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TABLE OF CONTENTS

ACKNOWLEDGEMENT.............................................................................................................04

ABSTRACT ..................................................................................................................................05

1 INTRODUCTION.............................................................................................................06

1.1 Definition of Process Design........................................................................................06


1.2 Scenario of Oil Market in Bangladesh.........................................................................06
1.3 What is Natural-Gas Condensate.................................................................................06
1.4 Composition of Natural-Gas Condensate.....................................................................07
1.5 Types of Condensate....................................................................................................07
1.6 Plant Definition............................................................................................................07
1.7 Product Application.....................................................................................................08

2 PLANT DESIGN BASIS...................................................................................................09

2.1 Plant Location..............................................................................................................09


2.2 Plant Area.....................................................................................................................09
2.3 Climate Condition........................................................................................................09
2.4 Utility Condition..........................................................................................................09
2.5 Feed Rate.....................................................................................................................09
2.6 Design Basis for Simulation by HYSYS.....................................................................09
2.7 Feed (Gas Condensate) Composition and Boiling Point.............................................10
2.8 Product Specification...................................................................................................10
2.9 Assumptions.................................................................................................................10

3 PROCESS BLOCK DIAGRAM.......................................................................................11

4 PROCESS DESCRIPTION...............................................................................................12

4.1 Preheating.....................................................................................................................12
4.2 Fractionation................................................................................................................12

5 MATERIAL AND ENERGY BALANCE.........................................................................14

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6 UTILITY REQUIREMENT..............................................................................................17

6.1 Power...........................................................................................................................17
6.2 Cooling Water..............................................................................................................17
6.3 Steam............................................................................................................................17

6.4 Air................................................................................................................................17

7 PROCESS FLOW DIAGRAM..........................................................................................18

8 COST ESTIMATION........................................................................................................19

8.1 Estimation of Capital Investment..................................................................................19


8.2 Estimation of Revenue..................................................................................................20
8.3 Estimation of Total Product Cost..................................................................................21

9 INVESTMENT ANALYSIS.............................................................................................22
9.1 Return on Investment....................................................................................................22
9.2 Payout Period...............................................................................................................23

10 SAFETY............................................................................................................................25

10.1 Definition...................................................................................................................25

10.2 Hazards Associated with Condensate Fractionation Activities...................................25

10.3 Planning and Prevention............................................................................................26

10.4 Risk Management Process Key Steps.........................................................................26

10.5 First Aid Measures......................................................................................................27

10.6 Extinguishing Media..................................................................................................27

10.7 Fire Fighting Instructions...........................................................................................27

10.8 Regular Checking and Monitoring..............................................................................28

10.9 Safety Sign.................................................................................................................28

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11 PLANT LAYOUT.............................................................................................................29
12 DISCUSSION....................................................................................................................30
13 CONCLUSION..................................................................................................................31
REFERENCES..............................................................................................................................32
APPENDICES...............................................................................................................................33
Appendix A........................................................................................................................33
Appendix B........................................................................................................................34

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ACKNOWLEDGEMENT

We express our profound gratitude to our Project Supervisor, Dr. Engr. Salma Akhter, Professor,
Chemical Engineering and Polymer Science(CEP), SUST, Sylhet for his constant supervision and
valuable guidance. This small endeavor would not have seen the light of the day without his
constant support, fruitful discussions in various capacities.
We would also like to extend our whole-hearted thanks and gratitude to the coordinator of this
course (CEP-418) Ms. Rahatun Akter, Lecturer, CEP, SUST for explaining to us the project work
and also necessary requisites for the same.
Our special thanks also goes to Mr. Suman Bikash Das, Chief Engineer, Rashidpur Condensate
Fractionation Plant for allowing us to visit the plant and rendering necessary information.
We would also like to thank Riazul Islam, Assistant Engineer, Rashidpur Condensate Fractionation
Plant for his kind help.

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ABSTRACT

A successful chemical engineer in this modern age of national and international competition needs
more than a knowledge and full understanding of the fundamental science and related engineering
concepts of material and energy balances, thermodynamics, reaction kinetics, mass transfer and
different simulation software. The engineer must also have to apply this knowledge to practical
situations to initiate and develop new or improve process and products that will be beneficial to
society. However, in achieving this goal, the chemical engineer must recognize the economic,
environmental and ethical applications that are involved in such developments. Keeping in these
mind, the “Plant Design Sessional” course is included in our academic syllabus. This course is
designed to challenge chemical engineers to combine basic knowledge from other courses and
principles and tools for process design with practical elements of economics, business practices
and organization along with principles of safety, environmental and sociological issues to design
an integrated chemical process plant. As a part of this course we are proposing a condensate
fractionation plant named “Kushiara Condensate Fractionation Plant” of a production capacity of
4000 bbl./day. The steady state simulation of condensate fractionation plant is carried out using
Aspen Hysys8.8 Process Simulator.

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1 INTRODUCTION
1.1 Definition of Process Design
The plant design project involves a small group of students working as a team to design a
nominated chemical plant. The tasks include the study of the available processes, process selection,
calculation of material and energy balances, preparation of flow sheets, design of selected plant
items, an assessment of factors affecting plant safety, sustainability and environmental impact,
estimation of plant cost and process economics, preparation of a design report and drawing of the
plant layout.

