Professional Documents
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Butadine
Butadine
Butadine
USING n-BUTANE
A PROJECT REPORT
Submitted by
ARVIND C.A. (41501203002)
PRAKASH RAO K.R. (41501203015)
SURYANARAYANAN K.S. (41501203018)
BONAFIDE CERTIFICATE
Certified that this project report " MANUFACTURE OF BUTADIENE USING nBUTANE " is the bonafide work of " ARVIND C.A. (41501203002), PRAKASH
RAO K.R. (41501203015) and SURYANARAYANAN K.S. (41501203018)" who
carried out the project work under my supervision.
Dr. R. KARTHIKEYAN
Dr. R. KARTHIKEYAN
SUPERVISOR
Professor
CHEMICAL ENGINEERING
CHEMICAL ENGINEERING
S.R.M.Engineering College
S.R.M.Engineering College
Kancheepuram District
Kancheepuram District
ACKNOWLEDGEMENT
We are extremely thankful to Prof. R. Venkataramani, Principal, S.R.M
Engineering College, for permitting to carry out this project and providing us with all
the facilities.
We take pride in expressing our deepest gratitude to our project guide,
Dr.R.Karthikeyan, Professor and Head, Department of Chemical Engineering, for
his invaluable guidance and encouragement at every stage of this project.
We extend our thanks to all the staff members of the Chemical Engineering
Department for their technical assistance and support.
iii
ABSTRACT
Butadiene is one of the most important industrial chemicals with applications ranging
from polymers and elastomers like SBR, NR, PBR, SBL, ABS, and CR to chemicals
like adiponitrile used in the manufacture of Nylon-66.
iv
TABLE OF CONTENTS
CHAPTER
TITLE
ABSTRACT
iv
LIST OF TABLES
vii
LIST OF FIGURES
viii
ix
INTRODUCTION
1.1 HISTORY
1.2 APPLICATIONS
1.3 PROPERTIES
PAGE NO
PROCESS
10
17
2.4 DESIGN
24
38
46
55
62
64
CONCLUSION
66
REFERENCES
67
vi
LIST OF TABLES
Table.1.
Uses of Butadiene
Table.2
Table.3
12
Table.4
17
Table.5
18
Table.6.
19
Table.7
20
Table.8
22
Table.9
24
Table.10
47
Table.11
47
Table.12
48
Table.13
49
Table.14
Exposure limits
65
vii
LIST OF FIGURES
Fig.1
MANUFACTURE OF BUTADIENE
Fig.2
32
Fig.3
PLANT LAYOUT
38
viii
ix
GREEK SYMBOLS
= relative volatility
H0R = Standard heat of reaction, kcal/kg
T = temperature difference, 0C
TL = log mean temperature difference, 0C
= Latent heat, kJ/kg
= viscosity, kg / m.s
= density, kg / m3
1. INTRODUCTION
1.1. HISTORY
E.CAVENTOU was the first to isolate butadiene by means of pyrolysis of amyl
alcohol. M.BERTHELOT produced it by passing a mixture of acetylene and ethylene
through a red-hot iron tube. In 1885, G. CIAMICIAN and P.MAGNAGHI elucidated
the structure of butadiene. H.E.ARMSTRONG and A.K.MILLER, in 1886,discovered
butadiene in the products obtained on cracking petroleum.
Ever since S.LEBEDEW in 1910 discovered that butadiene forms rubber like
polymers, practical interest in this compound and its derivatives developed. Butadiene
was produced on a large scale in Germany prior to World War II and in the USA
during the war. Simultaneously, methods were developed for manufacture of useful
butadiene polymers. After the war, the work of K.ZIEGLER and G.NATTA, among
others, on polymerization with organometallic catalytic agents led to better quality of
rubber.
1.2. APPLICATIONS
Butadiene, the principal diolefin and four-carbon industrial chemical, is primarily
used as a monomer or a co-monomer in production of synthetic rubber. It is the main
component of the general-purpose rubber designated SBR (70% butadiene and
remainder styrene). The stereospecific polybutadiene rubber (PBR) and thermoplastic
rubbers containing polybutadiene and polystyrene blocks are growing in importance.
The third rubber involving butadiene as monomer, is Nitrile rubber (NBR), in which
butadiene and 20 60 % acrylonitrile are copolymerised. The fourth type is
chloroprene rubber (CR) where the monomer is 2- chlorobutadiene. A number of
latex materials are also produced from butadiene in conjunction with other monomers.
Nitrile latices, produced from acrylonitrile and butadiene are important. Another
important area of use for butadiene is in the field of plastics. The main product is the
copolymer of acrylonitrile, butadiene and styrene known as ABS resin, where 10-15%
butadiene is incorporated. It is also used in the raw material for production of
adiponitrile and hexamethylenediamine as intermediates for production of Nylon-66.
They are also included in the production of cyclododecatriene as a step toward
making Nylon-12 and in manufacture of hexabromocylododecane. A new elastomer
PERCENTAGE OF TOTAL
SYNTHETIC ELASTOMERS
Styrene-butadiene rubber(SBR)
Polybutadiene(BR)
Polychloroprene(neoprene)
Nitrile rubber
63.3
32.0
23.0
5.6
2.7
15.7
4.7
11.0
21.0
13.0
8.0
1.3.
