Beruflich Dokumente
Kultur Dokumente
INTRODUCTION
INTRODUCTION
Page 1
MANUFACTURE OF PHENOL
Phenol is an aromatic compound with an OH group bonded to the phenyl ring with
chemical formula C6H5OH. Phenol is used in the production of disinfectants, dyes,
pharmaceuticals, plastics, germicides, preservatives, synthetic resins, antiseptic, detergents
and drugs.
Molecular structure:
Page 2
MANUFACTURE OF PHENOL
PHYSICAL PROPERTIES:
Phenol is a caustic, poisonous, white crystalline solid at room temperature. The
molecular weight and density of phenol are 94.11g/mole and 1.07g/cm 3 respectively. Phenol
is soluble in water is due to its ability to form hydrogen bonds with water.
PROPERTY
VALUE
Molecular formula
C6H6O
CAS number
108-95-2
Molecular weight
94.11 g/mole
Other names
Structure
Melting point
40.5 C, 314 K
Boiling point
181.7 C, 455 K
Density
1.07 g/cm
Solubility in water
8.3g/100ml
Triple point(Ttp)
314.06 K
Critical temperature(Tc)
692.4 K
358.15 K
PROPERTY
VALUE
Ignition temperature
988.15 K
8.6% in air
1.7% in air
Page 3
MANUFACTURE OF PHENOL
Heat of vaporization
45.606 KJ/mol
Heat capacity
33.91 KJ/mol
-165.1 KJ/mol
-96.44 KJ/mol
Heat of combustion
-3067 KJ/mol
CHEMICAL PROPERTIES:
(a) REACTION WITH FeCl3 :
Phenol gives violet coloration with ferric chloride
solution (neutral) due to the formation of a colored iron complex, which is a
characteristic to the existence of keto-enol tautomerism in phenols (predominantly
enolic form).
replace
C6H5ONa + H2O
Page 4
MANUFACTURE OF PHENOL
C6H5ONa + ClCH3
C6H5OK + IC2H5
C6H5OCH3 + NaOH
C6H5OC2H5 + KI
(c) Ethers are also formed when vapours of phenol and an alcohol are heated over
thoria (ThO2).
ThO2
C6H5OH + HOCH3
C6H5 - O - CH3
Methoxy benzene
3C6H5OH + POCI3
C6H6 + ZnO
Page 5
MANUFACTURE OF PHENOL
Zncl2
C6H5OH + NH3
C6H5NH2 + H2O
300o C
5C6H5SH + P2O5
Page 6
MANUFACTURE OF PHENOL
LITERATURE SURVEY
LITERATURE SURVEY
Page 7
MANUFACTURE OF PHENOL
COMMERCIAL PROCESSES:
1. Raschig process
2. Toluene two stage oxidation process
3. Sulfonation process
4. Cumene peroxidation process
RASCHIG PROCESS:
This process was developed in Germany in 1940. Benzene is first converted into
Chlorobenzene by passing a mixture of benzene vapour, hydrochloric acid vapour and air
under normal pressure at about 23c in presence of a copper iron catalyst, supported on
alumina. The reaction is exothermic in nature and so the temperature is maintained constant
by external cooling. The conversion per pass is 10%.
The Chlorobenzene after separation from unchanged reactants is hydrolyzed into
phenol by heating with steam at about 400-500c in presence of silica catalyst. The
conversion is again about 10% per pass in this second step. Hydrogen chloride set free in the
reaction is recovered and recycled. Crude phenol (97%) obtained according to the above
reaction is purified by distillation under vacuum. The yield is about 75-85% on benzene. A
small amount of HCl is sufficient to convert large amounts of benzene into phenol.
Page 8
MANUFACTURE OF PHENOL
overhead to two distillation columns in series. In the first column, crude phenol is separated
from overhead and unreacted benzoic acid is recycled to the second oxidizing reactor. Pure
form phenol is obtained at the second distillation column as overhead product
and supply's aromatics compounds and benzoic acid as a feed to crude phenol rectification
column. The yield of phenol on benzoic acid is about 75- 80%.
SULFONATION PROCESS:
It is one of the oldest methods of manufacture of phenol. Benzene sulphonic acid is
first prepared by passing vapour of benzene into concentrated sulphuric acid is about 150170C.The water formed during sulphonation process is distilled out because sulfuric acid
gets diluted and conditions accelerates backward reaction of the process. Benzene sulphonic
acid should be neutralized by reacting it with aqueous sodium sulphite to form salt of
benzene sulphonic acid. The sodium salt is filtered off and then fused with caustic in a cast
iron vessel at about 340-380C in the ratio (1:3) for about 5-6 hours. As a result, sodium
phenate is formed. The melt is cooled, extracted with water and then acidified with sulphur
dioxide. The latter is obtained as a result of neutralization of benzene sulphonic acid with
sodium sulphite. The upper oily layer of crude phenol is distilled under vacuum to get pure
phenol. The yield is about 80-90% on benzene. The lower layer contains sodium sulphite
which is separated and used for the neutralization of benzene sulphonic acid.
