Group 1 Project Report 2 DP2 Jan2023

UNIVERSITI KUALA LUMPUR
MALAYSIAN INSTITUTE OF CHEMICAL BIOENGINEERING TECHNOLOGY

DESIGN PROJECT 2 – CPB30404
Project Report 2
Assessment/Rubric/Marking Sheet
Project Title : Production of Phenol 750,000 MTA

Supervisor : Dr Nor Shahirah Binti Mohd Nasir
Date : 23 Jun 2023
Group no. : G1
Group Members:
Name ID
1 Muhammad Amir Aiman Bin Omar 55213120087
2 Muhammad Firhad Hazrani Bin Zaimi 55222120119
3 Nur Anis Natasha Binti Mohd Azlan 55213120082
4 Mohamed Hanif Bin Mohamed Rawi 55222120105
5 Ahmad Izzudin Arif Bin Ramlee 55222120127
6 Khairul Amin Bin Ahmad Shukri 55213218051
Very Satisfa
CRITERIA Poor Good Excellent
Poor ctory
DESIGN PROJECT 1
Review and arrange Design Project 1 by chapter:
Chapter 1, 2, 3, 4, 5, 6 and 10
2 4 6 8 10
DESIGN PROJECT 2 (Part 1)
Review and arrange Design Project 2 (Part 1) by chapter:
Chapter 7
FINANCIAL ANALYSIS
Chapter 8 Engineering Financial & Economic Analysis of
Chemical Process
8.1 Total investment
8.1.1 Equipment cost
4 8 12 16 20
8.1.2 Purchase cost estimation (PCE)
8.1.3 Physical plant cost (PPC)
8.1.4 Fixed capital
8.1.5 Working capital
8.1.6 Total investment
8.2 Production costs
8.2.1 Variable costs
3 6 9 12 15
8.2.2 Fixed costs
8.2.3 Annual production cost and production cost
ECONOMIC ANALYSIS
Chapter 8 Engineering Financial & Economic Analysis of
Chemical Process
8.3 Economic analysis
3 6 9 12 15
8.3.1 Cash flow
8.3.2 Payback period (*including graph)
8.3.3 Net present worth (NPW)
8.3.4 Return of investment (ROI/ROR)
PROCESS CONTROL & INSTRUMENTATION 15
Chapter 9 Process control and instrumentation
9.1 Control system 3 6 9 12
9.2 Control/Instrument variable in a plant with symbol
9.3 P&ID
MALAYSIAN INSTITUTE OF CHEMICAL BIOENGINEERING TECHNOLOGY
DESIGN PROJECT 2 – CPB30404
SAFETY AND HEALTH

Chapter 10 Safety and health
10.1 Safety & loss prevention
10.2 Type of incident, potential incident, and incident consequence
10.3 Hazardous material in the plant and chemical interaction hazard 4 8 12 16 20
10.4 Safety data sheets (SDS) and inherent safety design
10.5 Layers of Plant safety
10.6 HAZOP documentation
10.7 Emissions assessments
ENVIRONMENTAL CONSIDERATION
Chapter 11 Environmental Consideration
3 6 9 12 15
11.1 Environment aspect and impact
11.2 Type of wastewater treatment plant and related statutory law
CONCLUSION & RECOMMENDATION
1 2 3 4 5
State conclusion and recommendation of the overall project
REFERENCES, APPENDIX & NEATNESS
Sources of references are valid and cited in the report (Reference
1 2 3 4 5
style). Properly attach any appendix. Readability of report and quality
of language. Written according to format and tidy.
STUDENT NUMBER S1 S2 S3 S4 S5
TOTAL MARKS (120 MARKS)
VERIFICATION
General :
Comment
Accessed by :
Signature
Date :
PRODUCTION OF PHENOL 750,000 MTA
DESIGN PROJECT 2 (CPB30404)

PROJECT REPORT 1
NAME POSITION
1 MUHAMMAD FIRHAD HAZRANI BIN ZAIMI MANAGER & SITE SELECTION
2 AHMAD IZZUDIN ARIF BIN RAMLEE SAFETY & UTILITIES ENGINEER
HEAD OF MARKETING
3 NUR ANIS NATASHA BINTI MOHD AZLAN
DEPARTMENT
4 MUHAMMAD AMIR AIMAN BIN OMAR LAYOUT ENGINEER
5 MOHAMED HANIF BIN MOHAMED RAWI PROCESS ENGINEER
6 KHAIRUL AMIN BIN AHMAD SHUKRI DESIGN ENGINEER
LECTURER
DR NOR SHAHIRAH MOHD NASIR
SUPERVISOR
DR NOR SHAHIRAH MOHD NASIR

MALAYSIAN INSTITUTE OF CHEMICAL & BIOENGINEERING TECHNOLOGY
(UNIKL MICET)
FEBRUARY 2023
2
TABLE OF CONTENTS
CHAPTER 1.0: INTRODUCTION

1.1 Introduction .............................................................................................................. 12
1.2 Company Background ............................................................................................... 12
1.3 Motto, and Vision ...................................................................................................... 12
1.4 Mission ................................................................................................................... 12
1.5 Organization Chart .................................................................................................... 13
1.6 Job Description .......................................................................................................... 14
1.7 Logo Company ........................................................................................................... 15
CHAPTER 2.0: THE DESIGN PROBLEMS

2.1 Introduction to plant design ..................................................................................... 16
2.2 Application and Uses ................................................................................................. 17
2.2.1 Uses of Benzene .......................................................................................................... 17
2.2.2 Uses of Compressed Air .............................................................................................. 17
2.2.3 Uses of Phenol ............................................................................................................. 18
2.2.4 Uses of Catechol .......................................................................................................... 18
2.2.5 Uses of Benzoic Acid.................................................................................................... 19
2.2.6 Uses of Benzaldehyde ................................................................................................. 19
2.3 Background study raw material/product .................................................................. 20
2.3.1 Introduction ................................................................................................................ 20
2.4 Properties and Uses Materials .................................................................................. 20
2.4.1 Properties of Benzene ................................................................................................. 20
2.4.2 Properties of Compressed Air ..................................................................................... 21
2.4.3 Properties of Phenol.................................................................................................... 21
2.4.4 Properties of Catechol ................................................................................................. 22
2.4.5 Properties of Benzoic Acid .......................................................................................... 22
2.4.6 Properties of Benzaldehyde ........................................................................................ 23
2.5 Safety Data Sheet (MSDS) ......................................................................................... 24
2.5.1 MSDS Benzene ............................................................................................................ 24
2.5.2 MSDS Air ...................................................................................................................... 26
2.5.3 MSDS Phenol ............................................................................................................... 28
2.5.4 MSDS Catechol ............................................................................................................ 29
2.5.5 MSDS Benzoic acid ...................................................................................................... 30
3
2.5.6 MSDS Benzaldehyde .................................................................................................... 31
2.6 The Process Selection ................................................................................................ 32
2.6.1 Description of The Process Chosen ............................................................................. 32
2.6.2 Reaction Chemistry ..................................................................................................... 33
2.7 Advantages and Disadvantages of The Process ........................................................ 33
2.7.1 Production Phenol from Cumene................................................................................ 33
2.7.2 Other Considerations .................................................................................................. 34
2.7.3 Direct Route of Phenol from The Benzene.................................................................. 34
2.7.4 Other Considerations .................................................................................................. 35
CHAPTER 3.0: FEASIBILITY STUDY AND MARKET SURVEY

3.1 Introduction .............................................................................................................. 36
3.2 General Information .................................................................................................. 36
3.3 Process Technology ................................................................................................... 36
3.4 Market Data .............................................................................................................. 41
3.4.1 Market Assessment Production .................................................................................. 41
3.4.2 Global Phenol Market ................................................................................................. 43
3.4.3 Current and Future price of phenol ............................................................................ 45
3.4.4 Demand of Phenol ....................................................................................................... 45
3.4.5 Export and Import ....................................................................................................... 47
3.4.6 Target Customers ........................................................................................................ 48
3.4.7 Target Suppliers for Raw Materials ............................................................................. 50
3.5 Cost Estimation ......................................................................................................... 50
3.5.1 Pump ........................................................................................................................... 51
3.5.2 Compressor ................................................................................................................. 52
3.5.3 Turbine ........................................................................................................................ 53
3.5.4 Heat Exchanger ........................................................................................................... 53
3.5.5 Reactor ........................................................................................................................ 54
3.5.6 Distillation Column ...................................................................................................... 54
3.5.7 Flash Drum .................................................................................................................. 55
3.5.8 Condenser ................................................................................................................... 56
3.5.9 Storage Tank ................................................................................................................ 57
CHAPTER 4.0: PROCESS SELECTION

4.1 Introduction .............................................................................................................. 59
4
4.2 Block Flow Diagram (BFD) ......................................................................................... 60
4.3 Process Flow Diagram (PFD) ...................................................................................... 61
4.4 Process Description ................................................................................................... 62
CHAPTER 5.0: PLANT LOCATION

5.1 General Consideration ........................................................................................... 64
5.2 Site Location ............................................................................................................ 64
5.3 Introduction .............................................................................................................. 67
5.4 Type of Industry and Location .............................................................................. 67
5.5 Reasonable Available Land Price and Characteristics ..................................... 67
5.6 Availability of Raw Materials Supply .................................................................... 67
5.7 Vicinity of Market .................................................................................................... 68
5.8 Transportation ......................................................................................................... 68
5.8.1 Road ................................................................................................................... 69
5.8.2 Ship ................................................................................................................... 70
5.8.3 Airplanes .................................................................................................................. 71
5.9 Availability of Utilities.............................................................................................. 74
5.10 Availability of Labour .............................................................................................. 74
5.11 Waste and Effluent Disposal Facilities ................................................................ 75
5.12 Climate ................................................................................................................... 76
5.13 Political Stability and Attractive Government Incentives .................................. 78
5.14 Local Community .................................................................................................... 79
5.15 Site Layout ............................................................................................................... 80
5.16 Plant Layout............................................................................................................. 83
CHAPTER 6.0: MASS AND ENERGY BALANCE

6.1 Introduction .............................................................................................................. 85
6.1.1 Process Flow Diagram (PFD)........................................................................................ 86
6.1.2 Stream Table of Overall Process Flow ......................................................................... 87
6.2 ASPEN HYSYS ............................................................................................................. 88
6.2.1 Simulation of Mass Balance ........................................................................................ 89
6.2.2 Report Generated from Aspen Hysys Converted to Excel .......................................... 90
6.3 Introduction .............................................................................................................. 91
6.4 Simulation of Energy Balance .................................................................................... 92
6.5 Report Generated ..................................................................................................... 93
5
6.6 MASS BALANCE ....................................................................................................... 103
6.6.1 Introduction .............................................................................................................. 103
6.6.2 Molecular Weight ...................................................................................................... 103
6.6.3 Phenol Production Calculation .................................................................................. 103
6.6.4 Mass Balance Calculation .......................................................................................... 104
Mass Balance at Condenser (E- 107)............................................................................................. 104
Mass Balance at Distillation Column (T – 104).............................................................................. 105
Mass Balance at Pump (P-106) ..................................................................................................... 106
Mass Balance at condenser (E- 106) ............................................................................................. 107
Mass Balance at Distillation Column (T- 103) ............................................................................... 108
Mass Balance of Pump (P-104) ..................................................................................................... 109
Mass Balance at Distillation Column (T- 102) ............................................................................... 110
Mass Balance at Condenser (E- 105)............................................................................................. 111
Mass Balance at Distillation Column (Flash Drum T-101) ............................................................. 113
Mass Balance at Cooler (E-104) .................................................................................................... 114
Mass Balance at Turbine (TR-101) ................................................................................................ 115
Mass Balance at Heat Exchanger (E-102)...................................................................................... 116
Mass Balance at Reactor (R-101) .................................................................................................. 117
Mass Balance at Mixing Point ....................................................................................................... 118
Mass Balance at Pre- Heater (E-103) ............................................................................................ 119
Mass Balance at Heat Exchanger (E-102)...................................................................................... 120
Mass Balance at Mixing Point ....................................................................................................... 121
Mass Balance at Compressor (C-102) ........................................................................................... 122
6.7 ENERGY BALANCE .................................................................................................... 123
6.7.1 Introduction .............................................................................................................. 123
6.7.2 Energy Balance Reactive Process .............................................................................. 123
Reactor R-101 123
6.7.3 Energy Balance Non-Reactive Process ...................................................................... 124
Compressor (C-101) 124
Feed/Effluent Exchange E-102 ...................................................................................................... 125
Pre-Heater E-103 ................................................................................................................. 126
Condenser E-105 ................................................................................................................. 127
Condenser E-106 ................................................................................................................. 128
6
Condenser E-107 ................................................................................................................. 130
Mixing Point 1 ................................................................................................................. 131
Mixing Point 2 ................................................................................................................. 132
Distillation Column T-102.............................................................................................................. 133
CHAPTER 7.0: CHEMICAL ENGINEERING & MECHANICAL ENGINEERING

EQUIPMENT DESIGN
7.1 Fundamental knowledge ......................................................................................... 139
7.1.1 REACTOR R-101 ......................................................................................................... 139
7.1.2 General Information .................................................................................................. 139
7.1.3 Type of Flow Reactor ................................................................................................. 140
7.1.4 Type of Catalyst ......................................................................................................... 141
7.1.5 Material Construction ............................................................................................... 141
7.1.6 Working Principle ...................................................................................................... 142
7.1.7 Design Intention ........................................................................................................ 142
7.1.8 DISTILLATION COLUMN ............................................................................................. 144
7.1.10 Types of Continuous Columns (In general) ............................................................... 145
7.1.11 Type of Nature of the Feed Used .............................................................................. 145
7.1.12 Types of Column Internals Used ............................................................................... 146
7.1.13 Types of Column Tray Used ....................................................................................... 147
7.1.14 Material Construction Used ...................................................................................... 147
7.1.17 FLASH DRUM ............................................................................................................. 150
7.1.19 Type Of Separator ..................................................................................................... 151
7.1.20 Working Principle of Separator ................................................................................. 152
7.1.22 HEAT EXCHANGER ..................................................................................................... 154
7.1.25 Types of Heat Exchanger ........................................................................................... 156
7.1.26 Heat Exchanger Component and Material ................................................................ 157
7
7.2 DESIGN CALCULATION............................................................................................. 159
7.2.1 Reactor R-101 ............................................................................................................ 159
7.2.2 Operating Condition .................................................................................................. 159
7.2.3 Detail Calculation ...................................................................................................... 160
7.2.4 Distillation Column 1 (T-102) .................................................................................... 169
7.2.5 Details calculation ..................................................................................................... 169
7.2.6 General Consideration .............................................................................................. 181
7.2.12 General consideration ............................................................................................... 211
7.2.13 Compressor ............................................................................................................... 214
7.2.15 Flash Drum ................................................................................................................ 221
7.2.18 Heat Exchanger ......................................................................................................... 228
7.3 MECHANICAL DRAWING ......................................................................................... 238
7.3.1 Reactor R-101 (Multi-Tubular Packed Bed Reactor MPBR) ...................................... 238
7.3.2 3D Design View of Reactor R-101 (MPBR) Body, Packed Bed Tube, Hemisphere Head
& Closure 239
7.3.3 Full View, Top View & Cross Section View of 3D Design Reactor R-101 (MPBR) ...... 240
7.3.4 Distillation Column T-102, T-103, T-104 .................................................................... 241
7.3.5 Front View, Top View & Cross Section View of 3D Design Column Part (T-102, T-103,
T-104) by using Autodesk Inventor Professional Software 2023 ................................................ 241
7.3.6 Front View, Top View, & Isometric View of 3D Design Column Tray Part (T-102, T-
103, T-104) by using Autodesk Inventor Professional Software 2023 ........................................ 242
7.3.7 Front View, Top View, Cross Section View, & Isometric View of 3D Design Distillation
Column (T-102, T-103, T-104) by using Autodesk Inventor Professional Software 2023 ........... 243
7.3.8 Flash Drum ................................................................................................................ 244
7.3.9 Mechanical Drawing of Flash drum T- 101 ................................................................ 244
7.3.10 Heat Exchanger ......................................................................................................... 246
7.4 SPECIFICATION DATASHEET .................................................................................... 248
8
7.4.1 SPECIFICATION DATASHEET REACTOR R-101 (MULTI-TUBULAR PACKED BED
REACTOR) 248
7.5 Distillation Column .................................................................................................. 249
7.5.1 SPECIFICATION DATASHEET OF DISTILLATION COLUMN 1 (T-102) ........................... 249
7.6 SPECIFICATION DATASHEET OF FLASH DRUM (T-101) ............................................ 252
7.7 SPECIFICATION DATASHEET OF HEAT EXCHANGER (E-102) .................................... 253
CHAPTER 8: ENGINEERING ECONOMIC ANALYSIS OF CHEMICAL PROCESS

8.1 TOTAL INVESTMENT, FIXED AND WORKING CAPITAL ........................... 254
8.1.1 EQUIPMENT COST ............................................................................................... 254
8 8.1.2 PURCHASE COST ESTIMATION (PCE) ........................................... 278
9 8.1.3 PHYSICAL PLANT COST (PPC) ........................................................ 279
8.1.4 FIXED CAPITAL ..................................................................................................... 280
8.1.5 WORKING CAPITAL.............................................................................................. 280
8.1.6 TOTAL INVESTMENT ........................................................................................... 281
8.2 PRODUCTION COSTS ....................................................................................... 282
8.2.1 Variable costs ................................................................................................................. 282
Other Related Cost ................................................................................................................. 287
8.2.2 Fixed costs............................................................................................................... 288
8.2.3 Annual production cost .......................................................................................... 290
8.3 ECONOMIC ANALYSIS ..................................................................................................... 291
8.3.1 Cash Flow Diagram ....................................................................................................... 291
8.3.2 Net Present Worth ( NPW ) .......................................................................................... 296
8.3.3 Payback Period............................................................................................................... 297
8.3.4 Return of Investment ( ROI/ ROR ) ............................................................................. 298
CHAPTER 9.0: PROCESS CONTROL AND INSTRUMENTATION

9.1 Control System ........................................................................................................ 299
9.1.1 Objective of Control System...................................................................................... 300
9.1.2 Process Control Loop................................................................................................. 302
9.1.3 Control System in Phenol Production Plant .............................................................. 305
9.1.4 Feedback Control ...................................................................................................... 306
9.1.5 Cascade Control ........................................................................................................ 307
Reactor (R-101) .................................................................................................................. 309
9
Heat Exchangers (E-101,102,103,104,105,106,107) ......................................................... 312
Flash Drum (T-101) ............................................................................................................. 314
Distillation Column (T-102,103,104) ................................................................................... 317
9.2 Process & Instrumentation Diagram (P&ID) ........................................................... 320
9.3 Control/Instrument Variable In Plant...................................................................... 324
CHAPTER 10: SAFETY AND HEALTH

10.1 Safety and Loss Prevention ..................................................................................... 328
10.2 Type of Incident, Potential Incident, and Incident Consequence ........................... 329
10.2.1 Fire ................................................................................................................................. 329
10.2.2 Explosion ....................................................................................................................... 331
10.2.3 Chemical Spills and Leaks.......................................................................................... 333
10.3 Hazardous Material In The Plant ............................................................................. 335
10.3.1 Hazardous material ...................................................................................................... 335
10.3.1 Benzene......................................................................................................................... 335
10.3.2 Compressed Air ............................................................................................................ 337
10.3.3 Phenol ............................................................................................................................ 338
10.3.4 Catechol......................................................................................................................... 339
10.3.5 Benzoic Acid ................................................................................................................. 341
10.4 Safety Data Sheet (SDS)........................................................................................... 342
10.4.1 MSDS for Benzene ...................................................................................................... 344
10.4.2 MSDS Compressed Air ............................................................................................... 346
10.4.3 MSDS Phenol ............................................................................................................... 348
10.4.4 MSDS Catechol ............................................................................................................ 349
10.4.5 MSDS Benzoic Acid..................................................................................................... 350
10.4.6 MSDS Benzaldehyde .................................................................................................. 351
10.5 layers of Plant Safety ............................................................................................... 352
10.6 HAZOP Documentation ........................................................................................... 353
10.6.1 Objectives of HAZOP .................................................................................................. 354
10.6.2 HAZOP Process ........................................................................................................... 356
10.6.3 HAZOP Of Major Equipment ...................................................................................... 359
10.7 Emission Assessment ....................................................................................................... 362
CHAPTER 11: ENVIROMENTAL CONSIDERATION

11.1 Environment aspect and impact ............................................................................. 364
11.1.1 Waste disposal or management ........................................................................... 365
10
11.1.2 Noise......................................................................................................................... 366
11.1.3 Visual Impact ........................................................................................................... 367
11.1.4 Emission to environment ....................................................................................... 368
a) Benzene ................................................................................................................. 368
b) Air 369
c) Phenol 369
d) Benzoic acid .......................................................................................................... 369
e) Benzaldehyde ....................................................................................................... 371
f) Catechol ................................................................................................................. 371
11.2 Type of wastewater treatment plant and related statutory law ............................ 373
11.2.1 Relevant Environmental Acts And Regulations In Malaysia (LAWS OF
MALAYSIA ACT 127 ENVIRONMENTAL QUALITY ACT 1974, 1974). ......................... 374
11.2.2 PROCESS FLOW OF WASTEWATER TREATMENT PLANT ....................... 377
CHAPTER 12: CONCLUSION & RECOMMENDATION .................................................... 380

REFERENCES ................................................................................................................... 381
APPENDIX A 388
APPENDIX B 406
11
CHAPTER 1.0: INTRODUCTION
1.1 Introduction
This chapter includes the project introduction and company background.
1.2 Company Background

Our company’s name will be Royal Phenol Industry Sdn. Bhd. that would be known
internationally. The company will start operating in early January 2023, and is based at the
coast of Kertih, Terengganu. The company mainly sells high quality phenol purity products at
around 750,000 MT annually. The company’s production of phenol would meet the demand
from not only locally but internationally as well. This company’s projected workforce needs
around 600 employees to operate the plant, including on-site engineers, office workers and
drivers to transport our product.
1.3 Motto, and Vision

Motto: PHENOL QUALITY OUR PIORITY
Vision: Be the first phenol production plant with high purify in Malaysia
1.4 Mission
Mission: Provide the high purity and quality of phenol production
12
1.5 Organization Chart
13
1.6 Job Description
Table 1.1: Job description for each position
Position Job Description
Manager & Site Selection A site selection manager is a location strategy specialist
that works with the firm to comprehend its goals and
evaluate the potential of several locations to meet those
needs in order to support future expansion. Including
engineering, supply-chain management, construction,
utilities, logistics, regulatory compliance, taxes, incentive
negotiation, and human resources, an expert site selection
consultant integrates knowledge from several fields.
Safety & Utilities Engineer Safety & Utilities Engineer is in charge of the planning and
building of the electrical, gas, water, and sewer
infrastructure. To guarantee that these systems are
constructed effectively and securely, they collaborate with
a range of contractors and subcontractors.
Head of Marketing A head of marketing is in charge of planning strategies,
Department controlling spending, and establishing objectives for
marketing teams. She monitors consistency in brand
messaging, examines consumer behaviour, and spots
chances for market expansion. They increase brand
visibility and revenue thanks to their leadership abilities and
sector experience.
Layout Engineer Layout engineers do research, make plans, and supervise
the creation of circuit layouts. They turn schematics into
fully customised layouts of analogue, digital, and mixed-
signal designs by utilising their understanding of electronic
and mechanical systems.
Process Engineer A process engineer's job is to turn raw ingredients into
useful everyday goods. They are in charge of planning,
executing, managing, and improving the machinery and
industrial processes used in the manufacturing sector.
14
1.7 Logo Company
Figure 1.1`: Logo of company
15
CHAPTER 2.0: THE DESIGN PROBLEMS
2 Introduction
This chapter explains the design problems and includes the introduction to plant design.
2.1 Introduction to plant design

The objective of this design project is to obtain the production 750,000 metric tons of
phenol annually. There are many methods from the industries right now to obtain phenol, such
as production of phenol from cumene, phenol from coal and the direct route from raw material
benzene to phenol. There are several methods of phenol manufacturing process. There are
Cumene Peroxidation process, Rasching process, Toluene two-stage oxidation process,
Sulphonation process and direct route to phenol from benzene. After every aspect that being
consider like cost of raw material, safety precaution and handling the by product from the
process, direct route from the benzene to phenol was selected.
Figure 2.1: Chemical reaction of direct route phenol from benzene oxidation
Phenol (C6H5OH) is an organic, aromatic compound whose molecular structure is

benzene ring with single hydroxyl group. Phenols, like alcohols, form stronger hydrogen bonds.
As a result, they are more soluble in water and have higher boiling points than alcohols. At
room temperature, phenols exist as colourless liquids or white solids and can be highly toxic
and caustic. There are several industries that use phenol. It is mostly used in medical and
medicine as a disinfectant, antiseptic, and slimicide as well as in the production of a variety of
products. This project will be the studies of synthesis of phenol production direct route from
oxidation of benzene through the oxidation process by presence of copper chromium catalyst
reaction. The direct oxidation process presents a tremendous opportunity for economy of
operation without an acetone by-product.
16
2.2 Application and Uses
2.2.1 Uses of Benzene
A common industrial chemical is benzene. Crude oil contains benzene, which is also a
main component of gasoline. Plastics, resins, synthetic fibres, rubber lubricants, dyes,
detergents, pharmaceuticals, and pesticides are all made with it. Volcanoes and forest fires
naturally produce benzene. Benzene can be found in household products like glue, adhesives,
cleaning supplies, paint strippers, gasoline, and tobacco smoke. Most of benzene in the
environment comes from the usage of petroleum products.
Benzene is usually applied as a solvent in a variety of industrial, industrial, and research

activities. Products containing benzene are used by manufacturers as solvents during various
production stages and are made into chemical and plastic products. Resins, synthetic
products like nylon, Styrofoam, and others are a few examples. Asphalt used by roofing and
paving companies is made with the help of benzene. In addition, benzene also to being used
to make rubber and tyres. Benzene is also an element of the adhesives used to attach shoe
bottoms. Other chemical compound that being produces by present of the benzene are
detergents, pesticides, insecticides, herbicides, and dyes. Also, A lot of people and
manufacturers use benzene as fuel because of its high-octane number and natural availability.
Some people have added it to gasoline as a way to improve fuel efficiency.
Unfortunately, the chemical also carries health hazards related to benzene exposure. It
can cause several side effects, including headaches, dizziness, convulsions,
unconsciousness, and irritability. It can have both acute and chronic effects, depending on the
exposure. And this may occur if benzene is consumed directly, inhaled through the air, or
absorbed through the skin. People are typically exposed to benzene when they fill up their
automobile with gas, use benzene-containing home products, or drink contaminated water.
2.2.2 Uses of Compressed Air

Compressed air is regular air that has had its volume reduced with the help of a
compressor. Like regular air, compressed air consists mainly of hydrogen, oxygen, and water
vapour. Heat can be generated by compressed the air that will make pressure increased.
High-quality chemical products are produced, which results in the creation of hazardous,
corrosive, and changing materials. This means that polluted compressed air may react with
the chemicals. During the manufacturing process, compressed air usually comes into touch
with the actual product; as a result, it must comply to the strictest regulations and be constantly
monitored. Compressed air that is completely free of oil, dry, and consistent is required.
For the manufacturing of pharmaceutical products, particularly in clean rooms, very strict
hygiene standards are required. Therefore, it is crucial that the manufacture occurs in a place
17
clear of bacteria, particles, germs, and polluting oils. Because it frequently comes into contact
with the product itself during the production operations of the pharmaceutical sector, the
compressed air used with high requirements. Compressed air, for instance, needs to be oil-
free or sterile depending on its application. Continuous monitoring of compressed air with
product contact (24/7) is required to satisfy the requirement of proof.
2.2.3 Uses of Phenol

Phenols are widely applied in basic items and as synthesis intermediates in industry.
For example, phenol alone is employed (in low doses) as a disinfectant in mouthwash and
home cleaners. Perhaps the first surgical antiseptic was phenol. However, phenol is very
poisonous, and strong solutions can burn the skin and mucous membranes severely yet
painlessly. Phenol has been replaced by less harmful phenols, like n-hexylresorcinol, in cough
medicines and other antiseptic applications. Butylated hydroxytoluene (BHT) has a much
lower toxicity and is a common antioxidant in foods.
Phenol is a basic ingredient used in the manufacturing of polymers, explosives like picric
acid, and medications like aspirin. The component of photographic developer known as
common phenol hydroquinone turns exposed silver bromide crystals into black metallic silver.
In order to create azo dyes with intense colour, several substituted phenols are used in the
dye industry. Wood preservatives like creosote contain mixtures of phenols, particularly the
cresols.
Phenol is a disinfectant and antiseptic. It is effective against a variety of microorganisms,

including certain viruses and fungi, but only slowly so against spores. Phenol has been used
to relieve itching and sterilise skin. Phenol is also used to treat pharyngitis as an oral analgesic
or anaesthetic in medicines like Chloraseptic. Additionally, phenolization, a surgical procedure
to cure ingrown toenails, uses phenol and similar chemicals.
Due to its low cost, phenol is used commonly in small-scale applications. It is an

ingredient in the commercial paint removers used in the aviation sector to scrape off coatings
made of epoxy, polyurethane, and other chemically resistant materials. In the past, phenol
derivatives have been used to create cosmetic products like sunscreen, hair dye, and skin
lightening solutions. However, the European Union and Canada have restricted the use of
phenol in cosmetic goods due to safety concerns (Phenol – Wikipedia, n.d).
2.2.4 Uses of Catechol

The manufacturing of pesticides uses around half of the synthetic catechol, with the
remaining amount being utilised as a source to fine chemicals like pharmaceuticals and
perfumes. It is widely used as a building block in organic synthesis. Starting with catechol, a
18
number of tastes and scents with industrial significance are created. Vanillin is then produced
on a scale of roughly 10M kg per year by methylating catechol to create Guaiacol. Ethylvanillin,
a component of chocolate confections, is produced by converting the related monoethyl ether
of catechol, guethol. A common replacement for sandalwood oil is 3-trans-
Isocamphylcyclohexanol, which is made from catechol using guaiacol and camphor. Piperonal,
a floral smell, is made via condensation of catechol with glyoxal and decarboxylation of its
methylene diether (Catechol – Wikipedia, n.d).
2.2.5 Uses of Benzoic Acid

Most commonly, benzoic acid is found in industrial applications where it is used to make
a wide variety of product, including perfumes, dyes, topical treatments, and insect repellents.
The salt of benzoic acid, sodium benzoate, is often used in food as a pH adjuster and
preservative to keep food safe. It functions by increasing the inside pH of bacteria to an acidic
level, which is unsuitable for their existence and ability to grow.
In the food industries also commonly use benzoic acid as a medium to their products.
Foods that naturally contain benzoic acid include cinnamon, most berries, and ripe cloves.
Food preservation methods require the use of benzoic acid. Pickles, soft beverages, fruit
juices, and salad dressings are a few examples of benzoic acid in food. Benzoic acid is
typically present in processed foods to prevent the growth of bacteria, mould, and yeast.
Pharmaceuticals make use of benzoic acid. It acts as a preservative in pharmaceuticals.

Additionally, it can be found in soaps, bath products, detergents, hair and nail products,
skincare, cleaning, and new-born products. In the treatment, benzoic acid also can be use
because of It helps in bacterial infection prevention. It is used as an antifungal to treat
conditions including athlete's foot and ringworm. As a result of conjugation with glycine in the
liver, it is eliminated as hippuric acid. Hippuric acid that is excreted is not particularly harmful.
It is employed in the management of skin irritation caused on by burns, insect bites, etc.
2.2.6 Uses of Benzaldehyde

Chemical companies widely use the benzaldehyde compound in their product. The
common application from the benzaldehyde compound is to provide almond flavouring. It is
used to provide the almond scent to foods and beverages. Benzaldehyde is often used as an
ingredient in a variety of scented products to give them a pleasant scent. Benzaldehyde also
can be uses as a bee repellent because of the odour that come out from benzaldehyde. In
order to extract the honey from a honeycomb, it is used to lure the bees away from it
(Benzaldehyde – structure, Properties, Uses and FAQs, n.d).
19
The other use for benzaldehyde is used in industry because it serves as an intermediate
in the synthesis of a variety of chemical compounds. It acts as a base for certain chemical
additives, polymers, and pharmaceuticals. Benzaldehyde also can be present in
manufacturing of some personal care and cosmetic care. Additionally, soaps, fragrances, and
dyes like aniline and acridine are made using benzaldehyde. One of the reason
benzaldehydes was widely uses in variety industries because of its flavouring and smell
(Benzaldehyde – structure, Properties, Uses and FAQs, n.d).
2.3 Background study raw material/product

2.3.1 Introduction
The objective of this design project is to obtain the production 750, 000 metric tons of
phenol annually. There are many methods from the industries right now to obtain phenol, such
as production of phenol from cumene, phenol from coal and the direct route from raw material
benzene to phenol. After every aspect that was considered like cost of raw material, safety
precaution and handling the by product from the process, direct route from the benzene to
phenol was selected. It us because of the energy usage, the demand of the purity and the
handling by product simpler compared to other method.
There are several industries that use phenol. It is mostly used in medical and medicine
as a disinfectant, antiseptic, and slimicide as well as in the production of a variety of
products.in this project, to study the synthesis of phenol from benzene and compressed air as
a raw product. As the introduction of the process, benzene and compressed will mix at the
reactor to be react and will create some by product and the final product which is Phenol at a
certain purity.
2.4 Properties and Uses Materials

2.4.1 Properties of Benzene
Table 2.1: Benzene physical properties table
Physical properties of Benzene
Physical state Liquid
Colour Colourless
Odour Characteristic
Melting point 5.49 °C (41.9 °F)
Boiling point 80.09 °C (176.2 °F)
Flash point Closed cup: -11 °C (12.2 °F)
Solubility in water 1.88 g/l
3
Specific volume (ft / lb) 1.1403
20
Table 2.2: Benzene chemical properties table
Chemical properties of Benzene
Chemical formula C6H6
Chemical stability Stable
Compound Liquid
Flammable Highly flammable
Toxicity Toxic
Reactivity No specific data related to
reactivity this material
2.4.2 Properties of Compressed Air

Table 2.3: Compressed air physical properties table
Physical properties of compressed air
Physical state gas
Colour Colourless
Odour Odourless
Melting point -216.2 °C
Boiling point -194.3 °C
Flash point Not available
Solubility in water Solubility in oxygen > nitrogen
Molecular weight 28.96 g/mol
Table 2.4: Compressed air chemical properties table

Chemical properties of compressed air
Element Nitrogen, Oxygen, Argon, Cardon
dioxide
Chemical stability Stable
Compound gas
Flammable Non- flammable
Toxicity Non- Toxic
Reactivity No specific data related to reactivity this
material
2.4.3 Properties of Phenol

Table 2.5: Phenol physical properties table
Physical properties of phenol
Physical state liquid
Colour Colourless
Odour Phenolic, medicinal
21
Melting point 41°C
Boiling point 182°C
Flash point 79°C
Solubility in water Moderately soluble in water – 8g
phenol for 100g
Table 2.6: Phenol chemical properties table

Chemical properties of phenol
Chemical formula C6H5OH
Chemical stability Stable under recommended
storage condition
Compound liquid
Flammable Combustible liquid
Toxicity Toxic
Reactivity Forms explosive mixture with air on
intense heating
2.4.4 Properties of Catechol

Table 2.7: Catechol physical properties table
Physical properties of catechol
Physical state Solid
Colour Light brown
Odour aromatic
Melting point 103 - 106 °C
Boiling point 245 °C
Flash point 131 °C
Solubility in water Soluble in water
Table 2.8: Catechol chemical properties table

Chemical properties of Catechol
Chemical formula C6H6O2
Chemical stability Light sensitive, air sensitive
Compound Solid
Flammable May be combustible at high
temperature
Toxicity Toxic
Reactivity None known
2.4.5 Properties of Benzoic Acid

Table 2.9: Benzoic Acid physical properties table
Physical properties of Benzoic acid
Physical state Solid
Colour Off - white
22
Odour Aromatic
Melting point 121 - 123 °C
Boiling point 249 °C
Flash point 121 °C
Solubility in water Soluble
Density 1.32 g/ cm3
Table 2.10: Benzoic Acid chemical properties table

Chemical properties of Benzoic acid
Chemical formula C7H5O2
Chemical stability Stable under normal conditions
Compound solid
Flammable Non – flammable
Toxicity No - Toxic
intense heating
2.4.6 Properties of Benzaldehyde

Table 2.11: Benzaldehyde physical properties table
Physical properties of Benzaldehyde
Physical state Liquid
Colour Colourless
Odour Like bitter almond
Melting point -26 °C
Boiling point 178 - 179 °C
Flash point 63 °C
Solubility in water Slightly soluble in water
Density 1.05 g/ cm3
Table 2.12: Benzaldehyde chemical properties table

Chemical properties of Benzaldehyde
Chemical formula C7H6O
Chemical stability Stable under normal conditions (room
temperature)
Compound Liquid
Flammable Flammable
Toxicity No - Toxic
intense heating
23
2.5 Safety Data Sheet (MSDS)
2.5.1 MSDS Benzene
24
25
2.5.2 MSDS Air
26
27
2.5.3 MSDS Phenol
28
2.5.4 MSDS Catechol
29
2.5.5 MSDS Benzoic acid
30
2.5.6 MSDS Benzaldehyde
31
2.6 The Process Selection
2.6.1 Description of The Process Chosen
Production of Phenol from benzene (oxidation benzene)
1. Reactor – Raw material mix in the reactor with catalyst presence

2. Separation of Nitrogen in the Flash Drum
3. Separation of benzene from the product and by product in the distillation column
4. Purification of Phenol and benzaldehyde from benzoic acid and catechol using
distillation column.
5. Purification of Phenol from benzaldehyde and other purities.
The fresh benzene will combine with the recycle benzene from separation process. Then,
the mixing of benzene will combine with the compressed air, and both become fed to the
reactor. Two outlets from the heat exchanger are needed for the vapor and liquid effluent
phases because the effluent from the reactor is cooled by one. At the flash drum, the effluent
will next go through a separating process. The flash drum is used as the separation process
to separate non condensable oxygen and nitrogen. From the flash drum top product in that
consists of nitrogen, oxygen, benzene, and water is sent to the environmental abatement
process. For the bottom product will be fed into the distillation column.
32
The first distillation column used as a separation section to separate product and by-
product from the benzene. The benzene from this process will become recycled benzene and
return to the rector. The vapor distillate and bottom products of the distillation column are
carried on the purification process.
Purification process happened in the distillation column 2 and 3. The second distillation
column will separate out heavy by product which is catechol and benzoic acid. A condenser
is used to produce two distillate streams. The vapor distillate will be going to the flare hood to
be released. The third distillation column will be separating phenol from the other by product
which is benzaldehyde and the other impurities that cannot be removed through other process.
2.6.2 Reaction Chemistry
Above show the reaction chemistry and balance chemical equation of direct route of phenol
from benzene. On this process, the raw material that being use is benzene and air. This direct
route method from benzene to phenol involves oxidation process by presence of copper
chromium catalyst. In this reaction, raw material benzene will react with compressed air at the
reactor (R- 101) with present of Cu – Cr catalyst. From this reaction, there are 4 products will
be produced. Phenol was one of the products that must be final product required. The other
product will be by – product such as catechol, benzoic acid, and benzaldehyde. The by product
can be obtain from the purification process alongside the process.
2.7 Advantages and Disadvantages of The Process

2.7.1 Production Phenol from Cumene
The advantages of the cumene process are that it is a common production method. The
greatest industrial process for producing phenol and acetone simultaneously is the cumene
process. However, this cumene process have some disadvantages that can be consider
before selecting as suitable method for producing phenol in this project. First, the production
of the process will obtain the major by- product which is acetone, it can make the company
difficult to handle it and will minimize the production of phenol. Next, the cumene process is
involve multiple processes step before obtaining the final product which is phenol. Some steps
like oxidation of cumene and decomposition of cumene hydroperoxide, by using this step the
33
high yield of phenol will become problem because of the high purity demand for phenol in the
market. Finally, the safety of the process will have to be consider because this cumene
process can produces highly explosive intermediate cumene hydroperoxide.
2.7.2 Other Considerations

In term of the economic, the cost for purifying acetone is high because of the large
number of separation processes. The lower explosive limit (LEL) and Upper explosive limit
(UEL) are 0.9 % and 6.5 % respectively (“Occupational Safety and Health Administration,”
2014). For the safety, Employers and employees should follow to the safe handling guidelines
described on the manufacturer's Safety Data Sheet, which may involve wearing protective
gear such as gloves, safety goggles, respirators, and outerwear. Additionally, cumene-filled
workplaces should have proper ventilation to reduce the risk of worker exposure. The
American Conference of Governmental Industrial Hygienists (ACGIH®) has identified a safe
level of cumene in the workplace aerosol concentration. Occupational Safety & Health
Administration (OSHA) in the United States contains more details about cumene exposure.
For the environmental health for this cumene process is irritant to the respiratory system and
breathing cumene vapours should be avoided because inhaling large amounts of it for a long
time can make you feel dizzy and nauseous or sleepy. When something is ingested or vomited
into the lungs, the result can be chemical pneumonitis, which can be lethal. Following a fast
or acute exposure by ingesting or inhalation, cumene has a low level of toxicity. Both the eyes
and the skin may become slightly irritated by it.
2.7.3 Direct Route of Phenol from The Benzene

The advantages of this process are the process involves only single step and will obtain
direct phenol product from the raw material benzene which is oxidation of benzene. The other
benefit from this process is the by- product for this process which is catechol, benzaldehyde,
and benzoic acid can properly handle. The by- product can be handle safely because of the it
doesn’t produce a highly explosive compared to other method. The oxidation of benzene is a
single step process and the oxidising agent that involve is compressed air which is one of the
main advantages because of it was safe and environmentally friendly. Last but not least, this
oxidation benzene process can produce high yield of the phenol which is around 99 %.
However, there are some disadvantages from this process is the by- product which is
benzaldehyde. Benzaldehyde has a boiling point almost similar to phenol which is 179 °C, it
is resulting high energy to be consume for the separation process between benzaldehyde and
phenol. The other disadvantage of this process is the flare that was release to the environment
that consist of nitrogen, oxygen, benzene, and water.
34
2.7.4 Other Considerations
In term of economics, by using the single step process, which is benzene oxidation, the
cost for this process can be lowering and more focus to producing more product from the
process. In term of environmental, a flare system was created to capture all potential
environmental leakage points within the process unit and piping. Non-condensable
components are also included. The toxic character of phenol is what led to the addition of a
phenol storage tank. Due to the high reaction temperature and pressure, we first made sure
that the mass concentration of oxygen in the reactor was less than 5%. Both phenol and
benzene c\are flammable. Workers at the facility will be dressed in protective clothing that is
flame retardant, antistatic, and chemically impermeable.
35
CHAPTER 3.0: FEASIBILITY STUDY AND MARKET SURVEY
3 FEASIBILITY STUDY
3.1 Introduction
This chapter will go into depth regarding the feasibility study of phenol manufacturing.
This chapter covered the process technology utilized in phenol production as well as market
data. Market data includes market assessment production, current and future prices, phenol
demand, import and export. The cost estimation for the equipment and raw materials was
reviewed at the conclusion of this chapter.
3.2 General Information

In this project, group 2 produced 750,000 MTA of phenol by direct route phenol from
benzene through oxidation process. Phenol is used in a variety of industries. It is used in
medicine as a slimicide, antiseptic, and disinfectant, as well as in the production of a variety of
products. Exposure to phenol may endanger workers. The level of harm is determined by the
dose, duration, and work performed.(Phenol | NIOSH | CDC, n.d.) The production of Bisphenol A
(BPA), which is made from phenol and acetone, is the largest single market for phenol. BPA
is then used to make polycarbonate (the most common and fastest growing application for
BPA) and epoxy resins. Polycarbonate and epoxy resins are both used in a variety of industries
and in a wide range of everyday items.(Phenol | Shell Global, n.d.) Currently in the market stands,
46% of phenol sold is used to manufacture BPA (Scholarlycommons et al., 2017).
3.3 Process Technology

Today's era, various industries generate phenol since the need of phenol has expanded
decade after decade. Currently, phenol may be synthesized on an industrial scale utilizing
seven various methods, involving oxidation process (direct route of phenol from benzene),
cumene peroxidation (Hock Process), Rasching, Toluene two stage oxidation, production of
phenol from chlorobenzene and NaOH, and Benzene Sulfonation Process. Technology has
an essential role in increasing the quantity of phenol produced by the method that has been
employed in the manufacturing of phenol.
The process selected by Group 2 is direct route of phenol from benzene by oxidation
process. In this process, the catalyst is utilized which is Copper Chromium Oxide. The
36
presence of catalysts will minimize reaction activation energy while increase the pace of
processes. As a result, they are essential in the chemical industry, exhaust gas treatment, and
other chemical processes (8.1: Catalytic Reactions - Chemistry LibreTexts, n.d.).
In this operation, the type of reactor that Group 2 chose is packed bed reactor. Group 2
use one packed bed reactor which benzene hydroxylation was conducted at high pressure by
using benzene and compressed air as feeds. Due to its high conversion rate per catalyst weight
when compared to other catalytic reactors, packed bed reactors are one of the most often
utilized reactors in the chemical industry. Packed bed reactors are very adaptable, and they
are employed in a wide range of chemical processing applications, including absorption,
distillation, stripping, separation processes, and catalytic reactions. The physical size of the
beds might vary substantially depending on the applications in which they are employed. A
typical reactor is made up of a chamber, such as a tube or channel, containing catalyst particles
or pellets, and a liquid that passes past the catalyst. Across the length of the tube, the liquid
interacts with the catalyst, changing the chemical makeup of the material (What Is a Packed
Bed Reactor? | COMSOL Blog, n.d.). The conversion rate in reactor is 28.9%. As a result of
the high reactant and catalyst contact, more material is produced, yielding a high phenol
(99.83%). Fixed bed reactors are effective at high pressures and temperatures. It is also
inexpensive to build, operate, and maintain. Maintenance and operating expenditure might be
reduced in the company.
The other technology used in this process is three distillation columns in series which
are benzene column, catechol column, and phenol column. Distillation is a process that
separates a liquid mixture into fractions with higher concentrations of specific components by
utilizing differences in relative volatility. A feed stream enters the middle of a basic distillation
column, and two streams exit, one at the top and one at the bottom. Lower boiling point
components are concentrated in the stream leaving the top, while higher boiling point
components are concentrated in the stream leaving the bottom.(Distillation Fundamentals |
Neutrium, n.d.) Benzene column was optimized to separate the unreacted benzene from the
product phenol and recycle up to 97.7% of the total amount of unreacted benzene from the
reactor effluent. The Benzene column employed 32 trays with tray efficiency 0.32, catechol
column designed of 20 trays with tray efficiency 0.53, and phenol column featured of 22 trays
with tray efficiency 0.82. Since distillation columns offer a higher efficiency of mass transfer,
the company saves money on investment and maintenance. It also improved product quality
owing to better separation efficiency. If the firm produces high-quality phenol, the possibility
of customers to buy the product will increase. Next, the equipment used in this process
technology were stated specifically one by one as follows based on the Daowdat, Bryan;
Hoeltzel, Gerard D.; and Tannenbaum, Robert, "Direct Route to Phenol from Benzene" (2017).
37
Senior Design Reports (CBE). 98.
1. Feed Pump
Unit ID: P-101
Temperature: 92.1 °F
Type: Pump
Pressure: 638.2 psig
Material: Cast Iron
Work: 95.6 hp
Cast iron was chosen since it is the cheapest option and will not react with benzene.
2. Recycle Pump
Unit ID: P-102
Temperature: 176.6 °F
Type: Pump
Material: 316 Stainless Steel
Work: 457 hp
Due to the possibility of benzoic acid and other corrosive by-products being present in
the recycle, a construction material of 316 stainless steel was chosen.
3. Process Heat Exchangers
Feed Exchanger
Unit ID: E-102
Temperature: 662 °F
Type: Counter-current Heat Exchanger (Counter current heat exchangers are

inherently more efficient than parallel flow heat exchangers because they create a
more uniform temperature difference between the fluids, over the entire length of the
fluid path.)
38
Material: 316 Stainless Steel
Area: 8401.5 ft2
Unit E-102 was optimized for our process to cool the reactor effluent and harness that
thermal energy to pre-heat the reactor feed.
4. Reactors
Reactor Vessels
Unit ID: R-101 Temperature: 662 °F
Type: Packed bed Reactor Pressure: 580.1 psig
Material: Carbon Steel Outer Shell Height: 9.12 ft/unit
316 Stainless Steel Inner Lining
Diameter: 9.12 ft
Heat Removed per Intercooler: 14,926,269 BTU/hr
To reduce costs, the reactor vessel was constructed out of a carbon steel outer shell,
with a 1/8 in thick inner 316 stainless steel lining. The stainless steel is necessary to
resist high temperatures and prevent against potential deterioration from corrosive by-
products.
5. Catalyst Utilization
In the production of phenol by direct route of benzene, the technology that can be
found is, the catalyst utilization which is Copper Chromium Oxide. the catalyst does
not give any effect to the product, and it just increase the speed of chemical reaction.
6. Separations
Based on ASPEN thermodynamic data, operating parameters of 110.1 °F and 145

psig were selected for the flash drum to optimise non-condensable oxygen and
nitrogen off-gassing at 98% while reducing benzene loss to 0.8%. Following off-
gassing, the liquid exit from T-101 is sent to the first distillation column, T-102, which
separates the benzene and residual non-condensables from phenol and other organic
wastes.
39
a. Flash Drum
Unit ID: T-101 Temperature: 110.1 °F

Type: Flash Drum Pressure: 145 psig
Material: Carbon Steel Outer Shell Functional Height: 25.2 ft
316 Stainless Steel Inner Lining Diameter: 8.4 ft
b. Distillation Column 1 (Benzene Column)
Unit ID: T-102 Temperature: 389.8 °F

Type: Distillation Column Pressure: 8.7 psig
Material: Carbon Steel Outer Shell Functional Height: 48 ft
316 Stainless Steel Inner Lining Enriching Diameter: 15.5 ft
Distillation column 1 was optimized to separate the unreacted benzene from the
product phenol and recycle up to 97.7% of the total amount of unreacted benzene
from the reactor effluent.
7. Purification
The bottoms product from the first column (benzene column) is transferred to
distillation column 2 (catechol column) to separate out the heavier by-products, which
are represented as catechol and benzoic acid in our simulation. Due to the comparable
chemical structures of phenol and catechol, distillation column 2 was planned
considerably more carefully than would be required in reality. Other possible heavy
items would most likely be heavier and hence easier to remove. Catechol columns
were tailored to separate the undesirable heavier catechol by-product from the product
phenol, with up to 99.98% of the catechol removed from the phenol product. With a
distillate vapour percentage of 0.01, the partial condenser assists in the removal of
some of the benzaldehyde and creates two distillate streams at 377.1 °F utilising
cooling water. This column was designed to extract 99.98% catechol and 100%
benzoic acid. A thermosiphon reboiler maintains a temperature of 476.1 °F by using
high pressure steam. The vapour distillate is removed and mixed with the vapour exit
from T-102 and the vapour distillate from T-103 in a collecting hood. These fumes are
then directed towards a flare system.
40
3.4 Market Data
The market data will include market assessments of phenol production, present and
prospective phenol pricing, phenol demand, as well as import and export.
3.4.1 Market Assessment Production

Rapid economic expansion throughout the globe has significantly boosted residential
and commercial building activity. The rising demand for phenol and phenol derivatives from
the chemical and pharmaceutical industries is likely to propel the Phenol market forward over
the forecast period (Global Phenol Market: Industry Analysis & Forecast | Persistence Market
Research (PMR), n.d.). Asia is an important area in the global Bisphenol A market. Between
2021 and 2025, more than $1 billion will be spent on nine Bisphenol A projects that have
been planned or disclosed. Phenol is most often utilized as a raw material in the creation of
bisphenol-A (BPA), which is used as a building block in the production of polycarbonate
plastic, which is used to produce DVDs, tablets, flat screen TVs, and mobile phones (Global
Bisphenol A Industry Outlook to 2025 - Capacity and Capital Expenditure Forecasts with
Details of All Active and Planned Plants, n.d.).
The target markets of this company are the local and China markets. In Malaysia, there
is no significant rivalry in the manufacture of phenol by oxidation process, despite the
considerable demand for phenol to satisfy demand in Malaysia. China market is chosen as
the compound annual growth rate (CAGR) is quiet high which is 4.3%. The CAGR Ratio
compares returns over time to determine which nation is the better investment (Compound
Annual Growth Rate (CAGR) - What Is Compound Annual Growth Rate & How Is It
Calculated? n.d.).
The SWOT analysis framework is used to discover and analyze an organization's
strengths, weaknesses, opportunities, and threats. The acronym SWOT is made up of these
words. The major purpose of SWOT analysis is to raise awareness of the elements that
influence company decisions or the development of a corporate strategy. SWOT analyses
the internal and external environments, as well as the aspects that might influence the viability
of a choice, to accomplish this. This type of analysis is the most effective when it's used to
construct a phenol production plant (What Is a SWOT Analysis? Definition and Examples -
TechTarget, n.d.). The following is a SWOT analysis for a phenol manufacturing plant that
may be used to assess the company's goals:
41
I. SWOT Analysis: Strength
In this process plant strength analysis, the 2 elements that will be considered are
operational efficiency and capacity. The benefits of this method include the fact that it only
requires one step and produces direct phenol from the raw material benzene, which is
oxidation of benzene. In terms of economics, by implementing a single step process, such
as benzene oxidation, the cost of this process will be reduced, allowing greater emphasis to
be placed on generating more output from the process. This benzene oxidation technique
may give a high phenol yield of over 99%.
II. SWOT Analysis: Weakness

Nevertheless, there are certain drawbacks to this procedure, one of which being the
byproduct benzaldehyde. Since benzaldehyde has a boiling point almost identical to phenol
(179 °C), the separation procedure between the two requires a significant amount of energy.
Another downside of this procedure is the emission of flare into the atmosphere, which
contains nitrogen, oxygen, benzene, and water.
III. SWOT Analysis: Opportunity

The opportunities technique is a study of external evaluation that tries to boost the
future worth of the phenol company. The potential techniques for manufacturing phenol plants
are to maximize corporate profitability, such as lowering raw material transportation costs by
tracking down the major supplier near the production facility, which is located in Malaysia's
east coast area at Kerteh, Terengganu. As a result, on the phenol product market, by
extending market supply to a diverse range of industries that utilize phenol as a raw material,
as well as new product applications for targeted clients in local and global enterprises.
Moreover, developments in production and product, as well as utilization as a precursor in
several chemical preparations, provide lucrative opportunities to market participants from
2022 to 2029. Increased research and development initiatives will also help to boost the
industry (Phenol Market Overview, Industry Trends, Segmentation, Analysis, Scope, and
Forecast to 2029, n.d.).
IV. SWOT Analysis: Threat

Threat analysis is required because it may hamper the company's ability to achieve the
purpose and vision of the manufacturing facilities. Changes in phenol demand in various
42
countries may cause problems in the phenol business. Because phenol was irritating, it was
strictly restricted in terms of product quality and quantity management, which may endanger
public safety and the environment. Thus, a government economic crisis may represent a
danger to phenol manufacture, potentially leading to firm bankruptcy if raw material prices
increase owing to variances in exchange rates (FX), as well as a constraint on phenol product
demand supply due to high interest rates in various nations.
Concerns about the detrimental effects of phenol, on the other hand, are projected to
stymie industry expansion. If encountered directly on the skin, it may cause burns and
blisters, and if breathed, it can induce respiratory issues. Furthermore, tight regulations are
expected to provide a challenge to the phenol market during the forecast period of 2022-2029
(Phenol Market Overview, Industry Trends, Segmentation, Analysis, Scope, and Forecast to
2029, n.d.).
3.4.2 Global Phenol Market

Phenol, often known as carbolic acid, is an aromatic chemical with a moderate acidic
tendency. It was initially accomplished in 1834 by Friedlieb Ferdinand by the destructive
extraction of coal tar. It is an important raw ingredient in many chemical industrial processes
(Kumar & Mishra, 2018). Despite a significant rise in worldwide production capacity and
declining demand over the previous five years, the future market environment for phenol
remains promising.
Figure 3.1: The global phenol market in 2016 to 2021.

