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Production of Phenol and Acetone from Propylene and Benzene through Cumene Process
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i
MAPUA INSTITUTE OF TECHNOLOGY AT LAGUNA
Academic Year 2014 - 2015
PRODUCTION OF PHENOL-ACETONE FROM PROPYLENE AND BENZENE
THROUGH CUMENE PROCESS
Arban L. LEGASPI
Edrian A. MAÑALONG
Myke Vivienne F. SALVACION
Engr. Marlon O. Martinez
Submitted to the Faculty of Malayan Colleges Laguna
In Partial Fulfilment of the Requirements for the degree of
Bachelor of Science in Chemical Engineering
ii
The plant design attached hereto, entitled “PRODUCTION OF PHENOL-ACETONE
FROM PROPYLENE AND BENZENE THROUGH CUMENE PROCESS”,
prepared and submitted by Arban L. Legaspi, Edrian A. Mañalong, and Myke Vivienne
F. Salvacion in partial fulfillment of the requirements for the degree of Bachelor of Science
in Chemical Engineering is hereby accepted.
i
Copyright
“The author and the adviser authorize consultation and partial reproduction of this thesis
for personal use. Any other reproduction or use is subject to copyright protection. Citation
should clearly mention the reference of this work.”
Malayan Colleges Laguna, November 2014
The Adviser The Authors:
Engr. Marlon O. Martinez Arban L. Legaspi
Edrian A. Mañalong
Myke Vivienne F. Salvacion
ii
Biographical Sketch
ARBAN L. LEGASPI was born September 23, 1993 in Calamba, Laguna, Philippines. He
graduated from St. Peter Academy and is currently taking up Bachelor of Science in
Chemical Engineering at the Mapua Institute of Technology at Malayan Colleges Laguna.
He is a member of the Philippine Institute of Chemical Engineers - Junior Chapter Luzon
(PICHE) and Association of Chemical Engineering Students – Malayan Colleges Laguna
(ACES-MCL). He is a good team player who can absorb, understand, and consider ideas and
points of view from his colleagues.
EDRIAN A. MAÑALONG was born June 1, 1994 in San Pedro, Laguna, Philippines. He
graduated from Santa Rosa Science and Technology High school and is currently taking
up Bachelor of Science in Chemical Engineering at the Mapua Institute of Technology at
Malayan Colleges Laguna. He is a member of Philippine Institute of Chemical Engineers
(PICHE), Inc. – Junior Chapter Luzon and Association of Chemical Engineering Students
– Malayan Colleges Laguna (ACES-MCL). He was a dean’s lister (1st term, S.Y. 2013-
2014). He also competed in a chemical engineering quiz show held at the University of the
Philippines Diliman where his team won third place. He firmly believes that success comes
to those who work hard for it.
MYKE VIVIENNE F. SALVACION was born November 14, 1993 in San Leonardo,
Nueva Ecija, Philippines. She graduated from Holy Rosary College of Santa Rosa, Laguna
and is currently taking up Bachelor of Science in Chemical Engineering at the Mapua
Institute of Technology at Malayan Colleges Laguna. She is a member of the Philippine
Institute of Chemical Engineers - Junior Chapter Luzon (PICHE) and Association of
Chemical Engineering Students – Malayan Colleges Laguna (ACES-MCL). She attended
several leadership training programs and seminars that developed her character and
improved her level of competency. She prioritizes God above all before herself.
iii
Acknowledgement
This Plant design proposal would not be possible without the able guidance,
generous assistance and supervision of several individuals who had given their time and
effort to assist us, voiced out their concerns and guided us towards the fruitful and timely
completion of this work. They served as our mentors during the entire course of this project.
We would like to express our deepest appreciation to our adviser, Engr. Marlon
O. Martinez, who has the attitude and the substance of a genius: he continually and
patiently provided us with the necessary information required for the success of our design.
Without his help and support, the completion of this proposal design would not have been
possible. We would also like to extend our sincere gratitude to Engr. Rommel Santos for
sharing his experiences and opinions with regard to the technical side of our proposal.
The following individuals and groups also contributed to our success in completing
this work.
Engr. Jesunino Aquino
Engr. Rommel Santos
Engr. Marlon Martinez
Dr. Liza Patacsil
Our supportive parents
Fellow ChE batchmates
iv
Abstract
The aim of this work is the intensification of an industrial-scale production process of
phenol and acetone from propylene and benzene through the cheapest and most reliable
technology, the cumene process, to obtain higher profitability and reduce the energy
requirements of the process. In the first step, the demand and supply of the products and
raw materials of the process was analyzed and the capital requirements of the plant were
obtained using the class 5 estimate. The next step comprised of the simulation of the main
process and utilities using ASPEN HYSYS version 8.0. Parametric optimization was
carried out to adjust the process parameters and obtain an efficient and economically
feasible process. Consecutively, ISBL and OSBL equipment were sized and their costs
were determined using the methods presented in Towler. The final step comprised of a
class 3 estimation of the economic feasibility of the project. The capital investment of the
project remained almost intact at around 4.5 billion PHP. The IRR was 27% and the return
of investment was expected at year 7 starting from the construction period. Overall, the
designers find the project feasible and they recommend continuing the project to its
procurement, commissioning, and operational phase.
v
Executive Summary
Finding a configuration and operational conditions of a process in which a chemical
is manufactured in a reliable and economical manner, considering several factors such as
low energy consumption, low initial capital investment, low or negligible environmental
impact, and high product yield is the main goal of designing this plant which can produce
phenol and acetone from propylene and benzene through cumene process. Optimization of
the process involved was conducted when the flow sheet of the base case and detailed heat
and material balances of the process were available. Furthermore, the economic aspects of
the plant, including the sizing of all the equipment (ISBL and OSBL), capital investment,
and utility requirements, should be considered and evaluated thoroughly. In this paper, the
optimization of the process that involves the alkylation of propylene with benzene to
produce phenol and acetone through the renowned cumene process was carried out to make
the process more effective, reliable, and thus more profitable.
As compared to other processes available, cumene process has the lowest cost of
production (Tyman, 1996). Currently, the cumene process is universally favored in the
United Kingdom (UK) and United States of America (US) because of its lower cost and
higher product yield, thus this process will be adapted in this project. The huge majority of
cumene manufactured worldwide is utilized in the production of phenol and acetone
(Schmidt, 2005). Reactions occur in the presence of various catalyst.
In this project, the catalyst used were zeolites for the alkylation of benzene with
propylene (Norouzi, Hasani, Haddadi-Sisakht, & Mostoufi, 2014), copper oxide (CuO)
nanoparticles for the oxidation of cumene to produce cumene hydroperoxide (CHP)
(Zhang, Wang, Hongbing, Wu, & Zeng, 2007), and sulfonic acid resins for the cleaving of
hydroperoxide to produce phenol and acetone (Huang, Han, Wang, & Jin, 2002). The
following equations describe the reactions involved in the process:
𝑪𝟔𝑯𝟔 + 𝑪𝟑𝑯𝟔 → 𝑪𝟗𝑯𝟏𝟐
𝐵𝑒𝑛𝑧𝑒𝑛𝑒 + 𝑃𝑟𝑜𝑝𝑦𝑙𝑒𝑛𝑒 → 𝐶𝑢𝑚𝑒𝑛𝑒 (𝑖𝑠𝑜𝑝𝑟𝑜𝑝𝑦𝑙 𝑏𝑒𝑛𝑧𝑒𝑛𝑒)
𝑪𝟗𝑯𝟏𝟐 + 𝑪𝟑𝑯𝟔 → 𝑪𝟏𝟐𝑯𝟏𝟖
𝐶𝑢𝑚𝑒𝑛𝑒 + 𝑝𝑟𝑜𝑝𝑦𝑙𝑒𝑛𝑒 → 𝑃𝐷𝐼𝐵 (𝑝 − 𝑑𝑖𝑖𝑠𝑜𝑝𝑟𝑜𝑝𝑦𝑙 𝑏𝑒𝑛𝑧𝑒𝑛𝑒)
𝑪𝟔𝑯𝟓𝑪𝑯(𝑪𝑯𝟑) + 𝑶𝟐 → 𝑪𝟔𝑯𝟓𝑪(𝑪𝑯𝟑)𝟐𝑶𝑶𝑯
𝐶𝑢𝑚𝑒𝑛𝑒 + 𝑂𝑥𝑦𝑔𝑒𝑛 → 𝐶𝑢𝑚𝑒𝑛𝑒 𝑃𝑒𝑟𝑜𝑥𝑖𝑑𝑒 (𝐶𝐻𝑃)
𝑪𝟔𝑯𝟓𝑪(𝑪𝑯𝟑)𝟐𝑶𝑶𝑯 → 𝑪𝟔𝑯𝟓𝑶𝑯 + 𝑪𝑯𝟑𝑪𝑶𝑪𝑯𝟑
𝐶𝑢𝑚𝑒𝑛𝑒 𝐻𝑦𝑑𝑟𝑜𝑝𝑒𝑟𝑜𝑥𝑖𝑑𝑒 → 𝑃ℎ𝑒𝑛𝑜𝑙 + 𝐴𝑐𝑒𝑡𝑜𝑛𝑒
The first license for cumene production belongs to a corporation called UOP. Their
process involves reactions that occur in gas phase with the presence of SPA catalyst
(Stefanidakis & Gwyn, 1977). Another license belongs to Monsanto and Kellogg, which
uses a mixture of AlCl3 and HCl as the catalyst in a homogeneous liquid-phase reaction of
benzene and propylene. The transalkylation of PIPB is also possible in this process. Thus,
this process has a high yield. However, corrosion of pipes and equipment are still a problem
(Canfield, Cox, & McCarthy, 1986). Liquid-phase and zeolite-based catalytic processes
(1)
(2)
(3)
(4)
were already developed by CDTech, Mobil-Badger, and UOP to produce cumene
(Norouzi, Hasani, Haddadi-Sisakht, & Mostoufi, 2014).
Cumene can be further processed to produce more valuable products like phenol
and acetone through the cumene/hock process. This process deals with the oxidation of
cumene hydroperoxide (CHP), and is considered to be the key reaction of industrial phenol-
production process. Since the 1970’s, many investments were made for cumene oxidation.
For all these catalyst systems, copper compounds were excellent catalysts not only with
regard to the reaction activity but also with regard to the CHP selectivity (Zhang, Wang,
Hongbing, Wu, & Zeng, 2007).
At present, about 94.5% of phenol in the chemical market is manufactured by
cumene decomposition, which was developed in the 1950s. There are six types of catalysts
that can be used for CHP decomposition; these are Freidel–Crafts catalysts such as AlCl3,
inorganic and organic acids, silicates, metallic oxides such as Al2O3 and TiO2,
phosphorous compounds such as PCl3, PCl5 and POCl3, and sulfonated phenol
formaldehyde resins and sulfonated styrene resins. The solid acid catalysts have some
important advantages including adequate catalytic activity, less byproducts, no erosion,
easy separation of catalysts and products and easy catalyst recovery and recycling. CHP
decomposition catalyzed by sulfonic acid resins offers conversion greater than 99% and
selectivity over 98% (Huang, Han, Wang, & Jin, 2002).
In the present work, the phenol-acetone production plant was simulated using the
Aspen Hysys V8.0. The temperature and other relevant parameters were obtained by
optimization. The optimized value obtained can provide a lot of insight before the actual
plant commissioning is done. Furthermore, sizing and evaluating the economics of the
plant follows with a definitive class 3 estimate.
vi
Table of Contents
Copyright i
Biographical Sketch ii
Acknowledgement iii
Abstract iv
Executive Summary v
Table of Contents vi
Market Study 1
Process Description 48
Heat and Material Balance 58
Equipment Sizing and Specification 67
Economic Analysis 140
References 197
Appendices 205
List of Tables vii
List of Figures viii
List of Appendices ix
Definition of Terms x
1
Market Study
Introduction
Phenol and Acetone are one of the most important intermediates of the chemical
industry. The demand for these chemicals increases over the years and it is forecasted to
follow this trend, which, together with its wide range of applications, provides an excellent
platform for the design of a suitable and profitable process for phenol and acetone
production in the Philippines.
Production of phenol and acetone from propylene and benzene is possible through
the process of cumene. Other types of technologies exist to produce these products but the
cumene process is proven to be more cost-effective and efficient. Propylene and Benzene
are raw materials that are produced locally in the Philippines by the large petroleum
industry.
Phenol is an aromatic organic compound with the molecular formula C6H5OH
which is also known as carbolic acid. It is a white crystalline solid that is volatile having
molecule consists of a phenyl group (-C6H5) bonded to a hydroxyl group (-OH). Phenol is
mildly acidic, but requires careful handling due to its tendency to cause chemical burns.
The major uses of phenol involving its conversion to precursors to plastics,
consumes two thirds of its production. Bisphenol-A which is produced from condensation
of phenol with acetone, is a key precursor to polycarbonates and epoxide resins.
Condensation of phenol, alkylphenols, or diphenols with formaldehyde gives phenolic
resins, in which a famous example of it is the Bakelite. Partial hydrogenation of phenol
gives cyclohexanone, a precursor to nylon.
2
Phenol is also a versatile precursor to a large collection of drugs which is mostly
aspirin but also many herbicides and pharmaceutical drugs. It is also used as an oral
anesthetic/analgesic in products such as Chloraseptic or other brand name and generic
equivalents which is commonly used to temporarily treat pharyngitis.
On the other hand, Acetone is an organic compound with the formula (CH3)2CO
which is a colorless, volatile, flammable liquid, and is the simplest ketone. About a third
of the world's acetone is used as a solvent, and a quarter is consumed as acetone
cyanohydrin a precursor to methyl methacrylate It is a good solvent for many plastics and
some synthetic fibers and also used for thinning polyester resin, cleaning tools used with
it, and dissolving two-part epoxies and superglue before they harden. Acetone is also used
as one of the volatile components of some paints and varnishes.
Supply and Demand Analysis
Phenol and acetone belongs to the class of commodity chemicals, which is also
known as bulk commodities/bulk chemicals, which are currently manufactured on a large
scale to satisfy the needs of the local and global market. The demand for these chemicals
is closely connected to the demand of their derivative products (end products), and is then
linked to the established business sectors.
Demand of phenol based on import. Based on the import data of phenol as shown
in Table 1, the importation of phenol from different countries around the world has
increased. This data may suggest that production of phenol in the Philippines is not enough
since the country is importing the particular product at an increased rate.
3
Table 1
Import data for phenols in the Philippines
Year Trade Value Weight (kg)
2005 $764,633 2,192,213
2006 $1,623,574 1,105,156
2007 $4,170,608 3,174,993
2008 $4,927,117 3,120,126
2009 $1,797,902 1,042,860
2010 $2,661,669 2,444,078
2011 $1,737,026 4,330,795
Source: UN Comtrade: International trade statistics
Figure 1 shows that the demand for phenol will increase for the following years as
the trend line for the graph of supply per year is sloping upwards (positive slope). This
indicates that there is a high marketability for phenols right now and for the following years
to come in the Philippines.
Figure 1. Demand tend line for phenols in the Philippines based on import
data
Demand of acetone based on import. Based on the import data of acetone as
shown in Table 2, the importation of acetone from different countries around the world has
0
1,000,000
2,000,000
3,000,000
4,000,000
5,000,000
2004 2005 2006 2007 2008 2009 2010 2011 2012
Wei
ght
(Kg)
Year
4
increased. This data may suggest that production of acetone in the Philippines is not enough
since the country is importing the particular product at an increasing rate.
Table 2
Import data for acetone in the Philippines
Year Trade Value Weight (kg)
2005 $3,115,608 3,771,988
2006 $2,900,009 3,261,393
2007 $3,248,726 3,974,290
2008 $4,382,299 4,990,218
2009 $2,172,884 3,609,613
2010 $3,401,322 4,993,873
2011 $3,557,146 4,833,998
Source: UN Comtrade: International trade statistics
Figure 2 shows that the demand for acetone will increase for the following years as
the trend line for the graph of supply per year is sloping upwards (positive slope). This
indicates that there is a high marketability for acetone right now and for the following years
to come in the Philippines.
Figure 2. Demand trend line for Acetone in the Philippines based on Import
0
1,000,000
2,000,000
3,000,000
4,000,000
5,000,000
6,000,000
2004 2005 2006 2007 2008 2009 2010 2011 2012
wei
ght
(kg)
Year
5
Demand of phenol based on assumed consumption. According to Pandia,
application to the manufacture of bisphenol-A (BPA) and phenolic resin have the highest
percentage. The following depicts the percentage of phenol demand in terms of application:
Alkyl Phenols – 4%
Phenolic Resins – 30%
Caprolactam – 8%
Bisphenol-A – 40%
Others – 18%
In general, the industries that use phenol and/or acetone to manufacture these
intermediate chemicals are the plastic synthetic resin, paint, and adhesives industries.
Table 3 shows the value of output of industries that uses phenol in the manufacture
of their product. Phenol is included in the production of phenolic resins (a plastic synthetic
resin). Alternatively, phenol is combined with acetone to produce bisphenol-A, an
intermediate to produce epoxy resin which is used in the manufacture of paints, glues, and
adhesives. Depicted in Table 4 are the values of phenol used in phenolic resins and
bisphenol-A.
Table 3
Value of output of industries that uses phenol
Industry description Value of Output (in thousand pesos)
2009 2010
Manufacture of plastic synthetic resins 12,205,785 18,523,236
Manufacture of Paints 31,538,346 32,642,161
Manufacture of Glues and Adhesive 3,148,124 4,062,129
Source: National Statistics Office
6
Table 4
Assumed phenol consumption in 2009 and 2010
Year Phenol in Phenolic
Resin, kg
Phenol in Bisphenol-
A, kg Total Phenol
Consumption, kg
2009 8,360,126.71 8,801,615.41 17,161,742.12
2010 12,687,147.95 9,715,960.54 22,403,108.48
7
In assuming the phenol consumption in phenolic resin, the following are
considered:
1. Around 20% of the manufactured synthetic resin is phenolic resin,
which is based from the main 5 sub-category of the specified industry
(2009 Philippine Standard Industrial Classification manual), namely:
a. Polymers
b. Phenolic Resins
c. Polyamides
d. Silicones
e. Polyamides
It is assumed that the percentage of the industry is equally distributed to
these 5 main sub-category of the industry. This designates around 20%
of the industry to the manufacture of phenolic resin.
2. Phenolic resin is composed of phenol formaldehyde polymer (85%),
phenol (15%), formaldehyde (<1%) (Ergon Amor, MSDS, 2012).
3. Price of phenolic resin is around 43.8 pesos per unit kilogram, which is
the landed cost of the product through export (Export Data and Price of
phenolic resin, 2014).
In assuming the phenol consumption in phenolic resin, the following are
considered:
1. Bisphenol-A is an intermediate synthetic compound and monomer of epoxy
resins. Bisphenol-A epoxy resins are widely used in the manufacture of
paint (for metals) because of its binding properties, and adhesives.
8
Bisphenol-A contains 2 moles of phenol and 1 mole of acetone. Mass
percent would be: 76.42% phenol and 23.58% acetone, which is based on
their molecular masses. There is an existing huge industry of paint and
adhesives in the Philippines, as depicted by the huge output of the
manufacturing industry of paint and adhesives.
2. Paint products can be divided according to its applications. Generally, there
are five types of paints being manufactured: for wood, plastic, metals,
concrete, and others. Paints that contain epoxy resin are used in metals, and
so it is assumed that around 20% of the manufactured paints contain it
(assuming that the production is equally distributed).
3. Adhesives/glue that contain epoxy resin are widely used in the repair of
broken items in the household and industry. It is assumed that most adhesive
products contain epoxy resin (around 90%), and the content is around 70%
epoxy resin (E-BOND EPOXIES, INC., 2015).
4. Price of paint is 1026 pesos (Boysen Epoxy Enamel, 4L, 4.56 kg).
5. Price of adhesive is 3000 pesos (Bostik Clear Epoxy, 4.7 kg).
6. Around 30% of paint is epoxy resin, to which acts as a binder (Edwards &
Lawless, 2003).
Figure 3 is based on a 2 year forecast from 2009 and 2010. To make it more
accurate, growth rate of the divisions of the manufacturing industry was considered in the
forecast. The manufacture of plastic synthetic resins, paint, glues and adhesives falls under
the division of Chemicals and Chemical product, based on the 2009 Philippine Standard
Industrial Classification manual. The growth of this division is 39% per annum on average,
9
based on a 3 year annual average growth rate (2010-2013) analysis conducted by NSCB.
This percentage is usually the benchmark used in the analysis of growth rate of various
chemical industries. Actually, there are a total of 506 establishments under the Chemicals
and Chemical Products Division and around 98 establishments of those are the industry
considered in this study. This will give an average of 20% of the total division, which is
considerably high and therefore can be used to approximate the increase of the industries
considered under this division. Table 5 depicts the increase in the amount of phenol
consumption.
Figure 3. Two (2) year forecast of assumed phenol consumption in the
Philippines (Note that this is based only from bisphenol-A and phenolic resin
applicat ions of phenol)
-
20,000,000.00
40,000,000.00
60,000,000.00
80,000,000.00
100,000,000.00
120,000,000.00
140,000,000.00
2005 2010 2015 2020 2025 2030 2035
Phen
ol
in K
g
Year
10
Table 5
Percent increase in phenol consumption based on 39% per annum growth rate
Year Phenol consumption, kg Growth Rate (%)
2009 17,161,742.12 Actual data
2010 22,403,108.48 Actual data
2011 31,140,320.79 39
2012 43,285,045.9 39
2013 60,166,213.8 39
The values in Table 5 are forecasted up to year 2033, as shown in Figure 4.
Comparing the demand from Figure 3 to Figure 4, the growth rate makes the forecast line
steeper thus giving greater values for the demand of phenol in the Philippines. For a more
conservative analysis of the demand of phenol in the Philippines, demand of phenol based
on a 2 year data forecast will be considered in the study.
Figure 4. Forecast of assumed phenol consumption in the Philippines (5 vs. 2
year data point forecast)
-
50,000,000.00
100,000,000.00
150,000,000.00
200,000,000.00
250,000,000.00
300,000,000.00
2005 2010 2015 2020 2025 2030 2035
Phen
ol
in K
g
Year
5 year data point forecast
2 year data point forecast
11
Demand of acetone based on assumed consumption. According to Pandia
(2009), application to the manufacture of solvents and bisphenol-A have the highest
percentage of demand. The following depicts the percentage of phenol demand in terms of
application:
Solvent – 46%
Bisphenol-A – 25%
Methyl Methacrylate – 21%
MIBK – 8%
In general, the industries that use phenol and/or acetone to manufacture these
intermediate chemicals are the thinners/paint removers, paint, and adhesives industry.
Table 6 shows the value of output of industries that includes acetone in their
product. Acetone is included in the manufacture of thinners or paint removers, paints, glues
and adhesives. Depicted in Table 7 are the values of amount of acetone used in solvent and
bisphenol-A.
Table 6
Value of output of industries that uses acetone
Industry description Value of Output (in thousand pesos)
2009 2010
Manufacture of Thinners / Paint
Removers 505,851 567,136
Manufacture of Paints 31,538,346 32,642,161
Manufacture of Glues and Adhesive 3,148,124 4,062,129
Source: National Statistics Office
12
Table 7
Assumed acetone consumption in 2009 and 2010
Year Acetone in Solvent, kg Acetone in
Bisphenol-A, kg
Total Acetone Consumption,
kg
2009 2,564,664.57 2,797,217.17 5,361,881.74
2010 3,317,745.60 2,997,937.05 6,315,682.65
In assuming the phenol consumption in phenolic resin, the following are
considered:
1. Acetone is widely used as a raw material for paint manufacturing, according to
Dmitrievsky Chemical Plant (DMITRIEVSKY Chemical Plant, 2015),. It has
good solvent properties. Generally, acetone are included in thinners or paint
removers. There is a good market of acetone here in the Philippines and to prove
that, there is an existing provider of this chemical here in the Philippines,
namely TOPLINECHEM MARKETING CORPORATION (Toplinechem
Marketing Corporation, 2015).They are engaging with importing then
supplying chemical products such as acetone for more than a decade now to
various industries such as paint and adhesives. Boysen Paint Company is
currently producing thinners and their products do contain acetone, by looking
at the MSDS (Boysen Lacquer Thinner B50, MSDS). This is an enough
evidence that the company is using acetone.
2. Paint thinners are assumed to contain 13% acetone (W.M. Barr, MSDS, 2009)
3. Price of thinner is around 20 pesos per bottle (0.78kg)
Note that the assumption in acetone consumption in BPA is the same with phenol
consumption in BPA, since they have the same end industry such as the paints and
13
adhesives industry. Acetone is also an important raw material for the production of
bisphenol-A.
Figure 5 is based on a 2 year forecast from 2009 and 2010. To make it more
accurate, growth rate of the manufacturing industry was considered in the forecast. The
manufacture of thinners (paint removers), paint, glues and adhesives falls under the
Chemicals and Chemical products subsector. The growth of this subsector is 39% per
annum based on a 3 year annual average growth rate (2010-2013) analysis conducted by
NSCB. Table 8 depicts the increase in the amount of phenol consumption.
Figure 5. Two (2) year forecast of assumed acetone consumption in the
Philippines (Note that this is based only from Bisphenol-A and solvent
applicat ions of acetone)
-
5,000,000.00
10,000,000.00
15,000,000.00
20,000,000.00
25,000,000.00
30,000,000.00
2005 2010 2015 2020 2025 2030 2035
Ace
tone
in K
g
Year
14
Table 8
Increase in acetone consumption based on 39% per annum growth rate
Year Acetone consumption, kg Growth Rate (%)
2009 5,361,881.74 N/A
2010 6,315,682.65 N/A
2011 8,778,798.89 39
2012 12,202,530.45 39
2013 16,961,517.33 39
The values in Table 8 are forecasted up to year 2033, as shown in Figure 6.
Comparing the demand from Figure 5 to Figure 6, the growth rate makes the forecast line
steeper thus giving greater values for the demand of acetone in the Philippines. For a more
conservative analysis of the demand of acetone in the Philippines, demand of acetone based
on a 2 year data forecast will be considered in the study.
Figure 6. Forecast of assumed acetone consumption in the Philippines (5 vs. 2
year data point forecast)
-
10,000,000.00
20,000,000.00
30,000,000.00
40,000,000.00
50,000,000.00
60,000,000.00
70,000,000.00
80,000,000.00
2005 2010 2015 2020 2025 2030 2035
Ace
tone
in K
g
Year
5 year data point forecast
2 year data point forecast
15
Business and the Environment
Department of Environment and Natural Resources policies. The Department
of Environment and Natural Resources (DENR), through its Environmental Management
Bureau (EMB), has created a compilation and inventory of chemicals and chemical
substances that can be used throughout the country, as regards to the implementation of the
Republic Act No. 6969 known as “Toxic Substances and Hazardous and Nuclear Wastes
Control Act of 1990”. The national inventory is known as the Philippine Inventory of
Chemicals and Chemical Substances (PICCS).
Manufacturers, importers, distributors, and users of chemicals or chemical
substances that are included in the PICCS need no longer to secure clearance from the
DENR, provided that their chemicals or chemical substances are not listed in the Philippine
Priority Chemicals (PCL) and not subject to Chemical Control Order (CCO). The
chemicals or chemical substances that are not included in the PICCS cannot be
manufactured, imported, distributed, or used unless they have undergone the Pre-
Manufacture and Pre-Importation Notification (PMPIN) process.
PICCS have an online directory (EMB Philippines, 2015). Just providing the CAS
Registry Number. or the name of the chemical on the search bar will generate results.
Phenol and acetone can be searched and found on the PICCS, therefore these chemicals
can be manufactured and distributed throughout the country. PICCS is updated every five
years and the latest edition was released last 2011, containing around 44,000 chemical
substances.
The chemicals subject to CCO are: Cyanide, PCBs, Asbestos, Mercury, Lead, and
Ozone Depleting Chemicals. Phenol and acetone are not included in the list and therefore,
16
are exempt to the CCO rules. On the other hand, the Philippine Priority Chemical list does
not include acetone and phenol, which means it is exempted from the PCL rules.
Philippine Drug Enforcement Agency policies. The Philippine Drug
Enforcement Agency has a list of dangerous drugs which are controlled under RA 9165.
Acetone is included in the list under table II chemicals (Philippine Drug Enforcement
Agency (PDEA), 2015), and is therefore controlled by the PDEA. Certificate of exemption
should be secured prior to the preparation of this chemical.
Environmental Management Bureau. The proposed plant will have oxidation
towers, to which air comes in contact with cumene and phenol. In the process simulation
using Aspen Hysys software, the vapor product of the oxidation do contain these chemicals,
to which may impose harmful effects to environment. To be able to comply with the
Republic Act 8749, also known as the Clean Air Act proposed by the Environmental
Management Bureau, the designers planned to have a scrubber to capture the chemicals.
Based on this act, the maximum allowed release of phenol in the atmosphere is
100μg/NCM or 0.03 ppm. On the other hand, there are no data for the maximum allowed
level for cumene release on the said republic act. To avoid any harmful effects, it is
advisable to put up a flaring system to eliminate these chemicals in the release. Other air
cleaning system such as baghouse filters or cyclone might be in need if according to EIA,
there will be a considerable amount of particulates to be released in the atmosphere.
Philippine Clean Water Act of 2004 (R.A. 9275). In order for the proposed plant
to comply with the Philippine Clean Water Act of 2004, a design of waste water treatment
facility must be included in the overall design of the plant. Shown in Figure 7 is the initial
block flow diagram for the proposed plant. Possible waste waters to be produced are:
17
Cleaning water, Kitchen waste water, Greywater or sullage (generated from toilets, shower
baths, wash hand basins, etc.).
Figure 7. Init ial Block Flow Diagram for Waste Water Treatment Facility
One of the obstacles in the acceptability of SBR process has traditionally been the
need for precise, automated and reliable control of various stages of the process. The SBR
process is an activated sludge process in which the sewage is introduced into the SBR tank,
one batch at a time. Wastewater treatment is achieved by a timed sequence of operations
which occur in the same SBR Tank, consisting of filling, aeration, settling, decanting,
idling, and sludge wasting. The various stages in the sequence are the following:
18
Filling. During this stage the SBR (Sequencing Batch Reactor) Tank is filled with
the influent wastewater coming from the process area and other facilities in the plant. The
wastewater should be fed into the tank in a rapid, controlled manner.
Aeration. This stage involves the utilization of biochemical oxygen demand (BOD)
and ammonia nitrogen, where applicable, by microorganisms. The length of the aeration
period and the sludge mass determines the degree of treatment. The length of the aeration
period depends on the strength of the wastewater and the degree of nitrification provided
for in the treatment.
Settling. During this stage, aeration is stopped and the sludge settles leaving clear,
treated effluent above the sludge blanket. Time for settling varies from 45 to 60 minutes
depending on the number of cycles per day.
Decanting. At this stage of the process effluent is removed from the tank through
the decanter.
Idling. The SBR Tank waits idle until it is time to commence a new cycle with the
filling stage.
Sludge Wasting. Excess activated sludge is removed periodically during the SBR
operation. As with any activated sludge treatment process, sludge wasting is the main
control of the effluent quality and microorganism population size.
Solid Waste Management Act : Republic Act No. 9003. Usual solid waste that
can be generated from the future manufacturing plant of phenol and acetone are paper
works, kitchen/cafeteria wastes, and packaging wastes. The company has decided to have
a Material Recovery Facility (MRF) so that solid wastes can be segregated and the
company may earn money from the recycle of solid wastes.
19
Competition in the Market
Even though there are no operating plants that manufacture phenol and acetone in
the Philippines, other plants outside the country are producing the said chemicals at various
large capacities and these companies are considered to be competitors of the proposed
project. Table 9 shows the companies outside the country that produces phenol and acetone
at a large scale.
Table 9
Recent phenol capacities/expansions and active phenol projects
Company
Name Logo Product
Capacity
(per year) Location
INEOS Phenol
Phenol and
Acetone
680 kte Antwerp,
Belgium
650 kte Gladbeck,
Germany
540 kte Mobile AL,
USA
400 kte Nanjing,
China
The Dow
Chemical
Company
Acetone 410 MM lb U.S.
Phenol 662 MM lb U.S.
Formosa
Chemical and
Fibre
Corporation
Phenol and
Acetone
200,000
TPA Taiwan
LG Expansion
Phenol and
Acetone
150,000
TPA Korea
Kumho
Expansion
Phenol and
Acetone
150,000
TPA Korea
PTT Phenol
Phenol and
Acetone
200,000
TPA Thailand
FCFC
Phenol and
Acetone
220,000
TPA
Mailiao,
Taiwan
20
Esfahan
Phenol and
Acetone
135,000
TPA Iran
Pars Phenol
Phenol and
Acetone
270,000
TPA Iran
Saudi Kayan
Phenol and
Acetone
300,000
TPA Saudi Arabia
Sinopec
Tianjin
Phenol and
Acetone
320,000
TPA China
Ertisa
Phenol and
Acetone
200,000
TPA China
Sinopec
Gaoqiao
Petchem
Phenol and
Acetone 80,000 TPA China
Shell
Phenol and
Acetone
330,000
TPA Singapore
FCFC
Phenol and
Acetone
200,000
TPA
Ningbo,
China
21
Target Market
Adhesives. Acetone is utilized in a multiplicity of adhesive applications, such as
spray adhesives that can be bought from any DIY store, and glues used to adhere the shoe
parts in the footwear industry.
Agro chemicals. Acetone and phenol are both used as a raw material for the
manufacturing of pesticides and herbicides, such as 2,4 −
𝑑𝑖𝑐ℎ𝑙𝑜𝑟𝑜𝑝ℎ𝑒𝑛𝑜𝑥𝑦𝑎𝑐𝑒𝑡𝑖𝑐 𝑎𝑐𝑖𝑑 (2,4 − 𝐷) and Monoisopropylamine (MIPA), products
which are meant to protect crops and improve yields.
Automotive. Acetone and phenol are both used in the manufacture of
polycarbonate, a thoroughly used product in the automotive industry. Phenol is also used
in the manufacture of nylon, while acetone is the precursor for methyl methacrylate
(MMA)/Polymethyl methacrylate (PMMA).
Chemicals. Phenol and acetone are used throughout in the chemical industry as
solvents, drying agents, chain terminators, and intermediates in a variety of chemical
processes.
Coatings. Polycarbonate, a product widely used as a coating, is produced from
phenol and acetone. On the other hand, Methyl methacrylate (MMA)/Polymethyl
methacrylate (PMMA), produced from acetone, are used universally as coat vehicle
exteriors.
Cosmetics. Phenol and acetone are known to be included in a variety of hair and
skin products to kill and prevent microorganisms, cleanse the skin, and reduce body odor.
Phenol is used for skin peel products and is included in most sunscreen and lip balm
formulations. In nail polishes, acetone is mostly used as nail polish remover.
22
Food. Phenol is used as the main ingredient for synthetic vanilla. In the industry,
phenol and acetone are used as intermediated or solvents in the manufacture of vitamins as
well as supplements, packaging for food, and medications.
Cleaning. Acetone and acetone are one of the most used solvent in the world.
Home and electrical. Most of the electrical devices are made from phenol and
acetone. The by-product of the process, alphamethylstyrene (AMS), is also used in high-
heat electronics such as coffee machines and toasters.
Medical and pharma. Phenol is synthesized aspirin production.
Paint and ink. Acetone is used as a solvent and its main derivative, methyl
methacrylate (MMA), is the basis for acrylic paint. On the other hand, phenol derivatives
are used in laser and ink jet printers as a coating for the ink.
Pipes. Most pipes have phenolic coatings to prevent corrosion.
Rubber and Tyres. Phenol is the precursor for the nylon intermediates such as
caprolactam and adipic acid. Both are used in the manufacture of tyre cord in the whole
world.
Textiles. Carpolactam and adipic acid, which can be made from phenol, are used
to make synthetic yarn for clothing and other textile applications.
23
Target Companies
The following companies presented in the following tables are the potential buyers of
phenol and acetone. Most of these companies are located in Manila, Batangas, Cavite,
Bulacan, and Laguna, which are all near to the plant site.
Table 10
Paint Manufacturers in the Philippines
Company Name Address Tel no
NIPPON PAINT PHILIPPINES
INC.
#4 HOLOGRAM ST. LISP BRGY.
DIEZMO
Cabuyao , Laguna
(049)543-0763 /
845-1176
GOLDEN SUN PAINT
MANUFACTURING
195 MOLINO HEIGHTS MOLINO III
Bacoor, Cavite
(02)3616930
8815819
Mega Paint & Coating Corp 198 Manila East Road Binangonan
, Rizal 652-0565
Triple E Paint Trade JP Laurel Lipa City
, Batangas (043) 312-5214
Mega Paint & Coatings Corp Traders Arcade
Mandaue City , Cebu (032) 3441195
Tanville Paint Manufacturing
Inc
8001 Singer Compound Sitio Simona
San Isidro Taytay Rizal
,
ULTRACOTE PAINT &
COATINGS CORPORATION
E. RODRIGUEZ AVE.,
PASIG , METRO MANILA 6713410
Paint Plas Corporation San Antonio 722 Magsaysay Road
, Laguna (049)868-6416
PACIFIC PAINT (BOYSEN)
PHILIPPINES, INC.
292 D. Tuazon St. Quezon City, NCR -
Second District 1115
,
364-3505; 365-
0561 to 64
SUPER GLOBE, INC. C. RAYMUNDO AVE.,
PASIG , METRO MANILA 6439840
Pacific Paint & Oil
Manufacturing, Inc.
D. Tuazon
Quezon City, Metro Manila 02 364 3505
MAGNAFLO, INC. ( 97 03203
)
1707 E ANTEL GLOBAL
CORPORATE CENTER JULIA
VARGAS AVE. ORTIGAS
PASIG , METRO MANILA
FH Colors & Coating Corp 34 S Reyes SPL, Laguna (049) 869-7562
Techno Development &
Chemicals Corp
AC Cortes Ave
Mandaue City , Cebu (032) 3440268
24
Maincoat Inc HVG Arcade
Mandaue City , Cebu (032) 3468058
Do It Marketing Co Phils Inc 7946 C Padilla
Cebu City , Cebu (032) 2625662
MARDUKE INDUSTRIAL
SALES
5 Mindanao St. Filipinas Village
Malanday
CITY OF MARIKINA, NCR
02 941 9549
Davies Paints Philippines, Inc 1387-A Mercedes Avenue San Miguel
CITY OF PASIG, NCR 02 641 7101
SSCP Mla. Inc. _ Lot 1 Blk 9 Phase 1
PEZA, Rosario, Cavite
046 437-1053 /
0558 / 0358
Crystal Resins Incorporated 141 Cabrera Road, Sitio Burol San Juan
TAYTAY, RIZAL 22863011
UNI-JJET INDUSTRIAL
The Rose Condominium,Meralco Ave.,
San Antonio
CITY OF PASIG, NCR
02 2127419
eccs enterprises
Door 6 Omnor bldg. phase 2 diho subdv.
diversion rd. buhangin Buhangin
DAVAO CITY, DAVAO DEL SUR
082 241 2237
Table 11
Plastic product manufacturer in the Philippines
Company Name Address Tel no
NICO PLASTIC PRODUCTS
2 Sta Sabina, Villa Sabina
Subd. Talipapa
Novaliches Quezon City,
Metro Manila
(632) 9394931
JR Plastic Manufacturing
Corporation
Cadena De Amor San
Pedro Laguna
, Laguna
(049) 868-8235
J MCBEN PLASTIC
MANUFACTURING
Hon. Circle St., Sterling
Industrial Park,
Meycuayan , Bulacan
(044) 299-61-91/407-
1568
PLASTIC CONTAINER
PACKAGING CORPORATION
No. 24 Madison St.
Mandaluyong City, NCR -
Second District
631-8331 to 34; 632-
0895
INNOVA PLASTIC
MANUFACTURING CORP
146 SAN MIGUEL COMP.
9TH & 10TH AVE SAN
MIGUEL COMPD., 9TH
ST. BET. 9TH & 10TH
AVE., 101 CALOOCAN
CITY
, METRO MANILA
2422252/2430121
25
Altair Plastic Manufacturing,
Corporation
15 A. Marcelo St.
Valenzuela, Metro Manila 292-4240
BROTHERHOOD PLASTIC
ENTERPRISES
4987 VALENZUELA ST,
BGY 600, ZONE 059
SAMPALOC, MANILA
H. Ramos Plastic Manufacturing
Corporation
Oliveros St.
Valenzuela, Metro Manila 293-6598
N.C.K. Plastic Manufacturing 56 Centro St.
Valenzuela, Metro Manila 432-0413
NEW IDEAL PLASTIC
CORPORATION
C.M. RECTO STREET
MARIKINA, METRO
MANILA
948-5298
MANLY PLASTIC INC.
ENERGY ST. LISP I
DIEZMO
Cabuyao , Laguna
(049)531-6158
T.N.C. PLASTIC
MANUFACTURING
146 9TH ST., 10TH AVE.
101 CALOOCAN CITY
, METRO MANILA
3623835
Pan-Asia Plastic Mould
13 Humilidad St., Marulas
CITY OF VALENZUELA,
Metro Manila
(63) 02 514 8759
JAY-GEE PLASTIC PRODUCTS
1325 FM GUERRERO ST,
BGY 245, ZONE 022
TONDO, MANILA
MEYCAUAYAN PLASTIC
INDUSTRIAL CORP.
95 Marble House,
Meycuayan , Bulacan
CONSISTENT MARK PLASTIC
MANUFACTURING
# 1544 Woodridge Drive,
MIS I,
Meycuayan , Bulacan
0929-1999071
SUSAN MFTR OF PLASTIC
BAGS
3267 1ST STA V MAPA,
SAMPALOC, MANILA
TYCSH PLASTIC INC
2720 NEW PANADEROS
ST, BGY 888, ZONE 098
STA ANA, MANILA
OTTO PLASTIC CO 329 PUREZA ST INT 3,
SAMPALOC, MANILA
ORELEE PLASTIC
CORPORATION
750 EDSA COR. WOOD
ST., Brgy. 144
PASAY, METRO
MANILA
PERFORMANCE PLASTIC CORP.
MERIDIAN INDUSTRIAL
COMPLEX,
MACABLING
Santa Rosa, Laguna
26
JENDICK PLASTIC PRODUCTS
546 ILANG ILANG ST,
BGY 281, ZONE 026 SAN
NICOLAS, MANILA
ERTESS PLASTIC INDUSTRIES
INC.
#297 Provincial Rd.,
Meycuayan , Bulacan (044) 668-9503
TE MFTR OF PLASTIC
PRODUCTS
3312 1ST ST V MAPA,
BGY 395, ZONE 041
SAMPALOC, MANILA
PROLINE PLASTIC CO. Lot1 Blk3 FVI Compound,
Meycuayan , Bulacan 044-432-0766
VILLA JOSEPH YU MFG
PLASTIC & RUBBER
PRODS/CONTR
397 DAYAO ST, TONDO,
MANILA
GIPICOM PLASTIC INDUSTRIES 80044-Florida St., MIS II,
Meycuayan , Bulacan
80044-Florida St.,
MIS II,
Meycuayan , Bulacan
GLORIA PLASTIC PRODUCT
2472 MALAYA ST
BALUT, TONDO,
MANILA
KIAM LUA PLASTIC MFTR
2211 MALAYA ST, BGY
124, ZONE 010 TONDO,
MANILA
Eternity Plastic Manufacturing #261 N. San Rafael
Montalban, Rizal
CRK PLASTIC PRODUCTS
CORPORATION
675 JENNY'S AVE. EXT.
FORMERLY IN
MERCEDES AVE.,
PASIG , METRO
MANILA
Big Apple Plastic Packaging
San Vicente 1425 San
Vicente St., Dulo
, Laguna
(049)808-4630/0920-
7794607
South Star Plastic Industries
Corporation
Landayan 106 Cadena de
Amor St., Cataquiz 3
Subdivision
, Laguna
(049)847-5611
INFINITY PLASTIC PACKAGING
CONCEPTS INC.
726 RIZAL AVE. EXT.,
TANONG
MALABON, METRO
MANILA
INTERWORLD PLASTIC
MANUFACTURING CORP.
ILAYA ST. NIOG III
Bacoor, Cavite
(046) 870-0456
09178322688
PANAMA PLASTIC PRODUCTS
INC.
65 SIMON ST., ACACIA
MALABON, METRO
MANILA
27
ISLAND MULTI-POLYMER
PLASTIC CORPORATION
25- INDUSTRIAL AVE.,
Blk.A-4 CMPD.,
POTRERO
MALABON, METRO
MANILA
3661653
San Pedro Plastic Center
Poblacion Unit-A Mabini
St.
, Laguna
EARL METAL & PLASTIC
PARTS FABRICATORS INC.
L3 C3 Don Mariano Santos
Avenue
ANGONO, RIZAL
168 Plastic Corporation Nueva National Highway
, Laguna
FILIPINAS PLASTIC
CORPORATION
15 LIWAYWAY ST.,
ACACIA
MALABON, METRO
MANILA
288-41-30
Medical Plastic Corporation
San Vicente San Vicente
Road
, Laguna
(049)869-4045
UNIBLESS PLASTIC MFG.
CORPORATION
15 REPARO ST.,
POTRERO
MALABON, METRO
MANILA
SIN HING PLASTIC MFG. CORP
TINAJEROS
MALABON, METRO
MANILA
725 28 82
ALATONE PLASTIC INC.,
7 INDUSTRY ST.,
POTRERO
MALABON, METRO
MANILA
ELEVEN PLASTIC PRODUCT,
INC.
JENNY'S AVE.,
PASIG , METRO
MANILA
GREIF PHILS., INC. Brgy. Malaya, Pililla, Rizal
Rizal Region 4
674-
1375/1424/1439/1444
28
Table 12
Resins Manufacturer in the Philippines
Company Name Address Tel no
Crystal Resins Incorporated
141 Cabrera Road, Sitio Burol San
Juan
TAYTAY, RIZAL
22863011
PACIFIC RESINS, INC.
7/F Padilla Bldg., Emerald Ave.
Ortigas Center, Pasig City
Pasig, Metro Manila
(632) 638-5601 to
03
GREAT EASTERN RESINS
(PHILS) INDL CO INC
PUROK MALIGAYA,
MAMBUGAN, ANTIPOLO CITY
, Rizal
POLYMER PRODUCTS
(PHILS.), INC.
11 Joe Borris St., Bo. Bagong Ilog
Pasig City, NCR - Second District
1600
671-9837 to 39
ALCOS GLOBAL
CORPORATION
No. 12 Calle Obrero Bagumbayan
Libis Quezon City, NCR - Second
District 1110
635-0631
RI Chemical Coporation E. Rodriguez, Jr. Ave., Brgy.
Bagong Ilog Pasig City, 1600 671-9842 to 53
CHEMREZ TECHNOLOGIES,
INC.
65 Industria St.,
BagumbayanQuezon City 1110 635-0680
MARULAS INDUSTRIAL
CORP.
141 McArthur Highway, Marulas,
Valenzuela City
Valenzuela Metro Manila
(02) 291-8105 - 07
AKZO NOBEL / CASCO
ADHESIVES
LG 05 Royal Mansion, Wackwack
Rd., Mandaluyong City, M.M.
Mandaluyong Metro Manila
831-0870
Availability of Raw Materials
As shown on Table 13, Philippines imports large quantities of propylene and small
quantities of benzene from other countries. This doesn’t mean that the supply of propylene
and benzene in the country is not enough because the Philippines is also exporting these
products at a higher amount. The data shows that from 2010 to 2011, the production of
propylene and benzene in the local scene have increased dramatically, which means that
local petrochemical companies have started to produce these commodities at a larger scale.
29
The demand for propylene and benzene will surely increase in the future because they are
cheap and they are used in manufacturing a lot of chemicals such as phenol and acetone. It
can be settled that the local supply for benzene and propylene is enough, and that
importation of these chemicals is not needed for the proposed plant. Table 14 shows the
list of suppliers of the raw materials needed by the proposed plant.
Table 13
Import and Export Data of Propylene and Benzene
Propylene `Benzene
Year Import (kg) Export (kg) Import (kg) Export (kg)
2007 83,751,966 2,373,930 - -
2008 53,258,477 - - -
2009 60,528,698 7,292,410 - -
2010 46,477,418 98,106,469 663 19,453,901
2011 42,067,745 73,036,129 60 24,209,049
Source: UN Commodity Trade Statistics Database `
Table 14
List of Suppliers of raw materials in the Philippines
Company Location Propylene Benzene Capacity
Petron PRU (Propylene
Recovery Unit) Bataan PH ✓ -
140000
mtpy[1]
Petron Aromatics Facility Bataan PH - ✓ 150000
mtpy[2]
JG Summit - JGSOC Batanggas
PH ✓ -
190000
mtpy[3]
Sources:
[1] Petron, 2005
[2] Hanmin & Suratman, 2011
[3] JG SUMMIT HOLDINGS, INC. - Annual Report, 2013
30
SWOT Analysis
Table 15 shows the matrix for the SWOT (strengths, weaknesses, opportunities, threats)
analysis of the proposed project.
Table 15
SWOT/TOWS Matrix
SWOT
MATRIX
Strengths
1. Technology: Cost
Effective
manufacturing process
of phenol and acetone
through Cumene
Process
2. Location: Only
manufacturer of phenol
and acetone in the
Philippines
3. Inexpensive raw
materials as compared
to global chemical
prices
4. Low environmental
risks because of
employed
environmental
measures.
Weaknesses
1. Lack of company name
equity
2. Inertly high startup
cost: Will require
investment and loan per
capital
Opportunities
1. Growing end product
demand of phenol and
acetone
2. High profitability
because of high value of
phenol and acetone in
the market
3. Project may improve
local economy,
employment, and
communities
4. Raw Mat Availability: 2
large producers of
propylene and benzene
are JG Summit and
Petron, located here in
the Philippines
S-O Strategies
1-1 Selling of products at a
high acceptable price to
increase profitability.
1-3 Generation of more jobs
with more incentives for
employees
1-4 Possible project
partnership with JG
Summit and Petron
2-1 Flexibility in product
prices that will favor
profitability; Meet local
product demand
expectations
2-4 Project expansion after
10-15 years of success
W-O Strategies
1-1 Capture hearts of
investors; Deliver excellent
product quality; Genius
marketing campaigns for
B2B approach; Versatility
in product pricing
1-3 Gain government and
local community support
for the development of the
project
1-4 Establish partnership
with raw mat suppliers to
have a production stability
2-1 Demand and
profitability of the product
will prove project
31
3-1 More product yield that
will yield optimal profit
3-4 Continuous production
for maximum productivity
4-1 Safe and sound
production processes that
will cause no harm to
employees and
environment
feasibility, will easily gain
loan support from banks.
2-2 High profit will
compensate for the inertly
high startup cost, with an
expected return of
investment within 5 years.
2-4 Availability of the raw
materials in the local scene
will somehow reduce costs.
Threats
1. Competition from large,
multinational
manufacturers of
phenol and acetone
S-T Strategies
1-1 Cost effective
production of high quality
phenol and acetone to attain
better product prices (cost
driven sales)
2-1 Local manufacturers
that needs the products will
prefer local suppliers (B2B
support)
3-1 Support from JG
Summit and Petron will
yield success in lower cost
of production, excellent
product quality, and better
competitive prices
4-1 Local market and
government will favor
production of products
because of environmentally
friendly engineered
processes.
W-T Strategies
1-1 Establishment of R&D
department to further
improve quality of products
and decrease
manufacturing processes
costs.
2-1 Improvement and
redesign of manufacturing
processes if needed to favor
profitability
Determining the plant capacity. Based on the SWOT analysis and the strategies
that were made on Table 15, the company is confident to get the 40% of the market share.
