Super Final PD Papers

CHAPTER I
DESIGN BACKGROUND
Introduction
Petrochemicals, which are chemical products derived from petroleum, are the
building blocks for a wide range of materials such as solvents, detergents plastic
and adhesives. Because of its many uses, the Petrochemical industry in
Philippines has been a critical contributor to the country’s overall economic
growth. Despite of its importance, only a few companies have invested to partake
in this industry. With the ever-growing demand for petrochemical derivatives,
more petrochemical plants are needed in the Philippines.
One particular petrochemical that is greatly used in manufacturing diverse
products in the Philippines is benzene. Benzene is an organic chemical
compound with the chemical formula C 6H6. It is used primarily as a precursor to
the manufacture of chemicals with more complex structure such as
ethlybenzene, cumene and more. More than half is processed to ethylbenzene, a
precursor to styrene which is used to make polymers and plastics. Some 20% of
the benzene production is used to manufacture cumene which is needed to
produce phenol and acetone for resins and plastics.
Because of the several applications of benzene and the demand for
petrochemical derivatives such as plastics, the group has decided to design a
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benzene manufacturing plant. This plant produces benzene through the
hydrodealkylation of toluene.
Process Description
Hydrodealkylation is a chemical reaction that involves reacting an aromatic
hydrocarbon in the presence of Hydrogen gas to form a simpler aromatic
hydrocarbon devoid of a functional group. The Hydrodealkylation of Toluene is a
process used to produce benzene. The main reaction in the process is:
Toluene + H2 → Benzene + CH4
Toluene and hydrogen are converted in a reactor packed with a catalyst to
produce benzene and methane. The catalyst provides an alternative reaction
mechanism with a lower activation energy. Typically, the reaction reaches a
conversion of 90%. The reaction is highly exothermic and the typical operating
conditions are 500 to 660 degrees Celsius, and 20 to 60 bar. Figure 1 shows the
block diagram of the HDA process.
Figure 1: HDA Block Flow Diagram
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The HDA process begins with mixing fresh toluene with a stream of recycle
unreacted toluene, the mixing is achieved in a storage tank. The toluene is then
pumped to combine it with a stream of mixed hydrogen and fresh hydrogen gas.
The mixture of hydrogen and toluene is preheated before it is introduced to the
heater or furnace. In the furnace the stream is heated to 600 C, the reaction
temperature, then introduced into the reactor. The reactor is where the main
reaction happens:
C7H8 + H2 = C6H6 + CH4
This reaction is irreversible, and it requires catalyst. The catalyst consists of
chromium or molybdenum oxides, platinum or platinum oxides, on silica or
alumina.
The catalytic process occurs at lower temperatures and offers higher
selectivity but requires frequent regeneration of the catalyst. The products are
then cooled and introduced into a pair of separators that separate the unreacted
hydrogen. Portion of the unreacted hydrogen is compressed and recycle back to
the feed and the reactor. The products leaving the separators are then heated
before being introduced into a distillation column, where toluene is separated
from the stream and recycle to the feed. This allow for greater conversion. Then
further fractionation separates methane and toluene from the benzene product.
The heating requirements are achieved with low, high and medium pressure
steam. The cooling requirements are achieve by cooling water at temperature of
30 C and pressure of 1 bar.
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Raw Materials
1. Toluene
Toluene is an aromatic hydrocarbon. It is colorless, water Soluble
liquid with the smell associated to paint thinners. It is a mono-substituted
benzene derivative consisting of a methyl attached to a Phenyl group. This
will serve as the feed for the HDA process and will be converted to
Benzene
The toluene feed of the HDA plant will be bought from Petron
Bataan Refinery which has a Toluene capacity of 150000 MT. The refinery
is capable of providing the HDA plant’s feed. Otherwise, we can also
obtain Toluene from Shell Tabangao Refinery which also produces
Toluene from catalytic reforming.

2. Hydrogen
Hydrogen is chemical element with a standard atomic weight of
1.008. It is the lightest element. Large quantities of hydrogen are required
in petroleum and chemical industries for processing of fossil fuels. The key
consumers of H2 are hydrodealkylation, hydrodesulfurization and
hydrocracking.
The hydrogen will be supplied by Air Liquid’s Steam methane
reforming plant. The hydrogen will be recycled in the hydrodealkylation
process to minimize the H2 requirements.
3. Catalyst
The catalyst we will use in the reactor is a Molybdenum based
catalyst. Because this industrial Catalyst isn’t available locally, it will be
imported from Liaoning Haitai Sci-Tech Development Co., Ltd.
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Products
1. Benzene
Benzene is an organic chemical compound with the chemical
formula C6H6. It is used primarily as a precursor to the manufacture of
chemicals with more complex structure such as ethlybenzene, cumene
and more. More than half is processed to ethylbenzene, a precursor to
styrene which is used to make polymers and plastics. Some 20% of the
benzene production is used to manufacture cumene which is needed to
produce phenol and acetone for resins and plastics.

2. Fuel Gas (CH4)
The Fuel gas produced primarily consists of methane. Methane is a
chemical compund with the chemical formula CH 4. It is the simplest alkane
and is the main constituent of natural gas. This can be used to fuel fired
heaters in the plant.
Rationale of the Study
Benzene is an aromatic hydrocarbon and a commodity petrochemical
product. It is produced as by-product in stream crackers and refineries, thus its
supply and demand is driven by other products derived from it. Benzene is a
basic chemical and a building block for many other chemical synthesis of the
global chemical and petrochemical value chain.
Benzene is used in a broad range of economic sectors such as electrical
& electronics, construction, consumer products, transportation, and medical. This
petrochemical product has many derivatives such as ethyl benzene,
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nitrobenzene, cumene, cyclohexane, alkyl benzene, chlorobenzene, aniline, and
phenol.
The rapidly growing industries such as packaging, construction, bulk
chemicals & materials, automotive, textiles and building & construction have
substantially driven the applications for the benzene derivatives globally
influencing the benzene market growth. Rising population in tandem with the
increase in disposable incomes has led to growth of many consumer products
and bulk materials. Low cost of the feedstock and economical commodity product
prices have also contributed to the higher consumption of benzene derivatives.
The unusual supply–demand pattern has prompted researchers to
develop “on-purpose” routes to benzene. Several aromatic interconversion
technologies are available. In one strategy, toluene is converted to equimolar
amounts of benzene and xylene. This technology is known as toluene
disproportionation (TDP).
Other technologies used to balance supply are toluene hydrodealkylation
(HDA) and transalkylation (TA). In HDA, toluene reacts with hydrogen to give
benzene and methane. In TA, toluene and polymethylated benzenes
disproportionate to produce benzene, xylenes, and other aromatics.
Hydrodealkylation is a chemical reaction that often involves reacting
an aromatic hydrocarbon, such as toluene, in the presence of hydrogen gas to
form a simpler aromatic hydrocarbon devoid of functional groups. An example is
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the conversion of 1, 2, 4-trimethylbenzene to xylene. This chemical process
usually occurs at high temperature, at high pressure, or in the presence of
a catalyst. These are predominantly transition metals, such
as chromium or molybdenum.
Taking into considerations the different kinds of factors, such as the
environmental hazards, safety within the area, overall efficiency, feasibility,
layout, and equipment, the designers came up with the idea of hydrodealkylation
processing plant.
Location Plan
The designed Hydrodealkylation Plant will be located by Roman
Expressway at Limay, Bataan. Several factors are considered for the selection of
the location such as suitability of land, ease of access to transport, and
environmental and safety requirements.
The selected location provides ease of access to transport. It is
geographically located along the coast connected to the sea which means an
easy access for ships and vessels. Furthermore, the location is favorable due to
its proximity to Petron Bataan Refinery where we will get the HDA Plant’s Toluene
Feed.
The plant would provide numerous job opportunities for the people around
the area. To ensure public safety, the plant location is located as far from
residential area. Figure 2 shows the location plan of the plant.
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Figure 2: Plant Location and its proximity to Petron Bataan Refinery
Supply and Demand of the By-Product
The global market is expected to grow at a CAGR of 4–5 percent during
2016–2022: The impetus for this growth comes from demand in Asia, which is
expected to grow at 6-7 percent, due to increased automobile and construction
activities.
Major demand for aromatics is expected to come from the Asian region,
since most of the derivative units (styrene, phenol, PET, and gasoline) are
lined up in Asia. The automobile (4 – 5 percent growth) and construction
sectors (5 – 6 percent growth) would be the key segments driving the demand.
Around 1.5 MMT capacity additions planned for styrene in Asia and the Middle
East would also contribute to benzene’s demand growth.
Feedstock change in the western markets to yield less benzene. Lesser
yield from lighter feedstock will continue to reduce the output of aromatics in
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the US and the EU, thus making the regions increasingly import dependent.
This demand from the western markets will be met by surplus capacity
additions, planned in the Middle East and Asia through 2022.
With the wide applications of benzene such as for formulating high octane
fuels, for use as commercial solvent and for making paints, thinners and plastics,
the demand for benzene is projected to be high. To meet this demand, the
development of a hydrodealkylation plant is needed.
Figure 3: Demand and Supply Projection for 10 Years
Source: ICIS Global Petrochemical Supply
CHAPTER II
DESIGN OBJECTIVES AND REQUIREMENTS
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The principal thrust of this project proposal is to design a
Hydrodealkylation Process Plant that will process benzene as its raw materials to
produce toluene.
Specifically, this study aims to meet the following objectives for the
proposed plant in order to come up with a feasible and economical project design
1. To be able to construct three (3) design options following some of the
engineering standards and realistic constraints.

2. To gather data and information needed in relation to technical and
economic aspects that will justify the viability of the proposed project.
3. To assign the proper technical design specifications for the equipment
of the three design options following standard requirements.

4. To determine the capacity and efficiency of each of the plant by the
computation of the following:

4.1 Material Balance
4.2 Energy Balance
5. To present acceptable designs having processes that are capable of
operating under conditions which will yield a profit providing an
evaluation and under conditions which will yield a profit providing an
evaluation and computations of the economical expenditures:
5.1 Capital Expenditures

5.2 Operating Expenditures
5.3 Net Present Values
5.4 Rate of Return
5.5 Payback Period
6. To provide safety and loss prevention in the process designs under the
following:
6.1 Identification and assessment of the hazards;
6.2 Control of hazards;
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6.3 Control of the processes; and
6.4 Limitations of the loss
7. To choose the best design option following the Worst Case Design
philosophy.
8. To provide a construction management, project scheduling of
assembling each sections of the plant’s manufacturer’s site and the
sequence and arrangement of the major items of equipment given on
the process flow sheet.

