PROJECT

ON
NITROBENZENE

ACKNOWLEDGEMENT

We here by place our sincere thanks to Dr.R.KARHIKEYAN, Head of the

Department of Chemical Engineering , S.R.M Engineering College affiliated to
S.R.M University and the faculty members of Chemical Engineering Department for
their full hearted co-operation and encouragement for the successful completion of
this project.
We extend out thanks to Project guide D.BALAJI for the Motivation,
encouragement and guidance provided by him. We would also like to extend our
thanks to each and everyone who have helped us in completing this project
successfully.

ABSTRACT

The project deals extensively with the manufacture of nitrobenzene from mixed acid
and benzene .Since the demand for aniline has been increasing day by day
manufacture of benzene is more important. Nitrobenzene is obtained by treating
mixed acid and benzene. A detailed process flow sheet, material balance, energy
balance, have been done. A detailed design of equipments, cost estimation of plant,
plant layout and safety aspects have been discussed.

CONTENTS

Chapter No

Topic

Page NO.

1.

INTRODUCTION

2.

PHYSICAL PROPERTIES

3.

CHEMICAL PROPERTIES

4.

USES

12

5.

PROCESS DESCRIPTION

14

6.

MATERIAL BALANCE

19

7.

ENERGY BALANCE

25

8.

REACTOR DESIGN

29

9.

DISTILLATION COLUMN DESIGN

35

10.

COST ESTIMATION

44

11.

HEALTH AND SAFTEY FACTORS

51

12.

PLANT LAYOUT

55

13

CONCLUSION

62

14.

BIBLIOGRAPHY

64

1.INTRODUCTION

1.CHAPTER

Nitrobenzene was first synthesized in 1834 by treating Benzene with Fuming

Nitric Acid, and it was produced commercially in England in 1856. The relative case
of aromatic nitration has contributed significantly to the large and varied industrial
application of nitrobenzene and its derivative.

Nitrobenzene (oil of Mir bane) is a pale yellow liquid with an odor of bitter
almonds. Depending upon the compound impurity , its color varies from pale yellow
to yellowish brown. Nitrobenzene is one of the important raw materials for the dye
manufacture and most nitrobenzene produced is used directly or indirectly in dye
manufacture. It is manufactured on large scale only by aniline manufactures. Ref[1]

2.PHYSICAL PROPERTIES

2.CHAPTER
2.Physical Properties of Nitrobenzene :ref[4]
Molecular Weight

123.11

Boiling Point

210 - 211 C

Melting Point

6 C

Flash Point

88 C (closed cup)

Vapor Density

4.3 (air = 1)

Vapor Pressure

1 mm Hg at 44.4 C

Density/Specific Gravity

1.205 at 15/4 C (water = 1)

Log Octanol/Water Partition Coefficient

1.85

Henry's Law Constant

2.44 x 105 atm-m3/mole

Conversion Factor

1 ppm = 5.04 mg/m3

3.CHEMICAL PROPERTIES

3.CHAPTER
CHEMICAL PROPERTIES
1.

Nitrobenzene reactions involve substitution on the aromatic ring and reactions

involving the nitro group.

2.

Under electrophilic conditions, the substitution occurs at a slower rate than for
benzene and the nitro group promotes met substitution

3.

Nitrobenzene can undergo halogination,sulfonation and nitration, but it does

not undergo Friedel-crafts reactions.

4.

Under nucleophilic conditions, the nitro group promotes ortho and para
substitution.

5.

The reaction of nitro group to yield aniline is the most commercially important
reaction of nitrobenzene.

6.

Depending on the conditions, the reduction of nitrobenzene can lead to a

variety of products.

10

Reduction Products Of Nitrobenzene

Reagent

Product

Fe,Zn or Sn+HCl

Aniline

H2+metal catalyst+ heat

(gas phase or solution)

Aniline

SnCl2+acetic acid

Aniline

Zn+NaOH

Hydrazobenzene, azobenzene

Zn + H2O

N-Phenylhydroxylamine Azoxybenzene

Na3ASO3

Azoxybenzene

LiAIH4

Azobenzene

Na2S2O3 + Na3PO4

Sodium Phenylsulfamate,C6H5NHSO3NA

11

4.USES

12

4.CHAPTER

The largest end use of nitrobenzene is in the production of aniline.approximtely

95-98% of nitrobenzene is converted to aniline the demand for nitrobenzene
fluctuates with the demand for aniline production grew at an average annual rate of
almost 5% from 1984 to1988 but dropped by over 4% during the 1989-1990
economic downturn. For 1990,96% of the 532972 metric tons of nitrobenzene left
were used to produce variety of other products, such as para-aminiphenol and
nigrosine dyes. The U.S. producers of PAP are MALLINCHRODT,INC., RHONEPOULENC, and Hoechst cleanse with combined production capacities >35000 metric
tons. Mallinckrodt is the largest producer, with over 50% of capacity PAP primarily is
used as an intermediate for acetaminophen. Ref[4]

