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MANUFACTURE OF FORMALDEHYDE FROM METHANOL

A PROJECT REPORT Submitted by S. GAYATHRI (41501203005) G. MUTHAMILARASI (415012


03014)
in partial fulfillment for the award of the degree of BACHELOR OF TECHNOLOGY in
CHEMICAL ENGINEERING
S.R.M. ENGINEERING COLLEGE, KATTANKULATHUR-603 203, KANCHEEPURAM DISTRICT. ANNA
UNIVERSITY : CHENNAI - 600 025 MAY 2005
iii

BONAFIDE CERTIFICATE
Certified that this project report "MANUFACTURE OF FORMALDEHYDE FROM METHANOL" i
s the bonafide work of "S. GAYATHRI (41501203005) and G. MUTHAMILARASI (41501203
014)" who carried out the project work under my supervision.
Prof. Dr. R. KARTHIKEYAN HEAD OF THE DEPARTMENT CHEMICAL ENGINEERING S.R.M.Engin
eering College Kattankulathur - 603 203 Kancheepuram District
Prof. Dr. R. KARTHIKEYAN SUPERVISOR PROFESSOR & HEAD CHEMICAL ENGINEERING S.R.M.
Engineering College Kattankulathur - 603 203 Kancheepuram District
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ACKNOWLEDGEMENT Our heart felt thanks to the Director, Dr.T.P.Ganesan, and our P
rincipal, Prof. R.Venkatramani,M.Tech,F.I.E, for allowing us to carryout our pro
ject. We express our profound gratitude to Dr.R.Karthikeyan, Head of the
Department, Chemical engineering, who guided us in the right direction through t
he course of our project. We also thank our project co-ordinater Mrs.K.Kasturi,B
.Tech, for her valuable advice and encouragement.
Our special thanks to the members of the DTP section and library for their coope
ration
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ABSTRACT
Formaldehyde, one of the important industrial chemicals, finds its applications
in polymeric resins like phenol formaldehyde, adhesives, alkali resins for paint
s and coatings etcManufacture of formaldehyde (as formalin) is done by oxidation
of methanol, mainly by metal oxide process involving Fe/Mo catalyst with 95-99mo
l% conversion of methanol. This project is aimed at designing plant producing 37
wt% formalin and checking for feasibility of production.
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TABLE OF CONTENTS CHAPTERS TITLE ABSTRACT vii LIST OF TABLES viii LIST OF FIGURE
S LIST OF SYMBOLS 1 2 INTRODUCTION PROPERTIES 2.1 PHYSICAL PROPERTIES 2.2 THERMA
L PROPERTIES 2.3 CHEMICAL PROPERTIES ANALYSIS AND SPECIFICATIONS COMMERCIAL USES
OF FORMALIN LITERATURE REVIEW 5.1 SELECTION OF PROCESS PROCESS DESCRIPTION 6.1
FLOW SHEET MATERIAL BALANCE ENERGY BALANCE DESIGN PLANT LAYOUT MATERIALS OF CONS
TRUCTION 11.1 METALS 11.2 NON-METALS INSTRUMENTATION AND CONTROL ix 1 3 3 3 4 7
8 10 11 12 14 15 19 23 29 39 39 40 41 PAGE NO iv
3 4 5
6
7 8 9 10 11
12
vii

13 14 15 16
STORAGE AND TRANSPORTATION HEALTH AND SAFETY CONSIDERATIONS COST ESTIMATION CONC
LUSION REFERENCES
46 47 49 56 57
LIST OF TABLES
Table Number 1 2 3 4 5 6 7 Description Page No
Heat transfer data Storage temperatures Dose-response relationship Delivered cos
t of equipments Direct cost factor Indirect cost factor Auxillary cost factor
19 46 47 49 50 50 52
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LIST OF FIGURES Page No FIGURE 6.1 FIGURE 7.1 FIGURE 7.2 FIGURE 8.1 FIGURE 8.2 F
IGURE 8.3 FIGURE 8.4 FIGURE 8.5 FIGURE 8.6 FIGURE 10.1 FLOW SHEET REACTOR BALANC
E ABSORBER BALANCE ENERGY BALANCE FOR METHANOL VAPORIZER ENERGY BALANCE FOR REAC
TOR ENERGY BALANCE FOR HEAT EXCHANGER 1 ENERGY BALANCE FOR HEAT EXCHANGER 2 ENER
GY BALANCE FOR ABSORBER(BOTTOM) ENERGY BALANCE FOR ABSORBER (TOP) PLANT LAYOUT 1
4 17 18 19 20 21 21 21 22 38
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LIST OF SYMBOLS A D,d L m Nu n P Pr Re V T U Area (m2) Diameter (m) Length (m) M


ass (Kg) Nusselt number Number of tubes Pressure (atm) Prandtl number Reynolds n
umber Volume(m3) Temperature(K) Overall heat transfer coefficient(W/ m2.oC) Z GR
EEK LETTERS T TL L Tempe atu e diffe ence (oC) Loga ithmic mean tempe atu e diffe e
nce (oC) Viscosity of liquid Density (Kg/m3) Height (m)
x

1. INTRODUCTION Fo maldehyde occu s in natu e and it is fo med f om o ganic mate


ial by photochemical p ocesses in the atmosphe e. Fo maldehyde is an impo tant
metabolic p oduct in plants and animals (including humans), whe e it occu s in l
ow but measu able concent ations. It has a pungent odou and is an i itant to t
he eye, nose and th oat even at low concent ations. Howeve , Fo maldehyde does n
ot cause any ch onic damage to human health. Fo maldehyde is also fo med when o
ganic mate ial is incompletely combusted. Fo maldehyde is an impo tant indust ia
l chemical and is employed in the manufactu e of many indust ial p oducts and co
nsume a ticles. Fo maldehyde was fi st synthesized in 1859, when BUTLEROV hyd o
lyzed methylene acetate and noted the cha acte istic odou of the esulting solu
tion. In 1867,HOFMANN conclusively identified fo maldehyde, which he p epa ed by
passing methanol vapou and ai ove a heated platinum spi al. This method, but
with othe catalyst, still constitutes the p incipal method of manufactu e. Ind
ust ial p oduction of fo maldehyde became possible in 1882,when TOLLENS discove
ed a method of egulating the methanol vapou : ai atio and affecting the yield
of the eaction. In 1886 LOEW eplaced the platinum spi al catalyst by mo e eff
icient coppe gauze. A Ge man fi m, Hugo Blank, patented the fi st use of a silv
e catalyst in 1910.In 1905,Badische Anilin and Soda-Fab ik sta ted to manufactu
e fo maldehyde by a continous p ocess employing a c ystalline catalyst. Fo mald
ehyde output was 30 kg/day in the fo m of an aqueous 30 wt% solution. The methan
ol equi ed fo the p oduction of fo maldehyde was initially obtained f om the t
imbe indust y by ca bonizing wood. The development of high-p essu e synthesis o
f methanol by Badische Anilin and Soda-Fab ik in 1925 allowed the p oduction of
fo maldehyde on a t ue indust ial scale
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2. PROPERTIES 2.1 PHYSICAL PROPERTIES Fo maldehyde is a colo less gas at ambient


