1.

INTRODUCTION

Adipic acid (hexanedioic acid) (1,4-butanedicarboxylic acid) is a white

crystalline solid with a melting point of 153 ºC. From a commercial viewpoint, it is the
most important of all the aliphatic dicarboxylic acids, with a worldwide annual
production of abour 1.8 million metric tons. Its primary use is in the manufacture of
nylon-6,6 the polymide formed by its reaction with 1,6-hexamethylenediamine. This
polymer, discovered by W. H. Carothers of the Du Pont Company in the early 1930s,
has grown to be one of the most important materials employed in the manufacture of
synthetic fibers. Although the later introduction of polyesters, acrylic, polyolefin and
other polyamide fibers has reduced the share of the total market commanded by
nylon-6,6 its versatility has provided a healthy growth rate over the past three
decades for adipic acid. This coupled with the high quality standards demanded for
polymerization and processing into fibers, has led to other applications for adipic acid
in plasticizers, resins, plastics, foams, and also as a food acidulant.

1
 2. PROPERTIES OF ADIPIC ACID

Table 1 Physical and Chemical Properties of Adipic Acid

------------------------------------------------------------------------------------------------------------
Properties Values
------------------------------------------------------------------------------------------------------------
Molecular formula HOOC(CH2)COOH
Molecular weight 146.14
Melting point 153.0-153.1 ºC
Vapor pressure temp, vapor pressure
ºC Pa (mm Hg)
solid 18.5 9.7 0.073
32.7 19.3 0.145
47.0 38.0 0.285
liquid 205.5 1300 10
216.5 2000 15
244.5 6700 50
265.0 13300 100
specific gravity
solid 1.344 at 18 ºC
liquid 1.07 at 170 ºC
specific heat
solid 1590 J/kgK
liquid 2430 J/kgK
vapor 1680 J/kgK
heat of combustion 2800 KJ/mol
heat of fusion 16.7 KJ/mol
heat of vaporization 80.7 KJ/mol
dissociation constants temp,
in water ºC k1·105 k2·106
25 3.10 3.86
50 3.29 3.22
74 2.90 2.55
solubility in water temp, solubility,
ºC g/100 g water
15 1.44
34.1 3.08
40 5.12
50 9.24
60 17.6
70 34.1
87.1 94.8
100 160
distribution coefficients between wt % in water
water and various solvents -----------------
wt % in solvent
carbon tetrachloride >10
benzene >10
chloroform >10

2
 di-isopropyl ketone 4.8
butyl acetate 2.9
ethyl ether 2.2
methyl isobutyl ketone 1.2
ethyl acetate 0.91
methyl propyl ketone 0.55
methyl ethyl ketone 0.50
cyclohexanone 0.32
n-butanol 0.31
flash point, Cleveland open cup 210 ºC
fire point, Cleveland open cup 232 ºC
viscosity at melt temp,
ºC mPa·s (or cP)
160 4.54
193 2.64

------------------------------------------------------------------------------------------------------------

3
 3. ECONOMIC ASPECTS

Since about 90% of worldwide Adipic acid production is used in nylon-6,6 the
synthetic fiber producers are the predominant adipic acid manufacturers. Plant
capacities in the United States are shown in Table . Of the 688,000 t/yr adipic acid
capacity, 677,000 t/yr or 98%, is based on cyclohexane feedstock.
United States Tariff Commission data for adipic acid production and sales for
the ten year period 1966-1975 are given in Table. The sales figures represent only
about 10% of the total domestic production, illustrating the large extent of captive
use.
Nylon-6,6, from adipic acid and hexamethylenediamine, and nylon-6,6 from
caprolactam, make up the major portion of worldwide nylon production. In the
United States the ratio of nylon-6,6 to nylon-6 usage is about 3:1. Nylon-6,6 also
predominates in Great Britain and France, whereas in Japan, Italy,Brazil, and many
Eastern European contries nylon-6 commands the larger market share. These
preferences are reflected in the adipic acid capacities listed in Table.

Another economic factor is the decline of adipic acid as an intermediate for

production of hexamethylenediamine (HMD). In the early 1960s, nearly all nylon-6,6
producers made HMD via reaction of adipic acid with ammonia under dehydration
conditions to give adiponitrile(ADN), which was then hydrogenated to HMD. Thus,
adipic acid was needed for both the acid and amine portions of the nylon-6,6
polymer. The first departure from the use of adipic acid as a raw material for ADN
was made by Du Pont in 1948 with a new process based on furfural. In 1951, Du
Pont introduced another ADN route involving chlorination of butadiene to
dichlorobutanes; these reacted with NaCN to give 1,4-dicynobutene, which was
hydrogenated to AND. It was not until 1965, however, that a second major nylon-6,6
producer, Monsanto, began manufacture of ADN by a nonadipic acid route with the
commercialization of an electrochemical process for hydrodimerzing acrylonitrile to
adiponitrile. A process for direct hydrocyanation of butadiene to adiponitrile was
introduced by Du Pont in 1972. Facilities for production of 104 kt/yr of adiponitrile
from butadiene was started up in 1977, at Chalampe, France, by Butachemie(Du
Pont/Rhone Poulenc joint venture). The electrochemical route to adiponitrile is being
employed in the new plant at Seal Sands, United Kingdom, operated by

4
Monsanto/Montefibre. Start-up of these two facilities in Europe will provide a large
block of adiponitrile capacity based on raw materials other than adipic acid and is
expected to result in a temporary oversupply of adipic acid in Europe.

Adipic acid producers in United States

---------------------------------------------------------------------------------------------------
producer location capacity
---------------------------------------------------------------------------------------------------
Allied Hopewell, Virginia 11
Celanese Bay City, Texas 64
Du Pont Orange, Texas 136
Victoria, Texas 159
El Paso Odessa, Texas 36
Monsanto Pensacola, Florida 282
Total 688
-------------------------------------------------------------------------------------------------------

Adipic acid producers, other than the United States

-------------------------------------------------------------------------------------------------------
country city capacity kt/yr
-------------------------------------------------------------------------------------------------------
Belgium Antwerp 64

zanvoorde 20
Barazil sao Paulo 30
Canada Maitland, ontorio 40
China near Peking 55
France chalampe 250
Roussilon 80
Italy Novara 40
Japan Nobeoka 30
Wakayama 5
Shibukawa 10
Niihama 1

5
 Ube city 2
Poland Chorzow 6.5
Rumania Savinesti 3
United Kigdom Wilton 180
Ardeer 90
U. S. S. R. Severdonezk, 11
Ukraine
West Germany Ludwigshafen 120
Verdingen 35
Witten
Wanne-eickel 15
Total 1087.5
-------------------------------------------------------------------------------------------------------

6
 4. VARIOUS METHODS OF MANUFACTURING

1. nitric acid oxidation of cyclohexanol

Adipic acid is mostly manufactured by the nitric acid oxidation of cyclohexanol-
cyclohexanone mixture in which the ratio is 3:1 to cyclohexanone to cyclohexanol.
Although many variations of the cyclohexane oxidation step have been developed
or evaluated, technology for conversion of the intermediate ketone-alcohol mixture to
adipic acid is fundamentally the same as originally developed by Du Pont in the early
1940s. This step is accomplished by oxidation with 40 – 60% nitric acid in the
presence of copper and vanadium catalysts. The reaction proceeds at high rates,
and is quite exothermic. Yield of adipic acid is 92 – 96 % of the major by-products
being the shorter chain dicarbolylic acids, glutaric acids and succinic acids and CO 2 .
Nitric acid is reduced to a combination of NO 2, NO N2O and N2. Since essentially all
commercial adipic acid production arises from nitric acid oxidation, the trace
impurities patterns are similar in the products of most manufacturers.

