ProductionofCarbitol

INTRODUCTION
Carbitol or Diethylene glycol ethyl ether (DEGEE) is colorless
liquidwithfaint,sweet,pleasantodorandbittertaste.Itsboiling
point is relatively high and vapor pressure and evaporation rate
low.Likemostglycolethers,DEGEEhasverygoodsolubilityand
mixescompletelywithwaterandwithbothpolarandnonpolar
solvents.
In1993DEGEEwasregisteredasaningredientin178Swedish
chemicalproducts,andestimatedannualusewasjustunder500
tonsofpuresubstance.Themajorareaofusewasassolvent,but
thesubstancewasalsousedinpaint,varnish,cleanersandbinders.
In Sweden DEGEE is not used in pharmaceuticals or non
prescriptiondietsupplements,butdoesoccurincosmeticsandskin
careproducts(personalcommunication,CeciliaUlleryd,Swedish
MedicalProductsAgency,Nov.15,1996).
IntheUnitedStates,DEGEEwasreportedtooccurin80cosmetic
preparationsin1981.Thesubstance,underthenameTranscutol,
isusedinskinmedicationsandithasalsobeenfoundinchemical
airfreshenersforconsumeruse.TheuseofDEGEEinSweden
increasedrapidlyfrom1985to1992,andinthefollowingyearas
well. DEGEE, along with mono(EGBE) and diethylene glycol
butylether(DEGBE),havebeenidentifiedasthesolventsmost

widelyusedinwaterbasedpaintsandvarnishes.Globalusein
1993wasestimatedtobe31,000tons.

PROPERTIESANDUSESOFCARBITOL
Chemicalandphysicalcharacteristicsofcarbitol.
Properties
ChemicalFormula

Value
CH3CH2OCH2CH2OCH2CH2
OH

Molecularweight

134.2

Density(20oC)

0.99

Boilingpoint

202oC

Meltingpoint

76oC

Vaporpressure(25oC)

19Pa(0.14mmHg)

Relativeevaporationrate

0.02(nbutylacetate=1)

Saturationconcentration(25oC)

180ppm

Vaporpressure(25oC)

0.13mmHg

Vapordensity

4.62

Flashpoint

96C

Freezingpoint

76C

Refractiveindex(20oC)

1.4300

Latentheatofvaporization

85cal/g

Heatofcombustion

6330cal/g

FLAMMABILITY(FLASHPOINT):
This chemical has a flash point of 96 C (205 F). It is
combustible.Firesinvolvingthismaterialcanbecontrolledwitha
drychemical,carbondioxideorHalonextinguisher.Awaterspray
mayalsobeused.Theautoignitiontemperatureofthiscompound
is204C(400F).
REACTIVITY:
Thischemicalcanreactwithoxidizingmaterials.Itisincompatible
withstrongacids,acidchloridesandacidanhydrides.Itisalso
incompatiblewithalkalies.Itmayreactwithperoxides,oxygen,
nitricacidandsulfuricacid.

STABILITY:
This chemical is hygroscopic. ethanol or acetone should be
conditions.
Solutionsofthischemicalinwater,95%stablefor24hoursunder
normallab

USES:
Thiscompoundisusedasasolventfordyes,nitrocelluloseand
resins.
Itisusedinnonaqueousstainsforwood,forsettingthetwistand
conditioningyarnsandcloth,intextileprinting,textilesoaps,
lacquers,cosmeticsandquickdryingvarnishesandenamels.This
compoundisalsousedinbrakefluiddiluentandinorganic
synthesis.Itusedtodeterminesaponificationvaluesofoilsandas
neutralsolventformineraloilsoapandmineraloilsulphatedoil
mixtures(givingfinedispersionsinwater)
PRODUCTIONOFCARBITOL.
Polyethyleneglycolsashighastheoctaethyleneglycolhavebeen
prepared.Theethersofthesepolyethyleneglycolshaveattained
commercial significance, and this is particularly true of the
diethyleneglycolethylether,whichissoldcommerciallyunderthe
name of carbitol. This product is especially useful in the
manufactureoflaminatedglass,whereinthecelluloidinterleafis
mistedoverwithasprayofcarbitol,whichincreasestheadhesion
totheglass.Intheprintinganddyeingoftextilefabrics,itmakes
possiblemoreeconomicaluseofdyes.Carbitolisasolventwitha
mild odor, a low rate of evaporation, and a boiling point of
201.9oC. it enters into the manufacture of wood stains and
automobilepolishesandisusedasalacquersolvent.However,itis
particularlyvaluableinthecosmeticfield,whereitisemployedfor

creamsandhairtonics.
PreparationofGlycolEthers(carbitol)
C2H5OH+CH2

CH2

OH

O
CH2
Ethyl
Alcohol

CH2

CH2OC2H5

Ethylene
Oxide

Cellosolve

OC2H5

CH2
+

CH2

OH

CH2OC2H5
O

CH2

CH2
CH2
CH2OH
CARBITOL

ThereisalargequantityofdataavailableontheGermanprocess
forthemanufactureoftheglycolethers.Themonomethyl,ethyl,
and npropyl ethers of ethylene glycol are manufactured by the
continuous reaction of ethylene glycol are manufactured by the
continuousreactionofethyleneoxidewiththeanhydrousalcoholat
about200oCandat2545atmpressure.Onevolumeofethylene
oxideand6volumeofalcoholarefedtoapressuretowerpacked
with iron raschig rings. Excess of alcohol is used to give the
requiredhighratioofglycolether:diglycolether,tocontrolthe
heatlibratedinthereactor,andtoavoidhighconcentrationsofthe

ethyleneoxideandalcoholisexothermic,about2025kgcalperg
moleofethyleneoxidereacted.Thereactionproductemergesfrom
thebaseofthepressuretowerandisdistilledsemicontinuously.
Thealcohol is recycled; thepureglycol and diglycol ethers are
isolatedbybatchfractionation.Afterremovalofexcessalcohol,the
crudeproductcontainsabout85percentglycolether,10percent
diglycol ether, and 23 percent polygylcol ethers. The yield of
ethers is about 9095 percent on ethylene oxide and alcohol
consumed.Thereactioniscontrolledtogivecompleteconversion
ofethyleneoxide.Conditionsinthepressuretowerandfeedratios
for methyl, ethyl and nproply alcohols are given in table. The
contacttimehasbeencalculatedontheassumptionthatthereactor
capacityis3.5cubicm.
Eitheracidsorbasesmaybeusedascatalystsinthereaction
betweenethyleneoxideandalcohol.However,acidsarecorrosive
andmustbeneutralizedbeforetreatingthecrudereactionproduct,
andalkaliesleadtotheformationofresinswiththeacetaldehyde
presentintheethyleneoxide.Becauseoftheabovereasonsa
noncatalyticprocesswasdeveloped.TheGermansalsodeveloped
aprocessusingaqueousethylalcohol,butasthis involvesa
difficultproductsseparation,itisnotpreferred.

ConditionsforPreparationofGlycolEthers
Alcohol

Temp, C

Pressure
atm

Rate,lb/hr

Contac
t
time,
hr

Ethylene

Alcohol

oxide
200

40

120

720

About
4

Methyl
Ethyl

200210

35

100

600

About
5

220230

25

8090

450540

About
6

npropyl

MATERIALBALANCE

Basis:100Kgmoles
ofC2H4OThe
conversionistakenas
95%

Ofthe100Kgmolesofethyleneoxidesent,95%isreacting.
Thecrudestreamacontaintheproductsand5Kgmolesof
C2H4ONeglectingthe5KgmolesofC2H4Oi.e.assumingthatall
the5KgmolesofC2H4Oaregoingoutwiththetopproductofthe
tower.
Onaethyleneoxidefreebasis.Theweightfraction(%)ofcrude
productStream'a'is:
85%Monoglycolether
10%Diglycolether
5%Triglycolether
Themolefractionofthisstream'a'onaethyleneoxidefree
basisisas:89.885%Monoglycolether
7.101%Diglycolether
3.011%Triglycolether
Foracrudeproductof100Kgmoles(C2H4Ofree),
89.885Kgmolesofmonoglycolether=89.885Kgmoles
ofC2H4O7.101Kgmolesofcarbitol=14.202Kgmoles
ofC2H4O
3.011Kgmolesoftriglycolether=9.033KgmolesofC2H4O
Therefore,Totalethyleneoxidethathasreactedfor100Kgmoles
of(C2H4Ofree)crudeproduct=113.12KgmolesofC2H4O.
For100KgmolesofC2H4Osentonly95Kgmolesreacts.

Therefore,for95KgmolesofC2H4Oreacting,thetotalcrude
product(C2H4Ofree)formedis
(95x100)/113.12=83.981Kgmolesofcrudeproduct
Thecrudeproductis(83.981+5)Kgmolesfor100Kgmolesof
C2H4Ofeed.ThetotalC2H5OHreacting=[(83.981x89.885)/100
+(83.981x7.101)/100]=81.4504Kgmoles
Therecyclemustbesuchthattheratiois1:6
Totalrecycleis:(6x100)81.450=518.5
KgmolesThecompositionofthestreamb
is
518.55KgmolesofC2H4O+(83.981+5)Kgmolesofcrude
productThecompositionofstreamaonaC2H4Ofree
basisisknown.