PROPERTIES
carbonyl moieties like Fe(CO)3 , the two terminal bonds lengthen to .141 nm, and the
middle bond shortens even more to .145 nm.
reacts again with carbon monoxide and methanol to give adipic acid dimethyl ester.
Hydrolysis then leads to the formation of adipic acid.
Butadiene undergoes hydroformylation to give valeric aldehyde. In the production of
hexamethylenediamine, hydrogen cyanide reacts with butadiene in two steps and the
adiponitrile thus obtained is hydrogenated to give the diamine. Butadiene also reacts
in several ways to give 1,4-butanediol.
Linear dimerisation and trimerisation: Butadiene forms linear dimers or trimers in the
presence of Ni, Co, Pd, or Fe catalysts. Dimerisation of butadiene and simultaneous
reaction with carbon monoxide and alcohol leads to the synthesis of pelargonic acid,
which is a starting material in production of heat-resistant lubricants.
Cyclization, Diels-Alder Reaction: The Diels-Alder reaction is one of the best known
reactions of butadiene. Usually, a dienophile, i.e., an olefin with an activated double
bond, reacts with butadiene forming a cyclohexane ring. This addition reaction,
which is exclusively a 1,4-addition, can also take place with a second molecule of
butadiene
as
the
dienophile
component,
forming
4-vinylcyclohexene-1.
LITERATURE REVIEW
SELECTION OF PROCESS
If a high yield of Butadiene is required, the Houdry Catadiene process has proven
most economic.
2. PROCESS
2.1. PROCESS DESCRIPTION:
DEHYDROGENATION OF BUTANE:
CHEMICAL REACTIONS:
(a) Main reaction:
C4H10 CH2=CH.CH=CH2 + 2H2; H = +32.2 Kcal
(b) Side reaction:
C4H10
C4H8
+ H2
n-butylenes
A refinery gas of C4/C5 cut containing predominantly n-butane with some isopentane
is mixed with recycle gas and preheated to reaction temperature prior to contact with a
catalyst in a fixed bed, regenerative-heating system. A pair of reactors forms an
adiabatic cycle with the heat of reaction required during the 5-15 minutes make
period equal to that supplied by the combustion of carbon deposit on the catalyst
during the regenerative period. The temperature of reaction at the start of the make
period is 6500C, dropping to 5500C at the end before switching to regeneration. The
pressure is low, 120-150 mm absolute, to force the reaction to the right.
The product gases are oil-quenched, compressed, cooled and separated from the light
ends by absorption in naphtha following by stripping. The overhead is fractionated to
yield crude butadiene at the top, which is purified by (1) absorption using cuprous
ammonium acetate (CAA), (2) extractive distillation with furfural, (3) azeotropic
distillation with ammonia.
The more common absorption process involves contact of the close-boiling butadienebutene fraction with lean CAA solution, which dissolves butadiene. A desorption step
at higher temperature is followed by distillation, compression, and liquefaction of
butadiene to give 98-99% product purity. Mono-olefins may be required. Ammonia
is recovered in the distillation tower by water addition; it is then separated as
substantially anhydrous NH3 by fractionation.
2.2. MATERIAL BALANCE
REACTOR:
BASIS: 62.1571 kg (from fresh feed) 1.0717 kmol 1-min operation
Following reactions are taking place in the reactor:
C4H10
n-butane
C4H10
n-butane
H2
------------- II
n-butylenes
Yield is taken as 60 %
n-butane reacted in reaction I = 0.643 kmol
n-butane reacted in other reactions = 0.4287 kmol
n-butane reacted in reaction II is taken as 0.2143 kmol
n-butane reacted for the production of light ends
is taken as 0.1072 kmol = 0.1072 x 58 = 6.2157 kg
n-butane reacted for the production of heavy ends
is taken as 0.1072 kmol = 0.1072 x 58 = 6.2157 kg
Butadiene produced in reaction I = 0.643 kmol
= 0.643 x 54
= 34.7222 kg
Butene produced in reaction II = 0.2143 kmol
= 0.2143 x 56
= 12.0027 kg
H2 produced in reactions I and II = 0.643 x 4 + 0.2143 x 2
= 3.0007 kg
Conversion of butane is taken as 12 %
Butane entering into the reactor = (1/0.12)(0.643)
= 5.3584 kmol
= 5.3584 x 58 kg = 310.79 kg
Butane from recycle = 5.3584 1.0717 = 4.2867 kmol
= 248.63 kg
INPUT
kg
REACTOR
C4H10 : 310.79
OUTPUT
kg
C4H10
248.63
C 4 H6