(Source: MARKETSANDMARKETS, 2021)
43
By referring to the statement in the part of market assessment production above, China
is expected to represent a massive growth of US$ 3.1 Billion in the phenol market, with a
CAGR of 4.3% during the forecast period. Regarding to the high value of CAGR, the country
from Asia-Pacific region which is China has been selected in order to make the profit of selling
the phenol (Global Phenol Market: Industry Analysis & Forecast | Persistence Market Research
(PMR), n.d.). The worldwide phenol market was valued USD 12,566.8 million in 2016 and is
predicted to reach USD 15,855.8 million by 2021, rising at a CAGR of 4.8% during the forecast
period, as shown in Figure 3.1. The primary factors driving the development of the phenol
derivatives market are expansion and agreement operations done by various companies to
boost production capacity in the Asia-Pacific region. Through the polycarbonate and epoxy
resins, phenol derivatives find extensive uses in electronics and electrical products as well as
automobiles. Due to the increasing use of epoxy resins in the fabrication of wind turbine blades,
increased demand from end-use sectors such as wind energy boosted the use of phenol
derivatives. Phenol derivatives are in significant demand in the Asia-Pacific area, particularly
in China. In terms of value, the Asia-Pacific region was the fastest-growing market for phenol
derivatives in 2015, and this trend is predicted to continue through 2020. The Asia-Pacific
region's largest customers are China, India, South Korea, and Japan. The need for phenol
derivatives is mostly driven by these nations' expanding population and urbanization, which
produces a large demand for electronics and automotive items (Phenol Derivatives Market by
Derivatives & Region - Global Forecast 2026 | MarketsandMarkets, n.d.).
Figure 3.2: The global phenol market in 2022 to 2029 by region. (Source: DATA
BRIDGE, 2021)
44
Based on Figure 3.2, the forecast period is from 2022 to 2029 and the base year is in
2021. The Phenol Market is expected to witness CAGR of 5.64% the forecast period of 2022-
2030. The global phenol market was valued at USD 22.97 billion in 2021 and is predicted to
reach USD 30.72 billion by 2029, growing at a CAGR of 5.64% between 2022 and 2029. The
major players operating in the Phenol Market are KUMHO P&B CHEMICALS., INC (South
Korea), TPCC (China), Shell plc (UK), Mitsui Chemicals, Inc. (Japan), LG Chem (South
Korea), Honeywell International Inc. (US), Solvay (Belgium), Aditya Birla Group (India),
SHENGQUAN GROUP (China), PTT Phenol Company Limited. (Thailand), Bayer AG
(Germany), AdvanSix (US), Cepsa (Spain), INEOS (UK), Domo Investment Group NV.
(Belgium), Altivia (US), Formosa Plastics Corporation (Taiwan), Prasol Chemicals Pvt. Ltd.
(India), Sasol LTD (South Africa), China National Bluestar (Group) Co,Ltd. (China), and Merck
KGaA (Germany), among others (Phenol Market Overview, Industry Trends, Segmentation,
Analysis, Scope, and Forecast to 2029, n.d.).
3.4.3 Current and Future price of phenol

The table below displays the current phenol pricing per area of the globe, as referred to
by the international price of phenol's website. In terms of cost, the highest price among the six
locations listed below is USD 1622.58/TON for Northwestern Europe. Rotterdam, India, China,
the United States Gulf, and Southeast Asia are priced at USD 1531.0/TON, USD 1150.0/TON,
USD 1065/TON, USD 1052.0/TON, and USD 1195.0/TON, respectively. Based on current
estimates, the price of phenol will reach about USD 1200 - 1800/TON in the future if demand
increases.
Table 3.1: Current price of phenol based on area in the world (Source: Echemi,
2022)
Area Price unit

Northwestern Europe USD 1622.58/TON
Rotterdam USD 1531.0/TON
Southeast Asia USD 1195.0/TON
India USD 1150.0/TON
China USD 1065.0/TON
U.S. Gulf USD 1052.0/TON
3.4.4 Demand of Phenol

Phenol is an aromatic organic molecule generated from benzene that is produced
naturally and synthesized in large quantities. Global phenol consumption is expected to reach
12 million metric tons in 2022, representing a 2.5% annual rise over the previous five years.
45
With substantial end-use markets in polycarbonate and epoxy resins, BPA is the dominant
demand driver, accounting for roughly half of worldwide phenol consumption in 2022. Asia
drives global phenol demand, accounting for more than half of overall consumption (Phenol -
Chemical Economics Handbook (CEH) | S&P Global, n.d.). The pie chart below depicts global
phenol consumption:
Figure 3.3: World consumption phenol (Source: IHS Markit, 2022)
The global phenol market is primarily driven by BPA demand, which accounts for roughly
half of total phenol use. In consequence, demand for polycarbonate goods drives BPA use,
which has traditionally grown faster than GDP and is anticipated to continue in the future.
Polycarbonate is primarily employed in the automotive, original equipment manufacturer
(OEM), construction, optical media, and appliance sectors. In glazing/sheet, it often competes
with glass and acrylic resins, as well as acrylonitrile-butadiene-styrene (ABS) resins in
appliances and power equipment. Demand for epoxy resins also influences BPA consumption.
The majority of epoxy resins are manufactured for use in surface coatings, stiff printed circuit
boards, and adhesives. General economic circumstances have a significant impact on
46
demand for BPA, phenol-formaldehyde resins, and other phenol products. As a consequence,
phenol consumption follows the tendencies of the world's main countries (Phenol - Chemical
Economics Handbook (CEH) | S&P Global, n.d.).
Top Exporter Phenol 2020 Percentage (%)

South Korea 10.8
Saudi Arabia 8.65
Belgium 9.36
Thailand 8.61
United States 13.8
Figure 3.4: Production of phenol per year (Source: ICIS Market News,2015)
x-axis: year
y-axis: production per year (millions tones/year)
According to Figure 3.4, the anticipated market potential of phenol from 2009 to 2020.
The graph shows that phenol demand and supply will rise year after year. The supply graph is
higher than the demand graph. Furthermore, the supply graph revealed a greater growth year
after year. While the demand graph grows less steeply.
3.4.5 Export and Import
Table 3.2: Top exporter phenol based on percentage in 2020(Source: OEC, 2022)
Table 3.2 above shows the top country that export phenol in 2020. United States comes
as the higher exporter of phenol in 2020 which is about 13.8%, followed by South Korea,
Belgium, Saudi Arabia, and Thailand which is about 10.8% ,9.36%, 8.65%, 8.61%
respectively.
Table 3.3: Top importer phenol based on percentage in 2020(Source: OEC, 2022)
47
Top Importer Phenol 2020 Percentage (%)
China 27.3
India 6.01
Netherlands 10.5
Germany 6.38
Belgium 8.65
Table 3.3 shows the top phenol-importing countries in 2020. China is the largest
importer of phenol, accounting for 27.3% of total imports. This is because China will continue
to be the fastest growing of the main phenol markets during the projection period for a variety
of reasons, including continuous expansion in Bisphenol-A consumption, for which phenol is
the raw ingredient. Following that, rapid advances in industrial capacity and expanding
consumer spending in China have altered the country's society and economy. China is a
large manufacturer of industrial and consumer goods. China is the world's fastest expanding
market for products and services, far outperforming other economies.
3.4.6 Target Customers
Local Customers International Customers
Company Malayan Plastic &

Name: Adhesives and Formal Sumitomo Bakelite Coating
Chemical (M) Co., Ltd
Chemicals Advanced
Sdn. Bhd.
Sdn Bhd Material
No. 9, Jalan Lot 913/914/939,
Address: 5-8 Higashi- 4thfloor,65 Honghe
Utas 15/7 Kawasan Industri
Shinagawa 2- Road, Xinqiao
40200 Shah Taman Makmur,
chome, Town, Xinbei
Alam, Mk. Sg. Seluang,
Shinagawa-ku, District,
Selangor, 09600 Lunas,
Tokyo 140-0002, Changzhou,
Malaysia Kedah, Malaysia.
Japan Jiangsu, China
48
Application Phenol
Phenolic Frost Solid PC
of Phenol: formaldehyde resin
Resins Phenolic Resins for Sheet
(Formalphen 42 P) Can Coatings
Table 3.4: Local and International Target Customers.
49
3.4.7 Target Suppliers for Raw Materials
Table 3.5: Local Company Supplier for Raw Materials

Company name PETRONAS Penapisan (Terengganu) Sdn
Bhd
Address
No. 1119, Kawasan Perindustrian
Petronas, 24300, Kerteh,
Terengganu, Malaysia
Production product
BENZENE (99.9%PURITY,200 000 tpa)
capacity
Type of plant
Refinery Plant
Contact Number 09-830 3000
3.5 Cost Estimation

Cost estimate must be analyzed in order to improve profit and propel the firm to the top
of Malaysian phenol producers through the straight route of benzene. The plant is meant to
run 24 hours a day, five days a week. A few days will be set aside for maintenance and
shutdown. Pumps, compressors, turbines, heat exchangers, reactors, distillation columns,
flash drum, condensers, and storage tanks are among the nine pieces of equipment that will
be used in this process. All of the equipment's prices were investigated in order to assess the
plant's cost. The total number of pieces of equipment and their prices are simply estimates.
The cost of every equipment was linked to Alibaba.com.
50
3.5.1 Pump
There are 6 pumps used in this process. The type of pump used in this process is
Centrifugal Pump. The price shown below is referred to Alibaba.com website.
Figure 3.5: Pump (Source: Alibaba.com, 2022)

Price: RM 4,346.26
Supplier: Tiger (Hangzhou) Flow Systems Co., Ltd. Custom manufacturer
51
3.5.2 Compressor
In this plant, the type of compressor used is Multistage Compressor. This compressor
will be used to compressed fresh air feed into high pressure. The material of the compressor
used is Cast Iron. There are 2 compressors that will be used in this process.
Figure 3.6: High Pressure Multistage Air Compressor
(Source: Alibaba.com, 2022) Price: RM 681,489.30

Supplier: Xinlei Compressor Co., Ltd.
52
3.5.3 Turbine
The turbine's function is to generate electricity from the large pressure drop. This plant
requires two turbines: a vapour effluent turbine and a liquid effluent turbine. The turbine used
is a Centrifugal Pump Design made of stainless steel.
Figure 3.7: Turbine (Source: Alibaba.com, 2022)
Price: RM 27,450.39
Supplier: Baoding Milestone Import and Export Co., Ltd. Trading Company
3.5.4 Heat Exchanger

Heat exchanger used to cool down reactor effluent while simultaneously pre-heating
reactor feed. There are 4 heat exchangers required in this plant with material stainless steel.
Figure 3.8: Heat Exchanger (Source: Alibaba.com, 2022)

Price: RM 16,012.53
Supplier: Xiamen Openex Mechanical Technology Limited
53
3.5.5 Reactor
In this plant, we are using one packed bed reactors. The material used is carbon steel
outer shell with 316 stainless steel inner shell. Below shows the price of reactors.
Figure 3.9: Reactor (Source: Alibaba.com, 2022)

Price: RM 800,000
Supplier: Weihai Huixin Chemical Machinery Co., Ltd
3.5.6 Distillation Column

In this process, three distillation columns are used. The boiling point of the product and
byproduct is used to separate them in a distillation column. The first distillation column
separated benzene and other non-condensable from phenol and other organics, while the
second distillation column separated phenol from catechol and other impurities. The third was
employed in the separation of phenol from benzaldehyde and other impurities. This equipment
is critical for product purity. In this process, the distillation column is made of carbon steel with
a stainless-steel inner shell.
54
Figure 3.10: Reactor (Source: Alibaba.com, 2022)
Price: RM 4,117,578.48
Supplier: Shandong Jinta Machinery Group Co., L
3.5.7 Flash Drum

The function of flash drum is to separate non-condensable from desirable organics.
There is one flash drum used in this process.
Figure 3.11: Flash Drum (Source: Alibaba.com, 2022)

Price: RM 45,750.29
Supplier: Henan Durable Machine Co., Ltd.
55
3.5.8 Condenser
There are 3 condensers used in this plant.
Figure 3.12: Condenser (Source: Alibaba.com, 2022)

Price: RM 237,899.78
Supplier: Wuxi Sanjiu Cooling Equipment Co., Ltd.
56
3.5.9 Storage Tank
There are 4 storage tanks that will be used in this plant include storage tank for Benzene,
Catechol, Benzoic Acid and Phenol.
Figure 3.13: Storage Tank (Source: Alibaba.com, 2022)

Price: RM 137,250.41
Supplier: Hebei Dongding Chemical Trade Co., Ltd.
57
Table 3.6: Cost estimation for phenol plant
Invest Price (RM)
Pump (6 units) 4,346.26 X 6 = 260,77.56
Air Compressor (2 units) 681,489.30 X 2=135,2978,60
Turbine (2 units) 27,450.39 X 2 = 549,00.78
Heat Exchanger (4 units) 16,012.53 X 4 = 640,50.12
Reactor (1 units) 800,000
Distillation column (3 units) 4,117,578.48 X 3 = 123,52735.44
Flash Drum (1 units) 45,750.29
Storage Tanks (4 units) 137,250.41 X 4 = 549,001.64
Condenser (3 units) 237,899.78 X 3 = 713,699.34
Oxygen Tank 45,000
Catalyst (For 1year) 325
Benzene (For 1 year) 266,000,000
Manpower (600) 940,5405
Water Consumption (For 1 year) 1400,000
Electrical Consumption (For 1 year) 1,666,667
Land 12,500,000
Admin Building 3,333,000
Maintenance Cost (For 1 year) 3,200,000
Guard house 21,667
Medical Centre 500,000
Cafe 420,000
Locker room 333,000
Prayer room 170,000
Lab 900,000
Utilities 667,000
Workshop 700,000
Control tower 600,000
Total 451,766,139
The cost estimation involved in phenol production is shown in Table 3.6. All equipment prices
are based on Alibaba.com, and all prices given are estimates. It also includes the cost of raw
materials, water consumption, electrical consumption, manpower, land, the cost of the
administrative building, and the cost of maintenance. The costs of raw materials, water
consumption, electricity consumption, and maintenance are only estimates for a single year.
The estimated cost of constructing a methanol plant is RM 451,766,139.
58
CHAPTER 4.0: PROCESS SELECTION
4 DIAGRAM
4.1 Introduction
This chapter will show the Block Flow Diagram (BFD) and Process Flow Diagram
(PFD) of process selection for this design project. The briefly of process flow diagram
also will be covered on this chapter.
59
4.2 Block Flow Diagram (BFD)
60
4.3 Process Flow Diagram (PFD)
61
4.4 Process Description
The fresh benzene is pumped through pump (P-102) from benzene storage (TK-101) at
4400 kPa with 33°C. The recycle benzene, oxygen and nitrogen from streamline 14 also being
pumped through pump (P-101) to combine with the fresh benzene under same pressure. Both
of the benzene was pumped at the different streamline to prevent from any partial vaporization
that can be occurred if both of the stream were mixed. The other raw material is air will pass
through the air compressor (C-101) is pressurized to reaction pressure. Then, the compressed
air will go through the intercooling exchanger (E-101) for cooling down the air in order to
ensure structure are suitable in certain temperature for next reaction.
Next, the mixed of benzene in stream 4 and 14 is pre- heated using countercurrent heat
exchanger (E-102). At the outlet of the stream 5, the mixed benzene will undergo pre-heater
at pre- heater exchanger (E-103). The benzene is then mixed with the compressed air at the
stream 6 and become the fed for the reactor (R-101) at reaction conditions which are 351°C
and 4390 kPa. The outlet of the reactor is containing unreacted benzene, phenol, catechol,
benzaldehyde, oxygen, nitrogen, and water are then flow to feed exchanger (E-102) through
stream 7.
The outlet of the stream 8 will fed into the vapor effluent turbine (TR-101) for lowering
the pressure. The effluent then will cool with the cooling water at vapor cooler exchanger (E-
104). The effluent in stream 10 then entering the flash drum. The flash drum is used as
medium to maximize off gassing nitrogen and the non- condensable oxygen and benzene.
From the flash drum top product in stream 11 that consists of nitrogen, oxygen, benzene, and
water is send to the environmental abatement process (V-101) for flare system.
Next, the bottom product of flash drum (stream 12) will feed into first distillation column
(T-102) which is the benzene distillation column. The purpose of benzene distillation column
is to separate the benzene from phenol and other by-products. The top products of the
benzene distillation column will enter the condenser to condense the distillate vapor produces.
There are two outcomes from the condenser which is non-condensable that contain nitrogen,
oxygen, benzene, and water will send to the flare system (V-101). While the other outcome in
stream 13 that contain benzene, oxygen and nitrogen will send back to the reactor part as
recycle benzene. The bottom product of the benzene distillation column (T-102) containing
benzene, phenol, and by- products will be pumped to the next distillation column (T- 103)
which is the catechol distillation column.
Next part is purification process. The purification starts at the catechol distillation column
(T-103). The top product for catechol distillation column will enter condenser (E-106) to
produce 2 products. The first products produce from top product of catechol column consists
62
of benzene, phenol and benzaldehyde will be taken off to the flare system (V-101). The other
products produce from bottom product of catechol column which is phenol, benzaldehyde and
benzoic acid will feed to the next distillation column (T- 104) which is phenol distillation column.
The bottom product from catechol distillation column in stream 20 consists of catechol as main
by-product will be pumped to catechol storage.
The liquid distillate from condenser (E- 106) will feed in the phenol distillation column (T-
104). The purpose of phenol distillation column is to perform the most rigorous separation of
the entire process between phenol and benzaldehyde. Since phenol is the heavier component,
we proposed pulling the phenolic product off as a vapor at stage 20, which ensure the greatest
purity. This also accounts for the possibility of further removal of any other heavy products
that weren’t removed in catechol column. Since benzaldehyde serves as placeholder chemical
for category of potential by-product and is a much closer boiler to phenol than any real
potential by-product, we assert that our purification system is more than sufficient to attain a
desired purity of 99.8% phenol by mass. The phenol product with purity of 99.8% will sent to
the phenol storage through steam 22. The top product of the third distillation column which
are phenol, benzene, and benzaldehyde fed into the condenser (E-107) to produce liquid
distillate at stream 21. The bottom product that consists of the by-product of benzaldehyde
also will be pumped through pump (P-106) to the benzaldehyde storage.
63
CHAPTER 5.0: PLANT LOCATION
5 PLANT LOCATION
5.1 General Consideration

The location is selected based on a few key factors, including the proximity to our
product and other factors. One of Malaysia's most significant industrial estates is at
Kerteh, Terengganu. Today, many recent TVET and engineering school graduates work in
these large industrial settings. As a result, our company's name will be more well-known
among the locals. In the neighbourhood, the business may easily find qualified employees.
Additionally, it offers small town in rural area that consist all the services that locals and
employees need, like lodging, medical facilities and banking. Plants that covered in the region
help by the seaside to reduce noise pollution brought on by the machinery. Locals will not find
any trouble made by our company.
5.2 Site Location

The site selection is crucial part because of its distance that can be efficiently used in
terms of cost, money and energy. The location has to be strategic to smoothen the process of
the company. Diagram below shows the exact location of our company using google satellite
on 20th November 2022. It is calculated that 62,500 metric ton of phenols will be produced
monthly. So, estimated around 12 acres of land needed to build our plant.
64
Figure 5.1: The “X” marked shows where will we put up our power plants.
65
Figure 5.2: Roughly shows on how we planning to locate the power plant.
66
5.3 Introduction
Selection of a plant site is crucial as it must take numerous considerations into accounts
such as supply of raw materials, transportation, and environmental effect. Safeties of people
is the top priority as phenol is hazardous substances that can cause severe irritations.
5.4 Type of Industry and Location

This plant is located at Kawasan Perindustrian Kerteh, Kemaman, Terengganu. Kerteh
is a well-known region of their large industrial process of Oil and Gas. Manufacturing of phenol
can be categorized in a chemical processing industry.
5.5 Reasonable Available Land Price and Characteristics

Based on iProperty, as of 4.12PM, 26th September 2022, price per acre of industrial land
on Kerteh, Kemaman is RM 230,769.23. It is the lowest and most affordable price that offered
compared between Pasir Gudang and Gebeng which are RM 1,960,200.00 and RM
741,573.87 per acre respectively. Petronas has reserved some of the land area beside the
industrial land in Kerteh for future purposes. The suggested location also is not far from
residential communities. It took only 2.5 KM to find town which consist of mosque, schools,
and shop lots.
Figure 5.3: The location of our power plant to the nearest town in Kerteh, Terengganu
5.6 Availability of Raw Materials Supply

As this company will be using fresh benzene, copper chromium oxide as catalyst and
compressed air, it is decided to export from China through ship transportation and lorries will
be preparing to send off from the port to our location. Fresh benzene well get from Petronas
67
Aromatic Chemicals which are a mile away from us and they can produce up to 99.9% purity
of benzene (Petronas Chemicals Aromatics Sdn. Bhd. Company Profile - Malaysia | Financials
& Key Executives | EMIS, n.d.).
5.7 Vicinity of Market
Table 5.1: Listed chemical plant companies in Kerteh, Terengganu
As we can see, there are no production of phenols at Kerteh Industrial Land. This will
open a new market of phenols in Kerteh because of there are no single competitors, thus this
company can dominate the market of phenols in Kerteh. As year passes by, it shows that
phenols are in high demand and needed to produce phenol-based product. There are few
customers companies listed in table 5.1 (Target Customers) and this shows on how crucial to
get phenol for them to run their processes as their raw materials.
5.8 Transportation
In terms of transportation, there will be 3 type of transportation that can lead to our power
plant. Time plays critical role in order to import or export raw materials and product. The 3
ways of transportations are road, ship and airplanes.
68
5.8.1 Road
In Malaysia, roads are most common type of transportation and used in many types of
occasion. In order to connect from heart of Malaysia which is Kuala Lumpur to Terengganu,
East Coast Expressway or known as LPT is usual way to travel there. LPT 2 (Jabur – Kuala
Nerus) which has length of 358KM is longer than LPT 1 (Karak – Jabur) which only have
174KM. There will be two more phase of LPT which LPT 3 (Kuala Nerus – Kota Bharu) and
LPT 4 (Gambang – Johor Bahru). These roadways are planned to be operative on 2025 and
this will lead to development of Kerteh and thus become great industrial state. Toll rates from
Karak to Kerteh only takes RM29.50 for class 1, RM58.90 for class 2 and RM88.40 for class
3.
Figure 5.4: It takes approximately 5 hours from main city of Malaysia to Kerteh
69
5.8.2 Ship
Shipment is one of good ways to cargo throughout the whole world. It also can contain
things in a bulk so ship can carry huge amount of cargo at one time. In terms of importing our
raw materials and exporting our product to another country, shipping is the best way of
transportation because it is low cost compared to airplane.
Figure 5.5: It takes less than 10 minutes from our site to Kerteh Port for import and
export things.
70
5.8.3 Airplanes
Kerteh Airport cater small flights and airlines such as Malindo Air and helicopters to
offshore platforms and mostly charter plane for Petronas. Other than Kerteh Airport, Sultan
Mahmud Airport that is located at Kuala Terengganu can offer cargo carriage and this will be
an advantage if there are new equipment and machines that need to buy, we can use this
airport which have 6 daily flights of cargos.
Figure 5.6: Kerteh Airport mostly serves for Petronas employees.
71
Figure 5.7: Using the routes only take 10 minutes from our site location to Kerteh
Airport.
72
Figure 5.8: Machines and Equipment estimate took 2 hours to reach our site location
from Sultan Mahmud Airport
73
5.9 Availability of Utilities
Kerteh is still ongoing development to become great industrial estate but crucial things
such as TNB Electric power, water system pipeline under Syarikat Air Terengganu (SATU)
and road access is under good condition. Other than that, small towns in Kerteh area offers
many utilities as well as medical facilities, banking, and telecommunication line. Extra step of
bringing generator to our power plant is to ensure that if anything happens, our production will
still continue to run using the electricity supplied by generator. On the other hand, our site
location is next to seaside, so it is easier for us to flush using designated pipeline system as
long as do not harm environment and ocean life.
5.10 Availability of Labour

Individuals that work on power plant need to be skilled to run the machines and facilities.
Based on 600 of our workers, there are various background that they coming from. Many
prospects have been given to its local community near the power plant with several conditions
so that they can counted to be a competent worker. Fresh graduates from known Universities
such as Universiti Teknologi Petronas (UTP), Universiti Malaysia Pahang (UMP) and
Malaysian Institute of Chemical and Bio-Engineering Technology (UniKL MICET) can be
Process Engineer, Site Engineer or others that same level on it. On the other hand, a well –
known institute which is Institut Teknologi Petroleum Petronas (INSTEP) have been a huge
role in chemical industries in Malaysia since 1981. They have been producing many protégé
to work on chemical industries whether onshore or offshore.
74
INSTEP is famous in their programs and there are 3 most popular programs are
• Bridging Programmes - long-term programmes to produce job-ready technicians &

operators.
• Assessment & Certification - competency-based training programmes designed for
industry workforce in meeting statutory requirements.
• Professional Development Programmes - short-term programmes to upskill working
technicians & operators, as well as engineers.
"With customers and students from more than 35 countries, we have generated over 130,000
highly skilled oil and gas experts as we have gone from strength to strength. Over 30 refinery
and petrochemical facilities at more than 100 platforms throughout the world are currently
benefiting from the work of our alumni ", according to En. Idris, the CEO of INSTEP (Our
Leaders - INSTEP, n.d.).
5.11 Waste and Effluent Disposal Facilities

Every process in this world will produce product and by – product. It is determined
whether the by – product could be something useful or becoming waste. There are two types
of waste which are solid waste and liquid waste. For solid waste our company will gather all
the waste in designated area and sent it to the landfill. Nearest landfill from our site location is
Tapak Pelupusan Sampah Gelugor, Kerteh with a coordinate of 4°31'20"N 103°26'40"E. In
terms of liquid waste, we have our own water treatment facilities that can cater our own liquid
waste.
75
Figure 5.9: It estimated around 2.3 KM to reach the landfills to dispose our solid waste
5.12 Climate
Whether in Kerteh usually often humid and hot throughout the whole year except during
early November until middle of March because of Northeast Monsoon Wind that started to
blow at the end of every year(Kerteh Annual Weather Averages - Terengganu, MY, n.d.). The
sea wind ensures that Terengganu area especially Kerteh kept humid all the time. On the
other hand, there are no active volcanoes and minor risk of earthquakes since Malaysia is
outside of the ring of fire. Forest that has been reserved maintain the temperature in Kerteh
and Terengganu.
76
Figure 5.10: Temperatures of Kerteh for Year 2021 shows average of 28 Degree Celsius
Figure 5.11: Monsoon season starts usually on early November and ends on middle of
March every year
77
Figure 5.12: Wind Velocity shows during end of year is the strongest until it can reach up to
20KM/H
5.13 Political Stability and Attractive Government Incentives

The government will be given a five-year income tax exemption on 85% of the statutory
income for the states of Sabah, Sarawak, the Federal Territory of Labuan, and the designated
Eastern Corridor of Peninsular Malaysia, which includes Kelantan, Terengganu, Pahang, and
the district of Mersing in Johor. This exemption is due to the site's location in Kerteh. 15% of
the statutory income will be subject to taxation at the current corporation tax rate(Income Tax
Act 1967 INCOME TAX EXEMPTION, n.d.). When it comes to the investment tax credit, the
corporation will be given 80% of the credit for qualifying capital expenses paid within 5 years
of the date of the first capital expense. The allowance can be used to offset up to 85% of the
assessed year's statutory income.
The remaining portion of that statutory income will be subject to taxation at the current
company tax rate. Up until the whole amount has been used, any unused allowance may be
carried over to succeeding years. Any Malaysian company operating in Sabah, Sarawak, and
the designated Eastern Corridor of Peninsular Malaysia that engages in manufacturing,
agriculture, hospitality, tourism, or other industrial/commercial activity is eligible for the
78
infrastructure allowance. Company will receive a 100% allocation for capital expenditures on
infrastructure (such as reconstruction, extension, or 177 improvements of any permanent
structure including a bridge, jetty, port or road). In the year of assessment, the allowance may
be used to offset up to 85% of statutory income. The remaining portion of that statutory income
will be subject to taxation at the current company tax rate. Any unused allocation may be
carried over to the following years until it is used up completely.
5.14 Local Community

Local community around Kerteh are used to live with power plant and factories as long
as it is quite far from residential area. Local town also has fully equipped with utilities needed
such as banking, medical facilities, and education line. Buffer zone also has been made where
the locals know that they are entering factories zone. All in all, the agencies and company are
not required to build new kind of utilities for workers, employees and community for them to
live on.
79
5.15 Site Layout
80
Our plant has been divided into 5 different site which is we have administration site,
production plant site, warehouse and loading area site, product storage site and water
treatment also waste management site. At administration site, we have building up the
administration office, Lab department, utilities, employee centre, medical centre, café, parking
lot, fire fighter office and surau. All our management department office will be on the
administration building. Our Research and Development (R&D) will be on our lab building. All
employee locker, changing uniform place, PPE provider and meeting place will be on the
employee centre building. Example of utilities was toilet or washroom or rest room for our
employee uses on the administration building. Next, we also have the medical centre and fire
fighter station as function as facilities that provide medical treatment and medical transport for
emergency situation, or any unwanted accident happened in our plant during our day of
operation. Other than that, we also have café or canteen and surau for the place of Muslim
prayer. We also have pointed 3 assembly point which is assembly point A, B and C near with
the guard house and fire fighter station in order emergency assembly plan for all worker
assemble if there are emergency explosion or fire broke out on our plant.
Next, second site was our phenol production plant. Our production plant has been
covered by the blast wall. The blast wall is a barrier designed to protect vulnerable buildings
or other structures and the people inside them from the effects of a nearby explosion. Like a
blast-resistant building, a blast wall can be steel or concrete and also like blast-resistant
buildings, steel is a superior choice since it is strong, long-lasting, durable, and malleable.
Next, the third site of our plant was the dock loading area and warehouse. All new order of
equipment, raw material and other material will be store on our warehouse after had been
transferred for the dock loading area. Dock loading area was the place that all shipment order
material had been received and placed before it transferred into our warehouse for storage
record management.
The fourth side of our plant was product and by-product storage. All by-product and our
product will be store in a storage tank that located with the dock and near the road of our plant.
The purpose because we chose to place to storage near with the road and dock was make
easier in order to shipment and loading transport the product and by-product to delivered.
Next, the last section of our site was the waste management and water treatment site. Cooling
water or wastewater has been sent to our water treatment site in order to treat the water before
it can be sent back to our production plant or sent out from our plant to another reservoir. All
waste in our plant must be sent to the waste management department before the waste can
be sent out to the waste disposal place.
81
Our plant has 3 main gate and 3 guard house which is guard house A, B and C. The
main gate which is at guard house A are uses by all employee to park their vehicle at parking
lot at administration building before enter the production plant. The gate 2 which is at guard
house B are used for product or raw material transportation in and out in our plant. In order to
prevent from traffic jam in our plant, the guard house C which is the gate 3 are used for
outrance for transportation alternative.
82
5.16 Plant Layout
83
Our plant layout has been designed by using grouped layout method. The grouped
layout method was where all similar equipment was grouped together for example heat
exchanger were grouped all heat exchanger equipment in one department or site. This method
helped our easier to make operation, control and maintenance been perform in future. The
control room had been placed far away from production plant in term of safety of employee to
make shutdown without involved with hazardous and explosion if any emergency happened
in our plant production. Plant utilities was the place that plant air, water flow system and air
compressor instrument had been placed. The facilities had been placing near with the control
room. In term of maximum safety consideration, our production plant had been isolated with
the blast wall. The blast wall can be our plant production protection if any explosion or
emergency happed and natural hazardous also climate.
84
CHAPTER 6.0: MASS AND ENERGY BALANCE
6 PROCESS FLOW DIAGRAM
6.1 Introduction
This chapter will show the Process Flow Diagram (PFD) of process selection for this design
project. The chapter also shows the stream table that includes all information of the stream
such as stream number, total molar & mass flowrate, total enthalpy, temperature, and
pressure of the streamline that located from the Process Flow Diagram (PFD).
85
6.1.1 Process Flow Diagram (PFD)
86
6.1.2 Stream Table of Overall Process Flow
87
6.2 ASPEN HYSYS
This chapter will show the mass balance calculated using the Aspen HYSYS software.
By using Aspen HYSYS software, the energy balance for the equipments can be calculated
by the software, provided enough parameter for each equipment. The purpose for this method
is to compare the energy balance calculated manually and calculated by the software.
Hypothetically, the calculated energy balance should be the same for both manually and using
software. But due to the parameter of the equipment does not match the predicted value by
ASPEN some calculations are way off from the manual calculation. The contributing factor
can be due to the change of equipment used in the Process Flow Diagram were different than
the source material. Another factor is the flexibility of manual calculation, manual calculation
can be done on multiple input and multiple output stream of an equipment, while using ASPEN
need to the strict intake stream provided by the software. The result for the energy balance
for ASPEN HYSYS might have some difference with the manual calculation but it is due to the
factors mentioned earlier.
88
6.2.1 Simulation of Mass Balance
89
6.2.2 Report Generated from Aspen Hysys Converted to Excel
90
6.3 Introduction
This chapter will show the energy balance calculated using the Aspen HYSYS software.
By using Aspen HYSYS software, the energy balance for the equipments can be calculated
by the software, provided enough parameter for each equipment. The purpose for this method
is to compare the energy balance calculated manually and calculated by the software.
Hypothetically, the calculated energy balance should be the same for both manually and using
software. But due to the parameter of the equipment does not match the predicted value by
ASPEN some calculations are way off from the manual calculation. The contributing factor
can be due to the change of equipment used in the Process Flow Diagram were different than
the source material. Another factor is the flexibility of manual calculation, manual calculation
can be done on multiple input and multiple output stream of an equipment, while using ASPEN
need to the strict intake stream provided by the software. The result for the energy balance
for ASPEN HYSYS might have some difference with the manual calculation but it is due to the
factors mentioned earlier.
91
6.4 Simulation of Energy Balance
Figure 6.2: Simulation of the plant using Aspen Hysys
92
6.5 Report Generated
93
94
95
96
97
98
99
100
101
102
6.6 MASS BALANCE
6.6.1 Introduction
This chapter will show the manual calculation of mass balance for overall process production
phenol from benzene oxidation. Referred the Appendix A for the step of mass balance
calculation for all streamline numbers.
6.6.2 Molecular Weight

Information about the Molecular Weight (MW) for all the raw materials, products and the by-
product are shown as below: -(Appendix b Physical Property Tables - Google Search, n.d.).
Table 6.1: Molecular Weight Value

Molecular Weight (MW)
Compound
(g/mol)
Benzene, C6H6 78.11
Catechol, C6H4(OH)2 110.1
Benzaldehyde, C6H5CHO 106.1
Phenol, C6H5OH 94.11
Benzoic Acid, C6H5COOH 122.12
Oxygen, O2 32
Nitrogen, N2 28
Water, H2O 18
6.6.3 Phenol Production Calculation

Production Rate of Phenol = 750, 000 MTA
Assume that the plant operates 300 days per yr., and 24 hrs per day:
750,000 𝑀𝑇 1000 𝑘𝑔 1 𝑦𝑟 1 𝑑𝑎𝑦𝑠 1 ℎ𝑟 𝑘𝑚𝑜𝑙

× × × × ×
𝑦𝑟 1 𝑀𝑇 300 𝑑𝑎𝑦𝑠 24 ℎ𝑟𝑠 60 𝑚𝑖𝑛𝑠 94.11 𝑘𝑔
= 18.4477 kmol/ min
103
6.6.4 Mass Balance Calculation
Mass Balance at Condenser (E- 107)
F 26 kmol total/ min

F 25 kmol total/min
0.00002 kmol C6H6 / kmol total
F C6H6, 25 kmol C6H6 /min CONDENSER
25 26 0.99848 kmol C6H5OH / kmol total
F C6H4(OH)2, 25 kmol C6H4(OH)2 /min E- 107
0.00001 kmol C6H4(OH)2 / kmol total
F C6H5CHO, 25 kmol C6H5CHO /min
0.00148 kmol C6H5CHO / kmol total
F C6H5OH, 25 kmol C6H5OH /min
F C6H6, 26 kmol C6H6 /min
F C6H4(OH)2, 26 kmol C6H4(OH)2 /min
18.4477 kmol C6H5OH /min
Stream Number 25 26
Compound Molar Flow Rate (kmol/min)
Benzene, C6H6 0.0004 0.0004
Phenol, C6H5OH 18.4477 18.4477
Catechol, C6H4(OH)2 0.0002 0.0002
Benzaldehyde, C6H5CHO 0.0277 0.0277
Total Molar Flow Rate (kmol/min) 18.4760 18.4760
Total Mass Flow Rate (kg/min) 1739.1057 1739.1057
104
Mass Balance at Distillation Column (T – 104)
25
18.4760 kmol total/min
F, 23 kmol total/min
Distillation 0.0004 C6H6, 25 kmol C6H6 /min
23 Column (T – 104) 0.0002 C6H4(OH)2, 25 kmol C6H4(OH)2 /min
0.0277 C6H5CHO, 25 kmol C6H5CHO /min
18.4477, 25 kmol C6H5OH /min
27
F 27 kmol total/min
0.139 kmol C6H6, /kmol total
0.852 kmol C6H5OH, /kmol total
0.009 kmol C6H5CHO, /kmol total
Stream Number 23 25 27
Benzene, C6H6 0.0921 0.0004 0.0917
Phenol, C6H5OH 19.0098 18.4477 0.5621
Catechol, C6H4(OH)2 0.0002 0.0002 -
Benzaldehyde, C6H5CHO 0.0336 0.0277 0.0059
Total Molar Flow Rate (kmol/min) 19.1357 18.4760 0.6597
Total Mass Flow Rate (kg/min) 1799.7938 1739.1057 60.688
105
Mass Balance at Pump (P-106)
0.6597 kmol total/min F 28 kmol total/min

0.0917 kmol C6H6 /min F C6H6, 28 kmol C6H6 /min
PUMP
0.0059 kmol C6H5CHO /min 27 28 F C6H5CHO, 28 kmol C6H5CHO /min
(P-106)
0.5621 kmol C6H5OH /min F C6H5OH, 28 kmol C6H5OH /min
Stream Number 27 28
Benzene, C6H6 0.0917 0.0917
Phenol, C6H5OH 0.5621 0.5621
F, 22 kmol total/min 19.1357 kmol total/min
F C6H6, 22 kmol C6H6 /min Pump 0.0921 kmol C6H6 /min

22 23 0.0002 kmol C6H4(OH)2 /min
F C6H4(OH)2, 22 kmol C6H4(OH)2 /min (P- 105)
F C6H5CHO, 22 kmol C6H5CHO /min 0.0336 kmol C6H5CHO /min
F C6H5OH, 22 kmol C6H5OH /min 19.0098 kmol C6H5OH /min
Stream Number 22 23
Benzene, C6H6 0.0921 0.0921
Phenol, C6H5OH 19.0098 19.0098
Catechol, C6H4(OH)2 0.0002 0.0002
106
Mass Balance at condenser (E- 106)
21
F,21 kmol total/ min
0.0510 kmol C6H6 / kmol total
F,19 kmol total/min
0.9463 kmol C6H5OH / kmol total
F C6H6, 19 kmol C6H6 /min Condenser
19 (E- 106) 0.0027 kmol C6H5CHO / kmol total
F C6H5OH ,21 kmol C6H5OH /min
22

0.0921kmol C6H6 /min
0.0002 kmol C6H4(OH)2 /min
0.0336 kmol C6H5CHO /min
19.0098 kmol C6H5OH /min
Benzene, C6H6 0.0098 0.1019 0.0921
Phenol, C6H5OH 0.1821 19.1919 19.0098
Catechol, C6H4(OH)2 - 0.0002 0.0002
Benzaldehyde, C6H5CHO 0.0005 0.0341 0.0336
107
Mass Balance at Distillation Column (T- 103)
19
F18 kmol total/min 0.9930 C6H5OH/kmol total

Distillation 0.1019 kmol C6H6 /min
18 Column (T – 103)
F C6H4(OH)2, 18 kmol C6H4(OH)2 /min 0.0002 kmol C6H4(OH)2 /min
F C6H5CHO, 18 kmol C6H5CHO /min 0.0341 kmol C6H5CHO /min
F C6H5OH, 18 kmol C6H5OH /min 19.1919 kmol C6H5OH / min
F C6H5COOH, 18 kmol C6H5COOH /min

20
F19 kmol total/min
0.1286 kmol C6H5OH, /kmol total
0.8210 kmol C6H4(OH)2, /kmol total
0.0504 kmol C6H5COOH, /kmol total
F C6H5OH,20 kmol C6H5OH /min
F C6H4(OH)2,20 kmol C6H4(OH)2 /min
F C6H5COOH,20 kmol C6H5COOH /min
Benzene, C6H6 0.1019 0.1019 -
Phenol, C6H5OH 21.6774 19.1919 2.4855
Catechol, C6H4(OH)2 15.8680 0.0002 15.8678
Benzaldehyde, C6H5CHO 0.0341 0.0341 -
Benzoic Acid, C6H5COOH 0.9741 - 0.9741
108
Mass Balance of Pump (P-104)
19.3274 kmol total/min F 24 kmol total/min

15.8678 kmol C6H4(OH)2 /min FC6H4(OH)2, 24 kmol C6H4(OH)2 /min
20 Pump 24
0.9741 kmol C6H5COOH /min FC6H5COOH,24 kmol C6H5COOH /min
(P-104)
2.4855 kmol C6H5OH /min FC6H5OH ,24 kmol C6H5OH /min
Stream Number 20 24
Benzene, C6H6 - -
Phenol, C6H5OH 2.4855 2.4855
Catechol, C6H4(OH)2 15.8678 15.8678
Benzaldehyde, C6H5CHO - -
Benzoic Acid, C6H5COOH 0.9741 0.9741
109
Mass Balance at Distillation Column (T- 102)
13
F12 kmol total / min
F 13 kmol total/min
0.0004 kmol O2/kmol total
F C6H6, 13 kmol C6H6/min
0.0051 kmol N2/kmol total
Distillation F O2, 13 kmol O2/min
0.0028 kmol H2O/kmol total 12
Column (T- 102)
F N2, 13 kmol N2/min
F C6H6,12 kmol C6H6/min
F H2O, 13 kmol H2O/min
F C6H5OH, 12 kmol C6H5OH/ min
F C6H5CHO, 12 kmol C6H5CHO/ min
16
F C6H4(OH)2, 12 kmol C6H4(OH)2/ min
F C6H5COOH, 12 kmol C6H5COOH/min 38.6555 Kmol total/min
F O2, 12 kmol O2/ min 0.1019 Kmol C6H6/min
F N2, 12 kmol N2/ min 21.6774 Kmol C6H5OH/min
F H2O, 12 kmol H2O/ min 0.0341 Kmol C6H5CHO/min

15.8680 Kmol C6H4(OH)2/min
0.9741 Kmol C6H5COOH/min
Benzene, C6H6 267.0175 266.9156 0.1019
Phenol, C6H5OH 21.6774 - 21.6774
Catechol, C6H4(OH)2 15.8680 - 15.8680
Benzaldehyde, C6H5CHO 0.0341 - 0.0341
Oxygen, O2 0.1233 0.1233 -
Nitrogen, N2 1.5715 1.5715 -
Water, H2O 0.8628 0.8628 -
110
Mass Balance at Condenser (E- 105)
17
F 17 kmol total/min
0.5339 kmol C6H6/kmol total
268.4677 kmol C6H6/min
Condenser F O2, 17 kmol O2/min
0.1233 kmol O2/min 13 (E- 105)
1.5715 kmol N2/min
F H2O, 17 kmol H2O/min
0.8628 kmol H2O/min
14
F 14 kmol total/min
F O2, 14 kmol O2/min
Benzene, C6H6 266.9156 2.8771 264.0385
Oxygen, O2 0.1233 0.1024 0.0209
Nitrogen, N2 1.5715 1.5457 0.0258
Water, H2O 0.8628 0.8628 -
111
F 15 kmol total/min
264.0852 14 kmol total/min
264.0385 C6H6, 14 kmol C6H6/min Pump (P-101)
14 15 F O2, 15 kmol O2/min
0.0209 O2, 14 kmol O2/min
0.0258 N2, 14 kmol N2/min
Stream Number 14 15
Benzene, C6H6 264.0385 264.0385
Oxygen, O2 0.0209 0.0209
Nitrogen, N2 0.0258 0.0258
112
Mass Balance at Distillation Column (Flash Drum T-101)
F11 kmol total / min

0.0259 kmol C6H6/kmol total
0.00006 kmol C6H5OH/kmol total
11
0.9521 kmol N2/kmol total
0.00028 kmol H2O/kmol total
F10 kmol total / min F C6H5OH, 11 kmol C6H5OH/ min
F C6H6,10 kmol C6H6/min F O2, 11 kmol O2/ min
F C6H5OH, 10 kmol C6H5OH/ min F N2, 11 kmol N2/ min

Distillation Column
F C6H5CHO, 10 kmol C6H5CHO/ min 10 F H2O, 11 kmol H2O/ min
(Flash Drum T-101)
F C6H4(OH)2, 10 kmol C6H4(OH)2/ min
F C6H5COOH, 10 kmol C6H5COOH/min 308.1287 12 kmol total / min
F O2, 10 kmol O2/ min 267.0175 C6H6,12 kmol C6H6/min
F N2, 10 kmol N2/ min 21.6774 C6H5OH, 12 kmol C6H5OH/ min
F H2O, 10 kmol H2O/ min 0.0341 C6H5CHO, 12 kmol C6H5CHO/ min
12 15.8680 C6H4(OH)2, 12 kmol C6H4(OH)2/ min
0.9741 C6H5COOH, 12 kmol C6H5COOH/min
0.1233 O2, 12 kmol O2/ min
1.5715 N2, 12 kmol N2/ min
0.8628 H2O, 12 kmol H2O/ min
Benzene, C6H6 269.2165 2.1990 267.0175
Phenol, C6H5OH 21.6825 0.0051 21.6774
Catechol, C6H4(OH)2 15.8680 - 15.8680
Benzaldehyde, C6H5CHO 0.0341 - 0.0341
Oxygen, O2 1.9657 1.8424 0.1233
Nitrogen, N2 82.4083 80.8368 1.5715
Water, H2O 0.8651 0.0023 0.8628
113
Mass Balance at Cooler (E-104)
F9 kmol total / min 393.0143 kmol total / min
F C6H6,9 kmol C6H6/min 269.2165 kmol C6H6/min
F C6H5OH, 9 kmol C6H5OH/ min 21.6825 kmol C6H5OH/ min
F C6H5CHO, 9 kmol C6H5CHO/ min 0.0341 kmol C6H5CHO/ min

Cooler (E-104)
F C6H4(OH)2, 9 kmol C6H4(OH)2/ min 9 10 15.8680 kmol C6H4(OH)2/ min
F C6H5COOH, 9 kmol C6H5COOH/min 0.9741 kmol C6H5COOH/min
F O2, 9 kmol O2/ min 1.9657 kmol O2/ min
F N2, 9 kmol N2/ min 82.4083 kmol N2/ min
F H2O, 9 kmol H2O/ min 0.8651 kmol H2O/ min
Stream Number 9 10
Benzene, C6H6 269.2165 269.2165
Phenol, C6H5OH 21.6825 21.6825
Catechol, C6H4(OH)2 15.8680 15.8680
Oxygen, O2 1.9657 1.9657
Nitrogen, N2 82.4083 82.4083
Water, H2O 0.8651 0.8651
114
Mass Balance at Turbine (TR-101)
393.0143 kmol total / min

F8 kmol total / min
21.6825 kmol C6H5OH/ min
F C6H5OH, 8 kmol C6H5OH/ min
0.0341 kmol C6H5CHO/ min
F C6H5CHO, 8 kmol C6H5CHO/ min Turbine
8 9 15.8680 kmol C6H4(OH)2/ min
F C6H4(OH)2, 8 kmol C6H4(OH)2/ min (TR-101)
0.9741 kmol C6H5COOH/min
F C6H5COOH, 8 kmol C6H5COOH/min
1.9657 kmol O2/ min
F O2, 8 kmol O2/ min
82.4083 kmol N2/ min
F N2, 8 kmol N2/ min
0.8651 kmol H2O/ min
F H2O, 8 kmol H2O/ min
Stream Number 8 9
Benzene, C6H6 269.2165 269.2165
Phenol, C6H5OH 21.6825 21.6825
Catechol, C6H4(OH)2 15.8680 15.8680
Oxygen, O2 1.9657 1.9657
Nitrogen, N2 82.4083 82.4083
Water, H2O 0.8651 0.8651
115
Mass Balance at Heat Exchanger (E-102)
F7 kmol total / min 393.0143 kmol total / min

F C6H6,7 kmol C6H6/min 269.2165 kmol C6H6/min
F C6H5OH, 7 kmol C6H5OH/ min Heat Exchanger 21.6825 kmol C6H5OH/ min
F C6H5CHO, 7 kmol C6H5CHO/ min (E-102) 0.0341 kmol C6H5CHO/ min
7 8
F C6H4(OH)2, 7 kmol C6H4(OH)2/ min 15.8680 kmol C6H4(OH)2/ min
F C6H5COOH, 7 kmol C6H5COOH/min 0.9741 kmol C6H5COOH/min
F O2, 7 kmol O2/ min 1.9657 kmol O2/ min
F N2, 7 kmol N2/ min 82.4083 kmol N2/ min
F H2O, 7 kmol H2O/ min 0.8651 kmol H2O/ min
Stream Number 7 8
Benzene, C6H6 269.2165 269.2165
Phenol, C6H5OH 21.6825 21.6825
Catechol, C6H4(OH)2 15.8680 15.8680
Oxygen, O2 1.9657 1.9657
Nitrogen, N2 82.4083 82.4083
Water, H2O 0.8651 0.8651
116
Mass Balance at Reactor (R-101)
393.0143 kmol total / min

F 6 kmol total/min
21.6825 kmol C6H5OH/ min
28.9 % Conversion of C6H6 Reactor
0.0341 kmol C6H5CHO/ min
F C6H6, 6 kmol C6H6/min 6 (R-101) 7
15.8680 kmol C6H4(OH)2/ min
F O2, 6 kmol O2/min
0.9741 kmol C6H5COOH/min
F N2, 6 kmol N2/min
1.9657 kmol O2/ min
82.4083 kmol N2/ min
0.8651 kmol H2O/ min
Stream Number 6 7
Benzene, C6H6 378.6449 269.2165
Phenol, C6H5OH - 21.6825
Catechol, C6H4(OH)2 - 15.8680
Benzaldehyde, C6H5CHO - 0.0341
Benzoic Acid, C6H5COOH - 0.9741
Oxygen, O2 30.0987 1.9657
Nitrogen, N2 82.4083 82.4083
Water, H2O - 0.8651
As reactor is reactive
TOTAL MOLAR FLOWRATE INLET ≠ TOTAL MOLAR FLOWRATE OUTLET
117
Mass Balance at Mixing Point
6
F 6 kmol total/min
FC6H6,6 kmol C6H6/min
0.0209 Kmol O2/min (from
recycle stream,14) Mixing 378.6449 kmol C6H6/min
6(out)
0.0258 Kmol N2/min (from
Point
30.0987 kmol O2/min
recycle stream,14)
82.4083 kmol N2/min
2
F2 kmol total/min
F O2,2 kmol O2/min
F N2,2 kmol N2/min
Stream Number 6 2 6(out)

Benzene, C6H6 378.6449 - 378.6449
Oxygen, O2 0.0209 30.0778 30.0987
Nitrogen, N2 0.0258 82.3825 82.4083
118
Mass Balance at Pre- Heater (E-103)
F,5 kmol total/min 378.6916 kmol total/min

F C6H6,5 kmol C6H6/min Pre- Heater 378.6449 kmol C6H6/min
F O2,5 Kmol O2/min 5 (E-103) 6 0.0209 Kmol O2/min
F N2,5 Kmol N2/min 0.0258 Kmol N2/min
Stream Number 5 6
Benzene, C6H6 378.6449 378.6449
Oxygen, O2 0.0209 0.0209
Nitrogen, N2 0.0258 0.0258
119
Mass Balance at Heat Exchanger (E-102)
F,4(in) kmol total/min 378.6916 kmol total/min

Heat
F C6H6,4(in) kmol C6H6/min 378.6449 kmol C6H6/min
Exchanger
4(in) 5
F O2,4(in) Kmol O2/min 0.0209 Kmol O2/min
(E-102)
F N2,4(in) Kmol N2/min 0.0258 Kmol N2/min
Stream Number 4(in) 5

Benzene, C6H6 378.6449 378.6449
Oxygen, O2 0.0209 0.0209
Nitrogen, N2 0.0258 0.0258
120
Mass Balance at Mixing Point
from pump (P-101)

15
0.0209 Kmol O2/min 378.6916 kmol total/min
0.0258 Kmol N2/min 378.6449 kmol C6H6/min
Mixing
Point 4(out) 0.0209 Kmol O2/min
0.0258 Kmol N2/min
from pump (P-102)
4
F4 kmol total/min
Stream Number 15 4 4(out)

Benzene, C6H6 264.0385 114.6064 378.6449
Oxygen, O2 0.0209 - 0.0209
Nitrogen, N2 0.0258 - 0.0258
Total Molar Flow Rate
264.0852 114.6064 378.6916
(kmol/min)
121
F3 kmol total/min Pump 114.6064 kmol total/min