9. To provide a summary of findings, conclusion and recommendation for
Hydrodealkylation Process Plant.
CHAPTER III
TECHNICAL ASPECTS AND REQUIREMENTS
This chapter presents the data and information as well as the assumptions
related to the technical aspects and economical information needed for the
design of the manufacturing plant. Standards were used to come up with a
technically viable design. Technical catalogues were used to carefully identify the
design specifications of each equipment.
Three Designs are presented and the best design option will be selected
through the worst case design philosophy.
Plant Cycle and Process Flow Diagram of each Design Option

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A. Design Option 1
The first design option shows a simple hydrodealkylation plant with
the minimum required equipment. This design helps reduce costs by only
selecting the necessary equipment for the conversion of toluene to
benzene.
Presented is the process flow diagram of the design. It shows the
configuration of the plant equipment and the streams entering and exiting
each equipment.
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Fig ur e 3: Sim ula t io n Pr ocess Flow Diagr am
Hy d ro d e a l k y t i o n o f To l u e n e
S P 2 C1
S 1 4 Re c y c le Hy d ro g e n
S 1 2
S 1 3
S 2 0
S 2 2
S 1 5 S 1
M5
M6 Fuel G as
S 1 6
S P 1 S 2 5
S 1 7
M2 S 7
Hy dr ogen
M4
S 9
S 1 8
R1
S 6
S 8
M3 S 4
S 3 S C 2
S 2 8
S 5
E 2
E 1 E 5 F 1 S 2 6
S 2 S 2 3
S 1 S 1 0
M1 S 2 7
P 1
o lu ene
T
F 2
Benz ene
E 4
S 1 9
S 2 1
E 3
S C 1
S 2 4
o lu e n e Re c y c le
T
Figure 4. Design Option 1 PFD
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The process starts with combining the fresh toluene stream S1 with the
recycle toluene stream S24 in the mixer M-1 to form stream S2. The stream S2 is
then pumped (P-1) to 25.5 bar and is combined in a mixer M-3 with stream S16,
this stream is a mixture of fresh feed hydrogen mixed with unreacted hydrogen, it
also contains traces of toluene benzene and methane. The stream S16 is the
outlet of mixer M-2, this mixer combines the fresh stream of hydrogen S17 and
the unreacted recycle stream of hydrogen S14. The two phase stream exiting the
mixer M-3 is then introduced into heat exchanger E-1 in the tube side. High-
pressure stream is used in this heat exchanger in the shell side to heat up the
tube side process stream S4 to an outlet temperature of 163.9 C. The outlet
stream S5 is a one-phase stream of all vapor. The pressure drop for all the heat
exchangers are set to be 0.345 bar.
The process stream is then introduced into the heater E-2, where it is heated
up to 600 C. This temperature is the required temperature that will allow the
reaction to happen in the reactor. The now heated up stream S6 is combined with
recycle compress hydrogen S15 in mixer M-4. Since the reaction is highly
exothermic, the temperature is controlled by injection of quench hydrogen at the
reactor. The feed is then introduced to the main part of the process the reactor R-
1. The process stream now containing a high amount of benzene exits the
reactor at 671oC, this temperature must be decreased in order to separate the
unreacted components with the products. This is achieved by introducing the
product stream S8 to heat exchanger E-5. In this heat exchanger the process
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stream is cooled to 38 oC, by using cooling water. The outlet stream, S28, is a
two-phase stream that is introduced into the first separator F-1. This knock out
drum separates mostly all hydrogen and methane and it also contains traces of
toluene and benzene. The pressure and temperature of this flash drum must be
specified to 23.9 bar and 38oC.
The overhead stream S9 is then split into two streams S11 and S12 in splitter
SP1. Stream S12 is compressed in a compressor of efficiency of 75% to a
pressure of 25.5 bar. The compressed gas S13 is then introduced into splitter
SP-2, which splits the splitter into stream S14 and S15. Stream S14 is mixed with
the fresh feed of hydrogen, and stream S15 is used to control the temperature of
the reactor. The stream S11 is part of the fuel gas.
The bottom stream S10 of the separator F1 is introduce into the second
separator F2, which separates more hydrogen and methane from benzene and
toluene. The liquid bottom stream S19 is then heated up in heat exchanger E-3
to 90oC. The overhead stream S18 is combined with the overhead of the first
separator F-1 in mixer M-5 to makeup portion of the fuel gas.
Stream S19 is then introduced into a distillation column, which is simulated
by a stream calculator, SC1. In this piece of equipment the separation required
must be specified. In this case 99% of the benzene must exit at the overhead
and 98.85% of the toluene must exit at the bottom of the separation unit. The
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temperature and pressure of the overhead and the bottom must be specified in
order for the simulation to be properly represented. The temperatures are 112 oC
and 2.43 bar. The bottoms of this stream calculator S24 is the recycle toluene
that is mixed in M1 with the fresh toluene feed. The overhead of this separator is
then introduced into another stream calculator SC2, which simulates the
condenser and reflux drum and pump of the distillation tower. This stream
calculator separates all the hydrogen and methane in the overhead S25, from the
toluene and benzene in the bottoms S26. The stream S25 is then combined in a
mixer M6 with the rest of the gas that composes the fuel gas. The stream S26 is
then introduced into a heat exchanger E4 where the benzene product is cooled
down to 38oC before is sent to storage.
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B. Design Option 2.
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Fresh and recycled liquid toluene is pumped from TNK-100 and is
combined with a high pressure hydrogen feed and a recycled gas stream
MIX-100. The combined feed stream S4 is vaporized using high pressure
steam in exchanger E-100 and then heated further to 600 degCelsius in fired
heater E-101 prior to being fed into reactor R-100. The feed enters the reactor
at a pressure of 2500 kPa. The reactors is of the catalytic packed bed type, is
operated adiabatically and is intended to achieve 80% conversion of toluene.
The feed contains a large excess of hydrogen, which acts as a diluent to
moderate the temperature rise in the reactor. A small flow of cold gas, stream
S24, is used for further reactor temperature control. The reactor effluent is
cooled and partly condensed in exchanger E-102 using cooling water and
partial separation of this stream is achieved in high pressure (V-100) and low
pressure (V-101) flash drums. Part of the overhead vapour from V-100 is
recycled via compressor K-100 to the reaction section. The liquid product from
the low pressure flash drum is heated to near its bubble point in E-103 using
low pressure stream and is then distilled in the benzene column.
The column produces a high purity benzene distillate, S18, an impure
toluene bottoms stream, S19, which is recycled to the toluene storage tank,
and a small non-condensate gas stream, S16, vented from the column’s reflux
drum. This vent stream, the balance of vapour from V-100 and all the vapour
from V-101 are combined in MIX-101 and become fuel gas for use in the plant
or elsewhere on the site. The benzene product from the column is cooled in
exchanger E-104 using cooling water prior to being pumped in the storage.
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C. Design Option 3
The third design option is a pinch analysis. In this design,
energy is saved by using the outlet stream leaving the reactor as its
temperature is in the range of 620 ◦C, to preheat the feed stream
coming from the mixer, via a heat exchanger (Fehe) some energy
integration is achieved
Presented is the process flow diagram of the design. It shows
the configuration of the plant equipment and the streams entering and
exiting each equipment.
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The process starts by combining fresh toluene feed, recycled toluene, and
Hydrogen gas mixed with traces of methane. This initial feed is passed through a
heat exchanger to be heated before being heated again in a furnace at 600
degrees Celsius. The heated feed mixture is then fed to an adiabatic reactor
where it contains unreacted hydrogen, toluene, benzene, biphenyl, and methane.
It is then quenched and cooled in a high-pressure flash separator to condense
the aromatics from non-condensable hydrogen and methane. Liquid stream from
the high-pressure flash drum is fed to a low-pressure flash drum to separate
traces of hydrogen and methane rom the aromatics. Toluene, benzene, and
biphenyl are separated in two distillation columns. The first column separates the
product – Benzene – from biphenyl and Toluene before being fed to the second
distillation column, which will separate Toluene from biphenyl. Recycled Toluene
from the second distillation column is fed back to the initial stream, which is the
fresh Toluene.
Components of the Hydrodealkylation Processing Plant
This section includes all the equipment used to run the HDA processing
plant.
A. Mixer
Chemical mixers set up and operate machines that mix chemicals.
They also measure and weigh ingredients used in making a chemical
solution. It is their responsibility to regulate the flow of the ingredients into
a mixing vessel, as well as to monitor stirring to ensure that solutions only
mix for a specified period of time and to a desirable quality. They also test
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resulting solutions for parameters such as viscosity, temperature and
density.
Figure 7. Chemical Mixer

B. Pump
A pump is any device meant to facilitate the motion of a fluid.
Pumps displace fluids, causing it to move down or out of a pipe. Most
pumps use some sort of compressional action to displace the fluid. This
compressional action sometimes necessitates a motor that acts to put
pressure on the fluid in order to displace it. This motor can be powered by
a variety of fuels, as long as it has the necessary power to displace the
fluid. Most pumps are either positive displacement or rotodynamic.
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Figure 8. Pump
C. Compressor
A compressor is a mechanical device that increases the pressure of
a gas by reducing its volume. Compressors are similar to pumps: both
increase the pressure on a fluid and both can transport the fluid through
a pipe. As gases are compressible, the compressor also reduces the
volume of a gas. Liquids are relatively incompressible; while some can be
compressed, the main action of a pump is to pressurize and transport
liquids.
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Figure 9. Compressor
D. Pre-Heater
A preheater is any device designed to heat a substance before
another process (for example, combustion in a boiler) with the primary
objective of increasing the thermal efficiency of the process. They may be
used alone or to replace a recuperative heat system or to replace a steam
coil. The purpose of the preheater is to recover the heat from the
boiler flue gas which increases the thermal efficiency of the boiler by
reducing the useful heat lost in the flue gas. As a consequence, the flue
gases are also conveyed to the flue gas stack (or chimney) at a lower
temperature, allowing simplified design of the conveyance system and the
flue gas stack. It also allows control over the temperature of gases leaving
the stack (to meet emissions regulations, for example).
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Figure 10. Pre-heater
E. Heat Exchanger
A heat exchanger is a device used to transfer heat between two or
more fluids. Heat exchangers are used in both cooling and heating
processes. The fluids may be separated by a solid wall to prevent mixing
or they may be in direct contact. They are widely used in space
heating, refrigeration, air conditioning, power stations, chemical
plants, petrochemical plants, petroleum refineries, natural-gas processing,
and sewage treatment. The classic example of a heat exchanger is found
in an internal combustion engine in which a circulating fluid known
as engine coolant flows through radiator coils and air flows past the coils,
which cools the coolant and heats the incoming air. Another example is
the heat sink, which is a passive heat exchanger that transfers the heat
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generated by an electronic or a mechanical device to a fluid medium, often
air or a liquid coolant.
Figure 11. Heat Exchanger

