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A REPORT ON
PLANT DESIGN OF MONOCHLOROBENZENE
UNDER THE GUIDENCE
OF
PROF. A. K. SAHA
BY
ABHISEK PAUL ANTARIM DUTTA BIKRAMJIT SHA
12/CH/01 12/CH/09 12/CH/13
DIPANJAN BISWAS
12/CH/17
CERTIFICATE
This is to certify that the project report titled , " PRODUCTION OF 20000 METRIC
TONS/YEAR OF MONOCHLOROBENZENE BY THE DIRECT CHLORINATION
OF BENZENE" submitted by Abhisek Paul, Antarim dutta, Bikramjit Sha, Dipanjan Biswas
in partial fulfillments for the requirement for the award of Bachelor of Technology Degree in
Chemical Engineering during session 2012-2016 Haldia Institute of Technology, Haldia is an
authentic work carried out by him under supervision and guidance.
Date-
Place- Prof A. k. Saha
Department of Chemical Engineering
Haldia Institute of Technology
Introduction ..
Properties & uses ..
Manufacturing process .
Process flow sheet ..
Material Balance ..
Energy Balance .
Cost Estimation .
Conclusion .
Reference .
FIG-1
10 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
MATERIAL BALANCE
Basis: 330 days/year of operation.
The plant has to produce 23.3 kmols/hr of monochlorobenzene. Assume one hour of
operation.
Balance across Chlorinator
Assume that 100% chlorination occurs in the chlorinator at 40C. It is also assumed that 10%
of the HCl produced in the chlorinator is entrained as liquid in the product. The rest leaves as
vapour along with benzene, MCB and DCB. Only the p-isomer of DCB is formed in the
chlorinator. It is assumed that from the chlorinator, the stream d is led into a condenser from
where we recover the HCl product formed.
Reaction 1: C6 H6 + Cl2 C6H5Cl + HCl
Reaction 2: C6H5Cl + Cl2 C6H4Cl2 + HCl
MCB formed = 24.03 kmols/hr
DCB formed = 3.80 kmols/hr
HCl formed = 31.63 kmols/hr
Benzene remaining = 3.80 kmols/hr
Input into chlorinator:
Benzene present = 31.63 kmols/hr
Chlorine present = 31.63 kmols/hr
Output from chlorinator:
In stream d (29.65 kmols/hr):
MCB present = 0.44 kmols/hr
DCB present = 0.15 kmols/hr
HCl present = 28.47 kmols/hr
11 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
Benzene present = 0.59 kmols/hr
In stream a (33.46 kmols/hr) :
MCB present = 23.44 kmols/hr
DCB present = 3.65 kmols/hr
HCl present = 3.16 kmols/hr
Benzene present = 3.21 kmols/hr
Material balance across Neutralizer
To neutralize 3.16 kmol/hr of HCl, we need 3.16 kmol/hr of NaOH solution. The NaOH soln.
is made slightly alkaline so 2.5% extra soln. is taken. The strength of NaOH soln. taken is
(20+2.5) wt.%.
NaOH + HCl NaCl + H2O
Input to Neutralizer:
NaOH solution = 32.82 kmols/hr.
NaOH present =3.32 kmol/hr
Water present in soln.= 29.50 kmol/hr
Stream a (33.46 kmols/hr):
MCB present = 23.44 kmols/hr
DCB present = 3.65 kmols/hr
HCl present = 3.16 kmols/hr
Benzene present = 3.21 kmols/hr
Output from Neutraliser:
In stream b (35.98 kmols/hr):
NaCl present = 3.16 kmols/hr
Water present = 32.66 kmols/hr
NaOH present = 0.16 kmols/hr
In stream c (30.3 kmols/hr) :
MCB present = 23.44 kmols/hr
DCB present = 3.65 kmols/hr
Benzene present = 3.21 kmols/hr
Balance across benzene column
It is assumed that all the entering benzene in this column goes out as distillate as the top
product. The Distillate contains 98 vol% benzene and 2 vol% MCB. Let the distillate stream
be e.
