Technological Institute of the Philippines

EXECUTIVE
SUMMARY
 Technological Institute of the Philippines

ACN Corporation (ACN Corp.) will design an acrylonitrile

manufacturing plant with a capacity of 58 MT per day for ABC Incorporated.
This project aims to produce high purity (98%) acrylonitrile of superior
quality, implementation of the best practices and facilities that will be properly
monitored by well trained staff.
The ammoxidation of propylene (SOHIO process) is the route that has
been selected over two other processes that is being used in the industry in
producing acrylonitrile with a first order reaction. The process includes
vaporization of ammonia and propylene, reacting these two raw materials along
with a preheated air and further followed by purification steps. During the
process not only acrylonitrile is produced; by-products such as acetonitrile and
hydrogen cyanide are also produced. These two chemicals are also considered
for selling to acquire a greater profit. In this process proper safety procedures
must be followed as the products and by products are both dangerous and
unstable at atmospheric conditions. In storing acrylonitrile, nitrogen blanketing
must be applied in order to increase its safety level.
The ACN Corporation will be located at Laguna Technopark Special
Economic Zone, Biñan, Laguna, and the location offers easy access to excellent
airport and seaport facilities, tourism and recreational amenities. The city is
very accessible by land or by water which makes it beneficial place to do
business. In addition to that, the supplier of the raw material is located near the
chosen location of the plant which will operate thru continuous process.
The Acrylonitrile Corporation will address the following constraints
during its continuous operation.
I. Economic Constraints
II. Environmental Constraints
III. Health and Safety Constraints
 Technological Institute of the Philippines

I. Economic Constraints
The selected process which is Ammoxidation Process of Acrylonitrile is
a closed system process in which the amount of by-product is remarkably small.
The major constraints is the catalyst that will be used in the reactor is a concern
because of the high price value.
Regardless of the expensive value of the catalyst it will have a great
advantage in the yield and purity of the acrylonitrile that will be produced; the
purity will be the same for both catalyst but the yield of the bismuth
molybdenum oxide is 80% while for the iron antimony oxide is 75%. Catalyst
and their specific price are given in Table 1.1

Table 1.1: Comparative Price of Catalysts being used in the process

Catalyst Price (𝑃ℎ𝑝) per 30 kilogram

Bismuth Molybdenum Oxide 1,057,805

Iron-Antimony Oxide
751,918
 Technological Institute of the Philippines

II. Environmental Constraints

The environment is very significant and a major concern in each
industrial process. Environmental constraints prevents health problems,
maintains the ecosystem that surrounds the vicinity of the production plant,
reduces the environmental impact and be able to meet the environmental
standard of the Philippine law. All companies in our country are obligated to
apply for ISO 14001 in order to address issues or risk regarding environmental
aspects. It aims to reduce waste, improves resource efficiency, improve overall
environmental impact and manage environmental responsibilities. ACN
Corporation must not only meet the needs of the market, but also the
environment. Conducting wastewater treatment for heavy and light impurities
in the wastewater before releasing it to a body of water and also to meet the
standard of the DAO 2016-08. Our plant must be done and reducing the
concentrations of the hazardous gases to our environment is our priority.

Hydrogen Cyanide is one of the by-products of the acrylonitrile process.

Our process produces 5 ppm, and the acceptable level is 0.2 ppm. Low levels of
hydrogen cyanide (often from natural sources) are found in all parts of the
environment and are not thought to cause any significant environmental
damage. High concentrations following a spillage are however toxic to aquatic
life and micro-organisms in soils. The hydrogen cyanide in the process is one of
the final by products, and will be stored and will be contained in individual
drums and will be marketed to different industrial uses, such as mining and
electroplating industries.
 Technological Institute of the Philippines

Carbon Monoxide is one of the by-products of the acrylonitrile process.

It has high levels present in the atmosphere. High concentrations is toxic to
humans and animals. In order to lower the carbon monoxide emission, ACN
Corporation will install a gas absorber that will reduce the level of carbon
monoxide to the acceptable level. ACN Corporation will produce 1121.75 tons
per year of carbon monoxide, however the acceptable level is 100 tons per year.
The gas absorber will lower the emission to 56.71 tons per year, which is
acceptable to standard. The process to reduce will discussed further in waste
management section of the project.

