FEASIBILITY REPORT ON THE PRODUCTION OF

POLYPROPYLENE

REPORT SUBMITTED IN PARTIAL FULFILLMENT OF COURSE

REQUIREMENT OF PROJECT WORK I (CT - 453)
FOR
THE AWARD OF DEGREE
IN
BACHELOR OF TECHNOLOGY

Chemical Engineering
AT

UNIVERSITY SCHOOL OF CHEMICAL TECHNOLOGY

GURU GOBIND SINGH INDRAPRASTHA UNIVERSITY
DWARKA SEC 16 C, NEW DELHI (110078)

Under the guidance of: Submitted by:

Dr Neeru Anand Maninder Singh
University School of Chemical Technology 01616101415
(USCT), GGSIPU B.TECH CT

i
 CERTIFICATE

This is to certify that report entitled “FEASIBILITY REPORT ON THE PRODUCTION

OF POLYPROPYLENE ”which is submitted by “MANINDER SINGH”in partial fulfillment
of the requirement for the award of degree B.Tech in Chemical Engineering to USCT, GGSIPU,
Dwarka Sec-16C, Delhi is a record of the candidate own work carried out by him under my
supervision. The matter embodied in this report is original and has not been submitted for the
award of any other degree.

Date: DR. NEERU ANAND

(USCT, GGSIPU)

ii
 ACKNOWLEDGEMENT

I express my sincere gratitude to my supervisor DR. NEERU ANAND USCT, GGSIPU, for her
invaluable guidance, professional encouragement and advice through the course of this project
work. Her encouragement towards the current topic helped me a lot and created an area of
interest for my professional career ahead. I would also like to thank my parents for their
inspiration and kind support rendered in all my endeavors.

Date: MANINDER SINGH

iii
 CONTENTS

PAGES
List of figures viii
List of tables ix
Abstract x

1. INTRODUCTION 7
1.1 Polypropylene Scenario In India
1.2 Production Of Polypropylene
1.3 Health Effect
1.4 Uses Of Polypropylene
1.5 Demand Projection
2. PROCESS DESCRIPTION AND SELECTION 18
2.1 Polypropylene Manufacture with the help of Gas-Phase Technology
2.2 Polypropylene Manufacture with the help of Gas-Phase Technology
2.3 Polypropylene Manufacture with the help of Bulk-Phase Technology
2.4 Process Description
2.5 Process Flow Diagram

3. MATERIAL BALANCE AND ENERGY BALANCE 26

3.1 Basis Of Design

3.2 Material balance
3.2.1 Reactor
3.2.2 Dryer
3.2.3 Separation Vessel
3.2.4 Cyclone Separator

iv
 3.3 Energy Balance
3.3.1 Reactor
3.3.2 Heat Exchanger
3.3.3 Separation Vessel
3.3.4 Dryer

4. PROCESS EQUIPMENT DESIGN 45

4.1 Design Of Heat Exchanger
4.2 Design Of Reactor

5. ECONOMIC ANALYSIS AND SAFETY ANALYSIS 59

5.1 Purchased Equipment Cost

5.2 Estimation Of Capital Investment Cost
5.2.1 Direct Costs
5.2.2 Indirect Costs
5.2.3 Working Capital
5.2.4 Total Capital Investment
5.3 Estimation Of Total Product Cost
5.3.1 Manufacturing Cost
5.3.2 General Expenses
5.3.3 Total Product Cost
5.4 Gross Earnings/Income
5.5 Rate Of Return
5.6 Payback Period
5.7 Safety And Pollution

6. CONCLUSION
7. REFERENCES

v
vi
 LIST OF FIGURES

Figure. No. Title Page No.

1 Molecular structure of propylene 3

2 Polypropylene bags 7

3 Demand of polypropylene in various countries 11

4 PFD for Polypropylene manufacture through gas phase 13

technology
5 PFD For Bulk Polymerization 15
6 Flowsheet 19
7 Material balance around a reactor 21
8 Material balance around Cyclone separator 23
9 Material balance around Separation vessel 25
10 Material balance around Fluidized bed dryer 37
11 Energy balance around reactor 30
12 Energy balance around Heat exchanger 32
13 Energy balance around Separation vessel 34
14 Energy balance around dryer 36

vii
 LIST OF TABLES

Table No. Title Page No.

3.1 Input and output flow rates through reactor 29

3.2 Input and output flow rates Cyclone separator 30

3.3 Input and output flow rates Separation vessel 32
3.4 Input and output flow rates Dryer 34
4.1 Heat capacity and flow rates of inlet stream 37
4.2 Heat capacity and flow rates of outlet stream 38
4.3 Heat capacity and flow rates of inlet stream entering heat 39
exchanger
4.4 Heat capacity of inlet stream to separation vessel 41

4.5 Heat capacity of exit streams from the separation vessel 42

4.6 Heat capacity of outlet stream from dryer 43

viii
 Chapter 1
INTRODUCTION

1.1 Polypropylene Scenario In India

India is a developing country and its economic development is fueled by its ability to produce
goods. Plastic is a versatile material and demand for the polypropylene plastic is satisfied through
domestic production and export from the foreign nations. A large amount of PP is also imported
due to its versatility and to satisfy domestic requirement. The demands for polypropylene has
gone up by 8.9% in the last 5years and expected to increase to >20% in the next 5 years.

RELIANCE, HPL, HPCL and IOCL, MRPL, ONGC, BCPL are the major manufacturers of
Polypropylene in India. RELIANCE is the leading manufacturer of polypropylene In India. Asia
is the largest market for polypropylene after European countries. Due to its high demand and uses
its fairly popular in major economies like china and in developing economies like India. China is
the largest manufacture of PP in Asia and has the highest growth rate in production.PP has a huge
potential and is used in industries and daily households which is the reason for its rise in Indian
market. It is used in the manufacture of automobile parts and components which had a market of
39 billion US dollars in 2016. Similarly, another type of PP called the tubular quenched PP is
being widely used in the packaged food industry. Ascend in utilization consumption, given the
flooding rate of improvement the nation over, will see an upgraded use of polypropylene and its
subsidiaries in different application fragments in the coming years. West and Northern areas were
the significant interest generators in Indian polypropylene market in 2016, ICP and raffia were
the application fragments that appreciated the offer in 2016, attributable to their across the board
use in car parts and geo-material portions, separately. Both of these application sections are
required to keep overwhelming the market until the year 2030., Indian Oil Corporation Ltd.,
HPCL-Mittal Energy Ltd. Furthermore, Haldia Petrochemicals Ltd. Are the main players working
in Indian polypropylene market.

1
“With the boycott in poly packs underneath 50 microns in a large portion of the conditions of
India, individuals are moving towards the utilization of non-woven Polypropylene sacks for
convey sack applications. The preferred standpoint with non-woven Polypropylene packs are, it
very well may be gathered effortlessly by cloth pickers and can be taken for reusing, which was
not the situation with poly sacks underneath 50 microns. Littering was the explanation for this
boycott. So Polypropylene is additionally condition agreeable.”

1.2 Production of polypropylene

The industrial production processes can be grouped into:-

 Gaseous Phase Polymerization,

 Bulk Polymerization

 Slurry Polymerization.