Input into the benzene recovery column:
12 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
In Stream c (30.3 kmols/hr):
MCB present = 23.44 kmols/hr
DCB present = 3.65 kmols/hr
Benzene present = 3.21 kmols/hr
Output from the Benzene recovery column:
In stream e (3.26 kmols/hr) :
Benzene present = 3.21 kmols/hr
MCB present = 0.05 kmols/hr
In stream f (27.99 kmols/hr) :
MCB present = 24.21 kmols/hr
DCB present = 3.78 kmols/hr
Balance for Recycle stream
It is assumed that all the benzene from the benzene column goes to the purifier from which
all the benzene is recycled back into the feed stream.
Recycle r into feed stream = 3.21 kmols/hr
Fresh feed = 28.42 kmols/hr
Balance across Chlorobenzene column
The purity of the MCB in the distillate is assumed to be 99 mol% . The purity of the MCB in
the residue is assumed to be 3 mol% .
Input to the chlorobenzene column:
In stream f (27.99 kmols/hr) :
MCB present = 24.21 kmols/hr
DCB present = 3.78 kmols/hr
Output from the chlorobenzene column:
In stream g (24.23 kmols/hr)
MCB present = 23.99 kmols/hr
DCB present = 0.24 kmols/hr
In stream h (3.76 kmols/hr)
MCB present = 0.11 kmols/hr
DCB present = 3.65 kmols/hr
ENERGY BALANCE
Chlorinator
13 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
Assumption is made that the fresh benzene and chlorine to the chlorinator are stored at a
temperature of 30 0C. The reaction temperature is 40 C. The inlet gases are to be heated to
the reaction temperature. Thus the heat required for this process is
Where
H is the heat required.
Cp is the specific heat of component
Specific heat of benzene = 1.7514 kJ/kg K
Specific heat of chlorine = 8.28 + 0.00058T
This heat may be supplied by condensing at atmospheric pressure.
By a process of trial and error we find that the outlet temperature is 345 K.
14 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
Benzene Column
Assumption is made that no heat losses occur in the column. For such a column the heat
balance may be written as
Fhf +Qw =DhD +WhW +Qc
F is feed flow rate
D is the distillate flow rate
W is the underflow flow rate.
h indicates the enthalpy of the respective stream
Qw and Qc are the reboiler and condenser heat loads.
h=
Tr is refernce temperature taken as 0 K
hf = 555.4 kJ/kg
hd = 615.33 kJ/kg
hw = 538 kJ/kg
The condenser heat load may be calculated as
QC =
is the latent heat of vaporization the values for benzene and chlorobenzene are
393.3 kJ/kg and 331.1 kJ/kg respectively.
hence QC is obtained as 7.9588 x 103 kJ/hr
Substituting the values obtained we get
QW = 3.2192 x 106 kJ/hr = 894.22 kW
Chlorobenzene Column
Assumption is made that there are no heat losses. Hence the previous equation
holds.
Fhf +Qw =DhD +WhW +Qc
The values for the enthalpies of various streams are
hf = 505.7 kJ/kg
hd = 508 kJ/kg
hw = 497.3 kJ/kg
The condenser heat load is calculated as
QC =
Thus QC = 1.3226 x 106 kJ/hr = 367.4 kW
Hence QW = 2.8017 x 103 kJ/hr = 778.25 kW
15 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
MAJOR EQUIPMENT DESIGN
Process Design Of Chlorobenzene Distillation Column
For simplicity of calculation let us assume that the feed entering the distillation or
chlorobenzene column is a binary mixture of MCB and p-dichlorobenzene and the o-
dichlorobenzene is not entering as feed.
