Plant Layout Ayos PDF

CHAPTER I
INTRODUCTION
The petrochemical industry is a substantial contributor to the worlds

economic development. Petrochemicals connect the upstream oil and gas industry
to the downstream sectors such as energy, material, agricultural and industrial
sectors. It is a vital part of human life, and it is hard to imagine modern existence
without these products.
Naphtha, as a versatile feedstock, is considered to be the building block of
the petrochemical industry. One of the main products from the processing of
naphtha reformate are aromatics. Aromatics products are composed of benzene,
toluene and xylenes (BTX). BTX is considered as the primary petrochemicals
since they can be transformed into other finished petrochemical derivatives. BTX is
used to make a wide variety of products including plastics, resins, synthetic fibers,
rubber lubricants, dyes, detergents, drugs and pesticides.
This makes the global consumption of benzene, estimated at more than
40,000,000 tons in 2010, showed an unprecedented growth of more than
3,000,000 tons from the level seen in 2009. Likewise, the xylene consumption
showed unprecedented growth in 2010, growing by 2,800,000 tons, and a full ten
percent growth from 2009. (ChemSystems, 2011)
The accelerating economic and industrial growth of the ASEAN member
countries develops also an increase in demand of benzene, toluene and xylenes.
The projected BTX demand in the ASEAN Region is 103,420 metric tons by 2025
based from the United Nation Trade Commondity Statistics Database. There exist
a gap wherein the supply certainly cannot meet the demand in the ASEAN region.
Although eight manufacturing plants were identified on target market locations
producing BTX separately, the demand is still unsatisfied due its huge amount and
wide area of customers.
In line with this condition, the proponents are proposing a benzene, toluene
and xylenes manufacturing plant which will have a desired output to equally meet
the demand for BTX in the ASEAN region. The proposed BTX manufacturing plant
will process naphtha reformate into benzene, toluene and xylenes.
The proposed manufacturing plant will be strategically located in (7
6'4.32"S 11236'49.09"E) Manyar, Gresik Regency, East Java, Indonesia. One of
the reason is that East Java is considered to have the most attractive hourly wage
in Asia. This means that production costs are lower and thus, manufacturer profits
are higher. In terms of feedstock availability and accessibility, the target location is
70 kilometers from Tuban petrochemical plant which will be the primary supplier of
naphtha reformate feedstock. Tuban petrochemical plant has a rated output
capacity of 1 million metric tons of naphtha per year, a sufficient value to supply
the meet the required feedstock. Backup suppliers are PetroChina Dalian Refinery,
Liaoning, China and Ganga Rasayanie Pvt. Ltd., South India. Reserve supplier is
Petron Bataan Refinery, Philippines.The target location has sufficient manpower
and utilities to meet the requirements of the plant.
The target market of proposed plant are the ASEAN member countries
specifically Singapore, Cambodia, Indonesia and Vietnam. These four countries
were evaluated to have higher BTX import over export which indicates that these
countries have high demand for BTX. Singapore is the primary costumer for
benzene. Cambodia, Indonesia and Vietnam are the target consumers for toluene.
Cambodia and Indonesia are the target customer for xylenes.
The plant will continue to meet the demands for benzene, toluene and
xylenes of different countries of the target customers. The plant location is 1900
kilometers away from Singapore, 4700 kilometers from Vietnam and 4300
kilometers from Cambodia. These values indicate the efficient transportation of
BTX products to the target customers.
Figure 1. Target Location Aerial View
Figure 2. Target Location (2 km elevation)
CHAPTER II
DESIGN OBJECTIVES
The main objective of the project proposal is to scientifically design a
Benzene, Toluene and Xylene (BTX) Manufacturing Plant with a desired output
capacity of 104,300 metric tons (MT) of BTX per annum.
Furthermore, the project proposal also targets to undertake the following
specific objectives taking into consideration technical, in order to achieve a realistic
technical, economic and environmental plant design.
1. To formulate three (3) design options for the Benzene, Toluene and
Xylene (BTX) Manufacturing Plant taking into consideration the following multiple
realistic constraints:
1.1 Technical Efficiency
1.2 Economic Feasibility
1.3 Environment Sustainability
2. To design the technical aspects of the plant taking into consideration the
following:
2.1 Plant Lay-out
2.2 Process Flow Diagram
2.3 Equipment Specification
2.4 Mass and Energy Balances
2.5 Required Capacity
2.6 Over-all Plant Efficiency
2.7 Technical Standards and Catalogues
3. To design the economic analyses of the plant taking into consideration

the following:
3.1 Net Present Value
3.2 Payback Period
3.3 Rate of Return
3.4 Sensitivity Analysis
4. To prepare environmental management of the plant taking into
consideration the following:
4.1 Environment Base Line data
4.2 Health and Safety
4.3 Environmental Impact Assessment
4.4 Monitoring
5. To evaluate and choose the best plant design option using Pareto
optimum method.
6. To develop the project construction execution plan of the plant.
7.
To
formulate
recommendations.
the
corresponding
summary,
conclusions
and
CHAPTER III
TECHNICAL ASPECT
This chapter includes the calculation and preparation of the process flow
diagram, complete plant lay-out, equipment description and specifications, mass
balance and energy balance, required capacity and plant efficiency. Standards
were used to come up with a technically viable design. Technical catalogues were
used to carefully identify the design specifications of each equipment.
A. Design Option I
1. Process Description
Figure 3. Design Option I Process Flow Diagram

On this proposed design, reformate naphtha will pass through the solvent
extraction column to separate non-aromatics component to aromatic component.
Non-aromatics component along with the extracting solvent from naphtha will go to
raffinate stripping column to separate solvent then the solvent that was recovered
will be feed again to the extraction column while non-aromatics component will go
directly to the storage tank. On the other hand, aromatics components will pass
through the solvent recovery to remove solvent and improve the quality of
aromatics products. After this process, nearly pure aromatics will go through the
clay treater column to further remove present surface reactants. After all these
processes, aromatics will pass through the fractionation column to separate
Benzene, Toluene and Xylene by using the concept of difference in boiling point.
2. Plant Lay-out
Legend:
1 Area for Expansion
2 Process Area
3 Fire Fighting Unit
4 Control Room
5 Power Generation Unit
6 Laboratory
7 Plant Utilities
8 Waste Water Treatment
9 Emergency Water Storage
10 Workshop
12 Parking Area/Evacuation Area
13 Change Room
14 Canteen
15 Administration Building
16 Security
17 Material Recovery Facility
Figure 4. Plant top view
Figure 5. Plant Side View
3. Equipment Description and Specification

Specification Sheet No. 1
Height
Diameter
Orientation
Pressure
Temperature
Materials of Construction
Capacity
FEED SURGE DRUM

6.10m
5.50m
Vertical
15 psi
350C
Carbon Steel Plates
5000 gallons
Flow
Type
Discharge Pressure
Temperature
Seal Type
Driver Type
Material
PUMP 1
90 gpm 120 gpm
Centrifugal
30psi
50C
Single mechanical seal
Standard motor
Carbon Steel

PACKED BED EXTRACTION COLUMN
Height
17m
Diameter
0.93m
Pressure
120ps
Temperature
200C
Number and Type of Trays
3 beds with four stages
Materials of Constructions
Carbon Steel Plates
Height
Diameter
Temperature
Pressure
Application
Tray Type
Number of Trays
Tray Spacing
Tray thickness
Tray Material
Material of Construction
STRIPPING COLUMN
14m
.80m
56C
5.12 psi
Distillation
Sieve
34
0.6096 m
4.572x10-3m
Low and intermediate strength carbon
steel plates for pressure vessels
Carbon Steel Plates

STORAGE VESSEL 1
Height
4.00 m
Diameter
2.50 m
Orientation
Vertical
Pressure
50ps
Temperature
200C
Carbon Steel Plates
Capacity
120 gallons
Type
Process
Temperature
Pressure
Area
Material
Length
Shell
Inside Diameter
Incoming pipe
diameter
Outlet pipe diameter
Number of Tubes
Number of Passes
Material
Length
Tubes
Inside Diameter
Outside Diameter
Pitch
Incoming pipe
diameter
Baffling Number of Baffles
Baffle spacing
COOLER 1
Liquid-Liquid
Distillation
25 C
15 psi
1000ft2
Carbon Steel
1.95m
0.1625m
in, schedule 40 stainless steel
1 in, schedule 40 stainless steel
28
2, U-bend configuration
Copper, Schedule 40
1.905m
0.015875m
0.01905m
7/8 in, triangular pitch
1 in, schedule stainless steel
2
1 in. schedule 40 stainless steel
Flow
Type
Pressure
Temperature
Material
PUMP 2
90 gpm 120 gpm
Rotary
30psi
20C
Cast iron
Flow
Type
Pressure
Temperature
Material
PUMP 3
90 gpm 120 gpm
Rotary
30psi
20C
Cast iron
Type
Process
Temperature
Pressure
Material
Area
Shell
Tubes
Baffling
Material
Length
Inside Diameter
Incoming pipe
diameter
Number of Tubes
Number of Passes
Material
Length
Inside Diameter
Outside Diameter
Pitch
Incoming pipe
diameter
Number of Baffles
Baffle spacing
HEATER 1
Liquid-Liquid
Distillation
350 C
15 psi
Low and intermediate strength carbon steel
plates
1000ft2
Carbon Steel
2.1m
0.175m
28
Copper, Schedule 40
1.905m
0.015875m
0.01905m
2
Flow
Type
Discharge Pressure
Temperature
Material
PUMP 4
230 gpm
Rotary
30psi
20C
cast iron
Flow
Type
Discharge Pressure
Temperature
Seal Type
Driver Type
Material
PUMP 5
90 gpm 120 gpm
Centrifugal
30psi
50C
Standard motor
Carbon Steel

SOLVENT RECOVERY COLUMN
Height
14m
Diameter
3m
Temperature
38C
Pressure
10 psi
Application
Distillation
Tray Type
Sieve
Number of Trays
33
Tray Spacing
.45m
Tray thickness
4.75x10-3m
Tray Material
steel plates for pressure vessels
Stainless steel
Type
Process
Temperature
Pressure
Material
Area
Shell
Tubes
Baffling
Material
Length
Inside Diameter
Incoming pipe diameter
Number of Tubes
Number of Passes
Material
Length
Inside Diameter
Outside Diameter
Pitch
Number of Baffles
Baffle spacing
COOLER 2
Liquid-Liquid
Distillation
25 C
15 psi
steel plates
1000ft2
Carbon Steel
1.95m
0.1625m
28
Copper, Schedule 40
1.905m
0.015875m
0.01905m
2

STORAGE VESSEL 2
Height
5.50m
Diameter
5.00m
Orientation
Horizontal
Pressure
15psi
Temperature
290C
Carbon Steel Plates
Capacity
4000 gallons
Flow
Type
Pressure
Temperature
Material
Speed
Power
PUMP 6
60gpm
Rotary
30psi
20C
Cast iron
1800rpm
25-20 hp
Flow
Type
Pressure
Temperature
Material
Speed
Power
PUMP 7
60gpm
Rotary
30psi
20C
Cast iron
1800rpm
25-20 hp
Flow
Type
Discharge Pressure
Temperature
Seal Type
Driver Type
Material
PUMP 8
75gpm
Centrifugal
5psi
50
Standard motor
Carbon Steel
Type
Process
Temperature
Pressure
Material
Area
Shell
Tubes
Baffling
Material
Length
Inside Diameter
Incoming pipe
diameter
HEATER 2
Liquid-Liquid
Distillation
350C
15 psi
Low and intermediate strength carbon steel
plates
1000ft2
Carbon Steel
2.1m
0.175m
Number of Tubes
Number of Passes
28
Material
Copper, Schedule 40
Length
Inside Diameter
Outside Diameter
Pitch
1.905m
0.015875m
0.01905m
Incoming pipe
diameter
Number of Baffles
Baffle spacing

2

HEATER 3
Type
Liquid-Liquid
Process
Distillation
Temperature
350 C
Pressure
15 psi
Material
steel plates
Area
1000ft2
Material
Carbon Steel
Length
2.1m
Shell
Inside Diameter
0.175m
Tubes
Baffling
Number of Tubes
Number of Passes
Material
Length
Inside Diameter
Outside Diameter
Pitch
Number of Baffles
Baffle spacing
28
Copper, Schedule 40
1.905m
0.015875m
0.01905m
2
Height
Diameter
Pressure
Temperature
CARTRIDGE 1
7.6 m
1.2 m
15 psi
425C
Welded Carbon steels
Height
Diameter
Pressure
Temperature
CARTRIDGE 2
7.6 m
1.2m
15 psi
425C

BENZENE COLUMN
Height
17m
Diameter
0.93m
Pressure
15 psi
Temperature
100C
Carbon Steel Plates
Type
Packed bed column
Height
Diameter
Orientation
Pressure
Temperature
Capacity
STORAGE VESSEL 3
3.70m
2.50m
Vertical
15 psi
100C
Carbon Steel Plates
600 gallons

COOLER 2
Type
Liquid-Liquid
Process
Distillation
Temperature
25 C
Pressure
15 psi
Material
Low and intermediate strength
carbon steel plates
Area
1000ft2
Material
Carbon Steel
Length
1.95m
Shell
Inside Diameter
0.1625m
Number of Tubes
Number of Passes
28
Material
Copper, Schedule 40
Length
Inside Diameter
Outside Diameter
Pitch
1.905m
0.015875m
0.01905m

Number of Baffles
Baffle spacing

2
Tubes
Baffling

Flow
Type
Discharge Pressure
Temperature
Seal Type
Driver Type
Material
PUMP 9
70gpm
Centrifugal
5psi
50C
Standard Motor
Carbon Steel

REBOILER 1
Type
Liquid-Liquid
Process
Distillation
Temperature
350 C
Pressure
15 psi
Material
steel plates
Area
1000ft2
Material
Carbon Steel
Length
1.905m
Shell
Inside Diameter
0.15875m
Tubes
Baffling
Number of Tubes
Number of Passes
28
Material
Copper, Schedule 40
Length
Inside Diameter
Outside Diameter
Pitch
1.905m
0.015875m
0.01905m

Number of Baffles
Baffle spacing

2

PUMP 10
Height
Diameter
Pressure
Temperature
Type
55gpm
Centrifugal
5psi
50C
Standard Motor
Carbon Steel

TOLUENE COLUMN
Height
Diameter
Pressure
Temperature
Type
20m
1.039m
15psi
125C
Carbon Steel Plates
Packed bed column
Height
Diameter
Orientation
Pressure
Temperature
Capacity
STORAGE VESSEL 4
5.20m
4.6m
Vertical
15 psi
125C
Carbon Steel Plates
3000 gallons

COOLER 4
Type
Process
Temperature
Pressure
Material
Material
Length
Inside Diameter
Liquid-Liquid
Distillation
25 C
15 psi
steel plates
1000ft2
Carbon Steel
1.95m
0.1625m
Number of Tubes
Number of Passes
28
Material
Copper, Schedule 40
Length
Inside Diameter
Outside Diameter
Pitch
Number of Baffles
Baffle spacing
1.905m
0.015875m
0.01905m
2
Area
Shell
Tubes
Baffling
Flow
Type
Discharge Pressure
Temperature
Seal Type
Driver Type
Material
PUMP 11
50gpm
Centrifugal
5psi
50C
Standard Motor
Carbon Steel
Flow
Type
Discharge Pressure
Temperature
Seal Type
Driver Type
Material
PUMP 12
60gpm
Centrifugal
5psi
50C
Standard Motor
Carbon Steel

XYLENE COLUMN
Height
Diameter
Pressure
Temperature
Type
18m
0.98m
15 psi
160C
Carbon Steel Plates
Packed bed column

REBOILER 2
Type
Liquid-Liquid
Process
Distillation
Temperature
350C
Pressure
15 psi
Material
steel plates
Area
1000ft2
Material
Carbon Steel
Length
1.905m
Shell
Inside Diameter
0.15875m
Tubes
Baffling
Number of Tubes
Number of Passes
28
Material
Copper, Schedule 40
Length
Inside Diameter
Outside Diameter
Pitch
1.905m
0.015875m
0.01905m

Number of Baffles
Baffle spacing

2

COOLER 5
Type
Liquid-Liquid
Process
Distillation
Temperature
25 C
Pressure
15 psi
Material
steel plates
Area
1000ft2
Material
Carbon Steel
Length
1.95m
Shell
Inside Diameter
0.1625m
Tubes
Baffling
Number of Tubes
Number of Passes
28
Material
Copper, Schedule 40
Length
Inside Diameter
Outside Diameter
Pitch
1.905m
0.015875m
0.01905m

Number of Baffles
Baffle spacing

2
Height
Diameter
Orientation
Pressure
Temperature
Capacity
STORAGE VESSEL 5
3.40m
2.20m
Vertical
15 psi
160
Carbon Steel Plates
400 gallons
Flow
Type
Discharge Pressure
Temperature
Seal Type
Driver Type
PUMP 13
10gpm
Centrifugal
0.4931psi
50C
Standard Motor

REBOILER 3
Type
Liquid-Liquid
Process
Distillation
Temperature
350C
Pressure
15 psi
Material
steel plates
Area
1000ft2
Material
Carbon Steel
Length
1.905m
Shell
Inside Diameter
0.15875m
Tubes
Baffling
Number of Tubes
Number of Passes
28
Material
Copper, Schedule 40
Length
Inside Diameter
Outside Diameter
Pitch
1.905m
0.015875m
0.01905m

Number of Baffles
Baffle spacing

2

COOLER 6
Liquid-Liquid
Distillation
25 C
15 psi
steel plates
1000ft2
Material
Carbon Steel
Length
1.95m
Inside Diameter
0.1625m
Type
Process
Temperature
Pressure
Material
Area
Shell
Tubes
Baffling
Number of Tubes
Number of Passes
28
Material
Copper, Schedule 40
Length
Inside Diameter
Outside Diameter
Pitch
1.905m
0.015875m
0.01905m

Number of Baffles
Baffle spacing

2

Height
Diameter
Orientation
Pressure
Temperature
Capacity
STORAGE VESSEL
.70m
.50m
Vertical
15 psi
160C
Carbon Steel Plates
1 gallon
D. Material Balance
Assumptions:
1. All flow rates are steady.
2. Feed solvent and extracting solvent are immiscible.
3. Extracting solvent concentration remains constant.
4. All gases behave ideally.
5. No chemical reaction occurs during liquid-liquid extraction and extractive
distillation.
Figure 6. Liquid-liquid extraction section

Feed = 17,000 kg/Hr
The amount of naphtha reformate was based from the production of Tuban
Petrochemicals (133.92 MMkg per year).
Tetraethylene Glycol (TEG) = 58,571 kg/Hr
The amount of solvent was based from Environmental Protection Agency (EPA)
reference amount for Tetraethylene Glycol (TEG) used for aromatics extraction
solvent.
a. Pump 1
M1 = M2
M1 = 17,000 Kg/Hr
M2 = 17,000 Kg/Hr
b. Extraction Column
Raffinate Recovery = 36%
Feed + Lean Solvent = Raffinate + Rich Solvent
M2 + M3 = M4 + M5
17,000 Kg/Hr + 58,571 Kg/Hr = 0.36 (17,000 Kg/Hr) + M5
Rich Solvent = 69,451 Kg/Hr
M5 = 69,451 Kg/Hr
Raffinate = 6,300 Kg/Hr
M4 = 6,120 Kg/Hr
c. Stripper Column
Efficiency = 97%: Heuristics
Basis: Solvent-To-Extract Ratio = 2
M4 = M7 + M8
Rich Solvent = Extract + Solvent
Rich Solvent = 69,451 Kg/Hr
M8 = 2(M7)
69,451 Kg/Hr = M7 + M8
M7 = 23,150.33 Kg/Hr
M8 = 46,300.67 Kg/Hr (0.97)

M8 = 44,911.65 Kg/Hr
d. Condenser 1
M9 = M7
M7 = 23,150.33 Kg/Hr
M9 = 23,150.33 Kg/Hr
e. Vessel 1
M9 = M10
M10 = 23,150.33 Kg/Hr
f. Pump 2
M10 = M11
M11 = 23,150.33 Kg/Hr
g. Pump 3
M12 = M13
M12 = 23,150.33 Kg/Hr
h. Pump 4
M8 = M14
M11 = 23,150.33 Kg/Hr
i. Pump 5
M5 = M15
M11 = 69,451 Kg/Hr
j. Solvent Recovery Column

Efficiency = 95 %: Heuristics
Extract = 23,150.33 Kg/Hr
M15 = 69,451 Kg/Hr
Extract = Lean Solvent + Aromatics
M15 = M16 + M17
69,451 Kg/Hr = 0.95(58,571) + M17
M17 = 13,808.55 Kg/Hr
Figure 7. Fractionation Section
BTX Extract = 13,808.55 Kg/Hr

a. Pump 6
M17= M18
M18= 13,808.55 Kg/Hr
b. Heater 1
M18= M19
M19= 13,808.55 Kg/Hr
c. Clay Treater
M20 = 13,808.55 Kg/Hr
M21 = 13, 670.4645 Kg/Hr
d. Benzene Column
M21 = M22 + M23
Aromatics = 16.12% Benzene
M22 = M21 (93%) (16.12%)
M22 = (13,670.4645 Kg/Hr) (0.93) (0.1612)
M22 = 2,049.4214 Kg/Hr
M23 = M21 M22
M23 =13,670.4645 Kg/Hr 2,049.4214 Kg/Hr