2. Other rutes to Adipic acid

It has been known since the early 1950s that butadiene reacts with Con to form
aldehydes and ketones that could be treated further to give adipic acid. Processes
for producing adipic acid from butadiene and carbon monoxide have been explored
since around 1970 by a number of companies, essentially ARCO, Asahi, BASF,
British Petrolium, Du Pont, Monsanto and Shell.
BASF has developed a process sufficiently advanced to consider commercialization.
There are two main variations one a carboalkoxylation and the other a
hydrocarboxylation.

7
 5. MANUFACTURING PROCESS

PROCESS DESCRIPITION

In typical industrial adipic acid plant, as schematically illustrated in figure the

KA mixture is reacted in reactor A with 45 – 55 % nitric acid containing copper (0.1 –
0.5 %) and vanadium (0.02 – 0.1 %) catalyst. Design of the reactor for optimum yield
and heat removal has been the subject of considerable research and development
over the years of use of this process. The reaction occurs at 60 – 90 ºC and 0.1 –
0.4 MPa (14 – 58 psi). It is very exothermic (6280 KJ/kg = 1500 kcal/kg), and that
can reach an autocatalytic runaway state at temperatures above about 150 ºC.
Control is achieved by limiting the KA feed to a large excess of nitric acid in a stirred
tank or circulating loop reactor. Two stages of oxidation are sometimes employed to
achieve improved product quality. Oxides of nitrogen are removed by bleaching
with air in column C, then water is removed by vacuum distillation in column E.

The concentrated stream nominally adipic acid and lower dibasic acid co-
products in 35-50% HNO3 (organic free basis) is then cooled and crystallized(F).
Crude adipic acid product is removed via filtration or centrifugation (G). and the
mother liquor is returned to the oxidizer. Further refining is required to achieve
polymer grade material, usually by recrystallization from water. Residual lower
dibasic acids, nitrogen-containing impurities and metals are removed in this step.
Additional purification steps occasionally are employed, including slurry washing,
further recrystallization and charcoal treatment. The bleacher off-gas, containing NO
and NO2, reacts with air and is reabsorbed as nitric acid for reuse(D).

In order to control the concentration of lower dibasic acid by-products in the

system, a portion of the mother liquor stream is diverted to a purge treatment
process. Following removal of nitric acid by distillation copper and vanadium catalyst
are recovered by ion-exchange treatment. This area of the process has received

8
considerable attention in recent years as companies strive to improve efficiency
and reduce waste. Patents have appeared describing addition of SO 2 to improve
ion-exchange recovery of vanadium improved separation of glutaric acid and
succinic acid by dehydration and distillation of anhydrides formation of amides
improved nitric acid removal prior to dibasic acids recovery and other claims.

Because of the highly corrosive nature of the nitric acid streams, adipic acid
plants are constructed of stainless steel or titanium in the more corrosive areas and
thus have high investment costs.

Wastes and Emissions.

Nitric acid oxidation may be used to recover value from waste streams
generated in the cyclohexane oxidation portion of the process, such as the water
wash and nonvolatile residue streams. The nitric acid oxidation step produces three
major waste streams : an off-gas containing oxides nitrogen and CO 2; water
containing traces of nitric acid and organics from the water removal column; and a
dibasic acid purge stream containing adipic, glutaric and succinic acids. The off-gas
usually is passed through a reducing-flame burner to the atmosphere, or it may be
oxidized back to NOx st 1000-1300 ºC and recovered as nitric acid as claimed in
patent. The overhead water stream usually is treated and reused or disposed of.
The dibasic acids stream usually is either burned or disposed of by deepwell
injection or bio treatment. However as more uses for these acids are discovered the
necessity for their disposal diminishes. The principal emissions of concern from
these processes are related to nitric acid, either as the various oxides of nitrogen or
as a very dilute solution of the acid itself. The fate of these waste streams varies
widely, subject to the usually very complex environment and regulatory situations at
each individual manufacturing site. These issues are now a prome consideration
equal to economics, tn the design of chemical processing systems in the
petrochemical industry.

9
 6. MATERIAL BALANCE

Basis: For the production of 11000 tonnes per year.

Assume 40 tonnes per day of cyclohexanol is needed.

Material Balance over A reactor.

C6H12O + 2HNO3 C6H10O4 + 2 H20 + N20

M. W. 100 2 * 63 146 2 * 18 44

For 40 tonnes of C6H12O

C6H10O4 produced = 40 * 1000

24
= 1666.67 Kg/hr

For the production of 1666.67 Kg/hr of C 6H10O4

C6H12O required = 1666.67 * 100

146
= 1141.55 Kg/hr

HNO3 required = 1666.67 * 2* 63

146
= 1438.35 Kg/hr

H2O produced = 1666.67 * 2 * 18

146

= 410.95 Kg/hr

N2O produced = 1666.67 * 44

146

= 502.38 Kg/hr

But the reaction is 98 % complete.

Therefore total C6H12O required = 1141.55 + 0.02(1141.55)

= 1164.38 Kg/hr

And total HNO3 required = 1438.55 + 0.02(1438.55)

= 1467.11 Kg/hr

Therefore C6H12O unreacted = 1164.38 – 1141.55

= 23.28 Kg/hr

10
And HNO3 unreacted = 1467.11-1438.55
= 28.01 Kg/hr

Total material input to the reactor A

Component Kg/hr Kgmol/hr Wt. % Mol%

C6H12O 1164.38 11.64 44.24 33.34
HNO3 1467.11 23.28 55.76 66.66
Total 2631.49 34.92 100.00 100.00

Total material output to the reactor A

Component Kg/hr Kgmol/hr Wt. % Mol %

C6H10O4 1666.67 11.41 63.33 24.62
N2O 502.58 11.42 19.09 24.64
H2O 410.95 22.83 15.62 49.27
C6H12O 23.28 0.23 0.88 0.49
HNO3 28.01 0.44 1.08 0.98
Total 2631.49 46.33 100.00 100.00

