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ABSTRACT:
This report gives us the information regarding all the expenditure involved in the production
of ethyl benzene. All the information required for the preliminary design was provided by the
course coordinator.
The capital cost required for various equipment, utility costs, working labour costs, funds
required to purchase land and raw materials were estimated by taking appropriate assumptions
in calculations. The non-discounted and discounted cash flow diagrams were generated. A
preliminary Risk evaluation in the cost estimations was done using Sensitivity Analysis and
Profit Margin Analysis. Further, the Monte Carlo analysis was done to get a complete financial
picture of the project.
The Life Cycle Assessment was done for the product and entire process of production of
ethylbenzene to know the quantified environmental impact and energy consumption by the
plant, works as a primary tool used to support decision-making for Sustainable Development.
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PAGE
Contents NO.
Abstract 2
Result of LCA 11
Conclusion 12
References 12
Appendix 13
Estimation of cost of Raw materials, Revenue, Capital cost for
Equipment, Cost of utility and cost of labour 13
Cost of Raw materials
13
Capital cost of equipment
14
Utilities cost
18
Labour Cost 20
Manufacturing Costs
20
Economic Analysis
22
INTRODUCTION:
The topic of our interest is Design and Economics of the production plant of ethylbenzene. On
the basis of given data Capital cost for equipment, utilities, Labour cost and Manufacturing
cost were estimated after the assumption of location of plant.Later the profitability analysis
was done to get the annual revenue generation and cash flow sheets were prepared.Finally Life
cycle assessment for the entire process has been done to know the environmental impact of the
process.
ASSUMPTION:
• Plant is constructed in Surat, Dist- Adajan Patiya.
• The Plant construction period is of one year.
• The Chemical Engineering Plant Cost Index (CEPCI) was taken as 776.9 for the year
2022
• The depreciation method used is the MACRS 5-year schedule.
• The taxation rate is taken as 30 + 12%.
• The project is designed for plant life of 20 years.
• The Salvage value of the plant is zero
• The assumed discount rate is 10%
RESULTS:
Process flow Diagram: Figure 1: Ethylbenzene Process Flow Diagram
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0.6 7.2e-3
6.4e-3
0.5
5.6e-3
0.4 4.8e-3
4.0e-3
0.3
3.2e-3
0.2 2.4e-3
0.1 1.6e-3
0.8e-3
0.0
0.0e-3
Total IN: Electricity grid mix (producti...
IN: Electricity grid mix (producti... IN: Electricity grid mix (producti... Total IN: Electricity grid mix (produc...
IN: Electricity grid mix (produc... IN: Electricity grid mix (produc...
P a g e | 11
CONCLUSION:
• The plant is setup in Surat, Dist- Adajan Patiya. Area of land required 5 Acre, the
land was bought at 55 lac/acre, which comes out to be ₹2.75 Cr
• The plant construction period is 1 Year and the life of plant is 20 years
• The fixed capital investment (FCIL ) was estimated to be ₹ 1504598303
and working capital investment is ₹742822009, Salvage value was taken
to be 0
• Annual Cost of manufacturing is ₹866242029 and the revenue generated per year was
found to be ₹20827600800
• The net present value (NPV) is ₹5344.83 Cr
• Discounted payback period (DPBP) of 1.15 years, Present Value Ratio (PVR) of
33.47, and Discounted Cash flow diagram of return (DCFROR) of 350.58% indicates
the
healthy profitability aspects of the project.
• From the sensitivity analysis, NPV is least sensitive to fluctuations in FCIL and
significantly sensitive to COMd and revenue.
• Monte-Carlo simulations indicated the probability of profit as 61.20%.
• The product should be exported to locations of high demand during shortage times
and sold at a minimum ideal price of ₹ 250/kg to ensure good profit margins.
