Facility Inspection Report

60 kmta Caprolactam Facility

Prepared by:
International Process Plants
Hamilton Business Center
17A Marlen Drive
Hamilton, NJ 08691

IPP Confidential
 2

60 kmta Caprolactam Facility

Executive Summary
This Caprolactam Facility includes all intermediate and byproduct plants. The facility
starts with benzene and finishes with caprolactam and ammonium sulfate byproduct:

• Cyclohexane Plant – 80 kmta • Ammonium Sulfate – 108 kmta

• Cyclohexanone Plant – 55 kmta • Incinerator – 5 m3/hr liquid
• Oximation Plant – 62 kmta waste
• Caprolactam Plant – 60 kmta

The facility had some upgrades over the years. The majority of the site shut down in
2009, but the cyclohexane unit ran until August 2013.

Documentation is complete and well-organized. Much of it is electronic and has

already been shared with IPP. The facility received ISO-9001 certification in 1997
and ISO-14001 certification in 2004.

DCS is by Yokogawa (Centum CS-3000) and is used in the Oximation, Caprolactam,

Ammonia Sulfate, and Incinerator units.

The plant has been well-maintained and is still being kept up with a staff of four
employees. There is a nitrogen pad on the process and they are turning the rotating
equipment monthly.

There are abundant spare parts available with the facility.

Transportation to and from the facility by road is excellent and it is 24 km to the

nearest major port.

IPP Confidential
 3

Detailed Process Description – Caprolactam Facility

Overall Caprolactam Facility Process Flow Diagram

This Caprolactam Facility includes all intermediate and byproduct plants. The facility
starts with benzene and finishes with caprolactam and ammonium sulfate byproduct:
• Cyclohexane Plant – 80 kmta • Ammonium Sulfate – 108 kmta
• Cyclohexanone Plant – 55 kmta • Incinerator – 5 m3/hr liquid
• Oximation Plant – 62 kmta waste
• Caprolactam Plant – 60 kmta

The facility can be turned-down to about 40 kmta of caprolactam, or 67% of capacity.

The total facility uses the following raw material and utility quantities:
Benzene = 79 kmta Electricity = 52 GWhr/yr Nitrogen = 6.0 MMNm3/yr
Hydrogen = 10 kmta Steam = 720 kmta Fuel Oil = 1.0 kmta
Ammonia = 50 kmta Air = 33 MMNm3/yr
Sulfuric Acid = 78 kmta Water = 1.3 MMNm3/yr

The following chart shows more details about the sub-processes within each of the
individual units.

IPP Confidential
 4

Cyclohexane Plant
Hydrogenation of Benzene to Cyclohexane
U-5200 Plant Designation
No sub-series - unit operations listed below:
Benzene Evaporation
Hydrogenation
Separation
Ammonia Refrigeration Unit

Cyclohexanone Plant
Oxidation of Cyclohexane to Cyclohexanone
U-5000 Plant Designation
Series:
5000 Utilities (includes incinerator)
5400 Oxidation
5500 Absorption
5600 Neutralization/Hydrolysis
5700 Distillation
5800 Purification
5900 Conversion of Cyclohexanol to Cyclhexanone

Cyclohexanone-Oxime Plant
Oximation of Cyclohexanone to Oxime
U-6000 Plant Designation
Series
6000 Utilities
6100 Hydrogen Purification
6200 Hydroxylamine Preparation
6300 Oximation/Neutralization/Washing
6400 Touene/Oxime Distillation
6500 Toluene Extraction/Separation
6600 Ammonia Burner
6700 Nitric Adsorption Nitric Acid Plant
6800 NOx Removal

Caprolactam Plant
Rearrangement of Oxime to Caprolactam & Ammonium Sulfate
U-7000 Plant Designation
Series:
7000 Utilities (Includes Effluent Evaporator, Incinerator)
7200 Rearrangement
7300 Extraction
7400 Ion Exchange
7500 Hydrogenation
7600 Evaporation
7700 Distillation
7800 Flocculation

Ammonium Sulfate Plant

Recovery of Ammonium Sulfate byproduct
U-8500 Plant Designation
No sub-series - unit operations listed below:
Evaporation
Crystallization
Centrufigation
Drying
Solids Transport

IPP Confidential
 5

Detailed Process Description – Cyclohexane Facility

Cyclohexane Plant

The Cyclohexane Plant uses 73 kmta of benzene to produce 80 kmta of pure

cyclohexane. It can also produce a small heptane byproduct and has a small effluent
stream that is mostly water from the benzene drying column overheads. The plant
was the last plant running when it shut down in August, 2013.

