g6 Production Toluene Ry20 2019

FACULTY OF ENGINEERING TECHNOLOGY
CHEMICAL ENGINEERING TECHNOLOGY

(INDUSTRIAL CHEMICAL PROCESS)
SEMESTER 1, 2019/2020
PTT 452
PLANT DESIGN PROJECT II
PRODUCTION OF TOLUENE
PREPARED BY:
GROUP 6
DALILA BINTI MOHAMAD NAWI 161341848

KIRISHMA A/P RAMACHANDRAN 161341855
MUHAMMAD SAIFULLAH BIN MOHD 161341870
MOHTAR
NURUL AIN BT ABDULLAH 161341892
LIM CHEE HUNG 161341976
COORDINATOR:
MDM SITI NOR AZREEN BINTI AHMAD TERMIZI
SUPERVISOR:
DR ALINA RAHAYU MOHAMED

MADAM IZZATI BTE IBERAHIM
DATE: 3 rd. DECEMBER 2019
i
TABLE OF CONTENTS
LIST OF TABLES v
CHAPTER 1 : INTRODUCTION 1
1.1 Introduction of the product, characteristic and uses 1
1.1.1 The importance of toluene from Malaysian chemical industry point of view 2
1.1.2 The Production Capacities and Similar Plants operating in

Malaysia/Asia/World 4
1.1.3 Report the projected demands/supply for next 10 years in the form of graph 8
1.2 Process alternatives 11
1.3 Summarize and compare the 3 shortlisted alternatives 17
1.4 The best process among the suggested alternatives with justification 21
1.5 Critical Assessment of The Chosen Process 24
1.5.1 Operating capacity of the plant based on literature background 24
1.5.2 Process chemistries for all process involved in the plant 25
1.5.3 List of reactions, kinetics, and thermodynamics data of the involved reaction. 27
1.5.4 Attach of physical and chemical properties of all the raw materials, products
and byproducts in the process 33
1.6 Recognize and write down all the environmental (disposal of waste, if any), safety and
health concern. 35
CHAPTER 2 : MASS & ENERGY BALANCES 41
2.1 Summary of the Equipment in the Toluene Production Process 41
2.2 Plant Wide Mass Balance 42
2.2.1 Material balance for reactor (R-101) 42
2.2.2 Material balance for reactor (R-102) 43
2.2.3 Material balance for separator (T-100) 46
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2.2.4 Material balance for distillation column (D-100) 49
2.2.5 Sample calculation 52
2.3 Energy Balance of The Process Plant for Each Individual Unit 55
2.3 55
2.3.1 Pump (P-101) 55
2.3.2 Evoporator (EV-103) 58
2.3.3 Heater (H-101) 67
2.3.4 Reactor (R-101) 70
2.3.5 Heater (H-102) 75
2.3.6 Reactor (R-102) 78
2.3.7 Cooler (E-101) 81
2.3.8 Expander (Ex-100) 84
2.3.9 Separator (T-100) 87
2.3.10 Distillation column (D-100) 90
2.3.11 Pump (P-103) 95
2.3.12 Pump (P-104) 97
2.4 Utilities and Waste Handling 98
2.4.1 Utilities 98
2.4.2 Waste Handling 99
2.5 Calculation verification 100
2.5.1 Reactor 102
2.5.2 Mass Transfer Equipment 104
2.5.3 Heat Transfer Equipment 109
2.5.4 Reactor (R-101) 112
2.5.5 Separator (T-100) 114
2.5.6 Cooler (E-100) 116
CHAPTER 3: SIZING CAPACITY 118
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3.1 Mass Transfer Equipment Design 118
3.1.1 Oil-gas horizontal separator(T-100) 118
3.1.1.1 Residence time for separation 119
3.1.1.2 Diameter of separator vessel 120
3.1.1.3 Hold-up time for separation 120
3.1.1.4 Calculation of new parameter for separator 120
3.1.1.5 Calculation of effective length of liquid for the separation occur 120
3.1.1.6 Mechanical design for oil-gas horizontal separator 124
3.1.2 Distillation column (D-100) 134
3.1.2.1 Relative volatility more volatile compound to less volatile component 135
3.1.2.2 Minimum number of equilibrium stages 135
3.1.2.3 Theoretical stage 136
3.1.2.4 Location of the feed in at distillation column 137
3.1.2.5 Diameter and Height of the distillation column. 137
3.1.2.6 Plate Hydraulic Design 141
3.1.2.7 Mechanical design for oil-gas horizontal separator 148
3.1.3 Design of Condenser(E-100) 157
3.1.3.1 Shell-side coefficient 158
3.1.3.2 Tube-side coefficient 159
3.1.3.3 Overall Coefficient 160
3.1.3.4 Shell-side pressure drop 161
3.1.3.5 Calculation for number of tubes 161
3.1.3.6 Calculation of Shell Diameter 162
3.1.3.7 Mechanical design for condenser (E-100) 164
3.1.4 Design of Reboiler (Thermosyphons) (RB-100) 167
3.1.4.1 Tube-side pressure drop 170
3.1.4.2 Shell-side pressure drop 170
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3.1.4.3 Mechanical design for Reboiler (RB-100) 171
2.6 Heat Transfer Equipment Design 180
3.2.1 Cooler (E-102) 180
3.2.1.1 Heat Transfer Area 182
3.2.1.2 Number of tubes calculation 183
3.2.1.3 Bundle and shell diameter 183
3.2.1.4 Shell-side heat transfer coefficient (oil side) 184
3.2.1.5 Tube-side heat transfer coefficient (water side) 186
3.2.1.6 Overall coefficient 187
3.2.1.7 Pressure drop 187
3.2.2 Heater (H-102) 188
3.2.2.1 Temperature difference, ΔTm 189
3.2.2.5 Tube-side heat transfer coefficient 193
3.2.2.6 Shell-side heat transfer coefficient 194
3.2.2.7 Pressure drop 196
3.2.3 Evaporator (Ev-103) 200
3.2.3.1 Temperature difference, ΔTm 201
3.2.3.5 Tube-side heat transfer coefficient 205
3.2.3.6 Shell-side heat transfer coefficient 207
3.2.3.7 Pressure drop (tube) 209
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3.3 Reactor Design 218
3.3.1 Fixed Bed Reactor (R-101) 218
3.3.1.1 Dynamics 222
3.3.1.2 Volume of the bed 228
3.3.1.3 Height and Volume of Reactor 228
3.3.1.4 Reactor Tubes sizing 230
3.3.1.5 Reactor shell sizing 232
3.3.1.6 Jacketed Vessel 234
3.3.1.7 Design Pressure 237
3.3.1.8 Design Temperature 238
3.3.1.9 Material Construction 238
3.3.1.10 Minimum Wall Thickness of Cylindrical Section of the Shell 239
3.3.1.11 Head and Closure 240
3.3.2 Packed Bed Reactor (R-102) 241
3.3.2.1 Volume of the bed 244
3.3.2.2 Height and Volume of Reactor 244
3.3.2.3 Volume of the reactor 245
3.3.2.4 Reactor Tubes sizing 246
3.3.2.5 Reactor shell sizing 249
3.3.2.6 Jacketed Vessel 250
3.3.2.7 Design Pressure 253
3.3.2.8 Design Temperature 254
3.3.2.9 Material Construction 254
3.3.2.10 Minimum Wall Thickness of Cylindrical Section of the Shell 255
3.3.2.11 Head and Closure 256
3.4 Auxillary Equipment Design 262
3.4.1 Pump 262
v
3.4.1.1 Pipe selection of nozzle 262
3.4.1.2 Reynolds Number 263
3.4.1.3 Static head 264
3.4.1.4 Dynamic head 265
3.4.1.5 Total head, H 265
3.4.1.6 Head loss, hL 266
3.4.1.7 Shaft Power 266
3.4.1.8 Pump power 266
3.4.1.9 Power required for pumping 267
3.4.1.10 Pump selection 267
3.4.1.11 Impeller speed 268
3.4.1.12 Net positive suction head (NPSH) 269
3.4.2 Compressor 274
3.4.2.1 Selection of compressor 276
3.4.2.2 Polytropic efficiency, ƞ p 277
3.4.2.3 Polytropic Head, HP 278
3.4.2.4 Polytropic Power 279
3.4.2.5 Actual power 279
3.4.2.6 Brake Horse Power 279
2.7 Storage Tank 281
3.5.1 Toluene Production Tank 281
3.5.1.1 Calculation volume of tank: 282
3.5.1.2 Calculation diameter of tank: 282
3.5.1.3 Calculation thickness of tank wall: 283
3.5.1.4 Calculation Cone roof 283
3.5.1.5 Calculation of insulation for storage tank 284
3.5.2 Hydrogen Production Tank 285
3.5.2.1 Calculation Volume of Compressed Hydrogen in a Cylinder 285
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3.5.2.2 Calculation diameter of vessel 286
3.5.2.3 Calculation thickness of vessel wall 287
3.5.3 Feed Storage Tank 288
3.5.3.1 Calculation volume of tank 288
3.5.3.2 Calculation diameter of tank 288
3.5.3.3 Calculation thickness of tank wall 289
3.5.4 Distillate Storage Tank 291
3.5.4.1 Calculation volume of tank 291
3.5.4.2 Calculation diameter of tank 292
3.5.4.3 Calculation thickness of tank wall 292
3.5.4.4 Calculation Cone roof 293
3.6 Throttling Valve 294
CHAPTER 4: P&ID SYSTEM 300
4.1 Process Control System 300
4.1.1 Process Control at Evaporator, E-103 300
4.1.2 Process Control at Reactor, R-101 306
4.1.3 Process Control at Separator, T-100 314
CHAPTER 5: COST 319
5.1.1 Specification sheet 319
5.1.1.1 Cooler (E-101) 319
5.1.1.2 Oil Gas Separator (T-100) 321
5.1.1.3 Pump (P-101) 322
5.1.1.4 Pump (P-103) 324
5.1.1.5 Pump (P-104) 325
5.1.1.6 Evaporator (Ev-103) 326
5.1.1.7 Heater (H-101) 329
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5.1.1.9 Reactor(R-101) 334
5.1.1.10 Reactor (R-102) 336
5.1.1.11 Compressor (C-103) 338
5.1.1.12 Condenser (E-100) 340
5.1.1.13 Reboiler (RB-100) 342
5.1.1.14 Distillation Column (D-100) 343
5.1.2 Equipment Cost Estimation 345
5.1.2.1 Cooler (E-101) 345
5.1.2.2 Expander (Ex-100) 347
5.1.2.3 Separator (T-100) 348
5.1.2.4 Pump (P-101) 348
5.1.2.5 Pump (P-103) 353
5.1.2.5 Pump (P-104) 357
5.1.2.7 Evaporator (Ev-103) 361
5.1.2.8 Heater (H-101) 362
5.1.2.9 Heater (H-102) 364
5.1.2.10 Reactor (R-101) 366
5.1.2.11 Reactor (R-102) 369
5.1.2.12 Compressor (C-103) 371
5.1.2.13 Condenser (E-100) 372
5.1.2.14 Reboiler (RB-100) 375
5.1.3 Cost of utilities 381
5.1.3.1 Cooler (E-101) 382
5.1.3.2 Expander (Ex-100) 383
5.1.3.3 Separator (T-100) 384
5.1.3.4 Pump (P-101) 385
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5.1.3.5 Pump (P-103) 387
5.1.3.6 Pump (P-104) 388
5.1.3.7 Evaporator (Ev-103) 389
5.1.3.8 Heater (H-101) 390
5.1.3.9 Heater (H-102) 391
5.1.3.10 Reactor (R-101) 392
5.1.3.11 Reactor (R-102) 393
5.1.3.12 Compressor (C-103) 394
5.1.3.13 Condenser (E-100) 395
5.1.3.14 Reboiler (RB-100) 396
5.1.3.15 Distillation Column (D-100) 397
5.1.3.16 Estimation cost of utilities 398
5.2 Total Cost Estimation (Method of Guthrie) 400
5.2.1 Total capital investment, CTCI 400
5.2.1.1 Fixed Capital Investment, CFCI 400
5.3 Project Cost and Profitability Analysis 422
5.3.1 Design Capacity and Operating Capacity 422
5.3.2 Revenues from sales 422
5.3.3 Profitability Analysis 424
5.3.4 Payback Period (PBP) 431
5.3.5 Return on Investment (ROI) 432
5.3.6 Venture Profit (VP) 433
5.3.7 Net Present value and NPV ratio 434
5.3.8 Discounted payback period 435
5.3.9 Recommendation based on the Profitability Analysis 435
CHAPTER 6: ENVIRONMENTAL AND SAFETY ANALYSIS 438
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6.1 Method for safe disposal (Environmental Quality Act 1974) 438
6. 2 Waste management system 441
6.2.1 Treatment of waste gas from condenser (E-100) at stream 14 441
6.2.2 Packaging and storing liquid waste from condenser (E-100) at stream 21 443
6.2.3 Recycling of cooling water in distillation column and condenser 450
6.3 Total cost of waste management system 451
6.3.1 Cost of Dry Scrubber 451
6.3.2 Cost of Distillate Storage Tank 451
6.4 Environment and surroundings affected after building and operation of the plant 453
6.4.1 Plant Building 453
6.4.2 Plant Operation 454
6.4.3 Noise Pollution 454
6.4.4 Air Pollution 455
6.4.5 Thermal Pollution 455
6.4.6 Visual Impact 456
6.5 Hazard and Operability (HAZOP) Study 456
6.5.1 HAZOP Study Applied to Pump 459
6.5.2 HAZOP study for the Evaporator (E-103) 469
6.5.3 HAZOP Study Applied to Packed Bed Reactor 477
6.5.4 HAZOP Study Applied to Packed Bed Reactor 484
6.5.5 HAZOP Study of Compressor (C-103) 491
6.6 Chemical Handling, Transportation and Accident Precautions within the Plant 506
6.6.1 Cyclohexane 506
6.6.2 Methyl-cyclohexane 507
6.6.3 Benzene 508
6.6.4 Toluene 510
6.6.5 Butane 512
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APPENDIX 516
Naphtha (Tesoro Refining & Marketing Co., 2009) 516
TOLUENE (PETRO-CANADA, 2017A) 519
Hydrogen (MSDS Of Hydrogen, 2000) 523
2.8 BENZENE (Scientific, 2013) 526
Platinum (Petro-Canada, 2017b) 531
REFERENCES 534
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LIST OF FIGURES
Figure 1.1: Structure of Toluene 1
Figure 1.2: Importance of Toluene 2
Figure 1.3: The price of toluene in China (“Asia chemical profile : Toluene,”
2019). 5
Figure 1.4: The price of toluene in Europe 6
Figure 1.5: Consumption of toluene in worldwide in 2013 7
Figure 1.6: Graph of demand/supply of Toluene for next 10 years in Malaysia 8
Figure 1.7: Chart of World consumption of toluene (2017) 9
Figure 1.8: Hexane to Benzene 11
Figure 1.9: Heptane to methylbenzene(toluene) 11
Figure 1.10: Converting Methylbenzene to benzene (Dealkylation) 12
Figure 1.11: PYGAS Processing Block Diagram 13
Figure 1.12: Friedel-Craft Alkylation 14
Figure 1.13: Electrophilic Substitution mechanism 14
Figure 1.14: Regeneration of Aluminum Chloride 14
Figure 1.15: Process flow diagram of alkylation of benzene 15
Figure 1.16: Sulfonation of benzene ring 15
Figure 1.17: Sulphur trioxide electrophile attack Benzene ring 16
Figure 1.18: Transfer of hydrogen from the benzene ring to the negative oxygen
to form a water molecule 16
Figure 1.19: Desulfonation 4-Methylbenzenesulfonic acid 17
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Figure 1.20: Wurtz-Fittig reaction 17
Figure 1.21: Conversion of napthenes to aromatics 28
Figure 1.22: Hydroisomerization of Cyclopentanes 28
Figure 1.23: Dealkylation 28
Figure 1.24: Dehydrogenation of parrafins 29
Figure 1.25: Acid-catalyzed hydrocracking reactions 29
Figure 2.1 Block Flow Diagram for Reactor (R-101) 42
Figure 2.2: Block Flow Diagram for Reactor (R-102) 44
Figure 2.3: Block Flow Diagram for Separator (T-100) 46
Figure 2.4: Block Flow Diagram for Distillation Column (D-100) 49
Figure 2.5: Block Flow Diagram for Pump (P-101) 55
Figure 2.6: Block Flow Diagram for Evaporator (EV-103) 59
Figure 2.7: Block Flow Diagram for Compressor (C-100) 64
Figure 2.8: Block Flow Diagram for Heater (H-101) 67
Figure 2.9 : Block Flow Diagram for Heater (H-102) 75
Figure 2.10: Block Flow Diagram for Reactor (R-102) 78
Figure 2.11: Block Flow Diagram for Cooler (E-101) 81
Figure 2.12: Block Flow Diagram Expander (EX-100) 84
Figure 2.13: Block Flow Diagram for Seperator (T-100) 87
Figure 2.14: Block Flow Diagram for Distillation Column(D-100) 90
Figure 2.15: Block Flow Diagram of Energy Balance for Distillation Column (D-
100) 91
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Figure 2.18: Reactor 102
Figure 2.19: Separator 105
Figure 2.20: Cooler 109
Figure 2.21: Design of Reactor 101 112
Figure 2.22: HYSYS data of reactor 112
Figure 2.23: Composition table of Reactor 113
Figure 2.24: Design of Separator 114
Figure 2.25: HYSYS data of Separator 114
Figure 2.26: Composition in Separator 115
Figure 2.27: design of Cooler 116
Figure 2.28: Composition in Cooler 116
Figure 2.29: HYSYS data of Cooler 117
iii
iv
LIST OF TABLES
Table 1.1: Usage of Toluene in Malaysia (Sahri and Widajati, 2013) 4
Table 1.2: Table of toluene production capacity worldwide 7
Table 1.3: Table of demand/supply of Toluene for next 10 years in Malaysia 8
Table 1.4: Specification of naphtha feedstock (all components are in wt%) 22
Table 1.5: Destination codes and component classification 27
Table 1.6: Thermodynamic data for reforming compounds at 800 K, ideal gas in
kcal/mol 30
Table 2.1 Details Equipment in Production Process 41
Table 2.2 : Input stream for reactor (R-101) 43
Table 2.3: Output stream for reactor (R-101) 43
Table 2.4: Input stream for reactor (R-102) 45
Table 2.5: Output stream for reactor (R-102) 45
Table 2.6: Input stream for separator (T-100) 47
Table 2.7: Output stream for separator (T-100) 47
Table 2.8: Output stream for separator (T-100) 47
Table 2.9:Input stream for distillation column (D-100) 49
Table 2.10: Output stream for distillation column (D-100) 50
Table 2.11: Output stream for distillation column (D-100) 51
Table 2.12: Input-output stream for pump (P-101) 56
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Table 2.13: : Input-output stream for preheater (EV-103) 60
Table 2.14: Input-output stream for compressor(C-100) 64
Table 2.15: : Input-output stream for heater (H-101) 68
Table 2.16: Input-output stream for reactor (R-101) 71
Table 2.17: : Input-output stream for heater (H-102) 76
Table 2.18: Input-output stream for reactor (R-102) 79
Table 2.19: Input-output stream for cooler (E-101) 82
Table 2.20: Input-output stream for expander (Ex-100) 85
Table 2.21: Input-output stream for separator (T-100) 88
Table 2.22: : Input-output stream for distillation column (D-100) 92
Table 2.23 : Input-output stream for pump (P-103) 96
Table 2.24: : Input-output stream for pump (P-104) 98
Table 2.25: Details of Utility 98
Table 2.26: Details of Waste Handling 99
Table 2.27: Comparison of calculated data versus simulated data by HYSYS for
reactor R-101 102
separator T-100 106
cooler E-101 109
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CHAPTER 1 : INTRODUCTION
1.1 Introduction of the product, characteristic and uses
Toluene, is an organic compound which also can be recognized as methylbenzene. It

contains carbon in its chemical formula which is C 7 H 8. As toluene only contains carbon and
hydrogen atom in its chemical formula, it can be classified as hydrocarbon, a compound that
only contains carbon (C) and hydrogen (H) atoms. Toluene is a colorless, water-insoluble
liquid with the smell related with paint thinner (Pang, Boggs, Pulay, & Fogarasi, 1980).
Toluene is also classified as aromatic compound because of the presence of benzene
ring in its chemical structure. The aromatic compound and hydrocarbon characteristic in
toluene will both making the compound be called as aromatic hydrocarbon. Because there is
a methyl group (CH3) attached to the benzene ring, the compound is also be called as
methylbenzene in its IUPAC nomenclature. The chemical structure of toluene is as below
Figure 1.1: Structure of Toluene
Toluene occurs naturally at low levels in crude oil and is obtained from the light oil
by fractional distillation. Toluene is produced from specially selected fraction of petroleum,
rich in naphthalene by a process called catalytic reforming process. The process involves
catalytic dehydrogenation in the presence of hydrogen. The hydrogen will reduce the coke
formation to produce a mixture of aromatic hydrocarbons, mainly toluene.
1
Toluene is used as an intoxicative inhalant in a unintended manner by manufacturers.
People breathe in toluene-containing products (e.g., paint thinner, contact cement, model
glue, etc.) for its intoxicating effect. Many jurisdictions regulating the possession of toluene
to prevent minors from using this product for recreational drug purposes. As of 2007, 24 U.S.
states had laws penalizing use, possession with intent to use, and/or distribution of such
inhalants. In 2005 the European Union banned the general sale of products consisting of
greater than 0.5% toluene.
Toluene has various commercial and industrial applications and is a solvent in paints,
lacquers, thinners, glues, correction fluid and nail polish remover, and is used in the printing
and leather tanning processes. One of the cosmetic and personal care products like nail
products containing toluene are applied to the hard, largely impenetrable surface of the nail
where a smooth and glossy film is quickly formed upon evaporation of the solvents.
1.1.1 The importance of toluene from Malaysian chemical industry point of view
Importance
of toluene
Figure 1.2: Importance of Toluene
2
Toluene uses as fuel
Toluene is useful in transportation. It was used as an octane booster in gasoline which
was used as a fuel in the combustion system. Toluene will improve the octane number in
gasoline to improve the fuel’s resistance to knocking during combustion (Traumann, Tint, &
Reinhold, 2012).
Toluene uses in cosmetic and personal care product
Toluene also important in the application of cosmetic and personal care product such
as nail polish removers. This is because toluene can dissolve resins and plasticizers. Toluene
could increase the rate of smooth and glossy film or layer formed at the surface of nails.
Hence it could the use as formulation of nail product for the purpose of polishes, hardeners
and smoothly(SCCP, 2006)
Toluene uses as solvent
Toluene also used as a paint thinner due to the original paints could be too strong for
conventional coatings. This is because toluene is water-insoluble liquid but soluble in paint
and dye. Since it was soluble in paints, it was also used to wash the paints that on our hands.
Due to toluene has an easy accessibility, low cost and ease of concealment, some U.S states
have place restrictions on sale of these product to minors.(Kimberlite.S, 2019)
Toluene uses as recreational use
Toluene is usually using to produce paints, rubber, lacquers and glues. This is due to
the reason of it could help to dry and dissolve other substance. Moreover, it also could make
the other materials that dissolve with it become thinner. (ACE Consumer Education, 2009)
Toluene uses as biological purpose
For the biological usage, toluene also plays an important role in breaking or disrupting
the red blood cells for the extraction hemoglobin process. (Cruz, Rivera-García, &
Woodward, 2014)
Toluene uses for niche application
Toluene is use as a solvent in laboratory for carbon nanomaterials such as nanotubes
and fullerenes as an indicator. This is because the color of toluene solution is bright purple.
Furthermore, toluene also uses to remove the cocaine from coca leaves to produce carbonate
drinks like Coca-Cola.
3
Table 1.1: Usage of Toluene in Malaysia (Sahri and Widajati, 2013)
Usage of toluene Example

Organic Solvent Use in industry manufacture of
paint thinners, nail polish
remover, glue and correction
fluid
Blasting agents Use as an explosive in mining,
quarrying and tunneling
construction
Raw material for making Oxidation of toluene with
benzoic acid potassium permanganate
1.1.2 The Production Capacities and Similar Plants operating in
Malaysia/Asia/World
Toluene is an aromatic hydrocarbon that is widely used as an industrial feedstock and

as solvent. It also known as methylbenzene or phenyl methane, is a clear water insoluble
liquid with the typical smell of paint thinner, redolent of the sweet smell of the related
compund benzene(“Product Guide,” 2011). So, the production of toluene is required so that
this chemical can be export and import to another country. Toluene is important in
manufacture of benzene, xylenes, toluene di-isocyanate, synthetic drugs, benzyl chloride and
other aromatic derivatives. (“Asia chemical profile : Toluene,” 2019)
In Malaysia, Lotte Chemical Titan is one of the biggest companies in Malaysia that
produce toluene and other chemical products. This company consist of 11 plants, 2 co-
generation plants, and 3 tank farms and located on 2 sites at Pasir Gudang,Johor and Tanjung
Langsat,Johor. Over a year, the manufacturer of toluene are estimated to be 70,000 tonnes per
year (“Asia chemical profile : Toluene,” 2019).
4
China become the largest importer of toluene in Asia where it is estimated import
50000 tonnes of toluene every month from South Korea and southeast Asia (“Asia chemical
profile : Toluene,” 2019). However China still can produce sufficient supply of toluene such
as Sinopec Yangzi Petrochemical Company where manufacture 580000 tonnes per year
(“Asia chemical profile : Toluene,” 2019).From Figure 1.1, the price of toluene in China was
not stable due to slow growth seen in downstream sector and sufficient supply of alternatives
chemicals. The price of toluene from February to early May in 2012 was increased and be
estimated RM4901.40 per tonne due to high demand from other country. From early May to
June 22, the price plunged sharply because of poor demand from the buyer.
Figure 1.3: The price of toluene in China (“Asia chemical profile : Toluene,” 2019).
The other country in Asia that have the production of toluene is Sumitomo Chemical
that is located at Japan. This company manufacture 60000 tonnes per year of toluene and it
also produce another chemical. In March 2011, due to the natural disaster that occur in Japan,
several plants in that country were shut down and terminate all their production of chemicals.
They required high import from the other country especially in Asia. Hence toluene exports
from Japan in 2011 dipped to 175,402 tonnes, down by about 43% from the total exported in
2010 (“Asia chemical profile : Toluene,” 2019).
SK Global Chemical that is located in Ulsan, South Korea is largest exporter of
toluene in the region. From the source by ICIS, 1100000 tonne per year production of toluene
are estimated produce by that company follow by Honam Petrochemical that located in
5
Daesan, Korea which produce 120000 tonnes per year. High demand of other country
especially make exporter in South Korea look the other buyers in southeast Asia and India.
For the Europe, toluene production are estimated to be 10 million tone where in 1994,
the production of toluene in United States of American (USA) are estimate to be 3 million
tone. Based on the research about the global toluene market, as an overall, it is projected to
reach approximately 34,112 thousand tons by the end of 2023, increasing at a CAGR of
around 3% per year in the period 2017-2023 (By, 2018)
The 2 company that produce toluene are Arsol Aromatic in Gelsenkirchen,Germany
which produce 30000 tonne per year .Another company are Galp Chemical located in Oporto,
Portugal .These company produce 170000 tonne per year of toluene. Most toluene is
produced from the catalytic reforming of naphtha or from pyrolysis gasoline (pygas)
coproduced in the steam cracking of liquid feeds. A very small amount is still produced from
light oil formed by the carbonization of coal, and small quantities are recovered as a by-
product in styrene manufacture (Creswell, 2019). Figure 1.4 shows the price of toluene
started from early March 2009 until January 2011. Supply and demand of toluene in Europe
was predicted to remain fairly balanced.(“Choose language : Market Study : Toluene,” 2015)
Figure 1.4: The price of toluene in Europe
6
Figure 1.5: Consumption of toluene in worldwide in 2013
Table 1.2: Table of toluene production capacity worldwide

Plant Exact Country Region Production
Capacity
(tonnes/year)
Titan Chemicals Pasir Gudang, Malaysia Asia 70000
Johor
Sinopec Yangzi Jiangsu China Asia 580000
Petrochemical
Sumitomo Chiba Japan Asia 60000
Chemical
SK Global Ulsan South Asia 1100000
Chemicals Korea
Honam Daesan South Asia 120000
Petrochemical Korea
Arsol Aromatic Gelsenkirchen Germany Europe 30000
Galp Chemical Oporto Portugal Europe 170000
Malaysia Total 70000
Asia Total 1930000
Global Total 200000
1.1.3 Report the projected demands/supply for next 10 years in the form of graph
7
Malaysia Toluene Demand and Supply for the Past 5 Years and Next 10 Years
800
700
600
USD/tonne,(x10^6)
500
400
300
200
100
0
0 2 4 6 8 10 12 14 16 18
Year
supply demand
Figure 1.6: Graph of demand/supply of Toluene for next 10 years in Malaysia
Table 1.3: Table of demand/supply of Toluene for next 10 years in Malaysia
Year Supply, USD/kilo ton Demand, USD/kilo ton

2014 12990 457000
2015 14330 472000
2016 14320 567000
2017 12990 577000
2018 13660 588000
2019 15120 589000
2020 14550 590000
2021 13660 590000
2022 15650 596000
2023 14000 613000
2024 13340 634000
2025 19000 645000
2026 17000 652000
2027 16000 658000
2028 14000 680000
2029 16000 700000
8
Figure 1.7: Chart of World consumption of toluene (2017)
The graph drawn above is referred to the data found in the article. Due to the article,
the market demand for toluene in terms of volume was 457000 kilo ton in 2014 and is
projected to reach the worldwide capacity by 2029, 700000 kilo ton. Increase by 53 %. For
the toluene supply in term of worldwide capacity, the projected supply from 2019 until 2029
is based on the production capacity of Sinopec Yangzi Petrochemical Company (China). This
is because the previous toluene supply for worldwide cannot be found and obtained.
However, Asian countries holds the highest production capacity per year about 3010 kilo
tones. China as the largest importer of toluene in Asia(“Asia chemical profile : Toluene,”
2019).
The global toluene market is divided into 4 regions, namely North America, Asia
Pacific, Europe and the rest of the world. Asia Pacific is one of the largest markets of toluene.
South Korea and China are the key markets of toluene in Asia Pacific region. Although
Western Europe, North America, South America, and Japan may experience small or no
capacity increases (or even declines) over the forecast period, overall world capacity will
increase during 2017 till 2022. Capacity growth is driven by expansions in Northeast Asia
(primarily in China), Southeast Asia, and the Middle East. The buying activity from Chinese
importers is Asia’s toluene market direction in the second half of this year which has been the
key factor influencing its prices so far 2018 (SINGAPORE ICIS, 2018).
Consumption of Toluene worldwide to make on-purpose benzene, mixed xylenes,
and p-xylene in 2017, was about 47%. Toluene consumption can fluctuate between 60% and
70% of total chemical/solvent demand. This is due to the adjustments in operating rates for
hydrodealkylation/toluene disproportionation (HDA/TDP) units. Before the economic
downturn in 2008, strong demand for benzene and p-xylene derivatives between 2004 and
9
2007 led to increased operation of HDA/TDP units. A surge of new p-xylene capacity in
Asia, India, and the Middle East also put pressure on toluene disproportionation units. Hence,
toluene demand from TDP and selective toluene disproportionation (STDP) has decreased,
while consumption in transalkylation units has increased. Not only that, the direct conversion
of toluene to benzene from HDA units has declined in the past five years.
High demand from the polyester sector will result in higher volumes of toluene being
converted into mixed xylenes and p-xylene over the next five years. Hydrodealkylation
process which involves the direct conversion of toluene into benzene will continue to decline.
Consumption of toluene by processes that produce a mixture of benzene/xylenes on average
for the next five years is expected to increase 3.5% per year, followed by the start-up of
facilities in the Middle East, India, Northeast Asia, and Southeast Asia.
Accounting for 5% of world consumption in 2017, TDI production is the largest

single-derivative market for toluene. The stronger demand for polyurethanes has resulted in
increasing demand for toluene from TDI. An average annual growth rate for TDI production
of 3.4%, in developing countries and anticipated recovery in global markets with double-digit
growth anticipated in the Middle East and India due to continuously investment. The total
consumption of toluene was for blending into gasoline was about 28% in 2017. There is an
inherent value for toluene’s use in the gasoline pool, both to build octane and to reduce vapor
pressure. However, demand for toluene blending into the gasoline pool is a function of
supply, as the reformers need to operate at reasonable rates.
Toluene consumption by the solvent market grew at about 1.2% per year in the past
five years. Hence, this market is expected to grow by about 0.7% per year for the next five
years. The world toluene consumption has grown at about 3.7% per year since 2012.
However, the growth rate was only 1.6% per year looking only at chemical and solvent
applications (excluding gasoline blending). Toluene consumption in three regions—Northeast
Asia (mostly China), the Middle East, and Southeast Asia—will account for more than 99%
of the toluene volume growth, in the next five years as demand for toluene increases at about
2% per year.
10
1.2 Process alternatives
METHOD 1: Catalytic reforming

Reforming process takes place with straight chain hydrocarbons in the C6 to C8
range. For example, the gasoline or naphtha fractions rearrange themselves into compounds
containing benzene rings. Hydrogen is the by-product of this reaction.
For example, hexane, C6H14, loses hydrogen and turns into benzene.
Figure 1.8: Hexane to Benzene
Methylbenzene (toluene) is made from heptane using the same method:
Figure 1.9: Heptane to methylbenzene(toluene)
The feedstock of this process consists of a mixture of the naphtha or gasoline fractions
and hydrogen. To prevent the formation of carbon by decomposition of the hydrocarbons at
the high temperatures, hydrogen is released. Or else the carbon would contaminate the
catalyst.
A typical catalyst consists of a mixture of platinum and aluminium oxide. The process
that uses platinum is sometimes called as "platforming". The operating temperature is about
500°C, and the pressure varies either side of 20 atmospheres.
The process called as dealkylation. Dealkylation process removes methyl group from
the benzene ring. The methylbenzene is mixed with hydrogen at a pressure of 30 - 50
atmospheres with a temperature of 550°C to 650°C. The catalyst used is a mixture of silicon
dioxide and aluminium oxide.
11
Figure 1.10: Converting Methylbenzene to benzene (Dealkylation)
METHOD 2: Pyrolysis Gasoline Hydrotreating (PYGAS)

Optimized technology for two-stage pyrolysis gasoline hydrotreatment in cases where
di-olefins, olefins, and styrene in the raw pygas feed are saturated. This process is applied to
the C5+ fraction of raw pyrolysis gasoline.
The hydrotreating unit consists of three sections. First stage is to saturate mainly di-
olefins to olefins, called as hydrotreating section. Second stage is also called as hydrotreating
section to saturate the olefins and de-sulfurize the pygas. Next to stabilize the hydrotreated
streams and to recover the C6-C8 heart cut for further processing for aromatics extraction and
the C9+ cut, a fractionation section is introduced.
In the first stage hydrotreating section, raw pygas is fed into this section. The recycle
liquid stream preheat the pygas feed stream along with hydrogen to the desired temperature.
Later sent to the first stage HDT reactor where most di-olefins in the feed are selectively
saturated to olefins only. But stillpreserving the octane value of the hydrotreated stream.
The effluent of the reactor is sent to the first stage product separator. A fraction of the
liquid from the bottom of the product separator is recycled back to the first stage
hydrogenator. This is to control reactor temperature rise. At the top of the separator, excess
hydrogen and light hydrocarbons are removed and sent to the recycle gas compressor. The
separator liquid is then fed to the first stage stabilizer column. H 2 and light hydrocarbons are
separated and drawn as a vapor product in the receiver which is sent as offgas to the battery
limit (B.L.). The liquid stream from the stabilizer bottoms is C 5+ gasoline fraction. This C5+
stream is sent to a fractionation section to obtain a C6-C8 heart cut, which will be further
hydrotreated to saturate mono-olefins in the second stage hydrotreating section to produce
BTX.
The C6-C8 heart cut combined with a recycle vapor stream and makeup hydrogen is
preheated in the second stage feed/effluent heat exchanger. Before being heated further to the
desirable reaction temperature by a charge heater. The feed mixture passes through the fixed
12
catalyst beds in the second stage HDT reactor. Olefin species are saturated and sulfur species
are converted into H2S.
In the second stage feed/effluent heat exchanger, the reactor effluent is then cooled.
Then in subsequent manner in an after-cooler before being routed to a second stage product
separator. The unreacted hydrogen and other light components in the product separator are
separated from the hydrotreated liquid products. Later, recycled to the HDT reactor using a
recycle gas compressor. To control the level of impurities in the recycle gas, a small vapor
stream is purged as off gas.
The hydrotreated liquid stream is fed into the second stage stabilizer column. In the
overhead condenser, the column vapors are partially condensed and sent to an overhead
receiver. H2 and light hydrocarbons in the receiver are separated and drawn as a vapor
product, which is sent as offgas to the B.L. The liquid from the receiver is fully return back as
reflux to the column. The stabilizer’s bottoms product which is the hydrotreated C 6-C8 cut is
cooled. Further, sent to B.L. for further processing for Aromatics Extraction.
Figure 1.11: PYGAS Processing Block Diagram
METHOD 3: Prepared toluene by alkylation

Toluene could be producing with alkylation of benzene which was Friedel-Craft
Alkylation. Alkylation of benzene is a process that substituting an alkyl group into a benzene
ring which replaced a hydrogen atom by a methyl or ethyl group. For the alkylation process,
benzene is treated with alkyl halide such as chloromethane with catalyst such as aluminium
13
chloride. This process will give toluene and hydrochloric acid as product.(Qiao & Deng,
2001)
Figure 1.12: Friedel-Craft Alkylation
The chemicals reaction show benzene is react with chloromethane which choose
aluminium chloride as catalyst in room temperature(20°C-25°C) to produce
methylbenzene(toluene) and hydrochloric acid.
In this chemical’s reaction, the chloromethane and aluminium with react together to
form electrophile CH3+ to further react with benzene ring.
The electrophile CH3+ is further react with benzene ring which involve electrophilic
substitution mechanism.
Figure 1.13: Electrophilic Substitution mechanism

Then, the hydrogen at the benzene ring is removed by AlCl 4- and finally produce
hydrochloric acid and methylbenzene (toluene). The aluminium chloride is re-generated out
form the reaction.
Figure 1.14: Regeneration of Aluminum Chloride
14
The process of alkylation of benzene to produce toluene is only involve four CSTR
reactor and a separator as shown at Figure 1.19. Benzene was flow through three CSTR
reactor and finally flow to the separator to separate the catalyst such as aluminum chloride
and the byproduct such as hydrochloride acid from toluene (Qiao & Deng, 2001).
Figure 1.15: Process flow diagram of alkylation of benzene
METHOD 4: Prepared toluene by desulfonation 4-Methylbenzenesulfonic acid

Toluene could be obtained by desulfonation of 4-Methylbenzenesulfonic acid. In
order to obtain 4-Methylbenzenesulfonic acid, benzene ring will involve in sulfonation and
alkylation process. In the sulfonation, benzene ring will heat with sulfuric acid and form
benzenesulfonic acid. Benzenesulfonic acid will experience alkylation and form 4-
Methylbenzenesulfonic acid. Then the 4-Methylbenzenesulfonic acid will react with
phosphoric acid in the present of steam to form methylbenzene(toluene) and sulfuric acid.
Step1: Sulfonation of benzene ring
The benzene ring is reacting with sulphuric acid to form benzenesulfonic acid
Figure 1.16: Sulfonation of benzene ring

The sulfuric acid in this reaction will dissociation and form sulphur trioxide electrophile
15
Sulphur trioxide electrophile will attack the benzene ring in two stage to form
benzenesulfonic acid.
Figure 1.17: Sulphur trioxide electrophile attack Benzene ring

The second stage of the reaction is involved a transfer of hydrogen from the benzene ring to
the negative oxygen to form a water molecule.
Figure 1.18: Transfer of hydrogen from the benzene ring to the negative oxygen to form
a water molecule
Step 2: Alkylation of benzenesulfonic acid (Shi, 2017)

The hydrogen in the benzenesulfonic acid will replace by methyl group after
alkylation. Benzenesulfonic acid is react with alkyl halide such as chloromethane with
catalyst such as aluminium chloride in room temperature to form hydrochloric acid and 4-
Methylbenzenesulfonic acid.
Step 3: Desulfonation 4-Methylbenzenesulfonic acid (Jason, 1993)
Desulfonation is hydrolysis process of sulfonic acid. The reaction was applied to an
aryl and naphthyl sulfonic acid and it is a reverse process of sulfonation process. Thus, 4-
Methylbenzenesulfonic acid is react with aqueous sulfuric acid or phosphoric acid in the
present of steam (100°C of water) to form methylbenzene(toluene) and sulphuric acid.
16
Figure 1.19: Desulfonation 4-Methylbenzenesulfonic acid
METHOD 5: Prepared toluene by convert bromobenzene to toluene (Ridge, 1948)

Wurtz-Fittig reaction is applied to convert chlorobenzene to toluene in the present of
sodium and dry ether. Wurtz-Fittig reaction also called coupling reaction. The bromobenzene
will forms an organosodium as a nucleophile, then it will react with aryl halide which act as
an electrophile. At the first stage of the reaction is involved sodium-mediated formation of
alkyl and aryl radicals. Then, the aryl and alkyl radicals is combined to form an aromatic
compound. The organosodium will form at the second stage.
Figure 1.20: Wurtz-Fittig reaction
1.3 Summarize and compare the 3 shortlisted alternatives
CATALYTIC ALKYLATION PYROLYSIS

M REFORMING OF TOLUENE GASOLINE
ethod PROCESS HYDROTREATING
Criteria (PYGAS)
General process Catalytic reforming Benzene alkylation with Pygas hydrotreating
17
specification process by methanol as an alkylating (catalytic hydrogenation
dehydrogenation in the agent for the selective process)
presence of hydrogen formation of toluene and
xylene, particularly
toluene.
Green Chemistry Catalytic reforming  Benzene can occur Raw pygas(feed) can be
uses catalytic reactions naturally in the produced by fermentation
to process primarily environment. It is of biomass either than
low octane, heavy, emitted into the gasoline
straight run gasolines atmosphere by (Censullo, Jones, &
and naphthas into high erupting Wills, 2003)
octane aromatics volcanoes, from
(including benzene). It the smoke of forest
is not green as it used fires and, it is also
petroleum as its feed. found in some
(Schirber, 2013) plants and animals.
Benzene can
quickly evaporate
into the air and be
carried over long
distances. If it is
released into soil it
can break down
quickly and may
contaminate
groundwater.
 The Friedel-Crafts
alkylation process
can be cycled
indefinitely in the
catalytic acidic
melt without loss
of melt, addition of
catalyst or loss of
18
catalytic activity.
(Carter, 1999)
Sustainability Low because requires High sustainability Low because pygas
petroleum products. because the produced obtained mainly from
benzene is from biomass non-renewable sources
via methanol
Environmental The molecules with 6 The ability to indefinitely Cause air pollution
Impact carbon atoms tend to reuse catalyst will also (precursor to smog)
form aromatics which substantially reduce the
is undesirable because amount of waste
governmental generated and will
environmental substantially lower the
regulations in a cost of disposal and
number of countries environmental impact of
limit the number of the process.(Censullo et
aromatics (most al., 2003)
particularly benzene)
that gasoline may
contain
Energy High heat is use. High heat energy used High heat energy used
Consumption Steam consumption is
4000J or 119J
Flexibility of Has low flexibility as Unlimited catalyst used Limited catalyst used,
Operation it requires certain (Aluminum Chloride/ Nickel-Molybdenum
amount of pressure Sulfuric Acid/ (Ni/Mo)
and temperarue. Hydrofluoric Acid)
Requires naphta, it
transforms low octane
naphtha into high-
octane motor gasoline
blending stock and
aromatics rich in
19
benzene, toluene and
xylene with hydrogen
Safety Factors The benzene content  Benzene is used as Presence of raw
of reformate involved feed of process pygas(feed) that highly
makes it carcinogenic, and it colourless, flammable can cause fire
which has led to flammable liquid and explosion
governmental and easy to
regulations effectively evaporate quickly
requiring further when exposed to
processing to reduce air. It is a central
its benzene content. nervous system
toxin and a
carcinogen
(cancer-causing)
for human.
 Aluminium
chloride as catalyst
will also sublime
readily at 178֯°C to
transform into
hydrogen chloride
gas. When
hydrogen chloride
gas comes in
contact with
moisture, it forms
hydrochloric acid
which is corrosive
and can cause
irritation and burns
 Toluene and
benzene is
carcinogenic,
20
whereas toluene is
thought to have
little carcinogenic
potential.
Operating Reactor 1 Temperature :828℃ Temperature :840-920°C

conditions Inlet temperature :502℃ Pressure :136.6 psig Pressure: 100 psig
Exit temperature :433℃
Reactor 2
Inlet temperature :502℃
Exit temperature :471℃
Pressure :170-350 psig
Quality of the The purified toluene The toluene produced Ethylene :25%-31%
product produced is 99.8% is 90% concentration BTX :10%-13%
Propylene :12%-16%
Butylene :3%-8%
Butadiene :4%-5%
1.4 The best process among the suggested alternatives with justification
In the production of toluene, there are 3 methods that can be used such as catalytic
reforming, alkylation of toluene and pyrolysis gasoline hydro treating (pygas). The most
widely used method and also have more advantages compared to the others is catalytic
reforming that also known as hydroforming. This process using naphtha as feedstock and
involve platinum-iridium as catalyst. The major source of toluene is catalytic reforming
which approximately 87% of toluene can produced domestically and 94.5% of the production
capacity feedstock (Beauregard Dennis, 1385). The presence of catalyst is important to
increase the rate of desired action
These process involve catalytic dehydrogenation in the presence of hydrogen which it
can reduces the coke formation in order to yield a mixture of aromatic hydrocarbon especially
toluene (“Various Manufacturing Process of Toluene,” 2019).
Other than that, by choosing this process at the low pressure, it can increase the coke
laydown and thermodynamic equilibrium yields of reformate. As we know that, this process
21
converts heavy naphtha into high octane reformate which this reformate has low amount of
sulphur and it is important product for blending in gasoline.
The main advantages by using this process is higher number octane reformate produce
in the range 95-108 with a low feed quality. Other than that, this process can produce higher
hydrogen gas continuously at the higher catalyst activity and yield. This will produce high
amount of hydrogen which requires lower recycle ratio. The hydrogen gas produce during
hydrogenation and hydrocyclization could be recycle back to the feed stream. It allows for
more severe operation conditions such as low operational pressure which is at 200 psig, wide
boiling range feed, and low hydrogen-to feed ratio were applied which contributes to high
deactivation rate of the catalyst (M. González-Marcos et al., 2005).
This process does not need shutdown of the operation for catalyst regeneration, but it
uses a swing reactor which allows for one of the reactors to undergo in-situ regeneration
while the other reactors are in operation. In the production of toluene, bimetallic and
multimetallic catalyst are prefer compared to monometallic, so they can enhance resistance to
coking for example it can reduce the fouling, increase the coke tolerance, and also require
low temperature. (Hills, Porta, & Dwight, 1998)
Table 1.4 shows the some fairly typical straight-run heavy naphtha feedstock,
available for catalytic reforming, derived from various crude oils. It can be seen that they
differ significantly in their content of paraffin, naphthenes, olefins and aromatics.
Table 1.4: Specification of naphtha feedstock (all components are in wt%)
The production of toluene involves the raw material such as mixture of naphtha or
gasoline fractions and hydrogen involving platinum as catalyst. Sulfidation of platinum is
22
used to partially poison the platinum or reduce its activity. This is good to reduce a major
portion of hydrogenolysis or metal-catalysed cracking reactions. Other than that it also can
improve the liquid product yields and can reduce light gas production such as methane
(Treese, Pujadó, & Jones, 2015a). This process creates a large amount of hydrogen during the
hydro treating and hydrocracking process which it is the valuable byproducts.
From the perspective of economic and technical, catalytic reforming is better another
process because it required low temperature as the catalyst is added into first reactor. This
process ensure reformate, aromatics and hydrogen yields can remain consistent and constant.
Moreover, it will make sure that metals and chloride have a proper re-dispersion so that it can
maintain catalyst activity and able to handle upset scenarios without long-term shutdown and
also have higher on-stream efficiency. At the end of the process, 88% of toluene can be
produced domestically and the purification of toluene up to 99.8%.the catalytic reformation
has the highest conversion which could produce more yield that the others process and it will
also get a higher purity of toluene when compare with others process. Although the process
produces some hazardous by products such as methane but we can treat them and convert it
into valuable products such as using an electron beam/ultra-fine bubble hybrid system.
The difference of catalytic reforming process among the others are this process
produce less amount of benzene compared to alkylation process and pyrolysis gasoline hydro
treating. Since the benzene is one of the hazardous gas. So, this involve less potential of
carcinogenic effect. In the pygas process, benzene is component of pyrolysis gasoline and it
will biodegrade. Benzene tend to accumulate in food chain and river. Hence, it will disrupt
the aquatic life. We favour catalytic reforming process compared alkylation of toluene
because alkylation will release hydrogen chloride gas that will cause air pollution and
hazardous upon inhalation.
1.5 Critical Assessment of The Chosen Process
1.5.1 Operating capacity of the plant based on literature background
Based on previous literature background, the operating capacity of the plant for the
production of toluene is 1100000 tonnes per year. The massive amount production of toluene
23
especially in a chemical industry where toluene used as an industrial feedstock and a solvent
especially in the production of toluene di-isocyanate (TDI) which is an important raw
material in the production of polyurethane foams. The main chemical use of toluene is to
make benzene and xylenes using a number of technologies. The production of toluene will
increase year by year to fulfil the demand and supply (ECN, 2018)
In Malaysia Lotte Chemical Titan is the biggest producer of toluene and supply this
chemical for various usage such as a solvent, fullerene indicator, and cement for fine
polystyrene kits. Other than that, this company also use toluene as a raw material for toluene
diisocyanate for manufacture of polyurethane foam and trinitrotoluene (TNT) (“Product
Guide,” 2011)
The production capacity of toluene in this company are 70000 tonnes per year.
Although Malaysia is not the exporter or importer of toluene it still needs to increase the
production of this chemical for the use of chemical industries. Since toluene is manufactured
for use as an intermediate in the production of benzene (50 %) and toluene di-isocyanate (9
%), for gasoline blending (34 %), for solvents (5 %), and for the production of miscellaneous
chemicals (2 %) therefore the demand for this production is increasing rapidly (Foo & Eng,
2015)
From all the process that listed at the previous part, catalytic reforming is chosen as
the best process to produce toluene. Catalytic reformate is the major source of toluene,
accounting for approximately 87 percent of the toluene produced domestically and
approximately 94.5% of the production capacity feedstock.
The process begins when a mixture of the naphtha or gasoline fraction and
hydrogen is preheated in the heat exchangers and the mixture are totally vaporized in a
reactor. The mixture mixes with a hydrogen-rich recycle gas then passed through a second
and third reactor with different temperature. The reactor consists of dehydrogenated catalyst.
After that, the reaction gas passed through heat exchangers to a gas-liquid
condenser and separator. A large amount of separated wet gas is then compressed and
recirculate to the distillation column and then separated into toluene, liquid pressurized gas
and off gas such as methane, ethane and butane.
24
1.5.2 Process chemistries for all process involved in the plant
The best process among the suggested alternative of process sachems to produce
toluene is catalytic reformation. In catalytic reformation, dehydrogenation of naphthene to
convert into as exemplified to convert methylcyclohexane to become toluene. Naphtha feed
to the reformer contains a mixture of C6–C11 paraffins, naphthene, and aromatic
hydrocarbons in the temperature range of 85–200˚C. Most reformers process straight-run
naphtha with qualities that vary significantly depending on the crude oil origin and boiling
range (Abdullah & Aitani, 2014). The reaction conditions range of temperature is about 495
to 525°C, meanwhile for pressure is about 5 to 45 atm. The catalysts used in in catalytic
reformation normally is noble metals such as platinum or iridium. The feed for catalytic
reformer is naphtha. Low pressure reforming is commonly used for toluene production and
generally hold for feedstocks in the 495-525°C boiling point range. One mole of naphthene
conversion is about 98% with the number of carbon atoms in the precursor being retained in
toluene. Feed was preheating in the form of hydrotreating to remove impurities. Hydrotreater
employs a cobalt-molybdenum catalyst to convert organic sulfur and nitrogen compounds to
hydrogen sulphide and ammonia. The sulphide and ammonia will be removed from the
system together with the unreacted hydrogen. All metals in the feed will be retained by the
hydrotreater catalyst. The feed is redistilled before being charged to the catalytic reformer.
In the catalytic reformation, dehydrogenation and dehydrocyclization of naphtha to an
aromatic is a highly endothermic reaction will result a temperature to decrease. These two
reactions contain a high reaction rate and the aromatics compound such as toluene formed
have a high boiling point so end point of gasoline rises. Besides that, isomerization of
paraffins and naphtha also involve in catalytic reformation process. Isomerization is a rapid
reaction with only have a small heat effect when branched the isomers to increase octane
rating. The catalytic reformation also contains a non-desirable process such as hydrocracking
of paraffins to lower the molecular weight of the compound. Hydrocracking process is a slow
exothermic reaction that will release heat and produce a light gas. The favorable condition for
dehydrogenation and dehydrocyclization is at low pressure and high temperature condition,
meanwhile, for isomerization process both the pressure and temperature condition is
intermediate and the condition for hydrocracking both condition is high. (Lal, 2011)
All the catalytic reformation generally uses catalyst that contains iridium supported on
an alumina base. Commonly iridium is combined with platinum to form a more stable
25
catalyst which permits operation at lower pressure. Platinum is the main catalyst for
hydrogenation and dehydrogenation reaction, chlorinated alumina will provide an acid site
for isomerization, cyclization and hydrocracking reactions. Catalyst activity will be reduced
during operation by coke deposition and chloride loss. The activity of catalyst could be
restored by high temperature oxidation of carbon then followed by chlorination. The catalyst
activity will decrease during the o-stream period and the reaction temperature will also
increase as the catalyst ages to maintain the desired operating severity. Normally the catalyst
could be generated at least three times before it must be replaced and returned to manufacture
for reclamation.
Catalytic reformation operating with pressure and hydrogen which are compromises
among obtaining maximum yield, long period operating times between regeneration and
stable operation. It commonly necessary to operate at pressure from 170 to 350 psig (345-
2415 kPa). For the hydrogen charge ratios of 3-8 mol H 2/mol feed. The reaction temperature
required about 495-525°C are preferred to higher temperature due to the reason equilibrium
conversion to isomers is enhanced at the lower temperature. An active catalyst is necessary to
provide a reasonable reaction at the relatively low temperature. This is needed to convert to
hydrogen chloride in the reactor and consequently the feed to these units must be free of
water and oxygen to avoid catalyst deactivation occur and potential corrosion problems.
(Abdullah & Aitani, 2014)
For the process, the feed is pumped up to increase the pressure and flow through the
evaporator to became vapor. Then, the gas mixture is undergoing preheated process by heat
exchanger. Then, the vaporized mixture is flow through a fixed bed reactor for
dehydrogenation of naphthalene to aromatics. Since the dehydrogenation process is an
endothermic reaction and it will cause the temperature of mixture decrease. Hence, before
pass through to the second reactor, the mixture should pass through a fired heater to maintain
it required reaction temperature. The hot product that flow out from second reactor was been
cool down by cooler and send to a separator for separation process. Most of the hydrogen-
rich gas was been separated out from the mixture. Then, the liquid from the separator vessel
is flow to a distillation column. The upper product of the distillation is butane gas and
distillate liquid. Meanwhile, the bottom product is the high-octane liquid which is
toluene(Lal, 2011).
Table 1.5: Destination codes and component classification

Component Component Classification Destination Code
26
Hydrogen Reactant (Gas) Storage Tank
Naphtha Reactant (Liquid) Flow into reactor
Toluene Product Product Storage
Butane By-product (Gas) Scrubber system
Distillate By-product (Liquid) Storage tank
1.5.3 List of reactions, kinetics, and thermodynamics data of the involved reaction.
Reforming Reactions
To transform paraffins and naphthenes into benzene, toluene, and xylenes. With
minimal cracking to light gases. The percentage of feed converted to aromatics is the yield of
desired product. In motor fuel industry, the octane value which is obtained through
aromatization of paraffins and naphthenes undergoes Isomerization of the paraffins into
higher octane branched species. Also, the removal of low octane paraffins through cracking
to gaseous products. The liquid product with five or more carbons (C5+ reformate) is
described as yield. One of the main reactions in reforming.
Reaction Sites
Reforming catalysts consist of platinum with additional metals as modifiers or
attenuators supported on chlorided alumina. Separate and distinct reactions occur on the
iridium sites. While acidic chloride occurs in alumina sites. Dehydrogenation and
hydrogenolysis (C-C scission) performed by platinum sites. Meanwhile the acidic alumina
sites undergo isomerization, cyclization, and hydrocracking.
Naphthene Reactions
Naphtha feeds contain both five-member and six-member naphthene rings such as
cyclopentanes, substituted cyclopentanes, cyclohexanes, and substituted cyclohexanes. For
example, the six-carbon ring cyclohexanes can be directly dehydrogenated to produce
aromatics and hydrogen on platinum sites. This is a very fast reaction which produces
significant endotherms in the lead reactors due to the large amount of naphthenes typically in
the naphtha feed.(Treese, Pujadó, & Jones, 2015b)
Figure 1.21: Conversion of napthenes to aromatics
27
To give a cyclohexane intermediate prior to dehydrogenation to aromatics, the five-
member ring cyclopentanes must be hydroisomerized.
Figure 1.22: Hydroisomerization of Cyclopentanes
Aromatic Reactions
Aromatics are stable species and relatively inert. However, the side groups can react
under reforming conditions. Reactions of substituted aromatics are isomerization,
dealkylation, disproportionation, and transalkylation. Dealkylation makes the alkyl side chain
smaller or completely removing the side chain. Operates sufficiently high temperatures and
high pressures.
Figure 1.23: Dealkylation

Paraffin Reactions
The most difficult step in reforming is paraffin conversion. Hence, the ability to
convert paraffins selectively is most crucial part of this process. Paraffins is cyclized to form
aromatics. Paraffins are dehydrogenate to olefins and also isomerized to branched paraffins.
Paraffin hydrocracking, the least favourite reaction because it produces lower value light
hydrocarbons and consumes valuable hydrogen. Hydrocracking of paraffins lead to the
removal of lower value octane components in the reformate for gasoline blending.(Treese et
al., 2015a). It is important to maximize the selectivity of paraffin cyclization over paraffin
hydrocracking (BTX operation) to maximize the production of aromatics and hydrogen.
Paraffins are dehydrogenated on the platinum sites (Mills et al. 1953) to form olefins which
can then isomerize over the acid function of the catalyst to provide higher octane branched
paraffins.
28
Figure 1.24: Dehydrogenation of parrafins
Acid-catalyzed hydrocracking reactions convert paraffins to mostly C3 and C4

products.(Treese et al., 2015a) All of these paraffin reactions are to proceed through olefin
intermediates as shown above (bifunctional mechanism). Additional paraffin cracking
reactions occur on the metal sites producing in predominantly C1 and C2 products.
Figure 1.25: Acid-catalyzed hydrocracking reactions
Cyclohexanes and cyclopentanes as shown below (dehydrocyclization) are the most

desired reaction for paraffins. These reactions proceed through olefin intermediates. The
acidic alumina support act as a catalyst to cyclize the olefin. After cyclization, cyclohexane
rings undergo rapid dehydrogenation to aromatics.
Figure 1.26: Cyclohexane rings undergo rapid dehydrogenation to aromatics
Rates and Equilibrium

The dehydrogenation of naphthenes and paraffins is rapid, and equilibrium
concentrations are established in the initial portions of a catalyst bed. (Treese et al., 2015a)
Table 1.6: Thermodynamic data for reforming compounds at 800 K, ideal gas in
kcal/mol
29
Isomerization reactions are sufficiently fast that actual concentrations are near
equilibrium. (Treese et al., 2015a) The reaction rate for dehydrocyclization is reduced by the
low concentrations of the olefin intermediates that exist at equilibrium. Olefin equilibrium
concentrations are affected by hydrogen partial pressure significantly a significant impact on
aromatization. Decreasing the hydrogen partial pressures will increase the rate of
aromatization. However, this will cause a decrease in the rate of hydrocracking, and an
increase in the rate of coke formation. Figure 1.32 shows thermodynamic data for typical
compounds in reforming reactions at a reference temperature of 800 K. Thermodynamic data
can be obtained from standard sources (American Petroleum Institute Research Project 45;
Stull et al. 1969). Production of aromatics is desired by reforming conditions, especially high
temperatures and low pressures. To ensure full conversion to the equilibrium limits, current
reforming unit designs at low hydrogen partial pressures.
Reforming Process Conditions
Pressure
The average pressure is measured by the inlet pressure to the last reactor. Due to
practical operating constraints, this has led to a historical range of operating pressures from
345 kPa to 3,450 kPa (50–500 psig). The overall pressure drop can be as large as 50–60 psig.
It is advised to reduce the pressure drops in the unit as much as possible. So that, all the
reactors operate at a lower pressure. The advantage of lowering the pressure are increase in
aromatic, hydrogen, and reformate yields. Moreover, decreasing temperature requirement to
achieve a target product quality (utility savings). Lower pressure shortens the catalyst cycle.
30
Due to the increase in catalyst coking rate. The higher catalyst deactivation rate operating in
the 50–150 psig pressure range requires continuous catalyst regeneration.
Temperature and Space Velocity

The temperature of the catalyst beds is the primary control for product quality in
catalytic reforming. The operating temperature is in wide range for catalytic reforming. A
refiner can change the octane of reformate and the quantity of aromatics produced by
adjusting the heater outlet temperatures. The reactor temperature is usually expressed as the
weighted average inlet temperature (WAIT) is used to express the reactor temperature. The
summation of the product of the fraction of catalyst in each reactor multiplied by the inlet
temperature of the reactor is WAIT. Continuous units operate over a WAIT range of about
525–540 C (977–1,004 F). The Continuous Catalytic Reforming Platforming units operate at
higher temperatures to produce higher aromatic-rich product. This is because the main
reforming reactions are endothermic. A significant drop in temperature along the catalyst
beds. In the first reactor position, the temperature drop is the largest, due to the
dehydrogenation of the naphthenes contained in the naphtha feed. In the second reactor
position temperature drop is still substantial but smaller for each successive reactor. It is
easier to also define a weighted average bed temperature (WABT) for the temperature drops.
The summation of the weight fraction of catalyst in a bed multiplied by the average of the
inlet and outlet bed temperatures is WABT.
Space velocity is the amount of naphtha processed over a given amount of catalyst
over a set length of time. The reciprocal of the residence time or time of contact between
reactants and catalyst corresponded by space velocity. Since most refiners define their charge
rate by volume such as barrels, it is most common to define a liquid hourly space velocity
which is calculated by dividing the volumetric charge rate per hour by the total volume of
reforming catalyst in the reactors.(Treese et al., 2015a) Dividing the weight of naphtha feed
per hour by the total weight of catalyst in the reactors is weight hourly space. To adjust the
conversion of the naphtha feed in order to achieve the target product octane or aromatic yield,
combination of space velocity and reactor temperature is used. The higher the temperature
required to achieve a given product tarrget, the greater the space velocity. As the conversion
of the naphtha increased, producing higher octane reformate. The yield of C5+ reformate
declines because of the cracking of paraffins, forming C4 products. As the conversion level is
increases, he yields of aromatics and hydrogen will typically continue to rise.
Continuous Catalyst Regeneration Units
31
In the CCR Platforming unit, partially spent catalyst in the reactors is continuously
replaced with catalyst that has been freshly regenerated in an external regenerator (CCR
section) to maintain a low average coke level on the catalyst in the reactors. In a CCR
Platforming unit, the catalyst is regenerated approximately every 3–7 days, and the yields
remain constant. Each reactor effluent is reheated and sent to the next reactor with the last
reactor effluent going to the separator and the recovery section. CCR platforming unit has the
ability to continuously regenerate a controlled quantity of catalyst. Through a transfer pipe to
a catalyst hopper above the regeneration tower, the catalyst is lifted by nitrogen gas. Catalyst
then enters the regeneration tower. The catalyst flow of by gravity is controlled through a few
regeneration zones. The catalyst flows through the coke burn zone, Pt redispersion/chloriding
zone, and a drying zone (Treese et al., 2015a).
Regenerated catalyst is returned to the top of the reactor stack. This is achieved by a
transfer system similar to that used in the reactor-to-regenerator transfer. The catalyst enters
the first reactor then into a reduction zone. The reactors are continuously provided with
freshly regenerated catalyst. The product yields are maintained at a constant level. To permit
a shutdown of the regeneration system for normal inspection or maintenance without
interrupting the processing of naphtha feed, The regeneration and reactor sections of the unit
are easily isolated.
Secondary Recovery
For the low-pressure operations of the CCR unit, the need for effective liquid
recovery is more critical. C5+ yields at low pressure can be lost if the proper recovery
system is not installed. At low pressure in the gas-liquid separator, The flash pressure (low
pressure in gas-liquid separator) has been reduced. Allowing heavier hydrocarbons (C4–C6+)
to leave with the vapor resulting in lost C5+ product and lower purity hydrogen gas. First
separating the reactor effluent in the separator into vapor and liquid then recompressing the
vapor with a net gas booster compressor with discharge into a drum or absorber vessel. For
recontacting at higher pressure, the liquid from the separator is also pumped into the same
drum. Hence, a better gas-liquid separation is achieved leading to increased liquid recovery
and higher purity hydrogen.
32
1.5.4 Attach of physical and chemical properties of all the raw materials, products and
byproducts in the process
Name Use as Physical properties Chemical properties
Naphtha Feedstock  Insoluble in Water  Molecular

 Colorless (with a Weight: 100-215
kerosene odor) or red-  Specific Gravity:
brown (with an aromatic 0.75-0.85
odor).  Boiling Point: 70-
 They are 430 °F.
incompatible with strong  pH: Neutral
oxidizers.  Vapor Pressure:
<5mm mercury
Toluene Product  Physical state:  Boiling point:

Liquid 110.6 °C
 Colour: colourless  Formula: C7H8
 Odour: aromatic  Molar mass: 92.14
odour g/mol
 Solubility:  Density: 867
Insoluble in water. Soluble kg/m³
in ethanol. Soluble in ether.  Melting point: -95
Soluble in acetone. Soluble °C
in chloroform. Soluble in
carbondisulfide. Soluble in
acetic acid. Soluble in
33
ethylacetate. Soluble in
petroleum spirit.
Hydroge Byproduct  Appearance:  Formula: H2

n Colorless and odorless gas  Chemical
at room temperature structure: H–H
 Solubility in water:  Molecular weight:
0.0214 cm3 g−1 (0 °C, 1 2.0159
atm)  Density (gas):
0.08988 g L−1 (0 °C, 1
atm)
 Relative vapor
density (air = 1): 0.07
 Density (liquid):
70.8 g L−1 (at −253 °C )
 Melting point:
−259.35 °C
 Boiling point:
−252.88 °C (at 1 atm)
Butane Byproduct  Appearance:  Boiling Point:
colourless gas 10ºC (50 ºF)
 Stability: The  Vapour Pressure:
product is stable under 1976 mmHg
normal handling and  Density: 2.48
storage conditions.  Molecular
Weight: 58.12
g/mol
Distillate Byproduct  Solubility in water:  Density and
insoluble phase: 0.864 g/ml, Liquid
 Soluble in non-  Melting point:
polar solvents such as −47.4 °C (−53.3 °F; 226
aromatic hydrocarbons K)
 Boiling point:
34
138.5 °C (281.3 °F; 412
K)
Iridium catalyst  Appearance: Black  Bulk Density:
or Gray Sphere 710-770 (g/L)
 Odor: Odourless.
Bulk Density: 710-770
(g/L) Solubility in water:
insoluble
1.6 Recognize and write down all the environmental (disposal of waste, if any), safety
and health concern.
Chemical Environmental (disposal of Safety Health concern

waste, if any)
Main
product:
Toluene Waste disposal Protective equipment: Effect: Toluene
recommendations: Do not when working with exposure can
discharge into drains or the toluene, wear gloves if affect color vision
environment. Remove waste hand contact can occur. and hearing.
in accordance with local Glove type (light or Symptoms may
and/or national regulations. heavy duty) and material get worse as
Hazardous waste shall not be (Nitrile, Viton, Teflon) toluene levels in
mixed together with other depend on the task. Use the air or skin
waste. Different types of the information in the contact increases.
hazardous waste shall not be product’s MSDS to help Over time,
mixed together or it will with selection and wear exposure to high
create problems for the safety goggles, concentrations,
further management of the faceshield, coveralls, and day after day, may
waste. Hazardous waste shall boots as needed if there lead to tiredness
be managed responsibly. All is a splash hazard. and slow reaction,
35
entities that store, transport Condition to avoid: difficulty sleeping,
or handle hazardous waste Use the smallest amount numbness in the
shall take the necessary of the product that will hands or feet, or
measures to prevent risks of get the job done. female
pollution or damage to Ventilation protection: reproductive
people or animals. Recycle Make sure that there is system damage
by distillation. Do not general air flow and pregnancy
landfill. Incinerate under (ventilation) to carry loss. If swallowed,
surveillance with energy toluene away from the toluene can cause
recovery. May be discharged work area. For stationary liver and kidney
to company wastewater work, use local exhaust damage.
treatment plant. ventilation (such as a
snorkel, fume hood,
work table with down-
draft or side-draft
ventilation). Local
exhaust should vent to
the outdoors or have a
charcoal filter that is
changed as
recommended by
manufacturer.
Byproduct
:
Butene Waste disposal Effect: Exposure
Protective equipment:
recommendation: Remove to butene can
when working with
waste in accordance with occur via
butene, thoroughly
local and/or national inhalation,
washing hands and
regulations. Hazardous waste ingestion, eye or
removing outer
shall be managed skin contact. The
protective clothing
responsibly. All entities that main effect of
before entering clean
store, transport or handle inhaling butene
areas, usage of
hazardous waste shall take vapor is
impervious clothing such
36
the necessary measures to depression of the
as Buna–N-rubber or
prevent risks of pollution or central nervous
Viton gloves and
damage to people or animals system, with
impervious aprons, a
and environment. Incinerate symptoms such as
face mask or full-face
under surveillance with headache,
organic respirator to
energy recovery. Do not dizziness, nausea
reduce the inhalational
discharge into surface water. and vomiting. The
hazards and safety
effects listed
goggles/face shields for
below can begin
eye protection
to occur with
Condition to
avoid: exposure to air
Take precautions against levels of about
electrostatic charges. 100 ppm. They are
Keep away from naked reversible and
flames/heat. Keep away become more
from ignition noticeable and
sources/sparks. Observe serious as the
normal hygiene length of time of
standards. Keep exposure
container tightly closed. increases.
Measure the
concentration in the air
regularly.
Ventilation protection:
A well-designed hood
takes advantage of the
natural movement of the
contaminant. As the air
moves through the duct,
it creates friction against
the duct walls. Friction is
greater at the corners,
bends and obstructions
of the duct. The overall
37
duct length should be
kept as short as possible
with as few bends as
possible. Various types
of air-cleaning devices
can be used, like fabric
filters, charcoal filters,
cyclones, electrostatic
precipitators and
scrubbers.
Distillate Waste disposal Protective equipment: Effect: Exposure
recommendation: Cylinders always wear eye to distillate gas
should be returned to the protection when phase can cause
supplier for disposal of handling compressed dizziness or
contents. Small customer gases. Ordinary safety cardio-respiratory
owned cylinders should be glasses can cause eye arrest in humans,
made safe at a Gas Cylinder damage if gas released and high
Test Station before disposal. suddenly from a concentrations can
LPG cylinders should be cylinder. cause
returned to the owning Condition to avoid: asphyxiation. In
organization stamped on the Before use carefully read some cases,
cylinder when no longer the product label. Use of distillate gas form
required. safe work practices are may cause
recommended to avoid euphoria, nerve
eye or skin contact and and brain damage,
inhalation. Observe good hallucination or
personal hygiene, heart failure.
including washing hands
before eating, prohibit
eating, drinking and
smoking in contaminated
areas.
Do not store near
38
incompatible substances
and sources of ignition.
Cylinders should be
stored: upright,
prevented from falling,
in a secure area (below
45℃ in a dry), well
ventilated constructed of
non-combustible
material with firm level
floor (preferably
concrete), away from
areas of heavy traffic
and emergency exits.
Hydrogen Waste disposal Protective equipment: Effect:
recommendation: Do not Wear safety glasses with Individuals
discharge into areas where side shield and wear breathing such an
there is a risk of forming an working gloves when atmosphere may
explosive mixture with air. handling gas containers. experience
Waste gas should be flared Condition to avoid: symptoms which
through a suitable burner Keep away from heat, include headaches,
with flash back arrestor. Do hot surfaces, sparks, ringing in ears,
not discharge into any place open flames and other dizziness,
where its accumulation could ignition sources. No drowsiness,
be dangerous. Ensure that smoking. Use only non- unconsciousness,
the emission levels from sparking tools. Use only nausea, vomiting
local regulations or operating explosion-proof and depression of
permits are not exceeded equipment. Wear leather all the senses. The
safety gloves and safety skin of a victim
shoes when handling may have a blue
cylinders. Protect color. Under some
cylinders from physical circumstances,
damage (do not drag, death may occur.
roll, slide or drop).
39
While moving cylinder,
always keep in place
removable valve cover.
Never attempt to lift a
cylinder by its cap (the
cap is intended solely to
protect the valve)
all such spaces should be
provided with room
ventilation, in addition to
the aforementioned
hydrogen-concentration
monitoring. Rooms in
which hydrogenations or
other hydrogen-using
operations take place
must be kept at a
negative pressure with
respect to outside areas
to prevent outward
hydrogen flow. The
room pressure should be
monitored, with
provision for an alarm to
sound. (MSDS Of
Hydrogen, 2000)
40
CHAPTER 2 : MASS & ENERGY BALANCES
1.2 Summary of the Equipment in the Toluene Production Process
Table 2.7 Details Equipment in Production Process
Equipment Equipme Materials Operating Condition Phase state of Purpose

Name nt of stream
Code constructio Tin(˚ Tout(˚C Pin(ba Pout(ba Phase Phase
n C) ) r) r) in out
Preheater H-103 SS304 25 120 1.013 1.0132 Liquid Gas To vaporize
25 5 naphtha
Heater H-101 SS304 120 502 45.59 45.596 Gas Gas To heat the
62 2 gaseous naphtha
to required
reaction
temperature
Heater H-102 SS304 433 502 45.59 45.596 Gas Gas To increase
62 2 temperature of
naphtha
Reactor R-101 SS304 502 433 45.59 45.596 Gas Gas Dehydrogenatio
62 2 n reaction
Reactor R-102 SS304 502 496 45.59 45.596 Gas Gas Dehydrocyclizat
62 2 ion
Expander EX-100 SS304, 496 496 45.59 1.2159 Gas Gas To decrease
Cast Iron 62 pressure of
product
Cooler E-101 SS304, 496 78 1.215 1.2159 Gas Liquid Cold down the
Cooper, 9 gaseous product
Cooper- to liquid state
Nickel
Separator T-100 Lydall, HV 78 78 1.215 1.0132 Liquid Liquid To separate
fiberglass 9 5 and and liquid naphtha
gas gas and hydrogen
gas.
Compressor C-100 SS304, 120 120 1.013 45.596 Gas Gas To increase the
Cast Iron, 25 2 pressure of
Forged stream
steel
Pump P-101 Aluminium 25 25 0.709 1.0132 Liquid Liquid Pump naphtha
, Bronze, 28 5 from storage to
Nickel- preheater
alloy
Distillation D-100 SS304 38 Top- 1.013 1.0132 Liquid Liquid Separate off gas
column 82 25 5 and and and distillate
Botto gas gas from toluene
m-110
Condenser E-100 SS304, 82 25 1.013 1.0132 Gas Liquid Change the
Cooper, 25 5 and phase of
Brass, gas distillate to
Aluminium liquid phase and
reflux to
distillation
41
column
Reboiler RB-100 SS304 100 100 1.013 1.0132 Liquid Liquid Reflux the
25 5 and impurities into
gas distillation
column
Pump P-103 Aluminium 25 25 0.607 1.0103 Liquid Liquid Pump benzene
, Bronze, 95 5 and toluene
Nickel- composition
alloy back to
distillation
column.
2.2 Plant Wide Mass Balance
2.2.1 Material balance for reactor (R-101)
1.1.1 S6
1.1.18 S5 1.1.2 ṁTotal= 18412.99
1.1.19 ṁTotal= kg/hr
18412.99 kg/hr 1.1.3
1.1.20 (R-101) 1.1.4 xButane= 0.0011
1.1.21 xButane= 1.1.5 xIso-pentane=
0.0011 0.1169
1.1.22 xIso-pentane= 1.1.6 xN-pentane= 0.1330
0.1169 1.1.7 xCyclohexane=
1.1.23 xN-pentane= 0.0039
0.1330 1.1.8 xN-hexane= 0.0614
1.1.24 xCyclohexane= 1.1.9 xMethylcyclohexane=
0.0195 0.0043
1.1.10 xBenzene= 0.2690
1.1.11 xToluene= 0.3087
Figure 2.26 Block Flow Diagram for Reactor (R-101)
42
Table 2.8 : Input stream for reactor (R-101)
Mass Mass Molar

Mass Mole
Stream Components flowrate flowrate flowrate
fraction fraction
(kg/hr) (ton/hr) (kmol/hr)
Butane 20.25 0.02 0.0011 0.35 0.0016
Isopentane 2152.48 2.15 0.1169 29.83 0.1393
N-pentane 2448.93 2.45 0.1330 33.94 0.1585
Cyclohexane 359.05 0.36 0.0195 4.27 0.0199

Input
S5 N-hexane 5656.47 5.66 0.3072 65.64 0.3066
Methyl
1600.09 1.6 0.0869 16.30 0.0761
cyclohexane
Benzene 585.53 0.59 0.0318 7.50 0.0350
Toluene 552.39 0.55 0.0300 6.00 0.0280
Heptane 5037.80 5.04 0.2736 50.27 0.2348

Total
18412.99 18.42 1.0000 214.10 0.9998
Table 2.9: Output stream for reactor (R-101)

Mass Mass Molar
Mass Mole
Stream Component flowrate flowrate flowrate
fraction fraction
Butane 20.25 0.02 0.0011 0.35 0.0005
Isopentane 2152.48 2.15 0.1169 29.83 0.0465
N-pentane 2448.93 2.45 0.1330 33.94 0.0529
Cyclohexane 71.81 0.07 0.0039 0.85 0.0013
Output
N-hexane 1131.31 1.13 0.0614 13.13 0.0205
S6 Methyl
80.00 0.08 0.0043 0.81 0.0013
cyclohexane
Benzene 4953.52 4.95 0.2690 63.42 0.0988
Toluene 5684.55 5.68 0.3087 61.70 0.0962
Heptane 1007.57 1 0.0547 10.05 0.0157
Hydrogen 862.03 0.86 0.0468 427.59 0.6664
Total
18412.45 18.39 0.9998 641.67 1.0000
43
2.2.2 Material balance for reactor (R-102)
S7 S8
ṁTotal= 18412.45 kg/hr ṁTotal= 18412.86 kg/hr
(R-102)
xButane= 0.0011 xButane= 0.0011
xIso-pentane= 0.1169 xIso-pentane= 0.1169
xN-pentane= 0.1330 xN-pentane= 0.1330
xCyclohexane= 0.0039 xCyclohexane= 0.0039
xHexane= 0.0614 xHexane= 0.0000
xMethylcylohexane= 0.0043 xMethylcylohexane= 0.0043
xBenzene= 0.2690 xBenzene= 0.3247
xToluene= 0.3087 xToluene= 0.3590
xHeptane= 0.0547 xHeptane= 0.0000
xHydrogen =0.0468 xHydrogen =0.0570
Figure 2.27: Block Flow Diagram for Reactor (R-102)
44
Table 2.10: Input stream for reactor (R-102)
Mass Mass Molar
Mass Mole
Stream Component flowrate flowrate flowrate
fraction fraction
Butane 20.25 0.02 0.0011 0.35 0.0005
Isopentane 2152.48 2.15 0.1169 29.83 0.0465
N-pentane 2448.93 2.45 0.1330 33.94 0.0529
Cyclohexane 71.81 0.07 0.0039 0.85 0.0013
Input
N-hexane 1131.31 1.13 0.0614 13.13 0.0205
S7 Methyl
80.00 0.08 0.0043 0.81 0.0013
cyclohexane
Benzene 4953.52 4.95 0.2690 63.42 0.0988
Toluene 5684.55 5.68 0.3087 61.70 0.0962
Heptane 1007.57 1.00 0.0547 10.05 0.0157
Hydrogen 862.03 0.86 0.0468 427.59 0.6664
Total
18412.45 18.39 0.9998 641.67 1.0000

Molar
Mass Mass
Mass flowrate Mole
Stream Component flowrate flowrate
fraction (kmol/hr fraction
(kg/hr) (ton/hr)
)
Butane 20.25 0.02 0.0011 0.35 0.0005
Isopentane 2152.48 2.15 0.1169 29.83 0.0406
N-pentane 2448.93 2.45 0.1330 33.94 0.0462
Output Cyclohexane 71.81 0.07 0.0039 0.85 0.0012
N-hexane 0.00 0 0.0000 0.00 0.0000
S8 Methyl
80.00 0.08 0.0043 0.81 0.0011
cyclohexane
Benzene 5978.48 5.98 0.3247 76.54 0.1041
Toluene 6610.46 6.61 0.3590 71.74 0.0976
Heptane 0.00 0 0.0000 0.00 0.0000
Hydrogen 1050.45 1.05 0.0570 521.06 0.7088
Total
18412.86 18.41 1.0000 735.12 1.0000
1.1.1 Material balance for separator (T-100)
1.1.34 S11
1.1.35 ṁtotal=
1050.45kg/hr
1.1.36
1.1.37 xButane= 0.0000
S10 1.1.38 xIso-pentane=
ṁtotal= 18412.86 kg/hr 0.0000
1.1.39 xN-pentane= 45
xButane= 0.0011 0.0000
xIso-pentane= 0.1169 1.1.40 xCyclohexane=
xN-pentane= 0.1330 0.0000
xCyclohexane= 0.0039 1.1.41 xHexane= 0.0000
xHexane= 0.0000 1.1.42 xMethylcylohexane=
T-100
S12
ṁtotal= 17362.41 kg/hr
xButane= 0.0012
xIso-pentane= 0.1240
xN-pentane= 0.1410
xCyclohexane= 0.0041
xHexane= 0.0000
xMethylcylohexane= 0.0046
xBenzene= 0.3443
xToluene= 0.3807
xHeptane= 0.0000
xHydrogen =0.0000
Figure 2.28: Block Flow Diagram for Separator (T-100)
46
Table 2.12: Input stream for separator (T-100)
Mass
Mass flowrate Molar flowrate Mole
Stream Component flowrate Mass fraction
(ton/hr) (kmol/hr) fraction
(kg/hr)
Butane 20.25 0.02 0.0011 0.35 0.0005
Isopentane 2152.48 2.15 0.1169 29.83 0.0406
N-pentane 2448.93 2.45 0.1330 33.94 0.0462
Cyclohexane 71.81 0.07 0.0039 0.85 0.0012

Input
N-hexane 0.00 0 0.0000 0.00 0.0000
S10
Methyl
80.00 0.08 0.0043 0.81 0.0011
cyclohexane
Benzene 5978.48 5.98 0.3247 76.54 0.1041
Toluene 6610.46 6.61 0.3590 71.74 0.0976
Heptane 0.00 0 0.0000 0.00 0.0000
Hydrogen 1050.45 1.05 0.0570 521.06 0.7088
Total 18412.86 18.41 1.0000 735.12 1.0000
Table 2.13: Output stream for separator (T-100)

Mass Mass
Mass Molar flowrate Mole
fraction (kmol/hr) fraction
(kg/hr) (ton/hr)
Butane 0.00 0 0.0000 0.00 0.0000
Isopentane 0.00 0 0.0000 0.00 0.0000
N-pentane 0.00 0 0.0000 0.00 0.0000
Cyclohexane 0.00 0 0.0000 0.00 0.0000
N-hexane 0.00 0 0.0000 0.00 0.0000

Output S11 Methyl
0.00 0 0.0000 0.00 0.0000
cyclohexane
Benzene 0.00 0 0.0000 0.00 0.0000
Toluene 0.00 0 0.0000 0.00 0.0000
Heptane 0.00 0 0.0000 0.00 0.0000
Hydrogen 1050.45 1.05 1.0000 521.06 1.0000
Total 1050.45 1.05 1.0000 521.06 1.0000
Table 2.14: Output stream for separator (T-100)
Mass Mass
Mass Molar flowrate Mole
fraction (kmol/hr) fraction
(kg/hr) (ton/hr)
Butane 20.25 0.02 0.0012 0.35 0.0016
Output S12
Isopentane 2152.48 2.15 0.1240 29.83 0.1394
47
N-pentane 2448.93 2.45 0.1410 33.94 0.1586
Cyclohexane 71.81 0.07 0.0041 0.85 0.0040
N-hexane 0.00 0 0.0000 0.00 0.0000

Methyl
80.00 0.08 0.0046 0.81 0.0038
cyclohexane
Benzene 5978.48 5.98 0.3443 76.54 0.3576
Toluene 6610.46 6.61 0.3807 71.74 0.3351
Heptane 0.00 0 0.0000 0.00 0.0000
Hydrogen 0.00 0 0.0000 0.00 0.0000
Total 17362.41 17.36 1.0000 214.06 1.0000
48
2.2.4 Material balance for distillation column (D-100)
S14
ṁTotal= 10683.76 kg/hr
xButane= 0.0019
xN-pentane= 0.2292
S12 xCyclohexane= 0.0061
ṁTotal= 17362.41 kg/hr xHexane= 0.0000
xButane= 0.0012 xBenzene= 0.5539
xIso-pentane= 0.1240 xToluene= 0.0062
xN-pentane= 0.1410 xHeptane= 0.0000
xCyclohexane= 0.0041 D-100 xHydrogen =0.0000
xHexane= 0.0000
xBenzene= 0.3443
xToluene= 0.3807
xHeptane= 0.0000
xHydrogen =0.0000
S19
ṁ= 6684.56kg/hr
xButane= 0.0000
xN-pentane= 0.0000
xHexane= 0.0000
xBenzene= 0.0090
xToluene= 0.9800
xHeptane= 0.0000
xHydrogen =0.0000
Figure 2.29: Block Flow Diagram for Distillation Column (D-100)
Table 2.15:Input stream for distillation column (D-100)
49
Table 2.16: Output stream for distillation column (D-100)
50
Table 2.17: Output stream for distillation column (D-100)
51
2.2.5 Sample calculation
The amount of feed are calculated as below:
Amount of toluene produce = 52000 metric ton per year.

52000 metric ton per year
Amount of naphta feed =
35.55 %
= 146272.86 metric ton per year
146272.86 metric ton 1 year 1day 1000 kg
Feed flowrate of naphta = × × ×
year 331 days 24 hours metric ton
= 18412.10 kg/hr
Reaction occur in reactor (R-101)
Reaction 1
C6H12 C6H6 + 3H2

(Cyclohexane) (dehydrogenation) (Benzene + Hydrogen )
From the equation, it shows that 1 mole of cyclohexane will produce 1 mole of benzene and 3
mole of hydrogen.
The conversion of cyclohexane for dehydrogenation process is 80%
Benzene form
Benzene form ¿
initial molar flowrate of benzene feed x conversion x molecular weight of benzene
kmol g
= 4.2664 x 0.8 x 78.11
hr mol
= 266.60 kg/hr
Hydrogen form
kmol g
= 4.2664 x 0.8 x 3 x 2.601
hr mol
= 20.64 kg/h
Cyclohexane unreacted
kmol g
= 4.2664 x 0.2 x 84.16
hr mol
= 71.81 kg/hr
Total Reaction 1 = 266.60 + 20.64 + 71.81

= 359.05 kg/hr
Reaction 2
C6H14 C6H6 + 4H2

(N-hexane) (dehydrogenation) (Benzene + Hydrogen )
52
From the equation, it shows that 1 mole of N-hexane will produce 1 mole of benzene and 4
mole of hydrogen.
The conversion of N-hexane for dehydrogenation process is 80%.
Benzene form
= 65.6365 kmol/hr x 0.8 x 78.11
= 4101.49 kg/hr
Hydrogen form
= 65.6365 kmol/hr x 0.8 x 3 x 2.601
= 423.43 kg/hr
N-hexane unreacted
= 65.6365 kmol/hr x 0.2 x 86.18
= 1131.31 kg/hr
Total Reaction 2= 4101.49 + 423.43 + 1131.31

= 5656.24 kg/hr
Reaction 3
C7H14 C7H8 + 3H2

(Methylcyclohexane) (dehydrogenation) (Toluene + Hydrogen )
From the equation, it shows that 1 mole of methylcyclohexane will produce 1 mole of toluene
and 3 mole of hydrogen.
The conversion of methylcylohexane for dehydrogenation process is 95%.
Toluene form
= 16. 2967 kmol/hr x 0.95 x 92.14
= 1426.50 kg/hr
Hydrogen form
= 16. 2967 kmol/hr x 0.95 x 3 x 2.601
= 120.80 kg/hr
Methylcyclohexane unreacted
= 16. 2967 kmol/hr x 0.05 x 98.19
= 80.0 kg/hr
Total Reaction 3 = 1426.50 + 120.80 + 80.0

= 1627.3 kg/hr
53
Reaction 4
C7H16 C7H8 + 4H2

(Heptane) (dehydrogenation) (Toluene + Hydrogen )
From the equation, it shows that 1 mole of heptane will produce 1 mole of toluene and 4 mole
of hydrogen.
The conversion of heptane for dehydrogenation process is 80%.
Toluene form
= 50.2731 kmol/hr x 0.80 x 92.14
= 3705.73 kg/hr
Hydrogen form
= 50.2731 kmol/hr x 0.80 x 3 x 2.601
= 324.32 kg/hr
Heptane unreacted
= 50.2731 kmol/hr x 0.2 x 100.21
= 1007.57 kg/hr
Total Reaction 4 = 3705.73 + 324.32 + 1007.57

= 5037.62 kg/hr
Total mass flowrate for S4
= 359.05 +5656.24+1627.3+5037.62
= 18412.99 kg/hr
54
2.3 Energy Balance of The Process Plant for Each Individual Unit
1.1.2 Pump (P-101)
P-101
Figure 2.30: Block Flow Diagram for Pump (P-101)
55
Table 2.18: Input-output stream for pump (P-101)
Stream Component Mass Molar Work done Temperature Presssure

flowrate flowrate (kJ/hr) (ᴼC) (atm)
(kg/hr) (kmol/hr)
Input
S1 Butane 20.25 0.35 0 25 0.7
Isopentane 2152.48 28.83 0 25 0.7
N-pentane 2448.93 33.94 0 25 0.7
Cyclohexane 359.05 4.27 0 25 0.7
N-hexane 5656.47 65.64 0 25 0.7
Methyl 1600.09 16.30 0 25 0.7
cyclohexane
Benzene 585.53 7.50 0 25 0.7
Toluene 552.39 6.00 0 25 0.7
Heptane 5037.80 50.27 0 25 0.7
Output
S2 Butane 20.25 0.35 1.0150 25 1
Isopentane 2152.48 28.83 102.83 25 1
N-pentane 2448.93 33.94 118.79 25 1
Cyclohexane 359.05 4.27 13.6640 25 1
N-hexane 5656.47 65.64 255.9960 25 1
Methyl 1600.09 16.30 63.57 25 1
cyclohexane
Benzene 585.53 7.50 20.25 25 1
Toluene 552.39 6.00 19.80 25 1
Heptane 5037.80 50.27 221.1880 25 1
Work done of each unit (kJ/hr) 817.1030
Power requirement of each unit (kW) 0.2270
Pump 101 (pressure from 0.7 atm to 1 atm)

Assumption
E K=E P
ΔH=0 (no temperature change)
Q=W
Work done for S2:

Butane (v), 25ᴼC, 0.7atm →A Butane (v) , 25ᴼC, 1 atm
Ẇ A = V
^ ΔP
0.008314 kJ
1L 58.12 kg mol . K
= x (1atm – 0.7atm) x x
0.601 kg 1000 mol atm
0.082057
mol . K
0.0029 kJ 0.35 kmol 1000 mol
= x x
mol hr 1 kmol
=1.0150 kJ/hr
A N-pentane (l) , 25ᴼC, 1 atm

n-pentane (l) , 25ᴼC, 0.7atm →
Ẇ A = V
^ ΔP
56
0.008314 kJ
1L 72.12 kg mol . K
= x (1atm – 0.7atm) x x
0.63 kg 1000 mol atm
0.082057
mol . K
0.0035 kJ 33.94 kmol 1000 mol
= x x
mol hr 1 kmol
= 118.79 kJ/hr
Cyclohexane (l) , 25ᴼC, 0.7atm →A Cyclohexane (l) , 25ᴼC, 1atm

Ẇ A = V
^ ΔP
0.008314 kJ
1L 84.16 kg mol . K
= x (1atm – 0.7atm) x x
0.779 kg 1000 mol atm
0.082057
mol . K
0.0032 kJ 4.27 kmol 1000 mol
= x x
mol hr 1 kmol
= 13.6640 kJ/hr
n-hexane (l) , 25ᴼC, 0.7atm →A n-hexane (l) , 25ᴼC, 1atm

Ẇ A = V
^ ΔP
0.008314 kJ
1L 84.17 kg mol . K
= x (1atm – 0.7atm) x x
0.659 kg 1000 mol atm
0.082057
mol . K
0.0039 kJ 65.64 kmol 1000 mol
= x x
mol hr 1 kmol
= 255.9960 kJ/hr
methylcyclohexane (l) , 25ᴼC, 0.7atm → A methylcyclohexane (l) , 25ᴼC, 1atm

Ẇ A = V
^ ΔP
0.008314 kJ
1L 98.189 kg mol . K
= x (1atm – 0.7atm) x x
0.769 kg 1000 mol atm
0.082057
mol . K
0.0039 kJ 16.30 kmol 1000 mol
= x x
mol hr 1 kmol
= 63.57 kJ/hr
Benzene (l) , 25ᴼC, 0.7atm →A Benzene (l), 25ᴼC, 1atm

Ẇ A = V
^ ΔP
0.008314 kJ
1L 78.11 kg mol . K
= x (1atm – 0.7atm) x x
0.879 kg 1000 mol atm
0.082057
mol . K
0.0027 kJ 7.50 kmol 1000 mol
= x x
mol hr 1 kmol
57
= 20.25 kJ/hr
Toluene (l), 25ᴼC, 0.7atm) →A Toluene (l) , 25ᴼC, 1atm

Ẇ A = V
^ ΔP
0.008314 kJ
1L 92.13 kg mol . K
= x (1atm – 0.7atm) x x
0.866 kg 1000 mol atm
0.082057
mol . K
0.0033 kJ 6 kmol 1000 mol
= x x
mol hr 1 kmol
= 19.80 kJ/hr
Heptane (l), 25ᴼC, 0.7atm →A Heptane (l), 25ᴼC, 1atm

Ẇ A = V
^ ΔP
0.008314 kJ
1L 100.20 kg mol . K
= x (1atm – 0.7atm) x x
0.684 kg 1000 mol atm
0.082057
mol . K
0.0044 kJ 50.27 kmol 1000 mol
= x x
mol hr 1 kmol
= 221.1880 kJ/hr
A iso-Pentane (l) , 25ᴼC, 1atm

iso-Pentane (l), 25ᴼC, 0.7atm) →
Ẇ A = V
^ ΔP
0.008314 kJ
1L 72.15 kg mol . K
= x (1atm – 0.7atm) x x
0.082057
mol . K
0.0035 kJ 29.38 kmol 1000 mol
= x x
mol hr 1 kmol
= 102.83 kJ/hr
Work done required for this equipment,

^
Ẇ =Σṅ W ^
out - Σṅ W ¿
^¿ = 0
W
=[0.35(1.0150)+33.94(118.79)+4.27(13.6640)+65.64(255.9960)+16.30(63.57)+7.50(20.25)+
6(19.80)+50.27(221.1880)+29.38(102.83)] – 0
=817.1030 kJ/hr
Hence power required

817.1030 kJ 1hr 1 kW
Q̇= x x
hr 3600 s 1kJ / s
= 0.2270 kW
58
1.1.3 Evoporator (EV-103)
1.36.1 S2
S3
1.36.2 ṁ2= 18412.99 kg/hr
ṁ2= 18412.99 kg/hr
1.36.3
1.36.4 xButane = 0.0011
xButane = 0.0011
1.36.5 xIso-pentane =
xIso-pentane = 0.1169
0.1169
xN-pentane = 0.1330
1.36.6 xN-pentane = 0.1330
1.36.7 xCyclohexane=
xN-hexane= 0.3072
0.0195 (EV-103) xMethylcyclohexane= 0.0869
1.36.8 xN-hexane= 0.3072
xBenzene = 0.0318
1.36.9 xMethylcyclohexane=
xToluene = 0.0300
0.0869
xHeptane= 0.2736
1.36.10 xBenzene = 0.0318
1.36.11 xToluene = 0.0300
1.36.12 xHeptane= 0.2736
1.36.13
T = 120°C
1.36.14
P = 1 atm
1.36.15
1.36.16 T = 25°C
1.36.17 P = 1 atm
Figure 2.31: Block Flow Diagram for Evaporator (EV-103)
59
Table 2.19: : Input-output stream for preheater (EV-103)
References: Methylcyclohexane (l, 25ºC, 1 atm), Toluene (l, 25ºC, 1 atm), Benzene (l, 25ºC,
1 atm), Butane (v, 25ºC, 1 atm), N-pentane (l, 25ºC, 1 atm), Iso-pentane (l, 25ºC, 1 atm),
Cyclohexane (l, 25ºC, 1 atm), n-Hexane (l, 25ᴼC, 1 atm), Heptane (l, 25ᴼC, 1 atm)
Stream Component Mass Molar Enthalpy Temper Presssure

flowrate flowrate (kJ/mol) ature (atm)
(kg/hr) (kmol/hr) (ᴼC)
Input
S2 Butane 20.25 0.35 0 25 1
Isopentane 2152.48 28.83 0 25 1
N-pentane 2448.93 33.94 0 25 1
Cyclohexane 359.05 4.27 0 25 1
N-hexane 5656.47 65.64 0 25 1
Methyl 1600.09 16.30 0 25 1
cyclohexane
Benzene 585.53 7.50 0 25 1
Toluene 552.39 6.00 0 25 1
Heptane 5037.80 50.27 0 25 1
Output
S3 Butane 20.25 0.35 10.6017 120 1
Isopentane 2152.48 28.83 38.4889 120 1
N-pentane 2448.93 33.94 39.4028 120 1
Cyclohexane 359.05 4.27 42.2830 120 1
N-hexane 5656.47 65.64 47.4777 120 1
Methyl 1600.09 16.30 49.0069 120 1
cyclohexane
Benzene 585.53 7.50 42.5243 120 1
Toluene 552.39 6.00 49.3499 120 1
Heptane 5037.80 50.27 39.7786 120 1
Heat duties for each unit (kJ/hr) 7827664.50
Power requirement for each unit (kW) 2174.3513
Preheater H-103 (temperature increase from 25ᴼC to 120ᴼC)

Assumption
Q-W S=H+ E K + E P
W S=0 (no moving point)
E K =0 (system in stationary)
E p =0 (no change in height)
Enthaply for S3:
Butane (v), 25ᴼC, 1 atm → A Butane (v), 120ᴼC, 1 atm
120ᴼC
ΔĤ A= ∫ C p dT
25 ᴼC
120ᴼC
= ∫ 92.13x10−3 + 27.88x10−5 T + (-15.47x10−8 T 2) + 34.98 x 10−12 T 3
25 ᴼC
= 12.9955-2.3938
= 10.6017 kJ/mol
60
A n-Pentane (l) , 36.1ᴼC, 1 atm B n-Pentane (v), 36.1ᴼC, 1 atmC n-
n-Pentane (l), 25ᴼC, 1 atm → → →
Pentane (v), 120ᴼC, 1atm
36.1
ΔĤ A= ∫ C p dT
25
36.1
= ∫ 155.4 x 10−3 + 43.68 x 10−5
25
= 5.8946-4.0215
= 1.8731 kJ/mol
ΔĤ B= Δ H v = 25.77 kJ/mol
120
Δ Ĥ c= ∫ C p dT
36.1
120
= ∫ 114.8x 10−3 + 34.09 x 10−5T + (-18.99 x 10−8 T 2) + 42.26 x 10−12 T 3
36.1
= 16.1232 – 4.36345
= 11.7597 kJ/mol
Δ Ĥ total= 11.7597 + 25.77 + 1.8731

= 39.4028 kJ/mol
A cyclohexane (l), 81ᴼC, 1 atm B cyclohexane (l), 81ᴼC, 1 atm

cyclohexane (l), 25ᴼC, 1 atm → →
C cyclohexane (v), 120ᴼC, 1 atm
→
81
ΔĤ A= ∫ C p dT
25
81
= ∫ 94.140x 10−3 + 49.64 x 10−5 T + (-31.90 x 10−8 T 2) + 80.63 x 10−12 T 3

25
= 9.1975 – 2.5069
= 6.6906 kJ/mol
120
ΔĤ C= ∫ C p dT
81
120
= ∫ 94.140x 10−3 + 49.64 x 10−5 T + (-31.90 x 10−8 T 2) + 80.63 x 10−12 T 3

81
=14.6899-9.1975
=5.4924 kJ/mol
Δ Ĥ total= 6.6906 + 30.1 + 5.4924
= 42.2830 kJ/mol
A n-hexane (l), 68ᴼC, 1 atm B n-hexane (v), 68ᴼC, 1 atm C n-

n-hexane (l), 25ᴼC, 1 atm → → →
hexane (v), 120ᴼC, 1 atm
68
ΔĤ A= ∫ C p dT
25
68
= ∫ 216.3x 10−3 T
25
61
= 14.7084-5.4075
= 9.3009 kJ/mol
120
ΔĤ C= ∫ C p dT
68
120
= ∫ 137.44x 10−3 + 46.85 x 10−5 T + (-23.92 x 10−8 T 2) + 57.66 x 10−12 T 3
68
= 19.7312-10.4043
= 9.3268 kJ/mol
Δ Ĥ total= 9.3009 + 28.85 + 9.3268
= 47.4777 kJ/mol
A methylcyclohexane (l), 101ᴼC, 1 atm B

methylcyclohexane (l), 25ᴼC, 1 atm → →
C
methylcyclohexane (v), 101ᴼC, 1 atm methylcylohexane (v), 120ᴼC, 1 atm
→
101
ΔĤ A= ∫ C p dT
25
101
= ∫ 121.3x 10−3 + 56.53 x 10−5 T + (-37.72 x 10−8 T 2) + 100.8 x 10−12 T 3

25
= 15.0077- 3.2072
= 11.8005 kJ/mol
120
ΔĤ c= ∫ C p dT
101
120
= ∫ 121.3x 10−3 + 56.53 x 10−5 T + (-37.72 x 10−8 T 2) + 100.8 x 10−12 T 3

101
= 18.4141 – 15.0077
= 3.4064 kJ/mol
Δ Ĥ total= 11.8005 + 33.8 + 3.4064
= 49.0069 kJ/mol
A Benzene (l), 80.1ᴼC, 1 atm B Benzene (v), 80ᴼC, 1 atm C

Benzene (l), 25ᴼC, 1 atm → → →
Benzene (v), 120ᴼC, 1 atm
80.1
ΔĤ A= ∫ C p dT
25
80.1
= ∫ 126.5x 10−3 + 23.4 x 10−5T

25
= 10.8833 – 3.2356
= 7.6477 kJ/mol
120
ΔĤ c= ∫ C p dT
80.1
120
= ∫ 74.06x 10−3 + 32.95 x 10−5T + (-25.20 x 10−8 T 2) + 77.57 x 10−12 T 3
80.1
62
= 11.1185 – 6.9469
= 4.1716 kJ/mol
Δ Ĥ total= 7.6477 + 30.705 + 4.1716

= 42.5243 kJ/mol
A Toluene (l), 110.6ᴼC, 1 atm B Toluene (v), 110.6ᴼC, 1 atm C

Toluene (l), 25ᴼC, 1 atm → → →
Toluene (v), 120ᴼC, 1 atm
110.6
ΔĤ A= ∫ C p dT
25
110.6
= ∫ 148.8x 10−3 + 32.4 x 10−5 T

25
= 18.4389 – 3.8213
= 14.6177 kJ/mol
120
ΔĤ c= ∫ C p dT
110.6
120
= ∫ 94.18x 10−3 + 38.00 x 10−5 T + (-27.86 x 10−8 T 2) + 80.33 x 10−12 T 3

110.6
= 13.8813 – 12.6178
= 1.2622 kJ/mol
Δ Ĥ total= 14.6177 + 33.47 + 1.2622
= 49.3499 kJ/mol
A Heptane (l), 98.42ᴼC, 1 atm B Heptane (v), 98.42ᴼC, 1 atm C

Heptane (l), 25ᴼC, 1 atm → → →
Heptane (v), 120ᴼC, 1 atm
98.42
ΔĤ A= ∫ C p dT
25
98.42
= ∫ 61.26x 10−3 + 34.41 x 10−5 T + (-18.26 x 10−8 T 2) + 25.47 x 10−12 T 3

25
= 7.6383 – 1.6381
= 6.002
120
ΔĤ C= ∫ C p dT
98.42
120
= ∫ 61.26x 10−3 + 34.41 x 10−5 T + (-18.26 x 10−8 T 2) + 25.47 x 10−12 T 3
98.42
= 9.7249 – 7.6383
= 2.0866 kJ/mol
Δ Ĥ total= 6.002 + 31.69 + 2.0866
= 39.7786 kJ/mol
A Isopentane (l), 27.8ᴼC, 1 atm B Isopentane (v), 27.8ᴼC, 1 atmC

Isopentane (l), 25ᴼC, 1 atm → → →
Isopentane (v), 120ᴼC, 1 atm
63
27.8
ΔĤ A= ∫ C p dT
25
27.8
= ∫ 155.4x 10−3 + 43.68 x 10−5T +
25
= 4.4889 – 4.0215
= 0.4674 kJ/mol
120
ΔĤ C= ∫ C p dT
27.8
120
= ∫ 114.8x 10−3 + 34.09 x 10−5T + (-18.99 x 10−8 T 2) + 42.26 x 10−12 T 3
27.8
= 16.1233 – 3.3218
= 12.8015 kJ/mol
Δ Ĥ total= 0.4674 + 25.22 + 12.8015
= 38.4889 kJ/mol
Heat duties for this equipment,

ΔH˙ =Σṅ ^
H out - Σṅ ^
H¿
H ¿= 0 because of reference state
^
=[0.35(12.9955) + 33.94(37.5297) + 4.27(35.5924) + 65.64(38.1768) + 16.30(37.2064) +
7.50(34.8766) + 6(34.7322) + 50.27(33.7766) + 29.38(38.0215)] –0
=7827.6645
7827.6645 kmol 1 kJ 1000 mol
= x x
hr 1mol 1 kmol
=7827664.50 kJ/hr
Hence power required,

7827664.50 kJ 1hr 1 kW
= x x
hr 3600 s 1kJ / s
=2174.3513 kW
2.3.1.3 Compressor (C-100)
S4
S3 ṁ4= 18412.99 kg/hr
ṁ3= 18412.99 kg/hr
xButane = 0.0011
xButane = 0.0011 xIso-pentane = 0.1169
xIso-pentane = 0.1169 xN-pentane = 0.1330
xN-pentane = 0.1330 (C-100) xCyclohexane= 0.0195
xCyclohexane= 0.0195 xN-hexane= 0.3072
xN-hexane= 0.3072 xMethylcyclohexane= 0.0869
xMethylcyclohexane= 0.0869 xBenzene = 0.0318
xBenzene = 0.0318 xToluene = 0.0300
xToluene = 0.0300 xHeptane= 0.2736
xHeptane= 0.2736
T = 120°C
T = 120°C P = 45 atm
P = 1 atm
Figure 2.32: Block Flow Diagram for Compressor (C-100)

64
Table 2.20: Input-output stream for compressor(C-100)
Reference state: Methylcyclohexane (g, 120 ºC, 45 atm), Toluene (g, 120 ºC, 45 atm),
Benzene (g, 120ºC, 45 atm), Butane (g, 120 ºC, 45 atm), N-pentane (g, 120 ºC, 45 atm), Iso-
pentane (g, 120 ºC, 45 atm), Cyclohexane (g, 120 ºC, 45 atm)
Stream Component Mass Molar Workdone Temperatu Presssure

flowrate flowrate (kJ/hr) re (atm)
(kg/hr) (kmol/hr) (ᴼC)
S3 Butane 20.25 0.35 0 120 1
Isopentane 2152.48 28.83 0 120 1
N-pentane 2448.93 33.94 0 120 1
Cyclohexane 359.05 4.27 0 120 1
N-hexane 5656.47 65.64 0 120 1
Methyl 1600.09 16.30 0 120 1
cyclohexane
Benzene 585.53 7.50 0 120 1
Toluene 552.39 6.00 0 120 1
Heptane 5037.80 50.27 0 120 1
S4 Butane 20.25 0.35 150.8850 120 45
Isopentane 2152.48 28.83 17326.37 120 45
N-pentane 2448.93 33.94 2056.4320 120 45
Cyclohexane 359.05 4.27 38261.5560 120 45
N-hexane 5656.47 65.64 9277.96 120 45
Methyl 1600.09 16.30 2971.5 120 45
cyclohexane
Benzene 585.53 7.50 2845.80 120 45
Toluene 552.39 6.00 31745.5050 120 45
Heptane 5037.80 50.27 15245.2820 120 45
Work done for each unit (kJ/hr) 120984.7
Power requirement for each unit (kW) 33.6069
Compressor (C-100) (Pressure increase from 1atm to 45 atm)

Assumption
E K=E P
Q=W
Enthalpy for S4:

A Butane (v), 120ᴼC, 45 atm
Butane (v), 120ᴼC, 1atm →
WA = V^ ΔP
65
0.008314 kJ
1L 58.12 kg mol . K
= x (45atm – 1atm) x x
0.601 kg 1000 mol atm
0.082057
mol . K
0.4311 kJ 0.35 kmol 1000 mol
= x x
mol hr 1 kmol
= 150.8850 kJ/hr
A n-Pentane (v), 120ᴼC, 45 atm

n-Pentane (v), 120ᴼC, 1 atm →
WA = V^ ΔP
0.008314 kJ
1L 72.12 kg mol . K
0.082057
mol . K
0.5105 kJ 33.94 kmol 1000 mol
= x x
mol hr 1 kmol
=17326.37 kJ/hr
A cyclohexane (v), 120ᴼC, 45 atm

cyclohexane (v), 120ᴼC, 1 atm →
WA = V^ ΔP
0.008314 kJ
1L 84.16 kg mol . K
0.779 kg 1000 mol atm
0.082057
mol . K
0.4816 kJ 4.27 kmol 1000 mol
= x x
mol hr 1 kmol
= 2056.4320 kJ/hr
A n-hexane (v), 120ᴼC, 45 atm

n-hexane (v), 120ᴼC, 1 atm →
WA = V^ ΔP
0.008314 kJ
1L 84.17 kg mol . K
0.659 kg 1000 mol atm
0.082057
mol . K
0.5829 kJ 65.64 kmol 1000 mol
= x x
mol hr 1 kmol
= 38261.5560 kJ/hr
A methylcyclohexane (v), 120ᴼC, 45 atm

methycyclohexane (v), 120ᴼC, 1 atm →
WA = V
^ ΔP
0.008314 kJ
1L 98.189 kg mol . K
0.769 kg 1000 mol atm
0.082057
mol . K
0.5692 kJ 16.30 kmol 1000 mol
= x x
mol hr 1 kmol
66
= 9277.96 kJ/hr
A Benzene (v), 120ᴼC, 45 atm

Benzene (v), 120ᴼC, 1 atm →
WA = V
^ ΔP
0.008314 kJ
1L 78.11 kg mol . K
0.879 kg 1000 mol atm
0.082057
mol . K
0.3962 kJ 7.50 kmol 1000 mol
= x x
mol hr 1 kmol
= 2971.5 kJ/hr
A Toluene (v), 120ᴼC, 45 atm

Toluene (v), 120ᴼC, 1 atm →
WA = V^ ΔP
0.008314 kJ
1L 92.13 kg mol . K
0.866 kg 1000 mol atm
0.082057
mol . K
0.4743 kJ 6 kmol 1000 mol
= x x
mol hr 1 kmol
= 2845.80 kJ/hr
A Heptane (v), 120ᴼC, 45 atm

Heptane (v), 120ᴼC, 1 atm →
WA = V^ ΔP
0.008314 kJ
1L 100.20 kg mol . K
0.684 kg 1000 mol atm
0.082057
mol . K
0.6351 kJ 50.27 kmol 1000 mol
= x x
mol hr 1 kmol
= 31745.5050 kJ/hr
A Isopentane (v), 120ᴼC, 45 atm

Isopentane (v), 120ᴼC, 1 atm →
WA = V^ ΔP
0.008314 kJ
1L 72.15 kg mol . K
0.082057
mol . K
0.5189 kJ 29.38 kmol 1000 mol
= x x
mol hr 1 kmol
= 15245.2820 kJ/hr
Work done for this equipment,

^
ΔW=Σṅ W ^
out - Σṅ W ¿
67
The work inlet=0 because the value are being neglected
=[0.35(150.8850) + 33.94(17326.37) + 4.27(2056.4320) + 65.64(38261.5560) +
16.30(9277.96) + 7.50(2971.5) + 6(2845.80) + 50.27(31745.5050) + 29.38(15245.2820)] – 0
= 5342724.028 kJ/hr
=120984.7 kJ/hr

120984.7 kJ 1hr 1 kW
= x x
hr 3600 s 1kJ / s
=33.6069 kW
68
1.1.4 Heater (H-101)
S4 S5= 18412.99 kg/hr

ṁ4= 18412.99 kg/hr
(H-101) xButane = 0.0011
xButane = 0.0011 xIso-pentane = 0.1169
xIso-pentane = 0.1169 xN-pentane = 0.1330
xN-pentane = 0.1330 xCyclohexane = 0.0195
xCyclohexane= 0.0195 xN-hexane = 0.3072
xN-hexane= 0.3072 xMethylcyclohexane = 0.0869
xMethylcyclohexane= 0.0869 xBenzene = 0.0318
xBenzene = 0.0318 xToluene = 0.0300
xToluene = 0.0300 xHeptane = 0.2736
xHeptane= 0.2736
T = 502°C
T = 120°C P = 45 atm
P = 45 atm
Figure 2.33: Block Flow Diagram for Heater (H-101)
69
Table 2.21: : Input-output stream for heater (H-101)
Stream Component Mass flow Mole flow Enthalpy Temperature Pressure

rate (kg/hr) rate (KJ/hr) (ºC) (atm)
(kmol/hr)
Input
S4 Butane 20.25 0.35 0 120 45
Isopentane 2152.48 29.83 0 120 45
N-pentane 2448.93 33.94 0 120 45
Cyclohexane 359.05 4.27 0 120 45
N-hexane 5656.47 65.64 0 120 45
Methyl 0 120 45
1600.09 16.30
cyclohexane
Benzene 585.53 7.50 0 120 45
Toluene 552.39 6.00 0 120 45
Heptane 5037.80 50.27 0 120 45
Output
S5 Butane 20.25 0.35 62.4997 502 45
Isopentane 2152.48 29.83 77.1235 502 45
N-pentane 2448.93 33.94 77.1235 502 45
Cyclohexane 359.05 4.27 82.9198 502 45
N-hexane 5656.47 65.64 99.1243 502 45
Methyl 99.4018 502 45
1600.09 16.30
cyclohexane
Benzene 585.53 7.50 58.1823 502 45
Toluene 552.39 6.00 70.8050 502 45
Heptane 5037.80 50.27 57.0893 502 45
Heat duties of each unit (kJ/hr) 17195.72 10 3
Power requirement of each unit （kW) 4764.43
Heater 101 (temperature from 120° C to 502° C )

Assumption
Q-WS=H+EK+EP
WS= 0 (no moving point)
EK= 0 (system in stationary)
EP= 0 (no change in height)
Enthalpy for S5
Butane
Butane (v), 120° C, 45 atm A Butane (v), 120° C, 1 atm B Butane (v), 502 ° C,1
atm
C
Butane (v), 502 ° C, 45 atm
70
kj
0.008314
^ A = 1 L × ( 1−45 ) atm × 58.12kg ×
∆H
mol . k
0.601 kg 1000 mol L atm
0.081057
mol . k
= -0.4311 KJ/mol
kj
0.008314
^ C = 1 L × ( 1−45 ) atm × 58.12 kg ×
∆H
mol . k
0.601 kg 1000 mol L atm
0.081057
mol . k
= 0.4311 KJ/mol
^ A =∆ H
Since −∆ H ^ C =0the calculation can be neglected.
502
∆H
^ B= ∫ Cp dT
120
= 75.4958-12.9961
= 62.4997 KJ/mol
^
∆ H butane =¿ 62.4997 KJ/mol
∆ H =∑ ṅ ^
H −∑ ṅ H
^
out ¿
= ∑ ṅ( ^
H out − H
^ ¿)
H ¿ = 0 because of reference state
^
= [0.35(62.4997)+29.83(77.1235)+33.94(77.1235)+4.27(82.9198)+65.64(99.1243)
+16.30(99.4018)+ 7.50(58.1823)+6.00(70.8050)+50.27(57.0893)] - 0
= 17151.95 x 103J/hr
17151.95 x 103 J hr kW
× ×
Q= hr 3600 s kj
s
= 4764.43 kW
71
1.1.5 Reactor (R-101)
S5= 18412.99 kg/hr S6= 18412.99 kg/hr

(R-101)
xButane = 0.0011 xButane = 0.0005
xIso-pentane= 0.1169 xIso-pentane = 0.0465
xN-pentane = 0.1330 xN-pentane = 0.0529
xCyclohexane= 0.0195 xCyclohexane = 0.0013
xN-hexane = 0.3072 xN-hexane = 0.0205
xMethylcyclohexane = 0.0869 xMethylcyclohexane = 0.0013
xBenzene = 0.0318 xBenzene = 0.0988
xToluene = 0.0300 xToluene = 0.0962
xHeptane = 0.2736 xHeptane = 0.0157
xHydrogen = 0.6664
T = 502°C
P = 45 atm T = 433°C
P = 45 atm
72
Table 2.22: Input-output stream for reactor (R-101)

rate (kg/hr) rate (KJ/mol) (ºC) (atm)
(kmol/hr)
Input
S5 Butane 20.25 0.35 -124.7 502 14.8
Isopentane 2152.48 29.83 -152 502 14.8
N-pentane 2448.93 33.94 -146.4 502 14.8
Cyclohexane 359.05 4.27 -123.1 502 14.8
N-hexane 5656.47 65.64 -107.2 502 14.8
Methyl -159.9 502 14.8
1600.09 16.30
cyclohexane
Benzene 585.53 7.50 82.93 502 14.8
Toluene 552.39 6.00 50 502 14.8
Heptane 5037.80 50.27 -187.2 502 14.8
Output
S6 Butane 20.25 0.35 -137.95 433 14.8
Isopentane 2152.48 29.83 -170.38 433 14.8
N-pentane 2448.93 33.94 -162.78 433 14.8
Cyclohexane 71.81 0.85 -141.37 433 14.8
N-hexane 1131.31 13.13 -186.63 433 14.8
Methyl -181.53 433 14.8
80.00 0.81
cyclohexane
Benzene 4953.52 63.42 -70.42 433 14.8
Toluene 5684.55 61.70 -34.88 433 14.8
Heptane 1007.57 10.05 -200.54 433 14.8
Hydrogen 862.03 427.59 11.86 433 14.8
Heat duties of each unit (kJ/hr) 30458.45x103
Power requirement of each unit 8460.68
（kW)
Reactor 101 (temperature from 502° C to 433° C )
Assumptions
Q-WS=H+EK+EP
Enthalpy for S6 (outlet)
Butane
433
=∆ H fButane+ ∫ Cpdt
502
433
= -124.7 + ∫ 92.3 x 10−3+ 27.88 x 10−5 T −15.47 x 10−8 T 2+34.98 x 10−12 T 3 dt
502
73
=-124.7 + (-13.254)
=-137.95 KJ/mol
N-pentane
433
=∆ H fN − pentane + ∫ Cp dt
502
433
= -146.4 + ∫ 114.8 x 10−3 +34.09 x 10−5 T −18.99 x 10−8 T 2 + 42.26 x 10−12 T 3 dt
502
=-146.4-16.38
=-162.78 KJ/mol
Isopentane
433
=∆ H fisopentane + ∫ Cp dt
502
433
= -152.0 + ∫ 114.8 x 10−3 +34.09 x 10−5 T −18.99 x 10−8 T 2 + 42.26 x 10−12 T 3 dt
502
=-152.0 -16.38
=-170.38 KJ/mol
74
Cyclohexane
433
=∆ H fcyclohexane + ∫ Cp dt
502
433
−3 −5 −8 2 −12 3
= -123.1+ ∫ 94.14 x 10 +49.62 x 10 T −31.90 x 10 T +80.63 x 10 T dt
502
=-123.1 -18.27
=-141.37 KJ/mol
Methylcyclohexane
433
=∆ H fmethylcyclohexane + ∫ Cp dt
502
433
−3 −5 −8 2 −12 3
=-159.9+ ∫ 121.3 x 10 +56.53 x 10 T −37.72 x 10 T + 100.8 x 10 T dt
502
=-159.9 -21.63
=-181.53 KJ/mol
N-hexane
433
=∆ H fN −hexane + ∫ Cp dt
502
433
−3 −5 −8 2 −12 3
=-167.2+ ∫ 137.44 x 10 + 40.85 x 10 T −23.92 x 10 T +57.66 x 10 T dt
502
=-167.2 -19.43
=-186.63 KJ/mol
Heptane
433
=∆ H fHeptane + ∫ Cp dt
502
433
=-187.8+ ∫ 61.26 x 10−3+ 34.41 x 10−5 T −18.26 x 10−8 T 2 +25.47 x 10−12 T 3 dt

502
=-187.8-12.74
=-200.54 KJ/mol
Toluene
433
=∆ H fToluene + ∫ Cp dt
502
433
=50+ ∫ 94.18 x 10−3+ 38 x 10−5 T −27.86 x 10−8 T 2+ 80.33 x 10−12 T 3 dt
502
=50-15.12
=34.88 KJ/mol
75
Benzene
433
=∆ H fBenzene+ ∫ Cp dt
502
433
=82.93+ ∫ 74.06 x 10−3+32.95 x 10−5 T −25.2 x 10−8 T 2 +77.57 x 10−12 T 3 dt
502
=82.93-12.5
=70.42 KJ/mol
Hydrogen
= by referring table B.8 (H2 , 433° C)
=11.86 KJ/mol
∆ H =∑ ṅ ^
H −∑ ṅ H
^
out ¿
= -1683.76 - (-32142.21)
= 30458.45 x 103 KJ/hr
30458.45 x 103 KJ hr kW
× ×
Q̇= hr 3600 s kj
s
= 8460.68 kW
76
1.1.6 Heater (H-102)
S6= 18412.99 kg/hr S7= 18412.45 kg/hr

xIso-pentane = 0.1169 xIso-pentane = 0.1169
xCyclohexane = 0.0039 xCyclohexane = 0.0039
xN-hexane= 0.0614 (H-102) xN-hexane= 0.0614
xBenzene= 0.2690 xBenzene= 0.2690
xHydrogen= 0.0468 xHydrogen= 0.0468
T = 433°C T = 502°C
P = 15 bar P = 45 atm
Figure 2.34 : Block Flow Diagram for Heater (H-102)
77
Table 2.23: : Input-output stream for heater (H-102)
Benzene (g, 496 ºC, 45 atm), Butane (g, 496 ºC, 45 atm), N-pentane (g, 496 ºC, 45 atm), Iso-
(kmol/hr)
Input
S6 Butane 20.25 0.35 0 433 45
Isopentane 2152.48 29.83 0 433 45
N-pentane 2448.93 33.94 0 433 45
Cyclohexane 71.81 0.85 0 433 45
N-hexane 1131.31 13.13 0 433 45
Methyl 0 433 45
80.00 0.81
cyclohexane
Benzene 4953.52 63.42 0 433 45
Toluene 5684.55 61.70 0 433 45
Heptane 1007.57 10.05 0 433 45
Hydrogen 862.03 427.59 11.8600 433 45
Output
S7 Butane 20.25 0.35 13.2729 502 45
Isopentane 2152.48 29.83 16.3484 502 45
N-pentane 2448.93 33.94 16.3484 502 45
Cyclohexane 71.81 0.85 18.2540 502 45
N-hexane 1131.31 13.13 21.3909 502 45
Methyl 21.6208 502 45
80.00 0.81
cyclohexane
Benzene 4953.52 63.42 12.4817 502 45
Toluene 5684.55 61.70 15.1167 502 45
Heptane 1007.57 10.05 12.7486 502 45
Hydrogen 862.03 427.59 13.8900 502 45
Heat duties of each unit (kJ/hr) 4081.49103
Power requirement of each unit (kWh) 1133.74
78
Heater 102 (temperature from 433° C to 502° C )
Assumption
Q-WS=H+EK+EP
Enthalpy for S7
Butane
Butane (v), 433° C, 45 atm A Butane (v), 433C, 1Batm Butane (v), 502 ° C,1
atm
C
Butane (v), 502 ° C, 45 atm
^ A =∆ H
Since −∆ H ^ C =0the calculation can be neglected.
502
∆H
^ B= ∫ Cp dT
433
= 75.4958-62.2229
= 13.2729 KJ/mol
^ butane =¿ 13.2729 KJ/mol
∆H
∆ H =∑ ṅ ^
H −∑ ṅ H
^
out ¿
= ∑ ṅ( ^
H out − H
^ ¿)
=9152.71 – 5071.22
=4081.49 x 103J/hr
4081.49 x 103 J hr kW
× ×
Q̇= hr 3600 s kj
s
= 1133.74 kW
79
1.1.7 Reactor (R-102)
S8= 18412.86 kg/hr

S7= 18412.45 kg/hr
xButane = 0.0011
xButane = 0.0011
xN-pentane = 0.1330
xN-pentane = 0.1330
xCyclohexane = 0.0039
xCyclohexane = 0.0039
(R-102) xN-hexane = 0.0000
xN-hexane = 0.0614
xMethylcyclohexane = 0.0043
xBenzene = 0.3247
xBenzene = 0.2690
xToluene = 0.3590
xToluene = 0.3087
xHeptane = 0.000
xHeptane = 0.0468
xHydrogen = 0.0570
xHydrogen = 0.0468
T = 496°C
T = 502°C
P = 14.8 atm
P = 14.8atm
Figure 2.35: Block Flow Diagram for Reactor (R-102)
80
Table 2.24: Input-output stream for reactor (R-102)
Reactor 102 (temperature from 502° C to 496° C )
Assumptions
Q-WS=H+EK+EP
81
Heat duties and power generated

∆ H =∑ ṅ ^H −∑ ṅ H
^
out ¿
= 16997.08-508.451
= 6488.63 x 103 KJ/hr
6488.63 x 103 KJ hr kW
× ×
Q̇= hr 3600 s kj
s
= 1802.40 kW
82
1.1.8 Cooler (E-101)
S8= 18412.45 kg/hr S9= 18412.45 kg/hr

xCyclohexane = 0.0039 (E-101) xCyclohexane = 0.0039
xHydrogen = 0.0468 xHydrogen = 0.0468
T = 496°C
P = 14.8atm T = 78°C
P = 4.94 atm
Figure 2.36: Block Flow Diagram for Cooler (E-101)
83
Table 2.25: Input-output stream for cooler (E-101)
(kmol/hr)
Input
S8 C4H10 20.25 0.35 0 496 14.8
Iso-C5H12 2152.48 29.83 0 496 14.8
N-C5H12 2448.93 33.94 0 496 14.8
C6H12 71.81 0.85 0 496 14.8
C6H14 0.00 0.00 0 496 14.8
C7H14 80.00 0.81 0 496 14.8
C6H6 5978.48 76.54 0 496 14.8
C7H8 6610.46 71.74 0 496 14.8
C7H16 0.00 0.00 0 496 14.8
H2 1050.45 521.06 13.71 496 14.8
Output
S9 C4H10 20.25 0.35 -88.69 78 4.94
Iso-C5H12 2152.48 29.83 -104.16 78 4.94
N-C5H12 2448.93 33.94 -104.70 78 4.94
C6H12 71.81 0.85 -117.28 78 4.94
C6H14 0.00 0.00 0.00 78 4.94
C7H14 80.00 0.81 -140.1 78 4.94
C6H6 5978.48 76.54 -92.52 78 4.94
C7H8 6610.46 71.74 -108.32 78 4.94
C7H16 0.00 0.00 0.00 78 4.94
H2 1050.45 521.06 1.53 78 4.94
Heat duties of each unit (kJ/hr) -28103.69 x 103
（kW)
Cooler E-101 (temperature from 496° C to 78° C )
Assumptions
Q-WS=H+EK+EP
Heat duties and power generated

∆ H =∑ ṅ ^H −∑ ṅ H
^
out ¿
= -28103.69 x 103 KJ/hr
−28103.69 x 103 KJ hr kW
× ×
Q̇= hr 3600 s kj
s
= 7806.58 kW
84
85
1.1.9 Expander (Ex-100)
S9= 18412.86 kg/hr S10= 18412.86 kg/hr

xN-hexane = 0.0000 (Ex-100) xN-hexane = 0.0000
T = 496°C T = 496°C
P = 45 atm P = 1.2 atm
Figure 2.37: Block Flow Diagram Expander (EX-100)
86
Table 2.26: Input-output stream for expander (Ex-100)
Stream Component Mass flow Mole flow Workdone Temperature Pressure

rate (kg/hr) rate (KJ/hr) (ºC) (atm)
(kmol/hr)
Input
S9 Butane 20.25 0.35 0 496 45
Isopentane 2152.48 29.83 0 496 45
N-pentane 2448.93 33.94 0 496 45
Cyclohexane 71.81 0.85 0 496 45
N-hexane 0.00 0.00 0 496 45
Methyl 0 496 45
80.00 0.81
cyclohexane
Benzene 5978.48 76.54 0 496 45
Toluene 6610.46 71.74 0 496 45
Heptane 0.00 0.00 0 496 45
Hydrogen 1050.45 521.06 0 496 45
Output
S10 Butane 20.25 0.35 150.15 496 1.2
Isopentane 2152.48 29.83 15392.28 496 1.2
N-pentane 2448.93 33.94 17241.52 496 1.2
Cyclohexane 71.81 0.85 407.15 496 1.2
N-hexane 0.00 0.00 0 496 1.2
Methyl 459.27 496 1.2
80.00 0.81
cyclohexane
Benzene 5978.48 76.54 30156.76 496 1.2
Toluene 6610.46 71.74 33861.28 496 1.2
Heptane 0.00 0.00 0 496 1.2
Hydrogen 1050.45 521.06 67216.70 496 1.2
（kW)
Expander 100 (pressure from 45 atm to 1.2 atm)

Assumption
E K=E P
Q=W
Work done for S2:

Butane (v), 496ᴼC, 45atm → A Butane (v) , 496ᴼC, 1.2atm
Ẇ A = V
^ ΔP
0.008314 kJ
1L 58.12 kg mol . K
= x (45atm – 1.2atm) x x
0.601 kg 1000 mol atm
0.082057
mol . K
87
0.4292 kJ 0.35 kmol 1000 mol
= x x
mol hr 1 kmol
=150.2061 kJ/hr
Work done required for this equipment,

^
Ẇ =Σṅ W ^
out - Σṅ W ¿
W ¿= 0
^
Ẇ =150.15+15392.28+17241.52+407.15+0+459.27+30156.76+33861.28+0+67216.70
=164885.15 kJ/hr

164885.15 kJ 1hr 1 kW
Q̇= x x
hr 3600 s 1kJ / s
= 48.50 kW
88
1.1.10 Separator (T-100)
S10= 18412.86 kg/hr S12= 18412.86 kg/hr

(T-100)
T = 496°C T = 496°C
P = 1.2 atm P = 1 atm
Figure 2.38: Block Flow Diagram for Seperator (T-100)
89
Table 2.27: Input-output stream for separator (T-100)
Stream Component Mass Mole flow Enthalpy Temperature Pressure

flow rate rate (KJ/mol) (ºC) (atm)
(kg/hr) (kmol/hr)
Input
S10 Butane 20.25 0.35 0 496 1.2
Isopentane 2152.48 29.83 0 496 1.2
N-pentane 2448.93 33.94 0 496 1.2
Cyclohexane 71.81 0.85 0 496 1.2
N-hexane 0.00 0.00 0 496 1.2
Methyl 0 496 1.2
80.00 0.81
cyclohexane
Benzene 5978.48 76.54 0 496 1.2
Toluene 6610.46 71.74 0 496 1.2
Heptane 0.00 0.00 0 496 1.2
Hydrogen 1050.45 521.06 0 496 1.2
Output
S12 Butane 20.25 0.35 -0.019 496 1
Isopentane 2152.48 29.83 -0.023 496 1
N-pentane 2448.93 33.94 -0.023 496 1
Cyclohexane 71.81 0.85 -0.021 496 1
N-hexane 0.00 0.00 -0.026 496 1
Methyl -0.025 496 1
80.00 0.81
cyclohexane
Benzene 5978.48 76.54 -0.0176 496 1
Toluene 6610.46 71.74 -0.021 496 1
Heptane 0.00 0.00 -0.029 496 1
Hydrogen 1050.45 521.06 -0.006 496 1
Heat duties of each unit (kJ/hr) -7490
Power requirement of each unit -2.08
（kW)
Separator T-100 (pressure from 1.2 atm to 1 atm)

Assumption
E K=E P
Q=W
90
Work done for S2:
Butane (v), 496ᴼC, 1.2atm → A Butane (v) , 496ᴼC, 1atm
Ẇ A = V
^ ΔP
0.008314 kJ
1L 58.12 kg mol . K
= x (1atm – 1.2atm) x x
0.601 kg 1000 mol atm
0.082057
mol . K
= −0.019 kJ/mol
Q=ΣnΔĤ
=(0.35)(-0.019)+(33.94)(-0.023)+(29.83)(0.023)+(0.85)(-0.021)+(0.81)(-0.025)+(-0.021)
(71.74)+(76.54)(-0.0176)+(521.06)(-0.006)
=-7490 kJ/hr

