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INTRODUCTION
1.1 HISTORY:
Ethylene Glycol (1, 2 ethanediol), HOCH2CH2OH usually called glycol is the
simplest Diol. Diethylene glycol and Triethylene glycol are Oligomers of Mono
ethylene glycol.
Ethylene glycol was first prepared by Wurtz in 1859; treatment of 1,2 dibromoethane
with silver acetate yielding ethylene glycol diacetate via saponification with
potassium hydroxide and in 1860 from the hydration of ethylene oxide. There to have
been no commercial manufacture or application of ethylene glycol prior to World
War-I when it was synthesized from ethylene dichloride in Germany and used as
substituted for glycerol in the explosives industry and was first used industrially in
place of glycerol during World War I as an intermediate for explosives (ethylene
glycol dinitrate) but has since developed into a major industrial product.
The use of ethylene glycol as an antifreeze for water in automobile cooling systems
was patented in the United States in 1917, but this commercial application did not
start until the late 1920s. The first inhibited glycol antifreeze was put on the market in
1930 by National Carbon Co. (Now Union Carbide Corp.) under the brand name
prestone.
Carbide continued to be essentially the sole supplier until the late 1930s. In 1940
DuPont started up an ethylene glycol plant in Belle, West Virginia based on its new
formaldehyde methanol process. In 1937 Carbide started up the first plant based on
Leforts process for vapor phase oxidation of ethylene oxide.
The worldwide capacity for production of Ethylene Glycol via hydrolysis of ethylene
oxide is estimated to be 7106 ton/annum [1, 2].
1.2 CHEMISTRY:
Compound contains more than one oly group is called Polyhydric Alcohol (Dihydric
alcohol) or polyols (Diols). Diols are commonly known as Glycols, since they have a
sweet taste (Greek, glycys= Sweet).
Dihydric alcohols because compounds contain two OH groups on one carbon are
seldom encountered. This is because they are unstable and undergo spontaneous
decomposition to give corresponding carbonyl compound and water.
Figure-1[10]
According to IUPAC system of nomenclature, IUPAC name of glycol is obtained by
adding suffix Diol to the name of parent alkanes.
HO OH
H--C---C--H
H H
HO--C---C--OH
H
H H
H--C---C--H
HO
OH
1, 2 Glycol
1, 3 Glycol
1, 4 Glycol
(- Glycol)
(- Glycol)
(- Glycol)
Glycols are Diols. Compounds containing two hydroxyl groups attached to separate
carbon in an aliphatic chain. Although glycols may contain heteroatom can be
represented by the general formula C2nH4nOn-1(OH) 2. [3, 4]
Formula
Common name
IUPAC name
CH2OHCH2OH
Ethylene Glycol
Ethane-1, 2-Diol
1.3 USES:
The following is a summary of the major uses of ethylene glycol:
1.3.1 Antifreeze
engines. Solutions containing ethylene glycol have excellent heat transfer properties
and higher boiling points than pure water. Accordingly, there is an increasing
2
tendency to use glycol solutions as a year-round coolant. Ethylene glycol solutions are
also used as industrial heat transfer agents.
Mixtures of ethylene glycol and propylene glycol are used for defrosting and
de-icing aircraft and preventing the formation of frost and ice on wings and fuselages
of aircraft while on the ground. Ethylene glycol-based formulations are also used to
de-ice airport runways and taxiways as de-icing agent.
against freezing, which would break the emulsion. Carbon dioxide pressurized fire
extinguishers and sprinkler systems often contain ethylene glycol to prevent freezing.
1.3.2 Explosives
sulfuric acid to form solutions of nitroglycerin in ethylene glycol dinitrate, which are
added to dynamite in amounts ranging from 25 to 50%.
1.3.3 Polyester Fibers
The use of ethylene glycol for fibers is becoming the most important consumer
of glycol worldwide. These fibers, marketed commercially under various trade names
like Dacron, Fortel, Kodel, Terylene etc are made by the polymerization of ethylene
glycol with BisHydroxyEthyl Terephthalate (BHET).
1.3.4 Resins
Polyester resins made from maleic and phthalic anhydrides, ethylene glycol,
automobile bodies, boat hulls, suitcases and aircraft parts. Alkyd-type resins are
produced by the reaction of ethylene glycol with a dibasic acid such as o-phthalic,
maleic or fumaric acid. These resins are used to modify synthetic rubbers, in
adhesives, and for other applications.
Alkyds made from ethylene glycol and phthalic anhydride is used with similar
3
Ethylene glycol is used in hydraulic, brake and shock absorber fluids to help
presses and die casting machines, and in airplane hydraulic systems because of their
relatively low viscosity at high pressure. An added advantage of primary importance
is that these hydro lubes are inflammable.
1.3.6 Capacitors
Ethylene glycol, which is of high purity (iron and chloride free), is used
because it has a low vapor pressure, is non-corrosive to aluminum and has excellent
electrical properties.
1.3.7 Other uses
Ethylene glycol derivatives mainly ether and ester are used as absorption
fluids, Diethylene Glycol is used as a softener (Cork, adhesives, and paper) dye
additive (Printing and stamping), deicing agent for runway & air craft, drying agent
for gases (natural gas).
Poly (ethylene glycol) with varying molecular masses and numerous uses in
(Cleaning and dyeing agents), in Rubber industry (lubricating & Mold parting agents),
in ceramics (bonding agents and plasticizers).[3,4]
CHAPTER II
PROPERTIES
2.1 PHYSICAL PROPERTIES:
Monoethylene glycol and its lower polyglycols are clear, odorless, colorless,
Physical Properties
no.
1.
Molecular formula
C2H6O2
2.
Molecular weight
62
3.
1.1135
4.
197.60
5.
Freezing point oC
-13
6.
52.24
7.
19.07
8.
Critical Temp. oC
372
9.
6513.73
10.
0.1861
11.
Refractive index,
1.4318
12.
0.62 10-3
13.
19.83
14.
1.1135
15.
Flash point, oC
111
16.
410
17.
53
Lower
3.2
CH3CHO + H2O
(Ethylene Glycol)
(Acetaldehydes)
2.1.2 Oxidation
Ethylene glycol is easily oxidized to form a number of aldehydes and carboxylic acids
by oxygen, Nitric acid and other oxidizing agents.
The typical products derived from alcoholic functions are Glycolaldehyde
(HOCH2CHO), Glycolic acid (HOCH2COOH), Glyoxylic acid (HCO-COOH), Oxalic
Acid (HOOCCOOH), formaldehyde & formic acid.
HNO3
HOCH2CH2OH
[O]
HOCH2CHO
(Ethylene Glycol)
[O]
HOCH2CH2COOH
(Glycol aldehydes)
CHOCOOH
(Glycolic acid)
(Glyoxylic acid)
[O]
HOOC-COOH
(Oxylic acid)
[O]
HNO3
HOCH2CH2OH
[O]
HOCH2CHO
(Ethylene Glycol)
[O]
CHOCHO
(Glycol aldehydes)
CHOCOOH
(Glyoxal)
(Glyoxylic acid)
temperature is raised.
Na at 50 oC
Na at 160 oC
HOCH2CH2OH
HOCH2CH2ONa
NaOCH2CH2ONa
(Ethylene Glycol)
(Mono Alkoxide)
(Di Alkoxide)
PCl5
HOCH2CH2OH
HOCH2CH2Cl
(Ethylene Glycol)
(Ethylene chlorohydrins)
(1, 2-Dicholorochlorohydrins)
PBr3
HOCH2CH2OH
(Ethylene Glycol)
ClCH2CH2Cl
HOCH2CH2Br
BrCH2CH2Br
(Ethylene Bromohydrins)
(1, 2-Dibromohydrins)
With HCl in two step reaction, form ethylene chlorohydrins at 160 oC and
200 oC
7
HOCH2CH2OH
HOCH2CH2Cl
(Ethylene Glycol)
ClCH2CH2Cl
(Ethylene chlorohydrins)
(1, 2-Dicholorochlorohydrins)
The largest commercial use of ethylene glycol is its reaction with dicarboxylic
acids (1) to form linear polyesters. Poly (Ethylene Terephthalate) (PET) (2) is
produced by esterification of teraphthalic acid to form BisHydroxyEthyl Terephthalate
(BHET) (3). BHET polymerizes in a transesterification reaction catalyzed by
antimony oxide to form PET.
2HOCH2CH2OH
+
HOOC
COOH
(2)
(1)
Sb2O3
H*
COOCH2CH2OH
HOCH2CH2OOC
OOC
*H
COOCH2CH2
+ HOCH2CH2OH
n
(3)
HOCH2CH2OCH2CH2OH
CH3NH2
CH3
+ 2H2O
Ketones and aldehydes react with ethylene glycol under acidic conditions to
8
(6)
HOCH2CH2OH
+ RCOR+
R'
H2O
(7)
Ethylene glycol reacts with ethylene oxide to form di, tri, tetra and
polyethylene glycols.
CHAPTER III
LITERATURE SURVEY
The literature survey has been done with an aim to obtain information concerning
Ethylene Glycol and its production from number of sources. Such information sources
9
10
and compatiblizers for dye and printing ink components, latex paint, antifreeze, and
lubricants in a number of applications.
3.1.2 Triethylene Glycol:
Triethylene glycol is a colorless, water-soluble liquid with chemical properties
essentially identical to those of Diethylene glycol. It is a co product of ethylene glycol
produced via ethylene oxide hydrolysis. Significant commercial quantities are also
produced directly by the reaction of ethylene oxide with the lower glycols.