Cyclohexane Plant Process Flow Diagram

IPP Confidential
 6

The incoming benzene is heated to 60oC by cross-exchanging with the benzene

drying columns bottoms stream. The benzene is then dried in the drying column to
less than 100 ppm water and pumped from the bottom of the column.

The drying column has 20 sieve trays, a reboiler, and an overhead condenser
system. The carbon steel column is 0.7 meters diameter by 12.5 meters tall and is
rated for 2.6 bar at 115oC. There is an azeotropic mixture going overhead in the
column at 15,000 ppm water. This stream is used for reflux in the drying column.

The dry benzene is now pumped up to

high-pressure using two Sundyne
pumps and is then heated with hot oil
and evaporated at 130oC. The
benzene is mixed with hydrogen which
is compressed with a Demag
compressor rated for 41.6 bar. The
compressor is driven with a steam
turbine.
Hydrogen Compressor

The benzene/hydrogen mixture is then sent to the hydrogenation reactor which

operates at 30 bar and 340oC with 0.3% platinum catalyst on aluminum oxide
substrate. Hydrogen with purity as low as 74% can be used in this process. The
carbon steel reactor is 1.8 meters diameter by 6.1 meters tall. It is rated for 34 bar at
315oC.

Hydrogenation Reactor After-Reactor

IPP Confidential
 7

The hydrogenation reactor products then flow to the after-reactor which is filled with
zinc oxide catalyst in the first bed and platinum catalyst on aluminum oxide substrate
in the second bed. The after-reactor is 2.2 meters diameter by 5.2 meters tall. It is
rated for 34 bar at 315oC. All catalysts have been removed from the reactors.

The cyclohexane product is then cooled with a steam-generating boiler and some
other cross-exchangers for energy efficiency. The carbon steel boiler is 2.4 meters
diameter by 5.8 meters long and is rated for 21 bar at 226oC. The condensed
product is sent to the heptane column where n-heptane and other high-boiling
compounds are removed. Pure cyclohexane exits the top of the heptane column.
The pure cyclohexane product is then condensed and pumped to storage. The
heptane column has been removed because it was not necessary.

IPP Confidential
 8

Detailed Process Description – Cyclohexanone Plant

Cyclohexanone Plant Process Flow Diagram

The Cyclohexanone Plant uses 80 kmta of cyclohexane along with some air to
produce 55 kmta of pure cyclohexanone. The oxidation reaction takes place in a
series of four agitated reactors followed by multiple distillation and separation steps.
The plant closed in 2009.

The cyclohexane feed first enters the cooling scrubber column. The overheads from
this column go to the cyclohexane absorber while the bottoms stream proceeds to
the direct heat exchanger column. This column prepares the cyclohexane for the
oxidation reaction.

IPP Confidential
 9

The oxidation reaction takes place in

four agitated oxidation reactors in
series. Air is blown into the bottom of
the oxidation reactors while the
agitator spins at 190 rpm. Each
reactor is 35 cubic meters in volume
providing 37 minutes of residence
time. The oxidation of cyclohexane
takes place at 9.0 bar and 160oC with
a cobalt naphthenate catalyst. The
four carbon steel reactors are 3.4
meters diameter by 6.0 meters tall and
are rated for 12.8 bar at 190oC.
Oxidation Reactors (4)

The Demag model 06-MH-7C air

compressor is rated for 8,173 Nm3/hr
of air at a discharge pressure of 12 bar
and 220oC. The KKK steam turbine
spins the compressor at 14,235 rpm.

Process Air Compressor

The reaction products from the oxidation reactors flow to a series of separators. The
overhead vapors from the separators proceed to the series of three distillation
columns. The liquid in the separators flows to the stripper column. The bottoms or
heavies flow from the stripper column are sent to the incinerator. The overheads
from the stripper column proceed to the drying column. The drying column also
receives feed from the salt extraction column and from the dehydrogenation reactor.

