Académique Documents
Professionnel Documents
Culture Documents
By
Siddharth Maity
B.E., Mumbai University, 2006
Master of Engineering
in
Industrial Engineering
December 2009
MANUFACTURING OF PENTAERYTHRITOL
By
Siddharth Maity
B.E., Mumbai University, 2006
________________________________
Faculty Name
ACKNOWLEDGEMENTS
I take this opportunity to express my sincere gratitude towards Dr. Suraj M. Alexander for his
guidance, help and constant encouragement. This Project Report would not have been possible
I also thank Bhageria Dye-Chem for allowing me to visit their plant and providing me with data
INTRODUCTION____________________________________________________________6
Reactions of Pentaerythritol___________________________________________________________10
Product Applications____________________________________________________________________13
PROCESS SELECTION____________________________________________________17
PROCESS DESCRIPTION_________________________________________________19
THERMODYNAMIC FEASIBILITY_________________________________________20
MATERIAL BALANCE_____________________________________________________21
ENERGY BALANCE________________________________________________________29
DESIGN OF EQUIPMENT_________________________________________________34
CONCLUSION_____________________________________________________________63
REFERENCES_____________________________________________________________64
References
Abstract
Pentaerythritol, an organic compound has found its use in a wide range of industries due to its
multi-functionality and favorable physical & chemical properties. This project studies the various
chemical and industrial aspects involved in the manufacturing of this compound. Process
selection, Material & Energy Balance, Design of Equipments are some the topics from chemical
engineering which are covered during the course of this project. On the other hand, Plant layout
& selection of location, Service and Utilities, Cost estimation are some topics with industrial
engineering background. This project aims at using and analyzing all these ideas and the
available data to come up with a model which can be used for manufacturing of Pentaerythritol.
Introduction
In the year 1882, pentaerythritol was discovered as byproduct of the reaction between barium
hydroxide and impure formaldehyde. Several year later in 1891, Tollens along with his
coworkers found that the impurity was acetaldehyde, which condensed with the formaldehyde
under mildly alkaline conditions. The name pentaerythritol which was assigned to this compound
was derived from erythritol t o indicate the presence of 4 hydroxyl groups and the prefix “penta”
Pentaerythritol is a white crystalline compound. The high melting point, slight solubility in water
and the ready reactivity of its 4 hydroxide groups have been attributed to the compact symmetric
appearance and has a sweet taste characteristic of polyols. Pentaerythritol is nonhygroscopic and
stable in air and sublimes slowly on heating. It is moderately soluble in cold water, quite soluble
Uptil 1930 all pentaerythritol produced was used in manufacturing of pentaerythritol tetranitrate,
paints, varnishes industry and the production of resins. P.E is increasingly used in resins
CH2OH
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Structure:
HCOH2--------C-------CH2OH
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CH2OH
Physical form White, crystalline and odourless
Molecular weight 136.15
Composition C = 42.2% H = 8.8% O = 49%
Melting point 262oC
Boiling point 276oC at 30m.m pressure.
Specific gravity 1.396
Toxicity Low and nonirritating to skin
Heat of combustion -660 Kcal/Mole
Heat of formation 226.6 Kcal/Mole
Heat of vaporization 22 Kcal/Mole
Heat of sublimation 31.4 Kcal/Mole
optically inactive and stable in air. It is slightly soluble in cold water and readily soluble in hot
water.