Table 1.3: Comparison between the standard values and amount generated
by our process

By-product Law to be abided Acceptable Level Produced by the

Process

Hydrogen DAO 08 0.2 ppm 5 ppm

Cyanide Series of 2016

CO Philippine Clean 100 TONS / 1121.75

Air Act YEAR TONS/YEAR
 Technological Institute of the Philippines

III. Health and Safety Constraints

Health and safety constraints are the limitations that would affect every
worker in ACN Corporation. There are a lot of possible accidents or injuries
which might occur when working with the different materials and equipment
needed for the production of Acrylonitrile. During the production of
Acrylonitrile, the substances produced and used might greatly harm our
workers if not proper safety procedures are followed. These materials include
propylene, ammonia, and sulphuric acid, hydrogen cyanide and acetonitrile.
Their common denominator for the possible hazard is flammability and the
toxicity when mishandled. ACN Corporation is committed to ensure the safety
of every worker because they’re the asset and key to success of our company.

In order to maintain a safe and hazard-free environment for every

employee, the company shall apply for ISO 45001, a standard for occupational
health and safety management system. This shall maintain and improve the
employee’s safety, workplace risks, working conditions. Different assessment
records shall be made and alarms shall be placed in all areas where possible
dangers might happen. The following substances are evaluated in terms of the
material safety data sheet. Given in Table 1.5 are the safety, reactivity and
flammability of chemicals involved in our process. The hazard attributes for
Table 1.5 are shown in Figure 1.
 Technological Institute of the Philippines

A. PROPYLENE

Liquid propylene is used as a raw material for our production

process. The data from the material safety data sheet shows that it has a score of
4 in flammability. The National Fire Protection Association rating shows that
the propylene is very flammable with a flash point of below 73ºF that is shown
in Figure 1. The ACN Corporation established safety precautions and
firefighting instructions for handling and storage of propylene. All types of
combustible or ignition sources shall be kept away near the area where
Propylene is used or stored. There shall be a fire protection device such as fire
extinguisher, water spay and dry powder near these areas so that when flame
starts to kindle, it will immediately be reduced. Self-contained breathing device
must be worn when a flame starts to ignite because the oxygen level might
lower in that area.

Another danger with liquid propylene is that too much exposure

will result to burns, frostbites or blisters. In order to avoid contact and too much
exposure with this substance, personal protective equipment is highly
recommended. And all kinds of first aid equipment shall be readily available
near the danger area. When already exposed to liquid propylene, warming the
frostbite to 41°C to the affected area shall be made.

B. AMMONIA

Liquid ammonia is used a raw material for the production

process. The data from the material safety data sheet shows that it has a score of
3 in health hazard. The National Fire Protection Association rating shows that
the ammonia is extremely dangerous that is shown in Figure 1. The ACN
 Technological Institute of the Philippines

Corporation established safety precautions and exposure controls for handling

ammonia.

Ammonia is a highly toxic chemical in which when inhaled it

can cause cause severe irritation of the nose and throat. It can cause life-
threatening accumulation of fluid in the lungs (pulmonary edema). If direct
contact with the liquefied gas can chill or freeze the skin (frostbite). Symptoms
of more severe frostbite include a burning sensation and stiffness. The skin may
become waxy white or yellow. Blistering, tissue death and infection may
develop in severe cases. In order to prevent direct contact and inhalation of
ammonia personal protective equipment is recommended highly to the workers
and hazard control plan will be taught to the workers if any accident may occur
during the handling of the raw material. Different safety procedures will be
strictly enforced in handling the ammonia. First aid kits will be available within
the danger area.

C. SULFURIC ACID

Sulfuric acid is a clear, colorless and odorless liquid. It is water-

soluble and capable of causing serious damage, especially at when the chemical
is at high-concentration levels. The data from the material safety data sheet
shows that it has a score of 2 in health hazard. The National Fire Protection
Association rating shows that the sulfuric acid is hazardous that is shown in
Figure 1. The ACN Corporation established safety precautions and exposure
controls for handling sulfuric acid.