To determine the capacity of the plant, the phenol demand based from consumption will
be multiplied by 40%, as shown in Table 16. Note that market share may change after the
completion of the economic evaluation analysis.
32
Table 16
Projected phenol and acetone capacity of the proposed plant
Year Phenol, Kg Acetone, Kg Total, Kg
2017 34,000,000.00 20,983,104.88 54,983,104.88
2022 44,000,000.00 27,154,606.31 71,154,606.31
2027 54,000,000.00 33,326,108.00 87,326,108.00
2033 66,000,000.00 40,731,909.47 106,731,909.47
Figure 8 shows the projected phenol and acetone capacity of plant, which is 40%
of the projected demand based on consumption. Through careful analysis of the SWOT
and current state of Philippine economy, the company has decided to design a 54,000,000
kg (54,000 MT per year of phenol) manufacturing plant, in which 62% is 34,000 MT
(minimum and starting capacity of plant). This was purposely made to avoid big loss
through the normal wear and tear of equipment / facilities. If the management decides to
expand the production after 2027, addition of equipment and utilities will compensate.
Possible additional investments are reboiler, reactor, distillation column, storage tanks, and
condenser.
33
Figure 8. Projected phenol and acetone capacity of plant
Preliminary Economic Evaluation (Class 5 Estimate)
The ISBL (Inside Battery Limit) cost can be estimated using the following
correlation (Towler, 2013):
𝐶2 = 𝐶1 (𝑆2
𝑆1)
𝑛
𝐶2 = ISBL capital cost of the plant with capacity 𝑆2
𝐶1 = ISBL capital cost of the plant with capacity 𝑆1
𝑛 = typically 0.6 for chemical industry
-
20,000,000.00
40,000,000.00
60,000,000.00
80,000,000.00
100,000,000.00
120,000,000.00
2015 2020 2025 2030 2035
Cap
acit
y, K
g
Year
Phenol
Acetone
TOTAL
(5)
34
For various processes involving commodity chemicals, the empirical equation
below can also be used:
𝐶2 = 𝑎𝑆2𝑛
𝑎 and 𝑛 are correlation constants (Towler, 2013).
Table 17 shows the process cost correlation constants of a cumene plant and phenol
from cumene plant. These constants will be used in equations 5 and 6 to obtain an estimate
of the capital cost.
Table 17
Process cost correlation constants for the plant
PROCESS Licensor Capacity
Units S lower
S
upper a n
Cumene by Q-Max UOP tpy 150,000 450,000 0.012 0.6
Phenol from Cumene
(Zeolite Catalyst)
UOP/ABB
Lummus
MMlb /
year 200 600 6.192 0.6
Source: Towler and Sinnott, 2008
The first step towards getting the cost of the plant is to get the cost at S lower
because the desired capacity is out of range, lower than the given range. Table 18 shows
the cost of the two processes at lower capacity.
Table 18
Cost of the two processes at lower capacity
Process S lower C2 (MM USD)
1 150,000 15
2 200 149
(6)
35
Table 19 shows amount of the raw materials needed to produce the intermediate
(cumene), at the design capacity of the plant (Phenol: 54,000𝑀𝑇 and
Acetone: 33,326𝑀𝑇). The following table shows the capital cost of the plant.
Table 19
Capacity of plant obtained through stoichiometric ratio and proportion method
Chemical Molar mass kmol CAPACITY
Kg Ton
Propylene 42.08 573,797 24,145,362 24,145
Benzene 78.11 573,797 44,819,254 44,819
Cumene 120.19 573,797 68,964,616 68,965
Phenol 94.11 573,797 54,000,000 54,000
Acetone 58.08 573,797 33,326,108 33,326
Table 20 shows the cost of the actual plant at year 2006. In order to obtain the cost
at year 2017 when the plant is expected to fully operate, the CE index was used which is
given in Table 21.
Table 20
Cost of the actual plant at year 2006
Process S2 C2 (MM
USD)
1 68965 9
2 108 97
Total 106
Table 21
CE cost index up to year 2017 through extrapolation
CE
INDEX
2004 2005 2006 2007 2008 2009 2010 2017
444.2 468.2 499.6 525.4 575.4 521.9 555.3 635.607
Source: KLM Technology Group
36
The OSBL (Outside Battery Limit) cost can vary from 10% to 100% of the ISBL
cost depending on the complexity of the process and required support facilities (Towler,
2013). For this project, it was assumed that the OSBL cost is approximately 50% of ISBL
cost considering that we need to install a steam generator, waste water treatment facility,
and cooling water system. Table 22 shows the price of raw materials and products needed
in economic analysis of the plant.
Table 22
ICIS Indicative price of raw materials and products
RAW
MAT
Price
(USD/MT)
Price
(Peso/MT)
PRODUC
T
Price
(USD/MT
)
Price
(Peso/MT)
Propylene 1014.1252 43607.3836 Acetone 1807.7884 77734.9012
Benzene 1039.81 44711.82681 Phenol 1984.158 85318.794
Source: ICIS, 2015
Table 23 shows the preliminary total capital expenditures of the plant. It is expected
to have a return of investment at the 3rd year.
Table 23
Preliminary Total Capital Expenditures of the Plant
C(2017), MM USD 134
Location factor 1.12
ISBL CAPEX ₱ 6,765,790,879.94
OSBL OPEX ₱ 3,382,895,439.97
Contingency ₱ 1,014,868,631.99
TOTAL CAPEX ₱ 11,163,554,951.90
ANNUAL OPEX ₱ 3,056,866,780.17
ANNUAL REVENUE ₱ 7,197,816,569.04
ANNUAL EXPECTED NET INCOME ₱ 4,140,949,788.86
PAYBACK PERIOD (years) @ 100% capacity 2.70
37
To estimate the Internal Rate of Return (IRR) for this project, it was anticipated
that the plant will be installed within two years. Hence, capital expenditure was assumed
to be equally distributed in two consecutive years. Referring to the projected capacity
based on SWOT analysis on Table 15, the expected rate of return of the project is shown
on Table 24. Considering the turndown capacity of the plant, the payback period is
expected to be less than 5 years.
Table 24
Preliminary Project Cash Flow and IRR
Year Annual Revenue Annual Opex CASH FLOW TURNDOWN CAPACITY
(%)
0 2015 0 0 ₱(5,581,777,475.95) -
1 2016 0 0 ₱(5,581,777,475.95) - 2 2017 ₱598,908,284.52 ₱1,528,433,390.09 ₱2,070,474,894.43 50%
3 2018 ₱3,598,908,284.52 ₱1,528,433,390.09 ₱2,070,474,894.43 50%
4 2019 ₱5,398,362,426.78 ₱2,292,650,085.13 ₱3,105,712,341.65 75% 5 2020 ₱7,197,816,569.04 ₱3,056,866,780.17 ₱4,140,949,788.86 100%
6 2021 ₱7,197,816,569.04 ₱3,056,866,780.17 ₱4,140,949,788.86 100%
7 2022 ₱7,197,816,569.04 ₱3,056,866,780.17 ₱4,140,949,788.86 100% 8 2023 ₱7,197,816,569.04 ₱3,056,866,780.17 ₱4,140,949,788.86 100%
9 2024 ₱7,197,816,569.04 ₱3,056,866,780.17 ₱4,140,949,788.86 100%
10 2025 ₱7,197,816,569.04 ₱3,056,866,780.17 ₱4,140,949,788.86 100%
11 2026 ₱7,197,816,569.04 ₱3,056,866,780.17 ₱4,140,949,788.86 100% 12 2027 ₱7,197,816,569.04 ₱3,056,866,780.17 ₱4,140,949,788.86 100%
13 2028 ₱7,197,816,569.04 ₱3,056,866,780.17 ₱4,140,949,788.86 100%
14 2029 ₱7,197,816,569.04 ₱3,056,866,780.17 ₱4,140,949,788.86 100% 15 2030 ₱7,197,816,569.04 ₱3,056,866,780.17 ₱4,140,949,788.86 100%
16 2031 ₱7,197,816,569.04 ₱3,056,866,780.17 ₱4,140,949,788.86 100%
17 2032 ₱7,197,816,569.04 ₱3,056,866,780.17 ₱4,140,949,788.86 100%
18 2033 ₱7,197,816,569.04 ₱3,056,866,780.17 ₱4,140,949,788.86 100% IRR 25%
Rationale of the project feasibility. Based on the preliminary economic
evaluation, it is highly recommended to pursue the Front-End Engineering Design (FEED)
of this plant. Once, the FEED phase is complete, it is recommended to perform a more
38
detailed economic analysis to evaluate if the project shall be continued to Detail
Engineering, Procurement and Construction (EPC) phase.
Company Profile
The name of the company is PhAce Philippines Corporation. At PhAce co., safety,
operational excellence and customer satisfaction are at the heart of all we do because our
customers matter to us. We have a wealth of professional and technical expertise at our
disposal which enables us to provide our customers with the prompt and efficient service
and high quality products they have come to expect from our business. Our customers have
high expectations: uniform product quality, on-time delivery and reliable supply at
competitive prices. They also demand high safety and environmental standards from their
business partners. Our customers trust PhAce co., to meet their expectations, through
operational excellence.
Mission of the Company
Mission for the employees. Fostering an entrepreneurial culture that encourages
teamwork, innovation, and excellence for the employees.
Mission for the Environment. To address national and global environmental
issues by applying environmental biotechnology and to fill the knowledge gap that exists
on the biology of engineered systems, resulting in better translation of academic knowledge
into industry applications.
Mission for the Community. To let people enjoy a sustainable life without
compromising their freedom and quality of life
39
Mission for the Costumers. To continue to efficiently facilitate diverse methods
of empowerment and professionally disseminate performance based deliverables to meet
our customer’s needs.
Mission for the Stake Holders. Nurture a winning network of customers and
suppliers, together we create mutual, enduring value.
Vision of the Company
To be the leading provider of quality phenol and acetone in the Philippines, with an
established and viable global presence by the end of 2027. The following are the key values
of the company:
Excellence in safety, health and environmental performance
Focus on customer satisfaction, total quality and reliability
Fanatical support in all we do
Empowerment of employees to create real value for our customers and
ourselves
Create remarkable experiences
Teamwork because we are a Team!
Company Logo
Shown in Figure 9 is the logo of the company. The letters P and H symbolizes the
name Philippines, which is the mother country of the company. Ace part of the company
name means it will be the number one provider of phenol and acetone product, analogous
to the ace card which is the highest playing card in a deck. The globe sign symbolizes the
40
global competitiveness of the company, through its latest and innovative technology of
producing quality products. In general, the logo of the company represents clearly who
Phace Philippines Corporation is, and what will it contribute to the country and world in
the future.
Figure 9. Company Logo of Phace Philippines Corporation
Organizational Chart of the Company
Shown in Figure 10 is the organizational chart of Phace Philippines Corporation. It
is composed of three board of directors and a president that will run the company. There
are seven departments where seven vice presidents are assigned.
41
BOARD OF DIRECTOR 1
BOARD OF DIRECTOR 2
BOARD OF DIRECTOR 3
PRESIDENTEXECUTIVE
ASSISTANT / OIC
VP FOR TECHNICAL
VP FOR MARKETING AND SALES
HR DEPARTMENT
VP FOR ADMIN
VP FOR SUPPLY CHAIN
VP FOR FINANCE
VP FOR CORPORATE ACCOUNTS
Quality Control Director
R&D Director
Production Director
Maintenance and
Engineering
Distribution
Sales
Training
Remuneration
Hiring
Medical Services
Quality Management Representativ
e (QMR)
Document Controller
Ground & Building
Maintenance
Warehouse Manager
Logistics and Transport
Purchaser
Procurement
Accounting
Investment
CSR
Corporate Communicati
ons Officer
Figure 10. Organizat ional chart of PhAce Philippines Corporation
Plant Location
The parameters considered by the designers in choosing the location are the site
location, site quality, topography, soil conditions, climate conditions, and flood risk.
Through a serious deliberation of the plant designers, the chosen site location is Hermosa
Ecozone Industrial Park, Bataan. Hermosa is a first class municipality in the province
of Bataan. It is one of the Eleven (11) municipalities of Bataan. It has a total land area of
15,730.00 hectares in lieu of 11.40% of the entire provincial area and it is composed of 23
barangays with a population of 52,484 people in 8,988 households. The municipality of
Hermosa is predominantly agricultural. A large portion of the agricultural area, mostly in
42
the lowland, is planted with palay or the rice. Table 25 shows the general information that
describes the municipality of Hermosa, Bataan.
Table 25
General Information of the Geography of Hermosa, Bataan
Country Philippines
Region Central Luzon (Region 3)
Province Bataan
District First District of Bataan
Barangays 23
Mayor Danilo C. Malana
Area 157.00 km2 (60.62 sq mi)
Population 112,707
Density 730/km2
Time zone PST (UTC+8)
ZIP code 2111
Dialing code 47
Income class 1st class
Topography. Hermosa’s topography is characterized as mostly flat to gently
rolling. The highest point within the municipality is located in the southwest of Barangay
Tipo and Mabiga, which is 400 meters above sea level. It lies on the northern portion of
the province of Bataan about 100 kilometers from Manila which can be reached within two
hours by land from Manila through the North Luzon Expressway and about 45 minutes
from Subic and an hour and a half from Clark. The Population as of May 1, 2010 at
Hermosa reached 56, 997. Hermosa, Bataan is 21 kilometers from the Balanga City which
is the capital of Bataan and the center of trade and commerce. It is the location of Petron
Bataan Refinery (PBR) Petrochemical Industrial Complex which will be the main source
of propylene and benzene which is the main raw material for the production of acetone and
phenol.
43
Power supply. Hermosa is 100% electrified and is being served by the Peninsula
Electric Company (PENELCO). Also, Manila Electric Company (MERALCO) provides
electricity for the town. As of 2013, one more 600 megawatts GN powerplant was being
constructed by the GN power in the same site in Mariveles aside from the existing one
which is also a 600 megawatts. The residential electricity cost of the Peninsula Electric
Cooperative (PENELCO) is 2.24 per kilowatt hour, lower than that of the Manila Electric
Company (MERALCO). Table 26 shows the charges on electricity rates in Hermosa.
Table 26
Electric charge of PENELCO
RATE CHARGE Residential Commercial Industrial
Average Rate/KWH PhP 8.9858 PhP 7.8113 PhP 6.4708
Source: Peninsula Electric Cooperative, May 2014
Commercial/Industrial ports. there are numerous industries located at around
Hermosa, Bataan such as the Petron Bataan Refinery (PBR) Petrochemical Industrial
Complex, Total Petroleum Philippines, UniOil Philippines, Philippine National Oil
Company-Petrochemical Development Corporation (PNOC-PDC), Philippine Resins
Industries, Inc (PRII), Bataan 2020 Papermills, Ammunition Plant in DND Arsena, Orica
Philippines, Inc., Herma Group of Companies, different locators at Bataan Economic Zone
in Mariveles and Bataan Techno Park in Morong, and other light to medium industries in
other municipalities. There are ten private ports/discharging and loading points in the
different parts of the province and three national ports under the jurisdiction of Philippine
44
Ports Authority (PPA) as shown in tables 27 and 28. The town has a total of 1 bank, 21
schools, 15 medical clinics/health centers, and 2 recreational facilities.
Table 27
List of Airport near Hermosa Bataan
AIRPORT NAME LOCATION
Clark International Airport Clark Freeport Zone
Subic Bay International Airport Morong, Bataan
Table 28
List of Ports near Hermosa Bataan
PORT NAME LOCATION
Port of Lamao Lamao, Bataan
Port of Mariveles Mariveles, Bataan
Subic Bay Freeport Subic Bay, Bataan
Water supply. The Hermosa Water District supplies the water requirement of
Hermosa town proper while the economic zone has its own water system, the Bataan
Economic Zone Water System. There are three big watershed groups in Bataan, which are
the Subic watershed from Morong including half of Bagac, the Mt. Natib watershed from
Dinalupihan down to Balanga, and the Mariveles watershed from Mariveles to Limay,
Orion, Pilar and the other half of Bagac. The province is drained by more than 100 rivers
and small branches radiating from these watershed areas and provides a range of purposes,
such as irrigation, navigation, and water reservoir. The province’s water supply comes from
these freshwater sources and a widespread water reserve, extorted by numerous deep wells
and free flow areas in all municipalities. Shown in table 29 are the prices for water services
in Hermosa, Bataan.
45
Table 29
Prices of Balanga Water District Services
Cubic Meter Residential/Gov’t Commercial A Commercial B
0-10 PhP 130.00 PhP 195.00 PhP 227.50
11-20 PhP 144.50 –
PhP275.00
PhP216.75 -PhP
412.50
PhP252.85-PhP
481.00
21-30 PhP291.25 -PhP
437.50
PhP436.85-PhP
565.00
PhP509.40 -PhP
765.00
31-40 PhP455.75-PhP
620.00
PhP683.35-PhP
929.50
Ph796.90-PhP 1,
084
41-50 PhP640.50-PhP
825.00
PhP960.25-PhP
1,237
PhP1,119.85-PhP
1,142.50
51-100 PhP848.00-PhP
1,975
PhP1,271.50-PhP
2962.00
PhP1,482.75-PhP
2, 962.00
Source: Balanga Water District, June 2014
Communication. Telecommunication facilities are provided by PLDT,
Telecommunication Office (BUTEL) while Digitel is the major provider of
telecommunication services in the municipality. Hermosa is 100% electrified and is being
served by the Peninsula Electric Company (PENELCO). Smart/Globe/Sun Cell Sites,
RCPI, TeleFast, DHL, JRS, Fax and Parcel, LBC and Ddel Bros-UPS are leading
communications company operating in the area which provides adequate connectivity to
other cities enabling Hermosa, Bataan available for business. Shown in table 30 are the
prices of internet and landline services.
46
Table 30
Internet / Landline Rates
PARTICULARS COST
Voice / Landline:
Monthly Rental (Commercial) PhP 936.00 (21.53 USD)
Monthly Rental (Residential) PhP 617.00 (14.19USD)
Data / Internet:
Monthly Rental – 1MB up to 4MB
(Commercial) PhP 4, 000.00 (92.00 USD)
Monthly Rental – up to 1MB (Residential) PhP 999.00 (23.00 USD)
Source: PLDT, 2014
Climate and flood risks. Hermosa Creek can experience destructive earthquakes
with an average of one every 50 years, with occurrences at >7 Richter. When a strong
earthquake occurs, damage will be slight seen in specially designed structures but
considerable in ordinary substantial buildings with partial collapse, an example would be
moving of heavy furnitures but for poorly built structures, it will be demolished. There is
a medium-low occurence of periods with extreme drought but Flooding risk is extremely
high. Also, there is extremely high chance of cyclones hitting Hermosa Creek but zero
chance of having a landslide. The climate in Hermosa is classified as a tropical savanna
(winter dry season), with a tropical moist forest biozone. The soil in the area is high in
nitosols, andosols (nt), soil with deep, clay-enriched lower horizon with shiny ped surfaces.
Labor cost. One important factor in determining the annual operating expenses of
the plant is the labor cost, as shown in Table 31.
Table 31
47
DOLE labor price in Region 3
SECTOR DAILY MINIMUM WAGE
Non-Agriculture
Establishments with total assets of P30
million or more (690,000.00 USD or
more)
PhP 336.00 (7.728 USD)
Establishments with total assets less than
P30 million (689,999.00 USD or less) PhP 329.00 (7.567 USD)
Agriculture
Plantation PhP 306.00 (7.038USD)
Non-Plantation PhP 290.00 (6.67 USD)
Retail service
With 16 or more workers PhP 325.00 (7.475 USD)
With less than 16 workers PhP 311.00 (7.153 USD)
Source: DOLE Region 3 Effective October 11, 2012
48
Process Description
Shown in Figure 11 is the block flow diagram of the manufacturing process of
Phace Philippines Corporation in producing phenol and acetone through the advanced
cumene process. In general, the main process involved was the alkylation of benzene with
propylene to produce cumene, followed by a separation process through distillation to
recover cumene, then oxidation of cumene to produce cumene hydroperoxide (CHP),
followed by CHP cleaving to produce phenol and acetone, then finally a separation process
through distillation to recover each of the product separately. The main technology adapted
in the process was the cumene production process, which is currently considered to be the
latest and cheapest technology ever yet to consider for the production of phenol and acetone
from the main raw materials, benzene and propylene. For the process flow diagram (PFD)
of the process, please see Appendix F. For the piping and instrumentation diagram (PNID)
of the plant, see Appendix F.
49
Alkylation Reactor
(FIXED BED)
Distillation ColumnsPropylene
Benzene
Oxidation Tower
Cleavage ReactorDistillation Columns
(Zeolite catalyst)
Air
Acetone
OSBL: Steam generator, Power generator, Waste Water Treatment Facility, Cooling Water System
Cumene
DIPB, benzene
Cumene Hydroperoxide
(CHP)(CuO nanoparticle catalyst)
(Sulfonic resin catalyst)
Cumene
Phenol
Figure 11. Block Flow Diagram of Phenol and Acetone production through Cumene
Process
The route to cumene production. The utilization of cumene (isopropylbenzene)
in the manufacture of phenol and acetone is applied on a huge scale in the chemical
industry. It is achieved through the Friedel-Crafts alkylation of benzene with propylene.
In Freidel-Crafts reaction, Benzene is alkylated with propylene (propene) in the liquid or
gas phase, in the presence of a solid catalyst (Tyman, 1996). The reactions will occur in a
liquid phase at a particular temperature range and pressure that will result to either high or
complete conversion of propylene as well as maintain the reactants in the liquid phase,
throughout the reactor. Industrially, alkyl groups can be substituted into a benzene ring
using a variant on Freidel-Crafts alkylation. Shown in Figure 12 are the chemical structures
of the chemicals considered in the first part of the process.
50
Figure 12. Chemical Structures of Benzene plus Propylene to Cumene
To put an isopropyl group on the ring (isopropylbenzene/cumene), benzene is
reacted with propylene on a fixed bed reactor that contains an ideal catalyst. Figure 13
shows the diagram for the alkylation mechanism of benzene and propylene to form
cumene.
Figure 13. Diagram of the industrial alkylat ion of benzene to cumene
Zeolite based catalysts such as 𝛽, Y, ZSM-12, and MCM-22 can be used in the
liquid phase alkylation of benzene with propylene to produce cumene (Norouzi, Hasani,
51
Haddadi-Sisakht, & Mostoufi, 2014). Shown in Table 32 is the type of catalyst used in the
first reactor of the process. During the alkylation reaction, side reactions occur which
produces PDIB (𝑝 − 𝑑𝑖𝑖𝑠𝑜𝑝𝑟𝑜𝑝𝑦𝑙 𝑏𝑒𝑛𝑧𝑒𝑛𝑒). This results to additional consumption of
raw materials that negatively affects the economics of the process. In order minimize the
production of the side product and increase the selectivity of the main reaction over the
PDIB reaction, an excess amount of benzene is introduced in the reactor. The Benzene to
propylene mole ratio was maintained at more than 4 in the reactor (Perego & Ingallina,
2002). The excess amount of benzene will absorb the heat generated by the exothermic
reaction in the reactor to keep the selectivity of the cumene reaction high and suppress
undesirable reactions between propylene molecules to form higher linear hydrocarbons.
Table 32
Information on catalyst used for alkylation and transalkylation reactions
Catalyst 𝛽-zeolite catalyst
Particle Diameter 3.0 mm
Porosity 0.3
Price 8.367 USD per Kg
Source: Dai, Lei, Zhang, Li, & Chen, 2013
Price: Zauba, 2015
The alkylation reactions follows the Eley-Rideal kinetic model, which means that
the adsorption of propylene on the catalyst is the rate-determining step (Corma, Martinez-
Soria, & Schnoeveld, 2000). As shown in Table 33, the kinetic law reduces to first order
reaction. The reactor in the system consist of a fixed bed of catalysts pellets with an inlet
temperature range of 150 to 200℃. The pressure in the reactor is maintained high enough
between 2.5 to 3.5 MPa to ensure that the boiling point of the solution is at least 20℃ higher
52
than the temperature elsewhere in the reactor (Norouzi, Hasani, Haddadi-Sisakht, &
Mostoufi, 2014).
Table 33
Kinetics of alkylation and transalkylation reactions (𝐸 is in 𝑘𝐽/𝑘𝑚𝑜𝑙, rate of
react ion is in 𝑘𝑚𝑜𝑙/𝑚3 ∙ 𝑠, and concentration is in 𝑘𝑚𝑜𝑙/𝑚3)
TYPE REACTION RATE CONSTANTS
Alkylation Cumene Reaction 𝑘1 = 6510 𝑒𝑥𝑝 (−52564
𝑅𝑇)
DIPB Reaction 𝑘2 = 450 𝑒𝑥𝑝 (−55000
𝑅𝑇)
Source: Dimian and Bildea, 2008; Pathak et al., 2011
The route to phenol production. The next process involved the liquid phase air
oxidation of cumene, called cumene peroxidation process, to produce cumene peroxide at
the proper reaction temperature of 358K (Zhang, Wang, Hongbing, Wu, & Zeng, 2007).
Cumene is continuously fed to the oxidation vessel (fluidized bed) until 15 to 25 percent
of the cumene is oxidized. The mixture from the oxidizer should be around 60% to 80%
by weight cumene peroxide, which will then be fed to a reactor for the cleaving of CHP to
phenol and acetone. The cleavage mechanism is an example of 1,2 shift from carbon to
oxygen (Speight, 2002). Figure 14 depicts the mechanism of cumene oxidation to form
cumene hydroperoxide.
53
Figure 14. Diagram for the mechanism of Cumene Oxidation
In cumene oxidation, cumene is oxidized in air which removes the tertiary benzylic
hydrogen from cumene and hence forms a cumene radical. Table 34 shows the type of
catalysts used in the oxidation tower.
Table 34
Catalyst for Oxidation Data
Catalyst CuO Nanoparticle catalyst
Particle Diameter >140 nm
Density 790 kg/m3
Source US Research Nanomaterials, Inc.
Price 376 USD per Kg
Source: Zhang, Wang, Hongbing, Wu, & Zeng, 2007
Price: US Research Nanomaterials, Inc., 2015
54
The cumene radical then bonds with an oxygen molecule to give cumene
hydroperoxide radical. This in turn forms into cumene hydroperoxide by abstracting
benzylic hydrogen from another cumene molecule. This latter cumene converts into
cumene radical and feeds back into subsequent chain formations of cumene
hydroperoxides. Table 35 shows the kinetic reaction details for cumene oxidation.
Table 35
Cumene oxidation reaction details
Type of Reactor Fluidized Bed
Temperature (K) 318
Conversion (%) 17
Selectivity for CHP (%) >99
Reaction Pressure (atm) 1
Catalyst CuO Nanoparticle
Source: Zhang, Wang, Ji, Wu, & Zeng, 2007
Figure 15 depicts the mechanism for the decomposition of cumene hydroperoxide
to phenol and acetone using a particular acidic catalyst (either solid or liquid). Cumene
hydroperoxide is then hydrolysed in an acidic medium (the Hock rearrangement) to give
phenol and acetone.
55
Figure 15. Diagram for the Mechanism of CHP decomposit ion to Phenol and
Acetone
In the first step, the terminal hydroperoxy oxygen atom is protonated. This is
followed by a step in which the phenyl group migrates from the benzyl carbon to the
adjacent oxygen and a water molecule is lost, producing a resonance stabilized tertiary
carbocation. The resulting carbocation is then attacked by water, a proton is then
transferred from the hydroxy oxygen to the ether oxygen, and finally the ion falls apart into
phenol and acetone. Table 36 shows the optimum operation conditions for the cleaving
reactor.
56
Table 36
Optimum operation conditions and Reaction kinetics of Catalytic
Decomposition Process of Cumene Hydroperoxide
Type of Reactor Fluidized Bed Reactor
Temperature (℃) 75 to 85, preferably 80
Space Velocity (WHSV) (ℎ−1) 30 to 40
Selectivity (%) >98
Conversion (%) >99
Solid Holdup (catalyst) (wt%) 1 to 1.5
Catalyst Sulfonic Resin
Order of Reaction 1
Kinetic Rate Model of Decomposition 𝑘𝑚 = 1939.1 exp (−36.43 × 103𝐽𝑚𝑜𝑙−1
𝑅𝑇)
Source: Huang, Han, Wang, & Jin, 2002
The catalyst for the cleaving reaction requires an acid catalyst. Shown in Table 37
is the type of catalyst used in the cleaving reaction.
Table 37
Catalyst for Cleaving Reaction Data
Catalyst Sulfonic Resin
Particle Diameter 0.02mm
Density 0.00118 kg/m3
Source Wenzhou Foreign Trade Industrial Product
Co.,Ltd. (China)
Price 2930 USD per Kg
Source: Huang, D., Han, M., Wang, J., & Jin, Y., 2002
Price: ChemPep Inc., 2015
The products are separated by distillation. Acetone is firstly removed in the first
column. The bottom is vacuumed distilled to send unreacted cumene overhead. The
product is purified through catalytic hydrogenation through careful fractionation. In the
57
latter case, bottoms from the vacuum are further distilled to separate cumene from phenol,
phenol being the overhead product.
Economic advantage of the technology. The comparative cost for the currently
existing processes for the production of phenol is shown in Table 38. Currently, the
Cumene process is universally favored in the United Kingdom (UK) and United States of
America (US) because of its lower cost and higher product yield.
Table 38
Comparison of cost of production of phenol and acetone
Process Benzene -
Sulphonate
Chloro-
benzene Raschig
Cumene-
hydroperoxide
Benzene-
cyclohexane
Toluene
Oxidation
Net
Production
cost (£/ton)
81.7 78.3 57.1 45.7 51.5 59.5
Source: Tyman, 1996
58
Heat and Material Balance
In this plant design project, the software called Aspen Hysys (Version 8) was used
to simulate and generate heat and material balances for each equipment in the plant. Aspen
HYSYS is a comprehensive process modeling system that is currently utilized by leading
engineering companies worldwide. In general, this software is used to design as well as
optimize processes and operations involved in a manufacturing plant. Using the software,
material streams, compositions, and energy streams were obtained and described in depth.
The main Aspen Hysys simulation involves the modeling of the major three
processes of the plant. The first process involves the production of cumene through
alkylation reaction between benzene and propylene. The fluid package chosen in Aspen
Hysys is NRTL because it is generally used for chemical systems and HF alkylation with
highly non-ideal chemicals and it is thermodynamically consistent, which can be applied
to ternary and higher order systems. Table 33 shows the kinetic data for alkylation and
transalkylation reaction needed by Aspen Hysys for the first reactor. The second process
involves the oxidation of cumene to produce cumene hydroperoxide, and its kinetics of
reaction is described in Table 35. The last process involves the cleaving of cumene
hydroperoxide to produce phenol and acetone, and the kinetics of reaction is described in
Table 36. Table 39 shows the component list for the simulation of the main process.
59
Table 39
Data for the component list of the main process in Aspen Hysys
Component Type
Propene Pure Component
Oxygen Pure Component 14-iP-BZ Pure Component
Acetone Pure Component
Phenol Pure Component
Propane Pure Component Nitrogen Pure Component
CumHyPeroxid Pure Component
Cumene Pure Component Benzene Pure Component
Air Pure Component
H2O Pure Component
The utilities required of the process are simulated as well using Aspen Hysys. The
first utility involved the generation of steam and the second involves the closed loop
circulation of cooling water for the plant. Tables 40 and 41 depicts the component list for
the simulation of the stated utilities.
Table 40
Data for the component list of the steam gen utility in Aspen Hysys
Component Type
Propane Pure Component Nitrogen Pure Component
CO2 Pure Component
Oxygen Pure Component H2O Pure Component
60
Table 41
Data for the component list of the cooling water system utility in Aspen Hysys
Component Type
H2O Pure Component
For a more detailed simulation of the process and utilities of the plant using Aspen
Hysys, see Appendix A. Shown in Table 42 is the summarized material streams of the
process. Tables 43 and 44 shows the summarized compositions for each streams and energy
streams of the main process.
Table 42
Material Streams of the Process
STREAM Vapour
Fraction Temperature Pressure
Molar
Flow
Mass
Flow
Liquid
Volume
Flow
Heat
Flow
Unit C bar_g kgmole/h Kg/h m3/h kJ/h
Benzene 0 25 -0.01325 80 6248.8 14.166563 7961764
Benzene_to_mixer 0 28.243691 34.38675 80 6248.8 14.166563 8027489
Propylene 0 25 10.98675 79.67 3354 6.43999 295193.9
Prop_to_mixer 0 27.337761 34.38675 79.67 3354 6.43999 315840.3
To Heater 0 72.429121 34.38675 13810.09 1071616 1222.03203 7.49E+08
To_Alkylator 0 170 33.766222 13810.09 1071616 1222.03203 9.6E+08
To_valve 0 170 33.352865 13731.05 1071616 1219.635126 9.52E+08
Cumene_Bot 0 159.0118 0.18675 79.12 9510.42 10.997799 -660888
Benzene_Dist 0 70.053451 -0.01325 13651.93 1062105 1208.637325 7.4E+08
To_pump 0 70.044379 -0.01325 13570.42 1055764 1201.425477 7.35E+08
To_column1 0.44099 86.599685 0.28675 13731.05 1071616 1219.635126 9.52E+08
To-Mixer 0 73.139927 34.38675 13570.42 1055764 1201.425477 7.41E+08
To_OxiTow_1 0 44.85 -0.413686 164.12 19520 22.416604 -6893388
AIR 1 25 0 380 10963.1 12.673355 0
To_tee 1 83.159439 0.62675 380 10963.1 12.673355 648168.1
To_OT_1 1 83.159439 0.62675 95 2740.78 3.168339 162042
VAP_1 1 44.85 -0.012777 76.18 2248.24 2.775003 49224.18
To_OxiTow_2 0 44.85 -0.012777 162.99 20012.5 22.358325 -8675304
To_OT_2 1 83.159439 0.62675 95 2740.78 3.168339 162042
To_OT_3 1 83.159439 0.62675 95 2740.78 3.168339 162042
VAP_2 1 44.85 -0.022341 76.16 2232.43 2.757165 48642.77
To_OxiTow_3 0 44.85 -0.022341 161.87 20520.8 22.317883 -1E+07
61
VAP_3 1 44.85 -0.031921 76.55 2230.37 2.749782 48130.51
To_OxiTow_4 0 44.85 -0.031921 160.94 21031.2 22.297683 -1.2E+07
To_OT_4 1 83.159439 0.62675 95 2740.78 3.168339 162042
To_Cleaving 0 44.85 -0.041213 160.13 21445.2 22.274623 -1.4E+07
VAP_4 1 44.85 -0.041213 79.88 2326.75 2.830657 49449.35
To_CleavageR 0 45.080979 3.293705 160.13 21445.2 22.274623 -1.4E+07
Decomposition
Effluent 0 80 2.98675 235.34 21445.2 23.640879 -3.2E+07
Acetone Product 0 91.975505 2.68675 75.26 4369.79 5.531312 -1.8E+07
to next Column 0 214.120846 2.88675 160.08 17075.4 18.109567 -8943146
Dist_Cumene 0 151.888966 0 84.95 10004.3 11.412643 -1808721
Phenol Product 0 236.829828 2.78675 75.13 7071.12 6.696924 -8221078
TO_FLARE 1 44.85 -0.041213 308.77 9037.79 11.112607 195446.8
Acetone to
STORAGE 0 30 2.645381 75.260491 4369.79 5.531312 -1.9E+07
Phenol to
STORAGE 0 54.444444 2.745381 75.127467 7071.12 6.696924 -1.1E+07
To Mixer2 0 151.888859 0 84.993763 10009.6 11.418805 -1808819
To Cooler_E-100 0.02402 151.967835 0 164.11617 19520 22.416604 -2469708
1 0 44.885457 0 164.11617 19520 22.416604 -6892120
2 0 44.851035 0 162.98699 20012.5 22.358325 -8675266
3 0 44.85171 0 161.87431 20520.8 22.317883 -1E+07
4 0 44.852313 0 160.93841 21031.2 22.297683 -1.2E+07
Table 43
Composition of each streams for the process
Comp
Mole Frac
(Propene)
Comp
Mole Frac
(Oxygen)
Comp
Mole Frac (14-
iP-BZ)
Comp Mole Frac
(Acetone)
Comp
Mole Frac
(Phenol)
Comp
Mole Frac
(Propane)
Unit
Benzene_to_mixer 0 0 0 0 0 0
Propylene 0.990453 0 0 0 0 0.009547
Prop_to_mixer 0.990453 0 0 0 0 0.009547
To Heater 0.00574 0 0 0 0 0.009155
To_Alkylator 0.00574 0 0 0 0 0.009155
To_valve 0.000017 0 0.000001 0 0 0.009208
Cumene_Bot 0 0 0.000123 0 0 0
Benzene_Dist 0.000017 0 0 0 0 0.009261
To_pump 0.000027 0 0 0 0 0.009261
To_column1 0.000017 0 0.000001 0 0 0.009208
To-Mixer 0.000027 0 0 0 0 0.009261
To_OxiTow_1 0 0 0.000059 0 0.048226 0
AIR 0 0.21 0 0 0 0
62
To_tee 0 0.21 0 0 0 0
To_OT_1 0 0.21 0 0 0 0
VAP_1 0 0 0 0 0.000388 0
To_OxiTow_2 0 0 0.00006 0 0.048379 0
To_OT_2 0 0.21 0 0 0 0
To_OT_3 0 0.21 0 0 0 0
VAP_2 0 0 0 0 0.000316 0
To_OxiTow_3 0 0 0.00006 0 0.048563 0
VAP_3 0 0.007414 0 0 0.000264 0
To_OxiTow_4 0 0.000002 0.00006 0 0.04872 0
To_OT_4 0 0.21 0 0 0 0
To_Cleaving 0 0.000013 0.000061 0 0.048851 0
VAP_4 0 0.050234 0 0 0.000232 0
To_CleavageR 0 0.000013 0.000061 0 0.048851 0
Decomposition
Effluent 0 0.000009 0.000041 0.319595 0.352834 0
Acetone Product 0 0.000029 0 0.999369 0 0
to next Column 0 0 0.000061 0 0.518718 0
Dist_Cumene 0 0 0 0 0.093203 0
Phenol Product 0 0 0.000129 0 0.99987 0
TO_FLARE 0 0.014833 0 0 0.000299 0
Acetone to STORAGE 0 0.000029 0 0.999369 0 0
Phenol to STORAGE 0 0 0.000129 0 0.99987 0
To Mixer2 0 0 0 0 0.093121 0
To Cooler_E-100 0 0 0.000059 0 0.048226 0
1 0 0 0.000059 0 0.048226 0
2 0 0 0.00006 0 0.048379 0
3 0 0 0.00006 0 0.048563 0
4 0 0.000002 0.00006 0 0.04872 0
Benzene 0 0 0 0 0 0
Table 43 Cont inued
Composition of each streams for the process
Comp Mole Frac
(Nitrogen)
Comp Mole Frac
(CumHyPeroxid)
Comp
Mole Frac
(Cumene)
Comp
Mole Frac
(Benzene)
Unit
Benzene_to_mixer 0 0 0 1
Propylene 0 0 0 0
Prop_to_mixer 0 0 0 0
To Heater 0 0 0.000114 0.984991
63
To_Alkylator 0 0 0.000114 0.984991
To_valve 0 0 0.005869 0.984906
Cumene_Bot 0 0 0.999867 0.00001
Benzene_Dist 0 0 0.000108 0.990614
To_pump 0 0 0.000116 0.990597
To_column1 0 0 0.005869 0.984906
To-Mixer 0 0 0.000116 0.990597
To_OxiTow_1 0 0.000046 0.951664 0.000005
AIR 0.79 0 0 0
To_tee 0.79 0 0 0
To_OT_1 0.79 0 0 0
VAP_1 0.983624 0.000006 0.015981 0.000001
To_OxiTow_2 0.000726 0.122446 0.828385 0.000004
To_OT_2 0.79 0 0 0
To_OT_3 0.79 0 0 0
VAP_2 0.98583 0.000012 0.013841 0.000001
To_OxiTow_3 0.000524 0.246525 0.704323 0.000004
VAP_3 0.98067 0.000018 0.011632 0.000001
To_OxiTow_4 0.000378 0.368381 0.582455 0.000004
To_OT_4 0.79 0 0 0
To_Cleaving 0.000276 0.46976 0.481035 0.000003
VAP_4 0.939774 0.000024 0.009735 0.000001
To_CleavageR 0.000276 0.46976 0.481035 0.000003
Decomposition
Effluent 0.000188 0.000032 0.327299 0.000002
Acetone Product 0.000587 0 0.000008 0.000007
to next Column 0 0.000047 0.481174 0
Dist_Cumene 0 0.000088 0.906708 0
Phenol Product 0 0 0.000001 0
TO_FLARE 0.972092 0.000015 0.012759 0.000001
Acetone to
STORAGE 0.000587 0 0.000008 0.000007
Phenol to STORAGE 0 0 0.000001 0
To Mixer2 0 0.000088 0.90679 0
To Cooler_E-100 0 0.000046 0.951664 0.000005
1 0 0.000046 0.951664 0.000005
2 0.000726 0.122446 0.828385 0.000004
3 0.000524 0.246525 0.704323 0.000004
4 0.000378 0.368381 0.582455 0.000004
Benzene 0 0 0 1
64
Table 44
Energy streams of the process
Unit Q-pump-
102
Q-pump-
100
Q-Heater-
100 Q-PFR-100 Q-Cond-100 Q-Reb-100
kJ/h 65724.37458 20646.39492 210583600.9 7608739.103 586285321.7 372840106.2
Q-Pump-
101
Q-Cooler-
100
Q-Comp-
100 Q-OX-1 Q-OX-2 Q-OX-3
kJ/h 5909563.646 4423679.953 648168.1337 -
1896002.254 -
1902174.803 -
1857071.734
Q-OX-4 Q-Pump-
103 Q-PFR-101 Q-Cond-101 Q-Reb-101 Q-Cond-102
kJ/h -
1543792.885 9137.795762 18555061.4 2696181.269 7912592.66 22440817.75
Q-Reb-102 Q-Cooler-
102
Q-Cooler-
103 Q-100 Q-101 Q-102
kJ/h 21216913.9 611621.8101 2839892.353 1267.605212 38.009834 64.529379
Q-103
kJ/h 89.612062
Using Aspen Hysys software, a heat and material balance were simulated
for the steam generation system and cooling water system of the plant. For the utilities of
the plant, Tables 45, 46, and 47 depicts the requirement of the plant.
65
Table 45
Cooling Water Requirement of the Plant
PROPERTIES Inlet to Cooling Tower Outlet
Vapour / Phase Fraction 0 0
Temperature [C] 60 32.11818066
Pressure [kPa] 2059.956445 1101.325
Molar Flow [kgmole/h] 312354.6137 312354.6137
Mass Flow [kg/h] 5627099.751 5627099.751
Std Ideal Liq Vol Flow [m3/h] 5638.455471 5638.455471
Molar Enthalpy [kJ/kgmole] -282346.6114 -284460.2213
Molar Entropy [kJ/kgmole-C] 14.95464482 8.383744001
Heat Flow [kJ/h] -88192266744 -88852462549
Liq Vol Flow @Std Cond [m3/h] 5633.061288 5633.061288
Act. Volume Flow [m3/h] 5653.898758 5653.898758
Table 46
Steam requirement of the plant
PROPERTIES Inlet to Boiler Steam Generated
Vapour / Phase Fraction 0 1 Temperature [C] 244.9187093 253.6877563
Pressure [kPa] 4293.377832 4231.325
Molar Flow [kgmole/h] 20015.50196 20015.50196
Mass Flow [kg/h] 360581.279 360581.279 Std Ideal Liq Vol Flow [m3/h] 361.3089469 361.3089469
Molar Enthalpy [kJ/kgmole] -267779.0355 -236459.9051
Molar Entropy [kJ/kgmole-C] 49.47427638 108.9330054 Heat Flow [kJ/h] -5359731810 -4732863696
Liq Vol Flow @Std Cond [m3/h] 360.9632909 360.9632909
Act. Volume Flow [m3/h] 446.7531747 16932.16337
Table 47
Fuel requirement of the plant
PROPERTIES Values
Vapour / Phase Fraction 0
Temperature [C] 30
Pressure [kPa] 101.3
Act. Volume Flow [m3/h] 2.71
Type of Fuel Industrial LPG
66
Information on the conditions, availability, and price of utility services such as fuel,
steam, cooling water, process air, process water, and electricity can be obtained from the
provincial government of Hermosa, Bataan. Utility equipment are built outside the process
area to supply the requirements of several processes of the plant.
67
Equipment Sizing and Specification
This chapter includes the nature and methodology of the design process used in
generating specifications sheets for each equipment. The generated design concepts will
be further used in the detailed economic evaluation of the project. The economic evaluation
usually entails analyzing the capital and operating costs of the process to determine the
return of investment, which will be further elaborated in the next chapter.
Other equipment that already have sufficient data for economic performance
evaluation need no specifications to be generated. In general, ISBL equipment of the plant
were designed in this chapter and OSBL equipment were detailed for economic evaluation
purposes in the next chapter.
Calculation Sheets
To easily understand and check the design generated on this chapter, calculation
sheets are provided. All of the assumptions and approximations made were included in
these sheets.
Specification Sheets
The sheets consisted of the main specifications of the equipment as required in the
process of the manufacturing plant.