Material Balance over Bleacher C

Reaction : 2 H20 + N2O + O2 NO + NO2 + 2 H2O

M. W. 2 * 18 44 32 30 46 2 * 18

For the 502.58 Kg/hr of N2O

H2O required = 502.55 * 2 * 18

44

= 411.13 Kg/hr

O2 required =502.58 * 1 * 32
44

= 365.51 Kg/hr

For 502.58 Kg/hr of N2O

NO produced = 502.58 * 1 * 30
44
= 342.66 Kg/hr

NO2 produced = 502.58 * 1 * 46

44

11
 = 525.42 Kg/hr

H2O produced = 502.58 * 2 * 18

44

= 411.20 Kg/hr

Material Input

Component Kg/hr Kgmol/hr Wt. % Mol %

N2O 502.58 11.42 37.77 24.65
H2O 411.13 22.84 30.90 49.27
O2 365.51 11.42 27.49 24.65
C6H12O 23.28 0.23 1.74 0.49
HNO3 28.01 0.44 2.10 0.94
Total 1330.51 46.35 100.00 100.00

Material Output

Component Kg/hr Kgmol/hr Wt. % Mol %

NO 342.66 11.42 25.78 24.65
NO2 525.42 11.42 39.48 24.65
C6H12O 23.28 1.74 1.74 0.49
HNO3 28.01 0.44 2.10 0.94
H2O 411.20 22.84 30.90 49.27
Total 1330.57 46.35 100.00 100.00

Material Balance of D Absorber

In absorber NO, NO2, H2O and O2 reacted with each other and HNO3 produced
for reuse of HNO3. And unreacted C6H12O is reacted with sufficient HNO3 and
produce Dibasic acids like Glutaric acid and Succinic acid.
Off gases are vented from the top in which mainly CO 2 and N2O is contained.

Reaction 1 : NO + NO2 + O2 + H2O 2 HNO3

M. W. 30 46 32 18 2 * 63

Reaction 2 : 3C6H12O + 12HNO3 3C4H6O4 + C5H8O4 + 11H2O +2O2 + CO2

M. W. 3 * 100 12 * 63 3 * 118 132 11 * 18 2*32 44

+ 6 N2O 6 * 44

12
For Reaction 1
For 525.42 Kg/hr of NO2

NO required =525.42 * 30
46

= 342.66 Kg/hr

O2 required =525.42 * 32
46

= 365.50 Kg/hr

H2O required = 525.42 * 18

46

= 205.59 Kg/hr

HNO3 produced =525.42 * 2 * 63

46

= 1439.19 Kg/hr

For Reaction 2
For 23.28 Kg.hr of C6H12O

HNO3 required =23.28 * 12 * 63

3 * 100

= 58.66 Kg/hr

C4H6O4 produced = 23.28 * 3 * 118

3 * 100

= 27.47 Kg/hr

C5H8O4 produced = 23.28 * 32

3 * 100

= 10.24 Kg hr

H2O produced = 23.28 * 11 * 18

3 * 100

13
 = 15.36 Kg/hr

CO2 produced = 23.28 * 44

3 * 100

= 3.4144 Kg/hr

N2O produced = 23.28 * 6 * 44

3 * 100

= 20.48 Kg/hr

About 1439.19 Kg/hr of HNO3 is produced by reaction 1 from which anout 58.60
Kg/hr of HNO3 is reacted with C6H12O to produce dibasic acids.

Therefore total HNO3 in output = 1439.19 – 58.66

= 1380.53 Kg/hr

H2O in output stream = 15.36 Kg/hr

Material In

Component Kg/hr Kgmol/hr Wt. % Mol %

NO 342.66 11.42 10.95 19.92
NO2 525.42 11.42 16.79 19.92
O2 365.50 11.42 11.68 19.92
H2O 205.59 11.42 6.58 19.92
C6H12O 23.28 0.23 0.74 0.42
C6H10O4 1666.67 11.41 53.26 19.90
Total 3129.12 57.32 100.00 100.00

Material Out

Component Kg/hr Kgmol/hr Wt. % Mol%

C6H10O4 1666.67 11.41 53.26 32.45
HNO3 1380.53 21.91 44.11 62.31
C4H6O4 27.47 0.232 0.87 0.65
C5H8O4 10.24 0.077 0.37 0.28
H2O 15.36 0.85 0.49 2.4
O2 4.96 0.15 0.15 0.42
CO2 3.43 0.077 0.10 0.21
N2O 20.48 0.46 0.65 1.30
Total 3129.14 35.16 100.00 100.00

14
Material Balance over E Vaccum Concentration Column

Total HNO3 = 1380.53 + 28.01 = 1408.54

Total H2O = 15.36 + 411.20 = 426.56

In output stream about 35 to 50 % of HNO3 is involved so assuming that 42.5 % of

HNO3 is there in outer Stream.

H2O removes as waste is 222.88 Kg/hr.

Material In

Component Kg/hr Kgmol/hr Wt. % Mol %

C6H10O4 1666.67 11.41 47.08 19.78
HNO3 1408.54 22.35 39.79 38.74
C4H6O4 27.47 0.232 12.08 0.40
C5H8O4 10.24 0.077 0.77 0.11
H2O 426.56 23.69 0.28 41.07
Total 3539.48 57.68 100.00 100.00

Material Out
Component Kg/hr Kgmol/hr Wt. % Mol %
C6H10O4 1666.67 11.41 47.08 19.75
HNO3 1408.54 22.35 39.79 38.70
C4H6O4 27.47 0.232 0.77 0.40
C5H8O4 10.24 0.077 0.28 0.13
H2O 203.68 11.31 5.79 19.58
H2O Waste 222.88 12.38 6.29 21.44
Total 3539.48 57.75 100.00 100.00

Material Balance Over F Crystallizer

We get 98 % yield in this column and 2% of the product is washed away with the
Dibasic Acids. And about 50 % of the water is evaporated.

Material In
component Kg/hr Kgmol/hr Wt. % Mol%
C6H10O4 1633.33 11.18 50.34 24.93
HNO3 1408.54 22.35 43.39 49.84
H2O 203.68 11.31 6.27 25.23
Total 3245.55 44.84 100.00 100.00

15
Material Out
Component Kg/hr Kgmol/hr Wt. % Mol %
C6H10O4 1633.33 11.18 50.35 24.92
HNO3 1408.54 22.35 43.39 49.84
H2O 101.84 5.65 3.13 12.60
H2O vaucum 101.84 5.65 3.13 12.60
Total 3245.55 44.84 100.00 100.00

Material Balance over g Centrifuge or Filter

In filter 97.5 % of product is got and remaining is washed away with water HNO 3 is
recycled about 93 % and 7 % of HNO3 is washed away as waste.

1592.49 kg of adipic acid is introduced to H and 40.83 kg is washed away with water
about 1309.94 kg of HNO3 is recycled but 98.59 kg is washed away with water.

