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MAPUA INSTITUTE OF TECHNOLOGY AT LAGUNA Academic Year 2014 - 2015

PRODUCTION OF PHENOL-ACETONE FROM PROPYLENE AND BENZENE THROUGH CUMENE PROCESS

Arban L. LEGASPI Edrian A. MAÑALONG Myke Vivienne F. SALVACION

Engr. Marlon O. Martinez

Submitted to the Faculty of Malayan Colleges Laguna In Partial Fulfilment of the Requirements for the degree of

Bachelor of Science in Chemical Engineering

i

The plant design attached hereto, entitled “PRODUCTION OF PHENOL-ACETONE FROM PROPYLENE AND BENZENE THROUGH CUMENE PROCESS”, prepared and submitted by Arban L. Legaspi, Edrian A. Mañalong, and Myke Vivienne F. Salvacion in partial fulfillment of the requirements for the degree of Bachelor of Science in Chemical Engineering is hereby accepted.

ii

Copyright

“The author and the adviser authorize consultation and partial reproduction of this thesis for personal use. Any other reproduction or use is subject to copyright protection. Citation should clearly mention the reference of this work.”

Malayan Colleges Laguna, November 2014

The Adviser

The Authors:

Engr. Marlon O. Martinez

Arban L. Legaspi

Edrian A. Mañalong

Myke Vivienne F. Salvacion

i

Biographical Sketch

ARBAN L. LEGASPI was born September 23, 1993 in Calamba, Laguna, Philippines. He graduated from St. Peter Academy and is currently taking up Bachelor of Science in Chemical Engineering at the Mapua Institute of Technology at Malayan Colleges Laguna. He is a member of the Philippine Institute of Chemical Engineers - Junior Chapter Luzon (PICHE) and Association of Chemical Engineering Students – Malayan Colleges Laguna (ACES-MCL). He is a good team player who can absorb, understand, and consider ideas and points of view from his colleagues.

EDRIAN A. MAÑALONG was born June 1, 1994 in San Pedro, Laguna, Philippines. He graduated from Santa Rosa Science and Technology High school and is currently taking up Bachelor of Science in Chemical Engineering at the Mapua Institute of Technology at Malayan Colleges Laguna. He is a member of Philippine Institute of Chemical Engineers (PICHE), Inc. – Junior Chapter Luzon and Association of Chemical Engineering Students – Malayan Colleges Laguna (ACES-MCL). He was a dean’s lister (1st term, S.Y. 20132014). He also competed in a chemical engineering quiz show held at the University of the Philippines Diliman where his team won third place. He firmly believes that success comes to those who work hard for it.

ii

MYKE VIVIENNE F. SALVACION was born November 14, 1993 in San Leonardo, Nueva Ecija, Philippines. She graduated from Holy Rosary College of Santa Rosa, Laguna and is currently taking up Bachelor of Science in Chemical Engineering at the Mapua Institute of Technology at Malayan Colleges Laguna. She is a member of the Philippine Institute of Chemical Engineers - Junior Chapter Luzon (PICHE) and Association of Chemical Engineering Students – Malayan Colleges Laguna (ACES-MCL). She attended several leadership training programs and seminars that developed her character and improved her level of competency. She prioritizes God above all before herself.

Acknowledgement

This Plant design proposal would not be possible without the able guidance, generous assistance and supervision of several individuals who had given their time and effort to assist us, voiced out their concerns and guided us towards the fruitful and timely completion of this work. They served as our mentors during the entire course of this project. We would like to express our deepest appreciation to our adviser, Engr. Marlon O. Martinez, who has the attitude and the substance of a genius: he continually and patiently provided us with the necessary information required for the success of our design. Without his help and support, the completion of this proposal design would not have been possible. We would also like to extend our sincere gratitude to Engr. Rommel Santos for sharing his experiences and opinions with regard to the technical side of our proposal. The following individuals and groups also contributed to our success in completing this work. Engr. Jesunino Aquino Engr. Rommel Santos Engr. Marlon Martinez Dr. Liza Patacsil Our supportive parents Fellow ChE batchmates

iii

Abstract

The aim of this work is the intensification of an industrial-scale production process of phenol and acetone from propylene and benzene through the cheapest and most reliable technology, the cumene process, to obtain higher profitability and reduce the energy requirements of the process. In the first step, the demand and supply of the products and raw materials of the process was analyzed and the capital requirements of the plant were obtained using the class 5 estimate. The next step comprised of the simulation of the main process and utilities using ASPEN HYSYS version 8.0. Parametric optimization was carried out to adjust the process parameters and obtain an efficient and economically feasible process. Consecutively, ISBL and OSBL equipment were sized and their costs were determined using the methods presented in Towler. The final step comprised of a class 3 estimation of the economic feasibility of the project. The capital investment of the project remained almost intact at around 4.5 billion PHP. The IRR was 27% and the return of investment was expected at year 7 starting from the construction period. Overall, the designers find the project feasible and they recommend continuing the project to its procurement, commissioning, and operational phase.

iv

Executive Summary

Finding a configuration and operational conditions of a process in which a chemical is manufactured in a reliable and economical manner, considering several factors such as low energy consumption, low initial capital investment, low or negligible environmental impact, and high product yield is the main goal of designing this plant which can produce phenol and acetone from propylene and benzene through cumene process. Optimization of the process involved was conducted when the flow sheet of the base case and detailed heat and material balances of the process were available. Furthermore, the economic aspects of the plant, including the sizing of all the equipment (ISBL and OSBL), capital investment, and utility requirements, should be considered and evaluated thoroughly. In this paper, the optimization of the process that involves the alkylation of propylene with benzene to produce phenol and acetone through the renowned cumene process was carried out to make the process more effective, reliable, and thus more profitable. As compared to other processes available, cumene process has the lowest cost of production (Tyman, 1996). Currently, the cumene process is universally favored in the United Kingdom (UK) and United States of America (US) because of its lower cost and higher product yield, thus this process will be adapted in this project. The huge majority of cumene manufactured worldwide is utilized in the production of phenol and acetone (Schmidt, 2005). Reactions occur in the presence of various catalyst.

v

In this project, the catalyst used were zeolites for the alkylation of benzene with propylene (Norouzi, Hasani, Haddadi-Sisakht, & Mostoufi, 2014), copper oxide (CuO) nanoparticles for the oxidation of cumene to produce cumene hydroperoxide (CHP) (Zhang, Wang, Hongbing, Wu, & Zeng, 2007), and sulfonic acid resins for the cleaving of hydroperoxide to produce phenol and acetone (Huang, Han, Wang, & Jin, 2002). The following equations describe the reactions involved in the process:

𝑪𝟔 𝑯𝟔 + 𝑪𝟑 𝑯𝟔 → 𝑪𝟗 𝑯𝟏𝟐

(1)

𝐵𝑒𝑛𝑧𝑒𝑛𝑒 + 𝑃𝑟𝑜𝑝𝑦𝑙𝑒𝑛𝑒 → 𝐶𝑢𝑚𝑒𝑛𝑒 (𝑖𝑠𝑜𝑝𝑟𝑜𝑝𝑦𝑙 𝑏𝑒𝑛𝑧𝑒𝑛𝑒) 𝑪𝟗 𝑯𝟏𝟐 + 𝑪𝟑 𝑯𝟔 → 𝑪𝟏𝟐 𝑯𝟏𝟖

(2)

𝐶𝑢𝑚𝑒𝑛𝑒 + 𝑝𝑟𝑜𝑝𝑦𝑙𝑒𝑛𝑒 → 𝑃𝐷𝐼𝐵 (𝑝 − 𝑑𝑖𝑖𝑠𝑜𝑝𝑟𝑜𝑝𝑦𝑙 𝑏𝑒𝑛𝑧𝑒𝑛𝑒) 𝑪𝟔 𝑯𝟓 𝑪𝑯(𝑪𝑯𝟑 ) + 𝑶𝟐 → 𝑪𝟔 𝑯𝟓 𝑪(𝑪𝑯𝟑 )𝟐 𝑶𝑶𝑯

(3)

𝐶𝑢𝑚𝑒𝑛𝑒 + 𝑂𝑥𝑦𝑔𝑒𝑛 → 𝐶𝑢𝑚𝑒𝑛𝑒 𝑃𝑒𝑟𝑜𝑥𝑖𝑑𝑒 (𝐶𝐻𝑃) 𝑪𝟔 𝑯𝟓 𝑪(𝑪𝑯𝟑 )𝟐 𝑶𝑶𝑯 → 𝑪𝟔 𝑯𝟓 𝑶𝑯 + 𝑪𝑯𝟑 𝑪𝑶𝑪𝑯𝟑

(4)

𝐶𝑢𝑚𝑒𝑛𝑒 𝐻𝑦𝑑𝑟𝑜𝑝𝑒𝑟𝑜𝑥𝑖𝑑𝑒 → 𝑃ℎ𝑒𝑛𝑜𝑙 + 𝐴𝑐𝑒𝑡𝑜𝑛𝑒

The first license for cumene production belongs to a corporation called UOP. Their process involves reactions that occur in gas phase with the presence of SPA catalyst (Stefanidakis & Gwyn, 1977). Another license belongs to Monsanto and Kellogg, which uses a mixture of AlCl3 and HCl as the catalyst in a homogeneous liquid-phase reaction of benzene and propylene. The transalkylation of PIPB is also possible in this process. Thus, this process has a high yield. However, corrosion of pipes and equipment are still a problem (Canfield, Cox, & McCarthy, 1986). Liquid-phase and zeolite-based catalytic processes

were already developed by CDTech, Mobil-Badger, and UOP to produce cumene (Norouzi, Hasani, Haddadi-Sisakht, & Mostoufi, 2014). Cumene can be further processed to produce more valuable products like phenol and acetone through the cumene/hock process. This process deals with the oxidation of cumene hydroperoxide (CHP), and is considered to be the key reaction of industrial phenolproduction process. Since the 1970’s, many investments were made for cumene oxidation. For all these catalyst systems, copper compounds were excellent catalysts not only with regard to the reaction activity but also with regard to the CHP selectivity (Zhang, Wang, Hongbing, Wu, & Zeng, 2007). At present, about 94.5% of phenol in the chemical market is manufactured by cumene decomposition, which was developed in the 1950s. There are six types of catalysts that can be used for CHP decomposition; these are Freidel–Crafts catalysts such as AlCl3, inorganic and organic acids, silicates, metallic oxides such as Al2O3 and TiO2, phosphorous compounds such as PCl3, PCl5 and POCl3, and sulfonated phenol formaldehyde resins and sulfonated styrene resins. The solid acid catalysts have some important advantages including adequate catalytic activity, less byproducts, no erosion, easy separation of catalysts and products and easy catalyst recovery and recycling. CHP decomposition catalyzed by sulfonic acid resins offers conversion greater than 99% and selectivity over 98% (Huang, Han, Wang, & Jin, 2002). In the present work, the phenol-acetone production plant was simulated using the Aspen Hysys V8.0. The temperature and other relevant parameters were obtained by optimization. The optimized value obtained can provide a lot of insight before the actual

plant commissioning is done. Furthermore, sizing and evaluating the economics of the plant follows with a definitive class 3 estimate.

Table of Contents

Copyright

i

Biographical Sketch

ii

Acknowledgement

iii

Abstract

iv

Executive Summary

v

Table of Contents

vi

Market Study

1

Process Description

48

Heat and Material Balance

58

Equipment Sizing and Specification

67

Economic Analysis

140

References

197

Appendices

205

List of Tables

vii

List of Figures

viii

List of Appendices

ix

Definition of Terms

x

vi

Market Study

Introduction Phenol and Acetone are one of the most important intermediates of the chemical industry. The demand for these chemicals increases over the years and it is forecasted to follow this trend, which, together with its wide range of applications, provides an excellent platform for the design of a suitable and profitable process for phenol and acetone production in the Philippines. Production of phenol and acetone from propylene and benzene is possible through the process of cumene. Other types of technologies exist to produce these products but the cumene process is proven to be more cost-effective and efficient. Propylene and Benzene are raw materials that are produced locally in the Philippines by the large petroleum industry. Phenol is an aromatic organic compound with the molecular formula C6H5OH which is also known as carbolic acid. It is a white crystalline solid that is volatile having molecule consists of a phenyl group (-C6H5) bonded to a hydroxyl group (-OH). Phenol is mildly acidic, but requires careful handling due to its tendency to cause chemical burns. The major uses of phenol involving its conversion to precursors to plastics, consumes two thirds of its production. Bisphenol-A which is produced from condensation of phenol with acetone, is a key precursor to polycarbonates and epoxide resins. Condensation of phenol, alkylphenols, or diphenols with formaldehyde gives phenolic resins, in which a famous example of it is the Bakelite. Partial hydrogenation of phenol gives cyclohexanone, a precursor to nylon.

1

Phenol is also a versatile precursor to a large collection of drugs which is mostly aspirin but also many herbicides and pharmaceutical drugs. It is also used as an oral anesthetic/analgesic in products such as Chloraseptic or other brand name and generic equivalents which is commonly used to temporarily treat pharyngitis. On the other hand, Acetone is an organic compound with the formula (CH3)2CO which is a colorless, volatile, flammable liquid, and is the simplest ketone. About a third of the world's acetone is used as a solvent, and a quarter is consumed as acetone cyanohydrin a precursor to methyl methacrylate It is a good solvent for many plastics and some synthetic fibers and also used for thinning polyester resin, cleaning tools used with it, and dissolving two-part epoxies and superglue before they harden. Acetone is also used as one of the volatile components of some paints and varnishes.

Supply and Demand Analysis Phenol and acetone belongs to the class of commodity chemicals, which is also known as bulk commodities/bulk chemicals, which are currently manufactured on a large scale to satisfy the needs of the local and global market. The demand for these chemicals is closely connected to the demand of their derivative products (end products), and is then linked to the established business sectors. Demand of phenol based on import. Based on the import data of phenol as shown in Table 1, the importation of phenol from different countries around the world has increased. This data may suggest that production of phenol in the Philippines is not enough since the country is importing the particular product at an increased rate.

2

Table 1 Import data for phenols in the Philippines Year Trade Value 2005 $764,633 2006 $1,623,574 2007 $4,170,608 2008 $4,927,117 2009 $1,797,902 2010 $2,661,669 2011 $1,737,026 Source: UN Comtrade: International trade statistics

Weight (kg) 2,192,213 1,105,156 3,174,993 3,120,126 1,042,860 2,444,078 4,330,795

Figure 1 shows that the demand for phenol will increase for the following years as the trend line for the graph of supply per year is sloping upwards (positive slope). This indicates that there is a high marketability for phenols right now and for the following years to come in the Philippines.

5,000,000

Weight (Kg)

4,000,000 3,000,000 2,000,000 1,000,000 0 2004

2005

2006

2007

2008 Year

2009

2010

2011

2012

Figure 1. Demand tend line for phenols in the Philippines based on import data

Demand of acetone based on import. Based on the import data of acetone as shown in Table 2, the importation of acetone from different countries around the world has 3

increased. This data may suggest that production of acetone in the Philippines is not enough since the country is importing the particular product at an increasing rate.

Table 2 Import data for acetone in the Philippines Year Trade Value 2005 $3,115,608 2006 $2,900,009 2007 $3,248,726 2008 $4,382,299 2009 $2,172,884 2010 $3,401,322 2011 $3,557,146 Source: UN Comtrade: International trade statistics

Weight (kg) 3,771,988 3,261,393 3,974,290 4,990,218 3,609,613 4,993,873 4,833,998

Figure 2 shows that the demand for acetone will increase for the following years as the trend line for the graph of supply per year is sloping upwards (positive slope). This indicates that there is a high marketability for acetone right now and for the following years to come in the Philippines.

6,000,000

weight (kg)

5,000,000 4,000,000 3,000,000 2,000,000 1,000,000

0 2004

2005

2006

2007

2008 Year

2009

2010

2011

2012

Figure 2. Demand trend line for Acetone in the Philippines based on Import 4

Demand of phenol based on assumed consumption. According to Pandia, application to the manufacture of bisphenol-A (BPA) and phenolic resin have the highest percentage. The following depicts the percentage of phenol demand in terms of application: 

Alkyl Phenols – 4%



Phenolic Resins – 30%



Caprolactam – 8%



Bisphenol-A – 40%



Others – 18%

In general, the industries that use phenol and/or acetone to manufacture these intermediate chemicals are the plastic synthetic resin, paint, and adhesives industries. Table 3 shows the value of output of industries that uses phenol in the manufacture of their product. Phenol is included in the production of phenolic resins (a plastic synthetic resin). Alternatively, phenol is combined with acetone to produce bisphenol-A, an intermediate to produce epoxy resin which is used in the manufacture of paints, glues, and adhesives. Depicted in Table 4 are the values of phenol used in phenolic resins and bisphenol-A.

Table 3 Value of output of industries that uses phenol Value of Output (in thousand pesos) Industry description 2009 2010 Manufacture of plastic synthetic resins 12,205,785 18,523,236 Manufacture of Paints 31,538,346 32,642,161 Manufacture of Glues and Adhesive 3,148,124 4,062,129 Source: National Statistics Office 5

Table 4 Assumed phenol consumption in 2009 and 2010 Phenol in Phenolic Phenol in BisphenolYear Resin, kg A, kg 2009 8,360,126.71 8,801,615.41 2010 12,687,147.95 9,715,960.54

6

Total Phenol Consumption, kg 17,161,742.12 22,403,108.48

In assuming the phenol consumption in phenolic resin, the following are considered: 1. Around 20% of the manufactured synthetic resin is phenolic resin, which is based from the main 5 sub-category of the specified industry (2009 Philippine Standard Industrial Classification manual), namely: a. Polymers b. Phenolic Resins c. Polyamides d. Silicones e. Polyamides It is assumed that the percentage of the industry is equally distributed to these 5 main sub-category of the industry. This designates around 20% of the industry to the manufacture of phenolic resin. 2. Phenolic resin is composed of phenol formaldehyde polymer (85%), phenol (15%), formaldehyde (7 Richter. When a strong earthquake occurs, damage will be slight seen in specially designed structures but considerable in ordinary substantial buildings with partial collapse, an example would be moving of heavy furnitures but for poorly built structures, it will be demolished. There is a medium-low occurence of periods with extreme drought but Flooding risk is extremely high. Also, there is extremely high chance of cyclones hitting Hermosa Creek but zero chance of having a landslide. The climate in Hermosa is classified as a tropical savanna (winter dry season), with a tropical moist forest biozone. The soil in the area is high in nitosols, andosols (nt), soil with deep, clay-enriched lower horizon with shiny ped surfaces. Labor cost. One important factor in determining the annual operating expenses of the plant is the labor cost, as shown in Table 31.

Table 31 46

DOLE labor price in Region 3 SECTOR DAILY MINIMUM WAGE Non-Agriculture Establishments with total assets of P30 million or more (690,000.00 USD or PhP 336.00 (7.728 USD) more) Establishments with total assets less than PhP 329.00 (7.567 USD) P30 million (689,999.00 USD or less) Agriculture Plantation PhP 306.00 (7.038USD) Non-Plantation PhP 290.00 (6.67 USD) Retail service With 16 or more workers PhP 325.00 (7.475 USD) With less than 16 workers PhP 311.00 (7.153 USD) Source: DOLE Region 3 Effective October 11, 2012

47

Process Description

Shown in Figure 11 is the block flow diagram of the manufacturing process of Phace Philippines Corporation in producing phenol and acetone through the advanced cumene process. In general, the main process involved was the alkylation of benzene with propylene to produce cumene, followed by a separation process through distillation to recover cumene, then oxidation of cumene to produce cumene hydroperoxide (CHP), followed by CHP cleaving to produce phenol and acetone, then finally a separation process through distillation to recover each of the product separately. The main technology adapted in the process was the cumene production process, which is currently considered to be the latest and cheapest technology ever yet to consider for the production of phenol and acetone from the main raw materials, benzene and propylene. For the process flow diagram (PFD) of the process, please see Appendix F. For the piping and instrumentation diagram (PNID) of the plant, see Appendix F.

48

DIPB, benzene

Benzene

Propylene

Alkylation Reactor (FIXED BED) (Zeolite catalyst)

Distillation Columns Cumene Cumene

Oxidation Tower Air

(CuO nanoparticle catalyst)

Cumene Hydroperoxide (CHP)

Cleavage Reactor (Sulfonic resin catalyst)

Acetone Distillation Columns

Phenol

OSBL: Steam generator, Power generator, Waste Water Treatment Facility, Cooling Water System

Figure 11. Block Flow Diagram of Phenol and Acetone production through Cumene Process

The route to cumene production. The utilization of cumene (isopropylbenzene) in the manufacture of phenol and acetone is applied on a huge scale in the chemical industry. It is achieved through the Friedel-Crafts alkylation of benzene with propylene. In Freidel-Crafts reaction, Benzene is alkylated with propylene (propene) in the liquid or gas phase, in the presence of a solid catalyst (Tyman, 1996). The reactions will occur in a liquid phase at a particular temperature range and pressure that will result to either high or complete conversion of propylene as well as maintain the reactants in the liquid phase, throughout the reactor. Industrially, alkyl groups can be substituted into a benzene ring using a variant on Freidel-Crafts alkylation. Shown in Figure 12 are the chemical structures of the chemicals considered in the first part of the process.

49

Figure 12. Chemical Structures of Benzene plus Propylene to Cumene To put an isopropyl group on the ring (isopropylbenzene/cumene), benzene is reacted with propylene on a fixed bed reactor that contains an ideal catalyst. Figure 13 shows the diagram for the alkylation mechanism of benzene and propylene to form cumene.

Figure 13. Diagram of the industrial alkylat ion of benzene to cumene

Zeolite based catalysts such as 𝛽, Y, ZSM-12, and MCM-22 can be used in the liquid phase alkylation of benzene with propylene to produce cumene (Norouzi, Hasani,

50

Haddadi-Sisakht, & Mostoufi, 2014). Shown in Table 32 is the type of catalyst used in the first reactor of the process. During the alkylation reaction, side reactions occur which produces PDIB (𝑝 − 𝑑𝑖𝑖𝑠𝑜𝑝𝑟𝑜𝑝𝑦𝑙 𝑏𝑒𝑛𝑧𝑒𝑛𝑒). This results to additional consumption of raw materials that negatively affects the economics of the process. In order minimize the production of the side product and increase the selectivity of the main reaction over the PDIB reaction, an excess amount of benzene is introduced in the reactor. The Benzene to propylene mole ratio was maintained at more than 4 in the reactor (Perego & Ingallina, 2002). The excess amount of benzene will absorb the heat generated by the exothermic reaction in the reactor to keep the selectivity of the cumene reaction high and suppress undesirable reactions between propylene molecules to form higher linear hydrocarbons.

Table 32 Information on catalyst used for alkylation and transalkylation reactions Catalyst 𝛽-zeolite catalyst Particle Diameter 3.0 mm Porosity 0.3 Price 8.367 USD per Kg Source: Dai, Lei, Zhang, Li, & Chen, 2013 Price: Zauba, 2015

The alkylation reactions follows the Eley-Rideal kinetic model, which means that the adsorption of propylene on the catalyst is the rate-determining step (Corma, MartinezSoria, & Schnoeveld, 2000). As shown in Table 33, the kinetic law reduces to first order reaction. The reactor in the system consist of a fixed bed of catalysts pellets with an inlet temperature range of 150 to 200℃. The pressure in the reactor is maintained high enough between 2.5 to 3.5 MPa to ensure that the boiling point of the solution is at least 20℃ higher

51

than the temperature elsewhere in the reactor (Norouzi, Hasani, Haddadi-Sisakht, & Mostoufi, 2014).

Table 33 Kinetics of alkylation and transalkylation reactions (𝐸 is in 𝑘𝐽/𝑘𝑚𝑜𝑙, rate of react ion is in 𝑘𝑚𝑜𝑙/𝑚3 ∙ 𝑠, and concentration is in 𝑘𝑚𝑜𝑙/𝑚3 ) TYPE REACTION RATE CONSTANTS Alkylation

−52564 ) 𝑅𝑇 −55000 𝑘2 = 450 𝑒𝑥𝑝 ( ) 𝑅𝑇

Cumene Reaction

𝑘1 = 6510 𝑒𝑥𝑝 (

DIPB Reaction Source: Dimian and Bildea, 2008; Pathak et al., 2011

The route to phenol production. The next process involved the liquid phase air oxidation of cumene, called cumene peroxidation process, to produce cumene peroxide at the proper reaction temperature of 358K (Zhang, Wang, Hongbing, Wu, & Zeng, 2007). Cumene is continuously fed to the oxidation vessel (fluidized bed) until 15 to 25 percent of the cumene is oxidized. The mixture from the oxidizer should be around 60% to 80% by weight cumene peroxide, which will then be fed to a reactor for the cleaving of CHP to phenol and acetone. The cleavage mechanism is an example of 1,2 shift from carbon to oxygen (Speight, 2002). Figure 14 depicts the mechanism of cumene oxidation to form cumene hydroperoxide.

52

Figure 14. Diagram for the mechanism of Cumene Oxidation

In cumene oxidation, cumene is oxidized in air which removes the tertiary benzylic hydrogen from cumene and hence forms a cumene radical. Table 34 shows the type of catalysts used in the oxidation tower.

Table 34 Catalyst for Oxidation Data Catalyst CuO Nanoparticle catalyst Particle Diameter >140 nm Density 790 kg/m3 Source US Research Nanomaterials, Inc. Price 376 USD per Kg Source: Zhang, Wang, Hongbing, Wu, & Zeng, 2007 Price: US Research Nanomaterials, Inc., 2015

53

The cumene radical then bonds with an oxygen molecule to give cumene hydroperoxide radical. This in turn forms into cumene hydroperoxide by abstracting benzylic hydrogen from another cumene molecule. This latter cumene converts into cumene radical and feeds back into subsequent chain formations of cumene hydroperoxides. Table 35 shows the kinetic reaction details for cumene oxidation.

Table 35 Cumene oxidation reaction details Type of Reactor Temperature (K) Conversion (%) Selectivity for CHP (%) Reaction Pressure (atm) Catalyst Source: Zhang, Wang, Ji, Wu, & Zeng, 2007

Fluidized Bed 318 17 >99 1 CuO Nanoparticle

Figure 15 depicts the mechanism for the decomposition of cumene hydroperoxide to phenol and acetone using a particular acidic catalyst (either solid or liquid). Cumene hydroperoxide is then hydrolysed in an acidic medium (the Hock rearrangement) to give phenol and acetone.

54

Figure 15. Diagram for the Mechanism of CHP decomposit ion to Phenol and Acetone

In the first step, the terminal hydroperoxy oxygen atom is protonated. This is followed by a step in which the phenyl group migrates from the benzyl carbon to the adjacent oxygen and a water molecule is lost, producing a resonance stabilized tertiary carbocation. The resulting carbocation is then attacked by water, a proton is then transferred from the hydroxy oxygen to the ether oxygen, and finally the ion falls apart into phenol and acetone. Table 36 shows the optimum operation conditions for the cleaving reactor.

55

Table 36 Optimum operation conditions and Reaction kinetics of Catalytic Decomposition Process of Cumene Hydroperoxide Type of Reactor Fluidized Bed Reactor 75 to 85, preferably 80 Temperature (℃) −1 Space Velocity (WHSV) (ℎ ) 30 to 40 Selectivity (%) >98 Conversion (%) >99 Solid Holdup (catalyst) (wt%) 1 to 1.5 Catalyst Sulfonic Resin Order of Reaction 1 −36.43 × 103 𝐽𝑚𝑜𝑙 −1 Kinetic Rate Model of Decomposition 𝑘𝑚 = 1939.1 exp ( ) 𝑅𝑇 Source: Huang, Han, Wang, & Jin, 2002

The catalyst for the cleaving reaction requires an acid catalyst. Shown in Table 37 is the type of catalyst used in the cleaving reaction.

Table 37 Catalyst for Cleaving Reaction Data Catalyst Particle Diameter Density

Sulfonic Resin 0.02mm 0.00118 kg/m3 Wenzhou Foreign Trade Industrial Product Source Co.,Ltd. (China) Price 2930 USD per Kg Source: Huang, D., Han, M., Wang, J., & Jin, Y., 2002 Price: ChemPep Inc., 2015

The products are separated by distillation. Acetone is firstly removed in the first column. The bottom is vacuumed distilled to send unreacted cumene overhead. The product is purified through catalytic hydrogenation through careful fractionation. In the 56

latter case, bottoms from the vacuum are further distilled to separate cumene from phenol, phenol being the overhead product. Economic advantage of the technology. The comparative cost for the currently existing processes for the production of phenol is shown in Table 38. Currently, the Cumene process is universally favored in the United Kingdom (UK) and United States of America (US) because of its lower cost and higher product yield.

Table 38 Comparison of cost of production of phenol and acetone Process

Benzene - ChloroCumeneBenzeneToluene Raschig Sulphonate benzene hydroperoxide cyclohexane Oxidation

Net Production 81.7 cost (£/ton) Source: Tyman, 1996

78.3

57.1

57

45.7

51.5

59.5

Heat and Material Balance

In this plant design project, the software called Aspen Hysys (Version 8) was used to simulate and generate heat and material balances for each equipment in the plant. Aspen HYSYS is a comprehensive process modeling system that is currently utilized by leading engineering companies worldwide. In general, this software is used to design as well as optimize processes and operations involved in a manufacturing plant. Using the software, material streams, compositions, and energy streams were obtained and described in depth. The main Aspen Hysys simulation involves the modeling of the major three processes of the plant. The first process involves the production of cumene through alkylation reaction between benzene and propylene. The fluid package chosen in Aspen Hysys is NRTL because it is generally used for chemical systems and HF alkylation with highly non-ideal chemicals and it is thermodynamically consistent, which can be applied to ternary and higher order systems. Table 33 shows the kinetic data for alkylation and transalkylation reaction needed by Aspen Hysys for the first reactor. The second process involves the oxidation of cumene to produce cumene hydroperoxide, and its kinetics of reaction is described in Table 35. The last process involves the cleaving of cumene hydroperoxide to produce phenol and acetone, and the kinetics of reaction is described in Table 36. Table 39 shows the component list for the simulation of the main process.

58

Table 39 Data for the component list of the main process in Aspen Hysys Component Propene Oxygen 14-iP-BZ Acetone Phenol Propane Nitrogen CumHyPeroxid Cumene Benzene Air H2O

Type Pure Component Pure Component Pure Component Pure Component Pure Component Pure Component Pure Component Pure Component Pure Component Pure Component Pure Component Pure Component

The utilities required of the process are simulated as well using Aspen Hysys. The first utility involved the generation of steam and the second involves the closed loop circulation of cooling water for the plant. Tables 40 and 41 depicts the component list for the simulation of the stated utilities.

Table 40 Data for the component list of the steam gen utility in Aspen Hysys Component Propane Nitrogen CO2 Oxygen H2O

Type Pure Component Pure Component Pure Component Pure Component Pure Component

59

Table 41 Data for the component list of the cooling water system utility in Aspen Hysys Component

Type

H2O

Pure Component

For a more detailed simulation of the process and utilities of the plant using Aspen Hysys, see Appendix A. Shown in Table 42 is the summarized material streams of the process. Tables 43 and 44 shows the summarized compositions for each streams and energy streams of the main process.

Table 42 Material Streams of the Process STREAM

Vapour Fraction

Unit

Temperature

Pressure

Molar Flow

Mass Flow

Liquid Volume Flow

Heat Flow

C

bar_g

kgmole/h

Kg/h

m3/h

kJ/h

Benzene

0

25

-0.01325

80

6248.8

14.166563

7961764

Benzene_to_mixer

0

28.243691

34.38675

80

6248.8

14.166563

8027489

Propylene

0

25

10.98675

79.67

3354

6.43999

295193.9

Prop_to_mixer

0

27.337761

34.38675

79.67

3354

6.43999

315840.3

To Heater

0

72.429121

34.38675

13810.09

1071616

1222.03203

7.49E+08

To_Alkylator

0

170

33.766222

13810.09

1071616

1222.03203

9.6E+08

To_valve

0

170

33.352865

13731.05

1071616

1219.635126

9.52E+08

Cumene_Bot

0

159.0118

0.18675

79.12

9510.42

10.997799

-660888

Benzene_Dist

0

70.053451

-0.01325

13651.93

1062105

1208.637325

7.4E+08

To_pump

0

70.044379

-0.01325

13570.42

1055764

1201.425477

7.35E+08

To_column1

0.44099

86.599685

0.28675

13731.05

1071616

1219.635126

9.52E+08

To-Mixer

0

73.139927

34.38675

13570.42

1055764

1201.425477

7.41E+08

To_OxiTow_1

0

44.85

-0.413686

164.12

19520

22.416604

-6893388

AIR

1

25

0

380

10963.1

12.673355

0

To_tee

1

83.159439

0.62675

380

10963.1

12.673355

648168.1

To_OT_1

1

83.159439

0.62675

95

2740.78

3.168339

162042

VAP_1

1

44.85

-0.012777

76.18

2248.24

2.775003

49224.18

To_OxiTow_2

0

44.85

-0.012777

162.99

20012.5

22.358325

-8675304

To_OT_2

1

83.159439

0.62675

95

2740.78

3.168339

162042

To_OT_3

1

83.159439

0.62675

95

2740.78

3.168339

162042

VAP_2

1

44.85

-0.022341

76.16

2232.43

2.757165

48642.77

To_OxiTow_3

0

44.85

-0.022341

161.87

20520.8

22.317883

-1E+07

60

VAP_3

1

44.85

-0.031921

76.55

2230.37

2.749782

48130.51

To_OxiTow_4

0

44.85

-0.031921

160.94

21031.2

22.297683

-1.2E+07

To_OT_4

1

83.159439

0.62675

95

2740.78

3.168339

162042

To_Cleaving

0

44.85

-0.041213

160.13

21445.2

22.274623

-1.4E+07

VAP_4

1

44.85

-0.041213

79.88

2326.75

2.830657

49449.35

To_CleavageR Decomposition Effluent Acetone Product

0

45.080979

3.293705

160.13

21445.2

22.274623

-1.4E+07

0

80

2.98675

235.34

21445.2

23.640879

-3.2E+07

0

91.975505

2.68675

75.26

4369.79

5.531312

-1.8E+07

to next Column

0

214.120846

2.88675

160.08

17075.4

18.109567

-8943146

Dist_Cumene

0

151.888966

0

84.95

10004.3

11.412643

-1808721

Phenol Product

0

236.829828

2.78675

75.13

7071.12

6.696924

-8221078

TO_FLARE Acetone to STORAGE Phenol to STORAGE To Mixer2

1

44.85

-0.041213

308.77

9037.79

11.112607

195446.8

0

30

2.645381

75.260491

4369.79

5.531312

-1.9E+07

0

54.444444

2.745381

75.127467

7071.12

6.696924

-1.1E+07

0

151.888859

0

84.993763

10009.6

11.418805

-1808819

To Cooler_E-100

0.02402

151.967835

0

164.11617

19520

22.416604

-2469708

1

0

44.885457

0

164.11617

19520

22.416604

-6892120

2

0

44.851035

0

162.98699

20012.5

22.358325

-8675266

3

0

44.85171

0

161.87431

20520.8

22.317883

-1E+07

4

0

44.852313

0

160.93841

21031.2

22.297683

-1.2E+07

Table 43 Composition of each streams for the process

Unit Benzene_to_mixer Propylene Prop_to_mixer To Heater To_Alkylator To_valve Cumene_Bot Benzene_Dist To_pump To_column1 To-Mixer To_OxiTow_1 AIR

Comp Mole Frac (Propene)

Comp Mole Frac (Oxygen)

Comp Mole Frac (14iP-BZ)

Comp Mole Frac (Acetone)

Comp Mole Frac (Phenol)

Comp Mole Frac (Propane)

0 0.990453 0.990453 0.00574 0.00574 0.000017 0 0.000017 0.000027 0.000017 0.000027 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0.21

0 0 0 0 0 0.000001 0.000123 0 0 0.000001 0 0.000059 0

0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0.048226 0

0 0.009547 0.009547 0.009155 0.009155 0.009208 0 0.009261 0.009261 0.009208 0.009261 0 0

61

To_tee To_OT_1 VAP_1 To_OxiTow_2 To_OT_2 To_OT_3 VAP_2 To_OxiTow_3 VAP_3 To_OxiTow_4 To_OT_4 To_Cleaving VAP_4 To_CleavageR Decomposition Effluent Acetone Product to next Column Dist_Cumene Phenol Product TO_FLARE Acetone to STORAGE Phenol to STORAGE To Mixer2 To Cooler_E-100 1 2 3 4 Benzene

0 0 0 0 0 0 0 0 0 0 0 0 0 0

0.21 0.21 0 0 0.21 0.21 0 0 0.007414 0.000002 0.21 0.000013 0.050234 0.000013

0 0 0 0.00006 0 0 0 0.00006 0 0.00006 0 0.000061 0 0.000061

0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0.000388 0.048379 0 0 0.000316 0.048563 0.000264 0.04872 0 0.048851 0.000232 0.048851

0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0.000009 0.000029 0 0 0 0.014833 0.000029 0 0 0 0 0 0 0.000002 0

0.000041 0 0.000061 0 0.000129 0 0 0.000129 0 0.000059 0.000059 0.00006 0.00006 0.00006 0

0.319595 0.999369 0 0 0 0 0.999369 0 0 0 0 0 0 0 0

0.352834 0 0.518718 0.093203 0.99987 0.000299 0 0.99987 0.093121 0.048226 0.048226 0.048379 0.048563 0.04872 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Table 43 Cont inued Composition of each streams for the process Comp Mole Frac Comp Mole Frac (Nitrogen) (CumHyPeroxid) Unit Benzene_to_mixer Propylene Prop_to_mixer To Heater

0 0 0 0

0 0 0 0

62

Comp Mole Frac (Cumene)

Comp Mole Frac (Benzene)

0 0 0 0.000114

1 0 0 0.984991

To_Alkylator To_valve Cumene_Bot Benzene_Dist To_pump To_column1 To-Mixer To_OxiTow_1 AIR To_tee To_OT_1 VAP_1 To_OxiTow_2 To_OT_2 To_OT_3 VAP_2 To_OxiTow_3 VAP_3 To_OxiTow_4 To_OT_4 To_Cleaving VAP_4 To_CleavageR Decomposition Effluent Acetone Product to next Column Dist_Cumene Phenol Product TO_FLARE Acetone to STORAGE Phenol to STORAGE To Mixer2 To Cooler_E-100 1 2 3 4 Benzene

0 0 0 0 0 0 0 0 0.79 0.79 0.79 0.983624 0.000726 0.79 0.79 0.98583 0.000524 0.98067 0.000378 0.79 0.000276 0.939774 0.000276

0 0 0 0 0 0 0 0.000046 0 0 0 0.000006 0.122446 0 0 0.000012 0.246525 0.000018 0.368381 0 0.46976 0.000024 0.46976

0.000114 0.005869 0.999867 0.000108 0.000116 0.005869 0.000116 0.951664 0 0 0 0.015981 0.828385 0 0 0.013841 0.704323 0.011632 0.582455 0 0.481035 0.009735 0.481035

0.984991 0.984906 0.00001 0.990614 0.990597 0.984906 0.990597 0.000005 0 0 0 0.000001 0.000004 0 0 0.000001 0.000004 0.000001 0.000004 0 0.000003 0.000001 0.000003

0.000188 0.000587 0 0 0 0.972092

0.000032 0 0.000047 0.000088 0 0.000015

0.327299 0.000008 0.481174 0.906708 0.000001 0.012759

0.000002 0.000007 0 0 0 0.000001

0.000587 0 0 0 0 0.000726 0.000524 0.000378 0

0 0 0.000088 0.000046 0.000046 0.122446 0.246525 0.368381 0

0.000008 0.000001 0.90679 0.951664 0.951664 0.828385 0.704323 0.582455 0

0.000007 0 0 0.000005 0.000005 0.000004 0.000004 0.000004 1

63

Table 44 Energy streams of the process Unit kJ/h

kJ/h

kJ/h

Q-pump102 65724.37458 Q-Pump101

Q-pump100 20646.39492 Q-Cooler100

Q-Heater100 210583600.9 Q-Comp100

Q-PFR-100

Q-Cond-100

Q-Reb-100

7608739.103

586285321.7

372840106.2

Q-OX-1

Q-OX-2

Q-OX-3

5909563.646

4423679.953

648168.1337

1896002.254

1902174.803

1857071.734

Q-OX-4

Q-Pump103

Q-PFR-101

Q-Cond-101

Q-Reb-101

Q-Cond-102

1543792.885

9137.795762

18555061.4

2696181.269

7912592.66

22440817.75

Q-Cooler102 611621.8101

Q-Cooler103 2839892.353

Q-100

Q-101

Q-102

1267.605212

38.009834

64.529379

Q-Reb-102 kJ/h kJ/h

21216913.9 Q-103 89.612062

Using Aspen Hysys software, a heat and material balance were simulated for the steam generation system and cooling water system of the plant. For the utilities of the plant, Tables 45, 46, and 47 depicts the requirement of the plant.

64

Table 45 Cooling Water Requirement of the Plant PROPERTIES Vapour / Phase Fraction Temperature [C] Pressure [kPa] Molar Flow [kgmole/h] Mass Flow [kg/h] Std Ideal Liq Vol Flow [m3/h] Molar Enthalpy [kJ/kgmole] Molar Entropy [kJ/kgmole-C] Heat Flow [kJ/h] Liq Vol Flow @Std Cond [m3/h] Act. Volume Flow [m3/h]

Inlet to Cooling Tower 0 60 2059.956445 312354.6137 5627099.751 5638.455471 -282346.6114 14.95464482 -88192266744 5633.061288 5653.898758

Outlet 0 32.11818066 1101.325 312354.6137 5627099.751 5638.455471 -284460.2213 8.383744001 -88852462549 5633.061288 5653.898758

Table 46 Steam requirement of the plant PROPERTIES Vapour / Phase Fraction Temperature [C] Pressure [kPa] Molar Flow [kgmole/h] Mass Flow [kg/h] Std Ideal Liq Vol Flow [m3/h] Molar Enthalpy [kJ/kgmole] Molar Entropy [kJ/kgmole-C] Heat Flow [kJ/h] Liq Vol Flow @Std Cond [m3/h] Act. Volume Flow [m3/h]

Inlet to Boiler 0 244.9187093 4293.377832 20015.50196 360581.279 361.3089469 -267779.0355 49.47427638 -5359731810 360.9632909 446.7531747

Steam Generated 1 253.6877563 4231.325 20015.50196 360581.279 361.3089469 -236459.9051 108.9330054 -4732863696 360.9632909 16932.16337

Table 47 Fuel requirement of the plant PROPERTIES Vapour / Phase Fraction Temperature [C] Pressure [kPa] Act. Volume Flow [m3/h] Type of Fuel

Values 0 30 101.3 2.71 Industrial LPG

65

Information on the conditions, availability, and price of utility services such as fuel, steam, cooling water, process air, process water, and electricity can be obtained from the provincial government of Hermosa, Bataan. Utility equipment are built outside the process area to supply the requirements of several processes of the plant.

66

Equipment Sizing and Specification

This chapter includes the nature and methodology of the design process used in generating specifications sheets for each equipment. The generated design concepts will be further used in the detailed economic evaluation of the project. The economic evaluation usually entails analyzing the capital and operating costs of the process to determine the return of investment, which will be further elaborated in the next chapter. Other equipment that already have sufficient data for economic performance evaluation need no specifications to be generated. In general, ISBL equipment of the plant were designed in this chapter and OSBL equipment were detailed for economic evaluation purposes in the next chapter.

Calculation Sheets To easily understand and check the design generated on this chapter, calculation sheets are provided. All of the assumptions and approximations made were included in these sheets.