Triethylene glycol is an efficient hygroscopicity agent with low volatility, and about
45% is used as a liquid drying agent for natural gas. Its use in small packaged plants
located at the gas wellhead eliminates the need for line heaters in field gathering
systems as a solvent (11 %) Triethylene glycol is used in resin impregnants and other
additives, steam-set printing inks, aromatic and paraffinic hydrocarbon separations,
cleaning compounds, and cleaning poly (ethylene Terephthalate) production
equipment. The freezing point depression property of Triethylene glycol is the basis
for its use in heat-transfer fluids.
Approximately 13% Triethylene glycol is used in some form as a vinyl plasticizer.
Triethylene glycol esters are important plasticizers for poly (vinyl butyral) resins,
Nitrocellulose lacquers, vinyl and poly (vinyl chloride) resins, poly (vinyl acetate) and
synthetic rubber compounds and cellulose esters. The fatty acid derivatives of
Triethylene glycol are used as emulsifiers, emulsifiers, and lubricants. Polyesters
derived from Triethylene glycol are useful as low pressure laminates for glass fibers,
asbestos, cloth, or paper. Triethylene glycol is used in the manufacture of alkyd resins
used as laminating agents and adhesives.
3.1.3 Tetra ethylene Glycol:
Tetra ethylene glycol has properties similar to Diethylene and Triethylene glycols and
may be used preferentially in applications requiring a higher boiling point, higher
molecular weight, or lower hygroscopicity.
Tetra ethylene glycol is miscible with water and many organic solvents. It is a
humectants that, although less hygroscopic than the lower members of the glycol
series, may find limited application in the dehydration of natural gases. Other
possibilities are in moisturizing and plasticizing cork, adhesives, and other substances.
11
9.29 lb
0.00065
260F
12
for
the
necessary
safety
and
environmental
health
13
CHAPTER IV
MARKET SURVEY
4.1 ECONOMIC ASPECTS:
Ethylene glycol is one of the major products of the chemical industry. Its economic
importance is founded on its two major commercial uses as antifreeze and for fiber
production. Since Ethylene glycol is currently produced exclusively from ethylene
oxide production plant are always located close to plant that produce ethylene oxide.
The proportion of ethylene oxide that is converted to Ethylene glycol depends on
local condition, such as market situation and transport facilities. About 60% of total
world production is converted to ethylene glycol.
About 50% of the ethylene glycol that is used as antifreeze. Another 40% is used in
fiber industry. Consequently the ethylene glycol demand is closely connected to the
development of these two sectors In view of the increasing price of crude oil,
alternative production method based on synthesis gas is likely to become more
important and increasing competitive.
4.2 LEADING PRODUCERS IN WORLD:
NOCIL, Thane.
Year
2004
2005
November
Month
November
December
January
February
March
April
May
June
July
August
September
October
1st week
2nd week
Price(US$/MT)
1095
988
1045
1095
1095
971
734
736
808
836
883
883
830
822
2002
590
548
11
8
551
2003
615
647
64
29
682
24%
2004
654
691
106
104
750
10%
2005
830
833
103
133
803
7%
2006
830
830
90
60
860
7%
FIBER GRADE
INDUSTRIAL GRADE
10
Suspended matter
Substantially free
Substantially free
0.08
0.6
0.005
0.02
max
Ash, wt% max
0.005
0.005
0.08
0.3
0.07
0.05
760mm Hg:
IBP, C min
DP, C max
Odor
UV transmittance, % min at:
220 nm
250 nm
275 nm
350 nm
Specific gravity, 20/20C
Water solubility, 25C
196
200
Practically none
70
90
98
1.1151-1.1156
Completely miscible
196
199
70
90
95
99
1.1151-1.1156
CHAPTER V
PROCESS SELECTION AND DESCRIPTION
5.1 MANUFACTURING PROCESSES:
Up to the end of 1981, only two processes for manufacturing ethylene glycol have
been commercialized. The first, the hydration of ethylene oxide, is by far the most
important, and from 1968 through 1981 has been the basis for all of the ethylene
glycol production.
Manufacturing process involves laboratory methods and industrial methods.
5.1.1 Laboratory methods: [3, 4]
16
sodium carbonate solution. This reaction mixture is refluxed till an oily globule of
ethylene bromide disappears. The resulting solution is evaporated on a water bath and
semi solid residue is extracted with ether-alcohol mixture. Glycol is recovered from
solution by distillation. The best yield of glycol (83-84%) can be obtained by heating
ethylene bromide with potassium acetate in Glacial acetic acid.
formaldehyde.
simple, and can be summarized as follows: ethylene oxide reacts with water to form
glycol, and then further reacts with ethylene glycol and higher homologues in a series
of consecutive reactions as shown in the following equations.
17
H2C
O
O
O
H
H
Ethylene Glycol
Ethylene Oxide
CH2
H2C
+ H2C
CH2
CH2
H2C
+ H2C
O
H
O
H
CH2
O
H
CH2
O
H
O
H
H2C
CH2
Diethylene Glycol
CH2
CH2
CH2
H2C
O
H
O
H
CH2
H2C
+ H2O
CH2
CH2
CH2
CH2
CH2
Triethylene Glycol
CH2
O
H
Ethylene oxide hydrolysis proceeds with either acid or base catalysis or uncatalyzed
in neutral medium. Acid-catalyzed hydrolysis activates the ethylene oxide by
protonation for the reaction with water. Base-catalyzed hydrolysis results in
considerably lower selectivity to ethylene glycol. The yield of higher glycol products
is substantially increased since anions of the first reaction products effectively
compete with hydroxide ion for ethylene oxide. Neutral hydrolysis (pH 6-10),
conducted in the presence of a large excess of water at high temperatures and
pressures, increases the selectivity of ethylene glycol to 89-91%. In all these ethylene
oxide hydrolysis processes the principal byproduct is Diethylene glycol. The higher
glycols, i.e., Triethylene and Triethylene glycols, account for the remainder.
Although catalytic hydration of ethylene oxide to maximize ethylene glycol
production has been studied by a number of companies with numerous materials
patented as catalysts, there has been no reported industrial manufacture of ethylene
glycol via catalytic ethylene oxide hydrolysis. Studied catalyst include sulfonic acids,
carboxylic acids and salts, cation-exchange resins, acidic zeolites, halides, anionexchange resins, metals, metal oxide and metal salts. Carbon dioxide as a co catalyst
with many of the same materials has also received extensive study.
18
CH2
HOCH2CH2Cl
+ HOCl
NaOH
HOCH2CH2Cl
HOCH2CH2OH
(8)
NaCl
(9)
NaCl
(10)
O
HOCH2CH2Cl
Ca(OH)2
CH2
CH2
O
CH2
CH2
+ H2O
HOCH2CH2OH
(11)
methanol, hydrogen, and formaldehyde until 1968 at Belle, West Virginia. The
process consisted of the reaction of formaldehyde, water, and carbon monoxide with
an acid catalyst to form glycolic acid. The acid is esterified with methanol to produce
methyl glycolate. Subsequent reduction with hydrogen over a chromate catalyst yields
ethylene glycol and methanol. Methanol and formaldehyde were manufactured on site
from syngas.
CO
CH2O
HOOCCH2OH
CH3OOCCH2OH
H2 O
H+
CH3OH
H2
HOOCCH2OH
CH3OOCCH2OH
Cr2O3
HOCH2CH2OH
+
+
+
NaCl
(12)
H2O
(13)
CH3OH
(14)
Coal was the original feedstock for syngas at Belle; thus ethylene glycol was
commercially manufactured from coal at one time. Ethylene glycol manufacture from
syngas continues to be pursued by a number of researchers.
oxygen, and ethylene react with a catalyst to form the glycol mono and diacetate.
Catalysts can be based on palladium, selenium, tellurium, or thallium. The esters are
19
hydrolyzed to ethylene glycol and acetic acid. The net reaction is ethylene plus water
plus oxygen to give ethylene glycol. This technology has several issues which have
limited its commercial use.
CH3COOH
+ CH2
CH2
O2
Te2Br2
CH3COOCH2CH2OH + CH3COOCH2CH2OOCCH3
CH3COOCH2OOCCH3
3 H2O
2 HOCH2CH2OH + 3 CH3COOH
(15)
(16)
The catalysts and acetic are highly corrosive, requiring expensive construction
materials. Trace amounts of ethylene glycol mono-and diacetates are difficult to
separate from ethylene glycol limiting the glycols value for polyester manufacturing.
This technology (Halcon license) was practiced by Oxirane in 1978 and j1979 but was
discontinued due to corrosion problems.
Ethylene glycol can be manufactured by the transesterification of ethylene
C
O
2 CH3OH
Zr2Cl4
HOCH2CH2OH
CO(CH3O)2
(18)
Selectivity to ethylene glycol are excellent with little Diethylene glycol or higher
glycols produced. A wide range of catalysts may be employed including ion exchange
resins, zirconium and titanium compounds, tin compounds, phosphines, acids and
bases. The process produces a large quantity of dimethyl carbonate which would
require a commercial outlet.
Oxalic acid produced from syngas can be esterified and reduced with
2 ROH
4 H2
ROOCCOOR
Cu
HOCH2CH2OH
20
2 H2O
2 ROH
(20)
(21)
The Teijin process, which has not been commercialized to date, produces
ethylene glycol by the reaction of ethylene with thallium salts in the presence of water
and chloride or bromide ions. The major by-product in the reaction is acetaldehyde.
A redox metal compound (such as copper) oxidizable with molecular oxygen is added
to the reaction medium to permit the regeneration of the thallium salt.
The DuPont process, based on feeds derived from synthesis gas (CO and
PROCESSES
PARAMETER
CATALYST
NO
ADVANTAGES/DISA
DVANTAGES
21
1.