The bottoms from the drying column go to the forerun column. The overheads from
the forerun column are sent to the incinerator. The bottoms from the forerun column
are pumped to the large anone distillation column. The overheads from the anone
distillation column are the final cyclohexanone product which is condensed and sent
to storage. The bottoms from the column are pumped to the anol distillation column.
The bottoms or heavies from the anol distillation column are pumped to the
incinerator.

IPP Confidential
 10

The overheads from the anol

distillation column flow to the
dehydrogenation reactor which
converts the anol back to anone. The
products leaving the dehydrogenation
reactor are sent back to the drying
column as previously mentioned.

The dehydrogenation reactor uses a

copper-magnesium catalyst to convert
the cyclohexanol to cyclohexanone.
The charge is 8.8 metric tons and the
catalyst life is about one year. The
reaction takes place at atmospheric
pressure and 250oC. Heat is provided
for the dehydrogenation reactor with a
dedicated hot oil furnace. The carbon
steel reactor is a shell and tube design
with catalyst in the tubes and hot oil on
the shell side. The reactor is 2.6
meters diameter by 7.2 meters tall with
1,483 tubes.
Dehydrogenation Reactor

The overheads from the oxidation reactor separators mentioned earlier flow to the
series of three distillation columns. The overhead from these columns go back to the
oxidation reactor feed lines. The bottoms from the distillation columns are pumped to
a caustic mix vessel for neutralization. The bottoms from the mix vessel are then
pumped to a salt extraction column. The bottoms from this column are pumped to
the waste water line, and the overheads are sent back to the drying column as
previously mentioned.

The specifications for all of the columns in the Cyclohexanone Plant are shown in the
table below. Sulzer reciprocating vacuum pumps are used to supply vacuum on
some of the columns.

Cyclohexanone Plant Columns Diameter Height Pressure Temp Material of

(m) (m) (bar) (o C) Comments Construction
C5401 Cooling Scrubber 2.0 22.6 12.8 215 3-packed 304SS
C5402 Direct Heat Exchange Col 2.8 13.0 12.8 215 2-packed CS
C5501 Cyclohexane Absorber 0.9 14.3 12.8 90 2-packed 304SS
C5601 Stripper 1.2 13.6 2.3 175 1-packed 304SS
C5602 Salt Extraction Col 1.8 11.4 5.2 115 1-packed CS
C5701 1st Distillation Col 2.3 20.4 7.3 175 18-Sieve CS
C5702 2nd Distillation Col 2.2 21.5 7.3 175 18-Sieve CS
C5703 3rd Distillation Col 3.2 25.9 7.3 190 21-Sieve CS
C5801 Drying Col 1.2 16.3 2.3 190 14-Sieve CS
C5802 Fore Run Col 1.6 38.3 1.8/FV 190 60-Sieve CS
C5803 Anone Distillation Col 3.0 49.7 1.8/FV 190 80-Valve CS
C5804 Anol Distillation Col 3.0 28.6 1.8/FV 190 30-Sieve CS

IPP Confidential
 11

Detailed Process Description – Oximation Plant

Oximation Plant

The Oximation Plant uses 55 kmta of cyclohexanone along with some hydrogen and
nitric acid (produced in the unit) to manufacture 62 kmta of the oxime intermediate.
The hyam (hydrogen + nitric acid) reaction takes place in a large column reactor and
the oximation reaction takes place in a series of seven agitated reactors followed by
multiple distillation and separation steps. The plant, which is primarily 304 stainless
steel construction, closed in 2009.

IPP Confidential
 12

Oximation Plant Process Flow Diagram

Nitric acid is produced for the hyam reaction in a small nitric acid plant. The plant
can produce about 130 mt/day (dry basis) of 37% nitric acid. With some
modifications, it can probably produce the same amount of acid at the more typical
67% concentration.

The large process air turbo-

compressor is a Demag model 5ED4
rated for 1,800 m3/hr (inlet) of air. The
discharge pressure rating is 28.4 bar.
The unit is driven by a steam turbine
on one end and a 730 kW AEG tailgas
expander on the other end.

