Plant Design Manuscript
Plant Design Manuscript
Plant Design Manuscript
Arban L. LEGASPI
Edrian A. MAALONG
Myke Vivienne F. SALVACION
ii
Copyright
The author and the adviser authorize consultation and partial reproduction of this thesis
for personal use. Any other reproduction or use is subject to copyright protection. Citation
should clearly mention the reference of this work.
The Adviser
The Authors:
Arban L. Legaspi
Edrian A. Maalong
Biographical Sketch
ARBAN L. LEGASPI was born September 23, 1993 in Calamba, Laguna, Philippines. He
graduated from St. Peter Academy and is currently taking up Bachelor of Science in
Chemical Engineering at the Mapua Institute of Technology at Malayan Colleges Laguna.
He is a member of the Philippine Institute of Chemical Engineers - Junior Chapter Luzon
(PICHE) and Association of Chemical Engineering Students Malayan Colleges Laguna
(ACES-MCL). He is a good team player who can absorb, understand, and consider ideas and
points of view from his colleagues.
EDRIAN A. MAALONG was born June 1, 1994 in San Pedro, Laguna, Philippines. He
graduated from Santa Rosa Science and Technology High school and is currently taking
up Bachelor of Science in Chemical Engineering at the Mapua Institute of Technology at
Malayan Colleges Laguna. He is a member of Philippine Institute of Chemical Engineers
(PICHE), Inc. Junior Chapter Luzon and Association of Chemical Engineering Students
Malayan Colleges Laguna (ACES-MCL). He was a deans lister (1st term, S.Y. 20132014). He also competed in a chemical engineering quiz show held at the University of the
Philippines Diliman where his team won third place. He firmly believes that success comes
to those who work hard for it.
ii
MYKE VIVIENNE F. SALVACION was born November 14, 1993 in San Leonardo,
Nueva Ecija, Philippines. She graduated from Holy Rosary College of Santa Rosa, Laguna
and is currently taking up Bachelor of Science in Chemical Engineering at the Mapua
Institute of Technology at Malayan Colleges Laguna. She is a member of the Philippine
Institute of Chemical Engineers - Junior Chapter Luzon (PICHE) and Association of
Chemical Engineering Students Malayan Colleges Laguna (ACES-MCL). She attended
several leadership training programs and seminars that developed her character and
improved her level of competency. She prioritizes God above all before herself.
Acknowledgement
This Plant design proposal would not be possible without the able guidance,
generous assistance and supervision of several individuals who had given their time and
effort to assist us, voiced out their concerns and guided us towards the fruitful and timely
completion of this work. They served as our mentors during the entire course of this project.
We would like to express our deepest appreciation to our adviser, Engr. Marlon
O. Martinez, who has the attitude and the substance of a genius: he continually and
patiently provided us with the necessary information required for the success of our design.
Without his help and support, the completion of this proposal design would not have been
possible. We would also like to extend our sincere gratitude to Engr. Rommel Santos for
sharing his experiences and opinions with regard to the technical side of our proposal.
The following individuals and groups also contributed to our success in completing
this work.
Engr. Jesunino Aquino
Engr. Rommel Santos
Engr. Marlon Martinez
Dr. Liza Patacsil
Our supportive parents
Fellow ChE batchmates
iii
Abstract
iv
Executive Summary
In this project, the catalyst used were zeolites for the alkylation of benzene with
propylene (Norouzi, Hasani, Haddadi-Sisakht, & Mostoufi, 2014), copper oxide (CuO)
nanoparticles for the oxidation of cumene to produce cumene hydroperoxide (CHP)
(Zhang, Wang, Hongbing, Wu, & Zeng, 2007), and sulfonic acid resins for the cleaving of
hydroperoxide to produce phenol and acetone (Huang, Han, Wang, & Jin, 2002). The
following equations describe the reactions involved in the process:
(1)
+ ( )
+
(2)
+ ( )
( ) + ( )
(3)
+ ()
( ) +
(4)
The first license for cumene production belongs to a corporation called UOP. Their
process involves reactions that occur in gas phase with the presence of SPA catalyst
(Stefanidakis & Gwyn, 1977). Another license belongs to Monsanto and Kellogg, which
uses a mixture of AlCl3 and HCl as the catalyst in a homogeneous liquid-phase reaction of
benzene and propylene. The transalkylation of PIPB is also possible in this process. Thus,
this process has a high yield. However, corrosion of pipes and equipment are still a problem
(Canfield, Cox, & McCarthy, 1986). Liquid-phase and zeolite-based catalytic processes
plant commissioning is done. Furthermore, sizing and evaluating the economics of the
plant follows with a definitive class 3 estimate.
Table of Contents
Copyright
Biographical Sketch
ii
Acknowledgement
iii
Abstract
iv
Executive Summary
Table of Contents
vi
Market Study
Process Description
48
58
67
Economic Analysis
140
References
197
Appendices
205
List of Tables
vii
List of Figures
viii
List of Appendices
ix
Definition of Terms
vi
Market Study
Introduction
Phenol and Acetone are one of the most important intermediates of the chemical
industry. The demand for these chemicals increases over the years and it is forecasted to
follow this trend, which, together with its wide range of applications, provides an excellent
platform for the design of a suitable and profitable process for phenol and acetone
production in the Philippines.
Production of phenol and acetone from propylene and benzene is possible through
the process of cumene. Other types of technologies exist to produce these products but the
cumene process is proven to be more cost-effective and efficient. Propylene and Benzene
are raw materials that are produced locally in the Philippines by the large petroleum
industry.
Phenol is an aromatic organic compound with the molecular formula C6H5OH
which is also known as carbolic acid. It is a white crystalline solid that is volatile having
molecule consists of a phenyl group (-C6H5) bonded to a hydroxyl group (-OH). Phenol is
mildly acidic, but requires careful handling due to its tendency to cause chemical burns.
The major uses of phenol involving its conversion to precursors to plastics,
consumes two thirds of its production. Bisphenol-A which is produced from condensation
of phenol with acetone, is a key precursor to polycarbonates and epoxide resins.
Condensation of phenol, alkylphenols, or diphenols with formaldehyde gives phenolic
resins, in which a famous example of it is the Bakelite. Partial hydrogenation of phenol
gives cyclohexanone, a precursor to nylon.
Table 1
Import data for phenols in the Philippines
Year
Trade Value
2005
$764,633
2006
$1,623,574
2007
$4,170,608
2008
$4,927,117
2009
$1,797,902
2010
$2,661,669
2011
$1,737,026
Source: UN Comtrade: International trade statistics
Weight (kg)
2,192,213
1,105,156
3,174,993
3,120,126
1,042,860
2,444,078
4,330,795
Figure 1 shows that the demand for phenol will increase for the following years as
the trend line for the graph of supply per year is sloping upwards (positive slope). This
indicates that there is a high marketability for phenols right now and for the following years
to come in the Philippines.
5,000,000
Weight (Kg)
4,000,000
3,000,000
2,000,000
1,000,000
0
2004
2005
2006
2007
2008
Year
2009
2010
2011
2012
Figure 1. Demand tend line for phenols in the Philippines based on import
data
increased. This data may suggest that production of acetone in the Philippines is not enough
since the country is importing the particular product at an increasing rate.
Table 2
Import data for acetone in the Philippines
Year
Trade Value
2005
$3,115,608
2006
$2,900,009
2007
$3,248,726
2008
$4,382,299
2009
$2,172,884
2010
$3,401,322
2011
$3,557,146
Source: UN Comtrade: International trade statistics
Weight (kg)
3,771,988
3,261,393
3,974,290
4,990,218
3,609,613
4,993,873
4,833,998
Figure 2 shows that the demand for acetone will increase for the following years as
the trend line for the graph of supply per year is sloping upwards (positive slope). This
indicates that there is a high marketability for acetone right now and for the following years
to come in the Philippines.
6,000,000
weight (kg)
5,000,000
4,000,000
3,000,000
2,000,000
1,000,000
0
2004
2005
2006
2007
2008
Year
2009
2010
2011
2012
Figure 2. Demand trend line for Acetone in the Philippines based on Import
4
Alkyl Phenols 4%
Caprolactam 8%
Bisphenol-A 40%
Others 18%
In general, the industries that use phenol and/or acetone to manufacture these
intermediate chemicals are the plastic synthetic resin, paint, and adhesives industries.
Table 3 shows the value of output of industries that uses phenol in the manufacture
of their product. Phenol is included in the production of phenolic resins (a plastic synthetic
resin). Alternatively, phenol is combined with acetone to produce bisphenol-A, an
intermediate to produce epoxy resin which is used in the manufacture of paints, glues, and
adhesives. Depicted in Table 4 are the values of phenol used in phenolic resins and
bisphenol-A.
Table 3
Value of output of industries that uses phenol
Value of Output (in thousand pesos)
Industry description
2009
2010
Manufacture of plastic synthetic resins
12,205,785
18,523,236
Manufacture of Paints
31,538,346
32,642,161
Manufacture of Glues and Adhesive
3,148,124
4,062,129
Source: National Statistics Office
5
Table 4
Assumed phenol consumption in 2009 and 2010
Phenol in Phenolic
Phenol in BisphenolYear
Resin, kg
A, kg
2009
8,360,126.71
8,801,615.41
2010
12,687,147.95
9,715,960.54
Total Phenol
Consumption, kg
17,161,742.12
22,403,108.48
based on a 3 year annual average growth rate (2010-2013) analysis conducted by NSCB.
This percentage is usually the benchmark used in the analysis of growth rate of various
chemical industries. Actually, there are a total of 506 establishments under the Chemicals
and Chemical Products Division and around 98 establishments of those are the industry
considered in this study. This will give an average of 20% of the total division, which is
considerably high and therefore can be used to approximate the increase of the industries
considered under this division. Table 5 depicts the increase in the amount of phenol
consumption.
140,000,000.00
120,000,000.00
Phenol in Kg
100,000,000.00
80,000,000.00
60,000,000.00
40,000,000.00
20,000,000.00
-
2005
2010
2015
2020
Year
2025
2030
2035
Figure 3. Two (2) year forecast of assumed phenol consumpt ion in the
Philippines (Note that this is based only from bisphenol-A and phenolic resin
applicat ions of phenol)
9
Table 5
Percent increase in phenol consumption based on 39% per annum growth rate
Year
Phenol consumption, kg
Growth Rate (%)
2009
17,161,742.12
Actual data
2010
22,403,108.48
Actual data
2011
31,140,320.79
39
2012
43,285,045.9
39
2013
60,166,213.8
39
300,000,000.00
250,000,000.00
Phenol in Kg
200,000,000.00
150,000,000.00
100,000,000.00
2 year data point forecast
50,000,000.00
2005
2010
2015
2020
Year
2025
2030
2035
10
Solvent 46%
Bisphenol-A 25%
MIBK 8%
In general, the industries that use phenol and/or acetone to manufacture these
intermediate chemicals are the thinners/paint removers, paint, and adhesives industry.
Table 6 shows the value of output of industries that includes acetone in their
product. Acetone is included in the manufacture of thinners or paint removers, paints, glues
and adhesives. Depicted in Table 7 are the values of amount of acetone used in solvent and
bisphenol-A.
Table 6
Value of output of industries that uses acetone
Value of Output (in thousand pesos)
Industry description
2009
2010
Manufacture of Thinners / Paint
505,851
567,136
Removers
Manufacture of Paints
31,538,346
32,642,161
Manufacture of Glues and Adhesive
3,148,124
4,062,129
Source: National Statistics Office
11
Table 7
Assumed acetone consumption in 2009 and 2010
Acetone in
Year
Acetone in Solvent, kg
Bisphenol-A, kg
2009
2,564,664.57
2,797,217.17
2010
3,317,745.60
2,997,937.05
12
adhesives industry. Acetone is also an important raw material for the production of
bisphenol-A.
Figure 5 is based on a 2 year forecast from 2009 and 2010. To make it more
accurate, growth rate of the manufacturing industry was considered in the forecast. The
manufacture of thinners (paint removers), paint, glues and adhesives falls under the
Chemicals and Chemical products subsector. The growth of this subsector is 39% per
annum based on a 3 year annual average growth rate (2010-2013) analysis conducted by
NSCB. Table 8 depicts the increase in the amount of phenol consumption.
30,000,000.00
25,000,000.00
Acetone in Kg
20,000,000.00
15,000,000.00
10,000,000.00
5,000,000.00
2005
2010
2015
2020
Year
2025
2030
2035
Figure 5. Two (2) year forecast of assumed acetone consumpt ion in the
Philippines (Note that this is based only from Bisphenol-A and solvent
applicat ions of acetone)
13
Table 8
Increase in acetone consumption based on 39% per annum growth rate
Year
Acetone consumption, kg
Growth Rate (%)
2009
5,361,881.74
N/A
2010
6,315,682.65
N/A
2011
8,778,798.89
39
2012
12,202,530.45
39
2013
16,961,517.33
39
80,000,000.00
70,000,000.00
5 year data point forecast
Acetone in Kg
60,000,000.00
50,000,000.00
40,000,000.00
30,000,000.00
20,000,000.00
2 year data point forecast
10,000,000.00
2005
2010
2015
2020
Year
2025
2030
2035
15
are exempt to the CCO rules. On the other hand, the Philippine Priority Chemical list does
not include acetone and phenol, which means it is exempted from the PCL rules.
Philippine Drug Enforcement Agency policies. The Philippine Drug
Enforcement Agency has a list of dangerous drugs which are controlled under RA 9165.
Acetone is included in the list under table II chemicals (Philippine Drug Enforcement
Agency (PDEA), 2015), and is therefore controlled by the PDEA. Certificate of exemption
should be secured prior to the preparation of this chemical.
Environmental Management Bureau. The proposed plant will have oxidation
towers, to which air comes in contact with cumene and phenol. In the process simulation
using Aspen Hysys software, the vapor product of the oxidation do contain these chemicals,
to which may impose harmful effects to environment. To be able to comply with the
Republic Act 8749, also known as the Clean Air Act proposed by the Environmental
Management Bureau, the designers planned to have a scrubber to capture the chemicals.
Based on this act, the maximum allowed release of phenol in the atmosphere is
100g/NCM or 0.03 ppm. On the other hand, there are no data for the maximum allowed
level for cumene release on the said republic act. To avoid any harmful effects, it is
advisable to put up a flaring system to eliminate these chemicals in the release. Other air
cleaning system such as baghouse filters or cyclone might be in need if according to EIA,
there will be a considerable amount of particulates to be released in the atmosphere.
Philippine Clean Water Act of 2004 (R.A. 9275). In order for the proposed plant
to comply with the Philippine Clean Water Act of 2004, a design of waste water treatment
facility must be included in the overall design of the plant. Shown in Figure 7 is the initial
block flow diagram for the proposed plant. Possible waste waters to be produced are:
16
Cleaning water, Kitchen waste water, Greywater or sullage (generated from toilets, shower
baths, wash hand basins, etc.).
Figure 7. Init ial Block Flow Diagram for Waste Water Treatment Facilit y
One of the obstacles in the acceptability of SBR process has traditionally been the
need for precise, automated and reliable control of various stages of the process. The SBR
process is an activated sludge process in which the sewage is introduced into the SBR tank,
one batch at a time. Wastewater treatment is achieved by a timed sequence of operations
which occur in the same SBR Tank, consisting of filling, aeration, settling, decanting,
idling, and sludge wasting. The various stages in the sequence are the following:
17
Filling. During this stage the SBR (Sequencing Batch Reactor) Tank is filled with
the influent wastewater coming from the process area and other facilities in the plant. The
wastewater should be fed into the tank in a rapid, controlled manner.
Aeration. This stage involves the utilization of biochemical oxygen demand (BOD)
and ammonia nitrogen, where applicable, by microorganisms. The length of the aeration
period and the sludge mass determines the degree of treatment. The length of the aeration
period depends on the strength of the wastewater and the degree of nitrification provided
for in the treatment.
Settling. During this stage, aeration is stopped and the sludge settles leaving clear,
treated effluent above the sludge blanket. Time for settling varies from 45 to 60 minutes
depending on the number of cycles per day.
Decanting. At this stage of the process effluent is removed from the tank through
the decanter.
Idling. The SBR Tank waits idle until it is time to commence a new cycle with the
filling stage.
Sludge Wasting. Excess activated sludge is removed periodically during the SBR
operation. As with any activated sludge treatment process, sludge wasting is the main
control of the effluent quality and microorganism population size.
Solid Waste Management Act : Republic Act No. 9003. Usual solid waste that
can be generated from the future manufacturing plant of phenol and acetone are paper
works, kitchen/cafeteria wastes, and packaging wastes. The company has decided to have
a Material Recovery Facility (MRF) so that solid wastes can be segregated and the
company may earn money from the recycle of solid wastes.
18
Table 9
Recent phenol capacities/expansions and active phenol projects
Company
Capacity
Logo
Product
Name
(per year)
680 kte
Phenol and
Acetone
INEOS Phenol
650 kte
540 kte
400 kte
The Dow
Chemical
Company
Location
Antwerp,
Belgium
Gladbeck,
Germany
Mobile AL,
USA
Nanjing,
China
Acetone
410 MM lb
U.S.
Phenol
662 MM lb
U.S.
Formosa
Chemical and
Fibre
Corporation
Phenol and
Acetone
200,000
TPA
Taiwan
LG Expansion
Phenol and
Acetone
150,000
TPA
Korea
Kumho
Expansion
Phenol and
Acetone
150,000
TPA
Korea
PTT Phenol
Phenol and
Acetone
200,000
TPA
Thailand
FCFC
Phenol and
Acetone
220,000
TPA
Mailiao,
Taiwan
19
Esfahan
Phenol and
Acetone
135,000
TPA
Iran
Pars Phenol
Phenol and
Acetone
270,000
TPA
Iran
Saudi Kayan
Phenol and
Acetone
300,000
TPA
Saudi Arabia
Sinopec
Tianjin
Phenol and
Acetone
320,000
TPA
China
Ertisa
Phenol and
Acetone
200,000
TPA
China
Sinopec
Gaoqiao
Petchem
Phenol and
Acetone
80,000 TPA
China
Shell
Phenol and
Acetone
330,000
TPA
Singapore
FCFC
Phenol and
Acetone
200,000
TPA
Ningbo,
China
20
Target Market
Adhesives. Acetone is utilized in a multiplicity of adhesive applications, such as
spray adhesives that can be bought from any DIY store, and glues used to adhere the shoe
parts in the footwear industry.
Agro chemicals. Acetone and phenol are both used as a raw material for the
manufacturing
of
pesticides
and
herbicides,
such
as
2,4
21
Food. Phenol is used as the main ingredient for synthetic vanilla. In the industry,
phenol and acetone are used as intermediated or solvents in the manufacture of vitamins as
well as supplements, packaging for food, and medications.
Cleaning. Acetone and acetone are one of the most used solvent in the world.
Home and electrical. Most of the electrical devices are made from phenol and
acetone. The by-product of the process, alphamethylstyrene (AMS), is also used in highheat electronics such as coffee machines and toasters.
Medical and pharma. Phenol is synthesized aspirin production.
Paint and ink. Acetone is used as a solvent and its main derivative, methyl
methacrylate (MMA), is the basis for acrylic paint. On the other hand, phenol derivatives
are used in laser and ink jet printers as a coating for the ink.
Pipes. Most pipes have phenolic coatings to prevent corrosion.
Rubber and Tyres. Phenol is the precursor for the nylon intermediates such as
caprolactam and adipic acid. Both are used in the manufacture of tyre cord in the whole
world.
Textiles. Carpolactam and adipic acid, which can be made from phenol, are used
to make synthetic yarn for clothing and other textile applications.
22
Target Companies
The following companies presented in the following tables are the potential buyers of
phenol and acetone. Most of these companies are located in Manila, Batangas, Cavite,
Bulacan, and Laguna, which are all near to the plant site.
Table 10
Paint Manufacturers in the Philippines
Company Name
NIPPON PAINT PHILIPPINES
INC.
GOLDEN SUN PAINT
MANUFACTURING
Mega Paint & Coating Corp
Triple E Paint Trade
Mega Paint & Coatings Corp
Tanville Paint Manufacturing
Inc
ULTRACOTE PAINT &
COATINGS CORPORATION
Paint Plas Corporation
PACIFIC PAINT (BOYSEN)
PHILIPPINES, INC.
SUPER GLOBE, INC.
Pacific Paint & Oil
Manufacturing, Inc.
MAGNAFLO, INC. ( 97 03203
)
FH Colors & Coating Corp
Techno Development &
Chemicals Corp
Address
#4 HOLOGRAM ST. LISP BRGY.
DIEZMO
Cabuyao , Laguna
195 MOLINO HEIGHTS MOLINO III
Bacoor, Cavite
198 Manila East Road Binangonan
, Rizal
JP Laurel Lipa City
, Batangas
Traders Arcade
Mandaue City , Cebu
8001 Singer Compound Sitio Simona
San Isidro Taytay Rizal
,
E. RODRIGUEZ AVE.,
PASIG , METRO MANILA
San Antonio 722 Magsaysay Road
, Laguna
292 D. Tuazon St. Quezon City, NCR Second District 1115
,
C. RAYMUNDO AVE.,
PASIG , METRO MANILA
D. Tuazon
Quezon City, Metro Manila
1707 E ANTEL GLOBAL
CORPORATE CENTER JULIA
VARGAS AVE. ORTIGAS
PASIG , METRO MANILA
34 S Reyes SPL, Laguna
AC Cortes Ave
Mandaue City , Cebu
23
Tel no
(049)543-0763 /
845-1176
(02)3616930
8815819
652-0565
(043) 312-5214
(032) 3441195
6713410
(049)868-6416
364-3505; 3650561 to 64
6439840
02 364 3505
(049) 869-7562
(032) 3440268
Maincoat Inc
Do It Marketing Co Phils Inc
MARDUKE INDUSTRIAL
SALES
Davies Paints Philippines, Inc
SSCP Mla. Inc.
Crystal Resins Incorporated
UNI-JJET INDUSTRIAL
eccs enterprises
HVG Arcade
Mandaue City , Cebu
7946 C Padilla
Cebu City , Cebu
5 Mindanao St. Filipinas Village
Malanday
CITY OF MARIKINA, NCR
1387-A Mercedes Avenue San Miguel
CITY OF PASIG, NCR
_ Lot 1 Blk 9 Phase 1
PEZA, Rosario, Cavite
141 Cabrera Road, Sitio Burol San Juan
TAYTAY, RIZAL
The Rose Condominium,Meralco Ave.,
San Antonio
CITY OF PASIG, NCR
Door 6 Omnor bldg. phase 2 diho subdv.
diversion rd. buhangin Buhangin
DAVAO CITY, DAVAO DEL SUR
Table 11
Plastic product manufacturer in the Philippines
Company Name
Address
2 Sta Sabina, Villa Sabina
Subd. Talipapa
NICO PLASTIC PRODUCTS
Novaliches Quezon City,
Metro Manila
Cadena De Amor San
JR Plastic Manufacturing
Pedro Laguna
Corporation
, Laguna
Hon. Circle St., Sterling
J MCBEN PLASTIC
Industrial Park,
MANUFACTURING
Meycuayan , Bulacan
No. 24 Madison St.
PLASTIC CONTAINER
Mandaluyong City, NCR PACKAGING CORPORATION
Second District
146 SAN MIGUEL COMP.
9TH & 10TH AVE SAN
MIGUEL COMPD., 9TH
INNOVA PLASTIC
ST. BET. 9TH & 10TH
MANUFACTURING CORP
AVE., 101 CALOOCAN
CITY
, METRO MANILA
24
(032) 3468058
(032) 2625662
02 941 9549
02 641 7101
046 437-1053 /
0558 / 0358
22863011
02 2127419
Tel no
(632) 9394931
(049) 868-8235
(044) 299-61-91/4071568
631-8331 to 34; 6320895
2422252/2430121
15 A. Marcelo St.
Valenzuela, Metro Manila
4987 VALENZUELA ST,
BGY 600, ZONE 059
SAMPALOC, MANILA
Oliveros St.
Valenzuela, Metro Manila
56 Centro St.
Valenzuela, Metro Manila
C.M. RECTO STREET
MARIKINA, METRO
MANILA
ENERGY ST. LISP I
DIEZMO
Cabuyao , Laguna
146 9TH ST., 10TH AVE.
101 CALOOCAN CITY
, METRO MANILA
13 Humilidad St., Marulas
CITY OF VALENZUELA,
Metro Manila
1325 FM GUERRERO ST,
BGY 245, ZONE 022
TONDO, MANILA
95 Marble House,
Meycuayan , Bulacan
# 1544 Woodridge Drive,
MIS I,
Meycuayan , Bulacan
3267 1ST STA V MAPA,
SAMPALOC, MANILA
2720 NEW PANADEROS
ST, BGY 888, ZONE 098
STA ANA, MANILA
329 PUREZA ST INT 3,
SAMPALOC, MANILA
750 EDSA COR. WOOD
ST., Brgy. 144
PASAY, METRO
MANILA
MERIDIAN INDUSTRIAL
COMPLEX,
MACABLING
Santa Rosa, Laguna
25
292-4240
293-6598
432-0413
948-5298
(049)531-6158
3623835
0929-1999071
(044) 668-9503
044-432-0766
80044-Florida St.,
MIS II,
Meycuayan , Bulacan
2472 MALAYA ST
BALUT, TONDO,
MANILA
2211 MALAYA ST, BGY
124, ZONE 010 TONDO,
MANILA
#261 N. San Rafael
Montalban, Rizal
675 JENNY'S AVE. EXT.
FORMERLY IN
MERCEDES AVE.,
PASIG , METRO
MANILA
San Vicente 1425 San
Vicente St., Dulo
, Laguna
Landayan 106 Cadena de
Amor St., Cataquiz 3
Subdivision
, Laguna
726 RIZAL AVE. EXT.,
TANONG
MALABON, METRO
MANILA
ILAYA ST. NIOG III
Bacoor, Cavite
65 SIMON ST., ACACIA
MALABON, METRO
MANILA
(049)808-4630/09207794607
26
(049)847-5611
(046) 870-0456
09178322688
ISLAND MULTI-POLYMER
PLASTIC CORPORATION
27
3661653
288-41-30
(049)869-4045
725 28 82
6741375/1424/1439/1444
Table 12
Resins Manufacturer in the Philippines
Company Name
Address
141 Cabrera Road, Sitio Burol San
Crystal Resins Incorporated
Juan
TAYTAY, RIZAL
7/F Padilla Bldg., Emerald Ave.
PACIFIC RESINS, INC.
Ortigas Center, Pasig City
Pasig, Metro Manila
PUROK MALIGAYA,
GREAT EASTERN RESINS
MAMBUGAN, ANTIPOLO CITY
(PHILS) INDL CO INC
, Rizal
11 Joe Borris St., Bo. Bagong Ilog
POLYMER PRODUCTS
Pasig City, NCR - Second District
(PHILS.), INC.
1600
No. 12 Calle Obrero Bagumbayan
ALCOS GLOBAL
Libis Quezon City, NCR - Second
CORPORATION
District 1110
E. Rodriguez, Jr. Ave., Brgy.
RI Chemical Coporation
Bagong Ilog Pasig City, 1600
CHEMREZ TECHNOLOGIES,
65 Industria St.,
INC.
BagumbayanQuezon City 1110
141 McArthur Highway, Marulas,
MARULAS INDUSTRIAL
Valenzuela City
CORP.
Valenzuela Metro Manila
LG 05 Royal Mansion, Wackwack
AKZO NOBEL / CASCO
Rd., Mandaluyong City, M.M.
ADHESIVES
Mandaluyong Metro Manila
Tel no
22863011
(632) 638-5601 to
03
671-9837 to 39
635-0631
671-9842 to 53
635-0680
(02) 291-8105 - 07
831-0870
28
The demand for propylene and benzene will surely increase in the future because they are
cheap and they are used in manufacturing a lot of chemicals such as phenol and acetone. It
can be settled that the local supply for benzene and propylene is enough, and that
importation of these chemicals is not needed for the proposed plant. Table 14 shows the
list of suppliers of the raw materials needed by the proposed plant.
Table 13
Import and Export Data of Propylene and Benzene
Propylene
`Benzene
Year
Import (kg)
Export (kg)
Import (kg)
Export (kg)
2007
83,751,966
2,373,930
2008
53,258,477
2009
60,528,698
7,292,410
2010
46,477,418
98,106,469
663
19,453,901
2011
42,067,745
73,036,129
60
24,209,049
Source: UN Commodity Trade Statistics Database `
Table 14
List of Suppliers of raw materials in the Philippines
Company
Location
Propylene
Petron PRU (Propylene
Bataan PH
Recovery Unit)
Benzene
-
Bataan PH
JG Summit - JGSOC
Batanggas
PH
Sources:
[1] Petron, 2005
[2] Hanmin & Suratman, 2011
[3] JG SUMMIT HOLDINGS, INC. - Annual Report, 2013
29
Capacity
140000
mtpy[1]
150000
mtpy[2]
190000
mtpy[3]
SWOT Analysis
Table 15 shows the matrix for the SWOT (strengths, weaknesses, opportunities, threats)
analysis of the proposed project.
Table 15
SWOT/TOWS Matrix
SWOT
MATRIX
1.
2.
3.
4.
Opportunities
Growing end product
demand of phenol and
acetone
High
profitability
because of high value of
phenol and acetone in
the market
Project may improve
local
economy,
employment,
and
communities
Raw Mat Availability: 2
large producers of
propylene and benzene
are JG Summit and
Petron, located here in
the Philippines
Strengths
1. Technology:
Cost
Effective
manufacturing process
of phenol and acetone
through
Cumene
Process
2. Location:
Only
manufacturer of phenol
and acetone in the
Philippines
3. Inexpensive
raw
materials as compared
to global chemical
prices
4. Low
environmental
risks
because
of
employed
environmental
measures.
S-O Strategies
1-1 Selling of products at a
high acceptable price to
increase profitability.
1-3 Generation of more jobs
with more incentives for
employees
1-4
Possible
project
partnership
with
JG
Summit and Petron
2-1 Flexibility in product
prices that will favor
profitability; Meet local
product
demand
expectations
2-4 Project expansion after
10-15 years of success
30
Weaknesses
1. Lack of company name
equity
2. Inertly high startup
cost:
Will
require
investment and loan per
capital
W-O Strategies
1-1 Capture hearts of
investors; Deliver excellent
product quality; Genius
marketing campaigns for
B2B approach; Versatility
in product pricing
1-3 Gain government and
local community support
for the development of the
project
1-4 Establish partnership
with raw mat suppliers to
have a production stability
2-1
Demand
and
profitability of the product
will
prove
project
S-T Strategies
1-1
Cost
effective
production of high quality
phenol and acetone to attain
better product prices (cost
driven sales)
2-1 Local manufacturers
that needs the products will
prefer local suppliers (B2B
support)
3-1 Support from JG
Summit and Petron will
yield success in lower cost
of production, excellent
product quality, and better
competitive prices
4-1 Local market and
government will favor
production of products
because of environmentally
friendly
engineered
processes.