F C6H6,3 kmol C6H6/min 3 (P-102) 4 114.6064 kmol C6H6/min
Stream Number 3 4
Benzene, C6H6
114.6064 114.6064
Mass Balance at Compressor (C-102)
F1 kmol total/min 112.4603 kmol total/min

Compressor
F O2,1 kmol O2/min 1 2 30.0778 kmol O2/min
(C-102)
F N2,1 kmol N2/min 82.3825 kmol N2/min
Stream Number 1 2
Oxygen, O2 30.0778 30.0778
Nitrogen, N2 82.3825 82.3825
122
6.7 ENERGY BALANCE
6.7.1 Introduction
This chapter will show the energy balance calculation from the reactive and non-reactive
process equipment for process production of phenol from benzene oxidation. Referred the
Appendix B for the step of energy balance calculation.
6.7.2 Energy Balance Reactive Process

Reactor R-101
351℃ , 4390 kpa 351℃ , 4000 kpa
Reactor
6 7
(R-101)
C6H6 (l), O2 (g), C6H6 (l), C6H5OH (l), C6H5CHO (l),

N2 (g) C6H4(OH)2 (l), C6H5COOH (l), H2O(g),
O2 (g), N2 (g)
References: C6H6, C6H4(OH)2, C6H5CHO, C6H5OH, H2O, C6H5COOH, N2, O2, H2O
(25°C, 1 atm)
Inlet Outlet
Substance
ɳ𝒊𝒏 𝐇𝒊𝒏 ɳ𝒊𝒏 𝐇𝒊𝒏 ɳ𝒐𝒖𝒕 𝐇𝒐𝒖𝒕 ɳ𝒐𝒖𝒕 𝐇𝒐𝒖𝒕
(mol/min) (kJ/mol) (kJ/min) (mol/min) (kJ/mol) (kJ/min)
ɳ𝟏 = 𝐇𝟏 = ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) 33924.0840 24318.7572
378.6449 89.5934 269.2165 90.3316
ɳ𝟐 = 𝐇𝟑 = ɳ𝟒 = 𝐇𝟒 =
N2 (g) 779.1458 789.9742
82.4083 9.4547 82.4083 9.5861
ɳ𝟓 = 𝐇𝟓 = ɳ𝟔 = 𝐇𝟔 =
O2 (g) 285.6487 18.6553
30.0987 9.4909 1.9657 9.4904
ɳ𝟕 = 𝐇𝟕 =
C6H5OH (l) - - - 6615.7102
21.6825 305.1175
ɳ𝟖 = 𝐇𝟖 =
C6H5COOH (l) - - - 224.0499
0.9741 230.0071
ɳ𝟗 = 𝐇𝟗 =
C6H4(OH)2 (l) - - - 2384.2067
15.8680 150.2525
123
ɳ𝟏𝟎 = 𝐇𝟏𝟎 =
C6H5COOH (l) - - - 0.66227
0.0341 19.4214
ɳ𝟏𝟏 = 𝐇𝟏𝟏 =
H2O (l) - - - -225.9547
0.8651 -261.1891
Total 34988.8785 34125.465
𝑄 = Σ ɳ𝒐𝒖𝒕 𝐇𝒐𝒖𝒕 - Σ ɳ𝒊𝒏 𝐇𝒊𝒏 = -863.4135 kJ/min
6.7.3 Energy Balance Non-Reactive Process

Compressor (C-101)
30°C, 0kPa 196°C, 4000kPa

1
Compressor 2
C-101 Oxygen (O2, (g))

Oxygen (O2, (g))
Nitrogen (N2, (g)) Nitrogen (N2, (g))
References: O2, N2 (g, 30°C, 0kPa)
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0 ɳ𝟐 = 𝐇𝟐 =
O2 (g) 0 396.6198
82.3825 (Ref) 82.3825 4.8144
ɳ𝟑 = 𝐇𝟑 = 0 ɳ𝟒 = 𝐇𝟒 =
N2 (g) 0 145.3516
30.0778 (Ref) 30.0778 4.8325
Total 0 541.9714
𝑄 = Σ ɳ𝒐𝒖𝒕 𝐇𝒐𝒖𝒕 - Σ ɳ𝒊𝒏 𝐇𝒊𝒏 = 541.9714 kJ/min
124
Feed/Effluent Exchange E-102
93°C, 4400kPa 268°C, 4385kPa

4 Heat Exchanger 5
E-102 Benzene (C6H6, (l))

Benzene (C6H6, (l))
Oxygen (O2, (g)) Oxygen (O2, (g))
References: C6H6 (l, 93°C, 4400kPa) O2, N2 (g, 93°C, 4400kPa)
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0 ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) 0 8397.5866
378.6449 (Ref) 378.6449 22.178
ɳ𝟑 = 𝐇𝟑 = 0 ɳ𝟒 = 𝐇𝟒 =
O2 (g) 0 0.1064
0.0209 (Ref) 0.0209 5.0925
ɳ𝟓 = 𝐇𝟓 = 0 ɳ𝟔 = 𝐇𝟔 =
N2 (g) 0 0.1309
0.0258 (Ref) 0.0258 5.075
Total 0 8397.8240
125
Pre-Heater E-103
268°C, 4385kPa 351°C, 4390kPa

5
Pre-Heater 6

Benzene (C6H6, (l))
Oxygen (O2, (g)) Oxygen (O2, (g))
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0 ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) 0 3981.5693
378.6449 (Ref) 378.6449 10.515312
ɳ𝟑 = 𝐇𝟑 = 0 ɳ𝟒 = 𝐇𝟒 =
O2 (g) 0 0.05048
0.0209 (Ref) 0.0209 2.4153
ɳ𝟓 = 𝐇𝟓 = 0 ɳ𝟔 = 𝐇𝟔 =
N2 (g) 0 0.0621
0.0258 (Ref) 0.0258 2.407
Total 0 3981.6819
126
Condenser E-105
103°C, 34kPa
17
Benzene (C6H6, (l))
Oxygen (O2, (g))
Nitrogen (N2, (g))
Water (H2O, (l))
252°C, 68kPa Heat Exchanger
13
E-105
Benzene (C6H6, (g))
Oxygen (O2, (g)) 78°C, 34kPa
Nitrogen (N2, (g)) 14
Water (H2O, (l)) Benzene (C6H6, (l))
Oxygen (O2, (g))
Nitrogen (N2, (g))
References: C6H6, O2, N2 (g, 252°C, 68kPa), H2O (l, 252°C, 68kPa)
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0
C6H6 (g) 0 - - -
268.4677 (Ref)
ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) - - - -98.6753
2.8771 -34.2968
ɳ𝟑 = 𝐇𝟑 =
C6H6 (l) - - - -9602.9062
265.5906 -36.1568
ɳ𝟒 = 𝐇𝟒 = 0 ɳ𝟓 = 𝐇𝟓 =
O2 (g) 0 -0.14005
0.1233 (Ref) 0.1024 -1.3677
ɳ𝟔 = 𝐇𝟔 =
O2 (g) - - - -0.04379
0.0209 -2.0952
ɳ𝟕 = 𝐇𝟕 = 0 ɳ𝟖 = 𝐇𝟖 =
N2 (g) 0 -2.1068
1.5715 (Ref) 1.5457 -1.363
ɳ𝟗 = 𝐇𝟗 =
N2 (g) - - - -0.05387
0.0258 -2.088
ɳ𝟏𝟎 = 𝐇𝟏𝟎 = 0
H2O (g) 0 - - -
0.8628 (Ref)
127
ɳ𝟏𝟏 = 𝐇𝟏𝟏 =
H2O (l) - - - -36.4313
0.8628 -42.2245
Total 0 -9740.3573
Condenser E-106
Benzene (C6H6, (l))

Benzaldehyde (C6H5CHO, (l))
Phenol (C6H5OH, (l))
21
252°C, 68kPa
19 Heat Exchanger
192°C, 34kPa
E-106
Benzene (C6H6, (g))
Benzene (C6H6, (l))
Catechol (C6H4(OH)2, (g))
22
Catechol (C6H4(OH)2, (l))
Benzaldehyde (C6H5CHO, (g))
Phenol (C6H5OH, (g))
References: C6H6, C6H4(OH)2, C6H5CHO, C6H5OH, (g, 252°C, 68kPa)
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0
C6H6 (g) 0 - - -
0.1019 (Ref)
ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) - - - -0.34559
0.0098 -35.264
ɳ𝟑 = 𝐇𝟑 =
C6H6 (l) - - - -3.2478
0.0921 -35.264
ɳ𝟒 = 𝐇𝟒 = 0
C6H4(OH)2 (g) 0 - - -
0.0002 (Ref)
ɳ𝟓 = 𝐇𝟓 =
C6H4(OH)2 (l) - - - -0.02994
0.0002 -149.678
ɳ𝟔 = 𝐇𝟔 = 0
C6H5CHO (g) 0 - - -
0.0341 (Ref)
128
ɳ𝟕 = 𝐇𝟕 =
C6H5CHO (l) - - - -0.02436
0.0005 -48.72
ɳ𝟖 = 𝐇𝟖 =
C6H5CHO (l) - - - -1.63699
0.0336 -48.72
ɳ𝟗 = 𝐇𝟗 = 0
C6H5OH (g) 0 - - -
19.1919 (Ref)
ɳ𝟏𝟎 = 𝐇𝟏𝟎 =
C6H5OH (l) - - - -22.2308
0.1821 -122.08
ɳ𝟏𝟏 = 𝐇𝟏𝟏 =
C6H5OH (l) - - - -2320.7164
19.0098 -122.08
Total 0 -2348.2320
129
Condenser E-107
252°C, 68kPa 151°C, 34kPa

25
Heat Exchanger 26
Benzene (C6H6, (g))
Catechol (C6H4(OH)2, (g)) Catechol (C6H4(OH)2, (l))
Benzaldehyde (C6H5CHO, (g)) Benzaldehyde (C6H5CHO, (l))
Phenol (C6H5OH, (g)) Phenol (C6H5OH, (l))
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0
C6H6 (g) 0 - - -
0.0004 (Ref)
ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) - - - -0.01533
0.0004 -38.3144
ɳ𝟑 = 𝐇𝟑 = 0
C6H4(OH)2 (g) 0 - - -
0.0002 (Ref)
ɳ𝟒 = 𝐇𝟒 =
C6H4(OH)2 (l) - - - -0.04057
0.0002 -202.8263
ɳ𝟓 = 𝐇𝟓 = 0
C6H5CHO (g) 0 - - -
0.0277 (Ref)
ɳ𝟔 = 𝐇𝟔 =
C6H5CHO (l) - - - -1.54488
0.0277 -55.772
ɳ𝟕 = 𝐇𝟕 = 0
C6H5OH (g) 0 - - -
18.4477 (Ref)
ɳ𝟖 = 𝐇𝟖 =
C6H5OH (l) - - - -3184.6818
18.4477 -172.633
Total 0 -3186.2826
130
Mixing Point 1
C6H6 (l), 351℃ , 4390 kPa
Mixing Point
6 6(out)
2 1
C6H6 (l), O2 (g), N2 (g)
O2 (g), N2 (g), 196℃ , 4000
kPa 351℃ , 4000 kPa
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0 ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) 0 13.0860
378.6449 (Ref) 378.6449 0.0346
ɳ𝟑 = 𝐇𝟑 = 0 ɳ𝟒 = 𝐇𝟒 =
O2 (g) 0 370.4500
82.4083 (Ref) 82.4083 4.4953
ɳ𝟓 = 𝐇𝟓 = 0 ɳ𝟔 = 𝐇𝟔 =
N2 (g) 0 135.3504
30.0987 (Ref) 30.0987 4.5123
Total 0 519.3504
131
Mixing Point 2
C6H6 (l), O2 (g), N2 (g), 80℃ , 4400 kPa
15 Mixing Point
4(out)
4 2
C6H6 (l), O2 (g), N2 (g)
0)
C6H6 (l), 33℃ , 4400 kPa 93℃ , 4400 kPa
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0 ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) 0 623.8175
378.6449 (Ref) 378.6449 1.6475
ɳ𝟑 = 𝐇𝟑 = 0 ɳ𝟒 = 𝐇𝟒 =
C6H6 (l) 0 2879.2310
378.6449 (Ref) 378.6449 7.6040
ɳ𝟓 = 𝐇𝟓 = 0 ɳ𝟔 = 𝐇𝟔 =
O2 (g) 0 0.00973
0.0258 (Ref) 0.0258 0.37701
ɳ𝟕 = 𝐇𝟕 = 0 ɳ𝟖 = 𝐇𝟖 =
N2 (g) 0 0.00791
0.0209 (Ref) 0.0209 0.3785
Total 0 3503.066
132
Distillation Column T-102
150°C, 68kPa
Benzene (C6H6, (g))
13 Oxygen (O2, (g))

Nitrogen (N2, (g))
Water (H2O, (l))
53°C, 1000kPa Distillation

12
Column
Benzene (C6H6, (l)) T-102
198°C, 50kPa
16
Benzene (C6H6, (l))
Benzoic Acid (C6H5COOH, (l))
Oxygen (O2, (g))
Nitrogen (N2, (g))
Water (H2O, (l))
References: C6H6, C6H4(OH)2, C6H5CHO, C6H5OH, H2O, C6H5COOH (l, 53°C, 1000kPa),
N2, O2, (g, 53°C, 1000kPa)
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0 ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) 0 1.8640
21.6774 (Ref) 0.1019 18.29233
ɳ𝟑 = 𝐇𝟑 =
C6H6 (g) - - - 11480.10
266.9156 43.0102
ɳ𝟒 = 𝐇𝟒 = 0 ɳ𝟓 = 𝐇𝟓 =
C6H4(OH)2 (l) 0 2981.2814
15.8680 (Ref) 15.8680 187.8801
ɳ𝟔 = 𝐇𝟔 = 0 ɳ𝟕 = 𝐇𝟕 =
C6H5CHO (l) 0 0.849210
0.0341 (Ref) 0.0341 24.9035
ɳ𝟖 = 𝐇𝟖 = 0 ɳ𝟗 = 𝐇𝟗 =
C6H5OH (l) 0 3873.790
21.6774 (Ref) 21.6774 178.7018
133
ɳ𝟏𝟎 = 𝐇𝟏𝟎 = 0 ɳ𝟏𝟏 = 𝐇𝟏𝟏 =
C6H5COOH (l) 0 141.5066
0.9741 (Ref) 0.9741 145.2691
ɳ𝟏𝟐 = 𝐇𝟏𝟐 = 0 ɳ𝟏𝟑 = 𝐇𝟏𝟑 =
O2 (g) 0 0.3480
0.1233 (Ref) 0.1233 2.8227
ɳ𝟏𝟒 = 𝐇𝟏𝟒 = 0 ɳ𝟏𝟓 = 𝐇𝟏𝟓 =
N2 (g) 0 4.4206
1.5715 (Ref) 1.5715 2.813
ɳ𝟏𝟔 = 𝐇𝟏𝟔 = 0
H2O (l) 0 - - -
0.8628 (Ref)
ɳ𝟏𝟕 = 𝐇𝟏𝟕 =
H2O (g) - - - 41.3977
0.8628 47.9806
Total 0 18525.558
134
252°C, 68kPa
Benzene (C6H6, (g))

19 Benzaldehyde (C6H5CHO, (g))

18
Column
185°C, 50kPa
Benzaldehyde (C6H5CHO, (l)) 20
References: C6H6, C6H4(OH)2, C6H5CHO, C6H5OH, C6H5COOH (l, 198°C, 62kPa)
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0
C6H6 (l) 0 - - -
0.1019 (Ref)
ɳ𝟐 = 𝐇𝟐 =
C6H6 (g) - - - 1.8104
0.1019 17.7662
ɳ𝟑 = 𝐇𝟑 = 0 ɳ𝟒 = 𝐇𝟒 =
C6H4(OH)2 (l) 0 -267.4026
15.8680 (Ref) 15.8678 -16.8519
ɳ𝟓 = 𝐇𝟓 =
C6H4(OH)2 (g) - - - 0.01101
0.0002 55.0481
ɳ𝟔 = 𝐇𝟔 = 0
C6H5CHO (l) 0 - - -
0.0341 (Ref)
ɳ𝟕 = 𝐇𝟕 =
C6H5CHO (g) - - - 1.6262
0.0341 47.688
135
ɳ𝟖 = 𝐇𝟖 = 0 ɳ𝟗 = 𝐇𝟗 =
C6H5OH (l) 0 -39.8401
21.6774 (Ref) 2.4855 -16.029
ɳ𝟏𝟎 = 𝐇𝟏𝟎 =
C6H5OH (g) - - - 2181.7736
19.1919 113.682
ɳ𝟏𝟏 = 𝐇𝟏𝟏 = 0 ɳ𝟏𝟐 = 𝐇𝟏𝟐 =
C6H5COOH (l) 0 -12.6962
0.9741 (Ref) 0.9741 -13.0338
Total 0 1865.2822
136
252°C, 68kPa
Benzene (C6H6, (g))

25
Benzaldehyde (C6H5CHO, (g))

23 Column
180°C, 50kPa
27
Benzene (C6H6, (l))
References: C6H6, C6H4(OH)2, C6H5CHO, C6H5OH, (l, 192°C, 103kPa)
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0 ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) 0 -0.1395
0.0921 (Ref) 0.0917 -1.52076
ɳ𝟑 = 𝐇𝟑 =
C6H6 (g) - - - 0.0154
0.0004 38.40404
ɳ𝟒 = 𝐇𝟒 = 0
C6H4(OH)2 (l) 0 - - -
0.0002 (Ref)
ɳ𝟓 = 𝐇𝟓 =
C6H4(OH)2 (g) - - - 0.02994
0.0002 149.678
ɳ𝟔 = 𝐇𝟔 = 0 ɳ𝟕 = 𝐇𝟕 =
C6H5CHO (l) 0 -0.0122
0.0336 (Ref) 0.0059 -2.064
ɳ𝟖 = 𝐇𝟖 =
C6H5CHO (g) - - - 1.3495
0.0277 48.72
137
ɳ𝟗 = 𝐇𝟗 = 0 ɳ𝟏𝟎 = 𝐇𝟏𝟎 =
C6H5OH (l) 0 -8.3168
19.0098 (Ref) 0.5621 -14.796
ɳ𝟏𝟏 = 𝐇𝟏𝟏 =
C6H5OH (g) - - - 2252.0952
18.4477 122.08
Total 0 2245.0216
138
CHAPTER 7.0: CHEMICAL ENGINEERING & MECHANICAL ENGINEERING
EQUIPMENT DESIGN
7 Design and specification

7.1 Fundamental knowledge
7.1.1 REACTOR R-101
7.1.2 General Information
A reactor can refer to a variety of things depending on the context. Still, it is generally a
device or system designed to initiate, sustain, or control a chemical reaction. Reactors can be
found in various industries, including chemical production, oil and gas, nuclear power plants,
etc. In nuclear power plants, a reactor is a device that uses nuclear reactions to generate heat,
which is then used to produce electricity. In chemistry, a reactor is a vessel used to contain
and control chemical reactions. There two type system of reactor mainly flow system and batch
system. The reactor R-101 are using the flow system concept. The reactor R-101 are intended
to be used as the major equipment mainly the reactive process equipment in order to produce
phenol product from direct benzene oxidation process.
A flow system reactor, also known as a flow reactor or continuous flow reactor, is a type
of chemical reactor in which chemical reactions are carried out in a continuously flowing
stream rather than in a batch process. In a flow reactor, reactants are continuously pumped
into a reactor where they come into contact with one another, and if they are reactive, a
chemical reaction takes place. The process occurs in a tube, capillary, micro-structured device
or a series of tubes called a flow reactor (Flow Reactor - an Overview | ScienceDirect Topics,
n.d.).
Flow reactors are used to follow heterogeneous reactions over a range of timescales,
where one or more mobile phases (gas-phase reactants and aerosol particles) pass through
the experimental system. Flow reactors are preferred over traditional batch reactors due to
their inherent safety, as well as their ability to achieve continuous flow chemical processing.
There are several types of flow reactors which is Continuous Stirred Tank Reactor (CSTR),
Plug Flow Reactor (PFR) and Catalytic Reactor.
Figure 7.1: Reaction equations of direct route of phenol from benzene oxidation
139
Figure 7.1 above show the reaction chemistry and balance chemical equation of direct
route of phenol from benzene. On this process, the raw material that being use is benzene
and air. This direct route method from benzene to phenol involves oxidation process by
presence of copper chromium catalyst. This reaction is occurring in flow system of Reactor R-
101.
7.1.3 Type of Flow Reactor

Type of flow reactor that intended for Reactor R-101 are Multi-tubular Packed Bed
Reactor (MPBR). A packed bed reactor is a type of chemical reactor where reactants flow
through a reactor with continuous mixing, allowing for efficient heat and mass transfer and
precise control of reaction conditions. This reactor can be designed with different types of
catalysts, including heterogeneous catalysts and Supported Ionic Liquid Phase (SILP)
catalysts. A packed bed reactor is a type of chemical reactor in which a bed of solid particles,
typically a catalyst, is packed into a cylindrical or spherical vessel. The reactants are passed
through the bed, either in a continuous or batch flow, and react with the catalyst to produce
the desired chemical reaction. Used for heterogeneous catalysis such as gas phase reactions
with solid catalysts. Heterogeneous catalysis was catalyst and the reactants are in different
phases (Afandizadeh & Foumeny, 2001). Typically, a solid catalyst and a liquid /gaseous
reactant.
A multi-tubular packed bed reactor is a type of chemical

reactor that consists of multiple tubes packed with solid
catalyst particles. The packing material in the tubes provides
a large surface area for the reaction to take place, and the
tubes are often arranged in parallel to increase the overall
capacity of the reactor. Multi-tubular packed bed reactors are
commonly used in the chemical industry for processes such
as catalytic cracking, hydrogenation, and dehydrogenation
(Multi-Tubular Fixed Bed Reactor - an Overview |
ScienceDirect Topics, n.d.).
140
7.1.4 Type of Catalyst
Figure 7.3: Copper Chromite Catalyst (Cr2Cu2O5)
The type of catalyst that been used presence in reaction of phenol production from
benzene oxidation was copper chromium catalyst which well known as copper chromite
catalyst (Cr2Cu2O5) (Copper Chromite | Cr2Cu2O5 - PubChem, n.d.). The copper chromium
catalyst used in this process typically consists of copper and chromium oxides supported on
an alumina carrier. The exact composition and structure of the catalyst can vary depending on
the specific process conditions and requirements. Copper chromium catalysts are used in the
direct oxidation of benzene to phenol, a process known as the "Hock" process.
Benzene is oxidized to phenol using air or oxygen in the presence of a catalyst. The
catalytic mechanism involves the activation of oxygen by the copper and chromium species,
which leads to the formation of reactive oxygen species that react with benzene to form
phenol. The reaction conditions such as temperature, pressure, and reactant concentrations
can significantly affect the catalytic performance and selectivity of the catalyst. This reaction
typically is highly exothermic ((PDF) Direct Route to Phenol from Benzene, n.d.).
7.1.5 Material Construction

Material that been used for the designing reactor are stainless steel 316 (18cr/8ni Mo 2
½ per cent). Stainless steel 316 is a type of austenitic stainless steel, which is a non-magnetic
steel that contains high levels of chromium, nickel, and molybdenum. It is also known as
marine grade stainless steel due to its high resistance to corrosion in harsh environments such
as seawater and chloride environments. Stainless steel 316 contains higher levels of
molybdenum and nickel. Molybdenum and nickel enhance the corrosion resistance of
stainless steel, while chromium gives it its characteristic shiny appearance and improves its
resistance to staining (Sinnott R. K. Coulson J. M. & Richardson J. F., 2005). Some of the key
properties of stainless steel 316 include high resistance to corrosion and oxidation, excellent
formability and weldability, and good strength and toughness at both high and low
141
temperatures. It is available in various forms such as sheets, plates, bars, and tubes. Overall,
stainless steel 316 is a versatile and popular material that offers excellent corrosion resistance,
strength, and durability in a wide range of applications (Super Alloy Pyromet CTX-909 (UNS
N11909), n.d.).
7.1.6 Working Principle

A multi-tubular packed bed reactor (MPBR) is a type
of chemical reactor used in industrial processes for carrying
out catalytic reactions at high temperatures and pressures.
It consists of a shell that houses multiple tubes packed with
catalysts, which promote the desired chemical reaction. The
reaction conditions in this process feed with 351°C
temperature and 4000 kPa pressure.
The reactant which is benzene and compress air

(liquid+gas) will flow through the top of multi-tubular packed
bed reactor. Then, the reactant will flow through the catalyst
bed which is solid copper chromite catalyst in a continues
process. The chemical reaction takes place as they
encounter the active sites on the catalyst surface. The
reaction occurs in heterogeneous reaction.
As the reaction proceeds, the heat of reaction is

generated, which increases the temperature of the reaction mixture. The temperature control
is crucial to maintain optimal reaction conditions and prevent catalyst deactivation or product
degradation. This is achieved via conduction oil flowing around the outside of the reactor tubes
to remove the excess heat. A heat transfer medium is circulated through the space between
the uppermost and bottommost tube plates and surrounding the catalyst tubes, in which space
may be divided by deflecting plates to introduce or remove the heat of the reaction.
The product and by product that produced from the reaction will be discharge through
the bottom caps of multi-tubular packed bed reactor and transfer to the separation process.
7.1.7 Design Intention

The main intention of design Reactor R-101 using multi-tubular packed bed reactor is
as the reactor vessel for production of phenol occurs from benzene oxidation with the
142
presence of copper chromium oxide as catalyst. Multi-tubular packed bed reactor had been
chosen mainly the multi-tubular design allows for increased surface area and improved heat
transfer, leading to higher reaction rates and better selectivity. They are also suitable for high-
performance catalytic reactions and can be optimized through modelling to achieve optimal
mechanical design and catalyst operation. Furthermore, multi-tubular packed bed reactors
have a high conversion rate per weight of catalyst, effective at high temperatures and
pressures, and easy to construct.
The stainless steel 316 had been chosen for the materials construction rather than
stainless steel 304. Stainless steel 316 is a type of austenitic stainless steel that contains 16-
18% chromium, 10-14% nickel, and 2-3% molybdenum. The higher the chromium content, the
more resistant is the alloy to corrosion in oxidising conditions. Nickel is added to improve the
corrosion resistance in non-oxidising environments. It has excellent corrosion resistance
making it suitable for use in this benzene oxidation process with presence of copper chromium
oxide catalyst. Stainless steel 316 is also resistant to high temperatures and has good welding
and forming capabilities suitable for exothermic reaction process (“Environ. Ind. Corros. -
Pract. Theor. Asp.,” 2012).
143
7.1.8 DISTILLATION COLUMN
In industry, distillation is used for several reasons, including oil refining, water
purification, and the manufacture of alcoholic drinks. Distillation is a physical process that
extracts desirable pure compounds from a source using heat and other ways. It does not
include any chemical reactions; it separates but does not modify the components. Many large
and small industries use distillation (Use of Distillation System in Industry, n.d.). A distillation
column is a tube that offers surfaces for condensation and vaporization to occur before the
gas hits the condenser, allowing the more volatile fluids to be concentrated in the initial
fractions and the less volatile components to be focused in the later fractions (Distillation
Column | Chemical Instrument | Britannica, n.d.).
The distillation method is used to separate components based on their boiling points.
Variable boiling points chemicals, such as petrol, diesel and jet fuel, boil at different
temperatures. Distillation columns separate mixed input streams into their different products.
Advanced technology is taking over tower design, control, and operation. Internal tower
innovation produces more significant returns in boosting tower efficiency and capacity than
ever before. These developments appear to be decreasing the failure rate of distillation towers.
The rate of tower failure, on the other hand, is growing and will continue to rise. In this phenol
production, the total distillation column is three, separating benzene, catechol, and
benzaldehyde (Use of Distillation System in Industry, n.d.). In the process flow diagram, the
annotation of the three-distillation columns is T-102 (Benzene Column), T-103 (Catechol
Column), and T-104 (Phenol Column).
There are several varieties of distillation columns; each is intended to accomplish certain
sorts of separations and varies in complexity. There are two types of distillation columns: batch
column and distillation column. In batch operation, the feed to the column is introduced batch-
wise. In other words, the column is charged with a 'batch', and the distillation process is carried
out. When the task is completed, the next batch of feed is introduced (Distillation Column -
Basic Distillation Equipment and Operation, n.d.). The type of distillation column implemented
in the direct benzene oxidation process is continuous distillation. Continuous columns process
a continuous feed stream. No interruptions occur unless there is a problem with the column or
surrounding process units. They can handle high throughput and are the most common of the
two types compared to the batch column (Distillation Column - Basic Distillation Equipment
and Operation, n.d.).
144
7.1.10 Types of Continuous Columns (In general)
Continuous columns can be further classified according to the following:
a) The nature of the feed that is processing

• The binary column feed contains only two components (Distillation Column - Basic
Distillation Equipment and Operation, n.d.).
• Multi-component column - feed contains more than two components (Distillation
Column - Basic Distillation Equipment and Operation, n.d.).
b) The number of product streams they have

• A multi-product column has more than two product streams (Distillation Column -
Basic Distillation Equipment and Operation, n.d.).
c) Where the extra feed exits when it is used to help with the separation
• Extractive distillation - where the additional feed appears in the bottom product
stream (Distillation Column - Basic Distillation Equipment and Operation, n.d.).
• Azeotropic distillation - where the extra feed occurs at the top product stream
(Distillation Column - Basic Distillation Equipment and Operation, n.d.).
d) The type of column internals

• Tray column - where trays of various designs hold up the liquid to provide better
contact between vapour and liquid, hence better separation (Distillation Column -
Basic Distillation Equipment and Operation, n.d.).
• Packed column - instead of trays, 'packings' enhance contact between vapour and
liquid (Distillation Column - Basic Distillation Equipment and Operation, n.d.).
7.1.11 Type of Nature of the Feed Used

The nature of the feed implemented in this reaction is the binary column. The binary
distillation column divides a mixed input stream into two parts: top product (XD) and bottom
product (XB). The goal of this separation is to acquire the final product's purity. An essential
binary distillation column comprises numerous identically sized trays, a condenser, a reflux
drum, a reflux, a top product or distillate (XD), a reboiler, and a bottom product (XB). Figure 7.5
is a binary distillation column schematic diagram (White et al., n.d.).
145
Figure 7.5: Diagram of a binary distillation column
The mechanism of operation of the binary distillation column is as follows. The feed
stream enters the feed tray and is heated on the reboiler to generate vapour. The bottom
product (XB) is the non-volatile liquid released from the reboiler. Vapour rises to the top of the
column and is condensed by the condenser. The condensation is stored on the reflux drum.
Reflux occurs when some of this liquid is returned to the top of the distillation column. The top
product or distillate (XD) is a portion of the other liquid that is discharged. The controlled output
variables are the top product (XD) and bottom product (XB), the disturbance variable is the feed
flow rate change (F), and the manipulated input variables are the reflux flow rate (R) and the
steam flow rate (S) (White et al., n.d.).
7.1.12 Types of Column Internals Used

There are two types of column internals: tray column and packed column. The tray
column was chosen. The utilisation of trays in a tray column allows for better contact between
the liquid and vapour and, thus, better separation (Facts at Your Fingertips: Distillation Trays
and Packing - Chemical Engineering | Page 1, n.d.). Furthermore, a plate column (or tray
column) is a chemical equipment used to carry out unit operations where transferring mass
between a liquid and gas phase is necessary. It is, in other words, a specific gas-liquid
contactor. This gas-liquid contactor is unique because the gas and liquid interact at many
stages, each separated by two plates (except for the stages at the top and bottom of the
column). Distillation, liquid-liquid extraction, and gas-liquid absorption are frequent uses for
plate columns. Plate columns are generally used in batch and continuous processes (Plate
Column - Wikipedia, n.d.).
146
7.1.13 Types of Column Tray Used
There are five major types of tray columns; bubble cap tray, sieve deck tray, dual flow
tray, valve tray and baffle tray (Author et al., 2011). The tray chosen is sieve trays, metal plates
with holes and no moving parts. Sieve trays are perforated plates with holes punched into
them that range in size from 3/16 in to 1 in. The perforation is punched downward, and the
usual size is 0.5 inches. Vapour emerges from the holes, creating a multi-orifice impression.
The vapour velocity prevents liquid from draining through the perforations (weeping). The
number and size of the holes govern the passage of vapour through the tray deck to touch the
liquid (Author et al., 2011). According to the operating principle of the sieve tray, the vapour
rises from the holes or perforations to the tray above, countercurrent to the liquid flow. The
liquid is prevented from draining through the perforations by the vapour energy. The latter
passes over the tray and, through a down-comer, to the tray below.
Compared to the valve tray and bubble cap tray, the sieve tray has a decent capacity
and moderate efficiency, but its working range is not as flexible. More giant sieves are used
in fouling operations, whereas smaller sieves minimize weeping. Compared to other traditional
trays, the sieve tray's key benefits are its low maintenance costs and low susceptibility to foul.
Additionally, the sieve tray is affordable, quick to make, and straightforward to use. Also, the
sieve tray is simple, easy to fabricate, and inexpensive compared to other mass-transfer trays
(Sieve Trays | Munters, n.d.).
7.1.14 Material Construction Used

There are a few types for the material of construction of distillation columns, for
example, stainless steel, aluminium, carbon steel, alloy, titanium and many more. For this
distillation column particularly, the material chosen is carbon steel. A mixture of carbon and
iron is called carbon steel. Carbon steel, sometimes called mild steel, is one of the most widely
used materials in engineering. It is preferred since it is extensively used and reasonably priced.
It also has high ductility and tensile strength (Materials of Construction - Processdesign, n.d.).
Since distillation is the most popular method for commercially separating fluid mixtures, it plays
a significant role in many operations in the oil and chemical industries. Distillation columns
make up a large portion of the tall, slender towers that may be seen in an oil refinery or
chemical plant. The average column diameter is roughly 2.5 metres, however, towers up to 12
metres in diameter have been constructed. Column heights might reach 30 metres.
147
High-purity products, economies of scale, proven technology, competitive equipment supply,
use of low temperature, low-cost energy, and suitability for energy integration into surrounding
processes are all benefits of distillation (Porter, 2011). Distillation is one of the separation
methods used in the chemical industry to separate the mixtures of a liquid and gaseous
solution. The separation process depends on the differences in the volatilities in a boiling liquid
mixture (Sinnott, 2005). Relative volatility is a measure that compares the vapor pressures of
the components in a liquid chemical combination. This value is commonly utilised in the design
of big industrial distillation operations. It effectively reflects the ease or difficulty of utilising
distillation to separate the more volatile components of a mixture from the less volatile
components. By convention, relative volatility is referred to as alpha, α (Relative Volatility -
Wikipedia, n.d.).

A set of stacked plates form the distillation column. The fundamental operation and
terminology of the distillation process begin when the liquid feed comprising a combination of
two or more liquids enters the column at one or more points. The liquid runs over the plates,
and vapour bubbles up via perforations in the plates. Because of the many plates, the vapour
touches the liquid several times as it moves down the column - a vital step in distillation
columns. The liquid and vapour phases are brought into contact because as one molecule of
higher boiling material converts from vapour to liquid phase by energy release, another
molecule of the low boiling material utilises the free energy to convert from liquid to vapour
phase. The base of the distillation column holds a considerable volume of liquid, largely of the
higher boiling point liquid. Part of this liquid flows from the base, is heated in the re-boiler and
returned to the column. This is known as the boil-up. Some vapour escapes from the column's
top and is converted to liquid in the condenser. Some liquid is recirculated into the column as
reflux, while the remaining is the top product or distillate. Depending on the plate's efficiency,
the vapour and liquid phases on a particular plate approach thermal pressure and composition
equilibrium. The heated mixture is essentially pushed to the bottom. The tower is a heat
exchanger, removing heat from the rising vapours. Some of these condense and fall back
down the column as liquids. The temperature progressively drops as you progress along the
column (How Columns Work? - SRS Engineering HomeSRS Engineering Home, n.d.).
The design of a distillation column can be divided into the following steps:
1. Specify the degree of separation required: set product specifications.
2. Select the operating conditions: batch or continuous: operating pressure.
3. Select contacting device: plates or packing.
148
4. Determine the stage and reflux requirement: the number of equilibrium stages.
5. Column size: number of real stages and diameter.
6. Design the column internals: plates, distributors, and packing supports.
7. Mechanical design: vessel and internal fitting

(References: Chemical Engineering, Coulson & Richardson's, 4th Edition).

The main intention of the design of three distillation columns, T-102.T-103, & T-104,
that utilised tray distillation column (plate column) is as follows:
• Plate columns can handle a wide range of gas and liquid flow rates.
• Plate efficiency can be predicted more accurately.
• Plate column operation is considerably smooth.
• Cooling arrangements can be provided in the plate column.
• Plate columns provide stage-wise contact.
• When the liquid cause fouling or deposition of solids, even though the tray is
blocked, it is easier to clean it, and manholes can be provided over the plate
(Packed Column versus Tray Column - Chemical Engineering World, n.d.).
149
7.1.17 FLASH DRUM
Flash drum also known as a vapor – liquid separator is a device that used to separate
liquid mixture into its constituent phases. The design can be either in horizontal and vertical
vessel and can act as a 2- phase or 3- phase separator.
In a flash drum, a high-pressure liquid stream is introduced into the vessel, and the
pressure is suddenly reduced. This sudden pressure drop causes some of the liquid to
vaporize, resulting in a mixture of liquid and vapor in the vessel. The vapor phase and the
liquid phase are then separated, typically using a mist eliminator, and removed from the vessel
through separate outlets.
Flash evaporation is one of the simplest separation processes. A liquid stream

containing several components is partially vaporized in a” flash drum” at a certain pressure
and temperature. This results in two phases: a vapor phase, enriched in the more volatile
components, that will be withdraw at the top outlet and a liquid phase, enriched in the less
volatile components that will release at the bottom of the vessel by the gravity. This makes the
flash drum useful in various industrial processes, such as in the production of petroleum
products, where crude oil is separated into various fractions based on their boiling points.
The design and operation of a flash drum depend on several factors, including the
composition of the fluid, the pressure and temperature conditions, and the desired separation
efficiency. Proper design and operation of the flash drum are essential for achieving optimal
separation performance and preventing equipment failure. Figure 7.6 shows a schematic
drawing of a flash unit.
Figure 7.6: Flash Drum
150
7.1.19 Type Of Separator
Separator used in industry can be divided into horizontal separators, vertical

separators, and spherical separators according to the installation method. Each types have
their own advantages and design, and the correct separator should be selected based on the
specific requirements of the process.
TYPE DETAILS ADVANTAGES
Vertical Separator - This vessel is used to separate a liquid and • Easy to clean.
vapor mixture by gravity. • Less occupied area
- As the fluid enters the vessel the velocity • Sensitive level
decreases, allowing gravity to separate controlling
heavier liquid phase from lighter vapor • Large space for gas-
phase. liquid separation
- Inlet consists mixture of the vapor and liquid,
top outlet will withdraw vapor that less dense
and bottom outlet will withdraw liquid.
Horizontal - This vessel is oriented horizontally and • Small diameter

Separator consists of a mixture of fluid and separate • Large gas- liquid
outlets for the liquid and vapor phase. interface and perfect
- The mixture enters the vessel tangentially, separation effect
will create a centrifugal force that separates • Skid- mountable
the liquid and vapor phases. design, easy to install.
- This type of separator allows for the larger • Low cost
surface area of the liquid phase that can
enhance the separation efficiency.
Spherical - This vessel comes with spherical shape that • Compact design (
Separator is used to separate a mixture of liquid and operate in small space)
vapor by gravity. • Minimal liquid holdup-
- The mixed fluid enters from top of the have low volume to the
sphere, by gravity the liquid will settle at the surface area.
bottom of the sphere, the lighter vapor phase • Lower pressure drop-
rises to the top to be released. the flow path more
- Useful when there are space constraints, direct resulting in less
large volume to separate in the small space. resistance to the flow.
151
Theoretically, the horizontal vessel works well for a variety of principles, including high
liquid-to-vapor ratio crudes, foaming crudes, and others. Vertical vessels, on the other hand,
are perfect for applications with low to moderate liquid-to-vapor ratios. In addition, spherical
separators are effective for liquid-vapor mixtures with intermediate to low ratios. As a results,
the L/D was used to determine the selection criteria for the vessel shape. When the L/D ratio
is between 3 and 5, the separation arrangement is designed as a vertical separator and when
the ratio is larger than 5, the separation configuration is designed as a horizontal separator.
7.1.20 Working Principle of Separator

The following is a list of the operating principle of two-phase separator for vapor liquid
separator often used in oil refineries, natural gas processing , petrochemical and chemical
plants.
• Gravity Separator
• Centrifugal Vapor- liquid Separator
• Vapor -Liquid Filter Separator
In vapor-liquid separators gravity is utilized to cause the
denser fluid (liquid) to settle to the bottom of the vessel where
it is withdrawn, less dense fluid (vapor) is withdrawn from the
top of the vessel. A vapor-liquid separator may operate as a
3-phase separator, with two immiscible liquid phases of
different densities. For example, natural gas (vapor), water
and oil/condensate. The two liquids settle at the bottom of the
vessel with oil floating on the water. Separate liquid outlets
are provided. From the figure, the inlet mixture consists of
benzene, phenol, catechol, benzaldehyde, nitrogen, oxygen,
and benzoic acid at the suitable operation condition which is
at 10 atm and 53°C. The top outlet will withdraw the less
dense material in vapor phase which is nitrogen, oxygen, and
benzene, while the bottom part will withdraw more denser
material in liquid phase that included phenol ,catechol,
benzoic acid, and benzaldehyde . The feed to a vapor–liquid
separator may also be a liquid that is being partially or totally
flashed into a vapor and liquid as it enters the separator.
Figure 7.7: Vertical Separator
152
The main intention of design Flash Drum T- 101 using vertical separator is to separate
the liquid and vapor at the high efficiency. The mixture of the fluid consists of benzene, phenol,
catechol, benzaldehyde, nitrogen, oxygen, and benzoic acid were separate inside the vertical
vessel of separator in the at condition 10 atm and 53°C , the top outlet will withdraw the less
dense material in vapor phase, while the bottom part will withdraw more denser material in
liquid phase. The high efficiency of the design in vertical separator due to the present of
internal baffles or plates that help to enhance the separation process. Baffles are essentially
plates or structures that are installed inside the vertical separator to change the flow pattern
of the mixture and create more turbulence, which helps to separate the different components
based on their densities. The specific type of baffles used in separator will depend on the
specific requirement of the separation process and characteristic of the mixture that being
separated. A mesh pad type of mist separator was used in this vertical separator that function
as to remove liquid droplets from gas streams. Is consists of a mesh pad made up of multiple
layers of knitted wire or mesh that are stacked on top of each other.
Figure 7.8: Mesh pad mist separator
For the material for the design vessel, carbon steel and austenitic stainless steel 316
that be use for the body of the flash drum. Carbon steel is an alloy of iron and carbon, while
austenitic stainless steel is an alloy of iron, chromium, and nickel. When these two metals are
used together in application it is usually done by cladding or overlaying carbon steel with
austenitic stainless steel. This often done to take advantage of the properties of both metals ,
such as the strength and durability of carbon steel and the corrosion resistance of austenitic
stainless steel. Stainless steel 316 contains 16-18% chromium, 10-14% nickel, and 2-3%
molybdenum that have good benefit to use as the material to construct flash drum body such
as corrosion and high temperature resistance (Pasmore.B.J. 2020).
153
7.1.22 HEAT EXCHANGER
A shell and tube heat exchanger is a common type of heat exchanger used in various
industrial applications. It consists of a shell, which is a cylindrical container, and a bundle of
tubes, usually made of metal or plastic, inside the shell. The fluid to be heated or cooled flows
through the tubes, while the fluid providing the heat or absorbing the heat flows around the
tubes in the shell.
The basic operation of a shell and tube heat exchanger is to transfer heat from one
fluid to another. This can be accomplished through either direct contact or indirect contact. In
direct contact heat exchangers, the two fluids come into direct contact with each other and
transfer heat through conduction. In indirect contact heat exchangers, the two fluids do not
come into direct contact but instead transfer heat through a conductive barrier, such as the
tube wall.
The performance of a shell and tube heat exchanger depends on several factors,
including the heat transfer coefficient, the flow rate of both fluids, and the temperature
difference between the two fluids. The heat transfer coefficient is a measure of the efficiency
of the heat transfer process, and it is influenced by factors such as the surface area of the
heat exchanger, the thermal conductivity of the materials, and the fluid properties.
Shell and tube heat exchangers are commonly used in a variety of applications,
including power plants, chemical processing plants, refrigeration systems, and HVAC
systems. They are preferred over other types of heat exchangers because they can handle
high pressures and temperatures, are easy to maintain, and can handle a wide range of fluids.
Figure 7.9: A simplified diagram on how heat exchanger works
154
A heat exchanger is a device that transfers heat from one medium to another. The
working principle of a heat exchanger is based on the fundamental concept of heat transfer.
Heat transfer occurs due to the temperature difference between the two media. The basic
working principle of a heat exchanger involves two fluid circuits - one is the hot fluid and the
other is the cold fluid. The heat transfer occurs when these two fluids come in contact with
each other through the heat exchanger's surface area.
There are two types of heat transfer: conduction and convection. Conduction occurs
when heat is transferred from one molecule to another within a solid or fluid. Convection, on
the other hand, occurs when heat is transferred through the motion of fluid molecules. In a
heat exchanger, heat transfer occurs due to both conduction and convection. The hot fluid
transfers heat to the heat exchanger's surface, which is in contact with the cold fluid. The cold
fluid absorbs the heat and gets heated up, while the hot fluid cools down. As a result, the
temperature of both fluids approaches a common value, and the heat transfer process
continues until the desired temperature is achieved. The heat transfer rate in a heat exchanger
depends on several factors such as the fluid properties, flow rates, heat exchanger design,
and surface area. The heat exchanger's design and construction play a crucial role in
determining the heat transfer rate and efficiency.
In general, heat exchangers can be classified into two types: direct and indirect. In a
direct heat exchanger, the hot and cold fluids come in direct contact with each other, while in
an indirect heat exchanger, a heat transfer surface separates the two fluids. The most common
type of indirect heat exchanger is the shell-and-tube heat exchanger, which consists of a shell
(outer vessel) and tubes (inner vessels). The hot fluid flows through the tubes, while the cold
fluid flows around the tubes, transferring heat through the tube walls.
In summary, the working principle of a heat exchanger involves the transfer of heat
from one medium to another through the heat exchanger's surface area. The heat transfer
occurs due to both conduction and convection, and the heat exchanger's design and
construction play a crucial role in determining the heat transfer rate and efficiency.
155
7.1.25 Types of Heat Exchanger
Heat exchangers are widely used in various industries for efficient heat transfer
between fluids. They can be classified into several types based on their design, construction,
and application. Here are some of the commonly used types of heat exchangers:
1. Shell and Tube Heat Exchanger: This is the most common type of heat exchanger used in
industrial applications. It consists of a cylindrical shell with tubes inside it. The hot fluid flows
through the tubes, and the cold fluid flows around the tubes, transferring heat through the tube
walls. The shell-and-tube heat exchanger is versatile, easy to clean and maintain, and suitable
for handling high pressures and temperatures.
2. Plate Heat Exchanger: This type of heat exchanger consists of a series of thin plates, which
are stacked together with a small gap between them. The hot and cold fluids flow through
alternate channels, transferring heat through the plates. The plate heat exchanger is compact,
lightweight, and offers high heat transfer efficiency due to the large surface area.
3. Double Pipe Heat Exchanger: This is a simple type of heat exchanger consisting of two
concentric pipes. The hot fluid flows through the inner pipe, and the cold fluid flows through
the outer pipe, transferring heat through the pipe walls. The double pipe heat exchanger is
easy to fabricate, and suitable for handling low flow rates and low temperature differentials.
4. Spiral Heat Exchanger: This type of heat exchanger consists of two parallel channels, which
are wound into a spiral shape. The hot and cold fluids flow through alternate channels,
transferring heat through the channel walls. The spiral heat exchanger offers high heat transfer
efficiency, low pressure drops, and is suitable for handling high viscosity fluids.
5. Finned Tube Heat Exchanger: This type of heat exchanger consists of a tube with fins
attached to the outer surface. The hot fluid flows through the tube, while the cold fluid flows
around the fins, transferring heat through the fin surfaces. The finned tube heat exchanger is
suitable for handling high heat transfer rates and is commonly used in air conditioning and
refrigeration systems.
6. Plate-Fin Heat Exchanger: This type of heat exchanger consists of a stack of plates with
fins attached to them. The hot and cold fluids flow through alternate channels, transferring
heat through the plate and fin surfaces. The plate-fin heat exchanger is compact, lightweight,
and suitable for handling high heat transfer rates.
156
7.1.26 Heat Exchanger Component and Material
Heat exchangers are made up of various components, each playing a critical role in
efficient heat transfer between fluids. The primary components of a heat exchanger are:
1. Shell: It is the outermost part of a shell-and-tube heat exchanger and provides a protective
cover to the inner components. The shell is usually made of metal and should be strong
enough to withstand high pressures and temperatures.
2. Tubes: The tubes carry the hot fluid and are responsible for transferring heat to the cold
fluid. The tubes are usually made of metal and should be corrosion-resistant and thermally
conductive. Copper, stainless steel, and titanium are commonly used materials for tubes.
3. Tube sheets: These are the metal sheets that connect the tubes to the shell. The tube
sheets should be strong enough to hold the tubes and provide a tight seal between the tubes
and the shell.
4. Baffles: The baffles are the metal plates that are inserted into the shell to direct the fluid
flow and improve heat transfer efficiency. The baffles should be designed in such a way that
they do not obstruct the flow too much and provide maximum contact between the fluids.
5. Head: The head is the end cover of the shell and is responsible for maintaining the pressure
and providing access for cleaning and maintenance. The head should be designed to
withstand the high pressure and temperature of the fluids.
In addition to the components, the selection of the material is crucial for the efficient
operation of a heat exchanger. The choice of material depends on several factors such as
fluid properties, operating conditions, and cost. Some commonly used materials for heat
exchangers are:
1. Stainless steel: It is a popular choice for heat exchangers due to its high corrosion
resistance, durability, and ease of fabrication. It is suitable for handling a wide range of fluids
and temperatures.
2. Copper: It is a good conductor of heat and has excellent corrosion resistance. It is commonly
used for heat exchangers handling water-based fluids.
3. Titanium: It has excellent corrosion resistance and is suitable for handling corrosive fluids
such as acids and seawater. It is also lightweight and has a high strength-to-weight ratio.
4. Aluminum: It is lightweight, has good thermal conductivity, and is suitable for handling air-
based fluids. However, it is not suitable for handling corrosive fluids.
157
5. Carbon steel: It is a cost-effective option for heat exchangers handling non-corrosive fluids.
However, it is susceptible to corrosion and should be coated or treated to prevent corrosion.