In industries we either use gas-phase or bulk reactor systems.

In Gas-Stage And Slurry-Reactors, the polymer forms on to the heterogeneous catalyst particles.
This type of polymerization is carried in a fluidized bed reactor, propylene is passed onto a bed
containing the heterogeneous catalysts and the shaped polymer is isolated as a fine powder and
afterward later changed over into pellets. Un-reacted gas is reused and encouraged once again
into the reactor.

In Bulk Polymerization, liquid propylene acts as a solvent to prevent the precipitation of the
polymer. The polymerization proceeds at 60 to 80 °C and 30-40 atmosphere pressure are applied
to keep the propylene in the liquid state. For the bulk polymerization, typically reactors are used.
The bulk polymerization is limited to a maximum of 5% as co-monomer due to a limited
solubility of the polymer in the liquid propylene. Bulk slurry (or bulk): Uses liquid propylene
instead of liquid inert hydro-carbon diluents. The polymer does not dissolve into the diluents, but
rather rides on the liquid propylene. The formed polymer is withdrawn and any un-reacted
monomer is flashed off.

2
In the Slurry Polymerization, typically C4 - C6 alkanes are utilized as inert diluents
to suspend the growing polymer particles in the mixture. Propene is introduced into the mixture in
gas phase.

The properties of Polypropylene are strongly affected by its tacticity, the orientation of the methyl
groups relative to the methyl groups in the neighboring monomer units . The tacticity of
polypropylene can be chosen by the choice of an catalyst. In Hydrocarbon slurry or suspension:
Uses a liquid inert hydrocarbon diluent in the reactor to facilitate transfer of propylene to the
catalyst, the removal of heat from the system, for the deactivation/removal of the catalyst as well
as dissolving the atactic polymer. The range of grades that could be produced are very limited.

Some Properties Of Polypropylene:-

Technical Name Polypropylene (PP)

Chemical Formula

(C3H6)n
FIG:1 Molecular Structure Of
Propylene

130°C (266°F)

Melt Temperature
Typical Injection Molding Temperature 32 - 66 °C (90 - 150 °F)

Tensile Strength 32 MPa (4700 PSI)

Specific Gravity 0.91

3
Some of the most important properties of polypropylene are:

1. Chemical Resistance: bases and acids don't respond promptly with polypropylene, which
settles on it a decent decision for compartments of such fluids, for example, cleaning
operators, medical aid items, and that's only the tip of the iceberg.
2. Elasticity and Toughness: Polypropylene will act with elasticity only over a certain range
of deflection but it will also experience plastic deformation early on in the deformation
process, so it is generally considered as a "tough" material. Toughness is an engineering
term which is defined as the material's ability to deform (plastically, not elastically)
without breaking.
3. Fatigue Resistance: Polypropylene holds its shape even after a great deal of torsion,
twisting, and flexing. This property is particularly important for making helpful items.
4. Insulation: polypropylene has a high resistivity to power and is extremely helpful for
electronic segments.
5. Transmissivity: Although Polypropylene can be turned transparent, it is normally
produced to be naturally hazy in shading.

4
1.3 Health Effect

Polypropylene plastics break down when they are exposed to high temperatures that are typical of
the manufacturing process, especially when they are presented with a common mineral filler
called talc.

Talc, a plate-like layered structure magnesium silicate mineral, in which the octahedral brucite
layer is sandwiched between two tetrahedral silica sheets, has proved to be particularly efficient
filler on the mechanical properties and macromolecular orientation of compounds and
consequently an increase of the performance of reinforced polymeric matrix. At higher loadings
(10-40 weight%) it acts as a reinforcing filler, increasing tensile modulus and stiffness, but
reducing strain-to break and impact strength.

But polypropylene is actually safer to the environment because it take fewer natural resources to
produce and generate fewer waste products in production and disposal. They are widely recycled
and biodegradable (break down to carbon and hydrogen)also, When burned, they do not generate
toxic gases like chlorine from PVC plastics.

5
1.4 Uses Of Polypropylene[4]

Softening procedure of polypropylene can be accomplished with the assistance of expulsion and
trim. Normal expulsion procedures incorporate generation of soften blown and spun-security
strands to shape long folds for future transformation into an extensive variety of helpful items,
such as face masks, filters, diapers and wipes.

The most common shaping techniques includes injection molding, which is used for parts such as
cups, cutlery, vials, caps, containers, house wares, and automotive parts such as batteries. The
related techniques of blow molding and injection-stretch blow molding can also used, which
involve both extrusion and molding.

The large number of end-use applications of polypropylene are often possible because of the
ability to tailor grades with specific molecular properties and additives during the manufacturing
process. For example, antistatic additives can be added to help polypropylene surfaces resist the
dust and dirt. Many physical finishing techniques can also be used on polypropylene,
like machining. Surface treatments are applied to polypropylene parts in order to promote
adhesion of printing ink and paints.

Extended Polypropylene can be created through both strong and liquefy state handling. extended
PP is produced by liquefy handling with either substance or physical blowing operators.
Extension of polypropylene in solid state, because of its exceptionally crystalline structure, has
not been fruitful. In such manner, two techniques were produced for development of
Polypropylene. It was seen that Polypropylene can be extended to make EPP through controlling
its crystalline structure or through mixing with different polymers.

The current worldwide interest for this material creates a yearly market of around 45 million
metric tons and it is assessed that the interest will ascend to roughly 62 million metric tons by
2020. The real end employments of polypropylene are in the bundling business, which devours
about 30% of the aggregate, followed by the electrical and hardware fabricating, which utilizes
about 13% each. Family applications and car enterprises both devour around 10% each and

6
construction materials pursues with 5% of the market. Different applications together make up the
for whatever is left of the worldwide polypropylene utilization.

 Polypropylene is generally utilized in moisture‐proof wrapping, fat‐resistant films, and in

the fabrication of medicinal packaging because of its low moisture absorption, high
chemical resistance, and low permeability to moisture.

FIG 2: Polypropylene bags

Bulk bags are constructed with woven Polypropylene tapes that are cut from extruded sheets of
PP fabric. This permits Bulk Bags to reach up to top limit heaps of upwards of 4,400 lbs

• There are a few plastics that are utilized in the car business. While the majority of the
ones recorded may effortlessly be utilized in any vehicle, only three sorts of plastics compensate
for around 66% of the aggregate plastics being utilized: polypropylene (32%), polyurethane
(17%) and PVC (16%).PP is utilized in a wide assortment of uses. for example, car guards,
synthetic tankers, link protection, gas jars, cover filaments.

7


FIG: 3 Bumper of a car

 Melt turning of polypropylene is done. with the goal that polypropylene filaments can be
later used to make water safe texture and Water resistant fabric.

