1.

INTRODUCTION

Methanol, CH3 OH , M= 32.042 , also termed methyl alcohol or

carbinol , is one of the most important chemical raw materials . From its
discovery in late 1600s , methanol has grown to become 21st largest commodity
6
chemical with over 12 10 metric tonnes annually produced in the world .
Methanol has been called wood alcohol ( or wood spirit) because it was
abtained commercially from destructive distillation of wood for over a century [1]
It is the ninth largest organic chemical produced in U .S . & one of the largest
volume chemical produced in the world . Today it is produced mainly from the
steam reforming of natural gas via a synthesis gas intermediate. ethanol can &
is , however being produced from such alternative feedstocks as coal & residual
fuel oil [2]

Table 1. Specifications for Pure Methanol

Property Grade A Grade A A

methanol content,wt%,min 99.85 99.85

acetone & aldehydes,ppm,max 30 30
acetone,ppm,max 20
ethanol,ppm,max 10
acid ( as acetic acid),ppm,max 30 30
water content,ppm,max 1500 1000
specific gravity,20/20C 0.7928 0.7928
permanganate time,min 30 30
odor characteristic
distillation range at 101 Kpa 1C,must charactristic
 include 1C,must
color,platinum-cobalt scale,max 64.6C include
appearance 5 64.4C
residual on evaporation,g/100 ml clear- 5
carbonizable impurities colorless clear-
0.001 colorless
30 0.001
30
 . PROPERTIES & USES
Physical properties:Methanol is a clear ,colorless,highly polar liquid with a
mild odor.It is miscible with water , alcohol,ether & most common organic
solvents[2].General physical properties of methanol are presented in table 2.

Table 2.Physical properties of methanol[1]

Property value

Freezing pt. C -97.68

Boiling pt. C 64.7
Critical temp.C 239.43
Critical pressure,kPa 8096
Critical volume,ml/mol 118
Critical compressibility factor z in PV=znRT 0.224
Heat of formation (liquid)at 25C,kJ/mol -239.045
Free energy of formation of liquid at 25oC,Jg -166.81
Heat of fusion,J/g 103
Heat of vaporization at b.p..J/g 1129
Heat of combustion at 25C,J/g 22662
Flammable limits in air
Lower,vol% 6.0
Upper,vol 36
Autoignition temperatureoC 470
Flash point oC 12
Surface tension , dyn/cm 22.6
Specific heat
Of vapor at 25oC,J/gK 1.370
Of liquid at 25oC.J/gK 2.533
Vapor pressure at 25oC, Kpa 16.96
Solubility in water miscible
Density at 25oC ,gcm3 0.78663

Refractive index,n 1.3284

Viscosity of liquid,cP 0.541
Dielectric constant at 25oC 32.7
Thermal conductivity at 25oC ,W/mK 0.202
Chemical Properties: Methanol is the simplest aliphatic alcohol. As a typical
representative of this class of substances, its reactivity is determined by
functional hydroxyl groups.Reactions of methanol take place via cleavage of the
C-O or O-H bond & are characterized by the substitution of the H or OH
group. In contrast to higher aliphatic alcohols however, -elimination with
formation of a multiple bond cannot occur.
Important industrial reactions of methanol include following
a. Dehydrogenation & Oxidative dehydrogenation
b. Carbonylation
c. Esterification with organic or inorganic acids & acid derivatives.
d. Etherification
e. Addition to unsaturated bonds.
f. Replacement of hydroxyl groups
Uses: Fig. 1 gives methanol derivatives & uses.[2]
Other uses: Potentially methanol can be used as a replacement for diesel fuel &
gasoline or as a gasoline extender.It can also be used as a clean-burning boiler or
turbine fuel to generate electricity .Methanol can also be used to make gasoline in
Mobils MTG(methanol to gasoline) process.
Another large market for methanol is its use in the production of
single-cell protein(SCP).Methanol is used as o feedstock to produce olefins,as a
reducing-gas source for steel mills,to remove nitrogen from sewage sludge &
use in fuel cells[1]
 VARIOUS COMMERCIAL PROCESSES
The oldest process for the industrial production of methanol is the
dry distillation of wood,but this no longer has practical importance. Other
processes such as oxidation of hydrocarbons & production as a byproduct othe
Fisher-Tropsh synthesis according to Synthol process,have no importance today.
Methanol is currently produced on an industrial scale exclusively
by catalytic conversion of synthesis gas. Processes are classified according to the
pressure used:
a. High pressure process 25-30Mpa
b. Medium pressure process 10-25Mpa
c. Low pressure process 5-10mpa
The main advantages og low pressure process are are lower
investment & production cost,improved operational reliability,& greater flexibility
in the choice of plant size.
Industrial methanol production can be subdivided into 3 steps.
1. Production of synthesis gas
2. Synthesis of methanol
3. Processing of crude methanol[3]
 4. PRODUCTION TECHNOLOGY
1. Reference flow sheet Fig.2
2. Chemical reactions :
CO + 2H2 CH3OH H=-26.4 Kcal
Methanation reactions:
CO + 3H2 CH4 + H2O H= -50 Kcal
2CO + 2H2 CH4 + CO2 H= -60.3Kcal
Side reactions to higher mol. Wt. Compounds [ignored]
Methanol decomposition:
2CH3OH CH3-O-CH3 + H2O
3. Process description: Feed gas comprising of hydrogen & carbon
monoxide is compressed to 3000-5000 psi, mixed with recycle gas, 7 fed to
a high pressure converter. Internal preheat is usually employed. The reactor
is copper lined steel & contains a mixed catalyst of
zinc,chromium,manganese, or aluminium oxides.The temperature is
maintained at 300-375 C by proper space velocity & heat exchanger
design.
The ratio of hydrogen & CO in the feed gas is 1:4 to
1:8[1,5].Excess hydrogen improves catalyst effectiveness.
Exit gases from the reactor are cooled by heat exchange
with reactants, then with water. Methanol condenses under full operating pressure
to maximize yields-50% [3,4].The liquid methanol is depressurized, sent to a
fractionator to separate ether, 7 then to another tower to minimize the water
content.
Reactor design: Thick walled pressure vessels are constructed of relatively cheap
steel but must be lined with Cu to avoid the formation of iron carbonyl Fe(CO)5, a
volatile compound which poisons the catalyst in addition to causing severe
corrosion problems.
 Heat exchange to control the highly exothermic reaction is
accomplished by a simple design which looks like the Montecatini-Fauser design
in which the combination of a circulating high pressure water & waste heat boiler
acts as the principle heat control-as shown in fig.2
Catalyst fouling: Excess hydrogen over the minimum theoritical 2:1 H2/CO ratio
is used to avoid fouling of catalyst with higher molecular wt. Materials which
adsorbs on the catalyst under high CO partial pressures.
Earlier , synthesis gas is produced by steam reforming of natural gas
which contains mainly methane.
CH4 + H2O CO + 3H2
Inert gas accumalation: In carrying high recycle loads , possibility of
accumulating inert gas is avoided by maintaining a side stream purge of about
5% on recycle gas.
 MATERIAL BALANCE
Reactor :