Determining the plant capacity. Based on the SWOT analysis and the strategies
that were made on Table 15, the company is confident to get the 40% of the market share.
To determine the capacity of the plant, the phenol demand based from consumption will
be multiplied by 40%, as shown in Table 16. Note that market share may change after the
completion of the economic evaluation analysis.
31
Table 16
Projected phenol and acetone capacity of the proposed plant
Year
Acetone, Kg
Total, Kg
Phenol, Kg
2017
20,983,104.88
54,983,104.88
34,000,000.00
2022
27,154,606.31
71,154,606.31
44,000,000.00
2027
33,326,108.00
87,326,108.00
54,000,000.00
2033
40,731,909.47
106,731,909.47
66,000,000.00
Figure 8 shows the projected phenol and acetone capacity of plant, which is 40%
of the projected demand based on consumption. Through careful analysis of the SWOT
and current state of Philippine economy, the company has decided to design a 54,000,000
kg (54,000 MT per year of phenol) manufacturing plant, in which 62% is 34,000 MT
(minimum and starting capacity of plant). This was purposely made to avoid big loss
through the normal wear and tear of equipment / facilities. If the management decides to
expand the production after 2027, addition of equipment and utilities will compensate.
Possible additional investments are reboiler, reactor, distillation column, storage tanks, and
condenser.
32
120,000,000.00
100,000,000.00
Capacity, Kg
80,000,000.00
Phenol
60,000,000.00
Acetone
TOTAL
40,000,000.00
20,000,000.00
2015
2020
2025
Year
2030
2035
The ISBL (Inside Battery Limit) cost can be estimated using the following
correlation (Towler, 2013):
2
2 = 1 ( )
1
2 = ISBL capital cost of the plant with capacity 2
1 = ISBL capital cost of the plant with capacity 1
= typically 0.6 for chemical industry
33
(5)
(6)
Table 17 shows the process cost correlation constants of a cumene plant and phenol
from cumene plant. These constants will be used in equations 5 and 6 to obtain an estimate
of the capital cost.
Table 17
Process cost correlation constants for the plant
Capacity
PROCESS
Licensor
S lower
Units
UOP
tpy
150,000
Cumene by Q-Max
Phenol from Cumene UOP/ABB MMlb /
200
Lummus
year
(Zeolite Catalyst)
Source: Towler and Sinnott, 2008
S
a
upper
450,000 0.012
600
6.192
n
0.6
0.6
The first step towards getting the cost of the plant is to get the cost at S lower
because the desired capacity is out of range, lower than the given range. Table 18 shows
the cost of the two processes at lower capacity.
Table 18
Cost of the two processes at lower capacity
Process
1
2
34
S lower
150,000
200
C2 (MM USD)
15
149
Table 19 shows amount of the raw materials needed to produce the intermediate
(cumene),
at
the
design
capacity
of
the
plant
(Phenol:
54,000
and
Acetone: 33,326). The following table shows the capital cost of the plant.
Table 19
Capacity of plant obtained through stoichiometric ratio and proportion method
CAPACITY
Chemical
Molar mass
kmol
Kg
Ton
Propylene
42.08
573,797
24,145,362
24,145
Benzene
78.11
573,797
44,819,254
44,819
Cumene
120.19
573,797
68,964,616
68,965
Phenol
94.11
573,797
54,000,000
54,000
Acetone
58.08
573,797
33,326,108
33,326
Table 20 shows the cost of the actual plant at year 2006. In order to obtain the cost
at year 2017 when the plant is expected to fully operate, the CE index was used which is
given in Table 21.
Table 20
Cost of the actual plant at year 2006
Process
S2
1
2
Total
68965
108
Table 21
CE cost index up to year 2017 through extrapolation
2004
2005
2006
2007
2008
2009
CE
INDEX 444.2
468.2
499.6
525.4
575.4
521.9
Source: KLM Technology Group
35
C2 (MM
USD)
9
97
106
2010
555.3
2017
635.607
The OSBL (Outside Battery Limit) cost can vary from 10% to 100% of the ISBL
cost depending on the complexity of the process and required support facilities (Towler,
2013). For this project, it was assumed that the OSBL cost is approximately 50% of ISBL
cost considering that we need to install a steam generator, waste water treatment facility,
and cooling water system. Table 22 shows the price of raw materials and products needed
in economic analysis of the plant.
Table 22
ICIS Indicative price of raw materials and products
RAW
MAT
Price
(USD/MT)
Price
(Peso/MT)
PRODUC
T
1014.1252
43607.3836
Propylene
1039.81
44711.82681
Benzene
Source: ICIS, 2015
Acetone
Phenol
Price
(USD/MT
)
1807.7884
1984.158
Price
(Peso/MT)
77734.9012
85318.794
Table 23 shows the preliminary total capital expenditures of the plant. It is expected
to have a return of investment at the 3rd year.
Table 23
Preliminary Total Capital Expenditures of the Plant
C(2017), MM USD
Location factor
ISBL CAPEX
OSBL OPEX
Contingency
TOTAL CAPEX
ANNUAL OPEX
ANNUAL REVENUE
ANNUAL EXPECTED NET INCOME
PAYBACK PERIOD (years) @ 100% capacity
36
134
1.12
6,765,790,879.94
3,382,895,439.97
1,014,868,631.99
11,163,554,951.90
3,056,866,780.17
7,197,816,569.04
4,140,949,788.86
2.70
To estimate the Internal Rate of Return (IRR) for this project, it was anticipated
that the plant will be installed within two years. Hence, capital expenditure was assumed
to be equally distributed in two consecutive years. Referring to the projected capacity
based on SWOT analysis on Table 15, the expected rate of return of the project is shown
on Table 24. Considering the turndown capacity of the plant, the payback period is
expected to be less than 5 years.
Table 24
Preliminary Project Cash Flow and IRR
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Year
Annual Revenue
Annual Opex
CASH FLOW
2015
2016
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
2032
2033
0
0
598,908,284.52
3,598,908,284.52
5,398,362,426.78
7,197,816,569.04
7,197,816,569.04
7,197,816,569.04
7,197,816,569.04
7,197,816,569.04
7,197,816,569.04
7,197,816,569.04
7,197,816,569.04
7,197,816,569.04
7,197,816,569.04
7,197,816,569.04
7,197,816,569.04
7,197,816,569.04
7,197,816,569.04
IRR
0
0
1,528,433,390.09
1,528,433,390.09
2,292,650,085.13
3,056,866,780.17
3,056,866,780.17
3,056,866,780.17
3,056,866,780.17
3,056,866,780.17
3,056,866,780.17
3,056,866,780.17
3,056,866,780.17
3,056,866,780.17
3,056,866,780.17
3,056,866,780.17
3,056,866,780.17
3,056,866,780.17
3,056,866,780.17
(5,581,777,475.95)
(5,581,777,475.95)
2,070,474,894.43
2,070,474,894.43
3,105,712,341.65
4,140,949,788.86
4,140,949,788.86
4,140,949,788.86
4,140,949,788.86
4,140,949,788.86
4,140,949,788.86
4,140,949,788.86
4,140,949,788.86
4,140,949,788.86
4,140,949,788.86
4,140,949,788.86
4,140,949,788.86
4,140,949,788.86
4,140,949,788.86
25%
TURNDOWN
CAPACITY
(%)
50%
50%
75%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
Company Profile
The name of the company is PhAce Philippines Corporation. At PhAce co., safety,
operational excellence and customer satisfaction are at the heart of all we do because our
customers matter to us. We have a wealth of professional and technical expertise at our
disposal which enables us to provide our customers with the prompt and efficient service
and high quality products they have come to expect from our business. Our customers have
high expectations: uniform product quality, on-time delivery and reliable supply at
competitive prices. They also demand high safety and environmental standards from their
business partners. Our customers trust PhAce co., to meet their expectations, through
operational excellence.
38
Company Logo
Shown in Figure 9 is the logo of the company. The letters P and H symbolizes the
name Philippines, which is the mother country of the company. Ace part of the company
name means it will be the number one provider of phenol and acetone product, analogous
to the ace card which is the highest playing card in a deck. The globe sign symbolizes the
39
global competitiveness of the company, through its latest and innovative technology of
producing quality products. In general, the logo of the company represents clearly who
Phace Philippines Corporation is, and what will it contribute to the country and world in
the future.
40
BOARD OF
DIRECTOR 1
BOARD OF
DIRECTOR 2
PRESIDENT
VP FOR
TECHNICAL
VP FOR
MARKETING
AND SALES
HR
DEPARTMENT
Quality
Control
Director
Distribution
Training
R&D Director
Sales
Remuneration
Production
Director
Hiring
Maintenance
and
Engineering
Medical
Services
VP FOR
ADMIN
Quality
Management
Representativ
e (QMR)
Document
Controller
Ground &
Building
Maintenance
BOARD OF
DIRECTOR 3
EXECUTIVE
ASSISTANT / OIC
VP FOR
SUPPLY
CHAIN
VP FOR
FINANCE
VP FOR
CORPORATE
ACCOUNTS
Warehouse
Manager
Accounting
CSR
Logistics and
Transport
Investment
Corporate
Communicati
ons Officer
Purchaser
Procurement
Plant Location
The parameters considered by the designers in choosing the location are the site
location, site quality, topography, soil conditions, climate conditions, and flood risk.
Through a serious deliberation of the plant designers, the chosen site location is Hermosa
Ecozone Industrial Park, Bataan. Hermosa is a first class municipality in the province
of Bataan. It is one of the Eleven (11) municipalities of Bataan. It has a total land area of
15,730.00 hectares in lieu of 11.40% of the entire provincial area and it is composed of 23
barangays with a population of 52,484 people in 8,988 households. The municipality of
Hermosa is predominantly agricultural. A large portion of the agricultural area, mostly in
41
the lowland, is planted with palay or the rice. Table 25 shows the general information that
describes the municipality of Hermosa, Bataan.
Table 25
General Information of the Geography of Hermosa, Bataan
Country
Philippines
Region
Central Luzon (Region 3)
Province
Bataan
District
First District of Bataan
Barangays
23
Mayor
Danilo C. Malana
Area
157.00 km2 (60.62 sq mi)
Population
112,707
Density
730/km2
Time zone
ZIP code
Dialing code
Income class
PST (UTC+8)
2111
47
st
1 class
Power supply. Hermosa is 100% electrified and is being served by the Peninsula
Electric Company (PENELCO). Also, Manila Electric Company (MERALCO) provides
electricity for the town. As of 2013, one more 600 megawatts GN powerplant was being
constructed by the GN power in the same site in Mariveles aside from the existing one
which is also a 600 megawatts. The residential electricity cost of the Peninsula Electric
Cooperative (PENELCO) is 2.24 per kilowatt hour, lower than that of the Manila Electric
Company (MERALCO). Table 26 shows the charges on electricity rates in Hermosa.
Table 26
Electric charge of PENELCO
RATE CHARGE
Residential
Average Rate/KWH
PhP 8.9858
Commercial
Industrial
PhP 7.8113
PhP 6.4708
43
Ports Authority (PPA) as shown in tables 27 and 28. The town has a total of 1 bank, 21
schools, 15 medical clinics/health centers, and 2 recreational facilities.
Table 27
List of Airport near Hermosa Bataan
AIRPORT NAME
Clark International Airport
Subic Bay International Airport
LOCATION
Clark Freeport Zone
Morong, Bataan
Table 28
List of Ports near Hermosa Bataan
PORT NAME
Port of Lamao
Port of Mariveles
Subic Bay Freeport
LOCATION
Lamao, Bataan
Mariveles, Bataan
Subic Bay, Bataan
Water supply. The Hermosa Water District supplies the water requirement of
Hermosa town proper while the economic zone has its own water system, the Bataan
Economic Zone Water System. There are three big watershed groups in Bataan, which are
the Subic watershed from Morong including half of Bagac, the Mt. Natib watershed from
Dinalupihan down to Balanga, and the Mariveles watershed from Mariveles to Limay,
Orion, Pilar and the other half of Bagac. The province is drained by more than 100 rivers
and small branches radiating from these watershed areas and provides a range of purposes,
such as irrigation, navigation, and water reservoir. The provinces water supply comes from
these freshwater sources and a widespread water reserve, extorted by numerous deep wells
and free flow areas in all municipalities. Shown in table 29 are the prices for water services
in Hermosa, Bataan.
44
Table 29
Prices of Balanga Water District Services
Cubic Meter
Residential/Govt
0-10
11-20
PhP 130.00
PhP 144.50
PhP275.00
21-30
PhP291.25 -PhP
437.50
31-40
PhP455.75-PhP
620.00
41-50
PhP640.50-PhP
825.00
51-100
PhP848.00-PhP
1,975
Source: Balanga Water District, June 2014
Communication.
Commercial A
Commercial B
PhP 195.00
PhP216.75 -PhP
412.50
PhP436.85-PhP
565.00
PhP683.35-PhP
929.50
PhP960.25-PhP
1,237
PhP1,271.50-PhP
2962.00
PhP 227.50
PhP252.85-PhP
481.00
PhP509.40 -PhP
765.00
Ph796.90-PhP 1,
084
PhP1,119.85-PhP
1,142.50
PhP1,482.75-PhP
2, 962.00
by PLDT,
45
Table 30
Internet / Landline Rates
PARTICULARS
Voice / Landline:
Monthly Rental (Commercial)
Monthly Rental (Residential)
Data / Internet:
Monthly Rental 1MB up to 4MB
(Commercial)
Monthly Rental up to 1MB (Residential)
Source: PLDT, 2014
COST
PhP 936.00 (21.53 USD)
PhP 617.00 (14.19USD)
PhP 4, 000.00 (92.00 USD)
PhP 999.00 (23.00 USD)
Climate and flood risks. Hermosa Creek can experience destructive earthquakes
with an average of one every 50 years, with occurrences at >7 Richter. When a strong
earthquake occurs, damage will be slight seen in specially designed structures but
considerable in ordinary substantial buildings with partial collapse, an example would be
moving of heavy furnitures but for poorly built structures, it will be demolished. There is
a medium-low occurence of periods with extreme drought but Flooding risk is extremely
high. Also, there is extremely high chance of cyclones hitting Hermosa Creek but zero
chance of having a landslide. The climate in Hermosa is classified as a tropical savanna
(winter dry season), with a tropical moist forest biozone. The soil in the area is high in
nitosols, andosols (nt), soil with deep, clay-enriched lower horizon with shiny ped surfaces.
Labor cost. One important factor in determining the annual operating expenses of
the plant is the labor cost, as shown in Table 31.
Table 31
46
47
Process Description
48
DIPB, benzene
Benzene
Propylene
Alkylation
Reactor
(FIXED BED)
(Zeolite catalyst)
Distillation
Columns
Cumene
Cumene
Oxidation Tower
Air
Cumene
Hydroperoxide
(CHP)
Cleavage Reactor
(Sulfonic resin catalyst)
Acetone
Distillation
Columns
Phenol
Figure 11. Block Flow Diagram of Phenol and Acetone production through Cumene
Process
49
Zeolite based catalysts such as , Y, ZSM-12, and MCM-22 can be used in the
liquid phase alkylation of benzene with propylene to produce cumene (Norouzi, Hasani,
50
Haddadi-Sisakht, & Mostoufi, 2014). Shown in Table 32 is the type of catalyst used in the
first reactor of the process. During the alkylation reaction, side reactions occur which
produces PDIB ( ). This results to additional consumption of
raw materials that negatively affects the economics of the process. In order minimize the
production of the side product and increase the selectivity of the main reaction over the
PDIB reaction, an excess amount of benzene is introduced in the reactor. The Benzene to
propylene mole ratio was maintained at more than 4 in the reactor (Perego & Ingallina,
2002). The excess amount of benzene will absorb the heat generated by the exothermic
reaction in the reactor to keep the selectivity of the cumene reaction high and suppress
undesirable reactions between propylene molecules to form higher linear hydrocarbons.
Table 32
Information on catalyst used for alkylation and transalkylation reactions
Catalyst
-zeolite catalyst
Particle Diameter
3.0 mm
Porosity
0.3
Price
8.367 USD per Kg
Source: Dai, Lei, Zhang, Li, & Chen, 2013
Price: Zauba, 2015
The alkylation reactions follows the Eley-Rideal kinetic model, which means that
the adsorption of propylene on the catalyst is the rate-determining step (Corma, MartinezSoria, & Schnoeveld, 2000). As shown in Table 33, the kinetic law reduces to first order
reaction. The reactor in the system consist of a fixed bed of catalysts pellets with an inlet
temperature range of 150 to 200. The pressure in the reactor is maintained high enough
between 2.5 to 3.5 MPa to ensure that the boiling point of the solution is at least 20 higher
51
than the temperature elsewhere in the reactor (Norouzi, Hasani, Haddadi-Sisakht, &
Mostoufi, 2014).
Table 33
Kinetics of alkylation and transalkylation reactions ( is in /, rate of
react ion is in /3 , and concentration is in /3 )
TYPE
REACTION
RATE CONSTANTS
Alkylation
52564
)
55000
2 = 450 (
)
Cumene Reaction
1 = 6510 (
DIPB Reaction
Source: Dimian and Bildea, 2008; Pathak et al., 2011
The route to phenol production. The next process involved the liquid phase air
oxidation of cumene, called cumene peroxidation process, to produce cumene peroxide at
the proper reaction temperature of 358K (Zhang, Wang, Hongbing, Wu, & Zeng, 2007).
Cumene is continuously fed to the oxidation vessel (fluidized bed) until 15 to 25 percent
of the cumene is oxidized. The mixture from the oxidizer should be around 60% to 80%
by weight cumene peroxide, which will then be fed to a reactor for the cleaving of CHP to
phenol and acetone. The cleavage mechanism is an example of 1,2 shift from carbon to
oxygen (Speight, 2002). Figure 14 depicts the mechanism of cumene oxidation to form
cumene hydroperoxide.
52
In cumene oxidation, cumene is oxidized in air which removes the tertiary benzylic
hydrogen from cumene and hence forms a cumene radical. Table 34 shows the type of
catalysts used in the oxidation tower.
Table 34
Catalyst for Oxidation Data
Catalyst
CuO Nanoparticle catalyst
Particle Diameter
>140 nm
Density
790 kg/m3
Source
US Research Nanomaterials, Inc.
Price
376 USD per Kg
Source: Zhang, Wang, Hongbing, Wu, & Zeng, 2007
Price: US Research Nanomaterials, Inc., 2015
53
The cumene radical then bonds with an oxygen molecule to give cumene
hydroperoxide radical. This in turn forms into cumene hydroperoxide by abstracting
benzylic hydrogen from another cumene molecule. This latter cumene converts into
cumene radical and feeds back into subsequent chain formations of cumene
hydroperoxides. Table 35 shows the kinetic reaction details for cumene oxidation.
Table 35
Cumene oxidation reaction details
Type of Reactor
Temperature (K)
Conversion (%)
Selectivity for CHP (%)
Reaction Pressure (atm)
Catalyst
Source: Zhang, Wang, Ji, Wu, & Zeng, 2007
Fluidized Bed
318
17
>99
1
CuO Nanoparticle
54
Figure 15. Diagram for the Mechanism of CHP decomposit ion to Phenol and
Acetone
In the first step, the terminal hydroperoxy oxygen atom is protonated. This is
followed by a step in which the phenyl group migrates from the benzyl carbon to the
adjacent oxygen and a water molecule is lost, producing a resonance stabilized tertiary
carbocation. The resulting carbocation is then attacked by water, a proton is then
transferred from the hydroxy oxygen to the ether oxygen, and finally the ion falls apart into
phenol and acetone. Table 36 shows the optimum operation conditions for the cleaving
reactor.
55
Table 36
Optimum operation conditions and Reaction kinetics of Catalytic
Decomposition Process of Cumene Hydroperoxide
Type of Reactor
Fluidized Bed Reactor
75 to 85, preferably 80
Temperature ()
1
Space Velocity (WHSV) ( )
30 to 40
Selectivity (%)
>98
Conversion (%)
>99
Solid Holdup (catalyst) (wt%)
1 to 1.5
Catalyst
Sulfonic Resin
Order of Reaction
1
36.43 103 1
Kinetic Rate Model of Decomposition
= 1939.1 exp (
)
The catalyst for the cleaving reaction requires an acid catalyst. Shown in Table 37
is the type of catalyst used in the cleaving reaction.
Table 37
Catalyst for Cleaving Reaction Data
Catalyst
Particle Diameter
Density
Sulfonic Resin
0.02mm
0.00118 kg/m3
Wenzhou Foreign Trade Industrial Product
Source
Co.,Ltd. (China)
Price
2930 USD per Kg
Source: Huang, D., Han, M., Wang, J., & Jin, Y., 2002
Price: ChemPep Inc., 2015
The products are separated by distillation. Acetone is firstly removed in the first
column. The bottom is vacuumed distilled to send unreacted cumene overhead. The
product is purified through catalytic hydrogenation through careful fractionation. In the
56
latter case, bottoms from the vacuum are further distilled to separate cumene from phenol,
phenol being the overhead product.
Economic advantage of the technology. The comparative cost for the currently
existing processes for the production of phenol is shown in Table 38. Currently, the
Cumene process is universally favored in the United Kingdom (UK) and United States of
America (US) because of its lower cost and higher product yield.
Table 38
Comparison of cost of production of phenol and acetone
Process
Benzene - ChloroCumeneBenzeneToluene
Raschig
Sulphonate benzene
hydroperoxide cyclohexane Oxidation
Net
Production
81.7
cost (/ton)
Source: Tyman, 1996
78.3
57.1
57
45.7
51.5
59.5
In this plant design project, the software called Aspen Hysys (Version 8) was used
to simulate and generate heat and material balances for each equipment in the plant. Aspen
HYSYS is a comprehensive process modeling system that is currently utilized by leading
engineering companies worldwide. In general, this software is used to design as well as
optimize processes and operations involved in a manufacturing plant. Using the software,
material streams, compositions, and energy streams were obtained and described in depth.
The main Aspen Hysys simulation involves the modeling of the major three
processes of the plant. The first process involves the production of cumene through
alkylation reaction between benzene and propylene. The fluid package chosen in Aspen
Hysys is NRTL because it is generally used for chemical systems and HF alkylation with
highly non-ideal chemicals and it is thermodynamically consistent, which can be applied
to ternary and higher order systems. Table 33 shows the kinetic data for alkylation and
transalkylation reaction needed by Aspen Hysys for the first reactor. The second process
involves the oxidation of cumene to produce cumene hydroperoxide, and its kinetics of
reaction is described in Table 35. The last process involves the cleaving of cumene
hydroperoxide to produce phenol and acetone, and the kinetics of reaction is described in
Table 36. Table 39 shows the component list for the simulation of the main process.
58
Table 39
Data for the component list of the main process in Aspen Hysys
Component
Propene
Oxygen
14-iP-BZ
Acetone
Phenol
Propane
Nitrogen
CumHyPeroxid
Cumene
Benzene
Air
H2O
Type
Pure Component
Pure Component
Pure Component
Pure Component
Pure Component
Pure Component
Pure Component
Pure Component
Pure Component
Pure Component
Pure Component
Pure Component
The utilities required of the process are simulated as well using Aspen Hysys. The
first utility involved the generation of steam and the second involves the closed loop
circulation of cooling water for the plant. Tables 40 and 41 depicts the component list for
the simulation of the stated utilities.
Table 40
Data for the component list of the steam gen utility in Aspen Hysys
Component
Propane
Nitrogen
CO2
Oxygen
H2O
Type
Pure Component
Pure Component
Pure Component
Pure Component
Pure Component
59
Table 41
Data for the component list of the cooling water system utility in Aspen Hysys
Component
Type
H2O
Pure Component
For a more detailed simulation of the process and utilities of the plant using Aspen
Hysys, see Appendix A. Shown in Table 42 is the summarized material streams of the
process. Tables 43 and 44 shows the summarized compositions for each streams and energy
streams of the main process.
Table 42
Material Streams of the Process
STREAM
Vapour
Fraction
Unit
Temperature
Pressure
Molar
Flow
Mass
Flow
Liquid
Volume
Flow
Heat
Flow
bar_g
kgmole/h
Kg/h
m3/h
kJ/h
Benzene
25
-0.01325
80
6248.8
14.166563
7961764
Benzene_to_mixer
28.243691
34.38675
80
6248.8
14.166563
8027489
Propylene
25
10.98675
79.67
3354
6.43999
295193.9
Prop_to_mixer
27.337761
34.38675
79.67
3354
6.43999
315840.3
To Heater
72.429121
34.38675
13810.09
1071616
1222.03203
7.49E+08
To_Alkylator
170
33.766222
13810.09
1071616
1222.03203
9.6E+08
To_valve
170
33.352865
13731.05
1071616
1219.635126
9.52E+08
Cumene_Bot
159.0118
0.18675
79.12
9510.42
10.997799
-660888
Benzene_Dist
70.053451
-0.01325
13651.93
1062105
1208.637325
7.4E+08
To_pump
70.044379
-0.01325
13570.42
1055764
1201.425477
7.35E+08
To_column1
0.44099
86.599685
0.28675
13731.05
1071616
1219.635126
9.52E+08
To-Mixer
73.139927
34.38675
13570.42
1055764
1201.425477
7.41E+08
To_OxiTow_1
44.85
-0.413686
164.12
19520
22.416604
-6893388
AIR
25
380
10963.1
12.673355
To_tee
83.159439
0.62675
380
10963.1
12.673355
648168.1
To_OT_1
83.159439
0.62675
95
2740.78
3.168339
162042
VAP_1
44.85
-0.012777
76.18
2248.24
2.775003
49224.18
To_OxiTow_2
44.85
-0.012777
162.99
20012.5
22.358325
-8675304
To_OT_2
83.159439
0.62675
95
2740.78
3.168339
162042
To_OT_3
83.159439
0.62675
95
2740.78
3.168339
162042
VAP_2
44.85
-0.022341
76.16
2232.43
2.757165
48642.77
To_OxiTow_3
44.85
-0.022341
161.87
20520.8
22.317883
-1E+07
60
VAP_3
44.85
-0.031921
76.55
2230.37
2.749782
48130.51
To_OxiTow_4
44.85
-0.031921
160.94
21031.2
22.297683
-1.2E+07
To_OT_4
83.159439
0.62675
95
2740.78
3.168339
162042
To_Cleaving
44.85
-0.041213
160.13
21445.2
22.274623
-1.4E+07
VAP_4
44.85
-0.041213
79.88
2326.75
2.830657
49449.35
To_CleavageR
Decomposition
Effluent
Acetone Product
45.080979
3.293705
160.13
21445.2
22.274623
-1.4E+07
80
2.98675
235.34
21445.2
23.640879
-3.2E+07
91.975505
2.68675
75.26
4369.79
5.531312
-1.8E+07
to next Column
214.120846
2.88675
160.08
17075.4
18.109567
-8943146
Dist_Cumene
151.888966
84.95
10004.3
11.412643
-1808721
Phenol Product
236.829828
2.78675
75.13
7071.12
6.696924
-8221078
TO_FLARE
Acetone to
STORAGE
Phenol to
STORAGE
To Mixer2
44.85
-0.041213
308.77
9037.79
11.112607
195446.8
30
2.645381
75.260491
4369.79
5.531312
-1.9E+07
54.444444
2.745381
75.127467
7071.12
6.696924
-1.1E+07
151.888859
84.993763
10009.6
11.418805
-1808819
To Cooler_E-100
0.02402
151.967835
164.11617
19520
22.416604
-2469708
44.885457
164.11617
19520
22.416604
-6892120
44.851035
162.98699
20012.5
22.358325
-8675266
44.85171
161.87431
20520.8
22.317883
-1E+07
44.852313
160.93841
21031.2
22.297683
-1.2E+07
Table 43
Composition of each streams for the process
Unit
Benzene_to_mixer
Propylene
Prop_to_mixer
To Heater
To_Alkylator
To_valve
Cumene_Bot
Benzene_Dist
To_pump
To_column1
To-Mixer
To_OxiTow_1
AIR
Comp
Mole
Frac
(Propene)
Comp
Mole
Frac
(Oxygen)
Comp
Mole
Frac (14iP-BZ)
Comp
Mole Frac
(Acetone)
Comp
Mole
Frac
(Phenol)
Comp
Mole
Frac
(Propane)
0
0.990453
0.990453
0.00574
0.00574
0.000017
0
0.000017
0.000027
0.000017
0.000027
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0.21
0
0
0
0
0
0.000001
0.000123
0
0
0.000001
0
0.000059
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0.048226
0
0
0.009547
0.009547
0.009155
0.009155
0.009208
0
0.009261
0.009261
0.009208
0.009261
0
0
61
To_tee
To_OT_1
VAP_1
To_OxiTow_2
To_OT_2
To_OT_3
VAP_2
To_OxiTow_3
VAP_3
To_OxiTow_4
To_OT_4
To_Cleaving
VAP_4
To_CleavageR
Decomposition
Effluent
Acetone Product
to next Column
Dist_Cumene
Phenol Product
TO_FLARE
Acetone to STORAGE
Phenol to STORAGE
To Mixer2
To Cooler_E-100
1
2
3
4
Benzene
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0.21
0.21
0
0
0.21
0.21
0
0
0.007414
0.000002
0.21
0.000013
0.050234
0.000013
0
0
0
0.00006
0
0
0
0.00006
0
0.00006
0
0.000061
0
0.000061
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0.000388
0.048379
0
0
0.000316
0.048563
0.000264
0.04872
0
0.048851
0.000232
0.048851
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0.000009
0.000029
0
0
0
0.014833
0.000029
0
0
0
0
0
0
0.000002
0
0.000041
0
0.000061
0
0.000129
0
0
0.000129
0
0.000059
0.000059
0.00006
0.00006
0.00006
0
0.319595
0.999369
0
0
0
0
0.999369
0
0
0
0
0
0
0
0
0.352834
0
0.518718
0.093203
0.99987
0.000299
0
0.99987
0.093121
0.048226
0.048226
0.048379
0.048563
0.04872
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
62
Comp
Mole
Frac
(Cumene)
Comp
Mole
Frac
(Benzene)
0
0
0
0.000114
1
0
0
0.984991
To_Alkylator
To_valve
Cumene_Bot
Benzene_Dist
To_pump
To_column1
To-Mixer
To_OxiTow_1
AIR
To_tee
To_OT_1
VAP_1
To_OxiTow_2
To_OT_2
To_OT_3
VAP_2
To_OxiTow_3
VAP_3
To_OxiTow_4
To_OT_4
To_Cleaving
VAP_4
To_CleavageR
Decomposition
Effluent
Acetone Product
to next Column
Dist_Cumene
Phenol Product
TO_FLARE
Acetone to
STORAGE
Phenol to STORAGE
To Mixer2
To Cooler_E-100
1
2
3
4
Benzene
0
0
0
0
0
0
0
0
0.79
0.79
0.79
0.983624
0.000726
0.79
0.79
0.98583
0.000524
0.98067
0.000378
0.79
0.000276
0.939774
0.000276
0
0
0
0
0
0
0
0.000046
0
0
0
0.000006
0.122446
0
0
0.000012
0.246525
0.000018
0.368381
0
0.46976
0.000024
0.46976
0.000114
0.005869
0.999867
0.000108
0.000116
0.005869
0.000116
0.951664
0
0
0
0.015981
0.828385
0
0
0.013841
0.704323
0.011632
0.582455
0
0.481035
0.009735
0.481035
0.984991
0.984906
0.00001
0.990614
0.990597
0.984906
0.990597
0.000005
0
0
0
0.000001
0.000004
0
0
0.000001
0.000004
0.000001
0.000004
0
0.000003
0.000001
0.000003
0.000188
0.000587
0
0
0
0.972092
0.000032
0
0.000047
0.000088
0
0.000015
0.327299
0.000008
0.481174
0.906708
0.000001
0.012759
0.000002
0.000007
0
0
0
0.000001
0.000587
0
0
0
0
0.000726
0.000524
0.000378
0
0
0
0.000088
0.000046
0.000046
0.122446
0.246525
0.368381
0
0.000008
0.000001
0.90679
0.951664
0.951664
0.828385
0.704323
0.582455
0
0.000007
0
0
0.000005
0.000005
0.000004
0.000004
0.000004
1
63
Table 44
Energy streams of the process
Unit
kJ/h
kJ/h
kJ/h
Q-pump102
65724.37458
Q-Pump101
Q-pump100
20646.39492
Q-Cooler100
Q-Heater100
210583600.9
Q-Comp100
Q-PFR-100
Q-Cond-100
Q-Reb-100
7608739.103
586285321.7
372840106.2
Q-OX-1
Q-OX-2
Q-OX-3
5909563.646
4423679.953
648168.1337
1896002.254
1902174.803
1857071.734
Q-OX-4
Q-Pump103
Q-PFR-101
Q-Cond-101
Q-Reb-101
Q-Cond-102
1543792.885
9137.795762
18555061.4
2696181.269
7912592.66
22440817.75
Q-Cooler102
611621.8101
Q-Cooler103
2839892.353
Q-100
Q-101
Q-102
1267.605212
38.009834
64.529379
Q-Reb-102
kJ/h
kJ/h
21216913.9
Q-103
89.612062
Using Aspen Hysys software, a heat and material balance were simulated
for the steam generation system and cooling water system of the plant. For the utilities of
the plant, Tables 45, 46, and 47 depicts the requirement of the plant.