8
1.5 Demand Projection Of Polypropylene

The worldwide production of Polypropylene is 55.9 MMT in 2018 and is assessed to stretch
around 83.17 MMT by 2025, at a CAGR (compound yearly development rate) of 5.84% for a
specific period. While then again, as far as interest, its market of USD 97.4 billion will grow
each year from 2018 and would reach USD 147.23 billion by 2025 developing at a rate of 6.08%
yearly. Factors, for example, rising interest for the car, development and car enterprises,
expanding interest for shopper dispensable items, and inclination in bundling industry are the
keys which drive the market. Then again, costs of unpredictable crude material costs and financial
vulnerability in a few nations hinder the growth. The packaging sector represents over 30% of the
worldwide polypropylene request in 2018 and is driven by the interest from yet creating Chinese
and Indian markets.

China and Russia will be the main suppliers of polypropylene in the future and will represent
45% of the worldwide limit expansion throughout the following five years. Capacity increments
have acquired extensive cost investment funds in the Polypropylene business.. Western Europe is
relied upon to be the net importer for this period. Polypropylene’s extraordinary adaptability to
make numerous regular plastic items implies that the interest viewpoint is vigorously subject to
worldwide customer patterns. More than 50 million tons of polypropylene was expended all
around in 2017, an assumption that is relied upon to develop to about 75 million ton by 2025 to
take care of evergrowing worldwide demand development rate. Because of its flexibility,
polypropylene has an extensive variety of end utilizes, so understanding interest from these
different end use fragments is the way to comprehend polypropylene markets.Geographical
demand centres also play an important role in understanding the end-use industries The biggest
makers and purchasers of polypropylene on the planet, and because of the fast interests in
polypropylene generation has changed China from being one of the biggest shippers of
polypropylene to getting to be independent on this polymer. While different nations will likewise
keep on putting resources into polypropylene, this will basically serve request development rate
inside their very own demoesticmarket as per the assumptions in a report published
recently.The Polypropylene Global Supply Demand Analytics Service offers an entire long term
image of the worldwide polypropylene market and incorporates information, reports and figures
for the year 2040, with a coordinated perspective of unrefined petroleum, propylene and other key
feed-stocks through the polypropylene value chain.

9
 1.5.1 Polypropylene market in Asia and India[1]

As indicated by the recently distributed TechSci Research report "India Polypropylene Market
Study, 2015-2030", the polypropylene market in India is anticipated to develop at a CAGR of
around 11% in the period 2017 - 2030. rising industrialization and commercialization are central
point that are advancing propylene marekt in India. impact Copolymers Polypropylene is utilized
in the production of car segments, and with the nation's car parts market esteemed at around $ 39
billion for FY 2016, the development potential for the polypropylene advertise in India is
immense. Additionally, Tubular Quenched Polypropylene is generally utilized in the nation's
packaged food market, which is anticipated to develop to $ 110 billion till 2020

Polypropylene
demand (KTA)

FIG 3: Demand Of Polypropylene In Countries

In the terms of regional demand, West and Northern areas were the real interest generators in
Indian polypropylene market in 2016, ICP and raffia were the application sections that
appreciated the real offer in 2016, due to their broad use in car segments and geo textile material
portion individually. Both of these application fragments are required to keep overwhelming the
market until year 2030. Indian Oil Corporation Ltd, HPCL-Mittal Energy Ltd and Haldia
Petrochemicals Ltd Are the main players working in Indian polypropylene market.
10
 Chapter 2
PROCESS DESCRIPTION AND SELECTION

Polypropylene is one of the world's most broadly utilized polymers, second just to poly
regarding request in worldwide market. The worldwide market for polypropylene is more than 60
million metric tons every year, and it is used in an expansive and differing scope of end-utilizes
— from injection molding applications to films and sheeting, and additionally manufactured
raffia and different films, Traditionally, the most delegate kinds of propylene polymerization are
the accompanying three sorts hydrocarbon slurry or suspension, mass slurry, gas stage and cross
breed which utilizes mass and gas-stage polymerization reactors.

2.1 Methods Of Production Of Polypropylene[2]

1. Polypropylene Manufacture with the help of Gas-Phase Technology (Fluidized-Bed
Reactor)
2. Polypropylene Manufacture with the help of Bulk-Phase Technology
3. Polypropylene Manufacture with the help of Gas-Phase Technology (Stirred-Bed
Reactor)

2.1.1 Polypropylene Manufacture with the help of Gas-Phase

Technology (Fluidized-Bed Reactor)

Vapor stage polymerization, likewise called as gas stage or gas fluidized bed polymerization, is a
broadly utilized polymerization system for the vaporous monomers, for example, (LDPE,
HDPE), tetrafluoro (PTFE), and vinyl chloride (PVC). This incorporates high volume resins, for
example, propylene (PP), and numerous different polymers that are steady in the vaporous stage.

11
On a modern scale, in any case, vapor stage polymerization is for the most part utilized for the
make of HDPE, LDPE, and PEVA.

Fluidized bed polymerization was designed during the 1950s and the first commercial gas stage
polymerization plant utilizing a fluidized bed reactor was done by the Union Carbide in 1968.
The technique has the preferred standpoint that it doesn't require any diluent and that no leftover
catalysts stays in the resin grind or powder which is consistently expelled from reactors. An
exceedingly decontaminated monomer gas is consistently fed into the fluidized bed reactor.. At
the top of the reactor the gas is removed, compressed and cooled and fed back into the reactor to
control the temperature.

FIG 4: PFD for PP manufacture through gas phase technology

12
A regular gas stage polymerization of olefins happens at 80-100 °C and 30 - 35 bar pressure inthe
reactor. The thickness of the polyolefin varies somewhere in the range of 0.91 and 0.97 g/cm3.
mostly the catalyst utilized for polymerization are the Ziegler-Natta Phillips, and progress metal
catalysts.

2.1.2 Polypropylene Manufacture with the help of Bulk-Phase

Technology
Mass polymerization or mass polymerization is done by addition of a solvent radical initiator with
a pure monomer in fluid state. The initiator gets dissolved in the monomer. The response is
started by heating or by exposure to radiation. As the mixture continues to blend it gets
progressively thick. The reaction is exothermic and a colossal range of molecular masses are
delivered.

Bulk polymerization is carried out in the absence of any solvent and is thus very simple to
formulate. It is used mostly for step-growth polymers and many types of chain-growth polymers.
In the case of chain-growth reactions, which are generally exothermic, the heat evolved may
cause the reaction to become too vigorous and leads to difficulty incontrolling unless efficient
cooling is used.

FIG 5: PFD For Bulk Polymerization

13
 2.1.3 Polypropylene Manufacture with the help of Gas-Phase
Technology (Stirred-Bed Reactor)

Propylene and another co monomers are fed into the reactor. Hydrogen is added to control the
atomic weights. Polymerization conditions are set for the grade of polymer desired. The reaction
itself is extremely exothermic. Reactor cooling is accomplished by dissipation of condensed
reactor gas, which is infused into the reactor at the top of the column. .The polymer powder is
released from the reactor and isolated from the gas in a discharge cyclone separator at a pressure
of 1 atm. Any unreacted monomer isolated from the powder is packed and is either reused or it
comes back to the upstream olefins unit for recovery. The final degassing of the polymer is done
in a purge silo by flushing it with nitrogen. The purge off gas is sent into a recovery system.

