MASS BALANC

Data for Mass Balance

M.W g/gmol
TAZODONE 371.500
KSM 01 309.500
KSM 02 135.000
NA2CO3 106.000
NACL 58.000
HCL 36.000
H20 18.000
CO2 44.000

Mass balance over S

Moles of trazodone to be produced 0.538

kg of KSM 01 need 167.459
kg of KSM 02 need 73.044
Moles of KSM 01 need 0.541
Moles of KSM 02 need 0.541
kg of HCL produced 38.762
Mol of HCL 1.077
Mol of NA2CO3 NEED TO NUTRALIZE HCL 0.538
kg of NA2CO3 57.066
kg of NACL 62.450
kg of H2O 9.690
kg of CO2 23.688
kg of KSM 01 un reacted 0.837
kg of KSM 02un reacted 0.365

M.B OVER PNF:-(Output con

slurry 1009.481
 kg of salt out 62.450
kg of ML 947.031
Output from filter 65.736
Moisture in wet cake 3.287

M.B OVER SSR

input to crystallizer 943.745

M.B OVER C.F

Assumption:-2%moisture in product
input liquor 943.745
wet cake produced 204.082
ML 739.663
 M.B OVER VTD

ASSUMPTION:-NMT 0.5% MOISTURE IN PRODUCT

wet cake in 204.082
product 201.005
moisture in product 1.005
moisture removed in vtd 3.077

M.B. For 100% conversion

 MASS BALANCE
CAPACITY 200.000 kg/batch
CONVERSION 0.995
solvent IPA
Density 0.763 kg/L
IPA Needed for,
KSM01 376.406 kg
KSM02 164.363 kg
Na2CO3 128.448 kg
Total 669.217 kg
For 10% Excess
IPA req. 736.138 kg
Vol. 964.795 L
Mass balance over SSR1

kmol Chemical Input(kg) Output(kg)

kg IPA 736.138 736.138
kg TAZODONE 0.000 200.000
kmol KSM 01 167.459 0.837
kmol KSM 02 73.044 0.365
kg NA2CO3 57.066 0.000
kmol NACL 0.000 62.450
kmol HCL 0.000 0.000
kg H20 0.000 9.690
kg CO2 0.000 23.688
kg Total 1033.707 1033.169
kg
kg
kg

ER PNF:-(Output contain 95% solid)

kg Output(kg)
Chemical Input(kg)
 kg Chemical Input(kg) SALT ML
kg IPA 736.138 3.287 732.852
kg TAZODONE 200.000 0.000 200.000
kg KSM 01 0.837 0.000 0.837
KSM 02 0.365 0.000 0.365
NACL 62.450 62.450 0.000
H20 9.690 0.000 9.690
65.736 943.745
Total 1009.481 1009.481

M.B OVER SSR 2

kg OUTPUT
Chemical INPUT liquor crystal
IPA 732.852 732.852 0.000
TAZODONE 200.000 0.000 200.000
KSM 01 0.837 0.837 0.000
KSM 02 0.365 0.365 0.000
H20 9.690 9.690 0.000
743.745 200.000
Total 943.745 943.745

M.B OVER C.F

Output(kg)
Chemical Inpur(kg) ML WET CAKE
IPA+H2O 742.542 738.460 4.082
TAZODONE 200.000 0.000 200.000
KSM 01 0.837 0.837 0.000
KSM 02 0.365 0.365 0.000

739.663 204.082
Total 943.745 943.745
M.B OVER VTD

Output(KJ)
Chemical Input(KJ) Dry product Moisture
Moisture 4.082 1.005 3.077
Trazodone 200.000 200.000 0.000
201.005 3.077
Total 204.082 204.082

