total score
Rank
in
bottom
column
of
gas
11
Criterions
(2).
Oxidation
of
hydrocarbon gases.
Quality
of
product
and
bottom
Total score
13
15
Rank of scoring
(formaldehyde)
Consumption of energy
Catalyst
used
effectiveness
Low inhibitor
in
column of distillation
1.6
12
Nausea
Watery and/or burning eyes
Difficulty breathing
Headaches
Respiratory irritation
Sensitization
Formaldehyde has been shown to cause cancer in animals and according to
the Department of Health and Human Services (DHHS), formaldehyde may
reasonably be anticipated to be a carcinogen. Formaldehyde must be stored in a
moderately warm place. It is classified as C1 (Combustible Liquid) for the purpose of
storage and handling. This substance must be kept away from sources of heat or
ignition, strong alkalis, acids, combustibles and oxidizing agents.
Figure 4: Safety Information of Formaldehyde
14
2.0
Process Description
Unit 800 produces formalin (37wt% formaldehyde in water) from methanol using the silver catalyst process. Air is compressed and preheated,
fresh and recycled methanol is pumped and preheated, and these two streams are mixed to provide reactor feed. The feed mixture is about 39 mol
% methanol in air, which is higher than the upper flammability limit for methanol. In the reactor, the following two reactions occur:
CH3OH + 1/2O2
CH3OH
HCHO + H2O
H rxn=37.3 kcal/mole
HCHO + H2
H rxn=20.3 kcal/mole
The reactor is a unique configuration, in which the silver catalyst is in the form of wire gauze, suspended above a heat exchanger tube bank.
Because the net reaction is very exothermic, the heat generated in the adiabatic reactor section must be removed quickly, hence the close
proximity of the heat-exchanger tubes. The heat exchanger resembles a pool boiler, with a pool of water on the shell side. If the temperature of the
effluent is too high, the set point on the steam pressure line is lowered to increase the vaporization of boiler feed water (bfw). In general, the liquidlevel controller on the bfw is adjusted to keep the tube bundle fully immersed. The reactor effluent enters an absorber in which most of the
methanol and formaldehyde are absorbed into water, with most of the remaining light gases purged into the off-gas stream. The methanol,
formaldehyde, and water enter a distillation column, in which the methanol overhead is recycled; the bottoms product is a formaldehyde/water
mixture that contains 1 wt% methanol as an inhibitor. This mixture is cooled and sent to a storage tank, which is sized at four days capacity. This
storage tank is essential, because some of the downstream processes are batch. The composition in the storage tank exceeds 37wt%
15
formaldehyde, so the appropriate amount of water is added when the downstream process draws from the storage tank. This is not shown in the
PFD (Figure 5a).
Storage of formaldehyde/water mixtures is tricky. At high temperatures, undesirable polymerization of formaldehyde is inhibited, but formic
acid formation is favored. At low temperatures, acid formation is inhibited, but polymerization is favored. There are stabilizers that inhibit
polymerization, but they are incompatible with resin formation. Methanol, at concentrations between 5 wt% and 15 wt%, can also inhibit
polymerizaton, but no separation equipment for methanol currently exists on site, and methanol greater than 1 wt% also causes defective resin
production. With 1 wt% methanol, the storage tank contents must be maintained between 35C and 45C..
16
17
2.2
Process Description
The PFD shows a process to produce formaldehyde and water. Fresh methanol, at
30C and 120kPa mixes with recycled methanol, Stream 14, at 30C and 120kPa. Stream 1
(recycled and fresh methanol) is at 30C and 120kPa. Pump raises the pressure up to
300kPa. Stream 2 enters the heater which increases the temperature and pressure at 150C
and 265kPa respectively. Fresh air at 25C and 101.3kPa enter the compressor.
The
compressor raises the pressure to 300kPa in Stream 4. This stream was then passed
through a heater which raised the temperature to 200C in Stream 5. Stream 5 and Stream 3
were then entering the mixer. The combined mixture is at 171.9C and 255kPa in Stream 6.
The reactor converts 85% of the methanol. The exit reactor temperature is 200C
and 185 kPa. Heat is removed by Stream 7 passing through E-3 cooler which cools the
temperature into 100C at Stream 8 with a drop of pressure which is at 150 kPa. A valve
drops the pressure of this stream to 5 psia before it enters the absorber, T-101. Fresh water
is sent through the absorber at 30C and 150 kPa. Absorber is set to absorb 99% of the
formaldehyde that enters. Stream 9 then enters the formalin distillation column.
recycled back to the inlet of fresh methanol at 30C and 120 kPa. The bottoms, Stream 12 is
at temperature of 106.4C with the pressure of 150 kPa. Storage of formalin is tricky. At high
temperatures, undesirable polymerization of formaldehyde is inhibited, but formic acid
formation is favoured. At low temperatures, acid formation is inhibited, but polymerization is
favoured. With 2 wt% methanol, the storage tank contents must be maintained between
35C and 45C.
