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PROJECT REPORT
Title of the problem : Design a plant to produce 5000 tons per annum Methyl ethyl
1
Manufacture of Methyl Ethyl Ketone form
Secondary Butyl Alcohol
PROJECT REPORT
Title of the problem : Design a plant to produce 5000 tons per annum Methyl ethyl
2
INDIAN INSTITUTE OF CHEMICAL ENGINEERS
Jadavpur University Campus, Kolkata - 700032.INDIA
BONAFIDE CERTIFICATE
This is certify that dissertation of the project work (MEK).
……………………. …………………………….
Membership.Head of Department.
Place. Kolkata
Date:
Certified that the candidate ………………………………………………….was
Examined by us in the PROJECT WORK and VIVA VOCE examination held
On……………………
……………………. …………………...
Internal Examiner External Examiner
3
ABSTRACT
Thus the project based on manufacturing of MEK 5000 tons per year includes.
1. Material balance
2. Energy balance
a) Condenser
b) Absorption
5. Cost estimation
In carrying out this project we applied
a) Chemical process calculation
d) Economic
Thus the project covers all aspects required for the manufacturing of MEK and
Could be implemented in reality.
4
Contents
Manufacture of Methyl Ethyl Ketone form Secondary Butyl Alcohol ......................................................... 1
PROJECT REPORT ..................................................................................................................................... 1
Manufacture of Methyl Ethyl Ketone form Secondary Butyl Alcohol ......................................................... 2
PROJECT REPORT ..................................................................................................................................... 2
ABSTRACT ..................................................................................................................................................... 4
NOMENCULTURE ..................................................................................................................................... 7
INTRODUCTION ........................................................................................................................................ 9
METHYL ETHYL KETONE:- ................................................................................................................ 9
PHYSICAL AND CHEMICAL PROPERTIES OF MEK ......................................................................... 11
PHYSICAL PROPERTIES:- .................................................................................................................. 11
CHEMICAL PROPERTIES:-................................................................................................................. 13
Miscellaneous Reactions......................................................................................................................... 13
USES:- .................................................................................................................................................... 15
ECONOMIC ASPECT:- ......................................................................................................................... 15
TOXICOLOGY: ......................................................................................................................................... 17
PROCESS SELECTION AND DETAILS ................................................................................................. 18
PROCESSES MANUFACTURING METHODS .................................................................................. 18
PROCESS SELECTION ........................................................................................................................ 18
PROCESS DESCRIPTION .................................................................................................................... 19
RAW MATERIAL REQUIRMENT ...................................................................................................... 20
Major raw materials required:................................................................................................................. 20
VAPOR PHASE DEHYDROGENTAION OF 2-BUTANOL: ............................................................. 21
LIQUID PHASE OXIDATION OF BUTANE: ..................................................................................... 22
DIRECT OXIDATION OF N-BUTENES, HOECHST-WACKER PROCESS: ................................... 22
DIRECT OXIDATION N-BUTENES, MARUZEN PROCESS: .......................................................... 23
PROCESS SELECTION: ....................................................................................................................... 23
MATERIAL BALANCE ............................................................................................................................ 26
BASIS: .................................................................................................................................................... 26
REACTOR.............................................................................................................................................. 26
CONDENSER ........................................................................................................................................ 28
SEPARATOR ......................................................................................................................................... 28
ABSORBER ........................................................................................................................................... 29
MEK balance: ......................................................................................................................................... 29
5
EXTRACTOR ........................................................................................................................................ 31
MEK PRODUCT DISTILLATION COLUMN ..................................................................................... 32
Material balance.......................................................................................................................................... 34
REACTOR.............................................................................................................................................. 34
CONDENSER ........................................................................................................................................ 35
SEPARATOR ......................................................................................................................................... 36
ABSORBER ........................................................................................................................................... 36
EXTRACTOR ........................................................................................................................................ 37
SOLVENT RECOVERY DISTILLATION COLUMN ......................................................................... 37
MEK PRODUCT DISTILLATION COLUMN ..................................................................................... 38
ENERGY BALANCE ............................................................................................................................ 39
PIPING AND INSTRUMENTATION ....................................................................................................... 79
AUTOMATION CONTROL: ................................................................................................................ 79
FLOW CONTROL: ................................................................................................................................ 79
INSTRUMENTATION AND CONTROL OBJECTIVES: ................................................................... 79
TERMINOLOGY ................................................................................................................................... 83
PROPERTIES ......................................................................................................................................... 83
Physical Properties.................................................................................................................................. 83
Chemical Properties ................................................................................................................................ 84
HEALTH EFFECTS AND TOXICITY INFORMATION ........................................................................ 85
General.................................................................................................................................................... 85
PERSONAL PROTECTIVE EQUIPMENT .......................................................................................... 85
STORAGE, HANDLING, LABELLING AND TRANSPORTATION .................................................... 86
Labelling .............................................................................................................................................. 86
Waste Disposal ........................................................................................................................................... 87
FIRE PREVENTION AND FIRE FIGHTING........................................................................................... 87
TRAINING AND HEALTH MONITORING ............................................................................................ 88
FIRST AID ............................................................................................................................................. 88
CONCLUSION........................................................................................................................................... 89
6
NOMENCULTURE
8
INTRODUCTION
Methyl ethyl alcohol, also known as 2-butanone is a colorless organic liquid with an acetone like
odor and a low boiling point. It has very good solvent properties, a fast evaporation rate, and is
miscible with organic Solvents. MEK is an excellent solvent for a variety of resin systems used
The molecular formula of methyl ethyl ketone is CH3COCH2CH3 and its molecular structure is
represented as:
Ketones are organic compounds containing one or more carbonyl groups bound to two carbon
R --- CO --- R’
Based on the hydrocarbon ( R , R’ ) groups attached to the carbonyl group, ketones can be
classified. MEK has the molecular structure: CH3 – CO – C2H5.It is asymmetric or mixed
2-Butanone ,methyl ethyl ketone, MEK, is the 2nd link in the homologous series ofaliphatic
ketones and next to acetone, the most important commercially produced ketone.It is
9
catalyst at 400 – 5000C. At 80-95% sec butylalcohol conversion, MEKselectivity is greater than
95%. Butenes (dehydration) and higher ketones (auto condensation) are the by-products.Methyl
Ethyl Ketone (MEK) is a low –boiling, chemically stable compound also knownas 2- butanone.