Specification Sheets The sheets consisted of the main specifications of the equipment as required in the process of the manufacturing plant.

67

Storage Tanks Specification Sheets See Appendix B for calculation sheets V-101: Propylene Feed Storage Tank (Pressure Vessel) Project No. 1

STORAGE TANK

SHEET 1 of 1 REV DATE BY APVD REV DATE BY APVD 1 01/11/15 EAM ALL MFS 2 01/22/15 EAM

Quantity 6 ITEM NUMBER V-101 TYPE Pressure vessel SERVICE Propylene MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 1200 Temperature (deg C) 25 DESIGN CONDITIONS Pressure (kPa) 1372 Temperature (deg C) 93 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) 15 ~ 20 METALLURGY Material of Construction Carbon steel Joint Efficiency 0.85 Maximum Allowable Stress (Mpa) 88.94236908 Corrosion Allowance (mm) 3.8 SPECIFICATION FOR CONSTRUCTION Geometry Cylindrical Position Vertical Support/Foundation Concrete Outage Allowance (mm) 500 Innage Allowance (mm) 500 Inside Diameter (m) 7.2 Outside Diameter (m) 7.34 Minimum Thickness (mm) 70 T/T Height (m) 21.6 Closure/Head 2:1 ellipsoidal Minimum Thickness for Closure (mm) 66

SKETCH

7.34 m

500 mm 21.6 m

500 mm

68

V-102: Benzene Feeeed Storage Tank (Atmospheric Vessel) Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

ALL

STORAGE TANK

MFS 2

Quantity 6 ITEM NUMBER V-102 TYPE Atmospheric vessel SERVICE Benzene MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 100 Temperature (deg C) 25 DESIGN CONDITIONS Pressure (kPa) 445.9678571 Temperature (deg C) 93.33333333 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) 15 ~ 20 METALLURGY Material of Construction Carbon steel Joint Efficiency 0.85 Maximum Allowable Stress (Mpa) 88.94236908 Corrosion Allowance (mm) 3.8 SPECIFICATION FOR CONSTRUCTION Geometry Cylindrical Position Vertical Support/Foundation Concrete Outage Allowance (mm) 500 Innage Allowance (mm) 500 Inside Diameter (m) 7.4 Outside Diameter (m) 7.426 Minimum Thickness (m) 13 T/T Height (m) 22.2 Closure/Head 2:1 ellipsoidal Minimum Thickness for Closure (mm) 22

01/22/15

EAM

SKETCH

7.426 m

500 mm 22.2 m

500 mm

69

APVD

V-103: Acetone Product Storage Tank A (Pressure Vessel) Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

ALL

STORAGE TANK

MFS 2

Quantity 3 ITEM NUMBER V-103 TYPE Pressure vessel SERVICE Acetone MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 365.9 Temperature (deg C) 30 DESIGN CONDITIONS Pressure (kPa) 538 Temperature (deg C) 93 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) 15 ~ 20 METALLURGY Material of Construction Carbon steel Joint Efficiency 0.85 Maximum Allowable Stress (Mpa) 88.94236908 Corrosion Allowance (mm) 3.8 SPECIFICATION FOR CONSTRUCTION Geometry Cylindrical Position Vertical Support/Foundation Concrete Outage Allowance (mm) 500 Innage Allowance (mm) 500 Inside Diameter (m) 5.4 Outside Diameter (m) 5.448 Minimum Thickness (m) 24 T/T Height (m) 16.2 Closure/Head 2:1 ellipsoidal Minimum Thickness for Closure (mm) 20

01/22/15

EAM

SKETCH

5.448 m

500 mm 16.2 m

500 mm

70

APVD

V-104: Acetone Product Storage Tank B (Pressure Vessel) Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

ALL

STORAGE TANK

MFS 2

Quantity 3 ITEM NUMBER V-103a TYPE Pressure vessel SERVICE Acetone MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 365.9 Temperature (deg C) 30 DESIGN CONDITIONS Pressure (kPa) 538 Temperature (deg C) 93 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) 15 ~ 20 METALLURGY Material of Construction Carbon steel Joint Efficiency 0.85 Maximum Allowable Stress (Mpa) 88.94236908 Corrosion Allowance (mm) 3.8 SPECIFICATION FOR CONSTRUCTION Geometry Cylindrical Position Vertical Support/Foundation Concrete Outage Allowance (mm) 500 Innage Allowance (mm) 500 Inside Diameter (m) 2.9 Outside Diameter (m) 2.93 Minimum Thickness (mm) 15 T/T Height (m) 8.7 Closure/Head 2:1 ellipsoidal Minimum Thickness for Closure (mm) 11

01/22/15

EAM

SKETCH

2.93 m

500 mm 8.7 m

500 mm

71

APVD

V-105: Phenol Product Storage Tank A (Atmospheric Vessel) Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

ALL

STORAGE TANK

MFS

Quantity 3 ITEM NUMBER V-104 TYPE Atmospheric vessel SERVICE Phenol MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 375.9 Temperature (deg C) 54.44 DESIGN CONDITIONS Pressure (kPa) 548.2214286 Temperature (deg C) 93.33333333 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) 15 ~ 20 METALLURGY Material of Construction Carbon steel Joint Efficiency 0.85 Maximum Allowable Stress (Mpa) 88.94236908 Corrosion Allowance (mm) 3.8 SPECIFICATION FOR CONSTRUCTION Geometry Cylindrical Position Vertical Support/Foundation Concrete Outage Allowance (mm) 500 Innage Allowance (mm) 500 Inside Diameter (m) 5.8 Outside Diameter (m) 5.822 Minimum Thickness (m) 11 T/T Height (m) 17.4 Closure/Head 2:1 ellipsoidal Minimum Thickness for Closure (mm) 22

SKETCH

5.822 m

500 mm 17.4 m

500 mm

72

APVD

V-106: Phenol Product Storage Tank B (Atmospheric Vessel) Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

ALL

STORAGE TANK

MFS

Quantity 3 ITEM NUMBER V-104 TYPE Atmospheric vessel SERVICE Phenol MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 375.9 Temperature (deg C) 54.44 DESIGN CONDITIONS Pressure (kPa) 548.2214286 Temperature (deg C) 93.33333333 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) 15 ~ 20 METALLURGY Material of Construction Carbon steel Joint Efficiency 0.85 Maximum Allowable Stress (Mpa) 88.94236908 Corrosion Allowance (mm) 3.8 SPECIFICATION FOR CONSTRUCTION Geometry Cylindrical Position Vertical Support/Foundation Concrete Outage Allowance (mm) 500 Innage Allowance (mm) 500 Inside Diameter (m) 3.1 Outside Diameter (m) 3.112 Minimum Thickness (m) 6 T/T Height (m) 9.3 Closure/Head 2:1 ellipsoidal Minimum Thickness for Closure (mm) 12

SKETCH

3.112 m

500 mm 9.3 m

500 mm

73

APVD

V-107: Benzene Recycle Stream Hold-up Tank (Atmospheric Vessel) Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

ALL

STORAGE TANK

MFS 2

Quantity 1 ITEM NUMBER V-105 TYPE Atmospheric vessel SERVICE Benzene Recycle Stream MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 100 Temperature (deg C) 70.05 DESIGN CONDITIONS Pressure (kPa) 445.9678571 Temperature (deg C) 93.33333333 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) 15 ~ 20 METALLURGY Material of Construction Carbon steel Joint Efficiency 0.85 Maximum Allowable Stress (Mpa) 88.94236908 Corrosion Allowance (mm) 3.8 SPECIFICATION FOR CONSTRUCTION Geometry Cylindrical Position Vertical Support/Foundation Concrete Outage Allowance (mm) 500 Innage Allowance (mm) 500 Inside Diameter (m) 5.5 Outside Diameter (m) 5.518 Minimum Thickness (m) 9 T/T Height (m) 16.5 Closure/Head 2:1 ellipsoidal Minimum Thickness for Closure (mm) 17

01/22/15

EAM

SKETCH

5.518 m

500 mm 16.5 m

500 mm

74

APVD

V-108: Reflux Drum 1 (Atmospheric Vessel) Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

APVD

ALL

STORAGE TANK ITEM NUMBER V-106 TYPE Atmospheric vessel SERVICE Condensate from T-100 MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 100 Temperature (deg C) 70.05 DESIGN CONDITIONS Pressure (kPa) 446 Temperature (deg C) 93 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) 15 ~ 20 METALLURGY Material of Construction Carbon steel Joint Efficiency 0.85 Maximum Allowable Stress (Mpa) 88.94236908 Corrosion Allowance (mm) 3.8 SPECIFICATION FOR CONSTRUCTION Geometry Cylindrical Position Horizontal Support/Foundation Saddle Inside Diameter (m) 5.2 Outside Diameter (m) 5.208 Minimum Thickness (mm) 4 Height of Liquid (m) 2.6 Length (m) 15.6 Closure/Head 2:1 ellipsoidal Minimum Thickness for Closure (mm) 16

MFS

SKETCH

15.6 m

5.2 m

1.3 m

2.6 m

75

5.208 m

V-109: Reflux Drum 2 (Pressure Vessel) Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

APVD

ALL

STORAGE TANK ITEM NUMBER V-107 TYPE Pressure vessel SERVICE Condensate from D-102 MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 370 Temperature (deg C) 91.98 DESIGN CONDITIONS Pressure (kPa) 542 Temperature (deg C) 93 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) 15 ~ 20 METALLURGY Material of Construction Carbon steel Joint Efficiency 0.85 Maximum Allowable Stress (Mpa) 88.94236908 Corrosion Allowance (mm) 3.8 SPECIFICATION FOR CONSTRUCTION Geometry Cylindrical Position Horizontal Support/Foundation Saddle Inside Diameter (m) 0.9 Outside Diameter (m) 0.908 Minimum Thickness (mm) 4 Height of Liquid (m) 0.45 Length (m) 2.7 Closure/Head 2:1 ellipsoidal Minimum Thickness for Closure (mm) 4

MFS

SKETCH

2.7 m

0.9 m

0.225 m

0.45 m

76

0.908 m

V-110: Reflux Drum 3 (Atmospheric Vessel) Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

APVD

ALL

STORAGE TANK ITEM NUMBER V-108 TYPE Atmospheric vessel SERVICE Condensate from D-103 MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 101.3 Temperature (deg C) 151.9 DESIGN CONDITIONS Pressure (kPa) 445.9678571 Temperature (deg C) 179.6777778 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) 15 ~ 20 METALLURGY Material of Construction Carbon steel Joint Efficiency 0.85 Maximum Allowable Stress (Mpa) 88.94236908 Corrosion Allowance (mm) 3.8 SPECIFICATION FOR CONSTRUCTION Geometry Cylindrical Position Horizontal Support/Foundation Saddle Inside Diameter (m) 2 Outside Diameter (m) 2.008 Minimum Thickness (mm) 4 Height of Liquid (m) 1 Length (m) 6 Closure/Head 2:1 ellipsoidal Minimum Thickness for Closure (mm) 6

MFS

SKETCH

6m

2m

0.5 m

1m

77

2.008 m

V-111: Cumene Recycle Stream Hold-up Tank (Atmospheric Vessel) Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

ALL

STORAGE TANK

MFS 2

Quantity 1 ITEM NUMBER V-109 TYPE Atmospheric vessel SERVICE Cumene Recycle Stream MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 101.3 Temperature (deg C) 151.9 DESIGN CONDITIONS Pressure (kPa) 445.9678571 Temperature (deg C) 179.6777778 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) 15 ~ 20 METALLURGY Material of Construction Carbon steel Joint Efficiency 0.85 Maximum Allowable Stress (Mpa) 88.94236908 Corrosion Allowance (mm) 3.8 SPECIFICATION FOR CONSTRUCTION Geometry Cylindrical Position Vertical Support/Foundation Concrete Outage Allowance (mm) 500 Innage Allowance (mm) 500 Inside Diameter (m) 2.1 Outside Diameter (m) 2.11 Minimum Thickness (m) 5 T/T Height (m) 6.3 Closure/Head 2:1 ellipsoidal Minimum Thickness for Closure (mm) 7

01/22/15

EAM

SKETCH

2.11 m

500 mm 6.3 m

500 mm

78

APVD

V-112: Water Storage Tank (Atmospheric Vessel) Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

ALL

STORAGE TANK

MFS 2

Quantity 1 ITEM NUMBER V-105 TYPE Atmospheric vessel SERVICE WATER MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 100 Temperature (deg C) 30 DESIGN CONDITIONS Pressure (kPa) 445.9678571 Temperature (deg C) 93.33333333 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) 15 ~ 20 METALLURGY Material of Construction Carbon steel Joint Efficiency 0.85 Maximum Allowable Stress (Mpa) 88.94236908 Corrosion Allowance (mm) 3.8 SPECIFICATION FOR CONSTRUCTION Geometry Cylindrical Position Vertical Support/Foundation Concrete Outage Allowance (mm) 500 Innage Allowance (mm) 500 Inside Diameter (m) 4.3 Outside Diameter (m) 4.316 Minimum Thickness (m) 8 T/T Height (m) 12.9 Closure/Head 2:1 ellipsoidal Minimum Thickness for Closure (mm) 13

01/22/15

EAM

SKETCH

4.316 m

500 mm 12.9 m

500 mm

79

APVD

V-113: Fuel Storage (Pressure Vessel) Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

ALL

STORAGE TANK

MFS 2

Quantity 4 ITEM NUMBER V-111 TYPE Pressure vessel SERVICE LPG (Propane) MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 1080 Temperature (deg C) 30 DESIGN CONDITIONS Pressure (kPa) 1252 Temperature (deg C) 93 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) 15 ~ 20 METALLURGY Material of Construction Carbon steel Joint Efficiency 0.85 Maximum Allowable Stress (Mpa) 88.94236908 Corrosion Allowance (mm) 3.8 SPECIFICATION FOR CONSTRUCTION Geometry Cylindrical Position Vertical Support/Foundation Concrete Outage Allowance (mm) 500 Innage Allowance (mm) 500 Inside Diameter (m) 7.2 Outside Diameter (m) 7.33 Minimum Thickness (mm) 65 T/T Height (m) 21.6 Closure/Head 2:1 ellipsoidal Minimum Thickness for Closure (mm) 60

01/22/15

EAM

SKETCH

7.33 m

500 mm 21.6 m

500 mm

80

APVD

Reactors Specification Sheets See Appendix C for calculation sheets R-101: Plug Flow Reactor 1 Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

ALL

REACTOR

MFS

ITEM NUMBER R-101 TYPE Plug Flow Reactor (Packed Bed) MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 3478 Temperature (deg C) 170 DESIGN CONDITIONS Pressure (kPa) 3816 Temperature (deg C) 198 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) -14.7 SPECIFICATION OF REACTOR VESSEL Reactor Volume (m3) 113.3 Reactor Length (m) 10 Tube Diameter (m) 0.1201 CATALYST BED CHARACTERISTIC Void Fraction 0.7 Void Volume (m3) 79.3 Volume of Catalyst Bed (m3) 34 Particle Diameter (m) 0.003 Catalyst Name Sulfonic Resin Mass of Catalyst (kg) 7140 SHELL AND TUBING LAYOUT Square Pitch Size (mm) 100 Baffle Spacing (m) 0.781764019 Material Carbon Steel Tube Number 1000 TUBE I.D. (in) 4.813 TUBE O.D. (in) 5.563 Nominal Pipe Size (in) 5 Schedule No. 80XS, 80S Wall Thickness (in) 0.375 Cross Sectional Area (in2) 6.11 HEAT EXCHANGER SPECIFICATION Heat transfer coefficient (W/m2K) 636025.5 Shell Diameter (m) 3.9 Cross Sectional Area of Shell Side (m2) 0.3 Heat Evolved in the reaction (kW) 2114.0 Delta T (Degrees Celcius) 27.3 Water circulation rate (kg/h) 66676.3

81

Sketch

DATE

BY

APVD

R-106: Plug Flow Reactor 2 Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

ALL

REACTOR

MFS

ITEM NUMBER R-106 TYPE Plug Flow Reactor MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 400 Temperature (deg C) 80 DESIGN CONDITIONS Pressure (kPa) 572.3214286 Temperature (deg C) 93.33333333 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) -14.7 SPECIFICATION OF REACTOR VESSEL Reactor Volume (m3) 25.02 Reactor Length (m) 10 Tube Diameter (m) 0.1785 CATALYST BED CHARACTERISTIC Void Fraction 0.7 Void Volume (m3) 17.51 Volume of Catalyst Bed (m3) 7.51 Particle Diameter (m) 0.00002 Catalyst Name Zeolite Mass of Catalyst (g) 2.65854 SHELL AND TUBING LAYOUT Square Pitch Size (mm) 100 Baffle Spacing (m) 0.247215489 Material Carbon Steel Tube Number 100 TUBE I.D. (in) 7.187 TUBE O.D. (in) 8.625 Nominal Pipe Size (in) 8 Schedule No. 120 Wall Thickness (in) 0.719 Cross Sectional Area (in2) 17.86 HEAT EXCHANGER SPECIFICATION Heat transfer coefficient (W/m2K) 6172.20338 Shell Diameter (m) 1.236077446 Cross Sectional Area of Shell Side (m2) 0.030557749 Heat Evolved in the reaction (kW) 5154 Delta T (Degrees Celcius) 27.28 Water circulation rate (kg/h) 162558.9454

Sketch

82

DATE

BY

APVD

R-102: Oxidation Tower 1 Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

ALL

REACTOR

MFS

ITEM NUMBER R-102 TYPE Oxidation Tower VESSEL TYPE Atmospheric Vessel MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 100 Temperature (deg C) 44.85 DESIGN CONDITIONS Pressure (kPa) 446 Temperature (deg C) 93 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) 15 ~ 20 METALLURGY Material of Construction Carbon steel Joint Efficiency 0.85 Maximum Allowable Stress (Mpa) 88.942 Corrosion Allowance (mm) 3.8 SPECIFICATION FOR CONSTRUCTION Geometry Cylindrical Position Vertical Support/Foundation Concrete Outage Allowance (mm) 500 Innage Allowance (mm) 500 Inside Diameter (m) 4 Outside Diameter (m) 4.014 Minimum Thickness (mm) 7 T/T Height (m) 12 Height of fluid (m) 9 Closure/Head 2:1 ellipsoidal Minimum Thickness for Closure (mm) 12 CATALYST SPECIFICATIONS Name CuO Nanoparticle Density (kg/m3) 790 Diameter (m) 1.40E-07 Amount (Kg) 198.55 REACTOR MAIN SPECIFICATIONS Void Fraction of Bed 0.8 Bed Height (m) 0.1 Bed Volume (m3) 1.26 Bubble Size (cm) 2.44E-05 Type of Plate Porous

SKETCH

COOLING SYSTEM Type Duty (kW) Cooling water (kg/h)

83

Cooling Coil 526.7 16350

APVD

R-103: Oxidation Tower 2 Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

ALL

REACTOR

MFS

ITEM NUMBER R-103 TYPE Oxidation Tower VESSEL TYPE Atmospheric Vessel MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 99 Temperature (deg C) 45 DESIGN CONDITIONS Pressure (kPa) 445.97 Temperature (deg C) 93.33 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) 15 ~ 20 METALLURGY Material of Construction Carbon steel Joint Efficiency 0.85 Maximum Allowable Stress (Mpa) 88.94 Corrosion Allowance (mm) 3.8 SPECIFICATION FOR CONSTRUCTION Geometry Cylindrical Position Vertical Support/Foundation Concrete Outage Allowance (mm) 500 Innage Allowance (mm) 500 Inside Diameter (m) 4 Outside Diameter (m) 4.014 Minimum Thickness (mm) 7 T/T Height (m) 12 Height of fluid (m) 8 Closure/Head 2:1 ellipsoidal Minimum Thickness for Closure (mm) 12 CATALYST SPECIFICATIONS Name CuO Nanoparticle Density (kg/m3) 790 Diameter (m) 1.40E-07 Amount (Kg) 198.55 REACTOR MAIN SPECIFICATIONS Void Fraction of Bed 0.8 Bed Height (m) 0.1 Bed Volume (m3) 1.26 Bubble Size (cm) 2.42E-05 Type of Plate Porous

SKETCH

COOLING SYSTEM Type Duty (kW) Cooling water (kg/h)

84

Cooling Coil 528.4 16400

APVD

R-104: Oxidation Tower 3 Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

ALL

REACTOR

MFS

ITEM NUMBER R-104 TYPE Oxidation Tower VESSEL TYPE Atmospheric Vessel MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 98 Temperature (deg C) 45 DESIGN CONDITIONS Pressure (kPa) 445.9678571 Temperature (deg C) 93.33333333 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) 15 ~ 20 METALLURGY Material of Construction Carbon steel Joint Efficiency 0.85 Maximum Allowable Stress (Mpa) 88.94 Corrosion Allowance (mm) 3.8 SPECIFICATION FOR CONSTRUCTION Geometry Cylindrical Position Vertical Support/Foundation Concrete Outage Allowance (mm) 500 Innage Allowance (mm) 500 Inside Diameter (m) 4 Outside Diameter (m) 4.014 Minimum Thickness (mm) 7 T/T Height (m) 12 Height of fluid (m) 7 Closure/Head 2:1 ellipsoidal Minimum Thickness for Closure (mm) 12 CATALYST SPECIFICATIONS Name CuO Nanoparticle Density (kg/m3) 790 Diameter (m) 1.40E-07 Amount (Kg) 198.55 REACTOR MAIN SPECIFICATIONS Void Fraction of Bed 0.8 Bed Height (m) 0.1 Bed Volume (m3) 1.26 Bubble Size (cm) 2.30E-05 Type of Plate Porous

SKETCH

COOLING SYSTEM Type Duty (kW) Cooling water (kg/h)

85

Cooling Coil 515.9 16011.28

APVD

R-105: Oxidation Tower 4 Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

ALL

REACTOR

MFS

ITEM NUMBER R-105 TYPE Oxidation Tower VESSEL TYPE Atmospheric Vessel MEASUREMENT SYSTEM Metric System OPERATING CONDITIONS Pressure (kPa) 97.2 Temperature (deg C) 44.85 DESIGN CONDITIONS Pressure (kPa) 445.9678571 Temperature (deg C) 93.33333333 Minimum Pressure (kPa) 0 Minimum Metal Temperature (deg C) 15 ~ 20 METALLURGY Material of Construction Carbon steel Joint Efficiency 0.85 Maximum Allowable Stress (Mpa) 88.94236908 Corrosion Allowance (mm) 3.8 SPECIFICATION FOR CONSTRUCTION Geometry Cylindrical Position Vertical Support/Foundation Concrete Outage Allowance (mm) 500 Innage Allowance (mm) 500 Inside Diameter (m) 4 Outside Diameter (m) 4.014 Minimum Thickness (mm) 7 T/T Height (m) 12 Height of fluid (m) 7 Closure/Head 2:1 ellipsoidal Minimum Thickness for Closure (mm) 12 CATALYST SPECIFICATIONS Name CuO Nanoparticle Density (kg/m3) 790 Diameter (m) 1.40E-07 Amount (Kg) 198.5486557 REACTOR MAIN SPECIFICATIONS Void Fraction of Bed 0.8 Bed Height (m) 0.1 Bed Volume (m3) 1.256637061 Bubble Size (cm) 2.27E-05 Type of Plate Porous

SKETCH

COOLING SYSTEM Type Duty (kW) Cooling water (kg/h)

86

Cooling Coil 428.8 13310.26

APVD

Distillation Columns Specification Sheets See Appendix D for calculation sheets D-101: Distillation Tower 1 Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

ALL

DISTILLATION COLUMN

MFS 2

ITEM NUMBER D-101 TYPE Pressure Vessel MEASUREMENT SYSTEM Metric System SECTION Rectifying Stripping OPERATING CONDITIONS Pressure (kPa) 106 109.7 Temperature (deg C) 80.17 155.4 DESIGN CONDITIONS Pressure (kPa) 446 446 Temperature (deg C) 121 183 Minimum Pressure (kPa) 0 0 Minimum Metal Temperature (deg C) 15 to 20 15 to 20 MAIN SPECIFICATIONS No. of Trays 11 16 Internal Diameter (m) 12 10 Height (m) 9.9 14.4 Tray Spacing (m) 0.9 0.9 Tray Type Sieve Construction type Cartridge-type Packing type Structured Feed tray number 11 Side Stream Plate # N/A SPECIFICATION FOR CONSTRUCTION Material Carbon Steel Support/Foundation Concrete Orientation Vertical Minimum Thickness (mm) 36 30 Outside Diameter (mm) 12.1 10.1 Type of Closure 2:1 Ellipsoidal Minimum Thickness for Closure (mm) 36 30 Total Height of the Column (m) 31.80

01/21/15

EAM

SKETCH 12.1 m

13 m

31.8 m

18.8 m 10.1 m

87

APVD

PLATE LAYOUT FOR RECTIFYING SECTION

50 mm

30 mm 25 mm

12 m

10.08 m

50 mm

PLATE LAYOUT FOR STRIPPING SECTION

50 mm

40 mm 35 mm

10 m

7.6 m

50 mm

D-102: Distillation Tower 2 Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

ALL

DISTILLATION COLUMN

MFS

ITEM NUMBER D-102 TYPE Pressure Vessel MEASUREMENT SYSTEM Metric System SECTION Rectifying Stripping OPERATING CONDITIONS Pressure (kPa) 376.2 379.7 Temperature (deg C) 127.4 211.4 DESIGN CONDITIONS Pressure (kPa) 549 552 Temperature (deg C) 155 239 Minimum Pressure (kPa) 0 0 Minimum Metal Temperature (deg C) 15 to 20 15 to 20 MAIN SPECIFICATIONS No. of Trays 10 12 Internal Diameter (m) 0.7 1.4 Height (m) 6.6 9.6 Tray Spacing (m) 0.6 0.6 Tray Type Sieve Construction type Cartridge-type Packing type Structured Feed tray number 10 Side Stream Plate # N/A SPECIFICATION FOR CONSTRUCTION Material Carbon Steel Support/Foundation Concrete Orientation Vertical Minimum Thickness (mm) 3 6 Outside Diameter (m) 0.8 1.5 Type of Closure 2:1 Ellipsoidal Minimum Thickness for Closure (mm) 3 6 Total Height of the Column (m) 21.20

SKETCH 0.7 m

8.70 m

21.20 m 12.60 m

1.4 m

88

APVD

PLATE LAYOUT FOR RECTIFYING SECTION

50 mm

50 mm 40 mm

0.7 m

0.5915 m

50 mm

PLATE LAYOUT FOR STRIPPING SECTION

50 mm

50 mm 40 mm

1.4 m

1.204 m

50 mm

89

D-103: Distillation Tower 3 Project No. 1 SHEET 1 of 1 REV

DATE

BY

1

01/11/15

EAM

APVD

REV

DATE

BY

ALL

DISTILLATION COLUMN

MFS

SKETCH 2.9 m

6.5 m

ITEM NUMBER D-103 TYPE Pressure Vessel MEASUREMENT SYSTEM Metric System SECTION Rectifying Stripping OPERATING CONDITIONS Pressure (kPa) 105.5 369.7 Temperature (deg C) 153.4 235.5 DESIGN CONDITIONS Pressure (kPa) 446 542 Temperature (deg C) 181 263 Minimum Pressure (kPa) 0 0 Minimum Metal Temperature (deg C) 15 to 20 15 to 20 MAIN SPECIFICATIONS No. of Trays 21 34 Internal Diameter (m) 2.9 1.8 Height (m) 4.95 9.6 Tray Spacing (m) 0.45 0.6 Tray Type Sieve Construction type Cartridge-type Packing type Structured Feed tray number 21 Side Stream Plate # N/A SPECIFICATION FOR CONSTRUCTION Material Carbon Steel Support/Foundation Concrete Orientation Vertical Minimum Thickness (mm) 9 7 Outside Diameter (mm) 3 1.9 Type of Closure 2:1 Ellipsoidal Minimum Thickness for Closure (mm) 9 7 Total Height of the Column (m) 19.00 PLATE LAYOUT FOR RECTIFYING SECTION

19 m

12.5 m

50 mm

33 mm 25 mm

2.9 m

2.4505

50 mm

PLATE LAYOUT FOR STRIPPING SECTION

50 mm

38 mm 30 mm

1.8 m

1.53 m

50 mm

90

1.8 m

APVD

Heat Exchangers Specification Sheets Aspen Exchanger Design & Rating V.8.0 (Aspen EDR) software was used in obtaining appropriate, accurate, and acceptable sizing and specifications of heat exchangers of the manufacturing plant. The major design program used in Aspen EDR was the Aspen Shell & Tube Exchanger. Using this program, the following can be generated: 

Heat Exchanger Specification Sheet



Tube Layout



Drawing or diagrams



Cost Estimate

91

HE-101: Feed Heater

92

93

HE-103: D-101 Condenser

94

95

HE-104: D-101 Reboiler

96

97

HE-105: Cooler 1

98

99

HE-107: D-102 Condenser

100

101

HE-108: D-102 Reboiler

102

103

HE-109: D-103 Condenser

104

105

HE-110: D-103 Reboiler

106

107

HE-111: Product Cooler 1

108

109

HE-112: Product Cooler 2

110

111

Pipes Specification Sheets

112

113

114

115

116

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

Pumps Specification Sheets P-101

P-102

P-103

134

P-104

P-105

135

P-106

P-107

136

P-108

P-109

137

P-110

138

Compressor Specification Sheet

139

Economic Analysis

Before the initiation of the development of the process, at various stages in its development, process engineers must make economic evaluation. The discussion in this chapter determines whether the project should be undertaken or abandoned. The objective for this analysis is to have a class 4 to 3 estimate of the capital requirement as well as the production cost of the plant. The overall economic analysis of the plant will depend on the capital requirement and production cost of the product.

Method for Capital Requirement Estimation This section includes the components of calculating the fixed capital investment which is the total cost of designing, constructing, and installing a plant. Table 48 shows the composition of the fixed capital investment of the plant.

140

Table 48 Fixed capital investment of the plant ISBL CAPEX

1. MAJOR PROCESS EQUIPMENTS i. Storage Tanks ii. Distillation Columns iii. Reactors iv. Heat Exchangers v. Compressors vi. Pumps vii. Pipes 2. Building Cost 3. Trucks and other electric equipment OSBL CAPEX UTILITIES i. Cooling Tower ii. Boiler iii. Furnace iv. Scrubber v. Biological Waste Water Treatment Plant CONTINGENCY COMMISSIONING COST MINIMUM PAID UP CAPITAL REQUIRMENT ON BANKS EIA PROCESSING FEE

Estimating the ISBL and OSBL capital costs. The ISBL plant cost includes the cost of procuring and installing all the process equipment that makes up the new plant. Included in the previous chapter are the design and specifications of the major process equipment of the plant. Table 49 consists of the correlations to be used in estimating the cost of the equipment of the plant.

141

Table 49 Purchase Equipment Cost for Common Plant Equipment 𝑺𝒖𝒑𝒑𝒆𝒓 𝑺𝒍𝒐𝒘𝒆𝒓 Unit for EQUIPMENT Size, S Tanks Cone Roof 10 4000 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦, 𝑚 3 Pressure Vessels shell mass, vertical, cs 150 69200 kg shell mass, Horizontal, cs 250 69200 kg Distillation Columns Trays Sieve trays diameter, m 0.5 5 Reactors Jacketed, agitated 0.5 100 𝑣𝑜𝑙𝑢𝑚𝑒, 𝑚 3 jacketed, agitated, glass0.5 25 𝑣𝑜𝑙𝑢𝑚𝑒, 𝑚 3 lined Heat Exchanger U-tube shell and tube 10 1000 𝑎𝑟𝑒𝑎, 𝑚 2 Compressor driver power, Centrifugal 132 29000 kW Pumps flow Liters/s Single-stage centrifugal 0.2 500 (L/s) Utilities Cooling Tower flow Liters/s 100 10000 Boiler

kg/h steam

20000

800000

30

200

Furnace duty, MW Source: Towler and Sinnott, 2008

a

b

n

5700

700

0.7

-400

230

0.6

-2500

200

0.6

100

120

2

14000

15400

0.7

13000

34000

0.5

10000

88

1

8400

3100

0.6

3300

48

1.2

61000 90000 7000

650

0.9

93

0.8

71000

0.8

Equation 8 was used to obtain the purchase cost of the equipment. Given the parameters, if the value of S is not within the range or limit given in the table, the actual cost of the equipment can be derived from the computed cost using equation 9. 𝑪𝒆 = 𝒂 + 𝒃𝑺𝒏 𝐶𝑒 = 𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒 𝐶𝑜𝑠𝑡 𝑜𝑓 𝐸𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑆 = 𝑆𝑖𝑧𝑒 𝑃𝑎𝑟𝑎𝑚𝑒𝑡𝑒𝑟 𝑆𝑙𝑜𝑤𝑒𝑟 = 𝐿𝑜𝑤𝑒𝑟 𝐿𝑖𝑚𝑖𝑡 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑆𝑖𝑧𝑒 𝑃𝑎𝑟𝑎𝑚𝑒𝑡𝑒𝑟 142

(8)

𝑆𝑢𝑝𝑝𝑒𝑟 = 𝑈𝑝𝑝𝑒𝑟 𝐿𝑖𝑚𝑖𝑡 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑆𝑖𝑧𝑒 𝑃𝑎𝑟𝑎𝑚𝑒𝑡𝑒𝑟 𝑪𝒆,𝒇

𝑺𝒆,𝒇 = 𝑪𝒆,𝒊 ( ) 𝑺𝒆,𝒊

𝒏

(9)

For the cost of pipes, equation 10 may apply. The cost should already include the cost for fittings, paint, installation, and insulation. The basis for the correlation is January 2006. 𝑪𝒐𝒔𝒕 ($⁄𝒎) = 𝟖𝟖𝟎 (𝑫𝒊 , 𝒎𝒎)𝟎.𝟕𝟒

(10)

For pressure vessels, shell mass is needed in estimating the purchase cost based on Table 49. Equation 11 should be used in obtaining the shell mass of a pressure vessel. Density of carbon steel is 7900 𝑘𝑔⁄𝑚3 . 𝑺𝒉𝒆𝒍𝒍 𝒎𝒂𝒔𝒔 = 𝝅𝑫𝒄 𝑳𝒄 𝒕𝒘 𝝆

(11)

𝐷𝑐 = 𝑣𝑒𝑠𝑠𝑒𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚 𝐿𝑐 = 𝑣𝑒𝑠𝑠𝑒𝑙 𝑙𝑒𝑛𝑔𝑡ℎ, 𝑚 𝑡𝑤 = 𝑤𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠, 𝑚 𝜌 = 𝑚𝑒𝑡𝑎𝑙 𝑑𝑒𝑛𝑠𝑖𝑡𝑦, 𝑘𝑔⁄𝑚3 The basis of this cost estimation is on the year 2006. Note that the prices of the materials of construction and the costs of labor are subject to inflation. Through the use of published cost indices, the cost of the equipment can be obtained at any latest year. The following equations can be applied to consider the inflation of the cost. 𝑪𝒐𝒔𝒕 𝒊𝒏 𝒚𝒆𝒂𝒓 𝑨 = 𝑪𝒐𝒔𝒕 𝒊𝒏 𝒚𝒆𝒂𝒓 𝑩 ∗

𝑪𝒐𝒔𝒕 𝒊𝒏𝒅𝒆𝒙 𝒊𝒏 𝒚𝒆𝒂𝒓 𝑨 𝑪𝒐𝒔𝒕 𝒊𝒏𝒅𝒆𝒙 𝒊𝒏 𝒚𝒆𝒂𝒓 𝑩

(12)

𝐶𝑜𝑠𝑡 𝑖𝑛𝑑𝑒𝑥 𝑖𝑛 𝑦𝑒𝑎𝑟 2006 = 499.6 (𝐾𝐿𝑀 𝑇𝑒𝑐ℎ𝑛𝑜𝑙𝑜𝑔𝑦 𝐺𝑟𝑜𝑢𝑝) 𝐶𝑜𝑠𝑡 𝑖𝑛𝑑𝑒𝑥 𝑖𝑛 𝑦𝑒𝑎𝑟 2015 = 609.065 (𝐾𝐿𝑀 𝑇𝑒𝑐ℎ𝑛𝑜𝑙𝑜𝑔𝑦 𝐺𝑟𝑜𝑢𝑝) 𝑪𝒐𝒔𝒕 𝒊𝒏 𝒚𝒆𝒂𝒓 𝟐𝟎𝟏𝟓 = 𝟏. 𝟐𝟏𝟗 ∗ 𝑪𝒐𝒔𝒕 𝒊𝒏 𝒚𝒆𝒂𝒓 𝟐𝟎𝟎𝟔

143

(13)

Most plant and equipment cost data used which came from Towler were based on the location U.S. Golf Coast (USGC), as it was historically the main center of the chemical industry, for which most data were available. The differences in cost between locations can be estimated using the following equation. 𝑪𝒐𝒔𝒕 𝒐𝒇 𝒑𝒍𝒂𝒏𝒕 𝒊𝒏 𝒍𝒐𝒄𝒂𝒕𝒊𝒐𝒏 𝑨 = 𝑪𝒐𝒔𝒕 𝒐𝒇 𝒑𝒍𝒂𝒏𝒕 𝒐𝒏 𝑼𝑺𝑮𝑪 ∗ 𝑳𝑭𝑨

(14)

𝐿𝐹𝐴 = 𝐿𝑜𝑐𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑙𝑜𝑐𝑎𝑡𝑖𝑜𝑛 𝐴 𝑟𝑒𝑙𝑎𝑡𝑖𝑣𝑒 𝑡𝑜 𝑈𝑆𝐺𝐶 𝑏𝑎𝑠𝑖𝑠 𝐿𝐹𝐴 𝑓𝑟𝑜𝑚 𝑈𝑆𝐺𝐶 𝑡𝑜 𝑆𝑜𝑢𝑡ℎ 𝐸𝑎𝑠𝑡 𝐴𝑠𝑖𝑎 = 1.12 In costing, it is also very important to consider the installation cost of the equipment. Table 50 consists of the detailed typical factors for estimation of fixed capital costs. These can be used to make an approximate estimate of capital cost using equipment cost data published in the literature.

Table 50 Typical Installation Factor for Project Fixed Capital Cost fer fp fi fel fc fs fl fm Source: Towler and Sinnott, 2008

144

0.3 0.8 0.3 0.2 0.3 0.2 0.1 1.3

Equation 15 is used to determine the final cost of the equipment including the installation cost. 𝒊=𝑴

𝑪 = ∑ 𝑪𝒆,𝒊,𝑨 [(𝟏 + 𝒇𝒑 ) + 𝒊=𝟏

𝒇𝒆𝒓 + 𝒇𝒆𝒍 + 𝒇𝒊 + 𝒇𝒄 + 𝒇𝒔 + 𝒇𝒍 ] 𝒇𝒎

(15)

𝐶𝑒 = 𝐶𝑜𝑠𝑡 𝑜𝑓 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑖𝑛 𝑎𝑙𝑙𝑜𝑦, 𝑤𝑖𝑡ℎ𝑜𝑢𝑡 𝑡ℎ𝑒 𝑖𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑐𝑜𝑠𝑡 𝑀 = 𝑇𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑖𝑒𝑐𝑒𝑠 𝑜𝑓 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑓𝑒𝑟 = 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑒𝑟𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑝 = 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑃𝑖𝑝𝑖𝑛𝑔 𝑓𝑖 = 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝐼𝑛𝑠𝑡𝑟𝑢𝑚𝑒𝑛𝑡𝑎𝑡𝑖𝑜𝑛 𝑎𝑛𝑑 𝑝𝑟𝑜𝑐𝑒𝑠𝑠 𝐶𝑜𝑛𝑡𝑟𝑜𝑙 𝑓𝑒𝑙 = 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑎𝑙 𝑤𝑜𝑟𝑘𝑠 𝑓𝑐 = 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝐶𝑖𝑣𝑖𝑙 𝑒𝑛𝑔𝑖𝑛𝑒𝑒𝑟𝑖𝑛𝑔 𝑤𝑜𝑟𝑘𝑠 𝑓𝑠 = 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑆𝑡𝑟𝑢𝑐𝑡𝑢𝑟𝑒𝑠 𝑎𝑛𝑑 𝐵𝑢𝑖𝑙𝑑𝑖𝑛𝑔𝑠 𝑓𝑙 = 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝐿𝑎𝑔𝑔𝑖𝑛𝑔, 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛, 𝑎𝑛𝑑 𝑃𝑎𝑖𝑛𝑡 𝐶 = 𝑐𝑜𝑠𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑤𝑖𝑡ℎ 𝑡ℎ𝑒 𝑖𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟

Other cost factor that needs to be considered was the freight rate/cost. It is the cost incurred in moving the goods from USGC to Philippines through marine transportation. This includes packing, palletizing, documentation, loading, unloading charges, carriage costs, and marine insurance costs. For freight rate estimates, worldfreightrates.com offers a reliable calculator to get it. Origin port should be a USGC port such as New Orleans and the Destination port should be Subic Bay, Philippines. For imported goods, the Bureau of Customs imposes duties and taxes for importation. The duties and taxes includes the Value Added Tax (VAT), Import Processing Fee (IPF), and Customs Documentary Stamp imposed by the agency. The agency have their own useful and reliable calculator (Customs PH, 2015). Contingency and commissioning cost. The typical percentage of, or the “norm” for commissioning services for, a chemical plant process was estimated at 3.5% of the total

145

capital investment (Killcross, 2012). For the contingency cost, typically the factor was 10% of the total capital investment (Towler & Sinnott, 2008).