: 34.7222
C 4 H8
: 12.0027
H2
3.0007
Light ends
6.2157
Heavy ends
6.2157
TOTAL: 310.79 kg
TOTAL
: 310.79kg
ABSORBER:
Table.3. Materials entering the absorber
Component
Weight , kg
No. of kmoles
C4H10
248.63
58
4.2867
C 4 H6
34.7222
54
0.643
C 4 H8
12.0027
56
0.2143
H2
3.0007
1.5003
Light ends
6.2157
45 (assumption)
0.1393
Heavy ends
6.2157
60 (assumption)
0.1072
Total
310.79
6.8909
Moles of inert (H2 and Light ends) entering absorber through gas mixture (Gms) =
1.6396 kmol
Mole ratio of solute to inert in the entering gas mixture = Yb
= 5.2513/1.6396
= 3.2026
Let 99.99 % of solute be removed in the absorber
Mole ratio of solute to inert in the leaving gas mixture = Ya
= 3.2026x10-3
Mole ratio of solute to solvent (naphtha) entering the reactor = Xa = 0
(as pure naphtha is used)
Let Lms be pure solvent used & Xb be mole ratio of solute to solvent leaving the rector
Material balance for solute in the absorber:
Lms (Xb Xa) = Gms (Yb Ya)
For minimum solvent rate, (Lms)min , Xb = Xb*
10
kg
NAPHTHA
: 125.8
VENT GAS
ABSORBER
REACTOR
EFFLUENT
C4H10 :
C 4 H6 :
C 4 H8 :
H2 :
Light ends :
Heavy ends :
kg
H2
: 2.9976
Light ends : 6.2095
SOLUTION
248.63
34.7222
12.0027
3.0007
6.2157
6.2157
NAPHTHA : 125.8
C4H10 : 248.63
C4H6 : 34.7222
C4H8 : 12.0027
H2 : 0.003
Light ends : 0.006
Heavy ends : 6.2157
TOTAL : 436.59 kg
TOTAL : 436.59 kg
11
STRIPPER:
Let all naphtha be removed in the stripper
H2 and Light ends are not taken into account, as they are negligible
GAS MIXTURE
kg
STRIPPER
kg
Naphtha : 125.8
: 248.63
C4H10
C4H6
: 34.7222
: 12.0027
C4H8
Heavy ends: 6.2157
C4H10
: 248.63
C4H6
: 34.7222
C4H8
: 12.0027
Heavy ends: 6.2157
Naphtha : 125.8
TOTAL : 427.3706 kg
TOTAL : 427.3706 kg
BUTADIENE TOWER:
Let heavy ends be completely removed in the butadiene tower
Material balance in the butadiene tower:
CRUDE
BUTADIENE
GAS
MIXTURE
kg
BUTADIENE TOWER
kg
C4H10 : 248.63
C4H6 : 34.7222
C4H8 : 12.0027
C4H10 : 248.63
C4H6 : 34.7222
C4H8 : 12.0027
Heavy ends : 6.2157
TOTAL : 301.5706 kg
TOTAL : 301.5706 kg
12
MIXER SETTLER:
Crude butadiene is sent to mixer settler where cuprous ammonium acetate (CAA)
separates n-butane.
Material balance in the mixer settler:
Let 1 kg of CAA be used per kg of crude butadiene
kg
kg
MIXER
CAA : 295.3549
SETTLER
CRUDE
BUTADIENE
C4H10 : 248.63
C4H6 : 34.7222
C4H8 : 12.0027
TOTAL : 590.7098 kg
C4H10 : 248.63
CAA : 295.3549
C4H6 : 34.7222
C4H8: 12.0027
TOTAL : 590.7098 kg
STRIPPER:
Let all CAA be removed in the stripper
Material balance around stripper:
kg
kg
CAA : 295.3549
C4H6 : 34.7222
C4H8: 12.0027
STRIPPER
C4H6 : 34.7222
C4H8 : 12.0027
CAA : 295.3549
TOTAL : 342.0798 kg
TOTAL : 342.0798 kg
13
kg
NH3 : 9.3449
kg
AZEOTROPIC
DISTILLATION TOWER
NH3 : 9.3449
C4H6 : 34.7222
C4H6 : 34.7222
C4H8 : 12.0027
C4H8 : 12.0027
BUTADIENE
PURIFIER:
TOTAL : 56.0698
kg
TOTAL : 56.0698 kg
14
kg
kg
BUTADIENE
PURIFIER
H2O : 8.8134
BUTADIENE : 34.7222
NH3 : 9.3449
C4H6 : 34.7222
H2O : 8.8134
NH3 : 9.3449
TOTAL : 52.8805 kg
TOTAL : 52.8805 kg
COLD FLUID
(C4H10)
310.79
HOT FLUID(FUEL
GAS)
???
Specific heat,Cp(J/kgK)
1.6164 x 103
1.1 x 103
Outlet temperature(0C)
650
200
25
900
Temperature difference,T
(0C)
625
700
15
PREHEATER
Reactants
Products
Mass, m(kg)
310.79
310.79
Specific heat,Cp(J/kgK)
1.6164 x 103
1.94 x 103
16
T 25 = 520.520C
T = 545.50C
Outlet temperature of products = 545.50C
Outlet temp:
545.50C
kg
C4H10 : 248.63
C4H6 : 34.72
C4H8 : 12.00
H2 : 3.00
Light ends: 6.22
Heavy ends: 6.22
Total: 310.79 kg
REACTOR
C4H10: 310.79 kg
QUENCH TOWER:
Table.6. Required data for quench tower
Required data
Mass, m(kg)
???
310.79
Specific heat,Cp(J/kgK)
2.1 x 103
1.6164 x 103
Inlet temperature(0C)
25
545.5
Outlet temperature ( C)
300
55
Temperature difference, T
(0C)
275
490.5
17
Oil: 426.67 kg
Inlet temp: 250C
Inlet temp: 545.50C
kg
QUENCH TOWER
C4H10: 248.63
C4H6 : 34.72
C4H8: 12.00
H2 : 3.00
Light ends: 6.22
Heavy ends: 6.22
Total: 310.79 kg
Oil: 426.67 kg
Outlet temp: 3000C
C4H10: 248.63
C4H6 : 34.72
C4H8: 12.00
H2 : 3.00
Light ends: 6.22
Heavy ends: 6.22
Total: 310.79 kg
COOLER:
Table.7. Required data for cooler
Required data
Mass, m(Kg)
Specific heat, Cp (J/Kg K)
Inlet temperature(0C)
310.79
1.6164 X 103
75
???
