MANUFACTURE OF PHARMACEUTICAL GRADE ACETONE PLANT

FYDP FINAL PRESENTATION

G7
SUPERVISORS: PROF DR RADHA MISS CHAI SIEW WAH MR BAWADI LEADER & PROCESS ENGINEER: ROZALINA SHIELA RAMLAN

PROCESS & DESIGN ENGINEER: NGU YEN DUY VINH

FINANCIAL ANALYST: NURUL SHARINA SALIM

ENVIRONMENTAL, SAFETY & HEALTH OFFICER: SUHAIRA ADIB

2

PRESENTATION OUTLINE
1. 2. 3. 4. 5. 6. 7. 8. 9.

G7

INTRODUCTION (PROB. STATEMENT, OBJECTIVES AND LITERATURE REVIEW) CONCEPTUAL DESIGN & PROCESS FLOW SHEETING PFD, P&ID AND CONTROL STRATEGIES MAJOR EQUIPMENT DETAILS SAFETY AND LOSS PREVENTATION (HAZOP AND PLANT LAYOUT) WASTE TREATMENT HIGHLIGHTS ECONOMICS EVALUATION PROBLEM HIGHLIGHTS AND RECOMMENDATIONS CONCLUSIONS

G7

1. INTRODUCTION

G7
PROBLEM STATEMENTS
ABC Chemical Ltd., an international company manufacturing petrochemicals, is interested in expanding their business in the Asia-Pacific region Shortage of pharmaceutical grade acetone in the region by 2006 good potential to establish Pharmaceutical Grade Acetone plant

OBJECTIVE
To design Pharmaceutical Grade Acetone plant in Malaysia with a production capacity of 15,000 tonnes/yr at a purity of 99.9% of Pharmaceutical Grade Acetone, based on 8000 operating hrs/yr

ACETONE AN OVERVIEW CH3COCH3

G7

Acetone 1st and most important member of homologous series of Ketone It is clear, colorless and aromatic odour Most of Acetone is produced from:
Phenol is aromatic groups carcinogenic (cancer causing) activity strictly forbid by FDA for pharmaceuticals used

Cumene Hydroperoxide Process

C6H5C00H(CH3)2
C
C C C C C OH

+ CH3COCH3

Dehydrogenation of Isopropyl Alcohol (CH3)2CHOH (CH3)2CO + H2

Produced grade Acetone -99.9% purity -Suitable for pharmaceutical used

6

ACETONE APPLICATIONS

G7

Widely used as a solvent in the manufacture of

pharmaceutical and cosmetics Used to make functional compounds such as: anti oxidants, herbicides, higher ketones, condensate with formaldehyde/diphenylamine and vitamin intermediates.
7

ACETONE MARKET OUTLOOK

G7

Source: Shell Chemicals, Ltd - Japan

8

G7

2. CONCEPTUAL DESIGN & PROCESS FLOW SHEETING

CONCEPTUAL DESIGN
Conceptual design is used as preliminary procedure and starting point to design a process and plant Simple calculation is involved to justify the decision making and to make an overall view of the process
15 21

G7

TO OFF-GAS

DEMIN WATER
14 20

CW

E-408

9
CW

E-407

T-401

11

8
1

F-401 R-401
13 5 22 10
35 33 1

P-404A/B P-403A/B
23
CW

ACETONE TO STORAGE
24

E-404

E-409
16
18
LP

ISOPROPYL ALCOHOL

3 1 2

E-402
35
LP

CW

E-411

E-401 P-401A/B
19 7
E-403

T-403

E-410 T-402

12

V-401

P-405A/B

31

REACTOR STRUCTURE
17 18

Cooling Water

25

10

20
LP

E-406
CW

P-402A/B E-412

T-404

SEPARATION STRUCTURE
26

27

28
CW

29

RECYCLE STRUCTURE
RECYCLE ISOPROPYL ALCOHOL
30

E-405

10

WASTE TREATMENT

REACTOR STRUCTURE
ISOPROPYL ALCOHOL DEHYDROGENATION
Only 1 reactor is used in this process. The reactions that take place in this reactor are:
Main reaction: (CH3)2CHOH (CH3)2CO + H2 Side reactions: (CH3)2CHOH CH2 = CHCH3 + H2O CH3COCH3 (CH3)2CCHCOCH3 + H2O Conversion to Acetone = 83.6%

G7

Conversion to PY Conversion to MO

= 0.52% = 2.22%

Total Conversion = 86.3% Gas phase, reactor inlet temperature = 350oC, reactor pressure = 2 bar Catalyst used = ZnO2/ZrO2