OVERALL M.B.
Chemical Inlet Outlet
KSM01 167.459 0.837
KSM02 73.044 0.365
Na2CO3 57.066 0.000
IPA 736.138
H2O 0.000 745.829
TRAZODONE 0.000 200.000
CO2 0.000 23.688
HCL 0.000 0.000
NACL 0.000 62.450
Total 1033.707 1033.169
 ENERGY BALANCE
Data for Energy Balance
Chemical Cp (kJ/kg.k) ∆Hf (KJ/mol) ∆Hf (KJ/gm)
TAZODONE 1.590 299.750 0.807
KSM 01 1.620 -56.620 -0.183
KSM 02 1.340 100.800 0.747
NA2CO3 1.060 -1130.700 -10.667
NACL 0.864 -411.000 -7.086
HCL 0.799 -92.230 -2.562
H20 4.187 -285.830 -15.879
CO2 0.861 -393.510 -8.943
IPA 2.322 -
ƛ of IPA 733.333 KJ/kg
Energy Balance over SSR

Temp. Of Feed 30.000 °C

Temp. In Reactor 82.000 °C

-115.070 KJ/mol
Heat of Reaction(∆Hr ) -186.469 KJ
cp mix IN 2.069 KJ/kg.k
cpmix OUT 2.056 KJ/kg.k

Qsupply 111225.320 KJ

Hot water required In out

Temp.(°C) 92.000 70.000

Hot water required 1207.475 kg

 Energy Balance over SSR-2

STAGE 1
Temp.(°C) IN OUT
COOLING WATER 30.000 45.000
SLURRY 60.000 40.000
Qreq 37718.421 KJ
Amt. Of Cooling water 600.564 kg

STAGE 2
Temp.(°C) IN OUT
CHILLED WATER 7.000 32.000
SLURRY 40.000 15.000
Qreq 47148.027 KJ
Amt. Of chilled water 450.423 kg

STAGE 3
Temp.(°C) IN OUT
BRINE -5.000 13.000
SLURRY 15.000 2.000
Qreq 24516.974 KJ
Amt. Of Brine 436.556 kg
 Energy Balance over VTD

Data Required
Temp. in dryer 55.000
ƛ of IPA 733.333 KJ/kg
Condition Before After
Moisture 0.020 0.005
Solid in product 0.980 0.995
Moisture mass
Cpmix (in) 1.605 KJ/kg.k
Cpmix (out) 1.594 KJ/kg.k

Heat with feed 9824.327 KJ

Heat out with product 17618.352 KJ
Heat out with vapor 2649.092 KJ
Qsupply 10443.118 KJ

Hot water in out

Temp.(°C) 30.000 55.000

Amt. of Hot water req. 99.767 kg

 ENERGY BALANCE

Energy Balance over SSR-1

Chemical Input(KJ) Output(KJ)

IPA 0.000 0.000
TAZODONE 0.000 25440.000
KSM 01 8138.512 108.513
KSM 02 2936.351 39.151
NA2CO3 1814.184 0.000 mipa
NACL 0.000 4316.511
HCL 0.000 0.000 After reaction complet we cool up to 6
H20 0.000 3245.911 Qreq
CO2 0.000 1631.612
Heat of RXN 186.469 0.000 Hot water required
Heat supply 111225.320 0.000 Temp.(°C)
Heat of vaporization 0.000 89525.333
Total 124300.836 124307.033 flow rate of water req
y Balance over SSR-2

Input Output
Heat in with Reaction mass 109383.422 0.000
Heat removed by cooling water 0.000 37718.421
Heat removed by chilled water 0.000 47148.027
Heat removed by brine 0.000 24516.974
Total 109383.422 109383.422
gy Balance over VTD

In(kJ) Out(kJ)
Heat in with feed 9824.327 0.000
Heat out with dry product 0.000 17618.352
Heat out with vapor 0.000 2649.092
Heat supplied 10443.118 0.000
Total 20267.444 20267.444
 Process Design

Data Req.
Chemical
KSM01
KSM02
Na2CO3
Density of KSM01
Density of KSM02
Density of Na2CO3
Batch time
Moles of KSM01
Moles of KSM01
Density of IPA
X
L/D

