UNIVERSTY OF BENGHAZI

FACULTY OF ENGINEERING

CHEMICAL ENGINEERING DEPARMENT

Demercaptanization Of Light hydrocarbon

REPORT SUBMITTED FOR PARTIAL FULFILMENT FOR THE DEGREE OF

.B.SC. IN CHEMICAL ENGINEERING
By
SALEH MOHAMMED ALAWAMI 23587
ABD ALMOHAYMEN MOHAMMED BOLIFA 24407
RAFEEK SALEH ALAGOORY 24204
ESLAM MOHAMMED ALSULTANI 22687
HUSSAIN ALI ALQTRANI 24191

:Supervisor

MR. Mohamed Saleh EL-gabaili

Spring -2020
 ‫* اإلهداء *‬

‫إليك أيها النبع الكبير الفياض الذي ال يمل العطاء ‪ ،‬إليك يامن عشت األيام‬
‫والليالي وأنت تنتظر هذه اللحظة بفارغ الصبر ‪ ،‬إلي الذي سعى وشقى‪/‬‬
‫لننعم بالراحة والهناء ‪ ،‬إلي الذي لم يبخل بشيء في دفعنا إلي السعادة ‪.‬‬
‫إلى الوالد العزيز‬
‫إليك يامن كنت أنعم وسادة وضعت على حضنها رأسي ‪ ،‬يا من كنت‬
‫أستمد طاقتي وقوتي من دعواتك لي ‪ ،‬يا من صبرتي وسهرتي ألجلي ‪.‬‬
‫إلى الوالدة العزيزة‬
‫إليكم يا زهور حديقتنا وربيع عمرنا وإلهام تفكيرنا ‪ ،‬إليكم يامن النرتاح إال‬
‫بقربكم ‪ ،‬يامن فرحكم فرحنا وحزنكم حزننا ‪.‬‬

‫إلى إخواننا وأخواتنا‬

‫‪CERTIFICATE‬‬

‫‪:The project entitled‬‬

‫‪Demercaptanization Of Light hydrocarbon‬‬

‫‪: Submitted by‬‬

‫‪SALEH MOHAMMED ALAWAMI‬‬ ‫‪23587‬‬
‫‪ABD ALMOHAYMEN MOHAMMED BOLIFA‬‬ ‫‪24407‬‬
‫‪RAFEEK SALEH ALAGOORY‬‬ ‫‪24205‬‬
 ESLAM MOHAMMED ALSULTANI 22687
HUSSIAN ALI ALQTRANI 24191

In partial fulfillment of the award of B.SC. degree in Chemical Engineering has been carried out under my
.supervision and accepted for presentation /examination

..……….………………………… : Date: signature

.Supervisor : MR. Mohamed Saleh EL-gabaili

Corrected approved copy for records

………………..…………………… : Date: signature
.Supervisor : MR. Mohamed Saleh EL-gabaili

ACKNOWLEDGEMENTS

First of all, we would like to record all the praises, gratitude and thanks to almighty ALLAH, for helping us
.to conclude one of the most important phases our education

Secondly, we would like to express our deep and sincere gratitude to

Dr. Ali Hamed Elhudhiry

for his continuous help, advice and guidance during the entire course of the project work and in its
.preparation
Finally, our great thanks to all the staff members of the chemical engineering department. We are also
grateful to our parents for their unfailing encouragement and continuous support throughout the study at the
university. We are also grateful to our brothers, sisters, friends and everyone who helped us during this
.work

ABSTRACT

.General reviews for the technology of demercaptanization of light hydrocarbon was presented

A material and energy balance calculations has been made for each units the mass and energy conversation
.laws was satisfied

A process design for the heat exchanger and absorber , was carried out ,a good design parameter has
. obtained

An economic study was presented which indicates, a good profitability ,a pay-back will be achieved after 3
.years
 LIST OF FIGURES

Contents Page

Figure (1): schematic diagram of demercaptanization of light hydrocarbon stock

Figure (2) : material balance for absorber ( extractor )
Figure (3) : Material balance of deaerator
Figure (4) : Material balance of regenerator
Figure (5) : Material balance of settling tank
Figure (6) : Energy balance for the extraction
Figure (7) : Energy balance for deaerator
Figure (8) : Energy balance for the Heat-exchanger
Figure (9) : Energy balance for the regenerator
Figure (10) : Energy balance for the cooler
Figure (11) : Energy balance for the refrigerator
Figure (12) : Energy balance of the settling tank
Figure 13: shown equilibrium line and minimum slope
Figure 14: shown number of stage
Figure (15 ): Type of the heat exchanger : fixed tub
Figure (16) : overall coefficients ( join process side study duty to service
) side and read U from centre scale
Figure (17) : Explain position of the tubes in form triangular
Figure(18): shell-bundle clearance
Figure (19) : Tube-side heat-transfer factor
Figure (20) : Shell-side heat-transfer factor
Figure (21) : Tube-side friction factor
Figure (22) : shell-side friction factor segmental baffles
Figure (23): A Relation between NPV and Years of Project Life
 LIST OF TABLES

Contents Page

Table (1.1) : physical and chemical properties of components

Table (2.1) : Component mole fraction
Table( 2.2 ): Results of material balance (kmol/hr) based on feed(S1= 100 kmol/hr) basis
Table (2.3) : Material balance ( Real values kmol/hr ) after multiplying
by a scale factor of ( 2.416 )
.Table(4.1):Antoine constant for methyl mercaptane CH3SH
Table (4.2) : physical properties of each components for shell-side S6 at
K and 4 bar 325.9
Table(4.3) : Result of physical calculation
Table (4.4) : Constant for use in equation
Table (4.5) : Fouling factor ( coefficients)
Table (5.1): Shows Estimation Cash Flow Over 20 Years of Production
 CHAPTER (1)
INTRODUCTION

Merox is : an acronym for mercaptan oxidation. It is a proprietary chemical process used in oil refineries
and natural gas processing plants to remove mercaptans from LPG, propane, butanes, light naphthas,
kerosene and jet fuel by converting them to hydrocarbon disulfides
.
The Merox process requires an alkaline environment which, in some process versions, is provided by an
aqueous solution of caustic soda (NaOH), a strong base, commonly referred to as caustic. In other versions
.of the process, the alkalinity is provided by ammonia, which is a weak base

Processes within oil refineries or natural gas processing plants that remove mercaptans and/or hydrogen
sulfide (H2S) are commonly referred to as sweetening processes because they results in products which no
longer have the sour, foul odors of mercaptans and hydrogen sulfide. The hydrocarbon disulfides may
remain in the sweetened products, they may be used as part of the refinery or natural gas processing plant
.fuel, or they may be processed further
General for merox process sweetening used in Irans South Pars Gas Complex is exraction and caustic
. regeneration processes
:The effect of the main operating variables on mercaptans extraction
• .Temperature
.Concentration•
• .Flow rate
• . Amount of caustic solution as alkaline solution
Mercaptan's Disadvantages
.Impart foul smell •
.Reduce Octane Number by reducing its susceptibility to MMT •
.Elementary Sulfur and Presence of Mercaptans Cause Corrosion •
.Pollute Environment •
.Dangerous to Human Health •
:Caustic soda(NaOH)
:In this process , we use the caustic as alkaline dilute solution 5mol% to
• . It has ability to dissolve low molecular weight mercaptans
• .It convert mercaptans to sodium mercaptide which is the intermediate product
Table (1.1) : physical and chemical properties of components
Description

Alkaline sweetening of gas usually described process of mercaptan removal from gases. Alkaline
sweetening of gas is carried by extraction of methyl mercaptan CH3SH from gas with alkaline solutions
:according to reaction (1)
CH3SH + NaOH = CH3SNa + H2O (1)