Process Air Turbo-Compressor

The combustion of ammonia takes place at 5.0 bar and 880oC with five layers of 90%
platinum/10% ruthenium gauze catalyst. The total catalyst charge is typically 1,529
grams.

IPP Confidential
 13

There is a complete new ammonium burner system which was never used. The
original cost was $2.5MM. This includes the burner, the NO x removal reactor, and
some downstream boiler/exchanger equipment.

The reaction products from the ammonia burner proceed to the large absorber
column. The column is 3.0 meters diameter by 54.1 meters tall. It is constructed of
304 stainless steel and is rated for 7.5 bar at 95oC. The column has 31 sieve trays.

The overheads from the absorber column proceed to the NO x removal reactor which
uses palladium catalyst on an alumina support for destruction of the NO x products.
The stream then proceeds to the tail-gas expander mentioned earlier to assist in
driving the process air compressor. The expanded tail gas then exhausts through a
tall stack.

The bottoms from the absorber column

are pumped to the bleach tower. The
bleach tower is 1.3 meters diameter by
7.3 meters tall. It is constructed of 304
stainless steel and is rated for 7.5 bar
at 95oC. The column has 6 sieve trays
and was constructed in 2005. The
acid from the bottom of the bleach
tower is pumped to the hyam reactor.
The acid is about 37% concentration,
which also includes a phosphoric acid
component.

Absorber Column

IPP Confidential
 14

The hyam product is produced by the

reaction of hydrogen and nitric acid
with a palladium catalyst. The hyam
reactor is a gas-bubble reactor. There
are six reactor head vessels at the top
for separating the liquids and gases.
The liquids drop down to six filter
vessels at the bottom of the reactor for
catalyst separation and recycle. The
gases going overhead in the reactor
head vessels are compressed and
recycled back to the bottom of the
reactor column. The hyam reaction
takes place at 28 bar and 55oC with
9% palladium catalyst on a carbon
substrate. The catalyst has been
removed and recycled. The hyam
reactor is 2.1 meters diameter by 23.2
meters tall. It is constructed of carbon
steel and is rated for 31.8 bar at
115oC.
Hyam Reactor

The oximation reaction consists of the hyam reacting with cyclohexanone to produce
the cyclohexanone-oxime with a toluene solvent. Approximately 98% of the
cyclohexanone is converted in the oximation reaction section, while the remaining
2% is converted in the neutralization section of the plant. The seven agitated
oximation reactors are 3.7 meters diameter by 3.0 meters tall. They are constructed
of 304 stainless steel and are rated for 0.1 bar at 85oC.
The oximation reaction products then
proceed through two vacuum
distillation columns for removal of the
toluene and impurities. The bottoms
flow from the second vacuum
distillation column is cyclohexanone-
oxime product ready for rearrangement
in the caprolactam unit described in
the next section of this report. The
overheads from the two vacuum
distillation columns consist mainly of
toluene. This stream goes through an
extraction column and a toluene
stripper column for recovery and
recycle of the toluene back to the
oximation reactors. The bottoms
stream from the toluene stripper is
primarily water and is recycled to the
NO x absorber column in the nitric acid
plant. Oximation Reactor

IPP Confidential
 15

Detailed Process Description – Caprolactam Plant

Caprolactam Plant

The Caprolactam Plant uses 62 kmta of cyclohexanone-oxime along with some

oleum (fuming sulfuric acid) and ammonia water to manufacture 60 kmta of the
finished caprolactam product and ammonium sulfate byproduct. The Beckman
rearrangement reaction takes place in relatively small section of the plant. This is
followed by extraction with benzene solvent, distillation, and evaporation. The plant,
which is primarily 304 stainless steel construction, closed in 2009.

IPP Confidential
 16

Caprolactam Plant Process Flow Diagram

The Beckman rearrangement of the cyclohexanone-oxime to caprolactam takes

place with the addition of oleum in a small rearrangement vessel at 125oC and
atmospheric pressure. The reactor products are then neutralized with ammonia
water in a series of small atmospheric vessels.