13

5.PROCESS DESCRIPTION

14

5.CHAPTER
Nitrobenzene is prepared by direct nitration of benzene, using a nitric acid-sulphuric
acid mixture. The reaction vessel or nitrator is a specially built cast-iron or steel
kettle fitted with an efficient agitator. The kettle is jacketed and generally contains
internal cooling coils for proper control of the exothermic reaction.
Nitrobenzene can be produced by either a batch or a continuous process
with a typical batch, the reactor is charged with benzene, and the nitrating acid (5660% H2SO4,27-32wt% HNO3 and 8-17%wt% H2O) is added slowly below the
surface of the benzene. The temperature of the mixture is maintained at 55-55C by
adjusting the feed rate of the mixed acid and the amount of cooling. the temperature
can be raised to 90C towards the end of the reaction to promote completion of
reaction. The reaction mixture is fed into separator where the spent acid settles to the
bottom and is drawn off to be refortified. The crude nitrobenzene is drawn from the
top to the separator and washed in several steps. depending on the desired purity of
the nitrobenzene the product can be distilled. Usually a slight excess of the benzene is
used to ensure that little or no nitric acid remains in spent acid. Yield is about 98%.
Because of a continuous nitration process generally offers lower capital cost and more
efficient labor usage than a batch, most if not all of the nitrobenzene produce use
continuous process.
Benzene nitrating acid (56-65 wt% H2SO4,20-26%HNO3 & 15-18wt%
water) are fed into the nitrator, which can be a stirred cylindrical reactor with internal
cooling coils and external heat exchangers or cascade of such reactors.
The nitator also can be designed as a tubular reactor e.g. tube and shell
heat exchangers with appropriate cooling coils involving turbulent flow. Generally,
with a tubular reactor the reaction mixture is pumped through the reactor cycle loop
and a portion of the mixture is withdrawn and fed into the separator.

15

A slight excess of benzene usually is fed into the nitrator to ensure that
the nitric acids in the nitrating mixture is consumed to maximum possible extent and
to minimize the formation of di-nitrobenzene. the temperature of the nitrator is
maintained at 50-100C by varying the amount of cooling.
The reaction mixture flows from the nitrator into separator are
centrifuged here is separated into two phases. The aqueous phase or spent acid is
drawn from the bottom and concentrated in a sulfuric acid reconcentrated step or
recycled to the nitrator where it is mixed with nitric and sulfuric acid immediately
prior to being fed into the nitrator.
The

crude nitrobenzene is washed and distilled to remove water and

benzene and if required nitrobenzene can be refined by vacuum distillation. ref[3]

SPECIFICATION AND TEST METHODS

Specification and test Methods:
Specification for double-distilled nitrobenzene are give in table below,
Property

Value

Purity ,%

> 99.8

Color

Clear, light yellow to brown

Freezing Point, 0C

> 5.13

Distillation range (First drop), 0C

> 207

Dry point 0C

212

Moisture,%

<0.1

Acidity As nitric acid, %

<0.001

16

Several qualitative spot tests are applicable to nitrobenzene and depend on

characteristic color developed by its reaction with certain reagent. In general,
calorimetric methods are subject to interferences from aromatic nitro compounds.
Certain colorimetric methods are based on the nitration of nitrobenzene to mnitrobenzene and subsequent determination by the generation of a red-violet color
with acetone and alkali. A general micrometric method for the determination of
aromatic nitro compounds is based on reduction with titanium(lll) sulfate or chloride
in acidic solution followed by back titration of excess titanium (lll) ions with a
standard ferric alum solution. Now days most modern techniques use instrumental
methods such as gas chromatography and high pressure liquid chromatography.