Recycle purge

CO/H2

Basis: 100 tonnes of product---methanol

Production per hour=130.045 kmoles/hr
Accounting for the 5% fraction of methanol that decomposes to dimethyl
ether , total methanol that has to be produced is = 136.9 kmoles/hr.(rxn. C)

CO Balance: CO required to produce methanol is same as the methanol qty.

produced.(rxn. A)
But selectivity of this rxn.=87.5%[6]
Selectivity = amt. of desired product / amt. of undesired product
Therefore, total CO required = 136.9/.875 = 156.681 kmoles/hr out of which
(156.681- 136.9) = 19.591 kmoles/hr is utilized for side rxn.s b (methanation)
Now, 25% of CO is consumed in first rxn, & rest in second.
CO consumed here = (4.897 + 14.693) = 19.591 kmoles/hr

Ether Balance: Ether produced by decomposition of methanol = (136.9-

130.045)/2 = 3.4225 kmoles/hr.

Methane Balance: Methane produced in 2 side rxn.s = (4.897 + 14.693)= 12.2435

kmoles/hr
Water Balance: Water produced = (4.897 + 6.845/2) = 8.3195 kmoles/hr

Carbon dioxide: CO2 produced = 7.3465 kmoles/hr

Hydrogen Balance: Hydrogen required = 136.92 x 2 + 4.817 x 3 + 14.693 =

303.564 kmoles/hr
But synthesis gas contains CO & H2 in the ratio 1:4 [5]. Hence hydrogen
present in feed gas = 626.724 kmoles/hr.
Excess hydrogen in rxn. = 323.16 kmoles/hr

Conversion per pass: In one pass only about 50% of synthesis gas is converted
because thermodynamic equilibrium is reached[3,4]
A part of the product steam is purged & rest is recycled .Since
CO is the limiting reactant , we find recycle gas amount w.r.t. CO.
Unreacted CO = Purged CO + Recycled CO
0.5(CO + X) = 0.05 x 0.5 x (CO + X) + X
CO converted to methanol is found to be 130.045 kmoles/hr
From here we find the recycled amount of CO to be = 125.0855 kmoles/hr

Distillation column 1[Light Ends Coloumn]: Since we have ignored all other side
rxn.s,only ether is distilled in the coloumn.

Since we have ignored all other side reactions,only ether is distilled in column. We
assume that xD = 0.998 & xW = 0.005
Feed F = methanol + water + ether
= 130.045 + 8.315 + 3.4225
= 141.7865 kmoles/hr
xF = 0.02414
D = 2.256 kmoles/hr
W =138.369 kmoles/hr

Distillation column 2[Purification column] : Since we have ignored higher

alcohol formation reactions, only methanol & water enter this column.We also
ignore the very small amount of ether that may be present.Hence, feed to this
tower is just the binary mixture of methanol & water.

Enriching Reflux
Section L
D, XD

G
Stripping
Section

L W,XW

Feed to the tower is saturated liquid. A total condensor is used & reflux
returns to the column at its bubble point.
Total moles of feed = 138.36 kmoles/hr.This contains 130.045 kmoles/hr of
methanol.
Hence xF = 130.045/138.36 = 0.939
Specific grade A methanol is 99.85 wt%[1,3]
Then xD = (99.85/32.04)/(1-0.9985)/18 + 0.9985/32)
We assume a xW of 0.01
Using relations F = D + F & FxF = DxD + WxW,
We obtain D,distillate(methanol) = 130.189 kmoles/hr
W,residue(water) = 8.171 kmoles/hr\
 HEAT BALANCE

Reactor:CP data is obtained from Smith & Van Ness

Assumptions:The reactant stream is heated to a temperature of 100oC by heat
exchange with product stream.Reaction takes place at temperature of 340C.The
temp. of product
Gases reduces 200o C due to coolant & reactant stream.

Heat i/p + Heat generated = Heat o/p + Heat removed by coolant + Heat to waste
heat boiler

Heat i/p Qi = [mCPT]CO + [mCPT]H2

CO,CP = 30.142 kJ/kmolesK
H2 , CP=29.98 kJ/kmolesK
T = 100 25 =75 oC ; 25oC = reference temperature
then Qi = 1702472.244 kJ/hr

Heat generated = (H)n = 20101 x 103 kJ/kmolesK

Heat o/p, Qo = [mCPT]

CP, kJ/kmolesK
CH3OH 69.86
CO 30.83
H2 29.346
CH4 53.67
H2 O 36.507
CO2 48.135

T = 340 200 = 140 oC

then Qo = 4239286.35 kJ/hr

Heat removed by coolant water,Qw = 3391429.08 kJ/hr

Then heat sent to waste heat boilerQb = 14172756.8 kJ/hr
Condenser of Distillation column-2

CH3 OH Vapour 64.571C

64.571C

40C Water 25C

Heat Q = [m ]CH3OH = [mCPT]H2O

Mass flow rate of methanol = 1.157 kg/s
= 1737.522 kJ/kg K
then Q = 2010.72 kW
mass flow rate of coolant water = 32.069 kg/s
log mean temperature difference = 31.4775 oC
 PROCESS DESIGN-MAJOR EQUIPMENT
Distillation Tower 2.
This tower has a feed, binary mixture of methanol and water.

Assumptions :
1. Feed is the saturated liquid entering at b.p of methanol.
2. All assumptions for McCabe Thiele method hold good here.
3. No heat loss from column.