MEK is a flammable, colourless liquid possessing a typical ketonic odor.It has very good solvent
properties, a fast evaporation rate, and is miscible with organic solvents. MEK is an excellent
solvent for a variety of resin systems used in thePreparation of paints and lacquers.Interest in
MEK as a solvent for paints and adhesives has been growing in recentyears. It has broad
vinyl acetate and vinyl chloride – vinyl acetate copolymers.Moreover, MEK can be used as an
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PHYSICAL AND CHEMICAL PROPERTIES OF MEK
PHYSICAL PROPERTIES:-
(79.60C). Methyl Ethyl Ketone (MEK) is a chemically stable compound also known as 2-
butanone. MEK is a flammable, colourless liquid possessing a typical ketonic odor. It hasvery
good solvent properties, a fast evaporation rate, and is miscible with organicsolvents. MEK is an
excellent solvent for a variety of resin systems used in thepreparation of paints and lacquers. It is
highly miscible with water and manyconventional organic solvents and forms azeotrope with
1. Physical Properties of MEK (all values are at 200C, except where noted)
11
13. Explosive limits in air, vol.%
12
CHEMICAL PROPERTIES:-
Methyl Ethyl ketone can be widely utilized in chemical synthesis. Its reactivity
centers around the carbonyl group and its adjacent hydrogen atoms. Condensation,
ammonolysis, halogenations, and oxidation can be carried out under the proper
Self-Condensation:
unsaturated ketone:
O CH3 O
2CH3CCH2CH3 CH3CH2CCH3CCH2CH3
CH3 O
CH3CH2C==CHCCH2CH3+H2O
Reaction with aldehydes gives higher ketones, as well as ketals and cyclic compounds,depending
on reaction conditions. β - ii ketones are produced by the condensation ofMEK with aliphatic
esters. MEK condenses with glycols and organic oxides to givederivatives of dioxolane. sec-
O Ni NH2
CH3CCH2CH3+NH3+H2 CH3CHCH2CH3+H2O
An excess of MEK in this reaction will produce di-sec-butylamine.Reacting MEK with acetylene
CH3CCH2+HC CH CH3CH2CCOH CH
Miscellaneous Reactions
13
Oxidation of MEK with oxygen produces diacetyl, a flavouring material. Chlorinationyields
reaction conditions. The reaction of MEK with hydrogen peroxide gives amixture of peroxides
O OH
OOH
This initial addition product is the unstable precursor of seven stable peroxides andhydro
HOOC – OO – COOH
C2H5 C2H5
MEK peroxides are widely used as catalysts for the polymerisation of polyesterresins at room
temperature. The condensation product of MEK and m-phenyl diamine isan efficient curing
agent for epoxy resins. MEK and cobalt acetate function together as aspecific catalyst for single-
speed condensation times and causeless yellowing of the polymer than antimony trioxide. MEK
chemicalscan be reacted with MEK to form resins useful for adhesives, coatings, molded
products,and electrical insulation. MEK reacts with acrylonitrile to produce a dinitrile, which
14
USES:-
More than half the MEK produced in the United States finds application insurface coatings end
uses. Significant volumes are also used in the production ofadhesives, magnetic tapes, printing
inks, solvent extraction, cleaning fluids, dewaxingagents, and dyes.In surface coatings MEK is
widely used as a component in vinyl lacquer solventsystems. Its active solvency for vinyl acetate
and vinyl chloride – vinyl acetatecopolymers makes it possible to formulate high solids lacquers
solvent fornitrocellulose and is extensively used in furniture and automotive lacquers. The
lowspecific gravity of MEK enables formulators to produce larger volumes of base lacquersor
thinners per pound than is possible with heavier solvents. MEK is also a coatingssolvent for
many resin systems including alkyds and air-dried epoxies. It performs extremely well in fast
drying traffic paints and has become an important component inplacing air pollution regulated
solvents, such as toluene, which are frequently used inthese alkyd formulations.
MEK is a dewaxing agent in the refining of lubricating oils and is asolvent for adhesives, rubber,
cement, printing inks, paint removers and cleaningsolutions. It is used in vegetable oil extraction
ECONOMIC ASPECT:-
Demand for MEK has increased at a rate of 6.5% per year and is continued to grow
at about this rate in future. Apparently the long term decrease in demand owing to
15
Chemical industry, pharmaceutical industry – 13%
Adhesives – 11%
Miscellaneous – 16%
16
TOXICOLOGY:
The inhalation of MEK vapours has narcotic effects. The vapour irritates the eyes
and the nasal and pharyngeal membranes. Frequent and prolonged contact with MEKcauses skin
moisture loss and slight irritation .Sensitive persons may develop demitasses.Liquid MEK
temporarily irritates eyes and corneas .MEK is usually absorbed throughthe respiratory track. It
may also be absorbed through the skin.The odour threshold for MEK is 10 ppm .
Toxic concentration for water organisms :Average lethal concentration for fish – 5600 mg / lit
17
PROCESS SELECTION AND DETAILS
There are a few processes listed below for the production of MEK.
PROCESS SELECTION
The vapour phase dehydrogenation process gives high conversion of 2-butanol and high
selectivity of MEK of about 95 mole%. Other advantages of this process include better yield,
longer catalyst life, simple production separation and lower energy consumption.In
fuel.In dehydrogenation process, there is the feasibility of separating the MEK from the reaction
products.The dehydrogenation process can easily be carried out at moderate temperature and at
uneconomical.Chromic acid and sulphuric acid in aqueous acetone is required for selective
Of all the processes, it has been found that “dehydrogenation of secondary butyl alcohol” has
more advantages and is more economical compared to other processes, so this process has been
18
PROCESS DESCRIPTION
The cold feed of secondary butyl alcohol from feed tank is initially preheated in steam heater.
The preheated alcohol is taken to vaporizer and further superheated by the high temperature
reaction products discharged from reactor and gets vaporized. The alcohol vapors leaving from
vaporizer enter into a knockout drum to separate liquid alcohol and vapors entrained liquid. The
separated liquid is recycled back to vaporizer. The dry vapors of secondary butyl alcohol leaving
from the knockout drum are heated up to 500°C in super heaters and enter the reactor containing
In reactor, temperature is maintained between 400-550°C at which secondary butyl alcohol starts
dehydrated and produce methyl ethyl ketone and hydrogen. 90% of the feed is converted into
ZnO
CH3CH2-CHOH-CH3 CH3CH2-CO-CH3 + H2
heat is to be supplied. Hence, a multi-tube reactor is selected. In order to utilize the heat energy
and lower the temperature of the gaseous reaction products (contain MEK, unreacted secondary
butyl alcohol vapors and hydrogen); it is routed to vaporizer to preheat the feed. The reaction
products are then cooled in condenser. 80-85% of MEK and the unreacted secondary butyl
alcohol vapors get condensed in condenser. Outlet from condenser is taken to a separator where
liquid and gas get separated.The uncondensed vapors and non-condensable hydrogen from the
separator is taken to absorption column to separate hydrogen from the alcohol vapors. In
absorption column, aqueous ethanol is used as absorbent. Around 98% of MEK and secondary
19
butyl alcohol vapors are absorbed in aqueous ethanol. The hydrogen off gas from the top of the
The aqueous solution contains MEK and secondary butyl alcohol from the absorber is pumped
into an extraction column where 95% of MEK and alcohol is extracted into trichloroethane
(TCE). The raffinate is recycled back to absorber and the extract is passed to solvent recovery
distillation column. In solvent recovery distillation column, 99.9% MEK and alcohol are
separated from the solvent asdistillate and the residue containing TCE and traces of MEK and
The distillate from solvent recovery distillation column and the condensed MEK from condenser
are taken to product distillation column where the final purification occurs. In distillation
column, 99.9% pure methyl ethyl ketone is distilled as final product. The product MEK is cooled
and stored in product storage tank. The residue from distillation column bottom is mainly
contains unreacted secondary butyl alcohol which is recycled back to feed storage tank.
Plant capacity: 5000 tons Methyl ethyl ketone (99.9%) per annum
To produce 5000 tons per annum methyl ethyl ketone, the required secondary butyl alcohol is
2. Trichloroethane
3. Aqueous ethanol
20
4. Utilities:
5. Cooling water
6. Steam
7. Flue gas
There are a few processes listed below for the production of MEK.
MEK is prepared by vapor phase dehydrogenation of 2-butanol. A 2 step process from butanes,
which are first hydrated to give 2-butanol, is used. The dehydrogenation of2-butanol is an
The MEK concentration in the reaction mixture increases and reaches its maximum
21
6months use. They have a life expectance of several years.Sec-butyl alcohol is dehydrogenated
in a multiple tube reactor, the reaction heatbeing supplied by heat transfer oil. The reaction
products leave the reactor as gas and aresplit into crude MEK and hydrogen on cooling. The
hydrogen is purified by furthercooling. The crude MEK is separated from uncreated reactants
MEK is produced as a by-product in the liquid phase oxidation of n-butane toacetic acid.
