PRODUCTION OF

ACETIC ACID
MUHAMMAD IKMAL BIN HAMID
MUHAMMAD MUSTAQIM SAFIY BIN MUSTAFA MAAROF
MUHAMAD AL-NAZREEN BIN AKHIRUDDIN
MUHAMMAD AIZAT EDZMIR BIN KHIDZIR
MUHAMMAD ALIFF BIN MUHAMMAD SOHAIMI
ORGANIZATION STRUCTURE

CHIEF EXECUTIVE OFFICER

MUHAMMAD IKMAL BIN HAMID

SALES AND MARKETING DIRECTOR

MUHAMMAD AIZAT EDZMIR BIN KHIDZIR

INTELECTUAL PROPERTY DIRECTOR

MUHAMAD AL-NAZREEN BIN AKHIRUDDIN

CHIEF TECHNOLOGIST
MUHAMMAD MUSTAQIM SAFIY BIN MUSTAFA MAAROF

FINANCE DIRECTOR
MUHAMMAD ALIFF BIN MUHAMMAD SOHAIMI
 INTRODUCTION

The objective of the development of new acetic acid processes has been to reduce raw
material consumption, energy requirements, and investment costs.
Significant cost advantages resulted from the use of carbon dioxide and of low-priced
methane as feedstocks
Acetic acid is an important commodity used in chemical industries, with about 9 million tons
of world demands per year.
The demand is estimated to grow at a very high pace, next only to ester solvents, which is
the strongest growth segment of acetic acid.
METHANE

Methane is a chemical compound with the chemical formula CH4. It is a

group 14 hydride and the simplest alkane
The main component of natural gas. The relative abundance of
methane on Earth makes it an attractive fuel
Methane is used in industrial chemical processes and may be
transported as a refrigerated liquid
Methane is important forelectricity generation by burning it as a fuel in
agas turbineorsteam generator.
Compared to otherhydrocarbon fuels, methane produces lesscarbon
dioxidefor each unit of heat released.
 ACETIC ACID

Acetic acidis anorganic compoundwith thechemical formulaCH3COOH (also written as

CH3CO2H or C2H4O2).
Acetic acid is the main component ofvinegarapart from water.
It is an importantchemical reagentand industrial chemical.
The global demand for acetic acid is about 6.5 millionmetric tons per year.
The largest single use of acetic acid is in the production of vinyl acetatemonomer, closely
followed by acetic anhydride and ester production.
The majorestersof acetic acid are commonly used as solvents forinks,paintsandcoatings.

CH4 + 2O2 CO2 + 2H2O

CH4 + CO2
CH3COOH
SCREENING AND SCORING
 SITE LOCATION

Site selection for a plant, requires careful considerations of the numerous factors
Decisions are strategic, long-term and non-repetitive in nature.
A suitable site must be found for a new project, and the site and equipment layout planned
Provision must be made for the ancillary buildings and services needed for plant operation
and for the environmentally acceptable disposal of effluent.
 GENERAL CONSIDERATION ON
THE SITE SELECTION
Location with respect to marketing area
Raw material supply
Transport facilities
Availability of labor
Availability of utilities: water, fuel, power
Availability of suitable land
Environmental impact including effluent disposal
Local community consideration
Climate
Political and strategic consideration
 LIST OF SITE FOR
CONSIDERATION
From the factors that were listed, we have choose three suitable places to become the site
for our plant.
The listed sites are: Sl.
No.
Factor Factor
Weigh
Site Rating 0-5 Sliding scale

ts
1. Kerteh, Terengganu
Kerteh Gebeng Bintulu
2. Gebeng, Pahang 1. Location 5 4 3 4
2. Industrial 4 5 4 4
3. Bintulu, Sarawak Infrastructure
3. Community 4 4 3 4
Infrastructure
4. Availability of water 4 5 5 5
5. Effluent disposal 4 4 4 4
6. Availability of Power 4 4 4 4
7. Availability of Gas 2 4 4 4
8. Site size and Nature 3 5 4 5
9. Ecology and Pollution 2 3 3 3
PROCESS FLOW DIAGRAM (PFD)

