ABSTRACT

Naphthalene is available in the form of vapour that instantly condenses into an aromatic
substance that is solid and chemically neutral. Petroleum or coal tar can be used to make
naphthalene. The most popular method of production for coal tar is distillation and
fractionation. On this project we have studied about the different methods involved in
recovery of naphthalene widely and then we continued with recovery of naphthalene from
coal tar in tar distillation plant with the help of process flow diagram and specified the
working of equipment and utilities with the help of play layout. Naphthalene is primarily
used as an intermediary in the synthesis of phthalic anhydride, which accounts for more than
60% of total consumption.. In our study we wrote other uses of naphthalene for
production.The study aims to comprehend the intricacies of the recovery process and its
operational aspects.A comprehensive study involves the development of process flow
diagrams, identification of associated equipment, and the establishment of material balances
for equipment and the overall process. Finally, the study includes the estimation of costs
associated with the process, encompassing plant setup costs and various other expenditures.
 CHAPTER – 1
INTRODUCTION

Naphthalene, a crystalline organic compound represented by the chemical formula C 10H8,

stands as a fundamental building block for numerous aromatic compounds, boasting two
fused benzene rings. Derived mainly from coal tar, this white crystalline solid is renowned
for its distinctive mothball odor and finds widespread use due to its deodorizing and insect-
repellent properties. Its physical properties, including 80.2°C as its melting point and 218°C
as its boiling point, contribute to its versatile applications. In terms of chemical properties,
naphthalene's aromatic nature renders it highly reactive, enabling various reactions such as
nitration and sulfonation. Nitronaphthalenes, formed through nitration, play roles in dye and
explosive production, while sulfonation yields naphthalene sulfonic acids vital in detergents
and as intermediates in synthesizing other compounds. Naphthalene production typically
involves coal tar distillation, a process where coal tar is heated to separate fractions based on
boiling points, with naphthalene subsequently isolated through fractional distillation.

The uses of naphthalene are diverse, spanning plastics, resins, dyes, lubricants, fuels, also as a
pesticide for moth control. Additionally, it contributes to the manufacture of phthalic
anhydride and finds applications in medicinal contexts, showcasing properties such as
anticancer, antimicrobial, anti-inflammatory, antiviral, and more. Furthermore, it plays a role
in paint production and serves as a key component in insecticides like carbaryl.Coal tar, a
byproduct of coke production through destructive distillation of coal, is central to
naphthalene recovery. Millions of tons of coke generate substantial amounts of coal tar,
primarily employed in the recovery of naphthalene as a raw material. Tar distillation plants
are designed to produce various grades of pitch and naphthalene, along with by-products like
ammonia liquor and sodium phenolate.The intricate process of recovering naphthalene from
coke oven gas within a tar distillation plant involves cooling, condensation, and fractional
distillation. Starting with the cooling of coke oven gas to condense tar components, the
subsequent fractional distillation exploits varying boiling points, allowing the isolation of
naphthalene. Following this, the vaporized naphthalene undergoes further cooling and
condensation, resulting in a higher-purity liquid form ready for industrial applications.
Additional purification steps may be taken to eliminate impurities, enhancing the overall
quality of the recovered naphthalene.
1.1 WHAT IS NAPHTHALENE?

Naphthalene is a crystalline organic compound with the chemical formula C10H8.

It is a fundamental building block of many aromatic compounds and is known for
its distinctive and pungent odor.

Naphthalene is a white, solid aromatic hydrocarbon with two fused rings of

benzene. It is commonly found in coal tar and is a major component of mothballs,
which are used to protect clothing from moth larvae. Naphthalene has a unique,
strong odor and is often used for its deodorizing and insect-repellent properties.

PHYSICAL PROPERTIES

Molecular Formula: C10H8

Molecular Weight: 128.18 g/mol
Appearance: White crystalline solid
Odor: Strong, characteristic mothball odor
Melting Point: 80.2°C (176.4°F)
Boiling Point: 218°C (424.4°F)
Solubility: Naphthalene dissolves very slowly in water, it dissolves quickly in organic
solvents such as toluene and benzene.
CHEMICAL PROPERTIES

Naphthalene is highly reactive due to its aromatic nature and can undergo various chemical
reactions, such as:
 Nitration: It can be nitrated to form nitronaphthalenes, which are used in the production
of dyes and explosives.
 Sulfonation: Sulfuric acid can be used to sulfonate naphthalene, yielding naphthalene
sulfonic acids used in detergents and as intermediates in the synthesis of other
compounds.

PRODUCTION OF NAPHTHALENE

Naphthalene can be produced from various sources, primarily from the distillation of coal tar,
which is a byproduct of the coking process in the production of coke from coal. The steps for
naphthalene production include:
1.Coal Tar Distillation: Coal tar is heated in a distillation tower, and various fractions,
including naphthalene, are separated based on their boiling points.
2.Naphthalene Separation: Naphthalene is separated from other components in the coal tar
mixture using fractional distillation.