64
Table 45
Cooling Water Requirement of the Plant
PROPERTIES
Vapour / Phase Fraction
Temperature [C]
Pressure [kPa]
Molar Flow [kgmole/h]
Mass Flow [kg/h]
Std Ideal Liq Vol Flow [m3/h]
Molar Enthalpy [kJ/kgmole]
Molar Entropy [kJ/kgmole-C]
Heat Flow [kJ/h]
Liq Vol Flow @Std Cond [m3/h]
Act. Volume Flow [m3/h]
Outlet
0
32.11818066
1101.325
312354.6137
5627099.751
5638.455471
-284460.2213
8.383744001
-88852462549
5633.061288
5653.898758
Table 46
Steam requirement of the plant
PROPERTIES
Vapour / Phase Fraction
Temperature [C]
Pressure [kPa]
Molar Flow [kgmole/h]
Mass Flow [kg/h]
Std Ideal Liq Vol Flow [m3/h]
Molar Enthalpy [kJ/kgmole]
Molar Entropy [kJ/kgmole-C]
Heat Flow [kJ/h]
Liq Vol Flow @Std Cond [m3/h]
Act. Volume Flow [m3/h]
Inlet to Boiler
0
244.9187093
4293.377832
20015.50196
360581.279
361.3089469
-267779.0355
49.47427638
-5359731810
360.9632909
446.7531747
Steam Generated
1
253.6877563
4231.325
20015.50196
360581.279
361.3089469
-236459.9051
108.9330054
-4732863696
360.9632909
16932.16337
Table 47
Fuel requirement of the plant
PROPERTIES
Vapour / Phase Fraction
Temperature [C]
Pressure [kPa]
Act. Volume Flow [m3/h]
Type of Fuel
Values
0
30
101.3
2.71
Industrial LPG
65
Information on the conditions, availability, and price of utility services such as fuel,
steam, cooling water, process air, process water, and electricity can be obtained from the
provincial government of Hermosa, Bataan. Utility equipment are built outside the process
area to supply the requirements of several processes of the plant.
66
This chapter includes the nature and methodology of the design process used in
generating specifications sheets for each equipment. The generated design concepts will
be further used in the detailed economic evaluation of the project. The economic evaluation
usually entails analyzing the capital and operating costs of the process to determine the
return of investment, which will be further elaborated in the next chapter.
Other equipment that already have sufficient data for economic performance
evaluation need no specifications to be generated. In general, ISBL equipment of the plant
were designed in this chapter and OSBL equipment were detailed for economic evaluation
purposes in the next chapter.
Calculation Sheets
To easily understand and check the design generated on this chapter, calculation
sheets are provided. All of the assumptions and approximations made were included in
these sheets.
Specification Sheets
The sheets consisted of the main specifications of the equipment as required in the
process of the manufacturing plant.
67
STORAGE TANK
SHEET 1 of 1
REV
DATE
BY APVD REV DATE BY APVD
1
01/11/15 EAM
ALL
MFS
2
01/22/15 EAM
Quantity
6
ITEM NUMBER
V-101
TYPE
Pressure vessel
SERVICE
Propylene
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
1200
Temperature (deg C)
25
DESIGN CONDITIONS
Pressure (kPa)
1372
Temperature (deg C)
93
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
15 ~ 20
METALLURGY
Material of Construction
Carbon steel
Joint Efficiency
0.85
Maximum Allowable Stress (Mpa)
88.94236908
Corrosion Allowance (mm)
3.8
SPECIFICATION FOR CONSTRUCTION
Geometry
Cylindrical
Position
Vertical
Support/Foundation
Concrete
Outage Allowance (mm)
500
Innage Allowance (mm)
500
Inside Diameter (m)
7.2
Outside Diameter (m)
7.34
Minimum Thickness (mm)
70
T/T Height (m)
21.6
Closure/Head
2:1 ellipsoidal
Minimum Thickness for Closure (mm)
66
SKETCH
7.34 m
500 mm
21.6 m
500 mm
68
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
ALL
STORAGE TANK
MFS
2
Quantity
6
ITEM NUMBER
V-102
TYPE
Atmospheric vessel
SERVICE
Benzene
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
100
Temperature (deg C)
25
DESIGN CONDITIONS
Pressure (kPa)
445.9678571
Temperature (deg C)
93.33333333
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
15 ~ 20
METALLURGY
Material of Construction
Carbon steel
Joint Efficiency
0.85
Maximum Allowable Stress (Mpa)
88.94236908
Corrosion Allowance (mm)
3.8
SPECIFICATION FOR CONSTRUCTION
Geometry
Cylindrical
Position
Vertical
Support/Foundation
Concrete
Outage Allowance (mm)
500
Innage Allowance (mm)
500
Inside Diameter (m)
7.4
Outside Diameter (m)
7.426
Minimum Thickness (m)
13
T/T Height (m)
22.2
Closure/Head
2:1 ellipsoidal
Minimum Thickness for Closure (mm)
22
01/22/15
EAM
SKETCH
7.426 m
500 mm
22.2 m
500 mm
69
APVD
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
ALL
STORAGE TANK
MFS
2
Quantity
3
ITEM NUMBER
V-103
TYPE
Pressure vessel
SERVICE
Acetone
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
365.9
Temperature (deg C)
30
DESIGN CONDITIONS
Pressure (kPa)
538
Temperature (deg C)
93
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
15 ~ 20
METALLURGY
Material of Construction
Carbon steel
Joint Efficiency
0.85
Maximum Allowable Stress (Mpa)
88.94236908
Corrosion Allowance (mm)
3.8
SPECIFICATION FOR CONSTRUCTION
Geometry
Cylindrical
Position
Vertical
Support/Foundation
Concrete
Outage Allowance (mm)
500
Innage Allowance (mm)
500
Inside Diameter (m)
5.4
Outside Diameter (m)
5.448
Minimum Thickness (m)
24
T/T Height (m)
16.2
Closure/Head
2:1 ellipsoidal
Minimum Thickness for Closure (mm)
20
01/22/15
EAM
SKETCH
5.448 m
500 mm
16.2 m
500 mm
70
APVD
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
ALL
STORAGE TANK
MFS
2
Quantity
3
ITEM NUMBER
V-103a
TYPE
Pressure vessel
SERVICE
Acetone
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
365.9
Temperature (deg C)
30
DESIGN CONDITIONS
Pressure (kPa)
538
Temperature (deg C)
93
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
15 ~ 20
METALLURGY
Material of Construction
Carbon steel
Joint Efficiency
0.85
Maximum Allowable Stress (Mpa)
88.94236908
Corrosion Allowance (mm)
3.8
SPECIFICATION FOR CONSTRUCTION
Geometry
Cylindrical
Position
Vertical
Support/Foundation
Concrete
Outage Allowance (mm)
500
Innage Allowance (mm)
500
Inside Diameter (m)
2.9
Outside Diameter (m)
2.93
Minimum Thickness (mm)
15
T/T Height (m)
8.7
Closure/Head
2:1 ellipsoidal
Minimum Thickness for Closure (mm)
11
01/22/15
EAM
SKETCH
2.93 m
500 mm
8.7 m
500 mm
71
APVD
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
ALL
STORAGE TANK
MFS
Quantity
3
ITEM NUMBER
V-104
TYPE
Atmospheric vessel
SERVICE
Phenol
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
375.9
Temperature (deg C)
54.44
DESIGN CONDITIONS
Pressure (kPa)
548.2214286
Temperature (deg C)
93.33333333
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
15 ~ 20
METALLURGY
Material of Construction
Carbon steel
Joint Efficiency
0.85
Maximum Allowable Stress (Mpa)
88.94236908
Corrosion Allowance (mm)
3.8
SPECIFICATION FOR CONSTRUCTION
Geometry
Cylindrical
Position
Vertical
Support/Foundation
Concrete
Outage Allowance (mm)
500
Innage Allowance (mm)
500
Inside Diameter (m)
5.8
Outside Diameter (m)
5.822
Minimum Thickness (m)
11
T/T Height (m)
17.4
Closure/Head
2:1 ellipsoidal
Minimum Thickness for Closure (mm)
22
SKETCH
5.822 m
500 mm
17.4 m
500 mm
72
APVD
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
ALL
STORAGE TANK
MFS
Quantity
3
ITEM NUMBER
V-104
TYPE
Atmospheric vessel
SERVICE
Phenol
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
375.9
Temperature (deg C)
54.44
DESIGN CONDITIONS
Pressure (kPa)
548.2214286
Temperature (deg C)
93.33333333
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
15 ~ 20
METALLURGY
Material of Construction
Carbon steel
Joint Efficiency
0.85
Maximum Allowable Stress (Mpa)
88.94236908
Corrosion Allowance (mm)
3.8
SPECIFICATION FOR CONSTRUCTION
Geometry
Cylindrical
Position
Vertical
Support/Foundation
Concrete
Outage Allowance (mm)
500
Innage Allowance (mm)
500
Inside Diameter (m)
3.1
Outside Diameter (m)
3.112
Minimum Thickness (m)
6
T/T Height (m)
9.3
Closure/Head
2:1 ellipsoidal
Minimum Thickness for Closure (mm)
12
SKETCH
3.112 m
500 mm
9.3 m
500 mm
73
APVD
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
ALL
STORAGE TANK
MFS
2
Quantity
1
ITEM NUMBER
V-105
TYPE
Atmospheric vessel
SERVICE
Benzene Recycle Stream
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
100
Temperature (deg C)
70.05
DESIGN CONDITIONS
Pressure (kPa)
445.9678571
Temperature (deg C)
93.33333333
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
15 ~ 20
METALLURGY
Material of Construction
Carbon steel
Joint Efficiency
0.85
Maximum Allowable Stress (Mpa)
88.94236908
Corrosion Allowance (mm)
3.8
SPECIFICATION FOR CONSTRUCTION
Geometry
Cylindrical
Position
Vertical
Support/Foundation
Concrete
Outage Allowance (mm)
500
Innage Allowance (mm)
500
Inside Diameter (m)
5.5
Outside Diameter (m)
5.518
Minimum Thickness (m)
9
T/T Height (m)
16.5
Closure/Head
2:1 ellipsoidal
Minimum Thickness for Closure (mm)
17
01/22/15
EAM
SKETCH
5.518 m
500 mm
16.5 m
500 mm
74
APVD
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
APVD
ALL
STORAGE TANK
ITEM NUMBER
V-106
TYPE
Atmospheric vessel
SERVICE
Condensate from T-100
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
100
Temperature (deg C)
70.05
DESIGN CONDITIONS
Pressure (kPa)
446
Temperature (deg C)
93
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
15 ~ 20
METALLURGY
Material of Construction
Carbon steel
Joint Efficiency
0.85
Maximum Allowable Stress (Mpa)
88.94236908
Corrosion Allowance (mm)
3.8
SPECIFICATION FOR CONSTRUCTION
Geometry
Cylindrical
Position
Horizontal
Support/Foundation
Saddle
Inside Diameter (m)
5.2
Outside Diameter (m)
5.208
Minimum Thickness (mm)
4
Height of Liquid (m)
2.6
Length (m)
15.6
Closure/Head
2:1 ellipsoidal
Minimum Thickness for Closure (mm)
16
MFS
SKETCH
15.6 m
5.2 m
1.3 m
2.6 m
75
5.208 m
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
APVD
ALL
STORAGE TANK
ITEM NUMBER
V-107
TYPE
Pressure vessel
SERVICE
Condensate from D-102
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
370
Temperature (deg C)
91.98
DESIGN CONDITIONS
Pressure (kPa)
542
Temperature (deg C)
93
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
15 ~ 20
METALLURGY
Material of Construction
Carbon steel
Joint Efficiency
0.85
Maximum Allowable Stress (Mpa)
88.94236908
Corrosion Allowance (mm)
3.8
SPECIFICATION FOR CONSTRUCTION
Geometry
Cylindrical
Position
Horizontal
Support/Foundation
Saddle
Inside Diameter (m)
0.9
Outside Diameter (m)
0.908
Minimum Thickness (mm)
4
Height of Liquid (m)
0.45
Length (m)
2.7
Closure/Head
2:1 ellipsoidal
Minimum Thickness for Closure (mm)
4
MFS
SKETCH
2.7 m
0.9 m
0.225 m
0.45 m
76
0.908 m
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
APVD
ALL
STORAGE TANK
ITEM NUMBER
V-108
TYPE
Atmospheric vessel
SERVICE
Condensate from D-103
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
101.3
Temperature (deg C)
151.9
DESIGN CONDITIONS
Pressure (kPa)
445.9678571
Temperature (deg C)
179.6777778
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
15 ~ 20
METALLURGY
Material of Construction
Carbon steel
Joint Efficiency
0.85
Maximum Allowable Stress (Mpa)
88.94236908
Corrosion Allowance (mm)
3.8
SPECIFICATION FOR CONSTRUCTION
Geometry
Cylindrical
Position
Horizontal
Support/Foundation
Saddle
Inside Diameter (m)
2
Outside Diameter (m)
2.008
Minimum Thickness (mm)
4
Height of Liquid (m)
1
Length (m)
6
Closure/Head
2:1 ellipsoidal
Minimum Thickness for Closure (mm)
6
MFS
SKETCH
6m
2m
0.5 m
1m
77
2.008 m
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
ALL
STORAGE TANK
MFS
2
Quantity
1
ITEM NUMBER
V-109
TYPE
Atmospheric vessel
SERVICE
Cumene Recycle Stream
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
101.3
Temperature (deg C)
151.9
DESIGN CONDITIONS
Pressure (kPa)
445.9678571
Temperature (deg C)
179.6777778
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
15 ~ 20
METALLURGY
Material of Construction
Carbon steel
Joint Efficiency
0.85
Maximum Allowable Stress (Mpa)
88.94236908
Corrosion Allowance (mm)
3.8
SPECIFICATION FOR CONSTRUCTION
Geometry
Cylindrical
Position
Vertical
Support/Foundation
Concrete
Outage Allowance (mm)
500
Innage Allowance (mm)
500
Inside Diameter (m)
2.1
Outside Diameter (m)
2.11
Minimum Thickness (m)
5
T/T Height (m)
6.3
Closure/Head
2:1 ellipsoidal
Minimum Thickness for Closure (mm)
7
01/22/15
EAM
SKETCH
2.11 m
500 mm
6.3 m
500 mm
78
APVD
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
ALL
STORAGE TANK
MFS
2
Quantity
1
ITEM NUMBER
V-105
TYPE
Atmospheric vessel
SERVICE
WATER
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
100
Temperature (deg C)
30
DESIGN CONDITIONS
Pressure (kPa)
445.9678571
Temperature (deg C)
93.33333333
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
15 ~ 20
METALLURGY
Material of Construction
Carbon steel
Joint Efficiency
0.85
Maximum Allowable Stress (Mpa)
88.94236908
Corrosion Allowance (mm)
3.8
SPECIFICATION FOR CONSTRUCTION
Geometry
Cylindrical
Position
Vertical
Support/Foundation
Concrete
Outage Allowance (mm)
500
Innage Allowance (mm)
500
Inside Diameter (m)
4.3
Outside Diameter (m)
4.316
Minimum Thickness (m)
8
T/T Height (m)
12.9
Closure/Head
2:1 ellipsoidal
Minimum Thickness for Closure (mm)
13
01/22/15
EAM
SKETCH
4.316 m
500 mm
12.9 m
500 mm
79
APVD
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
ALL
STORAGE TANK
MFS
2
Quantity
4
ITEM NUMBER
V-111
TYPE
Pressure vessel
SERVICE
LPG (Propane)
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
1080
Temperature (deg C)
30
DESIGN CONDITIONS
Pressure (kPa)
1252
Temperature (deg C)
93
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
15 ~ 20
METALLURGY
Material of Construction
Carbon steel
Joint Efficiency
0.85
Maximum Allowable Stress (Mpa)
88.94236908
Corrosion Allowance (mm)
3.8
SPECIFICATION FOR CONSTRUCTION
Geometry
Cylindrical
Position
Vertical
Support/Foundation
Concrete
Outage Allowance (mm)
500
Innage Allowance (mm)
500
Inside Diameter (m)
7.2
Outside Diameter (m)
7.33
Minimum Thickness (mm)
65
T/T Height (m)
21.6
Closure/Head
2:1 ellipsoidal
Minimum Thickness for Closure (mm)
60
01/22/15
EAM
SKETCH
7.33 m
500 mm
21.6 m
500 mm
80
APVD
DATE
BY
01/11/15
EAM
APVD
REV
ALL
REACTOR
MFS
ITEM NUMBER
R-101
TYPE
Plug Flow Reactor (Packed Bed)
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
3478
Temperature (deg C)
170
DESIGN CONDITIONS
Pressure (kPa)
3816
Temperature (deg C)
198
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
-14.7
SPECIFICATION OF REACTOR VESSEL
Reactor Volume (m3)
113.3
Reactor Length (m)
10
Tube Diameter (m)
0.1201
CATALYST BED CHARACTERISTIC
Void Fraction
0.7
Void Volume (m3)
79.3
Volume of Catalyst Bed (m3)
34
Particle Diameter (m)
0.003
Catalyst Name
Sulfonic Resin
Mass of Catalyst (kg)
7140
SHELL AND TUBING LAYOUT
Square Pitch Size (mm)
100
Baffle Spacing (m)
0.781764019
Material
Carbon Steel
Tube Number
1000
TUBE I.D. (in)
4.813
TUBE O.D. (in)
5.563
Nominal Pipe Size (in)
5
Schedule No.
80XS, 80S
Wall Thickness (in)
0.375
Cross Sectional Area (in2)
6.11
HEAT EXCHANGER SPECIFICATION
Heat transfer coefficient (W/m2K)
636025.5
Shell Diameter (m)
3.9
Cross Sectional Area of Shell Side (m2)
0.3
Heat Evolved in the reaction (kW)
2114.0
Delta T (Degrees Celcius)
27.3
Water circulation rate (kg/h)
66676.3
81
Sketch
DATE
BY
APVD
DATE
BY
01/11/15
EAM
APVD
REV
ALL
REACTOR
MFS
ITEM NUMBER
R-106
TYPE
Plug Flow Reactor
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
400
Temperature (deg C)
80
DESIGN CONDITIONS
Pressure (kPa)
572.3214286
Temperature (deg C)
93.33333333
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
-14.7
SPECIFICATION OF REACTOR VESSEL
Reactor Volume (m3)
25.02
Reactor Length (m)
10
Tube Diameter (m)
0.1785
CATALYST BED CHARACTERISTIC
Void Fraction
0.7
Void Volume (m3)
17.51
Volume of Catalyst Bed (m3)
7.51
Particle Diameter (m)
0.00002
Catalyst Name
Zeolite
Mass of Catalyst (g)
2.65854
SHELL AND TUBING LAYOUT
Square Pitch Size (mm)
100
Baffle Spacing (m)
0.247215489
Material
Carbon Steel
Tube Number
100
TUBE I.D. (in)
7.187
TUBE O.D. (in)
8.625
Nominal Pipe Size (in)
8
Schedule No.
120
Wall Thickness (in)
0.719
Cross Sectional Area (in2)
17.86
HEAT EXCHANGER SPECIFICATION
Heat transfer coefficient (W/m2K)
6172.20338
Shell Diameter (m)
1.236077446
Cross Sectional Area of Shell Side (m2)
0.030557749
Heat Evolved in the reaction (kW)
5154
Delta T (Degrees Celcius)
27.28
Water circulation rate (kg/h)
162558.9454
Sketch
82
DATE
BY
APVD
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
ALL
REACTOR
MFS
ITEM NUMBER
R-102
TYPE
Oxidation Tower
VESSEL TYPE
Atmospheric Vessel
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
100
Temperature (deg C)
44.85
DESIGN CONDITIONS
Pressure (kPa)
446
Temperature (deg C)
93
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
15 ~ 20
METALLURGY
Material of Construction
Carbon steel
Joint Efficiency
0.85
Maximum Allowable Stress (Mpa)
88.942
Corrosion Allowance (mm)
3.8
SPECIFICATION FOR CONSTRUCTION
Geometry
Cylindrical
Position
Vertical
Support/Foundation
Concrete
Outage Allowance (mm)
500
Innage Allowance (mm)
500
Inside Diameter (m)
4
Outside Diameter (m)
4.014
Minimum Thickness (mm)
7
T/T Height (m)
12
Height of fluid (m)
9
Closure/Head
2:1 ellipsoidal
Minimum Thickness for Closure (mm)
12
CATALYST SPECIFICATIONS
Name
CuO Nanoparticle
Density (kg/m3)
790
Diameter (m)
1.40E-07
Amount (Kg)
198.55
REACTOR MAIN SPECIFICATIONS
Void Fraction of Bed
0.8
Bed Height (m)
0.1
Bed Volume (m3)
1.26
Bubble Size (cm)
2.44E-05
Type of Plate
Porous
SKETCH
COOLING SYSTEM
Type
Duty (kW)
Cooling water (kg/h)
83
Cooling Coil
526.7
16350
APVD
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
ALL
REACTOR
MFS
ITEM NUMBER
R-103
TYPE
Oxidation Tower
VESSEL TYPE
Atmospheric Vessel
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
99
Temperature (deg C)
45
DESIGN CONDITIONS
Pressure (kPa)
445.97
Temperature (deg C)
93.33
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
15 ~ 20
METALLURGY
Material of Construction
Carbon steel
Joint Efficiency
0.85
Maximum Allowable Stress (Mpa)
88.94
Corrosion Allowance (mm)
3.8
SPECIFICATION FOR CONSTRUCTION
Geometry
Cylindrical
Position
Vertical
Support/Foundation
Concrete
Outage Allowance (mm)
500
Innage Allowance (mm)
500
Inside Diameter (m)
4
Outside Diameter (m)
4.014
Minimum Thickness (mm)
7
T/T Height (m)
12
Height of fluid (m)
8
Closure/Head
2:1 ellipsoidal
Minimum Thickness for Closure (mm)
12
CATALYST SPECIFICATIONS
Name
CuO Nanoparticle
Density (kg/m3)
790
Diameter (m)
1.40E-07
Amount (Kg)
198.55
REACTOR MAIN SPECIFICATIONS
Void Fraction of Bed
0.8
Bed Height (m)
0.1
Bed Volume (m3)
1.26
Bubble Size (cm)
2.42E-05
Type of Plate
Porous
SKETCH
COOLING SYSTEM
Type
Duty (kW)
Cooling water (kg/h)
84
Cooling Coil
528.4
16400
APVD
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
ALL
REACTOR
MFS
ITEM NUMBER
R-104
TYPE
Oxidation Tower
VESSEL TYPE
Atmospheric Vessel
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
98
Temperature (deg C)
45
DESIGN CONDITIONS
Pressure (kPa)
445.9678571
Temperature (deg C)
93.33333333
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
15 ~ 20
METALLURGY
Material of Construction
Carbon steel
Joint Efficiency
0.85
Maximum Allowable Stress (Mpa)
88.94
Corrosion Allowance (mm)
3.8
SPECIFICATION FOR CONSTRUCTION
Geometry
Cylindrical
Position
Vertical
Support/Foundation
Concrete
Outage Allowance (mm)
500
Innage Allowance (mm)
500
Inside Diameter (m)
4
Outside Diameter (m)
4.014
Minimum Thickness (mm)
7
T/T Height (m)
12
Height of fluid (m)
7
Closure/Head
2:1 ellipsoidal
Minimum Thickness for Closure (mm)
12
CATALYST SPECIFICATIONS
Name
CuO Nanoparticle
Density (kg/m3)
790
Diameter (m)
1.40E-07
Amount (Kg)
198.55
REACTOR MAIN SPECIFICATIONS
Void Fraction of Bed
0.8
Bed Height (m)
0.1
Bed Volume (m3)
1.26
Bubble Size (cm)
2.30E-05
Type of Plate
Porous
SKETCH
COOLING SYSTEM
Type
Duty (kW)
Cooling water (kg/h)
85
Cooling Coil
515.9
16011.28
APVD
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
ALL
REACTOR
MFS
ITEM NUMBER
R-105
TYPE
Oxidation Tower
VESSEL TYPE
Atmospheric Vessel
MEASUREMENT SYSTEM
Metric System
OPERATING CONDITIONS
Pressure (kPa)
97.2
Temperature (deg C)
44.85
DESIGN CONDITIONS
Pressure (kPa)
445.9678571
Temperature (deg C)
93.33333333
Minimum Pressure (kPa)
0
Minimum Metal Temperature (deg C)
15 ~ 20
METALLURGY
Material of Construction
Carbon steel
Joint Efficiency
0.85
Maximum Allowable Stress (Mpa)
88.94236908
Corrosion Allowance (mm)
3.8
SPECIFICATION FOR CONSTRUCTION
Geometry
Cylindrical
Position
Vertical
Support/Foundation
Concrete
Outage Allowance (mm)
500
Innage Allowance (mm)
500
Inside Diameter (m)
4
Outside Diameter (m)
4.014
Minimum Thickness (mm)
7
T/T Height (m)
12
Height of fluid (m)
7
Closure/Head
2:1 ellipsoidal
Minimum Thickness for Closure (mm)
12
CATALYST SPECIFICATIONS
Name
CuO Nanoparticle
Density (kg/m3)
790
Diameter (m)
1.40E-07
Amount (Kg)
198.5486557
REACTOR MAIN SPECIFICATIONS
Void Fraction of Bed
0.8
Bed Height (m)
0.1
Bed Volume (m3)
1.256637061
Bubble Size (cm)
2.27E-05
Type of Plate
Porous
SKETCH
COOLING SYSTEM
Type
Duty (kW)
Cooling water (kg/h)
86
Cooling Coil
428.8
13310.26
APVD
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
ALL
DISTILLATION COLUMN
MFS
2
ITEM NUMBER
D-101
TYPE
Pressure Vessel
MEASUREMENT SYSTEM
Metric System
SECTION
Rectifying
Stripping
OPERATING CONDITIONS
Pressure (kPa)
106
109.7
Temperature (deg C)
80.17
155.4
DESIGN CONDITIONS
Pressure (kPa)
446
446
Temperature (deg C)
121
183
Minimum Pressure (kPa)
0
0
Minimum Metal Temperature (deg C)
15 to 20
15 to 20
MAIN SPECIFICATIONS
No. of Trays
11
16
Internal Diameter (m)
12
10
Height (m)
9.9
14.4
Tray Spacing (m)
0.9
0.9
Tray Type
Sieve
Construction type
Cartridge-type
Packing type
Structured
Feed tray number
11
Side Stream Plate #
N/A
SPECIFICATION FOR CONSTRUCTION
Material
Carbon Steel
Support/Foundation
Concrete
Orientation
Vertical
Minimum Thickness (mm)
36
30
Outside Diameter (mm)
12.1
10.1
Type of Closure
2:1 Ellipsoidal
Minimum Thickness for Closure (mm)
36
30
Total Height of the Column (m)
31.80
01/21/15
EAM
SKETCH
12.1 m
13 m
31.8 m
18.8 m
10.1 m
87
APVD
50 mm
30 mm
25 mm
12 m
10.08 m
50 mm
50 mm
40 mm
35 mm
10 m
7.6 m
50 mm
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
ALL
DISTILLATION COLUMN
MFS
ITEM NUMBER
D-102
TYPE
Pressure Vessel
MEASUREMENT SYSTEM
Metric System
SECTION
Rectifying
Stripping
OPERATING CONDITIONS
Pressure (kPa)
376.2
379.7
Temperature (deg C)
127.4
211.4
DESIGN CONDITIONS
Pressure (kPa)
549
552
Temperature (deg C)
155
239
Minimum Pressure (kPa)
0
0
Minimum Metal Temperature (deg C)
15 to 20
15 to 20
MAIN SPECIFICATIONS
No. of Trays
10
12
Internal Diameter (m)
0.7
1.4
Height (m)
6.6
9.6
Tray Spacing (m)
0.6
0.6
Tray Type
Sieve
Construction type
Cartridge-type
Packing type
Structured
Feed tray number
10
Side Stream Plate #
N/A
SPECIFICATION FOR CONSTRUCTION
Material
Carbon Steel
Support/Foundation
Concrete
Orientation
Vertical
Minimum Thickness (mm)
3
6
Outside Diameter (m)
0.8
1.5
Type of Closure
2:1 Ellipsoidal
Minimum Thickness for Closure (mm)
3
6
Total Height of the Column (m)
21.20
SKETCH
0.7 m
8.70 m
21.20 m
12.60 m
1.4 m
88
APVD
50 mm
50 mm
40 mm
0.7 m
0.5915 m
50 mm
50 mm
50 mm
40 mm
1.4 m
1.204 m
50 mm
89
DATE
BY
01/11/15
EAM
APVD
REV
DATE
BY
ALL
DISTILLATION COLUMN
MFS
SKETCH
2.9 m
6.5 m
ITEM NUMBER
D-103
TYPE
Pressure Vessel
MEASUREMENT SYSTEM
Metric System
SECTION
Rectifying
Stripping
OPERATING CONDITIONS
Pressure (kPa)
105.5
369.7
Temperature (deg C)
153.4
235.5
DESIGN CONDITIONS
Pressure (kPa)
446
542
Temperature (deg C)
181
263
Minimum Pressure (kPa)
0
0
Minimum Metal Temperature (deg C)
15 to 20
15 to 20
MAIN SPECIFICATIONS
No. of Trays
21
34
Internal Diameter (m)
2.9
1.8
Height (m)
4.95
9.6
Tray Spacing (m)
0.45
0.6
Tray Type
Sieve
Construction type
Cartridge-type
Packing type
Structured
Feed tray number
21
Side Stream Plate #
N/A
SPECIFICATION FOR CONSTRUCTION
Material
Carbon Steel
Support/Foundation
Concrete
Orientation
Vertical
Minimum Thickness (mm)
9
7
Outside Diameter (mm)
3
1.9
Type of Closure
2:1 Ellipsoidal
Minimum Thickness for Closure (mm)
9
7
Total Height of the Column (m)
19.00
PLATE LAYOUT FOR RECTIFYING SECTION
19 m
12.5 m
50 mm
33 mm
25 mm
2.9 m
2.4505
50 mm
50 mm
38 mm
30 mm
1.8 m
1.53 m
50 mm
90
1.8 m
APVD
Tube Layout
Drawing or diagrams
Cost Estimate
91
92
93
94
95
96
97
HE-105: Cooler 1
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
P-102
P-103
134
P-104
P-105
135
P-106
P-107
136
P-108
P-109
137
P-110
138
139
Economic Analysis
Before the initiation of the development of the process, at various stages in its
development, process engineers must make economic evaluation. The discussion in this
chapter determines whether the project should be undertaken or abandoned. The objective
for this analysis is to have a class 4 to 3 estimate of the capital requirement as well as the
production cost of the plant. The overall economic analysis of the plant will depend on the
capital requirement and production cost of the product.