Fortower(1):
F=83.981
F=D+W(1)
AndFxF=DxD+WxW(2)
NowfixingxDas0.99andxW=0.05,
xF=0.89885Wehavesolving(1)and
(2):
83.981x0.89885=
Dx0.99+(83.981D)0.05Solving
forDwehave
D=75.837Kg
molesAndW=

8.143Kgmoles

Letustakethe0.01molefractionlostisdistillateisallcarbitol(itis
lighterthentriglycolether)
Thereforecarbitollostaboveis0.75837Kgmoles
NowW=8.143Kgmolesandhas(8.143x0.05)=0.40715Kgmoles
ofmonoglycolether
ThecarbitolincrudestreamaonaC2H4O
freebasisis=(83.981x7.101)/100
=5.963Kgmoles
Ofthis5.963Kgmolesofcarbitol,0.75837Kgmolesofcarbitolis
lostindistillate.
Thereforecarbitolpresent=5.963
0.75837
=5.205
Kg
moles

Theremainingintriglycolether=8.1435.205
0.40715=
2.5307
Fortower(2):
F=8.143Kgmoles
FixingxDas0.99andthisisthepurityoftheproduct
andxW=0.05WehaveF=D+W
FxF=DxD+WxW

AndxFofcarbitol=5.205/8.143
=0.6398.143x0.6391=Dx0.99
+(8.143D)x0.05SolvingforD
weget
D=5.1040Kg
molesAndW
=3.038Kg
moles

For100Kgmolesoffeedwe
have5.1040Kgmolesof
carbitolof0.99purity25TPD=
186.567Kgmoles/day
Theethyleneoxidefeedis3655.309Kgmole/day
TheC2H5OHfeedis(81.450x186.567)/5.1040
=2977.249Kgmole/day
Crudeproduct(C2H4Ofree)is(83.981x3655.309)/100
=3069.765Kgmole/day
CrudeproductwithC2H4Ois(88.981x3655.309)/100
=3252.530Kgmoles/dayThe
C2H4Orecycleis(518.55x3655.309)/100

=18954.558Kgmole/day
Monoglycolether,distillatetower(1)=75.837x36.55309=2772.069
kgmoles/day

Foftower(2)is(8.143x3655.309)/100
=297.6510Kgmoles/dayAnd

Dis(5.1040x3655.309)/100

=186.566Kgmoles/day
Andwis(3.038x3655.309)/100=111.048Kgmoles/day

ENERGYBALANCE
Thedatumtemperatureistakenas30c.
1)ENERGYBALANCEAROUNDTHEREACTOR
Feedofethyleneoxideandethylalcoholcanbe
assumedatroomtemp(30c).
1hourofoperationistakenasthebasis.
Heatinput+generationrate
= heatoutputheatsuppliedexternally

b. Heatinput=(mcpt)alcohol+(mcpt)EtO
= 0+0,(t

reference

=t

feed

= 0
c. Generationrate
Theheatofreactionis23kcal/gmolofEtOreacted.
Generationrate=+Rfeedrateconversion

c. Heatoutput

= 234180103152.300.95
= 13.9100159109J/hr

= (mcpt)alcohol+
(mcpt)EtO

(mcpt)mge+(mcpt)carbitol+(mcpt)tge+

Theproductoutlettemperatureistakenasthatofreaction
temp,200c.(mcpt)alcohol=
789.77175170kJ/hr
(mcpt)mge=114.97210170kJ/hr
(mcpt)EtO=7.614115170kJ/hr
(mcpt)carbitol=9.0825481.4170kJ/hr
(mcpt)tge=439.6143.85125170kJ/hr
Thereforeheatoutput=28.780106kJ/hr
d. Heatsuppliedexternally=(28.78013.910)106kJ/hr
= 14.8700109J/hr
= 4130.5kW.
2) 2) ENERGY BALANCE AROUND THE ALCOHOL
RECOVERYTOWER
Heatinput+Reboilerload
=heatoutput+heatloadofcondenser
a.Heatinput

outputfromthereactorisfeedforthetower
hence,heatinput=28.780109J/hr.
b.Heatoutput
Theproductsofthetowerareat100c.
Theoutputofthetoweraredistillateandresidue.
heatoutwithdistillate=(mcpt)alcohol
=789.2715070kJ/hr.
heatoutwithresidue=(mcpt)carbitol+(mcpt)mge+
(mcpt)tge
= 9.0825343.2570

114.9710570
+ 3.8512376.7570
= 1.16718kJ/hr

Thetotalheatoutput=9.453106kJ/hr
c. CondenserloadReboilerload=(28.7809.453)109
= 19.327109J/hr.
3)ENERGYBALANCEAROUNDTOWER1(MGE
SEPARATION)

Heatinput+Reboilerload
=heatoutput+heatloadofcondenser
a.Heatinput
outputfromthealcoholrecoverytowerisfeedforthetower
hence,heatinput=1.1671109J/hr.
b.Heatoutput
Theproductsofthetowerareat150c.
Theoutputofthetoweraredistillateandresidue.
heatoutwithdistillate=(mcpt)mge
=
114.97205120kJ/hr.heatoutwith
residue=(mcpt)carbitol+(mcpt)tge
= 9.0825418.99120

+
3.8512457.52120

= 0.667106kJ/hr
Thetotalheatoutput=3.4952106kJ/hr
c. ReboilerloadCondenserload=(3.49521.1671)109
= 2.3281109J/hr.
4) ENERGY BALANCE AROUND TOWER 2
(PRODUCTTOWER).Heatinput+Reboilerload
= heatoutput+heatloadofcondenser
b. Heatinput
outputfromtower1isfeedforthe
towerhence,heatinput=
0.667109J/hr.
b.Heatoutput
Theproductsofthetowerareat202c.
Theoutputofthetoweraredistillateandresidue.
heatoutwithdistillate=(mcpt)carbitol
=
9.0825481.6172kJ/hr.heatoutwith
residue=(mcpt)tge
= 3.8512505.6172
= 0.3349106kJ/hr
Thetotalheatoutput=1.0872106kJ/hr
c. ReboilerloadCondenserload=(1.08720.667)109
= 0.4202109J/hr

MAJOREQUIPMENTDESIGN
DISTILLATIONCOLUMN

ProcessDesign
Thefeedrateforthetoweris297.6510
kmols/dayThereforeF=
297.6510kmols/day

=12.4021
kmols/hrThemolefractionofcarbitolin
thefeedis0.639.i.eXf=0.639
Neglectingtheresidualmonoglycoletherandotherimpurities,
thusthemixturecanbetreatedasbinarymixtureofcarbitoland
triglycolether.
Thedistillaterateis186.566kmols/day
ThereforeD=186.566kmols/day

=7.7735kmols/hr
Themolefractionofcarbitolinthe
distillateis0.99.i.exd=0.99
Theresiduerateis111.048kmols/day
ThereforeW=111.048
kmols/day

=4.627
kmols/hr

Themolefractionofcarbitolinthe
residueis0.05i.exw=0.05
Thefeedistakenassaturatedliquid,sinceitiscomingfroma
Reboiler.
Thereforeq=(HvHf)/(HvHl)
=1
Thereforetheslopeoftheqlineisq/(q1)=

Vaporpressuredata
Temperature
(K)
405
408
411
415
418
422
426
429
433
437
441
444
448
453

VaporpressureofMCB
(mmHg)
700
810
900
1000
1050
1150
1300
1400
1500
1700
1800
2000
2200
2400

VaporpressureofDCB
(mmHg)
190
210
240
260
300
330
370
400
450
500
575
625
680
740

Minimumrefluxratio(Rm)
Operatingrefluxratio

Vaporliquidequilibriumdata
Temperature
(K)
408
411
415
418
422
426
429
433
437
441
444
448
453

xa
(molefractionof
MCBinliquid)
0.92
0.79
0.68
0.61
0.52
0.42
0.36
0.30
0.22
0.15
0.10
0.05
0.01

ya
(molefractionof
MCBingas)
0.98
0.94
0.90
0.85
0.79
0.72
0.66
0.59
0.49
0.36
0.26
0.15
0.04

Fromgraph:
=0.17857=1.5xRm

=0.2678Slopeofoperating
linexd/(R+1)=0.7808Fromthegraphthenumberofidealstages
iseight.Thereforetotalnooftraysinthecolumnisseven.Number
ofstagesinenrichingsectionisfour.Numberofstagesinstripping
sectionisthree.
LiqflowrateinenrichingsectionL
d. =DxR
= 7.7735x0.2678
= 2.0817kmols/hr
VaporflowrateintheenrichingsectionG
G =L+D
= (1+R)D