M23 = 11,621.0431 Kg/Hr
Toluene Column Feed = 11,621.04314 Kg/Hr
e. Condenser 2
M22 = M24
M22 = 2,049.4214 Kg/Hr
M24 = 2,049.4214 Kg/Hr
Benzene Product = 2,049.4214 Kg/Hr
f. Pump 7
M25 = M23
M23 =11,621.04314 Kg/Hr
M25 =11, 621.04314 Kg/Hr
g. Toluene Column
M25 = M26 + M27
M26 = (M21) (93%) (72.52%)
M26 = (13,670.4645Kg/Hr) (0.93) (0.7252)
M26 = 9,219.85 Kg/Hr
M27 = M25 M26

M27 = 11, 621.04314 Kg/Hr 9,219.85 Kg/Hr
M27 = 2,401.1931 Kg/Hr
Xylene Column Feed = 2,401.1931 Kg/Hr
h. Condenser 3
M28 = M26
M26 = 9,219.85 Kg/Hr
M28 = 9,219.85 Kg/Hr
Toluene Product = 9,219.85 Kg/Hr
i. Pump 8
M29 = M27
M27 = 2,401.1931 Kg/Hr
M29 = 2,401.1931 Kg/Hr
j. Xylene Column
M29= M31 + M30
M29 = 2,401.1931 Kg/Hr

M30 = (M21) (93%) (11.36%)
M30 = (13,670.4645 Kg/Hr) (0.93) (0.1136)
M30 = 1,444.2572 Kg/Hr
M31 = M29 M30

M31 = 2,401.1931 Kg/Hr 1,444.2572 Kg/Hr
M31 = 956.9359 Kg/Hr
k. Condenser 4
M30= M32
M30= 1,444.2572 Kg/Hr
Xylene Product = 1,444.2572 Kg/Hr
l. Condenser 5
M33 = M31
M31 = 956.9359 Kg/Hr
M18 = 956.9359 Kg/Hr
C9+ Aromatics Product = 956.9359 Kg/Hr
Table 1. Summary of in-flow rates and out-flow rates in kg/hr

Equipment
In-Flow Rate (kg/hr)
Out-Flow Rate (kg/hr)
Pump 1
17,000
Extractor
69,451
Stripper
69,451
Condenser 1
23,150.33
Vessel 1
23,150.33
Pump 2
23,150.33
Pump 3
23,150.33
Pump 4
23,150.33
Pump 5
69,451
Recovery Column
23,150.33
Pump 6
13,808.55
Heater 1
13,808.55
Clay Treater
13,808.55
13,670.4645
Distillation Column
13,670.4645
2,049.4214
Condenser 2
2,049.4214
Pump 7
11,621.04314
Distillation Column
11,621.04314
Condenser 3
9,219.85
Pump 8
2,401.1931
Distillation Column
2,401.1931
Condenser 4
1,444.2572
Condenser 5
956.9359
13,808.55
9,219.85
1,444.2572
Benzene Product
2,049.4214 kg/hr
Toluene Product
9,219.85 kg/hr
Mixed Xylene Product
1,444.2572 kg/hr
BTX Product
12,713.5286 kg/hr
Production per hour = 12,713.5286 kg/hr

Production per year = (12,713.5286kg/hr) (24 hrs/day) (355 stream days/year)
Production per year = 108,319,263.7 kg/year
E. Energy balance
This section contains the calculations for energy requirements of heat transfer
equipment used in the BTX Manufacturing Plant.
1. Heating Equipments
a. Stripper Column
Mass of incoming aromatics: 23,267 kg/hr
Specific heat of aromatics: 1.825 kj/kgoc
Temperature of incoming aromatics: 200oc
Temperature of leaving aromatics: 56 oc
Mass of incoming solvent: 45, 118.58 kg/hr
Specific heat of solvent: 1.997103 kj/g c
Temperature of incoming solvent: 200 oc
Temperature of leaving solvent: 56 oc
Specific heat of seawater: 3.985 kj/kgoc
Temperature of incoming cooling water: 17 oc
Temperature of leaving cooling water: 30 oc
[mCp(T2-T1)]AROMATICS + [mCp(T2-T1)]SOLVENT = [mCp(T2-T1)]CW
Rich Solvent (TEG) = 58,571 Kg/Hr

Cp of TEG = 1.997103 kJ/g C
Cp = 1.997103 kJ/Kg-K
Rich solvent temperature =30C
T1 = 200C = 473.15 K
T2 = 329.15 K
Q = m Cp (T2 - T1)
Q = (58,571 Kg/Hr) (1.997103 kJ/g C) (473.15 K - 329.15 K)
Q = 168,444,014 kJ/hr
Q = 168,444,014 kJ/hr (1 hr/3600 s)
Q = 4,678.89 kW
b. Recovery Column
Cp of aromatics = 1.7867 kJ/Kg-K
T1 = 38C = 311.15 K
T2 = 56C = 329.15 K
Q1 = m Cp (T2 - T1)
Q1 = (50875.47 Kg/Hr) (1.7867 kJ/Kg-K) (450.15 K - 408.15 K)
Q1 = 1,636,185.64 kJ/hr
Q1 = 1,636,185.64 kJ/hr (1 hr/3600 s)
Q1 = 454.50 kW
c. Benzene Column
M = 13,987.2645 Kg/Hr
Cp of Benzene = 1.968 kJ/Kg-K
T1 = 425C = 698.15 K
T2 = 100C = 373.15 K
Q = m Cp (T2 - T1)
Q = (13,987.2645 Kg/Hr) (1.968kJ/Kg-K) (698.15 K - 373.15 K)
Q = 8,946,254.374 kJ/hr
Q = 8,946,254.374 kJ/hr (1 hr/3600 s)
Q = 2,485.07066 kW
d. Toluene Column
M = 9,433.5147.28 Kg/Hr
Cp of Toluene = 1.72 kJ/Kg-K
T1 = 100C = 373.15 K
T2 = 125C = 398.15 K
Q = m Cp (T2 - T1)
Q = (9,433.5147 Kg/Hr) (1.72 kJ/Kg-K) (398.15 K - 373.15 K)
Q = 405,641 kJ/hr
Q = 405,641 kJ/hr (1 hr/3600 s)
Q = 112.68 kW
e. Xylene Column
M = 2.096.9148 Kg/Hr
Cp of Xylene = 1.72 kJ/Kg-K
T1 = 125C = 398.15 K
T2 = 160C = 433.15 K
Q = m Cp (T2 - T1)
Q = (2.096.9148 Kg/Hr) (1.72 kJ/Kg-K) (433.15 K - 398.15 K)
Q = 126,224.21 kJ/hr
Q = 126,224.21 kJ/hr (1 hr/3600 s)
Q = 35.07 kW
f. Boiler
Q = (4, 678.89 + 454.50 + 2,424.4592 + 112.68 + 35.07) kW
Q = 3,342.2692 kW
Cp of steam = 1.996 kJ/Kg-K
T1 = 100C = 373.15 K
T2 = 350C = 623.15 K
Q = m Cp (T2 - T1)
342.2692 kW (1 kJ/s / 1 kW) (3600s/1 hr) = (Ms) (1.996 kJ/Kg-K) (623.15 K 373.15 K)
Ms = 2,469.2769 kg/hr
Table 2. Summary of Energy Requirements for Heating

Process
Energy requirement (kW)
Stripping
4, 678.89
Solvent Recovery
454.50
Benzene Distillation
2,424.4592
Toluene Distillation
35.07
Xylene Distillation
112.68
Total energy requirement
7,705.5992 kW
2. COOLING EQUIPMENT
a. Stripper Column
Mass of incoming aromatics: 23,267 Kg/Hr
Temperature of incoming aromatics: 200OC
Temperature of leaving aromatics: 56 OC
Mass of incoming solvent: 45, 118.58 Kg/Hr
Temperature of incoming solvent: 200 OC
Temperature of leaving solvent: 56 OC
Specific heat of seawater: 3.985 kj/kgoC
Temperature of incoming cooling water: 17 OC
Temperature of leaving cooling water: 30 OC
(23,267 Kg/Hr)(1.825 kJ/kgOC)(200OC-56 OC) + (45, 118.58 Kg/Hr)(1.997103
kJ/g C)(200OC-56 OC) = m (3.985 kJ/kgOC)(30 OC-17 OC)
mCW = 368, 495.2536 Kg/hr

QA = 1,698.491 KJ/s
QS = 3,604.258 KJ/s s
b. Recovery Column
Mass of incoming aromatics: 69,771 Kg/Hr
Temperature of incoming aromatics: 56OC
Temperature of leaving aromatics: 38OC
Mass of incoming solvent: 58,571 Kg/Hr
Temperature of incoming solvent: 56 OC
Temperature of leaving solvent: 38 OC
Specific heat of seawater: 3.985 kj/kgoc
Temperature of incoming cooling water: 17 OC
Temperature of leaving cooling water: 30 OC
(69,771 Kg/Hr)(1.825 kJ/kgOC)(56OC-38OC) + (58,571 Kg/Hr)(1.997103 kJ/g
C)(56OC-38OC) = m (3.985 kJ/kgOC)(30 OC-17 OC)
mCW = 258, 783.1112 Kg/hr
QA = 636.1129 KJ/s
QS = 584. 862 KJ/s
d. Benzene Column
Mass of incoming benzene: 2,096.9148 Kg/Hr
Incoming benzene temperature: 100c
Leaving benzene temperature: 25c
Specific heat of benzene: 1.968 kj/kgok
Incoming cooling water temperature: 30OC
Leaving cooling water temperature: 17 OC
Specific heat of sea water: 3.985 kj/kgoc
[mCp(T2-T1)]BW= [mCp(T2-T1)]CW
(2,096.9148 Kg/Hr)(1.968 kJ/kgOC)(100OC-25 OC) = m(3.985 kJ/kgOC)(30OC-17
OC)
mCW = 5,974.4160 Kg/hr

QB = 85.97 KJ/s
QCW = 85.97 KJ/s s
e. Toluene Column
Mass of incoming toluene: 2,096.9148 Kg/Hr
Incoming toluene temperature: 125c
Leaving toluene temperature: 25c
Specific heat of toluene: 1.72 kj/kgoc
[mCp(T2-T1)]T= [mCp(T2-T1)]CW
(9,433.5147Kg/Hr)(1.72 kJ/kgOC)(125 C-25 C) = m(3.985 kJ/kgOC)(30OC-17 OC)
mCW = 31,320.614 Kg/hr
QT = 450.712 KJ/s
QCW = 450.712 KJ/s
f. Xylene Column
Mass of incoming xylene: 1,477.7265 Kg/Hr
Incoming xylene temperature: 160c
Leaving xylene temperature: 25c
Specific heat of xylene: 1.72 kj/kgoc
[mCp(T2-T1)]X= [mCp(T2-T1)]CW
(1,477.7265 Kg/Hr)(1.72 kJ/kgOC )(160C-25 C) = m(3.985 kJ/kgOC)(30OC-17 OC)
mCW = 6,738.980516 Kg/hr
Qx = 95.31 KJ/s
QCW = 95.31 KJ/s
g. C9+ Tank
mass of incoming C9+ aromatics: 979.1085 Kg/Hr
incoming C9+ aromatics temperature: 160C
leaving C9+ aromatics temperature: 25C

specific heat of C9+ aromatics: 1.72 kJ/kgOC
incoming cooling water temperature: 30OC
leaving cooling water temperature: 17 OC
specific heat of sea water: 3.985 kJ/kgOC
(979.1085 Kg/Hr)(1.72 kJ/kgOC )(160C-25 C) = m(3.985 kJ/kgOC)(30OC-17 OC)
mCW = 4,985.553107 Kg/hr

QC9+ = 64.254 KJ/s
QCW = 64.254 KJ/s
Table 3. Summary of Energy Requirement for Cooling
Process
Stripping
1,698.491 kW
Solvent Recovery
636.1129 kW
85.97 kW
450.712 kW
Xylene Distillation
95.31 kW
C9+ Aromatics
64.254 kW
3,021.8499 kW
F. Capacity Calculation
Feed Surge Tank
Feed = 17,000 kg/hr
= 759 kg/m3
Minimum Level = 50%

V = [17,000 kg/hr (1 m3 / 759 kg)] (1.5)
V= 33.5968 m3 / hr (24 hr / day)
V = 806.3241 m3 / day
a. Benzene Product Tank

Benzene Product = 2,049.4214 kg/hr
= 876 kg/m
Minimum Level = 50%
V = 2,049.4214 kg/hr (1 m/876 kg) (1.5)
V = (3.509 m3 / hr) (24 hr / day)
V = 84.22 m3/day
b. Toluene Product Tank

Toluene Product = 9,219.85 kg/hr
= 876 kg/m
Minimum Level = 50%
V = 9,219.85 kg/hr (1 m/876 kg) (1.5)
V = (15.7874 m3 / hr) (24 hr / day)
V = 378.89 m3/day
c. Xylene Product Tank

Toluene Product = 1, 444.2572 kg/hr
= 870 kg/m
Minimum Level = 50%
V = 1, 444.2572 kg/hr (1 m/870 kg) (1.5)
V = (2.49 m3 / hr) (24 hr / day)
V = 59.76
d. C9+ Aromatics Tank

C9+ By-Product = 956.9359 kg/hr
= 914.4 kg/m
V = 956.9359 kg/hr (1 m3 / 914.4 kg)
V = 1.05 m3/hr (24 hr / day)
V = 25.12 m3/day
G. Plant Efficiency
The plant efficiency can be calculated from the mass balance data:
Efficiency = (output)/ (input) x 100%
Efficiency = (BTX)/Naphtha Reformate x 100%
Efficiency = (12,713.5286 kg/hr) / (17000 kg/hr) x 100%
Efficiency = 74.79 %
2. Design Option II
A. Process Description
Figure 8. Design option II Process flow diagram

Naphtha reformate will pass through the distillation column to separate nonaromatic component to aromatic component with the use of NFM solvent at 150
degree Celsius and 15 psig. After this, non-aromatic will go directly to the storage
tank while aromatic component along with the extracting solvent will go to the
stripping column for the separation of aromatics component to the solvent used
during extraction process. Stripping column is at 56 degree Celsius and 15psig.
After this process, aromatics fraction will go to the fractionation column for the
fractionation of Benzene, Toluene and Xylene at the desired pressure and
temperature.
B. Plant Lay-out
Legend:
2 Process Area
4 Control Room
6 Laboratory
7 Plant Utilities
10 Workshop
11 Change Room
Area for Expansion
13 Canteen
15 - Area for Expansion
16 Security
Figure 10. Plant Top view
C. Equipment Specification
Shell Material
Design Temperature
Design Pressure
Diameter
Length
Orientation
VESSEL A
A515 (Carbon Steel Plates for pressure
vessels for intermediate and higher
temperature service)
can withstand 150C
15psig
8 feet
14 feet
vertical

VESSEL B
Shell Material
Design Temperature
Design Pressure
Diameter
Length
Orientation

can withstand 150C
15psig
10 feet
17.5 feet
vertical

Type
Material
Maximum Temperature
Maximum capacity
Driver Type
PUMP B
Inline pump
Carbon Steel
175
300 gpm
Standard motor
Type
Material
Maximum Temperature
Maximum capacity
Driver Type
PUMP C
Inline pump
Carbon Steel
175
60 GPM
Standard motor
Type
Material
Maximum Temperature
Maximum capacity
Driver Type
PUMP D
Inline pump
Carbon Steel
175
20 gpm
Standard motor
Type
Material
Maximum Temperature
Maximum capacity
Driver Type
PUMP E
Inline pump
Carbon Steel
175
100 gpm
Standard motor

HEAT EXCHANGER A
Type
shell and tube heat exchanger
Shell Material
A285C (Low and intermediate strength
carbon steel plates for pressure vessels.)
Inside Diameter
6ft
Outside Diameter
6.60ft
Maximum Shell Temperature
350C
Maximum Shell Pressure
150 psig
Incoming pipe Diameter
0.75in, scheduled 40
Outlet Pipe diameter
Tube Material
A214 (Electric-resistance-welded carbon
steel heat exchanger and condenser tubes)
Maximum Tube Temperature
350C
Maximum Tube Pressure
150 psig
Tube Length
15 feet (average)
Outlet pipe Diameter
Number of passes
Area
1000 ft2
.Specification Sheet No. 8

HEAT EXCHANGER B
Type
Shell Material
carbon steel plates for pressure
vessels.)
Inside Diameter
6ft
Outside Diameter
6.60ft
350C
150 psig
Tube Material
A214 (Electric-resistance-welded
carbon steel heat exchanger and
condenser tubes)
350C
150 psig
Tube Length
15 feet (average)
Number of tubes
28
Number of passes
Area
900 ft2

HEAT EXCHANGER C
Type
Shell Material
vessels.)
Inside Diameter
6ft
Outside Diameter
6.60ft
350C
150 psig
Tube Material
condenser tubes)
350C
150 psig
Tube Length
15 feet (average)
Number of tubes
28
Number of passes
Area
500 ft2
Type
Tube Material
Design Pressure
Design Temperature
Heat Duty
Boiler
Fire-tube boiler
condenser tubes)
500 psig
400C
25 million BTU per hour

DISTILLATION COLUMN
Shell Material
A515 (Carbon Steel Plates for pressure vessels for
intermediate and higher temperature service)
Number of tray
60
Column temperature 150
Pressure
15psig
Height
32m
Diameter
1.5m
Tray Material
A285C (Low and intermediate strength carbon steel
plates for pressure vessels.)
Feed tray
30th from the bottom
Type of tray
bubble cap tray
Tray spacing
18in
Hole diameter
5mm
Hole spacing
15mm (triangular)
Tray thickness
3mm
Weir height
45 mm
Shell Material
Number of tray
Column temperature
Pressure
Height
Diameter
Tray Material
Feed tray
Type of tray
Tray spacing
Hole diameter
Hole spacing
Tray thickness
Weir height
STRIPPING COLUMN
30
56
5psig
14m
1.25m
vessels.)
5th from the bottom
bubble cap tray
15.75in
5mm
15mm (triangular)
3mm
45 mm
D. Material Balance
Assumptions:
distillation.
Table 5. Aromatics Composition of Reformate
Benzene
11.98 %
Toluene
53.88 %
Xylene
8.44 %
C9 aromatics
5.00 %
Paraffin
20.7 %
Feed = 17,150 kg/hr

N-Formyl Morpholine = 42,875 kg/hr
reference amount for Sulfolane used for aromatics extraction solvent.
Figure 13. Extractive Distillation Section

f. Pump 1
M1 = M2
M1 = 17,150 kg/hr - - - - - - - - - - mass of reformate
M2 = 17,150 kg/hr - - - - - - - - - - mass of reformate
g. Cooling System 1 (condenser 1)

M3 = M4
M3 = 42,875 kg/hr - - - - - - - - - - mass of solvent
M4 = - - - - - - - - - - mass of solvent
h. Extractive Distillation Column

recovery = 96% of non-aromatic content
M2 + M4 = M5 + M6
17,150 + 42,875 = M5 + 0.04*0.207*17,150 + 0.793*17,150* + 42,875
M5 = 3,408.05 kg/hr - - - - - - - - - - mass of raffinate (mostly paraffin)

M6 = 56,616.95 kg/hr - - - - - - - - - - mass of rich solvent
i. Cooling System 2 (condenser2 and pump 2)

non-aromatic reflux = 1.5%
M5 = M7 + M8
3,408.05 = 3,408.05*.015 + M8
M5 = 3,408.05 kg/hr - - - - - - - - - - mass of non-aromatics
M7 = 51.13 kg/hr - - - - - - - - - - mass of non-aromatics reflux
M8 =3,356.93 kg/hr - - - - - - - - - - mass of non-aromatics product
j. Pump 3
M6 = M9
M6 = 56,615.95 kg/hr - - - - - - - - - - mass of aromatics
M9 =56,615.95 kg/hr - - - - - - - - - - mass of aromatics
k. Stripper Column
recovery = 99.85% of solvent
rich solvent = aromatics + solvent recovered
M6 = M10 + M11
56,616.95 = M10 + 42,875*0.9985
M11 = 42,810.69 kg/hr - - - - - - - - - - mass of mass of stripped solvent
l. Cooling System 3 (condenser 3, pump 4)

aromatic reflux = 1.5%
M10 = M12 + M13
13,806.26 = 13806.26*.015 + M13
M12 = 207.09 kg/hr - - - - - - - - - - mass of aromatics reflux
M13 = 13,599.17 kg/hr - - - - - - - - - - mass of aromatics output
m. Benzene Fractionation Column

recovery = 94.5% of benzene component
M13 = M14 + M15
13,599.17 = 17,150*0.1,198*0.945 + M15
M13 = 13,599.17 kg/hr - - - - - - - - - - mass of input aromatics
M14 = 1,941.57 kg/hr - - - - - - - - - - mass of benzene output