1.2 Scenario of Oil Market in Bangladesh


The most profile and dynamic industries of this century are the petroleum and petrochemical.
Worldwide average demand of nearly 96 million barrels of oil and liquid fuels per day – that works
out to more than 35 billion barrels a year. Various kinds of oils are used in our everyday life that
comes out by the refining of crude and condensate. Bangladesh has 21 gas field in production and
about 12517.1 bbl./day condensate is produced as a byproduct from these gas field which is 2% of
the total gas production. This condensate can be used to produce varieties of useful products by
refining. That is why the demand of condensate refining is increasing day by day. New refining
plants are being established now a day. At present, 12 refineries, four are in the public sector and
the rest are private, process the current supply of condensate extracted from the country’s 21 gas
fields and sell them to BPC’s marketing companies. The state-owned and international oil
companies extracted some 560,000 tons of condensate in the ongoing fiscal 2015-16. At present,
560,000 tons of petrol, octane, diesel, kerosene and other products are being produced locally
against the total demand of over 350,000 million tons. The refinery sectors buy condensate at an
average cost of 43 BDT/L. The three petroleum marketing companies of BPC – Padma, Meghna
and Jamuna – are retailing diesel at Tk65 and kerosene at Tk65, petrol at Tk86 and octane at Tk89
per liter. Condensate produces in Bangladesh meet the requirement of all fractionation plant and
remain excess. Bangladesh government is set to export natural gas condensate after outpaced local
demand. Instead of selling the raw condensate, if we sell the finished product we can grain extra
profit and it will help solving country’s unemployment problem. For this reason we have chosen
to design a condensate fractionation plant.

1.3 What is Natural-Gas Condensate


Natural-gas condensate is a low-density mixture of hydrocarbon liquids that are present as gaseous
components in the raw natural gas produced from many natural gas fields. Some gas species within
the raw natural gas will condense to a liquid state if the temperature is reduced to below the
hydrocarbon dew point temperature at a set pressure. Condensate is a low density, high API gravity
colorless or light yellow liquid hydrocarbons which is generally found with natural gas. The natural
gas condensate is also referred to as simply condensate or gas condensate or sometimes natural
gasoline, because it contains hydrocarbons within the gasoline boiling range.

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1.4 Composition of Natural-Gas Condensate

There are hundreds of wet gas field worldwide and each has its own unique gas condensate
composition. Natural gas condensate is typically composed of hydrocarbons ranging from C 4 to
C15 in which mainly contain 25-95 % by wt. of C6, C7 and C8 organic compounds. In natural gas
condensate comprises hexane, cyclohexane and benzene as C6 hydrocarbon; heptane and toluene
as C7 hydrocarbon whereas octane, ethyl benzene and xylenes consider as C8 hydrocarbon. Natural
gas condensate also has minor amount of C5 (5-7% by wt.) as pentane and other hydrocarbons up
to C15. Beside these gas condensate has trace amount of hydrogen sulfide (H2S), carbon dioxide
(CO2), mercaptanes (RSH, R= -CH3, -C2H5) and aromatics. In general, gas condensate has a
specific gravity ranging from 0.5 to 0.8.

1.5 Types of Condensate

There are two types of condensate:


I. Lease condensate
II. Plant condensate

I Lease condensate: Raw natural gas that comes from crude oil wells is called associated
gas. This gas can exist separate from the crude oil in the underground formation, or
dissolved in the crude oil. Condensate produced from oil wells is often referred to as lease
condensate.
II Plant condensate: Dry gas wells typically produce only raw natural gas that does not
contain any hydrocarbon liquids. Such gas is called non-associated gas. Condensate from
dry gas is extracted at gas processing plants and, hence, is often referred to as plant
condensate.

1.6 Plant Definition


Name of The Plant Kushiara Condensate Fractionation Plant
Plant Location Fenchuganj, Sylhet
Feed Condensate from Bibiyana Gas field of
Chevron Bangladesh
Finished Product Diesel, Kerosene, Motor spirit
Feed Capacity 4000 barrel per day
Commencement of Production 1.40 × 106 barrel per year
Gasoline 2000 bbl./day
Production of Kerosene 1000 bbl./day
Diesel 1000 bbl./day
Cumulative Sales of Products(Annual Sale) $ 8,53,65,853.00

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1.7 Product Application
Gasoline:
 Serves as a popular cleaning agent.
 Its primary use is as transportation fuel.
 Works as a camping fuel.
 Used in portable generators to generate emergency electricity.
 Used in industries that depend heavily on gasoline such as companies that
manufacture pesticides, insecticides and fungicides.
Diesel:
 Diesel fuel is commonly used to fuel public buses and school buses.
 The construction industry depends on the power provided by diesel fuel.
 The military uses diesel fuel for tanks and trucks because diesel fuel is less
flammable and less explosive than other fuels.
 Diesel fuel is also used in diesel engine generators to generate electricity.
 Many industrial facilities, large buildings, institutional facilities, hospitals and
electric utilities have diesel generators for backup and emergency power supply.
Kerosene:
 It is less volatile, less flammable than petrol and used as domestic central heating
fuel, (paraffin) aircraft jet fuel
 Used as aircraft jet fuel
 Kerosene is a very effective lighting fuel.
 The chemical industry can use kerosene as a petroleum solvent or industry-grade
chemical lubricant.
 It is also found in some pesticides and is particularly helpful in the elimination of
head lice.
 Used as domestic purposes.