The only mercaptan in gas is methyl mercaptan CH3SH . Methyl mercaptide CH3SNa saturated alkaline
solution NaOH after extraction is supplied to regeneration. Regeneration proceeds in the presence of air
:and methyl mercaptide saturated alkaline solution at temperature of 50_70°C according to reaction (2)
CH3SNa + 0.5O2 + H2O → CH3SSCH3 + 2NaOH (2)

.Dimethyl disulfide formed during regeneration of alkali is separated from the alkaline solution by settling
.Sometimes, as an alkaline gas sweetening described mercaptane removal from gas
:Steps of the project
Material balance-1
Energy balance-2
Processs design of selected units-3
Economic evaluation-4
 CHAPTER (2)
MATERIAL BALANCE
Material balances are the basis of process design. A material balance taken over the complete process will
determine the quantities of raw materials required and products produced. Balances over individual process
.units set the process stream flows and compositions, and provide the basic equations for sizing equipment
Material balances are also useful tools for the study of plant operation and troubleshooting. They can be
used to check performance against design, to extend the often limited data available from the plant
instrumentation, to check instrument calibrations, and to locate sources of material loss. Material balances
.are essential Lo obtaining high-quality data from laboratory or pilot plants
: Conservation of mass
: The general conservation equation for any process system can be written as
Material out = Material in + Generation- Consumption - Accumulation
For a steady-state process, the accumulation term is zero. Except in nuclear processes , mass is neither
generated nor consumed, but if a chemical reaction takes place, a particular chemical species may be formed
:or consumed in the process. If there is no chemical reaction, the steady state balance reduces to
Material out = Material in
A balance equation can be written for each separately identifiable species present , elements, compounds, or
radicals, and for the total material. Balances can be written for mass or for number of moles (4)

Material Balance for the Absorption column (extraction) is :

S2 Treated LHCS

Mole Fraction
C1 = 0.6
C2 = 0.2
S3
C3 = 0.1
(NaOH)
C4 = 0.1 Solution 5mole%
air = z

S1 = 100kmol/hr
 S4
Figure (2) : material balance for the absorber ( extractor )

Take a basis of Total Feed S1 of 100 kmole/hr composition of feed stream S1 is given as

96wt% light hydrocarbons CH4 – nC4H10 and 4wt% CH3SH.

The light hydrocarbons Yi Composition is given as:

CH4 60 mol%

C2H6 20 mol%

C3 H8 10 mol%

C4 H10 10 mol%

Average Molecular weight = ∑ Yi × Mwi

Mw avg = (0.6×16)+(0.2×30)+(0.1×44)+(0.1×58)

Mw avg  25.8

Mwt of CH3SH = 48.11

expressing the composition of light hydrocarbon in terms of mole fraction;

taking 100kg of the total feed in S1.

96
25.8
Mole fraction of LHCS = = 0.978
96 4
+
25.8 48.11

 mole fraction of CH3SH = 1 – 0.978 = 0.022

 Total S1 = 97.8 kmole/hr Natural gas + 2.2 kmole/hr CH3SH

mole fraction of components in S1 will be :

0.6 ×97.8
CH4 = = 0.5868
100
 0.2× 97.8
C2H6 = = 0.1956
100

0.1× 97.8
C3H8 = = 0.0978
100

0.1× 97.8
n C4H10 = = 0.0978
100

2.2
CH3SH = = 0.022
100

We assume that all light hydrocarbons are Separated in S2 .

Note: that the Methyl mercaptane CH3SH is reacted with Alkali solution NaOH 5 mol% the following
reaction in taking place:

NaOH + CH3SH  CH3SNa + H2O

Moles of NaOH required equals to the moles of CH3SH consider all CH3SH is converted then;

CH3SH reacted = 2.2 kmol/hr

NaOH = 2.2 kmol/hr

CH3SNa = 2.2 kmol/hr

H2O = 2.2 kmol/hr

Alkali Solution in S3 is 5 mol% this will be

 quantity of Alkali solution in stream S3

2.2
will be = 44 kmol/hr
0.05

 stream S3 consisting of (44 kmol/hr + air z)

molar flow i
Mole fraction% =
Total molar flow

44
NaOH dilute mol% =
44+ z

z
Air z mol% =
z+ 44

So for Z is unknown, which represent a quantity of air which has been escaped from the bottom stream of
the regenerator.

We will assume that all light hydrocarbons has separated in the Top stream S2, then
S2 = (0.6 × 97.8) + (0.2 × 97.8) + (0.1 × 97.8) + (0.1 × 97.8)

= 97.8 kmol/hr

S2 can be estimated in other way, that in

S2 = (100)(1 – 0.022) = 97.8 kmol/hr

Mole fraction for natural gas equal 1.

The stream S4 containing Methyl mercaptides CH3SNa,water H2O and air Z .

S4 = CH3SNa + H2O + Z

Note the water in S4 must be H2O which has Produced in the reaction plus the water already existing in the
Alkali solution.

Thus water in S4 = 2.2 + (44 × 0.95) = 44 kmol/hr

 S4 = CH3SNa + H2O + Z = 2.2 + 44+ Z = 46.2 + Z

molar flow i
Mole fracrtion% =
Total molar flow

Mole fractions of components in S4 will be:

mole of CH 3 Sa 2.2
YCH3 SNa = =
total 46.2+ Z

mole of H 2 O 44
YH2O = = =
total 46.2+ Z

Z
Yz =
46.2+ Z

Note Z is a small amount of air

Which is unknown yet, and will be estimated later.

Material balance for dearator :

In this units air will be separated from the bottom stream of the absorbtion.

The source of this air has came out from the bottom of the regenerator.

Material Balance of the deaerator will be:-

S5

S4

S6

Figure (3) : Material balance of deaerator

 S4 = S6 + S5

In this unit all air was separated as a top products, a Traces of water vapor is expected to be lost with the air
stream S5.

For reason of simplicity, this trace of water will be neglected in the material balance.
 S4 = 46.2 + Z kmol/hr

S5 = Z kmol/hr

S6= 46.2 kmol/hr

Mole fraction for air z in stream S5 equal 1.

Mole fractions of components in S6 will be:

mole of CH 3 SNa 2.2

YCH3SNa = = =0.047619
mole of CH 3 SNa+ mole of H 2 O 2.2+44

mole of H 2 O 44
YH2O = = = 0.95238
mole of CH 3 SNa+ mole of H 2 O 2.2+ 44

Material Balance for the regenerator:-

S10

S 6 =S7

S9

S8

Figure (4) : Material balance of regenerator

In the regenerator a chemical reaction is occurring to convert methyl mercaptide CH3SNa , into dissulfide
CH3SSCH3 which is not soluble in an alkaline solution.