Calculation:
Volume of KSM01
160.000 Volume of KSM02
Volume of Na2CO3
tion complet we cool up to 65*c Volume of IPA
31124.989 KJ CA0
€
In out k
30.000 45.000 Vol. By integration
Total volume of reactor
495.581 kg Excess
New volume
Design volume
 Total capacity
Round off

D
L

Nozzle Design(For feed)

MOC
J
f
CA

Pd
Ds
Do
ts
K'
Do*ts

d0
tn(from data sheet)
dn
Thickness calculation:
trn
trn'
 trnf
tsr
Area removed
A
Area compansate by shell
As

Hi
Ho
Ai
Ao
Area compansate by Nozzle
An

A'

Ar

Here,Ar>+ve ;So, Reinforcedment pad is requires

Thickness of Reinforcedment pad
tp
tpf
 R
Process Design

Data Req.
Value Unit Data Req.
167.459 kg Pressure of Reactor
73.044 kg Pressure of Jacket
57.066 kg
1.200 kg/L
1.600 kg/L
2.540 kg/L
12.000 hr
541.063 mol
541.063 mol
0.763 kg/L Thickness of shell
0.995 ts
1.500 td
tf
Calculation:
139.549 L Di
45.652 L Do
22.467 L Lenght of Jacket
964.795 L
2.921 mol/L L/Do
0.500 t/Do
12.552 1/(Molar*hr) Model Brown check
295.851 L Pcr
1468.314 L Pallowble
1.250 Pallowble>Pi
1835.393 L tf
2000.000 L
 1149.996 L DATA PROVIDED
1200.000 L Parameter
viscosity of mixture
1.006 m density of mixture
2.516 m speed of agitator
height of liquid in tank
Length of agitator shaft between bearing & agitator
Width of blade
No of baffles in tank wall
shaft & agitator blade material
ultimate tensile stress
yield stress
Max allowable shear stress in shaft
Modulus of Elasticity
Turbine Diameter
reynold number
Power number (from curve-1)
Power requirement
Power requirement
Actual power requirement
Power output from motor

le Design(For feed)
SS304
0.850
124.000 N/mm2
2.000 mm

0.196 N/mm2
1.006 m
1.020 m
7.000 mm Y
0.161 20000000.000
7142.305 mm2 N/m2
actN
400.000 mm 15.000
5.000 mm mm
390.000 mm

0.363 mm
2.363 mm
 5.000 mm M
3.937 mm 12.000
14.000
2758.000 mm2 16.000
18.000
418.750 mm2

34.380 mm
19.849 mm
68.760 mm2
104.691 mm2 C(mm)
477.707
173.452 mm2

592.202 mm2

2165.798 mm2

, Reinforcedment pad is requires

5.582 mm
6.000 mm
 REACTOR DESIGN
Mechanical Design

Req. Design Material

0.196 N/mm2 Allowable stress (f)
0.441 N/mm2 Young’s modulus (E)
Poission’s ratio (µ)
Joint efficiency factor (J)
Density of MOC
Corrosion allowance
fos

Calculation:
ss of shell Torrispherical Head
0.937 mm Rc
3.937 mm Rk
7.000 mm Cs

1006.329 mm b
1020.329 mm th
2310.522 mm
td(top)
2.264 tf(top)
0.007
td(Bottom)
0.891 N/mm2 tf(Bottom)
0.223

7.000 mm

AGITATOR DESIGN
DATA PROVIDED
Notation Value unit
mu 6.250 cp
Rho 1856.500 kg/m3
n 100.000 rpm
Hl 1738.044 mm
La 2085.653 mm
W 150.000 mm
Nbaffles 4.000 -
IS-2062 Grade ST 42-W
σult 4200.000 kgf/cm2
σyield 2300.000 kgf/cm2
τshear 550.000 kgf/cm2
E 1950000.000 kg/cm2
Da 503.165 mm
Nre 125338.333
Np 5.000 -
P 141.284 kgfm/sec
P 1.884 hp
Pactual 2.487 hp
P' 3.000 hp

Flange(For 400mm)

