Plant Design Oral Defense1...v3

8/11/2019 Plant Design Oral Defense1...v3

1/51

ACRYLONITRILEPHILIPPINES

CORPORATION PLAN

DESIGN


2/51


3/51

VISION-MISSION STATEMEN

COMPANY MISSION

Acrylonitrile Philippines Corporation

aims to establish strong connection in

both local and international markets by

providing high quality acrylonitrileproduct.

COMPANY VISION

Acrylonitrile Philippines env

become the leading acrylon

manufacturer and supplier

Philippines; providing acrylointermediates in accordanc

standard conforming to the

product for chemical, latex,

textile fiber industries.


4/51

Incorporators and Officers


5/51

PRE-OPERATING PERIOD

Activities during the pre-operating period:

To conduct feasibility study or marketing plan,

Establishing the by-laws and required forms of incorporation,

Financing or seeking sources of capital

Hiring and training of personnel

Setting up and choosing potential plant location

Finalizing the plant layout design and its construction

The equipment design and specification, equipment installation

And the ordering and delivery of equipment and raw materials.


6/51

PRE-OPERATING PERIOD ORGANIZATICHART


7/51

OPERATING PERIOD

The plant will operate 360 days a year, 24 hours a day and seven days a weevery year during the month of December is allotted for the plant shutdown,

includes equipment maintenance and repair.

The employees are required to follow the work schedule. Work will start from

oclock in the morning (7:00 AM-3:00 PM). The second shift will start from 3:

11:00 PM. Evening shift will start from 11:00PM to 7:00 AM.


8/51

OPERATING PERIOD ORGANIZATIOCHART


9/51


10/51

CONSTRAINTS

ENVIRONMENTAL CONSTRAINTS

Potential environmental damage that would result from a plant a

spill have been considered. Potential emissions to the environm

the proposed acrylonitrile plant have been assessed in three ca

airborne emissions; waterborne emissions; and solid waste.

Nonetheless, emergency response plans should be developed

the environmental impact from a release of acrylonitrile. The co

regulates the production, handling, storage and release and dis

acrylonitrile and its byproducts through comprehensive environm

laws or standards.


11/51

CONSTRAINTS

ECONOMIC CONSTRAINTS

Acrylonitrile is widely used in the production of acrylic fibers, SA

resin and SBR latex and other smaller-volume applications inclu

paints, caulking, automobile seals, carpets, sweaters, seat cush

head rests, seals and gaskets.

The major constraint in this regard is the dependence of polyme

companies and clothing and carpets industries to the competitor

imports of acrylonitrile. The company will create strategic busine

partnership with different companies to supply their needs.


12/51

CONSTRAINTSHEALTH AND SAFETY CONSTRAINTS

Acrylonitrile is toxic if inhaled or swallowed or in contact with the

To avoid these incidents the APC will equip suitable first-aid uni

written procedure on how to handle exposures to acrylonitrile. H

identification, risk assessment and determining control (HIRADC

part of the safety practice of the company.

The company will have behavioral based safety (BBS)program.

trainings regarding occupational safety and health, internationa

organization for standardization (ISO), quality management pra

good manufacturing practices will be provided.


13/51

CONSTRAINTS

MANUFACTURABILITY AND SUSTAINABILITY CONSTRAINTS

Due to its systems of production, transportation designs and wit

training of personnel that must be implemented and acceptable

data of raw materials supply, the manufacturability is not limited

Common problems associated with the delivery of raw materials

to weather issues like storms and floods. However, it is of distrib

responsibility to address this. And to make our product sustaina

production schedule was set.


14/51

CONSTRAINTSETHICAL AND PROFESSIONAL CONSTRAINTS

The company follows the standards and rules set by the dep

of labor and employment.

The company practices the corporate social responsibility to

the active compliance with the law, ethical standards and int

norms. Yearly evaluation for the company will be done to asquality of management in people and processes and to quan

impact on the society on various areas.


15/51


16/51

MARKET FEASIBILITYFour Mathematical Methods Computed Standard

deviationDescription

Arithmetic Straight Line

Method(ASLM)

19.69 Arithmetic Straight Line Method

assumes that the annual increasfuture will be the same although

increase in percent will keep on

Arithmetic Geometric Curve

Method(AGCM)

19.73 In this method, the rate of increa

projected values is constant; ho

amount of change keeps on incr

Statistical Straight Line Method

(SSLM)

2.83 For this method, the change in t

uniform, while the change as a %for the year is decreasing.