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2 PLANT DESIGN BASIS

2.1 Plant Location: Fenchuganj, Sylhet.

2.2 Plant Area: 150 acre.

2.3 Climate Condition: Sylhet's climate is classified as tropical. Rainfall is significant most
months of the year, and the short dry season has little effect. The average annual temperature is
24.8 °C in Sylhet. The average annual rainfall is 3876 mm.

2.4 Utility Condition:


a) Steam at 28 bar and 250℃ .
b) Cooling water at 25℃.
c) Cooling air at 25℃.
d) Instrumental air at 6 to 7 bar.

2.5 Feed Rate: 4000 bbl./day.

2.6 Design Basis for Simulation by HYSYS


Fluid Package Peng-Robinson
Method of Simulation Pseudo-component generation and plate by
plate calculation
Properties generation HYSYS properties

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2.7 Feed (Gas Condensate) Composition and Boiling Point
Component Mole fraction Boiling point (℃ )
Propane 0.0817 -42.10200
i-Butane 0.0812 -11.73000
n-Butane 0.0807 -0.50199
i-Pentane 0.0734 27.87800
n-Pentane 0.0752 36.05900
n-Hexane 0.0749 68.73000
n-Heptane 0.0662 98.42900
n-Octane 0.0625 125.67000
n-Nonane 0.0539 150.81700
n-Decane 0.0487 174.14900
n-C11 0.0452 195.89000
n-C12 0.0450 216.27800
n-C13 0.0409 235.42900
n-C14 0.0305 253.50800
n-C15 0.0245 270.61800
n-C16 0.0206 286.79000
n-C17 0.0176 302.14900
n-C18 0.0155 316.70900
Benzene 0.0286 80.08900
Cyclopentane 0.0145 49.24800
MCyclopentane 0.0186 71.80900

2.8 Product Specification


Products API gravity Boiling point range (℃) Carbon components
Gasoline 60° 38-205 C4 − C12
Kerosene 42° 150-300 C8 − C16
Diesel 30° 151-370 C12 − C20

2.9 Assumptions
a) The cooling water and steam will be received from Shahjalal Fertilizer
Factory Limited (SFFL) and then sent back to it for treatment after use.

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3 PROCESS BLOCK DIAGRAM

Fig 01: Block Diagram

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4 PROCESS DESCRIPTION
4.1 Preheating
The feed (gas condensate) is pumped directly from the gas condensate storage tank by the pump
P-1104.The condensate is passed through a condensate preheat train (CPT) which is a series of
heat exchangers (two heat exchangers, all are shell and tube heat exchanger).CPT takes heat from
various process streams coming from the product of the distillation column and raise the
temperature of the condensate from ambient condition to 115⁰c. This oil is then further heated in
a furnace so that its temperature rises to 200⁰c before entering into C-1101. The product streams
from ADU (Atmospheric Distillation Unit) unit contains heat which is about 50% of the total
thermal energy required to preheat the condensate before distillation.

4.2 Fractionation
The ADU is the condensate fractionating unit which is designed for processing 4000 barrel/day
(BPD). The product from the ADU are gasoline (motor spirit), kerosene and diesel. The column
of ADU has 35 trays. Steam operated reboiler is used in this column. The type of tray used here is
sieve tray. The heated condensate from the heater H-1101 is directly fed to the 27th tray of the
distillation column C-1101. In the heater, the feed is heated to 200⁰c and so it is partially vaporized
(vapor fraction 0.8045). This partially vaporized feed is then sent to the column of Atmospheric
Distillation Unit (ADU). In fractionation column due to relative volatility of different components
of condensate it’s divided mainly in three portions. Heat transfer and mass transfer are played at
different stages and try to get equilibrium conditions.
The overhead condensate vapor is extracted at 84.18⁰c and then passed through overhead
condenser CN-1101 to exchange heat with the cooling water. After that this overhead condensed
product is sent to the fractionator reflux drum V-1101. The fractionator reflux drum V-1101
operates at 12 psig. The pressure of the reflux drum is controlled by departure of gas to the Flare
through the top. The liquid gasoline is extracted from the bottom in two ways. One goes to gasoline
storage and one goes to the distillation column top tray as reflux at 18.72⁰c at a reflux ratio of 2.
Kerosene is withdrawn from tray no.15 at 175.1⁰c.It flows by gravity into the stripper column C-
1102 consists of three trays. The light ends except kerosene are taken out from the top of the
stripper and fed back to the tray no. 14 of ADU at 188.2⁰c. The bottom product of the stripper is
kerosene at 197.5⁰c and it goes to an adjacent reboiler. The bottom portion of the reboiler is divided
into two parts. One portion goes to kerosene storage at 28.15⁰c after being heat exchanged with
the condensate feed through heat exchanger E-1101. Another portion goes back to the bottom of
the stripper at 204.4⁰c to strip away the light gasoline from the kerosene.
The diesel is taken out as the bottom product at 283.5⁰c. The diesel is then passed to a reboiler.
The bottom product from reboiler is divided into two parts. One portion goes to diesel storage at
25⁰c after being heat exchanged with the condensate feed through heat exchanger E-1102 followed

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by a cooler AC-1101. Another portion is fed back to the bottom tray of the column at 292.7⁰c at a
boil up ratio of 0.75.