−7490 kJ 1hr 1 kW
Q̇= x x
hr 3600 s 1kJ / s
= -2.08 kW
91
1.1.11 Distillation column (D-100)
1.36.21 S14= 10683.76kg/hr

1.36.22 xButane = 0.0019
S12= 17362.41 kg/hr 1.36.23 xIsopentane = 0.2015
1.36.24 xN-pentane = 0.2292
xButane = 0.0012 1.36.25 xCyclohexane =
xIso-pentane = 0.1240 0.0061
xN-pentane = 0.1410 1.36.26 xN-hexane = 0.0000
xCyclohexane = 0.0041 D-100 1.36.27 xMethylcyclohexane
xN-hexane = 0.0000 = 0.0012
xMethylcyclohexane = 0.0046 1.36.28 xBenzene = 0.5539
xBenzene = 0.3443 S19= 6684.56kg/hr
xToluene = 0.0062
xToluene = 0.3807 xHeptane = 0.0000
xHeptane = 0.0000 xButaneT=70ᴼC
1.36.29 = 0.0000
xHydrogen = 0.0000 xIso-pentane = 0.0000
1.36.30 P=1 bar
xN-pentane = 0.0000
T = 38°C xCyclohexane = 0.0010
P = 1 bar xN-hexane = 0.0000
xBenzene = 0.0090
xToluene = 0.9800
xHeptane = 0.0000
T = 75°C
P = 15 bar
Figure 2.39: Block Flow Diagram for Distillation Column(D-100)
92
Distillation column (D-100)
Q T H7
E-100
H1
D-100
H3
H2
Hin
H6
QB
H5
H4
RB-100
Figure 2.40: Block Flow Diagram of Energy Balance for Distillation Column (D-100)
93
Stream 12 (Inlet) Stream 14 (Outlet) Stream 19 (Outlet)
Component Weight Component Weight Component Weight
percent (%) percent (%) percent (%)
C4H10 0.12 C4H10 0.19 C4H10 -
Iso-C5H12 14.1 Iso-C5H12 22.92 Iso-C5H12 -
N-C5H12 12.4 N-C5H12 20.15 N-C5H12 -
C6H12 0.41 C6H12 0.61 C6H12 0.1
C6H14 0 C6H14 - C6H14 -
C7H14 0.46 C7H14 0.12 C7H14 1
C6H6 34.43 C6H6 55.39 C6H6 0.9
C7H8 38.07 C7H8 0.62 C7H8 98
C7H16 0 C7H16 - C7H16 -
H2 0 H2 - H2 -
Table 2.28: : Input-output stream for distillation column (D-100)
Assumptions
Q-WS=H+EK+EP
QB = QT
Cp for every stream is calculated using formula

Cp stream=Cp ( component ) × weight percent (%)
Cp for stream 12 (inlet)

Cp stream 12=Cp ( component ) × weight percent (%)
Cp=[ 0.12 ( 1.675 ) +14.1 ( 0.16 ) +12.4 ( 0.12 ) +0.41 ( 0.105 ) +0.46 ( 0.135 ) +38.07 ( 0.158 ) +34.43 ( 0.135 ) ] ÷100
Cp stream 12 = 0.147 KJ/Kg.K
Cp for stream 14 (Outlet)

Cp=[0.19 ( 1.675 )+20.15 ( 0.16 )+ 22.92 ( 0.12 ) +0.61 ( 0.105 ) +0.12 ( 0.135 ) +0.62 ( 0.156 ) +55.39(0.135)]÷100
Cp for stream 19 (Outlet)

Cp=[0.1 ( 0.105 )+1 ( 0.135 ) +98 ( 0.158 )+ 0.9 ( 0.135 ) ]÷ 100
For Top Distillation Column,

L F
Reflux ratio= = H 3 =1.25
D FH 2
kg
F H 3=1.2(10682.76 )
h
F H 1=F H 2 + F H 3=24036.21
H1 can be calculated by using the formula

94
H 1=F H 1 [∑ Latent heat ∙ wt % ¿+(∆ T ∙ Cp)]¿
= 9439921.025 kg/hr
Enthalpy for H7 is equal to the heat of vaporization
^
H 7=H v Butane =−124.7 KJ /mol
KJ ˙ 0.35 x 103 mol
H 7=124.7 x
mol h
=43654 KJ/h
Hence
QT= H1-H2-H3-H7
=9439921.025 – 0 – 0 – 43645
9396276.025 KJ 1hr 1 kW
¿ × ×
h 3600 s 1 KJ /s
= 2610.08 kW
Hin can be calculated by using formula

H ¿ =F Hin ×Cp( ∆ T )
Hin=17362.41 x 0.147 (80-25)
= 140375.08 KJ/hr
H5 can be calculated using formula

H 5=F B ×[ ∑ ( L. wt % ) + ( ∆ T Cp ) ]
H5= (6684.56) [(0.158)(110-100)]
=6684.56(1.58)
= 10561.6048 KJ/hr
95
QB is determined from a balance over a complete system
Input = output
Since QB=QT+H2+H5-Hin
=9439921.025 + 0 + 10561.6048 – 140375.08
=9310107.55 KJ/hr
9310107.55 KJ 1 hr 1 kW
= × ×
hr 3600 s 1 KJ /s
=2568.14 kW
Since QB is supply by steam, hence steam required is calculated using latent heat of steam
Latent heat of steam = 2174 KJ/kg
9310107.55 KJ
Hence, steam required =
2174 KJ /kg
= 4282.48 kg/hr
QC is removed by cooling water, the maximum temperature rise of water after passing
through condenser is 30°C
QC= water flow x 30 x 4.2

9439421.025
Water flow=
4.2× 30
Hence,
QC = 74920 kg/hr
96
1.1.12 Pump (P-103)
S15= 18412.99 kg/hr S16= 18412.99 kg/hr

xCyclohexane= 0.0011 xCyclohexane= 0.0011
(P-103)
xMethylcyclohexane= 0.5003 xMethylcyclohexane= 0.5003
T = 25°C T = 25°C
P = 0.6 atm P = 1 atm
97
Table 2.29 : Input-output stream for pump (P-103)
Stream Component Mass Molar Work done Temperature Pressure

flowrate flowrate (kJ/hr) (ᴼC) (atm)
(kg/hr) (kmol/hr)
Input
S15 N-pentane 3365.67 46.51 0 25 0.6
Cyclohexane 81.46 0.97 0 25 0.6
Methylcycloh 16.02 0.16 0 25 0.6
exane
Benzene 7396.48 94.69 0 25 0.6
Toluene 108.16 1.17 0 25 0.6
isoPentane 3816.97 52.90 0 25 0.6
Output
S16 N-pentane 3365.67 46.51 215.7823 25 1
Cyclohexane 81.46 0.97 4.2471 25 1
Methylcycloh 16.02 0.16 0.8280 25 1
exane
Benzene 7396.48 94.69 341.0172 25 1
Toluene 108.16 1.17 5.0446 25 1
isoPentane 3816.97 52.90 249.4909 25 1
98
1.1.13 Pump (P-104)
S20= 18412.99 kg/hr S21= 18412.99 kg/hr

xCyclohexane= 0.0060 (P-104) xCyclohexane= 0.0060
xMethylcyclohexane= 0.0012 xMethylcyclohexane= 0.0012
T = 25°C T = 25°C
P = 0.6 atm P = 1 atm
99
Table 2.30: : Input-output stream for pump (P-104)
Stream Component Mass Molar Work Temperatur Presssure

flowrate flowrate done e (atm)
(kg/hr) (kmol/hr) (kJ/hr) (ᴼC)
Input
S20 N-pentane 2252.58 31.32 0 25 0.6
Cyclohexa 65.16 33.94 0 25 0.6
ne
Methylcycl 12.82 0.77 0 25 0.6
ohexane
Benzene 5917.18 0.13 0 25 0.6
Toluene 86.53 0.94 0 25 0.6
isoPentane 2448.49 75.75 0 25 0.6
Output
S21 N-pentane 2252.58 31.32 145.3086 25 1
Cyclohexa 65.16 33.94 1486.053 25 1
ne 6
Methylcycl 12.82 0.77 3.9846 25 1
ohexane
Benzene 5917.18 0.13 0.4682 25 1
Toluene 86.53 0.94 4.0592 25 1
isoPentane 2448.49 75.75 357.2578 25 1
1.4 Utilities and Waste Handling
2.4.1 Utilities
Table 2.31: Details of Utility

Stream S1 S2 S3 S4 S5 S6
Type of utility Fluid Electricity Electricity Compressed Air Fluid Fluid
Purpose of Purging Heating Compressing Heating Mixing Heating

utility
Phase state of Liquid Liquid Liquid Liquid Liquid Liquid
100
utility
Temperature 25 25 120 120 502 433
(ºC)
Pressure (atm) 0.7 1 1 45 45 45
Heating duties _ _ 2174.3513 33.6069 33.6069 8460.68

(kW)
Cooling duties _ _ _ _ _ _
(kW)
Stream S7 S8 S9 S12 S14 S15 S16 S19
Type of utility Fluid Fluid Fluid Compressed Air Steam Fluid Fluid Water
Purpose of utility Mixing Cooling Cooling Distillation Storage Purging Distillation Storage
Phase state of Liquid Liquid Liquid Liquid/Gas Gas Liquid Liquid Liquid
utility
Temperature(ºC) 502 496 78 38 70 25 25 75
Pressure (atm) 14.8 14.8 4.94 0.987 0.987 0.6 1 14.80
Heating duties _ 1802.4 _ 2610.08 2586.14 0.304 816.4101 _

(kW)
Cooling duties _ _ 7806.58 _ _ _ _ 0.2041
(kW)
1.1.14 Waste Handling
Table 2.32: Details of Waste Handling
Stream Number 11 14
Type of Waste Gas Heterogeneous

Temperature (°C) 38 70
Pressure (bar) 15 1
Mass Flowrate (kg/hr) 1050.45 10683.76
101
Mode of Waste handling For Storage. For Storage.
and disposal Store Hydrogen gas in a Store the heterogeneous
High-Pressure tank. waste in a closed tank.
This is further sold to These wastes consist about
market. 50% of Benzene.
This sold to a potential
buyer.
1.5 Calculation verification
In previous part, manual calculations for material balance and energy balance were
done and has been compared with result obtain from Aspen HYSYS simulation. Aspen
HYSYS is a software for simulation program for chemical plants and oil refineries. It is
important to compare manual calculation with Aspen HYSYS in order to achieve a satisfied
and comparable result, so that the process plant can operate in a proper manner.
In this verification, one reactor, one mass transfer equipment and one heat transfer
equipment. For reactor, reactor R-101 simulated in Aspen HYSYS and compare with manual
calculation. For mass transfer, the separator T-100 is used to compare with Aspen HYSYS
simulation and for heat transfer, the cooler E-101 is used to compare with Aspen HYSYS
102
data. The thermodynamic system used for this simulation was Peng-Robinson (PR)
(Wassenhove et al., 2006). The discrepancy value is calculated by:
Discrepancy = HYSYS Data – Manual Calculation Data
103
1.1.15 Reactor
Reactor R-101 simulated, dehydrogenation of light naphtha (Stream 5) which convert

low octane naphtha into higher reformate products (Stream 6). Block diagram for reactor R-
101 showed at Figure 2.18 and the data calculated by using Aspen HYSYS as attached.
Table2.27 shows the comparison between the results from HYSYS software versus the
manually calculate data. The discrepancy data have large value for the reactor because the
type of reactor used in Aspen HYSYS is not similar with our reactor which is plug flow
reactor and we use fixed bed reactor. The catalyst criteria used also quite different in term of
size and weight. Therefore, heat capacity value will be different because of different
resources.
Figure 2.43: Reactor
Manual Calculation for reactor R-101

Outlet Stream (6)
Mass flowrate, ṁcomponent-a = (mass fraction,xcompenent-a) X (total mass flowrate)
ṁbutane = 0.0011 x 18412.45 kg/hr = 20.25 kg/hr
ṁisopentane = 0.1169 x 18412.45 kg/hr= 2152.48 kg/hr
ṁn-pentane =0.1330 x 18412.45 kg/hr = 2448.93 kg/hr
ṁcyclohexane =71.81kg/hr ṁn-hexane= 1131.31kg/hr ṁmethylcyclohexane=80.00kg/hr
ṁbenzene =4953.52kg/hr ṁtoluene=5684.55kg/hr ṁheptane=1007.57kg/hr
ṁhydrogen =862.03kg/hr
Molar flowrate, ṅcomponent-a = (mass flowrate, ṁcomponent-a / molecular weight,Mr)
ṅbutane = 20.25kg/hr ÷ 58.12kg/kmol = 0.35 kmol/hr
ṅisopentane = 2152.48kg/hr ÷ 72.15 kg/kmol = 29.83 kmol/hr
ṅn-pentane = 2448.93 kg/hr ÷ 72.15 kg/mol = 33.94 kmol/hr
ṅcyclohexane = 0.85 kmol/hr ṅn-hexane =13.13 kmol/hr
ṅmethylcylohexane =0.81 kmol/hr ṅbenzene =63.42 kmol/hr ṅtoluene =61.70 kmol/hr
ṅheptane =10.05 kmol/hr ṅhydrogen = 427.59 kmol/hr
Total molar flowrate, ṅT = (ṅbutane + ṅisopentane + ṅn-pentane + ṅcyclohexane + ṅmethylcyclohexane + ṅtoluene +
ṅheptane + ṅbenzene + ṅheptane + ṅhydrogen)
ṅT = 0.35kmol/hr + 29.83 kmol/hr+ 33.94kmol/hr + 0.85kmol/hr +0.00kmol/hr + 0.81kmol/hr
+ 76.54kmol/hr + 71.74kmol/hr + 0.00kmol/hr + 521.06kmol/hr
ṅT =641. 67 kmol/hr
104
Table 2.33: Comparison of calculated data versus simulated data by HYSYS for reactor
R-101
Inlet
Manual
Stream 5 Calculation HYSYS Data Discrepancy
Data
Total Mass Flowrate (kg/hr) 18412.99 18414.27 1.28
Total Molar Flowrate 214.10 214.10 0.00

(kmol/hr)
Temperature (℃) 502.00 502.0 0.00
Pressure (bar) 15.00 15.0 0.00
Duties (kW) -51632.00 -2822.22 48809.78
Composition Butane 0.0016 0.0016 0.00

Mole
Isopentane 0.1393 0.1393 0.00
Fractions
N-pentane 0.1585 0.1585 0.00

Cyclohexane 0.0199 0.0199 0.00
N-hexane 0.3066 0.3067 0.0001
Methyl 0.0761 0.0761 0.00
cyclohexane
Benzene 0.0350 0.0350 0.00
Toluene 0.0280 0.0280 0.00
Heptane 0.2348 0.2348 0.00
Mass Isopentane 0.1169 0.1169 0.00
Fraction N-pentane 0.1330 0.1330 0.00
Cyclohexane 0.0195 0.0195 0.00
N-hexane 0.3072 0.3073 0.0001
Methyl 0.0869 0.0869 0.00
cyclohexane
Benzene 0.0318 0.0318 0.00
Toluene 0.0300 0.0300 0.00
Heptane 0.2736 0.2736 0.00
Outlet
Manual
105
Data
Total Mass Flow (kg/hr) 18412.45 18414.27 1.82
Total Molar 641.67 214.1 -427.57

Flowrate(kmol/hr)
Temperature (℃) 433.00 502.0 69.00
Pressure (bar) 15.00 15.0 0.00
Duties (kW) -75804 -2822.22 72981.78

Mole Fractions
Isopentane 0.0465 0.1393 0.0928
N-pentane 0.0529 0.1585 0.1056
Cyclohexane 0.0013 0.0199 0.0069
N-hexane 0.0205 0.3067 0.2862
Methyl 0.0013 0.0761 0.0748
cyclohexane
Benzene 0.0988 0.0350 -0.0638
Toluene 0.0962 0.0280 -0.0682
Heptane 0.0157 0.2348 0.2191
Hydrogen 0.6664 0.0000 -0.6664
Mass Fraction
Isopentane 0.1169 0.1169 0.00
N-pentane 0.1330 0.1330 0.00
Cyclohexane 0.0039 0.0195 0.0156
N-hexane 0.0614 0.3073 0.2459
Methyl 0.0043 0.0869 0.0826
cyclohexane
Benzene 0.2690 0.0318 -0.2372
Toluene 0.3087 0.0300 -0.2787
Heptane 0.0547 0.2736 0.2189
Hydrogen 0.0468 0.0000 -0.0468
1.1.16 Mass Transfer Equipment
The mass transfer equipment simulated was the separator, T-100, separating the
hydrogen gas (Stream 10) from liquid aromatic compound before entering distillation
column. Block diagram for separator T-100 showed at Figure 5.2 and the data calculated by
using Aspen HYSYS as attached. Table 5.2 shows the comparison between the results from
106
HYSYS software versus the manually calculated data. Large discrepancy obtained in duties
because of significance figure used in Microsoft Excel table for manual calculation.
Figure 2.44: Separator
107
separator T-100
Inlet
Manual
Data
Total Mass Flowrate (kg/hr) 18412.86 18422.40 9.54
Total Molar Flowrate 735.12 735.10 -0.02

(kmol/hr)
Temperature (℃) 38.00 38.00 0.00
Pressure (bar) 5.00 5.00 0.00
Duties (kW) -1340.10 -1340.56 -0.4600

Mole
Isopentane 0.0406 0.0406 0.00
Fractions
N-pentane 0.0462 0.0462 0.00

Cyclohexane 0.0012 0.0012 0.00
N-hexane 0.0000 0.0000 0.00
Methyl 0.0011 0.0011 0.00
cyclohexane
Benzene 0.1041 0.1041 0.00
Toluene 0.0976 0.0977 0.0001
Heptane 0.0000 0.0000 0.00
Hydrogen 0.7088 0.7088 0.00
Fractions N-pentane 0.1330 0.1330 0.00
Cyclohexane 0.0039 0.0039 0.00
N-hexane 0.0000 0.0000 0.00
Methyl 0.0043 0.0043 0.00
cyclohexane
Benzene 0.3247 0.3247 0.00
Toluene 0.3590 0.3590 0.00
Heptane 0.0000 0.0000 0.00
Hydrogen 0.0570 0.0570 0.00
108
Outlet
Manual
Data
Total Mass Flow (kg/hr) 17362.41 13705.41 -3657
Total Molar 214.06 165.6 -48.46

Flowrate(kmol/hr)
Temperature (℃) 38.00 38.00 0.00
Pressure (bar) 15.00 5.00 0.00
Duties (kW) -314.44 -316.11 -1.6700

Composition Butane 0.0016 0.0006 -0.001
Mole Fractions
Isopentane 0.1394 0.0806 -0.0588
N-pentane 0.1586 0.1036 -0.055
Cyclohexane 0.0040 0.0044 0.00
N-hexane 0.000 0.0000 0.00
Methyl 0.0038 0.0045 0.0007
cyclohexane
Benzene 0.3576 0.3939 0.0363
Toluene 0.3351 0.4107 0.0756
Heptane 0.0000 0.00
0.000
Composition Butane 0.0012 0.0004 -0.0008
Mass Fractions
Isopentane 0.1240 0.0703 -0.0537
N-pentane 0.1410 0.0903 -0.0507
Cyclohexane 0.0041 0.0045 0.0004
N-hexane 0.0000 0.0000 0.00
Methyl 0.0046 0.0053 0.0007
cyclohexane
Benzene 0.3443 0.3718 0.0275
Toluene 0.3807 0.4574 0.0767
Heptane 0.0000 0.0000 0.00
Manual
Data
Total Molar Flowrate(kmol/hr) 521.06 569.50 48.44
Temperature (℃) 38.00 38.00 0.00
109
Pressure (bar) 15.00 15.00 0.00
Duties (kW) -1023.42 -1024.44
Composition Hydrogen 1.0000 1.0000 0.00

Mole
Fractions
Composition Hydrogen 1.0000 1.0000 0.00

Mass
Fractions
110
1.1.17 Heat Transfer Equipment
Cooler, E-101 was the simulated heat transfer element. Function of this equipment is to
cool down the temperature of fluid produced in reactor R-102 from 496℃ to 78℃. Block
diagram for cooler E-101 showed at Figure 5.3 and the data calculated by using Aspen
HYSYS as attached. Table 5.3 shows the comparison between the results from HYSYS
software versus the manually calculated data. Heat duties have huge different value number
between manual calculation with Aspen HYSYS data may because of different heat capacity
value used in calculation from different resources.
Figure 2.45: Cooler
Table 2.35: Comparison of calculated data versus simulated data by HYSYS for cooler
E-101
Inlet
Manual
Data
Total Mass Flowrate (kg/hr) 18412.45 18412.40 -0.05
Total Molar Flowrate 735.12 735.12 0.00

(kmol/hr)
Temperature (℃) 496.00 496.00 0.00
Pressure (bar) 14.99 14.99 0.00
Duties (kW) -2799.34 6658.33

Mole
Isopentane 0.0406 0.0406 0.00
Fractions
N-pentane 0.0462 0.0462 0.00
111
Cyclohexane 0.0012 0.0012 0.00
N-hexane 0.0000 0.0000 0.00
Methyl 0.0011 0.0011 0.00
cyclohexane
Benzene 0.1041 0.1042 0.0001
Toluene 0.0976 0.0977 0.0001
Heptane 0.0000 0.0000 0.00
Hydrogen 0.6664 0.7086 0.0422
Fraction N-pentane 0.1330 0.1330 0.00
Cyclohexane 0.0039 0.0039 0.00
N-hexane 0.0614 0.0000 -0.0614
Methyl 0.0043 0.0043 0.00
cyclohexane
Benzene 0.2690 0.3247 0.0557
Toluene 0.3087 0.3590 0.0503
Heptane 0.0468 0.0000 -0.0468
Hydrogen 0.0468 0.0570 0.0102
Outlet
Manual
Data
Total Molar 735.12 735.10 -0.02

Flowrate(kmol/hr)
Temperature (℃) 78.00 78.00 0.00
Pressure (bar) 5.005 1.216 -3.789
Duties (kW) -154014.99 582.22 154597.21

Mole Fractions
Isopentane 0.0406 0.0406 0.00
N-pentane 0.0462 0.4620 0.4158
Cyclohexane 0.0012 0.0012 0.00
N-hexane 0.0000 0.0000 0.00
Methyl 0.0011 0.0011 0.00
cyclohexane
Benzene 0.1041 0.1042 0.0001
112
Toluene 0.0976 0.0000 -0.0976
Heptane 0.0000 0.0000 0.00
Hydrogen 0.6664 0.7086 0.0422
Mass Fraction
Isopentane 0.1169 0.1109 -0.006
N-pentane 0.1330 0.1330 0.00
Cyclohexane 0.0039 0.0039 0.00
N-hexane 0.0614 0.0000 -0.0614
Methyl 0.0043 0.0043 0.00
cyclohexane
Benzene 0.2690 0.3247 0.0557
Toluene 0.3087 0.3590 0.0503
Heptane 0.0468 0.0000 -0.0468
Hydrogen 0.0468 0.0570 0.0102
113
1.1.18 Reactor (R-101)
Figure 2.46: Design of Reactor 101
Figure 2.47: HYSYS data of reactor
114
Figure 2.48: Composition table of Reactor
115
1.1.19 Separator (T-100)
Figure 2.49: Design of Separator
Figure 2.50: HYSYS data of Separator
116
Figure 5.9 Composition
Figure 2.51: Composition in Separator
117
1.1.20 Cooler (E-100)
Figure 2.52: design of Cooler
Figure 2.53: Composition in Cooler
118
Figure 2.54: HYSYS data of Cooler
119
CHAPTER 3: SIZING CAPACITY
3.1 Mass Transfer Equipment Design
3.1.1 Oil-gas horizontal separator(T-100)
In the design of a horizontal separator the vessel diameter cannot be determined

independently of its length, unlike for a vertical separator. The diameter and length, and the
liquid level, must be chosen to give sufficient vapour residence time for the liquid droplets to
settle out, and for the required liquid hold-up time to be met. The most economical length to
diameter ratio will depend on the operating pressure (Chemical Engineering Design pg463).
As a general guide the following values can be used:
Operating pressure,bar Length: Diameter
0-20 3
20-35 4
More than 35 5
120
Since the operating pressure of oil and gas separator is at 1.2 atm which is similar to
1.215 bar which in the range of 0-20. Hence, the ratio of length to diameter used in
calculation will be 3
Table 3.1: Density and volumetric flow rate of inlet of separator
Component Mass flow Density(kg/m3) Volumetric flow rate (m3/h)
rate(kg/h)
Butane 20.25 2.48 8.17
Iso-Pentane 2152.48 616 3.98
N-pentane 2448.93 626 3.91
Cyclohexane 71.81 779 0.092
MCH 80.00 770 0.104
Benzene 5978.48 876 6.825
Toluene 6610.46 867 7.625
Hydrogen 1050.45 0.089 11802.81
3.1.1.1 Residence time for separation
From HYSYS,
Density of liquid =757.3 kg/m3
Density of hydrogen gas =0.089 kg/m3
0.5 0.5
ut =0.07 [ ( pl − pg ) / p g ] =0.07 [ (757.3−0.089 ) /0.089 ] =6.46 m/s
From Chemical Engineering Design, Fourth Edition, calculation to design a could start with
trying to assume the separator is without a demister pad,
ua =ut ×0.15=6.46 ×0.15=0.969 m/s
Vapour volumetric flow rate= 3.279 m3/s

The relationship between the area for vapour flow, A, and the height above the liquid level, h,
can been found from tables giving the dimensions of the segments of circles; see Perry and
Green (1984). For preliminary designs, set the liquid height at half the vessel diameter,
h =Dv/2 and fv D 0.5,
where fv is the fraction of the total cross-sectional area occupied by the vapour.
Since, h=0.5D and L/D=3
Fraction of the total cross section area occupied by vapour, fv = h/d=0.5
π D2 2
The cross-section area for vapour flow = × 0.5=0.393 D
4
3.279
Vapour velocity, u v = 2
=8.344 D −2
0.393 D
121
The vapour residence time required for droplets to settle to liquid surface, tr
h 0.5 D
t r= = =0.515 D
ua 0.969
The actual residence time, ta=vessel length/ vapour velocity
L 4D
t a= = =0.479 D 3
uv 8.344 D−2
3.1.1.2 Diameter of separator vessel
For satisfactory separation required,

Let tr=ta
Hence, 0.515D = 0.479D3
D = 1.037m
3.1.1.3 Hold-up time for separation
Liquid volumetric flow-rate = 8.528 ×10-3m3/s

π 1.0372 2
Liquid cross-section area = × 0.5=0.422m
4
Length of vessel, L= 3D = 1.037 ×3=3.111m
Hold-up volume, V = LA = 0.422 ×3.111=1.313 m 3
Hold-up time, th=hold-up volume/liquid flow rate = 1.313/ 8.528 ×10-3 = 153.963 s ≈ 3 min
This is unsatisfactory, 10 minutes minimum required (Coker, 2007).
Hence, it needs to increase the liquid volume. This is best done by increasing the vessel
diameter. If the liquid height is kept at half the vessel diameter, the diameter must be
increased by a factor of roughly
Factor of roughly.fr = (10/4)0.5 = 1.581
3.1.1.4 Calculation of new parameter for separator
Thus, the new dimeter, DN = 1.037 ×1.581=1.639m

New length, LN = 3DN = 4.917 m
π × 1.6392 3
New hold-up volume, V N = ×0.5 × 4.917=5.187 m
4
122
New residence time, tN = 5.187/8.528 ×10-3 = 608.232 s ≈ 11 min
3.1.1.5 Calculation of effective length of liquid for the separation occur
0.5
pg CD
Effective length of the liquid where separation occur, Leff¿
420 TZQ
D P [ ][( )
pl− p g 140 ]
Where,
T = operating temperature = 78˚C
Q = gas flow rate = 0.2918 kg/s
P = operating pressure = 14.696 psia
CD = drag coefficient = 0.851
Z = gas compressibility = 0.88
Pg = density of gas = 0.089 kg/m3
Pl = density of liquid = 757.31 kg/m3
0.5
420 78 × 0.88× 0.2918 0.089 0.851
Leff =
[
1.639 14.696 ] [( )
757.31−0.089 140 ] =0.295 m
123
Figure 3.1: The compressibility chart for hydrogen
The reduce pressure in separator , PR = 1.215-1.013 = 0.2

The reduce temperature in separator, TR = 1
The compressibility that found from chart =0.88
The diameter of common oil-gas horizontal separator used in industry is 4.13ft which is
similar to 1.3m (A. KayodeCoker, 1995). The different of the diameter between calculated
and theoretical is 0.3m, hence, it is still in a acceptable range. In addition, when the diameter
of the separator is different, it will result a different value of length of separator based on the
formula L=3D. The common length of oil-gas horizontal separator used in industry is 12.39ft
124
which is equal to 3.8m (A. KayodeCoker, 1995). The different of length of separator between
theoretical and calculated is only 1.1m it also in an acceptable range. The liquid height inside
the common oil-gas horizontal separator used in industry for an efficient separation process
to be occurring is 1.03ft which is similar to 0.3m. In manual calculation, the liquid height in a
separator is 0.295 which is close to the theoretical value.
Table 3.2: Standard Sulzer KnitMesh mist eliminator types
From the table above, type of materials that choose to be an eliminator for oil-gas separator
will be metal 4540 which will minimum the pressure drops of the separator.
125
Table 3.3: Sulzer Mellachevron mist eliminator styles
For the style of the eliminator, we should choose the complex profile- integrals drainage
channel as eliminator design. This is due to the reason it is suitable for horizontal flow and
have a high efficiency.
3.1.1.6 Mechanical design for oil-gas horizontal separator
1. Design Pressure
A vessel must be designed to withstand the maximum pressure to which it is likely to be
subjected in operation. For vessels under internal pressure, the design pressure is normally
126
taken as the pressure at which the relief device is set. This will normally be 5 to 10 per cent
above the normal working pressure, to avoid spurious operation during minor process upsets.
When deciding the design pressure, the hydrostatic pressure in the base of the column should
be added to the operating pressure.
Since operating pressure of the column = 1.1216 bar

Then, the design pressure will be 10% above the operating pressure
Hence, the design pressure = 1.1(1.216) = 1.338 bar
2. Design Temperature
The strength of metals decreases with increasing temperature so the maximum allowable
design stress will depend on the material temperature. The design temperature at which the
design stress is evaluated should be taken as the maximum working temperature of the
material. For design temperature there will be normally 10˚C will be added to the operating
temperature. The design temperature of vessel must not be least than the maximum fluid at
the design pressure.
Since operating temperature of the column = 78 ˚C

Then, design temperature there will be normally 10˚C above operating temperature.
Hence, design temperature = 78+10 =88˚C
3. Materials of construction
127
Figure 3.2: Typical design stresses for plate (R.K.SINNOTT, 2002)
Since the operation temperature for oil-gas horizontal separator is only operate at 88˚C which
is equal to 190˚F only that below the maximum temperature 900˚F which required for carbon
steel. Hence, it is suitable to use carbon steel for materials of construction of separation
vessel.
4. Corrosion Allowance
The “corrosion allowance” is the additional thickness of metal added to allow for material
lost by corrosion and erosion, or scaling. The allowance to be used should be agreed between
the customer and manufacturer. Corrosion is a complex phenomenon, and it is not possible to
give specific rules for the estimation of the corrosion allowance required for all
circumstances. The allowance should be based on experience with the material of
construction under similar service conditions to those for the proposed design. For carbon and
low-alloy steels, where severe corrosion is not expected, a minimum allowance of 2.0 mm
should be used.
Since the design temperature is only 88˚C which is equal to 190˚F, then carbon steel will be
selected as materials of construction. Carbon steel also have a corrosion resistance for the
chemical substance at 88 ˚C
128
5. Design of thickness of the wall of vessel
Figure 3.3: Minimum thickness for different vessel diameter (R.K.SINNOTT, 2002)
Since the vessel diameter calculated is 1.639 m which in the range of 1-2m. Hence, the
minimum thickness of the vessel wall is 7 mm. The value is included corrosion allowance;
hence, the minimum vessel is 5 mm only.
To calculate the minimum thickness of walled vessel under internal pressure,
P(D)
t=
2 S−P
Where,
t = The minimum thickness required
D= Diameter of vessel = 1.639m
S= Maximum allowable stress = 12900psi = 889.424 bar
P = internal pressure =1.216 bar
1.216(1.639)
t= =0.00121m=1.21 mm ≈ 2 mm
2 ( 889.424 )−1.216
Since the minimum wall thickness required based on internal pressure is only 2 mm, while
the minimum thickness required based on wall is 5mm. Then, the minimum thickness
required based is larger than the minimum wall thickness required based on internal pressure.
Hence, the 5mm of the wall thickness will be choose as the design of the thickness of wall for
separation vessel.
6. Design of Flat End and Domed End.
Figure 3.4: The maximum allowable join efficiency
129
Since a double-welded butt or equivalent of spot category is selected,
The join efficiency = 0.85
For flat end
CP
Minimum thickness of flat end, t f =D
√ SE
Where,
D = diameter of plate = diameter of vessel = 1.639 m (R.K.SINNOTT, 2002)
C = design constant = 0.17 (Flagged-only end is chosen)(R.K.SINNOTT, 2002)
S = maximum allowable stress =889.424 bar
E = joint efficiency = 0.85
P = internal pressure = 1.216
0.17 ×1.216
t f =1.639
√ 889.424 ×0.85
=0.027 m=27 mm
For design of domed end,

Hemispherical heads will be selected as domed end design. For equal stress in the cylindrical
section and hemispherical head of a vessel the thickness of the head need only be half that of
the cylinder. However, as the dilation of the two parts would then be different, discontinuity
stresses would be set up at the head and cylinder junction.
PD
Minimum thickness of domes end, t d=
4 SE−P
S = maximum allowable stress =5900 psi = 406.791 bar
1.216 ×1.639
t d= =1.442 ×10−3 m=1.44 mm ≈ 2 mm
4( 406.791× 0.85)−1.216
130
7. Torque analysis
Any horizontal force imposed on the vessel by ancillary equipment, the line of thrustof which
does not pass through the centre line of the vessel, will produce a torque on the vessel. Such
loads can arise through wind pressure on piping and other attachments. However, the torque
will normally be small and usually can be disregarded. The pipe work and the connections for
any ancillary equipment will be designed so as not to impose a significant load on the vessel.
Preliminary Specifications:
Height of vessel 3m
Diameter of vessel 1.639m
Hemispherical head 2mm
Thickness of vessel 5mm
Maximum allowable stress 88.943N/mm2
131
Joint efficiency 0.85
Materials density (carbon steel) 7850kg/m3
Maximum wind velocity 1280N/m2
Density of material insulation (Minerals 130kg/m3

wool)
Insulation thickness 75mm
For Dead Weight of Vessel,

W v =C w πpDg (H+ L)(t ×10−3 )
Where,
Wv = Total weight of shell
Cw = A factor to account for the weight of nozzles, manway, internal support (1.08 for vessel)
p = Density of materials = 7850kg/m3
D = Diameter of vessel = 1.639m
g = Gravitational acceleration = 9.81m/s2
t = Thickness of wall = 5mm
H = Height of vessel = 3m
L = Length of vessel = 4.917m
132
W v =1.08 × π × 7850× 1.639× 9.81 ( 3+4.917 ) ( 5 ×10−3 )=16952 N
Weight of insulation,
Minerals wool density = 130kg/m3
Approximate volume of insulator,Vi = π(DLt) = π × 1.639 ×0.075 × 4.917=1.899 m3
Weight of insulation = V i × pi × g=1.899 ×130 × 9.81=2421.79 N
The actual weight of insulation should double for fitting (R.K.SINNOTT, 2002)
Hence, actual weight of insulation = 2(2421.79) = 4843.58
Total weight of vessel,WV = weight of shell + weight of insulation = 16952+4844 = 21796N
For Wind Loading

Wind loading will only be important on tall columns installed in the open. Columns and
chimney-stacks are usually free standing, mounted on skirt supports, and not attached to
structural steel work. Under these conditions the vessel under wind loading acts as a
cantilever beam. Since the oil-gas separator design is in horizontal position. Therefore, wind
loading for oil-gas horizontal is not importance.
The dynamic wind pressure = 1280N/m2
Mean diameter of vessel including insulation = 1.639+2(0.005+0.075) =1.799m
Loading Fw= (dynamic wind pressure) (mean diameter) = (1280)(1.799) = 2302.72N/m
FW 2
Bending moment at bottom tangent line, M x = ×H
2
2302.72
M x= × 32=10326.24 Nm
2
For analysis of stress
At bottom tangent line
Pressure stresses:
PD
σ b=
2t
PD
σ L=
4t
Where,
σc = circumferential stress
σL = longitudinal stress
133
1.216 ×1.639
σ c= =199.30 N /m2
2 ×0.005
1.216 × 1.639
σ L= =99.65 N /m 2
4 ×0.005
Dead weight stress:

WV 21796 844024 N
σ w= = =
π ( D+t ) t π ( 1.639+0.005 ) 0.005 m2
Bending stresses:
M D
σ b=±
IV 2( )
+t
π
I V= ( D 40 −D 4i )
64
Where,
σb = Bending stress
M = Total bending moment = 10326.24 Nm
D = Di = Diameter of vessel = 1.639m
Do = D+2(t) = 1.639+2(0.005) = 1.649m
π
I V= ( 1.6494 −1.6394 ) =0.0087 m4
64
10326.24 1.639
σ b=±
0.0087 2 ( )
+ 0.005 =± 978618.95 N /m2
The resultant longitudinal stress is:

σ z=σ L−σ W ±σ b
For upwind, σ z=99.65−844024 +978618.95=+ 134694.60 N /m2
For downwind, σ z=99.65−844024−978618.95=−1822543.30 N / m2
134
For Checking Elastic Stability
Critical buckling stress:
( Dt )
σ c =2× 104
0.005
σ =2× 10 (
1.639 )
4 2 2
c =61.013 N /mm =61013000 N /m
The maximum compressive stress will occur when the vessel is not under pressure =
844024+978618 = 1822642.95N/m2, well below the critical buckling stress.
Hence, design is satisfactory. Could reduce the plate thickness and recalculate
8. Design of Skirt Supports
135
Figure 3.5: Standard steel saddles
Since, the diameter of oil-gas horizontal separator is 1.639 and the total weight of oil-gas
horizontal separator is 21796N = 21.80kN
Hence, the 1.8 diameter categories will be selected as saddles design for oil-gas horizontal
separator.
9. Nozzles design
The Harker equation (1978), modified for SI unit for optimum pipe and nozzles diameter.
W 0.45
For feed opening, D opt =8.41 0.31
p
Where,
p = Density of fluids = 757.4 kg/m3
W= Mass flow rate =18412.86 kg/hr
18412.860.45
D opt =8.41 =98.664 mm=3.898 inch
757.40.31
The nearest standard pipe which is larger than 4.898inch will be selected.
Hence, 8-inch Schedule number 160 steel pipe will be used to account for future
improvement in the side of production capacity as well as optimum wall thickness for the
process.
136
10. Reinforcement
The overall strength of vessel is slightly reduced by the opening and must be compensated
with reinforcement.
Reinforcement area, Ar =(D¿ ¿ opt+2 × corrosionallowance )× designthickness ¿
Where,
Dopt = 98.664mm
Design thickness = 5mm
Corrosion allowance = 2mm
Ar =( 98.664+ 2× 2 ) × 5=513.32 mm2
3.1.2 Distillation column (D-100)
Toluene recovery system is to separate light component such as benzene, butane, iso-pentane,
n-pentane, cyclohexane from heavy component toluene. The light component will be
recycled to the esterification tank. The toluene recovery system contains only one distillation
column.
137
Due to lack of separate parameter, the use of the McCabe-Thiele procedure could introduce
considerable inaccuracies because of the difficulty in the graphical evaluation. Hence, the
relations for separating multi components mixtures will be used with a number of
assumptions to minimize the calculation.
Assumption: The feed contains as benzene, butane, iso-pentane, n-pentane, cyclohexane,
methylcyclohexane, toluene. Heavy components are toluene and methylcyclohexane.
i. Distillate will be light component, which is benzene, butane, iso-pentane, n-pentane,

cyclohexane, since the highest boiling point component is benzene which contain a boiling
point at 82 °C then in order to eliminate the light component from our product, toluene, the
boiling point of benzene will be chosen as top distillation column operating temperature.
When the benzene is vaporise, al the other light component will also be distilled out from
distillation column.
ii. Bottom will be pure toluene
iii. The feed is distilled in distillation tower at 82°C and 101.325 kPa.
iv. The reflux ratio is 1.25
3.1.2.1 Relative volatility more volatile compound to less volatile component
Pa Xb
Relative volatility, α = ×
X a Pb
Pa = The vapor pressure of light component
Xa = The concentration fraction of light component in the feed
Pb= The vapor pressure of heavy component
Xb= The concentration fraction of heavy component in the feed
Pa 84.8 29.3 29.3 0.73 6.2 1
= + + + + + =10358.81
X a 0.002 0.12 0.14 0.004 0.005 0.35
X b 0.38
= =0.826
Pb 0.46
Pa Xb
α= × =10358.81× 0.826=8556.38
X a Pb
Thus, the relative volatility between light and heavy component is 8556.38
138
3.1.2.2 Minimum number of equilibrium stages
Fenske Underwood Gilliland method was be used for calculating minimum number of
equilibrium stages (R.K.SINNOTT, 2002).
X LK X
N min =
ln
[( ) ( ) ]
X HK
D × HK B
X LK
lnα
0.72
N min =
ln ([ 0.38 )10683.76 × ( 0.38
0.72 )
6684.56
] =3.997 stages ≈ 4 stages
ln 8556.38
3.1.2.3 Theoretical stage
Most columns are designed to operate between 1.2 and 1.5 times the minimum reflux ratio
because this is approximately the region of minimum operating cost (Douglas, 1988).
Therefore, based on first estimates, the operating reflux ratio for the analytically method is
equated as:
Reflux ratio, R=1.2 Rmin
1.25
Therefore, Rmin = =1.042
1.2
Actual theoretical stage could be determined by following equation,
N −N min R−Rmin
N +1
=0.75 1−
R+1( 0.566 )
N −4 1.25−1.042
N +1
=0.75 1− (
1.25+1
0.566 )
N=12.4 stages ≈ 13 stages
139
This is determined by taking the quotient of the number of theoretical trays to the tray
efficiency. Typical values for tray efficiency range from 0.5 to 0.7 (Douglas, 1988). These
values depend on the type of trays being used, as well as the internal liquid and vapor flow
rates. Hence, by assumed that the tray efficiency is 0.6 (taking the average), the actual
number of stages is calculated as follow:
N
N actual =
e
13
N actual = =21.667 stages ≈ 22 stages
0.6
3.1.2.4 Location of the feed in at distillation column
The location of the feed is obtained by using Kirkbride method.
2
( X LK ) B
N
log D =0.206 log
NB
B
D [( X HK
)( ) (
X LK F ( X HK ) D )]
2
N ( 0.02 ) B
log D =0.206 log
NB [(
6684.56
10683.76
0.72
)( ) (
0.38 F ( 0.005 )D )] =0.263
ND
=1.832
NB
Since NActual = ND+NB
Therefore, ND = 22stages- NB
22−N B
=1.832
NB
N B =7.768 stages ≈ 8 stages
Since the feed must flow in a height that higher than the bottom stage.
Hence, the feed will enter the column at 8 theoretical stage.
140
3.1.2.5 Diameter and Height of the distillation column.
1. Principles to design the diameter of distillation column (Ibrahim, 2014):
2. The length to diameter ratio should be less than 30, preferably below 20, and tower height
is to be limited to 60 meters because of wind load and foundation concerns. If the tower is
higher than 60 m, then a design with smaller tray spacing should be considered.
3. The ratio of tower diameter to random packing size is greater than 10.
4. The tower diameter should be maintained at 1.2 meters at the top for vapour
disengagement.
5. The tower diameter should be maintained at 2 meters at the bottom for liquid level and
reboiler return.
6. Either plate or packed towers may be used when the column diameter is between 1.5-4.5 ft
(or area, 1.77-15.9 ft2).
The equation most often used for the calculation of column diameter is based on the well
known empirically-correlated Souders and Brown equation:
0.5
K pL − p v
UV =U v =
3600 (
pv )
Where,
UV = Maximum allowable superficial vapour velocity

pL= Liquid density
pV = Vapour density
K = Entrainment-related factor
p L=0.98 ( 867 ) +0.01 (770 )+ 0.01 ( 779 ) =865.15 kg/m 3
pV =0.002 ( 2.48 )+ 0.2 ( 610 )+ 0.23 ( 626 )+ 0.005 (779 )+ 0.56 ( 876 ) +0.005 ( 867 )
a pV =764.47kg/m3
141
The main variables that affect the K factor include plate spacing, type of tray, physical
properties, liquid load, hole diameter and fractional hole area. Of such variables, plate
spacing is the most important. In general, the K factor rises with plate spacing, where it is
proportional to plate spacing to the power of 0.5 to 0.6. At low plate spacing (<38 cm) the
power maybe somewhat higher due to the proximity of the froth envelop or excessive
splashing from dispersion at the plate (Kister et al., 1992). For the calculation of the K factor
in terms of plate spacing, the following equation may be used:
K=3600(−0.171 T 2 +0.27 T −0.047 T )
Where,
T = plate spacing (typically 18-24 inch) = 0.5m (approximate 18 inch)
The overall height of the column will depend on the plate spacing. Plate spacings from0.15 m
(6 in.) to 1 m (36 in.) are normally used. The spacing chosen will depend on the column
diameter and operating conditions. Close spacing is used with small-diameter columns, and
where head room is restricted; as it will be when a column is installed in a building. For
columns above 1 m diameter, plate spacings of 0.3 to 0.6 m will normally be used, and 0.5 m
(18 in.) can be taken as an initial estimate. This would be revised, as necessary, when the
detailed plate design is made.(R.K.SINNOTT, 2002) (pg557).
K=3600 ( −0.171 ( 0.5 )2+ 0.27 ( 0.5 )−0.047 ( 0.5 ) )=162.9 m/s
0.5
162.9 865.15−764.47
UV =U v =
3600 ( 764.47 ) =0.016 m/s
From the calculated vapour velocity UV, the column diameter can then be calculated using
the following equation:
4V
D=
√ 3600 π pV U V
142
The diameter obtained in this solution, corresponding to the maximum allowable flow rate, is
the minimum acceptable diameter for operation with essentially no entrainment carryover
from plate to plate. Assumed the maximum allowable flow rate = 20000 kg/hr(based on inlet
flowrate of the distillation column=17362kg/hr).
4(20000)
D=
√ 3600 × π × 764.47 × ( 0.016 )
=0.759 m
For the hole size, small holes slightly enhance tray capacity when limited by entrainment
flood. Reducing sieve hole diameters from 13 to 5 mm (12 to 136 in) at a fixed hole area
typically enhances capacity by 3 to 8 percent, more at low liquid loads. Small holes are
effective for reducing entrainment and enhancing capacity in the spray regime (QL < 20
m3 /hm of weir). Hole diameter has only a small effect on pressure drop, tray efficiency, and
turndown. On the debit side, the plugging tendency increases exponentially as hole diameters
diminish. Smaller holes are also more prone to corrosion. While 5 mm (136 in) holes easily
plug even by scale and rust, 13 mm (12 in) holes are quite robust and are therefore very
common (Kister et al., 2008). The small holes are only used in clean, noncorrosive services.
Holes smaller than 5 mm are usually avoided because they require drilling (larger holes are
punched), which is much more expensive. For highly fouling services, 19- to 25-mm (34 to
1in) holes are preferred (Kister et al., 2008). Hence, in this distillation column design, the
hole sizes are assumed as 13 mm.
The tower height can be related to the number of trays in the column. The following formula
assumes that a spacing of two feet between trays will be sufficient including additional five to
ten feet at both ends of the tower. This includes a fifteen percent excess allowance of space.
Since the design spacing distance in the design is 0.45 m, thus the height of the tower is
calculated as follow:
H=[ ( N Actual ×tray space ) +both end ] × allowance space
143
The end of the distillation column is assuming as 1.5m while it also given 15% of allowance
space for the distillation column.
H= [ ( 22 ×0.5 )+(2 ×1.5) ] × 1.15=16.1 m
Ratio of height of column to diameter of column, r = H/D = 16.1/0.759 = 21.212
From principles to design the diameter of distillation column (Ibrahim, 2014), it states that,
the
length to diameter ratio should be less than 30 for a safety purpose. Meanwhile, the ratio of
height of column to diameter of column calculated is only 21.212. It is still in a safety range.
Hence, the diameter of column which is 0.759m and the height of column which is 16.1m is
stratified.
3.1.2.6 Plate Hydraulic Design
1. Liquid flow arrangement
In order to find the liquid flow arrangement, we should first find the maximum liquid
volumetric flow rate.
liquid mass flow rate
Volumetric flow rate=
3600 ×liquid density
Liquid mass flow rate = 17362kg/hr
Liquid density = 865.15kg/m3
17362
Volumetric flow rate= =0.006 m3 / s
3600 ×865.15
Since, the diameter of column is 0.758m and the volumetric flow rate is 0.006 m3 /s
Then, we could select flow arrangement base on chart which has been adapted from a similar
figure given by Huang and Hodson
144
Figure 3.6: Selection of liquid flow rate arrangement (R.K.SINNOTT, 2002) (pg569)
Based on the chart, we can conclude that the liquid flow rate arrangement flow in a cross-
flow pattern.
2. Plate areas
Ac = total column cross section area = π(D/2)2 = π (0.759/2)2 = 0.452m2

Ad = cross-section area of down-comer = 0.12 Ac = 0.0542 m2
An = net area available for vapour-liquid disengagement = Ac-Ad = 0.398 m2
Aa = active area = Ac-2Ad = 0.344 m2
Ah = hole area = 0.03(Aa) = 0.0103 m2
145
3. Flooding diameter velocity
The flooding velocity can be estimated from the correlation given by Fair (1961):
p L −p v
u f =K
√ pv
Where,
K is a constant
Uf = flooding vapour velocity
pL= Liquid density = 865.15 kg/m3
pV = Vapour density = 764.47 kg/m3
LW
F LV = √ pv / pL
VW
Where,
LW = liquid mass flowrate = 17362 kg/hr = 4.823 kg/s
Vw = vapour mass flow rate = 20.25 kg/hr = 0.005kg/s
4.822
F LV = √ 764.47/865.15=0.563
0.005
146
Figure 3.7: Flooding velocity, sieve plate (R.K.SINNOTT, 2002)(pg568)
From the figure above, K value is around 0.5
865.15−764.47
u f =0.5
√ 764.47
=0.181
4. Entrainment of plate
Entrainment can be estimated from the correlation given by Fair (1961), which gives the
fractional entrainment (kg/kg gross liquid flow) as a function of the liquid-vapour factor
FLV, with the percentage approach to flooding as a parameter. The percentage flooding is
given by:
u n 0.163
precentage of flooding= = =0.90
u f 0.181
147
Figure 3.8: Entrainment correction for sieve plate (Fair, 1961)
The effect of entrainment on plate efficiency which determine on figure above is 0.9
5. Hole size of plate
The hole sizes used vary from 2.5 to 12 mm; 5 mm is the preferred size. Larger holes are
occasionally used for fouling systems. The holes are drilled or punched. Punching is cheaper,
but the minimum size of hole that can be punched will depend on the plate thickness. For
carbon steel, hole sizes approximately equal to the plate thickness can be punched, but for
stainless steel the minimum hole size that can be punched is about twice the plate thickness.
Typical plate thicknesses used are: 5 mm (3/16 in.) for carbon steel, and 3 mm (12 gauge) for
stainless steel.
148
When punched plates are used, they should be installed with the direction of punching
upward. Punching forms, a slight nozzle, and reversing the plate will increase the pressure
drop.(R.K.SINNOTT, 2002)(pg573)
Hence, for our plate design, the diameter of hole will be 5mm and the thickness of plate is 5
mm.
6. Weep point of plate
The lower limit of the operating range occurs when liquid leakage through the plate holes
becomes excessive. This is known as the weep point. The vapour velocity at the weep point is
the minimum value for stable operation. The hole area must be chosen so that at the lowest
operating rate the vapour flow velocity is still well above the weep point.
Several correlations have been proposed for predicting the vapour velocity at the weep point;
see Chase (1967). That given by Eduljee (1959) is one of the simplest to use, and has been
shown to be reliable.
The minimum design vapour velocity is given by:
uh =
[ K 2−0.9 ( 25.4−d h ) ]
0.5
pV
Where,
Uh = minimum vapour velocity through the hole
Dh = hole diameter = 5mm
K2 = constant
Height of liquid crest over the weir could be determine by (Francis weir formula):
2
min liquid rate
h w =750 ( LW × p ) 3
17362×104.16
At maximum liquid rate = =39.818 kg/ s
3600
149
Minimum liquid rate at 70% turndown ratio = 0.7 × 398.18=27.872 kg /s
2
27.872
h ow=750 (
4.823 ×865.15
3
)
=26.6
2
39.818
h w =750 ( 4.823 ×865.15)3
=33.7
Hence, hw+how = 33.7+26.6 = 60.3
150
Figure 3.9: Weep-point correction (Eduljae,1959)
From the figure, K2 is equal to 30.4
uh =
[ 30.4−0.9 ( 25.4−0.005 ) ] =0.273
764.470.5
7. Number of holes
Area of one hole = π(D/2)2 = π (0.005/2)2 = 1.963 ×10−5
Ah 0.0103
No of hole = = =542.71holes ≈ 543 holes
area of one hole 1.963 ×10−5
151
3.1.2.7 Mechanical design for oil-gas horizontal separator
1. Design Pressure
A column must be designed to withstand the maximum pressure to which it is likely to be


Since.
Feed temperature of column = 78 ˚C
Operating temperature of the top column = 82 ˚C
Operating temperature of the bottom column = 110 ˚C
Hence, design temperature for top column= 82+10 =92˚C
Design temperature for top column= 110+10 =120˚C
152
Since the highest operation temperature for distillation column is only operate at 120˚C
which is equal to 248˚F only that below the maximum temperature 900˚F which required for
carbon steel. Hence, it is suitable to use carbon steel for materials of construction of
distillation column.
should be used.
153
5. Design of thickness of the wall of vessel
Figure 3.11: Minimum thickness for different column diameter (R.K.SINNOTT, 2002)
Since the vessel diameter calculated is 0.759 m which in the range of 1-2m. Hence, the
minimum thickness of the vessel wall is 5 mm. The value is included corrosion allowance;
hence, the minimum column is 3 mm only.
To calculate the minimum thickness of walled vessel under internal pressure,
P(D)
t=
2 S−P
Where,
t = The minimum thickness required
D= Diameter of vessel = 0.759 m
S= Maximum allowable stress = 12900psi = 889.424 bar
P = internal pressure =1.01325 bar
1.01325(0.759)
t= =0.00121 m=2.32 mm ≈ 3 mm
2 ( 889.424 )−1.01325
Since the minimum wall thickness required based on internal pressure is only 3 mm, while
the minimum thickness required based on wall is 5mm. Then, the minimum thickness
required based is larger than the minimum wall thickness required based on internal pressure.
Hence, the 5mm of the wall thickness will be choose as the design of the thickness of wall for
separation vessel.
6. Design of Flat End and Domed End.
154
Figure 3.12: The maximum allowable join efficiency
Since a double-welded butt or equivalent of spot category is selected,

The join efficiency = 0.85
For flat end
CP
Minimum thickness of flat end, t f =D
√ SE
Where,
C = design constant = 0.17 (Flagged-only end is chosen)(R.K.SINNOTT, 2002)
S = maximum allowable stress =889.424 bar
P = internal pressure = 1.01325 bar
0.17 ×1.01325
t f =0.759
√ 889.424 × 0.85
=0.015 m=15 mm
For design of domed end,

Hemispherical heads will be selected as domed end design. For equal stress in the cylindrical
section and hemispherical head of a vessel the thickness of the head need only be half that of
the cylinder. However, as the dilation of the two parts would then be different, discontinuity
stresses would be set up at the head and cylinder junction.
PD
Minimum thickness of domes end, t d=
4 SE−P
S = maximum allowable stress =5900 psi = 406.791 bar
155
1.01325 ×0.759
t d= =5.571× 10−3 m=5.57 mm ≈ 6 mm
4( 406.291× 0.85)−1.01325
7. Torque analysis
Any horizontal force imposed on the vessel by ancillary equipment, the line of thrustof which
does not pass through the centre line of the vessel, will produce a torque on the vessel. Such
loads can arise through wind pressure on piping and other attachments. However, the torque
will normally be small and usually can be disregarded. The pipe work and the connections for
any ancillary equipment will be designed so as not to impose a significant load on the vessel.
Preliminary Specifications:
Height of vessel 16.1m
Diameter of vessel 0.759m
Hemispherical head 6mm
Thickness of vessel 5mm
Maximum allowable stress 88.943N/mm2
Joint efficiency 0.85
156
Materials density (carbon steel) 7850kg/m3
Maximum wind velocity 1280N/m2
Density of material insulation (Minerals 130kg/m3

wool)
Insulation thickness 75mm
For Dead Weight of Vessel,

W v =C w πpDg( H+ 0.8 D)(t ×10−3 )
Where,
Wv = Total weight of shell
Cw = A factor to account for the weight of nozzles, manway, internal support (1.15 for
distillation column)
p = Density of materials = 7850kg/m3
g = Gravitational acceleration = 9.81m/s2
H = Height of vessel = 16.1m
W S=1.15 × π ×7850 ×0.759 × 9.81 ( 16.1+0.8 × 0.759 ) ( 5 × 10−3 )=17640.13 N
Weight of insulation,
Minerals wool density = 130kg/m3
157
Approximate volume of insulator, Vi = π(DLt) = π × 0.759 ×16.1 ×0.75=28.792m 3
Weight of insulation = V i × pi × g=28.792 ×130 × 9.81=36718.44 N
The actual weight of insulation should double for fitting (R.K.SINNOTT, 2002)
Hence, actual weight of insulation, WI = 2(36718.44) = 73436.88N
Weight of plate,
π 2 π 2 2
Plate area A P= × D = × 0.759 =0.45 m
4 4
Total weight of plate, WP = pg ( A p ×t P ) × N Actual
W P= pg ( A p ×t P ) × N Actual=7850× 9.81× ( 0.45 ×0.002 ) ×22=1524.77 N
Total weight of vessel, WV = WS + WI+WP = 17640.13+1524.77+73436.88 = 92605.78N

For Wind Loading
Wind loading will only be important on tall columns installed in the open. Columns and
chimney-stacks are usually free standing, mounted on skirt supports, and not attached to
structural steel work. Under these conditions the vessel under wind loading acts as a
cantilever beam. Since the distillation is in vertical position. Therefore, wind loading for
distillation is very importance for safety purpose.
The dynamic wind pressure = 1280N/m2
Mean diameter of vessel including insulation = 0.759+2(0.005+0.075) =0.919m
Loading Fw= (dynamic wind pressure) (mean diameter) = (1280) (0.919) = 1392.818N/m
FW 2
Bending moment at bottom tangent line, M x = ×H
2
1392.818
M x= × 16.12=180516.21 Nm
2
For analysis of stress

At bottom tangent line
Pressure stresses:
PD
σ b=
2t
PD
σ L=
4t
Where,
σc = circumferential stress
158
σL = longitudinal stress
P = internal pressure = 1.01325 bar
1.01325 ×0.759
σ c= =76.91 N /m 2
2 ×0.005
1.01325 × 0.759
σ L= =38.45 N /m2
2 × 0.005
Dead weight stress:

WV 92605.78
σ w= = =7716579 N /m2
π ( D+t ) t π ( 0.759+0.005 ) 0.005
Bending stresses:
M D
σ b=±
IV 2( )
+t
π
I V= ( D 40 −D 4i )
64
Where,
σb = Bending stress
M = Total bending moment = 180516.21 Nm
D = Di = Diameter of vessel = 0.759m
Do = D+2(t) = 0.759+2(0.005) = 0.769m
π
I V= ( 0.7694 −0.7594 )=0.0088 m 4
64
180516.21 0.759
σ b=±
0.0088 2 ( )
+0.005 =±7887327.59 N /m 2
The resultant longitudinal stress is:

σ z=σ L−σ W ±σ b
For upwind, σ z=38.45−7716579+7887327.59=+170787.04 N /m2
For downwind, σ z=38.45−7716579−7887327.59=−15603868.14 N /m 2
159
For Checking Elastic Stability
Critical buckling stress:
( Dt )
σ c =2× 104
0.005
σ =2× 10 (
0.759 )
4 2 2
c =131.75 N /mm =131762305 N /m
The maximum compressive stress will occur when the vessel is not under pressure =
7716579+7887327.59=15603829.69 N /m2, well below the critical buckling stress.
Hence, design is satisfactory. Could reduce the plate thickness and recalculate
8. Design of Skirt Supports
160
Figure 3.13: Standard steel saddles
Since, the diameter of distillation column is 0.759 which is close to 0.8 and the total weight
of distillation column is 92605.78N = 92.61kN
Hence, the 0.8 diameter categories will be selected as saddles design for distillation column.
9. Nozzles design
W 0.45
For feed opening, D opt =8.41
p 0.31
Where,
17362.410.45
D opt =8.41 =83.49 mm=3.287 inch
865.150.31
161
process.
10. Reinforcement
with reinforcement.
Where,
Dopt = 83.49mm
Design thickness = 5mm
Ar =( 83.49+2 ×2 ) ×5=437.47 mm2
3.1.3 Design of Condenser(E-100)
Assumption:
1. Plant standards require tubes of 20 mm o.d., 16.8 mm i.d., 4.88 m (16 ft) long, of
admiralty brass
2. The vapors are to be totally condensed and no sub-cooling is required
Heat transferred from vapour = 2610.08 kW

2610.08
Cooling water flow =
4.2 x 30
162
= 20.715 kg/s
Assumed overall coefficient from Table 12.1
Overall coefficient is taken additive
U = 3500(0.9800) + 2500(0.001+.009+.010)
= 3930 W/m2 ºC
T 1−T 2 82−30
R= = = 1.7333
t 2−t 1 55−25
t 2−t 1 55−25
S= = = 0.5263
T 1−t 1 82−25
Use horizontal exchanger, condensation in the shell, four tube passes. For one shell pass, four
tube passes.
1−S
F t=
2
√ ( R +1 ) ln [ 1−RS ]
( R−1 ) ln
[ 2−S ( R+ 1−√ R 2+ 1 )
2−S ( R +1+ √ R 2+1 ) ]
1−0.5263
√(1.73332 +1) ln ⁡( 1−( 0.5263 ×1.7333 )
)
F t=
(1.7333−1 ) ln ¿ ¿¿
= 0.7934
( T 1 −t2 ) −( T 2 −t 1 ) ( 82−55 ) −(30−25)
ΔTlm = T 1 −t 2 =
ln
[ ]T 2−t 1
ln
(82−55)
(30−25)
= 33.05 ºC
ΔTlm = 13.05 ×0.7934=26.22 ºC
9310107
Trial area = = 90.343 m2
(26.22)(3930)
Surface area of one tube = 31.2 x 10-3 π x 5 = 0.490 m2 (ignore tube sheet thickness)
90.343
Number of tubes = = 184
0.490
Use square pitch, Pt = 1.25 x 31.2 mm = 239 mm
1
184
Tube Bundle diameter Db = 31.2 ( 0.158 ) 2.263
= 706.422mm
Db 706.422
Number of tubes in centre row Nt = = =¿ 29, assume 30
Pt 25
163
3.1.3.1 Shell-side coefficient
Estimate tube wall temperature Tw: assume condensing coefficient of 3930 W/m2 ºC
82+30
Mean shell-side temperature = = 56 ºC
2
55+25
Mean tube-side temperature = = 40 ºC
2
(56 – Tw)3930 = (56 – 40) 3900
Tw = 40.12 ºC
56+40.12
Mean temperature condensate = = 48.06 ºC
2
Physical properties at 48.06 ºC
From HYSYS,
Condensate viscosity = 0.000601 Ns/m2
Condensate density = 876.334kg/m3
Condensate thermal conductivity = 0.1691 W/m ºC
Vapor density at mean vapor temperature
m
PV = RT
MW
101325 0.02107
pv = x = 0.7997 kg/m3
8.31447 (273+ 48.06)
Wc 2568.14 ×1
Ƭh = = = 7.9447 x 10-4 kg/s
ln t 3600× 4.88 ×184
2
Nr = x 30 = 20
3
1 /3
876.334 ( 876.334−0.7997 ) 9.81
hc = 0.95 x 0.1691 [
0.000601 ×7.9447 x 10−4 ] x 10-1/6
= 2744.230 Wm2 ºC
Correction to Tw is needed.
3930
T w= × 40.12=57.46 ºC
2744.230
164
3.1.3.2 Tube-side coefficient
π 184
Tube cross-sectional area = (0.0168)2 x = 0.0102 m2
4 4
Density of water, at 40 ºC = 992.2 kg/m3
20.705 1
Tube velocity = × = 0.0426 m/s
992.2 0.490
4200(1.35+ 0.02× 40)0.0426 0.8
hi = = 14411.30 W/m2 ºC
16.80.2
Fouling factors: as neither fluid is heavily fouling, use 6000 W/m2 ºC for each side
kw = 50 W/m2 ºC
3.1.3.3 Overall Coefficient
20
0.02 ln
1 1 1 16 20 1 20 1
= + + + × + ×
U 6280 6000 2 ×50 16 5000 16.8 14411.30
U = 1422.196 W/m2 ºC
Significantly lower than the assumed value of 3900 W/m2 ºC

Repeat calculation using new trail value of 1422.196 W/m2 ºC
9310107
Trial area = = 249.667 m2
26.22× 1422.196
249.667
0.49
1
509
Db = 32.1 (
0.158 ) 2.263
= 1107.48 mm
1107.48
Number of tubes in centre row Nt = =¿ 45
25
2534.1994 ×1
Ƭh = = 2.834 x 10-4 kg/s
3600× 4.88 ×509
2
Nr = x 45 = 30
3
165
1 /3
876.334 ( 876.334−0.7997 ) 9.81
hc = 0.95 x 0.1691
[ 0.000601× 2.834 x 10−4 ] x 30-1/6
= 3222.005 Wm2 ºC
3930
T w= × 40.12=48.94 ºC
3222.004
184
New tube velocity = 0.0426 × = 0.0154 m/s
509
4200(1.35+ 0.02× 40)0.0154 0.8
hi = = 182.23 W/m2 ºC
16.80.2
20
0.02 ln
1 1 1 16 20 1 20 1
= + + + × + ×
U 6280 6000 2 ×50 16 5000 16.8 182.23
U = 1399.148 W/m2 ºC
Close enough to estimate, firm up design
3.1.3.4 Shell-side pressure drop
Use pull-through floating head, no need for close clearance.

