Sumitomo Chemical India Limited.

, Bhavnagar
Budgetary CAPEX Costing
Project : Costing for RB-601 Once through operation for Xylene Distillation in QP plant

Sr. No. Head * Cost in Note

Rs. Lakh
1 Major Equipments 3.00 1.5 Kl SS-316 Dish end Jacketed Receiver
0.75 Feed Distributor for RB-601 Falling Film Evaporator
1.00 RB-601 Evaporator Bottom Cap in SS-316 with Vapour Nozzle
1.00 T-611 Shell Extension to increase capacity from 4.2 to 5.2 Kl
Magnetic Level Indicator for T-611
2 Equipment Overhauling 0.00
3 Utility Cost 0.00
4 Civil Cost 0.00
5 Structural work Installation of Load cell in New Receiver
6 Process & Utility Piping Approx. Mtr Process + Utility Piping
9 Electrification 0.00
10 Instrumentation See "Instrument MTO" sheet
11 Insulation & Cladding 0.50 Equipment & Piping related insulation
12 Rigger charges for Equipment & Piping work 0.50 Equipment Installation, Shifting, Lifting
13 Consultancy charge 0.00 For structural stability
14 Provision for Hazop study recommendation 1.00
16 Sub-Total 7.8
17 Contingency 0.78 10% of subtotal
Sub-total 8.5 Say Rs. Lakh

Note:-
Kindly refer attached sheet of "Project Basis"
* All costs excluding taxes

Summary of Major Activities:-

1 Shell Extension of T-611 tank to increase capacity from 4.2 Kl to 5.2 Kl
2 Concentrate mass Receiver Load Cell installation
3 See "Equipment List" for nos. of Equipments to be relocate, dismantling & new installation
 Sumitomo Chemical India Ltd., Bhavnagar 27.02.2020
Project: RB-601 Once through operation for Xylene Distillation in QP plant

1 Existing RB-601 Falling Film Evaporator having 25 Sq. mtr of H.T.A will be used as Once through operation
2 Based on Trial 750 LPH of Feed rate is suitable to get desired concentration in one pass through Evaporator
3 Total % Evaporation v/v required is 80% to increase concentration of QP from 19% to 80%
4 In existing process, 1 hr of Settling is carried out in T-611 before feeding to RB-601 Pot
5 T-611 Settling & Feeding tank Shell extension is consider to increase capacity from 4.2 to 5.2 Kl to accommodate one batch volm.
6 Proper size Feed Distributor for RB-601 Falling film evaporator is consider
7 Control logic is consider based on initial concentration of QP in feed is 19%
8 Mass Flow meter(Sp. Gr, Totalizer) in Feed line with Control valve is consider for automation purpose
9 New 1.5 Kl SS-316 Jacketed receiver is consider to collect concentrated QP mass
10 Load cell for New Jacketed receiver is consider for quantification & automation purpose
11 Available Condenser is of sufficient size based on vapour load calculation
12 DVP-601 Dry Vacuum pump will be continue use for proposed ATFE system
 Existing RB-601 Boilup Rate, Vapour Velocity, Condenser Sizing Xylene Vapour Pr. Data
Available Data P, mmHg Temp.
Total Batch Volm. to be processed 4800 Ltr 5 25
Sp. Gr of Feed 0.9 7 30
4320.0 Kgs 10 35
Feed Composition 15 40
Qp (18%) 777.6 Kgs 20 45
Xylene(82%) 3542.4 Kgs 25 50
Concentrate Composition 40 60
Total Conc. mass (Sp. Gr = 1.4) 948.3 Kgs
Qp(82%) 777.6 Kgs
Xylene(18%) 170.7 Kgs Total Chilled water Flow #REF! m3/hr
Xylene to Evaporate 3371.7 Kgs
Limitation of skin Temprature 47 °C
% Evaporation required 78 %
Evaporation Rate
H.T.A of FFE 25 Sq. M
Overall H.T.C for FFE assume 250 Kcal/hr m2 °C
Operating Vacuum 755 mmhg
Vapour Temprature of Xylene @ 750 mmHg 45 °C
Pot Temprature to maintain 47 °C
Utility - Hot Water Temprature 60 °C
Latent heat of Xylene 83 Kcal/kg
Calculations:- 60
LMTD for Counter current Flow in FFE 54
47
40