M15 = 11,657.60 kg/hr - - - - - - - - - mass of mixed toluene, xylene & C9
n. Cooling System 4 (condenser4, pump5)

benzene reflux = 1.5%
M14 = M16 + M17
1,941.57 = 1,941.57*0.015 + M17
M14 = 1,941.57 kg/hr - - - - - - - - - - mass of benzene output
M16 = 29.12 kg/hr - - - - - - - - - - mass of benzene reflux
M17 = 1,912.45 kg/hr - - - - - - - - - - mass of benzene product
o. Pump 6
M15 = M18
M15 = 11,657.60 kg/hr - - - - - - - - - - mass of mixed toluene, xylene &C9
p. Toluene Fractionation Column

recovery = 97% of toluene
M18 = M19 + M20
11,657.60 = 17,150*0.5388*0.97 + M20
M19 = 8,963.21 kg/hr - - - - - - - - - - mass of toluene output
M20 = 2,694.39 kg/hr - - - - - - - - - mass of mixed xylene & C9 aromatics
q. Cooling System 5 (condenser5, pump7)

toluene reflux = 1.5%
M19 = M21 + M22
8,963.21 = 8,963.21*0.015 + M22
M19 = 8,963.21 kg/hr - - - - - - - - - - mass of toluene output
M21 = 134.44815 kg/hr - - - - - - - - - - mass of toluene reflux
M22 = 8,828.76 kg/hr - - - - - - - - - - mass of toluene product
r. Pump 8
M20 = M23
M20 = 2,694.39 kg/hr - - - - - - - - - mass of mixed xylene &C9 aromatics
s. Xylene Fractionation Column

Recovery = 97% of xylene
M23 = M24 + M25
2,694.39 = 17,150*0.0844*0.97 + M25
M24 = 1,404.04 kg/hr - - - - - - - - - - mass of xylene output
M25 = 1,290.35 kg/hr - - - - - - - - - - mass of C9 aromatics
t. Cooling System 6 (condenser7, pump9)

xylene reflux = 1.5%
M24 = M26 + M27
1,404.04 = 1,404.04*0.015 + M27
M24 = 1,404.04 kg/hr - - - - - - - - - - mass of xylene output
M26 = 21.06 kg/hr - - - - - - - - - - mass of xylene reflux
M27 = 1,382.98 kg/hr - - - - - - - - - - mass of xylene product
Table 6. Summary of in-flow rates and out-flow rates
Equipment
Pump 1
17,150
Cooling System 1
42,875
(condenser 1)
Extractive Distillation Column
60,024.95
Cooling System 2
3,408.05
(condenser2 and pump 2)
Pump 3
56,615.95
Stripper Column
13,806.26
Cooling System 3
13,806.26
(condenser 3, pump 4)
Benzene Fractionation
13,599.17
Column
Cooling System 4
1,941.57
(condenser4, pump5)
Pump 6
11,657.60
Toluene Fractionation
11,657.60
Column
Cooling System 5
8,963.21
(condenser5, pump7)
Pump 8
2,694.39
Xylene Fractionation Column
2,694.39
Cooling System 6
1,404.04
(condenser7, pump9)
Benzene Product
Toluene Product
BTX Product
3,356.93
42,810.69
13,599.17
1,941.57
1,912.45
8,963.21
8,828.76
1,404.04
1,382.98
1,941.57
8,963.21
1,404.04
12,308.82 kg/hr

Production per year = (12,308.82 kg/hr) (24 hrs/day) (355 stream days/year)
Production per year = 104,871,146.40 kg/year
E. Energy balance
This section contains the calculations for energy requirements of heat
transfer equipment used in the BTX Manufacturing Plant.
HEATING EQUIPMENT
a. Extractive Distillation Column
temperature of column:150 OC
temperature of incoming reformate: 50 OC
temperature of incoming solvent: 50 OC
specific heat of reformate: 1.7867 kJ/kgOC
specific heat of solvent: 4.184 kJ/kgOC
mass of reformate: 17,150 kg/hr
mass of solvent: 42,875 kg/hr
specific heat of steam: 1.996 kJ/kgOC
temperature of incoming steam: 300 OC
temperature of leaving steam: 100 OC
heat gain of reformate and solvent is equal to heat lost by steam

[mCp(T2-T1)]REFORMATE + [mCp(T2-T1)]SOLVENT = [mCp(T2-T1)]STEAM
17,150*1.7867*(150-50) + 42,875*4.184*(150-50) = m*1.996*(300-100)
m = 52,612.95 kg/hr - - - - - - - - - - mass of steam required

QREFORMATE = 851.16 kJ/s - - - - - - - - - - heat gained by reformate
QSOLVENT = 4,983.03 kJ/s - - - - - - - - - - heat gained by solvent
QSTEAM = 5,834.19 kJ/s - - - - - - - - - - heat loss of steam
b. Benzene Fractionation Column

temperature of column: 95 OC
temperature of incoming aromatics: 56 OC
specific heat of benzene: 1.856 kJ/kgOC
specific heat of mixed toluene, xylene and C9 aromatics: 1.825 kJ/kgOC
mass of benzene: 2,054.57 kg/hr
mass of mixed toluene, xylene and C9 aromatics: 11,687.38 kg/hr
heat gain of benzene and mixture is equal to heat lost by steam

[mCp(T2-T1)]BENZENE + [mCp(T2-T1)]MIXTURE = [mCp(T2-T1)]STEAM
2,054.57*1.856*(95-56) + 11,687.38*1.825*(95-56) = m*1.996*(300-100)
m = 2,456.33 kg/hr - - - - - - - - - - mass of steam required
QBENZENE = 148,717.99 kJ/s - - - - - - - - - - heat gained by benzene
QMIXTURE = 831,849.27 kJ/s - - - - - - - - - - heat gained by mixture
QSTEAM = 272.38 kJ/s kJ/s - - - - - - - - - - heat loss of steam
c. Toluene Fractionation Column

temperature of mixed xylene and C9 aromatics: 95 OC
specific heat of toluene: 1.809 kJ/kgOC
specific heat of mixed xylene and C9 aromatics: 1.825 kJ/kgOC
mass of toluene: 9,240.42 kg/hr
mass of mixed xylene and C9 aromatics: 2,559.96 kg/hr
heat gain of toluene and mixture is equal to heat lost by steam

[mCp(T2-T1)]TOLUENE + [mCp(T2-T1)]MIXTURE = [mCp(T2-T1)]STEAM
9,240.42*1.809*(125-95) + 2,559.96*1.825*(125-95) = m*1.996*(300-100)
m = 1607.30 kg/hr - - - - - - - - - - mass of steam required
QTOLUENE = 501,477.59 kJ/s - - - - - - - - - - heat gained by toluene
QMIXTURE = 140,157.81 kJ/s - - - - - - - - - - heat gained by mixture
QSTEAM = 178.23 kJ/s kJ/s - - - - - - - - - - heat loss of steam
d. Xylene Fractionation Column

temperature of C9 aromatics: 125 OC
specific heat of xylene: 1.841 kJ/kgOC

specific heat of C9 aromatics: 1.841 kJ/kgOC
mass of xylene: 1,447.46 kg/hr
mass of C9 aromatics: 1,389.71 kg/hr
heat gain of xylene and C9 aromatics is equal to heat lost by steam

[mCp(T2-T1)]XYLENE + [mCp(T2-T1)]C9 AROMATICS = [mCp(T2-T1)]STEAM
1,447.46*1.841*(155-125) + 1,389.71*1.841*(155-125) = m*1.996*(300-100)
m = 392.53 kg/hr - - - - - - - - - - mass of steam required
QXYLENE = 79,943.22 kJ/s - - - - - - - - - - heat gained by xylene
QC9 AROMATICS = 76,753.68 kJ/s - - - - - - - - - - heat gained by C9 aromatics
QSTEAM = 43.53 kJ/s - - - - - - - - - - heat loss of steam
Table 7. Summary of Energy Requirement for Heating

Process
Extractive Distillation
Column
Benzene Fractionation
Column
Toluene Fractionation
Column
Xylene Fractionation
Column
851.16
mass of steam
requirement
52,612.95
148,717.99
2,456.33
501,477.59
1,607.30
79,943.22
392.53
724389.96 kW
57,069.11
COOLING EQUIPMENT
a. Non-aromatics Cooler
mass of incoming non-aromatics: 3,408.05 kg/hr
incoming non-aromatics temperature: 150 OC
leaving non-aromatics temperature: 30 OC
specific heat of non-aromatics: 1.7867 kJ/kgOC
incoming cooling water temperature: 17 OC
heat lost by non-aromatics is equal to heat gained by cooling water

[mCp(T2-T1)]NA = [mCp(T2-T1)]CW
3,408.05*1.7867*(150-30) = m*3.985*(30-17)
m = 14,104.81 kg/hr - - - - - - - - - - required mass of cooling water
QNA = 202.97 kJ/s - - - - - - - - - - heat loss by non-aromatics
QCW = 202.97 kJ/s - - - - - - - - - - heat gained by cooling water
b. Aromatics Cooler
mass of incoming non aromatics: 13,806.26 kg/hr
incoming aromatics temperature: 56 OC
leaving aromatics temperature: 30 OC
specific heat of aromatics: 1.825 kJ/kgOC

specific heat of seawater: 3.985 kJ/kgOC
heat lost by aromatics is equal to heat gained by cooling water

[mCp(T2-T1)]A = [mCp(T2-T1)]CW
13,806.26*1.825*(56-30) = m*3.985*(30-17)
m = 12,645.63 - - - - - - - - - - required mass of cooling water
QA = 181.97 kJ/s - - - - - - - - - - heat loss by aromatics
c. Stripper Column
mass of incoming aromatics: 13741.95 kg/hr
specific heat of aromatics: 1.825 kJ/kgOC
temperature of incoming aromatics:150 OC
temperature of leaving aromatics: 56 OC
mass of incoming solvent: 42,875 kg/hr
specific heat of solvent: 4.184 kJ/kgOC
temperature of incoming solvent: 150 OC
temperature of leaving solvent: 56 OC
specific heat of seawater: 3.985 kJ/kgOC
temperature of incoming cooling water: 17 OC
temperature of leaving cooling water: 30 OC
heat lost by aromatics and solvent is equal to heat gained by cooling water
13,741.95*1.825*(150-56) + 42,875*4.184*(150-56) = m*3.985*(30-17)
QA = 654.84 kJ/s - - - - - - - - - - heat loss by aromatics
QA = 4,684.09 kJ/s - - - - - - - - - - heat loss by solvent
QCW = 5,338.89 kJ/s - - - - - - - - - - heat gained by cooling water
d. Benzene Cooler
mass of incoming benzene: 1,941.57 kg/hr
incoming benzene temperature: 95 OC
leaving benzene temperature: 30 OC
specific heat of benzene: 1.856 kJ/kgOC
heat lost by benzene is equal to heat gained by cooling water

[mCp(T2-T1)]B = [mCp(T2-T1)]CW
1941.57*1.856*(95-30) = m*3.985*(30-17)
QB = 65.06 - - - - - - - - - - heat loss by benzene
e. Toluene Cooler
mass of incoming toluene: 8,963.21 kg/hr
incoming toluene temperature: 125 OC
leaving toluene temperature: 30 OC
specific heat of toluene: 1.809 kJ/kgOC
heat lost by toluene is equal to heat gained by cooling water

[mCp(T2-T1)]T = [mCp(T2-T1)]CW
8,963.21*1.809*(125-30) = m*3.985*(30-17)
QT = 427.88 - - - - - - - - - - heat loss by toluene
f. Xylene Cooler
mass of incoming xylene: 1,404.04 kg/hr
incoming xylene temperature: 155 OC
leaving xylene temperature: 30 OC
specific heat of xylene: 1.841 kJ/kgOC

heat lost by xylene is equal to heat gained by cooling water
[mCp(T2-T1)]X = [mCp(T2-T1)]CW
1,404.04*1.841*(155-30) = m*3.985*(30-17)
QX = 89.75 - - - - - - - - - - heat loss by xylene
g. C9 Aromatics
mass of incoming C9+ aromatics: 1,290.35 kg/hr
incoming C9+ aromatics temperature: 155C
leaving C9+ aromatics temperature: 30C
specific heat of C9+ aromatics: 1.72 kJ/kgOC
incoming cooling water temperature: 30OC
1,290.35*1.72*(155C-30 C) = m3.985*(30OC-17 OC)
mCW = 5,355.183 Kg/hr
QC9+ = 77.0625 KJ/s
QCW = 77.0625 KJ/s
Table 8. Summary of Energy Requirement for Cooling

Process
Non-aromatics Cooler
Aromatics Cooler
Stripper Column
Benzene Cooler
Toluene Cooler
Xylene Cooler
C9+ Tank
202.97 kW
181.97 kW
654.84 kW
65.06 kW
427.88 kW
89.75 kW
77.0625 kW
1,609.6525 kW
A. Capacity Calculation
a. Feed Surge Tank
Feed = 17,150 kg/hr
= 759 kg/m3
Minimum Level = 50%
V = feed rate * time * (1m3/759kg)
= 17,150 * 2 * (1m3/759kg)
V = 45 m3
b. Non-aromatic Vessel
Feed = 3408.05 kg/hr
= 845 kg/m3
Minimum Level = 50%
= 3408.05 * 2 * (1m3/845kg)
V = 8.07 m3
Mass of cooling
water requirement
14104.81
12645.63
371006.61
4521.40
29734.05
6236.94
14104.81
451754.25
c. Aromatic Vessel
Feed = 13,806.26 kg/hr
= 874 kg/m3
Minimum Level = 50%
V = feed rate * time * (1m3/874 kg)
= 13,806.26 * 2 * (1m3/874 kg)
V = 31.59 m3
d. Benzene Vessel
Feed = 1,941.75 kg/hr
= 876.5 kg/m3
Minimum Level = 50%
V = feed rate * time * (1m3/876.5 kg)
= 1,941.75 * 2 * (1m3/876.5 kg)
V = 4.43 m3
e. Toluene Vessel
Feed = 8,963.21 kg/hr
= 866.9 kg/m3
Minimum Level = 50%
= 8,963.21 * 2 * (1m3/866.9 kg)
V = 21.67 m3
f. Xylene Vessel
Feed = 1,404.04 kg/hr
= 864 kg/m3
Minimum Level = 50%
= 1,404.04 * 2 * (1m3/864kg)
V = 3.25 m3
g. C9+ Aromatics Vessel

Feed = 1,290.35 kg/hr
= 876.5 kg/m3
Minimum Level = 50%
= 1,290.35 * 2 * (1m3/876.5 kg)
V = 3.0 m3
Efficiency =
100%
1912.45+8828.76+1382.98
17150
100%
= 70.69%
Production per hour = 11, 964.21 kg/hr

Production per year = 103, 370 ,774.4 kg/year
3. Design Option III

A. Process Description
Figure 15. Design Option III Process Flow Diagram

Fresh feed enters the extractor and flows upward, countercurrent to a
stream of lean solvent. As the feed flows through the extractor, aromatics are
selectively dissolved in the solvent. A raffinate stream, very low in aromatics
content, is withdrawn from the top of the extractor. The rich solvent, loaded with
aromatics, exits the bottom of the extractor and enters the stripper. The
nonaromatic components having volatilities higher than that of benzene are
completely separated from the solvent by extractive distillation and removed
overhead along with a small quantity of aromatics. This overhead stream is

recycled to the extractor, where the light non-aromatics displace the heavy nonaromatics from the solvent phase leaving the bottom of the extractor.
The stripper bottoms stream, which is substantially free of nonaromatic
impurities, is sent to the recovery column, where the aromatic product is separated
from the solvent. Because of the large difference in boiling point between the
Sulfolane solvent and the heaviest aromatic component, this separation is
accomplished with minimal energy input. To minimize solvent temperatures, the
recovery column is operated under vacuum. Lean solvent from the bottom of the
recovery column is returned to the extractor. The extract is recovered overhead
and sent on to distillation columns downstream for recovery of the individual
benzene and toluene products. The raffinate stream exits the top of the extractor
and is directed to the raffinate wash column. In the wash column, the raffinate is
contacted with water to remove dissolved solvent. The solvent-rich water is
vaporized in the water stripper by exchange with hot circulating solvent and then
used as stripping steam in the recovery column. Accumulated solvent from the
bottom of the water stripper is pumped back to the recovery column.
The raffinate product exits the top of the raffinate wash column. The amount
of Sulfolane solvent retained in the raffinate is negligible. The raffinate product is
commonly used for gasoline blending or aliphatic solvent applications. Under
normal operating conditions, Sulfolane solvent undergoes only minor oxidative
degradation. A small solvent regenerator is included in the design of the unit as a
safeguard against the possibility of air leaking into the unit. During normal
operation, a small slip-stream of circulating solvent is directed to the solvent

regenerator for removal of oxidized solvent. The extract product from a Sulfolane
unit may contain trace amounts of olefins and other impurities that would adversely
affect the acid-wash color tests of the final benzene and toluene products. To
eliminate these trace impurities, the extract is clay-treated prior to fractionation.
Because clay treating is done at mild conditions, clay consumption is minimal. The
treated extract is directed to the aromatics fractionation section, where high-purity
benzene, toluene, and mixed xylenes are recovered.
Any heavy aromatics in the feed are yielded as a bottoms product from the
fractionation section. In most cases, the C9 aromatics are recovered. The heavy
aromatics may also be blended back into the refinery gasoline pool or sold as a
high-octane blending component.
B. Plant Lay-out
Legend:
1 Process Area
3 Control Room
5 Laboratory
6 Plant Utilities
10 Workshop
11 Change Room
Area for Expansion
12 Canteen
15 Gate 1
16 Security
17 Gate 2
Figure 16. Plant Top View
C. Equipment Specification
PUMP 1
Flow
Type
Discharge Pressure
Temperature
Seal Type
Driver Type
Material
120 gpm
Centrifugal
30psi
100C
Standard motor
Carbon Steel

EXTRACTOR 1
Height
Diameter
Pressure
Temperature
17 meters
0.93 meters
120 psi
200C
Carbon Steel Plates

COOLER 1
Type
Process
Duty
Temperature
Pressure
Material
Area
Shell
Tubes
Baffling
Material
Length
Inside Diameter
Liquid-Liquid
Distillation
100 kW
150 C
30 psi
steel plates
1000ft2
Carbon Steel
1.95m
0.1625m
Number of Tubes
Number of Passes
28
Material
Copper, Schedule 40
Length
Inside Diameter
Outside Diameter
Pitch
1.905m
0.015875m
0.01905m

Number of Baffles
Baffle spacing

2

WASH COLUMN
Height
Diameter
Pressure
Temperature
Tray type
Number of Trays
Tray Spacing
Tray thickness
Tray Material
6.09 meters
0.44 meters
30 psi
100C
Sieve
18
0.02 m
0.005 m
steel plates
Carbon Steel Plates

STRIPPING COLUMN
Height
14 meters
Diameter
0.80 meters
Pressure
30 psi
Temperature
150 C
Tray type
Sieve
Number of Trays
34
Tray Spacing
0.6096 m
Tray thickness
0.0046 m
Tray Material
steel plates
Carbon Steel Plates
Flow
Type
Discharge Pressure
Temperature
Seal Type
Driver Type
Material
PUMP 2
120 gpm
Centrifugal
45 psi
150 C
Standard motor
Carbon Steel

COOLER 2
Type
Process
Duty
Temperature
Pressure
Material
Area
Shell
Tubes
Baffling
Material
Length
Inside Diameter
Liquid-Liquid
Distillation
100 kW
200 C
45 psi
steel plates
1000ft2
Carbon Steel
1.95m
0.1625m
Number of Tubes
Number of Passes
28
Material
Copper, Schedule 40
Length
Inside Diameter
Outside Diameter
Pitch
1.905m
0.015875m
0.01905m

Number of Baffles
Baffle spacing

2
Type
Length
Diameter
Oreintation
Pressure
Temperature
Capacity
SEPARATOR
Gas-Liquid
4.80 meters
1 meter
Horizontal
30 psi
150 C
Carbon Steel Plates
5000 gallons

Type
Length
Diameter
Oreintation
Pressure
Temperature
Capacity
WATER SEPARATOR
Liquid-Liquid
4.80 meters
1 meter
Horizontal
30 psi
150 C
Carbon Steel Plates
5000 gallons

REGENERATOR
Height
Diameter
Pressure
Temperature
Tray type
Number of Trays
Tray Spacing
Tray thickness
Tray Material
10 meters
1.2 meters
45 psi
200 C
Sieve
30
0.04 m
0.002 m
steel plates
Carbon Steel Plates

PUMP 3
Flow
Type
Discharge Pressure
Temperature
Seal Type
Driver Type
Material
120 gpm
Centrifugal
65 psi
200 C
Standard motor
Carbon Steel

RECOVERY COLUMN
Height
Diameter
Pressure
Temperature
Tray type
Number of Trays
Tray Spacing
Tray thickness
Tray Material
14 meters
3 meters
55 psi
200 C
Sieve
33
0.40 m
0.005 m
steel plates
Stainless Steel

PUMP 4
Flow
Type
Discharge Pressure
Temperature
Seal Type
Driver Type
Material
120 gpm
Centrifugal
65 psi
200 C
Standard motor
Carbon Steel

COOLER 3
Type
Process
Duty
Temperature
Pressure
Material
Area
Shell
Tubes
Baffling
Material
Length
Inside Diameter
Liquid-Liquid
Distillation
100 kW
200 C
45 psi
steel plates
1000ft2
Carbon Steel
1.95m
0.1625m
Number of Tubes
Number of Passes
28
Material
Copper, Schedule 40
Length
Inside Diameter
Outside Diameter
Pitch
1.905m
0.015875m
0.01905m

Number of Baffles
Baffle spacing

2

Type
Length
Diameter
Oreintation
Pressure
Temperature
Capacity
SEPARATOR 2
Liquid-Liquid
4.80 meters
1 meter
Horizontal
45 psi
200 C
Carbon Steel Plates
5000 gallons

PUMP 5
Flow
Type
Discharge Pressure
Temperature
Seal Type
Driver Type
Material
120 gpm
Centrifugal
65 psi
200 C
Standard motor
Carbon Steel