I have selected this method because it provides relatively pure product than others and can be
used with conventionally used reactors like CSTR,PFR

14
2.2 PROCESS DESCRIPTION

The feed mixture consists of propylene, hydrogen and butane is later added in to the reactor. The
propylene is fed to first reactor based on the density controller in the reactor. Reaction takes
place in the reactor at 75 deg c and a pressure 40kg/cm2g.the slurry is transferred from the first
reactor to second reactor through a pipe. . Reaction takes place in the reactor at 75 deg c and a
pressure 40kg/cm2g.

hydrogen is used to control the melt flow rate(MFR) of the polymer produced in the reactors. the
is fed to the reactor as a gas and mixed with the liquid polypropylene before entering the reactor.

Slurry discharged from the reactors consists of about 53% wt polymer and 47% wt liquid
propylene + propane mix. The slurry from the reactors is discharged to the flash pipe. Solid
polymer is separated from the gas in the flash drum and vaporized polypropylene leaves the flash
drum. Polymer drops to the bottom cone of the vessel for discharge. The gas from the flash drum
is sent to the high pressure propylene scrubber to recover propylene.

The polypropylene powder is sent to a bag filter where it traps the polypropylene powder mostly
and the filtered gas is sent to another propylene scrubber. The trapped powder is sent to a
separation vessel lat this stage it still contains about 1% wt of dissolved monomer along with 1-
1.5% wt of gas, ,where high pressure steam is used to fluidized the vessel. it also traps corrosive
gases like hcl .

Polymer is discharged from this vessel by gravity . the outgoing gas flows from the top of the
vessel through a cyclone for the separation of entrained polymer fines. The cyclone separator
discharges to the separation scrubber column where it separates steam at low pressure . the
cyclone separator delivers to the steam scrubber where the gas is then washed and cooled in the
scrubber and finally to the dryer.

The polymer leaving the separation from the bottom contains about 2.5% by weight of
condensed water.

15
2.3.1 Raw Materials

In the manufacture of polypropylene , propylene is used as a monomer and is sent in to the

reactor at 26 kg/cm2 which is around 25 atm. Propylene is still in gaseous from at a temperature
of 35-45 0C. it is of 99.5 % purity and contains small amounts of propane , hcl and hydrogen.

Along with it we add butene at 8 atm into the feed. Butene is used as a density controller
because it encourages cross linking of PP chains and therefore is used to control density. It is
sent in to the reactor at 8 atm at 35-45 0C temperature and it is in gaseous state. It is of 99.5 %
purity with traces of butanes.

One of the main steps in a polymerization reaction is the chain termination step for which we
use hydrogen. As hydrogen terminates the chains .this causes steric hindrance within the PP
material. It is sent to the second reactor at a pressure of 17 atm and at a temperature of 35-45
0
C in gaseous state. It is also of utmost purity with 0.5 % of incondensable like nitrogen .

2.3.2 Utilities

Various process utilities are there such as jacket water, industrial water,demineralised
water and drinking water
Jacket water is used for cooling purpose inside the plant. The jacket water heat
exchangers also used demineralised water as it will not allow any fouling or dirt on the
inside walls of the heat exchanger.
Caustic soda(20%w/v) is used for neutralization of waste water containing hcl is treated
and then discharged
Nitrogen and air streams are used to pneumatic conveying in the extruder section.
Nitrogen is also used in cooling of rotary equipments as it generates a lot of friction

16
17
2.5 Flow sheet

fig:6 flowsheet

18
 Chapter 3
MATERIAL BALANCE AND ENERGY BALANCE

3.1 BASIS OF DESIGN

The capacity of plant( i.e 100%) has been assume to be 225 ktpa of pure polypropylene , by bulk
phase technology based on 3 shifts per day and 312 days per year

The production of polypropylene is 720 tonnes per day. This means that 30 tonnes is produced in
1 hr.

main reaction:

730C

19
 MATERIAL BALANCE

3.2.1 Reactor

Assumption :- As Most Of The Single Pass Conversion For Polymerization Reactions Are 20-
35%

% Of Propylene Converted= 28 %

Butane Used= 5% (Assumption)

Flowrate(kg/h)
Propylene 25789
butane 5454.4 Flowrate(kg/h)

Propylene 470
PolyPropylene 30303.03

Reactor

Recycle stream(99.5%)

Flowrate(kg/h)

propylene 82436

20
Total Polypropylene Formed= 30303.03 kg/h

So Propylene Fed= X*0.28 =30000

Hence Propylene Fed to the reactor = 108225 Kg/h

Propylene Unreacted= 82906 kg/h

Butane Fed = 5454.5 Kg/h

Propylene injected= 25789

Propylene recycled = 82436

Total Feed In = 108225+5454.5kg=113679 Kg/h

Total Feed Out= 30303+470+82906=113679kg/h

Input Output
Flowrates (kg/h)
Polypropylene - 30000
Butane 5454.4 -
Propylene 108225 82436
Table 1: Input And Output Flow rates

21
3.2.2 MATERIAL BALANCE AROUND CYCLONE
SEPARATOR

Feed(F) 30927.8 kg/h Solids(S) 30456.8 kg/h

Solids 97% Solids 98.5%
Water 3% Water 1.5%

FIG 7: Cyclone Separator

Gas(S1) 470.9
kg/h
Solids 0%
Water 100%

Flow rate of feed in=30927kg/h

Flow rate of solids out=?

flow rate of gas out=?
22
Assumption,

Efficiency of cyclone separator is 100%

Applying overall material balance on cyclone separator

F=S+S1

Applying component balance ,Taking solids as tie component

(X1).F=(X2 ).S +(X3).S1

0.97*F=0.985*30456.85+S1*0

S=30927.8/h

Applying component balance for gas phase.

0.03*30927.8=y*1+0.015*30456.8

S1=470.9kg/h

Input Output(Solids) Output(gas)

Streams F S S1
Flowrates(kg/h) 30927.8 30456.85 470.9
polypropylene 30000 30000 -
Propylene 470.9 - 470.9
monomer
Entrained 456.8 456.8 -
polymer fines
Table 2: Input And Output Flow rates

23
3.2.3 MATERIAL BALANCE AROUND SEPARATION
VESSEL

Steam(W) 7692 kg/h

Steam 100 %
Water 0%

Feed(F) 30456.85kg/h
Solids 98.5 %
Gas 1.5% Output(S1) 30769.2 kg/h
Solids 97.5 %
Water 2.5%
Gas 0%

FIG 7: seperation vessel

Output(G) 7379 kg/h

Water 93.81 %
Gas 6.19%

24
Flow rate of feed in=30456.8kg/h

Flow rate of solids(S1) out=?

flow rate of gas(G) out=?