Material In
Component Kg/hr Kgmol/hr Wt. % Mol %
C6H10O4 1633.33 11.18 51.95 28.54
HNO3 1408.84 22.35 44.80 57.04
H2O 101.84 5.65 3.25 14.42
Total 3143.71 39.18 100.00 100.00

Material Out
Component Kg/hr Kgmol/hr Wt. % Mol %
C6H10O4 1592.49 10.90 50.65 27.82
HNO3 1309.94 20.79 41.66 53.07
H2O 101.84 5.65 3.25 14.45
HNO3 98.59 1.56 3.15 3.98
C6H10O4 40.83 0.279 1.29 0.68
Total 3143.69 39.17 100.00 100.00

Material Balance over H crystallizer

About 90 % of the water is removed in crystallizer.

Material In
Component Kg/hr Kgmol/hr Wt. % Mol %
C6H10O4 1592.49 10.90 93.98 65.86
H2O 101.84 5.65 6.02 34.14
Total 1694.33 16.55 100.00 100.00

Material Out
Component Kg/hr Kgmol/hr Wt. % Mol %
C6H10O4 1592.49 10.90 93.98 65.86
H2O 91.65 5.09 5.37 30.76
H2O Vaccum 10.18 0.56 0.65 3.38
Total 1694.32 16.55 100.00 100.00

16
Material Balance over I Filter

About 92 % of water is removed in which 4 % of adipic acid is also wash away.

Material In
Component Kg/hr Kgmol/hr Wt. % Mol %
C6H10O4 1592.49 10.90 99.36 95.11
H2O 10.18 0.56 0.64 4.89
Total 1602.67 11.46 100.00 100.00

Material Out
Component Kg/hr Kgmol/hr Wt. % Mol %
C6H10O4 1528.79 10.90 95.39 91.67
H2O 0.81 0.045 0.05 0.37
H2O waste 9.36 0.52 0.58 4.35
C6H10O4waste 63.7 0.43 3.98 3.61
Total 1602.66 11.89 100.00 100.00

In Dryer
In dryer about the rest water is evaporated and the pure product is obtained.
Hence the product is obtained about 1528.79 Kg/hr.
So the yearly production of the adipic acid is about 11000 tones/hr.

17
 7. ENERGY BALANCE

Temperature inside = 75 ºC
Energy through reactants  mCpdT

C6H12O + 2HNO3 C6H10O4 + 2H2O + N2O

Hr1 = Hf(product) - Hf(reactant)

= [ -235.51 + 2(-285.83) + (82.05)] – [725.12 + 2(-174.10)]

= -376.92 + 349.30

Hr1 = -27.62 KJ/mol

Hr1 = -6.598 Kcal/mol

So the reaction is exothermic.

Reactant(60 ºC) Cpm(Kcal/kgmol ºK)(333-298 ºK)

C6H12O 4.16
HNO3 12.22

Product (75 ºC) Cpm(Kcal/kgmol ºK)(373-298 ºK)

C6H10O4 3.976
H2O 6.97
N2O 25.94
C6H12O 4.16
HNO3 12.22

H(reactant) = (niCpmi)reT

= [(11.64 x 4.16) + (23.28 x 12.22) ](333-298)

= 11635.34 Kcal/hr

Simillarly
H(product) = (niCpmi)prT

= [(11.41x3.978) + (22.83x6.97) + (11.42x25.94) + (0.23x4.16) +

(0.44x12.22)](373-298)

= 38028.75 Kcal/hr

18
Hr1 = [-6.598x11.41]

= -75.283 Kcal/hr

Q1 = 38028.75 – (75.285) – 11635.34

= 26468.69 Kcal/hr

Energy Balance over C Bleacher

2H2O + N2O + O2 NO + NO2 + 2H2O

Hr2 = Hf(product) - Hf(reactant)

= [21.570 + 33.18 + 2x(-285.83)] – [2x(-285.83) + 82.05]

= -516.91 – (-489.01)

= -27.9 Kcal/kgmol ºK

Hr(reactant) = (niCpmi)reT

= [(22.84 x 6.97) + (11.42 x 25.94) + (11.42 x 7.007)]x[373-298]

= 40158.7 Kcal/hr

Hr(product) = (niCpmi)prT)

= [(11.42x7.14) + (11.42 x 9.46) + (22.84 x 6.97)](373-298)

= 26157.51 Kcal/hr

Hr2 = -27.9 x 11.42

= -318.618 Kcal/hr

Q2 = 26157.51 – 40158.7 – (-318.618)

= -13682.572 Kcal/hr

Energy Balance over D Absorber

NO + NO2 + O2 + H2O 2HNO3

Hf3 = Hf(product) - Hf(reactant)

19
 = [2x(-174.10)] – [21.570 + 33.18 + (-285.83)]

= - 348.2 + 231.08

Hf3 = -117.12

Hf(reactant) = (niCpmi)ret

= [(11.42 x 6.97) + (11.42 x 25.94) + (11.42 x 7.618) + (11.42 x

7.007)](373-298)

= 40328.30 Kcal/hr

Hf(product) = [22.84 x 12.22](373-298)

= 20932.86 Kcal/hr

Hf3 = (-117.12 x 11.42)

= -1337.5 Kcal/hr

Q3 = 20932.86 –(-1337.5) – 40328.30

= -18057.94 Kcal/hr

Heat Input Q = Q1 + Q2 – Q3

= 26468.68 - 13682.572 -18057.94

Q = 5728.17 Kcal/hr

20
 8. EQUIPMENT DESIGN

Mechanical design
Volume of Reactor = (1164.38/100) + (1467.11/63)
= 34.93 m3
So, here considering the other factors we are taking volume as 34.93m 3.
Volume of reactor = 34.93 m3
Operating Pressure = 1 kg/cm2
Operating Pressure = 75ºC
Material of Construction = carbon steel
Permissible stress = 970 kg/cm 2

Total volume = IID2h + IID3

4 12

Taking H/D = 1.5

So h = 1.5 D

II D3 + II D3 = 40
D = 2.8895 m.

Taking 10% excess pressure so

Design pressure is = 1.1 kg/cm2.

Now shell thickness ts = pDi

2fj-p
= 1.1 x 2.8895
2 x 970 x0.85 – 1.1

= 3.168 /1648

21
 = 0.003 cm.

CHECK FOR EXTERNAL PRESSURE

External pressure is 2 kg/cm2

So, Design Pressure is = 2 x1.1

= 2.2 kg/cm2

Now taking the effective length of the jacket = 592.04 cm.