PUMP 6
Flow
Type
Discharge Pressure
Temperature
Seal Type
Driver Type
Material
120 gpm
Centrifugal
65 psi
200 C
Standard motor
Carbon Steel
Height
Diameter
Pressure
Temperature
Materials of
Constructions
CLAY TREATER
Cartridge 1
Cartridge 2
7.6 m
7.6 m
0.93m
1.2 m
30 psi
65 psi
100C
425C
Welded Carbon
steels

BENZENE COLUMN
Height
Diameter
Pressure
Temperature
Type
17 meters
0.93 meters
15 psi
100 C
Packed bed column
Carbon Steel

PUMP 7
Flow
120 gpm
Type
Centrifugal
Discharge Pressure
30 psi
Temperature
100 C
Seal Type
Driver Type
Standard motor
Material
Carbon Steel

COOLER 4
Type
Process
Duty
Temperature
Pressure
Material
Area
Shell
Tubes
Baffling
Material
Length
Inside Diameter
Liquid-Liquid
Distillation
100 kW
150 C
30 psi
steel plates
1000ft2
Carbon Steel
1.95m
0.1625m
Number of Tubes
Number of Passes
28
Material
Copper, Schedule 40
Length
Inside Diameter
Outside Diameter
Pitch
1.905m
0.015875m
0.01905m

Number of Baffles
Baffle spacing

2

TOLUENE COLUMN
Height
Diameter
Pressure
Temperature
Type
20 meters
1.04 meters
15 psi
125 C
Packed bed column
Carbon Steel Plates

PUMP 8
Flow
Type
Discharge Pressure
Temperature
Seal Type
Driver Type
Material
120 gpm
Centrifugal
50 psi
180 C
Standard motor
Carbon Steel

XYLENE COLUMN
Height
Diameter
Pressure
Temperature
Type
18 meters
0.98 meters
15 psi
180C
Packed bed column
Carbon Steel Plates

COOLER 5
Type
Liquid-Liquid
Process
Distillation
Duty
100 kW
Temperature
125 C
Pressure
30 psi
Material
steel plates
Area
1000ft2
Shell
Material
Carbon Steel
Length
1.95m
Inside Diameter
0.1625m
Tubes
Baffling
Number of Tubes
Number of Passes
28
Material
Copper, Schedule 40
Length
Inside Diameter
Outside Diameter
Pitch
1.905m
0.015875m
0.01905m

Number of Baffles
Baffle spacing

2

COOLER 6
Type
Process
Duty
Temperature
Pressure
Material
Area
Shell
Tubes
Baffling
Material
Length
Inside Diameter
Liquid-Liquid
Distillation
100 kW
180 C
30 psi
steel plates
1000ft2
Carbon Steel
1.95m
0.1625m
Number of Tubes
Number of Passes
28
Material
Copper, Schedule 40
Length
Inside Diameter
Outside Diameter
Pitch
1.905m
0.015875m
0.01905m

Number of Baffles
Baffle spacing

2

PUMP 8
Flow
Type
Discharge Pressure
Temperature
Seal Type
Driver Type
Material
120 gpm
Centrifugal
50 psi
180 C
Standard motor
Carbon Steel

Height
Diameter
Oreintation
Pressure
Temperature
Capacity
VESSEL A
3.05 m
1.22 m
Vertical
45 psi
150 C
3000 gallons

Height
Diameter
Oreintation
Pressure
Temperature
Capacity
VESSEL B
5.2 m
2.3 m
Vertical
45 psi
150 C
5000 gallons

COOLER 7
Type
Process
Duty
Temperature
Pressure
Material
Area
Shell
Tubes
Baffling
Liquid-Liquid
Distillation
Material
Length
Inside Diameter
180 C
30 psi
steel plates
1000ft2
Carbon Steel
1.95m
0.1625m
Number of Tubes
Number of Passes
28
Material
Copper, Schedule 40
Length
Inside Diameter
Outside Diameter
Pitch
1.905m
0.015875m
0.01905m

Number of Baffles
Baffle spacing

2
D. Material Balance
Figure 18. Liquid-Liquid Extraction and Extractive Distillation

Assumptions:
distillation.
Feed = 15,500 kg/hr
Sulfolane = 100170 kg/hr
reference amount for Sulfolane used for aromatics extraction solvent.
a. Pump 1
M1 = M2
M1 = 15,500 Kg/Hr
M2 = 15,500 Kg/Hr
b. Extraction Column
Basis: Sulfolane Reflux = 42%
Raffinate Recovery = 33%
Feed + Solvent Reflux + Lean Solvent = Raffinate + Rich Solvent
M3 = 42,071.4 Kg/Hr
M2 + M3 + M4 = M5 + M6
15,500 Kg/Hr + 0.42 (100170 Kg/Hr) + 100,170 Kg/Hr = 0.33 (15500 Kg/Hr) +
M6
Rich Solvent = 152,626.4 Kg/Hr
M6 = 152,626.4 Kg/Hr
Raffinate = 5,115 Kg/Hr
M5 = 5,115 Kg/Hr
c. Condenser 1
M5 = M7
M5 = 5,115 Kg/Hr
M7 = 5,115 Kg/Hr
d. Wash Column
Efficiency = 98% : Heuristics
Assumption: 4,500 Kg/Hr Water Used
Water Wash-To-Water Ratio = 1.75
M9 = 1.75 (4,500 Kg/Hr)
M9 = 7,875 Kg/Hr
Water + Raffinate = Washed Raffinate + Water Wash

4,500 Kg/Hr + M7 = M8 + M9
4,500 Kg/Hr + 5115 Kg/Hr = M8 + 7,875 Kg/Hr
M8 = 1,740 Kg/Hr (0.98)
Washed Raffinate = 1,705.2 Kg/Hr
M8 = 1,705.2 Kg/Hr
e. Stripper Column
Basis: Solvent-To-Extract Ratio = 2
Rich Solvent = Extract + Solvent

Rich Solvent = 152,626.4 Kg/Hr
M11 = 2(M10)
152,626.4 Kg/Hr = M10 + M11
M10 = 50,875.47 Kg/Hr
M11 = 101750.93 Kg/Hr (0.95)

M11 = 96,663.38 Kg/Hr
f. Pump 2
M10 = M12
M10 = 50,875.47 Kg/Hr
M12 = 50,875.47 Kg/Hr
g. Condenser 2
M11 = M13
M11 = 96,663.38 Kg/Hr
M13 = 96,663.38 Kg/Hr
h. Separator 1
M13 = M3 + M14
96,663.38 Kg/Hr = 42071.4 Kg/Hr + M14
M14 = 59,679.53 Kg/Hr
i. Water Stripper
Effficiency = 80% : Heuristics
M9 + M14 = M15 + M16
M15 = 0.8 (M9)
M9 = 7,875 Kg/Hr
M15 = 6,300 Kg/Hr
7,875 Kg/Hr + 59,679.53 Kg/Hr = 6,300 Kg/Hr + M16

M16 = 61,254.53 Kg/Hr
j. Pump 3
M15 = M17
M15 = 6300 Kg/Hr
M17 = 6300 Kg/Hr
k. Regenerator
Basis: 99% Regeneration

M16 = M18 + M19
M18 = Waste
M18 = 1% (M16)
M18 = 612.55 Kg/Hr
M19 = (61,254.53 Kg/Hr 612.55 Kg/Hr) (0.98)

M19 = 59,429.14 Kg/Hr
Solvent Regenerated = 59,429.14 Kg/Hr
l. Recovery Column
Efficiency = 95 %: Heuristics
Extract = 50,875.47 Kg/Hr
M19 = 59,429.14 Kg/Hr
Water = 6,300 Kg/Hr
Extract + Solvent Regenerated + Water = Aromatics + Lean Solvent
50,875.47 Kg/Hr + 59,429.14 Kg/Hr + 6,300 Kg/Hr = M20 + 100,170 Kg/Hr
M20 = 16,434.61 Kg/Hr
m. Pump 4
M20 = M4
M20 = 100170 Kg/Hr
M4 = 100170 Kg/Hr
n. Condenser 3
M19 = M21
M21 = 16,434.61 Kg/Hr
M21 = 16,434.61 Kg/Hr
o. Separator 2
Basis: Water Recycled = 85%
M21 = 85% Water + M22
16,434.61 Kg/Hr = 0.85 (4,500 Kg/Hr) + M22
M22 = 12,609.61 Kg/Hr
p. Pump 5
Water used = 4,500 Kg/Hr
M23 = 0.85 (4,500 Kg/Hr)
M23 = 3,825 Kg/Hr
q. Pump 6
M22 = 12,609.61 Kg/Hr
M24 = M22
M24 = 12,609.61 Kg/Hr

a. Clay Treater
BTX Extract = 12,609.61 Kg/Hr
M1 = 12,609.61 Kg/Hr
M2 = 12,593.91 Kg/Hr
b. Benzene Column
M2 = M3 + M4
M3 = M2 (95%) (16.12%)
M3 = (12,609.61 Kg/Hr) (0.95) (0.1612)
M3 = 1,928.63 Kg/Hr
M4 = M2 M3
M4 = 12,593.91 Kg/Hr 1,928.63 Kg/Hr
M4 = 10,665.28 Kg/Hr
Toluene Column Feed = 10,665.28 Kg/Hr
c. Condenser 4
M3 = M5
M3 = 1,928.63 Kg/Hr
M5 = 1,928.63 Kg/Hr
Benzene Product = 1,928.63 Kg/Hr
d. Pump 7
M4 = 10,665.28 Kg/Hr
M7 = M4
M7 = 10,665.28 Kg/Hr
e. Toluene Column
M7 = M8 + M9
M8 = (M2) (95%) (72.52%)
M8 = (12,593.91 Kg/Hr) (0.95) (0.7252)
M8 = 8,676.45 Kg/Hr
M9 = M7 M8
M9 = 10,665.28 Kg/Hr 8,676.45 Kg/Hr
M9 = 1,988.83 Kg/Hr
Xylene Column Feed = 1,988.83 Kg/Hr
f. Condenser 5
M10 = M8
M8 = 8,676.45 Kg/Hr
M10 = 8,676.45 Kg/Hr
Toluene Product = 8,676.45 Kg/Hr
g. Pump 8
M12 = M9
M9 = 1,988.83 Kg/Hr
M12 = 1,988.83 Kg/Hr
h. Xylene Column
M12 = M13 + M14
M12 = 1,988.83 Kg/Hr
M13 = (M2) (95%) (11.36%)

M13 = (12,593.91 Kg/Hr) (0.95) (0.1136)
M13 = 1,359.13 Kg/Hr
M14 = M12 M13
M14 = 1,988.83 Kg/Hr 1,359.13 Kg/Hr
M14 = 629.70 Kg/Hr
i. Condenser 6
M13 =1359.13 Kg/Hr
M15= M13
M15 = 1,359.13 Kg/Hr
Xylene Product = 1,359.13 Kg/Hr
j. Pump 9
M14 = 629.70 Kg/Hr
M17 = M14
M17 = 629.70 Kg/Hr
k. Condenser 7
M17 = 629.70 Kg/Hr
M18 = m17
M18 = 629.70 Kg/Hr

C9+ Aromatics Product = 629.70 Kg/Hr
Table 9. Summary of In-flow Rate and Out-flow Rate

Equipment
Pump 1
15500
Extractor
157741.4
Condenser 1
5115
Wash Column
9615
Stripper
152626.4
Pump 2
50875.47
Condenser 2
96663.38
Separator 1
96663.38
Water Stripper
67554.53
Solvent Regenerator
61254.53
Pump 3
6300
Recovery Column
50875.47
Pump 4
100170
Condenser 3
16434.61
Separator 2
16434.61
Pump 5
3825
Pump 6
12609.61
Clay Treater
12609.61
Distillation Column 1
12593.91
Condenser 4
1928.63
Pump 7
10665.28
10665.28
Condenser 5
8676.45
Pump 8
1988.83
1988.83
Condenser 6
1359.13
Pump 9
629.70
Condenser 7
Benzene Product
Toluene Product
BTX Product

157741.4
9580.2
147538.85
59429.14
16434.61
12609.61
12593.91
1928.63
8676.45
1359.13
629.70
1928.63 kg/hr
8676.45 kg/hr
1359.13 kg/hr
11964.21 kg/hr

Production per year = 103, 370,774.4 kg/year
E. Energy balance
This section contains the calculations for energy requirements of heat transfer
equipment used in the BTX Manufacturing Plant.
F. Stripper Column
Rich Solvent (Sulfolane)= 152,626.4 Kg/Hr
Cp of Sulfolane = 1.497 J/g C
Cp = 1.497 kJ/Kg-K
Rich solvent temperature =30C
T1 = 30C = 303.15 K
T2 = 408.15 K
Q = m Cp (T2 - T1)
Q = (152,626.4 Kg/Hr) (1.497 kJ/Kg-K) (408.15 K - 303.15 K)
Q = 23,990,580.68 kJ/hr
Q = 23,990,580.68 kJ/hr (1 hr/3600 s)
Q = 6,664.05 kW
g. Solvent Regenerator
Regenerated Solvent = 61,254.53 Kg/Hr
Cp of Sulfolane = 1.497 kJ/Kg-K
T1 = 135 C = 408.15 K
T2 = 166 C = 439.15 K
Q = m Cp (T2 - T1)
Q = (61,254.53 Kg/Hr) (1.497 kJ/Kg-K) (439.15 K - 408.15 K)
Q = 2,842,638.97 kJ/hr
Q = 2,842,638.97 kJ/hr (1 hr/3600 s)
Q = 789.62 kW
h. Recovery Column
Cp of aromatics = 1.7867 kJ/Kg-K
T1 = 135C = 408.15 K
T2 = 177C = 450.15 K
Q1 = m Cp (T2 - T1)
Q1 = (50,875.47 Kg/Hr) (1.7867 kJ/Kg-K) (450.15 K - 408.15 K)
Q1 = 3,817,766.49 kJ/hr
Q1 = 3,817,766.49 kJ/hr (1 hr/3600 s)
Q1 = 1,060.49 kW
Solvent = 59,429.14 Kg/Hr

Cp of sulfolane = 1.497 kJ/Kg-K
T1 = 166C = 439.15 K
T2 = 177C = 450.15 K
Q2 = m Cp (T2 - T1)
Q2 = (59,429.14 Kg/Hr) (1.497 kJ/Kg-K) (450.15 K - 439.15 K)
Q2 = 978,619.65 kJ/hr
Q2 = 978,619.65 kJ/hr (1 hr/3600 s)
Q2 = 271.84 kW
Water = 6300 Kg/Hr

Cp of water = 4.187 kJ/Kg-K
T1 = 121C = 394.15 K
T2 = 177C = 450.15 K
Q3 = m Cp (T2 - T1)
Q3 = (6,300 Kg/Hr) (4.187 kJ/Kg-K) (450.15 K - 394.15 K)
Q3 = 1,477,173.6 kJ/hr
Q3 = 1,477,173.6 kJ/hr (1 hr/3600 s)
Q3 = 410.33 kW
Q = 1,060.49 kW + 271.84 kW + 410.33 kW

Q = 1,742.66 kW
i. Benzene Column
M = 12,593.91 Kg/Hr
Cp of Benzene = 1.92 kJ/Kg-K
T1 = 90C = 363.15 K
T2 = 100C = 373.15 K
Q = m Cp (T2 - T1)
Q = (12,593.91 Kg/Hr) (1.92 kJ/Kg-K) (373.15 K - 363.15 K)
Q = 241,803.07 kJ/hr
Q = 241,803.07 kJ/hr (1 hr/3600 s)
Q = 67.17 kW
j. Toluene Column
M = 10,665.28 Kg/Hr
Cp of Toluene = 1.72 kJ/Kg-K
T1 = 100C = 373.15 K
T2 = 125C = 398.15 K
Q = m Cp (T2 - T1)
Q = (10,665.28 Kg/Hr) (1.72 kJ/Kg-K) (398.15 K - 373.15 K)
Q = 458,607.04 kJ/hr
Q = 458,607.04 kJ/hr (1 hr/3600 s)
Q = 127.39 kW
k. Xylene Column
M = 1,988.83 Kg/Hr
Cp of Xylene = 1.72 kJ/Kg-K
T1 = 125C = 398.15 K
T2 = 160C = 433.15 K
Q = m Cp (T2 - T1)
Q = (1,988.83 Kg/Hr) (1.72 kJ/Kg-K) (433.15 K - 398.15 K)
Q = 119,727.57 kJ/hr
Q = 119,727.57 kJ/hr (1 hr/3600 s)
Q = 33.26 kW
l. Boiler
Q = (6,664.05 + 789.62 + 1742.66 + 67.17 + 127.39 + 33.26) kW
Q = 9,424.15 kW
Cp of steam = 1.996 kJ/Kg-K
T1 = 30C = 273.15 K
T2 = 177C = 450.15 K
Q = m Cp (T2 - T1)
9,424.15 kW (1 kJ/s / 1 kW) (3600s/1 hr) = (Ms) (1.996 kJ/Kg-K) (450.15 K 373.15 K)
33,926,940 kJ/hr = Ms (153.692 kJ/Kg)
Ms = 220,746.30 kg/hr
Steam = 220,746.30 kg/hr
Table 10. Summary of Energy Requirement

Process
Stripping
6664.05
Solvent Regeneration
789.62
Solvent Recovery
1742.66
67.17
127.39
Xylene Distillation
33.26
9424.15 kW
F. Capacity Calculation
e. Feed Surge Tank
Feed = 15500 kg/hr
= 759 kg/m3
Minimum Level = 50%
V = [15500 kg/hr (1 m3 / 759 kg)] (1.5)
V= 30.63 m3 / hr (24 hr / day)
V = 735 m3 / day
f. Raffinate Tank
Washed Raffinate = 1705.2 kg/hr
= 845 kg/m3
V = 1705.2 kg/hr (1 m3/ 845 kg)
V = (2.02 m3 / hr) (24 hr / day)
V = 48.43 m3/day
g. Benzene Product Tank

Benzene Product = 1,928.63 kg/hr
= 876 kg/m
Minimum Level = 50%
V = 1,928.63 kg/hr (1 m/876 kg) (1.5)
V = (3.30 m3 / hr) (24 hr / day)
V = 79.26 m3/day
h. Toluene Product Tank

Toluene Product = 8,676.45 kg/hr
= 876 kg/m
Minimum Level = 50%
V = 8,676.45 kg/hr (1 m/876 kg) (1.5)
V = (14.86 m3 / hr) (24 hr / day)
V = 356.57 m3/day
i. Xylene Product Tank

Toluene Product = 1359.13 kg/hr
= 870 kg/m
Minimum Level = 50%
V = 1,359.13 kg/hr (1 m/870 kg) (1.5)
V = (2.34 m3 / hr) (24 hr / day)

V = 56.24 m3/day
j. C9+ Aromatics Tank

C9+ By-Product = 629.70 kg/hr
= 914.4 kg/m
V = 629.70 kg/hr (1 m3 / 914.4 kg)
V = 0.69 m3/hr (24 hr / day)
V = 16.53 m3/day
G. Plant Efficiency
The plant efficiency can be calculated from the mass balance data:
Efficiency = (output)/ (input) x 100%
Efficiency = (BTX)/Naphtha Reformate x 100%
Efficiency = (11,964.21 kg/hr) / (15,500 kg/hr) x 100%
Efficiency = 76.93 %
CHAPTER IV
ECONOMICS
CAPITAL EXPENDITURE
Capital expenditures, or capex, is money used to purchase, upgrade,
improve, or extend the life of long-term assets. Long-term assets are typically
property, infrastructure, or equipment with a useful life of more than one year
OPERATION EXPENDITURE
An operating
expense, operating
expenditure, operational
expense,
operational expenditure or OPEX is an ongoing cost for running a production plant

or system.
Raw materials
These are the major materials required to manufacture the product. The
quantities can be obtained from the demand projection and multiplied by the
operating hours per year to get the annual requirements. The price of naphtha
reformate is obtained from the prices of potential suppliers, but in the preliminary
stages of a project prices can be taken from the literature.
Miscellaneous materials (plant supplies)

Under this heading are included all the miscellaneous materials required to
operate the plant that are not covered under the headings raw materials or
maintenance materials. As a rough guide the cost of miscellaneous materials is

taken as 5 percent of capital expenditure. These materials will include:
1. Safety clothing: hard hats, safety glasses etc.
2. Instrument charts and accessories
3. Pipe gaskets
4. Cleaning materials
Utilities (services)
This operating cost includes electricity, fuel, steam, water for process and
cooling. The quantities required were obtained from the energy balances. Utility
price was based on table 6.5
Maintenance, Repairs and Contingency