68
Storage Tanks Specification Sheets
See Appendix B for calculation sheets
V-101: Propylene Feed Storage Tank (Pressure Vessel)
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAMALLMFS
2 01/22/15 EAM
66
SKETCH
Minimum Thickness for Closure (mm)
Vertical
Concrete
500
500
7.2
7.34
70
21.6
2:1 ellipsoidal
Innage Allowance (mm)
Inside Diameter (m)
Outside Diameter (m)
Minimum Thickness (mm)
T/T Height (m)
Closure/Head
SPECIFICATION FOR CONSTRUCTION
Geometry Cylindrical
Position
Support/Foundation
Outage Allowance (mm)
Corrosion Allowance (mm)
Maximum Allowable Stress (Mpa)
Joint Efficiency
Material of Construction Carbon steel
0.85
88.94236908
3.8
METALLURGY
SERVICE Propylene
Minimum Metal Temperature (deg C)
1200
25
1372
93
0
15 ~ 20
Temperature (deg C)
Minimum Pressure (kPa)
Temperature (deg C)
DESIGN CONDITIONS
Pressure (kPa)
Pressure (kPa)
TYPE Pressure vessel
MEASUREMENT SYSTEM Metric System
OPERATING CONDITIONS
ITEM NUMBER V-101
Project No. 1
SHEET 1 of 1
STORAGE TANK
Quantity 6
7.34 m
500 mm
21.6 m
500 mm
69
V-102: Benzene Feeeed Storage Tank (Atmospheric Vessel)
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
2 01/22/15 EAM
22
SKETCH
Minimum Thickness for Closure (mm)
Vertical
Concrete
500
500
7.4
7.426
13
22.2
2:1 ellipsoidal
Innage Allowance (mm)
Inside Diameter (m)
Outside Diameter (m)
Minimum Thickness (m)
T/T Height (m)
Closure/Head
SPECIFICATION FOR CONSTRUCTION
Geometry Cylindrical
Position
Support/Foundation
Outage Allowance (mm)
Corrosion Allowance (mm)
Maximum Allowable Stress (Mpa)
Joint Efficiency
Material of Construction Carbon steel
0.85
88.94236908
3.8
METALLURGY
SERVICE Benzene
Minimum Metal Temperature (deg C)
100
25
445.9678571
93.33333333
0
15 ~ 20
Temperature (deg C)
Minimum Pressure (kPa)
Temperature (deg C)
DESIGN CONDITIONS
Pressure (kPa)
Pressure (kPa)
TYPE Atmospheric vessel
MEASUREMENT SYSTEM Metric System
OPERATING CONDITIONS
ITEM NUMBER V-102
Project No. 1
SHEET 1 of 1
STORAGE TANK
Quantity 6
7.426 m
500 mm
22.2m
500 mm
70
V-103: Acetone Product Storage Tank A (Pressure Vessel)
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
2 01/22/15 EAM
ITEM NUMBER V-103
Project No. 1
SHEET 1 of 1
STORAGE TANK
Quantity 3
TYPE Pressure vessel
MEASUREMENT SYSTEM Metric System
OPERATING CONDITIONS
METALLURGY
SERVICE Acetone
Minimum Metal Temperature (deg C)
365.9
30
538
93
0
15 ~ 20
Temperature (deg C)
Minimum Pressure (kPa)
Temperature (deg C)
DESIGN CONDITIONS
Pressure (kPa)
Pressure (kPa)
Corrosion Allowance (mm)
Maximum Allowable Stress (Mpa)
Joint Efficiency
Material of Construction Carbon steel
0.85
88.94236908
3.8
Minimum Thickness (m)
T/T Height (m)
Closure/Head
SPECIFICATION FOR CONSTRUCTION
Geometry Cylindrical
Position
Support/Foundation
Outage Allowance (mm)
20
SKETCH
Minimum Thickness for Closure (mm)
Vertical
Concrete
500
500
5.4
5.448
24
16.2
2:1 ellipsoidal
Innage Allowance (mm)
Inside Diameter (m)
Outside Diameter (m)
5.448 m
500 mm
16.2 m
500 mm
71
V-104: Acetone Product Storage Tank B (Pressure Vessel)
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
2 01/22/15 EAM
11
SKETCH
Minimum Thickness for Closure (mm)
Vertical
Concrete
500
500
2.9
2.93
15
8.7
2:1 ellipsoidal
Innage Allowance (mm)
Inside Diameter (m)
Outside Diameter (m)
Minimum Thickness (mm)
T/T Height (m)
Closure/Head
SPECIFICATION FOR CONSTRUCTION
Geometry Cylindrical
Position
Support/Foundation
Outage Allowance (mm)
Corrosion Allowance (mm)
Maximum Allowable Stress (Mpa)
Joint Efficiency
Material of Construction Carbon steel
0.85
88.94236908
3.8
METALLURGY
SERVICE Acetone
Minimum Metal Temperature (deg C)
365.9
30
538
93
0
15 ~ 20
Temperature (deg C)
Minimum Pressure (kPa)
Temperature (deg C)
DESIGN CONDITIONS
Pressure (kPa)
Pressure (kPa)
TYPE Pressure vessel
MEASUREMENT SYSTEM Metric System
OPERATING CONDITIONS
ITEM NUMBER V-103a
Project No. 1
SHEET 1 of 1
STORAGE TANK
Quantity 3
2.93 m
500 mm
8.7m
500 mm
72
V-105: Phenol Product Storage Tank A (Atmospheric Vessel)
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
22
SKETCH
Minimum Thickness for Closure (mm)
Vertical
Concrete
500
500
5.8
5.822
11
17.4
2:1 ellipsoidal
Innage Allowance (mm)
Inside Diameter (m)
Outside Diameter (m)
Minimum Thickness (m)
T/T Height (m)
Closure/Head
SPECIFICATION FOR CONSTRUCTION
Geometry Cylindrical
Position
Support/Foundation
Outage Allowance (mm)
Corrosion Allowance (mm)
Maximum Allowable Stress (Mpa)
Joint Efficiency
Material of Construction Carbon steel
0.85
88.94236908
3.8
METALLURGY
SERVICE Phenol
Minimum Metal Temperature (deg C)
375.9
54.44
548.2214286
93.33333333
0
15 ~ 20
Temperature (deg C)
Minimum Pressure (kPa)
Temperature (deg C)
DESIGN CONDITIONS
Pressure (kPa)
Pressure (kPa)
TYPE Atmospheric vessel
MEASUREMENT SYSTEM Metric System
OPERATING CONDITIONS
ITEM NUMBER V-104
Project No. 1
SHEET 1 of 1
STORAGE TANK
Quantity 3
5.822 m
500 mm
17.4 m
500 mm
73
V-106: Phenol Product Storage Tank B (Atmospheric Vessel)
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
12
SKETCH
Minimum Thickness for Closure (mm)
Vertical
Concrete
500
500
3.1
3.112
6
9.3
2:1 ellipsoidal
Innage Allowance (mm)
Inside Diameter (m)
Outside Diameter (m)
Minimum Thickness (m)
T/T Height (m)
Closure/Head
SPECIFICATION FOR CONSTRUCTION
Geometry Cylindrical
Position
Support/Foundation
Outage Allowance (mm)
Corrosion Allowance (mm)
Maximum Allowable Stress (Mpa)
Joint Efficiency
Material of Construction Carbon steel
0.85
88.94236908
3.8
METALLURGY
SERVICE Phenol
Minimum Metal Temperature (deg C)
375.9
54.44
548.2214286
93.33333333
0
15 ~ 20
Temperature (deg C)
Minimum Pressure (kPa)
Temperature (deg C)
DESIGN CONDITIONS
Pressure (kPa)
Pressure (kPa)
TYPE Atmospheric vessel
MEASUREMENT SYSTEM Metric System
OPERATING CONDITIONS
ITEM NUMBER V-104
Project No. 1
SHEET 1 of 1
STORAGE TANK
Quantity 3
3.112 m
500 mm
9.3m
500 mm
74
V-107: Benzene Recycle Stream Hold-up Tank (Atmospheric Vessel)
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
2 01/22/15 EAM
ITEM NUMBER V-105
Project No. 1
SHEET 1 of 1
STORAGE TANK
Quantity 1
TYPE Atmospheric vessel
MEASUREMENT SYSTEM Metric System
OPERATING CONDITIONS
METALLURGY
SERVICE Benzene Recycle Stream
Minimum Metal Temperature (deg C)
100
70.05
445.9678571
93.33333333
0
15 ~ 20
Temperature (deg C)
Minimum Pressure (kPa)
Temperature (deg C)
DESIGN CONDITIONS
Pressure (kPa)
Pressure (kPa)
Corrosion Allowance (mm)
Maximum Allowable Stress (Mpa)
Joint Efficiency
Material of Construction Carbon steel
0.85
88.94236908
3.8
Minimum Thickness (m)
T/T Height (m)
Closure/Head
SPECIFICATION FOR CONSTRUCTION
Geometry Cylindrical
Position
Support/Foundation
Outage Allowance (mm)
17
SKETCH
Minimum Thickness for Closure (mm)
Vertical
Concrete
500
500
5.5
5.518
9
16.5
2:1 ellipsoidal
Innage Allowance (mm)
Inside Diameter (m)
Outside Diameter (m)
5.518 m
500 mm
16.5 m
500 mm
75
V-108: Reflux Drum 1 (Atmospheric Vessel)
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
16
SKETCH
Minimum Thickness for Closure (mm)
Horizontal
Saddle
5.2
5.208
4
15.6
2:1 ellipsoidal
Inside Diameter (m)
Outside Diameter (m)
Minimum Thickness (mm)
Length (m)
Closure/Head
Height of Liquid (m) 2.6
Corrosion Allowance (mm)
Maximum Allowable Stress (Mpa)
Joint Efficiency
SPECIFICATION FOR CONSTRUCTION
Geometry Cylindrical
Position
Support/Foundation
Material of Construction Carbon steel
0.85
88.94236908
3.8
METALLURGY
SERVICE Condensate from T-100
Minimum Metal Temperature (deg C)
100
70.05
446
93
0
15 ~ 20
Temperature (deg C)
Minimum Pressure (kPa)
Temperature (deg C)
DESIGN CONDITIONS
Pressure (kPa)
Pressure (kPa)
TYPE Atmospheric vessel
MEASUREMENT SYSTEM Metric System
OPERATING CONDITIONS
ITEM NUMBER V-106
Project No. 1
SHEET 1 of 1
STORAGE TANK
2.6 m
15.6 m
5.208 m5.2 m
1.3 m
76
V-109: Reflux Drum 2 (Pressure Vessel)
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
ITEM NUMBER V-107
Project No. 1
SHEET 1 of 1
STORAGE TANK
TYPE Pressure vessel
MEASUREMENT SYSTEM Metric System
OPERATING CONDITIONS
METALLURGY
SERVICE Condensate from D-102
Minimum Metal Temperature (deg C)
370
91.98
542
93
0
15 ~ 20
Temperature (deg C)
Minimum Pressure (kPa)
Temperature (deg C)
DESIGN CONDITIONS
Pressure (kPa)
Pressure (kPa)
Material of Construction Carbon steel
0.85
88.94236908
3.8
Height of Liquid (m) 0.45
Corrosion Allowance (mm)
Maximum Allowable Stress (Mpa)
Joint Efficiency
SPECIFICATION FOR CONSTRUCTION
Geometry Cylindrical
Position
Support/Foundation
4
SKETCH
Minimum Thickness for Closure (mm)
Horizontal
Saddle
0.9
0.908
4
2.7
2:1 ellipsoidal
Inside Diameter (m)
Outside Diameter (m)
Minimum Thickness (mm)
Length (m)
Closure/Head
0.45 m
2.7 m
0.908 m0.9 m
0.225 m
77
V-110: Reflux Drum 3 (Atmospheric Vessel)
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
ITEM NUMBER V-108
Project No. 1
SHEET 1 of 1
STORAGE TANK
TYPE Atmospheric vessel
MEASUREMENT SYSTEM Metric System
OPERATING CONDITIONS
METALLURGY
SERVICE Condensate from D-103
Minimum Metal Temperature (deg C)
101.3
151.9
445.9678571
179.6777778
0
15 ~ 20
Temperature (deg C)
Minimum Pressure (kPa)
Temperature (deg C)
DESIGN CONDITIONS
Pressure (kPa)
Pressure (kPa)
Material of Construction Carbon steel
0.85
88.94236908
3.8
Height of Liquid (m) 1
Corrosion Allowance (mm)
Maximum Allowable Stress (Mpa)
Joint Efficiency
SPECIFICATION FOR CONSTRUCTION
Geometry Cylindrical
Position
Support/Foundation
6
SKETCH
Minimum Thickness for Closure (mm)
Horizontal
Saddle
2
2.008
4
6
2:1 ellipsoidal
Inside Diameter (m)
Outside Diameter (m)
Minimum Thickness (mm)
Length (m)
Closure/Head
1 m
6 m
2.008 m2 m
0.5 m
78
V-111: Cumene Recycle Stream Hold-up Tank (Atmospheric Vessel)
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
2 01/22/15 EAM
ITEM NUMBER V-109
Project No. 1
SHEET 1 of 1
STORAGE TANK
Quantity 1
TYPE Atmospheric vessel
MEASUREMENT SYSTEM Metric System
OPERATING CONDITIONS
METALLURGY
SERVICE Cumene Recycle Stream
Minimum Metal Temperature (deg C)
101.3
151.9
445.9678571
179.6777778
0
15 ~ 20
Temperature (deg C)
Minimum Pressure (kPa)
Temperature (deg C)
DESIGN CONDITIONS
Pressure (kPa)
Pressure (kPa)
Corrosion Allowance (mm)
Maximum Allowable Stress (Mpa)
Joint Efficiency
Material of Construction Carbon steel
0.85
88.94236908
3.8
Minimum Thickness (m)
T/T Height (m)
Closure/Head
SPECIFICATION FOR CONSTRUCTION
Geometry Cylindrical
Position
Support/Foundation
Outage Allowance (mm)
7
SKETCH
Minimum Thickness for Closure (mm)
Vertical
Concrete
500
500
2.1
2.11
5
6.3
2:1 ellipsoidal
Innage Allowance (mm)
Inside Diameter (m)
Outside Diameter (m)
2.11 m
500 mm
6.3 m
500 mm
79
V-112: Water Storage Tank (Atmospheric Vessel)
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
2 01/22/15 EAM
13
SKETCH
Minimum Thickness for Closure (mm)
Vertical
Concrete
500
500
4.3
4.316
8
12.9
2:1 ellipsoidal
Innage Allowance (mm)
Inside Diameter (m)
Outside Diameter (m)
Minimum Thickness (m)
T/T Height (m)
Closure/Head
SPECIFICATION FOR CONSTRUCTION
Geometry Cylindrical
Position
Support/Foundation
Outage Allowance (mm)
Corrosion Allowance (mm)
Maximum Allowable Stress (Mpa)
Joint Efficiency
Material of Construction Carbon steel
0.85
88.94236908
3.8
METALLURGY
SERVICE WATER
Minimum Metal Temperature (deg C)
100
30
445.9678571
93.33333333
0
15 ~ 20
Temperature (deg C)
Minimum Pressure (kPa)
Temperature (deg C)
DESIGN CONDITIONS
Pressure (kPa)
Pressure (kPa)
TYPE Atmospheric vessel
MEASUREMENT SYSTEM Metric System
OPERATING CONDITIONS
ITEM NUMBER V-105
Project No. 1
SHEET 1 of 1
STORAGE TANK
Quantity 1
4.316 m
500 mm
12.9m
500 mm
80
V-113: Fuel Storage (Pressure Vessel)
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
2 01/22/15 EAM
60
SKETCH
Minimum Thickness for Closure (mm)
Vertical
Concrete
500
500
7.2
7.33
65
21.6
2:1 ellipsoidal
Innage Allowance (mm)
Inside Diameter (m)
Outside Diameter (m)
Minimum Thickness (mm)
T/T Height (m)
Closure/Head
SPECIFICATION FOR CONSTRUCTION
Geometry Cylindrical
Position
Support/Foundation
Outage Allowance (mm)
Corrosion Allowance (mm)
Maximum Allowable Stress (Mpa)
Joint Efficiency
Material of Construction Carbon steel
0.85
88.94236908
3.8
METALLURGY
SERVICE LPG (Propane)
Minimum Metal Temperature (deg C)
1080
30
1252
93
0
15 ~ 20
Temperature (deg C)
Minimum Pressure (kPa)
Temperature (deg C)
DESIGN CONDITIONS
Pressure (kPa)
Pressure (kPa)
TYPE Pressure vessel
MEASUREMENT SYSTEM Metric System
OPERATING CONDITIONS
ITEM NUMBER V-111
Project No. 1
SHEET 1 of 1
STORAGE TANK
Quantity 4
7.33 m
500 mm
21.6 m
500 mm
81
Reactors Specification Sheets
See Appendix C for calculation sheets
R-101: Plug Flow Reactor 1
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
ITEM NUMBER R-101
Project No. 1
SHEET 1 of 1
REACTOR
Sketch
DESIGN CONDITIONS
TYPE Plug Flow Reactor (Packed Bed)
MEASUREMENT SYSTEM Metric System
OPERATING CONDITIONS
Pressure (kPa) 3478
Temperature (deg C) 170
Reactor Length (m) 10
Pressure (kPa) 3816
Temperature (deg C) 198
Minimum Pressure (kPa) 0
Minimum Metal Temperature (deg C) -14.7
SPECIFICATION OF REACTOR VESSEL
Reactor Volume (m3) 113.3
Particle Diameter (m) 0.003
Tube Diameter (m) 0.1201
Void Fraction 0.7
Void Volume (m3) 79.3
CATALYST BED CHARACTERISTIC
Volume of Catalyst Bed (m3) 34
Material Carbon Steel
TUBE I.D. (in) 4.813
Mass of Catalyst (kg) 7140
Square Pitch Size (mm) 100
Catalyst Name Sulfonic Resin
SHELL AND TUBING LAYOUT
Baffle Spacing (m) 0.781764019
Schedule No.
Wall Thickness (in)
Cross Sectional Area (in2)
TUBE O.D. (in)
5
80XS, 80S
0.375
6.11
Nominal Pipe Size (in)
5.563
Tube Number 1000
66676.3Water circulation rate (kg/h)
Heat Evolved in the reaction (kW) 2114.0
Delta T (Degrees Celcius) 27.3
HEAT EXCHANGER SPECIFICATION
636025.5Heat transfer coefficient (W/m2K)
Shell Diameter (m) 3.9
Cross Sectional Area of Shell Side (m2) 0.3
82
R-106: Plug Flow Reactor 2
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
ITEM NUMBER R-106
Project No. 1
SHEET 1 of 1
REACTOR
Sketch
DESIGN CONDITIONS
TYPE Plug Flow Reactor
MEASUREMENT SYSTEM Metric System
OPERATING CONDITIONS
Pressure (kPa) 400
Temperature (deg C) 80
Reactor Length (m) 10
Pressure (kPa) 572.3214286
Temperature (deg C) 93.33333333
Minimum Pressure (kPa) 0
Minimum Metal Temperature (deg C) -14.7
SPECIFICATION OF REACTOR VESSEL
Reactor Volume (m3) 25.02
Particle Diameter (m) 0.00002
Tube Diameter (m) 0.1785
Void Fraction 0.7
Void Volume (m3) 17.51
CATALYST BED CHARACTERISTIC
Volume of Catalyst Bed (m3) 7.51
Material Carbon Steel
TUBE I.D. (in) 7.187
Mass of Catalyst (g) 2.65854
Square Pitch Size (mm) 100
Catalyst Name Zeolite
SHELL AND TUBING LAYOUT
Baffle Spacing (m) 0.247215489
Schedule No.
Wall Thickness (in)
Cross Sectional Area (in2)
TUBE O.D. (in)
8
120
0.719
17.86
Nominal Pipe Size (in)
8.625
Tube Number 100
162558.9454Water circulation rate (kg/h)
Heat Evolved in the reaction (kW) 5154
Delta T (Degrees Celcius) 27.28
HEAT EXCHANGER SPECIFICATION
6172.20338Heat transfer coefficient (W/m2K)
Shell Diameter (m) 1.236077446
Cross Sectional Area of Shell Side (m2) 0.030557749
83
R-102: Oxidation Tower 1
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
Cooling water (kg/h)
Height of fluid (m) 9
COOLING SYSTEM
Type
Duty (kW)
Cooling Coil
526.7
16350Void Fraction of Bed 0.8
Bed Height (m) 0.1
Bubble Size (cm) 2.44E-05
Type of Plate Porous
Bed Volume (m3) 1.26
Diameter (m) 1.40E-07
Amount (Kg) 198.55
REACTOR MAIN SPECIFICATIONS
CATALYST SPECIFICATIONS
Density (kg/m3)
CuO Nanoparticle
790
Name
Closure/Head 2:1 ellipsoidal
Minimum Thickness for Closure (mm) 12
T/T Height (m) 12
Inside Diameter (m)
Outside Diameter (m)
Minimum Thickness (mm)
4
4.014
7
Position Vertical
Support/Foundation
Outage Allowance (mm)
Innage Allowance (mm)
Concrete
500
500
Geometry Cylindrical
Minimum Metal Temperature (deg C) 15 ~ 20
METALLURGY
Material of Construction Carbon steel
Joint Efficiency 0.85
Maximum Allowable Stress (Mpa) 88.942
Corrosion Allowance (mm) 3.8
SPECIFICATION FOR CONSTRUCTION
Pressure (kPa) 446
Temperature (deg C) 93
Minimum Pressure (kPa) 0
DESIGN CONDITIONS
TYPE Oxidation Tower
MEASUREMENT SYSTEM Metric System
VESSEL TYPE Atmospheric Vessel
OPERATING CONDITIONS
Pressure (kPa) 100
Temperature (deg C) 44.85
ITEM NUMBER R-102 SKETCH
Project No. 1
SHEET 1 of 1
REACTOR
84
R-103: Oxidation Tower 2
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
ITEM NUMBER R-103 SKETCH
Project No. 1
SHEET 1 of 1
REACTOR
DESIGN CONDITIONS
TYPE Oxidation Tower
MEASUREMENT SYSTEM Metric System
VESSEL TYPE Atmospheric Vessel
OPERATING CONDITIONS
Pressure (kPa) 99
Temperature (deg C) 45
Pressure (kPa) 445.97
Temperature (deg C) 93.33
Minimum Pressure (kPa) 0
Geometry Cylindrical
Minimum Metal Temperature (deg C) 15 ~ 20
METALLURGY
Material of Construction Carbon steel
Joint Efficiency 0.85
Maximum Allowable Stress (Mpa) 88.94
Corrosion Allowance (mm) 3.8
SPECIFICATION FOR CONSTRUCTION
Position Vertical
Support/Foundation
Outage Allowance (mm)
Innage Allowance (mm)
Concrete
500
500
Inside Diameter (m)
Outside Diameter (m)
Minimum Thickness (mm)
4
4.014
7
2:1 ellipsoidal
Minimum Thickness for Closure (mm) 12
T/T Height (m) 12
REACTOR MAIN SPECIFICATIONS
Void Fraction of Bed 0.8
Bed Height (m) 0.1
Bed Volume (m3) 1.26
Bubble Size (cm) 2.42E-05
Type of Plate Porous
Height of fluid (m) 8
COOLING SYSTEM
Type Cooling Coil
Diameter (m) 1.40E-07
Amount (Kg) 198.55
CATALYST SPECIFICATIONS
Density (kg/m3)
CuO Nanoparticle
790
Name
Closure/Head
528.4Duty (kW)
Cooling water (kg/h) 16400
85
R-104: Oxidation Tower 3
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
Height of fluid (m) 7
COOLING SYSTEM
Type Cooling Coil
CATALYST SPECIFICATIONS
Density (kg/m3)
CuO Nanoparticle
790
Name
Closure/Head 2:1 ellipsoidal
Minimum Thickness for Closure (mm) 12
T/T Height (m)
515.9Duty (kW)
Cooling water (kg/h) 16011.28
Bubble Size (cm) 2.30E-05
Type of Plate Porous
Bed Volume (m3) 1.26
Diameter (m) 1.40E-07
Amount (Kg) 198.55
REACTOR MAIN SPECIFICATIONS
Void Fraction of Bed 0.8
Bed Height (m) 0.1
12
Inside Diameter (m)
Outside Diameter (m)
Minimum Thickness (mm)
4
4.014
7
Position Vertical
Support/Foundation
Outage Allowance (mm)
Innage Allowance (mm)
Concrete
500
500
Minimum Pressure (kPa) 0
Geometry Cylindrical
Minimum Metal Temperature (deg C) 15 ~ 20
METALLURGY
Material of Construction Carbon steel
Joint Efficiency 0.85
Maximum Allowable Stress (Mpa) 88.94
Corrosion Allowance (mm) 3.8
SPECIFICATION FOR CONSTRUCTION
45
Pressure (kPa) 445.9678571
Temperature (deg C) 93.33333333
Project No. 1
SHEET 1 of 1
REACTOR
ITEM NUMBER R-104 SKETCH
DESIGN CONDITIONS
TYPE Oxidation Tower
MEASUREMENT SYSTEM Metric System
VESSEL TYPE Atmospheric Vessel
OPERATING CONDITIONS
Pressure (kPa) 98
Temperature (deg C)
86
R-105: Oxidation Tower 4
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
ITEM NUMBER R-105 SKETCH
Project No. 1
SHEET 1 of 1
REACTOR
DESIGN CONDITIONS
TYPE Oxidation Tower
MEASUREMENT SYSTEM Metric System
VESSEL TYPE Atmospheric Vessel
OPERATING CONDITIONS
Pressure (kPa) 97.2
Temperature (deg C) 44.85
Pressure (kPa) 445.9678571
Temperature (deg C) 93.33333333
Minimum Pressure (kPa) 0
Geometry Cylindrical
Minimum Metal Temperature (deg C) 15 ~ 20
METALLURGY
Material of Construction Carbon steel
Joint Efficiency 0.85
Maximum Allowable Stress (Mpa) 88.94236908
Corrosion Allowance (mm) 3.8
SPECIFICATION FOR CONSTRUCTION
Position Vertical
Support/Foundation
Outage Allowance (mm)
Innage Allowance (mm)
Concrete
500
500
12
Inside Diameter (m)
Outside Diameter (m)
Minimum Thickness (mm)
4
4.014
7
T/T Height (m)
13310.26
Type of Plate Porous
Bed Volume (m3) 1.256637061
Bubble Size (cm) 2.27E-05
Bed Height (m) 0.1
Void Fraction of Bed 0.8
Height of fluid (m) 7
COOLING SYSTEM
Type Cooling Coil
CATALYST SPECIFICATIONS
Density (kg/m3)
CuO Nanoparticle
790
Name
Closure/Head
428.8
2:1 ellipsoidal
Minimum Thickness for Closure (mm)
Diameter (m) 1.40E-07
Duty (kW)
Cooling water (kg/h)
Amount (Kg) 198.5486557
REACTOR MAIN SPECIFICATIONS
12
87
Distillation Columns Specification Sheets
See Appendix D for calculation sheets
D-101: Distillation Tower 1
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
2 01/21/15 EAM
Project No. 1
SHEET 1 of 1
DISTILLATION COLUMN
TYPE
MEASUREMENT SYSTEM
D-101
Pressure Vessel
Metric System
Pressure (kPa) 446 446
SKETCH
Pressure (kPa)
Temperature (deg C)
SECTION Rectifying Stripping
106
80.17
109.7
155.4
OPERATING CONDITIONS
DESIGN CONDITIONS
ITEM NUMBER
Temperature (deg C) 121 183
Minimum Pressure (kPa) 0 0
Internal Diameter (m) 12 10
Minimum Metal Temperature (deg C) 15 to 20 15 to 20
MAIN SPECIFICATIONS
No. of Trays 11 16
SPECIFICATION FOR CONSTRUCTION
Material
Support/Foundation
Feed tray number
Side Stream Plate #
11
N/A
Structured
Tray Type Sieve
Construction type Cartridge-type
Packing type
Height (m) 9.9 14.4
Tray Spacing (m) 0.9 0.9
10.1
Type of Closure
Orientation
Minimum Thickness (mm) 36 30
Carbon Steel
Concrete
Vertical
2:1 Ellipsoidal
31.80
Minimum Thickness for Closure (mm) 36 30
Total Height of the Column (m)
Outside Diameter (mm) 12.1
12.1 m
31.8 m
13 m18.8 m
10.1 m
88
D-102: Distillation Tower 2
PLATE LAYOUT FOR RECTIFYING SECTION
PLATE LAYOUT FOR STRIPPING SECTION
10.0
8m
50 mm
50 mm
12m
25 mm
30 mm7.
6m
50 mm
50 mm
10m
35 mm
40 mm
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
Project No. 1
SHEET 1 of 1
DISTILLATION COLUMN
TYPE
MEASUREMENT SYSTEM
D-102
Pressure Vessel
Metric System
Pressure (kPa) 549 552
SKETCH
Pressure (kPa)
Temperature (deg C)
SECTION Rectifying Stripping
376.2
127.4
379.7
211.4
OPERATING CONDITIONS
DESIGN CONDITIONS
ITEM NUMBER
Temperature (deg C) 155 239
Minimum Pressure (kPa) 0 0
Internal Diameter (m) 0.7 1.4
Minimum Metal Temperature (deg C) 15 to 20 15 to 20
MAIN SPECIFICATIONS
No. of Trays 10 12
SPECIFICATION FOR CONSTRUCTION
Material
Support/Foundation
Feed tray number
Side Stream Plate #
10
N/A
Structured
Tray Type Sieve
Construction type Cartridge-type
Packing type
Height (m) 6.6 9.6
Tray Spacing (m) 0.6 0.6
1.5
Type of Closure
Orientation
Minimum Thickness (mm) 3 6
Carbon Steel
Concrete
Vertical
2:1 Ellipsoidal
21.20
Minimum Thickness for Closure (mm) 3 6
Total Height of the Column (m)
Outside Diameter (m) 0.8
0.7 m
21.20 m
8.70 m12.60 m
1.4 m
89
PLATE LAYOUT FOR RECTIFYING SECTION
PLATE LAYOUT FOR STRIPPING SECTION
0.59
15m
50 mm
50 mm
0.7
m
40 mm
50 mm
1.20
4m
50 mm
50 mm
1.4
m
40 mm
50 mm
90
D-103: Distillation Tower 3
REV DATE BY APVD REV DATE BY APVD
1 01/11/15 EAM
ALL
MFS
Project No. 1
SHEET 1 of 1
DISTILLATION COLUMN
TYPE
MEASUREMENT SYSTEM
D-103
Pressure Vessel
Metric System
Pressure (kPa) 446 542
SKETCH
Pressure (kPa)
Temperature (deg C)
SECTION Rectifying Stripping
105.5
153.4
369.7
235.5
OPERATING CONDITIONS
DESIGN CONDITIONS
ITEM NUMBER
Temperature (deg C) 181 263
Minimum Pressure (kPa) 0 0
Internal Diameter (m) 2.9 1.8
Minimum Metal Temperature (deg C) 15 to 20 15 to 20
MAIN SPECIFICATIONS
No. of Trays 21 34
SPECIFICATION FOR CONSTRUCTION
Material
Support/Foundation
Feed tray number
Side Stream Plate #
21
N/A
Structured
Tray Type Sieve
Construction type Cartridge-type
Packing type
Height (m) 4.95 9.6
Tray Spacing (m) 0.45 0.6
1.9
Type of Closure
Orientation
Minimum Thickness (mm) 9 7
Carbon Steel
Concrete
Vertical
2:1 Ellipsoidal
19.00
Minimum Thickness for Closure (mm) 9 7
Total Height of the Column (m)
Outside Diameter (mm) 3
2.9 m
19 m
6.5 m12.5 m
1.8 m
PLATE LAYOUT FOR RECTIFYING SECTION
PLATE LAYOUT FOR STRIPPING SECTION
2.45
05
50 mm
50 mm
2.9
m
25 mm
33 mm
1.53
m
50 mm
50 mm
1.8
m
30 mm
38 mm
91
Heat Exchangers Specification Sheets
Aspen Exchanger Design & Rating V.8.0 (Aspen EDR) software was used in obtaining
appropriate, accurate, and acceptable sizing and specifications of heat exchangers of the
manufacturing plant. The major design program used in Aspen EDR was the Aspen Shell
& Tube Exchanger. Using this program, the following can be generated:
Heat Exchanger Specification Sheet
Tube Layout
Drawing or diagrams
Cost Estimate
92
HE-101: Feed Heater
93
94
HE-103: D-101 Condenser
95
96
HE-104: D-101 Reboiler
97
98
HE-105: Cooler 1
99
100
HE-107: D-102 Condenser
101
102
HE-108: D-102 Reboiler
103
104
HE-109: D-103 Condenser
105
106
HE-110: D-103 Reboiler
107
108
HE-111: Product Cooler 1
109
110
HE-112: Product Cooler 2
111
112
Pipes Specification Sheets
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
Pumps Specification Sheets
P-101
P-102
P-103
135
P-104
P-105
136
P-106
P-107
137
P-108
P-109
138
P-110
139
Compressor Specification Sheet
140
Economic Analysis
Before the initiation of the development of the process, at various stages in its
development, process engineers must make economic evaluation. The discussion in this
chapter determines whether the project should be undertaken or abandoned. The objective
for this analysis is to have a class 4 to 3 estimate of the capital requirement as well as the
production cost of the plant. The overall economic analysis of the plant will depend on the
capital requirement and production cost of the product.
Method for Capital Requirement Estimation
This section includes the components of calculating the fixed capital investment
which is the total cost of designing, constructing, and installing a plant. Table 48 shows the
composition of the fixed capital investment of the plant.
141
Table 48
Fixed capital investment of the plant
ISBL CAPEX 1. MAJOR PROCESS EQUIPMENTS
i. Storage Tanks
ii. Distillation Columns
iii. Reactors
iv. Heat Exchangers
v. Compressors
vi. Pumps
vii. Pipes
2. Building Cost
3. Trucks and other electric equipment
OSBL CAPEX UTILITIES
i. Cooling Tower
ii. Boiler
iii. Furnace
iv. Scrubber
v. Biological Waste Water Treatment Plant
CONTINGENCY
COMMISSIONING COST
MINIMUM PAID UP CAPITAL REQUIRMENT ON BANKS
EIA PROCESSING FEE
Estimating the ISBL and OSBL capital costs. The ISBL plant cost includes the
cost of procuring and installing all the process equipment that makes up the new plant.
Included in the previous chapter are the design and specifications of the major process
equipment of the plant. Table 49 consists of the correlations to be used in estimating the
cost of the equipment of the plant.
142
Table 49
Purchase Equipment Cost for Common Plant Equipment
EQUIPMENT Unit for
Size, S
𝑺𝒍𝒐𝒘𝒆𝒓
𝑺𝒖𝒑𝒑𝒆𝒓
a b n
Tanks
Cone Roof 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦, 𝑚3 10 4000 5700 700 0.7
Pressure Vessels
vertical, cs shell mass,
kg 150 69200 -400 230 0.6
Horizontal, cs shell mass,
kg 250 69200 -2500 200 0.6
Distillation Columns
Trays
Sieve trays diameter, m 0.5 5 100 120 2
Reactors
Jacketed, agitated 𝑣𝑜𝑙𝑢𝑚𝑒, 𝑚3 0.5 100 14000 15400 0.7
jacketed, agitated, glass-
lined 𝑣𝑜𝑙𝑢𝑚𝑒, 𝑚3 0.5 25 13000 34000 0.5
Heat Exchanger
U-tube shell and tube 𝑎𝑟𝑒𝑎, 𝑚2 10 1000 10000 88 1
Compressor
Centrifugal driver power,
kW 132 29000 8400 3100 0.6
Pumps
Single-stage centrifugal flow Liters/s
(L/s) 0.2 500 3300 48 1.2
Utilities
Cooling Tower flow Liters/s 100 10000 61000 650 0.9
Boiler kg/h steam 20000 800000 -
90000 93 0.8
Furnace duty, MW 30 200 7000 71000 0.8
Source: Towler and Sinnott, 2008
Equation 8 was used to obtain the purchase cost of the equipment. Given the
parameters, if the value of S is not within the range or limit given in the table, the actual
cost of the equipment can be derived from the computed cost using equation 9.
𝑪𝒆 = 𝒂 + 𝒃𝑺𝒏
𝐶𝑒 = 𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒 𝐶𝑜𝑠𝑡 𝑜𝑓 𝐸𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡
𝑆 = 𝑆𝑖𝑧𝑒 𝑃𝑎𝑟𝑎𝑚𝑒𝑡𝑒𝑟
𝑆𝑙𝑜𝑤𝑒𝑟 = 𝐿𝑜𝑤𝑒𝑟 𝐿𝑖𝑚𝑖𝑡 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑆𝑖𝑧𝑒 𝑃𝑎𝑟𝑎𝑚𝑒𝑡𝑒𝑟
(8)
143
𝑆𝑢𝑝𝑝𝑒𝑟 = 𝑈𝑝𝑝𝑒𝑟 𝐿𝑖𝑚𝑖𝑡 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑆𝑖𝑧𝑒 𝑃𝑎𝑟𝑎𝑚𝑒𝑡𝑒𝑟
𝑪𝒆,𝒇 = 𝑪𝒆,𝒊 (𝑺𝒆,𝒇
𝑺𝒆,𝒊)
𝒏
For the cost of pipes, equation 10 may apply. The cost should already include the
cost for fittings, paint, installation, and insulation. The basis for the correlation is January
2006.
𝑪𝒐𝒔𝒕 ($ 𝒎⁄ ) = 𝟖𝟖𝟎 (𝑫𝒊, 𝒎𝒎)𝟎.𝟕𝟒
For pressure vessels, shell mass is needed in estimating the purchase cost based on
Table 49. Equation 11 should be used in obtaining the shell mass of a pressure vessel.
Density of carbon steel is 7900 𝑘𝑔 𝑚3⁄ .
𝑺𝒉𝒆𝒍𝒍 𝒎𝒂𝒔𝒔 = 𝝅𝑫𝒄𝑳𝒄𝒕𝒘𝝆
𝐷𝑐 = 𝑣𝑒𝑠𝑠𝑒𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚
𝐿𝑐 = 𝑣𝑒𝑠𝑠𝑒𝑙 𝑙𝑒𝑛𝑔𝑡ℎ, 𝑚
𝑡𝑤 = 𝑤𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠, 𝑚
𝜌 = 𝑚𝑒𝑡𝑎𝑙 𝑑𝑒𝑛𝑠𝑖𝑡𝑦, 𝑘𝑔 𝑚3⁄
The basis of this cost estimation is on the year 2006. Note that the prices of the
materials of construction and the costs of labor are subject to inflation. Through the use of
published cost indices, the cost of the equipment can be obtained at any latest year. The
following equations can be applied to consider the inflation of the cost.
𝑪𝒐𝒔𝒕 𝒊𝒏 𝒚𝒆𝒂𝒓 𝑨 = 𝑪𝒐𝒔𝒕 𝒊𝒏 𝒚𝒆𝒂𝒓 𝑩 ∗𝑪𝒐𝒔𝒕 𝒊𝒏𝒅𝒆𝒙 𝒊𝒏 𝒚𝒆𝒂𝒓 𝑨
𝑪𝒐𝒔𝒕 𝒊𝒏𝒅𝒆𝒙 𝒊𝒏 𝒚𝒆𝒂𝒓 𝑩
𝐶𝑜𝑠𝑡 𝑖𝑛𝑑𝑒𝑥 𝑖𝑛 𝑦𝑒𝑎𝑟 2006 = 499.6 (𝐾𝐿𝑀 𝑇𝑒𝑐ℎ𝑛𝑜𝑙𝑜𝑔𝑦 𝐺𝑟𝑜𝑢𝑝)
𝐶𝑜𝑠𝑡 𝑖𝑛𝑑𝑒𝑥 𝑖𝑛 𝑦𝑒𝑎𝑟 2015 = 609.065 (𝐾𝐿𝑀 𝑇𝑒𝑐ℎ𝑛𝑜𝑙𝑜𝑔𝑦 𝐺𝑟𝑜𝑢𝑝)
𝑪𝒐𝒔𝒕 𝒊𝒏 𝒚𝒆𝒂𝒓 𝟐𝟎𝟏𝟓 = 𝟏. 𝟐𝟏𝟗 ∗ 𝑪𝒐𝒔𝒕 𝒊𝒏 𝒚𝒆𝒂𝒓 𝟐𝟎𝟎𝟔
(9)
(10)
(11)
(13)
(12)
144
Most plant and equipment cost data used which came from Towler were based on
the location U.S. Golf Coast (USGC), as it was historically the main center of the chemical
industry, for which most data were available. The differences in cost between locations can
be estimated using the following equation.
𝑪𝒐𝒔𝒕 𝒐𝒇 𝒑𝒍𝒂𝒏𝒕 𝒊𝒏 𝒍𝒐𝒄𝒂𝒕𝒊𝒐𝒏 𝑨 = 𝑪𝒐𝒔𝒕 𝒐𝒇 𝒑𝒍𝒂𝒏𝒕 𝒐𝒏 𝑼𝑺𝑮𝑪 ∗ 𝑳𝑭𝑨
𝐿𝐹𝐴 = 𝐿𝑜𝑐𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑙𝑜𝑐𝑎𝑡𝑖𝑜𝑛 𝐴 𝑟𝑒𝑙𝑎𝑡𝑖𝑣𝑒 𝑡𝑜 𝑈𝑆𝐺𝐶 𝑏𝑎𝑠𝑖𝑠
𝐿𝐹𝐴 𝑓𝑟𝑜𝑚 𝑈𝑆𝐺𝐶 𝑡𝑜 𝑆𝑜𝑢𝑡ℎ 𝐸𝑎𝑠𝑡 𝐴𝑠𝑖𝑎 = 1.12
In costing, it is also very important to consider the installation cost of the
equipment. Table 50 consists of the detailed typical factors for estimation of fixed capital
costs. These can be used to make an approximate estimate of capital cost using equipment
cost data published in the literature.
Table 50
Typical Installation Factor for Project Fixed Capital Cost
fer 0.3
fp 0.8
fi 0.3
fel 0.2
fc 0.3
fs 0.2
fl 0.1
fm 1.3
Source: Towler and Sinnott, 2008
(14)
145
Equation 15 is used to determine the final cost of the equipment including the
installation cost.
𝑪 = ∑ 𝑪𝒆,𝒊,𝑨[(𝟏 + 𝒇𝒑) +𝒇𝒆𝒓 + 𝒇𝒆𝒍 + 𝒇𝒊 + 𝒇𝒄 + 𝒇𝒔 + 𝒇𝒍
𝒇𝒎]
𝒊=𝑴
𝒊=𝟏
𝐶𝑒 = 𝐶𝑜𝑠𝑡 𝑜𝑓 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑖𝑛 𝑎𝑙𝑙𝑜𝑦, 𝑤𝑖𝑡ℎ𝑜𝑢𝑡 𝑡ℎ𝑒 𝑖𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑐𝑜𝑠𝑡
𝑀 = 𝑇𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑖𝑒𝑐𝑒𝑠 𝑜𝑓 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡
𝑓𝑒𝑟 = 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑒𝑟𝑒𝑐𝑡𝑖𝑜𝑛
𝑓𝑝 = 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑃𝑖𝑝𝑖𝑛𝑔
𝑓𝑖 = 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝐼𝑛𝑠𝑡𝑟𝑢𝑚𝑒𝑛𝑡𝑎𝑡𝑖𝑜𝑛 𝑎𝑛𝑑 𝑝𝑟𝑜𝑐𝑒𝑠𝑠 𝐶𝑜𝑛𝑡𝑟𝑜𝑙 𝑓𝑒𝑙 = 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑎𝑙 𝑤𝑜𝑟𝑘𝑠
𝑓𝑐 = 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝐶𝑖𝑣𝑖𝑙 𝑒𝑛𝑔𝑖𝑛𝑒𝑒𝑟𝑖𝑛𝑔 𝑤𝑜𝑟𝑘𝑠
𝑓𝑠 = 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝑆𝑡𝑟𝑢𝑐𝑡𝑢𝑟𝑒𝑠 𝑎𝑛𝑑 𝐵𝑢𝑖𝑙𝑑𝑖𝑛𝑔𝑠
𝑓𝑙 = 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑓𝑜𝑟 𝐿𝑎𝑔𝑔𝑖𝑛𝑔, 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛, 𝑎𝑛𝑑 𝑃𝑎𝑖𝑛𝑡
𝐶 = 𝑐𝑜𝑠𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑤𝑖𝑡ℎ 𝑡ℎ𝑒 𝑖𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟
Other cost factor that needs to be considered was the freight rate/cost. It is the cost
incurred in moving the goods from USGC to Philippines through marine transportation.
This includes packing, palletizing, documentation, loading, unloading charges, carriage
costs, and marine insurance costs. For freight rate estimates, worldfreightrates.com offers
a reliable calculator to get it. Origin port should be a USGC port such as New Orleans and
the Destination port should be Subic Bay, Philippines.
For imported goods, the Bureau of Customs imposes duties and taxes for
importation. The duties and taxes includes the Value Added Tax (VAT), Import Processing
Fee (IPF), and Customs Documentary Stamp imposed by the agency. The agency have
their own useful and reliable calculator (Customs PH, 2015).
Contingency and commissioning cost. The typical percentage of, or the “norm”
for commissioning services for, a chemical plant process was estimated at 3.5% of the total
(15)
146
capital investment (Killcross, 2012). For the contingency cost, typically the factor was 10%
of the total capital investment (Towler & Sinnott, 2008).
Method for Production Cost Estimation
In evaluating the financial attractiveness of a process, management requires the
details of both the total capital requirements and the production cost of producing a product.
The total production cost of the plant is subdivided into three main categories:
Direct costs. Known also as variable cost, tend to be proportional to the production
rate.
Indirect costs. Composed of fixed cost and plant overhead cost, tend to remain constant
regardless of the production rate.
General costs. It includes the costs of managing the firm, marketing the product,
research and development on new and old products, and financing the operation.
Table 51 shows the equations for calculating the components of production cost of a
particular chemical plant using numerical factors. Note that these factors were used for
approximation. For a good estimation of the production, they are very useful and reliable.
Most companies will have their own specific factors for their processes later in the
operational stage of their business. Equation 16 is used to obtain the production cost of the
plant.
𝑷𝒓𝒐𝒅𝒖𝒄𝒕𝒊𝒐𝒏 𝑪𝒐𝒔𝒕 = 𝑫𝒊𝒓𝒆𝒄𝒕 𝑪𝒐𝒔𝒕 + 𝑰𝒏𝒅𝒊𝒓𝒆𝒄𝒕 𝑪𝒐𝒔𝒕 + 𝑮𝒆𝒏𝒆𝒓𝒂𝒍 𝑪𝒐𝒔𝒕
(16)
147
Table 51
Calculation Procedure for Production Cost
DIRECT COST
RAW MATERIALS 𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝐼𝑛𝑐𝑜𝑚𝑖𝑛𝑔 𝑆𝑡𝑟𝑒𝑎𝑚 × 𝐶𝑜𝑠𝑡
CATALYSTS 𝐴𝑚𝑜𝑢𝑛𝑡 × 𝐶𝑜𝑠𝑡
UTILITIES:
ELECTRICITY
FUEL
WATER
COMMUNICATION
BIOLOGICAL WWTP [2]
𝑃𝑜𝑤𝑒𝑟 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 × 𝐶𝑜𝑠𝑡
𝐹𝑢𝑒𝑙 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 × 𝐶𝑜𝑠𝑡
𝑊𝑎𝑡𝑒𝑟 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 × 𝐶𝑜𝑠𝑡
𝐶𝑜𝑠𝑡 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟
$0.20 𝑝𝑒𝑟 𝑙𝑏 𝑜𝑓 𝑜𝑟𝑔𝑎𝑛𝑖𝑐𝑠
OPERATING LABOR 𝑁𝑒𝑡 𝑃𝑎𝑦 + 𝐵𝑒𝑛𝑒𝑓𝑖𝑡𝑠 + 𝐵𝑜𝑛𝑢𝑠
TRANSPORTATION COST 𝐹𝑢𝑒𝑙 × 𝑃𝑟𝑖𝑐𝑒
OPERATING SUPERVISION [1] 0.20 × 𝑂𝑃𝐸𝑅𝐴𝑇𝐼𝑁𝐺 𝐿𝐴𝐵𝑂𝑅
QUALITY CONTROL [1] 0.20 × 𝑂𝑃𝐸𝑅𝐴𝑇𝐼𝑁𝐺 𝐿𝐴𝐵𝑂𝑅
MAINTENANCE LABOR [1] 0.027 × 𝐹𝐼𝑋𝐸𝐷 𝐶𝐴𝑃𝐼𝑇𝐴𝐿 𝐶𝑂𝑆𝑇
MAINTENANCE MATERIAL [1] 0.018 × 𝐹𝐼𝑋𝐸𝐷 𝐶𝐴𝑃𝐼𝑇𝐴𝐿 𝐶𝑂𝑆𝑇
OPERATING SUPPLIES [1] 0.0075 × 𝐹𝐼𝑋𝐸𝐷 𝐶𝐴𝑃𝐼𝑇𝐴𝐿 𝐶𝑂𝑆𝑇
INDIRECT COST
FIXED CAPITAL COST:
DEPRECIATION [2]
LAND COST
𝐷𝐵 − 𝑆𝐿 𝑚𝑒𝑡ℎ𝑜𝑑 𝐿𝐸𝐴𝑆𝐸 𝑅𝐴𝑇𝐸 𝑃𝐸𝑅 𝑌𝐸𝐴𝑅
REAL PROPERTY TAX 𝑇𝑎𝑥 𝑅𝑎𝑡𝑒 × 𝐴𝑠𝑠𝑒𝑠𝑠𝑒𝑑 𝐿𝑎𝑛𝑑 𝑉𝑎𝑙𝑢𝑒
INSURANCE [1] 0.01 × 𝐹𝐼𝑋𝐸𝐷 𝐶𝐴𝑃𝐼𝑇𝐴𝐿 𝐶𝑂𝑆𝑇
GENERAL COST
ADMINISTRATIVE [1] 0.045 × 𝑂𝑃𝐸𝑅𝐴𝑇𝐼𝑁𝐺 𝐶𝑂𝑆𝑇
MARKETING [1] 0.135 × 𝑂𝑃𝐸𝑅𝐴𝑇𝐼𝑁𝐺 𝐶𝑂𝑆𝑇
RESEARCH AND DEVELOPMENT [1] 0.0575 × 𝑂𝑃𝐸𝑅𝐴𝑇𝐼𝑁𝐺 𝐶𝑂𝑆𝑇
[1] Silla, 2003
[2] Brown, 2006
148
Operational time of the plant was estimated to be 350 days per year. The total days
per year is 365 days, so there will be a 15 days no work day for employees. These 15 days
will be allotted to the maintenance of the plant.
Continuous processes were designed to operate 24 hours a day, 7 days a week,
throughout the year. Some downtime will be allowed for maintenance and, for some
processes, catalyst regeneration. Continuous processes will usually be more economical
for large-scale production. The plant attainment or operating rate is the percentage of the
available hours in a year that the plant operates, and is usually between 90 and 95% (Towler
& Sinnott, 2008).