F. Cooler
An industrial cooler will feature a large water tank to store water.
For better water conservation, an ecofriendly air cooler will have larger
storage capacity and utilize water resources to the maximum without
wastage. The cooler will absorb heated air into its system which is passed
through the water and cooling media. It is in this area where the actual
cooling system takes place where heat and moisture is absorbed and
evaporated. The resulting cold air is blown out of the system with the help
of powerful motor driven fans. The piping system distributes cold moisture,
water and air throughout the cooler.
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Figure 12. Cooler
G. Flash Drum
A flash drum is a very simple vessel which separates vapor from
liquid at a given temperature and pressure. Sometimes they are heated,
sometimes not. A liquid or liquid vapor mixture flows in, the vapor that boils
off goes out the pipes at the top and the liquid that remains flows out the
bottom.
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Figure 13. Flash Drum
H. Splitter
Component splitter works as its name says: it redistributes each of
the components present in the feed stream in between the so called
"overhead" and the "bottom" streams. Depending on specified conditions
of both outlet streams, you may need to include an energy stream feeding
the splitter as well.
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Figure 14. Splitter
I. Reactor
A chemical reactor is an enclosed volume in which a chemical
reaction takes place. In chemical engineering, it is generally understood to
be a process vessel used to carry out a chemical reaction, which is one of
the classic unit operations in chemical process analysis. The design of a
chemical reactor deals with multiple aspects of chemical engineering.
Chemical engineers design reactors to maximize net present value for the
given reaction. Designers ensure that the reaction proceeds with the
highest efficiency towards the desired output product, producing the
highest yield of product while requiring the least amount of money to
purchase and operate. Normal operating expenses include energy input,
energy removal, raw material costs, labor, etc. Energy changes can come
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in the form of heating or cooling, pumping to increase pressure, frictional
pressure loss or agitation.
Figure 15. Reactor

J. Storage Tank
Storage tanks are containers that hold liquids, compressed gases
(gas tank; or in U.S.A "pressure vessel", which is not typically labeled or
regulated as a storage tank) or mediums used for the short- or long-term
storage of heat or cold. The term can be used for reservoirs (artificial lakes
and ponds), and for manufactured containers. The usage of the word tank
for reservoirs is uncommon in American English but is moderately
common in British English. In other countries, the term tends to refer only
to artificial containers.
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Figure 16. Storage Tanks
K. Furnace
A furnace is a device used for high-temperature heating. The name
derives from Latin word fornax, which means oven. The heat energy to
fuel a furnace may be supplied directly by fuel combustion, by electricity
such as the electric arc furnace, or through induction heating in induction
furnaces.
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Figure 17. Furnace
L. Distillation Column
The distillation column is made up of a series of stacked plates. A
liquid feed containing the mixture of two or more liquids enters the column
at one or more points. The liquid flows over the plates, and vapor bubbles
up through the liquid via holes in the plates. As liquid travels down the
column, the vapor comes in contact with it several times due to the
multiple plates – a critical process in distillation columns. The liquid and
vapor phases are brought into contact because as one molecule of higher
boiling material converts from vapor to liquid phase by energy release,
another molecule of the low boiling material utilizes the free energy to
convert from liquid to vapor phase. The base of the distillation column
contains a large volume of liquid consisting mostly of the liquid with higher
boiling point (in our example, this would be water). Out of the base flows
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some of this liquid, some of which is heated in the re boiler and returned to
the column. This is called the boil up.
Figure 18. Distillation Column

M. Condenser
A condenser is a device (tube) which allows a vapour to pass
through a confined space and be cooled by a surrounding cooler fluid. An
air condenser is simply a naked tube where the cooler fluid is the
surrounding air. A water condenser (Liebig condenser) has the tube
enclosed in a larger tube so that cooling water is able to pass in the space
between the two tubes. The efficiency is improved by slanting the
apparatus so that the vapour to be condensed flows downwards through
the inner tube whilst the cooling water flows upward through the outer
tube, thus creating a counter current flow.
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Figure 19. Condenser
N. Reboiler
Reboilers are heat exchangers typically used to provide heat to the
bottom of industrial distillation columns. They boil the liquid from the
bottom of a distillation column to generate vapors which are returned to
the column to drive the distillation separation. The heat supplied to the
column by the reboiler at the bottom of the column is removed by
the condenser at the top of the column. Proper reboiler operation is vital to
effective distillation. In a typical classical distillation column, all the vapor
driving the separation comes from the reboiler. The reboiler receives a
liquid stream from the column bottom and may partially or completely
vaporize that stream. Steam usually provides the heat required for the
vaporization.
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Figure 20. Reboiler
Equipment Specifications
Presented is the list of equipment with their corresponding input and
output streams as well as their operating conditions.
Table 1. Equipment Specification for Design Option 1
Equipment Equipmen Input Output

Operating Parameters
Number t Type Streams Streams
M-1 Mixer S1,S24 S2 Pressure Drop = 0 bar
Outlet pressure = 25.5 bar,
P-1 Pump S2 S3
Efficiency 75%
Compress Outlet pressure = 25.5 bar,
C-1 S12 S13
or Efficiency 75%
E-1 Preheater S4 S5 Outlet Liquid Fraction = 0
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E-2 Heater S5 S6 Outlet temperature = 600 C
Heat
E-3 S19 S21 Outlet temperature = 90 C
Exchanger
E-4 Cooler S26 S27 Outlet temperature = 38 C
E-5 Cooler S8 S28 Outlet temperature = 38 C
Flash Pressure = 23.9 bar, Temp
F-1 S28 S9,S10
Drum = 38 C
Flash Pressure = 2.8 bar, Temp =
F-2 S10 S18,S19
Drum 38 C
Recycle stream flowrate =
SP-1 Splitter S9 S11,S12
440 kgmol/hr
Recycle to the reactor = 40
SP-2 Splitter S13 S14,S15
kgmol/hr
Duty = 0, product phases,
R-1 Reactor S7 S8 global temp = -22.2 C, 75%
Conversion
Overhead product = 99%
Stream
SC-1 S21 S23,S24 benzene, Bottoms product
Calc.
= 98.85 % toluene
Stream Overhead product = 100%
SC-2 S23 S25,S26
Calc. H2, 100% CH4
Equipment Equipment Input Output

Operating Parameters
Number Type Streams Streams
Toluene,
TNK-100 Tank S1, S2 Temperature = 25 degC
H2 Feed
Outlet Pressure = 25.8
P-100 Pump S2 S3
bar
Pressure Drop = 0.3 bar
E-100 Pre-heater S4 S5 Outlet Temperature =
225 degC
E-101 S5 S6 Outlet Temperature = 20
Furnace degC
R-100 Reactor S6 S7, S8 Outlet Temperature = 38
degC
E-102 Cooler S7 S9 Pressure Drop = 0 bar
High
V-100 Pressure S9 S10, S11 Pressure drop = 0
Flash Vessel
36
TEE-100 Splitter S10 S20, S21 Efficiency ratio = 73%
Level
VLV-100 Control S11 S12
bar
Valve
Low
V-101 Pressure S12 S13, S14 Pressure Drop = 0
Flash Vessel
Pressure drop = 0.3 bar
E-103 Pre-heater S14 S15 Outlet temperature = (0
degC
Pressure
VLV-101 Control S13 S26
bar
Valve
Fictitious Use Lowest Feed
X-100 S15 S16, S17
unit Pressure Option
Condenser Pressure =
2.5 bar
T-100 Column S17 S18, S19
Reboiler Pressure = 2.8
bar
Outlet Temperature = 38
E-104 Cooler S18 Benzene degC
Pressure drop = 0.2 bar
K-100 Compressor S20 S22 bar
Efficiency = 75%
TEE-101 Splitter S22 S23, S24 Flow Ratio = 5%
Control Outlet Pressure = 2.6
VLV-102 S21 S25
Valve bar
S3, S23,
M-100 Mixer S4 Pressure Drop = 0 bar
H2 Feed
S16, S25,
M-101 Mixer Fuel Gas Pressure Drop = 0 bar
S6
Equipm
Equipment Input Output Operating
ent
Type Streams Streams Parameters
Number
37
Toluene Toluene Outlet Pressure = 25.8
P-100 Pump
Feed Feed bar
Hydrogen
Feed,
M-100 Mixer S1 Pressure Drop = 0 bar
Toluene
Feed, S20
Heat Outlet temperature =
HX-100 S1, S4 S2, S26
Exchanger 90C
Operating
E-100 Furnace S2 S3
Temperature = 600C
Pressure Drop = 0.1
bar
R-100 Reactor S3 S4
Outlet Temperature =
38C
E-101 Cooler S26 S5 Pressure Drop = 0 bar
Pressure = 2.8 bar,
T-100 Flash Drum S5 S22, S6
Temp = 38 C
Pressure = 2.8 bar,
T-101 Flash Drum S6 S21, S7
Temp = 38 C
Distillation
D-100 S7, S9, S12 S8, S11
Column
S9, S10 Condenser Pressure =
C-100 Condenser S8
(Benzene) 2.5 bar
Reboiler Pressure =
RB-100 Reboiler S11 S12, S13
2.8 bar
Distillation
D-101 S13 S14, S17
Column
Condenser Pressure =
C-101 Condenser S14 S15, S16
2.5 bar
S18, S19 Reboiler Pressure =
RB-101 Reboiler S17
(Biphenyl) 2.8 bar
Recycled
P-101 Toluene S16 S20
bar
Pump
S-100 Splitter S22 S23, S24 Efficiency ratio = 73%
K-100 Compressor S24 S25 bar
Efficiency = 75%
Material Balance
38
After designing the process, a material balance calculation for each
equipment is determined. Presented below are the material balances.
Design Option 1
The first design option has a feed of 50000 tonnes of toluene and 1502
tonnes of hydrogen per year.
Converting into molar flowrate.
Toluene feed = (50000 tonnes/year) x (1000 kg/tonnes) x (1kmol/92.14 kg of
toluene) x (1 year/8640 hours)
=62.8 kmol/hr = 62.8 kg mol /hr
Hydrogen feed = (1502 tonnes/year) x (1000 kg/tonnes) x (1kmol/1 kg of
Hydrogen) x (1 year/8640 hours)
=173.899 kmol/hr = 173.899 kg mol / hr
Using Soave-Redlich-Kwong thermodynamic system, the simulation yielded the
material balance below.
Table 4. Mass Balance of Design Option 1
Equipment Number/ Mass Balance Calculations

Description Kg-mol/hr
M-1 mS1+mS24 = mS2

(Mixer) 62.8 + 20.772 = 83.572
M-2 mS17+mS14 = mS16

(Mixer) 173.899 + 230.871 = 404.77
39
M-3 mS16+mS3 = mS16
(Mixer) 404.77 + 83.572 = 488.342
M-4 mS6+mS15 = mS7

