SCALE UP AND DESIGN OF SECONDARY BUTYL

ALCOHOL PLANT

A PROJECT REPORT

Submitted by

T.PRADEEP KUMAR (312212203031),

P.GOPI (312212203302),

M.MANOJH (312212203304)

in partial fulfillment for the award of the degree

of

BACHELOR OF TECHNOLOGY

IN

CHEMICAL ENINEERING

SSN COLLEGE OF ENGINEERING

ANNA UNIVERSITY: CHENNAI 600025

APRIL 2016
1
 ANNA UNIVERSITY: CHENNAI 600025

BONAFIDE CERTIFICATE

Certified that this project report “SCALE UP AND DESIGN OF

SECONDARY BUTYL ALCOHOL PLANT” is the bonafide work of

“T.PRADEEP KUMAR, P.GOPI, M.MANOJH” who carried out the project

work under my supervision.

SIGNATURE SIGNATURE

Dr. R.PARTHIBAN Dr. D. BALAJI

HEAD OF THE DEPARTMENT SUPERVISOR

ASSOCIATE PROFESSOR

CHEMICAL ENGINEERING CHEMICAL ENINEERING

SSN COLLEGE SSN COLLEGE

OF ENGINEERING OF ENGINEERING

Old Mahabalipuram Road, Old Mahabalipuram Road,

Kalavakkam ,Tamil Nadu, Kalavakkam ,Tamil Nadu,

India– 603 110 India– 603 110

2
 TABLE OF CONTENTS

CHAPTER NO TITLE PAGE NO

Abstract

List of tables

List of figures

List of symbols

1 INTRODUCTION 1

1.1. Company profile

1.2. Products

2. RAW MATERIALS AND PRODUCTS

2.1 Raw materials and products

2.2 Property estimation

2.3 Properties of raw materials
2.4 Properties of products
2.5 By products

3. SELECTION PROCESS

3.1 Type of process

3.2 Direct process

3.3 Indirect process

3
4. PROCESS DESCRIPTION

4.1 Acid blending

4.2 Esterification

4.3 washing

4.4 Neutralization

4.5 Stripping

4.6 Hydrolysis

4.7 Compression

4.8 Distillation

5. MATERIAL BALANCE

5.1 Basis

5.2 First stage CSTR reactor

5.3 Second stage CSTR reactor

5.4 Hydrolysis column

5.5 SBA return column

6. ENERGY BALANCE

6.1 First stage CSTR reactor

6.2 Second stage CSTR reactor

6.3 Hydrolysis column

6.4 SBA return column

4
7. DESIGN EQUIPMENTS

7.1 Rector design

7.2 Distillation column

7.3 Condenser

8. ENGINEERING PROBLEMS

8.1 Material selection

8.2 Acid relief system

8.3 Slope and Pump out system

9. STROAGE INFORMATION

9.1 Product storage

9.2 Storage of butane feed

9.3 SBA storage

9.4 Storage of by products

9.5 Butane storage

9.6 Storage of chemicals

10. ECONOMIC BALANCE

10.1 Specification

10.2 Direct cost

10.3 Indirect cost

10.4 Estimation of total production cost

5
 10.5 Utilities

10.6 Insurance

10.7 Net profit

10.8 Payback period

11. SUMMARY AND CONCLUSION

12. REFERENCE

6
 ABSTRACT

Our project focuses on the equipment design for production of

Secondary Butyl Alcohol (SBA). It is an aliphatic alcohol with medium boiling

range, has a characteristics odor and partly miscible with water. It is used as an

intermediate for production of Methyl Ethyl Ketone (MEK). SBA is

particularly used in lacquers with alkyd resin basis as it reduces the viscosity

and improves the fluid behavior SBA finds its application in the manufacture of

pharma industries, as a solvent in paint and lacquers industry, manufacture of

Second Butyl Acetate nitro cellulose, etc. The following equipments where

designed: Reactor R-101 (tank flow) for the estertification involved in the

process, binary distillation column C-152 to separate SBA from heavies iso-

propanol. The performance equations were used for design of the reactor.

McCabe Thiele method was adopted in the design of binary distillation column

and standard procedures are followed in the calculation of distillation.

Furthermore the safety measures are adopted are listed, the process economics

was done and payback period was found out.

7
 LIST OF TABLES

S.NO TITLE PAGE NO

2.1 Raw materials

2.2 N-Butene properties

2.3 Sulphuric acid

2.4 SBA properties

5.1 Material balance of reactor 1

5.2 material balance of reactor 2

5.3 material balance of hydrolyser

5.4 Input of reactor 1 material balance

5.5 Output of reactor 1 material balance

5.6 Input of reactor 2 material balance

5.7 Output of reactor 2 material balance

5.8 Input of hydrolyser material balance

5.9 Output of hydrolyser material balance

5.10 Input SBA return column

5.11 Output distillate SBA return column

5.12 Output bottom product SBA return column

6.1 Input of reactor 1 Energy balance

8
6.2 Output of reactor 1 Energy balance

6.3 Input of reactor 2 Energy balance

6.4 Output of reactor 2 Energy balance

6.5 Input of hydrolyser Energy balance

6.6 Output of hydrolyser Energy balance

6.7 Input SBA return column

6.8 Output distillate SBA return column

6.9 Output bottom product SBA return column

7.1 Input of Reactor 1 Material balance

7.2 Output Reactor 1 Material balance

7.3 Reactor design summary

7.4 SBA vs HEAVIES

7.5 Relative volatility

7.6 Vapor liquid equilibrium data

7.7 Design summary distillation column

7.8 Parameters for Condenser

7.9 Calculations for Condenser

7.10 Final Design calculations for Condenser

9
 LIST OF FIGURES

S.NO TITLE PAGE NO

Fig 4.1 SBA synthesis

Fig 4.2 SBA Distillation column

Fig 5.1 First stage CSTR reactor

Fig 5.2 second stage CSTR reactor

Fig 5.3 Hydrolysis column

Fig 5.4 SBA return column

Fig 7.1 McCabe Thiele graph

Fig 7.2 Condenser (Co-Current)

10
 LIST OF SYMBOLS

µ Viscosity, kg/ms

A Area, m2

Þ Density, Kg/m3

D Diameter of the vessel

H Height of the vessel

L Length of the cylindrical vessel

F Total feed rate, mass/ time in Kg/h

X Conversion of reactant, mass of reactant/ feed

r Constant rate of the reaction in mol L-1 S-1

Vb Volume of the reactor in m3

Da Diameter of the agitator in m.

J Baffle width in m.

UJ Overall Heat transfer coefficient for jacket in w/m2K

α Relative volatility

σ Surface Tension of liquid in, dyn/cm

UC Maximum vapour velocity based on bubbling area, ft/s

LW Wier Length

11
 CHAPTER 1

INTRODUCTION

1.1 COMPANY PROFILE

Cetex petrochemicals ltd was established in 1990 with German technology,

located at Chennai, south India. The plant is located about 20kms north from
Chennai in manali industrial belt. Feed stock is drawn by pipeline from the
neigh boring Chennai Petroleum Corporation lid.