4.187 X 103
25
35
75-35 = 40
85
85-25=60
Outlet temperature(0C)
Temp. difference,T (0C)
( m Cp T) cold
fluid
= (m cp T) hot fluid
Water: 79.98 kg
Inlet temp: 250C
18
COOLER
Products (gas)
Mass : 310.79 kg
Inlet temp: 750C
Products (gas)
Mass : 310.79 kg
Outlet temp: 350C
Water: 79.98 kg
Outlet temp: 850C
BUTADIENE TOWER:
Condenser:
V = (mCpT) cooling medium
V= Amount of vapor leaving the tower = D (RD+1)
Let RD (reflux ratio) = 2.5
D = amount of distillate = F[(xF xB) / (xD xB)]
F = 5.25 kmoles
xF = 0.9796
xB = 0.001
xD = 0.9999
Substituting the above values, we get
D = 5.14 kmoles
Amount of vapor = V = 5.14 x (2.5 + 1) = 18 kmoles
= 295.35 Kg.
= 494.6 x 103 J/kg
m = mass of cooling medium =?
Cp of cooling medium = 3 X 103 J/kgK
19
Let T = 150C
V = (mCpT) cooling medium
295.35 X 494.6 X 103 = m X 3 X 103 X 15
m = 3246.26 Kg
= vapor flow rate at bottom of the tower.
= V - F (1-q)
q = 1(for saturated liquid feed)
= V = 295.35 Kg
Reboiler:
Table.8. Required data for reboiler
Required data
Hot fluid
Vapor, (Kg)
295.35
2321.5 X 10
20
515 X 103
m = 65.52 Kg
mass of heating medium required for reboiler = 65.52 Kg
CONDENSER
FEED, F
kmoles
C4H10 : 4.29
C4H6 : 0.64
C4H8 : 0.21
Heavy ends: 0.11
BUTADIENE
TOWER
DISTILLATE
XD = 0.9999
kmoles
C4H10 : 4.29
C4H6 : 0.64
C4H8 : 0.21
5.14
REBOILER
RESIDUE
XB = 0.001
5.25
xF = 0.9796
21
2.4. DESIGN
PREHEATER:
UOAOTL = (m Cp T) cold fluid = (m Cp T) hot fluid
UO = Overall heat transfer coefficient
= 1 / [(1/ho)+(ao/ai)(1/hi)]
Where ho = shell side heat transfer coefficient
hi = tube side heat transfer coefficient
Ao = surface area = 2 x x ro x L x n
Where, ro = outside radius
L = Length of the tube
n = no.of tubes
TL = log mean temperature difference = (T1 - T2) / ln[(T1/ T2)]
UOAOTL = (m Cp T) cold fluid
1 / [(1/ho)+(ao/ai)(1/hi)] x 2 x x ro x L x n x TL = (m Cp T) cold fluid
Table.9. Physical properties data for preheater
PHYSICAL PROPERTIES
BUTANE(TUBE SIDE
FLUID)
Cp (J/KgK)
(kg/m3)
(J/smoC)
1.1 x 103
1.8
0.0339
1.6164 x 103
2.5
0.0198
(kg/ms)
2 x 10-5
7.35x10 6 kg/ms
22
23
= [(900-650)-(200-25)] / ln(900-650/200-25)
= 210.2755 oC
24
L = 21 m
Volume of one reactor = D2L/ 4 = 148.44 m3
No of reactors required in parallel = 6048 / 148.44 = 41
DESIGN SUMMARY:
Diameter of each reactor = 3 m
Length of each reactor = 21 m
No. of reactors required in parallel = 41
ABSORBER:
H2
Light ends
NAPHTHA
xa = 0
ya = 0.0032
A
B
S
O
R
B
E
R
yb = 0.7621
C4H10
C4H6
C4H8
H2
Light ends
Heavy ends
GM = 0.0273 kmol/s
NAPHTHA
C4H10
xb = 0.8421
C4H6
C4H8
No. of transfer units NOY = (yb ya) / yL ----------- I
yL = [(yb yb*) (ya ya*)] / ln {( yb yb*) / (ya ya*)} ------ II
y* = 0.5 x (equilibrium relationship)
yb* = 0.5 xb = 0.5 x 0.8421 = 0.4211
ya* = 0.5 xa = 0.5 x 0 = 0
ya = 0.0032 ; ya* = 0
yb = 0.7621 ; yb* = 0.4211
Substituting the above values in equations I and II,
NOY = 11
25
26
BUTADIENE TOWER:
DISTILLATE
XD = 0.9999
kmoles
C4H10 : 4.29
C4H6 : 0.64
C4H8 : 0.21
B
U
T T
A O
DW
I E
E R
N
E
FEED, F
(SATURATED LIQUID)
kmoles
C4H10 : 4.29
C4H6 : 0.64
C4H8 : 0.21
Heavy ends: 0.11
5.14
5.25
xF = 0.9796
HEAVY ENDS: 0.11 kmoles
RESIDUE
XB = 0.001
27
NO. OF STAGES:
Let relative volatility = 2.5
Equilibrium curve is given by
y = x/(1+[-1]x) = 2.5x/(1+1.5x)
For saturated liquid feed, q= 1
Slope of feed line = q/q-1 =
y - intercept of rectifying section operating line = xD/ RD+1
= 0.9999/3.5
= 0.2857
By Mccabe - thiele diagram,
No. of theoretical stages = 12 - 1( for reboiler) = 11
28
XB
q -- LINE
STRIPPING
OPERATING
LINE
EQULIBRIUM
CURVE
y
X
29
RECTIFICATION
OPERATING
LINE
XFXD
COLUMN DIAMETER:
FLV bottom = (slope of bottom operating line )(v/L)
Assume tray spacing as 0.5 m
v = 2.2 kg/m3
L = 750 kg / m3
30
REBOILER:
Inlet temp. = 500C
REBOILER
Water: 65.52 kg
Outlet temp. = 750C
Vapor
Steam: 65.52 kg
Inlet temp. = 750C
31
K (Pr)1/3 = 0.0442
hi = (jHK/D) (Pr )1/3 = 703.6469 W/m2oC
hio = hi x di/do = 578.39 W/m2oC
Clean overall coefficient Uc = hio ho/ (hio + ho)
= (8513.6 x 578.39)/(8513.6 + 578.39)
= 541.5959 W/m2oC
UCAOTL = (m) hot
Let L = 10 ft = 3.048 m