Vapour Pressure Data (Pressure = 48269.0 Pa)
Temperature (K) Vapour Pressure of MCB Vapour Pressure of DCB
(mm Hg) (mm Hg)
405 700 190
408 810 210
411 900 240
415 1000 260
418 1050 300
422 1150 330
426 1300 370
429 1400 400
433 1500 450
437 1700 500
441 1800 575
444 2000 625
448 2200 680
453 2400 740
(Table no i)
Vapour Liquid Equilibrium Data :
Temperature (K) xa (mole fraction of MCB in ya (mole fraction of MCB in
liquid) vapour)
419.367 0.00 0.00
416.329 0.05 0.135
413.256 0.10 0.251
410.394 0.15 0.351
407.722 0.20 0.436
405.220 0.25 0.511
16 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
402.873 0.30 0.575
400.665 0.35 0.632
398.584 0.40 0.683
396.617 0.45 0.727
394.755 0.50 0.766
392.989 0.55 0.803
391.311 0.60 0.833
389.714 0.65 0.862
388.190 0.70 0.888
386.735 0.75 0.911
385.344 0.80 0.932
384.011 0.85 0.951
382.733 0.90 0.969
381.506 0.95 0.985
380.326 1.00 1.00
(Table no ii)
We have,
F = 27.04 kmols/hr
D = 23.52 kmols/hr
W = 3.52 kmols/hr
XF = 0.865
XD = 0.865
XW = 0.865
Average molecular weight of Feed = 117.15 kg/kmol
Average molecular weight of Distillate = 112.84 kg/kmol
Average molecular weight of Residue = 145.96 kg/kmol
D = 2653 kg/hr
W = 513.77 kg/hr
Assume that the feed is a saturated liquid at its boiling point.
So q =
q = 1.
Slope = (q\q-1) =
17 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
From the graph ;
minimum ( Xd \Rm + 1) = 0.73
minimum reflux Rm = 0.3561 mol reflux/mol D
Operating reflux ratio (1.5 Rm ) = 0.5341
Intercept = 0.64
No. of ideal stages = 11
No. of stages in the enriching section = 4
No. of stages in the stripping section = 7
L = RD = 12.56 kmol/hr
G = L+D = 36.08 kmol/hr
= L +qF = 39.6 kmols \hr
= G +(q-1)F = 36.08 kmols \hr
Properties :
(Table no iii)
AVERAGE PROPERTIES
18 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
(Table no iv)
ENRICHING SECTION
TRAY HYDRAULICS :
(1) Plate spacing , ts = 305 mm
(2) Hole diameter , dh =5 mm
(3) Hole pitch , lp =15 mm
(4) Tray thickness , tT =3 mm
(5) = = 0.10
(L/G) x = 0.015
19 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
Csb =0.23 m\s
Unf = 5.9982 ft\s
Assume Un =0.8 Unf = 1.4511 m/s.
Net area for flow , An = Ac - Ad
Vapour flow rate = 0.6583 m3/s
An = 0.6585 / 1.4511 = 0.4538 m2.
Ad = 0.0988 m2
Assume 0.77
( )
Where
Ac = = 0.785
Ad = 0.0988 Dc2
An = 0.785 Dc2 0.0988 Dc2
Dc = 0.81 m , Corrected Ad = 0.0622 m2
Ac = 0.5153 m2
Lw= 0.62 m
Active area, Aa = Ac 2Ad =0.3909 m2.
(7) Perforated area, Ap
corrected c = 99.9
= 180 - c = 80.1
Area of calming + distribution zone, Acz
Acz = 2(Lw * t) , t=thickness
Acz = 0.0351 m2 (that is 6.81% of Ac )
Awz = 0.0327 m2 .
let w = 20 mm
Aw = 0.0221 m2 (that is 4.3% of Ac )
Ad = 0.0622 m2
Ap = Ac 2 Ad Acz - Awz = 0.3231 m2
Ah = 0.1 Ap = 0.03231 m2
20 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
(8) No. of holes, nh = 1646 holes.
(9) Weir height , hw = 12 mm
(10) Weeping check :
hd = K1 + K2 ( )
[ ]
= 2.28 mm liq.
Now, hd + = 59.23 mm liq.