 Cetex has ventured into development of the chemicals like

specialized additive business; cetex aspires to upgrade treatment
chemicals and marine chemicals. Through marketing tie-ups with
leading majors like petarket,ro-Canada, cetex stands for high
performance specialty products in the Indian market place.
 Cetex petrochemicals are the largest manufactures of methyl ethyl
ketone (MEK) and Secondary butyl alcohol (SBA) in India. With the
consistent quality of its products and services, cetex commands a
formidable market share of more then 60% of India; cetex has a
distinction of being the only manufacture of MEK to ISO 4001 and
OSHAs 18001.
 The quality management system at cetex petrochemical is ISO 9000
certified. Product quality at cetex is at par with the international
levels and cetex has no history of products rejection since its
inception. The company is wall committed to continual improvement
and is prating deep rooted TPM, TQM and 55 initiative. In the
endeavour to achieve high standards in occupational health and
safety, cetex is working towards the OSHSs 18001 certification.
 Cetex gives top priority to worker safety and equipment
management. The company is well equipped in safety system and

12
 trained man power. The company today has truly impressive safety
record. No accidents have occurred in the past 13 years.
 Cetex has been conferred some of the country‟s highest awards for
following safety standards set by the industry. Cetex has won the
star safety awards for 1998 and 1999 from safety council, Tamilnadu
and is the winner of all Indian awards from national safety council
for three years 2000 to 2002. Cetex is zero effluent discharge
company and gas certified to be a very environment conscious
company.

1.1.1 MEK Plant:

 Largest manufacture of MEK and SBA in India
 MEK -6000 TPA, SBA-8000 TPA
 Technical collaboration up to 1988 provided by Edeleanu GmbH,
Germany a Deutsche Texaco Subsidiary.
 Trail production May 1990, commercial March-1991
 Plant located In Manali, outside of Chennai.

1.1.2 CAPACITY

 Design 4600 MT SBA

4700 MT MEK
 Revamp 7500 MT SBA
6000 MT MEK

1.1.3 RAW MATERIALS:

 Butene – Chennai Petroleum Corporation Limited
Gas Authority of India Limited

13
  Sulphuric acid – Sterilite
EID parry

1.2 PRODUCTS
 Methyl Ethyl Ketone
 Secondary Butyl Alcohol

1.2.1 Secondary Butyl Alcohol

 SBA also named as secondary butyl alcohol is one of the earliest
petrochemicals
 SBA is produced is large scale, since more than years. It is an
aliphatic alcohol in the medium boiling range, has a characteristic
odor and partly miscible with water.
 SBA is almost entirely (over 90%) intermediate for the production
of MEK as it is the case for this new solvent plant.
 SBA is particularly suitable for the lacquers on alkyd resin basis as
it reduces the viscosity and improves the behaviour.

1.2.2 BY PRODUCTS:

By products will be formed during the process or they are already

contained in the butane feed.

1.2.3 BUTANE:

They are contained in feed and will not take part in any reaction.
Butane formed will have the following composition.
n – Butane + i – butane = 75(wt %)
14
 n – Butane = 24 (wt %)
Polymer = nil
Water – saturated
The stream will be returned to CPCL for mogas or LPG use

1.2.4 POLYMER

In the esterification reactions polymers of C4 hydrocarbons are

generated. As they mostly C8 hydrocarbons this by product is an excellent
gasoline blending component with high octane number. However, so far
only provisions are made of burning it as boiler fuel.

Specific gravity at 20o C = 0.75

Boiling point = 120 – 2100 C

1.2.5 SECONDARY BUTYL ETHER

The SBE formed will have the following composition

SBE = 94 (wt %)

SBA = 3 (wt %)

C4 = 3 (WT %)

Water – saturated

The raw SBE can be used as motor gas blending component with
high octane number. So far SBE is considered to be burnt as fuel in the
steam boiler. A better purity SBE (min 90 %) which can be used as
solvent could be obtained by a subsequent distillation and would have the
following main problem.

15
1.2.6 HEAVIES

They consist mainly of IBA, NBA, IBA as well as higher alcohol

and ketones.

Boiling point = 108 – 1180 C

This mixture is not saleable product and is utilized as boiler fuel.

Specific gravity at 200 C = 0.81

1.2.7 UNIT DESCRIPTION

The new facilities are designed for an annual production of

4600MT of SBA by converting butenes with water. The SBA is
considered to be the intermediate product for 4000MT by
dehydrogenation of 4200MT of SBA. The remaining 4000MT of SBA
are provided for sale.

16
 CHAPTER 2

RAW MATERIALS AND PRODUCTS

2.1 RAW MATERIALS:

Table 2.1:

RAW MATERIALS SUPPLIERS

Butene CPCL, GAIL
Sulphuric Acid (98%) Sterlite, Eid Parry

2.2 PROPERTY ESTIMATION:

Property of each compound is the main parameter to make an equipment design

in the process industries and also it is a major tool for determining the material
and energy balances used to predict the cost effective analysis in a period of
time. In our project, we determine the property parameters of each chemical
compound by using software called „CRANIUM READER‟. It determines the
property by analyzing the chemical structure of a given compound.

17
2.3 PROPERTIES OF RAW MATERIALS:

2.3.1 N-BUTENE:

Table 2.2:

NAME N-Butene
FAMILY Hydrocarbon
FORMULA C4H8
NATURE LPG
BOILING POINT -2OC
SPECIFIC GRAVITY 0.6213
FLASH POINT 73OC
MOLECULAR WEIGHT 56.03
APPEARANCE Colorless
ODOR Aromatic
2.3.2 SULPHURIC ACID:

Table 2.3:

NAME Sulphuric acid

FAMILY Acid
FORMULA H2SO4
NATURE Liquid
SPECIFIC GRAVITY 1.834
MOLECULAR WEIGHT 98.04
DENSITY 0.586 Kg/cm
APPEARANCE Colorless to yellowish

18
2.4 PROPERTIES OF PRODUCT:

2.4.1 SECONDARY BUTYL ALCOHOL:

Table 2.4:

NAME Secondary Butyl Alcohol

FAMILY Hydrocarbon
FORMULA C4H9OH
NATURE Liquid
BOILING POINT 99OC
SPECIFIC GRAVITY 0.808
FLASH POINT 23.6 OC
MELTING POINT 1 OC
APPEARANCE Colorless
ODOR Sweet alcoholic odor

2.5 BY-PRODUCTS:

 Butane
 Polymers of C4 hydrocarbon
 SBE
 Heavies

2.5.1 BUTANE:

They are contained in the feed and will not take part in the reaction. They are
returned to CPCL, for LPG use.

19
2.5.2 POLYMERS:

In the esterification reaction polymers of C4 carbon are generated. As they are

mostly C8 hydrocarbons this product is an excellent gasoline blending
component with high octane number. However, so far provisions are made to
only burn it as boiler fuel.

2.5.3 SECONDARY BUTYL ETHER (SBE):

SBE or Secondary Butyl Ether can be used as gas blending component. It is

burnt as fuel in steam boiler.

2.5.4 HEAVIES:

They consist of mainly

 Indole-3-butyric acid (IBA)

 Isopropyl alcohol (IPA)

20
 CHAPTER 3

SELECTION PROCESS

3.1 TYPES OF PROCESS:

 Indirect hydration of n-butene with sulphuric acid.

 Direct hydration of n-butene to secondary butanol catalysed by strong
acidic ion exchangeresins.

3.2 DIRECT HYDRATION

Direct hydration is a heterogeneous catalysed process. The hydration of

n-butene to secondary butyl alcohol catalysed by strong acidic ion exchange
resin is an alternative route to conventional homogenous indirect hydration
catalysed by sulphuric acid.