Applying overall material balance on scrubber,

F+W=G+S1

Calculating flow rate of gas out by taking gas as tie component,

F*X1=G*X2

30456.85*0.015=G*0.0619

G=7379 kg/h

Calculating flow rate of output(S1) by taking solids as tie component,

F*X1=S1*X2

30456.85*0.985=S1*0.975

S1=30769.2 kg/h

input Water Gas Solid(output)

stream (output)
Streams F W G S1
Flow rates(Kg/h) 30456.85 7692 456.85 30769.2
Polypropylene 30000 - - 30000
Water 7690 7692 6921 769.2
Entrained 456.85 - 456.85 -
polymer fines
Table 3: Input And Output Flow rates

25
 3.2.4 MATERIAL BALANCE AROUND FLUIDIZED BED
DRYER:

Water(w) 769 kg/h

Solids 0%

Feed(F) 30769.2kg/h Water 100%

Solids 97.5 %
Water 2.5%

Product(p) 30000 kg/h

Solids 100%
Water 0%

FIG 8 : fluidized bed dryer

Basis: 30.769 ton/h of Slurry

Applying overall material balance on Dryer

F =P+W

Applying component balance and taking Water as tie element

(X1).F=(X2 ).P +(X3).W

(0.025).30769=(0).P +(1).W

26
W= 769 kg/Hr

Input(slurry) Output (water) Output(dryproduct)

Streams F W P
Flow rates(kg/h) 30769.2 769.2 30000
polypropylene 30000 - 30000
water 769.2 769.2 -
Table 4: Input And Output Flow rates

27
 Energy balance

3.3.1 Energy Balance Around Reactor

Temperature of inlet stream =300K

Inlet stream: -

Material specific heat(KJ/Kg.K) Flow rates (Kg/s)

1. PROPYLENE 1.531 108225
2. BUTANE 1.663 5454.4
Table 5:- heat capacity and flow rates

Heat in

1. Propylene

Q= m.CPΔT

= 108225*300*1.531

= 4.97*107KJ/hr

2. Butane

Q= m.CPΔT

=5454.4*1.633*300

=2.72*106 KJ/hr

28
Total Heat In =5.24*107KJ/hr

Heat of reaction =121.75 KJ/Mol

Moles of polypropylene formed=591666.67 moles

ΔHR=7.2*107 KJ/hr

Temperature of outlet stream =348 K

Outlet stream:-

Material specific heat(KJ/Kg.K) Flow rates (Kg/s) Mol. fraction

1.PROPYLENE 1.724 82906 0.732
2.POLYPROPYLENE 1.969 30303.3 0.268
Table 6:- heat capacity and flow rates

Heat out

Cp of mixture ,

Cp= 0.732*1.724+0.268*1.769

= 1.736

Heat carried by outlet stream,

Q= m.CPΔT

= 1.736*113209*348

29
 = 6.83*107 KJ/hr

Total heat out =6.83*107 KJ/hr

HEAT IN – HEAT OUT = ACCUMULATION

(5.24+7.2)*107– 6.83*107= Accumulation

Rate of Accumulation =5.61 *107 KJ/hr

Assumption: Cooling water at 25 C is used to remove heat from the reactor.

So, heat gained by cooling water =0.98 *10^7 KJ/hr

3.3.2 Energy Balance Around heat exchanger

Temperature of the inlet feed stream =348 K

Inlet stream: -

Material specific heat(KJ/Kg.K) Flow rates (Kg/s) Mol. fraction

1.PROPYLENE 1.724 82906 0.732
2.POLYPROPYLENE 1.969 30303.3 0.268
Table 7:- heat capacity and flow rates

Shell side calculation

Heat in

Cp of mixture ,

Cp= 0.732*1.724+0.268*1.769

= 1.736

30
 Q= m.CPΔT

= 1.736*113209*348

= 6.83*107 KJ/hr

Total heat out =6.83*107 KJ/hr

Temperature of the out let feed stream=298K

Outlet stream:-

Cp of mixture ,

Cp= 0.732*1.724+0.268*1.769

= 1.736

Heat carried by outlet stream,

Q= m.CPΔT

=1.736*113209*298

=5.85*107 KJ/hr

HEAT IN – HEAT OUT = ACCUMULATION

Heat removed =0.98*106KJ/hr eq.1

Tube side calculation

Water flow rate in = water flow rate out

Temperature of inlet water stream=288K

Temperature of Exit water stream=298K

Q= m.CPΔT

31
Heat in = F*4.18*288

= F*1203.8

Heat out =F*4.18*298

=F*1245.6

Heat removed = F*1245.6-F*1203.8

=F*(1245.6-1203.8)

=41.84*F

From eq.1

0.98*106KJ=41.84*F

F=23422.5 kg/hr water is required in shell side

32
 3.3.3 Energy Balance Around Separation Vessel:

Steam(W) 7692 kg/h

Steam 100 %
Water 0%

Feed(F) 30456.85kg/h
Solids 98.5 %
Gas 1.5% Output(S1) 30769.2 kg/h
Solids 97.5 %
Water 2.5%
Gas 0%
Fig :-9 Separation Vessel
Output(G) 7379 kg/h
Water 93.81 %
Gas 6.19%

Inlet stream :

Material specific heat(KJ/Kg.K)

33
1.FEED(F) 1.698

2. STEAM(W) 1.996

Table 8:- heat capacity

Heat in

Temperature of the output stream(G) is unknown.

Q= m.CPΔT

By,

Feed(F)=30456.8*1.698*348 =17.996*106 KJ/hr

Steam(W)=7692*1.996*473 =7.262*106KJ/hr

Total Heat In =25.258*106KJ/hr

Outlet stream:-

Material specific heat(KJ/Kg.K)

1.OUTPUT(S1) 2.025

2.OUTPUT(G) 2.233

Table 9:- heat capacity

Heat Out

Q= m.CPΔT

Output(S1) =30769*Cp*T =KJ/hr

Output(G) =7679*2.233 *413 =7.081*106KJ/hr

Total heat out =?KJ/hr

34
 HEAT IN – HEAT OUT = ACCUMULATION

We have to calculate the temperature of the outlet stream (S1)

25.258*106=7.081*106+30769*Cp*T

On solving ,

18.177*106=30769*Cp*T

At Cp=1.775

By solving further , T=333K

3.3.4 Energy Balance Around DRYER:

Product(p) 30000 kg/h

Feed(F) 30769.2kg/h F.B.DRYER Solids 100%

Solids 97.5 % Water 0%

Water 2.5%
fig 10:- F.B.DRYER

Water(w) 769 kg/h

Solids 0%
Inlet stream :- Water 100%

35
Material specific heat(KJ/Kg.K)
1.POLYPROPYLENE 1.925
2.WATER 4.18
Table 10:- heat capacity

Heat in

Temperature of the inlet stream is 333K

Q= m.CPΔT

By,

Feed(F)=30000*1.925*333 + 769*4.18*333

=20.3*106 KJ/hr

Total heat in=20.3*106 KJ/hr

Outlet Stream:-

Material specific heat(KJ/Kg.K)

1.POLYPROPYLENE 1.925
2.WATER 4.18
Table 11:- heat capacity

Total heat out =27*106KJ/hr

HEAT IN – HEAT OUT +HEAT SUPPLIED =ACCUMULATION

20.3*106 – 27*106+1.35*106+HEAT SUPPLIED =0

HEAT SUPPLIED = 5.35*106 KJ/hr

Here, we are supplying heat through the help of Nitrogen

CP of nitrogen stream at 10 bar =1.04 Kj/Kg.K

36
Temperature of the exit nitrogen stream=413 K

Flow rate of nitrogen stream =?