This item include the cost of maintenance labor, which can be as high as
the operating labor cost, and the materials including equipment spares needed for
the maintenance of the plant. The annual maintenance costs for chemical plants
are high, typically 5 to 15 per cent of the installed capital costs. As a first estimate
the annual maintenance cost is taken as 10 percent of the fixed capital cost and
considered to be divided evenly between labor and materials.
Operating labor
This is the manpower needed to operate the plant: that directly involved
with running the process. Chemical plants do not normally employ many people
and the cost of operating labor would not normally exceed 15 per cent of the total
operating cost. Labor cost is normally calculated from an estimate of the number of
shift and number of personnel needed. On that note, this proposed manufacturing
plant employees work in a three shifts per day basis with 50 personnel in total.
Supervision
This heading covers the direct operating supervision: the management
directly associated with running the plant. The number required will depend on the
size of the plant and the nature of the process. The site would normally be broken
down into a number of manageable units. A typical management team for a unit
would consist of four to five shift foremen, a general foreman, and an area
supervisor (manager) and his assistant. The cost of supervision is calculated from
an estimate of the total number required and the current salary levels. On average,
one supervisor would be needed for each four to five operators.
Laboratory costs
The annual cost of the laboratory analyses required for process monitoring
and quality control is a significant item in most modern chemical plants. The costs
should be calculated from an estimate of the number of analyses required and the
standard charge for each analysis, based on experience with similar processes. As
a rough estimate the cost can be taken as 25 percent of the operating labor cost
Plant Overheads
Plant overheads Included under this heading are all the general costs
associated with operating the plant not included under the other headings; such
as, general management, plant security, medical and canteen. It would also
normally include the plant technical personnel not directly associated with and
charged to a particular operating area. The plant overhead cost is usually
estimated from the total labor costs. A typical estimate would be 50 percent of the
labor costs.
Local taxes
This term covers local taxes, which are calculated on the value of the site. A
typical figure would be 5 percent of capital expenditure.
Insurance
The cost of the site and plant insurance: the annual insurance premium paid
to the insurers; usually about five percent of capital expenditure.
Payback Period is the length of time required to recover the cost of an

investment. The payback period of a given investment or project is an important
determinant of whether to undertake the position or project, as longer payback
periods are typically not desirable for investment positions.
Net Present Value is the difference between the present value of cash
inflows and the present value of cash outflows. NPV is used in capital budgeting to
analyze the profitability of a projected investment or project.
Rate of Return is a performance measure used to evaluate the efficiency of

an investment or to compare the efficiency of a number of different investments.
ROI measures the amount of return on an investment relative to the investments
cost.
DESIGN OPTION 1
EQUIPMENT
PROCESS
Raw materials
Extraction
Raffinate Stripping
Solvent Recovery
Clay Treater
Benzene Column
Toluene Column
Xylene Column
EQUIPMENT
Storage
Pump (1)
Packed Bed Column
Stripping Column
Cooler (1)
Storage Vessel (1)
Pump (2)
Pump (3)
Heater (1)
Pump (4)
Pump (5)
Solvent Recovery Column
Cooler (2)
Storage Vessel (2)
Pump (6)
Pump (7)
Heater (2)
Pump (8)
Heater Exchanger
Cartridge (2 columns)
Fractionation Column
Cooler (3)
Storage Vessel (3) (Product)
COST
$15,000.00
$4,000.00
$250,000.00
$450,000.00
$20,000.00
$20,000.00
$2,500.00
$2,500.00
$20,000.00
$2,000.00
$2,500.00
$450,000.00
$20,000.00
$12,000.00
$2,100.00
$2,100.00
$20,000.00
$4,000.00
$20,000.00
$22,000.00
$38,000.00
$20,000.00
$15,500.00
Pump (9)
Reboiler (1)
Pump (10)
Fractionation column
Cooler (4)
Pump (11)
Pump (12)
Reboiler (2)
Fractionation column
$3,900.00
$20,000.00
$3,800.00
$40,000.00
$20,000.00
$16,000.00
$3,800.00
$3,800.00
$20,000.00
$38,000.00
Cooler (5)
$20,000.00
$11,800.00
PROCESS
Xylene Column
EQUIPMENT
Reboiler (3)
Pump (13)
Cooler (6)
Storage Vessel (6) (Nonaromatics)
TOTAL
COST
$20,000.00
$3,500.00
$20,000.00
$11,000.00
$1,669,800.00
DETAILED EQUIPMENT COST

Extraction Column Purchased Cost:
Material
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and Control
Electrical Installation
Piping
Painting
Miscellaneous
Installed Equipment Cost
$250,000.00
Labor
Factor
Cost
Factor
Cost
5
$12,500.00
133
$16,625.00
4
$10,000.00
50
$5,000.00
3
$7,500.00
100
$7,500.00
1
$2,500.00
150
$3,750.00
6
$15,000.00
40
$6,000.00
8
$20,000.00
75
$15,000.00
30
$7,500,000.00
50
$3,750,000.00
0.5
$12,500.00
300
$37,500.00
4
$10,000.00
80
$8,000.00
$7,590,000.00
$3,849,375.00
$11,439,375.00
Stripping Column Purchased Cost:

Material
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Control
Piping
Factor, % in
PC
5
4
3
1
6
8
30
Painting
Miscellaneous
0.5
4
$450,000.00
Labor
Material
Factor, % in
Cost
MC
$22,500.00
133
$18,000.00
50
$13,500.00
100
$4,500.00
150
$27,000.00
40
$36,000.00
$13,500,000
.00
$22,500.00
$18,000.00
$13,662,000.00
$20,590,87.00
Factor, % in
PC
5
4
3
1
6
Installed Equipment Cost:
$27,000.00
$6,750,000.
00
$67,500.00
$14,400.00
$6,928,875.00
300
80
Clay Treater Column Purchased Cost (2):

Material
Painting
Miscellaneous
$29,925.00
$9,000.00
$13,500.00
$6,750.00
$10,800.00
75
50
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Control
Piping
Labor Cost
8
30
0.5
4
$44,000.00
Labor
Material
Factor, % in
Cost
MC
$2,200.00
133
$1,760.00
50
$1,320.00
100
$440.00
150
$2,640.00
40
$3,520.00
$1,320,000.
00
$2,200.00
$1,760.00
$1,335,840.00
75
50
300
80
Labor
Cost
$2,926.00
$880.00
$1,320.00
$660.00
$1,056.00
$2,640.00
$660,000.
00
$6,600.00
$1,408.00
$677,490.00
$2,013,330.00
Recovery Column Purchased Cost:

Material
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Control
Piping
Factor, % in
PC
5
4
3
1
6
8
30
Painting
Miscellaneous
0.5
4
$350,000.00
Labor
Material
Factor, % in
Cost
MC
$17,500.00
133
$14,000.00
50
$10,500.00
100
$3,500.00
150
$21,000.00
40
Labor Cost
$28,000.00
$105,000.0
0
$17,500.00
$14,000.00
$231,000.00
75
50
$21,000.00
$52,500.00
300
80
$52,500.00
$11,200.00
$191,625.00
$422,625.00
Benzene Column Purchased Cost:

Material
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Control
Piping
Factor, % in
PC
5
4
3
1
6
Painting
Miscellaneous
$23,275.00
$7,000.00
$10,500.00
$5,250.00
$8,400.00
8
30
0.5
4
$38,000.00
Labor
Material
Factor, % in
Cost
MC
$1,900.00
133
$1,520.00
50
$1,140.00
100
$380.00
150
$2,280.00
40
$3,040.00
$1,140,000.
00
$1,900.00
$1,520.00
$1,153,680.00
75
50
300
80
Labor
Cost
$2,527.00
$760.00
$1,140.00
$570.00
$912.00
$2,280.00
$570,000.
00
$5,700.00
$1,216.00
$585,105.00
$1,738,785.00
Toluene Column Purchased Cost:

Material
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Control
Piping
Painting
Miscellaneous
$40,000.00
Labor
Factor, %
in PC
5
4
3
1
6
Material Cost
8
30
$3,200.00 75
$1,200,000.00 50
0.5
4
$2,000.00 300
$1,600.00 80
$1,214,400.00
$2,000.00
$1,600.00
$1,200.00
$400.00
$2,400.00
Factor, % in
MC
133
50
100
150
40
$1,830,300.00
Xylene Column Purchased Cost:
$38,000.00
Labor
Material
Factor, % in
PC
5
4
3
1
6
Painting
Miscellaneous
$2,660.00
$800.00
$1,200.00
$600.00
$960.00
$2,400.00
$600,000.0
0
$6,000.00
$1,280.00
$615,900.00
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Control
Piping
Labor Cost
8
30
0.5
4
Material
Factor, % in
Cost
MC
$1,900.00
133
$1,520.00
50
$1,140.00
100
$380.00
150
$2,280.00
40
$3,040.00
$1,140,000.
00
$1,900.00
$1,520.00
$1,153,680.00
75
50
300
80
Labor
Cost
$2,527.00
$760.00
$1,140.00
$570.00
$912.00
$2,280.00
$570,000.
00
$5,700.00
$1,216.00
$585,105.00
$1,738,785.00
Heat Exchanger Purchased Cost:
$20,000.00
Labor
Material
Factor
Foundation
5
Structural Steel
4
Process Building
3
Insulation
1
6
8
Piping
30
Painting
0.5
Miscellaneous
4
Cost
$1,000.00
$800.00
$600.00
$200.00
$1,200.00
$1,600.00
$6,000.00
$1,000.00
$800.00
$13,200.00
Factor
133
50
100
150
40
75
50
300
80
$24,150.00
Pump Purchased Cost:

Material
Factor
Foundation
5
Structural Steel
4
Process Building
3
Insulation
1
6
8
Piping
30
Painting
0.5
Miscellaneous
4
Cost
$1,330.00
$400.00
$600.00
$300.00
$480.00
$1,200.00
$3,000.00
$3,000.00
$640.00
$10,950.00
Cost
Factor
$1835.00 133
$1468.00
50
$1101.00 100
$367.00 150
$2202.00
40
$2936.00
75
$11010.00
50
$1835.00 300
$1468.00
80
$24,222.00
$36,700.00
Labor
Cost
$2,440.00
$734.00
$1101.00
$5505.00
$880.8.00
$2202.00
$5505.00
$5505.00
$1174.4.00
$20,093.7
$44,315.25
Storage Vessel Purchased Cost:
$101,300.00
Labor
Material
Factor
Cost
Foundation
5
$5,065.00
Structural Steel
4
$4,052.00
Process Building
3
$3,039.00
Insulation
1
$1,013.00
6
$6,078.00
8
$8,104.00
Piping
30
$30,390.00
Painting
0.5
$5,065.00
Miscellaneous
4
$4,052.00
$66,858.00
Factor
133
50
100
150
40
75
50
300
80
$122,319.8
Cooler Purchased Cost:
$120,000.00
Labor
Material
Foundation
Structural Steel
Process Building
Insulation
Piping
Painting
Miscellaneous
Cost
$6,736.45
$2,026.00
$3,039.00
$1,519.50
$2,431.20
$6,078.00
$15,195.00
$15,195.00
$3,241.60
$55,461.75
Factor
Cost
5
$6,000.00
4
$4,800.00
3
$3,600.00
1
$1,200.00
6
$7,200.00
8
$9,600.00
30
$36,000.00
0.5
$6,000.00
4
$4,800.00
$79,200.00
Factor
133
50
100
150
40
75
50
300
80
Cost
$7,980.00
$2,400.00
$3,600.00
$1,800.00
$2,880.00
$7,200.00
$18,000.00
$18,000.00
$3,840.00
$65,700.00
$144,900.00
Boiler Purchased Cost:
$60,000.00
Labor
Material
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Control
Piping
Painting
Miscellaneous
Factor
5
4
3
1
6
8
30
0.5
4
Cost
$3,000.00
$2,400.00
$1,800.00
$600.00
$3,600.00
$4,800.00
$18,000.00
$3,000.00
$2,400.00
$39,600.00
Factor
133
50
100
150
40
Cost
$3,990.00
$1,200.00
$1,800.00
$900.00
$1,440.00
75
50
300
80
$3,600.00
$9,000.00
$9,000.00
$1,920.00
$32,850.00
$72,450.00
CAPITAL EXPENDITURES
Expenditures
Storages
Process Building
Ancillary Buildings
Site Development
Design and Engineering
Contractors Fee
Taxation
Land Cost
Offloading Facility
Fire Fighting
Quantity
50% PEC
25% PEC
30 % PEC
30% PEC
25% PEC
10% PEC
10% PEC
52000 square meter
TOTAL
Cost
$834,900.00
$417,450.00
$500,940.00
$500,940.00
$417,450.00
$166,980.00
$166,980.00
$3,006,120.00
$1,187,319.48
$1,700,00.00
$7,199,079.48
OPERATING EXPENDITURES
Expenditures
Raw Materials
TEG Solvent
Operating Labor
Maintenance, repairs and
contingency
Laboratory Testing
Office Supply/expenses
Legal fees
Insurance
Supervision
Local Taxes
Miscellaneous Maintenance
Plant Overheads
Electricity
Cooling Water
Steam for heating
Quantity
337.12$/ton
$0.04 per lb
47 persons
10% of Capital Expenditure
Cost
$48,828,460.8
$44,013,997.94
$1,107,600.00
$166,980.00
25% of Labor
5% of Labor
25% of Labor
50 % Labor
$276,900.00
$83,490.00
$55,380.00
$83,490.00
$276,900.00
$83,490.00
$83,490.00
$553,800.00
$1,300,000.00
$250,000.00
$300,000.00
$97,656,514.74
TOTAL:
Extraction Column
Stripping Column
Clay Treater Column (2)
Recovery Column
Benzene Column
Toluene Column
Xylene Column
Heat Exchanger
Cooler
Pump
Storage Vessel
Boiler
TOTAL
$11,439,375.00
$20,590,875.00
$2,013,330.00
$422,625.00
$1738785.00
$1,830,300.00
$1738785.00
$24,150.00
$24,150.00
$144,900.00
$122,319.8
$72,450.00
$40,162,044.80
Expenditures
Installed equipment Cost
Storages
Process Building
Ancillary Buildings
Site Development
Contractors Fee
Taxation
Land Cost
Offloading Facility
Fire Fighting
Quantity
50% PEC
25% PEC
30 % PEC
30% PEC
25% PEC
10% PEC
10% PEC
52,000 square meter
TOTAL
Cost
$40,162,044.80
$834,900.00
$417,450.00
$500,940.00
$500,940.00
$417,450.00
$166,980.00
$166,980.00
$3,006,120.00
$1,187,319.48
$1,700,00.00
$47,361,124.28
ECONOMIC INDICATORS
Cash Inflows:
Product
Benzene
Toluene
Xylene
Paraffin
C9 aromatics
PRICE (per ton)

Production
$1,014.00 17,461,070.33 kg/hr
$698.00
78,553,122 kg/hr
$1,602.00 12,305,071.34 kg/hr
$318.00
5,214,200 kg/hr
$324.00 8,153,093.868 kg/hr
TOTAL
Production per year

$17,705,525.00
$54,830,079.16
$19,712,724.00
$16,581,283.20
$2,641,602.413
$111,471,213.77
Total Project Cost = Capital Expenditure

= $47,361,124.28
Income Tax:
Indonesias income tax for Foreign Industrial Company is 25%.
Net Income = Taxable Income x 0.75
= $111,471,213.77 x 0.75
= $83,603,410.33
Net cash inflows = net income operating cost

= $83,603,410.33- $97,656,,514.74
= $14,410,650.84
Payback Period = capital cost / net cash inflows

= $47,361,124.28 / $14,410,650.84
= 3.29 years
Net Present Value = Total capital investment

Net Present Value =
=

(1 + )
$14,410,650.84x10
(1+0.05)10
$47,361,124.28
= $ 41,107,771.15
Rate of Return
=

100%

14,410,650.84
100%
$47,361,124.28
= 30.43%
DESIGN OPTION 2
DETAILED EQUIPMENT COSTS
Distillation Column Purchased Cost:
Material
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Control
Piping
Painting
Miscellaneous
Factor, %
in PC
5
4
3
1
6
8
30
0.5
4
Material Cost
$48,896.73
$39,117.39
$29,338.04
$9,779.35
$58,676.08
$78,234.77
$293,380.34
$4,889.67
$39,117.38
$601,429.78
$ 977,934.60
Labor
Factor,
% in MC
133
50
100
150
40
75
50
300
80

Material
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Control
Piping
Painting
Miscellaneous
$65,032.65
$19,558.69
$29,338.04
$14,669.02
$23,470.43
$58,676.08
$146,690.20
$14,669.02
$31,293.91
$403,398.02
$ 1,982,762.40
$ 456,369.48
Labor
Factor
5
4
3
1
6
Cost
$22,818.47
$18,254.78
$13,691.08
$4,563.69
$27,382.17
Factor
133
50
100
150
40
8
30
0.5
4
$36,509.56
$136,910.84
$2,281.85
$18,254.78
$280,667.23
75
50
300
80
Cost
Cost
$30,348.57
$9,127.39
$13,691.08
$6,845.54
$10,952.87
$27,382.17
$68,455.42
$6,845.54
$14,603.82
$188,252.41
$ 925,289.12
Benzene Fractionation Column Purchased Cost:

Material
Foundation
Structural Steel
Process Building
Insulation
Piping
Painting
Miscellaneous
Factor
5
4
3
1
6
8
30
0.5
4
Cost
$12,933.8038
$10,347.04304
$7,760.282277
$2,586.760759
$15,520.56455
$20,694.08607
$77,602.82277
$1,293.38038
$10,347.04304
$159,085.7867
Toluene Fractionation Column Purchased Cost:

Material
Foundation
Structural Steel
Process Building
Insulation
Piping
Painting
Miscellaneous
Factor
5
4
3
1
6
8
30
0.5
4
Cost
$12,281.8475
$9,825.478
$7,369.1085
$2,456.3695
$14,738.217
$19,650.956
$73,691.085
$1,228.18475
$9,825.478
$151,066.7243

$498,028.9161
$ 258676.08
Labor
Factor
Cost
133
$17,201.96
50
$5,173.522
100
$7,760.282
150
$3,880.141
40
$6,208.226
75
$15,520.56
50
$38,801.41
300
$3,880.141
80
$8,277.634
$106,703.8813
$ 524,465.7439
$ 245,636.95
Labor
Factor
Cost
133
$16,334.86
50
$4,912.739
100
$7,369.109
150
$3,684.554
40
$5,895.287
75
$1,4738.22
50
$36,845.54
300
$3,684.554
80
$7,860.382
$101,325.2419
Xylene Fractionation Column Purchased Cost:

Material
Foundation
Structural Steel
Process Building
Insulation
Piping
Painting
Miscellaneous
$ 239117.38
Labor
Factor
Cost
5
$11,955.8692
4
$9,564.695356
3
$7,173.521517
1
$2,391.173839
6
$14,347.04303
8
$19,129.39071
30
$71,735.21517
0.5
$1,195.58692
4
$9,564.695356
$147057.1911
Heat Exchanger Cooler Purchased Cost:

Material
Foundation
Structural Steel
Process Building
Insulation
Piping
Painting
Miscellaneous
Factor
Cost
133
$15,901.31
50
$4,782.348
100
$7,173.522
150
$3,586.761
40
$5,738.817
75
$14,347.04
50
$35,867.61
300
$3,586.761
80
$7,651.756
$98,635.92086
$484,810.4959
$ 339,017.3275
Labor
Factor
Cost
5
$16,950.86638
4
$13,560.6931
3
$10,170.51983
1
$3,390.173275
6
$20,341.03965
8
$27,121.3862
30
$101,705.1983
0.5
$1,695.086638
4
$13,560.6931
$208495.6564
Factor
Cost
133
$22,544.65
50
$6,780.347
100
$10,170.52
150
$5,085.26
40
$8,136.416
75
$20,341.04
50
$50,852.6
300
$5,085.26
80
$10,848.55
$139844.6476
$ 687357.6315

Material
Foundation
Structural Steel
Process Building
Insulation
Piping
Painting
Miscellaneous
$41725.20958
Labor
Factor
Cost
5
$2086.260479
4
$1669.008383
3
$1251.756287
1
$417.2520958
6
$2503.512575
8
$3338.016766
30
$12517.56287
0.5
$208.6260479
4
$1669.008383
25661.00389
Vessel Purchased Cost:

Material
Foundation
Structural Steel
Process Building
Insulation
Piping
Painting
Miscellaneous
$ 122567.80
Labor
Factor
Cost
5
$6128.39015
4
$4902.71212
3
$3677.03409
1
$1225.67803
6
$7354.06818
8
$9805.42424
30
$36770.3409
0.5
$612.839015
4
$4902.71212
75379.19885

Material
Factor Cost
133
$2774.726
50
$834.5042
100
$1251.756
150
$625.8781
40
$1001.405
75
$2503.513
50
$6258.781
300
$625.8781
80
$1335.207
17211.64895
$ 84597.86242
Factor
Cost
133
$8150.759
50
$2451.356
100
$3677.034
150
$1838.517
40
$2941.627
75
$7354.068
50
$18385.17
300
$1838.517
80
$3922.17
50559.21874
$ 248506.2206
$ 521565.1191
Labor
Foundation
Structural Steel
Process Building
Insulation
Piping
Painting
Miscellaneous
Factor Cost
5
26078.25596
4
20862.60476
3
15646.95357
1
5215.651191
6
31293.90715
8
41725.20953
30
156469.5357
0.5
2607.825596
4
20862.60476
320762.5482
Factor Cost
133
34684.08
50
10431.3
100
15646.95
150
7823.477
40
12517.56
75
31293.91
50
78234.77
300
7823.477
80
16690.08
215145.6116
$ 1061473.279