Statistical Parabolic Curve

Method (SPPM)

2.65 In SPPM, the change in the pred

may be increasing or decreasing

percentage change of the value

year may also be increasing or d


17/51

MARKET FEASIBILITYHISTORICAL DEMAND FOR

ACRYLONITRILEYear Net Weight (kg)

2004 12295122

2005 12993375

2006 10920990

2007 13337358

2008 17340349

2009 20762683

2010 23250395

2011 22615526

2012 24329797

2013 26468538

Year Net Weigh

2004 1,295,1

2005 2,993,3

2006 1,920,9

2007 3,337,3

2008 7,340,3

2009 9,762,6

2010 8,250,3

2011 10,180,8

2012 14,329,7

2013 16,468,5

HISTORICAL SUPPLY FOR

ACRYLONITRILE


18/51

MARKET FEASIBILITY Graphical representation of the historical demand

of acrylonitrile[national statistics office (NSO)

public reference unit, 2014]

0

5000000

10000000

15000000

20000000

25000000

30000000

2004 2005 2006 2007 2008 2009 2010 2011 2012 2013

N

etWeightin(kg)

Year

Graphical Representation o

Supply of Acrylonitrile [

Exchange Commission, Pu

Unit, 2014]

0

2,000,000

4,000,000

6,000,000

8,000,000

10,000,000

12,000,000

14,000,000

16,000,000

18,000,000

2004 2005 2006 2007 2008 2009

NetWeight(kg)

Year


19/51


20/51

MARKET FEASIBILITY

HISTORICAL DEMAND FOR PROPYLENE

Year Weight (kg)

2004 70,335,973

2005 71,771,401

2006 73,236,123

2007 74,730,7382008 76,255,855

2009 77,812,097

2010 79,400,099

2011 81,020,510

2012 85,567,875

2013 87,693,596

HISTORICAL SUPPLY FOR

Year Weig

2004 80,4

2005 79,5

2006 78,2

2007 79,72008 85,2

2009 79,8

2010 85,4

2011 88,0

2012 93,4

2013 90,7


21/51

MARKET FEASIBILITY

HISTORICAL DEMAND FOR AMMONIA

Year Weight (kg)

2004 93337297

2005 98249787

2006 103420828

2007 1088640302008 114593715

2009 120624964

2010 126973646

2011 133656470

2012 137667870

2013 141983340

HISTORICAL SUPPLY FOR A

Year We

2004 86

2005 96

2006 106

2007 1172008 119

2009 121

2010 133

2011 137

2012 145

2013 153


22/51

MARKET FEASIBILITYGRAPHICAL REPRESENTATION OF THE DEMAND

OF PROPYLENE AND AMMONIA [NATIONAL

STATISTICS OFFICE (NSO) PUBLIC REFERENCE

UNIT, 2014]

0

20000000

40000000

60000000

80000000

100000000

120000000

140000000

160000000

2004 2005 2006 2007 2008 2009 2010 2011 2012 2013

NetWeight(kg)

Year

Ammonia

Propylene

GRAPHICAL REPRESENT

SUPPLY OF PROPYLENE[NATIONAL STATISTICS O

PUBLIC REFERENCE UN

0

20000000

40000000

60000000

80000000

100000000

120000000

140000000

160000000

180000000

2004 2005 2006 2007 2008 2009

NetWeight(kg)

Year


23/51

MARKET FEASIBILITY PROJECTED DEMAND AND SUPPLY OF ACRYLONITRILE FOR THE NEX

YEARS USING STATISTICAL PARABOLIC PROJECTION METHOD AND

STATISTICAL STRAIGHT LINE METHODYear Demand (kg) Supply(kg) Difference(kg

)

2014 29,342,774 16,733,828 12,608,946

2015 31,675,639

18,396,716

13,278,923

2016 34,095,750

20,059,604

14,036,146

2017 36,603,106 21,722,492 14,880,614

2018 39,197,708 23,385,379 15,812,329

2019 41,879,555 25,048,267 16,831,288

2020 44,648,648 26,711,155 17,937,493

2021 47,504,986 28,374,042 19,130,944

2022 50,448,570

30,036,930

20,411,640


24/51

MARKET FEASIBILITYGRAPHICAL REPRESENTATION OF THE PROJECTED DEMAND AND SUP

ACRYLONITRILE

0.00

10,000,000.00

20,000,000.00

30,000,000.00

40,000,000.00

50,000,000.00

60,000,000.00

2014 2015 2016 2017 2018 2019 2020 2021 2022 2023

NetWeight(kg)