USES OF NAPHTHALENE

 Naphthalene is primarily used in the production of fuels, lubricants, resins, dyes, and
polymers.
 Most naphthalene is used as a pesticide to keep moths under control in interior storage
rooms.
 It is majorly used in the manufacture of phthalic anhydride in chemical industries.
 Apoptosis inhibitor, carcinogenic agent, plant metabolite, volatile oil component, and
environmental contaminant are some of its functions. It is an ortho-fused bicyclic arene.
 Medicinal use of naphthalene are: anticancer, antimicrobial, anti-inflammatory ,
anticonvulsant,antitubercular,antihypertensive,antiviral,antidiabetic,antineurodegenerativ
e,antipsychotic , and antidepressant.
 Paints and the pesticide carbaryl, which is used in gardens and homes, are also made with
naphthalene.

1.2 PROCESS OVERVIEW

Naphthalene recovery from coke oven gas in a tar distillation plant is a crucial process that
plays a pivotal role in the coal and steel industry. Coke oven gas, a byproduct of the coke-
making process, is a complex mixture of volatile and semi-volatile organic compounds,
including naphthalene, benzene, toluene, and xylene, collectively referred to as "tar.
The recovery process commences within a tar distillation plant, where the coke oven gas is
subjected to a series of intricate steps to isolate naphthalene. The first stage involves cooling
and condensation, during which coke oven gas is cooled, causing the tar components to
condense into liquid form. This condensed tar is then subjected to fractional distillation, a
process that exploits the varied boiling points of the tar constituents. Naphthalene, with its
relatively low boiling point, vaporizes and can be separated from the mixture. Subsequent to
fractional distillation, the vaporized naphthalene is further cooled and condensed into a liquid
state for collection. While this recovered naphthalene is of higher purity, additional
purification steps may be undertaken to eliminate impurities and other byproducts, thus
enhancing its quality for industrial use.

CHAPTER-2
 Literature review and Objective

The distillation tower design process is typically divided into two phases: a process
design followed by a mechanical design, as outlined by Karl Kolmetz. The primary
objective of the process design is to compute necessary stream flows and determine
the required number of theoretical stages, including factors such as reflux rate, side
draws, and heat duties, such as the number of pump around and specifications for
the condenser and reboiler. Subsequently, the mechanical design, also guided by
Karl Kolmetz, focuses on selecting tower internals, determining the column
diameter, and establishing the tower's height.

Both the process and mechanical designs can be streamlined using established
"cookbook" procedures commonly employed by Engineering Procurement and
Construction (EPC) firms, with Karl Kolmetz emphasizing their utility. These
designs can often be optimized to enhance profitability, operational efficiency, and
maintenance ease. Assessing profitability is best achieved through a life cycle cost
analysis, as advocated by Karl Kolmetz, encompassing the plant's initial capital
cost and the first ten years of operating and maintenance expenses, incorporating a
reliability factor that is crucial in the design of any process plant equipment, as
enhanced reliability significantly influences return on investment (ROI).

Karl Kolmetz also underscores several crucial considerations during distillation

equipment design, including selecting appropriate equipment for process
conditions, choosing equipment suitable for the expected run length, implementing
a successful approach to process control for reliable operations, and evaluating
factors such as fouling, corrosion, and polymerization potential. Additionally,
considerations for thermal and chemical stability, maintenance reliability, safety,
accessibility, and ease of repair are essential. The overarching goal, as highlighted
by Karl Kolmetz, is to determine the most economical option that minimizes life
cycle costs. This review, guided by Karl Kolmetz, encompasses generic rules for
distillation design that can be used for any kind of process, offering specific
insights tailored to natural gas processing, petrochemicals, refining, and
oleochemical industries.
This review delves into the 50-year research conducted at AO
VostochnyiNauchno–Issledovatel’skiiUglekhimicheskiiInstitut (VUKhIN), led by
V. G. Nazarov, focusing on the extraction of naphthalene and tar during the
primary cooling of coke–oven gas. The comprehensive examination also
encompasses related subjects, including the cooling of ammonia liquor and the
conditioning of coal tar through surface heat exchangers. Additionally, the review
brings forth laboratory results that had not been published during the author's
lifetime, offering a novel contribution to the existing body of knowledge on these
topics.

Objective:
Following objectives has been made on the basis of assumptions taken with respect
to Tar Distillation Plant:-
 To recover the naphthalene from coal tar.
 To design the tar distillation plant.
 To perform the material and energy balances over equipment using assumed
data.
 To estimate the Cost of recovery of naphthalene in tar distillation plant.

CHAPTER - 3
 METHODOLOGY AND PROCESS DESCRIPTION

In the recovery of naphthalene, there are various methods available, among which solvent
extraction and fractional distillation are prominent. For the current project, the chosen
methodology involves the utilization of fractional distillation. This method capitalizes on the
differences in the boiling points of components within the mixture.