Hydrolysis
of 1) Non- catalytic
Ethylene Oxide
Yield
1)Non
98% Catalytic
Selectivity: 98%
Temp:105oC
Pressure
1.5MPa
Carboxylic
2) catalytic:
Yield
95% Ion-exchange
2.
3.
4.
Pressure :
1-30 bar
oxide
from
Temp: 200oC
CO,H2,CH3OH
Pressure:
&
100atm
Metal salts.
the
Non Catalytic
highly corrosive.
very low yield &
solution
very costly
High
pressure
Cromate
Catalyst
process
Discontinued now a
day
from
or ammonium
Low yield
reaction
selectivity
Alkali
Temp:180oC
&
Formaldehyde
Ethylene glycol Yield :98%
ethylene Selectivity: 95%
low
Low selectivity
halide Give high yield and
salt.
Pressure:13bar
6.
yield
zeolites,
chlorohydrins
Ethylene glycol Yield : 90-95%
Transesterificati
High
to
Acidic selectivity
carbonate
5.
2)
leads
Temp:200oC
which
selectivity
Utility saving
Extra
Zirconium
purification
cost
& Produced
large
on of ethylene
titanium
amount
carbonate.
compound.
byproducts
Copper
catalyst
catalyst removal is
Reduction with
very difficult.
H2
22
of
7.
Rhodium
synthesis
catalyst
(Homogeneous
catalyst route.)
economical.
of Temp:
Pressure:
3400atm
As
crude
prices
prove
to
be
is
sensitive
8.
Hydrolysis
of Yield : 90%
Pd complexes
very
and
expensive.
Very low conversion
pdcl2+NaNO3
Temp: 160oC
Pressure:
2.4MPa
H2O+C2H4O
Ko
C2H4O + HOCH2CH2OH
HOCH2CH2OH
Ki
HO (CH2CH2O)2 H
---------------- (1)
---------------- (2)
One of the ways of increasing the monoglycol selectivity and, therefore, of decreasing
water excess is the application of catalysts accelerating only the first step of the
reaction (1). There are much research has been carried out to improve this process.
The search for better catalyst is an objective for increase the selectivity and decrease
the excess water. As evident from the kinetic data the distribution factor b = k1/k0 is
reduced -0.10.2 at the concentration of some salts of about 0.5 mol/l. This enables to
produce monoethyleneglycol with high selectivity at waterethyleneoxide molar ratio
close to 10.
5.2.2 Catalyst:
A cross-linked styrenedivinylbenzene anion exchange resin (SBR) in the HCO3/
CO3- form, activated by anion exchanging with sodium bicarbonate solution used as
catalysts. (Dow Chemical produced anion-exchange resins: DOWEX SBR). The
ethylene oxide hydration process in a catalytic fixed-bed tube reactor was studied .The
properties of initial resins are summarized below:
Functional group
Total exchange capacity (equiv./l)
Particle size (mm)
:
:
- [PhN (CH3)3] +
1.4
0.3-1.2
Ethylene oxides mixed with recycle water and pumped to glycol reactor where it is
reacted with water at 1050C &1.5 MPa in the presence of catalyst. The Reactor is
Catalytic Plug flow Fixed bed type. The reaction volume consists of two phase, the
liquid phase and ionite (catalyst) phase. The liquid streams through catalyst bed in a
plug flow regime. The catalytic and non catalytic ethylene oxide hydration takes place
in the ionite phase, and only non catalytic reaction takes place in the liquid phase. The
distribution of the components of the reaction mixture between liquid and ionite
phases is result of the rapid equilibrium. The glycol reactor operate at approximately
24
1.5MPa.pressure which is supplied by the reactor feed pump. The reactor effluent
goes to the evaporation unit for the evaporation of excess water.
5.3.2
Drying column bottoms essentially free of water are fed to the MEG refining column.
(PACKED COLUMN). About 15% of the feed to the MEG column enters as vapor
due to flashing. MEG product is withdrawn from the top of the column. Some MEG is
purged in the overhead to the vacuum jets to reduce the aldehydes in the product. The
25
MEG column bottoms primarily di-ethylene glycols are pumped from the column
bottom to the storage tank. The MEG column operates at a pressure of 10mmHg (A).
The vacuum is maintained by MEG column ejector system. The MEG column
condenser is mounted directly on the top of the MEG column.
5.3.5
The MEG leaving along with water from the Top of the multiple effect evaporator &
drying column are recovered in the MEG Recovery Column (PLATE COLUMN). The
column is operated under Atmospheric pressure.MEG leaving from the bottom of the
column and the water leaving from the top of the column are Recycle to reactor.
CHAPTER VI
MATERIAL BALANCE
Material balances are the basis of process design. A material balance taken over
complete process will determine the quantities of raw materials required and products
produced. Balances over Individual process until set the process stream flows and
compositions. The general conservation equation for any process can be written as
Material out = material in + accumulation
26
For a steady state process the accumulation term is zero. If a chemical reaction is
taking place a particular chemical species may be formed or consumed. But if there is
no chemical reaction, the steady state balance reduces to:
Material out = Material in
A balance equation can be written for each separately identifiable species present,
elements, compounds and for total material. [10]
6.1 BASIS:
Basis: 100000TPA
The process is planned and developed as a continuous process. A plant is operated for
24 Hours per day and 333 per year.
No of working days = 333days
Capacity =
1000000
333
= 300.3 T/days
= 201.47 Kmol/hr.
6.2 MOLECULAR WEIGHT (KG / KMOL):
Ethylene Glycol
: 62
Water
: 18
: 44.01
Water [H2O]
: 18
Nitrogen [N2]
: 28
REACTOR
Temp. = 100 0C
= 37597.68 Kg
= 2088.76 Kmol
Conversion = 100 %
Pressure = 1.5-2MPa
H2O
HOCH2CH2OH
--------- (1)
C2H4O + HOCH2CH2OH
HOCH2CH2OH
--------- (2)
(Higher Glycol)
As selectivity = 98%
Moles of undesired product formed =
204.70
98
= 2.088 Kmol
Moles of MEG to be produced from reactor = 206.788kmol
Moles of ethylene oxide reacted by reaction I
= 206.788 Kmol.
Moles of ethylene oxide reacted by reaction I I
= 2.088 Kmol.
Total Moles of ethylene oxide reacted = 206.788 + 2.088
= 208.876 Kmol.
As conversion = 100%
[6]
Moles of ethylene oxide charged = 208.876kmol
From the literature we know that the ratio of WATER TO ETHYLENE OXIDE =10
Amount of water fed to reactor = 2088.76 Kmol. (Including excess)
From the reaction moles of water reacted = 206.788 Kmol.
28
M.B.ON WATER:
Moles of water fed = Moles of water reacted + Moles of water unreacted
2088.76
In, Kg
9190.54
37597.68
-
Out, kg
33875.496
12691.4
221.328
= 0.851881.972
= 1599.6762 Kmol.
= 28794.1715 Kg
= 1881.972-1599.6762
= 282.2958 Kmol.
= 5081.324 Kg
There is some quantity of glycol carry over along with water from the top of
evaporator.
Amount of glycol carry over along with water from 1st effect
W1= 8285.66kg
MEG = 165.58kg
29
H2O = 8120.08kg
= 165.58 kg
F = 2088.76 Kmol
= (46788.224 kg)
M.E.G = 204.7Kmol
= 12691.4 Kg
Water =1881.972 Kmol
= 33875.496Kg
Pressure = 7 kg/cm2
Temp = 159 oC
Amount of glycol carry over along with water from IIst effect = 189.139kg
W2= 9689.31kg
MEG = 189.139kg
H2O = 9500.171kg
Temp = 141 oC
Pressure = 3.5 kg/cm2
To 3rd effect evaporator
Amount of glycol carry over along with water from IIst effect = 335.064 kg
W3= 11508.96kg
MEG = 335.064kg
H2O = 11173.89kg
To MEG Refining
column
X = 477.9588
Kmol
In, Kg
33875.496
12691.4
221.328
Liquid phase
5081.355
12001.617
221.328
Out, Kg
Vapor phase
28794.141
689.783
-
F = 477.9588 kmol
= 17304.2585 kg
MEG = 12001.606kg
Drying column
Pressure = 0.21 kg/cm2
Temp = 87 oC
H2O = 5081.324 kg
.
X = 188.306 Kmol
HG = 221.328kg.
= 11766.873 kg
MEG = 186.218kmol
= 115453545kg
HG = 2.088 Kmol
= 221.328kg
= 5018.324 Kgm
= 282.295 Kmol.
There is some quantity of glycol carry over along with water from the top of drying
column
Amount of glycol carry over along with water from drying column = 456.061kg
=7.3558 Kmol.
(Finding using VLE calculation)
Total quantity leaving from top of drying column
= (Amount of water +Amount of MEG)
= 282.295 +7.3558
= 289.65 Kmol.
TAKING OVERALL M.B
F =Y+X
477.9588 = 289.65 + X
X = 188.306 Kmol.
(Total quantity leaving from the bottom of drying column)
Now ,
Total amount of MEG leaving along with water during evaporation of water
= (Amount of MEG leaving from top of
TEE + Amount of MEG leaving from
top of drying column)
= 689.783+456.061
= 1145.844 Kgm.
= 18.4813 Kmol.
Amount of feed to MEG Recovery column
= (Amount of MEG leaving along with
water during evaporation + Amount of
water removed)
= 18.4813+1881.973
= 1900.451 Kmol.