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5 MATERIAL AND ENERGY BALANCE
HYSYS is a powerful software that was created by Hyprotech for simulation of chemical plants
and oil refineries. It includes tools for estimation of physical properties and liquid-vapor phase
equilibria, heat and material balances, and simulation of many types of chemical engineering
equipment. So we have used this simulation software to conduct the material and energy balance
of our proposed plant.

Fig 02: Simulation of overall process.

Fig 03: Simulation of distillation column with stripper

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Table 01: Component Mole Fraction of Products

Table 02: Material and Energy Balance

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Table 03: Heat Duty
Energy E-100 E-101 Q1 Qcond Qreb SS1
Stream Energy
Heat Duty 2.036 × 106 2.8 × 106 5.810 × 106 1.148 × 107 5.046 × 106 1 × 106
(Btu/hr.)

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6 UTILITY REQUIREMENT
Utility is the auxiliary component used in a industries. Continuous function of utility department
is imperative for running the plant. Utilities department helps to produce desire product more
economically. Components of utility department:
 Power
 Cooling water
 Steam
 Air
6.1 Power
The plant will need 1.5 MW of electricity daily which will be provided by Kushiara Power Plant,
Fenchuganj (50 MW).

6.2 Cooling Water


Cooling water is required to condense the overhead vapor of the distillation column. It will be
taken from SFFL at a rate of 1.227 × 106 lb/hr.
6.3 Steam
Steam at 28 bar and 250⁰c is required in the two reboiler (one in distillation column and one in
kerosene stripper) to partially vaporize the stream flowing in them. Steam will be taken from SFFL
at a rate of 6410 lb./hr.
6.4 Air
 Air is required to cool the diesel output from the condensate/diesel exchanger. Air will be
taken from the environment at a rate of 2.340 × 105 lb/hr.
 Another type of air is required for control system which is called instrumental air. This
requires pressurized air typically at 6 to 7 bar which is pressurized by compressor.

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7 PROCESS FLOW DIAGRAM

Fig 04: Process Flow Diagram

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8 COST ESTIMATION
An acceptable plant design must represent a plant that can produce a product which will sell at a
profit. Initially, sufficient capital must be committed to construct all aspects of the facility
necessary for the plant. Before determining costs for any type of industrial process these costs
should be of sufficient accuracy to provide reliable decision. Capital investment is the total amount
of money needed to supply the necessary plant and manufacturing facilities plus the amount of
money required as working capital for operation of the facilities.
The capital needed to supply the required manufacturing and plant facilities is called the fixed
capital investment, while that necessary for the operation of the plant is termed the working capital.
The sum of this two capital is known as total capital investment.
8.1 Estimation of Capital Investment
Various methods can be employed for estimating capital investment. We have chosen percentage
of delivered equipment cost method depends upon the detail information available and the
accuracy desired. Estimating by percentage of delivered equipment cost is commonly used for
preliminary and study estimate. The expected accuracy is in the range of± 20 − 30% . This
method is summarized in the following cost estimation.
𝐶𝑛 = ∑( 𝐸 + 𝑓1 𝐸 + 𝑓2 𝐸 + 𝑓3 𝐸 + ⋯ + 𝑓𝑛 𝐸) = 𝐸 ∑( 1 + 𝑓1 + 𝑓2 + ⋯ + 𝑓𝑛 )
Where 𝑓1, 𝑓2, 𝑓3, … 𝑓𝑛 are multiplying factors for piping, electrical, indirect costs etc.

Table 04: Equipment Cost


Equipment Name Quantity Cost ($)
Heat exchanger 02 1,50,000.00
Cooler 01 20,000.00
Distillation Column 01 11,00,000.00
Reboiler 02 50,000.00
Reflux Drum 01 10,000.00
Condenser 01 50,000.00
Stripper 01 3,00,000.00
Pump 08 1,20,000.00
Compressor 01 20,000.00
Storage Tank 06 90,000.00
Flare 01 10,000.00
Generator 01 50,000.00
Total 19,70,000.00

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Table 05: Capital Investment Using Percentage of Delivered Equipment Cost
Direct Cost
Cost ($)
Purchased equipment 19,70,000.00
Purchased equipment installation 9,25,900.00
Instrumentation and controls 7,09,200.00
Piping 13,39,600.00
Electrical systems 2,16,700.00
Buildings 3,54,600.00
Yard improvements 1,97,000.00
Service facilities 13,79,000.00
Land 45,00,000.00
Total Direct Cost 1,15,92,000.00
Indirect Cost
Engineering and supervisions 6,50,100.00
Construction expenses 8,07,700.00
Legal expenses 78,800.00
Contractors fee 4,33,400.00
Contingency 8,66,800.00
Total Indirect Plant Cost 28,36,800.00
Fixed Capital Investment 1,44,28,800.00
Working Capital 17,53,300.00
Total Capital Investment 1,61,82,100.00