3.1 Solvent Extraction

Solvent extraction is a versatile method employed in the recovery of naphthalene from

mixtures. The process involves carefully selecting a solvent in which naphthalene exhibits
solubility while keeping other components of the mixture relatively insoluble. Common
solvents for this purpose include benzene, toluene, and xylene. The choice of solvent is
critical, as it determines the efficiency of the extraction process. Once the solvent is selected,
the next step involves the thorough mixing of the chosen solvent with the mixture containing
naphthalene. This mixing facilitates the dissolution of naphthalene into the solvent, forming a
solution.

Following the mixing phase, the mixture is allowed to undergo phase separation, typically in
a dedicated separation vessel. During this stage, the solvent containing the dissolved
naphthalene separates from the other components of the mixture. The success of this
separation relies on the differing solubilities of the components in the chosen solvent. The
separated solvent, now enriched with dissolved naphthalene, undergoes further processing to
recover the isolated naphthalene. Common recovery methods include distillation or
evaporation, which serve to remove the solvent, leaving behind purified naphthalene.

An additional consideration in the solvent extraction process is the potential for solvent
recycling. Depending on the nature of the solvent used, it may be feasible to recover and
reuse the solvent, contributing to the overall sustainability of the process. Solvent recycling
can be achieved through distillation or other purification techniques, reducing both the
environmental impact and the overall cost of the operation.

3.2 Fractional Distillation

Fractional distillation is a separation process commonly employed in industries such as
petrochemical refining and the recovery of specific components from complex mixtures like
crude oil or coal tar. The process begins by heating the mixture in a distillation flask, causing
the component with the lowest boiling point (the most volatile) to vaporize first. The vapor
then rises through a fractionating column, a vertical structure with trays or packing material.
Within the column, the vapor undergoes condensation and re-vaporization on multiple
surfaces, facilitating separation based on boiling points. The higher boiling point components
condense and return to the flask, while the lower boiling point components continue upward.
At the top of the column, a condenser cools the vapor back into a liquid, which is collected in
a receiving flask. Different fractions are collected at different levels of the column, each
representing a component with a specific boiling point range. The temperature is monitored
throughout the process, and when a plateau is reached, it indicates that a specific fraction is
being distilled. The process is repeated as needed to collect additional fractions, resulting in a
more purified form of each component in the original mixture. In the context of recovering
naphthalene from coal tar, fractional distillation is employed to vaporize the components,
with naphthalene being among the first fractions collected due to its relatively low boiling
point. Subsequent purification steps may be applied to achieve a higher level of purity, such
as crystallization.

3.3Process flow diagram of tar distillation column:

3.4 Process for the recovery of Naphthalene:
There are two stages in tar distillation plant to rectify Naphthalene products out of crude coal
tar.

First Stage:

The crude coal tar containing around 5% moisture in the intermediate tar tank it is sent to a
gas fire furnace with the help of a plunger pump where it is heated to 120 °C to remove the
moisture content present in it. Since water boils at 100° C it is evaporated through the
evaporator and the remaining dehydrated tar is collected in a tank. The evaporated products
are condensed in a condenser cooler and these are separated into water and light oil with the
help of a separator. This light oil extracted is used as reflux to fractionating tank in the second
stage.

Second stage:

The dehydrated tar from 1st stage is sent to the gas fire furnace with the help of a plunger
pump where it is heated to 350 - 400 °C. This heated tar passes through an evaporator where
the temperature of 380-400 °C is maintained with the passage of superheated steam. At this
temperature all the fractions other than tar pitch are evaporated, hence tar pitch is rectified
from the evaporator. The superheated steam gives the up thrust to the oil vapor hence
facilitates the separation of oil vapors from tar pitch. The oil vapors coming out of the
evaporator are fed to the anthracene column where the temperature of 200- 220 °C is
maintained by the passage of superheated steam. Another input of the anthracene column is
heavy oil reflux. It lowers down the temperature of the column as it becomes higher than the
required temperature (max. 230 °C) due to the steam passage.

At a temperature of 220 °C or less anthracene settles down, hence rectified with the help of
submerge cooler in a fractionating tank. The vapors from the anthracene column along with
the light oil reflux are fed to the fractionating column where the fractions of phenol,
naphthalene, and heavy oil are condensed by a submerged cooler and collected in their
respective fractionating tanks. The vapors coming out of fractionating column contain light
oil and water. These are condensed in a condenser cooler and separated into their respective
fractionating tanks. This light oil is again used as a reflux in the fractionating column. After
the recovery of naphthalene from the fractionating column with naphthalene fraction 72-75%,
65-70 % naphthalene mixture (naphthalene + DNO + other oils) is charged in crystallizer to
make slurry of naphthalene crystals form in the mixture of liquid naphthalene and other oils.
The mixture initially at higher temperature is cooled to crystallization temperature by
atmospheric cooling.