tempe atu e that has a pungent, suffocating odo . At o dina y tempe atu es fo m
aldehyde gas is eadily soluble in wate , alcohols and othe pola solvents. It
has following physical p ope ties: Boiling point at 101.3 kPa = -19.2oC Melting
point = -118oC Density at 80oC = 0.9151g/cm3 At 20oC = 0 .8153 g/cm3 Vapo density
elative to ai = 1.04 C itical tempe atu e = 137.2 141.2 (oC) C itical p essu
e = 6.784 6.637 Mpa Cubic expansion coefficient = 2.83 x 103 K-1 2.2 THERMAL PROP
ERTIES Heat of fo mation at 25oC = -115.9 + 6.3 kJ/mol Heat of combustion at 25o
C = 561.5 kJ/mol Heat of vapou isation at 19.2oC = 23.32 kJ/mol Specific heat cap
acity at 25oC = 35.425 J/mol K Heat of solution at 23oC In wate = 62 kJ/mol In
methanol= 62.8 kJ/mol In 1-p opanal = 59.5 kJ/mol In 1-butanol = 62.4 kJ/mol Ent
opy at 25oC= 218.8 + 0.4 kJ/mol K 2.3 CHEMICAL PROPERTIES Fo maldehyde is one o
f the most eactive o ganic compounds known. The va ious chemical p ope ties a e
as follows: Decomposition At 150oC fo maldehyde unde goes hete ogeneous decompo
sition to fo m methanol and CO2 mainly. Above 350oC it tends to decompose in to
CO and H2.
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Polyme ization Gaseous fo maldehyde polyme izes slowly at tempe atu es below 100
oC, polyme ization accele ated by t aces of pola impu ities such as acids, alka
lis o wate . In wate solution fo maldehyde hyd ates to methylene glycol H H2C=
O + H2O HO C H Which in tu n polyme izes to polymethylene glycols, HO (CH2O)nH,
also called polyoxy methylenes. Reduction and Oxidation Fo maldehyde is eadily
educed to methanol with hyd ogen ove many metal and metal oxide catalysts. It
is oxidized to fo mic acid o CO2 and H2O. In the p esence of st ong alkalis o
when heated in the p esence of acids fo maldehyde unde goes cannizza o eaction
with fo mation of methanol and fo mic acid. In p esence of aluminum o magnesium
methylate, pa afo maldehyde eacts to fo m methyl fo mate (Tishchenko eaction)
2HCHO Addition eactions The fo mation of spa ingly wate -soluble fo maldehyde
bisulphite is an impo tant addition eaction. Hyd ocyanic acid eacts with fo ma
ldehyde to give glyconit ile. HCHO + HCN HOCH2 - C N HCOOCH3 OH
Fo maldehyde unde goes acid catalyzed P ins eaction in which it fo ms -Hydroxyme
thylted dducts with olefins. Acetylene undergoes  Reppe ddition rection wit
h formldehyde to form 2- butyne-1,4- diol.
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2 HCHO + HC CH
HOCH2CCH2OH
Strong lklis or clcium hydroxide convert formldehyde to  mixture of sugrs
in prticulr hexoses, by  multiple ldol condenstion, which probbly involves
 glycolldehyde intermedite. Acetldehyde, for exmple rects with formldehy
de to give penterythritol, C (CH2OH)4 Condenstion rections Importnt condens
tion rections re the rection of formldehyde with mino groups to give schiffs
bses, s well s the Mnnich rection. CH3COCH3 + (CH3)
2NH.HCl
+
HCHO
CH3COCH2CH2N(CH3) 2.HCl + H2O Formldehyde rects with mmoni to give hexmethy
lene tetermine nd with mmonium chloride to give monomethylmine, dimethylmin
e, or trimethylmine nd formic cid, depending upon rection conditions. Aromt
ic compounds such s benzene, niline, nd toluidine combine with formldehyde t
o produce the corresponding diphenyl methnes. In the presence of hydrochloric 
cid nd formldehyde, benzene is chloromethylted to form benzyl chloride. Form
ldehyde rects with hydroxylmine, hydrzines, or semicrdzide to produce form
ldehyde oxime, the corresponding hydrzones, nd semicrbzone, respectively. Re
sin formtion Formldehyde condenses with ure, melmine, urethnes, cynmide,
romtic sulfonmides nd mines, nd phenols to give wide rnge of resins.
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3. ANALYSIS AND SPECIFICATIONS Qulittive Methods: Qulittive detection of for


mldehyde is primrily by colorimetric methods. Schiffs fuchsin-bisulfite regent
is the generl regent used for detecting ldehydes. In the presence of strong
cids, it rects with formldehyde to form  specific bluish violet dye. Quntit
tive Methods: Physicl Methods: Quntittive determintion of pure queous solu
tions of formldehyde cn be crried out rpidly by mesuring their specific gr
vity. Gs chromtogrphy nd high-pressure liquid chromtogrphy cn lso be use
d for direct determintion. Chemicl Methods: The most importnt chemicl method
for determining formldehyde is the sodium sulfite method. It is bsed on the q
untittive libertion of sodium hydroxide when formldehyde rects with excess
sodium sulfite. CH2O + N2SO3 + H2O with n cid. Formldehyde in ir cn be det
ermined with the id of gs smpling pprtus. In this procedure formldehyde i
s bsorbed from  definite volume of ir by  wsh liquid nd is determined qun
tittively by  suitble method like prrosnline method. Formldehyde is sold
in queous solutions with concentrtions rnging from 25 56 wt% HCHO. Formldehy
de is sold s low methnol (uninhibited) nd high methnol (inhibited) grdes. F
ormldehyde solutions contin 0.5-12 wt% methnol or other dded stbilizers. Th
ey hve  pH of 2.5 3.5,the cid rection being due to the presence of formic ci
d. 4. COMMERCIAL USES OF FORMALDEHYDE Formldehyde resins re one of the mjor 
pplictions of formldehyde. Some of the derivtives re given below. Ure-form
ldehyde resins re produced by the controlled rection of ure nd formldehyde.
Their mjor uses re s dhesives for prticlebord, fiberbord nd 15 HOCH2SO3
N + NOH The stoichiometriclly formed sodium hydroxide is determined by titrt
ion

plywood. They re lso used for compression molded plstic prts, s wet-strengt
h dditives for pper treting, nd s bonders for glss fiber roofing mterils
. Phenol formldehyde is produced by the condenstion of phenol with formldehyd
e. The use of these resins is s n dhesive in wterproof plywood. These resins
re lso used for binding glss fiber insultion. Acetylenic chemicl uses of f
ormldehyde involve the rection with cetylene to form butynediol, which in tur
n cn be converted to butnediol, butyrolctone nd pyrrolidones. Their mjor p
plictions re s specilty solvent nd extrctive distilltion gents. Polycet
yl resins re produced from the nionic polymeriztion of formldehyde. These re
sins re used in plumbing mterils nd utomobile components. Penterythritol i
s formed by the rection of formldehyde, cetldehyde nd sodium hydroxide. Its
lrgest use is in the mnufcture of lkyd resins for pints nd other protecti
ve cotings. Hexmethylene tetrmine is formed by the rection between formldeh
yde nd mmoni. It is used s  prtil replcement for phosphtes s  deterge
nt builder nd s  chelting gent. Ure-formldehyde concentrtes re used s
controlled relese nitrogen fertilizers. Melmine resins re thermosetting resin
s produced from melmine nd formldehyde nd re primrily used for surfce co
tings. The direct use of formldehyde is to imprt wrinkle resistnce in fbrics
.
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5. LITERATURE SURVEY
Most of the worlds commercil formldehyde is mnufctured from methnol nd ir
either by  process using  silver ctlyst or one using  metl oxide ctlyst.
SILVER CATALYST PROCESS The silver ctlyst processes for converting methnol t
o formldehyde re generlly crried out t n tmospheric pressure nd t 600 7
20C .The rection temperture depends on the excess of methnol in the methnol-
ir mixture. The composition of mixture must lie outside the explosive limits. Th
e mount of ir used is lso determined by the ctlytic qulity of the silver s
urfce. The following rections tke plce CH3OH + O2 CH3OH HCHO + H2O HCHO + H2
Methnol conversion is 65 75% per pss. METAL OXIDE PROCESS In this process form
ldehyde is formed by oxidtion process only. The rections re CH3OH + O2 HCHO
+ O2 HCHO + H2O CO + H2O
The rections occur over  mixed oxide ctlyst contining molybdenum oxide nd
iron oxide in  rtio 1.5 to 3.The rection is crried out t 250 350 oC nd esse
ntilly t tmospheric pressure. Methnol conversion is 95 98% per pss.
5.1 SELECTION OF PROCESS It is estimted tht nerly 70% of commercil formldeh
yde is produced by metl oxide process. This process hs  very low rection tem
perture, which permits high ctlyst selectivity, nd the very simple method of
stem genertion. The conversion is round 95-98% per pss, which is greter th
n silver oxide process. 17