8.2 Estimation of Revenue


The second major component of an economical analysis is the estimation of revenue.
Determination of the necessary capital investment is only one part of a capital cost estimate. The
revenue generated by plant operation clearly is very important. Revenue comes from sale of the
product or products produced by the plant. The total annual revenue from product sales is the sum
of the unit price of each product multiplied by its rate of sales.
$ 𝑏𝑎𝑟𝑟𝑒𝑙 $
𝐴𝑛𝑛𝑢𝑎𝑙 𝑠𝑎𝑙𝑒𝑠 𝑟𝑒𝑣𝑒𝑛𝑢𝑒, = ∑(𝑆𝑎𝑙𝑒𝑠 𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡, )(𝑃𝑟𝑜𝑑𝑢𝑐𝑡 𝑠𝑎𝑙𝑒𝑠 𝑝𝑟𝑖𝑐𝑒, )
𝑦𝑟 𝑦𝑟 𝑏𝑎𝑟𝑟𝑒𝑙

Table 06: Total Annual Sales


Product Price, $/barrel Annual sale ($/yr)
Gasoline 60.00 4,20,00,000.00
Diesel 85.55 2,99,42,500.00
Kerosene 50.37 1,76,29,500.00
Total 8,95,72,000.00
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8.3 Estimation of Total Product Cost
The third major component of an economical analysis is the total of all costs of operating the plant,
selling the product, recovering the capital investment and contributing to corporate function such
as management and research and development. This costs usually are combined under the general
heading of total product cost. The latter, in turn, is generally divided into two categories –
manufacturing costs and general expenses. Manufacturing costs are also referred to as operating
or production costs. Further subdivision of the manufacturing costs is somewhat dependent upon
the interpretation of variable, fixed and overhead costs. Then adding manufacturing cost and
general expenses we find total product costs.
N.T: Market price of condensate 25$ per barrel (2016).

Table 07: Estimation of Total Product Cost


Manufacturing Cost
A. Direct Production Cost USD
Raw materials 3,50,00,000.00
Operating labor 51,21,951.00
Direct supervisory and clerical labor 5,63,410.00
Utilities 59,75,609.00
Maintenance and repair 50,70,732.00
Operating supplies 11,26,829.00
Laboratory charges 5,63,416.00
Patents and royalties 29,19,516.00
Total Direct Production Cost 5,63,41,463.00
B. Fixed Charges
Depreciation 16,34,715.00
Local taxes 3,85,714.00
Insurance 4,26,829.00
Rent 8,53,657.00
Financing 52,35,673.00
Total Fixed Charges 85,36,585.00
Total Manufacturing Cost 4,83,67,950.00
General Expenses
Administrative costs 71,70,731.75
Distribution and marketing costs 1,02,43,902.50
Research and development costs 30,73,170.75
Total general expenses 2,04,87,805.00
Total product cost 8,53,65,853.00

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9 INVESTMENT ANALYSIS
Profitability is the measure of the amount of profit that can be obtained from a given situation. It
is a common denominator for all business activities.

𝑮𝒓𝒐𝒔𝒔 𝒑𝒓𝒐𝒇𝒊𝒕 (𝒘𝒊𝒕𝒉𝒐𝒖𝒕 𝒅𝒆𝒑𝒓𝒆𝒄𝒊𝒂𝒕𝒊𝒐𝒏) = 𝑇𝑜𝑡𝑎𝑙 𝑎𝑛𝑛𝑢𝑎𝑙 𝑠𝑎𝑙𝑒 − 𝑇𝑜𝑡𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑐𝑜𝑠𝑡
= 8,95,72,000.00 – 8,53,65,853.00
= $ 42,06,147.00
𝑮𝒓𝒐𝒔𝒔 𝒑𝒓𝒐𝒇𝒊𝒕 (𝒘𝒊𝒕𝒉 𝒅𝒆𝒑𝒓𝒊𝒄𝒊𝒂𝒕𝒊𝒐𝒏)
= 𝑇𝑜𝑡𝑎𝑙 𝑎𝑛𝑛𝑢𝑎𝑙 𝑠𝑎𝑙𝑒 − 𝑇𝑜𝑡𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑐𝑜𝑠𝑡 − 𝐷𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛
= 8,95,72,000.00 – 8,53,65,853.00 – 16,34,715.00
= $ 25,71,432.00
𝐍𝐞𝐭 𝐩𝐫𝐨𝐟𝐢𝐭 = 𝐺𝑟𝑜𝑠𝑠 𝑝𝑟𝑜𝑓𝑖𝑡 (𝑤𝑖𝑡ℎ 𝑑𝑒𝑝𝑟𝑖𝑐𝑖𝑎𝑡𝑖𝑜𝑛) × (1 − 𝐼𝑛𝑐𝑜𝑚𝑒 𝑡𝑎𝑥)
= 25,71,432.00 × ( 1 − 0.15 )
= $ 2,1,85,717.20
𝑪𝒂𝒔𝒉 𝒇𝒍𝒐𝒘 = 𝑁𝑒𝑡 𝑝𝑟𝑜𝑓𝑖𝑡 + 𝐷𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛
= 2,1,85,717.20 + 16,34,715.00
= $ 38,20,432.20

9.1 Return on Investment


The return on investment is the expected profit divided by the total capital invested. This is the
percentage return that an investor may expect to eventually earn on his money. It is the after tax
return on investment that the company or individual must compare with the earnings from savings
accounts, capital bonds and other projects to determine whether this is a good project to invest. A
return on investment of at least 15% figured on after tax earnings is usually expected.
𝑁𝑒𝑡 𝑝𝑟𝑜𝑓𝑖𝑡
𝑹. 𝑶. 𝑰 = × 100
𝑇𝑜𝑡𝑎𝑙 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡
$ 21,85,717.20
= $1,61,82,100.00 × 100