Method for Production Cost Estimation In evaluating the financial attractiveness of a process, management requires the details of both the total capital requirements and the production cost of producing a product. The total production cost of the plant is subdivided into three main categories: Direct costs. Known also as variable cost, tend to be proportional to the production rate. Indirect costs. Composed of fixed cost and plant overhead cost, tend to remain constant regardless of the production rate. General costs. It includes the costs of managing the firm, marketing the product, research and development on new and old products, and financing the operation. Table 51 shows the equations for calculating the components of production cost of a particular chemical plant using numerical factors. Note that these factors were used for approximation. For a good estimation of the production, they are very useful and reliable. Most companies will have their own specific factors for their processes later in the operational stage of their business. Equation 16 is used to obtain the production cost of the plant. 𝑷𝒓𝒐𝒅𝒖𝒄𝒕𝒊𝒐𝒏 𝑪𝒐𝒔𝒕 = 𝑫𝒊𝒓𝒆𝒄𝒕 𝑪𝒐𝒔𝒕 + 𝑰𝒏𝒅𝒊𝒓𝒆𝒄𝒕 𝑪𝒐𝒔𝒕 + 𝑮𝒆𝒏𝒆𝒓𝒂𝒍 𝑪𝒐𝒔𝒕 (16)

146

Table 51 Calculation Procedure for Production Cost DIRECT COST RAW MATERIALS

𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝐼𝑛𝑐𝑜𝑚𝑖𝑛𝑔 𝑆𝑡𝑟𝑒𝑎𝑚 × 𝐶𝑜𝑠𝑡

CATALYSTS

𝐴𝑚𝑜𝑢𝑛𝑡 × 𝐶𝑜𝑠𝑡

UTILITIES: ELECTRICITY FUEL WATER COMMUNICATION BIOLOGICAL WWTP [2]

𝑃𝑜𝑤𝑒𝑟 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 × 𝐶𝑜𝑠𝑡 𝐹𝑢𝑒𝑙 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 × 𝐶𝑜𝑠𝑡 𝑊𝑎𝑡𝑒𝑟 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 × 𝐶𝑜𝑠𝑡 𝐶𝑜𝑠𝑡 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟 $0.20 𝑝𝑒𝑟 𝑙𝑏 𝑜𝑓 𝑜𝑟𝑔𝑎𝑛𝑖𝑐𝑠

OPERATING LABOR

𝑁𝑒𝑡 𝑃𝑎𝑦 + 𝐵𝑒𝑛𝑒𝑓𝑖𝑡𝑠 + 𝐵𝑜𝑛𝑢𝑠

TRANSPORTATION COST

𝐹𝑢𝑒𝑙 × 𝑃𝑟𝑖𝑐𝑒

OPERATING SUPERVISION [1]

0.20 × 𝑂𝑃𝐸𝑅𝐴𝑇𝐼𝑁𝐺 𝐿𝐴𝐵𝑂𝑅

QUALITY CONTROL [1]

0.20 × 𝑂𝑃𝐸𝑅𝐴𝑇𝐼𝑁𝐺 𝐿𝐴𝐵𝑂𝑅

MAINTENANCE LABOR [1]

0.027 × 𝐹𝐼𝑋𝐸𝐷 𝐶𝐴𝑃𝐼𝑇𝐴𝐿 𝐶𝑂𝑆𝑇

MAINTENANCE MATERIAL [1]

0.018 × 𝐹𝐼𝑋𝐸𝐷 𝐶𝐴𝑃𝐼𝑇𝐴𝐿 𝐶𝑂𝑆𝑇

OPERATING SUPPLIES [1]

0.0075 × 𝐹𝐼𝑋𝐸𝐷 𝐶𝐴𝑃𝐼𝑇𝐴𝐿 𝐶𝑂𝑆𝑇

INDIRECT COST FIXED CAPITAL COST: DEPRECIATION [2] LAND COST

𝐷𝐵 − 𝑆𝐿 𝑚𝑒𝑡ℎ𝑜𝑑 𝐿𝐸𝐴𝑆𝐸 𝑅𝐴𝑇𝐸 𝑃𝐸𝑅 𝑌𝐸𝐴𝑅 𝑇𝑎𝑥 𝑅𝑎𝑡𝑒 × 𝐴𝑠𝑠𝑒𝑠𝑠𝑒𝑑 𝐿𝑎𝑛𝑑 𝑉𝑎𝑙𝑢𝑒

REAL PROPERTY TAX INSURANCE [1]

0.01 × 𝐹𝐼𝑋𝐸𝐷 𝐶𝐴𝑃𝐼𝑇𝐴𝐿 𝐶𝑂𝑆𝑇 GENERAL COST

ADMINISTRATIVE [1]

0.045 × 𝑂𝑃𝐸𝑅𝐴𝑇𝐼𝑁𝐺 𝐶𝑂𝑆𝑇

MARKETING [1]

0.135 × 𝑂𝑃𝐸𝑅𝐴𝑇𝐼𝑁𝐺 𝐶𝑂𝑆𝑇

RESEARCH AND DEVELOPMENT [1]

0.0575 × 𝑂𝑃𝐸𝑅𝐴𝑇𝐼𝑁𝐺 𝐶𝑂𝑆𝑇

[1] Silla, 2003 [2] Brown, 2006

147

Operational time of the plant was estimated to be 350 days per year. The total days per year is 365 days, so there will be a 15 days no work day for employees. These 15 days will be allotted to the maintenance of the plant. Continuous processes were designed to operate 24 hours a day, 7 days a week, throughout the year. Some downtime will be allowed for maintenance and, for some processes, catalyst regeneration. Continuous processes will usually be more economical for large-scale production. The plant attainment or operating rate is the percentage of the available hours in a year that the plant operates, and is usually between 90 and 95% (Towler & Sinnott, 2008).

148

Cost of Major Process Equipment Cost of Atmospheric Vessels: Table 52 Purchase Cost of Atmospheric Vessels NUMBER V-102 V-105 V-106 V-107 V-108 V-110 V-111 V-112

Capacity (m3) 882.6555446 414.832 59.2617 354.32645 159.5609 8.221475 18.13027 161.0571

$ $ $ $ $ $ $ $

Cost 86,451.75 53,300.18 17,891.02 48,326.59 30,086.34 8,758.88 11,020.85 30,246.18

Quantity 6 3 3 1 1 1 1 1

$ $ $ $ $ $ $ $

Final 518,710.47 159,900.55 53,673.05 48,326.59 30,086.34 8,758.88 11,020.85 30,246.18

Table 53 Final Cost of Atmosphere Vessel Cost (2006) Cost (2015) Cost (2015 @ SE Asia)

$ $ $

860,722.91 1,049,221.22 1,175,127.77

$

3,760,408.86

₱ $ Freight Cost ₱ Bureau of Customs: Duties and Taxes Value Added Tax (VAT) ₱ Import Processing Fee ₱ Customs Documentary Stamp ₱ TOTAL COST ₱

169,218,398.55 2,991.65 134,624.25

Cost of Equipment (w/ Installation factor consideration)

149

4,462,850.14 51,643.37 265.00 173,867,781.32

Cost of Pressure Vessels: Table 54 Shell Mass of Pressure Vessels Number

𝐷𝑐 (m)

𝐿𝑐 (𝑚)

V-101 V-103 V-104 V-109 V-113

7.2 5.4 2.9 0.9 7.2

21.6 16.2 8.7 2.7 21.6

𝑡𝑤 (m)

𝜌 (𝑘𝑔⁄𝑚 3 )

SHELL MASS (kg)

7900 7900 7900 7900 7900

181409.9357 52107.1092 9392.592344 241.2366167 73335.93147

0.047 0.024 0.015 0.004 0.019

Table 55 Purchase Cost of Pressure Vessels Number V-101 V-103 V-104 V-109 V-113

$ $ $ $ $

COST 184,012.98 155,148.57 55,241.54 5,782.92 190,549.24

ADJUSTED COST $ 328,081.28 -

Quantity 6 3 3 1 4

FINAL $ 1,968,487.68 $ 465,445.71 $ 165,724.61 $ 5,782.92 $ 762,196.94

Table 56 Final Cost of Pressure Vessels Cost (2006)

$

3,367,637.87

Cost (2015) Cost (2015 @ SE Asia)

$ $

4,105,150.56 4,597,768.63

Cost of Equipment (w/ Location and Installation factor consideration)

$

14,712,859.60

₱ $ Freight Cost ₱ Bureau of Customs: Duties and Taxes Value Added Tax (VAT) ₱ Import Processing Fee ₱ Customs Documentary Stamp ₱ TOTAL COST ₱

150

662,078,682.01 2,991.65 134,624.25 12,401,086.40 156,326.46 265.00 674,770,984.12

Cost of Distillation Columns: Table 57 Purchase Cost of Trays for Distillation Columns NUMBER D-101-T

Dc (m) 12

# of trays 11

Cost per tray $ 3,100.00

Adjusted $ 17,856.00

FINAL COST $ 196,416.00

D-101-B

10

16

$

3,100.00

$

$

198,400.00

D-102-T D-102-B

0.7 1.4

10 12

$ $

158.80 335.20

-

$ $

1,588.00 4,022.40

D-103-T D-103-B

2.9 1.8

21 34

$ $

1,109.20 488.80

-

$ $

23,293.20 16,619.20

12,400.00

Table 58 Shell mass of Distillation Columns Number

𝐷𝑐 (m)

𝐿𝑐 (𝑚)

𝑡𝑤 (m)

𝜌 (𝑘𝑔⁄𝑚 3 )

SHELL MASS (kg)

D-101 Top Bot

12 10

9.9 14.4

0.036 0.03

7900 7900

106144.1113 107216.2741

D-102 Top Bot

0.7 1.4

6.6 9.6

0.003 0.006

7900 7900

343.985546 2001.37045

D-103 Top Bot

2.9 1.8

4.95 9.6

0.009 0.007

7900 7900

3206.436697 3002.055674

151

Table 59 Purchase Cost of Pressure Vessels for Distillation Columns Need Adjustment?

COST

ADJUSTED COST

Quantity

FINAL

D-101 Top Bot

Yes Yes

$ 184,012.98 $ 184,012.98

$ 237,860.51 $ 239,299.19

1 1

$ 237,860.51 $ 239,299.19

D-102 Top Bot

No No

$ 7,249.83 $ 21,605.15

-

1 1

$ 7,249.83 $ 21,605.15

D-103 Top Bot

No No

$ 28,797.22 $ 27,665.91

-

1 1

$ 28,797.22 $ 27,665.91

Number

Table 60 Final Cost of Distillation Columns Cost (2006) Cost (2015) Cost (2015 @ SE Asia)

$ $ $

1,002,816.61 1,222,433.45 1,369,125.46

Cost of Equipment (w/ Location and Installation factor consideration)

$

4,381,201.49

₱ $ Freight Cost ₱ Bureau of Customs: Duties and Taxes Value Added Tax (VAT) ₱ Import Processing Fee ₱ Customs Documentary Stamp ₱ TOTAL COST ₱

152

197,154,066.89 2,991.65 134,624.25 5,339,213.90 60,169.00 265.00 202,688,339.04

Cost of Reactors: Table 61 Purchase Cost of Fluidized Bed Reactors NUMBER

Volume (m3)

Need Adjustment

R-102 R-103 R-104 R-105

101.112 98.17203297 86.6518991 84.21924804

Yes No No No

Cost $ $ $ $

Adjusted Cost

400,830.51 395,867.04 363,917.27 357,011.49

$ $ $ $

403,945.40 395,867.04 363,917.27 357,011.49

Table 62 Purchase Cost of Packed Bed Reactors NUMBER

Volume (m3)

Need Adjustment

Cost

Adjusted Cost

R-101 R-106

113.3 25.02

Yes No

$ 400,830.51 $ 160,663.43

$ 437,443.24 $ 160,663.43

Table 63 Final Cost of Reactors Cost (2006) Cost (2015) Cost (2015 @ SE Asia) Cost of Equipment (w/ Location and Installation factor consideration) Freight Cost

$ $ $ $ ₱ $ ₱

2,118,847.87 2,582,875.55 2,892,820.61 9,257,025.97 416,566,168.43 2,991.65 134,624.25

Bureau of Customs: Duties and Taxes Value Added Tax (VAT) ₱ 11,263,464.96 Import Processing Fee ₱ 127,130.87 Customs Documentary Stamp ₱ 265.00 TOTAL COST ₱ 428,091,653.51

153

Cost of Heat Exchangers: Table 64 Cost of Heat Exchangers generated from Aspen Hysys V8.0 NUMBER HE-101 HE-103 HE-104 HE-105 HE-107 HE-108 HE-109 HE-110 HE-111 HE-112

Cost $ $ $ $ $ $ $ $ $ $

56,088.00 214,234.00 260,661.00 16,750.00 10,626.00 14,577.00 401,970.00 38,004.00 58,110.00 15,415.00

Table 65 Final Cost of Heat Exchangers Equipment Cost

$ 1,216,807.20 $ 1,362,824.06 Cost (2015 @ SE Asia) ₱ 61,327,082.88 $ 3,257.58 Freight Cost ₱ 146,591.10 Bureau of Customs: Duties and Taxes Value Added Tax (VAT) ₱ 5,784,498.72 Import Processing Fee ₱ 65,186.10 Customs Documentary Stamp ₱ 265.00 TOTAL COST ₱ 67,323,623.80

154

Cost of Pipes: Table 66 Purchase Cost of Pipes Pipes PIPE-100 PIPE-101 PIPE-102 PIPE-103 PIPE-104 PIPE-105 PIPE-106 PIPE-107 PIPE-108 PIPE-109 PIPE-110 PIPE-111 PIPE-112 PIPE-113 PIPE-114 PIPE-115 PIPE-116 PIPE-117 PIPE-118 PIPE-119 PIPE-106 PIPE-107 PIPE-108 PIPE-109 PIPE-110 PIPE-111 PIPE-113 PIPE-112 PIPE-114 PIPE-115 PIPE-116 PIPE-117 PIPE-118 PIPE-119 PIPE-120 PIPE-121 PIPE-121-10 PIPE-121-2

Di (mm) 26.64 26.64 26.64 26.64 26.64 26.64 26.64 26.64 26.64 26.64 26.64 26.64 26.64 26.64 26.64 26.64 26.64 26.64 26.64 52.5 102.3 102.3 102.3 254.5 77.93 77.93 40.89 77.93 52.5 52.5 52.5 52.5 40.89 40.89 40.89 26.64 26.64 26.64

L (m) 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 12 12 12 12 12 12 8 8 5 2 2 11 10 30 3 1 5 5 5 5 5 3 50 5 5 5

Cost per length (m) $ 9,985.69 $ 9,985.69 $ 9,985.69 $ 9,985.69 $ 9,985.69 $ 9,985.69 $ 9,985.69 $ 9,985.69 $ 9,985.69 $ 9,985.69 $ 9,985.69 $ 9,985.69 $ 9,985.69 $ 9,985.69 $ 9,985.69 $ 9,985.69 $ 9,985.69 $ 9,985.69 $ 9,985.69 $ 16,496.83 $ 27,026.55 $ 27,026.55 $ 27,026.55 $ 53,050.76 $ 22,097.55 $ 22,097.55 $ 13,711.32 $ 22,097.55 $ 16,496.83 $ 16,496.83 $ 16,496.83 $ 16,496.83 $ 13,711.32 $ 13,711.32 $ 13,711.32 $ 9,985.69 $ 9,985.69 $ 9,985.69

155

$ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $

Final cost 24,964.22 24,964.22 24,964.22 24,964.22 24,964.22 24,964.22 24,964.22 24,964.22 24,964.22 24,964.22 24,964.22 24,964.22 119,828.26 119,828.26 119,828.26 119,828.26 119,828.26 119,828.26 79,885.50 131,974.66 135,132.76 54,053.10 54,053.10 583,558.39 220,975.50 662,926.51 41,133.97 22,097.55 82,484.16 82,484.16 82,484.16 82,484.16 68,556.61 41,133.97 685,566.11 49,928.44 49,928.44 49,928.44

PIPE-121-3 PIPE-121-4 PIPE-121-5 PIPE-121-6 PIPE-121-7 PIPE-121-8 PIPE-121-9 PIPE-122 PIPE-123 PIPE-123-10 PIPE-123-2 PIPE-123-3 PIPE-123-4 PIPE-123-5 PIPE-123-6 PIPE-123-7 PIPE-123-8 PIPE-123-9

26.64 26.64 26.64 26.64 26.64 26.64 26.64 40.89 26.64 26.64 26.64 26.64 26.64 26.64 26.64 26.64 26.64 26.64

5 5 5 5 5 5 5 50 5 5 5 5 5 5 5 5 5 5

$ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $

9,985.69 9,985.69 9,985.69 9,985.69 9,985.69 9,985.69 9,985.69 13,711.32 9,985.69 9,985.69 9,985.69 9,985.69 9,985.69 9,985.69 9,985.69 9,985.69 9,985.69 9,985.69

$ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $

49,928.44 49,928.44 49,928.44 49,928.44 49,928.44 49,928.44 49,928.44 685,566.11 49,928.44 49,928.44 49,928.44 49,928.44 49,928.44 49,928.44 49,928.44 49,928.44 49,928.44 49,928.44

Table 67 Final Cost of Pipe Cost (2006) Cost (2015) Cost (2015 @ SE Asia)

$ $ $ $ Cost of Equipment (w/ Location and Installation factor consideration) ₱ $ Freight Cost ₱ Bureau of Customs: Duties and Taxes Value Added Tax (VAT) ₱ Import Processing Fee ₱ Customs Documentary Stamp ₱ TOTAL COST ₱

156

4,442,527.26 5,415,440.73 6,065,293.62 19,408,939.59 873,402,281.57 2,911.65 131,024.25 27,552,554.09 266,551.64 265.00 901,352,676.54

Cost of Pumps: Table 68 Purchase Cost of Pumps Number P-101 P-102 P-103 P-104 P-105 P-106 P-107 P-108 P-109 P-110

Flow rate (m3/h) 6.619 14.33 1245 22.98 22.78 21.99 21.29 20.73 361.3 5633

Flow rate (L/s) 1.838611111 3.980555556 345.8333333 6.383333333 6.327777778 6.108333333 5.913888889 5.758333333 100.3611111 1564.722222

$ $ $ $ $ $ $ $ $ $

Cost 3,399.68 3,551.87 56,741.85 3,743.91 3,739.28 3,721.06 3,705.03 3,692.28 15,409.32 330,313.69

Table 69 Final Cost of Pumps Cost (2006) Cost (2015) Cost (2015 @ SE Asia)

$ $ $

428,017.99 521,753.92 584,364.40

Cost of Equipment (w/ Location and Installation factor consideration)

$

1,869,966.07

Freight Cost

₱ $ ₱

84,148,472.96 3,257.58 146,591.10

Bureau of Customs: Duties and Taxes Value Added Tax (VAT) ₱ 1,583,017.47 Import Processing Fee ₱ 25,681.08 Customs Documentary Stamp ₱ 265.00 TOTAL COST ₱ 85,904,027.61

157

Cost of Compressor: Table 70 Purchase Cost of Compressor NUMBER K-100

Driver Power (kW) 1.80E+02

Need Adjustment No

$

Cost 78,319.38

Table 71 Final Cost of Compressor Cost (2006) Cost (2015) Cost (2015 @ SE Asia)

$ $ $

78,319.38 95,471.32 106,927.88

Cost of Equipment (w/ Location and Installation factor consideration)

$

342,169.23

₱ $ ₱

15,397,615.19 3,257.58 146,591.10

Freight Cost Bureau of Customs: Duties and Taxes Value Added Tax (VAT) ₱ Import Processing Fee Customs Documentary Stamp TOTAL COST

158

433,098.41 ₱ 4,699.16 ₱ 265.00 ₱ 15,982,268.86

Cost of OSBL Equipment Cost of Boiler: Table 72 Purchase Cost of Boiler kg/h steam 360581.279

Cost 1,504,690.06

$

Table 73 Final Cost of Boiler Cost (2006) Cost (2015) Cost (2015 @ SE Asia)

$ $ $

1,504,690.06 1,834,217.19 2,054,323.25

Cost of Equipment (w/ Location and Installation factor consideration)

$

6,573,834.39

₱ $ Freight Cost ₱ Bureau of Customs: Duties and Taxes Value Added Tax (VAT) ₱ Import Processing Fee ₱ Customs Documentary Stamp ₱ TOTAL COST ₱

159

295,822,547.73 2,882.82 129,726.90 13,266,225.67 90,281.40 265.00 309,309,046.70

Cost of Furnace: Table 74 Purchase Cost of Furnace duty, MW 174.1

$

Cost 3,411,507.62

Table 75 Final Cost of Furnace Cost (2006) Cost (2015) Cost (2015 @ SE Asia)

$ $ $

3,411,507.62 4,158,627.79 4,657,663.12

Cost of Equipment (w/ Location and Installation factor consideration)

$

14,904,521.99

₱ $ Freight Cost ₱ Bureau of Customs: Duties and Taxes Value Added Tax (VAT) ₱ Import Processing Fee ₱ Customs Documentary Stamp ₱ TOTAL COST ₱

160

670,703,489.66 2,882.82 129,726.90 23,354,129.56 204,690.46 265.00 694,392,301.57

Cost of Scrubber: Table 76 Purchase Cost of Scrubber Gas Effluent

Total Purchase Cost of Equipment

m3/h

8399

ft3/h

296607.9

acfm

4943.465 $

15,150.29

$ $ $ $ ₱ $ ₱

15,150.29 18,468.20 20,684.38 66,190.02 2,978,551.01 2,882.82 129,726.90

Bureau of Customs: Duties and Taxes Value Added Tax (VAT) ₱ Import Processing Fee ₱ Customs Documentary Stamp ₱ TOTAL COST ₱

95,464.89 909.02 265.00 3,204,916.81

Table 77 Final Cost of Scrubber Cost (2006) Cost (2015) Cost (2015 @ SE Asia) Cost of Equipment (w/ Location and Installation factor consideration) Freight Cost

161

Cost of Cooling Tower Table 78 Purchase Cost of Cooling Tower Flow rate (m3/h)

Flow rate (L/s) 5653.898758 1570.527433

Cost $ 331,770.12

Table 79 Final Cost of Cooling Tower Cost (2006) Cost (2015) Cost (2015 @ SE Asia) Cost of Equipment (w/ Location and Installation factor consideration) Freight Cost

$ 331,770.12 $ 404,427.78 $ 452,959.11 $ 1,449,469.15 ₱ 65,226,111.81 $ 2,911.65 ₱ 131,024.25

Bureau of Customs: Duties and Taxes Value Added Tax (VAT) ₱ 1,987,996.75 Import Processing Fee ₱ 19,906.21 Customs Documentary Stamp ₱ 265.00 TOTAL COST ₱ 67,365,304.01

162

Cost of Biological Waste Water Treatment: Table 80 Existing Activated Sludge Waste Water Treatment Plant in the Philippines Plant Location CAPEX Capacity

Existing Wastewater Treatment Plant Facility Toyota Motor Philippines Toyota Special Economic Zone, Santa Rosa City, Laguna, 4026 ₱

140,000,000.00 840 cubic meters per day

Table 81 Capital Cost of WWTP of Phace Philippines Corporation Location Capacity CAPEX

₱

Hermosa, Bataan 71.95 cubic meters per day 32,046,377.41

163

Indirect Costs of the Plant Depreciation cost. Double Declining Balance Method with switch over to Straight Line method was used in obtaining the depreciation of the investments per year. The cost basis which amounts to the sum of ISBL and OSBL Capex is 3,920,857,301.32 pesos. The useful life of the plant is fifteen years. The constant percentage of depreciation for double declining balance method can be obtain using equation 17, and for straight line using equation 18. To obtain the book value at any year, equation 19 can be used. 𝑹𝟏 =

𝟐 , 𝒇𝒐𝒓 𝟐𝟎𝟎% 𝑫𝒐𝒖𝒃𝒍𝒆 𝑫𝒆𝒄𝒍𝒊𝒏𝒊𝒏𝒈 𝑩𝒂𝒍𝒂𝒏𝒄𝒆 𝑵

(17)

𝑅1 = 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡 𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑜𝑓 𝐷𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛 𝑓𝑜𝑟 𝐷𝑜𝑢𝑏𝑙𝑒 𝐷𝑒𝑐𝑙𝑖𝑛𝑖𝑛𝑔 𝐵𝑎𝑙𝑎𝑛𝑐𝑒 𝑹𝟐 =

𝟏 𝑵

(18)

𝑅2 = 𝑆𝑡𝑟𝑎𝑖𝑔ℎ𝑡 𝐿𝑖𝑛𝑒 𝐷𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛 𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑩𝑽𝒌 = (𝟏 − 𝑹)𝒌 𝑩

(19)

Note that depreciation is an implicit and non-cash cost. It is an expired portion of the cost of the asset due to usage or wear and tear. The reason it is non-cash expense for the period is that because it is but an amortized cost of something already paid for in the past. The value of 𝑅1 is 13.33% and 𝑅2 is 6.67%. Table 82 shows the depreciation schedule of the plant.

164

Table 82 Depreciation schedule of the plant (values in Philippine Peso) k 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

B 3920857301 3659466815 3398076328 3136685841 2875295354 2613904868 2352514381 2091123894 1829733407 1568342921 1306952434 1045561947 784171460 522780974 261390487

R 13% 13% 13% 13% 13% 13% 13% 13% 13% 13% 13% 13% 13% 13% 13%

𝑑𝑘 𝑢𝑠𝑒𝑑 522780974 487928909 453076844 418224779 383372714 348520649 313668584 278816519 243964454 209112389 174260325 139408260 104556195 69704130 34852065

𝑑𝑘 𝑆𝐿 261390487 261390487 261390487 261390487 261390487 261390487 261390487 261390487 261390487 261390487 261390487 261390487 261390487 261390487 261390487

𝑑𝑘 𝐷𝐵 522780974 487928909 453076844 418224779 383372714 348520649 348520649 348520649 348520649 348520649 348520649 348520649 348520649 348520649 348520649

𝑑𝑘 𝐴𝑐𝑐𝑢 522780974 1010709882 941005752 871301623 801597493 731893363 697041298 697041298 697041298 697041298 697041298 697041298 697041298 697041298 697041298

𝐵𝑉𝑘 3659466815 3398076328 3136685841 2875295354 2613904868 2352514381 2091123894 1829733407 1568342921 1306952434 1045561947 784171460 522780974 261390487 0

Land cost. The manufacturing plant of Phace Philippines Corporation will be constructed in Hermosa Ecozone Industrial Park (HEIP). Shown in Table 83 is the summary of the description of the plant location. The Ecozone is 162-hectare industrial estate component of a 478-hectare mixed-use property development in the province of Bataan by the Hermosa Ecozone Development Corporation, of which Science Park of the Philippines, Inc. (SPPI) is a shareholder and General Manager. The project is registered Special Economic Zone (Ecozone) under the Philippine Economic Zone Authority (PEZA). These are areas designated by the government for development into balanced agricultural, industrial, commercial, and tourist/recreational regions.

165

Table 83 Land facts about Hermosa Ecozone Industrial Park (HEIP) Total Area 162 hectares Saleable Area 124 hectares Common Area 38 hectares Sold Area 18.9 hectares Remaining Area for Sale 105.1 hectares Source: Science Park of the Philippines, 2015

Each Ecozone is to be developed as an independent community with minimum government interference. It shall administer its own economic, financial, industrial and tourism development without help from the national government. It shall also provide adequate facilities to establish linkages with surrounding communities and other entities within the country. Lease rates for industrial land were averaged to $0.27 per sq. m per month. Based on the Plot Plan of the company, the total land area is 33129 SQM or 3.3129 hectares. See appendix F for the plot plan of the plant. Table 84 shows the cost of land lease per year.

166

Table 84 Cost of Land lease annually Rate Rate Cost of lease (monthly) (monthly) per month (USD/SQM) (PhP/SQM)

Cost of lease per year

YEAR

SQM

2015(construction) 2016(construction) 2017 2018 2019

33129 33129 33129 33129 33129

$ $ $ $ $

2020

33129

$ 0.27

₱ 12.15

₱ 402,517.35 ₱ 4,830,208.20

2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

33129 33129 33129 33129 33129 33129 33129 33129 33129 33129 33129

$ 0.27 $ 0.27 $ 0.27 $ 0.27 $ 0.27 $ 0.27 $ 0.27 $ 0.27 $ 0.27 $ 0.27 $ 0.27

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

0.27 0.27 0.27 0.27 0.27

₱ ₱ ₱ ₱ ₱

12.15 12.15 12.15 12.15 12.15 12.15 12.15 12.15 12.15 12.15 12.15 12.15 12.15 12.15 12.15 12.15

₱ ₱ ₱ ₱ ₱

402,517.35 402,517.35 402,517.35 402,517.35 402,517.35 402,517.35 402,517.35 402,517.35 402,517.35 402,517.35 402,517.35 402,517.35 402,517.35 402,517.35 402,517.35 402,517.35

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20

Fixed capital cost. Fixed capital cost is a production cost that does not vary with the production volume. In order to obtain this cost, refer to Table 51. Table 85 shows the fixed capital cost of the plant per year.

167

Table 85 Fixed Capital Cost of the Plant YEAR 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

Depreciation Cost 522,780,973.51 487,928,908.61 453,076,843.71 418,224,778.81 383,372,713.91 348,520,649.01 348,520,649.01 348,520,649.01 348,520,649.01 348,520,649.01 348,520,649.01 348,520,649.01 348,520,649.01 348,520,649.01 348,520,649.01

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

Land Rental Cost 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20 4,830,208.20

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

Fixed Capital Cost 527,611,181.71 492,759,116.81 457,907,051.91 423,054,987.01 388,202,922.11 353,350,857.21 353,350,857.21 353,350,857.21 353,350,857.21 353,350,857.21 353,350,857.21 353,350,857.21 353,350,857.21 353,350,857.21 353,350,857.21

Insurance cost. Insurance is the equitable transfer of the risk of a loss, from one entity to another in exchange for payment. Refer to Table 51 for the equation in obtaining insurance cost. Table 86 shows the annual insurance cost of the company.

168

Table 86 Annual insurance cost of the company Year 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

Cost 5,487,173.82 5,124,582.37 4,761,990.92 4,399,399.47 4,036,808.02 3,674,216.57 3,674,216.57 3,674,216.57 3,674,216.57 3,674,216.57 3,674,216.57 3,674,216.57 3,674,216.57 3,674,216.57 3,674,216.57

Direct Costs of the Plant Cost of the raw materials. The raw materials of the process are propylene and benzene and they will be sourced mainly from Petron and JG Summit. Table 87 shows the flow rate for each of the raw materials as required by the process and their indicative prices.

Table 87 Cost calculation basis for raw materials FLOWRATE Operational Time kg/h # of days # of Hours Propylene 3354 350 8400 Benzene 6248.800049 350 8400 Flowrates acquired from the Aspen Hysys Simulation Source of Price: ICIS Indicative Prices

169

MTpY 28,173.60 52,489.92

PRICE USD/MT 1014.13 1039.81

The inflation of the prices of the raw materials is approximated to 5%, as given from the trend of prices of propylene and benzene from the report of Pandia entitled “Global Acetone-Phenol Markets” in the year 2009. US Dollar to Philippines Peso conversion is averaged to forty five. Given in Table 88 and Table 89 are the cost of propylene and benzene annually.

Table 88 Annual cost of propylene Year 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

Turndown Capacity 50% 65% 75% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%

MTpY 14,086.80 14,086.80 21,130.20 28,173.60 28,173.60 28,173.60 28,173.60 28,173.60 28,173.60 28,173.60 28,173.60 28,173.60 28,173.60 28,173.60 28,173.60

Price (per MT) $ $ $ $ $ $ $ $ $ $ $ $ $ $ $

170

1,014.13 1,064.83 1,118.07 1,173.98 1,232.68 1,294.31 1,359.02 1,426.98 1,498.32 1,573.24 1,651.90 1,734.50 1,821.22 1,912.28 2,007.90

Cost ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

642,860,049.03 675,003,051.48 1,063,129,806.09 1,488,381,728.52 1,562,800,814.95 1,640,940,855.69 1,722,987,898.48 1,809,137,293.40 1,899,594,158.07 1,994,573,865.97 2,094,302,559.27 2,199,017,687.24 2,308,968,571.60 2,424,417,000.18 2,545,637,850.19

Table 89 Annual cost of benzene Year 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

Turndown Capacity 50% 65% 75% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%

MTPY 26,244.96 26,244.96 39,367.44 52,489.92 52,489.92 52,489.92 52,489.92 52,489.92 52,489.92 52,489.92 52,489.92 52,489.92 52,489.92 52,489.92 52,489.92

Price (per MT) $ $ $ $ $ $ $ $ $ $ $ $ $ $ $

1,039.81 1,091.80 1,146.39 1,203.71 1,263.90 1,327.09 1,393.44 1,463.12 1,536.27 1,613.09 1,693.74 1,778.43 1,867.35 1,960.72 2,058.75

Cost - Benzene ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

1,228,039,655.60 1,289,441,638.39 2,030,870,580.46 2,843,218,812.64 2,985,379,753.27 3,134,648,740.93 3,291,381,177.98 3,455,950,236.88 3,628,747,748.72 3,810,185,136.16 4,000,694,392.97 4,200,729,112.62 4,410,765,568.25 4,631,303,846.66 4,862,869,038.99

Cost of the catalysts. Life of catalysts for R-102 to R-105 (oxidation towers) is usually 3 years for copper oxide (CuO) synthetic catalyst (Cheng & Kung, 1994). For the packed bed plug flow reactor R-101 (Alkylation reactor), the life of catalyst for zeolite is usually 2 years (Anpo, Onaka, & Yamashita, 2003). For the cleavage reactor (R-106), the life of catalyst for sulfonic acid resins is usually 8 months (Rase, 2000). Shown in Table 90 is the amount of each catalyst used in each reactors and their corresponding prices. Shown in Table 91 is the final cost of catalyst for each of the reactor. Finally, shown in Table 92 is the total cost of the catalyst used annually.

171

Table 90 Amount and Pricing of Catalyst Used for each Reactor REACTOR Mass of catalyst (kg) Price (USD/Kg) Life of catalyst R-102 198.55 3 years 376.00 R-103 198.55 3 years 376.00 R-104 198.55 3 years 376.00 R-105 198.55 3 years 376.00 R-101 7140 2 years 8.37 R-106 2.65854 8 months 2930.00

Table 91 Final Cost of Catalyst for each Reactor REACTOR

Years of Operation

R-102 R-103 R-104 R-105 R-101 R-106

15 15 15 15 15 15

Cost of Catalyst $ $ $ $

77,213.89 77,213.89 77,213.89 77,213.89

$ 4,641,000.00 $ 5,051.23

Table 92 Total Cost of Catalysts per Year Year 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

Turndown Capacity 50% 65% 75% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%

Cost of Catalyst $ $ $ $ $ $ $ $ $ $ $ $ $ $ $

4,725,471.23 4,883,301.96 4,883,301.96 4,883,301.96 4,883,301.96 4,883,301.96 4,883,301.96 4,883,301.96 4,883,301.96 4,883,301.96 4,883,301.96 4,883,301.96 4,883,301.96 4,883,301.96 4,883,301.96

Freight $ $ $ $ $ $ $ $ $ $ $ $ $ $ $

2,940.47 2,940.47 2,940.47 2,940.47 2,940.47 2,940.47 2,940.47 2,940.47 2,940.47 2,940.47 2,940.47 2,940.47 2,940.47 2,940.47 2,940.47

172

VAT ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

50,962,913.44 50,962,913.44 50,962,913.44 50,962,913.44 50,962,913.44 50,962,913.44 50,962,913.44 50,962,913.44 50,962,913.44 50,962,913.44 50,962,913.44 50,962,913.44 50,962,913.44 50,962,913.44 50,962,913.44

Cost - Catalyst ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

157,352,176.60 193,885,504.66 215,873,595.62 270,843,823.01 270,843,823.01 270,843,823.01 270,843,823.01 270,843,823.01 270,843,823.01 270,843,823.01 270,843,823.01 270,843,823.01 270,843,823.01 270,843,823.01 270,843,823.01

Utility costs of the plant. The main process of the plant requires a cooling water system and a steam generation unit. Shown in Table 93 is the fuel requirement of the plant and in Table 94 is the water requirement of the plant.

Table 93 Fuel requirement of the plant and its price Fuel: Industrial LPG (Propane) Volume Flow (L/year) 781,536.00 Price (per Liter) 5.5 PHP

Table 94 Water requirement of the plant and its price WATER Volume Flow (m3/h) 6100.64 Volume of water (1 day) 146415.36 Volume of water (1 year) 585,662.28 Volume with Make-up (1 year) 592,983.06

The fuel requirement of the plant amounts to an average of 782 𝑚3 annually. The cost of the fuel consumption per year is shown in Table 95.

173

Table 95 Cost of Fuel Consumed Per Year Year

Turndown Capacity

2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

50% 65% 75% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%

Price (per Liter) ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

5.50 5.72 5.95 6.19 6.43 6.69 6.96 7.24 7.53 7.83 8.14 8.47 8.81 9.16 9.52

Cost - Fuel ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

2,149,224.00 2,235,192.96 3,486,901.02 4,835,169.41 5,028,576.19 5,229,719.24 5,438,908.00 5,656,464.32 5,882,722.90 6,118,031.81 6,362,753.09 6,617,263.21 6,881,953.74 7,157,231.89 7,443,521.16

The water requirement of the plant for both of its cooling water system and steam generation unit amounts to an average of 593,000 𝑚3 annually. The maximum required make-up water flow rate for cooling tower can be approximated with 1.25% of the total flow. This percentage accounts the evaporation and blowdown losses (Stanford, 2012). There will be a very high maintenance of cooling tower water because the cleaning will be frequent. For industries, the average cost of cooling water chemicals is $0.043 𝑝𝑒𝑟 𝑚3 of total water requirement (LLC-Consulting-Group, 2003). The cost of the consumable water per year is shown in Table 96.

174

Table 96 Cost of Consumed Water per Year Turndown Price (per 100 Year Capacity m3) 2017

50%

2018

65%

2019

75%

2020

100%

2021

100%

2022

100%

2023

100%

2024

100%

2025

100%

2026

100%

2027

100%

2028

100%

2029

100%

2030

100%

2031

100%

₱ 2,962.00 ₱ 2,962.00 ₱ 2,962.00 ₱ 2,962.00 ₱ 2,962.00 ₱ 2,962.00 ₱ 2,962.00 ₱ 2,962.00 ₱ 2,962.00 ₱ 2,962.00 ₱ 2,962.00 ₱ 2,962.00 ₱ 2,962.00 ₱ 2,962.00 ₱ 2,962.00

Cubic meter used

Cost - PW

585,662.28

₱

8,673,658.38

585,662.28

₱

11,275,755.89

585,662.28

₱

13,010,487.57

585,662.28

₱

17,347,316.76

585,662.28

₱

17,347,316.76

585,662.28

₱

17,347,316.76

585,662.28

₱

17,347,316.76

585,662.28

₱

17,347,316.76

585,662.28

₱

17,347,316.76

585,662.28

₱

17,347,316.76

585,662.28

₱

17,347,316.76

585,662.28

₱

17,347,316.76

585,662.28

₱

17,347,316.76

585,662.28

₱

17,347,316.76

585,662.28

₱

17,347,316.76

Cost of electricity. In order to obtain an approximation of the cost of electricity per year, it is vital to obtain the amount of energy the process and the building utilize annually. Electricity

consumption

for

commercial

buildings

can

be

assumed

to

be

17.3 𝑘𝑊ℎ 𝑝𝑒𝑟 𝑓𝑡 2 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟 (MGE). Shown in Table 97 is the electricity requirement of each of the buildings of the plant and in Table 98 the electricity requirement of the process annually.

175

Table 97 Electricity Requirement of the Buildings ELECTRICITY COST OF THE BUILDINGS LENGTH WIDTH AREA Area Buildings (m) (m) (m2) (ft2) 15,096.3 ADMIN BLDG 27.5 51 1402.5 7 43,400.0 MANUFACTURING 72 56 4032 4 QUALITY CONTROL 17.5 50.9 890.75 9,587.94 LAB CANTEEN 40 18 720 7,750.01 PRODUCTION 25.9 18 466.2 5,018.13 OFFICE RESEARCH&DEV 17.5 27 472.5 5,085.94 SECURITY OFFICE 27.83 12.2 339.526 3,654.62 MAINTENANCE 17.5 18 315 3,390.63 CONTROL ROOM 25 8 200 2,152.78 WAREHOUSE 20.04 22 440.88 4,745.59 TOTAL (kWh per Year)

kWh per YEAR 261,167.20 750,820.78 165,871.43 134,075.14 86,813.65 87,986.81 63,224.99 58,657.87 37,243.09 82,098.68 1,727,959.64

Table 98 Electricity requirement of the Process EQUIPMENT

POWER KW

P-101 P-102 P-103 P-104 P-105 P-106 P-107 P-108 K-100

5.735 18.26 164.2 0.3521 0.01056 0.01792 0.02498 2.538 180.0417

Electricity Requirement kWh/Day kWh/Year Process

P-109 P-110

2093 82.73 TOTAL

137.6 438.2 3940.8 8.4504 0.25344 0.43008 0.59952 60.912 4321.001 Utilities 50232 1985.52

176

48,160.00 153,370.00 1,379,280.00 2,957.64 88.70 150.53 209.83 21,319.20 1,512,350.28 17,581,200.00 694,932.00 21,394,018.18

In order to get the annual cost of electricity consumption, the electricity requirement of both the process and the buildings were combined. A total of 23,121,977.82 𝑘𝑊ℎ of electricity per year will be required by the whole plant. The cost of electricity for the industry in Hermosa, Bataan is 6.4708 𝑃ℎ𝑃 (Provincial Government of Bataan, n.d.). Shown in Table 99 is the annual cost of electricity of the company.

Table 99 Cost of Electricity Turndown Year Capacity 2017 50% 2018 50% 2019 75% 2020 100% 2021 100% 2022 100% 2023 100% 2024 100% 2025 100% 2026 100% 2027 100% 2028 100% 2029 100% 2030 100% 2031 100%

Consumption per Year Process ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

Buildings

138,436,412.87 138,436,412.87 138,436,412.87 138,436,412.87 138,436,412.87 138,436,412.87 138,436,412.87 138,436,412.87 138,436,412.87 138,436,412.87 138,436,412.87 138,436,412.87 138,436,412.87 138,436,412.87 138,436,412.87

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

11,181,281.23 11,181,281.23 11,181,281.23 11,181,281.23 11,181,281.23 11,181,281.23 11,181,281.23 11,181,281.23 11,181,281.23 11,181,281.23 11,181,281.23 11,181,281.23 11,181,281.23 11,181,281.23 11,181,281.23

Cost ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

80,399,487.66 101,164,949.59 115,008,590.88 149,617,694.10 149,617,694.10 149,617,694.10 149,617,694.10 149,617,694.10 149,617,694.10 149,617,694.10 149,617,694.10 149,617,694.10 149,617,694.10 149,617,694.10 149,617,694.10

Cost of communication. Communication within a company is a very important factor for success. In the business world, good communication is important for the daily operation of the plant. Table 100 summarizes the price of the communication the company should have. Table 101 shows the annual cost of communication within the company, divided to internet and landline services. 177

Table 100 Price of communication services ` Voice / Landline:

COST PhP 936.00 (21.53 USD) PhP 617.00 (14.19USD)

Monthly Rental (Commercial) Monthly Rental (Residential) Data / Internet: Monthly Rental – 1MB up to 4MB (Commercial) Monthly Rental – up to 1MB (Residential)

PhP 4, 000.00 (92.00 USD) PhP 999.00 (23.00 USD)

Table 101 Annual cost of communication services of the company Year 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

Internet 11,232.00 11,232.00 11,232.00 11,232.00 11,232.00 11,232.00 11,232.00 11,232.00 11,232.00 11,232.00 11,232.00 11,232.00 11,232.00 11,232.00 11,232.00

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

Landline 48,000.00 48,000.00 48,000.00 48,000.00 48,000.00 48,000.00 48,000.00 48,000.00 48,000.00 48,000.00 48,000.00 48,000.00 48,000.00 48,000.00 48,000.00

Operating cost of Waste Water Treatment Plant. For a biological sewage treatment plant, the annual operating expenses will be based on the amount of organics it will handle. Refer to Table 51 for the equation in obtaining the annual expenses of WWTP. Shown in Table 102 is the cost of biological WWTP operation annually. 178

Table 102 Cost of Biological WWTP Operation per Year Year 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

Cost ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

330,775.68 330,775.68 330,775.68 330,775.68 330,775.68 330,775.68 330,775.68 330,775.68 330,775.68 330,775.68 330,775.68 330,775.68 330,775.68 330,775.68 330,775.68

Operating labor. To determine labor costs, one must estimate the number of operators (crew size) and the wage rate. The preferred way to determine labor needs is to get a manufacturing estimate. However, because there is not enough time or because manufacturing has not staffed a project, which is often not practical. Table 103 shows the summary of labor cost annually. The management decided a 4% increase in labor per year. See Appendix E for the breakdown of wage and monetary benefits for each employees of the company.