Page 9
MANUFACTURE OF PHENOL
decomposition, phenol (15%), acetone (9%), Cumene (73%) are formed along with some methylstyrene and acetophenone. These separated in a separator. The Cumene is recycled to
be used again and phenol is either extracted or recovered by distillation. The yield is about
92%.
Page 10
MANUFACTURE OF PHENOL
The phenol/acetone capacity expansion in the world has been brisk in recent years due
to the strong demand for its derivatives such as Bisphenol A and phenolic resins. The largest
single market for phenol is in the production of Bisphenol A (BPA), which is manufactured
from phenol and acetone. About 40% of BPA is made up from phenol. World consumption of
phenol for BPA is estimated to grow at a good average annual rate during 20092014.
Increased demand and capacity for BPA will result in strong demand for phenol in these
regions. Bisphenol A of Asian demand is expected to increase by 13% this year. The secondlargest derivative market for phenol is phenol resins which are used in the moulding of heatresistant components for household appliances, counter-top and flooring laminates, and
foundry castings. From ICIS news, the global phenol market has been growing at an average
of 5% per year and total demand will recover from 7.9M tonnes in 2009 to reach 10.6M
tonnes by 2015. The phenol markets look especially promising in China since 2000.
SUPPLY OF PHENOL:
Shell, Sunoco, Georgia Gulf, Dow, JLM and INEOS are the major producer in United
State. Shell Chemical LP have a facility that is fully integrated from raw materials to end
products gives Shell Chemical LP a significant advantage in operating as a low cost producer
of phenol. However, INEOS Chemical is the world largest phenol producer. INEOS Chemical
produce 540 kilo tonne per year to USA and 1330 kilo tonne per year to Europe while Sunoco
produces over 590,000 TPA of phenol in its facility in Philadelphia, Penn, USA. Sunoco/UOP
phenol technology is currently used in 11 plants worldwide having a total phenol capacity of
more than 1,500,000 TPA. The capacity of phenol in China still cannot meet the demand thus
many enterprises are plan to expand or construct the new units.
Page 11
MANUFACTURE OF PHENOL
PROCESS DESCRIPTION
PROCESS DESCRIPTION
In this production process, purified Cumene is used as raw material input and is
mixed with recycle Cumene in the main feed stream. It is feed to the oxidation vessel which
Page 12
MANUFACTURE OF PHENOL
the condition is maintained at 110-115 C and pH range of 6.0 to 8.0. In the vessel, the
mixture from the feed is exposed to compressed air until Cumene has converted into Cumene
Hydroperoxide. This is the stoichiometry equation of the reaction.
C6H5CH (CH3)2 + O2
C6H5C (CH3)2OOH
Here in this reactor a side reaction also takes place. Cumene reacts with oxygen to
produce acetophenone and methylstyrene along with methane gas. The reaction involved is
The crude mixture from the oxidizer is concentrated before entering the reactor where
the Cumene Hydroperoxide is cleavage to phenol and acetone. The reaction is carried out in
mild temperature and pressure around 70 C and atmospheric pressure. Small amount of
sulphuric acid is added to the reactor as the reaction takes place. Here sulphuric acid acts as
catalyst. The reaction that takes place in this reactor is
C6H5C (CH3)2OOH
C6H5OH + CH3COCH3
Then the produced products are sent to the separator. In the separator all the gases are
allowed to outlet.
Now the entire crude is sent through a series of distillation columns. In the first
distillation column acetone is removed as the top. For this the distillation column is
maintained at the temperature of 100 C and normal atmospheric pressure. Then acetone is
obtained as a by-product from the top. Then the bottom product is sent to next distillation
column.
BAPATLA ENGINEERING COLLEGE, BAPATLA
Page 13
MANUFACTURE OF PHENOL
The second distillation column is maintained at the temperature of 160 C and a
normal atmospheric pressure. Here 95% of Cumene is separated as top product. Here
separated Cumene may be used as recycle. Then the remaining crude is sent to next
distillation column.
Third distillation column is used to separate methylstyrene. Here the temperature is
maintained at 175C and normal atmospheric pressure is maintained. Here 95% of methyl
styrene is removed as top along with traces of left out Cumene. Then the remaining crude is
sent to next distillation column.