Distillation Column
1982762.40
Stripping Column
925289.12
Benzene Fractionation Column
524465.7439
Toluene Fractionation Column
498028.9161
Xylene Fractionation Column
484810.4959
Heat Exchanger
687357.6315
Pump
84597.86242
Vessel
248506.2206
Boiler
1061473.279
TOTAL
$ 6497291.67
CAPITAL EXPENDITURE
Total Capital Expenditure
Installed equipment Cost
Storages
Ancillary Buildings
Site Development
Contractors Fee
Taxation
Land Cost
Offloading Facility
50% PEC
25% PEC
25% PEC
10% PEC
5% PEC
57.81 $/ m2
6497291.67
2,070,673.68
1,035,336.85
1,035,336.84
414,134.74
207,067.34
3,006,120.00
1187319.48
Fire Fighting
1,000,000.00
$ 16453280.6
TOTAL
OPERATION EXPENDITURE
MATERIAL
Raw materials
NFM Solvent
Operating Labor
Maintenance, repairs
and Contingency
Laboratory Testing
Office Expenses/supply
QUANTITY
307.12 $/ton
$500/ton
50 persons
10% of Capital
Expenditure
25% of Labor
5% of Capital
Expenditure
5% Labor
5% of Capital
Expenditure
25% Labor
5% of Capital
Expenditure
5% of Capital
Expenditure
50% Labor
Legal fees
Insurance
Supervision
Local Taxes
Miscellaneous
Plant Overheads
Electricity
Cooling water
Steam for heating
TOTAL
COST
44875760.16
9389625
4,055,555.56
2,393,511.58
1,013,888.89
1,196,755.79
202,777.78
1,196,755.79
1,013,888.89
1,196,755.79
1,196,755.79
2,027,777.79
1,500,000.00
300,000.00
500,000.00
$ 72059808.81
ECONOMIC INDICATORS
Cash Inflows:
Product
Benzene
Toluene
Xylene
Paraffin
C9 aromatics
TOTAL
Cost per ton

1014
698
1602
318
324

= $16453280.60
Thousand tons
per year
16294.074
75221.0352
11782.99
28601.04
10993.782
Total Cost
16522191.04
52504282.57
18876349.98
9095130.72
3561985.368
$ 100559939.7
Income Tax:
Net Income = Taxable Income x0.75
= 100559939.7 x 0.75
= $ 75419954.78
= 75419954.78 - 72059808.81
= $ 3360145.97

= 16453280.6 / 3360145.97
= 4.90 years
Net Present Value =

=

(1 + )
3360145.97 10
(1+0.05)10
16453280.6
= $ 4175100.85
=
=

100%

3360145.97
100%
16453280.6
= 20.42%
DESIGN OPTION 3
EQUIPMENT
Pump (1)
Packed Bed Column
Cooler (1)
Wash Column
COST
$4,000.00
$250,000.00
$20,000.00
$100,000.00
Stripping Column
Pump (2)
Cooler (2)
Separator (1)
Water Separator
Regenerator
Pump (3)
Recovery Column
Pump (4)
Cooler (3)
Separator (2)
Pump (5)
Pump (6)
Cartridge (2 columns)
Pump (6)
Benzene Column
Cooler (4)
Pump (7)
Toluene column
Cooler (5)
Pump (6)
Xylene column
Cooler (6)
Pump (8)
Cooler (7)
Vessel A
Vessel B
Boiler
TOTAL
$450,000.00
$2,500.00
$20,000.00
$100,000.00
$100,000.00
$150,000.00
$2,000.00
$350,000.00
$2,500.00
$20,000.00
$50,000.00
$2,500.00
$2,500.00
$44,000.00
$2,100.00
$38,000.00
$20,000.00
$2,100.00
$40,000.00
$20,000.00
$2,100.00
$38,000.00
$20,000.00
$3,800.00
$20,000.00
$9,800.00
$11,000.00
$20,000.00
$2,178,900.00
Expenditures
Storages
Process Building
Ancillary Buildings
Site Development
Contractors Fee
Taxation
Land Cost
Offloading Facility
Fire Fighting
Quantity
50% PEC
25% PEC
30 % PEC
30% PEC
25% PEC
10% PEC
10% PEC
52000 square meter
TOTAL
Cost
$1,089,450.00
$544,725.00
$653,670.00
$653,670.00
$544,725.00
$217,890.00
$217,890.00
$3,006,120.00
$1,187,319.48
$1,700,00.00
$8,115,459.48
OPERATING EXPENDITURES
Expenditures
Raw Materials
Sulfolane Solvent
Utilities
Quantity
337.12$/ton
$1.30 per kg
10% of Capital
Expenditure
10% of Capital
Expenditure
25% of Capital
Expenditure
25% of Labor
45% of Capital
Expenditure
5% of Labor
50% of Capital
Expenditure
10% of Capital
Expenditure
47 persons
15% of Labor
5% of Capital
Expenditure
5% of Capital
Expenditure
Miscellaneous
License Fees
Laboratory Testing
Office Supply/expenses
Legal fees
Transportation of products
Maintenance and Repairs
Operating Labor
Supervision
Insurance
Property Taxes
Miscellaneous Maintenance
Overhead Labor
Cost
$44,520,067.20
$130,021.00
$217,890.00
$217,890.00
$544,725.00
$544,725.00
$980,505.00
$108,945.00
$1,089,450.00
$217,890.00
$1,107,600.00
$326,835.00
$108,945.00
$108,945.00
$32,896.00
$108,945.00
$50,366,274.20
50 %of Labor
TOTAL:
Extraction Column Purchased Cost:
$250,000.00
Material
Factor
Foundation
Structural Steel
Process Building
Insulation
5
4
3
1
6
8
Labor
Cost
$12,500.00
$10,000.00
$7,500.00
$2,500.00
$15,000.00
$20,000.00
Factor
133
50
100
150
40
75
Cost
$16,625.00
$5,000.00
$7,500.00
$3,750.00
$6,000.00
$15,000.00
Piping
Painting
Miscellaneous
30
0.5
4
$7,500,000.00 50
$12,500.00 300
$10,000.00 80
$7,590,000.00
$3,750,000.00
$37,500.00
$8,000.00
$3,849,375.00
$11,439,375.00
Wash Column Purchased Cost:
$100,000.00
Material
Factor
Foundation
Structural Steel
Process Building
Insulation
Piping
Painting
Miscellaneous
5
4
3
1
6
8
30
0.5
4
Labor
Cost
Factor
$5,000.00
$4,000.00
$3,000.00
$1,000.00
$6,000.00
$8,000.00
$30,000.00
$5,000.00
$4,000.00
$66,000.00
Cost
133
50
100
150
40
75
50
300
80
$120,750.00
Regenerator Column Purchased Cost:
$150,000.00
Material
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Factor, % in
PC
5
4
3
1
6
$6,650.00
$2,000.00
$3,000.00
$1,500.00
$2,400.00
$6,000.00
$15,000.00
$15,000.00
$3,200.00
$54,750.00
Labor
Material
Cost
$17500.00
$14000.00
$10500.00
$3500.00
$21000.00
Factor, % in
MC
133
50
100
150
40
Labor
Cost
$23275.00
$7000.00
$10500.00
$5250.00
$8400.00
Control
Piping
Painting
Miscellaneous
8
30
0.5
4
$28000.00
$105000.00
$17500.00
$14000.00
$231000.00
75
50
300
80
$21000.00
$52500.00
$52500.00
$11200.00
$191625.00
$422,625.00
$450,000.00
Material
Labor
Factor, % in
Material
Factor, % in
PC
Cost
MC
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Control
Piping
5
4
3
1
6
Painting
Miscellaneous
0.5
4
8
30
$22,500.00
$18,000.00
$13,500.00
$4,500.00
$27,000.00
$36,000.00
$13,500,000
.00
$22,500.00
$18,000.00
$13,662,000.00
133
50
100
150
40
75
50
300
80
$29,925.00
$9,000.00
$13,500.00
$6,750.00
$10,800.00
$27,000.00
$6,750,000
.00
$67,500.00
$14,400.00
$6,928,875.00
$20,590,875.00
Separator Column Purchased Cost:
$150,000.00
Material
Factor, % in
Labor Cost
Labor
Material
Factor, % in Labor Cost
PC
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Control
Piping
Painting
Miscellaneous
5
4
3
1
6
8
30
0.5
4
Cost
$7,500.00
$6,000.00
$4,500.00
$1,500.00
$9,000.00
$12,000.00
$45,000.00
$7,500.00
$6,000.00
$99,000.00
MC
133
50
100
150
40
$9,975.00
$3,000.00
$4,500.00
$2,250.00
$3,600.00
$9,000.00
$22,500.00
$22,500.00
$4,800.00
$82,125.00
75
50
300
80

$181,125.00
Recovery Column Purchased Cost:
$350,000.00
Material
Factor, % in
PC
Foundation
5
Structural Steel
4
Process Building
3
Insulation
1
Instrumentation and 6
Control
Electrical
8
Installation
Piping
30
Painting
0.5
Miscellaneous
4

$422,625.00
Labor
Material
Cost
$17,500.00
$14,000.00
$10,500.00
$3,500.00
Factor, % in
MC
133
50
100
150
40
$21,000.00
75
$28,000.00
$105,000.00 50
$17,500.00 300
$14,000.00 80
$231,000.00
Labor Cost
$23,275.00
$7,000.00
$10,500.00
$5,250.00
$8,400.00
$21,000.00
$52,500.00
$52,500.00
$11,200.00
$191,625.00
Clay Treater Column Purchased Cost (2):
$44,000.00
Material
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Control
Piping
Painting
Miscellaneous
Factor, % in
PC
5
4
3
1
6
8
30
0.5
4
Labor
Material
Cost
$2,200.00
$1,760.00
$1,320.00
$440.00
$2,640.00
$3,520.00
$1,320,000.
00
$2,200.00
$1,760.00
$1,335,840.00
Factor, % in
MC
133
50
100
150
40
$1,056.00
$2,640.00
$660,000.
00
$6,600.00
$1,408.00
$677,490.00
75
50
300
80
Labor
Cost
$2,926.00
$880.00
$1,320.00
$660.00
$2,013,330.00
Benzene Column Purchased Cost:

Material
$38,000.00
Labor
Factor, % in
Material
Factor, % in
Labor
PC
Cost
MC
Cost
133
50
100
150
40
$2,527.00
$760.00
$1,140.00
$570.00
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Control
Piping
5
4
3
1
6
Painting
Miscellaneous
0.5
4
8
30
$1,900.00
$1,520.00
$1,140.00
$380.00
$2,280.00
$3,040.00
$1,140,000.
00
$1,900.00
$1,520.00
75
50
300
80
$912.00
$2,280.00
$570,000.
00
$5,700.00
$1,216.00
$1,153,680.00
$585,105.00
$1738785.00
Toluene Column Purchased Cost:

Material
$40,000.00
Labor
Factor, % in
Material
Factor, % in
Labor
PC
Cost
MC
Cost
133
50
100
150
40
$2,660.00
$800.00
$1,200.00
$600.00
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Control
Piping
5
4
3
1
6
$2,000.00
$1,600.00
$1,200.00
$400.00
Painting
Miscellaneous
0.5
4
$1,214,400.00
8
30
$2,400.00
$3,200.00
$1,200,000.
00
$2,000.00
$1,600.00
75
50
300
80
$615,900.00
$1,830,300.00
Xylene Column Purchased Cost:

Material
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Factor, %
in PC
5
4
3
1
6
$960.00
$2,400.00
$600,000.
00
$6,000.00
$1,280.00
$38,000.00
Labor
Material Cost
$1,900.00
$1,520.00
$1,140.00
$380.00
$2,280.00
Factor,
% in MC
133
50
100
150
40
Labor Cost
$2,527.00
$760.00
$1,140.00
$570.00
$912.00
Control
Piping
Painting
Miscellaneous
8
30
0.5
4
$3,040.00
$1,140,000.00
$1,900.00
$1,520.00
$1,153,680.00
75
50
300
80
$2,280.00
$570,000.00
$5,700.00
$1,216.00
$585,105.00

$1738785.00
Cooler Purchased Cost:
$140,000.00
Material
Factor
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Control
Piping
Painting
Miscellaneous
5
4
3
1
6
8
30
0.5
4
Labor
Cost
$7,000.00
$5,600.00
$4,200.00
$1,400.00
$8,400.00
$11,200.00
$42,000.00
$7,000.00
$5,600.00
$92,400.00
Factor
Cost
133
50
100
150
40
$9,310.00
$2,800.00
$4,200.00
$2,100.00
$3,360.00
$8,400.00
$21,000.00
$21,000.00
$4,480.00
$76,650.00
75
50
300
80
Installed Equipment
Cost
$169,050.00
$26,100.00
Material
Factor
Labor
Cost
Factor
Cost
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Control
Piping
Painting
Miscellaneous
5
4
3
1
6
8
30
0.5
4
$1,305.00
$1,044.00
$783.00
$261.00
$1,566.00
$2,088.00
$7,830.00
$1,305.00
$1,044.00
$17,226.00
133
50
100
150
40
$1,735.65
$522.00
$783.00
$391.50
$626.40
$1,566.00
$3,915.00
$3,915.00
$835.20
$14,289.75
75
50
300
80
Installed Equipment
Cost
$31,515.75
Storage Vessel Purchased Cost:
$20,000.00
Material
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Control
Piping
Painting
Miscellaneous
Installed Equipment
Labor
Factor
Cost
Factor
5
4
3
1
6
$1,000.00
$800.00
$600.00
$200.00
133
50
100
150
40
8
30
0.5
4
$1,200.00
$1,600.00
$6,000.00
$1,000.00
$800.00
$13,200.00
75
50
300
80
Cost
$1,330.00
$400.00
$600.00
$300.00
$480.00
$1,200.00
$3,000.00
$3,000.00
$640.00
$10,950.00
$24.150.00
Cost
$20,000.00
Material
Foundation
Structural Steel
Process Building
Insulation
Instrumentation and
Control
Piping
Painting
Miscellaneous
Labor
Factor
Cost
Factor
5
4
3
1
6
$1,000.00
$800.00
$600.00
$200.00
133
50
100
150
40
8
30
0.5
4
$1,200.00
$1,600.00
$6,000.00
$1,000.00
$800.00
$13,200.00
75
50
300
80
Installed Equipment
Cost
Cost
$1,330.00
$400.00
$600.00
$300.00
$480.00
$1,200.00
$3,000.00
$3,000.00
$640.00
$10,950.00
$24.150.00

Extraction Column
Wash Column
Regenerator Column
Stripping Column
Separator Column
Recovery Column
Clay Treater Column (2)
Benzene Column
Toluene Column
Xylene Column
Cooler
Pump
Storage Vessel
Boiler
TOTAL
$11,439,375.00
$120,750.00
$422,625.00
$20,590,875.00
$181,125.00
$422,625.00
$2,013,330.00
$1738785.00
$1,830,300.00
$1738785.00
$169,050.00
$31,515.75
$24.150.00
$24.150.00
$40,699,140.75
Total Capital Expenditure

Installed equipment
Cost
Storages
Process Building
Ancillary Buildings
Site Development
Design and
Engineering
Contractors Fee
Taxation
Land Cost
Offloading Facility
Fire Fighting
$40,699,140.75
50% PEC
25% PEC
30 % PEC
30% PEC
25% PEC
10% PEC
10% PEC
52000 square meter
TOTAL
$1,089,450.00
$544,725.00
$653,670.00
$653,670.00
$544,725.00
$217,890.00
$217,890.00
$3,006,120.00
$1,187,319.48
$1,700,00.00
$48,814,600.23
ECONOMIC INDICATORS
Cash Inflows:
Product
Benzene
Toluene
Xylene
Paraffin
C9 aromatics
PRICE (per ton)

$1014.00
$698.00
$1602.00
$318.00
$324.00
Production
Production per year
16663363.2 kg/hr
74964528 kg/hr
11742883.2 kg/hr
14732928 kg/hr
5440608 kg/hr
TOTAL
$16,896,650.28
$52,325,240.54
$18,812,098.89
$4,685,071.10
$1,762,756.99
$94,481,817.81

= $48,814,600.23
Income Tax:
Net Income = Taxable Income x 0.75
= $94,481,817.81 x 0.75
= $70,861,363.36
= $70,861,363.36 - $50,366,274.20
= $20,495,089.16
= $48,814,600.23/$20,495,089.16
= 2.39 years
Net Present Value = Total capital investment
Net Present Value =

(1 + )
$20,495,089.16x10
(1+0.05)10
$48,814,600.23
= $77,007,468.45
Rate of Return

100%

$20,495,089.16
100%
$48,814,600.23
=41.96%
CHAPTER VI
ENVIRONMENTAL MANAGEMENT
Environment sustainability is a one of the realistic constraints to be considered
in the design of the Benzene, Toluene and Xylene Manufacturing Plant. The BTX
plant should not be technically and economically feasible but be an aid in the
growth of the environment and community. An environment impact assessment
(EIA) was developed to determine potential impacts and identification of
procedures that may be used to mitigate these effects. The BTX manufacturing
plant, through the EIA, aims in the optimization of positive impacts and minimizing
negative impacts resulting from the proposed project.
A. General Information
Table 11. General Information of the Project
Title of the Project:
Benzene, Toluene and Xylene (BTX) Manufacturing

Plant
Type of Project:
The project is under the oil and gas downstream sector,

specifically, the petrochemical industry. The proposed
project will be processing naphtha reformate into
benzene, toluene and xylene.
B. Applicable Legislation, Conventions and Requirements

Table 12. Indonesia Quality standards for Petroleum and Petrochemical Refinery
Emission
Source
Fuel
Catalytic cracking unit
Heater, boiler process
Oil
Gas
Flare stack
All source (except flare stack)
Gas Turbine
Gas
Oil
Parameter
particulate
Sulphur dioxide
Nitrogen oxide
hydrocarbon
Particulate
Sulphur dioxide
Nitrogen oxide
opacity
Nitrogen oxide
Opacity
opacity
opacity
Nitrogen oxide
Nitrogen oxide
Emission
Quality
Standard unit:
mg/Nm3
400
1500
1000
200
300
1200
1400
40%
400
40%
40%
40%
400
600
Note :
Gas Volume is in standard condition (25C and 1 atm)
Opacity is used as monitoring practical indicator
Combustion with oil and gas fuel. O2 correction is 3%
Quality standards of emission is applied for 95% normal operation time for 3
months.
Table 13. Quality Standard of Wastewater Disposal Processes of Petroleum

Processing Activities (Baku Mutu Pembuangan Air Limbah Proses Dari
Kegiatan Pengolahan Minyak Bumi)
Parameter
BOD 5
COD
Minyak dan
Lemak (Oils and
Fats)
Dissolved
sulphides
Ammonia (as
NH3-N)
Phenol Total
Temperature
pH
Liquid waste
volume per
maximum raw
material volume
Max.
Content
(mg/L)
80
160
Max
contamination
Load (gram/m3)
80
160
20
20
0.5
0.5
0.8
45 C
6-9
1000
0.8
per 1000m3 feed
measurement method
methode pengukuran
SNI 06-2503-1991
SNI 06-6989.2-2004 atau
SNI 06-6989.15-2004 atau
APHA 5220
SNI 06-6989.10-2004
SNI 06-2470-1991 atau

APHA 4500 S2
SNI 06-6989.30-2005 atau
APHA 4500-NH3
SNI 06-6989.21-2005
SNI 06-6989.23-2005
SNI 06-6989.11-2004
Table 14. Quality Standard Drainage of Waste Water Disposal And Water
Coolers Petroleum Processing Activities (Baku Mutu Pembuangan Air
Limbah Drainase Dan Air Pendingin Kegiatan Pengolahan Minyak Bumi)
Jenis Air Limbah parameter
Max
measurement method
The Type Of
content methode pengukuran
Waste Water
(mg/L)
Drainage liquid
Oil and grease
15
SNI 06-6989.10-2004
waste
Total organic
110
SNI 06-6989.28-2005
carbon
Cooler liquid
Chlorine residue
2
Standard method 4500-Cl
m
Total organic
4.5
SNI 06-6989.28-2005 atau
carbon
APHA 5310
Note:
If drainage liquid waste mix with processing liquid waste, the mixed liquid waste
should meet quality standard of processing liquid waste disposal process.
Calculation is based on difference between outlet and inlet.
Table 15. Appendix III Indonesian Government Regulation Number 101 Year
2014 On The Management Of Hazardous And Toxic Waste. Quality Standard
Features on TCLP For Determination Of Toxic Waste Category B3.
ZAT PENCEMAR contaminants
TCLP-A
TCLP-B
Satuan (berat kering) Unit ( dry weight )

PARAMETER WAJIB MANDATORY PARAMETERS
ANORGANIK (inorganic)
Antimoni, Sb
Arsen, As
Barium, Ba
Berilium, Be
Boron, B
Kadmium, Cd
Krom valensi enam, Cr6+
Tembaga, Cu
Timbal, Pb
Merkuri, Hg
Molibdenum, Mo
Nikel, Ni
Selenium, Se
Perak, Ag
Tributyltin oxide
Seng, Zn
ANION
Klorida, ClSianida (total), CNFluorida, FIodida, INitrat, NO3Nitrit, NO2ORGANIK (organic)
Benzena (benzene)
Benzo(a)pirena Benzo ( a) pyrene
Karbon tetraklorida carbon tetrachloride
(mg/L)
(mg/L)
6
3
210
4
150
0,9
15
60
3
0,3
21
21
3
40
0,4
300
1
0,5
35
0,5
25
0,15
2,5
10
0,5
0,05
3,5
3,5
0,5
5
0,05
50
75000
21
450
40
15000
900
12500
3,5
75
5
2500
150
3
0,004
1,2
0,5
0,0005
0,2
1. Klorobenzena chlorobenzene
Kloroform chloroform
120
15
24
2 Klorofenol chlorophenol
Kresol (total) cresol
120
800
5
100
Di (2 etilheksil) ftalat diethylhexyl ) phthalate
2,4
0,4
300
90
15
12
6
50
15
2,5
3
1
80
0,52
90
180
10
0,065
15
30
Formaldehida formaldehyde
Heksaklorobutadiena hexabutadiene
200
0,18
25
0,03
Metil etil keton methylethyl ketone