18
2.3
Stream Summary
Name
mixer3.Out
pump.Out
E-2.Out
compressor.Out
pump.In
E-2.In
Mixer1.In1
E-1.In
Description
Upstream Op
Downstream Op
VapFrac
0.00
0.00
1.00
1.00
T [C]
30.0
40.8
150.0
183.0
120.00
300.00
265.00
300.00
P [kPa]
MoleFlow/Composition
Fraction
kgmole/h
Fraction
kgmole/h
Fraction
kgmole/h
Fraction
kgmole/h
METHANOL
1.0000
80.00
1.0000
80.00
1.0000
80.00
0.0000
0.00
OXYGEN
0.0000
0.00
0.0000
0.00
0.0000
0.00
0.21009
30.66
FORMALDEHYDE
0.0000
0.00
0.0000
0.00
0.0000
0.00
0.0000
0.00
WATER
0.0000
0.00
0.0000
0.00
0.0000
0.00
0.0000
0.00
HYDROGEN
0.0000
0.00
0.0000
0.00
0.0000
0.00
0.0000
0.00
NITROGEN
0.0000
0.00
0.0000
0.00
0.0000
0.00
0.78991
115.28
1.00
80.00
1.00
80.00
1.00
80.00
1.00
145.94
Total
Mass Flow [kg/h]
2563.35
2563.35
2563.35
4210.48
3.275
3.318
1062.108
1844.978
3.221
3.221
3.221
12.348
4.5485E+4
4.5485E+4
4.5485E+4
8.2977E+4
Energy [W]
-6.209E+5
-5.914E+5
3.901E+5
5.405E+5
H [kJ/kmol]
-27939.0
-26614.0
17552.9
13332.8
67.344
76.002
206.302
174.598
32.04
32.04
32.04
28.85
782.6941
772.6670
2.4135
2.2821
S [kJ/kmol-K]
MW
Mass Density [kg/m3]
19
Cp [kJ/kmol-K]
Thermal Conductivity [W/m-K]
Viscosity [Pa-s]
Molar Volume [m3/kmol]
Z Factor
121.168
124.240
53.538
29.787
0.2007
0.1970
0.0288
0.0360
5.0500E-4
4.4242E-4
1.3999E-5
2.4694E-5
0.041
0.041
13.276
12.642
0.0019
0.0048
1.0000
1.0000
Name
E-1.Out
Mixer1.Out
reactor.Out
E-3.Out
Downstream Op
Mixer1.In0
reactor.In
E-3.In
absorber.Feed_19_bottomFeed
VapFrac
1.00
1.00
1.00
1.00
200.0
171.9
200.0
100.0
265.00
255.00
185.00
150.00
Description
Upstream Op
T [C]
P [kPa]
MoleFlow/Composition
METHANOL
Fraction
kgmole/h
Fraction
kgmole/h
Fraction
kgmole/h
Fraction
kgmole/h
0.0000
0.00
0.35408
80.00
0.04512
12.00
0.04512
12.00
0.21009
30.66
0.1357
30.66
0.0100
2.66
0.0100
2.66
FORMALDEHYDE
0.0000
0.00
0.0000
0.00
0.2557
68.00
0.2557
68.00
WATER
0.0000
0.00
0.0000
0.00
0.21057
56.00
0.21057
56.00
HYDROGEN
0.0000
0.00
0.0000
0.00
0.04512
12.00
0.04512
12.00
NITROGEN
0.78991
115.28
0.51022
115.28
0.43348
115.28
0.43348
115.28
1.00
145.94
1.00
225.94
1.00
265.94
1.00
265.94
OXYGEN
Total
Mass Flow [kg/h]
4210.48
6773.83
6773.83
6773.83
2166.495
3301.453
5655.112
5500.552
12.348
15.570
15.279
15.279
8.2977E+4
1.2846E+5
1.512E+5
1.512E+5
Energy [W]
5.611E+5
9.511E+5
1.131E+6
8.768E+5
H [kJ/kmol]
13839.9
15154.6
15306.4
11868.9
20
S [kJ/kmol-K]
176.721
192.978
201.114
194.704
28.85
29.98
25.47
25.47
1.9435
2.0518
1.1978
1.2315
Cp [kJ/kmol-K]
29.871
38.773
35.231
33.560
0.0371
0.0329
0.0382
0.0295
2.5371E-5
2.0114E-5
1.9595E-5
1.5795E-5
14.845
14.612
21.265
20.683
Z Factor
1.0000
1.0000
1.0000
1.0000
MW
Viscosity [Pa-s]
Name
10
11
Upstream Op
absorber.LiquidDraw_19_bottomL
Distillation_column.VapourDraw_0_condenserV
Downstream Op
Distillation_column.Feed_17_feed
mixer2.In1
mixer2.In0
Description
Distillation_column.LiquidDraw_0_con
L
VapFrac
0.00
1.00
0.00
T [C]
89.9
96.0
96.0
150.00
130.00
130.00
P [kPa]
MoleFlow/Composition
METHANOL
Fraction
kgmole/h
Fraction
kgmole/h
Fraction
kgmole/h
0.04809
9.51
0.08429
1.46
0.08554
OXYGEN
0.0000
0.00
0.00001
0.00
0.0000
FORMALDEHYDE
0.3402
67.28
0.65246
11.26
0.45573
WATER
0.61167
120.97
0.26284
4.54
0.45873
HYDROGEN
0.00001
0.00
0.00011
0.00
0.0000
NITROGEN
0.00002
0.00
0.00028
0.00
0.0000
1.00
197.77
1.00
17.27
1.00
Total
Mass Flow [kg/h]
4504.31
466.77
745.56
6.063
407.604
1.108
5.243
0.589
0.902
1.1244E+5
9.8163E+3
1.717E+4
Energy [W]
-1.102E+6
6.119E+4
-1.292E+5
21
H [kJ/kmol]
-20057.5
12759.8
-15404.5
115.225
205.561
131.624
22.78
27.04
24.69
742.8699
1.1451
673.0442
107.931
38.135
129.112
S [kJ/kmol-K]
MW
Mass Density [kg/m3]
Cp [kJ/kmol-K]
Thermal Conductivity [W/m-K]
Viscosity [Pa-s]
0.2827
0.0226
0.2096
2.1966E-4
1.2334E-5
1.7283E-4
0.031
0.0015
23.609
1.0000
0.037
0.0016
Name
13
14
Off-gas
air
mixer2.Out
E-4.Out
absorber.VapourDraw_0_overheadV
E-4.In
mixer3.In1
Description
Upstream Op
Downstream Op
VapFrac
T [C]
P [kPa]
MoleFlow/Composition
METHANOL
compressor.In
0.36374
0.00001
1.00
1.00
96.0
30.0
84.6
25.0
130.00
120.00
140.00
101.30
Fraction
kgmole/h
Fraction
kgmole/h
Fraction
kgmole/h
Fraction
kgmole/h
0.08509
4.04
0.08509
4.04
0.01179
2.49
0.0000
0.00
0.0000
0.00