𝑹. 𝑶. 𝑰 = 13.51 %

22
9.2 Payout Period
It is defined as the minimum length of time theoretically necessary to recover the original capital
investment in the form of cash flow to the project based on total income minus all cost except
depreciation. Payback period is calculated [1] and discounted payback period is calculated
assuming 5% discount rate. The outcome for 30 years is given below:

Payback Period: 7.404 years

Discounted Payback Period: 9.476 years

Return for the Cash Flow: 13.18% per year

Cash Flow Net Cash Flow Discounted Cash Flow Net Discounted Cash Flow
$-
Year 0 $-16,182,100.00 $-16,182,100.00 $-16,182,100.00
16,182,100.00
Year 1 $2,185,717.20 $-13,996,382.80 $2,081,635.43 $-14,100,464.57
Year 2 $2,185,717.20 $-11,810,665.60 $1,982,509.93 $-12,117,954.64
Year 3 $2,185,717.20 $-9,624,948.40 $1,888,104.70 $-10,229,849.94
Year 4 $2,185,717.20 $-7,439,231.20 $1,798,194.95 $-8,431,654.99
Year 5 $2,185,717.20 $-5,253,514.00 $1,712,566.62 $-6,719,088.37
Year 6 $2,185,717.20 $-3,067,796.80 $1,631,015.83 $-5,088,072.55
Year 7 $2,185,717.20 $-882,079.60 $1,553,348.41 $-3,534,724.14
Year 8 $2,185,717.20 $1,303,637.60 $1,479,379.44 $-2,055,344.70
Year 9 $2,185,717.20 $3,489,354.80 $1,408,932.80 $-646,411.91
Year 10 $2,185,717.20 $5,675,072.00 $1,341,840.76 $695,428.85
Year 11 $2,185,717.20 $7,860,789.20 $1,277,943.58 $1,973,372.43
Year 12 $2,185,717.20 $10,046,506.40 $1,217,089.12 $3,190,461.55
Year 13 $2,185,717.20 $12,232,223.60 $1,159,132.50 $4,349,594.05
Year 14 $2,185,717.20 $14,417,940.80 $1,103,935.71 $5,453,529.76
Year 15 $2,185,717.20 $16,603,658.00 $1,051,367.34 $6,504,897.10
Year 16 $2,185,717.20 $18,789,375.20 $1,001,302.23 $7,506,199.34
Year 17 $2,185,717.20 $20,975,092.40 $953,621.17 $8,459,820.51
Year 18 $2,185,717.20 $23,160,809.60 $908,210.64 $9,368,031.15
Year 19 $2,185,717.20 $25,346,526.80 $864,962.52 $10,232,993.67
Year 20 $2,185,717.20 $27,532,244.00 $823,773.83 $11,056,767.50
Year 21 $2,185,717.20 $29,717,961.20 $784,546.50 $11,841,314.00
Year 22 $2,185,717.20 $31,903,678.40 $747,187.14 $12,588,501.14
Year 23 $2,185,717.20 $34,089,395.60 $711,606.80 $13,300,107.94

23
Year 24 $2,185,717.20 $36,275,112.80 $677,720.76 $13,977,828.71
Year 25 $2,185,717.20 $38,460,830.00 $645,448.35 $14,623,277.05
Year 26 $2,185,717.20 $40,646,547.20 $614,712.71 $15,237,989.77
Year 27 $2,185,717.20 $42,832,264.40 $585,440.68 $15,823,430.44
Year 28 $2,185,717.20 $45,017,981.60 $557,562.55 $16,380,992.99
Year 29 $2,185,717.20 $47,203,698.80 $531,011.95 $16,912,004.95
Year 30 $2,185,717.20 $49,389,416.00 $505,725.67 $17,417,730.62

Cash flow vs time


Cash flow Net cash flow Discounted cash flow Net discounted cash flow

$60,000,000.00

$50,000,000.00

$40,000,000.00
AMOUNT IN DOLLAR

$30,000,000.00

$20,000,000.00

$10,000,000.00

$0.00
0 5 10 15 20 25 30 35
($10,000,000.00)

($20,000,000.00)
TIME, YEAR

Fig 05: Cash Flow versus Time

24
10 SAFETY
10.1 Definition
Industrial safety in the context of occupational safety and health refers to the management of all
operations and events within an industry, for protecting its employees and assets by minimizing
hazards, risks, accidents and near misses. The relevant laws, compliance and best practices in the
industry have most of the issues addressed for the best protection possible. Employers are to make
sure that these are strictly adhered to have maximum safety.
Safety and health management is one of the vital constituents of condensate fractionation plant
industry activities because most of the operational conditions, chemicals and end products
(hydrocarbons and other compounds) associated with oil and gas production are well-known to
pose serious safety and health threats to the workers.