Year

Demand

Supply


25/51

MARKET FEASIBILITYPROJECTED DEMAND AND SUPPLY OF

AMMONIA FOR THE NEXT TEN YEARS USINGSTATISTICAL PARABOLIC PROJECTIONMETHOD

Year Demand (kg) Supply(kg)

2014 158691802 160108316

2015 173324518

175992401

2016 188508974 192558827

2017

204245172

2098075942018

220533110

227738701

2019 237372788

246352149

2020 254764207

265647939

2021 272707367

285626069

2022 291202268

306286539

2023 310248909

327629351

PROJECTED DEMAND AND SUPPL

PROPYLENE FOR THE NEXT TEN STATISTICAL PARABOLIC PROJECMETHOD

Year Demand (kg)

2014 110795095

2015 119243683

2016 127879141

2017

1367014672018 145710662

2019 154906727

2020 164289660

2021 173859462

2022 183616134

2023 193559674


26/51

MARKET FEASIBILITYGRAPHICAL REPRESENTATION OF THE

PROJECTED DEMAND AND SUPPLY OFAMMONIA

GRAPHICAL REPRESENTATIO

PROJECTED DEMAND AND SUPROPYLENE

0

50000000

100000000

150000000

200000000

250000000

300000000

350000000

2014 2015 2016 2017 2018 2019 2020 2021 2022 2023

NetWeigh

t(kg)

Year

Demand

Supply

0

50000000

100000000

150000000

200000000

250000000

2014 2015 2016 2017 2018 2019 2020 2

NetWeig

ht(kg)

Year


27/51

PROJECTED TIMETABLE1 3- Nov -1 3 1 7- Fe b- 14 2 4- Ma y- 14 2 8- Au g- 14 2 -D ec- 14 8 -Ma r- 15 1 2- Ju n- 15 1 6- Se p- 15 2 1- De c- 15 2 6- Ma r- 16 3 0-J

Feasibility Study and Project Planning

Incorporation

Financial Acquisition

Plant Site Negotiation

Plant Size Acquisition

Preparation of Engineering Design and Specification

Plant Construction Bidding

Plant Construction

Order and Fabrication of Equipment

Equipment Arrival

Hiring of Personnel

Installation of EquipmentOrder and Delivery of Raw Materials

Training of Personnel

Trial Run

Advertising and Promotion

Start of Normal Operation

Plant SiteNegotiation

Plant SizeAcquisition

Preparation ofEngineeringDesign and

Specification

PlantConstruction

Bidding

PlantConstruction

Order andFabrication of

Equipment

EquipmentArrival

Hiring ofPersonnel

Installation ofEquipment

Order andDelivery of Raw

Materials

Training ofPersonnel

Trial RunAdvertising and

PromotionStart of Normal

Operation

Start Date 7-Apr-149-Jun-145-May-145-May-1415-Aug-145-May-145-Jan-155-Oct-145-Jan-154-Jun-158-Jun-157-Sep-157-Sep-156-Mar-16

Duration 635691311153081202431509591181181365


28/51

PROCESS SELECTION

PROCESS 1

Manufacturing acrylonitrile by combining propylene, am

and air in a process called ammoxidation. During ammo

propylene, ammonia and air are fed through a catalyst a

temperature. The vessel containing the chemical reactiocalled a fluid bed reactor, where the powdered catalyst m

fluid-like throughout the reactor.

PROCESS 1 SOHIO PROCESS


29/51

PROCESS 1: SOHIO PROCESS


30/51

PROCESS SELECTION

PROCESS 2MANUFACTURE OF ACRYLONITRILE FROM ETHYLENE CYANOHYDRIN

Germany and the United States first produced acrylonitrile on a

industrial scale in the early 1940s. These processes were base

catalytic dehydration of ethylene cyanohydrin. Ethylene cyanohproduced from ethylene oxide and aqueous hydrocyanic acid a

the presence of a basic catalyst. The intermediate was then deh

in the liquid phase at 200 C in the presence of magnesium car

and alkaline or alkaline earth salts of formic acid.


31/51

PROCESS SELECTIONPROCESS 2

MANUFACTURE OF ACRYLONITRILE FROM ETHYLENE CYANOHYDRIN


32/51

PROCESS SELECTION

PROCESS 3MANUFACTURING OF ACRYLONITRILE FROM ACETYLENE AND HYDRO

ACID

Catalyst consisting of cuprous chloride and ammonium chloride

solution in hydrochloric acid. A large excess of acetylene is use

mol/mol HCN) at a pressure slightly above 0.1106 pa absolute

temperature of 80 to 90C.