2 CH3SNa + 0.5 O2 + H2O CH3SSCH3 + 2NaOH

The mole balance for this reaction will the known value of methyl mercaptide CH3SNa.
 CH3SNa = 2.2 kmol/hr

make an arrangement for the reaction to make the stoichiometric coefficient of CH3SNa = 1 thus, we
have,

0.5 1 1
CH3SNa + O + H O  CH3SSCH3 + NaOH.
2 2 2 2 2

0.5
O2 requied =  2.2 = 0.55 kmol/hr
2

1
H2O requied =  2.2 = 1.1 kmol/hr
2

Assume all CH3SNa is converted into CH3SSCH3, then :

1
CH3SSCH3 produced =  2.2 = 1.1 kmol/hr
2

NaOH = 1 2.2 = 2.2 kmol/hr

Theoretical flow rate of air in

0.55
S9 = = 2.619 kmol/hr
0.21

It is recommended to have an excess air, which will be taken as 20%

air flow rate in S9 = 1.2  2.619 = 3.14 kmol/hr

Then N2 = 0.79  3.14 = 2.48 kmol/hr

And O2 = 0.21  3.14 = 0.659 kmol/hr

Stream S8 must contains CH3SSCH3 and NaOH dilute solution in addition to some amount of air, then
quantity of air will be assumed to be in the range of 3-5% of air in stream S9

According stream S8 will be as follows :-

Air = 0.05  air in S9 = 0.05  3.14

Air = 0.157 kmol/hr

The air quantity is previous Assume as Z

Z air = 0.157

CH3SSCH3 = 1.1 kmol/hr

NAOH = 2.2 kmol/hr

H2O in S8 = water produced in the reaction inside inside the absorber – water consumed by the reaction in
the regeneration .

H2O in S8 = 2.2 – 1.1 = 1.1 kmol/hr

Note That the alkali solution is 5 mol% Concentration thus means that:

2.2
NaOH (Sol) in S8 = = 44 kmol/hr
0.05

Stream S8 = air + alkali solution is 5 mol% + disulfide + water

S8 = 0.157 + 44 + 1.1 + 1.1 = 46.357 kmol/hr

Mole fraction of components in S8 is:

0.157
Yair = = 0.00338
46.357

44
YNaOH(sol)= = 0.9491
46.357

1.1
YCH3SSCH3 = = 0.0237
46.357

1.1
YH2O = = 0.0237
46.357

stream S10 in the regeneration will be obtained by making a balance of air

Air in S9 – air in S8 - air reacted = air in S10

S10 = 3.14 –0.157– 0.55 = 2.433 kmol/hr

Material Balance for the extraction agent deaerator Previously estimated, with the unknown value of Z .

Now Z has been estimated = 0.157

S5 = 0.157

The bottom stream of the settling tank (E – 2) will be

S3 = 44 + Z = 44 + 0.157 = 44.157 kmol/hr

Material Balance for the setting tank E – 2:

S12 CH3SSCH3

S11

NaOH (sol)+ CH3SSCH3

Small amount of air
 Alkalli
solution+Air
S3 Figure (5) : Material balance of settling tank

In this unit the disulfide CH3SSCH3 will be separated in top stream S12.

 S11 = 45.257 kmol/hr , S3 = 44.157 kmol/hr

 S12 = S11 – S3

S12 = (45.257 – 44.157) kmol/hr

S12 = 1.1 kmol/hr

Note That there is an extra water circulating in the process Loop, which comes from the difference between
the H2O produced in the absorber reaction and H2O consumption in the regenerator, there for an adjustment
procedure for keeping the concentration of NaOH solution. Continuously constant must be carried out, in the
settler tank in which a small amount of H2O must be delivered by a makeup dose of NaOH. This will
maintain the NaOH concentration to be held constant " 95mol% H2O, 5mol% NaOH ".

Required of deal with 50000 TON ⁄ Y of LHCS feed to the process in S1

50000× 103
Based 8000 working hours S1 = kg ⁄ hr
8000

S1 = 6250 kg ⁄ hr

The basis of calculations was 100 Kmol ⁄ hr of S1

in kg ⁄ hr S1 = 100 Kmol ⁄ hr × MW avg

8 = 100 × 25.86 = 2586 kg ⁄ hr

6250
... scale factor = = 2.416
2586
All stream must be multiple by a factor of ( 2.416 )

Table (2.1) : Component mole fraction

Table ( 2.2 ): Results of material balance (kmol/hr) based on feed (S1= 100 kmol/hr) basis :

Table (2.3) : Material balance ( Real values kmol/hr ) after multiplying by a scale factor of
( 2.416 )
 CHAPTER (3)
Energy Balance

In process design , energy balances are made to determine the energy requirements of the process :
The heating , cooling and power required . In plant operation, an energy balance ( energy audit )
On the plant will show the pattern of energy use the suggest areas foe conservation and savings .

Conservation of energy :
As for material , a general equation can be written for the conservation of energy :
Energy out = Energy in + generation – consumption – accumulation
This is a statement of the first law of thermodynamics. An energy balance can be written for any process
step. Chemical reaction will evolve energy ( exothermic ) or consume energy ( endothermic ).
For steady-state processes the accumulation of both mass and energy will be zero .
Energy can exist in many forms and this, to some extent, makes an energy balance more complex than
material balance .

First , we need heat capacity date of each component at standard condition :

CP CH 4 = 35.7 KJ / Kmole . k
CP C 2 H 6 = 52.49 KJ / Kmole . k
CP C 3 H 8 = 73.6 KJ / Kmole . k
CP n C 4 H 10
= 98 KJ / Kmole . k
CP CH 3 SH = 48.67 KJ / Kmole . k
gas

CP Air = 29.16 KJ / Kmole . k

CP 5 %NAOH = 158 KJ / Kmole . k
CP H 2 O = 75.24 KJ / Kmole . k
CP CH 3 SSCH 3 = 107.1 KJ / Kmole . k
CP CH 3 SNA = 82.4 KJ / Kmole . k

Heat capacity for the mixture components in each stream will be calculated According to the following
equation : -
N
CP S = ∑ Y i CP i
i=1

N : Number of component
S : Stream number
Stream S1 :-

CP 1= Y CH 4 CP CH 4 + Y C 2 H 6 CP C2 H 6 + Y C 3 H 8 CP C 3 H 8 + Y n C 4 H 10
CP n C 4 H 10
+ Y CH 3 SH CP CH 3 SH
= 49.069KJ / Kmole . k

For Stream S2 :-
Heat capacity for sweet light hydrocarbons :-

CP 2= Y CH 4 CP CH 4 + Y C 2 H 6 CP C 2 H 6+ Y C 3 H 8 CP C 3 H 8+ Y n C 4 H 10
CP n C 4 H 10

= 47.998 KJ / Kmole . k

For Stream S3 :-
CP 3= Y 5 %NAOH CP 5 %NAOH + Y Air CP Air

= 157.542KJ / Kmole . k

For Stream four S4 :-

CP 4= Y H 2 O CP H 2 O + Y Air CP Air + Y CH 3 SNA CP CH 3 SNA

= 75.4189 KJ / Kmole . k

For Stream five S5 :-

CP 5 = CP Air = 29.1627 KJ / Kmole . k

For Stream six & seven S6 & S7 :-

CP 6∧7= Y H 2 O CP H 2 O + Y CH 3 SNA CPCH 3 SNA

= 75.58KJ / Kmole . k

For Stream eight S8 :-

CP 8 = Y 5 %NAOH CP 5 %NAOH + Y H 2 O CP H 2 O + Y Air CP Air +Y CH 3 SSCH 3 CP CH 3 SSCH 3

= 154.3924 KJ / Kmole . k
For Steam nine & ten S9 & S10 :-
CP 9∧10= CP Air=29.1627 KJ / Kmole . k

For Stream eleven S11 & S13 :-

CP 11=Y 5 %NAOH CP 5 %NAOH +Y Air CP Air + Y CH 3 SSCH 3 CPCH 3 SSCH 3

= 156.315 KJ / K mole . k

For Stream twelve S12 :-CP 12=CP CH 3 SSCH 3 = 107.1KJ / K mole . k

Calculate of energy balance for streams :-

The Reference temperature of 298 k0 will be taken for the energy calculation.
Note the any subset in indicating the number of the stream.