Autoxidation of n-butane of n-butane takes place in the liquid phaseaccording to the radical
mechanism yielding MEK as an intermediate and acetic acid asend product. MEK and acetic
acid (mass ratio 0.2: 1.0) are obtained by non-catalyzedliquid phase oxidation at 1800C and 53
bars with remixing. Continuous oxidation underplug flow conditions at 1500C, 65 bars and a
residence time of 2- 7 minutes forms MEKand acetic acid at a mass ratio of 3:1. this process has
slight economic advantage over thedehydrogenation of 2-butanol. But the key factor is
n – C4 H8 + ½ O2 CH3 – CO – C2H5
95% conversion of n-butanes can be obtained with the MEK selectivity of about 86%.The main
22
DIRECT OXIDATION N-BUTENES, MARUZEN PROCESS:
The Maruzen process is similar to the Hoechst-Wacker process except thatoxygen is transferred
commercial route to get MEK via direct oxidation of n-butenes, but itis patented and very less
information is available about this process. This process isgenerally not accepted due to
PROCESS SELECTION:
vapor phase over ZnO or Brass catalyst. It can, however be produced by theselective direct
produced C4raffinates). The remaining MEK is produced by process in which liquid butane
iscatalytically cracked giving both acetic acid and MEK.The vapor phase dehydrogenation
process gives high conversion of 2-butanol andhigh selectivity of MEK of about 95 mole%.
Other advantages of this process includebetter yield, longer catalyst life, simple production
MEK is produced as by product from liquid phase oxidation of n-butenes toacetic acid. The
process has slight economic advantage over dehydrogenation of 2-butanol, but the key factor is
the availability and price of n-butanes.Of all the processes, it has been found that
23
PROCESS DETAILS:
The cold feed of 2-butanol will be pumped from the feed tank to a steam heaterto a vertical
heated by reaction products discharged from the reactor. The wetalcohol vapor will be passed to
a knock out drum to remove any entrained liquid. Theliquid separated will be recycled and the
dry alcohol will be fed to the reactor via superheaters heated by flue gas. The super heaters will
be designed to raise the temperature of alcohol vapors to 5000C at which temperature the vapors
OH
The dehydrogenation reaction is endothermic and reversible and therefore aconsiderable amount
of heat is to be supplied and hence, a multi-tube reactor is selected.The gaseous reaction products
discharged from the reactor at a minimum of4000C will be passed on to the thermosyphon
vaporizer in order to initiate the preheatingof alcohol reactor feed. The reaction products will be
cooled to near saturation in thevaporizer so that they will enter the water condenser at 150 0C.
There about 80% MEKand alcohol will be condensed and sent to the storage while the remainder
This vapor will be fed to the bottom of the packed bed absorption column whereMEK and 2-
butanol will be absorbed in water. The water will be recycled from theextraction column and its
rate will be controlled to provide an aqueous effluentcontaining 10% MEK. The hydrogen
discharged from the top of the absorber will bedried and fed to the furnace.The aqueous effluent
from the absorber will be pumped into an extraction columnwhere it will be contacted with
1,1,2-Trichlorethane to extract MEK and alcohol. Inexcess of about 95% of the MEK and
24
alcohol will be extracted and remainder will bere-circulated back to the absorber.The
trichloroethane extract phase will be pumped to a distillation unit for theseparation unit for the
separation of solvent, which is recycled. The distillate from thiscolumn will be MEK and
alcohol, which will be, mixed liquid product form thecondenser and this will be treated in a
MEK product still for the purification ofMEK. The alcohol discharged from the bottom of this
column will be replaced back toalcohol feed tank. The MEK product will be cooled and stored.
25
MATERIAL BALANCE
BASIS:
Hydrogen 2
REACTOR
C4H10O C4H8O + H2
26
MEK = 0.876W (Kg/hr)
H2 = 0.0243W (Kg/hr)
Reactor
27
CONDENSER
In condenser, 80% of methyl ethyl ketone and unreacted SBA getscondensed. Condenser outlet
is two phased flow- contains condensed liquid anduncondensed/non condensable vapors.
Vapor phase:
H2 = 0.0243W (Kg/hr)
SEPARATOR
The condensed liquid and uncondensed vapors get separated in separator. The separated vapor
goes to absorber and the liquid is taken to product distillation column.
Vapor phase:
H2 = 0.0243W (Kg/hr)
Liquid Phase:
SBA = 0.02W
MEK = 0.7W (Kg/hr)
Vapor phase:
28
ABSORBER
Aqueous ethanol is used as absorbent. 98% of MEK and SBA areabsorbed in absorption
column.The raffinate from the extraction column contain
ns 99.5 wt% ethanol and 0.5wt% MEK is recycled back to absorber.Recycleflow rate is
controlled to provide an aqueous solution containing 10% MEK at absorberbottom outlet.
H2 = 0.0243W (Kg/hr)
Absorbent (E):
Ethanol = 99.5%
SBA = 0.02W(Kg/hr)
30
EXTRACTOR
In extraction column, trichloroethane is used to extract MEK and alcohol from the absorbent.
95% of the MEK and alcohol is extracted and remainder isrecirculated back to the absorber.
Trichloroethane
T (kg/hr)
Extract = X kg/hr
(MEK in Extract = 20%)
MEK balance:
0.1805W = 0.0081W + 0.2X
Solving for X in terms of SBA,
The amount of extract leaving from extractor, X = 0.862W
The composition of X is,
MEK = 0.172W
TCE = 0.67W
SBA = 0.02 W
Overall balance to find out the required TCE:
1.806W + T = 1.614W + 0.862W
T = 0.670W
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SOLVENT RECOVERY DISTILLATION COLUMN
The extracted solution from extractor is distilled in solvent recovery distillation column to
Distillate
MEK = 0.171W
SBA = 0.019W
MEK = 0.172W
SBA = 0.02W
TCE = 0.67W
Residue:
MEK = 0.001W
SBA = 0.001W
TCE = 0.67W
The distillate form solvent recovery column and the condensed liquid from separator are treated
32
Feed
From separator:
MEK = 0.7W
SBA = 0.08W
From solvent recovery column:
MEK = 0.171W
SBA = 0.019W
MEK = 0.87W
SBA = 0.001W
MEK = 0.871W
SBA = 0.099W
MEK = 0.001W
SBA = 0.098W
Amount of SBA required (W)
*Using the value of W = 656.3 in material balance across the equipment; we will get the mass
flow of the different streams.