∆T1 13 °C
∆T2 14 °C
LMTD 13.49 °C
Rate of Evaporation 550 Kg/hr

Batch Time Cycle for Evaporation 6.1 Hrs

Vapour Column & Condenser Sizing
Data
Evaporation Rate 550 Kg/hr
Molecular Wt., Mw Xylene 106 Kg/kmol
Universal Gas Const. R 8.314 M3 Kpa/ Kmol K
Absolute Pressure, P 0.67 Kpa
Vapour Temp. T 318 K
Existing Vapour Bend 0.35 m
Assume Overall U for Condenser, HTC 250 Kcal/hr m2 °C
Vapour Inlet T 45 °C
Condensate Outlet T 45 °C

Vapour Column Velocity :-

Vapour Density 0.027 Kg/m3
Vapour Flow Rate 20628.72 M3/hr
Vapour Velocity 59.59 m/s

Vapour Velocity inside FFE:-

Nos. of Tube 419 nos.
Tube I.D 19.00 mm
Length of Tube 1.00 m
Pump Flow Rate 12.00 m3/hr
Total C/S area of Tube 0.12 Sq. m
Vapour Velocity inside FFE 1.68 m/s
Residence Time 0.59 Sec.
1.01 Min.
Total residence time for Qp mass under Heating 6.13 Hrs
Condenser Sizing: -
Existing 25 Sq. m Condenser with CW, Additional 5+5+3 Sq. m with CHW provision

45 45

38
32

∆T1 7 °C
∆T2 13 °C
LMTD 9.69 °C
Heat to be removed, Q 45650 Kcal/hr
H.T.A Required 18.84 m2
30% Excess H.T.A 24.49 m2
Existing installed Condenser area 25 Sq. Mtr
 Existing RB-601 (Circulation Type Operation)
25 Sq. m
Shell O.D 600 mm
Tube Length 2.8 m
Circulation Flow(via Mass Flow meter) 15000 Kg/hr
(P-607/608- 12m3/hr, 38mH) 16.7 m3/hr
Tube ID 54 mm
Tube OD (T=5 mm) 64 mm
Nos. of Tube, A=Nt Pi Do L 44 Nos.
Vapour Nozzle of RB-601 Pot 350 mm
Avg. Evaporation Rate (from T.C) 550 Kg/hr
% Evaporation Capacity in one pass 37 %

54 60

47
42

∆T1 13 °C
∆T2 12 °C
LMTD 12 °C
Existing U, Overall HTC of RB-601 160 Kcal/hr m2 k
Vapour Density @ 755 mmHg Vac. 0.028 Kg/m3
Vapor Flow 19643 M3/hr
RB-601 Pot Vapour Nozzle Size 350 mm
Vapour Velocity @ Vapour Nozzle 57 m/sec
Residence Time for QP mass under heating 1.02 min.

Tube Wetting Rate & Film Thickness for circulation type RB-601
Γ = Tube Wetting Rate
Total Feed Flow 15000 Kg/hr
Flow per Tube 340.91 Kg/hr
Γi, Initial Wetting Rate of Tube 0.558 Kg/m Sec
Density of Initial Feed @ 25°C 900 Kg/m3
Viscosity of Initial Feed @ 25°C 0.00061 Kg/m sec
Density of Conc. mass @ 47°C 1390 Kg/m3
Viscosity of Conc. mass @ 47°C 0.000486 Kg/m sec
Γf, Final Wetting Rate of Tube 0.352 Kg/m Sec
m1, Initial Film Thickness 0.00050479 m
0.5048 mm
m2, Final Film Thickness 0.00030024 m
0.3002 mm
# GT ML Ref. 0.2-0.3 mm thickness

Liquid Velocity profile through Distributor plate& tube

Total Vol. Flow rate 16.7 m3/hr
Upper Distributor plate
Hole Dia 15.00 mm
Nos. of Hole 42 nos.
Flow through 1 hole 0.40 m3/hr
Liquid Velocity 0.62 m/sec
Lower Distributor plate
Hole Dia 14.00 mm
Nos. of Hole 145 nos.
Flow through 1 hole 0.11 m3/hr
Liquid Velocity 0.21 m/sec
Tubes
Liquid Velocity inside RB-601 tube 0.05 m/sec
# GT ML Ref. 0.05 m/sec Liquid Velocity through tube
Vapour Velocity inside RB-601 tube 54.17 m/sec
# GT ML Ref. 5-7.5 m/sec Vapour Velocity through tube
# RB-502 Ref. 40 m/sec Vapour Velocity through tube
 Proposed RB-601 (Once through Operation)
Existing RB-601 Heat Transfer Area 25 Sq. m
Shell O.D 600 mm
Length of RB-601 Tube (TS Length) 2.8 m
Tube ID 54 mm
Tube OD 64 mm
Nos. of Tube 44 Nos.
Vapour Nozzle 350 mm
Max. Evaporation Capacity based on H.T.A 772 Kg/hr
% Evaporation required for once through pass 80 %
Max. Cap. of Feed Flow of RB-601 1102 Kg/hr
1.2 m3/hr