5.35*106= m.CPΔT

5.35*106= m*1.04*413

m =12455 Kg/hr

density of nitrogen =7.9 Kg/m3

hence, 1,576 m3 nitrogen is required per hour.

Chapter 4
PROCESS EQUIPMENT DESIGN
37
4.1 DESIGN OF HEAT EXCHANGER

Mass Flow Rate Of Feed =30774.2 Kg/hr

Inlet Temperature Of Feed=75 0C(348K)

Outlet Temperature=250C(298K)

DATA:-

Hot Fluid Inlet Temperature =750c(348k)

Hot Fluid Outlet Temperature =250c(298k)

Cold Fluid Inlet Temperature =150c(288k)

Cold Fluid Inlet Temperature =250c(298k)

Fouling Factor Of Hot Fluid =0.0001

Fouling Factor Of Cold Fluid =0.00035

ENERGY BALANCE:-

Heat In = 1.89*107 Kj/Hr

Heat Out= 1.619*107 Kj/Hr

Coolant Flow Rate = =64674.95 Kg/Hr =64.67 M3/H

1. Viscosity

µ= 1 cP(0.01 pa s)

Thermal Conductivity

K =0.16 W/M /°K

38
TRIAL 1

1-1PASS COUNTERCURRENT EXCHANGER:-

LMTD Calculation

∆T1(Hot End ) = 75-25=500c

∆T2(Cold End) = 25-15=100c

LMTD = = 24.85 0c

Correction Factor :-

R= =5

S= = = 0.1666

F=0.96

Corrected LMTD= 23.96 0c

With the average value of heavy organics,

Uao= = 490

Assuming An Overall Coefficient (On Outside Area Basis),Uao=500 Kcal/H M20c

Area Required = = = 81.8 m2

Assuming An Outer Dia. = 22 mm

Assuming An Inner Dia. = 16 mm

Length Of The Tubes =3000 mm Long.

39
Put The Incoming Feed On The Shell Side And Cooling Water On The Tube Side. This Is
Because Feed Has Polypropylene Powder As Is More Viscous. The Surface In Contact With
Cooling Water Fouls More Quickly; Cleaning Of Tubes Can Be Done Easily.

Outside Surface Area Of A Tube = ( )(3)(0.022) = 0.2827 m2

Number Of Tubes Required = =290

Linear Velocity Of Water =

Flow Area =(290)( )(0.016)2=0.0582m2

Linear Velocity Of Water = = = 0.41 m/s

This Linear Velocity Is Low For Water As A Velocity Above 1m/S Should Be Maintained.

TRIAL 2:-

1-4 PASS COUNTERCURRENT EXCHANGER:-

Assuming An Outer Dia.= 22 mm

Assuming An Inner Dia.= 16 mm

Length Of The Tubes = 3000 mm Long.

Area Per Tube = 0.2827 m2

From The Count Table A 1-4 Pass 13.25 Inch Shell(336.5 mm) Having ¾ Inch,16 BWG Tubes
On 1 Inch (25.4 mm) 600 Triangular Pitch . The Total Number Of Such Tubes That Can Be
Accommodated In A 25 Inch Shell Is 96.

24 Tubes In Each Pass.

ESTIMATION OF HEAT TRANSFER COEFFICIENTS :-

Tube Side(Water)

Flow Area = ( )(24)(0.016)2 = 0.004825 m2

40
Velocity = = 3.72 m/s

Reynolds Number:-

Re = = = 74454

Prandlt number :-

Pr = =5.36

For turbulent flow through a circular pipe, dittus and boelter equation is used

Nu = 0.023 (Re)0.8(Pr)0.3

0.023 (Re)0.8(Pr)0.3

Where

hi= inside heat transfer coefficient

L = characteristic length

K = thermal conductivity

Re =32367

Pr = 5.36

L = 0.016

= 0.023*(32367)0.8(5.36)0.3

hi = 11704

Shell Side(Feed)

Tube Pitch = 25.4mm

B(Baffle Spacing) =0.15 m

41
Ds(Shell Dia.) =13.25 Inch Shell(336.5 mm)

C’(Clearance) = 25.4-22 = 3.4 *10-3 m

Flow Area = = = 0.00675m2

Gs= = = 4559111.1 kg/m2 h

D0 = 22mm = 2.2 cm

Equivalent diameter:-

DH =

DH =1.588cm

Re= = 2011

Prandlt number :-

Pr = = 110

Nu = 0.023 (Re)0.8(Pr)0.3

0.023 (Re)0.8(Pr)0.3

h0= 415

Calculation Of Ud0 ;

42
 0.0001

Ud0 = 321

This value is considerable smaller than the initial guess .

Second trial

1-4 pass, 16 mm tubes on a square pitch in a 13.25 Inch Shell(336.5 mm).

3000 mm tube length.

Number of tubes = 88, 22 tubes per pass.

Baffles with 0.1 m spacing

Estimation of heat transfer coefficients :

Tube side

Flow area per pass = ( )(0.016)2(22) = 0.00442 m2

Velocity = = 4.06 m/s

Re = = = 81222

Pr = =5.36

Nu = 0.023 (Re)0.8(Pr)0.3

0.023 (Re)0.8(Pr)0.3

Shell side

Tube Pitch = 25.4 mm

43
B(Baffle Spacing) =0.10 m

Ds(Shell Dia.) =13.25 Inch Shell(336.5 mm)

C’(Clearance) = 25.4-22 = 3.4 *10-3 m

Flow Area = = 0.00450

Gs= = = 6832091

D0 = 22mm = 2.2 cm

Equivalent diameter:-

DH =1.53cm

Re= = 2903

Prandlt number :-

Pr = = 110

Nu = 0.023 (Re)0.8(Pr)0.3

0.023 (Re)0.8(Pr)0.3

h0= 555

Calculation Of Ud0 ;

44
 0.0001

Ud0 = 401

This value is still considerable smaller than the initial guess .

Third Trial

1-4 pass, 16 mm tubes on a triangular pitch in a 13.25 Inch Shell(336.5 mm). Having ¾ Inch,16
BWG Tubes On 1.25 Inch (31.75 mm) 4500 mm tube length.

Number of tubes = 60, 15 tubes per pass.