The design intention of a heat exchanger is to transfer heat between two or more fluids
efficiently. The primary objective of a heat exchanger is to maximize the heat transfer rate
while minimizing the pressure drop and energy consumption. The design of a heat exchanger
should ensure that the fluids have maximum surface area contact and are in turbulent flow to
enhance the heat transfer. The geometry, size, and arrangement of the components should
be optimized to achieve the desired heat transfer rate and minimize fouling, corrosion, and
erosion. The selection of materials should consider the fluid properties, operating conditions,
and cost to ensure optimal performance and durability. Overall, the design intention of a heat
exchanger is to provide a cost-effective and reliable solution for efficient heat transfer in
various industrial applications.
158
7.2 DESIGN CALCULATION
7.2.1 Reactor R-101
Figure 7.10: Reaction equations of direct route of phenol from benzene oxidation
Figure 7.10 above show the reaction chemistry and balance chemical equation of direct route
of phenol from benzene. This direct route method from benzene to phenol involves oxidation
process by presence of copper chromium catalyst. This reaction is occurring in flow system of
Reactor R-101.
7.2.2 Operating Condition
Figure 7.11: Operating Condition for Reactor R-101
Figure 7.11 above shown the operating condition of reactor R-101 feed with 351°C
temperature and 4000 kPa pressure at stream 6 for inlet condition for reactant and stream 7
for outlet condition that produce product which is phenol and other by product.
159
7.2.3 Detail Calculation
There are several steps of calculations must be followed based on basic design and theory
before started to be created or design the packed bed reactor. The several steps of
calculations are shown in below Figure 7.12: -
Initial Initial Molar Volumetric Volume of

Concentration, Flow Rate, Flow Rate, Reactor,
𝐶_𝐴0 𝐹_𝐴0 𝑉_0 𝑉_𝑅
Volume of
Height of Diameter Weight of
Catalyst Bed,
Catalyst and Height catalyst,
𝑉_(𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡
Bed of Reactor 𝑊_𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡
𝑏𝑒𝑑)
Head and
Thickness Number of Outside Surface
Closure of
of Reactor Tubes Area of Total Tube
Reactor
General Design Baffle Shell Bundle

Considerations Spacing Diameter Diameter
Figure 7.12: Steps of calculation for Multi-Tubular Packed Bed Reactor (MPBR)
1. Initial Concentration, 𝑪𝑨𝟎

𝑷𝑨𝟎 𝒀𝑨𝟎 𝑷𝟎
𝑪𝑨𝟎 = =
𝑹𝑻𝟎 𝑹𝑻𝟎
By referring to Mass Balance from the Design Project 1
378.6449 𝑘𝑚𝑜𝑙/𝑚𝑖𝑛
𝒀𝑨𝟎 = Mole Fraction = = 0.77
491.1519 𝑘𝑚𝑜𝑙/𝑚𝑖𝑛
𝑷𝟎 = Initial Pressure = 4000 kPa
𝒌𝑷𝒂.𝒅𝒎𝟑
R = Ideal Gas Constant = 8.314
𝒎𝒐𝒍.𝑲
𝑻𝟎 = Initial Temperature = 351° C = 624.15 K
𝑷𝑨𝟎 𝒀𝑨𝟎 𝑷𝟎 0.77 (4000 𝑘𝑃𝑎) 𝒎𝒐𝒍

𝑪𝑨𝟎 = = = 𝑘𝑃𝑎.𝑑𝑚3
= 0.60
𝒅𝒎𝟑
𝑹𝑻𝟎 𝑹𝑻𝟎 8.314 (624.15𝐾)
𝑚𝑜𝑙.𝐾
160
2. Initial Molar Flow Rate, 𝑭𝑨𝟎
By referring to mass balance from the Design Project 1, value taken directly from
mass balance.
𝑘𝑚𝑜𝑙 𝒎𝒐𝒍
𝑭𝑨𝟎 = 378.65 = 6310.83
𝑚𝑖𝑛 𝒔
3. Volumetric Flow Rate, 𝑽𝟎

𝑚𝑜𝑙
𝑭𝑨𝟎 6310.83
𝑠 𝒅𝒎𝟑
𝑽𝟎 = = 𝑚𝑜𝑙 = 10520
𝑪𝑨𝟎 0.60 3 𝒔
𝑑𝑚
4. Volume of Reactor, 𝑽𝑹
𝑽𝑹 = 𝑽𝟎 x τ
𝑽𝟎 = Volumetric Flow Rate
τ = Residence time
Residence Time finding by referring the journal article used from Design Project 1
(Scholarlycommons et al., 2017) and Design Project 1 mass balance
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 (𝑗𝑜𝑢𝑟𝑛𝑎𝑙) 𝑅𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 𝑡𝑖𝑚𝑒 (𝑗𝑜𝑢𝑟𝑛𝑎𝑙)

=
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 (𝑖𝑛𝑙𝑒𝑡 𝑚𝑎𝑠𝑠 𝑏𝑎𝑙𝑎𝑛𝑐𝑒) 𝑅𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 𝑡𝑖𝑚𝑒 (𝑖𝑛𝑙𝑒𝑡 𝑚𝑎𝑠𝑠 𝑏𝑎𝑙𝑎𝑛𝑐𝑒)
29576.35 𝑘𝑔/𝑚𝑖𝑛 1.03 𝑚𝑖𝑛

=
3424.4996 𝑘𝑔/𝑚𝑖𝑛 𝑅𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 𝑡𝑖𝑚𝑒 (𝑖𝑛𝑙𝑒𝑡 𝑚𝑎𝑠𝑠 𝑏𝑎𝑙𝑎𝑛𝑐𝑒)
1.03 𝑚𝑖𝑛
= = 0.12 min = 7.2s
8.64
= τ = Residence time = 7.2s
𝑑𝑚3
𝑽𝑹 = 10520 x 7.2 s = 75744 𝑑𝑚3 = 75.74 𝒎𝟑
𝑠
161
5. Volume of Catalyst Bed, 𝑽𝑪𝒂𝒕𝒂𝒍𝒔𝒚𝒕 𝒃𝒆𝒅
𝑽𝑪𝒂𝒕𝒂𝒍𝒔𝒚𝒕 𝒃𝒆𝒅 = 𝜺 x 𝑽𝑹𝒆𝒂𝒄𝒕𝒐𝒓
𝑽𝒄𝒂𝒕𝒂𝒍𝒔𝒚𝒕 𝒃𝒆𝒅
𝜺=
𝑽𝑹𝒆𝒂𝒄𝒕𝒐𝒓
𝜺 = Porosity of catalyst
By referring the journal article (Scholarlycommons et al., 2017), the porosity of copper
chromium catalyst that been used was 0.42.
𝑽𝑪𝒂𝒕𝒂𝒍𝒔𝒚𝒕 𝒃𝒆𝒅 = 0.42 x 75.74 𝑚3 = 31.83 𝒎𝟑
6. Weight of Catalyst, 𝑾𝑪𝒂𝒕𝒂𝒍𝒔𝒚𝒕

𝑾𝑪𝒂𝒕𝒂𝒍𝒔𝒚𝒕 = 𝑽𝑪𝒂𝒕𝒂𝒍𝒔𝒚𝒕 𝒃𝒆𝒅 x 𝝆𝒄𝒂𝒕𝒂𝒍𝒚𝒔𝒕
𝜌𝐶𝑎𝑡𝑎𝑙𝑠𝑦𝑡 = Density of catalyst
By referring the journal article (Scholarlycommons et al., 2017), the density of copper
𝒌𝒈
chromium catalyst that been used was 641 . All catalyst properties were taken to
𝒎𝟑
be that of bulk alumina with a lifetime of 6 months.
kg
𝑾𝑪𝒂𝒕𝒂𝒍𝒔𝒚𝒕 = 31.83 m3 x 641 = 20390.21 kg
m3
Volume of Catalyst
𝟐 2
𝑽𝑪𝒂𝒕𝒂𝒍𝒔𝒚𝒕 = = = 8.80 x 𝟏𝟎−𝟑 𝐦𝟑
𝟑𝑽𝑹 3(75.74 m3 )
7. Diameter of Reactor
𝝅𝑫𝟐 𝑯
𝑽𝑹 =
𝟒
𝟒𝑽𝑹 4(75.74)
𝑫𝑹 = √ =√ = 5.67 m = 5.87 m (Extended 20% for catalyst bed)
𝟑𝝅 3𝜋
𝑫𝑹 = 5870 mm
8. Height of Reactor
Standard ratio diameter to height is 1:3.
162
𝑯𝑹 = 3𝑫𝑹 = 3 (5.67 m) = 17.21 m (Extended 20% for height catalyst bed)
𝑯𝑹 = 17210 mm
Height of Catalyst Bed
𝑯𝑪𝑩 = 3𝑫𝑹 = 3 (3.67 m) = 11.01 m
𝑯𝑪𝑩 = 11010 mm
9. Thickness of Reactor
Thickness:
𝑷𝒊𝑹𝒊
t= +𝒄
𝟐𝑺𝒆−𝑷𝒊
𝑷𝒊 = Internal Pressure
= 4000 kPa = 4000 N/mm2 x 0.001 N/mm2 = 4 N/mm2
𝑹𝒊 = Internal Radius
𝑫𝑹 5.87𝑚
= = = 2.935 m = 2935 mm
2 2
S = Design Stress
= Material that used for construction of Multi-tubular Packed Bed Reactor for Reactor
R-101 was stainless steel 316 (18cr/8Ni mo 2 ½ percent).
163
Figure 7.13: Design stress for stainless steel 316 in various temperatures refer Coulson
Richardson Book pg. 812 (Sinnott R. K. Coulson J. M. & Richardson J. F., 2005)
Perform the data interpolation:
351°C−350°C
Design stress, s at 351° C = 105 + ( ) (105-105) = 105 N/mm2
400°C−351°C
e = Joint Efficiency
= 1.0 double welded have been chosen for join efficiency used for Multi-tubular
Packed Bed Reactor designation.
Figure 7.14: Joint efficiency chosen by refer Coulson Richardson Book pg. 813
Chapter 13 (Mechanical Design of Process Equipment) (Sinnott R. K. Coulson J. M.
& Richardson J. F., 2005)
164
C = Corrosive Allowance
= 2 mm have been chosen for minimum corrosive allowance used for Multi-tubular
Packed Bed Reactor designation by refer Coulson Richardson Book pg. 813 (Sinnott
R. K. Coulson J. M. & Richardson J. F., 2005).
Thickness of MPBR:
𝑛
4 𝑥 2935 𝑚𝑚
𝑚𝑚2
t= 𝑛 𝑛 + 2 mm = 58.99 mm round off to 59 mm
2(105
𝑚𝑚2
) (1.0)−4𝑚𝑚2
10. Head & Closure of Reactor

Minimum Thickness of Hemisphere Head: -
Refer Coulson Richardson Book (Sinnott R. K. Coulson J. M. & Richardson J. F.,

2005)
𝑷𝒊𝑫𝒊
tm =
𝟒𝑺𝒆−𝟎.𝟒𝑷𝒊
𝑷𝒊 = Internal Pressure
= 4000 kPa = 4000 N/mm2 x 0.001 N/mm2 = 4 N/mm2
𝑫𝒊 = Internal Diameter
= 5870 mm
S = Design Stress = 105 N/mm2
e = Joint Efficiency = 1.0 double welded
𝑁
4 (5870𝑚𝑚)
𝑚𝑚2
tm = 𝑁 𝑁 = 56 mm
4(105 )(1.0)−0.4(4 )
𝑚𝑚2 𝑚𝑚2
Radius of Hemisphere:
𝐷𝑅 5.87𝑚
𝑹𝑯𝒆𝒎𝒊𝒔𝒑𝒉𝒆𝒓𝒆 = = = 2.935 m = 2935 mm
2 2
Volume of Hemisphere:
2 5.87 3
𝑽𝑯𝒆𝒎𝒊𝒔𝒑𝒉𝒆𝒓𝒆 = 𝝅( ) = 52.95 𝒎𝟑
3 2
165
11. Number of Tubes
𝑽𝑹
No. tubes =
𝝅 𝒙 𝒓𝟐 𝒙 𝑯𝑹
Tube radius, 𝒓𝟐 = 0.10 m (Brogan, 2011)
75.74 𝑚3
No. tubes = = 140 tubes
𝜋 𝑥 0.102 𝑚 𝑥 17.21𝑚
12. Outside Surface Area of Total Tube

𝑨𝟎 = 𝝅 x 𝑫𝟎 X No of tube X 𝑯𝑹
Outside tube diameter, 𝑫𝟎 = 0.3 m (Brogan, 2011)
𝑨𝟎 = 𝜋 x 0.3 m X 140 X 17.21 = 2270.81 𝒎𝟐
13. Bundle Diameter, 𝑫𝑩

𝟏
𝑵𝒐 𝒐𝒇 𝑻𝒖𝒃𝒆 𝒏𝟏
𝑫𝑩 = 𝑫𝟎 (
𝑲𝟏
)
Figure 7.15: Constants pitch for K1 and n1 value refer from Gavin Towler & R.K
Sinnot 2005 book (Gavin Towler, R K Sinnott - Chemical Engineering Design
Principles Practice and Economics of Plant and Process Design-Butterworth-
Heinemann (2007), n.d.)
166
By referring to the (Gavin Towler, R K Sinnott - Chemical Engineering Design
Principles Practice and Economics of Plant and Process Design-Butterworth-
Heinemann (2007), n.d.) book, the pitch pattern have been chosen was square pitch
and number of passes = 1 where:-
𝑲𝟏 = 𝟎. 𝟐𝟏𝟓
𝒏𝟏 = 𝟐. 𝟐𝟎𝟕
1
140 2.207
𝑫𝑩 = 0.3 m (
0.215
) = 5.56 m = 5650 mm
14. Shell Diameter, 𝑫𝒔

𝑫𝒔 = 𝑫𝑩 + Clearance
Figure 7.16: Shell-bundle clearance refer from Coulson Richardson Book (Sinnott R. K.
Coulson J. M. & Richardson J. F., 2005)
Clearance value between tubes obtained from the reference book was 6.4 mm.
𝑫𝒔 = 5650 mm + 6.4 mm = 5656 mm
15. Baffle Spacing, 𝑳𝒃

𝑫𝑺 5656 𝑚𝑚
𝑳𝒃 = = = 1131 mm
𝟓 5
16. Baffle Cut

Baffle Cut = (25% x 𝐿𝑏 ) + 𝐿𝑏 = 1413.8 mm
17. Design Consideration
167
I. Design Temperature
The overall temperature increase inside the Multi-tubular Packed Bed Reactor
which is Reactor R-101 and by assuming a permissible temperature fluctuation of
102 °C inside reactor.
II. Nozzle Size

4 nozzles are designed according to each stream flow for Multi-tubular Packed Bed
Reactor. The Inlet and outlet nozzle: -
Inlet Nozzle and Outlet Nozzle = 1000 m
𝐼𝑛𝑙𝑒𝑡 𝑁𝑜𝑧𝑧𝑙𝑒 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟

Standard Specification = ≤ 0.5
𝐼𝑛𝑙𝑒𝑡 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟
1000𝑚𝑚
Nozzle designation follow the standard = = 0.2 which was ≤ 0.5.
5000 𝑚𝑚
168
7.2.4 Distillation Column 1 (T-102)
7.2.5 Details calculation
DESIGN SPECIFICATIONS FOR DISTILLATION COLUMN 1 (T-102)
Figure 7.20: Block Diagram of Distillation Column, T-102
Table 7.1: Properties inlet and outlet stream for distillation column 1
Parameter S12 (Feed) S13 (Distillate) S16 (Bottom)
Temperature (°C) 53 150 198
Pressure (kPa) 1000 68 50
Molar flow (kmol/min) 308.1287 269.4732 38.6555
Mass flow (kg/hr) 24820.1731 20912.2256 3907.9211
169
Table 7.2: Inlet and outlet composition for distillation column 21
S12 (Feed) S13 (Distillate) S16 (Bottom)
Component Mol fraction Mol fraction Mol fraction

Phenol, C6H5OH 0.14 0.01 0.60
Benzene, C6H6 0.86 0.99 0.40
DETAILS OF CALCULATIONS STEP BY STEP
1) CALCULATION FOR MCCABE-THIELE METHOD
By using the compositions at feed. Feed is at saturated liquid condition; therefore,

according to q line equation q value should be 1.
q=1; saturated liquid

𝒑𝒐𝑨
Relative volatility, 𝜶𝑨𝑩 =
𝒑𝒐𝑩
730 𝑘𝑃𝑎
= (Ratio of mol fraction)
270 𝑘𝑃𝑎
= 2.701 ≈ 2.7
DATA FOR MCCABE-THIELE
𝑥𝐴 0 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.0
𝑦𝐴 0 0.23 0.40 0.53 0.64 0.73 0.80 0.86 0.91 0.96 1.0
Table 7.3: Data for McCabe-Thiele
Substitute the value of 𝑥𝐴 in the equation below and find the value of 𝑦𝐴 ;
𝜶𝑨𝑩 𝑿𝑨
𝒚𝑨 =
𝟏+(𝜶𝑨𝑩 −𝟏)𝑿𝑨
170
For value xA = 0 , For value xA = 0.60 ,
(2.1)(0)
yA =
1+(2.1−1)(0) (2.7)(0.60)
yA = = 0.80
1+(2.7−1)(0.60)
𝐲𝐀 = 0
𝐲𝐀 ≈ 0.76 = 0.80
For value xA = 0.10 ,
(2.7)(0.10)
yA =
1+(2.7−1)(0.10) (2.7)(0.70)
yA = = 0.86
1+(2.7−1)(0.70)
𝐲𝐀 ≈ 0.23
𝐲𝐀 ≈ 0.83
For value xA = 0.20 , For value xA = 0.80 ,
(2.7)(0.20)
yA = (2.7)(0.80)
1+(2.7−1)(0.20) yA = = 0.91
1+(2.7−1)(0.80)
𝐲𝐀 ≈ 0.40
𝐲𝐀 ≈ 0.89 = 0.90

(2.7)(0.30)
yA =
1+(2.7−1)(0.30) (2.7)(0.90)
yA = = 0.96
1+(2.7−1)(0.90)
𝐲𝐀 = 0.53
𝐲𝐀 ≈ 0.95
(2.7)(0.40)
yA =
1+(2.7−1)(0.40) (2.7)(1.0)
yA = = 1.0
1+(2.7−1)(1.0)
𝐲𝐀 = 0.64
𝐲𝐀 ≈ 1.0
(2.7)(0.50)
yA =
1+(2.7−1)(0.50)
𝐲𝐀 = 0.73
171
CALCULATION FOR Rmin and ROL
𝑅𝑚𝑖𝑛 = 𝑿𝑫 – 𝒀∗
𝒀∗ − 𝑿∗
𝑅𝑚𝑖𝑛 0.99−0.90
= 0.90−0.86
𝑅𝑚𝑖𝑛 = 𝟐. 𝟐𝟓
𝟏
𝑅𝑂𝐿 = 𝑿𝑫𝑨
𝑹𝒎𝒊𝒏 +𝟏
1
𝑅𝑂𝐿 = 2.25+1 (0.99)
𝑅𝑂𝐿 = 0.30
172
2) VAPOR-LIQUID EQUILIBRIUM CURVE GRAPH
Figure 7.21: Graph McCabe-Thiele
173
3) CALCULATION OF OPERATING REFLUX RATIO
Optimum will lie in range between 1.2 to 1.5 times the minimum reflux ratios. Assume
operating reflux ratio is 1.4 of minimum reflux ratio. Therefore, operating reflux ratio (R);
R = 1.4 × Rmin
R = 1.4 × 2.25
R = 3.15
4) CALCULATION OF RECTIFYING SECTION
𝑳𝟎
R =
𝑫
𝐿0
3.15 = 𝑘𝑔
20912.2256
ℎ𝑟
𝒌𝒈
𝑳𝟎 = 65873.51064
𝒉𝒓
According to constant molar overflow:

𝑘𝑔
𝐿𝑛 = 𝐿0 = 65873.51064
ℎ𝑟
𝑽𝒏 = 𝑳 𝟎 + 𝐷 Figure 7.22: Feeding Section

𝑘𝑔
𝑉𝑛 = (65873.51064 + 20912.2256)
ℎ𝑟
𝒌𝒈
𝑽𝒏 = 86785.736
𝒉𝒓
5) CALCULATION OF STRIPPING SECTION
According to the given data, feed is at saturated liquid condition therefore all feeding
liquids join with stripping section liquid.
𝐿𝑚 = 𝐹 + 𝐿n
𝑘𝑔
𝐿𝑚 = (24820.1731+65873.51064)
ℎ𝑟
𝒌𝒈
𝐿𝑚 = 90693.684
𝒉𝒓
𝑉𝑚 = 𝑉𝑛
𝒌𝒈
𝑉𝑚 = 86785.736
𝒉𝒓
174
6) CALCULATION OF LIQUID AND VAPOR DENSITY
The value of liquid and vapor density was calculated using HYSYS. The value obtained
from the journal.
(References: Direct Route Benzene, 2017)
𝒌𝒈 TOP BOTTOM
DENSITY ( )
𝒎𝟑
VAPOR,𝝆𝑽 4.19 4.09
LIQUID,𝝆𝑳 1068.06 905.1
7) CALCULATION OF DIAMETER ON RECTIFYING SECTION
The column diameter is calculated to avoid flooding, which occurs when liquid begins to
fill the column and exits as vapor due to inability to flow downward at the needed rate
(Seader, 2004). The vapor flow rate is the most important element in deciding column
diameter.
𝑳 𝝆𝑽
𝑭𝑳𝑽 = √𝝆
𝑽 𝑳
𝑳𝟎 𝝆𝑽
𝑽𝒎 𝑳
Where,
L = L0 = liquid mass flowrate, kg/hr
V = Vm = vapor mass flowrate, kg/ hr
𝟔𝟓𝟖𝟕𝟑.𝟓𝟏𝟎𝟔𝟒 𝟒.𝟏𝟗
𝑭𝑳𝑽 = √ = 0.048
𝟖𝟔𝟕𝟖𝟓.𝟕𝟑𝟔 𝟏𝟎𝟔𝟖.𝟎𝟔
Assume tray spacing = 0.5 m, 𝐹𝐿𝑉 = 0.03
According to Figure 7.23, K1 = 0.08 m
The flooding velocity can be estimated from the correlation given by fair,
175
Figure 7.23: Flooding velocity, sieve plates
0.08 m
0.03 m
𝝆𝑳 −𝝆𝑽
𝑼𝒇 = K1√
𝝆𝑽
Where,
Uf = flooding vapour velocity, m/s, based on the net column cross-sectional area, An
K1= a constant
𝟏𝟎𝟔𝟖.𝟎𝟔−𝟒.𝟏𝟗
𝑼𝒇 = 0.08 √ = 1.274 m/s
𝟒.𝟏𝟗
Assume 85% flooding condition,

𝐦 𝐦
𝑼𝒂 = 𝟎. 𝟖𝟓𝑼𝒇 = (𝟎. 𝟖𝟓) (𝟏. 𝟐𝟕𝟒 ) = 𝟏. 𝟎𝟖𝟐𝟗
𝐬 𝐬
𝟖𝟔𝟕𝟖𝟓.𝟕𝟑𝟔 𝒎𝟑
𝑉𝑛 = = 𝟐𝟒
𝟑𝟔𝟎𝟎 𝒔
𝑉𝑛 = 𝑼𝒂 𝑨𝒏
𝐕𝐧 𝟐𝟒
𝐀𝐧 = = = 𝟐𝟐 𝐦𝟐
𝐔𝐚 𝟏.𝟎𝟖𝟐𝟗
Assume 𝐴𝑑 = 12 % of 𝐴𝑐 ,
𝐴𝑛 = 𝐴𝑐 - 0.12 𝐴𝑐
𝑨𝒏 = 𝟎. 𝟖𝟖 𝑨𝒄
176
Therefore, according to above derived equation,
𝑨𝒏 = 𝟎. 𝟖𝟖 𝑨𝒄
𝑨𝒏 𝟐𝟐 𝒎𝟐
𝑨𝒄 = = = 𝟐𝟓 𝒎𝟐
𝟎.𝟖𝟖 𝟎.𝟖𝟖
𝝅𝑫𝟐𝑪
𝑨𝒄 =
𝟒
𝟒𝑨𝒄 (𝟒)(𝟐𝟓)𝒎𝟐
𝑫𝒄 = √ =√
𝝅 𝝅
𝑫𝒄 = 𝟓. 𝟔𝟒 𝒎 (Column diameter for rectifying section)
8) CALCULATION OF DIAMETER ON STRIPPING SECTION
𝑳 𝝆𝑽
𝑽 𝑳
𝑳𝟎 𝝆𝑽
𝑽𝒎 𝑳
Where,
𝟔𝟓𝟖𝟕𝟑.𝟓𝟏𝟎𝟔𝟒 𝟒.𝟎𝟗
𝑭𝑳𝑽 = √ = 0.05
𝟖𝟔𝟕𝟖𝟓.𝟕𝟑𝟔 𝟗𝟎𝟓.𝟏
0.08 m 0.5 m
Figure 7.24: Flooding

0.03 velocity, sieve plates
177
𝑼𝒇 = K1√
𝝆𝑽
Where,
K1= a constant
𝟗𝟎𝟓.𝟏−𝟒.𝟎𝟗
𝑼𝒇 = 0.08 √ = 1.187 m/s
𝟒.𝟎𝟗
𝒎 𝒎
𝑼𝒂 = 𝟎. 𝟖𝟓𝑼𝒇 = (𝟎. 𝟖𝟓) (𝟏. 𝟏𝟖𝟕 )=𝟏
𝒔 𝒔
Hence, there is no vapor amount changes in stripping section compare to the rectifying
section.
𝟖𝟔𝟕𝟖𝟓.𝟕𝟑𝟔 𝒎𝟑
𝑉𝑛 = = 𝟐𝟒
𝟑𝟔𝟎𝟎 𝒔
𝐕𝐧 𝟐𝟒
𝑨𝒏 = = = 𝟐𝟒 𝒎𝟐
𝑼𝒂 𝟏
𝑨𝒏 = 𝑨𝒄 - 0.12 𝑨𝒄
𝑨𝒏 = 𝟎. 𝟖𝟖 𝑨𝒄

𝑨𝒏 = 𝟎. 𝟖𝟖 𝑨𝒄
𝑨𝒏 𝟐𝟒 𝒎𝟐
𝑨𝒄 = = = 𝟐𝟕. 𝟑𝒎𝟐
𝟎.𝟖𝟖 𝟎.𝟖𝟖
𝝅𝑫𝟐𝑪
𝑨𝒄 =
𝟒
𝟒𝑨𝒄 (𝟒)(𝟐𝟕.𝟑)𝒎𝟐
𝑫𝒄 = √ =√
𝝅 𝝅
𝑫𝒄 = 𝟓. 𝟗𝟎 𝒎 (Column diameter for stripping section)
To conclude, the diameter rectifying and stripping section are quite the same. Hence, we
178
chose the rectifying section because we focus on the product separation at the top which
is benzene.
9) CALCULATION OF HOLE DIAMETER AND AREA
Holes size less than 6.5 mm. Entrainment may be greater with larger hole sizes. (Page
No. 568 Coulson & Richardson 6th volume 4th edition)
Therefore, the holes diameter is considered 6 mm.
10) NUMBER OF HOLES IN A TRAY AT RECTIFYING SECTION
For a plate there is one down comer on the plate and top-down comer also affected to
bottom plate. Therefore, two down comer areas need to be reduced from active areas. So,
𝑨𝒂 = 𝑨𝒄 - 2 𝑨𝒅
𝐴𝑎 = 𝐴𝑐 - 2(0.12)(𝐴𝑐 )
𝐴𝑎 = (25 𝑚 − 2 (0.12)(25))
𝑨𝒂 = 𝟏𝟗 𝒎𝟐
Assume holes area is 10 % of active area,
𝑨𝒉 = 𝟎. 𝟏 𝑨𝒂
Total holes area in a tray,

𝑨𝒉 = 𝟎. 𝟏(𝟏𝟗)𝒎𝟐
𝑨𝒉 = 𝟏. 𝟗 𝒎𝟐
𝑨𝟐𝒉 𝟏.𝟗𝟐
Area of a hole, A = 𝝅 =𝝅 = 𝟎. 𝟗𝟎𝟐𝟓𝒎𝟐
𝟒 𝟒
𝑨𝒉
Number of holes in a plate, n =
𝑨
1.9 𝑚2
n=
0.9025 𝑚2
n ≈ 17.86 = 18 holes
179
11) NUMBER OF HOLES IN A TRAY AT STRIPPING SECTION
𝐴𝑎 = 𝐴𝑐 - 2(0.12)(𝐴𝑐 )
𝐴𝑎 = (27.3 𝑚 − 2 (0.12)(27.3))
𝑨𝒂 = 𝟐𝟎. 𝟖 𝒎𝟐
𝑨𝒉 = 𝟎. 𝟏 𝑨𝒂

𝑨𝒉 = 𝟎. 𝟏(𝟐𝟎. 𝟖)𝒎𝟐
𝑨𝒉 = 𝟐. 𝟎𝟖 𝒎𝟐
𝑨𝟐𝒉 𝟐.𝟎𝟖𝟐
Area of a hole, A = 𝝅 =𝝅 = 𝟏. 𝟎𝟖 𝒎𝟐
𝟒 𝟒
𝑨𝒉
𝑨
2.08 𝑚2
n=
1.08 𝑚2
n ≈ 15.66 = 16 holes
12) CALCULATION HEIGHT OF COLUMN
Tray stack = No. of tray x tray spacing
Tray spacing = 0.5 m

No. of tray = 6
Tray stack = 6 x 0.5 m = 3 m (Height of column)
180
7.2.6 General Consideration
1. DESIGN PRESSURE
A vessel must be constructed to withstand the highest pressure that it is anticipated to

encounter during operation. The design pressure is typically considered as the
pressure at which the relief mechanism is fixed for vessels under internal pressure.
This is typically 5 - 10% higher than the standard working gauge pressure to prevent
spurious operation during small process disruptions.
(References: Chemical Engineering, Coulson & Richardson's, 4th Edition) Operating

pressure: 62 kPa
Design pressure, take as 10% above operating gauge pressure.
= (1000 − 100) 𝑘𝑃𝑎 × 1.1
= 990 𝑘𝑃𝑎
2. DESIGN TEMPERATURE
Since the metal strength decreases with increasing temperature, the maximum
allowable stress is temperature dependent. The design temperature at which the
design stress is assessed should be considered the maximum working temperature of
the material, taking into account any error in forecasting the vessel wall temperature.
(References: Chemical Engineering, Coulson & Richardson's, 4th Edition)
𝐷𝑒𝑠𝑖𝑔𝑛 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = 𝑇ℎ𝑖𝑔ℎ𝑒𝑠𝑡 𝑡𝑒𝑚𝑝 𝑜𝑓 𝑏𝑜𝑑𝑦 + 10℃
= 53℃ + 10℃
= 63℃
181
3. MATERIAL OF CONSTRUCTION
Figure 7.25: Typical maximum allowable stresses for plate under ASME BPV
(Table 13.2, Chemical Engineering, Coulson & Richardson’s, 4th Edition)
Material of construction = Carbon steel

𝑁
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑎𝑡 63℃ = 125 @ 125000 kPa
𝑚𝑚2
𝑁 𝑁
Tensile strength = 45 ksi x (6.8948 / 1ksi) = 310.266 @ 310266kPa
𝑚𝑚2 𝑚𝑚2
Corrosion allowance = 2 mm
By referring to Table 13.3 (Chemical Engineering, Coulson & Richardson’s, 4th

Edition), assume degree of radiography is 100% and type of joint is double welded
but where welded joint efficiency, J = 1
4. SHELL TUBE THICKNESS

𝑃𝑅
𝑇𝑢𝑏𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠, t s = +𝐶
𝑓1−0.6𝑃
P= Design pressure
R= Internal radius (Based on previous calculation the diameter was 1550mm, so the
radius is 775 mm)
f = maximum allowable stress of the material construction
J = Join efficiency
C = Corrosion allowance
(990 𝑘𝑃𝑎)(775 𝑚𝑚)

𝑇𝑢𝑏𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠, t s = + 2mm
(125000 𝑘𝑃𝑎)(1)−(0.6)(990 𝑘𝑃𝑎)
𝑇𝑢𝑏𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠, 𝑡𝑠 = 8.17 𝑚𝑚
182
The wall thickness is less than the minimum wall thickness. Take the minimum wall
thicknessfor vessel diameter between 1-2 m. Thus, the minimum wall thickness is 7
mm including corrosion allowance.
5. HEAD AND CLOSURE THICKNESS
Ellipsoidal
Where,
Pi = internal pressure
Di = internal diameter
S = Maximum allowable stress
E = Joint efficiency
C = corrosion allowance
𝐏𝐢 𝐃𝐢
Ellipsoidal thickness, t = +𝒄
𝟐𝑺𝑬−𝟎.𝟐 𝑷𝒊
(990 𝑘𝑃𝑎) 1550 𝑚𝑚

Ellipsoidal thickness, t = + 2 𝑚𝑚 = 7.143 mm
2(125000)𝑘𝑃𝑎−0.2 (990 𝑘𝑃𝑎)
thickness for vessel diameter between 1-2 m. Thus, the minimum wall thickness is 7
183
Mass flow (kg/hr) 3907.9211 1817.7498 2090.1713
184
Phenol, C6H5OH 0.59 0.99 0.13
Catechol, C6H4(OH)2 0.41 0.01 0.87
1. CALCULATION FOR MCCABE-THIELE METHOD
By using the compositions at the feed. Feed is at saturated liquid condition; therefore,
according to the q line equation, q value should be 1.

𝒑𝒐𝑨
𝒑𝒐𝑩
360 𝑘𝑃𝑎
=
171 𝑘𝑃𝑎
= 𝟐. 𝟏
Another method to get the value of relative volatility, 𝛼𝐴𝐵 ;
𝒀𝑨
𝑿𝑨
Relative volatility, 𝜶𝑨𝑩 = (𝟏−𝒀𝑨 )
(𝟏−𝑿𝑨 )
0.59
0.41
Relative volatility, 𝛼𝐴𝐵 = (1−0.59)
(1−0.41)
Relative volatility, 𝜶𝑨𝑩 = 𝟐. 𝟏
𝑥𝐴 0 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.0
𝑦𝐴 0 0.20 0.34 0.50 0.60 0.70 0.80 0.83 0.90 0.95 1.0
185
𝒚𝑨 =

(2.1)(0)
yA =
1+(2.1−1)(0) (2.1)(0.60)
yA =
1+(2.1−1)(0.60)
𝐲𝐀 = 0
𝐲𝐀 ≈ 0.76 = 0.80
(2.1)(0.10)
yA = For value xA = 0.70 ,
1+(2.1−1)(0.10)
𝐲𝐀 ≈ 0.20 (2.1)(0.70)
yA =
1+(2.1−1)(0.70)
For value xA = 0.20 , 𝐲𝐀 ≈ 0.83

(2.1)(0.20)
yA =
1+(2.1−1)(0.20)
𝐲𝐀 ≈ 0.34 For value xA = 0.80 ,
(2.1)(0.80)
yA =
For value xA = 0.30 , 1+(2.1−1)(0.80)
(2.1)(0.30)
yA = 𝐲𝐀 ≈ 0.89 = 0.90
1+(2.1−1)(0.30)
𝐲𝐀 ≈ 0.47 = 0.50
(2.1)(0.90)
(2.1)(0.40) yA =
yA = 1+(2.1−1)(0.90)
1+(2.1−1)(0.40)
𝐲𝐀 ≈ 0.58 = 0.60 𝐲𝐀 ≈ 0.95

(2.1)(0.50)
yA = (2.1)(1.0)
1+(2.1−1)(0.50)
yA =
1+(2.1−1)(1.0)
𝐲𝐀 ≈ 0.68 = 0.70
𝐲𝐀 ≈ 1.0
186
𝒀∗ − 𝑿∗
𝑅𝑚𝑖𝑛 0.99−0.80
=
0.80−0.59
𝑅𝑚𝑖𝑛 = 𝟎. 𝟗𝟎𝟒𝟖
𝟏
1
𝑅𝑂𝐿 = (0.99)
0.9048+1
𝑅𝑂𝐿 ≈ 0.5197
𝑅𝑂𝐿 = 0.52
187
2. VAPOR-LIQUID EQUILIBRIUM CURVE GRAPH
188
3. CALCULATION OF OPERATING REFLUX RATIO
R = 1.4 × Rmin
R = 1.4 × 0.9048
R = 1.27
4. CALCULATION OF RECTIFYING SECTION
𝑳𝟎
R =
𝑫
𝐿0
1.27 = 𝑘𝑔
1817.7498
ℎ𝑟
𝒌𝒈
𝑳𝟎 = 2308.5422
𝒉𝒓
According to constant molar overflow;

𝑘𝑔
𝐿𝑛 = 𝐿0 = 2308.5422
ℎ𝑟
𝑽𝒏 = 𝑳 𝟎 + 𝐷
𝑘𝑔 Figure 7.28: Feeding Section
𝑉𝑛 = (2308.5422 + 1817.7498)
ℎ𝑟
𝒌𝒈
𝑽𝒏 = 4126.292
𝒉𝒓
5. CALCULATION OF STRIPPING SECTION
𝑘𝑔
𝐿𝑚 = (3907.9211 +2308.5422)
ℎ𝑟
𝒌𝒈
𝐿𝑚 = 6216.4633
𝒉𝒓
𝑉𝑚 = 𝑉𝑛
𝒌𝒈
𝑉𝑚 = 4126.292
𝒉𝒓
189
6. CALCULATION OF LIQUID AND VAPOR DENSITY
from the journal.
𝒌𝒈 TOP BOTTOM
DENSITY ( )
𝒎𝟑
VAPOR,𝝆𝑽 4.21 4.91
LIQUID,𝝆𝑳 1072.7 1337.3
7. CALCULATION OF DIAMETER ON STRIPPING SECTION
diameter.
𝑳 𝝆𝑽
𝑽 𝑳
𝑳𝟎 𝝆𝑽
𝑽𝒎 𝑳
Where,
𝟐𝟑𝟎𝟖.𝟓𝟒𝟐𝟐 𝟒.𝟐𝟏
𝑭𝑳𝑽 = √ = 0.0350
𝟒𝟏𝟐𝟔.𝟐𝟗𝟐 𝟏𝟎𝟕𝟐.𝟕
190
0.09 m
0.5 m
0.04
𝑼𝒇 = K1√
𝝆𝑽
Where,
K1= a constant
𝟏𝟎𝟕𝟐.𝟕−𝟒.𝟐𝟏
𝑼𝒇 = 0.09 √ = 1.4338 m/s
𝟒.𝟐𝟏

𝐦 𝐦
𝑼𝒂 = 𝟎. 𝟖𝟓𝑼𝒇 = (𝟎. 𝟖𝟓) (𝟏. 𝟒𝟑𝟑𝟖 ) = 𝟏. 𝟐𝟏𝟖𝟕
𝐬 𝐬
𝟒𝟏𝟐𝟔.𝟐𝟗𝟐 𝒎𝟑
𝑉𝑛 = = 𝟏. 𝟏𝟒𝟔𝟐
𝟑𝟔𝟎𝟎 𝒔
𝐕𝐧 𝟏.𝟏𝟒𝟔𝟐
𝐀𝐧 = = = 𝟎. 𝟗𝟒 𝐦𝟐
𝐔𝐚 𝟏.𝟐𝟏𝟖𝟕
191
𝐴𝑛 = 𝐴𝑐 - 0.12 𝐴𝑐
𝑨𝒏 = 𝟎. 𝟖𝟖 𝑨𝒄
𝐴𝑛 = 0.88 𝐴𝑐
𝐀𝐧 𝟎.𝟗𝟒 𝐦𝟐
𝐀𝐜 = = = 𝟏. 𝟎𝟕𝐦𝟐
𝟎.𝟖𝟖 𝟎.𝟖𝟖
𝝅𝑫𝟐𝑪
𝑨𝒄 =
𝟒
𝟒𝑨𝒄 (𝟒)(𝟏.𝟎𝟕)𝒎𝟐
𝑫𝒄 = √ =√
𝝅 𝝅
𝑫𝒄 = 𝟏. 𝟓𝟓 𝒎 (Column diameter for rectifying section)
𝑳 𝝆𝑽
𝑽 𝑳
𝑳𝟎 𝝆𝑽
𝑽𝒎 𝑳
Where,
2308.5422 4.91
𝑭𝑳𝑽 = √ = 0.03
4126.292 1337.3
0.08 m 0.5 m
0.03
192
𝑼𝒇 = K1√
𝝆𝑽
Where,
K1= a constant
𝟏𝟑𝟑𝟕.𝟑−𝟒.𝟗𝟏
𝑼𝒇 = 0.08 √ = 1.318 m/s
𝟒.𝟗𝟏

𝐦 𝐦
𝑼𝒂 = 𝟎. 𝟖𝟓𝑼𝒇 = (𝟎. 𝟖𝟓) (𝟏. 𝟑𝟏𝟖 ) = 𝟏. 𝟏𝟐𝟎𝟑
𝐬 𝐬
Hence, there are no vapor amount changes in stripping section compared to the rectifying
section.
𝟒𝟏𝟐𝟔.𝟐𝟗𝟐 𝐦𝟑
𝑉𝑛 = = 𝟏. 𝟏𝟒𝟔𝟐
𝟑𝟔𝟎𝟎 𝐬
𝑉𝑛 = 𝐔𝐚 𝐀𝐧
𝐕𝐧 𝟏.𝟏𝟒𝟔𝟐
𝐀𝐧 = = = 𝟏. 𝟎𝟐𝟑𝟏 𝐦𝟐
𝐔𝐚 𝟏.𝟏𝟐𝟎𝟑
𝐴𝑛 = 𝐴𝑐 - 0.12 𝐴𝑐
𝑨𝒏 = 𝟎. 𝟖𝟖 𝑨𝒄

𝐴𝑛 = 0.88 𝐴𝑐
𝐀𝐧 𝟏.𝟎𝟐𝟑𝟏 𝐦𝟐
𝐀𝐜 = = = 𝟏. 𝟏𝟔𝟐𝟔𝐦𝟐
𝟎.𝟖𝟖 𝟎.𝟖𝟖
𝛑𝐃𝟐𝐂
𝐀𝐜 =
𝟒
𝟒𝑨𝒄 (𝟒)(𝟏.𝟏𝟔𝟐𝟔)𝒎𝟐
𝑫𝒄 = √ =√
𝝅 𝝅
𝑫𝒄 = 𝟏. 𝟓𝟎 𝒎 (Column diameter for stripping section)
193
To conclude, the diameter rectifying and stripping sections are pretty much the same.
Hence, we choose the rectifying section because we focus on the product separation at
the top, phenol.
9. CALCULATION OF HOLE DIAMETER AND AREA
Therefore, the diameter of the hole is considered 6 mm.
10. NUMBER OF HOLES IN A TRAY AT RECTIFYING SECTION
For a plate, there is one down comer on the plate and top-down comer also affected to
𝐴𝑎 = 𝐴𝑐 - 2(0.12)(𝐴𝑐 )
𝐴𝑎 = (1.07 𝑚 − 2 (0.12)(1.1626))
𝑨𝒂 = 𝟎. 𝟕𝟗𝟏𝟎 𝒎𝟐
𝑨𝒉 = 𝟎. 𝟏 𝑨𝒂

𝑨𝒉 = 𝟎. 𝟏(𝟎. 𝟕𝟗𝟏𝟎)𝒎𝟐
𝑨𝒉 = 𝟎. 𝟎𝟕𝟗𝟏𝒎𝟐
𝑨𝟐𝒉 𝟎.𝟎𝟕𝟗𝟏𝟐
Area of a hole, A = 𝝅 =𝝅 = 𝟎. 𝟎𝟎𝟓𝒎𝟐
𝟒 𝟒
𝑨𝒉
𝑨
0.0791 𝑚2
n=
0.005 𝑚2
194
n ≈ 16.14 = 16 holes
11. NUMBER OF HOLES IN A TRAY AT STRIPPING SECTION
𝐴𝑎 = 𝐴𝑐 - 2(0.12)(𝐴𝑐 )
𝐴𝑎 = (1.1626 𝑚 − 2 (0.12)(1.1626))
𝑨𝒂 = 𝟎. 𝟖𝟖𝟑𝟔 𝒎𝟐
𝑨𝒉 = 𝟎. 𝟏 𝑨𝒂

𝑨𝒉 = 𝟎. 𝟏(𝟎. 𝟖𝟖𝟑𝟔 )𝒎𝟐
𝑨𝒉 = 𝟎. 𝟎𝟖𝟖𝟒𝒎𝟐
𝑨𝟐𝒉 𝟎.𝟎𝟖𝟖𝟒𝟐
Area of a hole, A = 𝝅 =𝝅 = 𝟎. 𝟎𝟎𝟔𝟏𝒎𝟐
𝟒 𝟒
𝑨𝒉
𝑨
0.0884 𝑚2
n=
0.0061 𝑚2
n ≈14.5 = 15 holes
12. CALCULATION HEIGHT OF COLUMN
No. of tray = 15
195
Tray stack = 15 x 0.5 m = 7.5 m (Height of column)
1. DESIGN PRESSURE


pressure: 62 kPa
= (62 − 100) 𝑘𝑃𝑎 × 1.1
= 41.8 𝑘𝑃𝑎
the material, taking into account any error in forecasting the vessel wall temperature.
= 198℃ + 10℃
= 208℃
196
(Sources: Table 13.2, Chemical Engineering, Coulson & Richardson's, 4th Edition)
𝑁
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑎𝑡 208℃ = 103.4 𝑚𝑚 2 @ 103400 kPa
𝑁 𝑁
Tensile strength = 45 ksi x (6.8948 𝑚𝑚2
/ 1ksi) = 310.266 𝑚𝑚2
@ 310266kPa
By referring to Table 13.3 (Chemical Engineering, Coulson & Richardson's, 4th
Edition), assume degree of radiography is 100% and type of joint is double welded but
where welded joint efficiency, J = 1.

𝑃𝑅
𝑓1−0.6𝑃
P= Design pressure
radius is 775 mm)
J = Join efficiency
(41.8𝑘𝑃𝑎)(775 𝑚𝑚)
(103400 𝑘𝑃𝑎)(1)−(0.6)(41.8𝑘𝑃𝑎)
197
𝑇𝑢𝑏𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠, 𝑡𝑠 = 2.31𝑚𝑚
Ellipsoidal
Where,
𝐏𝐢 𝐃𝐢
Ellipsoidal thickness, t = 𝟐𝑺𝑬−𝟎.𝟐 𝑷𝒊
+𝒄
(41.8 kPa) 1550 mm

Ellipsoidal thickness, t = 2(103400)𝑘𝑃𝑎−0.2 (41.8 kPa) + 2 𝑚𝑚 = 2.31 mm
198
Mass flow (kg/hr) 1799.7938 1739.1057 60.688
199
Phenol, C6H5OH 0.78 0.99 0.15
Benzene, C6H6 0.22 0.01 0.85
1. CALCULATION FOR MCCABE-THIELE METHOD
By using the compositions at the feed. Feed is at saturated liquid condition; therefore,
according to the q line equation, q value should be 1.

𝒑𝒐𝑨
𝒑𝒐𝑩
452 𝑘𝑃𝑎
=
172 𝑘𝑃𝑎
= 𝟐. 𝟔
𝑥𝐴 0 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.0
𝑦𝐴 0 0.22 0.39 0.53 0.63 0.72 0.80 0.86 0.91 0.96 1.0
200
𝒚𝑨 =

(2.6)(0)
yA = (2.6)(0.60)
1+(2.6−1)(0) yA =
1+(2.6−1)(0.60)
𝐲𝐀 = 0
𝐲𝐀 = 0.80

(2.6)(0.10)
1+(2.6−1)(0.10)
𝐲𝐀 ≈ 0.22 (2.6)(0.70)
yA =
1+(2.6−1)(0.70)
For value xA = 0.20 , 𝐲𝐀 ≈ 0.86

(2.6)(0.20)
yA =
1+(2.6−1)(0.20)
𝐲𝐀 ≈ 0.39
(2.6)(0.80)
For value xA = 0.30 , yA =
1+(2.6−1)(0.80)
(2.6)(0.30)
yA =
1+(2.6−1)(0.30)
𝐲𝐀 = 0.91
𝐲𝐀 = 0.53

(2.6)(0.40)
yA = (2.6)(0.90)
1+(2.6−1)(0.40) yA =
1+(2.6−1)(0.90)
𝐲𝐀 = 0.63
𝐲𝐀 ≈ 0.96
(2.6)(0.50)
1+(2.6−1)(0.50)
𝐲𝐀 = 0.72 (2.6)(1.0)
yA =
1+(2.6−1)(1.0)
𝐲𝐀 ≈ 1.0
201
𝒀∗ − 𝑿∗
𝑅𝑚𝑖𝑛 0.99−0.90
=
0.90−0.78
𝑅𝑚𝑖𝑛 = 𝟎. 𝟕𝟓
𝟏
1
𝑅𝑂𝐿 = (0.99)
0.75+1
𝑅𝑂𝐿 = 0.56
202
2. VAPOR-LIQUID EQUILIBRIUM CURVE GRAPH
203
3. CALCULATION OF OPERATING REFLUX RATIO
R = 1.4 × Rmin
R = 1.4 × 0.75
R = 1.05
4. CALCULATION OF RECTIFYING SECTION
𝑳𝟎
R =
𝑫
𝐿0
1.05 = 𝑘𝑔
1739.1057
ℎ𝑟
𝒌𝒈
𝑳𝟎 = 1826.0610
𝒉𝒓
According to constant molar overflow;

𝑘𝑔
𝐿𝑛 = 𝐿0 = 1826.0610
ℎ𝑟
𝑽𝒏 = 𝑳 𝟎 + 𝐷
𝑘𝑔 Figure 7.35.: Feeding Section
𝑉𝑛 = (1826.0610 + 1739.1057)
ℎ𝑟
𝒌𝒈
𝑽𝒏 = 3565.1667
𝒉𝒓
5. CALCULATION OF STRIPPING SECTION
𝑘𝑔
𝐿𝑚 = (1799.7938 +1826.0610)
ℎ𝑟
𝒌𝒈
𝐿𝑚 = 3625.85
𝒉𝒓
𝑉𝑚 = 𝑉𝑛
𝒌𝒈
𝑉𝑚 = 3565.1667
𝒉𝒓
204
6. CALCULATION OF LIQUID AND VAPOR DENSITY
from the journal.
𝒌𝒈 Top Bottom
Density ( )
𝒎𝟑
Vapor,𝝆𝑽 4.19 4.09
Liquid,𝝆𝑳 1068.06 905.1
diameter.
𝑳 𝝆𝑽
𝑽 𝑳
𝑳𝟎 𝝆𝑽
𝑽𝒎 𝑳
Where,
𝟏𝟖𝟐𝟔.𝟎𝟔𝟏𝟎 𝟒.𝟏𝟗
𝑭𝑳𝑽 = √ = 0.0321
𝟑𝟓𝟔𝟓.𝟏𝟔𝟔𝟕 𝟏𝟎𝟔𝟖.𝟎𝟔
205
0.08 m

0.03 m velocity, sieve plates
𝑼𝒇 = K1√
𝝆𝑽
Where,
K1= a constant
𝟏𝟎𝟔𝟖.𝟎𝟔−𝟒.𝟏𝟗
𝑼𝒇 = 0.08 √ = 1.274 m/s
𝟒.𝟏𝟗

𝐦 𝐦
𝑼𝒂 = 𝟎. 𝟖𝟓𝑼𝒇 = (𝟎. 𝟖𝟓) (𝟏. 𝟐𝟕𝟒 ) = 𝟏. 𝟎𝟖𝟐𝟗
𝐬 𝐬
𝟑𝟓𝟔𝟓.𝟏𝟔𝟔𝟕 𝒎𝟑
𝑉𝑛 = =𝟏
𝟑𝟔𝟎𝟎 𝒔
𝐕𝐧 𝟏
𝐀𝐧 = = = 𝟎. 𝟗𝟐 𝐦𝟐
𝐔𝐚 𝟏.𝟎𝟖𝟐𝟗
𝐴𝑛 = 𝐴𝑐 - 0.12 𝐴𝑐
𝑨𝒏 = 𝟎. 𝟖𝟖 𝑨𝒄
206
𝐴𝑛 = 0.88 𝐴𝑐
𝐀𝐧 𝟎.𝟗𝟐 𝐦𝟐
𝐀𝐜 = = = 𝟏. 𝟎𝟒𝐦𝟐
𝟎.𝟖𝟖 𝟎.𝟖𝟖
𝝅𝑫𝟐𝑪
𝑨𝒄 =
𝟒
𝟒𝑨𝒄 (𝟒)(𝟏.𝟎𝟒)𝒎𝟐
𝑫𝒄 = √ =√
𝝅 𝝅
𝑫𝒄 = 𝟏. 𝟓𝟕𝟑 𝒎 (Column diameter for rectifying section)
𝑳 𝝆𝑽
𝑽 𝑳
𝑳𝟎 𝝆𝑽
𝑽𝒎 𝑳
Where,
1826.0610 4.09
𝑭𝑳𝑽 = √ = 0.03
3565.1667 905.1
0.08 m 0.5 m

0.03 velocity, sieve plates
207
𝑼𝒇 = K1√
𝝆𝑽
Where,
K1= a constant
𝟗𝟎𝟓.𝟏−𝟒.𝟎𝟗
𝑼𝒇 = 0.08 √ = 1.187 m/s
𝟒.𝟎𝟗

𝐦 𝐦
𝑼𝒂 = 𝟎. 𝟖𝟓𝑼𝒇 = (𝟎. 𝟖𝟓) (𝟏. 𝟏𝟖𝟕 ) = 𝟏
𝐬 𝐬
Hence, there are no vapor amount changes in stripping section compared to the rectifying
section.
𝟑𝟓𝟔𝟓.𝟏𝟕 𝐦𝟑
𝑉𝑛 = =𝟏
𝟑𝟔𝟎𝟎 𝐬
𝑉𝑛 = 𝐔𝐚 𝐀𝐧
𝐕𝐧 𝟏
𝐀𝐧 = = = 𝟏 𝐦𝟐
𝐔𝐚 𝟏
𝐴𝑛 = 𝐴𝑐 - 0.12 𝐴𝑐
𝑨𝒏 = 𝟎. 𝟖𝟖 𝑨𝒄

𝐴𝑛 = 0.88 𝐴𝑐
𝐀𝐧 𝟏 𝐦𝟐
𝐀𝐜 = = = 𝟏. 𝟏𝟒𝐦𝟐
𝟎.𝟖𝟖 𝟎.𝟖𝟖
𝛑𝐃𝟐𝐂
𝐀𝐜 =
𝟒
𝟒𝑨𝒄 (𝟒)(𝟏.𝟏𝟒)𝒎𝟐
𝑫𝒄 = √ =√
𝝅 𝝅
𝑫𝒄 = 𝟏. 𝟓𝟑𝟏 𝒎 (Column diameter for stripping section)
208
To conclude, the diameter rectifying and stripping sections are pretty much the same.
Hence, we choose the rectifying section because we focus on the product separation at
the top, phenol.
9. CALCULATION OF HOLE DIAMETER AND AREA
Therefore, the diameter of the hole is considered 6 mm.
10. NUMBER OF HOLES IN A TRAY AT RECTIFYING SECTION
For a plate, there is one down comer on the plate and top-down comer also affected to
𝐴𝑎 = 𝐴𝑐 - 2(0.12)(𝐴𝑐 )
𝐴𝑎 = (1.049 𝑚 − 2 (0.12)(1.049))
𝑨𝒂 = 𝟎. 𝟕𝟗𝟕𝟎 𝒎𝟐
𝑨𝒉 = 𝟎. 𝟏 𝑨𝒂

𝑨𝒉 = 𝟎. 𝟏(𝟎. 𝟕𝟗𝟕𝟎)𝒎𝟐
𝑨𝒉 = 𝟎. 𝟎𝟕𝟗𝟕 𝒎𝟐
𝑨𝟐𝒉 𝟎.𝟎𝟕𝟗𝟕𝟐
Area of a hole, A = 𝝅 =𝝅 = 𝟎. 𝟎𝟎𝟓𝒎𝟐
𝟒 𝟒
𝑨𝒉
𝑨
0.0797 𝑚2
n=
0.005 𝑚2
209
n ≈ 15.94 = 16 holes
11. NUMBER OF HOLES IN A TRAY AT STRIPPING SECTION
𝐴𝑎 = 𝐴𝑐 - 2(0.12)(𝐴𝑐 )
𝐴𝑎 = (1.14 𝑚 − 2 (0.12)(1.14))
𝑨𝒂 = 𝟎. 𝟖𝟕 𝒎𝟐
𝑨𝒉 = 𝟎. 𝟏 𝑨𝒂

𝑨𝒉 = 𝟎. 𝟏(𝟎. 𝟖𝟕 )𝒎𝟐
𝑨𝒉 = 𝟎. 𝟎𝟖𝟕𝒎𝟐
𝑨𝟐𝒉 𝟎.𝟎𝟖𝟕𝟐
Area of a hole, A = 𝝅 =𝝅 = 𝟎. 𝟎𝟎𝟓𝟗𝟓𝒎𝟐
𝟒 𝟒
𝑨𝒉
𝑨
0.087 𝑚2
n=
0.00595 𝑚2
n ≈14.62 = 15 holes
12. CALCULATION HEIGHT OF COLUMN
210
No. of tray = 15
Tray stack = 15 x 0.5 m = 7.5 m (Height of column)

7.2.12 General consideration
1. DESIGN PRESSURE


pressure: 62 kPa
= (103 − 100) 𝑘𝑃𝑎 × 1.1
= 3.3 𝑘𝑃𝑎
the material, considering any error in forecasting the vessel wall temperature.
= 192℃ + 10℃
= 202℃
211
(Sources: Table 13.2, Chemical Engineering, Coulson & Richardson's, 4th Edition)
𝑁
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑎𝑡 202℃ = 105 𝑚𝑚 2 @ 1050 00 kPa
𝑁 𝑁
Tensile strength = 45 ksi x (6.8948 𝑚𝑚2
/ 1ksi) = 310.266 𝑚𝑚2
@ 310266kPa
By referring to Table 13.3 (Chemical Engineering, Coulson & Richardson's, 4th

Edition), assume degree of radiography is 100% and type of joint is double welded but
where welded joint efficiency, J = 1.