Moc of Flange SS316 Data Outside diameter

Required nozzle thickness
for Flange Design pressure
Moc of Bolt 5% Cr Mo steel Design Allowable Stress
J

Gasket(MOC : Rubber with asbestos fabric)

m Nmin Go/Gi Dfi
2.500 10.000 1.005 400.000
mm mm
actGo bo b G
440.000 7.500 6.847 426.307
mm mm mm mm

BOLT DESIGN
Spacing(Bs) R Edge clearance Root diameter
75.000 20.000 16.000 9.540
75.000 22.000 17.000 11.190
75.000 25.000 18.000 13.190
75.000 27.000 20.000 14.480

Flange design data:

a1(mm) a2(mm) a3(mm) W1(N)
38.854 32.277 25.700 24634.305
n Arb(mm2) Rb(mm) Wm(N)
20.000 71.444 9.540 86779.854
ical Design

SS316
124.000 N/mm2
193000.000 N/mm2
0.330
0.850
8070.000 kg/m3
1.500 mm
4.000

ulation:
Torrispherical Head Jacket design(Lamped type)
1006.329 mm
60.380 mm Dia. Of half coil 100.000
1.771
Thickness of Jacket
205.301 mm tc 0.178
1.660 mm td 1.678
tf 3.000
3.160 mm
5.000 mm ts' 5.500
tc' 1.500
4.660 mm
5.000 mm Fps 20.178
Fps<Fallow allow
 SHAFT DIAMETER CALCULATION
Parameter Notation Value unit
Average rated torque on shaft Tc 21.497 kgf.m
Max torque induced in shaft Tm 32.245 kgf.m
shaft diameter d 3.103 cm
worst case bending force Fm 170.893 kgf
bending moment M 356.423 kgf.m
Equivalent bending moment Me 357.151 kgf.m
stress created by Me f 12183700.746 kgf/cm2
which is greater than allowable yield stress
shaft diameter d 5.500 cm

Max deflection in shaft Theta 5.903 cm

critical speed Nc 123.153 rpm
N/Nc 81.200
Here,N/Nc IS B/W 50 to 65% dacutal 5.500 cm
BLADE THICKNESS CALCULATION
Parameter Notation Value unit
Endurance limit for carbon steel f 2100.000 kgf/cm2
thickness of blade bt 0.409 mm
actual thickness of blade bts 5.000 mm

Flange(For 400mm)

400.000 mm Flange type Loose

5.000 mm Ffa 124000000.000 N/m2
196133.000 N/m2 Ffb 124000000.000 N/m2
76000000.000 N/m2 Fba 138000000.000 N/m2
0.850 Fbb 138000000.000 N/m2

c) B
Gi Go N Wm2
410.000 413.000 1.500 183295.871
mm mm mm N
G1 actG
411.500 426.307
mm mm

DESIGN
No. of bolts
 Ar(mm2) ncal. nactual C2(mm) C1(mm)
71.444 18.591 20.000 454.150 477.707
98.295 13.513 16.000 458.150 382.166
136.571 9.726 12.000 464.150 286.624
164.591 8.070 12.000 468.150 286.624

design data:
W2(N) W3(N) K mu Y
3346.817 8987.592 1.274 0.330 8.562
Ma(Nm) Mo(Nm) Mmax Bs actual(mm) Dfo(mm)
2230.245 1296.135 2230.245 75.000 509.707
gn(Lamped type)

mm

ess of Jacket
mm
mm
mm

mm
mm

N/mm2
 Bolt
Wm1 Am1 Am2 Amax.
36968.714 267.889 1328.231 1328.231
N mm2 mm2 mm2
Hub Property
g0 g1 h
5.000 7.075 7.500
mm mm mm