179

Table 103 Summary of Labor Cost per Year `Year 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

Net Pay (w/ Company benefits) Contribution 18,782,880.00 ₱ 2,262,292.48 19,534,195.20 ₱ 2,352,784.17 20,315,563.01 ₱ 2,446,895.54 21,128,185.53 ₱ 2,544,771.36 21,973,312.95 ₱ 2,646,562.22 22,852,245.47 ₱ 2,752,424.71 23,766,335.29 ₱ 2,862,521.69 24,716,988.70 ₱ 2,977,022.56 25,705,668.25 ₱ 3,096,103.46 26,733,894.98 ₱ 3,219,947.60 27,803,250.77 ₱ 3,348,745.51 28,915,380.81 ₱ 3,482,695.33 30,071,996.04 ₱ 3,622,003.14 31,274,875.88 ₱ 3,766,883.27 32,525,870.91 ₱ 3,917,558.60 TOTAL

Yearly Bonus ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

4,564,680.00 4,747,267.20 4,937,157.89 5,134,644.20 5,340,029.97 5,553,631.17 5,775,776.42 6,006,807.47 6,247,079.77 6,496,962.96 6,756,841.48 7,027,115.14 7,308,199.75 7,600,527.74 7,904,548.85

TOTAL ₱ 25,609,852.48 ₱ 26,634,246.57 ₱ 27,699,616.44 ₱ 28,807,601.09 ₱ 29,959,905.14 ₱ 31,158,301.34 ₱ 32,404,633.40 ₱ 33,700,818.73 ₱ 35,048,851.48 ₱ 36,450,805.54 ₱ 37,908,837.76 ₱ 39,425,191.27 ₱ 41,002,198.93 ₱ 42,642,286.88 ₱ 44,347,978.36 ₱ 487,191,272.95

Cost of transportation of goods. This cost includes the transportation of the products phenol and acetone to its respective users through truck loads. The total number of trucks of the company is twenty two with a capacity of 14 𝑚3 each. Table 104 shows the customers of the company and their location, as well as distance to be travelled by the trucks and the price of fuel per liter. Table 105 shows the annual cost on transportation.

180

Table 104 Price of Fuel and Consumption per Truck Customer number of Price of Fuel Distance Location companies per Liter (km) Manila 35 ₱ 34.60 197.6 Laguna 11 ₱ 34.60 285.2 Cavite 3 ₱ 34.60 247 Rizal 9 ₱ 34.60 279.8 Batangas 1 ₱ 34.60 415

L/distance(km)

L/week

0.3 0.3 0.3 0.3 0.3

4979.52 2395.68 518.7 2350.32 871.5

Table 105 Annual cost on transportation Customer Location Manila Laguna Cavite Rizal Batangas

Cost (weekly) ₱ ₱ ₱ ₱ ₱ TOTAL

172,291.39 82,890.53 17,947.02 81,321.07 30,153.90

Cost (Yearly) ₱ 8,269,986.82 ₱ 3,978,745.34 ₱ 861,456.96 ₱ 3,903,411.46 ₱ 1,447,387.20 ₱ 18,460,987.78

Other estimated costs. Table 106 and 107 shows the other costs related to the direct cost of the plant. Refer to Table 51 for the equations used in estimating the values under these costs.

181

Table 106 Operating, Quality Contol, and Laboratory Cost per Year Operating Supervision

Quality Control

Laboratory Costs

Cost

Cost

Cost

YEAR ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

5,121,970.50 5,326,849.31 5,539,923.29 5,761,520.22 5,991,981.03 6,231,660.27 6,480,926.68 6,740,163.75 7,009,770.30 7,290,161.11 7,581,767.55 7,885,038.25 8,200,439.79 8,528,457.38 8,869,595.67

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

5,121,970.50 5,326,849.31 5,539,923.29 5,761,520.22 5,991,981.03 6,231,660.27 6,480,926.68 6,740,163.75 7,009,770.30 7,290,161.11 7,581,767.55 7,885,038.25 8,200,439.79 8,528,457.38 8,869,595.67

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

2,560,985.25 2,663,424.66 2,769,961.64 2,880,760.11 2,995,990.51 3,115,830.13 3,240,463.34 3,370,081.87 3,504,885.15 3,645,080.55 3,790,883.78 3,942,519.13 4,100,219.89 4,264,228.69 4,434,797.84

Table 107 Maintenance Labor, Maintenance Material, and Operating Supplies Cost per year Maintenance Labor

Maintenance Material

Operating Supplies

Cost

Cost

Cost

YEAR 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

14,245,501.91 13,304,496.15 12,363,490.40 11,422,484.65 10,481,478.90 9,540,473.14 9,540,473.14 9,540,473.14 9,540,473.14 9,540,473.14 9,540,473.14 9,540,473.14 9,540,473.14 9,540,473.14 9,540,473.14

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

9,497,001.27 8,869,664.10 8,242,326.93 7,614,989.77 6,987,652.60 6,360,315.43 6,360,315.43 6,360,315.43 6,360,315.43 6,360,315.43 6,360,315.43 6,360,315.43 6,360,315.43 6,360,315.43 6,360,315.43

182

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

3,957,083.86 3,695,693.38 3,434,302.89 3,172,912.40 2,911,521.92 2,650,131.43 2,650,131.43 2,650,131.43 2,650,131.43 2,650,131.43 2,650,131.43 2,650,131.43 2,650,131.43 2,650,131.43 2,650,131.43

General Costs of the Plant General costs include the costs of managing the firm, marketing the product, research and development on new and old products, and financing the operation. Refer to Table 51 for the equations in obtaining the estimates for the general costs of the plant. Table 108 shows the summary for the general cost of the plant.

Table 108 General costs of the plant YEAR 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

Admin

Marketing

Research and Development

Cost

Cost

Cost

92,776,682.22 124,655,924.66 149,741,749.13 207,347,393.38 217,130,057.82 227,405,891.73 238,297,540.40 249,732,836.09 261,738,923.75 274,344,304.04 287,578,901.15 301,474,133.81 316,062,990.04 331,380,105.49 347,461,845.78

₱ 278,330,046.67 ₱ 373,967,773.99 ₱ 449,225,247.40 ₱ 622,042,180.13 ₱ 651,390,173.47 ₱ 682,217,675.18 ₱ 714,892,621.19 ₱ 749,198,508.28 ₱ 785,216,771.24 ₱ 823,032,912.13 ₱ 862,736,703.45 ₱ 904,422,401.44 ₱ 948,188,970.13 ₱ 994,140,316.48 ₱ 1,042,385,537.34

183

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

118,547,982.84 159,282,570.40 191,336,679.45 264,943,891.54 277,443,962.78 290,574,194.98 304,491,301.62 319,103,068.34 334,444,180.34 350,551,055.17 367,461,929.25 385,216,948.76 403,858,265.05 423,430,134.80 443,979,025.16

Income Statement of the Company The income statement or consolidated statement of operations is a summary of the incomes, expenditures, and taxes paid by the company over a fixed period of time. The income statement gives a good insight into the overall profitability and margins of a business. Table 109 shows the indicative price of the products of the company.

Table 109 Pricing of Products

Acetone Phenol

FLOWRATE kg/h 4369.793128 7071.121303

Operational Time # of days # of Hours 350 8400 350 8400

PRICE USD/MT 36,706.26 1807.788 59,397.42 1984.158 MTpY

Flowrates acquired from the Aspen Hysys Simulation Source of Price: ICIS Indicative Prices

The inflation of the prices of the raw materials was approximated to 5%, as given from the trend of prices of propylene and benzene from the report of Pandia entitled “Global Acetone-Phenol Markets” in the year 2009. US Dollar to Philippines Peso conversion is averaged to forty five. Given in Table 88 and Table 89 are the cost of propylene and benzene annually. Table 110 shows the annual revenue generated from acetone. Table 111 shows the annual revenue generated from phenol.

184

Table 110 Revenue from acetone Year 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

Turndown Capacity 50% 65% 75% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%

MTPY 18353.13 23859.07 27529.7 36706.26 36706.26 36706.26 36706.26 36706.26 36706.26 36706.26 36706.26 36706.26 36706.26 36706.26 36706.26

Price (per MT) $ $ $ $ $ $ $ $ $ $ $ $ $ $ $

1,807.79 1,898.18 1,993.09 2,092.74 2,197.38 2,307.25 2,422.61 2,543.74 2,670.93 2,804.47 2,944.70 3,091.93 3,246.53 3,408.85 3,579.30

Revenue ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

1,493,035,990.88 2,037,994,127.55 2,469,108,269.92 3,456,751,577.89 3,629,589,156.78 3,811,068,614.62 4,001,622,045.35 4,201,703,147.62 4,411,788,305.00 4,632,377,720.25 4,863,996,606.26 5,107,196,436.58 5,362,556,258.41 5,630,684,071.33 5,912,218,274.89

Table 111 Revenue from phenol Year 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

Turndown Capacity 50% 65% 75% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%

MTPY

Price (per MT)

Revenue - Phenol

29698.71 38608.32 44548.06 59397.42 59397.42 59397.42 59397.42 59397.42 59397.42 59397.42 59397.42 59397.42 59397.42 59397.42 59397.42

1984.158 2083.3659 2187.534195 2296.910905 2411.75645 2532.344272 2658.961486 2791.90956 2931.505038 3078.08029 3231.984305 3393.58352 3563.262696 3741.425831 3928.497122

₱ 2,651,711,939.36 ₱ 3,619,586,797.22 ₱ 4,385,268,619.71 ₱ 6,139,376,067.60 ₱ 6,446,344,870.98 ₱ 6,768,662,114.53 ₱ 7,107,095,220.25 ₱ 7,462,449,981.26 ₱ 7,835,572,480.33 ₱ 8,227,351,104.34 ₱ 8,638,718,659.56 ₱ 9,070,654,592.54 ₱ 9,524,187,322.17 ₱ 10,000,396,688.27 ₱ 10,500,416,522.69

185

Table 112 shows the detailed summary of the taxes and mandatory contributions of a corporation. Based on the table, the total tax rate that can be imposed on a corporation’s profit is 42.48%.

186

Table 112 Detailed summary of the taxes and mandatory contributions of a corporation Tax or mandatory contribution

Payments (number)

Notes on Payments

Time (hours)

Corporate income tax

1

online filing

42

Local business tax

1

Employer paid - Social security contributions

1

Real property tax

1

Statutory tax rate

30% 0.50%

online filing

38

2.89% to 6.50%

Tax base

taxable profit previous year turnover gross salaries

Total tax rate (% profit)

20.46 8.84

6.06

Employer paid - Health insurance

12

online filing

1.16% to 1.19%

assessed property value gross salaries

Employer paid - Housing development fund

12

online filing

2% or P100 per worker

gross salaries

0.56

Tax on interest

1

online filing

20%

interest

0.51

Employer paid - Employer's compensation

0

paid jointly

P 30

per employee per month

0.17

1

P 10,500

fixed fee

0.08

1

P 10,000

fixed fee

0.08

basic fee + 24% P 500

P 1.5 per check

vehicle weight fixed fee value added number of checks

P 0.5 per each P 4 various rates

insurance premium contract value

Community tax certificate Environmental tax

2%

Notes on TTR

4.44 1.24

Vehicle tax

1

BIR certificate

0

paid jointly

Value added tax (VAT)

1

online filing

Tax on check transactions

1

online filing

Tax on insurance contracts

1

online filing

Stamp duty

1

online filing

Employee paid - Social security contributions

0

paid jointly

1.33% to 2.98%

gross salaries

0

withheld

Employee paid - Payroll tax

0

paid jointly

1.16% to 1.19%

per employee per month

0

withheld

Employee paid - Housing development fund

0

paid jointly

2% or P 100 per worker

gross salaries

0

withheld

Totals:

36

113

193

187

12%

0.04 0 0 0 0 0

42.48

not included small amount small amount small amount

Table 113 shows the annual production cost and revenue of the company. Imposing the 42.48% on the revenue, the annual profit of the company is depicted in Table 114.

Table 113 Production Cost and Revenue of the Company per Year Year PRODUCTION COST

Table 114 Annual Profit of the Company Year PROFIT 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

Total REVENUE ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

₱ 3,270,703,198.73 ₱ 4,154,190,983.79 ₱ 4,833,394,458.10 ₱ 6,446,398,502.45 ₱ 6,678,358,290.60 ₱ 6,923,852,453.54 ₱ 7,222,621,590.59 ₱ 7,536,310,967.82 ₱ 7,865,665,868.56 ₱ 8,211,468,811.18 ₱ 8,574,541,409.64 ₱ 8,955,746,327.09 ₱ 9,355,989,327.03 ₱ 9,776,221,427.05 ₱ 10,217,441,160.17

2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

TAX

874,044,731.51 1,503,389,940.98 2,020,982,431.54 3,149,729,143.04 3,397,575,737.16 3,655,878,275.61 3,886,095,675.01 4,127,842,161.06 4,381,694,916.77 4,648,260,013.42 4,928,173,856.18 5,222,104,702.03 5,530,754,253.55 5,854,859,332.55 6,195,193,637.41

188

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

371,294,201.94 638,640,046.93 858,513,336.92 1,338,004,939.96 1,443,290,173.14 1,553,017,091.48 1,650,813,442.74 1,753,507,350.02 1,861,344,000.64 1,974,580,853.70 2,093,488,254.11 2,218,350,077.42 2,349,464,406.91 2,487,144,244.47 2,631,718,257.17

4,144,747,930.24 5,657,580,924.78 6,854,376,889.63 9,596,127,645.49 10,075,934,027.76 10,579,730,729.15 11,108,717,265.60 11,664,153,128.88 12,247,360,785.33 12,859,728,824.60 13,502,715,265.83 14,177,851,029.12 14,886,743,580.57 15,631,080,759.60 16,412,634,797.58

FINAL PROFIT ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

502,750,529.56 864,749,894.05 1,162,469,094.62 1,811,724,203.08 1,954,285,564.01 2,102,861,184.13 2,235,282,232.27 2,374,334,811.04 2,520,350,916.12 2,673,679,159.72 2,834,685,602.08 3,003,754,624.61 3,181,289,846.64 3,367,715,088.08 3,563,475,380.24

Cost of Permits and Licenses Before putting up a plant, the following government permits and license in Table 115 must be paid and accomplished. These fees are paid on a yearly basis.

Table 115 Required Permits and Licenses of the Company Mayor's Permit Sanitary Permit Location Clearance Building Permit Occupational Occupancy Fire Permit Community Tax Certificate Environmental Tax BIR Certificate SEC Company name verification and reservation Notarize articles of incorporation and treasurer's affidavit at the notary SEC company Registration Pay registration fee and Documentary stamp taxes at AAB (Authorized Agent Bank) Barangay Clearance Special Books of Account Application for certificate of registration (COR) and TIN at BIR Printing or receipts and invoices World Bank Group, 2015 Provincial Government of Bataan, 2015

189

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

2,500.00 1,000.00 6,000.00 25,000.00 10,000.00 5,000.00 6,000.00 10,500.00 10,000.00 500.00 40.00

₱

500.00

₱

3,645.00

₱

4,670.00

₱ ₱

800.00 400.00

₱

115.00

₱

4,000.00

Cost of Buildings Shown in Table 116 is the cost of the buildings inside the plant site. The cost was generated using Aspen Hysys Economic Evaluator software.

Table 116 Cost of buildings LENGTH (m)

WIDTH (m)

AREA (m2)

ADMIN BLDG

27.5

51

1402.5

QUALITY CONTROL LAB

17.5

50.9

890.75

40

18

720

PRODUCTION OFFICE

25.9

18

466.2

RESEARCH&DEV

17.5

27

472.5

SECURITY OFFICE

27.83

12.2

339.526

MAINTENANCE

17.5

18

315

CONTROL ROOM

25

8

200

20.04

22

440.88

Buildings

CANTEEN

WAREHOUSE

TOTAL

COST OF BUILDINGS $ 1,103,000.00 $ 1,362,200.00 $ 566,200.00 $ 502,700.00 $ 509,500.00 $ 366,100.00 $ 339,600.00 $ 227,900.00 $ 312,900.00 ₱ 238,054,500.00

Trucks and Electronic Devices Trucks owned by the company will be used in the transport of products to their respective users in the Philippines. Shown in Table 117 is the summary of the total cost of trucks owned by the company.

190

Table 117 Cost of trucks of the company Description Isuzu 8PC1 8 Wheeler Tank Truck 14,000 L Capacity ₱ 1,200,000.00 Assumption: Per day delivery Volume of Acetone Product per day: Volume of Phenol Product per day: Number of Trucks for Acetone: Number of Trucks for Phenol: TOTAL NUMBER OF TRUCKS: Cost of Trucks:

135.432 161.592 10 12 22 ₱ 26,400,000.00

In case of plant operation, a more effective and efficient way of communicating is through the use of radio. The personnel operating the main process of the plant are required to use radio in communicating with other personnel within the plant area. Shown in Table 118 is the cost of radio owned by the company.

Table 118 Cost of radio Number of Personnel that needs Radio Price of Two-Way Radio Total Cost Source: OLX Philippines, 2015

191

23 ₱ 4,500.00 ₱ 103,500.00

Project Evaluation Table 119 shows the summary of the expenses of the company. The total capital expense of the company is around 4.5 billion PhP. It can be deduced that the construction and operation of the plant requires very large amounts of capital.

Table 119 Total capital expenditure of the company ISBL CAPEX OSBL OPEX Contingency Commissioning Minimum Paid up Capital Requirement on Bank (SEC) EIA TOTAL CAPEX

₱ 2,814,539,354.81 ₱ 1,106,317,946.51 ₱ 392,085,730.13 ₱ 137,230,005.55 ₱ 500,000.00 ₱ 300,000.00 ₱ 4,450,973,036.99

About half of the total capital expenses of the company will come from bank financing. The debt capital is raised through long term bonds with the bank. Table 120 shows the description of the bank and the annuity.

Table 120 Capital loan and interest ₱ 2,225,336,518.50 BPI ₱ 2,225,336,518.50 6.00% 3 ₱ 2,650,411,398.91 10 ₱ 302,351,929.12

Cash on hand BANK Bank loan (PRINCIPAL) Interest rate (compounding per year) Tenor/Defer Future Worth at year 3 Number of terms Annuity

192

The internal rate of return (IRR) of the company was projected to be 24%, as shown in Table 121. At year 2020, the total capital expenditure is expected to be recovered, therefore the return of investment (ROI) is 6 years. Figure 16 shows the project cash flow of Phace Philippines Corporation. Based on the economic analysis of the project using class 3 estimation, the project is concluded to be feasible since it is highly profitable. The plant designers recommends to continue the project to its next stages such as detailed engineering design, procurement, construction, startup, trial runs, and production or commercial operation.

Table 121 Internal rate of return YEAR 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

Bank Annuity ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

Annual Profit -

314,565,371.62 314,565,371.62 314,565,371.62 314,565,371.62 314,565,371.62 314,565,371.62 314,565,371.62 314,565,371.62 314,565,371.62 314,565,371.62 IRR

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱

(2,315,228,518.50) (2,315,228,518.50) 502,750,529.56 550,184,522.43 847,903,723.00 1,497,158,831.45 1,639,720,192.39 1,788,295,812.51 1,920,716,860.64 2,059,769,439.42 2,205,785,544.50 2,359,113,788.09 2,520,120,230.46 3,003,754,624.61 3,181,289,846.64 3,367,715,088.08 3,563,475,380.24

193

₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ ₱ 24%

Cumulative Profit 502,750,529.56 1,052,935,051.99 1,900,838,774.99 3,397,997,606.45 5,037,717,798.84 6,826,013,611.34 8,746,730,471.99 10,806,499,911.41 13,012,285,455.91 15,371,399,244.01 17,891,519,474.46 20,895,274,099.07 24,076,563,945.71 27,444,279,033.79 31,007,754,414.03

CASH FLOW ₱5,000,000,000.00 ₱4,000,000,000.00 ₱3,000,000,000.00 ₱2,000,000,000.00 ₱1,000,000,000.00 ₱₱(1,000,000,000.00)

2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

₱(2,000,000,000.00) ₱(3,000,000,000.00)

Figure 16. Project Cash Flow of Phace Philippines Corporation

Breakeven Analysis If a proposal is intended to generate added volume, it is important to check the estimated volume to be produced, so that the added revenues balance the added costs. This volume is called the breakeven volume. The following equations must be used to obtain the break even volume. Table 122 shows the calculation basis for the breakeven volume. 𝑷𝒓𝒐𝒅𝒖𝒄𝒕𝒊𝒐𝒏 𝑪𝒐𝒔𝒕 = 𝑷𝒓𝒊𝒄𝒆 𝒐𝒇 𝑨𝒄𝒆𝒕𝒐𝒏𝒆 (𝑿𝟏 ) + 𝑷𝒓𝒊𝒄𝒆 𝒐𝒇 𝑷𝒉𝒆𝒏𝒐𝒍 (𝑿𝟐 ) (20) 𝑋2 = 1.618182165 𝑋1 𝑿𝟐 = 𝟏. 𝟔𝟏𝟖𝟏𝟖𝟐𝟏𝟔𝟓 𝑿𝟏

(21)

𝑷𝒓𝒐𝒅𝒖𝒄𝒕𝒊𝒐𝒏 𝑪𝒐𝒔𝒕 = 𝑷𝟏 𝑿𝟏 + 𝑷𝟐 (𝟏. 𝟔𝟏𝟖𝟏𝟖𝟐𝟏𝟔𝟓 𝑿𝟏 )

(22)

𝑿𝟏 =

𝑷𝒓𝒐𝒅𝒖𝒄𝒕𝒊𝒐𝒏 𝑪𝒐𝒔𝒕 𝑷𝟏 + 𝑷𝟐 (𝟏. 𝟔𝟏𝟖𝟏𝟖𝟐𝟏𝟔𝟓)

Let 𝑥 = 𝐵𝑟𝑒𝑎𝑘𝑒𝑣𝑒𝑛 𝑉𝑜𝑙𝑢𝑚𝑒

194

(23)

Table 122 Calculation Basis for Breakeven Analysis Year 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

PRODUCTION COST ₱ 2,712,464,361.58 ₱ 2,835,631,286.44 ₱ 4,366,775,747.44 ₱ 6,031,806,007.70 ₱ 6,300,526,376.70 ₱ 6,582,723,662.99 ₱ 6,880,225,862.31 ₱ 7,192,584,954.92 ₱ 7,520,543,056.81 ₱ 7,864,879,360.64 ₱ 8,226,411,988.37 ₱ 8,605,999,936.54 ₱ 9,004,545,118.75 ₱ 9,422,994,510.15 ₱ 9,862,342,399.22

Acetone (X1) MTPY Price (per MT) 18,353.13 $ 1,807.79 18,353.13 $ 1,862.02 27,529.70 $ 1,917.88 36,706.26 $ 1,975.42 36,706.26 $ 2,034.68 36,706.26 $ 2,095.72 36,706.26 $ 2,158.59 36,706.26 $ 2,223.35 36,706.26 $ 2,290.05 36,706.26 $ 2,358.75 36,706.26 $ 2,429.52 36,706.26 $ 2,502.40 36,706.26 $ 2,577.47 36,706.26 $ 2,654.80 36,706.26 $ 2,734.44

Phenol (X2) MTPY Price (per MT) 29,698.71 $ 1,984.16 29,698.71 $ 2,043.68 44,548.06 $ 2,104.99 59,397.42 $ 2,168.14 59,397.42 $ 2,233.19 59,397.42 $ 2,300.18 59,397.42 $ 2,369.19 59,397.42 $ 2,440.26 59,397.42 $ 2,513.47 59,397.42 $ 2,588.88 59,397.42 $ 2,666.54 59,397.42 $ 2,746.54 59,397.42 $ 2,828.93 59,397.42 $ 2,913.80 59,397.42 $ 3,001.22

Breakeven sales volume is the amount of product that you will need to produce and sell to cover total costs of production. Table 123 shows the breakeven volume of the products acetone and phenol. Table 123 Breakeven volume of acetone (𝑋1 ) and phenol (𝑋2 ) Year 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

X2/X1 1.618182165 1.618182165 1.618182165 1.618182165 1.618182165 1.618182165 1.618182165 1.618182165 1.618182165 1.618182165 1.618182165 1.618182165 1.618182165 1.618182165 1.618182165

X1 12,010.91 12,190.59 18,226.30 24,442.62 24,787.91 25,143.84 25,514.75 25,896.23 26,288.36 26,691.26 27,105.05 27,529.85 27,965.79 28,413.00 28,871.61

195

X2 19,435.85 19,726.59 29,493.47 39,552.61 40,111.36 40,687.31 41,287.52 41,904.81 42,539.35 43,191.32 43,860.91 44,548.32 45,253.75 45,977.41 46,719.52

A benefit-cost ratio (BCR) is an indicator, used in the formal discipline of costbenefit analysis, which attempts to summarize the overall value for money of a project or proposal. Table 124 shows the benefit to cost ratio of the plant. The ratio should be greater than 1 for the project to be justifiable.

Table 124 Benefit to cost ratio (f) of the plant n 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Year 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031

Production Cost (PhP) 3074233529 3916060631 4571068739 6120371891 6354543098 6602276466 6901796804 7216267436 7546434846 7893082804 8257034225 8639153123 9040346669 9461567344 9903815202

Revenue (PhP) 4144747930 5657580925 6854376890 9596127645 10075934028 10579730729 11108717266 11664153129 12247360785 12859728825 13502715266 14177851029 14886743581 15631080760 16412634798 TOTAL f

196

PW – PC (PhP) PW-R (PhP) 3074233529 4144747930 3158113412 4562565262 2972859482 4457841369 3210057091 5033046707 2687803956 4261854067 2252087605 3608828040 1898593799 3055862454 1600887537 2587625465 1350107487 2191134466 1138810578 1855396120 960743009.3 1571101554 810648596 1330368251 684108304.9 1126521503 577405847.5 953909337.1 487415051.1 807745809.7 26863875284 41548548335 1.546632714

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http://www.sciencepark.com.ph/heip-factsheet Silla, H. (2003). Chemical Process Engineerng Design and Economics. New Jersey, USA: Marcel Dekker, Inc. Special Economic Zones in Philippines. (n.d.). Retrieved from The Philippine Economic Zone

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http://training.itcilo.it/actrav_cdrom1/english/global/frame/epzppi.htm#anchor445 956 Speight, J. G. (2002). Chemical and Process Design Handbook. New York: McGRAWHILL. SPPI - Hermosa Ecozone Industrial Park. (n.d.). Retrieved from Science Park Philippines: http://www.sciencepark.com.ph/hermosa-ecozone-industrial-park-heip/ Stanford, H. W. (2012). HVAC Water Chillers and Cooling Towers. 6000 Broken Sound Parkway NW, Suite 300, FL: Taylor & Francis Group CRC Press. Stefanidakis, G., & Gwyn, J. E. (1977). Alkylation. Encyclopedia of Chemical Processing, 357. (2010). Summary Statistics for Manufacturing Establishments for All Employment Sizes by Industry Sub Class: Philippines, 2010. Manila, Philippines: National Statistics

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http://web0.psa.gov.ph/content/2009-annual-survey-philippine-business-andindustry-aspbi-manufacturing-sector-final-results T&D Water Technologies and Development. (n.d.). Retrieved from T&D Company: http://www.t-and-d-italy.com/ Toplinechem

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http://toplinechem.lookchem.com/products/CasNo-67-64-1-Acetone2064394.html Towler, G., & Sinnott, R. (2008). CHEMICAL ENGINEERING DESIGN: Principles, Practice, and Economics of Plant and Process Design. California: Elsevier. Toxic

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http://www.emb.gov.ph/laws/toxic%20substances%20and%20hazardous%20wast es/ra6969.PDF Toyota. (n.d.). Toyota Motor Philippines CSR. Retrieved from Toyota Motor Philippines: http://csr.toyota.com.ph/plant.html Tyman, J. (1996). Synthetic and Natural Phenols. Rosewood Drive, Danvers, MA: Elsevier.

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nano.com/inc/sdetail/222 Vatavuk, W. M. (1990). Estimating Cost of Air Pollution Control. Michigan, US.: Lewis Publishers. What You Need to Know About Real Property Tax (RPT). (n.d.). Retrieved from FORECLOSUREPHILIPPINES:

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http://www.doingbusiness.org/data/exploreeconomies/philippines/paying-taxes/ Zauba. (2015). Export Price of Zeolite. Retrieved November 11, 2014, from Zauba: https://www.zauba.com/export-zeolite/fp-philippines-hs-code.html Zhang, M., Wang, L., Hongbing, J., Wu, B., & Zeng, X. (2007). Cumene Liquid Oxidation to Cumene Hydroperoxide over CuO Nanoparticle with Molecular Oxygen Under Mild Condition. Journal of Natural Gas Chemistry, 393-398. Zhang, M., Wang, L., Ji, H., Wu, B., & Zeng, X. (2007). Cumene Liquid Oxidation to Cumene Hydroperoxide over CuO Nanoparticle with Molecular oxygen under Mild Condition. Journal of Natural Gas Chemistry, 393-398. Zhigang, L., Dai, C., Wang, Y., & Chen, B. (2009). Process Optimization on alkylation of benzenen with propylene. Energy Fuel, 23(6), 3159-3166. doi:10.1021/ef900052j

204

205

Appendix A

ASPEN HYSYS SIMULATION

Figure 1. Data for the components of the process in Aspen Hysys

Figure 2. React ion data for the main react ion in Alkylator

Figure 3. React ion data for the side react ion in Alkylator

206

Figure 4. React ion data for the cumene oxidation process

Figure 5. React ion data for the cleaving of cu mene hydroperoxide to phenol and acetone

Figure 6. React ion data for steam generat ion

207

Figure 7. Overview of the process

STEP BY STEP SIMULATION SNAPSHOTS

208

209

210

211

212

213

214

215

216

217

218

219

Appendix B STORAGE TANKS CALCULATION SHEETS

REV 1

CALCULATION SHEET CREATED BY CHECKED BY EAM ALL MFS

DATE 1/2/15

APPROVED BY

Service: Propylene Feed OPERATING CONDITIONS °C 25 T °F 77 Bar 12 P psia 174.0933 psig 159.3933 psia 226.1138 true VP and Reid VP at 37.8 °C kPaa 1559 (100°F) Type of Vessel Pressure vessel If TVP (true vapor pressure) of the chemical is greater than 90 𝑘𝑃𝑎(𝑎), then use a pressure vessel for the storage tank, otherwise use an atmospheric vessel for the storage tank. DESIGN CONDITIONS T P (MAWP) minimum P minimum design metal temperature

°C °F Bar psia psig psia psig °C

93.33333 200 13.72321 199.0933 184.3933 0 -14.7 15 ~ 20

The minimum design metal temperature is based from the ambient temperature here in the country .The design conditions were acquired based on the following table.

220

Operating T 0 to 200 degF Over 200 degF Reactors

Design T 250 degF operating + 50 degF operating + 50 degF

Operating P 0 to 25 psig 25 to 250 psig 250 to 1000 psig over 1000 psig

Design P 50 psig operating + 25 psig operating + 10% operating + 5%

LIQUID CAPACITY 28 day Capacity/Storage time 672 hr 3354 flow rate kg/hr 3689.4 Rated mass flow rate kg/hr 506.8 Density kg/m3 4892.022 m3 Rated Volume of liquid 1292335 gal use vertical tanks on concrete foundation

Assumptions: 



  



The storage for this chemical will be divided to 6 tanks, with 1 week storage time each. It is assumed that the transaction time between the company and the provider as well as delivery of the product will take 2 weeks. It is very important for continuous production to have enough storage of feed. Based on the rule of thumb of Chemical Engineering Design, if the rated volume of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations is typically used. The choses material of construction is carbon steel since propylene is not corrosive. ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry for storage tanks. Outage and Innage of the tank are assumed to be 500 𝑚𝑖𝑙𝑙𝑖𝑚𝑒𝑡𝑒𝑟𝑠. The outage is the allowance for spillage, and the innage is the non-pumpable volume. The pump should not be placed under the innage to avoid pump cavitation. Based on the rule of thumb for Chemical Engineering Design, Optimum length to diameter ratio for vessels is 3 (𝐿⁄𝐷 = 3). 𝜋𝐷2 4892.022 3 (3𝐷 − 0.50 − 0.5) = 𝑚 (𝑟𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒) 4 6

221

𝐷 = 7.133506 𝑚 ≅ 7200 𝑚𝑚 𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 7200 𝑚𝑚 = 21600 𝑚𝑚 Based on the Rules of thumb, the corrosion allowance for non-corrosive streams like propylene is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the vessel, first is determine the maximum allowable stress (S) which will be based on the type of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon steel at 250℉ is 12.9ksi or 12900psi. For cylindrical vessels: 𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 (1) 2𝑆𝐸 − 1.2𝑃𝑖

𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 (2) 4𝑆𝐸 + 0.8𝑃𝑖

Where: 𝑡𝑚𝑖𝑛 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑤𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 (𝑒𝑥𝑐𝑙𝑢𝑑𝑖𝑛𝑔 𝐶𝐴) 𝑃𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝐷𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑆 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

(1)𝑡𝑚𝑖𝑛 =

199.0933𝑝𝑠𝑖𝑎 ∗ 7200 𝑚𝑚 = 66.08574 𝑚𝑚 2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 1.2 ∗ 199.0933𝑝𝑠𝑖𝑎

222

(2)𝑡𝑚𝑖𝑛 =

199.0933𝑝𝑠𝑖𝑎 ∗ 7200𝑚𝑚 = 32.56463 𝑚𝑚 4 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 + 0.8 ∗ 199.0933𝑝𝑠𝑖𝑎

Choosing the higher value for 𝑡𝑚𝑖𝑛 , 𝑡𝑚𝑖𝑛 = 66.08574 + 3.8 ≅ 70𝑚𝑚 𝑂𝐷 = 2 ∗ 𝑡𝑚𝑖𝑛 + 𝐼𝐷 = 2 ∗ 70 + 7200 = 7340𝑚𝑚 For heads and closures, 2:1 ellipsoidal is the common in the chemical industry. 𝑡𝑚𝑖𝑛 = 𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 2𝑆𝐸 − 0.2𝑃𝑖

199.0933𝑝𝑠𝑖𝑎 ∗ 7200𝑚𝑚 ≅ 66𝑚𝑚 2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 199.0933𝑝𝑠𝑖𝑎

223

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CALCULATION SHEET CREATED BY CHECKED BY EAM ALL MFS

DATE 1/2/15

APPROVED BY

Service: Benzene Feed OPERATING CONDITIONS °C 25 T °F 77 Bar 1 P psia 14.50777 psig -0.19223 psia 3.24E+00 true VP and Reid VP at 37.8 °C kPaa 22.36 (100°F) Atmospheric Type of Vessel vessel If TVP (true vapor pressure) of the chemical is greater than 90 𝑘𝑃𝑎(𝑎), then use a pressure vessel for the storage tank, otherwise use an atmospheric vessel for the storage tank. DESIGN CONDITIONS T P (MAWP) minimum P minimum design metal temperature

°C °F Bar psia psig psia psig °C

93.33333 200 13.72321 199.0933 184.3933 0 -14.7 15 ~ 20

The minimum design metal temperature is based from the ambient temperature here in the country .The design conditions were acquired based on the following table. Operating T 0 to 200 degF Over 200 degF Reactors

Design T 250 degF operating + 50 degF operating + 50 degF

224

Operating P 0 to 25 psig 25 to 250 psig 250 to 1000 psig over 1000 psig

Design P 50 psig operating + 25 psig operating + 10% operating + 5%

LIQUID CAPACITY day

28

hr

672

flow rate

kg/hr

6248.8

Rated mass flow rate

kg/hr

6873.68

Density

kg/m3

872.2

m3

5295.933

gal

1399037

Capacity/Storage time

Rated Volume of liquid use vertical tanks on concrete foundation

Assumptions: 



  



The storage for this chemical will be divided to 6 tanks, with 1 week storage time each. It is assumed that the transaction time between the company and the provider as well as delivery of the product will take 2 weeks. It is very important for continuous production to have enough storage of feed. Based on the rule of thumb of Chemical Engineering Design, if the rated volume of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations is typically used. The chosen material of construction is carbon steel since benzene is not corrosive. ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry for storage tanks. Outage and Innage of the tank are assumed to be 500 𝑚𝑖𝑙𝑙𝑖𝑚𝑒𝑡𝑒𝑟𝑠. The outage is the allowance for spillage, and the innage is the non-pumpable volume. The pump should not be placed under the innage to avoid pump cavitation. Based on the rule of thumb for Chemical Engineering Design, Optimum length to diameter ratio for vessels is 3 (𝐿⁄𝐷 = 3). 𝜋𝐷2 5295.933 3 (3𝐷 − 0.50 − 0.5) = 𝑚 (𝑟𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒) 4 6 𝐷 = 7.321595 𝑚 ≅ 7400 𝑚𝑚 𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 7400 𝑚𝑚 = 22200 𝑚𝑚

Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the

225

vessel, first is determine the maximum allowable stress (S) which will be based on the type of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon steel at 250℉ is 12.9ksi or 12900psi. For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic pressure can be calculated from the following equation: 𝑇𝑡 =

𝜌𝐿 𝐻𝐿 𝑔 𝐷𝑡 + 𝐶𝐴 2𝑆𝑡 𝐸 103

Where: 𝑇𝑡 = 𝑡𝑎𝑛𝑘 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑎𝑡 𝑎 𝑐𝑒𝑟𝑡𝑎𝑖𝑛 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚𝑚 𝐻𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚 𝜌𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦, 𝑘𝑔/𝑚3 𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (𝑖𝑓 𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑏𝑙𝑒) 𝑔 = 𝑔𝑟𝑎𝑣𝑖𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛, 9.81 𝑚/𝑠 2 𝑆𝑡 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑓𝑜𝑟 𝑡𝑎𝑛𝑘 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙, 𝑁/𝑚𝑚2 𝐷𝑡 = 𝑡𝑎𝑛𝑘 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚 𝐶𝐴 = 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒

𝑇𝑡 =

1 872 ∗ (22200 − 500) (1000) ∗ 9.81 2 ∗ 88.942369 ∗ 0.85

7400 ∗ 1000 + 3.8 = 12.887𝑚𝑚 103

𝑇𝑡 ≈ 13𝑚𝑚 𝑂𝐷 = 2 ∗ 𝑇𝑡 + 𝐼𝐷 𝑂𝐷 = 2 ∗ 13 + 7400 = 7426 𝑚𝑚 For heads and closures, 2:1 ellipsoidal is the common in the chemical industry. 𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 2𝑆𝐸 − 0.2𝑃𝑖

226

𝑡𝑚𝑖𝑛 =

64.7𝑝𝑠𝑖𝑎 ∗ 7400𝑚𝑚 ≅ 22 𝑚𝑚 2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 64.7𝑝𝑠𝑖𝑎

227

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APPROVED BY

Service: Acetone Product A OPERATING CONDITIONS 30 °C T 86 °F 3.659 Bar 53.08393782 P psia psig 38.38393782 21.47 psia true VP and Reid VP at 37.8 °C 148 kPaa (100°F) Type of Vessel Pressure vessel If TVP (true vapor pressure) of the chemical is greater than 90 𝑘𝑃𝑎(𝑎), then use a pressure vessel for the storage tank, otherwise use an atmospheric vessel for the storage tank. DESIGN CONDITIONS °C 93.33333333 T °F 200 Bar 5.382214286 P (MAWP) psia 78.08393782 psig 63.38393782 psia 0 minimum P psig -14.7 minimum design metal temperature °C 15 ~ 20 The minimum design metal temperature is based from the ambient temperature here in the country .The design conditions were acquired based on the following table. Operating T 0 to 200 degF Over 200 degF Reactors

Design T 250 degF operating + 50 degF operating + 50 degF

Operating P 0 to 25 psig 25 to 250 psig 250 to 1000 psig over 1000 psig

LIQUID CAPACITY Capacity/Storage time day

228

Design P 50 psig operating + 25 psig operating + 10% operating + 5%

7

hr kg/hr kg/hr kg/m3 m3 gal

168 flow rate 4370 Rated mass flow rate 4807 Density 774.4 1042.841 Rated Volume of liquid 275489.4 use vertical tanks on concrete foundation

Assumptions:  

  



The storage for this chemical will be divided to 3 tanks, with 1 week total storage time. Based on the rule of thumb of Chemical Engineering Design, if the rated volume of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations is typically used. The choses material of construction is carbon steel since Acetone is not corrosive. ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry for storage tanks. Outage and Innage of the tank are assumed to be 500 𝑚𝑖𝑙𝑙𝑖𝑚𝑒𝑡𝑒𝑟𝑠. The outage is the allowance for spillage, and the innage is the non-pumpable volume. The pump should not be placed under the innage to avoid pump cavitation. Based on the rule of thumb for Chemical Engineering Design, Optimum length to diameter ratio for vessels is 3 (𝐿⁄𝐷 = 3). 𝜋𝐷2 1042.841 3 (3𝐷 − 0.50 − 0.5) = 𝑚 (𝑟𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒) 4 3 𝐷 = 5.397469 𝑚 ≅ 5400 𝑚𝑚 𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 5400 𝑚𝑚 = 16200 𝑚𝑚

Based on the Rules of thumb, the corrosion allowance for non-corrosive streams like propylene is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the vessel, first is determine the maximum allowable stress (S) which will be based on the type of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon steel at 250℉ is 12.9ksi or 12900psi. For cylindrical vessels:

229

𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 (1) 2𝑆𝐸 − 1.2𝑃𝑖

𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 (2) 4𝑆𝐸 + 0.8𝑃𝑖

Where: 𝑡𝑚𝑖𝑛 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑤𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 (𝑒𝑥𝑐𝑙𝑢𝑑𝑖𝑛𝑔 𝐶𝐴) 𝑃𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝐷𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑆 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (1)𝑡𝑚𝑖𝑛 =

78.08393782 𝑝𝑠𝑖𝑎 ∗ 5400 𝑚𝑚 = 19.30974 𝑚𝑚 2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 1.2 ∗ 78.08393782𝑝𝑠𝑖𝑎

(2)𝑡𝑚𝑖𝑛 =

78.08393782 𝑝𝑠𝑖𝑎 ∗ 5400𝑚𝑚 = 9.599945 𝑚𝑚 4 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 + 0.8 ∗ 78.08393782 𝑝𝑠𝑖𝑎

Choosing the higher value for 𝑡𝑚𝑖𝑛 , 𝑡𝑚𝑖𝑛 = 19.30974 + 3.8 ≅ 24𝑚𝑚 𝑂𝐷 = 2 ∗ 𝑡𝑚𝑖𝑛 + 𝐼𝐷 = 2 ∗ 24 + 5400 = 5448𝑚𝑚 For heads and closures, 2:1 ellipsoidal is the common in the chemical industry. 𝑡𝑚𝑖𝑛 =

𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 2𝑆𝐸 − 0.2𝑃𝑖

78.08393782 𝑝𝑠𝑖𝑎 ∗ 5400𝑚𝑚 ≅ 20𝑚𝑚 2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 78.08393782 𝑝𝑠𝑖𝑎

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CALCULATION SHEET CREATED BY CHECKED BY EAM ALL MFS

APPROVED BY

Service: Acetone Product B OPERATING CONDITIONS 30 °C T 86 °F 3.659 Bar 53.08393782 P psia psig 38.38393782 21.47 psia true VP and Reid VP at 37.8 °C 148 kPaa (100°F) Type of Vessel Pressure vessel If TVP (true vapor pressure) of the chemical is greater than 90 𝑘𝑃𝑎(𝑎), then use a pressure vessel for the storage tank, otherwise use an atmospheric vessel for the storage tank. DESIGN CONDITIONS °C 93.33333333 T °F 200 Bar 5.382214286 P (MAWP) psia 78.08393782 psig 63.38393782 psia 0 minimum P psig -14.7 minimum design metal temperature °C 15 ~ 20 The minimum design metal temperature is based from the ambient temperature here in the country .The design conditions were acquired based on the following table. Operating T 0 to 200 degF Over 200 degF Reactors

Design T 250 degF operating + 50 degF operating + 50 degF

Operating P 0 to 25 psig 25 to 250 psig 250 to 1000 psig over 1000 psig

LIQUID CAPACITY Capacity/Storage time day

231

Design P 50 psig operating + 25 psig operating + 10% operating + 5%

1

hr kg/hr kg/hr kg/m3 m3 gal

24 flow rate 4370 Rated mass flow rate 4807 Density 774.4 148.9773 Rated Volume of liquid 39355.62 use vertical tanks on concrete foundation

Assumptions:  

  



The storage for this chemical will be divided to 3 tanks, with 1 day total storage time. Based on the rule of thumb of Chemical Engineering Design, if the rated volume of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations is typically used. The choses material of construction is carbon steel since Acetone is not corrosive. ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry for storage tanks. Outage and Innage of the tank are assumed to be 500 𝑚𝑖𝑙𝑙𝑖𝑚𝑒𝑡𝑒𝑟𝑠. The outage is the allowance for spillage, and the innage is the non-pumpable volume. The pump should not be placed under the innage to avoid pump cavitation. Based on the rule of thumb for Chemical Engineering Design, Optimum length to diameter ratio for vessels is 3 (𝐿⁄𝐷 = 3). 𝜋𝐷2 148.9773 3 (3𝐷 − 0.50 − 0.5) = 𝑚 (𝑟𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒) 4 3 𝐷 = 2.877947𝑚 ≅ 2900 𝑚𝑚 𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 2900 𝑚𝑚 = 8700 𝑚𝑚

Based on the Rules of thumb, the corrosion allowance for non-corrosive streams like propylene is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the vessel, first is determine the maximum allowable stress (S) which will be based on the type of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon steel at 250℉ is 12.9ksi or 12900psi. For cylindrical vessels:

232

𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 (1) 2𝑆𝐸 − 1.2𝑃𝑖

𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 (2) 4𝑆𝐸 + 0.8𝑃𝑖

Where: 𝑡𝑚𝑖𝑛 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑤𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 (𝑒𝑥𝑐𝑙𝑢𝑑𝑖𝑛𝑔 𝐶𝐴) 𝑃𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝐷𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑆 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (1)𝑡𝑚𝑖𝑛 =

78.08393782 𝑝𝑠𝑖𝑎 ∗ 2900 𝑚𝑚 = 10.37005 𝑚𝑚 2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 1.2 ∗ 78.08393782𝑝𝑠𝑖𝑎

(2)𝑡𝑚𝑖𝑛 =

78.08393782 𝑝𝑠𝑖𝑎 ∗ 2900𝑚𝑚 = 5.155526 𝑚𝑚 4 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 + 0.8 ∗ 78.08393782 𝑝𝑠𝑖𝑎

Choosing the higher value for 𝑡𝑚𝑖𝑛 , 𝑡𝑚𝑖𝑛 = 10.37005 + 3.8 ≅ 15 𝑚𝑚 𝑂𝐷 = 2 ∗ 𝑡𝑚𝑖𝑛 + 𝐼𝐷 = 2 ∗ 15 + 2900 = 2930𝑚𝑚 For heads and closures, 2:1 ellipsoidal is the common in the chemical industry. 𝑡𝑚𝑖𝑛 = 𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 2𝑆𝐸 − 0.2𝑃𝑖

78.08393782 𝑝𝑠𝑖𝑎 ∗ 2900𝑚𝑚 ≅ 11 𝑚𝑚 2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 78.08393782 𝑝𝑠𝑖𝑎

233

REV 1

DATE 1/2/15

CALCULATION SHEET CREATED BY CHECKED BY EAM ALL MFS

APPROVED BY

Service: Phenol Product B OPERATING CONDITIONS °C 54.44 T °F 129.992 Bar 3.759 P psia 54.53472 psig 39.83472 psia 2.57E-02 true VP and Reid VP at 37.8 °C kPaa 0.1773 (100°F) Atmospheric Type of Vessel vessel

If TVP (true vapor pressure) of the chemical is greater than 90 𝑘𝑃𝑎(𝑎), then use a pressure vessel for the storage tank, otherwise use an atmospheric vessel for the storage tank. DESIGN CONDITIONS T

P (MAWP)

minimum P minimum design metal temperature

°C °F Bar psia psig psia psig °C

93.33333 200 5.482214 79.53472 64.83472 0 -14.7 15 ~ 20

The minimum design metal temperature is based from the ambient temperature here in the country .The design conditions were acquired based on the following table.