149
Cost of Major Process Equipment
Cost of Atmospheric Vessels:
Table 52
Purchase Cost of Atmospheric Vessels
NUMBER Capacity (m3) Cost Quantity Final
V-102 882.6555446 $ 86,451.75 6 $ 518,710.47
V-105 414.832 $ 53,300.18 3 $ 159,900.55 V-106 59.2617 $ 17,891.02 3 $ 53,673.05
V-107 354.32645 $ 48,326.59 1 $ 48,326.59
V-108 159.5609 $ 30,086.34 1 $ 30,086.34
V-110 8.221475 $ 8,758.88 1 $ 8,758.88 V-111 18.13027 $ 11,020.85 1 $ 11,020.85
V-112 161.0571 $ 30,246.18 1 $ 30,246.18
Table 53
Final Cost of Atmosphere Vessel Cost (2006) $ 860,722.91
Cost (2015) $ 1,049,221.22
Cost (2015 @ SE Asia) $ 1,175,127.77
Cost of Equipment (w/ Installation factor consideration) $ 3,760,408.86
₱ 169,218,398.55
Freight Cost $ 2,991.65
₱ 134,624.25
Bureau of Customs: Duties and Taxes
Value Added Tax (VAT) ₱ 4,462,850.14
Import Processing Fee ₱ 51,643.37
Customs Documentary Stamp ₱ 265.00
TOTAL COST ₱ 173,867,781.32
150
Cost of Pressure Vessels:
Table 54
Shell Mass of Pressure Vessels
Number
𝐷𝑐 (m)
𝐿𝑐(𝑚)
𝑡𝑤 (m)
𝜌 (𝑘𝑔 𝑚3)⁄
SHELL MASS (kg)
V-101 7.2 21.6 0.047 7900 181409.9357
V-103 5.4 16.2 0.024 7900 52107.1092
V-104 2.9 8.7 0.015 7900 9392.592344 V-109 0.9 2.7 0.004 7900 241.2366167
V-113 7.2 21.6 0.019 7900 73335.93147
Table 55
Purchase Cost of Pressure Vessels
Number COST ADJUSTED COST Quantity FINAL
V-101 $ 184,012.98 $ 328,081.28 6 $ 1,968,487.68
V-103 $ 155,148.57 - 3 $ 465,445.71
V-104 $ 55,241.54 - 3 $ 165,724.61 V-109 $ 5,782.92 - 1 $ 5,782.92
V-113 $ 190,549.24 - 4 $ 762,196.94
Table 56
Final Cost of Pressure Vessels
Cost (2006) $ 3,367,637.87
Cost (2015) $ 4,105,150.56
Cost (2015 @ SE Asia) $ 4,597,768.63
Cost of Equipment (w/ Location and Installation factor consideration)
$ 14,712,859.60
₱ 662,078,682.01
Freight Cost $ 2,991.65
₱ 134,624.25
Bureau of Customs: Duties and Taxes
Value Added Tax (VAT) ₱ 12,401,086.40
Import Processing Fee ₱ 156,326.46
Customs Documentary Stamp ₱ 265.00
TOTAL COST ₱ 674,770,984.12
151
Cost of Distillation Columns:
Table 57
Purchase Cost of Trays for Distillation Columns
NUMBER Dc (m) # of trays Cost per tray Adjusted FINAL COST
D-101-T 12 11 $ 3,100.00 $ 17,856.00 $ 196,416.00
D-101-B 10 16 $ 3,100.00 $ 12,400.00 $ 198,400.00
D-102-T 0.7 10 $ 158.80 - $ 1,588.00
D-102-B 1.4 12 $ 335.20 - $ 4,022.40
D-103-T 2.9 21 $ 1,109.20 - $ 23,293.20
D-103-B 1.8 34 $ 488.80 - $ 16,619.20
Table 58
Shell mass of Distillation Columns
Number 𝐷𝑐 (m)
𝐿𝑐(𝑚)
𝑡𝑤 (m)
𝜌 (𝑘𝑔 𝑚3)⁄
SHELL MASS (kg)
D-101
Top 12 9.9 0.036 7900 106144.1113
Bot 10 14.4 0.03 7900 107216.2741
D-102
Top 0.7 6.6 0.003 7900 343.985546
Bot 1.4 9.6 0.006 7900 2001.37045
D-103
Top 2.9 4.95 0.009 7900 3206.436697 Bot 1.8 9.6 0.007 7900 3002.055674
152
Table 59
Purchase Cost of Pressure Vessels for Distillation Columns
Number Need
Adjustment? COST
ADJUSTED
COST Quantity FINAL
D-101
Top Yes $ 184,012.98 $ 237,860.51 1 $ 237,860.51
Bot Yes $ 184,012.98 $ 239,299.19 1 $ 239,299.19
D-102
Top No $ 7,249.83 - 1 $ 7,249.83
Bot No $ 21,605.15 - 1 $ 21,605.15
D-103
Top No $ 28,797.22 - 1 $ 28,797.22
Bot No $ 27,665.91 - 1 $ 27,665.91
Table 60
Final Cost of Distillation Columns
Cost (2006) $ 1,002,816.61
Cost (2015) $ 1,222,433.45
Cost (2015 @ SE Asia) $ 1,369,125.46
Cost of Equipment (w/ Location and Installation factor consideration)
$ 4,381,201.49
₱ 197,154,066.89
Freight Cost $ 2,991.65
₱ 134,624.25
Bureau of Customs: Duties and Taxes
Value Added Tax (VAT) ₱ 5,339,213.90
Import Processing Fee ₱ 60,169.00
Customs Documentary Stamp ₱ 265.00
TOTAL COST ₱ 202,688,339.04
153
Cost of Reactors:
Table 61
Purchase Cost of Fluidized Bed Reactors
NUMBER Volume (m3) Need Adjustment Cost Adjusted Cost
R-102 101.112 Yes $ 400,830.51 $ 403,945.40
R-103 98.17203297 No $ 395,867.04 $ 395,867.04
R-104 86.6518991 No $ 363,917.27 $ 363,917.27
R-105 84.21924804 No $ 357,011.49 $ 357,011.49
Table 62
Purchase Cost of Packed Bed Reactors
NUMBER Volume (m3) Need Adjustment Cost Adjusted Cost
R-101 113.3 Yes $ 400,830.51 $ 437,443.24
R-106 25.02 No $ 160,663.43 $ 160,663.43
Table 63
Final Cost of Reactors
Cost (2006) $ 2,118,847.87
Cost (2015) $ 2,582,875.55
Cost (2015 @ SE Asia) $ 2,892,820.61
Cost of Equipment (w/ Location and Installation factor
consideration)
$ 9,257,025.97
₱ 416,566,168.43
Freight Cost $ 2,991.65
₱ 134,624.25
Bureau of Customs: Duties and Taxes
Value Added Tax (VAT) ₱ 11,263,464.96
Import Processing Fee ₱ 127,130.87
Customs Documentary Stamp ₱ 265.00
TOTAL COST ₱ 428,091,653.51
154
Cost of Heat Exchangers:
Table 64
Cost of Heat Exchangers generated from Aspen Hysys V8.0
NUMBER Cost
HE-101 $ 56,088.00
HE-103 $ 214,234.00
HE-104 $ 260,661.00
HE-105 $ 16,750.00
HE-107 $ 10,626.00
HE-108 $ 14,577.00
HE-109 $ 401,970.00
HE-110 $ 38,004.00
HE-111 $ 58,110.00
HE-112 $ 15,415.00
Table 65
Final Cost of Heat Exchangers
Equipment Cost $ 1,216,807.20
Cost (2015 @ SE Asia) $ 1,362,824.06
₱ 61,327,082.88
Freight Cost $ 3,257.58
₱ 146,591.10
Bureau of Customs: Duties and Taxes
Value Added Tax (VAT) ₱ 5,784,498.72
Import Processing Fee ₱ 65,186.10
Customs Documentary Stamp ₱ 265.00
TOTAL COST ₱ 67,323,623.80
155
Cost of Pipes:
Table 66
Purchase Cost of Pipes
Pipes Di (mm) L (m) Cost per length (m) Final cost
PIPE-100 26.64 2.5 $ 9,985.69 $ 24,964.22
PIPE-101 26.64 2.5 $ 9,985.69 $ 24,964.22
PIPE-102 26.64 2.5 $ 9,985.69 $ 24,964.22
PIPE-103 26.64 2.5 $ 9,985.69 $ 24,964.22
PIPE-104 26.64 2.5 $ 9,985.69 $ 24,964.22
PIPE-105 26.64 2.5 $ 9,985.69 $ 24,964.22
PIPE-106 26.64 2.5 $ 9,985.69 $ 24,964.22
PIPE-107 26.64 2.5 $ 9,985.69 $ 24,964.22
PIPE-108 26.64 2.5 $ 9,985.69 $ 24,964.22
PIPE-109 26.64 2.5 $ 9,985.69 $ 24,964.22
PIPE-110 26.64 2.5 $ 9,985.69 $ 24,964.22
PIPE-111 26.64 2.5 $ 9,985.69 $ 24,964.22
PIPE-112 26.64 12 $ 9,985.69 $ 119,828.26
PIPE-113 26.64 12 $ 9,985.69 $ 119,828.26
PIPE-114 26.64 12 $ 9,985.69 $ 119,828.26
PIPE-115 26.64 12 $ 9,985.69 $ 119,828.26
PIPE-116 26.64 12 $ 9,985.69 $ 119,828.26
PIPE-117 26.64 12 $ 9,985.69 $ 119,828.26
PIPE-118 26.64 8 $ 9,985.69 $ 79,885.50
PIPE-119 52.5 8 $ 16,496.83 $ 131,974.66
PIPE-106 102.3 5 $ 27,026.55 $ 135,132.76
PIPE-107 102.3 2 $ 27,026.55 $ 54,053.10
PIPE-108 102.3 2 $ 27,026.55 $ 54,053.10
PIPE-109 254.5 11 $ 53,050.76 $ 583,558.39
PIPE-110 77.93 10 $ 22,097.55 $ 220,975.50
PIPE-111 77.93 30 $ 22,097.55 $ 662,926.51
PIPE-113 40.89 3 $ 13,711.32 $ 41,133.97
PIPE-112 77.93 1 $ 22,097.55 $ 22,097.55
PIPE-114 52.5 5 $ 16,496.83 $ 82,484.16
PIPE-115 52.5 5 $ 16,496.83 $ 82,484.16
PIPE-116 52.5 5 $ 16,496.83 $ 82,484.16
PIPE-117 52.5 5 $ 16,496.83 $ 82,484.16
PIPE-118 40.89 5 $ 13,711.32 $ 68,556.61
PIPE-119 40.89 3 $ 13,711.32 $ 41,133.97
PIPE-120 40.89 50 $ 13,711.32 $ 685,566.11
PIPE-121 26.64 5 $ 9,985.69 $ 49,928.44
PIPE-121-10 26.64 5 $ 9,985.69 $ 49,928.44
PIPE-121-2 26.64 5 $ 9,985.69 $ 49,928.44
156
PIPE-121-3 26.64 5 $ 9,985.69 $ 49,928.44
PIPE-121-4 26.64 5 $ 9,985.69 $ 49,928.44
PIPE-121-5 26.64 5 $ 9,985.69 $ 49,928.44
PIPE-121-6 26.64 5 $ 9,985.69 $ 49,928.44
PIPE-121-7 26.64 5 $ 9,985.69 $ 49,928.44
PIPE-121-8 26.64 5 $ 9,985.69 $ 49,928.44
PIPE-121-9 26.64 5 $ 9,985.69 $ 49,928.44
PIPE-122 40.89 50 $ 13,711.32 $ 685,566.11
PIPE-123 26.64 5 $ 9,985.69 $ 49,928.44
PIPE-123-10 26.64 5 $ 9,985.69 $ 49,928.44
PIPE-123-2 26.64 5 $ 9,985.69 $ 49,928.44
PIPE-123-3 26.64 5 $ 9,985.69 $ 49,928.44
PIPE-123-4 26.64 5 $ 9,985.69 $ 49,928.44
PIPE-123-5 26.64 5 $ 9,985.69 $ 49,928.44
PIPE-123-6 26.64 5 $ 9,985.69 $ 49,928.44
PIPE-123-7 26.64 5 $ 9,985.69 $ 49,928.44
PIPE-123-8 26.64 5 $ 9,985.69 $ 49,928.44
PIPE-123-9 26.64 5 $ 9,985.69 $ 49,928.44
Table 67
Final Cost of Pipe
Cost (2006) $ 4,442,527.26
Cost (2015) $ 5,415,440.73
Cost (2015 @ SE Asia) $ 6,065,293.62
Cost of Equipment (w/ Location and Installation factor
consideration)
$ 19,408,939.59
₱ 873,402,281.57
Freight Cost $ 2,911.65
₱ 131,024.25
Bureau of Customs: Duties and Taxes
Value Added Tax (VAT) ₱ 27,552,554.09
Import Processing Fee ₱ 266,551.64
Customs Documentary Stamp ₱ 265.00
TOTAL COST ₱ 901,352,676.54
157
Cost of Pumps:
Table 68
Purchase Cost of Pumps
Number Flow rate (m3/h) Flow rate (L/s) Cost
P-101 6.619 1.838611111 $ 3,399.68
P-102 14.33 3.980555556 $ 3,551.87 P-103 1245 345.8333333 $ 56,741.85
P-104 22.98 6.383333333 $ 3,743.91
P-105 22.78 6.327777778 $ 3,739.28
P-106 21.99 6.108333333 $ 3,721.06 P-107 21.29 5.913888889 $ 3,705.03
P-108 20.73 5.758333333 $ 3,692.28
P-109 361.3 100.3611111 $ 15,409.32 P-110 5633 1564.722222 $ 330,313.69
Table 69
Final Cost of Pumps
Cost (2006) $ 428,017.99
Cost (2015) $ 521,753.92
Cost (2015 @ SE Asia) $ 584,364.40
Cost of Equipment (w/ Location and Installation factor
consideration) $ 1,869,966.07
₱ 84,148,472.96
Freight Cost $ 3,257.58
₱ 146,591.10
Bureau of Customs: Duties and Taxes
Value Added Tax (VAT) ₱ 1,583,017.47
Import Processing Fee ₱ 25,681.08
Customs Documentary Stamp ₱ 265.00
TOTAL COST ₱ 85,904,027.61
158
Cost of Compressor:
Table 70
Purchase Cost of Compressor
NUMBER Driver Power (kW) Need Adjustment Cost
K-100 1.80E+02 No $ 78,319.38
Table 71
Final Cost of Compressor
Cost (2006) $ 78,319.38
Cost (2015) $ 95,471.32
Cost (2015 @ SE Asia) $ 106,927.88
Cost of Equipment (w/ Location and Installation factor consideration)
$ 342,169.23
₱ 15,397,615.19
Freight Cost $ 3,257.58
₱ 146,591.10
Bureau of Customs: Duties and Taxes
Value Added Tax (VAT) ₱ 433,098.41
Import Processing Fee ₱ 4,699.16
Customs Documentary Stamp ₱ 265.00
TOTAL COST ₱ 15,982,268.86
159
Cost of OSBL Equipment
Cost of Boiler:
Table 72
Purchase Cost of Boiler
kg/h steam Cost
360581.279 $ 1,504,690.06
Table 73
Final Cost of Boiler
Cost (2006) $ 1,504,690.06
Cost (2015) $ 1,834,217.19
Cost (2015 @ SE Asia) $ 2,054,323.25
Cost of Equipment (w/ Location and Installation factor consideration)
$ 6,573,834.39
₱ 295,822,547.73
Freight Cost $ 2,882.82
₱ 129,726.90
Bureau of Customs: Duties and Taxes
Value Added Tax (VAT) ₱ 13,266,225.67
Import Processing Fee ₱ 90,281.40
Customs Documentary Stamp ₱ 265.00
TOTAL COST ₱ 309,309,046.70
160
Cost of Furnace:
Table 74
Purchase Cost of Furnace
duty, MW Cost
174.1 $ 3,411,507.62
Table 75
Final Cost of Furnace
Cost (2006) $ 3,411,507.62
Cost (2015) $ 4,158,627.79
Cost (2015 @ SE Asia) $ 4,657,663.12
Cost of Equipment (w/ Location and Installation factor consideration)
$ 14,904,521.99
₱ 670,703,489.66
Freight Cost $ 2,882.82
₱ 129,726.90
Bureau of Customs: Duties and Taxes
Value Added Tax (VAT) ₱ 23,354,129.56
Import Processing Fee ₱ 204,690.46
Customs Documentary Stamp ₱ 265.00
TOTAL COST ₱ 694,392,301.57
161
Cost of Scrubber:
Table 76
Purchase Cost of Scrubber
Gas Effluent m3/h 8399
ft3/h 296607.9
acfm 4943.465
Total Purchase Cost of Equipment $ 15,150.29
Table 77
Final Cost of Scrubber
Cost (2006) $ 15,150.29
Cost (2015) $ 18,468.20
Cost (2015 @ SE Asia) $ 20,684.38
Cost of Equipment (w/ Location and Installation factor consideration)
$ 66,190.02
₱ 2,978,551.01
Freight Cost $ 2,882.82
₱ 129,726.90
Bureau of Customs: Duties and Taxes
Value Added Tax (VAT) ₱ 95,464.89
Import Processing Fee ₱ 909.02
Customs Documentary Stamp ₱ 265.00
TOTAL COST ₱ 3,204,916.81
162
Cost of Cooling Tower
Table 78
Purchase Cost of Cooling Tower
Flow rate (m3/h) Flow rate (L/s) Cost
5653.898758 1570.527433 $ 331,770.12
Table 79
Final Cost of Cooling Tower
Cost (2006) $ 331,770.12
Cost (2015) $ 404,427.78
Cost (2015 @ SE Asia) $ 452,959.11
Cost of Equipment (w/ Location and Installation factor
consideration)
$ 1,449,469.15
₱ 65,226,111.81
Freight Cost $ 2,911.65
₱ 131,024.25
Bureau of Customs: Duties and Taxes
Value Added Tax (VAT) ₱ 1,987,996.75
Import Processing Fee ₱ 19,906.21
Customs Documentary Stamp ₱ 265.00
TOTAL COST ₱ 67,365,304.01
163
Cost of Biological Waste Water Treatment:
Table 80
Existing Activated Sludge Waste Water Treatment Plant in the Philippines
Existing Wastewater Treatment Plant Facility
Plant Toyota Motor Philippines
Location Toyota Special Economic Zone, Santa Rosa City, Laguna, 4026
CAPEX ₱ 140,000,000.00
Capacity 840 cubic meters per day
Table 81
Capital Cost of WWTP of Phace Philippines Corporation
Location Hermosa, Bataan
Capacity 71.95 cubic meters per day
CAPEX ₱ 32,046,377.41
164
Indirect Costs of the Plant
Depreciation cost. Double Declining Balance Method with switch over to Straight
Line method was used in obtaining the depreciation of the investments per year. The cost
basis which amounts to the sum of ISBL and OSBL Capex is 3,920,857,301.32 pesos. The
useful life of the plant is fifteen years. The constant percentage of depreciation for double
declining balance method can be obtain using equation 17, and for straight line using
equation 18. To obtain the book value at any year, equation 19 can be used.
𝑹𝟏 =𝟐
𝑵, 𝒇𝒐𝒓 𝟐𝟎𝟎% 𝑫𝒐𝒖𝒃𝒍𝒆 𝑫𝒆𝒄𝒍𝒊𝒏𝒊𝒏𝒈 𝑩𝒂𝒍𝒂𝒏𝒄𝒆
𝑅1 = 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡 𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑜𝑓 𝐷𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛 𝑓𝑜𝑟 𝐷𝑜𝑢𝑏𝑙𝑒 𝐷𝑒𝑐𝑙𝑖𝑛𝑖𝑛𝑔 𝐵𝑎𝑙𝑎𝑛𝑐𝑒
𝑹𝟐 =𝟏
𝑵
𝑅2 = 𝑆𝑡𝑟𝑎𝑖𝑔ℎ𝑡 𝐿𝑖𝑛𝑒 𝐷𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛 𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒
𝑩𝑽𝒌 = (𝟏 − 𝑹)𝒌𝑩
Note that depreciation is an implicit and non-cash cost. It is an expired portion of
the cost of the asset due to usage or wear and tear. The reason it is non-cash expense for
the period is that because it is but an amortized cost of something already paid for in the
past. The value of 𝑅1 is 13.33% and 𝑅2 is 6.67%. Table 82 shows the depreciation schedule
of the plant.
(17)
(18)
(19)
165
Table 82
Depreciation schedule of the plant (values in Philippine Peso)
k B R 𝑑𝑘 𝑢𝑠𝑒𝑑 𝑑𝑘 𝑆𝐿 𝑑𝑘 𝐷𝐵 𝑑𝑘 𝐴𝑐𝑐𝑢 𝐵𝑉𝑘
1 3920857301 13% 522780974 261390487 522780974 522780974 3659466815
2 3659466815 13% 487928909 261390487 487928909 1010709882 3398076328
3 3398076328 13% 453076844 261390487 453076844 941005752 3136685841
4 3136685841 13% 418224779 261390487 418224779 871301623 2875295354
5 2875295354 13% 383372714 261390487 383372714 801597493 2613904868
6 2613904868 13% 348520649 261390487 348520649 731893363 2352514381
7 2352514381 13% 313668584 261390487 348520649 697041298 2091123894
8 2091123894 13% 278816519 261390487 348520649 697041298 1829733407
9 1829733407 13% 243964454 261390487 348520649 697041298 1568342921
10 1568342921 13% 209112389 261390487 348520649 697041298 1306952434
11 1306952434 13% 174260325 261390487 348520649 697041298 1045561947
12 1045561947 13% 139408260 261390487 348520649 697041298 784171460
13 784171460 13% 104556195 261390487 348520649 697041298 522780974
14 522780974 13% 69704130 261390487 348520649 697041298 261390487
15 261390487 13% 34852065 261390487 348520649 697041298 0
Land cost. The manufacturing plant of Phace Philippines Corporation will be
constructed in Hermosa Ecozone Industrial Park (HEIP). Shown in Table 83 is the
summary of the description of the plant location. The Ecozone is 162-hectare industrial
estate component of a 478-hectare mixed-use property development in the province of
Bataan by the Hermosa Ecozone Development Corporation, of which Science Park of the
Philippines, Inc. (SPPI) is a shareholder and General Manager. The project is registered
Special Economic Zone (Ecozone) under the Philippine Economic Zone Authority
(PEZA). These are areas designated by the government for development into balanced
agricultural, industrial, commercial, and tourist/recreational regions.
166
Table 83
Land facts about Hermosa Ecozone Industrial Park (HEIP)
Total Area 162 hectares
Saleable Area 124 hectares
Common Area 38 hectares
Sold Area 18.9 hectares
Remaining Area for Sale 105.1 hectares
Source: Science Park of the Philippines, 2015
Each Ecozone is to be developed as an independent community with minimum
government interference. It shall administer its own economic, financial, industrial and
tourism development without help from the national government. It shall also provide
adequate facilities to establish linkages with surrounding communities and other entities
within the country. Lease rates for industrial land were averaged to $0.27 per sq. m per
month. Based on the Plot Plan of the company, the total land area is 33129 SQM or 3.3129
hectares. See appendix F for the plot plan of the plant. Table 84 shows the cost of land
lease per year.
167
Table 84
Cost of Land lease annually
YEAR SQM
Rate
(monthly)
(USD/SQM)
Rate
(monthly)
(PhP/SQM)
Cost of lease
per month
Cost of lease
per year
2015(construction) 33129 $ 0.27 ₱ 12.15 ₱ 402,517.35 ₱ 4,830,208.20
2016(construction) 33129 $ 0.27 ₱ 12.15 ₱ 402,517.35 ₱ 4,830,208.20
2017 33129 $ 0.27 ₱ 12.15 ₱ 402,517.35 ₱ 4,830,208.20
2018 33129 $ 0.27 ₱ 12.15 ₱ 402,517.35 ₱ 4,830,208.20
2019 33129 $ 0.27 ₱ 12.15 ₱ 402,517.35 ₱ 4,830,208.20
2020 33129 $ 0.27 ₱ 12.15 ₱ 402,517.35 ₱ 4,830,208.20
2021 33129 $ 0.27 ₱ 12.15 ₱ 402,517.35 ₱ 4,830,208.20
2022 33129 $ 0.27 ₱ 12.15 ₱ 402,517.35 ₱ 4,830,208.20 2023 33129 $ 0.27 ₱ 12.15 ₱ 402,517.35 ₱ 4,830,208.20
2024 33129 $ 0.27 ₱ 12.15 ₱ 402,517.35 ₱ 4,830,208.20
2025 33129 $ 0.27 ₱ 12.15 ₱ 402,517.35 ₱ 4,830,208.20
2026 33129 $ 0.27 ₱ 12.15 ₱ 402,517.35 ₱ 4,830,208.20 2027 33129 $ 0.27 ₱ 12.15 ₱ 402,517.35 ₱ 4,830,208.20
2028 33129 $ 0.27 ₱ 12.15 ₱ 402,517.35 ₱ 4,830,208.20
2029 33129 $ 0.27 ₱ 12.15 ₱ 402,517.35 ₱ 4,830,208.20 2030 33129 $ 0.27 ₱ 12.15 ₱ 402,517.35 ₱ 4,830,208.20
2031 33129 $ 0.27 ₱ 12.15 ₱ 402,517.35 ₱ 4,830,208.20
Fixed capital cost. Fixed capital cost is a production cost that does not vary with
the production volume. In order to obtain this cost, refer to Table 51. Table 85 shows the
fixed capital cost of the plant per year.
168
Table 85
Fixed Capital Cost of the Plant
YEAR Depreciation Land Rental Fixed Capital
Cost Cost Cost
2017 ₱ 522,780,973.51 ₱ 4,830,208.20 ₱ 527,611,181.71 2018 ₱ 487,928,908.61 ₱ 4,830,208.20 ₱ 492,759,116.81
2019 ₱ 453,076,843.71 ₱ 4,830,208.20 ₱ 457,907,051.91
2020 ₱ 418,224,778.81 ₱ 4,830,208.20 ₱ 423,054,987.01 2021 ₱ 383,372,713.91 ₱ 4,830,208.20 ₱ 388,202,922.11
2022 ₱ 348,520,649.01 ₱ 4,830,208.20 ₱ 353,350,857.21
2023 ₱ 348,520,649.01 ₱ 4,830,208.20 ₱ 353,350,857.21
2024 ₱ 348,520,649.01 ₱ 4,830,208.20 ₱ 353,350,857.21 2025 ₱ 348,520,649.01 ₱ 4,830,208.20 ₱ 353,350,857.21
2026 ₱ 348,520,649.01 ₱ 4,830,208.20 ₱ 353,350,857.21
2027 ₱ 348,520,649.01 ₱ 4,830,208.20 ₱ 353,350,857.21 2028 ₱ 348,520,649.01 ₱ 4,830,208.20 ₱ 353,350,857.21
2029 ₱ 348,520,649.01 ₱ 4,830,208.20 ₱ 353,350,857.21
2030 ₱ 348,520,649.01 ₱ 4,830,208.20 ₱ 353,350,857.21
2031 ₱ 348,520,649.01 ₱ 4,830,208.20 ₱ 353,350,857.21
Insurance cost. Insurance is the equitable transfer of the risk of a loss, from one
entity to another in exchange for payment. Refer to Table 51 for the equation in obtaining
insurance cost. Table 86 shows the annual insurance cost of the company.
169
Table 86
Annual insurance cost of the company
Year Cost
2017 ₱ 5,487,173.82
2018 ₱ 5,124,582.37
2019 ₱ 4,761,990.92 2020 ₱ 4,399,399.47
2021 ₱ 4,036,808.02
2022 ₱ 3,674,216.57
2023 ₱ 3,674,216.57 2024 ₱ 3,674,216.57
2025 ₱ 3,674,216.57
2026 ₱ 3,674,216.57 2027 ₱ 3,674,216.57
2028 ₱ 3,674,216.57
2029 ₱ 3,674,216.57 2030 ₱ 3,674,216.57
2031 ₱ 3,674,216.57
Direct Costs of the Plant
Cost of the raw materials. The raw materials of the process are propylene and
benzene and they will be sourced mainly from Petron and JG Summit. Table 87 shows the
flow rate for each of the raw materials as required by the process and their indicative prices.
Table 87
Cost calculation basis for raw materials
FLOWRATE Operational Time MTpY
PRICE
kg/h # of days # of Hours USD/MT
Propylene 3354 350 8400 28,173.60 1014.13
Benzene 6248.800049 350 8400 52,489.92 1039.81
Flowrates acquired from the Aspen Hysys Simulation
Source of Price: ICIS Indicative Prices
170
The inflation of the prices of the raw materials is approximated to 5%, as given
from the trend of prices of propylene and benzene from the report of Pandia entitled
“Global Acetone-Phenol Markets” in the year 2009. US Dollar to Philippines Peso
conversion is averaged to forty five. Given in Table 88 and Table 89 are the cost of
propylene and benzene annually.
Table 88
Annual cost of propylene
Year Turndown Capacity
MTpY Price (per MT) Cost
2017 50% 14,086.80 $ 1,014.13 ₱ 642,860,049.03
2018 65% 14,086.80 $ 1,064.83 ₱ 675,003,051.48
2019 75% 21,130.20 $ 1,118.07 ₱ 1,063,129,806.09 2020 100% 28,173.60 $ 1,173.98 ₱ 1,488,381,728.52
2021 100% 28,173.60 $ 1,232.68 ₱ 1,562,800,814.95
2022 100% 28,173.60 $ 1,294.31 ₱ 1,640,940,855.69 2023 100% 28,173.60 $ 1,359.02 ₱ 1,722,987,898.48
2024 100% 28,173.60 $ 1,426.98 ₱ 1,809,137,293.40
2025 100% 28,173.60 $ 1,498.32 ₱ 1,899,594,158.07
2026 100% 28,173.60 $ 1,573.24 ₱ 1,994,573,865.97 2027 100% 28,173.60 $ 1,651.90 ₱ 2,094,302,559.27
2028 100% 28,173.60 $ 1,734.50 ₱ 2,199,017,687.24
2029 100% 28,173.60 $ 1,821.22 ₱ 2,308,968,571.60 2030 100% 28,173.60 $ 1,912.28 ₱ 2,424,417,000.18
2031 100% 28,173.60 $ 2,007.90 ₱ 2,545,637,850.19
171
Table 89
Annual cost of benzene
Year Turndown
Capacity MTPY Price (per MT) Cost - Benzene
2017 50% 26,244.96 $ 1,039.81 ₱ 1,228,039,655.60 2018 65% 26,244.96 $ 1,091.80 ₱ 1,289,441,638.39
2019 75% 39,367.44 $ 1,146.39 ₱ 2,030,870,580.46
2020 100% 52,489.92 $ 1,203.71 ₱ 2,843,218,812.64
2021 100% 52,489.92 $ 1,263.90 ₱ 2,985,379,753.27 2022 100% 52,489.92 $ 1,327.09 ₱ 3,134,648,740.93
2023 100% 52,489.92 $ 1,393.44 ₱ 3,291,381,177.98
2024 100% 52,489.92 $ 1,463.12 ₱ 3,455,950,236.88 2025 100% 52,489.92 $ 1,536.27 ₱ 3,628,747,748.72
2026 100% 52,489.92 $ 1,613.09 ₱ 3,810,185,136.16
2027 100% 52,489.92 $ 1,693.74 ₱ 4,000,694,392.97 2028 100% 52,489.92 $ 1,778.43 ₱ 4,200,729,112.62
2029 100% 52,489.92 $ 1,867.35 ₱ 4,410,765,568.25
2030 100% 52,489.92 $ 1,960.72 ₱ 4,631,303,846.66
2031 100% 52,489.92 $ 2,058.75 ₱ 4,862,869,038.99
Cost of the catalysts. Life of catalysts for R-102 to R-105 (oxidation towers) is
usually 3 years for copper oxide (CuO) synthetic catalyst (Cheng & Kung, 1994). For the
packed bed plug flow reactor R-101 (Alkylation reactor), the life of catalyst for zeolite is
usually 2 years (Anpo, Onaka, & Yamashita, 2003). For the cleavage reactor (R-106), the
life of catalyst for sulfonic acid resins is usually 8 months (Rase, 2000). Shown in Table
90 is the amount of each catalyst used in each reactors and their corresponding prices.
Shown in Table 91 is the final cost of catalyst for each of the reactor. Finally, shown in
Table 92 is the total cost of the catalyst used annually.
172
Table 90
Amount and Pricing of Catalyst Used for each Reactor
REACTOR Mass of catalyst (kg) Price (USD/Kg) Life of catalyst
R-102 198.55 376.00 3 years
R-103 198.55 376.00 3 years
R-104 198.55 376.00 3 years
R-105 198.55 376.00 3 years
R-101 7140 8.37 2 years
R-106 2.65854 2930.00 8 months
Table 91
Final Cost of Catalyst for each Reactor
REACTOR Years of Operation Cost of Catalyst
R-102 15 $ 77,213.89
R-103 15 $ 77,213.89
R-104 15 $ 77,213.89
R-105 15 $ 77,213.89
R-101 15 $ 4,641,000.00
R-106 15 $ 5,051.23
Table 92
Total Cost of Catalysts per Year
Year Turndown
Capacity Cost of Catalyst Freight VAT Cost - Catalyst
2017 50% $ 4,725,471.23 $ 2,940.47 ₱ 50,962,913.44 ₱ 157,352,176.60 2018 65% $ 4,883,301.96 $ 2,940.47 ₱ 50,962,913.44 ₱ 193,885,504.66
2019 75% $ 4,883,301.96 $ 2,940.47 ₱ 50,962,913.44 ₱ 215,873,595.62
2020 100% $ 4,883,301.96 $ 2,940.47 ₱ 50,962,913.44 ₱ 270,843,823.01
2021 100% $ 4,883,301.96 $ 2,940.47 ₱ 50,962,913.44 ₱ 270,843,823.01 2022 100% $ 4,883,301.96 $ 2,940.47 ₱ 50,962,913.44 ₱ 270,843,823.01
2023 100% $ 4,883,301.96 $ 2,940.47 ₱ 50,962,913.44 ₱ 270,843,823.01
2024 100% $ 4,883,301.96 $ 2,940.47 ₱ 50,962,913.44 ₱ 270,843,823.01 2025 100% $ 4,883,301.96 $ 2,940.47 ₱ 50,962,913.44 ₱ 270,843,823.01
2026 100% $ 4,883,301.96 $ 2,940.47 ₱ 50,962,913.44 ₱ 270,843,823.01
2027 100% $ 4,883,301.96 $ 2,940.47 ₱ 50,962,913.44 ₱ 270,843,823.01 2028 100% $ 4,883,301.96 $ 2,940.47 ₱ 50,962,913.44 ₱ 270,843,823.01
2029 100% $ 4,883,301.96 $ 2,940.47 ₱ 50,962,913.44 ₱ 270,843,823.01
2030 100% $ 4,883,301.96 $ 2,940.47 ₱ 50,962,913.44 ₱ 270,843,823.01
2031 100% $ 4,883,301.96 $ 2,940.47 ₱ 50,962,913.44 ₱ 270,843,823.01
173
Utility costs of the plant. The main process of the plant requires a cooling water
system and a steam generation unit. Shown in Table 93 is the fuel requirement of the plant
and in Table 94 is the water requirement of the plant.
Table 93
Fuel requirement of the plant and its price
Fuel: Industrial LPG (Propane)
Volume Flow (L/year) 781,536.00
Price (per Liter) 5.5 PHP
Table 94
Water requirement of the plant and its price
WATER
Volume Flow (m3/h) 6100.64
Volume of water (1 day) 146415.36
Volume of water (1 year) 585,662.28
Volume with Make-up (1 year) 592,983.06
The fuel requirement of the plant amounts to an average of 782 𝑚3 annually. The
cost of the fuel consumption per year is shown in Table 95.
174
Table 95
Cost of Fuel Consumed Per Year
Year Turndown Capacity Price (per Liter) Cost - Fuel
2017 50% ₱ 5.50 ₱ 2,149,224.00
2018 65% ₱ 5.72 ₱ 2,235,192.96
2019 75% ₱ 5.95 ₱ 3,486,901.02
2020 100% ₱ 6.19 ₱ 4,835,169.41
2021 100% ₱ 6.43 ₱ 5,028,576.19
2022 100% ₱ 6.69 ₱ 5,229,719.24
2023 100% ₱ 6.96 ₱ 5,438,908.00
2024 100% ₱ 7.24 ₱ 5,656,464.32
2025 100% ₱ 7.53 ₱ 5,882,722.90
2026 100% ₱ 7.83 ₱ 6,118,031.81
2027 100% ₱ 8.14 ₱ 6,362,753.09
2028 100% ₱ 8.47 ₱ 6,617,263.21
2029 100% ₱ 8.81 ₱ 6,881,953.74
2030 100% ₱ 9.16 ₱ 7,157,231.89
2031 100% ₱ 9.52 ₱ 7,443,521.16
The water requirement of the plant for both of its cooling water system and steam
generation unit amounts to an average of 593,000 𝑚3 annually. The maximum required
make-up water flow rate for cooling tower can be approximated with 1.25% of the total
flow. This percentage accounts the evaporation and blowdown losses (Stanford, 2012).
There will be a very high maintenance of cooling tower water because the cleaning will be
frequent. For industries, the average cost of cooling water chemicals is $0.043 𝑝𝑒𝑟 𝑚3 of
total water requirement (LLC-Consulting-Group, 2003). The cost of the consumable water
per year is shown in Table 96.
175
Table 96
Cost of Consumed Water per Year
Year Turndown
Capacity
Price (per 100
m3)
Cubic meter
used Cost - PW
2017 50% ₱
2,962.00 585,662.28 ₱ 8,673,658.38
2018 65% ₱
2,962.00 585,662.28 ₱ 11,275,755.89
2019 75% ₱
2,962.00 585,662.28 ₱ 13,010,487.57
2020 100% ₱
2,962.00 585,662.28 ₱ 17,347,316.76
2021 100% ₱
2,962.00 585,662.28 ₱ 17,347,316.76
2022 100% ₱
2,962.00 585,662.28 ₱ 17,347,316.76
2023 100% ₱
2,962.00 585,662.28 ₱ 17,347,316.76
2024 100% ₱
2,962.00 585,662.28 ₱ 17,347,316.76
2025 100% ₱
2,962.00 585,662.28 ₱ 17,347,316.76
2026 100% ₱
2,962.00 585,662.28 ₱ 17,347,316.76
2027 100% ₱
2,962.00 585,662.28 ₱ 17,347,316.76
2028 100% ₱
2,962.00 585,662.28 ₱ 17,347,316.76
2029 100% ₱
2,962.00 585,662.28 ₱ 17,347,316.76
2030 100% ₱
2,962.00 585,662.28 ₱ 17,347,316.76
2031 100% ₱
2,962.00 585,662.28 ₱ 17,347,316.76
Cost of electricity. In order to obtain an approximation of the cost of electricity per
year, it is vital to obtain the amount of energy the process and the building utilize annually.
Electricity consumption for commercial buildings can be assumed to be
17.3 𝑘𝑊ℎ 𝑝𝑒𝑟 𝑓𝑡2 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟 (MGE). Shown in Table 97 is the electricity requirement of
each of the buildings of the plant and in Table 98 the electricity requirement of the process
annually.
176
Table 97
Electricity Requirement of the Buildings
ELECTRICITY COST OF THE BUILDINGS
Buildings LENGTH
(m)
WIDTH
(m)
AREA
(m2)
Area
(ft2)
kWh per
YEAR
ADMIN BLDG 27.5 51 1402.5 15,096.3
7 261,167.20
MANUFACTURING 72 56 4032 43,400.0
4 750,820.78
QUALITY CONTROL
LAB 17.5 50.9 890.75 9,587.94 165,871.43
CANTEEN 40 18 720 7,750.01 134,075.14
PRODUCTION
OFFICE 25.9 18 466.2 5,018.13 86,813.65
RESEARCH&DEV 17.5 27 472.5 5,085.94 87,986.81
SECURITY OFFICE 27.83 12.2 339.526 3,654.62 63,224.99
MAINTENANCE 17.5 18 315 3,390.63 58,657.87
CONTROL ROOM 25 8 200 2,152.78 37,243.09
WAREHOUSE 20.04 22 440.88 4,745.59 82,098.68
TOTAL (kWh per Year) 1,727,959.64
Table 98
Electricity requirement of the Process
EQUIPMENT POWER Electricity Requirement
KW kWh/Day kWh/Year
Process
P-101 5.735 137.6 48,160.00
P-102 18.26 438.2 153,370.00
P-103 164.2 3940.8 1,379,280.00
P-104 0.3521 8.4504 2,957.64
P-105 0.01056 0.25344 88.70
P-106 0.01792 0.43008 150.53
P-107 0.02498 0.59952 209.83
P-108 2.538 60.912 21,319.20
K-100 180.0417 4321.001 1,512,350.28
Utilities
P-109 2093 50232 17,581,200.00
P-110 82.73 1985.52 694,932.00
TOTAL 21,394,018.18
177
In order to get the annual cost of electricity consumption, the electricity requirement
of both the process and the buildings were combined. A total of 23,121,977.82 𝑘𝑊ℎ of
electricity per year will be required by the whole plant. The cost of electricity for the
industry in Hermosa, Bataan is 6.4708 𝑃ℎ𝑃 (Provincial Government of Bataan, n.d.).
Shown in Table 99 is the annual cost of electricity of the company.
Table 99
Cost of Electricity Consumption per Year
Year Turndown
Capacity Process Buildings Cost
2017 50% ₱ 138,436,412.87 ₱ 11,181,281.23 ₱ 80,399,487.66
2018 50% ₱ 138,436,412.87 ₱ 11,181,281.23 ₱ 101,164,949.59
2019 75% ₱ 138,436,412.87 ₱ 11,181,281.23 ₱ 115,008,590.88
2020 100% ₱ 138,436,412.87 ₱ 11,181,281.23 ₱ 149,617,694.10
2021 100% ₱ 138,436,412.87 ₱ 11,181,281.23 ₱ 149,617,694.10
2022 100% ₱ 138,436,412.87 ₱ 11,181,281.23 ₱ 149,617,694.10
2023 100% ₱ 138,436,412.87 ₱ 11,181,281.23 ₱ 149,617,694.10
2024 100% ₱ 138,436,412.87 ₱ 11,181,281.23 ₱ 149,617,694.10
2025 100% ₱ 138,436,412.87 ₱ 11,181,281.23 ₱ 149,617,694.10
2026 100% ₱ 138,436,412.87 ₱ 11,181,281.23 ₱ 149,617,694.10
2027 100% ₱ 138,436,412.87 ₱ 11,181,281.23 ₱ 149,617,694.10
2028 100% ₱ 138,436,412.87 ₱ 11,181,281.23 ₱ 149,617,694.10
2029 100% ₱ 138,436,412.87 ₱ 11,181,281.23 ₱ 149,617,694.10
2030 100% ₱ 138,436,412.87 ₱ 11,181,281.23 ₱ 149,617,694.10
2031 100% ₱ 138,436,412.87 ₱ 11,181,281.23 ₱ 149,617,694.10
Cost of communication. Communication within a company is a very important
factor for success. In the business world, good communication is important for the daily
operation of the plant. Table 100 summarizes the price of the communication the company
should have. Table 101 shows the annual cost of communication within the company,
divided to internet and landline services.
178
Table 100
Price of communication services
` COST
Voice / Landline:
Monthly Rental (Commercial) PhP 936.00
(21.53 USD)
Monthly Rental (Residential) PhP 617.00
(14.19USD)
Data / Internet:
Monthly Rental – 1MB up to 4MB
(Commercial)
PhP 4, 000.00
(92.00 USD)
Monthly Rental – up to 1MB
(Residential)
PhP 999.00
(23.00 USD)
Table 101
Annual cost of communication services of the company
Year Internet Landline
2017 ₱ 11,232.00 ₱ 48,000.00
2018 ₱ 11,232.00 ₱ 48,000.00
2019 ₱ 11,232.00 ₱ 48,000.00
2020 ₱ 11,232.00 ₱ 48,000.00
2021 ₱ 11,232.00 ₱ 48,000.00
2022 ₱ 11,232.00 ₱ 48,000.00
2023 ₱ 11,232.00 ₱ 48,000.00
2024 ₱ 11,232.00 ₱ 48,000.00
2025 ₱ 11,232.00 ₱ 48,000.00
2026 ₱ 11,232.00 ₱ 48,000.00
2027 ₱ 11,232.00 ₱ 48,000.00
2028 ₱ 11,232.00 ₱ 48,000.00
2029 ₱ 11,232.00 ₱ 48,000.00
2030 ₱ 11,232.00 ₱ 48,000.00
2031 ₱ 11,232.00 ₱ 48,000.00
Operating cost of Waste Water Treatment Plant. For a biological sewage
treatment plant, the annual operating expenses will be based on the amount of organics it
will handle. Refer to Table 51 for the equation in obtaining the annual expenses of WWTP.
Shown in Table 102 is the cost of biological WWTP operation annually.
179
Table 102
Cost of Biological WWTP Operation per Year
Year Cost
2017 ₱ 330,775.68
2018 ₱ 330,775.68
2019 ₱ 330,775.68
2020 ₱ 330,775.68
2021 ₱ 330,775.68
2022 ₱ 330,775.68
2023 ₱ 330,775.68
2024 ₱ 330,775.68
2025 ₱ 330,775.68
2026 ₱ 330,775.68
2027 ₱ 330,775.68
2028 ₱ 330,775.68
2029 ₱ 330,775.68
2030 ₱ 330,775.68
2031 ₱ 330,775.68
Operating labor. To determine labor costs, one must estimate the number of
operators (crew size) and the wage rate. The preferred way to determine labor needs is to
get a manufacturing estimate. However, because there is not enough time or because
manufacturing has not staffed a project, which is often not practical. Table 103 shows the
summary of labor cost annually. The management decided a 4% increase in labor per year.
See Appendix E for the breakdown of wage and monetary benefits for each employees of
the company.
180
Table 103
Summary of Labor Cost per Year
`Year Net Pay (w/
benefits)
Company
Contribution Yearly Bonus TOTAL
2017 ₱ 18,782,880.00 ₱ 2,262,292.48 ₱ 4,564,680.00 ₱ 25,609,852.48 2018 ₱ 19,534,195.20 ₱ 2,352,784.17 ₱ 4,747,267.20 ₱ 26,634,246.57
2019 ₱ 20,315,563.01 ₱ 2,446,895.54 ₱ 4,937,157.89 ₱ 27,699,616.44
2020 ₱ 21,128,185.53 ₱ 2,544,771.36 ₱ 5,134,644.20 ₱ 28,807,601.09
2021 ₱ 21,973,312.95 ₱ 2,646,562.22 ₱ 5,340,029.97 ₱ 29,959,905.14 2022 ₱ 22,852,245.47 ₱ 2,752,424.71 ₱ 5,553,631.17 ₱ 31,158,301.34
2023 ₱ 23,766,335.29 ₱ 2,862,521.69 ₱ 5,775,776.42 ₱ 32,404,633.40
2024 ₱ 24,716,988.70 ₱ 2,977,022.56 ₱ 6,006,807.47 ₱ 33,700,818.73 2025 ₱ 25,705,668.25 ₱ 3,096,103.46 ₱ 6,247,079.77 ₱ 35,048,851.48
2026 ₱ 26,733,894.98 ₱ 3,219,947.60 ₱ 6,496,962.96 ₱ 36,450,805.54
2027 ₱ 27,803,250.77 ₱ 3,348,745.51 ₱ 6,756,841.48 ₱ 37,908,837.76 2028 ₱ 28,915,380.81 ₱ 3,482,695.33 ₱ 7,027,115.14 ₱ 39,425,191.27
2029 ₱ 30,071,996.04 ₱ 3,622,003.14 ₱ 7,308,199.75 ₱ 41,002,198.93
2030 ₱ 31,274,875.88 ₱ 3,766,883.27 ₱ 7,600,527.74 ₱ 42,642,286.88
2031 ₱ 32,525,870.91 ₱ 3,917,558.60 ₱ 7,904,548.85 ₱ 44,347,978.36 TOTAL ₱ 487,191,272.95
Cost of transportation of goods. This cost includes the transportation of the
products phenol and acetone to its respective users through truck loads. The total number
of trucks of the company is twenty two with a capacity of 14 𝑚3 each. Table 104 shows
the customers of the company and their location, as well as distance to be travelled by the
trucks and the price of fuel per liter. Table 105 shows the annual cost on transportation.
181
Table 104
Price of Fuel and Consumption per Truck
Customer
Location
number of
companies
Price of Fuel
per Liter
Distance
(km) L/distance(km) L/week
Manila 35 ₱ 34.60 197.6 0.3 4979.52
Laguna 11 ₱ 34.60 285.2 0.3 2395.68
Cavite 3 ₱ 34.60 247 0.3 518.7
Rizal 9 ₱ 34.60 279.8 0.3 2350.32
Batangas 1 ₱ 34.60 415 0.3 871.5
Table 105
Annual cost on transportation
Customer Location Cost (weekly) Cost (Yearly)
Manila ₱ 172,291.39 ₱ 8,269,986.82
Laguna ₱ 82,890.53 ₱ 3,978,745.34
Cavite ₱ 17,947.02 ₱ 861,456.96
Rizal ₱ 81,321.07 ₱ 3,903,411.46
Batangas ₱ 30,153.90 ₱ 1,447,387.20
TOTAL ₱ 18,460,987.78
Other estimated costs. Table 106 and 107 shows the other costs related to the
direct cost of the plant. Refer to Table 51 for the equations used in estimating the values
under these costs.
182
Table 106
Operating, Quality Contol, and Laboratory Cost per Year
YEAR
Operating Supervision Quality Control Laboratory Costs
Cost Cost Cost
2017 ₱ 5,121,970.50 ₱ 5,121,970.50 ₱ 2,560,985.25
2018 ₱ 5,326,849.31 ₱ 5,326,849.31 ₱ 2,663,424.66
2019 ₱ 5,539,923.29 ₱ 5,539,923.29 ₱ 2,769,961.64
2020 ₱ 5,761,520.22 ₱ 5,761,520.22 ₱ 2,880,760.11
2021 ₱ 5,991,981.03 ₱ 5,991,981.03 ₱ 2,995,990.51
2022 ₱ 6,231,660.27 ₱ 6,231,660.27 ₱ 3,115,830.13
2023 ₱ 6,480,926.68 ₱ 6,480,926.68 ₱ 3,240,463.34
2024 ₱ 6,740,163.75 ₱ 6,740,163.75 ₱ 3,370,081.87
2025 ₱ 7,009,770.30 ₱ 7,009,770.30 ₱ 3,504,885.15
2026 ₱ 7,290,161.11 ₱ 7,290,161.11 ₱ 3,645,080.55
2027 ₱ 7,581,767.55 ₱ 7,581,767.55 ₱ 3,790,883.78
2028 ₱ 7,885,038.25 ₱ 7,885,038.25 ₱ 3,942,519.13
2029 ₱ 8,200,439.79 ₱ 8,200,439.79 ₱ 4,100,219.89
2030 ₱ 8,528,457.38 ₱ 8,528,457.38 ₱ 4,264,228.69
2031 ₱ 8,869,595.67 ₱ 8,869,595.67 ₱ 4,434,797.84
Table 107
Maintenance Labor, Maintenance Material, and Operating Supplies Cost per
year
YEAR
Maintenance Labor Maintenance Material Operating Supplies
Cost Cost Cost
2017 ₱ 14,245,501.91 ₱ 9,497,001.27 ₱ 3,957,083.86
2018 ₱ 13,304,496.15 ₱ 8,869,664.10 ₱ 3,695,693.38
2019 ₱ 12,363,490.40 ₱ 8,242,326.93 ₱ 3,434,302.89
2020 ₱ 11,422,484.65 ₱ 7,614,989.77 ₱ 3,172,912.40
2021 ₱ 10,481,478.90 ₱ 6,987,652.60 ₱ 2,911,521.92
2022 ₱ 9,540,473.14 ₱ 6,360,315.43 ₱ 2,650,131.43
2023 ₱ 9,540,473.14 ₱ 6,360,315.43 ₱ 2,650,131.43
2024 ₱ 9,540,473.14 ₱ 6,360,315.43 ₱ 2,650,131.43
2025 ₱ 9,540,473.14 ₱ 6,360,315.43 ₱ 2,650,131.43
2026 ₱ 9,540,473.14 ₱ 6,360,315.43 ₱ 2,650,131.43
2027 ₱ 9,540,473.14 ₱ 6,360,315.43 ₱ 2,650,131.43
2028 ₱ 9,540,473.14 ₱ 6,360,315.43 ₱ 2,650,131.43
2029 ₱ 9,540,473.14 ₱ 6,360,315.43 ₱ 2,650,131.43
2030 ₱ 9,540,473.14 ₱ 6,360,315.43 ₱ 2,650,131.43
2031 ₱ 9,540,473.14 ₱ 6,360,315.43 ₱ 2,650,131.43
183
General Costs of the Plant
General costs include the costs of managing the firm, marketing the product,
research and development on new and old products, and financing the operation. Refer to
Table 51 for the equations in obtaining the estimates for the general costs of the plant.
Table 108 shows the summary for the general cost of the plant.
Table 108
General costs of the plant
YEAR
Admin Marketing Research and Development
Cost Cost Cost
2017 ₱ 92,776,682.22 ₱ 278,330,046.67 ₱ 118,547,982.84
2018 ₱ 124,655,924.66 ₱ 373,967,773.99 ₱ 159,282,570.40
2019 ₱ 149,741,749.13 ₱ 449,225,247.40 ₱ 191,336,679.45
2020 ₱ 207,347,393.38 ₱ 622,042,180.13 ₱ 264,943,891.54
2021 ₱ 217,130,057.82 ₱ 651,390,173.47 ₱ 277,443,962.78
2022 ₱ 227,405,891.73 ₱ 682,217,675.18 ₱ 290,574,194.98
2023 ₱ 238,297,540.40 ₱ 714,892,621.19 ₱ 304,491,301.62
2024 ₱ 249,732,836.09 ₱ 749,198,508.28 ₱ 319,103,068.34
2025 ₱ 261,738,923.75 ₱ 785,216,771.24 ₱ 334,444,180.34
2026 ₱ 274,344,304.04 ₱ 823,032,912.13 ₱ 350,551,055.17
2027 ₱ 287,578,901.15 ₱ 862,736,703.45 ₱ 367,461,929.25
2028 ₱ 301,474,133.81 ₱ 904,422,401.44 ₱ 385,216,948.76
2029 ₱ 316,062,990.04 ₱ 948,188,970.13 ₱ 403,858,265.05
2030 ₱ 331,380,105.49 ₱ 994,140,316.48 ₱ 423,430,134.80
2031 ₱ 347,461,845.78 ₱ 1,042,385,537.34 ₱ 443,979,025.16
184
Income Statement of the Company
The income statement or consolidated statement of operations is a summary of the
incomes, expenditures, and taxes paid by the company over a fixed period of time. The
income statement gives a good insight into the overall profitability and margins of a
business. Table 109 shows the indicative price of the products of the company.
Table 109
Pricing of Products
FLOWRATE Operational Time MTpY
PRICE
kg/h # of days # of Hours USD/MT
Acetone 4369.793128 350 8400 36,706.26 1807.788
Phenol 7071.121303 350 8400 59,397.42 1984.158
Flowrates acquired from the Aspen Hysys Simulation
Source of Price: ICIS Indicative Prices
The inflation of the prices of the raw materials was approximated to 5%, as given
from the trend of prices of propylene and benzene from the report of Pandia entitled
“Global Acetone-Phenol Markets” in the year 2009. US Dollar to Philippines Peso
conversion is averaged to forty five. Given in Table 88 and Table 89 are the cost of
propylene and benzene annually. Table 110 shows the annual revenue generated from
acetone. Table 111 shows the annual revenue generated from phenol.
185
Table 110
Revenue from acetone
Year Turndown
Capacity MTPY Price (per MT) Revenue
2017 50% 18353.13 $ 1,807.79 ₱ 1,493,035,990.88 2018 65% 23859.07 $ 1,898.18 ₱ 2,037,994,127.55
2019 75% 27529.7 $ 1,993.09 ₱ 2,469,108,269.92
2020 100% 36706.26 $ 2,092.74 ₱ 3,456,751,577.89
2021 100% 36706.26 $ 2,197.38 ₱ 3,629,589,156.78 2022 100% 36706.26 $ 2,307.25 ₱ 3,811,068,614.62
2023 100% 36706.26 $ 2,422.61 ₱ 4,001,622,045.35
2024 100% 36706.26 $ 2,543.74 ₱ 4,201,703,147.62 2025 100% 36706.26 $ 2,670.93 ₱ 4,411,788,305.00
2026 100% 36706.26 $ 2,804.47 ₱ 4,632,377,720.25
2027 100% 36706.26 $ 2,944.70 ₱ 4,863,996,606.26
2028 100% 36706.26 $ 3,091.93 ₱ 5,107,196,436.58 2029 100% 36706.26 $ 3,246.53 ₱ 5,362,556,258.41
2030 100% 36706.26 $ 3,408.85 ₱ 5,630,684,071.33
2031 100% 36706.26 $ 3,579.30 ₱ 5,912,218,274.89
Table 111
Revenue from phenol
Year Turndown Capacity
MTPY Price (per MT) Revenue - Phenol
2017 50% 29698.71 1984.158 ₱ 2,651,711,939.36
2018 65% 38608.32 2083.3659 ₱ 3,619,586,797.22
2019 75% 44548.06 2187.534195 ₱ 4,385,268,619.71
2020 100% 59397.42 2296.910905 ₱ 6,139,376,067.60
2021 100% 59397.42 2411.75645 ₱ 6,446,344,870.98
2022 100% 59397.42 2532.344272 ₱ 6,768,662,114.53
2023 100% 59397.42 2658.961486 ₱ 7,107,095,220.25
2024 100% 59397.42 2791.90956 ₱ 7,462,449,981.26
2025 100% 59397.42 2931.505038 ₱ 7,835,572,480.33
2026 100% 59397.42 3078.08029 ₱ 8,227,351,104.34
2027 100% 59397.42 3231.984305 ₱ 8,638,718,659.56
2028 100% 59397.42 3393.58352 ₱ 9,070,654,592.54
2029 100% 59397.42 3563.262696 ₱ 9,524,187,322.17
2030 100% 59397.42 3741.425831 ₱ 10,000,396,688.27
2031 100% 59397.42 3928.497122 ₱ 10,500,416,522.69
186
Table 112 shows the detailed summary of the taxes and mandatory contributions of
a corporation. Based on the table, the total tax rate that can be imposed on a corporation’s
profit is 42.48%.