Energy balance for the Extraction column K 1 ( Absorber ) :-

S2 ,T2

S3 ,278 K0

S1 ,323 K0

S4 ,T4

Figure (6) : Energy balance for the extraction

The following reaction is taking place :
CH 3 SH + NAOH CH 3SNA + H2O

-: The reference heat reaction data of each component

∆ H ° R C 3 SH = -2.343*104 KJ / Kmole
∆ H ° R 5%NAOH = -2.807*105 KJ / Kmole
∆ H ° R CH 3 SNA = -1.295*105 KJ / Kmole
∆ H ° R H 2 O= -2.862*105 KJ / K mole

∆ H R = ∑ ∆ H Product −¿ ∑ ∆ H Reactants

∆ H R= (∆ H ° R CH 3 SNA+∆ H ° R H 2 O ¿ – (∆ H ° R CH 3 SH + ∆ H ° R 5 %NAOH )
5 5
∆ H R=( −1.295∗10 +2.96∗10 ) −¿+−¿2.807¿ 105 ¿
¿ −¿1.1137*105 KJ / Kmole

Assume T 2 =T 4 = T
(moles reacted of CH3SH = ∆ H R)
Input = output + ∆ H R (moeles reacted of CH3SH)
∆ H 1= S1 CP1(323 – 298)
∆ H 1= 241.6 × 49.069 (323 – 298)
= 2.96376×105 KJ /hr
∆ H 2= S2 CP2(T−¿298)
= 236.2848×47.998 ( T – 298 )
∆ H 3 = S3 CP3 (278−¿298)
∆ H 3 = 106.68×157.542(278−¿298)

=−¿3.361316×10 5 KJ /hr

∆ H 4= S4 CP 4 (T−¿298)

(∆ H 1+∆ H 3 ) = (∆ H 2+∆ H 4) +∆ H R ×( moeles reacted of CH 3 SH )

∆ H 4= 111.998512×75.4189(T−¿298)
(2.96376*105 + (-3.361316*105 )) = ( 236.68*47.998(T−¿298)) + (111.998512*75.4189(T−¿298) +
( -1.1137*105*5.3152)
T= 325.9K= 52.9℃
Energy balance for deaerator :
S5 ,325.9 K0

S4 ,325.9 K0

S6 ,325.9 K0

Figure (7) : Energy balance for dearator

Assume T 4=T 5=T 6= 325.9 K0

∆ H 4= S4 CP 4 (325.9−¿298)
∆ H 4= 111.998512×75.4189(325.9−¿298)
∆ H 4= 2.35665×105 KJ /hr
∆ H 5 = S4 CP 5(325.9−¿298)
∆ H 5 = 0.379312*29.1627(325.9−298 ¿
∆ H 5 =¿308.62 KJ /hr
∆ H 6 = S6 CP 6(325.9−¿298)
∆ H 6 =¿111.6192*75.58(325.9−¿298)
∆ H 6 =¿2.35369*105 KJ /hr

Energy balance for the Heat-exchanger

S6 , 325.9 K S7 ,343 K

Figure (8) : Energy balance for the Heat-exchanger

S6 = S7 , CP 6=CP 7

Q=∆ H 7 −∆ H 6
∆ H 6 = 2.3536*105 KJ /hr
∆ H 7 =111.6192*75.58(343−¿298)
=3.79628*105
Q = 3.79628*105−¿2.35369*105
= 1.44258*105 KJ /hr

Steam flow rate :

λ : Latent heat of saturated steam at 120 ℃= 2203.13 K J / Kg

Q 1.44258∗105
m steam=
λ = 2203.13
m steam= 65.478Kg/hr

Energy balance for the regenerator p-1:

S10 ,T10

S7,343 K0
 S9 ,298K0

S8 ,T8

Figure (9) : Energy balance for the regenerator

The following reaction is taking place:

2CH 3SNA+0.5O2+0.5 H 2 O CH 3 SS CH 3 + 2NAOH

Based on 2CH 3SNA by dividing 2 at chemical reaction:

2CH 3SNA+0.5O2+0.5 H 2 O 0.5CH 3 SS CH 3 +NAOH
∆ H ° R CH 3 SNA = -1.295*105 KJ / Kmole
∆ H ° R H 2 O= -2.862*105 KJ / Kmole
∆ H ° R CH 3 SSCH 3= -2.4*104 KJ / Kmole
∆ H ° R 5%NAOH = -2.807*105 KJ / Kmole

∆ H R =∑ ∆ H Product −¿ ∑ ∆ H Reactants

1 1
∆ H R= ( ∆ H ° RCH 3 SSCH 3+∆ H ° R 5%NAOH )−¿ (∆ H ° R CH 3 SNA + ∆ H ° R H 2 O)
2 2
∆ H R=(0.5*-2.4*104 +-2.807*105)– (-1.295*105 +0.5*-2.862*105)

= -2.01*104 KJ / Kmole
Assume that the temperature of stream T S 8=T S 10
Energy balance will be :
Enthalpy input =Enthalpy output + heat of generated
(∆ H 7 +∆ H 9 ) = (∆ H 8 +∆ H 10 )+∆ H R ׿SNA)
∆ H 7 = 3.79628*105 KJ /hr
∆ H 9 = zero at ambient temperature

∆ H 8 = S8 CP 8(T−¿298)

∆ H 8 = 111.998512¿154.3924(T−¿298)

∆ H 10 = S10 CP 10(T−¿298)

∆ H 10 =5.878128×29.1627(T−¿298)

(3.79628×10^5+0) = (111.998512×154.3924(T−¿298) + 5.878128×29.16 27(T−¿298))+

(-2.01×10^4×5.3152)
T = 325.856 K0 = 52.85℃
Energy balance for the cooler:

S8 , 325.85 K S13 , 298 K

Figure (10) : Energy balance for the cooler

Q = ∆ H 13−∆ H 8
∆ H 13=Zero at 298 K0

Q = −∆ H 8
Q = −¿( S8 CP 8(T−¿298))
Q =−¿4.815743*105 KJ /hr
Cooling water flow rate :
CP H O= 75.24 KJ / K mole . k
2

∆ T = - 27.85
Q
m H O=
2
CP. ∆ T
5
m H O= −4.815743∗10
2
75.24∗(−27.85)
m H O= 232.07 Kmole/hr
2

m H O= 4177.27Kg/hr
2

Energy balance for the refrigerator x-1 :

S13 , 298 K S11 , 278 K

 Figure (11) : Energy balance for the refrigerator

∆ H 13= Zero

∆ H 11= S11 CP 11(278 – 298 )

∆ H 11= 109.340912 × 156.315 (278 – 298 )

∆ H 11= -3.4183 ×105 KJ /hr

Q = ∆ H 11 −¿ ∆ H 12
Q = -3.4183 ×105 KJ /hr

Energy balance of the settling tank E- 1 :-

S12 , CP12

S11 , CP 11

S3 , Cp 3

Figure (12) : Energy balance of the settling tank

∆ H 11= S11 CP 11(278 – 298 )

∆ H 11= 109.340912 × 156.315 (278 – 298 )

∆ H 11= -3.4183 ×105 KJ /hr

∆ H 12= S12 CP 12(T – 298 )

∆ H 12= 2.6576×107.1×(T – 298 )

∆ H 3 = -3.36136×105 KJ /hr
∆ H 11 =∆ H 12 +∆ H 3

-3.4183 ×105 = 2.6576×107.1×(T – 298 )+ -3.36136×105

T = 278 K0
 CHAPTER (4)
EQUIPMENT DESIGN

Absorption
L , X0 G , Y1

L , XN G , YN+1

Is the unit operation in which one or more components of a gas stream are removed from the gas mixture
by being absorbed onto a non-volatile liquid (called a “solvent”)
:Absorption can be
physical, when the solute is dissolved into the solvent because it has higher solubility in the solvent
than other gases
chemical, when the solute reacts with the solvent, and the resulting product still remains in the solvent
:Design calculation of absorber
We want to scrub Methyl mercaptane CH3SH in the absorbation tower using caustic soda NaOH 5mol%
.stream
:Assume
.There is no interaction between solvent and solute
:Calculate the number of stage
:Using a McCabe-Thiele diagram for the absorption operation
Draw an equilibrium line on the X-Y coordinate by equilibrium constant k for the solute )1
Y B= K X B