3. Acetaldehyde (CH3CHO)
Molecular weight 44
Boiling Point 293.59 K
Melting Point 150.19 K
Liquid Molar Volume 5.652 x 10-2 m3/Kg mol
Heat of Formation -3769.3 KJ/Kg
Gibbs Free energy -2923.81 KJ/Kg
Heat of Fusion 73.07 KJ/Kg
Heat of Combustion -25054.02 KJ/Kg
Liquid Cp 2.483 KJ/Kg-K
Density 1015.7 Kg/m3
4. Formaldehyde (HCHO)
Molecular Weight 48
Boiling Point 235.49 K
Melting Point 129.9 K
Liquid Molar Volume 5881 x 10-2 m3/Kg mol
Heat of Formation -5471.53 KJ/Kg
Gibbs Free Energy -4387.74 KJ/Kg
Heat of Combustion -23077.02 KJ/Kg
Liquid Cp 2.343 KJ/Kg-K
Density 1087 Kg/m3
Molecular Weight 68
Melting Point 533.04 K
Heat of Formation -9529.9 KJ/Kg
Gibbs Free Energy -8552 KJ/Kg
Liquid Cp 2.247 KJ/Kg K
Density 1918.9 Kg/m3
Solubility Data
solvent
Water 25 0C 9.23 97 0C 77.2
Methanol(100%) 25 0C 0.75 50 0C 2.10
Ethanol (100%) 25 0C 0.33 50 0C 1.00
Ether 25 0C 0.45 50 0C 5.00
Ethanol amine 25 0C 0.80 100 0C 10.00
Glycerol 25 0C 16.5 100 0C 44.5
Reactions of Pentaerythritol
1. Oxidation: The polyols are readily attacked by a variety of oxidizing agents like
2. Reduction: The polyols can be reduced by conc. HCL in the presence of certain
catalyst. The end product is secondary alkyl iodide and alkenes without alteration of
3. Esterification: Esters with organic acids can be produced in the usual manner with
acid anhydrides or acid chlorides. Esters with inorganic acids are nitrates which are
explosive.
4. Etherification: ether of the polyols are readily produced by reaction with methyl or
pentaerythritol contents, melting range, hydroxyl content, ash content, acidity, moisture content,
water solubility, color and physical state. The method used for analysis is the Benzal Method.
such as dipentaerythritol.
Byproduct:
water or alcohol.
• Sodium formate: It is the main byproduct heaving field about 10%. It is separated from
The product pentaerythritol is made from acetaldehyde and formaldehyde in the presence of an
alkaline condensing agent. Initial reaction is three successive molecules of formaldehyde added
|
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HCOH2--------C-------CHO
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CH2OH
These reactions are truly catalytic and consume no base. They are also reversible. The equlibria
of above reactions are displaced continuously to the right by a second possible reaction between
two aldehydes in the presence of base i.e. crossed Cannizaro, and the last reaction is not
reversible which gives pentaerythritol.
4. CH2OH
|
|
HCOH2--------C-------CHO + HCHO + NaOH (CH2OH) + HCOONa + Na FORMATE
|
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CH2OH
In the last reaction base, which is a reactant rather than a catalyst is consumed stoichiometrically.
Side Reactions:
Most of the side reactions occur due to formaldehyde and acetaldehyde reacting with each other.
Reactions of acetaldehyde with itself are rapid. However these reactions can be minimized by
Formaldehyde can react with itself to form sugar like products which eventually caramelize to
import color and odor to the products. The self canizzaro of formaldehyde to for CO 2 and
temperature. The desired cannizaro does not progress rapidly below 400C and PH10.
Product Applications
1. Pentaerythritol is principally used in the surface coating field due to its tetrafunctionality
producing higher viscosity, ability of drying vehicles more rapidly than lower polyols,
2. The resins based on pentaerythritol are used in variety of products such as paints,
4. Pentaerythritol esters of fatty acids are used as plasticizers and also as lubricants.
5. Resins prepared from pentaerythritol such as acrolain is used for electrical insulation,
8. It is used in fire retardant surface coatings. When exposed to high temperatures these
coatings froth and swell to produce a solid, non combustible residue which serves to
mixed with TNT to form the explosive pentolite. It also forms the core of the explosive
primacord fuses used for detonating demolition charges and the booster charges used on
blasting.