m = 65.52/60 = 1.092 kg/s
541.5959 x x 0.0191 x 3.048 x n x 25 = 1.092 x 2321.5 x 103
n = 1.092 x 2321.5 x 103/(541.5959 x x 0.0191 x 3.048 x 25) 1024
Shell inner diameter = 37 inch = 0.9398 m
DESIGN SUMMARY:
Length of each tube = 10 ft = 3.048 m
Outer diameter of each tube = inch = 0.0191 m
Inner diameter of each tube = 0.0157 m
No. of tubes = 1024
Shell inner diameter = 37 in. = 0.9398 m
32
procedures.
2. Production rate:
To achieve the desired product output.
3. Product Quality:
To maintain the product composition within specified quality standards.
4. Cost:
To operate at the lowest production cost, commensurate with other Objects.
REACTOR CONTROL:
The schemes used for reactor control depend on the process and the type of reactor. If
a reliable on-line analyzer is available, and the reactor dynamics are suitable, the
product composition can be monitored continuously and the rector conditions and
feed flows controlled automatically to maintain the desired product composition and
yield. More often, the operator is the final link in the control loop, adjusting the
controller set points to maintain the product within specification, based on periodic
laboratory analysis.
Reactor temperature will normally be controlled by regulating the flow of heating or
cooling medium. Pressure is usually held constant. Material balance control will be
necessary to maintain the correct flow of reactants to the reactor and flow of products
and unreacted materials from the reactor.
Instrumentation:
33
Temperature Measurement:
The temperature-measuring element in a control system for a jacketed tank is
generally thermocouple. The five most commonly used thermocouple are copperconstantan, iron-constantan, chromel-alumel, platinum-platinum 13% rhodium,
platinum-platinum 10% rhodium.
Flow rate Measurement:
The industrial devices for flow rate estimation are orifice meter, venturi meter, pitted
tube, and rotameter. The piping system must be made of special corrosion resistant
material meant for corrosive fluids.
Level Measurement:
The flow-shaft type is employed either in open vessels or in pressure vessels. This
method is suitable for a wide range of liquids and semi-liquids. Difficulties are
sometimes encountered when the liquid deposits on the floor and when the liquid
level is foaming or turbulent.
2.6. PLANT LAYOUT
34
EFFULENT
TERATMENT
RAW
MATERIAL
STORAGE
SCRAP AREA
FINISHED
BOILER
HOUSE
AND
WATER
PLANT
EXTENSION AREA
PROCESSING
AREA
SAFETY
DEPT
C
A
N
T
E
E
N
HEALTH
CENTER
ADMINISTRATIVE
OFFICE
W
O
R
K
S
H
O
P
PRODUCT
STORAGE
SECURITY
OFFICE
MAIN ROAD
Maintenance costs
Construction costs
The first thing that should be done is to determine the direction of the prevailing wind.
This can be done by consulting Weather Bureau records.
determine the general location of many things.
flammable materials should be located on the downwind side. Then if a spill occurs
35
the prevailing winds are not apart to carry any vapors over the plant, where they could
be ignited by an open flame, spark, or a hot surface.
Items that should be located Upwind of the plant:
Plant Offices
Electrical substation
Central Laboratories
Air Compressors
Cafeteria
Parking lot
Store house
Medical Building
Change house
Non-explosive and
Fire station
Non-flammable materials
Boiler house
Fired heaters
For a similar reason the powerhouse, boilers, water pumping, and air supply facilities
should be located 250 ft (75 m) from the rest of the plant, and on the upwind side.
This is to minimize the possibility that these facilities will be damaged in case of a
major spill. This is especially important for the first two items, where there are
usually open flames.
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Every precaution should be taken to prevent the disruption of utilities, since this could
mean the failure of pumps, agitators, and instrumentation. For this reason, it may also
be wise to separate the boilers and furnaces from the other utilities. Then, should
fired equipment explode, the other utilities will not be damaged.