187
Table 112
Detailed summary of the taxes and mandatory contributions of a corporation
Tax or
mandatory
contribution
Payments
(number)
Notes on
Payments
Time
(hours)
Statutory
tax rate Tax base
Total
tax rate
(%
profit)
Notes
on TTR
Corporate
income tax 1 online filing 42 30%
taxable profit
20.46
Local business
tax 1 0.50%
previous year
turnover 8.84
Employer paid
- Social security
contributions 1 online filing 38
2.89% to 6.50%
gross salaries
6.06
Real property
tax 1 2%
assessed property
value 4.44
Employer paid
- Health insurance 12 online filing
1.16% to 1.19%
gross salaries
1.24
Employer paid
- Housing
development fund 12 online filing
2% or P100 per worker
gross salaries
0.56
Tax on interest 1 online filing 20% interest 0.51
Employer paid
- Employer's
compensation 0 paid jointly P 30
per employee per month
0.17
Community tax
certificate 1 P 10,500 fixed fee 0.08
Environmental
tax 1 P 10,000 fixed fee 0.08
Vehicle tax 1 basic fee +
24% vehicle weight
0.04
BIR certificate 0 paid jointly P 500 fixed fee 0
Value added
tax (VAT) 1 online filing 113 12%
value added
0 not
included
Tax on check
transactions 1 online filing
P 1.5 per check
number of checks
0 small
amount
Tax on
insurance
contracts 1 online filing
P 0.5 per each P 4
insurance premium
0 small
amount
Stamp duty 1 online filing various
rates contract
value 0
small amount
Employee paid
- Social security
contributions 0 paid jointly
1.33% to 2.98%
gross salaries
0 withheld
Employee paid
- Payroll tax 0 paid jointly
1.16% to 1.19%
per employee per month
0 withheld
Employee paid
- Housing
development fund 0 paid jointly
2% or P 100 per worker
gross salaries
0 withheld
Totals: 36 193 42.48
188
Table 113 shows the annual production cost and revenue of the company. Imposing
the 42.48% on the revenue, the annual profit of the company is depicted in Table 114.
Table 113
Production Cost and Revenue of the Company per Year
Year PRODUCTION COST Total REVENUE 2017 ₱ 3,270,703,198.73 ₱ 4,144,747,930.24
2018 ₱ 4,154,190,983.79 ₱ 5,657,580,924.78
2019 ₱ 4,833,394,458.10 ₱ 6,854,376,889.63 2020 ₱ 6,446,398,502.45 ₱ 9,596,127,645.49
2021 ₱ 6,678,358,290.60 ₱ 10,075,934,027.76
2022 ₱ 6,923,852,453.54 ₱ 10,579,730,729.15
2023 ₱ 7,222,621,590.59 ₱ 11,108,717,265.60 2024 ₱ 7,536,310,967.82 ₱ 11,664,153,128.88
2025 ₱ 7,865,665,868.56 ₱ 12,247,360,785.33
2026 ₱ 8,211,468,811.18 ₱ 12,859,728,824.60 2027 ₱ 8,574,541,409.64 ₱ 13,502,715,265.83
2028 ₱ 8,955,746,327.09 ₱ 14,177,851,029.12
2029 ₱ 9,355,989,327.03 ₱ 14,886,743,580.57 2030 ₱ 9,776,221,427.05 ₱ 15,631,080,759.60
2031 ₱ 10,217,441,160.17 ₱ 16,412,634,797.58
Table 114
Annual Profit of the Company
Year PROFIT TAX FINAL PROFIT 2017 ₱ 874,044,731.51 ₱ 371,294,201.94 ₱ 502,750,529.56
2018 ₱ 1,503,389,940.98 ₱ 638,640,046.93 ₱ 864,749,894.05
2019 ₱ 2,020,982,431.54 ₱ 858,513,336.92 ₱ 1,162,469,094.62
2020 ₱ 3,149,729,143.04 ₱ 1,338,004,939.96 ₱ 1,811,724,203.08 2021 ₱ 3,397,575,737.16 ₱ 1,443,290,173.14 ₱ 1,954,285,564.01
2022 ₱ 3,655,878,275.61 ₱ 1,553,017,091.48 ₱ 2,102,861,184.13
2023 ₱ 3,886,095,675.01 ₱ 1,650,813,442.74 ₱ 2,235,282,232.27 2024 ₱ 4,127,842,161.06 ₱ 1,753,507,350.02 ₱ 2,374,334,811.04
2025 ₱ 4,381,694,916.77 ₱ 1,861,344,000.64 ₱ 2,520,350,916.12
2026 ₱ 4,648,260,013.42 ₱ 1,974,580,853.70 ₱ 2,673,679,159.72 2027 ₱ 4,928,173,856.18 ₱ 2,093,488,254.11 ₱ 2,834,685,602.08
2028 ₱ 5,222,104,702.03 ₱ 2,218,350,077.42 ₱ 3,003,754,624.61
2029 ₱ 5,530,754,253.55 ₱ 2,349,464,406.91 ₱ 3,181,289,846.64
2030 ₱ 5,854,859,332.55 ₱ 2,487,144,244.47 ₱ 3,367,715,088.08 2031 ₱ 6,195,193,637.41 ₱ 2,631,718,257.17 ₱ 3,563,475,380.24
189
Cost of Permits and Licenses
Before putting up a plant, the following government permits and license in Table
115 must be paid and accomplished. These fees are paid on a yearly basis.
Table 115
Required Permits and Licenses of the Company
Mayor's Permit ₱ 2,500.00
Sanitary Permit ₱ 1,000.00
Location Clearance ₱ 6,000.00
Building Permit ₱ 25,000.00
Occupational ₱ 10,000.00
Occupancy ₱ 5,000.00
Fire Permit ₱ 6,000.00
Community Tax Certificate ₱ 10,500.00
Environmental Tax ₱ 10,000.00
BIR Certificate ₱ 500.00
SEC Company name verification and reservation ₱ 40.00
Notarize articles of incorporation and treasurer's
affidavit at the notary ₱ 500.00
SEC company Registration ₱ 3,645.00
Pay registration fee and Documentary stamp taxes at
AAB (Authorized Agent Bank) ₱ 4,670.00
Barangay Clearance ₱ 800.00
Special Books of Account ₱ 400.00
Application for certificate of registration (COR) and TIN
at BIR ₱ 115.00
Printing or receipts and invoices ₱ 4,000.00
World Bank Group, 2015
Provincial Government of Bataan, 2015
190
Cost of Buildings
Shown in Table 116 is the cost of the buildings inside the plant site. The cost was
generated using Aspen Hysys Economic Evaluator software.
Table 116
Cost of buildings
Buildings LENGTH
(m) WIDTH
(m) AREA (m2)
COST OF BUILDINGS
ADMIN BLDG 27.5 51 1402.5 $
1,103,000.00
QUALITY CONTROL LAB
17.5 50.9 890.75 $
1,362,200.00
CANTEEN 40 18 720 $
566,200.00
PRODUCTION OFFICE 25.9 18 466.2 $
502,700.00
RESEARCH&DEV 17.5 27 472.5 $
509,500.00
SECURITY OFFICE 27.83 12.2 339.526 $
366,100.00
MAINTENANCE 17.5 18 315 $
339,600.00
CONTROL ROOM 25 8 200 $
227,900.00
WAREHOUSE 20.04 22 440.88 $
312,900.00
TOTAL
₱
238,054,500.00
Trucks and Electronic Devices
Trucks owned by the company will be used in the transport of products to their
respective users in the Philippines. Shown in Table 117 is the summary of the total cost of
trucks owned by the company.
191
Table 117
Cost of trucks of the company
Description
Isuzu 8PC1
8 Wheeler
Tank Truck
14,000 L Capacity
₱ 1,200,000.00
Assumption: Per day delivery
Volume of Acetone Product per day: 135.432
Volume of Phenol Product per day: 161.592
Number of Trucks for Acetone: 10
Number of Trucks for Phenol: 12
TOTAL NUMBER OF TRUCKS: 22
Cost of Trucks: ₱ 26,400,000.00
In case of plant operation, a more effective and efficient way of communicating is
through the use of radio. The personnel operating the main process of the plant are required
to use radio in communicating with other personnel within the plant area. Shown in Table
118 is the cost of radio owned by the company.
Table 118
Cost of radio
Number of Personnel that needs Radio 23
Price of Two-Way Radio ₱ 4,500.00
Total Cost ₱ 103,500.00
Source: OLX Philippines, 2015
192
Project Evaluation
Table 119 shows the summary of the expenses of the company. The total capital
expense of the company is around 4.5 billion PhP. It can be deduced that the construction
and operation of the plant requires very large amounts of capital.
Table 119
Total capital expenditure of the company
ISBL CAPEX ₱ 2,814,539,354.81
OSBL OPEX
₱
1,106,317,946.51
Contingency ₱ 392,085,730.13
Commissioning
₱
137,230,005.55 Minimum Paid up Capital Requirement on Bank
(SEC)
₱
500,000.00
EIA ₱ 300,000.00
TOTAL CAPEX
₱
4,450,973,036.99
About half of the total capital expenses of the company will come from bank
financing. The debt capital is raised through long term bonds with the bank. Table 120
shows the description of the bank and the annuity.
Table 120
Capital loan and interest
Cash on hand ₱ 2,225,336,518.50
BANK BPI
Bank loan (PRINCIPAL) ₱ 2,225,336,518.50
Interest rate (compounding per year) 6.00%
Tenor/Defer 3
Future Worth at year 3 ₱ 2,650,411,398.91
Number of terms 10
Annuity ₱ 302,351,929.12
193
The internal rate of return (IRR) of the company was projected to be 24%, as shown
in Table 121. At year 2020, the total capital expenditure is expected to be recovered,
therefore the return of investment (ROI) is 6 years. Figure 16 shows the project cash flow
of Phace Philippines Corporation.
Based on the economic analysis of the project using class 3 estimation, the project
is concluded to be feasible since it is highly profitable. The plant designers recommends to
continue the project to its next stages such as detailed engineering design, procurement,
construction, startup, trial runs, and production or commercial operation.
Table 121
Internal rate of return
YEAR Bank Annuity Annual Profit
Cumulative Profit
2015 ₱ - ₱ (2,315,228,518.50)
2016 ₱ - ₱ (2,315,228,518.50)
2017 ₱ - ₱ 502,750,529.56 ₱ 502,750,529.56
2018 ₱ 314,565,371.62 ₱ 550,184,522.43 ₱ 1,052,935,051.99
2019 ₱ 314,565,371.62 ₱ 847,903,723.00 ₱ 1,900,838,774.99
2020 ₱ 314,565,371.62 ₱ 1,497,158,831.45 ₱ 3,397,997,606.45
2021 ₱ 314,565,371.62 ₱ 1,639,720,192.39 ₱ 5,037,717,798.84
2022 ₱ 314,565,371.62 ₱ 1,788,295,812.51 ₱ 6,826,013,611.34
2023 ₱ 314,565,371.62 ₱ 1,920,716,860.64 ₱ 8,746,730,471.99
2024 ₱ 314,565,371.62 ₱ 2,059,769,439.42 ₱ 10,806,499,911.41
2025 ₱ 314,565,371.62 ₱ 2,205,785,544.50 ₱ 13,012,285,455.91
2026 ₱ 314,565,371.62 ₱ 2,359,113,788.09 ₱ 15,371,399,244.01
2027 ₱ 314,565,371.62 ₱ 2,520,120,230.46 ₱ 17,891,519,474.46
2028 ₱ - ₱ 3,003,754,624.61 ₱ 20,895,274,099.07
2029 ₱ - ₱ 3,181,289,846.64 ₱ 24,076,563,945.71
2030 ₱ - ₱ 3,367,715,088.08 ₱ 27,444,279,033.79
2031 ₱ - ₱ 3,563,475,380.24 ₱ 31,007,754,414.03
IRR 24%
194
Figure 16. Project Cash Flow of Phace Philippines Corporation
Breakeven Analysis
If a proposal is intended to generate added volume, it is important to check the
estimated volume to be produced, so that the added revenues balance the added costs. This
volume is called the breakeven volume. The following equations must be used to obtain
the break even volume. Table 122 shows the calculation basis for the breakeven volume.
𝑷𝒓𝒐𝒅𝒖𝒄𝒕𝒊𝒐𝒏 𝑪𝒐𝒔𝒕 = 𝑷𝒓𝒊𝒄𝒆 𝒐𝒇 𝑨𝒄𝒆𝒕𝒐𝒏𝒆 (𝑿𝟏) + 𝑷𝒓𝒊𝒄𝒆 𝒐𝒇 𝑷𝒉𝒆𝒏𝒐𝒍 (𝑿𝟐)
𝑋2
𝑋1= 1.618182165
𝑿𝟐 = 𝟏. 𝟔𝟏𝟖𝟏𝟖𝟐𝟏𝟔𝟓 𝑿𝟏
𝑷𝒓𝒐𝒅𝒖𝒄𝒕𝒊𝒐𝒏 𝑪𝒐𝒔𝒕 = 𝑷𝟏𝑿𝟏 + 𝑷𝟐(𝟏. 𝟔𝟏𝟖𝟏𝟖𝟐𝟏𝟔𝟓 𝑿𝟏)
𝑿𝟏 =𝑷𝒓𝒐𝒅𝒖𝒄𝒕𝒊𝒐𝒏 𝑪𝒐𝒔𝒕
𝑷𝟏 + 𝑷𝟐 (𝟏. 𝟔𝟏𝟖𝟏𝟖𝟐𝟏𝟔𝟓)
Let 𝑥 = 𝐵𝑟𝑒𝑎𝑘𝑒𝑣𝑒𝑛 𝑉𝑜𝑙𝑢𝑚𝑒
₱(3,000,000,000.00)
₱(2,000,000,000.00)
₱(1,000,000,000.00)
₱-
₱1,000,000,000.00
₱2,000,000,000.00
₱3,000,000,000.00
₱4,000,000,000.00
₱5,000,000,000.00
2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031
CASH FLOW
(20)
(21)
(22)
(23)
195
Table 122
Calculation Basis for Breakeven Analysis
Acetone Phenol
Year PRODUCTION COST (X1) MTPY Price (per MT) (X2) MTPY Price (per MT)
2017 ₱ 2,712,464,361.58 18,353.13 $ 1,807.79 29,698.71 $ 1,984.16
2018 ₱ 2,835,631,286.44 18,353.13 $ 1,862.02 29,698.71 $ 2,043.68 2019 ₱ 4,366,775,747.44 27,529.70 $ 1,917.88 44,548.06 $ 2,104.99
2020 ₱ 6,031,806,007.70 36,706.26 $ 1,975.42 59,397.42 $ 2,168.14
2021 ₱ 6,300,526,376.70 36,706.26 $ 2,034.68 59,397.42 $ 2,233.19 2022 ₱ 6,582,723,662.99 36,706.26 $ 2,095.72 59,397.42 $ 2,300.18
2023 ₱ 6,880,225,862.31 36,706.26 $ 2,158.59 59,397.42 $ 2,369.19
2024 ₱ 7,192,584,954.92 36,706.26 $ 2,223.35 59,397.42 $ 2,440.26 2025 ₱ 7,520,543,056.81 36,706.26 $ 2,290.05 59,397.42 $ 2,513.47
2026 ₱ 7,864,879,360.64 36,706.26 $ 2,358.75 59,397.42 $ 2,588.88
2027 ₱ 8,226,411,988.37 36,706.26 $ 2,429.52 59,397.42 $ 2,666.54
2028 ₱ 8,605,999,936.54 36,706.26 $ 2,502.40 59,397.42 $ 2,746.54 2029 ₱ 9,004,545,118.75 36,706.26 $ 2,577.47 59,397.42 $ 2,828.93
2030 ₱ 9,422,994,510.15 36,706.26 $ 2,654.80 59,397.42 $ 2,913.80
2031 ₱ 9,862,342,399.22 36,706.26 $ 2,734.44 59,397.42 $ 3,001.22
Breakeven sales volume is the amount of product that you will need to produce and
sell to cover total costs of production. Table 123 shows the breakeven volume of the
products acetone and phenol.
Table 123
Breakeven volume of acetone (𝑋1) and phenol (𝑋2)
Year X2/X1 X1 X2
2017 1.618182165 12,010.91 19,435.85
2018 1.618182165 12,190.59 19,726.59
2019 1.618182165 18,226.30 29,493.47
2020 1.618182165 24,442.62 39,552.61
2021 1.618182165 24,787.91 40,111.36
2022 1.618182165 25,143.84 40,687.31
2023 1.618182165 25,514.75 41,287.52
2024 1.618182165 25,896.23 41,904.81
2025 1.618182165 26,288.36 42,539.35
2026 1.618182165 26,691.26 43,191.32
2027 1.618182165 27,105.05 43,860.91
2028 1.618182165 27,529.85 44,548.32
2029 1.618182165 27,965.79 45,253.75
2030 1.618182165 28,413.00 45,977.41
2031 1.618182165 28,871.61 46,719.52
196
A benefit-cost ratio (BCR) is an indicator, used in the formal discipline of cost-
benefit analysis, which attempts to summarize the overall value for money of a project or
proposal. Table 124 shows the benefit to cost ratio of the plant. The ratio should be greater
than 1 for the project to be justifiable.
Table 124
Benefit to cost ratio (f) of the plant
n Year
Production Cost
(PhP) Revenue (PhP) PW – PC (PhP) PW-R (PhP)
0 2017 3074233529 4144747930 3074233529 4144747930
1 2018 3916060631 5657580925 3158113412 4562565262
2 2019 4571068739 6854376890 2972859482 4457841369
3 2020 6120371891 9596127645 3210057091 5033046707
4 2021 6354543098 10075934028 2687803956 4261854067
5 2022 6602276466 10579730729 2252087605 3608828040
6 2023 6901796804 11108717266 1898593799 3055862454
7 2024 7216267436 11664153129 1600887537 2587625465
8 2025 7546434846 12247360785 1350107487 2191134466
9 2026 7893082804 12859728825 1138810578 1855396120
10 2027 8257034225 13502715266 960743009.3 1571101554
11 2028 8639153123 14177851029 810648596 1330368251
12 2029 9040346669 14886743581 684108304.9 1126521503
13 2030 9461567344 15631080760 577405847.5 953909337.1
14 2031 9903815202 16412634798 487415051.1 807745809.7
TOTAL 26863875284 41548548335
f 1.546632714
197
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206
Appendix A
ASPEN HYSYS SIMULATION
Figure 1. Data for the components of the process in Aspen Hysys
Figure 2. React ion data for the main react ion in Alkylator
Figure 3. React ion data for the side react ion in Alkylator
207
Figure 4. React ion data for the cumene oxidation process
Figure 5. React ion data for the cleaving of cumene hydroperoxide to phenol
and acetone
Figure 6. React ion data for steam generat ion
208
Figure 7. Overview of the process
STEP BY STEP SIMULATION SNAPSHOTS
209
210
211
212
213
214
215
216
217
218
219
220
Appendix B
STORAGE TANKS CALCULATION SHEETS
CALCULATION SHEET
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 EAM ALL
MFS
Service: Propylene Feed
OPERATING CONDITIONS
T °C 25
°F 77
P
Bar 12
psia 174.0933
psig 159.3933
true VP and Reid VP at 37.8 °C
(100°F)
psia 226.1138
kPaa 1559
Type of Vessel Pressure vessel
If TVP (true vapor pressure) of the chemical is greater than 90 𝑘𝑃𝑎(𝑎), then use a pressure
vessel for the storage tank, otherwise use an atmospheric vessel for the storage tank.
DESIGN CONDITIONS
T °C 93.33333
°F 200
P (MAWP)
Bar 13.72321
psia 199.0933
psig 184.3933
minimum P psia 0
psig -14.7
minimum design metal temperature °C 15 ~ 20
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
221
Operating T Design T Operating P Design P
0 to 200 degF 250 degF 0 to 25 psig 50 psig
Over 200 degF operating + 50 degF 25 to 250 psig operating + 25 psig
Reactors operating + 50 degF 250 to 1000 psig operating + 10%
over 1000 psig operating + 5%
LIQUID CAPACITY
Capacity/Storage time day 28
hr 672
flow rate kg/hr 3354
Rated mass flow rate kg/hr 3689.4
Density kg/m3 506.8
Rated Volume of liquid m3 4892.022
gal 1292335
use vertical tanks on concrete foundation
Assumptions:
The storage for this chemical will be divided to 6 tanks, with 1 week storage time
each. It is assumed that the transaction time between the company and the provider
as well as delivery of the product will take 2 weeks. It is very important for
continuous production to have enough storage of feed.
Based on the rule of thumb of Chemical Engineering Design, if the rated volume
of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations
is typically used.
The choses material of construction is carbon steel since propylene is not corrosive.
ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry
for storage tanks.
Outage and Innage of the tank are assumed to be 500 𝑚𝑖𝑙𝑙𝑖𝑚𝑒𝑡𝑒𝑟𝑠. The outage is
the allowance for spillage, and the innage is the non-pumpable volume. The pump
should not be placed under the innage to avoid pump cavitation.
Based on the rule of thumb for Chemical Engineering Design, Optimum length to
diameter ratio for vessels is 3 (𝐿 𝐷 = 3)⁄ .
𝜋𝐷2
4(3𝐷 − 0.50 − 0.5) =
4892.022
6𝑚3(𝑟𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒)
222
𝐷 = 7.133506 𝑚 ≅ 7200 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 7200 𝑚𝑚 = 21600 𝑚𝑚
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams like
propylene is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the
minimum thickness of the vessel, first is determine the maximum allowable stress (S)
which will be based on the type of material used. Using table 13.2 in Towler, the Maximum
allowable stress for carbon steel at 250℉ is 12.9ksi or 12900psi.
For cylindrical vessels:
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
2𝑆𝐸 − 1.2𝑃𝑖 (1)
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
4𝑆𝐸 + 0.8𝑃𝑖 (2)
Where:
𝑡𝑚𝑖𝑛 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑤𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 (𝑒𝑥𝑐𝑙𝑢𝑑𝑖𝑛𝑔 𝐶𝐴)
𝑃𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
𝐷𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝑆 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
(1)𝑡𝑚𝑖𝑛 =199.0933𝑝𝑠𝑖𝑎 ∗ 7200 𝑚𝑚
2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 1.2 ∗ 199.0933𝑝𝑠𝑖𝑎= 66.08574 𝑚𝑚
223
(2)𝑡𝑚𝑖𝑛 =199.0933𝑝𝑠𝑖𝑎 ∗ 7200𝑚𝑚
4 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 + 0.8 ∗ 199.0933𝑝𝑠𝑖𝑎= 32.56463 𝑚𝑚
Choosing the higher value for 𝑡𝑚𝑖𝑛,
𝑡𝑚𝑖𝑛 = 66.08574 + 3.8 ≅ 70𝑚𝑚
𝑂𝐷 = 2 ∗ 𝑡𝑚𝑖𝑛 + 𝐼𝐷 = 2 ∗ 70 + 7200 = 7340𝑚𝑚
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
2𝑆𝐸 − 0.2𝑃𝑖
𝑡𝑚𝑖𝑛 =199.0933𝑝𝑠𝑖𝑎 ∗ 7200𝑚𝑚
2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 199.0933𝑝𝑠𝑖𝑎≅ 66𝑚𝑚
224
CALCULATION SHEET
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 EAM ALL
MFS
Service: Benzene Feed
OPERATING CONDITIONS
T °C 25
°F 77
P
Bar 1
psia 14.50777
psig -0.19223
true VP and Reid VP at 37.8 °C
(100°F)
psia 3.24E+00
kPaa 22.36
Type of Vessel Atmospheric
vessel
If TVP (true vapor pressure) of the chemical is greater than 90 𝑘𝑃𝑎(𝑎), then use a pressure
vessel for the storage tank, otherwise use an atmospheric vessel for the storage tank.
DESIGN CONDITIONS
T °C 93.33333
°F 200
P (MAWP)
Bar 13.72321
psia 199.0933
psig 184.3933
minimum P psia 0
psig -14.7
minimum design metal temperature °C 15 ~ 20
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Operating T Design T Operating P Design P
0 to 200 degF 250 degF 0 to 25 psig 50 psig
Over 200 degF operating + 50 degF 25 to 250 psig operating + 25 psig
Reactors operating + 50 degF 250 to 1000 psig operating + 10%
over 1000 psig operating + 5%
225
LIQUID CAPACITY
Capacity/Storage time day 28
hr 672
flow rate kg/hr 6248.8
Rated mass flow rate kg/hr 6873.68
Density kg/m3 872.2
Rated Volume of liquid m3 5295.933
gal 1399037
use vertical tanks on concrete foundation
Assumptions:
The storage for this chemical will be divided to 6 tanks, with 1 week storage time
each. It is assumed that the transaction time between the company and the provider
as well as delivery of the product will take 2 weeks. It is very important for
continuous production to have enough storage of feed.
Based on the rule of thumb of Chemical Engineering Design, if the rated volume
of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations
is typically used.
The chosen material of construction is carbon steel since benzene is not corrosive.
ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry
for storage tanks.
Outage and Innage of the tank are assumed to be 500 𝑚𝑖𝑙𝑙𝑖𝑚𝑒𝑡𝑒𝑟𝑠. The outage is
the allowance for spillage, and the innage is the non-pumpable volume. The pump
should not be placed under the innage to avoid pump cavitation.
Based on the rule of thumb for Chemical Engineering Design, Optimum length to
diameter ratio for vessels is 3 (𝐿 𝐷 = 3)⁄ .
𝜋𝐷2
4(3𝐷 − 0.50 − 0.5) =
5295.933
6𝑚3(𝑟𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒)
𝐷 = 7.321595 𝑚 ≅ 7400 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 7400 𝑚𝑚 = 22200 𝑚𝑚
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in
or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the
226
vessel, first is determine the maximum allowable stress (S) which will be based on the type
of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon
steel at 250℉ is 12.9ksi or 12900psi.
For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic
pressure can be calculated from the following equation:
𝑇𝑡 =𝜌𝐿𝐻𝐿𝑔
2𝑆𝑡𝐸
𝐷𝑡
103+ 𝐶𝐴
Where:
𝑇𝑡 = 𝑡𝑎𝑛𝑘 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑎𝑡 𝑎 𝑐𝑒𝑟𝑡𝑎𝑖𝑛 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚𝑚
𝐻𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚
𝜌𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦, 𝑘𝑔/𝑚3
𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (𝑖𝑓 𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑏𝑙𝑒)
𝑔 = 𝑔𝑟𝑎𝑣𝑖𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛, 9.81 𝑚/𝑠2
𝑆𝑡 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑓𝑜𝑟 𝑡𝑎𝑛𝑘 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙, 𝑁/𝑚𝑚2
𝐷𝑡 = 𝑡𝑎𝑛𝑘 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚
𝐶𝐴 = 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒
𝑇𝑡 =872 ∗ (22200 − 500) (
11000) ∗ 9.81
2 ∗ 88.942369 ∗ 0.85∗
74001000103
+ 3.8 = 12.887𝑚𝑚
𝑇𝑡 ≈ 13𝑚𝑚
𝑂𝐷 = 2 ∗ 𝑇𝑡 + 𝐼𝐷
𝑂𝐷 = 2 ∗ 13 + 7400 = 7426 𝑚𝑚
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
2𝑆𝐸 − 0.2𝑃𝑖
227
𝑡𝑚𝑖𝑛 =64.7𝑝𝑠𝑖𝑎 ∗ 7400𝑚𝑚
2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 64.7𝑝𝑠𝑖𝑎≅ 22 𝑚𝑚
228
CALCULATION SHEET
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 EAM ALL
MFS
Service: Acetone Product A
OPERATING CONDITIONS
T °C 30
°F 86
P
Bar 3.659
psia 53.08393782
psig 38.38393782
true VP and Reid VP at 37.8 °C
(100°F)
psia 21.47
kPaa 148
Type of Vessel Pressure vessel
If TVP (true vapor pressure) of the chemical is greater than 90 𝑘𝑃𝑎(𝑎), then use a pressure
vessel for the storage tank, otherwise use an atmospheric vessel for the storage tank.
DESIGN CONDITIONS
T °C 93.33333333
°F 200
P (MAWP)
Bar 5.382214286
psia 78.08393782
psig 63.38393782
minimum P psia 0
psig -14.7
minimum design metal temperature °C 15 ~ 20
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Operating T Design T Operating P Design P
0 to 200 degF 250 degF 0 to 25 psig 50 psig
Over 200 degF operating + 50 degF 25 to 250 psig operating + 25 psig
Reactors operating + 50 degF 250 to 1000 psig operating + 10%
over 1000 psig operating + 5%
LIQUID CAPACITY
Capacity/Storage time day 7
229
hr 168
flow rate kg/hr 4370
Rated mass flow rate kg/hr 4807
Density kg/m3 774.4
Rated Volume of liquid m3 1042.841
gal 275489.4
use vertical tanks on concrete foundation
Assumptions:
The storage for this chemical will be divided to 3 tanks, with 1 week total storage
time.
Based on the rule of thumb of Chemical Engineering Design, if the rated volume
of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations
is typically used.
The choses material of construction is carbon steel since Acetone is not corrosive.
ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry
for storage tanks.
Outage and Innage of the tank are assumed to be 500 𝑚𝑖𝑙𝑙𝑖𝑚𝑒𝑡𝑒𝑟𝑠. The outage is
the allowance for spillage, and the innage is the non-pumpable volume. The pump
should not be placed under the innage to avoid pump cavitation.
Based on the rule of thumb for Chemical Engineering Design, Optimum length to
diameter ratio for vessels is 3 (𝐿 𝐷 = 3)⁄ .
𝜋𝐷2
4(3𝐷 − 0.50 − 0.5) =
1042.841
3𝑚3(𝑟𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒)
𝐷 = 5.397469 𝑚 ≅ 5400 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 5400 𝑚𝑚 = 16200 𝑚𝑚
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams like
propylene is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the
minimum thickness of the vessel, first is determine the maximum allowable stress (S)
which will be based on the type of material used. Using table 13.2 in Towler, the Maximum
allowable stress for carbon steel at 250℉ is 12.9ksi or 12900psi.
For cylindrical vessels:
230
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
2𝑆𝐸 − 1.2𝑃𝑖 (1)
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
4𝑆𝐸 + 0.8𝑃𝑖 (2)
Where:
𝑡𝑚𝑖𝑛 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑤𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 (𝑒𝑥𝑐𝑙𝑢𝑑𝑖𝑛𝑔 𝐶𝐴)
𝑃𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
𝐷𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝑆 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
(1)𝑡𝑚𝑖𝑛 =78.08393782 𝑝𝑠𝑖𝑎 ∗ 5400 𝑚𝑚
2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 1.2 ∗ 78.08393782𝑝𝑠𝑖𝑎= 19.30974 𝑚𝑚
(2)𝑡𝑚𝑖𝑛 =78.08393782 𝑝𝑠𝑖𝑎 ∗ 5400𝑚𝑚
4 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 + 0.8 ∗ 78.08393782 𝑝𝑠𝑖𝑎= 9.599945 𝑚𝑚
Choosing the higher value for 𝑡𝑚𝑖𝑛,
𝑡𝑚𝑖𝑛 = 19.30974 + 3.8 ≅ 24𝑚𝑚
𝑂𝐷 = 2 ∗ 𝑡𝑚𝑖𝑛 + 𝐼𝐷 = 2 ∗ 24 + 5400 = 5448𝑚𝑚
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
2𝑆𝐸 − 0.2𝑃𝑖
𝑡𝑚𝑖𝑛 =78.08393782 𝑝𝑠𝑖𝑎 ∗ 5400𝑚𝑚
2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 78.08393782 𝑝𝑠𝑖𝑎≅ 20𝑚𝑚
231
CALCULATION SHEET
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 EAM ALL
MFS
Service: Acetone Product B
OPERATING CONDITIONS
T °C 30
°F 86
P
Bar 3.659
psia 53.08393782
psig 38.38393782
true VP and Reid VP at 37.8 °C
(100°F)
psia 21.47
kPaa 148
Type of Vessel Pressure vessel
If TVP (true vapor pressure) of the chemical is greater than 90 𝑘𝑃𝑎(𝑎), then use a pressure
vessel for the storage tank, otherwise use an atmospheric vessel for the storage tank.
DESIGN CONDITIONS
T °C 93.33333333
°F 200
P (MAWP)
Bar 5.382214286
psia 78.08393782
psig 63.38393782
minimum P psia 0
psig -14.7
minimum design metal temperature °C 15 ~ 20
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Operating T Design T Operating P Design P
0 to 200 degF 250 degF 0 to 25 psig 50 psig
Over 200 degF operating + 50 degF 25 to 250 psig operating + 25 psig
Reactors operating + 50 degF 250 to 1000 psig operating + 10%
over 1000 psig operating + 5%
LIQUID CAPACITY
Capacity/Storage time day 1
232
hr 24
flow rate kg/hr 4370
Rated mass flow rate kg/hr 4807
Density kg/m3 774.4
Rated Volume of liquid m3 148.9773
gal 39355.62
use vertical tanks on concrete foundation
Assumptions:
The storage for this chemical will be divided to 3 tanks, with 1 day total storage
time.
Based on the rule of thumb of Chemical Engineering Design, if the rated volume
of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations
is typically used.
The choses material of construction is carbon steel since Acetone is not corrosive.
ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry
for storage tanks.
Outage and Innage of the tank are assumed to be 500 𝑚𝑖𝑙𝑙𝑖𝑚𝑒𝑡𝑒𝑟𝑠. The outage is
the allowance for spillage, and the innage is the non-pumpable volume. The pump
should not be placed under the innage to avoid pump cavitation.
Based on the rule of thumb for Chemical Engineering Design, Optimum length to
diameter ratio for vessels is 3 (𝐿 𝐷 = 3)⁄ .
𝜋𝐷2
4(3𝐷 − 0.50 − 0.5) =
148.9773
3𝑚3(𝑟𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒)
𝐷 = 2.877947𝑚 ≅ 2900 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 2900 𝑚𝑚 = 8700 𝑚𝑚
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams like
propylene is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the
minimum thickness of the vessel, first is determine the maximum allowable stress (S)
which will be based on the type of material used. Using table 13.2 in Towler, the Maximum
allowable stress for carbon steel at 250℉ is 12.9ksi or 12900psi.
For cylindrical vessels:
233
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
2𝑆𝐸 − 1.2𝑃𝑖 (1)
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
4𝑆𝐸 + 0.8𝑃𝑖 (2)
Where:
𝑡𝑚𝑖𝑛 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑤𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 (𝑒𝑥𝑐𝑙𝑢𝑑𝑖𝑛𝑔 𝐶𝐴)
𝑃𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
𝐷𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝑆 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
(1)𝑡𝑚𝑖𝑛 =78.08393782 𝑝𝑠𝑖𝑎 ∗ 2900 𝑚𝑚
2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 1.2 ∗ 78.08393782𝑝𝑠𝑖𝑎= 10.37005 𝑚𝑚
(2)𝑡𝑚𝑖𝑛 =78.08393782 𝑝𝑠𝑖𝑎 ∗ 2900𝑚𝑚
4 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 + 0.8 ∗ 78.08393782 𝑝𝑠𝑖𝑎= 5.155526 𝑚𝑚
Choosing the higher value for 𝑡𝑚𝑖𝑛,
𝑡𝑚𝑖𝑛 = 10.37005 + 3.8 ≅ 15 𝑚𝑚
𝑂𝐷 = 2 ∗ 𝑡𝑚𝑖𝑛 + 𝐼𝐷 = 2 ∗ 15 + 2900 = 2930𝑚𝑚
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
2𝑆𝐸 − 0.2𝑃𝑖
𝑡𝑚𝑖𝑛 =78.08393782 𝑝𝑠𝑖𝑎 ∗ 2900𝑚𝑚
2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 78.08393782 𝑝𝑠𝑖𝑎≅ 11 𝑚𝑚
234
CALCULATION SHEET
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 EAM ALL
MFS
Service: Phenol Product B
OPERATING CONDITIONS
T °C 54.44
°F 129.992
P
Bar 3.759
psia 54.53472
psig 39.83472
true VP and Reid VP at 37.8 °C (100°F)
psia 2.57E-02
kPaa 0.1773
Type of Vessel Atmospheric
vessel
If TVP (true vapor pressure) of the chemical is greater than 90 𝑘𝑃𝑎(𝑎), then use a pressure
vessel for the storage tank, otherwise use an atmospheric vessel for the storage tank.
DESIGN CONDITIONS
T °C 93.33333
°F 200
P (MAWP)
Bar 5.482214
psia 79.53472
psig 64.83472
minimum P psia 0
psig -14.7
minimum design metal temperature °C 15 ~ 20
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Operating T Design T Operating P Design P
0 to 200 degF 250 degF 0 to 25 psig 50 psig
Over 200 degF operating + 50 degF 25 to 250 psig operating + 25 psig
Reactors operating + 50 degF 250 to 1000 psig operating + 10%
over 1000 psig operating + 5%
235
LIQUID CAPACITY
Capacity/Storage time day 1
hr 24
flow rate kg/hr 7071
Rated mass flow rate kg/hr 7778.1
Density kg/m3 1050
Rated Volume of liquid m3 177.7851
gal 46965.86
use vertical tanks on concrete foundation
Assumptions:
The storage for this chemical will be divided to 3 tanks, with 1 day total storage
time.
Based on the rule of thumb of Chemical Engineering Design, if the rated volume
of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations
is typically used.
The choses material of construction is carbon steel since Acetone is not corrosive.
ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry
for storage tanks.
Outage and Innage of the tank are assumed to be 500 𝑚𝑖𝑙𝑙𝑖𝑚𝑒𝑡𝑒𝑟𝑠. The outage is
the allowance for spillage, and the innage is the non-pumpable volume. The pump
should not be placed under the innage to avoid pump cavitation.
Based on the rule of thumb for Chemical Engineering Design, Optimum length to
diameter ratio for vessels is 3 (𝐿 𝐷 = 3)⁄ .
𝜋𝐷2
4(3𝐷 − 0.50 − 0.5) =
177.7851
3𝑚3(𝑟𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒)
𝐷 = 3.045342 𝑚 ≅ 3100 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 3100 𝑚𝑚 = 9300 𝑚𝑚
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in
or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the
vessel, first is determine the maximum allowable stress (S) which will be based on the type
of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon
steel at 250℉ is 12.9ksi or 12900psi.
236
For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic
pressure can be calculated from the following equation:
𝑇𝑡 =𝜌𝐿𝐻𝐿𝑔
2𝑆𝑡𝐸
𝐷𝑡
103+ 𝐶𝐴
Where:
𝑇𝑡 = 𝑡𝑎𝑛𝑘 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑎𝑡 𝑎 𝑐𝑒𝑟𝑡𝑎𝑖𝑛 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚𝑚
𝐻𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚
𝜌𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦, 𝑘𝑔/𝑚3
𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (𝑖𝑓 𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑏𝑙𝑒)
𝑔 = 𝑔𝑟𝑎𝑣𝑖𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛, 9.81 𝑚/𝑠2
𝑆𝑡 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑓𝑜𝑟 𝑡𝑎𝑛𝑘 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙, 𝑁/𝑚𝑚2
𝐷𝑡 = 𝑡𝑎𝑛𝑘 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚
𝐶𝐴 = 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒
𝑇𝑡 =1050 ∗ (9300 − 500) (
11000) ∗ 9.81
2 ∗ 88.942369 ∗ 0.85∗
31001000103
+ 3.8 = 5.658425 𝑚𝑚
𝑇𝑡 ≈ 6 𝑚𝑚
𝑂𝐷 = 2 ∗ 𝑇𝑡 + 𝐼𝐷
𝑂𝐷 = 2 ∗ 6 + 5800 = 3112 𝑚𝑚
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
2𝑆𝐸 − 0.2𝑃𝑖
𝑡𝑚𝑖𝑛 =79.53𝑝𝑠𝑖𝑎 ∗ 3100𝑚𝑚
2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 79.53𝑝𝑠𝑖𝑎≅ 12 𝑚𝑚
237
CALCULATION SHEET
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 EAM ALL
MFS
Service: Benzene Recycle Stream
OPERATING CONDITIONS
T °C 70.05
°F 158.09
P
Bar 1
psia 14.50777
psig -0.19223
true VP and Reid VP at 37.8 °C
(100°F)
psia 4.96E+00
kPaa 34.23
Type of Vessel Atmospheric
vessel
DESIGN CONDITIONS
T °C 93.33333
°F 200
P (MAWP)
Bar 4.459679
psia 64.7
psig 50
minimum P psia 0
psig -14.7
minimum design metal temperature °C 15 ~ 20
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Operating T Design T Operating P Design P
0 to 200 degF 250 degF 0 to 25 psig 50 psig
Over 200 degF operating + 50 degF 25 to 250 psig operating + 25 psig
Reactors operating + 50 degF 250 to 1000 psig operating + 10%
over 1000 psig operating + 5%
LIQUID CAPACITY
Capacity/Storage time day -
238
hr 0.5
flow rate kg/hr 1.06E+06
Rated mass flow rate kg/hr 1161340
Density kg/m3 819.4
Rated Volume of liquid m3 708.6529
gal 187206.3
use vertical tanks on concrete foundation
The outage and innage of the tank is assumed to be 500 millimeters. The outage is the
allowance for spillage, and the innage is the non-pumpable volume. The pump should not
be placed under the innage to avoid pump cavitation.
The optimum Length to diameter ratio for vessels is 3. The volume is divided in 2, since it
is a liquid holdup tank.
𝜋𝐷2
4(3𝐷 − 0.50 − 0.5) =
708.6529
2𝑚3(𝑟𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒)
𝐷 = 5.431252 𝑚 ≅ 5500 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 5500 𝑚𝑚 = 16500 𝑚𝑚
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in
or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the
vessel, first is determine the maximum allowable stress (S) which will be based on the type
of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon
steel at 250℉ is 12.9ksi or 12900psi.
For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic
pressure can be calculated from the following equation:
𝑇𝑡 =𝜌𝐿𝐻𝐿𝑔
2𝑆𝑡𝐸
𝐷𝑡
103+ 𝐶𝐴
239
Where:
𝑇𝑡 = 𝑡𝑎𝑛𝑘 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑎𝑡 𝑎 𝑐𝑒𝑟𝑡𝑎𝑖𝑛 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚𝑚
𝐻𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚
𝜌𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦, 𝑘𝑔/𝑚3
𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (𝑖𝑓 𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑏𝑙𝑒)
𝑔 = 𝑔𝑟𝑎𝑣𝑖𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛, 9.81 𝑚/𝑠2
𝑆𝑡 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑓𝑜𝑟 𝑡𝑎𝑛𝑘 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙, 𝑁/𝑚𝑚2
𝐷𝑡 = 𝑡𝑎𝑛𝑘 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚
𝐶𝐴 = 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒
𝑇𝑡 =819.4 ∗ (5500 − 500) (
11000) ∗ 9.81
2 ∗ 88.942369 ∗ 0.85∗
55001000103
+ 3.8 = 8.47𝑚𝑚
𝑇𝑡 ≈ 9𝑚𝑚
𝑂𝐷 = 2 ∗ 𝑇𝑡 + 𝐼𝐷
𝑂𝐷 = 2 ∗ 9 + 5500 = 5518𝑚𝑚
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
2𝑆𝐸 − 0.2𝑃𝑖
𝑡𝑚𝑖𝑛 =64.7𝑝𝑠𝑖𝑎 ∗ 5500𝑚𝑚
2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 64.7𝑝𝑠𝑖𝑎≅ 17 𝑚𝑚
240
CALCULATION SHEET
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 EAM ALL
MFS
Service: Condensate from Distillation Column 1
OPERATING CONDITIONS
T °C 70.05
°F 158.09
P
Bar 1
psia 14.50777
psig -0.19223
true VP and Reid VP at 37.8 °C
(100°F)
psia 4.96E+00
kPaa 34.23
Type of Vessel
Atmospheric
vessel
DESIGN CONDITIONS
T °C 93.33333
°F 200
P (MAWP)
Bar 4.459679
psia 64.7
psig 50
minimum P psia 0
psig -14.7
minimum design metal temperature °C 15 ~ 20
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Operating T Design T Operating P Design P
0 to 200 degF 250 degF 0 to 25 psig 50 psig
Over 200 degF operating + 50 degF 25 to 250 psig operating + 25 psig
Reactors operating + 50 degF 250 to 1000 psig operating + 10%
over 1000 psig operating + 5%
LIQUID CAPACITY
Liquid holdup time min 5
hr 0.083333
flow rate kg/hr 1.43E+06
241
Rated mass flow rate kg/hr 1568930
Density kg/m3 819.4
Rated Volume of liquid m3 159.5609
gal 42151.51
The outage and innage of the tank is assumed to be 500 millimeters. The outage is the
allowance for spillage, and the innage is the non-pumpable volume. The pump should not
be placed under the innage to avoid pump cavitation.
𝐷 = (4
3𝜋∗ 159.5609 ∗ 2)
1/3
𝐷 ≅ 5200 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 5200 𝑚𝑚 = 15600 𝑚𝑚
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in
or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the
vessel, first is determine the maximum allowable stress (S) which will be based on the type
of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon
steel at 250℉ is 12.9ksi or 12900psi.
For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic
pressure can be calculated from the following equation:
𝑇𝑡 =𝜌𝐿𝐻𝐿𝑔
2𝑆𝑡𝐸
𝐷𝑡
103+ 𝐶𝐴
Where:
𝑇𝑡 = 𝑡𝑎𝑛𝑘 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑎𝑡 𝑎 𝑐𝑒𝑟𝑡𝑎𝑖𝑛 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚𝑚
𝐻𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚
𝜌𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦, 𝑘𝑔/𝑚3
242
𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (𝑖𝑓 𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑏𝑙𝑒)
𝑔 = 𝑔𝑟𝑎𝑣𝑖𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛, 9.81 𝑚/𝑠2
𝑆𝑡 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑓𝑜𝑟 𝑡𝑎𝑛𝑘 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙, 𝑁/𝑚𝑚2
𝐷𝑡 = 𝑡𝑎𝑛𝑘 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚
𝐶𝐴 = 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒
𝑇𝑡 =819.4 ∗ (5200 − 500) (
11000) ∗ 9.81
2 ∗ 88.942369 ∗ 0.85∗
52001000103
+ 3.8 = 3.80𝑚𝑚
𝑇𝑡 ≈ 4 𝑚𝑚
𝑂𝐷 = 2 ∗ 𝑇𝑡 + 𝐼𝐷
𝑂𝐷 = 2 ∗ 4 + 5200 = 5208𝑚𝑚
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
2𝑆𝐸 − 0.2𝑃𝑖
𝑡𝑚𝑖𝑛 =64.7𝑝𝑠𝑖𝑎 ∗ 5200𝑚𝑚
2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 64.7𝑝𝑠𝑖𝑎≅ 16 𝑚𝑚
243
CALCULATION
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 EAM ALL
MFS
SERVICE: CONDENSATE from Distillation Column 2
OPERATING CONDITIONS
T °C 91.98
°F 197.564
P
Bar 3.7
psia 53.67876
psig 38.97876
true VP and Reid VP at 37.8 °C
(100°F)
psia 2.15E+01
kPaa 148
Type of Vessel Pressure vessel
DESIGN CONDITIONS
T °C 93.33333
°F 200
P (MAWP)
Bar 5.423214
psia 78.67876
psig 63.97876
minimum P psia 0
psig -14.7
minimum design metal temperature °C 15 ~ 20
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Design Temperature and Design Pressure
Operating T Design T Operating P Design P
0 to 200 degF 250 degF 0 to 25 psig 50 psig
Over 200 degF operating + 50 degF 25 to 250 psig operating + 25 psig
Reactors operating + 50 degF 250 to 1000 psig operating + 10%
over 1000 psig operating + 5%
LIQUID CAPACITY
Capacity/Storage time min 5
hr 0.083333
244
flow rate kg/hr 5.59E+03
Rated mass flow rate kg/hr 6153.4
Density kg/m3 700.5
Rated Volume of liquid m3 0.732025
gal 193.3804
The outage and innage of the tank is assumed to be 500 millimeters. The outage is the
allowance for spillage, and the innage is the non-pumpable volume. The pump should not
be placed under the innage to avoid pump cavitation.
𝐷 = (4
3𝜋∗ 0.732025 ∗ 2)
1/3
𝐷 ≅ 900 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 900 𝑚𝑚 = 2700 𝑚𝑚
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams like
propylene is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the
minimum thickness of the vessel, first is determine the maximum allowable stress (S)
which will be based on the type of material used. Using table 13.2 in Towler, the Maximum
allowable stress for carbon steel at 250℉ is 12.9ksi or 12900psi.
For cylindrical vessels:
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
2𝑆𝐸 − 1.2𝑃𝑖 (1)
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
4𝑆𝐸 + 0.8𝑃𝑖 (2)
245
Where:
𝑡𝑚𝑖𝑛 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑤𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 (𝑒𝑥𝑐𝑙𝑢𝑑𝑖𝑛𝑔 𝐶𝐴)
𝑃𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
𝐷𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝑆 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
(1)𝑡𝑚𝑖𝑛 =78.67876𝑝𝑠𝑖𝑎 ∗ 900 𝑚𝑚
2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 1.2 ∗ 78.67876𝑝𝑠𝑖𝑎= 3.242912 𝑚𝑚
(2)𝑡𝑚𝑖𝑛 =78.67876𝑝𝑠𝑖𝑎 ∗ 900𝑚𝑚
4 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 + 0.8 ∗ 78.67876𝑝𝑠𝑖𝑎= 1.612162 𝑚𝑚
Choosing the higher value for 𝑡𝑚𝑖𝑛,
𝑡𝑚𝑖𝑛 = 3.242912 + 3.8 ≅ 4 𝑚𝑚
𝑂𝐷 = 2 ∗ 𝑡𝑚𝑖𝑛 + 𝐼𝐷 = 2 ∗ 4 + 900 = 908𝑚𝑚
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
2𝑆𝐸 − 0.2𝑃𝑖
𝑡𝑚𝑖𝑛 =78.67876𝑝𝑠𝑖𝑎 ∗ 900𝑚𝑚
2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 78.67876𝑝𝑠𝑖𝑎≅ 4𝑚𝑚
246
CALCULATION
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 EAM ALL
MFS
OPERATING CONDITIONS
T °C 151.9
°F 305.42
P
Bar 1.013
psia 14.69637
psig -0.00363
true VP and Reid VP at 37.8 °C
(100°F)
psia 2.07E-01
kPaa 1.427
Type of Vessel
Atmospheric
vessel
DESIGN CONDITIONS
T °C 179.6778
°F 355.42
P (MAWP)
Bar 4.459679
psia 64.7
psig 50
minimum P psia 0
psig -14.7
minimum design metal temperature °C 15 ~ 20
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Operating T Design T Operating P Design P
0 to 200 degF 250 degF 0 to 25 psig 50 psig
Over 200 degF operating + 50 degF 25 to 250 psig operating + 25 psig
Reactors operating + 50 degF 250 to 1000 psig operating + 10%
over 1000 psig operating + 5%
LIQUID CAPACITY
Capacity/Storage time min 5
247
hr 0.083333
flow rate kg/hr 6.80E+04
Rated mass flow rate kg/hr 74822
Density kg/m3 758.4
Rated Volume of liquid m3 8.221475
gal 2171.884
The outage and innage of the tank is assumed to be 500 millimeters. The outage is the
allowance for spillage, and the innage is the non-pumpable volume. The pump should not
be placed under the innage to avoid pump cavitation.