From the material balance of this tower, we obtain,

D, Distillate (methanol) = 130.189 kmoles/hr
W, Residue (water) = 8.171 kmoles/hr
Since feed is saturated liquid, slope of q-line is .Using equilibrium data for
methanol from Perry.
XD/ (Rm + 1) = 0.655; Rm = 0.5226

Assume reflux ratio 1.5 times the minimum, then R = 0.7839; XD/ (R +1) = 0.559
The plot gives
No. of ideal stages = 17
No. of ideal stages in tower = 16
No. of enriching section stages = 11
No. of stripping section stages = 6
Feed enters at 11th tray.
L = R.D = 102.055 kmoles /hr
G = L + D = 232.244 kmoles /hr
L = L + qF = 240.415 kmoles /hr
G = G = 232.244 kmoles /hr
Table 3 :
 Enriching section Stripping section
Top Bottom Top Bottom
Liq. Kmoles/hr 102.055 102.055 240.415 240.415
Vap. Kmoles/hr 232.244 232.244 232.244 232.244
(M)liq kg/kmol 31.962 31.146 31.146 18.1404
(M)vap kg/kmol 31.962 31.538 31.538 18.1404
X 0.9973 0.939 0.939 0.01
Y 0.9973 0.967 0.967 0.01
Tliq 64.512 64.981 64.981 92.501
Tvap 64.571 67.201 67.201 98.418
Liq kg/hr 3261.88 3178.6 7487.9 4361.13
Vap kg/hr 7422.98 7324.5 7324.5 4212.9
PL kg/m3 453.56 484.58 484.58 978.25
Pv kg/m3 1.1536 1.1295 1.1295 0.5928
(L/G (PG/PL)0.5 0.02216 0.02095 0.04936 0.02548

Surface tension for mixture is evaluated as follows (Perry)

mix = w w + o o
w, surface tension of pure water = 71.4 dynes/cm
o, surface tension of pure methanol = 22.6 dyn/cm
w is defined by relation,
log (w)q = log (XwVw)q (XwVw +XoVo) 1-q + 0.441 q o Vo 2/3 - w Vw 2/3
1 - w XoVo T q
Vw, Molar volume of water = 18.09 cm3 /mol
Vo, molar volume of methanol = 40.98 cm3/mol
For methanol, q = 1
Xo = 0.9675; Xw = 0.03285
Solving, w = 7.5 x 10-3; o = 0.9925
Then mix = 22.827 dyn/cm

ENRICHING SECTION
Plate hydraulics
Tray spacing ts = 18 = 500 mm
Hole diameter dh = 5.0 mm
Hole pitch lp = 15 mm
Tray thickness tT = 3 mm
Total Hole Area / Perforated area, Ah/Ap = 0.1
From table 3 it is seen
0.5
(L/G)(G/L) = 0.02216, is maximum at top.
Using Perry : For ts = 18, Csb, flood = 0.295 ft/s
Unf = (Csb, flood) ( )0.2 (L v) 0.5
20 r
= (0.295) (22.827)0.2 (484.58 1.1295)0.5
20 1.1295
= 6.267 ft/s = 1.91 m/s
Un = 0.8 Unf = 1.52 m/s
Vol flow rate of vapour at top = 7324.5 = 1.801 m3/s
3600 1.1295
Net area, An = 1.801 / 1.52 = 1.1786 m2
Assume Lw/Dc = 0.75 Lw Weir length
Dc Plate diameter
c = 2 sin-1 (Lw/Dc) = 97.2
Ac = 0.785 Dc2

Downcomer area, Ad = 0.785 Dc2 c - 0.75 Dc2 cos 97.2

360 4 2
= 0.08795 Dc2
An = Ac - Ad
1.1786= 0.69705 Dc2
Dc = 1.3 m

Lw = 0.975 m 1m
Then Lw/Dc = 0.77
Ac = 1.3266 m2
Ad = 0.1486 m2
Active area, Aa = Ac 2 Ad = 1.029 m2
Perforated area, Ap = Aa Acz A2z = 0.8039 m2
Calming zone, Acz = 0.134 Ac = 0.1459 m2
Waste peripheral zone, Awz = 0.06 Ac = 0.07959 m2
Then Ah = 0.08039 m2
No. of holes, nh = 0.08039 / (0.005)2 = 4094.23
4
Weir height, h2 = 50 mm (assumption)

Weeping check :
Head loss through holes, hd = k1 + k2 PG Uh2
PL
k1 = 0; k2 = 50.8 /Cv2
For Ah / Aa = 0.07812 and tt / dL = 0.6,
Cv = 0.74; K2 = 92.77 (Sieve trays)
Vol. flow of vap at top = 1.7874 m3/s
Uh (at top) = 1.7874 / 0.08039 = 22.34 m/s
Uh (at bottom) = 1.801 / 0.08039 = 22.4 m/s
Then hd (at top) = 92.768 (1.1536 / 453.56) 22.342
= 146.79 mm clear liquid
hd (at bot.) = 108.49 mm (min)
h = 409 (/dLL) = 4.117 mm clear liq
2/3
how = Fw (664) (q/Lw)
q = 18.22 10-4 m3/s; q1 = 28.882 GPM
q1 / Lw2.5 = 28.882 / (3.2802)2.5 = 1.4814
Lw / Dc = 0.77
For these values, F w = 1.005
how = 1.005 664 (18.22 10-4 / 1.0)2/3 = 9.955 mm
Now, (hd + h) (min) = 112.60 mm
(hw + how ) = 59.955
These are design values
For An / Aa = 0.07812, (hd + h) = 17 mm
which is less than design value.
Hence no weeping.

how Segmental weir hit

h Head loss due to bubble formation
hds Dynamic seal
hhg Hydraulic gradient
ht Total pressure drop across plate

D.C. Flooding Check

hds = hw + how + (hhg / 2) (hhg neglected)
q (max. at top) = 19.97 10-4 m3/s = 31.667 GPM
For q1 / Lw2.5 = 1.624 and Lw/Dc = 0.77, Fw = 1.01
how = 10.64 mm (max. at top)
hds = 60.64 mm
Ua (bot.) = 1.75 m/s = 5.7414 ft/s
Ua (top) = 1.737 m/s = 5.699 ft/s
Fg a = Uag = 1.86
 = 0.59 ; t = 0.2
he1 = .hds = 35.78 mm
hf = he1 / t = 178.9 mm
had = 165.2 (q/Ada)2 Ada - Min. flow area under down comer.
C 13 to 38 mm
Let C = 1 in = 25 mm
Lap = hds - C = 35.64 mm
Ada = Lw hap = 0.03564 m2
had = 0.5187 mm
ht = hd (top) + he1 = 146.79 + 35.78 = 165.75 mm
D.C. Back-up
hdc = ht + hw + how + hhg + had = 24.36 mm
Taking dc = 0.5 ; h1dc S = 243.6 / 0.5 = 487 mm
hdc < ts. NO FLOODING.