SPECIPIC REACTION OF DIRECT HYDRATION

Direct process is one step process since the main product secondary
butanol is formed directly from hydration of butane promoted by solid acid
catalyst.

C4H8 +H2O → CH3-CH2 – CH (OH) –CH3 + H2SO4

Acid catalysts which may be employed in the hydration process of the

present invention are for instance:

 Ion exchange resin with a polystyrene cross linked with di-vinyl benzene
matrix, e.g. Amberlyst RTM, types resin (Rohm&Hass), etc.
 Acid resins with high thermal stability, e.g. Poly Phenyl Sulphonate,
perflouroperoxide etc.
 Strong acid support on inert materials e.g. Sulphuric acid supported on
bentonite, poly phosphoric acid etc.

21
ADVANTAGES

 The main advantage of direct hydration is elimination of sulphuric acid.

 Environmentally friendly process.

DISADVANTAGES

 The conditions used in direct hydration is more vigorous because of a

relatively low activity of the catalyst demanding to use high temperature
to obtain reasonable reaction rate.
 High pressure must be used to compensate the high temperature and to
obtain acceptable conversion.

3.3 INDIRECT HYDRATION

Indirect hydration is a homogenous catalysed process. For a long time the

hydration of butene in industrial scale has been catalysed with sulphuric acid.

SPECIFIC REACTION OF INDIRECT HYDRATION

Indirect hydration process is taking place in two steps. The first step is
absorption of butene is concentrated sulphuric acid that leads to formation of
alkyl hydrogen sulphate followed by dilution with water and hydrolysis.

C4H7 – OSO3H + CH3CH = CHCH3 → C4H9 – SO4 – C4H9

(Fresh Butene)

CH3CH = CHCH3 + H2SO4 → C4H7- - OSO3H

(Fresh Acid)

C4H9 – SO4 – C4H9 + 2H2O → 2CH3 – CH2 – CH (OH) –CH3 + H2SO4

22
ADVANDAGES

 Low temperature and pressure.

 Use of olefin at low hydrocarbon feed.

DISADVANTAGES

 Use of highly corrosive reagent (i.e. H2SO4) that requires large energy
consumption forregeneration.
 Both the process direct and indirect is used in industrial scale in parallel
due to its different advantages and disadvantages.

At CETEX petrochemicals Private Limited, SBA is produced by indirect

hydration of n-butene with sulphuric acid.

23
 CHAPTER 4
PROCESS DESCRIPTION (MANUFACTURE OF SBA)

4.1 Acid blending:

The fresh acid is supplied with a concentration of 98%. For
estertification a concentration of acid required is 75%. The fresh acid is
therefore diluted with spent acid with concentration of 60% from distillation and
washing column.
4.2 Estertification:
Esterification reaction is carried out in liquid phase under a pressure of
5bar and at a temperature of 450C. It takes place in a two stage reactor system
with stirred vessel reactor in counter current feed arrangement. Butane is
pumped from storage to reactor. H2SO4 is returned from second stage decanter.
Both butane and acid stream are flowing counter currently upwards through a
reactor. The butane stream added with residual butane stream recycled to the
reactor stream to adjust the butane concentration in feed to 70% which is
optimum for conversion efficiency and selectivity.
The heat is removed through a water cooled jacket. The mixture is the
passed into a decanter where two phases formed, the lower ester phase which is
rich in ester and excess sulphuric acid flows cascade controlled to prehydrolysis
column. Upper layer which is butane mixture still containing unreacted butane
for final reaction is passed to second stage reactor. Fresh acid with
concentration of 75% is fed into bottom of second reactor.

CH3CH=CHCH3 + H2SO4 C4H7 - OSO3H

C4H7-OSO3H + CH3CH=CHCH3 C4H9 – SO4 – C4H9

24
4.3 Washing:
It is used to separate the two phase ester solution and butane from
reactors. The lower layer contains sulphuric acid with little ester. The upper
layer contains butane and unreacted butane. The entrained ester separates and
goes to the bottom part of column where it‟s concentrated with water in order to
remove acidic compounds. The wash water flow is controlled by feedback
control. The washed butane stream leaves from top of column.

4.4 Neutralization:
The butane from wash water still acidic and it contains polymers
generated in the reaction section. To meet the quality and specification for LPG,
it is washed with hot caustic and its vaporized. Traces of acid are removed by
neutralization with caustic.

4.5 Stripping:
The neutral vaporized butane now contains water, so it was removed by
using stripping process.

4.6 Hydrolysis:
The fresh ester is obtained from prehydrolysis column. The ester
hydrolysis partially under pressure of 2 bar. Due to H2SO4 hydration the
temperature will increase to about 650C. The prehydrolysis ester is passed by
means of process pressure to hydrolysis glass column. By depressurizing and
heating some dissolved butane will be released from the ester. The butane is
passed to column. Traces of acid are washed out spilt butane in the upper
section of column. The dehydrolysed, diluted ester is fed to top of hydrolysis
column. From there it flows downward and is heated by the up flowing vapors
generated in the bottom. By this the ester will totally hydrolyze to SBA and
sulphuric acid.

25
 C4H9 – SO4 – C4H9 + 2H2O 2CH3 – CH2 – CH(OH) – CH3 + H2SO4

4.7 Compression:

The SBA / water vapors leaving C-104 top are condensed in E-104, the
liquid iscollected in V-105. In V-105 two phases will form. The lower is water
with SBAwhich is drained via interface control to V-152. The upper layer which
is the raw SBA is pumped for distillation to C-151.
In V-105, the released gas from C-102 will accumulate which is added to
the feedstream C-104 in order to become neutralized. This gas is brought to
about 5bar bycompressor K-101 and condenser in E-106.
The liquid butene is sent to the reaction section. In order to maintain
constantpressure in C-104 the suction pressure of K-101 is controlled by
pressure controlwith flow back. A small amount of butene is recycled through
butene chiller E-105 to V-105. The butene vaporizes there and generates low
temperature. By thismost of the SBA contained in gas stream to K-101 will be
condensed. Another partof liquid butene is passed to E-205 in V-202B to
separate SBA from H2.

4.8 Distillation:
The raw SBA collected in V-105 I pumped with p-107 under LC/FC
cascadecontrol to the upper section of SBE/Water column C-151. Kin this
column SBE aswell as water are separated from the raw SBA. Part of the water
is withdrawn asside stream directly from the column to V-152; the other part is
distilled overhead.
The SBE with some SBA and water is going overhead on vapor phase,
forming aternary azeotrope. After condensing in E-152 the liquid is collected in
V-151, V-152 is connected to BH-system, so that the column system is

26
operating at nearlyatmospheric pressure. In V-I51 water separates from the
organic phase (mainlySBE, some SBA and water).

The water phase, separated in V-151 which contains some SBA, flows
controlledby interface (LXC) to the accumulator V-l 52. In V-152 also the water
streams arecollected which are separated in V-l05 and C-154. The total water is
pumped withp-155 to C-155 the flow is controlled by LC/FC cascade. The heat
required tor thedistillation in C-151 is supplied by the reboiler E-151 at the
bottom, heated withsteam. The heat input to the system is controlled by the flow
rate of steam. Thebottom product from C-151 is pumped with P-151 to C-152 to
separate the SBAfrom the heavy components formed during the reaction.
Bottoms of C-252containing mainly SBA and heavy ketones are added via P-
254 to the column C-152 feed.