Select baffle spacing = shell diameter, 45 % cut.
From figure 12.10, clearance = 99 mm
Shell i.d. = 302.7845+99 = 401.7845 mm
Use Kern’s method to make an approximate estimate.
25−20
Cross-flow area As = x 401.7845 x 401.7845 x 10-6
25
= 0.0323 m2
Mass flow-rate, based on inlet condition
3068.0666 1
Mass velocity, Gs = × = 26.3852 kg/s m2
3600 0.0323
1.1
Equivalent diameter de = (252 – 0.917 x 202) = 14.201 mm
20
166
3.1.3.5 Calculation for number of tubes
From Table 12.3 of Coulson & Richardson’s Chemical Engineering, standard pipe was
chosen:
Internal diameter, di = 16 mm
Outside diameter, do = 20 mm
Length of pipe, L is assumed to be 4.88 m
From Perry Chemical Handbook 8th edition,
U = 750 W/m2 ºC
Provisional area
2610.08× 1000
A= = 105.3 m2
33.05× 750
Allowing for tube-sheet thickness, take
L = 4.83 m
Area of one tube = 4.83 x 20 x 10-3 π = 0.303 m2
Ratio of area of tube to area of space=0.4
( 105.3 ) 0.4
( 0.303 )
As the shell-side fluid is relatively clean use 1.25 triangular pitch.
1
Nt
Tube Bundle diameter, Db =Do
K1 ( ) n1
where
Nt = number of tubes,
Db = bundle diameter, mm,
Do = tube outside diameter, mm.
167
3.1.3.6 Calculation of Shell Diameter
Figure 3.14: Triangular pitch and Square pitch
K1 = 0.158 n1 = 2.268
1
139
Bundle diameter Db = 20( 0.249 ) 2.207
= 351 mm
By referring the Figure 12.10 from Coulson & Richardson’s Chemical Engineering Volume
6,
168
Figure 3.15: Shell-bundle clearance
Use a split-ring floating head type.

bundle diametrical clearance = 50 mm,
Shell diameter, Ds = 351 + 50 = 401 mm.
169
3.1.3.7 Mechanical design for condenser (E-100)
1. Design Pressure

Since.
Outlet temperature = 25 ˚C
Outlet temperature = 25+10 =35 ˚C
170
Since the highest operation temperature for distillation column is only operate at 82˚C which
steel. Hence, it is suitable to use carbon steel for materials of construction of condenser.
should be used.
171
chemical substance at 82 ˚C.
5. Shell and rube wall thickness
Shell Wall thickness:
Pi D i
e=
2 jf −P i
Where
e = tank thickness required at depth h L, mm.
ρi = design pressure, N/mm2
J = joint factor (if applicable)
f t = Design stress for tank material, N/mm2
Di = Shell diameter, mm.
Assuming joint factor = 0.85
1.01325(401)
e=
2× 0.85× 220−1.01325
= 1.089 mm
Corrosive allowance = 2mm
Minimum shell wall thickness = e + corrosion allowance
= 1.089 + 2
= 3.089 mm = 4mm
Tube wall thickness
1.01325(4830)
e=
2× 0.85× 220−1.01325
= 13.12 mm
Minimum tube wall thickness = 13.12 + 2
= 15.12 mm
9. Nozzles design
W 0.45
For feed opening, D opt =8.41 0.31
p
Where,
172
17362.410.45
D opt =8.41 =83.49 mm=3.287 inch
865.150.31
process.
10. Reinforcement
with reinforcement.
Where,
Dopt = 83.49mm
Design thickness = 4 mm
Ar =( 83.49+2 ×2 ) × 4=349.96 mm2
3.1.4 Design of Reboiler (Thermosyphons) (RB-100)
Assumption:
1. Density, viscosity, thermal conductivity and heat capacity of glucose and lactic acid is
not affected by temperature
Calculation:
1 shell pass, 2 tube passes
Select u-tube with 25 mm inner diameter, 30 mm outer diameter, 6.1 m long
Tube arrangement: square pattern
Assume U = 1500 W/ m2.°C
Heat transferred from vapour = 2568.14 kW = 9310107.55
Latent Heat of Steam = 2174KJ/kg
173
Boiling point at 90°C
Molecular weight = 78.114g/mol
Critical temperature = 562 K
Steam Saturation temperature 110°C
2568140
Stream required =
2174
= 1181.297 kg/s
Mean overall temperature = (110-90) = 20°C
(90+273)
Reduce temperature, T r= =0.646
562
174
Figure 3.17: Vertical thermosyphon design correction
From the chart above, design heat flux = 18000W/m2

6685.54 42000
Heat load= × =998.51 kW
3600 78.114
998.51× 1000
Arearequired= =55.47 m 2
18000
By assuming using 25mm i.d, 30mm o.d, 2.44m-long tubes.(R.K.SINNOTT, 2002)
(pg746)
Areaof one tubes=π × 0.025× 2.44=0.192 m2
55.7
No of tubes= =290tubes
0.192
Approximate diameter of bundle for 1.25 square pitch(R.K.SINNOTT, 2002)(pg746)
1
No of tube
Db =A [ K ] n
175
Since, the reboiler that we design is 2 passes reboiler and it flow in a square pitch pattern,
then, from the figure above, we could determine that K= 0.156 and n = 2.263
1
290
Db =55.47 [ 0.156 ] 2.263
=1544 mm
The shell diameter clearance for square pitch is 14mm (R.K.SINNOTT, 2002)(pg746)
Therefore, the shell inside diameter, D s =1544+14=1558 mm=1.588 m
The outlet diameter for pipe diameter is equal to total tube cross-section area
π
A p =290 ( 0.025 )2 × =0.142 m 2
4
D p= √ A p=√ 0.142=0.377 m
3.1.4.1 Tube-side pressure drop
Re= 615.6563
jf = 1.4 x 10-2
neglect viscosity correction term
6.1× 103
-2 995 ×0.01982
Δ Pt = 2 (8 x 1.4 x 10 ( ) + 2.5) ( )
25 2
= 11.6353 N/m2
= 0.0116 kPa
3.1.4.2 Shell-side pressure drop
Re= 814.2276
From Figure 12.30, jf = 5.3 x 10-2
10.7868
Linear velocity=
0.1145
= 94.2079 m/s
668.0816 6.1× 103 0.1145 ×94.2079 2
ΔPs= 8 x 5.3 x 10-2 x x x
21.3015 133.62 2
= 308456.3289 N/m2
= 308 kPa (too high)
176
3.1.4.3 Mechanical design for Reboiler (RB-100)
1. Design Pressure

Since.
Outlet temperature = 92 ˚C
Outlet temperature = 92+10 =102 ˚C
177
Since the highest operation temperature for distillation column is only operate at 82˚C which
steel. Hence, it is suitable to use carbon steel for materials of construction of reboiler.
should be used.
178
5. Shell and rube wall thickness
Shell Wall thickness:

Pi D i
e=
2 jf −P i
Where
e = tank thickness required at depth h L, mm.
ρi = design pressure, N/mm2
Di = Shell diameter, mm.
Assuming joint factor = 0.85
1.01325(1588)
e=
2× 0.85× 220−1.01325
= 4.314 mm
Corrosive allowance = 2mm
Minimum shell wall thickness = e + corrosion allowance
= 4.314 + 2
= 6.314 mm = 7mm
Tube wall thickness

1.01325(377)
e=
2× 0.85× 220−1.01325
= 1.024 mm
Minimum tube wall thickness = 1.024 + 2
= 3.024 mm
9. Nozzles design
179
W 0.45
For feed opening, D opt =8.41
p 0.31
Where,
p = Density of fluids = 867 kg/m3
W= Mass flow rate =6684 kg/hr
6684 0.45
D opt =8.41 =54.36 mm=2.14 inch
867 0.31
process.
10. Reinforcement
with reinforcement.
Where,
Dopt = 83.49mm
Design thickness = 7 mm
Ar =( 54.36+2 ×2 ) ×7=408.52 mm2
180
Table 3.4: Specification sheet of Distillation Column (D-100)
DISTILLATION COLUMN D-100
Identification : Item : Distillation Dat : 2/5/2019

Column e
: Item
No : D-100
: Lim Chee Hung

: No :1 By
required
Function: To separate Toluene from its liquid mixture
Operation: Continuous
Operating Data
181
Material Handled: Feed Distillate Bottom
Total amount(kg/hr) 17362.41 10683.76 6684.56
Composition(kg/hr)
Butane 20.25 20.25 0
Isopentane 2152.48 2152.48 0
N-pentane 2448.93 2448.93 6.68
Cyclohexane 71.81 65.14 0
Methylcyclohexane 80.00 13.15 66.84
182
Benzene 5978.48 5917.71 60.32
Toluene 6610.46 66.11 6550.72
Temperature(˚C) 78 82 110
Design Data
No. of Trays : 22 Recommended : 0.759

Column Diameter (m)
Feed stage (From bottom) :8

Reflux Ratio
Pressure (bar) : 1.01325 : 1.25

Tray Spacing (m)
Column Height (m) : 16.1 : 0.5

Materials of
Construction
: Carbon
steel AISI
183
Liquid Density (kg/m3) : 865.15 1080
Vapour Density (kg/m3) : 764.47
Maximum Vapor : 0.016

Flowrate (m3/s)
Utility: Cooling water, steam
Plate Specification
Liquid Flow : Cross-flow Plate Materials : Carbon steel

Arrangement AISI 1080
Plate Area(m2) :5
: 0.452 Plate thickness

2
Hole Area (m ) (mm) : 70
: 0.0103
No. of Hole Turndown ratio : 0.273
184
Flooding Diameter : 543 (%) : 0.9
Velocity
: 0.181 Weep point
Entrainment on
plate efficiency
Mechanical Design Data
Column Diameter (m) : 0.759 Total weight of : 92605.78

vessel (N)
Design Pressure (bar) : 1.115

Bending
Moment at bottom
tangent line (Nm)
Design Temperature : 92 : 180516.21

(˚C)
Critical
Buckling
:5 stress(N/m2)
Wall Thickness (mm)
:2 Reinforcement
Corrosion Allowance Area (mm2)
(mm)
185
Type of Domed Ends : 131762305
Domed End Thickness :

(mm) Hemispherical
:437.47
Flat End Thickness :6
(mm)
Insulation materials
: 15
: Mineral
wool
186
Table 3.5: Specification sheet of Oil-Gas Horizontal Separator (T-100)
OIL-GAS HORIZONTAL SEPERATOR T-100
Identification : Item : Oil-gas Date : 2/5/2019

Horizontal
Separator
: T-100
: Item By : Lim Chee Hung

No
:1
: No
required
Function: To separate Hydrogen from its liquid mixture
187
Operating Data
Material Handled: Feed Liquid Outlet Gas

(S12) Outlet (S11)
Total amount(kg/hr) 18412.86

17326.41 1050.45
Composition(kg/hr)
Butane 20.25
20.25 0
Isopentane 2152.48
2152.48 0
N-pentane 2448.93
2448.93 0
Cyclohexane 71.81
71.81 0
188
Methylcyclohexane 80.00 80.00 0
Benzene 5978.48 5978.48 0
Toluene 6610.46 6610.46 0
Hydrogen 1050.45 0
Design Data
Volumetric Flowrate : 3.279 Residence Time : 11

3
(m /s) (min)
: 1.2519 : 1.639
Pressure (bar) Diameter (m)
189
Column Height (m) : 4.917 Hold-up Volume : 5.187
Liquid Density (kg/m3) : 757.3 Effective length : 0.295

(m)
Vapour Density (kg/m3) : 0.089 : Carbon

Materials of steel AISI
Construction 1080
Vapour Velocity : 3.11
(m/s)
Design Pressure (bar) : 1.1216 Total weight of : 16952

vessel (N)
Design Temperature : 88
(˚C) Bending
Moment at bottom
190
Wall Thickness (mm) :5 tangent line (Nm) : 10326.24
Corrosion Allowance :2 Critical

(mm) Buckling
stress(N/m2)
Type of Domed Ends

Reinforcement
Area (mm2)
: : 61013000
Domed End Thickness Hemispherical
(mm)
:2
Flat End Thickness
(mm)
: 513.32
: 27
: Mineral
wool
191
Table 3.6: Specification sheet Condenser (E-100)
CONDENSER E-100
Identification : Item : Date : 2/5/2019

CONDENSER
: E-100

No :1
: No
required
Function: To condense the top product from distillation column from gas to liquid
phase
Type: Horizontal, with condensation in the shell, and the cooling medium in the tubes
Heat Duty: 2610.08kW
192
Overall Coefficient: 3930 W/m2 ºC
Tube side
Fluid Handled : Product Length(mm) : 4830

from D-100
No of Tube : 139
: 10683.76
Flow Rate(kg/h) No. of Passes :4

: 82
Temperature(ºC) Arrangement : square

: 1.01325
Pressure(bar) Materials : Carbon

: 20 construct steel AISI
1080
Outside Diameter(mm)
: 16
193
Inside Diameter(mm)
Utility: Cooling water
Shell side
Fluid Handled : cooling Buddle : 351

water Diameter (mm)
Temperature(ºC)
: 25 Shell Diameter
Pressure(bar) : 401
: 1.01325 Nozzle (mm)
: 54.36
Materials
construct
: Carbon steel
AISI 1080
Insulation
194
Type: Minerals wood
Thickness: 75mm
Table 3.7: Specification sheet of Reboiler (RB-100)

REBOILER RB-100
Identification : Item : REBOILER Date : 2/5/2019
: RB-100
: Item :1 By : Lim Chee Hung

No
195
: No
required
Function: To vaporise the bottom product from distillation column to increase purity
of toluene.
Type: Thermosyphons
Heat Duty: 998.51kW
Tube side
Fluid Handled : Product Length(mm) : 2440

from D-100
No of Tube : 290
196
Flow Rate(kg/h) : 6684.56 No. of Passes :4
Temperature(ºC) : 82 Arrangement : square
Pressure(bar) : 1.01325 Materials : Carbon

construct steel AISI
1080
Outside Diameter(mm) : 30
:0.0116
Inside Diameter(mm) : 25
Pressure
drop(kPa)
Shell side
Fluid Handled : Buddle : 1544

Condensing Diameter (mm)
steam
197
Temperature(ºC) : 110 Shell Diameter : 1594
Pressure(bar) : 1.01325 Nozzle (mm) : 54.36
Pressure drop(kPa) :308 Materials : Carbon steel

construct AISI 1080
Insulation
Type: Minerals wood
Thickness: 75mm
198
199
1.6 Heat Transfer Equipment Design
3.2.1 Cooler (E-102)
Cooler E-102 is used to reduce the temperature of the mixture of component from 769K to
351K before it enters expander.
The general equation for heat transfer across a surface is:

𝑄 = 𝑈𝐴∆𝑇𝑚
Where,
𝑄 = heat transferred per unit time, W
𝑈 = the overall heat transfer coefficient, W/m2. °C
𝐴 = heat transfer area, m2
∆𝑇𝑚 = the mean temperature difference, the temperature driving force, °C
The simplest expression for ∆𝑇𝑚 is determined when the following assumption hold:
1. Stream flows are at steady state.
2. Stream flows are countercurrent or concurrent to each other.
3. The overall heat transfer coefficient is constant throughout the exchanger.
4. Each stream undergoes only sensible enthalpy changes (heating or cooling) with constant
specific heat.
5. Heat losses are negligible.
The ∆𝑇𝑚 is then a function only of driving forces at the two ends of the exchanger, ∆𝑇1 and
∆𝑇2 in the form of a log mean:
The temperature difference can be calculated from the following equation:
Where = true temperature difference
= temperature correlation factor
The temperature correlation factor can be calculated from the following equation:
1−S
√ R 2+1 ln( 1−RS )
F t=
2−S ( R+1− √ R2 +1 )
(R−1)ln( )
2−S ( R+1+ √ R2 +1 )
200
Where R = shell-side fluid flow-rate times the fluid mean specific heat; divided by the tube-
side fluid flow-rate times the tube-side fluid specific heat
S = temperature efficiency of the exchanger
T 1−T 2
R=
t 2−t 1
769−351
¿
318−308
= 41.8
t 2−t 1
S=
T 1−t 2
318−308
¿
769−308
=0.0217
1−S
√ R 2+1 ln ( 1−RS )
F t=
2−S ( R+1− √ R2 +1 )
(R−1)ln ( )
2−S ( R+1+ √ R2 +1 )
¿ √ 41.82 +1 ln ⁡¿ ¿
( T 1−t 2 )−(T 2 −t1 )

T =
Δ lm T 1 −t 2
ln( )
T 2 −t 1
ln ∆T A =6.0355
ln ∆T B =−2.30
( 418 ) +10
¿
6.0355+ 2.3
= 51.35 K
.. ∆ T m=F
˙ t ∆ T lm
=1.0578 x 51.35
=54.319 K
For the temperature correction factor Ft, several assumptions was made based on the log
meant temperature difference.
201
Assumptions:
1. Equal heat transfer areas in each pass.
2. Constant overall heat transfer coefficient.
3. Temperature of the shell-side fluid in any pass is constant.
4. No leakage of fluid between shell passes.
T1 = 769
T2 =351
t2 =318
t1 =308
3.2.1.1 Heat Transfer Area
Referring to Coulson & Richardson Chemical Engineering Design, the general equation for
heat transfer across a surface is:
Where Q = heat transferred per unit time, W,

U = the overall heat transfer coefficient, W/m2.K,
A = heat transfer area, m2, and
ΔT m = the mean temperature difference, K.
Referring to Coulson & Richardson Chemical Engineering Design Table 12.1 page 637, the
range for overall heat transfer coefficient for coolant for a system with light oil as the hot
fluid and water as the cold fluid, overall coefficient will be in the range of Btu/hr-ft 2. F. To
start with, the overall coefficient is taken to be 100 Btu/hr-ft 2. F. The heat duty calculated
from energy balance of E-101 are 7806.58 J/s.
100 Btu/hr-ft2. F = 900 W/m2 C̊

Q=UAΔT m
Q
A0 =
U ∆T m
7806.58 J / s
¿
900 W
×54.319 ° ∁
m2 . ° ∁
=449.47 m2
202
3.2.1.2 Number of tubes calculation
The inner and outer diameter of the tubes can be refer to Coulson & Richardson Chemical
Engineering Design Table 12.3 page 645. The outer diameter chosen is 50mm (0.050m) and
inner diameter chosen is 43.6mm (0.0436). The smaller diameters 5 8 to 1 in. (16 to 25 mm)
are preferred for most duties, as they will give more compact, and therefore cheaper coolant.
However, the component used can cause heavy fouling because of high volume of hydrogen,
and thus higher diameter are chosen. The outside diameter chosen is 0.05m and the inner
diameter is 0.436m, the length chosen is 7.32m as the usage of longer tubes will reduce the
shell diameter; which will generally result in a lower cost coolant.
At =π d 0 L
= π × 0.050 m× 7.32m=1.1498 m2
Number of tubes
A o 158.188m 2
Np= =
A t 1.1498m 2
=137.58 ≈ 138 tubes
Cross-sectional area of the tube

2
π d 2 π (0.0436 m)
= = =¿1.49301×10-3m2
4 4
Total area of the tube

A= N p ( cross−sectional area of the tube )
=138(1.49301×10-3m2)
=0.206 m2
3.2.1.3 Bundle and shell diameter
203
An estimate of the bundle diameter Db can be obtained from the following equation where, K1
and n1 are constant value taken from Coulson & Richardson Chemical Engineering Design
Table 12.4 page 649.
K1 = 0.156
n1 = 2.291
Db =d 0 ¿
=(0.050m)(138tubes/0.156)1/2.291
=0.9665 m
For a split-ring floating head exchanger, the typical shell clearance from Figure 12.10 of
Coulson & Richardson Chemical Engineering Design page 646 is 58mm, so the shell inside
diameter,
Ds=0.9665m + 0.058m
=1.0245m
3.2.1.4 Shell-side heat transfer coefficient (oil side)
Kern’s method will be used. The area for cross-flow for the hypothetical row of tubes at
the shell equator using the following formula:
( p t−d 0 ) D s l B
A s=
pt
Where l B is baffle spacing
Tube pitch, pt
pt =1.25 d 0
=1.25(0.05m)
=0.0625m
Baffle spacing
l B =0.4 D s
=0.4(1.0245m)
=0.4098m
Flow area, As=[(Pt-do)(Ds)(IB)]/Pt]
204
( 0.0625 m−0.050 m )( 1.0245 m )( 0.4098 m )
=
0.0625m
2
=0.084 m
The shell-side mass velocity Gs and the linear velocity us is calculated using the following
formula respectively.
Ws Gs
Gs = u s=
As ρ
where W s = fluid flow-rate on the shell side,
ρ = density of shell-side fluid.
5.115 g /s
Gs= 2
=60.89 kg /m2 . s
0.084 m
60.89/m 2 . s
Us= =0.0823 m/s
740 kg /m3
The shell-side equivalent diameter for equilateral square pitch arrangement is calculated
using the following formula referring to Coulson & Richardson Chemical Engineering
Design page 672.
p 2t −π d 20
4( ) 1.27 (p 2−0.785 d 2 )
4 = 1 0
d e= d0
π d0
1.27
=[ × 0.06252−0.785(0.0 52 )¿
0.05
=0.0494m
The shell-side Reynolds number can be calculated using the following formula.
Gs d e
Re =
μ
(60.89 kg /m2 . s)(0.0494 m)
¿
0.00051
=5897.97
Prandlt number
μCp
Pr =
kf
2.202 kJ
0.00051 kg/ms( ).
= kg . K
0.15 W /m . K
=7.49x10-3
205
For the calculated Reynolds number, the value of jh can be obtained from Figure 12.29 of
Coulson & Richardson Chemical Engineering Design page 673, for the 25% cut of
segmented baffles.
From Figure 12.29, jh=8x10 -3
Neglecting the viscosity correction:
1
k f j h ReP r 4
h s= ¿
de
=0.15(8 x 10−3 )(5897.97)¿ ¿
=280.153 W/m2.K
3.2.1.5 Tube-side heat transfer coefficient (water side)
Tube-side Coefficient
number of tubes 138 tubes
= =69
number of passes 2 passes
Total flow area = Tube cross-sectionl area x tube side coefficient
=1.49301×10-3 m2 × 69 tubes/passes =0.10302 m2
Component Mass Velocity

ṁ component
Gt =
total flow area
112.49 kg
= s kg/m2.s
=1091.92
0.10302
Component linear velocity
Gt
V=
ρcomponent
1091.92kg /m2 . s
= =1.10045 m/ s
992.25
Prandlt number
μCp
Pr=
kf
206
0.6532× 10−3 (4.0737)
= = 4.23×10-3
0.6286 W /m. K
Reynolds number
ρv d i
Re=
μ
992.25 kg/m3 (1.10045 m/s)( 0.0436 m)
= =72854.12
0.6532× 10−3
Ratio length and inner diameter of tube

L 7.32 m
= =165.83
d i 0.0436 m
From the Re and the ratio of length and inner diameter of tube that was calculated, the value
of heat transfer factor, jh can be extrapolated from Figure 12.23 of the Coulson and
Richardson Chemical Engineering Design page 665.
Heat transfer factor, jf =4.7×10−2

..˙ hi=k f j h RePr 0.33 ¿ ¿
=¿
=8130.78 W /m . K
3.2.1.6 Overall coefficient
d0
d 0 ln ( )
1 1 1 di d0 1 d0 1
= + + + x + x
U 0 h0 hod 2 kw d i h id d i hi
4500 W 5000W
Assume h od= 2
,h id = 2
m .K m .K
0.050 m
0.050 m(ln )
1 1 1 0.0436 m 0.050 m 0.050 m 1
=[ + + + + ×
U o
280.153 W 4500W 16 W 5000 W 0.0436 m 8130.78 W
m2
.K
m2
.K 2 (m
.K) (
0.0436 m
m 2 )
.K
m
.
=4.37611 ×10-3 W/m2.K
207
3.2.1.7 Pressure drop
The pressure drops at the tube-side can be calculated using the following formula.
D s L ρ u2s
ΔPs =8 j f ( )( )( )¿
de l B 2
where Δ Pt = tube-side pressure drop, Pa,

N p = number of tube side passes,
j f = tube-side friction factors (from Figure 12.24 in Chemical Engineering Design)
ut = tube-side velocity, m/s,
L = length of one tube, m
−2 7.32 m 1.12
∆ Pt =[8 (4.7 × 10 )( )¿× 992.25( )]
0.0436 m 2
=37895.6 Pa.s
The pressure drops at the shell-side can be calculated using the following formula.
7.32 m kg 0.082 32 0.00051 −0.14

=[8(5.5x10 -1)
0.0436 m
x 740 3
m 2 (0.00011
¿ ]=1851.31 Pa.s
3.2.2 Heater (H-102)
The heater H-102 is used to supply heat to naphta component from 433oC to 502oC before
entering the reactor. This stream consists of naphta components and combustion gas which is
propane as the heat source. Propane is used because of its high temperature range from -1.111
o
C to 1093.333 oC in page 471, Product and Process Design Principles.
Table 3.8: Properties of raw material for E-101
Mixture of gas (Tube) Steam(Shell)
Temperature inlet (K) 706 783
Temperature outlet (K) 775 723
Specific heat (kJ/kg.K) 2.202 1.68

Thermal conductivity (W/m.K) 0.1499 105.6
208
Density (kg/m3) 740 493
Viscosity (kg/ms) 0.00051 0.00011
Feed flowrate (kg/s) 5.115 7.69
T1=
783K
T2=723k
t2= 775k
t1=706k
209
The mass flowrate for cold fluid (propane) can be calculated using the formula
ṁC p ∆ T ( hot fluid ) =ṁC p ∆ T (cold fluid )
5.115 ( 2.202 ) ( 775−706 )=ṁ ( 1.68 ) ( 783−723 )
ṁ=7.69 kg/s
3.2.2.1 Temperature difference, ΔTm

ΔT m=F t ∆ T lm
Where ΔT m = true temperature difference
F t = temperature correlation factor
1−S
√ R 2+1 ln( 1−RS )
F t=
2−S ( R+1− √ R2 +1 )
(R−1)ln( )
2−S ( R+1+ √ R2 +1 )
T 1−T 2
R=
t 2−t 1
783−723
¿
775−706
=0.8698
t 2−t 1
S=
T 1−t 1
775−706
¿
775−706
=0.896
210
1−S
√ R 2+1 ln ( 1−RS )
F t=
2−S ( R+1− √ R2 +1 )
(R−1)ln ( )
2−S ( R+1+ √ R2 +1 )
¿ √ 0.8698+1 ln ⁡¿ ¿
( T 1−t 2 )−(T 2 −t1 )
T =
Δ lm T 1 −t 2
ln( )
T 2 −t 1
(783−775 )−(723−706)
¿
783−723
ln ⁡( )
723−706
= 11.94oC
..˙ ∆ T m=F t ∆ T lm
=4.3239× 11.94oC
=51.63oC

U = the overall heat transfer coefficient, W/m2.K,
range for overall heat transfer coefficient for shell and tube heat exchangers for a system with
process mixture (gas) as the cold fluid and combustion gas as the hot fluid the overall
coefficient will be in the range of 10-50 W/m 2o C. To start with, the overall coefficient is
taken to be 10 W/m2o C. The heat duty calculated from energy balance of E-101 are 1133.74
J/s
211
Q=UAΔT m
Q
A0 =
U ∆T m
1133.74 J /s
¿
10 W
×51.63 ° ∁
m2 .° ∁
=2.196 m2
are preferred for most duties, as they will give more compact, and therefore cheaper,
exchangers.
Higher diameter of tubes are used for heater with heavy fouling materials, in this project,
hydrogen content is high in the heater as the inlet consist of hydrocarbon, thus higher
diameter is required. The preferred lengths of tubes for heat exchangers are: 6 ft. (1.83 m), 8
ft (2.44 m), 12 ft (3.66 m), 16 ft (4.88 m) 20 ft (6.10 m), 24 ft (7.32 m). For a given surface
area, the use of longer tubes will reduce the shell diameter; which will generally result in a
lower cost exchanger, particularly for high shell pressures. The optimum tube length to shell
diameter will usually fall within the range of 5 to 10. The length chosen is 7.32 m.
At =π d 0 L
= π × 0.050 m× 7.32m=1.149 m2
Number of tubes
A o 2.196 m2
Np= =
A t 1.149 m2
=1.9112≈ 2 tubes

2
π d 2 π (0.0436 m)
= = =¿1.49301×10-3m2
4 4
212
A= N p ( cross sectional area of the tube)
=2(1.49301×10-3m2)
=2.98608×10-3 m2
Referring to Coulson & Richardson Chemical Engineering Design page 660, high velocity
will give high heat transfer and also high pressure drop. Hence, the velocity must be high
enough to prevent any suspended solids settled, but no so high that can cause corrosion. The
optimum velocity for the tube side is between 5 to 10 m/s and for the shell side is 0.3 to 1
m/s.
Tube velocity:
ṁtube
ut = x no of passes
ρtube A
In order to make use of the allowable pressure drop, 4 passes is needed. Value obtained is
within the value of optimum velocity for high pressure
5.115 kg/ s
= 2
× 4=9.26 m/s
(740 kg /m3)(2.98608 ×10−3 m )
Table 12.4 page 649.
Db =d 0 ¿
=(0.05m)(2tubes/0.158)1/2.263
=0.1535m
Coulson & Richardson Chemical Engineering Design page 646 is 45 mm, so the shell inside
diameter,
213
Ds = 0.1535m + 0.045m
= 0.198m
3.2.2.5 Tube-side heat transfer coefficient
= =0.5 ≈ 1
Total flow area = Tube cross sectional area x tube side coefficient
=1.49301×10-3m2× 1tubes/passes = 1.49301×10-3m2

ṁ component
Gt =
total flow area
5.115 kg
= s g/m2.s
=3425.96 k
1.49301 x 1 0−3 m 2
Gt
v=
ρcomponent
3425.96 k g /m2 . s
= =4.63 m/s
740
Prandlt number
μCp
Pr =
kf
0.00051(2.202)
= = 7.4918×10-3
0.1499 W /m. K
Reynolds number
ρv d i
Re=
μ
740 kg/m 3 (4.63 m/s )(0.0436 m)
= =292886.42
0.00051
214
L 7.32 m
= =167.89
d i 0.0436 m
Heat transfer factor, jh =2.1×10−3

1
4
k f j h ReP r
h s= ¿
de
=¿
=571.29 W /m. K
3.2.2.6 Shell-side heat transfer coefficient
Kern’s method will be used. The area for cross-flow A s for the hypothetical row of tubes at
( p t−d 0 ) D s l B
A s=
pt
Tube pitch,
pt =1.25 d 0
=1.25(0.05m)
=0.0625m
Baffle spacing
l B =0.4 D s
=0.4(0.198m)
=0.0792m
Flow area, As = [(Pt-do)(Ds)(IB)]/Pt]

( 0.0625 m−0.0436 m )( 0.198 m ) ( 0.0792m )
=
0.0625 m
-3
=4.74x10 m
215
Ws Gs
Gs = u s=
As ρ

7.69 kg/s
Gs = −3 2
=1622.36 kg /m2 . s
4.74 x 10 m
1622.36/m 2 . s
Us= =3.2908 m/s
493 kg /m 3
The shell-side equivalent diameter for equilateral triangular pitch arrangement is calculated
Design page 672.
d e =4 ¿ ¿
0.0625 m π
=[ 4 ( 2 )
× 0.87 ( 0.0625 m )− ¿ ¿
2
=0.074m
Gs d e
Re=
μ
(1622.36 kg /m2 . s)(0.074 m)
¿
0.00011
=1091405.82
Prandlt number
μCp
Pr=
kf
1.68 kJ
0.00011 kg /ms ( ).
= kg . K
105.6 W / m . K
=17363.27
segmented baffles.
216
Neglecting the viscosity correction:
1
k j ReP r 4
h s= f h ¿
de
=105.6(2 x 10−3)(1091405.82)¿ ¿
=44322187.63 W/m2.K
3.2.2.7 Pressure drop
Δ Pt =N p ¿

∆ Pt =2[8(2.1 ×1 0−3)(
7.32 m
)¿ ×
740 ( 9.26s m ) ]
0.0436 m 2
=34843.66 Pa.s
D s L ρu 2s
( )
Δ Ps =8 j f ( ¿
d e lB 2
¿
where Δ Ps = shell-side pressure drop, Pa,

j f = shell-side friction factor (from Figure 12.30 in Chemical Engineering Design)
L = tube length, m,
217
l B = baffle spacing, m,
0.198 m 7.32m
=[8(2x10 -3) [( ¿ 493 kg/m 3 ¿ ¿
0.074 m 0.0792m
=0.0866 Pa
d0
d 0 ln ( )
1 1 1 di d0 1 d0 1
= + + + x + x
4500 W 5000W
Assume h od= 2
,h id = 2
m .K m .K
The fouling factors coefficient can be retrieved on Chemical Engineering Design (Sinnot),
page 640, table 12.2 for flue gas.
0.050 m
0.05 m(ln )
1 1 1 0.0436 m 0.050 m 0.050 m 1
=[ + + + + ×
U o
44322187.63W 4500 W 16 W 5000W 0.0436 m 571.29 W
m2
.K
m2
.K 2( m
.K ) (
0.0436 m
m2
. K
) m
=2.6729×10-3 W/m2.K
3.2.2.9 Mechanical Design
Design Pressure
Referring to Coulson & Richardson’s Chemical Engineering Design page 810, a vessel must
be designed to withstand the maximum pressure to which it is likely to be subjected in
operation. For vessels under internal pressure, the design pressure is normally taken as the
218
pressure at which the relief device is set. The design pressure will be normally be 5 to 10%
above the normal working pressure.
Operating pressure =45 bar = 4.5 N/mm 2

110 %
Design pressure=Pi=4.5N/ mm 2 × =4.95 N /mm 2
100 %
Design Temperature
Operating temperature=100° ∁
Based on Table 13.2 from Coulson & Richardson’s Chemical Engineering Design page 812,
the design temperature =100° ∁
The strength of metal decreases with the increasing temperature, hence the maximum
allowable design stress depends in the material temperature. The design temperature at which
the design stress is evaluated should be taken as the maximum working temperature of the
material, with due allowance for any uncertainty involved in predicting vessel wall
temperatures.
Material Construction
From Coulson & Richardson’s Chemical Engineering Design page 811, the selection of a
suitable material must take into account the suitability of the material for fabrication as well
as the compatibility of the material with the process environment. The material that will be
used is stainless steel 18Cr/8Ni Ti stabilised (321) , and the design stress is 115N/mm2 as
shown in Table 13.2 page 812 of Chemical Engineering Design.
Design stress, f=115N/mm2
Minimum Wall Thickness of Cylindrical Section of the Shell
From Coulson & Richardson’s Chemical Engineering Design page 815, for a cylindrical
shell, the minimum thickness required to resist internal pressure can be determined from the
equation below; the cylindrical stress will be greater of the two principal stress.
219
P i Di
e=
2 J f −Pi
where, e= wall thickness,

Pi=¿ design pressure,
Di =shell diameter,
J= joint factor, and
f= design stress.
From Coulson & Richardson’s Chemical Engineering Design page 812, the strength of a
welded joint will depend on the type of joint and the quality of the welding. The soundness of
welds is checked by visual inspection and by non-destructive testing (radiography). The
possible lower strength of a welded joint compared with the virgin plate is usually allowed
for in design by multiplying the allowable design stress for the material by a “welded joint
factor”, J. The value of the joint factor is used in design will depend on the type of joint and
amount of radiography required by the design code.Taking the factor as 1.0 implies that the
joint is equally as strong as the virgin plate, this is achieved by radiographing the complete
weld length and cutting out and remaking any defects. Therefore, it is assumed that the joint
factor is 1.0
P i Di
e=
2 J f −Pi
4.95 N /m m 2(0.0436 m)
¿ =9.59× 4
115 N mm
(
2 ( 1.0 )
mm 2)−4.95 N / m m 2
From Coulson & Richardson’s Chemical Engineering Design page 813, the corrosion
allowance is the additional thickness of metal added to allow for material lost by corrosion
and erosion, or scaling. The allowance to be used should be agreed between the customer and
manufacturer. Corrosion is a complex phenomenon, and it is not possible to give specific
rules for the estimation of the corrosion allowance required for all circumstances. The
allowance should be based on experience with the material of construction under similar
service conditions to those for the proposed design. Most design codes and standards specify
a minimum allowance of 2.0 mm.
220
Minimum wall thickness = e + corrosion allowance =9.59 ×10−4mm+2=2.0009mm
There will be a minimum wall thickness required to ensure that any vessel is sufficiently rigid
to withstand its own weight, and any incidental loads. As a general guide, the wall thickness
of any vessel should not be less than 5 m.
Head and Closure

From Coulson & Richardson’s Chemical Engineering Design page 817, the standard
torispherical heads (dished ends) are the most commonly used end closure for vessels up to
operating pressure of 15 bar. They can be used for higher pressures, but above 10 bar their
cost should be compared with that of an equivalent ellipsoidal head. Torispherical heads will
be chosen as our operating pressure are below 10 bar.
The following equation can be used to calculate the minimum thickness required:
Pi D i
e=
2 J f −0.2 Pi
4.95 N /mm 2 (0.0436 m)

=9.424 ×10−4
= 115 N 4.95 N mm
(
2 ( 1.0 )
mm 2 )
−0.2(
mm 2
)
Addition of corrosion allowance of 2 mm =6.3775 ×10−5mm + 2mm =2.0mm
3.2.3 Evaporator (Ev-103)
The evaporator Ev-103 is used to convert the naphta component from liquid to gas
component from 25oC to 120oC before entering the reactor. This stream consists of naphta
components and steam as the heat source. Steam is used because of its temperature range
221
from 220oC to 450 oC in page 471, Product and Process Design Principles. The evaporators
that will be used is long tube evaporators because its suitability for low viscosity of fluid.
Table 3.9: Properties of raw material for Ev-101
Mixture of liquid (Tube) Steam(Shell) (hot fluid)
(cold fluid)
Temperature inlet (K) 298 450
Temperature outlet (K) 393 350
Specific heat (kJ/kg.K) 2.202 4.3071

Thermal conductivity (W/m.K) 0.1499 0.017
Density (kg/m3) 740 890
Viscosity (kg/ms) 0.00051 0.00001
Feed flowrate (kg/s) 0.604 7.69
T1=
Shell 450K
T2=350k
t2= 393k
Tube
t1=298k
Figure 3.19: Long tube evaporator
The mass flowrate for cold fluid (propane) can be calculated using the formula
ṁC p ∆ T ( cold fluid )= ṁC p ∆T (hot fluid )
0.604 ( 2.202 ) ( 393−298 )=ṁ ( 4.3071 )( 450−350 )
ṁ=0.29 kg/s
222
3.2.3.1 Temperature difference, ΔTm

ΔT m=F t ∆ T lm
Where ΔT m = true temperature difference
F t = temperature correlation factor
1−S
√ R 2+1 ln ( 1−RS )
F t=
2−S ( R+1− √ R2 +1 )
(R−1)ln ( )
2−S ( R+1+ √ R2 +1 )
T 1−T 2
R=
t 2−t 1
450−350
¿
393−298
=1.053
t 2−t 1
S=
T 1−t 1
393−298
¿
450−298
=0.625
1−S
√ R 2+1 ln ( 1−RS )
F t=
2−S ( R+1− √ R2 +1 )
(R−1)ln ( )
2−S ( R+1+ √ R2 +1 )
223
¿ √ 1.053 2+1 ln ⁡¿ ¿
( T 1−t 2 )−(T 2 −t1 )

T =
Δ lm T 1 −t 2
ln( )
T 2 −t 1
( 450−393 )−( 350−298)
¿
450−393
ln ⁡( )
350−298
= 54.46oC
..˙ ∆ T lm=F t ∆ T lm
=1.852× 54.46oC
=100.86oC

U= the overall heat transfer coefficient, W/m2.K,
range for overall heat transfer coefficient for long-tube evaporators for a system with light oil
as the cold fluid and steam as the hot fluid the overall coefficient will be in the range of 900-
12000 W/m2o C for vaporisers equipment. To start with, the overall coefficient is taken to be
900 W/m2o C. The power required calculated from energy balance of evaporators are
2174.3513kW.
224
Q=UAΔT m
Q
A0 =
U ∆T m
2174.3513 J /s
¿
900 W
×100.86 ° ∁
m2 . ° ∁
=0.024 m2
are preferred for most duties, as they will give more compact, and therefore cheaper,
exchangers.
Higher diameter of tubes are used for heater with heavy fouling materials, in the production
of toluene, hydrogen content is high in the heater as the inlet consist of hydrocarbon, which
will induce fouling, thus higher diameter is required. The preferred lengths of tubes for heat
exchangers are: 6 ft. (1.83 m), 8 ft (2.44 m), 12 ft (3.66 m), 16 ft (4.88 m) 20 ft (6.10 m), 24
ft (7.32 m). For a given surface area, the use of longer tubes will reduce the shell diameter;
which will generally result in a lower cost exchanger, particularly for high shell pressures.
The optimum tube length to shell diameter will usually fall within the range of 5 to 10. The
length chosen is 7.32 m.
At =π d 0 L
= π × 0.050 m× 7.32m=1.149 m2
Number of tubes
A o 0.024 m 2
Np= =
A t 1.149 m2
=0.21≈ 1 tubes
225
2
π d 2 π (0.0436 m)
= = =¿1.49301×10-3m2
4 4

A= N p ( cross sectional area of thetube)
=1(1.49301×10-3m2)
=1.149301×10-3 m2
Referring to Coulson & Richardson Chemical Engineering Design page 660, high velocity
will give high heat transfer and also high pressure drop. Hence, the velocity must be high
enough to prevent any suspended solids settled, but no so high that can cause corrosion. The
optimum velocity for the tube side is between 5 to 10 m/s and for the shell side is 0.3 to 1
m/s.
Tube velocity:
ṁ tube
ut = x no of passes
ρtube A
In order to make use of the allowable pressure drop, 2 passes is needed. Value obtained is
within the value of optimum velocity for high pressure
2.604 kg /s
= ×2=6.12 m/s <10
(740 kg /m3)(1.149301× 10−3 m2)
Table 12.4 page 649. K1 = 0.156 and n1 =2.291
Db =d 0 ¿
=(0.05m)(1tubes/0.156)1/2.291
=0.1125m
Coulson & Richardson Chemical Engineering Design page 646 is 45 mm, so the shell inside
diameter,
226
Ds = 0.1125m + 0.045m
= 0.157m
3.2.3.5 Tube-side heat transfer coefficient
= =0.5 ≈ 1
Total flow area = Tube cross sectiona; area x tube side coefficiet
=1.49301×10-3m2× 1tubes/passes = 1.49301×10-3m2
ṁ component
Gt =
total flow area
2.604 kg
= s g/m2.s
=1744.13 k
1.49301 x 1 0−3 m 2

Gt
v=
ρcomponent
1744.13 k g /m2 . s
= =2.36 m/ s
740
Prandlt number
μCp
Pr=
kf
0.00051(2.202)
= = 7.4918×10-3
0.1499 W /m. K
227
Reynolds number
ρv d i
Re=
μ
740 kg/m 3 (2.36 m/s)( 0.0436 m)
= =149300.08
0.00051

L 7.32 m
= =167.89
d i 0.0436 m
Heat transfer factor, jh =2.8×10−3

..˙ hi=k f j h ℜ Pr 0.33 ¿ ¿
=¿
=359.09 W /m . K
3.2.3.6 Shell-side heat transfer coefficient
Kern’s method will be used. The area for cross-flow for the hypothetical row of tubes at
( p t−d 0 ) D s l B
A s=
pt
Tube pitch, pt
pt =1.25 d 0
=1.25(0.05m)
=0.0625m
Baffle spacing
l B =0.4 D s
=0.4(0.157m)
=0.0628m
Flow area, As = [(Pt-do)(Ds)(IB)]/Pt]

( 0.0625 m−0.050 m )( 0.157 m ) ( 0.0628 m )
=
0.0625 m
228
=1.972 x10-3 m
Ws Gs
Gs = u s=
As ρ
7.69 kg /s
Gs = −3 2
=3899.59 kg/m 2 . s
1.972 x 1 0 m
3899.59/m2 . s
Us= =4.38 m/s
890 kg /m3
The shell-side equivalent diameter for equilateral triangular pitch arrangement is calculated
Design page 672.
2
pt π d0
4 ( x 0.87 p t− . )
2 2 4
d e=
π d0
2
=[ 4 ( 0.0625
2
m
)× 0.87 ( 0.0625 m )− π2 ¿ ¿
=0.074m
Gs d e
Re=
μ
(3899.59 kg /m2 . s)(0.074 m)
¿
0.00011
=2623360.55
Prandlt number
μCp
Pr=
kf
229
4.3071 J
0.00011 kg /ms ( ).
= kg . K
0.017 W /m. K
=0.0279
segmented baffles.
1
4
k f j h ReP r
h s= ¿
de
=(0.017)(7 x 10−3)¿ ¿
=8.15x10-4 W/m2.K
3.2.3.7 Pressure drop (tube)
Δ Pt =N p ¿

6.12 m 2
∆ Pt =1[8(2.8 × 10−3)(
7.32 m
)¿×
740 ( s )]
0.0436 m 2
=12531.07 Pa.s
230
D s L ρu 2s
( )
Δ Ps =8 j f ( ¿
d e lB 2
¿
where Δ Ps = shell-side pressure drop, Pa,

j f = shell-side friction factor (from Figure 12.30 in Chemical Engineering Design)
L = tube length, m,
l B = baffle spacing, m,
Jf=2.5x10-2
0.157 m 7.32 m
=[8(2.5x10 -2) [( ¿ 890 kg/m 3 ¿¿
0.074 m 0.0628 m
=0.0167 Pa
d0
d 0 ln( )
1 1 1 di d0 1 d0 1
= + + + x + x
4500 W 5000W
Assume h od= 2
,h id = 2
m .K m .K
The fouling factors coefficient can be retrieved on Chemical Engineering Design (Sinnot),
page 640, table 12.2 for flue gas.
0.050 m
0.05 m( ln )
1 1 1 0.0436 m 0.050 m 0.050 m 1
=[ + + + + ×
U o
8.15 x 10−4 W 4500 W 16 W 5000 W 0.0436 m 359.09 W
m2
.K
m2
.K 2( m
.K ) 0.0436 m
( m 2
.K
) m
=1226.99 W/m2.K
231
232
Table 3.10: Specification sheet for Evaporator (Ev-103)
EVAPORATOR SPECIFICATION DATA Equipment No : Ev-103
SHEET Description : Evaporator
OPERATING DATA
Split-ring floating-head shell and tube exchanger NO OF 1
UNIT
SHELL PER 1
UNIT
SPECIFICATION DATA TUBE-SIDE DATA
TYPE SHELL AND MEAN 345.5 K
TUBE TEMPERATURE
1 SHELL PASS AREA OF ONE 1.149 m2

TUBE
2 TUBE PASS NUMBER OF 1 tube
TUBES
PRESSURE DROP 12531.07 Pa.s
TUBE STANDARD DIMENSION TOTAL TUBE 1.149301×10-3 m2
AREA
TUBE ARRANGEMENT Square CROSS- 1.49301×10-3m2
SECTIONAL AREA
TUBE PITCH 0.0625m TUBE VELOCITY 6.12 m/s
OUTSIDE DIAMETER 0.050m TUBE PER PASS 1
INSIDE DIAMETER 0.0436 m TOTAL FLOW 1.49301×10-3m2
AREA
WALL THICKNESS 0.002 m MASS VELOCITY 1744.13kg/m2.s
LENGTH 7.32 m LINEAR 2.36 m/s
VELOCITY
MATERIAL Carbon steel
(grade: A285 Gr
A)
OPERATING CONDITION
DATA SHELL-SIDE DATA
HEAT DUTY 7827664.50ckj/h MEAN 400K
r TEMPERATURE
HEAT TRANSFER AREA 0.024 m2 BUNDLE 0.1125m
DIAMETER
2
OVERALL HEAT 1226.99 W/m .K SHELL DIAMETER 0.157m
TRANSFER COEFFICIENT
UTILITIES Steam BAFFLE SPACING 0.0628m
233
CROSS FLOW 1.972 x10-3 m
TUBE-SIDE DATA
AREA
INLET TEMPERATURE 298 K MASS VELOCITY 3899.59 kg /m2 . s
OUTLET TEMPERATURE 393 K LINEAR 4.38 m/s
VELOCITY
INLET PRESSURE 1.013 bar EQUIVALENT 0.074m
DIAMETER
Type of baffles 2mm
End thickness Single segmented baffle
Material Carbon steel (grade: A285 Gr A)
Table 3.11: Specification sheet for Heater (H-101)

Equipment No : H-101
HEATER SPECIFICATION DATA SHEET
Description : Heater
OPERATING DATA
Capacity Split-ring floating- NO OF 1
(inside tube) head shell and tube UNIT
exchanger
SHELL PER 1
UNIT
TYPE
SHELL AND MEAN 584 K
TUBE TEMPERATURE
TUBE
2 TUBE PASS NUMBER OF 29 tubes
TUBES
AREA
SECTIONAL AREA
AREA
234
VELOCITY
MATERIAL Killed carbon
steel (grade:
A515)
OPERATING
CONDITION
HEAT DUTY 4764.43 J/s MEAN 598K
TEMPERATURE
2
HEAT TRANSFER AREA 10.654 m BUNDLE 0.1601m
DIAMETER
OVERALL HEAT 1.9852×10-3 SHELL DIAMETER 0.2051m
TRANSFER COEFFICIENT W/m2.K
UTILITIES Combustion gas BAFFLE SPACING 0.08204 m
(propane)
CROSS FLOW 3.37x10-3 m2

TUBE-SIDE DATA
AREA
INLET TEMPERATURE 393 K MASS VELOCITY 1151.38 kg /m 2 . s
VELOCITY
INLET PRESSURE 45 atm EQUIVALENT 0.0237m
DIAMETER
Design temperature 100∁
Corrosion allowance 2mm
Type of baffles 2mm
Material Killed carbon steel (grade: A515)
235
Table 3.12: Specification sheet for Heater (H-102)
OPERATING DATA
exchanger
SHELL PER 1
UNIT
TYPE
SHELL AND MEAN 740.5 K
TUBE TEMPERATURE
TUBE
TUBES
AREA
SECTIONAL AREA
AREA
VELOCITY
MATERIAL Stainless steel
OPERATING
CONDITION
236
TEMPERATURE
2
DIAMETER
-3
OVERALL HEAT 2.6729×10 SHELL DIAMETER 0.198m
(propane)
CROSS FLOW 0.023 m2

TUBE-SIDE DATA
AREA
VELOCITY
DIAMETER
Design pressure
Type of head Torispherical head
Type of baffles 2mm
Material Stainless steel 18Cr/8Ni Ti stabilised (321)
237
Table 3.13: Specification sheet for Cooler (E-101)
Equipment No : E-101
Description : Cooler
OPERATING DATA
TUBE-SIDE DATA
MEAN TEMPERATURE 313 K
AREA OF ONE TUBE 1.149 m2
TUBE STANDARD DIMENSION TOTAL TUBE 0.206 m2
AREA
SECTIONAL
AREA
TUBE PITCH 0.0625m TUBE 1.10 m/s
VELOCITY
OUTSIDE DIAMETER 0.050m TUBE PER 1
PASS
INSIDE DIAMETER 0.0436 m TOTAL FLOW 0.10302m2
AREA
WALL THICKNESS 0.002 m MASS 1091.92kg/m2.s
VELOCITY
VELOCITY
INLET PRESSURE 45 atm MATERIAL Killed carbon steel
(grade: A515)
OPERATING
CONDITION
TEMPERATU
RE
DIAMETER
OVERALL HEAT SHELL 1.0245m
4.37611 ×10-3
TRANSFER COEFFICIENT DIAMETER
UTILITIES Cooling water BAFFLE 0.4098 m
SPACING
238
CROSS FLOW 0.0833 m2
AREA
MASS 60.89 kg /m2 . s
VELOCITY
LINEAR 0.0823 m/s
VELOCITY
3.3 Reactor Design
3.3.1 Fixed Bed Reactor (R-101)
Table 3.14: Molar Mass of each component

Component Molar Mass g/mol Source
Butane 58.124 PubChem,2019
Isopentane 72.151 Chemicalbook,2019
239
N-pentane 72.151 PubChem,2019
Cyclohexane 84.162 PubChem,2019
N-hexane 86.178 PubChem,2019
Methyl cyclohexane 98.189 PubChem,2019
Benzene 78.114 PubChem,2019
Toluene 92.141 PubChem,2019
Heptane 100.205 PubChem,2019
Hydrogen 2.016 PubChem,2019
240
Table 3.15: Information of the Inlet stream (R-101)
Mass Temperature Pressure(bar Density,p(kg/m3)
Mass Mole
Stream Components flowrate )
fraction fraction
(kg/hr)
502 45.5962 519.7
Butane 20.25 0.0011 0.0016
502 45.5962 -
Isopentane 2152.48 0.1169 0.1393
502 45.5962 600.8
N-pentane 2448.93 0.1330 0.1585
Inpu 502 45.5962 744.1
Cyclohexane 359.05 0.0195 0.0199
t
502 45.5962 664.3
S5 N-hexane 5656.47 0.3072 0.3066
Methyl 502 45.5962 -
1600.09 0.0869 0.0761
cyclohexane
502 45.5962 764.2
Benzene 585.53 0.0318 0.0350
502 45.5962 792.6
Toluene 552.39 0.0300 0.0280
502 45.5962 711.4
Heptane 5037.80 0.2736 0.2348
Total 18412.9 4797.1
1.0000 0.9998
9
241
Mass Pressure Density,p
Mass Mole
Stream Component flowrate Temperatu (Bar) (kg/m3)
fraction fraction
(kg/hr) re(oC)
Butane 20.25 0.0011 0.0005 433 45.5962 591.2
Isopentane 2152.48 0.1169 0.0465 433 45.5962 -
N-pentane 2448.93 0.1330 0.0529 433 45.5962 674.1
Cyclohexane 71.81 0.0039 0.0013 433 45.5962 815.8
Output
N-hexane 1131.31 0.0614 0.0205 433 45.5962 738.2
S6 Methyl 433 45.5962 -
80.00 0.0043 0.0013
cyclohexane
Benzene 4953.52 0.2690 0.0988 433 45.5962 833.8
Toluene 5684.55 0.3087 0.0962 433 45.5962 865.1
Heptane 1007.57 0.0547 0.0157 433 45.5962 786.3
Hydrogen 862.03 0.0468 0.6664 433 45.5962 -
Total 5304.5
18412.45 0.9998 1.0000
Volume inlet = (0.0011×519.7) + (0.1133×600.8) + (0.0195×744.1) + (0.3072×664.3) +

(0.0318×764.2) + (0.003×792.6) + (0.2736×711.4)
= 508.54 m3
242
Volume of outlet = (0.0011×591.2) + (0.1130×674.1) + (0.0039 ×815.8) + (0.0614×738.2) +
(0.2690 ×833.8) + ( 0.3087 ×865.1) + (0.0547×786.3) + (0.0468×5600)
= 921.47 m3
Volume of reactor = 1430.01 m3
Since Fixed Bed reactor is used, then the volume needed for conversion for the reaction can
be calculated by using the design equation as below (introduction design )
XA
V dX
=∫ A
F A 0 0 −r A
V= Working volume of ideal , m3
FAO= Molar flow rate of limiting reactant A at inlet, kmol/s
XA= Fractional conversion of limiting reactant required
dC A
−r A = = Rate of chemical reaction in kmol/(m3.s)
dt
Rate of reaction
A catalytic reforming unit with 2 reactors in series was analyzed and simulated in this
paper. Kinetics proposed by Smith was adopted to describe the reactions occurring during
catalytic reforming. Simulation results were compared with the actual data.
MATHEMATICAL MODEL(TREESE, PUJADÓ, & JONES, 2015)

3.3.1.1 Dynamics
If some pseudo ingredients (i) are appropriately used to simplify the feedstock of naphtha
catalytic reforming, four dominant idealized reactions (Smith, 1959) can be used to describe
the catalytic reforming process so that the catalytic reforming system can be simplified
significantly. These four reactions are called model reactions. The chemical reaction
equations are as follows
Cycloalkane ⇄ Arene (A)+3H2 (H) (1)
Cycloalkane (E) + H2 ⇄ Alkane (P) (2)
243
Hydrocracking of alkane (3)
Hydrocracking of cycloalkane (4)
According to Smith (1959), hydrocracking produces nearly the same amounts of moles of
C1~C6 cuts. Therefore, the model reaction Eq.(3) and Eq.(4) can be represented by the
following formula:
(5)
(6)
where, n is the number of carbon atoms. For a certain reforming feedstock, the n value can
be obtained through the average mole weight M f (kg/kmol) of the feedstock and the family of
component x P, x E, x A. Their relation is
n=Mf−2xp+6xA
where, x p + x E + x A=1 and x P, x E, x A are mole fractions of alkane, cycloalkane, and
aromatics, respectively.
Table 3.16: Molecular Weight of inlet component

Component Molecular Weight
244
[kg/kmol]
n - Butane, C4H10 58.124
Isopentane 72.151
n – Pentane 72.151
Cyclohexane 84.162
n – Hexane 86.178
Methylcyclohexane 98.189
Benzene 78.114
Toluene 92.141
Heptane 100.205
245
Average Molecular weight, Mf 82.379
Alkane in S5 Mole fractions
Butane 0.0016
Isopentane 0.1393
N-Pentane 0.1585
N-hexane 0.3066
Heptane 0.2348
Total Mole fractions of alkane, xp 0.8408
Aromatics Mole fractions

246
Benzene 0.0350
Toluene 0.0280
Total Mole Fraction of Aromatics, xA 0.063
n=Mf−2xp+6xA
Mf = 82.379
xp = 0.8408
xA = 0.063
n = 82.379 – 2( 0.8408) + 6(0.063)
= 81.075
The corresponding empirical reaction rate equations (Rase, 1977) are based on model
reaction Eqs.(1)~(4).
Cycloalkane transformed into arene:
r1=η kp1 (PE−PAPH3/Kp1) (8)
kp1= 9.87exp(23.21−34750/1.8T) (9)

247
34750
kp1 = 9.87 exp( 23.21 - ¿
1.8× 725.15 K
kp1 = 0.3252
Kp1=PAPH3/PE= 1.04×10−3exp(46.15−46045/1.8T)
= 1.04×10−3exp(46.15−46045/1.8×725.15)
= 5.154 × 10-19
r1 = 81.075 × 0.3252 ( -8.645×1014/ 5.154 × 10-19 )
= -4.422 × 1034
Cycloalkane transformed into alkane:
r2=η kp2 (PEPH−PP/Kp2) (10)
kp2=9.87exp(35.98−59600/1.8T) (11)
kp2=9.87exp(35.98−59600/1.8×725.15)
= 1.500×10-19
Kp2=PP/(PE·PH)=9.87exp(8000/(1.8×725.15)−7.12)
= 4684.975
r2 = 81.075× 1.500×10-19 ( 1.039×108/4684.975)
= 2.697 ×10-13
Hydrocracking of alkane:
r3=ηkp3PP/P (12)
kp3=exp(42.97−62300/1.8T) (13)
kp3=exp(42.97−62300/1.8×725.15)
= 1.930 ×10-21
248
5
r3 = 81.075× 1.930 ×10-21( )
9
= 8.693×10 -20
Hydrocracking of cycloalkane:
r4=ηkp4PE/P (14)
kp4=exp(42.97−62300/1.8T) (15)
kp4=exp(42.97−62300/1.8×725.15)
= 1.930 × 10-21
r4=ηkp4PE/P
2
= 81.075×1.930 × 10-21( )
9
= 8.693×10-20
where, η is corrective coefficient of catalyst; k p1 is reaction rate constant corresponding to r 1,
kmol/(h·kg cat·MPa); k p2 is reaction rate constant corresponding to r 2, kmol/(h·kg
cat·MPa2); k p3 is reaction rate constant corresponding to r 3, kmol/(h·kg cat); k p4 is reaction
rate constant corresponding to r 4, kmol/(h·kg cat); K p1 is equilibrium constant of cycloalkane
transformed into arene, (MPa)3; K p2 is equilibrium constant of cycloalkane transformed into
alkane, MPa−1; P is pressure of system or component fractional pressure, MPa; r 1 is reaction
rate of cycloalkane transformed into arene, kmol/(h·kg cat); r 2 is reaction rate of cycloalkane
transformed into alkane, kmol/(h·kg cat); r 3 is reaction rate of hydrocracking of alkane,
kmol/(h·kg cat); r 4 is reaction rate of hydrocracking of cycloalkane, kmol/(h·kg cat).
Occurrence of hydrocracking reaction occurring in the catalytic reforming process is the main
causative factor catalyst deactivation. For different periods of catalytic activity, the carbon
accumulation extent are not the same. Therefore, the values η are different from each other.
For new catalyst, η=1 and in other conditions, 0<η<1. The value of η can be calculated based
on working conditions and time span of the catalytic activity.
249
Where: 𝜌 is the bulk density of the catalyst (kg/m3) and n is the catalyst effectiveness factor.
The values of n are: 0< n <1; for new catalyst n = 1
The rate of reactions written for each specie following the reaction paths in Figure 2 are as
follows:
Rate of reaction of Aromatics (𝑟)
r A =r 1 ρb
= -4.422 × 1034 × 670
rA = -2.963 × 1037
Rate of reaction of Naphthene (𝑟)

r N = ρb (r 1−r 2−r 3)
= 670 ( -4.422 × 1034 -2.697 ×10-13 -8.693×10 -20)
= -2.963×1037
Rate of reactions of Paraffin (𝑟)

r p =ρb (r 2−r 4 )
= 670 ( 2.697 ×10-13 -8.693×10-20)
= - 1.807×10-10
Rate of reaction of H2 (𝑟)

n ( n−3 )
r H =ρb (3 r 1 −r 2− r 3+ r4 )
3 3
250
81.075 81.075−3
= 670 ( (3×-4.422 × 1034 ) -2.697 ×10-13 - 8.693×10 -20 + 8.693×10-20)
3 3
= -1.327 ×1035
ri = -5.913 ×1037
dC A
dt
As we know that,
XA
V dX
=∫ A
F A 0 0 −r A
Where FAO= 18412.99 kg/hr ; 214.10 Kmol/hr
XA = 80%
FAO= 71.367 Kmol/hr
FAO = 0.0198 Kmol/sec
For % conversion
0.8
W d Xa
=∫
0.0198 0 5.913× 1027
W=1071.54Kg
3.3.1.2 Volume of the bed
As we know that the bulk density of the catalyst 1100 kg/m3

As we know that the bulk density of the catalyst
Bulk density of the catalyst : 670 kg/m3
Hence, the volume of the catalyst will be V catalyst = 1071.54/670=1.599 m3
Porosity = (1-(r b/r d) x 100 = (1-(670/1100)) x 100 = 39.1%
= 0.391
251
v Bed = v catalyst /(1- Bed Porosity )=1.599 /(1-0.391)
v Bed = 2.626 m3
height and diameter of the bed
V Bed
HB=
πd 2
( )
4
H:D = 3:1 c
D3 = 4VBed / 3π
Dbed= 1.115 m3
HBed = 3.345m3
3.3.1.3 Height and Volume of Reactor
HR = H Bed + 0.15 (HBed)

HR = 3.345 + 0.15(3.345)
= 3.827 m3
Volume of the reactor

πD2
VReactor = HR( ¿
4
= 3.737 m3
Space Time and Space Velocity

Space time = VR / Volumetric flow rate
Volumetric flow rate
ṁ
vo=
p
˙ ¿mass flow rate
m=¿
p=¿ density
252
Butane inlet S5,
20.25 kg /hr
vo=
519.7 kg / m3
= 0.0390 m3/hr
N-pentane= 4.076 m3/hr

Cyclohexane = 0.483 m3/hr
N-hexane = 8.515 m3/hr
Benzene = 0.766 m3/hr
Toluene = 0.697 m3/hr
Heptane = 7.082 m3/hr
Total v0 = 21.619 m3/hr
(Rosen, 2014)
τ = V/v0
3.737 m3
=
21.619 m3 /hr
=0.173 hr
Space time=10.38 min

Space velocity = 1/space time
= 1/10.38
=0.096 min-1
3.3.1.4 Reactor Tubes sizing
a) Number of tubes
The number of tubes to be installed for the catalyst in multitubular reactor will be determined
using the equation below:
253
Volume of catalyst bed ,V bed (m 3 )
Number of tube, N =
Volume of catalyst bed per tube , V tube (m 3)
1.599
Number of tubes= = 12.11≈13
3.827 ×0.00345
π d 20
Volume of catalyst bed per tube, V tube ( m 3) = x Ltube
4
= 12.694 m3
The selection of tube will follow the fabricated tubing available in the market The tube
selected is the tube with NPS 2 inch (with outer diameter of 60.3mm) from ASME Schedule
10S. The number of tubes are fixed at 300 tubes. As reported in the Perry’s Chemical
Engineer’s Handbook, maximum number of tubes for multitubular reactor used in the
industries is 4000 tubes.
b) Tubes Arrangement
Generally, the tube will be arranged in triangular pattern as it give higher heat transfer rates.
The tube used 1.25 times the tube outside diameter.
Figure 3.20: Pipe size
254
Figure 3.21: Tube Characteristic
𝑑𝑜 = 0.0603 𝑚 𝑃𝑡 = 1.25𝑑𝑜 = 0.075375𝑚

c) Tube Bundle Diameter
Where 𝐷𝑏= bundle diameter

𝑁𝑡= number of tubes
𝑑𝑜= tube outer diameter
¿ 0.0603 ¿
¿ 0.3404 m
=0.3404/0.075375𝑚
= 4.516≈ 4 tubes
255
d) Total crosssectional area of the tube
Total cross section area of the tube can be obtained by dividing the volume of the bed
with the height of the bed.
2.626
At= =0.7851 m
3.345
3.3.1.5 Reactor shell sizing
a. Shell diameter
The reactor shell sizing can be determined by considering a clearance between the
outermost tube in the bundle and the shell inside diameter. The shell diameter must be
selected to give as close a fit to bundle as is practical. This can reduce the bypassing
possibility of heat transfer media round the outside of the bundle. For fixed and tube, the
typical shell clearance obtained from Figure 12.10 of Coulson & Richardson Chemical
Design 646.
Clearance, C(mm) =10 Db+ 8
With the bundle diameter 0.3404m, clearance calculated is 11.404mm
Shell diameter, Ds= Db – C= 0.3404-0.011404= 0.3290m
b. Baffle configuration
The function of using baffle is to increase the fluid velocity, and so to improve the rate of
heat transfer. Single segmental baffle with 25% baffle cut will be sued for optimum heat
transfer rate. The baffle spacing used is normally at the range of 0.2 to 1.0 shell diameter.
Since close baffle spacing give higher heat transfer coefficient, factor of 0.25 will be used.
Baffle spacing = 0.25Ds=0.0823m
Number of baffles = Lt/lB=7.32m/0.0823= 88 baffles
c. Area for cross flow

256
( Pt −D O )× D S × B s
A S=
Pt
0.01508 m×0.329 × 0.0823
¿ =5.417 ×10−3 m 2
0.075375 m
d. Process fluid inlet
˙ 0.45 ρ0.13
Di=0.363mv
Volumetric flow ratemv=