Now critical pressure is given as

Pc = 2.42E (t/Do) 5/2__________

(1-u2)3/4 (L/Do) - 0.45(t/Do)1/2

u = 0.33
E = 1.95 x 106 Kg/cm2

Pc = 2.42 x 1.94 x 106 (0.003/288.956)2.5_______________

(1-0.332)3/4 (592.04/288.956) - 0.45(0.003/288.956) 0.5

= 9.72 × 10-7 kg/cm2

Herr the value obtained of allowable stress is lower than the design pressure so we
have to take thickness = 2 cm.

So, Do = 292.95

For this,

Pc = 2.42 x 1.94 x 106 (2/292.95)2.5______________

(1-0.332) (592.04/292.95) - 0.45(2/292.95) 0.5
= 11.31 kg/cm2.

22
Pa(allowable) = 11.31/4

= 2.78 kg/cm2.

Here both allowable stresses is more than the design pressure and considering
corrosion allowance we will take 2.5 cm thickness.

DESIGN OF JACKET
Internal jacket diameter = 290 cm.
Internal design pressure = 2 x 1.1
= 2.2 kg/cm2.

Tj = PDi
2fj-p

= 2.2 x 290_____
2 x 970 x 0.85 – 2.2

= 0.3874 cm.

By considering the corrosion allowance and other factor we have to take thickness
as 2 cm.
Here we are using torispherical head.
Th = PRcW
2fj

where W = ¼ ( 3 + Rc/Rk)

Taking Rk = 0.06 Rc

W = ¼ ( 3 + 1/0.06)

23
 = 1.77

th = 1.1 x 1000 x 1.77

2 x 970 x 0.85
= 1.18 cm.

By considering corrosion allowance and others we will take thickness of head as 2

cm.

AGITATOR DESIGN (Propeller Type)

Internal pressure in vessel = 1 kg/cm 2.

Diameter of Agitator = 60 cm.
Speed = 90 rpm.
Here Reynolds number

Nre = NDa2 / 

= 990 x 90/60 x (60/100)2

300 x 10-3
= 1782

Power Curve
P = 6 x 990 x 903 x (0.65)5
9.81 x 75 x 603

= 2.11 hp.

Gland losses (10%) = 0.211

Power input = 2.32
Transmission losses (20%) = 0.46

24
Total hp = 2.995.

Thus we will take 5hp to allow fitting losses.

SHAFT DESIGN

Average rate of torque Tc = (hp x 75 x 60) / 2 x N

= ( 5 x 750 x 60) / 2 x 90
= 398.08 Nm.

Now taking maximum torque as 1.5 times the average torque

Tm = 1.5 x 398.08
= 597.13 Nm.

Now we will find polar modulus of section of the shaft cross section.
Zp = 1.5Tc
Fs

= 597.13 x 1000
= 10.8569 cm3.

d3 = 10.8569
16

d = 3.81cm.

So we will take diameter of shaft with considering other factor is 4cm.

Now torque Tm resisted by a force Fm

Fm = Tm 0.75Rb

25
 = 597.13 x 100
0.75 x 30

= 2653.91 N

Maximum bending moment

M = Fm x l

= 2653.91 x 2

= 5307.82 Nm.

Equivalent bending moment

Me = 1/2[M (M2 + Tm2 1/2)]

= 5324 Nm.
F= Me
Z
Z = d3
32

=  x (0.043)
32

= 6.28 x 10-6

f = 5324
6.28 x 10-6

= 847.77 N/mm 2.

26
Which is higher than the permissible stress. Hence use 6 cm diameter.

Deflection of shaft

 = Wl3
3EI

= 2653.91 x 2003 x 103

3 x 19.5 x104 x  x 64 x 104
64
= 57mm

= 5.7 cm.

Now critical speed is

Nc = 60 x 4.987
5.70.5

= 125.874 rpm.

Hence use 6.5 cm diameter.

BLADE DESIGN

The stress in the blade is given as

F = F(0.75 Rb – Rh)
Bt x Bw
6
where

27
Rb = Radius of blade
Rh = hub radius
Bt = thickness of blade
Bw = width of blade

= 597.13 x 1000 x 6
10 x 602

f = 99.52 N/mm2.

The stress is permissible.

HUB AND KEY DESIGN

Hub diameter of agitator = 2 x shaft dia.
= 2 x 65
= 130 mm.
= 13.0 cm

Length of hub = 2.5 x 65

= 162.5mm

= 16.25cm.

Length of key = 1.5 x shaft dia

= 97.5mm
= 9.75 cm.

Tmax = lbfs = ltfc

d/2 2

103 x 597.13 = 9.75 x b x 65 x102 = 9.75 x T x 130 x 102

3.25 2

28
b = 2.89 mm
t = 3.05 mm.

STUFFING BOX AND GLAND DESIGN

Here b = d + d0.5

= 6.5 + 6.50.5

= 6cm.

Now thickness t = Pb
2f

= 1.1 x 9.05
2 x 970

= 0.005 cm.
A = b + 2t

= 9.05 + 2(0.005)

= 9.06 cm.

Load on gland

F = (d12 – d2) x p
4

= 3424 N

29
Size of stud

3424 =  x do2 x 4 x 55
4

= 4.45mm.

30
 9. PLANT LOCATION

The geographical location of the final plant can have strong influence on the
success of an industrial venture. Considerable care must be exercised in selecting
the plant should be located where the minimum cost of production and safe living
conditions for plant operation as well as the surrounding community, are also
important.

A general consensus as to the plant location should be obtained before a

design project reaches the detailed estimate stage, and a firm location should be
established upon completion of the detailed-estimate design. The choice of the final
site should first be based on a complete survey of the advantages and
disadvantages of various geographical areas and, ultimately, on the advantages and
disadvantages of available real state. The following factors should be considered in
selecting a plant site :

(1). Raw Materials availability

(2). Markets
(3). Energy viability
(4). Climate
(5). Transportation facilities
(6). Water supply
(7). Water Disposal
(8). Labor supply
(9). Taxation and Legal restrictions
(10). Site Characteristics
(11). Flood and Fire protection
(12). Community factors

The factors that must be evaluated in a plant-location study indicate the need for a
vast amount of information, both quantitative (statically) and qualitative. Fortunately,
a large

31
number of agencies, public and private, publish useful information of this type greatly
reducing the actual original gathering of the data.

(1). RAW MATERIALS AVAILABILLITY

The source of raw materials is one of the most important factors influencing the
selection of a plant site. This is particularly true if large volumes of raw materials are
consumed. Because location near the raw materials source permits considerable
reduction in transportation and storage charges. So the plant of Acrylonitrile and
other raw materials is located near Acrylic Fiber plant.

(2). MARKET
The location of markets intermediate distribution centers affects the cost of
production distribution and the time required for shipping. Proximity t the major
markets is an important consideration in the selection of a plant site. Because the
buyer usually finds it advantageous to purchase from nearby sources. We are
providing raw material to the textile industries so good market availability in nearby
cities.