𝐷 = (4
3𝜋∗ 8.221475 ∗ 2)
1/3
𝐷 ≅ 2000 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 2000 𝑚𝑚 = 6000 𝑚𝑚
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in
or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the
vessel, first is determine the maximum allowable stress (S) which will be based on the type
of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon
steel at 250℉ is 12.9ksi or 12900psi.
For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic
pressure can be calculated from the following equation:
𝑇𝑡 =𝜌𝐿𝐻𝐿𝑔
2𝑆𝑡𝐸
𝐷𝑡
103+ 𝐶𝐴
Where:
𝑇𝑡 = 𝑡𝑎𝑛𝑘 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑎𝑡 𝑎 𝑐𝑒𝑟𝑡𝑎𝑖𝑛 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚𝑚
248
𝐻𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚
𝜌𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦, 𝑘𝑔/𝑚3
𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (𝑖𝑓 𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑏𝑙𝑒)
𝑔 = 𝑔𝑟𝑎𝑣𝑖𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛, 9.81 𝑚/𝑠2
𝑆𝑡 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑓𝑜𝑟 𝑡𝑎𝑛𝑘 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙, 𝑁/𝑚𝑚2
𝐷𝑡 = 𝑡𝑎𝑛𝑘 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚
𝐶𝐴 = 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒
𝑇𝑡 =758.4 ∗ (2000 − 500) (
11000) ∗ 9.81
2 ∗ 88.942369 ∗ 0.85∗
20001000103
+ 3.8 = 4𝑚𝑚
𝑇𝑡 ≈ 4 𝑚𝑚
𝑂𝐷 = 2 ∗ 𝑇𝑡 + 𝐼𝐷
𝑂𝐷 = 2 ∗ 4 + 2000 = 2008𝑚𝑚
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
2𝑆𝐸 − 0.2𝑃𝑖
𝑡𝑚𝑖𝑛 =64.7𝑝𝑠𝑖𝑎 ∗ 2000𝑚𝑚
2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 64.7𝑝𝑠𝑖𝑎≅ 6 𝑚𝑚
249
CALCULATION
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 EAM ALL
MFS
Service: Cumene Recycle Stream
OPERATING CONDITIONS
T °C 151.9
°F 305.42
P
Bar 1.013
psia 14.69637
psig -0.00363
true VP and Reid VP at 37.8 °C
(100°F)
psia 1.81E-01
kPaa 1.247
Type of Vessel
Atmospheric
vessel
DESIGN CONDITIONS
T °C 179.6778
°F 355.42
P (MAWP)
Bar 4.459679
psia 64.7
psig 50
minimum P psia 0
psig -14.7
minimum design metal temperature °C 15 ~ 20
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Operating T Design T Operating P Design P
0 to 200 degF 250 degF 0 to 25 psig 50 psig
Over 200 degF operating + 50 degF 25 to 250 psig operating + 25 psig
Reactors operating + 50 degF 250 to 1000 psig operating + 10%
over 1000 psig operating + 5%
LIQUID CAPACITY
Capacity/Storage time day -
250
hr 1
flow rate kg/hr 1.25E+04
Rated mass flow rate kg/hr 13750
Density kg/m3 758.4
Rated Volume of liquid m3 18.13027
gal 4789.511
The outage and innage of the tank is assumed to be 500 millimeters. The outage is the
allowance for spillage, and the innage is the non-pumpable volume. The pump should not
be placed under the innage to avoid pump cavitation.
The optimum Length to diameter ratio for vessels is 3. The volume is divided in 2, since it
is a liquid holdup tank.
𝜋𝐷2
4(3𝐷 − 0.50 − 0.5) =
18.13027
1𝑚3(𝑟𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒)
𝐷 = 2.091816 𝑚 ≅ 2100 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 2100 𝑚𝑚 = 6300 𝑚𝑚
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in
or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the
vessel, first is determine the maximum allowable stress (S) which will be based on the type
of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon
steel at 250℉ is 12.9ksi or 12900psi.
For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic
pressure can be calculated from the following equation:
𝑇𝑡 =𝜌𝐿𝐻𝐿𝑔
2𝑆𝑡𝐸
𝐷𝑡
103+ 𝐶𝐴
251
Where:
𝑇𝑡 = 𝑡𝑎𝑛𝑘 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑎𝑡 𝑎 𝑐𝑒𝑟𝑡𝑎𝑖𝑛 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚𝑚
𝐻𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚
𝜌𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦, 𝑘𝑔/𝑚3
𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (𝑖𝑓 𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑏𝑙𝑒)
𝑔 = 𝑔𝑟𝑎𝑣𝑖𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛, 9.81 𝑚/𝑠2
𝑆𝑡 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑓𝑜𝑟 𝑡𝑎𝑛𝑘 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙, 𝑁/𝑚𝑚2
𝐷𝑡 = 𝑡𝑎𝑛𝑘 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚
𝐶𝐴 = 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒
𝑇𝑡 =758.4 ∗ (6300 − 500) (
11000) ∗ 9.81
2 ∗ 88.942369 ∗ 0.85∗
21001000103
+ 3.8 = 5𝑚𝑚
𝑇𝑡 ≈ 5𝑚𝑚
𝑂𝐷 = 2 ∗ 𝑇𝑡 + 𝐼𝐷
𝑂𝐷 = 2 ∗ 5 + 2100 = 5𝑚𝑚
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
2𝑆𝐸 − 0.2𝑃𝑖
𝑡𝑚𝑖𝑛 =64.7𝑝𝑠𝑖𝑎 ∗ 2100𝑚𝑚
2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 64.7𝑝𝑠𝑖𝑎≅ 7 𝑚𝑚
252
CALCULATION SHEET
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 EAM ALL
MFS
Service: Water
OPERATING CONDITIONS
T °C 30
°F 86
P
Bar 1
psia 14.50777
psig -0.19223
true VP and Reid VP at 37.8 °C (100°F)
psia 9.49E-01
kPaa 6.545
Type of Vessel Atmospheric
vessel
DESIGN CONDITIONS
T °C 93.33333
°F 200
P (MAWP)
Bar 4.459679
psia 64.7
psig 50
minimum P psia 0
psig -14.7
minimum design metal temperature °C 15 ~ 20
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Operating T Design T Operating P Design P
0 to 200 degF 250 degF 0 to 25 psig 50 psig
Over 200 degF operating + 50 degF 25 to 250 psig operating + 25 psig
Reactors operating + 50 degF 250 to 1000 psig operating + 10%
253
over 1000 psig operating + 5%
LIQUID CAPACITY
Capacity/Storage time day 1
hr 24
flow rate kg/hr 6100.649
Rated mass flow rate kg/hr 6710.714
Density kg/m3 1000
Rated Volume of liquid m3 161.0571
gal 42546.78
use vertical tanks on concrete foundation
Assumptions:
Based on the rule of thumb of Chemical Engineering Design, if the rated volume
of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations
is typically used.
The chosen material of construction is carbon steel since water is not corrosive.
ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry
for storage tanks.
Outage and Innage of the tank are assumed to be 500 𝑚𝑖𝑙𝑙𝑖𝑚𝑒𝑡𝑒𝑟𝑠. The outage is
the allowance for spillage, and the innage is the non-pumpable volume. The pump
should not be placed under the innage to avoid pump cavitation.
Based on the rule of thumb for Chemical Engineering Design, Optimum length to
diameter ratio for vessels is 3 (𝐿 𝐷 = 3)⁄ .
𝜋𝐷2
4(3𝐷 − 0.50 − 0.5) =
161.0571
1𝑚3(𝑟𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒)
𝐷 = 4.2029 𝑚 ≅ 4300 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 4300 𝑚𝑚 = 12900 𝑚𝑚
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams is 0.15in
or 3.8mm. The typical joint efficiency is 0.85. To calculate the minimum thickness of the
vessel, first is determine the maximum allowable stress (S) which will be based on the type
of material used. Using table 13.2 in Towler, the Maximum allowable stress for carbon
steel at 250℉ is 12.9ksi or 12900psi.
254
For liquid storage tanks, the minimum wall thickness required to resist the hydrostatic
pressure can be calculated from the following equation:
𝑇𝑡 =𝜌𝐿𝐻𝐿𝑔
2𝑆𝑡𝐸
𝐷𝑡
103+ 𝐶𝐴
Where:
𝑇𝑡 = 𝑡𝑎𝑛𝑘 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑎𝑡 𝑎 𝑐𝑒𝑟𝑡𝑎𝑖𝑛 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚𝑚
𝐻𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑝𝑡ℎ, 𝑚
𝜌𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦, 𝑘𝑔/𝑚3
𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (𝑖𝑓 𝑎𝑝𝑝𝑙𝑖𝑐𝑎𝑏𝑙𝑒)
𝑔 = 𝑔𝑟𝑎𝑣𝑖𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛, 9.81 𝑚/𝑠2
𝑆𝑡 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑓𝑜𝑟 𝑡𝑎𝑛𝑘 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙, 𝑁/𝑚𝑚2
𝐷𝑡 = 𝑡𝑎𝑛𝑘 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚
𝐶𝐴 = 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒
𝑇𝑡 =1000 ∗ (12900 − 500) (
11000) ∗ 9.81
2 ∗ 88.942369 ∗ 0.85∗
43001000103
+ 3.8 = 7.259𝑚𝑚
𝑇𝑡 ≈ 8𝑚𝑚
𝑂𝐷 = 2 ∗ 𝑇𝑡 + 𝐼𝐷
𝑂𝐷 = 2 ∗ 8 + 4300 = 4316𝑚𝑚
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
2𝑆𝐸 − 0.2𝑃𝑖
𝑡𝑚𝑖𝑛 =64.7𝑝𝑠𝑖𝑎 ∗ 4300𝑚𝑚
2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 64.7𝑝𝑠𝑖𝑎≅ 13 𝑚𝑚
255
CALCULATION SHEET
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 EAM ALL
MFS
Service: LPG Fuel (Propane)
OPERATING CONDITIONS
T °C 30
°F 86
P
Bar 10.8
psia 156.6839
psig 141.9839
true VP and Reid VP at 37.8 °C (100°F)
psia 188.9842
kPaa 1303
Type of Vessel Pressure vessel
DESIGN CONDITIONS
T °C 93.33333
°F 200
P (MAWP)
Bar 12.52321
psia 181.6839
psig 166.9839
minimum P psia 0
psig -14.7
minimum design metal temperature °C 15 ~ 20
LIQUID CAPACITY
Capacity/Storage time day 45
hr 1080
Volumetric Flow Rate m3/hr 2.71
Rated Volumetric Flow Rate m3/hr 2.981
Rated Volume of liquid m3 3219.48
gal 850496.5
use vertical tanks on concrete foundation
The minimum design metal temperature is based from the ambient temperature here in the
country .The design conditions were acquired based on the following table.
Operating T Design T Operating P Design P
256
0 to 200 degF 250 degF 0 to 25 psig 50 psig
Over 200 degF operating + 50 degF 25 to 250 psig operating + 25 psig
Reactors operating + 50 degF 250 to 1000 psig operating + 10%
over 1000 psig operating + 5%
Assumptions:
The storage for the fuel will be 45 days (1 𝑎𝑛𝑑1
2 𝑚𝑜𝑛𝑡ℎ𝑠), since the company
plans to buy fuel only on days that the price is ideally low. The capacity of the fuel
tank is enough for this to be possible. The storage tank is divided into 4.
Based on the rule of thumb of Chemical Engineering Design, if the rated volume
of the liquid is greater than 10,000 gallons, vertical tanks on concrete foundations
is typically used.
ASME BPV (ASME Boiler and Pressure Vessel Code) suggest circular geometry
for storage tanks.
Outage and Innage of the tank are assumed to be 500 𝑚𝑖𝑙𝑙𝑖𝑚𝑒𝑡𝑒𝑟𝑠. The outage is
the allowance for spillage, and the innage is the non-pumpable volume. The pump
should not be placed under the innage to avoid pump cavitation.
Based on the rule of thumb for Chemical Engineering Design, Optimum length to
diameter ratio for vessels is 3 (𝐿 𝐷 = 3)⁄ .
𝜋𝐷2
4(3𝐷 − 0.50 − 0.5) =
3219.48
4𝑚3(𝑟𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒)
𝐷 = 7.103344𝑚 ≅ 7200 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 = 3𝐷 = 3 ∗ 7200 𝑚𝑚 = 21600 𝑚𝑚
Based on the Rules of thumb, the corrosion allowance for non-corrosive streams like
propylene is 0.15in or 3.8mm. The typical joint efficiency is 0.85. To calculate the
minimum thickness of the vessel, first is determine the maximum allowable stress (S)
which will be based on the type of material used. Using table 13.2 in Towler, the Maximum
allowable stress for carbon steel at 250℉ is 12.9ksi or 12900psi.
For cylindrical vessels:
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
2𝑆𝐸 − 1.2𝑃𝑖 (1)
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
4𝑆𝐸 + 0.8𝑃𝑖 (2)
257
Where:
𝑡𝑚𝑖𝑛 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑤𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 (𝑒𝑥𝑐𝑙𝑢𝑑𝑖𝑛𝑔 𝐶𝐴)
𝑃𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
𝐷𝑖 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝑆 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
𝐸 = 𝑗𝑜𝑖𝑛𝑡 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
(1)𝑡𝑚𝑖𝑛 =181.68 𝑝𝑠𝑖𝑎 ∗ 7200 𝑚𝑚
2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 1.2 ∗ 64.7𝑝𝑠𝑖𝑎= 60.24897 𝑚𝑚
(2)𝑡𝑚𝑖𝑛 =181.68 𝑝𝑠𝑖𝑎 ∗ 7200 𝑚𝑚
4 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 + 0.8 ∗ 64.7 𝑝𝑠𝑖𝑎= 29.72649 𝑚𝑚
Choosing the higher value for 𝑡𝑚𝑖𝑛,
𝑡𝑚𝑖𝑛 = 60.24897 + 3.8 ≅ 65 𝑚𝑚
𝑂𝐷 = 2 ∗ 𝑡𝑚𝑖𝑛 + 𝐼𝐷 = 2 ∗ 65 + 2900 = 7330𝑚𝑚
For heads and closures, 2:1 ellipsoidal is the common in the chemical industry.
𝑡𝑚𝑖𝑛 =𝑃𝑖𝐷𝑖
2𝑆𝐸 − 0.2𝑃𝑖
𝑡𝑚𝑖𝑛 =181.68 𝑝𝑠𝑖𝑎 ∗ 7200𝑚𝑚
2 ∗ 12900𝑝𝑠𝑖 ∗ 0.85 − 0.2 ∗ 64.7 𝑝𝑠𝑖𝑎≅ 65 𝑚𝑚
258
Appendix C
REACTORS CALCULATION SHEETS
CALCULATION
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 EAM ALL
MFS
LEGEND:
𝐴𝑐 = 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑢𝑏𝑒, 𝑚2
𝑑𝑡 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑢𝑏𝑒, 𝑚
𝑑𝑝 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚
𝜌𝑝 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑘𝑔 𝑚3⁄
𝑉𝐵𝑒𝑑 = 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑏𝑒𝑑, 𝑚3
휀 = 𝑉𝑜𝑖𝑑 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛
�̇� = 𝐼𝑛𝑙𝑒𝑡 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑡𝑜 𝑡ℎ𝑒 𝑟𝑒𝑎𝑐𝑡𝑜𝑟, 𝑘𝑔/𝑠
𝐺 = 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡 𝑎𝑟𝑒𝑎, 𝑘𝑔/𝑚2𝑠
ℎ = ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑠𝑝ℎ𝑒𝑟𝑖𝑐𝑎𝑙 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑊/𝑚2𝐾
𝑑𝑠 = 𝑆ℎ𝑒𝑙𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚
𝐴𝑠 = 𝐶𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑠ℎ𝑒𝑙𝑙 𝑠𝑖𝑑𝑒, 𝑚2
�̇�𝑤 = 𝑤𝑎𝑡𝑒𝑟 𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑒, 𝑘𝑔/ℎ
𝑄 = 𝐻𝑒𝑎𝑡 𝑒𝑣𝑜𝑙𝑣𝑒𝑑 𝑓𝑟𝑜𝑚 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛, 𝐾𝑊
∆𝑇 = 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟, ℃
DATA FROM ASPEN HYSYS
Total Volume (m3) 113.3
Number of tubes 1000
Length (m) 10
Diameter of tube (m) 0.1201
Void Fraction 0.7
Void Volume (m3) 79.3
Ac (m2) 0.011328591
CATALYST BED SPECIFICATIONS
Volume of Catalyst bed (m3) 34
700
dp (m) 0.003
Mass of catalyst (kg) 7140
HEAT TRANSFER CALCULATIONS IN THE REACTOR
Mass flow (kg/s) 297.6710076
𝜌𝑃 (𝑘𝑔 𝑚3)⁄
259
G (kg/m2s) 28903.69239
h (W/m2K) 636025.5239
Square Pitch Size (mm) 100
Minimum Area Required
(m2) 10
Baffle Spacing 1/5 of dt
Shell Diameter Required
(m) 3.908820095
Baffle Spacing (m) 0.781764019
As (m2) 0.305577491
Heat Evolved in the
reaction (kW) 2114
27.28
Water circulation rate
(kg/h) 66676.29231
TUBE SPECIFICATIONS
Material Carbon Steel
TUBE I.D. (in) 4.728346457
4.813
TUBE O.D. (in) 5.563
Nominal Pipe Size (in) 5
Schedule No. 80XS, 80S
Wall Thickness (in) 0.375
Cross Sectional Area (in2) 6.11
𝑨𝒄 =𝝅
𝟒 𝒅𝒕
𝟐
𝐴𝑐 =𝜋
4∗ (0.1201𝑚)2 = 0.011328591 𝑚2
𝑽𝒐𝒍𝒖𝒎𝒆 𝒐𝒇 𝒄𝒂𝒕𝒂𝒍𝒚𝒔𝒕 𝒃𝒆𝒅 = 𝑻𝒐𝒕𝒂𝒍 𝒗𝒐𝒍𝒖𝒎𝒆 − 𝑽𝒐𝒊𝒅 𝒗𝒐𝒍𝒖𝒎𝒆
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑏𝑒𝑑 = 113.3 − 79.3 = 34𝑚3
𝑴𝒂𝒔𝒔 𝒐𝒇 𝒄𝒂𝒕𝒂𝒍𝒚𝒔𝒕 = (𝟏 − 𝜺)𝝆𝒑𝑽𝑩𝒆𝒅
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = (1 − 0.7)(700)(34) = 7140 𝑘𝑔
𝑮 =𝟏. 𝟏 ∗ �̇�
𝑨𝒄=
1.1 ∗ 297.6710076 𝑘𝑔/𝑠
0.011328591 𝑚2= 28903.69239
𝑘𝑔
𝑚2𝑠
∆𝑇 (℃)
260
𝒉 =𝟏𝟓. 𝟏𝑮𝟎.𝟗𝟓
𝒅𝒕𝟎.𝟒𝟐 =
15.1 ∗ 28903.692390.95
0.12010.42= 636025.5239
𝑊
𝑚2𝐾
(1) 𝐴𝑆𝑆𝑈𝑀𝑃𝑇𝐼𝑂𝑁𝑆: 𝑆𝑞𝑢𝑎𝑟𝑒 𝑝𝑖𝑡𝑐ℎ 𝑠𝑖𝑧𝑒 = 100 𝑚𝑚
𝑴𝒊𝒏𝒊𝒎𝒖𝒎 𝑨𝒓𝒆𝒂 𝑹𝒆𝒒𝒖𝒊𝒓𝒆𝒅 = (𝒕𝒖𝒃𝒆 𝒑𝒊𝒕𝒄𝒉)𝟐(# 𝒐𝒇 𝒕𝒖𝒃𝒆𝒔)
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝐴𝑟𝑒𝑎 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = (100
1000)
2
(1000) = 10 𝑚2
𝒅𝒔 = (𝒎𝒊𝒏𝒊𝒎𝒖𝒎 𝒂𝒓𝒆𝒂 𝒓𝒆𝒒𝒖𝒊𝒓𝒆𝒅 (𝟏 + 𝟎. 𝟐)
𝝅 𝟒⁄)
𝟎.𝟓
𝑑𝑠 = (10 (1 + 0.2)
𝜋 4⁄)
0.5
= 3.908820095 𝑚
𝑩𝒂𝒇𝒇𝒍𝒆 𝑺𝒑𝒂𝒄𝒊𝒏𝒈 =𝟏
𝟓 𝒅𝒔 =
1
5∗ 3.908820095 = 0.781764019 𝑚
𝑨𝒔 =𝒅𝒔 ∗ 𝑩𝒂𝒇𝒇𝒍𝒆 𝒔𝒑𝒂𝒄𝒊𝒏𝒈
𝟎. 𝟏∗ 𝟎. 𝟎𝟏
𝐴𝑠 =3.908820095 ∗ 0.781764019
0.1∗ 0.01 = 0.305577491 𝑚2
�̇�𝒘 =𝑸
𝑪𝒑𝒘 ∆𝑻=
2114 𝐾𝐽/𝑠
4.184𝐾𝐽
𝑘𝑔 ∙ 𝐾 ∗ 27.28℃∗
3600𝑠
ℎ= 66676.29231 𝑘𝑔 ℎ⁄
261
CALCULATION
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 MFS ALL
EAM
LEGEND:
𝐴𝑐 = 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑢𝑏𝑒, 𝑚2
𝑑𝑡 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑢𝑏𝑒, 𝑚
𝑑𝑝 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚
𝜌𝑝 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑘𝑔 𝑚3⁄
𝑉𝐵𝑒𝑑 = 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑏𝑒𝑑, 𝑚3
휀 = 𝑉𝑜𝑖𝑑 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛
�̇� = 𝐼𝑛𝑙𝑒𝑡 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑡𝑜 𝑡ℎ𝑒 𝑟𝑒𝑎𝑐𝑡𝑜𝑟, 𝑘𝑔/𝑠
𝐺 = 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡 𝑎𝑟𝑒𝑎, 𝑘𝑔/𝑚2𝑠
ℎ = ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑠𝑝ℎ𝑒𝑟𝑖𝑐𝑎𝑙 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑊/𝑚2𝐾
𝑑𝑠 = 𝑆ℎ𝑒𝑙𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚
𝐴𝑠 = 𝐶𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑠ℎ𝑒𝑙𝑙 𝑠𝑖𝑑𝑒, 𝑚2
�̇�𝑤 = 𝑤𝑎𝑡𝑒𝑟 𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑒, 𝑘𝑔/ℎ
𝑄 = 𝐻𝑒𝑎𝑡 𝑒𝑣𝑜𝑙𝑣𝑒𝑑 𝑓𝑟𝑜𝑚 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛, 𝐾𝑊
∆𝑇 = 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟, ℃
DATA FROM ASPEN HYSYS
Total Volume (m3) 25.02
Number of tubes 100
Length (m) 10
Diameter of tube (m) 0.1785
Void Fraction 0.7
Void Volume (m3) 17.51
Ac (m2) 0.025024553
CATALYST BED SPECIFICATIONS
Volume of Catalyst bed
(m3) 7.51
0.00118
dp (m) 0.00002
Mass of catalyst (kg) 0.00265854
HEAT TRANSFER CALCULATIONS IN THE REACTOR
Mass flow (kg/s) 5.957000989
G (kg/m2s) 261.8508784
h (W/m2K) 6172.20338
Square Pitch Size (mm) 100
Minimum Area Required
(m2) 1
𝜌𝑃 (𝑘𝑔 𝑚3)⁄
262
Baffle Spacing 1/5 of dt
Shell Diameter Required
(m) 1.236077446
Baffle Spacing (m) 0.247215489
As (m2) 0.305577491
Heat Evolved in the
reaction (kW) 5154
27.28
Water circulation rate
(kg/h) 162558.9454
TUBE SPECIFICATIONS
Material Carbon Steel
TUBE I.D. (in) 7.027559055
7.187
TUBE O.D. (in) 8.625
Nominal Pipe Size (in) 8
Schedule No. 120
Wall Thickness (in) 0.719
Cross Sectional Area (in2) 17.86
𝑨𝒄 =𝝅
𝟒 𝒅𝒕
𝟐
𝐴𝑐 =𝜋
4∗ (0.1785𝑚)2 = 0.025024553 𝑚2
𝑽𝒐𝒍𝒖𝒎𝒆 𝒐𝒇 𝒄𝒂𝒕𝒂𝒍𝒚𝒔𝒕 𝒃𝒆𝒅 = 𝑻𝒐𝒕𝒂𝒍 𝒗𝒐𝒍𝒖𝒎𝒆 − 𝑽𝒐𝒊𝒅 𝒗𝒐𝒍𝒖𝒎𝒆
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑏𝑒𝑑 = 25.02 − 17.51 = 7.51 𝑚3
𝑴𝒂𝒔𝒔 𝒐𝒇 𝒄𝒂𝒕𝒂𝒍𝒚𝒔𝒕 = (𝟏 − 𝜺)𝝆𝒑𝑽𝑩𝒆𝒅
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = (1 − 0.7)(7.51)(0.00118) = 2.65854 𝑘𝑔
𝑮 =𝟏. 𝟏 ∗ �̇�
𝑨𝒄=
1.1 ∗ 5.957000989 𝑘𝑔/𝑠
0.025024553 𝑚2= 261.85087
𝑘𝑔
𝑚2𝑠
𝒉 =𝟏𝟓. 𝟏𝑮𝟎.𝟗𝟓
𝒅𝒕𝟎.𝟒𝟐 =
15.1 ∗ 28903.692390.95
0.12010.42= 6172.203192
𝑊
𝑚2𝐾
∆𝑇 (℃)
263
(1) 𝐴𝑆𝑆𝑈𝑀𝑃𝑇𝐼𝑂𝑁𝑆: 𝑆𝑞𝑢𝑎𝑟𝑒 𝑝𝑖𝑡𝑐ℎ 𝑠𝑖𝑧𝑒 = 100 𝑚𝑚
𝑴𝒊𝒏𝒊𝒎𝒖𝒎 𝑨𝒓𝒆𝒂 𝑹𝒆𝒒𝒖𝒊𝒓𝒆𝒅 = (𝒕𝒖𝒃𝒆 𝒑𝒊𝒕𝒄𝒉)𝟐(# 𝒐𝒇 𝒕𝒖𝒃𝒆𝒔)
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝐴𝑟𝑒𝑎 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = (100
1000)
2
(100) = 1 𝑚2
𝒅𝒔 = (𝒎𝒊𝒏𝒊𝒎𝒖𝒎 𝒂𝒓𝒆𝒂 𝒓𝒆𝒒𝒖𝒊𝒓𝒆𝒅 (𝟏 + 𝟎. 𝟐)
𝝅 𝟒⁄)
𝟎.𝟓
𝑑𝑠 = (1 (1 + 0.2)
𝜋 4⁄)
0.5
= 1.236077446 𝑚
𝑩𝒂𝒇𝒇𝒍𝒆 𝑺𝒑𝒂𝒄𝒊𝒏𝒈 =𝟏
𝟓 𝒅𝒔 =
1
5∗ 1.236077446 = 0.2472154892 𝑚
𝑨𝒔 =𝒅𝒔 ∗ 𝑩𝒂𝒇𝒇𝒍𝒆 𝒔𝒑𝒂𝒄𝒊𝒏𝒈
𝟎. 𝟏∗ 𝟎. 𝟎𝟏
𝐴𝑠 =1.236077446 ∗ 0.247215489
0.1∗ 0.01 = 0.03055774903 𝑚2
�̇�𝒘 =𝑸
𝑪𝒑𝒘 ∆𝑻=
2114 𝐾𝐽/𝑠
4.184𝐾𝐽
𝑘𝑔 ∙ 𝐾 ∗ 27.28℃∗
3600𝑠
ℎ= 162558.9454 𝑘𝑔 ℎ⁄
264
CALCULATION
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 EAM ALL
MFS
Legend:
𝜏 = 𝑟𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 𝑡𝑖𝑚𝑒, ℎ
𝑉𝑜 = 𝑖𝑛𝑙𝑒𝑡 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒, 𝑚3 ℎ⁄
𝑉 = 𝑇𝑜𝑡𝑎𝑙 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝑉𝑜𝑙𝑢𝑚𝑒, 𝑚3
𝐷 = 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚
𝐿 = 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝐿𝑒𝑛𝑔𝑡ℎ, 𝑚
𝑢𝑜 = 𝑠𝑢𝑝𝑒𝑟𝑓𝑖𝑐𝑖𝑎𝑙 𝑔𝑎𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑚/𝑠
𝜌𝑝 = 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡, 𝑘𝑔 𝑚3⁄
𝑑𝑝 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚
𝐴𝑐 = 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚2
휀 = 𝑉𝑜𝑖𝑑 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑏𝑒𝑑
𝜇𝑔 = 𝑣𝑖𝑠𝑐𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑔𝑎𝑠, 𝑃𝑎 ∙ 𝑠 𝑜𝑟 𝑘𝑔 (𝑚 ∙ 𝑠)⁄
𝜌𝑔 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑔𝑎𝑠, 𝑘𝑔 𝑚3⁄
∆𝑃 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 𝑎𝑐𝑟𝑜𝑠𝑠 𝑡ℎ𝑒 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑏𝑒𝑑, 𝑃𝑎
𝑢𝑚𝑓 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑏𝑒𝑑, 𝑚/𝑠
𝑢𝑓 = 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑚/𝑠
𝑢𝑡 = 𝑇𝑒𝑟𝑚𝑖𝑛𝑎𝑙 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑓𝑜𝑟 𝑠𝑝ℎ𝑒𝑟𝑖𝑐𝑎𝑙 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒𝑠, 𝑚/𝑠
휀𝑚𝑓 = 𝑃𝑜𝑟𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑎𝑡𝑖𝑜𝑛
𝑢𝑏 = 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑏𝑢𝑏𝑏𝑙𝑒 𝑟𝑖𝑠𝑒, 𝑚/𝑠
𝑑𝑏𝑚 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑏𝑢𝑏𝑏𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑐𝑚
𝑑𝑏𝑜 = 𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑢𝑏𝑏𝑙𝑒, 𝑐𝑚
𝛿 = 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑏𝑒𝑑 𝑜𝑐𝑐𝑢𝑝𝑖𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑏𝑢𝑏𝑏𝑙𝑒𝑠
265
REACTOR VESSEL
Residence time (h) 4
25.278
V (m3) 101.112
D (m) 4
Reactor L (m) 12
u (m/s) 0.000558766
Height of Fluid (m) 9
CATALYST INFORMATION
790
diameter (m) 1.40E-07
Ac (cm2) 1.54E-10
DESIGN OF THE BED
0.8
Bed Height (m) 0.1
Bed Volume (m3) 1.256637061
2.15E-05
1.597
154.6318456
Mass of Catalyst (Kg) 198.5486557
4.33E-08
1.20404E-07
3.92E-07
STATUS PASSED
BUBBLE VELOCITY AND CLOUD SIZE
0.490948231
0.001390645
2.44E-05
Type of plate Porous
1.17376E-05
0.401772564
𝑽 = 𝝉𝑽𝒐
𝑉 = 4 ∗ 25.278 = 101.112 𝑚3
𝑉𝑜 (𝑚3 ℎ)⁄
𝜌𝑃 (𝑘𝑔 𝑚3)⁄
휀
∆𝑃 (Pa)
𝜌𝑔 (𝑘𝑔/𝑚3)
𝜇𝑔 (𝑃𝑎. 𝑠)
𝑢𝑚𝑓 (𝑚 𝑠⁄ )
𝑢𝑓 (𝑚 𝑠⁄ )
𝑢𝑡 (𝑚 𝑠⁄ )
휀𝑚𝑓
𝑢𝑏 (m/s)
𝑑𝑏𝑚 (𝑐𝑚)
𝑑𝑏0 (𝑐𝑚)
𝛿
266
𝑫 = (𝟒
𝟑𝝅𝑽)
𝟏/𝟑
= (4
3𝜋∗ 101.112)
1/3
= 4 𝑚
𝑳 = 𝟑𝑫 = 3 ∗ 4 = 12 𝑚
𝒖𝒐 =𝑽𝒐
𝝅𝟒 𝑫𝟐
=25.278/3600
𝜋4 ∗ 42
= 0.000558766 𝑚/𝑠
𝑨𝒄 =𝝅
𝟒𝒅𝒑
𝟐 =𝜋
4(1.40𝑒 − 7)2 = 1.54𝑒 − 10
ASSUMPTION: Bed height is 0.1m
𝑩𝒆𝒅 𝒗𝒐𝒍𝒖𝒎𝒆 =𝝅
𝟒∗ 𝑫𝟐 ∗ 𝑩𝒆𝒅 𝒉𝒆𝒊𝒈𝒉𝒕
𝐵𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 =𝜋
4∗ 42 ∗ 0.1 = 1.256637061 𝑚3
∆𝑷 = 𝒃𝒆𝒅 𝒉𝒆𝒊𝒈𝒉𝒕 ∗ (𝝆𝒑 − 𝝆𝒇) ∗ (𝟏 − 𝜺) ∗ 𝒈
∆𝑃 = 0.1 ∗ (790 − 1.597) ∗ (1 − 0.8) ∗ 9.80665 = 154.6318456 𝑃𝑎
𝑴𝒂𝒔𝒔 𝒐𝒇 𝒄𝒂𝒕𝒂𝒍𝒚𝒔𝒕 = (𝟏 − 𝜺) ∗ 𝝆𝒑 ∗ 𝑩𝒆𝒅 𝒗𝒐𝒍𝒖𝒎𝒆
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = (1 − 0.8) ∗ 790 ∗ 1.256637061 = 198.5486557 𝑘𝑔
𝒖𝒎𝒇 =(𝝋𝒅𝒑)𝟐
𝟏𝟓𝟎𝝁[𝒈(𝝆𝒑 − 𝝆𝒇)]
𝜺𝟑
𝟏 − 𝜺
𝑢𝑚𝑓 =(0.6 ∗ 1.40𝑒 − 7)2
150 ∗ 2.15𝑒 − 5[9.80665(790 − 1.597)]
0.83
1 − 0.8= 4.33𝑒 − 8 𝑚/𝑠
𝒖𝒇 =(𝝆𝒑 − 𝝆𝒇)𝒈𝒅𝒑
𝟐
𝟏𝟓𝟎𝝁
𝜺𝟑
𝟏 − 𝜺
𝑢𝑓 =(790 − 1.597) ∗ 9.80665 ∗ (1.40𝑒 − 7)2
150 ∗ 2.15𝑒 − 5
0.83
1 − 0.8= 1.20404𝑒 − 7 𝑚/𝑠
𝒖𝒕 =𝒈(𝝆𝒑 − 𝝆𝒇)𝒅𝒑
𝟐
𝟏𝟖𝝁
𝑢𝑡 =9.80665(790 − 1.597)(1.40𝑒 − 7)2
18 ∗ 2.15𝑒 − 5= 3.92𝑒 − 7 𝑚/𝑠
∴ 𝑺𝒊𝒏𝒄𝒆 𝒖𝒎𝒇 < 𝒖𝒇 < 𝒖𝒕 , 𝒔𝒂𝒕𝒊𝒔𝒇𝒚𝒂𝒃𝒍𝒆 𝒇𝒐𝒓 𝒑𝒓𝒐𝒑𝒆𝒓 𝒃𝒆𝒅 𝒐𝒑𝒆𝒓𝒂𝒕𝒊𝒐𝒏
267
𝜺𝒎𝒇 = (𝟎. 𝟎𝟕𝟏
𝛙)
𝟏/𝟑
The typical ψ is 0.6
휀𝑚𝑓 = (0.071
0.6)
1/3
= 0.490948231
𝒖𝒃 = 𝒖𝒐−𝒖𝒎𝒇 + (𝟎. 𝟕𝟏)(𝒈 𝒅𝒃)𝟏/𝟐
𝑢𝑏 = 0.000558766 − (4.33𝑒 − 8) + (0.71)(9.80665 ∗ (1.40𝑒 − 7))12
= 0.001390645 𝑚/𝑠
𝒅𝒃𝒎 = 𝟎. 𝟔𝟓𝟐[𝑨𝒄(𝒖𝒐 − 𝒖𝒎𝒇)]𝟎.𝟒
𝑑𝑏𝑚 = 0.652[(1.54𝑒 − 10)(0.000558766 − (4.33𝐸 − 08)) ∗ 100]0.4
= 2.44𝑒 − 05 𝑐𝑚
𝒅𝒃𝒐 = 𝟎. 𝟎𝟎𝟑𝟕𝟔(𝒖𝒐 − 𝒖𝒎𝒇)𝟐
𝑑𝑏𝑜 = 0.00376((0.000558766 − (4.33𝐸 − 08)) ∗ 100)2
𝜹 =𝒖𝒐 − 𝒖𝒎𝒇
𝒖𝒃
𝛿 =0.000558766 − (4.33𝑒 − 08)
0.001390645= 0.401772564
268
CALCULATION
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 EAM ALL
MFS
Legend:
𝜏 = 𝑟𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 𝑡𝑖𝑚𝑒, ℎ
𝑉𝑜 = 𝑖𝑛𝑙𝑒𝑡 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒, 𝑚3 ℎ⁄
𝑉 = 𝑇𝑜𝑡𝑎𝑙 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝑉𝑜𝑙𝑢𝑚𝑒, 𝑚3
𝐷 = 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚
𝐿 = 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝐿𝑒𝑛𝑔𝑡ℎ, 𝑚
𝑢𝑜 = 𝑠𝑢𝑝𝑒𝑟𝑓𝑖𝑐𝑖𝑎𝑙 𝑔𝑎𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑚/𝑠
𝜌𝑝 = 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡, 𝑘𝑔 𝑚3⁄
𝑑𝑝 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚
𝐴𝑐 = 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚2
휀 = 𝑉𝑜𝑖𝑑 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑏𝑒𝑑
𝜇𝑔 = 𝑣𝑖𝑠𝑐𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑔𝑎𝑠, 𝑃𝑎 ∙ 𝑠 𝑜𝑟 𝑘𝑔 (𝑚 ∙ 𝑠)⁄
𝜌𝑔 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑔𝑎𝑠, 𝑘𝑔 𝑚3⁄
∆𝑃 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 𝑎𝑐𝑟𝑜𝑠𝑠 𝑡ℎ𝑒 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑏𝑒𝑑, 𝑃𝑎
𝑢𝑚𝑓 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑏𝑒𝑑, 𝑚/𝑠
𝑢𝑓 = 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑚/𝑠
𝑢𝑡 = 𝑇𝑒𝑟𝑚𝑖𝑛𝑎𝑙 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑓𝑜𝑟 𝑠𝑝ℎ𝑒𝑟𝑖𝑐𝑎𝑙 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒𝑠, 𝑚/𝑠
휀𝑚𝑓 = 𝑃𝑜𝑟𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑎𝑡𝑖𝑜𝑛
𝑢𝑏 = 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑏𝑢𝑏𝑏𝑙𝑒 𝑟𝑖𝑠𝑒, 𝑚/𝑠
𝑑𝑏𝑚 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑏𝑢𝑏𝑏𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑐𝑚
𝑑𝑏𝑜 = 𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑢𝑏𝑏𝑙𝑒, 𝑐𝑚
𝛿 = 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑏𝑒𝑑 𝑜𝑐𝑐𝑢𝑝𝑖𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑏𝑢𝑏𝑏𝑙𝑒𝑠
269
REACTOR VESSEL
Residence time (h) 4
24.54308240
V (m3) 98.17203297
D (m) 4
Reactor L (m) 12
u (m/s) 0.00054252
Height of Fluid (m) 8
CATALYST INFORMATION
790
diameter (m) 1.40E-07
Ac (cm2) 1.54E-10
DESIGN OF THE BED
0.8
Bed Height (m) 0.1
Bed Volume (m3) 1.256637061
2.15E-05
1.597
154.6318456
Mass of Catalyst (Kg) 198.5486557
4.33E-08
1.20404E-07
3.92E-07
STATUS PASSED
BUBBLE VELOCITY AND CLOUD SIZE
0.490948231
0.001374398
2.42E-05
Type of plate Porous
1.10649E-05
0.394700865
𝑽 = 𝝉𝑽𝒐
𝑉𝑜 (𝑚3 ℎ)⁄
𝜌𝑃 (𝑘𝑔 𝑚3)⁄
휀
∆𝑃 (Pa)
𝜌𝑔 (𝑘𝑔/𝑚3)
𝜇𝑔 (𝑃𝑎. 𝑠)
𝑢𝑚𝑓 (𝑚 𝑠⁄ )
𝑢𝑓 (𝑚 𝑠⁄ )
𝑢𝑡 (𝑚 𝑠⁄ )
휀𝑚𝑓
𝑢𝑏 (m/s)
𝑑𝑏𝑚 (𝑐𝑚)
𝑑𝑏0 (𝑐𝑚)
𝛿
270
𝑉 = 4 ∗ 24.54300824 = 98.17203296 𝑚3
𝑫 = (𝟒
𝟑𝝅𝑽)
𝟏/𝟑
= (4
3𝜋∗ 98.17203297)
1/3
= 4 𝑚
𝑳 = 𝟑𝑫 = 3 ∗ 4 = 12 𝑚
𝒖𝒐 =𝑽𝒐
𝝅𝟒 𝑫𝟐
=24.54300824/3600
𝜋4 ∗ 42
= 0.0005425195944 𝑚/𝑠
𝑨𝒄 =𝝅
𝟒𝒅𝒑
𝟐 =𝜋
4(1.40𝑒 − 7)2 = 1.54𝑒 − 10
ASSUMPTION: Bed height is 0.1m
𝑩𝒆𝒅 𝒗𝒐𝒍𝒖𝒎𝒆 =𝝅
𝟒∗ 𝑫𝟐 ∗ 𝑩𝒆𝒅 𝒉𝒆𝒊𝒈𝒉𝒕
𝐵𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 =𝜋
4∗ 42 ∗ 0.1 = 1.256637061 𝑚3
∆𝑷 = 𝒃𝒆𝒅 𝒉𝒆𝒊𝒈𝒉𝒕 ∗ (𝝆𝒑 − 𝝆𝒇) ∗ (𝟏 − 𝜺) ∗ 𝒈
∆𝑃 = 0.1 ∗ (790 − 1.597) ∗ (1 − 0.8) ∗ 9.80665 = 154.6318456 𝑃𝑎
𝑴𝒂𝒔𝒔 𝒐𝒇 𝒄𝒂𝒕𝒂𝒍𝒚𝒔𝒕 = (𝟏 − 𝜺) ∗ 𝝆𝒑 ∗ 𝑩𝒆𝒅 𝒗𝒐𝒍𝒖𝒎𝒆
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = (1 − 0.8) ∗ 790 ∗ 1.256637061 = 198.5486557 𝑘𝑔
𝒖𝒎𝒇 =(𝝋𝒅𝒑)𝟐
𝟏𝟓𝟎𝝁[𝒈(𝝆𝒑 − 𝝆𝒇)]
𝜺𝟑
𝟏 − 𝜺
𝑢𝑚𝑓 =(0.6 ∗ 1.40𝑒 − 7)2
150 ∗ 2.15𝑒 − 5[9.80665(790 − 1.597)]
0.83
1 − 0.8= 4.33𝑒 − 8 𝑚/𝑠
𝒖𝒇 =(𝝆𝒑 − 𝝆𝒇)𝒈𝒅𝒑
𝟐
𝟏𝟓𝟎𝝁
𝜺𝟑
𝟏 − 𝜺
𝑢𝑓 =(790 − 1.597) ∗ 9.80665 ∗ (1.40𝑒 − 7)2
150 ∗ 2.15𝑒 − 5
0.83
1 − 0.8= 1.20404𝑒 − 7 𝑚/𝑠
𝒖𝒕 =𝒈(𝝆𝒑 − 𝝆𝒇)𝒅𝒑
𝟐
𝟏𝟖𝝁
𝑢𝑡 =9.80665(790 − 1.597)(1.40𝑒 − 7)2
18 ∗ 2.15𝑒 − 5= 3.92𝑒 − 7 𝑚/𝑠
∴ 𝑺𝒊𝒏𝒄𝒆 𝒖𝒎𝒇 < 𝒖𝒇 < 𝒖𝒕 , 𝒔𝒂𝒕𝒊𝒔𝒇𝒚𝒂𝒃𝒍𝒆 𝒇𝒐𝒓 𝒑𝒓𝒐𝒑𝒆𝒓 𝒃𝒆𝒅 𝒐𝒑𝒆𝒓𝒂𝒕𝒊𝒐𝒏
271
𝜺𝒎𝒇 = (𝟎. 𝟎𝟕𝟏
𝛙)
𝟏/𝟑
The typical ψ is 0.6
휀𝑚𝑓 = (0.071
0.6)
1/3
= 0.490948231
𝒖𝒃 = 𝒖𝒐−𝒖𝒎𝒇 + (𝟎. 𝟕𝟏)(𝒈 𝒅𝒃)𝟏/𝟐
𝑢𝑏 = 0.000542519594 − (4.33𝑒 − 8) + (0.71)(9.80665 ∗ (1.40𝑒 − 7))12
= 0.001374398 𝑚/𝑠
𝒅𝒃𝒎 = 𝟎. 𝟔𝟓𝟐[𝑨𝒄(𝒖𝒐 − 𝒖𝒎𝒇)]𝟎.𝟒
𝑑𝑏𝑚 = 0.652[(1.54𝑒 − 10)(0.000542519594 − (4.33𝐸 − 08)) ∗ 100]0.4
= 2.42𝑒 − 05 𝑐𝑚
𝒅𝒃𝒐 = 𝟎. 𝟎𝟎𝟑𝟕𝟔(𝒖𝒐 − 𝒖𝒎𝒇)𝟐
𝑑𝑏𝑜 = 0.00376((0.000542519594 − (4.33𝐸 − 08)) ∗ 100)2
= 1.106494791𝑒 − 09 𝑐𝑚
𝜹 =𝒖𝒐 − 𝒖𝒎𝒇
𝒖𝒃
𝛿 =0.000542519594 − (4.33𝑒 − 08)
0.001374398= 0.3947010211
272
CALCULATION
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 EAM ALL
MFS
Legend:
𝜏 = 𝑟𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 𝑡𝑖𝑚𝑒, ℎ