0.0000
0.00
0.0126
2.66
0.21009
30.66
FORMALDEHYDE
0.52729
25.03
0.52729
25.03
0.00341
0.72
0.0000
0.00
WATER
0.38748
18.39
0.38748
18.39
0.36952
78.03
0.0000
0.00
HYDROGEN
0.00004
0.00
0.00004
0.00
0.05682
12.00
0.0000
0.00
NITROGEN
0.0001
0.00
0.0001
0.00
0.54588
115.28
0.78991
115.28
1.00
47.46
1.00
47.46
1.00
211.17
1.00
145.94
OXYGEN
Total
Mass Flow [kg/h]
1212.33
1212.33
4845.70
4210.48
408.701
1.545
4481.601
3571.331
1.491
1.491
12.615
12.348
2.6986E+4
2.6986E+4
1.2007E+5
8.2977E+4
Energy [W]
-6.803E+4
-2.742E+5
6.450E+5
3.519E+5
H [kJ/kmol]
-5159.7
-20797.0
10996.4
8679.3
S [kJ/kmol-K]
158.519
98.072
186.396
171.110
25.54
25.54
22.95
28.85
2.9663
784.9130
1.0812
1.1790
Cp [kJ/kmol-K]
96.021
95.849
31.247
29.178
0.1376
0.2351
0.0323
0.0250
7.9774E-5
2.6044E-4
1.6451E-5
1.8110E-5
8.611
0.033
21.222
24.471
0.3647
0.0015
1.0000
1.0000
MW
Viscosity [Pa-s]
Molar Volume [m3/kmol]
Z Factor
3.0
EQUIPMENT SIZING
This chapter covers the equipment design and sizing of the formaldehyde production plant.
The main units to be design are the reactor, absorber, distillation column, cooler and
heater(E-1,E-2,E-3,E-4), pump and the compressor. The reactor design cover mainly the
volume of the reactor. The absorber design is concerned with determining the height and
diameter of the packed tower. The design of the distillation column covered the minimum
and actual number of stages, the diameter and the height of the column. The coolers and
heaters design covered the determination of area of the equipment with respect to process
conditions. Lastly, the compressor and the pump were designed by determining the work of
the shaft according to the pressure drop across the unit.
PUMP
From Heuristic for Pump (Table 11.9) R.Turton, 2014, pg.330
Density of fluid =
= 772.5588 kg/m3
head =
= 23.7505 mm
23
Volumetric flowrate
= 2563.35
= 0.0553 m3/min
Fluid pumping = 1.67 0.0553 m3/min 1.8 bar
= 0.166 kW
Power shaft =
= 0.2 kW
ABSORBER
From Summary Table,
Liquid mass flow,L(Stream 9)
= 4504.31 kg/h
= 742.8699 kg/m3
= 1.0812 kg/m3
= 0.0355
From equipment summary(Appendix B),
2 in Ceramic Berl Saddle
Packing factor 45, 1.00 kPa/m pressure drop
Parameter at flooding = 0.2
G = 0.555 lb/ft2.s
24
Area =
= 5.3356 ft2
A = 5.3356 ft2 =
D = 2.6064 ft = 0.7944 m
Volume
= Area Length
5.3356 ft 2
0.0929m 2
1ft 2
10m
= 4.96 m3
COMPRESSOR
From Heuristic for Pump (Table 11.10) R.Turton, 2014, pg.331
Rule 2 :
From Summary Table,
Mass flow(stream 4) = 4210.48 kg/h
MW = 28.85
T = 25C (298K)
Cp = 29.787
k=
Cv = 20.7865
a = (k-1)/k
= 1.433
= 0.3024
25
Mass flow =
= 40.54
Wrev ad =
= 129.494 kW
Given that = 0.7
Wact =
DISTILLATION COLUMN
From Summary table,
L = 695.77 kg/m3
L = 27 000 kg/h
G = 1.2315 kg/m3
G = 23 000 kg/h
= 0.0447
For 18 inch tray spacing (P.Wankat, Equilibrium Staged Separations, Prentice Hall,1988, pg
387)
Csb = 0.28
A=
5.07 m2 =
d = 2.54m
26
; Length = 19m
= 5.07m2 x 19m
= 96.33m3
In order to determine the number of stages, Fenske equation are used as shown below:
xoverhead = 0.65426
top = 2.203
xbottom = 0.28112
bottom = 0.5335
avg =
= 1.17528
Nmin =
=
= 9.7134878
Ntheo = 2Nmin
= 2(9.7134878)
= 19.426976
tray = 0.7
Nact = (
x1.1)
= 30.5281 trays
REACTOR
Component
Molecular Weight
Density (kg/m3)
Methanol
32.04
791.80
Formaldehyde
30.03
815.30
Water
18.02
999.97
Hydrogen
2.008
0.089
O2 (air)
50
0.69402
N2 (air)
From Appendix B
Component
Molar Flow
Composition
Mass flow
(kg/h)
Volume
flow
(m3/h)
CH3OH
31.45
0.11312
829.2601
1.047310
CH2O
62.67
0.2254
1652.3623
2.026692
H2O
66.82
0.24033
1761.8112
1.761864
H2
1.66
0.0059706
43.76927
491.78955
Oxygen
0.15
0.0005395
3.95497
27.13638
N2
115.28
0.41463
3039.5696
5543.8697
278.03
7330.8
6067.6315
Volume = 140.44m3
=
= 9.2583x10-3 h-1
From stream summary
28
9.2583x10-3 =
V = 130.8919 m3
given H = 2D
130.8919 =
D = 4.3678 m
H = 8.7356m
Vmax =
=
= 174.21648 m2
E-1 HEATER
Q = 20556.7896 W
Assume F = 0.9 U = 30W/m2.oC
Th,in = 336oC Th,out = 383oC
Tlm =
=
= 165.9482 oC
29
Q = UAFTlm
)(0.9)(165.9542 oC)
20556.7896 = (
A = 4.58795m2
A=
V
D = 2.43m
= Area Length
Assume L = 2D
= 4.62m2 2(2.43m)
= 22.54m2
Vmax
= 29.99m3
E-2 HEATER
Q = 981487.8304 W
Assume F = 0.9 U = 30W/m2.oC