STRIPPING SECTION
ts = 500 mm
dh = 5.0 mm
lp = 15 mm pitch
tT = 3 mm
Ah / Ap = 0.1
(L/G) (fG / PL)0.5 = 0.04936 (max. at top)
Csb , flood = 0.28 ft/s
Surface tension is calculated to be 38.289 dyne / cm = mix
Unf = 6.596 ft/s
Un = 0.8 Unf = 5.277 ft/s
= 1.6084 m/s
Vol. flow rate of vapour at top (max) = 1.8013 m2 /s
An = 1.1199 m2
Assuming a Lw / Dc = 0.75; c = 97.2C.
Dc is found to be 1.267 m. We assume Dc = 1.3 m for simplification of design and
to bring down tower cost.
Lw = 0.955 1m Lw / Dc = 0.77
Ac = 1.3266 m2 Acz = 0.1459 m2
Ad = 0.1486 m2 Ah = 0.08039 m2
nh = 4094.23 Ap = 0.8039 m2
Aa = 1.029 m2 Awz = 0.07959 m2
Weeping Check
Ah / Aa = 0.07812 ; tT / dh = 0.6
Then Cv = 0.74 ; K2 = 92.77
Vol. flow of vapour at top = 1.8013 m3 /s
Vol. flow of vapour at bot. = 1.9741 m3/s
Ah = 0.08039 m2
Un (at top) = 22.4 m/s
Uh (at bot.) = 24.56 m/s
hd (at top) = 108.499 mm clear liq. (max)
hd (bottom) = 33.909 mm clear liq. (min)
h = 3.2 mm liq.
q (bottom) = 12.3836 x 10-4 m3/s ; q1 = 19.63 GPM
For q1 / Lw2.5 = 1.0069 and Lw / dc = 0.77, Fw = 1/02
how = 7.793 mm clear liquid
(hd + h) min = 37.109 mm; hw + how = 57.793 mm
For Ah / Aa = 0.07812
(hd + h) plot = 15.5 < design value
NO WEEPING

D.C. Flooding Check

q (max. at top) = 42.92 10-4 m3/s
q1 = 680.4 GPM
For q1 / (Lw)2.5 = 45.42 and Lw / Dc = 0.77
Fw = 1.75
how = 20.57 mm liq
hds = hw + how = 70.57 mm
Ua (top) = 1.7507 m/s
= 5.743 ft/s
Fga = 1.104 = 0.21 ; = 0.61
he1 = 43.048 mm
hf = 215.34 mm
c = 25 mm, hap = 45.57 mm
Ada = 0.04557 m2
hda = 1.4655 mm
ht = 151. 547 mm
Actual D.C. Back-up
hdc = 223.58 mm
hdc1 = hdc / dc dc = 0.5
= 447.165 < ts NO FLOODING

Column Efficiency
a. Enriching Section
Calculation of EOG : hw = 50 mm
Avg. vapour rate = 7373.74 kg/hr
Avg. density = 1.14155 kg/m3
Aa = 1.029 m2 ; Ua (top) = 1.737 m/s
Df = (Dc + Lw)/2 = 1.15 m
Avg. liquid rate = 3220.24 kg/hr
Avg. liquid density = 469.07 kg/m3
q = 19.97 10-4 m3/sec
w = q/Df = 17.36 10-4 m3/sec. m
Ng = (0.776 + 0.00457 hw 0.238 UaPg0.5 + 105 w) (Nscg)-0.5
Nscg = (g/gDg) = 0.578, Schimdt No.
Gas viscosity and diffusivity in mixture are evaluated as follows :

Tvap = 65.886C
(g)CH3OH = 0.015 10-3 p. ; (g)H2O = 1200 x 10-8 p.
y1 = 0.98215 y2 = 0.01785
g = 1.153 kg/m3
Dg = DAB = 10-3 T1.75 [ 1/A + 1/B ] 0.5
P [ ( i A)0.33 + (iB)0.33 ]2+
iA = 29.9
iB = 9.44
DAB = 29.38 10-6 m2/s
Ng = 0.977
NL = KL. a. L
KL a = (3.875 108 Dl) 0.5 (0.4 UaPg 0.5 + 0.17)
Liquid diffusivity Calculation
Dl = ( 7.4 10-8 ( MB) 0.5 T ) (nB A) 6
CH3OH = 1.9
MB = 32.04
T = 337.5 K
nB = 0.34 cp
A = 14.8 cm3 / gmol, molar volume of water
De = DAB = 113.7 10-10 m2/s
KL . a = 1.259 (sec)-1
L = hL . Aa / (1000 q)
hL = hL1 = 35.78 mm
Aa = 1.029 m2
q = 19.95 10-4 m3 / sec
L = 18.43 sec
NL = 23.2115
mtop = 0.241
mbot = 0.35
Gm / Lm 2.27
t = 0.547
b = 0.7945 = 0.7877
Nog = [ (1/Ng) + ( / NL) ]-1 = 0.9436
EOG = 1 e-NOG = 0.6115

Murphee Plate Efficiency, EMV

ZL = DcCos (c/2) = 0.8597 m
L = 18.43 sec
DE = 6.675 10-3 Ua1.44 + 0.92 10-4 x hL 0.00562
= 0.01246 m2/s
NPe, Peclet No. = Ze2 / DE L = 3.218
For EOG = 0.4816 and NPe = 3218,
Emv / EOG = 1.1
Emv = 0.67265

Overall Column Efficiency, EOC

EOC = Nth / Nact
EOC = log (1 + Ea ( - 1)) / log
Ea / Emv = 1/ [ 1+Emv ( / 1-4) ]
For 80% flooding and (L/G) (PG / PL)0.5 = 0.0215,
= 0.14
Ea = 0.6063
Eoc = 0.5773
Nact = Nth / Eoc = 19.05 = 19 trays
Tower height = ts Nact
= 9.5 m

Stripping Section
Cal. of EOG : hw = 50 mm
Avg. vapour rate = 5768.7 kg/hr
Avg. density = 0.7964 kg / m3
Ua = 1.7507 m/s
Df = 1.15 m
Avg. liquid rate = 5924.15 kg/hr
Avg. density = 731.415 kg/m3
q = 27.6518 10-4 m3/s
w = 24.045 10-5 m3/sec m
Nsg = 0.429
Properties of gas mixtures after evaluation are as follows :
Mg = 1.29 x 10-5 Pas
Pg = 0.9358 kg/m3
Dg = 32.14 10-6 m2/s
Ng = 0.9563

Liquid diffusivity, De = 39.6 10-10 m2/s

L = 16.03 sec
NL = 16.832

mtop = 0.35
mbot = 4.44
Gm / Lm = 0.978
t = 0.342
b = 4.32 = 2.3425
Nog = 0.844
EOG = 0.5701