11

REACTOR AND CATALYST SELECTION

MULTITUBULAR FIXED BED REACTOR Easy to scale up Shell and tube configuration Catalyst is not deactivated frequently Plug flow pattern

G7

ZnO2/ZrO2 Can operate at high temperature More resistance to poison Longer life time > 3 years

12

RECYCLE STRUCTURE
GAS PURGE FEED REACTOR SEPARATION SYSTEM PRODUCT

G7

UNREACTED LIQUID

EP3= (Product + Byproducts) Raw Materials (Reactors + Compressor)

EP3 no recycle = RM 1.52 X 108/yr EP3 with recycle = RM 1.56 X 108/yr

13

SEPARATION STRUCTURE
GAS PURGE VAPOR FEED REACTOR PHASE SPLIT LIQUID SEPARATOR LIQUID LIQUID RECOVERY SYSTEM

G7

PRODUCT

DESIGN DECISIONS: Phase splitter: flash drum Separator: Scrubber Solvent used for Scrubber: Demin Water Solvent inlet temp: 25oC to recover product

14

SEPARATION STRUCTURE
2 ALTERNATIVES:

LIQUID RECOVERY SYSTEMS

G7

1. Direct Sequence vapor load = 1910.3 kmol/hr

Acetone
Acetone unreacted IPA Water

unreacted IPA

Water

ADVANTAGES: 1. Pure acetone (99.9%) is produced. 2. High yield of acetone produced

DISADVANTAGES: 1. Generate large amount of waste water 2. High operating and capital cost high vapor load
15

SEPARATION STRUCTURE-cont
2. Indirect Sequence vapor load = 151.4 kmol/hr

G7

Acetone

Acetone unreacted IPA Water

Acetone unreacted IPA

Un reacted IPA

Water

ADVANTAGES: 1. Lower vapor load 2. Lower energy requirement

DISADVANTAGE: 1. Loss of Acetone

16

HEAT INTEGRATION
HEAT INTEGRATION CONCEPT
To meet the temperature requirements of the streams, heating and cooling are needed Heat within the process can be integrated to reduce the consumption of hot and cold utilities As a result, reduce operating cost

G7

There are 7 major streams in the heat exchanger network:

Stream 1 2 3 Description Feed to reactor To phase separator Waste water Type Cold Hot Hot

4
5 6 7

Acetone to storage
Condenser 1 Reboiler 2 Recycle IPA

Hot
Hot Cold Hot
17

HEAT INTEGRATION
By using PINCH Analysis: Final grid diagram

G7

1. Heat exchanger 1: Hot stream 2 and cold stream 6 Heat load: 636.08 kW Hot stream supply temperature: 518 K Hot stream target temperature: 361 K Cold stream supply temperature: 351 K Cold stream target temperature: 352.43 K

2. Heat exchanger 2: Hot stream 4 and cold stream 1 Heat load: 38.58 kW Hot stream supply temperature: 375 K Hot stream target temperature: 361 K Cold stream supply temperature: 373 K Cold stream target temperature:382.1 K

18

HEAT INTEGRATION
For E 401 Before heat integration: Hot utilities Feed To reactor After heat integration: Reactor effluent

G7

To reactor Feed

To condenser

19

PROCESS FLOWSHEET
15 21

G7
TO OFF-GAS

DEMIN WATER
14 20

CW

E-408

9
CW

E-407

T-401

11

8
1

F-401 R-401
13 5 22 10
35 33 1

P-404A/B P-403A/B
23
CW

ACETONE TO STORAGE
24

E-404

E-409
16
18
LP

ISOPROPYL ALCOHOL

3 1 2

E-402
35
LP

CW

E-411

E-401 P-401A/B
19 7
E-403

T-403

E-410 T-402

12

V-401

P-405A/B

31

Cooling Water

25 17 18
LP

10

20

E-406
CW

P-402A/B E-412

T-404

27

WASTE TREATMENT
26 28
CW

29

RECYCLE ISOPROPYL ALCOHOL

30

E-405

20

ALTERNATIVE DESIGNS
OBJECTIVES:

G7

To evaluate the literature alternative designs To select the best design To integrate new ideas into the best design

21

(extracted from a revamp project by Ryan Kellogg and teammates, Rice University, 12 Oct. 1998 )

Alternative 1

G7

1. DISADVANTAGES 2. 3. 4. 5. 6.

The load on the vaporizer is too high The purity of acetone is low since there is only one column The load on the column will be high No heat integration No guarantee for the recycle stream of 88.8wt% IPA Too simple configuration
REJECTED!!
22

(extracted from an Optimization Project by Mike Tremoulet and team members, Oct. 11, 1998)

Alternative 2

G7

DISADVANTAGES

1. 2.