The molar yield is up to 90 per cent in relation to hydrogen cya

75 to 80 per cent in relation to acetylene. The main by-products

acetaldehyde, vinyl acetylene, divinyl acetylene, vinyl chloride,


33/51

PROCESS SELECTIONMANUFACTURING OF ACRYLONITRILE FROM ACETYLENE AND HYDR

ACID


34/51

PROCESS SELECTION TABCOMPARISON


35/51

CRITERIA FOR PLANT LOCATTRANSPORTATION FACILITIES AVAILABLE- Transportation access to

markets adds to economic scale in production, distribution, and consumtherefore transportation increasing economic growth.

ACCESSIBILITY TO THE TARGET MARKET- Accessibility to the target

affects the cost of the product and it requires a lot of time for distribution

WATER SOURCE QUALITY AND QUANTITY- Numerous plant uses lar

of water in operating plant and some operations that needed the supply

SPECIAL BUSINESS INCENTIVES-Incentives create a good relation to

manufacturer and the consumers

CLIMATIC CONDITIONS-Climate affects the operation of the plant, the

the transportation of the raw material and the products.


36/51

CRITERIA FOR PLANT LOCATUTILITIES COSTS AND AVAILABILITY-Plant operations are dependent

and electricity; therefore utilities should take into consideration

TREATMENT FACILITY- The location of the plant should have a correct

disposal and treatment facility because it is one of the requirements by t

CONSTRUCTION COST- Cost of the construction includes the equipme

construction of the plant, and the land.

OPERATING LABOUR- It will determine the number of manpower that ineeded in the operation of the plant.

TAXES- Taxes will affect the business in one way or other

LIVING CONDITIONS AND EXPANSION POSSIBILITIES- The chosen

must be economic zone and have large area for future expansion and d

considering the projected business growth


37/51

PLANT LOCATION 1

TIPCO Estates corporation (TECO) Special EconoZone, Mabalacat, Pampanga, Philippines

Is a 68-hectare privately industrial complex and w

proclaimed as TECO special economic zone.

Industrial firms have chosen to locate here includ

sorting facilities, chemical processing, warehous

storage and manufacturing services.


38/51

PLANT LOCATION 2Light Industry & Science Park III (LISP III)

LISP III is a 109hectare industrial park in Sto. T

Batangas.

LISP III is an Ecozone. Companies operating in t

ecozones are entitled to a tax incentive package

other benefits accorded by the Philippine econom

authority (PEZA) to qualified export-oriented com


39/51

PLANT LOCATION 3The first cavite industrial estate (FCIE) situated in

Lankaan, Dasmarinas In Cavite.

It has a 154.5 hectare industrial subdivision esta

in 1991.

It was built to serve all the basic needs of manufconcerns from light-to-medium scale industry. It

classified as a special economic zone area by

Philippines Economic Zone Areas (PEZA).

SUMMARY OF CRITERIA FOR PLANLOCATION


40/51

LOCATIONCriteria %

(TECO)Pampanga

(LISP)Batangas

(FCIE)Cavite

Transportation Facilities 10 8 7 6

Accessibility to Target Markets10 8 7 6

Water source quality and quantity

10

8

8

7

Special Business Incentives

10 9 9 9

Climatic Conditions

10 8 6 7

Utilities Costs And Availability

10 7 7 8

Treatment Facility

5 4 4 4

Construction Cost 10 7 7 7

Operating Labour

10 7 8 9

Taxes

5 4 4 4

Living conditions/expansion

possibilities10 9 8 6

Total

100

79

75

73


41/51

PRODUCT DESCRIPTIONProperties Other Charateris

Melting point (C) -83.55 Colourless liquid with a swe

odour; vapours may be ign

distance; the compound ca

electrostatic charges throug

agitation; acrylonitrile polym

when hot, which may cause

to explode;uninhibited acry

explosive at room temperat

compound reacts violently

oxidizers, strong acids and

silver nitrate; the compounddecomposes in a fire, relea

gases; vapour is heavier th

may travel along the groun

assemble at lowest place; c

adverse effects well below

threshold.

Boiling point (C) 77.3

Solubility in water (g/litre) (20C) 73.5

Specific density (20C) 0.8060

Relative vapour density 1.8

Vapour pressure (kPa) (23.6C) 13.3

Flash point (open cup) 0C

Flash point (closed cup) -4.4C

Octanol/water partition coefficient 0.12

Flammability (explosive) limits 3 - 17 %

Relative molecular mass 53.06

Assay 99%

Autoignition temp. 897 F

Refractive index n20/D 1.391(lit.)