140
Table 48
Fixed capital investment of the plant
ISBL CAPEX
Estimating the ISBL and OSBL capital costs. The ISBL plant cost includes the
cost of procuring and installing all the process equipment that makes up the new plant.
Included in the previous chapter are the design and specifications of the major process
equipment of the plant. Table 49 consists of the correlations to be used in estimating the
cost of the equipment of the plant.
141
Table 49
Purchase Equipment Cost for Common Plant Equipment
Unit for
EQUIPMENT
Size, S
Tanks
Cone Roof
10
4000
, 3
Pressure Vessels
shell mass,
vertical, cs
150
69200
kg
shell mass,
Horizontal, cs
250
69200
kg
Distillation Columns
Trays
Sieve trays
diameter, m
0.5
5
Reactors
Jacketed, agitated
0.5
100
, 3
jacketed, agitated, glass0.5
25
, 3
lined
Heat Exchanger
U-tube shell and tube
10
1000
, 2
Compressor
driver power,
Centrifugal
132
29000
kW
Pumps
flow Liters/s
Single-stage centrifugal
0.2
500
(L/s)
Utilities
Cooling Tower
flow Liters/s
100
10000
Boiler
kg/h steam
20000
800000
30
200
Furnace
duty, MW
Source: Towler and Sinnott, 2008
5700
700
0.7
-400
230
0.6
-2500
200
0.6
100
120
14000
15400
0.7
13000
34000
0.5
10000
88
8400
3100
0.6
3300
48
1.2
61000
90000
7000
650
0.9
93
0.8
71000
0.8
Equation 8 was used to obtain the purchase cost of the equipment. Given the
parameters, if the value of S is not within the range or limit given in the table, the actual
cost of the equipment can be derived from the computed cost using equation 9.
= +
=
=
=
142
(8)
=
,
,
= , (
)
,
(9)
For the cost of pipes, equation 10 may apply. The cost should already include the
cost for fittings, paint, installation, and insulation. The basis for the correlation is January
2006.
($) = ( , ).
(10)
For pressure vessels, shell mass is needed in estimating the purchase cost based on
Table 49. Equation 11 should be used in obtaining the shell mass of a pressure vessel.
Density of carbon steel is 7900 3 .
=
(11)
= ,
= ,
= ,
= , 3
The basis of this cost estimation is on the year 2006. Note that the prices of the
materials of construction and the costs of labor are subject to inflation. Through the use of
published cost indices, the cost of the equipment can be obtained at any latest year. The
following equations can be applied to consider the inflation of the cost.
=
(12)
2006 = 499.6 ( )
2015 = 609.065 ( )
= .
143
(13)
Most plant and equipment cost data used which came from Towler were based on
the location U.S. Golf Coast (USGC), as it was historically the main center of the chemical
industry, for which most data were available. The differences in cost between locations can
be estimated using the following equation.
=
(14)
=
= 1.12
In costing, it is also very important to consider the installation cost of the
equipment. Table 50 consists of the detailed typical factors for estimation of fixed capital
costs. These can be used to make an approximate estimate of capital cost using equipment
cost data published in the literature.
Table 50
Typical Installation Factor for Project Fixed Capital Cost
fer
fp
fi
fel
fc
fs
fl
fm
Source: Towler and Sinnott, 2008
144
0.3
0.8
0.3
0.2
0.3
0.2
0.1
1.3
Equation 15 is used to determine the final cost of the equipment including the
installation cost.
=
= ,, [( + ) +
=
+ + + + +
]
(15)
= ,
=
=
=
=
=
=
=
= , ,
=
Other cost factor that needs to be considered was the freight rate/cost. It is the cost
incurred in moving the goods from USGC to Philippines through marine transportation.
This includes packing, palletizing, documentation, loading, unloading charges, carriage
costs, and marine insurance costs. For freight rate estimates, worldfreightrates.com offers
a reliable calculator to get it. Origin port should be a USGC port such as New Orleans and
the Destination port should be Subic Bay, Philippines.
For imported goods, the Bureau of Customs imposes duties and taxes for
importation. The duties and taxes includes the Value Added Tax (VAT), Import Processing
Fee (IPF), and Customs Documentary Stamp imposed by the agency. The agency have
their own useful and reliable calculator (Customs PH, 2015).
Contingency and commissioning cost. The typical percentage of, or the norm
for commissioning services for, a chemical plant process was estimated at 3.5% of the total
145
capital investment (Killcross, 2012). For the contingency cost, typically the factor was 10%
of the total capital investment (Towler & Sinnott, 2008).
146
Table 51
Calculation Procedure for Production Cost
DIRECT COST
RAW MATERIALS
CATALYSTS
UTILITIES:
ELECTRICITY
FUEL
WATER
COMMUNICATION
BIOLOGICAL WWTP [2]
$0.20
OPERATING LABOR
+ +
TRANSPORTATION COST
0.20
0.20
0.027
0.018
0.0075
INDIRECT COST
FIXED CAPITAL COST:
DEPRECIATION [2]
LAND COST
0.01
GENERAL COST
ADMINISTRATIVE [1]
0.045
MARKETING [1]
0.135
0.0575
147
Operational time of the plant was estimated to be 350 days per year. The total days
per year is 365 days, so there will be a 15 days no work day for employees. These 15 days
will be allotted to the maintenance of the plant.
Continuous processes were designed to operate 24 hours a day, 7 days a week,
throughout the year. Some downtime will be allowed for maintenance and, for some
processes, catalyst regeneration. Continuous processes will usually be more economical
for large-scale production. The plant attainment or operating rate is the percentage of the
available hours in a year that the plant operates, and is usually between 90 and 95% (Towler
& Sinnott, 2008).
148
Capacity (m3)
882.6555446
414.832
59.2617
354.32645
159.5609
8.221475
18.13027
161.0571
$
$
$
$
$
$
$
$
Cost
86,451.75
53,300.18
17,891.02
48,326.59
30,086.34
8,758.88
11,020.85
30,246.18
Quantity
6
3
3
1
1
1
1
1
$
$
$
$
$
$
$
$
Final
518,710.47
159,900.55
53,673.05
48,326.59
30,086.34
8,758.88
11,020.85
30,246.18
Table 53
Final Cost of Atmosphere Vessel
Cost (2006)
Cost (2015)
Cost (2015 @ SE Asia)
$
$
$
860,722.91
1,049,221.22
1,175,127.77
3,760,408.86
$
Freight Cost
TOTAL COST
169,218,398.55
2,991.65
134,624.25
149
4,462,850.14
51,643.37
265.00
173,867,781.32
(m)
()
V-101
V-103
V-104
V-109
V-113
7.2
5.4
2.9
0.9
7.2
21.6
16.2
8.7
2.7
21.6
(m)
( 3 )
7900
7900
7900
7900
7900
181409.9357
52107.1092
9392.592344
241.2366167
73335.93147
0.047
0.024
0.015
0.004
0.019
Table 55
Purchase Cost of Pressure Vessels
Number
V-101
V-103
V-104
V-109
V-113
$
$
$
$
$
COST
184,012.98
155,148.57
55,241.54
5,782.92
190,549.24
ADJUSTED COST
$
328,081.28
-
Quantity
6
3
3
1
4
FINAL
$ 1,968,487.68
$ 465,445.71
$ 165,724.61
$
5,782.92
$ 762,196.94
Table 56
Final Cost of Pressure Vessels
Cost (2006)
3,367,637.87
Cost (2015)
Cost (2015 @ SE Asia)
$
$
4,105,150.56
4,597,768.63
14,712,859.60
$
Freight Cost
TOTAL COST
150
662,078,682.01
2,991.65
134,624.25
12,401,086.40
156,326.46
265.00
674,770,984.12
Dc (m)
12
# of trays
11
Adjusted
$ 17,856.00
FINAL COST
$
196,416.00
D-101-B
10
16
3,100.00
198,400.00
D-102-T
D-102-B
0.7
1.4
10
12
$
$
158.80
335.20
$
$
1,588.00
4,022.40
D-103-T
D-103-B
2.9
1.8
21
34
$
$
1,109.20
488.80
$
$
23,293.20
16,619.20
12,400.00
Table 58
Shell mass of Distillation Columns
Number
(m)
()
(m)
( 3 )
SHELL MASS
(kg)
D-101
Top
Bot
12
10
9.9
14.4
0.036
0.03
7900
7900
106144.1113
107216.2741
D-102
Top
Bot
0.7
1.4
6.6
9.6
0.003
0.006
7900
7900
343.985546
2001.37045
D-103
Top
Bot
2.9
1.8
4.95
9.6
0.009
0.007
7900
7900
3206.436697
3002.055674
151
Table 59
Purchase Cost of Pressure Vessels for Distillation Columns
Need
Adjustment?
COST
ADJUSTED
COST
Quantity
FINAL
D-101
Top
Bot
Yes
Yes
$ 184,012.98
$ 184,012.98
$ 237,860.51
$ 239,299.19
1
1
$ 237,860.51
$ 239,299.19
D-102
Top
Bot
No
No
$ 7,249.83
$ 21,605.15
1
1
$ 7,249.83
$ 21,605.15
D-103
Top
Bot
No
No
$ 28,797.22
$ 27,665.91
1
1
$ 28,797.22
$ 27,665.91
Number
Table 60
Final Cost of Distillation Columns
Cost (2006)
Cost (2015)
Cost (2015 @ SE Asia)
$
$
$
1,002,816.61
1,222,433.45
1,369,125.46
4,381,201.49
$
Freight Cost
TOTAL COST
152
197,154,066.89
2,991.65
134,624.25
5,339,213.90
60,169.00
265.00
202,688,339.04
Cost of Reactors:
Table 61
Purchase Cost of Fluidized Bed Reactors
NUMBER
Volume (m3)
Need Adjustment
R-102
R-103
R-104
R-105
101.112
98.17203297
86.6518991
84.21924804
Yes
No
No
No
Cost
$
$
$
$
Adjusted Cost
400,830.51
395,867.04
363,917.27
357,011.49
$
$
$
$
403,945.40
395,867.04
363,917.27
357,011.49
Table 62
Purchase Cost of Packed Bed Reactors
NUMBER
Volume (m3)
Need Adjustment
Cost
Adjusted Cost
R-101
R-106
113.3
25.02
Yes
No
$ 400,830.51
$ 160,663.43
$ 437,443.24
$ 160,663.43
Table 63
Final Cost of Reactors
Cost (2006)
Cost (2015)
Cost (2015 @ SE Asia)
Cost of Equipment (w/ Location and Installation factor
consideration)
Freight Cost
$
$
$
$
2,118,847.87
2,582,875.55
2,892,820.61
9,257,025.97
416,566,168.43
2,991.65
134,624.25
11,263,464.96
Import Processing Fee
127,130.87
Customs Documentary Stamp
265.00
TOTAL COST
428,091,653.51
153
Cost
$
$
$
$
$
$
$
$
$
$
56,088.00
214,234.00
260,661.00
16,750.00
10,626.00
14,577.00
401,970.00
38,004.00
58,110.00
15,415.00
Table 65
Final Cost of Heat Exchangers
Equipment Cost
$
1,216,807.20
$
1,362,824.06
Cost (2015 @ SE Asia)
61,327,082.88
$
3,257.58
Freight Cost
146,591.10
Bureau of Customs: Duties and Taxes
Value Added Tax (VAT)
5,784,498.72
Import Processing Fee
65,186.10
Customs Documentary Stamp
265.00
TOTAL COST
67,323,623.80
154
Cost of Pipes:
Table 66
Purchase Cost of Pipes
Pipes
PIPE-100
PIPE-101
PIPE-102
PIPE-103
PIPE-104
PIPE-105
PIPE-106
PIPE-107
PIPE-108
PIPE-109
PIPE-110
PIPE-111
PIPE-112
PIPE-113
PIPE-114
PIPE-115
PIPE-116
PIPE-117
PIPE-118
PIPE-119
PIPE-106
PIPE-107
PIPE-108
PIPE-109
PIPE-110
PIPE-111
PIPE-113
PIPE-112
PIPE-114
PIPE-115
PIPE-116
PIPE-117
PIPE-118
PIPE-119
PIPE-120
PIPE-121
PIPE-121-10
PIPE-121-2
Di (mm)
26.64
26.64
26.64
26.64
26.64
26.64
26.64
26.64
26.64
26.64
26.64
26.64
26.64
26.64
26.64
26.64
26.64
26.64
26.64
52.5
102.3
102.3
102.3
254.5
77.93
77.93
40.89
77.93
52.5
52.5
52.5
52.5
40.89
40.89
40.89
26.64
26.64
26.64
L (m)
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
12
12
12
12
12
12
8
8
5
2
2
11
10
30
3
1
5
5
5
5
5
3
50
5
5
5
155
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
Final cost
24,964.22
24,964.22
24,964.22
24,964.22
24,964.22
24,964.22
24,964.22
24,964.22
24,964.22
24,964.22
24,964.22
24,964.22
119,828.26
119,828.26
119,828.26
119,828.26
119,828.26
119,828.26
79,885.50
131,974.66
135,132.76
54,053.10
54,053.10
583,558.39
220,975.50
662,926.51
41,133.97
22,097.55
82,484.16
82,484.16
82,484.16
82,484.16
68,556.61
41,133.97
685,566.11
49,928.44
49,928.44
49,928.44
PIPE-121-3
PIPE-121-4
PIPE-121-5
PIPE-121-6
PIPE-121-7
PIPE-121-8
PIPE-121-9
PIPE-122
PIPE-123
PIPE-123-10
PIPE-123-2
PIPE-123-3
PIPE-123-4
PIPE-123-5
PIPE-123-6
PIPE-123-7
PIPE-123-8
PIPE-123-9
26.64
26.64
26.64
26.64
26.64
26.64
26.64
40.89
26.64
26.64
26.64
26.64
26.64
26.64
26.64
26.64
26.64
26.64
5
5
5
5
5
5
5
50
5
5
5
5
5
5
5
5
5
5
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
9,985.69
9,985.69
9,985.69
9,985.69
9,985.69
9,985.69
9,985.69
13,711.32
9,985.69
9,985.69
9,985.69
9,985.69
9,985.69
9,985.69
9,985.69
9,985.69
9,985.69
9,985.69
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
49,928.44
49,928.44
49,928.44
49,928.44
49,928.44
49,928.44
49,928.44
685,566.11
49,928.44
49,928.44
49,928.44
49,928.44
49,928.44
49,928.44
49,928.44
49,928.44
49,928.44
49,928.44
Table 67
Final Cost of Pipe
Cost (2006)
Cost (2015)
Cost (2015 @ SE Asia)
$
$
$
$
Cost of Equipment (w/ Location and Installation factor
consideration)
$
Freight Cost
TOTAL COST
156
4,442,527.26
5,415,440.73
6,065,293.62
19,408,939.59
873,402,281.57
2,911.65
131,024.25
27,552,554.09
266,551.64
265.00
901,352,676.54
Cost of Pumps:
Table 68
Purchase Cost of Pumps
Number
P-101
P-102
P-103
P-104
P-105
P-106
P-107
P-108
P-109
P-110
$
$
$
$
$
$
$
$
$
$
Cost
3,399.68
3,551.87
56,741.85
3,743.91
3,739.28
3,721.06
3,705.03
3,692.28
15,409.32
330,313.69
Table 69
Final Cost of Pumps
Cost (2006)
Cost (2015)
Cost (2015 @ SE Asia)
$
$
$
428,017.99
521,753.92
584,364.40
1,869,966.07
Freight Cost
84,148,472.96
3,257.58
146,591.10
1,583,017.47
Import Processing Fee
25,681.08
Customs Documentary Stamp
265.00
TOTAL COST
85,904,027.61
157
Cost of Compressor:
Table 70
Purchase Cost of Compressor
NUMBER
K-100
Need Adjustment
No
Cost
78,319.38
Table 71
Final Cost of Compressor
Cost (2006)
Cost (2015)
Cost (2015 @ SE Asia)
$
$
$
78,319.38
95,471.32
106,927.88
342,169.23
15,397,615.19
3,257.58
146,591.10
Freight Cost
Bureau of Customs: Duties and Taxes
Value Added Tax (VAT)
158
433,098.41
4,699.16
265.00
15,982,268.86
Cost
1,504,690.06
Table 73
Final Cost of Boiler
Cost (2006)
Cost (2015)
Cost (2015 @ SE Asia)
$
$
$
1,504,690.06
1,834,217.19
2,054,323.25
6,573,834.39
$
Freight Cost
TOTAL COST
159
295,822,547.73
2,882.82
129,726.90
13,266,225.67
90,281.40
265.00
309,309,046.70
Cost of Furnace:
Table 74
Purchase Cost of Furnace
duty, MW
174.1
Cost
3,411,507.62
Table 75
Final Cost of Furnace
Cost (2006)
Cost (2015)
Cost (2015 @ SE Asia)
$
$
$
3,411,507.62
4,158,627.79
4,657,663.12
14,904,521.99
$
Freight Cost
TOTAL COST
160
670,703,489.66
2,882.82
129,726.90
23,354,129.56
204,690.46
265.00
694,392,301.57
Cost of Scrubber:
Table 76
Purchase Cost of Scrubber
Gas Effluent
m3/h
8399
ft3/h
296607.9
acfm
4943.465
$
15,150.29
$
$
$
$
15,150.29
18,468.20
20,684.38
66,190.02
2,978,551.01
2,882.82
129,726.90
TOTAL COST
95,464.89
909.02
265.00
3,204,916.81
Table 77
Final Cost of Scrubber
Cost (2006)
Cost (2015)
Cost (2015 @ SE Asia)
Cost of Equipment (w/ Location and Installation factor
consideration)
Freight Cost
161
Cost
$ 331,770.12
Table 79
Final Cost of Cooling Tower
Cost (2006)
Cost (2015)
Cost (2015 @ SE Asia)
Cost of Equipment (w/ Location and Installation factor
consideration)
Freight Cost
$
331,770.12
$
404,427.78
$
452,959.11
$ 1,449,469.15
65,226,111.81
$
2,911.65
131,024.25
19,906.21
Customs Documentary Stamp
265.00
TOTAL COST
67,365,304.01
162
140,000,000.00
840 cubic meters per day
Table 81
Capital Cost of WWTP of Phace Philippines Corporation
Location
Capacity
CAPEX
Hermosa, Bataan
71.95 cubic meters per day
32,046,377.41
163
, %
(17)
1 =
=
(18)
2 =
= ( )
(19)
164
Table 82
Depreciation schedule of the plant (values in Philippine Peso)
k
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
B
3920857301
3659466815
3398076328
3136685841
2875295354
2613904868
2352514381
2091123894
1829733407
1568342921
1306952434
1045561947
784171460
522780974
261390487
R
13%
13%
13%
13%
13%
13%
13%
13%
13%
13%
13%
13%
13%
13%
13%
522780974
487928909
453076844
418224779
383372714
348520649
313668584
278816519
243964454
209112389
174260325
139408260
104556195
69704130
34852065
261390487
261390487
261390487
261390487
261390487
261390487
261390487
261390487
261390487
261390487
261390487
261390487
261390487
261390487
261390487
522780974
487928909
453076844
418224779
383372714
348520649
348520649
348520649
348520649
348520649
348520649
348520649
348520649
348520649
348520649
522780974
1010709882
941005752
871301623
801597493
731893363
697041298
697041298
697041298
697041298
697041298
697041298
697041298
697041298
697041298
3659466815
3398076328
3136685841
2875295354
2613904868
2352514381
2091123894
1829733407
1568342921
1306952434
1045561947
784171460
522780974
261390487
0
165
Table 83
Land facts about Hermosa Ecozone Industrial Park (HEIP)
Total Area
162 hectares
Saleable Area
124 hectares
Common Area
38 hectares
Sold Area
18.9 hectares
Remaining Area for Sale
105.1 hectares
Source: Science Park of the Philippines, 2015
166
Table 84
Cost of Land lease annually
Rate
Rate
Cost of lease
(monthly)
(monthly)
per month
(USD/SQM) (PhP/SQM)
Cost of lease
per year
YEAR
SQM
2015(construction)
2016(construction)
2017
2018
2019
33129
33129
33129
33129
33129
$
$
$
$
$
2020
33129
$ 0.27
12.15
402,517.35 4,830,208.20
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
33129
33129
33129
33129
33129
33129
33129
33129
33129
33129
33129
$ 0.27
$ 0.27
$ 0.27
$ 0.27
$ 0.27
$ 0.27
$ 0.27
$ 0.27
$ 0.27
$ 0.27
$ 0.27
0.27
0.27
0.27
0.27
0.27
12.15
12.15
12.15
12.15
12.15
12.15
12.15
12.15
12.15
12.15
12.15
12.15
12.15
12.15
12.15
12.15
402,517.35
402,517.35
402,517.35
402,517.35
402,517.35
402,517.35
402,517.35
402,517.35
402,517.35
402,517.35
402,517.35
402,517.35
402,517.35
402,517.35
402,517.35
402,517.35
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
Fixed capital cost. Fixed capital cost is a production cost that does not vary with
the production volume. In order to obtain this cost, refer to Table 51. Table 85 shows the
fixed capital cost of the plant per year.
167
Table 85
Fixed Capital Cost of the Plant
YEAR
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
Depreciation
Cost
522,780,973.51
487,928,908.61
453,076,843.71
418,224,778.81
383,372,713.91
348,520,649.01
348,520,649.01
348,520,649.01
348,520,649.01
348,520,649.01
348,520,649.01
348,520,649.01
348,520,649.01
348,520,649.01
348,520,649.01
Land Rental
Cost
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
4,830,208.20
Fixed Capital
Cost
527,611,181.71
492,759,116.81
457,907,051.91
423,054,987.01
388,202,922.11
353,350,857.21
353,350,857.21
353,350,857.21
353,350,857.21
353,350,857.21
353,350,857.21
353,350,857.21
353,350,857.21
353,350,857.21
353,350,857.21
Insurance cost. Insurance is the equitable transfer of the risk of a loss, from one
entity to another in exchange for payment. Refer to Table 51 for the equation in obtaining
insurance cost. Table 86 shows the annual insurance cost of the company.
168
Table 86
Annual insurance cost of the company
Year
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
Cost
5,487,173.82
5,124,582.37
4,761,990.92
4,399,399.47
4,036,808.02
3,674,216.57
3,674,216.57
3,674,216.57
3,674,216.57
3,674,216.57
3,674,216.57
3,674,216.57
3,674,216.57
3,674,216.57
3,674,216.57
Table 87
Cost calculation basis for raw materials
FLOWRATE
Operational Time
kg/h
# of days
# of Hours
Propylene
3354
350
8400
Benzene
6248.800049
350
8400
Flowrates acquired from the Aspen Hysys Simulation
Source of Price: ICIS Indicative Prices
169
MTpY
28,173.60
52,489.92
PRICE
USD/MT
1014.13
1039.81
The inflation of the prices of the raw materials is approximated to 5%, as given
from the trend of prices of propylene and benzene from the report of Pandia entitled
Global Acetone-Phenol Markets in the year 2009. US Dollar to Philippines Peso
conversion is averaged to forty five. Given in Table 88 and Table 89 are the cost of
propylene and benzene annually.
Table 88
Annual cost of propylene
Year
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
Turndown
Capacity
50%
65%
75%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
MTpY
14,086.80
14,086.80
21,130.20
28,173.60
28,173.60
28,173.60
28,173.60
28,173.60
28,173.60
28,173.60
28,173.60
28,173.60
28,173.60
28,173.60
28,173.60
170
1,014.13
1,064.83
1,118.07
1,173.98
1,232.68
1,294.31
1,359.02
1,426.98
1,498.32
1,573.24
1,651.90
1,734.50
1,821.22
1,912.28
2,007.90
Cost
642,860,049.03
675,003,051.48
1,063,129,806.09
1,488,381,728.52
1,562,800,814.95
1,640,940,855.69
1,722,987,898.48
1,809,137,293.40
1,899,594,158.07
1,994,573,865.97
2,094,302,559.27
2,199,017,687.24
2,308,968,571.60
2,424,417,000.18
2,545,637,850.19
Table 89
Annual cost of benzene
Year
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
Turndown
Capacity
50%
65%
75%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
MTPY
26,244.96
26,244.96
39,367.44
52,489.92
52,489.92
52,489.92
52,489.92
52,489.92
52,489.92
52,489.92
52,489.92
52,489.92
52,489.92
52,489.92
52,489.92
1,039.81
1,091.80
1,146.39
1,203.71
1,263.90
1,327.09
1,393.44
1,463.12
1,536.27
1,613.09
1,693.74
1,778.43
1,867.35
1,960.72
2,058.75
Cost - Benzene
1,228,039,655.60
1,289,441,638.39
2,030,870,580.46
2,843,218,812.64
2,985,379,753.27
3,134,648,740.93
3,291,381,177.98
3,455,950,236.88
3,628,747,748.72
3,810,185,136.16
4,000,694,392.97
4,200,729,112.62
4,410,765,568.25
4,631,303,846.66
4,862,869,038.99
Cost of the catalysts. Life of catalysts for R-102 to R-105 (oxidation towers) is
usually 3 years for copper oxide (CuO) synthetic catalyst (Cheng & Kung, 1994). For the
packed bed plug flow reactor R-101 (Alkylation reactor), the life of catalyst for zeolite is
usually 2 years (Anpo, Onaka, & Yamashita, 2003). For the cleavage reactor (R-106), the
life of catalyst for sulfonic acid resins is usually 8 months (Rase, 2000). Shown in Table
90 is the amount of each catalyst used in each reactors and their corresponding prices.
Shown in Table 91 is the final cost of catalyst for each of the reactor. Finally, shown in
Table 92 is the total cost of the catalyst used annually.
171
Table 90
Amount and Pricing of Catalyst Used for each Reactor
REACTOR Mass of catalyst (kg) Price (USD/Kg) Life of catalyst
R-102
198.55
3 years
376.00
R-103
198.55
3 years
376.00
R-104
198.55
3 years
376.00
R-105
198.55
3 years
376.00
R-101
7140
2 years
8.37
R-106
2.65854
8 months
2930.00
Table 91
Final Cost of Catalyst for each Reactor
REACTOR
Years of Operation
R-102
R-103
R-104
R-105
R-101
R-106
15
15
15
15
15
15
Cost of Catalyst
$
$
$
$
77,213.89
77,213.89
77,213.89
77,213.89
$ 4,641,000.00
$
5,051.23
Table 92
Total Cost of Catalysts per Year
Year
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
Turndown
Capacity
50%
65%
75%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
Cost of Catalyst
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
4,725,471.23
4,883,301.96
4,883,301.96
4,883,301.96
4,883,301.96
4,883,301.96
4,883,301.96
4,883,301.96
4,883,301.96
4,883,301.96
4,883,301.96
4,883,301.96
4,883,301.96
4,883,301.96
4,883,301.96
Freight
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
2,940.47
2,940.47
2,940.47
2,940.47
2,940.47
2,940.47
2,940.47
2,940.47
2,940.47
2,940.47
2,940.47
2,940.47
2,940.47
2,940.47
2,940.47
172
VAT
50,962,913.44
50,962,913.44
50,962,913.44
50,962,913.44
50,962,913.44
50,962,913.44
50,962,913.44
50,962,913.44
50,962,913.44
50,962,913.44
50,962,913.44
50,962,913.44
50,962,913.44
50,962,913.44
50,962,913.44
Cost - Catalyst
157,352,176.60
193,885,504.66
215,873,595.62
270,843,823.01
270,843,823.01
270,843,823.01
270,843,823.01
270,843,823.01
270,843,823.01
270,843,823.01
270,843,823.01
270,843,823.01
270,843,823.01
270,843,823.01
270,843,823.01
Utility costs of the plant. The main process of the plant requires a cooling water
system and a steam generation unit. Shown in Table 93 is the fuel requirement of the plant
and in Table 94 is the water requirement of the plant.