6. PROCESS DESCRIPTION
Metl oxide process: Vporized methnol is mixed with ir nd optionlly recycle
d til gs is pssed through ctlyst filled tubes in  het exchnger rector.
The following rections tke plce in the rector.
CH3OH+ O2 HCHO + O2
HCHO +H2O +37 Kcl/g-mol CO+H2O+51 Kcl/g-mol
The temperture inside the rector is mintined t 250-350C.
The het relesed by the exothermic rection is removed by vporiztion of  hig
h boiling het trnsfer fluid on outside of the tubes. Stem is normlly produce
d by condensing the het trnsfer fluid. The ctlyst is grnulr or sphericl s
upported Fe/Mo nd hs n effective life of 12 18 months. A typicl rector hs s
hort tubes of 1-1.5m nd  lrge shell dimeter of 2.5 m or more. The exit gses
from the rector pss through  het exchnger where the temperture is reduced
to 110oC nd then to the bsorption column where wter is used s the scrubbing
medium.
The bsorber cn be either of pcked or try type. It is necessry to remove the
het of solution plus the residul sensible het of the feed gses, nd this is
done by circulting down flow liquid through externl het exchngers nd in so
me cses by the use of cooling coils. The bottom strem from the bsorber repres
ents the finl product. Formldehyde concentrtion in the product is djusted by
controlling the mount of wter dded to the top of the bsorber. Formic cid i
s removed by ion exchnge. A lrge portion of the bsorber overhed gs is recyc
led bck to the feed system. The methnol conversion rnges from 95-99mol% nd d
epends on the selectivity, ctivity nd spot temperture of the ctlyst, the l
ter being influenced by the het trnsfer rte. The overll plnt yield of form
ldehyde is 88-95 mol%.
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The finl product contins up to 55wt% formldehyde nd 0.5-1.5 wt% methnol.
PURGE GAS RECYCLE GAS
WATER
St
2
BFW R E A C T O R
BLOWER AIR
1 `
St
A B S O R B E R
CW
St
3
CW
BFW
F O R M A L I N
METHANOL
1. METHANOL VAPORIZER 2. HEAT EXCHANGER 1 3. HEAT EXCHANGER 2
DEIONISER
19

FIG 6.1 FLOW SHEET 7. MATERIAL BALANCE Bsis: 100 kmoles of methnol in fresh fe
ed per hour Moleculr weight of methnol = 32 kg/kmole Weight of methnol in fee
d = 3200 kg CH3OH + O2 Assume methnol conversion is 97 %. Hence methnol recte
d = 97 kmoles = 3104 kg Assume tht 1% of methnol rects to form formic cid. H
CHO + O2 CO + H2O HCHO + H2O
Actul O2 required = 51.925 kmoles = 1661.60 kg Actul O2 supplied (250% excess)
= 181.738 kmoles = 5815.62 kg Excess O2 = 181.738 51.925 = 129.813 kmoles =4154
.02 kg Assume tht 57% of oxygen requirement comes from recycle strem nd 43% c
omes from fresh feed. O2 from fresh feed = 181.738 x 0.43 = 78.147 kmoles = 2500
.70 kg Corresponding N2= 78.147 x (79/21) = 298.982 kmoles = 8371.50 kg
Assume tht the percentge composition of recycle strem is O2 - 7.78%
20

N2 - 88.3% H2O - 3.89% O2 from recycle strem = 103.590 kmoles =3314.88 kg N2 in


recycle strem = 1175.910 kmoles =32925.48 kg H20 in recycle strem = 51.795 km
oles =932.31 kg Rector outlet: Unrected methnol = 2 kmoles=64 kg HCHO formed
= 92.15 kmoles=2764.50 kg H2O formed = 154.64 kmoles=2783.52 kg CO formed = 4.85
kmoles= 135.8 kg Nitrogen =1484.185 kmoles=41157.20 kg Unrected oxygen =129.81
3 kmoles =4154.02 kg HCOOH formed = 1 kmole = 46 kg
O2= 3314.82 kg N2 = 32925.48 kg H20 = 932.31 kg CH3OH = 64 kg O2=4153.92 kg N2=4
1157.20kg H20 = 2783.4 kg
Methnol =3200kg
REACTOR
HCHO=2764.5 kg CO=135.8 kg HCOOH=46 kg
Air
O2=2500.71kg N2 =8231.50 kg TOTAL INPUT =51104.82 kg TOTAL OUTPUT =51104.82 kg F
IG 7.1
21

ABSORBER
Gms (Y-Yb) = Lms (X- Xb) Gms =molr flow rte of gs on solute free bsis Lms
=molr flow rte of liquid on solute free bsis X =% of solute in liquid t inl
et Xb =% of solute in liquid t outlet Y =frction of solute in gs t inlet Yb
=frction of solute in gs t outlet
Gs flow rte = Gms= 1653.645 kmoles/hr M= 0.0678 (VLE dt) M= (Lms) min Gms (L
ms) min = 112.117 kmoles Yb = 5/95 = 0.0526 Y = 3.14 X104 X = 0 Xb =0.7758 Assu
me Lms = 1.4 (Lms) min Lms = 157.71 kmoles
22

FROM REACTOR CH3OH = 64 kg O2=4153.92 kg N2=41157.20kg H20 = 2783.4 kg HCHO=2764


.5 kg CO =135.8 kg HCOOH=46 kg
RECYCLE STREAM 20=1165.39 kg H O2=4153.92 kg N2=41156.64 kg PRODUCT STREAM HCHO=
2764.5 kg H20=4593.02 kg
ABSORBER
CH3OH=64 kg HCOOH=46 kg
SOLVENT H20=2838.78 kg
TOTAL INPUT = 53943.46 kg
FIG 7.2
TOTAL OUTPUT = 53943.46 kg
8. ENERGY BALANCE DATA TABLE 1: Ltent het of vporiztion, (KJ/Kg) 1099.90 (at
64.7 oC) 2255(at 100 oC) 3278.20 (at 400 oC) 2228.69(at 110 oC) Specific heat ca
pacity Cp(KJ/Kg oC) 2.513 0.928 1.04 1.88 1.13 0.6 0.5 1.75
Methano O2 N2 H2 O CO HCOOH HCHO Oi
1) Methano vaporizer RECYCLE AIR (25oC) O2 :3314.8 Kg N2: 32925 Kg H20:932.31 K
g CH3OH = 3200 Kg H20 (400 oC)
Methano Vaporizer
23
AIR(285 oC) METHANOL