The neutralization process produces ammonium sulfate, which must be extracted

from the lactam product. This is done using benzene in a packed, pulsating
extraction column. The ammonium sulfate extraction column is 1.0 meters diameter
by 13.8 meters tall. It is constructed of 304 stainless steel and is rated for 3.6 bar
and full-vacuum at 115oC. The bottoms stream from the ammonium sulfate
extraction column are pumped to the ammonium sulfate unit described later in this
report.

The overheads from the ammonium sulfate extraction column are fed to the
caprolactam extraction column. This extraction takes place with benzene in a
rotating-disc extraction column. The rotating discs are variable speed from 34 to 61
rpm. The column is 1.7 meters diameter by 18.1 meters tall. It is constructed of 304
stainless steel and is rated for 1.8 bar at 115oC. The bottoms stream from the
column goes to the incinerator. The overheads proceed to the re-extraction column.

IPP Confidential
 17

The re-extraction column is another

pulsating packed column. It is 1.7
meters diameter by 16.3 meters tall. It
is constructed of 304 stainless steel
and is rated for 4.0 bar and full-
vacuum at 115oC. The overheads
from the re-extraction column are
condensed and go back to the
benzene storage vessel. The bottoms
stream is pumped to the top of the
benzene stripper column.

The benzene stripper column is 1.8

meters diameter by 14.5 meters tall. It
is constructed of 304 stainless steel
and is rated for 2.3 bar at 165oC. This
packed column boils the benzene
overhead where it is condensed and
sent back to the benzene storage
vessel. The bottoms stream is
pumped to the ion exchange beds.
Columns

There are six ion exchange beds operating in two groups of three beds. One group
of beds will be in service while the other group is being regenerated. The first bed in
each series is packed with anion resin, the second bed with cation resin, and the
third and final bed again with anion resin.

The product from the ion exchange section is then hydrogenated in a two-stage
hydrogenation reaction system rated for 10.8 bar. The system uses Raney nickel as
catalyst. This process saturates and of the unsaturated compounds in the product.

The aqueous caprolactam solution which was just hydrogenated is now sent through
two vacuum distillation columns to take the caprolactam concentration from 30% to
85%. The first vacuum distillation column is 1.4 meters diameter by 10.5 meters tall
with eight sieve trays. It is constructed of 304 stainless steel and is rated for 4.8 bar
and full vacuum at 165oC. The second vacuum distillation column is 2.7 meters
diameter by 13.9 meters tall with 10 sieve trays. It is constructed of 304 stainless
steel and is rated for 2.8 bar and full vacuum at 135oC. Vacuum is supplied by two
liquid-ring vacuum pumps.

IPP Confidential
 18

The 85% caprolactam solution is then

sent through three evaporator stages
which remove enough water to take it
to 99.9% concentration. A small
amount of caustic is added at this point
to increase the stability of the
caprolactam product. The evaporators
have carbon steel shells with 304
stainless steel tubes and operate
under a vacuum. The finished product
is then pumped to storage or sent to
the flaker operations. Vacuum is
supplied by two liquid-ring vacuum
pumps.

Evaporator

IPP Confidential
 19

Detailed Process Description – Ammonium Sulfate Plant

Ammonium Sulfate Plant

The Ammonium Sulfate Plant produces 108 kmta of solid ammonium sulfate
byproduct. The plant consists of evaporation, crystallization, centrifugation, and
drying processes. The plant, which is almost entirely 304 stainless steel
construction, closed in 2009.

Ammonium Sulfate Plant Process Flow Diagram

IPP Confidential
 20

The plant receives its feed as a 52% ammonium sulfate solution from the bottom of
the ammonium sulfate extraction column in the Oximation Plant mentioned earlier in
this report. The solution first enters the evaporator section of the plant. The
evaporators take 30 m3/hr of solution from 52% to 60% ammonium sulfate in the first
evaporator and from 60% to 65% in the second stage evaporator. This equates to
about 8,750 lbs/hr of water removal capabilities.

1st Stage Evaporator 2nd Stage Evaporator

The solution drops from the second evaporator into a large crystallizer. The
crystallizer is 7.2 meters diameter by 9.3 meters long. It is constructed of 304
stainless steel and is rated for atmospheric pressure at 100oC.