10. Alkyd resin paint is esters of polybasic acids and polyhydric alcohols which have been
modified by oil and fatty acids. Pentaerythritol is used as a polyhydric acid. In particular,
alkyd paint made with pentaerythritol has superior adhersion, weather & water resistance,
11. Due to its properties it is also used for many types of varnish enamels.
12. Pentaerythritol and fatty acid esters give plasticity to synthetic resins. Pentaerythritol
tetraacetate, when used as a plasticizer for celluloses, acetates and cellulose esters, gives
13. Pentaerythritol and esters of monobasic long chain fatty acids (stearic acid, palmitic
acid), depending on the degree of Esterification, take various physical forms and are used
ionic surface active agents, and are used in softening processes for synthetic fibers and
chemical fibers (acetate, vinylon, nylon). They are also used for smoothing in various
processes of synthetic textile production. Because fatty acid esters of pentaerythritol are
highly stable, have a relatively high boiling point and are low in volatility, they are used
as brake oil as well as lubricating oil and corrosion preventive oil in aircraft engines.
Manufacturers of Pentaerythritol:
➢ Celanese AG (Germany)
➢ Polialco SA (Spain)
Following are the two methods which can be used in the manufacturing of pentaerythritol. These
manufacturing methods are based on the reaction between formaldehyde and acetaldehyde in the
Method – 1
precipitate of CaCO3. Formaldehyde and acetaldehyde are reacted in the presence of Calcium
Hydroxide in S.S. Reactor. The reaction mixture is pumped to precipitator where soda-ash is
added to precipitate CaCO3 leaving formate as sodium formate. After filtration, slurry is
concentrated in a triple effect evaporator. Then crystallization is followed by filtration in the pan
filter. P.E. cake is dissolved and deionised to remove final traces of sodium formate and then the
mixture is again crystallized followed by filtration in second pan filter. The P.E. cake is then
In this process, recovery of sodium formate and additional P.E. from mother liquor decides the
profit and loss margin. Hence the recovery units are the parts of operation and are not separated
from the main unit in any case. The process requires a large number of equipments made up of
S.S. including two pan filters. This causes a rise in the initial equipment cost, making it
unfeasible for profit making. Another factor which adds to the investment is the requirement of
two separate units for removal calcium carbonate and sodium formate. Considering all these
This method uses acids in place soda-ash in the manufacturing of pentaerythritol from
formaldehyde and acetaldehyde. This process is far more economical as compared to the earlier
method. The following main considerations are taken into account for the selection of this
process:
1. The yield in this process is 85 to 90 % which is higher than that in the previous process.
2. Easy removal of sodium ions as they directly combine with formate ions to give sodium
formate.
4. Byproduct sodium formate can be used to produce formic acid which can be reused in the
same plant.
Process Description
Method 2
A solution of formaldehyde (20 to 30% by wt.) is added to 50% NaOH solution. While the
slowly added under the surface of the formaldehyde alkali solution. Since the reaction is
exothermic, external cooling is used to maintain the reaction temperature around 20 to 30 0C.
The mole ratio of formaldehyde to acetaldehyde generally used is between 4.5:1 and 5:1. A ratio
of 1:15 mole hydroxide ion per m ole of acetaldehyde appears to be the optimum amount of
condensing agent.The crude reaction mixture is transferred to the neutralization tank here formic
acid is added to reduce the PH of the solution to 7.8 to 8 and subsequently to remove the sodium
ions present as sodium formate. The solution is then evaporated to a specific gravity of about
1.270. It is then chilled to crystallize pentaerythritol and the resulting slurry is filtered. The
mother liquor goes to the recovery system, where it is reworked and sodium ions are removed as
sodium formate.
The filter cake contains P.E. and Poly-pentaerythritol. The latter material is formed by the side
CH2C(CH2OH)3 ) and other byproducts found in the reaction. The yield of pentaerythritol is
Mother liquor is concentrated in an evaporator crystallizer to the point where sodium formate
comes out of solution. It is separated from P.E. in solution by centrifugation without cooling.
This phase is batch wise with automatically controlled loading and washing cycle. Formate is
Filtrate from the centrifuge is cooled and P.E crystallizes. After filtering in a press filter, these
crystals are dissolved in water and activated carbon is added. The solution goes through a plate
frame press and then is recycled back to P.E evaporator feed tank.