(Mixer) 488.342 + 23.333 = 511.675
M-5 mS11+m18 = mS20

(Mixer) 173.468 + 1.801 = 175.269
M-6 mS20+m25 = mS22

(Mixer) 175.269 + 0.422 = 175.691
P-1 mS2 = mS3

(Pump) 83.572 = 83.572
C-1 mS12 = mS13

(Compressor) 254.204 = 254.204
E-1 mS4 = mS5

(Preheater) 488.342 = 488.342
E-2 mS5 = mS6

(Heater) 488.342 = 488.342
E-3 mS19 = mS21

(Heat Exchanger) 82.202 = 82.202
E-4 mS26 = mS27

(Cooler) 61.008 = 61.008
E-5 mS8 = mS28
(cooler) 511.675 = 511.675
F-1 mS28 = mS9 + mS10

(Flash Drum) 511.675 = 427.672 + 84.003
40
F-2 mS10 = mS18 + mS19
(Flash Drum) 84.003 = 1.801+ 82.202
SP-1 mS9 = mS11 + mS12

(Splitter) 427.672 = 173.268 + 254.204
SP-2 mS13 = m14 + mS15

(Splitter) 254.204 = 230.871 + 23.333
R-1 mS7 = mS8

(Reactor) 511.675 = 511.675
SC-1 mS21 = mS23 + mS24

(Column) 82.202 = 61.43 + 20.772
SC-2 mS23 = mS25 + mS26

(Column) 61.43 = 0.422 + 61.008
Conversion = Benzene Output / Toluene Input x 100%
= 61.008 kmol/hr / 62.8 kmol/hr
= 97.15% conversion
Design Option 2
Presented here is the material balance based on each equipment’s
processes.
50,000 Metric Ton/year x 1000 kg/ton = 50,000,000 kg/year
50,000,000 kg/year x 1 year/365days = 136,986.3014 kg/day
136,986.3014 kg/day x 1day/24hrs = 5707.762557 kg/hr
41
Equipment Number/ Mass Balance Calculations

Description (kg/hr)
E-100 mS5+mwr = mS4

(Heater) 5,693.49 + 14.27 = 5707.76
E-101 mS6+mvr = mS5

(Furnace) 5,679.26 + 14.23 = 5,693.49
R-100
mS7+mff = mS6
(Reactor)
4,713.79 + 681.51 = 5,679.26
E-102 mS9+mSwr = mS7

(Cooler) 4,702.00 + 11.78= 4,713.79
V-100 mS11+mS10 = mS9

(Flash Vessel) 4,673.79 + 28.21 = 4,702.00
V-101 mS14+mS13 = mS12 = mS11

(Flash Vessel) 4,645.75 + 28.04= 4,673.79
E-103 mS15+mwr = mS14

(Heater) 4,634.13 + 11.61 = 4,645.75
X-100 mS17+mS16 = mS15

(Fictitious Unit) 4606.33 + 27.8 = 4,634.13
T-100 mS18+mS19 = mS17

(Distillation Column) 4,594.81 + 11.52 = 4606.33
E-104 Benzene + mvr = mS18

(Cooler) 4,583.32 + 11.49 = 4,594.81
42
= 4,583.32 kg/hr / 5707.76 kg/hr
= 80.3% conversion
Design Option 3
Presented here is the material balance based on each equipment’s
processes.
50,000 Metric Ton/year x 1000 kg/ton = 50,000,000 kg/year
50,000,000 kg/year x 1 year/365days = 136,986.3014 kg/day
136,986.3014 kg/day x 1day/24hrs = 5707.762557 kg/hr
Equipment / Mass Balance Calculations

Description (kg/hr)
mS2+mwr = mS1
Heater
5,693.49 + 14.27 = 5707.76
mS3+mvr = mS2
Furnace
5,679.26 + 14.23 = 5,693.49
Reactor mS4+mff = mS3

4,713.79 + 681.51 = 5,679.26
mS26+mSwr = mS4
Heater
4,702.00 + 11.78= 4,713.79
43
mS26+mwr = mS4
Cooler
4,690.25 + 11.76 = 4,702.00
mS6+mS22 = mS5
Flash Vessel
4,645.75 + 28.14= 4,662.10
mS15+mwr = mS14
Flash Vessel
4,662.10 + 27.91 = 4,634.13
mS8+mS19 = mS7
Distillation Column
4622.55 + 11.59 = 4,634.13
Condenser Benzene + mwr = mS18

4,610.99 + 11.56 = 4,622.55
= 4,610.99 kg/hr / 5707.76 kg/hr
= 85.78% conversion
Energy Balance
Design Option 1
Presented is the Energy Balance for the design option 1.
44
Equipment Number/ Energy Balance Calculations
Description
Win + PVin = PVout

Win + (190000 Pa)( 2.464255607x10-3 m3/s) =
P-1
2550000 Pa (2.464255607x10-3 m3/s)
(Toluene Pump)
Win = 5815.643233 J/s = 5.815 kW
Qin = mCp(tout-tin)
Qin = (9751.383976 kg/hr)(6149 J/kg-K)(436.905-
E-1
316.219)(1hr/3600)
(Preheater)
Qin = 2010134.62 J/s = 2010.13462 kW
Qin = mCp(tout-tin)
Qin = (9751.383976 kg/hr)(6149 J/kg-K)(873-
E-2
436.905)(1hr/3600)
(Heater)
Qin = 7263557.141 J/s = 7263.557141 kW
Qin = mCp(tout-tin)
Qin = (6681.287316 kg/hr)(1707.76 J/kg-K)(363-
E-3
311)(1hr/3600)
(Heat Exchanger)
Qin = 164811.6199 J/s = 164.8116199 kW
Qout = mCp(tin-tout)
Qout = (4768.758649 kg/hr)(1700.08 J/kg-K)(385-
E-4
311)(1hr/3600)
(Cooler)
Qout = 166649.4636 J/s = 166.6594636 kW
Qout = mCp(tin-tout)
Qout = (10021.00649 kg/hr)(5354.2 J/kg-K)
E-5
(944.015-311)(1hr/3600)
(cooler)
Qout = 9434468.386 J/s = 9434.468386 kW
Efficiency = Output/Input x 100%
Efficiency = 9454.32296/7030.514404 x 100%
Efficiency = 98.5%
45
Design Option 2
Presented here is the energy balance based on each equipment’s
processes.
5707.762557kg/hr x 1hr/3600sec = 1.5854895999kg/sec
1.5854895999kg/sec x 15,485.6 kJ/kg = 24,552.25775kW
Equipment Energy Balance Calculations
ES4=24,552.25775kW
Ewr=24,552.25775(.0025)
=61.38kW
Heater
ES5=24,552.2577 – 61.38
=24,490.88kW
ES5=24,490.88kW
Evr=24,490.88(.0025)
=61.23kW
Furnace
ES5=24,490.88 – 61.23
=24,429.65kW
ES6=24,429.65kW
Eff=24,429.65(.12)
=2931.56kW
Reactor
ES7=24,429.65(.95) – 2,931.56
=20,276.61kW
46
ES7=20,276.61kW
Ewr=20,276.61(.0025)
=50.69kW
Cooler ES9=20,276.61 – 50.69
=20,225.92kW
ES9=20,225.92kW
ES10=20,225.92(.006)
=121.36kW
Flash Vessels
ES11=20,225.92 – 121.36
=20,104.56kW
mS12=20,104.56kW
mS13=20,104.56(.006)
=120.63kW
Flash Vessels
mS14=20,104.56 – 120.63
=19,983.94kW
ES14=19,983.94kW
Ewr=19,983.94(.0025)
=49.96kW
Heater
ES15=19,983.94 – 49.96
=19,933.98kW
ES15=19,933.98kW
ES16=19,933.98(.006)
=119.60kW
Fictitious Unit
ES17=19,933.98 – 119.60
=19,814.37kW
ES17=19,814.37kW
ES19=19,814.37(.0025)
=49.54kW
ES18=19,814.37 – 49.54
Column
=19,764.84kW
47
ES18=19,764.84kW
Ewr=19,764.84(.0025)
=49.41kW
Cooler Benzene=19,764.84-49.41
=19,715.42kW
Ev=23.3kg/hr x 1hr/3600s
Compressor =6.47E-3 x 15,485.6 kJ/kg
=100.23kW
Effeciency = Output/Input x 100%
Efficiency = 19,715.42kW/24,552.25775kW x 100%
Efficiency = 80.3%
Design Option 3
Presented here is the energy balance based on each equipment’s
processes.
5707.762557kg/hr x 1hr/3600sec = 1.5854895999kg/sec
1.5854895999kg/sec x 15,485.6 kJ/kg = 24,552.25775kW
48
Equipment Energy Balance Calculations
ES1=24,552.25775kW
Ewr=24,552.25775(.0025)
=61.38kW
Heater
ES2=24,552.2577 – 61.38
=24,490.88kW
ES2=24,490.88kW
Evr=24,490.88(.0025)
=61.23kW
Furnace
ES3=24,490.88 – 61.23
=24,429.65kW
ES3=24,429.65kW
Eff=24,429.65(.12)
=2931.56kW
Reactor
ES4=24,429.65(.95) – 2,931.56
=20,276.61kW
ES4=20,276.61kW
Ewr=20,276.61 (.0025)
=50.691525kW
Heater ES26=20,276.61– 50.691525
=20,225.91848kW
ES4=20,225.91848kW
Ewr=20,225.91848 (.0025)
=50.56479619kW
Cooler
ES26=20,225.91848kW -50.56479619kW
=20,175.35368kW
49
ES5=20,175.35368kW
ES22=20,175.35368kW (.006)
=121.0521221kW
Flash Vessels
ES6=20,175.35368kW -121.0521221kW
=20,054.30156kW
ES6=20,054.30156kW
ES21=20,054.30156kW (.006)
=120.3258093kW
Flash Vessels
ES7=20,054.30156kW - 120.3258093kW
=19933.97575kW
ES7 =19933.97575kW
ES19 = 19933.97575kW (.0025)
=49.83493938kW
Column ES8= 19933.97575kW – 49.83493938kW
=19,884.14081kW
ES18=19,884.14081kW
Ewr=19,884.14081kW (.0025)
= 49.71035203kW
Condenser Benzene=19,884.14081kW - 49.71035203kW
=19,834.43046kW
Efficiency = Output/Input x 100%
Efficiency = 19,834.43046kW /24,552.25775kW x 100%
Efficiency = 85.78%
50
CHAPTER IV
ECONOMIC STUDY AND ANALYSIS
This chapter presents all the required calculations and the data regarding
the financial aspects of the designed Hydrodealkylation Plant. In this chapter the
payback period, rate of return and net present value is to be considered to
determine the most economical.
DESIGN OPTION 1
All capital and expenses for operation and construction of the designed
are estimated based on research.
A. Capital Expenditures
The Capital Expenditures (CAPEX) of the HDA Plant is summarized in the
Table 10 shown below.
Table 10. Estimation of Capital Expenditures for Design Option 1
Total Cost
PLANT EXPENSES Quantity Cost (Php)
(Php)
Admin 1 14,100,000.00
Control Room 1 18,600,000.00
Workshop and
Buildings 1 16,900,000.00
Powerhouse
Warehouse 1 13,700,000.00
Security Office 1 6,900,000.00
51
15,000
Land 5000/sqm 75,000,000.00
sqm
Vehicles 5 1,800,000.00 9,000,000.00
Toluene Feed
1 1,512,930.00 1,512,930.00
storage tanks
Mixers 6. 200,000 1,800,000
Pump 1 238,215.00 238,215.00
Compressor 1 200,000.00 200,000.00
Preheater 1 13,329,900.00 13,329,900.00
Furnace 1 29,049,250.00 29,049,250.00
Equipments Cooler 2 12,645,019 25,290,038
Heater 1 11,650,000.00 11,650,000.00
Flash Drum 2 500,000 1,000,000
Splitter 2 1,100,000.00 2,200,000.00
Distillation
2 41,736,000.00 83,472,000.00
Column
Benzene Storage
1 1,512,930 1,512,930
Tanks
Water
Treatment Reverse Osmosis 36,500,000.00
Facility
Storage
4 3,760,000.00 15,040,000.00
Facility
30% of Building
Installation Contractor Fee and Equipment 70,200,000.00
cost
Personal
Protective 12,000 5,000.00 60,000,000.00
Equipments
Health and
Safety Fire
150 3,000.00 450,000.00
Extinguishers
CCTV System 120 10,000.00 1,200,000.00
52
B. Operating Expenditures
Operating expenditure or OPEX will be the ongoing cost for running the
proposed HDA plant as summarized in Table 11
Table 11. Estimation of Operating Expenditure for design option 1
OPERATING EXPENDITURES (Yearly)