The overhead SBA product is condensed in E-154 and the liquid

collected in V-153. From there, p-154 pumps one part back to the top of C-152
as reflux, the flow controlled by FC and manually controlled to MEK synthesis.
Since V-151 and V-153 are connected to the BM-system, the operating pressure
of C-151 and C-152 isnearly atmospheric. The heat required for the distillation
in C-152 is supplied bythe reboiler E-153 at the bottom, heated with steam. The
heat input to the systemis controlled by the flow rate of steam. In the bottom
product of C-152 beside theheavies a certain amount SBA is still left. This is
due to L.P. steam temperaturelimitation at which the distillation heat is supplied
to the column. From the bottomC-152 the liquid is pumped with p-153 to the
heavies column of C-153, to separatethe left SBA from the heavies. The heat
required for the distillation in C-153 issupplied by the reboiler C-155 at the
bottom, heated with hot oil. The vaporsleaving C-153 from top are routed to the
bottom part of C-152. Reflux to C-153 is supplied from P-154. The bottom
product from C-153 is released undercontrol to V-273 fuel byproducts

27
accumulator. The raw SBE which contains some SBA is pumped from V-151 to
the extractor C-154 the SBA is recovered with water.The ether enters the
extractor at bottom, whereas the water is fed to the topsection, coming from C-
155 controlled by FC. The SBE leaves from top of C-154,controlled by the level
of V-151 and flowing to V-273. The water phase, whichcontains the extracted
SBA, is passed from bottom of C-154 to V-152. The flow iscontrolled by
interface (LXC). The water collected in V-152 is pumped with P-156. Part of
the water is heated in E-157 exchanging against C-155 bottomsproduct. In -155
SBA and MEK, are stripped out, the necessary heat is suppliedwith steam
heated reboiler E-156. The stripped water is pumped from the bottomwith P-
156. Part if the water, which is cooled in E-157 and E-158, is fed underflow
control to C-154. The other part is used for the prehydrolysis in C-102 and
fordilution of acid in XM-131 or caustic in V-106. As the demand of water is
higherthan the quantity coming from C-155, makeup water is added to the
bottom part ofcolumn C-155, the quantity is controlled by the level in C-155.
The vapors leavingC-155 at top contains water also. They enter C-156 where
the MEK is separated asa mixture with SBA and water. The necessary heat is
supplied with steam heatedreboiler E-159, the vapors are condensed by E-160.
Part of the condensed liquid isreturned to C-15 as reflux, the other part
overflows to V-273. C-155/156 operatesunder nearly atmospheric pressure as
they are connected to the BH-system. Thebottom product C-155 which is water
and SBA is partly used as reflux for C-155and is partly returned to V-105. The
boiling point of water is 1000C and the boiling point of alcohol is 990C. The
boiling point of entrainer is 1100C

28
Fig: 4.2.Distillation column

29
 CHAPTER 5

MATERIAL BALANCE

5.1 BASIS:
20,000 tons/years 2777.77 kg/hr 37.52kgmol/hr

Working days: 300 X 24

5.1.1 Reactor: 1

C4H9-OSO3H + CH3CH=CHCH3 C4H9-SO4-C4H9

Table: 5.1

Stochiometry CH3CH=CHCH3 C4H9-OSO3H C4H9-SO4-C4H9

No. of moles (kmol/hr) 23.44 23.44 18.76
Molar flow rate (kg/hr) 1312.64 3609.76 3939.6

5.1.2 Reactor: 2

CH3CH=CHCH3 + H2SO4 C4H9-SO4-OSO3H

Table: 5.2

Stochiometry CH3CH=CHCH3 H2SO4 C4H9-SO4-

OSO3H
No. of moles (kmol/hr) 30.04 30.04 23.45
Molar flow rate (kg/hr) 1682.24 2943.92 3609.76

30
5.1.3 Hydrolysis column:

C4H9-SO4-C4H9 + 2H2O 2CH3-CH2-CH(OH)-CH3 + H2SO4

Table: 5.3

Stochiometry C4H9-SO4- 2 H2O 2 CH3-CH2- H2SO4

C4H9 CH(OH)-CH3
No. of moles
(kmol/hr) 18.76 37.52 37.52 18.76
Molar flow rate
(kg/hr) 3939.6 675.36 2776.48 1839.36

5.2 FIRST STAGE CSTR REACTOR:

Fig: 5.1

Input:

31
Table: 5.4

Reactant Mole% Molar flow Weight% Mass flow

rate rate (kg/hr)
(kmol/hr)
Butene 50 23.44 26.66 1312.64
Acid rich 50 23.44 73.33 3609.72
ester
Total: 46.90 4922.36

Output:

Table: 5.5

Products Mole% Molar flow Weight% Mass flow

rate rate (kg/hr)
(kmol/hr)
Unreacted
butane 29.40 13.72 8.64 425.1
Butene 26.29 12.272 8.13 400.76
Polymer 4.13 1.872 2.20 108.284
Ester 40.01 18.76 80.08 3939.6
Sulphuric acid 2.64 1.232 0.94 46.28
Total: 47.80 4919.26

32
5.3 SECOND STAGE CSTR REACTOR:

Fig: 5.2

Input:

Table: 5.6

Reactants Mole% Molar flow rate Weight % Mass flow

(kmol/hr) rate (kg/hr)
Fresh acid 41.31 30.04 55.35 2943.92
Unreacted 41.31 30.04 31.62 1682.24
butane
Butene 14.6 10.66 9.99 531.36
Polymer 2.65 1.927 3.03 161.16
Total 72.707 5318.68

33
Output:

Table: 5.7

Products Mole% Molar flow rate Weight% Mass flow

(kmol/hr) rate (kg/hr)
Butane 19.70 13.996 9.950 533.28
Polymer 03.07 2.182 3.019 161.75
Acid 18.75 13.322 16.34 875.86
Acid rich 50.23 35.68 67.38 3609.76
ester
Unreacted 8.10 5.76 3.28 176.16
butane
Total 71.03 5356.81

5.4 HYDROLYSIS COLUMN:

Fig: 5.3

34
Input:

Table: 5.8

Reactants Mole% Molar flow rate Weight% Mass flow

(kmol/hr) rate (kg/hr)
Ester 11.97 18.76 55.53 3609.80
Water 82.80 129.8 33.13 2153.35
Sulphuric acid 5.23 8.202 11.34 737.14
Total 156.762 6500.47

Output:

Table: 5.9

Products Mole% Molar folw rate Weight% Mass flow

(kmol/hr) rate (kg/hr)
SBA 43.60 37.52 42.75 2776.48
Water 15.41 13.262 3.675 238.72
SBE 00.33 0.284 1.05 36.96
Acid 00.139 0.121 0.179 11.66
Spend acid 40.26 34.64 52.29 3396.64
Iso-pentanol 0.25 0.215 0.379 24.34
Total 86.04 6495.1

35
5.5 SBA RETURN COLUMN:

Fig: 5.4

Input:

Table: 5.10

Reactant Mole% Molar flow rate Weight% Mass flow

(kmol/hr) rate (kg/hr)
SBA 99.3 31.24 98.92 2313.06
Iso-pentanol 00.7 0.22 1.08 25.24
Total 31.46 2338.3

Top product Output:

Table: 5.11

Products Mole% Molar flow rate Weight % Mass flow

(kmol/hr) rate (kg/hr)
SBA 100 29.678 100 2191.4

36
Bottom product:

Table: 5.12

Products Mole% Molar flow rate Weight% Mass flow

(kmol/hr) rate (kg/hr)
SBA 86.20 1.562 83.49 115.65
Iso-pentanol 13.769 0.25 16.50 22.86
Total 1.812 138.51

37
 CHAPTER 6

ENERGY BALANCE:

6.1. FIRST STAGE CSTR REACTOR:

Inlet Temperature: 350 C.