:Where
 yB
Y B= ,yelom
=noitcarf foeht
etulos B∈ehtsag
esahp
1− y B B
xB
X=
B noitartnecnoc
,x = elom
noitcarf
(¿ f)oeht
etulos B∈eht
diuqil esahp
1− x B B

PV
muirbiliuqe
K= tnatsnoc rof eht
etulos B
Platot

PV
Vapor pressure for the solute B =
PlatotlatoT
=erusserp
Y 1∧L
Draw an operating line; the values of X 0 , Y N+1 , are generally known – note that the point )2
G
( X ¿ ¿ 0 ,Y 1 )¿ must be on the operating line

L L
Y =
N+1 X N+ [Y −
1 X ] :Operating line equation
G G 0
:Where
noitartnecnoc
Y N +=
1 si
eht foeht
etulos ∈ehttelni sag
maerts
noitartnecnoc
X N= sieht foeht
etulos ∈eht
teltuo diuqilmaerts
noitartnecnoc
Y= 1 si
eht foeht
etulos ∈eht
teltuo sag
maerts
noitartnecnoc
X= 0 si
eht foeht
etulos ∈ehttelnidiuqilmaerts

L = Liquid flow rate

G = Gas flow rate
locate the point ( X ¿ ¿ 0 ,Y 1 )¿ and step off stages between the operating line and the equilibrium line from )3
X N X =X 0 until it reaches the final concentration of
L
Note : the minimum line it is the line drawing from the initial point of ( X ¿ ¿ 0 ,Y 1 )¿ until touching the
G
Y= Y N +1 equilibrium line at point where
The plant handles 241.6 kmole/hr of a mixture of light hydrocarbon and CH3SH whose mole fraction is
.0.022
.of CH3SH are absorbed into nearly pure alkali dilute solution NaOH (X=0.0002) 99%
05℃
. The absorber operates at 4bar and
:Complete the material balance to determine
1. CH3SH mole fraction in alkali dilute solution NaOH stream exiting the absorber
2. L/G minimum for absorber
3. Actual L/G for absorber, absorbed composition CH3SH is NaOH, G and Number of theoretical
plates if L/G =1.5* L/G min

458.9_279.9 Temperature K
 4.35381 A
1122.494 B
21.748- C
.Table(4.1):Antoine constant for methyl mercaptane CH3SH

: Antoine equation for methyl mercaptane CH3SH

B
−¿ A =
gol 01 PV
T +C
:Where

PV
.vapor pressure (bar)=
.T=Temprature (K)
494.2211 V
gol 0118353.4
P= −¿
323847.12
−

P V=
93342.4 ¯¿

PV
= Equilibrium constant K
Platot
4.24339
K= = 1.0608
4
lomk
G=
6.142 Gas inlet absorber
rh
nHC H3220.0
S= 6.142
∗ 2513.5
= lomK rh
/ :Number of mole CH3SH inlet absorber
y N220.0
+=
1 :Mole fraction CH3SH inlet absorber
y N + 1 220.0
Y N+1 = = 4220.0
=
1− y N + 1 220.0
1−
Kmol
Gas outlet absorber G=236.2848
hr

of CH3SH exit with gas outlet absorber 1%

nHC H10.0
= 2513.5
3S × 251350.0
= lomK rh
/ :Number of mole CH3SH in gas outlet from absorber
251350.0
y=
1 8422000.0
= :Mole fraction CH3SH in gas outlet from absorber
251350.0 8482.632
+

y1
8422000.0
Y=
1 = 9422000.0
=
1−8422000.0
y 1 1−
 L
Minimum slope ( )
G min

We need two points, the initial point of ( X ¿ ¿ 0 ,, Y 1 )¿ and final point is ( X , Y N+1 ) at equilibrium line
(X ¿ ¿0 ,,
0,2000.09422000.
Y 1=
) ( )¿

Equilibrium line data: (0,0) and (〖X,Y〗_(N+1))

Y
0.0224 =¿
N+1

Y =XK
N+1 8060.1
= X
Y 4220.0
N +1
X= = 1120.0
=
K8060.1
Minimum operating line data: ( X ¿ ¿ 0 ,, Y 1 )¿ and ( X , Y N+1 )

(X ¿ ¿0 ,,
0,2000.09422000.
Y 1=
) ( )¿

X
( ,Y0,1120.0
N + 1=
) ( 4220. )

L 4220.0944200.0
−
ls
epo ( ) = 160.1
=
G nim1120.0 2000.0
−

30.0

20.0

20.0

Y
10.0

10.0

0
0 10.0 10.0 20.0 20.0 30.0
X

Figure (13): shown equilibrium line and minimum slope

Mole fraction for CH3SH in the NaOH exiting the absorber X N

 Operating line data: ( X ¿ ¿ 0 ,Y 1 )¿ and ( X N , Y N+1 )

L L
epols ( ) =5.1 ( ) =5.1160.1
× 5195.1
=
G po G nim
L4220.0
9422000.0
−
epols ( )= 5195.1
=
G po 2000.0
X N−
 331410.0
X N=
X331410.0
N
x N= = 639310.0
=
1+ X331410.0
N 1+

Number of stage

Approximately 16 stages

egats rebrosbA
30.0

30.0

20.0

20.0

10.0

10.0

0
0 10.0 10.0 20.0 20.0 30.0

Figure (14): shown number of stage

Note that the operating line in the McCabe- Thiele diagram for absorption is above the equilibrium line. This
is because the solute is transferred from the gas phase (i.e. the gas mixture) to the liquid phase (i.e. the
.solvent)
Liquid flow rate L

.of CH3SH absorbed in the NaOH 99%

:Number of mole CH3SH in liquid outlet from absorber

nHC H99.0
= 2513.5
3S × 262.5
= lomK rh
/
262.5 = x N×639310.0
L
latot = ×L
latot

L85.773
latot = lomK rh
/
L 85.773
HOaN = 262.5
− 813.273
= lomK rh
/

Actual L/G

L (L G
/ 5195.1
)po
0028
lautcA = = =5.1
G K 8060.1

Actual Number of stage

 N
N= :Actual number of stage
E 0 tca

:Where
.N= Theoretical number of stage
E
.Stage efficiency around 70%= 0

61
58.22
= ≅32
egats .N
= tca
7.0

: Heat Exchanger Design

: Kern's method was used (r , f1 )

F
gure i
(
15 ): Type of the heat exchanger : fixed tub

.The heat exchanger is used to bring the temperature of S6 from 325.9 K to S7 343 K
The mixture of stream S6 will be in the shell-side, while steam will be in the tube-side. Steam enters at 393
K to 383 K physical properties of tube-side will be taken at an average temperature between input and
.output
325.9+343
Then Tav= =334.45 k
2

: Calculation of the physical properties

Molecular
Component Mole fraction Viscosity (µ) ρ ¿ ( Density
weight (M)
(y)
))klom − 1 .Kg
)pa.sec( m − 3¿ .kg(
−3
H2O 0.95238 18 ×01 0.518 986
−3
CH3SNa 0.047619 70 ×01 0.069 1078
 :

Table (4.2) : physical properties of each components for shell-side S6 at 325.9 K and 4 bar