Table 6.3 Material balance over drying column
Component
In, Kg
32
Out, Kg
Liquid phase
Vapor phase
Water
MEG
HG
5081.324
12001.606
221.328
11545.3545
221.328
5081.324
456.061
-
D= 184.54 Kmol
= 11448.8616 kg
MEG = 184.355kmol
(0.999.high purity)
F = 188.306 Kmol
= 11766.873 kg
MEG = 186.218kmol
=11545.545kg
HG = 0.18454kmol
Temp = 93.2 oC
HG =2.088kmol
= 221.328kg
W = 3.766 Kmol
= 317.664 kg
MEG = 1.8523kmol
HG = 1.9136kmol
Assuming 99% recovery, of total MEG feed to distillation column, is obtained in the
distillate.
Kmol of Distillate
(D)
= 184.355 / 0.999
= 184.54 Kmol / hr.
= 184.54 x 62.04
= 11448.8618 kg / hr.
Amt. of HG in Distillate
= 184.54 x 0.001
= 0.18454 Kmol / hr.
= 0.18454 x 106
= 19.561 kg / hr.
= 11766.873 kg/hr
TAKING OVER ALL M.B.
F=D+W
188.306 = 184.54 + W
W = 3.766 Kmol /hr.
M.B. ON MEG
F x (Xf MEG) = D x (Xd MEG) + W x (Xb MEG)
188.306 x 0.9889 = 184.54 x 0.999 + 3.766 x Xb MEG
Xb MEG = 0.4918 (mol.fr.of MEG in Bottoms)
XbHG = (1- 0.4918)
= 0.5081 (mol.fr.of HG in Bottoms)
= 0.4918 x 3.766
= 1.8521 Kmol / hr
Kmol of HG in Bottoms
= 0.5081 x 3.766
= 1.9135 Kmol / hr.
In, Kg
11545.545
221.328
Out, Kg
Vapor phase
11430.01
19.56124
Liquid phase
114.8426
202.8416
D= 1881.97kmol
= 11766.873 kg
MEG =1.88kmol
H2O =1880.08kmol
F = 1900.451kmol
= 35021.339 kg
MEG = 18.481kmol
=1145.844kg
Plate column
H2O =1881.97kmol
= 33875.496kg.
34
W = 18.481kmol
=1205.55 kg
MEG = 17.122kmol
H2O = 1.3584kmol
= 1881.97 x 0.999
= 1880.08 Kmol / hr
Kmol of Distillate
(D)
= 1880.08 / 0.999
= 1881.97 Kmol / hr.
= 1881.97 x 18.044
= 33958.266 kg /hr
= 1881.97 x 0.001
= 1.88 Kmol / hr
= 1.88 x 62
= 116.56 kg/ hr.
Amount of feed ( F )
= 1900.451 Kmol/hr
= 35021.339 kg/hr.
= 18.481 x 0.9264
35
= 17.122 Kmol / hr
= 17.122 x 62
= 1061.56 kg/hr.
= 18.481 17.130
= 1.3584 Kmol / hr
= 1.3584 x 18
= 143.99 kg/ hr.
In, Kg
33875.496
1145.844
Liquid phase
24.4512
1061.546
Out, Kg
Vapor phase
33841.44
116.56
Triple
Component
Ethylene oxide
Water
MEG
HG
effect Water
In, kg
9190.54
37597.68
33875.496
Out, Kg
Liquid phase
Vapor phase
33875.496
12691.4
221.328
5081.355
28794.141
evaporator
MEG
HG
Drying column Water
MEG
HG
MEG refining MEG
12691.4
221.328
5081.324
12001.606
221.328
11545.545
12001.617
221.328
11545.3545
221.328
114.8426
689.783
5081.324
456.061
11430.01
221.328
33875.496
202.8416
24.4512
19.56124
33841.44
1145.844
1061.546
116.56
column
HG
MEG recovery Water
column
MEG
36
CHAPTER VII
ENERGY BALANCE
The first law of thermodynamics demands that energy be neither created nor
destroyed. The following is a systematic energy balance performed for each unit of
the process. The datum temperature for calculation is taken as 0C.
The different properties like specific heat, heat of reaction, heat of vaporization, etc.
are taken to be constant over the temperature range.
7.1 REACTOR: [9,11]
= 37597.68 Kg
= 2088.76 Kmol
REACTOR
Temp. = 100 0C
Conversion = 100 %
Pressure = 1.5-2MPa
H2O
HOCH2CH2OH
(Water)
C2H4O + HOCH2CH2OH
HOCH2CH2OH
IN
Ethylene oxide
------------- (1)
(Higher Glycol)
kmol
-77704
37
------------ (2)
C p ( kj
kmol k
99.106
Water
OUT
MonoEthyleneGlyocol
Di-EthyleneGlyocol
Water
-285830
75.673
-454800
-285831
-562570
75.673
189.39
441.602
H 0 f H 0 fp H 0 f R
= [-454800] - [-(77704) + (-285830)]
= -91266 KJ/ Kmol of EO Reacted
= -91266 x 206.788
= -18.872 x 106 KJ / hr
H 0
H 0 fp H 0
f R
Enthalpy of reactants
As reactants are added at 250C, so, its Enthalpy becomes 0.
Enthalpy of products
H R
= m x Cp x T
- 4.3043 x 106
= m x 75.79627 x 20
= 2.8394 x 103 Kg / hr (cooling rate) [9,11]
wS S + wF (tF t1) Cp = w1 1
W1= 8285.66kg
MEG = 165.58kg
H2O = 8120.08kg
F = 2088.76 Kmol
= (46788.224 kg)
M.E.G =Second
204.7Kmol
effect:
= 12691.4 Kg
Water =1881.972 Kmol
= 33875.496Kg
To 2nd
effect evaporator
W2= 9689.31kg
H2O = 9500.171kg
Temp = 141 oC
From 2nd
effect
evaporator
To 3rd effect
evaporator
Third effect:
rd
3 effect evaporator
Pressure = 0.25 kg/cm2
To MEG Recovery column
Temp
= 118 oC
Material balances:
w1 + w2 + w
3 = w1-3
Y= 1610.8012kmol
39
To MEG Refining
column
X = 477.9588
Kmol
tF = 1050C
Consider steam is entered at 12 kg/cm2 so Ts = 190.8250C
(After finding boiling point of solution)
Also last effect operates at a vacuum of 0.25 Kg/cm2
So t3 = 106.15oC (steam temp at 0.25 kg/cm2)
Consider for forward feed multiple effect evaporator pressure differences between
effects will be nearly equal.
So average pressure difference
Steam or
, KJ/Kg
, KJ/Kg
e, KPa
vapor
(Steam)
(MEG)
temp. C
Steam chest, 1st
1179.69
TS= 190.82
S = 2210.8
794.63
t1=175.17
1 = 2244.1
1 = 982.935
409.57
t2=152.585
2 = 2284.0
2 = 1001.15
24.53
t3= 106.155
3 = 2379.1
3 =1022.317
effect
Steam chest,
2nd effect
Steam chest, 3rd
effect
Vapor to
condenser
7.2.1 First effect:
Cp avg. = xiCpi
= 4.196 KJ/Kg o K
avg = 2016.38 KJ/Kg
WSS + wF (tF t1) Cp = w11
(WS x 1973.62) + (46788.224 x - 70.17 x 4.196) = w1 x 2016.38
w1 = 0.9787WS 6830.42
----------------------------- (1)
= 2088.28 KJ/Kg
40
w1 + w2 + w3 = w1-3
0.9787WS 6830.42 +0.9022WS 4245.22 + 0.70WS 697.42 = 28794.1716 +
689.783
WS = 15.445 x 103 Kg/hr ( steam rate is required.)
From above equations we calculated,
w1 = 8285.66 Kg/hr
w2 = 9689.31 Kg/hr
w3 = 11508.96 Kg/hr
Now , Enthalpy out from the bottom of the last effect,
Tbottom = 122oC
Trefrence = 25oC
T = 97oC.
Enthalpy out from Bottom = (mCpT )MEG + ( mCpT )WATER + ( mCpT )HG
= [(12001.606 x 3.077) + (5081.324 x 4.378) + (221.328 x 4.1032)] x 97
= 5.828 x 106 KJ / hr
41
F = 477.9588 kmol
= 17304.2585 kg
MEG = 12001.606kg
Drying column
Pressure = 0.21 kg/cm2
Temp = 87 oC
HG = 221.328kg.
X = 188.306 Kmol
= 11766.873 kg
MEG = 186.218kmol
= 115453545kg
Toperating = 87 oC
Trefrence = 25 oC
HG = 2.088 Kmol
= 221.328kg
Hence T = 62oC.