54 60

25 47

∆T1 13 °C
∆T2 29 °C
LMTD 19 °C
U, Overall HTC of RB-601 FFE 160 Kcal/hr m2 k
Vapour Density @ 755 mmHg Vac. 0.028 Kg/m3
Vapor Flow 27562 M3/hr
RB-601 Pot Vapour Nozzle Size 350 mm Admin:
Vapour Velocity @ Vapour Nozzle 80 m/sec 80 m/sec Vapour Velocity i
High.
Recommended Vapour Velocity under vacuum 60 m/sec
Max. Evaporation Rate to keep velocity 60 m/s 582 Kg/hr
Feed Flow required to maintain for once through 746 Kg/hr
0.8 m3/hr
Liquid Velocity inside RB-601 tube 0.002 m/sec
Residence Time for QP mass under heating 2.30 min. Admin:
Batch Time Cycle 5.8 Hrs 1 Batch output equivalen
LC QP is 1.05 T
Sectional Capacity (Equivalent QP 70% LC) 3.8 TPD
114 TPM
Additional Chilled water flow required in RB-601 0 m3/hr
Chilled water TR/batch 3 TR/ Batch

Findings :-
1. Existing RB-601 25 Sq. mtr Area having Capacity equivalent to 165 TPM QP as 70% LC
2. Existing RB-601 Vapour Nozzle Size (14") gives Capacity equivalent to 125 TPM as QP 70% LC

Tube Wetting Rate & Film Thickness for once through RB-601
Γ = Tube Wetting Rate
Total Feed Flow 745.6292307692 Kg/hr
Flow per Tube 16.78 Kg/hr
Γi, Initial Wetting Rate of Tube 0.027 Kg/m Sec
Density of Initial Feed @ 25°C 900 Kg/m3
Viscosity of Initial Feed @ 25°C 0.00061 Kg/m sec
Density of Conc. mass @ 47°C 1390 Kg/m3
Viscosity of Conc. mass @ 47°C 0.000486 Kg/m sec
Γf, Final Wetting Rate of Tube 0.008 Kg/m Sec
m1, Initial Film Thickness 0.00018500 m
0.1850 mm
m2, Final Film Thickness 0.00008593 m
0.0859 mm

648

Liquid Velocity profile through Distributor plate& tube

Total Vol. Flow rate 0.8 m3/hr
Upper Distributor plate
Hole Dia 15.00 mm
Nos. of Hole 42 nos.
Flow through 1 hole 0.02 m3/hr
Velocity 0.03 m/sec
Lower Distributor plate
Hole Dia 14.00 mm
Nos. of Hole 145 nos.
Flow through 1 hole 0.01 m3/hr
Velocity 0.01 m/sec
Tubes
Liquid Velocity inside RB-601 tube 0.002 m/sec

Vapour Velocity inside RB-601 tube 56.73 m/sec

 Condenser Sizing based on Max. Evaporation Rate for once through Xylene
Existing 25 Sq. m Condenser with CW & 02 nos. 5+5 Sq. m with CHW P, mmHg
As vapour temperature is 25 deg C, condenser with chilled water req. 5
7
25 25 10
15
12 20
8 25
40
∆T1 13 °C
∆T2 17 °C
LMTD 14.17 °C Existing Condens
Heat to be removed, Q 48272.0 Kcal/hr Tag
H.T.A Required 13.63 m2 HE-601
30% Excess H.T.A 17.72 m2 HE-602
Say 18 Sq. Mtr HE-603
Chilled water flow required 12.1 m3/hr HE-604
Line size required 46.2 mm
Say 50.0 mm

For trial, HE-602 Chilled Water Return will be given to HE-601 Chilled water
supply.

Admin:
80 m/sec Vapour Velocity is too
High.