= 1.2678x7.7735
= 9.855kmols/hr
LiqflowrateinthestrippingsectionL
d. =L+qF
= 2.0817+12.4021
= 14.4838kmols/hr
VaporflowrateinthestrippingsectionG
e. =G+(q1)F
=9.855kmols/hr

EVALUATIONOFAVERAGEPROPERTIESOFTHE
MIXTURE

DENSITYCALCULATION

Liqphasecalculations
Carbitoldensityatvarioustemperatures
(
!
)202c
=
3
5.977kmol/m .( ! )213c

= 5.857kmol/m . ( ! )
3
261c=5.379kmol/m .
Triglycolether(TGE)densityatvarioustemperatures
(
!
)202c
=
3
6.6209kmol/m .(!)213c
3
= 6.5141kmol/m . ( ! )
3
261c=6.0870kmol/m .
Vaporphase
calculationsAssuming
idealgas
PV=nRT
WithP=1
atm
R=0.082
3
m atm/kmolkT=
tempinKelvin
Carbitoldensityatvarious
temperatures(!)204c=
3
0.025565kmol/m .
(!)218c=
3
0.024835kmol/m .(!)282c
3
=0.21970kmol/m .
Triglycoletherdensityatvarious
3
temperatures(!)204c=0.25566kmol/m .
(!)218c=
3
0.02483kmol/m .(!)282c
3
=0.021972kmol/m .
Mixtureproperties
3

(!l)kg/m =avgmolecularwt/(x1!carbitol+x2!TGE)
(!l)202c=134.16/(0.99/5.977+0.01/6.6209)
=802.65
3
kg/m (!l)213c=
3
838.248kg/m

(!l)261c=885.248kg/m

( )

!v 204c

( )

!v 218c

( )

!v 282c

=3.4298kg/m
3
=3.3550kg/m
=3.233kg/m

Theaveragepropertiesintheenrichingsectionand
strippingsectioncanbesummarizedintothetableas
below.

PROPERTY

ENRICHING
SECTION
2.0817

TOP

14.4838

BOTTOM

9.855

9.855

9.855

9.855

0.99

0.7

0.7

0.13

0.99

0.93

0.93

0.18

134.16

138.80

138.80

147.92

134.16

135.12

135.12

147.12

202
214
279.28

213
218
288.939

213
218
2010.38

261
282
2142.44

1322.14

1331.60

1331.60

1449.86

Liqdensity!l

802.65

838.32

838.32

885.248

9DS GHQVLW\ !v

3.4298

3.35502

3.35502

3.233

Liqflowrate
kmols/hr
Vapflowrate
kmols/hr
Liqmole
fractionx
Vapmole
fractiony
Avg(liq)
molecularwt
g/mol
Avg(vap)
molecularwt
g/mol
Templiq(c)
Tempvap(c)
Liqflowrate
kg/hr(L)
Vapflowrate
kg/hr(G)
kg/m

kg/m

TOP

BOTTOM

STRIPPING
SECTION

2.0817

14.4838

0.01380

L/G[!v!l)0.5

0.013726

0.09550

0.08930

ENRICHINGSECTIONDESIGN
1.TOWERDIAMETERCALCULATION
0.5

ThemaximumvalueofL/G[ !v!l) is0.1380atthetopofthe

section
ChoosingIntaloxsaddles,
polypropyleneNominalsize=
25mm
2

Surfacearea=206m /m .
/

Fp=105permeter
3

Fromsteamtablesthedensityofwaterat202cis802.65kg/m .
% !water!liq=862.28/802.65=1.0742
l

1/3

1/3

(mix)=x11 +x22

1/3

1/3

1/3

= 0.99(0.4 )+0.01(0.92 )
= 0.7360
l(mix)=0.4cp

Fromgraph(1838)
2

0.2

G )S% !g!l*g)=0.22
2

SolvingweobtainGf=7.954kg/m s
Choosing65%flooding
2

WegetG=0.65Gf=5.17027kg/m s.
Thereforethecrosssectionalareaofthetower
Ac=massflowrate/G

= 1322.14/(3600x5.17027)
2

= 0.07103m
0.5

Thediameterofthecolumn={(4xAc)/}
Dc=0.30073m
TakingthecorrectedDc=0.300
mThereforeAc=0.07068m
=0.76085ft

towerdia/packingdia(Dc/dp)=0.30/0.025
=12(>10)

WETTINGRATE
3

Lmin=279.28/(802.65x60x4.546097x10 )Gallons/min
=1.2756GPM
Degreeofwetting
Lmin/towerareainft

= 1.2756/0.760855
2

= 1.676536GPM/ft
2

Henceacceptable(greaterthanthelimitsof0.5GPM/ft ).
PRESSUREDROPCALCULATIONS
Pressuredropcanbecalculatedusingtheequation
(C3*Utl)

S &2*10
where

!g*Utg

equation18.48

C2,C3areconstantstobeevaluatedfromtable18.7Utl,
Utgaresuperficialliqandvaporflowrate(ft/sec).

!g

is

avgvapordensity(lb/ft ).
SUHVVXUH GUopininchwater/ftpacking

)
$F !
Utl= L/
=284.11/(3600x0.7068x802.48x0.3048)
l

=4.4647x10 ft/s.

Utg=G$F !g

=1326.87/
(3600x0.7068x3.39241x0.3048)
=5.0431ft/s.
3

Densityofgas!g=3.3924Kg/m =0.21177lb/ft
C2=0.31

C3=0.0222
(C3*Utl)

!g*Utg
&2*10
(0.0222*0.004464)
2
= 0.31*10
*0.21177*5.0431
= 1.6700inwater/ftpacking
= 139.06mmwater/mpacking

STRIPPINGSECTIONDESIGN
1.TOWERDIAMETERCALCULATION
0.5

ThemaximumvalueofL/G[ !v!l) is0.09550atthetopofthe

section
ChoosingIntaloxsaddles,
polypropyleneNominalsize=
25mm
2

Surfacearea=206m /m .

Fp=105permeter
Fromsteamtablesthedensityofwaterat213cis
3

848.662kg/m .
% !water!liq=862.28/838.32=1.01233
l

1/3

1/3

(mix)=x11 +x22

1/3

1/3

1/3

= 0.7(0.4 )+0.3(0.94 )
= 0.7663
l(mix)=0.45cp

Fromgraph(1838)

2)S

0.2

!g!l*g)=0.15
2

SolvingweobtainGf=7.038kg/m s
Choosing65%flooding
2

WegetG=0.65Gf=4.574kg/m s.
Thereforethecrosssectionalareaofthetower
Ac=massflowrate/G
= 1331.60/(3600x4.574)
2

= 0.0808m
0.5

Thediameterofthecolumn={(4xAc)/}
Dc=0.3205
mTakingthecorrectedDc=0.300m
ThereforeAc=0.07068m
=0.76085ft

towerdia/packingdia(Dc/dp)=0.30/0.025

=12(>10)

WETTINGRATE
3

Lmin=2010.38/(838.32x60x4.546097x10 )Gallons/min
=8.791GPM
Degreeofwetting
Lmin/towerareainft

= 8.791/0.760855
2

= 11.555GPM/ft
2

Henceacceptable(greaterthanthelimitsof0.5GPM/ft ).
PRESSUREDROPCALCULATIONS

Pressuredropcanbecalculatedusingtheequation
(C3*Utl)

S &2*10
where

!g*Utg

equation18.48

C2,C3areconstantstobeevaluatedfromtable18.7Utl,
Utgaresuperficialliqandvaporflowrate(ft/sec).
3

!gis

avgvapordensity(lb/ft ).

SUHVVXUH GUopininchwater/ftpacking

Utl=L/$F !l)
= 2076.41/(3600x0.7068x861.78x0.3048)
= 0.031067ft/s.

U =
tg

G$F!g

=1390.73/(3600x0.7068x3.29401x0.3048)
=5.443ft/s.

'HQVLW\ RI JDV!g=3.29401Kg/m =0.20565lb/ft

C2=0.31
C3=0.0222

(C3*Utl)

!g*Utg
&2*10
(0.0222*0.0.31067)
2
= 0.31*10
*0.20565*5.443
= 1.8917inwater/ftpacking
= 157.60mmwater/mpacking

AVERAGECONDITIONSFORENRICHINGAND
STRIPPINGSECTION
PROPERTY

ENRICHING

STRIPPING

SECTON

SECTION

Liqflowratekmols/hr

2.0817

14.4838

Liqflowratekgs/hr

284.10

2076.41

Vaporflowrate

9.855

9.855

Tempofliqc

207.5

247.5

Tempofvapc

211

250

'HQVLW\ RI OLT !liq

820.485

861.784

3.39241

3.2940

0.425

0.46

0.010025
12.622

0.010756
15.6123

kmols/hr

kg/m

'HQVLW\ RI YDS !vap

kg/m

cp

cp

vap

liqdynes/cm
l
2
D ABcm /sec
V
2
D ABcm /sec

LiqSchmidtnumber

16.408x10

17.58x10

0.05278
315.609

0.06082
303.627

0.559

0.5368

sl

VapSchmidtnumber

sg

TOWERHEIGHTCALCULATION

ENRICHINGSECTION
Theheightoftheenrichingsectioncanbegivenby

Z=H

og*

og

Where
+

Hog=Hg m*Gm/Lm*Hl
Nog=NTln1)
isthestrippingfactorgivenbymGm/Lm
0.33
1.11
*Z *Scg
% 'c

Hg

Fromfig18.65
%

Dc=0.3m
L=284.10/(0.7068x3600)
=1.11653kg/sm
f1

lwater)

0.16

0.16

= (0.425/1.0)

= 0.872
1.25

f2!water!l)

= (1000/820)

1.25

= 1.0322
f3

0.8
water/ l)

0.8

=(72.8/12.622)

0.5

/(L*f1*f2*f3*f4)

=4.0625
Hg=0.029*50*(0.3)

1.11

0.33

*(Z)

0.5

*(0.559) /
0.5

(1.11653*0.872*1.3022*4.0625) =0.5365*(Z)

0.33

ByCornellmethodeqn1856
Hl!&

0.5

l!lDl) (z/3.05)

0.15

Liquidrate=5.2147Kg/m s
!