Outlet Temperature: 500 C

Reference Temperature: 250 C

Inlet:

Table 6.1:

Reactants Mass Balance ΔT CP Q= m*CP*Δt

Rate (Kg/hr) (Kelvin) (KJ/Kg0K) (KJ/hr)
Butene 1312.62 10 0.083 1089.475
Acid Rich 3609.72 10 1.42 51258.025
Ester
Total 4922.34 52347.49

38
Outlet:

Table 6.2:

Reactants Mass Flow ΔT CP Q= m*CP*Δt

Rate Kg/hr Kelvin KJ/Kg 0K KJ/hr
Unreacted 425.1 25 0.083 882.0825
Butene
Butane 400.76 25 2.32 23244.08
Polymer 108.28 25 2.152 5825.46
Ester 3939.6 25 22455.72
Acid (H2SO4) 46.28 25 1642.94
Total 4920.02 54050.2825

Q reaction: Outlet heat – Inlet heat

= 54050.2825 – 52347.49 = 1702.7925 KJ/hr

Cooling Water requirement:

Water Inlet Temperature: 303 K (300 C)

Water Outlet Temperature: 313 K (400 C)

Q = m*CP*ΔT

m = Q/ CP* ΔT

m = 1702.7925/ (4.184*10) = 40.697 KJ/hr

39
6.2 SECOND STAGE CSTR REACTOR:

Inlet Temperature: 430 C

Outlet Temperature: 550 C

Reference Temperature: 250 C

Inlet:

Table 6.3:

Reactants Mass Flow ΔT CP Q= m*CP*Δt

Rate Kg/hr Kelvin KJ/Kg 0K KJ/hr
Fresh Acid 2943.92 18 1.42 75246.5952
Unreacted 1682.24 18 0.083 2513.26
Butene
Butane 531.36 18 2.32 22189.593
Polymer 161.16 18 2.152 6242.69
Total 5318.68 106192.138

40
Outlet:

Table 6.4:

Reactants Mass Flow ΔT CP Q= m*CP*Δt

Rate Kg/hr Kelvin KJ/Kg 0K KJ/hr
Butane 533.28 25 2.32 30930.29
Polymer 161.75 25 2.152 8702.15
Acid 875.86 25 1.42 31093.03
Acid Rich 3609.76 25 0.82 74000.08
Ester
Unreacted 176.16 25 0.083 365.538
Butene
Total 5356.81 145091.088

Q reaction: Outlet heat – Input heat

= 145091.088 – 106192.138 = 38898.95 KJ/hr

Cooling Water requirement:

Water Inlet Temperature: 305 K

Water Outlet Temperature: 318 K

Q = m*CP*ΔT

m = Q/ CP* ΔT

m = 38898.95/ (4.184*13) = 715.158 KJ/hr

41
6.3 HYDROLYSIS COLUMN:

Inlet Temperature: 650 C

Top Temperature: 420 C

Bottom Temperature: 1400 C

Reference Temperature: 250 C

Inlet:

Table 6.5:

Reactants Mass Flow ΔT CP Q= m*CP*Δt

Rate Kg/hr Kelvin KJ/Kg 0K KJ/hr
Ester 3609.8 40 0.228 32921.376
Water Wash 2153.35 40 4.184 360384.656
Sulphuric 727.14 40 1.42 41869.552
Acid
Total 6490.29 435175.584

42
Outlet:

Table 6.6:

Reactants Mass Flow ΔT CP Q= m*CP*Δt

Rate Kg/hr Kelvin KJ/Kg 0K KJ/hr
SBA 2776.48 17 0.189 8684.83
Water 238.72 17 4.189 16979.676
SBE 36.96 17 2.212 1389.84
Acid 11.66 17 1.42 281.47
Spend Acid 3396.64 17 1.42 81994.88
Iso Pentanol 24.64 17 1.43 552.92
Total 6485.1 109883.617

Q reaction: Outlet heat – Input heat

= 109883.617 – 435175.584 = -325291.967

6.1.4 SBA WATER COLUMN:

Inlet Temperature: 1080 C

Top Temperature: 1040 C

Bottom Temperature: 110.70 C

Reference Temperature: 250 C

43
Inlet:

Table 6.7:

Reactants Mass Flow ΔT CP Q= m*CP*Δt

Rate Kg/hr Kelvin KJ/Kg 0K KJ/hr
SBA 2313.06 83 0.184 35325.052
Heavies 25.24 83 1.32 266.53
Total 35591.58

Outlet:

Table 6.8:

Distillate Mass Flow ΔT CP Q= m*CP*Δt

Rate Kg/hr Kelvin KJ/Kg 0K KJ/hr
SBA 2197.4 79 0.184 31941.40

Table 6.9:

Bottom Mass Flow ΔT CP Q= m*CP*Δt

Product Rate Kg/hr Kelvin KJ/Kg 0K KJ/hr
SBA 115.653 85.7 0.184 1823.70
Heavies 22.86 85.7 1.32 2586.015
Total 4409.715

Outlet heat = Distillate + Bottom

= 31941.40 + 4409.715 = 36351.115 KJ/hr

Q reaction: Outlet heat – Inlet heat

= 36351.115 – 35591.58 = 759.535 KJ/hr

44
 CHAPTER 7

DESIGN OF EQUIPMENTS

7.1 DESIGN OF REACTOR

Table: 7.1

Reactant Mole% Molar flow Weight% Mass flow

rate rate (kg/hr)
(kmol/hr)
Butene 50 23.44 26.66 1312.64
Acid rich 50 23.44 73.33 3609.72
ester
Total: 46.90 4922.36

Output:

Table: 7.2

Products Mole% Molar flow Weight% Mass flow

rate rate (kg/hr)
(kmol/hr)
Unreacted
butane 29.40 13.72 8.64 425.1
Butene 26.29 12.272 8.13 400.76
Polymer 4.13 1.872 2.20 108.284
Ester 40.01 18.76 80.08 3939.6
Sulphuric acid 2.64 1.232 0.94 46.28
Total: 47.80 4919.26

45
Volume of the reactor:

Rate of esterification reaction = (-) 163.14 mol L-1 S-1

Performance equation for tank flow model reactor

F(X) = r Vb

Where,

F = Total feed rate, mass / time.

X = Conversion of reactant, mass of reactant / feed

r = Constant rate reaction, (mass of reactant converted) / (unit volume* unit

time)

Vb = Volume of the reactor

X = 0.40

Vb = (4919.26*0.40) / (163.14)

Vb = 12.06 m3

Volume = πr2 H ---------- (2)

H /D ratio = 1.9 ----------- (3)

Substituting (3) in (2) we get:

D=2m

H = 3.81 m

Diameter of agitator (blade)

46
Da /D = 1/3

Da= 0.66 m

Where,

Da is the diameter of the agitator.

E is the distance of the blade from the bottom of the reactor.

E/D = 1/3

E = 0.66 m

Where, J is the baffle width.