Poperating = 0.25 kg /cm2
Enthalpy in = 2.802 x 106 kJ / hr
7.3.1 Enthalpy out from Top
= ( m )water + ( m )MEG +( mCpT )
= [(5081.324 x 2366.1) + (456.061 x 1109 .75)] + [289.65 x 75.2 x 64]
= 12.529 x 106 kJ / hr
7.3.2 Enthalpy out from Bottom
= (mCpT )MEG + ( mCpT )HG
= [(186.218 x 187.90) + (432.72 x 2.088)] x 62
= 2.225 x 106 kJ / hr
Total Enthalpy out
= 11448.8616 kg
MEG = 184.355kmol
(0.999.high purity)
HG = 0.18454kmol
F = 188.306 Kmol
= 11766.873 kg
MEG = 186.218kmol
=11545.545kg
HG =2.088kmol
= 221.328kg
W = 3.766 Kmol
= 317.664 kg
MEG = 1.8523kmol
HG = 1.9136kmol
44
= 1.6485 x106 kJ / hr
Condenser load, QC :
= QV ( QReflux + QD )
= [(25.58 x 106 ) (1.6485 x106 + 2.341 x 106 )]
= 21.595 x 106 kJ / hr
Assuming cooling water enters the condenser at 25oC & leave at 45oC
QC = (mCpT )cooling water
21.595 x 106 = m x 75.7962 x 20
m = 11.63 x 103 kg / hr (Rate of cooling water)
7.4.2 For bottom:
Tbottom = 94.6 oC
= 69.6 oC
=
=
45
steam = 2205.82 kJ / kg
QB = m steam
21.794 x 106 = m x 2205.82
m = 9.88 x 10 3 kg / hr ( Rate of steam )
7.5 MEG RECOVERY COLUMN:
D= 184.54 Kmol
= 11448.8616 kg
MEG = 184.355kmol
(0.999.high purity)
F = 188.306 Kmol
HG = 0.18454kmol
= 11766.873 kg
Plate column
MEG = 186.218kmol
=11545.545kg
HG =2.088kmol
= 221.328kg
W = 3.766 Kmol
= 317.664 kg
MEG = 1.8523kmol
HG = 1.9136kmol
Trefrence = 25oC
T = 169 oC
Poperating = 760 mmHg
Cpmean of MEG = 197.24 kJ / kmol oK
Cpmean of H2O
= 76.55 kJ / kmol oK
H2O = 2231.8 kJ / Kg
= 173 oC
= ( mCpT )feed
= [(18.481 x 187.97) MEG + (1881.97x 74.51) WATER] x 80
= 143.71x 103 kJ / hr
Reboiler load
QB = [( 603.39 x 103 + 172.12 x 106 + 24.40 x 106 ) (143.71x 103) ]
= 196.97 x 106 kJ / hr
Amount of steam required,
Consider the steam enter at 2 kg/cm2 & 118.719oC
steam =2037.51 kJ / kg
QB = m steam
196.97 x 106 = m x 2037.51
48
[9,11]
CHAPTER VIII
REACTIONS KINETICS & THERMODYNAMICS
E. O = 9190.54 Kg
= 208.876 Kmols
Water = 37597.68 Kg
= 2088.76 Kmol
REACTOR
Temp. = 50 0C
Conversion = 100
%
Here,
FAO
208.876 Kmol/hr
9190.544 Kg/hr
V0
10.649 m3/hr
FAO
= CAO V0
= 19.6136 Kmol/m3
= 19.6136 mol/lit
Similarly,
CBO
= 5.555 Kmol/m3
55.555 mol/lit
dt
Where,
Gyi
rA
dt
Rate constant Ko is given by,
K0
where T = temperature o K
K0
= 1.5627 x 10-7
K0
L2
L2
= 0.0005625
mol2. Sec
mol2. hr
Kct
L2
= 0.21334
mol2. Sec
L2
mol2. hr
Now,
CAO XA =
CBO XB
19.6136 XA
1
55.555 XB
1
XB = 0.3530 XA
- rA
- rA
19.6136 (1 XA)}
0.1
654.5
0.005
0.2
532.40
0.3
424.57
0.4
330.131
0.5
248.286
0.6
178.2369
0.7
119.1836
0.8
70.31
0.9
30.86
0.98
53.60
0.0018
0.0023
0.00302
0.00402
0.00561
0.0084
0.01
0.03
0.186
1
) & finding the area under he curve at
rA
Xa = 0.98
FAO
d XA
0
- rA
XA
d XA
- rA
V
V
0.01227
= 2562.90 lit
= 2.56 m3
Now we have
Volume of Catalyst
Total bed Volume
1 =
Volume of Catalyst
2.56 m3
Consider = 0.6
Total Volume of Catalyst = 1.024 m3
8.2 THERMODYNAMICS
As we know the Gibbs free energy is given by following equation
G = -RT lnK
Where K = Kequ = (ka * kb)/ (kc * kd)
From reaction,
ka and kb are rate constants for the products.
Similarly kc and kd are rate constants for the reactants. But assuming reaction is
exothermic and irreversible; the values of kc and kd will not be in consideration to
finding out equilibrium rate constant.
Hence, Kequ is given by
Kequ = ka kb
52
Enthalpy, Gibbs free energy and specific heat data are below at reaction temperature
100 0C in the form of functional group. [11]
-O- group: Cp = 19.28 KJ /.Kg K, G = -15.38 KJ / Kg K
H = -1467.62 KJ /.Kg K
-CH2- group: Cp = 20.43 KJ /.Kg K, G = -3.87 KJ / Kg K
H = -1516.94 KJ /Kg K
-OH- group: Cp = -1.83 KJ /.Kg K, G = -36.785 KJ / Kg K
H = 96.75 KJ /.Kg K
H2O: G = -8.728 KJ / Kg K
H2O
HOCH2CH2OH
G = [(-81.31)]-[(-23.12) + (-8.728)]
G = - 49.53 KJ/Kmol K
Ka = exp [-(-49.53) / (8314*373)]
Ka =1.00
ln(K2/K1)= E/R[(1/T1)-(1/T2)]
--------- (1)
[15]
ln(9.5/8)= E/8.314[(1/368)-(1/373)]
T2 reaction at 100 oC= 373K
T1 reaction at 95 oC=368K
0.26236 = 6.2382* E *10-6
E = 7.52*E*-7 J/mol
53
CHAPTER IX
MAJOR EQUIPMENT DESIGN
9.1
Consider the reactants are flow on tube side and cooling water are on shell side
Catalysts are fill inside the tube.
9.1.1 Process Design: [22]
Consider length of tube
Diameter of tube
= 4m
= 2.5 cm
(d)2 (L)
4
(2.5 x 10-2)2 (4)
4
1.9634 x 10-3 m3
=
=
=
Shell Side
(Water) (30oC )
5.1865 (KJ/Kg oK)
9 x 10-4 (Kg/m.Sec)
0.62 (w/m.oK)
995.40 (Kg/m3)
No. of tube
=
No. of tubes
Tube side
(Ethylene oxide + H2O) (65oC)
4.840 (KJ/Kg oK)
4.187 x 10-4 (Kg/m.Sec)
0.54 (w/m.oK)
973.09 (Kg/m3)
Volume of reactor
Volume of one tube
2.56
0.001963
1304 Nos.
=
=
Atp
(d) 2 (Ntp)
4
(2.5 x 10-2)2 (1304)
4
0.64 m2
54
Velocity:
m
U = Atp
m = 12.996 Kg/Sec
Now,
=
NRe
12.996
973.09 x 0.64
0.02 m/sec
=
=
Now,
NRe
AO
=
=
=
AO
du
x (1 )
Shell diameter:
CL Aox ( PR 2 xdo)
0.637
L
Ctp
0.5
Ds
=
Consider the Triangular pitch
CTP
=
0.9
CL
=
0.7
Take PR
=
=
Ds
0.637
Ds
1.123 m
0.7
0.9
__(Ds)2
0.875 CTP
(PR)2 (d)2
CL
=
____(1.123)2
0.875 0.9
(1.25)2 (0.025)2
0.7
=
DexGs
= 0.36 x
0.55
Cpx
x
k
55
0.333
x b
w
0.14
0.5
4 3 PT2 d2
2
4
d
Pitch ratio
= PR
1.5=
De
PT
d
PT
0.0025
PT
= 0.03125 m
4
x 0.0025
De =
As
0.018 m
Gs =
m
As
DsxCxB
PT
=
=
=
PT do
0.03125 0.025
0.00625
=
=
=
0.4 Ds
0.4 x 1.125
0.45
As
As
= 0.101 m2
Gs
=
Gs
m
As
12.996
0.10
= 128.58 Kg/m2.sec
(hox 0.018)
0.62
0.018 x128.58
0.36 x
9 x10 4
ho
0.55
1825.04
0.333
x 1
0.14
w
m 20 k
hixdi
k
0.8
= 0.023 x ( 2905.09) x (
(Cp ) 0.4
)
k
hix 0.025
( 4.84 x103 x 4.187 x10 4 ) 0.4
= 0.023 x ( 2905.09) 0.8 (
)
0.54
0.254
hi
672.163
w
m 20 k
1
1
0.005
ho
hi
=
=
Uo =
1
1
0.005
1825.08 672.163
142.133
w
m 20 k
Now,
Total H.T area available = 409.66 m2
Rate of H.T. is given by
Q
= UAT
(1.1956 x 106) =
A
117.03 x A x 20
420.59 m2 > A available
gc x ()3 x Dp x
150 (1 )
=
(1 ) (G)2
+ 1.75
Nre
150 x (0.4)
+ 1.75
(0.4) (19.4608 )2
P
Z
2905.09
Shell side P:
P
f x (Gs2) x (Nb + 1) x Ds
2 x x Dex s
f
= 0.3977
= 1
Nb
= L/B = 4 / 0.45
= 8.88 9
P =
P =
15 N / m2
Pd
D
C
2 f J Pd
1.575 x 1.123
+ 0.2
So
ts = 14 mm
D= 184.54 kmol
= 11448.8616 kg
D
I
S
T
I
L
L
A
T
I
O
N
F = 188.306 kmol
= 11766.873 kg
MEG = 186.218kmol
=11545.545kg
HG =2.088kmol
= 221.328kg.
MEG =
184.355kmol
(0.999.high purity)
HG = 0.18454kmol
W = 3.766 kmol
= 317.664 kg
MEG = 1.8523kmol
HG = 1.9136kmol
Steam
Condensate
PROCESS DESIGN:
Let ,
Mole fraction of MEG
XF= 0.9889
XD = 0.999
XW = 0.4918
So,
1.334 / 0.1333
= 10.077
Psat MEG = 1.4757 KPa
Now at bottom
So,
= 1.4757 / 0.1673
= 8.8174
Thus, average
average = 9.3933
Now we have the equation
Y = X / {1+ (-1)}
From the above eqn we can generate the vapor- liquid equilibrium data given as
follow.