P IURP ILJ 60)

C=0.8(fromfig1859)
0.5

Hl=0.035*0.8/3.28*(315.69) *(Z/3.05)
=0.1282*(Z)

0.15

0.15

Hog=0.5365*(Z)

0.33

0.1214*4.734*0.1282*(Z)
0.33

0.5365*(Z)

0.15

+0.0737*(Z)

0.15

Nog=NTln1)
isthestrippingfactorgivenbymGm/Lm
mistheslopeofequilibriumlineinenriching
section.m(top)=0.1
m(bottom)=
0.1428m(avg)
=0.1214
Gm/Lm=
9.855/2.0817

= 4.73
4=

0.57
50
NT=4
Nog=4ln0.5750/(0.57501)
=5.2144

Z=H

og*

og

= {0.5365*(Z)

0.33

+0.0737*(Z)

0.33

0.15

}5.2144

0.15

= 2.796*(Z) +0.3844*(Z)
= Solvingtheaboveequationbytrailanderror,weget
=
= Z=5.35m
=
= Thereforeheightofenrichingsectionis5.35m

STRIPPINGSECTION

Theheightofthestrippingsectioncanbegivenby

Z=H

og*

og

Where
+

Hog=Hg m*Gm/Lm*Hl
Nog=NTln1)
isthestrippingfactorgivenbymGm/Lm
0.33
1.11
*Z *Scg
% 'c

Hg

Fromfig18.65
%

Dc=0.3m
L=2076.41/(0.7068x3600)
=8.160kg/sm
f1

lwater)

0.16

0.5

/(L*f1*f2*f3*f4)

0.16

= (0.46/1.0)

= 0.8831
1.25

f2!water!l)

= (1000/861.78)

1.25

= 1.204
f3

0.8
water/ l)

0.8

= (72.8/15.612)
= 3.427
Hg=0.029*50*(0.3)

1.11

0.33

*(Z)

0.5

*(0.559) /
0.5

(6017.69*0.8831*1.204*3.427) =0.052*(Z)

0.33

ByCornellmethodeqn1856
Hl!&

0.5

l!lDl) (z/3.05)

0.15

Liquidrate=8.160Kg/m s
!

P IURP ILJ 60)

C=0.8(fromfig1859)
0.5

Hl=0.07*0.8/3.28*(303.627) *(Z/3.05)
=0.2516*(Z)

0.15

0.15

Hog=0.0527*(Z)
=0.0527*(Z)

0.33

0.33

+0.86751*0.25167*(Z)

+0.21826*(Z)

0.15

0.15

Nog=NTln1)
isthestrippingfactorgivenbymGm/Lm
mistheslopeofequilibriumlineinstrippingsection.
m(top)=0.3
m (bottom) = 2.25

m (avg) = 0.1.275
Gm/Lm=0.6804

=0.86751
NT=3
Nog=3ln0.8675/(0.86751)
=3.218

Z=H

og*

og

= {0.0527*(Z)
= 0.1673*(Z)

0.33

0.33

+0.21826*(Z)

+0.7023*(Z)

0.15

}3.218

0.15

Solvingtheaboveequationbytrailanderror,weget
Z=0.84m
Thereforeheightofstrippingsectionis0.84m
Totalheightofthetoweris
Z=(5.35+0.84)
=6.19m
(B)MECHANICALDESIGNOFDISTILLATIONCOLUMN

DiameterofthetowerDi=0.3m
Workingpressure=1atm=1.0329kg/m
Designpressurepd=1.1362kg/m

ShellmaterialPlainCarbonsteel
Permissibletensilestress(ft)=950kg/cm
Insulationthickness=50mm
Densityofinsulation=770kg/m
Topdisengagingspace=1m

Bottomseparatorspace=2m
Skirtheight=2m
Densityofmaterialcolumn=7700kg/m
Windpressure=130kg/m

1)Shellthickness
ts=PDi/(2fJP)+C
3

P=designpressureinkg/cm
f=allowabletensilestresskg/cm

C=corrosionallowance(2mm)
J=jointfactor
ts=(1.1362*300)/(2*950*0.851.1362)+Cts=
2.2112mm
minimumthicknessallowableis6mmts=
6mm
2)HeadDesign
Shallowdishedandtorisphericalhead
Thicknessofheadisgivenby
th=PRCW/2fJ
Rc=crownradius,300mm
W=stressintensificationfactor
W=0.25(3+(RC/RK)
Rk=knuckleradius,6%ofcrownradius.
W=1.7706mm

th=1.1362*300*1.7706/2*950*0.85
ts=0.3737mm

minimumthicknessists=6mm
3)Shellthicknessatdifferentheights
AtadistanceXmfromthetopoftheshellthestress
are;AxialStress:(tensile)

f =p D
ap

i___

4(tsC)

= 1.1362*300/4*(62)
3

= 142.025kg/m
4)Compressivestressduetoweightofshelluptoadistance
2
2
Xfds=/4*(Do Di )sX
2
2
/4*(Do Di )
= sX
3

= 0.77Xkg/m
5) Compressivestressduetoweightofinsulation

d(ins)

= D t

ins inins

Dm(tsC)
fd(ins)=412*50*770*X

306*(62)
fd(ins)=1.1015X
6)compressiveStressduetotheweightoftheliquidandpacking

fd=OLT DQG SDFNLQJ ZW XQLW KHLJKW ;

Dm(tsC)
Forthechosenpacking,25mmplasticintaloxsaddles
=0.91
3

approximatewt/m kg/m =76Number

3

ofelementsperm =55800
2

Totalvolumeofthepacking=*Dc *h/4
=0.4375m

Totalvoidvolume=0.91*0.4375=
0.3981m

Totalvolumeoftheactualpacking=0.039379m

3
3

Averagedensityoftheliqinthecolumnis841.13kg/m .
fd=(76+841.13*0.3981)/0.4375*XDm(tsc)

= 24.42Xkg/cm
7)

Stressduetotheweightoftheattachments
Thetotalweightoftheattachments

Theweightoftheheadistakenas1020kgsW a
=(1020+140X)
Fd(att)=(1020+140X)/(*30.6*0.4)
2

= 26.525+3.640Xkg/cm
8) TotalcompressivedeadweightstressatheightX(sumof27)

fds=29.9315X+26.525
9)Stressduetowindloadatdistance
2

Xfws=1.4*PwX /*Do(tsc)
2

= (1.4*130*X )/(*31.2*.4)
2

= 4.642X
10) Stressinupwindside

max

=f +f f
ws

ap

dx

0.8*950=4.642X +142.02529.9315X26.525
2

4.642X 29.9315X644.5
=0solvingforX
X=15.2177m
11)stressindown
side

max

=f +f +f

ws

ap

dx

4.642X 29.9315X928.55
=0X=17.730m
Fromthis,wholetowerof6mmthicknessisenough.
12)Skirtdesign
ThematerialofconstructionforskirtiscarbonsteelIS:2062
1962

Minimumweightofvessel
Wmin=(Di+ts)ts(H2)s+2WH
H=11.29(Totalheightoftowerincludingskirtheight)
3

s=7700kg/m (specificweightofshellmaterial)
WH=1020kg(weightofhead)

Wmin=(0.3+0.006)(0.006)(11.292)7700+2*1020
Wmin=2171.33kg

Maximumweightofvessel
Wmax=Ws+Wi+Wl+Wa
Ws=10800kg(weightofshellduringtest)Wi=4200kg
(weightofinsulation)
Wl=656.67kg(weightofwaterduringtest)Wa=4400kg
(weightofattachments)
Wmax=20056.67kg
Windload
PW=K1pwHD
Forminimumweightofcolumn,D=0.3m
Pw(min)=0.7*130*11.29*0.3=308.217kg
Pw(max)=0.7*130*11.29*0.312=320.54kg