Cost/Salary
Plant Expenses Quantity Total
(Php)
Raw Material 3,070,000,000
Electricity 4,000,000
Utilities Water 1,500,000
Fuel 1,000,000
Office
100,000
Supplies
Property
15% of total
Taxes, 76,326,789.45
capital
Permits and
investment
Licenses
10% of total
Maintenance capital 50,884,526.3
investment
Operating General 720000 720000
1
Labor Manager
Plant
Operation 2 600000 600000
Manager
Engineering 480000 480000
8
Supervisor
HSSE 420000 420000
1
Supervisor
Accounting 1 360000 360000
Manager
53
Admin. Staffs 15 264000 264000
Plant 288000 288000
12
Operators
Chemist 5 300000 300000
Laboratory 210000 210000
3
Staff
Plant 360000 360000
5
Mechanics
Plant 360000 360000
2
Electricians
Security 144000 144000
5
Guards
Doctor 1 300000 300000
general plant upkeep and
overhead, payroll overhead,
Plant packaging, medical services, 15% of total
Overhead safety and protection, capital 76,326,789.45
Cost restaurants, recreation, investment
salvage, laboratories, and
storage facilities
External tree planting, feeding program 400,000
C. Total Project Cost
Table 12. Total Project Cost
Total Project Cost

Capital Expenditures 508,845,263
Operating Expenditures (Yearly) 3,285,344,105
D. Economic Indicators
1. Net Present Value
54
Net present value (NPV) is the difference between the present value
of cash inflows and the present value of cash outflows to analyze the
profitability the project. Table 4.6 shows the NPV of the proposed power plant
after ten (10) years of operation.

Let A= Benzene Generated: 61.008 kmol/hr * 78.11kg/kmol * 8760hr/yr
41174.33355 MT/Year
Let B= Proposed Price: Php 80000/MT
Gross Income = AxB = Php 3,339,546,684 (Assumed to include taxes)
Net Annual Income = GI - OPEX
= 3,339,546,684 - 3,285,344,105
=Php 54,202,578
Table 13. Net Present Value Estimation
Year Cash Flow Present Value

0 -508,845,263 -508,845,263
1 54,202,578 -454,642,685
2 54,202,578 -400,440,107
3 54,202,578 -346,237,529
4 54,202,578 -292,034,951
5 54,202,578 -237,832,373
6 54,202,578 -183,629,795
7 54,202,578 -129,427,217
8 54,202,578 -75,224,639
9 54,202,578 -21,022,061
10 54,202,578 33,180,517
55
2. Payback Period
Payback period refers to the period of time required to recoup the
funds expended in the proposed power plant, or to reach its break-even
point.
Payback Period = Total Capital Investment / Total Net Annual Income
Payback Period = 508,845,263 / 54,202,578
Payback Period =9.387842456 Years
3. Rate of Return or Rate of Investment
Rate of return will measure the profit as a percentage of investment of
the proposed power plant after years of operation, and calculated as follows:
After 10 years of operation
Rate of Return = Current value – Original Value/ original value x 100%
Rate of Return = 33,180,517/ 508,845,263 x 100%

Rate of Return within 10 yrs of operation= 6.520747939%
DESIGN OPTION 2
56
Capital Expenditures (CAPEX) is the money invested to acquire any fixed,
physical, non-consumable asset. Table 14 represents the summary of the
CAPEX of the HDA Plant.
Table 14. Estimation of Capital Expenditures
PLANT EXPENSES Quantity Cost (Php) Total Cost (Php)

Admin 1 14,100,000.00
Control Room 1 18,600,000.00
Workshop and
Buildings 1 16,900,000.00
Powerhouse
Warehouse 1 13,700,000.00
15,000
Land 5000/sqm 75,000,000.00
sqm
1,800,000.0
Vehicles 5 9,000,000.00
0
Equipments 3,250,000.0
Reactor 1 3,250,000.00
0
Pump 1 238,215.00 238,215.00
Compressor 1 200,000.00 200,000.00
Distillation
1 938,428.00 938,428.00
Column
8,250,000.0
Furnace 1 8,250,000.00
0
1,650,000.0
Cooler 2 3,300,000.00
0
3,250,000.0
Reactor 1 3,250,000.00
0
Heat Exchanger 2 8,500,000.0 17,000,000.00
57
0
1,100,000.0
Splitter 2 2,200,000.00
0
5,500,000.0
Mixer 2 11,000,000.00
0
Valve 3 275,000.00 825,000.00
Water
Facility
Storage 3,760,000.0
4 15,040,000.00
Facility 0
30% of
Building and
Installation Contractor Fee 36,195,492.90
Equipment
cost
Personal
Protective 12,000 5,000.00 60,000,000.00
Equipments
Health and
Safety Fire
150 3,000.00 450,000.00
Extinguishers
CCTV System 120 10,000.00 1,200,000.00
Operating Expenditure or OPEX will be the ongoing cost for running the
processing plant. Table 15 represents the summary of the CAPEX of the HDA
Plant.
Table 15. Estimation of Operating Expenditure

Cost/Salary
(Php)
58
Fuel 1,000,000
Office
100,000
Supplies
Property
15% of total
Taxes,
capital 53,105,570.39
Permits and
investment
Licenses
10% of total
investment
General
1 60,000/month 720,000
Manager
Plant
Operation 2 50,000/month 1,200,000
Manager
Engineering
8 40,000/month 3,840,000
Supervisor
HSSE
1 35,000/month 420,000
Supervisor
Accounting
1 30,000/month 360,000
Manager
Admin. Staffs 15 22,000/month 3,960,000
Operating
Labor Plant
12 24,000/month 3,456,000
Operators
Chemist 5 25,000/month 1,500,000
Laboratory
3 17,500/month 630,000
Staff
Plant
5 30,000/month 1,800,000
Mechanics
Plant
2 30,000/month 720,000
Electricians
Security
5 12,000/month 720,000
Guards
Doctor 1 25,000/month 300,000
59
storage facilities
Table 16 Total Project Cost
Total Project Cost

Capital Expenditures 354,037,135.90
Operating Expenditures 3,168,240,854
1. Net Present Value

profitability the project. Table X.XX shows the NPV of the proposed
processing plant after ten (10) years of operation

Let A = Benzene Generated: 4,583.324114kg/hr (24hrs/day)
(1ton/1000kg)
Benzene Generated: 110tons/day
Let B= Proposed Price: Php80,000/ton
Let C= Operating Time: 365days
60
Gross Income = AxBxC
Gross Income = (110 tons/day)( Php80,000/ton)(365days)
Gross Income = Php3,212,000,000 (Assumed to include taxes)
Net Annual Income = GI – OPEX
= Php3,212,000,000 - Php3,168,240,854
Net Annual Income = Php43,759,146

0 -354,037,135.90 -354,037,135.90
1 43,759,146 -310,277,989.90
2 43,759,146 -266,518,843.90
3 43,759,146 -222,759,697.90
4 43,759,146 -179,000,551.90
5 43,759,146 -135,241,405.90
6 43,759,146 -91,482,259.90
7 43,759,146 -47,723,113.90
8 43,759,146 -3,963,967.90
9 43,759,146 39,759,178.10
10 43,759,146 83,554,324.10
1. Payback Period
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Payback period refers to the length of time required to recover the
amount of money invested for the processing plant and it is calculated as
follows:
Payback Period = Php354,037,135.90/ Php43,759,146
Payback Period = 8.091years
1. Rate of Return or Rate of Investment
Rate of return will measure the gain or loss on an investment over a
specified period of time. It is expressed as a percentage increase over the
initial investment cost and it is as calculated as follows:
Rate of Return = Php83,554,324.10/ Php354,037,135.90x 100%
DESIGN OPTION 3
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Capital investment refers to the fund needed for the proposed procesing
plant, Table 18 shows the estimation of required amount of money needed to be
invested and its summary, respectively.
Table 18. Estimation of Capital Expenditures
PLANT EXPENSES Quantity Cost (Php) Total Cost (Php)

Admin 1 14,100,000.00
Control Room 1 18,600,000.00
Workshop and
Buildings 1 16,900,000.00
Powerhouse
Warehouse 1 13,700,000.00
15,000
Land 5000/sqm 75,000,000.00
sqm
1,800,000.0
Vehicles 5 9,000,000.00
0
Equipments 3,250,000.0
Reactor 1 3,250,000.00
0
Pump 2 238,215.00 476,430.00
Compressor 1 200,000.00 200,000.00
Distillation
2 938,428.00 1,876,856.00
Column
8,250,000.0
Furnace 1 8,250,000.00
0
1,650,000.0
Cooler 1 1,650,000.00
0
3,250,000.0
Reactor 1 3,250,000.00
0
8,500,000.0
Reboiler 2 17,000,000.00
0
Splitter 1 1,100,000.0 1,100,000.00
0
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5,500,000.0
Mixer 1 5,500,000.00
0
Water
Facility
Storage Facility 3,760,000.0 15,040,000.00