Operating T 0 to 200 degF Over 200 degF Reactors

Design T 250 degF operating + 50 degF operating + 50 degF

234

Operating P 0 to 25 psig 25 to 250 psig 250 to 1000 psig over 1000 psig

Design P 50 psig operating + 25 psig operating + 10% operating + 5%

LIQUID CAPACITY day Capacity/Storage time hr flow rate kg/hr Rated mass flow rate kg/hr Density kg/m3 m3 Rated Volume of liquid gal

1 24 7071 7778.1 1050

177.7851 46965.86 use vertical tanks on concrete foundation

Assumptions:  

  



The storage for this chemical will be divided to 3 tanks, with 1 day total storage time. Based on the rule of thumb of Chemical Engineering Design, if the rated volume of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations is typically used. The choses material of construction is carbon steel since Acetone is not corrosive. ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry for storage tanks. Outage and Innage of the tank are assumed to be 500 𝑚𝑖𝑙𝑙𝑖𝑚𝑒𝑡𝑒𝑟𝑠. The outage is the allowance for spillage, and the innage is the non-pumpable volume. The pump should not be placed under the innage to avoid pump cavitation. Based on the rule of thumb for Chemical Engineering Design, Optimum length to diameter ratio for vessels is 3 (𝐿⁄𝐷 = 3). 𝜋𝐷2 177.7851 3 (3𝐷 − 0.50 − 0.5) = 𝑚 (𝑟𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒) 4 3 𝐷 = 3.045342 𝑚 ≅ 3100 𝑚𝑚 𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 3100 𝑚𝑚 = 9300 𝑚𝑚

Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the vessel, first is determine the maximum allowable stress (S) which will be based on the type of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon steel at 250℉ is 12.9ksi or 12900psi.

235

For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic pressure can be calculated from the following equation: 𝑇𝑡 =

𝜌𝐿 𝐻𝐿 𝑔 𝐷𝑡 + 𝐶𝐴 2𝑆𝑡 𝐸 103

Where: 𝑇𝑡 = 𝑡𝑎𝑛𝑘 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑎𝑡 𝑎 𝑐𝑒𝑟𝑡𝑎𝑖𝑛 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚𝑚 𝐻𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚 𝜌𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦, 𝑘𝑔/𝑚3 𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (𝑖𝑓 𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑏𝑙𝑒) 𝑔 = 𝑔𝑟𝑎𝑣𝑖𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛, 9.81 𝑚/𝑠 2 𝑆𝑡 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑓𝑜𝑟 𝑡𝑎𝑛𝑘 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙, 𝑁/𝑚𝑚2 𝐷𝑡 = 𝑡𝑎𝑛𝑘 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚 𝐶𝐴 = 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒

𝑇𝑡 =

1 1050 ∗ (9300 − 500) (1000) ∗ 9.81 2 ∗ 88.942369 ∗ 0.85

3100 ∗ 1000 + 3.8 = 5.658425 𝑚𝑚 103

𝑇𝑡 ≈ 6 𝑚𝑚 𝑂𝐷 = 2 ∗ 𝑇𝑡 + 𝐼𝐷 𝑂𝐷 = 2 ∗ 6 + 5800 = 3112 𝑚𝑚 For heads and closures, 2:1 ellipsoidal is the common in the chemical industry. 𝑡𝑚𝑖𝑛 =

𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 2𝑆𝐸 − 0.2𝑃𝑖

79.53𝑝𝑠𝑖𝑎 ∗ 3100𝑚𝑚 ≅ 12 𝑚𝑚 2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 79.53𝑝𝑠𝑖𝑎

236

REV 1

DATE 1/2/15

CALCULATION SHEET CREATED BY CHECKED BY EAM ALL MFS

APPROVED BY

Service: Benzene Recycle Stream OPERATING CONDITIONS 70.05 °C T 158.09 °F 1 Bar P psia 14.50777 psig -0.19223 psia 4.96E+00 true VP and Reid VP at 37.8 °C 34.23 kPaa (100°F) Atmospheric Type of Vessel vessel DESIGN CONDITIONS °C 93.33333 200 °F Bar 4.459679 64.7 psia 50 psig 0 psia -14.7 psig 15 ~ 20 °C

T P (MAWP) minimum P minimum design metal temperature

The minimum design metal temperature is based from the ambient temperature here in the country .The design conditions were acquired based on the following table. Operating T 0 to 200 degF Over 200 degF Reactors

Design T 250 degF operating + 50 degF operating + 50 degF

Operating P 0 to 25 psig 25 to 250 psig 250 to 1000 psig over 1000 psig

Design P 50 psig operating + 25 psig operating + 10% operating + 5%

LIQUID CAPACITY Capacity/Storage time

237

day

-

hr

0.5

flow rate

kg/hr

1.06E+06

Rated mass flow rate

kg/hr

1161340

Density

kg/m3

819.4

m3

708.6529

gal

187206.3

Rated Volume of liquid

use vertical tanks on concrete foundation The outage and innage of the tank is assumed to be 500 millimeters. The outage is the allowance for spillage, and the innage is the non-pumpable volume. The pump should not be placed under the innage to avoid pump cavitation. The optimum Length to diameter ratio for vessels is 3. The volume is divided in 2, since it is a liquid holdup tank. 𝜋𝐷2 708.6529 3 (3𝐷 − 0.50 − 0.5) = 𝑚 (𝑟𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒) 4 2 𝐷 = 5.431252 𝑚 ≅ 5500 𝑚𝑚 𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 5500 𝑚𝑚 = 16500 𝑚𝑚 Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the vessel, first is determine the maximum allowable stress (S) which will be based on the type of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon steel at 250℉ is 12.9ksi or 12900psi. For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic pressure can be calculated from the following equation: 𝑇𝑡 =

𝜌𝐿 𝐻𝐿 𝑔 𝐷𝑡 + 𝐶𝐴 2𝑆𝑡 𝐸 103 238

Where: 𝑇𝑡 = 𝑡𝑎𝑛𝑘 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑎𝑡 𝑎 𝑐𝑒𝑟𝑡𝑎𝑖𝑛 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚𝑚 𝐻𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚 𝜌𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦, 𝑘𝑔/𝑚3 𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (𝑖𝑓 𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑏𝑙𝑒) 𝑔 = 𝑔𝑟𝑎𝑣𝑖𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛, 9.81 𝑚/𝑠 2 𝑆𝑡 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑓𝑜𝑟 𝑡𝑎𝑛𝑘 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙, 𝑁/𝑚𝑚2 𝐷𝑡 = 𝑡𝑎𝑛𝑘 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚 𝐶𝐴 = 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒

𝑇𝑡 =

1 819.4 ∗ (5500 − 500) (1000) ∗ 9.81 2 ∗ 88.942369 ∗ 0.85

5500 ∗ 1000 + 3.8 = 8.47𝑚𝑚 103

𝑇𝑡 ≈ 9𝑚𝑚 𝑂𝐷 = 2 ∗ 𝑇𝑡 + 𝐼𝐷 𝑂𝐷 = 2 ∗ 9 + 5500 = 5518𝑚𝑚 For heads and closures, 2:1 ellipsoidal is the common in the chemical industry. 𝑡𝑚𝑖𝑛 =

𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 2𝑆𝐸 − 0.2𝑃𝑖

64.7𝑝𝑠𝑖𝑎 ∗ 5500𝑚𝑚 ≅ 17 𝑚𝑚 2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 64.7𝑝𝑠𝑖𝑎

239

REV 1

DATE 1/2/15

CALCULATION SHEET CREATED BY CHECKED BY EAM ALL MFS

APPROVED BY

Service: Condensate from Distillation Column 1 OPERATING CONDITIONS 70.05 °C T 158.09 °F 1 Bar P psia 14.50777 psig -0.19223 psia 4.96E+00 true VP and Reid VP at 37.8 °C 34.23 kPaa (100°F) Atmospheric Type of Vessel vessel DESIGN CONDITIONS T P (MAWP) minimum P minimum design metal temperature

°C 93.33333 200 °F Bar 4.459679 64.7 psia 50 psig 0 psia -14.7 psig 15 ~ 20 °C

The minimum design metal temperature is based from the ambient temperature here in the country .The design conditions were acquired based on the following table. Operating T 0 to 200 degF Over 200 degF Reactors

Design T 250 degF operating + 50 degF operating + 50 degF

Operating P 0 to 25 psig 25 to 250 psig 250 to 1000 psig over 1000 psig

LIQUID CAPACITY min Liquid holdup time hr flow rate kg/hr

240

Design P 50 psig operating + 25 psig operating + 10% operating + 5%

5 0.083333 1.43E+06

Rated mass flow rate Density Rated Volume of liquid

kg/hr kg/m3 m3 gal

1568930 819.4 159.5609 42151.51

The outage and innage of the tank is assumed to be 500 millimeters. The outage is the allowance for spillage, and the innage is the non-pumpable volume. The pump should not be placed under the innage to avoid pump cavitation. 1/3 4 𝐷 = ( ∗ 159.5609 ∗ 2) 3𝜋

𝐷 ≅ 5200 𝑚𝑚 𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 5200 𝑚𝑚 = 15600 𝑚𝑚

Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the vessel, first is determine the maximum allowable stress (S) which will be based on the type of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon steel at 250℉ is 12.9ksi or 12900psi. For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic pressure can be calculated from the following equation: 𝑇𝑡 =

𝜌𝐿 𝐻𝐿 𝑔 𝐷𝑡 + 𝐶𝐴 2𝑆𝑡 𝐸 103

Where: 𝑇𝑡 = 𝑡𝑎𝑛𝑘 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑎𝑡 𝑎 𝑐𝑒𝑟𝑡𝑎𝑖𝑛 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚𝑚 𝐻𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚 𝜌𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦, 𝑘𝑔/𝑚3

241

𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (𝑖𝑓 𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑏𝑙𝑒) 𝑔 = 𝑔𝑟𝑎𝑣𝑖𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛, 9.81 𝑚/𝑠 2 𝑆𝑡 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑓𝑜𝑟 𝑡𝑎𝑛𝑘 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙, 𝑁/𝑚𝑚2 𝐷𝑡 = 𝑡𝑎𝑛𝑘 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚 𝐶𝐴 = 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒

𝑇𝑡 =

1 819.4 ∗ (5200 − 500) (1000) ∗ 9.81 2 ∗ 88.942369 ∗ 0.85

5200 ∗ 1000 + 3.8 = 3.80𝑚𝑚 103

𝑇𝑡 ≈ 4 𝑚𝑚 𝑂𝐷 = 2 ∗ 𝑇𝑡 + 𝐼𝐷 𝑂𝐷 = 2 ∗ 4 + 5200 = 5208𝑚𝑚 For heads and closures, 2:1 ellipsoidal is the common in the chemical industry. 𝑡𝑚𝑖𝑛 =

𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 2𝑆𝐸 − 0.2𝑃𝑖

64.7𝑝𝑠𝑖𝑎 ∗ 5200𝑚𝑚 ≅ 16 𝑚𝑚 2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 64.7𝑝𝑠𝑖𝑎

242

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CALCULATION CREATED BY CHECKED BY EAM ALL MFS

APPROVED BY

SERVICE: CONDENSATE from Distillation Column 2 OPERATING CONDITIONS 91.98 °C T 197.564 °F 3.7 Bar 53.67876 P psia psig 38.97876 psia 2.15E+01 true VP and Reid VP at 37.8 °C 148 kPaa (100°F) Type of Vessel Pressure vessel

DESIGN CONDITIONS T P (MAWP) minimum P minimum design metal temperature

°C °F Bar psia psig psia psig °C

93.33333 200 5.423214 78.67876 63.97876 0 -14.7 15 ~ 20

The minimum design metal temperature is based from the ambient temperature here in the country .The design conditions were acquired based on the following table. Design Temperature and Design Pressure Operating T 0 to 200 degF Over 200 degF Reactors

Design T 250 degF operating + 50 degF operating + 50 degF

Operating P 0 to 25 psig 25 to 250 psig 250 to 1000 psig over 1000 psig

LIQUID CAPACITY min Capacity/Storage time hr 243

Design P 50 psig operating + 25 psig operating + 10% operating + 5%

5 0.083333

flow rate Rated mass flow rate Density Rated Volume of liquid

kg/hr kg/hr kg/m3 m3 gal

5.59E+03 6153.4 700.5 0.732025 193.3804

The outage and innage of the tank is assumed to be 500 millimeters. The outage is the allowance for spillage, and the innage is the non-pumpable volume. The pump should not be placed under the innage to avoid pump cavitation. 1/3 4 𝐷 = ( ∗ 0.732025 ∗ 2) 3𝜋

𝐷 ≅ 900 𝑚𝑚 𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 900 𝑚𝑚 = 2700 𝑚𝑚

Based on the Rules of thumb, the corrosion allowance for non-corrosive streams like propylene is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the vessel, first is determine the maximum allowable stress (S) which will be based on the type of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon steel at 250℉ is 12.9ksi or 12900psi. For cylindrical vessels: 𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 (1) 2𝑆𝐸 − 1.2𝑃𝑖

𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 (2) 4𝑆𝐸 + 0.8𝑃𝑖

244

Where: 𝑡𝑚𝑖𝑛 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑤𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 (𝑒𝑥𝑐𝑙𝑢𝑑𝑖𝑛𝑔 𝐶𝐴) 𝑃𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝐷𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑆 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

(1)𝑡𝑚𝑖𝑛 =

78.67876𝑝𝑠𝑖𝑎 ∗ 900 𝑚𝑚 = 3.242912 𝑚𝑚 2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 1.2 ∗ 78.67876𝑝𝑠𝑖𝑎

(2)𝑡𝑚𝑖𝑛 =

78.67876𝑝𝑠𝑖𝑎 ∗ 900𝑚𝑚 = 1.612162 𝑚𝑚 4 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 + 0.8 ∗ 78.67876𝑝𝑠𝑖𝑎

Choosing the higher value for 𝑡𝑚𝑖𝑛 , 𝑡𝑚𝑖𝑛 = 3.242912 + 3.8 ≅ 4 𝑚𝑚 𝑂𝐷 = 2 ∗ 𝑡𝑚𝑖𝑛 + 𝐼𝐷 = 2 ∗ 4 + 900 = 908𝑚𝑚 For heads and closures, 2:1 ellipsoidal is the common in the chemical industry. 𝑡𝑚𝑖𝑛 = 𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 2𝑆𝐸 − 0.2𝑃𝑖

78.67876𝑝𝑠𝑖𝑎 ∗ 900𝑚𝑚 ≅ 4𝑚𝑚 2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 78.67876𝑝𝑠𝑖𝑎

245

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CALCULATION CREATED BY CHECKED BY EAM ALL MFS

APPROVED BY

OPERATING CONDITIONS 151.9 °C T 305.42 °F 1.013 Bar P psia 14.69637 psig -0.00363 psia 2.07E-01 true VP and Reid VP at 37.8 °C 1.427 kPaa (100°F) Atmospheric Type of Vessel vessel

DESIGN CONDITIONS °C 179.6778 355.42 °F Bar 4.459679 64.7 psia 50 psig 0 psia -14.7 psig 15 ~ 20 °C

T P (MAWP) minimum P minimum design metal temperature

The minimum design metal temperature is based from the ambient temperature here in the country .The design conditions were acquired based on the following table. Operating T 0 to 200 degF Over 200 degF Reactors

Design T 250 degF operating + 50 degF operating + 50 degF

Operating P 0 to 25 psig 25 to 250 psig 250 to 1000 psig over 1000 psig

Design P 50 psig operating + 25 psig operating + 10% operating + 5%

LIQUID CAPACITY Capacity/Storage time

246

min

5

hr

0.083333

flow rate

kg/hr

6.80E+04

Rated mass flow rate

kg/hr

74822

Density

kg/m3

758.4

m3 Rated Volume of liquid

8.221475

gal

2171.884 The outage and innage of the tank is assumed to be 500 millimeters. The outage is the allowance for spillage, and the innage is the non-pumpable volume. The pump should not be placed under the innage to avoid pump cavitation. 1/3 4 𝐷 = ( ∗ 8.221475 ∗ 2) 3𝜋

𝐷 ≅ 2000 𝑚𝑚 𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 2000 𝑚𝑚 = 6000 𝑚𝑚

Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the vessel, first is determine the maximum allowable stress (S) which will be based on the type of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon steel at 250℉ is 12.9ksi or 12900psi. For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic pressure can be calculated from the following equation: 𝑇𝑡 =

𝜌𝐿 𝐻𝐿 𝑔 𝐷𝑡 + 𝐶𝐴 2𝑆𝑡 𝐸 103

Where: 𝑇𝑡 = 𝑡𝑎𝑛𝑘 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑎𝑡 𝑎 𝑐𝑒𝑟𝑡𝑎𝑖𝑛 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚𝑚

247

𝐻𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚 𝜌𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦, 𝑘𝑔/𝑚3 𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (𝑖𝑓 𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑏𝑙𝑒) 𝑔 = 𝑔𝑟𝑎𝑣𝑖𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛, 9.81 𝑚/𝑠 2 𝑆𝑡 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑓𝑜𝑟 𝑡𝑎𝑛𝑘 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙, 𝑁/𝑚𝑚2 𝐷𝑡 = 𝑡𝑎𝑛𝑘 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚 𝐶𝐴 = 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒

𝑇𝑡 =

1 758.4 ∗ (2000 − 500) (1000) ∗ 9.81 2 ∗ 88.942369 ∗ 0.85

2000 ∗ 1000 + 3.8 = 4𝑚𝑚 103

𝑇𝑡 ≈ 4 𝑚𝑚 𝑂𝐷 = 2 ∗ 𝑇𝑡 + 𝐼𝐷 𝑂𝐷 = 2 ∗ 4 + 2000 = 2008𝑚𝑚 For heads and closures, 2:1 ellipsoidal is the common in the chemical industry. 𝑡𝑚𝑖𝑛 = 𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 2𝑆𝐸 − 0.2𝑃𝑖

64.7𝑝𝑠𝑖𝑎 ∗ 2000𝑚𝑚 ≅ 6 𝑚𝑚 2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 64.7𝑝𝑠𝑖𝑎

248

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CALCULATION CREATED BY CHECKED BY EAM ALL MFS

APPROVED BY

Service: Cumene Recycle Stream OPERATING CONDITIONS 151.9 °C T 305.42 °F 1.013 Bar P psia 14.69637 psig -0.00363 psia 1.81E-01 true VP and Reid VP at 37.8 °C 1.247 kPaa (100°F) Atmospheric Type of Vessel vessel

DESIGN CONDITIONS °C 179.6778 355.42 °F Bar 4.459679 64.7 psia 50 psig 0 psia -14.7 psig 15 ~ 20 °C

T P (MAWP) minimum P minimum design metal temperature

The minimum design metal temperature is based from the ambient temperature here in the country .The design conditions were acquired based on the following table. Operating T 0 to 200 degF Over 200 degF Reactors

Design T 250 degF operating + 50 degF operating + 50 degF

Operating P 0 to 25 psig 25 to 250 psig 250 to 1000 psig over 1000 psig

Design P 50 psig operating + 25 psig operating + 10% operating + 5%

LIQUID CAPACITY Capacity/Storage time

249

day

-

hr

1

flow rate

kg/hr

1.25E+04

Rated mass flow rate

kg/hr

13750

Density

kg/m3

758.4

m3

18.13027

gal

4789.511

Rated Volume of liquid

The outage and innage of the tank is assumed to be 500 millimeters. The outage is the allowance for spillage, and the innage is the non-pumpable volume. The pump should not be placed under the innage to avoid pump cavitation. The optimum Length to diameter ratio for vessels is 3. The volume is divided in 2, since it is a liquid holdup tank. 𝜋𝐷2 18.13027 3 (3𝐷 − 0.50 − 0.5) = 𝑚 (𝑟𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒) 4 1 𝐷 = 2.091816 𝑚 ≅ 2100 𝑚𝑚 𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 2100 𝑚𝑚 = 6300 𝑚𝑚 Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the vessel, first is determine the maximum allowable stress (S) which will be based on the type of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon steel at 250℉ is 12.9ksi or 12900psi. For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic pressure can be calculated from the following equation: 𝑇𝑡 =

𝜌𝐿 𝐻𝐿 𝑔 𝐷𝑡 + 𝐶𝐴 2𝑆𝑡 𝐸 103

250

Where: 𝑇𝑡 = 𝑡𝑎𝑛𝑘 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑎𝑡 𝑎 𝑐𝑒𝑟𝑡𝑎𝑖𝑛 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚𝑚 𝐻𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚 𝜌𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦, 𝑘𝑔/𝑚3 𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (𝑖𝑓 𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑏𝑙𝑒) 𝑔 = 𝑔𝑟𝑎𝑣𝑖𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛, 9.81 𝑚/𝑠 2 𝑆𝑡 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑓𝑜𝑟 𝑡𝑎𝑛𝑘 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙, 𝑁/𝑚𝑚2 𝐷𝑡 = 𝑡𝑎𝑛𝑘 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚 𝐶𝐴 = 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒

𝑇𝑡 =

1 758.4 ∗ (6300 − 500) (1000) ∗ 9.81 2 ∗ 88.942369 ∗ 0.85

2100 ∗ 1000 + 3.8 = 5𝑚𝑚 103

𝑇𝑡 ≈ 5𝑚𝑚 𝑂𝐷 = 2 ∗ 𝑇𝑡 + 𝐼𝐷 𝑂𝐷 = 2 ∗ 5 + 2100 = 5𝑚𝑚 For heads and closures, 2:1 ellipsoidal is the common in the chemical industry. 𝑡𝑚𝑖𝑛 = 𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 2𝑆𝐸 − 0.2𝑃𝑖

64.7𝑝𝑠𝑖𝑎 ∗ 2100𝑚𝑚 ≅ 7 𝑚𝑚 2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 64.7𝑝𝑠𝑖𝑎

251

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CALCULATION SHEET CREATED BY CHECKED BY EAM ALL MFS

APPROVED BY

Service: Water OPERATING CONDITIONS °C 30 T °F 86 Bar 1 P psia 14.50777 psig -0.19223 psia 9.49E-01 true VP and Reid VP at 37.8 °C kPaa 6.545 (100°F) Atmospheric Type of Vessel vessel

DESIGN CONDITIONS T

P (MAWP)

minimum P minimum design metal temperature

°C 93.33333 °F 200 Bar 4.459679 psia 64.7 psig 50 psia 0 psig -14.7 °C 15 ~ 20

The minimum design metal temperature is based from the ambient temperature here in the country .The design conditions were acquired based on the following table. Operating T 0 to 200 degF Over 200 degF Reactors

Design T 250 degF operating + 50 degF operating + 50 degF 252

Operating P 0 to 25 psig 25 to 250 psig 250 to 1000 psig

Design P 50 psig operating + 25 psig operating + 10%

over 1000 psig LIQUID CAPACITY day Capacity/Storage time hr flow rate kg/hr Rated mass flow rate kg/hr Density kg/m3 m3 Rated Volume of liquid gal

operating + 5%

1 24 6100.649 6710.714 1000

161.0571 42546.78 use vertical tanks on concrete foundation

Assumptions: 

  



Based on the rule of thumb of Chemical Engineering Design, if the rated volume of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations is typically used. The chosen material of construction is carbon steel since water is not corrosive. ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry for storage tanks. Outage and Innage of the tank are assumed to be 500 𝑚𝑖𝑙𝑙𝑖𝑚𝑒𝑡𝑒𝑟𝑠. The outage is the allowance for spillage, and the innage is the non-pumpable volume. The pump should not be placed under the innage to avoid pump cavitation. Based on the rule of thumb for Chemical Engineering Design, Optimum length to diameter ratio for vessels is 3 (𝐿⁄𝐷 = 3). 𝜋𝐷2 161.0571 3 (3𝐷 − 0.50 − 0.5) = 𝑚 (𝑟𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒) 4 1 𝐷 = 4.2029 𝑚 ≅ 4300 𝑚𝑚 𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 4300 𝑚𝑚 = 12900 𝑚𝑚

Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the vessel, first is determine the maximum allowable stress (S) which will be based on the type of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon steel at 250℉ is 12.9ksi or 12900psi.

253

For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic pressure can be calculated from the following equation: 𝑇𝑡 =

𝜌𝐿 𝐻𝐿 𝑔 𝐷𝑡 + 𝐶𝐴 2𝑆𝑡 𝐸 103

Where: 𝑇𝑡 = 𝑡𝑎𝑛𝑘 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑎𝑡 𝑎 𝑐𝑒𝑟𝑡𝑎𝑖𝑛 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚𝑚 𝐻𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚 𝜌𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦, 𝑘𝑔/𝑚3 𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (𝑖𝑓 𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑏𝑙𝑒) 𝑔 = 𝑔𝑟𝑎𝑣𝑖𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛, 9.81 𝑚/𝑠 2 𝑆𝑡 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑓𝑜𝑟 𝑡𝑎𝑛𝑘 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙, 𝑁/𝑚𝑚2 𝐷𝑡 = 𝑡𝑎𝑛𝑘 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚 𝐶𝐴 = 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒

𝑇𝑡 =

1 1000 ∗ (12900 − 500) (1000) ∗ 9.81 2 ∗ 88.942369 ∗ 0.85

4300 ∗ 1000 + 3.8 = 7.259𝑚𝑚 103

𝑇𝑡 ≈ 8𝑚𝑚 𝑂𝐷 = 2 ∗ 𝑇𝑡 + 𝐼𝐷 𝑂𝐷 = 2 ∗ 8 + 4300 = 4316𝑚𝑚 For heads and closures, 2:1 ellipsoidal is the common in the chemical industry. 𝑡𝑚𝑖𝑛 = 𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 2𝑆𝐸 − 0.2𝑃𝑖

64.7𝑝𝑠𝑖𝑎 ∗ 4300𝑚𝑚 ≅ 13 𝑚𝑚 2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 64.7𝑝𝑠𝑖𝑎

254

REV 1

DATE 1/2/15

CALCULATION SHEET CREATED BY CHECKED BY EAM ALL MFS

APPROVED BY

Service: LPG Fuel (Propane) OPERATING CONDITIONS 30 °C T 86 °F 10.8 Bar 156.6839 P psia 141.9839 psig 188.9842 psia true VP and Reid VP at 37.8 °C 1303 kPaa (100°F) Type of Vessel Pressure vessel DESIGN CONDITIONS °C °F Bar psia psig psia psig °C

T

P (MAWP)

minimum P minimum design metal temperature

93.33333 200 12.52321 181.6839 166.9839 0 -14.7 15 ~ 20

LIQUID CAPACITY day hr m3/hr m3/hr m3 gal

Capacity/Storage time Volumetric Flow Rate Rated Volumetric Flow Rate Rated Volume of liquid

45 1080 2.71 2.981 3219.48 850496.5

use vertical tanks on concrete foundation

The minimum design metal temperature is based from the ambient temperature here in the country .The design conditions were acquired based on the following table. Operating T

Design T

Operating P 255

Design P

0 to 200 degF Over 200 degF Reactors

250 degF operating + 50 degF operating + 50 degF

0 to 25 psig 25 to 250 psig 250 to 1000 psig over 1000 psig

50 psig operating + 25 psig operating + 10% operating + 5%

Assumptions: 



 



1

The storage for the fuel will be 45 days (1 𝑎𝑛𝑑 2 𝑚𝑜𝑛𝑡ℎ𝑠), since the company plans to buy fuel only on days that the price is ideally low. The capacity of the fuel tank is enough for this to be possible. The storage tank is divided into 4. Based on the rule of thumb of Chemical Engineering Design, if the rated volume of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations is typically used. ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry for storage tanks. Outage and Innage of the tank are assumed to be 500 𝑚𝑖𝑙𝑙𝑖𝑚𝑒𝑡𝑒𝑟𝑠. The outage is the allowance for spillage, and the innage is the non-pumpable volume. The pump should not be placed under the innage to avoid pump cavitation. Based on the rule of thumb for Chemical Engineering Design, Optimum length to diameter ratio for vessels is 3 (𝐿⁄𝐷 = 3). 𝜋𝐷 2 3219.48 3 (3𝐷 − 0.50 − 0.5) = 𝑚 (𝑟𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒) 4 4 𝐷 = 7.103344𝑚 ≅ 7200 𝑚𝑚 𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 7200 𝑚𝑚 = 21600 𝑚𝑚

Based on the Rules of thumb, the corrosion allowance for non-corrosive streams like propylene is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the vessel, first is determine the maximum allowable stress (S) which will be based on the type of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon steel at 250℉ is 12.9ksi or 12900psi. For cylindrical vessels: 𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 (1) 2𝑆𝐸 − 1.2𝑃𝑖

𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 (2) 4𝑆𝐸 + 0.8𝑃𝑖 256

Where: 𝑡𝑚𝑖𝑛 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑤𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 (𝑒𝑥𝑐𝑙𝑢𝑑𝑖𝑛𝑔 𝐶𝐴) 𝑃𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝐷𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑆 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (1)𝑡𝑚𝑖𝑛 =

181.68 𝑝𝑠𝑖𝑎 ∗ 7200 𝑚𝑚 = 60.24897 𝑚𝑚 2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 1.2 ∗ 64.7𝑝𝑠𝑖𝑎

(2)𝑡𝑚𝑖𝑛 =

181.68 𝑝𝑠𝑖𝑎 ∗ 7200 𝑚𝑚 = 29.72649 𝑚𝑚 4 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 + 0.8 ∗ 64.7 𝑝𝑠𝑖𝑎

Choosing the higher value for 𝑡𝑚𝑖𝑛 , 𝑡𝑚𝑖𝑛 = 60.24897 + 3.8 ≅ 65 𝑚𝑚 𝑂𝐷 = 2 ∗ 𝑡𝑚𝑖𝑛 + 𝐼𝐷 = 2 ∗ 65 + 2900 = 7330𝑚𝑚 For heads and closures, 2:1 ellipsoidal is the common in the chemical industry. 𝑡𝑚𝑖𝑛 = 𝑡𝑚𝑖𝑛 =

𝑃𝑖 𝐷𝑖 2𝑆𝐸 − 0.2𝑃𝑖

181.68 𝑝𝑠𝑖𝑎 ∗ 7200𝑚𝑚 ≅ 65 𝑚𝑚 2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 64.7 𝑝𝑠𝑖𝑎

257

Appendix C REACTORS CALCULATION SHEETS

REV 1

DATE 1/2/15

CALCULATION CREATED BY CHECKED BY EAM ALL MFS

LEGEND: 𝐴𝑐 = 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑢𝑏𝑒, 𝑚2 𝑑𝑡 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑢𝑏𝑒, 𝑚 𝑑𝑝 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚 𝜌𝑝 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑘𝑔⁄𝑚3 𝑉𝐵𝑒𝑑 = 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑏𝑒𝑑, 𝑚3 𝜀 = 𝑉𝑜𝑖𝑑 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑚̇ = 𝐼𝑛𝑙𝑒𝑡 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑡𝑜 𝑡ℎ𝑒 𝑟𝑒𝑎𝑐𝑡𝑜𝑟, 𝑘𝑔/𝑠 𝐺 = 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡 𝑎𝑟𝑒𝑎, 𝑘𝑔/𝑚2 𝑠 ℎ = ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑠𝑝ℎ𝑒𝑟𝑖𝑐𝑎𝑙 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑊/𝑚2 𝐾 𝑑𝑠 = 𝑆ℎ𝑒𝑙𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚 𝐴𝑠 = 𝐶𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑠ℎ𝑒𝑙𝑙 𝑠𝑖𝑑𝑒, 𝑚2 𝑚̇𝑤 = 𝑤𝑎𝑡𝑒𝑟 𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑒, 𝑘𝑔/ℎ 𝑄 = 𝐻𝑒𝑎𝑡 𝑒𝑣𝑜𝑙𝑣𝑒𝑑 𝑓𝑟𝑜𝑚 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛, 𝐾𝑊 ∆𝑇 = 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟, ℃ DATA FROM ASPEN HYSYS Total Volume (m3) 113.3 Number of tubes 1000 Length (m) 10 Diameter of tube (m) 0.1201 Void Fraction 0.7 Void Volume (m3) 79.3 Ac (m2) 0.011328591

CATALYST BED SPECIFICATIONS Volume of Catalyst bed (m3) 34 700 𝜌𝑃 (𝑘𝑔⁄𝑚 3 ) dp (m) 0.003 Mass of catalyst (kg) 7140 HEAT TRANSFER CALCULATIONS IN THE REACTOR Mass flow (kg/s) 297.6710076 258

APPROVED BY

G (kg/m2s) h (W/m2K) Square Pitch Size (mm) Minimum Area Required (m2) Baffle Spacing Shell Diameter Required (m) Baffle Spacing (m) As (m2) Heat Evolved in the reaction (kW)

28903.69239 636025.5239 100

∆𝑇 (℃)

27.28

Water circulation rate (kg/h)

66676.29231

10 1/5 of dt 3.908820095 0.781764019 0.305577491 2114

TUBE SPECIFICATIONS Material Carbon Steel 4.728346457 TUBE I.D. (in) 4.813 TUBE O.D. (in) 5.563 Nominal Pipe Size (in) 5 Schedule No. 80XS, 80S Wall Thickness (in) 0.375 Cross Sectional Area (in2) 6.11

𝝅 𝟐 𝒅 𝟒 𝒕 𝜋 𝐴𝑐 = ∗ (0.1201𝑚)2 = 0.011328591 𝑚2 4 𝑨𝒄 =

𝑽𝒐𝒍𝒖𝒎𝒆 𝒐𝒇 𝒄𝒂𝒕𝒂𝒍𝒚𝒔𝒕 𝒃𝒆𝒅 = 𝑻𝒐𝒕𝒂𝒍 𝒗𝒐𝒍𝒖𝒎𝒆 − 𝑽𝒐𝒊𝒅 𝒗𝒐𝒍𝒖𝒎𝒆 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑏𝑒𝑑 = 113.3 − 79.3 = 34𝑚3 𝑴𝒂𝒔𝒔 𝒐𝒇 𝒄𝒂𝒕𝒂𝒍𝒚𝒔𝒕 = (𝟏 − 𝜺)𝝆𝒑 𝑽𝑩𝒆𝒅 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = (1 − 0.7)(700)(34) = 7140 𝑘𝑔 𝑮=

𝟏. 𝟏 ∗ 𝒎̇ 1.1 ∗ 297.6710076 𝑘𝑔/𝑠 𝑘𝑔 = = 28903.69239 2 2 𝑨𝒄 0.011328591 𝑚 𝑚 𝑠

259

𝟏𝟓. 𝟏𝑮𝟎.𝟗𝟓 15.1 ∗ 28903.692390.95 𝑊 𝒉= = = 636025.5239 2 𝟎.𝟒𝟐 0.42 0.1201 𝑚 𝐾 𝒅𝒕 (1) 𝐴𝑆𝑆𝑈𝑀𝑃𝑇𝐼𝑂𝑁𝑆: 𝑆𝑞𝑢𝑎𝑟𝑒 𝑝𝑖𝑡𝑐ℎ 𝑠𝑖𝑧𝑒 = 100 𝑚𝑚 𝑴𝒊𝒏𝒊𝒎𝒖𝒎 𝑨𝒓𝒆𝒂 𝑹𝒆𝒒𝒖𝒊𝒓𝒆𝒅 = (𝒕𝒖𝒃𝒆 𝒑𝒊𝒕𝒄𝒉)𝟐 (# 𝒐𝒇 𝒕𝒖𝒃𝒆𝒔) 100 2 𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝐴𝑟𝑒𝑎 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = ( ) (1000) = 10 𝑚2 1000 𝒎𝒊𝒏𝒊𝒎𝒖𝒎 𝒂𝒓𝒆𝒂 𝒓𝒆𝒒𝒖𝒊𝒓𝒆𝒅 (𝟏 + 𝟎. 𝟐) 𝟎.𝟓 𝒅𝒔 = ( ) 𝝅⁄𝟒 10 (1 + 0.2) 0.5 𝑑𝑠 = ( ) = 3.908820095 𝑚 𝜋 ⁄4 𝑩𝒂𝒇𝒇𝒍𝒆 𝑺𝒑𝒂𝒄𝒊𝒏𝒈 =

𝟏 1 𝒅𝒔 = ∗ 3.908820095 = 0.781764019 𝑚 𝟓 5

𝒅𝒔 ∗ 𝑩𝒂𝒇𝒇𝒍𝒆 𝒔𝒑𝒂𝒄𝒊𝒏𝒈 ∗ 𝟎. 𝟎𝟏 𝟎. 𝟏 3.908820095 ∗ 0.781764019 𝐴𝑠 = ∗ 0.01 = 0.305577491 𝑚2 0.1 𝑨𝒔 =

𝒎̇𝒘 =

𝑸 2114 𝐾𝐽/𝑠 3600𝑠 = ∗ = 66676.29231 𝑘𝑔⁄ℎ 𝑪𝒑𝒘 ∆𝑻 4.184 𝐾𝐽 ∗ 27.28℃ ℎ 𝑘𝑔 ∙ 𝐾

260

REV 1

DATE 1/2/15

CALCULATION CREATED BY CHECKED BY MFS ALL EAM

LEGEND: 𝐴𝑐 = 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑢𝑏𝑒, 𝑚2 𝑑𝑡 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑢𝑏𝑒, 𝑚 𝑑𝑝 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚 𝜌𝑝 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑘𝑔⁄𝑚3 𝑉𝐵𝑒𝑑 = 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑏𝑒𝑑, 𝑚3 𝜀 = 𝑉𝑜𝑖𝑑 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑚̇ = 𝐼𝑛𝑙𝑒𝑡 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑡𝑜 𝑡ℎ𝑒 𝑟𝑒𝑎𝑐𝑡𝑜𝑟, 𝑘𝑔/𝑠 𝐺 = 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡 𝑎𝑟𝑒𝑎, 𝑘𝑔/𝑚2 𝑠 ℎ = ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑠𝑝ℎ𝑒𝑟𝑖𝑐𝑎𝑙 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑊/𝑚2 𝐾 𝑑𝑠 = 𝑆ℎ𝑒𝑙𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚 𝐴𝑠 = 𝐶𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑠ℎ𝑒𝑙𝑙 𝑠𝑖𝑑𝑒, 𝑚2 𝑚̇𝑤 = 𝑤𝑎𝑡𝑒𝑟 𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑒, 𝑘𝑔/ℎ 𝑄 = 𝐻𝑒𝑎𝑡 𝑒𝑣𝑜𝑙𝑣𝑒𝑑 𝑓𝑟𝑜𝑚 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛, 𝐾𝑊 ∆𝑇 = 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟, ℃ DATA FROM ASPEN HYSYS Total Volume (m3) 25.02 Number of tubes 100 Length (m) 10 Diameter of tube (m) 0.1785 Void Fraction 0.7 Void Volume (m3) 17.51 0.025024553 Ac (m2) CATALYST BED SPECIFICATIONS Volume of Catalyst bed 7.51 (m3) 0.00118 𝜌𝑃 (𝑘𝑔⁄𝑚 3 ) dp (m) 0.00002 0.00265854 Mass of catalyst (kg) HEAT TRANSFER CALCULATIONS IN THE REACTOR 5.957000989 Mass flow (kg/s) 261.8508784 G (kg/m2s) 6172.20338 h (W/m2K) Square Pitch Size (mm) 100 Minimum Area Required 1 (m2) 261

APPROVED BY

Baffle Spacing Shell Diameter Required (m) Baffle Spacing (m) As (m2) Heat Evolved in the reaction (kW)

1/5 of dt 1.236077446 0.247215489 0.305577491 5154

∆𝑇 (℃)

27.28

Water circulation rate (kg/h)

162558.9454

TUBE SPECIFICATIONS Material Carbon Steel 7.027559055 TUBE I.D. (in) 7.187 TUBE O.D. (in) 8.625 Nominal Pipe Size (in) 8 Schedule No. 120 Wall Thickness (in) 0.719 Cross Sectional Area (in2) 17.86