17

PROCESS FLOW DIAGRAM

18

6.Material Balance

19

6.CHAPTER
Individual Material Balance for Mixed Acid
Reaction Involved
H2SO4 + HNO3
Mol.wt

98

HNO3 (H2SO4)

63

161

Basis :
1 Ton of Mixed acid

H2SO4 600 Kg
1000 Kg of Mixed Acid

Mixer
HNO3 400 Kg
Where,
H2SO4

= Wt / Mol.wt
= 600/98 = 6.1224 no of moles

HNO3

= Wt / Mol.wt
= 400 /63 = 6.349 no of moles

Mixed acid = Wt/Mol.wt

= 1000/161 = 6.2111 no of moles
Where,
Mass In

= Mass of HNO3 + Mass of H2SO4

20

= 400 + 600 =

Mass Out

1000 Kg

= Mass of HNO3(H2SO4)
= 1000 Kg

Mass In = Mass Out

Nitration:
Reaction Involved:
C6H6 + HNO3(H2SO4)
Mol.Wt 78

C6H5NO2 + H2O + H2SO4

161

123

18

98

C6H6 650 Kg
HNO3(H2SO4)

C6H5NO2 840.84 Kg
Nitration

1000 Kg

H2O 129.36 Kg
H2SO4

646.8 Kg

Unreacted C6H6 13Kg

UnreactedHNO3(H2SO4) 20 Kg

C6H6

Wt /Mol.wt

= 650 /78 = 8.333 no of Moles

HNO23(H2SO4) = Wt / Mol.wt

21

= 1000 /161 = 6.2111

C6H5NO2 :
Wt %

= 51% of C6H5NO2
= 50.96 /100* 1650 = 840.84 Kg

No of Moles = 840.84 /123

=

6.836 Moles

H2SO4 :
Wt %

= 39.2 % of H2SO4
= 39.2 / 100* 1650 = 646.8 Kg

No of Moles = 646.8 /98

= 6.6 Moles
H2O :
Wt %

= 7.84% of Moles
= 7.84/100 *1650 = 129.36 Kg

No of Moles = 129.36 Kg /18 = 7.18 Moles.

Unreacted of C6H6 2%:
= Wt / Mol.wt

2 / 100 * 650 = 13 Kg

= Wt / Mol.wt =

2 /100 * 1000 = 20 Kg

Unreacted of HNO3(H2SO4) 2%:

Mass In

= Mass of HNO3(H2SO4) + Mass of C6H6

22

= 1000 + 650

= 1650 Kg

Mass Out = Mass of C6H5NO2 + Mass of H2O + Mass of H2SO4 +

Mass of Unreacted C6H6 + Mass of Unreacted HNO3(H2SO4)
= 840.84 + 646.8 + 129.36 + 13+ 20
Mass Out = 1650 Kg

Mass In = Mass Out

Material Balance in Separator ;

C6H5NO2 840.84 Kg
UnreactedC6H6 13Kg

C6H5NO2 840.84 Kg

Separator

H2O129.36Kg

H2O129.36 Kg

H2SO4646.8 Kg

H2SO646.8 Kg

UnreactedC6H613Kg
UnreacteHNO3(H2SO4)20Kg
UnreacteHNO3(H2SO4)20Kg

Mass In

= Mass of C6H5NO2 + Mass of H2O + Mass of H2SO4 +

Mass of Unreacted C6H6 + Mass of Unreacted HNO3(H2SO4)

Mass In

= 840.84 + 646.8 + 129.36 + 13+ 20 = 1650 Kg

Mass Out = 1650 Kg

Mass In = Mass Out

23

Material Balance for Distillation Column:

Unreacted C6H6 13Kg

C6H5NO2 840.84 Kg
Unreacted C6H6 13Kg

D
I
S
T
I
L
L
C6H5NO2 840.84 Kg

Mass In

= Mass of C6H5NO2 + Unreacted of C6H6

= 840.84 + 13 = 853.84 Kg

Mass Out

= Mass of C6H5NO2 + Mass of unreacted of C6H6

= 840.84 + 13 = 853.84 Kg

Mass In = Mass Out

24

7.ENERGY BALANCE

25

7.CHAPTER
Individual Energy Balance for Mixed Acid:
Reaction Involved:
H2SO4 + HNO3
Temp 0C
Cp(KJ/Kg k)

HNO3(H2SO4)

30

30

55

1.402

2.013

1.641

Cp of HNO3 (H2SO4) ;
Cp of mix

{ Mass fraction of H2S04 * Cp H2S04} +

{Mass fraction of HNO H2S03 * Cp HNO3}

{(600/1000) * 1.402} + {(400/1000) * 2.013}

Cp of Mix

1.6464 KJ / Kg k

H Reaction

= (HF) Product (HF) Reactant

(HF) reactant

= (HF) H2SO4 + (HF) HNO3

(HF) H2SO4

= -193.69 Kcal /Mol at 25 0 C. ref[2]

= -8269.377 KJ/Kg
= - 8269.377*600

(HF) H2SO4

= - 4.9616*106 KJ

(HF) HNO3

= -41.35 KCal / Mol at 25 0 C. ref[3]