J/D = 1/12

J = 0.16 m

Where, W is the blade width

W/Da =1/5

W = 0.1332 m

Where, Lb is the blade length

Lb / Da = 1/4

Lb = 0.1665 m

Cooling jacket:

Markowitz has given the following rules for selecting the jacket type:

47
For ˂ 1.89 m3 use the simple jacket.

For ˃ 1.89 m3 use the dimple or half pipe coil.

Hence dimple or half pipe coil is used here.

Q = UJ AJ (TJ - TR)

Where,

UJ = Overall Heat transfer coefficient for jacket

AJ = Area of the cooling jacket

TJ = Average Temperature of the cooling jacket

TR = Temperature of the reactor

TJ = (Tj1 + Tj2) / 2

Where,

TJ = Average temperature of the cooling jacket

Tj1 = Inlet temperature of the cooling water

Tj2 = Outlet temperature of the cooling water

TJ = (30+40) / 2

UJ = 50 – 80 Btu / h-0F-ft2

Assumed UJ = 58.5 Btu / h-0F-ft2 = 454.24 W /m2K

48
Form chemical process engineering Design and economics by Harry Silla

(Table. 7.6 Approximate STR Heta-Transfer coefficient Source Ref. 7.33a)

AJ = f (Vr)

QJ = -7631.233 KJ /hr

QJ = 454.24*AJ* (-10)

= - 7631.233 = 454.24*AJ* (-10)

AJ = 1.68 m2

DESIGN SUMMARY:

Table 7.3:

Height of the reactor 3.81 m

Volume of the reactor 12.06 m3
Diameter of agitator (blade) 0.66 m
Diameter of the reactor 2m
Width of blade 0.1332 m
Length of blade 0.1665 m
Width of baffle 0.16 m
Area of cooling jacket 1.68 m2

49
7.2 DESIGN OF DISTILLATION COLUMN

SBA vs. HEAVIES

Table 7.4:

SBA HEAVIES (ISOPROPANOL)

A = 7.4743 A = 7.68
B = 1314.19 B = 1380.43
C = 186.51 C = 137.18
Boiling point = 99.50 C Boiling point = 1500 C

McCabe THIELE METHOD:

VAPOUR LIQUID EQUILIPRIUM DATA:

y = α.x / [1 + (α-1) x]

Vapour pressure estimated from Antoine equation:

LnP = A- (B/ T+C)

50
TABLE 7.5:

T 0C Pa Pb Relative
Volatility
99.5 17.63 6.344 2.61
104.5 19.18 6.34 3.02
109.5 20.70 8.03 2.57
114.5 22.28 8.98 2.48
119.5 23.93 9.99 2.39
124.5 25.64 11.07 2.31
129.5 27.42 12.22 2.24
134.5 29.14 13.44 2.16
139.5 31.15 14.74 2.11
144.5 33.10 16.10 2.05
150 49.65 17.69 2.80

Average α Value: 2.43

The high α value clearly states that impurities can be distilled from the
product

51
TABLE 7.6:

X Y
0 0
0.1 0.21
0.2 0.377
0.3 0.51
0.4 0.61
0.5 0.70
0.6 0.78
0.7 0.85
0.8 0.90
0.9 0.95
1.0 1.0

Mole Fraction of feed, Distillate and product are given by,

XF = 0.6

XD = 0.99

XB = 0.045

To find the Intercept:

Y = XD/ (R+D)

Given Reflux Ratio = 2.3

Now Y = 0.99/ 3.3 Y = 0.30

From the graph:

No. of Theoretical Stage = 12 ; Feed Plate = 8th Plate

52
Figure 7.1: McCabe Thiele Method-Graph

BINARY DISTILLATION SIEVE TRAY:

EFFICIENCY:

Connell‟s Equation is used to find the column efficiency (McCabe smith,

Pg.718)

E = 0.492 (α*µf)-0.245

53
Where,

µf = 0.425 cp (Viscosity of feed)

E = 0.375

No. of Actual Plate = 12/ 0.375

No. of actual plate = 32

Total No. of plates = 32+1 = 33

CALCULATION OF COLUMN HEIGHT:

COLUMN HEIGHT:

Tray spacing is given as 0.5 m

Height = no. of trays x Tray spacing

= 33*0.5

= 16.5 m

TOP PRODUCT:

Average Molecular weight = Total mass/ Total no. of moles

= 115.653/ 1.562

= 74.041 Kg/Kg mole

FLOODING VELOCITY:

KV is constant.

54
It is given that ρ1 (density of liquid) = 799 Kg/ m3, ρV (Vapour) = 2.36 Kg/ m3

UC = KV [ρ1 – ρV/ ρV] 0.5 (σ/ 20)0.2 [McCabe Smith Pg. 708]

Where,

UC = Maximum vapour velocity based on bubbling area, ft. /s

σ = Surface Tension of liquid in, dyn/cm

= 0.13[(799 – 2.36)/ 2.36] 0.5 (23/20) 0.2

= 2.45ft/s = 0.7476 m/s

VOLUMETRIC FLOWRATE:

V = D(R +1) = 1.562*3.3 = 5.155 Kmole/hr = 30.198*5.155 = 155.65 m3/hr\

TOWER CROSS SECTIONAL AREA:

A = V/U

= 155.65 / (0.7476*3600)

= 0.0578 m2

DIAMETER:

πD2/ 4 = 0.0578 m2

D = 0.271 m

BOTTOM PRODUCT:

Average Molecular Weight = Total mass / Total no. of moles

= 22.86 / 0.25

= 91.44 Kg /Kgmole

55
FLOODING VELOCITY:

KV is constant.

It is given that ρ1 (density of liquid) = 721 Kg/m3, ρ V (Vapour) = 3.21 Kg/m3

UC = KV [ρ1 – ρV/ ρV] 0.5 (σ/ 20)0.2 [McCabe Smith Pg. 708]

Where,

UC = maximum vapour velocity based on bubbling area, ft/s

σ = surface tension of liquid in, dyn/cm

= 0.13[(721 –3.21)/3.21] 0.5 (21.4/20) 0.2

= 1.99 ft/s = 0.606 m/s

VOLUMETRIC FLOW RATE:

V = B(R + 1) = 0.25*3.3 = 0.825 Kmole/hr = 31.63*0.4125 = 26.095m3/hr

TOWER CROSS SECTIONAL AREA:

A = V/U

= 26.095 / (0.606*3600)

= 0.1196 m2

DIAMETER:

πD2 /4 = 0.1196 m2

D = 1.234 m

Hence the diameter of the column is taken as 1.234 m.