33
Material balance
REACTOR
H2 = 15.75 (Kg/hr)
34
CONDENSER
Vapor phase:
MEK = 115.5Kg/hr
H2 = 15.75 Kg/hr
35
SEPARATOR
Vapor phase:
Vapor phase:
H2 = 15.75 (Kg/hr)
Liquid Phase:
SBA = 13.13(Kg/hr)
MEK = 459.4 (Kg/hr)
ABSORBER
H2 = 15.75Kg/hr
H2 = 15.75 Kg/hr
SBA = 13.13Kg/hr
MEK =118.5Kg/hr
36
EXTRACTOR
Trichloroethane
439.7 kg/hr
MEK =118.5Kg/hr
Distillate
Residue:
37
MEK PRODUCT DISTILLATION COLUMN
Feed
From separator:
MEK = 459.41 Kg/hr
SBA = 52.5 Kg/hr
From solvent recovery column:
MEK = 112.23 Kg/hr
SBA = 12.47 Kg/hr
MEK = 571 Kg/hr
38
ENERGY BALANCE
Feed Preheater
Total secondary butyl alcohol = 662.86 Kg/hr
Feed inlet temperature = 298K
Feed outlet temperature = 373 K
Specific heat of SBA = 2.67 KJ/Kg K
Heat duty of preheater = m × Cp × ΔT
Q = 662.86 × 2.67 × (373-298)
=132737.7 KJ/hr------------------ 1
Steam Requirement
Steam inlet temperature = 413K
Condensate Outlet temperature = 363 K
Latent heat of steam @ 413K = 2133 KJ/Kg
Specific heat @ 413K =2.26 KJ/Kg K
Heat energy of steam in = m (λ + CpΔT)
= m [2133 + (2.26×140)]
= 2449.4m
Heat energy of steam condensate out = m ×4.2 × 90
= 378m
Heat given by steam = 2449.4m - 378m
=2071.4m -------------------------- 2
Equating (1) & (2)
Steam required, m = 132737.7 / 2071.4
m =64 Kg/hr
Vaporizer
SBA inlet temperature = 373K
SBA vapor outlet temperature = 385K
SBA Latent heat of vaporization = 562.6 KJ/Kg
39
Heat energy of SBA entering into vaporizer = m × Cp × ΔT
= 176983.62 KJ/hr------------------ (1)
Heat energy of SBA leaving the vaporizer= m (λ + CpΔT)
= 662.86 (562.6+2.67×110)
= 567607 KJ/hr--------------------- (2)
Heat added to vaporize SBA = 2-1
Q added =390623.4 KJ/hr --------------------- (3)
Heating medium in vaporizer = Reaction product leaving the reactor @ 633K
Temperature of reaction products leaving the vaporizer = T2
Heat energy of reaction product entering vaporizer
= mMEKCpΔT + mSBACpΔT + m Hydrogen CpΔT
QMEK = 575×2.3× (633-T2)
=1322.5(633-T2)
QSBA = 65.63×2.03× (633-T2)
= 133.23× (633-T2)
Q Hydrogen = 15.75×14.7× (633-T2)
=231.52× (633-T2)
Qtotal = 1687.25× (633-T2)---------- (4)
Equating (3) & (4)
T2 = 401.5K
Q total = 390598.38 KJ/hr
Super Heater-I
In S.H-I, the SBA vapors are heated to 573K from 385K. Flue gas is available at 673K.
Heat duty of super heater-I = 656.3×2.03× (573-385)
Q = 250470.33 KJ/hr
Super Heater-II
In S.H-II, the SBA vapors are heated to 773K from 573K.
Heat duty of super heater-I = 656.3×2.03× (773-573)
Q = 266457.8 KJ/hr
Reactor
Dehydrogenation of secondary butyl alcohol is an endothermic reaction. Conversion is
considered as 90%
C4H10O C4H8O + H2
Heat of reaction (ΔHR):
42
= 384957.78 + 84518
= 469475.78 KJ/hr
43
Solvent recovery column
Feed:
MEK = 112.88 Kg/hr
SBA = 13.13 Kg/hr
TCE = 439.7 Kg/hr
Total, F = 565.71 Kg/hr
Feed temperature is 28°C
Enthalpy of Feed, HF = [ (112.88×2.3) + (13.13×2.67) + (439.7×1.1) ] × (28)
= 21793.83 KJ/hr
Distillate:
MEK = 112.23 Kg/hr
SBA = 12.47 Kg/hr
Distillate temperature from T-x-y diagram, 81°C
Enthalpy of distillate, HD=23605.34 KJ/hr
Residue:
MEK = 0.66Kg/hr
SBA = 0.66 Kg/hr
TCE = 439.7 Kg/hr
Residue temperature is 115°C
Enthalpy of residue, HR = 56000 KJ/hr
Overhead condenser:
Heat load on condenser, QC =V×λ
V = (1+R) D
R = 2Rm
Rm = 0.3 (from x-y diagram)
R = 0.6
V = 199.5 Kg/hr
44
Qc = 100208.85 KJ/hr
Cooling water requirement:
Mw = 100208.85/(4.186×8)
=2992.3 Kg/hr
Reboiler:
QB = Qc + HR- HF
= 131941.5 KJ/hr
Steam requirement:
Heat energy of steam in = m (λ + CpΔT)
= m [2133 + (2.26 ×140)]
= 2449.4m
Heat energy of steam condensate out = m × 4.2 × 90
= 378m
Heat given by steam = 2449.4m - 378m
= 2071.4m
Steam required, m = 131941.5 / 2071.4
m = 63.69 Kg/hr
Product MEK distillation column
Feed:
MEK = 571.64 Kg/hr
SBA = 64.97 Kg/hr
Enthalpy of Feed, HF = [ (571.64×2.3) + (64.97×2.67) ]× (25)
= 37206.05 KJ/hr
Distillate:
MEK = 571 Kg/hr
SBA = 0.66 Kg/hr
Distillate temperature from T-x-y diagram, 79°C
Enthalpy of distillate, HD= 103889.9 KJ/hr
45
Residue:
MEK = 0.64Kg/hr
SBA = 64.32 Kg/hr
Residue temperature is 102°C
Enthalpy of residue, HR = 17667.05 KJ/hr
Overhead condenser:
Heat load on condenser, QC =V×λ
Qc = 277934.34 KJ/hr
Cooling water requirement:
Mw = 277934.34 / (4.186×8)
=8299.5 Kg/hr
Reboiler:
QB = Qc + HR- HF
= 258395.34 KJ/hr
Steam requirement:
Heat energy of steam in = m (λ + CpΔT)
= m [2133 + (2.26 ×140)]
= 2449.4m
Heat energy of steam condensate out = m × 4.2 × 90
= 378m
Heat given by steam = 2449.4m - 378m
= 2071.4m
Steam required, m = 258395.34 / 2071.4
m = 125 Kg/hr
46
DESIGN OF CONDESER
Amount of heat removed by condenser
Q = 469475.78 KJ/hr
Amount of cooling water required
Inlet cooling water temp = 24°C
Outlet cooling water temp = 32°C
Mass flow of CW = 469475.78 / (4.186× 8)
= 14019.22 Kg/hr
LMTD: (COUNTER CURRENT FLOW)
Th1=128.5°C Th2= 37°C
Tc2 = 32°C Tc1 =24°C
LMTD = (128.5-32) – (37-24) / ln ((128.5-32) / (37-24))
= (96.5-13) / ln (96.5 / 13)
= 83.5 / ln 7.423
= 41.75°C
True temperature difference
S = (Tc2– Tc1) / (Th1- Tc1) = (32 – 24 ) / (128.5 – 24)= 8 / 104.5
= 0.077
R = (Th1 - Tc2) / (Tc2- Tc1)= (128.5 – 32) / (32 - 24) = 96.5 / 8
= 12
From graph Ft = 12 × 0.077 = 0.924
ΔTln = 41.75 × 0.924
=38.58°C
Assume Overall heat transfer coefficient = 581.5 W / m2°C
TO FIND NUMBER OF TUBS:
BWG = 16
Tube outer diameter (OD) = 3/4 ’’ = 0.0191 m