In the fourth distillation column phenol and acetophenone are separated. Here, in this
distillation column the temperature is maintained at 190C and a pressure of normal
atmospheric pressure is maintained. Here all the phenol is separated as top and acetophenone
is removed from the bottom. Then the removed phenol is sent to crystallizer to form crystal
form of phenol which is 99% pure is obtained.
Page 14
MANUFACTURE OF PHENOL
PROCESS
FLOW DIAGRAM
FLOW DIAGRAM
Page 15
MANUFACTURE OF PHENOL
GASES
CUMENE
B1
B8
ACETONE
B3
11
AIR
8
5
METSTY
CUMENE1
14
17
B10
B5
B9
B11
PHENOL
16
15
ACETOPHE
COLUMN I, B5= DISTILLATION COLUMN II, B9= DISTILLATION COLUMN III, B10=
DISTILLATION COLUMN IV, B11= CRYSTALLIZER.
Page 16
MANUFACTURE OF PHENOL
MATERIAL BALANCES
MATERIAL BALANCE
Page 17
MANUFACTURE OF PHENOL
BASIS: 100 TPD OF PHENOL
Here we have a yield of 90% and conversion is 60%.
From the reactions all the stoichiometric coefficients are same. So in order to produce
one mole of phenol one mole of cumene and one mole of air are required if the conversion is
100%. But here conversion is only 60%. So in order to produce 100 tons i.e. 1063 kmol of
phenol we need 1968.52 kmol of cumene. Out of which 90% converted to phenol and
remaining will be converted as by-products methylstyrene and acetophenone.
Here we are taking 50% excess air for better reactivity. We are also considering air
contains only oxygen and nitrogen in the ratio 21:79 respectively. So the feed for the process
is 1968.52 kmol of cumene, 2952.78 kmol of oxygen and 11108.07714 kmol of nitrogen.
OXIDISER:
INPUT
COMPONENT
CUMENE
BAPATLA ENGINEERINGOXYGEN
COLLEGE, BAPATLA
NITROGEN
TOTAL
WEIGHT(kgs)
236222.44
94488.96
311026.1599
641737.5599
Page 18
MANUFACTURE OF PHENOL
OUTPUT
CLEAVAGE
INPUT
COMPONENT
WEIGHT(kgs)
NITROGEN
311026.1599
CUMENE
HYDROPEROXIDE
161576
CUMENE
94488.96
OXYGEN
59528.0704
METHYLSTYRENE
6968.5608
ACETOPHENONE
7086.672
METHANE
944.8896
HYDROGEN
118.1112
TOTAL
641737.424
COMPONENT
WEIGHT(kgs)
NITROGEN
311026.1599
CUMENE
HYDROPEROXIDE
161576
CUMENE
94488.96
OXYGEN
59528.0704
METHYLSTYRENE
6968.5608
ACETOPHENONE
7086.672
METHANE
944.8896
BAPATLA ENGINEERING
COLLEGE, BAPATLA
HYDROGEN
TOTAL
118.1112
641737.424
TANK:
Page 19
MANUFACTURE OF PHENOL
OUTPUT
COMPONENT
WEIGHT(kgs)
NITROGEN
311026.1599
CUMENE
94488.96
OXYGEN
59528.0704
METHYLSTYRENE
6968.5608
ACETOPHENONE
7086.672
METHANE
944.8896
HYDROGEN
118.1112
PHENOL
99922
ACETONE
61654
TOTAL
641737.424
SEPERATOR:
INPUT
Page 20
MANUFACTURE OF PHENOL
COMPONENT
WEIGHT(kgs)
NITROGEN
311026.1599
CUMENE
94488.96
OXYGEN
59528.0704
METHYLSTYRENE
6968.5608
ACETOPHENONE
7086.672
METHANE
944.8896
HYDROGEN
118.1112
PHENOL
99922
ACETONE
61654
TOTAL
641737.424
OUTPUT
COMPONENT
TOP(kgs)
BOTTOM (kgs)
NITROGEN
311026.1599
---
CUMENE
---
94488.96
OXYGEN
59528.0704
---
METHYLSTYRENE
---
6968.5608
ACETOPHENONE
---
7086.672
METHANE
944.8896
---
HYDROGEN
118.1112
---
PHENOL
---
99922
ACETONE
---
61654
TOTAL
371671.2311
641737.424
DISTILLATION COLUMN I
Page 21
MANUFACTURE OF PHENOL
INPUT
COMPONENT
WEIGHT(kgs)
CUMENE
94488.96
METHYLSTYRENE
6968.5608
ACETOPHENONE
7086.672
PHENOL
99922
ACETONE
61654
TOTAL
270120.1928
OUTPUT
COMPONENT
TOP(kgs)
BOTTOM (kgs)
ACETONE
61654
---
CUMENE
---
94488.96
METHYLSTYRENE
---
6968.5608
ACETOPHENONE