FRESH AIR O2: 2500 Kg N2: 8231.5Kg (400 oC) SUPERHEATED STEAM FIG 8.1
mCp T(inlet stream) = m (steam) (m Cp (recyce) + m Cp (air) +m Cp (methano iq)+
m(methano) +m Cp (methano gas) )(285-25) = 18.08x105 = m x 3278.20 Steam requir
ed m = 551.52 Kg 2)Reactor CH3OH = 3200 Kg O2 = 5815.6 Kg N2 = 41157.2 Kg H20 =
932.31 Kg (285 C)
o
Isotherma Reactor
CH3OH = 64 Kg O2 = 4153.92 Kg N2 = 41157.20 Kg H20 = 2783.61 Kg CO = 135.80 Kg H
COOH = 46 Kg HCHO = 2764.50 Kg
FIG 8.2 Reactions: CH3OH + 1/2 O2 HCHO + 1/2 O2 For an isotherma reaction: H(pro
ducts) + Ho - H(reactants) =H Substituting values from table 1, H = 13.8687x106 KJ
(reactor) = m CpT(cooling oil) 13.8687x106 = m x 1.75x 110 Oil required m = 72045
.058 Kg (H = m CP T) (T=285-25=260) HCHO + H20 Ho = -4839 KJ/Kg CO + H20 Ho = -7115.
35 KJ/Kg
24

3) Heat exchanger 1: Oil (120 oC) H20 (25 oC) Oil (230 oC) FIG 8.3 mCp T(cooling
oil) = mCP T(H20) + m (steam) 13.8687x106 = m x 1.88 x 75 + m x 2255 Water require
d m = 5144.19 Kg 4) Heat exchanger 2: team (100 oC) Reactor outet (285 oC) H20
(25 oC) FIG 8.4 mCp T(products) = m CpT(H20) + m (steam) 9.1815x106 = m x 1.88 x 7
5 + m x 2255 Water required m = 3405.60 Kg 5)Absorber: Bottom: Products (gases)
(110 oC) Water (25 oC) FIG 8.5 mCp T(cooling H20) = m (condensing water) m x 1.88
x 25 = 2783.61 x 2228.7 Cooing water required m = 13996.121 Kg Top: Water (50 o
C) 25 Water (50 oC) H20 (iquid) (110 oC) (110 oC) team (100 oC)

Products (gases) (110 oC)


Products (gases) (30 oC) Water(25 oC) FIG. 8.6
mCpT(cooling H20) = mCpT (product gases) m x 1.88 x 25 = mCp (110-30) Cooling wate
r required m = 81457.60 Kg
26

9. DESIGN HEAT EXCHANGER 1 U0A0TL = (m CPT) OIL Where U0 = Overall heat transfer c
o-efficient (KW/m2 oC) A0= Outside tube area (m2) TL = Logarithmic mean temperatu
re (oC) TL = (230 100) (30 -25) ln (130/5) = 38.3659 oC U0x 2 x R x L x n x TL = 38
52.409 U0 = 1 1/h0 + (A0/Ai) ( 1/hi) Nu =0 .023 (Re)0.8 (Pr)0.3 Assume that d0 =
BWG NO = 16 d0= 0.0191 m di = 0.0157 m m = AV V=m/A = (72045.05 /3600) x (0.0157
/2)2 x 864.9939 = 119.56 m/s Nu = 0.023 x (120262.0154) (1.9989) = 5504.1158 hi
= 44.87 kW/ m2 oC Assume ho = 1.7201 kW/ m2 oC
27

1 Uo = (1/1.7021) + (1.216/44.87) Uo = 1.6270 kW/ m2 oC Assume L = 2.7432 m 1.62


70 x 3.14 x 0.0191x111 x 2.7432 x n = 3852.409 n = 147 tubes
HEAT EXCHANGER 2 U0A0 TL = (m CPT) PRODUCTS TL = (285 100) ( 110 -25) ln (185/85) =
128.584 oC U0x 2 x R x L x n x TL = 2550.4324 U0 = 1 1/h0 + (A0/Ai) (1/hi) Nu =0
.023 (Re)0.8 (Pr)0.3 Assume that d0 = BWG NO = 16 d0= 0.0191 m di = 0.0157 m m =
AV V=m/A = (51105.03/3600) x (0.0157/2)2 x 900 = 81.517m/s
28

Nu = 0.023 x (138695.051) (0.6795) = 21676.058 hi = 181.714 kW/ m2 oC Assume ho


= 1.7201 kW/ m2 oC 1 Uo = Assume L = 3.048 m 1.682 x 3.14 x 0.0191x128.5842 x 3.
048x n = 2550.4324 n = 65 tubes REACTOR DESIGN Specification: acked multiple tu
bula eacto Assumption: Shell diamete of each eacto =39 = 0.99 m Tube specif
ications: 1 1/2" BWG (No 16) (1/1.7021) + (1.216/181.714) Uo = 1.682kW/ m2 oC
Co esponding numbe of tubes = 307
Volume of one tube: ID = 0.03479 m L = 1.5 m
Volume =
action =
0.2627 m3
catalyst

R2L = x0.01742 x 1.5=1.426 x10-3 m3 Volume of 307 tubes =0.4379 m3 Void f


0.4 (assumption) Volume occupied by catalyst/ eacto = 0.4379 x 0.6 =
Space velocity = 5 m3 of gas cha ged to the eacto (at NT) h - m3 of
pe tube (assumption)

Space velocity fo

307 tubes = 1535 m3 of gas cha ged to the

eacto 29

h - m3 of catalyst Volumet ic flow ate: (at NT) No of moles ente ing the eact
o /h = 1803.43 Kmol/h  essu e = 1.1 atm; Tempe atu e = 298 K R = 0.08206 atm
m3 / Kmol K V= nRT V = 1803.43 x 0.08206 x 298 1.1 = 40,091.70 m3 of gas/h
Volumet ic flow ate Volume of catalyst = Space velocity Numbe of eacto s equ
i ed = volume of catalyst Volume occupied by Catalyst pe eacto = 26.1183/0.26
27 = 99.42 ~ 100 eacto s ABSORBER DESIGN Abso be height Z =Noy x Hoy Noy = yb
- ya YL ; YL = (yb-yb *)- ( ya-ya * ) ln ((yb-yb *)/ ( ya-ya * )) = 26.1183 m3
Hoy = Gms / Kya ; where Gms = mass flow rate of gases (Kg/s) K ya = overall mass
transfer coefficient based on gas phase (Kmol/m3 s ) Calculation of Noy: ya = 3
.13 x 10 4 yb = 0.0499 xa = 0 xb = 0.4368 30

Kya = 0.4 Kmol/m3s


(assumption) (x,y are mole fractions of HCHO in liquid and gas phase resp)
Gms (ya-yb) =1.32 Lms (xb-xa ) xb = 0.5877 yb * = 0.067
tuting the above values, YL = 0.00298 Noy = 16.69 ~ 17
of Hoy: Gms = 2764.50 Kg/hr = 0.7679 Kg/ s Gas density
quid density = 1000 Kg/m3 Viscosity = 0.0009 Kg/ms K4 =

xb * yb * = 0.039 substi
transfer units Calculation
at 110oC = 0.90 Kg/m3 Li
0.9; FP = 1