56
PROVISIONAL PLATE DESIGN:

Column Diameter DC = 1.234 m

Column area AC = 0.1196 m2

DOWNCOMER AREA:

Ad = 12% AC

= 0.12*0.1196 m2

Ad = 0.01435 m2

NET AREA OF THE COLUMN:

An = Ac - Ad

An = 0.1052 m2

WIER LENGTH (LW):

LW = 0.77*Dc

= 0.77*1.234

= 0.950 m

57
DESIGN SUMMARY:

Table 7.7:

TOTAL NUMBER OF TRAYS 33

HIGHT OF COLUMN 16.5 m

COLUMN DIAMETER 1.234 m

AREA OF THE COLUMN 0.1196 m2

WIER LENGTH 0.950 m

7.3 DESIGN OF CONDENSER

Mass flow rate (m) = 2197.4 Kg/hr

Enthalpy () = 608.1 KJ/Kg
Heat load, Q = m()
Q = 371.17 KW CPt

„m‟ of cooling water =



CP = 4.2 KJ/Kg.K
( ) ( )
LMTD = ( )
( )

LMTD = 108.33 OC = 

„m‟ of cooling water = = 0.815 Kg/hr

Inside Pipe Thermal Conductivity (Kp) = 40 W m-1K-1

58
 CO-CURRENT FLOW

Figure 7.2: Condenser

Table 7.8
HOT COLD
PARAMETERS SYMBOL FLUID FLUID UNIT
Inlet Temperature Tin 90 30 C
Outlet Temperature Tout 70 40 C
Thermal Conductivity k 0.34 0.6154 W m-1K-1
Specific Heat Capacity Cp 400 4178.4 J kg-1 K-1
Viscosity m 0.0003 0.0008 Pa s
Density rho 1351 995.65 kg m-3
Mass Flow Rate m 0.61 0.00022 kg s-1
Inside Diameter di 0.07 0.0508 m
Outside Diameter do 0.08 0.054 m
Pressure Loss Coefficient Kp 1 1

Table 7.9
HOT COLD
CALCULATIONS SYMBOL FLUID FLUID UNIT
Heat Transfer Q 7076 9.19248 W
Prandtl Number Pr 0.35294 5.4182
Flow Area A 0.00156 0.00203 m2
Hydraulic Diameter Dh 0.016 0.0508 m
Heat Transfer Surface Area As 0.00026 0.00024 m2
Fluid Velocity V 0.28976 0.00011 m s-1
Reynolds Number Re 20878.4 6.90981
Friction Factor f 0.00647 19.5871
Nusselt Number Nu 32.0181 -627.8
Heat Transfer Coefficient h 680.385 -7605.3 W m-2K-1
Pressure Drop DP 170.29 3.2E-05 Pa
59
Table 7.10
PARAMETER SYMBOL VALUE UNIT
Length L 0.00152 m
Log Mean Temp Diff
o
(cocurrent) DTLMTD 108.33 C
Overall Heat Transfer
Coefficient UA 0.18804 W K-1
Heat Transfer Qoverall 9.19248 W

60
 CHAPTER 8

ENGINEERING PROBLEMS

8.1 MATERIAL SELECTION

Carbon steel is generally for equipment and piping in MEK unit and for parts
of the SBA. For sulphuric acid having a concentration above 90%, carbon steel;
can also be used for equipment in contact with acidic fluids below 90%
concentration different materials are required, depending on the operating
conditions.

 Carbon steel with lead lining is the cheapest solutions. However the
application is limited to 60-100 0C depending on the concentrations.
 Carbon steel with PVDF (Polyvinylidene-flouride). The application is
suitable up to 120 0C for all concentrations and pressure below 10 bar.
 Glass is suitable for all concentration and temperature up to 200 0C, it is
however sensitive to mechanical damage and suitable for low pressure
only.
 Graphite and carbon fiber are suitable for heat exchangers at all
concentrations, temperature up to 140 0C, and for pressure up to 10 bar
depending on the temperature.
 Carbon steel with glass lining is suitable for all concentrations and
temperature up to 250 0C; however it is also sensitive to mechanical
damage.
 Carbon steel with Teflon lining is suitable for all concentration and
temperature up to 200 0C.
 FOR PIPING MOSTLY Teflon lining is specified. However depending
on the availability and cost, other materials could be taken when
considering above guidelines.

61
8.2 ACID RELIEF SYSTEM

All safety valves which may relive from acid containing equipment‟s are
connected to separate acid relieving heater. As in most cases also hydrocarbons
(butenes) may be contained, this heater is routed to the acid blow down vessel.
Here the butane will be flashed off and passed to flare connection from the
vessel. The remaining acid passed to the tank. Acid spills can be transferred to
the same vessel by means of acid slops pump.

8.3 SLOPE AND PUMPOUT SYSTEM

An underground slop line heater is provided. The heater is connected to

an underground slop vessel. At several points in the plant above ground funnels
are provided, into which any equipment or lines containing solvents can be
drained via flexible hoses. The slope header is submerged into the collector
vessel, which is connected to the balancing pump the slop is pumped to vessel.

62
 CHAPTER 9

STORAGE INFORMATION

9.1 PRODUCT STORAGE

The following conceptual designs are used.

9.2 STORAGE OF BUTENE FEED

The feed butane will be supplied by pipeline, in order to cover for

interruption of the supply, an intermediate storage is required. It is
recommended to have a storage capacity of about a day, based on a production
of 4000 TAP MEK. For this a storage capacity of 120 m3 is required. Bullets
will be the most economical storage type for butenes, one bullet with the size:
Diameter: 3000mm; Length: 10000mm between tangent lines.

For safety reasons it is strongly recommended to arrange all necessary

nozzles for instruments, safety valves, filling line etc, into the on top manhole
cover. Only the section line should be at bottom.

The section line should be with an additional quick acting emergency

valves. Butene bullets of above size are conventionally erected with support on
foundations. In recent past, however many of the bullets have been laid in their
entire length in to the bad of sand and covered with earth, only one front end is
accessible behind a concrete shelter. The main reason for this method is safety
aspects and a low pressure design. It is therefore preferred solutions. In case of
non-buried arrangement a sun protection shield is to be provided for the
cylindrical part covering about 2/3 of the circumference in order to avoid
heating of butane by sun radiation.

63
9.3 SBA STORAGE

The SBA obtained from distillation is considered as an intermediate

product. Two check tanks each with capacity of 10m3 will be provided within
the MEK unit which allow analysing the average of one day production before
pumped as feed to the MEK synthesis. The check tanks are used alternatively.
One tank having a capacity of 40 m3 is recommended. This tank should be
located in the tank yard, Depending on the quality of the specie material
collected this should be either worked up in SBA distillation (in this case it will
be pumped to V-105 via provided line) or slowly blended into the MEK unit
feed. One pump is required.

All storage tanks for situations shall equipped with following installation:

 Breathing device with flame arrester.

 Filling line entering at top with internal pipe down to tank bottom.
 Level indicator with high and low alarm showing level in control room.
 Level gauges covering nearly the entire tank height.
 Sample connection.
 Temperature indication in control room and local thermometer.
 Water spray ring at tank roof, with water supply from fire water system.
 Concrete wall or earth dike around the tanks in order to collect the
spillage in case of emergency.

9.4 STORAGE FOR BY PRODUCTS

The only by products which will be recovered and which therefore need
storage volume is butane. All other by products will be directly burned as fuel.

64
9.5 BUTANE STORAGE

The butane contained in the feed and which not takes part on any reaction
will be returned to supplier to pipeline. As intermediate storage two bullets of
above 5 m3 and capacity are provided.

9.6 STORAGE FOR CHEMICALS

9.6.1 SULPHURIC ACID

The fresh sulphuric acid will be supplied by tracks with a concentration

of 98%, a storage capacity for the demand of seven days is recommended,
resulting in a tank with 65 m3 capacity. Carbon steel is suitable for tank
materials. The tank shall be located in an above ground concrete pit which allow
to collect spillage of whole tank content. The tank foundation must be elevated
that in case of total liquid spillage this cannot reach the tank wall.

The pit wall bottom and the tank foundation have to be acid resistance
lined. Mainly two systems are used for lining, either acid resistant tiles or with
several layers of special plastics. Lining with tiles requires in any case a liquid
tight barrier can be an acid resistant plastic foil or lead requirements outlined
above do so apply to the acid process area. In order to ingress of moist air into
the tank, blanketing with dry instrument is required. The consumption will be
about 1 Nm3/h.