Th,in = 296oC Th,out = 90oC
Tlm =
= 88.994 oC
981487.8304 = (30)(A)(0.9)(88.994 oC)
A = 408.4702m2
E-4 COOLER
Q = 206.16826 kW
U = 280 W/m2 oC
F = 0.9
Tw,in = 30 oC Tw,out = 45 oC
Tin = 96 oC
Tout = 30.1 oC
Tlm =
= 8.1644 oC
Q = FUATlm
Q = (280) A (0.9)(8.1644)
A = 100.2 m2
D= 11.30m
V=2266.5m3
Vmax=302538.43m3
E-3 COOLER
Q = 253939.854 W
U = 30 W/m2 oC
F = 0.9
Tw,in = 30 oC Tw,out = 400oC
Tin = 200 oC
Tout = 100 oC
31
Tlm =
= 108.8694 oC
Q = FUATlm
253939.854= (0.9)(30)A(108.8694)
A= 86.3896 m2
D= 10.49m
V= 1813.203m3
From Heuristic
Appendix
Error(%)
Pump
0.2 kW
0.3 kW
33.3
Absorber
0.7944 m
0.86 m
7.7
Compressor
184.99 kW
183 kW
1.09
Cooler E-4
100.2 m2
Cooler E-3
86.3896 m2
28.16 m2
67.4
Heater E-1
4.58795 m2
4.62 m2
0.694
Heater E-2
408.4702 m2
405 m2
0.8568
Distillation Column
D= 2.54 m
D= 2.5 m
1.6
Number of tray= 31
Number of tray= 31
130.8919 m3
140.44 m3
6.8
Reactor
4.0
ECONOMIC ANALYSIS
This economic terms is refer to the evaluation of capital costs and others operating
costs that associated with the construction and operation of chemical process. The
economic evaluation for build a new plant can be divided into four sections which are:
4.1)
4.2)
4.3)
Engineering Economic Analysis (non-discounted cash flow and discounted cash flow)
4.4)
Profitability Analysis
33
Cp ($)
Fp
FM
FBM
FBM
CBM($)
CBM ($)
96,284.46
4.00
4.00
385,137.84
385,137.84
- Tower
7,258.051
0.61
4.07
3.36
29,540.27
24,540.27
- Packing
7,262.987
4.10
4.10
29,778.25
29,778.25
64,501.511
0.61
4.07
6.45
262,521.15
416,031.70
3,208.63
1.83
1.83
182,025.50
182,025.50
Compressor
70,154.33
2.70
2.70
189,416.69
189,416.69
Pump
2,672.24
1.57
4.00
4.00
10,714.35
10,714.35
- E-1
25,535.10
3.29
3.29
84,010.48
84,010.48
- E-2
60,492.29
3.29
3.29
199,019.62
199,019.62
- Reboiler
41,895.06
2.78
3.29
6.24
137,834.75
261,626.21
- E-3
23,877.44
3.29
3.29
78,556.78
78,556.78
- E-4
25,351.66
3.29
3.29
83,406.96
83,406.96
- Condenser
44,033.22
2.78
3.29
6.24
144,869.30
274,978.62
TOTAL
472,526.98
8.22
13.1
3
44.51
52.08
1,816,831.9
4
2,219,109.71
Reactors
Absorber:
Distillation
Column:
- Tower
- Tray
Heaters:
Coolers:
Table above gives the value in USD of the equipment that is used in the project of the plant. The
sample calculation is shown below.
34
Power Shaft ( kW )=
Fluid Power
Efficiency
From heuristic, sizing of the pump, the value of the shaft power of the pump is calculated in
Equipment design. From there, Power Shaft = 0.2kW. The constant value of k1, k2, and k3 are
collected in Appendix A, Table A.1.
k1 = 3.3892, k2 = 0.0536, k3 = 0.15838
So,
35
From the Table A.3, the identification number of the material is needed to be identified first
before proceeding to the graph of material factors, FM.
For this pump, centrifugal type and made of carbon steel. So, refer to the graph of material
factors in the text book, Figure A.18,
For this pump used carbon steel material. So, FM= 1.57
The constant for bare module factor is to be determined in Table A.4 in the text book. The
condition is centrifugal type of pump. The values are, B1 = 1.89, B2 = 1.35
FBM
B1 +B2FMFP
1.89 + 1.35(1.57)(1)
4.0095
FBM
B1 + B2
FBM
1.89 + 1.35
3.24
The bare module cost in base conditions is then calculated by using this following formula.
CBM
CBM
Cp FBM0
($2,672.2408) (3.24)
$8,658.060
Cp FBM
36
($2,672.2408) (4.0095)
$10,714.35
394
I2014
I2
C2 (2014)
C1 (2001) I 1
C2 (2014)
2,219,109.71[
3,243,142.201
580.2
394
I2
C2 (2014)
C2 (2014)
C1 (2001) I 1
580.2
1,814,775.65[ 394
2,672,418.356
CTM
C BM ,i
1.18
1.18 ($3,243,142.201)
$ 3,826,907.572
i=1
37
CGR
CGR
4.2:
C BM ,i
CTM + 0.50
$5,163,116.75
$5,163,116.75
RM17,657,859.29
i=1
( RM$3.42 )
The costs that associated with day-to-day operation of plant are needs to be estimated before
the economic feasibility of a proposed process can be assessed. The manufacturing costs are
expressed in units of dollars per unit time. The factors that effecting of cost manufacturing are
Fixed capital investment, FCI, Cost of raw material, CRM, Cost of utility, CUT, Cost of waste
treatment, CWTand Cost of Operating Labor COL. The total for each cost and further calculation
can be refers at each tablethat summarize below.