There is a possibility of saving energy in E-401 The RW used in E-403 is a waste. Proper heat integration needed REJECTED!!
23

(extracted from a debottlenecking project, Spring 2000 )

Alternative 3

G7

DISADVANTAGES

1.The sequence does not minimize the loading according to vapor loading calculations 2.No guarantee of 88.8wt% of IPA in the recycle stream 3. High load on the second column due to high amount of water present REJECTED!! 24

(proposed process)
15 21

Alternative 4

G7
TO OFF-GAS

DEMIN WATER
14 20

CW

E-408

9
CW

E-407

T-401

11

8
1

F-401 R-401
13 5 22 10
35 33 1

P-404A/B P-403A/B
23
CW

ACETONE TO STORAGE
24

E-404

E-409
16
18
LP

ISOPROPYL ALCOHOL

3 1 2

E-402
35
LP

CW

E-411

E-401 P-401A/B
19 7
E-403

T-403

E-410 T-402

12

V-401

P-405A/B

31

Cooling Water

25 17 18
LP

10

20

E-406
CW

P-402A/B E-412

T-404

27

WASTE TREATMENT
26 28
CW

29

RECYCLE ISOPROPYL ALCOHOL

30

E-405

25

Selected process evaluation

ADVANTAGES
1. 2. 3. 4. 5. 6. 7. The replacement of high pressure steam with molten salt to preheat the feed (not heat integration, only energy saving) A complete heat integration has been done on the proposed process to maximize the heat recovery Fewer loads on the second distillation column due to the distillation sequencing (water separated in 1st column) The number of trays of the columns is less than the other sequencing Easy to separate IPA and acetone, the purity of 99.9mole percent of acetone can be achieved Maximize the heat recovery by crossing of the reactor effluent with the inlet feed to the reactor The recycle stream IPA has the weight percent of IPA almost the same as the fresh feed of 88.8%

G7

ACCEPTED!!!

26

G7

3. PROCESS FLOW DIAGRAM (PFD) & CONTROL STRATEGIES

27

PROCESS FLOW DIAGRAM

15 21

G7
TO OFF-GAS

DEMIN WATER
14 20

CW

E-408

9
CW

E-407

T-401

11

8
1

F-401 R-401
13 5 22 10
35 33 1

P-404A/B P-403A/B
23
CW

ACETONE TO STORAGE
24

E-404

E-409
16
18
LP

ISOPROPYL ALCOHOL

3 1 2

E-402
35
LP

CW

E-411

E-401 P-401A/B
19 7
E-403

T-403

E-410 T-402

12

V-401

P-405A/B

31

Cooling Water

25 17 18
LP

10

20

E-406
CW

P-402A/B E-412

T-404

27

WASTE TREATMENT
26 28
CW

29

RECYCLE ISOPROPYL ALCOHOL

30

E-405

28

PROCESS CONTROL OBJECTIVES

G7

1. To assure the production rate of acetone at 150 metric tonnes per year at more than 99.99% purity. 2. To minimize the raw materials required 3. To optimize the usage of cooling and heating utilities. 4. To enable safe plant operation and avoid explosion. 5. To minimize all waste and emission.

29

REACTOR SECTION
PS PS

G7
PI TI

RELIEF TO ATMOSPHERE AT SAFETY LOCATION

RELIEF TO ATMOSPHERE AT SAFETY LOCATION

002

003

ARC 001

DEMINERALIZED WATER
TI 001 FRC PI 001 TRC 002 WEIGHT AVERAGE TEMPERATURE TRC 002' FRC 002 RC 001 004 PS

To offgas

F-401 T-401
FRC 005

LRC 002

R-401
FRC TRC 003 FRC 003 PS TI 002 006

Air

Fuel

TRC

E-402
001 PI 003

IPA FROM TANK

LRC

E-401

001

V-401
TRC 004

TO T-402 1
FR C 00 1

30
RECYCLE IPA

REACTOR SECTION
No. Unit Operation Control Philosophy Strategy Controlled Variable
Manipulated Variable Flow rates of reactor effluent and bypass stream Flow rate of molten salt from F-401

G7

1.

IPA Feed Preheat E-401

Control the temperature of fresh feed to R101

Parallel feedback controller

The exit product temperature of E-401

The exit product temperature of E-402 and the flow rate of molten salt The temperature of R401 and flow rate of molten salt The exit product temperature of E-403 The liquid level of V401 The hydrogen purity in the offgas and flow rate of water to T-401 The liquid level of T401 Ratio of liquid feed and fresh water

2.