˙ 21.619 m3/hr
Density, ρ=533.011 kg/m 3
Di=3.273 m
The 14 in Sch 80S pipe with inlet diameter of 366.9can well accommodate the inlet nozzle
size.
e. Process fluid outlet
For process fluid outlet, the same formula that used in nozzle calculation
˙ 0.45 ρ0.13
Di=0.363mv
Di= 3.272m
The 16 in Sch 80S pipe with inlet diameter of 371mm can well accommodate the inlet nozzle
size
3.3.1.6 Jacketed Vessel
Jacket is used in exothermic vessel to reduce the temperature fluctuation of the vessel.
Conventional jacket is selected. The heating or cooling medium circulates in the annular
space between the jacket and vessel walls and the heat is transferred through the wall of the
vessel. Circulation baffles are usually installed in the annular space to increase the velocity of
the liquid flowing through the jacket and improve the heat transfer coefficient.
257
a) Heat Transfer Coefficient of Jacket.
General heat transfer formula is Q

The cooling medium used for jacket is cooling water. Assume the inlet temperature of water
is 298 K and the outlet temperature is 313 K (Sinnott, 2005).
Mean temperature difference,

At 305.5 K, specific heat capacity, Cp = 4.174 kJ/kgK
From Energy Balance calculated, Q for reactor is 8460.68 kW
Mass flow rate of cooling water,
8460.68 kW 1kJ / s 3600 s

¿ × =135.263 kg /s×
( 4.174 kJ /kgK )(313 K −298 K ) 1 KW 1hr
=486946.8kg/h
From Coulson & Richardson’s Chemical Engineering, pg 775 (Sinnott, 2005), the spacing
between the jacket and vessel wall will depend on the size of the vessel, but will typically 100
mm and the pitch between the spirals is 300mm. Thus, the baffle forms a continuous spiral
channel, section 100mm x 300mm.
According to Coulson & Richardson’s Chemical Engineering, pg 650 (Sinnott, 2005),

optimum baffle cut is between 20 to 25 % as it give a good heat transfer rate without
excessive drop. Thus, assume 25% of spiral baffle cut.
Height of jacket equal to 70% of vessel height since the vessel is 70% filled,
Height of jacket, Hj = 0.7
H = 0.7 ¿) = 0.7805 m = 780.5mm
height of jacket
Number of spiral =
pitch
780.5mm
=
300 mm
258
= 2.602≈ 3
Length of channel, L = No. spirals x π x Reactor diameter

=3(π)(1.115m ¿
=10.508 m
Cross sectional area of channel = (100 mm × 300 mm) = 30,000 mm2
2
1m
= 30,000 mm2x( )
1000 mm
= 0.03 m2
Hydraulic mean diameter,
=
1m
=150 mm×
1000 mm
=0.15m
Physical properties for water at 305.5 K (Holman, 2010),

Density, ρ= 994.8 kg/ m3
Viscosity, µ = 7.61 x 10-4kg/ms
Thermal conductivity,
Cp = 4.174 kJ/kgK

Cp = 4.174 kJ/kgK
CP× μ
Prandtl Number, Pr¿
Kf
=5.10
259
Velocity through channel,
31.5886 kg /s
¿
994.8 kg/m 3 ×0.03 m 2
=1.0585m/s
Reynolds number, Re
¿
994.8 kg/m3 ( 1.0585s m )0.15 m
−4
7.61 ×10 kg/ms
=207555.0197
Nu=1.10 ℜ0.62 Pr 0.33 ¿
The viscosity correction factor, is neglected since viscosity of water is not significant.
Nu=1.10(207555.0197)0.62(5.10)0.33
=3728.3223
Heat transfer coefficient of jacket, hj to vesssel wall for agitated vessel can be calculated
using following equation:
Nu x K f
h j=
de
0.623W
3728.3223×
mK
h j= =154849.96529 W /m 2 K
0.15 m
a) Pressure Drop across Jacket Vessel
Pressure drop equation (Sinnott, 2005):

L u2
ΔP= 8 x f x xρ
de 2
Value of f can be determined by referring graph in Figure 3.4. When Re = 207555.0197
207555 with the pipe roughness is assumed to 0.03, 0.0075
260
5.6901 m
∆ P=8 ×0.0075 × × 994.8 kg /m3 ¿ ¿
0.15 m
1 N /m 2
=1268.4326 kg/ms2×
1kg /m s2
=1268.4326N/m2
3.3.1.7 Design Pressure
0.001 N /mm 2
Operating pressure=1000 kPa×
1 kPa
= 1N/mm2
The hydrostatic pressure in the base of the column should be added to the operating pressure
if significant. Phydrostatic =ρgh=¿(685.300kg/m3)(9.81m/s2)(3.345m)
¯¿ 0.1 N /m m2
=22487.743kg/ms2×1 × ¿
106 kg /m s2 1 ¯¿ ¿
= 2.249 ×10-3 N/mm2
Hydrostatic pressure can be neglected since it is not significant.

above the normal working pressure, to avoid spurious operation during minor process upsets
(Sinnott, 2005). Thus, for safety reason, take pressure 10% above operating pressure.
N 110 %
¿1 × =1.1 N /mm 2
mm 2
100 %
3.3.1.8 Design Temperature
261
temperatures (Sinnott,2005).
Operating temperature = 502 ℃
Monel 400 is a nickel-copper alloy
Monel 400 has great mechanical properties at subzero temperatures, can be used in
temperatures up to 1000° F,
3.3.1.9 Material Construction
Other common names: Alloy 400

Monel 400 is a nickel-copper alloy (about 67% Ni – 23% Cu) that is resistant to sea water
and steam at high temperatures as well as to salt and caustic solutions. Alloy 400 is a solid
solution alloy that can only be hardened by cold working. This nickel alloy exhibits
characteristics like good corrosion resistance, good weldability and high strength. A low
corrosion rate in rapidly flowing brackish or seawater combined with excellent resistance to
stress-corrosion cracking in most freshwaters, and its resistance to a variety of corrosive
conditions led to its wide use in marine applications and other non-oxidizing chloride
solutions. This nickel alloy is particularly resistant to hydrochloric and hydrofluoric acids
when they are de-aerated. As would be expected from its high copper content, alloy 400 is
rapidly attacked by nitric acid and ammonia systems.
temperatures up to 1000° F, and its melting point is 2370-2460° F. However, alloy 400 is low
in strength in the annealed condition so, a variety of tempers may be used to increase the
strength.
262
3.3.1.10 Minimum Wall Thickness of Cylindrical Section of the Shell
For a cylindrical shell the minimum thickness required to resist internal pressure can be
determined from equation below (Sinnott, 2005):
Pi D i
e= 2 Jf −Pi
where,
e = wall thickness
Pi = design pressure
Di = shell diameter
J = joint factor
f = design stress
According to (Sinnott, 2005), the possible lower strength of a welded joint compared
with the virgin plate is usually allowed for in design by multiplying the allowable design
stress for the material by a “welded joint factor” J. The value of the joint factor used in design
will depend on the type of joint and amount of radiography required by the design code.
Taking the factor as 1.0 implies that the joint is equally as strong as the virgin plate; this is
achieved by radiographing the complete weld length, and cutting out and remaking any
defects.
1000 mm ¿
(1 N /mm 2 )×(1.115 m)¿
e= 1m 240 N 1N
( 2 ×1 ×
mm 2)−(
m m2
)
= 2.3278 mm
(Sinnott, 2005) said that low-alloy steels severe corrosion is not expected, a minimum
allowance of 2.0 mm should be used.
So minimum wall thickness is
263
e + corrosion allowance = 2.3278mm + 2mm = 4.3278mm
This value should not be less than 7mm (including 2mm of corrosion allowance ) according
to Coulson Richardson’s Chemical Engineering, pg 814 (Sinnott, 2005). Hence, use the
minimum wall thickness of 7 mm. a much thicker wall is needed to ensure the vessel is
sufficient rigid to withstand its own weight.
3.3.1.11 Head and Closure
Standard torispherical heads (dished ends) are the most commonly used end closure for
vessels up to operating pressures of 15 bar. They can be used for higher pressures, but above
10 bar their cost should be compared with that of an equivalent ellipsoidal head.
Above 15 bar an ellipsoidal head will usually prove to be the most economical closure to use.
P i Rc C s
End Thickness, e h=
2 fJ −Pi (C s −0.2)
Where,
Cs = Stress concentration factor for torispherical heads
1
C s= ¿
4
Rc = crown radius
Rk = knuckle radius
According to Coulson & Richardson’s Chemical Engineering, pg 819 (Sinnott, 2005), the
crown radius should not be greater than the diameter of the cylindrical section and the ratio of
the knuckle to crown radii should not be less than 0.06, to avoid buckling.
So, we can assume Rc = DT = 1.115m (1000mm/1m) =1115mm
Rk = 0.06 Rc Rc = 0.06 (1115mm) = 66.90 mm
264
1
Cs = ¿
4
=1.771 mm
Assume the joint factor, J = 1 where the joint is equally as strong as the virgin plate; this is
defects
(1 N / m m2 )1115 mm(1.771)
e h=
240 N 1N
2
( mm 2) −(
m m2
)(1.771−0.2)
=4.1273 mm
e + corrosion allowance = 4.1273mm + 2mm = 6.1273 m
3.3.2 Packed Bed Reactor (R-102)
Table 3.17: Information of the Inlet stream into PFR- R-102

Mass Mass
o
Mole Temperature( Pressur Density,
Strea Compone flowrat C) e (bar) p
fractio fractio
m nt e (kg/m3)
(kg/hr) n n
Butane 20.25 0.001 0.000 502 45.596 519.7
1 5 2
Isopentane 2152.4 0.116 0.046 502 45.596 -
8 9 5 2
N-pentane 2448.9 0.133 0.052 502 45.596 600.8
Inpu 3 0 9 2
t Cyclohexa 71.81 0.003 0.001 502 45.596 744.1
ne 9 3 2
S7 N-hexane 1131.3 0.061 0.020 502 45.596 664.3
1 4 5 2
Methyl 502 45.596 -
0.004 0.001
cyclohexan 80.00 2
3 3
e
Benzene 4953.5 0.269 0.098 502 45.596 764.2
2 0 8 2
Toluene 5684.5 0.308 0.096 502 45.596 792.6
265
5 7 2 2
Heptane 1007.5 0.054 0.015 502 45.596 711.4
7 7 7 2
Hydrogen 862.03 0.046 0.666 502 45.596 7.82×10
-10
8 4 2
Total 18412.4 0.999 1.000
5 8 0
Volume inlet = (0.0011×519.7) + (0.1133×600.8) + (0.0195×744.1) + (0.3072×664.3) +

(0.0318×764.2) + (0.003×792.6) + (0.2736×711.4) + (0.0468 × 7.82×10-10 )
= 508.54 m3

Mass Temperature Pressure
Mass Mole
Stream Component flowrate (0C) (bar)
fraction fraction
(kg/hr)
Butane 20.25 0.0011 0.0005 433 45.5962
Isopentane 2152.48 0.1169 0.0406 433 45.5962
N-pentane 2448.93 0.1330 0.0462 433 45.5962
Cyclohexan 433 45.5962
Outpu 71.81 0.0039 0.0012
e
t N-hexane 0.00 0.0000 0.0000 433 45.5962
S8
Methyl 433 45.5962
80.00 0.0043 0.0011
cyclohexane
Benzene 5978.48 0.3247 0.1041 433 45.5962
Toluene 6610.46 0.3590 0.0976 433 45.5962
Heptane 0.00 0.0000 0.0000 433 45.5962
Hydrogen 1050.45 0.0570 0.7088 433 45.5962
Total
18412.86 1.0000 1.0000
Volume of outlet = (0.0011×591.2) + (0.1130×674.1) + (0.0039 ×815.8) + (0.0614×738.2) +

(0.2690 ×833.8) + ( 0.3087 ×865.1) + (0.0547×786.3)
= 659.69 m3
Volume of reactor = 1168.23 m3
Since plug flow reactor is used, then the volume needed for conversion for the reaction can
be calculated by using the design equation as below (introduction design )
266
XA
V dX
=∫ A
F A 0 0 −r A
V= Working volume of ideal , m3
FAO= Molar flow rate of limiting reactant A at inlet, kmol/s
XA= Fractional conversion of limiting reactant required
dC A
dt
rA= -5.913 ×1037
dC A
dt
rA= -5.913 ×1037
As we know that,
XA
V dX
=∫ A
F A 0 0 −r A
Where FAO= 18412.99 kg/hr ; 214.10 Kmol/hr
XA = 80%
FAO= 71.367 Kmol/hr
FAO = 0.0198 Kmol/sec
For % conversion
0.8
W d Xa
=∫
0.0198 0 5.913× 1027
267
W=1071.54Kg
3.3.2.1 Volume of the bed
As we know that the bulk density of the catalyst 1100 kg/m3

As we know that the bulk density of the catalyst
Bulk density of the catalyst : 670 kg/m3
Hence, the volume of the catalyst will be V catalyst = 1071.54/670=1.599 m3
Porosity = (1-(r b/r d) x 100 = (1-(670/1100)) x 100 = 39.1%
= 0.391
v Bed = v catalyst /(1- Bed Porosity )=1.599 /(1-0.391)

v Bed = 2.626 m3
height and diameter of the bed
V Bed
HB=
πd 2
( )
4
H:D = 3:1 c
D3 = 4VBed / 3π
Dbed= 1.115 m3
HBed = 3.345m3
3.3.2.2 Height and Volume of Reactor
HR = H Bed + 0.15 (HBed)

HR = 3.345 + 0.15(3.345)
= 3.827 m3
268
3.3.2.3 Volume of the reactor
πD2
VReactor = HR( ¿
4
= 3.737 m3
Space Time and Space Velocity

Space time = VR / Volumetric flow rate
ṁ
Volumetric flow rate vo=
p
˙ ¿mass flow rate
m=¿
p=¿ density
Butane inlet S7,
20.25 kg /hr
vo=
519.7 kg / m3
= 0.0390 m3/hr
N-pentane= 4.076 m3/hr

Cyclohexane = 0.0965 m3/hr
N-hexane = 1.7048m3/hr
Benzene = 6.4820m3/hr
Toluene = 7.1720 m3/hr
Heptane = 1.4163m3/hr
Hydrogen = 1.1023 m3/hr
Total v0 = 22.049 m3/hr
(Rosen, 2014)
τ = V/v0
3.737 m3
=
22.049 m3 /hr
=0.169 hr
269
Space time=10.14 min
Space velocity = 1/space time
= 1/10.14
=0.099 min-1
For viscosity at the outlet stream

Tout = 706.15 K
log10 µliq = A + B/T + CT + CT 2
By referring (Yaws C.L., 1995),

For all components
µG = A + BT + CT 2
Viscosity at outlet stream, µ =
533.517
Total viscosity, µ = =72.885kg/m3
7.32
Component yi µ 1 yi× µ×
Mj
2
1
Mj
2
n - Butane, 0.0005 165.106 7.626 0.630

C4H10
n - Pentane 0.0529 152.665 8.494 68.597
Cyclohexane 0.0013 155.380 9.174 1.853
270
n - Hexane 0.0205 148.389 9.283 28.237
Benzene 0.0988 176.894 8.838 154.462
Toluene 0.0962 163.536 9.599 151.013
Heptane 0.0157 135.001 10.010 21.216
Hydrogen 0.664 161.106 1.005 107.509
3.3.2.4 Reactor Tubes sizing
a) Number of tubes
The number of tubes to be installed for the catalyst in multitubular reactor will be determined
using the equation below:
Volume of catalyst bed ,V bed (m 3 )
Number of tube, N = 3
Volume of catalyst bed per tube , V tube (m )
1.599
Number of tubes= = 12.11≈13
3.827 ×0.00345
3 π d 20
Volume of catalyst bed per tube, V tube ( m ) = x Ltube
4
271
= 12.694 m3
The selection of tube will follow the fabricated tubing available in the market The tube
selected is the tube with NPS 2 inch (with outer diameter of 60.3mm) from ASME Schedule
10S. The number of tubes are fixed at 300 tubes. As reported in the Perry’s Chemical
Engineer’s Handbook, maximum number of tubes for multitubular reactor used in the
industries is 4000 tubes.
b) Tubes Arrangement
Generally, the tube will be arranged in triangular pattern as it give higher heat transfer rates.
The tube used 1.25 times the tube outside diameter.
Figure 3.22: Pipe Size
Figure 3.23: Tube Characteristic

𝑑𝑜 = 0.0603 𝑚 𝑃𝑡 = 1.25𝑑𝑜 = 0.075375𝑚
c) Tube Bundle Diameter
Db =d 0 ¿
Where 𝐷𝑏= bundle diameter
𝑁𝑡= number of tubes
272
𝑑𝑜= tube outer diameter
¿ 0.0603 ¿
¿ 0.3404 m
=0.3404/0.075375𝑚
= 4.516≈ 4 tubes
d) Total crosssectional area of the tube
Total cross section area of the tube can be obtained by dividing the volume of the bed
with the height of the bed.
2.626
At= =0.7851 m
3.345
3.3.2.5 Reactor shell sizing
a. Shell diameter
The reactor shell sizing can be determined by considering a clearance between the
outermost tube in the bundle and the shell inside diameter. The shell diameter must be
selected to give as close a fit to bundle as is practical. This can reduce the bypassing
possibility of heat transfer media round the outside of the bundle. For fixed and tube, the
typical shell clearance obtained from Figure 12.10 of Coulson & Richardson Chemical
Design 646.
Clearance, C(mm) =10 Db+ 8
273
With the bundle diameter 0.3404m, clearance calculated is 11.404mm
Shell diameter, Ds= Db – C= 0.3404-0.011404= 0.3290m
b. Baffle configuration
The function of using baffle is to increase the fluid velocity, and so to improve the rate of
heat transfer. Single segmental baffle with 25% baffle cut will be sued for optimum heat
transfer rate. The baffle spacing used is normally at the range of 0.2 to 1.0 shell diameter.
Since close baffle spacing give higher heat transfer coefficient, factor of 0.25 will be used.
Baffle spacing = 0.25Ds=0.0823m
Number of baffles = Lt/lB=7.32m/0.0823= 88 baffles
c. Area for cross flow

( Pt −D O )× D S × B s
A S=
Pt
0.01508 m×0.329 × 0.0823
¿ =5.417 ×10−3 m 2
0.075375 m
d. Process fluid inlet
˙ 0.45 ρ0.13
Di=0.363mv
Volumetric flow ratemv=

˙ 22.049m3/hr
Di=3.303 m
The 14 in Sch 80S pipe with inlet diameter of 366.9can well accommodate the inlet nozzle
size.
e. Process fluid outlet
For process fluid outlet, the same formula that used in nozzle calculation
˙ 0.45 ρ0.13
Di=0.363mv
Di= 3.301m
The 16 in Sch 80S pipe with inlet diameter of 371mm can well accommodate the inlet nozzle
size
274
3.3.2.6 Jacketed Vessel
Jacket is used in exothermic vessel to reduce the temperature fluctuation of the vessel.
Conventional jacket is selected. The heating or cooling medium circulates in the annular
space between the jacket and vessel walls and the heat is transferred through the wall of the
vessel. Circulation baffles are usually installed in the annular space to increase the velocity of
the liquid flowing through the jacket and improve the heat transfer coefficient.
a) Heat Transfer Coefficient of Jacket.
General heat transfer formula is Q

The cooling medium used for jacket is cooling water. Assume the inlet temperature of water
is 298 K and the outlet temperature is 313 K (Sinnott, 2005).
Mean temperature difference,

At 305.5 K, specific heat capacity, Cp = 4.174 kJ/kgK
From Energy Balance calculated, Q for reactor is 8460.68 kW
Mass flow rate of cooling water,
8460.68 kW 1kJ / s 3600 s

¿ × =135.263 kg /s×
( 4.174 kJ /kgK )(313 K −298 K ) 1 KW 1hr
=486946.8kg/h
From Coulson & Richardson’s Chemical Engineering, pg 775 (Sinnott, 2005), the spacing
between the jacket and vessel wall will depend on the size of the vessel, but will typically 100
mm and the pitch between the spirals is 300mm. Thus, the baffle forms a continuous spiral
channel, section 100mm x 300mm.
275
According to Coulson & Richardson’s Chemical Engineering, pg 650 (Sinnott, 2005),
optimum baffle cut is between 20 to 25 % as it give a good heat transfer rate without
excessive drop. Thus, assume 25% of spiral baffle cut.
Height of jacket equal to 70% of vessel height since the vessel is 70% filled,
Height of jacket, Hj = 0.7
H = 0.7 ¿) = 0.7805 m = 780.5mm
height of jacket
Number of spiral =
pitch
780.5mm
=
300 mm
= 2.602≈ 3
Length of channel, L = No. spirals x π x Reactor diameter

=3(π)(1.115m ¿
=10.508 m
Cross sectional area of channel = (100 mm × 300 mm) = 30,000 mm2
2
1m
= 30,000 mm2x( )
1000 mm
= 0.03 m2
Hydraulic mean diameter,
=
1m
=150 mm×
1000 mm
=0.15m
Physical properties for water at 305.5 K (Holman, 2010),

Cp = 4.174 kJ/kgK
276
Cp = 4.174 kJ/kgK
CP× μ
Prandtl Number, Pr¿
Kf
=5.10
Velocity through channel,
31.5886 kg /s
¿
994.8 kg/m 3 ×0.03 m 2
=1.0585m/s
Reynolds number, Re
¿
994.8 kg/m3 ( 1.0585s m )0.15 m
−4
7.61 ×10 kg/ms
=207555.0197
Nu=1.10 ℜ0.62 Pr 0.33 ¿
The viscosity correction factor, is neglected since viscosity of water is not significant.
Nu=1.10(207555.0197)0.62(5.10)0.33
=3728.3223
Heat transfer coefficient of jacket, hj to vesssel wall for agitated vessel can be calculated
using following equation:
Nu x K f
h j=
de
277
0.623W
3728.3223×
mK
h j= =154849.96529 W /m 2 K
0.15 m
b) Pressure Drop across Jacket Vessel
Pressure drop equation (Sinnott, 2005):

L u2
ΔP= 8 x f x xρ
de 2
Value of f can be determined by referring graph in Figure 3.4. When Re = 207555.0197

207555 with the pipe roughness is assumed to 0.03, f=0.0075
5.6901 m
∆ P=8 ×0.0075 × × 994.8 kg /m3 ¿ ¿
0.15 m
1 N /m 2
=1268.4326 kg/ms2×
1kg /m s2
=1268.4326N/m2
3.3.2.7 Design Pressure
0.001 N /mm 2
Operating pressure=1000 kPa×
1 kPa
= 1N/mm2
The hydrostatic pressure in the base of the column should be added to the operating pressure
if significant. Phydrostatic =ρgh=¿(685.300kg/m3)(9.81m/s2)(3.345m)
¯¿ 0.1 N /m m2
=22487.743kg/ms2×1 × ¿
106 kg /m s2 1 ¯¿ ¿
= 2.249 ×10-3 N/mm2
Hydrostatic pressure can be neglected since it is not significant.

278
above the normal working pressure, to avoid spurious operation during minor process upsets
(Sinnott, 2005). Thus, for safety reason, take pressure 10% above operating pressure.
N 110 %
¿1 × =1.1 N /mm 2
mm 2
100 %
3.3.2.8 Design Temperature
temperatures (Sinnott,2005).
Operating temperature = 502 ℃
Monel 400 is a nickel-copper alloy
temperatures up to 1000° F,
3.3.2.9 Material Construction
Other common names: Alloy 400

Monel 400 is a nickel-copper alloy (about 67% Ni – 23% Cu) that is resistant to sea water
and steam at high temperatures as well as to salt and caustic solutions. Alloy 400 is a solid
solution alloy that can only be hardened by cold working. This nickel alloy exhibits
characteristics like good corrosion resistance, good weldability and high strength. A low
corrosion rate in rapidly flowing brackish or seawater combined with excellent resistance to
stress-corrosion cracking in most freshwaters, and its resistance to a variety of corrosive
conditions led to its wide use in marine applications and other non-oxidizing chloride
solutions. This nickel alloy is particularly resistant to hydrochloric and hydrofluoric acids
when they are de-aerated. As would be expected from its high copper content, alloy 400 is
rapidly attacked by nitric acid and ammonia systems.
temperatures up to 1000° F, and its melting point is 2370-2460° F. However, alloy 400 is low
in strength in the annealed condition so, a variety of tempers may be used to increase the
strength.
279
3.3.2.10 Minimum Wall Thickness of Cylindrical Section of the Shell
For a cylindrical shell the minimum thickness required to resist internal pressure can be
determined from equation below (Sinnott, 2005):
Pi D i
e= 2 Jf −Pi
where,
e = wall thickness
Pi = design pressure
Di = shell diameter
J = joint factor
f = design stress
According to (Sinnott, 2005), the possible lower strength of a welded joint compared
with the virgin plate is usually allowed for in design by multiplying the allowable design
stress for the material by a “welded joint factor” J. The value of the joint factor used in design
will depend on the type of joint and amount of radiography required by the design code.
Taking the factor as 1.0 implies that the joint is equally as strong as the virgin plate; this is
defects.
1000 mm ¿
(1 N /mm 2 )×(1.115 m)¿
e= 1m 240 N 1N
( 2 ×1 ×
mm 2)−(
m m2
)
= 2.3278 mm
(Sinnott, 2005) said that low-alloy steels severe corrosion is not expected, a minimum
allowance of 2.0 mm should be used.
e + corrosion allowance = 2.3278mm + 2mm = 4.3278mm
This value should not be less than 7mm (including 2mm of corrosion allowance ) according
to Coulson Richardson’s Chemical Engineering, pg 814 (Sinnott, 2005). Hence, use the
280
minimum wall thickness of 7 mm. a much thicker wall is needed to ensure the vessel is
sufficient rigid to withstand its own weight.
3.3.2.11 Head and Closure
Standard torispherical heads (dished ends) are the most commonly used end closure for
vessels up to operating pressures of 15 bar. They can be used for higher pressures, but above
10 bar their cost should be compared with that of an equivalent ellipsoidal head.
Above 15 bar an ellipsoidal head will usually prove to be the most economical closure to use.
P i Rc C s
End Thickness, e h=
2 fJ −Pi (C s −0.2)
Where,
Cs = Stress concentration factor for torispherical heads
1
C s= ¿ )
4
Rc = crown radius
Rk = knuckle radius
According to Coulson & Richardson’s Chemical Engineering, pg 819 (Sinnott, 2005), the
crown radius should not be greater than the diameter of the cylindrical section and the ratio of
the knuckle to crown radii should not be less than 0.06, to avoid buckling.
So, we can assume Rc = DT = 1.115m (1000mm/1m) =1115mm
Rk = (0.06)Rc = 0.06 (1115mm) = 66.90 mm
1
Cs = ¿
4
=1.771 mm
Assume the joint factor, J = 1 where the joint is equally as strong as the virgin plate; this is
defects
281
(1 N / m m2 )1115 mm(1.771)
e h=
240 N 1N
2
( mm 2) −(
m m2
)(1.771−0.2)
=4.1273 mm
e + corrosion allowance = 4.1273mm + 2mm = 6.1273 m
282
Table 3.19: Specification sheet of Reactor (R-101)
TOLUENE REACTOR SPECIFICATION SHEET
IDENTIFICATION
Item Reactor
Item No R-101
Function To allow catalytic reforming to occur in
the presence of catalyst(Platinum-
Rhenium) that convert light naphtha to
Toluene
OPERATING DATA
Operation Continuous
Inlet pressure (kPa) 4559.62
Outlet pressure (kPa) 4559.62
Temperature (℃) 502oC
Reactor sizing Data
Volume reactor (m3) 1168.23m3 Cross section area 0.7851m
of the tube
Vessel filled (%) 70% Number of tubes 13
Length (m) 3.345m3 Weight of the 0.087kg
catalyst
3
Diameter(m) 1.115m Height of bed (m) 3.345
Velocity through 1.0585min-1 Volume of the 2.626
channel(m/s) bed(m3)
Space time(min) 10.38 min Space velocity (min- 0.096
1
)
Cooling Jacket Data
Type of jacket Conventional jacket Number of spiral 3
with spiral baffle
Fluid handled Cooling water Length of 10.508
channel(m)
Height of the jacket 0.7805 Cross sectional area 0.03 m2
(m) m2
Spacing between the 0.10 Hydraulic mean 0.15m
jacket and vessel diameter(m)
(m)
Pitch between the 0.30 Pressure drop across 1268.4326
283
spiral (m) jacket vessel (N/m2)
MATERIAL CONSTRUCTION
Vessel
Type of material for impeller Monel 400- Nickel-copper alloy
Type of material for support Monel 400- Nickel-copper alloy
284
Table 3.20: Specification sheet of Reactor (R-102)
IDENTIFICATION
Item Reactor
Item No R-102
Toluene
OPERATING DATA
Reactor sizing Data
of the tube
catalyst
Diameter(m) 1.115m3 Height of bed (m) 3.345
1
)
Cooling Jacket Data
with spiral baffle
channel(m)
(m) m2
(m)
285
Vessel
286
3.4 Auxillary Equipment Design
3.4.1 Pump
A wide range of processes and applications require the use of pump for their
operations in various industries. A great variety of high-pressure pumps are available in
different sizes, design and characteristic. Pumps play an importance role in the production
process and are indispensable for smooth operations. The main purpose of a pump to provide
the energy needed to move a liquid from one location to another and it also design to increase
the pressure of the liquid.
S1=18412.99kg/hr S2=18412.99kg/hr
T=298K P-101 T=298K
P=0.71atm P=1.01atm
Table 3.21: Physical properties of inlet and outlet stream of P-101
Parameter Inlet flow Outlet flow
Temperature(K) 298 298
Pressure(bar) 0.7093 1.0133
Density(kg/m3) 740 740
Dynamic viscosity(kg/ms) 0.00051 0.00051
Flowrate(kg/s) 5.1147 5.1147
The density and dynamic viscosity of the mixture are shown in Handbook of Petroleum
Refining Process, Page 527 in Table 10.5.1 (Robert A. Meyers, 2004).
3.4.1.1 Pipe selection of nozzle
By referring Chemical Engineering Design, page 221, the optimum diameter can be
calculated by using the following formula.
For carbon steel:
d ,optimum=293G 0.53 ρ−0.37
5.1147 kg 0.53
=293( ) ¿
s
287
¿
=60.3847mm(1∈ 25,4 mm ¿
=2.3773in
..˙ the resulting size is 2.3773 in which is not standard pipe size
By referring Plant Design and Economics Book for Chemical Engineers, page 962 in Table
1
D-13, nominal pipe size choose is 2 , schedule 40.
2
25.4 mm
Outside diameter=2.88in( )
1∈¿ ¿
=73.1520mm
25.4 mm
Inside diameter=2.469in( )
1∈¿ ¿
=62.7126mm
73.1520mm−62.7126 mm
Wall thickness=
2
=5.2197mm
3.4.1.2 Reynolds Number
By referring Chemical Engineering Design, page 202

4G
Re=
µ πdi
5.1147 kg
4( )
s
=
0.00051 kg 1m
π( )(62.7126 mm)( )
ms 1000 mm
=203612.9056
..Since
˙ Re>4000, so the flow is turbulent flow
From Table 5.2, absolute roughness commercial steel pipe=0.046mm
absolute roughness , ε
Relative roughness, e=
pipe inside diameter , di
0.046 mm
=
62.7126 mm
=0.0007
By referring Fluid Mechanics Third Edition Book, page 952 in Figure A-12, we can get the
value of friction factor by plotting the value of Reynolds number and absolute roughness.
Friction factor,f =0.0295
288
Figure 3.24: Moody diagram
3.4.1.3 Static head
Evaporator
z2
Storage tank z 1
Assumption for pipe length and elevation L

z 1=1.5m z 2=3m
Elevation, Δz=1.5m
Total pipe length=25m+25m
=50m
Difference in pressure, ΔP=1.0133bar-0.7093bar
=0.3040bar
ΔP
Static head= +Δz
ρg
=0.3040 −¿
¯ ¿ +1.5m
=5.6877m
289
3.4.1.4 Dynamic head
π 2
A= di
4
π
= ¿
4
=0.0031m 2
ṁ
Liquid velocity, v1 =
ρA
5.1147 kg / s
= ( 740 kg )(0.0031m 2)
m3
=2.2296m/s
Volumetric flowrate, Q= v1 A
=2.2296m/s(0.0031m 2 ¿
=24.8823m3 /hr
By referring Chemical Engineering Design, page 204 in Table 5.3, miscellaneous losses of
pipe fittings and valves are obtained
Table 3.22: Miscellaneous losses of pipe fittings and valves
Fitting/Valve Number of velocity head, K Equivalent pipe diameter
Entry 0.5 25
Elbow 0.8x2 40x2
Exit 1.0 50
Total Σ K L=3.1 155
Length of miscellaneous losses, L=pipe length + (equivalent pipe diameter x di)

=50m + (155 x 0.06277)
=59.7185m
ρv 2
Pressure drop in pipeline, Δ Pf =8 f ( L ) 1
di 2
59.7185m 740 kg
= 8(0.0295)( ¿( )¿¿
0.0627 m m3
=413436.6645N/m 2
Δ Pf
Dynamic head=
ρg
413436.6645 N /m2
= 740 kg 9.81 m
( )( )
m3 s2
=56.9519m
290
3.4.1.5 Total head, H
Total head, H= static head + dynamic head

= 5.6877m + 56.9519m
= 62.6396m
3.4.1.6 Head loss, h L
By referring Fluid Mechanics Third Edition: Fundamental and Applications, page 376
L v 21
h L, total =(f + Σ K L )
D 2g
59.7185m
= [(0.0295 +3.1¿ x ¿ ¿]
0.0627 m
= 7.9044m
3.4.1.7 Shaft Power
−Ẇ s P 2−P1 ( v 22−v12)

= + + g ( z 1−z 2 ) + ^
F
ṁ ρ 2⍺
Where −W ˙ s=shaft power, kW
ṁ=mass flowrate, kg/s
P 2−P1
=flow energy
ρ
v 22−v 21
=kinetic energy, ⍺=1 (turbulent flow)
2⍺
g( z 1−z 2 ¿=¿ potential energy
^
F=h L g Outlet velocity, v 2=√ 2 gΔz
9.81 m
= (7.9044m)(9.81m/ s2 ¿
= 77.5422m
√ s )(1.5 m)
= 2(
=5.4249m/s
−W ˙ s 105 kg/m s 2
= ¿ ¿( +¿ ¿+(9.81m/s2 ¿ (1.5 m ) +¿
ṁ 1 ¯¿ ¿
77.5422m
m2
= 145.5675 2
s
m2
-Ẇ s= 145.5675 2 (5.1147kg/s)(1kW/1000kgm2 /s 3 ¿
s
= 0.7445 kW
291
3.4.1.8 Pump power
−Ẇ s
W˙ p =
ƞ
where Ẇ p =¿ pump power, Kw
Ẇ s = shaft power
Ƞ = pump efficiency
By referring Chemical Engineering Design, page 224 in Figure 5.9, centrifugal pump
efficiency, ƞ=72%
Figure 3.25: Centrifugal pump efficiency
−0.7445 kW
Ẇ p =
0.72
= 1.0340kW
3.4.1.9 Power required for pumping
By referring Chemical Engineering Design, page 220

Power,P = volumetric flowrate, Q x pressure drop, ΔP
292
100 kPa
= 0.0070m 3 /s (1.0133bar-0.7093bar)(
1 ¯¿ ¿
= 0.2128 kW
3.4.1.10 Pump selection
By referring Chemical Engineering Design, page 200 in Figure 5.6, pump selection is made
on flow rate and head required, together with other process considerations such as corrosion
or the presence of solids in the fluid. From the calculated total head, H=62.6396m and
volumetric flowrate, Q=24.8823m 3 /hr , single stage with 3500 rpm centrifugal pump is
selected.
Figure 3.26: Centrifugal pump selection. *Single stage>1750 rpm, multi-stage 1750 rpm
3.4.1.11 Impeller speed
v
Impeller speed, n=
πD
√ 2 Hg
=
πD
√ 2( 62.6396 m)(9.81 m/s 2¿ )
= ¿
π (150 x 10−3 m)
293
35.0570 m/ s 60 s
= x
0.4712 m 1min
=4463.9643rpm
By referring Chemical Engineering Design, page 209 in Figure 5.10
Flowrate=24.8823m 3 /hr
Head, H=62.6396m
Efficiency=0.72
The impeller size, D=150mm is selceted.
Figure 3.27: Pump characteristics for a range of impeller sizes

(a)250mm (b)225mm (c)200mm (d)175mm (e)150mm
3.4.1.12 Net positive suction head (NPSH)
The pressure at the inlet pump must be high enough to prevent cavitation occuring in the
pump. Cavitation occurs when bubbles of vapour or gas form in the pump casing. Vapour
bubbles will form if the pressure falls below the vapour pressure of the liquid.
The net positive suction head available ( NPSH available ¿ is the pressure at the pump suction,
above the vapour pressure of the liquid, expressed as head of liquid.
P v2 P
NPSH available = + z1 - 1 - v - h L
ρg 2 g ρg
294
where P= the pressure above the liquid in the feed vessel, N/m 2
ρ= the density of the liquid at the pump suction temperature, kg/m3
H= the height of liquid above the pump suction, m
Pf = the pressure loss in the suction piping, N/m 2
Pv = the vapour pressure of the liquid at the pump suction, N/m 2
By referring Principle of Chemical Process Handbook, page 476 in Table B.4, the vapor
pressure of every component are calculated using Antoine equation.
B
log 10 Pv = A−
T +C
Pv in mmHg, T in ᴼC
A, B, C is the Antoine coefficient
For n-hexane
A B C
6.88555 1175.817 224.867
1175.817
For isopentane, log 10 Pv =6.88555−
25+ 224.867
133.32 Pa 1kg /m s2
Pv = 2.1798mmHg x x
1 mmHg 1 Pa
= 20168.5109 kg/m s2
27747. kg /m s2
NPSH available =¿ 0.7093 ¯¿ ¿ + 1.5m - ¿ ¿ - 740 kg 9.81 m - 7.9044m
( )( )
m3 s2
= 0.3347m
295
Table 3.23: Specification Sheet of Pump, P-101
CENTRIFUGAL PUMP DATA SHEET Equipment No: P-101
Description: Pump
OPEARTING DATA
TYPE Centrifugal LIQUID Butane, Isopentane, n-
Pentane, Cyclohexane, n-
Hexane,
Methylcyclohexane,
Benzene, Toluene,
Heptane
INLET 25ᴼC OUTLET 25ᴼC
TEMPERATURE TEMPERATURE
INLET PRESSURE 0.7093bar OUTLET PRESSURE 1.0133bar
VISCOSITY 0.00051kg/ms DENSITY 740kg/m3
MASS FLOWRATE 5.1147kg/s VOLUMETRIC 0.0070m 3 /s
FLOWRATE
TECHNICAL DATA
OUTSIDE DIAMETER 73.1520mm
WALL THICKNESS 5.2197mm
INSIDE DIAMETER 62.7126mm
AREA 0.0031m 2
LIQUID VELOCITY INLET 2.2296m/s
ABSOLUTE ROUGHNESS 0.046mm
RELATIVE ROUGHNESS 0.0007
LENGTH OF MISCELLANOUS LOSSES 59.7185m
FRICTION LOSS IN PIPE 413436.6645kg/m s2
DIFFERENTIAL IN ELEVATION 1.5m
DIFFERENTIAL IN PRESSURE 0.3040bar
STATIC HEAD 5.6877m
DYNAMIC HEAD 56.9519m
TOTAL HEAD 62.6396m
TOTAL HEAD LOSS 7.9044m
LIQUID VELOCITY OUTLET 5.4249m/s
PUMP EFFICIENCY 72%
SHAFT POWER 0.7445kW
PUMP POWER 1.0340kW
FLUID POWER 0.2128kW
NPSH available 0.3347M
IMPELLER TIP SPEED 35.0570m/s
IMPELLER SPEED 4463.9643rpm
MATERIALS OF CONSTRUCTION
SHAFT CARBON STEEL
IMPELLER CARBON STEEL
CASING CARBON STEEL
296
Description: Pump
OPEARTING DATA
TYPE Centrifugal LIQUID Isopentane, n-Pentane,
Cyclohexane,
Methylcyclohexane,
Benzene, Toluene,
VISCOSITY 0.00054kg/ms DENSITY 758.1667kg/m3
FLOWRATE
TECHNICAL DATA
AREA 0.0031 m 2
STATIC HEAD 33.0520m
DYNAMIC HEAD 27m
TOTAL HEAD 60.0520m
PUMP EFFICIENCY 71%
PUMP POWER 3.1472kW
NPSH available 27.0214
SHAFT CARBON STEEL
CASING CARBON STEEL
297
Description: Pump
OPEARTING DATA
Cyclohexane,
Methylcyclohexane,
Benzene, Toluene,
FLOWRATE
TECHNICAL DATA
AREA 0.0031 m 2
DYNAMIC HEAD 27m
TOTAL HEAD 60.0520m
PUMP EFFICIENCY 71%
PUMP POWER 3.1472kW
SHAFT CARBON STEEL
CASING CARBON STEEL
298
3.4.2 Compressor
1.40 S3=18412.99kg/hr 1.37 S4=18412.99kg/hr

1.41 T=393K 1.38 T=393K
1.42 P=1 atm C-100 1.39 P=45 atm
Table 3.26: Properties of Butane in C-100

Parameters Inlet stream (S3) Outlet stream (S4)
Temperature, T(K) 393 393
Pressure, P(bar) 1.01325 45.5962
Mass flowrate, ṁ (kg/hr) 18412.99 18412.99
By referring Thermodynamics Book, page 898 in Table A-1

The critical temperature of Butane, T C=425.2K
The critical pressure of Butane, PC =38 bar
Table 3.27: The value of compressibility factor, Z are obtain from Thermodynamics Book,
page 922 in Figure A-15.
Reduced Reduced pressure, Compressibility
temperature, T R PR factor, Z
Inlet stream T P
T R= P R=
TC PC
393 K = 0.98
= ¯
425.2 K 1.01325 ¯ ¿ ¿
=0.9243 38 ¿ ¿
=0.0267
Outlet stream T P
T R= P R=
TC PC
393 K = 0.79
= ¯
425.2 K 45.5962 ¿¯ ¿
=0.9243 38 ¿ ¿
=1.1999
Z inlet + Z outlet
Z avg=
2
0.98+0.79
=
2
= 0.8850
299
Figure 3.28: Nelson-Obert generalized compressibility chart
300
From calculated Z avg , the value of density can be determined by equation below:
ρ
P=Z RT
M
P M
For inlet: ρ= 1 W
ZRT
=¿ ¿
= 1.8393 kg/m3
P M
For outlet: ρ= 2 W
ZRT
=¿ ¿
= 102.6726 kg/m3
3.4.2.1 Selection of compressor
z1
From PV= (RT), specific volume can be calculated
MW
ZR T ¿
For inlet: v ¿=
P¿ M W
m3
= 0.98(8.314 kPa. )(393 K )
kmol . K
¿¿
= 0.5437 m3 /kg
ZR T out
For outlet: v out =
P out M W
m3
= 0.79(8.314 kPa. kmol . K )(393 K )
¿¿
= 0.0097 m3 /kg
From calculated v ¿ and v out, the inlet and outlet flowrate can be calculated:
Q = ṁ v
For inlet: Q¿ =ṁ¿ v ¿
= 18412.99 kg/hr x 0.5437 m3 /kg
= 10011.1427 m 3 /hr
For inlet: Qout = ṁout v out
= 18412.99 kg/hr x 0.0097 m3 /kg
= 180.4473 m3 /hr
By referring Chemical Engineering Design Book, Page 477 in Figure 10.60
Flowrate at inlet condition=10011.1427 m 3 /hr
Discharge pressure=45.5962 bar
..˙ Both are in the operating range of centrifugal compressor
301
Figure 3.29: Compressor operating ranges
3.4.2.2 Polytropic efficiency, ƞ p
m3 1 hr 35.3147 ft 3
Q ¿ =10011.1427 x x
hr 60 min 1 m3
3
ft
= 5892.3417
min
By referring figure polytropic efficiency for centrifugal and axial-flow compressor, refer
Chemical Process Engineering Design and Economics, page 226, polytropic efficiency for
302
ft 3
centrifugal compressor for Q=5892.3417 is 0.722
min
Figure 3.30: Polytropic efficiency for centrifugal compressor
3.4.2.3 Polytropic Head, H P
By referring Ludwig’s Applied Process Design for Chemical and Petrochemical Plants page
870:
n−1
z avg R T 1 n
H
Polytropic head, P = (
MW ( ) ¿
n−1
[R c n −1]
n k
( ¿=( )ƞ
n−1 k−1 p
where z avg=compressibility average
R= gas constant
T 1= inlet temperature
M W =molecular weight
k=specific heat ratio
Rc =compression ratio
CP
For butane, specific heat ratio k=
CV
where PC =¿ specific heat
C v = specific volume
kJ
1.7164 . K
k= kg
1.5734 kJ /kg . K
= 1.0901
303
n k P2
( )=( ) ƞp compression ratio, Rc =
n−1 k −1 P1
n 1.0901
( ¿=( )(0.722) =
n−1 1.0901−1
¯¿
45.5962 ¿
1.01325 ¯¿ ¿
n = 0.8973 = 45
3
kPa . m
(
0.8850 8.314
kmol ) . K ( 393 )
0.8973
H P=
58.124
kg ( )
0.8973−1
[45(−8.7371 )−1]
kmol
= 434.6679 kNm/kg
..˙ By referring Product and Process Design Principle, Page 169 from Heuristic 36, for
compression ratio between 16-64, number of stage required is 3.
3.4.2.4 Polytropic Power
Polytropic power, (-W poly ¿= H P x ṁ

(-W poly ¿=434.6679 kNm/kg x 5.1147 kg/s
=2223.1959 kW
The negative sign show that the power is put into the system
3.4.2.5 Actual power
(−W poly)
Actual power, (-W actual ¿ =
ƞP
2223.2044 kW
=
0.722
= 3079.2304 kW
3.4.2.6 Brake Horse Power
By referring Ludwig’s Applied Process Design for Chemical and Petrochemical Plants, page
873 in Table 3.2, the percentage mechanical losses as percentage of a gas power requirement
is 3%
Mechanical losses = Power x % mechanical losses
= 3079.2304 kW x 0.03
=92.3769 kW
Brake horse power (Bhp) = 𝑝𝑜𝑤𝑒𝑟 + 𝑜𝑣𝑒𝑟𝑎𝑙𝑙 𝑚𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑙𝑜𝑠𝑠
3079.2304 𝑘𝑊 + 92.3769 𝑘𝑊 = 3171.6073 𝑘𝑊
304
Table 3.28: Specification Sheet of Compressor(C-103)
Identification: Item Centrifugal Compressor
Item no. C-103
No. required 1
Operating Data
Materials Handled Naphta
Inlet flow Outlet flow
Gas flow rate (kg/hr) 18412.99 18412.99
Operating 120 120
temperature (°C)
Operating pressure, P 1.01325 45.5962
(bar)
Density, ρ (kg/m3) 1.8393 102.6726
Compressibility 0.98 0.79
factor, z
Volumetric flow rate, 1001.1427 180.4473
𝑉̇ (m3/hr)
Technical Data
Compression ratio, Rc 45
Number of stage required 3
Polytropic exponent, n
Ratio of specific heat capacities, k 1.0901
Polytropic efficiency (%) 72
Polytropic head, kNm/kg 434.6679
Polytropic Power (kW) 22223.2044
Actual Power (kW) 3079.2304
Mechanical losses (kW) 92.3769 kW
Brake horsepower (kW) 3171.6073 𝑘𝑊
Materials of Construction : Carbon steel

305
1.7 Storage Tank
3.5.1 Toluene Production Tank
The primary function of a storage tank is to hold or store liquid substance such as
finished product. Internal floating roof tank (IFR) constructed by carbon steel since it stored
low temperature fluid and moderate corrosion resistance. IFR are designed because can
control the evaporation loss of toluene and reduce the volatilization (El-samanody et al.,
2016).
The flexible floating roof can float up and down to close the liquid level, so gas space
above liquid level can be greatly reduced. Thus, it can reduce the evaporation loss of the
stored liquid. IFR can effectively prevent the stored liquid from being polluted by wind, rain,
sand or dust even though under various weather (El-samanody et al., 2016). There is no heat
change for the tank. The detailed calculation was shown below. A few assumptions have been
made prior to the staged sizing.
Assumption:
1) Material volume should be 80% of the tank total volume
2) Basis of the amount to be stored is 5 days,τ
3) The material construction for this tank is carbon steel, SA 283 Gr.C
Table 3.29: Properties data of Toluene

Properties Information Data
Mass flowrate, ṁ 6684.56 kg/hr
Density, ρtoluene 867 kg/m3

306
Composition 0.98
3.5.1.1 Calculation volume of tank:
0.98
Dalton Law: actual density, Pτ = x toluene ρtoluene = × 867 kg/m3 = 8.4966 kg/m3
100
6684.56 kg/hr
Volumetric flowrate, ṽ = mass flowrate, ṁ ÷ actual density, Pτ = 8.4966 kg/ m3
= 786.73 m3/hr
Volume of tank, Vtank = volumetric flowrate, ṽ x time, τ

= 786.73 m3/hr ×24hr/day × 1 day
= 18881.52 m3
3.5.1.2 Calculation diameter of tank:
(π D 2 h L )
Volume of tank, Vtank =
4
Table 3.30: Properties of tank diameter from Coulson & Richardson’s Chemical
Engineering, pg 650 (Sinnott, 2005).
307
hL
Based on table, by taking ratio of = 0.25
D
π D2 (0.25 D)
Volume=
4
0.25 π D 3
18881.52=
4
75526.08
D 3=
0.25 π
75526.08
D 3= =96124.10
0.78571
Diameter , D=45.8 m
Height , h L =0.25 D=0.25 ( 45.8 )=11.45 m
Based on (ICARUS Refernce,1998), the diameter and the height of our tank is in range of
their properties data.
3.5.1.3 Calculation thickness of tank wall:
The thickness (e s) of the tank wall can be determine by using this Equation 1 which provided
in the Coulson & Richardson’s Chemical Engineering, pg 650 (Sinnott, 2005).
ρL H L g D t
es = - Equation 1
2 f t J 103
Where e s = tank thickness required at depth h L, mm.

h L = liquid depth, m.
ρ L = liquid density, kg/m3
g = gravitational acceleration, 9.81 m/ s2
308
DT = tank diameter, m
kg
e=
( 867
m )
(11.45 m)(9.81)( 45.8 m)
3
s
136 N
2( 2
)(1)(10 3)
mm
¿ 16.40 mm
According to El-samanody et al. (2016), the corrosion allowance of floating roof design data
is 3 mm.
Total thickness=16.40mm+ 3 mm=19.4 mm≈ 20 mm
3.5.1.4 Calculation Cone roof
45.8
Radius cone , r= =22.9 m ≈ 23 m
2
Bottom surface area tank=π r 2= ( 227 ) ×22.9 =1648.15m

2 2
According to the Coulson & Richardson’s Chemical Engineering, pg 650 (Sinnott, 2005), the
equation calculation for height of cone roof tanks is:
1 1
¿ ×tank height= × (11.45 )=3.81 m
3 3
3.5.1.5 Calculation of insulation for storage tank
Insulation of storage tanks is a major factor in the functionality of storage facilities. It

acts as process control that can prevent tanks from freezing or being heated by solar radiation
and reduce heat loss. A fire resistant reduces the risk of a fire outside the tank igniting a
flammable medium and can minimize the surface (contact) temperature of the tank.
According to Wanko et al. (2016), suitable material in insulation of storage tank is
w
rockwool. Based on Wanko et al. (2016), the thermal conductivity for rockwool is 0. 08
m. k
N
and design stress is 40 . The external convection heat transfer coefficient is also given
mm2
W
0.11
m. k
309
k
Thickness of the insulator, r¿
h
Where;
W
k= thermal conductivity of insulating material,
m2 K
W
h = external convection heat transfer coefficient ,
m2 K
k 0.08
Thickness of the insulator, r¿ = =0.72 m≈ 727 mm
h 0.11
310
3.5.2 Hydrogen Production Tank
Hydrogen is typically stored and transported in two forms, as a compressed hydrogen

gas or as a cryogenic liquid. According to Ouammi et al. (2018), a compressed hydrogen is
shipped in tube trailers at pressure up to 3000 psi (about 200 bar). However, the low
hydrogen-carrying capacity of these tube trailers results in high delivery costs. Hydrogen rail
delivery is currently economically feasible only for cryogenic liquid hydrogen. However,
almost no hydrogen is transported by rail. Reasons include the lack of timely scheduling and
transport to avoid excessive hydrogen boil-off and the lack of rail cars capable of handling
cryogenic liquid hydrogen. Therefore, compressed gas vessels with high pressure is used.
3.5.2.1 Calculation Volume of Compressed Hydrogen in a Cylinder
According to Mitran et al. (2017), the Ideal Gas Law ( PV =nRT ) was applied. In a
high-pressure cylinder, the volume will be affected by the content’s compressibility factor, Z
( PV =ZnRT ).
For this calculation, we assume ideal gas behavior for simplicity (At P=15 ,̄ Z =1) (Masla &
Littman, 1953).
The Ideal Gas Law PV =nRT ,
Where, P is pressure
V is volume
n is the number of mol
R id the gas constant
T is the absolute temperature
When the temperature is kept constant, the equation will be derived:
P1 × V 1=P2 ×V 2
where, P1 is the pressure of the compressed gas in the cylinder(psi)
V2 is the internal volume of the cylinder, often referred to as water

volume(litre)
(30 litre ) (Masla & Littman, 1953).
P2 is the atmospheric pressure (1atm @14.7psi)
V2 is the volume of gas at pressure P2(litre)

311
( 2540 psi ) × ( 30 L )= (14.7 ) V 2
2540 ×30
V 2= =5183.67 L ≈ 5.18 4 m 3
14.7
3.5.2.2 Calculation diameter of vessel
(π D 2 h L )
Volume of vessel, Vvessel =
4
hL
Based on table, by taking ratio of = 0.5 (Masla & Littman, 1953).
D
π D 2 (0.5 D)
Volume=
4
0.5 π D 3
5.184=
4
20.736
D 3=
0.5 π
20.736
D 3= =13.20 m
1.571
Diameter , D=2.36 m ≈3 m
Height , h L =0.25 D=0.25 ( 3 )=11.45 m
Diameter and height of tank are in range compared to value from Hydrogen Tank Plant
Design and Economics for Chemical Engineers, pg 962 (Peters et al., 2003)
312
3.5.2.3 Calculation thickness of vessel wall
The thickness (e s) of the vessel wall can be determine by using Joint Efficiency (J.E)
Factor is equal to 1 which provided in the Coulson & Richardson’s Chemical Engineering, pg
644 (Sinnott, 2005). Thickness for a cylindrical pressure vessel for stainless steel material is
63 mm.
313
3.5.3 Feed Storage Tank
According to Thiele & Kay, (1933), the density of light naphtha is equal to 740 kg/m3 at
293.15 K at standard atmospheric pressure. The mass flowrate is at 18412.10 kg/hr.
Atmospheric storage tanks can be consist of three type which is open top storage tanks, fixed
roof tanks and floating roof storage tanks. Floating roof tanks(FRT) are widely used to store
large amount of crude oil to Thiele & Kay, (1933).
3.5.3.1 Calculation volume of tank
Assume total compound for naphtha is equal to 1. The compound of naphtha is butane,
isopentane, n-pentane, cyclohexane, n-hexane, methylcyclohexane, benzene, toluene and
heptane.
100
Dalton Law: actual density, Pτ = x total compound × ρnaphtha = × 740 kg/m3 = 740 kg/m3
100
18412.10 kg/hr
Volumetric flowrate, ṽ = mass flowrate, ṁ ÷ actual density, Pτ = 740 kg /m3
= 24.88 m3/hr

= 24.88 m3/hr ×24hr/day × 1 day
= 597.12 m3 ≈ 600 m
3.5.3.2 Calculation diameter of tank
(π D 2 h L )
4
314
hL
D
π D2 (0.5 D)
Volume=
4
0.5 π D 3
597.12=
4
2388.48
D 3=
0.5 π
2388.48
D 3= =1520.55
1.5714
Diameter , D=11.49 m ≈ 12m
Height , h L =0.5 D=0.5 ( 12 )=6 m
3.5.3.3 Calculation thickness of tank wall
ρL H L g D t
es = - Equation 1
2 f t J 103

315
f t = Design stress for tank material, 136 N/mm2 from Coulson & Richardson’s Chemical
kg
e=
( 740
m )
(6 m)(9.81)(12m)
3
s
136 N
2( 2
)(1)(10 3)
mm
¿ 1.92 ≈2.0 mm
According to El-samanody et al. (2016), the corrosion allowance of vessel tank design data is
2 mm.
Total thickness =2mm+ 2mm=4 mm
316
3.5.4 Distillate Storage Tank
3.5.4.1 Calculation volume of tank
Each density value in distillate liquid properties obtained from Heat Transfer Books
(Holman, 2010).
Table 3.33: Properties of distillate liquid
Composition in Mole Density(kg/m3) Mass
distillate liquid Fraction Flowrate(kg/hr)
N-pentane 0.219 626 2252.58
Cyclohexane 0.238 811 65.16
Methylcyclohexane 0.0054 770 12.82
Benzene 0.0009 876 5917.18
Toluene 0.006 867 86.53
Isopentane 0.530 616 2448.49
317
1 1
Average density , ρaverage = = =658 kg / m3
0.219 0.238 0.0054 0.0009 0.006 0.530 0.0015
+ + + + +
626 811 770 876 867 616
Assume the total composition of distillate liquid is equal to 1,
100
Dalton Law: actual density, Pτ = x distillate ρ average = ×658 kg/m3 = 658 kg/m3
100
2252.58+65.16+12 .82+5917.18+86.53+2448.49
Average mass flowrate, ṁaverage =
6
¿ 1797.13 kg /hr
1797.13 kg/hr
Volumetric flowrate, ṽ = mass flowrate, ṁ ÷ actual density, Pτ = 658 kg / m3
= 2.73 m3/hr

= 2. 73 m3/hr ×24hr/day × 1 day
= 65.52 m3
3.5.4.2 Calculation diameter of tank
(π D 2 h L )
4
318
hL
D
π D 2 (0.5 D)
Volume=
4
3
0.5 π D
65.52=
4
262.08
D 3=
0.5 π
262.08
D 3= =166.78
1.5714
Diameter , D=5.5 m
Height , h L =0.5 D=0.5 ( 5.5 )=2.75 m ≈ 3 m
3.5.4.3 Calculation thickness of tank wall
ρL H L g D t
es = - Equation 1
2 f t J 103

319
kg
e=
( 658
m )
3
(2.75 m)(9.81)(5.5 m)
s
136 N
2( 2
)(1)(10 3)
mm
¿ 0.359 ≈ 360 mm
According to El-samanody et al. (2016), the corrosion allowance of floating roof design data
is 3 mm.
Total thickness=360 mm+3 mm=364 mm
3.5.4.4 Calculation Cone roof
Assume diameter of cone is same with diameter of tank

5.5
Radius cone , r= =2.75 m≈ 3 m
2
Bottom surface area tank=π r 2= ( 227 ) ×2.75 =23.77 m

2 2
According to the Coulson & Richardson’s Chemical Engineering, pg 650 (Sinnott, 2005), the
equation calculation for height of cone roof tanks is:
1 1
¿ ×tank height= × ( 2.75 )=0.92 m≈ 1.0 m
3 3
320
3.6 Throttling Valve
Figure 3.31: Throttling Valve

The newly developed digital electronics developed by Rexroth offer simplified optimization
of hydraulic controller parameters and improved control quality.
New on-board digital electronics for improved control quality

Machine manufacturers can now realize hydraulic systems with reduced dimensions and
improved control behavior thanks to the new Rexroth 2-way proportional throttle valves.
These cartridge valves are designed for a maximum operating pressure of 420 bar. The newly
developed on-board electronics enable compensation of decentralized disturbances for
improved control quality. This enables machine and system manufacturers to use smaller
system components to further support the traditional strengths of hydraulics, force density
and low space requirements. These requirements were taken into account by Rexroth in the
development of the new 2WFCE throttle valves with a maximum operating pressure increase
from 315 to 420 bar.
Inlet pressure of throttling valve is 45 bar while outlet pressure is 1 bar. The pressure
reduction can be achieved by using this Rexroth smart valve.
321
Table 3.35: Specification Sheet of toluene storage tank from Coulson & Richardson’s
Chemical Engineering, pg 650 (Sinnott, 2005).
Toluene Storage Tank
Application : Silo for storing toluene
Identification Item : Internal Floating Roof (IFR)
Item No. : -
No. required : 1
Function : Storage of toluene produced
Type Material : SA-516M Gr.4

Construction
Configuration : Single vertical standing, cylindrical shape vessel
Material Temperature, ℃ : 75 °C
Pressure, bar : 15
Mass flowrate, kg/hr : 6684.56 kg/ hr
Design data Design Temperature, : 120

˚C
Design Pressure, bar : 15.10
Diameter : 45.8 m
Height : 11.45 m
Volume : 18881.60 𝑚3
Thickness of wall : 19.40 mm
Type of head : Cone roof shape
Thickness of head : 16.40 mm
Material of : Carbon steel

construction
Insulation Material Rockwool
:
Thickness 727 mm
:
322
Table 3.36: Specification Sheet of Hydrogen Storage Tank
High Pressure Hydrogen Tank for Storage
Application : Compressed Hydrogen Gas
Identification Item : 175 Bar Compressed Gas
Storage System
Item No. : -
No. required : 1
Function : Storage of hydrogen produced
Type Material : Stainless Steel
Construction
Configuration : Horizontal, cylindrical shape vessel
Material Temperature, ℃ : 38℃
Pressure, bar : 15
Design data Design Temperature, : -40 to 100
˚C
Design Pressure, bar : 175
Diameter : 3m
Straight Length : 11.45 m
Volume : 5.20 𝑚3
Thickness of wall : 63 mm
Orientation : Horizontal
Vessel Head : Ellipsoidal
Material of construction : Stainless steel
Inside Dish Depth : 2m
Level : 0.35m
323
Table 3.37: Specification Sheet of Feed Storage Tank
Feed Storage Tank
Application : Silo for storing liquid naphtha
Identification Item : Atmospheric Storage Tank
(FRT)
Item No. : -
No. required : 1
Type Material : Carbon Steel
Construction
Pressure, bar : 0.71
Design data Design Temperature : 70 & -17
(UPPER AND
LOWER), ˚C
Design Pressure, mbar : 0.00
Diameter : 12 m
Height : 6m
Volume : 600 m3
Type of head : Flat roof
Table 3.38: Specification Sheet of Distillate Storage Tank

Distillate Storage Tank
Application : Silo for storing distillate liquid
Identification Item : Fixed Roof Tank (FRT)
Item No. : -
No. required : 1
324
Type Material : Carbon steel
Construction
Pressure, bar : 1
˚C
Diameter : 5.5 m
Height : 2.75 m
Volume : 66 𝑚3
Type of head : Cone roof shape
Thickness of head : 364 mm
Material of construction : Carbon steel
325
Table 3.39: Specification Sheet of Butane Storage Tank
Butane Storage Tank
Application : Butane Gas
Identification Item : As per ASME sec VIII Div. 1
Pressure Vessel Cod
Item No. : -
No. required : 1
Function : Storage of butane produced
Type Material : Stainless Steel
Construction
Configuration : Horizontal, cylindrical shape vessel
Material Temperature, ℃ : 70
Pressure, bar : 1
Design data Design Temperature : -20 to 50
Limit, ˚C
Design Pressure, bar : 18
Diameter : 1.2 m
Volume : 0.6 𝑚3
Orientation : Horizontal
Vessel Head : Ellipsoidal
Material of construction : Stainless steel
326
CHAPTER 4: P&ID SYSTEM
4.1 Process Control System
4.1.1 Process Control at Evaporator, E-103
To increase the outlet stream of the Evaporator from 25˚C to 120˚C before entering the
compressor. In the evaporator, the steam is used to increase the temperature of inlet stream from 25˚C
to 120˚C, so that the plant operates safely and can achieve maximum energy recovery. Hence, the
temperature is measured in order to control the inlet stream of the heat exchanger in the tube side.
In the following paragraphs the load variable will be assumed to be the flow rate and
concentration of the feed stream. A later paragraph, Other Control Loops, will discuss the control of
other variables, such as steam enthalpy, material balance, and absolute pressure controls. The control
systems to be considered in achieving final product concentration include (1) feedback, (2) cascade,
and (3) feedforward, (4) auto-select, and (5) advanced controls. For ease of illustration, a double-
effect, co-current flow evaporator will be used. Extension to more or fewer effects will not change the
basic control system configuration. The choice of the control system should be based on the needs
and characteristics of the process. Evaporators as a process class tend to be capacious (mass and
energy storage capability) and have significant dead time (30 sec or greater).
If the major process loads (feed rate and feed density) are reasonably constant and the only
corrections required are for variations in heat losses or tube fouling, feedback control will suffice. If
steam flow varies because of demands elsewhere in the plant, a cascade configuration will probably
be the proper choice. If, however, the major load variables change rapidly and frequently, it is
strongly suggested that feedforward in conjunction with feedback be considered. Selective control can
be superimposed on either control configuration, which will stay inactive until a limit is reached (such
as running out of steam), at which point control is transferred to keep the operation (the demand for
steam) under that limit. Advanced controls usually combine all the previous features and add to it a
multivariable model-based predictive capability.
327
Table 4.1 Control Strategy at E-103
Level Control
Objective To maintain level set point at a given value.
Measurement Level of fluid in evaporator
Sensor Vibrating Level Sensor
Manipulated Flowrate of Steam entering the Evaporator.