Nitrobenzena nitrobenzene
800
8
100
1
Fenol (total, non-terhalogenasi) Phenol (halogenated

Stirena (styrene
56
6
7
1
1,1,1,2-Tetrakloroetana tetrachloroethane
40
1,1,2,2-Tetrakloroetana tetrachloroethane
Tetrakloroetena tetrachloroethane
Toluena Toluene
Triklorobenzena (total) trichlorobenzene
1,1,1-Trikloroetana trichloroethane
1,1,2-Trikloroetana trichloroethane
5,2
20
210
12
120
4,8
0,65
2,5
35
1,5
15
0,6
Trikloroetena trichloroethane
2,4,5-Triklorofenol trichlorophenol
2,4,6-Triklorofenol trichlorophenol
Vinil klorida vinyl chloride
Ksilena (total) xylene
2
1600
8
0,12
150
0,25
200
1
0,015
25
1,2-Diklorobenzena 1,2dichlorobenzene
1,4-Diklorobenzena 1,4 dichlorobenzene
1. 1,2-Dikloroetana 1,2- dichloroethane
1,1-Dikloroetena 1,1-dichloroethane
Diklorometana (metilen klorida) Dichloromethane (
methylene chloride )
1. 2,4-Diklorofenol 2,4 - diklorofenol
2,4-Dinitrotoluena 2,4 - Dinitrotoluene
Etilbenzena ethylbenzene
Ethylene diamine tetra acetic acid (EDTA)
Note:
1. TCLP (Toxicity Characteristic Leaching Procedure).
2. Hazardous waste category 1 (Limbah B3 Kategori 1) is wastes that have
contamination level more than TCLP-A.
3. Hazardous waste category 2 (Limbah B3 Kategori 2) is wastes that have
contamination level more than TCLP-B, and less than/same as TCLP-A
4. For Petroleum refinery wastes, category 1 consists of primary refinery sludge
from gravitational separation during processing or storage, secondary refinery
sludge, residue at the bottom of tank, solid slop.
5. Category 2: used catalysts, used active carbon beside waste with code A110d,
used filters (include clays spent filter), dust from air pollution control facilities.
Table 16. International Conventions Relating To Environmental and Social
Aspects
Year of Signing
Description
Conventions relating to flora and fauna
1992
Convention on Biological
Diversity, Rio de janeiro
1979
Convention on the
conservation of migratory
species of wild animals
1992, new York
United nations framework

convention on climate
change
Kyoto protocol
1997, Kyoto
Conventions on air protection

1987
Vienna convention for the
protection of ozone layer,
Vienna, 1985 and
montreal protocol on
ozone depleting
substances, montreal
Social issues/consultations
1998
Convention on access to
information, public
participation in decision
Comments
Applicable to the Plant
because some
ecosystems are in the
zone affected by the
planned Plant
Applicable because
igration routes of some
migrating animal species
might cross the zone
affected by the proposed
project.
Applicable because the
operation of the project
will cause certain
changes in amounts of
greenhouse gas
emissions.
Applicable because the
operation
Applicable because of the

need to inform the public
about the environmental
making and access to

justice in environmental
matters (Aarhus
convention)
1966
International labour
organization (ILO)
Convention 122
Employment Policy
1977
International labour
organization (ILO)
Convention 142
Occupational orientation
and occupational training
for development of
human resources
Occupational health conventions
1978
ILO Convention 150
labor regualtions: role,
functions and
organization
1949
1923
1950
1959
1963
1979
1983
ILO convention 95
Protection of wages
ILO Convention 14.
weekly rest in industry
ILO Convention 87
Freedom of association
and protection of the right
to organize
ILO convention 105
abolition of forced labor
ILO convention 119
guarding of machinery
ILO convention 148
working environment (air
pollution, noise and
vibration
Ilo convention 155
occupational safety and
health
impact of the project
The convention is
applicable
Applicacble because the

plant pursues training
and development of
potential employees
The convention is
applicable. Measures for
regulation of labor issues
are to be taken at the
national, regional and
local levels, as well as
the level of different
sectors of economic
activities
applicable
applicable
applicable
applicable
applicable
applicable
Covers all sectors of

economic activities and
all employees
Table 17. Main Guidelines from International Financial Institutions

Date of adoption
description
Leading financial and banking organizations
2006
The equator principles
2007
Revised
recommendations of the
organizations for
economic cooperation
and development (OECD)
referring to general
approaches for the
identification and the
assessment for the
identification and the
assessment of
environmental impact in
case of project financing.
Comments
The equator principles are
applied by the worlds
leading financial
organizations to make
decisions relating to
project financing. They
constitute a system of
indicator identification,
assessment and
prevention of potential
environment and social
risks. The principle apply
to all new project
financings with total
project capital costs of
USD 10M or more.
OECD recommendations
are applied by the worlds
leading financial
organizations when
making decisions related
to financing of project with
a repayment period of 2
years and more.
In general, the OECD
recommendations are
similar to the equator
principles regarding key
issues.
C. Project site Description

Table 18. Project Site Description
Location
(7 6'4.32"S 11236'49.09"E) Manyar, gresik

regecy, east java, Indonesia
Site description
entirely vegeatation, facing the shore of Madura

Strait
Existing Land Use
The land is vacant
Infrastructures
Adjacent
industries
Road
LPG Storage PT Maspion Energy

Mitratama
HESS Indonesia-Pangkah Ltd
TPC Indonesia
JL beta Maspion Road
Maximum Land And/Or

Water Area
Source(s) Of Water
5.2 hectares
Quality
Seawater for cooling
Seawater
Demineralized water for cooling and heating

Energy Requirement
Source And the Rate Of
Consumption.
Bunker fuel (oil)
The Type Of Human

Settlements
Socioeconomic Activity
Demography
Culture.
Health And Safety Issues
No nearby human settlements
Employment Issues
Agricultural, industrial
1,177,201 population (2010)
Religion is dominated by Islam
suspected terrorist activity
political demonstrations and protests
petty crimes
natural disaster
5.9 % unemployment rate (2014)
D. Environment- Baseline Data

The baseline data was gathered from environmental information of
Gresnik, East Java and Indonesia. It is important to determine the
environmental baseline data of Gresnik, East Java, Indonesia in order to
establish acceptable environment parameters.
Table 19. Environment- Baseline Data
Topography
Climate
Temperature
Humidity
wind speed
and direction,
seasonal storm data
Water quality
Air quality
Noise
Rain rice field

Dry field
3,856,275 Ha
40,569,786 Ha
Garden
(building
and
business purposes, etc)
Forest
Irrigation reservoir
Lake
Entirely tropical
23C 33C
79%
8 km/h
9,778,637 Ha
5,550,015 Ha
492,160 Ha
169,740 Ha
monsoons from the south and east in June through

September and from the northwest in December
through March
21%
62.31 mcg PM10/nm3
74.14 mcg NO2/nm3
12.6 mcg so2/nm3
70 db (A)
E. Safety and Health

1. Personal protective equipment
Personal Protective Equipment (PPE) is considered to be any device or
appliance designed to be worn or held by an individual for protection against one
or more safety hazards. Indonesian regulation implements the PPE Directive
(89/686/EEC) regulated by European Union. This applies to the safety products
intended for appropriate use within the premises of the proposed plant.
The personal protective equipment are designed and tested for proper use
and application. The first step to check the quality of PPE is to conduct testing to
assess the compliance with relevant test standards. Harmonized standards have
been published for the PPE directive and compliance provides a presumption of
conformity with the Bureau of Health and Safety Regulations of the Directive.
2. Material handling and storage
2.1 Naphtha Reformate
2.1.1 Hazards Identification
Naphtha reformate is classified under EU REGULATION (EC) No.
1272/2008 that can cause skin irritation, aspiration hazard, may be fatal if
swallowed and enters airways, has reproductive toxicity, has suspected of
damaging fertility or the unborn child, germ cell mutagenicity, may cause
genetic defects, carcinogenicity, specific target organ systemic toxicity single exposure, may cause drowsiness or dizziness, chronic aquatic
toxicity, dangerous for the environment
swallowed and harmful by inhalation.
may cause lung damage if
2.1.2. Handling and Storage

Naphtha reformate is highly flammable liquid and vapour. keep away
from open flames, hot surfaces and sources of ignition. take precautionary
measures against static discharges. take necessary action to avoid static
electricity discharge (which might cause ignition of organic vapors).
Extinguish all ignition sources. Containers must be properly grounded
before beginning transfer. Use only non-sparking tools. Check atmosphere
for explosiveness and oxygen deficiencies. Carefully vent any internal
pressure before removing closure.
Observe precautions pertaining to confined space entry. Do not use
compressed air for filling, discharging or handling. Handle empty containers
with care; vapor residue may be flammable/explosive. Decontaminate
containers thoroughly before reuse/disposal. Isolate, vent, drain, wash and
purge systems or equipment before maintenance or repair. All equipment
must conform to applicable electrical code. Do not pressurize, cut, weld,
braze solder, drill, or grind on containers. Use only bottom loading of
tankers, in compliance with European regulations.
2.2 Benzene
2.2.1 Hazard Identification
Benzene is classified according to the GHS-US as a flammable
liquid, acute toxic (oral), skin corrosion/irritant , serious eye damage/eye
irritant, germ cell mutagenic, carcinogenic, specific target organ toxic (single
exposure), specific target organ toxic (repeated exposure) and aspiration

hazard.
2.2.2 Handling and Storage
Benzene residual vapors are flammable so it is advised to handle
empty containers with care. Eliminate all ignition sources if safe to do so. If
heating is necessary for drummed product, loosen or remove bung or lid
before warming/heating product to avoid overpressurization in the drum.
Wash hands and other exposed areas with mild soap and water before
eating, drinking or smoking and when leaving work. Provide good ventilation
in process area to prevent formation of vapor. No bare lights. No smoking.
Use only non-sparking tools. Obtain special instructions before use. Do not
handle until all safety precautions have been read and understood. Use
only outdoors or in a well-ventilated area. Do not breathe vapors, mist. Do
not eat, drink or smoke when using this product. Wash hands, forearms and
face thoroughly after handling.
2.3 Toluene
Prolonged and/or repeated contact to toluene may cause irritation
and/or dermatitis. May be absorbed through the skin. May cause irritation of
the digestive tract. May cause effects similar to those for inhalation
exposure. Aspiration of material into the lungs may cause chemical
pneumonitis, which may be fatal. Inhalation of high concentrations may
cause central nervous system effects characterized by nausea, headache,
dizziness, unconsciousness and coma. Inhalation of vapor may cause

respiratory tract irritation. May cause liver and kidney damage. Vapors may
cause dizziness or suffocation. Overexposure may cause dizziness,
tremors, restlessness, rapid heart beat, increased blood pressure,
hallucinations, acidosis, kidney failure. Prolonged or repeated skin contact
may cause dermatitis. May cause cardiac sensitization and severe heart
abnormalities. May cause liver and kidney damage.
Wash thoroughly after handling. Use with adequate ventilation.
Ground and bond containers when transferring material. Avoid contact with
eyes, skin, and clothing. Empty containers retain product residue, (liquid
and/or vapor), and can be dangerous. Keep container tightly closed. Avoid
contact with heat, sparks and flame. Avoid ingestion and inhalation. Do not
pressurize, cut, weld, braze, solder, drill, grind, or expose empty containers
to heat, sparks or open flames.
Keep away from heat, sparks, and flame. Keep away from sources of
ignition. Store in a tightly closed container. Store in a cool, dry, wellventilated area away from incompatible substances.
2.4 Xylene
Mixed Xylene is classified as a flammable liquid. Other hazards of
xylene include skin corrosion/irritation, serious eye damage/eye irritation,
carcinogenicity, reproductive toxicity, specific target organ toxicity (single

exposure), specific target organ toxicity (single exposure), respiratory
irritation, target organ toxicity (repeated exposure and aspiration hazard.
Handle empty containers with care because residual vapors are
flammable. Wash hands and other exposed areas with mild soap and water
before eating, drinking or smoking and when leaving work. Provide good
ventilation in process area to prevent formation of vapor. No bare lights. No
smoking. Take precautionary measures against static discharge. Use only
non-sparking tools. Use only outdoors or in a well-ventilated area. Avoid
breathing vapors, mist. Obtain special instructions before use. Do not
handle until all safety precautions have been read and understood. Always
wash hands after handling the product. Wash hands, forearms and face
thoroughly after handling.
F. Environmental Impact Assessment

1. Wastewater
Table 20. Wastewater Impact Assessment
Wastewater
Sources
Waste Water Treatment

Process
Potential Impact Risks on

Environment
Raffinate Water Washing

Tank Bottom draining
Contaminated storm water runoff
Leaks and spill
Tanker vehicle washing
Utilities
Rake/defatting
Neutralization
Sedimentation
Activation
Sedimentation
Anaerobic Treatment
Potential damage of tanks due to increased
corrosion from wastewater in tanks.
The plant will implement zero discharge of
wastewater, therefore, no water will be
discharged to aquatic and terrestrial biota.
Potential Impact Risks on

Health and Safety
Wastewater contains pathogenic organisms

similar to those in the original human excreta.
Disease prevention programmes have centred
upon four groups of pathogens potentially
present in such wastes: bacteria, viruses,
protozoa and helminths.
Potential risk of diarrhoea and cholera.Typhoid,
paratyphoid and other Salmonella type
diseases are also caused by bacterial
pathogens.
Also, there is a potential risk of dermal contact
and inhalation from spill sand leaks.
Figure 20. Wastewater Treatment Process
Wastewater effluent will undergo raking and defatting. Raking is a method

widely used
to remove vegetation and dregs from wastewater, Then,
Neutralization takes place. Neutralization involves adding an acid or a base to

wastewater to make its pH level 7. After that is sedimentation. Sedimentation is the
process of allowing the fluid particles to settle down, after which they can be
separated. After sedimentation, sludge is already produced. Activation is the
process of adding oxygen and organisms to the primary treated wastewater, which
forms biological floc that can be easily separated. Secondary sedimentation is
added to eliminate more sludge. The Anaerobic Treatment is ideally suited for high
strength wastewater, anaerobic treatment does not require any oxygen to
decompose the organic content in wastewater. Anaerobic treatment processes the
sludge to produce water, concentrate and solids as by-product. Water and

concentrate will reflux to the rake/defatting stage. Effluent is ready for reuse after
secondary sedimentation. Anaerobic Treatment: Ideally suited for high strength
wastewater, anaerobic treatment does not require any oxygen to decompose the
organic
content
in
wastewater.
6.2. Solid and Hazardous Waste

Table 21. Solid and Hazardous Waste Impact Assessment
Polymer Solids from sulfolane regenerator
Sludge from oil/water separations systems
Spill cleanup material
Contaminated equipment and protective
clothing
Composition And
Polymer solids came from sulfolane solvent,
Classification
which is classified as hazardous substance.
Potential Impact Risks On
Risk of site contamination from hazardous
Environment
waste
Sources
Risk of contamination to water bodies

Risk of fire and explosions due to the
flammable and combustible nature of
petrochemical by-products
Potential Impact Risks On

Health And Safety
Waste Handling System
Risk of leaks and accidental releases from

equipment, tanks, pipes etc during loading and
unloading (handling)
Potential risk of loss of life or injury due to fire
The polymer solids will be recycled by
Havenplus Indo Ltd, a plastic recycling
company located also on Java, Indonesia.
6.3 Gaseous Emissions

Table 22. Gaseous Emissions Impact Assessment
Identify the sources of
Non-methane Volatile Organic Compounds
gaseous emissions
(NMVOCs) from BTX
Exhaust gases from the combustion of fuels
Flue gas
Venting and flaring
Fugitive emissions
Release of VOCs during operational
activities
Potential Impact Risks
on Environment
Potential Impact
Risks on
Health and
safety
Potential Impact
Risks on Labour
Employment and
Community
Potential risk of ground contamination and

contamination of surface, and sub-surface water
bodies during operational activities (soil and
groundwater)
Potential risk of respiratory irritation, discomfort,
or illness to workers
Potential risk of dermal contact and inhalation
Potential risk of contamination of water bodies
and community drinking water
The following equation was used to calculated gaseous emissions from

the boiler:
=
( )

Where:
SP = Steam produced
Hs = 1190 btu/lb, enthalpy of steam @ 100 PSIG
Hw = Enthalpy of feedwater @ saturation temperature
Be = Boiler efficiency
VHI = Fuel heating value of bunker fuel
G. Mitigating Measures
Table 23. Mitigating Measures
AMOUNT
Mitigation measures
DO 1
Wastewater No
process
water is
used
DO 2
No
process
water is
used
DO 3
Zero
Discharge
Policy
Sludge is
recycled by
GBG
Indonesia
Solid and
Hazardous
Waste
No solids
and
hazardous
waste is
produced
No solids
and
hazardous
waste is
produced
Hazardous
waste are
recycled by
Havenplus
Indo Ltd
Solid
wastes are
to
collected
by
municipal
waste
disposal
unit
Solid
wastes
are to
collected
by
municipal
waste
disposal
unit
Solid wastes
are to
collected by
municipal
waste
disposal unit
An
API
oil-water
separator should also be
used to separate gross
amounts of oil and
suspended solids from
the
wastewater
effluents/storm
water
runoff.
Using steam and sour
water strippers remove
hydrocarbons
Storage
equipment
should meet standards
for structural design and
integrity.
Dewatering technologies
can
be
used
to
significantly reduce the
volume of sludge, and
recycle oil and water
A Spill Response Plan
should be prepared, and
the
capability
to
implement
the
plan
should be in place.
The Spill Response Plan
should address potential
oil, chemical, and fuel
spills
from
facilities,
transport
vehicles,
loading and unloading
operations,
pipeline
ruptures, and proximity of
water bodies.
AMOUNT
DO 1
DO 2
Mitigation measures
DO 3
Deployment of vapour
recovery systems to
collect
the
VOCs
emitted during transfer
process operations.
Gaseous
emissions
1.29 x 103
MT per
year CO2
29.9 X 103
MT per
year CO2
Equipment
for
transferring the product
into and out of storage
will
consist
of
12.7 X 103
aboveground
piping,
MT per year hoses/loading
arms,
CO2
valves,
pumps,
instrumentation
and
alarms.
Installing an internal or
external floating roof
tank
to
minimize
evaporation losses of
the
product
being
stored.
Above Storage Tanks
(ASTs) should have a
secondary containment
area that contains spills
and allows leaks to be
more easily detected
H. Monitoring Plan
The proposed monitoring plan is designed to determine the effectiveness
of mitigation and to verify predictions and comply with the Indonesian
environmental laws.
Geographic Information System (GIS) monitoring will be implemented to
evaluate the impacts and analyse changes in different environmental

parameters. The method will use a GIS software in mapping out the
contaminants in soil and water using the spatial interpolation tools from GIS.
Ambient air analyzer will be placed on strategic locations outside the plant to
monitor air quality. Parameters to measured are:
Quality of water discharged or leaching to groundwater, surface water or
soil
Air quality and Noise
Quantity and quality of wastes
Any relevant public health indicators

List ofchemicals and their quantities
1. Atmospheric Analysis Standards

The monitoring plan strictly comply with standards to maintain accurate
analysis of parameters. These standards include ASTM D3249 - 95(2011) Standard Practice for General Ambient Air Analyzer Procedures, ASTM D3685 /
D3685M - 13 - Standard Test Method for Determination of Total Suspended
Particulate Matter in the Atmosphere (High-Volume Sampler Method), ASTM
D4600 - 95(2010) - Standard Test Method for Determination of Benzene-Soluble
Particulate Matter in Workplace Atmospheres, and ASTM D6209 - 13 - Standard
Test Method for Determination of Gaseous and Particulate Polycyclic Aromatic
Hydrocarbons in Ambient Air (Collection on Sorbent-Backed Filters with Gas
Chromatographic/Mass Spectrometric Analysis)
2. Environmental Assessment and Risk Management Standards

The monitoring plan significantly follow standards set by the ISO such as
ISO 31000 - Risk management. ISO 31000 deals with risks affecting organizations
can have consequences in terms of economic performance and professional
reputation, as well as environmental, safety and societal outcomes. Therefore,
managing risk effectively helps organizations to perform well in an environment full
of uncertainty. Other environmental assessment and risk management standards
considered were ASTM E2725 - 10 - Standard Guide for Basic Assessment and
Management of Greenhouse Gases, ASTM E2365 - 14 - Standard Guide for
Environmental Compliance Performance Assessment and ASTM E2348 06(2010) Standard Guide for Framework for a Consensus-based Environmental
Decision-making Process.
3. Environmental Toxicology Standards

Toxicology standards provide the proper procedures for carrying out tests
and other evaluation procedures to assess and identify the potential impacts of
certain substances on the species and constituents of the ecosystem to which
the toxins were released. toxicology standards considered were astm F1127 07(2013) - Standard Guide for Containment of Hazardous Material Spills by
Emergency Response Personnel and ASTM F1525 / F1525M - 09 - Standard
Guide for Use of Membrane Technology in Mitigating Hazardous Chemical
Spills.
4. Waste Management Standards

These standards provide the guides, practices, and test methods
pertinent to the process of handling industrial wastes. D5231 - 92(2008) Standard Test Method for Determination of the Composition of Unprocessed
Municipal Solid Waste, ASTM D4447 - 10 - Standard Guide for Disposal of
Laboratory Chemicals and Samples, ASTM D4687 - 14 - Standard Guide for
General Planning of Waste SamplingAND ASTM D4844 - 03(2009) - Standard
Guide for Air Monitoring at Waste Management Facilities for Worker Protection.
5. Water Testing Standards