Cost of Manufacturing
Cost (RM/yr)
Fixed capital investment, FCI
17,657,859.29
Cost of raw material, CRM
17,894,936.27
Cost of utility, CUT
1,570,791.195
Cost of waste treatment, CWT
0
Cost of Operating Labor COL
252,000
Table 8 : The Cost for Factor Affect in Cost of Manufacturing
38
AMOUNT (tonne/yr,
CURRENT PRICE
COSTS (RM/yr)
Methanol
Deionised water
Air Supply (Oxygen
m3/yr)
21,556.75
15,571.52
30,033.46
RM 0.81/kg
RM 3.42/1000kg
RM 1.20/100 std m3
17,460,966.01
74,093.37
359,876.894
and Nitrogen
TOTAL
17,894936.27
Table 9 : Cost of Raw Material
AMOUNT (kW)
0.2
184.99
COST (RM)
431.41
456,039.97
E-1
20.5567896
RM 60.534/GJ
11,015.56
E-2
98.14878304
RM 50.719/GJ
150,705.82
Reboiler
Cooler:
608.484209
RM 50.719/GJ
934,317.408
E-3
253.93985
RM 1.211/GJ
9,307.603
E-4
206.1682623
RM 1.211/GJ
7,556.64
Condenser
TOTAL
38.65419867
RM 1.211/GJ
1,416.784
1,570,791.195
39
Nnp
NOL
Equipment
10
2.931
= 13.1895
COL
14 operators
252,000 RM/yr
COMd =
=(0.18x17,657,859.195)+b(2.73x252,000)+1.23(1,570,791.195+0+17,894,936.27
=
COM =
=
=
27,809,219.45 RM/yr
0.280 FCI + 2.73 COL +1.23 (CUT +CWT +CRM)
(0.28 x17,657,859.195) + (2.73x252,000)
+1.23(1,570,791.195+0+17,894,936.27
29,575,005.36 RM/yr
= RM 17,657,859.29
COM
= RM 29,575,005.36/yr
Direct Manufacturing
Costs
Factors
Value used
Cost (RM/yr)
40
Raw Material
Waste Treatment
Utilities
Operating Labour
Direct Supervisory and
(0.1-0.25)COL
Clerical Labour
Maintenance and Repair
Operating Supplies
Laboratory Charges
Patents and Royalties
Total Direct
(0.02-0.1)FCI
(0.1-0.2)(0.06FCI)
(0.1-0.2)COL
(0-0.06)COM
CRM+CWT+CUT+1.33COL+
Manufacturing Costs
CRM
CWT
CUT
COL
0.18COL
0.06FCI
0.009FCI
0.15COL
0.03COM
17,894,936.27
0
1,570,791.195
252,000
45,360
1,059,471.557
158,920.734
37,800
887,250.16
21,906,529.92
0.03COM+0.069FCI
Table 11: Direct Manufacturing Cost
Fixed Manufacturing
Value used
Cost (RM)
Costs
Depreciation
Local Taxes and
Factors
0.1FCI
(0.014-0.05)FCI
0.1FCI
0.032FCI
1,657,785.929
565,051.497
Insurance
Plant Overhead Cost
(0.50-0.7)
0.708COL+
814,098.934
(COL+0.18COL+0.06FCI)
0.708COL+0.068FCI
0.036FCI
3,036,936.361
+Depreciation
Table 12: Indirect Manufacturing Costs
General Manufacturing
Value used
Cost (RM)
Costs
Administration Costs
Factors
0.15(COL+0.18COL+0.06FCI)
0.177COL
203,524.734
(0.02-0.2)COM
+0.009FCI
0.11COM
3,253,250.59
Costs
Research and
0.05COM
0.05COM
1,478,750.27
Development
Total General
0.177COL+0.009FCI+0.16COM
4,935,525.291
Manufacturing Costs
Total Costs
CRM+CWT+CUT+2.215COL
29,878,991.87
+0.190COM+0.146FCI+
41
Depreciation
Table 13: General Manufacturing Costs
CRM+ CWT+CUT+1.33COL+0.03COM+0.069FCI
21,906,529.92 RM/yr
3,144,936.36 RM/yr
4,935,525.60
Total Cost =
=
CRM + CWT + CUT + 2.215 COL + 0.19 COM + 0.146 FCI + depreciation
17,894,936.27 + 0 + 1,570,791.195 + (2.215 x 252,000) + (0.19 x
29,575,005.36) + (0.146 x 17,657,859.29) + (0.1 x 17,657,859.29)
29,878,991.87 RM/yr
42
4.3
In this engineering economic analysis, the subjects included in this chapter are the nondiscounted cash flow and discounted cash flow.
4.3.1
Cash Flow
0.0
-0.39
-10.59
-7.06
-3.58
3.03
3.56
2.99
2.65
2.65
2.40
2.15
2.15
2.15
3.47
3.97
Table 14: Non-Discounted Cash Flow
Cash Flow
Cumulative
0.0
-0.39
-10.65
-17.28
-20.64
-17.98
-14.75
-12.20
-10.01
-7.89
-6.23
-4.42
-2.86
-1.35
1.01
3.72
43
Payback Period
5.0
0.0
Project Value (millions of RInggit)
-5.0
-10.0
-15.0
-20.0
-25.0
-1 0 1 2 3 4 5 6 7 8 9 10 111213
Project Life (Years)
CCR=
After calculation, the value of cumulative cash ratio is about 1.44. This indicates that the project
has the potential to be profitable where project with CCR greater than one are potentially
profitable but if not, the project is said not profitable.