Baffles with 0.1 m spacing

Estimation of heat transfer coefficients :

Tube side

Flow area per pass = ( )(0.016)2(15)= 0.003216

Velocity = = 5.956

Re = = = 119126.3

Pr = =5.36

Nu = 0.023 (Re)0.8(Pr)0.3

0.023 (Re)0.8(Pr)0.3

Shell side

Tube Pitch = 25.4 mm

45
B(Baffle Spacing) =0.075 m

Ds(Shell Dia.) =13.25 Inch Shell(336.5 mm)

C’(Clearance) = 25.4-22 = 3.4 *10-3 m

Flow Area = = 0.003378

Gs= = = 9109455

D0 = 22mm = 2.2 cm

Equivalent diameter:-

DH =

DH = 1.588 cm

Re= = 4018

Prandlt number :-

Pr = = 110

Nu = 0.023 (Re)0.8(Pr)0.3

0.023 (Re)0.8(Pr)0.3

h0= 720

Calculation Of Ud0 ;

46
 0.0001

Ud0 = 488

This value is almost equal to the initial guess . therefore the design is acceptable

4.2 DESIGN OF REACTOR

Residence time ,T= 23 minutes

Now,

Density of liquid propylene = 511 kg/m3

Density of liquid butane = 577 kg/m3

Density of polypropylene = 946 kg/m3

So, rate of Propylene flowing into the reactor = 88745 kg/h

Rate of Butane flowing into the reactor =5454 kg/h

Total flow rate into the reactor,F = 183.12 m3/h

Since t = V/F

V=t*F

V=( )

V= 230 m3

Volume of the reactor (d=4.5 m)

47
L= 13.3 m

1. Thickness of shell

Temperature inside the reactor = 75 C

Pressure inside the reactor = 36 atm

Material of construction : low alloy carbon steel

Allowable stress =1.18 *108 N/m2

Diameter of the reactor = 4.5 m

T = P.di/(2fj – P) Where,

T = Thickness Of The Shell

Di = Internal Diameter

J = Joint Efficiency

P = Design Pressure

F = Permissible Stress

Internal Pressure = 36 Atm = 36.4 *105 N/m2

Design Pressure P = (10 % Extra)

P = 1.1 *36 *105= 39.6 *105 N/m2

J=1
F = 1.18*108

d= 4.5 m

t = P.di/(2fj – P) [7]
t =

t = 0.076 m
48
 t = 76 mm = 80 mm

2. HEAD DESIGN

For 2 : 1 ellipsoidal dished head

th =

where,
p = internal design pressure
D = major axis of ellipse
V = stress intensification factor = ( 2 + k2)/4
k = major axis/minor axis common value of k is 2

th =

t= 0.113 m

t= 113 mm= 120 mm

3. THICKNESS OF JACKET

internal design pressure = 4.89 *105 N/ m2

t=

t=0.0093 m

t= 9.3 mm = 10 mm

4. SKIRT SUPPORT FOR REACTOR

Dead Weight of reactor = dead weight of contents + dead weight of material of reactor
+weight of jacket

Dead weight of the material of reactor = = 114.6 ton

weight of contents= 94.199 ton

49
 weight of jacket = 1.43 ton

Material of construction : IS : 2002-1962 Grade 2B

Allowable tensile stress = 1.18 x 108 N/ m2
Yield stress = 2.55 x 108 N/ m2
Wind pressure upto = 1300 N/ m2Stress due to dead weight:

fd =

where,
fd = Stress
W = Dead weightt of vessel
Dok = Outside diameter of the skirt
tsk = thickness of skirt

W= 210.23 ton=2.06*106 N

fd = = 145832.04 / t N/ m2

assuming height of skirt = 2m

stress due to wind load=Plw = kP1h1Do [ where k = 0.7 ]
The bending moment due to wind at the base of the vessel
MW=PW*.H/2
Fw=0.7*1300*13*4.5* *

= 21756.8/t n/ m2

5. Stress Due To Seismic Load

fsb = (2/3) x CWH/ ( Rok tsk)

fsb= 202220.4/t n/m2

Maximum tensile stress = fsb – fd

(202220.4- 145832)/ts

Fmax= 56388.4/t

50
Now,permissible tensile stress = 1.18 x 108 N/ m2
T=56388.4/(1.18 *108)
=0.477 mm
Maximum compressible strength =
Fcmax=(202220.4 +145832.04) / t
Fcmax=348052/t
Fcpermissible= 1/3 Y.P
Fcpermissible = 2.58*108 N/ m2
So thickness to be used = 4.1 mm =10mm

Chapter 5

Cost estimation

51
Manufacturing cost is the sum total of direct production costs + fixed charges and plant
overhead costs

5.1 Cost of purchased equipment

Equipment Cost (in lakhs) Total cost(in lakhs)

Reactor 25 50
Heat Exchanger 2 2
Separation Vessel 6 6
Cyclone Separator 3 3
Steam Scrubber 6 6
Fluidized Bed Dryer 7.5 7.5
Extruder 10.5 10.5
Pumps 1.5 10.5
Cooler 2 1
Storage Tank 2 4
Total Cost 100.5 lakhs
Ref:-indiamart.com[6]

5.2 ESTIMATION OF CAPITAL INVESTMENT COST[8]

5.2.1 Direct Costs

Cost of the materials used to create a product is a direct cost. It includes the cost of the
equipment purchased , installation charges, instrumentation and control , piping, buildings
,land and electrical equipment.

a) Purchased Equipment Cost(Pec)

Pec is taken as 15-40% of Fixed-Capital Investment

Let the Purchased Equipment Cost be 25% of Fixed-Capital Investment

FIXED CAPITAL INVESTMENT = 100.5 *105/0.25

52
 = 402x105 Rs

b) Installation Charges

Let the Installation Cost be 40% of the Purchased Equipment Cost

= 0.4*100.5*105 Rs

= 40.2x105 Rs

c) Instrumentation And Control

Let the Instrumentation Cost be 20% of the Purchased Equipment Cost

=20.1 x105 Rs

d) Cost of piping

Let the Piping Cost be 45% of Purchased Equipment Cost

=45.225 x105 Rs

e) Electrical Cost

Let the Electrical cost be 25% of Purchased Equipment Cost

=25.125 x105 Rs

f) Building Cost

Let the Buildings, process and auxiliary cost be 50% of Purchased Equipment Cost

= 50.25 x105 Rs

g) Service Cost

Let the service cost be 70% of Purchased Equipment Cost

53
 =70.35 x105 Rs

h) Land Cost

Let the land cost be 6% of Purchased Equipment Cost

=6.03 x105 Rs

So, total direct cost = 659.28 x105 Rs

5.2.2 Indirect costs

Indirect costs in a plant includes the Engineering and Supervision, Construction

Expenses, Contractor’s fee, Contingency and Start up expenses.

a) Engineering And Supervision cost

Let the engineering and supervision costs be 20% of Direct Costs

= 131.856 x105 Rs

b) Construction Expenses

Let the construction expense be 10% of Direct Costs

= 65.928 x105 Rs

c) Contractor’s fee

Let the contractor’s fee be 10% of Direct Costs

= 65.928 x105 Rs

d) Contingency expenses

Let the contingency cost be 7.5% of Fixed-Capital Investment

= 49.446 x105 Rs

Thus, Indirect Cost = 313.158 x105 Rs

54
Fixed Capital Investment is the sum of Direct Costs + Indirect Costs

Fixed Capital Investment = 972.438 x105 Rs

5.2.3 Working Capital

Let the Working Capital be 20 % of the Total Capital Investment.

5.2.4 Total Capital Investment

Total capital investment is the sum of Fixed Capital Investment + Working Capital

= Fixed Capital Investment + (0.2 x Total Capital Investment)

Total Capital Investment =972.438 x105/0.8 = 1215.54 x105 Rs

5.3 TOTAL PRODUCT COST

5.3.1 Manufacturing cost
5.3.1.1 Fixed charges

a) Depreciation cost = depreciation is the gradual decrease in the value of the stock

Depreciation Cost is taken as 10% of Fixed Capital Investment for Machinery &
Equipment and 5 % of Building.