---
7086.672
PHENOL
---
99922
TOTAL
61654
208466.2
DISTILLATION COLUMN II
Page 22
MANUFACTURE OF PHENOL
INPUT
COMPONENT
WEIGHT(kgs)
CUMENE
94488.96
METHYLSTYRENE
6968.5608
ACETOPHENONE
7086.672
PHENOL
99922
TOTAL
208466.2
OUTPUT
COMPONENT
TOP(kgs)
BOTTOM (kgs)
CUMENE
89764.512
4724.448
METHYLSTYRENE
---
6968.5608
ACETOPHENONE
---
7086.672
PHENOL
---
99922
TOTAL
89764.512
118701.688
Page 23
MANUFACTURE OF PHENOL
INPUT
COMPONENT
WEIGHT(kgs)
CUMENE
4724.448
METHYLSTYRENE
6968.5608
ACETOPHENONE
7086.672
PHENOL
99922
TOTAL
118701.688
OUTPUT
COMPONENT
TOP(kgs)
BOTTOM (kgs)
CUMENE
4724.448
---
METHYLSTYRENE
6620.13276
348.4
ACETOPHENONE
---
7086.672
PHENOL
---
99922
TOTAL
11344.58
107357.072
DISTILLATION COLIMN 1V
Page 24
MANUFACTURE OF PHENOL
INPUT
COMPONENT
WEIGHT(kgs)
METHYLSTYRENE
348.4
ACETOPHENONE
7086.672
PHENOL
99922
TOTAL
107357.072
OUTPUT
COMPONENT
TOP(kgs)
BOTTOM (kgs)
METHYLSTYRENE
348.4
---
ACETOPHENONE
---
7086.672
PHENOL
99922
---
TOTAL
100270.4
7086.672
CRYSTALLIZER
OUTPUT(kgs)
TOP
BOTTOM
COMPONENT
INPUT (kgs)
METHYLSTYRENE
348.4
348.4
---
PHENOL
99922
---
99922
TOTAL
100270.4
348.4
99922
Page 25
MANUFACTURE OF PHENOL
ENERGY BALANCE
ENERGY BALANCE
Page 26
MANUFACTURE OF PHENOL
Hydrocarbon Groups
=C(H,C)
=C(2C)
=C(2H)
C(3H,C)
CO(2C)
ai
4.0749
1.9570
4.1763
3.8452
5.43750
bi
-1.0735
-0.31938
-0.47392
-0.33997
0.72091
di
0.21413
0.11911
0.099928
0.19489
-0.18312
= (139.2
10-12) T3
Oxygen
= (29.1
10-12) T3
Cumene peroxide = (1.345 105) + (3.806 102) T
Page 27
MANUFACTURE OF PHENOL
Methyl styrene = 268.625 -0.567T + (1.33 10-3) T2
Acetophenone = 262.84 -0.44113T + (9.989 10-4) T2
Phenol = (187.858) - (0.565) T + (1.468 10-3) T2
Acetone = (187.858) - (0.565) T + (1.468 10-3) T2
Acetone = 5.11 10
KJ/Kg
2
Acetophenone = 3.5 10
Cumene = 3.12 10
KJ/Kg
KJ/Kg
Page 28
MANUFACTURE OF PHENOL
2
Methylstyrene = 3.26 10 KJ/Kg
OXIDISER:
Reference temperature: 25C
Reactor temperature:
110C
Enthalpy of inlet + Heat of reaction = enthalpy of outlet + heat added (or) evolved
Enthalpy associated with inlet =
CpT
=55105.85 KJ/day
Enthalpy associated with outlet =
CpT
= 24886763 KJ/day
Heat of reaction = heat of formation of products heat of formation of reactants
Heat of reaction = -114172.078 KJ/mol
So, heat evolved from the reactor = 2547742 KJ/day
CLEAVAGE:
Reference temperature: 25C
Reactor temperature:
70C
Enthalpy of inlet + Heat of reaction = enthalpy of outlet + heat added (or) evolved
Enthalpy associated with inlet =
CpT
=22288834 KJ/day
Page 29
MANUFACTURE OF PHENOL
Enthalpy associated with outlet =
CpT
= 24396697.87 KJ/day
Heat of reaction = heat of formation of products heat of formation of reactants
Heat of reaction = 62036.78 KJ/mol
So, heat evolved from the reactor = 2045826.31 KJ/day
DISTILLATION COLUMN I
Reference temperature = 25C
Entering stream temperature =700C
Page 30
MANUFACTURE OF PHENOL
DISTILLATION COLUMN II
Reference temperature = 25C
Entering stream temperature =1100C
Page 31
MANUFACTURE OF PHENOL
Enthalpy of feed + reboiler feed = enthalpy of bottom + enthalpy of top + condenser
load
DISTILLATION COLUMN IV
Reference temperature = 25C
Entering stream temperature =600C
Page 32
MANUFACTURE OF PHENOL
CRYSTALLIZER:
Phenol crystallizes at 40.5C. Phenol comes out from the distillation column at 120C.