Variables
Disturbance Change of inlet flowrate S2.
Constraints a) The system may not be stable (oscillate or deviate from desirable output)
b) No corrective action until after the disturbance has upset the process that
is the pressure deviates from set point
Control Feedforward Control System

Structure
Additional a) High Level alarm LAH is added to warn if the level of evaporator (E103)
Considerations is over minimum level which may cause explosion.
b) PI controller is used to tune feedback control loop as the system may
(Safety)
oscillate or deviate greatly from the desired loop.
Pressure Control
Objective To maintain the pressure inside E-103 at set point (3 bar) and avoid
overpressure.
Measurement Pressure inside E-103
Sensor Strain Gauge Pressure
Manipulated Exit pressure at S3
Variables
328
Disturbance 1. Change of feed pressure.
2. Change of heat duty of E-103
3. Change in temperature of E-103
Constraints 1. Pressure of light naphtha should not exceed set point to avoid damage of
Ev-103.
o
. 2. Temperature of Ev-103 should not exceed 120 C.
. 3. Very oscillatory responses, or even unstable.
. 4. No corrective action occurs until after the disturbance has upset the
process, that is, until after the pressure in Ev-103 deviates from set
Control Cascade Control Loop

Structure
Additional 1) PT-103 convert the signal into suitable range of input of PC-103.
Considerations(
Controller will then split into two signal in which one is to control the
S afety)
control valve of CV-10 for venting and another signal acts as a primary
controller is being send to FC-103 to manipulated the set point of
secondary controller which is FC103.
2) FT-103 is then send signal to the final control element which is CV10
to control the flow rate of light naphtha to regulate the pressure inside
the reactor.
3) High pressure alarm, PAH-103 is installed in which will aware the
operator, if the pressure is higher than the set pressure. Where PAH-
302 receive signal from PT-103 indicated that the pressure increase.
Temperature Control
Type of Control Loop Closed loop(feedback) control
Objective To control and maintain the temperature in
the Evaporator, E-103 component at the
desired set point, 375K
Measurement Temperature in the evaporator and

temperature of outlet stream, S3
Sensor Thermocouple
329
Manipulated Variable The flowrate of inlet steam or inlet liquid,
S2
Disturbances Variable 1) Heat loss to the surrounding

2) Change in density of naphta
component
3) Change in inlet temperature of naphta
component
Control Variable TE detects and measures any temperature

deviation in E-103 and send signals to TT.
TT transmits it as electronic signal to TIC.
The controller output signal is sent to current-
to-pneumatic transducer (I/P) where it will
convert to equivalent pneumatic signal that is
compatible with control valve. CV-01 is
adjusted to regulate the flowrate of naphta
that entering the evaporator.
Type of Controller To provide rapid response, PID controller are

used when the error are occur in the system.
Proportional controller will take the action to
control the temperature back to the set point
while the integral control is used to eliminate
the offset. Derivative controller is use to
control the system back to the set point
rapidly.
Constraints 1) Temperature of E-103 should not

exceed design temperature of 102°C
2) No corrective action occurs until the
disturbance upset the process that is
until the temperature in E103
deviates from set point
(102°C)
330
3) Very oscillatory responses or even
instable
Additional Safety Considerations 1) High temperature alarm, TAH will be

installed at the upstream to ensure
that temperature are not over the
operating temperature.
2) Gate valve is installed at upstream
and downstream pipeline stream
3) Bypass valve (glove valve) is
installed in order to control the
flowrate in any case of control valve
failure
4) Control valve is air to open( fail
close) in which it will close in any
case of failure
331
HINT:
LC- Level Controller
LTLAH- Level Transmitter- High Level Alarm

I/P- Current to Pneumatic Transducer
PI- Pressure Indicator
PC- Pressure Controller
PAHTC- Temperature Control High Alarm Pressure

TT- Temperature Transmitter
TAH- High Temperature Alarm
Figure 4.1 P&ID Control for Evaporator, E-103
332
4.1.2 Process Control at Reactor, R-101
For R-101, temperature and pressure of fluid (gas phase) in the tank should be controlled in
order to prevent failure during working process of plant. In this process, this parameter is maintained
at 502 ℃ and 45 bars throughout the working operation and a desired product composition can be
obtained. Therefore, there are several control systems needed to achieve steady state operation of
reactor.
This objective can be achieved by manipulating the feed flow of cooling oil in cooling jacket.
The temperature sensor will detect the amount of the heat flow in the reactor, and three transmitter
(TT) will detect any changes of the temperature and then transmit the signal to temperature indicator
controller (TIC). By sending electrical signal to the I/P transducer, the pneumatic signal by the
transducer will be sent to the final control element, the control valve which regulate the coolant flow.
Another way to maintain the temperature is manipulate the feed flowrate heating medium of
heater (H-101). The temperature sensor will detect the heat flow in the reactor and three transmitter
(TT) will detect any changes of the temperature. Then, it will transmit the current to the temperature
indicator controller (TIC) to send pneumatic signal into control valve at heater (H-101).
Moreover, maintain the operating condition of pressure can be achieved by control the
flowrate of feed at S4 and drain valve at reactor. Pressure sensor will detect the gas flow in reactor
and pressure transmitter will detect any changes of pressure value or pressure drop. After that, it will
transmit the signal to pressure indicator controller (PIC). By sending electrical signal to the I/P
transducer, the FC will monitor and adjust any process error. The pneumatic signal which has been
converted by the electrical signal by the transducer will be sent to the final control element, the
control valve which regulate the flow at pipeline S4 and drain valve.
The purpose of this control system is to ensure the chemical reaction inside the reactor is
maintained at a constant temperature and constant pressure. The type of temperature sensor will be
used is thermocouple. A thermocouple is a junction between two different metals that produces a
voltage related to a temperature difference in reactor (Cinar, 1983). It also can operate across the
widest temperature range from -200 ℃ to 1750 ℃ and the type of pressure sensor used is pressure
gauge (Yusuf, Aderemi, Patel, and Mujtaba, 2019).
Table 4.2 Control Strategy for R-101

Temperature Control
Type of Control Feedback control loop
loop
333
Objective To control temperature in the reactor at 502˚C
Measurement Inlet temperature of R-101
Manipulated Flowrate of cooling oil in the cooling jacket

variables
Control Action TE detects and measures any temperature deviation in R-101 and sends signal
to TT (TT01, TT02, TT03). TT transmits it as electronic signal to electronic
feedback indicating controller (TIC). The controller output signal is sent to
current-to-pneumatic transducer (I/P) where it is converted to equivalent
pneumatic signal that is compatible with control valve. Control valve is
adjusted to regulate the flowrate of cool oil entering the cooling jacket and the
amount of hot oil exiting cooling jacket. The controller output signal also sent
to current-to-pneumatic transducer to control the amount of heat supply to the
heater to maintain the temperature of R-101 (Price, 2003).
Disturbance 1. Change in inlet temperature of naphtha

2. Change in inlet flow rate of naphtha.
3. Change in cooling oil pressure in cooling jacket, causing a change in
outlet cooling oil flow rate.
4. Heat loss to surrounding.
Constraints 1. Temperature of R-101 should not exceed design temperature of

502˚C to prevent personnel injury.
2. Flowrate of naphtha should not exceed 18412.99 kg/h. respectively to
avoid damage of R-101.
3. Pressure of cooling oil should maintain at 1 bar to prevent change of
334
outlet cooling oil flowrate.
4. Very oscillatory responses, or even instable.
5. No corrective action occurs until after the disturbance has upset the
process, that is, until after the temperature in R-101 deviates from setpoint
(502˚C).
Additional 1. Install high temperature alarm to alert operator if overheated.

Consideration 2. Globe valve selected as the bypass valve on the control valve as it
allows better control with opening. This valve is needed for manually
control the process when failure of control valve happens.
3. Drain valve is needed to drain the piping segment during shut down
and maintenance.
4. PID controller has tuned because the system may oscillate and
greatly deviate from setpoint.
6. Gate valve are installed at inlet and outlet stream of coolant for start- up
and shutdown purpose.
Control
Structure
Km
𝑌𝑆𝑃 𝑌̃𝑆𝑃 𝐸 𝑃 𝑃′ 𝑈 𝑌𝑈
Km TC FC CV Process
+ +
𝑌𝑚
PE
PT
D 𝑌𝐷
Ysp = set point (502˚C)
335
Km=steady state gain for sensor and transmitter (TE and TT)
Ỹsp = internal set point used by controller
E = error signal
P = TIC controller output
P’ = I/P transducer output
U = manipulated variable (Flowrate of coolant in cooling jacket)
Yu = change in temperature in R-101 due to flow rate of coolant

D = disturbance
Yd = change in temperature in R-101 due to disturbance
Y = temperature in R-101
Ym = measured value of Y (temperature in R-101)
Pressure Control
Type of Control Feedback control loop
loop
Objective To maintain the pressure inside R-101 at 45 bar due to the operating condition.
Measurement Inlet pressure of R-101.
Manipulated Flowrate of S4.

variables
Flowrate of the drain out pipe.
336
Control Variable PE detects and measures any pressure deviation of R-101 and sends signal to
PT. PT transmits it as electronic signal to electronic feedback indicating
controller (PIC). The controller output signal is sent to currentto-pneumatic
transducer (I/P) where it is converted to equivalent pneumatic signal that is
compatible with control valve. Control valve is adjusted to regulate the
flowrate of naphtha at S4 and the flowrate of
drain out pipe. Drain valve is apply at the drain out pipe to control the amount
of naphtha which is superfluous in the reaction.
Disturbance 1. Change of feed flowrate at S4.

2. Change of heat duty of R-100.
3. Change in temperature of R-100.
4. Change in the flowrate of drain out pipe.
Constraints 1. Flowrate of S4 should not exceed 18412.99 kg/h. respectively to

avoid damage of R-101.
2. Temperature of R-101 should not exceed 502˚C.
3. Very oscillatory responses, or even instable.
4. No corrective action occurs until after the disturbance has upset the
process, that is, until after the pressure in R-101 deviates from setpoint (45
bar).
337
Additional 1. Install high pressure alarm, to alert operator if overpressure to
Consideration prevent explosion happen.
2. Globe valve, is selected as the bypass valve on the control valve as it
allows better control with opening. This valve is needed for manually
control the process when failure of control valve happens.
3. Drain valve, is needed to drain the piping segment during shut down
and maintenance. Furthermore, it also prevents overflow of naphtha on the
R-101.
4. PI controller has tuned because the system may oscillate and greatly
deviate from setpoint.
338
Control
Structure D 𝑌𝐷
Disturbance Process
𝑌𝑆𝑃 𝑌̃𝑆𝑃 𝐸 𝑃 𝑃′ 𝑈 𝑌𝑈
Km TC FC CV Process
+ +
𝑌𝑚
PE
PT
Ysp = set point (45 bar)

Km = steady state gain for sensor and transmitter (PE and PT)
Ỹsp = internal set point used by controller
E = error signal
P = PIC controller output
P’ = I/P transducer output
U = manipulated variable (Flowrate of naphtha at S4)
Yu= change in pressure in R-101 due to flow rate of naphtha at S4
D = disturbance
Yd = change in pressure in R-101 due to disturbance
Y = pressure in R-101
Ym = measured value of Y (pressure in R-101)
339
Figure 4.2 P&ID Control for Reactor R-101
340
4.1.3 Process Control at Separator, T-100
Separators have to be carefully operated in order to achieve the required production

rates and product quality. The 3 main objectives of designing the process control system
separators are to set stable conditions for operation, to regulate conditions in the separators so
that the product always meet the required specifications, to achieve the objective most
efficiently. Process variables like pressures, flow rates and levels must be monitored and
controlled in all separation processes. Each of the process variables has its own control loop,
which typically consists of a sensor and transmitter, controller and control valve. Each
control loop keeps track of the associated process variable. An adjustment is made to a
process variable by varying the opening of its control valve. The stream flow rate is therefore
adjusted and a desirable variable is being controlled.
In T-100 section, level and pressure of fluid in the tank should be controlled to avoid
any failure in the plant process and also to yield maximum product. The final control element
that will be used is the control valve which is an actuator valve. The valve that is chosen is
the air-to-open valve. If there is overpressure inside the separator, the control valve will be
"Air or current to open" which means the flow restriction decreases with increased control
signal value. Also, it is simple in construction and very reliable. It operates by the injection
of a single, low pressure air signal into the diaphragm housing. Direct acting actuator is
chosen where the actuator stem pushed downwards as a result of applying signal air to the
top of the diaphragm.
For level control, feedback control loop is used. In the feedback control, the process
variable, level of fluid in T-100, is measured and applied a proportional–integral (PI) based
feedback level controller, which compares the process variable with the desired level set
point (0.295m) and in turn calculate and generates the control action required to open or
close the control valve, CV-102. The reason that feedback control system is chosen is
because, regardless of the disturbance source, the controller will take corrective action.
Moreover, it is the simplest process control using single transmitter. It also reduces
sensitivity of the controlled variable to disturbances and changes in the process. PI controller
is used for tuning the level back to set point. Derivative action is not used because the level
measurement are often noisy as a result of the splashing and turbulence of liquid entering the
tank.
The level control system works when the liquid level inside the separator is sensed and
measured by level transmitter (LT) and LT transmit signal to the level controller (LC). The
LC will then compares this measurement with the set point and adjust the outlet valve. The
difference between the LC measurement and LC set point is the error signal. When the error
is not zero, the LC opens or closes the control valve to return the level to the setpoint.
Another drain valve (V-101) are installed on the bottom of the separator for safety and
maintenance purposes.
For pressure control, it is important to maintain the pressure in the separator T-100 at
1.215 bar. Type of control loop used is feedback control. In the feedback control, the process
variable, pressure in T-100, is measured and applied a proportional–integral (PI) based
feedback pressure controller, which compares the process variable with the desired pressure
setpoint (1.215 bar) and in turn calculate and generates the control action required to open or
close the control valve, (CV-101).The reason that using feedback control is that regardless of
341
the disturbance source, the controller will take corrective action. Moreover, it is the simplest
process control using single transmitter. It also reduces sensitivity of the controlled variable
to disturbances and changes in the process. PI controller is used with only small amount of
integral control action. The control valve will control the hydrogen outlet on stream 11 and it
will also act as pressure relieve valve in the case of emergency.
In conclusion, the control system is designed for early detection of any leaks to
surroundings, as the main constituent of naphta consist of hydrocarbon which is hazardous
and toxic to the environment, it is crucial to control the system inside the separators. The
control system also is design to avoid over pressurizing the separators to avoid any injury to
the personnel. Also, level control system is design to maintain enough liquid level so that the
pumps do not cavitates and also to avoid having liquid entrained in the gas.
Table 4.3 Control Strategy for T-100

Pressure control
Type of control loop Feedback control loop
Objective To maintain the pressure inside the T-100 to not exceed 1.215 bar to avoid
overpressure and to maintain the composition of liquid naphta
Measurement Pressure inside T-100

Manipulated Flowrate of naphta at S10
variable
Disturbance Change of feed flowrate

Constraint 1. Pressure should not exceed the operating pressure which is
1.215 bar
2. No corrective action happens until the disturbance upset the
process, which is when the pressure of T-100 deviates from
setpoint pressure at 1.215 bar.
3. Flowrate of the S10 should be maintained at
18412.86kg/hr to prevent change of outlet steam flowrate.
4. Pressure inside the separator cannot be lower than the feed
pressure. When pressure in the vessel is lower than the feed
pressure, part of the liquid feed flashes to form a gas phase and
this has to be avoided as hydrocarbons are flammable and
hazardous.
342
Control action Pressure element (PE) will detect and measures any pressure deviation
inside T-100 and send signal to pressure transmitter (PT). PT transmits it as
electronic signal to electronic feedback pressure controller (PC). PC will
control the control valve (CV-101) to regulate the pressure inside the
separator. The control valve (air-to-open) will receive the signal and adjusts
the opening of the valve to maintain the pressure.
Additional 1. Install a high pressure alarm (PAH) to alert the personnel when the
consideration pressure inside the separator exceed the operating pressure
2. Air to open valve is used inside the separator. The flow restriction
will decreases with increased of the control signal value, thus
regulating pressure inside the pressure
3. The control valve CV-101 will act as the pressure safety valve (PSV)
in the event of emergency.
4. Use a high pressure switch (PSH) to shut off the feed when a high
pressure occurs
5. Sensors for hazardous gases should be located in the area near the
separators
Level Control
Type of control loop Feedback Control Loop
Objective To maintain the level of liquid in the separator at 0.295m for separation to
occur and also to prevent overflow and prevent vapour blowing out into the
liquid filled lines by maintaining the liquid level.
Measurement Level of fluid in the separator T-100

Manipulated Exit flowrate from T-100 to S12
variable
Disturbance Change of inlet flowrate S10 and exit flowrate S11
343
Constraint 1. Inlet flowrate of naphta should not exceed or below
18412.86kg/hr to avoid overflow and to maintain the pressure.
2. No corrective action occurs until after the disturbance has upset
the process, that is when the flow rate deviates from the setpoint
(0.295m)
Control action LE detects and measures any deviation of level of fluid in the tank and send
signal to LT. LT transmits it as electronic signal to electronic feedback level
indicating controller (LIC). LIC compares this measurement with the
setpoint and adjust the control valve CV-102. CV-102 is adjusted to control
the flow rate of fluid exit from the separator. When the level of liquid is too
low, the low level switch (LSL) will shut down the pump to prevent the
pump from pumping out more liquid.
Additional 1. Centrifugal pump ( P-101) is added to increase or decrease the

consideration
flowrate of the exit fluid
2. Control valve (CV-102) is selected to control the fluid exit
flowrate
3. Drain valve, (V-101) are needed to drain the piping segment
during shutdown and maintenance.
4. Use a low level switch (LSL) to shut down the pump if a low
level occurs to ensure that the pumps do not cavitates.
344
Figure 4.3 P&ID Control for Separator, T-100
Hint:
LT: level transmitter
LIC: Level Indicator Control
PSH: Pressure Switch High
PT: Pressure Transmitter
PC: Pressure Control
PAH: Pressure Alarm Switch
345
CHAPTER 5: COST
5.1.1 Specification sheet
5.1.1.1 Cooler (E-101)
Equipment No : E-101
COOLER SPECIFICATION DATA SHEET
Description : Cooler
OPERATING DATA
TUBE-SIDE DATA
MEAN TEMPERATURE 313 K
AREA OF ONE TUBE 1.149 m2
TUBE STANDARD DIMENSION TOTAL TUBE 0.206 m2
AREA
SECTIONAL
AREA
TUBE PITCH 0.0625m TUBE 1.10 m/s
VELOCITY
OUTSIDE DIAMETER 0.050m TUBE PER 1
PASS
INSIDE DIAMETER 0.0436 m TOTAL FLOW 0.10302m2
AREA
WALL THICKNESS 0.002 m MASS 1091.92kg/m2.s
VELOCITY
VELOCITY
INLET PRESSURE 45 atm MATERIAL Killed carbon steel
(grade: A515)
OPERATING
CONDITION
346
TEMPERATU
RE
DIAMETER
OVERALL HEAT SHELL 1.0245m
4.37611 ×10-3
TRANSFER COEFFICIENT DIAMETER
UTILITIES Cooling water BAFFLE 0.4098 m
SPACING
CROSS FLOW 0.0833 m2
AREA
MASS 60.89 kg /m2 . s
VELOCITY
LINEAR 0.0823 m/s
VELOCITY
347
5.1.1.2 Oil Gas Separator (T-100)
OIL-GAS HORIZONTAL SEPARATOR T-100
Identification : Item : Oil-gas Date : 2/5/2019

Horizontal
Separator
: T-100

No
:1
: No
required
Function: To separate Hydrogen from its liquid mixture
Operating Data
Material Handled: Feed Liquid Outlet Gas
348
Total amount(kg/hr) (S12) Outlet (S11)
Composition(kg/hr) 18412.86 17326.41 1050.45
Butane
Isopentane 20.25 20.25 0
N-pentane 2152.48 2152.48 0
Cyclohexane 2448.93 2448.93 0
Methylcyclohexane 71.81 71.81 0
Benzene 80.00 80.00 0
Toluene 5978.48 5978.48 0
349
Hydrogen 6610.46 6610.46 0
1050.45 0
Temperature(˚C)
78 78 78
Design Data
Volumetric Flowrate : 3.279 Residence Time : 11

3
(m /s) (min)
: 1.2519 : 1.639
Pressure (bar) Diameter (m)
: 4.917 : 5.187
Column Height (m) Hold-up Volume
: 757.3 : 0.295
3
Liquid Density (kg/m ) Effective length
(m)
350
Vapour Density (kg/m3) : 0.089 Volume(m3) 103.7
Vapour Velocity : 3.11 Materials of : Carbon

Construction steel AISI
1080
(m/s)
Design Pressure (bar) : 1.1216 Total weight of : 16952

vessel (N)
Design Temperature : 88
(˚C) Bending
Moment at bottom
tangent line (Nm)
:5 : 10326.24
Wall Thickness (mm)
Critical
Buckling
:2 stress(N/m2)
Corrosion Allowance
(mm)
Reinforcement
351
Type of Domed Ends : Area (mm2) : 61013000
Hemispherical
Domed End Thickness

(mm) :2
: 513.32
Flat End Thickness
(mm)
: 27
: Mineral
wool
5.1.1.3 Pump (P-101)

Description: Pump
OPEARTING DATA
TYPE Centrifugal LIQUID Butane, Isopentane, n-
Pentane, Cyclohexane, n-
Hexane,
Methylcyclohexane,
Benzene, Toluene,
Heptane
352
VISCOSITY 0.00051kg/ms DENSITY 740kg/m3
FLOWRATE
TECHNICAL DATA
AREA 0.0031m 2
STATIC HEAD 5.6877m
DYNAMIC HEAD 56.9519m
TOTAL HEAD 62.6396m
PUMP EFFICIENCY 72%
PUMP POWER 1.0340kW
NPSH available 0.3347M
SHAFT CARBON STEEL
CASING CARBON STEEL
353
5.1.1.4 Pump (P-103)

Description: Pump
OPEARTING DATA
Cyclohexane,
Methylcyclohexane,
Benzene, Toluene,
FLOWRATE
TECHNICAL DATA
AREA 0.0031 m 2
DYNAMIC HEAD 27m
TOTAL HEAD 60.0520m
PUMP EFFICIENCY 71%
PUMP POWER 3.1472kW
SHAFT CARBON STEEL
CASING CARBON STEEL
354
5.1.1.5 Pump (P-104)

Description: Pump
OPEARTING DATA
Cyclohexane,
Methylcyclohexane,
Benzene, Toluene,
FLOWRATE
TECHNICAL DATA
AREA 0.0031 m 2
DYNAMIC HEAD 27m
TOTAL HEAD 60.0520m
PUMP EFFICIENCY 71%
PUMP POWER 3.1472kW
SHAFT CARBON STEEL
CASING CARBON STEEL
355
5.1.1.6 Evaporator (Ev-103)
Equipment No : Ev-103
Description : Evaporator
OPERATING DATA
Split-ring floating-head shell and tube exchanger NO OF 1
UNIT
SHELL PER 1
UNIT
TYPE SHELL AND MEAN 345.5 K
TUBE TEMPERATURE

TUBE
2 TUBE PASS NUMBER OF 1 tube
TUBES
AREA
SECTIONAL AREA
AREA
VELOCITY
MATERIAL Carbon steel
(grade: A285 Gr
A)
OPERATING CONDITION
HEAT DUTY 7827664.50ckj/h MEAN 400K
r TEMPERATURE
DIAMETER
2
OVERALL HEAT 1226.99 W/m .K SHELL DIAMETER 0.157m
356
TRANSFER COEFFICIENT
UTILITIES Steam BAFFLE SPACING 0.0628m
CROSS FLOW 1.972 x10-3 m

TUBE-SIDE DATA
AREA
VELOCITY
INLET PRESSURE 1.013 bar EQUIVALENT 0.074m
DIAMETER
Type of baffles 2mm
Material Carbon steel (grade: A285 Gr A)
357
358
5.1.1.7 Heater (H-101)
OPERATING DATA
exchanger
SHELL PER 1
UNIT
TYPE
SHELL AND MEAN 584 K
TUBE TEMPERATURE
TUBE
TUBES
AREA
SECTIONAL AREA
AREA
VELOCITY
MATERIAL Killed carbon
steel (grade:
A515)
OPERATING
CONDITION
TEMPERATURE
2
DIAMETER
359
OVERALL HEAT 1.9852×10-3 SHELL DIAMETER 0.2051m
(propane)
CROSS FLOW 3.37x10-3 m2

TUBE-SIDE DATA
AREA
INLET TEMPERATURE 393 K MASS VELOCITY 1151.38 kg /m 2 . s
VELOCITY
DIAMETER
Design temperature 100∁
Type of baffles 2mm
360
5.1.1.8 Heater (H-102)
OPERATING DATA
exchanger
SHELL PER 1
UNIT
TYPE
SHELL AND MEAN 740.5 K
TUBE TEMPERATURE
TUBE
TUBES
AREA
SECTIONAL AREA
AREA
VELOCITY
MATERIAL Stainless steel
OPERATING
CONDITION
TEMPERATURE
DIAMETER
-3
OVERALL HEAT 2.6729×10 SHELL DIAMETER 0.198m
(propane)
361
CROSS FLOW 0.023 m2
TUBE-SIDE DATA
AREA
VELOCITY
DIAMETER
Design pressure
Type of head Torispherical head
Type of baffles 2mm
Material Stainless steel 18Cr/8Ni Ti stabilised (321)
362
363
5.1.1.9 Reactor(R-101)

IDENTIFICATION
Item Reactor
Item No R-101
the presence of catalyst (Platinum-Iridium)
that convert light naphtha to Toluene
OPERATING DATA
Reactor sizing Data
of the tube
catalyst
1
)
Cooling Jacket Data
with spiral baffle
channel(m)
(m) m2
(m)
364
Vessel Carbon Steel
365
5.1.1.10 Reactor (R-102)

IDENTIFICATION
Item Reactor
Item No R-102
Toluene
OPERATING DATA
Reactor sizing Data
of the tube
3
Length (m) 3.345m Weight of the 0.087kg
catalyst
1
)
Cooling Jacket Data
with spiral baffle
channel(m)
(m) m2
(m)
366
Vessel
367
Identification: Item Centrifugal Compressor

Item no. C-103
No. required 1
Operating Data
Materials Handled Naphta
Inlet flow Outlet flow
Gas flow rate (kg/hr) 18412.99 18412.99
Operating temperature 120 120
(°C)
Operating pressure, P 1.01325 45.5962
(bar)
Density, ρ (kg/m3) 1.8393 102.6726
Compressibility factor, z 0.98 0.79
Volumetric flow rate, 𝑉̇ 1001.1427 180.4473
(m3/hr)
Technical Data
Compression ratio, Rc 45
Number of stage required 3
Polytropic exponent, n
Ratio of specific heat capacities, k 1.0901
Polytropic efficiency (%) 72
Polytropic head, kNm/kg 434.6679
Polytropic Power (kW) 22223.2044
Actual Power (kW) 3079.2304
Mechanical losses (kW) 92.3769 kW
Brake horsepower (kW) 3171.6073 𝑘𝑊
368
Materials of Construction : Carbon steel
369
5.1.1.12 Condenser (E-100)
CONDENSER E-100
Identification : Item : CONDENSER Date : 2/5/2019
: E-100
: Item No : :1 By : Lim Chee Hung
No
required
Function: To condense the top product from distillation column from gas to liquid phase
Type: Horizontal, with condensation in the shell, and the cooling medium in the tubes
Heat Duty: 2610.08kW

Tube side
Fluid Handled : Product from Length(mm) : 4830
D100 No of Tube : 139
Pressure(bar) : 1.01325 Materials construct : Carbon steel
Outside Diameter(mm) : 20 AISI 1080
Inside Diameter(mm) : 16

Shell side
Fluid Handled : cooling water Buddle Diameter : 351
Temperature(ºC) : 25 (mm)
Pressure(bar) : 1.01325 Shell Diameter : 401
Nozzle (mm) : 54.36
Materials construct : Carbon steel AISI
1080
Insulation
Type: Minerals wood Thickness:
75mm
370
371
5.1.1.13 Reboiler (RB-100)
REBOILER RB-100
Identification : Item : REBOILER Date : 2/5/2019
: RB-100
: Item :1 By : Lim Chee Hung
No : No
required
Function: To vaporise the bottom product from distillation column to increase purity of
toluene.
Operation: Continuous Type:
Thermosyphons
Heat Duty: 998.51kW
Tube side
Fluid Handled : Product from Length(mm) : 2440
D100 No of Tube : 290
Pressure(bar) : 1.01325 Materials construct : Carbon steel
Outside Diameter(mm) : 30 AISI 1080
Inside Diameter(mm) : 25 Pressure drop(kPa) :0.0116
Shell side
Fluid Handled : Condensing Buddle Diameter : 1544
steam (mm)
Temperature(ºC) : 110 Shell Diameter : 1594
Pressure(bar) : 1.01325 Nozzle (mm) : 54.36
Pressure drop(kPa) :308 Materials construct : Carbon steel AISI
1080
Insulation
Type: Minerals wood
Thickness: 75mm
372
5.1.1.14 Distillation Column (D-100)
DISTILLATION COLUMN D-100

Identification : Item : Distillation Date : 2/5/2019
: Item No : Column
No : D-100 By : Lim Chee Hung
required :1
Function: To separate Toluene from its liquid mixture
Operating Data
Material Handled: Feed Distillate Bottom
Total amount(kg/hr) 17362.41 10683.76 6684.56
Composition(kg/hr)
Butane 20.25 20.25 0
Isopentane 2152.48 2152.48 0
N-pentane 2448.93 2448.93 6.68
Cyclohexane 71.81 65.14 0
Methylcyclohexane 80.00 13.15 66.84
Benzene 5978.48 5917.71 60.32
Toluene 6610.46 66.11 6550.72
Design Data
No. of Trays : 22 Recommended Column : 0.759
Feed stage (From bottom) :8 Diameter (m)
Pressure (bar) : 1.01325 Reflux Ratio : 1.25
Column Height (m) : 16.1 Tray Spacing (m) : 0.5
Liquid Density (kg/m3) : 865.15 Materials of : Carbon steel
Vapour Density (kg/m3) : 764.47 Construction AISI 1080
Maximum Vapor Flowrate : 0.016
(m3/s)
Plate Specification
Liquid Flow : Cross-flow Plate Materials : Carbon steel AISI
Arrangement 1080
Plate Area(m2) : 0.452 Plate thickness :5
Hole Area (m2) : 0.0103 (mm) : 70
No. of Hole : 543 Turndown ratio (%) : 0.273
Flooding Diameter : 0.181 Weep point : 0.9
Velocity Entrainment on
plate efficiency
Column Diameter (m) : 0.759 Total weight of : 92605.78
Design Pressure (bar) : 1.115 vessel (N)
Design Temperature (˚C) : 92 Bending Moment at : 180516.21
373
Wall Thickness (mm) :5 bottom tangent line
:2 (Nm)
Corrosion Allowance Critical Buckling : 131762305
(mm) : Hemispherical stress(N/m2)
Type of Domed Ends :6 Reinforcement Area :437.47
Domed End Thickness (mm2)
(mm) : 15
Flat End Thickness (mm) : Mineral wool
374
5.1.2 Equipment Cost Estimation
5.1.2.1 Cooler (E-101)
The cost of purchased equipment is the basis of several predesign methods for
estimating capital investment. Sources of equipment prices, methods of adjusting equipment
prices for capacity, and methods of estimating auxiliary process equipment are therefore
essential to the estimator in making reliable cost estimates. It is often necessary to estimate
the cost of a piece of equipment when no cost data are available for the particular size of
operational capacity involved (Peters et al., 2004). To estimate the purchased cost of
equipment, the correlations in the following can be used:
𝐶𝑒 = 𝑎 + 𝑏𝑆𝑛 (Towler and Sinnott, 2013), page 321
Where Ce = Purchased equipment cost on a U.S. Gulf Coast basis, Jan. 2010 a, b = cost
constant, S = Size of parameter, n = Exponent for that type of equipment
The values of a, b, n and S of each equipment can be found in the Chemical

Engineering Design book in Table 7.2 at page 322 to page 324 (Towler and Sinnott, 2013).
Based on the unit of S given, the value is taken from previous Task 3: Design of equipment.
The cost data available for making preliminary or predesign estimate are only valid at the
time they were developed which is year 2014 in this case. Because prices may have changed
considerably with time due to changes in economic conditions, some method must be used
for updating cost data applicable at a past date to cost that are representative of conditions at
a later time. This can be done by use of cost indexes. A cost index is an index value for a
given time showing the cost at that time relative to a certain base time (Peters et al., 2004).
The cost index used in this plant design is the Marshall and Swift installed-equipment index
as shown in Table 5.1 because it is recommended for process equipment and chemical plant
investment estimates (Peters et al, 2004), page 239.
375
Table 5.1: Marshall and Swift Installed - Equipment Index (Green and Perry, 2010; Duff and
Phelps, 2019)
Year Marshall and Swift Installed-Equipment
Index
2014 1725.36
2015 1778.60
2016 1831.84
2017 1885.08
2018 1938.42
2019 1991.66
If the cost at some time in the past is known, the equivalent cost at present can be determined
by multiplying the original cost by the ratio of present index value to the index value
applicable when the original cost was obtained. The equation is:
In
C n=C k ( ) (Peters et al, 2004), page 236
Ik
Calculation for cooler, E-101:
376
The dimension unit for size, S is L/s. Thus, mass flow rate is obtained from previous
calculation design at Chapter 3 which is 18412.4 kg/hr. Given density of fluid flow is 740
kg/m3. (Handbook of Industrial Hydrocarbon Process, 2011 Pages 395)
mass flowrate , ṁ 18412.4
Volumetric flow rate = =
density , ᵖ 740
1000 L 1 hr
¿ 24.882 m3 / hr × ×
1m 3
3600 s
= 0.0612 L/s
Given a= 8000, b= 240 and n= 0.9 based on Towler and Sinnot, 2013 at page 324.
C 2014=a+b Sn
= 8000 + 240(0.0615)0.9
=8019.51 USD
From Marshall and Swift installed-equipment index as shown in Table 1, I2014 =1725.36 and
I2019 =1991.66
I 2019 1991.66
( )
C 2019=C 2014
I 2014
=8019.51 ×
1725.36
=9260USD
Based on the assumption above and USD/ MYR currency chart, 1 USD = RM 4.19.
Thus, the purchased cost for cooler E-101
RM 4.19 RM 1 million
=9260 USD × × =RM 0.039 million
1 USD RM 1× 106
The price of killed carbon steel grade A515 for cooler E-101 is 1,140 USD @
RM4777(Oakley Steel, 2019). The total cooler purchased cost is RM 4357 @ RM 0.04357
million.
377
5.1.2.2 Expander (Ex-100)
According to Peters and Timmerhaus, n.d, the present cost of equipment can be calculated
using equation below:
index value at present time
Present cost=originalcost × ( )
index value at time original cost was obtained
Figure 5.1: Expander Purchased Equipment Cost (Loh et al., 2002).
Table 5.2: Information of Expander

Material Carbon Steel
Pressure (bar) 15
Power Output used (hp) 60, 000
Electricity consumption 112 MWatt
378
Purchased cost (USD) 10 million
The original cost for expander was based on the 2002 was showed in Figure 5.1. The
Marshall and Swift Installed Equipment at year 2002 is 1104.20 (Green and Perry, 2010;
Duff and Phelps, 2019).
I 2019 1991.66
C 2019=C 2002 ( )
I 2002
=10 000 000 ×
1104.20
=8 million USD
There for the cost for expander (Ex-100) in Malaysian Ringgit is:
8 000 000 USD × × =RM 0.2 million
1 USD RM 1× 106
379
5.1.2.3 Separator (T-100)
Based on F.O.B Gulf Coast U.S.A on 2014, the cost purchased at 2014 for Carbon steel
separator at 1.338 bar and 88℃ is 7300 USD.
I 2019 1991.66
( )
C 2019=C 2014
I 2014
=17300 ×
1725.36
=19970USD
Thus, the cost for separator in Malaysian Ringgit is:

RM 4.19 RM 1million
19970 USD × × =RM 0.084 million
1 USD RM 1× 106
5.1.2.4 Pump (P-101)
The function of Pump-101 is to transport the naphtha from the feed tank to the evaporator.
Naphtha is fed into the evaporator at flowrate of 18412.92 kg/hr at 1.0133bar.
Pump size factor from (Warren et al, 2009)

S=Q(H)0.5
Q = Flow rate (gallon/min)
H = Pump Head (ft) from specification sheet
Conversion of flowrate:
1kg/hr = 0.0044 gal/min
Hence, 18412.92 kg/hr = 81.017 gallon/min
1m = 3.37 ft
Hence, H = 64.6396m = 212.0722ft
S=81.017 gpm(212.0722 ft )0.5
= 1179.8262 gpm. ft 0.5
ln S=7.0731
Base pump purchase cost at a CE index of 619.2 (Chemengonline,2019),
C B=exp {9.7171−0.6019¿ ¿
C B=exp ⁡{9.7171−0.6019 (7.0731 ) +0.0519 ( 7.03712 )

C B=$ 3071.52
380
381
F.O.B purchase cost,
C P =F T F M C B
FM is a material factor
FT is a pump-type factor
Table 5.3: Expander Purchased Equipment Cost (Loh et
al., 2002).
The liquid transport

by this pump is acidic
and tend to cause corrosion
to the equipment. Hence, stainless steel is chosen as the construction material of this pump to
prevent the corrosion that may cause by the transport liquid.
Table 5.4: FT Factors and Ranges for Electric Motors
382
The type factor used for the electric motor is 1.70 as it fulfilled the requirement for
the pump for 81.017 gpm and pump head at 212.0722ft. It also uses only one stages. Thus
FT,1.70 was used.
383
C P =F T F M C B
C P =1.7× 2.0 × $ 3071.52
C P =$ 10443.17
Pump efficiency for Q=81.017 gpm and In Q= 4.3947

η P=−0.316+0.24015 ( ¿ Q )−0.01199 ¿
η P=−0.316+0.24015 ( 4.3947 ) −0.01199 ¿
η P=0.5078
Pump break horsepower, PB
Density, ρ of the organic products:
Since, 1kg/m3 = 0.06243Ib/ft3
From specification sheet of P-101,
740 kg
ρ= 3
=46.1967 Ib /ft 3
m
QHρ
PB =
33000 η P
81.017 ×212.0722× 46.1967
PB =
33 000 ×0.5078
PB =47.3657
ln PB =3.879
η M =¿0.80 +0.0319 ( ln P B )−0.00182 ln ¿¿¿ ¿
η M=¿0.80 +0.0319 (3.879 )−0.00182¿ ¿

η M =¿0.8964 ¿
Power Consumption, PC
PB
PC =
ηM
47.3657
PC =
0.8964
PC =52.8399 Hp
ln PC =3.9673
C B=exp {5.8259+0.13141 ( ln PC ) +0.053255 ¿
C B=exp {5.8259+0.13141 ( 3.967 ) +0.053255 ¿
C B=$ 2044.55
384
C P =1.7× 7161.28=$ 3475.74
Total cost of centrifugal pump and motor

= $ 10443.17+ $ 3475.74
=$ 13918.91
Since 1 $=RM 4.19
Total cost =RM 58320.23=RM 0.05832million
385
5.1.2.5 Pump (P-103)
The function of Pump-103 is to transport the organic products from the reflux accumulator
back to the distillation column. Organic products is fed into the distillation column at
flowrate of 10683.76 kg/hr.

S=Q(H)0.5
1m = 3.37 ft
Hence, H = 60.0520m = 202.3752ft
S=47.0085 gpm(202.3752 ft )0.5

= 668.7365 gpm. ft 0.5
ln S=6.5054
C B=exp {9.7171−0.6019¿ ¿
C B=exp ⁡{9.7171−0.6019 ( 6.5054 ) +0.0519 ( 6.50542 )

C B=$ 2974.76
C P =F T F M C B
386
Table 5.5: Material of Construction Factor for
Centrifugal Pumps, FM (Warren et al, 2009)
The liquid
transport by this pump is
acidic and tend to cause corrosion to the equipment. Hence, stainless steel is chosen as the
construction material of this pump to prevent the corrosion that may cause by the transport
liquid.
387
the pump for 127.99 gpm and pump head at 240.34 ft. It also uses only one stages. Thus
FT,1.70 was used.
C P =F T F M C B
C P =1.7× 2.0 × $ 2974.76
C P =$ 10114.18

η P=−0.316+0.24015 ( ¿ Q )−0.01199 ¿
η P=−0.316+0.24015 ( 3.8503 )−0.01199 ¿
η P=0.4309
758.1667 kg
ρ= 3
=47.3323 Ib /ft 3
m
QHρ
PB =
33000 η P
47.0085 ×202.3752 ×47.3323
PB =
33 000 ×0.4309
PB =31.6666
ln PB =3.4553
388
η M =¿0.80 +0.0319 ( ln P B )−0.00182 ln ¿¿¿ ¿
η M=¿0.80 +0.0319 (3.4553 )−0.00182¿ ¿

η M=¿0.8885 ¿
PB
PC =
ηM
31.6666
PC =
0.8885
PC =39.017 Hp
ln PC =3.6640
C B=exp {5.8259+0.13141 ( ln PC ) +0.053255 ¿
C B=exp {5.8259+0.13141 ( 3.664 ) +0.053255 ¿
C B=$ 2415.87
C P =1.7× 2415.87=$ 4106.98
Total cost of centrifugal pump and motor = $ 10114.18+ $ 4106.98

=$ 14221.16
Since 1 $=RM 4.19
Total cost for P-103 =RM 59586.66=RM 0.5958 million
389
5.1.2.5 Pump (P-104)
The function of Pump-104 is to transport the organic products from the condenser to the
distillate gas tank. Organic products is fed into the tank at flowrate of 10683.76 kg/hr.

S=Q(H)0.5
1m = 3.37 ft
Hence, H = 60.0520m = 202.3752ft
S=47.0085 gpm(202.3752 ft )0.5

= 668.7365 gpm. ft 0.5
ln S=6.5054
C B=exp {9.7171−0.6019¿ ¿
C B=exp ⁡{9.7171−0.6019 ( 6.5054 ) +0.0519 ( 6.50542 )

C B=$ 2974.76

C P =F T F M C B
390
Table 5.7: Material of Construction Factor for
Centrifugal Pumps, FM (Warren et al, 2009)
The liquid
transport by this pump is
acidic and tend to cause corrosion to the equipment. Hence, stainless steel is chosen as the
construction material of this pump to prevent the corrosion that may cause by the transport
liquid.
391
the pump for 127.99 gpm and pump head at 240.34 ft. It also uses only one stages. Thus
FT,1.70 was used.
C P =F T F M C B
C P =1.7× 2.0 × $ 2974.76
C P =$ 10114.18

η P=−0.316+0.24015 ( ¿ Q )−0.01199 ¿
η P=−0.316+0.24015 ( 3.8503 )−0.01199 ¿
η P=0.4309
758.1667 kg
ρ= 3
=47.3323 Ib /ft 3
m
QHρ
PB =
33000 η P
47.0085 ×202.3752 ×47.3323
PB =
33 000 ×0.4309
PB =31.6666
ln PB =3.4553
η M =¿0.80 +0.0319 ( ln P B )−0.00182 ln ¿¿¿ ¿
η M=¿0.80 +0.0319 (3.4553 )−0.00182¿ ¿

η M=¿0.8885 ¿
PB
PC =
ηM
31.6666
PC =
0.8885
PC =39.017 Hp
392
ln PC =3.6640
C B=exp {5.8259+0.13141 ( ln PC ) +0.053255 ¿
C B=exp {5.8259+0.13141 ( 3.664 ) +0.053255 ¿
C B=$ 2415.87
C P =1.7× 2415.87=$ 4106.98
Total cost of centrifugal pump and motor = $ 10114.18+ $ 4106.98

=$ 14221.16
Since 1 $=RM 4.19
Total cost for P-104 =RM 59586.66=RM 0.5958 million
393
By referring Product & Process Design Principles Second Edition in Table 16.32 page 553
(Warren D. Seider, J.D. Seader, Daniel R. Lewin, 2012), the correlation below can be used to
estimate the purchased cost of evaporator:
C p=4500 A 0.55 Heat surface area, A= 0.024m 2
= 4500(0.2583)0.55 = 0.2583 ft 2
= 2137.38 $
The cost index used is Chemical Engineering(CE) plant cost index shown in Table below:
Table 5.9: Marshall and Swift Installed-Equipment Index (Green and Perry, 2010; Duff
and Phelps, 2019
Index
2014 1725.36
2015 1778.60
2016 1831.84
2017 1885.08
2018 1938.42
2019 1991.66
394
The equation is:
I
C n=C k ( n )
Ik
Where k= reference year for which cost is known
n= year for which cost is to be estimated
C n= estimated cost of item in year n
C k= cost of item in reference year k
I n= cost index in year n
I k = cost index in reference year k
From Marshall and Swift installed-equipment index as shown in Table above,

I 2000= 394, I 2019=1991.66
Cost of purchased equipment for Evaporator (Ev-103):
I 2019
C 2019=C 2000 ( )
I 2000
1991.66
= 2137.38 ( )
394
= 10804.41$ / RM 45270.44
395
5.1.2.8 Heater (H-101)
By referring Product & Process Design Principles Second Edition page 523 (Warren et al.,
2012) the equation below is used:
Floating head: C B=exp ⁡{11.667−0.8709 [ ¿ ( A ) ] +0.09005 ¿
= exp {11.667-0.8709[In(114.6786 ft 2 ¿ ¿+0.09005 ¿
= 14215.74$
The f.o.b purchase cost for these heat exchangers is determined from
C P =F P F M F L C B
= (1.1737)(1)(1.25)(14215.74)
= 20856.27$
where F P is based on the shell-side pressure, P, in psig and is given by equation as below
which is applicable from 100 to 2000 psig :
P
F P=0.9803+0.018 ( )100
+0.0017 ¿
661.3178
= 0.9803 + 0.018 ( ¿+0.0017 ¿
100
= 1.1737
Material factor, F M is for various combination of tube and shell materials as given in Table
5.10 as a function of the surface area, A in ft 2 according to equation below:
Table 5.10: Materials of Construction Factors, Fm, for Shell-and-Tube Heat
Exchangers
F M =a+¿
114.6786 0
=0+( ¿
100
=1
The factor F L is a tube-length corrections as follows:
Table 5 11: Tube length corrections
396
Cost of purchased equipment of Heater(H-101):
I 2019
C 2019=C 2000 ( )
I 2000
1991.66
= 20856.27( )
394
=105427.38$ /year
=RM 441740.74
397
5.1.2.9 Heater (H-102)
By referring Product & Process Design Principles Second Edition page 523 (Warren et al.,
2012) the equation below is used:
Floating head: C B=exp ⁡{11.667−0.8709 [ ¿ ( A ) ] +0.09005 ¿
= exp {11.667-0.8709[In(23.6375 ft 2 ¿ ¿+0.09005 ¿
= 3387.90$
The f.o.b purchase cost for these heat exchangers is determined from
= (1.1737)(3.6040)(1.25)(3387.90)
= 17913.58$
where F P is based on the shell-side pressure, P, in psig and is given by equation as below
which is applicable from 100 to 2000 psig :
P
F P=0.9803+0.018 ( )
100
+0.0017 ¿
661.3178
= 0.9803 + 0.018 ( ¿+0.0017 ¿
100
= 1.1737
F
Material factor, M is for various combination of tube and shell materials as given in Table
16.25 as a function of the surface area, A in ft 2 according to equation below:
F M =a+¿
23.6375 0.07
= 2.70 + ( ¿
100
= 3.6040
The factor F L is a tube-length corrections as follows:
From Marshall and Swift installed-equipment index as shown in Table above,

I 2000= 394, I 2019=1991.66
Cost of purchased equipment of Heater(H-102):
398
I 2019
C 2019=C 2000 ( )
I 2000
1991.66
= 17913.58 ( )
394
=90552.69$ / year
=RM 379415.78
399
5.1.2.10 Reactor (R-101)
Table 5.12: Marshall and Swift Installed -Equipment Index (Green and Perry, 2010;
Duff and Phelps, 2019)
Index
2010 1457.40
2011 1565.64
2012 1618.88
2013 1672.12
2014 1725.36
2015 1778.60
2016 1831.84
2017 1885.08
400
2018 1938.42
2019 1991.66
For reactor 1, the unit of size, S is in L/s. volumetric flow rate is obtained from the previous
calculation of equipment design at Chapter 3 which is 21.619 m3/s, converting it to m3/s,
m3 1 hr 3
21.619 m3/hr = 21.619 × =0.3603 m /s
hr 60 s
m 3 1000 L
S=0.3603 × =360.3 L/ s
s 1m 3
From the Table 7.2 at page 322 to page 324 (Towler and Sinnott, 2013),
401
Figure 5 2: Purchased Equipment Cost for Common Plant Equipment
For reactors (jacketed, agitated) it gives a = 61,500, b = 32,500 and n = 0.8.
C 2010 = 𝑎 + 𝑏𝑆𝑛
C 2010= 61,500 + 32,500 (360.3)0.8
= 9429300 USD
From Marshall and Swift installed-equipment index as shown in Table 5.12 above,
I 2010= 1457.40, I 2019= 1991.66
I 2019
C 2019=C 2010 ( )
I 2010
1991.66
C 2019=9429300USD ( )
1457.40
¿ 12885933.61USD
Based on the assumption above,
1 USD = RM 4.19
402
Thus, cost of R-101 = 12885933.61USD × ×
1USD RM 1 x 106
¿ RM 53.99 million
The catalyst used in the reactor is iridium, thus the cost of the catalyst is estimated. The
catalyst price is US $10 per kilogram (Alibaba, 2019) is based on quotations from a number
of catalyst manufacturers. From previous calculation of equipment design, the reactor
volumes is 11.6823 m3.
Bulk density of the catalyst = 670 kg/m3
Hence, the cost of the catalyst ¿ 10 ×11.6823 × 670
¿ 78271410 USD x 4.19
¿ RM 327,957
403
5.1.2.11 Reactor (R-102)
For reactor 2, the unit of size, S is in L/s. volumetric flow rate is obtained from the previous
calculation of equipment design at Chapter 3 which is 22.049 m3/s, converting it to m3/s,
m3 1 hr 3
22.049 m3/hr = 22.049 × =0.3675 m /s
hr 60 s
m 3 1000 L
S=0.3675 × =367.48 L/ s
s 1m 3
From the Table 7.2 at page 322 to page 324 (Towler and Sinnott, 2013),
For reactors (jacketed, agitated) it gives a = 61,500, b = 32,500 and n = 0.8.

C 2010 = 𝑎 + 𝑏𝑆𝑛
C 2010= 61,500 + 32,500 (367.48)0.8
=9615980 USD
From Marshall and Swift installed-equipment index as shown in Table 5.1 above,
I2010 = 1457.40, I2019 = 1991.66
404
I 2019
C 2019=C 2010 ( )
I 2010
1991.66
C 2019=9615980USD ( )
1457.40
¿ 13141047.57 USD
Based on the assumption above,
1 USD = RM 4.19
RM 4.19 RM 1million
Thus, cost of R-101 = 13141047.57 USD × ×
1 USD RM 1 x 106
¿ RM 55.06 million
The catalyst used in the reactor is iridium, thus the cost of the catalyst is estimated. The
catalyst price is US $10 per kilogram (Alibaba, 2019) is based on quotations from a number
of catalyst manufacturers. From previous calculation of equipment design, the reactor
volumes is 5.5912m3 Bulk density of the catalyst = 670 kg/m3
Hence, the cost of the catalyst
= volume of reactor x bulk density of catalyst x catalyst
price/kg
¿ 10 ×5.5912 ×670
¿ 37461.04 USD x 4.19
¿ RM 156,961.76
405
Base purchase cost C B , for three major types of compressors, based on data from Garret
(1989) and Walas (1988) are plotted in Figure 5.3, (Warren D. Seider, 2013) as a function of
consumed power, Pc , in horsepower for a cost index in mid-2000 (CE = 394). The base cost,
which includes an electric motor drive, is for cast iron or carbon-steel construction. Pc is
calculated in previous task which is 3171.61 kW, the compressor used is centrifugal
compressor.
Figure 5.3: Base f.o.b purchase costs for centrifugal, reciprocating and screw
compressors.
P
From the graph, for size factor, c = 3171.61kW, the purchase cost for centrifugal
compressor is $1,000,000.
Converting it to MYR =$ 1,000,000 x 4.19
¿ RM 4,190,000
406
5.1.2.13 Condenser (E-100)
Purchase cost calculation
Where:
CP = Purchased cost
FP = Pressure factor
FM = Material factor equipment
FL = Tube-length correction
CB = Base cost
C B=exp ⁡¿
Q=U A ∆Tm
Q 261080
A= =
U (∆ Tm) 3930 W ×26.22 ° C
m2 . C
1422.196
=25.3296 m2 ; 272.6455 ft2
C B=exp ⁡¿
C B= $ 8729.3330
FM is the material factor obtained from the various combination of materials used for the
construction of shell and tube condenser. For the E-100, material used for the both side shell
and tube are Carbon steel AISI 1080. Hence, the coefficient for a and b will be 1.75 and 0.13
respectively.
F M =a+¿
F M =1.75+ ¿
= 2.8893
Table 5.13: Materials of construction factor for shell and tube Heat Exchanger
407
Meanwhile, FP is the pressure factor, given by the equation below based on the pressure on
the shell side which is applicable for the pressure from 100 up to 1000psig. Pressure design
for the condenser E-100 is about 1.01325 bar (14.6959psig).
F P=0.9803+0.018 ( 100P )+0.0017 ¿

F P=0.9803+0.018 ( 14.6959
100 )
+0.0017 ¿
= 0.9830
FL is the tube length correction which is define as the table below which is obtained from the
textbook of Product and Process Design Principles by J.D Seader page 523. The tube length
of E-100 is 15.8465 ft. hence, FL = 1.05
Tube length FL
(ft)
8 1.25
12 1.12
408
16 1.05
20 1.00
Thus, the estimation purchase cost for E-101 calculated:

C P =0.9830× 2.8893 ×1.05 ×8729.3330
= $ 26032.5383
To convert the cost into the currency value, the CE Plant cost index of year 2018 and based
on year 2000 is used:
I
Cost =Base cost (C P )( )
I Base
1991.66
Cost =26032.5383 ( 1457.40 ) ,USD 2019
The USD, 2019 converted to RM (million)

= 35629.2454 × RM 4.19
= RM 149286.54
409
5.1.2.14 Reboiler (RB-100)
Purchase cost calculation

Where:
CP = Purchased cost
FP = Pressure factor
FM = Material factor equipment
FL = Tube-length correction
CB = Base cost
C B=exp ⁡¿
Q=U A ∆Tm
Q 998510
A= =
U (∆ Tm) 1500 W ×20 ° C
m2 . C
A = 33.2837 m2 ; 358.2628 ft2
C B=exp ⁡¿
C B=$ 12756.0469
FM is the material factor obtained from the various combination of materials used for the
construction of shell and tube reboiler. For the RB-100, material used for the both side shell
and tube are Carbon steel AISI 1080. Hence, the coefficient for a and b will be 1.75 and 0.13
respectively.
F M =a+¿
F M =1.75+ ¿
= 2.8893
Table 5 14: Materials of construction factor for shell and tube Heat Exchanger
410
Meanwhile, FP is the pressure factor, given by the equation below based on the pressure on
the shell side which is applicable for the pressure from 100 up to 1000psig. Pressure design
for the condenser RB-100 is about 1.01325 bar (14.6959psig).
F P=0.9803+0.018 ( 100P )+0.0017 ¿

F P=0.9803+0.018 ( 14.6959
100 )
+0.0017 ¿
= 0.9830
FL is the tube length correction which is define as the table below which is obtained from the
textbook of Product and Process Design Principles by J.D Seader page 523. The tube length
of RB-100 is 8.005 ft. hence, FL = 1.25
Tube length FL
(ft)
8 1.25
12 1.12
16 1.05
20 1.00
Thus, the estimation purchase cost for RB-100 calculated:

C P =0.9830× 2.8893 ×1.25 × 12756.0469
= $ 45286.8669
411
I
I Base
1991.66
Cost =45286.8669 ( 1457.40 ) =$ 61888.3226 ,USD 2019

= 61888.3226 × RM 4.19
= RM 259312.07
412
Purchase Cost Calculation
C P =F M C V +C PL
The f.o.b purchase cost, at a CE index = 394 of the empty vessel, Cv, but including nozzles,
manholes and supports, based on the weight in pounds of the shell and the two heads, W,
depends on orientation. The correlating equations are
Horizontal vessels for 1000 < W < 920,000 lb:
Cv=exp ⁡{8.717−0.2330 [ ln ( W ) ]+ 0.04333¿
The weight W, in the cost correlations for pressure vessel or tower depends on the wall
thickness of shell and two heads. Although the thickness of the head may be requires to be
somewhat thicker than shell, particularly at a high pressure, it is sufficient for cost estimation
purposes to assume head thickness equal to shell thickness, ts. Then, with 2:1 elliptical heads,
the weight of the shell and the two heads is approximately:
W =π ( Di+ t s)( L+0.8 Di )t s ρ
L= Cylinder
0.8 Di = 2 heads
p= density of carbon steel; 490 1b/ft3
P d Di
t p=
2 SE−1.2 Pd
Pd = internal design gauge pressure in psig

Di = Inside shell diameter, inches
S= Max. allowable stress of the shell material
E = fractional weld efficiency = 1
The weld efficiency, E accounts mainly for the integrity of weld for the longitidunal seam.
For carbon steel up to 1.25 in. in thickness, only 10% spot X-ray check of the weld is
necessary and value of 0.85 for E should be used. For larger wall thicknesses, a 100 % X-ray
check is requires, giving a value of 1.0 for E
Pd =exp ¿ ¿
Pd = exp ¿
413
Pd = 23.7625 psig
23.7625× 29.8819
tp =
( 2× 15000× 1 )−(1.2 ×23.2725)
tp = 0.0237
L 2
)(
For this column Di
Pd
633.8583 2
( )
29.8819
23.7625
¿ 18.9353∈¿
Since it is greater that 1.34, the vessel thickness for wind load is calculated
t v =t P ¿
tv= 0.0237 [ 0.75+ ( 0.22 ×1 ) 18.953 ]

= 0.1166 in
To note that vessels are generally fabricated from metal plate, whose thicknesses can be
assumed to come in the following increments:
1/16 in. increments for 3/16 to ½ in. inclusive
1/8 in. increments for 5/8 to 2 in. inclusive
¼ in. increments for 2 ¼ to 3 in. inclusive
1
Adding a corrosion allowance of in. gives a total thickness of 0.1791 in . Since this is in
16
3 1 1
the range of to in., the steel plate increment of in. Therefore, specify a plate
16 2 16
thicknes, ts, of 1.0625 in.
W =π ( 29.8819+1.0625 ) ( 52.8215+0.8 ( 29.8819 ) ) 1.0625(0.284)

¿ 2250.5608 lb
414
2
Cv = exp { 8.717−0.2330 [ ln ( 2250.5608 ) ] +0.00433 [ ln ( 2250.5608 ) ] }
= $ 1308.3211
Towers for 3< Di < 24 ft and 27< L< 170 ft :
CPL= 237.1 Di0.63316 L0.80161
= 237.1(3.2808)0.63316 (52.8215)0.80161
= $12073.8751
Cp = 1($ 1308.3211) + $12073.8751

= $ 13382.1962
The purchase cost at the CE index of 400 for just the tower, ladder , platforms is
( 400 )
Cp = ( 13382.1962 )
394
= $13585.9860
Plates calculation
Vertical towers for plates Mulet et al. (1981) present a method for estimating the purchase
cost of trays installed in a vertical tower. This cost is added to (Eq. 16.52) Cp to obtain
purchase cost. The cost of installed trays, CT, all with downcomers, is given by
C T =N T F NT FTT FTM C BT
NT = number of trays. If that number is greater than 20, the factor FNT = 1.
Here the base cost, CBT for sieve trays at a CE cost index of 394, where the indides diameter
of the tower is in feet and the equation is valid for 2 to 16 ft
CBT = 369 exp(0.1739 Di)

= 369 exp(0.1739 x 3.2808)
=$ 652.8372
The factor FTT accounts for type of tray:
415
FTT = 1.0
FTM, depends on the column diameter in feet , corrects for the material of construction:
FTM = 1.0
CT = 22 ×1 ×1× 1×$ 652.8372

= $ 14362.4184 per tray
Upgrading cost index to 410
410
CT = × $ 14362.4184
394
= $ 14945.6638
The total purchase cost of distillation column is
$13585.9860 + $ 14945.6638 = $ 28531.6498

= $ 28531.6498× RM 4.20
= RM 119832.93
5.1.3 COST OF UTILITIES
416
5.1.3.1 Cooler (E-101)
Utility Requirement
For cooler E-101, unit cost for electricity at 2019= 0.1 USD/kWh (“Malaysia electricity
prices,” 2019)
Actual power = 0.330 kW
USD 24 hrs 331days
Cost of electricity of E-101 at year 2019= 0.1 x 0.330 kW x x
kWh day year
= 262 $/year x RM 4.19/1USD
= RM 1097
Unit cost for oil coolant at 2006= 0.50USD/1000kg

Mass flowrate= 0.80 kg/s
0.08 USD 0.604 kg 24 hrs 331 days 3600 s
Cost of oil coolant of E-101 at year 2016= x x x x
1000 kg s day year 1 hrs
= 1036.41$/year
Based on the assumption above and USD/ MYR currency chart, 1 USD = RM 4.19. Thus, the
utility cost for cooler E-101 in year 2016
¿ 1036 USD × × =RM 0.0043 million.
1 USD RM 1× 106
Table 5.15: Chemical Engineering (CE) Plant Cost Index (Green and Perry, 2008)
Chemical Engineering (CE), Plant Cost
Year
Index
2015 556.70
2016 541.10
2017 562.10
2018 603.1
417
2019 609.5
Therefore, utility cost of cooler for 2019 is calculated by using information table Plant Cost
Index on 2016:
I 2019 609.5
( )
C 2019=C 2016
I 2016
=0.0043 million ×
541.10
=¿RM 4730 @ RM 0.00473 million.
418
5.1.3.2 Expander (Ex-100)
Utility Requirement
Utility requirement calculation for expander, Ex-100. By referring the data information on
Product & Process Design Principles Second Edition page 525 (Warren et al., 2012), the
electricity consumption of the expander for Ex-100 is 120 MWatt per hour and the cost
electricity is 0.1 USD per kWh.
MWatt 1×10 6 Watt 1k 0.1USD 24 hr
120 × × 3
× × ×331 days=95328USD
hr 1M 1 ×10 Watt 1 kWatt 1 day
Based on the table from Chemical Engineering Design by R.K Sinnot page 264 as reference,
the cost of utility on 2016 is:
USD/ MYR currency chart, 1 USD = RM 4.19. Thus, the utility cost for expander Ex-100 =
95328 USD × × =RM 0.4 million
1 USD RM 1× 106
Table 5.16: Chemical Engineering (CE) Plant Cost Index (Green and Perry, 2008)
Year
Index
2015 556.70
2016 541.10
2017 562.10
2018 603.1
2019 609.5
419
Therefore, cost of expander for 2019 is calculated by using information table Plant Cost
Index on 2016:
I 2019 609.5
( )
C 2019=C 2016
I 2016
=0.4 million ×
541.10
=¿RM 4500 @ RM 0.0045 million.
420
5.1.3.3 Separator (T-100)
Based on our previous calculations data, we can use the data to determine the Bare Module
Cost (BMC). The real cost will be obtaining by multiplying by a factor of 4 (Dubas, 2016).
The utility cost calculated will be in US Dollar (USD).
For a horizontal Two-Phase Separator. Volume of separator (m3) is calculated to be 103.7 m3.
The Bare Module Cost (BMC) for 2016 comes up as:
= 210,000 + ( ( v−10 ) 11.1 ) ×1200
= 387049.54 x 4
= 1548198 USD
Then for gas-oil separator T-100, unit cost currency for electricity at 2019= 0.1 USD/kWh
(“Malaysia electricity prices,” 2019)
USD 24 hrs 331days
Cost of electricity of E-101 at year 2016= 0.1 x 0.110 kW x x
kWh day year
= 87 $/year
USD/ MYR currency chart, 1 USD = RM 4.19. Thus, the utility cost for separator, T-100 on
2016 is:
RM 4.19 RM 1million
=(1548198+87 USD) × × =RM 6.5 million
1 USD RM 1× 106
Table 5 17: Chemical Engineering (CE) Plant Cost Index (Green and Perry, 2008)
Year
Index
2015 556.70
2016 541.10
2017 562.10
421
2018 603.1
2019 609.5
Therefore, cost of utility for separator on 2019 is calculated by using information table Plant
Cost Index on 2016:
I 2019 609.5
( )
C 2019=C 2016
I 2016
=6.5 million ×
541.10
=¿RM 0.732 million.
422
5.1.3.4 Pump (P-101)
The cost for utilities such as steam, electricity, cooling water and nitrogen gas varies
widely depending on the amount needed, plant location and source. Typical cost of utilities
for steam, electricity, cooling water are given in Table 6-14, page 266 from the Plant Design
and Economics for Chemical Engineers book (Peters et al, 2004) which is given on U.S. basis
year 2000. However, for cost of utility of nitrogen gas, it was referred to Chemical
Engineering Design book in Table 6.5, page 265 with U.S. basis year 2004 (Sinnot, 2005).
Since the cost is not present cost, cost index was used to calculate for present cost of utilities
in year 2017. The cost index used is Chemical Engineering (CE) plant cost index as shown in
Table 5.3 because it is recommended for chemical plant investment estimates (Peters et al,
2004; Ulrich and Vasudevan, 2006). The power of pump and compressor were obtained from
previous calculation in Chapter 3: Equipment Design while mass flowrate of steam, cooling
water and nitrogen gas were obtained from previous Chapter 2 which is mass and energy
balance calculated. Table 5.18 is the estimation cost of utilities.
Table 5.18: Chemical Engineering (CE) Plant Cost Index (Green and Perry, 2008; folk,
2011; Chemengonline, 2019; Wong, 2019)
Chemical Engineering (CE)Plant Cost
Year
Index
2015 556.70
2016 541.10
2017 562.10
423
2018 603.1
2019 609.5
Utility cost for P-101,

Cost of utility = unit cost x annual utility requirement x 24hours/day x 331 days/year
By taking compressor, C-101 as example for calculation of cost of electricity:
Typical unit cost for electricity = 0.1 USD/kWh
Actual power = 1.0340 kW (from previous Chapter 3: Equipment Design)
0.1usd 24 h 331days
Cost of electricity of P-101 at year 2019 = ×1.0340 kW × ×
kWh day year
821.4 USD
¿
year
= RM 3441.67/year
424
5.1.3.5 Pump (P-103)

By taking pump, P-103 as example for calculation of cost of electricity:
0.1usd 24 h 331 days
kWh day year
2500USD
¿
year
= RM 10475/ year
425
5.1.3.6 Pump (P-104)

By taking pump, P-104 as example for calculation of cost of electricity:
0.1usd 24 h 331 days
kWh day year
2500USD
¿
year
= RM 10475/year
426
Unit cost for electricity at 2019= 0.1 USD/kWh (“Malaysia electricity prices,” 2019)
Actual power =2270 kW
USD 24 hrs 331days
Cost of electricity of Ev-103 at year 2019= 0.1 x 2270 kW x x
kWh day year
= 1803288 $/year
= RM 7.56 million
Unit cost for steam at 2006= 0.06USD/1000kg

Mass flowrate= 0.604kg/s
0.06 USD 0.604 kg 24 hrs 331 days 3600 s
Cost of steam of Ev-103 at year 2006= x x x x
1000 kg s day year 1hrs
= 1036.41$/year
I 2019
C 2019=C 2006 ( )
I 2006
609.5
= 1036.41 ( )
500
= 1263.38 $/year
= RM 5293.58
427
5.1.3.8 Heater (H-101)
USD 24 hrs
Cost of electricity of Heater, H-101 at year 2019= 0.1 x 4764.43 kW x x
kWh day
331days
year
= 3,784,863.19 $/year
=RM 15.86 million
Unit cost for cooling water at 2006= 0.020USD/m3

Mass flowrate = 5.115kg/s
5.115kg 3600 s 24 hrs 331days
Cooling water = x x x
s 1hr 1 day 1 year
3
kg m
= 146280816 x
year 997 kg
m3
= 146720.98
year
0.020USD m3 609.5
Cost of cooling water of H-101 at year 2006= 3 x 146720.98 x( )
m year 500
= 3577.0575 $/ year
= RM 0.1499 million
428
5.1.3.9 Heater (H-102)
USD 24 hrs
Cost of electricity of Heater, H-102 at year 2019= 0.1 x 1133.74 kW x x
kWh day
331days
year
= 908805.98 $/year
=RM 3.81 million/ year
Unit cost for cooling water at 2006= 0.020USD/m3