Table 93
Fuel requirement of the plant and its price
Fuel: Industrial LPG (Propane)
Volume Flow (L/year)
781,536.00
Price (per Liter)
5.5 PHP
Table 94
Water requirement of the plant and its price
WATER
Volume Flow (m3/h)
6100.64
Volume of water (1 day)
146415.36
Volume of water (1 year)
585,662.28
Volume with Make-up (1 year) 592,983.06
The fuel requirement of the plant amounts to an average of 782 3 annually. The
cost of the fuel consumption per year is shown in Table 95.
173
Table 95
Cost of Fuel Consumed Per Year
Year
Turndown Capacity
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
50%
65%
75%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
5.50
5.72
5.95
6.19
6.43
6.69
6.96
7.24
7.53
7.83
8.14
8.47
8.81
9.16
9.52
Cost - Fuel
2,149,224.00
2,235,192.96
3,486,901.02
4,835,169.41
5,028,576.19
5,229,719.24
5,438,908.00
5,656,464.32
5,882,722.90
6,118,031.81
6,362,753.09
6,617,263.21
6,881,953.74
7,157,231.89
7,443,521.16
The water requirement of the plant for both of its cooling water system and steam
generation unit amounts to an average of 593,000 3 annually. The maximum required
make-up water flow rate for cooling tower can be approximated with 1.25% of the total
flow. This percentage accounts the evaporation and blowdown losses (Stanford, 2012).
There will be a very high maintenance of cooling tower water because the cleaning will be
frequent. For industries, the average cost of cooling water chemicals is $0.043 3 of
total water requirement (LLC-Consulting-Group, 2003). The cost of the consumable water
per year is shown in Table 96.
174
Table 96
Cost of Consumed Water per Year
Turndown
Price (per 100
Year
Capacity
m3)
2017
50%
2018
65%
2019
75%
2020
100%
2021
100%
2022
100%
2023
100%
2024
100%
2025
100%
2026
100%
2027
100%
2028
100%
2029
100%
2030
100%
2031
100%
2,962.00
2,962.00
2,962.00
2,962.00
2,962.00
2,962.00
2,962.00
2,962.00
2,962.00
2,962.00
2,962.00
2,962.00
2,962.00
2,962.00
2,962.00
Cubic meter
used
Cost - PW
585,662.28
8,673,658.38
585,662.28
11,275,755.89
585,662.28
13,010,487.57
585,662.28
17,347,316.76
585,662.28
17,347,316.76
585,662.28
17,347,316.76
585,662.28
17,347,316.76
585,662.28
17,347,316.76
585,662.28
17,347,316.76
585,662.28
17,347,316.76
585,662.28
17,347,316.76
585,662.28
17,347,316.76
585,662.28
17,347,316.76
585,662.28
17,347,316.76
585,662.28
17,347,316.76
consumption
for
commercial
buildings
can
be
assumed
to
be
175
Table 97
Electricity Requirement of the Buildings
ELECTRICITY COST OF THE BUILDINGS
LENGTH
WIDTH
AREA
Area
Buildings
(m)
(m)
(m2)
(ft2)
15,096.3
ADMIN BLDG
27.5
51
1402.5
7
43,400.0
MANUFACTURING
72
56
4032
4
QUALITY CONTROL
17.5
50.9
890.75
9,587.94
LAB
CANTEEN
40
18
720
7,750.01
PRODUCTION
25.9
18
466.2
5,018.13
OFFICE
RESEARCH&DEV
17.5
27
472.5
5,085.94
SECURITY OFFICE
27.83
12.2
339.526
3,654.62
MAINTENANCE
17.5
18
315
3,390.63
CONTROL ROOM
25
8
200
2,152.78
WAREHOUSE
20.04
22
440.88
4,745.59
TOTAL (kWh per Year)
kWh per
YEAR
261,167.20
750,820.78
165,871.43
134,075.14
86,813.65
87,986.81
63,224.99
58,657.87
37,243.09
82,098.68
1,727,959.64
Table 98
Electricity requirement of the Process
EQUIPMENT
POWER
KW
P-101
P-102
P-103
P-104
P-105
P-106
P-107
P-108
K-100
5.735
18.26
164.2
0.3521
0.01056
0.01792
0.02498
2.538
180.0417
Electricity Requirement
kWh/Day
kWh/Year
Process
P-109
P-110
2093
82.73
TOTAL
137.6
438.2
3940.8
8.4504
0.25344
0.43008
0.59952
60.912
4321.001
Utilities
50232
1985.52
176
48,160.00
153,370.00
1,379,280.00
2,957.64
88.70
150.53
209.83
21,319.20
1,512,350.28
17,581,200.00
694,932.00
21,394,018.18
In order to get the annual cost of electricity consumption, the electricity requirement
of both the process and the buildings were combined. A total of 23,121,977.82 of
electricity per year will be required by the whole plant. The cost of electricity for the
industry in Hermosa, Bataan is 6.4708 (Provincial Government of Bataan, n.d.).
Shown in Table 99 is the annual cost of electricity of the company.
Table 99
Cost of Electricity
Turndown
Year
Capacity
2017
50%
2018
50%
2019
75%
2020
100%
2021
100%
2022
100%
2023
100%
2024
100%
2025
100%
2026
100%
2027
100%
2028
100%
2029
100%
2030
100%
2031
100%
Buildings
138,436,412.87
138,436,412.87
138,436,412.87
138,436,412.87
138,436,412.87
138,436,412.87
138,436,412.87
138,436,412.87
138,436,412.87
138,436,412.87
138,436,412.87
138,436,412.87
138,436,412.87
138,436,412.87
138,436,412.87
11,181,281.23
11,181,281.23
11,181,281.23
11,181,281.23
11,181,281.23
11,181,281.23
11,181,281.23
11,181,281.23
11,181,281.23
11,181,281.23
11,181,281.23
11,181,281.23
11,181,281.23
11,181,281.23
11,181,281.23
Cost
80,399,487.66
101,164,949.59
115,008,590.88
149,617,694.10
149,617,694.10
149,617,694.10
149,617,694.10
149,617,694.10
149,617,694.10
149,617,694.10
149,617,694.10
149,617,694.10
149,617,694.10
149,617,694.10
149,617,694.10
Table 100
Price of communication services
`
Voice / Landline:
COST
PhP 936.00
(21.53 USD)
PhP 617.00
(14.19USD)
PhP 4, 000.00
(92.00 USD)
PhP 999.00
(23.00 USD)
Table 101
Annual cost of communication services of the company
Year
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
Internet
11,232.00
11,232.00
11,232.00
11,232.00
11,232.00
11,232.00
11,232.00
11,232.00
11,232.00
11,232.00
11,232.00
11,232.00
11,232.00
11,232.00
11,232.00
Landline
48,000.00
48,000.00
48,000.00
48,000.00
48,000.00
48,000.00
48,000.00
48,000.00
48,000.00
48,000.00
48,000.00
48,000.00
48,000.00
48,000.00
48,000.00
Table 102
Cost of Biological WWTP Operation per Year
Year
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
Cost
330,775.68
330,775.68
330,775.68
330,775.68
330,775.68
330,775.68
330,775.68
330,775.68
330,775.68
330,775.68
330,775.68
330,775.68
330,775.68
330,775.68
330,775.68
Operating labor. To determine labor costs, one must estimate the number of
operators (crew size) and the wage rate. The preferred way to determine labor needs is to
get a manufacturing estimate. However, because there is not enough time or because
manufacturing has not staffed a project, which is often not practical. Table 103 shows the
summary of labor cost annually. The management decided a 4% increase in labor per year.
See Appendix E for the breakdown of wage and monetary benefits for each employees of
the company.
179
Table 103
Summary of Labor Cost per Year
`Year
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
Yearly Bonus
4,564,680.00
4,747,267.20
4,937,157.89
5,134,644.20
5,340,029.97
5,553,631.17
5,775,776.42
6,006,807.47
6,247,079.77
6,496,962.96
6,756,841.48
7,027,115.14
7,308,199.75
7,600,527.74
7,904,548.85
TOTAL
25,609,852.48
26,634,246.57
27,699,616.44
28,807,601.09
29,959,905.14
31,158,301.34
32,404,633.40
33,700,818.73
35,048,851.48
36,450,805.54
37,908,837.76
39,425,191.27
41,002,198.93
42,642,286.88
44,347,978.36
487,191,272.95
180
Table 104
Price of Fuel and Consumption per Truck
Customer number of Price of Fuel Distance
Location
companies
per Liter
(km)
Manila
35
34.60
197.6
Laguna
11
34.60
285.2
Cavite
3
34.60
247
Rizal
9
34.60
279.8
Batangas
1
34.60
415
L/distance(km)
L/week
0.3
0.3
0.3
0.3
0.3
4979.52
2395.68
518.7
2350.32
871.5
Table 105
Annual cost on transportation
Customer Location
Manila
Laguna
Cavite
Rizal
Batangas
Cost (weekly)
TOTAL
172,291.39
82,890.53
17,947.02
81,321.07
30,153.90
Cost (Yearly)
8,269,986.82
3,978,745.34
861,456.96
3,903,411.46
1,447,387.20
18,460,987.78
Other estimated costs. Table 106 and 107 shows the other costs related to the
direct cost of the plant. Refer to Table 51 for the equations used in estimating the values
under these costs.
181
Table 106
Operating, Quality Contol, and Laboratory Cost per Year
Operating Supervision
Quality Control
Laboratory Costs
Cost
Cost
Cost
YEAR
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
5,121,970.50
5,326,849.31
5,539,923.29
5,761,520.22
5,991,981.03
6,231,660.27
6,480,926.68
6,740,163.75
7,009,770.30
7,290,161.11
7,581,767.55
7,885,038.25
8,200,439.79
8,528,457.38
8,869,595.67
5,121,970.50
5,326,849.31
5,539,923.29
5,761,520.22
5,991,981.03
6,231,660.27
6,480,926.68
6,740,163.75
7,009,770.30
7,290,161.11
7,581,767.55
7,885,038.25
8,200,439.79
8,528,457.38
8,869,595.67
2,560,985.25
2,663,424.66
2,769,961.64
2,880,760.11
2,995,990.51
3,115,830.13
3,240,463.34
3,370,081.87
3,504,885.15
3,645,080.55
3,790,883.78
3,942,519.13
4,100,219.89
4,264,228.69
4,434,797.84
Table 107
Maintenance Labor, Maintenance Material, and Operating Supplies Cost per
year
Maintenance Labor
Maintenance Material
Operating Supplies
Cost
Cost
Cost
YEAR
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
14,245,501.91
13,304,496.15
12,363,490.40
11,422,484.65
10,481,478.90
9,540,473.14
9,540,473.14
9,540,473.14
9,540,473.14
9,540,473.14
9,540,473.14
9,540,473.14
9,540,473.14
9,540,473.14
9,540,473.14
9,497,001.27
8,869,664.10
8,242,326.93
7,614,989.77
6,987,652.60
6,360,315.43
6,360,315.43
6,360,315.43
6,360,315.43
6,360,315.43
6,360,315.43
6,360,315.43
6,360,315.43
6,360,315.43
6,360,315.43
182
3,957,083.86
3,695,693.38
3,434,302.89
3,172,912.40
2,911,521.92
2,650,131.43
2,650,131.43
2,650,131.43
2,650,131.43
2,650,131.43
2,650,131.43
2,650,131.43
2,650,131.43
2,650,131.43
2,650,131.43
Table 108
General costs of the plant
YEAR
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
Admin
Marketing
Cost
Cost
Cost
92,776,682.22
124,655,924.66
149,741,749.13
207,347,393.38
217,130,057.82
227,405,891.73
238,297,540.40
249,732,836.09
261,738,923.75
274,344,304.04
287,578,901.15
301,474,133.81
316,062,990.04
331,380,105.49
347,461,845.78
278,330,046.67
373,967,773.99
449,225,247.40
622,042,180.13
651,390,173.47
682,217,675.18
714,892,621.19
749,198,508.28
785,216,771.24
823,032,912.13
862,736,703.45
904,422,401.44
948,188,970.13
994,140,316.48
1,042,385,537.34
183
118,547,982.84
159,282,570.40
191,336,679.45
264,943,891.54
277,443,962.78
290,574,194.98
304,491,301.62
319,103,068.34
334,444,180.34
350,551,055.17
367,461,929.25
385,216,948.76
403,858,265.05
423,430,134.80
443,979,025.16
Table 109
Pricing of Products
Acetone
Phenol
FLOWRATE
kg/h
4369.793128
7071.121303
Operational Time
# of days
# of Hours
350
8400
350
8400
PRICE
USD/MT
36,706.26 1807.788
59,397.42 1984.158
MTpY
The inflation of the prices of the raw materials was approximated to 5%, as given
from the trend of prices of propylene and benzene from the report of Pandia entitled
Global Acetone-Phenol Markets in the year 2009. US Dollar to Philippines Peso
conversion is averaged to forty five. Given in Table 88 and Table 89 are the cost of
propylene and benzene annually. Table 110 shows the annual revenue generated from
acetone. Table 111 shows the annual revenue generated from phenol.
184
Table 110
Revenue from acetone
Year
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
Turndown
Capacity
50%
65%
75%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
MTPY
18353.13
23859.07
27529.7
36706.26
36706.26
36706.26
36706.26
36706.26
36706.26
36706.26
36706.26
36706.26
36706.26
36706.26
36706.26
1,807.79
1,898.18
1,993.09
2,092.74
2,197.38
2,307.25
2,422.61
2,543.74
2,670.93
2,804.47
2,944.70
3,091.93
3,246.53
3,408.85
3,579.30
Revenue
1,493,035,990.88
2,037,994,127.55
2,469,108,269.92
3,456,751,577.89
3,629,589,156.78
3,811,068,614.62
4,001,622,045.35
4,201,703,147.62
4,411,788,305.00
4,632,377,720.25
4,863,996,606.26
5,107,196,436.58
5,362,556,258.41
5,630,684,071.33
5,912,218,274.89
Table 111
Revenue from phenol
Year
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
Turndown
Capacity
50%
65%
75%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
MTPY
Revenue - Phenol
29698.71
38608.32
44548.06
59397.42
59397.42
59397.42
59397.42
59397.42
59397.42
59397.42
59397.42
59397.42
59397.42
59397.42
59397.42
1984.158
2083.3659
2187.534195
2296.910905
2411.75645
2532.344272
2658.961486
2791.90956
2931.505038
3078.08029
3231.984305
3393.58352
3563.262696
3741.425831
3928.497122
2,651,711,939.36
3,619,586,797.22
4,385,268,619.71
6,139,376,067.60
6,446,344,870.98
6,768,662,114.53
7,107,095,220.25
7,462,449,981.26
7,835,572,480.33
8,227,351,104.34
8,638,718,659.56
9,070,654,592.54
9,524,187,322.17
10,000,396,688.27
10,500,416,522.69
185
Table 112 shows the detailed summary of the taxes and mandatory contributions of
a corporation. Based on the table, the total tax rate that can be imposed on a corporations
profit is 42.48%.
186
Table 112
Detailed summary of the taxes and mandatory contributions of a corporation
Tax or
mandatory
contribution
Payments
(number)
Notes on
Payments
Time
(hours)
Corporate
income tax
online filing
42
Local business
tax
Employer paid
- Social security
contributions
Real property
tax
Statutory
tax rate
30%
0.50%
online filing
38
2.89% to
6.50%
Tax base
taxable
profit
previous
year
turnover
gross
salaries
Total
tax rate
(%
profit)
20.46
8.84
6.06
Employer paid
- Health insurance
12
online filing
1.16% to
1.19%
assessed
property
value
gross
salaries
Employer paid
- Housing
development fund
12
online filing
2% or P100
per worker
gross
salaries
0.56
Tax on interest
online filing
20%
interest
0.51
Employer paid
- Employer's
compensation
paid jointly
P 30
per
employee
per month
0.17
P 10,500
fixed fee
0.08
P 10,000
fixed fee
0.08
basic fee +
24%
P 500
P 1.5 per
check
vehicle
weight
fixed fee
value
added
number of
checks
P 0.5 per
each P 4
various
rates
insurance
premium
contract
value
Community tax
certificate
Environmental
tax
2%
Notes
on TTR
4.44
1.24
Vehicle tax
BIR certificate
paid jointly
Value added
tax (VAT)
online filing
Tax on check
transactions
online filing
Tax on
insurance
contracts
online filing
Stamp duty
online filing
Employee paid
- Social security
contributions
paid jointly
1.33% to
2.98%
gross
salaries
withheld
Employee paid
- Payroll tax
paid jointly
1.16% to
1.19%
per
employee
per month
withheld
Employee paid
- Housing
development fund
paid jointly
2% or P
100 per
worker
gross
salaries
withheld
Totals:
36
113
193
187
12%
0.04
0
0
0
0
0
42.48
not
included
small
amount
small
amount
small
amount
Table 113 shows the annual production cost and revenue of the company. Imposing
the 42.48% on the revenue, the annual profit of the company is depicted in Table 114.
Table 113
Production Cost and Revenue of the Company per Year
Year
PRODUCTION COST
Table 114
Annual Profit of the Company
Year
PROFIT
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
Total REVENUE
3,270,703,198.73
4,154,190,983.79
4,833,394,458.10
6,446,398,502.45
6,678,358,290.60
6,923,852,453.54
7,222,621,590.59
7,536,310,967.82
7,865,665,868.56
8,211,468,811.18
8,574,541,409.64
8,955,746,327.09
9,355,989,327.03
9,776,221,427.05
10,217,441,160.17
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
TAX
874,044,731.51
1,503,389,940.98
2,020,982,431.54
3,149,729,143.04
3,397,575,737.16
3,655,878,275.61
3,886,095,675.01
4,127,842,161.06
4,381,694,916.77
4,648,260,013.42
4,928,173,856.18
5,222,104,702.03
5,530,754,253.55
5,854,859,332.55
6,195,193,637.41
188
371,294,201.94
638,640,046.93
858,513,336.92
1,338,004,939.96
1,443,290,173.14
1,553,017,091.48
1,650,813,442.74
1,753,507,350.02
1,861,344,000.64
1,974,580,853.70
2,093,488,254.11
2,218,350,077.42
2,349,464,406.91
2,487,144,244.47
2,631,718,257.17
4,144,747,930.24
5,657,580,924.78
6,854,376,889.63
9,596,127,645.49
10,075,934,027.76
10,579,730,729.15
11,108,717,265.60
11,664,153,128.88
12,247,360,785.33
12,859,728,824.60
13,502,715,265.83
14,177,851,029.12
14,886,743,580.57
15,631,080,759.60
16,412,634,797.58
FINAL PROFIT
502,750,529.56
864,749,894.05
1,162,469,094.62
1,811,724,203.08
1,954,285,564.01
2,102,861,184.13
2,235,282,232.27
2,374,334,811.04
2,520,350,916.12
2,673,679,159.72
2,834,685,602.08
3,003,754,624.61
3,181,289,846.64
3,367,715,088.08
3,563,475,380.24
Table 115
Required Permits and Licenses of the Company
Mayor's Permit
Sanitary Permit
Location Clearance
Building Permit
Occupational
Occupancy
Fire Permit
Community Tax Certificate
Environmental Tax
BIR Certificate
SEC Company name verification and reservation
Notarize articles of incorporation and treasurer's
affidavit at the notary
SEC company Registration
Pay registration fee and Documentary stamp taxes at
AAB (Authorized Agent Bank)
Barangay Clearance
Special Books of Account
Application for certificate of registration (COR) and TIN
at BIR
Printing or receipts and invoices
World Bank Group, 2015
Provincial Government of Bataan, 2015
189
2,500.00
1,000.00
6,000.00
25,000.00
10,000.00
5,000.00
6,000.00
10,500.00
10,000.00
500.00
40.00
500.00
3,645.00
4,670.00
800.00
400.00
115.00
4,000.00
Cost of Buildings
Shown in Table 116 is the cost of the buildings inside the plant site. The cost was
generated using Aspen Hysys Economic Evaluator software.
Table 116
Cost of buildings
LENGTH
(m)
WIDTH
(m)
AREA
(m2)
ADMIN BLDG
27.5
51
1402.5
QUALITY CONTROL
LAB
17.5
50.9
890.75
40
18
720
PRODUCTION OFFICE
25.9
18
466.2
RESEARCH&DEV
17.5
27
472.5
SECURITY OFFICE
27.83
12.2
339.526
MAINTENANCE
17.5
18
315
CONTROL ROOM
25
200
20.04
22
440.88
Buildings
CANTEEN
WAREHOUSE
TOTAL
COST OF
BUILDINGS
$
1,103,000.00
$
1,362,200.00
$
566,200.00
$
502,700.00
$
509,500.00
$
366,100.00
$
339,600.00
$
227,900.00
$
312,900.00
238,054,500.00
190
Table 117
Cost of trucks of the company
Description
Isuzu 8PC1
8 Wheeler
Tank Truck
14,000 L Capacity
1,200,000.00
Assumption: Per day delivery
Volume of Acetone Product per day:
Volume of Phenol Product per day:
Number of Trucks for Acetone:
Number of Trucks for Phenol:
TOTAL NUMBER OF TRUCKS:
Cost of Trucks:
135.432
161.592
10
12
22
26,400,000.00
Table 118
Cost of radio
Number of Personnel that needs Radio
Price of Two-Way Radio
Total Cost
Source: OLX Philippines, 2015
191
23
4,500.00
103,500.00
Project Evaluation
Table 119 shows the summary of the expenses of the company. The total capital
expense of the company is around 4.5 billion PhP. It can be deduced that the construction
and operation of the plant requires very large amounts of capital.
Table 119
Total capital expenditure of the company
ISBL CAPEX
OSBL OPEX
Contingency
Commissioning
Minimum Paid up Capital Requirement on Bank
(SEC)
EIA
TOTAL CAPEX
2,814,539,354.81
1,106,317,946.51
392,085,730.13
137,230,005.55
500,000.00
300,000.00
4,450,973,036.99
About half of the total capital expenses of the company will come from bank
financing. The debt capital is raised through long term bonds with the bank. Table 120
shows the description of the bank and the annuity.
Table 120
Capital loan and interest
2,225,336,518.50
BPI
2,225,336,518.50
6.00%
3
2,650,411,398.91
10
302,351,929.12
Cash on hand
BANK
Bank loan (PRINCIPAL)
Interest rate (compounding per year)
Tenor/Defer
Future Worth at year 3
Number of terms
Annuity
192
The internal rate of return (IRR) of the company was projected to be 24%, as shown
in Table 121. At year 2020, the total capital expenditure is expected to be recovered,
therefore the return of investment (ROI) is 6 years. Figure 16 shows the project cash flow
of Phace Philippines Corporation.
Based on the economic analysis of the project using class 3 estimation, the project
is concluded to be feasible since it is highly profitable. The plant designers recommends to
continue the project to its next stages such as detailed engineering design, procurement,
construction, startup, trial runs, and production or commercial operation.
Table 121
Internal rate of return
YEAR
2015
2016
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
Bank Annuity
Annual Profit
-
314,565,371.62
314,565,371.62
314,565,371.62
314,565,371.62
314,565,371.62
314,565,371.62
314,565,371.62
314,565,371.62
314,565,371.62
314,565,371.62
IRR
(2,315,228,518.50)
(2,315,228,518.50)
502,750,529.56
550,184,522.43
847,903,723.00
1,497,158,831.45
1,639,720,192.39
1,788,295,812.51
1,920,716,860.64
2,059,769,439.42
2,205,785,544.50
2,359,113,788.09
2,520,120,230.46
3,003,754,624.61
3,181,289,846.64
3,367,715,088.08
3,563,475,380.24
193
24%
Cumulative Profit
502,750,529.56
1,052,935,051.99
1,900,838,774.99
3,397,997,606.45
5,037,717,798.84
6,826,013,611.34
8,746,730,471.99
10,806,499,911.41
13,012,285,455.91
15,371,399,244.01
17,891,519,474.46
20,895,274,099.07
24,076,563,945.71
27,444,279,033.79
31,007,754,414.03
CASH FLOW
5,000,000,000.00
4,000,000,000.00
3,000,000,000.00
2,000,000,000.00
1,000,000,000.00
(1,000,000,000.00)
2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031
(2,000,000,000.00)
(3,000,000,000.00)
Breakeven Analysis
If a proposal is intended to generate added volume, it is important to check the
estimated volume to be produced, so that the added revenues balance the added costs. This
volume is called the breakeven volume. The following equations must be used to obtain
the break even volume. Table 122 shows the calculation basis for the breakeven volume.
= ( ) + ( ) (20)
2
= 1.618182165
1
= .
(21)
= + (. )
(22)
+ (. )
Let =
194
(23)
Table 122
Calculation Basis for Breakeven Analysis
Year
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
PRODUCTION COST
2,712,464,361.58
2,835,631,286.44
4,366,775,747.44
6,031,806,007.70
6,300,526,376.70
6,582,723,662.99
6,880,225,862.31
7,192,584,954.92
7,520,543,056.81
7,864,879,360.64
8,226,411,988.37
8,605,999,936.54
9,004,545,118.75
9,422,994,510.15
9,862,342,399.22
Acetone
(X1) MTPY Price (per MT)
18,353.13 $
1,807.79
18,353.13 $
1,862.02
27,529.70 $
1,917.88
36,706.26 $
1,975.42
36,706.26 $
2,034.68
36,706.26 $
2,095.72
36,706.26 $
2,158.59
36,706.26 $
2,223.35
36,706.26 $
2,290.05
36,706.26 $
2,358.75
36,706.26 $
2,429.52
36,706.26 $
2,502.40
36,706.26 $
2,577.47
36,706.26 $
2,654.80
36,706.26 $
2,734.44
Phenol
(X2) MTPY Price (per MT)
29,698.71 $
1,984.16
29,698.71 $
2,043.68
44,548.06 $
2,104.99
59,397.42 $
2,168.14
59,397.42 $
2,233.19
59,397.42 $
2,300.18
59,397.42 $
2,369.19
59,397.42 $
2,440.26
59,397.42 $
2,513.47
59,397.42 $
2,588.88
59,397.42 $
2,666.54
59,397.42 $
2,746.54
59,397.42 $
2,828.93
59,397.42 $
2,913.80
59,397.42 $
3,001.22
Breakeven sales volume is the amount of product that you will need to produce and
sell to cover total costs of production. Table 123 shows the breakeven volume of the
products acetone and phenol.
Table 123
Breakeven volume of acetone (1 ) and phenol (2 )
Year
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
X2/X1
1.618182165
1.618182165
1.618182165
1.618182165
1.618182165
1.618182165
1.618182165
1.618182165
1.618182165
1.618182165
1.618182165
1.618182165
1.618182165
1.618182165
1.618182165
X1
12,010.91
12,190.59
18,226.30
24,442.62
24,787.91
25,143.84
25,514.75
25,896.23
26,288.36
26,691.26
27,105.05
27,529.85
27,965.79
28,413.00
28,871.61
195
X2
19,435.85
19,726.59
29,493.47
39,552.61
40,111.36
40,687.31
41,287.52
41,904.81
42,539.35
43,191.32
43,860.91
44,548.32
45,253.75
45,977.41
46,719.52
A benefit-cost ratio (BCR) is an indicator, used in the formal discipline of costbenefit analysis, which attempts to summarize the overall value for money of a project or
proposal. Table 124 shows the benefit to cost ratio of the plant. The ratio should be greater
than 1 for the project to be justifiable.
Table 124
Benefit to cost ratio (f) of the plant
n
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Year
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
Production Cost
(PhP)
3074233529
3916060631
4571068739
6120371891
6354543098
6602276466
6901796804
7216267436
7546434846
7893082804
8257034225
8639153123
9040346669
9461567344
9903815202
Revenue (PhP)
4144747930
5657580925
6854376890
9596127645
10075934028
10579730729
11108717266
11664153129
12247360785
12859728825
13502715266
14177851029
14886743581
15631080760
16412634798
TOTAL
f
196
PW PC (PhP)
PW-R (PhP)
3074233529
4144747930
3158113412
4562565262
2972859482
4457841369
3210057091
5033046707
2687803956
4261854067
2252087605
3608828040
1898593799
3055862454
1600887537
2587625465
1350107487
2191134466
1138810578
1855396120
960743009.3
1571101554
810648596
1330368251
684108304.9
1126521503
577405847.5
953909337.1
487415051.1
807745809.7
26863875284
41548548335
1.546632714
References
(n.d.). Retrieved from http://www.hermosa.gov.ph/index.php/about-hermosa/municipalprofile
Acetone
Technical
Grade.
(n.d.).
Retrieved
from
Bruce
Scientific:
http://www.brucescientific.com/acetone-technical-grade.html
Anpo, M., Onaka, M., & Yamashita, H. (2003). Studies in Surface Science and Catalysis.
Tokyo, Japan: Elsevier.
Boyer, C. C., & Smith, L. A. (2010). United States of America Patent No. US
2010/0048966 A1.
Brown, T. (2006). Engineering Economics and Economic Design for Process Engineers.
New York: CRC Press.
Canfield, R. C., Cox, R. C., & McCarthy, D. M. (1986). Monsanto/Lummus crest process
produces lowest cost cumen. Proceedings of the AIChE 1988 Spring Meeting, New.
Certificate of Exemption. (n.d.). Retrieved from Dangerous Drugs Board - Republic of the
Philippines: http://www.ddb.gov.ph/legal-services/certificate-of-exemption
Chemical Control Order. (n.d.). Retrieved from Chemical Management Section - EMB:
http://www.emb.gov.ph/portal/chemical/Permitings/ChemicalControlOrder.aspx
ChemPep
Inc.