The solution is then pumped from the crystallizer to the two Escher Wyss centrifuges
for thickening. Mother liquor from the centrifuges is recycled back to the crystallizer.
Thickened product is transported by screw conveyor to the dryer.

Centrifuges

IPP Confidential
 21

The dryer is 2.3 meters diameter by 8.4 meters long. It is constructed of 304
stainless steel and is rated for 0.1 bar at 180oC. Air for the dryer is steam-heated
with a large 304 stainless steel exchanger. The heater is 1.4 meters diameter by 4.0
meters long and is rated for 1.8 bar at 103oC.

The dry ammonium sulfate discharges from the dryer onto a flat conveyor belt. The
conveyor takes the product to a bucket elevator which transfers the product through
some sieves and onto another conveyor belt going to the warehouse. The product
dumps onto the large concrete warehouse floor and is moved with front-end loaders
to desired warehouse locations.

IPP Confidential
 22

Detailed Process Description – Incinerator Unit

Incinerator

The incinerator unit was completely replaced in 1999. It is a vertical, water-cooled

incinerator rated for 1200oC. The carbon steel burner unit is 3.4 meters diameter by
12.3 meters tall. It has the capacity to incinerate five cubic meters per hour of liquid
waste. There are several large stainless steel components to this system such as
the separator and the smelt dissolver. This incinerator unit was designed and
constructed by the Tsukishima Kikai Company.

There is an older incinerator which is unused but still in place.

IPP Confidential
 23

Utilities & Tank Farm

There are two incoming electrical feeders with automatic switching gear which is
included in the plant sale.

There are 13 transformers in the 1,000 to 2,000 kva range. The frequency for all
electrical equipment in this facility is 60 Hz.

There are three cooling tower cells with three Worthington cooling tower water
pumps. The cooling tower is in poor condition, but the pumps are in good condition.

There are four Trane chillers which appear to be about 300 tons of refrigeration
capacity each.

There is a 500 kW emergency generator driven with a diesel motor.

There are two Centac instrument air compressors. The compressor is missing from
one of the units.

There are two diesel-driven fire water pumps capable of 18 bar discharge pressure.

The flare is said to be 55 meters tall, but it appears to be much taller.

There are about 17 major tanks in the tank farms. They are a mix of carbon steel
and 304 stainless steel construction.

IPP Confidential
 24

Equipment List
Ma jor Equipme nt De scription Dia me te r He ight Pre ssure Te mp Ma te ria l of
Qua ntity (m) (m) (ba r) (o C) Ye a r Comme nts Construction
Cyclohe x a none Pla nt (5000)
C5401 Cooling Scrubber 1 2.0 22.6 12.8 215 3-packed 304SS
C5402 Direct Heat Exchange Col 1 2.8 13.0 12.8 215 2-packed CS
C5501 Cyclohexane Absorber 1 0.9 14.3 12.8 90 2-packed 304SS
C5601 Stripper 1 1.2 13.6 2.3 175 1-packed 304SS
C5602 Salt Extraction Col 1 1.8 11.4 5.2 115 1-packed CS
C5701 1st Distillation Col 1 2.3 20.4 7.3 175 18-Sieve CS
C5702 2nd Distillation Col 1 2.2 21.5 7.3 175 18-Sieve CS
C5703 3rd Distillation Col 1 3.2 25.9 7.3 190 21-Sieve CS
C5801 Drying Col 1 1.2 16.3 2.3 190 14-Sieve CS
C5802 Fore Run Col 1 1.6 38.3 1.8/FV 190 60-Sieve CS
C5803 Anone Distillation Col 1 3.0 49.7 1.8/FV 190 80-Valve CS
C5804 Anol Distillation Col 1 3.0 28.6 1.8/FV 190 30-Sieve CS
E5502 Ammonia Evaporator 1 1.3 6.2 26.4 75 CS
E5701A/B - C5701 Reboilers 2 1.1 5.5 16.8 280 CS
E5702 - C5702 Reboiler 1 1.7 6.7 7.3 175 1988 CS
E5703A/B - C5703 Reboiler 2 1.6 7.2 7.3 175 CS
E5705 Distillation Condenser 1 2.3 7.2 2.3 115 CS
E5801 - C5801 Reboiler 1 1.0 5.2 16.8 280 CS
E5802 - C5802 Reboiler 1 1.1 4.0 16.8 280 1987 CS
E5806 - C5803 Reboiler 1 1.0 5.2 16.8 280 CS
E5807 - C5803 Condenser 1 1.8 7.7 1.8 115 CS
E5812 - C5804 Reboiler 1 1.4 5.4 16.8 280 1999 CS
E5813 - C5804 Condenser 1 1.5 6.4 1.8 130 CS
F5901 Hot Oil Furnace 1 3.1 23.2 ATM 565 CS
R5411-14 Oxidation Reactors 1-4 4 3.4 6.0 12.8 190 Agitated CS
R5419 Post Oxidation Reactor 1 3.4 6.5 12.8 190 CS
R5901 Anol Reactor 1 2.6 7.2 1,483 tubes CS/CS
S5401 Water Separator 1 2.5 7.6 14.3 175 CS
S5601-3 Separator/Neutralizer 1-3 3 2.6 7.8 20.4 190 CS
S5702 Reflux Vessel 1 3.1 7.7 2.3 115 CS
V5004 Ammonia Storage Tank 1 1.5 8.2 27.5 62 CS
V5401A Cyclohexane Recirc Tank 1 3.8 8.4 2.3 115 304SS