𝑃𝑅
𝑓1−0.6𝑃
P= Design pressure
radius is 775 mm)
212
J = Join efficiency
(3.3𝑘𝑃𝑎)(775 𝑚𝑚)
(105000 𝑘𝑃𝑎)(1)−(0.6)(3.3𝑘𝑃𝑎)
𝑇𝑢𝑏𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠, 𝑡𝑠 = 2.0244𝑚𝑚
Ellipsoidal
Where,
𝐏𝐢 𝐃𝐢
Ellipsoidal thickness, t = 𝟐𝑺𝑬−𝟎.𝟐 𝑷𝒊
+𝒄
(3.3 kPa) 1550 mm

Ellipsoidal thickness, t = 2(105000)𝑘𝑃𝑎−0.2 (3.3 kPa) + 2 𝑚𝑚 = 2.02436 mm
213
7.2.13 Compressor
F = Feed, P = Product
F(-210°C, 1 atm, F(-210°C, 6 atm,

gas) Flowrate: gas) Flowrate:
5.945kmol/min N2 : COMPRESSOR 5.945kmol/min N2 :
0.811kmol/kmol 0.811kmol/kmol
O2 : 0.189 kmol/kmol O2 : 0.189 kmol/kmol
214
215
216
217
218
219
220
7.2.15 Flash Drum
Figure 7.39: Dimension of vertical separator
Benzene, C6H6 - 0.0259 kmol/min
Oxygen, O2 - 0.0217 kmol/min

11
Benzene ,C6H6 - 0.8959 kmol/min Nitrogen, N2 - 0.9521 kmol/min
Flash
Oxygen, O2 - 0.0217 kmol/min
Drum
Nitrogen, N2 - 0.9521 kmol/min 10 ( T-101)
Catechol, C6H4(OH)2 - 0.05 kmol/min
Phenol, C6H5OH - 0.07 kmol/min Benzene ,C6H6 - 0.87 kmol/min
12 Catechol, C6H4(OH)2 - 0.05 kmol/min
Phenol, C6H5OH - 0.07 kmol/min
Parameter Stream 10 Stream 11 Stream 12
( Feed) ( Top ) ( Bottom )
Pressure ( kPa) 1000 1000 1000
Total Molar 389.4411 84.8782 304.5629
( kmol/min)
Table 7.10: Operating condition of Flash Drum
221
Stream 11 Total Molar Flowrate ( N2 , O2, C6H6 )
= 2.1990 + 1.8424 + 80.8368
= 84.8782 kmol/ min total
Stream 12 Total Molar Flowrate ( C6H6, C6H5OH, C6H4(OH)2 )
= 267.0175 + 21.6774 + 15.8680
= 304.5629 kmol/ min total
1) Total Molecular Weight ( vapour) ( N2 , O2, C6H6 )
MW = [ ( XC6H6 MWC6H6 ) + ( XO2 . MWO2 ) + ( XN2 . MWN2 )]
= (0.0259 x 78.11) + ( 0.0217 x 32) + ( 0.9521 x 28)
= 29.38 g/ mol
2) Density leaving top (vapour)

𝑔
𝑃. 𝑀𝑊𝑣 10 𝑎𝑡𝑚. (29.38 38 )
𝜌𝑣 = = ( 𝑚𝑜𝑙 )
𝑅𝑇 𝑚 3 . 𝑎𝑡𝑚
8.2057 × 10−5 × 326.15 𝐾
𝐾. 𝑎𝑡𝑚
= 10977.887 g/ m3
3) Molecular weight (liquid ) ( C6H6, C6H5OH, C6H4(OH)2 )
MW = [ (XC6H6 MWC6H6 ) + ( XC6H6OH . MWC6H6OH ) + ( XC6H4(OH)2 . MW C6H4(OH)2 )]
= (0.87 x 78.11) + (0.07 x 94.11) + (0.005 x 110.1)
= 80.05 g/ mol
4) Specific Volume , VL
𝑀𝑊C6H6 𝑀𝑊C6H6OH 𝑀𝑊C6H6(OH)2

= [𝑋C6H6 ] + [𝑋C6H6OH ] + [𝑋C6H6(OH)2 ]
𝜌C6H6 𝜌C6H6OH 𝜌C6H6(OH)2
𝑔 𝑔 𝑔
78.11 94.11 110.1
= 0.87 𝑚𝑜𝑙 𝑚𝑜𝑙 𝑚𝑜𝑙
𝑔 ] + 0.07 𝑔 ] + 0.05 𝑔 ]
876000 3 1070000 3 3340000 3
𝑚 𝑚 𝑚
VL = 8.54 x 10-5 m3/ mol
222
5) Density Liquid (bottom)
𝑔
𝑀𝑊𝐿 80.05
𝜌𝐿 = = 𝑚𝑜𝑙
𝑉𝐿 𝑚3
8.54 × 10−5
𝑚𝑜𝑙
= 937353.63 g/ m3
Liquid Flowrate, WL
= 304.5624 kmol / min = 1827344 mol/hr
Vapour Flowrate, Wv
= 84878.2 mol/min = 5092692 mol/ hr
6) Flow parameter
𝑊𝐿 𝜌𝑉
= √
𝑊𝑉 𝜌𝐿
𝑘𝑚𝑜𝑙 𝑔
1827.344 10977.887 3
= ℎ𝑟 √ 𝑚
𝑘𝑚𝑜𝑙 937353.63 𝑔
5092.692 𝑚3
ℎ𝑟
= 0.04
7) Vapour velocity, Vv
𝜌𝐿 − 𝜌𝑉
𝑉𝑉 = 𝐾𝑑𝑟𝑢𝑚 √
𝜌𝑉
According to ( Flash Distillation, n.d ) , Kdrum is an empirical constant that depends on the
type of drum . Kdrum value is typically range 0.1 to o.36 ft/s. ( Flash Distillation, n.d ) has fit
Walkins’ correlation to the equation as below :
Kdrum = exp [A + B In FlV + C ( In FlV) 2 + D ( In FlV ) 3 + E In ( FlV )4 ]
Constants: A = -1.877478079
B = - 0.8145804597
223
C = - 0.1870744085
D = -0.0145228667
E = -0.0010148518
Hence the Kdrum value is,
Kdrum = exp [(-1.877478079) + (- 0.8145804597 (In 0.015)) + (- 0.1870744085 ( In

0.015) 2 ) + (-0.0145228667 ( In 0.015 ) 3 ) + (-0.0010148518 (In 0.015 )4 )]
= 0.36 ft/s
After that , the value of vapor velocity can be calculated,
𝑔 𝑔
𝑓𝑡 937353.63 𝑚3 − 10977.887 𝑚3
= 0.36 √ 𝑔
𝑠 10977.887 3
𝑚
= 3.31 ft/s
8) Cross area, Ac
𝑉 (𝑀𝑊𝑣 )
𝐴𝑐 =
𝑉𝑉 (3600)𝜌𝑣
𝑚𝑜𝑙 𝑔
5092692 (29.38 )
𝐴𝑐 = ℎ𝑟 𝑚𝑜𝑙
𝑓𝑡 𝑔 1𝑚3
3.31 (3600) (10977.887 3 ) ( )
𝑠 𝑚 35.3147𝑓𝑡 3
= 40.4 ft2
=3.75 m2
9) Diameter, D
4(𝐴𝐶 )
𝐷= √
𝜋
4(3.75𝑚2 )
𝐷= √
𝜋
= 2.19 m
Mechanical Design
Height and Thickness calculation

224
Calculation is based on (Flash Distillation, n.d ) and Richardson and Coulson Volume
Shell thickness, Ts
Operating Pressure, Po = 10 atm / 1013.25 kPa
Design Pressure, Pd = 1.1 x Po
= 1.1 x 1013.25 kPa
= 1114.575 kPa
Diameter, D = 2.19 m
Maw allowable stress, S = 12900 psi
Welded Joint Efficiency, E = 0.85 (Double Welded Joint)

𝑃𝑑 𝐷
Shell thickness, t 𝑡=
2 𝑆𝐸−1.2 𝑃
1114.6 𝑘𝑃𝑎 × 2.19 𝑚

𝑡=
(2 × 88942.369 𝑘𝑃𝑎 )(0.85) − (1.2 × 1114.6 𝑘𝑃𝑎)
= 0.1777
The value of the shell thickness obtained is being rounded to the nearest quarter to allow the
allowance of corrosion. Therefore, the value of shell thickness, t is as below.
t = 0.1777 + 0.25
t = 0.4271 m
10) Liquid Hold up, VH
The selected Retention time value for this flash separator is 10 minutes , which assumed from
figure .
Figure 7.40: Standard Retention Time, TH for distillation Process
VH = Retention time, TH X Liquid Volumetric Flowrate, QL
1 ℎ𝑟 𝑓𝑡 1𝑚3
= [10 min × ] × [ 3.31 × 40.4 𝑓𝑡 2 × ]
60 𝑚𝑖𝑛 𝑠 35.315𝑓𝑡 3
VH = 0.63
225
11) Liquid height , HL
𝑉𝐻 0.63
𝐻𝐿 = =
𝐴 𝜋×𝐷÷4
= 0.3663
12) Vapour height , HV
Hv = ( 1.5 x D) + 0.9144 m
= 4.1944
13) Liquid pool height, Hf
Hf = (1.5 x D) + 0.3048 m
= 3.5898
14) Total height
Hv + Hf + HL = 8.1505
𝑇𝑜𝑡𝑎𝑙 8.1505
=
𝐷 2.19
= 3.72 (vertical separator)
Based on (Flash Distillation, n.d ) and Richarson and Coulson Volume 6 that the total
height over diameter , L/D ratio should lies between 3 to 5 in order to prove the type of
separator used is a vertical separator. Hence, from the calculation L/D obtained is 3. It has
proved that the vertical separator is the right separator to be chosen.
Head Selection
There are three types of head selection that consists of :
1) Torisperical ( for P < 1134.97 kPa)

2) Ellipsoidal ( for P > 1134.97 kPa )
3) Hemispherical ( for very high pressure )
Hence, according to the range of pressure the torispherical head is selected. In addition,
the Torispherical head is cheap and most commonly used for pressure less than 15 bar .
Meanwhile for the selection of support, bracket support is used because it suits with all types
of vessels which is normally vertical and cylinder.
226
Figure 7.41: Tori spherical Head.
Mist Eliminator Selection
There are two type of mist eliminator or demister selection consists of :
• Mesh Pad Demisters

• Vane- type Demister
Hence , this design chooses mesh pad eliminator. It consists of multiple layers of woven
or knitted wire mesh, which trap droplets and cause them to coalesce into larger droplets that
are too heavy to be carried by the gas stream.
Figure 7.42: Mesh pad Eliminator
227
Cold Side
Benzene Hot Side
IN 100‘C Benzene
IN 300‘C
Hot Side Cold Side

Benzene Benzene OUT
OUT 200‘C
250‘C
I. . Log mean temperature difference (LMTD)
To calculate the log mean temperature difference (LMTD) for a shell and tube heat exchanger,
we need to know the inlet and outlet temperatures for both the shell and tube sides. The LMTD
can be calculated using the following equation:
(𝑇1 −𝑡2 )−(𝑇2 −𝑡1 )

LMTD = (𝑇1 −𝑡2 )
𝑙𝑛
(𝑇2 −𝑡1 )
(300−250)−(200−100)
∆Tlm =
𝑙𝑛 (300−250)
(200−100)
∆𝐓𝐥𝐦 = 72.12°C / 345.27 K
II. Calculate heat transfer, Q
To calculate the heat transfer, we need to know the mass flow rate and specific heat capacity
of the fluids on both the shell and tube sides. The heat transfer can be calculated using the
following equation:
Q = mCp(ΔT)
where:
m = mass flow rate
Cp = specific heat capacity
Δ T = temperature difference
228
For the shell side, the fluid is benzene. The specific heat capacity of benzene at constant
pressure (Cp) is 0.331 kJ/kg K.
For the tube side, the fluid is also benzene. The mass flow rate for the tube side is 378.69
kmol/min, and the specific heat capacity of benzene at constant pressure is 0.331 kJ/kg K.
We need to convert the mass flow rate from kmol/min to kg/min to use the specific heat
capacity. The molar mass of benzene is 78.11 g/mol.
First, we calculate the mass flow rate in kg/min:
mass flow rate (kg/min) = molar flow rate (kmol/min) * molar mass (g/mol) / 1000 (g/kg) mass
flow rate (kg/min) = 378.69 kmol/min * 78.11 g/mol / 1000 mass flow rate (kg/min) = 29,573.53
kg/min
Then, we can calculate the heat transfer on the tube side:
Q = mCp(ΔT)
Q = 29,573.53 kg/min * 0.331 kJ/kg K * (300 - 250) K
Q = 1,568,964.68 kJ/hr
III. Heat transfer surface area, A
According to the Chemical Engineering Design (Fourth Edition) by Coulson & Richardson’, the
value of overall heat transfer coefficient may be derived from the diagram below at organic
solvent for hot and cold fluid. The assuming value of overall heat transfer coefficient for heat
exchanger. Assuming a value of U = 300 W/m2K, we can calculate the heat transfer area:
Q
A=
U∆Tlm
A = 1,568,964.68 kW / (300 W/m2K * 72.12°C)
A = 54.95 m2
IV. Tube surface area, At
The surface area of a tube can be calculated using the following equation:
A = πDL
229
where:
D = diameter of tube
L = length of tube
A = πDL
A = 3.1416 * 3 in * (10 ft * 12 in/ft)
A = 1,128.66 in2 * (0.00064516 m2/in2)
A = 0.7289 m2
V. The number of tubes
𝑨
𝑵𝒕 =
𝑨𝒕
54.95 m2
𝑁𝑡 =
0.7289 m2
𝑁𝑡 = 75.4 ≈ 76
Therefore, approximately 76 tubes with a diameter of 3 inches and a length of 10 feet would
be needed for this shell and tube heat exchanger.
VI. Tube cross sectional area
The tube cross-sectional area can be calculated using the following formula:
A = (π/4) D2
A = (π/4) * D2
A = (3.1416/4) * (0.0762 m)2
A = 0.00457 m2
VII. Tube length
230
Based on the Coulson and Richardson, the maximum length for the tube that is widely used
in industrial is around 10 feet with the diameter of 3 inches, in this case the length of each tube
is fixed at 10 feet long.
VIII. Tube arrangement
A common tube layout for shell and tube heat exchangers is the triangular pitch layout, where
the tubes are arranged in an equilateral triangular pattern.
IX. Tube inner diameter
The diameter ratio is defined as the ratio of the outer diameter of the tube to the inner diameter
of the tube. In this case, the diameter ratio is given as 1.3.
D_inner = D_outer / diameter ratio
D_inner = D_outer / 1.3
To solve for D_inner, we need to know the outer diameter of the tube. The problem statement
only provides the diameter of 3 inches, which we assumed to be the outer diameter in our
previous calculations. Therefore, we can calculate the inner diameter as follows:
D_inner = 2.3077 in * (0.0254 m/in)
D_inner = 0.0587 m
X. Shell diameter
Assuming a triangular pitch layout, we can use the following equation to estimate the shell
diameter:
Ds = (Nt * Dt) / sin(60°)
where: Ds = shell diameter Nt = number of tubes Dt = tube outer diameter
From our previous calculations, we found that we need approximately 76 tubes with an outer
diameter of 3 inches (0.0762 m).
Substituting these values into the equation, we get:
Ds = (Nt * Dt) / sin(60°)
Ds = (76 * 0.0762 m) / sin(60°)

231
Ds = 1.6495 m
XI. Bundle diameter
The bundle diameter is the outer diameter of the tube bundle, which is the group of tubes that
are housed inside the shell. The bundle diameter can be calculated using the following
equation:
Dt
Db = Nt(1/2) ×S× ( )
sin(π/Nt)
where:
Db = bundle diameter
Nt = number of tubes
Dt = tube outer diameter
S = tube pitch (distance between the centers of adjacent tubes)
S = 1.25 * Dt S = 1.25 * 0.0762 m S = 0.09525 m
Db = Nt(1/2) * S * (Dt / sin(π/Nt))
Db = 75(1/2) * 0.09525 m * (0.0762 m / sin(π/75))
Db = 0.9562 m
XII. Baffle
The baffle spacing and number of baffles can be calculated using the following equations:
Baffle spacing (Ls): Ls = 0.25 × Ds
Number of baffles (N): N = 1 + 2 × (L / Ls)
where: L = shell length
232
We previously calculated the shell diameter to be approximately 1.6495 meters. Assuming a
shell length of 10 ft (3.048 m), we can calculate the baffle spacing and number of baffles as
follows:
Ls = 0.25 * shell diameter
Ls = 0.25 * 1.6495 m
Ls = 0.4124 m
Number of baffles:
N = 1 + 2 * (L / Ls)
N = 1 + 2 * (3.048 m / 0.4124 m)
N = 15.4 ≈ 𝟏𝟔
XIII. Shell Area
To calculate the shell area, we need to know the tube surface area and the number of tubes.
The tube surface area can be calculated using the following equation:
At = π × Dt × Lt × Nt
where:
Lt = tube length
Nt = number of tubes
At = π × Dt × Lt × Nt
At = π × 0.0762 m × 3.048 m × 75
At = 65.53 m2
To calculate the shell area, we need to know the effective length of the tube (Le) and the
number of tubes in a single pass (Ntp). The effective length of the tube is the length of the
tube that is actually exposed to the fluid and can be calculated using the following equation:
Le = Lt - 2 × (0.5 × Dt)
where:
233
Lt = tube length
Substituting the values we have, we get:
Le = Lt - 2 × (0.5 × Dt)
Le = 3.048 m - 2 × (0.5 × 0.0762 m)
Le = 2.8956 m
The shell area can then be calculated using the following equation:
As = Ntp × Le × π × (Ds/2)2
where:
Ntp = number of tubes in a single pass
Le = effective length of tube
Ds = shell diameter
As = Ntp × Le × π × (Ds/2)2
As = 38 × 2.8956 m × π × (1.6495 m / 2)2
As = 33.84 m2
XIV. Effective Diameter
Using the tube pitch of 1.25 inches, we can calculate the pitch circle diameter (Pt) using the
following equation:
Pt = Ds + 1.25 inches
Pt = 1.6495 m + 0.03175 m
Pt = 1.68125 m
where: Ds = shell diameter (previously estimated to be approximately 1.6495 meters)
Using the outer diameter of the tube (Do) that we previously calculated as 0.07976 meters,
we can now calculate the effective diameter (De) using the equation:
234
𝑃 𝐷𝑜2
De = 4( 𝑡 × 0.87 Pt - 1/2 π × )
2 4
Substituting the values we have, we get:
𝑃𝑡 𝐷𝑜2
De = 4( × 0.87 Pt - 1/2 π × )
2 4
De = 4(1.68125 m / 2 × 0.87 * 1.68125 m - 1/2× π × 0.07976 m^2 / 4)
De = 1.6199 m
XV. General Consideration
a) Reynold number
Re = (879 kg/m^3 * 0.2708 m/s * 0.0769 m) / 0.00067 Pa·s
Re = 2.8x10^4
b) Heat transfer coefficient
Nu = 0.023 * Re^(0.8) * Pr^(0.4)
where:
Nu = Nusselt number
Re = Reynolds number (previously calculated to be approximately 2.8x10^4)
Pr = Prandtl number, which can be calculated as the ratio of the fluid's specific heat at constant
pressure to its thermal conductivity. For benzene at 25°C, Pr is approximately 7.75.
Calculating the nusselt number:
Nu = 0.023 * (2.8x10^4)^(0.8) * 7.75^(0.4)
235
Nu = 147.5
Convert nuselt number into heat transfer coefficient:
h = Nu * k / D
where:
h = heat transfer coefficient
k = thermal conductivity of benzene at 25°C, which is approximately 0.13 W/m·K
D = inner diameter of the tube (previously calculated to be approximately 0.0769 m)
h = 147.5 * 0.13 W/m·K / 0.0769 m
h = 248 W/m^2·K
c) Pressure drop (shell side)
ΔP = (1.58 * (G_s/ρ_s)^0.5 * (μ_s/k_s)^0.14 * (L/D_e) * (F)^0.5) * (ρ_s/2)
where:
ΔP = pressure drop in the shell side
G_s = mass velocity of benzene on the shell side, which can be calculated as the mass flow
rate divided by the cross-sectional area of the shell side: G_s = m_dot_s / A_shell
m_dot_s = mass flow rate of benzene on the shell side (previously calculated to be
approximately 0.441 kg/s)
A_shell = cross-sectional area of the shell (previously calculated to be approximately 0.0372

m^2)
ρ_s = density of benzene on the shell side, which can be assumed to be constant at 879
kg/m^3
μ_s = viscosity of benzene on the shell side, which can be assumed to be constant at 0.00067
Pa·s
k_s = thermal conductivity of benzene on the shell side, which can be assumed to be constant
at 0.13 W/m·K
L = length of the heat exchanger (previously given to be approximately 10 ft or 3.048 m)
236
D_e = effective diameter of the heat exchanger (previously calculated to be approximately
0.3338 m)
F = correction factor for the baffles, which depends on the baffle spacing and can be looked
up in a table (for example, for a baffle spacing of 0.4 times the shell diameter, F is
approximately 0.57)
Substituting the values, we get:
G_s = 0.441 kg/s / 0.0372 m^2 G_s = 11.83 kg/m^2·s
ΔP = (1.58 * (11.83/879)^0.5 * (0.00067/0.13)^0.14 * (3.048/0.3338) * (0.57)^0.5) * (879/2)
ΔP = 443 Pa
d) Pressure drops (tube side)
ΔP = NP (8 * Jf * (L/D_i) + 2.5) * (ρ_u^2 / 2)
where:
ΔP = pressure drop in the tube side
NP = number of tube passes (previously given to be 2)
Jf = friction factor for flow in the tube, which can be estimated using the Darcy-Weisbach
equation or looked up in a table (given as 0.09)
L = length of the heat exchanger (previously given to be approximately 10 ft or 3.048 m)
D_i = inner diameter of the tube (previously calculated to be approximately 0.0246 m)
ρ_u = density of benzene in the tube, which can be assumed to be constant at 879 kg/m^3
Substituting the values, we get:
ΔP = 2 (8 * 0.09 * (3.048/0.0246) + 2.5) * (879^2 / 2)
ΔP = 2675 Pa
237
7.3 MECHANICAL DRAWING
7.3.1 Reactor R-101 (Multi-Tubular Packed Bed Reactor MPBR)
The 3D design of Reactor R-101 (Multi-Tubular Packed Bed Reactor MPBR) had been
created and drawn by using Computer Aided Design Software (CAD). The CAD software had
been chosen in order to draw the 3D model of MPBR Reactor R-101 was Autodesk Inventor
Professional Software 2021. In this chapter, all view of 3D design and dimension of MPBR
Reactor R-101 will be shown below.
Figure 4.1: Autodesk Inventor Professional Software Interface
238
7.3.2 3D Design View of Reactor R-101 (MPBR) Body, Packed Bed Tube, Hemisphere
Head & Closure
239
7.3.3 Full View, Top View & Cross Section View of 3D Design Reactor R-101 (MPBR)
240
7.3.4 Distillation Column T-102, T-103, T-104
The 3D design of distillation column (T-102, T-103, T-104) had been created and drawn
by using Computer Aided Design Software (CAD). The CAD software had been chosen in
order to draw the 3D model of distillation column (T-102, T-103, T-104) was Autodesk Inventor
Professional Software 2023. In this chapter, all views of 3D design and dimension distillation
column (T-102, T-103, T-104) will be shown below.
7.3.5 Front View, Top View & Cross Section View of 3D Design Column Part (T-102, T-
103, T-104) by using Autodesk Inventor Professional Software 2023
Figure 4.2.0: Front view of Figure 4.2.1: Cross Section Figure 4.2.2: Top view of
3D Design of Column Part view of 3D Design of 3D Design of Column Part
Column Part
241
7.3.6 Front View, Top View, & Isometric View of 3D Design Column Tray Part (T-102, T-
103, T-104) by using Autodesk Inventor Professional Software 2023
Figure 4.2.3: Front view of 3D Design of

Column Tray Part
Figure 4.2.4: Top view of 3D Design of Column Tray Part
Figure 4.2.5: Isometric view of 3D Design of Column Tray Part
242
7.3.7 Front View, Top View, Cross Section View, & Isometric View of 3D Design
Distillation Column (T-102, T-103, T-104) by using Autodesk Inventor
Professional Software 2023 Figure 4.2.7: Isometric Figure 4.2.8: Cross

Figure 4.2.6: Front view of View of 3D Design of section view of 3D Design
3D Design of Distillation Distillation Column of Distillation Column
Column
Figure 4.2.9: Top view of 3D Design

of distillation Column
243
7.3.8 Flash Drum
7.3.9 Mechanical Drawing of Flash drum T- 101
Figure below show the mechanical drawing for Flash Separator by using Autodesk
Inventor. There are four different view which is cross sectional view, mist eliminator view, top
view, and overall view. The diameter = 2.19 m and wall thickness = 0.25 m , the drawing
below dimension is in millimetre (mm) unit.
Figure 4.3.1: Cross Sectional view
Figure 4.3.2: Mist eliminator
244
Figure 4.3.3: Top view
Figure 4.3.4: External view (Overall)
245
Figure 4.4.1: Side view of the shell and tube heat exchanger drawn using Autocad.
Figure 4.4.2: front view of the heat exchanger drawn by using Autocad
246
Figure 4.4.3: Isometric view of the heat exchanger drawn by using Inventor
Figure 4.4.4: Top view of the heat exchanger drawn by using Inventor
247
7.4 SPECIFICATION DATASHEET
7.4.1 SPECIFICATION DATASHEET REACTOR R-101 (MULTI-TUBULAR PACKED BED
REACTOR)
248
7.5 Distillation Column
7.5.1 SPECIFICATION DATASHEET OF DISTILLATION COLUMN 1 (T-102)
SPECIFICATION DATA SHEET
GENERAL INFORMATION
Type of equipment Tray distillation column 1
Number of Unit T-102
Number required 1
Function Separate phenol from benzene
Operation Continuous
Material of construction Carbon Steel
Author NUR ANIS NATASHA BINTI MOHD AZLAN & MUHAMMAD FIRHAD
HAZRANI BIN ZAIMI
OPERATING CONDITION
Operating pressure 1000 kPa
Operating temperature 53 ℃
Feed Flowrate 308.1287 kmol/min
Pressure at Feed 1000 kPa
Pressure at Top 68 kPa
Pressure at Bottom 50 kPa
Temperature at Feed 53 ℃
Temperature at Top 150 ℃
Temperature at Bottom 198 ℃
DESIGN INFORMATION
NAME SIGN VALUE
Relative Volatility a 2.7
q value q 1
ROL 0.30
Minimum Reflux Ratio Rmin 2.25
Operating Reflux Ratio R 3.15
Number of theoretical plates 5
Liquid flow rate of rectifying section Lo,Ln 65873.51064 kg/hr
Flooding velocity of rectifying section Ua 1.0829 m/s
Column diameter of rectifying section Dc 5.64 m
Flooding velocity of Stripping section Ua 1 m/s
Column Diameter of Stripping Section Dc 5.90 m
Tray Space of both section It 0.5 m
Hole diameter Dh 120 mm
Number of holes in a plate at rectifying Section 18
Number of holes in a plate at stripping Section 16
Height of the column 3m
Number of Stages from McCabe-Thiele Method 6
GENERAL CONSIDERATION
NAME SIGN VALUE
Design pressure 990 kPa
Design temperature 63 ℃
Wall thickness ts 8.17 mm
Head thickness t 7.143 mm
Corrosion allowance C 2 mm
Tensile strength 310266 kPa
Maximum allowable stress 125000 kPa
Joint efficiency J 1
249
SPECIFICATION DATA SHEET

GENERAL INFORMATION
Type of equipment Tray distillation column 2
Number of Unit T-103
Number required 1
Function Separate phenol from catechol
Operation Continuous
Material of construction Carbon Steel
Author NUR ANIS NATASHA BINTI MOHD AZLAN
OPERATING CONDITION
Operating pressure 62 kPa
Operating temperature 198 ℃
Feed Flowrate 38.6555 kmol/min
Pressure at Feed 62 kPa
Pressure at Top 68 kPa
Pressure at Bottom 50 kPa
Temperature at Feed 198 ℃
Temperature at Top 252 ℃
Temperature at Bottom 185 ℃
DESIGN INFORMATION
NAME SIGN VALUE
Relative Volatility a 2.1
q value q 1
ROL 0.52
Minimum Reflux Ratio Rmin 0.9048
Operating Reflux Ratio R 1.27
Number of theoretical plates 14
Liquid flow rate of rectifying section Lo,Ln 2308.5422 kg/hr
Flooding velocity of rectifying section Ua 1.2187 m/s
Column diameter of rectifying section Dc 1.55 m
Flooding velocity of Stripping section Ua 1.1203 m/s
Column Diameter of Stripping Section Dc 1.50 m
Tray Space of both section It 0.5 m
Hole diameter Dh 120 mm
Number of holes in a plate at rectifying Section 16
Number of holes in a plate at stripping Section 15
Height of the column 7.5 m
Number of Stages from McCabe-Thiele Method 15
GENERAL CONSIDERATION
NAME SIGN VALUE
Design pressure 41.8 kPa
Design temperature 208 ℃
Wall thickness ts 2.31 mm
Head thickness t 2.31 mm
Corrosion allowance C 2 mm
Tensile strength 310266 kPa
Maximum allowable stress 103400 kPa
Joint efficiency J 1
250
251
7.6 SPECIFICATION DATASHEET OF FLASH DRUM (T-101)
MECHANICAL DESIGN SPESIFICATION SHEET
FLASH DRUM T- 101
Identification : Flash Drum ( Separator )
Item No : T -101
Date : 4/4/2023
By : MOHAMED HANIF BIN MOHAMED RAWI
Function : Separate Phenol and other components
Type : Vertical Liquid – Vapor column
Operating Condition
Material construction Stainless Steel
Temperature 326.5 K
Pressure 10 atm
Cross sectional area 3.75 m2
Diameter 2.19 m
Height for vapor phase 4.1944 m
Height for liquid pool 3.5898 m
Height of liquid 0.3663 m
Volume 30.5644 m3
Density of vapor 10977.887 g/m3
Density of liquid 937353.63 g/m3
Mechanical Design
Material construction Carbon Steel with Austenitic Stainless
( UN S31600)
Mist eliminator ( thickness) Mesh type (0.1524 m )
Shell thickness 0.25 m
Type of head Ellipsoidal
Type of support Bracket
Nozzle diameter 0.5 m
252
7.7 SPECIFICATION DATASHEET OF HEAT EXCHANGER (E-102)
253
CHAPTER 8: ENGINEERING ECONOMIC ANALYSIS OF CHEMICAL PROCESS
8.1 TOTAL INVESTMENT, FIXED AND WORKING CAPITAL
8.1.1 EQUIPMENT COST
Since equipment costing is one of the most important investments that must be considered,
all the equipment used in the manufacturing of phenol is expected to be further investigated.
As a result, it will be possible to assess profit and payback rate in the future. The cost of the
equipment was determined using R.K. Sinnott's 2005 and A.M. Gerrard's 2007 studies.
Published cost indices are utilized in the standard update procedure for historical cost data.
Based on statistics for labor, material, and energy costs released in government statistical
digests, these compare current costs to historical expenses. Based on R.K. Sinnott, 2005,
below is the formula to calculate the cost of escalation of years.
𝐶𝑂𝑆𝑇 𝐼𝑁𝐷𝐸𝑋 𝐼𝑁 𝑌𝐸𝐴𝑅 𝐴

𝐶𝑂𝑆𝑇 𝐼𝑁 𝑌𝐸𝐴𝑅 𝐴 = 𝐶𝑂𝑆𝑇 𝐼𝑁 𝑌𝐸𝐴𝑅 𝐵 𝑋
𝐶𝑂𝑆𝑇 𝐼𝑁𝐷𝐸𝑋 𝐼𝑁 𝑌𝐸𝐴𝑅 𝐵
To evaluate the equipment and plant costs for the chemical and process industries, Chemical
Engineering Plant Cost Index (CEPCI) is used.
254
Figure 8.1.1: CHEMICAL ENGINEERING PLANT COST INDEX (CEPCI) TABLE
(Cost Indices – Towering Skills, 2020)
255
8 REACTOR (R-101)
Using the cost curve from A.M. Gerrard, 2007, the cost of the reactor is calculated. The
reactor's 75.74 𝑚3 volume was required by the curve. However, A.M. Gerrard's curve cost
is for carbon steel. The stainless steel 316 that we used for our reactor necessitates the
use of a multiplication factor of 1.7. While the cost of the curve is only paid for pressures
up to 3 bars, the reaction's pressure is 4000 kPa, or roughly 40 bar. Therefore, a
multiplication factor of 1.9 is required.
55,000
Figure 8.1.2: Curve Cost of a Reactor (A.M. Gerrard, 2007).
256
Purchased cost formula (R.K. Sinnott, 2005):
Purchased cost: cost from figure × material factor × pressure factor
Purchased cost in year 2000 = £ 55,000 × 1.7 × 1.9
Purchased cost in year 2000 = £ 177,650
𝑅𝑀 5.78
𝐶𝑜𝑠𝑡 = £ 177,650 𝑋
£1
Cost = RM 1,026,817
𝐶𝑜𝑠𝑡 𝐼𝑛𝑑𝑒𝑥 2023

𝐶𝑜𝑠𝑡 𝑖𝑛 𝑌𝑒𝑎𝑟 2023 = 𝐶𝑜𝑠𝑡 𝑌𝑒𝑎𝑟 2000 𝑋
798.0
𝐶𝑜𝑠𝑡 𝑖𝑛 𝑌𝑒𝑎𝑟 2023 = 𝑅𝑀 1,026,817 𝑋
394.0
𝐶𝑜𝑠𝑡 𝑖𝑛 𝑌𝑒𝑎𝑟 2023 = 𝑅𝑀 2,086,472
257
9 Compressor, C-101
Referring to R.K. Sinnott, 2005, the power of the compressor used is 150 kW, as there is
no exact calculation done for the compressor. The figure below shows the purchase cost
of equipment, and cost factors based on 2004 for use in the calculation.
Figure 8.1.3: Purchase cost equipment with cost factor.
258
𝐶𝑜𝑠𝑡 = £ 1160 𝑋 150(0.8)
𝑅𝑀 5.78
𝐶𝑜𝑠𝑡 = £ 63,875 𝑋
£1
Cost = RM 369,197

798.0
𝐶𝑜𝑠𝑡 𝑖𝑛 𝑌𝑒𝑎𝑟 2023 = 𝑅𝑀 369,197 𝑋
444.2
𝐶𝑜𝑠𝑡 𝑖𝑛 𝑌𝑒𝑎𝑟 2023 = 𝑅𝑀 665,419
259
10 Heat Exchangers
- E-102
The cost for a heat exchanger will be obtained by using the Heat Transfer Surface Area of
each Heat Exchanger unit. Cost curve and cost of each unit will be determined based on
materials used R.K. Sinnott, 2005. Besides material, pressure and type factors will affect the
price of equipment. Based on the calculation for E-102 in chapter 7, heat transfer surface area
is 54.92 𝑚2 . Tube and shell material used is stainless steel. Based on the stream table in
chapter 6, the pressure is 4400 kPA which is about 44 bar.
Figure 8.1.5: Curve cost of Shell and Tube Heat Exchanger.
Figure 8.1.6: Table of material, pressure, and type factors
260
Purchased cost: cost from figure × type factor × pressure factor.
𝑅𝑀 5.78
𝐶𝑜𝑠𝑡 = £ 39,000 𝑋
£1
Cost = RM 112,710

798.0
444.2
261
- E-101/ E -103/ E-104
For other exchangers, assumed heat transfer heat area is 100 𝑚2 . Tube and shell
material used is stainless steel. Based on the stream table in chapter 6, the
pressure is 4400 kPA which is about 44 bar.
Figure 8.1.7: Curve cost of Shell and Tube Heat Exchanger.
Figure 8.1.8: Table of material, pressure, and type factors.
262
𝑅𝑀 5.78
𝐶𝑜𝑠𝑡 = £ 26,000 𝑋
£1
Cost = RM 150,280

798.0
444.2
𝐶𝑜𝑠𝑡 𝑖𝑛 𝑌𝑒𝑎𝑟 2023 𝑓𝑜𝑟 3 𝐻𝑒𝑎𝑡 𝐸𝑥𝑐ℎ𝑎𝑛𝑔𝑒𝑟𝑠 = 𝑅𝑀 270,856 𝑋 3
𝐶𝑜𝑠𝑡 𝑖𝑛 𝑌𝑒𝑎𝑟 2023 𝑓𝑜𝑟 3 𝐻𝑒𝑎𝑡 𝐸𝑥𝑐ℎ𝑎𝑛𝑔𝑒𝑟𝑠 = 𝑅𝑀 812,568
263
11 Condenser
- E-105
The cost for condenser will be obtained by using the Heat Transfer Surface Area of each
condenser unit. The cost curve from R.K. Sinnott, 2005 cannot be referred to as the
pressure of condenser only 0.5 bar. Therefore, the cost curves of shell and tube heat
exchangers from A.M. Gerrard, 2007 as shown in Figure 8.1.9 will be used in cost
determination. The material used for condensers is carbon steel. Assumed the heat
transfer surface area is 500 𝑚2
Figure 8.1.9: Curve cost of condenser.
Cost of Condenser at 500 𝑚2 = £ 85,000

𝑅𝑀 5.78
𝐶𝑜𝑠𝑡 = £ 85, 000 𝑋
£1
Cost = RM 491,300
264
798.0
394.0
Cost = RM 998,312
- E-106/ E-107
Assumed heat transfer is 150 𝑚2
Cost of Condenser at 150 𝑚2 = £ 28,000
𝑅𝑀 5.78
𝐶𝑜𝑠𝑡 = £ 28, 000 𝑋
£1
Cost = RM 491,300

798.0
394.0
Cost for 2 condensers= RM 328,856 X 2
Cost for 2 condensers= RM 657,712
265
12 Distillation Column
- T-102
The cost for distillation column will be obtained by using the vessel height. Cost curves
vertical pressure vessel as shown in Figure 8.1.10 will be used in cost determination.
Cost of each unit will be determined based on diameter R.K. Sinnott, 2005. Besides
diameter, material and pressure factors will affect the price of equipment. Referred to
Figure 8.1.11, the consideration factors in distillation column. Based on the calculation
for T-102 in chapter 7, the height is 3.0 m and diameter are 1.0 m. Distillation column
material used is stainless steel. Based on the stream table in chapter 6, the pressure is
45 kPA which is about 0.45 bar.
Figure 8.1.10: Curve cost of distillation column.
Figure 8.1.11: Table of Diameter, Material, and Pressure Factors.
266
Purchased cost: cost from figure × material factor × pressure factor.
𝑅𝑀 5.78
𝐶𝑜𝑠𝑡 = £ 5,000 𝑋
£1
Cost = RM 28,900

798.0
444.2
267
- T-103/ T-104
Purchased cost: cost from figure × material factor × pressure factor.
𝑅𝑀 5.78
𝐶𝑜𝑠𝑡 = £ 10,500 𝑋
£1
Cost = RM 60,690

798.0
444.2
𝐶𝑜𝑠𝑡 𝑖𝑛 𝑌𝑒𝑎𝑟 2023 𝑓𝑜𝑟 2 𝐶𝑜𝑙𝑢𝑚𝑛𝑠 = 𝑅𝑀 109,38 𝑋 2
𝐶𝑜𝑠𝑡 𝑖𝑛 𝑌𝑒𝑎𝑟 2023 𝑓𝑜𝑟 2 𝐶𝑜𝑙𝑢𝑚𝑛𝑠 = 𝑅𝑀 218,768
268
13 Flash Drum (T-101)
The vessel height will be used to calculate the cost of the flash drum. To determine
costs, cost curves for vertical pressure vessels like those in Figure 8.1.12 will be
employed. Based on diameter, the price of each unit will be decided. Along with
dimension, material and pressure variables will impact equipment cost. Referring to
Figure 8.1.13, the distillation column consideration considerations. Based on Chapter
7, the flash drum's height and diameter are 8.15 m and 2.2 m, respectively. Carbon
steel is the material used for flash drums. According to the chapter 6 stream table, the
pressure is 1000 kPa, or roughly 10 bar.
Figure 8.1.12: Curve cost of column flash drum.
Figure 8.1.13: Table of Diameter, Material, and Pressure Factors.
269
Purchased cost in year 2004 = £ 18, 000 × 1.0 × 1.2
𝑅𝑀 5.78
𝐶𝑜𝑠𝑡 = £ 21,600 𝑋
£1
Cost = RM 124,848

798.0
444.2
270
14 Flare
Since a precise calculation for the flare's volume has not been made, assume that it is 8
𝑚3 . The flare equipment purchase cost is shown in the curve cost table below based on
the year 2000.
Figure 8.1.14: Curve cost of Flare.
Cost of Flare at 8 𝑚3 = £ 49,000
𝑅𝑀 5.78
𝐶𝑜𝑠𝑡 = £ 49, 000 𝑋
£1
Cost = RM 283,220
271
798.0
394.0
Cost = RM 575,497
15 Storage Tanks
There are four storage tanks, Benzene Tank, Phenol Tank, and 2 By-product Tanks, all of
which are crucial to the plant. Cone-roofed storage tanks with a capacity of 5000 𝑚3 each
are the basis for the computation of the storage tank. The purchase price for tanks is
shown in the figure below together with the cost constant and index for that specific
category of machinery by R.K. Sinnott, 2005.
Figure 8.1.15: Purchasing Cost for Storage Tanks.
𝐶𝑜𝑠𝑡 = £ 1400 𝑋 5000(0.55)
272
𝑅𝑀 5.78
𝐶𝑜𝑠𝑡 = £ 151,552 𝑋
£1
Cost = RM 875,970

798.0
444.2
𝐶𝑜𝑠𝑡 𝑖𝑛 𝑌𝑒𝑎𝑟 2023 = 𝑅𝑀 1,578,797
𝐶𝑜𝑠𝑡 𝑖𝑛 𝑌𝑒𝑎𝑟 2023 𝑓𝑜𝑟 4 𝑡𝑎𝑛𝑘𝑠 = 𝑅𝑀 1,578,797 𝑋 4
𝐶𝑜𝑠𝑡 𝑖𝑛 𝑌𝑒𝑎𝑟 2023 𝑓𝑜𝑟 4 𝑡𝑎𝑛𝑘𝑠 = 𝑅𝑀 6,315,188
273
16 Pumps
- Feed Pump (P-102)
According to Daowdat et al. (2012), the compressor's power is 3 kW because the

pump's power was not precisely calculated. The cost of the pump can be
determined by consulting the small centrifugal pump cost curve. 2007; A.M.
GERRARD. We utilized a little centrifugal pump as the feed pump.
Figure 8.1.16: Curve Cost of Small Centrifugal Pump.
Cost of Small Centrifugal Pump at 3 kW= £ 1, 900
𝑅𝑀 5.78
𝐶𝑜𝑠𝑡 = £ 1, 900 𝑋
£1
Cost = RM 10, 982
274
798.0
𝐶𝑜𝑠𝑡 𝑖𝑛 𝑌𝑒𝑎𝑟 2023 = 𝑅𝑀 10, 982 𝑋
394.0
Cost = RM 22, 310
- Recycle Pump (P-101)
According to Daowdat et al. (2012), the compressor's power is assumed 14 kW

because the pump's power was not precisely calculated. The cost of the pump can be
determined by using the large centrifugal pump cost curve. 2007; A.M. GERRARD. We
use a sizable centrifugal pump as the recycle pump.
Figure 8.1.17: Curve Cost of Large Centrifugal Pump.
275
Cost of Small Large Centrifugal Pump at 14 kW= £ 22, 000
𝑅𝑀 5.78
𝐶𝑜𝑠𝑡 = £ 22, 000 𝑋
£1
Cost = RM 127,160

798.0
𝐶𝑜𝑠𝑡 𝑖𝑛 𝑌𝑒𝑎𝑟 2023 = 𝑅𝑀 127, 160 𝑋
394.0
Cost = RM 164, 428
- Shutdown Pump (P-103/ P-104/ P-105/ P-106)
276
Figure 8.1.18: Curve Cost of Small Centrifugal Pump.
Cost of Small Large Centrifugal Pump at 3 kW= £ 1, 900
𝑅𝑀 5.78
𝐶𝑜𝑠𝑡 = £ 1, 900 𝑋
£1
Cost = RM 10, 982

798.0
𝐶𝑜𝑠𝑡 𝑖𝑛 𝑌𝑒𝑎𝑟 2023 = 𝑅𝑀 10, 982 𝑋
394.0
Cost = RM 22, 310
Cost for 4 Shutdown Pump = RM 22, 310 X 4
Cost for 4 Shutdown Pump = RM 89, 239
Because of this is a shutdown pump, the control and the maintenance should be ready every
second. So, the total overall cost for shutdown pump: RM 356, 956.
277
8 8.1.2 PURCHASE COST ESTIMATION (PCE)
No. Equipment Current Price No. of Units Net Price

(2023)
1. Reactor, R-101 RM 2,086,472 1 RM 2,086,472
2. Compressor, C-101 RM 665,419 1 RM 665,419
3. Heat Exchanger, E-102 RM 203,142 1 RM 203,142
4. Heat Exchanger, E-101/E-103/E-104 RM 270,856 3 RM 812,568
5. Condenser, E-105 RM 998,312 1 RM 998,312
6. Condenser, E-106/ E-107 RM 328,856 2 RM 657,712
7. Distillation Column, T-102 RM 52,088 1 RM 52,088
8. Distillation Column, T-103/T-104 RM 109,385 2 RM 218,770
9. Flash Drum, T-101 RM 150,012 1 RM 150,012
10. Pump, P-101 RM 164,428 1 RM 164,428
11. Pump, P-102 RM 22,310 1 RM 22,310
12. Pump, P-103/P-104/P-105/P-106 RM 89,239 4 RM 356,956
13. Flare RM 575,497 1 RM 575,497
14. Storage Tank RM 1,578,797 4 RM 6,315,188
TOTAL PURCHASE COST OF EQUIPMENT RM 13,278,874
278
9 8.1.3 PHYSICAL PLANT COST (PPC)
The approach for estimating PPC is done by referring to Table 6.1 from R.K. Sinnott,
2005.
Figure 8.1.19: Typical factors for estimation of physical plant cost.
PPC = PCE X 3.40
PPC = RM 13, 278, 874 X 3.40
PPC = RM 45, 148, 172
279
8.1.4 FIXED CAPITAL
The method used to calculate FCI is based on Table 6.1 from R.K. Sinnott, 2005.
Figure 8.1.20: Typical factors for estimation of project fixed capital cost.
FCI = PPC X 1.45
FCI = RM 45, 148, 172 X 1.45
FCI = RM 65, 464 850
8.1.5 WORKING CAPITAL
For Working Capital or known as Working Capital Investment, it is roughly estimated

20% out of Fixed Capital Cost.
Working Capital = 20% X RM 65, 464, 850
Working Capital = RM 13, 092, 970
280
8.1.6 TOTAL INVESTMENT
The value of working capital and fixed capital costs is added to determine the total
investment. Calculating this value is done to determine how profitable it is to produce
methanol.
Total Investment = Working Capital + Fixed Capital Cost
Total Investment = RM 13, 092, 970 + RM 65, 464 850
Total Investment = RM 78, 557, 820
281
8.2 PRODUCTION COSTS
8.2.1 Variable costs
Raw Materials
The raw materials that will be used for the plant are benzene and air. Calculation of catalyst
used in Reactor R-101 will also be included.
• Benzene
Table 8.2.1: The detail price for benzene
Raw Material Benzene
Price per kg (RM) RM 4.10
Mass Flowrate (kg/min) 32846.5439
Total price per annual (RM) Rm 5.8 x 1010
(Source: Malaysia’s Benzene Market Report 2022 - Prices, Size, Forecast, and
Companies, n.d.)
• Catalyst, copper chromium oxide

Estimated lifespan = 10 years
282
Table 8.2.2: The detail price for catalyst
Raw Material Catalyst
Price per kg (RM) RM 2244 x 2 = Rm 4488
Total price per annual (RM) RM 448,800
(Source: Adapted from Sigma Aldrich, 2021)
Figure 8.2.1: The import price for

benzene
Figure 8.2.2: The detail price for catalyst
283
Table 8.2.3: The water rates for each state
284
Table 8.2.4: The electricity rates by tariff
category
285
Utilities
Water (Utility) Calculation
Estimated usage of water = 800,000 liter / year
Cost of water = RM 1.15 / liter
800,000 x Rm 1.15 = Rm 920,000
Table 8.2.5: The detail price for water (utility) calculation (Malaysia, 2017)
Electricity (Utility) Calculation

Estimated Electrical Consumption = 220 kWh/day
Electrical Tariff (based on type of industry) = RM

35.50/kWh
220 kWh Rm 35.50 300 day
𝑥 𝑥 = Rm 234,300
day kWh 1 yr
Table 8.2.6: The detail price for electricity (utility) calculation (Malaysia, 2017)
Total Utilities = Rm 920,000 + Rm 234,300
Total Utilities = Rm 115,4300
286
Other Related Cost
It requires up to 10% of the maintenance cost for miscellaneous operational materials.