Minimumwindmoment
MW(min)=PW(min)*H/2
= 308.217*11.29/2
= 1739.88kgm
Maximumwindmoment
MW(min)=PW(min)*H/2
= 320.54*11.29/2
= 1809.44kgm
Bendingstresses
2

fb(min)=4Mw(min)*D *t
2

=4*1739.88*0.3 *t

=2.461/t

kg/cm

fb(max)=4Mw(max)*D *t
= 4*1809.88
2
*0.3 *t

= 2.5604/tkg/cm
Minimumdeadloadstress
Fds(min)=Wmin/dt
= 2171.33/*0.3*t
2
= 0.23038/tkg/cm
Maximumdeadload
Fds(max)=Wmax/dt
=0.21280/tkg/cm

Maximumtensilestresswithoutanyeccentricloadfz=
fbs(max)fbs(min)
980*0.8=0.0994/tt=
0.1449mm

Maximumcompressivestresswithoutanyeccentricload

f =f
z

bs(max)

bs(min)

fz=0.125E(t/Do)
6
= 0.125*2.04*10 *t/0.3
= 850000t
850000t=2.5604/t+2.461/tt=2.4305
m

Minimumskirtthicknessis7mm,byproviding1mmcorrosion
allowance
ts=8mm
DESIGNOFSKIRTBEARINGBOLTS
Maximumcompressivestressbetweenbearingplateand

foundationfc=Wmax/A+Mw/2
A=(Dol)/2
l=outerradiusofbearingplateminusouterradiusof
2
skritZ=Rm l
Rm=(Dol)/2
2

fc=20056/((0.3l)l)+1809.44/((0.3l) l
Theallowablecompressivestressofconcretefoundationvariesfrom
2
5.5to9.5MN/m
6
2
0.55*10 =20056/((0.3l)l)+1809.44/((0.3l) l
l=57mm
Asrequiredwidthofbearingplateisverysmalla100mm
widthisselected
l=0.1m
6

thereforefc=0.50253*10 kg/m

thicknessofbearingplate
tbp=l(3fc/f)
6

=100(3*0.5026*10 /96*10 )=12.53mm

Bearingplatethicknessof12.53mmisrequired
Astheplatethicknessrequiredislessthan20mm,no
reinforcementisrequired.
fmin=Wmin/AMs/Z
2

= 2171.33/(0.30.1)0.1+1739.88/(0.30.1) 0.1
2

= 103897kg/m
Themodulusvalueistaken,lessthanzeroimpliesthatthevesselmust
beanchoredtotheconcretefoundationbymeansofanchorboltsto
preventoverturningowningtothebendingmomentinducedby
thewindorseismicload.
Thereforeanchorboltsaretobe
usedPbolt*n=fmin*A
where
Pbolt=loadononeanchorbolt

10.211

fmin=stressdeterminedbyeqn
A=areaofthecontactbetween
bearingplateand
foundation
= 103897.5*3.14*(0.30.1)*0.1
2

= 6528.07kg/m
6

Forhotrolledcarbonsteelf=5.73*10
2
kg/m (arn)f=nPbolt
arn=1139.2
2
mm For
2
12X1.5,ar=63mm
Numberofbolts=11392/63=18bolts
Therefore18boltsaretobedistributedequally.
MINOREQUIPMENTDESIGN
CONDENSER

ProcessDesign
Therefluxcondenser,condensesvaporofthecolumnandsenditasthe
reflux.
Thevaporflowrateis
9.855kmols/hr.Tvap=202c.(sat
vap).
Molecularwtofvap=134
+HDW RI FRQGHQVDWLRQ 202c

=21000Btu/lbmol

= 364.52kJ/kg.
= 48846kJ/kmol.
HeatloadQ=9.85548846
= 481377.33kJ/hr.
= 133.71kW.
Lettheoverloadbe10%.
ThereforeQ=1.1133.71kW
=147.0875kW.

Letwateratatempof25cbeusedtocondensethe
vapor.Fixingtheoutlettempofwateras35c.
Thewaterflowrate
Wc=147.0875/Cpwater(ToutTin)
= 147.0875/4.18710
= 3.512kg/s.
Tvap=202c,
7lmtd={(20235)(20225)}/ln{(20235)/(202

25)}=171.95c

Letusassumeanoverallheattransfercoefficient,(U)of
567.83J/m2sc.Astheheatloadisverylow,weshalluseaDPHE.
RequiredareaforheattransferisA

= Q/

7lmtd

= 147.08875/(171.95567.83)
= 1.369m2.

= Choosing2NPS,40SCHand1.25asthetubes.
=

N=A/

(Ld02)

Innerdiaof2NPSpipe
Outerdiaof2NPSpipe
Innerdiaof1.25NPSpipe
Outerdiaof1.25NPSpipe

=5.25cm
=6.032cm
=3.505cm
=4.216cm

=
= Takingthelengthofthepipeas6ft(

1.828m)Lengthavailableforheat
transfer=1.528m
=
= Heattransferarea,outsideareaofinnerpipe=Ld02N
= whereN,isthenumber

ofhairpins.Therefore,
=
2
= =1.369m /(1.5280.042162)=3.382
=
= TakingthenumberofhairpinsNas4.
=
= Thereforethecorrectedheattransferarea=1.61906m

= Correctedoverallheattransfercoefficient=480W/m c
=
= Locationofthefluids,thevaporistakenintheannulusandwater

inthetube.

=
= OVERALLHEATTRANSFERCOEFFICIENTCALCULATION
=
=

(Ud)
Theoverallheattransfercoefficientisgivenbythe
equation

= 1/Ud=1/ho+(Do/Di)(1/hi)+{xwDo/(Dwk)}+dirtfactor
=
=
= where,
= ho,hiareoutsideandinsideheattransfer

coefficients.xw,Dwarewallthicknessandmean
walldiameter.
= kiswallmaterialthermalconductivity.
=
= 1)ANNULUSSIDE(carbitolvapors)
=
= Theindividualheattransfercoefficient

= ho=0.725{[K3!2g@ >'7@`0.25
where,
Kisthethermalconductivityofcondensate=0.12461W/mK

3.

! LV WKH GHQVLW\ RI FRQGHQVDWH

NJ P

gisaccelerationduetogravity

=9.81m/s2.

Distheoutsidediaofthetube

=0.04216m

LV WKH KHDW RI FRQGHQVDWLRQ

N- NJ

LV WKH YLVFRVLW\ RI WKH FRQGHQVDWH

FS

7 LV WHPS GLIIHUHQFH RI WKH FRQGHQVDteandthewall=202116

=86c.

ho=959.92W/m2K

Therefore,

2)Insideheattransfercoefficient(tubeside)
hidi/K=0.023(Re)0.8(NPr)0.4
Where,
ReistheReynoldsnumber.NPris
theprandtlnumber.
5H

'9!

= 4Massflowrate/('
= 43.512/(0.035050.85103)
= 150092.0
NPr=CP.

= 4.181030.85103/0.16
= 5.82

Therefore

0.8

0.4

hidi/K=0.023(150092) (5.82) =643.84

hi=643.84K/di
= 643.840.61/0.03505
= 11205.3W/m2K
3) WallResistancecanbeexpressedas
Meantempofthewallis116c.
{xwDo/(Dwk)}=0.003550.04216/(0.0384945)
=8.64109105m2K/W

4)Dirtfactorof0.0005isassumed.
Therefore,

1/Ud=1/ho+(Do/Di)(1/hi)+{xwDo/(Dwk)}+dirtfactor
= 0.0889/(0.0736611205.3) + (1/959.92) + 8.64109105 +
0.0005
= 1.73588103.
Ud=576.076W/m2K

SincetheUassumed<Ud,thedesignisacceptablefromheattransferpoint
ofview.
PRESSUREDROPCALCULATIONS

1)TUBESIDE

PT=(4fLvt2/2gDi)tg

TubesideReynoldsnumber=NRe=150092.0
Frictionfactorf=0.079(NRe)1/4
=0.079(150092)
1/4
=4.013103
Tubesidevelocityvt=3.656m/s
PT=
= (44.01310314.6243.6562/
(29.80.03505)9969.8
= 44.54kPa.
2) ANNULUSSIDE
PA=(4fLva2/2gDH)g
AnnulussideReynoldsnumbercanbecalculatedas
= DHMassflowrate/(areaofannulus)
= 0.010640.3668/(0.009710
3
7.683104)
= 508.91103

Frictionfactorf=0.079(NRe)1/4

=0.079(508910)1/4
=2.957104

Annulussidevelocityis138.784m/satoneendnegligibleatotherend.
Thereforetheannulussidevelocity=(138.78+0)0.5
=69.392m/s.
PA=
= (42.95710414.62469.3922/(29.80.01064))3.349.8
= 13.0728kPa.

Hencethepressuredropsareacceptable.