• The detailed environmental impact of the project was quantified using LCA
REFERENCES:
• https://www.dnaindia.com/mumbai/report-industries-seek-power-
tariff-cut-in-maharashtra-2778706
• https://www.statista.com/statistics/1171072/price-benzene-forecast-
globally/#:~:text=The%20average%20global%20price%20of,U.S.%
20dollars%20per%20metric%20ton
• https://www.indiamart.com/proddetail/ethylbenzene-
11667336712.html
• https://www.toweringskills.com/financial-analysis/cost-
indices/#chemical-engineering-plant-cost-index-cepci
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APPENDIX:
The production of EB takes place via the direct addition reaction between ethylene and
benzene:
The reaction between EB and ethylene to produce DEB also takes place:
Additional reactions between DEB and ethylene yielding triethylbenzene (and higher) are
also possible. However, in order to minimize these additional reactions, the molar ratio of
benzene to ethylene is kept high, at approximately 8:1. The production of DEB is
undesirable, and its value as a side product is low. In addition, even small amounts of DEB in
EB cause significant processing problems in the downstream styrene process. Therefore, the
maximum amount of DEB in EB is specified as 2 ppm. In order to maximize the production
of the desired EB, the DEB is separated and returned to a separate reactor in which excess
benzene is added to produce EB via the following equilibrium reaction:
The incoming benzene contains a small amount of toluene impurity. The toluene reacts with
ethylene to form ethyl benzene and propylene:
Revenue
Cost of Ethyl benzene = ₹ 250/kg
Ethyl benzene produced annually = 83310403kg
Total revenue generated annually = ₹ 20827600800
Cost of Land
Area of land required = 20000 m2 (5 acres approximately)
Cost of land for 5 acres = ₹ 28000000/-
2. REACTOR
K1 = 3.497 K2= 0.4485 and K3 =0.1074
CEPCI at 2001 = 397, CEPCI at 2022= 776.9
logCp0= K1+ K2 (logA)+ K3(logA)2, so Cp = $18293.87
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3. VESSELS
Design pressure, P= 2.5
K1=3.55565, K2=0.3776 and K3=0.0905
CEPCI at 2001 = 397, CEPCI at 2022= 776.9
logCp0= K1+ K2 (logA)+ K3(logA)2, so Cp = $15409.55
Fp =
If Fp<1, then Fp= 1
Identification number = 18 gives Fp=1
Also, B1=1.49 B2=1.52
Fbm=B1+B2(Fp)(Fm)= 2.853776
Cbm = Cp*Fbm = $43975.396
At base condition, Fp=0.8972 i.e = 1, , Fm=1, Fbase=B1 + B2 = 3.01
Cbase = $ 51890.97
4. PUMPS
Design pressure, P= 1.1 bar
K1=3.4771, K2=0.135 and K3==0.1438
CEPCI at 2001 = 397, CEPCI at 2022= 776.9
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5. DISTILLATION COLUMN
K1 = 3.4974, K2 = 0.4485 and K3 = 0.1074
CEPCI at 2001 = 397, CEPCI at 2022 = 776.9
logCpo = K1 + K2 (logA) + K3 (logA)2, so Cp = $ 2636.085
Fp=
Identification number = 18 gives Fm=3.1
Also, B1 = 2.25, B2 = 1.82 Fbm = B1 + B2(Fp)(Fm) = 4.182
Cbm = Cp*Fbm = $ 279529.7
For trays,
K1 = 2.9949, K2 = 0.4465 and K3 = 0.3961
CEPCI at 2001 = 397, CEPCI at 2022 = 776.9
logCpo = K1 + K2 (logA) + K3 (logA)2, so Cp = $1490.64
N = 28
Fq = 1 (N>=20),
Identification number = 61, Fbm = 1.8
Cbm = Cpo*N*Fbm*Fq = $343952.5
UTILITY COST
1. Electricity
For electricity cost total annual electricity consumption was calculated which turns out to be
184836 kWh. The cost of industrial electricity in Gujarat is ₹ 5.925/kWh. This gives an
annual electricity cost of ₹ 1095153.3.