Depreciation Cost = 99.75 x105 Rs

b) Taxes

Let the cost of local taxes be 2% of Fixed Capital Investment

local taxes = 19.44 x105 Rs

c) Cost for Insurance

55
 Let the Insurance Cost be 0.5% of the Fixed Capital Investment

Cost for Insurance = 4.862 x105 Rs

Total Fixed Charges

Total fixed charges = 124.05 x105 Rs

Let the fixed charges be 15% of Total Product Cost

Total Product Cost = 827.7 x105 Rs

5.3.1.2 Direct Production Costs

a) Raw Materials

Let the raw materials cost be 30% of The total Product Cost

Raw Materials = 248.1 x105 Rs

b) Operating Labor

Let the operating labor cost be 15% of the Total Product Cost

Operating Labor =124.05 x105 Rs

c) Direct Supervisory and Clerical Labor

Let the Direct Supervisory and Clerical Labor cost = 15% of Operating Labor

Direct Supervisory and Clerical Labor =18.60 x105 Rs

d) Utilities

Let the Cost of Utilities be 15% of the Total Product Cost

Utilities = 124.15 x105 Rs

e) Maintenance and Repairs

56
Let the Maintenance and Repair Cost be 5% of Fixed Capital Investment

Maintenance and Repair Cost =48.62 x105 Rs

f) Operating Supplies

Let the Cost of Operating Supplies be 15% of Maintenance & Repairs

Operating Supplies =7.29 x105 Rs

g) Laboratory Charges

Let the Laboratory charges be 15% of Operating Labour Charges

Laboratory charges =18.60 x105 Rs

h) Patent and Royalties

Let the cost of Patent and royalties be 3% of Total Product Cost

Patent and royalties charges =24.83 x105 Rs

Total direct production cost = 614.24 x105 Rs

5.3.1.3 Plant Overhead Cost

Plant-overhead costs around 50-70% of the cost for operating labor, supervision, and
maintenance or 5 to 15% of total product cost.

Let the plant-overhead cost = 10% of Total Product Cost

= 82.7 x105 Rs

Manufacturing Cost is the sum of Direct Production cost + Fixed charges +Plant Overhead
cost

=820.99 x105 Rs

57
5.3.2 General expenses
General Expenses are the sum of Administrative Costs, Distribution and Selling Costs and
Research and Development Costs.

a) Administrative Costs

It includes the costs for executive salaries, clerical wages, legal fees, office supplies, and
communications

Let the administrative costs be 4% of Total Product Cost

= 33.10 x105 Rs

b) Distribution and Selling Costs

Let the costs for Distribution and selling be 12% of Total Product Cost

= 99.32 x105 Rs

c) Research and Development costs

Let the costs for Research and development be 5% of Total Product Cost

=41.38 x105 Rs

d) Financing

Let the cost for interest be 5% of Total Capital Investment

=60.77 x105 Rs

Total General Expenses = Administrative costs + Distribution and selling costs + Research
and Development costs + Financing
Total General Expenses =234.57 x105 Rs

5.3.3 Total Product cost

Total Product cost = Manufacturing Cost + Total General Expenses

58
Total Product cost =1055.56 x105 Rs

5.4 GROSS EARNINGS/INCOME

Market Selling Price of polypropylene per ton= Rs. 1000/MT

Total Income = Selling price x amount of product manufactured

=3120 x105 Rs

Gross earnings = Total Income – Total Product Cost

= 3120 x105- 1055.56 x105

=2064.44 x105 Rs

Gross earnings cost (i.e. the taxes) = 45% of the Gross earnings

= 928.99 x105 Rs

Net Profit = (Gross earnings – Taxes)

=(2064.44 – 928.99) x105 Rs

=1135.45 x105 Rs

5.5 RATE OF RETURN

Rate of Return = [Net profit×100]/Total Capital Investment

=[(1135.45 x105x100)/ 1215.54 x105]

=65.7%

5.6 PAYBACK PERIOD

Payback period = fixed capital investment / net profit

Payback period =(972.438 x105 /[(1135.45 x105 +99.75 x105)])

= 0.787 years = 10 months

59
5.7 SAFETY AND POLLUTION

In 1984 leak of methyl isocyanate caused more than 2000 causalities and drew the
world attention towards the serious hazards of chemical industry. A polymer
(polypropylene) manufacturing plant or any chemical manufacturing industry
sho uld adopt a range of safety techniques to guarantee the safety and wellbeing of
a

its staff and the smooth operation of the equipment and prevent hazards or
operability issues that can cause trouble. This should therefore apply for a
polypropylene manufacturing plant .Such safety measures can be categorized in
different ways; broadly they could be classified as the following:
 Design strategies and continuous inspection.

 Health and safety communication.

 Safety practices and personal protective measures.

 Emergency planning

Pollutants

A plant design of polypropylene production has an environmental impact in the

form of pollution problems in the area where the plant is located. It is the
responsibility of the management to consider possible techniques to minimize the
emission of solid and liquid waste by complying with the emission standards and
discharge limits which are provided by the central environmental authority (CEA).
Possible pollutants in the polymer production include dust particles of raw polymer
powder, HCL,propylene,TEAL apart from that spent catalyst and other waste from
blow down.
The following points can be helpful in eliminating these pollutants:

 Design of equipment for better conversion

 Improving performance of separation vessels

60
Solid waste :- due to various reasons there is some loss in the dryer and other equipment. This
leads to wastage of polymer. To prevent such loses instead of pneumatic conveying of powder N2
should be used

Noise pollution: Air blowers, boilers and pumps can be regarded as the main sources of
noise. Noise level should not be maintained beyond the maximum permissible level. Sound
proofing walls could be a form of minimizing the effect of noise

61
 Chapter 6

Conclusion

This process gives me high purity with low energy consumption, also bulk phase
polymerization has a low impact on the environment. This process has high efficiency
and overall productivity . the rate of return is found to be 81.7% and the payback period
is 10 months.The project is technically feasible and economically viable.

62
 REFERENCES

[1] http://www.thermopedia.com/content/1065/
[2] Shreve, R.N. and Austin, G.T., “Chemical Process Industries”. 5th ed. New
Delhi:
McGraw-Hill Education India Pvt Ltd
[3] Richardson, J.F., Harher, J.H. and Backhurst, J.R. “Coulson and
Richrdson’s Chemical Engineering”. Vol 2, 5th ed. Woburn:
Butterworth-Heinemann(2002)

[4] https://en.wikipedia.org/wiki/Polypropylene pg:-6

[5] https://www.mcdermott.com/What-We-
Do/Technology/Lummus/Petrochemicals/Olefins/Polypropylene-
Production/Novolen-Gas-Phase-Process
[6] https://dir.indiamart.com/impcat/heattransfer-exchangers.html
[7] Process-Equipment-Design-By-M-V-Joshi .5th ed(1976) pg :-50
[8] Timmerhaus, Klaus D., Peters, Max S. “Plant Design And Economics
For Chemical Engineers”. 4th ed. Singapore: McGraw Hill Book
Co.(1991) pg:- 53

63