Cyclohe x a ne Pla nt (5200)

C5201 Benzene Drying Col 1 0.7 12.5 2.6 115 CS
E5205 Benzene Evaporator 1 1.8 6.1 3.7 315 CS
E5208 Waste Heat Boiler 1 2.4 5.8 20.9 226 CS
R5201 1st Reactor (0.3% Pt on Al) 1 1.8 6.8 34.0 315 2,664 tubes CS/CS
R5202 Post Reactor (ZnO + Pt/Al) 1 2.2 5.2 34.0 315 CS

Ox ima tion Pla nt (6000)

C6301 Water Extraction Col 1 0.5 20.0 1.8 85 4-packed 304SS
C6401 1st Vacuum Col 1 1.9 20.8 2.0/FV 140 2-packed 304SS
C6402 2nd Vacuum Col 1 1.0 14.9 1.8/FV 165 1-packed 304SS
C6501 Extraction Col 1 2.0 11.8 3.5/FV 115 1-packed 304SS
C6502 Toluene Stripper 1 2.1 24.5 2.1 135 21-sieve 304SS
C6503 Waste Water Stripper 1 0.9 11.8 2.0 125 9-sieve 304SS
C6601 Ammonia Absorber 1 0.8 9.2 7.3 125 2-packed 304SS
C6701 NOx Absorber 1 3.0 54.1 7.5 95 31-sieve 304SS
C6702 Bleaching Tower 1 1.3 7.3 7.5 95 2005 6-trays 304SS
E6201 Hyam Reactor Cooler 1 1.3 9.5 5.0 55 CS
E6401 - C6401 Reboiler 1 1.2 5.3 3.3 185 CS
E6402 - C6401 Condenser 1 1.1 5.1 1.8 85 304SS
E6502 - C6502 Reboiler 1 1.2 5.0 5.3 190 CS
E6603 Ammonia Evaporator 1 2.0 6.2 26.4 75 CS
E6604 - R6601 Waste Heat Boiler 1 2.1 5.6 6.5 350 CS
E6802 - R6801 Waste Heat Boiler 1 1.6 4.6 6.0 350 CS
R6201 Hyam Reactor 1 2.1 23.2 31.8 115 CS
R6301-07 Oximation Reactors 7 3.7 3.0 0.1 85 Agitated 304SS
R6601 Ammonia Burner (+1 spare) 2 1.5 2.1 6.5 1000
R6801 NOx Remover (+1 spare) 2 1.8 1.6 6.0 750
S6201A-F Filtration Vessels 6 1.6 3.5 34.0 115 304SS
S6801 Mist Separator 1 1.6 7.0 7.5 75 304SS
T6201 - R6201 Let-down Tank 1 4.8 6.1 ATM 115 304SS
V6204 Buffer Vessel 1 5.8 7.6 ATM 115 304SS
V6403 Toluene Oxime Vessel 1 4.8 3.8 ATM 80 304SS
V6701/2 - C6701 Buffer Vessels 2 5.8 7.6 ATM 80 304SS
V7203A/B Crude Caprolactam Tanks 2 5.0 6.1 ATM 115 304SS
V7301 Benzene Storage Tank 1 4.8 6.1 ATM 65 304SS