: Molecular weight of mixture

∑Miy w i = Mw Mixture

Mw Mixture = ( 0.95238×18 ) + ( 0.047619×70 )

gK
elomK
⁄ Mw Mixture = 20.476

: Viscosity of mixture
: for the mixture of the component of H2o and CH3SNa was estimated

W 1 W 2 1
+ =
M w1 M erutxim
w2 μ

Mw 1 , Mw2 : viscosity of H2o and CH3SNa component

W1,W2 : mass fraction of H2o and CH3SNa component

Mass flow rate = Mole flow rate × Molecular weight

gK rh
⁄ H2o : mass flow rate = 106.304×18=1913.472
gK rh
⁄ CH3 : mass flow rate = 5.3152×70=372
gK rh
⁄ Total mass flow rate = 2285.472
ssam wolf etar
tnenopmoc
fo
= Wi
latotssam wolf etar

1913.472
W(H2O) = = 0.837
2285.472
372
W(CH3SNa) = = 0.1627
2285.472

1 w H 2O wHC aNS
3
= +
μtxim eru μ H 2 o μHC aNS
3
 1 0.837 0.1627
= +
μ mixture 0.518× 10−3
0.069 × 10−3

μmixture =3.02001× 10
−4
Pa. sec .

Density : is considered to be an additive property for components mixture it was estimate as following :
ρ N
mixture =∑ Xi ρ i
i=1

N : Number of component .
Xi : weight fraction .
ρ i : Density of component .
Wieght of I
Weight fraction Wi =
Total weight
Weight of H2 = 18 ×0.95238=17.14 Kg ⁄ Kmole
weight of CH3SNa = 70 ×0.047619 = 3.33 Kg ⁄ Kmole
Total weight = 17.14 + 3.33 = 20.47 Kg ⁄ Kmole
17.14
Weight fraction of H2O = = 0.837
20.47
3.33
Weight fraction of CH3 SNa = =0.1626
20.47
ρ mixture¿( 0837× 986)+(0.1627× 1078)
ρ mixture = 1000.67 Kg ⁄ Kmole

Heat capacity : is previously calculated

Cp N
mixture= ∑ YiCp i
i=1

1
Cp mixture = 75.58 KJ ⁄ (Kmol. K )×
MW Mix
1
Cp mixture = 75.58
20.476
Cp mixture = 3.6911 KJ ⁄ (Kg. K )
The following equation was used
K = 3.56 ×10−5 Cp ¿

Cp : heat capacity of the mixture KJ ⁄ (Kg. K )

ρ :Density of the mixture Kg ⁄ m 3
Mw : molecular weight of the mixture Kg ⁄ Kmol
K = 3.56 ×10−5 Cp ¿

K = 3.56 ×10−5 ( 3.6911 ) ׿

K = 0.48 W ⁄ m2

Tube side :
Physical properties of steam at 120℃ and 1atm
Mw = 1.286 ×10−2 centi poise=1.286× 10−6 pa . se c

ρ=0.5625 Kg ⁄ m3
Cp = 34.5 KJ ⁄ (Kmol. k )
K = 0.02628 W ⁄ (m . k)
ρ Cp k
Mw Kg KJ w
Pa.sec 3
m Kmol. k (m . k)
Tube-side
1.286 ×10−6 0.5625 34.5 0.1691
( Steam )
Shell-side
3.02001× 10− 4 1000.67 75.58 10.831
(mixture)
Table(4.3) : Result of physical calculation

Figure (16) : overall coefficients ( join process side study duty to service side and read U
from centre scale )
 : design by Kern's method
51.5822
1196.3( ×) 07( 9.25
− 460.04
=) K W = Heat load
0063
460.04 gk
090.2
= = Heating steam folw
6619.1
( )×021 011 )
( − s

07( 9.25
− −021
) ( −011 )
∆
mT = 32.31
= ℃
07 9.25
−
nl (
021 − 011 )
(70−52.9)
R= = 1.70
(120−110)

(120−110)
S= =0.584
(70−52.9)

)( From fig
Ft = 0.97
32.31
× 38.21
= ℃ ∆
Tm = 0.97
)( From fig
w
2 U=500
m℃
Q
=A
U 0∆
mT

2 40.064 ×10 3
m A= = 6.2453
500 × 12.83
:Selection of tube dimensions
mm 16=d o
mm 14=d o
Tube length L= 1.2 meter
Area of one tubeπ .d o .L
=
2
m
610.0
π ( 2.1
) 2060.0
( =)

A
= Number of tube
a
3542.6
95.301
=
2060.0
:Tube arrangements
 Table (4.4) : Constant for use in equation
.select a triangle pitch tube arrangements
Triangle pitch and 1-tube pass
K=0.319 , n=2.142

Figure (17) : Explain position of the tubes in form triangular

:Bundle diameter
d o¿ D= b

D =02
b ¿

Figure(18): shell-bundle clearance

DdnuB
b+ retemaid
≤ ecnaraelc
30.832
D= s +51
30.352
= mm
30352.0
D= s m

:Tube-side calculation
a c *Total flow area =Number of tube

: cross-sectional area of tube:a c

π 2 π
d = 410.0
∗( )2 =a c
4 i 4
 ×01 −4
m 2
1.5393=a c

:S0
−4
3935.1
× ×01 Total flow area=103.59
2
m Total flow area =0.0159
:Mass velocity (kg m−2 sec −1)

rh −1
=aets.
kg 65.478m
m

ssam wolf etar

latot wolfaera
=G

81810.0 2 −1
3341.1
= gk m −ces =G
9510.0

m − 3¿ Density steam at 120℃ ,1atm (0.5625 kg

m
:)ces
/ ( Steam linear volecity
3341.1
G −1
n=t = 230.2
= mces
5265.0
P
h i¿ : ( Calculation of tube-side convection coefficient
h di i
= ( jh )(R e)¿
kf
Gd i
R=
e
μ
c pμ
p=
r
k
3341.1( 410.0
×) ( )
12446.5 =R =
e −6
682.1( ×01 )
3 −5
6619.1
( ×01 682.1
)× ( ×01 )
0.1457=p=
r
1961.0
( )
 Figure (19) : Tube-side heat-transfer factor

2.1 L
85.714 = =
410.0 di

−3
j=
h 3×01

: Convection heat transfer coefficient will be estimated from the given empirical conflation

(k )( jh)(R e)(p 33.0

r)
h=i
di
−3 33.0
9161.0( × 2×01 5.64421
)× ( 7541.0
)× ( )
1592.335 =h=i
410.0( )

: Shell-side calculation
.Baffle spacing (LB) is ranged between ( 0.2 – 1 ) time Ds 0.3 will be selected
LB = 0.3* Ds = 0.3*0.25303
m 0.075 =
Tube-pitch (p) = 1.25 do = 1.25*(0.016)
P = 0.02 m
: Cross-flow area
= As
20.0
( 610.0
− 30352.0
)( 670.0
)( ) tp−
( d oD) SLb
=
20.0 pt

As = 0.00384 m2
: Mass viscosity
gK mshell 2285.15
2 Gs = = = 165.3
m .s As 3600∗0.00348

: Equivalent diameter
1.1 1.1
De = ( pt2 – 0.917 do2 ) = ((0.02)2 - 0 .917(0.016)2) = 0.011 m
de 0.016

: Reynold ,s number
 3.561
( 110.0
)( ) Gd e
−4 = = Re
10020.3 ×01 μ
Re = 6020.84

Figure (20) : Shell-side heat-transfer factor

From Fig (4.6) : vol ( 6 ) ‚ for 25 baffle cut

Jh = 2*10-2
: Prandtle number

3 pC μ
1196.3( ∗01 )¿ ¿ = k = Pr

9201.0
P r=
.Shell-side convection heat transfer coefficient (hs)will be estimated
h sd
= jh (R e)¿
e

k
h sK( )( jh)(R e)¿ ¿

h=
84.0
s ( 20.0
)(48.0206
)( )¿ ¿
98.8396
h=s w ¿m℃
.