(3). ENERGY AVAILABILITY

Power and steam requirements are high in most industrial plants, and duel is
ordinarily required to supply these utilities. Consequently, power and fuel can be
combined as one major factor in the choice of the plant site. For this IOP(Integrated
off site plant ) is located nearby the plant.

(4). TRANSPORTATION FACILITIES

Water, railroads, and highways are the common means of transportation used by
major industrial conducers. The kind and amount of products and raw materials
determine the ost suitable type of transportation facilities. In any case careful
attention should be given to local freight rates ans existing railroads lines. So here
the road and railroad facility is available. Motor trucking are widely used and can
have access to all three types of transportation, and certainly, at least two types
should be available. There is usually need for convenient air and rail transportation
facilities between the

32
plant and the main company headquarters, and effective transportation facilities for
the plant personnel are necessary.

(5). WATER SUPPLY

The process industries use large quantities of water for cooling, washing, steam
generation, and as a raw material. The plant, therefore, must be located where a
dependable supply of water is available. A large river or lake is preferable, although
deep wells or artesian wells may be satisfactory if the amount of water required is
not too great. Consulting the stage geological survey can check the level of the
existing water table, and information on the constancy of the water table and the
year-round capacity of local rivers to lake should be obtained. If the water supply
shows seasonal fluctuate\ions, time be desirable to construct a reservoir or to drill
several standby wells. The temperature, mineral content, silt or sand content, and
cost for supply and purification treatment must be considered when choosing a water
supply. So here facility of taking water from rivers and frim wells is also possible.

(6). WASTE DISPOSAL

In recent years, many legal restrictions have been placed on the methods for
disposing of waste materials from the process industries. The site selected for a
plant should have adequate capacity and facilities for correct waste disposal. Even
though a given area has minimal restrictions on pollution, it should not be assumed
that this condition will continue to exist. In choosing a plant site the permissible
tolerance levels for various methods of waste disposal should be considered
carefully, and attention should be given to potential requirements for additional
waste-treatment facilities. the waste water should go to Effluent Treatment Plant
and solid waste should go for dumping for land filling.

(7). LABOUR SUPPLY

The type and supply of labor available in the vicinity of a proposed plant site must be
examined. Consideration should be given to prevailing pay scales, restrictions on
number of hours worked per week, completing industries that

33
can cause dissatisfaction or high turnovers rates, among the workers, and variations
in the skill and productivity of the workers.

(8). EQUIPMENT LAYOUT

In making plant layout, ample space should be assigned to each piece of
equipment ,accessibility is an important for maintenance. It is poor economy to fit
the equipment layout too closely into a building. A slightly larger building should be
preferred. The operations that constitute a process are essentially series of unit
operations that may be carried out simultaneously. This sort of layout will make
possible decision of operating labor so that one or two operators can be detailed to
tend all equipment of a like nature.

(9). TAXATION AND LEGAL RESTRICTIONS

State and local tax rates on property income, unemployment insurance, and similar
items vary from one location to another. Similarly local regulations on zoning,
building codes, nuisance aspects, and transportation facilities can have a major
influence on the final choice of a plant site. In fact, zoning difficulties and obtaining
the many required permits can often be much more important in terms of cost and
time delays than many of the factors discussed in the preceding sections.

(10). SITE CHARACTERISTICS

The characteristics of the land at a proposed plant site should be examined carefully.
The topography of the tract of land and the soil structure must be considered. The
topography of the tract of land and the soil structure must be considered, since either
or both may have a pronounced effect on construction costs. The cost of the land is
important as well as local building costs and living conditions. Future changes may
make it desirable or necessary to expand the plant facilities. Therefore, even though
no immediate expansion is planned, a new plant should be constructed at a localities
where additional space is available.

(11). FLOOD AND FIRE PROTECTION

Here the plant is located such as so there is very less problems flooding. Dere the
plant height is not more then suitable so there is very less problem damage.

34
(12). COMMUNITY FACTORS
The characteristics and facilities of a community can have quite an effect on the
location of the plant. If a certain minimum number of facilities for satisfactory living of
plant personnel do not exist, it often becomes a burden for the plant to subsidize
such facilities. Cultural facilities of the community free important to sound growth.
Temples, libraries, schools, civic theatres, concert associations and other similar
groups if active and dynamic do much to make a community progressive. The
problem of recreation deserves special consideration.

(13). SAFETY
A great deal of planning is governed by local and national safety and fire code
requirements.

35
 10. COST ESTIMATION

Working days per annum (300 days)

CAPACITY

Capacity of Adipic Acid is 36.67 tones/day.

Fixed Capital Investment for the year 1972 = 14.86 crores.

SCALE UP 0F OLD COSTS :

For the year 1972 Marshal Cost Index = 360

For the year 2002 Marshal Cost Index = 1453

Hence, Present F.C.I = Original cost Index value at present time

Index value at original time

= 14.86 x 1453
360

= 58.99  60 crores

ESTIMATION OF DIRECT COSTS :

List of equipments used are Reactor, Storage tank, Transfer pumps, Dryer,
Bleacher, Vaccum Distillation Column, Ancillary equipments etc.

CRORES
.
1). Purchased Equipments(30% FCI) 18

2). Purchased Equipments installed(10% FCI) 6

3). Instrumentation and Controls, Installed (3% FCI) 1.8

4). Piping installed(20% FCI) 12

5). Electrical, installed(7% FCI) 4.2

6). Building including services(8% FCI) 4.8

7). Yard improvement(3% FCI) 1.8

8). Service facilities installed(7% FCI) 4.2

9). Land(2% FCI) 1.2

36
Total 54

ESTIMATION OF INDIRECT COSTS

CRORES

1). Engineering and Supervision(5% FCI) 3

2). Construction Expenses 1.2

3). Contractor’s Fee(1% FCI) 0.6

4). Contingency(5% FCI) 3

Total 7.8

FIXED CAPITAL INVESTMENT

F.C.I. = Direct costs + Indirect costs

= 54 + 7.8

= 61.8 crores of Rs.

WORKING CAPITAL

Working capital 20% of Total Capital Investment

But TCI = F.C.I. + Working Capital

T.C.I. = 61.8 + 0.2(T.C.I)

= 77.25 crores.

Working capital = 0.2(77.25)

= 15.45 crores.

ESTIMATION OF TOTAL PRODUCT COSTS :

Present market rate of Adipic Acid per tone is 72500

Production of Adipic Acid per day = 36.67 tones.

Cost of Adipic Acid for 36.67 tones = 26,58,575

Therefore Cost of Adipic Acid per annum

= 2658575 x 300
= 79.75 crores.