(2015).
Retrieved
from
http://www.chempep.com/ChemPep_Products2_Resins_for_Peptide_Synthesis_S
ulfonic_Acid_Resin.htm
Cheng, W.-H., & Kung, H. H. (1994). Methanol Production and Use. New York:
MARCEL DEKKER, INC.
197
Corma, A., Martinez-Soria, V., & Schnoeveld, E. (2000). Alkylation of benzene with shortchain olefins over MCM-22 zeolite: Catalytic behavior and kinetic mechanism. J.
Catal, 163-173.
Customs
PH.
(2015).
Retrieved
from
http://customs.gov.ph/references/tax-
computation/tax-calculator/
Dai, C., Lei, Z., Zhang, J., Li, Y., & Chen, B. (2013). Monolith catalysts for the alkylation
of benzene with propylene. Chemical Engineering Science, 100, 342-351.
Retrieved October 5, 2014
Dimian, A. C., & Bildea, C. S. (2008). Chemical Process Design: Computer-Aided Case
Studies. Hoboken, N.J.: Wiley-VCH.
DMITRIEVSKY Chemical Plant. (2015). Raw Material for Paint. Retrieved from
DMITRIEVSKY
Chemical
Plant:
http://www.dcpt.ru/en/raw-material-for-
paint.html
Download trade data: UN Comtrade: International trade statistics. (n.d.). Retrieved from
UN Comtrade Database: http://comtrade.un.org/data/
E-BOND
EPOXIES,
INC.
(2015).
Retrieved
from
http://www.impactrecovery.com/images/uploads/E-Bond_Epoxy.pdf
Edwards, L., & Lawless, J. (2003). The Natural Pain Book. Great Britain: Rodale.
EMB Philippines. (2015). Retrieved from http://emb.gov.ph/internal/CasREgistry.aspx
Export Data and Price of phenolic resin. (2014, November 3). Retrieved from Zauba:
https://www.zauba.com/export-phenolic-resin-hs-code.html
Hanmin, L., & Suratman, N. (2011, April 13). Philippines' Petron to expand Bataan
refinery, triple C3 output. Retrieved October 14, 2014, from ICIS:
198
http://www.icis.com/resources/news/2011/04/13/9452036/philippines-petron-toexpand-bataan-refinery-triple-c3-output/
Huang, D., Han, M., Wang, J., & Jin, Y. (2002). Catalytic decomposition process of
cumene hydroperoxide using sulfonic resins as catalyst. Chemical Engineering
Journal, 215-223.
ICIS. (2015). Retrieved from http://www.icis.com/chemicals/channel-info-chemicals-a-z/
Industrial Flares. (n.d.). Retrieved from United States Environmental Protection Agency:
http://www.epa.gov/ttnchie1/ap42/ch13/final/c13s05.pdf
INEOS Phenol Company. (n.d.). Retrieved October 12, 2014, from INEOS Phenol:
http://www.ineos.com/businesses/ineos-phenol/company/
(2013). JG SUMMIT HOLDINGS, INC. - Annual Report. Retrieved October 15, 2014, from
http://traffic.libsyn.com/jgsummit/2014-0611-jgsummit-ar-2013-lowres.pdf
Killcross, M. (2012). Chemical and Process Plant Commissioning HandBook. MA 02451,
USA: Elsevier.
(2009). Lacquer Thinner Material Safety Data Sheet. W. M. Barr. Retrieved November 6,
2014, from http://www.wsc.edu.ph/facility_services/msds/lacquer_thinner.pdf
LLC-Consulting-Group. (2003). Assessment of Parabolic Trough and Power Tower Solar
Technology Cost and Performance Forecasts. Chicago, Illinois: NREL.
MGE. (n.d.). Managing Energy Costs in Office Buildings. Retrieved from Responsible
Energy:
https://www.mge.com/images/PDF/Brochures/business/ManagingEnergyCostsIn
OfficeBuildings.pdf
199
Norouzi, H. R., Hasani, M. A., Haddadi-Sisakht, B., & Mostoufi, N. (2014). Economic
Design and Optimization of Zeolite-Based Cumene Production Plant. Chemical
Engineering Communications, 1270-1293. doi:10.1080/00986445.2013.806312
OLX
Philippines.
(2015).
Retrieved
from
http://www.olx.ph/index.php/view+classifieds/id/70659896/Two+way+radio+Mo
torola+SMP468+Pandia, R. M. (2009). Global Phenol-Acetone Markets. GLOBAL PETROCHEMICALS
CONFERENCE, WORLD REFINING ASSOCIATION, Cologne, Germany.
Retrieved October 12, 2014
Pathak, A. S., Agarwal, S., Gera, V., & Kaistha, N. (2011). Design and Control of a vaporphase conventional process and reactive distillation process for cumene production.
Ind. Eng. Chem. Res., 3312-3326.
Paying Taxes in the Philippines. (n.d.). Retrieved from World Bank Group - Doing
Business:
http://www.doingbusiness.org/data/exploreeconomies/philippines/paying-taxes/
Perego, C., & Ingallina, P. (2002). Recent advances in the industrial alkylation of
aromatics: New catalysts and new processes. Catal. Today, 3-22.
Petron. (2005, December 11). Petron Approves 178.4-M Contract for petrochem project.
Retrieved
October
14,
2014,
http://www.petron.com/PETRON_APPROVES_$178.4M_CONTRACT_FOR_PETROCHEM_PROJECT.html
200
from
Petron:
from
http://msds.ergon.com/files/corrosion-
engineering/msds_phenolicresin0909.pdf
Philippine Drug Enforcement Agency (PDEA). (2015). Frequently Asked Questions.
Retrieved
from
Philippine
Drug
Enforcement
Agency
(PDEA):
http://pdea.gov.ph/compliance-service/faqs
Philippine Inventory of Chemicals and Chemical Substances. (n.d.). Retrieved from EMB
Philippines: http://www.emb.gov.ph/eeid/PICCS.htm
(2009). Philippine Standard Industrial Classification. Manila, Philippines: National
Statistical Coordination Board (NSCB). Retrieved November 5, 2014, from
http://www.nscb.gov.ph/activestats/psic/publication/NSCB_PSIC_2009.pdf
Priority Chemicals List. (n.d.). Retrieved from Chemical Management Section - EMB:
http://www.emb.gov.ph/portal/chemical/Permitings/PriorityChemicalList.aspx
Provincial Government of Bataan. (n.d.). Cost of Doing Business. Retrieved from
Provincial
Government
of
http://www.bataan.gov.ph/home/business2/costofdoingbusiness2.html
201
Bataan:
Park
of
the
Philippines.
(2015).
Retrieved
from
http://www.sciencepark.com.ph/heip-factsheet
Silla, H. (2003). Chemical Process Engineerng Design and Economics. New Jersey, USA:
Marcel Dekker, Inc.
Special Economic Zones in Philippines. (n.d.). Retrieved from The Philippine Economic
Zone
Authority
(PEZA):
http://training.itcilo.it/actrav_cdrom1/english/global/frame/epzppi.htm#anchor445
956
Speight, J. G. (2002). Chemical and Process Design Handbook. New York: McGRAWHILL.
SPPI - Hermosa Ecozone Industrial Park. (n.d.). Retrieved from Science Park Philippines:
http://www.sciencepark.com.ph/hermosa-ecozone-industrial-park-heip/
Stanford, H. W. (2012). HVAC Water Chillers and Cooling Towers. 6000 Broken Sound
Parkway NW, Suite 300, FL: Taylor & Francis Group CRC Press.
Stefanidakis, G., & Gwyn, J. E. (1977). Alkylation. Encyclopedia of Chemical Processing,
357.
(2010). Summary Statistics for Manufacturing Establishments for All Employment Sizes by
Industry Sub Class: Philippines, 2010. Manila, Philippines: National Statistics
202
Office
(NSO).
Retrieved
November
5,
2014,
from
http://web0.psa.gov.ph/content/2010-annual-survey-philippine-business-andindustry-aspbi-manufacturing-sector-final-results
(2009). Summary Statistics for Manufacturing Establishments for All Employment Sizes by
Industry Sub-Class: Philippines, 2009. Manila, Philippines: National Statistics
Office
(NSO).
Retrieved
November
6,
2014,
from
http://web0.psa.gov.ph/content/2009-annual-survey-philippine-business-andindustry-aspbi-manufacturing-sector-final-results
T&D Water Technologies and Development. (n.d.). Retrieved from T&D Company:
http://www.t-and-d-italy.com/
Toplinechem
Marketing
Corporation.
(2015).
Retrieved
from
http://toplinechem.lookchem.com/products/CasNo-67-64-1-Acetone2064394.html
Towler, G., & Sinnott, R. (2008). CHEMICAL ENGINEERING DESIGN: Principles,
Practice, and Economics of Plant and Process Design. California: Elsevier.
Toxic
Substances
and
Hazardous
Wastes.
(1990).
Retrieved
from
EMB:
http://www.emb.gov.ph/laws/toxic%20substances%20and%20hazardous%20wast
es/ra6969.PDF
Toyota. (n.d.). Toyota Motor Philippines CSR. Retrieved from Toyota Motor Philippines:
http://csr.toyota.com.ph/plant.html
Tyman, J. (1996). Synthetic and Natural Phenols. Rosewood Drive, Danvers, MA:
Elsevier.
203
US
Research
Nanomaterials,
Inc.
(2015).
Retrieved
from
http://www.us-
nano.com/inc/sdetail/222
Vatavuk, W. M. (1990). Estimating Cost of Air Pollution Control. Michigan, US.: Lewis
Publishers.
What You Need to Know About Real Property Tax (RPT). (n.d.). Retrieved from
FORECLOSUREPHILIPPINES:
http://www.foreclosurephilippines.com/real-
property-tax-rpt-philippines/
World
Bank
Group.
(2015).
Retrieved
from
http://www.doingbusiness.org/data/exploreeconomies/philippines/paying-taxes/
Zauba. (2015). Export Price of Zeolite. Retrieved November 11, 2014, from Zauba:
https://www.zauba.com/export-zeolite/fp-philippines-hs-code.html
Zhang, M., Wang, L., Hongbing, J., Wu, B., & Zeng, X. (2007). Cumene Liquid Oxidation
to Cumene Hydroperoxide over CuO Nanoparticle with Molecular Oxygen Under
Mild Condition. Journal of Natural Gas Chemistry, 393-398.
Zhang, M., Wang, L., Ji, H., Wu, B., & Zeng, X. (2007). Cumene Liquid Oxidation to
Cumene Hydroperoxide over CuO Nanoparticle with Molecular oxygen under Mild
Condition. Journal of Natural Gas Chemistry, 393-398.
Zhigang, L., Dai, C., Wang, Y., & Chen, B. (2009). Process Optimization on alkylation of
benzenen with propylene. Energy Fuel, 23(6), 3159-3166. doi:10.1021/ef900052j
204
205
Appendix A
Figure 2. React ion data for the main react ion in Alkylator
Figure 3. React ion data for the side react ion in Alkylator
206
Figure 5. React ion data for the cleaving of cu mene hydroperoxide to phenol
and acetone
207
208
209
210
211
212
213
214
215
216
217
218
219
Appendix B
STORAGE TANKS CALCULATION SHEETS
REV
1
CALCULATION SHEET
CREATED BY
CHECKED BY
EAM
ALL
MFS
DATE
1/2/15
APPROVED BY
C
F
Bar
psia
psig
psia
psig
C
93.33333
200
13.72321
199.0933
184.3933
0
-14.7
15 ~ 20
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
220
Operating T
0 to 200 degF
Over 200 degF
Reactors
Design T
250 degF
operating + 50 degF
operating + 50 degF
Operating P
0 to 25 psig
25 to 250 psig
250 to 1000 psig
over 1000 psig
Design P
50 psig
operating + 25 psig
operating + 10%
operating + 5%
LIQUID CAPACITY
28
day
Capacity/Storage time
672
hr
3354
flow rate
kg/hr
3689.4
Rated mass flow rate
kg/hr
506.8
Density
kg/m3
4892.022
m3
Rated Volume of liquid
1292335
gal
use vertical tanks on concrete foundation
Assumptions:
The storage for this chemical will be divided to 6 tanks, with 1 week storage time
each. It is assumed that the transaction time between the company and the provider
as well as delivery of the product will take 2 weeks. It is very important for
continuous production to have enough storage of feed.
Based on the rule of thumb of Chemical Engineering Design, if the rated volume
of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations
is typically used.
The choses material of construction is carbon steel since propylene is not corrosive.
ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry
for storage tanks.
Outage and Innage of the tank are assumed to be 500 . The outage is
the allowance for spillage, and the innage is the non-pumpable volume. The pump
should not be placed under the innage to avoid pump cavitation.
Based on the rule of thumb for Chemical Engineering Design, Optimum length to
diameter ratio for vessels is 3 ( = 3).
2
4892.022 3
(3 0.50 0.5) =
( )
4
6
221
= 7.133506 7200
= 3 = 3 7200 = 21600
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams like
propylene is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the
minimum thickness of the vessel, first is determine the maximum allowable stress (S)
which will be based on the type of material used. Using table 13.2 in Towler, the Maximum
allowable stress for carbon steel at 250 is 12.9ksi or 12900psi.
For cylindrical vessels:
=
(1)
2 1.2
(2)
4 + 0.8
Where:
= ( )
=
=
=
=
(1) =
199.0933 7200
= 66.08574
2 12900 0.85 1.2 199.0933
222
(2) =
199.0933 7200
= 32.56463
4 12900 0.85 + 0.8 199.0933
2 0.2
199.0933 7200
66
2 12900 0.85 0.2 199.0933
223
REV
1
CALCULATION SHEET
CREATED BY
CHECKED BY
EAM
ALL
MFS
DATE
1/2/15
APPROVED BY
C
F
Bar
psia
psig
psia
psig
C
93.33333
200
13.72321
199.0933
184.3933
0
-14.7
15 ~ 20
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Operating T
0 to 200 degF
Over 200 degF
Reactors
Design T
250 degF
operating + 50 degF
operating + 50 degF
224
Operating P
0 to 25 psig
25 to 250 psig
250 to 1000 psig
over 1000 psig
Design P
50 psig
operating + 25 psig
operating + 10%
operating + 5%
LIQUID CAPACITY
day
28
hr
672
flow rate
kg/hr
6248.8
kg/hr
6873.68
Density
kg/m3
872.2
m3
5295.933
gal
1399037
Capacity/Storage time
Assumptions:
The storage for this chemical will be divided to 6 tanks, with 1 week storage time
each. It is assumed that the transaction time between the company and the provider
as well as delivery of the product will take 2 weeks. It is very important for
continuous production to have enough storage of feed.
Based on the rule of thumb of Chemical Engineering Design, if the rated volume
of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations
is typically used.
The chosen material of construction is carbon steel since benzene is not corrosive.
ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry
for storage tanks.
Outage and Innage of the tank are assumed to be 500 . The outage is
the allowance for spillage, and the innage is the non-pumpable volume. The pump
should not be placed under the innage to avoid pump cavitation.
Based on the rule of thumb for Chemical Engineering Design, Optimum length to
diameter ratio for vessels is 3 ( = 3).
2
5295.933 3
(3 0.50 0.5) =
( )
4
6
= 7.321595 7400
= 3 = 3 7400 = 22200
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in
or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the
225
vessel, first is determine the maximum allowable stress (S) which will be based on the type
of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon
steel at 250 is 12.9ksi or 12900psi.
For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic
pressure can be calculated from the following equation:
=
+
2 103
Where:
= ,
= ,
= , /3
= ( )
= , 9.81 / 2
= , /2
= ,
=
1
872 (22200 500) (1000) 9.81
2 88.942369 0.85
7400
1000
+ 3.8 = 12.887
103
13
= 2 +
= 2 13 + 7400 = 7426
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
=
2 0.2
226
64.7 7400
22
2 12900 0.85 0.2 64.7
227
REV
1
DATE
1/2/15
CALCULATION SHEET
CREATED BY
CHECKED BY
EAM
ALL
MFS
APPROVED BY
Design T
250 degF
operating + 50 degF
operating + 50 degF
Operating P
0 to 25 psig
25 to 250 psig
250 to 1000 psig
over 1000 psig
LIQUID CAPACITY
Capacity/Storage time
day
228
Design P
50 psig
operating + 25 psig
operating + 10%
operating + 5%
hr
kg/hr
kg/hr
kg/m3
m3
gal
168
flow rate
4370
Rated mass flow rate
4807
Density
774.4
1042.841
Rated Volume of liquid
275489.4
use vertical tanks on concrete foundation
Assumptions:
The storage for this chemical will be divided to 3 tanks, with 1 week total storage
time.
Based on the rule of thumb of Chemical Engineering Design, if the rated volume
of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations
is typically used.
The choses material of construction is carbon steel since Acetone is not corrosive.
ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry
for storage tanks.
Outage and Innage of the tank are assumed to be 500 . The outage is
the allowance for spillage, and the innage is the non-pumpable volume. The pump
should not be placed under the innage to avoid pump cavitation.
Based on the rule of thumb for Chemical Engineering Design, Optimum length to
diameter ratio for vessels is 3 ( = 3).
2
1042.841 3
(3 0.50 0.5) =
( )
4
3
= 5.397469 5400
= 3 = 3 5400 = 16200
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams like
propylene is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the
minimum thickness of the vessel, first is determine the maximum allowable stress (S)
which will be based on the type of material used. Using table 13.2 in Towler, the Maximum
allowable stress for carbon steel at 250 is 12.9ksi or 12900psi.
For cylindrical vessels:
229
(1)
2 1.2
(2)
4 + 0.8
Where:
= ( )
=
=
=
=
(1) =
78.08393782 5400
= 19.30974
2 12900 0.85 1.2 78.08393782
(2) =
78.08393782 5400
= 9.599945
4 12900 0.85 + 0.8 78.08393782
2 0.2
78.08393782 5400
20
2 12900 0.85 0.2 78.08393782
230
REV
1
DATE
1/2/15
CALCULATION SHEET
CREATED BY
CHECKED BY
EAM
ALL
MFS
APPROVED BY
Design T
250 degF
operating + 50 degF
operating + 50 degF
Operating P
0 to 25 psig
25 to 250 psig
250 to 1000 psig
over 1000 psig
LIQUID CAPACITY
Capacity/Storage time
day
231
Design P
50 psig
operating + 25 psig
operating + 10%
operating + 5%
hr
kg/hr
kg/hr
kg/m3
m3
gal
24
flow rate
4370
Rated mass flow rate
4807
Density
774.4
148.9773
Rated Volume of liquid
39355.62
use vertical tanks on concrete foundation
Assumptions:
The storage for this chemical will be divided to 3 tanks, with 1 day total storage
time.
Based on the rule of thumb of Chemical Engineering Design, if the rated volume
of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations
is typically used.
The choses material of construction is carbon steel since Acetone is not corrosive.
ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry
for storage tanks.
Outage and Innage of the tank are assumed to be 500 . The outage is
the allowance for spillage, and the innage is the non-pumpable volume. The pump
should not be placed under the innage to avoid pump cavitation.
Based on the rule of thumb for Chemical Engineering Design, Optimum length to
diameter ratio for vessels is 3 ( = 3).
2
148.9773 3
(3 0.50 0.5) =
( )
4
3
= 2.877947 2900
= 3 = 3 2900 = 8700
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams like
propylene is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the
minimum thickness of the vessel, first is determine the maximum allowable stress (S)
which will be based on the type of material used. Using table 13.2 in Towler, the Maximum
allowable stress for carbon steel at 250 is 12.9ksi or 12900psi.
For cylindrical vessels:
232
(1)
2 1.2
(2)
4 + 0.8
Where:
= ( )
=
=
=
=
(1) =
78.08393782 2900
= 10.37005
2 12900 0.85 1.2 78.08393782
(2) =
78.08393782 2900
= 5.155526
4 12900 0.85 + 0.8 78.08393782
2 0.2
78.08393782 2900
11
2 12900 0.85 0.2 78.08393782
233
REV
1
DATE
1/2/15
CALCULATION SHEET
CREATED BY
CHECKED BY
EAM
ALL
MFS
APPROVED BY
If TVP (true vapor pressure) of the chemical is greater than 90 (), then use a pressure
vessel for the storage tank, otherwise use an atmospheric vessel for the storage tank.
DESIGN CONDITIONS
T
P (MAWP)
minimum P
minimum design metal temperature
C
F
Bar
psia
psig
psia
psig
C
93.33333
200
5.482214
79.53472
64.83472
0
-14.7
15 ~ 20
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Operating T
0 to 200 degF
Over 200 degF
Reactors
Design T
250 degF
operating + 50 degF
operating + 50 degF
234
Operating P
0 to 25 psig
25 to 250 psig
250 to 1000 psig
over 1000 psig
Design P
50 psig
operating + 25 psig
operating + 10%
operating + 5%
LIQUID CAPACITY
day
Capacity/Storage time
hr
flow rate
kg/hr
Rated mass flow rate
kg/hr
Density
kg/m3
m3
Rated Volume of liquid
gal
1
24
7071
7778.1
1050
177.7851
46965.86
use vertical tanks on concrete foundation
Assumptions:
The storage for this chemical will be divided to 3 tanks, with 1 day total storage
time.
Based on the rule of thumb of Chemical Engineering Design, if the rated volume
of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations
is typically used.
The choses material of construction is carbon steel since Acetone is not corrosive.
ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry
for storage tanks.
Outage and Innage of the tank are assumed to be 500 . The outage is
the allowance for spillage, and the innage is the non-pumpable volume. The pump
should not be placed under the innage to avoid pump cavitation.
Based on the rule of thumb for Chemical Engineering Design, Optimum length to
diameter ratio for vessels is 3 ( = 3).
2
177.7851 3
(3 0.50 0.5) =
( )
4
3
= 3.045342 3100
= 3 = 3 3100 = 9300
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in
or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the
vessel, first is determine the maximum allowable stress (S) which will be based on the type
of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon
steel at 250 is 12.9ksi or 12900psi.
235
For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic
pressure can be calculated from the following equation:
=
+
2 103
Where:
= ,
= ,
= , /3
= ( )
= , 9.81 / 2
= , /2
= ,
=
1
1050 (9300 500) (1000) 9.81
2 88.942369 0.85
3100
1000
+ 3.8 = 5.658425
103
6
= 2 +
= 2 6 + 5800 = 3112
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
=
2 0.2
79.53 3100
12
2 12900 0.85 0.2 79.53
236
REV
1
DATE
1/2/15
CALCULATION SHEET
CREATED BY
CHECKED BY
EAM
ALL
MFS
APPROVED BY
T
P (MAWP)
minimum P
minimum design metal temperature
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Operating T
0 to 200 degF
Over 200 degF
Reactors
Design T
250 degF
operating + 50 degF
operating + 50 degF
Operating P
0 to 25 psig
25 to 250 psig
250 to 1000 psig
over 1000 psig
Design P
50 psig
operating + 25 psig
operating + 10%
operating + 5%
LIQUID CAPACITY
Capacity/Storage time
237
day
hr
0.5
flow rate
kg/hr
1.06E+06
kg/hr
1161340
Density
kg/m3
819.4
m3
708.6529
gal
187206.3
+
2 103
238
Where:
= ,
= ,
= , /3
= ( )
= , 9.81 / 2
= , /2
= ,
=
1
819.4 (5500 500) (1000) 9.81
2 88.942369 0.85
5500
1000
+ 3.8 = 8.47
103
9
= 2 +
= 2 9 + 5500 = 5518
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
=
2 0.2
64.7 5500
17
2 12900 0.85 0.2 64.7
239
REV
1
DATE
1/2/15
CALCULATION SHEET
CREATED BY
CHECKED BY
EAM
ALL
MFS
APPROVED BY
C 93.33333
200
F
Bar 4.459679
64.7
psia
50
psig
0
psia
-14.7
psig
15 ~ 20
C
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Operating T
0 to 200 degF
Over 200 degF
Reactors
Design T
250 degF
operating + 50 degF
operating + 50 degF
Operating P
0 to 25 psig
25 to 250 psig
250 to 1000 psig
over 1000 psig
LIQUID CAPACITY
min
Liquid holdup time
hr
flow rate
kg/hr
240
Design P
50 psig
operating + 25 psig
operating + 10%
operating + 5%
5
0.083333
1.43E+06
kg/hr
kg/m3
m3
gal
1568930
819.4
159.5609
42151.51
The outage and innage of the tank is assumed to be 500 millimeters. The outage is the
allowance for spillage, and the innage is the non-pumpable volume. The pump should not
be placed under the innage to avoid pump cavitation.
1/3
4
= ( 159.5609 2)
3
5200
= 3 = 3 5200 = 15600
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in
or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the
vessel, first is determine the maximum allowable stress (S) which will be based on the type
of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon
steel at 250 is 12.9ksi or 12900psi.
For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic
pressure can be calculated from the following equation:
=
+
2 103
Where:
= ,
= ,
= , /3
241
= ( )
= , 9.81 / 2
= , /2
= ,
=
1
819.4 (5200 500) (1000) 9.81
2 88.942369 0.85
5200
1000
+ 3.8 = 3.80
103
4
= 2 +
= 2 4 + 5200 = 5208
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
=
2 0.2
64.7 5200
16
2 12900 0.85 0.2 64.7
242
REV
1
DATE
1/2/15
CALCULATION
CREATED BY
CHECKED BY
EAM
ALL
MFS
APPROVED BY
DESIGN CONDITIONS
T
P (MAWP)
minimum P
minimum design metal temperature
C
F
Bar
psia
psig
psia
psig
C
93.33333
200
5.423214
78.67876
63.97876
0
-14.7
15 ~ 20
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Design Temperature and Design Pressure
Operating T
0 to 200 degF
Over 200 degF
Reactors
Design T
250 degF
operating + 50 degF
operating + 50 degF
Operating P
0 to 25 psig
25 to 250 psig
250 to 1000 psig
over 1000 psig
LIQUID CAPACITY
min
Capacity/Storage time
hr
243
Design P
50 psig
operating + 25 psig
operating + 10%
operating + 5%
5
0.083333
flow rate
Rated mass flow rate
Density
Rated Volume of liquid
kg/hr
kg/hr
kg/m3
m3
gal
5.59E+03
6153.4
700.5
0.732025
193.3804
The outage and innage of the tank is assumed to be 500 millimeters. The outage is the
allowance for spillage, and the innage is the non-pumpable volume. The pump should not
be placed under the innage to avoid pump cavitation.
1/3
4
= ( 0.732025 2)
3
900
= 3 = 3 900 = 2700
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams like
propylene is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the
minimum thickness of the vessel, first is determine the maximum allowable stress (S)
which will be based on the type of material used. Using table 13.2 in Towler, the Maximum
allowable stress for carbon steel at 250 is 12.9ksi or 12900psi.
For cylindrical vessels:
=
(1)
2 1.2
(2)
4 + 0.8
244
Where:
= ( )
=
=
=
=
(1) =
78.67876 900
= 3.242912
2 12900 0.85 1.2 78.67876
(2) =
78.67876 900
= 1.612162
4 12900 0.85 + 0.8 78.67876
2 0.2
78.67876 900
4
2 12900 0.85 0.2 78.67876
245
REV
1
DATE
1/2/15
CALCULATION
CREATED BY
CHECKED BY
EAM
ALL
MFS
APPROVED BY
OPERATING CONDITIONS
151.9
C
T
305.42
F
1.013
Bar
P
psia 14.69637
psig -0.00363
psia 2.07E-01
true VP and Reid VP at 37.8 C
1.427
kPaa
(100F)
Atmospheric
Type of Vessel
vessel
DESIGN CONDITIONS
C 179.6778
355.42
F
Bar 4.459679
64.7
psia
50
psig
0
psia
-14.7
psig
15 ~ 20
C
T
P (MAWP)
minimum P
minimum design metal temperature
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Operating T
0 to 200 degF
Over 200 degF
Reactors
Design T
250 degF
operating + 50 degF
operating + 50 degF
Operating P
0 to 25 psig
25 to 250 psig
250 to 1000 psig
over 1000 psig
Design P
50 psig
operating + 25 psig
operating + 10%
operating + 5%
LIQUID CAPACITY
Capacity/Storage time
246
min
hr
0.083333
flow rate
kg/hr
6.80E+04
kg/hr
74822
Density
kg/m3
758.4
m3
Rated Volume of liquid
8.221475
gal
2171.884
The outage and innage of the tank is assumed to be 500 millimeters. The outage is the
allowance for spillage, and the innage is the non-pumpable volume. The pump should not
be placed under the innage to avoid pump cavitation.
1/3
4
= ( 8.221475 2)
3
2000
= 3 = 3 2000 = 6000
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in
or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the
vessel, first is determine the maximum allowable stress (S) which will be based on the type
of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon
steel at 250 is 12.9ksi or 12900psi.
For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic
pressure can be calculated from the following equation:
=
+
2 103
Where:
= ,
247
= ,
= , /3
= ( )
= , 9.81 / 2
= , /2
= ,
=
1
758.4 (2000 500) (1000) 9.81
2 88.942369 0.85
2000
1000
+ 3.8 = 4
103
4
= 2 +
= 2 4 + 2000 = 2008
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
=
=
2 0.2
64.7 2000
6
2 12900 0.85 0.2 64.7
248
REV
1
DATE
1/2/15
CALCULATION
CREATED BY
CHECKED BY
EAM
ALL
MFS
APPROVED BY
DESIGN CONDITIONS
C 179.6778
355.42
F
Bar 4.459679
64.7
psia
50
psig
0
psia
-14.7
psig
15 ~ 20
C
T
P (MAWP)
minimum P
minimum design metal temperature
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Operating T
0 to 200 degF
Over 200 degF
Reactors
Design T
250 degF
operating + 50 degF
operating + 50 degF
Operating P
0 to 25 psig
25 to 250 psig
250 to 1000 psig
over 1000 psig
Design P
50 psig
operating + 25 psig
operating + 10%
operating + 5%
LIQUID CAPACITY
Capacity/Storage time
249
day
hr
flow rate
kg/hr
1.25E+04
kg/hr
13750
Density
kg/m3
758.4
m3
18.13027
gal
4789.511
The outage and innage of the tank is assumed to be 500 millimeters. The outage is the
allowance for spillage, and the innage is the non-pumpable volume. The pump should not
be placed under the innage to avoid pump cavitation.
The optimum Length to diameter ratio for vessels is 3. The volume is divided in 2, since it
is a liquid holdup tank.