Aside from that shipping and packing services will be determined by the product's
nature. As a result, it will have no bearing on the process computation.
Table 8.2.7: The calculation of miscellaneous

cost
Miscellaneous Cost
Miscellaneous = 10% of maintenance cost
= 10% x Rm 32,000,000 = Rm 320,000
287
8.2.2 Fixed costs
Fixed costs are any additional costs. The volume of output has no bearing on
these fixed expenses. Fixed costs include things like interest charges and insurance
fees. The first is the upkeep expense, which makes up 5% of the fixed capital expense.
The cost of operating labour is calculated directly using the anticipated number
of shifts and day employees needed. Every shift, allow for an additional five men. Each
employee makes Rm 70k annually with a daily total of 120 employees. Manpower
estimates can be made.
Therefore, up to 20% of the overall operating labour cost will be made up of

supervision expenses. Up to half of all operating labour will be accounted for by plant
overheads. Plant overhead includes costs such as general administration, security,
medical, canteen, and safety that are involved with the operation of the plant. The plant
overheads are computed at 50% of the operational labour (Sinnott, 2005). The cost of
15% of the fixed capital cost will be used to compute capital charges. Up to 1% of fixed
capital costs are spent on royalties and insurance, respectively. Rates are equal to 2%
of Fixed Capital Cost. R&D costs are computed at a rate of 25% of Direct Production
Cost, general overheads at 20% of Direct Production Cost, and sales expenses at 30%
of Direct Production Cost. Below are the equations for direct production cost; here is a
summary of all these calculations.
Direct Production Cost = Sub Total A + Sub Total B
Sub Total A = Raw Materials + Utilities+ Miscellaneous
Sub Total B = Maintenance + Operating + Overheads + Capital Charges + Insurances
288
Table 8.2.8: The details of calculation by aspects
ASPECT CRITERIA COST
a) Maintenance 5% of Fixed Capital Cost 5

x Rm 65,464,850 = Rm3,273,242.50
100
b) Operating labor Manning Estimates (Rm 70 k

x 120 = Rm 8400 k
𝑦𝑒𝑎𝑟.𝑝𝑒𝑟𝑠𝑜𝑛
70k per year per person X
120 employees)
c) Supervision 20% of Operating Labour 20

x Rm 8400 k = Rm 1680 k
100
(b)
d) Plant Overheads 50% of Operating Labour 50

x Rm 8400 k = Rm 4200 k
100
(b)
e) Capital Charges 15% of Fixed Capital Cost 15

x Rm 65,464,850 = Rm 9,819,727.5
100
f) Insurances 1% of Fixed Capital Cost 1

x Rm 65,464,850 = Rm 654,648.5
100
g) Rates 2% of Fixed Capital Cost 2

x Rm 65,464,850 = Rm 1,309,297
100
h) Royalties 1% of Fixed Capital Cost 1

x Rm 65,464,850 = Rm 654,648.5
100
i) Sales Expenses 30% of Direct Production 30

x RM 5,600,029,992,000
100
Cost
= Rm 1,680,008,998,000
j) General 20% of Direct Production 20
x RM 5,600,029,992,000
100
Overheads Cost
= Rm 1,120,005,998,000
k) Research and 25% of Direct Production 25
x RM 5,600,029,992,000
100
Development Cost
= Rm 1,400,007,498,000
289
8.2.3 Annual production cost
Table 8.2.9: Annual production cost
Variable Cost Typical Values (MYR)
Raw Materials Rm 5.8 x 1010
Utilities Rm 920,000
Miscellaneous Materials Rm 320,000
Shipping & Packaging Not Applicable
Sub Total A RM 58,000,000,000
Fixed Cost Typical Values (MYR)
Maintenance Rm 3,273,242.50
Operating Labour Rm 8400 k
Supervision Rm 1680 k
Plant Overheads Rm 4200 k
Capital Charges Rm 9,819,727.5
Rates Rm 1,309,297
Insurance Rm 654,648.5
Royalties & License Fees Rm 654,648.5
Sub Total B RM 29,991,564
Direct Production Costs (A+B) RM 58,029,991,560
Sales Expense Rm 1,680,008,998,000
General Overheads Rm 1,120,005,998,000
Research & Development Rm 1,400,007,498,000
Sub Total C RM 4,200,022,494,000
Annual Production Cost (A+B+C) RM 4,258,052,486,000
290
8.3 ECONOMIC ANALYSIS
8.3.1 Cash Flow Diagram
Cash flow is a crucial aspect for businesses and organizations to ensure financial stability and
sustainability. It indicates the overall net amount of money earned or expended within the given
period. It involves maintaining checks on earnings and spending, controlling working capital,
and optimizing cash flow for the project. A precise representation of the resources needed for
the project and the timing of profits can be obtained from a cash-flow diagram. ( Sinnott, 2005)
The figure shown below .
Figure 8.3.1 : Project cash- flow diagram
291
CASH IN
Sales Price = RM 312/kg ( 2023)
For the first three years, no sales income counted as plant is in start up phase. Due to
the increasing of the price on raw material and the covid-19 occur around the world.
Sales price will increase to RM 312/kg for year 4, and RM 320/kg for year 5. The
price used will be back to RM 300/kg for the proceeding years.
• Year 4 and Year 6 onward

= RM 312/kg x 750, 000, 000 kg/year
= RM 2.34 x 1011
• Year 5
= RM 320/kg x 750, 000, 000 kg/year
= RM 2.40 x 1011
• Year 9 ( less production due to major maintenance )

= RM 300/kg x 750, 000, 000 kg/year
= RM 2.25 x 1011
INVESTMENT
Total Investment = RM 78, 557, 820
Interest is 10 % of Total Investment and stays the same throughout the years.
10
× 𝑅𝑀 78,557,820
100
292
= RM 7,855,782
CASH OUT
Investment = RM 78, 557, 820
The investment in production is only for the first 3 years to start-up the plant.
• Year 1
25
× 𝑅𝑀 78,557,820
100
= RM 19,639,455
• Year 2
45
× 𝑅𝑀 78,557,820
100
= RM 35,351,019
• Year 3
30
× 𝑅𝑀 78,557,820
100
= RM 23,567,346
RAW MATERIAL
Benzene = RM 5.8 x 1010
Catalyst = RM 448,800
Total = RM 5.8 x 1010
293
FIXED COST
RM 29, 991,564
VARIABLE COST
RM 58,000,000,000
294
Table 8.3.1: Cash Flow table from year 1 until year 9
Year 1 2 3 4 5 6 7
CASH IN ( RM )
Sale Income - - - 2.34 x 2.40 x 2.34 x 2.34 x

1011 1011 1011 1011
Interest 7.856 7.856 7.856 7.856 7.856 7.856 7.856
(10%) x 106 x 106 x 106 x 106 x 106 x 106 x 106
Total IN 7.856 7.856 7.856 2.34 x 2.40 x 2.34 x 2.34 x
x 106 x 106 x 106 1011 1011 1011 1011
CASH OUT ( RM )
Investment 1.964 3.535 2.357 - - - -
x 107 x 107 x 107
Raw 5.8 x 5.8 x 5.8 x 5.8 x 5.8 x 5.8 x 5.8 x
Material 1010 1010 1010 1010 1010 1010 1010
Fixed cost 2.9 x 2.9 x 2.9 x 2.9 x 2.9 x 2.9 x 2.9 x
107 107 107 107 107 107 107
Variable 5.8 x 5.8 x 5.8 x 5.8 x 5.8 x 5.8 x 5.8 x
cost 1010 1010 1010 1010 1010 1010 1010
Total OUT 1.16 x 1.16 x 1.16 x 1.16 x 1.16 x 1.16 x 1.16 x
1011 1011 1011 1011 1011 1011 1011
Net Cash -1.16 x -1.16 x -1.16 x 1.18 x 1.24 x 1.18 x 1.18 x
Flow 1011 1011 1011 1011 1011 1011 1011
Cumulative -1.16 x -2.32 x -3.48 x -2.3 x -1.06 x 1.2 x 1.3 x
Cash 1011 1011 1011 1011 1011 1010 1011
295
8.3.2 Net Present Worth ( NPW )
𝐸𝑠𝑡𝑖𝑚𝑎𝑡𝑒𝑑 𝑛𝑒𝑡 𝑐𝑎𝑠ℎ 𝑓𝑙𝑜𝑤 𝑖𝑛 𝑦𝑒𝑎𝑟 𝑛 ( 𝑁𝐹𝑊)

(𝑁𝑃𝑊 )𝑜𝑓 𝑐𝑎𝑠ℎ 𝑓𝑙𝑜𝑤 𝑖𝑛 𝑦𝑒𝑎𝑟 𝑛 =
(1 + 𝑟)𝑛
Where;
n = Life of Project ( year when project start making returns )
r = The discount rate ( interest rate
𝑏𝑎𝑛𝑘 𝑖𝑛𝑡𝑒𝑟𝑒𝑠𝑡 𝑟𝑎𝑡𝑒 (%)
𝑟=
100%
𝑛=𝑡
𝑁𝐹𝑊
𝑇𝑜𝑡𝑎𝑙 𝑁𝑃𝑊 𝑜𝑓 𝑝𝑟𝑜𝑗𝑒𝑐𝑡 = ∑
( 1 + 𝑟)𝑛
𝑛=1
(Sinnot, 2005)
To calculate the NPW, the estimated net cash flow in year 5 is chosen because it has gained
profit. Therefore, n will 5.
10 (%)
𝑟=
100%
= 0.1
NFW ( at year 5 ) = RM 1.24 x 1011
RM 1.24 × 1011
(𝑁𝑃𝑊 )𝑜𝑓 𝑐𝑎𝑠ℎ 𝑓𝑙𝑜𝑤 𝑖𝑛 𝑦𝑒𝑎𝑟 5 =
(1 + 0.1)5
𝑁𝑃𝑊 𝑜𝑓 𝑐𝑎𝑠ℎ 𝑓𝑙𝑜𝑤 𝑦𝑒𝑎𝑟 5 = 𝑅𝑀 7.699 × 1010
296
8.3.3 Payback Period
The cash flow diagram for phenol production is computer as below. Based on the diagram,
the payback time of the investment will be the first 6 years. The break – even point is in year
6 where all the debt from investment is settled. Production starts to have profit in year 6 and
onwards.
CASH FLOW DIAGRAM

4.00E+11
3.00E+11
POSITIVE
PROFIT
CUMULATIVE NET CASH FLOW (RM)
2.00E+11 BREAK- EVEN POINT
1.00E+11
0.00E+00
0 1 2 3 4 5 6 7 8 9 10
-1.00E+11
NEGATIVE
INVESTMENT
MAXIMUM
-2.00E+11
-3.00E+11
-4.00E+11
YEAR
Figure 8.3.3 : graph of payback period year vs cumulative cash flow
297
8.3.4 Return of Investment ( ROI/ ROR )
(Sinnot, 2005)
Where;
F = Maximum cumulative Cash flow ( RM 3.57 x 1011)
C = Minimum cumulative cash flow ( RM -3.48 x 1011)
G = Life of Project ( 9 years)
𝑅𝑀 3.57 × 1011 − (𝑅𝑀 − 3.48 × 1011 )

𝑅𝑂𝑅 = | | × 100%
𝑅𝑀 − 3.48 × 1011 × 9
ROR = 22.5 %
𝐶𝑢𝑚𝑢𝑙𝑎𝑡𝑖𝑣𝑒 𝑛𝑒𝑡 𝑐𝑎𝑠ℎ 𝑓𝑙𝑜𝑤 𝑎𝑡 𝑡ℎ𝑒 𝑒𝑛𝑑 𝑜𝑓 𝑝𝑟𝑜𝑗𝑒𝑐𝑡

𝑅𝑂𝑅 = | | × 100%
𝑃𝑟𝑜𝑗𝑒𝑐𝑡 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 × 𝐿𝑖𝑓𝑒 𝑜𝑓 𝑃𝑟𝑜𝑗𝑒𝑐𝑡
298
CHAPTER 9.0: PROCESS CONTROL AND INSTRUMENTATION
9.1 Control System
A control system refers to a set of devices or mechanisms that manage, direct,

command, or regulate the behaviour of other devices or systems using control loops. Its
purpose is to achieve a desired response or output by controlling the input or operation of the
system it is managing. Control systems can range from simple ones like a home heating
controller with a thermostat controlling a domestic boiler, to complex industrial control systems
used in large-scale processes or machines. These systems are designed through the field of
control engineering, which involves the process of designing, analyzing, and optimizing control
systems.(“What Is a Control System? (Open Loop & Closed Loop Control Systems Explained)
| Electrical4U,” n.d.).
In a control system, there are two types of control systems which is Open Loop Control
System and Closed Loop Control System. Closed loop ontrol system are knows as Feedback
Control while open loop control system knows as Feedforward Control. A feedback control
system plays a crucial role in achieving the desired control. In continuously modulated control,
a feedback controller is used to automatically control a process or operation. The control
system compares the value or status of the process variable (PV) being controlled with the
desired value or setpoint (SP) and applies the difference as a control signal to bring the
process variable output of the plant to the same value as the setpoint. A feedforward control
system is a type of control system that anticipates disturbances or changes in the system and
adjusts the control inputs accordingly to minimize the impact on the system's output. Unlike
feedback control systems that rely on measuring the output and comparing it to a desired
setpoint, feedforward control systems proactively respond to known disturbances or inputs.
Based on the 750,000 MTA Phenol production plant, it crucial to implementing a good
control system in order to control the major equipment in the plant for example Reactor R-101
(Packed Bed Reactor) to ensure that increase the performance of the reaction and equipment.
Other than that, Control systems are essential for ensuring the safety of personnel, equipment,
and the environment within a plant. They can detect abnormal conditions, such as high
temperatures, leaks, or pressure deviations, and trigger appropriate responses to mitigate
risks, such as shutting down equipment or activating safety protocols.
299
Control systems find applications in various industries to enhance production,
efficiency, and safety. Control systems are essential in plants for process optimization, safety,
equipment protection, energy efficiency, quality control, flexibility, data analysis, and regulatory
compliance. They contribute to the smooth and efficient operation of the plant while ensuring
productivity, safety, and compliance with industry standards.
9.1.1 Objective of Control System
1. Stability
Control systems aim to maintain stability by ensuring that the system operates within
desired limits and does not exhibit excessive oscillations or instability. The control system
continuously adjusts inputs and parameters to keep the system stable and prevent
undesirable behaviour (4.0: Prelude to Control System Design Objectives - Engineering
LibreTexts, n.d.). For example, controlling the flow through the pipeline in the Phenol
production in order to maintain the stability of the flow flowing into the equipment.
2. Disturbance Rejection
Control systems aim to minimize the impact of disturbances or external factors that
can affect the system's behaviour. The control system actively compensates for known or
unpredictable disturbances, ensuring that the system remains robust and maintains the
desired performance despite external influences (4: Control System Design Objectives -
Engineering LibreTexts, n.d.). For example, increase temperature for the reaction in Reactor
R-101, the control system may activate a flow of cooling system to counteract the disturbance
and maintain the desired temperature.
3. Regulation
Control systems regulate and maintain specific variables or parameters within

predefined ranges or setpoints. This could include controlling temperature, pressure, flow rate,
speed, position, or any other relevant parameter. The control system continuously adjusts
inputs to maintain the desired values of these variables (Zywno, n.d.). For example, phenol
production involves various exothermic reactions especially on Reactor R-101, where
temperature control is crucial to maintain the desired reaction rate and product quality. Control
300
systems utilize temperature sensors and feedback mechanisms to adjust heat transfer
mechanisms such as cooling or heating to maintain the temperature within the optimal range.
4. Product Specification
In the case of phenol production, the control system helps in maintaining the required
purity of the main product, Phenol, as well as other co-products like Benzoic acid, Catechol,
and Benzaldehyde. By closely monitoring and controlling the process variables, such as
temperature, pressure, and reactant ratios, the control system ensures that the production
process operates within the specified limits to achieve the desired product quality.
The target production of 450,000 metric tons per year sets the benchmark for the
quantity of phenol to be produced. The control system optimizes the process parameters to
meet this target while maintaining the quality standards. It regulates the feed rates, reactant
concentrations, and reaction conditions to achieve the desired purity of phenol, which in your
case is approximately 99% or higher.
By maintaining the high purity of the main product, phenol, the supplier can fulfill the
client's target and provide a high-quality product. This is crucial for ensuring customer
satisfaction, meeting market demand, and building a reputation for reliable and trustworthy
products. The control system helps minimize variations, deviations, and inconsistencies in the
production process, thereby reducing the risk of producing substandard products that do not
meet the specified limits.
5. Safety and Environmental Regulations
In the context of phenol production, control systems play a critical role in ensuring
compliance with safety and environmental regulations. Safety and environmental
considerations are of utmost importance in any industrial process, including the production of
phenol. By implementing the process control system, it helps monitor and control various
process parameters to ensure safe operation. They continuously monitor factors such as
temperature, pressure, flow rates, and levels to prevent any deviations that could lead to
hazardous conditions. Alarms and interlocks can be integrated into the control system to
301
provide early warnings and automatically shut down the process if critical safety thresholds
are exceeded.
For example, 750,000 MTA phenol production process involves various temperature-
sensitive reactions and processes. By involving the cascade control systems (combination of
2 feedback system), its continuously monitor and regulate temperatures at different stages of
the production process to prevent overheating, which could lead to hazardous conditions or
even equipment failure. By maintaining temperatures within safe operating limits, the risk of
accidents or thermal runaway can be minimized.
Other than that, phenol production may produce various waste streams that require
proper management and treatment to comply with environmental regulations. Control systems
can help track and control the handling, treatment, and disposal of waste materials generated
during the production process. They can also ensure that waste streams are appropriately
segregated, treated, and disposed of in accordance with regulatory requirements. Last but not
least, control systems can incorporate emergency shutdown systems that can rapidly respond
to critical situations. These systems can initiate emergency shutdown procedures in case of
incidents or potential hazards, safeguarding personnel, equipment, and the environment.
Emergency shutdown systems can be designed to activate automatically or manually in
response to specific triggers or safety concerns.
9.1.2 Process Control Loop

Process control loops are an integral part of control systems used in industrial processes to
regulate and maintain specific variables or parameters within predefined ranges. A control loop
consists of various components that work together to monitor, analyze, and adjust the process
variables to achieve the desired control objective. By referring to figure 9.1 below, there was
the process control loop flow diagram.
302
Process Sensor Transmitter
Control
Transducer Controller
Valve
Figure 9.1: Process control loop flow diagram.
A. Process
The process refers to the system or operation that needs to be controlled. It could be a
chemical reactor, a heating system, a water treatment plant, or any other industrial process.
The process variable (PV) is the parameter within the process that requires control, such as
temperature, pressure, flow rate, or level.
B. Sensor
The sensor is a device used to measure the process variable (PV). It converts the physical
quantity (e.g., temperature, pressure) into an electrical signal that can be interpreted by the
control system. The sensor provides feedback to the control loop by continuously monitoring
the PV.
C. Transmitter
The transmitter is a device that receives the electrical signal from the sensor and converts it
into a standardized output signal, such as a 4-20 mA current signal or a 0-10 V voltage signal.
The transmitter amplifies and conditions the signal to ensure accurate transmission to the
controller.
D. Controller
The controller is the central component of the control loop responsible for comparing the
measured PV with the desired setpoint (SP) and generating control signals. It receives the
standardized signal from the transmitter and computes the error, which is the difference
between the PV and SP. The controller applies a control algorithm to determine the appropriate
action to be taken.
303
E. Transducer
The transducer is a device that receives the control signal from the controller and converts it
into a suitable form to actuate or control the process. In this context, the transducer could be
an I/P (current-to-pressure) transducer or a P/I (pressure-to-current) transducer, depending
on whether the process requires a pressure control valve or any other actuator.
F. Control Valve
The control valve is an actuator that receives the output signal from the transducer and adjusts
the process parameter accordingly. It modulates the flow of fluid (liquid, gas, or steam) to
control the process variable. The control valve can regulate the flow rate, pressure, or level
within the process by opening or closing to varying degrees based on the control signal
received.
There are 4 basic elements in order to operate the control system. By referring the
figure 9.2 below. These four elements work together in a closed-loop control system, where
the output is continuously monitored and fed back to the controller to regulate and maintain
the process or system within the desired range or setpoint. The controller compares the input
and feedback signals to generate the appropriate control action, which is then applied to the
process, influencing its behaviour and driving it towards the desired output. This feedback loop
allows the control system to continuously adjust and adapt to changes and disturbances,
ensuring accurate and stable control of the system.
Figure 9.2: 4 basic elements in process control system.
304
I. Process
The process refers to the system or plant being controlled. The process receives inputs,
undergoes transformations, and produces outputs. It is the system that the control system
aims to regulate and optimize.
II. Controller
The controller is the component responsible for making decisions and generating control
signals to manipulate the process variables. It receives information about the process state
through sensors or measurements, compares it with the desired setpoints or reference values,
and determines the appropriate control action to be taken.
III. Sensor/Measurement Device

Sensors are used to measure the process variables or parameters that are critical for control.
They provide feedback to the controller by converting physical quantities, such as
temperature, pressure, flow rate, or level, into electrical signals that can be processed. The
accuracy and reliability of sensors are crucial for the effectiveness of the control system.
IV. Final Control Element

The final control element is the device or mechanism responsible for implementing the control
action determined by the controller. It receives the control signal from the controller and adjusts
the process variables accordingly. The most common final control element is a control valve,
which regulates the flow of fluids or gases.
9.1.3 Control System in Phenol Production Plant

There are 4 major equipment had been specified to implement the control system which are:
I. Reactor
II. Heat-exchanger
III. Flash drum vessel
IV. Distillation column
There are two control system had been implemented in the 4 major equipment in the phenol
production plant namely Feedback Control and Cascade Control.
305
9.1.4 Feedback Control
Figure 9.3: Feedback Control
Feedback control is a fundamental concept in control systems engineering that

involves using feedback information from the output of a system to regulate and adjust its
behaviour. It is a closed-loop control technique where the system's output is continuously
monitored and compared with a desired reference or setpoint. The feedback loop is completed
when the actuator's actions affect the process, causing changes in the output. The sensor
measures these changes, and the cycle continues with the updated information being fed back
to the controller for further adjustments. This continuous feedback loop allows the control
system to dynamically adapt to disturbances, uncertainties, and variations in the process to
maintain stability and achieve the desired performance.
By utilizing feedback information, the control system can actively regulate the process
and correct deviations from the desired behaviour. It enables the system to compensate for
disturbances, maintain setpoints, reject external influences, and improve accuracy, stability,
and robustness. By referring the table 9.1 below, there are the advantages and disadvantages
of feedback control.
Table 9.1: Advantages and disadvantages of Feedback Control.
Advantages Disadvantages
Can eliminate the error of the process Disturbances significantly impact systems
continuously. before control action is initiated.
Does not require measurements of When used improperly, can cause instability
disturbances. due to nonlinearity.
Too slow of a system or a system with high
Simple to implement.
deadtime do not work well.
306
9.1.5 Cascade Control
Figure 9.4: Cascade control.
Cascade control is a control strategy that involves using multiple control loops in a
hierarchical manner to improve the performance of a control system. It is particularly useful
when dealing with processes that have significant time delays, non-linearities, or disturbances.
Simple definition of the cascade control was combination of the two feedback control system.
In a cascade control configuration, there are two control loops namely Master Control which
is the primary or outer loop and Slave Control which is the secondary or inner loop. The
primary loop regulates the main process variable, while the secondary loop controls a
secondary variable that directly affects the primary variable (“Marine Engines and Auxiliary
Machinery,” 2008).
The primary loop is responsible for controlling the main process variable, which is
typically the variable of highest importance or the one that directly affects the product quality
or performance. It receives a setpoint (desired value) and compares it to the measured value
of the process variable using a feedback controller. The output of the primary controller is used
to manipulate a manipulated variable, often referred to as the setpoint of the secondary loop.
The secondary loop is nested within the primary loop and focuses on controlling the
secondary variable, which influences the primary variable. The secondary variable is typically
measured and controlled by a separate sensor and controller. The secondary controller
receives the setpoint from the primary controller and compares it to the measured value of the
secondary variable. Based on this comparison, it generates a control signal to manipulate a
307
manipulated variable, usually a control valve or actuator. By referring the table 9.2 below, there
was the advantage and disadvantage of the cascade control.
Table 9.2: Advantages and disadvantages of Feedback Control.
Advantages Disadvantages
Improved and fast response. More complexity of control system.
Reduced interference. Sensitivity to the mismatch model.
Better rejection of load changes. Complexity in the tuning process.
308
Reactor (R-101)
Figure 9.5: Cascade and feedback control diagram on Reactor R-101.
Figure 9.6: Block flow diagram of temperature cascade control for R-101.
309
Figure 9.7: Block flow diagram of inlet flow feedback control for R-101.
Figure 9.8: Block flow diagram of level feedback control for R-101.
Figure 9.9: Block flow diagram of pressure feedback control for R-101.
310
Table 9.3: Reactor R-101 temperature cascade control.
Table 9.4: Reactor R-101 flow feedback control.
Table 9.5: Reactor R-101 level feedback control.
Table 9.6: Reactor R-101 pressure feedback control.
311
Heat Exchangers (E-101,102,103,104,105,106,107)
Figure 9.10: Cascade control diagram on heat exchangers.
312
Figure 9.11: Block flow diagram of temperature cascade control for heat exchangers.
Table 9.7: Heat exchanger temperature cascade control.
313
Flash Drum (T-101)
Figure 9.12: Feedback control diagram on Flash Drum (T-101).
Figure 9.13: Block flow diagram of pressure feedback control for Flash drum.
314
Figure 9.14: Block flow diagram of flow feedback control for Flash drum.
Figure 9.15: Block flow diagram of level feedback control for Flash drum.
Table 9.8: Flash drum flow feedback control.
315
Table 9.9: Flash drum pressure feedback control.
Table 9.10: Flash drum level feedback control.
316
Distillation Column (T-102,103,104)
Figure 9.17: Feedback and cascade control diagram on distillation column.
317
Figure 9.18: Block flow diagram of temperature cascade control for top product distillation
column.
Figure 9.19: Block flow diagram of temperature cascade control for bottom product
distillation column.
318
Table 9.11: Distillation column top product cascade control.
Table 9.12: Distillation column bottom product cascade control.
Cascade Control System on Bottom Product Temperature for Distillation Column

Type of Control
Cascade control system.
System
To ensure that bottom product leaving the distillation
Control Objective
column has the desired consistency temperature.
Master Loop Temperature Controlling (TIC).
Slave Loop Reboiler feed in flowrate controlling (FIC).
Process Variable Temperature and flow transmitter.
Manipulated
Reboiler steam in flow control valve (FCV).
Variable
Manipulated the Reboiler steam in flow control valve
Action to increase heat input to regulate the desired bottom
column temperature.
319
9.2 Process & Instrumentation Diagram (P&ID)
Figure 9.20: P&ID for phenol production plant.
320
Figure 9.21: Zoom in P&ID for feed process.
321
Figure 9.22: Zoom in P&ID for flash drum process.
322
Figure: 9.23: Zoom in P&ID for distillation column
323
Figure 9.24: Line symbols that indicate in the P&ID.
9.3 Control/Instrument Variable In Plant
Table 9.13: Instrumentation abbreviations in P&ID.
Parameter Letter Code Symbol Expansion Function
Detect changes in
Temperature temperature and
TE
Sensor convert them into
electrical signals.
Transmitting
Temperature
TT measured
Transmitter
temperature signals.
Indicating
Temperature
temperature as well
Temperature TIC Indicator
as controlling the
Control
temperature.
Temperature Alarm system for

TAH
Alarm High. high temperature.
Temperature Alarm system for

TAL
Alarm Low lower temperature.
324
Transmitting
Flow
FT measured flowrate
Transmitter
signal.
Indicating flow as
Flow Indicator
FIC well as controlling
Control
the flow
Flow
Measure the flowrate
and transfer the
Flow
FY information after
Transducer
converting it into the
readable form.
Regulator or control
Flow Control
FCV the flowrate.
Valve
Transmitting
Pressure
PT measured pressure
Transmitter
signal.
Pressure Indicating pressure

PIC Indicator as well as controlling
Control the pressure.
Pressure
Measure the
pressure and
Pressure transfer the
PY
Transducer information after
readable form.
Pressure Regulator or control

PCV
Control Valve the pressure.
325
Pressure Indicating the gauge
PG
Gauge value.
Transmitting
Level
LT measured level
Transmitter
signal.
Detect changes in
level and convert
LE Level Sensor
them into electrical
signals.
Indicating level as
Level Indicator
LIC well as controlling
Control
the flow
Measure the level

and transfer the
Level
Level LY information after
Transducer
readable form.
Level Control Regulator or control

LCV
Valve the level.
Alarm system for

Level Alarm
LAL Low level of flow
Low
substance.
Alarm system for

Level Alarm
LAH high level of flow
High
substance.
326
Power source for
Switch Pump HS Hand Switch
Pump.
327
CHAPTER 10: SAFETY AND HEALTH
10.1 Safety and Loss Prevention
Safety and loss prevention in an industrial plant are crucial to ensuring the well-
being of employees, safeguarding assets, and maintaining uninterrupted operations.
The workplace poses various hazards to employees, and it is the responsibility of
employers to ensure their safety in accordance with the Occupational Safety and
Health Act 1994. Employers must effectively manage and control hazards to minimize
risks to an acceptable level. Risk refers to the likelihood and severity of harm resulting
from accidents, injuries, or fatalities.
In process safety design, prioritizing safety and loss prevention is crucial for
preventing accidents and reducing workplace hazards. It saves lives, protects physical
assets, prevents employee suffering, and avoids unnecessary costs. Safety design
should include effective hazard and risk management throughout the design process.
Hazard and risk management involve identifying occupational safety and health
hazards, assessing the associated risks based on the probability and severity of
potential harm, implementing preventive measures to mitigate risks, and
communicating these risks to workers. Hazards encompass all aspects of technology
and activities that generate risks and potential harm.
Risk assessment is a systematic process of evaluating and analyzing risks

associated with hazardous substances, processes, actions, or events. Various risk
analysis strategies can be employed to assess workplace risks based on the
probability and potential severity of consequences. Controlling hazards and processes
is another effective method to prevent accidents, especially when dealing with
chemicals such as phenol production. If risks cannot be eliminated, control measures
should be used to lower the risks. A hierarchy of controls helps select the most
appropriate risk management method, starting from the most effective to the least
effective measures.
328
Elimination and substitution are the most effective methods of removing hazards
from the workplace. If elimination is not feasible, risk minimization can be achieved
through process or activity modifications, changes in work procedures through
administrative controls, and the use of Personal Protective Equipment (PPE) by
employees.
However, process hazards in industries, particularly in chemical plants, present

significant risks, such as highly hazardous materials and unsafe environments with
hidden hazards. These hazards can have severe consequences, including accidents
and fatalities due to explosions. To limit losses and identify process deviations and
external events in the production of high purity phenol, conducting a HAZOP (Hazard
and Operability) study is crucial. HAZOP study is a systematic and structured
technique for examining systems and managing risks. It helps identify potential
hazards and operability issues resulting from seemingly safe components or
operational methods. The purpose of a HAZOP study is to investigate deviations that
may occur in the production plant or process equipment, thereby identifying risks to
the process and equipment's operability.
10.2 Type of Incident, Potential Incident, and Incident Consequence
The production of phenol in a chemical plant exposes workers to various hazardous

risks that can potentially lead to accidents or incidents causing harm to their health and
property. Despite meticulous design and operation, accidents can still occur, ranging
from minor occurrences like small spills or releases to major incidents that necessitate
evacuation and result in personal injuries or even fatalities. It is essential to have a
comprehensive plan in place to identify potential scenarios and ensure that personnel
receive proper training on how to respond in the event of an incident or accident. The
following examples outline both minor and major incidents related to the phenol
industry or involving phenol.
10.2.1 Fire
Fire hazards in a phenol industry can arise from various sources and processes
within the facility. Phenol, being a highly flammable and combustible substance,
329
requires specific precautions to prevent and mitigate fire incidents. Phenol has a
relatively low flash point and can easily ignite when exposed to an ignition source such
as sparks, open flames, or hot surfaces. Phenol can release flammable vapors at
ambient temperatures, increasing the potential for fire hazards in areas where it is
stored, handled, or processed. Phenol can also react with certain materials, including
oxidizing agents, which may lead to increased fire hazards and the potential for violent
reactions.
The fire hazards can also extend to the storage and handling of chemicals, large
quantities of phenol are often stored in tanks or drums. Improper storage practices,
such as inadequate ventilation, incompatible materials, or improper segregation, can
increase the risk of fire. Transferring flammable chemicals such as benzene and
phenol through pipelines or using pumps and valves can pose fire hazards if leaks or
spills occur during the process. Contamination of chemical to external factor can also
contribute to fire hazard. Chemicals such as phenol may become contaminated with
other substances, including incompatible chemicals or impurities. This can lead to
increased fire hazards and potential for uncontrolled reactions.
The equipment in the plant also poses a fire hazard, phenol production processes
involve various heat sources, such as reactors, heat exchangers, and distillation
columns. Malfunctioning equipment or inadequate maintenance can lead to
overheating or ignition, triggering a fire. Fire hazards can arise from electrical
equipment, sparks from friction, hot work activities such as welding and cutting or static
electricity discharge in areas where phenol is present. Process upsets, such as
uncontrolled reactions, over pressurization, or equipment failures, can result in the
release of phenol or other flammable substances, leading to fire hazards.
In order to avoid various problems from fire hazards, the need to mitigate fire
hazards in a phenol industry is essential to the industry and robust fire prevention and
protection measures need to implement. There are many methods to prevent industrial
fire, the following are several example:
⚫ Implementing fire-resistant construction materials and passive fire protection

measures in buildings and storage areas.
⚫ Installing fire detection and suppression systems, such as smoke detectors, fire
sprinklers, or fixed firefighting systems.
⚫ Conducting regular inspections and maintenance of electrical systems and

equipment to prevent electrical fires.
330
⚫ Implementing proper storage practices, including segregation, ventilation, and
control of ignition sources.
⚫ Providing fire safety training to employees, including fire prevention, emergency

response, and evacuation procedures.
⚫ Establishing emergency response plans and conducting regular drills to ensure

effective response in the event of a fire incident.
⚫ Compliance with relevant fire codes, standards, and regulations is crucial to

minimize fire hazards and ensure the safety of personnel, the facility, and the
surrounding environment in a phenol industry.
No. Incident cases Location and date

1 INEOS Phenol chemical plant fire caused by Pasadena, Texas.
explosion that triggered as liquified petroleum March 23, 2023.
gas was being transferred from one tanker to
another through a hose, and the first tanker had
an unintentional leak On person are injured in
the blast but no casualty recorded in the incident
Table 10.1 explaining the incident that causes fire in the plant
10.2.2 Explosion
Explosions are a significant hazard that can occur in a phenol industry due to the
nature of the chemicals involved and the potential for certain conditions to trigger
explosive reactions. Phenol, being a flammable substance, can pose explosion risks if
not handled and controlled properly. Some factors that contribute to explosion hazard
in the industry are as follow:
Hazardous Chemicals and Reactivity: Phenol is known to react violently with certain
substances, including oxidizing agents, strong acids, and bases. Incompatible
materials or improper handling can lead to uncontrolled reactions and the generation
of explosive mixtures.
Process Upsets and Overpressure: Phenol production processes involve high

temperatures and pressures. Equipment failures, process upsets, or inadequate
pressure relief systems can result in overpressure situations, causing vessels,
pipelines, or other equipment to rupture, leading to explosions.
Ignition Sources: Explosions require an ignition source to trigger the combustion of

flammable substances. In a phenol industry, potential ignition sources include sparks,
331
open flames, electrical equipment, static electricity discharge, or hot surfaces. Failure
to control or eliminate these ignition sources can increase the likelihood of explosions.
Vapor Cloud Explosions: Phenol, being volatile, can form flammable vapor clouds if
released into the atmosphere. If these vapors come into contact with an ignition source
within their flammable range, a vapor cloud explosion may occur. Vapor cloud
explosions can have significant consequences, leading to widespread damage and
injuries.
Dust Explosions: In addition to phenol, other substances used or produced in the

phenol industry may generate combustible dust. Dust explosions can occur when fine
particles of combustible material are dispersed in the air, creating a combustible dust
cloud. If ignited, the dust cloud can rapidly propagate the explosion, causing significant
damage.
This hazards can be prevented by following the standard guideline provided by OSHA
and the local statutory law to prevent explosions in a phenol industry, several measures
that can be implemented includes:
⚫ Conducting hazard assessments, such as Process Hazard Analysis (PHA) or

Hazard and Operability Studies (HAZOP) on the equipment such as boilers, heat
exchanger and distillation column that are explosion prone, then identify potential
explosion hazards
⚫ Implementing proper process design and engineering controls, including pressure

relief systems, flame arrestors, explosion-proof electrical equipment, and isolation
measures.
⚫ Ensuring effective grounding and bonding practices to control static electricity

risks.
⚫ Implementing proper housekeeping practices to minimize the accumulation of

combustible dust and controlling ignition sources in areas where dust is present.
⚫ Providing comprehensive training to employees regarding safe handling

procedures, recognizing potential hazards, and responding to emergency
situations.
⚫ Regularly inspecting and maintaining equipment, including pressure vessels,

piping systems, and electrical installations, to prevent failures that can lead to
explosions.
⚫ Conducting periodic audits and compliance checks to ensure adherence to
332
applicable regulations and industry best practices for explosion prevention.
By implementing these measures and promoting a strong safety culture, the risk of
explosions in a phenol industry can be significantly reduced, protecting personnel, the
facility, and the surrounding environment.
No. Incident cases Location and date

1 Explosion and Fire at Ineos Phenol Plant due Mobile, Alabama.
to one of the two trains in the unit where September 13, 2002
cumene hydroperoxide is split into phenol and
acetone exploded, fortunately no injuries were
recorded.
2 A wastewater tank exploded and started a fire Rayong, Bangkok.
inside the factory of PTT Phenol Co.the August 22, 2016
incident occurred about 2.17am. A 537 cubic
metre tank containing wastewater
contaminated with hydrocarbon exploded and
caught fire. The cause of the explosion is still
being investigated.
Table 10.2 explaining the incident that causes explosion in the plant
10.2.3 Chemical Spills and Leaks
Chemical spillage in the phenol industry presents significant hazards to personnel, the
environment, and the facility itself. Spilled chemicals, such as benzene, benzoic acid,
catechol, and compressed air, can cause health effects, fire and explosion risks, and
environmental damage. Exposure to benzene, for example, can lead to acute or
chronic health issues, including skin irritation, respiratory problems, organ damage, or
even cancer. Furthermore, some chemicals are highly flammable, and spills can create
flammable vapor clouds that increase the risk of fires or explosions if ignited.
Chemical spill incidents can occur due to various factors, including human error,
equipment failure, accidental impacts, and inadequate maintenance. Improper
handling, poor storage practices, lack of training, or failure to follow standard operating
procedures can result in spills. Equipment failures, such as leaks, ruptures, or
malfunctioning valves and pipes, can also contribute to uncontrolled chemical
releases. Additionally, accidental impacts or mishandling of chemical containers can
333
cause spills, and inadequate maintenance practices increase the likelihood of leaks or
equipment failures.
To prevent chemical spillage in the phenol industry, several preventive measures

should be implemented. Safe handling and storage practices are crucial, including
proper training and education for employees, appropriate storage facilities with
secondary containment measures (such as bunds or trays), and clear labeling and
color-coding systems for chemicals to avoid mix-ups and accidental spillage.
Robust equipment and infrastructure play a vital role in spill prevention. Regular
inspection and maintenance of equipment, valves, pipes, and containment vessels are
necessary to prevent leaks or failures. Safety devices, including pressure relief valves,
rupture disks, or leak detection systems, should be installed to minimize the risk of
chemical spills. Ensuring the integrity of storage tanks, pipelines, and transfer systems
is also essential to prevent leaks or ruptures.
Emergency response and contingency planning are critical components of spill

prevention. Developing and regularly updating an emergency response plan that
outlines procedures for containment, cleanup, and evacuation is essential. Providing
spill response kits and equipment, such as absorbents, neutralizing agents, personal
protective equipment (PPE), and spill containment booms, in easily accessible
locations enables prompt response to spills. Conducting drills and training exercises
helps familiarize employees with emergency protocols and spill cleanup procedures.
Compliance with applicable regulations, industry standards, and guidelines is

imperative. Adhering to proper handling, storage, and transport practices for chemicals
is necessary to minimize spill risks. Conducting risk assessments and hazard analyses
to identify vulnerabilities and implementing appropriate risk mitigation measures further
enhances spill prevention efforts. Regularly reviewing and updating standard operating
procedures to incorporate lessons learned from incidents, near misses, or changes in
regulations ensures ongoing improvement in spill prevention measures.
By implementing these preventive measures, the phenol industry can reduce the risk
of chemical spillage, protecting the safety of personnel, minimizing environmental
impact, and maintaining the integrity of the facility.
334
10.3 Hazardous Material In The Plant
10.3.1 Hazardous material
Chemicals encompass elements, chemical compounds, or mixtures that exist in

various forms, such as solids, liquids, gases, or vapors, and can occur naturally or be
synthetically produced. In industrial settings, certain chemicals are classified as
hazardous substances, posing potential risks known as chemical hazards. These
hazardous substances can adversely affect workers when exposed to them, as defined
by Safe Work Australia (2010).
Chemical hazards and toxic substances have the potential to present a wide range of
health risks, including irritation, sensitization, carcinogenicity, as well as physical
hazards such as flammability, corrosion, and explosiveness. Another way to define
chemical hazards is through the energy-based classification, where hazardous energy
is released due to disruption of molecular bonding caused by chemical reactions. This
typically refers to reactive chemical hazards found in industrial chemicals, pesticides,
agricultural chemicals, pharmaceuticals, cosmetics, and food-related chemicals.
These hazards can have detrimental effects on worker health through direct contact or
exposure to the chemicals. Dangerous substances can be listed as follow:
Class 1: Explosive
Class 2: Gases
Class 3: Flammable liquid
Class 4: Flammable solid
Class 5: Oxidizing substances, hydrogen peroxide
Class 6: Toxic substances and infection substances
Class 7: Radioactive material
Class 8: Corrosives
Class 9: Miscellaneous hazardous material
10.3.1 Benzene
Benzene is used in this industry as the raw material in producing phenol, but it poses
significant hazards to human health and safety. Benzene is a colorless liquid with a
335
sweet, aromatic odor. It is highly volatile, meaning it evaporates quickly at room
temperature, forming vapor that is heavier than air. This vapor can travel long distances
and pose inhalation risks. Benzene is also flammable, with a low flash point and a wide
explosive range. It can ignite easily when exposed to open flames, sparks, or heat
sources.
Exposure to benzene can have detrimental effects on human health. It is classified as

a carcinogen, meaning it can cause cancer, particularly leukemia. Benzene exposure
can occur through inhalation, skin contact, or ingestion. Short-term exposure to high
levels of benzene can cause symptoms like dizziness, headaches, nausea, and
respiratory irritation. Long-term exposure, even at low concentrations, can lead to
serious health problems, including bone marrow damage and blood disorders.
To handle benzene safely in industrial environments, several precautions should be

taken. Firstly, engineering controls should be implemented to minimize exposure.
These may include closed systems, ventilation, and local exhaust systems to capture
and remove benzene vapors. Personal protective equipment (PPE) should be
provided, such as respiratory protection, gloves, goggles, and protective clothing, to
protect workers from contact with benzene.
Proper storage and handling procedures are essential. Benzene should be stored in
approved containers, away from ignition sources and incompatible substances. Good
housekeeping practices should be followed to prevent spills and leaks. If a spill does
occur, immediate action should be taken to contain and clean it up safely, following
established spill response protocols.
Regular monitoring and testing of benzene levels in the air and other environmental
matrices should be conducted to ensure compliance with occupational exposure limits
and to identify any potential leaks or releases. Additionally, employee training and
education programs should be implemented to raise awareness about the hazards of
benzene, safe handling practices, and emergency procedures.
It is crucial to comply with applicable regulations, standards, and guidelines concerning

the use and handling of benzene. Regular audits and inspections can help ensure that
safety measures are in place and are being followed.
By understanding the hazards associated with benzene and implementing proper

safety measures, industrial workers can minimize the risks of exposure and potential
health effects. Prioritizing safety and adhering to best practices when handling
benzene is essential to protect both workers and the surrounding environment.
336
10.3.2 Compressed Air
Compressed air is one of the most crucial utility components in industry, it is to oxidize
the raw benzene before entering the reactor. One of the primary hazards of
compressed air is the potential for high-pressure releases. Compressed air is stored
at high pressures, which can cause serious injuries if not controlled or released safely.
If a compressed air system experiences a failure, such as a ruptured hose, damaged
fittings, or a faulty pressure relief device, it can result in the sudden release of high-
pressure air. This release can cause projectiles, flying debris, or uncontrolled
movement of equipment, posing risks to nearby personnel.
Another hazard is the potential for direct contact with compressed air streams. The
force of compressed air can cause injuries such as cuts, abrasions, or tissue damage
if the air stream is directed towards the body or sensitive areas, such as the eyes or
ears. Direct contact with compressed air can also lead to respiratory issues if it
contains contaminants, such as oil or harmful particles, which can be propelled into
the lungs upon inhalation.
In addition, compressed air systems can pose risks related to the presence of moisture
and oil. If the compressed air contains excessive moisture, it can lead to the formation
of condensate in the system. This condensate, if not properly drained, can accumulate
in pipes, equipment, or tools, causing corrosion, malfunctions, or contamination of
products. Oil contamination in compressed air systems can arise from lubricants used
in compressors and can result in adverse effects on downstream processes or end
products.
To handle compressed air safely, several precautions should be followed. Proper

training and education should be provided to employees to ensure they understand
the hazards associated with compressed air and the necessary safety protocols. This
includes training on appropriate use of personal protective equipment (PPE), such as
safety glasses, hearing protection, and appropriate clothing.
Regular inspection and maintenance of compressed air systems are essential to

identify and address any potential issues or failures. This includes checking for leaks,
ensuring proper pressure relief devices are in place, and verifying the condition of
hoses, fittings, and connectors. Any damaged or worn components should be promptly
repaired or replaced.
Safe work practices should be established, including guidelines for the proper use of
compressed air tools and equipment. This includes ensuring that compressed air is not
337
directed towards the body or other personnel, and that tools are used in accordance
with manufacturer recommendations. Compressed air should never be used for
cleaning purposes on the skin, clothing, or in the vicinity of other individuals.
Proper filtration and drying systems should be installed to remove moisture and
contaminants from the compressed air supply. Regular maintenance of these systems,
including replacing filters and draining condensate, is necessary to prevent issues
associated with moisture and oil contamination.
By understanding the hazards of compressed air and implementing appropriate safety

measures, such as training, maintenance, and safe work practices, the risks
associated with compressed air can be minimized. It is crucial to prioritize safety,
promote awareness, and ensure compliance with relevant regulations and guidelines
to protect personnel and maintain a safe working environment.
10.3.3 Phenol
Phenol, which is the product of in our industry, presents several hazards that need to
be recognized and managed effectively. As the purity of the phenol produced, which
around 99% the hazard pose by the chemical is more significant than the raw material
such as benzene used in the industry.
One of the primary hazards of phenol is its toxicity to humans. Phenol can be harmful
if inhaled, ingested, or comes into contact with the skin. Inhalation of phenol vapors
can cause irritation to the respiratory system, leading to coughing, shortness of breath,
and chest tightness. Prolonged or repeated exposure to phenol may result in more
severe health effects, including damage to the liver, kidneys, and central nervous
system.
Phenol is also corrosive to the skin and eyes. Direct contact with phenol can cause
severe burns, skin irritation, and eye damage. Therefore, appropriate personal
protective equipment (PPE), such as gloves, protective clothing, goggles, and face
shields, should be worn when handling phenol to prevent skin and eye exposure.
Another hazard associated with phenol is its flammability. Phenol is a flammable liquid
with a relatively low flashpoint, meaning it can ignite easily when exposed to an ignition
source. Phenol vapors can form explosive mixtures in the air, increasing the risk of fire
and explosions. Adequate fire prevention and protection measures, including the use
338
of spark-resistant equipment, proper grounding, and effective ventilation systems,
should be in place to minimize the risk of fires and explosions.
Furthermore, phenol can pose environmental hazards. If released into the

environment, phenol can contaminate soil, water bodies, and air, leading to adverse
effects on ecosystems and aquatic life. Proper containment and handling procedures
should be followed to prevent spills and leaks, and any accidental releases should be
promptly reported and addressed to mitigate environmental impact.
To manage the hazards associated with phenol, several preventive measures should
be implemented. Workers should receive proper training on the safe handling, storage,
and use of phenol, including awareness of its hazards and appropriate response in
case of exposure or spills. Good ventilation systems should be in place to control and
minimize exposure to phenol vapors. Adequate storage facilities should be utilized,
including secondary containment measures, to prevent leaks and spills.
Regular inspections and maintenance of equipment and storage containers are crucial
to identify and address any potential leaks or failures. Emergency response plans and
spill containment protocols should be established to ensure a prompt and effective
response in the event of a phenol spill or release. Proper disposal methods for phenol
waste should be followed to prevent environmental contamination.
Compliance with applicable regulations, industry standards, and guidelines is essential

to manage the hazards associated with phenol. Periodic audits and assessments
should be conducted to verify compliance, identify areas for improvement, and
implement necessary corrective actions.
10.3.4 Catechol
Catechol, one of the byproduct in the production of phenol, presents specific hazards
that require careful understanding and management. Proper recognition of these
hazards is essential for ensuring the safe handling and utilization of catechol in
industrial settings.
One significant hazard associated with catechol is its potential to cause skin and eye
irritation. Direct contact with catechol can result in skin burns, irritation, and dermatitis.
Therefore, it is crucial to wear appropriate personal protective equipment (PPE), such
as gloves, protective clothing, goggles, and face shields, to minimize the risk of skin
and eye contact.
339
Another hazard to consider is the flammability of catechol. It is a flammable substance,
and its vapors can form explosive mixtures in the air, increasing the risk of fire and
explosions. Implementing proper fire prevention and protection measures, including
adequate ventilation, spark-resistant equipment, and proper grounding, is vital to
minimize the potential for fires and explosions.
Additionally, catechol may have toxic effects if inhaled or ingested. Inhalation of

catechol vapors can lead to respiratory irritation and difficulty breathing, while ingestion
can cause gastrointestinal disturbances and, in severe cases, liver and kidney
damage. Ensuring proper ventilation in areas where catechol is used and preventing
ingestion through safe handling practices are essential precautions to minimize these
risks.
Catechol also poses environmental hazards. If catechol is released into the

environment, it can contaminate soil and water bodies, resulting in adverse effects on
ecosystems and aquatic life. Adhering to proper containment and handling procedures,
promptly addressing spills or leaks, and reporting incidents are necessary to prevent
environmental contamination.
To effectively manage the hazards associated with catechol, several preventive

measures should be implemented. Comprehensive training should be provided to
workers, covering safe handling, storage, and use of catechol, along with knowledge
of its hazards and appropriate response procedures in case of exposure or spills.
Employing good ventilation systems to control and minimize exposure to catechol
vapors, as well as ensuring proper storage facilities with secondary containment
measures, is critical to prevent leaks and spills.
Regular inspections and maintenance of equipment and storage containers are

important to identify and address any potential leaks or failures. Establishing
emergency response plans and spill containment protocols will enable a prompt and
effective response in the event of a catechol spill or release. Proper disposal methods
for catechol waste should also be followed to prevent environmental contamination.
Compliance with applicable regulations, industry standards, and guidelines is crucial

in managing the hazards associated with catechol. Regular audits and assessments
can help verify compliance, identify areas for improvement, and implement necessary
corrective actions.
340
10.3.5 Benzoic Acid
Benzoic acid, also a byproduct in phenol production are a commonly used chemical in
various industrial applications, possesses specific hazards that require careful
recognition and effective management. It is important to understand these hazards and
the physical and chemical properties of benzoic acid to ensure its safe handling and
use in industrial settings.
One of the primary hazards of benzoic acid is its potential to cause skin and eye
irritation. Direct contact with benzoic acid can result in skin burns, redness, and
irritation. Eye exposure to benzoic acid can lead to severe irritation and damage.
Therefore, it is crucial to wear appropriate personal protective equipment (PPE),
including gloves, protective clothing, goggles, and face shields, to minimize the risk of
skin and eye contact.
Another hazard associated with benzoic acid is its potential for respiratory irritation.
Inhaling benzoic acid dust or vapors can irritate the respiratory system, causing
coughing, a sore throat, and breathing difficulties. It is essential to have proper
ventilation systems in place to control and reduce exposure to benzoic acid vapors and
maintain a safe working environment.
Additionally, benzoic acid is a combustible substance and poses a fire hazard. It has a
relatively low flashpoint, meaning it can ignite easily when exposed to an ignition
source. To minimize the risk of fires and ensure safe handling, it is important to
implement effective fire prevention and protection measures, such as appropriate
storage, grounding, and the use of fire-resistant equipment.
Safe handling of benzoic acid requires careful consideration of its physical and
chemical properties. Benzoic acid is a white crystalline solid with a distinct odor. It is
soluble in water, alcohol, and ether. While benzoic acid is generally stable under
normal conditions, it can decompose at high temperatures or in the presence of strong
oxidizing agents.
To handle benzoic acid safely, several precautions should be taken. Workers should
receive comprehensive training on the safe handling, storage, and use of benzoic acid,
including knowledge of its hazards and the appropriate response in case of exposure
or spills. Adequate ventilation systems should be in place to control airborne
concentrations of benzoic acid and minimize inhalation risks. It is crucial to handle
benzoic acid in well-ventilated areas or under fume hoods.
341
Proper storage of benzoic acid is essential to prevent spills, leaks, and contamination.
It should be stored in tightly sealed containers, away from heat sources, ignition, and
incompatible substances. Regular inspections and maintenance of storage containers
should be carried out to promptly identify and address any potential leaks or failures.
In the event of a spill, it is important to follow appropriate spill containment and cleanup
procedures. Contaminated materials should be handled and disposed of according to
applicable regulations and guidelines. Spill kits, absorbent materials, and the
necessary PPE should be readily available.
By understanding the hazards of benzoic acid, implementing suitable safety measures,

and following proper handling procedures, the risks associated with benzoic acid can
be effectively managed. Prioritizing safety, providing adequate training and education,
maintaining proper ventilation, and ensuring correct storage and handling practices are
crucial for protecting personnel and maintaining a safe working environment.
10.4 Safety Data Sheet (SDS)

The safety data sheet (SDS) is a comprehensive document that contains specific and
detailed information about a chemical. It includes details about the chemical's
properties, physical characteristics, hazard information, exposure limits, handling and
storage guidelines, and emergency response procedures. In workplaces where
hazardous chemicals are used, the SDS plays a crucial role in identifying and
minimizing risks associated with these substances. It is a legal requirement to have an
SDS for each hazardous chemical, ensuring that necessary information regarding the
chemical hazards and safe handling practices is readily available. The SDS typically
consists of sixteen sections, as mandated by OSHA, and it is important to review and
update the document at least every three years to ensure compliance with regulations.
The 16 section of the SDS provides additional information and guidance according to
the standard format outlined by OSHA. The section are as follow:
Section 1: Identification of substance or mixture and of the company or undertaking
Section 2: Hazard Identification
Section 3: Composition or information on ingredients
Section 4: First Aid measure
Section 5: Firefighting measures
342
Section 6: Accidental release measures
Section 7: Handling and storage
Section 8: Exposure control or Personal protection
Section 9: Physical and chemical properties
Section 10: Stability and reactivity
Section 11: Toxicological information
Section 12: Ecological information
Section 13: Disposal considerations
Section 14: Transport information
Section 15: Regulatory information
Section 16: Other information
343
10.4.1 MSDS for Benzene
344
345
10.4.2 MSDS Compressed Air
346
347
10.4.3 MSDS Phenol
348
10.4.4 MSDS Catechol
349
10.4.5 MSDS Benzoic Acid
350
10.4.6 MSDS Benzaldehyde
351
10.5 layers of Plant Safety
Safety and loss prevention in industrial settings can be conceptualized as a series of

layers, where each layer serves as a backup in case the preceding one fails. This
layered approach creates a system with multiple levels of safety that work together to
prevent disasters. The diagram illustrates the importance of incorporating safety
measures into the design and implementation of processes. When a process is
inherently safe, the need for additional safety controls is reduced, resulting in an overall
safer chemical plant. The primary objective of safety is to remain at the lower levels of
the safety hierarchy, as close to the base of the triangle as possible, rather than striving
to reach the top. In complex process plants that involve various hazards and intricate
activities, it is essential to establish a system that either entirely prevents accidents
and incidents or significantly reduces their likelihood.
Layers Description
Inherent Safety Designing processes and systems to be inherently
safe, reducing or eliminating hazards at their
source.
Process Controls Implementing engineering controls, such as
automated systems, alarms, interlocks, and safety
instrumented systems (SIS).
Operating Procedures Developing clear and comprehensive operating
procedures that outline safe practices, including
startup, shutdown, and maintenance.
Training and Education Providing regular training and education to ensure
employees have the necessary knowledge and
skills to work safely.
Maintenance Practices Establishing effective maintenance practices to
ensure equipment integrity and reliability, including
inspections and testing.
Safety Audits Conducting regular safety audits to assess
compliance with safety standards, identify
deficiencies, and implement corrective actions.
352
Emergency Response Developing and practicing emergency response
plans, including evacuation procedures,
communication protocols, and first aid training.
Safety Culture Cultivating a strong safety culture where safety is
prioritized, valued, and actively promoted at all
levels of the organization.
It's important to note that these layers work together as a system, with each layer
providing an additional level of protection. If one layer fails, the subsequent layers are
intended to prevent or mitigate incidents and maintain a safe operating environment.
The goal is to establish multiple barriers to ensure safety and minimize the likelihood
of accidents or hazardous events.
10.6 HAZOP Documentation
In order to effectively prevent accidents, it is crucial to identify the hazards present in

a chemical factory. Hazards can manifest in various forms, and while some are easily
identifiable, others may be less apparent or hidden. For instance, common hazards in
the workplace include mechanical hazards, pressure hazards, temperature hazards,
electrical hazards, and radiation hazards. However, these hazards can be further
classified into different types based on the nature of the associated activities. These
classifications encompass physical hazards, biological hazards, chemical hazards,
safety hazards, psychosocial hazards, environmental hazards, and ergonomic
hazards. The table below provides examples of events corresponding to each hazard
category. It is important to note that these hazards primarily relate to workplace safety
and are considered more evident in nature.
Risk is defined as the combination of the likelihood of a hazardous event or exposure

occurring within a specified timeframe and the potential severity of the resulting injury
or damage to people, property, or the environment. This assessment considers both
the probability of the risk event happening and the potential impact it may have on the
company. It is essential to protect workers from occupational risks they may encounter,
which involves a risk management process encompassing risk analysis, risk
assessment, and risk control practices.
When it comes to identifying hazards in process plants, risk evaluation plays a

significant role. According to Richard Wood (2019), qualitative risk assessment
methods, such as scenario-based assessments using risk matrices, are commonly
353
employed. Additionally, semi-quantitative analysis, such as the Hazard Identification,
Risk Assessment, and Risk Control (HIRARC) approach, is utilized. Moreover,
quantitative risk assessment methods, such as Hazard and Operability (HAZOP)
studies, Fault Tree Analysis (FTA), and Event Tree Analysis (ETA), are also commonly
applied to assess risks in a more quantitative manner.
Overall, the evaluation of risk involves a range of techniques and approaches to assess
and manage the potential risks associated with hazardous events, enabling
organizations to make informed decisions and implement appropriate control
measures.
10.6.1 Objectives of HAZOP
HAZOP, which stands for Hazard and Operability, is a well-documented study that
forms part of a Quantitative Risk Assessment (QRA) process. It is a thorough
examination technique used to investigate how a process or plant system deviates
from its design intent, thereby creating risks for personnel, equipment, and operability
issues. Initially developed for facilities handling highly hazardous materials, HAZOP
studies have proven effective in enhancing the safety, efficiency, and reliability of
chemical and petrochemical plants.
Over time, the application of HAZOP has expanded to various other types of facilities
due to its success in not only identifying hazards but also identifying operational
problems. As a result, HAZOP has been adopted in areas such as medical diagnostic
systems, road safety measures, and hazard analysis in industrial settings. The study
is typically conducted by a multidisciplinary team of experts who follow a systematic
approach, employing specific "guide words" to identify potential hazards arising from
deviations in process design during plant operation or modification.
By utilizing guide words and systematically examining the process or plant, a HAZOP
study aims to identify potential risks, consequences, and mitigation measures. It serves
as a valuable tool for proactive hazard identification and risk management, enabling
organizations to address potential issues and improve the overall safety and
operational performance of their facilities.
Objectives of HAZOP include but not restricted to:
1. To systematically identify and recognize potential hazards in the process or

plant design.
2. To assess the risks associated with identified hazards by evaluating their
354
severity and likelihood.
3. To improve safety in the process or plant by provides insights into potential

hazards and helps develop strategies to mitigate risks and enhance safety
measures.
4. To identify operability issues that may arise from deviations in the process
design. This allows for improvements in the plant's operability, efficiency, and
reliability.
5. To give recommendations for risk reduction, process improvement, and the

implementation of necessary control measures to mitigate the identified
hazards and enhance overall safety.
6. To serve as an important decision-making tool for management and

stakeholders.
355
10.6.2 HAZOP Process
The process of conducting a HAZOP (Hazard and Operability) study involves several
steps:
1. Define the scope: Clearly define the scope of the study, including the process or
plant to be analyzed, the boundaries, and the objectives to be achieved.
2. Assemble the team: Form a multidisciplinary team consisting of experts

from various relevant disciplines, such as process engineering, operations,
safety, and maintenance.
3. Familiarize with the system: Gain a thorough understanding of the process or

plant system, its design, and its intended operations through documentation
review, site visits, and discussions with relevant personnel.
4. Identify guide words: Select a set of guide words to systematically examine the
process or plant for potential deviations and associated hazards. These guide
words, such as "more," "less," "no," "part of," "reverse," etc., are used to
stimulate creative thinking and uncover potential issues.
5. Conduct brainstorming sessions: Conduct brainstorming sessions with the

team, systematically applying the guide words to each element of the
process or plant. This helps identify possible deviations, hazards, and
operability issues.
6. Analyze and evaluate risks: Analyze the identified deviations and hazards to
assess their potential risks in terms of severity and likelihood. This may involve
using risk matrices, scoring systems, or qualitative/quantitative methods.
7. Generate recommendations: Based on the analysis, develop recommendations

to mitigate or eliminate the identified risks. These recommendations may include
process modifications, control measures, operational procedures, or training
requirements.
8. Document the findings: Record all the findings, including the identified hazards,
risks, and recommended actions, in a comprehensive HAZOP report. This report
serves as a valuable reference document for future safety improvements.
9. Implement and follow-up: Ensure that the recommended actions are implemented
and monitor their effectiveness. Periodic reviews and follow-ups may be
necessary to track progress, address any new hazards, or incorporate changes in
the process or plant.
356
By following this systematic process, a HAZOP study helps uncover potential hazards,
assess risks, and provide practical recommendations for enhancing safety and
operability in the process or plant under examination.
Table 10.3 example of Guide Words.
357
Table 10.4 the deviations and common cause in HAZOP
358
10.6.3 HAZOP Of Major Equipment
Study Process Deviations Possible Possible Action