EMV :
ZL = 0.8597
DE = 0.0133 m2/s
NPe = 3.47
For EOG = 1.335 and NPe = 3.47
Emv / EOG = 1.5
Emv = 0.855

EOC :
For 80% flooding and (L/G) (PG / PL)0.5 = 0.04936, = 0.07
Ea = 0.8033
Eoc = 0.859
NA = 6.98 = 7 trays
Tower height = 3.5 m

8. PROCESS DESIGN -MINOR EQUIPMENT

Total condensor (horizontal)
Methanol vapours leaving top of the distillation tower are condensed using cooling

water on tube side. From energy balance and mass balance, we have

mass m1 of methanol vapors = 1.1586 kg/s

mass m2 of cooling water = 32.069 kg/s.
Log Mean Temperature difference is found to be 31.4775C
Assume overall h.t. coeff. Ud = 500 W/m2k
H.T. area A = Q/U (LMTD)
Q from heat balance, = 2010.72 kJ/s
Choosing 3/4 in O.D. 16 BWG tubes with O.D. = 19.05 mm
I.D. = 15.748 mm
a = 0.05987 m2/m length
And with shell length L = 16 ft = 4.88 m,
No. of tubes Nt = 127.75 / (4.88 0.05) (0.05987)
= 441.77 tubes
Let us choose TEMA L or M-type with 480 tubes of 3/4 in O.D. on 1 - in pitch
1 4 passes
Shell dia = 27 - 686 mm
Corrected H.T. area = 138.768 m2
Corrected Uod = 460.43 W/m2 . K
Shell side mean temp. = 64.571C
Tube side mean temp. = 32.5C
Assuming a condensing film transfer co-efficient of 1500 W/m2K,
(64.571 Tw) A (1500) = (64.571 32.5) A (460.4)
Tw = 54.726C, Wall temp.
Tf = (64.571 + 54.726) / 2) = 59.6485C, film temp.

Tube side velocity :

Flow area at = /4 [15.748 10-3]2 480
4
= 0.02379 m
Vt = 32.069 / (994 0.02379) = 1.35 m/s
Let Nv be avg. number of tubes in vertical row.
L = 746 kg/ m3 ; = 0.59 cp; K = 0.163 W/mk.
Tubes in central row = Db / PT
Db = Do [ Nt / K1 ] 1/n
= 586 mm
K1 = 0.249 and n1 = 2.207 Table 12.4 of Coulson and Richardson
Then tubes in central row = 23
(PT = 25. mm) and Nv = (2/3) (23) = 16
Film transfer coefficients :
ho = 0.95 KL L (L v) 1/3
[ Nv -1/6 ]
L. h

h the tube loading, condensate flow per unit length of the tube.
h = 1.157 / (4.88 48) = 4.93 10-6 kg/ms
v = 1.87 kg/m3
ho = 1296 W/m2K
Tube side : T = 32.5C
P = 994 kg / m3
= 0.724 cp
K = 0.62 w/mk
(NRe) = DiVP / = 2.9228
(NPo) = Cp / K = 4.87
NNu = 0.023 (NRe)0.8 (NPr)0.4 = 161.949
hi Do / K = 161.949
1/Uod = 1/1295.5 + 19.05 / (15.746 6375) + 19.03 10-3 ln (19.05 /
15.748) 1 / (2 45) + 5 10-4
Dirt factor is assumed.
Uod = 597.65 W/m2K > Uad assumed

Pressure drop : Bells method, using Perry Tube side cooling water.
(NRe) = 29228
(NPr) = 4.87
hi = 6375 W/m2K
PL = 2fLVt2 t / D1
f = 0.079 (NRe) 0.25 = 0.006
PL = 6739.85 N/m2
PE = 2.5 [Pt Vt2 / 2] = 2264.45 N/m2
Ptotal = Np [ PL + PE ] = 36.012 KN/m2
Shell Side : Methanol vapours
vap (64.571 C) 1.93 kg/m3
vap 0.0135 cp
Let Nb, No. of baffle = 5
Ls, baffle spacing = L / (Nb + 1) = 0.81
Sm = [ (P1 = Do) Ls] (Ds/P1)
= 0.1136 m2
Vs = m/sm = 7.24 m/s
NRe = 91703
Let us consider 30% baffle cut,
Lc = 0.3 0.686 = 0.205 m
PP, pitch parallel to flow = ( 3 / 2) 25.4 = 22m
Nc, No. of tube rows crossed in each cross flow region,
 = Ds (1 2 (lc/Ds) / PP = 12.47
P in cross flow section
Pc = [ b. fK . W2 Nc / t. Sm2 ] [w / b] 0.14
b = 2 10-3 fK = 0.1
Pc = 0.469 KPa
(P)t = 2P# + (Nb 1) + Nb Pw
P in end zones, PE = Pc [ 1 + Ncw / Nc ]
New number of effective tubes, = 0.8 Lc/PP
= 7.45 = 8
PE = 0.796 KPa
Window Zone : Pw = bw2 (2 + 0.6 Ncw) / Sm. Sw. P.
B = 5 10-4
Sw, area of flow through window = 150 inch2
Swt, area occupied by tubes = (Nt/8) (1-Fc) Do2
Ls / Ds = 0.3, Fc = 0.55
Swt = 0.009798 m2
Pw = 0.831 KN/m2
(P)t = 2PE + (Nb 1) Pc + Nb. Pw
= 8.923 KN/m2
 9. MECHANICAL DESIGN

Major : Distillation Tower 2,

Shell diameter = 1300 mm = 51.18 = 4.2651
Working pressure = 1 atm = 14.7 lb/sq- in gauge
Design pressure = 16.17 lb / sq- in gauge
Shell length = 13 m = 42.6504 - in
Shell material = SA 283, Grade C
Shell, double welded butt joints stress relieved but not radiographed.
Tray spacing = 18 in
Skirt height = 3m
Corrosion allowance, C = 1/8 in
Tray support rings = 2.5 in 2.5 in 3/8 in angles
Insulation = 3 in on column
Accessories one caged ladder
Overhead vapor line - 12 in, outside dia
Making use of Brownell and Young, calculation of minimum shell thickness.
tsh = P/(SXE 0.4 P) +C
= 0.1605 in
But min. shell thickness must be 8 mm = 5/16 in
SA 283, Grade C, has allowable stress.
f = 12m650 psi
E, Joint Efficiency