Table-9.2 Vapor-Equilibrium data
X 1 0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Now plotting x-y diagram & Using McCabe Theile method for determining the
theoretical stages.
no. of theoretical stages = 18
9.2.2 Packed Column Diameter And Column Height:
The necessary data required is as follows :
Reflux Ratio
= 0.71
Feed
Kmol of Feed F
= 188.306 kmol
Kmol of Distillate D
= 184.54 kmol
60
Kmol of Bottom W
= 184.54 kmol
Liquid density L
= 954 Kg/m3
Vapor Density G
= 2.099Kg/m3
Liquid Viscosity
diagram) Owing to its low pressure drop per theoretical stage metal Pall Ring is often
preffered to other packings for vacuum distillation.
Here, L/D =0.71
L = 131.0234 Kmol / hr
Vapor rate = V = L+D
= 184.54 + 131.0234
= 375.5634 Kmol / hr.
Mass flow rate of vapor
Mg =
(375.5634 x 62.044)
(3600)
M g = 6.4726 Kg /s
Mass flow rate of liqid
131.0234 x 62.044
3600
Ml =
M l = 2.2581 Kg /s
Flow parameter
X
Ml
Mg
g l
--------------------------- (2)
=2.099Kg/m3
=954 Kg/m3
2.2581
6.4726
2.099
(954 2.099)
X = 0.01638
61
Ml
Mg
g l
V/S
G 2 f P l0.1
m 2 ref.
m
We get Y = 0.0125
Y
G 2 f P l0.1
----------------------------------------- (3)
Owing to its low-pressure drop, the metal pall ring is used as a packing for vacuum
distillation,
Pall Ring (Metal):
Size: 38 mm (1.499)
Packing Factor fp (m-1) = 131
Deigned H.E.T.P. (m) = 0.5425
= Viscosity of liquids = 2.2 x 10-3 Kg/m s
g = Density of gas = 2.099 kg / m3
l = Density of liquid = 954 kg / m3
G' in kg / m2. s
From equation (3)
Y
G'2
G 2 f P l0.1
G'2 = 0.3515 kg / m2 s
G = 0.5929 kg / m2 s
Taking vapor mass velocity as 60% if flooding velocity.
Hence, Area of tower =
At
Mg
0.6 G
62
2
D
4
= 18.19
10 + 2 + 2
= 14 m
MECHANICAL DESIGN [23, 24, 26]
9.2.3 Shell Design:
Shell Thickness (based on external pressure):
Diameter of tower = Di = 5m
Height of column = 14 m
Pressure inside column is vacuum.
Outside pressure is 1 atm = 0.1 MN /m2
Hence design pressure = Pd = 0.1 x 1.05
= 0.105 MN /m2
Shell is I.S. 2825-1969
Allowable stress = f = 98.1 MN /m2
Welding joint efficiency factor = J = 0.85
Thickness of shell,
63
The inside depth of the end can be calculated from the following correlation,
hi = Ri -
Ri Di / 2 x( Ri Di / 2 2ri
Ri = 5m
Di = Do =5m (initial approximation)
ri = 0.1 x Ro
= 0.5m
hi = 5 -
(5 5 / 2) x (5 5 / 2 2 x0.5)
= 0.9686 m
Effective length of tower W/O stiffner = (Tangent to Tangent length + 2/3 x hi)
= 12 + 2/3x 0.9688
= 12.6459m
Do / L = 5/ 12.6459
= 0.3953
K value corresponding to this = 0.246 & m =2.43
Modulus of elasticity E = 1x 105 MN/m2
Corroded shell thickness,
P = KxE x (t/Do)m
0.105 = 0.246 x 1 x 105 (t/4)2.43
t = 0.02467 m
Take standard thickness = 26 m
t = 26 m
Checking for plastic deformation,
1
= 0.9 x 505.2
= 454.68 cm
Temperature = Td
= T + 50 oC
= 95 + 50
= 145 oC
Ro / t
Ro / 100t
Factor B
(assumed)
1.2
1.3
1.4
1.5
P=
factB
14.22 xRo / t
378.9
349.75
324.77
303.2
3.78
3.49
3.24
3.03
4400
4500
4800
5000
0.7402
0.8201
0.9421
1.051 Pdesign
th = 1.5 +0.2
th = 17 mm
Standard thickness available
th = 18 mm
p = P x Do / 4 x ts
= 1.05 x 5.052 / 4 x 0.026
= 51.005 MN/ m2
Axial Stress Due to dead Load up to X m
(a) Stress due to Shell weight s
fs = Ws / x D x ts
Ws = weight of shell = x D x t x s x X
fs = x D x t x s x X / x D x ts
=
s x X
= 0.7848 X MN / m2
= 196.3495 m3
Consider void fraction for packing = 0.5
Liquid hold up = Vb x
66
= 196.3495 x 0.5
= 98.1747 m3
Weight of liquid = Vl x l
= 137.44 x 954
= 93658 kg
= 918.511 x 103 N
Total weight of packing = packed bed volume x density of packing
= x D2x H /4 x p
= x52x 10 /4 x 430
= 83.43 x 103 kg
= 824.08 x 103 N
l = Weight of (liquid + packing) / x D x ts
Weight of ( liquid + packing) =Weight of liquid + total weight of packing
= ( 918.511 x 103 + 824.08 x 103 )
= 1.7465MN
l = 1.7465 x X / x ( 5.052) x( 0.026 )
= 4.243 x X MN/m2
( d ) Stress due to attachments
Weight of head = /4 x D2 x thead x s
= 0.785 x ( 5.052 )2 x ( 0.018 ) x ( 784480 )
Whead =0.02831 MN
Weight of ladder + liq distributor = 1373.4 x X N
a = Whead + (Wladder & liquid distributor) / x Di x t
= 0.02831 + 0.0013734 x X / x ( 5 ) x (0.026)
a = 0.06931 + 0.003362 x X MN/m2
Total dead load stress
dead = s + in + l + a
= 0.7848 X + 0.01084 X + 4.243 X + 0.06931 + 0.003362 X
dead =0.06931 +4.3246 xX N/m2
67
The total load due to wind acting on the bottom and upper part of thr vessel are
determined by
Pw = K1 x K2 x Pwindpress x H x Do ( insulated )
Where,
Pw = wind pressure = 1000 n/m2
K1 = coefficient depending upon the shape factor = 0.7 for cylindrical surface
K2 = coefficient depending upon the period of vibration of the vessel
= 1 if period of vibration is 0.5 sec or less
=2 if period of vibration is exceed 0.5
Do( insulated ) = Di + 2 tin
Period of Vibration is given by
T = 6.35 x 10-5 x ( H / D )1.5 x ( W / t ) 0.5
H = L + Skirt height
W = total weight
Now,
Weight of shell
Ws = x Dits x L x s
= (3.14) x (5) x (0.026) x ( 14 ) x (78480)
Ws = 0.4487 M N
Weight of insulation
Win = x D x tin x L x in
= ( 3.14 ) x ( 5 ) ( 0.05 ) x ( 14 ) x ( 5.64*103 )
Win = 0.06266 MN
Weight of ( liquid + packing) = 1.7465 MN
Weight of attachment = Weight of two heads + Weight of ladder, pipes, liq distributor
= 2 (0.02831) + 1.3734 x 10-3
Wa = 0.058 N
Total Weight = WS + Win + W (liquid + packing) + Wa
= 0.4487 + 0.06266 + 1.7465 + 0.058
W = 2315.86 KN
H = L + Skirt height
= 14 + 4
68
H = 18 m
a) Period of Vibration
T = 6.35 x 10-5 x ( H / D )1.5 x ( W / ts ) 0.5
T = 6.35 x 10-5 x ( 18 / 5.052 )1.5 x ( 2315.86 / 0.026) 0.5
T = 0.127 sec < 0.5 sec
K2 =1
K1 = 0.7 for cylindrical vessel
b) Wind load
Pw = K1 x K2 x Pwindpress x H x Do ( insulated )
Do( insulated ) = Di + 2 tin
= 5 + 2 (0.05)
Pw = ( 0.7 ) x ( 1 ) x ( 1000 ) x ( X ) x ( 5.1 )
Pw = 3.571 x X KN / m
Do = 5.1 m
Bending moment
i.e Wind moment at the base of the vessel due to wind load is given by
Mwind = { Pwmd x H }/2
= 3.571 x X x X /2
Mwind = 1.785 x X2 KN m
Resulting bending stress
i.e Wind Stress in axial direction is given by
wind = 4 x Mwind / x ts x D2
= 4 x ( 1.785 x X2) / 3.14 x ( 0.02 6) x ( 5.052 )2
wind
= 0.00349 x X2 MN/m2
The minimum weight of vessel with two head and the shell is given by
Wmin = Ws + 2 Whead
= 0.4487 + ( 2x 0.03831)
Wmin =0.50532 MN
The maximum weight of vessel with two head and the shell is given by
Wmax = Wmin + Winsulation + Wattachment + W( liquid + packing )
= 0.50532 + 0.062665 + 0.058 + 1.74657
Wmax = 2.37248 MN
70
PARAMETER
DESCRIPTION
Tower MOC
Tower ID
Tower OD
Shell thickness
Shell head thickness
Height of tower(Without support)
Height of packed Bed
Type of Head
No. of Beds of packing
P/Z Selected
Tower Support
Skirt MOC
Skirt Height
Skirt thickness
Type
MOC
Bulk Density
HETP
72
SS304
5m
5.052 m
26 mm
18mm
14m
10 m
Torrispherical
2 , each of height 5 m
50 N/M2/m
Skirt Support
SS304
4m
8 mm
Pall Ring
Metal (S S)
430 kg/m3
0.5425m
CHAPTER X
INSTRUMENTATION AND CONTROL
resistance
thermocouples,
radiation
pyrometers
and
optical
Temp. Range C
-27 to 400
-40 to 540
-85 to 425
-200 to 1700
-250 to 1700
Up to 300
1300 to 2500
U Tube Manometer
74
Differential Manometer
Inclined Manometer
Bourdon Tube
Bellows
Diaphragm valve
Mc Leod gauge
Pirani gauge
2. Management Consideration:
Less cost of cables.