9.6.2 SPENT SULPHURIC ACID

For intermediate storage of spent sulphuric acid with a concentration of

60% carbon steel tanks with lead lining are recommended. The volume of spend
acid to be disposed is about 0.75 Nm3/h. For storage of up to 3 days a capacity
of 65 m3 provided. The spent acid tanks shall be located in lined pit together
with the tank for fresh acid.

65
9.2.3 CAUSTIC

The required storage or preparation facilities depend on the supply of the

caustic. It is resumed that it is in liquid from with 50% concentration. It should
be supplied to the SBA unit with a proportioning pump. The pump should be
adjustable in the range of 1-50 I/h.

66
 CHAPTER 10

ECONOMIC BALANCE

10.1 SPECIFICATIONS

Basis; 20000 tons/year of secondary butyl alcohol

No. of working days per year = 300 days

Production of SBA per year = 17464000 kg

Cost of SBA per kg = Rs.90

SO, Gross sale for one year (Total income) = 17464000 x 90 = Rs.
15717760000

Turnover ratio = Gross annual sales / Fixed capacity investment

For a chemical industry,

Turnover = 1

So, Gross annual sales = Fixed capacity investment

Hence, Fixed capacity investment cost = Direct cost + indirect cost

10.2 DIRECT COST

It is 70% of fixed capacity investment.

Direct cost = 15717760000 x 0.7 = 1100232000

Direct cost consists of,

 Equipment
 Installation
 Piping
 Insulation
67
  Painting

EQUIPMENT COST

It is 34% of fixed capital

=1571760000 x 0.34

=Rs. 534398400

LAND COST

Land cost =0.1 x 1571760000

=Rs. 157176000

INSTRUMENT AND INSTALLATION COST

These costs accounts to 20% of equipment cost

= x 0.2 = Rs.54225720

ELECTRICAL AND INSTRUMENT COST

This accounts for 29% of equipment cost

= 534398400 x 0.29

= Rs. 1549755536

BUILDING, PROCESS AND AUXILLARY COST

This is 30% of equipment cost

= 534398400 x 0.31

= Rs.165663504

68
SERVICE FACILITIES AND YARD IMPROVEMENT

This is about 20% of equipment cost

= 534398400 x 0.2

= Rs.106879680

10.3 INSDIRECT COST

These are the expenses which are not including with material and labor of actual
installation of complete facilities. This account for 30% of fixed capital
investment.

=15717760000 x 0.3

= 4715328000

The indirect cost consists of

 Engineering supervision
 Construction expenses and construction fees
 Contingency

CONSTRUTION EXPENSES AND FEED

It is about 5% of fixed capital

=15717760000 x 0.05 = Rs. 785888000

CONTIGENCY

It is 5% of fixed cost

=15717760000 x 0.05 =Rs. 785888000

69
10.4 ESTIMATION OF TOTAL PRODUCTION COST

Total annual income = Rs. 15717760000

Total gross earning = 15% of total income

= 15717760000 x 0.15 = Rs. 2357664000

PRODUCTION COST

Production cost = Total annual income – Gross earning

=15717760000 - 2357664000

=Rs. 13360096000

Total production cost = Direct production cost + Fixed charges + Plant overhead

DIRECT PRODUCTION COST

It is 75% of total production cost

= 13360096000 x 0.75

= Rs. 10020072000

RAW MATERIAL COST

Cost of butane for 11725 kg = Rs. 132821257

Cost of sulphuric acid for 21470.8 kg = Rs. 87486592

Total = 132821257 + 87486592 = Rs. 220307849

DIRECT SUPERVISOORY AND CLINICAL COST

It is 5% of total production cost

= 13360096000 x 0.05

70
 =Rs. 33399900

10.5 UTILITIES

MAINTENANCE AND REPAIR COSTIt is 8% of total productioncost

=1336009600 x 0.08

= Rs. 1068807680

PATENTS AND ROYALTIES COST

It is 15% of total production cost

= 13360096000 x 0.15

= Rs. 2004014400

FIXED CHARGES

It is 20% of total production cost,

= 13360096000 x 0.2

= Rs. 2672019200

PLANT OVERHEADS

This includes cost of following general plant and overheads payroll i.e.
Overheads packing medical services, safety and production, restaurant,
recreation, salvage, laboratories and storage facilities.

This cost is 5% of production cost,

= 1336009600 x 0.05

= Rs. 668004800

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DEPRECIATION

Depreciation for machinery is 10% of fixed capital cost

= 15717760000 x 0.1

= Rs. 1571776000

Depreciation for building is 3% of the land cost

= 1571776000 x 0.03

= Rs. 47153280

Total depreciation = Rs. 1618929280

10.6 INSURANCE

It is 1% of fixed capital cost

= 15717760000 x 0.01

= Rs. 1571776000

GENERAL EXPENSES

Administrative cost includes cost for executive officers, clinical wages,

legal fees, office supplies and communication.

It is 5% of total production cost,

= 13360096000 x 0.05

= Rs. 658004800

DISTRIBUTION AND SELLING COST

It includes cost for sales officers, sales men and shipping

It is 7% of total production cost,

72
 = 1336009600 x 0.07

=Rs. 935206720

FINANCING

It is about 2% of total production cost,

= 13360096000 x 0.02

=Rs.267201920

GROSS EARNING COST

It is the net profile obtained after deduction of tax from good earnings

Tax payable = 30% of gross profit

= 1336006900 x 0.3

= Rs. 400802880

Tax payable = 30% of gross profit

= 4008028800 x 0.3

= 1202408640

10.7 NET PROFIT

Net profit = Gross – Tax

= 4008028800 - 1202408640

= Rs. 2805620160

10.8 PAYBACK PERIOD

Payback period = (Depreciated fixed capital investment / (Annual profit +

Average deprecation) / YR)

73
 = 15717760000 / (2805620160 +1618929280) years

= 3.55 years

Payback period = 3 years 201 days.

74
 CHAPTER 11

SUMMARY AND CONCLUSION

Indirect Hydration is an effective method for manufacturing Secondary

Butyl Alcohol. Property estimation, Antoine co-efficient‟s and heat capacity
were estimated using “CRANIUM READER” and factory manuals. Material
and energy balance were carried out for various equipment‟s in the plant. The
following equipments were designed: Reactor R-101 (tank flow) for the
esterification involved in the process, binary distillation column C-152 to
separate SBA from heavies‟ iso-propanol

CHAPTER 12

REFERENCE

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1. Coulson, J.M and Richardson J.F; 6th ed., Fluid Flow, Heat Transfer
and MassTransfer-Volume 1, B.H.
2. George T. Austin; 5th ed., “Shreve‟s Chemical Process Industries”
3. Harry Silla; 2nd ed., „Chemical Process Engineering Design
andEconomics‟, Marcel Dekker Inc., New York, 2003.
4. Perry,R.H and D. Green, eds; Perry‟s Chemical Engineering Handbook
6th ed., Mc GrawHill, New York, 1984.
5. Sinnot R.K.; 3rd ed., „Chemical Engineering Design-Volume 6, B.H.
6. Warren Lee McCabe, Julian Smith and Peter Harriott; 7th ed.,‟Unit
Operations of Chemical Engineering‟, Mc Graw Hill, New York, 1956.

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