Mass flowrate= 5.115kg/s
5.115kg 3600 s 24 hrs 331days
Cooling water= x x x
s 1hr 1 day 1 year
3
kg m
= 146280816 x
year 997 kg
m3
= 146720.98
year
0.020USD m3 609.5
Cost of cooling water of H-102 at year 2006= 3 x 146720.98 x( )
m year 500
= 3577.0575 $/ year
= RM 0.01 million
429
5.1.3.10 Reactor (R-101)
Electricity
The operation requires energy input in the form of electricity. The unit cost for electricity at
2019 = 0.1 USD/kWh (“Malaysian electricity prices”, 2019)
The actual power is calculated in previous task,
Cost of electricity of R-101 in year 2019 =
USD 24 hrs 331 days 3600 s

0.1 × 8.46068 kW × × ×
kWh day year 1hrs
¿ $ 24,196,191.09 per year
¿ RM 101,382,040.7
430
5.1.3.11 Reactor (R-102)
Electricity
Actual power =1.80240 kW
Cost of electricity of R-102 in year 2019 =

0.1 ×1.80240 kW × × ×
kWh day year 1 hrs
¿ $ 5,154,575 per year
¿ RM 21,597,671.83
431
Electricity
Actual power =0.0336069 kW
Cost of electricity of C-103 in year 2019
= 0.1 × 0.0336069 kW × × ×
kWh day year 1hrs
¿ $ 96110.356 per year
¿ RM 402,702.39
432
5.1.3.13 Condenser (E-100)
Utilities of condenser used are electricity for power requirement

24 hr 350 days
Cost utility=Unit cost × Annual utility requirement × ×
day year
Typical unit cost for electricity = $0.045/kWh from Table 6-14, page 266 (Peter et al, 2014)

Cost electricity at year 2000
0.045 24 hr 350 days
¿ ×2610.08 kW × ×
kWh day year
¿ $ 986610.24 / year
Based Chemical Engineering (CE) plant cost index, I2000= 394.1 and I2019= 609.5
I
Cost =Base cost ×
Ibase
I
Cp ( 2019 )=Cp ( 2000 ) ×
I 2000
609.5
$ 986610.24 ×
394.1
= $ 1525853.695
The USD, 2019 converted to RM
Cp(2019) = $ 1525853.695 × RM 4.19
= RM 6561170.89
Utilities of condenser used are cooling water

24 hr 350 days
day year
Typical unit cost for cooling water = $0.02/1000 gal.
Flowrate of cooling water = 19700.3793 gal/hr
0.02 $ 19700.3793 gal 24 hr 350 days
Cost utility= × × ×
1000 gal hr day year
= $3309.6637 /year
I
Cost =Base cost ×
Ibase
I
Cp ( 2018 )=Cp ( 2000 ) ×
I 2000
609.5
$ 3309.6637 ×
394.1
= $ 5118.5994
Cp(2019) = $ 5118.5994 × RM 4.19
= RM 21446.93
433
5.1.3.14 Reboiler (RB-100)
Utilities of reboiler used are electricity for power requirement

24 hr 350 days
day year
Typical unit cost for electricity = $0.045/kWh from Table 6-14, page 266 (Peter et al, 2014)

Cost electricity at year 2000
0.045 24 hr 350 days
¿ × 998.51kW × ×
kWh day year
¿ $ 377436.78/ year
I
Cost =Base cost ×
Ibase
I
Cp ( 2018 )=Cp ( 2000 ) ×
I 2000
609.5
$ 377436.78×
394.1
= $ 583729.3007

Cp(2019) = $ 583729.3007 × RM 4.19
= RM 2445825.77
Utilities of reboiler used are steam
24 hr 350 days
day year
Typical unit cost for cooling water = $6.60/1000kg
Flowrate of steam = 1181.297 kg/s = 1129143.193 gal/hr
6.60 $ 1129143.193 gal 24 hr 350 days
= $6259969.62/year
Based Chemical Engineering (CE) plant cost index, I2000= 394.1 and I2016= 500
I
Cost =Base cost ×
Ibase
I
Cp ( 2018 )=Cp ( 2000 ) ×
I 2016
500
¿ $ 6259969.62×
394.1
¿ $ 79421084.27
The USD, 2019converted to RM
Cp(2019) = $79421084.27 × RM 4.19
= RM 332774343.10
434
Utilities of distillation column used are cooling water

24 hr 350 days
day year
Typical unit cost for cooling water = $0.02/1000 gal.
Flowrate of cooling water =19700.37 gal/hr
0.02 $ 19700.37 gal 24 hr 350 days
= $3309.6622 /year
I
Cost =Base cost ×
Ibase
I
Cp ( 2018 )=Cp ( 2000 ) ×
I 2000
609.5
$ 3309.6622×
394.1
= $ 5118.5971
Cp(2019) = $5118.5971 × RM 4.19
= RM 6804.45
Utilities of distillation column used are steam

24 hr 350 days
day year
Typical unit cost for cooling water = $6.60/1000kg
Flowrate of steam = 15216.31 gal/hr
6.60 $ 15216.31 gal 24 hr 350 days
= $843592.2264/year
Based Chemical Engineering (CE) plant cost index, I2000= 394.1 and I2016= 500
I
Cost =Base cost ×
Ibase
I
Cp ( 2018 )=Cp ( 2000 ) ×
I 2016
500
¿ $ 843592.2264 ×
394.1
¿ $ 1070276.867
Cp(2019) = $ 1070276.867 × RM 4.19
= RM 4484460.073
435
436
5.1.3.16 Estimation cost of utilities
Table 5.19: Estimation cost of utilities

Type of Co Type Cost per unit Annu Unit Annua
equipment de of utility utilities al utility of utility l utility
requirem requirem cost (RM
ent in ent million/ye
appropria ar)
te unit
Cooler E- Electri 0.1 0.33 kW 0.001

101 city USD/kWh 1
Oil 0.50 0.80 kg/s 0.004

coolant USD/1000kg 7
Expande Ex Electri 0.1USD/kW 1200 kW 0.004

r -100 city h 000 5
Separato T- Electri 0.1USD/kW 0.11 kW 0.73

r 100 city h
Pump P- Electri 0.1 1.03 kW 0.003

101 city USD/kWh 4

103 city USD/kWh
437
104 city USD/kWh
Evapora Ev Electri 0.1 2270 kW 7.56

tor -103 city USD/kWh
Steam 0.06USD/10 0.604 kg/s 0.006

00kg 0
Heater H- Electri 0.1 4764. kW 15.86

101 city USD/kWh 43
Coolin 0.020 USD/ 5.12 kg/s 0.15

g water m 3
Heater H- Electri 0.1 1133. kW 3.81

102 city USD/kWh 74
Coolin 0.020 USD/ 5.12 kg/s 0.01

g water m 3
438
Reactor R- Electri 0.1 8.46 kW 101.3
101 city USD/kWh 8
Reactor R- Electri 0.1 1.80 kW 21.60

102 city USD/kWh
Compre C- Electri 0.1 0.03 kW 0.40

ssor 103 city USD/kWh
Condens E- Electri 0.1 2610. kW 6.56

er 100 city USD/kWh 08
Coolin 0.020 USD/ 20.72 kg/s 0.02

3
g water m
Reboiler RB Electri 0.1 2610. kW 2.45

-100 city USD/kWh 08
Steam 0.06USD/10 1181. kg/s 332.7

00kg 30 7
439
Distillati D- Coolin 0.020 USD/ 20.72 kg/s 0.006
3
on column 100 g water m 8
Steam 0.06USD/10 16 kg/s 4.448

00kg
Total 157.2
cost of 98
utility
440
5.2 TOTAL COST ESTIMATION (METHOD OF GUTHRIE)
5.2.1 Total capital investment, CTCI
Total capital investment (CTCI) is the money required in supplying the necessary plant
and manufacturing facilities include with the money needed as working capital in order to
operate the toluene production plant. There are many methods that can be applied to estimate
the total capital investment including the Method of Guthrie. Therefore, the equation for the
total capital investment by Guthrie method is as followed (Seider, 2003):
C TCI =C FCI +C WC + C L
Where C TCI = Total capital investment, RM million

C FCI = Fixed capital investment, RM million
C WC = Working capital, RM million
C L = Land capital purchase land for the plant, RM million
5.2.1.1 Fixed Capital Investment, CFCI
Fixed capital investment is total amount of money needed to supply the necessary
plant and production facilities. Referring to the journal Peters et al. (2004), the equation for
the fixed capital investment are showed at below:
¿ Capital Investment ,C FCI =Direct costs+ Indirect costs
Direct costs in CFCI are stand for the capital necessity to install process equipment
include all the components for complete process including the purchased material equipment,
instrumentation (pipe installation, electrical system installation, buildings, yard (land)
installation and safety facility).
441
Direct Cost
A. Purchased material equipment
Both direct and indirect cost is calculated by using the total purchased cost equipment as the
basis which is RM 49.46 million.
According to Peters et al. (2004) page 244, the purchased-equipment delivery is 23% of the
total purchased equipment cost.
23 %
Purchased−Equipment Delivery= ×Total Purchased equipment cost
100 %
Purchased−Equipment Delivery=0.23 × RM 49.46 million=RM 11.62 million
B. Pipe Installation
This section involves the cost for piping cover labor, valves, fittings, pipe, support
and other items including the complete erection of all piping used directly in manufacturing
plant such as use of utilities, sewer, steam, oil cooling medium, water cooling system and the
others piping process. Piping estimation methods involve either some degree of piping take-
off from detailed flowsheets or use of a factor technique when neither detailed drawings nor
flowsheets are available. Factoring by percentage of purchased-equipment cost and
percentage of fixed-capital investment is based strictly on experience gained from piping
costs for similar previously installed chemical process plants. Table 5.1 shows a rough
estimation cost of piping for various types of chemical processes.
Table 5.20: Estimated cost of piping (Peters et al. 2004) page 245.
Types of Percent of purchase equipment Percent of
442
process plant fixed capital
investment
Material Labour Total
Solid 9 7 16 4
Solid-fluid 17 14 31 7
Fluid 46 30 76 13
The toluene production plant is a gas-liquid (fluid) process plant and approximately 76 %, so
the piping cost was calculated.
76 %
Piping cost= × Purchased equipment cost
100 %
Piping cost=0.76 × RM 49.46 million
¿ RM 37.91 million
C. Electrical system installation
The electrical system includes power wiring, lighting, transformation and service
(instrument and control wiring). In most chemical plants, the installed cost of electrical
systems is estimated to be 15% to 30% of the delivered purchased-equipment cost or between
4% to 8% of the fixed-capital investment Peters et al. (2004) page 246. Therefore, toluene
production plant has 30 % purchased-equipment delivery cost used as the cost estimation of
electrical installation.
443
30 %
Electrical system ( installation cost ) = × Purchased equipment delivery cost
100 %
Electrical system ( installation cost ) =0.3 × RM 11.62 million=RM 3.5 million
D. Building
The cost of building includes services, expenses for labor, materials and supplies
involved in the erection of all buildings connected with toluene production plant. In terms of
building, the cost for plumbing, heating, lighting, ventilation and safety. The cost of building
for different types of process plants are showed in Table 2 as a percentage of purchased-
equipment cost Peters et al. (2004) page 247.
Table 5.21: Cost building including services based on purchased-equipment cost Peters
et al. (2004) page 246
Type of process Percentage of Purchased-equipment cost
plant
New plant at New unit at Expansion at

new site existing site existing site
Solid 68 25 15
Solid-fluid 47 29 7
Fluid-gas 45 5-18 6
For toluene production plant as well as new plant at new site,
444
Cost of buildings = 45% of Purchased equipment cost
45 %
Building cost ( include services )= × Purchased equipment cost
100 %
Building cost ( include services )=0.45 × RM 49.46 million=RM 54 million
E. Yard (Land)
Costs for fencing, grading, roads, sidewalks, railroad sidings, landscaping, and similar
items are all considered as parts of yard improvement. The cost for these items in most
chemical plants approximates 15% to 47% of the purchased-equipment cost. This is
equivalent to approximately 2% to 5% of the fixed-capital investment (Peters et al. (2004)).
For the toluene production plant, 47% of the purchased-equipment cost was used to estimate
the yard improvement cost.
47 %
Yard Improvement= × Purchased equipment cost
100 %
Yard Improvement=0.47× RM 49.46 million
¿ RM 23.23 million
The total estimation cost for direct is RM 130.26 million
Indirect Cost
The indirect costs in the C FCI represent the construction overhead and all of the plant
components which are not directly related to the process operation. The indirect costs include
engineering and supervision, construction expenses, legal expenses and contractor’s fee. The
total indirect costs are shown where the percentage of purchased-equipment cost, percentage
of direct plant cost or percentage of fixed capital investment for each equipment is based on
Peters et al. (2004), page 248.
A. Engineering and Supervision
445
The costs for construction design and engineering, including internal or licensed
software, computer-based drawings, purchasing, accounting, construction and cost
engineering, travel, communications, and home office expense plus overhead, constitute the
capital investment for engineering and supervision. After referring Peters et al. (2004), this
cost, since it cannot be directly charged to equipment, materials, or labor, is normally
considered an indirect cost in fixed-capital investment and is approximately 30% of the
delivered-equipment cost or 8% of the fixed-capital investment for the process plant.
30 %
Engineering∧Supervision= × Purchased equipment delivery cost
100 %
Engineering∧Supervision=0.3 × RM 11.62 million=RM 3.5 million
B. Legal Expenses
Legal expenses result largely from land purchases, equipment purchase, and
construction contracts. Understanding and proving compliance with government,
environmental, and safety requirements also constitute major sources of legal expenses.
These usually total on the order of 1% to 3% of fixed-capital investment (Peters et al., 2004).
For the toluene production plant, 3% of fixed-capital investment was used for the estimation
of legal expenses.
C. Construction Expenses
The construction expenses, another indirect plant cost include temporary construction
and operation, construction tools and rentals, home office personnel located at the
construction site, construction payroll, travel and living, taxes and insurance, and other
construction overhead. For ordinary chemical process plants, the construction expenses
average roughly between 8% to 10% of the fixed-capital investment of the plant (Peters et al.
(2004)). For the toluene production plant, 10% of fixed-capital investment was used for the
estimation of construction expenses.
D. Contractor’s Fee
446
The contractor’s fee varies for different situations, but it can be estimated to be about
2% to 11.5% of the direct plant cost or 1.5% to 6% of the fixed-capital investment (Peters et
al. (2004). For toluene production plant, 11.5% of the direct plant cost was used for the
estimation of contractor’s fee
11.5 %
Contracto r ' s Fee= × Direct plant cost
100 %
Contracto r ' s Fee=0.115 × RM 130.26 million
¿ RM 15 million
Total Indirect Cost = RM 3.5 million + RM15 million = RM 18.5 million
Thus, the total fixed capital investment calculated:

¿ Capital Investment ,C FCI =Direct costs+ Indirect costs
¿RM130.26 million + RM18.5 million
= RM 148.76 million
5.2.1.2 Working Capital, CWC

The meaning of working capital is the additional investment needed, over and above
the fixed capital, to start the plant and operate until income is earned. It includes the cost of
start-up, catalyst charge, raw materials and intermediates in the process. By the way, most of
the working capital is recovered at the end of project. Based on Sinnot (2005), page 244, the
working capital, CWC is about 7.3 % of fixed capital investment, CFCI.
WorkingCapital ,C WC =0.073 ×C FCI =0.073 ×RM148.76 million
= RM 10.8 million
5.2.1.3 Land Capital, CL

The location area of the toluene production plant is affecting the land capital cost. By
referring the journal from D. Mutiara (2017), the design of toluene plant using catalytic
reforming location area is 3800 m2 (40903 ft2). Thus, land capital of the cost was calculated
by using price per square foot at Port Dickson Industrial Park for toluene production plant
based on EdgeProp Malaysia on 2019. The chosen data value is RM1859 per square feet.
447
Figure 5.4: Land Sale Price per Square Foot in Port Dickson (EdgeProp, 2019)
RM 1859
Land Capital , C L =40903 ft 2 ×
1 ft 2
Land Capital , C L =RM 76.04 million
From the calculation above, the total capital investment, CTCI was calculated by
adding the value of fixed capital cost (C FCI), working capital cost (CWC) and land capital cost
(CL).
C TCI =C FCI +C WC + C LC TCI =RM 148.76 million+ RM 10.8 million+ RM 76.04 million
¿ RM 235.6 million
5.2.2 Cost of Manufacturing (COM) without Depreciation
Cost of manufacture (COM) is all expenses directly connected with the manufacturing
operation or physical equipment of a process plant itself. It can be divided to three
classification:
i. Direct manufacturing cost/ variable production cost
ii. Fixed charges/ fixed manufacturing cost
iii. Plant overhead cost
Cost of manufacture (COM) can be calculated using equation below:
COM = DMC + FC + POC (Peters et al., 2004), page 273

Where, DMC = Direct manufacturing cost
FC = Fixed charges
POC = Plant overhead cost
448
5.2.2.1 Direct Manufacturing Cost, DMC without Depreciation
Direct manufacturing costs or variable production costs is cost that include all
expenses directly associated with the manufacturing operation. These involves expenditures
for raw material, operating labor, direct supervisory and clerical labor, utilities, maintenance
and repairs, operating supplies, laboratory charges, patents and royalties, catalyst and waste
disposal.
A. Raw Material
In the chemical industry, one of the major costs in a production operation is for the raw
materials used in this process. Raw material for production of toluene is naphtha. The
material price has been mentioned in assumption where the price is fixed for whole period of
operation. The mass flow rate of raw materials needed were obtained from previous Chapter
1 which is 519.36 USD/metric ton.
Since 1 metric ton =1000L = 1 m3,
519.36USD m3
Price of naphtha per kg = × =0.7018USD /kg
m3 740 kg
Cost of raw material was calculated using following equation:
Plant operation: 24 hours, 331 days per year
From assumption above: 1 USD = RM 4.19
24 h 331 days RM 4.19 RM 1 million
Cost of Raw Material = (cost per unit )( )( )( )( )
day year USD RM 1× 106
Hence,
USD 18412.99 kg 24 h 331 days RM 4.19 RM 1 million
(
Cost of naphtha = 0.7018
kg )(h
(
day))(
year
)(
USD
)(
RM 1× 106
)
=RM 430.1212 million per year
B. Operating Labor
The operating labor is divided into two types which are skilled labor and unskilled
labor. The typical labor requirements for process equipment are mentioned in Peters et al.
(2004), page 264 as shown in Figure 5.2 below. The average salary for a production operator
449
in Malaysia was RM 20,400 per year (Payscale, 2017, updated salary on 15 October 2017).
Figure 5.2 is the operator needed per shift for this HDPE process plant. The Table 5 the
estimation operating labor.
Figure 5.5: Typical labor requirement for process equipment (Peters et al., 2004), page264
Table 5.22: Operator needed per shift

Type of Number of Operator/shift/equipment Operator per
Equipment Equipment shift
Pump 3 0.00 0.00
Compressor 1 0.20 0.20
Distillation 1 0.00 0.00

column
Condenser 1 0.10 0.10
450
Reboiler 1 0.10 0.10
Separator 1 0.25 0.25
Evaporator 1 0.25 0.25
Heater 2 0.10 0.10
Cooler 1 0.10 0.10
Total operator /shift 1.10
Table 5.23: Labor Cost Estimation per Year

No Aspect Value
.
1 Operation hour/day 24
451
2 Shift/day 3
3 Hour/shift 8
4 Total shift /year 993
5 Shift/week/operator 5
6 Shift/year/operator 240
7 Operator required /shift 4.1375
8 Total Operator/shift 1.10
9 Total operating labour 4.5513
10 Cost of one labour (RM/year) 24000
452
11 Cost of Total Operating Labour (RM million 0.1092
/year)
4.5513*24000/RM106
C. Direct Supervisory and Clerical Labor
Direct supervisory and clerical labor plays the role to cover the minor yet significant
part of production in order to ensure product quality standards. The cost is average about 15
percent of the cost for operating labor (Peters et al., 2004), page 266.
Direct Supervisory and Clerical Labor = 0.15 * Cost for operating labor
= 0.15 * RM 0.1092 million/ year
= RM0.01638 million/ year
E. Utilities
The cost of utilities has been calculated above in Section 5.1 which is RM 157.298
million/year.
F. Maintenance and Repair
In the process industries, the total plant cost per year for maintenance and repairs
ranges from 2 to 10 percent of the fixed-capital investment with 7 percent being a reasonable
value (Peters et al., 2004), page 268.
Maintenance and repairs = 0.07 * Fixed-capital investment, CFCI
= 0.07 * RM 148.76 million
= RM10.4132 million
453
G. Operating Supplies
Operating supplies is generally referring to the items that cannot be considered as raw
materials or maintenance and repairs elements. For example, lubricants, test chemicals,
custodial supplies and so on. The annual cost of this section can be estimated as 0.5-1% of
fixed capital investment (Peters et al., 2004), page 273. For estimation, 1% of fixed capital
investment was selected to calculate operating supplies cost.
Operating supplies = 0.01 * Fixed-capital investment, CFCI

= 0.01 * RM 148.76 million
= RM 1.4876 million
H. Laboratory Charges
The cost of laboratory tests for control of operations and for product quality control is
covered in this manufacturing cost. This cost may be taken as 10 to 20 percent of the
operating labour (Peters et al., 2004), page 268. For estimation, highest value of 20% of
operating labour was selected to calculate laboratory charges.
Laboratory Charges = 0.2 x cost of operating labour
= 0.2 x RM 0.1092 million/year
= RM 0.02184 million/year
I. Patents and Royalties
Patents cover many products and manufacturing processes. The cost is 1 percent of
the fixed capital investment (Sinnott, 2005), page 267.
Patents and royalties = 0.01 * Fixed-capital investment, CFCI
=0.01 * RM 148.76 million
= RM 1.4876 million
J. Catalyst
454
Cost for catalyst can be significant and should be estimated based on catalyst
requirement and price for the particular process. The catalyst used in this plant is Platinum-
Iridium catalyst. The price of catalyst has been mentioned in assumption above section 5.1
where the price is fixed for whole period of operation at 1 USD/kg.
Price of catalyst used in R-101 = RM 0.328 million
Price of catalyst used in R-102 = RM 0.157 million
Hence, total catalyst used, = RM 0.328 + RM 0.157
=RM 0.485
Table 5.24: Estimation of Direct Manufacturing Cost (DMC)

No Direct Manufacturing Cost % % Cost without
Operating Fixed depreciation (RM
labour capital million)
investment
I Raw materials - - 430.1212
II Operating labour - - 0.1092
III Direct supervisory and clerical 15 - 0.01638

labour
IV Utilities - - 157.298
455
V Maintenance and repairs - 7 10.4132
VI Operating supplies - 1 1.4876
VII Laboratory chargers 20 - 0.02184
VII Patents and Royalties - 1 1.4876

I
IX Catalyst - - 0.485
Total Direct manufacturing Cost DMC (RM million) 601.44
5.2.2.2 Fixed Charges, FC
Fixed charges are cost that change little or not at all with the amount of production.
These include cost for local taxes, insurance and financing.
A. Local Taxes
The magnitude of local taxes depends on the particular locality of the plant and the
regional laws. Annual local taxes for plants are ordinarily range of 35 percent of fixed capital
456
investment (Peters et al., 2004), page 269. For estimation, 35% of fixed capital investment
was selected to calculate local taxes.
Local taxes = 0.35 * Fixed-capital investment, CFCI

= 0.35 * RM 148.76 million
= RM 52.066 million
B. Insurance
Insurance rates depend on the type of process being carried out in the manufacturing
operation and on the extent of available protection facilities. These rates amount to about 1
percent of the fixed capital investment per year (Peters et al., 2004), page 269.
Insurance = 0.01 * Fixed-capital investment, CFCI
= 0.01 * RM 148.76 million
= RM 1.4876 million
C. Financing
Interest is considered to be the compensation paid for the use of borrowed capital. A fixed
rate of interest is established at the time the capital is borrowed. Financing cost is estimated
to be 0-10% of total capital investment (Peters et al., 2004), page 274. For estimation, highest
value of 10% of total capital investment was selected for calculation.
Financing = 0.10 * Total capital investment, CTCI
= 0.10* RM 235.6 million
= RM 23.56 million
Table 5.25: Fixed Charges, FC

No Fixed Charges % Fixed % Total Cost (RM
Capital Capital
Investment Investment
457
million)
I Local taxes 4 - 52.066
II Insurance 1 - 1.4876
III Financing - 10 23.56
Total Fixed Charges, FC (RM 71.1136

million)
5.2.2.3 Plant Overheat Cost, POC
Plant overhead cost are expenditures required for routine general plant services whereby
non-manufacturing machinery, equipment and buildings are required to provide such
services. The plant overhead cost for chemical plants is about 50 to 70percent of the total
expenses for operating labour, supervision and maintenance (Peters et al., 2004), page 270.
70% was selected to calculate plant overhead cost.
POC = 0.7* (Operating Labour + Supervisory & Clerical Labour + Maintenance & repair)
= 0.7*(RM 0.1092 million + RM 0.01638 million + RM 10.4132 million)
= RM 7.3772 million
Thus, cost of manufacture (COM) without depreciation was calculated as below:

COM without depreciation = DMC + FC + POC
458
= RM 601.44 million + RM 77.1136 million + RM 7.3772
million
= RM 685.9308 million
Figure 5.3 is the pie diagram for cost of manufacture (COM) without depreciation.
From the figure, it can be seen that direct manufacturing cost is major cost in cost of
manufacturing with 93%, followed by fixed charges 5% and plant overhead cost 2%.
Cost of Manufacture without depreciation

Plant
Fixed Overheat
charges,FC Cost, POC
11% 1%
Direct
Manufacturin
g Cost ,DMC
88%
Direct Manufacturing Cost ,DMC Fixed charges,FC Plant Overheat Cost, POC
Figure 5.6: COM without Depreciation
459
5.2.3 Cost of Manufacture (COM) with Depreciation
In the three component of COM, only direct manufacturing cost (DMC) will depreciate
while fixed charges and indirect plant overhead cost will not be depreciated. Method used to
calculate depreciation is Modified Accelerated Cost Recovery System (MACRS). Figure 5.4
shows the recovery periods for selected chemical industry-related assets classes while Figure
5.5 is the MACRS depreciation rates. Type of assets of petroleum refining production plant is
manufacture of chemical and allied products, so the recovery period is 10 years. Thus, 10-
year depreciation rate was selected.
Figure 5.7: Recovery periods for selected chemical industry-related assets classes
(Peterset al., 2004), page 310
460
Figure 5.8: MACARS Depreciation Rates (Peters et al., 2004), page 313
461
5.2.3.1 Direct Manufacturing Cost, DMC with Depreciation
The DMC without depreciation calculated before is RM 1388.451 million.

Amount of cumulative depreciation was calculated using the following equation:
dk* = rk* x B (Sullivan et al., 2014), page 319
Where, dk*= cumulative depreciation through year k,
rk* = depreciation rate through year k
B = cost basis = DMC
So, amount of cumulative depreciation for 5 years recovery period,
D5* = r5* x B
=((0.1+0.18+0.144+0.1152+0.0922+0.737+0.0655+0.0655+0.0656+0.0656)
*RM601.44 million)
DMC with depreciation = DMC without depreciation – d5*
= RM601.44 million- RM 581.7128 million
5.2.3.2 Fixed Charges, FC
Fixed charges, FC will not be depreciated, so it remains at RM 77.1136million
5.2.3.3 Plant Overhead Cost, POC
Plant overhead cost is an indirect cost which also will not depreciated.
So, it remains at RM 7.3771 million
Thus, cost of manufacture (COM) with depreciation was calculated as below:
COM with depreciation = DMC with depreciation + FC + POC
= RM 37.58 million + RM 77.1136million + RM 7.3771 million
Figure 5.6 shows the cost of manufacture (COM) with depreciation in pie diagram. It can
be seen that, after depreciation, direct manufacturing cost is still the major cost in COM with
59%, followed by fixed charges (31%) and plant overhead costs (10%).
462
Cost of Manufacture with depreciation
Plant Overheat
Cost, POC
4%
Fixed charges,FC
37% Direct
Manufacturing
Cost ,DMC with
Depreciation
59%
Direct Manufacturing Cost ,DMC with Depreciation Fixed charges,FC

Plant Overheat Cost, POC
Figure 5.9: COM with Depreciation
463
5.2.4 General Expenses, GE
General expenses may be classified into administrative costs, distribution and marketing
costs, and research and development costs. Table 5.7 shows the estimation of general
expenses.
A. Administrative
Costs provided for the administrative activities which include the salaries for
administrators, secretaries, accountants, computer support staff, engineering and legal
personnel. It is also include costs for the office supplies and equipment, communications,
buildings and so on.
The administrative costs may be approximated as about 20% of operating labor.

Administrative Costs = 0.2 x cost of operating labour
= 0.2 x RM 0.1092million
B. Distribution and Marketing Costs
This cost includes salaries, wages, supplies, and other expenses for sale offices,
salaries, commissions, and traveling expenses for sales representatives, shipping expenses,
costs of containers, advertising expenses, and technical sales service. The costs of most
chemical plants are in the range of 2 to 20 % of total product cost. For estimation, 20% of
total product cost was selected to calculate this cost.
C. Research and Development Costs
This cost is for maintaining the quality of HDPE and also research on the alternative
processes to improve process and product. It is about 5% of total product costs.
Distribution and Marketing Costs = 20% of CTPC
Research and Development Costs = 5% of CTPC
464
20%+5% = 25% of CTPC is unknown
While remaining 75% of CTPC has been calculated.
75% of CTPC = COM without depreciation + Administrative Costs
75% of CTPC = RM (685.9308 +0.02184) million = RM 685.9526 million
Distribution and Marketing Costs = 20% of CTPC = RM 685.9526 million ×20%/75%
Research and Development Costs = 5% of CTPC = RM 685.9526 million × 5%/75%

465
Table 5.26: Estimation of General Expenses
No Component % % Total Cost (RM
operating
product million)
labour cost
I Administrative costs 20 - 0.02184
II Distribution and marketing - 20 182.9207

costs
III Research and Development - 5 45.7301

costs
Total General Expenses (RM million) 228.6726
5.2.3 Total Production Cost
A. Estimation of total production cost
Total product cost includes all cost that related to the operation of the plant, selling
the products, recovering the capital investment and contributing to corporate functions such
as management, planning, organizing staff development programs and research and
466
development (R&D). The total product cost is generally divided into two categories: cost of
manufacture (COM) and the general expenses (GE).
Total production cost, CTPC = COM + GE (Peters et al., 2004), page 274
Where, CTPC = Total Production Cost
COM = Cost of Manufacture
GE = General Expenses
Total production cost without depreciation, CTPC= COM without depreciation + GE

= RM 689.9308 million + RM 228.6726 million
467
5.3 PROJECT COST AND PROFITABILITY ANALYSIS
The Project Profitability report is used to monitor the planned and real cost related to
a project. Profitability analysis is a part of the financial analysis that deals in putting measures
of profit into perspective.
5.3.1 Design Capacity and Operating Capacity
Design capacity and operating capacity Production rate of toluene plant are expected
to be 70% on the first year operation followed by 90% and 100% for coming year. The reason
for this assumption is on the beginning of the plant is because skilled labor may take some
time to learn to operate the plant without any problem and also the plant needs sufficient time
for the company to test the market value of toluene. After getting good respond from
customer and the demand is increasing then full production will be supply to fulfil the
demand. The operating capacity of toluene is 146,272.86 metric tonnes per year. The plant
was operated for 24 hours per day and 331 days per year.
5.3.2 Revenues from sales
In accounting, revenue is the income that a business has from its normal business
activities, usually from the sale of goods and services to customers. Revenue is also referred
to as sales or turnover. The total annual revenue by referring to Peters et al., 2004 (page 258),
the total annual revenue from product sales is
kg USD
(
annual revenue sales=∑ sales of product ,
yr )( product sales price ,
kg )
Table 5.27: Cost of product substances
Substances Cost/unit
Toluene RM 4.901 per kg
Hydrogen RM 67.04 per kg
Benzene RM 4.609 per kg
468
Butane RM 29.33 per kg
As mentioned in assumption above, the product sales price toluene product is

RM4.90140 per kg. While the sale of toluene product is 6684.56 kg/hr, (Toluene price
analysis, 2019).
kg 24 hr 331 days RM 4.9040
annual revenue sales for toluene=6684.56 × × ×
hr day year kg
¿ RM 260.41 million/ year
However, the side product which is hydrogen, butane and benzene are planned to generate
revenue, the sale of hydrogen product is 1050.45 kg per hour.
Updated price from manufacturer as in 2019 state that the price of hydrogen is $16 per kg
(California fuel cell partnership, 2019) , hence,
kg hr days USD 16 MYR 4.19
annual revenue sales for hydrogen=1050.45 ×24 ×331 × ×
hr day year kg USD
¿ 559.43 million/ year
Updated price from manufacturer in 2019 state that the price for butane is $7 per kg, the sales
of product is 20.25 kg/hr
kg hr days USD 7 MYR 4.19
annual revenue sales for butane=20.25 ×24 × 331 × ×
hr day year kg USD
¿ RM 4. 72 million
Updated price from manufacturer in 2019 state that the price for benzene is $1.1 per kg
(Alibaba.com, 2019), the sales of product is 5917.71 kg/hr
kg hr days USD 1.1 MYR 4.19
annual revenue sales for benzene=5917.71 × 24 ×331 × ×
hr day year kg USD
¿ RM 216.67 million
Hence, the total revenues are =RM 260.41 m+559.43 m+4.72 m + 216.67
=RM 1041.23 million
469
5.3.3 Profitability Analysis
The feasibility of toluene production in Malaysia is evaluated by profitability analysis.

The profitability of the project will be the largest factor that makes a project economically
attractive. To this stage, almost all the design and cost information required for the
profitability analysis were obtained.
The value for the profitability analysis were already calculated in 5.2 and tabulated in
table below
Table 5.28: Summary of project cost
Parameters Unit value
COM with depreciation RM million/year RM 122.0707m
COM without depreciation RM million/year RM 685.9308m
DMC with depreciation RM million/year RM 19.7272m
DMC without depreciation RM million/year RM601.44m
Operating labor cost RM million/year RM 0.1092m
Raw materials RM million/year RM 430.1212m
470
Utilities RM million/year RM 157.298m
Direct Supervisory RM million/year RM0.01638m
Maintenance RM million/year RM 10.4132m
Fixed Cost RM million/year RM71.1136m
Financing RM million/year RM 23.56m
Local taxes RM million/year RM 52.066m
Insurance RM million/year RM 1.4876m
Plant overhead costs RM million/year RM 7.3772m
Tax rate % 35%
471
Plant operation days 331
Plant Life years 10
Start-up time year 0
Start-up cost = 0.1 (Cfci) RM million/year 1487.6
Total production cost RM 918.6034 million
472
Table 5.29: Cumulative discounted after tax cash flow
Year - - 0 1 2 3 4 5 6 7 8 9 10 End
2 2 to 10
0
1. -
Land (RM 76.
million) 04
2. -
Fixed- 148.
capital 76
investment,
CFCI (RM
million)
473
3. -
Working 10.8
Capital,
CWC (RM
million)
4. Start- -
up cost = 14.88
0.1 CFCI
(RM
million)
(Peters et
al., 2004,
pg340)
474
5. Total 2
Capital 35.6
Investment,
CTCI (RM
million)
6. 0.7 0.9 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Operating 0 0 0 0 0 0 0 0 0
rate,
fraction of
design
capacity
7. 72 93 104 104 104 104 104 104 104 104

Annual 8.39 6.50 0.56 0.56 0.56 0.56 0.56 0.56 0.56 0.56
revenue
sales (RM
million) x
(6)
475
8. 64 82 918 918 918 918 918 918 918 918
Expenditur 3.02 6.74 .60 .60 .60 .60 .60 .60 .60 .6
e/Cash
operating
income
(RM
million)
(8) = (6) x
CTPC
476
9. 85. 10 121 121 121 121 121 121 121 121
Gross 37 9.76 .96 .96 .96 .96 .96 .96 .96 .96
profit/
Operating
Income
(RM
million)
(9) =(7) –
(8)
10. 0.2 0.3 0.1 0.1 0.0

Depreciatio 20 92 152 576
n rate for 5
year
recovery
period use
MACRS
11. 29. 47. 28. 17. 8.5 0 0 0 0 0

Annual
depreciatio
n (RM
million)
477
(11)=CFCI 75 60 56 14 7
x (10)
12. Net 55. 62. 93. 104 113 121 121 121 121 121
income 62 16 4 .82 .39 .96 .96 .96 .96 .96
before
taxes/taxab
le
income(R
M million)
(12)=(9) –
(11)
13. 19. 21. 32. 36. 39. 42. 42. 42. 42. 42.
Income tax 47 76 69 69 69 69 69 69 69 69
(t = 35%)
(13) = 0.35
x (12)
478
14. Net 36. 40. 60. 68. 76. 79. 79. 79. 79. 79.
income 15 4 71 13 7 27 27 27 27 27
after taxes/
Net profit
(RM
million)
(14) = (12)
– (13)
15. - - - 65. 88 89. 85. 85. 79. 79. 79. 79. 79.
After taxes 76. 148. 25.68 9 27 27 27 27 27 27 27 27
cash flow 04 76
(RM
million)
(15) = (14)
+ (11)
16. 1 1 1 1.1 1.2 1.3 1.4 1.4 1.4 1.4 1.4 1.4 1.4
Discount 1 31 6 6 6 6 6 6 6
factor at
i=marr =
10%
(16)=(1+i
479
¿ (Peters
−j
et al.,
2004), pg
298
17. - - - 72. 10 118 124 124 124 124 124 124 124
Discounted 76. .148 25.68 49 6.48 .82 .49 .49 .49 .49 .49 .49 .49
after taxes 04 .76
cash flow
(RM
million)
(17) = (15)
x (16)
480
18. - - - - - 47. 171 296 420 545 669 794 918
Cumulative 76. 224. 250.4 177.99 71.51 31 .80 .29 .78 .27 .76 .25 .74
discounted 04 8 8
after taxes
cash flow
(RM
million)
19. 86.
Capital 94
recovery
(19)=(1) +
(3)
481
20. End 100
project 5.68
value (20)
= (18) at
year 10 +
(19)
482
Cumulative cash position, CCP against Year
Cumulative cash position, CCP (RM million) 1000
800
600
400
200
0
-2 -1 0 1 2 3 4 5 6 7 8 9 10
-200
-400
Year
Figure 5.10: Cumulative cash position, CCP against Year
Cumulative cash position (CCP) and Cumulative Cash Ratio
The profits are gathered at the positive side of the Cumulative Cash Position (CCP)
until the end of the project at year 10. At the end of the project life, both of the land and
working capital are recovered instantaneously.
Cumulative cash position (CCP) = net income after tax + depreciation – total capital
investment (Peters et al., 2004)
CCP = RM (79.27+ 918.60)million – RM (235.6) million
= 762.27 million
As CCP depends on the size of project, the cumulative cash ratio (CCR) is used to indicate
whether the project is profitable. If CCR >1, the project is potentially profitable.
CCR is calculated based on the following equation:
CCR =
∑ of All Positive Cash Flows
∑ of All Negative Cash Flows
CCP
=1+
¿ capital investment +Working Capital+ Startup expenses
483
762.27
=1+
148.76+10.8+14.88
= 5.3698
Since the CCR is 5.3698 which is larger than 1, the project of the production of touluene is
potentially profitable.
5.3.4 Payback Period (PBP)
The payback period is the length of time required to recover the cost of an investment.
The payback period of a given investment or project is an important determinant of whether
to undertake the position or project, as longer payback. PBP also is the time criterion for both
of the non-discounted and discounted profitability criteria which do not consider the time
value of money. PBP is the measurement of profitability through the length of time needed
for the total return to equal the capital investment. In other words, PBP is the point where the
cash flow rises above the negative total capital investment (Peters et al., 2004).
Table 5.30: Cumulative non- discounted cash position

Time (year) Cumulative non-cash position (RM
million)
0 -224.8
PBP 0
2 117.9
484
PBP−0 0−(−224.8)
=
2−PBP 117.9−0
PBP = 1.312 year
The non-discounted PBP obtained is 1.312 or 1 year and 4 months In order to determine the
feasibility of the project the non-discounted PBP should be compared with the PBP obtained
from the minimum acceptable rate of return. The reference value of PBP is given as :
FCI
TCI
PBP ref =
FCI
TCI
marr +
n
Where, FCI is fixed capital investment
TCI is total capital investment
marr is internal rate of return (10%)
n is life span
148.76 ×10 6
235.6 ×10 6
PBP ref =
148.76 ×106
235.6 ×106
0.1+
10
= 3.8703 year
Since the non-discounted PBP is 1.312 or 1 year and 4 months is less than PBP ref with
3.8703 year, the project is acceptable and feasible to proceed.
5.3.5 Return on Investment (ROI)
485
Another simple measure of economic performance is the return on investment,
ROI.ROI is expressed in percentage per year as it is the annual return on investment which
will be expressed as followed:
NP
ROI=
CTCI
where NP is the net income (Peters et al., 2004). The net income is not constant from year to
year for the project and thus, the average ROI over the entire project is recommended to be
used and is expressed as followed:
N
1
( )∑ N P , j
N j=1
ROI= N
∑ CTCI , j
j=−b
where N is the evaluation period, NP, j is the net income in year j, -b is the year in which the
first investment is made in the project with respect to zero as the start-up time and C TCI is the
total capital investment in year j.
∑ N P , j=
j=1
N
1
( )∑ N P , j
N j=1
ROI= N
∑ CTCI , j
j=−b
79.27 million
=
RM 235.6 millions
=0.3364 = 33.64 %
The ROI calculated can be compared directly with minimum acceptable rate of return, m arr
value supplied. If the ROI equal or exceed the m arr, then the project offers an acceptable rate
of return (Peters et al., 2004). By comparison with the minimum acceptable rate of return
given which is 10%, the calculated ROI with 33.64% is higher. Hence, the project is
profitable
486
5.3.6 Venture Profit (VP)
Venture profit (VP) is the profitability measure of the amount of cash flow over and
above that required to meet the minimum acceptable rate of return and recover the total
capital investment. The venture profit is calculated by subtracting the total amount earned at
the minimum acceptable rate of return and the total capital investment from the total cash
flow. The equation is shown as followed (Peters et al., 2004).
N N
VP=∑ N P , j - marr ( ∑ C TCI , j )
j=1 j =−b
Where VP = Venture Profit (RM million)

Np,j = net income of year j
marr = minimum acceptable rate of return (10%,0.1)
CTCI, j = Total capital investment of year j
N
VP=∑ N P , j – 0.1 (RM 235.6 millions)
j=1
= 55.71 million
VP
VPave =
10
VP
=
10
= 5.571
Based on (Peters et al., 2004) any positive value of VP indicates that the cash flow to the
project is greater than the amount necessary to repay the investment and obtain a return that
meets the minimum acceptable rate. In other words, the earning is at a greater rate than the
minimum acceptable rate. Since the venture profit of toluene, RM 55.71 million is greater
than zero, this project is said to be profitable. According to the same author, this method of
calculating venture profit is effective as an optimization criterion.
5.3.7 Net Present value and NPV ratio
487
Net present value (NPV) is the method that consider the time value of money which is
the cash criterion for the discounted profitability criteria. NPV is a measurement that used by
many companies as it includes the time value of money and its effect on profitability. In
addition, NPV allows the conversion of all money flows to be discounted to the present time.
The appropriate discount rate to use for discrete discounting factor present worth is as
followed:
Discounting factor = (1 + i)-j (Peters et al., 2004), page 298
Where
I = minimum acceptable rate of return, 10%
J = the specified interest period in unit of year
According to Perry’s Chemical Engineers’Handbook 8 th Edition, page 9-30, NPV is

expressed as:
NPV = Present worth of all cash inflows – Present worth of all investment items
Hence, the NPV is RM 17.969 million/year. Since NPV is a positive value, the project earns
more than the discount factor used (Perry and Green, 2007).
NPV ratio is used to determine whether the project is economically satisfactory. If NPV ratio
> 0, the project is economically satisfactory, if NPV ratio < 0, the project is not economically
satisfactory and if NPV ratio = 0, the project is in an economic break-even. NPV ratio is
calculated as followed (Perry and Green, 2004), page 9-30,
Present value of all positive cash flows

NPV ratio =
Present value of all negative cash flows
810.06 million
NPV ratio =
250.48 million
NPV ratio = 3.234
Since NPV ratio > 0, this project is economically satisfactory.
5.3.8 Discounted payback period
488
Discounted payback period or discounted PBP is the time required, after start-up to
recover the fixed capital investment required for the project with all of the cash flows are
discounted. Discounted PBP is the time criterion for the discounted profitability criteria
where the calculation is in a similar manner to the non-discounted PBP. Figure 5.5 and Table
5.24 portray the cumulative cash flow after taxed and discounted.
Table 5.31: Cumulative discounted cash position
Time (year) Cumulative non-cash position (RM
million)
0 -148.76
PBP 0
2 106.48
PBP−0 0−(−148.76)
=
2−PBP 106.48−0
PBP – = 1.1656
PBP = 1 year 2 months
5.3.9 Recommendation based on the Profitability Analysis
Based on the profitability analysis, the project is evaluated by the non-consideration

of time value of money as well as the consideration of time value money. The method that
489
not consider the time value of money consists of return on investment (ROI), payback period
(PBP), and venture profit (VP). On the other hand, the method that consider the time value of
money consist of net present value and NPV ratio, discounted payback period, and
discounted cash flow rate of return (DCFRR). The summary of the profitability analysis is
tabulated in Table 5.27:
Table 5.32: Summary of the profitability analysis
Method Value Conclusion
Cumulative cash RM 762.7 million both of the land and
working capital are
position (CCP)
recovered instantaneously
Cumulative cash ratio 5.63698 If CCR >1, the project is
potentially profitable.
(CCR)
Return on investment 33.64% The value is higher than
mar (10%). The
(ROI)
project is acceptable.
Payback Period (PBP) 4 years
Venture Profit RM 55.71 million Since the venture profit
of acetic acid, RM 55.71
million is greater than zero,
this project is said to be
profitable
Net Present Value RM 17.699 million/year Since NPV is a positive
value, the project earns more
than the discount factor used
NPV ratio NPV ratio = 3.234 Since NPV ratio > 0, this
project is economically
satisfactory.
Discounted payback 1 year
490
Period
From the calculation above, it shows that the plant of production of Toluene by
catalytic reforming process is highly recommended for investment in which is 33.64 % shows
a high rate return of investment, in which it exceed the minimum rate of return in which it is
offer an acceptable rate of return. In term of payback period, the payback period for both non
discounted and discounted payback period which is 3.8703 years and 1.1656 years
respectively.
491
CHAPTER 6: ENVIRONMENTAL AND SAFETY ANALYSIS
6.1 Method for safe disposal (Environmental Quality Act 1974)
In Malaysia, the Occupational Safety and Health Act, 1994 is a tool which provided a
new legal and administrative as a driving force to promote, encourage and stimulate the high-
quality standards of health and safety at workplace. Both parties such as employers and
employees must give their support and cooperate to comply the law and not misuse safety in
order to increasing the promotion of safety awareness and effective safety organization and
performance in companies.
Any organization has a legal and moral obligation to safeguard the health and welfare
of its employees and the public. All manufacturing processes there are additional, special,
hazard associated with the chemical used and the process condition. The designer must be
aware of these hazards and ensure through the application of sound engineering practices that
the risks are reduced to acceptable levels (Guimarães & Ph, 2013).
Furthermore, environmental issues become very important. Hence, to reduce and

minimize environmental pollutants a good waste treatment system is also very important
(Guimarães & Ph, 2013). The chemical waste in the form of solid, liquid and gases must be
treated before being discharged into sewage, drain and atmospheres. Any chemical plant to
be set up in Malaysia must follow the rules and regulations under the Department of
Environment (DOE) Malaysia, which includes the Environmental 359
“Quality Act 1974. Under Environmental Quality Act (Sewage and Industrial Effluents)
Regulation 1979 and Environment Quality Act (Clean Air) 1978. The plant owner or waste
generator must ensure that waste generated disposed appropriately to prevent environmental
pollution. The proper and suitable methods should be implemented in dealing with the waste
disposal.” (“ENVIRONMENTAL QUALITY ACT, 1974 (Act 127),” 1974)
Production of toluene plant is not excluded from these regulations. As this plant
produces toluene, distillate mixture and other gaseous like hydrogen and butane gas which
need to be treated before release to environment. The plant will follow the Malaysia Ambient
Air Quality Standard and need some waste treatment facilities to minimize the pollution from
our plant.
In our plant, butane gas is one of our side products. Due to the reason of the amount
of butane gas is too low and its purity also difficult to control, we are classified it as a waste
product for our plant. Butane gas could not release to atmosphere due to eniroment impact.
Hence, we are choosing to use air scrubber to purify the air before release to atmosphere. Air
scrubber is a relatively new term that describes an industrial air purification system that
removes gases or particles from the air. It is commonly used to clean industrial exhaust
streams and gas emissions.
Gas leaks in industrial facilities are not something to be taken lightly, as exposure to
these gases can cause severe health issues and even death. It was in the interests of the
company not to recognize the serious effects of the gases as the amount of compensation the
company would ultimately be liable to pay would depend on the extent of the injuries
(Eckerman & Børsen, 2018). Portable gas leak detectors should also be used so you and
your employees can detect leaks remotely and notify the facility to ensure quick and safe
evacuation. When leaks do happen, it’s important to keep detailed data relating to the size
and location of the leak. By understanding the scale of the problem, we’ll be better prepared
to tackle any new issues that might spring up.
Generally floating roof tanks can accept petroleum products of vapor pressure

lower than 13 psia at max storage temperature which usually being max ambient
temperature . Naphtha can be stored in FR tanks, on the condition that it fulfills this
condition. Nevertheless naphtha has a lot of grades (sg~0.60 - 0.75,); vapor pressures higher
than 13 psia at max ambient temperature cannot be excluded for some grades of light
naphtha. For the feed of our plant, we are choosing light naphtha as our raw materials. Hence,
the storage tank for light naphtha should fulfil the condition of store in 13 psia at 25˚C due to
its boiling point.
In the case of on-board storage of hydrogen for vehicular applications, automobile

manufacturers require lightweight, compact, safe, and cost-effective storage plus the ability to
achieve a driving range of at least 300 miles. The 300-mile driving range requires 5-10 kg of
usable hydrogen depending upon the size of the vehicle Hydrogen can be stored in three ways
(Ni, 2006):
 As a compressed gas in high-pressure tanks.
 As a liquid in dewars or tanks (stored at -253°C).
 As a solid by either absorbing or reacting with metals or chemical compounds or

storing in an alternative chemical form.
Storage of hydrogen in chemical compounds offers a much wider range of possibilities to

meet the transportation requirements, but no single material investigated to date exhibits all
the necessary properties. The storage solution requires breakthroughs in materials
performance that can only come from innovative and basic research that looks beyond the
materials considered, to date. The exacting demands on storage capacity, charge and
discharge conditions, stability, and cost span the traditional disciplines of chemistry, physics,
materials science and engineering.
Last but not least, it is very important to prevent any leakage of toluene. Toluene is a
highly flammable liquid and it can cause mild damage to the skin and the eyes. However, the
most-common hazard associated with this chemical is inhalation (“Toluene Toluene Safety
Data Sheet,” 2018). Products containing toluene can produce dangerous fumes which can
cause nausea, headaches, unconsciousness, and even death if inhaled. Handling of empty
drums requires care equal to or greater than full drums. An empty toluene drum can be more
dangerous than a full drum if not properly purged for reuse. Keep fire and flames from
emptied drums and avoid breathing residue ordos. Toluene shall not be stored in occupied
buildings unless kept in approved storage rooms especially designed for such use. Such
storage rooms shall be in accordance with Subpart 'H' Hazardous Materials 1910.106, OSHA
General Industry Standards, and Uniform Fire Prevention and Building Code, Part 1171
requirement (Beauregard, 2000) Where proper indoor storage is not available, toluene shall
be stored outdoors or in unoccupied buildings. The building or area must be free of ignition
sources, and prominent signs shall provide appropriate warning such as 'Flammable - Keep
Fire Away'.
Toluene storage must be separated from occupied buildings as follows:
1-3 drums (1-150 gals.) - 15 feet from buildings and property line
3 to 10 drums (151 to 500 gals.) - 25 feet from buildings and property line
10 to 100 drums (501 to 5000 gals.) - 50 feet from buildings and property line
6. 2 Waste management system
In a chemical processing plant, there are many wastes including solid waste, liquid
waste and gaseous waste. All these wastes cannot be directly discharged into the
environment. Instead, the wastes should be treated in order to reduce the negative impacts to
the environment. As for the production of toluene, the butane gas from the condenser (E-
100), require a treatment before discharging to the environment. Besides, the distillate liquid
produced also from condenser (E-100) had been deliver to the waste management industry,
3R Quest Sdn Bhd that nearest with our toluene production plant. 3R Quest is one of
company that provide waste management services for the collection and treatment of
scheduled waste. However, the way of distillate ‘s packaging is very important seems that
were to be transported to that respective company.
6.2.1 Treatment of waste gas from condenser (E-100) at stream 14
Disposal of gases by adsorption or by reaction are widely used in chemical production

plant. The equipment that widely used in treating gases is the scrubber. There are many types
of scrubber including entrainment scrubber, venturi scrubber, particulate, scrubber and so on.
By referring the Disposal of Gases, Asia Industrial Gases Association (AIGA) 2013, one of a
type is dry scrubber that are efficiently and effectively designed to remove butane from the
air for this production plant. This scrubber system known as solid-state adsorber.
Figure 6.1 Scrubber system
At stream 14, the waste gas to be disposed of is fed into a vessel that containing a bed
solid adsorbent and the gas had be fed directly as illustrated in Figure 6.1. This method is
recommended where a solid adsorbent is available which strongly and readily adsorbs the
butane from gas. Its based on the concept hydrocarbon separation from gas using solid
material (adsorbent) as adsorption process (Yang et al., (2017)). Hence, butane is adsorbate
in this process.
Table 6.1: Specification and capacity of waste

Waste Stream Source Amount
Butane gas 14 Condenser (E- 10683 kg/hr

100)
Table 6.2: Specification of column, C-100

Material construction of column Stainless steel
Inlet diameter of column(m) 0.7
Outlet diameter of column(m) 1.3
Type of adsorbent used Activated carbon adsorbent
Mass of adsorbent (g) 750
Purge the system with an inert gas to remove air because the waste gas is flammable,
then check that absorbent is not spent (e.g.: from the operating log which records cumulative
throughput). The feed rate adjusted until the specified waste gas flowrate achieved by using
valve (V-3) So, it can reduce or increase the flowrate of waste gas. The removal of butane in
gas occurred in column (C-100) that filled of solid adsorbent. Then, the produced clean gas
will release to the environment. Supervise the disposal operation, monitoring absorber vent
for breakthrough and adjusting flowrate if necessary.
When disposal operation is complete, waste supply gas valve closed. The system
purged with inert gas (where installed) and the flow control valve is closed. After that, the
solid adsorbent is regenerate again safely. Provision should be made to monitor the waste gas
input flowrate and the concentration of waste gas in the adsorber vent.
6.2.2 Packaging and storing liquid waste from condenser (E-100) at stream 21
At stream 21, liquid waste was produced and transported to 3R Quest Sdn Bhd, the
company that provide waste management services for the collection and treatment of our
production. However, the tank trucks are needed to deliver the liquid waste. Before that, the
distillate liquid was stored in distillate storage tank. Referring to the calculation for the
volume, height, inner diameter had been calculated at Task 3, the specification sheet of
distillate liquid storage tank as shown at Table 6.3.
Item No. : -
No. required : 1
Construction
Pressure, bar : 1
˚C
Diameter : 5.5 m
Height : 2.75 m
Volume : 66 𝑚3
construction
6.2.2.1 Tank trucks for transportation of liquid waste
Figure 6.2 Tank trucks
A vehicle that’s specially designed to carry liquid waste is referred to as a tank truck.
A liquid fluctuates to all direction in the tank when the truck is running on a slope and the
fluctuations will cause major changes in the center of mass when tank truck has a large
capacity. The other name is it can affect the stability of truck and trailer (tank). The instability
may can cause the trailer to jack-knife or rollover. To overcome this problem, using a multi-
compartment model reduces the changes of the axle load and hence keeps the trailer stable as
shown in Figure 6.3 (b). According to the Anster Resources (2016), the specification sheet
for the tank trucks and the trailer is shown at Table 6.4 and the components installed at tank
trucks is shown from Figure 6.4 until Figure 6.10 referred to the book of Best Management
Practices: Handbook for Hazardous Waste Containers, USEPA, 1997).
Figure 6.3 How multi-compartments work at driving truck
Table 6.4: Specification Sheet of Tank Trucks

Tank Trucks
Application : For transportation to waste
management industrial
Identification Item : Stainless Steel Tank Trailer
Function : transport distillate liquid as waste
Type Material : Stainless steel
Construction
Configuration : Ellipse and round rectangular shape for stability
Height of 1:0.79:0.65
gravity ratio
Components of Center of gravity : Low
trailer Design : Ellipse tank trailer
Body : Cylinder manufactured by
coiling and welding steel
plates
Heads : Integrated(unibody) with
roundness tolerance less than
3mm
Liquid Baffle Plate : To reduce the fluctuations of
the liquid in the tank
Transverse baffle : Have manhole on each plate
plates (not less than 550mm in
diameter)
Manhole cover : The cover on the trailer’s
manhole
Breather valve : To prevent overspill
Spill-proof sensor : The alarm installed on the
manhole cover to prevent
liquid spill
Air release valve : Function to adjust the pressure
made inside tank automatically
Liquid vapor : To prevent leakage of the
recovery valve liquid waste
Liquid line system Bottom : Prevent leakage and explosion
valve in an accident
Liquid : Used for quick unloading of
outlet the liquid in the tank
valve
Top loading : Harmful to the workers and
time consuming
Dssssssssd Bottom loading : Recommended, safe and
efficient because loading
speed is fast
Figure 6.4: Ellipse tank trailer
Figure 6.5: Tank heads

Figure 6.6 Liquid baffles plate
Figure 6.7 : Manhole cover
Figure 6.8: Bottom valve

Figure 6.9: Liquid outlet valve
Figure 6.10: Tanker loading

6.2.3 Recycling of cooling water in distillation column and condenser
In the process of distillation vapors passing through the condenser tube are cooled
and condensed by water flowing through condenser tube in the condenser unit of the
apparatus. In almost all industries the water used for cooling the condenser tube comes from
the nearest water resource. Water after circulating through the condenser tube is left simply
into the drain as wastewater.
Mechanism
Using recycling water technique (Sharma, 2004) the technique is based on a
simple principle that is recycling water in condenser Unit. Sharma (2004) made some
modifications in the existing distillation technique by introducing a collection, cooling and
pumping devices to recycle water in the condenser tube again and again. This technique is
low cost and very effective. The water was cooled first by a simple indigenous cooling
technique before it was allowed to enter again in condenser unit (recycling).(Mekala,
Davidson, Samad, & Boland, 2008) Cooling technique involved collecting water from the
outlet tube of the condenser unit in an earthen pot of about 50 litre capacity put on a cement
container filled with wet sand. Once the water is filled in the earthen pot about ¾ of its
capacity from the condenser unit it gets cooled.
Then it is lifted to a reservoir tank of about 60 litre capacity placed at a height of 4
feet from the earthen pot, with the help of a small submersible motor placed in the earthen
pot. The water lifting system has been made automatic by connecting an automatic water
level controller with two relays in series. This has mad the recycler fully automatic means
whenever water level reaches to a definite height in the earthen pot, the submersible motor
switches on automatically by the water level controller. Reservoir tank can be used as plastic
or earthen material depending on convenience. Cooling is more effective if reservoir tank is
also an earthen pot. By this method hot water coming from condenser tube cool down in the
earthen pot before it is lifted by submersible motor tank. The process of recycling water in
the condenser tube goes on continuously and automatically.
6.3 Total cost of waste management system
6.3.1 Cost of Dry Scrubber
Table 6.5: Specification and capacity of waste

Waste Stream Source Amount
Butane gas 14 Condenser (E- 10683 kg/hr

100)
Table 6.6: Specification of column, C-100

Material construction of column Stainless steel
Inlet diameter of column(m) 0.7
Outlet diameter of column(m) 1.3
Type of adsorbent used Activated carbon adsorbent

Mass of adsorbent (g) 750
Price of Dry Scrubber (Alibaba.com): RM 58373.00
6.3.2 Cost of Distillate Storage Tank

Item No. : -
No. required : 1
Construction
Pressure, bar : 1
˚C
Diameter : 5.5 m
Height : 2.75 m
Volume : 66 𝑚3
construction
For equipment purchase calculation of catalyst tank and product storage tank, the calculation
will be using equation from (Saider et al.). Since the type of product that load inside the tank
are gases, the type on tank uses is silo or storage bin and typically the operation provded is 8
hr (Saider et al.). The calculation of mass flow rate in the tank is;
𝐶𝑝 = 450 × S 0.46 (Saider et al.)
Where;
𝐶𝑝 = 𝐸𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑝𝑢𝑟𝑐ℎ𝑎𝑠𝑒 𝑐𝑜𝑠𝑡
𝑆 = Capacity
Mass of load inside tank

1797.13 kg/ hr × 8 hr
= 14377.04 kg
The Equipment Purchase cost will be calculate using equation;
𝐶𝑝 = 450 × S 0.46
= 450 × 14377.04 0.46
= 36790.91 𝑈𝑆𝐷, 2000
I
I Base
Cost =36790.91 ( 1991.66

1457.40 )
,USD 2019

= 50277.88 × RM 4.19
= RM 210664.32
6.4 Environment and surroundings affected after building and operation of the plant
6.4.1 Plant Building
During the activities of construction, land cleaning, construction of road, construction

of plants and landscaping will be involved. A plant can affect the environment by its
construction and by its operation, these effects or impacts can be either temporary or
permanent. A plant and its auxillary components for example pipelines, storage system, new
transmission lines and waste disposal take up space on the ground and in the air and in many
cases emit pollutants into the air. The plant’s footprints on the ground eliminates
opportunities for others to purchase or use the land. It also can affect the existing or future uss
of adjoining and nearby land parcels.
According to the regulations, construction should design, install and maintain erosion
controls to minimize the discharge of pollutants. These controls should include mechanisms
to curtail storm water controls and by minimizing the amount of soil exposed during
construction activity.
The materials used in building construction have a serious impact on the environment
because mostly the materials used in the construction of buildings are produced in a non-
sustainable way.
Hence, an action should be taken to reduce the effect on environment such as avoid
open burning. Geographical sites should be study before construction to prevent excessive
soil erosion, sedimentation and pollution. Other than that for the building, installing a more
efficient HVAC system or investing more in building automation.
6.4.2 Plant Operation
All industrials processes produce waste products and full considerations must be
considering to ensure that all the difficulties and total cost for the waste management. The
disposal of toxic and harmful effluents covered by local regulations based on the
Environmental Quality Act 1974.
6.4.3 Noise Pollution
Noise pollution generally defined as regular exposure to elevated sounds level that
may lead to adverse effects in humans or other living organisms. This pollution occurs in
plants mostly from industrial sounds such as compressors, fans, and generators. Noise
pollution can be hazardous to many people especially worker’s health in various ways. Since
noise pollution leads to sleep disturbance, it affects the individual’s work performance during
the day, it leads to hypertension and cardiovascular disease and costs the health system
additional time and money.
We as a person who is responsible with the safety of workers must consider many
things such as care needs when selecting and specifying equipment such as compressors, air
cooler fans, induced and forced draught fans for furnaces and other noisy plant. Some of
equipment should be fitted with silencers. Vendor’s specifications should be checked to
ensure that equipment complies with statutory noise levels for the protection of employees as
well as for noise pollution considerations. Noisy equipment should as far as practicable be
sited well away from the site boundary and also far away from residential area. Earth banks
and screens of tress can be used to reduce the noise level perceived outside the site.
In order to discover the noise impact, existing noise levels (ambient sound) are measured in
different locations onsite and near the site either before the plant is built or when it is not
operating. This sets benchmarks for impact measurements. Measurements are taken at the
same location with the proper plant operating. The difference in sound levels is attributable to
the plant
6.4.4 Air Pollution
Air pollution consists of chemicals or particles in the air that can harm the health of
humans, animals and plants. It also can damage the building (Cerbu et al., 2010). There are
many forms of pollutants such as gases, solid particles or liquid droplets. Production of
toluene produce air pollution due to the emission of feed naphta from liquid to gas. Example
of waste that can cause air pollution for this production of toluene are distillate liquid, butane
and also leaking of raw material from the pipeline or equipment itself. Although the gas
emission to the atmosphere are recover before entering into the atmosphere however fugitive
leaking of raw material for valve during overpressure may also one of the source result in the
air pollution. The product from distillation column may also result in the emission of butane
which will cause significant harm to plants and wildlife. However, as volatile organic
compounds, butane can be involved in the formation of ground level ozone which can cause
damage to crops and materials (“Pollutant Fact Sheet,” 2019).
Hence, an action should be taken such as checking the pipeline or valve to prevent
any leakage from occurred. Active leak detection and repair programme should begin to
cover all the valve, compressor to reduce leakage. The improvement in material construction
for the equipment. Particulate may be filter first before release to the atmosphere
6.4.5 Thermal Pollution
For this production, there are a lot of process that involve release of heat that result in
thermal pollution to the environment and surrounding. Cooling water that required in the
heater, condenser and distillation column to maintain the temperature of the reaction.
6.4.6 Visual Impact
The appearance of the plant should be considered at the design stage. Few people
object to the fairyland appearance of a process plant illuminated at night but it is a different
scene in daylight. There is a little that can be done to change the appearance of a modern
style plant where most of the equipment and piping will be outside and in full view but some
steps can be taken to minimise the visual impact. Large equipment such as storage tank,
reactor and distillation column can be painted to blend in with or even contrast with the
surroundings. Landscaping and screening by belts of trees can also help improve the overall
appearance of the site.
During plant development, visual impacts including aesthetics, light, glare and night
sky impacts should be considered for all project alternatives. The view from road or facility
and views toward the road or facility that will be existence during the construction phase and
the operational phase must be evaluated.
Project alternatives will need to be sufficiently developed prior to completing the
analysis in order to completely describe the changes each alternative will have on the visual
environment.
6.5 Hazard and Operability (HAZOP) Study
Hazard and Operability study (HAZOP) is vital to be conducted in order to prevent

major accidents from occurring. Hazard and Operability Analysis (HAZOP) is a structured
and systematic technique for system examination and risk management. In particular,
HAZOP is often used as a technique for identifying potential hazards in a system and
identifying operability problems likely to lead to nonconforming products. HAZOP is based
on a theory that assumes risk events are caused by deviations from design or operating
intentions. Identification of such deviations is facilitated by using sets of “guide words” as a
systematic list of deviation perspectives. This approach is a unique feature of the HAZOP
methodology that helps stimulate the imagination of team members when exploring potential
deviations.
The HAZOP process is used to identify potential hazards and operational problems in
terms of plant design and human error. The technique is applied during final design of the
process and plant items before commencement of construction. HAZOPs have also proven to
provide financial benefits to the plant owner/operator by minimizing the time and money
spent in installing add on control and safety systems, the need for which may become evident
at the time of plant commissioning in the absence of a HAZOP.
The HAZOP study requires detail information about the whole process which
includes the process flow diagram (PFD) and process and instrumentation diagram (P&ID),
specifications of equipment used in the plant, material and energy balance performed in the
previous tasks. A list of guide words are shown in the Table 6.2 below.
Table 6.8: List of Guide Word.