Selection of head torispherical

Thickness + = 0.885 pr / (fE 0.1 p) + C
= 0.16 - in
Min. thickness should be 15/16 in
Black Dia = O.D. + O.D / 24 + 2 Sf + 2/3 icr
Sf Standard st. flange = 3 in
icr Inside corner radius = 15/16
then B.D. = 70.6 in
Weight of head = (/4) d2 t (/1728)
= 346.89 lb
= 157 kg

Calculation of axial stress

Assume di = d0 = 5.18 in
Axial stress, fap = Pd/4 (ts c) = 1003.13 psi

Calculation of dead weight

dead wt. shell = 3.4x
dead wt. insulation = ins tins / 144 (ts c)
= 4.44x
insulation asbestos, ins = 40 lb/cuft
Weight of top head = 346.89 lb
Weight of ladder = 25.00 lb per ft
Weight of 12 in schedule 30 pipe (Appendix K)
= 43.8 lb per ft
Weight of pipe insulation = /4 (1.52 1.02) 40
= 39.3 lb per ft.
Adding up all these weights, W = 346.89 + 108.1x
f dead wt. attachments (not including trays) = W/d (ts c)
= 11.506 + 3.586 x
The wt. of trays plus liquid (below = 4) is calculated as follows
n = (x/2) 1
f dead wt. (liq + trays) = (x/2 1) 25 (D2 / 4)
12 D (t c)
 = 5.925 x - 11.85
Adding all, fdw = 17.351 x - 0.344
Calculation of stress due to wind loads :
Assume wind pressure = 25 psi
fwx = 15.89 deff. x2 / d02 (ts c)
def = insulated tower + vapor line
= (51.2 + 6) + (12+6) = 75.2 in
fwx = 2.43x2

Calculation of combined stresses under operating conditions

Upwind side : ft (max) = fwx + fap - fdx
ft (max) = 2.43 X2 + 1003.13 - 17.351 X
i.e. = (12650) (0.85)

Solving, x = 67 ft
Downwind side : fc (max)=fwx - fap + fdx
fc (max) = 2.43 X2 + 17.351 X - 1003.474
From elastic stability,
fc = 1.5 106 (t/r)
= 10986.3 psi 1/3 (yield pressure = 40,000)
Solving x = 66.76 ft.
If credit is taken for the stiffening effect of tray support rings, a higher
allowable compressive stress will result. Therefore tt = ts + (Ay / dy)
ty equivalent thickness of shell, inches
Ay c.s.a of one circumferential stiffener, in
tx = ts (since no longitudinal stiffeners are used)
The tray support rings are 2 2 3/8 -in angles
Ay = 1.73 sq in
dy = 18 (tray spacing)
ty = 0.1875 + 1.73/18 = 0.2836 in
But fc = 1.5 106 (ty tx)1/2 / r 1/3 y.p.
12,011.8 1/3 (40000)
2.43 x2 + 17.351 x 12.0131 = 0
Solving, x = 66.83 ft.
Stress conditions are satisfied for a tower height of 42.65 in. We choose 6
courses of 8 ft wide and 5/16 in plate.
So the actual tower height = 6 8 = 48 ft.

Design of Flanges
Design pressure = 16.17 psi
Flange material - ASTM A 201, grade B.
Bolting material - ASTM A 193, grade B-7
Gasket material - Stainless steel
Shell outside dia = 51.18 in
Shell thickness = 5/16 in
Allowable stress of flange material = 15,000 psi
Allowable stress of bolting material = 20,000 psi

Calculation of gasket width

do/di = (Y pm / (y p (m+1)))
Y, min. design seating stress = 3700
m, gasket factor = 2.75
do/di = 1.002
Assume di of gasket to be 53 in
Then do = 53.06 in
Min. gasket width = (53.06 53)/2 = 0.028 in
Therefore use a -in gasket width
Then mean gasket diameter G = 53.5 in
Then do = 54 in
Calculation of bolt loads
Load to seat gasket, Wm2 = Hy = b GY
bo = 0.5/2 = 0.25 = b
Wm2 = Hy = 1,55,470 lb
Load to keep joint under operation,Hp= 2bGpm = 7474lb
Load from internal pressure, H = (G2/4)p = 36,350 lb
Total operating load, Wm1 = H + Hp = 46,541.7 lb
Wm2 > Wm1
Controlling load is 1,55,470 lb
Calculation of minimum bolting area
Am2 = Wm2 / fb fb = 20,000 psi
= 7.7735 sq in
By using shape constants,
K = A/B = O.D. of flange / shell dia = 1.24
A = 63.46 in
Taking 5/4 in bolt size whose root area = 0.202 sq in, no. of bolts is
n = 2y G gasket width
Root area fb
= 154 bolts
Ab, actual total c.s.a of bolt = (154) (0.202)
= 31.108 sq in

Moment Computations
For bolting up condition (no internal pressure)

Design load is given by,

W = (Ab + Am) f /2 = 3, 8, 8815
The corresponding level arm is given by :
hG = (C G) / 2 = 11.5
C O.D. of gasket + 2 dia of bolt = 56.5 in
Flange Moment :
Ma = WhG = 5,83,225.5 lb
For operating condition,
W = Wm2
For HD ; HD = 0.785 B2p
= 33,249.13 lb
The lever arm hD = (C B) / 2 = 2.66 in
Moment MD = HD hD
= 88442.7 in lb
HG = Hy H
= 1,19,120 lb
hG = 1.5
Moment MG = HG hG = 1,78,680 in-lb
HT is given by HT = H HD = 3100 lb
The corresponding lever arm, hT = (hD + hG) / 2
= 2.08 in
Moment MT = HT hT
= 6448 in lb
The summation of moments for operating condition Mo = MD + MG + MT
= 2,73,570.7 in-lb
Therefore the operating moment is controlling and Mmax = 2,73,570.7 in-lb