= - 2749.165 KJ/ Kg
= - 2749.165 * 400

(HF) HNO3 = -1.0996 * 106 KJ

26

(HF) reactant = (-4.9616- 1.0996) * 106 KJ

= - 6.0612 * 106 KJ
(HF) Product = - 236.619 K Cal/ Mol
= - 6149.155 KJ/ Kg
= - 6149.155 * 1000
= - 6.149 * 106 KJ
(HF) reaction = (- 6.149 + 6.0612) * 106 KJ
= -0.088 KJ
Energy In = (m.cp.dt) HNO3 + (m.cp.dt) H2SO4
= [400 * 2.013 *(30-25)] + [1000 * 1.402(30-25)]
= 8232 KJ
Energy Out = (m.cp.dt) Product + H reaction
= 1000 * 1.641 *(55-25) -0.088 * 106
= 8636.1 KJ

27

Overall Energy Balance:

Reaction Involved:
C6H6 + HNO3(H2SO4)
Temp 0C
Cp(KJ/Kg K)
Energy In

C6H5NO2 + H2O(H2SO4)

30

55

95

1.769

1.641

1.528

95
1.97

= (m.cp.dt)C6H5NO2 + (m.cp.dt) mix acid

= (650 * 1.769 * 55) + (1000 * 1.641 *30)
= 112471.75 KJ

Energy Out = (m.cp.dt)C6H5NO2 + (m.cp.dt) H2O(H2SO4) +

(m.cp.dt) unreacted C6H6 + (m.cp.dt) unreacted mix acid + Hrxn
= [840.84 * 1.528 *(95-55)] + [776.16 * 1.97(95-25)] +
[13 * 1.769 *(95-25)] + [20 * 1.641 * (95-25)] 1510080.0
= 113251.79 KJ

Energy In = Energy Out

28

8.Design For Reactor

29

12.CHAPTER
Ideal steady state operation is carried out :
We know that for a 2nd order reaction,

V
______
FAO

XA
_______
-rA

(or)
V /VO

XA/ KCAO(1-XA)2

Where,
Vo

Feed rate,

CAo

Moles of A/VOL of fluid

XA

Conversion (98%)

We know that K is const = 1.412 Lit/min.mol . ref[2]

Volume of C6H6

Volume of HN03

volume of C6H6/ Density of C6H6

650 /876 = 742.0L

Volume of HNO3 / Density of HNO3

400/ 1504 = 265.9L

Volume of H2SO4 = Volume of H2SO4/ Density of H2SO4

=

600 / 1834 = 327.2L

30

Total Volume

= 445.03 l/day = 445.03/24 = 18.54 l/hr = 18.54 / 60 = 0.309 l/min

= 18.54/ 3600 = 5.15*10-3
= 0.00515 l/sec.

CAO

=
=

CAO

No of Moles/ Total Volume

6.122/0.0052

=1177.31/60 = 19.62 Mol/Lit

= 19.62 Mol/Lit

= V /VO

= XA* CA / K *CAO*(1-XA)2

V / VO

Vol of the reaction

0.98 * 0.309/ 1.412*19.62*(1-0.98)2 =

= 27.33 Lit
=

0.02733 m3

We know that,
/4 D2 H = 0.027
* D2

= 0.027*4

= 0.185 m3

/4* (0.185)2 H = 0.027

H

0.027 * 4 * 1 /*0.1852

1.019 m3

31

27.33 Litres

We know that ,
Thickness of vessel

t = P*D /2FN-P

Operating Pressure
Design Pressure

= 3+15% = 3.15 atm = 3.15*1.01325 bars*105 N/m2

= 319173.75 N/m3

Design Presure
Shear Stress ,

= 3 atm

if

= yield stress /2

We know that
Yield stress

= 207*106 ref[5]

Shear Stress

= 207*106 / 2

Shear Stress

= 103*106 w/m3

We know that
hwelding efficiency =0.85 ref[5]
Thickness of vessel

t = P*D /2FN-P
= 319173.75*09 / (2*103*106*0.85)-319173.75
t = 1.64*10-3m

Thickness of vessel

= 1.64 mm

32

DESIGN SUMMARY

Volume of the reactor

2.77 m3

Diameter of the reactor

0.185 m3

Height of the reactor

1.019 m3

Thickness of vessel

1.64 mm

33

REACTOR

34

9.DISTILLATION COLUMN

35

9.CHAPTER
Basis ; 1 hour of operation.
Feed

Volume of feed

= 35.576 Kg/hr.

Distillate

= Volume of distillate = 0.5416 Kg/hr.

Bottom Product B = Volume of bottom

Xf

= 35.03

Kg/hr.