At crystallization temperature, the formation of a crystal (nucleation) starts and phase change
occurs. Due to latent heat the temperature remains constant during the air cooling and the
nucleation process continues. When the temperature starts falling again it indicates the
completion of nucleation process. Now the formation of naphthalene crystals is completed.
At this time, water cooling is done by spraying water on the outer surface of crystallizer for
the overgrowth of crystals. After 48 hours of crystallization process these crystals are
centrifuged in screw conveyer and double screw conveyer respectively to separate
naphthalene crystals from the slurry. The naphthalene crystals are further hydraulically
pressed to form hot pressed naphthalene (HPN) cakes. These cakes are sent to dispatch
section and sold in the market where it is refined and converted into its derivatives as per
demand.
 CHAPTER- 4
PLANT LAYOUT

To convert coal to coke: coal from coal tower enters into coke oven batteries under extensive
temperature coke oven gas is released. But it can not be processed further because of
impurities present into it. To remove the impurities gas in ejected into gas condensation plant
there tar and ammonia liquor is removed from gas.Then ammonium sulphate is recovered
from coke oven gas in ammonium sulphate plant . Coke oven gas is released into benzol
recovery plant to release benzene. Tar recovered from Gas condensation plant in processed
further in tar distillation plant for to recover phenol, anthracene and naphthalene.For
naphthalene recovery crystillizer is used in naphthalene fractionation through screw conveyor
hot pressed naphthalene cake is made. These cakes are sent to dispatch section and sold in the
market where it is refined and converted into its derivatives as per demand.
 CHAPTER- 5
DESIGNING OF DISTILLATION COLUMN
One of the main pieces of equipment that we design is the distillation column.In order to
concentrate the more volatile liquid in the initial fractions and the less volatile components in
the later fractions, a distillation column is a tube that offers surfaces on which condensations
and vaporizations can occur prior to the gas entering the condenser.

Steps for Designing of Distillation Column:

In the chemical industry, distillation is a commonly used procedure to separate distinct
components from mixtures. This operation works by heating a mixture to turn it into vapor
and then cooling the vapor to obtain a purified liquid. The key equipment employed for this
purpose is a distillation column. We will go over the detailed design of a distillation column
in this project, complete with examples and the necessary formulas.

Step 1: Describe the Problem:

Identifying the issue is the first stage in creating a distillation column. This entails defining
the target product purity, the composition of the feed, and the operational parameters like
temperature and pressure. The reflux ratio is determined by the desired product purity, and
the number of trays or packing needed is determined by the composition of the feed.

Step 2: Determine the Operating Pressure:

Finding the distillation column's operating pressure is the second step. In order to accomplish
this, the vapor-liquid equilibrium (VLE) statistics for each combination component are
assessed. The operational pressure is the pressure at which the mixture's constituent parts boil
at different rates. Experiments or published literature are two ways to get the VLE data.

Step 3: Determine the Number of Trays:

Finding the number of trays needed for the distillation column is the third stage in the design
process. The feed composition and desired product purity determine how many trays are
needed. The Fenske equation, which is provided by: is used to determine the minimal number
of trays needed.

Nmin = (log (D/F)) / (log (α – 1))

where F is the reflux ratio, α is the relative volatility of the components, and D is the number
of theoretical plates required for the separation, and Nmin is the minimal number of trays.

Step 4: Tray Efficiency:

Tray efficiency is the ratio of the actual separation on a tray to the theoretical separation.. An
essential factor that influences the quantity of trays needed for the column is the tray
efficiency. Correlations can be used to estimate the tray efficiency or it can be measured
experimentally. The Murphree tray efficiency, which can be found by: is the correlation that
is most frequently utilized.

Em = (Hmin – Hl) / (Hv – Hl)

where Hv is the enthalpy of vapor entering the tray, H min is the minimal reflux ratio, and H l is
the enthalpy of liquid exiting the tray., and Em is the Murphree tray efficiency.

Step 5: Column Diameter:

The column diameter is determined by taking into account the vapor flow rate, the number of
trays required, and the space between trays. The diameter can be calculated using the
following formula:

Dc = (4 * F * V / (π * ρ * (1 – ε))) ^ 0.5

Where the variables in this equation are the column diameter (Dc), reflux ratio (F), vapour
flow rate (V), vapour density (ρ), and tray fraction (ε) of the column.

Step 6: Liquid Flow Rate:

The intended liquid residence time on each tray and the tray spacing are used to calculate the
liquid flow rate. The following formula can be used to determine the liquid flow rate:

L = V / (ε * (1 + K))

Where ε is the percentage of the column occupied by trays, K is the vapour-liquid

equilibrium ratio, L is the liquid flow rate, and V is the vapour flow rate.
Step 7: Reboiler Duty:
The reboiler duty is the amount of heat required to evaporate the liquid input and maintain the
column operating at the proper temperature.
The reboiler duty can be calculated using the following equation:

Q = L * (Hv – Hf)

where Hf is the enthalpy of the feed, Q is the reboiler duty, L is the liquid flow rate, and H v is
the enthalpy of vapor entering the calculation—the enthalpy of vapor entering is equal to the
enthalpy of liquid leaving the tray.