4
0
30% of 33,825,985.8
Building and
Installation Contractor Fee
Equipment
cost
Personal
Protective 10,000 5,000.00 50,000,000.00
Equipment
Fire
150 3,000.00 450,000.00
Extinguishers
Health and
Safety
CCTV System 1 250,000.00 250,000.00
Operating expenditure or OPEX will be the ongoing cost for running
the proposed processing plant as shown in table 19 and its summary is
presented in table 20
Table 19. Estimation of Operating Expenditure

Cost/Salary
(Php)
Fuel 1,000,000
Office
100,000
Supplies
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Property 49,922,890.77
15% of total
Taxes,
capital
Permits and
investment
Licenses
10% of total
investment
General
1 60,000 60,000
Manager
Plant
Operation 2 50,000 100,000
Manager
Engineering
8 40,000 320,000
Supervisor
HSSE
1 35,000 35,000
Supervisor
Accounting
1 30,000 30,000
Manager
Admin. Staffs 15 22,000 330,000
Operating
Labor Plant
12 24,000 288,000
Operators
Chemist 5 25,000 125,000
Laboratory
3 17,500 52,500
Staff
Plant
5 30,000 150,000
Mechanics
Plant
2 30,000 60,000
Electricians
Security
5 12,000 60,000
Guards
Doctor 1 25,000 25,000
storage facilities
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Table 20. Total Project Cost
Total Project Cost

332,819,271.80
Capital Expenditures
3,572,859,099
Operating Expenditures
Net Present Value

profitability the project. Table 4.6 shows the NPV of the proposed power plant
after ten (10) years of operation.

Let A = Benzene Generated: 4,610.990057 kg/hr(24hrs/day)
(1ton/1000kg)
Benzene Generated: 110.6637614 tons/day
Let B= Proposed Price: Php89,000/ton
Let C= Operating Time: 365days
Gross Income = AxBxC
Gross Income = (110.6637614 tons/day)( Php89,500/ton)(365days)
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Gross Income = Php3,615,108,426 (Assume to include taxes)
Net Annual Income = G.I – OPEX
Net Annual Income = Php3,615,108,426 - Php3,572,859,099

Net Annual Income = Php42,249,326.53

0 -332,819,271.80 -332,819,271.80
1 42,249,326.53 -290,569,945.27
2 42,249,326.53 -248,320,618.74
3 42,249,326.53 -206,071,292.21
4 42,249,326.53 -163,821,965.68
5 42,249,326.53 -121,572,639.15
6 42,249,326.53 -79,323,312.62
7 42,249,326.53 -37,073,986.09
8 42,249,326.53 5,175,340.44
9 42,249,326.53 47,424,666.97
10 42,249,326.53 89,673,993.50
Payback Period
Payback period refers to the period of time required to recoup the
funds expended in the proposed power plant, or to reach its break-even
point.
67
Payback Period = Php332,819,271.80/ Php42,249,326.53
Payback Period = 7.8775 years
Rate of Return or Rate of Investment

Rate of return will measure the profit as a percentage of investment of
the proposed power plant after years of operation, and calculated as follows:
Rate of Return = Php89,673,993.50/ Php332,819,271.80x 100%
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CHAPTER V
Environmental Management of the Project
This chapter includes the environmental impacts of the Hydrodealkylation
Processing Plant and the mitigation to lessen their effect to the safety and health
of the people and the environment.
Socio-Economic Benefit of Hydrodealkylation Processing Plant
Positive benefits are being extended for the local community in terms of
the income for local economy and employment for residents during the
construction and operational phase of the designed power plant. Employment for
both skilled and semi-skilled workers were to be offered. Job such as
administration staff, medical staff and even catering services will be offered.
These personnel will be mostly hired from the residents of Limay, Bataan. Local
equipment to be used during the construction of the processing plant will also
result to economic boost to the resources coming from the community and will
produce a positive impact. The construction phase will also require numerous
skilled and semi-skilled employment. The management will also offer training
which is necessary for many new staff which will boost their skills and additional
techniques will be offered for the local market. When the operation phase started,
employment opportunities will also be offered especially for those skilled worker
in the community. The project will also provide revenue to local supporting
businesses within Bataan. During local activities such as fiestas and holidays, the
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management will also offer assistance as well as participation can also be
expected. Since the management believe of what education can do, it will offer
scholarship for selected students from the local community. In conclusion, the
socio-economic impact of the processing plant would be positive and the
management would do its best to manage all the concerns and expectation of the
community in a fair and well-balanced manner.
Social, Political and Ethical Considerations
Decision making is a critical part when it comes to management of a
processing plant. Potential impact of strategic decision to the local community
and the people residing in it should always be considered. Decisions made by
the management will always consider virtues such as patronage, charity and
volunteerism to extend the sense of social responsibility.
Laws and regulation has always been a part of every decision making
activities. Decision from a legal stand point will be considered by the
management. The operation of the processing plant will always be working
according to laws and regulation. Compliance from the national and local
government laws will be highly perceived during the construction and operation
phase of the processing plant.
Ethical decisions will be considered based on the manner consistent to the
ethical principles and shared values in the society. Ethical principles will be
based on the values of the people living in Bataan. In making ethical decisions,
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the management will perceive and eliminate unethical alternatives to prevent
ethical violations.
Health and Safety
Safety is the top priority of our management. We value the health and
safety of our employees and staff more than anything else. The local public holds
a positive attitude about the project and believe it can improve the development
of the local economy when it is completed so it is a responsibility of the
management to consider the health and safety of the local community as well.
Here is the main step the management will implement to ensure the health and
safety of everyone that is concerned all throughout the process.
A. Hazard Prevention and Control

The management identify all the hazard that exist all throughout the
processing plant. Staffs assign per worksite and machine operations are
well trained and tasked to ensure that each equipment is taken care of so
that less hazard can be expected. Maintenance and repair of all
equipment are scheduled and should be implemented during the date
indicated to ensure that they work according to its purpose in a safe and
sound manner. All employees, including all levels of management, are
tasked to obey the site’s safety and health rules and regulations.
B. Medical Services
The company provides a professional doctor to employ medical
care not just for the employees but for the near residences. Medicines for
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both in-site and travelling purposes are also provided by the company. The
company also has its own medical equipment in case of urgent needs.
C. Personal Protective Equipment (PPE)

Personal Protective Equipment is the last line of defense of workers
most especially those engaged on high risk operation. Each employees
will have their own PPEs issued by the company to minimize exposure to
serious workplace conditions. Training are also provided to orient each
employee on how to use all equipment included in their PPEs. PPEs are
also engaged to maintenance and repair which is scheduled and damaged
PPEs should be replaced immediately.
Table 22.
Summary of Recommended PPE According To Hazard
OBJECTIVE WORKPLACE HAZARD SUGGESTED PPE
Eye and Flying particles, molten

Safety Glasses with side-shields,
face metal, liquid chemicals,
protective shades.
protection gases or vapors, light
radiation.
Falling objects, inadequate

Head Plastic Helmets with top and side
height clearance, and
protection impact protection.
overhead power cords
Hearing Hearing protectors (ear plugs or ear

Noise, ultra-sound.
protection muffs).
Falling or rolling objects, Safety shoes and boots for

Foot
pointed objects. Corrosive protection against moving &falling
protection
or hot liquids objects, liquids and chemicals.
Hazardous materials, cuts Gloves made of rubber or synthetic

Hand
or lacerations, vibrations, materials (Neoprene), leather, steel,
protection
extreme temperatures. insulating materials, etc.
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Respiratory Dust, fogs, fumes, mists, Facemasks with appropriate filters
protection gases, smokes, vapors for dust removal and air purification
(chemicals, mists)
D. Security
Security personnel are located in every entry and exit point within
the plant to ensure that all person that enters and exits the plant are
authorized to minimize safety issues. Scanning devices are also provided
to ensure that all personal materials of workers that enters and exits the
plant will not cause any trouble in both the operation and the safety of all
staff. Closed Circuit Television Cameras (CCTV) are installed all over the
area for high security purposes. Footage will always be checked every
now and then. These measures are implemented to make sure that all the
workers are secure and safe and can work without any worries in their
minds.
E. Workplace Inspection
The management conducts monitoring and inspection, both
announced and surprised, to ensure that the workplace as well as the
equipment of the processing plant are safe to work with. A thorough
examination is done to identify any hazard and to apply corrective
measures to minimize hazard present in the workplace. This improves the
overall safety of the workers.