= unreacted of benzene /mol.wt / (Unrect/mol) + (prod/mol.wt)

= 2/78 / (2/78) + (98/123) = 0.036

Xd

nitrobenzene /mol.wt / (nitroben/mol) + (prod/mol.wt)

= 100/78 / (100/78) + (0/123) =

Xb

= Unrectbenz/mol.wt / (unrectbenz/mol) + (nitrobenzene/mol)

= 0/78 / (0/78) + (100/123)

= 0

Average Molecular weight of feed

= 123*0.98+78*(1-0.98) =
Feed rate

122.1

= 35.576 /122.1
= 0.29 Kg mole / hr

Also,
Fxf = Dxd + Bxb
From above,
D = Fx xf-xb / xd-xb . ref[2]
= 0.29*(0.03-0/1-0)
D = 0.0087 Kg mole/hr

36

B = 0.29-0.0087 = 0.2813 Kg mole/hr.

Slope of q-line ;
We know that q = Hg-Hf / Hg-Hl
q=1
slope of q-line:
slope of q-line = q/q-1
= 1/1-1
Tan-1() = 0
q line is st.line
Xd / Rm+1

= 0.05

Rm+1 = 1/0.05
Rm+1 = 20
Rm

= 19

= 1.2 Rm

= 22.8 23

Xd

Rm+1

= 0.042

23+1

37

From Mc-cabe Thile Graph

X

0 0.01 0.02 0.03 0.045 0.07 0.10 0.155 0.20 0.30

0 0.03 0.485 0.63 0.74 0.82 0.88 0.92 0.94 0.964

Ideal Plate

16 (From Graph)

Actual Plate =

Ideal/n

Actual Plate =

26.66

16/0.6

Height:
Plate Spacing
Ht

= 450 mm = 0.45m

= (Actual Plate-1)*0.45 + 2(0.45)

= 12.45m

Diameter :
Vap rate

= v = D(R+1)
= 0.0087(23+1)
n = 0.21 Kg moles/hr

Top Column :
Vol.rate

= nRT/P
= 0.21*8.314*103*(82+273)/ 1.01325*105 = 6.1170 m3/hr

Vol rate

= 1.7*10-3 m3/sec

Velocity

= 1 m/sec

38

Area

= Vol rate / Velocity

= 1.7*10-3 /1

Area

= 1.7*10-3 m2

= D2 /4

D2 = 4A / ;

D = 4A /

D = 0.047 m
Bottom column:
Vol.rate

= nRT/P
= 0.21*8.314*103*(210+273)/ 1.01325*105 = 8.32 m3/hr

Area

= Vol .rate / Velocity

Velocity

= 1 m/sec

Area

= 2.31*10-3 m2

= D2 / 4

D2 = 4a / ; D = 4A/
D = 0.054 m
Both diameters are approximately same ,
we choose the larger diameter (i.e) bottom diameter
Bottom diameter D= 0.054 m

39

DESIGN SUMMARY

Ideal plate

16.00

Actual Plates

26.66

Column Height

12.45m

Column Diameter

0.054 m

40

DISTILLATION COLUMN

41

TOPSIDE

42

BOTTOM SIDE

43

10.COST ESTIMATION

44

10.CHAPTER
Cost of a Kg of Nitrobenzene in Market

= 35 Rs

The Capacities of Plant is 840.84 Kg/day for 1 year

= 29429.4

Gross `sales for 1 year or Total income

= Rs.87*106

Estimation of capital investment cost Turnover

= Gross Annual Sales

Fixed Capital

For Chemical Industries Turn Over ratio

= 1

Therefore gross annual sales

= Fixed Capital Investment

Therefore Fixed capital Investment

= Rs.30.87*106

1. DIRECT COST
It is taken as 70% of fixed capital investment
Hence direct cost

= 0.7 * 30.87* 106 = Rs 21.6*106

The cost involved in direct costs are

Equipment and installation + instrumentation = piping + electrical + insulation+
Paintings which amount for 50% of the fixed capital
1. Equipment cost is 24% of fixed capital cost = Rs.7.4 * 106
2.Installation and painting is 40% of delivered equipment cost = Rs3*106
3.Instrumentation and control and installation cost = 10% of delivered equipment
cost this cost is equal to Rs7.4*106
4.Piping and installation cost is 25% of the delivered cost = Rs1.85*106
5.Electrical and installation cost Rs 33.33% of the delivered cost.
45

6.Building , Process and Auxiliary

This cost is 39.1667 of the purchased equipment cost
this cost is equal to 391667*7.4*106 = Rs289*106
7.Service Facilities and yard improvement is 40% of the delivered equipment cost
this cost is equal to 0.4*7.4*106 = 2.96*106
8. Load cost is 1% of fixed capital
this cost is equal to 0.001*30.87*106 = Rs 30.87*106