Ca prola cta m Pla nt (7000)

C7301 Ammonium Sulf Extraction Col 1 1.0 13.8 3.6/FV 115 Pulsating-Pack 304SS
C7302 CPL Extraction Col 1 1.7 18.1 1.8 85 Rotating Disc 304SS
C7303 Re-extraction Col 1 1.7 16.3 4.0/FV 115 Pulsating-Pack 304SS
C7304 Benzene Distillation Col 1 1.0 6.1 2.3 115 12-sieve 304SS
C7305 Benzene Stripper Col 1 1.8 14.5 2.3 165 2-packed 304SS
C7306 Condensate Stripper 1 0.4 3.7 2.3 165 1-packed 304SS
C7401-6 Ion Exchange Beds 6 1.7 4.4 7.3 115 1-packed 304SS
C7601 1st Distillation Col 1 1.4 10.5 4.8 165 8-sieve 304SS
C7602 2nd Distillation Col 1 2.7 13.9 2.8 135 10-sieve 304SS
C7801 Scrubber 1 0.9 3.8 - 115 304SS
E7202 Neutralization Cooler 1 1.0 7.4 3.8 115 304SS
E7601 1st Dist Col Reboiler 1 1.2 5.1 5.3 190 CS
E7602 2nd Dist Col Reboiler 1 1.5 4.7 4.8 165 CS
E7604 2nd Dist Col Condenser 1 1.5 7.5 2.8 115 CS
S7702 Lactam Distillation Separator 1 2.5 7.9 1.8 165 304SS

Ammonium Sulfa te Pla nt (8500)

E8502 Heater #2 1 1.4 4.0 1.8 103 304SS
E8504 Condenser #1 1 1.2 6.6 1.8 67 304SS
G8501 Dryer 1 2.3 8.4 0.1 180 304SS
V8501 1st Effect Evaporator 1 3.2 6.5 0.5/FV 120 304SS
V8504 2nd Effect Evaporator 1 3.8 7.1 0.9.FV 100 304SS
X8501 Crystallizer 1 7.2 9.3 ATM 100 304SS
X8503 Wet Scrubber 1 3.2 7.7 ATM 103 304SS

Incine ra tor (0100)

F0101 Incinerator 1 3.4 12.3 0.3 1,200 1999 CS
F0201 Incinerator (abandoned) 1 CS
S0105 Separator 1 3.2 22.6 0.3 100 304SS
V0102 Smelt Dissolver 1 4.2 4.5 0.2 100 1999 304SS

Ta nk Fa rms
T0201 Caustic Tank 1 5.8 6.9 ATM 132 304SS
T0202 Oleum Tank 1 1.5 2.7 ATM 172 304SS
T0203 Sulfate Tank 1 4.0 5.4 ATM 73 304SS
T0301 Sulfuric Acid (98%) Tank 1 8.2 10.6 ATM 45 CS
T0302 Oleum Tank 1 8.1 9.1 ATM 45 CS
T0303 Ammonium Sulfate Tank 1 10.4 12.1 ATM 60 304SS
T0304A Caustic Tank 1 4.8 6.1 ATM 55 304SS
T0304B Caustic Tank 1 2.9 20.0 17.6 343 CS
T5201A/B Benzene Tanks 2 8.5 10.6 ATM 65 CS
T5202A Cyclohexane Tank 1 8.2 10.6 ATM 65 CS
T5202B Cyclohexane Tank 1 13.4 15.6 ATM 65 CS
T5802A Intermediate Tank 1 5.7 7.6 0.1 190 1987 CS
T5803 Cyclohexanone Tank 1 11.6 14.4 ATM 90 CS
T7801A/B/C Caprolactam Tanks 3 9.0 12.1 ATM 140 304SS

IPP Confidential