44
The rate of return on investment (ROROI) represents the non-discounted rate at which money is
made from a fixed capital investment. It can be calculated by the following equation:
ROROI=
The use of FCIL, whether in payback period and ROROI given above seems reasonable, due
this is the capital that must be recovered by project revenue. Other alternatives also can be
used. For example, the total capital investment (FCI L + WC + Land) and the fixed capital
investment minus the salvage value (FCIL S) could be used replacing the FCIL in the above
equation.
Thus the value of rate of return on investment is equal to 5.393%
45
Cash Flow
Cumulative
0.0
-0.39
-10.65
-17.28
-20.64
-17.89
-14.75
-12.20
-10.01
-7.89
-6.03
-4.42
-2.86
-1.35
1.01
3.75
Parsh
ojec
t Li
(Y ear
s)
C
F lo
wfeDiag
r am
The above graph shows the discounted cash flow diagram versus life of the project. The
difference between the discounted and the non-discounted cash flow is the non-discounted
profitability does not consider the time value of money whereas the discounted profitability does
consider it. The criterion is that latter each of yearly cash flows is discounted back to time zero.
The discounted payback period (DPBP) is defined as the time required, after start up, to recover
the FCIL required for the project with all cash flows discounted back to zero. After calculation,
the DPBP of our project is 7.44 years.
The discounted cumulative cash position, also known as net present value or net present worth
can be calculated by using the following equation:
46
Same as the cumulative cash ratio (CCR), the present value ratio (PVR) calculated must be
greater than unity to indicate the profitable project and vice versa. The PVR can be calculated
by:
PVR=
The ratio is then calculated to give the value of 1.18 which is greater than unity. This value
shows that the project that we built will deem profitable.
The discounted cash flow rate of return or DFCROR is defined as the interest rate at which all
the cash flow must be discounted in order for the NPV of the project to be equal to 0. The
equation is as follows:
DCFROR=Interest discount rate for which the net present valueof the project is equal zero
The DCFROR represent the highest after tax interest of discount rate at which the project can
just break even.
Take the NPV is equal to RM 4.09 million, the NPV for several discount rates were calculated
and the results are shown below:
Interest of Discount Rate (%)
NPV (RM million)
0
9.54
3
4.09
6
0.18
7
-0.87
9
-2.65
Table 16: Evaluating DFCROR
The value of the DFCROR is found at NPV is equal to 0. So, interpolating the value of the NPV
and the interest rate gives the value of DFCROR of 6.17%
47
48
4.4
Profitability Analysis
(R-COMd-
Cash Flow
dk)*(1-t)
(Non-
COMd
+dk
Investmen
Year
0
0
1
2
2
t
0.00
0.39
10.59
7.06
3.58
dk
FCIL-Sdk
17.66
17.66
17.66
17.66
17.66
3.5
Cumulative
Cumulative Cash
Cash Flow
Cash Flow
Flow (Non-
discounted)
0.00
(0.39)
(10.59)
(7.06)
(3.58)
(discounted)
0.00
(0.39)
(10.29)
(6.66)
(3.37)
(discounted)
0.00
(0.39)
(10.68)
(17.34)
(20.71)
discounted)
0.00
(0.39)
(10.99)
(18.05)
(21.63)
30.6
3
5.6
14.13
8
30.6
27.82
3.03
3.03
2.77
(17.94)
(18.60)
5
3.3
8.48
8
30.6
27.82
3.56
3.56
3.16
(14.78)
(15.04)
9
2.0
5.09
8
30.6
27.82
2.99
2.99
2.58
(12.19)
(12.05)
3
2.0
3.05
8
30.6
27.82
2.65
2.65
2.22
(9.97)
(9.40)
3
1.0
1.02
8
30.6
27.82
2.65
2.65
2.16
(7.81)
(6.74)
8
30.6
27.82
2.40
2.40
1.90
(5.92)
(4.34)
8
30.6
27.82
2.15
2.15
1.64
(4.27)
(2.19)
10
8
30.6
27.82
2.15
2.15
1.60
(2.68)
(0.05)
11
8
30.6
27.82
2.15
2.15
1.55
(1.13)
2.10
12
12
27.82
3.47
3.47
3.97
2.43
2.79
1.31
4.09
5.57
9.54
49
50
The project is to be built in industrial land at Tanjung Malim, Perak. It is situated near the
state border of Selangor and Perak. It is chosen because the strategic location that is
away from residential area and due to its reasonable price. With the area of 43,562
square feet or 14 acres, the location is desirable with vast area and closer to other
industrial chemical plant, given the project will be built in the industrial area. Also the
transportation cost for product selling or material buying is low.
Location
Perlis
Kedah
RM23.00,US$7.36
Annual
Assessment Rate
(% of Property Value)
0.15
8 - 12
Penang:
Island
10 - 13.5
Mainland
RM18,US$5.63
Perak
Selangor
RM8.50 70,US$2.72 - 22
8 - 13
Negeri Sembilan
8 - 13
Melaka
12 - 13.2
Johor
0.33 - 1.0
Pahang
7-9
Terengganu
5 - 10
Kelantan
RM9.00,US$2.88
5 - 12
9 - 15
10
Sabah:
- KKIP
- POIC
RM12.00,US$3.75
Table 18: Location of Land and Selling Price
51
5.0
PINCH ANALYSIS
Pinch analysis is a technique for designing a process to minimize the energy
consumption and to maximize the heat recovery. It also reduces the cost of the
production in terms of utility consumption. To do the pinch analysis, the minimum
52
approach temperature is assumed to be 10C. Thus the pinch analysis could be done
using the Heat Exchanger Network software included in the Analysis, Synthesis, and
Design of Chemical Processes text book, forth edition published by Pearson in its CDROM appendix. Below are listed the stream data table and a few figures in designing the
heat exchanger network.