Feed rate of phenol = 99922 Kg/day
Enthalpy to be removed =
DESIGN OF
DISTILLATION COLUMN
BAPATLA ENGINEERING COLLEGE, BAPATLA
Page 33
MANUFACTURE OF PHENOL
L
D
=2
4Vw
v U v
l v
v
Page 34
MANUFACTURE OF PHENOL
Then, Uv = (-0.171 0.52 + 0.27 0.5 0.047)
10703.892
v 3.892
= 0.7849 m/s
(De) =
4 299766
3.892 0.7849 24 3600
= 1.2025m
PLATE DESIGN:
1.563252
4
= 1.9193 m2
Down comer area Ad = 12 % of Ac = 0.12 1.9193
= 0.2303 m2
Net area An = Ac - Ad = 1.9193 0.2303
= 1.698 m2
Hole area Ah = 10% of net area = 0.1 An
= 0.1689 m2
Page 35
MANUFACTURE OF PHENOL
Fig 11.31, Coulson & Richardson, (6th vol)
Ad
From graph ( A c
Lw
100 vs (
Dc
0.2303
= ( 1.9193
Corresponding, (
100 = 12
Lw
= 0.74
Dc
Assume parameters
Weir height (hw) = 50mm
Hole diameter (dh) = 5mm
Plate thickness (pt) = 5mm
From plot ( D c
vs ( D c
Lw
We have ( D c
= 0.74
Lh
Corresponding ( D c = 0.18
Therefore Lh = 0.18 1.56325
= 0.281m
BAPATLA ENGINEERING COLLEGE, BAPATLA
Page 36
MANUFACTURE OF PHENOL
HOLE PITCH:
Hole pitch (distance between the hole centres) L p should not be less than 2.0 hole
diameter, and the normal range will be 2.5 to 4.0 diameter.
Consider,
Hole pitch (Lp) = 3 hole diameter
=3 5
=15 mm
Consider the holes are in equilateral triangle pattern.
Then,
Ah
Ap
[ ]
dh
0.9
=
Lp
Ap = perforated area =
[ ]
5
= 0.9 15
Ah
0.1
= 0.1
0.1689
0.1
1.689 m2
FLOODING VELOCITY:
Ut = K1
v v
v
Page 37
MANUFACTURE OF PHENOL
Here, FLV is liquid vapour flow rate =
Lw v
V w l
1.1658 3.892
299760 1070
=0.0707
From graph, K1 = 0.15
Then, Uf = 2.104 m/s
Height of the bottom edge of apron above the plate,
hap=hw
(5 to 10 mm)
The height is normally set at 5 to 10 mm below the outlet of the weir height, take it as
7mm.