𝑉𝑜 = 𝑖𝑛𝑙𝑒𝑡 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒, 𝑚3 ℎ⁄
𝑉 = 𝑇𝑜𝑡𝑎𝑙 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝑉𝑜𝑙𝑢𝑚𝑒, 𝑚3
𝐷 = 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚
𝐿 = 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝐿𝑒𝑛𝑔𝑡ℎ, 𝑚
𝑢𝑜 = 𝑠𝑢𝑝𝑒𝑟𝑓𝑖𝑐𝑖𝑎𝑙 𝑔𝑎𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑚/𝑠
𝜌𝑝 = 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡, 𝑘𝑔 𝑚3⁄
𝑑𝑝 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚
𝐴𝑐 = 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚2
휀 = 𝑉𝑜𝑖𝑑 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑏𝑒𝑑
𝜇𝑔 = 𝑣𝑖𝑠𝑐𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑔𝑎𝑠, 𝑃𝑎 ∙ 𝑠 𝑜𝑟 𝑘𝑔 (𝑚 ∙ 𝑠)⁄
𝜌𝑔 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑔𝑎𝑠, 𝑘𝑔 𝑚3⁄
∆𝑃 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 𝑎𝑐𝑟𝑜𝑠𝑠 𝑡ℎ𝑒 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑏𝑒𝑑, 𝑃𝑎
𝑢𝑚𝑓 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑏𝑒𝑑, 𝑚/𝑠
𝑢𝑓 = 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑚/𝑠
𝑢𝑡 = 𝑇𝑒𝑟𝑚𝑖𝑛𝑎𝑙 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑓𝑜𝑟 𝑠𝑝ℎ𝑒𝑟𝑖𝑐𝑎𝑙 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒𝑠, 𝑚/𝑠
휀𝑚𝑓 = 𝑃𝑜𝑟𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑎𝑡𝑖𝑜𝑛
𝑢𝑏 = 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑏𝑢𝑏𝑏𝑙𝑒 𝑟𝑖𝑠𝑒, 𝑚/𝑠
𝑑𝑏𝑚 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑏𝑢𝑏𝑏𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑐𝑚
𝑑𝑏𝑜 = 𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑢𝑏𝑏𝑙𝑒, 𝑐𝑚
𝛿 = 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑏𝑒𝑑 𝑜𝑐𝑐𝑢𝑝𝑖𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑏𝑢𝑏𝑏𝑙𝑒𝑠
REACTOR VESSEL
Residence time (h) 4
21.66297478
V (m3) 86.6518991
D (m) 4
Reactor L (m) 12
u (m/s) 0.000478857
Height of Fluid (m) 7
CATALYST INFORMATION
790
𝑉𝑜 (𝑚3 ℎ)⁄
𝜌𝑃 (𝑘𝑔 𝑚3)⁄
273
diameter (m) 1.40E-07
Ac (cm2) 1.54E-10
DESIGN OF THE BED
0.8
Bed Height (m) 0.1
Bed Volume (m3) 1.256637061
2.15E-05
1.597
154.6318456
Mass of Catalyst (Kg) 198.5486557
4.33E-08
1.20404E-07
3.92E-07
STATUS PASSED
BUBBLE VELOCITY AND CLOUD SIZE
0.490948231
0.001310736
2.44E-05
Type of plate Porous
8.62027-06
0.365301355
𝑽 = 𝝉𝑽𝒐
𝑉 = 4 ∗ 21.66297478 = 86.6518991 𝑚3
𝑫 = (𝟒
𝟑𝝅𝑽)
𝟏/𝟑
= (4
3𝜋∗ 86.6518991)
1/3
= 4 𝑚
𝑳 = 𝟑𝑫 = 3 ∗ 4 = 12 𝑚
𝒖𝒐 =𝑽𝒐
𝝅𝟒 𝑫𝟐
=21.66297478/3600
𝜋4 ∗ 42
= 0.0004788568775 𝑚/𝑠
𝑨𝒄 =𝝅
𝟒𝒅𝒑
𝟐 =𝜋
4(1.40𝑒 − 7)2 = 1.54𝑒 − 10
휀
∆𝑃 (Pa)
𝜌𝑔 (𝑘𝑔/𝑚3)
𝜇𝑔 (𝑃𝑎. 𝑠)
𝑢𝑚𝑓 (𝑚 𝑠⁄ )
𝑢𝑓 (𝑚 𝑠⁄ )
𝑢𝑡 (𝑚 𝑠⁄ )
휀𝑚𝑓
𝑢𝑏 (m/s)
𝑑𝑏𝑚 (𝑐𝑚)
𝑑𝑏0 (𝑐𝑚)
𝛿
274
ASSUMPTION: Bed height is 0.1m
𝑩𝒆𝒅 𝒗𝒐𝒍𝒖𝒎𝒆 =𝝅
𝟒∗ 𝑫𝟐 ∗ 𝑩𝒆𝒅 𝒉𝒆𝒊𝒈𝒉𝒕
𝐵𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 =𝜋
4∗ 42 ∗ 0.1 = 1.256637061 𝑚3
∆𝑷 = 𝒃𝒆𝒅 𝒉𝒆𝒊𝒈𝒉𝒕 ∗ (𝝆𝒑 − 𝝆𝒇) ∗ (𝟏 − 𝜺) ∗ 𝒈
∆𝑃 = 0.1 ∗ (790 − 1.597) ∗ (1 − 0.8) ∗ 9.80665 = 154.6318456 𝑃𝑎
𝑴𝒂𝒔𝒔 𝒐𝒇 𝒄𝒂𝒕𝒂𝒍𝒚𝒔𝒕 = (𝟏 − 𝜺) ∗ 𝝆𝒑 ∗ 𝑩𝒆𝒅 𝒗𝒐𝒍𝒖𝒎𝒆
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = (1 − 0.8) ∗ 790 ∗ 1.256637061 = 198.5486557 𝑘𝑔
𝒖𝒎𝒇 =(𝝋𝒅𝒑)𝟐
𝟏𝟓𝟎𝝁[𝒈(𝝆𝒑 − 𝝆𝒇)]
𝜺𝟑
𝟏 − 𝜺
𝑢𝑚𝑓 =(0.6 ∗ 1.40𝑒 − 7)2
150 ∗ 2.15𝑒 − 5[9.80665(790 − 1.597)]
0.83
1 − 0.8= 4.33𝑒 − 8 𝑚/𝑠
𝒖𝒇 =(𝝆𝒑 − 𝝆𝒇)𝒈𝒅𝒑
𝟐
𝟏𝟓𝟎𝝁
𝜺𝟑
𝟏 − 𝜺
𝑢𝑓 =(790 − 1.597) ∗ 9.80665 ∗ (1.40𝑒 − 7)2
150 ∗ 2.15𝑒 − 5
0.83
1 − 0.8= 1.20404𝑒 − 7 𝑚/𝑠
𝒖𝒕 =𝒈(𝝆𝒑 − 𝝆𝒇)𝒅𝒑
𝟐
𝟏𝟖𝝁
𝑢𝑡 =9.80665(790 − 1.597)(1.40𝑒 − 7)2
18 ∗ 2.15𝑒 − 5= 3.92𝑒 − 7 𝑚/𝑠
∴ 𝑺𝒊𝒏𝒄𝒆 𝒖𝒎𝒇 < 𝒖𝒇 < 𝒖𝒕 , 𝒔𝒂𝒕𝒊𝒔𝒇𝒚𝒂𝒃𝒍𝒆 𝒇𝒐𝒓 𝒑𝒓𝒐𝒑𝒆𝒓 𝒃𝒆𝒅 𝒐𝒑𝒆𝒓𝒂𝒕𝒊𝒐𝒏
𝜺𝒎𝒇 = (𝟎. 𝟎𝟕𝟏
𝛙)
𝟏/𝟑
The typical ψ is 0.6
휀𝑚𝑓 = (0.071
0.6)
1/3
= 0.490948231
𝒖𝒃 = 𝒖𝒐−𝒖𝒎𝒇 + (𝟎. 𝟕𝟏)(𝒈 𝒅𝒃)𝟏/𝟐
𝑢𝑏 = 0.000478857 − (4.33𝑒 − 8) + (0.71)(9.80665 ∗ (1.40𝑒 − 7))12
= 0.001310736 𝑚/𝑠
275
𝒅𝒃𝒎 = 𝟎. 𝟔𝟓𝟐[𝑨𝒄(𝒖𝒐 − 𝒖𝒎𝒇)]𝟎.𝟒
𝑑𝑏𝑚 = 0.652[(1.54𝑒 − 10)(0.000478857 − (4.33𝐸 − 08)) ∗ 100]0.4
= 2.297854424𝑒 − 05 𝑐𝑚
𝒅𝒃𝒐 = 𝟎. 𝟎𝟎𝟑𝟕𝟔(𝒖𝒐 − 𝒖𝒎𝒇)𝟐
𝑑𝑏𝑜 = 0.00376((0.000478857 − (4.33𝐸 − 08)) ∗ 100)2 = 8.62027223𝑒 − 06
𝜹 =𝒖𝒐 − 𝒖𝒎𝒇
𝒖𝒃
𝛿 =0.000478857 − (4.33𝑒 − 08)
0.001310736= 0.3653014032
276
CALCULATION
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 EAM ALL
MFS
Legend:
𝜏 = 𝑟𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 𝑡𝑖𝑚𝑒, ℎ
𝑉𝑜 = 𝑖𝑛𝑙𝑒𝑡 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒, 𝑚3 ℎ⁄
𝑉 = 𝑇𝑜𝑡𝑎𝑙 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝑉𝑜𝑙𝑢𝑚𝑒, 𝑚3
𝐷 = 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚
𝐿 = 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝐿𝑒𝑛𝑔𝑡ℎ, 𝑚
𝑢𝑜 = 𝑠𝑢𝑝𝑒𝑟𝑓𝑖𝑐𝑖𝑎𝑙 𝑔𝑎𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑚/𝑠
𝜌𝑝 = 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡, 𝑘𝑔 𝑚3⁄
𝑑𝑝 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚
𝐴𝑐 = 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒, 𝑚2
휀 = 𝑉𝑜𝑖𝑑 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑏𝑒𝑑
𝜇𝑔 = 𝑣𝑖𝑠𝑐𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑔𝑎𝑠, 𝑃𝑎 ∙ 𝑠 𝑜𝑟 𝑘𝑔 (𝑚 ∙ 𝑠)⁄
𝜌𝑔 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑔𝑎𝑠, 𝑘𝑔 𝑚3⁄
∆𝑃 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 𝑎𝑐𝑟𝑜𝑠𝑠 𝑡ℎ𝑒 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑏𝑒𝑑, 𝑃𝑎
𝑢𝑚𝑓 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑏𝑒𝑑, 𝑚/𝑠
𝑢𝑓 = 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑒𝑑 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑚/𝑠
𝑢𝑡 = 𝑇𝑒𝑟𝑚𝑖𝑛𝑎𝑙 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑓𝑜𝑟 𝑠𝑝ℎ𝑒𝑟𝑖𝑐𝑎𝑙 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒𝑠, 𝑚/𝑠
휀𝑚𝑓 = 𝑃𝑜𝑟𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑖𝑑𝑖𝑧𝑎𝑡𝑖𝑜𝑛
𝑢𝑏 = 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑏𝑢𝑏𝑏𝑙𝑒 𝑟𝑖𝑠𝑒, 𝑚/𝑠
𝑑𝑏𝑚 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑏𝑢𝑏𝑏𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑐𝑚
𝑑𝑏𝑜 = 𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑢𝑏𝑏𝑙𝑒, 𝑐𝑚
𝛿 = 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑏𝑒𝑑 𝑜𝑐𝑐𝑢𝑝𝑖𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑏𝑢𝑏𝑏𝑙𝑒𝑠
277
REACTOR VESSEL
Residence time (h) 4
21.05481201
V (m3) 84.21924804
D (m) 4
Reactor L (m) 12
u (m/s) 0.000465414
Height of Fluid (m) 7
CATALYST INFORMATION
790
diameter (m) 1.40E-07
Ac (cm2) 1.54E-10
DESIGN OF THE BED
0.8
Bed Height (m) 0.1
Bed Volume (m3) 1.256637061
2.15E-05
1.597
154.6318456
Mass of Catalyst (Kg) 198.5486557
4.33E-08
1.20404E-07
3.92E-07
STATUS PASSED
BUBBLE VELOCITY AND CLOUD SIZE
0.490948231
0.001297292
2.27E-05
Type of plate Porous
8.14301-06
0.358724213
𝑽 = 𝝉𝑽𝒐
𝑉 = 4 ∗ 21.05481201 = 84.21924804 𝑚3
𝑉𝑜 (𝑚3 ℎ)⁄
𝜌𝑃 (𝑘𝑔 𝑚3)⁄
휀
∆𝑃 (Pa)
𝜌𝑔 (𝑘𝑔/𝑚3)
𝜇𝑔 (𝑃𝑎. 𝑠)
𝑢𝑚𝑓 (𝑚 𝑠⁄ )
𝑢𝑓 (𝑚 𝑠⁄ )
𝑢𝑡 (𝑚 𝑠⁄ )
휀𝑚𝑓
𝑢𝑏 (m/s)
𝑑𝑏𝑚 (𝑐𝑚)
𝑑𝑏0 (𝑐𝑚)
𝛿
278
𝑫 = (𝟒
𝟑𝝅𝑽)
𝟏/𝟑
= (4
3𝜋∗ 84.21924804)
1/3
= 4 𝑚
𝑳 = 𝟑𝑫 = 3 ∗ 4 = 12 𝑚
𝒖𝒐 =𝑽𝒐
𝝅𝟒 𝑫𝟐
=21.05481201/3600
𝜋4 ∗ 42
= 0.000465414 𝑚/𝑠
𝑨𝒄 =𝝅
𝟒𝒅𝒑
𝟐 =𝜋
4(1.40𝑒 − 7)2 = 1.54𝑒 − 10
ASSUMPTION: Bed height is 0.1m
𝑩𝒆𝒅 𝒗𝒐𝒍𝒖𝒎𝒆 =𝝅
𝟒∗ 𝑫𝟐 ∗ 𝑩𝒆𝒅 𝒉𝒆𝒊𝒈𝒉𝒕
𝐵𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 =𝜋
4∗ 42 ∗ 0.1 = 1.256637061 𝑚3
∆𝑷 = 𝒃𝒆𝒅 𝒉𝒆𝒊𝒈𝒉𝒕 ∗ (𝝆𝒑 − 𝝆𝒇) ∗ (𝟏 − 𝜺) ∗ 𝒈
∆𝑃 = 0.1 ∗ (790 − 1.597) ∗ (1 − 0.8) ∗ 9.80665 = 154.6318456 𝑃𝑎
𝑴𝒂𝒔𝒔 𝒐𝒇 𝒄𝒂𝒕𝒂𝒍𝒚𝒔𝒕 = (𝟏 − 𝜺) ∗ 𝝆𝒑 ∗ 𝑩𝒆𝒅 𝒗𝒐𝒍𝒖𝒎𝒆
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = (1 − 0.8) ∗ 790 ∗ 1.256637061 = 198.5486557 𝑘𝑔
𝒖𝒎𝒇 =(𝝋𝒅𝒑)𝟐
𝟏𝟓𝟎𝝁[𝒈(𝝆𝒑 − 𝝆𝒇)]
𝜺𝟑
𝟏 − 𝜺
𝑢𝑚𝑓 =(0.6 ∗ 1.40𝑒 − 7)2
150 ∗ 2.15𝑒 − 5[9.80665(790 − 1.597)]
0.83
1 − 0.8= 4.33𝑒 − 8 𝑚/𝑠
𝒖𝒇 =(𝝆𝒑 − 𝝆𝒇)𝒈𝒅𝒑
𝟐
𝟏𝟓𝟎𝝁
𝜺𝟑
𝟏 − 𝜺
𝑢𝑓 =(790 − 1.597) ∗ 9.80665 ∗ (1.40𝑒 − 7)2
150 ∗ 2.15𝑒 − 5
0.83
1 − 0.8= 1.20404𝑒 − 7 𝑚/𝑠
𝒖𝒕 =𝒈(𝝆𝒑 − 𝝆𝒇)𝒅𝒑
𝟐
𝟏𝟖𝝁
𝑢𝑡 =9.80665(790 − 1.597)(1.40𝑒 − 7)2
18 ∗ 2.15𝑒 − 5= 3.92𝑒 − 7 𝑚/𝑠
∴ 𝑺𝒊𝒏𝒄𝒆 𝒖𝒎𝒇 < 𝒖𝒇 < 𝒖𝒕 , 𝒔𝒂𝒕𝒊𝒔𝒇𝒚𝒂𝒃𝒍𝒆 𝒇𝒐𝒓 𝒑𝒓𝒐𝒑𝒆𝒓 𝒃𝒆𝒅 𝒐𝒑𝒆𝒓𝒂𝒕𝒊𝒐𝒏
279
𝜺𝒎𝒇 = (𝟎. 𝟎𝟕𝟏
𝛙)
𝟏/𝟑
The typical ψ is 0.6
휀𝑚𝑓 = (0.071
0.6)
1/3
= 0.490948231
𝒖𝒃 = 𝒖𝒐−𝒖𝒎𝒇 + (𝟎. 𝟕𝟏)(𝒈 𝒅𝒃)𝟏/𝟐
𝑢𝑏 = 0.000465414 − (4.33𝑒 − 8) + (0.71)(9.80665 ∗ (1.40𝑒 − 7))12
= 0.001297292 𝑚/𝑠
𝒅𝒃𝒎 = 𝟎. 𝟔𝟓𝟐[𝑨𝒄(𝒖𝒐 − 𝒖𝒎𝒇)]𝟎.𝟒
𝑑𝑏𝑚 = 0.652[(1.54𝑒 − 10)(0.000465414 − (4.33𝐸 − 08)) ∗ 100]0.4
= 2.27𝑒 − 05 𝑐𝑚
𝒅𝒃𝒐 = 𝟎. 𝟎𝟎𝟑𝟕𝟔(𝒖𝒐 − 𝒖𝒎𝒇)𝟐
𝑑𝑏𝑜 = 0.00376((0.000465414 − (4.33𝐸 − 08)) ∗ 100)2 = 8.14301𝑒 − 06
𝜹 =𝒖𝒐 − 𝒖𝒎𝒇
𝒖𝒃
𝛿 =0.000465414 − (4.33𝑒 − 08)
0.001297292= 0.358724213
280
Appendix D
DISTILLATION COLUMNS CALCULATION SHEETS
CALCULATION
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 EAM ALL
MFS
TRAY VAPOR
Mole flow Mass Rate Vol Rate Density
kmol/h kmol/s kg/h kg/s m3/h kg/m3
1 18330 5.091667 1426408 396.2244 516004.5 2.764332
2 18500 5.138889 1440915 400.2542 519853 2.771774
3 18500 5.138889 1440845 400.2348 518852.8 2.776983
4 18500 5.138889 1440652 400.181 517814.2 2.782179
5 18490 5.136111 1440455 400.1265 516777.1 2.787382
6 18490 5.136111 1440258 400.0716 515741.5 2.792596
7 18480 5.133333 1440058 400.0161 514706.8 2.797822
8 18480 5.133333 1439856 399.96 513672.4 2.803063
9 18470 5.130556 1439650 399.9029 512637.2 2.808322
10 18470 5.130556 1439440 399.8444 511599.9 2.813605
11 18460 5.127778 1439222 399.784 510558.6 2.818917
12 12040 3.344444 941574.2 261.5484 332641.8 2.830595
13 12050 3.347222 942553.4 261.8204 332358.5 2.835954
14 12060 3.35 942676.9 261.8547 331801.6 2.841086
15 12060 3.35 942769.9 261.8805 331236.9 2.846211
16 12060 3.35 942861.1 261.9059 330673.4 2.851336
17 12060 3.35 942951.5 261.931 330110.5 2.856473
18 12060 3.35 943035.5 261.9543 329540.6 2.861667
19 12060 3.35 943086.7 261.9685 328929.7 2.867137
20 12040 3.344444 942890.6 261.9141 328104.8 2.873749
21 11870 3.297222 937918.6 260.5329 325842.2 2.878444
22 10460 2.905556 893579.4 248.2165 306986.9 2.910806
23 8872 2.464444 939337.1 260.927 281593.3 3.335794
24 9413 2.614722 1102676 306.299 305734.7 3.606644
25 9841 2.733611 1177582 327.1062 320596 3.673105
26 9940 2.761111 1193788 331.6078 323502 3.690203
27 9958 2.766111 1196744 332.4288 323575.7 3.698496
TRAY LIQUID
281
Mole flow Mass Rate Vol
Rate Density
Surface
Tension
kmol/
h kmol/s kg/h kg/s m3/h kg/m3 dyne/cm
1 4849 1.3469
44
37880
9.7
105.224
9
466.715
2 811.6506 20.8
2 4847 1.3463
89
37873
9.8
105.205
5
466.705
5 811.5178 20.8
3 4843 1.3452
78
37854
6.1
105.151
7
466.508
4 811.4453 20.8
4 4840 1.3444
44
37834
9.8
105.097
2
466.307
5 811.3741 20.8
5 4836 1.3433
33
37815
2.1
105.042
3
466.104
3 811.3036 20.8
6 4831 1.3419
44
37795
2.5
104.986
8
465.898
2 811.2341 20.8
7 4827 1.3408
33
37775
0.4
104.930
7
465.688
3 811.1658 20.8
8 4822 1.3394
44
37754
4.9
104.873
6
465.473
3 811.0989 20.7
9 4817 1.3380
56
37733
4.4
104.815
1
465.251
2 811.0339 20.7
10 4811 1.3363
89
37711
6.8
104.754
7
465.018
8 810.9712 20.7
11 1.21E
+04
3.3666
67
95108
4.6
264.190
2
1172.85
6 810.9133 20.7
12 1.21E
+04
3.3694
44
95206
3.8
264.462
2
1174.40
2 810.6797 20.7
13 1.21E
+04
3.3722
22
95218
7.3
264.496
5
1174.68
6 810.5885 20.7
14 1.21E
+04
3.3722
22
95228
0.4
264.522
3
1174.91
1 810.5128 20.7
15 1.21E
+04
3.3722
22
95237
1.5
264.547
6
1175.13
2 810.4378 20.7
16 1.21E
+04
3.3722
22
95246
1.9
264.572
8
1175.35
2 810.3631 20.7
17 1.21E
+04
3.3722
22
95254
5.9
264.596
1
1175.56
3 810.2895 20.6
18 1.21E
+04
3.3722
22
95259
7.1
264.610
3
1175.72
5 810.2209 20.6
19 1.21E
+04
3.3666
67
95240
1
264.555
8
1175.54
7 810.1769 20.6
20 1.20E
+04
3.3194
44
94742
9
263.174
7
1169.26
2 810.2793 20.6
21 1.05E
+04
2.9277
78
90308
9.8
250.858
3
1113.26
6 811.2073 20.5
282
22 8951 2.4863
89
94884
7.5
263.568
8
1204.50
7 787.7476 18.6
23 9492 2.6366
67
11121
87
308.940
8
1475.75
2 753.6406 16.1
24 9920 2.7555
56
11870
93 329.748
1598.41
8 742.6672 15.3
25 1.00E
+04
2.7833
33
12032
98
334.249
5
1625.00
6 740.4884 15.1
26 1.00E
+04
2.7888
89
12062
54
335.070
6
1629.94
7 740.0571 15.1
27 9844 2.7344
44
11831
50
328.652
9
1599.04
3 739.9114 15.1
FLV AND MINIMUM DIAMETER CALCULATIONS
TRA
Y FLV
1 0.015498 0.13 0.131023749 2.241293072 1.905099111
2 0.015361 0.13 0.131023749 2.238088186 1.902374958
3 0.015369 0.13 0.131023749 2.235880711 1.900498604
4 0.015379 0.13 0.131023749 2.233686444 1.898633477
5 0.015388 0.13 0.131023749 2.231496069 1.896771658
6 0.015397 0.13 0.131023749 2.229309033 1.894912678
7 0.015406 0.13 0.131023749 2.227124756 1.893056043
8 0.015414 0.13 0.130897521 2.222799031 1.889379176
9 0.015423 0.13 0.130897521 2.220620053 1.887527045
10 0.015432 0.13 0.130897521 2.218441184 1.885675006
11 0.038962 0.14 0.140966561 2.386744898 2.028733163
12 0.059748 0.12 0.120828481 2.041246954 1.735059911
13 0.059754 0.12 0.120828481 2.03919572 1.733316362
14 0.059809 0.12 0.120828481 2.037250936 1.731663295
15 0.059865 0.12 0.120828481 2.03531525 1.730017963
16 0.059922 0.12 0.120828481 2.033384669 1.728376969
17 0.059978 0.12 0.120711512 2.029489979 1.725066482
18 0.060033 0.12 0.120711512 2.027554414 1.723421252
19 0.060076 0.12 0.120711512 2.025557372 1.721723766
20 0.05984 0.12 0.120711512 2.023346131 1.719844211
21 0.057356 0.115 0.115569335 1.936679592 1.646177654
22 0.064547 0.125 0.123198835 2.022971011 1.719525359
23 0.078772 0.115 0.110117671 1.65149126 1.403767571
24 0.075022 0.11 0.104261741 1.492496605 1.268622114
25 0.071968 0.11 0.103987725 1.472803274 1.251882783
26 0.071352 0.11 0.103987725 1.468940064 1.248599055
27 0.069897 0.11 0.103987725 1.467138741 1.24706793
𝑲𝟏 𝒄𝒐𝒓𝒓𝒆𝒄𝒕𝒆𝒅 𝑲𝟏 𝒖𝒇 (𝒎 𝒔⁄ ) 𝟖𝟓% 𝑭𝒍𝒐𝒐𝒅𝒊𝒏𝒈
283
TRAY
1 157.6680381 70.34690823 79.93967 10.08872 10.2
2 158.8439865 70.97306867 80.65121 10.13352 10.3
3 158.5383449 70.90644155 80.5755 10.12877 10.3
4 158.2210005 70.83402462 80.49321 10.12359 10.3
5 157.9041107 70.76154556 80.41085 10.11841 10.3
6 157.587675 70.68902188 80.32843 10.11323 10.3
7 157.2715292 70.61639846 80.24591 10.10803 10.3
8 156.9554532 70.61162574 80.24048 10.10769 10.3
9 156.6391507 70.53847439 80.15736 10.10245 10.3
10 156.3221946 70.46488128 80.07373 10.09718 10.2
11 156.0040071 65.36266496 74.27576 9.724753 9.9
12 101.6405367 49.79335622 56.58336 8.487884 8.6
13 101.5539838 49.80099888 56.59204 8.488535 8.6
14 101.3838101 49.76500847 56.55115 8.485467 8.6
15 101.2112729 49.72756575 56.5086 8.482275 8.6
16 101.0391093 49.6901107 56.46603 8.479079 8.6
17 100.8670884 49.70070778 56.47808 8.479984 8.6
18 100.6929506 49.66226797 56.4344 8.476704 8.6
19 100.5063116 49.61908907 56.38533 8.473018 8.6
20 100.2542358 49.5487323 56.30538 8.467009 8.6
21 99.56290608 51.40907483 58.4194 8.624494 8.8
22 93.80155737 46.36821628 52.69115 8.190755 8.3
23 86.04238696 52.09981369 59.20433 8.68224 8.8
24 93.4189498 62.59240354 71.12773 9.516441 9.7
25 97.95987487 66.512532 75.58242 9.80992 10
26 98.84782498 67.29193886 76.46811 9.86723 10
27 98.87035813 67.38991711 76.57945 9.874411 10
1. Calculation of the diameter for the rectifying and stripping part of the distillation
column.
The first tray is to be considered in this calculation
𝑭𝑳𝑽 = 𝑳𝒘
𝑽𝒘 √
𝝆𝑽
𝝆𝑳
𝐹𝐿𝑉 =105.2249 𝑘𝑔/𝑠
396.2244 𝑘𝑔/𝑠∗ √
2.764332𝑘𝑔𝑚3
811.6506𝑘𝑔𝑚3
= 0.0155
Assumed plate spacing is 0.9 𝑚
𝐾1 = 0.13, which is based from figure 11.29 of Towler
𝑽𝒘 (𝒎𝟑 𝒔)⁄ 𝑨𝒏 (𝒎𝟐) 𝑨𝒅 (𝒎𝟐) 𝑫𝒄 (𝒎)
284
𝑪𝒐𝒓𝒓𝒆𝒄𝒕𝒆𝒅 𝑲𝟏 = 𝑲𝟏[𝝈 𝟎. 𝟎𝟐⁄ ]𝟎.𝟐
𝐶𝑜𝑟𝑟𝑒𝑐𝑡𝑒𝑑 𝐾1 = 0.13[20.8 0.02⁄ ]0.2 = 0.131023749
𝒖𝒇 = 𝑲𝟏 √𝝆𝑳 − 𝝆𝑽
𝝆𝑽
𝑢𝑓 = 0.131023749 √811.6506 − 2.764332
2.764332= 2.241293072 𝑚/𝑠
𝐴𝑡 85% 𝑙𝑜𝑎𝑑𝑖𝑛𝑔, 𝑢𝑓 = 2.241293072 ∗ 0.85 = 1.905099111 𝑚/𝑠
𝑽𝒘 = 𝟏. 𝟏 ∗�̇�
𝝆
𝑉𝑤 = 1.1 ∗396.2244 𝑘𝑔 𝑠⁄
𝑘𝑔 𝑚3⁄= 157.6680381 𝑚3 𝑠⁄
𝑨𝒏 =𝑽𝒘
𝒖𝒇 @ 𝟖𝟓% 𝒍𝒐𝒂𝒅𝒊𝒏𝒈
𝐴𝑛 =157.6680381
1.905099111= 70.3469082 𝑚2
𝑨𝒅 =𝑨𝒏
𝟏 − 𝟎. 𝟏𝟐
𝐴𝑑 =70.3469082
1 − 0.12= 79.94 𝑚2
𝑫𝒄 = √𝟒 𝒙 𝑨𝒅
𝝅
𝐷𝑐 = √4 ∗ 79.94
𝜋= 10.089 ≅ 10.2 𝑚
2. Plate Design
The Stripping section will be the basis of the calculation
𝐷𝑐 = 10 𝑚
𝑨𝒄 =𝝅
𝟒 𝑫𝒄
𝟐
𝐴𝑐 =𝜋
4∗ 102 = 78.53981634 𝑚2
% 𝐷𝑜𝑤𝑛𝑐𝑜𝑚𝑒𝑟 = 12%
285
𝑨𝒅 = %𝑫𝒐𝒘𝒏𝒄𝒐𝒎𝒆𝒓 ∗ 𝑨𝒄
𝐴𝑑 = 0.12 ∗ 78.53981634 = 9.424777961 𝑚2
𝑨𝒏 = 𝑨𝒄 − 𝑨𝒅
𝐴𝑛 = 78.53981634 − 9.424777961 = 69.11503838 𝑚2
𝑨𝒂 = 𝑨𝒄 − 𝟐𝑨𝒅
𝐴𝑎 = 78.53981634 − 2 ∗ 9.424777961 = 59.69026042 𝑚2
%𝐻𝑜𝑙𝑒 𝐴𝑟𝑒𝑎 = 6%
𝑨𝒉 = 𝑨𝒄 ∗ % 𝑯𝒐𝒍𝒆 𝑨𝒓𝒆𝒂
𝐴ℎ = 78.53981634 ∗ 0.06 = 4.721238898 𝑚2
𝑨𝒅
𝑨𝒄∗ 𝟏𝟎𝟎% =
59.69026042
78.53981634∗ 100 = 12%
𝑙𝑤 𝐷𝑐 = 0.76⁄ , which is based from figure 11.33 of Towler
𝒍𝒘 = 𝟎. 𝟕𝟔 ∗ 𝑫𝒄
𝑙𝑤 = 0.76 ∗ 10 = 7.6 𝑚
ℎ𝑤 is set to be 40 𝑚𝑚
3. Weeping Test
The Stripping section will be the basis of the calculation
�̇�𝒎𝒂𝒙,𝑳 = 𝟏. 𝟏 ∗ �̇�𝑳
�̇�𝑚𝑎𝑥,𝐿 = 1.1 ∗ 335.0706𝑘𝑔
𝑠= 368.5776268 𝑘𝑔/𝑠
�̇�𝒎𝒊𝒏,𝑳 = 𝟎. 𝟓 ∗ �̇�𝑳
�̇�𝒎𝒊𝒏,𝑳 = 0.5 ∗ 250.8583 = 125.4291356 𝑘𝑔/𝑠
𝐦𝐚𝐱 𝒉𝒐𝒘 = 𝟕𝟓𝟎 [𝑳𝒘
𝝆𝑳𝒍𝒘]
𝟐/𝟑
max ℎ𝑜𝑤 = 750 [368.5776268
811.2073 ∗ 7.6]
2/3
= 114.6701249 𝑚𝑚
𝒎𝒊𝒏 𝒉𝒐𝒘 = 𝟕𝟓𝟎 [𝑳𝒘
𝝆𝑳𝒍𝒘]
𝟐/𝟑
min ℎ𝑜𝑤 = 750 [114.6701249
739.9114 ∗ 7.6]
2/3
286
ℎ𝑤 + ℎ𝑜𝑤 = 40 + 59.42894361 = 99.42894361 𝑚𝑚
𝐾2 is 31, based from figure 11.32 of Towler
Hole diameter is set to be 8 𝑚𝑚
�̌�𝒉 𝒎𝒊𝒏𝒊𝒎𝒖𝒎 =𝑲𝟐 − 𝟎. 𝟗(𝟐𝟓. 𝟒 − 𝒉𝒐𝒍𝒆 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓)
𝝆𝒗𝟎.𝟓
�̌�ℎ 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 = 31 − 0.9(25.4 − 8)
3.6984960.5= 7.976507131 𝑚/𝑠
𝑈ℎ = 0.5 𝑥 𝑉𝑚𝑎𝑥𝑉
𝐴ℎ
𝐴𝑐𝑡𝑢𝑎𝑙 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑎𝑝𝑜𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 =0.5 ∗ 281593.3
2 ∗ 4.71238898 ∗ 3600= 8.299437091
𝟖. 𝟐𝟗𝟗𝟒𝟑𝟕𝟎𝟗𝟏 > 𝟕. 𝟗𝟕𝟔𝟓𝟎𝟕𝟏𝟑𝟏
𝑷𝑨𝑺𝑺𝑬𝑫
4. Pressure Drop
The Stripping section will be the basis of the calculation
Plate thickness is set to 5 𝑚𝑚
𝑴𝒂𝒙 𝑽𝒂𝒑𝒐𝒓 𝑽𝒆𝒍𝒐𝒄𝒊𝒕𝒚 =𝟏. 𝟏 ∗ 𝑸𝒎𝒂𝒙
𝑨𝒉
𝑀𝑎𝑥 𝑉𝑎𝑝𝑜𝑟 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 1.1 ∗332641.8
3600 ∗ 4.71238898= 21.56879178 𝑚/𝑠
(𝐴ℎ 𝐴𝑝⁄ ) × 100 is set to be 8%, based from figure 11.36 of Towler
𝐶𝑜 is set to be 0.83, based from figure 11.36 of Towler
𝑯𝒅 = 𝟓𝟏 𝒙 𝑴𝒂𝒙 𝑽𝒂𝒑𝒐𝒓 𝑽𝒆𝒍𝒐𝒄𝒊𝒕𝒚
𝑪𝒐𝟐
𝟐
∗𝝆𝒗
𝝆𝑳
𝐻𝑑 = 51 ∗ (21.56879178
0.83)
2
∗2.830595
739.9114= 131.753965 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝑯𝒓 =𝟏𝟐𝟓𝟎𝟎
𝝆𝑳
𝐻𝑟 =12500
739.9114= 16.89391468 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝑯𝒕 = 𝑯𝒅 + 𝑯𝒓 + (𝑯𝒘 + 𝑯𝒐𝒘)
𝐻𝑡 = 131.753965 + 16.89391468 + (40 + 114.6701249)= 303.3180046 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
287
5. Downcomer Liquid Backup
The Stripping section will be the basis of the calculation
𝑀𝑎𝑥 𝑙𝑖𝑞𝑢𝑑 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 =1629.947
3600= 0.452763128 𝑚3 𝑠⁄
𝑁𝑜 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠 = 8, due to very high liquid loading
𝒉𝒂𝒑 = 𝒉𝒘 − 𝟓
ℎ𝑎𝑝 = 40 − 5 = 35
𝑨𝒂𝒑 = (𝒉𝒂𝒑
𝟏𝟎𝟎𝟎) 𝒍𝒘
𝐴𝑎𝑝 = (35
1000) ∗ 7.6 = 0.266 𝑚2
Since 𝐴𝑎𝑝 < 𝐴𝑑:
𝒉𝒅𝒄 = 𝟏𝟔𝟔 [𝑳𝒘𝒅
𝝆𝑳𝑨𝒎]
𝟐
ℎ𝑑𝑐 = 166 ∗ [
368.57762688
739.9114 ∗ 0.266]
2
= 9.096270081 𝑚𝑚
𝒉𝒃 = (𝒉𝒘 + 𝒉𝒐𝒘) + 𝒉𝒕 + 𝒉𝒅𝒄
ℎ𝑏 = (40 + 114.6701249) + 303.3180046 + 9.096270081 = 467.0843996 𝑚𝑚
1 2⁄ (𝑝𝑙𝑎𝑡𝑒 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 + 𝑊𝑒𝑖𝑟 ℎ𝑒𝑖𝑔ℎ𝑡) = 470
𝟏 𝟐⁄ (𝒑𝒍𝒂𝒕𝒆 𝒔𝒑𝒂𝒄𝒊𝒏𝒈 + 𝑾𝒆𝒊𝒓 𝒉𝒆𝒊𝒈𝒉𝒕) > 𝒉𝒃
𝑷𝑨𝑺𝑺𝑬𝑫
𝑹𝒆𝒔𝒊𝒅𝒆𝒏𝒄𝒆 𝒕𝒊𝒎𝒆 = 𝒕𝒓 =𝑨𝒅𝒉𝒃𝒄𝝆𝑳
𝑳𝒘𝒅
𝑡𝑟 =9.424777961 ∗ 467.0843996 ∗ 739.9114
114.6701249 ∗ 1000= 28.40𝑠
𝒕𝒓 > 𝟑𝒔
𝑷𝑨𝑺𝑺𝑬𝑫
6. Entrainment
The Stripping section will be the basis of the calculation
288
𝒖𝒗 =𝟏. 𝟏 ∗ 𝑸𝒗
𝑨𝒏
𝑢𝑣 =1.1 ∗ 332641.8
69.11503838 ∗ 3600= 1.47059944 𝑚/𝑠
% 𝑭𝒍𝒐𝒐𝒅𝒊𝒏𝒈 =𝒖𝒗
𝒖𝒇∗ 𝟏𝟎𝟎
% 𝐹𝑙𝑜𝑜𝑑𝑖𝑛𝑔 =1.47059944
2.041246954∗ 100 = 72%
% 𝑭𝒍𝒐𝒐𝒅𝒊𝒏𝒈 < 𝟖𝟓
𝑷𝑨𝑺𝑺𝑬𝑫
Fractional entrainment is 0.0125, based from figure 11.31 of Towler
𝑭𝒓𝒂𝒄𝒕𝒊𝒐𝒏𝒂𝒍 𝒆𝒏𝒕𝒓𝒂𝒊𝒏𝒎𝒆𝒏𝒕 < 𝟎. 𝟏
𝑷𝑨𝑺𝑺𝑬𝑫
7. Tray Layout
The Stripping section will be the basis of the calculation
Unperforated strip and Calming Zone is bot set at 50 mm
𝐿𝑤 𝐷𝑐⁄ is 0.76, which is based from figure 11.34 of Towler
𝜃𝑐 is 98°, which is based from figure 11.34 of Towler
𝐴𝑛𝑔𝑙𝑒 𝑠𝑢𝑏𝑡𝑒𝑛𝑑𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑒𝑑𝑔𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑙𝑎𝑡𝑒 = 180 − 98 = 82
𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉, 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒆𝒅𝒈𝒆 𝒔𝒕𝒓𝒊𝒑𝒔
= (𝑫𝒄
−𝟐 ∗ 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒔𝒕𝒓𝒊𝒑
𝟏𝟎𝟎𝟎) (
𝝅 ∗ 𝑨𝒏𝒈𝒍𝒆 𝒔𝒖𝒃𝒕𝒆𝒏𝒅𝒆𝒅 𝒃𝒚 𝒕𝒉𝒆 𝒆𝒅𝒈𝒆 𝒐𝒇 𝒕𝒉𝒆 𝒑𝒍𝒂𝒕𝒆
𝟏𝟖𝟎)
𝑀𝑒𝑎𝑛 𝑙𝑒𝑛𝑔𝑡ℎ, 𝑢𝑛𝑝𝑒𝑟𝑓𝑜𝑟𝑎𝑡𝑒𝑑 𝑠𝑡𝑟𝑖𝑝𝑠 = (10 −2 ∗ 50
1000) (
𝜋 ∗ 82
180) = 14.16858287 𝑚
𝐴𝒓𝒆𝒂 𝒐𝒇 𝑼𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝑬𝒅𝒈𝒆 = 𝑾𝒆𝒊𝒓 𝑯𝒆𝒊𝒈𝒉𝒕 𝒙 𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑢𝑛𝑝𝑒𝑟𝑓𝑜𝑟𝑎𝑡𝑒𝑑 𝑠𝑡𝑟𝑖𝑝𝑠 = 0.05 ∗ 14.16858287 = 0.708429143 𝑚2
𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉 𝒐𝒇 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆 = 𝒍𝒘 + 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒔𝒕𝒓𝒊𝒑 𝒍𝒆𝒏𝒈𝒕𝒉
𝑀𝑒𝑎𝑛 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑎𝑙𝑚𝑖𝑛𝑔 𝑧𝑜𝑛𝑒 = 7.6 +50
1000= 7.65 𝑚
𝑨𝒓𝒆𝒂 𝒐𝒇 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆𝒔 = 𝟐(𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉 ∗ 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆)
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑐𝑎𝑙𝑚𝑖𝑛𝑔 𝑧𝑜𝑛𝑒𝑠 = 2 (7.65 ∗50
1000) = 0.765 𝑚2
𝑨𝒑 = 𝑨𝒂 − 𝑨𝒓𝒆𝒂 𝒐𝒇 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒔𝒕𝒓𝒊𝒑 − 𝒂𝒓𝒆𝒂 𝒐𝒇 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆
289
𝐴𝑝 = 59.69026042 − 0.708429143 − 0.765 = 58.2068327 𝑚2
𝐴ℎ
𝐴𝑝=
4.71238898
58.21683127= 0.080945474
𝑙𝑝 𝑑ℎ⁄ is 3.3, which is based from figure 11.35 of Towler
𝟐. 𝟓 < 𝟑. 𝟑 < 𝟒. 𝟎
𝑺𝑨𝑻𝑰𝑺𝑭𝑨𝑪𝑻𝑶𝑹𝒀
𝑨𝒓𝒆𝒂 𝒐𝒇 𝒐𝒏𝒆 𝒉𝒐𝒍𝒆 =𝝅
𝟒𝒉𝒐𝒍𝒆 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓𝟐
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑜𝑛𝑒 ℎ𝑜𝑙𝑒 =𝜋
4∗ (
8
1000)
2
= 5.02655𝑒 − 05
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒉𝒐𝒍𝒆𝒔 =𝑨𝒉
𝑨𝒓𝒆𝒂 𝒐𝒇 𝒐𝒏𝒆 𝒉𝒐𝒍𝒆
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 ℎ𝑜𝑙𝑒𝑠 =4.71238898
5.02655𝑒 − 05= 93750
290
CALCULATION
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 MFS ALL
EAM
TRAY
VAPOR Mole flow Mass Rate Vol Rate Density
kmol/h kmol/s kg/h kg/s m3/h kg/m3
1 96.33 0.026758 5593 1.553611 799.2007 6.998242
2 97.2 0.027 5644 1.567778 805.9617 7.002814
3 97.17 0.026992 5643 1.5675 805.3451 7.006934
4 97.04 0.026956 5639 1.566389 804.5153 7.009189
5 96.59 0.026831 5624 1.562222 802.894 7.004661
6 95.16 0.026433 5580 1.55 798.7686 6.985753
7 92.25 0.025625 5501 1.528056 790.1682 6.961808
8 89.3 0.024806 5437 1.510278 780.876 6.962693
9 87.63 0.024342 5395 1.498611 775.7699 6.954382
10 86.56 0.024044 5327 1.479722 772.2426 6.898091
11 172.7 0.047972 1.08E+04 2.988889 1552.955 6.928727
12 167.1 0.046417 1.10E+04 3.041667 1545.278 7.086104
13 158 0.043889 1.21E+04 3.35 1544.723 7.807227
14 161.9 0.044972 1.53E+04 4.255556 1667.957 9.184888
15 184.7 0.051306 1.97E+04 5.483333 1948.277 10.13203
16 202.2 0.056167 2.25E+04 6.236111 2146.496 10.4589
17 208.4 0.057889 2.34E+04 6.491667 2215.003 10.55078
18 210 0.058333 2.36E+04 6.558333 2232.074 10.57761
19 210.5 0.058472 2.37E+04 6.572222 2235.372 10.58437
20 210.5 0.058472 2.37E+04 6.575 2234.898 10.59109
21 210.3 0.058417 2.36E+04 6.563889 2232.072 10.58658
22 209.5 0.058194 2.35E+04 6.516667 2223.214 10.55229
TRAY
LIQUID
Mole flow Mass Rate Vol Rate Density Surface
Tension
kmol/h kmol/s kg/h kg/s m3/h kg/m3 dyne/cm
1 21.94 0.006094 1275 0.354167 1.847276 690.2053 15
291
2 21.91 0.006086 1273 0.353611 1.84531 689.8569 15
3 21.78 0.00605 1269 0.3525 1.838167 690.3617 15
4 21.33 0.005925 1254 0.348333 1.812396 691.9017 15
5 19.89 0.005525 1210 0.336111 1.733741 697.9129 15
6 16.99 0.004719 1132 0.314444 1.586969 713.3096 15.1
7 14.04 0.0039 1068 0.296667 1.457147 732.9392 15.3
8 12.37 0.003436 1025 0.284722 1.373964 746.0164 15.5
9 11.3 0.003139 956.9 0.265806 1.259486 759.7545 16.2
10 332.8 0.092444 2.78E+04 7.730556 35.54694 782.9085 17.5
11 3.27E+02 0.090889 2.80E+04 7.786111 35.71434 784.8389 17.5
12 3.18E+02 0.088333 2.91E+04 8.094444 37.04695 786.5695 17.4
13 3.22E+02 0.089444 3.24E+04 8.997222 41.6149 778.327 16.6
14 3.45E+02 0.095778 3.68E+04 10.225 48.31121 761.9349 15.5
15 3.62E+02 0.100639 3.95E+04 10.98056 52.54772 752.2687 14.8
16 3.69E+02 0.102361 4.04E+04 11.23333 53.99058 749.0196 14.5
17 3.70E+02 0.102806 4.07E+04 11.3 54.36786 748.2362 14.5
18 3.71E+02 0.102917 4.07E+04 11.31667 54.45887 748.0875 14.4
19 3.71E+02 0.102944 4.07E+04 11.31667 54.46241 748.0388 14.4
20 3.70E+02 0.102889 4.07E+04 11.30556 54.38167 748.414 14.4
21 3.70E+02 0.102667 4.05E+04 11.25833 54.05371 749.8098 14.4
22 365 0.101389 3.98E+04 11.04444 52.68442 754.6823 14.6
FLV AND MINIMUM DIAMETER CALCULATIONS
TRAY FLV
1 0.023 0.12 0.113290501 1.11937399 0.951467891
2 0.023 0.12 0.113290501 1.118719403 0.950911493
3 0.023 0.12 0.113290501 1.118800341 0.95098029
4 0.022 0.12 0.113290501 1.119878269 0.951896528
5 0.022 0.12 0.113290501 1.125149214 0.956376832
6 0.020 0.115 0.108714439 1.093157047 0.92918349
7 0.019 0.115 0.109000911 1.113090902 0.946127267
8 0.018 0.115 0.109284402 1.12592005 0.957032043
9 0.017 0.11 0.105460467 1.097236511 0.932651035
10 0.490 0.058 0.056471536 0.598961503 0.509117278
11 0.245 0.081 0.078865422 0.835650383 0.710302826
12 0.253 0.082 0.079747615 0.83640646 0.710945491
13 0.269 0.083 0.079963853 0.794396284 0.675236842
𝑲𝟏 𝒄𝒐𝒓𝒓𝒆𝒄𝒕𝒆𝒅 𝑲𝟏 𝒖𝒇 (𝒎 𝒔⁄ ) 𝟖𝟓% 𝑭𝒍𝒐𝒐𝒅𝒊𝒏𝒈
292
14 0.264 0.082 0.07792453 0.705444189 0.59962756
15 0.232 0.081 0.076266069 0.65271718 0.554809603
16 0.213 0.081 0.075954345 0.638267341 0.54252724
17 0.207 0.08 0.075016637 0.627264885 0.533175152
18 0.205 0.08 0.074912879 0.625527938 0.531698747
19 0.205 0.08 0.074912879 0.625304552 0.531508869
20 0.205 0.08 0.074912879 0.625262287 0.531472944
21 0.204 0.08 0.074912879 0.625988714 0.532090407
22 0.200 0.08 0.075119824 0.630820234 0.536197199
TRAY
1 0.244200229 0.218157855 0.247907 0.561823 0.7
2 0.246266085 0.22013213 0.25015 0.564359 0.7
3 0.246077669 0.219947796 0.249941 0.564123 0.7
4 0.245824113 0.219509674 0.249443 0.563561 0.7
5 0.245328716 0.21804105 0.247774 0.561672 0.7
6 0.244068169 0.223269081 0.253715 0.568366 0.7
7 0.241440298 0.216909776 0.246488 0.560213 0.7
8 0.238600992 0.211916461 0.240814 0.553727 0.7
9 0.237040792 0.216034365 0.245494 0.559082 0.7
10 0.235963019 0.393953564 0.447675 0.754981 0.9
11 0.474513969 0.567837912 0.64527 0.906413 1.1
12 0.472168228 0.564520064 0.6415 0.903761 1.1
13 0.4719986 0.594160131 0.675182 0.927183 1.1
14 0.509653591 0.722457707 0.820975 1.022398 1.2
15 0.595306779 0.912043986 1.036414 1.14874 1.3
16 0.655873927 1.027584971 1.16771 1.219334 1.4
17 0.676806438 1.078980276 1.226114 1.249455 1.4
𝑽𝒘 (𝒎𝟑 𝒔)⁄ 𝑨𝒏 (𝒎𝟐) 𝑨𝒅 (𝒎𝟐) 𝑫𝒄 (𝒎)
293
18 0.682022634 1.090315225 1.238995 1.256 1.4
19 0.683030249 1.092316131 1.241268 1.257152 1.4
20 0.682885361 1.092158243 1.241089 1.257061 1.4
21 0.682021895 1.089511487 1.238081 1.255537 1.4
22 0.679315449 1.07687644 1.223723 1.248236 1.4
1. Calculation of the diameter for the rectifying and stripping part of the distillation
column.