Thermodynamic Feasibility
Compound ∆HF (KJ/Kmol) ∆G (KJ/Kmol)
CH3CHO -16580.52 128647.64
HCHO -108415.5 -409702.8
NaOH -197610.8 -136567.6
HCOONa -6480332.2 -340609.96
P.E. -764200.42 -553219.656
= – 218911.576 KJ/Kmol
∆G = –RT ln Ka at T = 298 K
Material Balance
Required Materials:
Reaction:
Input Data:
Output Data:
Moles of CH3CHO = 757.5 / 44 = 17.2 kg.mole.
HCHO 2350 kg
CH3CHO 1050 kg
NaOH 757.5 kg
H2O 5057.5 kg
= [wt. of (P.E. + HCOONa) + wt. of H2O(x)] / [vol. of (P.E. + HCOONa) + vol. of H2O(x)]
Hence, x = 2727.94 kg
Assume that 14.8% of P.E. is lost i.e. will not crystallizer in the crystallizer.
WaterP.E+Water= 0.06=x/(1994+x)
Hence, x = 127.28 kg
water(x)
1.37=1783.94+347.23+x991.07+248.73+x
Hence, x = 1185 kg
Input Output
H2O 2600.66 kg P.E. 347.23 kg
P.E. 347.23 kg H2O 1185 kg
HCOONa 1783.94 kg H2O (to atm) 1415.66 kg
Total Input 4731.83 kg HCOONa 1783.94 kg
Total Output 4731.83 kg
2. Sodium formate from dryer having 0.3% moisture = 0.03 X 1694.7 = 5.08 kg
H reactant = ∑ m.Cp.dt = (2350 X 0.526 + 1050 X 0.54 + 757.5 X 0.3125) X (298 – 303)
= -10199.1 Kcal/day
Q = m.CP.dt = m X 1 X (303-293)
= 453154.758 kcal/day
= 383471.19 kcal/day
Heat required for vaporization of 121.28 kg of water = 121.28 X 540 = 65491.2 kcal
Hence, Total heat required = 66822.3 + 65491.2 = 132313.5 kcal
Assuming 10% heat loss due to radiation, Hence Heat required = 1.1 X 1323 = 145544.85 kcal
The same amount is to be present in the liquor coming out of the evaporator.
Flow rate:
Total Flow rate (kg/hr) P.E Flow rate (kg/hr) Liquid Flow Rate (kg/hr)
Feed Solution 433.958 97.55 336.40
Thick Liquor 285.54 97.55 167.90
Water + CH2O 148.418 168.5
evaporated
∆T = Th – Tc
Th = 248 0F
Tc = (212 + 192) / 2 = 46 0F
Assume B.P.R. = 1 0F
Hf= 298(298+90)m.Cp.dt
= 28321.17 kg/hr
Hproduct= 298398m.Cp.dt
= 17131.39 kcal/hr
Let, mc = X kg/hr
Hc = 188.17 Btu/lb = 105.64 Kcal/kg (sensible heat for condensate at 221 0F)
The Enthalpy Balance Equation is given by: mf.Hf + ms.Hs = (mf – m)Hv + mc.Hc + ms.Hc
In the neutralization tank formic acid is added to neutralize the excess alkali and to effect
removal of the metallic ion of the condensing agent. Formic cid maybe added to reduce pH of
solution to 7.8 to 8 and subsequently to remove the sodium ion present as sodium formate.
Selection of Equipment: The reaction is carried out in a cylindrical vessel provided with the
drain value at the bottom for the gravity flow. To achieve the good mixing of the reactants, a 6
Selection of MOC: In the selection of material of construction for any vessel, the factors to be
considered are initial lost, corrosive action of the reactants, cost of replacement, maintenance and
probable life. Taking the corrosive action of NaOH into account, the best choice to use is
Stainless Steel.