2.INDIRECT COST:
This is expenses which are not included with material and labor of actual
installation of complete facilities
this cost is equal to 0.3*30.87*106 = Rs6.174*106
a) engineering are supervision : this cost is 20% of the fixed capital investment
this cost is equal to 0.2*30.87*106
b) Construction expenses and contractor fees. this cost is 10% of direct cost
This cost is equal 0.1*21.6*106 = Rs2.16*106
c) Contingency : This cost in 5% of the capital
This cost is equal to 0.5*30.87*106 = Rs1.544*106

46

Working Capital:
In 20% of total capital investment total capital investment = fixed cap+ Working cap
=30.87*106+0.8(Total cost investment)
total capital capital investment = 30.87 *106/0.8 = Rs 38.58*106
Working Capital = 38.58*106-30.87*106 = Rs 7.71*106
Estimation of Total Product Cost
Total annual income = Rs.30.87*106
Total Grass Earnings = 10% of total annual incomes
= 0.1*30.87*106 = Rs3.08*106
Product Cost

= Total annual Gross earnings income

=30.87*106-3.08*106 = Rs 27.79*106

Total Product Cost = Direct Production Fixed + Charge Plant + Overhead

DIRECT PRODUCTION COST
It is 60% of total product cost the
Direct Production cost is equal to = 0.6*27.79*106
1. Raw Material : It is 20% of total product
cost the cost of raw material is = 27.79*106 = Rs.5.56*106
2. Operating Labor is 15% of the total product cost
The cost of operating labor is = 0.15*27.79*106 = 4.168*106

47

3. Direct supervisory and clinical labor is 20% of operating labour.

The cost of direct supervisory and clinical labor is = .15*27.79*106= Rs.5.56*106
= Rs4.168*106= Rs.5.56*106
4. Utilities : In 15% of total Product cost
The cost of utilities is = 0.15*27.79*106 = Rs4.168*106
5. Maintenance and Repairs : it is 3.6% of fixed capital investment
The cost of maintenance = 0.0036*30.87*106
6. Operating Supplies : it is 0.5% of the fixed capital investment
The cost of operating supplies is = 0.005*30.87*106
7. Laboratory Charge is 6.6667% of the operating labor cost
The cost of Laboratory Charges is = 0.6667*4.168*106 = Rs 0.281681*106
8. Patents and Royalties : it is 1.45% of the fixed capital cost
the cost of patents and royalties is = 0.0145*30.87*106 = Rs.447675.00
9. Fixed charge : it is 20% of total product cost.
The cost of fixed charges is

= Rs 5.56*106

DEPRECIATION
Depreciation for building is 3% of land cost
= 0.03*30.87*105
Total depreciation value = Rs0.93*106

48

3. INSURANCE
This is 1 % of the fixed capital investment
The insurance value = 0.01*30.87*106 = Rs 308700
4. Rent : This is 3.0555% of total product cost
Rent value = 0.030555*27.79*106 = Rs.849123.45
C) Plant overheads : The includes cost for following general plant upkeep and
Overheads payroll, overhead packaging, medical services safety and protection,
Restaurants, recreation salvage, laboratories and storage facilities. This cost is 5%
of total product cost plant overhead is equal to = 0.05*27.79*106 = Rs 1389500.00

ll GENERAL EXPENSES:
a) Administrative cost:
Includes cost for executive officer, clinical wage, legal fees, office
Supplies and communication. This cost is 5% of the total product cost
Administrative cost = 0.005*27.79*106 = Rs.1389500.00
b) Distribution and selling cost:
Includes cost for sales offices, sales man shopping and advertising
This cost is 7 of the total product cost
Distribution and selling cost

= 0.07*27.79*106 = Rs. 1945300.00

49

c) Research and development

This cost is 1% of total product cost. Research and
Development cost

= 0.01*27.79*106 = Rs 277900.00

D) Gross earning cost: it is the net profit obtained after deduction of tax from
gross earning
Gross earning cost = 60%
Net profit

= Rs 1.848*106

d) Pay back period: with interest charge

Pay back = Depreciable fixed capital investment
Average profit/year-Average depreciation/year
= (30.87-3.08)*106 /(1.846+3.08)*106
= 5.612 years
Pay back = 5years 233 days ref[2]

50

11.HEALTH AND SAFTEY FACTORS

51

11.CHAPTER
Nitrobenzene is a very toxic substance the maximum allowable concentration
for nitrobenzene is 1ppm or 5 mg/m.It is readily absorbed by contact with skin and
by inhalation of vapor, If a worker was exposed for 8 hours to 1ppm nitrobenzene in
the working atmosphere, about 25mg of nitrobenzene would be absorbed, of which
about one-third would be by skin absorption and the remainder by inhalation . The
primary effect of nitrobenzene is the conversion of hemoglobin to met hemoglobin;
thus the conversion eliminates hemoglobin from the oxygen-transport

cycle.