Calculation of flange thickness :

t = (y. Mmax / f.B)
For K = 1.24, from figure, y = 10
t = 1.63 -in = 41.5 mm

Stress due to seismic loads

Total dead wt. stress fdw = 17.351 - 0.344
X, Actual tower length = 48
fdw = 832,504 psi
The total wt. of dead loads is
= fdw c.s.a. of tower
Wx = 48 ft = fdw d ts
= 41829.9 lb
Wavg = 41829.9 / 48 = 871/46 lb/ft
From table 9.3, C = 0.04
Msx = 4CWX2 [3H X] / H2
= 4 0.04 4182.9 482 [ 3 60 48] / 602
= 5,65406.4 in-lb
Corresponding stress is fsx = Msx / r2 (ts c)
= 1,466.524 psi
At X = 48.0 ft wind load stress is
Fwx = 2.43 X2 = 5,598 psi < fsx
Wind loads are controlling rather than seismic.
 10. MECHANICAL DESIGN-MINOR EQUIPMENT
Horizontal condensor
using M.V. Joshi
Shell side : 1 4 passes
Material carbon steel
Corrosion allowance = 3mm
Working pressure = 0.1 N/mm2
Design pressure = 0.11 N/mm2
Permissible stress for carbon steel = 95 N/mm2
Tube side :
Working pressure = 0.5 N/mm2
No. of tables 688
do = 19.05 mm
di = 15.748 mm
Length, L = 4.88 m
Design pressure = 0.55 N/mm2
Shell thickness ts = PD / (2fJ + P)
= 0.47 mm
Minimum thickness of shell must be 6.3 mm, with corrosion allowance, let
ts=8mm
Head thickness Shallow dished and Torispherical head
th = PRcW / 2 fJ
Rc, Crown radius
W, stress intensification factor
Rx, Knuckle radius = 0.06Rc
W = [3 + (Rc/Rk)] = 1.77
Rc = 1, Rk = 0.06
tn = (0.11 x 686 x 1.77)/(2x 95x1) = 0.858mm
from IS 4503 1967
min head thickness = 10mm
Baffles :
No. of baffles = 5
Thickness = 6mm IS : 4503 1967
Tie Rods and spaces
From IS 4503 1967, for shell dia = 686mm
Dia of rod = 12mm
No. of tie rods = 6
Flanges
Flange material, IS 2004 1962, Class R
Bolting steel 5% G M steel
o

Gasket material asbestos composition

Allowable stress of bolting material = 138 MN/m2
Determination of gasket width
do/di = 1.002 with y = 25.5 MN/m2
m = 2.75
Assumed gasket width = 1.6mm
Let di of gasket = 7.4mm
Then do =0.7054m
Taking a gasket width of 0.01m = N
do = 0.724
mean gasket dia, G= di + N = 0.705m
Estimation of bolt loads
Load due to design pressure,H =G2 P/4 = 0.043 MN
Load to keep joint tight under operation, Hp = G (2b)mp = 0.0082MN
Total operating load, Wm = H + Hp = 0.0512MN
Load to seat gasket under botten up condition Wm2 = GB = 0.3456MN
Wm2 is controlling
Calculation of minimum bolting area,
Am2 = Wm2 / S = 0.3456/138 = 2.5 x 10-3m2
Total flange moment
Mo = W1a1 + W2a2 + W2a3
a1 = (C-B)/2 = 0.037M
a3 = (C-G)/2 = 0.0275M
a2 = (A1 + A3)/2 = 0.03225m
Mo = 1.8054 x 10-3 MN
For bolting up condition
Mg = Wa3
W = (Am2 + Ab)Sg /2
Ab = 44 (1.54 x 10-4)
= 6.76x10-3 m2
W = 0.639MN
Mg = 0.0176MN
Mg > Mo; Mg is controlling
Mg = M
Calculation of flange thickness,
t = (My/BS Fo )
For K = 1.163; y = 15 S Fo = 100
Bolt circle dia, C = O.D gasket + 2 x bolt dia
C = 0.724 + 2 x 0.018
= 0.76m
No. of bolts = 44, bolt dia = 18mm
Calculation of flange O.D
A = C + bolt dia + 0.02
= 0.798m

Check of gasket width

AbSg/GN = 42.22 <2y
Hence, satisfied.

Flange moment computations

For operating conditions, Wo = W1 + W2 + W3
W1 = B2P/4
= 0.04066 B shell dia
W2 = H-W1
= 0.00234 MN
Hp, gasket load = 0.0082MN
Then t = 0.062m
Standard flange thickness = 50mm
Tube sheet thickness
tTS = FG ( 0.25P/f) f = 95, F = 1
= 0.0268m
= 27mm.
With corrosion allowances, tTS = 30mm
Nozzle : shell side
Select inlet x outlet dia = 100mm
Vent = 50mm
Drain = 50mm
Opening for relief valve = 75mm
Nozzle thickness tn = PD/ (2fJ P)
J = 1, for seamless pipe
tn = 5.9836 x 10-2mm
using a corrosion allowance of 3mm
tn = 4mm

Tube side
Inlet and outlet dia = 100mm
Nozzle thickness tn = 3.6mm
With corrosion allowance, tn = 8mm

Support for the vessel saddle

Material low carbon steel
 POLLUTION CONTROL AND SAFETY
The first accounts of the poisonous action of methylated spirits were
published in 1855. However the number of cases of poisoning increased only after
production of low order methanol. Methanol vapour is taken up in an amount of
70 80% by lungs. The compound is distributed throughout body fluids and is
largely oxidized to formaldehyde and then to formic acid. This leads to
hyperacidity of blood which is ultimately responsible for methanol poisoning.
Methanol has a slight irritant action on the eyes, skin and mucous
membranes in humans. Chronic methanol poisoning is characterized by damage
to visual and central nervous systems.
The treatment of acute oral methanol poisoning should be initiated as
quickly as possible with following measures.
1. Administration of ethanol because ethanol has a greater affinity for alcohol
dehydrogenase than methanol, oxidation of methanol is inhibited; production
of formaldehyde and formic acid is suppressed.
2. Gastric lavage
3. Hemodialysis
4. Treatment with alkali
5. Administration of CNS stimulants
6. Drinking larger volumes of fluid
7. Eye bandage; eyes should be protected against light
8. Patient should be kept warm

Occupational Health:
No special precautions need be taken when handling methanol since it is
not corrosive, caustic or environmentally harmful. However, absorption through
skin constitutes danger, and methanol should be prevented from coming in direct
contact with skin.
 Appropriate workplace hygiene measures should be adopted if methanol is
handled constantly. Rooms in which methanol is stored or handled must be
ventilated adequately. Gas testing tubes can be used to measure the concentration
in air. Respirators must be worn if substantially high concentrations are present.
Filter masks can be used only for escape or life saving purposes because they are
exhausted very quickly. Respirators with a self contained air supply and heavy
duty chemical protective clothing should be used for longer exposures to high
methanol concentrations.
 PLANT LAYOUT
The management of equipment and facilities specified from process flow
sheet considerations is a necessary requirement for accurate pre construction cost
estimation or for future design involving piping, structural and electrical facilities.
Careful attention to the development of plots and elevation plans will point out
unusual plant requirements and therefore, give reliable information about building
and site costs required for precise pre construction cost accounting. Rational
design must include arrangements such as processing areas, storage areas and
handling areas in efficient coordination and with regards to such factors are given
below.
1. New site development or addition to a previously developed site.
2. Future expansion
3. Economic distribution of services water, process steams power and gas.
4. Weather condition
5. Safety consideration possible hazards of fire, explosions and fumes
6. building code requirements
7. Waste disposal problems
8. Sensible use of floor and elevation space.