hw + how =16.95 mm
Since from the graph; actual design > minimum design there is no weeping (from fig. 18-11)
(11) Downcomer flooding :
hdc =ht + hw+ how+ hda+ hhg
Dynamic Seal; hds = hw + how +hhg/2
Q = 4.02165 x 10-4 m3/s = 6.382 gal/min
Lw = 0.62 m = 2.05 ft ; Fw = 1.005
how =5.00 mm
hds = 12 +5+0.15\2 =17.075 mm
ht = hd+hl1
hl1= hds
Ua = 1.6845 m/s = 5.5707 ft/s
21 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
= 0.1079 lb/ft3
Fa = Ua = 1.83
= 0.59
Ng=
22 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
NL = KLaL
KLa = ( )
= 1.568 /s
L = (hfAat) / (1000q)
hf = 193.90 mm
L = 38.29 s
NL = 60.038
=M
= = 2.886 ; M = 0.385
= 1.111
Nog = = 0.974
NPe =
Emv = 0.3237
(c) Overall column efficiency, Eoc
Eoc = =
23 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
NA = 12.66 12 trays
NA = 12 trays
Tower height, = ts * NA
= 305 * 12 = 3660 mm
H = 3.66 m
STRIPPING SECTION
TRAY HYDRAULICS :
(1) Plate spacing , ts = 305 mm
(2) Hole diameter , dh =5 mm
(3) Hole pitch , lp =15 mm
(4) Tray thickness , tT =3 mm
(5) = = 0.10
24 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
=
= 100.7
Ac = = 0.785
Ad = 0.0988 Dc2
An = 0.785 Dc2 0.0988 Dc2
Dc = 0.94 m , Corrected Ad = 0.0883 m2
Ac = 0.6939 m2
Lw= 0.73 m
Active area, Aa = Ac 2Ad =0.5173 m2.
(7) Perforated area, Ap
corrected c = 99.9
= 180 - c = 80.1
Area of calming + distribution zone, Acz
Acz = 2(Lw * t) , t=thickness
Acz = 0.05446 m2 (that is 7.85% of Ac )
Awz = 0.0251 m2 (that is 3.6% of Ac )
let w = 40 mm
Ad = 0.0883 m2
Ap = Ac 2 Ad Acz - Awz = 0.4377 m2
Ah = 0.1 Ap = 0.043774 m2
(8) No. of holes, nh = 2230 holes.
(9) Weir height , hw = 12 mm
(10) Weeping check :
hd = K1 + K2
25 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
Frances Weir Equation :
how= Fw x 664 x [ ]
[ ]
= 1.7109 mm liq.
Now, hd + = 52.54 mm liq.
hw + how =21.616 mm
Since from the graph; actual design > minimum design(10 mm) there is no weeping.
(11) Downcomer flooding :
hdc =ht + hw+ how+ hda+ hhg
Dynamic Seal; hds = hw + how +hhg/2
Q = 1.4527 x 10-3 m3/s = 22.5973 gal/min
Lw = 0.73 m = 2.395 ft ; Fw = 1.025
how =10.74 mm
hds = 12 +10.75+0.15\2 =22.815mm
ht = hd+hl1
hl1= hds
Ua = 1.388 m/s = 4.5548 ft/s
= 0.1133 lb/ft3
Fa = Ua = 1.5331
= 0.6
2
h l= 0.6 x22.185 = 13.689 mm
ht = 50.75 + 13.689 = 64.439 mm.
Loss under downcomer, hda
hda = 165.2 ( q/Ada)2
Assume clearance C = 13 mm.
26 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
hap = 22.815 C = 9.815 mm
Ada = Lwhap = 7.164 x 10-3 m2
hda = 4.94 mm
hdc = ht + hw + how + hda + hhg = 64.439+12+10.74+4.94+0.15 = 98.094 mm
ts = 305 mm
As hdc < ts , there is no downcomer flooding.
Summary of tray calculations
Dc = 0.94m
Lw = 0.73m
hw = 12 mm
ts = 305 mm
dh = 5mm
lp = 15 mm, triangular pitch.
tt = 3 mm
nh = 2230
% flooding = 80%
(12) Column Efficiency
(a) Point Efficiency, EOG
Ng =
27 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
=M
= = 0.911 ; M = 1.635
= 1.489
Nog = = 0.6156
NPe =
Emv = 0.565
(c) Overall column efficiency, Eoc
Eoc = =
28 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
Total number of plates = 12 + 13 = 25 plates.