IPA Feed Preheat E-402

Control the temperature of fresh feed to R101

Cascade controller

3.

Reactor R-401

i. Control the temperature of the reaction ii. Pressure indication

Cascade controller Indicator Parallel feedback controller Feedback forward

Flow rate of molten salt from F-401 Flow rates of cooling water and bypass stream Flow rate of bottom stream from V-401 Flow rate of water to T-402 Flow rate of bottom stream from T-401 Flow rates of the fresh water and liquid feed to T-401

4.

Reactor effluent cooler E-403 Flash drum V-401

Control the temperature of to the flash drum V-401 Control the level of liquid in the flash drum V-401

5.

i.Control the purity of overhead product (offgas) ii.Control the flow rate of the water to scrubber
iii. Pressure indication

Cascade controller

Indicator Feedback forward

6.

Scrubber T-401

iv. Control the level of liquid in the scrubber T-401 v. Control the ratio of feed gas and fresh water

Ratio

31

SEPARATION SECTION

G7
To offgas

FRC 009

FF C

TRC
005
FRC

TI 003 PRC 001 1 FRC 007

001

011 LRC 004 1

PRC

002

TRC

007 FI TI
004

LRC 006

E-404 ACETONE TO STORAGE

10 18 From From V-401 V-401 PDI 001

RC
002

002

FI

1
003
FI

FF C
004
FI

008

002

TRC
FRC

ART

TRC 004 44 34 FRC 008 LRC 003 2 C-401 TRC 006

33 PDI 002

RC
004

012

013

FRC

FRC 1
015

FF C

T-402
FRC 010 LRC 2 005 34 PRC 003 TRC
010

TI
005

LRC 008

T-403 RECYCLE IPA

1
005
FI

006
FI

10
FRC
016

RC
005

PDI 003

TRC 009

FRC 014

20

LRC 2 007

T-404

32

WASTE TREATMENT

SEPARATION SECTION
Unit Operation Control Philosophy Strategy Controlled Variable Manipulated Variable

G7
-

i. Pressure drop indication ii. Pressure indication iii. To control the temperature of the liquid iv. Control top receiver liquid level v. Control bottom liquid level

Indicator Indicator Feedback Temperature column of

the liquid in

Flow rate of LPS

Feed-forward

Top receiver liquid level

Flow rate of top product

Feed-forward

Bottom liquid level

Flow rate of liquid

Acetone T-403

column

vi. Control column top temperature vii. Control flow rate of liquid feed to T-403

Cascade controller

The column top temperature of T403 and flow rate of cooling water to condenser Liquid feed

Flow rate of cooling water to condenser Flow rate of liquid feed

Feedback

viii. Temperature indication

Indicator

ix. Control the ratio of product draw rate to reflux

Ratio controller

Ratio of product draw rate to reflux

Flow rate of the reflux

x. Control acetone purity

Cascade controller

The acetone purity in top product stream

Flow rate of reflux

33

HEATER SECTION

G7

TI ORT

FRC
FRC

From R-401

TRI Sum

Convection section

PI
P

TI

F-401
PI TRC
TI

FRC
FRC

TRC
TRC

From E-402

To E-402

TRI PI TI
To R-401

Radiant section
PI

FRC

Sum FRCV

Lead/Lag

PI

EQ

RC

FRC FRC TI M

K-402

TI
FRC

Air preheater

Air preheater

PI
FRC

Fuel
M

K-401

Air

34

HEATER SECTION
No . 1. 2. 3. Control Philosophy Maintain outlet temperature of F-401 at SP of 410oC Control the ratio of air to fuel Assure the excess oxygen Strategy Cascade Ratio Cascade - Multi-variable Control - Static feed forward - lead-lag control Indicator Indicator Feedback Compressor pressure indication Temperature indication Temperature indication Indicator Indicator Indicator - Multi-variable Control - Static feed forward Controlled Variables - Temperature of the outlet - Fuel flow rate Ratio of the air and fuel flow rates - oxygen composition at stack - air flow rate

G7
Manipulated Variables Fuel flow rate Flow rate of air The ratio control loop (2) Fuel gas flow rate Flow rate of molten salt -

4.

Correct the delay time of the temperature control Pressure indication Temperature indication Control flow rate of the molten salt to F-401

Temperature of the outlet

5. 6. 7. 8. 9. 10 .

Molten salt -

11.