: Calculation of the overall heat transfer coefficient

 T
a
b
l
e

(
4
.
5
)

F
o
u
l
i
ng factor ( coefficients)
do do do
1 1 1
= + +
d nl
o ( )
d i
+
∗1
di
+
∗1
di
U h s h od 2K w hi
d
hi

.are dirt coefficient it will be taken as 3000 w ¿m . ℃ both h: od ‚h id

.KW : tube metal thermal conductivity

.KW : 50 ‚ Copper-Nickel alloy
610.0 610.0 610.0
1
=
1
+
1
610.0
+
nl (
410.0 )
410.0
+
∗1
410.0
+
∗1
79.438955
U 0003 2∗54 0003533.2951
w ¿m℃
. U = 686.089
.Since calculated U > assumed U ‚ Then the design will accepted

: Pressure drop in Tube-side calculation

 Figure (21) : Tube-side friction factor

From fig (4.8) (vol (6) at : Re = 1592.335

Jf = 4.8*10-3
: Neglect the viscosity correction term
ρu
[ (dL )+5.2 ] 2
t
∆ p=t N p 8 jf
t 2

2.1
∆ p=t 1 8∗
[
8.4 ∗01 −3
(
410.0
.2
]
)5+5265.0 ∗ ¿¿

∆ p=t ¿ pa 6.7255

: Pressure drop in shell-side calculation

 Figure (22) : shell-side friction factor segmental baffles

From figure (4.8) vol. (6) at : Re : 6020.84 for 25 baffle cut

Jf = 5.5*10-2

Gs 163.3
m ¿s Linear viscosity : = = 0.165
ρ 1000.67

D S L ρ u s2
∆ p=s 8 j f( )( )( )
d e LB 2

352.0
−2 2.176.0001( 561.0
)( )2
∆ p=s 8∗
5.5 ∗01 ( )( )( )
110.0 570.0 2
∆p
Pa 2205.61 = s

KPa 2.2 =
 Chapter 5

Economic Analysis
5.1 Introduction
Most chemical engineering design projects are carried out to provide information from which estimates
of capital and operating costs can be made. Chemical plants are built to make a profit, and an estimate of
the investment required and the cost of production is needed before the profitability of a project can be
assessed. Cost estimation is a specialized subject and a profession in its own right, but the design engineer
must be able to make rough cost estimates to decide between project alternatives and optimize the
design.

The equipment size, flow rate, raw material, byproduct, and ethylbenzene production are a very important
factor in the following steps.

 Fixed capital cost.

 ISBL Plant Costs.

 Offsite Costs.

 Engineering Costs (home office costs or contractor charges).

 Contingency Charges.

 Working capital.

 Cash cost of production.

 Total cost of production.

 The cash flow in each year of the project.

 The simple payback period.

 The net present value with a 15% cost of capital for 10, 15 and 20 years of production.

 Discounted cash flow rate of return (DCFROR) or (IRR).

Taking into consideration that the factory may shutdown for 65 days for periodic maintenance or
unexpected emergency cases. According to this the factory works for 300days (7200 hr ) in a year

5.2 Capital cost

 Step Count Method
Bridgewater’s method, which correlates plant cost against number of processing steps (Bridgewater and
Mumford, 1979).

0.675
Q
Q ≥60,000 :C=4320 N ( )
S

0.3
Q
Q<60,000 :C=380,000 N ( )
S

Where:

C= ISBL capital cost in U.S. $, U.S. Gulf Coast, 2000 basis;

Q = plant capacity in metric tons per year;

s = reactor conversion;

N = number of functional units.

A functional unit includes all the equipment and ancillaries needed for a significant process step or
function, such as a reaction, separation, or other major unit operation. Pumping and heat exchange are not
normally considered as functional units.

The data that we have:

We have Three function units (absorber ,regeneration, settler).

Q = 50000 metric tons per year (50 kMTA)

The reactor conversion 100%.

 0.3
50000
C=380,000 × ( 3 ) × ( 1 ) =29.28 MM expressed on a 2000 USGC basis .

Note also that the costs are not on the same time basis.

 Cost Escalation
Some method has to be used to update old cost data for use in estimating at the design stage and to
forecast the future construction cost of the plant. The method usually used to update historical cost data
.makes use of published cost indices. These relate present costs to past costs

tsocxedni raey
∈ A
tsoc raey
∈ A=
tsoc raey
∈ B×
tsocxedni raey
∈ B

By looking up the index in the Chemical Engineering Plant Cost Index (CEPCI):

Index in Dec 2000 = 394.1

Index in jan2020 = 668

668
cost ∈ year 2020=29.28 × =$ 49.629 MM
394.1

Location factor

cost ∈location A=cost of plant onUSGC × LF A

LF A for mdille east=1.07

The exchange rate in 2003 averaged about 1 $= 0.799 LYD, and in 2020 it averaged about 1 $ = 0.641545
LYD.

The location factor for Middle East is thus:

0.641545
1.07 × =0.859
0.799

∴ cost ∈Middle East=$ 49.629 MM ×0.859=$ 42.63 MM ∈M . D2020

The OSBL capital cost is estimated as 40% of ISBL cost. The engineering cost and contingency are estimated
as 10% and 15% of the sum (ISBL + OSBL) cost, respectively.

OSBL=0.4 × $ 42.63 MM =$ 17.1 MM

EC =0.1× ( 42.63+17.1 ) =$ 6 MM

Contingency=0.15 × ( 42.63+ 17.1 )=$ 9 MM

∴ Total ¿ capital cost ( TFCC )=ISBL+OSBL+ EC + Cont .

TFCC=$ 75 MM

5.3 Material Price

$
Caustic soda feed 35
kg
$
Natural gas feed 0.11
Scf

 Revenues and by-product cost

 Key-product
Natural gas

Scf $ $
146 ×10 8 × 0.011 =160.6 MM
year Scf year

 Raw material cost

 Caustic soda
 kg $ hr $
212 × 35 ×7200 =53.4 MM
hr kg yea r year

5.4 Gross margin (GM)

$
GM =REV + BP−RM =160.6+0−53.4=107 MM
year

5.5 Utility costs

Prices:

$
Cooling water ∶0 .345
GJ

$
Low−pressure steam ∶9.66
GJ

$ GJ hr $
Cooling water ∶0 .345 ×0.823 ×7200 =0.00205 MM
GJ hr year year

$ GJ hr $
Low−pressure steam : 9.66 × 0.144 × 7200 =0.01 MM
GJ hr year year

$
Total utility costs=0.00205+0.01=0.01205 MM
year

5.6 Variable cost of production (VCOP)

$
VCOP=RM −BP+UTS=53.4−0+ 0.01205=53.412 MM
year

5.7 Fixed operation costs

Fixed cost of production (FCOP) Consist of:

5.7.1 Labor (NU of shift position, Supervision and Direct overhead)

5.7.2 Maintenance
5.7.3 Overhead expense
5.7.4 Plant overhead
5.7.5 working capital
5.7.1 Labor:
Assume that:

4.8 operator per shift position, and 4 shift positions for the plant.

Operator salaries vary by region and experience level. For initial estimates, an average value of $30,000 per
shift position per year.