Then,
hap=hw
(8 mm)
= 42 mm
Residual drop = hr =
12.5 10 3
l
Lw =
= 12.1359mm
[ ]
Lw
lw . L
Page 38
MANUFACTURE OF PHENOL
l w =
=710.94 Kg/m3
how =33.675mm
hd
[ ]
Uh
= 51 C o
L
V
K 20.9 ( 25.4d h )
[ V ]
1/ 2
;(
dh
in mm)
Here
, K2
hw +h ow
=50+33.675
= 83.675 mm
Corresponding
K2
=30.6
Here,
Ah
Ap
100=10
Corresponding
Then,
hd
Co
=0.842
=15.1593 mm
ht
hd
+(
hw +h ow
)+
hr
Pt
3
) = 9.81 L h t 10 =811.9273 Pa
Page 39
MANUFACTURE OF PHENOL
CLEARANCE AREA:
A ap A m=h ap . l w
= 0.1253 m2
HEADLOSS IN DOWNCOMER:
Lwd
hdc =166
L . Am
Where,
Lwd
3.59244Kg/s
l=710.94 Kg /m
A m =0.1253 m2
Then,
hdc =8.5357 mm
RESULTS:
Total no of stages
= 14
= 0.5 m
Column height
=7m
= 1.2025 m
= 0.7849 m/s
= 1.9193 m2
= 0.2303 m2
Page 40
MANUFACTURE OF PHENOL
Net area (An)
= 1.689 m2
Hole area
= 0.1689 m2
= 1.1568 m
= 50 mm
= 5 mm
= 5mm
= 0.281 m
= 15mm
= 1.689 m2
= 12.1359 mm
= 33.6750 mm
= 15.1593 mm
= 6.5655 m/s
= 116.4167mm
= 811.9273Pa
= 2.1401 m/s
= 0.0707
= 4.2mm
= 0.1253m
= 208.6274 mm
= 11.2402 sec
Page 41
MANUFACTURE OF PHENOL
COST ESTIMATION
Page 42
MANUFACTURE OF PHENOL
COST ESTIMATION
A capital investment is required for any other industrial process. The capital
investment plus working capital must be available to pay salaries, keep raw materials and
product on hand and handle other special items required a direct cash outlay thus in an
analysis of costs, manufacturing costs and general expenses including income tax must be
taken into consideration.
Capital investment is defined as the total amount of money needed to supply the
necessary plant and manufacturing facilities plus the amount of money required as working
capital for operating of the facilities.
Total capital cost = Fixed capital investment + Working capital requirement
Fixed capital investment = Direct cost + Indirect cost
Fixed capital investment represents the capital necessary for the installed process
equipment with all auxiliaries that are needed for complete process operation. Expenses for
piping, instruments, insulation, foundations and site preparation are typical examples of costs
included in the manufacturing fixed capital investment.
Page 43
MANUFACTURE OF PHENOL
DIRECT COST:
1. PURCHASED EQUIPMENT COST:
EQUIPMENT
COST/UNIT
NUMBER OF
TOTAL COST
IN $
UNITS
IN $
REACTOR
600 10
1200 10
DISTILLATION
3
100 10
3
400 10
SEPERATOR
3
200 10
3
200 10
CRYSTALLIZER
60 10
200 10
9.3 Cr
COLUMN
TOTAL
2. INSULATION COST:
Insulation cost is 10 15 % of PEC
Assuming 15%
Therefore Insulation cost (IC) = 1.395 Cr
3. PIPING & INSTALLATION COST:
It is 18 25% of PEC
Assuming 22%
Therefore Piping and installation cost (PIC) = 1.86Cr
Page 44
MANUFACTURE OF PHENOL
Page 45
MANUFACTURE OF PHENOL
9. LAND COST:
It is 20% of PEC
Therefore land cost (LC) = 1.86 Cr
10. TECHNOLOGY & ENGG FIELD:
It is 20% of PEC
Therefore technology & engg field(TEF ) = 1.86 Cr
TOTAL DIRECT COST = Rs. 34.41 Cr
INDIRECT COST:
1. ENGG & SUPERVISION COST:
It is 15 30 % of PEC
Assuming 25%
Therefore Engg & supervision cost (ESC) = 2.325 Cr
2. CONSTRUCTION EXPENSES & CONTRACTORS FEE:
It is 34% of PEC
Therefore Construction Expanses & Contractors Fee (ESC) = 3.162 Cr
3. CONTINGENCY:
It is 8 20% 0f PEC
Assuming 15%
Therefore contingency = 1.395 Cr
TOTAL INDIRECT COST = Rs. 6.882 Cr
Page 46
MANUFACTURE OF PHENOL
Therefore,
FIXED CAPITAL INVESTMENT (FCI) = DIRECT COST + INDIRECT COST
= 34.14 + 6.882
= Rs.41.292 Cr
1. FIXED COST:
a. DEPRECIATION:
It is 10% of FCI
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Therefore depreciation = 4.1292 Cr
b. LOCAL TAXES:
It is 3 4% of FCI
Assuming 4%
Therefore local taxes = 1.65168 Cr
c. INSURANCE:
It is 0.4 1%
Assuming 1%
Therefore insurance = 0.41292 Cr
TOTAL FIXED CHARGES = Rs. 6.1938 Cr
BUT FIXED CHARGES = 15% OF TOTAL PRODUCTION COST (TPC)
THEREFORE TPC = 6.1938 (100/15)
= 41.292 Cr
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MANUFACTURE OF PHENOL
Assuming 15 %
Therefore Operating labour cost (OLC) = 6.1938 Cr
c. DIRECT SUPERVISORY & ELECTRICAL LABOUR
It is 20 % of Operating Labour
Therefore Direct Supervisory & electrical labour (DSEL) = 1. 23876 Cr
d. UTILITIES:
It is 10 20% of TPC
Assuming 13%
Therefore cost of utilities = 6 1938 Cr
e. MAINTENANCE:
It is 2 10% of FCI
Assuming 5%
Therefore maintenance cost (MC) = 2.0646 Cr
f. OPERATING SUPPLIES:
It is 10 20% of maintenance cost
Assuming 15%
Therefore operating supplies cost (OSC) = 0.30969 Cr
g. LABORATORY CHARGES:
It is 10 20 % of Operating Labour cost
Assuming 15 %
Therefore labour charges = 0.92907 Cr
h. PATENT AND ROYALITIES:
It is 2 6% of TPC
BAPATLA ENGINEERING COLLEGE, BAPATLA
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MANUFACTURE OF PHENOL
Assuming 3%
Therefore Patent & Royalties (PAR) = 1.23876 Cr
Therefore,
TOTAL DIRECT PRODUCTION COST = Rs. 23.53644 Cr
GENERAL EXPENSES:
a. ADMINISTRATION COST:
It is 20 30% of Operating Cost
Assuming 25%
Therefore Administration Cost (AC) = 1.58485 Cr
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MANUFACTURE OF PHENOL
Therefore distribution & Marketing cost (DMC) = 3.530466 Cr