Balance the passes temperatures

Temperature of the outlet

Inlet flow rates

35

G7

4. UNIT OPERATIONS & MAJOR EQUIPMENT

36

UNIT OPERATIONS
15 21

G7
TO OFF-GAS

DEMIN WATER
14 20

CW

E-408

9
CW

E-407

T-401

11

8
1

F-401 R-401
13 5 22 10
35 33 1

P-404A/B P-403A/B
23
CW

ACETONE TO STORAGE
24

E-404

E-409
16
18
LP

ISOPROPYL ALCOHOL

3 1 2

E-402
35
LP

CW

E-411

E-401 P-401A/B
19 7
E-403

T-403

E-410 T-402

12

V-401

P-405A/B

31

Cooling Water

25 17 18
LP

10

20

E-406
CW

P-402A/B E-412

T-404

27

WASTE TREATMENT
26 28
CW

29

RECYCLE ISOPROPYL ALCOHOL

30

E-405

37

MAJOR EQUIPMENT SUMMARIES

G7

EQUIPMENT TAG NUMBER R 401 T 401 T 402 T 403

EQUIPMENT REACTOR

DESIGNER ROZALINA SHIELA

ACETONE SCRUBBER SUHAIRA WATER COLUMN ACETONE COLUMN NGUYEN DUY VINH NURUL SHARINA

38

REACTOR R 401
Type Type of head Operating temp. & press. Number of tubes Number of baffles Multi tubular fixed bed reactor Torispherical flanged dished 350oC, 200kPa 498 7

G7

Insulation material
Support type Material of cons. Configuration Diameter, mm Height, mm Content

Mineral wool
Skirt Stainless Steel 316L (18Cr/11Ni/3Mo) Shell 1917 10021 Molten salt Tube 61 7012 4720kg ZnO2/ZrO2 1917mm

10021mm

39

ACETONE SCRUBBER T 401

Operating Pressure Operating Temperature Type Type of Packing Vessel Diameter Packing Height Material of Construction Support Type Insulation Material Total Cost 165 kPa 20C - 38C Packed Tower Pall Ring Metal (1 in.) 0.37 m 1.60 m SS, 18Cr / 8Cr Skirt Mineral Wool RM 79, 288

G7

1600mm

370mm
40

WATER COLUMN T 402

Tower ID Tower OD Tower Height Tray Spacing 1141 mm 1151 mm 11 m 250 mm
1 2 3 4 5 6 7

G7

Total Tray
Feed Tray Location Design Temperature Design Pressure Material Nuts and Bolts Material Vessel Support Types of Head Gasket Material

44
15th from top tray 111.4
oC

36 37 38 40 41 42 43

212 kPa Stainless steel 5 Cr Mo Steel Skirt Torispherical Corrugated Metal Jacket Steel

44

41

ACETONE COLUMN T 403

Tower ID Tower OD Tower Height Tray Spacing 1935 mm 1949 mm 1850 mm 550 mm
1 2 3 4 5 6 7

G7

Total Tray
Feed Tray Location Design Temperature Design Pressure Material Nuts and Bolts Material Vessel Support Types of Head

31
6th from top tray 80
oC

24 25 26 27 28 29 30

140 kPa Stainless steel 5 Cr Mo Steel Skirt Torispherical

31

Gasket Material

Corrugated Metal Jacket Steel

42

G7

5. SAFETY & LOSS PREVENTATION (HAZOP & PLANT LAYOUT

43

HAZOP STUDY
HAZOP Hazard and Operability study a structured techniques to perform a systematic study of a process using guidewords to discover how deviations from the design intent can occur in equipments, actions or materials, and whether the consequences of these deviations can result in a hazard
GUIDE WORDS NO (NOT, NONE) More / Less As Well As (More Than) Part Of Reverse Other Than INTERPRETATION None of the design intent is achieved Quantitative increases or decreases in parameter An additional activity occurs Qualitative decreases (only some of the design intent is achieved) The logical opposite of the intention occurs Complete substitution (another activity takes place)

G7

44

HAZOP STUDY cont

G7

Streams involved Reactor Node 1: Inlet stream to Reactor R 401 Node 2: Reactor R 401 outlet stream Node 3: Inlet to Reactor R 401 from Furnace F 401 stream