High concentration of sulfuric acid is extremely corrosive and

can cause serious burns when not handled properly. This chemical is unique
because it not only causes chemical burns, but also secondary thermal burns as
 Technological Institute of the Philippines

a result of dehydration. This dangerous chemical is capable of corroding skin,

paper, metals, and even stone in some cases. If sulfuric acid makes direct
contact with the eyes, it can cause permanent blindness. If ingested, this
chemical may cause internal burns, irreversible organ damage, and possibly
death.

Exposure to sulfuric acid aerosols at high concentrations leads to

severe eye and respiratory tract irritation and tissue damage. Consistent
exposure to sulfuric acid aerosols, even at low concentrations, can cause a
person’s teeth to erode.

Proper ventilation and storage facility will be applied when

dealing with highly concentrated sulfuric acid there will be a danger zone when
handling with this chemical proper, personal protective equipment will be
strictly enforced to prevent and inhalation and direct contact to the skin and
eyes of the workers.
Hazard control plans and safety procedures will be taught to the
workers especially in emergency, first aid equipment will be near the vicinity of
the danger area for the prevention of serious damage.

D. HYDROGEN CYANIDE

Hydrogen cyanide is a systemic chemical asphyxiant it is a by-

product of the process of acrylonitrile. The data from the material safety data
sheet shows that it has a score of 3 in health hazard. The National Fire
Protection Association rating shows that the hydrogen cyanide is extremely
dangerous that is shown in Figure 1. The ACN Corporation established safety
precautions and exposure controls for handling hydrogen cyanide.
 Technological Institute of the Philippines

It interferes with the normal use of oxygen by nearly every organ of the
body. Exposure to hydrogen cyanide can be rapidly fatal. It has whole-body
(systemic) effects, particularly affecting those organ systems most sensitive to
low oxygen levels: the central nervous system (brain), the cardiovascular
system (heart and blood vessels), and the pulmonary system (lungs). Hydrogen
cyanide gas has a distinctive bitter almond odor (others describe a musty “old
sneakers smell”), but a large proportion of people cannot detect it; the odor
does not provide adequate warning of hazardous concentrations. It also has a
bitter burning taste and is often used as a solution in water.

Proper ventilation and storage for the by-product hydrogen

cyanide will be applied in handling the chemical. Proper personal protective
equipment is required for the workers that will handle the chemical together
with a self-contained breathing apparatus to prevent inhalation of the vapour of
the chemical. Proper storage controls and alarm will be applicable in dealing
with hydrogen cyanide because of its high toxicity level and also to prevent
leakage and major accidents. The chemical is also highly flammable in which
fire protection device is needed within the vicinity of the storage of hydrogen
cyanide.

Hazard control plans and safety procedures will be strictly

enforced to the workers in case of leakage or any accidents that may happen
during the handling of the chemical.

E. ACETONITRILE
Acetonitrile is a colourless liquid is the simplest organic nitrile.
It is produced mainly as a by-product of acrylonitrile manufacture. The data
from the material safety data sheet shows that it has a score of 3 in
flammability. The National Fire Protection Association rating shows that the
 Technological Institute of the Philippines

acetonitrile is flammable with a flash point of below 100 ºF that is shown in

Figure 1. The ACN Corporation established safety precautions and firefighting
instructions for handling and storage of acetonitrile.

Toxic vapors are generated when heated Behavior in Fire: Vapor

heavier than air and may travel a considerable distance to a source of ignition
and flash back. Vapour/air mixtures are explosive. Risk of fire and explosion on
contact with strong oxidants. Heating will cause rise in pressure with risk of
bursting.

Proper ventilation and storage for the by-product acetonitrile

will be applied in handling the chemical. Proper personal protective equipment
is required for the workers that will handle the chemical together with a self-
contained breathing apparatus to prevent inhalation of the vapour of the
chemical. Proper storage controls and alarm will be applicable in dealing with
acetonitrile to prevent leakage and major accidents. The chemical is also highly
flammable in which fire protection device is needed within the vicinity of the
storage of acetonitrile.