𝝅 𝟐 𝒅 𝟒 𝒕 𝜋 𝐴𝑐 = ∗ (0.1785𝑚)2 = 0.025024553 𝑚2 4 𝑨𝒄 =

𝑽𝒐𝒍𝒖𝒎𝒆 𝒐𝒇 𝒄𝒂𝒕𝒂𝒍𝒚𝒔𝒕 𝒃𝒆𝒅 = 𝑻𝒐𝒕𝒂𝒍 𝒗𝒐𝒍𝒖𝒎𝒆 − 𝑽𝒐𝒊𝒅 𝒗𝒐𝒍𝒖𝒎𝒆 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑏𝑒𝑑 = 25.02 − 17.51 = 7.51 𝑚3 𝑴𝒂𝒔𝒔 𝒐𝒇 𝒄𝒂𝒕𝒂𝒍𝒚𝒔𝒕 = (𝟏 − 𝜺)𝝆𝒑 𝑽𝑩𝒆𝒅 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = (1 − 0.7)(7.51)(0.00118) = 2.65854 𝑘𝑔 𝑮=

𝟏. 𝟏 ∗ 𝒎̇ 1.1 ∗ 5.957000989 𝑘𝑔/𝑠 𝑘𝑔 = = 261.85087 𝑨𝒄 0.025024553 𝑚2 𝑚2 𝑠

𝒉=

𝟏𝟓. 𝟏𝑮𝟎.𝟗𝟓 15.1 ∗ 28903.692390.95 𝑊 = = 6172.203192 2 𝟎.𝟒𝟐 0.42 0.1201 𝑚 𝐾 𝒅𝒕 262

(1) 𝐴𝑆𝑆𝑈𝑀𝑃𝑇𝐼𝑂𝑁𝑆: 𝑆𝑞𝑢𝑎𝑟𝑒 𝑝𝑖𝑡𝑐ℎ 𝑠𝑖𝑧𝑒 = 100 𝑚𝑚 𝑴𝒊𝒏𝒊𝒎𝒖𝒎 𝑨𝒓𝒆𝒂 𝑹𝒆𝒒𝒖𝒊𝒓𝒆𝒅 = (𝒕𝒖𝒃𝒆 𝒑𝒊𝒕𝒄𝒉)𝟐 (# 𝒐𝒇 𝒕𝒖𝒃𝒆𝒔) 100 2 𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝐴𝑟𝑒𝑎 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = ( ) (100) = 1 𝑚2 1000 𝒎𝒊𝒏𝒊𝒎𝒖𝒎 𝒂𝒓𝒆𝒂 𝒓𝒆𝒒𝒖𝒊𝒓𝒆𝒅 (𝟏 + 𝟎. 𝟐) 𝟎.𝟓 𝒅𝒔 = ( ) 𝝅⁄𝟒 1 (1 + 0.2) 0.5 𝑑𝑠 = ( ) = 1.236077446 𝑚 𝜋 ⁄4 𝑩𝒂𝒇𝒇𝒍𝒆 𝑺𝒑𝒂𝒄𝒊𝒏𝒈 =

𝟏 1 𝒅𝒔 = ∗ 1.236077446 = 0.2472154892 𝑚 𝟓 5

𝒅𝒔 ∗ 𝑩𝒂𝒇𝒇𝒍𝒆 𝒔𝒑𝒂𝒄𝒊𝒏𝒈 ∗ 𝟎. 𝟎𝟏 𝟎. 𝟏 1.236077446 ∗ 0.247215489 𝐴𝑠 = ∗ 0.01 = 0.03055774903 𝑚2 0.1 𝑨𝒔 =

𝒎̇𝒘 =

𝑸 2114 𝐾𝐽/𝑠 3600𝑠 = ∗ = 162558.9454 𝑘𝑔⁄ℎ 𝐾𝐽 𝑪𝒑𝒘 ∆𝑻 4.184 ℎ ∗ 27.28℃ 𝑘𝑔 ∙ 𝐾

263

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CALCULATION CREATED BY CHECKED BY EAM ALL MFS

Legend: 𝜏 = 𝑟𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 𝑡𝑖𝑚𝑒, ℎ 𝑉𝑜 = 𝑖𝑛𝑙𝑒𝑡 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒, 𝑚3 ⁄ℎ 𝑉 = 𝑇𝑜𝑡𝑎𝑙 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝑉𝑜𝑙𝑢𝑚𝑒, 𝑚3 𝐷 = 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚 𝐿 = 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝐿𝑒𝑛𝑔𝑡ℎ, 𝑚 𝑢𝑜 = 𝑠𝑢𝑝𝑒𝑟𝑓𝑖𝑐𝑖𝑎𝑙 𝑔𝑎𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑚/𝑠 𝜌𝑝 = 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡, 𝑘𝑔⁄𝑚3 𝑑𝑝 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚 𝐴𝑐 = 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚2 𝜀 = 𝑉𝑜𝑖𝑑 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑏𝑒𝑑 𝜇𝑔 = 𝑣𝑖𝑠𝑐𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑔𝑎𝑠, 𝑃𝑎 ∙ 𝑠 𝑜𝑟 𝑘𝑔⁄(𝑚 ∙ 𝑠) 𝜌𝑔 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑔𝑎𝑠, 𝑘𝑔⁄𝑚3 ∆𝑃 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 𝑎𝑐𝑟𝑜𝑠𝑠 𝑡ℎ𝑒 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑏𝑒𝑑, 𝑃𝑎 𝑢𝑚𝑓 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑏𝑒𝑑, 𝑚/𝑠 𝑢𝑓 = 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑚/𝑠 𝑢𝑡 = 𝑇𝑒𝑟𝑚𝑖𝑛𝑎𝑙 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑓𝑜𝑟 𝑠𝑝ℎ𝑒𝑟𝑖𝑐𝑎𝑙 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒𝑠, 𝑚/𝑠 𝜀𝑚𝑓 = 𝑃𝑜𝑟𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝑢𝑏 = 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑏𝑢𝑏𝑏𝑙𝑒 𝑟𝑖𝑠𝑒, 𝑚/𝑠 𝑑𝑏𝑚 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑏𝑢𝑏𝑏𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑐𝑚 𝑑𝑏𝑜 = 𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑢𝑏𝑏𝑙𝑒, 𝑐𝑚 𝛿 = 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑏𝑒𝑑 𝑜𝑐𝑐𝑢𝑝𝑖𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑏𝑢𝑏𝑏𝑙𝑒𝑠

264

APPROVED BY

REACTOR VESSEL Residence time (h) 𝑉𝑜 (𝑚

3⁄

ℎ)

V (m3) D (m) Reactor L (m) u (m/s) Height of Fluid (m)

4 25.278 101.112 4 12 0.000558766 9

CATALYST INFORMATION 𝜌𝑃 (𝑘𝑔⁄𝑚 3 )

790

diameter (m) Ac (cm2)

1.40E-07 1.54E-10

DESIGN OF THE BED 𝜀

0.8

Bed Height (m)

0.1

Bed Volume (m3)

1.256637061

𝜇𝑔 (𝑃𝑎. 𝑠)

2.15E-05

𝜌𝑔 (𝑘𝑔/𝑚 3 )

1.597

∆𝑃 (Pa)

154.6318456

Mass of Catalyst (Kg) 𝑢𝑚𝑓 (𝑚⁄𝑠 )

198.5486557 4.33E-08

𝑢𝑓 (𝑚⁄𝑠 )

1.20404E-07

𝑢𝑡 (𝑚⁄𝑠 )

3.92E-07

STATUS

PASSED

BUBBLE VELOCITY AND CLOUD SIZE 𝜀𝑚𝑓

0.490948231

𝑢𝑏 (m/s)

0.001390645

𝑑𝑏𝑚 (𝑐𝑚)

2.44E-05

Type of plate 𝑑𝑏0 (𝑐𝑚)

Porous 1.17376E-05

𝛿

0.401772564

𝑽 = 𝝉𝑽𝒐 𝑉 = 4 ∗ 25.278 = 101.112 𝑚3 265

𝑫=(

𝟏/𝟑 1/3 𝟒 4 𝑽) = ( ∗ 101.112) = 4 𝑚 𝟑𝝅 3𝜋

𝑳 = 𝟑𝑫 = 3 ∗ 4 = 12 𝑚 𝑽𝒐 25.278/3600 𝒖𝒐 = 𝝅 = = 0.000558766 𝑚/𝑠 𝜋 2 𝟐 ∗ 4 𝑫 4 𝟒 𝑨𝒄 =

𝝅 𝟐 𝜋 𝒅 = (1.40𝑒 − 7)2 = 1.54𝑒 − 10 𝟒 𝒑 4

ASSUMPTION: Bed height is 0.1m 𝝅 𝑩𝒆𝒅 𝒗𝒐𝒍𝒖𝒎𝒆 = ∗ 𝑫𝟐 ∗ 𝑩𝒆𝒅 𝒉𝒆𝒊𝒈𝒉𝒕 𝟒 𝜋 𝐵𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 = ∗ 42 ∗ 0.1 = 1.256637061 𝑚3 4 ∆𝑷 = 𝒃𝒆𝒅 𝒉𝒆𝒊𝒈𝒉𝒕 ∗ (𝝆𝒑 − 𝝆𝒇 ) ∗ (𝟏 − 𝜺) ∗ 𝒈 ∆𝑃 = 0.1 ∗ (790 − 1.597) ∗ (1 − 0.8) ∗ 9.80665 = 154.6318456 𝑃𝑎 𝑴𝒂𝒔𝒔 𝒐𝒇 𝒄𝒂𝒕𝒂𝒍𝒚𝒔𝒕 = (𝟏 − 𝜺) ∗ 𝝆𝒑 ∗ 𝑩𝒆𝒅 𝒗𝒐𝒍𝒖𝒎𝒆 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = (1 − 0.8) ∗ 790 ∗ 1.256637061 = 198.5486557 𝑘𝑔 (𝝋𝒅𝒑 )𝟐 𝜺𝟑 [𝒈(𝝆𝒑 − 𝝆𝒇 )] 𝟏𝟓𝟎𝝁 𝟏−𝜺 2 (0.6 ∗ 1.40𝑒 − 7) 0.83 [9.80665(790 − 1.597)] = = 4.33𝑒 − 8 𝑚/𝑠 150 ∗ 2.15𝑒 − 5 1 − 0.8

𝒖𝒎𝒇 = 𝑢𝑚𝑓

(𝝆𝒑 − 𝝆𝒇 )𝒈𝒅𝟐𝒑 𝜺𝟑 𝟏𝟓𝟎𝝁 𝟏−𝜺 (790 − 1.597) ∗ 9.80665 ∗ (1.40𝑒 − 7)2 0.83 𝑢𝑓 = = 1.20404𝑒 − 7 𝑚/𝑠 150 ∗ 2.15𝑒 − 5 1 − 0.8 𝒖𝒇 =

𝒈(𝝆𝒑 − 𝝆𝒇 )𝒅𝟐𝒑 𝟏𝟖𝝁 9.80665(790 − 1.597)(1.40𝑒 − 7)2 𝑢𝑡 = = 3.92𝑒 − 7 𝑚/𝑠 18 ∗ 2.15𝑒 − 5 𝒖𝒕 =

∴ 𝑺𝒊𝒏𝒄𝒆 𝒖𝒎𝒇 < 𝒖𝒇 < 𝒖𝒕 , 𝒔𝒂𝒕𝒊𝒔𝒇𝒚𝒂𝒃𝒍𝒆 𝒇𝒐𝒓 𝒑𝒓𝒐𝒑𝒆𝒓 𝒃𝒆𝒅 𝒐𝒑𝒆𝒓𝒂𝒕𝒊𝒐𝒏

266

𝟎. 𝟎𝟕𝟏 𝟏/𝟑 ) 𝛙 The typical ψ is 0.6 0.071 1/3 𝜀𝑚𝑓 = ( ) = 0.490948231 0.6 𝜺𝒎𝒇 = (

𝒖𝒃 = 𝒖𝒐 −𝒖𝒎𝒇 + (𝟎. 𝟕𝟏)(𝒈 𝒅𝒃 )𝟏/𝟐 𝑢𝑏 = 0.000558766 − (4.33𝑒 − 8) + (0.71)(9.80665 ∗ (1.40𝑒 − = 0.001390645 𝑚/𝑠

1 7))2

𝒅𝒃𝒎 = 𝟎. 𝟔𝟓𝟐[𝑨𝒄 (𝒖𝒐 − 𝒖𝒎𝒇 )]𝟎.𝟒 𝑑𝑏𝑚 = 0.652[(1.54𝑒 − 10)(0.000558766 − (4.33𝐸 − 08)) ∗ 100]0.4 = 2.44𝑒 − 05 𝑐𝑚 𝒅𝒃𝒐 = 𝟎. 𝟎𝟎𝟑𝟕𝟔(𝒖𝒐 − 𝒖𝒎𝒇 )𝟐 𝑑𝑏𝑜 = 0.00376((0.000558766 − (4.33𝐸 − 08)) ∗ 100)2 𝜹=

𝒖𝒐 − 𝒖𝒎𝒇 𝒖𝒃 𝛿=

0.000558766 − (4.33𝑒 − 08) = 0.401772564 0.001390645

267

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DATE 1/2/15

CALCULATION CREATED BY CHECKED BY EAM ALL MFS

Legend: 𝜏 = 𝑟𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 𝑡𝑖𝑚𝑒, ℎ 𝑉𝑜 = 𝑖𝑛𝑙𝑒𝑡 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒, 𝑚3 ⁄ℎ 𝑉 = 𝑇𝑜𝑡𝑎𝑙 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝑉𝑜𝑙𝑢𝑚𝑒, 𝑚3 𝐷 = 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚 𝐿 = 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝐿𝑒𝑛𝑔𝑡ℎ, 𝑚 𝑢𝑜 = 𝑠𝑢𝑝𝑒𝑟𝑓𝑖𝑐𝑖𝑎𝑙 𝑔𝑎𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑚/𝑠 𝜌𝑝 = 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡, 𝑘𝑔⁄𝑚3 𝑑𝑝 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚 𝐴𝑐 = 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚2 𝜀 = 𝑉𝑜𝑖𝑑 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑏𝑒𝑑 𝜇𝑔 = 𝑣𝑖𝑠𝑐𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑔𝑎𝑠, 𝑃𝑎 ∙ 𝑠 𝑜𝑟 𝑘𝑔⁄(𝑚 ∙ 𝑠) 𝜌𝑔 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑔𝑎𝑠, 𝑘𝑔⁄𝑚3 ∆𝑃 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 𝑎𝑐𝑟𝑜𝑠𝑠 𝑡ℎ𝑒 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑏𝑒𝑑, 𝑃𝑎 𝑢𝑚𝑓 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑏𝑒𝑑, 𝑚/𝑠 𝑢𝑓 = 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑚/𝑠 𝑢𝑡 = 𝑇𝑒𝑟𝑚𝑖𝑛𝑎𝑙 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑓𝑜𝑟 𝑠𝑝ℎ𝑒𝑟𝑖𝑐𝑎𝑙 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒𝑠, 𝑚/𝑠 𝜀𝑚𝑓 = 𝑃𝑜𝑟𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝑢𝑏 = 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑏𝑢𝑏𝑏𝑙𝑒 𝑟𝑖𝑠𝑒, 𝑚/𝑠 𝑑𝑏𝑚 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑏𝑢𝑏𝑏𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑐𝑚 𝑑𝑏𝑜 = 𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑢𝑏𝑏𝑙𝑒, 𝑐𝑚 𝛿 = 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑏𝑒𝑑 𝑜𝑐𝑐𝑢𝑝𝑖𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑏𝑢𝑏𝑏𝑙𝑒𝑠

268

APPROVED BY

REACTOR VESSEL Residence time (h) 𝑉𝑜 (𝑚

3⁄

ℎ)

V (m3) D (m) Reactor L (m) u (m/s) Height of Fluid (m)

4 24.54308240 98.17203297 4 12 0.00054252 8

CATALYST INFORMATION 𝜌𝑃 (𝑘𝑔⁄𝑚 3 )

790

diameter (m) Ac (cm2)

1.40E-07 1.54E-10

DESIGN OF THE BED 𝜀

0.8

Bed Height (m)

0.1

Bed Volume (m3)

1.256637061

𝜇𝑔 (𝑃𝑎. 𝑠)

2.15E-05

𝜌𝑔 (𝑘𝑔/𝑚 3 )

1.597

∆𝑃 (Pa)

154.6318456

Mass of Catalyst (Kg) 𝑢𝑚𝑓 (𝑚⁄𝑠 )

198.5486557 4.33E-08

𝑢𝑓 (𝑚⁄𝑠 )

1.20404E-07

𝑢𝑡 (𝑚⁄𝑠 )

3.92E-07

STATUS

PASSED

BUBBLE VELOCITY AND CLOUD SIZE 𝜀𝑚𝑓

0.490948231

𝑢𝑏 (m/s)

0.001374398

𝑑𝑏𝑚 (𝑐𝑚)

2.42E-05

Type of plate 𝑑𝑏0 (𝑐𝑚)

Porous 1.10649E-05

𝛿

0.394700865

𝑽 = 𝝉𝑽𝒐 269

𝑉 = 4 ∗ 24.54300824 = 98.17203296 𝑚3 𝟏/𝟑 1/3 𝟒 4 𝑫 = ( 𝑽) = ( ∗ 98.17203297) = 4 𝑚 𝟑𝝅 3𝜋

𝑳 = 𝟑𝑫 = 3 ∗ 4 = 12 𝑚 𝑽𝒐 24.54300824/3600 𝒖𝒐 = 𝝅 = = 0.0005425195944 𝑚/𝑠 𝜋 2 𝟐 ∗ 4 𝑫 4 𝟒 𝑨𝒄 =

𝝅 𝟐 𝜋 𝒅 = (1.40𝑒 − 7)2 = 1.54𝑒 − 10 𝟒 𝒑 4

ASSUMPTION: Bed height is 0.1m 𝝅 𝑩𝒆𝒅 𝒗𝒐𝒍𝒖𝒎𝒆 = ∗ 𝑫𝟐 ∗ 𝑩𝒆𝒅 𝒉𝒆𝒊𝒈𝒉𝒕 𝟒 𝜋 𝐵𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 = ∗ 42 ∗ 0.1 = 1.256637061 𝑚3 4 ∆𝑷 = 𝒃𝒆𝒅 𝒉𝒆𝒊𝒈𝒉𝒕 ∗ (𝝆𝒑 − 𝝆𝒇 ) ∗ (𝟏 − 𝜺) ∗ 𝒈 ∆𝑃 = 0.1 ∗ (790 − 1.597) ∗ (1 − 0.8) ∗ 9.80665 = 154.6318456 𝑃𝑎 𝑴𝒂𝒔𝒔 𝒐𝒇 𝒄𝒂𝒕𝒂𝒍𝒚𝒔𝒕 = (𝟏 − 𝜺) ∗ 𝝆𝒑 ∗ 𝑩𝒆𝒅 𝒗𝒐𝒍𝒖𝒎𝒆 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = (1 − 0.8) ∗ 790 ∗ 1.256637061 = 198.5486557 𝑘𝑔 𝒖𝒎𝒇 𝑢𝑚𝑓

(𝝋𝒅𝒑 )𝟐 𝜺𝟑 = [𝒈(𝝆𝒑 − 𝝆𝒇 )] 𝟏𝟓𝟎𝝁 𝟏−𝜺 (0.6 ∗ 1.40𝑒 − 7)2 0.83 [ ( )] = 9.80665 790 − 1.597 = 4.33𝑒 − 8 𝑚/𝑠 150 ∗ 2.15𝑒 − 5 1 − 0.8

(𝝆𝒑 − 𝝆𝒇 )𝒈𝒅𝟐𝒑 𝜺𝟑 𝒖𝒇 = 𝟏𝟓𝟎𝝁 𝟏−𝜺 (790 − 1.597) ∗ 9.80665 ∗ (1.40𝑒 − 7)2 0.83 𝑢𝑓 = = 1.20404𝑒 − 7 𝑚/𝑠 150 ∗ 2.15𝑒 − 5 1 − 0.8 𝒈(𝝆𝒑 − 𝝆𝒇 )𝒅𝟐𝒑 𝒖𝒕 = 𝟏𝟖𝝁 9.80665(790 − 1.597)(1.40𝑒 − 7)2 𝑢𝑡 = = 3.92𝑒 − 7 𝑚/𝑠 18 ∗ 2.15𝑒 − 5 ∴ 𝑺𝒊𝒏𝒄𝒆 𝒖𝒎𝒇 < 𝒖𝒇 < 𝒖𝒕 , 𝒔𝒂𝒕𝒊𝒔𝒇𝒚𝒂𝒃𝒍𝒆 𝒇𝒐𝒓 𝒑𝒓𝒐𝒑𝒆𝒓 𝒃𝒆𝒅 𝒐𝒑𝒆𝒓𝒂𝒕𝒊𝒐𝒏 270

𝟎. 𝟎𝟕𝟏 𝟏/𝟑 ) 𝛙 The typical ψ is 0.6 0.071 1/3 𝜀𝑚𝑓 = ( ) = 0.490948231 0.6 𝜺𝒎𝒇 = (

𝒖𝒃 = 𝒖𝒐 −𝒖𝒎𝒇 + (𝟎. 𝟕𝟏)(𝒈 𝒅𝒃 )𝟏/𝟐 𝑢𝑏 = 0.000542519594 − (4.33𝑒 − 8) + (0.71)(9.80665 ∗ (1.40𝑒 − = 0.001374398 𝑚/𝑠

1 7))2

𝒅𝒃𝒎 = 𝟎. 𝟔𝟓𝟐[𝑨𝒄 (𝒖𝒐 − 𝒖𝒎𝒇 )]𝟎.𝟒 𝑑𝑏𝑚 = 0.652[(1.54𝑒 − 10)(0.000542519594 − (4.33𝐸 − 08)) ∗ 100]0.4 = 2.42𝑒 − 05 𝑐𝑚 𝒅𝒃𝒐 = 𝟎. 𝟎𝟎𝟑𝟕𝟔(𝒖𝒐 − 𝒖𝒎𝒇 )𝟐 𝑑𝑏𝑜 = 0.00376((0.000542519594 − (4.33𝐸 − 08)) ∗ 100)2 = 1.106494791𝑒 − 09 𝑐𝑚 𝜹=

𝒖𝒐 − 𝒖𝒎𝒇 𝒖𝒃 𝛿=

0.000542519594 − (4.33𝑒 − 08) = 0.3947010211 0.001374398

271

REV 1

CALCULATION CREATED BY CHECKED BY EAM ALL MFS

DATE 1/2/15

Legend: 𝜏 = 𝑟𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 𝑡𝑖𝑚𝑒, ℎ 𝑉𝑜 = 𝑖𝑛𝑙𝑒𝑡 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒, 𝑚3 ⁄ℎ 𝑉 = 𝑇𝑜𝑡𝑎𝑙 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝑉𝑜𝑙𝑢𝑚𝑒, 𝑚3 𝐷 = 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚 𝐿 = 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝐿𝑒𝑛𝑔𝑡ℎ, 𝑚 𝑢𝑜 = 𝑠𝑢𝑝𝑒𝑟𝑓𝑖𝑐𝑖𝑎𝑙 𝑔𝑎𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑚/𝑠 𝜌𝑝 = 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡, 𝑘𝑔⁄𝑚3 𝑑𝑝 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚 𝐴𝑐 = 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚2 𝜀 = 𝑉𝑜𝑖𝑑 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑏𝑒𝑑 𝜇𝑔 = 𝑣𝑖𝑠𝑐𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑔𝑎𝑠, 𝑃𝑎 ∙ 𝑠 𝑜𝑟 𝑘𝑔⁄(𝑚 ∙ 𝑠) 𝜌𝑔 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑔𝑎𝑠, 𝑘𝑔⁄𝑚3 ∆𝑃 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 𝑎𝑐𝑟𝑜𝑠𝑠 𝑡ℎ𝑒 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑏𝑒𝑑, 𝑃𝑎 𝑢𝑚𝑓 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑏𝑒𝑑, 𝑚/𝑠 𝑢𝑓 = 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑚/𝑠 𝑢𝑡 = 𝑇𝑒𝑟𝑚𝑖𝑛𝑎𝑙 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑓𝑜𝑟 𝑠𝑝ℎ𝑒𝑟𝑖𝑐𝑎𝑙 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒𝑠, 𝑚/𝑠 𝜀𝑚𝑓 = 𝑃𝑜𝑟𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝑢𝑏 = 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑏𝑢𝑏𝑏𝑙𝑒 𝑟𝑖𝑠𝑒, 𝑚/𝑠 𝑑𝑏𝑚 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑏𝑢𝑏𝑏𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑐𝑚 𝑑𝑏𝑜 = 𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑢𝑏𝑏𝑙𝑒, 𝑐𝑚 𝛿 = 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑏𝑒𝑑 𝑜𝑐𝑐𝑢𝑝𝑖𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑏𝑢𝑏𝑏𝑙𝑒𝑠

REACTOR VESSEL Residence time (h) 𝑉𝑜 (𝑚

3⁄

ℎ)

V (m3) D (m) Reactor L (m) u (m/s) Height of Fluid (m)

4 21.66297478 86.6518991 4 12 0.000478857 7

CATALYST INFORMATION 𝜌𝑃 (𝑘𝑔⁄𝑚 3 )

790 272

APPROVED BY

diameter (m) Ac (cm2)

1.40E-07 1.54E-10

DESIGN OF THE BED 𝜀

0.8

Bed Height (m)

0.1

Bed Volume (m3)

1.256637061

𝜇𝑔 (𝑃𝑎. 𝑠)

2.15E-05

𝜌𝑔 (𝑘𝑔/𝑚 3 )

1.597

∆𝑃 (Pa)

154.6318456

Mass of Catalyst (Kg) 𝑢𝑚𝑓 (𝑚⁄𝑠 )

198.5486557 4.33E-08

𝑢𝑓 (𝑚⁄𝑠 )

1.20404E-07

𝑢𝑡 (𝑚⁄𝑠 )

3.92E-07

STATUS

PASSED

BUBBLE VELOCITY AND CLOUD SIZE 𝜀𝑚𝑓 0.490948231 𝑢𝑏 (m/s)

0.001310736

𝑑𝑏𝑚 (𝑐𝑚)

2.44E-05

Type of plate 𝑑𝑏0 (𝑐𝑚)

Porous 8.62027-06

𝛿

0.365301355

𝑽 = 𝝉𝑽𝒐 𝑉 = 4 ∗ 21.66297478 = 86.6518991 𝑚3 𝑫=(

𝟏/𝟑 1/3 𝟒 4 𝑽) = ( ∗ 86.6518991) = 4 𝑚 𝟑𝝅 3𝜋

𝑳 = 𝟑𝑫 = 3 ∗ 4 = 12 𝑚 𝑽𝒐 21.66297478/3600 𝒖𝒐 = 𝝅 = = 0.0004788568775 𝑚/𝑠 𝜋 2 𝟐 ∗ 4 𝑫 4 𝟒 𝑨𝒄 =

𝝅 𝟐 𝜋 𝒅𝒑 = (1.40𝑒 − 7)2 = 1.54𝑒 − 10 𝟒 4 273

ASSUMPTION: Bed height is 0.1m 𝝅 𝑩𝒆𝒅 𝒗𝒐𝒍𝒖𝒎𝒆 = ∗ 𝑫𝟐 ∗ 𝑩𝒆𝒅 𝒉𝒆𝒊𝒈𝒉𝒕 𝟒 𝜋 𝐵𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 = ∗ 42 ∗ 0.1 = 1.256637061 𝑚3 4 ∆𝑷 = 𝒃𝒆𝒅 𝒉𝒆𝒊𝒈𝒉𝒕 ∗ (𝝆𝒑 − 𝝆𝒇 ) ∗ (𝟏 − 𝜺) ∗ 𝒈 ∆𝑃 = 0.1 ∗ (790 − 1.597) ∗ (1 − 0.8) ∗ 9.80665 = 154.6318456 𝑃𝑎 𝑴𝒂𝒔𝒔 𝒐𝒇 𝒄𝒂𝒕𝒂𝒍𝒚𝒔𝒕 = (𝟏 − 𝜺) ∗ 𝝆𝒑 ∗ 𝑩𝒆𝒅 𝒗𝒐𝒍𝒖𝒎𝒆 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = (1 − 0.8) ∗ 790 ∗ 1.256637061 = 198.5486557 𝑘𝑔 (𝝋𝒅𝒑 )𝟐 𝜺𝟑 [𝒈(𝝆𝒑 − 𝝆𝒇 )] 𝟏𝟓𝟎𝝁 𝟏−𝜺 2 (0.6 ∗ 1.40𝑒 − 7) 0.83 [9.80665(790 − 1.597)] = = 4.33𝑒 − 8 𝑚/𝑠 150 ∗ 2.15𝑒 − 5 1 − 0.8

𝒖𝒎𝒇 = 𝑢𝑚𝑓

(𝝆𝒑 − 𝝆𝒇 )𝒈𝒅𝟐𝒑 𝜺𝟑 𝒖𝒇 = 𝟏𝟓𝟎𝝁 𝟏−𝜺 (790 − 1.597) ∗ 9.80665 ∗ (1.40𝑒 − 7)2 0.83 𝑢𝑓 = = 1.20404𝑒 − 7 𝑚/𝑠 150 ∗ 2.15𝑒 − 5 1 − 0.8 𝒈(𝝆𝒑 − 𝝆𝒇 )𝒅𝟐𝒑 𝒖𝒕 = 𝟏𝟖𝝁 9.80665(790 − 1.597)(1.40𝑒 − 7)2 𝑢𝑡 = = 3.92𝑒 − 7 𝑚/𝑠 18 ∗ 2.15𝑒 − 5 ∴ 𝑺𝒊𝒏𝒄𝒆 𝒖𝒎𝒇 < 𝒖𝒇 < 𝒖𝒕 , 𝒔𝒂𝒕𝒊𝒔𝒇𝒚𝒂𝒃𝒍𝒆 𝒇𝒐𝒓 𝒑𝒓𝒐𝒑𝒆𝒓 𝒃𝒆𝒅 𝒐𝒑𝒆𝒓𝒂𝒕𝒊𝒐𝒏

𝟎. 𝟎𝟕𝟏 𝟏/𝟑 𝜺𝒎𝒇 = ( ) 𝛙 The typical ψ is 0.6 0.071 1/3 𝜀𝑚𝑓 = ( ) = 0.490948231 0.6 𝒖𝒃 = 𝒖𝒐 −𝒖𝒎𝒇 + (𝟎. 𝟕𝟏)(𝒈 𝒅𝒃 )𝟏/𝟐 1

𝑢𝑏 = 0.000478857 − (4.33𝑒 − 8) + (0.71)(9.80665 ∗ (1.40𝑒 − 7))2 = 0.001310736 𝑚/𝑠 274

𝒅𝒃𝒎 = 𝟎. 𝟔𝟓𝟐[𝑨𝒄 (𝒖𝒐 − 𝒖𝒎𝒇 )]𝟎.𝟒 𝑑𝑏𝑚 = 0.652[(1.54𝑒 − 10)(0.000478857 − (4.33𝐸 − 08)) ∗ 100]0.4 = 2.297854424𝑒 − 05 𝑐𝑚 𝒅𝒃𝒐 = 𝟎. 𝟎𝟎𝟑𝟕𝟔(𝒖𝒐 − 𝒖𝒎𝒇 )𝟐 𝑑𝑏𝑜 = 0.00376((0.000478857 − (4.33𝐸 − 08)) ∗ 100)2 = 8.62027223𝑒 − 06 𝒖𝒐 − 𝒖𝒎𝒇 𝒖𝒃 0.000478857 − (4.33𝑒 − 08) 𝛿= = 0.3653014032 0.001310736 𝜹=

275

REV 1

DATE 1/2/15

CALCULATION CREATED BY CHECKED BY EAM ALL MFS

Legend: 𝜏 = 𝑟𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 𝑡𝑖𝑚𝑒, ℎ 𝑉𝑜 = 𝑖𝑛𝑙𝑒𝑡 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒, 𝑚3 ⁄ℎ 𝑉 = 𝑇𝑜𝑡𝑎𝑙 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝑉𝑜𝑙𝑢𝑚𝑒, 𝑚3 𝐷 = 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚 𝐿 = 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝐿𝑒𝑛𝑔𝑡ℎ, 𝑚 𝑢𝑜 = 𝑠𝑢𝑝𝑒𝑟𝑓𝑖𝑐𝑖𝑎𝑙 𝑔𝑎𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑚/𝑠 𝜌𝑝 = 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡, 𝑘𝑔⁄𝑚3 𝑑𝑝 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚 𝐴𝑐 = 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚2 𝜀 = 𝑉𝑜𝑖𝑑 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑏𝑒𝑑 𝜇𝑔 = 𝑣𝑖𝑠𝑐𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑔𝑎𝑠, 𝑃𝑎 ∙ 𝑠 𝑜𝑟 𝑘𝑔⁄(𝑚 ∙ 𝑠) 𝜌𝑔 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑔𝑎𝑠, 𝑘𝑔⁄𝑚3 ∆𝑃 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 𝑎𝑐𝑟𝑜𝑠𝑠 𝑡ℎ𝑒 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑏𝑒𝑑, 𝑃𝑎 𝑢𝑚𝑓 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑏𝑒𝑑, 𝑚/𝑠 𝑢𝑓 = 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑚/𝑠 𝑢𝑡 = 𝑇𝑒𝑟𝑚𝑖𝑛𝑎𝑙 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑓𝑜𝑟 𝑠𝑝ℎ𝑒𝑟𝑖𝑐𝑎𝑙 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒𝑠, 𝑚/𝑠 𝜀𝑚𝑓 = 𝑃𝑜𝑟𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝑢𝑏 = 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑏𝑢𝑏𝑏𝑙𝑒 𝑟𝑖𝑠𝑒, 𝑚/𝑠 𝑑𝑏𝑚 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑏𝑢𝑏𝑏𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑐𝑚 𝑑𝑏𝑜 = 𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑢𝑏𝑏𝑙𝑒, 𝑐𝑚 𝛿 = 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑏𝑒𝑑 𝑜𝑐𝑐𝑢𝑝𝑖𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑏𝑢𝑏𝑏𝑙𝑒𝑠

276

APPROVED BY

REACTOR VESSEL Residence time (h) 𝑉𝑜 (𝑚

3⁄

ℎ)

V (m3) D (m) Reactor L (m) u (m/s) Height of Fluid (m)

4 21.05481201 84.21924804 4 12 0.000465414 7

CATALYST INFORMATION 𝜌𝑃 (𝑘𝑔⁄𝑚 3 )

790

diameter (m) Ac (cm2)

1.40E-07 1.54E-10

DESIGN OF THE BED 𝜀

0.8

Bed Height (m)

0.1

Bed Volume (m3)

1.256637061

𝜇𝑔 (𝑃𝑎. 𝑠)

2.15E-05

𝜌𝑔 (𝑘𝑔/𝑚 3 )

1.597

∆𝑃 (Pa)

154.6318456

Mass of Catalyst (Kg) 𝑢𝑚𝑓 (𝑚⁄𝑠 )

198.5486557 4.33E-08

𝑢𝑓 (𝑚⁄𝑠 )

1.20404E-07

𝑢𝑡 (𝑚⁄𝑠 )

3.92E-07

STATUS

PASSED

BUBBLE VELOCITY AND CLOUD SIZE 𝜀𝑚𝑓

0.490948231

𝑢𝑏 (m/s)

0.001297292

𝑑𝑏𝑚 (𝑐𝑚)

2.27E-05

Type of plate 𝑑𝑏0 (𝑐𝑚)

Porous 8.14301-06

𝛿

0.358724213

𝑽 = 𝝉𝑽𝒐 𝑉 = 4 ∗ 21.05481201 = 84.21924804 𝑚3 277

𝑫=(

𝟏/𝟑 1/3 𝟒 4 𝑽) = ( ∗ 84.21924804) = 4 𝑚 𝟑𝝅 3𝜋

𝑳 = 𝟑𝑫 = 3 ∗ 4 = 12 𝑚 𝑽𝒐 21.05481201/3600 𝒖𝒐 = 𝝅 = = 0.000465414 𝑚/𝑠 𝜋 2 𝟐 ∗ 4 𝑫 4 𝟒 𝑨𝒄 =

𝝅 𝟐 𝜋 𝒅 = (1.40𝑒 − 7)2 = 1.54𝑒 − 10 𝟒 𝒑 4

ASSUMPTION: Bed height is 0.1m 𝝅 𝑩𝒆𝒅 𝒗𝒐𝒍𝒖𝒎𝒆 = ∗ 𝑫𝟐 ∗ 𝑩𝒆𝒅 𝒉𝒆𝒊𝒈𝒉𝒕 𝟒 𝜋 𝐵𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 = ∗ 42 ∗ 0.1 = 1.256637061 𝑚3 4 ∆𝑷 = 𝒃𝒆𝒅 𝒉𝒆𝒊𝒈𝒉𝒕 ∗ (𝝆𝒑 − 𝝆𝒇 ) ∗ (𝟏 − 𝜺) ∗ 𝒈 ∆𝑃 = 0.1 ∗ (790 − 1.597) ∗ (1 − 0.8) ∗ 9.80665 = 154.6318456 𝑃𝑎 𝑴𝒂𝒔𝒔 𝒐𝒇 𝒄𝒂𝒕𝒂𝒍𝒚𝒔𝒕 = (𝟏 − 𝜺) ∗ 𝝆𝒑 ∗ 𝑩𝒆𝒅 𝒗𝒐𝒍𝒖𝒎𝒆 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = (1 − 0.8) ∗ 790 ∗ 1.256637061 = 198.5486557 𝑘𝑔 (𝝋𝒅𝒑 )𝟐 𝜺𝟑 [𝒈(𝝆𝒑 − 𝝆𝒇 )] 𝟏𝟓𝟎𝝁 𝟏−𝜺 2 (0.6 ∗ 1.40𝑒 − 7) 0.83 [9.80665(790 − 1.597)] = = 4.33𝑒 − 8 𝑚/𝑠 150 ∗ 2.15𝑒 − 5 1 − 0.8

𝒖𝒎𝒇 = 𝑢𝑚𝑓

(𝝆𝒑 − 𝝆𝒇 )𝒈𝒅𝟐𝒑 𝜺𝟑 𝟏𝟓𝟎𝝁 𝟏−𝜺 (790 − 1.597) ∗ 9.80665 ∗ (1.40𝑒 − 7)2 0.83 𝑢𝑓 = = 1.20404𝑒 − 7 𝑚/𝑠 150 ∗ 2.15𝑒 − 5 1 − 0.8 𝒖𝒇 =

𝒈(𝝆𝒑 − 𝝆𝒇 )𝒅𝟐𝒑 𝟏𝟖𝝁 9.80665(790 − 1.597)(1.40𝑒 − 7)2 𝑢𝑡 = = 3.92𝑒 − 7 𝑚/𝑠 18 ∗ 2.15𝑒 − 5 𝒖𝒕 =

∴ 𝑺𝒊𝒏𝒄𝒆 𝒖𝒎𝒇 < 𝒖𝒇 < 𝒖𝒕 , 𝒔𝒂𝒕𝒊𝒔𝒇𝒚𝒂𝒃𝒍𝒆 𝒇𝒐𝒓 𝒑𝒓𝒐𝒑𝒆𝒓 𝒃𝒆𝒅 𝒐𝒑𝒆𝒓𝒂𝒕𝒊𝒐𝒏

278

𝟎. 𝟎𝟕𝟏 𝟏/𝟑 ) 𝛙 The typical ψ is 0.6 0.071 1/3 𝜀𝑚𝑓 = ( ) = 0.490948231 0.6 𝜺𝒎𝒇 = (

𝒖𝒃 = 𝒖𝒐 −𝒖𝒎𝒇 + (𝟎. 𝟕𝟏)(𝒈 𝒅𝒃 )𝟏/𝟐 𝑢𝑏 = 0.000465414 − (4.33𝑒 − 8) + (0.71)(9.80665 ∗ (1.40𝑒 − = 0.001297292 𝑚/𝑠

1 7))2

𝒅𝒃𝒎 = 𝟎. 𝟔𝟓𝟐[𝑨𝒄 (𝒖𝒐 − 𝒖𝒎𝒇 )]𝟎.𝟒 𝑑𝑏𝑚 = 0.652[(1.54𝑒 − 10)(0.000465414 − (4.33𝐸 − 08)) ∗ 100]0.4 = 2.27𝑒 − 05 𝑐𝑚 𝒅𝒃𝒐 = 𝟎. 𝟎𝟎𝟑𝟕𝟔(𝒖𝒐 − 𝒖𝒎𝒇 )𝟐 𝑑𝑏𝑜 = 0.00376((0.000465414 − (4.33𝐸 − 08)) ∗ 100)2 = 8.14301𝑒 − 06 𝜹=

𝒖𝒐 − 𝒖𝒎𝒇 𝒖𝒃 𝛿=

0.000465414 − (4.33𝑒 − 08) = 0.358724213 0.001297292

279

Appendix D DISTILLATION COLUMNS CALCULATION SHEETS

REV 1

DATE 1/2/15

CALCULATION CREATED BY CHECKED BY EAM ALL MFS

APPROVED BY

VAPOR TRAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

TRAY

Mole flow kmol/h kmol/s 18330 5.091667 18500 5.138889 18500 5.138889 18500 5.138889 18490 5.136111 18490 5.136111 18480 5.133333 18480 5.133333 18470 5.130556 18470 5.130556 18460 5.127778 12040 3.344444 12050 3.347222 12060 3.35 12060 3.35 12060 3.35 12060 3.35 12060 3.35 12060 3.35 12040 3.344444 11870 3.297222 10460 2.905556 8872 2.464444 9413 2.614722 9841 2.733611 9940 2.761111 9958 2.766111

Mass Rate kg/h kg/s 1426408 396.2244 1440915 400.2542 1440845 400.2348 1440652 400.181 1440455 400.1265 1440258 400.0716 1440058 400.0161 1439856 399.96 1439650 399.9029 1439440 399.8444 1439222 399.784 941574.2 261.5484 942553.4 261.8204 942676.9 261.8547 942769.9 261.8805 942861.1 261.9059 942951.5 261.931 943035.5 261.9543 943086.7 261.9685 942890.6 261.9141 937918.6 260.5329 893579.4 248.2165 939337.1 260.927 1102676 306.299 1177582 327.1062 1193788 331.6078 1196744 332.4288

LIQUID 280

Vol Rate m3/h 516004.5 519853 518852.8 517814.2 516777.1 515741.5 514706.8 513672.4 512637.2 511599.9 510558.6 332641.8 332358.5 331801.6 331236.9 330673.4 330110.5 329540.6 328929.7 328104.8 325842.2 306986.9 281593.3 305734.7 320596 323502 323575.7

Density kg/m3 2.764332 2.771774 2.776983 2.782179 2.787382 2.792596 2.797822 2.803063 2.808322 2.813605 2.818917 2.830595 2.835954 2.841086 2.846211 2.851336 2.856473 2.861667 2.867137 2.873749 2.878444 2.910806 3.335794 3.606644 3.673105 3.690203 3.698496

