1.

INTRODUCTION
Toluene is an aromatic hydrocarbon. This means it is made up of carbon and hydrogen

atoms, with a formula of C 7H8. It has the strong and sweet smell of paint thinner, but this is not
what makes it aromatic. Aromatic means that it is a member of the benzene family (retrieved
from https://www.reference.com/science/toluene-used-9bc16bafda0b74b8).

Figure1.1: Toluene Structural Diagram

(Retrieved from http://www.chemspider.com/Chemical-Structure.1108.html).

Toluene is a colourless, water-insoluble, flammable liquid, C 7H8 , having a benzene like

odour, obtained chiefly from coal tar and petroleum, used as a solvent in the manufacture of
benzoic acid, benzaldehyde, TNT, and other organic compounds. Toluene also called
methylbenzene and phenylmethane (retrieved from http://www.dictionary.com/browse/toluene).
Toluene is a colourless and odourless liquid with molecular weight of 92.138 g/mol. The
flash point is 40 F and insoluble in water. The boiling point of toluene is 110. 6C and melting
point is -94.9 C. The toluene is a non-corrosive liquid with density 867 kg/m 3 (retrieved from
https://pubchem.ncbi.nlm.nih.gov/compound/toluene#section=Top).

Toluene is part of the process of making saccharin, antiseptics and paint thinners. It is
also in use in making perfumes, dyes, antifreeze and medicine, and it is utilized to produce the
polymers that create plastics and nylon. It is naturally found in coal tar and is a by product of the
production of gasoline and coke.
Though less toxic than benzene, toluene is dangerous to breathe, ingest or spill on the
skin. Exposure can make a person light-headed and nauseous and can distort hearing and
colour vision. Extreme exposure can lead to unconsciousness and death (retrieved from
https://www.reference.com/science/toluene-used-9bc16bafda0b74b8).
Another application of toluene is consumed in the manufacture of toluene diisocyanate
(TDI) which is used in the manufacture of polyurethane flexible foams used in upholstery,
mattresses and automotive seats. Smaller uses for TDI include polyurethane elastomers and
coatings.Other minor chemical uses include the manufacture of phenol, caprolactam,
nitrobenzene, benzoic acid and benzyl chloride. In non-chemical uses, toluene is used in large
quantities as an octane booster in gasoline but most of that portion is not removed from refinery
streams (retrieved from http://www.icis.com/resources/news/2007/11/07/9076550/toluene-usesand-market-data/).

Figure 1.2: One of the uses of the toluene (retrieved from

http://www.marathonpetroleum.com/Brands_Products/Products/Specialty_Products/Petrochemi
cals/Toluene/).

2.0

TOLUENE MARKET SURVEY

Toluene is a colorless, water insoluble, volatile, inflammable liquid with odor that

resembles paint thinner. It is primarily obtained from petroleum and coal tar. Toluene is
commonly used as industrial feedstock and as solvent. It is used in paints, inks, adhesives,
disinfectants etc. It is also used as a raw material to manufacture benzene, xylene, TNT,
production of pharmaceuticals, dyes and cosmetic nail products.
Toluene is often mixed with gasoline as it improves its octane number. In 2010 almost
85% of the toluene produced globally was used as solvents and in production of benzene and
xylene. The global demand for toluene is expected to grow at a steady rate. The Asia-Pacific
region is alone expected to dominate the market. The demand for toluene will be driven by
countries like China, India, and South Korea owing to their robust GDP growth in recent times.
The Chinese demand for toluene will drive the demand for toluene from the Asia-Pacific
region. Developing countries such as those in Asia-Pacific, Latin America, and Eastern Europe,
and the Middle East are likely to see an increase in construction activity during the period 20122018. So this paint market has the potential to drive the toluene market since it is used as a
solvent.
There are some factors that might restrict the growth of this market. One of the most
prominent factors is the ever fluctuating crude oil prices. Also, the demand for other aromatic
products might also act as a restrain for toluene demand. Long term exposure to Toluene has
detrimental effect on central nervous system and can also harm the human brain.
Toluene is consumed in the manufacture of toluene diisocyanate (TDI) which is used in
the manufacture of polyurethane flexible foams used in upholstery, mattresses and automotive
seats. Smaller uses for TDI include polyurethane elastomers and coatings. Other minor
chemical uses include the manufacture of phenol, nitrobenzene, benzoic acid and benzyl
chloride. In non-chemical uses, toluene is used in large quantities as an octane booster in

gasoline but most of that portion is not removed from refinery streams. Since the site will be in
Klang it is suitable to be carry out because it is the industry area. The raw material can be get
easier since it is the industry area hence will lower the cost of production.