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bfw to E-301 851 0.00023638 0.236388 0.1058279 0.003 776.9 1.96 82.22360025 45971790.47
bfw to E-302 1121 0.00031138 0.311388 0.0803554 0.003 776.9 1.96 62.43403642 45982480.52
bfw to E-303 4341 0.00120583 1.205833 0.0208025 0.003 776.9 1.96 16.16738118 46109969.31
bfw to E-304 5424 0.00150666 1.506666 0.0166629 0.003 776.9 1.96 12.95130282 46152848.3
cw to E-305 118300 0.03286111 32.86111 0.0008307 0.003 776.9 1.96 0.651311 50621924.18
lps to E-306 4362 0.06028192 1.211666 0.0000193 0.0041 776.9 1.96 0.0230466751 66047945.28
cw to tE-307 174100 0.04836111 48.36111 0.0005869 0.003 776.9 1.96 0.4618770149 52831201.91
hps to E-308 3124 1.44629629 0.867777 0.0000261 0.0034 776.9 1.96 0.0269653671 55345553.18
cw to E-309 125900 0.03497222 34.97222 0.0007848 0.003 776.9 1.96 0.6156323407 50922829.39
459986542.5
3. Natural gas
Given Energy consumed per hour in Fired Heater is 22376 MJ/h
From the given thermal efficiency, the Energy that should be supplied by combusting the
Natural Gas will be = 22376/0.75 = 29834.67 MJ/h
Using the Gross Calorific value of Natural gas, the required flow rate of Natural Gas was
evaluated and the cost was calculated
Gross calorific value 50MJ/kg
Flow rate supplied 29834.67/50 = 596.69 kg/hr
Cost per Kg 53.04 Kg
Annual consumption 596.69*24*365 = 5.227 kilo ton
Annual cost = 5.227*106 * 53.04 = Rs 277.24 million
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Now,
The Total Annual Utility cost = Annual cost of electricity + Annual cost of Water and Steam
+ Annual cost of Natural Cost
Total Annual Utility cost = ₹1095153.3+ ₹ 459986542.5 + ₹ 277240313.4
Total Annual Utility cost = ₹ 738322009.2
Labour Cost
Particulate processing steps P = 0
Non-particulate processing steps NNP = 16
Number of working weeks in a year = 49 (excluding 15 public holidays and 7 paid leaves)
Number of working shifts in a week = 5 (excluding 2 weekly off-day)
Hence, Number of working shifts in a year = 49 × 5 = 245
Number of working hours per operator in a year = 245 × 8 = 1960
Number of operators per shift = (6.29 + 31.7 P2 + 0.23 NNP) 0.5 = 3.1575
Total operators = 4.4694 × 3.1575 = 14.112
Manufacturing costs
Type of Manufacturing cost Value (₹)
Labour 4500000
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Economic Analysis
Cash Flow Analysis
The cash flow analysis was done for the plant. The data used in the analysis are summarised
in Table 6. The method of Depreciation used in the cash flow analysis is Modified
Accelerated Cost Recovery System (MACRS) with a 5-year schedule. The details of MACRS
depreciation calculations are summarised in Table below.
in Cr
FCI GR ₹ 153.21
Land ₹ 2.75
FCI L ₹ 150.46
Working Capital, WC ₹ 27.58
Salvage, S ₹ 0
Life of Equipment, n 20.00
Depreciable capital, D ₹ 150.46
Revenue, R ₹ 2,082.76
Manufacturing cost, COM d ₹ 866.24
PROFIBILITY ANALYSIS
• Time criterion of profitability
The discounted worth of Land = ₹ -2.75 Cr
The discounted worth of Working capital = ₹ -25.07 Cr
Sum of the discounted worth of Land and WC = ₹ -27.82 Cr
From interpolating in the cumulative cash flow diagram, we get
Discounted payback period (DPBP) = 1.15 years
So, a period of 1.15 years after the plant start-up is required to recover our FCIL
DPBP is just 1.15 years which means all our FCIL is quickly recovered compared to
the total plant life of 20 years
We know that, Net Present Value at Discounted Cash Flow Rate of Return
(DCFROR) = ₹ 0
From interpolating the above data, we get
Discounted Cash Flow Rate of Return (DCFROR) = 350.58 %
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SENSIVITY ANALYSIS
The evaluation of risk in evaluating profitability is done using the Sensitivity Analysis
applied to NPV. The variations in NPV value due to the effect of dynamic market
fluctuations are quantified and the Sensitivity coefficients are determined.
Minimum -227.85
Maximum 806.83
Mean 31.17