Mole flow kmol/ h 1

4849

2

4847

3

4843

4

4840

5

4836

6

4831

7

4827

8

4822

9

4817

10

4811

11 12 13 14 15 16 17 18 19 20 21

1.21E +04 1.21E +04 1.21E +04 1.21E +04 1.21E +04 1.21E +04 1.21E +04 1.21E +04 1.21E +04 1.20E +04 1.05E +04

Mass Rate

Vol Rate

Density

Surface Tension

kg/m3

dyne/cm

811.6506

20.8

811.5178

20.8

811.4453

20.8

811.3741

20.8

811.3036

20.8

811.2341

20.8

811.1658

20.8

811.0989

20.7

811.0339

20.7

810.9712

20.7

810.9133

20.7

810.6797

20.7

810.5885

20.7

810.5128

20.7

810.4378

20.7

810.3631

20.7

810.2895

20.6

810.2209

20.6

810.1769

20.6

810.2793

20.6

811.2073

20.5

kmol/s

kg/h

kg/s

m3/h

1.3469 44 1.3463 89 1.3452 78 1.3444 44 1.3433 33 1.3419 44 1.3408 33 1.3394 44 1.3380 56 1.3363 89 3.3666 67 3.3694 44 3.3722 22 3.3722 22 3.3722 22 3.3722 22 3.3722 22 3.3722 22 3.3666 67 3.3194 44 2.9277 78

37880 9.7 37873 9.8 37854 6.1 37834 9.8 37815 2.1 37795 2.5 37775 0.4 37754 4.9 37733 4.4 37711 6.8 95108 4.6 95206 3.8 95218 7.3 95228 0.4 95237 1.5 95246 1.9 95254 5.9 95259 7.1 95240 1 94742 9 90308 9.8

105.224 9 105.205 5 105.151 7 105.097 2 105.042 3 104.986 8 104.930 7 104.873 6 104.815 1 104.754 7 264.190 2 264.462 2 264.496 5 264.522 3 264.547 6 264.572 8 264.596 1 264.610 3 264.555 8 263.174 7 250.858 3

466.715 2 466.705 5 466.508 4 466.307 5 466.104 3 465.898 2 465.688 3 465.473 3 465.251 2 465.018 8 1172.85 6 1174.40 2 1174.68 6 1174.91 1 1175.13 2 1175.35 2 1175.56 3 1175.72 5 1175.54 7 1169.26 2 1113.26 6

281

22

8951

23

9492

24

9920

25 26 27

1.00E +04 1.00E +04 9844

2.4863 89 2.6366 67 2.7555 56 2.7833 33 2.7888 89 2.7344 44

94884 7.5 11121 87 11870 93 12032 98 12062 54 11831 50

263.568 8 308.940 8 329.748 334.249 5 335.070 6 328.652 9

1204.50 7 1475.75 2 1598.41 8 1625.00 6 1629.94 7 1599.04 3

787.7476

18.6

753.6406

16.1

742.6672

15.3

740.4884

15.1

740.0571

15.1

739.9114

15.1

FLV AND MINIMUM DIAMETER CALCULATIONS TRA Y

FLV

𝑲𝟏

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

0.015498 0.015361 0.015369 0.015379 0.015388 0.015397 0.015406 0.015414 0.015423 0.015432 0.038962 0.059748 0.059754 0.059809 0.059865 0.059922 0.059978 0.060033 0.060076 0.05984 0.057356 0.064547 0.078772 0.075022 0.071968 0.071352 0.069897

0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.14 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.115 0.125 0.115 0.11 0.11 0.11 0.11

𝒄𝒐𝒓𝒓𝒆𝒄𝒕𝒆𝒅 𝑲𝟏

0.131023749 0.131023749 0.131023749 0.131023749 0.131023749 0.131023749 0.131023749 0.130897521 0.130897521 0.130897521 0.140966561 0.120828481 0.120828481 0.120828481 0.120828481 0.120828481 0.120711512 0.120711512 0.120711512 0.120711512 0.115569335 0.123198835 0.110117671 0.104261741 0.103987725 0.103987725 0.103987725

282

𝒖𝒇 (𝒎⁄𝒔)

2.241293072 2.238088186 2.235880711 2.233686444 2.231496069 2.229309033 2.227124756 2.222799031 2.220620053 2.218441184 2.386744898 2.041246954 2.03919572 2.037250936 2.03531525 2.033384669 2.029489979 2.027554414 2.025557372 2.023346131 1.936679592 2.022971011 1.65149126 1.492496605 1.472803274 1.468940064 1.467138741

𝟖𝟓% 𝑭𝒍𝒐𝒐𝒅𝒊𝒏𝒈

1.905099111 1.902374958 1.900498604 1.898633477 1.896771658 1.894912678 1.893056043 1.889379176 1.887527045 1.885675006 2.028733163 1.735059911 1.733316362 1.731663295 1.730017963 1.728376969 1.725066482 1.723421252 1.721723766 1.719844211 1.646177654 1.719525359 1.403767571 1.268622114 1.251882783 1.248599055 1.24706793

TRAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

𝑽𝒘 (𝒎𝟑⁄𝒔)

157.6680381 158.8439865 158.5383449 158.2210005 157.9041107 157.587675 157.2715292 156.9554532 156.6391507 156.3221946 156.0040071 101.6405367 101.5539838 101.3838101 101.2112729 101.0391093 100.8670884 100.6929506 100.5063116 100.2542358 99.56290608 93.80155737 86.04238696 93.4189498 97.95987487 98.84782498 98.87035813

𝑨𝒅 (𝒎𝟐 )

𝑨𝒏 (𝒎𝟐 )

70.34690823 70.97306867 70.90644155 70.83402462 70.76154556 70.68902188 70.61639846 70.61162574 70.53847439 70.46488128 65.36266496 49.79335622 49.80099888 49.76500847 49.72756575 49.6901107 49.70070778 49.66226797 49.61908907 49.5487323 51.40907483 46.36821628 52.09981369 62.59240354 66.512532 67.29193886 67.38991711

79.93967 80.65121 80.5755 80.49321 80.41085 80.32843 80.24591 80.24048 80.15736 80.07373 74.27576 56.58336 56.59204 56.55115 56.5086 56.46603 56.47808 56.4344 56.38533 56.30538 58.4194 52.69115 59.20433 71.12773 75.58242 76.46811 76.57945

𝑫𝒄 (𝒎)

10.08872 10.13352 10.12877 10.12359 10.11841 10.11323 10.10803 10.10769 10.10245 10.09718 9.724753 8.487884 8.488535 8.485467 8.482275 8.479079 8.479984 8.476704 8.473018 8.467009 8.624494 8.190755 8.68224 9.516441 9.80992 9.86723 9.874411

10.2 10.3 10.3 10.3 10.3 10.3 10.3 10.3 10.3 10.2 9.9 8.6 8.6 8.6 8.6 8.6 8.6 8.6 8.6 8.6 8.8 8.3 8.8 9.7 10 10 10

1. Calculation of the diameter for the rectifying and stripping part of the distillation column. The first tray is to be considered in this calculation 𝑭𝑳𝑽 =

 

𝑳𝒘 𝝆𝑽 √ 𝑽𝒘 𝝆𝑳

𝑘𝑔 2.764332 3 105.2249 𝑘𝑔/𝑠 𝑚 𝐹𝐿𝑉 = ∗√ = 0.0155 𝑘𝑔 396.2244 𝑘𝑔/𝑠 811.6506 3 𝑚 Assumed plate spacing is 0.9 𝑚 𝐾1 = 0.13, which is based from figure 11.29 of Towler 283

𝑪𝒐𝒓𝒓𝒆𝒄𝒕𝒆𝒅 𝑲𝟏 = 𝑲𝟏 [𝝈⁄𝟎. 𝟎𝟐]𝟎.𝟐 𝐶𝑜𝑟𝑟𝑒𝑐𝑡𝑒𝑑 𝐾1 = 0.13[20.8⁄0.02]0.2 = 0.131023749 𝒖𝒇 = 𝑲𝟏 √

𝝆𝑳 − 𝝆𝑽 𝝆𝑽

811.6506 − 2.764332 𝑢𝑓 = 0.131023749 √ = 2.241293072 𝑚/𝑠 2.764332 𝐴𝑡 85% 𝑙𝑜𝑎𝑑𝑖𝑛𝑔, 𝑢𝑓 = 2.241293072 ∗ 0.85 = 1.905099111 𝑚/𝑠 𝑽𝒘 = 𝟏. 𝟏 ∗ 𝑉𝑤 = 1.1 ∗

𝒎̇ 𝝆

396.2244 𝑘𝑔⁄𝑠 = 157.6680381 𝑚3 ⁄𝑠 𝑘𝑔⁄𝑚3

𝑽𝒘 𝒖𝒇 @ 𝟖𝟓% 𝒍𝒐𝒂𝒅𝒊𝒏𝒈 157.6680381 𝐴𝑛 = = 70.3469082 𝑚2 1.905099111 𝑨𝒏 =

𝑨𝒏 𝑨𝒅 = 𝟏 − 𝟎. 𝟏𝟐 70.3469082 𝐴𝑑 = = 79.94 𝑚2 1 − 0.12 𝑫𝒄 = √ 𝐷𝑐 = √

𝟒 𝒙 𝑨𝒅 𝝅

4 ∗ 79.94 = 10.089 ≅ 10.2 𝑚 𝜋

2. Plate Design The Stripping section will be the basis of the calculation 𝐷𝑐 = 10 𝑚 𝝅 𝟐 𝑫 𝟒 𝒄 𝜋 𝐴𝑐 = ∗ 102 = 78.53981634 𝑚2 4 𝑨𝒄 =

% 𝐷𝑜𝑤𝑛𝑐𝑜𝑚𝑒𝑟 = 12% 284

𝑨𝒅 = %𝑫𝒐𝒘𝒏𝒄𝒐𝒎𝒆𝒓 ∗ 𝑨𝒄 𝐴𝑑 = 0.12 ∗ 78.53981634 = 9.424777961 𝑚2 𝑨𝒏 = 𝑨𝒄 − 𝑨𝒅 𝐴𝑛 = 78.53981634 − 9.424777961 = 69.11503838 𝑚2 𝑨𝒂 = 𝑨𝒄 − 𝟐𝑨𝒅 𝐴𝑎 = 78.53981634 − 2 ∗ 9.424777961 = 59.69026042 𝑚2 %𝐻𝑜𝑙𝑒 𝐴𝑟𝑒𝑎 = 6% 𝑨𝒉 = 𝑨𝒄 ∗ % 𝑯𝒐𝒍𝒆 𝑨𝒓𝒆𝒂 𝐴ℎ = 78.53981634 ∗ 0.06 = 4.721238898 𝑚2 𝑨𝒅 59.69026042 ∗ 𝟏𝟎𝟎% = ∗ 100 = 12% 𝑨𝒄 78.53981634 

𝑙𝑤 ⁄𝐷𝑐 = 0.76, which is based from figure 11.33 of Towler 𝒍𝒘 = 𝟎. 𝟕𝟔 ∗ 𝑫𝒄 𝑙𝑤 = 0.76 ∗ 10 = 7.6 𝑚



ℎ𝑤 is set to be 40 𝑚𝑚

3. Weeping Test The Stripping section will be the basis of the calculation

𝑚̇𝑚𝑎𝑥,𝐿

𝒎̇𝒎𝒂𝒙,𝑳 = 𝟏. 𝟏 ∗ 𝒎̇𝑳 𝑘𝑔 = 1.1 ∗ 335.0706 = 368.5776268 𝑘𝑔/𝑠 𝑠

𝒎̇𝒎𝒊𝒏,𝑳

max ℎ𝑜𝑤

𝒎̇𝒎𝒊𝒏,𝑳 = 𝟎. 𝟓 ∗ 𝒎̇𝑳 = 0.5 ∗ 250.8583 = 125.4291356 𝑘𝑔/𝑠

𝑳𝒘 𝟐/𝟑 𝐦𝐚𝐱 𝒉𝒐𝒘 = 𝟕𝟓𝟎 [ ] 𝝆𝑳 𝒍𝒘 368.5776268 2/3 = 750 [ ] = 114.6701249 𝑚𝑚 811.2073 ∗ 7.6 𝑳𝒘 𝟐/𝟑 ] 𝝆𝑳 𝒍𝒘 114.6701249 2/3 = 750 [ ] 739.9114 ∗ 7.6

𝒎𝒊𝒏 𝒉𝒐𝒘 = 𝟕𝟓𝟎 [ min ℎ𝑜𝑤

285

ℎ𝑤 + ℎ𝑜𝑤 = 40 + 59.42894361 = 99.42894361 𝑚𝑚  

𝐾2 is 31, based from figure 11.32 of Towler Hole diameter is set to be 8 𝑚𝑚 𝑲𝟐 − 𝟎. 𝟗(𝟐𝟓. 𝟒 − 𝒉𝒐𝒍𝒆 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓) 𝝆𝒗 𝟎.𝟓 31 − 0.9(25.4 − 8) ̌ℎ 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 = 𝑈 = 7.976507131 𝑚/𝑠 3.6984960.5

̌ 𝒉 𝒎𝒊𝒏𝒊𝒎𝒖𝒎 = 𝑼

0.5 𝑥 𝑉𝑚𝑎𝑥𝑉 𝐴ℎ 0.5 ∗ 281593.3 𝐴𝑐𝑡𝑢𝑎𝑙 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑎𝑝𝑜𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = = 8.299437091 2 ∗ 4.71238898 ∗ 3600 𝑈ℎ =

𝟖. 𝟐𝟗𝟗𝟒𝟑𝟕𝟎𝟗𝟏 > 𝟕. 𝟗𝟕𝟔𝟓𝟎𝟕𝟏𝟑𝟏 𝑷𝑨𝑺𝑺𝑬𝑫 4. Pressure Drop The Stripping section will be the basis of the calculation 

Plate thickness is set to 5 𝑚𝑚 𝟏. 𝟏 ∗ 𝑸𝒎𝒂𝒙 𝑨𝒉 332641.8 𝑀𝑎𝑥 𝑉𝑎𝑝𝑜𝑟 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 1.1 ∗ = 21.56879178 𝑚/𝑠 3600 ∗ 4.71238898 𝑴𝒂𝒙 𝑽𝒂𝒑𝒐𝒓 𝑽𝒆𝒍𝒐𝒄𝒊𝒕𝒚 =

 

(𝐴ℎ ⁄𝐴𝑝 ) × 100 is set to be 8%, based from figure 11.36 of Towler 𝐶𝑜 is set to be 0.83, based from figure 11.36 of Towler 𝑴𝒂𝒙 𝑽𝒂𝒑𝒐𝒓 𝑽𝒆𝒍𝒐𝒄𝒊𝒕𝒚𝟐 𝝆𝒗 𝑯𝒅 = 𝟓𝟏 𝒙 ∗ 𝑪𝒐𝟐 𝝆𝑳 2 21.56879178 2.830595 𝐻𝑑 = 51 ∗ ( ) ∗ = 131.753965 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 0.83 739.9114 𝑯𝒓 = 𝐻𝑟 =

𝟏𝟐𝟓𝟎𝟎 𝝆𝑳

12500 = 16.89391468 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 739.9114

𝑯𝒕 = 𝑯𝒅 + 𝑯𝒓 + (𝑯𝒘 + 𝑯𝒐𝒘 ) 𝐻𝑡 = 131.753965 + 16.89391468 + (40 + 114.6701249) = 303.3180046 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 286

5. Downcomer Liquid Backup The Stripping section will be the basis of the calculation 𝑀𝑎𝑥 𝑙𝑖𝑞𝑢𝑑 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 = 

1629.947 = 0.452763128 𝑚3 ⁄𝑠 3600

𝑁𝑜 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠 = 8, due to very high liquid loading 𝒉𝒂𝒑 = 𝒉𝒘 − 𝟓 ℎ𝑎𝑝 = 40 − 5 = 35 𝑨𝒂𝒑 = ( 𝐴𝑎𝑝 = (



𝒉𝒂𝒑 )𝒍 𝟏𝟎𝟎𝟎 𝒘

35 ) ∗ 7.6 = 0.266 𝑚2 1000

Since 𝐴𝑎𝑝 < 𝐴𝑑 :

ℎ𝑑𝑐

𝑳𝒘𝒅 𝟐 𝒉𝒅𝒄 = 𝟏𝟔𝟔 [ ] 𝝆𝑳 𝑨𝒎 368.5776268 2 8 = 166 ∗ [ ] = 9.096270081 𝑚𝑚 739.9114 ∗ 0.266

𝒉𝒃 = (𝒉𝒘 + 𝒉𝒐𝒘 ) + 𝒉𝒕 + 𝒉𝒅𝒄 ℎ𝑏 = (40 + 114.6701249) + 303.3180046 + 9.096270081 = 467.0843996 𝑚𝑚 1⁄2 (𝑝𝑙𝑎𝑡𝑒 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 + 𝑊𝑒𝑖𝑟 ℎ𝑒𝑖𝑔ℎ𝑡) = 470 𝟏⁄𝟐 (𝒑𝒍𝒂𝒕𝒆 𝒔𝒑𝒂𝒄𝒊𝒏𝒈 + 𝑾𝒆𝒊𝒓 𝒉𝒆𝒊𝒈𝒉𝒕) > 𝒉𝒃 𝑷𝑨𝑺𝑺𝑬𝑫 𝑨𝒅 𝒉𝒃𝒄 𝝆𝑳 𝑳𝒘𝒅 9.424777961 ∗ 467.0843996 ∗ 739.9114 𝑡𝑟 = = 28.40𝑠 114.6701249 ∗ 1000 𝑹𝒆𝒔𝒊𝒅𝒆𝒏𝒄𝒆 𝒕𝒊𝒎𝒆 = 𝒕𝒓 =

𝒕𝒓 > 𝟑𝒔 𝑷𝑨𝑺𝑺𝑬𝑫 6. Entrainment The Stripping section will be the basis of the calculation

287

𝟏. 𝟏 ∗ 𝑸𝒗 𝑨𝒏 1.1 ∗ 332641.8 𝑢𝑣 = = 1.47059944 𝑚/𝑠 69.11503838 ∗ 3600 𝒖𝒗 =

𝒖𝒗 ∗ 𝟏𝟎𝟎 𝒖𝒇 1.47059944 % 𝐹𝑙𝑜𝑜𝑑𝑖𝑛𝑔 = ∗ 100 = 72% 2.041246954 % 𝑭𝒍𝒐𝒐𝒅𝒊𝒏𝒈 =

% 𝑭𝒍𝒐𝒐𝒅𝒊𝒏𝒈 < 𝟖𝟓 𝑷𝑨𝑺𝑺𝑬𝑫 

Fractional entrainment is 0.0125, based from figure 11.31 of Towler 𝑭𝒓𝒂𝒄𝒕𝒊𝒐𝒏𝒂𝒍 𝒆𝒏𝒕𝒓𝒂𝒊𝒏𝒎𝒆𝒏𝒕 < 𝟎. 𝟏 𝑷𝑨𝑺𝑺𝑬𝑫

7. Tray Layout The Stripping section will be the basis of the calculation   

Unperforated strip and Calming Zone is bot set at 50 mm 𝐿𝑤 ⁄𝐷𝑐 is 0.76, which is based from figure 11.34 of Towler 𝜃𝑐 is 98°, which is based from figure 11.34 of Towler 𝐴𝑛𝑔𝑙𝑒 𝑠𝑢𝑏𝑡𝑒𝑛𝑑𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑒𝑑𝑔𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑙𝑎𝑡𝑒 = 180 − 98 = 82

𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉, 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒆𝒅𝒈𝒆 𝒔𝒕𝒓𝒊𝒑𝒔 = (𝑫𝒄 𝟐 ∗ 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒔𝒕𝒓𝒊𝒑 𝝅 ∗ 𝑨𝒏𝒈𝒍𝒆 𝒔𝒖𝒃𝒕𝒆𝒏𝒅𝒆𝒅 𝒃𝒚 𝒕𝒉𝒆 𝒆𝒅𝒈𝒆 𝒐𝒇 𝒕𝒉𝒆 𝒑𝒍𝒂𝒕𝒆 )( ) 𝟏𝟎𝟎𝟎 𝟏𝟖𝟎 2 ∗ 50 𝜋 ∗ 82 𝑀𝑒𝑎𝑛 𝑙𝑒𝑛𝑔𝑡ℎ, 𝑢𝑛𝑝𝑒𝑟𝑓𝑜𝑟𝑎𝑡𝑒𝑑 𝑠𝑡𝑟𝑖𝑝𝑠 = (10 − )( ) = 14.16858287 𝑚 1000 180

−

𝐴𝒓𝒆𝒂 𝒐𝒇 𝑼𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝑬𝒅𝒈𝒆 = 𝑾𝒆𝒊𝒓 𝑯𝒆𝒊𝒈𝒉𝒕 𝒙 𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑢𝑛𝑝𝑒𝑟𝑓𝑜𝑟𝑎𝑡𝑒𝑑 𝑠𝑡𝑟𝑖𝑝𝑠 = 0.05 ∗ 14.16858287 = 0.708429143 𝑚2 𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉 𝒐𝒇 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆 = 𝒍𝒘 + 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒔𝒕𝒓𝒊𝒑 𝒍𝒆𝒏𝒈𝒕𝒉 50 𝑀𝑒𝑎𝑛 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑎𝑙𝑚𝑖𝑛𝑔 𝑧𝑜𝑛𝑒 = 7.6 + = 7.65 𝑚 1000 𝑨𝒓𝒆𝒂 𝒐𝒇 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆𝒔 = 𝟐(𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉 ∗ 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆) 50 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑐𝑎𝑙𝑚𝑖𝑛𝑔 𝑧𝑜𝑛𝑒𝑠 = 2 (7.65 ∗ ) = 0.765 𝑚2 1000 𝑨𝒑 = 𝑨𝒂 − 𝑨𝒓𝒆𝒂 𝒐𝒇 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒔𝒕𝒓𝒊𝒑 − 𝒂𝒓𝒆𝒂 𝒐𝒇 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆 288

𝐴𝑝 = 59.69026042 − 0.708429143 − 0.765 = 58.2068327 𝑚2 𝐴ℎ 4.71238898 = = 0.080945474 𝐴𝑝 58.21683127 

𝑙𝑝 ⁄𝑑ℎ is 3.3, which is based from figure 11.35 of Towler 𝟐. 𝟓 < 𝟑. 𝟑 < 𝟒. 𝟎 𝑺𝑨𝑻𝑰𝑺𝑭𝑨𝑪𝑻𝑶𝑹𝒀 𝝅 𝒉𝒐𝒍𝒆 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓𝟐 𝟒 𝜋 8 2 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑜𝑛𝑒 ℎ𝑜𝑙𝑒 = ∗ ( ) = 5.02655𝑒 − 05 4 1000 𝑨𝒓𝒆𝒂 𝒐𝒇 𝒐𝒏𝒆 𝒉𝒐𝒍𝒆 =

𝑨𝒉 𝑨𝒓𝒆𝒂 𝒐𝒇 𝒐𝒏𝒆 𝒉𝒐𝒍𝒆 4.71238898 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 ℎ𝑜𝑙𝑒𝑠 = = 93750 5.02655𝑒 − 05 𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒉𝒐𝒍𝒆𝒔 =

289

REV 1

CALCULATION CREATED BY CHECKED BY MFS ALL EAM

DATE 1/2/15

APPROVED BY

VAPOR TRAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Mole flow kmol/h kmol/s 96.33 0.026758 97.2 0.027 97.17 0.026992 97.04 0.026956 96.59 0.026831 95.16 0.026433 92.25 0.025625 89.3 0.024806 87.63 0.024342 86.56 0.024044 172.7 0.047972 167.1 0.046417 158 0.043889 161.9 0.044972 184.7 0.051306 202.2 0.056167 208.4 0.057889 210 0.058333 210.5 0.058472 210.5 0.058472 210.3 0.058417 209.5 0.058194

Mass Rate kg/h kg/s 5593 1.553611 5644 1.567778 5643 1.5675 5639 1.566389 5624 1.562222 5580 1.55 5501 1.528056 5437 1.510278 5395 1.498611 5327 1.479722 1.08E+04 2.988889 1.10E+04 3.041667 1.21E+04 3.35 1.53E+04 4.255556 1.97E+04 5.483333 2.25E+04 6.236111 2.34E+04 6.491667 2.36E+04 6.558333 2.37E+04 6.572222 2.37E+04 6.575 2.36E+04 6.563889 2.35E+04 6.516667

Vol Rate m3/h 799.2007 805.9617 805.3451 804.5153 802.894 798.7686 790.1682 780.876 775.7699 772.2426 1552.955 1545.278 1544.723 1667.957 1948.277 2146.496 2215.003 2232.074 2235.372 2234.898 2232.072 2223.214

Density kg/m3 6.998242 7.002814 7.006934 7.009189 7.004661 6.985753 6.961808 6.962693 6.954382 6.898091 6.928727 7.086104 7.807227 9.184888 10.13203 10.4589 10.55078 10.57761 10.58437 10.59109 10.58658 10.55229

LIQUID TRAY

1

Mole flow kmol/h 21.94

kmol/s 0.006094

Mass Rate kg/h 1275

Vol Rate

Density

kg/s m3/h kg/m3 0.354167 1.847276 690.2053 290

Surface Tension dyne/cm 15

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

21.91 21.78 21.33 19.89 16.99 14.04 12.37 11.3 332.8 3.27E+02 3.18E+02 3.22E+02 3.45E+02 3.62E+02 3.69E+02 3.70E+02 3.71E+02 3.71E+02 3.70E+02 3.70E+02 365

0.006086 0.00605 0.005925 0.005525 0.004719 0.0039 0.003436 0.003139 0.092444 0.090889 0.088333 0.089444 0.095778 0.100639 0.102361 0.102806 0.102917 0.102944 0.102889 0.102667 0.101389

1273 1269 1254 1210 1132 1068 1025 956.9 2.78E+04 2.80E+04 2.91E+04 3.24E+04 3.68E+04 3.95E+04 4.04E+04 4.07E+04 4.07E+04 4.07E+04 4.07E+04 4.05E+04 3.98E+04

0.353611 0.3525 0.348333 0.336111 0.314444 0.296667 0.284722 0.265806 7.730556 7.786111 8.094444 8.997222 10.225 10.98056 11.23333 11.3 11.31667 11.31667 11.30556 11.25833 11.04444

1.84531 1.838167 1.812396 1.733741 1.586969 1.457147 1.373964 1.259486 35.54694 35.71434 37.04695 41.6149 48.31121 52.54772 53.99058 54.36786 54.45887 54.46241 54.38167 54.05371 52.68442

689.8569 690.3617 691.9017 697.9129 713.3096 732.9392 746.0164 759.7545 782.9085 784.8389 786.5695 778.327 761.9349 752.2687 749.0196 748.2362 748.0875 748.0388 748.414 749.8098 754.6823

15 15 15 15 15.1 15.3 15.5 16.2 17.5 17.5 17.4 16.6 15.5 14.8 14.5 14.5 14.4 14.4 14.4 14.4 14.6

FLV AND MINIMUM DIAMETER CALCULATIONS TRAY

FLV

𝑲𝟏

1

0.023

0.12

0.113290501

1.11937399

0.951467891

2 3 4 5 6 7 8 9

0.023 0.023 0.022 0.022 0.020 0.019 0.018 0.017

0.12 0.12 0.12 0.12 0.115 0.115 0.115 0.11

0.113290501 0.113290501 0.113290501 0.113290501 0.108714439 0.109000911 0.109284402 0.105460467

1.118719403 1.118800341 1.119878269 1.125149214 1.093157047 1.113090902 1.12592005 1.097236511

0.950911493 0.95098029 0.951896528 0.956376832 0.92918349 0.946127267 0.957032043 0.932651035

10 11 12 13

0.490 0.245 0.253 0.269

0.058 0.081 0.082 0.083

0.056471536 0.078865422 0.079747615 0.079963853

0.598961503 0.835650383 0.83640646 0.794396284

0.509117278 0.710302826 0.710945491 0.675236842

𝒄𝒐𝒓𝒓𝒆𝒄𝒕𝒆𝒅 𝑲𝟏

291

𝒖𝒇 (𝒎⁄𝒔)

𝟖𝟓% 𝑭𝒍𝒐𝒐𝒅𝒊𝒏𝒈

14 15 16 17 18 19

0.264 0.232

0.082 0.081

0.07792453 0.076266069

0.705444189 0.65271718

0.59962756 0.554809603

0.213 0.207 0.205 0.205

0.081 0.08 0.08 0.08

0.075954345 0.075016637 0.074912879 0.074912879

0.638267341 0.627264885 0.625527938 0.625304552

0.54252724 0.533175152 0.531698747 0.531508869

20 21 22

0.205 0.204 0.200

0.08 0.08 0.08

0.074912879 0.074912879 0.075119824

0.625262287 0.625988714 0.630820234

0.531472944 0.532090407 0.536197199

TRAY

𝑽𝒘 (𝒎𝟑⁄𝒔)

𝑨𝒏 (𝒎𝟐 )

𝑨𝒅 (𝒎𝟐 )

𝑫𝒄 (𝒎)

1

0.244200229

0.218157855

0.247907

0.561823

0.7

2

0.246266085

0.22013213

0.25015

0.564359

0.7

3

0.246077669

0.219947796

0.249941

0.564123

0.7

4

0.245824113

0.219509674

0.249443

0.563561

0.7

5

0.245328716

0.21804105

0.247774

0.561672

0.7

6

0.244068169

0.223269081

0.253715

0.568366

0.7

7

0.241440298

0.216909776

0.246488

0.560213

0.7

8

0.238600992

0.211916461

0.240814

0.553727

0.7

9

0.237040792

0.216034365

0.245494

0.559082

0.7

10

0.235963019

0.393953564

0.447675

0.754981

0.9

11

0.474513969

0.567837912

0.64527

0.906413

1.1

12

0.472168228

0.564520064

0.6415

0.903761

1.1

13

0.4719986

0.594160131

0.675182

0.927183

1.1

14

0.509653591

0.722457707

0.820975

1.022398

1.2

15

0.595306779

0.912043986

1.036414

1.14874

1.3

16

0.655873927

1.027584971

1.16771

1.219334

1.4

17

0.676806438

1.078980276

1.226114

1.249455

1.4

292

18

0.682022634

1.090315225

1.238995

1.256

1.4

19

0.683030249

1.092316131

1.241268

1.257152

1.4

20

0.682885361

1.092158243

1.241089

1.257061

1.4

21

0.682021895

1.089511487

1.238081

1.255537

1.4

22

0.679315449

1.07687644

1.223723

1.248236

1.4

1. Calculation of the diameter for the rectifying and stripping part of the distillation column. The first tray is to be considered in this calculation 𝑭𝑳𝑽 =

 

𝑳𝒘 𝝆𝑽 √ 𝑽𝒘 𝝆𝑳

𝑘𝑔 6.998242 3 0.354167 𝑘𝑔/𝑠 𝑚 𝐹𝐿𝑉 = ∗√ = 0.0229547 𝑘𝑔 1.553611 𝑘𝑔/𝑠 690.2053 3 𝑚 Assumed plate spacing is 0.9 𝑚 𝐾1 = 0.12, which is based from figure 11.29 of Towler 𝑪𝒐𝒓𝒓𝒆𝒄𝒕𝒆𝒅 𝑲𝟏 = 𝑲𝟏 [𝝈⁄𝟎. 𝟎𝟐]𝟎.𝟐 𝐶𝑜𝑟𝑟𝑒𝑐𝑡𝑒𝑑 𝐾1 = 0.12[20.8⁄0.02]0.2 = 0.11329 𝒖𝒇 = 𝑲𝟏 √

𝝆𝑳 − 𝝆𝑽 𝝆𝑽

690.2053 − 6.998242 𝑢𝑓 = 0.11329 √ = 1.11937 𝑚/𝑠 6.998242 𝐴𝑡 85% 𝑙𝑜𝑎𝑑𝑖𝑛𝑔, 𝑢𝑓 = 1.11937 ∗ 0.85 = 0.95147 𝑚/𝑠 𝑽𝒘 = 𝟏. 𝟏 ∗ 𝑉𝑤 = 1.1 ∗

𝒎̇ 𝝆

1.553611 𝑘𝑔⁄𝑠 = 0.22420 𝑚3 ⁄𝑠 𝑘𝑔⁄𝑚3

𝑽𝒘 𝒖𝒇 @ 𝟖𝟓% 𝒍𝒐𝒂𝒅𝒊𝒏𝒈 0.22420 𝐴𝑛 = = 0.21816 𝑚2 0.95147 𝑨𝒏 =

293

𝑨𝒏 𝑨𝒅 = 𝟏 − 𝟎. 𝟏𝟐 0.21816 𝐴𝑑 = = 0.247907 𝑚2 1 − 0.12 𝑫𝒄 = √

𝟒 𝒙 𝑨𝒅 𝝅

4 ∗ 0.247907 𝐷𝑐 = √ = 0.568123 ≅ 0.7𝑚 𝜋

2. Plate Design The Stripping section will be the basis of the calculation 𝐷𝑐 = 0.7𝑚 𝝅 𝟐 𝑫 𝟒 𝒄 𝜋 𝐴𝑐 = ∗ 0.72 = 1.53938 𝑚2 4 𝑨𝒄 =

% 𝐷𝑜𝑤𝑛𝑐𝑜𝑚𝑒𝑟 = 19% 𝑨𝒅 = %𝑫𝒐𝒘𝒏𝒄𝒐𝒎𝒆𝒓 ∗ 𝑨𝒄 𝐴𝑑 = 0.12 ∗ 1.53938 = 0.29248 𝑚2 𝑨𝒏 = 𝑨𝒄 − 𝑨𝒅 𝐴𝑛 = 1.53938 𝑚2 − 0.29248 = 1.246898𝑚2 𝑨𝒂 = 𝑨𝒄 − 𝟐𝑨𝒅 𝐴𝑎 = 1.53938 𝑚2 − 2 ∗ 0.29248 = 0.955416 𝑚2 %𝐻𝑜𝑙𝑒 𝐴𝑟𝑒𝑎 = 4% 𝑨𝒉 = 𝑨𝒄 ∗ % 𝑯𝒐𝒍𝒆 𝑨𝒓𝒆𝒂 𝐴ℎ = 1.53938 ∗ 0.04 = 0.06158 𝑚2 𝑨𝒅 0.29248 ∗ 𝟏𝟎𝟎% = ∗ 100 = 19% 𝑨𝒄 1.53938 

𝑙𝑤 ⁄𝐷𝑐 = 0.86, which is based from figure 11.33 of Towler 𝒍𝒘 = 𝟎. 𝟖𝟔 ∗ 𝑫𝒄 𝑙𝑤 = 0.86 ∗ 0.7 = 1.204 𝑚 294



ℎ𝑤 is set to be 50 𝑚𝑚

3. Weeping Test The Stripping section will be the basis of the calculation

𝑚̇𝑚𝑎𝑥,𝐿

𝒎̇𝒎𝒂𝒙,𝑳 = 𝟏. 𝟏 ∗ 𝒎̇𝑳 𝑘𝑔 = 1.1 ∗ 335.0706 = 12.4483 𝑘𝑔/𝑠 𝑠

𝒎̇𝒎𝒊𝒏,𝑳

max ℎ𝑜𝑤

𝒎̇𝒎𝒊𝒏,𝑳 = 𝟎. 𝟓 ∗ 𝒎̇𝑳 = 0.5 ∗ 250.8583 = 3.89306 𝑘𝑔/𝑠

𝑳𝒘 𝟐/𝟑 𝐦𝐚𝐱 𝒉𝒐𝒘 = 𝟕𝟓𝟎 [ ] 𝝆𝑳 𝒍𝒘 2/3 1.204 = 750 [ ] = 41.7727𝑚𝑚 690.2053 ∗ 1.204 𝑳𝒘 𝟐/𝟑 ] 𝝆𝑳 𝒍𝒘 2/3 1.204 = 750 [ ] 690.2053 ∗ 1.204

𝒎𝒊𝒏 𝒉𝒐𝒘 = 𝟕𝟓𝟎 [ min ℎ𝑜𝑤

ℎ𝑤 + ℎ𝑜𝑤 = 50 + 19.901597 = 69.9 𝑚𝑚  

𝐾2 is 30.5, based from figure 11.32 of Towler Hole diameter is set to be 4 𝑚𝑚 𝑲𝟐 − 𝟎. 𝟗(𝟐𝟓. 𝟒 − 𝒉𝒐𝒍𝒆 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓) 𝝆𝒗 𝟎.𝟓 30.5 − 0.9(25.4 − 4) ̌ℎ 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 = 𝑈 = 3.45379𝑚/𝑠 6.9982420.5

̌ 𝒉 𝒎𝒊𝒏𝒊𝒎𝒖𝒎 = 𝑼

0.5 𝑥 𝑉𝑚𝑎𝑥𝑉 𝐴ℎ 0.5 ∗ 281593.3 𝐴𝑐𝑡𝑢𝑎𝑙 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑎𝑝𝑜𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = = 3.48427 2 ∗ 4.71238898 ∗ 3600 𝑈ℎ =

𝟑. 𝟒𝟖𝟒𝟐𝟕 > 𝟑. 𝟒𝟓𝟑𝟕𝟗 𝑷𝑨𝑺𝑺𝑬𝑫 4. Pressure Drop The Stripping section will be the basis of the calculation

295



Plate thickness is set to 4 𝑚𝑚 𝟏. 𝟏 ∗ 𝑸𝒎𝒂𝒙 𝑨𝒉 12.4483 𝑀𝑎𝑥 𝑉𝑎𝑝𝑜𝑟 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 1.1 ∗ = 11.0926 𝑚/𝑠 3600 ∗ 0.06158 𝑴𝒂𝒙 𝑽𝒂𝒑𝒐𝒓 𝑽𝒆𝒍𝒐𝒄𝒊𝒕𝒚 =

 

(𝐴ℎ ⁄𝐴𝑝 ) × 100 is set to be 6%, based from figure 11.36 of Towler 𝐶𝑜 is set to be 0.81, based from figure 11.36 of Towler 𝑴𝒂𝒙 𝑽𝒂𝒑𝒐𝒓 𝑽𝒆𝒍𝒐𝒄𝒊𝒕𝒚𝟐 𝝆𝒗 𝑯𝒅 = 𝟓𝟏 𝒙 ∗ 𝑪𝒐𝟐 𝝆𝑳 2 11.0926 6.998242 𝐻𝑑 = 51 ∗ ( ) ∗ = 88.5926 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 0.81 690.2053 𝑯𝒓 = 𝐻𝑟 =

𝟏𝟐𝟓𝟎𝟎 𝝆𝑳

12500 = 16.710363 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 690.2053

𝑯𝒕 = 𝑯𝒅 + 𝑯𝒓 + (𝑯𝒘 + 𝑯𝒐𝒘 ) 𝐻𝑡 = 88.5926 + 16.710363 + (50 + 19.901597) = 197.0757 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 5. Downcomer Liquid Backup The Stripping section will be the basis of the calculation 𝑀𝑎𝑥 𝑙𝑖𝑞𝑢𝑑 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 = 

1629.947 = 0.452763128 𝑚3 ⁄𝑠 3600

𝑁𝑜 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠 = 8, due to very high liquid loading 𝒉𝒂𝒑 = 𝒉𝒘 − 𝟓 ℎ𝑎𝑝 = 50 − 5 = 45 𝑨𝒂𝒑 = ( 𝐴𝑎𝑝 = (



𝒉𝒂𝒑 )𝒍 𝟏𝟎𝟎𝟎 𝒘

45 ) ∗ 1.204 = 0.04816𝑚2 1000

Since 𝐴𝑎𝑝 < 𝐴𝑑 : 𝒉𝒅𝒄

𝑳𝒘𝒅 𝟐 = 𝟏𝟔𝟔 [ ] 𝝆𝑳 𝑨𝒎

296

ℎ𝑑𝑐

2 12.4483 8 = 166 ∗ [ ] = 19.820257 𝑚𝑚 690.2053 ∗ 0.04816

𝒉𝒃 = (𝒉𝒘 + 𝒉𝒐𝒘 ) + 𝒉𝒕 + 𝒉𝒅𝒄 ℎ𝑏 = (50 + 19.901597) + 197.0757 + 19.820257 = 308.6687𝑚𝑚 1⁄2 (𝑝𝑙𝑎𝑡𝑒 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 + 𝑊𝑒𝑖𝑟 ℎ𝑒𝑖𝑔ℎ𝑡) = 470 𝟏⁄𝟐 (𝒑𝒍𝒂𝒕𝒆 𝒔𝒑𝒂𝒄𝒊𝒏𝒈 + 𝑾𝒆𝒊𝒓 𝒉𝒆𝒊𝒈𝒉𝒕) > 𝒉𝒃 𝑷𝑨𝑺𝑺𝑬𝑫 𝑨𝒅 𝒉𝒃𝒄 𝝆𝑳 𝑳𝒘𝒅 0.29248 ∗ 19.820257 ∗ 690.2053 𝑡𝑟 = = 3.016677𝑠 12.4483 ∗ 1000 𝑹𝒆𝒔𝒊𝒅𝒆𝒏𝒄𝒆 𝒕𝒊𝒎𝒆 = 𝒕𝒓 =

𝒕𝒓 > 𝟑𝒔 𝑷𝑨𝑺𝑺𝑬𝑫 6. Entrainment The Stripping section will be the basis of the calculation 𝟏. 𝟏 ∗ 𝑸𝒗 𝑨𝒏 1.1 ∗ 1.553611 𝑢𝑣 = = 0.547783 𝑚/𝑠 1.246898𝑚2 ∗ 3600 𝒖𝒗 =

𝒖𝒗 ∗ 𝟏𝟎𝟎 𝒖𝒇 0.547783 % 𝐹𝑙𝑜𝑜𝑑𝑖𝑛𝑔 = ∗ 100 = 65% 1.11937 % 𝑭𝒍𝒐𝒐𝒅𝒊𝒏𝒈 =

% 𝑭𝒍𝒐𝒐𝒅𝒊𝒏𝒈 < 𝟖𝟓 𝑷𝑨𝑺𝑺𝑬𝑫 

Fractional entrainment is 0.018, based from figure 11.31 of Towler 𝑭𝒓𝒂𝒄𝒕𝒊𝒐𝒏𝒂𝒍 𝒆𝒏𝒕𝒓𝒂𝒊𝒏𝒎𝒆𝒏𝒕 < 𝟎. 𝟏 𝑷𝑨𝑺𝑺𝑬𝑫

7. Tray Layout The Stripping section will be the basis of the calculation  

Unperforated strip and Calming Zone is bot set at 50 mm 𝐿𝑤 ⁄𝐷𝑐 is 0.86, which is based from figure 11.34 of Towler 297



𝜃𝑐 is 118°, which is based from figure 11.34 of Towler 𝐴𝑛𝑔𝑙𝑒 𝑠𝑢𝑏𝑡𝑒𝑛𝑑𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑒𝑑𝑔𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑙𝑎𝑡𝑒 = 180 − 118 = 62

𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉, 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒆𝒅𝒈𝒆 𝒔𝒕𝒓𝒊𝒑𝒔 = (𝑫𝒄 −