MechanicalDesign
Letthematerialofconstructionbe15C8,carbonsteel.
T(tensilestrength)=410N/mm

y(yieldstrength)=

220N/mm2.Thepressureintheannulusis
takenas1atm.Thedesignpressurebe
takenas
P=1.251
atm=
1.25atm
1)Thetotalloadoftheboltisgivenby
Fa=Pressureannularcrosssectionalarea
= (1.251)7.683103
= 19.461N
2)Thetotalloadcapacityoftheboltisgivenby
=C(Ar)1.418
=2.29(Ar)1.418
Therefore,stressareaoftheboltAr=(19.461/4.52268)1.418
=4.52268mm2.
3)Fromtable9.8,fortheobtainedAr

,boltdiad=
3mm

pitch

=o.5mm.

4)Initialtensionloadinabolt
Fi=2805d
= 4815N
5) Effectofappliedloadonboltstress
Thefinalloadonthebolt=KFa+Fi,Kforasbestosgasket=
0.6F=0.619.461+4815
=4826.67N

5)Numberofbolts,

Anempiricalruleforthenumberofboltsinpipejointsisgivenby
N=0.024Dc+2,Dc=diaofcylinder
60.32mmN=3.44768
Asastandardwecanprovide6bolts
6)Themaximumspacingoftheboltinanyfluidtightjoint
s

s=6d
s=18mm
7)Theextensionatoneendisthesameasthatofthe
pipe.Theboltcirclediameterisgivenby
D2=D1+3.2d
D1=1.8D
+20=
128.576m
m
D2=128.57+3.23
= 138.176mm
8) Theflangethicknessisgivenby

t=0.35D+9mm
= 0.3560.32+9
= 31.12mm

POLLUTIONANDSAFETY
Therawmaterialethyleneoxideusedfortheproductionofcarbitolwill
explodeinthepresenceofcommonigniters.PureEtOvaporisdifficult

toignitecomparedtooxideairorhydrocarbonairmixtures,requiring
sparkenergiesabouttenthousandtimeslarger.
Thedesignoftheplantshouldbesuchthatthegasmixtureshandledare
alwaysoutsidetheexplosivelimit.Theactualsafeoperatingrangesare
dependent on operating temperatures, pressures, equipment
configurations, gas composition, dynamics of catalyst and
instrumentation.
Healthaffects
Toxiceffects
Therearenoreportsoneffectsofoccupationalexposure.Thereisone
casereportdescribingamanwhodrankabout300mlofDEGEE.He
developed severe symptoms of poisoning: CNS effects, breathing
difficulty,thirst,acidosisandalbuminuria.
An unpublished report (Kligman, 1972) cited by Opdyke describes
dermalapplicationof20%DEGEEinpetroleumjelly,underocclusion,
to25volunteersfor48hours.Theapplicationresultedinnoirritationor
sensitization.Inanothersensitizationstudy,pureDEGEEwasapplied
underocclusiontothebacksof98youngmenfor7days,followedbya
3day application 10 days later. No skin sensitization or edema was
observed,but7ofthemenhadpronouncedskinreddening.
ACUTE/CHRONICHAZARDS:
When heated to decomposition this compound emits acrid smoke,
irritatingfumesandtoxicfumesofcarbonmonoxideandcarbondioxide
PersonalProtectionandExposureControl
Eye:Weargogglestoavoid

splash.Skin:Useprotective
gloves.

Inhalation:Usemaskwhilespraying.Avoidinhalation.
EngineeringControls:SufficientventilationtokeepwithinOSHA
PEL/TLVlimit.Thedriedfilmoftheproductmaycontainallorsomeof
thefollowingOSHAchemicalsAndmaybecomeadustnuisancewhen
removedbysandingorgrinding.OSHArecommendsaPEL/TWAof15
mg/m3fortherespirablefraction.ACGIHrecommendsTLV/TWAof10
mg/m3fortotaldust.Useapprovedmask,eyegogglesandgloveswhile
sanding,orgrinding.Skinabsorptionmaycontributetotheoverall
exposureofthematerial.

HEALTHEFFECTSOFOVEREXPOSUREANDFIRSTAID

PrimaryRoutes

Symptoms

FirstAid

Eye

Maycauseburningand
irritationupon
directcontact.

Flushwithwater.Seek
medicalattention

Skin

Directskincontactmay Washwithsoapand
causeskin
water.
irritationanddermatitis.

Ingestion

Severeoralintoxication Donotinduce
willleadto
vomiting.Seekmedical
intenseburningofthe
attention.
throatandmay
resultindrowsiness,
numbnessand
headachefollowedby
weakness&
nausea.

Inhalation

Acuteoverexposurein
mistformmay
resultinirritationof
throat&lungs.

Removepersontofresh
air.Apply
artificialrespiration.

COSTESTIMATIONANDECONOMICS

MarshallandShiftindexin1992forequipmentsis
943.1Costestimationbasedontheequipment
Costofthebarecolumnsis
3*11000.Saddlescost720/m3.
Totalcostofthepacking,forthe3columns
3*315.Costofthereactoris16000.
Therearefiveheatexchangers,reboilersandcondensers,ofshelland
tubetype.Theapproximatecostoftheeachexchangeris3000.
ThecostofoneDPHEis1500.
Thereforethetotalcostoftheequipment=
66445.Taking1=Rs63.
Totalcostoftheequipment=Rs
66445*63*1048/943.1.
=Rs4.65115*106.

ESTIMATIONOFDIRECTCOST
COMPONENTS

COSTS

Purchasedequipmentcost(E)

Rs4.65115*106

Purchasedequipmentinstallation
(39%ofE)

Rs1.8139*106

Instrumentation(installedcost),
28%E

Rs1.3023*106

Pipinginstalled,31%E

Rs1.4418*106

Electricalinstallation,10%E

Rs0.465115*106

Yardimprovement,10%E

Rs0.465115*106

Servicefacility,55%E

Rs2.55813*106

Land,6%E

Rs0.279069*106

TOTALDIRECTCOST(D)

Rs13.999*106

ESTIMATIONOFINDIRECTCOST

=Rs1.48836*106
1. Enggandsupervision(32%E)
2. Construction+contractorfees(25%directcost)
=Rs3.4997*106
Thereforetotalindirectcost(I)

=Rs4.988118*106

DIRECTANDINDIRECTCOST(TOTAL)=Rs18.9871*106
Contingence(10%D+I)

=Rs1.89871*106

Fixedcapitalinvestment(FCI),
contingence+D+I

=Rs20.88801*106

WorkingCapital:(1020%ofFixedcapitalinvestment)
ConsidertheWorkingCapital=15%ofFixedcapitalinvestment
i.e.,Workingcapital=15%of20.88801*106=0.15
20.88801*106

=Rs3.13320*10

TotalCapitalInvestment(TCI):
Totalcapitalinvestment
e. Fixedcapitalinvestment+Workingcapital
6

f. Rs24.02121*10

i.e.,Totalcapitalinvestment=Rs24.02121*106
EstimationofTotalProductcost:
I. ManufacturingCost=Directproductioncost+Fixedcharges
+Plantoverheadcost.
A.

FixedCharges:(1020%totalproductcost)
i. Depreciation:(dependsonlifeperiod,salvagevalueand
methodofcalculationabout13%ofFCIformachinery
and
equipmentand23%forBuildingValueforBuildings)
Considerdepreciation=13%ofFCIformachineryand
equipmentand3%forBuildingValueforBuildings)
i.e.,Depreciation=Rs.2.71541106
ii. LocalTaxes:(14%offixedcapitalinvestment)
Considerthelocaltaxes=3%offixedcapital
investment

i.e.LocalTaxes=0.0320.88801*106
= Rs.0.6266106
iii. Insurances:(0.41%offixedcapitalinvestment)
ConsidertheInsurance=0.7%offixedcapital
investment

i.e.Insurance=0.007Rs20.88801*106
= Rs.0.14621607106
iv. Rent:(812%ofvalueofrentedlandandbuildings)
Considerrent=10%ofvalueofrentedlandand
buildings

Rent=Rs.0.1302322x106
Thus,FixedCharges=Rs.3.61844106
B.DirectProductionCost:(about60%oftotalproductcost)
NowwehaveFixedcharges=1020%oftotalproductcharges
(given)ConsidertheFixedcharges=15%oftotalproductcost
1

Totalproductcharge=fixedcharges/15%

Totalproductcharge=3.61844106/15%

Totalproductcharge=3.61844106/0.15

Totalproductcharge(TPC)=Rs.24.1229106

% RawMaterials:(1050%oftotalproductcost)
Considerthecostofrawmaterials=25%oftotalproductcost
Rawmaterialcost=25%of24.1229106

Rawmaterialcost=Rs.6.03073106

ii. OperatingLabour(OL):(1020%oftotalproductcost)
Considerthecostofoperatinglabour=12%oftotalproduct
cost

operatinglabourcost=12%of24.1229106
Operatinglabourcost=Rs2.89478106

iii. DirectSupervisoryandClericalLabour(DS&CL):

iv. (1025%ofOL)

ConsiderthecostforDirectsupervisoryandclericallabour=12%ofOL

Directsupervisoryandclericallabourcost
= 12%of2.89478106

= 0.34736106
iv. Utilities:(1020%oftotalproductcost)
ConsiderthecostofUtilities=12%oftotalproductcost

Utilitiescost=12%of24.1229106
=0.1224.1229106

Utilitiescost=Rs.2.8946410

v.Maintenanceandrepairs(M&R):
(210%offixedcapitalinvestment)
Considerthemaintenanceandrepaircost
=5%offixedcapitalinvestment
i.e.Maintenanceandrepaircost=0.0520.88801106

=Rs.1.0444106
vi.OperatingSupplies:(1020%ofM&Ror0.51%ofFCI)
ConsiderthecostofOperatingsupplies=15%ofM&R
Operatingsuppliescost=15%of1.0444106
Operatingsuppliescost=Rs.0.15666106
vii.LaboratoryCharges:(1020%ofOL)Consider
theLaboratorycharges=15%ofOL

Laboratorycharges=15%of2.89478106
Laboratorycharges=Rs.0.43421210

= PatentandRoyalties:(06%oftotalproductcost)
ConsiderthecostofPatentandroyalties=4%oftotalproduct
cost
d.
e.