F. ACRYLONITRILE

Acrylonitrile is the product of our production process. The data

from the material safety data sheet shows that it has a score of 3 in health
hazard. The National Fire Protection Association rating shows that the
acrylonitrile is extremely dangerous that is shown in Figure 1. The ACN
Corporation established safety precautions and exposure controls for handling
acrylonitrile.
 Technological Institute of the Philippines

Exposure to acrylonitrile irritates the mucous membranes and causes a

headache, nausea, dizziness, impaired judgment, difficulty breathing, limb
weakness, cyanosis, convulsions and collapse. Acrylonitrile is reasonably
anticipated to be a human carcinogen and may be associated with an increased
risk of developing lung and prostate cancer.

The primary potential hazards of Acrylonitrile handling is

explosion or flammability. Both reactions are exothermic reaction accompanied
by heat. The heat of exothermic reactions is their primary hazard.

A useful means of preventing unwanted polymerization in

storage is to confirm that product specifications are met. Product specifications
insure that substances which can initiate polymerization are not present in
dangerous amounts. Acrylonitrile is incompatible with a variety of chemicals
and conditions which can lead to violent reactions, usually initiation of rapid
exothermic polymerization.
Although extremely pure Acrylonitrile is stable at temperatures
of 100°C or more, in the presence of even trace amounts of these incompatible
materials polymerization can be rapid and unpredictable.

The potential for unwanted polymerization is minimized by the

inhibitor system: water (0.2 to 0.5 weight percent) and MEHQ (35 to 45 ppm).
Nitrogen blanketing substantially reduces the potential for flammability of
vapors above the surface of liquid Acrylonitrile. During nitrogen blanketing,
oxygen is purged from the vapor space in the vessel or tank. The oxygen level
should be purged to below 8%. Although the MEHQ and water inhibitor system
will remain effective well below 8% oxygen in the vapor space, complete
exclusion of oxygen is discouraged because the inhibitor system becomes
ineffective when oxygen is absent.
 Technological Institute of the Philippines

Proper ventilation and storage for the product acrylonitrile will

be applied in handling the chemical. Proper personal protective equipment is
required for the workers that will handle the chemical together with a self-
contained breathing apparatus to prevent inhalation of the vapour of the
chemical. Proper storage controls and alarm will be applicable in dealing with
acrylonitrile to prevent leakage and major accidents. The chemical is also
highly flammable in which fire protection device is needed within the vicinity
of the storage of acrylonitrile.

Table 1.5: Table showing the flammability, health and reactivity of

materials and by-products.

Material Flammability Health Reactivity

Propylene 4 1 2
Ammonia 2 3 2
Sulfuric Acid 0 2 2
Hydrogen Cyanide 0 3 0
Acetonitrile 3 2 0
Acrylonitrile 3 3 1

Figure 1: NFPA Ratings

 Technological Institute of the Philippines

SUMMARY

In the process that we will use in this design, the following constraints
were discusses. The following constraints are economic, environmental and
health and safety.

In economic constraints we consider alternative catalyst for our process

because it is cheaper than bismuth molybdenum oxide but it will lower the
product yield of the acrylonitrile. The ACN corporation decided that we will
still use the bismuth molybdenum oxide because it will give us higher product
yield than the alternative even the cost of catalyst is expensive.

In environmental constraints in the process that we use we produce by-

products that is harmful for our environment. First is the hydrogen cyanide high
concentration of this chemical is toxic in aquatic life and micro-organism if
release in bodies of water. Instead of releasing the HCN we will put it in a
storage and will proceed to a safe storage and can be marketed to different
industrial uses. Second is the carbon monoxide high concentrations is toxic to
humans and animals 35 ppm of carbon monoxide is fatal. In order to lower the
carbon monoxide emissions the ACN Corporation put up a gas absorber that
will absorb the gas. So our action is to put a gas absorber to absorb the carbon
monoxide.

In health and safety constraints the ACN Corporation establish for the
safety precautions for every chemicals that will be use in the process. The
safety precautions and the data’s gathered are from the material safety data
sheet of the chemicals that will be use. Mostly of the chemicals to be use is a
health hazard so we put up precautionary measures and exposure control for
handling and storing the chemicals safely.