Itteration
tf Cf
C1-C2(m) 18.599 1.000
0.024 22.092 1.411
-0.076 21.608 1.350
-0.178 21.672 1.358
-0.182 21.663 1.357
21.664 1.357
21.664 1.357
21.664 1.357
21.664 1.357
tf(mm) Cf
tf(mm) 21.664 1.357
22.000
 Storage Tank Design
Parameter Value Unit
Volume 1500.000 L
MOC SS304
f 180.000 kgf/cm2
IPA den. 0.001 kg/cm3
j 0.850
h/d 1.500
p' 0.013 kgf/cm2
Di 1.084 m
h 1.626 m
p 0.114 kgf/cm2
2.000 mm
t 0.403 mm
td 2.403 mm
tf 5.000 mm

Bracket Support
Number of brackets 4.000
Height of brackets from foundation 1.000 m
Bolt Circle Diameter 1.200 m
Base plate dimension
A 14.000 cm
B 15.000 cm
Distance between vessel wall and bracket end 150.000 mm
Gusset plates are 140mm apart from each other 140.000 mm
Channel size
a 150.000 mm
b 75.000 mm
Area 21.000 cm2
Modulus of section 19.000 cm3
Radius of gyration 2.200 cm
Weight 170.000 N/m
Tensile stress of MOC of bracket and lug 140.000 N/mm2
Compressive stress 124.000 N/mm2
Bending stress 158.000 N/mm2
Wind pressure 0.000 N/m2
Weight of vessel 1657.751 N
ank Design
Torrispherical Head
Rc 1.084 mm
Rk 0.065 mm
Cs 1.771

b 0.394 mm
th 0.078 mm

td(Bottom) 2.078 mm
tf(Bottom) 5.000 mm

tf (top) 5.000 mm
SF 15.000 mm
Do 1089.035 mm
B.D(th<1in) 1145.008 mm

Support
Weight
Density 7800.000 kg/m3
Shell 432.935 kg
Head 80.316 kg
Fluid 1144.500 kg
Pw 0.000 N
(compressive stress) P 414.438 N
(avg. pre. Acting on each bracket)Pavg 0.020 N/mm2
Base Plate
Thickness of base plate (t) 0.921 mm
standrad 5.000 mm

Web Plate
Height of web plate 75.000 mm
theta 45.000 degree
 0.785 rad
C 0.600 m
Load acting on web plate 248.663 Nm
Thickness of Web plate 1.187 mm
standrad 5.000 mm
 Pump Design
Pump Design for IPA
Data Required
Flowrate(Q) 0.002 m2
Pipe ID(d) 0.060 m
Fluid Viscosity(µ) 0.0024 kg.m/s
Fluid Density(ρ) 786.000 kg/m3
V.P of IPA 5370.225 pa
Height 15.000 m
Horizontal distance 5.000 m
Total Distance 20.000 m
Velocity(v) 0.708 m/s
Reynold No.(Nre) 13906.582
Flow type Turbulent

Head Loss:
(1) Loss due to fitting (3) Loss due to pipe friction
(i) Due to 90° f(For turbulent flow,) 0.007
No. Of elbow(n) 4.000 Hfp 0.248 m
Hf 0.133 m
(ii) Due to 45° Total friction Loss 0.631 m
No. Of elbow(n) 4.000
Hf 0.041 m Net Positive Suction Head calculation
(2) Loss due to valve HEAD:
(i) Due to Ball valve Patm 13.141 m
No. Of valve(n) 4.000 Hs 0.500 m
Hf 0.005 m Psurface 0.000 m
(ii)Due to Check Valve Pvapor pressure 0.696 m
No. Of valve(n) 4.000
Hf 0.204 m NPSH 12.314 m
 Equipment QTY COST RS
SSR 2.000 244770.000
PNF 1.000 840000.000
CF 1.000 700000.000
VTD 1.000 1330000.000
Storsge Tank 1.000 140000.000
Pumps 3.000 28000.000

Total equipment cost 4223538.000 Rs

Direct cost
Item
Purchased equipment % Rs.
100.000 4223538.000
Purchased Equipment Installation 14.000 591295.320
Instrumentation & controls (installed) 8.000 337883.040
Insulation Cost 3.000 126706.140
Piping (installed) 20.000 844707.600
Electrical (installed 10.000 422353.800
Buildings (including services) 18.000 760236.840
Yard Improvements 5.000 211176.900
Service Facilities 20.000 844707.600
Land 10.000 422353.800
Total 208.000 8784959.040

Indirect cost
Item % Rs.
Engineering and Supervision 21.000 886942.980
Construction expense 16.000 675766.080
Contractor’s fee 6.000 253412.280
Contingency 15.000 633530.700
Start up expenses 3.000 126706.140
Total 2576358.180

Fixed capital 11361317.220 Rs.