37
Total product cost per annum

= 79.75 crores.
DIRECT PRODUCTION COSTS :

CRORES

1). Raw Materials(30% T.P.C.) 23.927

2). Operating Labor(5% T.P.C) 3.987

3). Direct Supervisory & Clerical Labor(15% O.L) 0.4805

4). Utilities(7% T.P.C) 5.5825

5). Maintenance and Repairs(2% T.P.C) 1.595

6). Operating Supplies(0.75% F.C.I) 0.598

7). Laboratory Charges(15% O.L.) 0.47805

Total 36.6456

FIXED CHARGES

CRORES

1). Depreciation(10% T.P.C) 7.975

2). Local Taxes(2% F.C.I) 1.236

3). Insurance(0.7% F.C.I) 0.4326

Total 9.6436

PLANT OVERHEAD COST :

This includes costs for the following :

General plant up[keep and overhead, Payroll overhead, packaging, medical
services, safety and protection, restaurants, recreation, salvage, laboratories, and
storage facilities.

Plant Overhead Cost(5% T.P.C) = 3.9875

Manufacturing Cost = Direct production + Fixed charges + Plant

Overhead cost

38
 = 36.6456 + 9.6436 + 3.9875

= 50.2767 crores.

GENERAL EXPENSES

G.E. = Administrative Costs + Distribution & Selling Costs + R & D Costs

Administrative costs include costs for the following executive salaries, clerical
wages, legal fees, office supplies, and communications.

Distribution and selling costs includes : costs for sales offices, salesman,
shippinf, and advertising.

CRORES

1). Administrative Costs(2% T.P.C) 1.595

2). Distribution & Selling Costs(6% T.P.C) 4.785

3). R & D(1% T.P.C) 0.7975

Total 7.1775

TOTAL PRODUCTION COST :

Total production cost = Manufacturing cost + General Expenses

= 50.2767 + 7.1775

= 57.4542

GROSS EARNINGS :

G.E. = Total income - Manufacturing cost / Total product

= 79.75 - 57.4542

= 22.2958

Hence, Net Amount Earnings = 80% Total Gross Earnings

= 0.8(22.2958)

= 17.82664

Income Tax = 20% Total gross earnings

= 0.2(17.82664)

39
 = 3.5673 crores.

Rate of Return :

% rate of return = Earnings per year x 100

Net investment

Net Annual Earnings = 17.83664

Net Investment = 549

% Rate of Return = 17.83664

54

= 33.3 %

Let X be the Year of Return Investment

X = Net Investment
Net earnings per year

= 54 crores of Rs.
17.83664 crores of Rs. / year

X = 3.03 year.

Hence Payout Period = 3.03 year.

40
 11. HEALTH AND SAFETY FACTORS

Adipic acid is one of many food additives approved by the Food and Drug
Administration as generally recognized as safe and is classified as a miscellaneous
and/or general-purpose food additive buffer and neutralizing agent. One study
covering several years of animal feeding, metabolism, and pathological testing,
concluded that adipic acid is, in fact, just as safe as citric acid and tartaric acids. The
principal hazard in the handling of adipic acid is the danger of dust explosions.
Minimum explosive concentration (dust) is 0.010-0.015 g/L. In high dust areas,
exposure may cause irritation along wrists, neck, and ankles and to the mucous
membranes of the nose, eyes, and throat; Bureau of Mines organic respirator,
goggles, gloves, and apron should be used. Although there are no special precaution
in the normal handling of adipic acid, goof industrial housekeeping practices,
personal hygiene, and avoidance of prolonged and repeated skin or eye contact is
indicated.

41
 12. ANALYTICAL METHODS

The analytical procedures for food-grade adipic acid are described in Food
Chemical Codex. Assay is by direct titration . Melting point is determined by the
capillary melting point method using the Thomas-Hoover apparatus or equivalent.
Arsenic is determined by the silver diethyldithiocarbomate procedure. Heavy metals
(as Pb) are determined turbidimetrically as the sulfide. Ash is determined
gravimetrically as the residue remaining after ashing 100 g of adipic acid at 850 ºC in
a platinum dish. Waste is determined titrimetrically by the Karl Fisher method.
Other methods not specifically for food-grade adipic acid include iron in the
ash by the colorimetric thioglycolic acid method and copper by chloroform extraction
of the diethyldithiocarbomate copper complex from an aquoues ammoniacal solution.
Organic nitrogen compounds (NH3 salts, amides, nitriles) are determined by distilling
NH3 from an alkaline solution of adipic acid and titrating the distillate. Nitrates can be
obtained in the same procedure by addition of Devarda’s alloy to the distillation pot
after organic nitrogen is removed and continuing the distillation. APHA color of
adipic acid is measured on 20 g of adipic acid in 100 mL of methanol solution against
APHA standards. Silicone and hydrocarbon oils are determined by chloroform by
extraction from an aqueous solution of diammonium adipate. After a back-extraction
with aqueous caustic, the oils are separated chromatographically on solicit acid and
measured by infrared spectroscopy.
Acidic impurities can be determined by gas chromatography of their methyl or
trimethylsilyl esters. Levels as low as 10 ppm may be detected if adipic acid is first
concentrated by crystallization from chlorobenzene. Chromatography determination
of the esters has also become the method of choice for determining adipic acid in
oxidation mixtures, synthetic fatty acid mixtures, and synthetic polyamides.

42
 13. USES OF ADIPIC ACID AND ITS DERIVATIVES

Ninety percent of the adipic acid produced in the United States is consumed
in the manufacture of fibers or engineering plastics (qv). The acid is used directly or
to produce 1,6-hexamethylenediamine. In western Europe, in 1974, 86% of the acid
was consumed in nylon fibers with another 8% accounted for in polyamide plastics
production. Large quantities are used as esters and polyesters in plasticizer and
polyurethane compositions and as food acidulants. Lesser quantities find uses as
lubricants, in plastics, leather processing, and a number of other applications.

Esters: The largest consumption of adipic acid after polyamiders is in the

manufacture of esters, about 90% of which are marketed as plasticizers(qv) and
about 10% as high performance lubricants. Table 7 lists production and selling prices
in 1975.
The higher esters of adipic acid are particullarly valuable as plasticizers for
poly(vinyl chloride) (pvc) and its copolymers, natural and sythetic rubbers,
polustyrene, and cellulose derivatives. These esters are easily incorporated into the
polymer system by the usual methods, have a high degree of compatibility, and
impart exceptionally good low temperaure properties. Compatibilities of a number of
typical adipates with poly(vinyl chloride), polystyrene, ethylcellulose, and
nitrocellulose are given in Table 8.
Significant quantities of adipate diesters are employed in PVC for food
packaging films, electrical insulation, and coated fabrics(qv). Their low temperature
for most performance in PVC compositions are outstanding with brittleness
temperatures for most adipate compostions falling between –41 and –54 ºC. These
are much lower than comparable compositions plasticized with di(2-
ethylhexyl)phthalate or tricresyl phosphate. Dioctyl adipate in conjunction with other
plasticizers in acrylamide-ethylene-vinyl chloride copolymer produces a binder for
nonwoven cellulose-nylon blend materials with improved hand and folding
properties. Transparent resins can be prepared by plymerizing diallyl adipate,
divinyl adipate and allyl vinyl adipate. These unsaturated esters have been

43
Co polymerized with unsaturated esters of monocarboxylic acids such as vinyl
acetate to give similar resins.

A number of esters of adipic acid are important synthetic lubricants. The 2-

ethylhexyl, 2-ethylbutyl and 2-butyloctyl adipates are excellent low temperatures
lubricants. Dioctyl and didecyl are used as high temperature lubricants. The diester
of propylene gycol and adipic acid in isobutanol forms a stable hydraulic fluid with
good lubricating properties and does not cause corrosion of metal parts.