10.2 Hazards Associated with Condensate Fractionation Activities


Motor vehicle accident: Workers and equipment are required to be transported to and from plant
sites. Working sites are often located in remote areas of the plant and require traveling long
distances to get to the sites. Vehicle crashes are the leading cause of worker fatalities. Vehicle
crashes may also result from fatigue due to long driving distance and long working shifts.
Contact injury: Workers may struck by, entangled or crushed by tools, machinery, heated or other
objects.
Fire and explosions: Workers in the condensate fractionation industries face the risk of fire and
explosion due to ignition of flammable vapors or gases and hydrocarbons produced from the
industries. Ignition sources can include static, electrical energy sources, open flames (flare),
lightning, cigarettes, cutting and welding tools, hot surfaces, and frictional heat.

Falls and slips: Workers might be required to access platforms and equipment located high above
the ground, uneven surface or slippery surface which sometimes result into fall or slip hazards.

Confined space: Workers are often required to enter confined spaces such as petroleum and other
storage tanks. Workers may come into contact with chemicals which causes inhalation of toxic
chemicals, dermal or skin diseases, cancer or neoplasm, eye issues etc.

Ergonomic hazard: Workers might be exposed to ergonomics-related injury risks, such as lifting
heavy items, bending, reaching overhead, pushing and pulling heavy loads, working in awkward
body postures, and performing the same or similar tasks repetitively.
High pressure lines and equipment: Workers might be exposed to hazards from high-pressure lines.
Internal erosion of lines might result in leaks or line bursts, exposing workers to high-pressure
hazards from compressed gases or from high-pressure lines.

25
Electrical and other hazardous energy: Workers might be exposed to uncontrolled electrical,
mechanical, hydraulic, or other sources of hazardous energy if equipment is not designed, installed,
and maintained properly.

10.3 Planning and Prevention


Prevention is better than cure. Safety planning is required to prevent or reduce incidents that could
lead to injuries or deaths. The following planning and preventive measures can be taken.
 Identification of the hazards and queue according to their priority.
 Establish ways to protect workers, including developing and implementing safe practices.
 Provide personal protective equipment (PPE).
 Communicate the hazards and train workers.
 Establish a plan for contractor safety and training.
 Regular workplace inspections and audits.
 Confined spaces that contain or have the potential to contain a serious atmospheric hazard
must be classified as permit-required confined spaces, tested prior to entry, and
continuously monitored.
 Use of the right tools and proper placement of materials.
 Education of workers about the risk.
 Early recognition and reporting of injury signs and symptoms.
 Administrative controls such as operating procedures must be developed and implemented
to ensure safe operations.

10.4 Risk Management Process Key Steps


Planning:
 Identify persons taking part in the risk management process.
 Gather health and safety information pertinent to the industry.
 Define strategy and workflows as per the business or legal requirement.

Risk identification:
 Identify possible safety and health hazards within workplace through work area
inspections, previous accident or ill health records.

Risk assessment:
 Identify existing precautionary measures and what went wrong.
 Evaluate the risk arising from each identified hazard.
 Determine what kind of injury or ill health might occur.
 Rank the risks on the basis of severity

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Risk recording:
 Record the findings of risk assessment for defining control measures, audit, internal review,
regulatory purposes.

Risk control:
 Define and implement preventive measures to minimize or eliminate the risk of an incident
or accident.

Follow on assessment:
 Ensure that implemented control measures are being used and are effective.
 Reassess the efficiency of preventive or control measures.

Monitor and review:


 Regular review and updating of risk assessment.

10.5 First Aid Measures


Eye Contact: For direct contact, remove contact lenses if present and easy to do. Immediately hold
eyelids apart and flush the affected eye(s) with clean water for at least 20 minutes. Seek immediate
medical attention.
Skin Contact: Remove contaminated shoes and clothing, and flush affected area(s) with large
amounts of water. If skin surface is damaged, apply a clean dressing and seek medical attention.
Inhalation (Breathing): Immediately move victim away from exposure and into fresh air in a
position comfortable for breathing. If respiratory symptoms or other symptoms of exposure
develop, seek immediate medical attention.

10.6 Extinguishing Media


Dry chemical, carbon dioxide, or foam is recommended. Water spray is recommended to cool or
protect exposed materials or structures. Carbon dioxide can displace oxygen. Use caution when
applying carbon dioxide in confined spaces. Simultaneous use of foam and water on the same
surface is to be avoided as water destroys the foam. Water may be ineffective for extinguishment,
unless used under favorable conditions by experienced fire fighters.

10.7 Fire Fighting Instructions


For fires beyond the initial stage, emergency responders in the
immediate hazard area should wear protective clothing. When the
potential chemical hazard is unknown, in enclosed or confined
spaces, a self-contained breathing apparatus should be worn. In
addition, wear other appropriate protective equipment as
conditions warrant.

27
Isolate immediate hazard area and keep unauthorized personnel out. Stop spill/release if it can be
done safely. Move undamaged containers from immediate hazard area if it can be done safely.
Water spray may be useful in minimizing or dispersing vapors and to protect personnel. Cool
equipment exposed to fire with water, if it can be done safely. Avoid spreading burning liquid with
water used for cooling purposes.