PatentandRoyalties=4%of24.1229106
PatentandRoyaltiescost=Rs.0.964919106

Thus,DirectProductionCost=Rs.14.7676106
C.PlantoverheadCosts(5070%ofOperatinglabour,supervision,and
maintenanceor515%oftotalproductcost);includesforthefollowing:
generalplantupkeepandoverhead,payrolloverhead,packaging,medical
services, safety and protection, restaurants, recreation, salvage,
laboratories,andstoragefacilities.
Considertheplantoverheadcost=60%ofOL,DS&CL,andM
&RPlantoverheadcost
=60%of((2.8947106)+(0.3473106)+
(1.04441106))Plantoverheadcost=Rs.2.5719106
Thus,Manufacturecost=Directproductioncost+Fixedcharges+Plant
overheadcosts.
Manufacturecost=Rs.20.9580106
AI.

GeneralExpenses=Administrativecosts+distributionand
sellingcosts+researchanddevelopment
costs

Administrativecosts:(26%oftotalproductcost)
ConsidertheAdministrativecosts=5%oftotalproduct
cost

Administrativecosts=Rs.1.20614510

B.

DistributionandSellingcosts:(220%oftotalproductcost);
includescostsforsalesoffices,salesmen,shipping,andadvertising.
ConsidertheDistributionandsellingcosts=15%oftotalproductcost
Distributionandsellingcosts=15%of2.41229107

DistributionandSellingcosts=Rs.3.6184106

C.ResearchandDevelopmentcosts:(about5%oftotalproductcost)

ConsidertheResearchanddevelopmentcosts=5%oftotalproduct

cost
ResearchandDevelopmentcosts=5%of2.41229107
ResearchandDevelopmentcosts=Rs.1.2010106

D.Financing (interest): (010% of total capital

investment) Consider interest = 5% of total capital
investment

i.e.interest=5%of2.40212107
Interest=Rs.1.20106106
Thus,GeneralExpenses=Rs.7.23178106
III.TotalProductcost=Manufacturecost+General
ExpensesTotalproductcost=Rs.28.1897106

V.GrossEarnings/Income:
WholesaleSellingPriceofcarbitolperton=70

HenceWholesaleSellingPriceofcarbitolperton.=6370=Rs.
4400TotalIncome=SellingpriceQuantityofproductmanufactured
=4400(25T/day)(330days/year)
TotalIncome=Rs.36.3106
Grossincome=TotalIncomeTotalProductCost
=36.310624.122106
GrossIncome=Rs.12.1771106
LettheTaxratebe45%(common)
Taxes=45%ofGrossincome

=45%of12.1771106
Taxes=Rs.5.4796106
NetProfit=GrossincomeTaxes=Grossincome(1Tax
rate)Netprofit=(12.1771106)(5.4796106)
=Rs.6.6974106
RateofReturn:
Rateofreturn=Netprofit100/TotalCapital
InvestmentRateofReturn=6.6974106100/
(24.02121106)RateofReturn=27.881%

PLANTLOCATIONANDlayout
THELOCATIONOFTHEPLANTCANHAVEACRUCIAL
EFFECTONTHEPROFITABILITYOFAPROJECT,ANDTHE
SCOPEFORFUTUREEXPANSION.MANYFACTORSMUSTBE
CONSIDERED WHEN SELECTING A SUITABLE SITE, AND
ONLYABRIEFREVIEWOFTHEPRINCIPALFACTORSWILL
BEGIVENINTHISSECTION.THEPRINCIPALFACTORSTO
BECONSIDEREDARE:
g.

LOCATION, WITH RESPECT TO THE MARKETING

AREA.

h.

RAWMATERIALSUPPLY.

i.

TRANSPORTFACILITIES.

j.

AVAILABILITYOFLABOUR.

k.

AVAILABILITYOFUTILITIES:WATER,FUEL,POWER.

l.

AVAILABILITYOFSUITABLELAND.

m.

ENVIRONMENTALIMPACT,ANDEFFLUENTDISPOSAL.

n.

LOCALCOMMUNITYCONSIDERATIONS.

o.

CLIMATE.

p.

POLITICALSTRATEGICCONSIDERATIONS.

MARKETINGAREA

FOR MATERIALS THAT ARE PRODUCED IN BULK

QUANTITIES: SUCH AS CEMENT, MINERAL ACIDS AND
FERTILIZERS, WHERE THE COST OF THE PRODUCT PER
TONISRELATIVELYLOWANDTHECOSTOFTRANSPORT
A SIGNIFICANT FRACTION OF THE SALES PRICE, THE
PLANT SHOULD BE LOCATED CLOSE TO THE PRIMARY
MARKET. THIS CONSIDERATION WILL BE LESS
IMPORTANT FOR LOW VOLUME PRODUCTION, HIGH
PRICEDPRODUCTS;SUCHAS
PHARMACEUTICALS. IN AN INTERNATIONAL MARKET,
THERE MAY BE AN ADVANTAGE TO BE GAINED BY
LOCATING THE PLANT WITHIN AN AREA WITH
PREFERENTIALTARIFF.
.
RAWMATERIALS
THE AVAILABILITY AND PRICE OF SUITABLE RAW
MATERIALS WILL OFTEN DETERMINE THE SITE
LOCATION. PLANTS PRODUCING BULK CHEMICALS ARE
BEST LOCATED CLOSE TO THE SOURCE OF THE MAJOR
RAW MATERIAL; WHERE THIS IS ALSO CLOSE TO THE
MARKETINGAREA.
TRANSPORT
THETRANSPORTOFMATERIALSANDPRODUCTSTO
AND FROM PLANT WILL BE AN OVERRIDING
CONSIDERATIONINSITESELECTION.

IFPRACTICABLE,ASITESHOULDBESELECTEDTHAT
ISCLOSEATLEASTTWOMAJORFORMSOFTRANSPORT:
ROAD, RAIL, WATERWAY OR A SEAPORT. ROAD
TRANSPORT IS BEING INCREASINGLY USED, AND IS
SUITABLE FOR LOCAL DISTRIBUTION FROM A CENTRAL
WAREHOUSE. RAIL TRANSPORT WILL BE CHEAPER FOR
THELONGDISTANCETRANSPORTOFBULKCHEMICALS.
AIRTRANSPORTISCONVENIENTANDEFFICIENTFOR
THE MOVEMENT OF PERSONNEL AND ESSENTIAL
EQUIPMENTANDSUPPLIES,ANDTHEPROXIMITYOFTHE
SITETOAMAJORAIRPORTSHOULDBECONSIDERED.
AVAILABILITYOFLABOUR
LABOUR WILL BE NEEDED FOR CONSTRUCTION OF
THE PLANT AND ITS OPERATION. SKILLED
CONSTRUCTION WORKERS WILL USUALLY BE BROUGHT
INFROMOUTSIDETHESITE,BUTTHERESHOULDBEAN
ADEQUATE POOL OF UNSKILLED LABOUR AVAILABLE
LOCALLY; AND LABOUR SUITABLE FOR TRAINING TO
OPERATE THE PLANT. SKILLED TRADESMEN WILL BE
NEEDEDFORPLANTMAINTENANCE.LOCALTRADEUNION
CUSTOMS AND RESTRICTIVE PRACTICES WILL HAVE TO
BE CONSIDERED WHEN ASSESSING THE AVAILABILITY
AND SUITABILITY OF THE LABOUR FOR RECRUITMENT
ANDTRAINING.
UTILITIES(SERVICES)

THE WORD UTILITIES IS NOW GENERALLY USED

FOR THE ANCILLARY SERVICES NEEDED IN THE
OPERATION OF ANY PRODUCTION PROCESS. THESE
SERVICES WILL NORMALLY BE SUPPLIED FROM A
CENTRALFACILITY;ANDWILLINCLUDE:

ELECTRICITY: POWER REQUIRED FOR

ELECTROCHEMICAL

PROCESSES,

MOTORS,

LIGHTINGS,ANDGENERALUSE

STEAM FOR PROCESS HEATING: THE STEAMS

REQUIREDFORTHEPROCESSAREGENERATED
INTHETUBEBOILERSUSINGMOSTECONOMIC
FUEL.