Exposure to nitrobenzene may irritate the skin and eyes. nitrobenzene affects the
central

nervous

and

produces

fatigue,

headache,vertigo,vomiting,

general

weakmess,and in some cases unconscious and coma. There generally is a latent period
of 1-4 hours before signs or symptoms appear. Nitrobenzene is a powerful met
hemoglobin former, and cyanosis appears when the met hemoglobin level reaches
15%. Chronic exposure can lead to spleen and liver damage, jaundice and anemia.
Alcohol in any form should not be ingested by the victim of nitrobenzene poisoning
for several days after the nitrobenzene poisoning or exposure. Impervious protective
clothing should be worn in areas where risk of splash exists. Ordinary work clothes
that have been splashed should be worn in areas where risk of splash exists.
Ordinary work clothes that have been splashed should be removed immediately, and
the skin washed thoroughly with soap and warm water. In areas of high vapor
concentrations full face marks with organic-vapor canister or air-supplied respirators
should be used. clean work clothing should be worn daily and showering after each
shift should be mandatory.
With respect to the hazards of fire and explosion, nitrobenzene is classified as a
moderate hazard when exposed to heat or flame. Nitrobenzene is classified by the
ICCas a classB poisonous liquid. Ref[1]

52

ENVIRONMENT EFFECTS
First draft prepared by L. Davies, Office of Chemical Safety, Therapeutic Goods
Administration, Australian Department of Health and Ageing, Canberra, Australia
Published under the joint sponsorship of the United Nations Environment
Programmer, the International Labor Organization and the World Health
Organization, and produced within the framework of the Inter-Organization
Programmer for the Sound Management of Chemicals.
The International Programmer on Chemical Safety (IPCS), established in 1980, is a
joint venture of the United Nations Environment Programmer (UNEP), the
International Labor Organization (ILO) and the World Health Organization (WHO).
The overall objectives of the IPCS are to establish the scientific basis for assessment
of the risk to human health and the environment from exposure to chemicals, through
international peer review processes, as a prerequisite for the promotion of chemical
safety, and to provide technical assistance in strengthening national capacities for the
sound management of chemicals.
The Inter-Organization Programmer for the Sound Management of Chemicals
(IOMC) was established in 1995 by UNEP, ILO, the Food and Agriculture
Organization of the United Nations, WHO, the United Nations Industrial
Development Organization, the United Nations Institute for Training and Research
and the Organization for Economic Co-operation and Development (Participating
Organizations), following recommendations made by the 1992 UN Conference on
Environment and Development to strengthen cooperation and increase coordination in
the field of chemical safety. The purpose of the IOMC is to promote coordination of
the policies and activities pursued by the Participating Organizations, jointly or
separately, to achieve the sound management of chemicals in relation to human health
and the environment.
Nitrobenzene.
(Environmental health criteria ; 230)
1.Nitrobenzenes - toxicity

53

2.Nitrobenzenes - adverse effects

3.Environmental exposure
4.Risk assessment I. International Programmer for Chemical Safety II.Series. ref[1]

HANDLING AND STORAGE TRANSPORTATION

Nitrobenzene samplings handling procedures in the united states are
described by ASTMP 3436-75.They are classified by the U.S interstate commission
(ICC)as a poisonous liquid,classB (regulation 173 347) and as a class 6 poison by
united nations as such they must be packaged in ICC specifications contains when
shipped by rail, water or highway and all of ICC regulations regarding loading
handling and labeling must be followed. nitrobenzene ordinarily is transported in
tanks, cars, tank trucks, or metal drums.
Carbon steel or cast iron is considered materials of choice for handling nitrobenzene
except when decolonization must be kept to minimum. Stainless steel (400 series) is
recommended for color critical applications. Nitrobenzene attacks, copper alloys,
brass and copper. It is rated on class IIIA combustible liquids (NFPA std no.30) and
usually can be handled with little danger of fire. Ref[2]

54

12.PLANT LAYOUT

55

15.CHAPTER
Plant layout is the functional arrangement of machinery and equipment in a
existing plant. Plant layout may be defined as the floor plan for determining and
arranging the desired equipment of a plant, in the one best place, to permit the
quickest flow of materials at lowest cost and least amount of handling in processing
the raw material from the receipt of raw material to the shipment of finished products.
The material handling planned in the layout begins at the receiving point , where the
material arrives as raw material, then continuous progressively from storage through
process, moving the from of worked material from department to department , from
machine to machine, the material flows in and out of temporary storage is fed through
assembly lines for final assembly. Provision is made for inspection, packaging and
storing the material as finished product.
Advantages of good plant layout to the workers :

Reduces the effort of the workers.