(equilibrium data)
0.5 K4 v (l - v ) 13.1 F ( l /l )0.1
Mass flow ate pe unit a ea V = (Kg/m2s ) Substituting the values, V = 1.4616 K
g/m2s Column a ea = Gms/V =0.5252 m2
Column diamete =(0.5252 x 4/)0.5 = 0.8179 m Hoy = Gma/Kya=Gms/(column a ea x Kya
) = 0.19 m Calculation of height: (fo the top of the abso be ) Z = 17 x 0.19 Z
= 3.33m
31

10. LANT LAYOUT INTRODUCTION The economic const uction and efficient ope ation
of a p ocess unit will depend upon how well the plant and equipment specified on
the p ocess flowsheet is laid out and on the p ofitability of the p oject with
its scope fo futu e expansion. lant location and site selection should be made
befo e the plant layout. lant location and site selection: The location of the
plant has a c ucial effect on the p ofitability of the p oject. The impo tant f
acto s that a e to be conside ed while selecting a site a e: 1. Location, with
espect to ma ket a ea 2. Raw mate ial supply 3. T anspo t facilities 4. Availabi
lity of Labou 5. Availability of utilities 6. Availability of suitable land 7.
Envi onmental impact and effluent disposal 8. Local community conside ations 9.
Climate 10. olitical and st ategic conside ations 1. Ma keting a ea Fo mate ia
ls that a e p oduced in bulk quantities, such as cement, mine al acids, and fe t
ilize s whe e the cost of p oduct pe tone is elatively low and the cost of t a
nspo t a significant f action of the sales p ice, the plant should be located cl
ose to the p ima y p oduct. This conside ation will be less impo tant fo low vo
lume p oduction, high-p iced p oducts, such as pha maceutical. 2. Raw mate ials
The availability and p ice of suitable aw mate ials will often dete mine the si
te location. lants p oducing bulk chemicals a e best located close to the sou c
e of
32

majo aw mate ial, whe e this is also close to the ma keting a ea. Fo the p od
uction of fo maldehyde the site should be p efe ably nea a methanol plant. 3. T
anspo t T anspo t of aw mate ials and p oducts is an impo tant facto to be co
nside ed. T anspo t of p oducts can be in any of the fou modes of t anspo t. 4.
Availability of labou Labou will be needed fo const uction of the plant and
its ope ation. Skilled const uction wo ke s will usually be b ought in f om outs
ide the site a ea, but the e should be an adequate pool of unskilled labou s ava
ilable locally; and labou suitable fo t aining to ope ate the plant. Skilled t
adesman will be needed fo plant maintenance. Local t ade union customs and es
t ictive p actices will have to be conside ed when assessing the availability an
d suitability of the local labou fo ec uitment and t aining. 5. Envi onmental
impact and effluent disposal All indust ial p ocesses p oduce waste p oducts, a
nd full conside ation must be given to the difficulties and cost of thei dispos
al. The disposal of toxic and ha mful effluents will be cove ed by the local eg
ulations and the app op iate autho ities must be consulted du ing the initial su
vey to dete mine the standa ds that must be met. 6. Local community conside ati
on The p oposed plant must fit n with and be acceptable to the local community.
Full conside ation must be given to the safe location of the plant so that it do
es not impose a significant additional isk to the community on a new site, the
local community must be able to p ovide adequate facilities fo the plant pe son
nel. 7. Land Sufficient suitable land must be available fo the p oposed plant a
nd fo futu e expansion. The land should ideally be flat, well d ained and have
suitable loadbea ing cha acte istics full site evaluation should be made to dete
mine the need fo piling o othe special foundations. 8. Climate 33

Adve se climatic conditions, at a site will inc ease costs. Abno mally low tempe
atu es will equi e the p ovision of additional insulation and special heating
fo equipment and pipe uns. 9. olitical and st ategic conside ations Capital g
ants, tax concessions and othe inducements a e often given by gove nments to d
i ect new investment to p efe ed locations; such as a eas of high unemployment.
The availability of such g ants can be ove iding conside ation in the site sel
ection. Afte conside ing the location of the site the plant layout is completed
. It involves placing of equipment so that the following a e minimized: 1. 2. 3.
4. 5. Damage to pe sons and p ope ty in case of fi e explosion o toxic elease
Maintenance costs Numbe of people equi ed to ope ate the plant. Const uction
costs Cost of planned expansion.
In plant layout fi st thing that should be done is to dete mine the di ection of
the p evailing wind. Wind di ection will decide the location of the plant. List
of items that should be placed upwind and downwind of the plant is given down.
Items that should be located upwind of the plant. Labo ato ies Fi e station Offi
ces building Canteen and Change house Sto ehouse Medical facilities Elect ical s
ubstation Wate t eatment plant Wate pumps Wo kshops
34

Items that should be located downwind of the plant Blowdown tanks Settling tanks
Bu ning fla es The va ious units that should be laid out include 1. Main p oces
sing unit 2. Sto age fo aw mate ials and p oducts 3. Maintenance wo kshops 4.
Labo ato ies fo p ocess cont ol 5. Fi e stations and othe eme gency se vices 6
. Utilities: steam boile s, comp essed ai , powe gene ation, ef ige ation 7. E
ffluent disposal plant 8. Offices fo gene al administ ation 9. Canteens and oth
e amenity buildings,such as medical cente s 10. Ca pa ks 1.  ocessing a ea 
ocessing a ea also known as plant a ea is the main pa t of the plant whe e the a
ctual p oduction takes place. The e a e two ways of laying out the p ocessing a
ea 1.) G ouped layout 2.) Flowline layout G ouped layout G ouped layout places a
ll simila pieces of equipment adjacent. This p ovides fo ease of ope ation and
switching f om one unit to anothe . This is suitable fo all plants.
35

Flowline layout Flowline layout uses the line system, which locates all the equi
pment in the o de in which it occu s on the flowsheet. This minimizes the lengt
h of t ansfe lines and the efo e educes the ene gy needed to t anspo t mate ia
ls. This is used mainly fo small volume p oducts. 2. Sto age house The main sta
ge a eas should be placed between the loading and unloading facilities and the p
ocess they se ve. The amount of space equi ed fo sto age is dete mined f om h
ow much is to be sto ed in what containe s. In aw mate ial sto age, liquids a e
sto ed in small containe s o in a pile on the g ound. Automatic sto age and e
t ieving equipment can be substantially cut down sto age 3. Labo ato ies Quality
cont ol labo ato ies a e a necessa y pa t of any plant and must be included in
all cost estimates. Adequate space must be p ovided in them fo pe fo ming all t
ests, and fo clea ing and sto ing labo ato y sampling and testing containe s. 4
. T anspo t The t anspo t of mate ials and p oducts to and f om the plant will b
e an ove iding conside ation in site selection. If p acticable, a site should b
e selected that is close to at least two majo fo ms of t anspo t: oad, ail, w
ate way o a seapo t. Rail t anspo t will be cheape fo long distance t anspo t
of bulk chemicals. Road t anspo t is being inc easingly used and is suitable fo
local dist ibution. Road a ea also used fo fi e fighting equipment and othe
eme gency vehicles and fo maintenance equipment. This means that the e should b
e a oad a ound the pe imete of the site. No oads should be a dead end. All ma
jo t affic should be kept away fo m the p ocessing a eas. It is wise to locate
all loading and unloading facilities ,as well as plant offices, pe sonnel facili
ties nea the main oad to minimize t affic congestion within the plant and to
educe dange . 5. Utilities
36