Node 4: Outlet from Reactor R 401 to Furnace F 401 stream

Scrubber Node 1: Stream form Flash Drum V 401 to inlet Acetone Scrubber T - 401

45

PS PS

RELIEF TO ATMOSPHERE AT SAFETY LOCATION

RELIEF TO ATMOSPHERE AT SAFETY LOCATION

PI TI

002

003

ARC 001

DEMINERALIZED WATER
TI 001 FRC PI 001 TRC 002 WEIGHT AVERAGE TEMPERATURE TRC 002' FRC 002 RC 001 004 PS

To offgas

F-401 T-401
FRC 005

LRC 002

R-401
FRC TRC 003 FRC 003 PS TI 002 006

Air

Fuel

TRC

E-402
001 PI 003

IPA FROM TANK

LRC

E-401

001

V-401
TRC 004

TO T-402 1
FR C

46
RECYCLE IPA

00

NODE 1: Inlet stream to Reactor R 401

Intention: To transport fluid to reactor
Item No. 1 GUIDE WORD NO DEVIATION No flow POSSIBLE CAUSES Power failure Pump failure Line blockage (i.e. isolation valve closed) Pipe is fractured. Defective pump Heat exchanger tube fouling Piping leaking Line restriction Standby pump is running together with the service pump Defective pump Operation of pumps in parallel Increased pumping capacity Backflow due to back pressure from downstream Emergency venting Incorrect differential pressure

Parameter: Flow
CONSEQUENCE SAFEGUARDS

G7

No process fluid to the reactor. No reaction occurs. No product / no reactor effluent. Failure of reactor Less process fluid to the reactor. Less reaction occurs. Low yield of product. More process fluid to the reactor. More molten salt needed Build up the pressure in the reactor Pipe vibration is increased Failure of Reactor Loss product yield from the reactor effluent Desired flow could not be achieved

Install control valves that fails open Install flow indicator and flow control valve Install low flow alarm to alert operator Install shut down valve Install flow indicator and flow control valve Install low flow alarm to alert operator Make bypass line Install flow indicator and flow control valve Install high and trip flow alarm to alert operator

LESS

Less flow

MORE

More flow

REVERS E

Reverse flow

Install pressure differential indicator to detect the differential pressure Installed the check valve correctly Emergency venting/purging 47

NODE 2: Reactor R 401outlet stream

Intention: To transport product / reactor effluent from Reactor R 401 to Flash Drum V 401 Parameter : Flow
Item No. 1 GUIDE WORD NO DEVIATION No flow POSSIBLE CAUSES Power failure Reactor is empty Line blockage (i.e. isolation valve closed) No reaction occur No inlet / feed to reactor Less reaction occur Line / outlet nozzle blockage Piping leaking Not enough heat supply for the reaction to occur More feed enter reactor CONSEQUENCE No product from reactor Feed cannot exchange heat before enter reactor No reaction occur SAFEGUARDS

G7

Install control valves that fails open Install flow indicator and flow control valve Install low flow alarm to alert operator Install shut down valve Install flow indicator and flow control valve Install low flow alarm to alert operator

LESS

Less flow

Less product from reactor Feed can exchange less heat before enter reactor Less reaction occurs lead to low yield of product.

MORE

More flow

More product to the downstream Build up the pressure in the heat exchanger, condenser and flash drum Pipe vibration is increased Reactor trip Loss product yield from the reactor effluent Desired flow could not be achieved

Install flow indicator and flow control valve Install high and trip flow alarm to alert operator

REVERSE

Reverse flow

Backflow due to back pressure from downstream Emergency venting Incorrect differential pressure

Install pressure differential indicator to detect the differential pressure Installed the check valve correctly Emergency venting/purging

48

NODE 3: Inlet to Reactor R 401 from Furnace F 401 stream

Intention: To transport molten slat from Furnace F 401 to Reactor R 401 Parameter : Flow
Item No. 1 GUIDE WORD NO DEVIATION No flow POSSIBLE CAUSES Power failure Furnace trip Defective control valve No molten salt Line blockage Piping leaking Defective control valve Less amount of molten salt in furnace Line restriction Defective pump Defective pump Defective control valve Standby pump is running together with the service pump Backflow due to back pressure from downstream Emergency venting Incorrect differential pressure CONSEQUENCE No heat supply to reactor No product from reactor No reaction occur SAFEGUARDS

G7

Install control valves that fails open Install low flow alarm to alert operator Install shut down valve Install bypass line Install flow indicator and flow control valve Install low flow alarm to alert operator

LESS

Less flow

Less heat supply to reactor Generate side reaction in reactor Less product from reactor Less reaction occur Too high heat supply to the reactor Generate side reaction Pipe and tube in reactor vibration is increased High outlet reactor temperature Reactor trip Loss product yield from the reactor effluent Less reaction occur Generate side reaction

MORE

More flow

Recycle some molten salt to furnace Install high and trip flow alarm to alert operator

REVERSE

Reverse flow

Install pressure differential indicator to detect the differential pressure Installed the check valve correctly Emergency venting/purging