Reduces the number of handling.

Permits working at maximum efficiency.

Reduces the number of accidents.

Provides basis for higher earnings.

Advantages of a good plant layout in labour cost:

Increases output per man hour.

Reduces number of operators.

Loss setup time involved

56

Advantages of a good plant lay out in production control:

Reduces production control expenses

Pace production

Fundamental concepts of plant layout :

In apprising the advantages of good layout in the light of conditions prevailing in a
particular plant ,it is well to bear in mind the following concepts of plant layout.

Major part of production works is not processing , as is initially suppose but

material handling.

Then speed of production in the plant is determined primarily by the

adequacies of its material handling facilities.

A good plant layout is designed to provide the proper facility for material
handling.

The factory is altered or constructed around the prescribed plant layout.

The production efficiency of the plant is determined by the limitations of its

layout.

TYPES OF DEPARTMENT

Processing department.

This department performs machining assembly and packaging.

Service department.

These constitute the facilities provided to keep the processing

department in operation without interruption.

Administrative department.

57

This department administrative sales,engineering,accounting production

control, departments etc.

PLANNING THE PROCESSING

The plant layout engineer should obtain data on building elevation, column
spacing, door and conveyors.

The conveyors should be placed at reasonable height to mal functioning and

waste.

The traffic in the plant may be greatly by location store rooms close to the
building entrances.

In addition to the above vehicular traffic should be separated from pedestrian

traffic and the roads should be wider.

PLANNING THE PLANT SERVICE FACILITIES:

Material received at a plant arrives via the particular forms of transportation

which are generally prescribed.

Liquids such as chemicals are transported in tank cars, drums or pipelines

The receiving department must be well equipped to receive the material in all
modes.

The design of a receiving involves the following considerations:

1. Space, 2. climate conditions, 3. variety of vehicles

STORE ROOM:

A store room is the reservoir for raw material.

Worked materials, finished products, maintenance supplies etc are kept.

58

The functional requirements of a store room are:

1. protection to materials
2. handling of the materials
3. control points
The above factors also help the layout engineer to design the store
room as per requirements.

INSPECTION ROOM:

The inspection room or quality control room should be located near then
production unit, so that the samples from the production plant
Can be checked for its quality requirements.

The labs should be well equipped and should be properly planned.

WATER STORAGE:

Water is used in the plant for variety of purposes.

A plant must have adequate water supply to crater all these needs.

By far the most reliable and effectives means of fire protection is the
automatic sprinkler system.

The sprinkler system is fitted with a sensitive transducer which lets water up
to a height of 15 feet.

So the water storage system should be planned out with most more.

59

POWER AND LIGHTING SYSTEM:

Power and lighting systems forms the main part of the plant.

The significant features of the power plant operations are,

1. For supplying steam.
2. Providing heat for process operations.
3. supplying power to run motor.
4. providing light to plant.
5. power for surplus use.

PLANNING OF ADMINISTRATIVE BLOCK:

Location of an administrative block depends upon the geographic

location with respect to the plant functions.

The general administrative block should have administrative rooms,

conference room and vault room storage of documents and records.

The employee service facility consists of parking lots,

Employment office cafeteria, first aid stations and medical
department etc.

ref[6]

60

PLANT LAYOUT

61

13.CONCLUSION

62

13.CHAPTER

The Manufacture of Nitrobenzene has been described in detail. The

necessary flow diagram, material and Energy balance for the production of 1 Ton of
Nitrobenzene has been worked out in detail. The design aspects are above described
in detail. The cost has been estimated .

63

14.BIBLIOGRAPHY

64

14.CHAPTER

1. KIRK AND OTHMER, Encyclopedia of Chemical Technology Vol.15.

2nd Ed.Pg:176-190
2. ROBERT H .PERRY : PERRYS Chemical Engineers Hand Book 5th &
6th Ed. Mc Graw Hill international Editions , Pg:642-644
3. GEORGE T. AUSTIN : Shreves Chemical Process Industries 5th Mc
Graw Hill international Editions , Pg:776-778
4. BAHL.B.S & ARUN BAHL : A text book of organic Chemistry,
19990,chand , Pg:350-355
5. IS CODES : 2825 ; 1969,4503-1967, Pg:5
6. JOSHI.M.V: Process Equipment Design 3 rd Ed.Pg :45

65