F. Calamity Drills
Calamities such as typhoon, earthquake and fire are phenomena
which cannot be controlled. The company conducts calamity drills every
month to train employees what to do during every situation that may
happen during a calamity. Evacuation plans are also distributed to make
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sure that all employees have the knowledge of each escape route near
their location. Alarms are also installed all throughout every facility to
make sure that everyone can be hear signals of emergency situation.
Waste Management
Waste are the by-product of each process within the plant that cannot be
reused and needs disposal. Waste management is the process in which waste
that can cause impact on the environment as well as the surrounding community
are treated using technology available in accordance to local, national and
international legal framework. Proper disposal are studied and planned to make
sure that it will cause the least amount of effect on the environment and the
community around the processing plant. Water treatment facilities are also
implemented to ensure that the waste water generated from the plant will not
affect the groundwater and the water system where the waste will be disposed.
Here are the waste that the HDA processing plant will produced and the ways on
how the management will handle waste management.
A. Unused Toluene
Toluene, also known as toluol, is an aromatic hydrocarbon. It is a
colorless, water-insoluble liquid with the smell associated with paint
thinners. It is a mono-substituted benzene derivative, consisting of
a CH3 group attached to a phenyl group. As such, its IUPAC systematic
name is methylbenzene. Toluene is predominantly used as an
industrial feedstock and a solvent.
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As the solvent in some types of paint thinner, contact cement and
model airplane glue, toluene is sometimes used as a recreational inhalant
and has the potential of causing severe neurological harm.
Proper Disposal of Toluene
1. Turn off any sources of ignition or any device that can spark. Toluene and
toluene vapor are highly flammable.
2. Put on safety glasses and safety gloves. Liquid toluene can chemically
burn the skin, causing redness, and toluene vapor can damage the eyes.
Be careful not to inhale any of the toluene vapor.
3. Clean up any toluene spills by covering them with sand, clay, dirt or an
organic commercial product. You can allow small spills to evaporate.
4. Place toluene in a nonchlorinated waste container for disposal. Store this
container in an unoccupied building or outdoors.
5. Call a chemical waste disposal service to remove the container containing
toluene. According to Practice Green Health, you must have toluene
removed within three days of accumulating more than 55 gallons of this
hazardous waste.
B. Wastewater
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Wastewater (or waste water) is any water that has been affected by
human use. Wastewater is "used water from any combination of domestic,
industrial, commercial or agricultural activities, surface
runoff or stormwater, and any sewer inflow or sewer
infiltration". Therefore, wastewater is a byproduct of domestic, industrial,
commercial or agricultural activities. The characteristics of wastewater
vary depending on the source. Types of wastewater include: domestic
wastewater from households, municipal wastewater from communities
(also called sewage) or industrial wastewater from industrial activities.
Wastewater can contain physical, chemical and biological pollutants.
Wastewater Treatment
Reverse osmosis (RO) is a water purification technology that uses
a partially permeable membrane to remove ions, unwanted molecules and
larger particles from drinking water. In reverse osmosis, an applied
pressure is used to overcome osmotic pressure, a colligative property, that
is driven by chemical potential differences of the solvent,
a thermodynamic parameter. Reverse osmosis can remove many types of
dissolved and suspended chemical species as well as biological ones
(principally bacteria) from water, and is used in both industrial processes
and the production of potable water. The result is that the solute is
retained on the pressurized side of the membrane and the pure solvent is
allowed to pass to the other side. To be "selective", this membrane should
76
not allow large molecules or ions through the pores (holes), but should
allow smaller components of the solution (such as solvent molecules, i.e.,
water, H2O) to pass freely.
Mitigation Measures
Mitigating measures are set of plans and activities to lessen the effect of
the processing plant on the environment as well as the local government. Here
are the list of the primary mitigating measures that the processing plant will
implement during construction and operating phase.
A. During Construction
1. The construction team will implement the covering of piles of cement
and other load to minimize emission of dust in the surrounding.

2. Unauthorized person are not allowed to enter the premises during
construction phase so potential hazards can be lessen.

3. Equipment to be installed in the plant are of high specification and are
selected properly to minimize emissions, odor and noise from
spreading on nearby communities.

4. Planting activities will be done on the location to make up for the loss
of trees and plant species that are affected by the construction.

5. New areas will be provided by the management in cooperation with the
local government for native species to prevent habitat loss.
B. During Operation
1. Air quality will be monitored all throughout the process to ensure that
emissions are of the level allowable by the local and national law.
Alarms will be designated on air vents to make sure that no amounts of
77
emission will exceed the standard and that welfare of the employees
and the environment are considered.

2. Proper storage of raw materials are studied and planned to ensure
elimination of possible chemical hazard that can be resulted by
mishandling of such raw materials.

3. PPE program will be strictly observed all throughout the plant to ensure
the safety of employees at work.

4. Communication and coordination between the company, local
government unit and the nearby residents will be practiced to build
social interaction and to monitor the safety of the local residents and
the environment. Problems that may arise will be dealt with immediate
action.
5. Waste disposal will be according to the local and national standards to
ensure that it will cause no harm with the nearby communities and the
environment surrounding the processing plant.
Environmental Standards
This section provides the list of the main laws and regulation that the
company work with accordingly.
A. Presidential Decree (PD) 1586: Philippine Environmental Impact
Statement
The main objective of this law is to maintain the balance between
the environment and the socio-economic development of the country. It
aims to protect the environment despite the increasing demand of natural
resources and development to attain sustainability.
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B. Republic Act (RA) 6969: Philippine Toxic Substances and Hazardous
and Nuclear Waste Act
It is the policy of the State to regulate, restrict or prohibit the
importation, manufacture, processing, sale, distribution, use and disposal
of chemical substances and mixtures that present unreasonable risk
and/or injury to health or the environment; to prohibit the entry, even in
transit, of hazardous and nuclear wastes and their disposal into the
Philippine territorial limits for whatever purpose; and to provide
advancement and facilitate research and studies on toxic chemicals.
C. Republic Act (RA) 8749: Philippine Clean Air Act
The Act provides for the creation of a national program of air
pollution management focusing primarily on pollution prevention; for the
promotion of mass media communication in order to create social
awareness and active participation in air quality planning and monitoring
D. Republic Act (RA) 9003: Philippine Ecological Solid Waste
Management Act
This Act makes provision for the efficient solid waste management,
for the volume reduction of the waste, its environment friendly disposal,
composting, recycling, re-use, recovery, green charcoal process; for the
collection, treatment and disposal in environmentally sound solid waste
management facilities whereas it shall be possible to correctly dispose the
79
proper segregation, collection, transport, storage, treatment and disposal
of solid waste
80
CHAPTER VI
PROJECT DESIGN TRADE-OFFS
In selecting the best design, multiple realistic constraints will be
considered. The table below presents the summary of the multiple realistic
constraints of the three design options.
Table 23. Multiple Realistic Constraints
Multiple
Realistic Design Option 1 Design Option 2 Design Option 3
Constraints
Percent
97.15% 80.3% 85.78%
Conversion
Net Present
Php33,180,517.0 Php83,554,324.10 Php89,673,993.50
Value
Level of
High Low Medium
Waste
Design Philosophies
A. Worst Case Design
Using scale from one to ten, each realistic constraints are scored and are
evaluated using worst case design.
Technical Scale Calculation
Design Option 1:
81
100%:10 = 97.15%:X; X = 9.72
Design Option 2:
100%:10 = 80.3%:X; X = 8.03
Design Option 3:
100%:10 = 85.78%:X; X = 8.58
Economical Scale Calculation
Design Option 1:
90M:10 = 33M:X; X = 3.69
Design Option 2:
90M:10 = 84M:X; X = 9.28
Design Option 3:
90M:10 = 89M:X; X = 9.96
Envvironmental Scale Calculation
Design Option 1:
No waste:10 = High waste: X; X = 3
Design Option 2:
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No waste:10 = Low Waste: X; X = 9
Design Option 3:
No waste:10 = Medium Waste: X; X = 6
Table 24 Worst Case Design
Multiple Realistic Design Option 1 Design Option 2 Design Option 3

Constraints
Technical 9.72 8.03 8.58
Economical 3.69 9.28 9.96
Environmental 3 9 6
Worst Result DO1 = 3
Worst Result DO2 = 8.03
Worst Result DO3 = 6
Based on the Worst Case Design philosophy, the designers find that
Design Option 2 is the best design to opt to in the selection of Hydrodealkylation
Processing Plant among the three design options.
83
B. Pareto Optimum Design
Degree of Importance:
Technical = 4
Economical = 3
Environmental = 5
Table 25. Pareto Optimum
Multiple Design Design Design Degree of