Step 8: Condenser Duty:

The quantity of heat that has to be extracted from the column in order to condense the vapor
and achieve the required level of product purity is known as the condenser duty.

How is condenser duty calculated?

The following formula can be used to determine the condenser duty:

Qc = V * (Hf – Hv)

We employ a combination of sensible and latent heat in our second formula.

where Hf is the enthalpy of the feed, H v is the enthalpy of vapor entering the tray, V is the
vapor flow rate, and Qc is the condenser duty.

Step 9: Reflux Ratio:

The ratio of the liquid product to the liquid that is returned to the column is known as the
reflux ratio. The number of trays needed and the desired product purity (distillery column
design technique) define the reflux ratio. The following formula can be used to determine the
reflux ratio:

F = L / (D – 1)
Where D is the number of theoretical plates needed for the separation, L is the liquid flow
rate, and F is the reflux ratio.

Step 10: Column Height:

The diameter of the column, the number of trays needed, and the space between the trays are
used to calculate the column height. To find the height, apply the formula below:

Hc = (N * Htray) + Hv + Hf + Hcond

Where, Hf is the height of the feed plate, H condis the height of the condenser, Hv is the height
of the vapor disengagement space, Hc is the column height and N is the number of trays.

Designing:
Feed, F = 12500 kg/hr

Feed Fraction, Xf = 12.53% = 0.1253

Distillate fraction, Xd = 90% = 0.90

Bottom fraction, Xw= 5% = 0.05

Equation Involved
F = D+W

F(Xf) = D(Xd) + W(Xw)

12500 = D + W ----(eq.1)

12500(0.1253) = D(0.90) + W(0.05) -----(eq.2)

By Solving eq.1 and eq.2,

D = 1107.4 kg/hr

W = 11392.6 kg/hr

ENERGY BALANCE CALCULATIONS

For Heater:
 Q = mcp∆T

= 12500 × 12.62 × (325 – 125)

= 31 × 103 MJ/hr

= 31 × 106 KJ/hr

Assumptions:

Using LPG as fuel gas and also assuming pure butane

For 1 kg LPG = 33786.2 KJ

? = 31 × 106 KJ

Therefore LPG required = 917 kg/hr

MODEL CALCULATIONS
Equipment Heat Hot Fluid Cold Fluid
transferred

Q = 31 × 103 MJ/hr m = 917 kg/hr m = 1071 kg/hr

Condenser T1 = 125 0C T1 = 55 0C
T2 = 325 0C T2 = 25 0C

Q = 313842 KJ/hr m = 139 kg/hr m = 1 kg/hr

Reboiler T1 = 280 0C T1 = 325 0C
T2 = 325 0C T2 = 280 0C

Feed, F=12500 kg/hr

Xf=0.1253, Xd = 0.90, Xw = 0.05

Using F=D+W & F(Xf) = D(Xd) + W(Xw)

By solving

D=1107.4 kg/hr

W=11392.6 kg/hr
Avg. Molecular wt. of vapor = 0.9(144) + 0.1(128) = 142.4 kg/k-mole

Vapor density = (142.4 x 273)/ (22.41x533) =3.254 kg/m3

Volumetric flow rate of gas, QG=(1107.4x533x22.414)/(142.4x273x3600)= 0.0945 m3/sec

Liquid Density= (1058+1022)/2 = 1040 kg/m3

Avg. Mol wt. of liquid =100/((5/128)+(95/144)) = 143.11 kg/k-mole

Volumetric flow rate of liquid, QL = 11392.6/ (3600x1040) = 3.04x10-3 m3/sec.

Tower Diameter:

Assume t = 0.5 m

(L/G')( ρG/ρL)0.5 = ((QL X ρL)/ (QG X ρG) (ρG/ρL) 0.5)

= 0.575 (>0.1)

Assume w=0.7T and area used by one downspout = 8.8%

Tower area, AT=0.1622 m2

T = (4 AT / π) 0.5 = 0.4545 m

Then corrected area = π(T2/4)=0.159 m2

W=0.7(.45) = 0.315 m

Ad= 0.088 AT = 0.01427 m2

Aa = AT - 2Ad - 0. 2AT = 0.10128 m2

Weir crest, h1 and weir height, hw

Take h1 = 25 mm and hw = 50 mm

h1/T=0.055 and T/W = 1.428

h1 = 0.666 (QL/W) 2/3 (Weff/w)-2/3 = 0.03 (Weff/W)-2/3

(Weff/W)2 = (T/W)2-[((T/W)2- 1)0.5 + 2h1T/(TW)]2

By Iteration h1 =0.0345, Weff/W = 0.809

Dry Pressure drop:

Co = 1.09(do/L), where Co = orifice coeff.

do = hole diameter

L = plate thickness

Co= 1.635

Ao= 0.1275, Aa= .0129 m2

Vo = QG/Ao=7.3255 m/s

Take = 1.25x10-5 kg/m-s

f = 0.079 x Re-25 = 0.00145

(2hDgPL)/(Vo2ρG)=Co[(0.4(1.25-(Ao/An))+(4lf/dO)+(1-

(Ao/An))2]

by solving hD= 0.01822 m

Hydraulic head:

V=QG/Aa = 0.9330 m/s

Z = (T+W)/2 = 0.3825

hL= 6.1 x 10-3+ 0.725 hw- 0.238 hwVaρG0.5 + (1.225QL/Z)

= 0.03208 m

Residual pressure drop:

HR= (6σgc)/ ( ρLdog) = 3.612x10-4 m

Pressure drop at the liquid entry There will be a downspout apron set at

hw-0.025 = 0.025 m, above the tray

The area for the liq. Flow under the apron = 0.025xW

= 0.007875 m2

Then h2 = (3 QL2)/(2gAda2) = 1.796x10-4 m

back up in downspout

h3 = hg+ h2 = 0.05083 m

Check on flooding

hW + h1 + h3 = 0.1408 [<t/2 = 0.25]

Therefore tray spacing is satisfactory.

Result:

No. of plates = 13 (Using McCabe Thiele Method)

Taking one for recoiling, no. of plates = 13-1 = 12

Actual no. of plates = 12/0.8 = 15

Height of the tower

15x0.5 = 7.5 mResidence time in downspout = (Ada t)/QL = 1.295 sec

 CHAPTER- 6
MASS AND ENERGY BALANCE ALONG
EQUIPMENT:
Mass and Energy balance along Distillation Column:

Let us consider the following scenario: a

fractionating column running at a constant pressure P is to constantly separate F lb/hr of a
mixture of components A and B, with X F weight fraction of component A. XD and XW weight
fractions of component A are to be contained in the top product and the bottom product,
respectively. The feed, overhead, and bottom product temperatures—t F, tD, and tw,
respectively—are all stated. These streams have comparable enthalpies of hF, hD, and hW.

Mass Balance:

Overall material balances can be used to compute the D and W terminal stream flow rates.

In a steady state,

F = D + W ---------- [1]

F*XF = D*XD + W*XW -------- [2]

The previous equations can be solved simultaneously because there are only two unknowns,
D and W. Therefore, stream D's amount can be computed as follows:

F*XF= D*XD + [F-D]*XW [substitute value of W]

Equation [1] or an equation similar to equation [3] can be used to determine the amount of
stream W.

W = F*[XD-XF]/ [XD-XW]---------[4]

Energy balance:

The energy balance of the system, assuming that there is no heat loss from the system to the
environment, can be written as

Heat in = Heat out

F*hF + qr = D*hD + W*hW + qc ------------- [5]

Where,

qr = heat added in reboiler, Btu/hr

qc = heat extracted from the condenser, Btu/hr

According to equation [5], the heat extracted in the condenser is fixed at a specific value and
cannot be changed if the reboiler heat input is fixed. In a similar vein, the reboiler heat input
is fixed, if the heat extracted in the condenser is fixed. Thus, before moving further with the
design, one of these two quantities needs to be defined.

Energy and material balance for the condenser

This can be written as,

V1 = L0 + D -------------- [6], therefore,

V1*Y1 = L0*X0 + D*XD ------------- [7] [mass balance]

V1*H1 = qc + L0*h0 + D*hd ---------------- [8] [energy balance]

Please see the diagram

V1 is vapour in lb/hr, Y1 is the mass fraction of A in vapour, L0 is reflux, X0 is the mass

fraction of A in reflux, D is the overhead product in lb/hr, H 1 is the enthalpy of vapour and h D
is the enthalpy of overhead product.

Y1 = X0 = XD and h0 = hDare the results of using a total condenser, which is one in which all
of the vapor entering the condenser is condensed as indicated by the diagram.

rom equation [8] , qc = V1*H1 – hD*[L0 + D] since h0 = hD.

We obtain qc by substituting for V1 in equation [6].

Heat removed by condenser is therefore,

qc = [L0 + D]*H1 - hD*[L0 + D] = [L0 + D]*[H1-hD]

Dividing this equation by D on both sides,

qc/D = [L0/D + 1]*[H1 – hD] --------- [9]

The external reflux ratio is the ratio L0/D.

Fixing the reflux ratio is the same as fixing qc, according to equation [9].

Once qc is known, the reboiler heat input qr may now be calculated from equation [5] which is
F*hF + qr = D*hD + W*hW + qc

As a result, all required terminal conditions have now been established, and material and
energy balances have been used to compute any unknown quantities.
 CHAPTER –7
COST ESTIMATION

7.1 Estimation of cost of naphthalene recovery plant

Accurate cost estimation can be made after the designing stage since precise plant facility
information and full equipment specifications are available.

Cost estimates made during the initial design phase are occasionally referred to as guesswork.
A plant design needs to show a process that can run in a way that can generate revenue.