Mechanical Design Calculation: Since the kinetic data is not available, we have to design the
Residence time, T = V/ vo
Hence, V = [ ∏ D2 (1.25D) ] / 4
D = 71.89 cm = 72 cm
Shell Thickness: In the tank the pressure is atmospheric, hence the maximum pressure will at the
bottom due to the hydraulic pressure. Taking maximum design pressure to be 20 psi.
E = Joint efficiency
C = Corrosion Allowance
ts = [((20 X 72) / (2 X 20000 X 0.8))+ 0.005] X 2.54
ts = 0.127 cm = 1.27mm
We can take thickness of bottom and head equal to shaft i.e. 5mm. Select the elliptical head and
Space allowance
= ( ∏ / 4 ) X D2 ( h1 – b )
= 369420 – (∏ D3) / 24 = ( ∏ / 4 ) X D2 ( h1 – b )
Hence, h1 = 96.72 cm
This is the height of the liquid level from bottom of elliptical head.
In order to provide better mixing, 6 blade turbine agitator is the best choice.
Da = 0.6 X 72 = 43.2 cm
n = 75/60 = 1.25
From table, a = 1, b = 40
Number Required 1
Type Cylindrical, closed tank with turbine type
agitator
Normal Capacity 370 ltr
Critical Dimension Overall height = 90cm
Inside diameter = 72 cm
Diameter = 44cm
Rpm = 75
gravity flow
Cost Rs 2,00,00 (Approx)
To evaporate 1 lb of water, steam required is about 1 to 1.3 lb or 1000 to 1200 Btu heat is
required.
Circulation and heat transfer in this type of evaporator is strongly affected by the liquid level as
indicated by an external gauge glass, which is only about half way of the tube. Slight reduction
in level below the optimum results in incomplete wetting of the tube walls with a consequent
increase in tendency to foul and causes rapid reduction in capacity. When this type of evaporator
is used with a liquid that can deposit scale, it is customary to operate with the liquid level
appreciably higher than the optimum level which is above the top tube sheet.
• Relatively inexpensive
• Mild scaling solution can be used for mechanical cleaning as the tubes are short and large
in diameter
engineering: Mc Cabe)
The liquid Flowrate coming out of the evaporator is calculated using material balance. Since the
inlet steam pressure is known, a certain volume is assumed in the evaporator to find the
corresponding temperature for saturated steam. Using this value the total temperature difference
The energy balance equations for the evaporator are used in order to calculate the heat duty.
Taking the ud values from Mc Cabe, the total heat transfer area for the evaporator is calculated.
By manipulating the temperature drop appropriate area is calculated. For this calculated area,
Q = 1316857.143 Kcal/hr
∆T = 45 0F
For Sheet Diameter: C/S Area of one tube = (π/4).d2.l = (3.14/4) X (2.2)2 X (48) = 182.463 in2
From McCabe, 30% of A is the area of downcomer = 182.463 X 0.3 = 54.4 in2
Hence, d ≈ 8 inches
Length & Number of tubes: in standard short tube evaporators the length varies from 4 to 8 ft
and the diameter is around 2 to 4 inches. In this case, the length is assumed as 4ft and diameter as
2 inches.
A staggered arrangement is used as it permits higher tube accommodation, for a given distance
between the tubes. From the approximate calculations, the shell inside diameter is taken as 21.2
inches.
Thickness of Shell = [(P.d) / (2.f.E) ] + Corrosion Allowance
Design of evaporator and its accessories: The standard evaporator consists of a vertical
cylinder with calendria across which the heat exchange takes place. The cylindrical body
terminates at the top in a “save all”, the objective of which is to separate the liquid droplets
which maybe entrained with the vapor from the solution. Previously the evaporator body was
fabricated with cast iron; however more recently fabrication using steel plate is becoming more
common.
Height of the Vessel: The space above the tubular calendria represents the greater part of the
volume taken up by the equipment. The objective is to diminish the risk of entrainment of
Calendria: It is the continuation of the shell or body of the evaporator. It is often fixed to the
shell. The bore of the holes provided in the tube plate is about 1/32 inch greater than the outer
diameter of the tubes. Vertical baffles are often placed in the calendria with the object of
Solution which has been projected over the top tube plate is returned to the bottom by the
downcomer. This center well is often used to collect the concentrated solution in order to transfer
Air source for condenser: Air introduced into the condensers comes from various sources such
as air contained in the heating system, air introduced in the cold rejection water, air entering by
leakage.