Stream
mCp(kJ/s.K)
Tin(C)
Tout(C)
Q(kW)
2.4793
200
100
247.93
1.2638
96
30
83.41
1.1898
40.8
150
-129.93
1.2109
183
200
-20.59
53
Using the stream data collected from the stream summary table, temperature interval
diagram is performed in Figure 14.
54
From the cascade diagram, it was determined that the pinch temperature is at 190C
below and 200C above. The minimum number of heat exchanger is then determined in
Figure 15 and 16 below.
55
56
The Temperature versus Enthalpy diagram in Figure 17 is plotted to depict the pinch
location.
57
58
59
= 343.44 kW
= 76.51%
60
6.0
ENVIRONMENTAL CONSIDERATION
The impact of the production of formalin in a plant to the environment is one of the most
important considerations in the design of chemical processes. As the process engineer that
designing the plant, the environment consideration should be on the highest priority because it
is included in considerations of safety and economic issue on plant design. A good environment
consideration or waste treatment will reduce a cost on plant design and also reduce the injuries
or any hazardous incident on the plant that also match on the one of the Engineering Codes Of
Ethics engineers shall hold paramount the safety, health and welfare of the public in the
performance of their duties. The effect of a process can have on the environment is usually
61
through the materials that come out of the process. There are three types of waste categories
which is waste by gas, waste by liquid and waste by solids. To overcome these wastes, there
are many solutions with different ways of treatment according to the phase of the waste existed.
As the existed waste is in gas phase, it has the potential to pollute the air by its concentration to
the air. As the existed waste is in liquid form, it may pollute the water and for solid form of waste,
it will pollute the landscape.
The production of formalin in a plant will generate waste that caused pollution to the
environment or more worst to the surrounding including indoor plant environment.Formalin is a
37% aqueous (water) solution of formaldehyde, a pungent gas, with the chemical formula
HCHO, used as an antiseptic, disinfectant and others. The waste produces by formalin
production in this plant design was observed by process flow diagram to be in vapour phase
with mixture of oxygen, nitrogen, hydrogen, methanol, water and formaldehyde.These
substances then are subjected to off-gas stream after it is separated by absorber unit in a plant.
These substances then are treated as a waste.
These wastes are existed as a vapor, thus it has the potential to pollute the air if it is not treated
well. Since it contains methanol and formaldehyde that are categories as the toxic substance
(formaldehyde) and reactive substance (methanol) under hazardous material under Schedule 2,
it must be channeled to the right way of treatment.
6.1
Methanol
Its a light, volatile, colorless, clear and flammable liquid. It has a distinctive sweetish smell and
close to alcohol in odor and colorlessness. Methanol is very toxic to humans if ingested.
Permanent blindness is caused if as little as 10 mL of methanol is received and 30 mL could
cause death. Even slight contact with the skin causes irritation. Methanol has an explosive
nature in its vapor form when in contact with heat of fires.
Flash point
Auto ignition temperature
Explosive limits
11-12 oC
385 oC
36%
62
6.2
6%
36%
Table 20 : Methanol properties
This material is a highly toxic material that the ingestion of 30 ml is reported to cause fatal
accidents to adult victims. Formaldehyde ranges from being toxic, allergenic, and carcinogenic.
The occupational exposure to formaldehyde has side effects that are dependent upon the
composition and the phase of the material. These side effects range from headaches, watery
eyes, sore throat, difficulty in breathing, poisoning and in some extreme cases cancerous.
Formaldehyde is flammable in the presence of sparks or open flames.
Flash point
Auto ignition temperature
Explosive limits
Lower Explosion Limit
Upper Explosion Limit
64 oC
430 oC
36%
6%
36%
Table 21 : Formaldehyde properties
However, in this plant design the off-gas stream that contains methanol and formaldehyde that
seems to be the most dangerous waste is less. The highest percentage by waste in this formalin
production was nitrogen with 54.6%.
Waste
Methanol
Oxygen
Formaldehyde
Water
Hydrogen
Nitrogen
Fraction
0.01179
0.0126
0.00341
0.36952
0.05682
0.54588
Table 22 : Waste fraction
Mole flow
2.49
2.66
0.72
78.03
12.00
115.28
There so many ways to treat vapor waste such as flare system and relief system. In this design
plant, the waste is treated with flare and relief systems before it is discharge to the atmosphere.
Furthermore, Malaysian Government has introduced Environmental Quality Act 1947 in order to
save the environment. Under this regulation, the entire factory that produced waste must treated
the waste before discharge in order to reduce the pollution and environment quality. Other than
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waste treatment, flare system provided a good part of plants safety system. Governmental laws
& regulations require the flare to be located a safe distance from the operating units and
populated areas.A typical flare system includes a flare (a long, narrow pipemounted vertically), a
steam ring mounted at the top of the flare (used to dispense hydrocarbon vapors), an ignition
source at the top of the flare, a fan mounted at the base of the flare (used for forced-draft
operation), a knockout drum with water seal, and a flare header.The flare stack range height
from 200 to 350 feet and far enough from surrounding and other equipments.