The wo d Utilities is now gene ally used fo ancilla y se vices needed in the ope
ation of any p oduction p ocess. These se vices will no mally be supplied f om a
cent al site facility and will include: Elect icity Steam fo p ocess heating C
ooling wate Wate fo gene al use Ine t gas supplies
Elect icity Elect ical powe will be needed at all the sites. Elect ochemical p
ocesses that equi e la ge quantities of powe need to be located close to a che
ap sou ce of powe . T ansfo me s will be used to step down the supply voltage to
the voltages used on the pu pose. Steam fo p ocess heating The steam fo p oce
ss heating is usually gene ated in wate tube boile s using the most economical
fuel available. The p ocess tempe atu e can be obtained with lowp essu e steam.
A competitively p iced fuel must be available on site fo steam gene ation. Cool
ing wate Chemical p ocesses inva iably equi e la ge quantities of wate fo co
oling. The cooling wate equi ed can be taken f om a ive o lake o f om the
sea. Wate fo gene al use Wate is needed in la ge quantities fo gene al pu po
se and the plant must be located nea the sou ces of wate of suitable quality,
p ocess wate may be d awn f om ive f om wells o pu chased f om a local autho
ity. Offices The location of this building should be a anged so as to minimize
the time spent by pe sonnel in t avelling between buildings. Administ ation off
ices in which a
37

elatively la ge numbe of people wo king should be located well f om potentiall


y haza dous p ocess. Canteen Canteen should be spacious and la ge enough fo the
wo ke s with good and hygienic food. Fi e station Fi e station should be locate
d adjacent to the plant a ea, so that in case of fi e o eme gency, the se vice
can be put into action Medical facilities Medical facilities should be p ovided
with at least basic facilities giving fi st aid to the inju ed wo ke s.  ovisio
n must be made fo the envi onmentally acceptable disposal of effluent. The layo
ut of the plant can be made effective by 1. Adopting the sho test un of connect
ing pipe between equipments and the least amount of st uctu al steel wo k and th
e eby educing the cost. 2. Equipment that need f equent ope ato attention shou
ld be located convenient to cont ol ooms. 3. Locating the vessels that equi e
f equent eplacement of packing o catalyst outside the building 4.  oviding at
least two escape outes fo ope ato s f om each level in p ocess buildings. 5.
Convenient location of the equipment so that it can be tied with any futu e expa
nsion of the p ocess.
38

EXTENSION AREA
RAW MATERIAL STORAGE

ROCESSING AREA
SAFETY HEALTH DET CENTER
C A C N A N T T E E E E N
W W O O R R K K S S H H O O 
ADMINISTRATIVE OFFICE FINISHED RODUCT STORAGE
SECURITY OFFICE
MAIN ROAD ENTRY FIG 10.1 LANT LAYOUT EXIT
39

11. MATERIALS OF CONSTRUCTION


Mate ials of const uction may be divided into two gene al classifications of met
als and non-metals. 11.1 Metals u e metals and metallic alloys a e included und
e this classification. Some commonly used metals a e discussed in the following
section. I on and steel Although many mate ials have g eate co osion esistan
ce than i on and steel, cost aspects favo the use of i on and steel. As a esul
t, they a e often used as mate ials of const uction when it is known that some c
o osion will occu . In gene al, cast i on and ca bon steel exhibit about the sa
me co osion esistance. They a e not suitable with dilute acids, but can be use
d with st ong acids, since a p otective coating composed of co osion p oducts f
o ms on the metal su face. Ca bon steel plates fo eacto vessels a e a good ex
ample. This application gene ally equi es a minimum level of mechanical p ope t
ies, weldability, fo mability, and toughness as well as some assu ance that thes
e p ope ties will be unifo m th oughout. Stainless steel The e a e mo e than 100
diffe ent types of stainless steels. These mate ials a e high ch omium o high
nickel-ch omium alloys of i on containing small amounts of othe essential const
ituents. They have excellent co osion- esistance and heat esistance p ope ties
. The addition of molybdenum to the alloy inc eases the co osion esistance and
high tempe atu e st ength. If nickel is not included, the low tempe atu e b ittl
eness of the mate ial is inc eased and the ductility and pit type co osion esi
stance a e educed. The p esence of ch omium in the alloy gives esistance to ox
idizing agents. Aluminum
40

The lightness and elative ease of fab ication of aluminum and its alloys a e fa
cto s favo ing the use of these mate ials. Aluminum esists attack by acids beca
use a su face film of ine t hyd ated by aluminum oxide is fo med. This film adhe
es to the su face and offe s good p otection unless mate ials, which can emove
the oxide, such as halogen acids o alkalis, a e p esent. 11.2 Non-metals last
ics In compa ison with metallic mate ials, the use of plastics is limited to el
atively mode ate tempe atu e and p essu es.gene ally,plastics have excellent es
istance to weak mine al acids and a e unaffected by ino ganic salt solutions-a e
as whe e metals a e not enti ely suitable. One of the most chemical esistant pl
astics comme cially available today is tet efluo oethylene.This the moplastic is
p actically unaffected by all alkalis and acids except fluo ine and chlo ine ga
s at elevated tempe atu es and molten metals. Epoxies einfo ced with fibe glass
have ve y high st engths and esistance to heat. Chemical esistance of the epo
xy esin is excellent in non-oxidizing and weak acids not good against st ong ac
ids.
12. INSTRUMENTATION AND CONTROL Inst uments a e p ovided to monito key p ocess
va iable du ing plant ope ation. It is desi able that the p ocess va iable to be
monito ed be measu ed di ectly; often howeve this is imp actical and some depe
ndent va iable, that is easie to measu e, is monito ed in its place. The tempe
atu e inst ument may fo m pa t of a cont ol loop cont olling, say, eflux flow;
with the composition of the ove heads checked f equently by sampling and labo at
o y analysis. Objectives The p ima y objectives of the designe when specifying
inst umentation and cont ol schemes a e: 1) Safe plant ope ation:
41

To keep the p ocess va iables within known safe ope ating limits. To detect dang
e ous situations as they develop and to p ovide ala ms and automatic shut down s
ystems. To p ovide inte locks and ala ms to p event dange ous ope ating p ocedu
es. 2)  oduction ate: To achieve the design p oduct output 3)  oduct quality:
To maintain the p oduct composition within the specified quality standa ds. 4)
Cost: To ope ate at the lowest p oduction cost, commensu ate with the othe obje
ctives. In a typical chemical p ocessing plant these objectives a e achieved by
a combination of automatic cont ol, manual monito ing and labo ato y analysis. G
uide ules: The following p ocedu e can be used when d awing up p elimina y pipi
ng and inst umentation diag ams. 1. Identify and d aw in those cont ol loops tha
t a e obviously needed fo steady plant ope ation, such as: Level cont ols Flow
cont ols  essu e cont ols Tempe atu e cont ols 2. Identify the key p ocess va i
ables that need to be cont olled to achieve the specified p oduct quality. Inclu
de cont ol loops using di ect measu ement of the cont olled va iable, whe e poss
ible, if not p acticable, select a suitable dependent va iable. 3. Identify and
include those additional cont ol loops equi ed fo safe ope ation, not al eady
cove ed in steps 1 & 2
42