Number Required 1
Type Short tube, vertical calendria type evaporator
Normal Capacity 328.25 ltr/hr
Working Pressure 2 atm
Critical Dimension Overall height = 220 inches
Number of tubes = 22 to 24
Material of construction Stainless steel
Baffles As per requirement
Nozzles or jet stream At steam inlet to increase velocity
Cost Rs 6,00,000(Approx)
List of Major Equipments
1. Reactor
Number Required 1
Type S.S. jacketed cylindrical type reaction vessel
manhole etc.
Heat transmitting surface 4 square meter.
Agitator type Anchor type with explosion proof motor
Number Required 1
Type Vertical Cylindrical round bottom tank
Normal Capacity 370 ltr
Dimensions D = 72cm, H = 90cm, Thickness = 5mm
MOC Stainless Steel
Agitator Turbine type, 6 bladed
3. Centrifuge
Number Required 5
Type Basket Type
Normal Capacity 85 ltr
Cake Capacity 400 kg/ltr
Overall Dimensions Basket = 60cm I.D , Depth = 30cm,
Number Required 1
Type Counter current rotary dryer
Normal capacity 150 kg/hr
Dimensions & other details L = 12.5 ft, D = 2.5 ft, Speed = 5 RPM, H.P = 10
Outgoing Temp = 90 0C
5. Evaporator
Number Required 1
Type Short tube calendria type
Normal capacity 1600 ltr
Dimensions & other details D = 55cm, Ht = 550 cm, Shell thickness = 5cm
6. Evaporator Crystallizer
of HCOONa
No. Required 1
Type Single effect evaporator crystallizer with pump
7. Holding Tank
Number Required 2
Type Cylindrical type
Normal Capacity 160 ltr
Dimensions D = 60cm , H = 75 cm
MOC Stainless Steel
Cost Rs 50,000 (Approx)
8. Pumps
Number Required 8
Type Centrifugal
Normal Capacity 15 Gallons per minute
Drive Motor 3 H.P
MOC Stainless Steel
Cost Rs 50,000 (Approx)
9. Boiler
Feed pump.
Controllers are gaining utmost importance in industries due to their efficiency, compactness,
response and hazard control capability. These advantages of automatic systems outweigh their
variables depend on physical and chemical conditions, which vary with time. To control the
product quality it is necessary that different process variables like temperature and pressure are
maintained to prefix values. Fully automatic plant gives uniform products, avoids accidents and
minimizes the cost of labor; however it causes an increase in the initial cost of the project. the
present project is operated on batch basis and requires moderate capital investment.
Process control and automation together with their instrumentation can be considered as the
mechanical brain and nerves of modern chemical processes. However automatic control is highly
expensive. As far as the current plant is concerned no automation is recommended except for a
temperature controller. The temperature controller is used to control and stop the reaction. Also
For temperature measurements of the reactor, thermo couples type measuring services are used.
One pressure gauge is also used for the reactor for safety purposes. Various values are provided
in pipe lines for manually controlling the quantity and flow rates of liquids. As the process is
One of the most important parts of the final planning is the site location. Careful selection and
engineering research is necessary for attaining the advantage of the process and development
• Raw material supply: Raw material should be cheaply and regularly available. Plant site
near to the raw material source permits considerable reduction in transportation and
storage charges.
• Market: Plant location near to the market reduces the cost of product distribution and
shipping time. If the plant is not situated near to the market for its final product, quick
• Power and fuel supply: Electricity and fuel should be available regularly otherwise the
• Water supply: Process industries require water for processing, cooling, steam generation.
When an industry requires large amounts of water it should be located at areas with
• Climate: Weather has a serious effect on the economic operation of a plant. The
temperature and humidity should be favorable for human body. Pentaerythritol reacts
transportation. These services should be available near the plant for cheap and quick
transportation.