Waste
Flare
header
Warm
Flare
Knockou
t drum
Flare
Stack
Discharge to
air
Steam of
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7.0
PLANT LAYOUT
Site Location
Proposed Site Location (Taman Bahtera)
The most important steps in building a chemical plant is to decide and verify whether a
certain location is suitable location to build a chemical plant. In this project, we need to produce
formalin in a large scale which is about 10 k tone per year. Based on the calculations done in
economic analysis, the production of formalin cost about RM 3677938.24. A strategic plant is
needed as it is the main contribution to either success or the failure of a chemical plant. The site
selection is very important because it will ensure that the cost of the final product will be a
suitable value. Final site selection choice should be based on the important criteria and factors
listed below:
Strategic location means that the purposed chemical plant is near to road system where
the raw material can be easily be transported. This will decrease the cost of
transportation for delivering the raw material. In Taman Bahtera, Selangor, it is near to
the PLUS North-South Express, which made the transportations of raw materials or
product will be easier. Other that than, the nearest town to Taman Bahtera is Tangjong
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Malim where it is a well-known industrial area. The nearest residential area located at
Taman Bahtera is Kampung Bilal where future employers can live there and the distance
between the location and the residential area is in a safe distance where any plant faulty
will not affect the residential area.
c. Transport Facilities
The transport facilities means that the facilities that are needed in getting the material or
to sell the product. In Taman Bahtera, the PLUS North-South Express is the nearest
express way for delivering raw materials or products. This land property is about 3 KM
from the Tanjong Malim North-South Express exit. The North-South Express is the main
express way in Malaysia where it connects Perlis to Johor. Thus, where ever the
destination of the product to or the raw materials from, the facilities to transports them is
gratify. The Taman Bahtera are also place only about 60 KM from the capital city of
Malaysia which is Kuala Lumpur.
d. Utilities
Utilities means that the proposed chemical plant side have services such as electricity,
gas or water in that proposed area. In Taman Bahtera, the location have such utilites
since Tangjong Malim is an industrial area. Company such as Proton BHD are located in
Tangjong Malim. The proposed site is near to the power plant for electricity support due
to high demand of power to run a chemical plant. Other utilities such as water are easily
obtained at the location.
7.1
selected based on several criterions. For example the criterions are utilities, transportation and
cost of land. Once again the screening and scoring method was used to narrow down the
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choices of locations. To evaluate the location, first the screening process was done. The
selection of the process is tabulated in screening table as below:
Criterions
Gambang,
Bangi,
Taman
Pahang
Selangor
Bahtera,
Selangor
+
Transport Facilities
Utilities
Total score
Rank
As the process of screening done, further investigation was done by the process of scoring. This
critical analysis was performed to ensure that the best location was been selected. The scoring
data was tabulated in a table as shown below:
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Criterions
Selangor
5
Lumpur)
Transport facilities
Utilities
Total score
16
17
Rank of scoring
By referring to the scoring data above, the location chosen was Taman Bahtera, Selangor. This
is because Taman Bahtera have a cheaper price compared to Bangi which is RM 9 psf for
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Taman Bahtera while RM 35 psf for Bangi. For the other criterions such as location, transport
facilities and utilities both location share the same score but in the end, we noticed that Taman
Bahtera, Selangor have a higher total score than Bangi, Selangor.
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Selection Criteria
Location
Transport
Energy Sources
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7.2
Location of Plant
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7.3
Site Layout
This site layout is constructed based on few factors including cost and the layout can be seen
as above. The process units and ancillary building should be laid out to give the most
economical flow of materials and personnel around the site. (Ray Sinnot, 2009)
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Cante
en
Safe Zone
Intermediate Zone
Danger Zone
From the layout above, upon entering the plant from the front, we can see the loading
and unloading bay at the right side. The waste water treatment plant located at the left side of
the plant. The road designed to be big as to have space for transportation. Heading straight
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from the loading and unloading bay will be the space for unloading the raw material. Raw
material will be pumped into the tank farm for process inside the plant.
The canteen is located in the same building as the administration office as the workers
need to come to the office to register at the office. The parking lot of the plant is located outside
the plant as it the safety precaution to avoid any unwanted incidents. The administrations office,
unloading bay, waste water treatment plant and canteen is considered as a safe zone.
As we go along the main road, we can see the processing plant room on the right side
and opposite it is the preparation plant room. The distance between these two rooms are remain
close as it will ease the works to go back and forth to do their routine job. This will save the time
and increase the efficiencies of working hours to maintain the production of formalin. The
preparation plant room and the processing plant room is a considered as a danger zoom
because most the plants equipment are located here. In the danger zone, employers need to
wear their PPE (personal protective equipment) before entering the danger zone.
Behind the preparation plant room is located the tank farm. Tank farm is a place where
the facility keep or storage for the product that have been produce by the plant which is
formalin. The area of the tank farm is large enough as it able to store greater amount of
formalin. The tank farm is considered as an intermediate zone as employers still need to gear
up their PPE.
The plant layout is the simplest plant layout which can help in improving the efficiencies
to produce the formalin. All the utilities of the plant is located around the chemical plant. This to
ensure that the plant is supplied with sufficient energy sources to maintain the plant operation to
produce formalin.
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7.4
Plant Layout
into consideration which are cost of equipment, cost construction, process requirement,
operational and maintenance, future expansion and modular construction.
At plant layout of the actual site, the 3D layout is established. As refer to the figure
below, the 3D block diagram of plant layout is shown. The plant layout consists of processing
plant room which is located on the bottom left, preparation plant room on the bottom-middle and
on very left, the tank farm is located. For a green building, it is mainly the green zone which
consists of administration office, loading and unloading bay, and lastly waste water treatment.
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8.0
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consideration or waste treatment will reduce a cost on plant design and also reduce the injuries
or any hazardous incident on the plant that also match on the one of the Engineering Codes Of
Ethics engineers shall hold paramount the safety, health and welfare of the public in the
performance of their duties
Finally the plant layout part, site location for plant is specified and the cost of land area is
estimated. In Taman Bahtera,Selangor the price and is RM9.00 per square feet. This location
had been specified by considering the land price, strategic, transport facility and utility. Site
layout had been constructed so that it can give most economical flow of material and personnel
around the site. Finally, plant layout had been constructed and is based on several factors that
are economic considerations, process requirements, convenience of the operation and
maintenance, safety, future expansion and modular construction.
In conclusion, this report shows that many tasks needs to be done in planning to build a
plant and is different based on the process involve. Our report on formalin production plant
shows that huge revenue of RM 30,677,938.24 can be made and thus it is considered that the
plant should be constructed.
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