75
control room decreased and hence, in case of emergency decision has to be taken by
almost single handed as against group decision in present situation.
In single loop control system failure of one controller affects only one control loop,
while case of DCS one component / card carries out lot of functions and hence failure
of it causes failure of many loops.
This calls for very high MTBF (Mean Time Between Failures) and high degree of
redundancy making such systems costly.
A limitation may be felt in operating number of control loops simultaneously in case
of emergency, if adequate numbers of CRT consoles are not installed.
personnel are required.
77
Skilled
CHAPTER XI
PLANT UTILITY
The utilities such as water, air, steam, electricity etc. are required for most of the
chemical process industries. These utilities are located at a certain distance from
processing area, from processing area hazardous and storage area etc, where a
separate utility department works to fulfill the utilities requirements.
Steam Generation
Cooling water
Water
Electricity
Compressed air
79
CHAPTER XII
SAFETY, HEALTH AND POLLUTION CONTROL
(2)
Control of hazards
(3)
(4)
MATERIAL NAME:
ETHYLENE OXIDE
USES:
Chemical intermediate
SYNONYMS:
Oxirane
HAZARDS IDENTIFICATION
Skin Contact:
Exposure to rapidly expanding gases may cause frost burns to eyes
and/or skin. Liquid solutions of ethylene oxide cause serious chemical
burns of the skin and eye lesions. Onset of effects may be delayed for
several hours.
Skin Protection: Wear protective gloves and clean body-covering clothing.
Eye Contact: Couses burns
Eye Protection:
Use chemical safety goggles. Maintain eye wash fountain and quickdrench facilities in work area.
General Information:
Do not attempt to rescue the victim unless proper repiratory protection
is worn.
Inhalation:
Remove to fresh air. Do not attempt to rescue the victim unless proper
Expiratory protection is worn
Skin Contact:
Remove contaminated clothing. Flush exposed area with water and
follow by washing with soap if available
Eye Contact:
Immediately flush eyes with large amounts of water for at least 30
minutes while holding eyelids open. Transport to the nearest medical
facility for additional treatment.
Advice to Physician:
Contact a Poison Control Center or toxicologist for guidance.
Explosion
The vapour is heavier than air, spreads along the ground and distant
ignition is possible. Sustained fire attack on vessels may result in a
Boiling Liquid Expanding Vapour Explosion (BLEVE
Extinguishing Media:
Shut off supply. If not possible and no risk to surroundings, let the fire
burn itself out.
Unsuitable:
Protective measures:
Avoid contact with spilled or released material. Isolate hazard area and
they deny entry to unnecessary or unprotected personnel. Stay unwinds
and keeps out of low areas. Extinguish ant make flames. Do not
smoke. Remove ignition sources. Avoid sparks.
Clean Up Methods:
Use water spray (fog) to reduce vapors or divert vapour cloud drift. Do
not use water in ajet. Alcohol foam applied to surface of liquid pools
may slow release of EO vapors into the atmosphere.
Handling:
Ventilate workplace in such a way that the Occupational Exposure
Limit (OEL) is not exceeded. The vapor is heavier than air spreads
along the ground and distant ignition is possible. Electrostatic charges
may be generated during pumping. Electrostatic discharge may cause
fire.
Storage:
Ethylene oxide (EO), an extremely flammable and toxic gas, and other
hazardous vapours may evolve and collect in the headspace of storage
82
DISPOSAL CONSIDERATIONS:
Material Disposal:
PRODUCT NAME :
SYNONYMS:
1,2 - ethanediol
HAZARDS IDENTIFICATION:
Color:
Colorless
Physical State:
Liquid
Odor:
Sweet
Eye Contact:
83
FIRST-AID MEASURES:
Eye Contact:
Flush eyes thoroughly with water for several minutes. Remove contact
lenses after the initial 1-2 minutes and continue flushing for several
additional minutes.
Skin Contact:
Wash skin with plenty of water.
Inhalation:
Move person to fresh air. If not breathing, give artificial respiration; if
by mouth to mouth use rescuer protection (pocket mask, etc).
Extinguishing Media:
84
Handling:
Do not swallow. Avoid contact with eyes. Wash thoroughly after
handling. Spills of these organic materials on hot fibrous insulations
may lead to lowering of the autoignition temperatures possibly
resulting in spontaneous combustion.
Storage:
Do not store near food, foodstuffs, drugs or potable water supplies.
Additional storage and handling information on this product may be
obtained by calling your sales or customer service contact. Ask for a
product brochure.
PERSONAL PROTECTION:
Eye/Face Protection:
Use safety glasses. If exposure causes eye discomfort, use a full-face
respirator.
Skin Protection:
Use protective clothing chemically resistant to this material. Selection
of specific items such as face shield, boots, apron, or full body suit will
depend on the task. Remove contaminated clothing immediately.
Hand protection:
If hands are cut or scratched, use gloves chemically resistant to this
material even for brief exposures. Use gloves with insulation for
thermal protection, when needed. Examples of preferred glove barrier
materials include: Butyl rubber. Natural rubber
85
Stability/Instability:
Thermally stable at recommended temperatures and pressures.
Thermal Decomposition
Decomposition products depend upon temperature, air supply and the
presence of other materials.Decomposition products can include and
are not limited to: Aldehydes. Alcohols. Ethers.
TOXICOLOGICAL INFORMATION:
Acute Toxicity:
Ingestion
For ethylene glycol: Lethal Dose, Human, adult 3 Ounces LD50, Rat
6,000 - 13,000 mg/kg
Skin Absorption
LD50, Rabbit > 22,270 mg/kg
Inhalation
LC50, 7 h, Aerosol, Rat > 3.95 mg/l
ECOLOGICAL INFORMATION:
DISPOSAL CONSIDERATIONS:
General Precautions:
Maintain good housekeeping. Follow the laid down procedure strictly.
Sampling and draining of hydrocarbon should be done under strict
supervision. Do not operate an equipment unauthorized. Use only approved
type of tools. Anticipate the hazards during vessel cleaning and take
prevention steps in advance.
3.
An emergency manual can be prepared to outline procedures and drills and detail
responsibilities of each individual involved.
Training
Valuable Check On The Adequacy and Condition of exits
and Alarm system
Instills a Sense of Security Among The Occupiers if Careful Plans Are Made.
Exits Drills
Plant Drills (Mock drills in plant area)
Mutual Aid Drills
On-Site / Off site Drills etc.
12.5 SAFETY IN PROCESS DESIGN:
Accidents are minimized by correct deign using scientific and performance data
without false economy.
12.5.1 Reactor:
The reactor is a heart of plant and vital for safety. Most reactions have hazard
potential. Here, reaction is exothermic and at higher pressure compared to
atmospheric pressure and also deals with the materials like Benzene and Cyclohexane
which are highly volatile.
12.5.2 Heat Transfer:
For safe operation,
Prevent mixing.
88
Waste arises mainly as byproducts or unused reactants from the process, or as offspecification product produced through mis-operation. In emergency situations,
material may be discharged to the atmosphere through vents normally protected by
bursting discs and relief valves.
12.6.2 GASEOUS WASTES:
If the liquid effluent is flammable, it can be burnt in the incinerator. But as in this case
if it contains salts; acids and substantial amount of alkali it is to be subjected to
effluent treatment. Generally common effluent treatment plant (if the facility is
situated in and Industrial area with the CETP) serves the purpose. The level of
effluent treatment up to secondary treatment is sufficient for the effluent from the
plant like one on the hard.
12.6.3 SOLID WASTE:
The principle factors which determine the nature of an aqueous industrial effluent and
on which strict controls will be placed by responsible authority are:
pH
Suspended solids
Toxicity
Biological oxygen demand
For the present case pH of the effluent stream is expected to be alkaline and hence
addition of acids is recommended to neutralize the same. The suspended solids can be
90
removed by settling, using Chemical treatment may be given to remove some of the
chemicals.
Oxygen concentration in waste course must be maintained at a level sufficient to
support aquatic life. For this reason the biological oxygen of an effluent is of
paramount importance. Standard BOD 5 tests can be applied for the determination of
the same. The test measures the quantity of oxygen which a given volume of effluent
will absorb in 5 days at constant temperature of 20 0C. It is a measure of the organic
matter present in the effluent. Ultimate oxygen demand test can be performed if
required.
Waste water should be discharged into sewers with the agreement of the local water
pollution control authorities or state pollution control boards.
12.6.5 NOISE:
Noise can cause serious nuisance in the neighbourhood of a process plant. Care need
to be taken when selecting and specifying equipments such as compressors, air-cooler
fans, induced and force draft fans for furnaces, and other noisy plant. Excessive noise
can also be generated when venting through steam and other relief valves, and from
flare stacks. Such equipments should be fitted with silencers.Noisy equipments should
be as far away form the site boundary.