Realistic Option 1 Option 2 Option 3 Importance
Constraints
Technical 9.72 8.03 8.58 4
Economical 3.69 9.28 9.96 3
Environmental 3 9 6 5
Design Option 1 = 4(9.72) + 3(3.69) + 5(3)
= 65.76
Design Option 2 = 4(8.03) + 3(9.28) + 5(9)
= 104.96
Design Option 3 = 4(8.58) + 3(9.96) + 5(6)
= 94.2
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Based on the Pareto Optimum Design philosophy, the designers find that
Design Option 2 is the best design to opt to in the selection of Hydrodealkylation
Processing Plant among the three design options.
CHAPTER VII
PROJECT CONSTRUCTION EXECUTION PLAN
The proposed project execution plan for the hydrodealkylation processing
plant in Limay, Bataan is presented in this chapter. This chapter discusses about
different factors to be considered before and during the construction phase as
well as during operation phase of the processing plant. This includes the
discussion of the scope of the work, the goal of the execution plan, allocation of
resources, and scheduling and commissioning of the proposed project.
Scope of Project Construction Execution
The scope of the project execution plan involves the sequence of events
that will be involved in the construction phase, the resources and the
organization of the project including the personnel to make the HDA processing
85
plant possible. The planning phase as well as the preparations to be made
before the construction of the plant are also included in this section. The
engineers and experts involved in the construction phase will decide and
consider details and studies for the erection of the hydrodealkylation processing
plant such as the plant location, resource allocation, the current demand and the
forecast on the local and international market, technical details and construction
plan.
Scheduling of the proposed project will be agreed upon after the
agreement and setting of a plan for the processing plant. Set of time frame will
assigned to each activity to make sure that each task were accomplished. These
activities include the planning, procurement, construction, start up, and
commissioning of the project. Target goals and objectives for every activity will be
set to provide a clear image of the expected output.
Organizational Considerations
Coordination of many different fields of expertise concerned with the
project construction is required for the execution of the project. This would
include the administration department, technical department, and financial
department. The administration of department will be the one to oversee the
overall operation. A general manager will be assigned for the task. The
department will serve as the framework of the project. The main function of this
department is to provide connections with different departments in order to
provide an efficient and reliable communication of information.
86
The financial department will manage the costs, revenues, and other
financial aspects that is concerned with the construction and operation of the
project. The department will study the cost effectiveness while considering the
quality of the equipment and materials required for each phase of construction as
well as operation.
The technical department will include engineering principles such as civil,
electrical, and mechanical and instrumentation expertise who will provide
detailed engineering plans in the construction of the power plant. This includes
the structural details, piping layout, electrical layouts and instrumentation details
that will be installed. This department also weighs in the economical aspect of
the construction along with the technical expertise that the construction of the
proposed project entails.
Construction Management
The construction manager will supervise and coordinate the construction
of the proposed hydrodealkylation processing plant considering the choice of
location based on the three key requirements for the viability of plant which are
the fuel source, ease of access for transportation and source of water as well as
the consideration of the location of the supplier of raw material which is the
Petron Refinery situated in Bataan.
Quality Assurance and Technical Specifications
All deliverables and quality of the products delivered during the
construction phase of the processing plant will be checked by the material
87
engineers and quality control specialists to ensure the legitimacy of the
equipment and materials delivered. Specification of every equipment will also be
checked by the engineers to ensure that it is optimal for the operation and could
handle different temperatures, pressures and other parameter ranges involved.
This stage also pertains to the control towards the quality of the product
generated from the plant to the consumers. Environmental considerations
through the emissions that may be released and the waste generated from the
plant are also covered in this section. The procedures in controlling the quality is
to ensure that the generated toluene adheres to the quality criteria or meets the
requirements or demand of the consumer.
Quality assurance differs from quality control as it is system of maintaining
standards in manufactured products by testing a sample of the output against the
specification. The equipment used is also checked if it complies with the
temperature and pressure capacity which will take part in the continuous plant
operations. Redesigning or reconsideration of other product will be observed
when limitations are met. For the total capacity of the plant, each of the
components needed for the plant should be of the right specifications.
Resources Allocation
Different forms of resources including materials and manpower are the
main focus of this section. The management and allocation of the resources must
be optimal to ensure that every department will be able execute their work in the
best way. Resources will be allocated and scheduled economically and will be
88
monitored to prevent over-allocation and under-allocation. The project manager
will be assigned for monitoring of resources to ensure smooth operations during
the construction phase.
Plant Layout
The layout of the proposed hydrodealkylation processing plant is shown in
the figure below. This includes the key equipment which requires installation. The
layout considers the distances of equipment in relation to other components in
order to save time and costs for transportation and is essential to operation. It is
also arranged in order to achieve efficient coordination, productivity, and flexibility
between the components while taking into account the safety measures involved.
Figure 21. 3D layout of the Proposed HDA Processing Plant
The 3D model presented includes the setup of the proposed
hydrodealkylation processing plant, the facilities shown include the parking area,
the warehouse, the substation, the administration building, and the
89
manufacturing area which houses the components necessary for
hydrodealkylation process.
Project Commissioning and Execution
Construction of the processing plant requires various permits which should
be obtained from the government. This includes the management of the different
contracts and permits which may refer to building, lease, purchase and
operation. Compliance should be acquired from the Department of Environment
and Natural Resources (DENR) especially when there will be environmental
changes to be performed.
The HDA processing plant is composed of different components which has
their own respective functions. The overall system and components of the
processing plant should be designed, installed, tested, operated and maintained
according to the operational requirements. Proper design of plant should be
observed, since it is the key to achieve the designed output. The size of the
design chosen is considered for the land occupancy on its erection. Safety
installation of equipment in the processing plant should be conformed properly.
The plant performance can be calculated and evaluated and it is ideal to test
them to assure proper functioning and can start with the operations.
The plant operations require maintenance as there are plenty of things to be
considered to be able to have an efficient run. Preventive maintenance is an
unceasing procedure as long as the plant is running and this should be complied.
To enable the processing plant, meet its plant life effectively and efficiently,
without any hitch, it should be used and maintained properly.
90
Through the phase of project development, proper schedule should be
followed, having time management and discipline also need to be considered,
otherwise it will have an adverse effect to the construction period of the plant that
may also delay the plant operation.
The construction of the plant will be able to provide opportunities for the
locality that they may have development in the community. Building ties with the
local government and community sets a platform for further mutual
understanding. Such negative effects that the plant may impart should be solved,
as the wellness of the residents should be a priority.
Project Scheduling and Overall Management
The project manager who is in charge of the entirety of the construction
execution phase will need to plan, budget, oversee and document all aspect of
the erection of the processing plant. They may work closely with the upper
management to make sure that the scope and direction of the construction phase
is on schedule, as well as other departments for support.
Project management requires detailed planning with realistic goals and is
set to be achieved with the given resources and time. A Gantt chart is presented
below which shows the planned construction execution, with the activities listed
as well as the expected time of construction divided quarterly.
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Figure 22. Summary of Tasks in the Construction of the Proposed HDA
Processing Plant
Figure X shows the pacing of every task with the given time frames in which
it should be followed, when a certain task is slacking, the project manager will
have to shift from monitoring to controlling in order to achieve the task within the
allocated time due to the possibility of one task piling over the other and thus,
delaying the construction phase, and ultimately, the start of commission and
operation of the project.
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CHAPTER VIII
SUMMARY OF FINDINGS, CONCLUSIONS AND RECOMMENDATIONS
This chapter presents an overall rundown of pertinent details regarding the
designed plant, and consists of summary of findings, conclusion and
recommendations for the development of Hydrodealkylation Processing Plant.
Summary of Findings
The following results relative to the Hydrodealkylation Processing Plant
were summarized as follows:
1. The Hydrodealkylation Processing Plant total required input of raw
materials, toluene (5708 kg/hr) and hydrogen (301 kg/hr) is sufficient to produce
110 tons of benzene annually which will able the plant to meet the growing global
demand of benzene materials.
2. The proposed processing plant of benzene material in the country will
supply the local industries and manufacturers, specifically polymers, which have
great demand in the use of benzene material to produce by products. Exportation
of the product is also considered.
3. The proposed plant will be located at Roman Expressway at Limay,
Bataan, near other industrial plants. The land area for the proposed plant is 1.5
hectares which approximate value is Php75,000,000.00. The capital expenditure
(CAPEX) estimate that the total project of the equipment cost specification for the
93
designed plant is approximately Php354,037,135.90 and the operating
expenditure (OPEX) is Php3,168,240,854.
4. The investment‘s payback period calculated as 8.091 years and rate of
return of 23.60% is assessed to be apparent.
Conclusions
Based from the analysis of information and data gathered, the proponents
established the following conclusions:
1. The annual growth estimation rate of benzene material indicates its high
escalation in terms of demands and use. With the current demand trend of
benzene material, Asia Pacific region contributes the most.
2. Technical information and data, specifications and capacity of
equipment, resources of raw materials and process flow is considered in
evaluating the capability of the proposed plant, which has the capacity to
produce 4,583 kg/h of benzene material, to meet the growing demand of the
benzene material.
3. Alternative designs are made to fully consider the most appropriate
and efficient design and operation in the production of benzene. Selection of
the best design was conducted based on the conversion, net present value,
waste produced and equipment capacity in each design.
94
4. The proposed hydrodealkylation production plant has an approximate
of 8 years for payback period.
5. The proposed Hydrodealkylation Processing Plant is a minimal waste
production plant. Recovery system for the waste produced, such toluene and
waste water, are installed for further use of the materials, thus decreasing the
cost requirements for materials. The recovered materials will then be stored
and used in the next process.
6. Environmental Impact Assessment is conducted to identify the
hazards that may be produced before, during and after the construction and
processing of the plant to the people around the community, to the
environment and to the staffs. Mitigations, preventions and protections are also
readily identified to prevent the people and environment from these hazards.
7. For the project construction execution plan, four phases of
preparation is set for the smooth flow which are the conceptualization phase,
feasibility study phase, basis of design phase and basic design phase.
Different phases are also set for the quality control and assurance.
Recommendations
Based on the foregoing findings and conclusions presented, the following
recommendations are suggested for further development of the
Hydrodealkylation Processing Plant:
95
1. Installation of water treatment facilities for further processing of the
water collected in water reserve tanks. The treated water can be used for other
activities inside the plant and thus can also be reused in the process.
2. Additional information and data about the equipment specifications,
process and other factors affecting the process are required to develop cost-
effective, reliable, emission-compliant systems.
3. Proper maintenance of the equipment is also suggested to maintain
the efficiency of the process and prolong the life of equipment. A regular
schedule of maintenance for equipment decreases the possibility of having
faulty equipment during the process that may cause delay.
4. More critical calculations for the designed plant are recommended to
ensure that the total costs are accurate
5. Further research must be conducted to select alternative catalyst to
be used in the process and alternative process methods of more efficient
production of benzene.
6. Larger plant capacity is also suggested for the next advocates of this
production plant, since the demand trend of the benzene globally is very high.
7. Further research for more efficient waste treatment of the plant must
be conducted while taking inconsideration the health, safety and environment
during the construction and operation of the process plant.
96

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CHAPTER I

and adhesives. Because of its many uses, the Petrochemical industry in

Philippines has been a critical contributor to the country’s overall economic

in this industry. With the ever-growing demand for petrochemical derivatives,

more petrochemical plants are needed in the Philippines.

One particular petrochemical that is greatly used in manufacturing diverse

products in the Philippines is benzene. Benzene is an organic chemical

compound with the chemical formula C 6H6. It is used primarily as a precursor to

the manufacture of chemicals with more complex structure such as

ethlybenzene, cumene and more. More than half is processed to ethylbenzene, a

the benzene production is used to manufacture cumene which is needed to

produce phenol and acetone for resins and plastics.

Because of the several applications of benzene and the demand for

petrochemical derivatives such as plastics, the group has decided to design a

Hydrodealkylation is a chemical reaction that involves reacting an aromatic

hydrocarbon in the presence of Hydrogen gas to form a simpler aromatic

hydrocarbon devoid of a functional group. The Hydrodealkylation of Toluene is a

Toluene + H2 → Benzene + CH4

Toluene and hydrogen are converted in a reactor packed with a catalyst to

produce benzene and methane. The catalyst provides an alternative reaction

mechanism with a lower activation energy. Typically, the reaction reaches a

block diagram of the HDA process.

Figure 1: HDA Block Flow Diagram

The mixture of hydrogen and toluene is preheated before it is introduced to the

C7H8 + H2 = C6H6 + CH4

This reaction is irreversible, and it requires catalyst. The catalyst consists of

chromium or molybdenum oxides, platinum or platinum oxides, on silica or

The catalytic process occurs at lower temperatures and offers higher

hydrogen. Portion of the unreacted hydrogen is compressed and recycle back to

before being introduced into a distillation column, where toluene is separated

steam. The cooling requirements are achieve by cooling water at temperature of

30 C and pressure of 1 bar.

liquid with the smell associated to paint thinners. It is a mono-substituted

benzene derivative consisting of a methyl attached to a Phenyl group. This

is capable of providing the HDA plant’s feed. Otherwise, we can also

obtain Toluene from Shell Tabangao Refinery which also produces

Toluene from catalytic reforming.

1.008. It is the lightest element. Large quantities of hydrogen are required

consumers of H2 are hydrodealkylation, hydrodesulfurization and

reforming plant. The hydrogen will be recycled in the hydrodealkylation

process to minimize the H2 requirements.

catalyst. Because this industrial Catalyst isn’t available locally, it will be

imported from Liaoning Haitai Sci-Tech Development Co., Ltd.

formula C6H6. It is used primarily as a precursor to the manufacture of

chemicals with more complex structure such as ethlybenzene, cumene

and more. More than half is processed to ethylbenzene, a precursor to

benzene production is used to manufacture cumene which is needed to

produce phenol and acetone for resins and plastics.

chemical compund with the chemical formula CH 4. It is the simplest alkane

heaters in the plant.

Rationale of the Study

Benzene is an aromatic hydrocarbon and a commodity petrochemical

product. It is produced as by-product in stream crackers and refineries, thus its

global chemical and petrochemical value chain.

Benzene is used in a broad range of economic sectors such as electrical

& electronics, construction, consumer products, transportation, and medical. This

petrochemical product has many derivatives such as ethyl benzene,

The rapidly growing industries such as packaging, construction, bulk

substantially driven the applications for the benzene derivatives globally

increase in disposable incomes has led to growth of many consumer products

prices have also contributed to the higher consumption of benzene derivatives.

The unusual supply–demand pattern has prompted researchers to