Tube Inner diameter (ID) =0.620” = 0.0157m
Length of tube = 8ft= 2.44m
47
Outer surface area of each tube =πDL
= (22 /7) × 0.0191 × 2.44m
= 0.146m2
HEAT TRANSFER AREA:
Q = UAΔTln
U assumed = 581.5 W/m2 °C
469475.78 = 581.5 × 38.58 ×A
A = 20.93m2
NUMBER OF TUBE = Heat transfer area / Outer surface area of each tube
Nt = 20.93 / 0.146
= 143.36
Near tube count = 150tubes
Pitch (triangular) = 15 /16 inch
Number of shell pass = 1
Number of tube pass = 4
Shell side condensing vapor
Tube side cooling water
TUBE SIDE
Cooling water mean temperature = 28°C
Water properties at this temperature
Density = 993Kg / m3
Viscosity = 0.85Cp
Thermal conductivity =0.620W / m2°C
Water flow rate = 14019.22 / 993*3600 = 0.004 m3/sec
Flow area = (Nt/n)× π/4 ×Di2
=0.0027m2/pass
49
Pressure drop calculations
Tube side:
NRe= 27145.1
f = 0.079(Re)-0.25=0.079(27145.1)-0.25
= 6.155×10-3
F = friction factor
Pressure Drop along the pipe length
(Δp)L = (ΔH)L×ρ×g
= 4fLVp2 /2g(ID) ×ρ×g
= (4×6.155×10-3× 2.44×1469.642×9.81) / 2×9.81×0.0157×1000
= 4.128KPa
Pressure Drop in the end zone
(Δp)e = 2.5×ρ×Vp2/2 = (2.5×993×1.469642) / 2
=2.68KPa
Total Pressure Drop in the pipe = (Δp)total= (4.128KPa+2.68KPa)2
= 13.616KPa ˂ 70KPa
Shell side: Kern’s method
Baffle spacing (B) = Ds = 340mm
C1 = 0.0254 – 0.0191 = 0.0063
PT= pitch =0.0 254m
ashell=shell diameter×C1×B /PT= (0.34×0.0063×0.34) /0.0 254
= 0.0287 m2
De =18.29mm
f = 1.87(1923)-.2= 0.412
No of baffles, Nb = L/Ls
Total pressure drop = Shell side pressure drop + Tube side pressure drop
= 37.35Kpa (less than the acceptable pressure drop 70Kpa)
MECHENICAL DESIGN:
Shell side:
No. of shell – 1
No. of pass – 4
Tube side:
51
Length of tube = 8ft = 2.44m
Shell side:
= 0.23mm
Approx. = 10mm
Head: (Torrispherical head)
th= (PRcW / 2fJ)
th=thichness of head
W = 1 / 4 (3+(Rc / Rk)1/2 )
Rc= crown radius = outer diameter of shell = 340mm
52
Rk = knuchle radius = 0.06Rc
W = 1 / 4 (3+(Rc / 0.06Rc)1/2 ) = 1.77
th= (0.11) (340)(1.77) / 2(95)(0.85) = 0.41mm
Minimum shell thichness = 6mm
53
m = gasket factor
Gasket material chosen is asbestos with a suitable binder for the operating conditions.
Thickness = 10mm
m = 2.75
y = 2.60(9.81) = 25.5N/mm2
do / di = ((25.5 - 0.11(2.75) / (25.5 – 0.11(2.75+1))1/2
= 1.0004
di = in side diameter of gasket = outside diameter of shell
= 360+5
= 365mm
do = outside diameter of the gasket
= 1.004(365) = 366.46mm
Minimum gasket width = (365 – 365) / 2 =0.73mm
But minimum gasket width = 6mm
G = 365+2(6) = 377mm
G = diameter at the location of gasket load reaction.
Calculation of minimum bolting area:
Minimum bolting area (Am) = Ag = Wg/ Sg
Sg= tensile strength of bolt material (MN/m2)
Consider, 5% Cr-Mo steel, as design material for bolt
At = 128.5°C
Sg=138×106N/m2Am= (0.6037×106) / 138×106 = 4.375×10-4m2
Calculation for optimum bolt size:
g1= go / 0.707 = 1.41go
g1=thickness of the hub at the back of the flange
go=thickness of the hub at the small end =10+2.5 = 12.5mm
Selecting bolt size M18×2
R = Radial distance from bolt circle to the connection of hub & back of flange
R = 0.027
54
C = Bolt circle diameter = ID + 2(1.41(go+R)
C = Bolt circle diameter = ID + 2(1.41(0.0125) +0.027)
= 0.340 +2[(1.41)(0.0125)+0.027]
= 0.429m
Estimation of bolt load:
Bolt due to design pressure(H) = πG2P / 4
H = π (377)2 (0.11) / 4 = 0.0491×106N
Load to keep the joint tight under operating conditions.
Hp= πg (2b)mp
b = Gasket width = 6mm = 0.006m
Hp= π (0.377) (2) (0.006) (2.75) (0.11×106) = 4.3×103 N
Total operating load (Wo) H+Hp= 0.0491×106N+4.3×103 N
= 0.0534×106N
Load to seat gasket under bolt – up condition = Wg
Wg= π g b y
= π× 0.377×0.006×25.5×106
= 0.18128×106N
Wg>Wo
Wg is the controlling load
Controlling load = 0.18128×106N
Actual flange outside diameter (A) = C + bolt diameter + 0.02
= 0.43m + 0.018 + .002
= 0.468m
Check for gasket width:
Ab= minimum bolt area = 44×1.54×10-4m2
AbSg/ πGN = (44×1.54×10-4) 3.8×10-4 / 3.14(0.377)(0.012)
= 18.1N/mm2
2y = 2×25.5 =51N/mm2
2y>AbSg/ πGN
55
Bolting condition is satisfied.
n= number of bolts = 22
Let CF = 1
SFO = Nominal design stresses for the flange material at design temperature.
SFO = 100 x 106 N
M = 0.017 x 106 J
B = 0.360 m.
K = (A / B) = (Flange diameter / Inner Shell diameter)
= 0.468 / 0.360
= 1.3
Y=8
t = √ (0.017 x 106 x 1 x 8) / (0.360x100x106 = 0.061 m
d = 18 x 2 = 36mm
CF =√ [0.06128 / (2(36 x 10-3) + 0.061)]
= 0.68
CF = (0.83)2
t = 0.061 x 0.83 = 0.0506 m
t = 50mm = 0.05m
Tube sheet thickness :(Cylindrical Shell).
T1s = Gc√ (KP / f)
57
Gc= mean gasket diameter for cover = 0.377
P = design pressure.
K = factor = 0.25 (when cover is bolted with full faced gasket)
F = permissible stress at design temperature.
t1s = 0.377 √ (0.25 x 0.11 x 106) / ( 95 x 106) = 0.0064 m
Channel and channel Cover
th=Gc√ (KP/f) ( K = 0.3 for ring type gasket)
= 0.377√[(0.3 x 0.11)/ 95]
= 0.007 m = 7 mm
Consider corrosion allowance = 4 mm.
th=0.004 + 0.007 = 0.011 m.
Saddle support:
Material: Low carbon steel
Total length of shell: 2.44 m
Diameter of shell: 0.360 mm
Knuckle radius = 0.06 x 0.360 = 0.0216 m = ro
Total depth of head (H)=√ (Doro/2)
= √ (0.360 x 0.0216 /2)
= 0.0235 m
Weight of the shell and its contents = 1875 kg = W
R=D/2=0.360 / 2 = 0.18m = 180 mm
Distance of saddle center line from shell end = A =0.5R=0.09 m.