Figure 1 : Selected PFD for production of acetic acid

 EQUIPMENTS DESIGN

REACTOR
Rule 8 High production rates at short residence times (sec or min).
DESIGN TEMPERATURE 709.878 K
LIQUID VOLUME 27.8 L
VESSEL DIAMETER 0.1524 m
VESSEL TANGENT TO 1.524 m
TANGENT HEIGHT

DESIGN GAUGE 577689 N/sqm-gauge

PRESSURE
VOLUME OF REACTOR 4995.7 L
EQUIPMENT Jacketed nonagitated
DESCRIPTION
EQUIPMENT WEIGHT 453.592 kg

REACTOR 1
 REACTOR 2

DESIGN TEMPERATURE 709.878 K

LIQUID VOLUME 27.8 L

VESSEL DIAMETER 0.1524 m

VESSEL TANGENT TO 1.524 m

TANGENT HEIGHT
DESIGN GAUGE PRESSURE 577689 N/sqm-gauge

VOLUME OF REACTOR 3551.52 L

Conversion (methane)
EQUIPMENT DESCRIPTION Jacketed nonagitated

EQUIPMENT WEIGHT 453.592 kg

X = 0.97
EQUIPMENTS DESIGN

SEPARATOR

Rule 3 Vertical vessel
Rule 4 L/D between 2.5 and 5 with optimum at 3.0
Rule 5 Liquid holdup time is 5 min based on volume of vessel
Rule 9 Gas velocity u is given by
DESIGN TEMPERATURE 606.234 K
OPERATING TEMPERATURE 578.457 K
VESSEL DIAMETER 0.9144 m
VESSEL HEIGHT 3.6576 m
VOLUME OF SEPARATOR 2401.9 L
EQUIPMENT DESCRIPTION VERTICAL
EQUIPMENT WEIGHT 1179.34 kg
 EQUIPMENTS DESIGN

HEATER COOLER
TUBE DESIGN 616.483 K TUBE DESIGN TEMPERATURE 709.878 K
TEMPERATURE TUBE OPERATING 308.15 K
TUBE OPERATING 588.706 K TEMPERATURE
TEMPERATURE TUBE DESIGN GAUGE 415796 N/sqm-gauge
TUBE DESIGN GAUGE 243421 N/sqm-gauge PRESSURE
PRESSURE TUBE OUTSIDE DIAMETER 0.0254 m
TUBE OUTSIDE DIAMETER 0.0254 m TUBE LENGTH EXTENDED 6.096 m
TUBE LENGTH EXTENDED 6.096 m HEAT TRANSER AREA 0.3966 m2
HEAT TRANSER AREA 0.498 m2 EQUIPMENT DESCRIPTION Double Pipe
EQUIPMENT DESCRIPTION Double Pipe
EQUIPMENT WEIGHT 122.47 kg EQUIPMENT WEIGHT 127 kg
 COSTING
AND
PROFITABILITY
ANALYSIS
ESTIMATING DESIRED PURCHASED COST

Equipment
(2001) C2 (2016)
number
1 1 3.29 $1 807.17 $5 945.59 $8 402.3 x (2
Heater units)

- - 4.0 $7 186.21 $28 744.84 $40 622.15 (2

Reactor units)

1 1 4.07 $4 825.03 $19 637.87 $27 752.2 x (2

Separator units)

1 1 3.29 $1 684.61 $5 542.37 $7 832.47

Cooler

Total $161 385.77

Results of Capital Cost Estimation

TOTAL CAPITAL COST

FIXED CAPITAL ESTIMATIONS $292 108.24

WORKING CAPITAL $43 816.24
COST OF LAND , $750 000

TOTAL CAPITAL COST $1 085 924.48

 RAW MATERIAL COST

needed
Air = 85724.7 L/hr
Cost per unit = $0.35/m3

$254 047/yr
Methane needed = 24822.5 L/hr
Cost per unit = $0.42/m3

Total cost of raw material = $339 397/yr

 ELECTRICITY COST

From data given in Aspen , the energy consumed for total plant operation are calculated in
electricity.