COST ESTIMATION
Monochlorobenzene plant size = 62.5 T/day
Taking cost indices of (1134 in 1997) and (100 in 1926)
Fixed capital investement in 1926 = Rs 12.82 crores
Fixed capital investment = Rs 170 crores
Estimation of total investment cost:
1) Direct cost:
a) Purchased equipment cost:(15 40% of FCI )
Assume 30% of FCI
=Rs 51 crores
b) Installation cost:(35 45% of PEC)
Assume 35%
=Rs 17.85 crores
c) Instrument and control installed:(6 30% of PEC)
Assume 25% of PEC
=Rs 12.75 crores
d) Piping installation cost:(10 80% of PEC)
Assume 60%
=Rs. 30.6 crores
e) Electrical installation cost:(10 40% of PEC)
Assume 35% of PEC
=Rs 17.85 crores
f) Building process and auxilliary:(10-70% of PEC)
Assume 60%
=Rs 30.6 crores
g) Service facilities:(30-80% 0f PEC)
Assume 50%
=Rs 25.5 crores
h) Yard improvement:(10-15% of PEC)
Assume 10%
=Rs 5.1 crores
i) Land:(4-8% of PEC)
Assume 6%
=Rs 3.06 crores
Therefore direct cost =Rs 194.31 crores
Indirect cost:
Expenses which are not directly involved with material and labour of actual installation or
complete facility
a) Engineering and supervision:(5-30% of DC)
Assume 25%
=Rs 48.57 crores
b)Construction expenses:(10% of DC)
=Rs 19.431 crores
c)Contractors fee:(2-7% 0f DC)
Assume 6%
29 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
=Rs 11.65 crores
d)Contingency:(8-20% of DC)
Assume 12%
=Rs 23.31 crores
Therefore total indirect cost =Rs 102.96 crores
Fixed capital investment:
Fixed capital investment(FCI) = DC+IC
= 102.96 + 194.31 = Rs 297.27 crores
Working capital investment:
10 20% of FCI
Assume 16%
=Rs 47.56 crores
1)Total capital investment:
= FCI + WC
=Rs 345.53 crores
Estimation of total product cost(TPC):
Fixed charges:
a) Depreciation:(10% of FCI for machinery)
=Rs 29.727 crores
b) Local taxes:(3-4% of FCI)
Assume 3%
=Rs 8.9181 crores
c) Insurances:(0.4-1% of FCI)
Assume 0.7%
=Rs 2.080 crores
d)Rent:(8-12% of FCI)
Assume 10%
=Rs 29.727 crores
Therefore total fixed charges =Rs 70.45 crores
But, Fixed charges = (10-20% of TPC)
Assume 15%
Therefore Total product cost = Rs 469.66 crores
Direct production:
a) Raw material:(10-50% 0f TPC)
Assume 40%
=Rs 187.86 crores
b)Operating labour(OL):(10-20% of TPC)
Assume 15%
=Rs 70.449 crores
c)Direct supervisory and electric labour:(10-25% of OL)
Assume 20%
=Rs 14.08 crores
b) Utilities:(10-20% of TPC)
Assume 15%
=Rs 70.449 crores
Maintainence:(2-10% of FCI)
Assume 8%
=Rs 23.381 crores
c) Operating supplies (OS):(10-20% of maintainence)
Assume 15%
30 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
=Rs 3.50 crores
d) Laboratory charges:(10-20% of OL)
Assume 12%
=Rs 8.45 crores
e) Patent and royalties:(2-6% of TPC)
Assume 4%
=Rs 18.78 crores
Plant overhead cost:
50-70% of (OL+OS+M)
Assume 65%
=Rs 63.40 crores
General expenses:
a) Administration cost:(40-60% of OL)
Assume 50%
=Rs 35.22 crores
b) Distribution and selling price:(2-30% of TPC)
Assume 20%
=Rs 93.932 crores
c) Research and development cost:(3% of TPC)
=Rs 14.0898 crores
Therefore general expenses(GE) =Rs 143.24 crores
Therefore manufacturing cost(MC)= Product cost+fixed chages+Plant overhead expenses
=Rs 603.51 crores
Total production cost:
Total production cost =MC + GE
=Rs 746.75 crores
Gross earnings and rate of return:
The plant is working for say 320 days a year
Selling price =Rs. 25 /kg
Total income =62.5320100025
=Rs 500 crores
Gross income =Total income total product cost
=Rs 30.34 crores
Tax =50%
Net profit =Rs 15.17 crores
Rate of return =net profit/total capital investment
= 4.41 %
31 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e
CONCLUSION
REFERENCE
32 | P r o d u c t i o n o f M o n o c h l o r o b e n z e n e