Other facilities that are generally placed upwind of operating units are plant officers,
mechanical shops and central laboratories. All of these involve a number of people
who need to be protected. Also, shops and laboratories frequently that are used
primarily for quality control are sometimes located in the production area.
STORAGE FACILITIES
Tank farms and warehouses that contain non-hazardous, nonflammable, and non
explosive materials should be located upwind of the plant. Those that do not fit this
category should not be located downwind of the plant, where they could be damaged
and possibly destroyed by a major spill in the processing area. Nor should they be
located upwind of the plant where, if some of their contents are spilled. the processing
area might be damaged. They should be located atleast 250 ft (75 m) to the side of
any processing. Some authorities suggest this should be 500 ft. The same reasoning
applies to hazardous shipping and receiving areas.
Sometimes, storage tanks are located on a hill, in order to allow the gravity feeding of
tank cars. Care must be taken under these circumstances to see that any slop over
cannot flow into the processing, utilities, or services areas in case of a tank fir.
When liquefied petroleum gases are used, the areas for containing spills are always
below grade because the gases are denser than air. The gases will accumulate in the
low areas will also not be asphyxiated.
SPACING OF ITEMS
The OSHA has standards for hazardous materials that give the minimum distances
between containers and the distances between these items and the property line,
public roads and building. These depend on the characteristics of the material, the
type and size of the container, whether the tank is above ground or buried and the type
37
of protection provided. Specific details are provided for compressed gas equipment
containing acetylene-air, hydrogen-oxygen and nitrous oxide, as well as liquefied
petroleum gases. They also prohibit the storage and location of vessels containing
flammable and combustible materials inside buildings, unless special precautions are
taken.
Again, the major reason for including the layout in the preliminary plant design is that
the transporting equipment and buildings may be sized to make certain that no needed
equipment is omitted and that the chosen plant site will be large enough. At this
point, since most of the energy transfer equipment has not been sized, only its
approximate location can be given.
PROCESSING AREA
There are two ways of laying out a processing area. The grouped layout places all
similar pieces of equipment adjacent.
switching from one unit to another. For instance, if there are 10 batch reactors, these
would all be placed in the same general area and could be watched by minimum of
operators; if they were spread out over a wide area, more operators might be added.
This scheme is best for large plants. The flow line layout uses the train or line
system, which locates all the equipment in the order in which it occurs on the flow
sheet. This minimizes the length of transfer lines and therefore reduces the energy
needed to transport materials. In industries, it is used mainly for small volume
products. Often, instead of using the grouped or flow line layout exclusively, a
combination that best suits the specific situation is used.
PLACING OF EQUIPMENT
Once a general scheme is decided upon, the processing area is divided into unit areas.
The units should be grouped so that the number of operating personnel is minimized.
The maximum loss concept must also be considered. Some companies place a limit
in the maximum loss that can be expected if a fire or explosion occurs. This permits
those watching the controllers to quickly investigate and determine the cause of any
problems that might arise.
controlled from one location, this could reduce the number of operations required. In
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this case, the control room should be located in a relatively unexposed area near the
edge of the processing area, but away from fired heaters. This is to protect both the
employees and the equipment.
ELEVATION
If there is no special reason for elevating equipment it should be placed on the ground
level. The superstructure to support on elevated piece of equipment is expensive. It
can also be a hazard should there be an earthquake, fire or explosion. Then it might
collapse and destroy the equipment it is supporting as well as that nearby. Some
pieces of equipment will be elevated to simplify the plant operations. An example of
this is the gravity feed of reactors from elevated tanks. This eliminates the need for
some materials-handling equipment. This especially true for solids and slurry feed.
MAINTENANCE
Maintenance costs are very large in the chemical industry. In some cases, the cost of
maintenance exceeds the companys profit. The engineer must design to reduce these
costs. The easiest way to reduce maintenance costs is to allow lots of extra space and
to construct everything at ground level for easy access. However, this may increase
construction and operating expenses and the ease of operability. The engineer should
determine what type of equipment need to be serviced by mobile cranes. These
pieces of equipment will need to be located on the perimeters of the plant or on a
roadway.
The roadways along which the crane will travel must have adequate
overhead and horizontal clearness. Adequate space must be left around all equipment
so that it can be easily serviced and operated. For instance, a floating-head heat
exchanger must have enough space so that the tube bundle can be removed from the
shell and taken elsewhere for repairs. For tanks containing coils and agitators, enough
headroom must be provided so that these can be removed.
CONSTRUCTION AND BUILDING
Proper placing of equipment can result in large savings during the construction of the
plant. For instance, large columns that are field-erected should be located at one end
39
of the site so that they can be built, welded, and tested without interfering with the
construction of the rest of the plant.
RAILROADS, ROADWAY AND PIPE RACKS
The main purpose of railroads is to provide an inexpensive means for obtaining raw
materials and for shipping products. This means that they should be close to raw
materials and or/ product storage. Buildings and loading docks should be set back 8 ft
(2.4m) from the center of the railroad track. Spurs and switches should be laid out
with a 100 ft (30m) radius. Roads are used not only for these purposes but to provide
access for fire fighting equipment and other emergency vehicles, and for maintenance
equipment. This means that there should be a road around the perimeter of the site.