Node Parameter Causes Consequences Required
Valve fails or No reaction Shutdown

malfunctioning occurs plant
NONE
Monitor
Blockage or Ineffective
Performance
Leakage in cooling system
Compressor,
Pipeline for reactor
Valve
Leak of Reaction Fabricate

reactant to efficiency tubes and
shell reactor decrease shell as well
LESS
Packed Checklist
Valve reading Low yield
Bed flow before start-
failure product
Reactor up
Instruct
Failure of Temperature operators
control valve increase and update
procedures
Exceed flow
Install high
MORE rate of feed Pipe rupture
alarm flow
stream
Regular
Over Maintenance
Valve fully
specification and
open
product monitoring
program.
359
Temperature
More control
equipment
MORE Runaway system,
damage
reaction temperature
Packed
alarms
Bed temperature
Temperature
Reactor
Less control
reduced product
LOW Incomplete system,
quality
reaction temperature
alarms

Pressure
Excessive reactor vessel relief valves,
MORE
pressure failure pressure
Packed alarms
Bed Pressure Pressure
Reactor control
Reduced inadequate
LESS system,
efficiency reaction
pressure
alarms
Temperature
control
More column
HIGH system,
Overheating damage
temperature
Distillation alarms
Temperature
column Temperature
Less control
reduced
LOW Insufficient system,
product quality
separation, temperature
alarms
360
pressure,
More column failure relief valves,
HIGH
Excessive Pressure pressure
alarms
Distillation flooding Pressure
Pressure
column control system, Reflux control
Less
pressure alarms system, reflux
LOW Reduced
Reflux Ratio High flow
efficiency,
More Overloading, measurement
liquid carryover
Study Process Deviatio Possible Possible Action Required

Node Parameter ns Causes Consequences
Reflux control
More system, reflux
HIGH , liquid carryover
Overloading flow
Distillation Reflux measurement
column Ratio Reflux control
Inadequate reduced product system, reflux
LOW
separation, purity flow
measurement,
361
10.7 Emission Assessment
Emission assessment plays a crucial role in evaluating and managing the environmental
impact of industrial processes. It involves the measurement and analysis of various emissions,
including dust and noise, to determine their magnitude, sources, and potential effects on the
environment and human health. Here is an overview of the emission assessment for different
types of emissions:
Particulate Matter (Dust) Emissions:
⚫ Measurement: Dust emissions are typically quantified using particulate matter sampling
techniques such as high-volume samplers, dust meters, or gravimetric analysis.
⚫ Sources: Dust emissions can originate from activities such as material handling, grinding,
crushing, and combustion processes.
⚫ Impact: Dust emissions can contribute to air pollution, respiratory issues, and
environmental degradation. They may also pose a risk to nearby ecosystems.
⚫ Control Measures: Effective control measures include dust suppression systems, proper
ventilation, enclosed equipment, and regular maintenance of dust control equipment.
Gaseous Emissions:
⚫ Measurement: Gaseous emissions are measured using various techniques such as gas
analyzers, continuous emissions monitoring systems (CEMS), or laboratory analysis of
collected samples.
⚫ Sources: Gaseous emissions can arise from combustion processes, chemical reactions,
or the release of volatile organic compounds (VOCs) from industrial activities.
⚫ Impact: Gaseous emissions contribute to air pollution, greenhouse gas emissions, and
can have adverse effects on human health, ecosystems, and climate change.
⚫ Control Measures: Control measures include the use of pollution control technologies like
scrubbers, catalytic converters, and the implementation of cleaner production practices to
minimize emissions.
362
Noise Emissions:
⚫ Measurement: Noise emissions are typically measured using sound level meters or noise
dosimeters to quantify the intensity and frequency of noise.
⚫ Sources: Noise emissions originate from equipment operation, machinery, industrial

processes, and transportation activities.
⚫ Impact: Excessive noise can cause hearing damage, stress, sleep disturbances, and
have negative impacts on human well-being. It can also disrupt wildlife habitats and
ecological balance.
⚫ Control Measures: Noise control measures involve engineering controls, such as noise
barriers, mufflers, sound insulation, and implementing proper maintenance and
operational practices.
Water Emissions:
⚫ Measurement: Water emissions are evaluated by analyzing the quality of discharged

water through sampling and laboratory analysis for parameters like pH, temperature,
suspended solids, and specific pollutants.
⚫ Sources: Water emissions can result from industrial processes, cooling systems,
wastewater discharges, and accidental spills.
⚫ Impact: Water emissions can degrade water quality, harm aquatic life, and contaminate
water sources, impacting ecosystems and human health.
⚫ Control Measures: Control measures include wastewater treatment systems,

implementing best management practices, and adhering to regulatory requirements for
wastewater discharge.
Emission assessments are vital for identifying potential environmental impacts, ensuring
compliance with regulations, and implementing effective mitigation measures. It helps
industries monitor and reduce emissions, minimize their environmental footprint, and promote
sustainable practices for a cleaner and healthier environment.
363
CHAPTER 11: ENVIROMENTAL CONSIDERATION
11.1 Environment aspect and impact
According to ISO 14001:2015, an environmental aspect is any aspect of an

organization's operations, goods, or services that has the potential to have an influence on the
environment. Any activity that takes place within your organisation and interacts with the
environment, or that potentially has an environmental impact, is considered an environmental
element. This includes interactions with the environment, both good and bad (What Are
Environmental Aspects and Impacts? n.d.).
Aspects can be divided into direct and indirect. Direct environmental elements are those
that are connected to an organization's own operations, goods, and services, over which the
organisation has direct managerial authority (such as how we handle garbage on our
premises) (Verbanac, 2017). The focus, however, will frequently be on indirect environmental
aspects of non-industrial organisations' operations (such as how a subcontractor handles trash
on the job site, chain-controlled aspects, customer-controlled aspects, etc.). We must research
how the actions, goods, and services of our organisation impact the environment in order to
identify environmental elements. When identifying environmental factors, it's common to take
into account things like emissions into the air, releases into water and land, raw material
consumption, waste production, the use of natural resources, effects on biodiversity, etc
(Verbanac, 2017).
Benzene, a chemical by-product of crude oil that is commonly utilised in industry but is
harmful to people, animals, and the environment, is one of the main ones. According to
Chevron Phillips' Safety Data Sheet, the LC50 (50% fatal concentration) of liquid benzene for
aquatic life exposure over 96 hours is 5.3 ppm. Additionally, because benzene is known to
cause cancer, it is not a good idea to release it into the environment. The unregulated release
of phenol into the environment, which puts aquatic life in peril, poses similar problems. Flares
are introduced into the process design to prevent the release of trace amounts of organic
compounds into the environment, such as non-condensable parts and unrecycled benzene.
Each reactor's gas effluent is mixed, cleaned, and delivered to a flare to burn off any remaining
organic molecules once condensation has taken place. Additionally, a benzene storage tank
was created in case a pipeline malfunctioned. While the organic species in liquid waste that
cannot be released into the environment directly are removed at the on-site waste treatment
facility.
364
11.1.1 Waste disposal or management
Every process in this world will produce product and by – product. It is determined
whether the by – product could be something useful or becoming waste. There are two types
of waste which are solid waste and liquid waste. For solid waste our company will gather all
the waste in designated area and sent it to the landfill. Nearest landfill from our site location is
Tapak Pelupusan Sampah Gelugor, Kerteh with a coordinate of 4°31'20"N 103°26'40"E. In
terms of liquid waste, we have our own water treatment facilities that can cater our own liquid
waste to minimise the cost of disposing their scheduled waste and aims to treat scheduled
wastes more efficiently in an environmentally sustainable and socially responsible manner.
Numerous by-products, including catechol, benzoic acid, and benzaldehyde, are produced as
a result of the benzene and oxygen reaction that results in the creation of phenol. The by-
products were transferred into their own storage tanks and can then be sold off to other plants
that might want to buy the stated material, the surplus benzene will be recycled back into the
feed line in order to reduce the waste created. Despite their low purity, by-products can
nonetheless be marketed in order to lessen their negative effects on the environment and to
make more money by doing so than by investing in a treatment facility. For instance, phenol
will then be sold to DD Plastic Sdn Bhd in Kemaman because it is widely used as a raw material
for the development of other products, such as bisphenol-A (BPA). The flare gas from the
purification process was then burned in the flare system since it is one of the safest
environmental combustions of organic compounds. The flare gas contains oxygen, nitrogen,
benzene, phenol, and other gases.
365
Figure 11.1: It estimated around 2.3 km to reach the landfills to
dispose our solid waste.
11.1.2 Noise
The Factory and Machinery (Noise Exposure) Regulations of 1989 were replaced by
the Occupational Safety and Health (Noise Exposure) Regulations 2019, which went into
effect on June 1, 2019. This manual is intended to help clients (project owners) and principal
contractors plan for and carry out the Noise Exposure Regulations obligations in their building
projects. The 2019 Industry Code of Practise for Management of Occupational Noise
Exposure and Hearing Conservation is written to aid people in adhering to the Noise Exposure
Regulations' requirements. In 2019, excessive noise exposure at work was linked to 91% of
reported occupational illnesses. According to the Noise Exposure Regulations, excessive
noise is defined as a maximum sound pressure level that is greater than 115 dB(A) at any
time, a peak sound pressure level that is greater than 140 dB(C), or a daily personal noise
dosage that is greater than 50% (Official Website Department of Occupational Safety and
Health - Controlling Noise in Construction Site, n.d.).
For new industrial developments, the maximum permitted sound level on-site cannot
exceed the set noise regulations. Planning Guidelines for Environmental Noise Limits and
Control state that during the daytime and at night, respectively, the maximum allowable limit
sound levels are 70 dB and 60 dB. Pumps, compressors, and other devices that produce noise
are common. Equipment will be placed away from the community to minimise disruption.
Workers who are subjected to noise pollution will work in shifts and receive PPE like earplugs
and earmuffs.
366
11.1.3 Visual Impact
The projected factory will be a part of a large industrial chemical complex on Kerteh,
Terengganu's shore. Priority must be given to safety while designing the facility's layout before
it is used for human habitation. This would need putting the reaction process part inside a
containment tank in a far-off area of the plant in order to prevent accidental explosions. The
facility must also abide by all federal, state, and local regulations. To avoid visual hindrance
since the plant would span a sizable area of land, the plant was built far from habitation.
367
11.1.4 Emission to environment
Materials
a) Benzene
The air contains benzene due to emissions from the burning of coal and oil,
petrol stations and automobile exhaust. Humans exposed to benzene by acute (short-
term) inhalation exposure may experience fatigue, headaches, eye, skin, and respiratory
tract irritation, and at high concentrations, coma. Chevron Phillips' Safety Data Sheet for
liquid benzene states that the LC50 (50% fatal concentration) for aquatic life at 96 hours
of exposure is 5.3 ppm. In occupational settings, chronic (long-term) inhalation exposure
has been linked to a range of blood problems, such as anaemia and a reduction in red
blood cell count. High amounts of exposure by inhalation have been linked to
reproductive consequences in females, and animal studies have shown negative effects
on the growing foetus. In persons exposed to benzene at work, leukaemia (cancer of the
tissues that produce white blood cells) has been seen to occur more frequently. Benzene
is a recognised human carcinogen across all routes of exposure, according to the EPA.
If the storage for the benzene in this procedure leaks, the liquid benzene will leak into
the drain and eventually into the ocean, harming aquatic life and perhaps limiting its
lifespan as well as altering its appearance and behaviour. Smog is created when
benzene gas is released into the atmosphere and combines with other pollutants. This
may naturally deteriorate, but it also could adhere to a raindrop and fall to the earth,
contaminating the water and soil. Benzene exposure is reduced by reducing evaporation
and avoiding spills and splashes. Engineering measures, such as the use of hoods,
canopies, and adequate ventilation combined with the use of personal protective
equipment, are desirable when exposures may occur. Respirators and other comparable
personal protective equipment may be utilised in situations when engineering controls
are not practical.
368
b) Air
Due to the high pressure employed in this facility, air is an odourless gas that may
result from high exposure if the tank bursts and is released into the environment.
However, we utilised high-quality tanks for the manufacturing of phenol since they can
bear high pressure and are made of durable materials. As a result, there is little chance
that it will be discharged into the environment.
c) Phenol
A hazardous substance, phenol affects the environment, especially water and

aquatic life like fish. It is a widespread pollutant that is created by a number of chemical
industries, notably the phenol manufacturing industry. In an environment where phenol
is common, aquatic life's food supply, average weight, and fertility all substantially fall.
The Australian Water Quality Guidelines for Fresh and Marine Waters (ANZECC, 1992)
stated that the amount of waste chemicals should be kept to a maximum of 50
micrograms per litre (0.00005 g/L) in fresh or marine waters because the half-life of
phenol in water is between 2 and 20 days before it eventually ends up in the environment.
This water contamination may have been caused by the plant's release of tainted phenol
waste into nearby bodies of water. This waste may be extremely harmful to fish even at
concentrations below the lethal level and can have genotoxic effects, liver dysfunction,
endocrine dysfunction, and slowed growth. Therefore, industrial drainage water should
be treated before entering water sources to remove chemical pollutants using techniques
like evaporation, distillation, precipitation, and others in order to protect public health.
d) Benzoic acid
Benzoic acid exposure can have the following negative health effects right away
or shortly after:
✓ Eye injury
✓ Skin irritation that causes a rash, redness, and/or a burning sensation
✓ Inhalation of the irritant may induce coughing, wheezing, and/or shortness of
breath as well as irritation of the nose, throat, and lungs.
369
In addition to these short-term effects of contact, prolonged or recurrent exposure to
benzoic acid can result in skin that is dried out, cracked, and irritated. Skin allergies may
develop after prolonged exposure to high quantities of benzoic acid, especially in those
who are more vulnerable. Even exposure to very low levels can result in a skin rash and
irritation if an allergy develops. If benzoic acid is accidentally spilled:
Control personnel's entry and evacuate the area and remove all sources of
ignition.
Clean up with a HEPA-filter hoover and dispose of in sealed containers.
Once the area has been cleaned, ventilate it and scrub it.
DON'T wash down the drain (Benzoic Acid – Uses and Safety, 2015).
370
e) Benzaldehyde
Benzaldehyde is a very dangerous and very flammable substance. At room

temperature, it undergoes autooxidation and, in the presence of air, yields benzoic acid.
Aquatic animals may be harmed if liquid sewage is thrown into a drain and then flows
into the ocean. If it is discharged into the ground or water, however, it might biodegrade.
Because of its increased soil mobility, benzaldehyde can swiftly transition during
chemical reactions from moist soil surfaces to dry surfaces.
f) Catechol
Catechol is one of the most prevalent organic pollutants in the environment.

Pollutants are released into the environment when catechol is produced and used.
Catechol, a result of the interaction between benzene and phenol, has a strong scent
and is a persistent water pollutant that is damaging to the environment. Catechol is
extremely hazardous to fish and prevents the biological growth of microorganisms. If
catechol is found in the water or among aquatic organisms, it will eventually have an
effect on the ecosystem. In order to protect against the hazards of catechol to public
health and the environment, the chemicals shouldn't be allowed to discharge through the
drain and catechol-based aqueous waste needs to be treated with an efficient,
economical, and environmentally safe treatment before being discharged.
Equipment
Accidents can happen in the plant when it is being constructed and used. Thus,
there is a considerable likelihood that the environment and surrounds will be impacted
by the chemicals produced by the plants, such as catechol, benzoic acid, benzaldehyde,
and phenol, due to the equipment utilised in the facilities, such as storage tanks,
pipelines, distillation columns, and others. There may be a safety issue if the staff was
unable to correctly control equipment like the compressor, reactor, distillation column,
flash drum, or condenser. The safe flammability, pressure, temperature, and material
flow parameters for each piece of equipment should be included in the process safety
information. This can be prevented by recording the chemical dangers. Employee
training, safety and protection systems in case of exposure to hazardous chemicals, and
controls to prevent exposure are important to ensure worker safety in the process. The
workforce must also wear the proper PPE for the job.
371
When designing the reactor for this kind of operation, process safety was also taken
into consideration. In response to the difficult operating conditions, the reactor effluent is
cooled and depressurized to enable safer and more pleasant downstream operating
conditions. Additionally, to lower the chance of an ignite in the event of a leak, storage tanks
must be maintained away from the processing machinery. Pipeline leaks can be avoided by
insulating the pipes and ensuring that all the equipment was sized properly. By establishing
tank inspection and cleaning procedures, worker exposure to hazardous chemicals should be
prevented. If there is a chemical leak, such as from a product or equipment failure that causes
a harmful gas to release during or after the process, environmental pollution may result.
Chemical spills, gas explosions, and other mishaps are all potential outcomes. Chemical spills
can be located by looking for pipeline leaks, human mistake, or leaks in reactor, condenser,
or distillation column equipment. For instance, the benzaldehyde storage tank may have
leaked, releasing chemicals that eventually biodegraded into the soil and water. Meanwhile,
the air storage tank has a high risk of exploding due to the high pressure employed in the
oxygen tank.
372
11.2 Type of wastewater treatment plant and related statutory law
A contaminant is spread into the environment through pollution, which is primarily the
result of human activity. However, natural disasters also contribute to pollution. It disrupts the
ecosystem, the physical systems or living things inside it, causing instability, disorder, an
illness, or discomfort. Therefore, it is the duty of every individual to guarantee that their actions
do not harm the environment, and this should be especially true in petrochemical plants. The
waste must be processed in accordance with regional and international standards before it is
released into the environment.
The Malaysian government has built the necessary legislative and administrative
frameworks, such as the Environmental Quality Act of 1974, to support environmentally sound
and sustainable growth. According to these regulations, it is the factory owner's responsibility
to make sure that the waste produced is processed before it is released in order to reduce
pollution and improve environmental 370 quality. Zero Liquid Discharge (ZLD) plants,
sometimes referred to as waste minimization and treatment facilities, are specialized facilities
that work to reduce waste generation and stop the release of liquid waste streams into the
environment. These facilities use cutting-edge treatment techniques to treat and manage the
leftover waste as well as recover and reuse water. By maximizing water reuse and reducing
waste output, waste minimization and treatment facilities' main goal is to achieve zero liquid
discharge. Below are some of the main objectives that need to be fulfil:
1) Spend less money through cutting back on raw material purchases, waste
treatment and disposal expenses, and other operating expenses.
2) Reach national and state waste minimization policy objectives.
3) Lower potential environmental risks.
4) Preserve the environment, worker health, and public health.
373
11.2.1 Relevant Environmental Acts And Regulations In Malaysia (LAWS OF
MALAYSIA ACT 127 ENVIRONMENTAL QUALITY ACT 1974, 1974).
Environmental Quality Act (EQA) 1974 is the fundamental environmental law and
regulation in Malaysia. Several EQA parts concern the limitation of pollution and wastewater
flow to the atmosphere, including:
➢ Under Section 51 (1) (Regulations), the plant is
a) Prohibited from discharging any matter, whether liquid, solid, or gaseous into the
environment.
b) Prohibited from using any equipment, facility, vehicle, or ship capable of causing
pollution.
c) Need to be constructed or installed with any equipment to prevent or minimize
pollution.
d) Prohibited from discharge any environmentally hazardous substances into the
environment.
e) Measured, assessed, controlled, reduced, or eliminate environmental risk.
f) Hire persons qualified to maintain and operate any equipment or control equipment.
➢ Under Section 31 (1), the plant needs to be:
a) Install and operate any control equipment or additional control equipment.

b) Repaired, altered, or replaced with any equipment or control equipment.
c) Erect or increase the height of any chimney.
d) Measured, take a sample of, analyzed, recorded, and reported any environmentally
hazardous substances, pollutants, wastes, effluents or emissions containing pollutants
conducted a study on any environmental risk.
e) Installed, maintained, and operated monitoring programmed at the expense of the
owner or occupier.
f) Adopted any measure to reduce, mitigate, disperse, remove, eliminate, destroy or
dispose of pollution, within such time and in such manner as may be specified in the
notice issued by the government.
➢ Under Section 23, all the equipment or control equipment needs to be

maintained in a proper and efficient manner.
➢ Requirement and approval of plans: Section 20 (1),
374
a) Plans and specifications of the proposed work, building, erection or alteration together
with details of the control equipment if any to be installed.
b) A layout plan indicating the site of the proposed work, building, erection or alteration,
which will take place in relation to the surrounding areas.
c) The details of the trade, industry or process proposed to be carried out on such
premises.
d) Descriptions of waste constituents and characteristics.
➢ Restrictions on pollution of the atmosphere: Section 22 (1) and (2), the

plant is
a) Prohibited from, unless licensed, emitting or discharging any environmentally
hazardous substances, pollutants or wastes into the atmosphere in contravention of
the acceptable conditions specified under section 21.
b) Prohibited from placing any matter in a place where it may be released into the
atmosphere.
c) Prohibited from causing the discharge of odors, which by virtue of their nature,
concentration, volume or extent are obnoxious or offensive.
d) Prohibited from burning any wastes of the trade, process or industry.
e) Prohibited from using any fuel burning equipment not equipped with any device or
control equipment required to be fitted to such equipment.
➢ Restriction on noise pollution: Section 23 (1), the plant is

a) Prohibited from, unless licensed, emitting or causing or permitting to be emitted any
noise greater in volume, intensity or quality in contravention of the acceptable
conditions specified under section 21.
➢ Restrictions on pollution of the soil: Section 24 (1) and (2), the plant is
a) Prohibited from, unless licensed, polluting or causing or permitting to be polluted any

soil or surface of any land in contravention of the acceptable conditions specified under
section 21.
b) Prohibited from placing any matter whether liquid, solid or gaseous in any place where
it may gain access to any soil.
c) Prohibited from establishing on any land a refuse dump, garbage tip, soil and rock
disposal site, sludge deposit site, waste-injection well or otherwise used land for the
disposal of or a repository for solid or liquid wastes so as to be obnoxious or offensive
375
to human beings or interfere with underground water or be detrimental to any beneficial
use of the soil or the surface of the land.
➢ Prohibition against placing, deposit, etc. of scheduled wastes: Section

34B (1), the plant is
a) Prohibited from placing, depositing, or disposing of, or causing or permitting to place,

deposit or dispose of, except at prescribed premises only, any scheduled wastes on
land or into Malaysian waters.
b) Prohibited from receiving or sending or causing or permitting to be received or sent
any scheduled wastes in or out of Malaysia.
c) Prohibited from transiting or causing or permitting the transit of scheduled wastes,
without any prior written approval of the Government.
➢ Restrictions on pollution of inland waters: Section 25 (1) and (2), the plant
is
a) Prohibited from, unless licensed, emitting, discharging, or depositing any

environmentally hazardous substances, pollutants or wastes into any inland waters in
contravention of the acceptable conditions specified by the Government.
b) Prohibited from placing any waste in or on any waters or in a place where it may gain
access to any waters.
c) Prohibited from placing any waste in a position where it falls, descends, drains,
evaporates, is washed, is blown or percolates or is likely to fall, descend, drain,
evaporate, or be washed, be blown, or percolated into any waters, or knowingly or
through his negligence, whether directly or indirectly, causes or permits any wastes to
be placed in such a position.
d) Prohibited from causing the temperature of the receiving waters to be raised or lowered
by more than the prescribed limits.
➢ Prohibition of discharge of wastes into Malaysian waters: Section 29 (1),

the plant is
a) Prohibited from, unless licensed, discharging environmentally hazardous substances,

pollutants or wastes into the Malaysian waters in contravention of the acceptable
conditions specified under section 21.
376
11.2.2 PROCESS FLOW OF WASTEWATER TREATMENT PLANT
Separator ( Sedimentation) PRIMARY
TREATMENT
Biological treatment
Activated carbon Adsorption. SECONDARY
TREATMENT
Air Stripping
Advanced oxidation Processes ( AOPs)

TERTIARY
TREATMENT
Biological Treatment
Effluent discharge or Reuse.
The specific methos and system must be chosen carefully for treating the wastewater that is
being contaminated with benzene chemical. It's essential to understand that the specific
treatment strategy will depend on a variety of variables, including the initial benzene
concentration, focus on effluent quality, legal requirements, current infrastructure, and
wastewater characteristics. For this phenol production , the wastewater that being
contaminated by the benzene chemical have go through specific method such as primary
treatment, secondary treatment, and tertiary treatment ( biological digestion ) to reduce the
concentration of benzene before releasing it to environment.
PRIMARY TREATMENT
When wastewater reaches the treatment facility, it is initially through screening and grit
removal procedures. Large particles and debris are removed to help the subsequent treatment
operations and avoid equipment damage.
During this phase, the wastewater enters a primary sedimentation tank where gravity enables
the separation of oils and grease and the settling of suspended solids. The primary sludge, or
settled solids, are collected, and transferred for further treatment.
SECONDARY TREATMENT
377
Biological treatment
The effluent is afterwards treated using biological methods. The activated sludge process,
which involves mixing wastewater with a culture of microorganisms (activated sludge) in an
aeration tank, is one common procedure. In the wastewater, the bacteria biodegrade organic
pollutants like benzene. The secondary sludge is produced after the mixture has been passed
through a secondary sedimentation tank, where the microbes and other solids have settled
out. The cleaned water, sometimes referred to as effluent, advances to another phase.
Activated carbon Adsorption.
Activated carbon is usually used to adsorb benzene from the wastewater. The activated
carbon bed, which attracts and retains the benzene molecules, is used to filter wastewater. To
retain its adsorption capacity, the activated carbon can be periodically replaced or
regenerated.
Air Stripping
To help volatile chemicals, like benzene, move from the liquid phase to the gas phase, air
stripping involves exposing the wastewater to air or a stream of air bubbles. The wastewater
is treated to remove the benzene, which is then caught in the off-gas stream.
TERTIARY TREATMENT (ADVANCE TREATMENT)
The effluent may go through further treatment procedures to improve the removal of pollutants,
such as benzene. Filtration, chemical coagulation, and disinfection are a few examples of
these procedures. Filtration involves putting the effluent through various filters, like sand or
activated carbon, to get rid of any trace pollutants and suspended solids that are still present.
Fine particles can be captured and removed using chemical coagulation. Pathogens are
eliminated using disinfection methods including chlorination or ultraviolet (UV) irradiation,
which also ensures the treated water meets legal requirements.
Advanced oxidation Processes ( AOPs)
AOPs can be used to break down benzene in wastewater, such as ozone oxidation or
ultraviolet (UV) light in combination with hydrogen peroxide. Due to the highly reactive
378
hydroxyl radicals produced by these reactions, benzene molecules are reacted with and
removed.
Biological Treatment
Whereas aerobic biological methods of treatment can be efficient, anaerobic treatment is

typically not suitable for benzene. Benzene can be biodegraded by aerobic bacteria in the
presence of enough oxygen and a suitable setting. Aerobic treatment methods, such as
biofiltration or activated sludge processes, can be used to encourage aerobic microorganisms
to break down benzene.
Effluent discharge or Reuse.
After the treatment processes, the treated water (effluent) is normally discharged in
accordance with legal requirements into a receiving body of water, like a river or the ocean.
For certain uses like irrigation or industrial processes, the treated water may occasionally
undergo extra treatment.
379
CHAPTER 12: CONCLUSION & RECOMMENDATION
In conclusion, based on the previous report done throughout Design Project 1 and
Design Project 2, it can be said that the production of Phenol for 750, 000 MTA by using Direct
Route from Benzene as the raw material with the catalyst is reasonable. Even the waste for
this project contaminated with the hazardous chemical, which is benzene, that being treatment
with the most suitable ways to prevent any pollution toward the environment and people
surrounding. Each of the equipment sizing and costs that were involved in this project was
calculated and the value was quite satisfactory. However, the cost for the raw materials is quite
high, but the demand for the high purity of phenol is still high in the market that can make the
profit to produce the products for the equipment like Reactor, Distillation column, condenser,
and flash drum. Based on the PI&D of the phenol production, all the process control and the
fluid flow were following all the requirements that can produce the high quality of phenol with
the other by- product like benzaldehyde, catechol, and benzoic acid. For the safety aspects,
every chemical that is being used in this project has their own safety data sheet (SDS) and
the risk assessment like Hazard and Operability study (HAZOP) to prevent any unintentional
incident occurring. Lastly, this project of production of phenol from benzene was accomplish
by reach the high purity product which is 99 %
380
REFERENCES
(PDF) Direct Route to Phenol from Benzene. (n.d.). Retrieved April 19, 2023, from
https://www.researchgate.net/publication/316349782_Direct_Route_to_Phenol_from_B
enzene.
4.0: Prelude to Control System Design Objectives - Engineering LibreTexts. (n.d.). Retrieved
June 22, 2023, from
https://eng.libretexts.org/Bookshelves/Industrial_and_Systems_Engineering/Introductio
n_to_Control_Systems_(Iqbal)/04%3A_Control_System_Design_Objectives/4.00%3A_
Prelude_to_Control_System_Design_Objectives.
4: Control System Design Objectives - Engineering LibreTexts. (n.d.). Retrieved June 22,
2023, from
https://eng.libretexts.org/Bookshelves/Industrial_and_Systems_Engineering/Introductio
n_to_Control_Systems_(Iqbal)/04%3A_Control_System_Design_Objectives.
8.1: Catalytic reactions - Chemistry LibreTexts. (n.d.). Retrieved November 22, 2022, from
https://chem.libretexts.org/Bookshelves/Inorganic_Chemistry/Book%3A_Inorganic_Che
mistry_(Saito)/08%3A_Reaction_and_Physical_Properties/8.01%3A_Catalytic_reaction
s.
Afandizadeh, S., & Foumeny, E. A. (2001). Design of packed bed reactors: guides to catalyst
shape, size, and loading selection. Applied Thermal Engineering, 21(6), 669–682.
https://doi.org/10.1016/S1359-4311(00)00072-7
Alaquainc, T. (2021, May 24). Use of Distillation System in Industry. ALAQUA - Global
Processing Equipment Supplier. https://www.alaquainc.com/use-of-distillation-system-
in-industry/
appendix b physical property tables - Google Search. (n.d.). Retrieved January 15, 2023, from
https://courses.chemeng.ntua.gr/download/2486.
A-to-Z Guide to Thermodynamics, Heat & Mass Transfer, and Fluids Engineering Online -
Home. (n.d.). A-to-Z Guide to Thermodynamics, Heat & Mass Transfer, and Fluids
Engineering Online - Home. https://doi.org/10.1615/atoz.f.flash_distillation
Benzaldehyde - Structure, Properties, Uses and FAQs. (n.d.). Retrieved November 20, 2022,
from https://www.vedantu.com/chemistry/benzaldehyde.
381
Benzene | Wisconsin Department of Health Services. (2016). Wisconsin Department of Health
Services. https://www.dhs.wisconsin.gov/chemical/benzene.htm
Benzoic Acid – Uses and Safety - VelocityEHS. (n.d.). Retrieved November 20, 2022, from
https://www.ehs.com/2015/02/benzoic-acid-uses-and-safety/.
Benzoic Acid – Uses and Safety. (2015, February 16). VelocityEHS.

https://www.ehs.com/2015/02/benzoic-acid-uses-and-
safety/#:~:text=Immediately%20or%20shortly%20after%20exposure
Brogan, R. J. (2011). Shell and tube heat exchangers. A-to-Z Guide to Thermodynamics, Heat
and Mass Transfer, and Fluids Engineering.
https://doi.org/10.1615/ATOZ.S.SHELL_AND_TUBE_HEAT_EXCHANGERS
C. (2019, November 9). Packed column versus Tray column. Chemical Engineering World.
https://chemicalengineeringworld.com/packed-column-versus-tray-column/
Comparison between horizontal separator & vertical separator. (n.d.). Comparison Between
Horizontal Separator & Vertical Separator. https://www.hcpetroleum.hk/wap/news-
detail/23
Compound Annual Growth Rate (CAGR ) - What is Compound Annual Growth Rate & How is
it Calculated? (n.d.). Retrieved November 22, 2022, from https://cleartax.in/s/what-is-
cagr-and-how-is-it-useful.
Compressed air in the pharmaceutical industry | BEKO TECHNOLOGIES. (n.d.). Retrieved

November 20, 2022, from https://www.beko-technologies.com/en-
en/solutions/industries/pharmaceutical-industry/.
Cost Curves for Preliminary Estimates. A.M. Gerrard. (2007).
Cost Indices – Towering Skills. (2020). https://toweringskills.com/financial-analysis/cost-

indices/
Coulson Richardson's Chemical Engineering Vol.6 Chemical Engineering Design 4th Edition.
(2005)
Distillation column | chemical instrument. (n.d.). Encyclopedia Britannica.

https://www.britannica.com/science/distillation-column
382
Distillation Fundamentals | Neutrium. (n.d.). Retrieved November 22, 2022, from
https://neutrium.net/unit-operations/distillation-fundamentals/.
Engineering, C. (2020, March 1). Facts at your Fingertips: Distillation Trays and Packing -
Chemical Engineering. Chemical Engineering.
https://www.chemengonline.com/distillation-column-trays-packing/
Environmental and Industrial Corrosion - Practical and Theoretical Aspects. (2012).

Environmental and Industrial Corrosion - Practical and Theoretical Aspects.
https://doi.org/10.5772/45617
Flow Reactor - an overview | ScienceDirect Topics. (n.d.). Retrieved April 25, 2023, from
https://www.sciencedirect.com/topics/engineering/flow-reactor.
Gavin Towler, R K Sinnott - Chemical Engineering Design Principles Practice and Economics
of Plant and Process Design-Butterworth-Heinemann (2007). (n.d.). Retrieved April 28,
2023, from https://studylib.net/doc/25893707/gavin-towler--r-k-sinnott---chemical-
engineering-design-p...
Global Bisphenol A Industry Outlook to 2025 - Capacity and Capital Expenditure Forecasts
with Details of All Active and Planned Plants. (n.d.). Retrieved November 22, 2022, from
https://www.globaldata.com/store/report/bisphenol-a-market-analysis/.
Global Phenol Market: Industry Analysis & Forecast | Persistence Market Research (PMR).
(n.d.). Retrieved November 22, 2022, from
https://www.persistencemarketresearch.com/market-research/phenol-market.asp.
Gravity Separators – Visual Encyclopedia of Chemical Engineering Equipment. (2022, April

8). Gravity Separators – Visual Encyclopedia of Chemical Engineering Equipment.
https://encyclopedia.che.engin.umich.edu/gravity-separators/
How Columns Work? - SRS Engineering Home. (n.d.). SRS Engineering Home.
https://www.srsengineering.com/our-products/distillation-columns/how-columns-work/
Income Tax Act 1967 INCOME TAX EXEMPTION. (n.d.).
Kerteh Annual Weather Averages - Terengganu, MY. (n.d.). Retrieved November 22, 2022,
from https://www.worldweatheronline.com/kerteh-weather-
averages/terengganu/my.aspx.
383
Kolmetz, K. Kolmetz Handbook of Process Equipment Design Distillation Column Selection,
Sizing and Troubleshooting.
Kumar, A., & Mishra, A. K. (2018). Biological Importance of Phenol Derivatives as Potent
Bioactive Compound: A Review. Letters in Organic Chemistry, 15(4), 251–264.
https://doi.org/10.2174/1570178614666171130155539
LAWS OF MALAYSIA ACT 127 ENVIRONMENTAL QUALITY ACT 1974. (1974).
Malaysia, P. (2017). Utilities Electricity Rates. https://www.mida.gov.my/wp-

content/uploads/2021/04/CODB-ENGLISH-Utilities.pdf
Malaysia’s Benzene Market Report 2022 - Prices, Size, Forecast, and Companies. (n.d.).
Www.indexbox.io. Retrieved June 12, 2023, from
https://www.indexbox.io/store/malaysia-benzene-market-analysis-forecast-size-trends-
and-insights/#:~:text=What%20is%20the%20average%20export.
Marine engines and auxiliary machinery. (2008). The Maritime Engineering Reference Book,
344–482. https://doi.org/10.1016/B978-0-7506-8987-8.00006-8
Materials of construction - processdesign. (n.d.). Materials of Construction - Processdesign.

https://processdesign.mccormick.northwestern.edu/index.php/Materials_of_construction
Mist Eliminators – Vane Type & Wire Mesh Demister Pads. (n.d.). Mist Eliminators – Vane
Type & Wire Mesh Demister Pads. https://www.mist-eliminator.org/
Multi-Tubular Fixed Bed Reactor - an overview | ScienceDirect Topics. (n.d.). Multi-Tubular

Fixed Bed Reactor - an Overview | ScienceDirect Topics. https://doi.org/10.1016/B978-
0-444-53292-3.50046-8
Occupational Safety and Health Administration. (2014). In Federal Regulatory Directory (pp.
278–290). https://doi.org/10.4135/9781452241067.n11
Official Website Department of Occupational Safety and Health - Controlling Noise in

Construction Site. (n.d.). Www.dosh.gov.my.
https://www.dosh.gov.my/index.php/construction-safety-v/controlling-noise-in-
construction-site
Our Leaders - INSTEP. (n.d.). Retrieved November 23, 2022, from https://www.instep.my/our-
people/our-leaders/.
384
P. (n.d.). Copper chromite. Copper Chromite | Cr2Cu2O5 - PubChem.
https://pubchem.ncbi.nlm.nih.gov/compound/3084101
Pasmore, J. (2020, April 21). Carbon, LIBS, and The Difference Between L+H Steels.
Analyzing Metals. https://www.thermofisher.com/blog/metals/carbon-libs-and-the-
difference-between-lh-steels/Plate column - Wikipedia. (n.d.). Plate Column - Wikipedia.
https://en.wikipedia.org/wiki/Plate_column
Petronas Chemicals Aromatics Sdn. Bhd. Company Profile - Malaysia | Financials & Key
Executives | EMIS. (n.d.). Retrieved November 23, 2022, from
https://www.emis.com/php/company-
profile/MY/Petronas_Chemicals_Aromatics_Sdn_Bhd_en_2470266.html.
Phenol - Chemical Economics Handbook (CEH) | S&P Global. (n.d.). Retrieved November 23,
2022, from https://www.spglobal.com/commodityinsights/en/ci/products/phenol-
chemical-economics-handbook.html.
Phenol | Definition, Structure, Uses, & Facts | Britannica. (n.d.). Retrieved November 20, 2022,
from https://www.britannica.com/science/phenol.
Phenol | NIOSH | CDC. (n.d.). Retrieved November 22, 2022, from

https://www.cdc.gov/niosh/topics/phenol/default.html.
Phenol | Shell Global. (n.d.). Retrieved November 22, 2022, from

https://www.shell.com/business-customers/chemicals/our-products/phenol.html.
Phenol Derivatives Market by Derivatives & Region - Global Forecast 2026 |

MarketsandMarkets. (n.d.). Retrieved November 23, 2022, from
https://www.marketsandmarkets.com/Market-Reports/phenol-derivative-market-
383.html.
Phenol Market Overview, Industry Trends, Segmentation, Analysis, Scope, and Forecast to
2029. (n.d.). Retrieved November 23, 2022, from
https://www.databridgemarketresearch.com/reports/global-phenol-market.
Porter, E. (2011, February 10). DISTILLATION. DISTILLATION.

https://doi.org/10.1615/AtoZ.d.distillation
Relative volatility - Wikipedia. (n.d.). Relative Volatility - Wikipedia.

https://en.wikipedia.org/wiki/Relative_volatility
385
S., W. (n.d.). Distillation Column - Basic Distillation Equipment and Operation. Distillation
Column - Basic Distillation Equipment and Operation.
https://www.wermac.org/equipment/distillation_part1.html
Scholarlycommons, S., Daowdat, B., Hoeltzel, G. D., & Tannenbaum, R. (2017). Direct Route
to Phenol from Benzene. https://repository.upenn.edu/cbe_sdr
Scholarlycommons, S., Daowdat, B., Hoeltzel, G. D., & Tannenbaum, R. (2017). Direct Route
to Phenol from Benzene. https://repository.upenn.edu/cbe_sdr
Separator types. (2021, December 9). PetroWiki. https://petrowiki.spe.org/Separator_types

Sieve Trays - Munters. (n.d.). Sieve Trays | Munters.
https://www.munters.com/en/munters/products/mass-transfer/sieve-trays/
Sigma Aldrich. (2021). Blue-White Screening & Protocols for Colony Selection. Merck.
https://www.sigmaaldrich.com/MX/en/technical-documents/technical-
article/genomics/cloning-and-expression/blue-white-screening
Sinnott R. K. Coulson J. M. & Richardson J. F. (2005). Coulson Richardson' s Chemical

Engineering Vol.6 Chemical Engineering Design 4th Edition.
http://search.ebscohost.com/login.aspx?direct=true&scope=site&db=nlebk&db=nlabk&
AN=195093.
Super Alloy Pyromet CTX-909 (UNS N11909). (2013, July 10). AZoM.com.
https://www.azom.com/article.aspx?ArticleID=9597
Uses of Benzene - Industrial and Domestic Applications of Benzene. (n.d.). Retrieved

November 20, 2022, from https://byjus.com/chemistry/uses-of-benzene/.
Verbanac, R. (2017, November 17). ISO 14001 environmental aspects: 4 steps in

identification. 14001Academy. https://advisera.com/14001academy/knowledgebase/4-
steps-in-identification-and-evaluation-of-environmental-aspects/
What are Environmental Aspects and Impacts? (n.d.). ISO 14000 Store.
https://14000store.com/articles/what-is-an-environmental-aspect/
What is a Control System? (Open Loop & Closed Loop Control Systems Explained) |
Electrical4U. (n.d.). Https://Www.Electrical4u.Com/. Retrieved June 22, 2023, from
https://www.electrical4u.com/control-system-closed-loop-open-loop-control-system/.
386
What Is a Packed Bed Reactor? | COMSOL Blog. (n.d.). Retrieved November 22, 2022, from
https://www.comsol.com/blogs/packed-bed-reactor/.
What Is a SWOT Analysis? Definition and Examples - TechTarget. (n.d.). Retrieved November
22, 2022, from https://www.techtarget.com/searchcio/definition/SWOT-analysis-
strengths-weaknesses-opportunities-and-threats-analysis.
White, C. H., Lauder, G. V, & Bart-Smith, H. (n.d.). Design of Adaptive Internal Control Model
on Binary Distillation Column You may also like Tunabot Flex: a tuna-inspired robot with
body flexibility improves high-performance swimming. https://doi.org/10.1088/1742-
6596/1175/1/012104
Zywno, M. (n.d.). 1.3 Control Objectives. Ryerson University.
387
APPENDIX A
(Appendix b Physical Property Tables - Google Search, n.d.)
Mass Balance at Condenser ( E-107)

1. Stream 26
❖ C6H5OH ❖ C6H5CHO
F C6H5OH, 26 = F26 (y C6H5OH, 26) F C6H5CHO, 26 = F26 (y C6H5CHO, 26 )
18.4477 = F26 (0.99848 ) = 18.4758 (0.0015 )
F26 = 18.4758 = 0.0277
❖ C6H6 ❖ C6H4(OH)2
F C6H6, 26 = F26 (y C6H6, 26 ) F C6H4(OH)2, 26 = F26 (y C6H4(OH)2, 26 )
= 18.4758 (0.00002 ) = 18.4758 (0.00001 )
= 0.0004 = 0.0002
2. Condenser balance
Condenser is non – reactive part, Total in = Total out
❖ C6H6 Balance
F C6H6, 25 = F C6H6, 26
= 0.0004
❖ C6H5OH
F C6H5OH, 25 = F C6H5OH, 26
= 18.4477
❖ C6H4(OH)2
F C6H4(OH)2, 25 = F C6H4(OH)2, 26
= 0.002
❖ C6H5CHO
F C6H5CHO, 25 = F C6H5CHO, 26
= 0.0277
3. Stream 25
F 25 kmol total/min = F C6H6 + F C6H4(OH)2 + F C6H5CHO + F C6H5OH
= 0.0004 + 0.0002 + 0.0277 + 18.4477
= 18.4760
388
Mass Balance at Distillation Column (T-104)
1. Stream 27
Assumption :
i. Total Flowrate at stream 25
= 5.0803 kmol total/ min (from reference)
ii. Total Flowrate at stream 27
The ratio method being used to get F27 , by using the information from reference and the
calculated total molar flowrate at stream 25
❖ F27 kmol total/ min
5.0803 0.1814
=
18.476 𝐹27
F27 = 0.6597
❖ C6H6
F C6H6 = F27, (y C6H6)
= 0.6597 (0.139)
= 0.0917
❖ C6H5OH
F C6H5OH = F27, (y C6H5OH)
= 0.6597 (0.852)
= 0.5621
❖ C6H5CHO
F C6H5CHO = F27, (y C6H5CHO)
= 0.6597 (0.009)
= 0.0059
2. Distillation Column Balance
Distillation Column is non- reactive , Total IN = Total OUT
❖ C6H6 Balance
F C6H6 ,23 = F C6H6,25 + F C6H6,27
= 0.0004 + 0.0917
= 0.0921
❖ C6H5OH Balance
389
F C6H5OH ,23 = F C6H5OH,25 + F C6H5OH,27
= 18.4477+ 0.5621
= 19.0098
❖ C6H5CHO Balance
F C6H5CHO ,23 = F C6H5CHO,25 + F C6H5CHO,27
= 0.0277+ 0.0059
= 0.0336
❖ C6H4(OH)2 Balance
F C6H4(OH)2 ,23 = F C6H4(OH)2,25
= 0.0002
1. Pump Balance
Pump is non-reactive, Total,IN= Total,OUT
❖ C6H6 Balance
F C6H6, 28 = F C6H6, 27
= 0.0917
❖ C6H5OH Balance
F C6H5OH, 28 = F C6H5OH, 27
= 0.5621
❖ C6H5CHO Balance
= 0.0059
1. Pump Balance
Pump is non – reactive, Total IN = Total OUT
❖ C6H6 Balance
F C6H6, 22 = F C6H6, 23
= 0.0921
❖ C6H5OH Balance
F C6H5OH, 22 = F C6H5OH, 23
= 19.0098
390
❖ C6H5CHO Balance
= 0.0336
F C6H4(OH)2, 22 = F C6H4(OH)2, 23
= 0.0002
Mass Balance at Condenser (E -106)
1. Stream 21
Assumption :
i. Total Flowrate at stream 21
ii. Total Flowrate at stream 22
The ratio method being used to get F21 , by using the information from reference and the
calculated total molar flowrate at stream 22
❖ F21
5.2618 0.0529
=
19.1357 𝐹21
F21 = 0.1924
❖ C6H6
F C6H6 = F21, (y C6H6)
= 0.1924 (0.0510)
= 0.0098
❖ C6H5OH
F C6H5OH = F21, (y C6H5OH)
= 0.1924 (0.9463)
= 0.1821
❖ C6H5CHO
F C6H5CHO = F21, (y C6H5CHO)
= 0.1924 (0.0027)
= 0.0005
391
2. Condenser Balance
Condenser is a non – reactive , Total IN = Total OUT
❖ C6H6 Balance
F C6H6 ,19 = F C6H6,21 + F C6H6,22
= 0.0098 + 0.0921
= 0.1019
❖ C6H5OH Balance
F C6H5OH ,19 = F C6H5OH,21 + F C6H5OH,22
= 0.1821 + 19.0098
= 19.1919
❖ C6H5CHO Balance
F C6H5CHO ,19 = F C6H5CHO,21 + F C6H5CHO,22
= 0.0005 + 0.0336
= 0.0341
F C6H4(OH)2 ,19 = F C6H4(OH)2,22
= 0.0002
3. Composition Phenol at stream 19

F C6H5OH, 19 = F19, (y C6H5OH, 19)
19.1919 = 19.3281 (y C6H5OH, 19)
= 0.9930
392
Mass Balance at Distillation Column (T -103)
1. Stream 20
Assumption :
By using the information of molar composition and total molar flowrate in stream 18 which
are 0.9930 and 19.1919 kmol/ min respectively. Use it to obtain the flowrate of phenol in
stream 19.
❖ F C6H5OH,20
0.9930 0.1286
=
19.1919 𝐹𝐶6𝐻5𝑂𝐻
F C6H5OH,20 = 2.4855
❖ F19 kmol total/min

F C6H5OH, 20 = F20 (y C6H5OH, 20)
2.4855 = F20 x 0.1286
= 19.3274
❖ C6H4(OH)2
F C6H4(OH)2,20 = F20 (y C6H4(OH)2, 20)
= 19.3274 x 0.8210
= 15.8678
❖ C6H5COOH
F C6H5COOH,20 = F20 (y C6H5COOH, 20)
= 19.3274 x 0.0504
= 0.9741

Distillation column is non- reactive, Total IN = Total OUT
❖ C6H6 Balance
F C6H6, 18 = F C6H6, 19
= 0.1019
❖ C6H5OH Balance
F C6H5OH, 18 = F C6H5OH, 19 + F C6H5OH, 20
= 19.1919 + 2.4855
= 21.6774
❖ C6H5CHO Balance
= 0.0341
393
❖ C6H4(OH)2
F C6H4(OH)2 , 18 = F C6H4(OH)2, 19 + F C6H4(OH)2, 20
= 0.0002 + 15.8678
= 15.8680
❖ C6H5COOH
F C6H5COOH , 18 = F C6H5COOH, 20
= 0.9741
Mass balance at Pump (P-104)
1. stream 24
Pump is non-reactive , Total In = Total , out
F C6H4(OH)2, 20 = F C6H4(OH)2, 24
= 15.8678
❖ C6H5COOH Balance
F C6H5COOH, 20 = F C6H5COOH, 24
= 0.9741
❖ C6H5OH Balance
F C6H5OH, 20 = F C6H5OH, 24
= 2.4855
Mass balance at Distillation (T-102)

1. Stream 12
Assumption :
• Total Flowrate at stream 12

= 43.8707 kmol total/min (from reference)
• Total flowrate at stream 16
= 5.5037 kmol total/ min ( from reference)
From the information , F12 can be obtain by using ratio method .
❖ F 12
5.5037 43.8707
=
38.6555 𝐹12
F12 = 308.1287
394
❖ C6H5OH
F C6H5OH, 12 = F C6H5OH,16
= 21.6774
❖ C6H5CHO
= 0.0341
❖ C6H4(OH)2
F C6H4(OH)2, 12 = F C6H4(OH)2, 16
= 15.8680
❖ C6H5COOH
F C6H5COOH, 12 = F C6H5COOH, 16
= 0.9741
❖ O2
F O2, 12 = F12 ( y O2, 12)

= 308.1287 x 0.0004
= 0.1233
❖ N2
F N2, 12 = F12 ( y N2, 12)

= 308.1287 x 0.0051
= 1.5715
❖ H2O
F H2O, 12 = F12 ( y H2O, 12)
= 308.1287 x 0.0028
= 0.8628
❖ C6H6
F12 = F C6H6,12 + F C6H5OH, 12 + F C6H5CHO, 12 + F C6H4(OH)2, 12 + F C6H5COOH, 12 +

F O2, 12 + F N2, 12 + F H2O, 12
308.1287 = F C6H6,12 + 21.6774 + 0.0341 + 15.8680 + 0.9741+ 0.1233+ 1.5715+ 0.8628
F C6H6,12 = 267.0175

Distillation column is non- reactive, Total In= Total Out.
395
❖ C6H6 Balance
F C6H6 12 = F C6H6 13 + F C6H6, 16

267.0175 = F C6H6 13 + 0.1019
F C6H6 26 = 266.9156
❖ O2 Balance
F O2, 13 = F O2, 12
= 0.1233
❖ N2 Balance
F N2, 13 = F N2, 12
= 1.5715
❖ H2O Balance
F H2O, 13 = F H2O, 12
= 0.8628
Mass Balance at (E- 105)

1. Stream 17
Assumption :

= 38.3696 kmol total/min ( from reference)
= 0.7673 kmol total/min ( from reference)
F13 can we get by using ratio method.
❖ F 17
38.3696 0.7673
=
269.4732 𝐹14
= 5.3888
❖ C6H6
F C6H6, 17 = F14 (y C6H6, 17)
= 5.3888 ( 0.5339)
= 2.8771
❖ O2
F O2, 17 = F14 ( y O2, 17)
= 5.3888 ( 0.019)
= 0.1024
396
❖ H2O
F H2O, 17 = F H2O, 13
= 0.8628
❖ N2
F N2 , 17 = F17 – ( F C6H6,17 + F O2,17 + F H2O,17 )
= 5.3888 – (2.8771 + 0.1024 + 0.8628)
= 1.5457
2. Condenser Balance
As the condenser is non-reactive, Total,IN = Total, OUT
❖ C6H6 Balance
F C6H6, 14 = F C6H6, 13 + F C6H6, 17
= 265.5906
❖ O2 Balance
F O2, 14 = F O2, 13 + F O2, 17
= 0.0209
❖ N2 Balance
F N2 , 14 = F N2 , 13 + F N2 , 17
= 0.0258
Mass balance at Pump (P-101)
1. Pump Balance
As pump is non-reactive , Total,IN = Total,OUT
❖ C6H6 Balance
F C6H6,15 = F C6H6, 14
= 264.0385
❖ O2 Balance
F O2, 15 = F O2, 14
= 0.0209
❖ N2 Balance
F N2,15 = F N2, 14
= 0.0258
397
Mass balance at Distillation Column (Flash Drum, T-101)
1. Stream 11
Assumption ;