Capital investment:

A substantial sum of money needs to be provided before an industrial plant is put into
operation in order for
• Purchasing the required equipment
• Installation of necessary machinery and equipment
• Land facilities
• Service facilities
• All pipe controls inn services
• Necessarily to have money available for payment of expenses involved in the plant
operation.

This is broadly divided into :

Working capital investment

Fixed capital investment

i. Indirect cost
ii. Direct cost
Direct cost:
Purchased equipment cost = E
Components % of E

Purchased equipment installation 47%E

Instrumentation (installed) 12%E

Piping (installed) 66%E

Electrical (installed) 11%E

Building (including services) 18%E

Yard improvement 10%E

Service facilities 70%E

Land 6%E

TOTAL DIRECT COST =D

INDIRECT COST:

Engineering and supervision 33%E

construction expenses 41%E

Total indirect cost I

Total direct and indirect cost D+I

Contractor fee 5%(I+D)=x

Contingency 10%(I+D)=y

E/fixed capital investment D+x+I+y

Working capital investment (W.C.I) 15% total capital

Cost estimation of our plant

Purchase cost of quipment
Intermediate tar tank I110 32000(1000L capacity)
Dehydration tar tank X116 371596 (1000L capacity)
Evaporator E119 (Two stage) 30000000(capacity3tons/hr
concentration)
Furnace Q110 100000(voltage 220-240V &frequency
50-60 hz)
Fractionating column D121 850000(5L)
Condenser E112A 285000(production capacity 2m²to100
m²)
Condenser E112B 285000(production capacity 2m2to
 100m2)
Cooler (naphthalene submerged) E111 110000(voltage 480V & frequency 50
Hz)
Cooler (anthracene submerged) E112 110000(voltage 480V & frequency 50
Hz)
Separator H114 220000(capacity = 700-1500lph)
Separator H114A 220000 (capacity = 700-1500lph)
Distillation column D121 1800000(220-415V)
Crystallizer 900000(capacity = 500 L/hr)
Pump 75000(3HP-300HP)
Storage Tank 125000(1000-5000L)
Storage Tank 125000 (1000-5000L)
Storage Tank 125000 (1000-5000L)
Total: Rs35733596

Total purchase: Rs 35733596

Direct cost:
Cost of purchased equipment: Rs 35733596

installation of purchased equipment = 0.47 *35733596= Rs16794790

Process Control & Instrumentation = 0.12*35733596= Rs4288032

Piping (installed) = 0.66*35733596=Rs23584173

Building (Including Services) = 0.18*35733596= Rs6432047

Yard improvements = 0.1* 35733596=Rs3573359

Service facilities (installed) = 0.7*35733596=Rs25013517

Land = Rs50000000(4 acres)

Total direct plant cost = Rs165419514

Indirect cost
Supervision & Engg. = 0.33*35733596=Rs11792086

Building costs = 0.41*35733596=Rs14650774

Total Indirect Cost =Rs26442860

Total Direct & Indirect Cost =Rs191862374

Contractor’s fee = 0.05*35733596=Rs1786679

Contingency=0.1*35733596=Rs3573359
Fixed capital investment:
Fixed Capital Investment = Total direct + indirect cost + contingency +

Contractor’s fee=Rs197222412

Total capital investment = F.C.I + W.C

W.C=0.15 (T.C.I)

= 0.15(197222412+WC)

=Rs34803955.06

Total capital investment =TCI= Rs232026367.1

7.2 Manufacturing Labour cost:

The total amount of money a business spends on employees is known as the labor cost in
manufacturing.

It includes not only wages but also

• Costs associated with contract labor

• taxes of labour costs
• bonuses
• other additional expenses like employee benefit plans.

Beyond salary, a corporation must pay for a variety of expenses, including

• Overtime
• sick pay
• maternity pay
• investments in training costs.

Direct labour cost:

Direct costs are those associated with the tools and raw materials needed to manufacture the
goods. If the worker is interacting directly with the manufacturing unit's tools or raw
materials, then their salary is a direct labour cost. Direct labor expenditures typically include
the salaries of engineers, manufacturing managers, assembly line workers, and truck drivers.

Indirect labour cost:

The salaries that a manufacturing company pays payroll personnel, administrative assistants,
sales team members, and office managers are known as indirect labour costs. Rent,
depreciation, insurance, and quality control are further examples of indirect costs.

For our plant we are estimating this information:

 On average, a worker in this plant works 6 shifts a week, 49 weeks (deducting 2

weeks from 52 for sick leave and vacation leave)a year
 The factory runs three shifts a day, 365 days a year.
i. Morning shift (6:00 am – 2:00 pm)
ii. Evening shift (2:00 pm-10:00 pm)
iii. Night shift (10:00 pm-6:00 pm)
 The average salary for a labour in this plant is Rs 64080 per year
➢minimum daily wage of labour is approximately INR 178.
➢INR 5340 per month.

1. Number of operating labour:

An estimation of the labour force required for each shift can be obtained using Alkhayat and
Gerrard's correlation.