COOLING WATER: NATURAL AND FORCED DRAFT

COOLINGTOWERSAREGENERALLYUSEDTOPROVIDE
THECOOLINGWATERREQUIREDONSITE.

WATER FOR GENERAL USE: THE WATER REQUIRED

FOR THE GENERAL PURPOSE WILL BE TAKEN FROM
LOCAL WATER SUPPLIES LIKE RIVERS, LAKES AND
SEAS. BECAUSE OF THIS REASON ALL THE PLANTS
LOCATEDONTHEBANKSOFRIVER.

DEMATERIALIZEDWATER:DEMATERIALIZEDWATER,
FROM WHICH ALL THE MINERALS HAVE BEEN
REMOVED BY IONEXCHANGE IS USED WHERE PURE
WATERISNEEDEDFORTHEPROCESSUSE,INBOILER
FEEDWATER.

REFRIGERATION: REFRIGERATION IS NEEDED FOR

THE PROCESSES, WHICH REQUIRE TEMPERATURES
BELOWTHATAREPROVIDEDBYTHECOOLINGWATER.

INERTGASSUPPLIES.

COMPRESSED AIR: IN AN ETHYLENE OXIDE PLANT

COMPRESSEDAIRISONEOFTHERAWMATERIALS.ITIS
ALSONEEDEDFORPNEUMATICCONTROLLERSETC.
EFFLUENTDISPOSALFACILITIES:FACILITIESMUSTBE
PROVIDEDFORTHEEFFECTIVE
DISPOSALOFTHEEFFLUENTWITHOUTANY
PUBLICNUISANCE.

ENVIRONMENTALIMPACT,ANDEFFLUENTDISPOSAL
ALL INDUSTRIAL PROCESSES PRODUCE WASTE
PRODUCTS, AND FULL CONSIDERATION MUST BE GIVEN
TO THE DIFFICULTIES AND COAT OF THEIR DISPOSAL.
THEDISPOSALOFTOXICANDHARMFULEFFLUENTSWILL
BE COVERED BY LOCAL REGULATIONS, AND THE
APPROPRIATE AUTHORITIES MUST BE CONSULTED
DURING THE INITIAL SITE SURVEY TO DETERMINE THE
STANDARDSTHATMUSTBEMET.
LOCALCOMMUNITYCONSIDERATIONS
THE PROPOSED PLANT MUST FIT IN WITH AND BE
ACCEPTABLE TO THE LOCAL COMMUNITY. FULL
CONSIDERATIONMUSTBEGIVENTOTHESAFELOCATION

OF THE PLANT SO THAT IT DOES NOT IMPOSE A

SIGNIFICANTADDITIONALRISKTOTHECOMMUNITY.
LAND(SITECONSIDERATIONS)
SUFFICIENT SUITABLE LAND MUST BE AVAILABLE
FORTHEPROPOSEDPLANTANDFUTUREEXPANSION.THE
LAND SHOULD BE IDEALLY FLAT, WELL DRAINED AND
HAVE LOADBEARING CHARACTERISTICS. A FULL SITE
EVALUATIONSHOULDBEMADETODETERMINETHENEED
FORPILINGOROTHERFOUNDATIONS.
CLIMATE
ADVERSE CLIMATIC CONDITIONS AT SITE WILL
INCREASE COSTS. ABNORMALLY LOW TEMPERATURES
WILL REQUIRE THE PROVISION OF ADDITIONAL
INSULATIONANDSPECIALHEATINGFOREQUIPMENTAND
PIPING. STRONGER LOCATIONS WILL BE NEEDED AT
LOCATIONS SUBJECT TO HIGH WIND LOADS OR
EARTHQUAKES.
POLITICALANDSTRATEGICCONSIDERATIONS
CAPITAL GRANTS, TAX CONCESSIONS, AND OTHER
INDUCEMENTSAREOFTENGIVENBYGOVERNMENTSTO
DIRECT NEW INVESTMENT TO PREFERRED LOCATIONS;
SUCH AS AREAS OF HIGH UNEMPLOYMENT. THE
AVAILABILITY OF SUCH GRANTS CAN BE THE
OVERRIDINGCONSIDERATIONINSITESELECTION.

PLANTLAYOUT
Theeconomicconstructionandefficientoperationofaprocess
unitwilldependonhowwelltheplantandequipmentspecifiedon
the process flow sheet is laid out. The principal factors are
consideredare:

Economicconsiderations:constructionandoperatingcosts.

Theprocessrequirements.

Convenienceofoperation.

Convenienceofmaintenance.

Safety.

Futureexpansion.
Modularconstruction.

Costs

Thecostofconstructioncanbeminimizedbyadoptingalayout

that gives the shortest run of connecting pipe between

equipment, and at least amount of structural steel work.
However,thiswillnotnecessarilybethebestarrangementfor
operationandmaintenance.

Processrequirements

An example of the need to take into account process

consideration is the need to elevate the base of columns to

providethenecessarynetpositivesuctionheadtoapumpor
theoperatingheadforathermosyphonreboiler.


Operations

Equipment that needs to have frequent attention should be

locatedconvenienttothecontrolroom.Valves,samplepoints,
andinstrumentsshouldbelocatedatconvenientpositionsand
heights. Sufficient working space and headroom must be
providedtoalloweasyaccesstoequipment.

Maintenance

Heatexchangersneedtobesitedsothatthetubebundlescan

beeasilywithdrawnforcleaningandtubereplacement.Vessels
that require frequent replacement of catalyst or packing
shouldbelocatedontheoutsideofbuildings.Equipmentthat
requiresdismantlingfor
maintenance,suchascompressorsandlargepumps,shouldbeplaces
undercover.
Safety
Blast walls may be needed to isolate potentially hazardous
equipment,andconfinetheeffectsofanexplosion.
Atleasttwoescaperoutesforoperatorsmustbeprovidedfrom
eachlevelinprocessbuildings.
Plantexpansion
Equipmentshouldbelocatedsothatitcanbeconvenientlytied
inwithanyfutureexpansionoftheprocess.

Spaceshouldbeleftonpipealleysforfutureneeds,andservice
pipesoversizedtoallowforfuturerequirements.

Modularconstruction
Inrecentyearstherehasbeenamovetoassemblesectionsof
plantattheplantmanufacturerssite.Thesemoduleswillincludethe
equipment, structural steel, piping and instrumentation. The
modulesarethentransportedtotheplantsite,byroadorsea.The
advantagesofmodularconstructionare:
f.

Improvedqualitycontrol.

g.

Reducedconstructioncost.

h.

Lessneedforskilledlabouron
site.Someofthedisadvantagesare;

Higherdesigncosts&morestructuralsteelwork.

More flanged constructions & Possible problems with

assembly,onsite.
THEPLANTLAYOUTKEYWORDS
% RawmaterialStorage
% ProductStorage
% ProcessSite
% Laboratories
% Workshop
% Canteen&Changehouse

% FireBrigade
% CentralControlRoom
% Securityoffice
10.Administrative
Building

= SiteforExpansionProject.
= Effluent

treatment

plant13.Powerhouse
= Emergency

water

storage15.Plantutilities
Adetailedplantlayoutisdrawnandsubmittedwiththisthesisreport.
Thisplantlayoutisjustareferenceplantlayout.Theremaybealotof
changesinactualplantlayout.

BIBLIOGRAPHY
(1)

a. R.H.PERRYANDDONW.GREEN,PERRYS
CHEMICALENGINEERSHANDBOOK,6

TH

ED.

MCGRAWHILLINTERNATIONALEDITION,
b.

H.SAWISTOWSKI &W.SMITH, MASS TRANSFER

PROCESSCALCULATIONS,INTERSCIENCEPUBLISHERS,

c.

R.K.SINNOTT,COULSONANDRICHARDSONS
CHEMICALENGINEERINGSERIES,VOLUME6,CHEMICAL
EQUIPMENTDESIGN3

RD

ED.,BUTTERWORTH

HEINEMANN,PAGENO:828855,891895
d.

JOSHI M. V., PROCESS EQUIPMENT DESIGN, 2

ND

ED.,MCMILLANINDIALTD,
e.

MAXS.PETERSANDKLAUSTIMMERHAUS,PROCESS
PLANTDESIGNANDECONOMICSFORCHEMICAL
ENGINEERS,3

RD

ED.,MCGRAWHILLBOOKCOMPANY,

PAGENO:207208,484485.
f. (7)B.CBHATTACHARYA,CHEMICALEQUIPMENT

DESIGN,CHEMICALENGINEERINGEDUCATION
DEVELOPMENTCENTRE.
g.
h. (8) L.E. BROWNELL AND E.H. YOUNG, PROCESS

EQUIPMENTDESIGN,JOHNWILEY&SONSINC.NEW
YORK,