= 386.1 Cr
Gross profit = Total income Total production cost
= 386.1 41.24994
= 344.85 Cr
Assuming tax to be 35%
Net profit = Gross profit ( 1tax )
= 344.85 ( 10.35 )
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MANUFACTURE OF PHENOL
= 244.1525 Cr
100
= 63.23%
Payout period = TCI / (Net profit + Depreciation)
= 47.4858 / (244.1525 + 4.1292)
= 0.1912 years
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PLANT LAYOUT
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PLANT LAYOUT
The choice of final site should be based on complete survey advantages and
disadvantages of various geographical areas and, ultimately, on the advantages and
disadvantages of available real estate.
The source of raw material is one of the most important factors influencing the
location of the plant site because location near the raw materials source permits considerable
reduction in transportation and storage charges. Proximity to major markets is one important
consideration in selection of plant site. It should be noted that markets are needed for byproducts as well as for major final products. Power and fuel can be combined as another
major factor in the choice of a plant site as their requirements are high in most of the
industrial plants. A location near a source of fuel supply or large hydro electric installations
may be essential for economic operations.
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MANUFACTURE OF PHENOL
The plant site should have access to all types of transportation; certainly two types
should be available. The proximity to rail road centers and possibility of canal, river, lake or
oceans transport must be considered. The kind and amount of products and raw materials
determine the most suitable type of transportation facilities. Attention should be paid to local
freight rates and existing road lines.
Climate is a factor that should be examined when selecting a plant site. Improper
selection can have serious effect on the economic operation of a plant. The process industries
use large quantities of water for cooling, washing, steam generation and as a raw material.
The plant therefore must be located where a dependable supply of water is available. The
temperature, mineral content silt or sand content, bacteriological content and cost for supply
and purification treatment must also be considered while choosing the water supply. The site
selected for a plant should have adequate capacity and facilities for waste water disposal.
The permissible tolerance levels for various methods of waste disposal should be
consider carefully and potential requirements for additional waste treatment facilities should
be consider, even though a given area has minimal restrictions on pollution.
Type and supply of skilled and unskilled work force available in the vicinity of
proposed plant should be examined. Similarity state and local tax rates on property income,
unemployed insurance, local regulations on zoning, building codes, nuisance aspects and
transportation facilities have a major influence on the final choice of plant site.
Considering all the above factors and keeping in view the latest development trends,
storage facilities for raw materials and intermediate and finished products may be located, in
isolated areas or in adjoining areas. The plant can be located near any refinery such as MRPL,
IOCL, OR IPCL. As water needed in large quantity, the site near river will be quite feasible
as water can be obtained from it.
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MANUFACTURE OF PHENOL
Plant layout involves the layout of process units in a plant and the equipment within
these process units. The layout can play an important parting determining construction and
manufacturing costs and thus be planned carefully with the attention being gives to future
problems that may arise. Plant layout means the disposition of the various equipments,
material and man power etc., and services of the plant within the area of the site selected
previously. The plant layout begins with the design of the factory building and goes up to the
location and movement of the work table. All the facilities like equipments, raw materials,
machinery, tools, fixtures workers etc., are given a proper place. Rational design must include
arrangement of processing areas, storage areas and handling areas in efficient co-ordination
and with regards to such factors as
1. New site development or addition to a previously developed site.
2. Future expansion.
3. Economic distribution of services- water, process steams, power and gas.
4. Weather condition.
5. Safety consideration- possible hazards of fire, explosion and fumes.
6. Building code requirements.
7. Waste disposal problems.
8. Sensible use of floor and elevation space.
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MANUFACTURE OF PHENOL
The number of movements of workers and materials should be minimized. It
is better to transport materials in optimum bulk rather than in small amounts.