= 12.0884 kmol total/min
= 43.8707 kmol total/min
F11 can be find by using ratio method
❖ F11
43.8707 12.0884
=
308.1287 𝐹11
= 84.9037
❖ C6H6
F C6H6,11 = F11 (y C6H6,11)
= 84.9037 ( 0.0259 )
= 2.1990
❖ C6H5OH
F C6H5OH,11 = F11 (y C6H5OH,11)
= 84.9037 ( 0.00006 )
= 0.0051
❖ O2
F O2,11 = F11 (y O2,11)
= 84.9037 (0.0217)
= 1.8424
❖ N2
F N2,11 = F11 (y N2,11)
= 84.9037 (0.9521)
= 80.8368
❖ H2O
F H2O,11 = F11 (y H2O,11)
= 84.9037 (0.00028 )
= 0.0023
398
Distillation Column is non- reactive , Total,IN = Total,OUT
❖ C6H6 Balance
F C6H6,10 = F C6H6,11 + F C6H6,12
= 269.2165
❖ C6H5OH Balance
F C6H5OH,10 = F C6H5OH,11 + F C6H5OH,12
= 21.6825
❖ C6H5CHO Balance
F C6H5CHO,10 = F C6H5CHO,12
= 0.0341
F C6H4(OH)2,10 = F C6H4(OH)2,12
= 15.8680
F C6H5COOH,10 = F C6H5COOH,12
= 0.9741
❖ O2 Balance
F O2,10 = F O2,11 + F O2,12
= 1.9657
❖ N2 Balance
F N2,10 = F N2,11 + F N2,12
= 82.4083
❖ H2O Balance
F H2O,10 = F H2O,11 + F H2O,12
= 0.8651
Mass Balance at Cooler ( E-104)
1. Cooler Balance
Cooler is non-reactive, Total,IN = Total,OUT
❖ C6H6 Balance
F C6H6,9 = F C6H6,10
= 269.2165
❖ C6H5OH Balance
F C6H5OH,9 = F C6H5OH,10
= 21.6825
399
❖ C6H5CHO Balance
= 0.0341
F C6H4(OH)2,9 = F C6H4(OH)2,10
= 15.8680
= 0.9741
❖ O2 Balance
F O2,9 = F O2,10
= 1.9657
❖ N2 Balance
F N2,9 = F N2,10
= 82.4083
❖ H2O Balance
F H2O,9 = F H2O,10
= 0.8651
Mass balance at Turbine ( TR-101)
1. Turbine Balance
Turbine is non-reactive, Total,IN = Total,OUT
❖ C6H6 Balance
F C6H6,8 = F C6H6,9
= 269.2165
❖ C6H5OH Balance
= 21.6825
❖ C6H5CHO Balance
= 0.0341
F C6H4(OH)2,8 = F C6H4(OH)2,9
= 15.8680
400
= 0.9741
❖ O2 Balance
F O2,8 = F O2,9
= 1.9657
❖ N2 Balance
F N2,8 = F N2,9
= 82.4083
❖ H2O Balance
F H2O,8 = F H2O,9
= 0.8651
Mass Balance at Heat Exchanger ( E-102)
1. Heat Exchanger Balance

Heat exchanger is non-reactive, Total,IN = Total,OUT
❖ C6H6 Balance
F C6H6,7 = F C6H6,8
= 269.2165
❖ C6H5OH Balance
= 21.6825
❖ C6H5CHO Balance
= 0.0341
F C6H4(OH)2,7 = F C6H4(OH)2,8
= 15.8680
= 0.9741
❖ O2 Balance
F O2,7 = F O2,8
= 1.9657
401
❖ N2 Balance
F N2,7 = F N2,8
= 82.4083
❖ H2O Balance
F H2O,7 = F H2O,8
= 0.8651
Mass balance at Reactor ( R-101)
❖ Conversion & Selectivity of Benzene

Conversion = 28.9%
Selectivity = 95.2%
(Ball et al., 2014)
𝐹𝑓𝑒𝑒𝑑 − 𝐹𝑜𝑢𝑡𝑙𝑒𝑡
𝐶𝑜𝑛𝑣𝑒𝑟𝑠𝑖𝑜𝑛 =
𝐹𝑓𝑒𝑒𝑑
𝐹𝑓𝑒𝑒𝑑 − 𝐹𝐶6𝐻6,7
𝐶𝑜𝑛𝑣𝑒𝑟𝑠𝑖𝑜𝑛 =
𝐹𝑓𝑒𝑒𝑑 − 269.2165
0.289 =
F feed / F C6H6,6 = 378.6449
2. Reactor Balance (Atomic Balance)

❖ Oxygen Balance
2 F O2,6 = 1(F C6H5OH) +1(F C6H5CHO) + 2(F C6H4(OH)2) + 2(F C6H5COOH) +
2(F O2) + 1(H2O)
2 F O2,6 = 21.6825 + 0.0341 + 2(15.8680) + 2(0.9741) + 2(1.9657) + 0.8651
2 F O2,6 = 60.1973
F O2,6 = 30.0987
402
3.Nitrogen Balance
N2 feed to the reactor same amount as the total for N2 outlet of the reactor
❖ F N2,6 = F N2,7
= 82.4083
Mass balance at Mixing point
1. stream 6
❖ C6H6 Balance
F C6H6,6 = F C6H6,6
= 378.6449
❖ O2 Balance
F O2,6 = 0.0209
❖ N2 Balance
F N2,6 = 0.0258
2. Mixing Point Balance
❖ O2 Balance
F O2,2 = F O2,6(out) + F O2,6
= 30.0778
❖ N2 Balance
F N2,2 = F N2,6(out) + F N2,6
= 82.3825
Mass balance at Pre – heater (E -103)
1. Pre- Heater Balance

Pre- Heater is non- reactive, Total,IN = Total,OUT
❖ C6H6 Balance
F C6H6,5 = F C6H6,6
= 378.6449
❖ O2 Balance
403
F O2,5 = F O2,6
=0.0209
❖ N2 Balance
F N2,5 = F N2,6
= 0.0258
Mass balance at Heat Exchanger (E- 102)
1. Heat Exchanger Balance

Heat exchanger is non- reactive, Total,IN = Total,OUT
❖ C6H6 Balance
F C6H6,4(in) = F C6H6,5
= 378.6449
❖ O2 Balance
F O2,4(in) = F O2,5
=0.0209
❖ N2 Balance
F N2,4(in) = F N2,5
= 0.0258
Mass balance at mixing point
1. Mixing Point Balance
F C6H6,15 + F C6H6,4 = F C6H6,4(out)

264.0385 + F C6H6,4 = 378.6449
F C6H6,4 = 114.6064
2. Stream 4
Total : F4 = F C6H6,4
= 114.6064
404
Mass balance at Pump ( P-102)
1.Pump Balance
Pump is non-reactive, Total,IN = Total,OUT
❖ C6H6 Balance
F C6H6,3 = F C6H6,4
= 114.6064
Mass Balance at Compressor ( C-102)
1. Compressor Balance
Compressor is non-reactive, Total,IN = Total,OUT
❖ O2 Balance
F O2,1 = F O2,2
=30.0778
❖ N2 Balance
F N2,1 = F N2,2
= 82.3825
405
APPENDIX B
(Appendix b Physical Property Tables - Google Search, n.d.)
Compressor (C-101)
References: O2, N2 (g, 30°C, 0kPa)
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0 ɳ𝟐 = 𝐇𝟐 =
O2 (g) 0 396.6198
82.3825 (Ref) 82.3825 4.8144
ɳ𝟑 = 𝐇𝟑 = 0 ɳ𝟒 = 𝐇𝟒 =
N2 (g) 0 145.3516
30.0778 (Ref) 30.0778 4.8325
Total 0 541.9714
∆𝐻2
N2 (g), (30°C, 0 kPa) N2 (g), (196°C, 4000 kPa)
𝐻𝑎
𝐻𝑏
N2 (g), (196°C, 0 kPa)
196 196
𝐻𝑎 = ∫30 𝑐𝑝dT 𝐻𝑎 = ∫30 (29.00 × 10−3 ) + (0.2199 × 10(−5) ) + (0.5723 × 10(−8) ) +
(−2.871 × 10(−12) ) dT
𝑘𝐽
𝐻𝑎 = 4.81437
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑏 = 0 . N2 is ideal gas, thus changes in pressure are negligible.
𝑚𝑜𝑙
𝑘𝐽 𝑘𝐽 𝒌𝑱
∆𝐻2 = 𝐻𝑎 + 𝐻𝑏 = 4.81437 + 0 = 𝟒. 𝟖𝟏𝟒𝟑𝟕 𝒎𝒐𝒍
𝑚𝑜𝑙 𝑚𝑜𝑙
406
∆𝐻4
O2 (g), (30°C, 0 kPa) O2 (g), (196°C, 4000 kPa)
𝐻𝑎
𝐻𝑏
O2 (g), (196°C, 0 kPa)
196 196
𝐻𝑎 = ∫30 𝑐𝑝dT 𝐻𝑎 = ∫30 (29.10 × 10−3 ) + (1.158 × 10(−5) ) + (−0.6076 × 10(−8) ) +
𝑘𝐽
(1.311 × 10(−12) ) dT 𝐻𝑎 = 4.83252
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑏 = 0 . O2 is ideal gas, thus changes in pressure are negligible.
𝑚𝑜𝑙
∆𝐻2 = 𝐻𝑎 + 𝐻𝑏 = 4.83252 + 0 = 𝟒. 𝟖𝟑𝟐𝟓𝟐 𝒎𝒐𝒍
407
Reactor R-101
References: C6H6, C6H4(OH)2, C6H5CHO, C6H5OH, H2O, C6H5COOH, N2, O2, H2O
(25°C, 1 atm)
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) 33924.0840 24318.7572
378.6449 89.5934 269.2165 90.3316
ɳ𝟐 = 𝐇𝟑 = ɳ𝟒 = 𝐇𝟒 =
N2 (g) 779.1458 789.9742
82.4083 9.4547 82.4083 9.5861
ɳ𝟓 = 𝐇𝟓 = ɳ𝟔 = 𝐇𝟔 =
O2 (g) 285.6487 18.6553
30.0987 9.4909 1.9657 9.4904
ɳ𝟕 = 𝐇𝟕 =
C6H5OH (l) - - - 6615.7102
21.6825 305.1175
ɳ𝟖 = 𝐇𝟖 =
C6H5COOH (l) - - - 224.0499
0.9741 230.0071
ɳ𝟗 = 𝐇𝟗 =
C6H4(OH)2 (l) - - - 2384.2067
15.8680 150.2525
ɳ𝟏𝟎 = 𝐇𝟏𝟎 =
C6H5COOH (l) - - - 0.66227
0.0341 19.4214
ɳ𝟏𝟏 = 𝐇𝟏𝟏 =
H2O (l) - - - -225.9547
0.8651 -261.1891
Total 34988.8785 34125.465
408
409
410
411
Mixing Point 1
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0 ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) 0 13.0860
378.6449 (Ref) 378.6449 0.0346
ɳ𝟑 = 𝐇𝟑 = 0 ɳ𝟒 = 𝐇𝟒 =
O2 (g) 0 370.4500
82.4083 (Ref) 82.4083 4.4953
ɳ𝟓 = 𝐇𝟓 = 0 ɳ𝟔 = 𝐇𝟔 =
N2 (g) 0 135.3504
30.0987 (Ref) 30.0987 4.5123
Total 0 519.3504
412
Mixing Point 2
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0 ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) 0 623.8175
378.6449 (Ref) 378.6449 1.6475
ɳ𝟑 = 𝐇𝟑 = 0 ɳ𝟒 = 𝐇𝟒 =
C6H6 (l) 0 2879.2310
378.6449 (Ref) 378.6449 7.6040
ɳ𝟓 = 𝐇𝟓 = 0 ɳ𝟔 = 𝐇𝟔 =
O2 (g) 0 0.00973
0.0258 (Ref) 0.0258 0.37701
ɳ𝟕 = 𝐇𝟕 = 0 ɳ𝟖 = 𝐇𝟖 =
N2 (g) 0 0.00791
0.0209 (Ref) 0.0209 0.3785
Total 0 3503.066
413
414
Feed/Effluent Exchange E-102
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0 ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) 0 8397.5866
378.6449 (Ref) 378.6449 22.178
ɳ𝟑 = 𝐇𝟑 = 0 ɳ𝟒 = 𝐇𝟒 =
O2 (g) 0 0.1064
0.0209 (Ref) 0.0209 5.0925
ɳ𝟓 = 𝐇𝟓 = 0 ɳ𝟔 = 𝐇𝟔 =
N2 (g) 0 0.1309
0.0258 (Ref) 0.0258 5.075
Total 0 8397.8240
C6H6 (l), (93°C,4400kPa) C6H6 (l), (268°C, 4385kPa)
𝐻𝑎
𝐻𝑏
C6H6 (l), (268°C,4400kPa)
268 268 𝑘𝐽
𝐻𝑎 = ∫93 𝑐𝑝dT 𝐻𝑎 = ∫93 0.126734 dT 𝐻𝑎 = 22.17845
𝑚𝑜𝑙
𝑚3 𝑁𝑚−2 𝐽
𝐻𝑏 = 1.14𝑥10−3 (−0.1 𝑎𝑡𝑚) ( 101325 ) = -11.551
𝑘𝑔 𝑎𝑡𝑚 𝑘𝑔
𝐽 𝑔 1 𝑘𝑔 𝑗 𝑘𝐽
=-11.551 x 78.11 x = -84.8118 = -0.0009
𝑘𝑔 𝑚𝑜𝑙 1000 𝑔 𝑚𝑜𝑙 𝑚𝑜𝑙
∆𝐻2 = 𝐻𝑎 + 𝐻𝑏 = 22.17845 + (−0.0009) = 22.178
𝑚𝑜𝑙 𝑚𝑜𝑙 𝒎𝒐𝒍
415
∆𝐻4
O2 (g), (93°C, 4400kPa) O2 (g), (268°C, 4385kPa)
𝐻𝑎
𝐻𝑏
O2 (g), (268°C, 4400kPa)
268 268 𝑘𝐽
𝐻𝑎 = ∫93 𝑐𝑝dT 𝐻𝑎 = ∫93 0.0291 dT 𝐻𝑎 = 5.0925
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑏 = 0 (Ideal gas)
𝑚𝑜𝑙
∆𝐻4 = 𝐻𝑎 + 𝐻𝑏 = 5.0925 + 0 = 𝟓. 𝟎𝟗𝟐𝟓 𝒎𝒐𝒍
∆𝐻6
N2 (g), (93°C, 4400kPa) N2 (g), (268°C, 4385kPa)
𝐻𝑎
𝐻𝑏
N2 (g), (268°C, 4400kPa)
268 268 𝑘𝐽
𝐻𝑎 = ∫93 𝑐𝑝dT 𝐻𝑎 = ∫93 0.0290 dT 𝐻𝑎 = 5.075
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
∆𝐻6 = 𝐻𝑎 + 𝐻𝑏 = 5.075 + 0 = 𝟓. 𝟎𝟕𝟓 𝒎𝒐𝒍
416
Pre-Heater E-103
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0 ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) 0 3981.5693
378.6449 (Ref) 378.6449 10.515312
ɳ𝟑 = 𝐇𝟑 = 0 ɳ𝟒 = 𝐇𝟒 =
O2 (g) 0 0.05048
0.0209 (Ref) 0.0209 2.4153
ɳ𝟓 = 𝐇𝟓 = 0 ɳ𝟔 = 𝐇𝟔 =
N2 (g) 0 0.0621
0.0258 (Ref) 0.0258 2.407
Total 0 3981.6819
∆𝐻2
C6H6 (l), (268°C,4385kPa) C6H6 (l), (351°C, 4390kPa)
𝐻𝑎
𝐻𝑏
C6H6 (l), (351°C,4385kPa)
351 351 𝑘𝐽
𝐻𝑎 = ∫268 𝑐𝑝dT 𝐻𝑎 = ∫268 0.126734 dT 𝐻𝑎 = 10.518922
𝑚𝑜𝑙
𝐻𝑏 = 1.14𝑥10−3 (−0.4 𝑎𝑡𝑚) ( 101325 ) = -46.2042
𝐽 𝑔 1 𝑘𝑔 𝐽 𝑘𝐽
=-46.2042 x 78.11 x = -3.61 = -0.00361
∆𝐻2 = 𝐻𝑎 + 𝐻𝑏 = 10.518922 + (−0.00361) = 10.515312
𝑚𝑜𝑙 𝑚𝑜𝑙 𝒎𝒐𝒍
417
∆𝐻4
O2 (g), (268°C, 4385kPa) O2 (g), (351°C, 4390kPa)
𝐻𝑎
𝐻𝑏
O2 (g), (351°C, 4385kPa)
351 351 𝑘𝐽
𝐻𝑎 = ∫268 𝑐𝑝dT 𝐻𝑎 = ∫268 0.0291 dT 𝐻𝑎 = 2.4153
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
∆𝐻4 = 𝐻𝑎 + 𝐻𝑏 = 2.4153 + 0 = 𝟐. 𝟒𝟏𝟓𝟑 𝒎𝒐𝒍
∆𝐻6
N2 (g), (268°C, 4380kPa) N2 (g), (351°C, 4390kPa)
𝐻𝑎
𝐻𝑏
N2 (g), (351°C, 4380kPa)
351 351 𝑘𝐽
𝐻𝑎 = ∫268 𝑐𝑝dT 𝐻𝑎 = ∫268 0.0290 dT 𝐻𝑎 = 2.407
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
∆𝐻6 = 𝐻𝑎 + 𝐻𝑏 = 2.407 + 0 = 𝟐. 𝟒𝟎𝟕 𝒎𝒐𝒍
418
Condenser E-105
References: C6H6, O2, N2 (g, 252°C, 68kPa), H2O (l, 252°C, 68kPa)
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0
C6H6 (g) 0 - - -
268.4677 (Ref)
ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) - - - -98.6753
2.8771 -34.2968
ɳ𝟑 = 𝐇𝟑 =
C6H6 (l) - - - -9602.9062
265.5906 -36.1568
ɳ𝟒 = 𝐇𝟒 = 0 ɳ𝟓 = 𝐇𝟓 =
O2 (g) 0 -0.14005
0.1233 (Ref) 0.1024 -1.3677
ɳ𝟔 = 𝐇𝟔 =
O2 (g) - - - -0.04379
0.0209 -2.0952
ɳ𝟕 = 𝐇𝟕 = 0 ɳ𝟖 = 𝐇𝟖 =
N2 (g) 0 -2.10679
1.5715 (Ref) 1.5457 -1.363
ɳ𝟗 = 𝐇𝟗 =
N2 (g) - - - -0.05387
0.0258 -2.088
ɳ𝟏𝟎 = 𝐇𝟏𝟎 = 0
H2O (g) 0 - - -
0.8628 (Ref)
ɳ𝟏𝟏 = 𝐇𝟏𝟏 =
H2O (l) - - - -36.4313
0.8628 -42.2245
Total 0 -9740.3573
419
∆𝐻2
C6H6 (g), (150°C, 68kPa) C6H6 (l), (103°C, 34kPa)
𝐻𝑎 𝐻𝑐
C6H6 (g), (103°C, 68kPa) C6H6 (l), (103°C, 68kPa)

𝐻𝑏
103 103 𝑘𝐽
𝐻𝑎 = ∫150 𝑐𝑝dT 𝐻𝑎 = ∫150 0.07440 dT 𝐻𝑎 = −3.4968
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑏 = −30.8 (Heat Condensation)
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
𝑘𝐽 𝑘𝐽 𝑘𝐽 𝒌𝑱
∆𝐻2 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = −3.4968 + (−30.8 )+ 0 = −𝟑𝟒. 𝟐𝟗𝟔𝟖 𝒎𝒐𝒍
𝑚𝑜𝑙 𝑚𝑜𝑙 𝑚𝑜𝑙
∆𝐻3
C6H6 (g), (150°C, 68kPa) C6H6 (l), (78°C, 34kPa)
𝐻𝑎 𝐻𝑐
C6H6 (g), (78°C, 68kPa) C6H6 (l), (78°C, 68kPa)

𝐻𝑏
78 78 𝑘𝐽
𝐻𝑎 = ∫150 𝑐𝑝dT 𝐻𝑎 = ∫150 0.07440 dT 𝐻𝑎 = −5.3568
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻3 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = −5.3568 + (−30.8 )+ 0 = −𝟑𝟔. 𝟏𝟓𝟔𝟖 𝒎𝒐𝒍
420
∆𝐻5
O2 (g), (150°C, 68kPa) O2 (g), (103°C, 34kPa)
𝐻𝑎
𝐻𝑏
O2 (g), (103°C, 68kPa)
103 103 𝑘𝐽
𝐻𝑎 = ∫150 𝑐𝑝dT 𝐻𝑎 = ∫150 0.0291 dT 𝐻𝑎 = −1.3677
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
∆𝐻5 = 𝐻𝑎 + 𝐻𝑏 = −1.3677 + 0 = −𝟏. 𝟑𝟔𝟕𝟕 𝒎𝒐𝒍
∆𝐻6
O2 (g), (150°C, 68kPa) O2 (g), (78°C, 34kPa)
𝐻𝑎
𝐻𝑏
O2 (g), (78°C, 68kPa)
78 78 𝑘𝐽
𝐻𝑎 = ∫150 𝑐𝑝dT 𝐻𝑎 = ∫150 0.0291 dT 𝐻𝑎 = −2.0952
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
∆𝐻6 = 𝐻𝑎 + 𝐻𝑏 = −2.0952 + 0 = −𝟐. 𝟎𝟗𝟓𝟐 𝒎𝒐𝒍
421
∆𝐻8
N2 (g), (150°C, 68kPa) N2 (g), (103°C, 34kPa)
𝐻𝑎
𝐻𝑏
N2 (g), (103°C, 68kPa)
103 103 𝑘𝐽
𝐻𝑎 = ∫150 𝑐𝑝dT 𝐻𝑎 = ∫150 0.0290 dT 𝐻𝑎 = −1.363
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
∆𝐻8 = 𝐻𝑎 + 𝐻𝑏 = −1.363 + 0 = −𝟏. 𝟑𝟔𝟑 𝒎𝒐𝒍
∆𝐻9
O2 (g), (150°C, 68kPa) O2 (g), (78°C, 34kPa)
𝐻𝑎
𝐻𝑏
O2 (g), (78°C, 68kPa)
78 78 𝑘𝐽
𝐻𝑎 = ∫150 𝑐𝑝dT 𝐻𝑎 = ∫150 0.0290 dT 𝐻𝑎 = −2.088
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
∆𝐻9 = 𝐻𝑎 + 𝐻𝑏 = −2.088 + 0 = −𝟐. 𝟎𝟖𝟖 𝒎𝒐𝒍
422
∆𝐻11
H2O (g), (150°C, 68kPa) H2O (l), (103°C, 34kPa)
𝐻𝑎 𝐻𝑐
H2O (g), (103°C, 68kPa) H2O (l), (103°C, 68kPa)

𝐻𝑏
103 103 𝑘𝐽
𝐻𝑎 = ∫150 𝑐𝑝dT 𝐻𝑎 = ∫150 0.0335dT 𝐻𝑎 = −1.5745
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻11 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = −1.5745 + (−40.65 )+ 0 = −𝟒𝟐. 𝟐𝟐𝟒𝟓 𝒎𝒐𝒍
423
Condenser E-106
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0
C6H6 (g) 0 - - -
0.1019 (Ref)
ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) - - - -0.34559
0.0098 -35.264
ɳ𝟑 = 𝐇𝟑 =
C6H6 (l) - - - -3.2478
0.0921 -35.264
ɳ𝟒 = 𝐇𝟒 = 0
C6H4(OH)2 (g) 0 - - -
0.0002 (Ref)
ɳ𝟓 = 𝐇𝟓 =
C6H4(OH)2 (l) - - - -0.02994
0.0002 -149.678
ɳ𝟔 = 𝐇𝟔 = 0
C6H5CHO (g) 0 - - -
0.0341 (Ref)
ɳ𝟕 = 𝐇𝟕 =
C6H5CHO (l) - - - -0.02436
0.0005 -48.72
ɳ𝟖 = 𝐇𝟖 =
C6H5CHO (l) - - - -1.63699
0.0336 -48.72
ɳ𝟗 = 𝐇𝟗 = 0
C6H5OH (g) 0 - - -
19.1919 (Ref)
ɳ𝟏𝟎 = 𝐇𝟏𝟎 =
C6H5OH (l) - - - -22.2308
0.1821 -122.08
ɳ𝟏𝟏 = 𝐇𝟏𝟏 =
C6H5OH (l) - - - -2320.7164
19.0098 -122.08
Total 0 -2348.2320
424
∆𝐻3
C6H6 (g), (252°C, 68kPa) C6H6 (l), (192°C, 34kPa)
𝐻𝑎 𝐻𝑐
C6H6 (g), (192°C, 68kPa) C6H6 (l), (192°C, 68kPa)

𝐻𝑏
192 192 𝑘𝐽
𝐻𝑎 = ∫252 𝑐𝑝dT 𝐻𝑎 = ∫252 0.07440 dT 𝐻𝑎 = −4.464
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻3 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = −4.464 + (−30.8 )+ 0 = −𝟑𝟓. 𝟐𝟔𝟒 𝒎𝒐𝒍
C6H4(OH)2 (g), (252°C, ∆𝐻5 C6H4(OH)2 (l), (192°C,

68kPa) 34kPa)
𝐻𝑎 𝐻𝑐
C6H4(OH)2 (g), (192°C, C6H4(OH)2 (l), (192°C,

68kPa) 𝐻𝑏 68kPa)
192 192 𝑘𝐽
𝐻𝑎 = ∫252 𝑐𝑝dT 𝐻𝑎 = ∫252 1.2963 dT 𝐻𝑎 = −77.778
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻5 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = −77.778 + (−71.9 )+ 0 = −𝟏𝟒𝟗. 𝟔𝟕𝟖 𝒎𝒐𝒍
425
C6H5OH (g), (252°C, ∆𝐻8 C6H5CHO (l), (192°C,
68kPa) 34kPa)
𝐻𝑎 𝐻𝑐
C6H5CHO (g), (192°C, C6H5CHO (l), (192°C,

192 192 𝑘𝐽
𝐻𝑎 = ∫252 𝑐𝑝dT 𝐻𝑎 = ∫252 0.172 dT 𝐻𝑎 = −10.32
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻8 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = −10.32 + (−38.40 )+ 0 = −𝟒𝟖. 𝟕𝟐 𝒎𝒐𝒍
C6H5OH (g), (252°C, ∆𝐻11 C6H5OH (l), (192°C,

68kPa) 34kPa)
𝐻𝑎 𝐻𝑐
C6H5OH (g), (192°C, C6H5OH (l), (192°C,

192 192 𝑘𝐽
𝐻𝑎 = ∫252 𝑐𝑝dT 𝐻𝑎 = ∫252 1.233 dT 𝐻𝑎 = −73.98
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻11 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = −73.98 + (−48.1 )+ 0 = −𝟏𝟐𝟐. 𝟎𝟖 𝒎𝒐𝒍
426
Condenser E-107
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0
C6H6 (g) 0 - - -
0.0004 (Ref)
ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) - - - -0.01533
0.0004 -38.3144
ɳ𝟑 = 𝐇𝟑 = 0
C6H4(OH)2 (g) 0 - - -
0.0002 (Ref)
ɳ𝟒 = 𝐇𝟒 =
C6H4(OH)2 (l) - - - -0.04057
0.0002 -202.8263
ɳ𝟓 = 𝐇𝟓 = 0
C6H5CHO (g) 0 - - -
0.0277 (Ref)
ɳ𝟔 = 𝐇𝟔 =
C6H5CHO (l) - - - -1.54488
0.0277 -55.772
ɳ𝟕 = 𝐇𝟕 = 0
C6H5OH (g) 0 - - -
18.4477 (Ref)
ɳ𝟖 = 𝐇𝟖 =
C6H5OH (l) - - - -3184.6818
18.4477 -172.633
Total 0 -3186.2826
427
∆𝐻2
C6H6 (g), (252°C, 68kPa) C6H6 (l), (151°C, 34kPa)
𝐻𝑎 𝐻𝑐
C6H6 (g), (151°C, 68kPa) C6H6 (l), (151°C, 68kPa)

𝐻𝑏
151
𝐻𝑎 = ∫252 𝑐𝑝dT
151
𝐻𝑎 = ∫252 0.07440 dT
𝑘𝐽
𝐻𝑎 = −7.5144
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻2 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = −7.5144 + (−30.8 )+ 0 = −𝟑𝟖. 𝟑𝟏𝟒𝟒 𝒎𝒐𝒍
C6H4(OH)2 (g), (252°C, ∆𝐻4 C6H4(OH)2 (l), (151°C,

68kPa) 34kPa)
𝐻𝑎 𝐻𝑐
C6H4(OH)2 (g), (151°C, C6H4(OH)2 (l), (151°C,

151
151
𝐻𝑎 = ∫252 1.2963 dT
𝑘𝐽
𝐻𝑎 = −130.9263
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻4 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = −130.9263 + (−71.9 )+ 0 = −𝟐𝟎𝟐. 𝟖𝟐𝟔𝟑 𝒎𝒐𝒍
428
C6H5OH (g), (252°C, ∆𝐻6 C6H5CHO (l), (151°C,
68kPa) 34kPa)
𝐻𝑎 𝐻𝑐
C6H5CHO (g), (151°C, C6H5CHO (l), (151°C,

151
151
𝐻𝑎 = ∫252 0.172 dT
𝑘𝐽
𝐻𝑎 = −17.372
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻6 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = −17.372 + (−38.40 )+ 0 = −𝟓𝟓. 𝟕𝟕𝟐 𝒎𝒐𝒍
C6H5OH (g), (252°C, ∆𝐻8 C6H5OH (l), (151°C,

68kPa) 34kPa)
𝐻𝑎 𝐻𝑐
C6H5OH (g), (151°C, C6H5OH (l), (151°C,

151
151
𝐻𝑎 = ∫252 1.233 dT
𝑘𝐽
𝐻𝑎 = −124.533
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻8 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = −124.533 + (−48.1 )+ 0 = −𝟏𝟕𝟐. 𝟔𝟑𝟑 𝒎𝒐𝒍
429
References: C6H6, C6H4(OH)2, C6H5CHO, C6H5OH, H2O, C6H5COOH (l, 53°C, 1000kPa),
N2, O2, (g, 53°C, 1000kPa)
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0 ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) 0 1.8640
21.6774 (Ref) 0.1019 18.29233
ɳ𝟑 = 𝐇𝟑 =
C6H6 (g) - - - 11480.10
266.9156 43.0102
ɳ𝟒 = 𝐇𝟒 = 0 ɳ𝟓 = 𝐇𝟓 =
C6H4(OH)2 (l) 0 2981.2814
15.8680 (Ref) 15.8680 187.8801
ɳ𝟔 = 𝐇𝟔 = 0 ɳ𝟕 = 𝐇𝟕 =
C6H5CHO (l) 0 0.849210
0.0341 (Ref) 0.0341 24.9035
ɳ𝟖 = 𝐇𝟖 = 0 ɳ𝟗 = 𝐇𝟗 =
C6H5OH (l) 0 3873.790
21.6774 (Ref) 21.6774 178.7018
ɳ𝟏𝟎 = 𝐇𝟏𝟎 = 0 ɳ𝟏𝟏 = 𝐇𝟏𝟏 =
C6H5COOH (l) 0 141.5066
0.9741 (Ref) 0.9741 145.2691
ɳ𝟏𝟐 = 𝐇𝟏𝟐 = 0 ɳ𝟏𝟑 = 𝐇𝟏𝟑 =
O2 (g) 0 0.3480
0.1233 (Ref) 0.1233 2.8227
ɳ𝟏𝟒 = 𝐇𝟏𝟒 = 0 ɳ𝟏𝟓 = 𝐇𝟏𝟓 =
N2 (g) 0 4.42063
1.5715 (Ref) 1.5715 2.813
ɳ𝟏𝟔 = 𝐇𝟏𝟔 = 0
H2O (l) 0 - - -
0.8628 (Ref)
ɳ𝟏𝟕 = 𝐇𝟏𝟕 =
H2O (g) - - - 41.3977
0.8628 47.9806
Total 0 18525.558
∆𝐻2
C6H6 (l), (53°C,1000kPa) C6H6 (l), (198°C, 50kPa)
𝐻𝑎
𝐻𝑏
C6H6 (l), (198°C,1000kPa)
430
198 198 𝑘𝐽
𝐻𝑎 = ∫53 𝑐𝑝dT 𝐻𝑎 = ∫53 0.126734 dT 𝐻𝑎 = 18.37643
𝑚𝑜𝑙
𝐻𝑏 = 1.14𝑥10−3 (−9.4 𝑎𝑡𝑚) ( 101325 ) = -1085.7987
=-1085.7987 x 78.11 x = -84.8118 = -0.0841
∆𝐻2 = 𝐻𝑎 + 𝐻𝑏 = 18.37643 + −0.0841 = 𝟏𝟖. 𝟐𝟗𝟐𝟑𝟑 𝒎𝒐𝒍
∆𝐻3
C6H6 (l), (53°C,1000kPa) C6H6 (g), (150°C,68kPa)
𝐻𝑎 𝐻𝑐
C6H6 (l), (150°C,1000kPa) C6H6 (g), (150°C,1000kPa)

𝐻𝑏
150 150 𝑘𝐽
𝐻𝑎 = ∫53 𝑐𝑝dT 𝐻𝑎 = ∫53 0.126734 dT 𝐻𝑎 = 12.2932
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑏 = 30.8 (Heat Vaporization)
𝑚𝑜𝑙
𝐻𝑐 = 1.14𝑥10−3 (−9.2 𝑎𝑡𝑚) ( 101325 ) = -1062.6966
=-1062.6966 x 78.11 x = -83.007 = -0.0830
∆𝐻3 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = 12.2932 + 30.8 + (−0.0830) = 𝟒𝟑. 𝟎𝟏𝟎𝟐 𝒎𝒐𝒍
C6H4(OH)2 (l), (53°C, ∆𝐻5 C6H4(OH)2 (l), (198°C,

1000kPa) 50kPa)
𝐻𝑎
𝐻𝑏
C6H4(OH)2 (l), (198°C,

1000kPa)
431
198 198 𝑘𝐽
𝐻𝑎 = ∫53 𝑐𝑝dT 𝐻𝑎 = ∫53 1.2963 dT 𝐻𝑎 = 187.9635
𝑚𝑜𝑙
𝐻𝑏 = 7.95 𝑥 10−4 (−9.4 𝑎𝑡𝑚) ( 101325 ) = -757.202
=-757.202 x 110.11 x = -83.3755 = -0.0834
∆𝐻5 = 𝐻𝑎 + 𝐻𝑏 = 187.9635 + (−0.0834) = 𝟏𝟖𝟕. 𝟖𝟖𝟎𝟏 𝒎𝒐𝒍
C6H5CHO (l), (53°C, ∆𝐻7 C6H5CHO (g), (198°C,

1000kPa) 50kPa)
𝐻𝑎
𝐻𝑏
C6H5CHO (l), (198°C,

1000kPa)
198 198 𝑘𝐽
𝐻𝑎 = ∫53 𝑐𝑝dT 𝐻𝑎 = ∫53 0.172 dT 𝐻𝑎 = 24.94
𝑚𝑜𝑙
𝐻𝑏 = 3.61 𝑥 10−4 (−9.4 𝑎𝑡𝑚) ( 101325 ) = -343.8363
=-343.8363 x 106.124 x = -36.4893 = -0.0365
∆𝐻7 = 𝐻𝑎 + 𝐻𝑏 = 24.94 + (−0.0365) = 𝟐𝟒. 𝟗𝟎𝟑𝟓 𝒎𝒐𝒍
C6H5OH (l), (53°C, ∆𝐻9 C6H5OH (l), (198°C,

1000kPa) 50kPa)
𝐻𝑎
𝐻𝑏
C6H5OH (l), (198°C,
1000kPa)
432
198 198 𝑘𝐽
𝐻𝑎 = ∫53 𝑐𝑝dT 𝐻𝑎 = ∫53 1.233 dT 𝐻𝑎 = 178.785
𝑚𝑜𝑙
𝐻𝑏 = 9.28 𝑥 10−4 (−9.4 𝑎𝑡𝑚) ( 101325 ) = -883.87824
=-883.87824 x 94.11 x = -83.18178 = -0.0832
∆𝐻9 = 𝐻𝑎 + 𝐻𝑏 = 178.785 + (−0.0832) = 𝟏𝟕𝟖. 𝟕𝟎𝟏𝟖 𝒎𝒐𝒍
C6H5COOH (l), (53°C, ∆𝐻11 C6H5COOH (l), (198°C,

1000kPa) 50kPa)
𝐻𝑎
𝐻𝑏
C6H5COOH (l), (198°C,

1000kPa)
198 198 𝑘𝐽
𝐻𝑎 = ∫53 𝑐𝑝dT 𝐻𝑎 = ∫53 1.0026 dT 𝐻𝑎 = 145.377
𝑚𝑜𝑙
𝐻𝑏 = 9.28 𝑥 10−4 (−9.4 𝑎𝑡𝑚) ( 101325 ) = -883.87824
=-883.87824 x 122.12 x = -107.9392 = -0.1079
∆𝐻11 = 𝐻𝑎 + 𝐻𝑏 = 145.377 + (−0.1079) = 𝟏𝟒𝟓. 𝟐𝟔𝟗𝟏 𝒎𝒐𝒍
∆𝐻13
O2 (g), (53°C, 1000kPa) O2 (g), (150°C, 68kPa)
𝐻𝑎
𝐻𝑏
O2 (g), (150°C, 1000kPa)
433
150 150 𝑘𝐽
𝐻𝑎 = ∫53 𝑐𝑝dT 𝐻𝑎 = ∫53 0.0291 dT 𝐻𝑎 = 2.8227
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
∆𝐻13 = 𝐻𝑎 + 𝐻𝑏 = 2.8227 + 0 = 𝟐. 𝟖𝟐𝟐𝟕 𝒎𝒐𝒍
∆𝐻15
N2 (g), (53°C, 1000kPa) N2 (g), (150°C, 68kPa)
𝐻𝑎
𝐻𝑏
N2 (g), (150°C, 1000kPa)
150 150 𝑘𝐽
𝐻𝑎 = ∫53 𝑐𝑝dT 𝐻𝑎 = ∫53 0.0290 dT 𝐻𝑎 = 2.813
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
∆𝐻15 = 𝐻𝑎 + 𝐻𝑏 = 2.813 + 0 = 𝟐. 𝟖𝟏𝟑 𝒎𝒐𝒍
∆𝐻17
H2O (I), (53°C, 1000kPa) H2O (g), (150°C, 68kPa)
𝐻𝑎 𝐻𝑐
H2O (l), (150°C, 1000kPa) H2O (g), (150°C, 1000kPa)

𝐻𝑏
150 150 𝑘𝐽
𝐻𝑎 = ∫53 𝑐𝑝dT 𝐻𝑎 = ∫53 0.0754 dT 𝐻𝑎 = 7.3138
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑏 = 40.65 (Heat Vaporization)
𝑚𝑜𝑙
𝐻𝑐 = 1.0 𝑥 10−3 (−9.2 𝑎𝑡𝑚) ( 101325 ) = -932.19
=-932.19 x 18.01528 x = -16.794 = -0.01679
∆𝐻17 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = 7.3138 + 40.65 + (−0.01679) = 𝟒𝟕. 𝟗𝟖𝟎𝟔 𝒎𝒐𝒍
434
References: C6H6, C6H4(OH)2, C6H5CHO, C6H5OH, C6H5COOH (l, 198°C, 62kPa)
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0
C6H6 (l) 0 - - -
0.1019 (Ref)
ɳ𝟐 = 𝐇𝟐 =
C6H6 (g) - - - 1.81038
0.1019 17.7662
ɳ𝟑 = 𝐇𝟑 = 0 ɳ𝟒 = 𝐇𝟒 =
C6H4(OH)2 (l) 0 -267.4026
15.8680 (Ref) 15.8678 -16.8519
ɳ𝟓 = 𝐇𝟓 =
C6H4(OH)2 (g) - - - 0.01101
0.0002 55.0481
ɳ𝟔 = 𝐇𝟔 = 0
C6H5CHO (l) 0 - - -
0.0341 (Ref)
ɳ𝟕 = 𝐇𝟕 =
C6H5CHO (g) - - - 1.62616
0.0341 47.688
ɳ𝟖 = 𝐇𝟖 = 0 ɳ𝟗 = 𝐇𝟗 =
C6H5OH (l) 0 -39.8401
21.6774 (Ref) 2.4855 -16.029
ɳ𝟏𝟎 = 𝐇𝟏𝟎 =
C6H5OH (g) - - - 2181.7736
19.1919 113.682
ɳ𝟏𝟏 = 𝐇𝟏𝟏 = 0 ɳ𝟏𝟐 = 𝐇𝟏𝟐 =
C6H5COOH (l) 0 -12.69622
0.9741 (Ref) 0.9741 -13.0338
Total 0 1865.2822
435
∆𝐻2
C6H6 (l), (198°C,62kPa) C6H6 (g), (252°C,68kPa)
𝐻𝑎 𝐻𝑐
C6H6 (l), (252°C,62kPa) C6H6 (g), (252°C,62kPa)

𝐻𝑏
252 252 𝑘𝐽
𝐻𝑎 = ∫198 𝑐𝑝dT 𝐻𝑎 = ∫198 0.126734 dT 𝐻𝑎 = 6.84342
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑏 = 30.8 (Heat vaporization)
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻2 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = 6.84342 + 30.8 + 0 = 𝟏𝟕. 𝟕𝟔𝟔𝟐 𝒎𝒐𝒍
C6H4(OH)2 (l), (198°C, ∆𝐻4 C6H4(OH)2 (l), (185°C,

62kPa) 50kPa)
𝐻𝑎
𝐻𝑏
C6H4(OH)2 (l), (185°C,

62kPa)
185 185 𝑘𝐽
𝐻𝑎 = ∫198 𝑐𝑝dT 𝐻𝑎 = ∫198 1.2963 dT 𝐻𝑎 = −16.8519
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑏 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻4 = 𝐻𝑎 + 𝐻𝑏 = −16.8519 + 0 = −𝟏𝟔. 𝟖𝟓𝟏𝟗 𝒎𝒐𝒍
436
C6H4(OH)2 (l), (198°C, ∆𝐻5 C6H4(OH)2 (g), (252°C,
62kPa) 68kPa)
𝐻𝑎 𝐻𝑐
C6H4(OH)2 (l), (252°C, C6H4(OH)2 (g), (252°C,

252 252 𝑘𝐽
𝐻𝑎 = ∫198 𝑐𝑝dT 𝐻𝑎 = ∫198 1.2963 dT 𝐻𝑎 = −16.8519
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻5 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = −16.8519 + 71.9 + 0 = 𝟓𝟓. 𝟎𝟒𝟖𝟏 𝒎𝒐𝒍

62kPa) 68kPa)
𝐻𝑎 𝐻𝑐
C6H5CHO (l), (252°C, C6H5CHO (g), (252°C,

252 252 𝑘𝐽
𝐻𝑎 = ∫198 𝑐𝑝dT 𝐻𝑎 = ∫198 0.172 dT 𝐻𝑎 = 9.288
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻7 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = 9.288 + 38.40 + 0 = 𝟒𝟕. 𝟔𝟖𝟖 𝒎𝒐𝒍
437
C6H5OH (l), (198°C, ∆𝐻9 C6H5OH (l), (185°C,
62kPa) 50kPa)
𝐻𝑎
𝐻𝑏
C6H5OH (l), (185°C,
62kPa)
185 185 𝑘𝐽
𝐻𝑎 = ∫198 𝑐𝑝dT 𝐻𝑎 = ∫198 1.233 dT 𝐻𝑎 = −16.029
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑏 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻9 = 𝐻𝑎 + 𝐻𝑏 = −16.029 + 0 = −𝟏𝟔. 𝟎𝟐𝟗 𝒎𝒐𝒍
C6H5OH (l), (198°C, ∆𝐻10 C6H5OH (l), (252°C,

62kPa) 68kPa)
𝐻𝑎 𝐻𝑐
C6H5OH (l), (252°C, C6H5OH (g), (252°C,

252 252 𝑘𝐽
𝐻𝑎 = ∫198 𝑐𝑝dT 𝐻𝑎 = ∫198 1.233 dT 𝐻𝑎 = 66.582
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻10 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = 66.582 + 48.1 + 0 = 𝟏𝟏𝟑. 𝟔𝟖𝟐 𝒎𝒐𝒍
438
∆𝐻12
C6H5COOH (l), (198°C, C6H5COOH (l), (185°C,
62kPa) 50kPa)
𝐻𝑎
𝐻𝑏
C6H5COOH (l), (185°C,

62kPa)
185 185 𝑘𝐽
𝐻𝑎 = ∫198 𝑐𝑝dT 𝐻𝑎 = ∫198 1.0026 dT 𝐻𝑎 = −13.0338
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑏 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻12 = 𝐻𝑎 + 𝐻𝑏 = −13.0338 + 0 = −𝟏𝟑. 𝟎𝟑𝟑𝟖 𝒎𝒐𝒍
439
References: C6H6, C6H4(OH)2, C6H5CHO, C6H5OH, (l, 192°C, 103kPa)
Inlet Outlet
Substance
ɳ𝟏 = 𝐇𝟏 = 0 ɳ𝟐 = 𝐇𝟐 =
C6H6 (l) 0 -0.1395
0.0921 (Ref) 0.0917 -1.52076
ɳ𝟑 = 𝐇𝟑 =
C6H6 (g) - - - 0.0154
0.0004 38.40404
ɳ𝟒 = 𝐇𝟒 = 0
C6H4(OH)2 (l) 0 - - -
0.0002 (Ref)
ɳ𝟓 = 𝐇𝟓 =
C6H4(OH)2 (g) - - - 0.02994
0.0002 149.678
ɳ𝟔 = 𝐇𝟔 = 0 ɳ𝟕 = 𝐇𝟕 =
C6H5CHO (l) 0 -0.0122
0.0336 (Ref) 0.0059 -2.064
ɳ𝟖 = 𝐇𝟖 =
C6H5CHO (g) - - - 1.3495
0.0277 48.72
ɳ𝟗 = 𝐇𝟗 = 0 ɳ𝟏𝟎 = 𝐇𝟏𝟎 =
C6H5OH (l) 0 -8.3168
19.0098 (Ref) 0.5621 -14.796
ɳ𝟏𝟏 = 𝐇𝟏𝟏 =
C6H5OH (l) - - - 2252.0952
18.4477 122.08
Total 0 2245.0216
∆𝐻2
C6H6 (l), (192°C,103kPa) C6H6 (l), (180°C, 50kPa)
𝐻𝑎
𝐻𝑏
C6H6 (l), (180°C,103kPa)
180 180 𝑘𝐽
𝐻𝑎 = ∫192 𝑐𝑝dT 𝐻𝑎 = ∫192 0.126734 dT 𝐻𝑎 = −1.52076
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑏 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻2 = 𝐻𝑎 + 𝐻𝑏 = −1.52076 + 0 = −𝟏. 𝟓𝟐𝟎𝟕𝟔 𝒎𝒐𝒍
440
∆𝐻3
C6H6 (l), (192°C,103kPa) C6H6 (g), (252°C,68kPa)
𝐻𝑎 𝐻𝑐
C6H6 (l), (252°C,103kPa) C6H6 (g), (252°C,103kPa)

𝐻𝑏
252 252 𝑘𝐽
𝐻𝑎 = ∫192 𝑐𝑝dT 𝐻𝑎 = ∫192 0.126734 dT 𝐻𝑎 = 7.60404
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻3 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = 7.60404 + 30.8 + 0 = 𝟑𝟖. 𝟒𝟎𝟒𝟎𝟒 𝒎𝒐𝒍
C6H4(OH)2 (l), (192°C, ∆𝐻5 C6H4(OH)2 (g), (252°C,

103kPa) 68kPa)
𝐻𝑎 𝐻𝑐
C6H4(OH)2 (l), (252°C, C6H4(OH)2 (g), (252°C,

252 252 𝑘𝐽
𝐻𝑎 = ∫192 𝑐𝑝dT 𝐻𝑎 = ∫192 1.2963 dT 𝐻𝑎 = 77.778
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻5 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = 77.778 + 71.9 + 0 = 𝟏𝟒𝟗. 𝟔𝟕𝟖 𝒎𝒐𝒍
441
C6H5CHO (l), (192°C, ∆𝐻7 C6H5CHO (l), (180°C,
103kPa) 50kPa)
𝐻𝑎
𝐻𝑏
C6H5CHO (l), (180°C,
103kPa)
180 180 𝑘𝐽
𝐻𝑎 = ∫192 𝑐𝑝dT 𝐻𝑎 = ∫192 0.172 dT 𝐻𝑎 = −2.064
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑏 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻7 = 𝐻𝑎 + 𝐻𝑏 = −2.064 + 0 = −𝟐. 𝟎𝟔𝟒 𝒎𝒐𝒍

103kPa) 68kPa)
𝐻𝑎 𝐻𝑐
C6H5CHO (l), (252°C, C6H5CHO (g), (252°C,

252 252 𝑘𝐽
𝐻𝑎 = ∫192 𝑐𝑝dT 𝐻𝑎 = ∫192 0.172 dT 𝐻𝑎 = 10.32
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻8 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = 10.32 + 38.40 + 0 = 𝟒𝟖. 𝟕𝟐 𝒎𝒐𝒍
442
C6H5OH (l), (192°C, ∆𝐻10 C6H5OH (l), (180°C,
103kPa) 50kPa)
𝐻𝑎
𝐻𝑏
C6H5OH (l), (180°C,
103kPa)
180 180 𝑘𝐽
𝐻𝑎 = ∫192 𝑐𝑝dT 𝐻𝑎 = ∫192 1.233 dT 𝐻𝑎 = −14.796
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑏 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻10 = 𝐻𝑎 + 𝐻𝑏 = −14.796 + 0 = −𝟏𝟒. 𝟕𝟗𝟔 𝒎𝒐𝒍
C6H5OH (l), (192°C, ∆𝐻11 C6H5OH (l), (252°C,

103kPa) 68kPa)
𝐻𝑎 𝐻𝑐
C6H5OH (l), (252°C, C6H5OH (g), (252°C,

252 252 𝑘𝐽
𝐻𝑎 = ∫192 𝑐𝑝dT 𝐻𝑎 = ∫192 1.233 dT 𝐻𝑎 = 73.98
𝑚𝑜𝑙
𝑘𝐽
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑐 = 0 (<5 atm)
𝑚𝑜𝑙
∆𝐻11 = 𝐻𝑎 + 𝐻𝑏 + 𝐻𝑐 = 73.98 + 48.1 + 0 = 𝟏𝟐𝟐. 𝟎𝟖 𝒎𝒐𝒍
443

Group 1 Project Report 2 DP2 Jan2023

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Group 1 Project Report 2 DP2 Jan2023

Uploaded by

Copyright:

Available Formats

UNIVERSITI KUALA LUMPUR

MALAYSIAN INSTITUTE OF CHEMICAL BIOENGINEERING TECHNOLOGY

Project Title : Production of Phenol 750,000 MTA

SAFETY AND HEALTH

DESIGN PROJECT 2 (CPB30404)

1 MUHAMMAD FIRHAD HAZRANI BIN ZAIMI MANAGER & SITE SELECTION

2 AHMAD IZZUDIN ARIF BIN RAMLEE SAFETY & UTILITIES ENGINEER

5 MOHAMED HANIF BIN MOHAMED RAWI PROCESS ENGINEER

6 KHAIRUL AMIN BIN AHMAD SHUKRI DESIGN ENGINEER

UNIVERSITI KUALA LUMPUR

CHAPTER 1.0: INTRODUCTION

CHAPTER 2.0: THE DESIGN PROBLEMS

CHAPTER 3.0: FEASIBILITY STUDY AND MARKET SURVEY

CHAPTER 4.0: PROCESS SELECTION

CHAPTER 5.0: PLANT LOCATION

CHAPTER 6.0: MASS AND ENERGY BALANCE

CHAPTER 7.0: CHEMICAL ENGINEERING & MECHANICAL ENGINEERING

CHAPTER 8: ENGINEERING ECONOMIC ANALYSIS OF CHEMICAL PROCESS

CHAPTER 9.0: PROCESS CONTROL AND INSTRUMENTATION

CHAPTER 10: SAFETY AND HEALTH

CHAPTER 11: ENVIROMENTAL CONSIDERATION

CHAPTER 12: CONCLUSION & RECOMMENDATION .................................................... 380

1.2 Company Background

1.3 Motto, and Vision

Figure 1.1`: Logo of company

2.1 Introduction to plant design

Phenol (C6H5OH) is an organic, aromatic compound whose molecular structure is

Benzene is usually applied as a solvent in a variety of industrial, industrial, and research

2.2.2 Uses of Compressed Air

2.2.3 Uses of Phenol

Phenol is a disinfectant and antiseptic. It is effective against a variety of microorganisms,

Due to its low cost, phenol is used commonly in small-scale applications. It is an

2.2.4 Uses of Catechol

2.2.5 Uses of Benzoic Acid

Pharmaceuticals make use of benzoic acid. It acts as a preservative in pharmaceuticals.

2.2.6 Uses of Benzaldehyde

2.3 Background study raw material/product

2.4 Properties and Uses Materials

2.4.2 Properties of Compressed Air

Table 2.4: Compressed air chemical properties table

2.4.3 Properties of Phenol

Table 2.6: Phenol chemical properties table

2.4.4 Properties of Catechol

Table 2.8: Catechol chemical properties table

2.4.5 Properties of Benzoic Acid

Table 2.10: Benzoic Acid chemical properties table

2.4.6 Properties of Benzaldehyde

Table 2.12: Benzaldehyde chemical properties table

1. Reactor – Raw material mix in the reactor with catalyst presence

2.6.2 Reaction Chemistry

2.7 Advantages and Disadvantages of The Process

2.7.2 Other Considerations

2.7.3 Direct Route of Phenol from The Benzene

3.2 General Information

3.3 Process Technology

Unit ID: P-101

Pressure: 638.2 psig

Material: Cast Iron

Unit ID: P-102

Pressure: 638.2 psig

Material: 316 Stainless Steel

3. Process Heat Exchangers

Unit ID: E-102