4.
Decide & show those ancilla y inst uments needed fo monito ing of the plant ope
ation by the ope ato s; and fo t ouble-shooting and plant development. it is w
ell wo thwhile including additional connections fo inst uments, which may be ne
eded fo futu e t oubleshooting and development ,even if the inst uments a e not
installed pe manently. This would include ext a the mo wells, p essu e tapings,
o ifice flanges, and ext a sample points.
5. 6.
Decide on the location of sample points. Decide on the need fo eco de s and th
e location of the eadout points, local o cont ol oom. This step would be done
in conjunction with step 1 to 4
7.
Decide on the ala ms and inte locks need, this would be done in conjunction with
step 3.
Typical cont ol Systems Level cont ol In any equipment whe e an inte face exists
between two phases some means of maintaining the inte face at the equi ed leve
l must be p ovided. This may be inco po ated in the design of the equipment. The
cont ol valve should be placed on the discha ge line f om the pump.  essu e co
nt ol  essu e cont ol will be necessa y fo most systems handling vapo o gas.
The method of cont ol will depend on the natu e of p ocess. Flow cont ol Flow c
ont ol is usually associated with invento y cont ol in a sto age tank o othe e
quipment. The e must be a ese voi to take up the changes in flow ate. To p ov
ide flow cont ol on a comp ession o pump unning at a fixed speed and supplying
a nea constant volume output, a by-pass would be used. Heat Exchange s He e, t
he tempe atu e can be cont olled by va ying the flow of the cooling o heating m
edium. If the exchange is between two p ocess st eams whose flows a e fixed, bypass cont ol will have to be used.
43

Cascade cont ol With this a angement, the output of one cont olle is used to a
djust the set point of anothe . Cascade cont ol a give smoothe cont ol in situa
tions whe e di ect cont ol of va iable would lead to unstable ope ation. The slav
e cont olle can be used to compensate fo any sho t-te m va iations in, say, a s
e vice st eam flow, which would upset the cont olled va iable, the p ima y cont
olle and long te m va iations.
Reacto cont ol The schemes used fo eacto cont ol depend on the p ocess and t
ype of eacto . If a eliable on-line analyze is available and the eacto dyna
mics a e suitable, the p oduct composition can be monito ed continuously and the
eacto conditions and feed flows cont olled automatically to maintain the desi
ed p oduct composition and yield. Mo e often, the ope ation is the final link i
n the cont ol loop, adjusting the cont olle set points to maintain the p oduct
within specification, based on pe iodic labo ato y analyze .
Reacto tempe atu e will no mally be cont olled by egulating the flow of the he
ating o cooling medium.  essu e is usually held constant. Mate ial balance con
t ol will be necessa y to maintain the co ect flow of eactants to the eacto
and flow of p oduct and un eacted mate ials f om the eacto .
Ala ms and safety t ips, and inte locks Ala ms a e used to ale t ope ato s of se
ious and potentially haza dous, deviations in p ocess conditions. Key inst umen
ts a e fitted with switches and elays to ope ate audible and visual ala ms on t
he cont ol panels. Whe e delay o lack of esponse f om the ope ato may lead to
a haza dous situation, the inst ument would be fitted with t ip system to take
action automatically to ave t the haza d. Inte locks a e included to p event ope
ations depa ting f om the equi ed sequence. They may be inco po ated in the co
nt ol system design, as pneumatic o mechanical locks.
44

13. STORAGE AND TRANSORTATION Fo maldehyde solutions can be sto ed and t anspo
ted in containe s made of stainless steel, aluminum, enamel o polyeste esins.
I on containe s lined with epoxide esin o plastic may also be used, although
stainless steel containe s a e p efe ed, especially fo highe fo maldehyde con
cent ations. Unp otected vessels of i on, coppe , nickel and zinc alloys must no
t be used. With a dec ease in tempe atu e and/o inc ease in concent ation, aque
ous fo maldehyde solutions tend to p ecipitate pa afo maldehyde. On othe hand,
as the tempe atu e inc eases, so does the tendency to fo m fo mic acid. T ace me
tallic impu ities such as i on can boost the ate of fo mation of fo mic acid. T
he efo e, an app op iate sto age tempe atu e must be maintained. Stabilize s can
also be added to p event polyme ization. Methanol is gene ally used as a stabil
ize . Othe compounds used as a stabilize fo fo maldehyde a e ethanol, p opano
l, u ea, melamine, hyd azine hyd ate and bismelamines. Table 2 Sto age tempe atu
es fo comme cial fo maldehyde solutions Fo maldehyde content,wt% Methanol cont
ent,wt% Sto age tempe atu e,oC 30 7-10 1 37 <1 35 37 7 21 37 10-12 6-7 50 1-2 6065 50 1-2 45 14. HEALTH AND SAFETY CONSIDERATIONS Sou ces of human exposu e to f
o maldehyde a e engine exhaust, tobacco smoke, natu al gas, fossil fuels, waste
incine ation, and oil efine ies. It is an essential inte mediate in cell metabo
lism in mammals and humans. All tissues contain measu able amounts of fo maldehy
de, e.g., human blood 2-3 ppm. Fo maldehyde causes eye, uppe espi ato y t act,
and skin i itation and is skin sensitize . Although senso y i itation, e.g.,
eye i itation, has been epo ted at concent ations as low as 0.1 ppm in uncont
olled studies, significant eye/nose/th oat
45

i itation does not gene ally occu until concent ations of 1 ppm, based on cont
olled human chambe studies. Table 3 Dose esponse elationship following human
exposu e to gaseous fo maldehyde Exposu e level,ppm Effect Odo th eshold I it
ation th eshold in eyes ,nose, o th oat St onge discomfo t Immediate dyspnea,b
u ning in nose and th oat, heavy coughing and lac imation Nec osis of mucous mem
b anes, >50 la yngospasm,pulmona y edema 10- 50 i itation of uppe espi ato y
t act,coughing,lac imination,ext eme 0.05 1.0 0.2 1.6 3-6
Fo maldehyde is classified as a p obable human ca cinogen by the Inte national A
gency fo Resea ch on Cance (IARC).Lifetime inhalation studies with odents have
shown nasal cance at fo maldehyde concent ations that a e ove whelmed cellula
defense mechanisms,ie,6 to 15 ppm.No nasal cance was seen at 2 ppm o lowe le
vels. Available data do not indicate that fo maldehyde p oduces mutagenic, tet o
genic, emb yo toxic effects in man at concent ations which humans a e exposed to
o can tole ate.
46

15. COST ESTIMATION ESTIMATION OF THE TOTAL CAITAL INVESTMENT The total capital
investment I involves the following: A: FIXED CAITAL INVESTMENT IN THE ROCESS A
REA, IF B: THE CAITAL INVESTMENT IN THE AUXILLARY SERVICES,IA C: THE CAITAL IN
VESTMENT AS WORKING CAITAL, IW i.e., I=IF+IA+W A. FIXED CAITAL INVESTMENT IN T
HE ROCESS AREA, IF This is the investment in all p ocessing equipment within th
e p ocessing a ea. Fixed capital investment in the p ocess a ea, IF= Di ect plan
t cost + Indi ect plant cost The app oximate delive ed cost of majo equipments
used in the p oposed Fo maldehyde manufactu ing plant a e fu nished below: (Tabl
e 4) S.NO 1 2 3 4 5 6 7 8 EQUIMENT Heat Exchange Reacto s Abso ption column De
ionize umps Blowe Sto age tank sealed Miscellaneous Total UNITS 3 100 1 1 3 1
1 Cost in Lakhs /Unit 20 3.85 50 1 0.3 0.1 1.5 Cost in Lakhs 60 385 50 1 0.9 0.
1 1.5 1 500
47