2
18.13027 3
(3 0.50 0.5) =
( )
4
1
= 2.091816 2100
= 3 = 3 2100 = 6300
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in
or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the
vessel, first is determine the maximum allowable stress (S) which will be based on the type
of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon
steel at 250 is 12.9ksi or 12900psi.
For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic
pressure can be calculated from the following equation:
=
+
2 103
250
Where:
= ,
= ,
= , /3
= ( )
= , 9.81 / 2
= , /2
= ,
=
1
758.4 (6300 500) (1000) 9.81
2 88.942369 0.85
2100
1000
+ 3.8 = 5
103
5
= 2 +
= 2 5 + 2100 = 5
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
=
=
2 0.2
64.7 2100
7
2 12900 0.85 0.2 64.7
251
REV
1
DATE
1/2/15
CALCULATION SHEET
CREATED BY
CHECKED BY
EAM
ALL
MFS
APPROVED BY
Service: Water
OPERATING CONDITIONS
C
30
T
F
86
Bar
1
P
psia
14.50777
psig
-0.19223
psia
9.49E-01
true VP and Reid VP at 37.8 C
kPaa
6.545
(100F)
Atmospheric
Type of Vessel
vessel
DESIGN CONDITIONS
T
P (MAWP)
minimum P
minimum design metal temperature
C 93.33333
F
200
Bar 4.459679
psia
64.7
psig
50
psia
0
psig
-14.7
C
15 ~ 20
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Operating T
0 to 200 degF
Over 200 degF
Reactors
Design T
250 degF
operating + 50 degF
operating + 50 degF
252
Operating P
0 to 25 psig
25 to 250 psig
250 to 1000 psig
Design P
50 psig
operating + 25 psig
operating + 10%
operating + 5%
1
24
6100.649
6710.714
1000
161.0571
42546.78
use vertical tanks on concrete foundation
Assumptions:
Based on the rule of thumb of Chemical Engineering Design, if the rated volume
of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations
is typically used.
The chosen material of construction is carbon steel since water is not corrosive.
ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry
for storage tanks.
Outage and Innage of the tank are assumed to be 500 . The outage is
the allowance for spillage, and the innage is the non-pumpable volume. The pump
should not be placed under the innage to avoid pump cavitation.
Based on the rule of thumb for Chemical Engineering Design, Optimum length to
diameter ratio for vessels is 3 ( = 3).
2
161.0571 3
(3 0.50 0.5) =
( )
4
1
= 4.2029 4300
= 3 = 3 4300 = 12900
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in
or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the
vessel, first is determine the maximum allowable stress (S) which will be based on the type
of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon
steel at 250 is 12.9ksi or 12900psi.
253
For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic
pressure can be calculated from the following equation:
=
+
2 103
Where:
= ,
= ,
= , /3
= ( )
= , 9.81 / 2
= , /2
= ,
=
1
1000 (12900 500) (1000) 9.81
2 88.942369 0.85
4300
1000
+ 3.8 = 7.259
103
8
= 2 +
= 2 8 + 4300 = 4316
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
=
=
2 0.2
64.7 4300
13
2 12900 0.85 0.2 64.7
254
REV
1
DATE
1/2/15
CALCULATION SHEET
CREATED BY
CHECKED BY
EAM
ALL
MFS
APPROVED BY
P (MAWP)
minimum P
minimum design metal temperature
93.33333
200
12.52321
181.6839
166.9839
0
-14.7
15 ~ 20
LIQUID CAPACITY
day
hr
m3/hr
m3/hr
m3
gal
Capacity/Storage time
Volumetric Flow Rate
Rated Volumetric Flow Rate
Rated Volume of liquid
45
1080
2.71
2.981
3219.48
850496.5
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Operating T
Design T
Operating P
255
Design P
0 to 200 degF
Over 200 degF
Reactors
250 degF
operating + 50 degF
operating + 50 degF
0 to 25 psig
25 to 250 psig
250 to 1000 psig
over 1000 psig
50 psig
operating + 25 psig
operating + 10%
operating + 5%
Assumptions:
The storage for the fuel will be 45 days (1 2 ), since the company
plans to buy fuel only on days that the price is ideally low. The capacity of the fuel
tank is enough for this to be possible. The storage tank is divided into 4.
Based on the rule of thumb of Chemical Engineering Design, if the rated volume
of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations
is typically used.
ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry
for storage tanks.
Outage and Innage of the tank are assumed to be 500 . The outage is
the allowance for spillage, and the innage is the non-pumpable volume. The pump
should not be placed under the innage to avoid pump cavitation.
Based on the rule of thumb for Chemical Engineering Design, Optimum length to
diameter ratio for vessels is 3 ( = 3).
2
3219.48 3
(3 0.50 0.5) =
( )
4
4
= 7.103344 7200
= 3 = 3 7200 = 21600
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams like
propylene is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the
minimum thickness of the vessel, first is determine the maximum allowable stress (S)
which will be based on the type of material used. Using table 13.2 in Towler, the Maximum
allowable stress for carbon steel at 250 is 12.9ksi or 12900psi.
For cylindrical vessels:
=
(1)
2 1.2
(2)
4 + 0.8
256
Where:
= ( )
=
=
=
=
(1) =
181.68 7200
= 60.24897
2 12900 0.85 1.2 64.7
(2) =
181.68 7200
= 29.72649
4 12900 0.85 + 0.8 64.7
2 0.2
181.68 7200
65
2 12900 0.85 0.2 64.7
257
Appendix C
REACTORS CALCULATION SHEETS
REV
1
DATE
1/2/15
CALCULATION
CREATED BY
CHECKED BY
EAM
ALL
MFS
LEGEND:
= , 2
= ,
= ,
= , 3
= , 3
=
= , /
= , /2
= , /2
= ,
= , 2
= , /
= ,
= ,
DATA FROM ASPEN HYSYS
Total Volume (m3)
113.3
Number of tubes
1000
Length (m)
10
Diameter of tube (m)
0.1201
Void Fraction
0.7
Void Volume (m3)
79.3
Ac (m2)
0.011328591
APPROVED BY
G (kg/m2s)
h (W/m2K)
Square Pitch Size (mm)
Minimum Area Required
(m2)
Baffle Spacing
Shell Diameter Required
(m)
Baffle Spacing (m)
As (m2)
Heat Evolved in the
reaction (kW)
28903.69239
636025.5239
100
()
27.28
66676.29231
10
1/5 of dt
3.908820095
0.781764019
0.305577491
2114
TUBE SPECIFICATIONS
Material
Carbon Steel
4.728346457
TUBE I.D. (in)
4.813
TUBE O.D. (in)
5.563
Nominal Pipe Size (in)
5
Schedule No.
80XS, 80S
Wall Thickness (in)
0.375
Cross Sectional Area (in2)
6.11
= (0.1201)2 = 0.011328591 2
4
=
=
= 113.3 79.3 = 343
= ( )
= (1 0.7)(700)(34) = 7140
=
.
1.1 297.6710076 /
=
= 28903.69239 2
2
0.011328591
259
. . 15.1 28903.692390.95
=
=
= 636025.5239 2
.
0.42
0.1201
(1) :
= 100
= ( ) (# )
100 2
= (
) (1000) = 10 2
1000
( + . ) .
= (
)
10 (1 + 0.2) 0.5
= (
) = 3.908820095
4
=
1
= 3.908820095 = 0.781764019
.
.
3.908820095 0.781764019
=
0.01 = 0.305577491 2
0.1
=
2114 /
3600
=
= 66676.29231
4.184 27.28
260
REV
1
DATE
1/2/15
CALCULATION
CREATED BY
CHECKED BY
MFS
ALL
EAM
LEGEND:
= , 2
= ,
= ,
= , 3
= , 3
=
= , /
= , /2
= , /2
= ,
= , 2
= , /
= ,
= ,
DATA FROM ASPEN HYSYS
Total Volume (m3)
25.02
Number of tubes
100
Length (m)
10
Diameter of tube (m)
0.1785
Void Fraction
0.7
Void Volume (m3)
17.51
0.025024553
Ac (m2)
CATALYST BED SPECIFICATIONS
Volume of Catalyst bed
7.51
(m3)
0.00118
( 3 )
dp (m)
0.00002
0.00265854
Mass of catalyst (kg)
HEAT TRANSFER CALCULATIONS IN THE REACTOR
5.957000989
Mass flow (kg/s)
261.8508784
G (kg/m2s)
6172.20338
h (W/m2K)
Square Pitch Size (mm)
100
Minimum Area Required
1
(m2)
261
APPROVED BY
Baffle Spacing
Shell Diameter Required
(m)
Baffle Spacing (m)
As (m2)
Heat Evolved in the
reaction (kW)
1/5 of dt
1.236077446
0.247215489
0.305577491
5154
()
27.28
162558.9454
TUBE SPECIFICATIONS
Material
Carbon Steel
7.027559055
TUBE I.D. (in)
7.187
TUBE O.D. (in)
8.625
Nominal Pipe Size (in)
8
Schedule No.
120
Wall Thickness (in)
0.719
Cross Sectional Area (in2)
17.86
= (0.1785)2 = 0.025024553 2
4
=
=
= 25.02 17.51 = 7.51 3
= ( )
= (1 0.7)(7.51)(0.00118) = 2.65854
=
.
1.1 5.957000989 /
=
=
261.85087
0.025024553 2
2
. . 15.1 28903.692390.95
=
= 6172.203192 2
.
0.42
0.1201
262
(1) :
= 100
= ( ) (# )
100 2
= (
) (100) = 1 2
1000
( + . ) .
= (
)
1 (1 + 0.2) 0.5
= (
) = 1.236077446
4
=
1
= 1.236077446 = 0.2472154892
.
.
1.236077446 0.247215489
=
0.01 = 0.03055774903 2
0.1
=
2114 /
3600
=
= 162558.9454
4.184
27.28
263
REV
1
DATE
1/2/15
CALCULATION
CREATED BY
CHECKED BY
EAM
ALL
MFS
Legend:
= ,
= , 3
= , 3
= ,
= ,
= , /
= , 3
= ,
= , 2
=
= , ( )
= , 3
= ,
= , /
= , /
= , /
=
= , /
= ,
= ,
=
264
APPROVED BY
REACTOR VESSEL
Residence time (h)
(
V (m3)
D (m)
Reactor L (m)
u (m/s)
Height of Fluid (m)
4
25.278
101.112
4
12
0.000558766
9
CATALYST INFORMATION
( 3 )
790
diameter (m)
Ac (cm2)
1.40E-07
1.54E-10
0.8
0.1
1.256637061
(. )
2.15E-05
(/ 3 )
1.597
(Pa)
154.6318456
198.5486557
4.33E-08
( )
1.20404E-07
( )
3.92E-07
STATUS
PASSED
0.490948231
(m/s)
0.001390645
()
2.44E-05
Type of plate
0 ()
Porous
1.17376E-05
0.401772564
=
= 4 25.278 = 101.112 3
265
=(
/
1/3
4
)
= ( 101.112) = 4
= = 3 4 = 12
25.278/3600
=
=
= 0.000558766 /
= (1.40 7)2 = 1.54 10
4
= 42 0.1 = 1.256637061 3
4
= ( ) ( )
= 0.1 (790 1.597) (1 0.8) 9.80665 = 154.6318456
= ( )
= (1 0.8) 790 1.256637061 = 198.5486557
( )
[( )]
2
(0.6 1.40 7)
0.83
[9.80665(790 1.597)]
=
= 4.33 8 /
150 2.15 5
1 0.8
( )
( )
< < ,
266
. /
)
= + (. )( )/
= 0.000558766 (4.33 8) + (0.71)(9.80665 (1.40
= 0.001390645 /
1
7))2
= . [ ( )].
= 0.652[(1.54 10)(0.000558766 (4.33 08)) 100]0.4
= 2.44 05
= . ( )
= 0.00376((0.000558766 (4.33 08)) 100)2
=
267
REV
1
DATE
1/2/15
CALCULATION
CREATED BY
CHECKED BY
EAM
ALL
MFS
Legend:
= ,
= , 3
= , 3
= ,
= ,
= , /
= , 3
= ,
= , 2
=
= , ( )
= , 3
= ,
= , /
= , /
= , /
=
= , /
= ,
= ,
=
268
APPROVED BY
REACTOR VESSEL
Residence time (h)
(
V (m3)
D (m)
Reactor L (m)
u (m/s)
Height of Fluid (m)
4
24.54308240
98.17203297
4
12
0.00054252
8
CATALYST INFORMATION
( 3 )
790
diameter (m)
Ac (cm2)
1.40E-07
1.54E-10
0.8
0.1
1.256637061
(. )
2.15E-05
(/ 3 )
1.597
(Pa)
154.6318456
198.5486557
4.33E-08
( )
1.20404E-07
( )
3.92E-07
STATUS
PASSED
0.490948231
(m/s)
0.001374398
()
2.42E-05
Type of plate
0 ()
Porous
1.10649E-05
0.394700865
=
269
= 4 24.54300824 = 98.17203296 3
/
1/3
4
= ( )
= ( 98.17203297) = 4
= = 3 4 = 12
24.54300824/3600
=
=
= 0.0005425195944 /
= (1.40 7)2 = 1.54 10
4
= 42 0.1 = 1.256637061 3
4
= ( ) ( )
= 0.1 (790 1.597) (1 0.8) 9.80665 = 154.6318456
= ( )
= (1 0.8) 790 1.256637061 = 198.5486557
( )
=
[( )]
( )
=
. /
)
= + (. )( )/
= 0.000542519594 (4.33 8) + (0.71)(9.80665 (1.40
= 0.001374398 /
1
7))2
= . [ ( )].
= 0.652[(1.54 10)(0.000542519594 (4.33 08)) 100]0.4
= 2.42 05
= . ( )
= 0.00376((0.000542519594 (4.33 08)) 100)2
= 1.106494791 09
=
271
REV
1
CALCULATION
CREATED BY
CHECKED BY
EAM
ALL
MFS
DATE
1/2/15
Legend:
= ,
= , 3
= , 3
= ,
= ,
= , /
= , 3
= ,
= , 2
=
= , ( )
= , 3
= ,
= , /
= , /
= , /
=
= , /
= ,
= ,
=
REACTOR VESSEL
Residence time (h)
(
V (m3)
D (m)
Reactor L (m)
u (m/s)
Height of Fluid (m)
4
21.66297478
86.6518991
4
12
0.000478857
7
CATALYST INFORMATION
( 3 )
790
272
APPROVED BY
diameter (m)
Ac (cm2)
1.40E-07
1.54E-10
0.8
0.1
1.256637061
(. )
2.15E-05
(/ 3 )
1.597
(Pa)
154.6318456
198.5486557
4.33E-08
( )
1.20404E-07
( )
3.92E-07
STATUS
PASSED
0.490948231
(m/s)
0.001310736
()
2.44E-05
Type of plate
0 ()
Porous
8.62027-06
0.365301355
=
= 4 21.66297478 = 86.6518991 3
=(
/
1/3
4
)
= ( 86.6518991) = 4
= = 3 4 = 12
21.66297478/3600
=
=
= 0.0004788568775 /
= (1.40 7)2 = 1.54 10
4
273
= 42 0.1 = 1.256637061 3
4
= ( ) ( )
= 0.1 (790 1.597) (1 0.8) 9.80665 = 154.6318456
= ( )
= (1 0.8) 790 1.256637061 = 198.5486557
( )
[( )]
2
(0.6 1.40 7)
0.83
[9.80665(790 1.597)]
=
= 4.33 8 /
150 2.15 5
1 0.8
( )
=
. /
= (
)
= . [ ( )].
= 0.652[(1.54 10)(0.000478857 (4.33 08)) 100]0.4
= 2.297854424 05
= . ( )
= 0.00376((0.000478857 (4.33 08)) 100)2 = 8.62027223 06
275
REV
1
DATE
1/2/15
CALCULATION
CREATED BY
CHECKED BY
EAM
ALL
MFS
Legend:
= ,
= , 3
= , 3
= ,
= ,
= , /
= , 3
= ,
= , 2
=
= , ( )
= , 3
= ,
= , /
= , /
= , /
=
= , /
= ,
= ,
=
276
APPROVED BY
REACTOR VESSEL
Residence time (h)
(
V (m3)
D (m)
Reactor L (m)
u (m/s)
Height of Fluid (m)
4
21.05481201
84.21924804
4
12
0.000465414
7
CATALYST INFORMATION
( 3 )
790
diameter (m)
Ac (cm2)
1.40E-07
1.54E-10
0.8
0.1
1.256637061
(. )
2.15E-05
(/ 3 )
1.597
(Pa)
154.6318456
198.5486557
4.33E-08
( )
1.20404E-07
( )
3.92E-07
STATUS
PASSED
0.490948231
(m/s)
0.001297292
()
2.27E-05
Type of plate
0 ()
Porous
8.14301-06
0.358724213
=
= 4 21.05481201 = 84.21924804 3
277
=(
/
1/3
4
)
= ( 84.21924804) = 4
= = 3 4 = 12
21.05481201/3600
=
=
= 0.000465414 /
= (1.40 7)2 = 1.54 10
4
= 42 0.1 = 1.256637061 3
4
= ( ) ( )
= 0.1 (790 1.597) (1 0.8) 9.80665 = 154.6318456
= ( )
= (1 0.8) 790 1.256637061 = 198.5486557
( )
[( )]
2
(0.6 1.40 7)
0.83
[9.80665(790 1.597)]
=
= 4.33 8 /
150 2.15 5
1 0.8
( )
( )
< < ,
278
. /
)
= + (. )( )/
= 0.000465414 (4.33 8) + (0.71)(9.80665 (1.40
= 0.001297292 /
1
7))2
= . [ ( )].
= 0.652[(1.54 10)(0.000465414 (4.33 08)) 100]0.4
= 2.27 05
= . ( )
= 0.00376((0.000465414 (4.33 08)) 100)2 = 8.14301 06
=
279
Appendix D
DISTILLATION COLUMNS CALCULATION SHEETS
REV
1
DATE
1/2/15
CALCULATION
CREATED BY
CHECKED BY
EAM
ALL
MFS
APPROVED BY
VAPOR
TRAY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
TRAY
Mole flow
kmol/h
kmol/s
18330
5.091667
18500
5.138889
18500
5.138889
18500
5.138889
18490
5.136111
18490
5.136111
18480
5.133333
18480
5.133333
18470
5.130556
18470
5.130556
18460
5.127778
12040
3.344444
12050
3.347222
12060
3.35
12060
3.35
12060
3.35
12060
3.35
12060
3.35
12060
3.35
12040
3.344444
11870
3.297222
10460
2.905556
8872
2.464444
9413
2.614722
9841
2.733611
9940
2.761111
9958
2.766111
Mass Rate
kg/h
kg/s
1426408
396.2244
1440915
400.2542
1440845
400.2348
1440652
400.181
1440455
400.1265
1440258
400.0716
1440058
400.0161
1439856
399.96
1439650
399.9029
1439440
399.8444
1439222
399.784
941574.2
261.5484
942553.4
261.8204
942676.9
261.8547
942769.9
261.8805
942861.1
261.9059
942951.5
261.931
943035.5
261.9543
943086.7
261.9685
942890.6
261.9141
937918.6
260.5329
893579.4
248.2165
939337.1
260.927
1102676
306.299
1177582
327.1062
1193788
331.6078
1196744
332.4288
LIQUID
280
Vol Rate
m3/h
516004.5
519853
518852.8
517814.2
516777.1
515741.5
514706.8
513672.4
512637.2
511599.9
510558.6
332641.8
332358.5
331801.6
331236.9
330673.4
330110.5
329540.6
328929.7
328104.8
325842.2
306986.9
281593.3
305734.7
320596
323502
323575.7
Density
kg/m3
2.764332
2.771774
2.776983
2.782179
2.787382
2.792596
2.797822
2.803063
2.808322
2.813605
2.818917
2.830595
2.835954
2.841086
2.846211
2.851336
2.856473
2.861667
2.867137
2.873749
2.878444
2.910806
3.335794
3.606644
3.673105
3.690203
3.698496
Mole flow
kmol/
h
1
4849
4847
4843
4840
4836
4831
4827
4822
4817
10
4811
11
12
13
14
15
16
17
18
19
20
21
1.21E
+04
1.21E
+04
1.21E
+04
1.21E
+04
1.21E
+04
1.21E
+04
1.21E
+04
1.21E
+04
1.21E
+04
1.20E
+04
1.05E
+04
Mass Rate
Vol
Rate
Density
Surface
Tension
kg/m3
dyne/cm
811.6506
20.8
811.5178
20.8
811.4453
20.8
811.3741
20.8
811.3036
20.8
811.2341
20.8
811.1658
20.8
811.0989
20.7
811.0339
20.7
810.9712
20.7
810.9133
20.7
810.6797
20.7
810.5885
20.7
810.5128
20.7
810.4378
20.7
810.3631
20.7
810.2895
20.6
810.2209
20.6
810.1769
20.6
810.2793
20.6
811.2073
20.5
kmol/s
kg/h
kg/s
m3/h
1.3469
44
1.3463
89
1.3452
78
1.3444
44
1.3433
33
1.3419
44
1.3408
33
1.3394
44
1.3380
56
1.3363
89
3.3666
67
3.3694
44
3.3722
22
3.3722
22
3.3722
22
3.3722
22
3.3722
22
3.3722
22
3.3666
67
3.3194
44
2.9277
78
37880
9.7
37873
9.8
37854
6.1
37834
9.8
37815
2.1
37795
2.5
37775
0.4
37754
4.9
37733
4.4
37711
6.8
95108
4.6
95206
3.8
95218
7.3
95228
0.4
95237
1.5
95246
1.9
95254
5.9
95259
7.1
95240
1
94742
9
90308
9.8
105.224
9
105.205
5
105.151
7
105.097
2
105.042
3
104.986
8
104.930
7
104.873
6
104.815
1
104.754
7
264.190
2
264.462
2
264.496
5
264.522
3
264.547
6
264.572
8
264.596
1
264.610
3
264.555
8
263.174
7
250.858
3
466.715
2
466.705
5
466.508
4
466.307
5
466.104
3
465.898
2
465.688
3
465.473
3
465.251
2
465.018
8
1172.85
6
1174.40
2
1174.68
6
1174.91
1
1175.13
2
1175.35
2
1175.56
3
1175.72
5
1175.54
7
1169.26
2
1113.26
6
281
22
8951
23
9492
24
9920
25
26
27
1.00E
+04
1.00E
+04
9844
2.4863
89
2.6366
67
2.7555
56
2.7833
33
2.7888
89
2.7344
44
94884
7.5
11121
87
11870
93
12032
98
12062
54
11831
50
263.568
8
308.940
8
329.748
334.249
5
335.070
6
328.652
9
1204.50
7
1475.75
2
1598.41
8
1625.00
6
1629.94
7
1599.04
3
787.7476
18.6
753.6406
16.1
742.6672
15.3
740.4884
15.1
740.0571
15.1
739.9114
15.1
FLV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
0.015498
0.015361
0.015369
0.015379
0.015388
0.015397
0.015406
0.015414
0.015423
0.015432
0.038962
0.059748
0.059754
0.059809
0.059865
0.059922
0.059978
0.060033
0.060076
0.05984
0.057356
0.064547
0.078772
0.075022
0.071968
0.071352
0.069897
0.13
0.13
0.13
0.13
0.13
0.13
0.13
0.13
0.13
0.13
0.14
0.12
0.12
0.12
0.12
0.12
0.12
0.12
0.12
0.12
0.115
0.125
0.115
0.11
0.11
0.11
0.11
0.131023749
0.131023749
0.131023749
0.131023749
0.131023749
0.131023749
0.131023749
0.130897521
0.130897521
0.130897521
0.140966561
0.120828481
0.120828481
0.120828481
0.120828481
0.120828481
0.120711512
0.120711512
0.120711512
0.120711512
0.115569335
0.123198835
0.110117671
0.104261741
0.103987725
0.103987725
0.103987725
282
()
2.241293072
2.238088186
2.235880711
2.233686444
2.231496069
2.229309033
2.227124756
2.222799031
2.220620053
2.218441184
2.386744898
2.041246954
2.03919572
2.037250936
2.03531525
2.033384669
2.029489979
2.027554414
2.025557372
2.023346131
1.936679592
2.022971011
1.65149126
1.492496605
1.472803274
1.468940064
1.467138741
1.905099111
1.902374958
1.900498604
1.898633477
1.896771658
1.894912678
1.893056043
1.889379176
1.887527045
1.885675006
2.028733163
1.735059911
1.733316362
1.731663295
1.730017963
1.728376969
1.725066482
1.723421252
1.721723766
1.719844211
1.646177654
1.719525359
1.403767571
1.268622114
1.251882783
1.248599055
1.24706793
TRAY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
()
157.6680381
158.8439865
158.5383449
158.2210005
157.9041107
157.587675
157.2715292
156.9554532
156.6391507
156.3221946
156.0040071
101.6405367
101.5539838
101.3838101
101.2112729
101.0391093
100.8670884
100.6929506
100.5063116
100.2542358
99.56290608
93.80155737
86.04238696
93.4189498
97.95987487
98.84782498
98.87035813
( )
( )
70.34690823
70.97306867
70.90644155
70.83402462
70.76154556
70.68902188
70.61639846
70.61162574
70.53847439
70.46488128
65.36266496
49.79335622
49.80099888
49.76500847
49.72756575
49.6901107
49.70070778
49.66226797
49.61908907
49.5487323
51.40907483
46.36821628
52.09981369
62.59240354
66.512532
67.29193886
67.38991711
79.93967
80.65121
80.5755
80.49321
80.41085
80.32843
80.24591
80.24048
80.15736
80.07373
74.27576
56.58336
56.59204
56.55115
56.5086
56.46603
56.47808
56.4344
56.38533
56.30538
58.4194
52.69115
59.20433
71.12773
75.58242
76.46811
76.57945
()
10.08872
10.13352
10.12877
10.12359
10.11841
10.11323
10.10803
10.10769
10.10245
10.09718
9.724753
8.487884
8.488535
8.485467
8.482275
8.479079
8.479984
8.476704
8.473018
8.467009
8.624494
8.190755
8.68224
9.516441
9.80992
9.86723
9.874411
10.2
10.3
10.3
10.3
10.3
10.3
10.3
10.3
10.3
10.2
9.9
8.6
8.6
8.6
8.6
8.6
8.6
8.6
8.6
8.6
8.8
8.3
8.8
9.7
10
10
10
1. Calculation of the diameter for the rectifying and stripping part of the distillation
column.
The first tray is to be considered in this calculation
=
2.764332 3
105.2249 /
= 0.0155
396.2244 /
811.6506 3
= [. ].
1 = 0.13[20.80.02]0.2 = 0.131023749
=
811.6506 2.764332
= 0.131023749
= 2.241293072 /
2.764332
85% , = 2.241293072 0.85 = 1.905099111 /
= .
= 1.1
396.2244
= 157.6680381 3
3
@ %
157.6680381
=
= 70.3469082 2
1.905099111
=
=
.
70.3469082
=
= 79.94 2
1 0.12
=
=
4 79.94
= 10.089 10.2
2. Plate Design
The Stripping section will be the basis of the calculation
= 10
= 102 = 78.53981634 2
4
=
% = 12%
284
= %
= 0.12 78.53981634 = 9.424777961 2
=
= 78.53981634 9.424777961 = 69.11503838 2
=
= 78.53981634 2 9.424777961 = 59.69026042 2
% = 6%
= %
= 78.53981634 0.06 = 4.721238898 2
59.69026042
% =
100 = 12%
78.53981634
is set to be 40
3. Weeping Test
The Stripping section will be the basis of the calculation
, = .
= 1.1 335.0706
= 368.5776268 /
max
, = .
= 0.5 250.8583 = 125.4291356 /
/
= [
]
368.5776268 2/3
= 750 [
] = 114.6701249
811.2073 7.6
/
]
114.6701249 2/3
= 750 [
]
739.9114 7.6
= [
min
285
+ = 40 + 59.42894361 = 99.42894361
= 7.976507131 /
3.6984960.5
0.5
0.5 281593.3
=
= 8.299437091
2 4.71238898 3600
=
. > .
