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PAGE
DECLARATION CERTIFICATION LIST OF TABLES LIST OF FIGURES TABLE OF CONTENTS LIST OF NOMENCLATURES ACKNOWLEDGMENT ABSTRACT
ii iii iv v vi viii x xi
CHAPTER 1
INTRODUCTION
1.1.
1.2
AVAILABLE PROCESS 1.2.1 Esterification Process 1.2.1.1 Reaction Mechanism 1.2.1.2 Side reaction 1.2.2 General Process Description
1.3
ALTERNATIVE METHOD 1.3.1 1.3.2 1.3.3 1.3.4 Batchwise Esterification Continuous Esterification Cascade Esterification Equilibrium Limited Reaction
10
1.4
1.5
RAW MATERIAL SELECTION 1.5.1 1.5.2 1.5.3 1.5.4 Acrylic Acid 2-Ethylhexanol DBSA PTZ, Hydroquinone, HMME
26
CHAPTER 2
MARKET ANALYSIS
2.1.
32
2.2.
SUPPLY AND DEMAND OF 2-EHA 2.2.1. Global 2.2.2. Malaysia 2.2.2.1. BASF Malaysia 2.2.2.2. Branches 2.2.2.3. Sales 2.2.3. Acrylic acid production 2.2.4. Local demand for 2-EHA 2.2.5. Forecast 2-EHA
34
2.3.
AN OVERVIEW ON RAW MATERIALS 2.3.1. Acrylic Acid (AA) 2.3.1.1. Demand for AA 2.3.1.2. Demand for AA 2.3.2. 2-Ethylhexanol (2-EH) 2.3.2.1. Demand for 2-EH 2.3.2.2. Supplier for 2-EH 2.3.3. Catalyst 2.3.3.1. DBSA supply/demand 2.3.3.2. Producer/Suppliers for DBSA
41
2.4.
MARKET PRICE ANALYSIS 2.4.1. Price of 2-EHA 2.4.2. Price of AA 2.4.3. Price of 2-EH 2.4.4. Price of DBSA
50
2.5.
BREAK EVEN ANALYSIS 2.5.1. 2.5.2. Introduction Process economics and estimation
53
2.5.3. Total Capital investment 2.5.3.1. Fixed Capital Investment (FCI) 2.5.3.2. Operating cost 2.5.3.3. Start-up cost 2.5.4. Total Cost (TC)
2.5.5. Total Revenue 2.5.6. 2.5.7. Break Even Point Calculation of Break Even Analysis 2.5.7.1. Estimation of Total Operating cost 2.5.7.1.1. Cost of Raw Materials, CRM 2.5.7.1.2. Cost of Utilities, CUT 2.5.7.1.3. Equipment prices 2.5.7.2. Estimation of Fixed Capital Investment 2.5.7.3. Total Direct Manufacturing Cost (DMC) 2.5.7.3.1. Operating Labor 2.5.7.4. Total Fixed Manufacturing Cost (FMC) 2.5.7.5. Total General Expenses (GE) 2.5.8. Total Investment
2.6.
CONCLUSION
74
CHAPTER 3
3.1.
INTRODUCTION
75
3.2
SELECTION CRITERIA 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 3.2.9 Marketing Area Raw Material Transportation Availability of Labor Utilities Environmental Impact and Effluent Disposal Local Community Plant Consideration Land Climate
75
3.3
SITE LOCATION SUGGESTED 3.3.1 Description of Suggested Location 3.3.1.1 Tanjung Langsat 3.3.1.2 Teluk Kalung 3.3.1.3 Pulau Indah
80
3.4
CHAPTER 4
4.1
ENVIRONMENTAL CONSIDERATION 4.1.1 4.1.2 4.1.3 Introduction Environmental exposure Laws and regulations 4.1.3.1 Environmental Quality (clean air) 4.1.3.2 EIA
99
4.2
SAFETY CONSIDERATION 4.2.1 4.2.2 INTRODUCTION Introduction to Occupational Risk Assessment 4.2.3 Safety Considerations on Chemicals 4.2.3.1 Chemical storage 4.2.3.2 Exposure to chemical 4.2.4 Leaking prevention and safety procedure 4.2.4.1 Leaking protective equipment 4.2.4.2 Leak detector 4.2.5 Safety consideration at plant site 4.2.5.1 Emergency planning 4.2.6 Fire prevention and safety 4.2.6.1 Fire extinguishers 4.2.6.2 Fire detector 4.2.6.3 Fire alarm 4.2.7 Unit evacuation alarm 4.2.7.1 Total plant evacuation 4.2.8 4.2.9 Personal protective equipment Material safety data sheet
107
4.3
130
4.4
HAZOP 4.4.1 4.4.2 4.4.3 HAZOP study on heat exchanger HAZOP study on reactor HAZOP study on distillation column
133
CHAPTER 5
MASS BALANCE
5.1
INTRODUCTION
145
5.2
SAMPLE CALCULATION 5.2.1 Mass Balance around 2nd Distillation Column 5.2.2 Mass Balance around 1st Distillation Column 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 Mass Balance around Mixer Mass Balance around TEE-100 Mass Balance around Decanter Mass Balance around Reactor Overall Mass Balance
146
CHAPTER 6
ENERGY BALANCE
6.1
INTRODUCTION
166
6.2
ENERGY BALANCE 6.2.1 Balance at each equipment 6.2.1.1 E-101 6.2.1.2 E-102 6.2.1.3 E-107 6.2.1.4 Reactor 6.2.1.5 T-101 6.2.1.6 T-102 6.2.1.7 Decanter
168
CHAPTER 7
REFERENCES
LIST OF NOMENCLATURES
AA 2-EH 2-EHA DBSA GDP DOP PVC BEP FMC DMC GE FCI COM COMd PBP Cp Hv Hf H Tref C K Q Hr
Acrylic acid 2-Ethylhexanol 2-Ethylhexyl acrylate Dodecylbenzenesulfonic acid Growth domestic product di-octyl phthalate polyvinyl chloride Breakeven point Fixed manufacturing cost Direct manufacturing cost General Expenses Fixed capital investment Cost of manufacturing without depreciation Cost of manufacturing with depreciation Payback period Heat capacity Enthalpy of vapour Enthalpy of fluid Enthalpy of difference Reference temperature Celcius Kelvin Heat Hour