Total capital 13366255.553 Rs.
Working capital 2004938.333 Rs.
TOTAL RS GST rate including GST
489540.000 18.000 577658.000
840000.000 18.000 991200.000
700000.000 18.000 826000.000
### 18.000 1569400.000
140000.000 18.000 165200.000
84000.000 12.000 94080.000
4223538.000

COST ESTIMATION
Raw material cost
Chemical Amount cost per kg cost per year
KSM01 167.459 1200.000 10449447.777
KSM02 73.044 1000.000 3798264.539
Na2CO3 57.066 150.000 445114.401
IPA 736.138 90.000 3445128.163
Total 18137954.880
Direct production cost
Iitem % Rs.
R/M cost - 18137954.880
Operating labor 10.000 422353.800
Utility 15.000 633530.700
Maintance 5.000 568065.861
Operating & supply 12.000 1363358.066
Lab & testting 15.000 1704197.583
Patent and royalties 3.000 126706.140
Total 22956167.031
Genrel expence
Item % Rs.
Administration exp 12.000 1363358.066
Distribution & market 10.000 1136131.722
R&D 5.000 568065.861
Sales & servises 5.000 568065.861
Total 3635621.510
Fixed charge
Item % Rs.
Deprecation 186706.140
Tax 4.000 454452.689
Insurance 1.000 113613.172
Intrest 10.000 1336625.555
Total 2091397.556
Total production cost 28683186.097
 Profitability Analysis
52.000
Product selling price 3500.000 Rs./Kg
Production capacity 10400.000 Kg/year
Total selling 36400000.000 Rs.

Gross profit 7716813.903 Rs.

Net profit 5271075.434 Rs.
Taxable income 7530107.763 Rs.
GST(30%) 2259032.329 Rs.

Rate of return 39.436 %

Payback time 2.155 year
Tunover ratio 3.204 -
Break even capacity 8195.196 Kg/yr.
Break even point 78.800 %
 Nozzle &Flange Cost

Cost 300.000 Rs/kg Density 8000.000

Nozzle
Dia.(mm) Hi+Ho Di pad Cost/Nozzle Nos.
400.0000 104.2290 390.0000 1358.3640 2909.6667 1.0000
100.0000 76.4880 90.0000 211.0080 484.8044 4.0000
75.0000 72.6940 65.0000 106.2105 297.9482 2.0000
30.0000 63.3840 20.0000 0.000 59.7077 2.0000

Flange
Dia.(mm) dfo dfi tf Cost/Flange Nos.
400.0000 509.707 400.000 22.000 4136.561 1.0000
100.0000 223.083 100.000 17.0000 1273.626 4.0000
75.0000 161.150 75.000 12.000 459.944 2.0000
30.0000 116.150 30.000 12.000 284.653 2.0000
 kg/m3

Total Cost
2909.6667
1939.2178
595.8964
119.4155
5564.196

Total Cost
4136.561
5094.505
919.889
569.307
10720.262
 M R Ed Rb
12.000 20.000 16.000 9.540
14.000 22.000 17.000 11.190
16.000 25.000 18.000 13.190
18.000 27.000 20.000 14.480
Ar(mm2) nactual C2(mm) C1(mm) C1-C2
71.444 20.000 454.150 477.707 0.024
98.295 16.000 458.150 382.166 -0.076
136.571 12.000 464.150 286.624 -0.178
164.591 12.000 468.150 286.624 -0.182