The first tray is to be considered in this calculation
𝑭𝑳𝑽 = 𝑳𝒘
𝑽𝒘 √
𝝆𝑽
𝝆𝑳
𝐹𝐿𝑉 =0.354167 𝑘𝑔/𝑠
1.553611 𝑘𝑔/𝑠∗ √
6.998242𝑘𝑔𝑚3
690.2053𝑘𝑔𝑚3
= 0.0229547
Assumed plate spacing is 0.9 𝑚
𝐾1 = 0.12, which is based from figure 11.29 of Towler
𝑪𝒐𝒓𝒓𝒆𝒄𝒕𝒆𝒅 𝑲𝟏 = 𝑲𝟏[𝝈 𝟎. 𝟎𝟐⁄ ]𝟎.𝟐
𝐶𝑜𝑟𝑟𝑒𝑐𝑡𝑒𝑑 𝐾1 = 0.12[20.8 0.02⁄ ]0.2 = 0.11329
𝒖𝒇 = 𝑲𝟏 √𝝆𝑳 − 𝝆𝑽
𝝆𝑽
𝑢𝑓 = 0.11329 √690.2053 − 6.998242
6.998242= 1.11937 𝑚/𝑠
𝐴𝑡 85% 𝑙𝑜𝑎𝑑𝑖𝑛𝑔, 𝑢𝑓 = 1.11937 ∗ 0.85 = 0.95147 𝑚/𝑠
𝑽𝒘 = 𝟏. 𝟏 ∗�̇�
𝝆
𝑉𝑤 = 1.1 ∗1.553611 𝑘𝑔 𝑠⁄
𝑘𝑔 𝑚3⁄= 0.22420 𝑚3 𝑠⁄
𝑨𝒏 =𝑽𝒘
𝒖𝒇 @ 𝟖𝟓% 𝒍𝒐𝒂𝒅𝒊𝒏𝒈
𝐴𝑛 =0.22420
0.95147= 0.21816 𝑚2
294
𝑨𝒅 =𝑨𝒏
𝟏 − 𝟎. 𝟏𝟐
𝐴𝑑 =0.21816
1 − 0.12= 0.247907 𝑚2
𝑫𝒄 = √𝟒 𝒙 𝑨𝒅
𝝅
𝐷𝑐 = √4 ∗ 0.247907
𝜋= 0.568123 ≅ 0.7𝑚
2. Plate Design
The Stripping section will be the basis of the calculation
𝐷𝑐 = 0.7𝑚
𝑨𝒄 =𝝅
𝟒 𝑫𝒄
𝟐
𝐴𝑐 =𝜋
4∗ 0.72 = 1.53938 𝑚2
% 𝐷𝑜𝑤𝑛𝑐𝑜𝑚𝑒𝑟 = 19%
𝑨𝒅 = %𝑫𝒐𝒘𝒏𝒄𝒐𝒎𝒆𝒓 ∗ 𝑨𝒄
𝐴𝑑 = 0.12 ∗ 1.53938 = 0.29248 𝑚2
𝑨𝒏 = 𝑨𝒄 − 𝑨𝒅
𝐴𝑛 = 1.53938 𝑚2 − 0.29248 = 1.246898𝑚2
𝑨𝒂 = 𝑨𝒄 − 𝟐𝑨𝒅
𝐴𝑎 = 1.53938 𝑚2 − 2 ∗ 0.29248 = 0.955416 𝑚2
%𝐻𝑜𝑙𝑒 𝐴𝑟𝑒𝑎 = 4%
𝑨𝒉 = 𝑨𝒄 ∗ % 𝑯𝒐𝒍𝒆 𝑨𝒓𝒆𝒂
𝐴ℎ = 1.53938 ∗ 0.04 = 0.06158 𝑚2
𝑨𝒅
𝑨𝒄∗ 𝟏𝟎𝟎% =
0.29248
1.53938∗ 100 = 19%
𝑙𝑤 𝐷𝑐 = 0.86⁄ , which is based from figure 11.33 of Towler
𝒍𝒘 = 𝟎. 𝟖𝟔 ∗ 𝑫𝒄
𝑙𝑤 = 0.86 ∗ 0.7 = 1.204 𝑚
295
ℎ𝑤 is set to be 50 𝑚𝑚
3. Weeping Test
The Stripping section will be the basis of the calculation
�̇�𝒎𝒂𝒙,𝑳 = 𝟏. 𝟏 ∗ �̇�𝑳
�̇�𝑚𝑎𝑥,𝐿 = 1.1 ∗ 335.0706𝑘𝑔
𝑠= 12.4483 𝑘𝑔/𝑠
�̇�𝒎𝒊𝒏,𝑳 = 𝟎. 𝟓 ∗ �̇�𝑳
�̇�𝒎𝒊𝒏,𝑳 = 0.5 ∗ 250.8583 = 3.89306 𝑘𝑔/𝑠
𝐦𝐚𝐱 𝒉𝒐𝒘 = 𝟕𝟓𝟎 [𝑳𝒘
𝝆𝑳𝒍𝒘]
𝟐/𝟑
max ℎ𝑜𝑤 = 750 [1.204
690.2053 ∗ 1.204 ]
2/3
= 41.7727𝑚𝑚
𝒎𝒊𝒏 𝒉𝒐𝒘 = 𝟕𝟓𝟎 [𝑳𝒘
𝝆𝑳𝒍𝒘]
𝟐/𝟑
min ℎ𝑜𝑤 = 750 [1.204
690.2053 ∗ 1.204 ]
2/3
ℎ𝑤 + ℎ𝑜𝑤 = 50 + 19.901597 = 69.9 𝑚𝑚
𝐾2 is 30.5, based from figure 11.32 of Towler
Hole diameter is set to be 4 𝑚𝑚
�̌�𝒉 𝒎𝒊𝒏𝒊𝒎𝒖𝒎 =𝑲𝟐 − 𝟎. 𝟗(𝟐𝟓. 𝟒 − 𝒉𝒐𝒍𝒆 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓)
𝝆𝒗𝟎.𝟓
�̌�ℎ 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 = 30.5 − 0.9(25.4 − 4)
6.9982420.5= 3.45379𝑚/𝑠
𝑈ℎ = 0.5 𝑥 𝑉𝑚𝑎𝑥𝑉
𝐴ℎ
𝐴𝑐𝑡𝑢𝑎𝑙 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑎𝑝𝑜𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 =0.5 ∗ 281593.3
2 ∗ 4.71238898 ∗ 3600= 3.48427
𝟑. 𝟒𝟖𝟒𝟐𝟕 > 𝟑. 𝟒𝟓𝟑𝟕𝟗
𝑷𝑨𝑺𝑺𝑬𝑫
4. Pressure Drop
The Stripping section will be the basis of the calculation
296
Plate thickness is set to 4 𝑚𝑚
𝑴𝒂𝒙 𝑽𝒂𝒑𝒐𝒓 𝑽𝒆𝒍𝒐𝒄𝒊𝒕𝒚 =𝟏. 𝟏 ∗ 𝑸𝒎𝒂𝒙
𝑨𝒉
𝑀𝑎𝑥 𝑉𝑎𝑝𝑜𝑟 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 1.1 ∗12.4483
3600 ∗ 0.06158= 11.0926 𝑚/𝑠
(𝐴ℎ 𝐴𝑝⁄ ) × 100 is set to be 6%, based from figure 11.36 of Towler
𝐶𝑜 is set to be 0.81, based from figure 11.36 of Towler
𝑯𝒅 = 𝟓𝟏 𝒙 𝑴𝒂𝒙 𝑽𝒂𝒑𝒐𝒓 𝑽𝒆𝒍𝒐𝒄𝒊𝒕𝒚
𝑪𝒐𝟐
𝟐
∗𝝆𝒗
𝝆𝑳
𝐻𝑑 = 51 ∗ (11.0926
0.81)
2
∗6.998242
690.2053= 88.5926 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝑯𝒓 =𝟏𝟐𝟓𝟎𝟎
𝝆𝑳
𝐻𝑟 =12500
690.2053= 16.710363 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝑯𝒕 = 𝑯𝒅 + 𝑯𝒓 + (𝑯𝒘 + 𝑯𝒐𝒘)
𝐻𝑡 = 88.5926 + 16.710363 + (50 + 19.901597) = 197.0757 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
5. Downcomer Liquid Backup
The Stripping section will be the basis of the calculation
𝑀𝑎𝑥 𝑙𝑖𝑞𝑢𝑑 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 =1629.947
3600= 0.452763128 𝑚3 𝑠⁄
𝑁𝑜 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠 = 8, due to very high liquid loading
𝒉𝒂𝒑 = 𝒉𝒘 − 𝟓
ℎ𝑎𝑝 = 50 − 5 = 45
𝑨𝒂𝒑 = (𝒉𝒂𝒑
𝟏𝟎𝟎𝟎) 𝒍𝒘
𝐴𝑎𝑝 = (45
1000) ∗ 1.204 = 0.04816𝑚2
Since 𝐴𝑎𝑝 < 𝐴𝑑:
𝒉𝒅𝒄 = 𝟏𝟔𝟔 [𝑳𝒘𝒅
𝝆𝑳𝑨𝒎]
𝟐
297
ℎ𝑑𝑐 = 166 ∗ [
12.44838
690.2053 ∗ 0.04816]
2
= 19.820257 𝑚𝑚
𝒉𝒃 = (𝒉𝒘 + 𝒉𝒐𝒘) + 𝒉𝒕 + 𝒉𝒅𝒄
ℎ𝑏 = (50 + 19.901597) + 197.0757 + 19.820257 = 308.6687𝑚𝑚
1 2⁄ (𝑝𝑙𝑎𝑡𝑒 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 + 𝑊𝑒𝑖𝑟 ℎ𝑒𝑖𝑔ℎ𝑡) = 470
𝟏 𝟐⁄ (𝒑𝒍𝒂𝒕𝒆 𝒔𝒑𝒂𝒄𝒊𝒏𝒈 + 𝑾𝒆𝒊𝒓 𝒉𝒆𝒊𝒈𝒉𝒕) > 𝒉𝒃
𝑷𝑨𝑺𝑺𝑬𝑫
𝑹𝒆𝒔𝒊𝒅𝒆𝒏𝒄𝒆 𝒕𝒊𝒎𝒆 = 𝒕𝒓 =𝑨𝒅𝒉𝒃𝒄𝝆𝑳
𝑳𝒘𝒅
𝑡𝑟 =0.29248 ∗ 19.820257 ∗ 690.2053
12.4483 ∗ 1000= 3.016677𝑠
𝒕𝒓 > 𝟑𝒔
𝑷𝑨𝑺𝑺𝑬𝑫
6. Entrainment
The Stripping section will be the basis of the calculation
𝒖𝒗 =𝟏. 𝟏 ∗ 𝑸𝒗
𝑨𝒏
𝑢𝑣 =1.1 ∗ 1.553611
1.246898𝑚2 ∗ 3600= 0.547783 𝑚/𝑠
% 𝑭𝒍𝒐𝒐𝒅𝒊𝒏𝒈 =𝒖𝒗
𝒖𝒇∗ 𝟏𝟎𝟎
% 𝐹𝑙𝑜𝑜𝑑𝑖𝑛𝑔 =0.547783
1.11937∗ 100 = 65%
% 𝑭𝒍𝒐𝒐𝒅𝒊𝒏𝒈 < 𝟖𝟓
𝑷𝑨𝑺𝑺𝑬𝑫
Fractional entrainment is 0.018, based from figure 11.31 of Towler
𝑭𝒓𝒂𝒄𝒕𝒊𝒐𝒏𝒂𝒍 𝒆𝒏𝒕𝒓𝒂𝒊𝒏𝒎𝒆𝒏𝒕 < 𝟎. 𝟏
𝑷𝑨𝑺𝑺𝑬𝑫
7. Tray Layout
The Stripping section will be the basis of the calculation
Unperforated strip and Calming Zone is bot set at 50 mm
𝐿𝑤 𝐷𝑐⁄ is 0.86, which is based from figure 11.34 of Towler
298
𝜃𝑐 is 118°, which is based from figure 11.34 of Towler
𝐴𝑛𝑔𝑙𝑒 𝑠𝑢𝑏𝑡𝑒𝑛𝑑𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑒𝑑𝑔𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑙𝑎𝑡𝑒 = 180 − 118 = 62
𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉, 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒆𝒅𝒈𝒆 𝒔𝒕𝒓𝒊𝒑𝒔
= (𝑫𝒄
−𝟐 ∗ 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒔𝒕𝒓𝒊𝒑
𝟏𝟎𝟎𝟎) (
𝝅 ∗ 𝑨𝒏𝒈𝒍𝒆 𝒔𝒖𝒃𝒕𝒆𝒏𝒅𝒆𝒅 𝒃𝒚 𝒕𝒉𝒆 𝒆𝒅𝒈𝒆 𝒐𝒇 𝒕𝒉𝒆 𝒑𝒍𝒂𝒕𝒆
𝟏𝟖𝟎)
𝑀𝑒𝑎𝑛 𝑙𝑒𝑛𝑔𝑡ℎ, 𝑢𝑛𝑝𝑒𝑟𝑓𝑜𝑟𝑎𝑡𝑒𝑑 𝑠𝑡𝑟𝑖𝑝𝑠 = (1.4 −2 ∗ 50
1000) (
𝜋 ∗ 62
180) = 1.406735 𝑚
𝐴𝒓𝒆𝒂 𝒐𝒇 𝑼𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝑬𝒅𝒈𝒆 = 𝑾𝒆𝒊𝒓 𝑯𝒆𝒊𝒈𝒉𝒕 𝒙 𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑢𝑛𝑝𝑒𝑟𝑓𝑜𝑟𝑎𝑡𝑒𝑑 𝑠𝑡𝑟𝑖𝑝𝑠 = 0.05 ∗ 1.406735 = 0.0703368𝑚2
𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉 𝒐𝒇 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆 = 𝒍𝒘 + 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒔𝒕𝒓𝒊𝒑 𝒍𝒆𝒏𝒈𝒕𝒉
𝑀𝑒𝑎𝑛 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑎𝑙𝑚𝑖𝑛𝑔 𝑧𝑜𝑛𝑒 = 1.204 +50
1000= 1.254 𝑚
𝑨𝒓𝒆𝒂 𝒐𝒇 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆𝒔 = 𝟐(𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉 ∗ 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆)
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑐𝑎𝑙𝑚𝑖𝑛𝑔 𝑧𝑜𝑛𝑒𝑠 = 2 (1.254 ∗50
1000) = 0.1254 𝑚2
𝑨𝒑 = 𝑨𝒂 − 𝑨𝒓𝒆𝒂 𝒐𝒇 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒔𝒕𝒓𝒊𝒑 − 𝒂𝒓𝒆𝒂 𝒐𝒇 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆
𝐴𝑝 = 0.955416 − 0.0703368 − 0.1254 = 0.758679 𝑚2
𝐴ℎ
𝐴𝑝=
0.06158
0.758679 𝑚2= 0.081161
𝑙𝑝 𝑑ℎ⁄ is 3.1, which is based from figure 11.35 of Towler
𝟐. 𝟓 < 𝟑. 𝟏 < 𝟒. 𝟎
𝑺𝑨𝑻𝑰𝑺𝑭𝑨𝑪𝑻𝑶𝑹𝒀
𝑨𝒓𝒆𝒂 𝒐𝒇 𝒐𝒏𝒆 𝒉𝒐𝒍𝒆 =𝝅
𝟒𝒉𝒐𝒍𝒆 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓𝟐
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑜𝑛𝑒 ℎ𝑜𝑙𝑒 =𝜋
4∗ (
4
1000)
2
= 1.25664𝑒 − 05
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒉𝒐𝒍𝒆𝒔 =𝑨𝒉
𝑨𝒓𝒆𝒂 𝒐𝒇 𝒐𝒏𝒆 𝒉𝒐𝒍𝒆
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 ℎ𝑜𝑙𝑒𝑠 =0.06158
1.25664𝑒 − 05= 4900
299
CALCULATION
REV DATE CREATED BY CHECKED BY APPROVED BY
1 1/2/15 MFS ALL
EAM
TRAY VAPOR
Mole flow Mass Rate Vol Rate Density
kmol/h kmol/s kg/h kg/s m3/h kg/m3
1 577.7 0.160472 68029.07 18.89696 19426.52 3.501866
2 577.3 0.160361 67994.22 18.88728 18630.87 3.649546
3 578 0.160556 68095.24 18.91535 17932.72 3.797263
4 578.6 0.160722 68202.51 18.94514 17287.34 3.945228
5 579.2 0.160889 68332.34 18.98121 16691.86 4.093752
6 579.8 0.161056 68493.52 19.02598 16141.47 4.243326
7 580.1 0.161139 68664.11 19.07336 15624.33 4.394692
8 580.1 0.161139 68850.3 19.12508 15135.73 4.548858
9 579.7 0.161028 69062.62 19.18406 14672.46 4.706954
10 578.9 0.160806 69294.75 19.24854 14229.42 4.869823
11 577.7 0.160472 69535.34 19.31537 13803.61 5.037477
12 576.2 0.160056 69765.68 19.37936 13393.9 5.208765
13 574.4 0.159556 69949.14 19.43032 12998.19 5.381451
14 572.5 0.159028 70066.96 19.46305 12618.47 5.552729
15 570.3 0.158417 70086.87 19.46858 12253.47 5.719758
16 568.1 0.157806 69995.96 19.44332 11904.11 5.879981
17 565.8 0.157167 69772.48 19.38124 11568.81 6.031087
18 563.2 0.156444 69389.88 19.27497 11245.18 6.170632
19 560.2 0.155611 68800.89 19.11136 10929 6.29526
20 556.2 0.1545 67917.21 18.86589 10613.41 6.399188
21 550.7 0.152972 66581.9 18.49497 10288.89 6.471245
22 517.3 0.143694 63531.38 17.64761 9460.717 6.715282
23 516.2 0.143389 64358.21 17.87728 9243.674 6.962406
24 515.1 0.143083 65105 18.08472 9033.46 7.207095
25 514.2 0.142833 65765.63 18.26823 8832.594 7.445789
26 513.4 0.142611 66339.64 18.42768 8641.826 7.676578
27 512.8 0.142444 66832.01 18.56445 8461.178 7.898665
28 512.4 0.142333 67254.8 18.68189 8290.901 8.111881
29 512.2 0.142278 67614.66 18.78185 8130.311 8.316368
30 512.3 0.142306 67918.56 18.86627 7978.81 8.512367
31 512.5 0.142361 68171.86 18.93663 7835.755 8.700101
32 512.9 0.142472 68379.98 18.99444 7700.711 8.879698
33 513.4 0.142611 68544.55 19.04015 7573.014 9.051158
300
34 514.1 0.142806 68667.73 19.07437 7452.289 9.214314
35 514.9 0.143028 68749.07 19.09696 7338.101 9.368783
36 515.9 0.143306 68785.15 19.10699 7229.977 9.513882
37 516.9 0.143583 68766.07 19.10169 7127.151 9.648464
38 518.1 0.143917 68679.32 19.07759 7029.238 9.770521
39 519.1 0.144194 68488.76 19.02466 6934.568 9.876428
40 519.8 0.144389 68130.68 18.92519 6840.936 9.959263
41 519.8 0.144389 67468.01 18.74111 6743.263 10.00525
42 517.9 0.143861 66224.57 18.39571 6631.836 9.985858
43 512.1 0.14225 63858.69 17.73853 6488.824 9.841335
44 499.6 0.138778 59577.27 16.54924 6296.449 9.462043
45 483.2 0.134222 53513.75 14.86493 6100.489 8.772043
46 477.6 0.132667 48610.16 13.50282 6045.466 8.040763
47 485.5 0.134861 46927.33 13.03537 6118.838 7.669322
48 493.3 0.137028 46786.9 12.99636 6154.611 7.601927
49 496.9 0.138028 46869.59 13.01933 6124.889 7.652317
50 498.6 0.1385 46954.53 13.04293 6068.412 7.737532
51 499.7 0.138806 47035.15 13.06532 6005.085 7.832554
52 500.6 0.139056 47114.38 13.08733 5941.014 7.93036
53 501.4 0.139278 47193.01 13.10917 5877.868 8.028934
54 502.3 0.139528 47271.19 13.13089 5816.08 8.127672
55 503.1 0.13975 47349.03 13.15251 5755.739 8.226403
TRAY
LIQUID
Mole flow Mass Rate Vol Rate Density Surface
Tension
kmol/h kmol/s kg/h kg/s m3/h kg/m3 dyne/cm
1 492.4 0.136778 57989.95 16.10832 76.61432 756.9074 17.4
2 493.1 0.136972 58090.97 16.13638 76.92985 755.1161 19
3 493.7 0.137139 58198.23 16.16618 77.24954 753.3797 22.5
4 494.3 0.137306 58328.06 16.20224 77.5818 751.8266 29.8
5 494.9 0.137472 58489.24 16.24701 77.91597 750.6708 43.5
6 495.2 0.137556 58659.83 16.2944 78.18978 750.2237 67.5
7 495.1 0.137528 58846.03 16.34612 78.37033 750.8713 106
8 494.8 0.137444 59058.34 16.40509 78.4317 752.9907 164
9 494 0.137222 59290.48 16.46958 78.34191 756.8168 241
10 492.8 0.136889 59531.06 16.53641 78.09256 762.3141 337
11 4.91E+02 0.136472 59761.4 16.60039 77.69905 769.1394 443
12 4.90E+02 0.135972 59944.86 16.65135 77.17555 776.7338 552
13 4.88E+02 0.135417 60062.69 16.68408 76.56319 784.4852 654
301
14 4.85E+02 0.134833 60082.6 16.68961 75.87267 791.8872 744
15 4.83E+02 0.134222 59991.68 16.66436 75.11872 798.625 816
16 4.81E+02 0.133583 59768.2 16.60228 74.28265 804.6052 868
17 4.78E+02 0.132861 59385.6 16.496 73.32044 809.9461 901
18 4.75E+02 0.132 58796.61 16.33239 72.14571 814.9703 916
19 4.71E+02 0.130917 57912.93 16.08693 70.6062 820.2244 911
20 4.66E+02 0.129361 56577.63 15.71601 68.45231 826.5261 884
21 5.92E+02 0.164556 70602.5 19.61181 84.5613 834.9268 824
22 591.3 0.16425 71429.33 19.84148 84.25948 847.7305 985
23 590.2 0.163944 72176.12 20.04892 83.96778 859.5692 1.13E+03
24 589.3 0.163694 72836.75 20.23243 83.71539 870.0521 1.26E+03
25 5.89E+02 0.163472 73410.77 20.39188 83.51417 879.0217 1.37E+03
26 5.88E+02 0.163306 73903.13 20.52865 83.36783 886.4706 1.46E+03
27 587.5 0.163194 74325.93 20.64609 83.28101 892.4715 1.53E+03
28 587.4 0.163167 74685.78 20.74605 83.24952 897.1317 1.59E+03
29 587.4 0.163167 74989.68 20.83047 83.26963 900.5646 1.63E+03
30 587.6 0.163222 75242.98 20.90083 83.33702 902.8758 1.66E+03
31 588 0.163333 75451.1 20.95864 83.44922 904.1559 1.68E+03
32 588.5 0.163472 75615.67 21.00435 83.60139 904.4786 1.69E+03
33 589.2 0.163667 75738.85 21.03857 83.79104 903.9015 1.69E+03
34 590.1 0.163917 75820.19 21.06117 84.01419 902.4689 1.67E+03
35 591 0.164167 75856.27 21.07119 84.26458 900.2154 1.65E+03
36 592.1 0.164472 75837.19 21.06589 84.529 897.1736 1.62E+03
37 593.2 0.164778 75750.44 21.04179 84.79026 893.3862 1.58E+03
38 594.2 0.165056 75559.89 20.98886 85.00098 888.9295 1.53E+03
39 595 0.165278 75201.81 20.88939 85.07374 883.9603 1.46E+03
40 594.9 0.16525 74539.13 20.70531 84.81858 878.8066 1.38E+03
41 593 0.164722 73295.69 20.35991 83.85035 874.125 1.27E+03
42 587.2 0.163111 70929.82 19.70273 81.42911 871.0621 1.12E+03
43 574.8 0.159667 66648.39 18.51344 76.53283 870.8472 888
44 558.3 0.155083 60584.88 16.82913 69.45836 872.2474 560
45 552.7 0.153528 55681.28 15.46702 63.95781 870.5939 239
46 560.6 0.155722 53998.46 14.99957 62.30325 866.7037 77.7
47 568.4 0.157889 53858.02 14.96056 62.30435 864.4344 31.1
48 572 0.158889 53940.71 14.98353 62.46854 863.486 20.6
49 573.7 0.159361 54025.65 15.00713 62.61684 862.7975 18.4
50 574.8 0.159667 54106.27 15.02952 62.76265 862.0776 17.8
51 575.7 0.159917 54185.5 15.05153 62.90914 861.3296 17.7
52 576.6 0.160167 54264.13 15.07337 63.0583 860.5392 17.6
53 577.4 0.160389 54342.31 15.09509 63.20683 859.7538 17.5
54 578.2 0.160611 54420.15 15.11671 63.35389 858.9867 17.5
302
55 577.7 0.160472 54370.04 15.10279 63.35391 858.1955 17.4
FLV AND MINIMUM DIAMETER CALCULATIONS
TRAY FLV
1 0.058 0.08 0.077802551 1.141191479 0.970012757
2 0.059 0.08 0.079183503 1.136240194 0.965804165
3 0.061 0.08 0.0819069 1.150786712 0.978168705
4 0.062 0.079 0.085558733 1.177998341 1.00129859
5 0.063 0.079 0.092282413 1.246222173 1.059288847
6 0.064 0.079 0.100758536 1.335956563 1.135563078
7 0.066 0.079 0.11027632 1.437229608 1.221645167
8 0.067 0.078 0.118811198 1.524000834 1.295400709
9 0.068 0.078 0.128319309 1.622044109 1.378737493
10 0.069 0.078 0.137219105 1.711328391 1.454629132
11 0.070 0.078 0.14493369 1.785001076 1.517250915
12 0.070 0.078 0.15145249 1.843249113 1.566761746
13 0.071 0.078 0.156676605 1.885176832 1.602400307
14 0.072 0.078 0.160769326 1.913170082 1.626194569
15 0.072 0.078 0.163767091 1.928183864 1.638956284
16 0.073 0.077 0.163677382 1.907653032 1.621505077
17 0.073 0.077 0.164903428 1.903868437 1.618288171
18 0.074 0.077 0.165448876 1.894172251 1.610046413
19 0.074 0.077 0.165267859 1.879208042 1.597326836
20 0.073 0.077 0.164276401 1.859744525 1.580782846
21 0.093 0.076 0.159879594 1.80897986 1.537632881
22 0.10 0.1 0.218012426 2.439782224 2.073814891
23 0.10 0.1 0.224083402 2.479730186 2.107770658
24 0.10 0.1 0.229017205 2.505845993 2.129969094
25 0.10 0.1 0.232883175 2.519621757 2.141678493
26 0.10 0.1 0.235865582 2.523621899 2.145078614
27 0.10 0.1 0.238085138 2.519545708 2.141613852
28 0.11 0.098 0.235125375 2.461469283 2.09224889
29 0.11 0.098 0.236296668 2.447561394 2.080427185
30 0.11 0.098 0.237160138 2.43093614 2.066295719
31 0.11 0.098 0.237728874 2.411803198 2.050032719
32 0.11 0.098 0.238011213 2.390314803 2.031767583
33 0.11 0.098 0.238011213 2.366576523 2.011590045
34 0.11 0.098 0.237445187 2.337865273 1.987185482
𝑲𝟏 𝒄𝒐𝒓𝒓𝒆𝒄𝒕𝒆𝒅 𝑲𝟏 𝒖𝒇 (𝒎 𝒔⁄ ) 𝟖𝟓% 𝑭𝒍𝒐𝒐𝒅𝒊𝒏𝒈
303
35 0.11 0.098 0.236873712 2.309812591 1.963340702
36 0.11 0.098 0.236006019 2.279646292 1.937699348
37 0.11 0.098 0.234828873 2.247419235 1.91030635
38 0.12 0.097 0.230942584 2.190679651 1.862077704
39 0.12 0.097 0.228789614 2.15235003 1.829497526
40 0.12 0.097 0.226225498 2.113000914 1.796050777
41 0.12 0.097 0.222498188 2.067757222 1.757593639
42 0.11 0.098 0.219211675 2.03559698 1.730257433
43 0.11 0.098 0.209267926 1.957396007 1.663786606
44 0.11 0.098 0.190834847 1.822286311 1.548943364
45 0.10 0.1 0.164237975 1.627915784 1.383728416
46 0.11 0.098 0.128559531 1.328516683 1.129239181
47 0.11 0.098 0.107046422 1.131421859 0.96170858
48 0.11 0.098 0.098581068 1.046017957 0.889115264
49 0.11 0.098 0.096379272 1.018842628 0.866016234
50 0.11 0.098 0.095742349 1.006046898 0.855139863
51 0.11 0.098 0.09563453 0.998306859 0.848560831
52 0.11 0.098 0.095526224 0.990492196 0.841918367
53 0.11 0.098 0.095417424 0.982762126 0.835347807
54 0.11 0.098 0.095417424 0.976277754 0.829836091
55 0.11 0.098 0.095308125 0.968783015 0.823465563
TRAY
1 157.6680381 70.34690823 79.93967 10.08872 10.2
2 158.8439865 70.97306867 80.65121 10.13352 10.3
3 158.5383449 70.90644155 80.5755 10.12877 10.3
4 158.2210005 70.83402462 80.49321 10.12359 10.3
5 157.9041107 70.76154556 80.41085 10.11841 10.3
6 157.587675 70.68902188 80.32843 10.11323 10.3
7 157.2715292 70.61639846 80.24591 10.10803 10.3
8 156.9554532 70.61162574 80.24048 10.10769 10.3
9 156.6391507 70.53847439 80.15736 10.10245 10.3
10 156.3221946 70.46488128 80.07373 10.09718 10.2
11 156.0040071 65.36266496 74.27576 9.724753 9.9
12 101.6405367 49.79335622 56.58336 8.487884 8.6
13 101.5539838 49.80099888 56.59204 8.488535 8.6
𝑽𝒘 (𝒎𝟑 𝒔)⁄ 𝑨𝒏 (𝒎𝟐) 𝑨𝒅 (𝒎𝟐) 𝑫𝒄 (𝒎)
304
14 101.3838101 49.76500847 56.55115 8.485467 8.6
15 101.2112729 49.72756575 56.5086 8.482275 8.6
16 101.0391093 49.6901107 56.46603 8.479079 8.6
17 100.8670884 49.70070778 56.47808 8.479984 8.6
18 100.6929506 49.66226797 56.4344 8.476704 8.6
19 100.5063116 49.61908907 56.38533 8.473018 8.6
20 100.2542358 49.5487323 56.30538 8.467009 8.6
21 99.56290608 51.40907483 58.4194 8.624494 8.8
22 93.80155737 46.36821628 52.69115 8.190755 8.3
23 86.04238696 52.09981369 59.20433 8.68224 8.8
24 93.4189498 62.59240354 71.12773 9.516441 9.7
25 97.95987487 66.512532 75.58242 9.80992 10
26 98.84782498 67.29193886 76.46811 9.86723 10
27 98.87035813 67.38991711 76.57945 9.874411 10
8. Calculation of the diameter for the rectifying and stripping part of the distillation
column.
The first tray is to be considered in this calculation
𝑭𝑳𝑽 = 𝑳𝒘
𝑽𝒘 √
𝝆𝑽
𝝆𝑳
𝐹𝐿𝑉 =16.10832 𝑘𝑔/𝑠
18.89696 𝑘𝑔/𝑠∗ √
3.501866𝑘𝑔𝑚3
756.9074𝑘𝑔𝑚3
= 0.05798
Assumed plate spacing is 0.6 𝑚
𝐾1 = 0.08, which is based from figure 11.29 of Towler
𝑪𝒐𝒓𝒓𝒆𝒄𝒕𝒆𝒅 𝑲𝟏 = 𝑲𝟏[𝝈 𝟎. 𝟎𝟐⁄ ]𝟎.𝟐
𝐶𝑜𝑟𝑟𝑒𝑐𝑡𝑒𝑑 𝐾1 = 0.08[20.8 0.02⁄ ]0.2 = 0.077802
𝒖𝒇 = 𝑲𝟏 √𝝆𝑳 − 𝝆𝑽
𝝆𝑽
𝑢𝑓 = 0.077802√756.9074 − 3.501866
3.501866= 1.14119𝑚/𝑠
𝐴𝑡 85% 𝑙𝑜𝑎𝑑𝑖𝑛𝑔, 𝑢𝑓 = 1.14119 ∗ 0.85 = 0.970012 𝑚/𝑠
𝑽𝒘 = 𝟏. 𝟏 ∗�̇�
𝝆
305
𝑉𝑤 = 1.1 ∗18.89696 𝑘𝑔 𝑠⁄
3.501866 𝑘𝑔 𝑚3⁄= 3.9358799 𝑚3 𝑠⁄
𝑨𝒏 =𝑽𝒘
𝒖𝒇 @ 𝟖𝟓% 𝒍𝒐𝒂𝒅𝒊𝒏𝒈
𝐴𝑛 =3.9358799
0.970012= 2.06119894 𝑚2
𝑨𝒅 =𝑨𝒏
𝟏 − 𝟎. 𝟏𝟐
𝐴𝑑 =5.201478
1 − 0.12= 5.91077 𝑚2
𝑫𝒄 = √𝟒 𝒙 𝑨𝒅
𝝅
𝐷𝑐 = √4 ∗ 5.91077
𝜋= 2.743324 ≅ 2.9 𝑚
9. Plate Design
The Stripping section will be the basis of the calculation
𝐷𝑐 = 2.9 𝑚
𝑨𝒄 =𝝅
𝟒 𝑫𝒄
𝟐
𝐴𝑐 =𝜋
4∗ 2.92 = 2.54469 𝑚2
% 𝐷𝑜𝑤𝑛𝑐𝑜𝑚𝑒𝑟 = 19%
𝑨𝒅 = %𝑫𝒐𝒘𝒏𝒄𝒐𝒎𝒆𝒓 ∗ 𝑨𝒄
𝐴𝑑 = 0.19 ∗ 2.54469 = 9.424777961 𝑚2
𝑨𝒏 = 𝑨𝒄 − 𝑨𝒅
𝐴𝑛 = 78.53981634 − 9.424777961 = 0.43491 𝑚2
𝑨𝒂 = 𝑨𝒄 − 𝟐𝑨𝒅
𝐴𝑎 = 2.54469 − 2 ∗ 9.424777961 = 1.5777078 𝑚2
%𝐻𝑜𝑙𝑒 𝐴𝑟𝑒𝑎 = 10%
𝑨𝒉 = 𝑨𝒄 ∗ % 𝑯𝒐𝒍𝒆 𝑨𝒓𝒆𝒂
𝐴ℎ = 2.54469 ∗ 0.1 = 0.254469 𝑚2
306
𝑨𝒅
𝑨𝒄∗ 𝟏𝟎𝟎% =
9.424777961
2.54469∗ 100 = 19%
𝑙𝑤 𝐷𝑐 = 0.85⁄ , which is based from figure 11.33 of Towler
𝒍𝒘 = 𝟎. 𝟖𝟓 ∗ 𝑫𝒄
𝑙𝑤 = 0.85 ∗ 2.9 = 1.53 𝑚
ℎ𝑤 is set to be 38 𝑚𝑚
10. Weeping Test
The Stripping section will be the basis of the calculation
�̇�𝒎𝒂𝒙,𝑳 = 𝟏. 𝟏 ∗ �̇�𝑳
�̇�𝑚𝑎𝑥,𝐿 = 1.1 ∗ 16.10832𝑘𝑔
𝑠= 23.17830 𝑘𝑔/𝑠
�̇�𝒎𝒊𝒏,𝑳 = 𝟎. 𝟓 ∗ �̇�𝑳
�̇�𝒎𝒊𝒏,𝑳 = 0.5 ∗ 16.10832 = 7.48028 𝑘𝑔/𝑠
𝐦𝐚𝐱 𝒉𝒐𝒘 = 𝟕𝟓𝟎 [𝑳𝒘
𝝆𝑳𝒍𝒘]
𝟐/𝟑
max ℎ𝑜𝑤 = 750 [16.10832
756.9074 ∗ 7.6]
2/3
= 114.6701249 𝑚𝑚
𝒎𝒊𝒏 𝒉𝒐𝒘 = 𝟕𝟓𝟎 [𝑳𝒘
𝝆𝑳𝒍𝒘]
𝟐/𝟑
min ℎ𝑜𝑤 = 750 [16.10832
756.9074 ∗ 7.6]
2/3
ℎ𝑤 + ℎ𝑜𝑤 = 38 + 24.36576 = 62.36576𝑚𝑚
𝐾2 is 30.2 , based from figure 11.32 of Towler
Hole diameter is set to be 3 𝑚𝑚
�̌�𝒉 𝒎𝒊𝒏𝒊𝒎𝒖𝒎 =𝑲𝟐 − 𝟎. 𝟗(𝟐𝟓. 𝟒 − 𝒉𝒐𝒍𝒆 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓)
𝝆𝒗𝟎.𝟓
�̌�ℎ 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 = 30.2 − 0.9(25.4 − 3)
3.5018660.5= 3.17409 𝑚/𝑠
𝑈ℎ = 0.5 𝑥 𝑉𝑚𝑎𝑥𝑉
𝐴ℎ
307
𝐴𝑐𝑡𝑢𝑎𝑙 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑎𝑝𝑜𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 =0.5 ∗ 281593.3
2 ∗ 0.254469 ∗ 3600= 3.1744096
𝟑. 𝟏𝟕𝟒𝟒𝟎𝟗𝟔 > 𝟑. 𝟏𝟕𝟒𝟎𝟗
𝑷𝑨𝑺𝑺𝑬𝑫
11. Pressure Drop
The Stripping section will be the basis of the calculation
Plate thickness is set to 3 𝑚𝑚
𝑴𝒂𝒙 𝑽𝒂𝒑𝒐𝒓 𝑽𝒆𝒍𝒐𝒄𝒊𝒕𝒚 =𝟏. 𝟏 ∗ 𝑸𝒎𝒂𝒙
𝑨𝒉
𝑀𝑎𝑥 𝑉𝑎𝑝𝑜𝑟 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 1.1 ∗16.10832
3600 ∗ 0.254469= 12.35446 𝑚/𝑠
(𝐴ℎ 𝐴𝑝⁄ ) × 100 is set to be16%, based from figure 11.36 of Towler
𝐶𝑜 is set to be 0.9, based from figure 11.36 of Towler
𝑯𝒅 = 𝟓𝟏 𝒙 𝑴𝒂𝒙 𝑽𝒂𝒑𝒐𝒓 𝑽𝒆𝒍𝒐𝒄𝒊𝒕𝒚
𝑪𝒐𝟐
𝟐
∗𝝆𝒗
𝝆𝑳
𝐻𝑑 = 51 ∗ (12.35446
0.9)
2
∗3.501866
756.9074= 74.485526 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝑯𝒓 =𝟏𝟐𝟓𝟎𝟎
𝝆𝑳
𝐻𝑟 =12500
756.9074= 14.971371 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝑯𝒕 = 𝑯𝒅 + 𝑯𝒓 + (𝑯𝒘 + 𝑯𝒐𝒘)
𝐻𝑡 = 74.485526 + 14.971371 + (38 + 24.36576) = 176.5540 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
12. Downcomer Liquid Backup
The Stripping section will be the basis of the calculation
𝑀𝑎𝑥 𝑙𝑖𝑞𝑢𝑑 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 =1629.947
3600= 0.02363 𝑚3 𝑠⁄
𝑁𝑜 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠 = 1, due to very high liquid loading
𝒉𝒂𝒑 = 𝒉𝒘 − 𝟓
ℎ𝑎𝑝 = 38 − 5 = 33
308
𝑨𝒂𝒑 = (𝒉𝒂𝒑
𝟏𝟎𝟎𝟎) 𝒍𝒘
𝐴𝑎𝑝 = (33
1000) ∗ 1.53 = 0.05049 𝑚2
Since 𝐴𝑎𝑝 < 𝐴𝑑:
𝒉𝒅𝒄 = 𝟏𝟔𝟔 [𝑳𝒘𝒅
𝝆𝑳𝑨𝒎]
𝟐
ℎ𝑑𝑐 = 166 ∗ [
368.57762688
756.9074 ∗ 0.43491 ]
2
= 50.18383 𝑚𝑚
𝒉𝒃 = (𝒉𝒘 + 𝒉𝒐𝒘) + 𝒉𝒕 + 𝒉𝒅𝒄
ℎ𝑏 = (38 + 24.36576) + 176.5540 + 50.183839471 = 313.834𝑚𝑚
1 2⁄ (𝑝𝑙𝑎𝑡𝑒 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 + 𝑊𝑒𝑖𝑟 ℎ𝑒𝑖𝑔ℎ𝑡) = 319
𝟏 𝟐⁄ (𝒑𝒍𝒂𝒕𝒆 𝒔𝒑𝒂𝒄𝒊𝒏𝒈 + 𝑾𝒆𝒊𝒓 𝒉𝒆𝒊𝒈𝒉𝒕) > 𝒉𝒃
𝑷𝑨𝑺𝑺𝑬𝑫
𝑹𝒆𝒔𝒊𝒅𝒆𝒏𝒄𝒆 𝒕𝒊𝒎𝒆 = 𝒕𝒓 =𝑨𝒅𝒉𝒃𝒄𝝆𝑳
𝑳𝒘𝒅
𝑡𝑟 =9.424777961 ∗ 50.183839471 ∗ 756.9074
9.424777961 ∗ 1000= 3.08𝑠
𝒕𝒓 > 𝟑𝒔
𝑷𝑨𝑺𝑺𝑬𝑫
13. Entrainment
The Stripping section will be the basis of the calculation
𝒖𝒗 =𝟏. 𝟏 ∗ 𝑸𝒗
𝑨𝒏
𝑢𝑣 =1.1 ∗ 18.89696
2.06119894 ∗ 3600= 1.52524 𝑚/𝑠
% 𝑭𝒍𝒐𝒐𝒅𝒊𝒏𝒈 =𝒖𝒗
𝒖𝒇∗ 𝟏𝟎𝟎
% 𝐹𝑙𝑜𝑜𝑑𝑖𝑛𝑔 =1.52524
1.14119∗ 100 = 60%
% 𝑭𝒍𝒐𝒐𝒅𝒊𝒏𝒈 < 𝟖𝟓
𝑷𝑨𝑺𝑺𝑬𝑫
309
Fractional entrainment is 0.015, based from figure 11.31 of Towler
𝑭𝒓𝒂𝒄𝒕𝒊𝒐𝒏𝒂𝒍 𝒆𝒏𝒕𝒓𝒂𝒊𝒏𝒎𝒆𝒏𝒕 < 𝟎. 𝟏
𝑷𝑨𝑺𝑺𝑬𝑫
14. Tray Layout
The Stripping section will be the basis of the calculation
Unperforated strip and Calming Zone is bot set at 50 mm
𝐿𝑤 𝐷𝑐⁄ is 0.85, which is based from figure 11.34 of Towler
𝜃𝑐 is 97°, which is based from figure 11.34 of Towler
𝐴𝑛𝑔𝑙𝑒 𝑠𝑢𝑏𝑡𝑒𝑛𝑑𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑒𝑑𝑔𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑙𝑎𝑡𝑒 = 180 − 97 = 83
𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉, 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒆𝒅𝒈𝒆 𝒔𝒕𝒓𝒊𝒑𝒔
= (𝑫𝒄
−𝟐 ∗ 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒔𝒕𝒓𝒊𝒑
𝟏𝟎𝟎𝟎) (
𝝅 ∗ 𝑨𝒏𝒈𝒍𝒆 𝒔𝒖𝒃𝒕𝒆𝒏𝒅𝒆𝒅 𝒃𝒚 𝒕𝒉𝒆 𝒆𝒅𝒈𝒆 𝒐𝒇 𝒕𝒉𝒆 𝒑𝒍𝒂𝒕𝒆
𝟏𝟖𝟎)
𝑀𝑒𝑎𝑛 𝑙𝑒𝑛𝑔𝑡ℎ, 𝑢𝑛𝑝𝑒𝑟𝑓𝑜𝑟𝑎𝑡𝑒𝑑 𝑠𝑡𝑟𝑖𝑝𝑠 = (10 −2 ∗ 50
1000) (
𝜋 ∗ 83
180) = 2.46265𝑚
𝐴𝒓𝒆𝒂 𝒐𝒇 𝑼𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝑬𝒅𝒈𝒆 = 𝑾𝒆𝒊𝒓 𝑯𝒆𝒊𝒈𝒉𝒕 𝒙 𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑢𝑛𝑝𝑒𝑟𝑓𝑜𝑟𝑎𝑡𝑒𝑑 𝑠𝑡𝑟𝑖𝑝𝑠 = 0.05 ∗ 2.46265 = 0.123132 𝑚2
𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉 𝒐𝒇 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆 = 𝒍𝒘 + 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒔𝒕𝒓𝒊𝒑 𝒍𝒆𝒏𝒈𝒕𝒉
𝑀𝑒𝑎𝑛 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑎𝑙𝑚𝑖𝑛𝑔 𝑧𝑜𝑛𝑒 = 1.53 +50
1000= 1.58 𝑚
𝑨𝒓𝒆𝒂 𝒐𝒇 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆𝒔 = 𝟐(𝑴𝒆𝒂𝒏 𝒍𝒆𝒏𝒈𝒕𝒉 ∗ 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆)
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑐𝑎𝑙𝑚𝑖𝑛𝑔 𝑧𝑜𝑛𝑒𝑠 = 2 (1.53 ∗50
1000) = 0.158 𝑚2
𝑨𝒑 = 𝑨𝒂 − 𝑨𝒓𝒆𝒂 𝒐𝒇 𝒖𝒏𝒑𝒆𝒓𝒇𝒐𝒓𝒂𝒕𝒆𝒅 𝒔𝒕𝒓𝒊𝒑 − 𝒂𝒓𝒆𝒂 𝒐𝒇 𝒄𝒂𝒍𝒎𝒊𝒏𝒈 𝒛𝒐𝒏𝒆
𝐴𝑝 = 1.577707 − 0.123132 − 0.158 = 1.29657 𝑚2
𝐴ℎ
𝐴𝑝=
0.254469
1.29657= 0.196262
𝑙𝑝 𝑑ℎ⁄ is 2.6, which is based from figure 11.35 of Towler
𝟐. 𝟓 < 𝟐. 𝟔 < 𝟒. 𝟎
𝑺𝑨𝑻𝑰𝑺𝑭𝑨𝑪𝑻𝑶𝑹𝒀
𝑨𝒓𝒆𝒂 𝒐𝒇 𝒐𝒏𝒆 𝒉𝒐𝒍𝒆 =𝝅
𝟒𝒉𝒐𝒍𝒆 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓𝟐
310
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑜𝑛𝑒 ℎ𝑜𝑙𝑒 =𝜋
4∗ (
3
1000)
2
= 7.06858𝑒 − 05
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒉𝒐𝒍𝒆𝒔 =𝑨𝒉
𝑨𝒓𝒆𝒂 𝒐𝒇 𝒐𝒏𝒆 𝒉𝒐𝒍𝒆
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 ℎ𝑜𝑙𝑒𝑠 =0.254469
7.06858𝑒 − 05= 36000
311
Appendix E
Wage and Monetary Benefits Breakdown
See attached A3 document.
312
Appendix F
Attached A3 documents
Process Flow Diagram
Piping and Instrumentations Diagram
Plot Plan
Phases of the Project
vii
List of Tables
Table Number Title Page
1 Import data for phenols in the Philippines 3
2 Import data for acetone in the Philippines 4
3 Value of output of industries that uses phenol 6
4 Assumed phenol consumption in 2009 and 2010 6
5 Percent increase in phenol consumption based on
39% per annum growth rate 10
6 Value of output of industries that uses acetone 11
7 Assumed acetone consumption in 2009 and 2010 12
8 Increase in acetone consumption based on 39%
per annum growth rate 14
9 Recent phenol capacities/expansions and active
phenol projects 19
10 Paint Manufacturers in the Philippines 23
11 Plastic product manufacturer in the Philippines 24
12 Resins Manufacturer in the Philippines 28
13 Import and Export Data of Propylene and Benzene 29
14 List of Suppliers of raw materials in the Philippines 29
15 SWOT/TOWS Matrix 30
16 Projected phenol and acetone capacity of the
proposed plant 32
17 Process cost correlation constants for the plant 34
18 Cost of the two processes at lower capacity 34
19 Capacity of plant obtained through stoichiometric
ratio and proportion method 35
20 Cost of the actual plant at year 2006 35
21 CE cost index up to year 2017 through
extrapolation 35
22 ICIS Indicative price of raw materials and products 36
23 Preliminary Total Capital Expenditures of the Plant 36
24 Preliminary Project Cash Flow and IRR 37
25 General Information of the Geography of
Hermosa, Bataan 42
26 Electric charge of PENELCO 43
27 List of Airport near Hermosa Bataan 44
28 List of Ports near Hermosa Bataan 44
29 Prices of Balanga Water District Services 45
30 Internet / Landline Rates 46
31 DOLE labor price in Region 3 47
32 Information on catalyst used for alkylation and
transalkylation reactions 51
33 Kinetics of alkylation and transalkylation reactions
(E is in kJ/kmol, rate of reaction is in kmol/m^3∙s,
and concentration is in kmol/m^3) 52
34 Catalyst for Oxidation Data 53
35 Cumene oxidation reaction details 54
36 Optimum operation conditions and Reaction kinetics
of Catalytic Decomposition Process of Cumene
Hydroperoxide 56
37 Catalyst for Cleaving Reaction Data 56
38 Comparison of cost of production of phenol
and acetone 57
39 Data for the component list of the main process in
Aspen Hysys 59
40 Data for the component list of the steam gen utility in
Aspen Hysys 59
41 Data for the component list of the cooling water system
utility in Aspen Hysys 60
42 Material Streams of the Process 60
43 Composition of each streams for the process 61
44 Energy streams of the process 64
45 Cooling Water Requirement of the Plant 65
46 Steam requirement of the plant 65
47 Fuel requirement of the plant 65
48 Fixed capital investment of the plant 141
49 Purchase Equipment Cost for Common
Plant Equipment 142
50 Typical Installation Factor for Project
Fixed Capital Cost 144
51 Calculation Procedure for Production Cost 147
52 Purchase Cost of Atmospheric Vessels 149
53 Final Cost of Atmosphere Vessel 149
54 Shell Mass of Pressure Vessels 150
55 Purchase Cost of Pressure Vessels 150
56 Final Cost of Pressure Vessels 150
57 Purchase Cost of Trays for Distillation Columns 151
58 Shell mass of Distillation Columns 151
59 Purchase Cost of Pressure Vessels for
Distillation Columns 152
60 Final Cost of Distillation Columns 152
61 Purchase Cost of Fluidized Bed Reactors 153
62 Purchase Cost of Packed Bed Reactors 153
63 Final Cost of Reactors 153
64 Cost of Heat Exchangers generated from Aspen
Hysys V8.0 154
65 Final Cost of Heat Exchangers 154
66 Purchase Cost of Pipes 155
67 Final Cost of Pipe 156
68 Purchase Cost of Pumps 157
69 Final Cost of Pumps 157
70 Purchase Cost of Compressor 158
71 Final Cost of Compressor 158
72 Purchase Cost of Boiler 159
73 Final Cost of Boiler 159
74 Purchase Cost of Furnace 160
75 Final Cost of Furnace 160
76 Purchase Cost of Scrubber 161
77 Final Cost of Scrubber 161
78 Purchase Cost of Cooling Tower 162
79 Final Cost of Cooling Tower 162
80 Existing Activated Sludge Waste Water Treatment
Plant in the Philippines 163
81 Capital Cost of WWTP of Phace Philippines
Corporation 163
82 Depreciation schedule of the plant (values in
Philippine Peso) 165
83 Land facts about Hermosa Ecozone
Industrial Park (HEIP) 166
84 Cost of Land lease annually 167
85 Fixed Capital Cost of the Plant 168
86 Annual insurance cost of the company 169
87 Cost calculation basis for raw materials 169
88 Annual cost of propylene 170
89 Annual cost of benzene 171
90 Amount and Pricing of Catalyst Used for
each Reactor 172
91 Final Cost of Catalyst for each Reactor 172
92 Total Cost of Catalysts per Year 172
93 Fuel requirement of the plant and its price 173
94 Water requirement of the plant and its price 173
95 Cost of Fuel Consumed Per Year 174
96 Cost of Consumed Water per Year 175
97 Electricity Requirement of the Buildings 176
98 Electricity requirement of the Process 176
99 Cost of Electricity Consumption per Year 177
100 Price of communication services 178
101 Annual cost of communication services
of the company 178
102 Cost of Biological WWTP Operation per Year 179
103 Summary of Labor Cost per Year 180
104 Price of Fuel and Consumption per Truck 181
105 Annual cost on transportation 181
106 Operating, Quality Contol, and Laboratory
Cost per Year 182
107 Maintenance Labor, Maintenance Material, and
Operating Supplies Cost per year 182
108 General costs of the plant 183
109 Pricing of Products 184
110 Revenue from acetone 185
111 Revenue from phenol 185
112 Detailed summary of the taxes and mandatory
contributions of a corporation 187
113 Production Cost and Revenue of the
Company per Year 188
114 Annual Profit of the Company 188
115 Required Permits and Licenses of the Company 189
116 Cost of buildings 190
117 Cost of trucks of the company 191
118 Cost of radio 191
119 Total capital expenditure of the company 192
120 Capital loan and interest 192
121 Internal rate of return 193
122 Calculation Basis for Breakeven Analysis 195
123 Breakeven volume of acetone (X_1)
and phenol (X_2) 195
124 Benefit to cost ratio (f) of the plant 196
viii
List of Figures
Figure Number Title Page
1 Demand tend line for phenols in the
Philippines based on import data 3
2 Demand trend line for Acetone in the
Philippines based on Imports 5
3 2 year forecast of assumed phenol
consumption in the Philippines (Note
that this is based only from Bisphenol-A
and phenolic resin applications of phenol) 9
4 Forecast of assumed phenol consumption
in the Philippines (5 vs. 2 year data point forecast) 10
5 2 year forecast of assumed acetone
consumption in the Philippines (Note that
this is based only from Bisphenol-A and
solvent applications of acetone) 13
6 Forecast of assumed acetone consumption
in the Philippines (5 vs. 2 year data point forecast) 14
7 Initial Block Flow Diagram for Waste
Water Treatment Facility 17
8 Projected phenol and acetone capacity of plant 33
9 Company Logo of Phace Philippines Corporation 40
10 Organizational chart of PhAce Philippines
Corporation 41
11 Block Flow Diagram of Phenol and Acetone
production through Cumene Process 49
12 Chemical Structures of Benzene plus Propylene
to Cumene 50
13 Diagram of the industrial alkylation of benzene
to Cumene 50
14 Diagram for the mechanism of Cumene Oxidation 53
15 Diagram for the Mechanism of CHP decomposition
to Phenol and Acetone 55
16 Project Cash Flow of Phace Philippines
Corporation 194
List of Appendices
Appendix Number Title Page
A Aspen Hysys Simulation ix
B Storage Tanks Calculation Sheets x
C Reactors Calculation Sheets xi
D Distillation Columns Calculation Sheets xii
E Wage and Monetary Benefits Breakdown xiii
F Attached A3 documents xiv
x
Definition of Terms
Annual cost. The sum of the annuitized values of a cash flow series.
Annuity. A series of uniform payments or withdrawals occurring at equal time intervals.
Capital. A firm’s investment in long-term assets that are not bought or sold in the normal
course of business, e.g., plant equipment, buildings, and site upgrades. These assets are
depreciated.
Cash flow. The flow of money into or out of a company, a project, a personal account, and
so on.
Cash flow diagram. A diagram showing all cash flows and the time they occur. Cash flows
in are shown by an arrow into the timeline and cash flows out by an arrow away from the
timeline.
Chemical engineering plant cost index (CEPI). An index of the costs to design, purchase
and install chemical plant equipment. It is maintained by Chemical Engineering and
includes costs (1) for equipment, machinery and supports (61% of the index weighting);
(2) for construction labor (22%); (3) for buildings (7%); and (4) for engineering and
supervision (10%). The period 1957 to 1959 is defined as an index of 100.
Depreciation. A deduction from revenues (allowed by the government when calculating
income taxes) of a fraction of the capital invested in a plant. This deduction may be
considered as a fund to allow eventual replacement of the plant. It is not a cash flow.
Expense. A firm’s costs that are chargeable against sales in a specific period.
Fixed costs. Production costs that do not vary with production volume.
Future worth. This the projected value of a present sum of money when it grows at a
specified interest rate for a given number of years.
General expense. Broad corporate level expenses — research and development,
marketing, sales, and administrative costs.
Inflation. The devaluing of money because the volume of money increases faster than the
supply of goods.
Interest. The return from the investment of funds or the money paid for the use of
borrowed money.
Internal rate of return. See Return on investment (ROI).
Manufacturing costs. The cost to manufacture a product. It is comprised of operating
labor (wages), employee benefits, supervision (wages and benefits), laboratory costs,
maintenance costs, utility costs, depreciation, insurance and taxes, operating (consumable)
supplies, plant overhead, and contract manufacturing costs.
Product cost. The sum of production cost and general expense.
Production cost. The cost to produce a product. It is made up of raw material costs,
packaging material costs, manufacturing costs, and delivery costs.
Project life. The years a process or project is expected to operate without major revision.
This is determined by the shorter of product or process obsolescence or by depreciable life.
Return on investment (ROI). The interest rate at which the net present value of a cash
flow series is zero. This is the percent return from an investment.
Unit cost. Production costs expressed in dollars per unit of production (e.g. $/ton, $/lb,
$/case).
Variable costs. Those costs that vary with production volume.