𝟐 ∗ 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒔𝒕𝒓𝒊𝒑 𝝅 ∗ 𝑨𝒏𝒈𝒍𝒆 𝒔𝒖𝒃𝒕𝒆𝒏𝒅𝒆𝒅 𝒃𝒚 𝒕𝒉𝒆 𝒆𝒅𝒈𝒆 𝒐𝒇 𝒕𝒉𝒆 𝒑𝒍𝒂𝒕𝒆 )( ) 𝟏𝟎𝟎𝟎 𝟏𝟖𝟎 2 ∗ 50 𝜋 ∗ 62 𝑀𝑒𝑎𝑛 𝑙𝑒𝑛𝑔𝑡ℎ, 𝑢𝑛𝑝𝑒𝑟𝑓𝑜𝑟𝑎𝑡𝑒𝑑 𝑠𝑡𝑟𝑖𝑝𝑠 = (1.4 − )( ) = 1.406735 𝑚 1000 180 𝐴𝒓𝒆𝒂 𝒐𝒇 𝑼𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝑬𝒅𝒈𝒆 = 𝑾𝒆𝒊𝒓 𝑯𝒆𝒊𝒈𝒉𝒕 𝒙 𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑢𝑛𝑝𝑒𝑟𝑓𝑜𝑟𝑎𝑡𝑒𝑑 𝑠𝑡𝑟𝑖𝑝𝑠 = 0.05 ∗ 1.406735 = 0.0703368𝑚2 𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉 𝒐𝒇 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆 = 𝒍𝒘 + 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒔𝒕𝒓𝒊𝒑 𝒍𝒆𝒏𝒈𝒕𝒉 50 𝑀𝑒𝑎𝑛 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑎𝑙𝑚𝑖𝑛𝑔 𝑧𝑜𝑛𝑒 = 1.204 + = 1.254 𝑚 1000 𝑨𝒓𝒆𝒂 𝒐𝒇 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆𝒔 = 𝟐(𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉 ∗ 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆) 50 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑐𝑎𝑙𝑚𝑖𝑛𝑔 𝑧𝑜𝑛𝑒𝑠 = 2 (1.254 ∗ ) = 0.1254 𝑚2 1000 𝑨𝒑 = 𝑨𝒂 − 𝑨𝒓𝒆𝒂 𝒐𝒇 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒔𝒕𝒓𝒊𝒑 − 𝒂𝒓𝒆𝒂 𝒐𝒇 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆 𝐴𝑝 = 0.955416 − 0.0703368 − 0.1254 = 0.758679 𝑚2 𝐴ℎ 0.06158 = = 0.081161 𝐴𝑝 0.758679 𝑚2 

𝑙𝑝 ⁄𝑑ℎ is 3.1, which is based from figure 11.35 of Towler 𝟐. 𝟓 < 𝟑. 𝟏 < 𝟒. 𝟎 𝑺𝑨𝑻𝑰𝑺𝑭𝑨𝑪𝑻𝑶𝑹𝒀 𝝅 𝒉𝒐𝒍𝒆 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓𝟐 𝟒 𝜋 4 2 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑜𝑛𝑒 ℎ𝑜𝑙𝑒 = ∗ ( ) = 1.25664𝑒 − 05 4 1000 𝑨𝒓𝒆𝒂 𝒐𝒇 𝒐𝒏𝒆 𝒉𝒐𝒍𝒆 =

𝑨𝒉 𝑨𝒓𝒆𝒂 𝒐𝒇 𝒐𝒏𝒆 𝒉𝒐𝒍𝒆 0.06158 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 ℎ𝑜𝑙𝑒𝑠 = = 4900 1.25664𝑒 − 05 𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒉𝒐𝒍𝒆𝒔 =

298

REV 1

DATE 1/2/15

CALCULATION CREATED BY CHECKED BY MFS ALL EAM

APPROVED BY

VAPOR TRAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

Mole flow kmol/h kmol/s 577.7 0.160472 577.3 0.160361 578 0.160556 578.6 0.160722 579.2 0.160889 579.8 0.161056 580.1 0.161139 580.1 0.161139 579.7 0.161028 578.9 0.160806 577.7 0.160472 576.2 0.160056 574.4 0.159556 572.5 0.159028 570.3 0.158417 568.1 0.157806 565.8 0.157167 563.2 0.156444 560.2 0.155611 556.2 0.1545 550.7 0.152972 517.3 0.143694 516.2 0.143389 515.1 0.143083 514.2 0.142833 513.4 0.142611 512.8 0.142444 0.142333 512.4 0.142278 512.2 0.142306 512.3 0.142361 512.5 0.142472 512.9 0.142611 513.4

Mass Rate kg/h kg/s 68029.07 18.89696 67994.22 18.88728 68095.24 18.91535 68202.51 18.94514 68332.34 18.98121 68493.52 19.02598 68664.11 19.07336 68850.3 19.12508 69062.62 19.18406 69294.75 19.24854 69535.34 19.31537 69765.68 19.37936 69949.14 19.43032 70066.96 19.46305 70086.87 19.46858 69995.96 19.44332 69772.48 19.38124 69389.88 19.27497 68800.89 19.11136 67917.21 18.86589 66581.9 18.49497 63531.38 17.64761 64358.21 17.87728 65105 18.08472 65765.63 18.26823 66339.64 18.42768 66832.01 18.56445 67254.8 18.68189 67614.66 18.78185 67918.56 18.86627 68171.86 18.93663 68379.98 18.99444 68544.55 19.04015 299

Vol Rate m3/h 19426.52 18630.87 17932.72 17287.34 16691.86 16141.47 15624.33 15135.73 14672.46 14229.42 13803.61 13393.9 12998.19 12618.47 12253.47 11904.11 11568.81 11245.18 10929 10613.41 10288.89 9460.717 9243.674 9033.46 8832.594 8641.826 8461.178 8290.901 8130.311 7978.81 7835.755 7700.711 7573.014

Density kg/m3 3.501866 3.649546 3.797263 3.945228 4.093752 4.243326 4.394692 4.548858 4.706954 4.869823 5.037477 5.208765 5.381451 5.552729 5.719758 5.879981 6.031087 6.170632 6.29526 6.399188 6.471245 6.715282 6.962406 7.207095 7.445789 7.676578 7.898665 8.111881 8.316368 8.512367 8.700101 8.879698 9.051158

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

514.1 514.9 515.9 516.9 518.1 519.1 519.8 519.8 517.9 512.1 499.6 483.2 477.6 485.5 493.3 496.9 498.6 499.7 500.6 501.4 502.3 503.1

0.142806 0.143028 0.143306 0.143583 0.143917 0.144194 0.144389 0.144389 0.143861 0.14225 0.138778 0.134222 0.132667 0.134861 0.137028 0.138028 0.1385 0.138806 0.139056 0.139278 0.139528 0.13975

68667.73 68749.07 68785.15 68766.07 68679.32 68488.76 68130.68 67468.01 66224.57 63858.69 59577.27 53513.75 48610.16 46927.33 46786.9 46869.59 46954.53 47035.15 47114.38 47193.01 47271.19 47349.03

19.07437 19.09696 19.10699 19.10169 19.07759 19.02466 18.92519 18.74111 18.39571 17.73853 16.54924 14.86493 13.50282 13.03537 12.99636 13.01933 13.04293 13.06532 13.08733 13.10917 13.13089 13.15251

7452.289 7338.101 7229.977 7127.151 7029.238 6934.568 6840.936 6743.263 6631.836 6488.824 6296.449 6100.489 6045.466 6118.838 6154.611 6124.889 6068.412 6005.085 5941.014 5877.868 5816.08 5755.739

9.214314 9.368783 9.513882 9.648464 9.770521 9.876428 9.959263 10.00525 9.985858 9.841335 9.462043 8.772043 8.040763 7.669322 7.601927 7.652317 7.737532 7.832554 7.93036 8.028934 8.127672 8.226403

LIQUID TRAY

1 2 3 4 5 6 7 8 9 10 11 12 13

Mole flow kmol/h 492.4 493.1 493.7 494.3 494.9 495.2 495.1 494.8 494 492.8 4.91E+02 4.90E+02 4.88E+02

kmol/s 0.136778 0.136972 0.137139 0.137306 0.137472 0.137556 0.137528 0.137444 0.137222 0.136889 0.136472 0.135972 0.135417

Mass Rate kg/h 57989.95 58090.97 58198.23 58328.06 58489.24 58659.83 58846.03 59058.34 59290.48 59531.06 59761.4 59944.86 60062.69

kg/s 16.10832 16.13638 16.16618 16.20224 16.24701 16.2944 16.34612 16.40509 16.46958 16.53641 16.60039 16.65135 16.68408

300

Vol Rate

Density

m3/h 76.61432 76.92985 77.24954 77.5818 77.91597 78.18978 78.37033 78.4317 78.34191 78.09256 77.69905 77.17555 76.56319

kg/m3 756.9074 755.1161 753.3797 751.8266 750.6708 750.2237 750.8713 752.9907 756.8168 762.3141 769.1394 776.7338 784.4852

Surface Tension dyne/cm 17.4 19 22.5 29.8 43.5 67.5 106 164 241 337 443 552 654

14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

4.85E+02 4.83E+02 4.81E+02 4.78E+02 4.75E+02 4.71E+02 4.66E+02 5.92E+02 591.3 590.2 589.3 5.89E+02 5.88E+02 587.5 587.4 587.4 587.6 588 588.5 589.2 590.1 591 592.1 593.2 594.2 595 594.9 593 587.2 574.8 558.3 552.7 560.6 568.4 572 573.7 574.8 575.7 576.6 577.4 578.2

0.134833 0.134222 0.133583 0.132861 0.132 0.130917 0.129361 0.164556 0.16425 0.163944 0.163694 0.163472 0.163306 0.163194 0.163167 0.163167 0.163222 0.163333 0.163472 0.163667 0.163917 0.164167 0.164472 0.164778 0.165056 0.165278 0.16525 0.164722 0.163111 0.159667 0.155083 0.153528 0.155722 0.157889 0.158889 0.159361 0.159667 0.159917 0.160167 0.160389 0.160611

60082.6 59991.68 59768.2 59385.6 58796.61 57912.93 56577.63 70602.5 71429.33 72176.12 72836.75 73410.77 73903.13 74325.93 74685.78 74989.68 75242.98 75451.1 75615.67 75738.85 75820.19 75856.27 75837.19 75750.44 75559.89 75201.81 74539.13 73295.69 70929.82 66648.39 60584.88 55681.28 53998.46 53858.02 53940.71 54025.65 54106.27 54185.5 54264.13 54342.31 54420.15

16.68961 16.66436 16.60228 16.496 16.33239 16.08693 15.71601 19.61181 19.84148 20.04892 20.23243 20.39188 20.52865 20.64609 20.74605 20.83047 20.90083 20.95864 21.00435 21.03857 21.06117 21.07119 21.06589 21.04179 20.98886 20.88939 20.70531 20.35991 19.70273 18.51344 16.82913 15.46702 14.99957 14.96056 14.98353 15.00713 15.02952 15.05153 15.07337 15.09509 15.11671

301

75.87267 75.11872 74.28265 73.32044 72.14571 70.6062 68.45231 84.5613 84.25948 83.96778 83.71539 83.51417 83.36783 83.28101 83.24952 83.26963 83.33702 83.44922 83.60139 83.79104 84.01419 84.26458 84.529 84.79026 85.00098 85.07374 84.81858 83.85035 81.42911 76.53283 69.45836 63.95781 62.30325 62.30435 62.46854 62.61684 62.76265 62.90914 63.0583 63.20683 63.35389

791.8872 798.625 804.6052 809.9461 814.9703 820.2244 826.5261 834.9268 847.7305 859.5692 870.0521 879.0217 886.4706 892.4715 897.1317 900.5646 902.8758 904.1559 904.4786 903.9015 902.4689 900.2154 897.1736 893.3862 888.9295 883.9603 878.8066 874.125 871.0621 870.8472 872.2474 870.5939 866.7037 864.4344 863.486 862.7975 862.0776 861.3296 860.5392 859.7538 858.9867

744 816 868 901 916 911 884 824 985 1.13E+03 1.26E+03 1.37E+03 1.46E+03 1.53E+03 1.59E+03 1.63E+03 1.66E+03 1.68E+03 1.69E+03 1.69E+03 1.67E+03 1.65E+03 1.62E+03 1.58E+03 1.53E+03 1.46E+03 1.38E+03 1.27E+03 1.12E+03 888 560 239 77.7 31.1 20.6 18.4 17.8 17.7 17.6 17.5 17.5

55

577.7

0.160472 54370.04 15.10279 63.35391 858.1955

17.4

FLV AND MINIMUM DIAMETER CALCULATIONS

TRAY

FLV

𝑲𝟏

𝒄𝒐𝒓𝒓𝒆𝒄𝒕𝒆𝒅 𝑲𝟏

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

0.058 0.059 0.061 0.062 0.063 0.064 0.066 0.067 0.068 0.069 0.070 0.070 0.071 0.072 0.072 0.073 0.073 0.074 0.074 0.073 0.093 0.10 0.10 0.10 0.10 0.10 0.10 0.11 0.11 0.11 0.11 0.11 0.11 0.11

0.08 0.08 0.08 0.079 0.079 0.079 0.079 0.078 0.078 0.078 0.078 0.078 0.078 0.078 0.078 0.077 0.077 0.077 0.077 0.077 0.076 0.1 0.1 0.1 0.1 0.1 0.1 0.098 0.098 0.098 0.098 0.098 0.098 0.098

0.077802551 0.079183503 0.0819069 0.085558733 0.092282413 0.100758536 0.11027632 0.118811198 0.128319309 0.137219105 0.14493369 0.15145249 0.156676605 0.160769326 0.163767091 0.163677382 0.164903428 0.165448876 0.165267859 0.164276401 0.159879594 0.218012426 0.224083402 0.229017205 0.232883175 0.235865582 0.238085138 0.235125375 0.236296668 0.237160138 0.237728874 0.238011213 0.238011213 0.237445187 302

𝒖𝒇 (𝒎⁄𝒔)

1.141191479 1.136240194 1.150786712 1.177998341 1.246222173 1.335956563 1.437229608 1.524000834 1.622044109 1.711328391 1.785001076 1.843249113 1.885176832 1.913170082 1.928183864 1.907653032 1.903868437 1.894172251 1.879208042 1.859744525 1.80897986 2.439782224 2.479730186 2.505845993 2.519621757 2.523621899 2.519545708 2.461469283 2.447561394 2.43093614 2.411803198 2.390314803 2.366576523 2.337865273

𝟖𝟓% 𝑭𝒍𝒐𝒐𝒅𝒊𝒏𝒈

0.970012757 0.965804165 0.978168705 1.00129859 1.059288847 1.135563078 1.221645167 1.295400709 1.378737493 1.454629132 1.517250915 1.566761746 1.602400307 1.626194569 1.638956284 1.621505077 1.618288171 1.610046413 1.597326836 1.580782846 1.537632881 2.073814891 2.107770658 2.129969094 2.141678493 2.145078614 2.141613852 2.09224889 2.080427185 2.066295719 2.050032719 2.031767583 2.011590045 1.987185482

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

TRAY 1 2 3 4 5 6 7 8 9 10 11 12 13

0.11 0.11 0.11 0.12 0.12 0.12 0.12 0.11 0.11 0.11 0.10 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11

0.098 0.098 0.098 0.097 0.097 0.097 0.097 0.098 0.098 0.098 0.1 0.098 0.098 0.098 0.098 0.098 0.098 0.098 0.098 0.098 0.098

𝑽𝒘 (𝒎𝟑⁄𝒔)

157.6680381 158.8439865 158.5383449 158.2210005 157.9041107 157.587675 157.2715292 156.9554532 156.6391507 156.3221946 156.0040071 101.6405367 101.5539838

0.236873712 0.236006019 0.234828873 0.230942584 0.228789614 0.226225498 0.222498188 0.219211675 0.209267926 0.190834847 0.164237975 0.128559531 0.107046422 0.098581068 0.096379272 0.095742349 0.09563453 0.095526224 0.095417424 0.095417424 0.095308125

𝑨𝒏 (𝒎𝟐 )

70.34690823 70.97306867 70.90644155 70.83402462 70.76154556 70.68902188 70.61639846 70.61162574 70.53847439 70.46488128 65.36266496 49.79335622 49.80099888 303

2.309812591 2.279646292 2.247419235 2.190679651 2.15235003 2.113000914 2.067757222 2.03559698 1.957396007 1.822286311 1.627915784 1.328516683 1.131421859 1.046017957 1.018842628 1.006046898 0.998306859 0.990492196 0.982762126 0.976277754 0.968783015

𝑨𝒅 (𝒎𝟐 )

79.93967 80.65121 80.5755 80.49321 80.41085 80.32843 80.24591 80.24048 80.15736 80.07373 74.27576 56.58336 56.59204

1.963340702 1.937699348 1.91030635 1.862077704 1.829497526 1.796050777 1.757593639 1.730257433 1.663786606 1.548943364 1.383728416 1.129239181 0.96170858 0.889115264 0.866016234 0.855139863 0.848560831 0.841918367 0.835347807 0.829836091 0.823465563

𝑫𝒄 (𝒎)

10.08872 10.13352 10.12877 10.12359 10.11841 10.11323 10.10803 10.10769 10.10245 10.09718 9.724753 8.487884 8.488535

10.2 10.3 10.3 10.3 10.3 10.3 10.3 10.3 10.3 10.2 9.9 8.6 8.6

14 15 16 17 18 19 20 21 22 23 24 25 26 27

101.3838101 101.2112729 101.0391093 100.8670884 100.6929506 100.5063116 100.2542358 99.56290608 93.80155737 86.04238696 93.4189498 97.95987487 98.84782498 98.87035813

49.76500847 49.72756575 49.6901107 49.70070778 49.66226797 49.61908907 49.5487323 51.40907483 46.36821628 52.09981369 62.59240354 66.512532 67.29193886 67.38991711

56.55115 56.5086 56.46603 56.47808 56.4344 56.38533 56.30538 58.4194 52.69115 59.20433 71.12773 75.58242 76.46811 76.57945

8.485467 8.482275 8.479079 8.479984 8.476704 8.473018 8.467009 8.624494 8.190755 8.68224 9.516441 9.80992 9.86723 9.874411

8.6 8.6 8.6 8.6 8.6 8.6 8.6 8.8 8.3 8.8 9.7 10 10 10

8. Calculation of the diameter for the rectifying and stripping part of the distillation column. The first tray is to be considered in this calculation 𝑭𝑳𝑽 =

 

𝑳𝒘 𝝆𝑽 √ 𝑽𝒘 𝝆𝑳

𝑘𝑔 3.501866 3 16.10832 𝑘𝑔/𝑠 𝑚 𝐹𝐿𝑉 = ∗√ = 0.05798 𝑘𝑔 18.89696 𝑘𝑔/𝑠 756.9074 3 𝑚 Assumed plate spacing is 0.6 𝑚 𝐾1 = 0.08, which is based from figure 11.29 of Towler 𝑪𝒐𝒓𝒓𝒆𝒄𝒕𝒆𝒅 𝑲𝟏 = 𝑲𝟏 [𝝈⁄𝟎. 𝟎𝟐]𝟎.𝟐 𝐶𝑜𝑟𝑟𝑒𝑐𝑡𝑒𝑑 𝐾1 = 0.08[20.8⁄0.02]0.2 = 0.077802 𝒖𝒇 = 𝑲𝟏 √

𝝆𝑳 − 𝝆𝑽 𝝆𝑽

756.9074 − 3.501866 𝑢𝑓 = 0.077802√ = 1.14119𝑚/𝑠 3.501866 𝐴𝑡 85% 𝑙𝑜𝑎𝑑𝑖𝑛𝑔, 𝑢𝑓 = 1.14119 ∗ 0.85 = 0.970012 𝑚/𝑠 𝑽𝒘 = 𝟏. 𝟏 ∗

304

𝒎̇ 𝝆

𝑉𝑤 = 1.1 ∗

18.89696 𝑘𝑔⁄𝑠 = 3.9358799 𝑚3 ⁄𝑠 3.501866 𝑘𝑔⁄𝑚3

𝑽𝒘 𝒖𝒇 @ 𝟖𝟓% 𝒍𝒐𝒂𝒅𝒊𝒏𝒈 3.9358799 𝐴𝑛 = = 2.06119894 𝑚2 0.970012 𝑨𝒏 =

𝑨𝒏 𝟏 − 𝟎. 𝟏𝟐 5.201478 𝐴𝑑 = = 5.91077 𝑚2 1 − 0.12 𝑨𝒅 =

𝑫𝒄 = √

𝟒 𝒙 𝑨𝒅 𝝅

4 ∗ 5.91077 𝐷𝑐 = √ = 2.743324 ≅ 2.9 𝑚 𝜋

9. Plate Design The Stripping section will be the basis of the calculation 𝐷𝑐 = 2.9 𝑚 𝝅 𝟐 𝑫 𝟒 𝒄 𝜋 𝐴𝑐 = ∗ 2.92 = 2.54469 𝑚2 4 𝑨𝒄 =

% 𝐷𝑜𝑤𝑛𝑐𝑜𝑚𝑒𝑟 = 19% 𝑨𝒅 = %𝑫𝒐𝒘𝒏𝒄𝒐𝒎𝒆𝒓 ∗ 𝑨𝒄 𝐴𝑑 = 0.19 ∗ 2.54469 = 9.424777961 𝑚2 𝑨𝒏 = 𝑨𝒄 − 𝑨𝒅 𝐴𝑛 = 78.53981634 − 9.424777961 = 0.43491 𝑚2 𝑨𝒂 = 𝑨𝒄 − 𝟐𝑨𝒅 𝐴𝑎 = 2.54469 − 2 ∗ 9.424777961 = 1.5777078 𝑚2 %𝐻𝑜𝑙𝑒 𝐴𝑟𝑒𝑎 = 10% 𝑨𝒉 = 𝑨𝒄 ∗ % 𝑯𝒐𝒍𝒆 𝑨𝒓𝒆𝒂 𝐴ℎ = 2.54469 ∗ 0.1 = 0.254469 𝑚2 305

𝑨𝒅 9.424777961 ∗ 𝟏𝟎𝟎% = ∗ 100 = 19% 𝑨𝒄 2.54469 

𝑙𝑤 ⁄𝐷𝑐 = 0.85, which is based from figure 11.33 of Towler 𝒍𝒘 = 𝟎. 𝟖𝟓 ∗ 𝑫𝒄 𝑙𝑤 = 0.85 ∗ 2.9 = 1.53 𝑚



ℎ𝑤 is set to be 38 𝑚𝑚

10. Weeping Test The Stripping section will be the basis of the calculation

𝑚̇𝑚𝑎𝑥,𝐿

𝒎̇𝒎𝒂𝒙,𝑳 = 𝟏. 𝟏 ∗ 𝒎̇𝑳 𝑘𝑔 = 1.1 ∗ 16.10832 = 23.17830 𝑘𝑔/𝑠 𝑠

𝒎̇𝒎𝒊𝒏,𝑳 = 𝟎. 𝟓 ∗ 𝒎̇𝑳 𝒎̇𝒎𝒊𝒏,𝑳 = 0.5 ∗ 16.10832 = 7.48028 𝑘𝑔/𝑠 𝐦𝐚𝐱 𝒉𝒐𝒘 = 𝟕𝟓𝟎 [ max ℎ𝑜𝑤 = 750 [

𝑳𝒘 𝟐/𝟑 ] 𝝆𝑳 𝒍𝒘

16.10832 2/3 ] = 114.6701249 𝑚𝑚 756.9074 ∗ 7.6

𝑳𝒘 𝟐/𝟑 𝒎𝒊𝒏 𝒉𝒐𝒘 = 𝟕𝟓𝟎 [ ] 𝝆𝑳 𝒍𝒘 16.10832 2/3 min ℎ𝑜𝑤 = 750 [ ] 756.9074 ∗ 7.6 ℎ𝑤 + ℎ𝑜𝑤 = 38 + 24.36576 = 62.36576𝑚𝑚  

𝐾2 is 30.2 , based from figure 11.32 of Towler Hole diameter is set to be 3 𝑚𝑚 𝑲𝟐 − 𝟎. 𝟗(𝟐𝟓. 𝟒 − 𝒉𝒐𝒍𝒆 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓) 𝝆𝒗 𝟎.𝟓 30.2 − 0.9(25.4 − 3) ̌ℎ 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 = 𝑈 = 3.17409 𝑚/𝑠 3.5018660.5

̌ 𝒉 𝒎𝒊𝒏𝒊𝒎𝒖𝒎 = 𝑼

𝑈ℎ =

0.5 𝑥 𝑉𝑚𝑎𝑥𝑉 𝐴ℎ

306

𝐴𝑐𝑡𝑢𝑎𝑙 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑎𝑝𝑜𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 =

0.5 ∗ 281593.3 = 3.1744096 2 ∗ 0.254469 ∗ 3600

𝟑. 𝟏𝟕𝟒𝟒𝟎𝟗𝟔 > 𝟑. 𝟏𝟕𝟒𝟎𝟗 𝑷𝑨𝑺𝑺𝑬𝑫 11. Pressure Drop The Stripping section will be the basis of the calculation 

Plate thickness is set to 3 𝑚𝑚 𝟏. 𝟏 ∗ 𝑸𝒎𝒂𝒙 𝑨𝒉 16.10832 𝑀𝑎𝑥 𝑉𝑎𝑝𝑜𝑟 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 1.1 ∗ = 12.35446 𝑚/𝑠 3600 ∗ 0.254469 𝑴𝒂𝒙 𝑽𝒂𝒑𝒐𝒓 𝑽𝒆𝒍𝒐𝒄𝒊𝒕𝒚 =

 

(𝐴ℎ ⁄𝐴𝑝 ) × 100 is set to be16%, based from figure 11.36 of Towler 𝐶𝑜 is set to be 0.9, based from figure 11.36 of Towler 𝑴𝒂𝒙 𝑽𝒂𝒑𝒐𝒓 𝑽𝒆𝒍𝒐𝒄𝒊𝒕𝒚𝟐 𝝆𝒗 ∗ 𝑪𝒐𝟐 𝝆𝑳 2 12.35446 3.501866 𝐻𝑑 = 51 ∗ ( ) ∗ = 74.485526 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 0.9 756.9074 𝑯𝒅 = 𝟓𝟏 𝒙

𝑯𝒓 = 𝐻𝑟 =

𝟏𝟐𝟓𝟎𝟎 𝝆𝑳

12500 = 14.971371 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 756.9074

𝑯𝒕 = 𝑯𝒅 + 𝑯𝒓 + (𝑯𝒘 + 𝑯𝒐𝒘 ) 𝐻𝑡 = 74.485526 + 14.971371 + (38 + 24.36576) = 176.5540 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 12. Downcomer Liquid Backup The Stripping section will be the basis of the calculation 𝑀𝑎𝑥 𝑙𝑖𝑞𝑢𝑑 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 = 

1629.947 = 0.02363 𝑚3 ⁄𝑠 3600

𝑁𝑜 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠 = 1, due to very high liquid loading 𝒉𝒂𝒑 = 𝒉𝒘 − 𝟓 ℎ𝑎𝑝 = 38 − 5 = 33

307

𝑨𝒂𝒑 = ( 𝐴𝑎𝑝 = ( 

𝒉𝒂𝒑 )𝒍 𝟏𝟎𝟎𝟎 𝒘

33 ) ∗ 1.53 = 0.05049 𝑚2 1000

Since 𝐴𝑎𝑝 < 𝐴𝑑 : 𝑳𝒘𝒅 𝟐 ] 𝝆𝑳 𝑨𝒎 2 368.5776268 8 = 166 ∗ [ ] = 50.18383 𝑚𝑚 756.9074 ∗ 0.43491 𝒉𝒅𝒄 = 𝟏𝟔𝟔 [

ℎ𝑑𝑐

𝒉𝒃 = (𝒉𝒘 + 𝒉𝒐𝒘 ) + 𝒉𝒕 + 𝒉𝒅𝒄 ℎ𝑏 = (38 + 24.36576) + 176.5540 + 50.183839471 = 313.834𝑚𝑚 1⁄2 (𝑝𝑙𝑎𝑡𝑒 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 + 𝑊𝑒𝑖𝑟 ℎ𝑒𝑖𝑔ℎ𝑡) = 319 𝟏⁄𝟐 (𝒑𝒍𝒂𝒕𝒆 𝒔𝒑𝒂𝒄𝒊𝒏𝒈 + 𝑾𝒆𝒊𝒓 𝒉𝒆𝒊𝒈𝒉𝒕) > 𝒉𝒃 𝑷𝑨𝑺𝑺𝑬𝑫 𝑨𝒅 𝒉𝒃𝒄 𝝆𝑳 𝑳𝒘𝒅 9.424777961 ∗ 50.183839471 ∗ 756.9074 𝑡𝑟 = = 3.08𝑠 9.424777961 ∗ 1000 𝑹𝒆𝒔𝒊𝒅𝒆𝒏𝒄𝒆 𝒕𝒊𝒎𝒆 = 𝒕𝒓 =

𝒕𝒓 > 𝟑𝒔 𝑷𝑨𝑺𝑺𝑬𝑫 13. Entrainment The Stripping section will be the basis of the calculation 𝟏. 𝟏 ∗ 𝑸𝒗 𝑨𝒏 1.1 ∗ 18.89696 𝑢𝑣 = = 1.52524 𝑚/𝑠 2.06119894 ∗ 3600 𝒖𝒗 =

𝒖𝒗 ∗ 𝟏𝟎𝟎 𝒖𝒇 1.52524 % 𝐹𝑙𝑜𝑜𝑑𝑖𝑛𝑔 = ∗ 100 = 60% 1.14119 % 𝑭𝒍𝒐𝒐𝒅𝒊𝒏𝒈 =

% 𝑭𝒍𝒐𝒐𝒅𝒊𝒏𝒈 < 𝟖𝟓 𝑷𝑨𝑺𝑺𝑬𝑫

308



Fractional entrainment is 0.015, based from figure 11.31 of Towler 𝑭𝒓𝒂𝒄𝒕𝒊𝒐𝒏𝒂𝒍 𝒆𝒏𝒕𝒓𝒂𝒊𝒏𝒎𝒆𝒏𝒕 < 𝟎. 𝟏 𝑷𝑨𝑺𝑺𝑬𝑫

14. Tray Layout The Stripping section will be the basis of the calculation   

Unperforated strip and Calming Zone is bot set at 50 mm 𝐿𝑤 ⁄𝐷𝑐 is 0.85, which is based from figure 11.34 of Towler 𝜃𝑐 is 97°, which is based from figure 11.34 of Towler 𝐴𝑛𝑔𝑙𝑒 𝑠𝑢𝑏𝑡𝑒𝑛𝑑𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑒𝑑𝑔𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑙𝑎𝑡𝑒 = 180 − 97 = 83

𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉, 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒆𝒅𝒈𝒆 𝒔𝒕𝒓𝒊𝒑𝒔 = (𝑫𝒄 −

𝟐 ∗ 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒔𝒕𝒓𝒊𝒑 𝝅 ∗ 𝑨𝒏𝒈𝒍𝒆 𝒔𝒖𝒃𝒕𝒆𝒏𝒅𝒆𝒅 𝒃𝒚 𝒕𝒉𝒆 𝒆𝒅𝒈𝒆 𝒐𝒇 𝒕𝒉𝒆 𝒑𝒍𝒂𝒕𝒆 )( ) 𝟏𝟎𝟎𝟎 𝟏𝟖𝟎 2 ∗ 50 𝜋 ∗ 83 𝑀𝑒𝑎𝑛 𝑙𝑒𝑛𝑔𝑡ℎ, 𝑢𝑛𝑝𝑒𝑟𝑓𝑜𝑟𝑎𝑡𝑒𝑑 𝑠𝑡𝑟𝑖𝑝𝑠 = (10 − )( ) = 2.46265𝑚 1000 180 𝐴𝒓𝒆𝒂 𝒐𝒇 𝑼𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝑬𝒅𝒈𝒆 = 𝑾𝒆𝒊𝒓 𝑯𝒆𝒊𝒈𝒉𝒕 𝒙 𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑢𝑛𝑝𝑒𝑟𝑓𝑜𝑟𝑎𝑡𝑒𝑑 𝑠𝑡𝑟𝑖𝑝𝑠 = 0.05 ∗ 2.46265 = 0.123132 𝑚2 𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉 𝒐𝒇 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆 = 𝒍𝒘 + 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒔𝒕𝒓𝒊𝒑 𝒍𝒆𝒏𝒈𝒕𝒉 50 𝑀𝑒𝑎𝑛 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑎𝑙𝑚𝑖𝑛𝑔 𝑧𝑜𝑛𝑒 = 1.53 + = 1.58 𝑚 1000 𝑨𝒓𝒆𝒂 𝒐𝒇 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆𝒔 = 𝟐(𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉 ∗ 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆) 50 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑐𝑎𝑙𝑚𝑖𝑛𝑔 𝑧𝑜𝑛𝑒𝑠 = 2 (1.53 ∗ ) = 0.158 𝑚2 1000 𝑨𝒑 = 𝑨𝒂 − 𝑨𝒓𝒆𝒂 𝒐𝒇 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒔𝒕𝒓𝒊𝒑 − 𝒂𝒓𝒆𝒂 𝒐𝒇 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆 𝐴𝑝 = 1.577707 − 0.123132 − 0.158 = 1.29657 𝑚2 𝐴ℎ 0.254469 = = 0.196262 𝐴𝑝 1.29657 

𝑙𝑝 ⁄𝑑ℎ is 2.6, which is based from figure 11.35 of Towler 𝟐. 𝟓 < 𝟐. 𝟔 < 𝟒. 𝟎 𝑺𝑨𝑻𝑰𝑺𝑭𝑨𝑪𝑻𝑶𝑹𝒀 𝑨𝒓𝒆𝒂 𝒐𝒇 𝒐𝒏𝒆 𝒉𝒐𝒍𝒆 =

𝝅 𝒉𝒐𝒍𝒆 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓𝟐 𝟒

309

𝜋 3 2 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑜𝑛𝑒 ℎ𝑜𝑙𝑒 = ∗ ( ) = 7.06858𝑒 − 05 4 1000 𝑨𝒉 𝑨𝒓𝒆𝒂 𝒐𝒇 𝒐𝒏𝒆 𝒉𝒐𝒍𝒆 0.254469 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 ℎ𝑜𝑙𝑒𝑠 = = 36000 7.06858𝑒 − 05 𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒉𝒐𝒍𝒆𝒔 =

310

Appendix E Wage and Monetary Benefits Breakdown See attached A3 document.

311

Appendix F Attached A3 documents 

Process Flow Diagram



Piping and Instrumentations Diagram



Plot Plan



Phases of the Project

312

List of Tables

Table Number

Title

Page

1

Import data for phenols in the Philippines

3

2

Import data for acetone in the Philippines

4

3

Value of output of industries that uses phenol

6

4

Assumed phenol consumption in 2009 and 2010

6

5

Percent increase in phenol consumption based on 39% per annum growth rate

10

6

Value of output of industries that uses acetone

11

7

Assumed acetone consumption in 2009 and 2010

12

8

Increase in acetone consumption based on 39% per annum growth rate

9

14

Recent phenol capacities/expansions and active phenol projects

19

10

Paint Manufacturers in the Philippines

23

11

Plastic product manufacturer in the Philippines

24

12

Resins Manufacturer in the Philippines

28

13

Import and Export Data of Propylene and Benzene

29

14

List of Suppliers of raw materials in the Philippines

29

15

SWOT/TOWS Matrix

30

vii

16

Projected phenol and acetone capacity of the proposed plant

32

17

Process cost correlation constants for the plant

34

18

Cost of the two processes at lower capacity

34

19

Capacity of plant obtained through stoichiometric ratio and proportion method

35

20

Cost of the actual plant at year 2006

35

21

CE cost index up to year 2017 through extrapolation

35

22

ICIS Indicative price of raw materials and products

36

23

Preliminary Total Capital Expenditures of the Plant

36

24

Preliminary Project Cash Flow and IRR

37

25

General Information of the Geography of Hermosa, Bataan

42

26

Electric charge of PENELCO

43

27

List of Airport near Hermosa Bataan

44

28

List of Ports near Hermosa Bataan

44

29

Prices of Balanga Water District Services

45

30

Internet / Landline Rates

46

31

DOLE labor price in Region 3

47

32

Information on catalyst used for alkylation and transalkylation reactions

51

33

Kinetics of alkylation and transalkylation reactions (E is in kJ/kmol, rate of reaction is in kmol/m^3∙s, and concentration is in kmol/m^3)

52

34

Catalyst for Oxidation Data

53

35

Cumene oxidation reaction details

54

36

Optimum operation conditions and Reaction kinetics of Catalytic Decomposition Process of Cumene Hydroperoxide

56

37

Catalyst for Cleaving Reaction Data

56

38

Comparison of cost of production of phenol and acetone

39

Data for the component list of the main process in Aspen Hysys

40

59

Data for the component list of the steam gen utility in Aspen Hysys

41

57

59

Data for the component list of the cooling water system utility in Aspen Hysys

60

42

Material Streams of the Process

60

43

Composition of each streams for the process

61

44

Energy streams of the process

64

45

Cooling Water Requirement of the Plant

65

46

Steam requirement of the plant

65

47

Fuel requirement of the plant

65

48

Fixed capital investment of the plant

49

Purchase Equipment Cost for Common Plant Equipment

50

141

142

Typical Installation Factor for Project Fixed Capital Cost

144

51

Calculation Procedure for Production Cost

147

52

Purchase Cost of Atmospheric Vessels

149

53

Final Cost of Atmosphere Vessel

149

54

Shell Mass of Pressure Vessels

150

55

Purchase Cost of Pressure Vessels

150

56

Final Cost of Pressure Vessels

150

57

Purchase Cost of Trays for Distillation Columns

151

58

Shell mass of Distillation Columns

151

59

Purchase Cost of Pressure Vessels for Distillation Columns

152

60

Final Cost of Distillation Columns

152

61

Purchase Cost of Fluidized Bed Reactors

153

62

Purchase Cost of Packed Bed Reactors

153

63

Final Cost of Reactors

153

64

Cost of Heat Exchangers generated from Aspen Hysys V8.0

154

65

Final Cost of Heat Exchangers

154

66

Purchase Cost of Pipes

155

67

Final Cost of Pipe

156

68

Purchase Cost of Pumps

157

69

Final Cost of Pumps

157

70

Purchase Cost of Compressor

158

71

Final Cost of Compressor

158

72

Purchase Cost of Boiler

159

73

Final Cost of Boiler

159

74

Purchase Cost of Furnace

160

75

Final Cost of Furnace

160

76

Purchase Cost of Scrubber

161

77

Final Cost of Scrubber

161

78

Purchase Cost of Cooling Tower

162

79

Final Cost of Cooling Tower

162

80

Existing Activated Sludge Waste Water Treatment Plant in the Philippines

81

Capital Cost of WWTP of Phace Philippines Corporation

82

163

Depreciation schedule of the plant (values in Philippine Peso)

83

163

165

Land facts about Hermosa Ecozone Industrial Park (HEIP)

166

84

Cost of Land lease annually

167

85

Fixed Capital Cost of the Plant

168

86

Annual insurance cost of the company

169

87

Cost calculation basis for raw materials

169

88

Annual cost of propylene

170

89

Annual cost of benzene

171

90

Amount and Pricing of Catalyst Used for each Reactor

172

91

Final Cost of Catalyst for each Reactor

172

92

Total Cost of Catalysts per Year

172

93

Fuel requirement of the plant and its price

173

94

Water requirement of the plant and its price

173

95

Cost of Fuel Consumed Per Year

174

96

Cost of Consumed Water per Year

175

97

Electricity Requirement of the Buildings

176

98

Electricity requirement of the Process

176

99

Cost of Electricity Consumption per Year

177

100

Price of communication services

178

101

Annual cost of communication services of the company

178

102

Cost of Biological WWTP Operation per Year

179

103

Summary of Labor Cost per Year

180

104

Price of Fuel and Consumption per Truck

181

105

Annual cost on transportation

181

106

Operating, Quality Contol, and Laboratory Cost per Year

107

182

Maintenance Labor, Maintenance Material, and Operating Supplies Cost per year

182

108

General costs of the plant

183

109

Pricing of Products

184

110

Revenue from acetone

185

111

Revenue from phenol

185

112

Detailed summary of the taxes and mandatory contributions of a corporation

113

187

Production Cost and Revenue of the Company per Year

188

114

Annual Profit of the Company

188

115

Required Permits and Licenses of the Company

189

116

Cost of buildings

190

117

Cost of trucks of the company

191

118

Cost of radio

191

119

Total capital expenditure of the company

192

120

Capital loan and interest

192

121

Internal rate of return

193

122

Calculation Basis for Breakeven Analysis

195

123

Breakeven volume of acetone (X_1) and phenol (X_2)

195

124

Benefit to cost ratio (f) of the plant

196

List of Figures

Figure Number

Title

1

Demand tend line for phenols in the Philippines based on import data

2

3

Demand trend line for Acetone in the Philippines based on Imports

3

Page

5

2 year forecast of assumed phenol consumption in the Philippines (Note that this is based only from Bisphenol-A and phenolic resin applications of phenol)

4

Forecast of assumed phenol consumption in the Philippines (5 vs. 2 year data point forecast)

5

9

10

2 year forecast of assumed acetone consumption in the Philippines (Note that this is based only from Bisphenol-A and solvent applications of acetone)

6

Forecast of assumed acetone consumption in the Philippines (5 vs. 2 year data point forecast)

7

8

13

14

Initial Block Flow Diagram for Waste Water Treatment Facility

17

Projected phenol and acetone capacity of plant

33

viii

9

Company Logo of Phace Philippines Corporation

10

Organizational chart of PhAce Philippines Corporation

11

49

Chemical Structures of Benzene plus Propylene to Cumene

13

41

Block Flow Diagram of Phenol and Acetone production through Cumene Process

12

40

50

Diagram of the industrial alkylation of benzene to Cumene

50

14

Diagram for the mechanism of Cumene Oxidation

53

15

Diagram for the Mechanism of CHP decomposition to Phenol and Acetone

16

55

Project Cash Flow of Phace Philippines Corporation

194

List of Appendices

Appendix Number

Title

Page

A

Aspen Hysys Simulation

ix

B

Storage Tanks Calculation Sheets

x

C

Reactors Calculation Sheets

xi

D

Distillation Columns Calculation Sheets

xii

E

Wage and Monetary Benefits Breakdown

xiii

F

Attached A3 documents

xiv

Definition of Terms Annual cost. The sum of the annuitized values of a cash flow series. Annuity. A series of uniform payments or withdrawals occurring at equal time intervals. Capital. A firm’s investment in long-term assets that are not bought or sold in the normal course of business, e.g., plant equipment, buildings, and site upgrades. These assets are depreciated. Cash flow. The flow of money into or out of a company, a project, a personal account, and so on. Cash flow diagram. A diagram showing all cash flows and the time they occur. Cash flows in are shown by an arrow into the timeline and cash flows out by an arrow away from the timeline. Chemical engineering plant cost index (CEPI). An index of the costs to design, purchase and install chemical plant equipment. It is maintained by Chemical Engineering and includes costs (1) for equipment, machinery and supports (61% of the index weighting); (2) for construction labor (22%); (3) for buildings (7%); and (4) for engineering and supervision (10%). The period 1957 to 1959 is defined as an index of 100. Depreciation. A deduction from revenues (allowed by the government when calculating income taxes) of a fraction of the capital invested in a plant. This deduction may be considered as a fund to allow eventual replacement of the plant. It is not a cash flow. Expense. A firm’s costs that are chargeable against sales in a specific period. Fixed costs. Production costs that do not vary with production volume.

x

Future worth. This the projected value of a present sum of money when it grows at a specified interest rate for a given number of years. General expense. Broad corporate level expenses — research and development, marketing, sales, and administrative costs. Inflation. The devaluing of money because the volume of money increases faster than the supply of goods. Interest. The return from the investment of funds or the money paid for the use of borrowed money. Internal rate of return. See Return on investment (ROI). Manufacturing costs. The cost to manufacture a product. It is comprised of operating labor (wages), employee benefits, supervision (wages and benefits), laboratory costs, maintenance costs, utility costs, depreciation, insurance and taxes, operating (consumable) supplies, plant overhead, and contract manufacturing costs. Product cost. The sum of production cost and general expense. Production cost. The cost to produce a product. It is made up of raw material costs, packaging material costs, manufacturing costs, and delivery costs. Project life. The years a process or project is expected to operate without major revision. This is determined by the shorter of product or process obsolescence or by depreciable life. Return on investment (ROI). The interest rate at which the net present value of a cash flow series is zero. This is the percent return from an investment. Unit cost. Production costs expressed in dollars per unit of production (e.g. $/ton, $/lb, $/case). Variable costs. Those costs that vary with production volume.