49

NODE 4: Outlet from Reactor R 401 to Furnace F 401 stream

Intention: To transport molten slat from Reactor R 401 to Furnace F 401
Item No. 1 GUIDE WORD NO DEVIATION No flow POSSIBLE CAUSES Power failure Furnace trip No molten salt enter reactor Line blockage Reactor nozzle blockage Piping leaking Less amount of molten salt enter furnace Line restriction Molten salt leak to reactor tube Changing in density and viscosity of molten salt More molten salt enter reactor High pressure in reactor Reactor relief valve failure Less pressure from reactor High furnace pressure Incorrect differential pressure CONSEQUENCE Amount of molten salt in furnace decrease More fuel and combustion needed to maintain furnace temperature Build up molten salt in furnace Some molten salt enter the product Need to top up molten salt in furnace Amount of molten salt in furnace decrease SAFEGUARDS

G7

Install control valves that fails open Install low flow alarm to alert operator Install shut down valve Install bypass line

LESS

Less flow

Install flow indicator and flow control valve Install low flow alarm to alert operator

MORE

More flow

Tube metal vibration Build up pressure High pipe vibration

Install flow indicator and flow control valve Install high and trip flow alarm to alert operator

REVERSE

Reverse flow

Reactor trip Loss product yield from the reactor effluent Amount of molten salt in furnace decrease

Install pressure differential indicator to detect the differential pressure Installed the check valve correctly Emergency venting/purging

50

Plant Layout PLANT LAYOUT

The Acetone plant will be located at Tok Arun, Paka, Terengganu The plant layout will includes the basic arrangement of production site storage for product and raw material workshops laboratories

G7

wastewater treatment plant

Supporting buildings for utilities offices and amenity safety structures; - fire station - assembly points
51

FOR TA PURPOSES

RADIUS = 60 m
FURNACE REACTOR ABSORBER WATER DISTILLATION COLUMN ACETONE DISTILLATION COLUMN RECYCLE DISTILLATION COLUMN

FIRE STATION

UTILITIES (COOLING WATER, WASTE WATER TREATMENT) PUMPS HOUSE MAIN CONTROL BUILDING

PARKING LOT

FIRE ASSEMBLY AREA

PROCESS AREA
HSE DEPARTMENT/ CLINIC

OFFSITES
WAREHOUSE MAINTENANCE/ WORKSHOP UTILITIES

STORAGE TANKS

To Port

IPA

ACETONE

410m

PARKING LOT/ FIRE ASSEMBLY AREA SURAU

LABORATORY

KEYS: Bicycle parking lot

CONTRACTORS PARKING LOT

Flare system

TECHNICAL & SERVICES DEPARTMENT PROCUMENT DEPARTMENT

HRM CAFE TRAINING CENTER SPORT COMPLEX

Gate

ENGINEERING SERVICES DEPARTMENT

Guard station

NON-PROCESS AREA
PARKING LOT/FIRE ASSEMBLY AREA

Fence

52
450m

PLANT LAYOUT cont

Process Area
Units / Buildings Reaction Unit Separation Unit Utilities Unit Wastewater Treatment Unit Tank Farm Central Control Room Laboratory Chemical Storage Flare Area Fire Station Warehouse Function(s)

G7

Major processing unit where Isopropyl Alcohol (IPA) reacted in reactor to form Grade Acetone and Hydrogen which is carried out in vapor phase Consists of three distillation columns for separation purposes Supply cooling water, low pressure steam, instrument air and some other utilities to the main process unit To treat the wastewater effluent from the process unit before being release to the environment Consists of two tanks that store the raw material from supplier before being processed and also stores the product before being exported To control and monitor the whole process area To test and analyzed product and material To store chemical substance for waste treatment, lubricants, and catalyst pellets used for the process To burn all excess gas that is emitted from the process units as well as to burn some of the waste gas from waste treatment area To respond to fire emergency To stores all the equipments spare parts 53

PLANT LAYOUT cont

Non Process Area
Units / Buildings Guard Post Function(s)
Guard posts are located at the entrance of the site. The security checkpoints are important to ensure unauthorized access to the plant

G7

Administration Building Cafeteria Clinic

A place where employee does their paperwork, conduct meetings and seminars, briefing and administration work Provide and serve meals to employees It offers emergency and fast treatment to the injured employees before being sent to the nearest hospital for further treatment.