No road should be dead-end. For safety there should be two ways to reach every
location. All major traffic should be kept away from the processing areas.
PLANNING FOR EXPANSION AND IMPREMENTS
Obviously, if the equipment has been over designed to meet the anticipated future
expansion, no extra space needs to be provided. If, however, additional equipment
will be required, space should be allocated for it. The net result will be an increase in
these initial costs of construction and some increase in material transfer costs, because
the transfer lines will be longer.
BUILDING
Building with the layout of the plant is the direction as to what types of buildings are
to be construction, and the size of teach. When laying out buildings, a standard size
bay (area in which there are no structural supports) is 20ft x 20ft (6m x 6m). Under
normal conditions a 20-ft (6m) span does not need any center supports. The extension
of bay in one direction can be done inexpensively. This only increases the amount of
steel in the long girders, and requires stronger supports. Lavatories, change rooms,
lunch rooms and medical facilities is dictated by OSHA. It depends on the number of
workers employed. Research laboratories and office buildings usually not included in
the preliminary cost estimate. However, if they are contemplated, their location
should be indicated on the pilot plan.
40
PROCESSING BUILDINGS
Quality control laboratories are necessary part of any plant, and must be included in
all cost estimates. Adequate space must be proved in them for performing all tests,
and for cleaning and storing laboratory sampling and testing containers.
Packaging equipment generally must be in enclosed buildings, and is often located at
one end of the warehouse. If the material being packaged is hazardous, either this
operation will be performed in a separate building, or a firewall will separate it from
any processing or storage areas.
WAREHOUSE
The engineer must decide whether warehouses should be at ground level or at dock
level. The latter facilitates loading trains and trucks, but costs 15-20 percent more
than one placed on the ground. It is usually difficult to justify the added expense of a
dock-high warehouse.
2.7. COST ESTIMATION
ESTIMATION OF THE TOTAL CAPITAL INVESTMENT:
The total capital investment I involves the following:
A. The fixed capital investment in the process area, IF.
I = IF + IA + IW
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Fixed Capital Investment In The Process Area, If = Direct Plant Cost + Indirect Plant
Cost
The approximate delivered cost of major equipment used in the proposed
Butadiene
Equipment
Units
Cost in lakhs/unit
Cost in lakhs
Furnace
2.4 x 106
2.4 x 106
Reactor
41
2.6 x 106
1.066 x 108
Heat exchanger
7 x 105
35 x 105
Distillation column
8 x 105
24 x 105
Absorption column
6 x 105
6 x 105
Stripper
4 x 105
8 x 105
Mixer settler
5 x 105
5 x 105
Pump
10000
10000
Ejector
10000
10000
10
Compressor
10000
10000
11
Miscellaneous
3.17 x 106
3.17 x 106
1.2 x 108 lakhs
TOTAL
Items
100
Equipment installation
15
Insulation
15
Instrumentation
15
Piping
75
30
Foundation
10
Electrical
15
Clean up
5
Total direct cost factor
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280
Direct plant cost = (Delivered cost of major equipments) (Total direct cost factor) /
100
Direct plant cost = (1.2 x 108 * 280) / 100
= 3.36 x 108 lakhs
Table.12. Indirect cost factor
S.No.
Item
30
Engineering fee
13
Contingency
13
56
Indirect plant cost = (Direct plant cost)(Total indirect cost factor) / 100
= (3.36 x 108 * 56) / 100
= 1.8816 x 108 lakhs
Fixed capital investment in the process area, IF = Direct plant cost + Indirect plant
cost
= 3.36 x 108 + 1.8816 x 108
= 5.2416 x 108 lakhs
B. The capital investment in the auxiliary services, IA.
Such items as steam generators, fuel stations and fire protection facilities are
commonly stationed outside the process area and serve the system under
consideration.
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Items
Auxillary buildings
Water supply
0.7
Roads
0.5
0.2
Communication
0.2
10
0.2
Total
12.3
1.5
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Property taxes
Insurance
Safety expenses
45
Administrative services
For this purpose we shall charge 15% of the installed cost of the plant
= (Installed cost * 15) / 100
= (5.8863 x 108 * 15) / 100
= 8.8294 x 107 lakhs
B. COST PROPORTIONAL TO PRODUCTION RATE
The factors proportional to production rate are
Maintenance cost
46
47
B. GROSS PROFIT
Gross profit = Total sales income - manufacturing cost
= 7.425 x 108 - 5.5978 x 108
= 1.8272 x 108 lakhs
C. NET PROFIT
It is defined as the annual return on the investment made after deducting depreciation
and taxes. Tax rate is assumed to be 40%.
Net profit = Gross profit Depreciation - (Gross profit*Tax rate)
= 1.8272 x 108 - 1.2371 x 107 - (1.8272 x 108 *0.4)
= 9.7262 x 107 lakhs
D. ANNUAL RATE OF RETURN
Rate of return = (100*Net profit/Installed cost)
= (100*9.7262 x 107) / 5.8863 x 108 = 16.5235%
E. PAYOUT PERIOD
Payout period = Depreciable fixed investment / ((profit)+(depreciation))
= 5.8863 x 108 / (9.7262 x 107+ 1.2371 x 107)
= 5.36908 years
2.8. PROCESS SAFETY
Introduction:
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In recent years there has been an increased emphasis on process safety as a result of
number of serious accidents. This is due in part to the worldwide attention to issues in
the chemical industry brought on by several dramatic accidents involving gas releases,
major explosions and several environmental accidents. Public awareness and of these
and other accidents has provided a driving force for industry to improve its safety
record. Local and national governments are taking a hard look at safety in industry as
a whole and the chemical industry in particular. There has been an increasing amount
of government regulations.