Admin:
1 Batch output equivalent to 70%
LC QP is 1.05 T
Recommended Wetting Rate for Liquid is 0.1-0.3 Kg/m sec
Recommended Film Thickness should be 0.2-0.4 mm

Reynold's no= Nre of Film 2889

NRe>2100, Flow regime becomes turbulent flow, so Film H.T.C, hi=NRe^0.4
Film Heat Transfer coefficient reduction, h1/ 3
Xylene
Temp.
25
30
35
40
45
50
60

Existing Condenser & Sub-cooler detail

Sq. m Utility & size Duty Type
25 CW-3" Cond. STHE
5 CHW-1.5" Cond. STHE
5 CHW-1.5" Cond. STHE
3 CHW-1.0" Cooler Spiral
 Indicates New Equipments installation in plant 27.02.2020
Indicates Existing Equipments to be dismantle permanently

Equipment List RB-601 Once through operation Xylene Distillation in QP

Tag No. Existing use Proposed Use Capacity Location MOC Wt, Ton Remarks
V-602 Water wash vessel Water wash vessel 7 Kl T.F SS-316 2.2
T-609 Organic Mass Storage tank Organic Mass Storage tank 4.2 Kl G.F SS-316 1
T-608 Emulsion Recovery tank Emulsion Recovery tank 4.2 Kl G.F SS-316 1
T-611 Settling & Feed tank to RB-601 Pot Settling & Feed tank for RB-601 Evaporator 4.2 Kl Fo. F SS-316 1 Shell Extension to increase capacity to 5.2 Kl
RB-601 Distillation Pot -- 3.2 Kl Fo.F SS-316 2 Permanent removal
New Bottom Cap with Vapour Nozzle fabrication,
FFE Xylene Distillation Evaporator Xylene Distillation Evaporator 25 Sq. m Fo. F SS-316 1
Replacement of Feed Distributor

Receiver -- Concentrate mass collection 1.5 Kl G.F SS-316 1 Top & Bottom Dish End, Jackated Receiver

P-607 RB-601 Circulation pump RB-601 Circulation & Transfer Pump 12cmh,38mH,10 Hp G.F SS-316
P-608 RB-601 Circulation pump RB-601 Circulation & Transfer Pump 12cmh,38mH,10 Hp G.F SS-316
HE-601 RB-601 Primary condenser RB-601 Primary condenser 25 Sq. m Fo. F SS-316
HE-602 RB-601 Second. condenser RB-601 Second. condenser 5 Sq. m Fo. F SS-316
HE-603 RB-601 Tertiary condenser RB-601 Tertiary condenser 5 Sq. m Fo. F SS-316
HE-604 Distilled Xylene subcooler Distilled Xylene subcooler 3 Sq. m Fo. F SS-316
DVP-601 RB-601 Vacuum Pump Everest RB-601 Vacuum Pump Everest 600 m3/hr T. F SS-316 Everest DVP with post condenser
V-609 Hot Water Vessel Hot Water Vessel 5 Kl F.F SS-316
V-606 Evamole mixing Vessel Evamole mixing Vessel 4 Kl S.F SS-316
Buffer for Vacuum Buffer for Vacuum 0.25 Kl T. F SS-316
 Instruments MTO
Tag Equipment Size Duty MOC TYPE Qty. Cost(lac) Remarks

FI-New RB-601 Evaporator 25 Feed Flow Indication(Sp.gr) SS Mass 1 4.5 Conductivity is too low
CV-New RB-601 Evaporator 25 Feed Flow Control SS Ball 1 1.2 Fail to Close
FI-New ATFE 25 Concentrate mass Flow(Sp.gr) SS Mass 1 5 Sp. Gr measurement
XV-New Sub-Cooler 25 CHWS CS+SS Ball 1 0.4 Fail to Close
XV-New ATFE 40 Conc. mass SS Ball 1 0.25 Fail to Close
CI-T2201 T-609 25 Conductivity Indication SS 1 0.0 Existing use from T-611
FIC-T2201 T-609 25 Emulstion seperation SS Ball 1 0.0 Existing use from T-611
XV-New Buffer 50 Vacuum SS Ball 1 0.5 HE-601 vacuum
XV-New Buffer 50 Vacuum SS Ball 1 0.5 RB-601 Vacuum
XV-New RB-601 40 Vent SS Ball 1 0.3 RB-601 Vent
VFD-New P-607 & 608 VFD for Feed Pump 2
LT-New RB-601 25 Level transmitter for drain Radar 1 1.5 RB-601 Drain purpose

Total Instrument Cost 14.15

Cabling, Programming 0.7
Overall Cost 14.85
 Barchart for ATFE Installation in QP