Longitudinal Bending Moment
M1 = QA [1-(1-A/L+ (R2-H2)/ (2AL))/ (1+4H/ (3L))]
Q = [W (L+4H/3)] / 2
= 1875(2.44 + 4 x 0.1398/3)/2
= 2462.25 kg / m
M1 = [2462.25x0.2 { 1- (1-0.2/2.44+(0.182-0.062352)/(2x2.44x0.2)) }]
. /[(1+4x0.06235/(3x2.44))]
58
= 8.55kg-m
Bending moment at center of the span
M2 = QL/4[(1+2(R2-H2)/L)/ (1+4H/(3L))-4A/L]
M2 = 785.416 kg-m
Stresses in shell at the saddle
(a) At the topmost fibre of the cross section
f1 =M1/(k1π R2 t) k1=k2=1
=8.55/(3.14 x 0.182 x 0.01)= 8404.104 kg/m2
The stresses are well within the permissible values.
Stress in the shell at mid-point
f2 =M2/ (k2π R2 t)
= 160.8 kg/cm2
Axial stress in the shell due to internal pressure
fp= PD/4t
= 0.11 x 106 x 0.340/ (4 x 0.01)
= 93.5 kg/cm2
f2 + fp = 254.3 kg/cm2
The sum f2 and fp is well within the permissible values.
59
ABSORBER
Gas Inlet:
MEK = 115.5Kg/hr
SBA = 13.13Kg/hr
H2 = 15.75Kg/hr
Gas out:
MEK = 2.3Kg/hr
H2 = 15.75Kg/hr
Liquid inlet:
MEK = 5.32 Kg/hr
Aq.ethanol = 1054Kg/hr
Liquid outlet:
MEK = 118.5 Kg/hr
SBA = 13.13 Kg/hr
Aq.ethanol = 1054Kg/hr
At absorber top:
(L/G)× (ρg/ρl)0.5= (1059.32/18.05)× (1.25/797)
= 0.092
At absorber bottom:
(L/G)× (ρg/ρl)0.5= (1185.63/144.38)×(1.7/818)
= 0.017
60
Flow parameter (L/G)× (ρg/ρl)0.5is greater at top of the absorber. So flooding conditions are
considered at top and the percentage is 80%
From Generalized pressure drop correlation chart, at 0.5 inch of water/ ft pressure drop,
G2Fp(ρw/ρl)µL0.2/(ρg×ρl×g) = 0.05
Packing material is 1/2” Raschig rings and packing factor Fp from design data table
61
Fp= 2100m-1; surface area, a=368m2/m3
G2×2100×1.25× (0.0011)0.2/(1.25×797×9.81) = 0.05
G2=0.727 Kg/m2s
Superficial mass flow rate of gas, G = 0.85Kg/m2s
Cross sectional area, Ac = Gt/G
Ac = 0.26m2
(π/4)×Dc2 = 0.26
Diameter, Dc =0.58m
Dc/dp = 0.58/0.013 = 44.6 (greater than the minimum ratio of 10)
Wetting rate:
Lw = L/(Ac×ρl×a)
= 1059.32/ (0.26×797×368)
= 0.138 m2/hr
= 1.4 ft2/hr (greater than 0.85ft2/hr)
62
Pressure drop:
ΔP = C2×10C3Utl ×Utg2
= 0.02×10(0.9×0.0041) × 2.62
= 13.63 mm H2O/meter packing
Height of the absorber:
Z = HTU×NTU
HTU = HG+ (mG/L) HL
HG = 0.029×Ψ×D1.11×Z0.33×Scg0.5 / (Lf1f2f3)0.5
ScG= gas-phase Schimidt number (dimensionless number)
= µG/ρgDg = 0.45
ψ =Correlation parameter
For 80% flooding, ψ = 60
f1= (µL/µw) 0.16, with µW=1.0 mPa.s
f2 = (ρw/ρL) 1.25 with ρw=1000 kg/m3
f3 = (σw/σl) 0.8, with σw = 72.8 mN/m
f1= 1.015
f2 = 1.32
f3 = 0.9
HG = 0.029×60× (0.58)1.11×Z0.33× (0.45)0.5 / (1.13×1.015×1.32×0.9)0.5
HG= 0.54 Z0.33
HL = (φC/3.28) × (µL/ρLDL) 0.5× (Z/3.05)0.15
φ = Correlation parameter for given packing, m
C = correlation factor for high gas rates
µL =liquid viscosity, Pa.s
ρL =Liquid density , kg/m3
DL =liquid –diffusion coefficient, m2 /s
Z =height of packing,m
φ = 0.03
63
µL = 1.09cP
C = 0.6
HL = (φC/3.28) × (µL/ρLDL) 0.5× (Z/3.05)0.15
= (0.03×0.6/3.28)× [(0.0011/797×35)]0.5 × (Z/3.05)0.15
= 0.148Z0.15
Y Y* 1/(Y-Y*)
0.05 0.043 142.86
0.1 0.07 33.33
0.15 0.11 25
0.2 0.165 28.6
0.25 0.19 16.67
0.34 0.26 12.5
0.4 0.3 10
64
MECHENICAL DESIGN:
Material used = carbon steel
Thickness of the shell = ts
ts = (PD / 2fJ-P)+C
D –inner diameter of the column = 0.58m
Working pressure = 1.013×105N/m2
Design pressure =1.1143×105 N/m2
Permissible stress, f =95×106 N/m2
Joint efficiency, J= 0.85
Corrosion allowance = 5mm
ts = (1.1143×105×1/2×95×106×0.85-1.1143×106)
ts = 5.69mm = 6mm (approx.)
Outer diameter of the column Do = 0.592m
DESIGN OF GASKET AND BOLT SIZE CALCULATIONS:
Width of the gasket, N = 10mm
Gasket material – ASBESTOS
Gasket factor, m =2
Minimum design seating stress y =11.2N/mm2
Basic gasket seating widthbo = N/2 = 10/2 = 5mm
Effective gasket seating width, b= 5.6mm
BOLT LOAD CALCULATIONS:
Wm1 = π×b×G×Y
G = Mean diameter = (Dfi + Dfo) / 2 = 0.586m
Wm1= 115407.31 N
Flange Thickness:
tf =G×(P/Kf)0.5 + C
K = 1/ (0.3+ (1.5WmhG)/H×G)
Hydrostatic end force H = π/4 × G2×P
=51.25 Kw
Radial distance from gasket load to bolt circle,
hG= 0.015m
Wm = 346305.225 N
66
K = 1.19
tf = 23mm
HEAD DESIGN: FLANGED AND SHALLOW
Material – stainless steel
Permissible stress, f = 130N/mm2
Design pressure, p= 1.1143×105 N/m2
Stress identification factor, W = 1/4× (3+ (Rc/R1))
Crown radius, Rc = 0.5 m
Knuckle radius, R1 = 6% of Di = 0.03m
W = 2.83
Thickness of head, th = (P×Rc×W)/2×f
= 4.45mm = 5mm (approx.)
Nozzle thickness:
Material – SS
Dn =0.25m
Thickness,tn = (P×D×N)/ (2×f×J-P)
= 2.6mm = 3mm(approx.)