4. Pressure Drop
The Stripping section will be the basis of the calculation
332641.8
= 1.1
= 21.56879178 /
3600 4.71238898
=
2
21.56879178
2.830595
= 51 (
)
= 131.753965
0.83
739.9114
=
=
12500
= 16.89391468
739.9114
= + + ( + )
= 131.753965 + 16.89391468 + (40 + 114.6701249)
= 303.3180046
286
1629.947
= 0.452763128 3
3600
35
) 7.6 = 0.266 2
1000
Since < :
= [
]
368.5776268 2
8
= 166 [
] = 9.096270081
739.9114 0.266
= ( + ) + +
= (40 + 114.6701249) + 303.3180046 + 9.096270081 = 467.0843996
12 ( + ) = 470
( + ) >
>
6. Entrainment
The Stripping section will be the basis of the calculation
287
1.1 332641.8
=
= 1.47059944 /
69.11503838 3600
=
1.47059944
% =
100 = 72%
2.041246954
% =
% <
7. Tray Layout
The Stripping section will be the basis of the calculation
,
= (
)(
)
2 50 82
, = (10
)(
) = 14.16858287
1000
180
=
= 0.05 14.16858287 = 0.708429143 2
= +
50
= 7.6 +
= 7.65
1000
= ( )
50
= 2 (7.65
) = 0.765 2
1000
=
288
4.71238898
=
= 0.080945474
58.21683127
8 2
= (
) = 5.02655 05
4 1000
=
4.71238898
=
= 93750
5.02655 05
=
289
REV
1
CALCULATION
CREATED BY
CHECKED BY
MFS
ALL
EAM
DATE
1/2/15
APPROVED BY
VAPOR
TRAY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Mole flow
kmol/h
kmol/s
96.33
0.026758
97.2
0.027
97.17
0.026992
97.04
0.026956
96.59
0.026831
95.16
0.026433
92.25
0.025625
89.3
0.024806
87.63
0.024342
86.56
0.024044
172.7
0.047972
167.1
0.046417
158
0.043889
161.9
0.044972
184.7
0.051306
202.2
0.056167
208.4
0.057889
210
0.058333
210.5
0.058472
210.5
0.058472
210.3
0.058417
209.5
0.058194
Mass Rate
kg/h
kg/s
5593
1.553611
5644
1.567778
5643
1.5675
5639
1.566389
5624
1.562222
5580
1.55
5501
1.528056
5437
1.510278
5395
1.498611
5327
1.479722
1.08E+04
2.988889
1.10E+04
3.041667
1.21E+04
3.35
1.53E+04
4.255556
1.97E+04
5.483333
2.25E+04
6.236111
2.34E+04
6.491667
2.36E+04
6.558333
2.37E+04
6.572222
2.37E+04
6.575
2.36E+04
6.563889
2.35E+04
6.516667
Vol Rate
m3/h
799.2007
805.9617
805.3451
804.5153
802.894
798.7686
790.1682
780.876
775.7699
772.2426
1552.955
1545.278
1544.723
1667.957
1948.277
2146.496
2215.003
2232.074
2235.372
2234.898
2232.072
2223.214
Density
kg/m3
6.998242
7.002814
7.006934
7.009189
7.004661
6.985753
6.961808
6.962693
6.954382
6.898091
6.928727
7.086104
7.807227
9.184888
10.13203
10.4589
10.55078
10.57761
10.58437
10.59109
10.58658
10.55229
LIQUID
TRAY
Mole flow
kmol/h
21.94
kmol/s
0.006094
Mass Rate
kg/h
1275
Vol Rate
Density
kg/s
m3/h
kg/m3
0.354167 1.847276 690.2053
290
Surface
Tension
dyne/cm
15
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
21.91
21.78
21.33
19.89
16.99
14.04
12.37
11.3
332.8
3.27E+02
3.18E+02
3.22E+02
3.45E+02
3.62E+02
3.69E+02
3.70E+02
3.71E+02
3.71E+02
3.70E+02
3.70E+02
365
0.006086
0.00605
0.005925
0.005525
0.004719
0.0039
0.003436
0.003139
0.092444
0.090889
0.088333
0.089444
0.095778
0.100639
0.102361
0.102806
0.102917
0.102944
0.102889
0.102667
0.101389
1273
1269
1254
1210
1132
1068
1025
956.9
2.78E+04
2.80E+04
2.91E+04
3.24E+04
3.68E+04
3.95E+04
4.04E+04
4.07E+04
4.07E+04
4.07E+04
4.07E+04
4.05E+04
3.98E+04
0.353611
0.3525
0.348333
0.336111
0.314444
0.296667
0.284722
0.265806
7.730556
7.786111
8.094444
8.997222
10.225
10.98056
11.23333
11.3
11.31667
11.31667
11.30556
11.25833
11.04444
1.84531
1.838167
1.812396
1.733741
1.586969
1.457147
1.373964
1.259486
35.54694
35.71434
37.04695
41.6149
48.31121
52.54772
53.99058
54.36786
54.45887
54.46241
54.38167
54.05371
52.68442
689.8569
690.3617
691.9017
697.9129
713.3096
732.9392
746.0164
759.7545
782.9085
784.8389
786.5695
778.327
761.9349
752.2687
749.0196
748.2362
748.0875
748.0388
748.414
749.8098
754.6823
15
15
15
15
15.1
15.3
15.5
16.2
17.5
17.5
17.4
16.6
15.5
14.8
14.5
14.5
14.4
14.4
14.4
14.4
14.6
FLV
0.023
0.12
0.113290501
1.11937399
0.951467891
2
3
4
5
6
7
8
9
0.023
0.023
0.022
0.022
0.020
0.019
0.018
0.017
0.12
0.12
0.12
0.12
0.115
0.115
0.115
0.11
0.113290501
0.113290501
0.113290501
0.113290501
0.108714439
0.109000911
0.109284402
0.105460467
1.118719403
1.118800341
1.119878269
1.125149214
1.093157047
1.113090902
1.12592005
1.097236511
0.950911493
0.95098029
0.951896528
0.956376832
0.92918349
0.946127267
0.957032043
0.932651035
10
11
12
13
0.490
0.245
0.253
0.269
0.058
0.081
0.082
0.083
0.056471536
0.078865422
0.079747615
0.079963853
0.598961503
0.835650383
0.83640646
0.794396284
0.509117278
0.710302826
0.710945491
0.675236842
291
()
14
15
16
17
18
19
0.264
0.232
0.082
0.081
0.07792453
0.076266069
0.705444189
0.65271718
0.59962756
0.554809603
0.213
0.207
0.205
0.205
0.081
0.08
0.08
0.08
0.075954345
0.075016637
0.074912879
0.074912879
0.638267341
0.627264885
0.625527938
0.625304552
0.54252724
0.533175152
0.531698747
0.531508869
20
21
22
0.205
0.204
0.200
0.08
0.08
0.08
0.074912879
0.074912879
0.075119824
0.625262287
0.625988714
0.630820234
0.531472944
0.532090407
0.536197199
TRAY
()
( )
( )
()
0.244200229
0.218157855
0.247907
0.561823
0.7
0.246266085
0.22013213
0.25015
0.564359
0.7
0.246077669
0.219947796
0.249941
0.564123
0.7
0.245824113
0.219509674
0.249443
0.563561
0.7
0.245328716
0.21804105
0.247774
0.561672
0.7
0.244068169
0.223269081
0.253715
0.568366
0.7
0.241440298
0.216909776
0.246488
0.560213
0.7
0.238600992
0.211916461
0.240814
0.553727
0.7
0.237040792
0.216034365
0.245494
0.559082
0.7
10
0.235963019
0.393953564
0.447675
0.754981
0.9
11
0.474513969
0.567837912
0.64527
0.906413
1.1
12
0.472168228
0.564520064
0.6415
0.903761
1.1
13
0.4719986
0.594160131
0.675182
0.927183
1.1
14
0.509653591
0.722457707
0.820975
1.022398
1.2
15
0.595306779
0.912043986
1.036414
1.14874
1.3
16
0.655873927
1.027584971
1.16771
1.219334
1.4
17
0.676806438
1.078980276
1.226114
1.249455
1.4
292
18
0.682022634
1.090315225
1.238995
1.256
1.4
19
0.683030249
1.092316131
1.241268
1.257152
1.4
20
0.682885361
1.092158243
1.241089
1.257061
1.4
21
0.682021895
1.089511487
1.238081
1.255537
1.4
22
0.679315449
1.07687644
1.223723
1.248236
1.4
1. Calculation of the diameter for the rectifying and stripping part of the distillation
column.
The first tray is to be considered in this calculation
=
6.998242 3
0.354167 /
= 0.0229547
1.553611 /
690.2053 3
690.2053 6.998242
= 0.11329
= 1.11937 /
6.998242
85% , = 1.11937 0.85 = 0.95147 /
= .
= 1.1
1.553611
= 0.22420 3
3
@ %
0.22420
=
= 0.21816 2
0.95147
=
293
=
.
0.21816
=
= 0.247907 2
1 0.12
=
4 0.247907
=
= 0.568123 0.7
2. Plate Design
The Stripping section will be the basis of the calculation
= 0.7
= 0.72 = 1.53938 2
4
=
% = 19%
= %
= 0.12 1.53938 = 0.29248 2
=
= 1.53938 2 0.29248 = 1.2468982
=
= 1.53938 2 2 0.29248 = 0.955416 2
% = 4%
= %
= 1.53938 0.04 = 0.06158 2
0.29248
% =
100 = 19%
1.53938
is set to be 50
3. Weeping Test
The Stripping section will be the basis of the calculation
, = .
= 1.1 335.0706
= 12.4483 /
max
, = .
= 0.5 250.8583 = 3.89306 /
/
= [
]
2/3
1.204
= 750 [
] = 41.7727
690.2053 1.204
/
]
2/3
1.204
= 750 [
]
690.2053 1.204
= [
min
+ = 50 + 19.901597 = 69.9
= 3.45379/
6.9982420.5
0.5
0.5 281593.3
=
= 3.48427
2 4.71238898 3600
=
. > .
4. Pressure Drop
The Stripping section will be the basis of the calculation
295
12.4483
= 1.1
= 11.0926 /
3600 0.06158
=
2
11.0926
6.998242
= 51 (
)
= 88.5926
0.81
690.2053
=
=
12500
= 16.710363
690.2053
= + + ( + )
= 88.5926 + 16.710363 + (50 + 19.901597) = 197.0757
5. Downcomer Liquid Backup
The Stripping section will be the basis of the calculation
=
1629.947
= 0.452763128 3
3600
45
) 1.204 = 0.048162
1000
Since < :
= [
]
296
2
12.4483
8
= 166 [
] = 19.820257
690.2053 0.04816
= ( + ) + +
= (50 + 19.901597) + 197.0757 + 19.820257 = 308.6687
12 ( + ) = 470
( + ) >
>
6. Entrainment
The Stripping section will be the basis of the calculation
.
1.1 1.553611
=
= 0.547783 /
1.2468982 3600
=
0.547783
% =
100 = 65%
1.11937
% =
% <
7. Tray Layout
The Stripping section will be the basis of the calculation
,
= (
)(
)
2 50 62
, = (1.4
)(
) = 1.406735
1000
180
=
= 0.05 1.406735 = 0.07033682
= +
50
= 1.204 +
= 1.254
1000
= ( )
50
= 2 (1.254
) = 0.1254 2
1000
=
= 0.955416 0.0703368 0.1254 = 0.758679 2
0.06158
=
= 0.081161
0.758679 2
4 2
= (
) = 1.25664 05
4 1000
=
0.06158
=
= 4900
1.25664 05
=
298
REV
1
DATE
1/2/15
CALCULATION
CREATED BY
CHECKED BY
MFS
ALL
EAM
APPROVED BY
VAPOR
TRAY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Mole flow
kmol/h
kmol/s
577.7
0.160472
577.3
0.160361
578
0.160556
578.6
0.160722
579.2
0.160889
579.8
0.161056
580.1
0.161139
580.1
0.161139
579.7
0.161028
578.9
0.160806
577.7
0.160472
576.2
0.160056
574.4
0.159556
572.5
0.159028
570.3
0.158417
568.1
0.157806
565.8
0.157167
563.2
0.156444
560.2
0.155611
556.2
0.1545
550.7
0.152972
517.3
0.143694
516.2
0.143389
515.1
0.143083
514.2
0.142833
513.4
0.142611
512.8
0.142444
0.142333
512.4
0.142278
512.2
0.142306
512.3
0.142361
512.5
0.142472
512.9
0.142611
513.4
Mass Rate
kg/h
kg/s
68029.07
18.89696
67994.22
18.88728
68095.24
18.91535
68202.51
18.94514
68332.34
18.98121
68493.52
19.02598
68664.11
19.07336
68850.3
19.12508
69062.62
19.18406
69294.75
19.24854
69535.34
19.31537
69765.68
19.37936
69949.14
19.43032
70066.96
19.46305
70086.87
19.46858
69995.96
19.44332
69772.48
19.38124
69389.88
19.27497
68800.89
19.11136
67917.21
18.86589
66581.9
18.49497
63531.38
17.64761
64358.21
17.87728
65105
18.08472
65765.63
18.26823
66339.64
18.42768
66832.01
18.56445
67254.8 18.68189
67614.66 18.78185
67918.56 18.86627
68171.86 18.93663
68379.98 18.99444
68544.55 19.04015
299
Vol Rate
m3/h
19426.52
18630.87
17932.72
17287.34
16691.86
16141.47
15624.33
15135.73
14672.46
14229.42
13803.61
13393.9
12998.19
12618.47
12253.47
11904.11
11568.81
11245.18
10929
10613.41
10288.89
9460.717
9243.674
9033.46
8832.594
8641.826
8461.178
8290.901
8130.311
7978.81
7835.755
7700.711
7573.014
Density
kg/m3
3.501866
3.649546
3.797263
3.945228
4.093752
4.243326
4.394692
4.548858
4.706954
4.869823
5.037477
5.208765
5.381451
5.552729
5.719758
5.879981
6.031087
6.170632
6.29526
6.399188
6.471245
6.715282
6.962406
7.207095
7.445789
7.676578
7.898665
8.111881
8.316368
8.512367
8.700101
8.879698
9.051158
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
514.1
514.9
515.9
516.9
518.1
519.1
519.8
519.8
517.9
512.1
499.6
483.2
477.6
485.5
493.3
496.9
498.6
499.7
500.6
501.4
502.3
503.1
0.142806
0.143028
0.143306
0.143583
0.143917
0.144194
0.144389
0.144389
0.143861
0.14225
0.138778
0.134222
0.132667
0.134861
0.137028
0.138028
0.1385
0.138806
0.139056
0.139278
0.139528
0.13975
68667.73
68749.07
68785.15
68766.07
68679.32
68488.76
68130.68
67468.01
66224.57
63858.69
59577.27
53513.75
48610.16
46927.33
46786.9
46869.59
46954.53
47035.15
47114.38
47193.01
47271.19
47349.03
19.07437
19.09696
19.10699
19.10169
19.07759
19.02466
18.92519
18.74111
18.39571
17.73853
16.54924
14.86493
13.50282
13.03537
12.99636
13.01933
13.04293
13.06532
13.08733
13.10917
13.13089
13.15251
7452.289
7338.101
7229.977
7127.151
7029.238
6934.568
6840.936
6743.263
6631.836
6488.824
6296.449
6100.489
6045.466
6118.838
6154.611
6124.889
6068.412
6005.085
5941.014
5877.868
5816.08
5755.739
9.214314
9.368783
9.513882
9.648464
9.770521
9.876428
9.959263
10.00525
9.985858
9.841335
9.462043
8.772043
8.040763
7.669322
7.601927
7.652317
7.737532
7.832554
7.93036
8.028934
8.127672
8.226403
LIQUID
TRAY
1
2
3
4
5
6
7
8
9
10
11
12
13
Mole flow
kmol/h
492.4
493.1
493.7
494.3
494.9
495.2
495.1
494.8
494
492.8
4.91E+02
4.90E+02
4.88E+02
kmol/s
0.136778
0.136972
0.137139
0.137306
0.137472
0.137556
0.137528
0.137444
0.137222
0.136889
0.136472
0.135972
0.135417
Mass Rate
kg/h
57989.95
58090.97
58198.23
58328.06
58489.24
58659.83
58846.03
59058.34
59290.48
59531.06
59761.4
59944.86
60062.69
kg/s
16.10832
16.13638
16.16618
16.20224
16.24701
16.2944
16.34612
16.40509
16.46958
16.53641
16.60039
16.65135
16.68408
300
Vol Rate
Density
m3/h
76.61432
76.92985
77.24954
77.5818
77.91597
78.18978
78.37033
78.4317
78.34191
78.09256
77.69905
77.17555
76.56319
kg/m3
756.9074
755.1161
753.3797
751.8266
750.6708
750.2237
750.8713
752.9907
756.8168
762.3141
769.1394
776.7338
784.4852
Surface
Tension
dyne/cm
17.4
19
22.5
29.8
43.5
67.5
106
164
241
337
443
552
654
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
4.85E+02
4.83E+02
4.81E+02
4.78E+02
4.75E+02
4.71E+02
4.66E+02
5.92E+02
591.3
590.2
589.3
5.89E+02
5.88E+02
587.5
587.4
587.4
587.6
588
588.5
589.2
590.1
591
592.1
593.2
594.2
595
594.9
593
587.2
574.8
558.3
552.7
560.6
568.4
572
573.7
574.8
575.7
576.6
577.4
578.2
0.134833
0.134222
0.133583
0.132861
0.132
0.130917
0.129361
0.164556
0.16425
0.163944
0.163694
0.163472
0.163306
0.163194
0.163167
0.163167
0.163222
0.163333
0.163472
0.163667
0.163917
0.164167
0.164472
0.164778
0.165056
0.165278
0.16525
0.164722
0.163111
0.159667
0.155083
0.153528
0.155722
0.157889
0.158889
0.159361
0.159667
0.159917
0.160167
0.160389
0.160611
60082.6
59991.68
59768.2
59385.6
58796.61
57912.93
56577.63
70602.5
71429.33
72176.12
72836.75
73410.77
73903.13
74325.93
74685.78
74989.68
75242.98
75451.1
75615.67
75738.85
75820.19
75856.27
75837.19
75750.44
75559.89
75201.81
74539.13
73295.69
70929.82
66648.39
60584.88
55681.28
53998.46
53858.02
53940.71
54025.65
54106.27
54185.5
54264.13
54342.31
54420.15
16.68961
16.66436
16.60228
16.496
16.33239
16.08693
15.71601
19.61181
19.84148
20.04892
20.23243
20.39188
20.52865
20.64609
20.74605
20.83047
20.90083
20.95864
21.00435
21.03857
21.06117
21.07119
21.06589
21.04179
20.98886
20.88939
20.70531
20.35991
19.70273
18.51344
16.82913
15.46702
14.99957
14.96056
14.98353
15.00713
15.02952
15.05153
15.07337
15.09509
15.11671
301
75.87267
75.11872
74.28265
73.32044
72.14571
70.6062
68.45231
84.5613
84.25948
83.96778
83.71539
83.51417
83.36783
83.28101
83.24952
83.26963
83.33702
83.44922
83.60139
83.79104
84.01419
84.26458
84.529
84.79026
85.00098
85.07374
84.81858
83.85035
81.42911
76.53283
69.45836
63.95781
62.30325
62.30435
62.46854
62.61684
62.76265
62.90914
63.0583
63.20683
63.35389
791.8872
798.625
804.6052
809.9461
814.9703
820.2244
826.5261
834.9268
847.7305
859.5692
870.0521
879.0217
886.4706
892.4715
897.1317
900.5646
902.8758
904.1559
904.4786
903.9015
902.4689
900.2154
897.1736
893.3862
888.9295
883.9603
878.8066
874.125
871.0621
870.8472
872.2474
870.5939
866.7037
864.4344
863.486
862.7975
862.0776
861.3296
860.5392
859.7538
858.9867
744
816
868
901
916
911
884
824
985
1.13E+03
1.26E+03
1.37E+03
1.46E+03
1.53E+03
1.59E+03
1.63E+03
1.66E+03
1.68E+03
1.69E+03
1.69E+03
1.67E+03
1.65E+03
1.62E+03
1.58E+03
1.53E+03
1.46E+03
1.38E+03
1.27E+03
1.12E+03
888
560
239
77.7
31.1
20.6
18.4
17.8
17.7
17.6
17.5
17.5
55
577.7
17.4
TRAY
FLV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
0.058
0.059
0.061
0.062
0.063
0.064
0.066
0.067
0.068
0.069
0.070
0.070
0.071
0.072
0.072
0.073
0.073
0.074
0.074
0.073
0.093
0.10
0.10
0.10
0.10
0.10
0.10
0.11
0.11
0.11
0.11
0.11
0.11
0.11
0.08
0.08
0.08
0.079
0.079
0.079
0.079
0.078
0.078
0.078
0.078
0.078
0.078
0.078
0.078
0.077
0.077
0.077
0.077
0.077
0.076
0.1
0.1
0.1
0.1
0.1
0.1
0.098
0.098
0.098
0.098
0.098
0.098
0.098
0.077802551
0.079183503
0.0819069
0.085558733
0.092282413
0.100758536
0.11027632
0.118811198
0.128319309
0.137219105
0.14493369
0.15145249
0.156676605
0.160769326
0.163767091
0.163677382
0.164903428
0.165448876
0.165267859
0.164276401
0.159879594
0.218012426
0.224083402
0.229017205
0.232883175
0.235865582
0.238085138
0.235125375
0.236296668
0.237160138
0.237728874
0.238011213
0.238011213
0.237445187
302
()
1.141191479
1.136240194
1.150786712
1.177998341
1.246222173
1.335956563
1.437229608
1.524000834
1.622044109
1.711328391
1.785001076
1.843249113
1.885176832
1.913170082
1.928183864
1.907653032
1.903868437
1.894172251
1.879208042
1.859744525
1.80897986
2.439782224
2.479730186
2.505845993
2.519621757
2.523621899
2.519545708
2.461469283
2.447561394
2.43093614
2.411803198
2.390314803
2.366576523
2.337865273
0.970012757
0.965804165
0.978168705
1.00129859
1.059288847
1.135563078
1.221645167
1.295400709
1.378737493
1.454629132
1.517250915
1.566761746
1.602400307
1.626194569
1.638956284
1.621505077
1.618288171
1.610046413
1.597326836
1.580782846
1.537632881
2.073814891
2.107770658
2.129969094
2.141678493
2.145078614
2.141613852
2.09224889
2.080427185
2.066295719
2.050032719
2.031767583
2.011590045
1.987185482
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
TRAY
1
2
3
4
5
6
7
8
9
10
11
12
13
0.11
0.11
0.11
0.12
0.12
0.12
0.12
0.11
0.11
0.11
0.10
0.11
0.11
0.11
0.11
0.11
0.11
0.11
0.11
0.11
0.11
0.098
0.098
0.098
0.097
0.097
0.097
0.097
0.098
0.098
0.098
0.1
0.098
0.098
0.098
0.098
0.098
0.098
0.098
0.098
0.098
0.098
()
157.6680381
158.8439865
158.5383449
158.2210005
157.9041107
157.587675
157.2715292
156.9554532
156.6391507
156.3221946
156.0040071
101.6405367
101.5539838
0.236873712
0.236006019
0.234828873
0.230942584
0.228789614
0.226225498
0.222498188
0.219211675
0.209267926
0.190834847
0.164237975
0.128559531
0.107046422
0.098581068
0.096379272
0.095742349
0.09563453
0.095526224
0.095417424
0.095417424
0.095308125
( )
70.34690823
70.97306867
70.90644155
70.83402462
70.76154556
70.68902188
70.61639846
70.61162574
70.53847439
70.46488128
65.36266496
49.79335622
49.80099888
303
2.309812591
2.279646292
2.247419235
2.190679651
2.15235003
2.113000914
2.067757222
2.03559698
1.957396007
1.822286311
1.627915784
1.328516683
1.131421859
1.046017957
1.018842628
1.006046898
0.998306859
0.990492196
0.982762126
0.976277754
0.968783015
( )
79.93967
80.65121
80.5755
80.49321
80.41085
80.32843
80.24591
80.24048
80.15736
80.07373
74.27576
56.58336
56.59204
1.963340702
1.937699348
1.91030635
1.862077704
1.829497526
1.796050777
1.757593639
1.730257433
1.663786606
1.548943364
1.383728416
1.129239181
0.96170858
0.889115264
0.866016234
0.855139863
0.848560831
0.841918367
0.835347807
0.829836091
0.823465563
()
10.08872
10.13352
10.12877
10.12359
10.11841
10.11323
10.10803
10.10769
10.10245
10.09718
9.724753
8.487884
8.488535
10.2
10.3
10.3
10.3
10.3
10.3
10.3
10.3
10.3
10.2
9.9
8.6
8.6
14
15
16
17
18
19
20
21
22
23
24
25
26
27
101.3838101
101.2112729
101.0391093
100.8670884
100.6929506
100.5063116
100.2542358
99.56290608
93.80155737
86.04238696
93.4189498
97.95987487
98.84782498
98.87035813
49.76500847
49.72756575
49.6901107
49.70070778
49.66226797
49.61908907
49.5487323
51.40907483
46.36821628
52.09981369
62.59240354
66.512532
67.29193886
67.38991711
56.55115
56.5086
56.46603
56.47808
56.4344
56.38533
56.30538
58.4194
52.69115
59.20433
71.12773
75.58242
76.46811
76.57945
8.485467
8.482275
8.479079
8.479984
8.476704
8.473018
8.467009
8.624494
8.190755
8.68224
9.516441
9.80992
9.86723
9.874411
8.6
8.6
8.6
8.6
8.6
8.6
8.6
8.8
8.3
8.8
9.7
10
10
10
8. Calculation of the diameter for the rectifying and stripping part of the distillation
column.
The first tray is to be considered in this calculation
=
3.501866 3
16.10832 /
= 0.05798
18.89696 /
756.9074 3
756.9074 3.501866
= 0.077802
= 1.14119/
3.501866
85% , = 1.14119 0.85 = 0.970012 /
= .
304
= 1.1
18.89696
= 3.9358799 3
3.501866 3
@ %
3.9358799
=
= 2.06119894 2
0.970012
=
.
5.201478
=
= 5.91077 2
1 0.12
=
4 5.91077
=
= 2.743324 2.9
9. Plate Design
The Stripping section will be the basis of the calculation
= 2.9
= 2.92 = 2.54469 2
4
=
% = 19%
= %
= 0.19 2.54469 = 9.424777961 2
=
= 78.53981634 9.424777961 = 0.43491 2
=
= 2.54469 2 9.424777961 = 1.5777078 2
% = 10%
= %
= 2.54469 0.1 = 0.254469 2
305
9.424777961
% =
100 = 19%
2.54469
is set to be 38
, = .
= 1.1 16.10832
= 23.17830 /
, = .
, = 0.5 16.10832 = 7.48028 /
= [
max = 750 [
/
]
16.10832 2/3
] = 114.6701249
756.9074 7.6
/
= [
]
16.10832 2/3
min = 750 [
]
756.9074 7.6
+ = 38 + 24.36576 = 62.36576
= 3.17409 /
3.5018660.5
0.5
306
0.5 281593.3
= 3.1744096
2 0.254469 3600
. > .
16.10832
= 1.1
= 12.35446 /
3600 0.254469
=
2
12.35446
3.501866
= 51 (
)
= 74.485526
0.9
756.9074
=
=
=
12500
= 14.971371
756.9074
= + + ( + )
= 74.485526 + 14.971371 + (38 + 24.36576) = 176.5540
12. Downcomer Liquid Backup
The Stripping section will be the basis of the calculation
=
1629.947
= 0.02363 3
3600
307
= (
= (
33
) 1.53 = 0.05049 2
1000
Since < :
]
2
368.5776268
8
= 166 [
] = 50.18383
756.9074 0.43491
= [
= ( + ) + +
= (38 + 24.36576) + 176.5540 + 50.183839471 = 313.834
12 ( + ) = 319
( + ) >
>
13. Entrainment
The Stripping section will be the basis of the calculation
.
1.1 18.89696
=
= 1.52524 /
2.06119894 3600
=
1.52524
% =
100 = 60%
1.14119
% =
% <
308
,
= (
)(
)
2 50 83
, = (10
)(
) = 2.46265
1000
180
=
= 0.05 2.46265 = 0.123132 2
= +
50
= 1.53 +
= 1.58
1000
= ( )
50
= 2 (1.53
) = 0.158 2
1000
=
= 1.577707 0.123132 0.158 = 1.29657 2
0.254469
=
= 0.196262
1.29657
309
3 2
= (
) = 7.06858 05
4 1000
0.254469
=
= 36000
7.06858 05
=
310
Appendix E
Wage and Monetary Benefits Breakdown
See attached A3 document.
311
Appendix F
Attached A3 documents
Plot Plan
312
List of Tables
Table Number
Title
Page
10
11
12
14
19
10
23
11
24
12
28
13
29
14
29
15
SWOT/TOWS Matrix
30
vii
16
32
17
34
18
34
19
35
20
35
21
35
22
36
23
36
24
37
25
42
26
43
27
44
28
44
29
45
30
46
31
47
32
51
33
52
34
53
35
54
36
56
37
56
38
39
40
59
41
57
59
60
42
60
43
61
44
64
45
65
46
65
47
65
48
49
50
141
142
144
51
147
52
149
53
149
54
150
55
150
56
150
57
151
58
151
59
152
60
152
61
153
62
153
63
153
64
154
65
154
66
155
67
156
68
157
69
157
70
158
71
158
72
159
73
159
74
160
75
160
76
161
77
161
78
162
79
162
80
81
82
163
83
163
165
166
84
167
85
168
86
169
87
169
88
170
89
171
90
172
91
172
92
172
93
173
94
173
95
174
96
175
97
176
98
176
99
177
100
178
101
178
102
179
103
180
104
181
105
181
106
107
182
182
108
183
109
Pricing of Products
184
110
185
111
185
112
113
187
188
114
188
115
189
116
Cost of buildings
190
117
191
118
Cost of radio
191
119
192
120
192
121
193
122
195
123
195
124
196
List of Figures
Figure Number
Title
Page
10
13
14
17
33
viii
10
11
49
13
41
12
40
50
50
14
53
15
16
55
194
List of Appendices
Appendix Number
Title
Page
ix
xi
xii
xiii
Attached A3 documents
xiv
Definition of Terms
Annual cost. The sum of the annuitized values of a cash flow series.
Annuity. A series of uniform payments or withdrawals occurring at equal time intervals.
Capital. A firms investment in long-term assets that are not bought or sold in the normal
course of business, e.g., plant equipment, buildings, and site upgrades. These assets are
depreciated.
Cash flow. The flow of money into or out of a company, a project, a personal account, and
so on.
Cash flow diagram. A diagram showing all cash flows and the time they occur. Cash flows
in are shown by an arrow into the timeline and cash flows out by an arrow away from the
timeline.
Chemical engineering plant cost index (CEPI). An index of the costs to design, purchase
and install chemical plant equipment. It is maintained by Chemical Engineering and
includes costs (1) for equipment, machinery and supports (61% of the index weighting);
(2) for construction labor (22%); (3) for buildings (7%); and (4) for engineering and
supervision (10%). The period 1957 to 1959 is defined as an index of 100.
Depreciation. A deduction from revenues (allowed by the government when calculating
income taxes) of a fraction of the capital invested in a plant. This deduction may be
considered as a fund to allow eventual replacement of the plant. It is not a cash flow.
Expense. A firms costs that are chargeable against sales in a specific period.
Fixed costs. Production costs that do not vary with production volume.
Future worth. This the projected value of a present sum of money when it grows at a
specified interest rate for a given number of years.
General expense. Broad corporate level expenses research and development,
marketing, sales, and administrative costs.
Inflation. The devaluing of money because the volume of money increases faster than the
supply of goods.
Interest. The return from the investment of funds or the money paid for the use of
borrowed money.
Internal rate of return. See Return on investment (ROI).
Manufacturing costs. The cost to manufacture a product. It is comprised of operating
labor (wages), employee benefits, supervision (wages and benefits), laboratory costs,
maintenance costs, utility costs, depreciation, insurance and taxes, operating (consumable)
supplies, plant overhead, and contract manufacturing costs.
Product cost. The sum of production cost and general expense.
Production cost. The cost to produce a product. It is made up of raw material costs,
packaging material costs, manufacturing costs, and delivery costs.
Project life. The years a process or project is expected to operate without major revision.
This is determined by the shorter of product or process obsolescence or by depreciable life.
Return on investment (ROI). The interest rate at which the net present value of a cash
flow series is zero. This is the percent return from an investment.
Unit cost. Production costs expressed in dollars per unit of production (e.g. $/ton, $/lb,
$/case).
Variable costs. Those costs that vary with production volume.