12.6.6 VISUAL IMPACT:
The appearance of the plant should be considered at the design stage. Few people
object to fairyland appearance of a process plant illuminated at the night, but it is
different scene at daytime. There is little that can be done to change the appearance of
modern style plant, where most of the equipment and piping will be outside and in full
view but some steps should be taken to minimize the visual impact.
12.6.7 ENVIRONMENTAL AUDITING:
DEVIATION
NONE
NO FLOW
MORE
OF
MORE FLOW
MORE PRES
MORE TEMP
POSSIBLE
CAUSE
1) No
EO/H2O
available at
the storage
tank
2) J1/J2 pump
fails (motor,
fault, loss of
drive, etc.)
CONSEQUENCES
ACTION REQUIRED
temperature
LESS
OF
LESS FLOW
MORE
THAN
HIGH E.O
CONC IN
STREAM.
PART
OF
WATER
FLOW TO
REACTOR
OTHER
MAINT.
2) Warring of high
temperature at
storage, if not install.
1) Check design of
pumps and install a
stand by pump.
2) Install a kickback
on pump.
3) Check proper
operation of cooling
water system.
2) cooling
water supply
to reactor
cooling
system stop
1)
Leaking
flanges
of
valve stab not
blanked and
leaking.
2) Pump J2
fails or not
running
properly and
J1 running
well.
Valve V2-1,
and V2-2 are
not working
properly
Material loss to
adjacent area
Institute regular
patrolling and
inspection of transfer
line.
Formation of more
Higher glycol in the
reaction which will
affect the product.
(excess E.O in
reactor)
Leads to formation
of more higher
glycol
Leads to formation
of more higher
glycol
1) Install a stand by
pump.
2) Check design of
pump.
3) Install kickback on
pump.
1) Institute regular
inspection of valve.
2) Install by pass line
with standby
Valve.
1) Institute regular
inspection of valve.
2) Install by pass line
with standby valve.
Install low point drain
and N2 purge point
and N2 vent line.
93
Line cannot be
completely
drainage or purge.
CHAPTER XIII
PLANT LOCATION AND LAY OUT
The location of markets or intermediates distribution centers can heavily affect the
cost of product distribution. Primarily to large market can be beneficial in the
following three ways:
The cost of transportation of the finished goods to the market is brought
drastically down.
The delay in supplying the goods to the market can be continently reduced &
avoided.
The market is studied properly & easily i.e. the future requirements can be
easily & accurately predicted.
13.1.3 Energy availability
Electricity power, steam supply & heating oil requirements are high in most of the
chemical plants. The power & fuel can be considered as one major factor in the choice
of the plant site. The local cost of power can help in determining whether power
should be purchased or self generated. As far as our plant is concerned, both
electricity power & fuel (gaseous, liquid or solid) as well as heating oil can be made
available easily in Baroda or from nearby sources.
13.1.4 Water supply
The chemical process industries use large quantities of water for cooling, heating,
washing & as a raw material. Therefore the plant site should be nearer to the source of
water. Baroda has plenty of such source like Ajwa lake, Mahi river & so. So, the
situation favors Baroda.
13.1.5 Climate
Weather can have serious effect on the economic operating of the plant. Temperature
& humidity of weather should be favorable.
13.1.6 Transportation
The everyday products are always needed to be transported from the plant site to the
marked or other plants & the raw materials necessary from the sources to the plant.
Hence transportation holds a great deal in the final product cost. A plant should have
easy access to transport facilities. Not only that, the transport facilities available to the
95
plant should also be sufficient, quick & available at reasonable rates. Water, railway &
national high-ways are the most common means of transportation. These facilities are
very much necessary for the transfer of raw material & product transportation.
Luckily Baroda has all of these facilities.
13.1.7 Labor supply
Availability of skilled laborers with constant supply & reasonable pay rate should be
considered in the selection of the plant site. Labor problem should be minimum.
13.1.8 Waste disposal
The plant site should be such that it should have the best & adequate facilities for
waste disposal. The permissible tolerance levels for various methods of waste disposal
should be considered carefully & attention should be given to potential requirements
for waste treatment facilities.
13.1.9 Taxes & legal phases
The state & local tax rates on property (such as plant machinery, building etc.),
income, and unemployment insurance & similar items have major influence on the
plant site selection.
13.1.10 Site characterization
The characteristics of the land at the proposed plant site should be examined carefully.
The topography of the tract of the land & the soil structure must be considered, since
either or both have pronounced effect on construction costs.
13.1.11 Fire & explosion protection
The site should be such that it should have the best possible & quickest fire protection
facility available during the emergency. If possible (means if the company can afford)
the plant should be having its own fire station, fully equipped latest fire fighting
equipments & skilled firemen team. So, in case of emergencies it wont have to rely
totally on the external sources.
13.1.12 Advanced library & training center
This is the characteristic of a good & developed organization. To develop the plant
properly, trained staff is a prime requirement & for further research & development of
96
13.1.15 Existence of hospitals, marketing centers, schools, banks, post offices, clubs
An ideal industry or organization is that which takes full care of its employees &
persons who are directly or indirectly involved with it. To cope up with the situation
of casualties or accidents pressure of a well-equipped hospital is a must. Other than
this a reputed school & the banking & postal facilities are the prime requirement of
the families of the employees.
13.1.16. Housing facilities
Housing facilities ( i.e., residential quarters ) for the company employees should be
well maintained & provided with constant supply of water, electricity & things
necessary for life.
3.1.17 Securities
The security of the plant site & the housing facility from the unsocial elements is
necessary & should be given equal attention.
13.1.18 Facilities for expansion
Considering all the major factors discussed above affecting the plant location, it is
quite reasonable to select Baroda, to establish an industrial estate for the plant
location. Justification for the same is discussed below.
97
All the transportation facilities (rail, road & water) are easily available to
Baroda & are very adequate.
Waste disposal will not be a much problem as it is a separate chemical estate
& no specific attention is required.
Electricity & water supply are easily in abundant in supply.
The raw materials necessary are easily available from the nearby industrial
area & the industrial estate is always running with large number of chemical
industries, & hence getting skilled & experienced labor at reasonable rates is
not a problem.
13.2 PLANT LAYOUT:
After the process flow diagrams are completed & before detailed piping, structural &
electrical design can begin, the layout of process units in the plant must be planned.
Plant layout means the allocation of space, arrangement of equipment & machinery in
such a manner so that maximum utilization of manpower, machines & material is
done & minimum material handling is required.
The following factors should be considered in selecting the plant layout.
New site development or additions to previously developed site.
Type & quantity of product to be produced.
Possible future expansion.
Economic distribution of utilities & services.
Type of building & building code requirements.
Health & safety considerations.
Waste disposal problems.
Sensible use of floor & elevation space.
Operational convenience & accessibility.
Type of process & product control.
Space available & space required.
Maximum advantages of gravity flow are taken to reduce the operational cost
in the piping & flow design.
98
99
CHAPTER XIV
COST ESTIMATION
A plant design obviously must present a process that is capable of operating under
conditions, which will yield a profit. Since net profit equals total income minus all
expenses, it is essential that the chemical engineer be aware of many different types of
costs involved in manufacturing processes.
14.1 ESTIMATION CAPITAL COST:
14.1.1 Purchased Equipment Cost:
Table-14.1 Purchase Cost of equipments
Sr. No.
1
2
3
4
5
6
7
8
9
10
Equipment
MEG
STORAGE
TANK
HG STORAGE
TANK
ETHYLENE OXIDE
STORAGE
TANK
PLUG
FLOW
REACTOR
TRIPPLE
EFFECT
EVAPORATOR
VACUUM
DISTILLATION
COLUMN (PACKED
COLUMN)
DISTILLATION
COLUMN (PLATE
COLUMN)
DRYING COLUMN
CENTRIFUGAL
PUMP
HEAT EXCHANGER
No. of
EquipMents
Cost per
Unit (Rs.
Thusd)
Estimated
Cost
(Rs. Thusd)
200
400
200
200
200
400
500
500
85
85
70
70
75
75
1
6
50
10
50
60
20
140
100
11
12
13
BOILER
DM WATER
PLANT
COOLING
TOWER
50
100
25
25
10
20
Item
% of PEC
100
2125
40
850
15
318.75
Building cost
Yard improvement cost
60
12
18
10
1275
255
382.5
212.5
70
10
1487.5
212.5
Purchased Equipment
Delivered cost
Purchased
Equipment
Installation cost
Instrumentation & Control cost
(Installed)
Piping cost (Installed)
Electrical Installation cost
Item
% of PEC
Cost (Rs.
1
2
3
4
15
20
5
10
Thusd)
1067.81
1423.75
355.93
711.875
Amount
Ethylene oxide
Styrene Divinylbenzene
73450827.65 (Kg/Yr)
1.024 M3
Cost
Cost ( thuds
Rs)
30952.1787
91491.47
(Rs/m3)
(Catalyst)
TOTAL COST OF RAW MATERIAL
102
0.9368
Fixed Cost:
(1) Depreciation
Amount kg/year
MEG
99829190.88
60
= 59897.514 40338.00
= 19559.51 thusds Rs.
Tax Paid
It is given by P.O.P
11735.70 + 1067.8115
= 0.83 Years
RATE OF RETURN:
It is given by R.O.R
Net Profit
R.O.R =
=
= 91.85 %
105
X 100
REFERENCES
[1] Ullmann, Ullamanns Encyclopedia of Industrial Chemistry, Wiley-VCHVerlag Gmbu & Co. Weinheim, 2003, sixth edition, vol-12 (p-593-608).
[2] Kirk & Othmer, Encyclopedia of Chemical Technology, John Wiley & Sons,
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