10.8 Regular Checking and Monitoring


1. Pipe lines
2. Equipment
3. Storage tanks
4. Control systems
5. Thunder protection
6. Flare system
7. Safe and oriented loading

10.9 Safety Sign

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11 PLANT LAYOUT

29
12 DISCUSSION
We have assumed the plant location near the Shahjalal Fertilizer Factory Limited (SFFL) to use
their steam and cooling water for our process. This is to reduce our plant cost.
The material and energy balance is done by using ASPEN HYSYS. In this simulation the
condensate fractionator (distillation column) is the main unit operation. The overall simulation,
plant efficiency, product composition, cost depends on the type of fractionator column used. Here
in our design, we have used a distillation column with reboiler. The column consists of 35 sieve
trays. The column can be modified by eliminating the reboiler or replacing the reboiler by steam
injection. Besides, the number of trays, feed tray, kerosene extraction tray, type of tray (bubble
cap, valve) can be changed. So the choice of distillation column, tray number, type has left a scope
of further investigation for optimizing the cost and product quality.
The total capital investment is determined on the basis of method-C (Percentage of Delivered
Equipment Cost) which is a preliminary estimate type of expected accuracy of± 20 − 30%. We
have chosen this method, because only equipment cost data was available to us. The equipment
cost is taken from different websites.

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13 CONCLUSION
As a chemical engineer we must know the material and energy balances, thermodynamics, reaction
kinetics, mass transfer, heat transfer, plant economics, process safety and different simulation
software. “Plant Design and Sessional” course gives us a field where we can apply all the
knowledge combinedly. As a part of this course we have chosen to propose a condensate
fractionation plant as the country is going to export the extra raw gas condensate. If we export it
after fractionation then it will help to support our economy and unemployment problem. Our
proposed plant “Kushiara Condensate Fractionation Plant” is capable of producing 1.40 × 106
barrel per year. The main products are gasoline, kerosene and diesel produced at a rate of 2000,
1000 and 1000 bbl. /day consecutively. The HYSYS simulation of the process gives component
mole fraction of the products which are quite satisfactory. The plant will require a total capital
investment of $1,61,82,100.00 and return on investment is 13.51 % and payback period is 7.404
year. So it will be beneficial for the government, other national and international organizations to
invest in this proposed plant.

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REFERENCES
 Max S. Peters, Klaus D. Timmerhaus, Ronald E. West , Plant Design and Economics for
Chemical Engineers.
 www.bpc.gov.bd
 Perry, Robert H.; Green, Don W., Perry's Chemical Engineers' Handbook
 www.chevron.com
 en.wikipedia.org

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APPENDICES

Appendix A -Ratio Factors for Estimating Capital-Investment Items Based on Delivered


Equipment Cost

Direct Cost Item Percent of Delivered equipment Cost for


Fluid Processing Plant ($)
Purchased Equipment-Delivered (including 100
fabricated equipment and process machinery)
Purchased-Equipment Installation 47
Instrumentation and Controls (installed) 36
Piping (installed) 68
Electrical (installed) 11
Buildings (including services) 18
Yard Improvements 10
Service Facilities (installed) 70
Total Direct Plant Cost 360
Indirect Cost Item
Engineering and Supervision 33
Construction Expenses 41
Legal Expenses 4
Contractor’s Fee 22
Contingency 44
Total Indirect Plant Costs 144
Fixed-Capital Investment 504
Working Capital (about 15% of total capital 89
investment)
Total Capital Investment 593

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Appendix B -Estimation of Total Product Cost (Showing Individual Components)
I. Manufacturing cost = direct production costs + fixed charges + plant overhead costs
A. Direct production costs (about 60% of total product cost)
1. Raw materials (10-50% of total product cost)
2. Operating labor (10-20% of total product cost)
3. Direct supervisory and clerical labor (10-25% of operating labor)
4. Utilities (10-20% of total product cost)
5. Maintenance and repairs (2-10% of fixed-capital investment)
6. Operating supplies (10-20% of cost for maintenance and repairs, or 0.5-1% of fixed capital
investment)
7. Laboratory charges (10-20% of operating labor)
8. Patents and royalties (0-6% of total product cost)

B. Fixed charges (10-20% of total product cost)


1. Depreciation (depends on life period, salvage value, and method of calculation-about
10% of fixed-capital investment for machinery and equipment and 2-396 of building
value for buildings)
2. Local taxes (1-496 of fixed-capital investment)
3. Insurance (0.4-1% of fixed -capital investment)
4. Rent (8-12% of value of rented land and buildings)
5. Financing (interest) (0-10% of total capital investment)

C. Plant-overhead costs (50-70% of cost for operating labor, supervision, and maintenance, or 5-
15% of total product cost); includes costs for the following: general plant upkeep and overhead,
payroll overhead, packaging, medical services, safety and protection, restaurants, recreation,
salvage, laboratories, and storage facilities.

II. General expenses = administrative costs + distribution and selling costs + research and
development costs (5-15% of total product cost)

A. Administrative costs (about 15% of costs for operating labor, supervision, and maintenance,
or 2-6% of total product cost); includes costs for executive salaries, clerical wages, legal
fees, office supplies, and communication.

34
B. Distribution and selling costs (2-20% of total product cost); includes costs for sales offices,
salesmen, shipping, and advertising.
C. Research and development costs (2-5% of every sales dollar or about 5% of total product
cost).

III. Total product cost = manufacturing cost + general expenses

IV. Gross earnings cost


(gross earnings = total income - total product cost; amount of gross earnings cost depends on
amount of gross earnings for entire company and income-tax regulations; a general range for gross-
earnings cost is 15-40% of gross earnings)

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