Although the plant will be built in Klang, Selangor, but the global demand will be take into
consideration because our company are conducting export trade to the China which is
continuously provide high demand. As reported by ICIS, world toluene demand in 2006 was
23m

tonnes

with Asia surpassing North America as

the

largest

consuming

region,

according to US-based consultant CMAI. More than 50% of toluene demand is used in the
production of benzene and xylenes, around 25% in solvents and 7-8% in the TDI, benzoic
acid and caprolactam. However, it was statistics about ten years ago and there was
slightly changes in the global market which North America are slowly surpassing the
demand in China but we cannot export our product to North America because longer
transportation.
Our company must take into consideration of our competitor such as FINN
Chemical Sdn.Bhd, Minda Kota, Bis Chemical Sdn.Bhd and Shell Sdn.Bhd. Our target
actually to make production of toluene about 50 tonnes per year by the end of 2020.

production of toluene(tonne)
60
50
40

production of
toluene(tonne)

30

Logarithmic (production of
toluene(tonne))

20
10
0
2015

2016

2017

2018

2019

2020

2021

Figure 2.1: projecting of production of toluene

3.0

SITE SELECTION

Figure 3.0: distance between raw materials and plant

Petronas Chemicals Aromatics Sdn. Bhd. operates in the production of aromatics
products (Paraxylene and Benzene). The company was founded in 1995 and based in Kuala
Lumpur, Malaysia. Petronas Chemicals Aromatics operates as a subsidiary of Petroleum
National Berhad (Petronas). The location of the site will be in Klang since there is a Klang Port
which will be easier for the import and exportation of the raw material and the product. The
location of the site is suitable for the transportation of the raw material from both Port Klang and
Petroleum National Berhad.

4.0

PROCESS SELECTION

4.1

Process flow diagram

Figure 4.1 : process flow diagram 1

In this process, the alkane is first enter to the dehydrogenation zone. Then it will mixed
with the benzene to transfers the mixture in the alkylation zone. In the alkylation zome, the
reaction will occurs then the product is brought to the fractionation column. There are 2 output
streams in the first and second fractionation column. In the thrid column it will separate the
product into linear alkylbenzene and heavy alkylbenzene. The heavy alkylbenzene is obtained
by using the recovery column.

Figure 4.2: Process flow diagram 2 (Luyben, 2010)

In this process flow diagram the feed is benzene and ethylene. However, in this plant
design the reactant used is methyl chloride but this process flow diagram can be used because
both methyl chloride and ethylene is both react with benzene to produce alkylbenzene. This
diagram shows that, the reactant is inserted into reactor 2 times before transporting it to the
distillation column. Then in the distillation column, the unreacted substance is recycled back into
the feed stream. Then the product is further purified into another distillation column.

Figure 4.3: process flow diagram 3

Benzene is first proceed to the column for the prufication of the feed. Then the benzene
and the alkyl then enter the reactor. In this reactor there is also a output stream for recycling the
reactant. Then the mixture of the benzene,alkyl and alkylbenzene is then brought to the second
column for the further purification. The recycle stream of column 2 is brought back to the
reactor. Then the product is brought to the cooler.

4.2

I.

Criteria for the selection

Cost
The cost can be divided into two which is chemical cost and production cost. The
chemical cost cover for the reactant used for the process. The operating cost, labours
cost, maintenance cost and many more will be take account for the production cost

II.

Safety
The plant design must have safety design for any hazardous.

III.

Production rate
Rate of production must be able to produce the amount of the demand of the product

IV.

Purity
The purity of the product must be according to the calculation and the purity that demand
wanted.

V.

4.3

Environmental
The design must have environmental friendly design.

Process flow diagram screening

alternatives
CRITERIA
Chemical cost
Production cost
Safety
Production rate
purity
environmental
Total
rank

4.4

PFD 1

PFD 2

+
0
0
+
0
0
2
2

+
+
0
+
+
0
4
1

PFD 3
0
+
+
0
0
3

Modified process flow diagram

I.

The methyl chloride is produced by the plant instead of buying it from supplier by

II.
III.
IV.

reacting the methane with the chlorine.

The methyl chloride is purified by using the absorber and neutralizer.
The reactor is having 3 distillation column for more purification of the products.
The reactor vessel is having only 1 reactor instead of 2 reactor like pfd 2 because

V.

there are distillation column that can cover for the unreacted product for recycling.
The reactor used will be packed bed reactor for the enabling the reactant to making
contact with the catalyst.

Figure 4.4 : modified process flow diagram

REFERENCE
1. TOLUENE https://pubchem.ncbi.nlm.nih.gov/compound/toluene#section=Top
2. definition toluene http://www.dictionary.com/browse/toluene
3. uses of toluene https://www.reference.com/science/toluene-used-9bc16bafda0b74b8