• Labor supply: Availability of labor at stable pay rates should be considered. The other
factors that need to be considered are the intelligence, stability, efficiency of the labor for
economic planning.
• Taxes and regulation laws: State and local tax rates on property, income, building codes,
restrictions on transportation are some of the factors which need to considered while
• Site characteristics: Soil structure, availability of excess space for future expansions and
• Layout of the plant: The advantage of gravity flow should be taken if possible in order to
reduce the pumping cost. Water, steam and power should be available for cheap. Safety
of the site location should be considered in order to avoid hazards such as fire explosions.
The site should have a proper waste disposal system. Proper usage of the floor and
• Equipment layout: While designing the plant layout ample of space should be provided to
all the equipments as they may need replacement, repairs and maintenance at regular time
intervals. If the equipments are placed very close to each other in a plant it raises the risk
material. In this case reaction mass and also the mass form evaporator.
Service and utilities
The main services required for the manufacturing of Pentaerythritol from formaldehyde and
I. Neutralization Reaction
The requirement can be served by municipal water supply or the industries own water supply is
recommended.
• Cooling Water: It is required to extract the exothermic heat of reaction to maintain the
• Process Air: The heated air or steam is required in the plant as a heating medium in the
• Steam: Steam is required in the plant for heating and for evaporation of water in the
evaporator. It is also used in holding tanks to keep the reaction mixture in solution form.
• Electricity: When power requirement is high, industries should have their own power
stations. However in small scale industries, power is supplied by the state government
electricity board.
A computation of all data relative to the cost of raw materials, land, buildings, labor and
supervision, equipment cost, taxes, insurance, interest etc. should be obtained by the designer on
an approximate pre-construction cost estimation basis. This data can be used for the actual
operation cost accounting if the project goes commercial. It gives the investors a rough estimate
All the costs taken into account may vary according to the market demand and supply.
COST ESTIMATION:
Total Equipment Cost (P.E.C) = Total Cost (A) + Total Cost (B)
Total Direct Cost (T.D.C) = I.E.C + P.C + I.C + L.C + Building + I.E.F
Total physical plant cost (P.P.C) = Total cost of auxiliary items + T.E.C
= Rs. 2,88,52,000
NaOH (50%) = Rs. 9/kg X 1050 kg/day X 300 days/yr = Rs. 28,35,000
Cost of Power:
Total Cost of Power = 51.84 X 0.9 KWHR x 300 days X 24 hrs X 5 Rs/Unit KWHR
Cost of Steam:
Steam required per year = 4090 kg/day X 300 days/yr = 12,27,000 kg/yr
Utility Cost
Fix charges
Product sales value, Penterythritol = 72 Rs/kg X 2000 kg/day X 300 days/yr= 432 lakhs/year
Sodium formate recovery (Bypdt) = 15 rs/kg X 1700 kg/day X 300 days/year = Rs. 76.5 lakhs
Payout Period=1+366.4478-84.0888.52
Pentaerythritol is produced using formaldehyde and acetaldehyde using acids instead of soda-ash
as it is more economical.
Required Materials:
Based on the production requirements, Material Balance for the entire process and Material
balance for individual equipments is carried out. Sodium Formate is separated from P.E in the
Sodium Formate recovery unit, where it is converted into Formic acid. Energy Balance and
Design of Equipments is studied based on which the requirements and cost of the equipments is
approximated. Cost Analysis helps in determining the pay-back period for the project which
works out to 4.2 years. For the Cost Analysis all the factors which contribute towards the total
McCabe W.L., Smith J.C., Harriot P., “Unit Operations of Chemical Engineering 5th Edition”
Peters M.S., Timmerhaus K.D., “Plant Design and Economics for Chemical Engineering 3rd
Edition”
Websites:
www.chemicalland.com
www.chemicalregister.com
www.pentaprocess.com
www.chemicalweekly.com
www.kanoriachem.com