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PROJECT REPORT
ON
RECOVERY OF NAPHTHALENE FROM COAL TAR IN TAR
DISTILLATION PLANT
(Capacity 5 Metric Ton per day)
Bachelor of Technology
in
Chemical Engineering
of
National Institute of Technology, Raipur
Table of contents
Declaration
Acknowledgement
Certificate
Abstract
Chapter1 – Introduction
1.1What is naphthalene?
1.2 Process description
Chapter 2- Literature, review and objective
Chapter 3– Methodology and process description
3.1 Solvent extraction
3.2 Fractional distillation
3.3 Flow diagram of tar distillation plant
3.4 Process of recovery of naphthalene
Chapter 4- Plant layout
Chapter 5- Designing of equipment
• Distillation column
Chapter 6- Energy and Material Balance
Chapter 7 – Cost estimation
7.1 Cost estimation of plant
7.2 Manufacturing labor cost
7.3 Depreciation
7.4 Estimated Profit
Chapter 8 – Conclusion and References
DECLARATION
We, hereby declare that the work that is being presented in the
project entitled “RECOVERY OF NAPHTHALENE FROM
COAL TAR IN TAR DISTILLATION PLANT (Capacity 5
Metric Ton per day)” in partial fulfillment of the requirement of
the degree in Bachelor of Technology (Chemical Engineering), is
an authentic record of our work carried out under the supervision
of Dr. V.K.Singh, Associate Professor Department of Chemical
Engineering, National Institute of Technology, Raipur.
The matter presented in this report has not been submitted to any
other university/institute.
Date:29/11/2023
Fiza tandon
Roll no. 20113021
Sachin chaurasiya
Roll no. 20113053
Suchit kukna
Roll no. 20113068
Fiza tandon
Roll no. 20113021
Sachin chaurasiya
Roll no. 20113053
Suchit kukna
Roll no. 20113068
Date:29/11/2023
Dr. V.K. SINGH
Associate Professor
Department of Chemical Engineering
NIT Raipur
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
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 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
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.
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).
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.
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
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.
where Hv is the enthalpy of vapor entering the tray, Hmin is the minimal reflux ratio, and Hl is
the enthalpy of liquid exiting the tray., and Em is the Murphree tray efficiency.
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.
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 Hv is
the enthalpy of vapor entering the calculation—the enthalpy of vapor entering is equal to the
enthalpy of liquid leaving the tray.
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.
Qc = V * (Hf – Hv)
where Hf is the enthalpy of the feed, Hv is the enthalpy of vapor entering the tray, V is the vapor
flow rate, and Qc is the condenser duty.
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.
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, Hcondis 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
Equation Involved
F = D+W
12500 = D + W ----(eq.1)
D = 1107.4 kg/hr
W = 11392.6 kg/hr
= 31 × 103 MJ/hr
= 31 × 106 KJ/hr
Assumptions:
? = 31 × 106 KJ
MODEL CALCULATIONS
Equipment Heat Hot Fluid Cold Fluid
transferred
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
Tower Diameter:
Assume t = 0.5 m
= 0.575 (>0.1)
T = (4 AT / π) 0.5 = 0.4545 m
W=0.7(.45) = 0.315 m
Take h1 = 25 mm and hw = 50 mm
do = hole diameter
L = plate thickness
Co= 1.635
Vo = QG/Ao=7.3255 m/s
(2hDgPL)/(Vo2ρG)=Co[(0.4(1.25-(Ao/An))+(4lf/dO)+(1-
(Ao/An))2]
Hydraulic head:
Z = (T+W)/2 = 0.3825
= 0.03208 m
Pressure drop at the liquid entry There will be a downspout apron set at
The area for the liq. Flow under the apron = 0.025xW
= 0.007875 m2
h3 = hg+ h2 = 0.05083 m
Check on flooding
Result:
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 XF 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—tF, 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]
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
Where,
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.
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, H1 is the enthalpy of vapour and hD 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.
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
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.
i. Indirect cost
ii. Direct cost
Direct cost:
Purchased equipment cost = E
Components % of E
Land 6%E
INDIRECT COST:
Contingency 10%(I+D)=y
Direct cost:
Cost of purchased equipment: Rs 35733596
Indirect cost
Supervision & Engg. = 0.33*35733596=Rs11792086
Building costs = 0.41*35733596=Rs14650774
Contingency=0.1*35733596=Rs3573359
Fixed capital investment:
Fixed Capital Investment = Total direct + indirect cost + contingency +
Contractor’s fee=Rs197222412
W.C=0.15 (T.C.I)
= 0.15(197222412+WC)
=Rs34803955.06
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.
• 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
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.
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
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:
Profit obtained= Rs 40
Our plant will produce 5 tons of naphthalene then estimated profit will be:
= Rs 6000000/month
= Rs 72000000/year
PAYBACK PERIOD:
The payback period illustrates how long it takes to recover project costs.
=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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