There for we can take the thickness of the nozzle as 3mm (No corrosion allowance because the
material is stainless steel)
67
STRESS ANALYSIS AND SHELL THICKNESS AT DIFFERENT HEIGHTS:
Axial stress due to pressure,fap =PDi /4(ts-C)
= (1.1143×105×1) / (4×(6×103-0.0008)
fap = 5.35×106N/m2
Stress due to dead load,
Compressive stress due to weight of shell unto ‘x’ distance,
Outer diameter = 0.012m
Density of shell material = 7700Kg/m3
fds = π/4(Do2-Di2) ×ρ×X / π/4×(Do2-Di2) =7700.08xKg/m2
Compressive stress due weight of installation at height x
Material of insulation – ASBESTOS
Thickness – 3cm
Density - 2200Kg/m3
Dins – diameter of insulation
Dm – mead diameter of vessel
Dins= Dm
fds = (π ×Dins×tins×ρins×x)/(π ×Pm×ts-C))
Total weight :
= weight of steel +weight of attachments (liquid + packing + head + ladder
= π/4× (Do2-Di2)×H×ρs×9.81+π/4× (Di2×H×ρ1×0.77) +(π/4×Di2×H×ρp) +40660.5+1600H
= 65362.53 N
Diameter of skirt = 0.58m
Height of skirt = 1.5m
Wind of pressure = 500N/m2
Stress due to dead load:
fd = Total weight / (π×D×tsk)
= 65362.53/(π×0.58×tsk)
= 20816.09/tsk
Due to wind load
Pw = k×P1×h1×Do
K = 0.7
Pw = 4.32×106×N/m2
Bending moment due to wind at the base of the vessel,
Mw = P1w×h1/2
70
Mw = 4.32×106Nm
fwb=(5.44×106/tsk)
Stress due to seismic load:
Load F = C×W
W – total weight of the vessel =65362.53N
C – Seismic coefficient – 0.08
fsb= 2/3× (CWH / π×Rok×tsk)
fsb= 26644.598 /tsk
Maximum stress at the bottom of the skirt
fmax=(fwb orfsb) - fdb
(5.44×106)tsk-20816.09/tsk = 140×106
tsk = 0.0387m
tsk = 38.7mm
Thus, Present cost of Plant = (original cost) × (present cost index)/(past cost index) = (1.61 x
107) × (402/110) = Rs 5.88×107
i.e., Fixed Capital Cost (FCI) = Rs. 5.88×107
(10-80% of Purchased equipment cost) Consider the piping cost = 40% Purchased equipment
cost
40% of Purchased equipment cost = 0.40 ×1.47×107
= Rs. 5.88×106
Electrical, installed:
(10-40% of Purchased equipment cost) Consider Electrical cost = 25% of Purchased equipment
cost
25% of 1.47×107= Rs.3.675×106
Buildings, process and Auxiliary:
(10-70% of Purchased equipment cost) Consider Buildings, process and auxiliary cost = 40% of
PEC
40% of 1.47×107= Rs. 5.88×106
Service facilities and yard improvements:
(40-100% of Purchased equipment cost)
Consider the cost of service facilities and yard improvement = 60% of PEC
60% of 1.47×107= Rs. 8.82×106
72
Land: (1-2% of fixed capital investment or 4-8% of Purchased equipment cost) Consider the cost
of land = 6% PEC = 6% of 1.47×107
= Rs. 0.882×106
Thus, Direct cost = Rs. 4.865×107 ----- (82.75% of FCI)
Indirect costs:
Expenses which are not directly involved with material and labor of actual installation of
complete facility (15-30% of Fixed-capital investment)
Engineering and Supervision: (5-30% of direct costs)
Consider the cost of engineering and supervision = 10% of Direct costs
Cost of engineering and supervision = 10% of 4.865×107
= Rs. 4.865×106
73
Working capital = 15% of 6.6×107= Rs.0.99 ×107
Total Capital Investment (TCI):
Total capital investment = Fixed capital investment + Working capital
= 6.6×107 + 0.99 ×107
Total capital investment = Rs. 7.5×107
Estimation of Total Product cost:
Manufacturing Cost = Direct production cost + Fixed charges + Plant overhead cost.
(Depends on life period, salvage value and method of calculation-about 13% of FCI for
machinery and equipment and 2-3% for Building Value for Buildings)
Consider depreciation = 13% of FCI for machinery and equipment and 3% for Building Value
for Buildings)
Depreciation = (0.13×5.88×107) + (0.03×5.88×106) = Rs. 7.82×106
74
Local Taxes:
(1-4% of fixed capital investment) Consider the local taxes = 3% of fixed capital
Local Taxes = 0.03×6.6×107
= Rs.1.98×106
Insurances:
(0.4-1% of fixed capital investment) Consider the Insurance = 0.7% of fixed capital investment
Insurance = 0.007×6.6×107= Rs. 0.462×106
Rent:
(8-12% of value of rented land and buildings)
Consider rent = 10% of value of rented land and buildings
= Rs. 0.67×106
Thus, Fixed Charges = Rs. 11×106
Direct Production Cost: (about 60% of total product cost)
Now we have Fixed charges = 10-20% of total product charges – (given)
Consider the Fixed charges = 15% of total product cost
Total product charge = fixed charges/15%
Total product charge = 11×106/15%
75
Direct Supervisory and Clerical Labor (DS & CL): (10-25% of OL)
Consider the cost for Direct supervisory and clerical labor = 12% of OL
Direct supervisory and clerical labor cost = Rs. 1.05×106
Utilities: (10-20% of total product cost)
Consider the cost of Utilities = 12% of total product cost
Utilities cost= 12% of 7.3×107
Utilities cost = Rs. 8.76×106
Consider the maintenance and repair cost = 5% of fixed capital investment Maintenance and
repair cost = 0.05×6.6×107= Rs. 3.3×106
Operating Supplies: (10-20% of M & R or 0.5-1% of FCI)
Consider the cost of Operating supplies = 15% of M & R
Operating supplies cost = 15% of 3.3×106
= 0.495×106
Operating supplies cost = Rs. 0.495×106
Laboratory Charges: (10-20% of OL)
Consider the Laboratory charges = 15% of OL
Laboratory charges = 15% of 8.76×106
Laboratory charges = Rs. 1.34×106
Patent and Royalties: (0-6% of total product cost)
= 4% of total product cost
Patent and Royalties = 4% of 7.3×107
Patent and Royalties cost = Rs. 2.92×106
Thus, Direct Production Cost = Rs. 4.5×107 ----- (61.5% of TPC)
76
Plant overhead Costs:
(50-70% of Operating labor, supervision, and maintenance or 5-15% of total product cost)
Includes for the following: General plant upkeep and overhead, payroll overhead, packaging,
medical services, safety and protection, restaurants, recreation, salvage, laboratories, and storage
facilities.
Consider the plant overhead cost = 60% of OL, DS & CL, and M & R Plant overhead cost
= 60% of ((8.76×106) + (3.3×106) + (1.05×106))
Plant overhead cost = Rs. 7.866×106
Thus, Manufacture cost = Direct production cost + Fixed charges + Plant overhead costs.
Manufacture cost = (4.5×107) + (11×106) + (7.866×106)
78
PIPING ANDINSTRUMENTATION
The main objective in the of the plant is to produce a particular product of given quality.
Instrumentation involves provision of controller to certain equipment’s to measure flow rate,
temperature, pressure etc. to maintain quality of the product.
The profit made by company also depend on the production cost. Therefore the purchase
instrumentation is justified because it gives product of uniform and better quality and makes the
operation uniform and smooth. Moreover, an efficiently controlled plant means high safety. In
chemical industry, this is a very important condition.
The most commonly encountered problem in chemical industry is the regulator type
problem, in which the set point is constant and we compensate the offset as rapidly as possible
without instability.
The function fulfilled by an instrument may be;
Indicating
Recording
Controlling
AUTOMATION CONTROL:
Improvement in automatic instrumentation and control generally has lagged behind the
petroleum and petrochemical industry, probably because of more difficult measurement
requirements. However recent dramatic increases in feed stock, quality control and other cost
coupled with lower prices on computer have greatly increased the incentive for computer
controls.