Sr. No. Activity Time Req. Jan-20 Feb-20 March-20

1 Capex approval 1 Week
2 Detailing & Hazop 2 Week
3 Datasheet,PR, quotation 3 Week
4 Delivery of long delivery items (Subcooler) 4 Week
5 Overhauling of Equipments 1 Week
Schedule for work planning to dismantle existing Installed ATFE in GT ML Plant
6 Existing ATFE Piping, F.F structral(cement sheet/roof) dismantling 2 Days
7 Hot work required for ATFE supporting leg cutting to dismantle ATFE 8 Hrs
8 Site clearance i.e dyke, fencing breaking nr. GT ML for crain approch 2 Days
9 ATFE dismantling from GT ML through telescopic crain 08 Hrs
10 Gala packing related structral work(Folding Gala) after dismantling ATFE 2 Days
11 F.F Cement sheet roof refitting after dismantling ATFE 2 Days
Schedule for work planning to Install ATFE in QP Plant
1. Pre Shutdown(without Hot work)
12 Existing Piping & Cable tray rerouting for installation of equipments 2 Week
13 Dismantling of T-616 (preshutdown) shifting out plant 1 Week
14 Dismantling of V-1209 Agitator, latern, motor, G.B, piping, instruments 2 Days
2. Post Shutdown
15 Structral work to dismantle V-1209, RB-601 Pot, Evaporator, T-609, P-611 & P-612 5 Days
16 Civil work for T-616 Dyke & slab breaking for installation of T-609 2 Days
17 Dismantling of V-1209, RB-601 Pot, Evaporator, T-609, P-611 & P-612 2 Days
18 Structral fab. & erection for RB-601 Pot, ATFE,Subcooler, T-609, P-611 & P-612 5 Days
19 Top Floor cement sheet roof opening for ATFE installation 1 Day
20 ATFE Installation through Heavy duty Telescopic Crain 08 Hrs
21 Piping, Instrumentation, Electrification, Insulation & cladding work 1 Week
22 Testing, Trials & commionsioning 2 Days
23 Plant restart

Hot work required:-

1 Shift Hot Work required for Structral related work to dismantle ATFE in GT ML Plant
10 Days Hot Work required for Structral & Piping work to install ATFE in QP plant

Heavy duty crain required:-

02 Days (8 hrs/ day basis) Heavy duty Telescopic crain required for dismantling, Shifting & installation of ATFE
 Line List & Piping MTO
Line Duty Pipe, m Bend S.end Flange Valve Reducer DW S.G
1 T-611 to ATFE 25 NB SS-316, SCH 40 12 4 6 6 3 0 1
Unit Cost 520 55 55 60 1350 -- 3000
Total Cost 6240 220 330 360 -- -- -- 7150
2 Vapour Bend ATFE to HE-601 350 NB SS, SCH 10s 6 3 3 3 -- 6*14 --
Unit Cost 18000 8000 3800 1500 5000
Total Cost 108000 24000 11400 4500 -- 5000 -- 152900
3 CHWS to HE-601, 50 NB MS 30 6 0 8 1 -- --
Unit Cost 250 60 -- 150 1200 -- --
Total Cost 7500 360 -- 1200 -- -- -- 9060
4 CHWR from HE-601, 50 NB MS 30 6 8 8 1 -- --
Unit Cost 250 60 -- 150 1200 -- --
Total Cost 7500 360 -- 1200 1200 -- -- 10260
5 ATFE to Subcooler, 25 NB SS 6 1 4 4 -- -- 1
Unit Cost 520 55 55 60 1350 -- 3000
Total Cost 3120 55 220 240 -- -- -- 3635
6 CHWS to Subcooler, 25 NB MS 30 6 0 8 -- 1 --
Unit Cost 250 25 0 55 -- 500 --
Total Cost 7500 150 0 440 -- -- -- 8090
7 CHWR from Subcooler, 25 NB MS 30 6 0 8 -- 1 --
Unit Cost 250 25 0 55 -- 500 --
Total Cost 7500 150 0 440 -- -- -- 8090
8 Vacuum line to RB-601, 40 NB SS-316 36 6 8 8 3 -- --
Unit Cost 770 100 100 100 2500
Total Cost 27720 600 800 800 7500 -- -- 37420
9 Vent Line RB-601 to common vent, 40 NB SS-316 18 4 6 6 1 -- --
Unit Cost 770 100 100 100 2500
Total Cost 13860 400 600 600 2500 -- -- 17960

Piping Material Cost 254565

Total Mtr of Piping 250
Fabrication + Fitting Cost 125000
Existing Piping modification (RB-601, T-609,P-611,612 related) 150 mtr 75000
Net Piping Cost 454565
thickness 4.78 mm
 Sheet10

T-611 Shell Extension

Existing Tank Capacity 4.4 Kl

Total Batch Volume 4.8 Kl
Tank Dead Level to maintain 0.8 Kl
Proposed Capacity required 5.6 Kl
Tank Inside Diameter 1.8 m
Capacity to increase 1.2 Kl
Shell Extension height 0.471809389 m
Say 500 mm
Cost for Shell Fabrication, fitting 56520 Rs.

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