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ENGINEERING
PROBLEMS AND SAFETY
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MANUFACTURE OF PHENOL
SAFETY CONSIDERATIONS:
There is every incentive and a real necessity foe including a survey of safety and fire
hazards in a study of chemical engineering processes. Some of the important safety
considerations in the chemical industries where toxic substances are manufactured, handled
or used are summarized here. Suitable services should be installed where ever possible to
give warning in case of liberation quantities of these substances. Every operation or process
involving use of irritating and the packing of the product should be effected by mechanical
means is apparatus provided with adequate enclosures and dust collecting systems in order to
curtail atmospheric contamination. Any spillage of irritating or toxic dry compounds should
be removed as quickly as possible, preferably by vacuum apparatus.
All personnel exposed to toxic substances should be provided overalls or working
clothing and also a time allowance of not less than 10 minutes at the expense of the employer
for the use of baths at the end of days work.
One or more aid tips or cabinets, containing sufficient and suitable first aid dressing
and other equipment should be provided and maintained in easily available locations for
immediate temporary treatment in case of accident or sudden illness.
BAPATLA ENGINEERING COLLEGE, BAPATLA
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MANUFACTURE OF PHENOL
to electrostatic discharge. All phenol workers should be properly trained on its hazards and
the proper protective measure required. This training should also include emergency actions.
All phenol operations should be enclosure to eliminate any potential exposure routes.
Containers of this material may be hazardous when empty since they retrain product residue
observe all warnings and precaution listed for the product.
EXPOSURE CONTROL/PERSONAL PRODUCTION
Airborne exposure limits
OSHA Permissible Exposure limit (PEL)
ACGIH Threshold limit value (TLV)
VENTILATION SYSTEM:
A system of local is generally preferred because it can control the emission of the
contaminant at its source, preventing dispersion of it into the general work area. Please refer
to the ACGIH document, Industrial ventilation manual of recommended practices most recent
edition for details.
PERSONAL RESPIRATORS (NIOSH APPROVED):
If the exposure limit is exceeded a full face piece respirator with organic vapour
cartridge and dust/mist filter may be worn up to 50 times the exposure limit or the maximum
use concentration specified by the appropriate regulatory agency or respirator supplier
whichever is lowest. For emergencies or instance where the exposure levels are not known
use a full face piece positive pressure air supplied respirator.
SKIN PROTECTION:
Wear impervious protective clothing including boots, gloves, lab coat, apron or
coveralls to prevent skin contact. Butyl rubber and neoprene are suitable materials for
personal protective equipment.
EYE PROTECTION:
Use chemical safety goggles and or full face shield where dusting or splashing of
solution is possible. Maintain eye wash fountain and quick-drench facilities in work area.
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CONCLUSION
1. In this pre- preliminary feasibly report a design of a plant to produce 100 TPD of phenol is
proposed and its feasibility was studied.
2. Demand of phenol is increasing year by year 2009 2015. From last year data estimation
had been made until year 2015 which shown an increase quantity from 7.9 m tons in 2009 to
reach 10.6 m tons by 2015.
3. After analysing properties of phenol, we found that there are many side effects if we
expose to phenol such as irritation, corneal damage or blindness in humans.
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BIBLIOGRAPHY
TEXT BOOKS:
1. Analysis synthesis and design of chemical processes by Richard Turton, Richard C. Bailie,
Wallanc B. Whiting, Joseph a. Shaeiwitz.
2. Plant design and economics for chemical engineers, 4th edition, by Max S. Peters, Klaus
D.Timmerhaus.
3. Coulson & Richardson's Chemical Engineering by R.K. Sinnott- Volume VI, chemical
Engineering design.
4. Perry's Chemical Engineers' Handbook, 8th Edition, Robert H. Perry, Don W. Green
5. Properties of Gases and Liquids, fifth edition, Bruce E.Poling, John M. Prausnitz, John
P.OConnel.
WEB REFERENCES:
1. http://www.sciencedirect.com
2. http://webbook.nist.gov/chemistry/name-ser.html
3. http://www.wikipedia.com
4. http://www.tradeindia.com
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