Water testing standards are instrumental in specifying and evaluating the
methods and facilities used in examining the various characteristics of and
contaminants in water for health, security, and environmental purposes.
CHAPTER VI
EVALUATION OF DESIGN OPTIONS
Design options were evaluated using Pareto optimum method and the best
design option was chosen.
Table 24. Summary of Multiple Realistic Constraint VS Design Options
Mutiple
Realistic
Constraint
Technical
Economic
Environmental
Specific
Constraint
Design
Option I
Design
Option II
Design
Option III
Plant Overall
Efficiency
Net Present
Value (NPV)
Gaseous
Carbon
Dioxide
Emission
74.33 %
70.69%
76.93 %
USD 41.107
M
1.29 x 103
MT per year
CO2
USD 4.17 M
USD 77.01 M
29.9 X 103
MT per year
CO2
12.7 X 103
MT per year
CO2
Specific
Constraint
Design
option I
Design
Option II
Design Option
III
Normalization
Coefficient
(base of 10)
5
Plant
Overall
Efficiency
Net Present
Value
Gaseous
Carbon
Dioxide
Emission
74.33 %
(7.92)
70.69%
(5)
76.93 %
(10)
(7)
(5)
(8)
3.5
1.29 x 103 MT
per year CO2
(low)
(10)
29.9 X 103 MT
per year CO2
(high)
(5)
12.7 X 103 MT
per year CO2
(medium)
(8)
1.5
Design option I = (7.92 x 5) + (3.5 x 7) + (10 x1.5)

Design option I = 79.1
Design option II = (5 x 5) + (3.5 x 5) + (5x1.5)
Design option II = 50
Design option III = (10 x 5) + (3.5 x 8) + (8 x1.5)
Design option III = 90
Based from the table and computations, design option I has a 79.1
evaluation value, design option II has 50 evaluation value and design option III has
90 evaluation value. Therefore, the best design option using Pareto Optimum
evaluation is design option III.
CHAPTER VII
PROJECT CONSTRUCTION AND EXECUTION PLAN
CONSTRUCTION MANAGEMENT AND STRATEGY

The construction stage begins with a pre-construction meeting brought
together by the superintendent. The pre-construction meeting is meant to make
decisions dealing with work hours, material storage, quality control, and site
access. After the decision was made, construction materials will be moved onto
the construction site and set it up.
The most common strategy used in managing the construction phase is by
applying Contractor Progress Payment Schedule which is a schedule wherein
contractors and suppliers will be paid for the current progress of installed work.
Progress payments are partial payments for work completed during a portion,
usually a month, during a construction period. Progress payments are made to
general contractors, subcontractors, and suppliers as construction projects
progress.
QUALITY CONTROL AND ASSURANCE

Since the plant will produce multiple finished products, it will follow multiple
quality control and assurance methods to maintain the quality of the products.
Quality is significant indicator in the specification of benzene, toluene and xylene.
The sales specification is based on the ASTM D4492 10, ASTM D6526 - 12 and
ASTM D5136 - 09(2013) . These standards indicates a 99.80% or higher purity of
benzene, 98% or higher purity of toluene and 98% or higher purity of mixed
xylene.
Gas chromatography and capillary column gas chromatography are used
for determining the concentrations of known impurities in finished benzene,
toluene and xylene. This is an integral quality control tool that generally applied to
determine impurities each of the finished products.
WORK SCHEDULING AND OVERALL MANAGEMENT

In order to finish the work on time, proper project scheduling should be
observed. One and the most common way of doing work scheduling is by making
a Gantt chart. A Gantt chart is a horizontal bar chart developed as a production
control tool in 1917 by Henry L. Gantt, an American engineer and social scientist,
now frequently used in project management, a Gantt chart provides a graphical
illustration of a schedule that helps to plan, coordinate, and track specific tasks in a
project.
PROJECT COMMISSIONING
Project commissioning is the process of assuring that all systems and
components of an industrial plant is designed, installed, tested, operated, and
maintained according to the operational requirements of the owner or final client.
On this design, commissioning lasts for four weeks. On this time span, engineers
and safety inspectors will check the installation of different equipment and its
controls to ensure plant safety. Then, plant will be operated and then check the
operating pressure and temperature to ensure the quality of products. After series
of test run, plant is now ready for production.
First Month
1st 2nd
Land Acquisition
Negotiation
Titling
Permits
Layouting and Site Preparation
Procurement / Bidding of materials
Foundation of Equipments
Buildings
Fabrication
Delivery
Equipment Installation
Insulation
Piping Installation
Painting
Safety Inspection
Dry-run
Operation Proper
3rd
4th
Gantt Chart
Second Month
1st 2nd 3rd 4th
Third Month
1st 2nd 3rd
4th
Fourth Month
1st 2nd 3rd
4th
Gantt Chart
Fifth Month
1st 2nd 3rd
Land Acquisition
Negotiation
Titling
Permits
Buildings
Fabrication
Delivery
Insulation
Piping Installation
Painting
Safety Inspection
Dry-run
Operation Proper
4th
Sixth Month
1st 2nd
3rd
4th
Seventh Month
1st 2nd 3rd
4th
Eighth Month
1st 2nd 3rd
4th
Gantt Chart
Ninth Month
1st 2nd 3rd
Land Acquisition
Negotiation
Titling
Permits
Buildings
Fabrication
Delivery
Insulation
Piping Installation
Painting
Safety Inspection
Dry-run
Operation Proper
4th
Tenth Month
1st 2nd 3rd
4th
Eleventh Month
1st 2nd 3rd
4th
Twelveth Month
1st 2nd 3rd
4th
Thirteenth Month
1st 2nd 3rd
Land Acquisition
Negotiation
Titling
Permits
Buildings
Fabrication
Delivery
Insulation
Piping Installation
Painting
Safety Inspection
Dry-run
Operation Proper
4th
Gantt Chart
Fourteenth Month
1st 2nd 3rd 4th
Fifteenth Month
1st 2nd 3rd
4th
Sixteenth Month
1st 2nd 3rd
4th
Seventeenth Month
1st 2nd 3rd 4th
Land Acquisition
Negotiation
Titling
Permits
Buildings
Fabrication
Delivery
Insulation
Piping Installation
Painting
Safety Inspection
Dry-run
Operation Proper
Gantt Chart
Eighteenth Month
1st 2nd 3rd 4th
Nineteenth Month
1st 2nd 3rd 4th
Twentieth Month
1st 2nd 3rd
4th
CHAPTER VIII
SUMMARY, CONCLUSION AND RECOMMENDATION
BIBLIOGRAPHY
Agatonovic, V. and E. Vaisman. 2005. Sulfolane impacted soil and
groundwater treatability study. EBA Engineering Consultants, Ltd. And University
of Calgary Tomographic Imaging and Porous Media Laboratory.
Al Harbi, A. 2004. Corrosion problem in sulfolane extraction unit (U 7300).
Second Middle East Nondestructive Testing Conference, Vol. 9, No. 4. April.
Alberta Environment. 2009. Alberta Tier 1 Soil and groundwater
remediation guidelines. February.
Barr Engineering. 2010. Site Characterization Work Plan, North Pole
Refinery, prepared for Flint Hills Resources Alaska, LLC. April.
Beveridge, J.,Mair and Mathu Hamaiengar, Analytical Chemistry, Vol.30,
No.2, February1958.
Booz, Allen and Hamilton, Inc. Foster D. Snell Division. Benzene Emission
Control Costs in Selected Segments of the Chemical Industry. Florham Pack,
New Jersey. June 1978.
Boucher and Jones Fuels. 2010. HT Severe Hydrocracking Clearly
Superior. www.boucherandjone.com/hydrocracking.htm, accessed May 11, 2010.
Cader, G.A., and B.B. Horton. Equipment Component Analysis for
Identification of Potential Fugitive Emission Sources. U.S. Environmental
Protection Agency, Research Triangle Park, North Carolina. June 1978.
Canadian Council of Ministers of the Environment (CCME). 2006.
Canadian Environmental Quality Guidelines for Sulfolane: Water and Soil,
Scientific Supporting Document.
CCR Technologies, Ltd. 2001. Canadian Gas Treating Solvent Quality

Control Unique Challenges. 2001 Sulfur Recovery Symposium, Canmore,
Alberta.
Chauvel, A., Lefebvre G., Petrochemical Processes, 1989, Volume I,
Edition Technip, Paris.
Chou, C.C. and R.A. Swatloski. 1983. Biodegradation of sulfolane in
refinery wastewater. Proceedings of the 27th Purdue Industrial Waste
Conference. Ann Arbor Science Publishers: Ann Arbor, MI. pp. 559-566.
Distillation
Column
Design.
Copyright
1997.
http://lorien.ncl.ac.uk/ming/distil/distil0.htm
Doucette, W.J., J.K. Chard, B.J. Moore, W.J. Staudt and J.V. Headley.
2005. Uptake of sulfolane and diisopropanolamine (DIPA) by cattails (Typha
latifolia). Microchemical Journal, Vol. 81, pp. 41-49.
Douglas, James. Conceptual Design of Chemical Processes. McGrawHill, Inc., 1988, Section A.3.
Drazaj, B., Hocevar, S., and Pejovnik, S., "Zeolite, Synthesis, Structure,
Technology and Application", Elsevier Science Publishing Company, Inc., New
York, 1985.
Equilon Enterprises, LLC. 1998. RECAP Screening Option Report: RiskBased Assessment for the RCRA Corrective Measures Study, submitted to
Louisiana Department of Environmental Quality. November 1998.
Ethirajulu, K., Roy, A., Chemical Age of India, 38, 45 (1987).
Fahim, M. A., El-Kilani, A. S., J. of Separation Science and Technology,

25, 1803 (1990).
Fedorak, P.M. and D.L. Coy. 1996. Biodegradation of sulfolane in soil and
groundwater samples from a sour gas plant. Environmental Technology, Vol. 17.
pp. 10931102.
Fredenslund, A., Gmehling, J., Michelsen, M. L., Rasmussen, P.,
Prausnitz, J. M., Ind. Eng. Chem., Process Des. Dev., 16, 450 (1977).
Galil, N., M. Rebhun and Y. Brayer. 1988. Disturbances and inhibition in
biological treatment of wastewater from an integrated refinery. Water Science
and Technology, Vol. 20, No. 10, pp. 21-29.
Ganapati, M., Aromatic technologies state of the art, Chemical Weekly,
8 December, 1992, p. 129.
Gosling, C.D., F.P. Wilcher, L. Sullivan, R.A. Mountiford, Process LPG to
BTX products, Hydrocarbon Processing, December 1991, p. 69.
Greene, E.A., L.M. Gieg, D.L. Coy, and P.M. Fedorak. 1998. Sulfolane
biodegradation potential in aquifer sediments at sour natural gas plant sites.
Water Resources, Vol. 32, No. 12, pp. 3680-3688.
Gupta, A.K., Invited lecture, QIP short term course on Advances of
Petrochemicals, organized QIP Center, Indian institute of Technology, Roorkee
(India), 21 June-5 July, 1994.
Hansen, K. H., Coto, B., Kahlmany, B., "SEP 9212, IVCSEP," Institute of
Kemiteknik, DK-2800, Lyngby, Denmark(1992).
Henley, E. J., Seader, J. D., "Equilibrium-Stage Separations in Chemical

Engineering," John Wiley & Sons, New York (1981).
IBRD/WB, 1999, Pollution Prevention and Abatement Handbook 1998,
Toward Cleaner Production, The International Bank for Reconstruction and
Development / The World Bank, Washington, U.S.A., April 1999.
Jacobs, P.A., and Van Santen, R.A., "Zeolite Facts, Figure, Further",
Elsevier Science Publishing company, Inc., New York, 1989 .
Kaul et al., U.S. Pat 5,186,819, Feb. 16,1993
Kebberkvs, B.B., "Enviromental Chemical Analysis", Blackie Academic
and Proffesional, London, 1998.
King, C. Judson. Separation Processes, Second Edition. McGraw-Hill,
Inc., 1980, Chapters 4-6
Kirk-Othmer, "Encyclopedia of Chemical Technology" , Vol. 1, John Wiley
and Sons, Inc., New York, 3rd Edition, 1983,P.544-563. 9. Keller ll, G.E.,
Anderson, R.A., and Yon, C.M.,"Handbook of Separation Process Technology",
Wily Interscience Publishing, New York, 1987.
KSA/RC, 2004, Royal Commission Environmental Regulations 2004,
Volume I and II, The Royal Commission for Jubail and Yanbu, Kingdom of Saudi
Arabia, 2004.
Little, D.M., Catalytic Reforming, 1985, Penn Well Books, Tulsa,
Oklahoma.
Mall, I.D. Petrochemical Process Technology, first edi., New Delhi,

Macmillan India,2007 7. Wiseman, P., Petrochemicals, 1986, Ellis Horwood Ltd,
Chichester, p. 33
McCabe, Warren. Unit Operations of Chemical Engineering, Fifth Edition.
McGraw-Hill, Inc, 1993, Chapters 18 and 19.
Mukhopadhyay, M., Dongaonkar, K., Ind. Eng. Chem., Process Des. Dev.,
22, 521 (1983).
Owaysi et al., U.S. Pat. 4,567,315, Jan.28,1986.
Popco onshore gas plant spill news release. January 23.
Powell, D. et al. Development of petroleum Refinery plot plans. Epa450/3-78-025. June 1978
Rahman, M., Mikitenko, P., Asselinenu, L., Chem. Eng. Sci., 39, 1543
(1984).
Richards, W., Neuzil Downers Grove, U.S. Pat 3,663,638 May 16, 1972.
Santa Barbara County Fire Department (SBCFD). 2008.
Schneider, D.F. 2004. Avoid Sulfolane Regeneration Problems. Chemical
Engineering Progress, Vol. 100, No. 7, pp. 34-39. July 2004.
Seader, J. and Henley, E. Separation Process Principles. John Wiley &
Sons, 1998, Chapters 7 and 8.
Sorensen, J. M., "Phase Equilibria and Separation Processes. MAN 8106:
ESTM," Institute for Kemiteknik, Lyngby, Denmark (1980).
St. Fort, R. 2006. Sulfolane attenuation by surface and subsurface soil

matrices. Journal of Environmental Science and Helath part A, Vol. 41, pp. 12111231.
TASNEE,
2005,
Environmental
Information
Report,
TASNEE
Petrochemicals Ethylene Project, TASNEE Petrochemicals, October 2005.

TTC Labs, Inc. 2010. Sulfolane Technical Assistance and Evaluation,
prepared for OASIS Environmental, Anchorage, Alaska. April 2010.
UOP. 2006. Sulfolane Process. Whitepaper.
APPENDIXES
APPENDIX A
(Demand Projection)
DEMAND PROJECTION
Demand projection is the activity of estimating the quantity of a product or
service that consumers will purchase in future. Demand forecasting involves
techniques including both informal methods, such as educated guesses, and
quantitative methods, such as the use of historical sales data or current data
from test markets. The demand projection of this project study is based in the
United Nations Commodity Trade Statistics Database.
200000000
180000000
160000000
140000000
120000000
100000000
80000000
60000000
40000000
20000000
0
2005
2010
2015
2020
2025
2030
2035
2040
2045
Benzene Demand Projection

Benzene is a colorless liquid with a sweet odor. It is widely used and it
ranks in the top 20 chemicals for production volume. Some industries use
benzene to make other chemicals which are used to make plastics, resins, nylon
and synthetic fibers. Benzene is also used to make some types of rubbers,
lubricants, dyes, detergents, drugs, and pesticides. As a gasoline additive,

benzene increases the octane rating and reduces knocking comprising a few
percent of its mass. In some countries, concern over its negative health effects
and the possibility of benzene's entering the groundwater have led to strict
regulation of gasoline's benzene content, with limits typically around 0.62 1.0
%.
350000000
300000000
250000000
200000000
150000000
100000000
50000000
0
2005
2010
2015
2020
2025
2030
2035
2040
2045
Toluene Demand Projection

Toluene is a colorless, water-insoluble liquid and it has many uses in
different industries. In the explosives industry, it is essential in making the
flammable, explosive compound known as TNT or trinitrotoluene. In the plastics
industry, it is a component in the manufacturing of nylon and plastic bottles. Hair
dyes and nail products include toluene, as well, utilized by the cosmetics
industry. It is also a common solvent for paints, paint thinners, silicone sealants,
many chemical reactants, rubber, printing ink, adhesives, lacquers, leather

tanners, and disinfectants.
Toluene can be used as an octane booster in gasoline fuels used in
internal combustion engines. Toluene at 86% by volume fueled all the turbo
Formula 1 teams pioneered by the Honda team. Toluene at 100% can be used
as a fuel for both two-stroke and four-stroke engines.
50000000
45000000
40000000
35000000
30000000
25000000
20000000
15000000
10000000
5000000
0
2000
2005
2010
2015
2020
2025
2030
2035
2040
2045
Xylene Demand Projection

Xylene is a clear, colorless, sweet-smelling solution of three aromatic
hydrocarbon isomers. The majority more than 90 percent of mixed xylene
isomers is used for blending into petrol and gasoline, and the rest in different
solvent applications for the printing industry, pharmaceuticals, perfumes,
fabricated items and pesticide formulations. It is a good cleaning agent for silicon
wafers and steel. It is also used to sterilize many substances. Xylene found in
small proportions in gasoline and jet fuel. It is a raw material in the production of
a monomer which is a simple compound with molecules that join together to form
polymers called terephthalic acid.
APPENDIX B
(Market Share)
MARKET SHARE
The target costumers of Benzene, Toluene and Xylene plant are the
ASEAN Country particularly Singapore, Cambodia, Indonesia and Vietnam.
Those are the countries where benzene, toluene and xylene are in great
demand. According to United Nations Commodity Trade Statistics Data Base,
among the ASEAN Countries, for benzene products, Singapore is the primary
costumer. While for toluene products, Cambodia, Indonesia and Vietnam are the
target consumers. And for xylene products the companys major costumer is
Indonesia.
Product
Country
Benzene
Singapore
246,272,210.00
196,267,253.00
Cambodia
233,820.00
Indonesia
92,117,424.00
Vietnam
88,372,340.00
448,728.00
Indonesia
35,248,531.00
Toluene
Xylene
Import (kg)
Export (kg)
Product
Country
Demand (kg)
Companies
Market Share
Benzene
Singapore
50,004,957.00
16,668,319.00
Cambodia
233,820.00
233,820.00
Indonesia
92,117,424.00
30,705,808.00
Toluene
Vietnam
87,923,612.00
43,961,806.00
Xylene
Indonesia
35,248,531.00
11,749,510.33
TOTAL MARKET SHARE
103,319,263.33
Benzene Market Share in Singapore
BTX
Manufacturing
Plant
33%
Petrochemical
Corporation of
Singapore Private
Limited
34%
Chemical ITOCHU
SINGAPORE
33%
Toluene Market Share in Cambodia
BTX
Manufacturing
Plant
100%
Toluene Market Share in Indonesia
BTX Manufacturing Innova Corporate

India
Plant
34%
33%
Tuban
Petrochemical
33%
Toluene Market Share in Vietnam
BTX
Manufacturing
Plant
50%
Petrochemical
Corporation of
Singapore Private
Limited
50%
Xylene Market Share in Indonesia
BTX
Manufacturing
Plant
33%
PT. BiWon
Chemical
34%
PT. Anugrah
Putra Kencana
33%
APPENDIX C
(Material Safety Data Sheet)

Plant Layout Ayos PDF

Transféré par

Informations du document

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Plant Layout Ayos PDF

Transféré par

Droits d'auteur :

Formats disponibles

CHAPTER I

The petrochemical industry is a substantial contributor to the worlds

Figure 1. Target Location Aerial View

Figure 2. Target Location (2 km elevation)

3. To design the economic analyses of the plant taking into consideration

Figure 3. Design Option I Process Flow Diagram

Figure 4. Plant top view

Figure 5. Plant Side View

3. Equipment Description and Specification

FEED SURGE DRUM

Specification Sheet No. 2

Specification Sheet No. 3

Specification Sheet No. 4

Specification Sheet No. 5

Specification Sheet No. 6

Specification Sheet No. 7

Specification Sheet No. 8

Specification Sheet No. 9

Specification Sheet No. 10

Specification Sheet No. 11

Specification Sheet No. 12

Specification Sheet No. 13

Specification Sheet No. 14

Specification Sheet No. 15

Specification Sheet No. 16

Specification Sheet No. 17

Specification Sheet No. 18

1 in, schedule stainless steel

Specification Sheet No. 19

Specification Sheet No. 20

Specification Sheet No. 21

Specification Sheet No. 22

Specification Sheet No. 22

Specification Sheet No. 23

Incoming pipe diameter

1 in, schedule stainless steel

Specification Sheet No. 24

Specification Sheet No. 25

Incoming pipe diameter

1 in, schedule stainless steel

Specification Sheet No. 26

Specification Sheet No. 27

Specification Sheet No. 28

Specification Sheet No. 29

Specification Sheet No. 30

Specification Sheet No. 31

Specification Sheet No. 32

Specification Sheet No. 33

Incoming pipe diameter

1 in, schedule stainless steel

Specification Sheet No. 34

Incoming pipe diameter

1 in, schedule stainless steel

Specification Sheet No. 35

Specification Sheet No. 36

Specification Sheet No. 37

Outlet pipe diameter

1 in, schedule 40 stainless steel

Incoming pipe diameter

1 in, schedule stainless steel

Specification Sheet No. 38

Incoming pipe diameter

1 in, schedule stainless steel

Specification Sheet No. 39