For many reasons, the public often associates chemical industry with environmental
and safety problems. It is vital for the future of the chemical industry that process
safety has a higher priority in the design and operation of chemical process facilities.
Industrial accidents:
An accident has been defined as an unplanned or unexpected event, which causes or is
likely to cause an injury.
An accident occurs as a result of unsafe actions or exposure to an unsafe environment.
Unsafe actions or unsafe mechanical or physical conditions exist only because of
faults of a particular person.
Faults of persons are inherited from the environment and reasons for the faults are:
Improper attitude
Physical unsuitability
Accident prevention:
Form the foregoing, it will be seen that the occurrence of an injury is the culmination
of a series of events or circumstances that invariably occur in a fused and logical
order.
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Knowledge of the factors in the accident sequence guides and assists in selecting the
point of attack in prevention work. It permits simplification without sacrifice of
effectiveness. The most important point is that unsafe conditions or actions are the
immediate cause of accidents. The supervision and management can control the
actions of employed persons and so prevent unsafe acts and also guard or remove
unsafe conditions, even though previous events or circumstances in the sequence are
unfavorable.
The four factors that converge to cause accidents are:
Personal factor
Hazard factor
Unsafe factor
The solution under the four factors would also lead to two steps. These are planning
and organizing to
1. Prevent unsafe mechanical or physical conditions.
2. Prevent unsafe action being committed.
Unsafe conditions examples:
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Inadequately guarded.
Unguarded.
Engineering revision.
Instruction.
Persuasion.
Appeal.
Personal adjustment.
Discipline.
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1.
2.
3.
2.
3.
4.
Temperature conditions.
5.
Types of ventilation
1.
Natural ventilation
2.
Mechanical ventilation
Natural ventilation
Forces, which operate to induce natural ventilation in building, are due to:
The temperature differences of the air within and without the building.
Cross ventilation.
2.
Roofed ventilation.
3.
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Mechanical ventilation
It is brought out by either one or both of the following two methods:
Exhaust ventilation
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Helmets:
Every employee inside the factory should always wear the safety helmet to avoid
head injuries. No worker will be allowed to enter any plant without a helmet.
Safety goggles:
The goggles must be worn while entering the process areas. Special goggles must be
worn for gas welding and grinding operations.
Safety shoes:
All the employees working inside a factory should wear safety shoes and gumboots
should be used while handling acids and alkalis.
Hand gloves:
While operating any valve or equipment and also while executing any maintenance
work including electrical maintenance work, the employees should wear appropriate
type of safety gloves.
Dust mask:
While working in a dusty atmosphere, the employees must wear dust masks to prevent
dust and fumes from entering the sensitive respiratory organs, which can cause a lot
of irritation and in the long run painful and incurable diseases.
Plastic aprons:
This along with the hood gives protection to the operation and maintenance staff
while handling dangerous acids and other hazardous chemicals particularly when
there is possible leakage.
In spite of safety appliances, the companys medical center is equipped to meet any
emergency and any employee coming in contact with acids or any hazardous
chemicals must be treated at the medical center immediately.
54
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on time and temperature and can be stopped by adding a potassium cyanide solution
to butadiene. Secondly, butadiene can polymerize under the influence of oxygen and
high temperatures, especially during its manufacture, to give rubber-like polymers
(fouling), Antioxidants, like TBC, exclusion of oxygen, low temperatures, and short
exposures to higher temperatures reduce this polymerization. Thirdly, butadiene can
polymerize, initiated by oxygen, high temperatures, and rust, to give a glassy,
granular, opalescent, and very hard polymer, the so-called Popcorn.
It forms
preferentially in off-stream tubes. Its growth is favored when Popcorn seeds are
present in the plant. The formation of Popcorn in closed areas can lead to pressures of
> 1000 bar, causing the bursting of off-stream tubes or containers. It can be prevented
by the addition of TBC and by the careful elimination of all Popcorn seeds. Popcorn
is spontaneously
inflammable in air and, hence, must be kept moist during its removal. Liquefied
butadiene is stored at normal temperatures in liquid-gas containers or, today, for
safety reasons at a temperature of 40C in almost pressureless containers.
It is
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Butadiene is of low acute toxicity. Like some other hydrocarbons butadiene causes
narcotic effects after inhalation of high concentrations, some-times preceded by
excitation and hyperventilation.
Table.14. Exposure limits
Country
Exposure Limit
Belgium
10 ppm
Germany
Italy
10 ppm (predicted)
Japan
Latin America
1 ppm (predicted)
The Netherlands
50 ppm
United Kingdom
10 ppm
United States
CONCLUSION
Butadiene is one of the most important chemicals. Also with the major advancements
like production of a new elastomer system based on carboxy-terminated butadiene
acrylonitrile polymers (CBTN) as an alternative to urethane technology and its wide
applications, butadiene has become one of the most widely used chemicals in the
world.
This project has analyzed the salient features of the process of manufacture of
Butadiene. It has also dealt with the various design aspects of the important
equipments, cost estimation and project feasibility.
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REFERENCES
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