Most plant eventually improves their control by installing conventional pneumatic and more
recently electronic controller on measure flow and temperature loops. This type of control is still
needed by most plants today.
FLOW CONTROL:
Flow control is usually associated with inventory contrary controlling storage or other equipment
to provide flow control on a compressor or pump running at a fixed speed and supplying a rear
constant volume output. A bypass control would be used .
79
1. Safe plant operation:
a) To keep the process variables within known safe operating limits.
b) To keep dangerous situation as they develop and to provide alarms to provide alarms
and automatic shutdown system.
c) To provide interlocks and alarms to prevent dangerous operating procedures.
2. Production rate:
To achieve the design product output.
3. Product quality:
To maintain the product composition within the specified quality standards.
4. Cost:
Operate at the lowest production cost, commensurate with the other objectives.
These are not separate objectives and have been considered together. The
order in which they are listed is not meant to imply the precedence of any objective
over another, other than that of putting safety first. Product quality, production rate
the cost of production rate cost of production will be dependent on sales
requirements.
acetone-like odour. It is stable under ordinary conditions but can form peroxides on prolonged
To maintain a safe working environment in the plant standard operating procedures will
To develop awareness and provide knowledge about MEK, Secondary butyl alcohol,
Ethanol, Hydrogen and TCE, MSDS information boards, Information boards about health
Danger and toxic symbol plates will be mounted at critical work places.
Flame and fire detectors will be installed to alert the workers in case of leakage or fire.
0.1
This Indian Standard was adopted by the Bureau of Indian Standards on 17 August 1987, after
the draft finalized by the Chemical Hazards Sectional Committee had been approved by the
Chemical Division Council.
0.2
Methyl ethyl ketone is used as solvent for variety of resinous materials, such as vinyl films,
glyptal resins, adhesives, printing inks, lacquers, lubricant oil, refining and cleaning fluids. It is
used as a catalyst carrier, in vegetable oil extraction processes, in preparation of flavours,
antioxidants, perfumes, in the manufacture of n amyl ketone and methyl ethyl ketone peroxides.
81
0.3
In the preparation of this code, considerable assistance has been derived from the following
publications.
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SCOPE
This standard describes properties of methyl ethyl ketone, the nature of hazards associated with it
and essential information on storage, handling, packing, labelling, disposal of waste, cleaning of
spillages, training of personnel, personal protective equipment and first aid.
This code, however, does not deal with the specifications for design of buildings, chemical
engineering plants, storage vessels and equipment for operations control.
TERMINOLOGY
For the purpose of this standard, the definitions given in IS : 4155-1966* and IS : 4167-1981†
shall apply.
PROPERTIES
General Information—Methyl ethyl ketone is a colourless, mobile, volatile liquid with acetone
type odour. It is flammable liquid with dangerous risk of fire and explosion, if not properly
handled.
Common Name—MEK
Chemical Name—Methyl ethyl ketone, 2-butanone
EmpiricalFormula—C4H8O
Structural formula—
Molecular Weight—72·12
Physical Properties
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Chemical Properties
Reactivity—Methyl ethyl ketone, with a strong oxidizing agent, can cause spontaneous ignition
and violent reaction. Its oxidation in air can give oxides of carbon and nitrogen. Direct
oxidationcan lead to peroxide formation. It undergoes reactions typical of carbonyl groups. It
condenses with variety of reagents. Methyl ethyl ketone reacts violently with certain transition
metal oxides, for example, chromium oxide.‘Methyl ethyl ketone reacts with oxidizing agents,
strong acids mixtures of strong bases and chlorinated solvents and potassium t-butoxide’
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HEALTH EFFECTS AND TOXICITY INFORMATION
General
Health Effects
1) Methyl ethyl ketone is neither highly toxic nor it exhibits cumulative toxological
properties. It is slightly more toxic than acetone. Inhalation of vapours over prolonged
periods may irritate the mucous membrane and cause nausea and eventually loss of
consciousness.
2) Eyes—Eye contact causes irritation and burning sensation of the eyelids.
3) Ingestion—Ingestion causes irritation to the digestive tract. Larger quantities (25 g) can
cause narcosis.
4) Skin Contact—It can be absorbed through skin which defats and irritates the skin. When
methyl ethyl ketone is mixed with normal hexane, it causes synergistics effect.
5) Medical Monitoring—Provide regular medical monitoring, including blood cell count of
those exposed to in a material in the work place.
Personal protective equipment should include general purpose breathing apparatus, rubber gloves
and protective clothing to avoid contact with liquid. Safety goggles or face shields should be
used to prevent splashing of the liquid into the eyes.
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STORAGE, HANDLING, LABELLING AND TRANSPORTATION
6) Storage—Storage under roof is preferable in all seasons. The drums should be tightly
closed and should not be exposed to sources of heat such as walls of boiler room and
kitchen. Storage place should be well ventilated and provided with fire-proof electrical
fittings and spark resistant tools. Do not store methyl ethyl ketone near strong oxidizing
agents. ‘NO SMOKING’ sign should be displayed in the storage area.
7) Handling—Wear neoprene rubber gloves, protective clothing and face shield while
handling this material. Use general purpose breathing apparatus.
Labelling
1) NO SMOKING
2) NO NAKED FLAME
3) AVOID SPILLAGE
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Waste Disposal
All relevant regulations of local and State Authorities for prevention and control of pollution
should be observed.Water contaminated with methyl ethyl ketone should be sent for effluent
treatment before discharging to the river or creek.Best way to dispose of the methyl ethyl ketone
waste is by incineration in a furnace.
Preventing Fire Hazard—Fire can be prevented if the material is kept away from heat or flame.
The fire hazard can also be avoided bypreventing mixing of oxidizing materials with methyl
ethyl ketone and using non-sparking tools near this solvent.
Fire:
Fire can be prevented to a large extent by employees through basic knowledge and
understanding about characteristic and behavior of Fires. With this awareness, effective actions
can be taken to prevent the combination of events which result in the fire. Hence ,it is essential to
explain basic chemistry of fire, Types of fire and fundamental fire/explosion prevention, fire con
troll/extinguishments etc.
What is fire ?
Fire is a chemical reaction, in which substance (fuel) combines with oxygen. The reaction is
exothermic and usually associated with emission of light and smoke.
Oxygen + heat + fuel = FIRE
Remove any one = NO FIRE.
Types of Extinguishers to be Used—Foam dry chemical powder and carbon dioxide can be
used to extinguish the flame. Water spray is ineffective for extinguishing, but may be used to
keep fire exposed containers cool.
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TRAINING AND HEALTH MONITORING
Training and Education—Persons handling or working on plant involving methyl ethyl ketone
shall have training such that they can be expected to carry out their jobs effectively and safely.
They should be familiar with accepted method of handling and should be appraised of the use of
protective equipment for safe handling. During instructions, stress should be given that persons
know the hazards due to eye contacts, skin contacts, inhalations and ingestion. All persons
should be familiar with the location of alarm boxes, first-aid boxes, fire extinguishers and
personal protective equipment including the use of breathing apparatus.Safety In handling
methyl ethyl ketone depends, to a great extent, upon the effectiveness of employees education,
proper safety instructions, intelligent supervision and the use of safe equipment.
Health Monitoring
FIRST AID
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CONCLUSION
Thus the project based on manufacturing of MEK 5000 tons per year includes.
1) Material balance
2) Energy balance
a) Condenser
b) Absorption
5) Cost estimation
d. Economic
Thus the project covers all aspects required for the manufacturing of MEK and Could be
implemented in reality.
PLANT LAYOUT
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