GUIDE WORDS MEANING COMMENTS
NO, NOT NONE The complete negation of No part of the design intention is
the intention achieved but nothing else happens
MORE, HIGHER, Quantitative increase Applies to quantities such as flow
GREATER rate and temperature and to
activities such as heating and
reaction
LESS, LOWER Quantitative decrease Applies to quantities such as flow
rate and temperature and to
activities such as heating and
reaction
AS WELL AS Qualitative increase All the design and operating
intentions are achieved along with
some additional activity, such as
contamination of process streams
PART OF Qualitative decrease Only some of the design intentions
are achieved some are not
REVERSE The logical opposite of Most applicable to activities such as
flow or chemical reaction. Also
applicable to substances, for
example, poison instead of antidote
OTHER THAN Complete substitution No part of the original intention is
achieved – the original intention is
replaced by something else
SOONER THAN Too early or in the wrong Applies to process steps or actions
order
LATER THAN To late or in the wrong order Applies to process steps or actions
WHERE ELSE In additional locations Applies to process locations, or
locations in operating procedures
6.5.1 HAZOP Study Applied to Pump
Figure 6.11 shows the P&ID for pump (P-101) whereas Table XX is the HAZOP study
applied to pump (P-101).
Figure 6.11: P&ID for pump (P-101)

Recommendation from the HAZOP study for the Pump (P-101)
1. Add lock procedure for valve.
2. Install flow meter and low flow alarm.
3. Install high pressure alarm.
4. Feedstock must check prior to usage to consider possible contamination and interruption of
supply.
5. Install check valve.
Table 6.9: HAZOP Table of Pump, P-101
Project: production of toluene
Rev no: P-101 Date：19/11/2019
HAZOP Team members: Group 6
Subsystem Description: Increase the pressure of for the flow of naphtha.

Diagram:
Parameter: Pressure, Flowrate
Item Study Node Process Deviations Possible Causes Possible Action Required
parameter Consequences
1A Pressure No Pressure 1- Blocked inlet and outlet of Line Trip, and 1- Install switch on manual
the pump no produce valve as safety lock
2- Ingress of air in pump permeate water 2- Install auto vent online
3-Pump Failure 3- Set up a filter with tiny
4- Blockage at route and mesh on the entrance of water
clogging before pump 4- Periodical inspection &
5- Fouling of check valves maintenance
6- Manual valve failure
1B Low Pressure 1- Decrease in level of Line Trip, and 1- Placed start and stop key of
naphtha regard to inlet suction no produce raw naphtha pump in
2- Strainer blockage permeate water 2- Installing moisture sensor
3- Pipe or Vessel Rupture near sand filter pump
4- Flange failure 3- Controlling of manual
5- Pump Corrosion valves
4- Periodical inspection &
maintenance
1C Increase ∆ P 1-Finish normal using time of Change in Install resin catcher before
Pressure cartridge recovery, cartridge
difference 2- corrosion in routing passing
3- Running away washer suspended
among piping & stick on particles
cartridge
1D Flowrate No Flowrate 1-Valve closed No naphtha 1- add lock procedure for the
2-failure in naphtha supply. causes no valve/
3- Naphtha line plugged. reaction. 2- Install naphtha flow meter,
low flow alarm.
1E Low 1- No regular manual valve in Line Trip, and 1- Controlling of manual

Flowrate outlet of naphtha, Concentrate no produce valves
of Reverse Osmosis, High permeate water 2- Regular backwash of sand
Pressure Pump filter
2- Failure in pump suction 3- Periodical inspection &
3- Check valve blockage maintenance
4- Finishing using time of
sand filter
1F High 1- No regularize manual valve Line Trip, and Programming on PLC that no
Flowrate 2- Mechanical failure in no produce start additional pump when
flange 3- Start accidental permeate water one pump is running
pump and cracking
pipe
2A Pump itself Service 1- Tow phase in pump in No unloading of Maintenance & periodical
failures cause electrical failure Acid, diffusion repairing
2- Pump corrosion of Acid on place
3-Mechanical failure in Acid
instrument
2B Pump 1-Enter error electrical phase Line Trip, and Install auto vent on routing
reversed into pump no produce
2- Decrease on vessel level permeate water
3- No getting air on apparatus
followed by repairing
2C Abnormal 1- Fault at PLC programming Damage to Maintenance & periodical
Operation 2- Mechanical failure in valves repairing
(failure valves 3- Interruption air of
valve) pneumatic valves
2D Increase 1- Deficit silica & anthracite Quick blockage 1- Install opacity tester
opacity height in sand filter of filters 2- Set up diffusion water
2- Creation flood channel
among sand filter
3- Inappropriate granular in
sand filter
4- Running away nozzle
5- Inefficient rinse after
backwash
6- Use more extra of sand
filter

Rev no: P-103 Date：19/11/2019
Subsystem Description: Transport the organic products from the reflux accumulator back to the distillation column
Diagram:
1A Pressure No Pressure 1- Blocked inlet and outlet of Line Trip, and 1- Install switch on manual valve as safety
the pump no produce lock
3-Pump Failure 3- Set up a filter with tiny mesh on the
4- Blockage at route and entrance of water
clogging before pump 4- Periodical inspection & maintenance
5- Fouling of check valves
1B Low Pressure 1- Decrease in level of naphtha Line Trip, and 1- Placed start and stop key of raw distillate
regard to inlet suction no produce pump in
2- Strainer blockage permeate water 2- Installing moisture sensor near sand filter
3- Pipe or Vessel Rupture pump
4- Flange failure 3- Controlling of manual valves
5- Pump Corrosion 4- Periodical inspection & maintenance
1C Increase ∆ P 1-Finish normal using time of Change in Install resin catcher before cartridge
Pressure cartridge recovery,
cartridge
1D Flowrate No Flowrate 1-Valve closed No distillate 1- Add lock procedure for the valve.
2- Failure in distillate reflux. reflux causes the 2- Install distillate flow meter, low flow alarm.
3- Distillate line plugged. reflux ratio
changes then the
purity of
product
changes.
1E Low 1- No regular manual valve in Line Trip, and 1- Controlling of manual valves
Flowrate outlet of distillate, Concentrate no produce 2- Regular backwash of sand filter
of Reverse Osmosis, High permeate water 3- Periodical inspection & maintenance
Pressure Pump
2- Failure in pump suction
3- Check valve blockage
4- Finishing using time of sand
filter
1F High 1- No regularize manual valve Line Trip, and Programming on PLC that no start additional
Flowrate 2- Mechanical failure in flange no produce pump when one pump is running
3- Start accidental pump permeate water
and cracking
pipe
2A Pump itself Service 1- Tow phase in pump in cause No unloading of Maintenance & periodical repairing
failures electrical failure Acid, diffusion
instrument
2C Abnormal 1- Fault at PLC programming Damage to Maintenance & periodical repairing
Operation 2- Mechanical failure in valves valves
(failure 3-Interruption air of pneumatic
valve) valves
among sand filter
sand filter
backwash
6- Use more extra of sand filter

Rev no: P-104 Date：19/11/2019
Subsystem Description: Transport the organic product from the condenser to the distillate tank.
Diagram:
1A Pressure No Pressure 1- Blocked inlet and outlet of Line Trip, and 1- Install switch on manual valve as safety
the pump no produce lock
3-Pump Failure 3- Set up a filter with tiny mesh on the
4- Blockage at route and entrance of water
clogging before pump 4- Periodical inspection & maintenance
5- Fouling of check valves
1B Low Pressure 1- Decrease in level of naphtha Line Trip, and 1- Placed start and stop key of distillate pump
regard to inlet suction no produce in
2- Strainer blockage permeate water 2- Installing moisture sensor near sand filter
3- Pipe or Vessel Rupture pump
4- Flange failure 3- Controlling of manual valves
5- Pump Corrosion 4- Periodical inspection & maintenance
1C Increase ∆ P 1-Finish normal using time of Change in Install resin catcher before cartridge
Pressure cartridge recovery,
cartridge
1D Flowrate No Flowrate 1-Valve closed No distillate 1- Add lock procedure for the valve.
2- Failure in distillate outcome. outcome. 2- Install distillate flow meter, low flow
3- Distillate line plugged. alarm.
1E Low 1- No regular manual valve in Line Trip, and 1- Controlling of manual valves
Flowrate outlet of distillate, Concentrate no produce 2- Regular backwash of sand filter
of Reverse Osmosis, High permeate water 3- Periodical inspection & maintenance
Pressure Pump
2- Failure in pump suction
3- Check valve blockage
4- Finishing using time of sand
filter
1F High 1- No regularize manual valve Line Trip, and Programming on PLC that no start additional
Flowrate 2- Mechanical failure in flange no produce pump when one pump is running
3- Start accidental pump permeate water
and cracking
pipe
2A Pump itself Service 1- Tow phase in pump in cause No unloading of Maintenance & periodical repairing
failures electrical failure Acid, diffusion
instrument
2C Abnormal 1- Fault at PLC programming Damage to Maintenance & periodical repairing
Operation 2- Mechanical failure in valves valves
(failure 3-Interruption air of pneumatic
valve) valves
among sand filter
sand filter
backwash
6- Use more extra of sand filter
6.5.2 HAZOP study for the Evaporator (E-103)
Figure 6.12: P&ID for Evaporator (E-103)
Recommendation from the HAZOP study for the Evaporator(E-103)

1. Install High Level Alarm
2. Use PI controller to tune feedback control loop
3. Install High Pressure Alarm
4. Install High Temperature Alarm
5. Install bypass and control valve
Table 6.12: HAZOP Table of Expander, E-103

Project: Production of toluene
Rev no: E-103 Date: 20 November
HAZOP Team Members: Group 6
Subsystem description: to increase the outlet stream before entering the compressor
Diagram: Figure
Parameter: Level, Pressure, Temperature
Item Study Process Deviation Possible Causes Possible Consequen

node Parameter s
1A Light Level Higher 1. Overflow of the 1. Overpressure of the

naphta light naphta vessel
inlet 2. May cause explosio
1B Lower 1. Undesired 1. Unable to produce
composition sufficient amount o
2. Not avhieve target produt
flowrate
1C Part of 1. Leakage in 1. Ratio difference

pipelines
1D Pressure Higher 1. High flowrate 1. Evaporator might b

explode
1E Low 1. Low fluid supply 1. Back flow of fluid

supply
1F Temperature Higher 1. High fluid supply 1. Overheating affect

temperature downstream process
Low 1. Low fluid supply 1. No heating process

temperature
2A Steam Flow Higher 1.Failure of V-106 1. Temperature of ligh

inlet naphta too high will
affect the process
2B Low 1.Valve V-102 1. Temperature of ligh

partially closed naphta too low
2C No 1. Pipe blockage 1. Tempera
2. V-105 closed of light naphta
remains constan
2. Temperature of light
naphta remains cons
2D Reverse 1. Failure of steam 1. Loss of heating

source resulting in
backflow
2. Backflow due to
high backpressure
Table 6.13: HAZOP Table of Heater, H-101

Rev no: H-101 Date: 20 Novem
Subsystem description: to increase the temperature before entering reactor

Parameter: Flow, Pressure, Temperature
Item Study Process Deviation Possible Causes Possible Conseq

node Parameter s
1A Feed Flow No 1. All feed 1. No feed and

stream valves are closed reaction
from
compresso
r
1B Lower 1. Leaking 1. Spilla

feed line reactants that
the less feed
reactor.
1C Higher 1. Control 1. High

valves fails to reactant feed
open cause high re
1D As well as 1. Impurities of feed 1. Impurities in
naphta product and p
side reactions
occur
1E Temperature Higher 1. Overheat 1. Form

ing feed naphta undesired pro
1G Pressure Higher 1. High 1. Impro

feed flow rate conversion o
product
2A Heater Flow No 1. Operator 1. No fl

itself switch off heater supply affect
downstream
2B High 1. Pressure 1. Can c

of heater explosion if t
increase pressure cann
withstand by
2C Low 1. Leakage 1. Conta
in heater on of cooling
2D Other than 1. Choosing 1. Down

wrong material process
in heater contaminated
Table 6.14: HAZOP Table of Heater, H-102

Rev no: H-102 Date: 20 Novembe
Subsystem description: to increase the temperature before entering reactor
Diagram: Figure XXX

Parameter: Flow, Pressure, Temperature
Ite Study Process Deviation Possible Causes Possible Conseque

m node Parameter s
1A Coils Flow Higher 1. Control 1. Heater

valve fails open possibility in ru
on heating
1B Lower 1. Partially 1. Remov

plugged cooling cooling
line 2. Remov
2. Control cooling
valves fails to
respond
1C Part of 1. Partial 1. Diminis

cooling water cooling, possib
failure away
1D Temperature High 1. High 1. Cooling

cooling water system capacity
supply limited
temperature
1E Low 1. Low 1. No con

cooling water handles
supply
temperature
2A Gas Flow Higher 1. Pressure 1. Can ups

inlet increase downstream pr
2B Low 1. Inlet valve 1. Can ups

partially close downstream pr
2C No 1. Inlet valve close 1. No und

2. Break in heater gas possible up
downstream pr
2. Spillage
heater that can
undesired
composition
2D Temperature Higher 1. High gas supply 1. Temper

temperature of gas too high
affect the down
process
2E Low 1. Low gas supply 1. Temper
temperature of gas too low
affect the down
process
3A Heate Pressure High 1. High flowrate 1. Heater

r itself explode
3B Low 1. Low fluid supply 1. Back flow of fluid

supply
3C Temperature High 1. High fluid supply 1. Overheating can ha

temperature
3D Low 1. Low fluid supply 1. No heating process

temperature
6.5.3 HAZOP Study Applied to Packed Bed Reactor
Figure 6.13 shows the p&ID for reactor 1 (R-101) and the table below shows the HAZOP
study for the reactor
Figure 6.13: HAZOP study for (R-101)

Recommendation from the HAZOP study for the packed bed reactor R-101:
1. Install temperature transmitter (TT) to detect any changes of the temperature.
2. Install a high-temperature shutdown system (this system would automatically shut
down the process in the event of a high reactor temperature; the shutdown
temperature would be higher than the alarm temperature to provide the operator with
the opportunity to restore cooling before the reactor is shut down.
3. Install a pressure indicator controller (PIC) to measure pressure inside the reactor and
high pressure alarm
4. Study the inlet stream source to consider possible contamination and interruption of
supply.
5. Install a flow meter and low flow alarm.
Table 6.15: HAZOP Table of Reactor, R-101
Rev no: R-101 Date：19/11/2019
Subsystem Description: Dehydrogenation reaction
Diagram:
Parameter: Pressure, Flow, Temperature
Ite Study Process Deviation Possible Causes Possible Consequences Action Required
m Node parameter s
1A Feed Flow No flow 1. Stock storage 1. No feed entering 1. Operator must do a check-up
Stream tank are empty the reactor thus prior to the start-up to ensure
2. clogged of feed no reaction occur proper feed quantities
pipeline 2. No feed and no 2. Update maintenance
3. pipeline rupture reaction procedure
4. all feed valves 3. No reaction occur 3. Update maintenance
are closed 4. No feed entering, procedure and repair the
no reaction ruptured pipe
4. Update the start-up procedure
and ensure all valve are either
open/close according to
procedure
1B High 1. Control valve 1. High feed of 1. Check on the valve type,
fails to open reactant that may materials of construction and
cause improper do a regular maintenance of
conversion to valves
product
1C Low 1. Partially plugged 1. Less feed and 1. Check and update the
feed line less reaction maintenance procedure
2. Corrosion occur 2. Cause structural 2. Do regular checkup and
3. Leaking feed line damage to maintenance on the pipeline
pipeline 3. Update maintenance
3. Spills reactant. procedure and make sure that
Less feed the spills are properly handled
supplied to with spill kits and proper
reactor, improper clean-up PPE.
reactor
conversion
1D As well as 1. Contaminatio 1. Possible side 1. Stock feed has to be

n of feed stock reactions, checked prior to usage
reactants. unknown
chemical
exposures,
contaminatio
n of product.
1E Reverse 1. Back flow of feed 1. Less amount of 1. Use proper valves such as
flow of feed entering check valves to prevent back
feed reactor flow of feed
1F Temperature High 1. High feed supply 1. Improper 1. Install a temperature sensor

temperature conversion to (thermocouple)
product.
1G Pressure High 1. High feed flow 1. Improper 1. Install high pressure alarm.
rate. conversion to
product
2A Outlet Flow No 1. Pipeline blockage 1. No product 1. Install low flow alarm.

stream exiting Operator must check product
2. Damage in level during operation of unit.
pipeline
2B High 1. Control valve 1. High product 1. Do a VOC testing

fails to open flow with
improper product
quality
2C Low 1. Partially plugged 1. Less product 1. Install flow meter and low
product line obtained. Improper flow alarm.
product quality. 2. Update maintenance
2. Leaking product 2. Spill of product. procedures. Ensure that spill
line Less product. containment, spill kits, clean-
Improper product up PPE is available.
quality.
As well as Contamination of Unknown chemical Raw materials must be
product in the product. Low checked prior to usage
product quality
As well as Leaking product line 1. Spill of Update maintenance
product. Less procedures. Ensure that spill
product. containment, spill kits, clean-
Improper up PPE is available
product
quality.
3A Control Flow No Control valve fails 1. Could not Select valve fail to open
system closed. regulate the
process back
to desired
condition.
Improper
conversion to
product.
High 1. higher flow of hot 1. Higher reaction 1. Install flow meter, high flow
oil rate. Improper alarm. Valve must be correct
conversion to type, material of construction
product and properly maintained.
Low 1. Control valve fails 1. Unable to control 1. Install a low flow alarm.
to respond. the process back Check and update
to desired maintenance
condition.
6.5.4 HAZOP Study Applied to Packed Bed Reactor
Recommendation from the HAZOP study for the packed bed reactor R-102:
1. Install temperature transmitter (TT) to detect any changes of the temperature.
2. Install a high-temperature shutdown system (this system would automatically shut
down the process in the event of a high reactor temperature; the shutdown
temperature would be higher than the alarm temperature to provide the operator with
the opportunity to restore cooling before the reactor is shut down.
3. Install a pressure indicator controller (PIC) to measure pressure inside the reactor and
high pressure alarm
4. Study the inlet stream source to consider possible contamination and interruption of
supply.
5. Install a flow meter and low flow alarm.
Table 6.16: HAZOP Table of Reactor, R-102
Rev no: R-102 Date：19/11/2019
Subsystem Description: Dehydrocyclization process
Diagram:
Parameter: Pressure, Flow, Temperature
Study Process
Item Deviations Possible Causes Possible Consequences Action Required
Node parameter
1A Feed Flow No flow 1. Reactor 1 tank are 1. No feed entering the 1. Operator must do a
Stream empty reactor thus no reaction check-up prior to the
2. clogged of feed occur start-up to ensure proper
pipeline 2. No feed and no reaction feed quantities
3. pipeline rupture 3. No reaction occur 2. Update maintenance
4. All feed valves are 4. No feed entering, no procedure
closed reaction 3. Update maintenance
procedure and repair the
ruptured pipe
4. Update the start-up
procedure and ensure all
valve are either
open/close according to
procedure
Check on the valve type,
High feed of reactant that
materials of construction and
1B High Control valve fails to open may cause improper
do a regular maintenance of
conversion to product
valves
1. Check and update the

1. Less feed and less
maintenance procedure
reaction
2. Do regular checkup and
2. Cause structural damage
1. Partially plugged feed maintenance on the pipeline
to pipeline
line 3. Update maintenance
1C Low 3. Spills reactant. Less feed
2. Corrosion occur procedure and make sure
supplied to reactor,
3. Leaking feed line that the spills are properly
improper reactor
handled with spill kits and
conversion
proper clean-up PPE.
Possible side
Contamination reactions, unknown Reactor 1 feed has
1D As well as of feed from chemical exposures, to be checked prior
reactor 1. contamination of to usage
product.
1E Reverse Back flow of feed Less amount of feed Use proper valves such
flow of entering reactor as check valves to
prevent back flow of
feed feed
High feed supply Improper conversion to Install a temperature

1F Temperature High
temperature product. sensor (thermocouple)
High feed flow Improper conversion to Install high pressure

High
1G Pressure rate. product alarm.
Install low flow alarm.

Flow 1. No product exiting
Outlet Operator must check
2A No Pipeline blockage 2. Damage in pipeline
stream product level during
operation of unit.
Control valve fails High product flow with
Do a VOC testing
2B High to open improper product
quality
2C Low 1. Partially plugged 1. Less product obtained. 1. Install flow meter and
product line Improper product low flow alarm.
quality. 2. Update maintenance
2. Leaking product 2. Spill of product. Less procedures. Ensure that
line product. Improper product spill containment, spill
quality. kits, clean-up PPE is
available.
Unknown chemical in the

Contamination of Raw materials must be
As well as product. Low product
product checked prior to usage
quality
Update maintenance
Spill of product. Less procedures. Ensure that
As well as Leaking product line product. Improper product spill containment, spill
quality. kits, clean-up PPE is
available
Could not regulate the
process back to desired
Control Flow Control valve fails
3A No condition. Improper Select valve fail to open
system closed.
conversion to product.
Install flow meter, high

Higher reaction rate. flow alarm. Valve must
High Higher flow of hot oil Improper conversion to be correct type, material
product of construction and
properly maintained.
Unable to control the Install a low flow alarm.
Control valve fails to
Low process back to desired Check and update
respond.
condition. maintenance
6.5.5 HAZOP Study of Compressor (C-103)
Recommendation from the HAZOP study for the compressor (C-103):

1. Add lock procedure for valve V-501.
2. Install flow meter and low flow alarm.
3. Install high pressure alarm.
4. Feedstock must be check prior to usage to consider possible contamination and
interruption of supply.
5. Install check valve.
Table 6.17: HAZOP Table of Compressor, C-103
Rev no: C-103 Date：19/11/2019
Subsystem Description: To increase the pressure of the stream
Parameter: Flow, Motor
Ite Study Node Process Deviations Possible Causes Possible Consequences Action Required
m parameter
1A Feed Stream Flow No 1. Failure in naphta 1. No feed naphta, no 1. Install low flow meter,
supply reaction. low flow alarm.
2. S3 line plugged 2. No feed naphta, no 2. Install low flow meter,
reaction. low flow alarm.
1B High 1. High naphta pressure Damage to the compressor, Install high flow alarm, high
improper conversion to pressure alarm. Open pressure
product, damage compressor relief valve manually.
1C Low Partially plugged Low pressure may cause Install low flow alarm
feed line backflow
1D As well as Contamination of Possible side reactions, Stock feed has to be checked

feed stock reactants. unknown chemical exposures, prior to usage
contamination of product.
1E Reverse flow Back flow of feed Failure of naphta supply to the Use proper valves such as
of feed due to backpressure reactor check valves to prevent back
flow of feed
2A Compressor Motor No Motor of compressor Pressure remain constant Interlock with feed line
itself malfunction
High Power failure Naptha feed continues, possible Valve must be failed to close in
accumulation of ethylene the event of power loss
Table 6.18: HAZOP Table of Cooler, E-101
Project: Production of Toluene Page: 1

Rev no: Equipment No. 9 Date：
19/11/2019
HAZOP Team members: Group 6 (Toluene)
Subsystem description: - Subsystem Intention: -
Diagram: Cooler (E-101)

Parameter: - Parameter Design Intent: -
Item Study Node Process Deviations Possible Causes Possible Consequences Action Required
parameter
1A Inlet Pipe Flow 1. No cooling 1. Coolant valve 1. Temperature 1. Install high
flows malfunction increase in fluid temperature alarm
2. More cooling 2. Failure of inlet flow (TAH)
flows coolant valve to 2. Input of process 2. Install
close fluid temperature
3. Less cooling 3. Pipe leakage temperature too indicator before
flows 4. Failure of low process pipeline
process fluid 3. Process fluid 3. Install
4. Reverse inlet valve temperature too temperature
process fluid low indicator before
flow 4. Product off set process fluid line
install
1B Temperature 1. More 4. Installation of
temperature 1. Too much 1. Overheat occur flowmeter
2. Less cooling power 2. Damage the 5. Install check valve
temperature 2. Not enough equipment
cooling 3. Temperature drop
1C Pressure 1. More
pressure 1. Valve is
closed 1. Bursting of tube 1. Install high
2. Failure of 2. Crack of tube temperature
process alarm
fluid valve 2. Install low
temperature
alarm
1. Install high
pressure alarm
1. Instruct operators
2A Outlet Pipe Flow 1. Less cooling 1. See 1A.3 1. Damage the on procedures
flows equipment
1. The phase of
fluid unchanged
2B Temperature 1. More 1. See 1B.2 1. Damage the

temperature equipment 1. See 1B.1
2. The phase of fluid
unchanged
2C Pressure 1. More 1. Failure of 1. Risk of explosion

pressure process 1. See 1C.1
fluid valve
Table 6.19: HAZOP Table of Expander, Ex-100
Project: Production of Toluene Page:

Rev no: Equipment No. 8 Date：20.11.2019
Diagram: Expander (Ex- 100)

Ite Study Process Deviation Possible Causes Possible Consequences Action Required
m Node parameter s
1A Feed Flow No 1. Clogged of feed pipeline 1. No reaction 1. Set up filter in pipe
pipeline 2. Without suitable controller occurs 2. Set up the control system on
and control valve 2. See 1A.1 expander
3. Pipe rupture 3. See 1A.1 3. Same as above
Less 1. Partially plugged feed line 1. Less feed and

2. Leaking feed lines less reaction. 1. Check and update maintenance.
Improper 2. Check pre startup checklist to
product ensure that this valve is closed
conversion.
2. Same as above.
1B Pressure More 1. Controller failure
2. Valve malfunction 1. Damage
equipment
2. Risk of
explosion
2A Outlet Flow Less 1. See 1A.1 1. Low efficiency 1. Install check valve
pipeline of process 2. Installation of flowmeter
More 1. Blockage in pipelines 1. Low quality of 1. Install flowmeter
2. Valve malfunction product 2. Install check valve
2. Same as above
2B Pressure More 1. Controller failure 1. Damage the 1. Regular check and maintenance of
2. Valve malfunction equipment controller
2. Install pressure indicator
Table 6.20: HAZOP Table of Separator, T-100
Project: Production of Toluene Page: 2

Rev no: Equipment No. 10 Date：19.11.2019
Diagram: Separator (T-100)

Item Study Process Deviations Possible Causes Possible Consequences Action Required
Node parameter
1A Inlet pipe Flow 1. No fluid flows 1. Valve 1. Low level of 1. Install check valve
2. More fluid malfunction fluid 2. Installation of flowmeter
flows 2. Pipe leakage 2. Low efficiency
3. Less fluid of process
flows
1B Pressure 1. More pressure 1. Install high pressure alarm

2. Less pressure 1. See 1A.1 1. See 1A.1 and 2. Install low pressure alarm
2. See 1A.2 1A.2
3. Operator fails to
take action on
alarm
2A Outlet Flow 1. No fluid flows 1. Blockage in 1. Pressure surge 1. See 1A.1 and 1A.2
pipe H2 2. More fluid vessel 2. Risk of explosion
gas flows 2. Valve 3. The purity of
3. Less fluid malfunction product low
flows 4. Low efficiency
of process
2B Pressure 1. No pressure 1. Damage the 1. See 1B.1
2. More pressure equipment 2. Instruct operators on procedure
1. Clogging in 2. Risk of explosion 3. Install check valve
pipeline 3. Crack on
2. Control valve pipelines
failure
3A Outlet Flow 1. No fluid flows 1. See 2A.1 1. Low quality of 1. Install flowmeter
pipe 2. More fluid 2. See 2A.2 product 2. Update maintenance procedure
liquid flows 3. See 2B.1 2. Less feed and 3. Operator must check liquid
flow 3. Less flow less reaction flow during operation unit
fluid
3B Pressure 1. Outlet pipeline is 1. Improper 1. Update the maintenance
1. More pressure plugged product procedures
2. Less pressure 2. Outline pipe is conversion 2. Valve must be of the correct type,
cut material construction and proper
maintained
3. See 1B.1 and 1B.2
4A Separator Level 1. More 1. The blockage of 1. Flooding 1. Install flowmeter
vessel 2. Less outlet inside vessel 2. Install level meter and level
3. No 2. The inlet flow 2. Possible spill sensor
rate is beyond the of feed flow 3. See 3A.3
optimum limit of 3. No feed and
flow rate therefore no
3. All feed valves reaction
are closed
Table 6.21: HAZOP Table of Distillation Column, DC-100

Project name: Production of toluene Date:
19.11.2019
Process: To separate off gas and distillate from toluene
Section; Purification Column (DC-100) Reference drawing: Figure 6.3
Ite Study Process Deviation Possible causes Possible Action required

m node
parameters (guide consequence

words)
1A Input Flow High 1. Valve passed 1. Increased in 1. Install flow controller

line temperature and
pressure
1B Low 1. Controller failure 1. Delay of 1. Maintenance of controller regularly

process
1C Temperature High 1. Hotter vapor 1. Overheating 1. Always check on the vapor flow
from separator happened
Table 6.22: HAZOP Table of Condenser, E-100
Project name: Production of toluene Date: Page 1 of 1
19.11.2019
Process: To change the phase of distillate to liquid phase and reflux to distillation column
Section; Condenser (E-100) Reference drawing: Figure 6.3
Ite Study Process Deviation Possible causes Possible Action required

m node
parameters (guide consequence

words)
1A Condenser Level No  Inlet flow  Pressure  Install a by-pass

itself stops surges pipeline
 Flow  Draining  Maintenance on
control valve fail pipeline
close
1B More  Outlet of  Leakage  Maintenance on

waste water  Flooding pipeline
Table 6.23: HAZOP Table of Reboiler, RB-100
Project name: Production of toluene Date:

19.11.2019
Process: To reflux the impurities into distillation column
Section; Reboiler Reference drawing: Figure 6.3
Ite Study Process Deviatio Possible causes Possible Action required

m node n
parameters consequence
(guide
words)
1A Reboiler Temperature Less  Stea  Not  Steam control valve to allow

m flow is enough boil- for steam to increase and provide
itself low up to the more heating duty
 Flow column  Installation of a flow control
rate of the  Distill valve on the feed inlet on the reflux
medium be ation column stream to adjust flow
heated will fail to
increased operate
 Produc
t off-
specifications
1B More  Feed  Reboil  Steam control valve to allow

flow er overheating for steam controlling
decreased and damaged.  Installation of a flow control
 Stea  Produc valve on the feed inlet on the reflux
m flow rate t off stream to adjust flow
increased specification
 Increa
sing amount
of vapor in the
column which
causes its
failure and
increases
pressure drop
and causes
flooding.
6.6 Chemical Handling, Transportation and Accident Precautions within the Plant
Safely managing the chemicals in your workplace is good for business and it is good
for everyone. It will improve employees’ safety and health. It will potentially introduce cost
savings, through more effective work practices such as correct storage, handling, use and
disposal procedures. Potential harm to the environment will also be reduced.
6.6.1 Cyclohexane
Chemical Cylohexane is a very toxic chemcials that requires expert

Handling advice on control measures if a less toxic chemical cannot be
substituted. Control measures includes:
1. Enclosing chemical processes for severely irritating

and corrosive chemicals
2. Using local exhaust ventilation for chemicals that
may be harmful with a single exposure
3. Using general ventilation to control exposures to
skin and eye irritants.
4. Label process containers
5. Provide employees with hazard information and
training
6. Monitor airborne chemical concentrations
7. Provide eye wash fountains and emergency showers
Transportatio  Land transport: ADR / RID with UN number UN

n 1145, has a proper shipping name of CYCLOHEXANE
with class 3, with packing group II, it is environmentally
hazardous and required special precautions for user. The
tunnel restriction code is D/E
 Sea transport: IMDG with UN number UN 1145,
has a proper shipping name of CYCLOHEXANE with
class 3, with packing group II, it is environmentally
hazardous and required special precautions for user. The
Ems code is F-E S-D
 Air transport: IATA with UN number UN 1145, has
a proper shipping name of CYCLOHEXANE with class 3,
with packing group II, it is environmentally hazardous and
required special precautions for user.
Accident Use personal protective equipment. Ensure adequate

Precaution ventilation. Remove all sources of ignition. Evacuate personnel to
safe areas. Beware of vapors accumulating to form explosive
concentrations. Vapors can accumulate in low areas. Prevent
product from entering drains. Prevent further leakage or spillage if
safe to do so. If the product contaminates rivers and lakes or drains
inform respective authorities.
Methods for cleaning up : Contain spillage, and then collect

with non-combustible absorbent material, (e.g. sand, earth,
diatomaceous earth,
vermiculite) and place in container for disposal according to

local / national regulations.
6.6.2 Methyl-cyclohexane
Chemical Put on appropriate personal protective equipment. Do

Handling not ingest. Avoid contact with eyes, skin and clothing.
Avoid breathing vapor or mist. Avoid release to the
environment. Use only with adequate ventilation. Wear
appropriate respirator when ventilation is inadequate. Do
not enter storage areas and confined spaces unless
adequately ventilated. Keep in the original container or an
approved alternative made from a compatible material,
kept tightly closed when not in use. Store and use away
from heat, sparks, open flame or any other ignition source.
Use explosion-proof electrical (ventilating, lighting and
material handling) equipment. Use only non-sparking tools.
Take precautionary measures against electrostatic
discharges. Empty containers retain product residue and
can be hazardous. Do not reuse container.
Transportatio Under DOT transport information. UN no UN 2296, with
n shipping name of METHYLCYCLOHEXANE with class 3,
with packing group II, it is environmentally hazardous and
required special precautions for user. Has a limited quantity,
for passenger aircraft, the quantity limitation is 5L, while for
cargo aircraft is 60L. The special provisions is B1, IB2, T4 and
TP1.
Accident Wear protective gloves. Wear eye or face protection. Keep

Precaution away from heat, hot surfaces, sparks, open flames and other
ignition sources. No smoking. Use explosion proof electrical,
ventilating, lighting and all material-handling equipment. Use only
non-sparking tools. Take precautionary measures against static
discharge. Keep container tightly closed. Use only outdoors or in a
well-ventilated area. Avoid release to the environment. Avoid
breathing vapor. Wash hands thoroughly after handling.
6.6.3 Benzene
Chemical FLAMMABLE MATERIAL. Handle with care. Avoid

Handling contact with any sources of ignition, flames, heat, and
sparks. Ensure all equipment is grounded/bonded. Avoid
skin contact. Avoid eye contact. Avoid inhalation of
product vapours or mists. Avoid confined spaces and areas
with poor ventilation. Avoid contact with any incompatible
or reactive materials. Wear proper personal protective
equipment (See Section 8). Empty containers may contain
product residue. Do not pressurize, cut, heat, or weld
empty containers. Do not reuse containers without
commercial cleaning and/or reconditioning. Personnel who
handle this material should practice good personal hygiene
during and after handling to help prevent accidental
ingestion of this product. Properly dispose of contaminated
leather articles including shoes that cannot be
decontaminated. Thoroughly wash all severely
contaminated clothing before reuse. Store away from heat
and sources of ignition. Store in dry, cool, well-ventilated
area. Store away from incompatible and reactive materials
(See section 5 and 10). Avoid direct sunlight. Ensure the
storage containers are grounded/bonded.
Transportatio Benzene is transported mainly by sea or inland waterway and

n is subject to a number of international guidelines for safe
handling of cargoes. These include the International Maritime
Dangerous Goods (IMDG) from the International Maritime
Organisation (IMO), the International Safety Guidelines for
Oil Tankers and Terminals (ISGOTT) and the ADNR (Accord
europeen relatif au transport international des marchandises
Dangereuses par voie de Navigation interieure au Rhine)
regulations. In the US, marine transport must be in compliance
with the US Coast Guard Benzene Standard. When transported
by road, rail, or air, benzene is regulated worldwide as a
Flammable Liquid. Static charges can accumulate during
shipping, unloading, pouring, or transferring operations. Take
precautionary measures against electrostatic discharges. To
avoid fire or explosion, dissipate static electricity during
transfer by grounding and bonding containers and equipment
before transferring material
Accident Take precautions to prevent a fire (e.g. remove sources of

Precaution ignition). Take precautions to ensure your own safety before
attempting rescue (e.g. wear appropriate protective equipment).
Move victim to fresh air. Call a Poison Centre or doctor if the
victim feels unwell. Avoid direct contact. Wear chemical
protective clothing if necessary. Quickly take off contaminated
clothing, shoes and leather goods (e.g. watchbands, belts).
Immediately flush with lukewarm, gently flowing water for 15-20
minutes. If irritation or pain persists, see a doctor. Double bag,
seal, label and leave contaminated clothing, shoes and leather
goods at the scene for safe disposal. If ingested, have victim rinse
mouth with water. If vomiting occurs naturally, have victim lean
forward to reduce risk of aspiration. Have victim rinse mouth with
water again. Immediately call a Poison Centre or doctor.
6.6.4 Toluene
Chemical Train personnel in proper handling and storage

Handling techniques. Wash thoroughly after handling toluene. Avoid
breathing toluene vapor, mist or gas. Do not pressurize,
cut, weld, braze, solder, drill, grind or expose empty
containers to heat, sparks or open flames. Due to its
flammability, bonding and grounding should be in
accordance with NFPA 77-1983. Follow recommended
practices on static electricity when transferring or
dispensing toluene. Store toluene in accordance with 29
CFR 1910. An outside or detached structure is preferred.
When storing inside, use a standard flammable storage
room or safety cabinet. Avoid contact with nitric acid,
sulfuric acid, strong oxidizing agents and organic
chlorides.
Transportatio Toluene shall be transported only in originally sealed

n containers or in approved safety cans of 5 gallon capacity or
less, or in truck mounted equipment designed for transporting
hazardous chemicals. A bulk solvent exporter would normally
distribute this solvent in bulk vessels or tank trucks. For
transportation purposes, toluene is classed as a flammable
liquid with a fire hazard rating of 2. A full bulk chemical
distributor would export the solvent throughout regions such as
the UK, Europe, Africa and America. This product is a
packing group 2.
Accident Toluene can be accidentally inhaled or ingested, and if you

Precaution work with this chemical it can also come into contact with your
skin or eyes. In the case of any type of exposure to toluene, it is
important that it be managed appropriately in order to minimize
hazards to your health. If contacted with skin, immediately flush
skin with plenty of water, and cover the irritated skin with an anti-
bacterial cream. Seek medical attention. If there is an eye contact,
immediately flush eyes with plenty of water for at least 15
minutes, removing contacts if present. Seek medical attention. If
ingested, do not induce vomiting. Call a medical professional
immediately, especially if large amounts of this chemical were
swallowed. If inhaled, seek fresh air immediately. Administer
oxygen if breathing is labored, and use artificial respiration if not
breathing. Seek medical attention.
6.6.5 Butane
Chemical Wear leather safety gloves and safety shoes when

Handling handling cylinders. Protect cylinders from physical
damage; do not drag, roll, slide or drop. While moving
cylinder, always keep in place removable valve cover.
Never attempt to lift a cylinder by its cap; the cap is
intended solely to protect the valve. When moving
cylinders, even for short distances, use a cart (trolley, hand
truck, etc.) designed to transport cylinders. Never insert an
object (e.g, wrench, screwdriver, pry bar) into cap
openings; doing so may damage the valve and cause a leak.
Use an adjustable strap wrench to remove over-tight or
rusted caps. Slowly open the valve. If the valve is hard to
open, discontinue use and contact your supplier. Close the
container valve after each use; keep closed even when
empty. Never apply flame or localized heat directly to any
part of the container. High temperatures may damage the
container and could cause the pressure relief device to fail
prematurely, venting the container contents.
Transportatio In accordance with DOT, the transport document description is

n UN 1011 Butane. the UN-non(DOT) is UN 1011 with shipping
name of BUTANE. DOT class of 2.1- Class 2.1- Flammable
gas 49 CFR 173.115. Hazard labels is 2.1 – flammable gas
Avoid transport on vehicles where the load space is not
separated from the driver's compartment. Ensure vehicle driver
is aware of the potential hazards of the load and knows what to
do in the event of an accident or an emergency. Before
transporting product containers: - Ensure there is adequate
ventilation. - Ensure that containers are firmly secured. -
Ensure cylinder valve is closed and not leaking. - Ensure valve
outlet cap nut or plug (where provided) is correctly fitted. -
Ensure valve protection device (where provided) is correctly
fitted.
Accident Evacuate area. Ensure adequate air ventilation. Eliminate

Precaution ignition sources. Prevent from entering sewers, basements and
workpits, or any place where its accumulation can be dangerous.
Consider the risk of potentially explosive atmospheres. Try to stop
release. Wear self-contained breathing apparatus when entering
area unless atmosphere is proven to be safe. Evacuate area. Ensure
adequate ventilation. Stop leak if safe to do so.
6.6.6 Naphta
Chemical Keep away from fire, sparks and heated surfaces. No
Handling smoking near areas where material is stored or handled.
The product should only be stored and handled in areas
with intrinsically safe electrical classification. Keep away
from flame, sparks, excessive temperatures and open
flame. Use approved containers. Keep containers closed
and clearly labeled. Empty or partially full product
containers or vessels may contain explosive vapors. Do not
pressurize, cut, heat, weld or expose containers to sources
of ignition. Store in a well-ventilated area. The storage area
should comply with NFPA 30 "Flammable and
Combustible Liquid Code". The cleaning of tanks
previously containing this product should follow API
Recommended Practice (RP) 2013 "Cleaning Mobile
Tanks In Flammable and Combustible Liquid Service" and
API RP 2015 "Cleaning Petroleum Storage Tanks". Keep
away from food, drink and animal feed. Incompatible with
oxidizing agents. Incompatible with acids.
Transportatio CFR
n Proper shipping name : PETROLEUM DISTILLATES
N.O.S. UN-No. : 1268
Class : 3
Packing group : II
Hazard inducer : (Naphtha; Low boiling point naphtha)
IMDG-CODE
UN-No. : UN 1268
Description of the goods: PETROLEUM DISTILLATES,
N.O.S.
(Naphtha; Low boiling point naphtha)
Class : 3
Packaging group : II
IMDG-Labels : 3
EmS Number : F-E S-E
Marine pollutant : No
Accident Evacuate personnel to safe areas. Ventilate the area. Remove

Precaution all sources of ignition. Response and clean-up crews must be
properly trained and must utilize proper protective equipment.
6.6.7 Hydrogen gas

Chemical Keep away from heat, sparks, and open flame. Use only
Handling spark-proof tools and explosion-proof equipment. Protect
cylinders from damage. Use a suitable hand truck to move
cylinders; do not drag, roll, slide, or drop. Hydrogen is the
lightest known gas. It may leak out of systems that are air-tight
for other gases and may collect in poorly ventilated upper reaches
of buildings. Leak check system with soapy water; never use a
flame. All piped hydrogen systems and associated equipment
must be grounded. Electrical equipment must be non-sparking or
explosion-proof. Do not crack or open hydrogen cylinder valves
unless connected to utilization equipment; escaping gas may
ignite spontaneously. Open valve slowly. If valve is hard to open,
discontinue use and contact your supplier. Close cylinder valve
after each use; keep closed even when empty. Never attempt to
lift a cylinder by its cap; the cap is intended solely to protect the
valve. Never insert an object (e.g., wrench, screwdriver, pry bar)
into cap openings; doing so may damage the valve and cause a
leak. Use an adjustable strap wrench to remove over-tight or
rusted caps. For other precautions in using hydrogen,
Transportat
ion
Cylinders should be transported in a secure position, in a well-
ventilated vehicle. Cylinders transported in an enclosed, non-
ventilated compartment of a vehicle can present serious safety
hazards. Shipment of compressed gas cylinders that have been filled
without the owner’s consent is a violation of federal law [49 CFR
173.301(b)]. Hydrogen is not listed as a marine pollutant by DOT.
Accident In event of fire, evacuate all personnel from danger area.

Precaution Immediately deluge cylinders with water from maximum distance until
cool; then move them away from fire area if without risk. Continue
cooling water spray while moving cylinders. Do not extinguish flames
emitted from cylinders; allow them to burn out. Self-contained breathing
apparatus may be required by rescue workers. On-site fire brigades must
comply with OSHA 29 CFR 1910.156. If inhaled, Remove to fresh air. If
not breathing, give artificial respiration. If breathing is difficult, qualified
personnel may give oxygen. Call a physician.
APPENDIX
Naphtha (Tesoro Refining & Marketing Co., 2009)
1. FIRE AND EXPLOSIVE HAZARDS DATA
Explosion Flammability Flash Point: -20° C to -50°

Flammability Range Autoignition
: C (Exists in the form of
(LEL to UEL): Temperature degree C:
Highly flammable Vapor at ambient
1.1%to5.9% 531°C
moderately explosive Temperature)
2. REACTIVE HAZARDS
Hazardous Combustion Products :

Impact: Stable Carbon Di-oxide (CO2 ), Carbon Monoxide
(CO)
Stability to Static Discharge: Can Ignite (Hazardous Decomposition Products) : No
(Conditions to avoid): Avoid Contact With

Reactivity: With Oxidisers
Oxidizers
Hazardous
May Not Occur
Polymerization
3. HAZARD SPECIFICATION
NFPA HAZARD HEALTH FLAMMABILITY STABILITY SPECIAL

SIGNAL 1 3 0 0
Known Hazards
Combustible Liquid : Yes Water Reactive Material : No Irritant : No
Flammable Material :Yes Oxidiser: No Sensitizer : No
Pyrophoric Material :No Organic Peroxide: No Carcinogen : No
Explosive Material :Yes Corrosive Material: No Mutagen : No
Unstable Material :No Compressed Gas: Yes Others (Specify) : No
4. SAFE USAGE DATA
Ventilation : General
Non Respiratory PPE’S :

Personal Protective Eyes : Safety Goggle, Face shield, or Hood
Equipments(PPE’S): Body: PVC clothing.
Gloves : Neoprene, Polyvinyl Chloride(PVC)
Respiratory (Specify): Emergency Life Saving
Apparatus(ELSA), Self Contained Breathing
Apparatus(SCBA).
Handling & Storage : Should Be Stored Inair Tight Closed
Precautions
Containers Away From Source Of Ignition, With Protection
Against Static Discharges.
5. EMERGENCY RESPONSE DATA
Fire Extinguishing Media :3% Aquous Film Forming

Foam(AFFF), Dry
Chemical Powder(DCP),Carbon Di Oxide(CO2,)
Special Procedures :Water Spray May Be Used To Cool
Fire
Containers Or Exposed Equipments.
Unusual Hazardous :----
Exposure ( Skin and eye First Aid Measure:
contact, inhalation, Ingestion) Remove Victim To Fresh Air. Seek Medical Help.
Spills Steps to be taken : Collect In Container.
Waste disposal method : On Large Scale Absorb And Landfill.
Allow For Atmospheric Evaporation.
TOLUENE (PETRO-CANADA, 2017A)
1. Hazard(s) identification
Classification
This chemical is considered hazardous by the 2012 OSHA Hazard Communication Standard
(29 CFR 1910.1200)
Flammable liquids-Category 2
Skin Corrosion/irritation-Category 2
Serious Eye Damage/Eye Irritation-Category 2
Reproductive Toxicity-Category 2
Specific target organ toxicity (single exposure)-Category 3
Target Organs - Respiratory system, Central nervous system
(CNS).
Specific target organ toxicity - (repeated exposure)Category 2
Target Organs - Kidney, Liver, spleen, Blood.
Aspiration Toxicity: Category 1
Hazard Statements
Highly flammable liquid and vapor
May be fatal if swallowed and enters airways
Causes skin irritation
Causes serious eye irritation
May cause respiratory irritation
May cause drowsiness or dizziness
Suspected of damaging the unborn child
Causes damage to organs through prolonged or repeated exposure
Precautionary Statements
Prevention
Obtain special instructions before use
Do not handle until all safety precautions have been read and understood
Use personal protective equipment as required
Wash face, hands and any exposed skin thoroughly after handling
Wear eye/face protection
Do not breathe dust/fume/gas/mist/vapors/spray
Do not eat, drink or smoke when using this product
Use only outdoors or in a well-ventilated area
Keep away from heat/sparks/open flames/hot surfaces. - No smoking
Keep container tightly closed
Ground/bond container and receiving equipment
Use explosion-proof electrical/ventilating/lighting/equipment
Use only non-sparking tools
Take precautionary measures against static discharge
Keep cool
Response
IF exposed or concerned: Get medical attention/advice
Inhalation
IF INHALED: Remove victim to fresh air and keep at rest in a
position comfortable for breathing Skin
If skin irritation occurs: Get medical advice/attention
IF ON SKIN (or hair): Take off immediately all contaminated
clothing. Rinse skin with water/shower Wash contaminated
clothing before reuse Eyes
IF IN EYES: Rinse cautiously with water for several minutes. Remove contact lenses, if
present and easy to do. Continue rinsing If eye irritation persists: Get medical
advice/attention
Ingestion
IF SWALLOWED: Immediately call a POISON
CENTER or doctor/physician Do NOT induce
vomiting
Fire
In case of fire: Use CO2, dry chemical, or foam for extinction
Storage
Store locked up
Store in a well-ventilated place. Keep container tightly closed
Disposal
Dispose of contents/container to an approved
waste disposal plant Hazards not otherwise
classified (HNOC)
WARNING. Reproductive Harm - https://www.p65warnings.ca.gov/.
2 . First-aid measures
General Advice If symptoms persist, call a physician.
Eye Contact Rinse immediately with plenty of water, also under the eyelids, for at
least 15 minutes. Get medical attention.
Skin Contact Wash off immediately with plenty of water for at least 15 minutes. If
skin irritation persists, call a physician.
Inhalation Move to fresh air. If not breathing, give artificial respiration. Get
medical attention if symptoms occur. Risk of serious damage to the
lungs.
Ingestion Clean mouth with water and drink afterwards plenty of water. Do not
induce vomiting. Call a physician or Poison Control Center immediately.
If vomiting occurs naturally, have victim
lean forward.
Most important Breathing difficulties. Causes central nervous system depression:

symptoms and effects Inhalation of high vapor concentrations may cause symptoms like
headache, dizziness, tiredness, nausea and vomiting
Notes to Physician Treat symptomatically
Suitable Extinguishing Use water spray, alcohol-resistant foam, dry chemical or carbon dioxide.
Media Cool closed containers exposed to fire with water spray.
Unsuitable No information available

Extinguishing Media
Flash Point 4 °C / 39.2 °F
Method - No information available

Autoignition 535 °C / 995 °F
Temperature
Explosion Limits
Upper 7.1 vol %
Lower 1.1 vol %
Oxidizing Properties Not oxidising
Specific Hazards Arising from the Chemical

Flammable. Containers may explode when heated. Vapors may form explosive mixtures with
air. Vapors may travel to source of ignition and flash back.
Hazardous Combustion Products

Carbon monoxide (CO) Carbon dioxide (CO2)
Protective Equipment and Precautions for Firefighters
As in any fire, wear self-contained breathing apparatus pressure-demand, MSHA/NIOSH
(approved or equivalent) and full protective gear.
NFPA
Health : 3
Flammability: 3
Personal Precautions Use personal protective equipment. Ensure adequate
ventilation. Remove all sources of ignition. Take
precautionary measures against static discharges.
Environmental Precautions Should not be released into the environment. Do not flush
into surface water or sanitary sewer system.
Methods for Containment and Clean Soak up with inert absorbent material. Keep in
suitable, closed containers for disposal.
Hydrogen (MSDS Of Hydrogen, 2000)
1. HAZARDS IDENTIFICATION
Main Hazards
All cylinders are transportable gas container. Hydrogen is highly flammable and is the
lightest gas known. It burns in air with an intensely hot, almost invisible flame. The
flammability limits in the air are between 4.0 -75.0% by volume and flammable explosive
gas-air mixtures may be formed.
Adverse Health Effects
Hydrogen is non-toxic but could act as a simple asphyxiant under confine space.
Chemical Hazards
Hydrogen is relatively inert under standard condition. However it becomes highly reactive
under excessive temperature and pressure. Ignition of hydrogen in air can occur with very
small energy sources such as heat static electricity or sparks.
Biological Hazards
Hydrogen has a smallest density compare to the other element known and disperses very
rapidly into the atmosphere. Hydrogen has unknown biological hazards.
Vapour Inhalation
Hydrogen is a simple asphyxiant, but disperses rapidly into the atmosphere.
FIRST AID MEASURES
Eye/Skin Contact No known effect.

Prompt medical attention is mandatory in all cases of overexposure to hydrogen. Rescue
personnel should be equipped with self-contained breathing apparatus. Conscious persons
should be assisted to an uncontaminated area and inhale fresh air. Quick removal from the
contaminated area is most important. Unconscious persons should be removed to an
uncontaminated area, and given mouth- to-mouth resuscitation and supplemental oxygen. The
patient should be keep still and warm.
Label Elements
Hazard Pictograms
Signal Word: Danger
Precautionary Statements:
P210: Keep away from heat/ sparks/open flames/ hot surface. No Smoking
P377: leaking gas fire: Do not extinguish, unless leak can be stopped safely.
P381: Eliminate all ignition sources if safe to do so.
P403: Store in a well-ventilated place.
Hazard Statements:
H220: Extremely flammable gas.
2. FIRE FIGHTING MEASURES
Extinguishing Media
Use fog-water spray, (in the absence of fog equipment a fine spray of water may be use to
fight hydrogen flame). Specific Hazards
Do not extinguish the fire unless the leakage can be stopped immediately. Hydrogen is highly
flammable. May form explosive gas mixture with air. Hydrogen can act as a simple
asphyxiant “by reducing the oxygen concentration in the air below a level where it support
life”. Beware of autoignition if leak rate is high. The flame of burning hydrogen is very
difficult to see in daylight.
Emergency Actions
If possible shut off ignition source of excess hydrogen. Evacuate the area. Post warnings
signs to prevent persons from approaching with lit cigarettes or open flames. Use water to
keep all cylinders cool. Remove cylinders from the vicinity of the fire if possible. Remove all
cylinders with signs of overheating to a safe area. Keep the cylinder cool by spraying with
water at a
safe distance. CONTACT THE
NEAREST AFROX BRANCH.
Protective Clothing
Self-contained breathing apparatus, safety gloves and shoes/boots should be worn when
handling containers.
Environmental Precautions
As the gas is lighter than air, ensure that hydrogen gas is not trapped in confine space.
Otherwise this could lead to the formation of a highly explosive gas-air mixture. Ventilate all
confined area using forced draught if necessary. Ensure that all electrically powered
equipment are flameproof.
1.8 BENZENE (Scientific, 2013)
Section 1. Composition and Information on Ingredients

Exposure Limits
(ACGIH)
Name CAS # % TLV-TWA(8 STEL CEILING
(V/V) h)
1) Benzene 71-43-2 99.6 0.5 ppm 2.5 ppm Not
2) Toluene 108-88-3 0.3 50 ppm Not establishe
3) Non-aromatics Mixture 0.1 Not established d
established Not Not
established establishe
d
Not
establishe
d
Manufacturer Not applicable
Recommendation
Other Exposure Consult local, state, provincial or territory authorities for
acceptable exposure limits.
Limits
Section 2. Hazards Identification.
Potential Health Flammable liquid. Exercise caution when handling this material. Contact with this
product may cause skin and eye Effects irritation. Prolonged or repeated contact may cause skin
irritation, defatting, drying and dermatitis. Inhalation of this product may cause respiratory tract
irritation and Central Nervous System (CNS) Depression, symptoms of which may include; weakness,
dizziness, slurred speech, drowsiness, unconsciousness and in cases of severe overexposure; coma and
death. Aspiration of liquid drops into the lungs may produce potentially fatal chemical pneumonitis
(fluid in the lungs), severe lung damage, or respiratory failure. May cause cancer. May cause
heritable genetic effects (mutagenicity). For more information refer to Section 11 of this MSDS.
Section 3. First Aid Measures
Eye Contact IMMEDIATELY flush eyes with running water for at least 15 minutes, keeping
eyelids open. Seek medical attention.
Skin Contact Remove contaminated clothing - launder before reuse. Wash gently and thoroughly the
contaminated skin with running water and non-abrasive soap. Seek medical
attention.
Inhalation Evacuate the victim to a safe area as soon as possible. If the victim is not breathing,
perform artificial respiration. Allow the victim to rest in a well ventilated area.
Seek medical attention.
Ingestion DO NOT induce vomiting because of danger of aspirating liquid into lungs. Seek
medical attention.
Note to Physician Not available
Section 4. Fire-fighting Measures
Flammability Class I - flammable liquid Flammable LOWER: 1.3%; UPPER: 7.1%
(NFPA). Limits (NFPA).
Flash Points CLOSED CUP: -11°C (12°F) Auto- 498 °C (928°F) (NFPA )
Ignition
Temperature
Fire Extremely flammable in Explosion Do not cut, weld, heat, drill or
Hazards presence of open flames, Hazards in pressurize empty container.
in sparks, and heat. Vapours are Presence of Containers may explode in heat
Presence heavier than air and may travel Various of fire. Runoff to sewer may
of considerable distance to Substances create fire or explosion hazard.
Various sources of ignition and flash
Substances back. Rapid escape of vapour
may generate static charge
causing ignition. This product
can accumulate static charge
and ignite. May accumulate in
confined spaces.
Products of Carbon oxides (CO, CO2), aldehydes, ketones, smoke and irritating vapours as
products of incomplete combustion.
Combustion
Section 5. Accidental Release Measures

Material Release IN THE EVENT OF A LARGE SPILL CONSIDER THE FOLLOWING CONTROL
MEASURES: Consult current National or Spill Emergency Response Guide Book (NAERG) for
appropriate spill measures if necessary. Evacuate non-essential personnel. Extinguish all ignition
sources. Ventilate area. Stop leak if safe to do so. Ensure clean-up personnel wear appropriate personal
protective equipment. Dike spilled material. Use appropriate inert absorbent material to absorb spilled
product. Collect used absorbent for later disposal. Ground and bond all equipment used to clean up the
spilled material, as it may be a static accumulator. Avoid contact with spilled material. Avoid breathing
vapours or mists of material. Avoid contaminating sewers, streams, rivers and other water courses with
spilled material. Notify appropriate authorities immediately.
Section 6. Handling and Storage
Handling FLAMMABLE MATERIAL. Handle with care. Avoid contact with any sources of
ignition, flames, heat, and sparks. Ensure all equipment is grounded/bonded. Avoid
skin contact. Avoid eye contact. Avoid inhalation of product vapours or mists. Avoid
confined spaces and areas with poor ventilation. Avoid contact with any incompatible
or reactive materials. Wear proper personal protective equipment (See Section 8).
Empty containers may contain product residue. Do not pressurize, cut, heat, or weld
empty containers. Do not reuse containers without commercial cleaning and/or
reconditioning. Personnel who handle this material should practice good personal
hygiene during and after handling to help prevent accidental ingestion of this product.
Properly dispose of contaminated leather articles including shoes that cannot be
decontaminated. Thoroughly wash all severely contaminated clothing before reuse.
Storage Store away from heat and sources of ignition. Store in dry, cool, well-ventilated
area. Store away from incompatible and reactive materials (See section 5 and 10).
Avoid direct sunlight. Ensure the storage containers are grounded/bonded.
Section 7. Personal protective Equipment
Engineering Controls For normal application, special ventilation is not necessary. If user's operations
generate vapours or mist, use ventilation to keep exposure to airborne contaminants
below the exposure limit. Make-up air should always be supplied to balance air
removed by exhaust ventilation. Ensure that eyewash station and safety shower are
close to work-station.
Personal Protection - The selection of personal protective equipment varies, depending upon
conditions of use.
Eyes Eye protection (i.e., safety glasses, safety goggles and/or face shield) should be
determined based on conditions of use. If product is used in an application where
splashing may occur, the use of safety goggles and/or a face shield should be
considered.
Body Wear appropriate clothing to prevent skin contact. As minimum long sleeves and
trousers should be worn.
Respiratory Where concentrations in air may exceed the occupational exposure limits given in
Section 2 (and those applicable to your area) and where engineering, work practices or
other means of exposure reduction are not adequate, NIOSH approved respirators may
be necessary to prevent overexposure by inhalation.
Hands Wear appropriate chemically protective gloves.
Feet Wear appropriate footwear to prevent product from coming in contact with feet and
skin.
Section 7. Ecological Information

Environmental Not available Persistance/ Not available
Fate Bioaccumulation
Potential
BOD5 and COD Not available Products of Not available
Biodegradation
Additional Remarks No additional
remark.
Section 8. Disposal Considerations
Waste Disposal Spent/ used/ waste product may meet the requirements of a hazardous waste. Consult
your local or regional authorities. Ensure that waste management processes are in
compliance with government requirements and local disposal regulations.
Section 9. Transport Information
TDG Classification BENZENE, 3, UN1114, Special See Transportation of Dangerous
PGII (CL-TDG) Provisions for Goods Regulations.
Transport
Platinum (Petro-Canada, 2017b)
1. Hazard(s) identification
Classification
This chemical is considered hazardous by the 2012 OSHA Hazard Communication Standard
(29 CFR 1910.1200)
Flammable solids Category 2

Specific target organ toxicity (single Category 3
exposure) Target Organs - Respiratory
system.
Combustible dust Yes
Label Elements
Hazard Statements
Flammable solid
May form combustible dust concentrations in air
May cause respiratory irritation
Precautionary Statements
Prevention
Avoid breathing dust/fume/gas/mist/vapors/spray
Use only outdoors or in a well-ventilated area
Keep away from heat/sparks/open flames/hot surfaces. - No smoking
Ground/bond container and receiving equipment
Use explosion-proof electrical/ventilating/lighting/equipment
Wear protective gloves/protective clothing/eye protection/face protection
Inhalation
IF INHALED: Remove victim to fresh air and keep at rest in a
position comfortable for breathing Call a POISON CENTER or
doctor/physician if you feel unwell Fire
In case of fire: Use CO2, dry chemical, or foam for extinction
Storage
Store in a well-ventilated place. Keep container tightly closed
Store locked up
Disposal
Dispose of contents/container to an approved waste disposal plant
Hazards not otherwise classified (HNOC)
None identified
Other hazards
May cause drowsiness or dizziness. May cause pulmonary edema. May cause eye, skin, and
respiratory tract irritation.
2 . First-aid measures
General Advice If symptoms persist, call a physician.

Eye Contact Rinse immediately with plenty of water, also under the eyelids, for at
least 15 minutes. Get medical attention.
Wash off immediately with plenty of water for at least 15 minutes.
Skin Contact
Obtain medical attention.
Move to fresh air. If breathing is difficult, give oxygen. Obtain medical
Inhalation
attention.
Ingestion Clean mouth with water and drink afterwards plenty of water. Get
medical attention if symptoms occur.
Most important symptoms None reasonably foreseeable.
and effects
Notes to Physician Treat symptomatically
3 . Fire-fighting measures
Suitable Extinguishing Use water spray, alcohol-resistant foam, dry chemical or carbon
Media dioxide. Cool closed containers exposed to fire with water spray.
Specific Hazards Arising from the Chemical
Flammable. Keep product and empty container away from heat and sources of ignition.
Containers may explode when heated.
Hazardous Combustion Products

Carbon monoxide (CO) Carbon dioxide (CO2)
Protective Equipment and Precautions for Firefighters
As in any fire, wear self-contained breathing apparatus pressure-demand, MSHA/NIOSH
(approved or equivalent) and full protective gear.
NFPA
Health Flammability Instability Physical hazards
2 2 0 N/A
4 . Accidental release measures
Personal Precautions Ensure adequate ventilation. Use personal protective equipment.
Avoid dust formation.
Remove all sources of ignition. Take precautionary measures against
static discharges.
Environmental Precautions Should not be released into the environment. See Section 12 for
additional ecological
information.
Methods for Containment and Clean Sweep up or vacuum up spillage and collect in
suitable container for disposal. Keep in suitable, closed containers for disposal.
5. Handling and storage
Handling Wear personal protective equipment. Ensure adequate ventilation. Avoid

dust formation. Do not get in eyes, on skin, or on clothing. Avoid
ingestion and inhalation. Keep away from open flames, hot surfaces and
sources of ignition. Use only non-sparking tools. Use explosion-proof
equipment. Take precautionary measures against static discharges.
Storage Flammables area. Keep containers tightly closed in a dry, cool and well-
ventilated place. Keep away from open flames, hot surfaces and sources
of ignition.
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FACULTY OF ENGINEERING TECHNOLOGY

CHEMICAL ENGINEERING TECHNOLOGY

DALILA BINTI MOHAMAD NAWI 161341848

DR ALINA RAHAYU MOHAMED

DATE: 3 rd. DECEMBER 2019

1.1 Introduction of the product, characteristic and uses 1

1.1.2 The Production Capacities and Similar Plants operating in

1.2 Process alternatives 11

1.3 Summarize and compare the 3 shortlisted alternatives 17

1.5 Critical Assessment of The Chosen Process 24

1.5.1 Operating capacity of the plant based on literature background 24

1.5.2 Process chemistries for all process involved in the plant 25

CHAPTER 2 : MASS & ENERGY BALANCES 41

2.1 Summary of the Equipment in the Toluene Production Process 41

2.2 Plant Wide Mass Balance 42

2.2.1 Material balance for reactor (R-101) 42

2.2.2 Material balance for reactor (R-102) 43

2.2.3 Material balance for separator (T-100) 46

2.2.5 Sample calculation 52

2.3.1 Pump (P-101) 55

2.3.2 Evoporator (EV-103) 58

2.3.3 Heater (H-101) 67

2.3.4 Reactor (R-101) 70

2.3.5 Heater (H-102) 75

2.3.6 Reactor (R-102) 78

2.3.7 Cooler (E-101) 81

2.3.8 Expander (Ex-100) 84

2.3.9 Separator (T-100) 87

2.3.10 Distillation column (D-100) 90

2.3.11 Pump (P-103) 95

2.3.12 Pump (P-104) 97

2.4 Utilities and Waste Handling 98

2.4.2 Waste Handling 99

2.5 Calculation verification 100

2.5.1 Reactor 102

2.5.2 Mass Transfer Equipment 104

2.5.3 Heat Transfer Equipment 109

2.5.4 Reactor (R-101) 112

2.5.5 Separator (T-100) 114

2.5.6 Cooler (E-100) 116

CHAPTER 3: SIZING CAPACITY 118

3.1.1 Oil-gas horizontal separator(T-100) 118

3.1.1.1 Residence time for separation 119

3.1.1.2 Diameter of separator vessel 120

3.1.1.3 Hold-up time for separation 120

3.1.1.4 Calculation of new parameter for separator 120

3.1.1.6 Mechanical design for oil-gas horizontal separator 124

3.1.2 Distillation column (D-100) 134

3.1.2.2 Minimum number of equilibrium stages 135

3.1.2.3 Theoretical stage 136

3.1.2.4 Location of the feed in at distillation column 137

3.1.2.5 Diameter and Height of the distillation column. 137

3.1.2.6 Plate Hydraulic Design 141

3.1.2.7 Mechanical design for oil-gas horizontal separator 148

3.1.3 Design of Condenser(E-100) 157

3.1.3.1 Shell-side coefficient 158

3.1.3.2 Tube-side coefficient 159

3.1.3.3 Overall Coefficient 160

3.1.3.4 Shell-side pressure drop 161

3.1.3.5 Calculation for number of tubes 161

3.1.3.6 Calculation of Shell Diameter 162

3.1.3.7 Mechanical design for condenser (E-100) 164

3.1.4 Design of Reboiler (Thermosyphons) (RB-100) 167

3.1.4.1 Tube-side pressure drop 170