Polyesters: The production of complex linear polyesters and polymeric plasticizers

excceded 28,000 t in 1974 and consisted mostly of adipic acid polyesters. The most
important application for polyesters of adipic acid is in the manufacture of
polyurethant elastomers. It is estimated that in1971, 22,000 t of adipic acid was
consumed in the production of polyester-urethane resins for elastomers and surface
coatings with the remaining 82% of polyurethanes based on polyether polyols
because of their inherent price advantage.

Food Additives: Adipic acid is approved for use in all nonstandardized foods as
stipulated by the FDA in its Standards of Identity for foods. This does not preclude
the use of adipic acid in standardized foods on a product-by-product basis. Adipic
acid is now used in gelatin desserts, powdered concentrations for fruit-flavoured
beverages, bottled beverages, nonstandardized jams, and jellies, canned
vegetables, candies, flavoring extracts, and baking powder. Where citric acid, tartaric
acid and potassium bititrate are used in food applications, adipic acid can in many
instances not only perfomr the same function but improve upon the desired results.
Because it is less hygroscopic than competitive acidulants, dry products containing
adipic acid offer longer storage life under humid conditions.

Polyamides : In 1988, 77 % of U. S. demand for adipic acid was for nylon-6,6 fiber,
while 11 % was used in nylon-6,6 resins. In western Europe only about 66 % was
for polyamide, because of the stronger competition from nylon-6. The fiber
applications include carpets, apparel, tire cord and miscellaneous. Nylon-6,6 resins
were distributed between injection molding for such applications as automotive and
electrical parts and for extrusion resins for strapping, film and wire and cable.

44
Polyurethanes : About 3 % of the U. S. polyurethanes market in 1988 was derived
from the condensation product of polyisocynates with low molecular weight
polyadipates having hydroxyl end groups. In 1986 this amounted to 29000 t or 4 %
of total adipic acid consumption. The percentage was similar in Western Europe.
About 90 5 of these adipic acid containing polyurethanes are used in flexible or
semirigid foams and elasomers, with the remainder used in adhesives, coatings and
spandex fibers.

Plasticizers : About 2.5 % of U. S. adipic acid consumed in 1988 was used in basic
types of adipic ester based plasticizers. Simple adipate esters prepared from C 8 –
C13 alcohols are used especially as PVC plasticizers. For special applications
requiring low volatility or extraction resistance polyester derivatives of diols or polyols
are preferred.

Adiponitrile Synthesis : 1,6-hexanediamine, the second ingredient in the

production of nylon-6,6 polyamide is prepared by hydrogenation of adiponitrile. In
several large plants around the world, the nitrile is produced from adipic acid by
dehydration of the ammonium salt. A significant percentage of adipic acid capacity
in Western Europe currently is used for this purpose. The technology has been
reviewed in the literature. Although this was the primary adiponitrile process for
several years, new processes based on propylene and butadiene have supplanted
this technology in the United States. For several years, Du Pont operated a process
based on the chlorination and cyanation of butadiene but this was shut down in
1983. Du Pont produces adiponitrile at two large U. S. plants and one French joint
venture by direct nickel- catalyzed homogeneous hydrocyanation of butadiene.
Monsanto and Asahi developed and practiced the electrolytic coupling of acrylonitrile
process, used in the United States, Western Europe and Japan.

Miscellaneous Applications : About 2 % of U. S. consumption in 1988 was

distributed among several other applications, amounting to several thousand tons
each. Wet-strength resins based on polysmide-epichlorohydrin products consumed

45
about 6800 t in 1986. Unsaturated polyester resins (3600 t in 1986) are used in
surface coatings,

flexible alkyd resins, coil coatings and other coatings because of their curing
properties. Adipic acid also is used as a food acidulant in jams, jellies and gelatins.
Although it has only 2 % of the acidulatn market, 3200 t were used for this purpose
in 1989. The synthetic subricant market consumed about 1800 t as the C 8 – C13
adipate esters in 1986, for this gas turbines, compressors and military jet engines.
An environmentally significant use of the acid and especially its dibasic acids by-
products is as a buffer in the operation.

46
 14. LIST OF MANUFACTURERS

1. Du Pont De Nemours E. I. Inc

Barkley Mill Plaza, Wilmington, D. E. 19898, U. S. A.
2. BASF (UK) Ltd.
PO Box 4, Earl Road, Cheadle, Chess SKB – 6 QG,
3. HULS AG.
PO Box 1320, D 4370, Marl,
W. Germany.
4. UCB Flat SA
Avenue Louise 326, B 1050,
Brussels, Belgium.
5. Chem Systems International Ltd.
28, St. James Square,
London SW 1.
6. Instyut Chemie Prezemystowej,
Nowa sarzyma, Warsza wa,
Rydyiera 8, Poland.
7. Technology Transfer Centre,
Korean Advanced Institute, Daejeon 150,
Deogjin doug-Jung-gu,
Seol 170, Korea.

47
 15. CONCLUSION

This report is prepared purely for academic purpose. It is prepared solely from
literature survey. It provides preliminary information and use idea and insight into
processes and design aspects. Some data has been assumed and some calculated
to give approximate figure.

This report also evaluates the material balance and equipment design cost
estimation and this report is purely academic in nature is has its own limitations
regarding its applicability to commercial plant.

The project needs further sound evaluation in respect to design aspects, practical
typical case which are likely to arrive should be accounted and subsequently
corrected.

48
 16. BIBLIOGRAPHY

1. Kirk-Othmer, Concise Encyclopedia of Chemical Technology, (Wiley-

Interscience publication, 1991) vol 1.
2. John J. Ncketta Encyclopedia of chemical processing and Design vol. 1.
3. Wolfgang Gerhartz, VCH Verlagsgesllschaft (Ed.),Ullmans Encyclopedia of
Industrial Chemistry, (Weinheim, Federal Republic of Germany, 1985), vol. 1.
4. Snell-Ettre, Encyclopedia of Industrial Chemical Analysis, (John Wiley & sons, Inc.,
1971), Vol 1.
5. Robert H. Perry and Don Green, Perry’s Chemical Engineering Handbook, (Mc.
Graw Hill, Inc.; 1984), 6th Ed.
6. SBP Handbook of Petrochemical & Downstream Projects
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