DIRECT COST FACTOR (Table 5) S.No 1 2 3 4 5 6 7 8 9 Items Delive ed cost of majo


equipments Equipment installations Insulation Inst umentation iping Land and
building Foundation Elect ical Clean up Total di ect cost facto Di ect plant co
st = (Delive ed cost of majo equipments) X (Total di ect cost facto )/100 Di ec
t plant cost = (500 x 280)/100 = 1400 lakhs INDIRECT COST FACTOR (Table 6) S.NO
1 2 3 ITEMS Ove head cont acto etc Enginee ing fee Contingency Total indi ect
cost facto INDIRECT COST FACTOR 30 13 13 56 Di ect Cost Facto 100 15 15 15 75
30 10 15 5 280
Indi ect plant cost = (Di ect plant cost) x (Total indi ect cost facto )/100 = (
1400 x 56)/100 = 784 lakhs Fixed capital investment in p ocess a ea, IF = Di ect
plant cost + Indi ect plant cost = 1400 + 784 = 2184 lakhs
48

B.THE CAITAL INVESTMENT IN THE AUXILLARY SERVICES,IA Such items like steam gene
ato s, fuel stations and fi e p otection facilities a e commonly stationed outs
ide the p ocess a ea and se ve the system unde conside ation. Table 7: S.No 1 2
3 4 5 6 7 8 9 10 Items Auxilia y buildings Wate supply Elect ic main substatio
n  ocess waste system Raw mate ial sto age Fi e p otection system Roads Sanita
y and waste disposal Communication Ya d and fence lighting Total Auxilla y Se vi
ce Cost Facto 5 2 1.5 1 1 0.7 0.5 0.2 0.2 0.2 12.3
Capital investment in the auxilla y se vices = (Fixed capital investment in p oc
ess a ea) x (Auxilia y se vices cost )/100 = (2184 x 12.3)/100 = 268.632 lakhs I
nstalled cost = Fixed capital investment in the p ocess a ea + Capital investmen
t in the auxilia y se vices = 2184 + 268.632 = 2452.632 lakhs
49

C.THE CAITAL INVESTMENT AS WORKING CAITAL, IW This is the capital invested in


the fo m of cash to meet day-to-day ope ational expenses, invento ies of aw mat
e ials and p oducts. The wo king capital may be assumed as 15% of the total capi
tal investment made in the plant (I) Capital investment as wo king capital, IW =
((2184 + 268.632) X 15) /85 = 432.817 lakhs Total capital investment, I = IF+ I
A + IW = 2184 + 268.632 + 432.817 = 2885.449 lakhs ESTIMATION OF MANUFACTURING C
OST The manufactu ing cost may be divided into th ee items, as follows A. Cost p
opo tional to total investment B. Cost p opo tional to p oduction ate C. Cost
p opo tional to labou equi ement A. COST ROORTIONAL TO TOTAL INVESTMENT This
includes the facto s, which a e independent of p oduction ate and p opo tional
to the fixed investment such as Maintenance- labou and mate ial  ope ty taxes
Insu ance Safety expenses  otection, secu ity and fi st aid Gene al se vices,
labo ato y, oads, etc. Administ ative se vices =( Installed cost x 0.15) = 2452
.632 x 0.15 = 367.894 lakhs B. COST ROORTIONAL TO RODUCTION RATE The facto s
p opo tional to p oduction ate a e Raw mate ial costs Utilities cost-powe , fue
l, wate , steam, etc. Maintenance cost Chemical,wa ehouse,shipping expenses 50
Fo all this pu pose we shall cha ge 15% of the installed cost of the plant

Assuming that the cost p opo tional to p oduction ate is nea ly 60% of total ca
pital investment, Cost p opo tional to p oduction ate = (Total capital investme
nt x 0.6) = 2885.449 x 0.6 = 1732.269 lakhs C. COST ROORTIONAL TO LABOUR REQUI
REMENT The cost p opo tional to labou equi ement might amount 10% of total man
ufactu ing cost. Cost p opo tional to labou equi ement = (367.894 + 1731.269)
x (0.1)/(0.9) = 233.240 lakhs The efo e, manufactu ing cost = (364.894 + 1731.26
9 + 233.240) = 2332.403 lakhs SALES RICE OF RODUCT Ma ket p ice of Fo maldehyd
e = Rs.15 /kg  oduction ate Total sales income ROFITABILITY ANALYSIS A.DERIC
IATION Acco ding to sinking fund method: R= (V- VS) I/ (1+I)n R = Unifo m annual
payments made at the end of each yea V = Installed cost of the plant VS = Salv
age value N = Life pe iod (assumed to be 15 yea s) I = Annual inte est ate (tak
en as 15%) R B.GROSS ROFIT G oss p ofit = Total sales income Manufactu ing cost
= 3179.52 2332.40 = 847.117 lakhs = (2452.632 x 0.15) / ((1+ 0.15)15 -1) = 51.5
47 lakhs = 21196.8 TA = 3179.52 lakhs
51

C.NET ROFIT It is defined as the annual etu n on the investment made afte ded
ucting dep eciation and taxes. Tax ate is assumed to be 40% Net p ofit = G oss
p ofit Dep eciation (G oss p ofit x Tax ate) = 847.117- 51.547-(847.117x 0.4) =
456.723 lakhs D.ANNUAL RATE OF RETURN RATE OF RETURN = (100 x Net p ofit) /Inst
alled cost = (100 x 456.723)/2452.632 = 18.619% E.AYOUT ERIOD ayout pe iod =
Dep eciable fixed investment /( ofit + Dep eciation) = 2452.632 / (456.723 + 51
.547) = 4.825 yea s
16. CONCLUSION The metal oxide p ocess was selected fo the manufactu e of fo ma
ldehyde. F om mass balance and ene gy balance, the va ious equipments we e desig
ned and cost estimation was made. The payout pe iod was found to be 5 yea s. Hen
ce the p oject is feasible .
52

REFERENCES
1. Austin , G.T. Sh eves Chemical  ocess Indust ies,Fifth edition McG awHill,198
4 2. Cha les E.D yden , Outlines of Chemical Technology fo 21st Centu y, Thi d
edition , NEW YORK RESS,1997 3. John Mc.Ketta - Encyclopedia of Chemical Techno
logy,vol 8,1997 4. Ki k and Othme - Encyclopedia of Chemical Technology,vol 11,
1997 5. Mccabe, Smith and Ha iot - Unit Enginee ing ,sixth edition,McG aw Hill,
2001 Ope ations in Chemical
6. e y, R.H., and D.W. GREEN , e ys chemical enginee s Handbook, Seventh editi
on, McG aw-Hill,1997. 7. Robe t E.T eybal - Mass T ansfe Ope ations, Thi d edit
ion, 1984. 8. Ullmann - Encyclopedia Of Chemical Technology, Vol. A11, 1997.
53

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