NOL=(6.29+31.7P2+0.23Nnp)0.5

In our plant process we have a total(P) 3 steps that is handling solid (transportation) and we
have (Nnp)8 process steps involved handle matter without accounting for the number of
pumps and vessels.

NOL= (6.29+31.7× (3)2+0.23×8)0.5

=17.12
=17
Each shift needs 17 labours.
2.Number of shifts per labour per year=6*49=294 shifts/year
Number of total shifts in a year =365*3=1095shifts/year
Number of total shifts in a year/ Number of shifts per labour per year=1095/294=3.72

3. Total number of labour needs to be hired for the plant:

no. of labour=17*3.7=62.9=70 labours

4.Total cost of operating labours:

70*64080=Rs 4485600

7.3 Depreciation:

The term we use to describe a fixed asset's decrease in value over time is depreciation. In
general, depreciation primarily affects fixed assets—that is, actual, physical assets owned by
your company—like real estate, automobiles, and machinery. Only fixed assets are
depreciable for tax purposes; other intangible assets, such as trademarks or branding, are only
shown on your company's balance sheet for accounting purposes.

For our project we are using straight line method to calculate the depreciation of a fixed asset

Equipment Purchasing Cost Useful Salvage value Depreciation

(C) life
Intermediate Rs32000(1000L 7 years 3200(10%C) 4114.2
tar tank I 110 capacity)
Dehydration Rs371596 (1000L) 12 years 55739.4(15%C) 26321.3
tar tank X116
Evaporator Rs30000000 15 years 15000000(50%C 1000000
E119 (Two (capacity 3tons/hr
stage) concentration)
Furnace Q110 Rs100000(voltage 20 years 30000(30%C) 3500
220-240V
&frequency 50-
60 hz)
Distillation Rs850000(5L) 10 years 127500(15%C) 72250
column D121
Condenser Rs285000(production 16 years 22800(8%C) 16387.5
E112B capacity 2m²to100
m²)
Separator Rs220000(capacity = 20 years 17600(8%C) 10120
 H114 700-1500lph)
Crystallizer Rs900000(capacity = 8 years 200000(22%C) 87500
500 L/hr)
Pump Rs75000(3HP- 15 years 11250(15%C) 4250
300HP)
Storage Tank Rs125000(1000- 25 years 2500(2%C) 4900
5000L)

7.4 ESTIMATED PROFIT:

In a tar distillation plant, various raw materials and utilities are essential for the distillation
process. The specific components can vary based on the plant's design and the desired output,
but here are some common raw materials and utilities used in tar distillation:

1. Raw Materials:

 Coal Tar: The primary raw material in tar distillation, obtained from the carbonization of
coal.
 Crude Coke Oven Gas: A byproduct of coal carbonization, often used for energy or as a
feedstock for other processes.

2. Utilities:

 Steam: Used for heating in various stages of the distillation process.

 Cooling Water: Essential for condensing vapours and cooling different sections of the
distillation unit.
 Electricity: Powers motors, pumps, and other electrical equipment in the distillation
plant.
 Compressed Air: Utilized in pneumatic control systems and for other operational needs.
 Nitrogen: Sometimes used as an inert gas to prevent undesired reactions in the
distillation process.
 Cooling Media (e.g., cooling towers): Employed for temperature control in different
parts of the distillation process.
 Chemicals: Depending on the specific requirements of the process, various chemicals
may be used for purification or as catalysts. Cost of raw material= Rs 390/kg (liquid coal
tar)
Cost of raw material = Rs 390/kg

Cost of making 1 Kg of naphthalene = Rs 60

Selling cost of 1 Kg of Naphthalene = Rs 100

Profit obtained= Rs 40

Our plant will produce 5 tons of naphthalene then estimated profit will be:

Cost of making 5000kg of Naphthalene = Rs 300000/day

Selling price of 5 tons of naphthalene = Rs 500000/day

Estimated profit = Rs 200000/day

= Rs 6000000/month

= Rs 72000000/year

PAYBACK PERIOD:

The payback period illustrates how long it takes to recover project costs.

Payback Period = Initial investment / Cash flow per year

=232026367/72000000

=3.22 years

CHAPTER- 8
CONCLUSION
Naphthalene market is poised for growth during the forecast period, projecting a Compound
Annual Growth Rate (CAGR) surpassing 3%. Despite the adverse impact of COVID-19 in
2020, the market has rebounded to pre-pandemic levels, showcasing resilience and a
trajectory towards steady expansion. The upward trend is attributed to increasing demand
within the textile industry, coupled with emerging applications in the construction sector,
presenting promising market opportunities. The study not only anticipates a rise in
naphthalene demand but also underscores the profitability of its recovery, emphasizing an
acceptable payback period. The research delves into the recovery process intricacies,
focusing on operational aspects. Moreover, the study comprehensively addresses the design
of key equipment for plant processes, providing detailed insights into material and energy
balances of both feed and byproducts. This holistic examination positions the naphthalene
market on a positive trajectory, emphasizing its resilience, diversification, and profitability in
the foreseeable future.

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