Exposure limit 17%


42/51

OVERALL MATERIAL AND ENER


43/51

OVERALL MATERIAL AND ENERBALANCE

Mass Output

Componen

t

Weight

(kg)

N2 18010.72

O2 459.07

HCN 187.50

C3H6 0.0079

NH3 417.98

CO2 1209.95

Acrylonitri

le3640.36

Acrolein 197.50

Acetonitril

e110.76

H2O 4599.73

Reactor feed

Componen

t

Weight

(kg)

C3H6 85.6470

NH3 102.776

4

Compressed Air

Compone

nt

Weight

(kg)

N2 18010.722

63

O2 5467.7064

34

Equipment 1: Fluidised Bed Reactor



44/51

QUENCHER




45/51

0.00786

kg/hr C3H6

459.0222 kg/hr O2

18008.92

kg/hr N2

1209.833

kg/hr CO2

187.4856 kg/hr HCN

3603.851 kg/hr AN

109.7509

kg/hr ACR

195.583

kg/hr ACN

Top Products

Component Weight (kg)

C3H6 0.007859942

O2 459.0221773

N2 18008.92156

CO2 1209.832592

HCN 187.485553

Acrylonitrile 3603.851149

Acetonitrile 109.7509203

Acrolein 195.5829506

H2O 4571.733389

4571.733 kg/hr H2O

Vaporizer




46/51

0.007859942 kg/hr C3H6

459.0221773 kg/hr O2

18008.92156 kg/hr N2

1209.832592 kg/hr CO2

0.360385115 kg/hr AN

67873.13 kg/hr H2O

187.485553 kg/hr HCN

3603.490764 kg/hr AN

109.7509203 kg/hr ACR

195.5829506 kg/hr ACN

72444.863 kg/hr H2O

After Reaction:

134.5736363 kg/hr HCN

72444.863 kg/hr H2O

3603.490764 kg/hr AN

195.5829506 kg/hr ACN

109.7509203 kg/hr ACR

0.00786 kg/hr C3H6

459.0222 kg/hr O2

18008.92 kg/hr N2

1209.833 kg/hr CO2

187.4856 kg/hr HCN

3603.851 kg/hr AN

109.7509 kg/hr ACR

195.583 kg/hr ACN

4571.733 kg/hr H2O

Absorber




47/51

Component Top

Kg/hr

C3H3N 3571.05934

7

HCN 131.209295

4

H2O 3571.05934

7

Total 7273.32799

134.57363

63

kg/hr

HCN

67873.130

22

kg/hr

H2O

3603.4907

64

kg/hr AN

195.58295

06

kg/hr

CAN

109.75092

03

kg/hr

ACR

Compone

nt Bottom

C3H3N 32.431417

CH3CN195.582

95

HCN3.36434

09

H2O124907.

17

Total125138.

55

Recovery Column




48/51

Component

Organic

phase

Kg/hr

C3H3N 3571.05935

HCN 131.209295

H2O 178.552967

Total 3880.82161

Component

C3H3N

HCN

H2O

Total

Decanter




49/51

HCN 131.2

5

Total 131.25

Component Input

Kg/hr

C3H3N 3571.059347

HCN 131.2092954

H2O 178.5529674

Total 3880.82161

C3H3N 3571.0

47

H2O 178.55

74

Total 3749.6

14

Head Column




50/51

C3H3N 3571.0

7

H2O 36.071

4

Total 3607.1

4

Component Inlet

Kg/hr

C3H3N 3571.059347

H2O 178.5529674

Total 3749.612314

H2O 1

Total

Product Column:


TABLE OF STANDARDS


51/51

Code Description

Batas Pambansa Bilang 68 Corporation Code of the Philippines Articles o

Republic Act No. 8749 Philippine Clean Air Act of 1999 Wast

Republic Act No. 9275 Philippine Clean Water Act of 2004

Wast

Presidential Decree No. 984 Pollution Control Law of 1976 Wast

DENR Administrative Order No. 90-35 Revised Effluent Regulations of 1990 Wast

Presidential Decree No. 856 Sanitation Code of the Philippines Wast

Presidential Decree No. 442 The Labor Code of the Philippines

Manag

OSHA Occupational Safety and Health Administration Health

NIOSH National Institute of Occupational Safety and

Health

Health

Presidential No. 442 Labor Code of the Philippines Management Stu

Documents

Plant Design Oral Defense1...v3