Some points to be considered in plant layout are,

Effluent plant is located at the end of the premises
Administration buildings, canteens are located near the entrance of the industry
where they will not interfere with production and its is convenient to contact
the people outside the industry.
Laboratory and workshops are placed in the position form where it is easy to
communicate with all other departments.
 Location of services like power plant, cooling water, pump house, and switch
house are done such that their usage is not hindered and they are easily
accessible in case of fire.
Pipelines laid are minimal and human safety is taken into account.
Storage layout: storage facilities for raw materials and products may be located
in isolated areas or in adjoining areas. Hazardous materials become a decided
menace to life and should be isolated when stored. Storage tanks must be
separated to facilitate suitable quantity. Process water may be drawn from
river, wells or purchased from local authority. Electrical power will be needed
at all sites. So plant should be located close to a cheap source of power. A
competitively priced fuel must be available for steam and power generation.
Effluent disposal: Effluent disposal should be according to the Indian
standards. The appropriate authorities must be consulted during the initial site
survey to determine the standards that must be met.
Local community considerations: The local community must be able to provide
adequate facilities for the plant personnel: schools, banks, housing and
recreational cultural facilities etc... Also the plant should be located so that the
local community is not harmed. The proposed plant must fit in with and be
acceptable to the local community.
Availability of suitable land: Sufficient suitable land be available for the
proposed plant and for future expansion. The land should be ideally flat, well
drained and have suitable load bearing capacity. A full site evaluation should
be made to determine the need for pining or other special foundations. It
should also be available at low cost.
Political and strategic consideration: Capital grants, tax concessions and other
incentives provided by governments to direct new investment to preferred
locations, such as areas of high un-employment should be the overriding
considerations in the site selection.
 Climate: Adverse climatic conditions at a site will increase costs. Abnormally
low temperatures will require the provision of additional insulation & special
heating for equipment & pipe runs. Stronger structures will be needed at
locations subject to high winds or earthquakes.
 COST ESTIMATION & PLANT ECONOMICS
Methaonol Plant Capacity=100 TPD
Cost in 1971=Rs 3.6 x 108 ; Cost index ,year 1971=132[4 ]
Cost index,year 2002=402
Fixed capital investment=3.6 x 108 x402/132 i.e,FCI=Rs.10.96x 107 This is nothing but
the present cost of the plant.
Using Peter & Timmerhaus
Estimation of total investment cost:
a. Direct cost:
A. i.Purchased equipment cost(PEC)
Taking a 25% FCI,PEC=Rs. 2.74 x 108
ii. Installation cost
Taking a 35% PEC,this is=0.822 x 108
iii. Instrumentation & Control cost
Taking a 15% PEC,this cost=Rs.0.411x 108
iv Piping,installed cost
Taking a 50% PEC,this is=1.37x 108 Rs
v. Electrical & installed cost
Taking a 25%PEC, this is=Rs.0.685 x 108
B. Building,process,auxillary
Taking a 45% PEC,this is=1.233 x 108 Rs.
C. Services- facilities & yard improvement
Taking a 75%,this is =2.055 x 108 Rs.
D. Land
Taking a 6%,this is =0.1644 x 108 Rs.
Then Total Direct cost=9.4804 x 107 Rs. Which is around 86% of FCI
b. Indirect costs
A. Engineering & supervision cost:
Taking a 15% of D.C. this is=1.42206 x 108 Rs.
B. Construction expenses & contractors fee;
Taking a 10%,this=0.94804 x 108
C. Fixed Capital Investment=Direct cost+ Indirect cost
i.e, new FCI=12.7273 x 108 Rs.
D. Working capital
Taking 15% TCI, WC=0.15 TCI

Total Capital Investment,TCI=FCI+WC

Solving,TCI=14.975 x 108
WC=2.246 x 108

Estimation of Total Product Cost:

1. Manufacturing Cost=Direct Product cost+ Fixed charges + Plant overhead cost
A. Fixed Charges:
Depreciation=1.30972 x 108 Rs.
Local taxes-taking a 2.55 of FCI, is =0.318 x 108 Rs.
Insurance taking a 0.7% of FCI, is =0.089 x 108 Rs.
Rent =0.13974 x 107 Rs.
Then total Fixed Charges= 1.85646 x 108 Rs.

B. Diect Production cost: We know FC is about 10-20% of TPC.Taking a

15%,TPC=12.3764 x 108 Rs.

Raw materials-taking a 25% of TPC, is=3.0941 x 108 Rs.

 Operating lobour- taking a 15% of TPC, is = 1.856 x 108
Direct supervisory & clerical labour-taking a 15% ,is = 0.278 x 108 Rs.
Utilities taking a 15% of TPC,is=Rs.1.856 x 108
Maintenance & repairs-taking a 5%,is = 0.6364 X 108
Operating supplies-taking a 15%,is = 0.0955 x 108
Laboratory charges-taking a 15% of OL,is=0.2784 x 108 Rs.

Total Direct Production cost=8.0944 x 108 Rs. Which is about 60.54% of TPC

C. Plant Overhead Costs:

Taking a 8% of TPC, this is=0.99 x 108 Rs..

Therefore total manufacturing cost=10.9409 x 108 Rs.

2. General Expenses = Administrative cost+ Distribution & selling cost + research

development cost
Administrative cost-taking a 4% of TPC,is= 0.495 x 108
Distribution & Selling cost- taking a 12% of TPC,is = 1.485 x 108 Rs.
Research & Development cost- a 5% of TPC= 0.61882 x 108 Rs.
Then General E xpenses=2.599 x 108 Rs.

3. Total Product Cost = Manufacturing cost + General Expenses = 13.5399 x 108 Rs.
This is greater than the assumed value(12.3764 x 108)

PROFIT ANALYSIS:
A. Earnings:
Total gross earnings= Total income TPC = 1.2 x 109 Rs.
Calculation of total income:
Annual working days=340
Annual methanol prodution =100 tonnes
Wholesale price of methanol = Rs.85/kg
Annual total income= 2.55 x 109 Rs.

B. Annual Rate of Return=gross profit/TCI =48.4 %

Gross profit = gross earnings tax
Tax = 30% of gross earnings

C. Pay-back period = 100/R.O.R = 2 years