$ $
NU of shift position=4 ×4.8 × 30000 =0.567 MM
year year

5.7.2 Supervision:
Supervision usually taken as 25% of operating labor.

$ $
¿ 0.25 ×0.567 MM =0.144 MM
year year

5.7.3 Direct overhead:

Direct salary overhead usually 40 to 60% of operating labor plus supervision.

$
¿ 0.4 × ( 0.567+0.144 )=0.288 MM
year

$
Labor=1.01 MM
year

5.7.4 Maintenance:
Maintenance, which includes both materials and labor, and is typically estimated as 3 to 5% of total fixed
capital cost, depending on the expected plant reliability. Plants with more moving equipment or more
solids handling usually require higher maintenance.

$ $
¿ 0.03 ×TFCC=0.03× 75 MM =2.25 MM
year year
5.7.5 Overhead expense:
Is typically estimated as 65% of maintenance and labor costs.

$
¿ 0.65 × ( Maintenance +labor ) =0.65 × ( 2.25+1.01 )=2.11 MM
year

5.7.6 Plant overhead:

Is typically estimated as 2% of ISBL and OSBL.

$
¿ 0.02 ( ISBL+OSBL )=0.02 × ( 42.63+ 17.1 )=1.19 MM
year

Interest on debt financing: (about 6% of working capital)

Calculate working capital (WC):

CCOP× 49 14 × RM
wc= +0.01 TFCC−
day day
operating operating
yr yr

FCOP¿0.576+0.144+0.288+2.25+2.11+1.19+(0.06×WC)

CCOP=VCOP+ FCOP

CCOP=53.412+(0.576+0.144 +0.288+2.25+2.11+1.19+ ( 0.06∗WC ) )

( 53.412+ 6.558+0.06 WC ) × 49 14 × 53.44 $

WC= +(0.01×75)− =8.13 MM
300 300 year

By (try & error)

5.7.7 Interest on debt financing

$ $
IDF=8.13 ×0.06=0.4878 MM ∴ FCOP=6.558+ .4878=7.0458
year year

5.8 Annual capital charge ratio

ACCR=
[ i ( 1+i )n ]
[ ( 1+i )n−1 ]
Where

i: interest rate
n: number of years.

At 10% cost of capital, and 15-year project life ACCR = 0.131

Fixed capital investment

¿ 0.131 ×TFCC=0.131 ×75

There is no royalty amortization.

$
Total Annual Capital Cha rge(ACC )=9.81 MM
year

$
CCOP=VCOP+ FCOP=53.412+7.0458=60.5 MM
year

$
TCOP=CCOP+ ACC=60.5+ 9.81=70.31 MM
year

5.9 Economic Evaluation Of Projects

Cash Flow Table:

In years 1 and 2 of the project, there are capital expenses but no revenues or operating costs. The capital
expenses are not operating losses, so they have no effect on taxes or depreciation. They are negative cash
flows.

In year 3 the plant operates at 50% capacity and generates 50% of the design basis revenue. All of the
working capital must be invested. The plant incurs 100% of the fixed cost of production but only 50% of the
variable cost. Because the plant makes a profit, depreciation can be charged. Using the straight-line
method of depreciation with a 15-year recovery period, the annual depreciation charge is one-fifteenth of
the total fixed capital investment = $81.57MM/15 = $5.4MM.

The effect of charging depreciation is that the taxable income is negative, so no taxes are owed in year 4
(taxes are paid based on the previous year’s income)
 Table (5.1): Shows Estimation Cash Flow Over 20 Years of Production

PV Tax Gr.
of cash pai Taxble Deprc Profi revenu cap Yea
NPV CF factor flow d inc n t CCOP e ex r
- 0.909 22.
-20.4 20.4 1 -22.4 0 0 0 0 0 0 4 1
- 0.826 52.
-63.5 43.2 4 -52.2 0 0 0 0 0 0 2 2
0.751
-34.7 28.9 3 38.4 0 41.6 5.0 46.5 33.8 80.3 8.1 3
0.683 100.
33.7 68.4 0 100.1 0.0 95.2 5.0 1 60.5 160.6 0.0 4
0.620 14. 100.
87.0 53.3 9 85.9 3 95.2 5.0 1 60.5 160.6 0.0 5
135. 0.564 14. 100.
5 48.5 5 85.9 3 95.2 5.0 1 60.5 160.6 0.0 6
179. 0.513 14. 100.
6 44.1 2 85.9 3 95.2 5.0 1 60.5 160.6 0.0 7
219. 0.466 14. 100.
6 40.1 5 85.9 3 95.2 5.0 1 60.5 160.6 0.0 8
256. 0.424 14. 100.
0 36.4 1 85.9 3 95.2 5.0 1 60.5 160.6 0.0 9
289. 0.385 14. 100.
1 33.1 5 85.9 3 95.2 5.0 1 60.5 160.6 0.0 10
319. 0.350 14. 100.
2 30.1 5 85.9 3 95.2 5.0 1 60.5 160.6 0.0 11
346. 0.318 14. 100.
6 27.4 6 85.9 3 95.2 5.0 1 60.5 160.6 0.0 12
371. 0.289 14. 100.
4 24.9 7 85.9 3 95.2 5.0 1 60.5 160.6 0.0 13
394. 0.263 14. 100.
0 22.6 3 85.9 3 95.2 5.0 1 60.5 160.6 0.0 14
414. 0.239 14. 100.
6 20.6 4 85.9 3 95.2 5.0 1 60.5 160.6 0.0 15
433. 0.217 14. 100.
3 18.7 6 85.9 3 95.2 5.0 1 60.5 160.6 0.0 16
450. 0.197 14. 100.
3 17.0 8 85.9 3 95.2 5.0 1 60.5 160.6 0.0 17
465. 0.179 14. 100.
7 15.4 9 85.9 3 100.1 0.0 1 60.5 160.6 0.0 18
479. 0.163 15. 100.
6 13.9 5 85.1 0 100.1 0.0 1 60.5 160.6 0.0 19
493. 0.148 15. 100.
5 13.9 6 93.2 0 100.1 0.0 1 60.5 160.6 -8.1 20

5.10 Simple Pay-Back Time

A simple method for estimating the payback time is to divide the total investment by the average annual
cash flow:

total investment
Simple Pay−Back Time=
average annual cash flow

Average annual cash flow from year 3-20 = 28.2

81.57
Simple Pay−Back Time= =2.9 ≅ 3 years
28.2

Figure (23): A Relation between NPV and Years of Project Life

135.5
1
33.7
0.0
0 5 10 15 20 25

-1
References :

[1] – Coulson & Richardson's – " Chemical Engineering Design " R. K. SINNOTT
AMSTERDAM " – Volume (6) – fourth Edition .

[2] – Don .W. Green and Robert. H. Perry – 1934. " Perry's Chemical Engineers handbook " -8th – edition –
2008.

[3] – Anthony. L. Hines and Robert N Maddox- ‘‘ Mass Transfer Fundamentals and Applications ". 1985

[4] – A.U. Kopilov Preparation technology and processing of sulphurous hydrocarbons based on extraction
of traditional processes: Avtoref Dis. Dr.of technic science – Kazan, 2010. – P. 12.

[5] – V.A. Fomin , A.F. Vildanov, A.M. Mazgarov, A.l. Lugovskoy. Introduction of BBF
Demercaptanization process of Ryazan PROCESSING PLANT on HFCS – 1987.
No. 12. – P.14-15 .

[6] A.G. Akhmadullina, L.N. Orlova, I.K. Khrushcheva and others. Mercaptides transformation during the
oxidation with molecular oxygen in aqueous alkaline solutions. Journal of Applied Chemistry, No. 1, 1989,
p. 53-57.