Voltage used = 2.3 kV 30 kV

Rate = $0.06/ kWh
Quantity used = 3550 kW
Total of electric used = $213/hr
= $1 840 320/yr
 WASTEWATER TREAMENT COST

From
stream 12 . Volume per hour of wastewater is 582.623 L/hr equivalent to 0.5826 m 3/hr
For primary filtration, cost is $41/1000m3

Cost hourly = 0.5826 m3/hr

= $0.0238/hr
= $205.623/yr
ESTIMATION OF MANUFACTURING
COST

OPERATING LABOR COST $811200/yr

RAW MATERIALS $349,307.39/yr
ELECTRICITY $2,751,148.8/yr
WASTE WATER TREATMENT $205.623/yr
REVENUE FROM SALE

R =

= $ 5 905 872/yr

COM d 0.180 FCI 2.73COL 1.23(CUT CWT C RM )
= 0.18(292,108.24) + 2.73(811 200) + 1.23 (2 385 340)
= $5 201 124/yr

= 0.280(292,108.24) + 2.73(811200) +1.23(2 385 340)

= $5 230 334/yr

= 0.177(811200) + 0.009(292,108.24) + 0.16(5 230 334)

= $983 065/yr

= 0.708(811200) +0.068(292,108.24) +0.1(292,108.24)
= $623 404/yr

= 2 385 340 +1.33(811200) +0.069(292,108.24) + 0.03(5 230 334)

= $3 641 301/yr
NONDISCOUNTED CASH FLOW

End of
Year (k)
Investment dk - d] k R COM d
(R COM -
+
dk
) x (1-t)
dk
Cash
Flow
Cumulative
Cash Flow
0 (75)* - - - - (75) (75)
1 17.52 - - - - (17.52) (92.52)
2 ( 11.68 + 4.4)= - - - - (16.08) (108.6)
16.08

3 5.84 23.36 591 520 48.19 48.19 (60.41)

4 5.84 17.52 591 520 48.19 48.19 (12.22)
5 5.84 11.68 591 520 48.19 48.19 35.97
6 5.84 5.84 591 520 48.19 48.19 84.16
7 5.84 0 591 520 48.19 48.19 132.35
8 - 0 591 520 46.15 46.15 178.5
9 - 0 591 520 46.15 46.15 224.65
10 - 0 591 520 46.15 46.15 270.8
11 - 0 591 520 46.15 46.15 316.95
12 - 0 591 520 46.15 46.15 363.1
 PBP 0.61 years

CCP $363.1 x 104

CCR 3.01

ROROI 102% p.a

 DISCOUNTED CASH FLOW

End of Year Non-discounted cash flow discounted cash flow Cumulative discounted cash
(k) flow
0 (75) (75) (75)
1 (17.52) (17.52)/1.15 = (15.23) (90.23)
2 (16.08) (16.08)/1.152 = (12.16) (102.39)
3 48.19 48.19/1.153 = 31.69 (70.7)
4 48.19 48.19/1.154 = 27.55 (43.15)
5 48.19 48.19/1.155 = 23.96 (19.19)
6 48.19 48.19/1.156 = 20.83 1.64
7 48.19 48.19/1.157 = 18.12 19.76
8 46.15 46.15/1.158 = 15.09 34.85
9 46.15 46.15/1.159 = 13.12 47.97
10 46.15 46.15/1.1510 = 11.41 59.38
11 46.15 46.15/1.1511 = 9.92 69.3
12 46.15 46.15/1.1512 = 8.63 77.93
Discount rate 15%

DPBP 0.74 years

NPV $77.93 x 104

PVR 1.76