54

G7

6. WASTE TREATMENT HIGHLIGHTS

55

LAW AND REGULATIONS

Environmental Quality Act (EQA), 1974 Environmental Quality (Clean Air) Regulation 1978

G7

Environmental Quality (Sewage and Industrial Effluent) Regulation 1979

Environmental Quality (Scheduled Waste) Regulation 1989 Other closely related regulations - Environmental Quality (Compounding of Offences) Rules 1978 - Environmental Quality (Licensing) Regulations 1977

56

TYPE OF WASTE
SOLID
garbage, rubbish spent catalyst

G7
Sent to Kualiti Alam

WASTE

GASEOUS
Hydrogen
Propylene

Flaring

LIQUID
Water IPA Mesityl Oxide

Wastewater Treatment

57

WASTE WATER TREATMENT

G7

Corrugated Plate Interceptor

Equalization + Neutralization Basin

Aeration Tank

Secondary Clarifier

Guard Pond

Return Activated Sludge Thickener

Effluent Discharge

Filter Press

Dewatered Sludge Solid Handling & Processing

58

G7

7. ECONOMIC EVALUATION

59

ECONOMICS EVALUATION
Cash flow analysis

G7

Assumptions:

The plant has a project plant life of 15 years. The plant construction period is 3 years before commencing production. Hence, the total investment cost is distributed evenly between the 3 years. Interest rate is 15%. Local taxes are assumed to be at 35% annually. It is assumed that operating cost, sale income and cost of sale beginning from the fourth operating year to the end of project plant life increase about 1% up to year. Equipment cost is calculated from the correlations obtained from Ulrich (1984)

60

ECONOMICS EVALUATION cont

Discounted Cash Flow Analysis
60 40

G7

20

0 0 2 4 6 8 10 12 14 16

Cumulative DCF

-20

-40

-60

-80

-100

-120

-140 Year Cumulative DCF for 45% Cumulative DCF for 50% Cumulative DCF for 55%

*compared to PETRONAS MARR = 17-18% (as per Dec 2004)

61

ECONOMICS EVALUATION cont

Discounted Pay Back Period

G7

62

ECONOMICS EVALUATION cont

Spider plot
Spider Plot of ROI vs Percent Different
105 90 75 60 45
15% ROI equipment cost utilities raw material revenue

G7

Rate of Investment (ROI)

30 15 0 -30 -20 -10 -15 Percent Different (%) 0 10 20 30 40 50 60

63

ECONOMICS EVALUATION cont

Cash Flow Analysis

G7

Parameters TCI/CAPEX

RM million 162.1

Revenue ROR
Net Profit

403.9 18.02%
262.39

Rate of Investment (ROI) = 18.02% (>15% required ROI) It is recommended that ABC Chemical should invest in this project
64

SITE EVALUATION
Factors Type of Industrial Area Raw Materials Utilities IPA Gebeng Industrial Area 7 2 8.5 Kidurong Industrial Area 5 1 6 Paka Industrial Area 9 2 9 Pasir Gudang Industrial Area 6 3 5.3 8 2 8.3

G7
Teluk Kalong Industrial Area

Available Area
Land Price Space for Expansion Cost of Living Transportation Price of Utilities Existing Infrastructure

10
6 8 5 9 8 10 10

7
4 5 8 8 8 10 10

8
8 8 8 8.3 7.7 10 10

4
2 3 3 8.3 7 10 10

9
8 5 8 9.3 6 10 10

Existing Services for Industrial Accidents

Training Centre Government Incentives TOTAL SCORE PERCENTAGE (%) RANKING

8
7 159 / 200 80.0% 2

0
7 132 / 200 66.0% 4

10
7 161 / 200 80.5% 1

5
7 121 / 200 60.5% 5

10
7 159 / 200 79.5%

67 3

Proposed Plant: PAKA INDUSTRIAL AREA

68

G7

8. PROBLEMS HIGHLIGHTS & RECOMMENDATIONS

69

PROBLEM HIGHLIGHTS AND RECOMMENDATIONS

Some new methods of designing have been found, for example: Lobo Evans method for furnace designing and membrane process. Time Constraints A proper schedule for each stage is recommended More connections / references to the industries are advised to get useful inputs from industrial people. The outcome of the project can be proposed to the industry for application if the project is economically sounds

G7

70

G7

9. CONCLUSIONS

71

CONCLUSIONS

G7

It has been proven conceptually that the setting up of Acetone plant in Malaysia is feasible and crucial in order to meet the high demand of it in the Asian region.
Process route chosen for the process is Dehydrogenation of Isopropyl Alcohol Acetone produce is Grade Acetone, 99.9% purity Paka Industrial area, Terengganu is identified to be the best location for Acetone production plant. Basic utilities such as steam and raw water are obtained from neighboring CUF.

Simulation via HYSYS is used to verify manual calculation

Waste treatment designed meets the Department of Environment, Malaysia (DOE) environmental standard and regulations Proposed plant design is economically justified with payback period of 4 years after plant startup, ROR is 18.02% and Net Profit of RM 262.39 million

72

G7

THANK YOU~

73

G7

Q and A SESSION

74