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Manufacture of Acetic acid through the methanol carbonylation route.
Article in Chemical · May 2014
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A
Project Report on
PLANT DESIGN FOR MANUFACTURING ACETIC ACID
Submitted in partial fulfillment of the requirements for the award of Degree of
BACHELOR OF TECHNOLOGY IN PETROCHEMICAL ENGINEERING
By
T.PRUDHVI RAJ 10021A2512
Under the esteemed guidance of
Mr.P.Anil kumar
Lecturer
DEPARTMENT OF PETROLEUM ENGINEERING & PETROCHEMICAL ENGINEERING

UNIVERSITY COLLEGE OF ENGINEERING (A) KAKINADA
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY KAKINADA
KAKINADA – 533003, AP
(2010-2014)
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CERTIFICATE
This is to certify that the project report entitled “PLANT DESIGN FOR MANUFACTURING
ACETIC ACID” is a bonafide work done by T.Prudhvi Raj (10021A2512) Submitted in partial fulfillment of
the requirements for the award of Degree of Bachelor of Technology in Petro Chemical Engineering during the
academic year 2013-2014.
The results of investigations enclosed in this report have been verified and found
satisfactory. The results embodied in this project report have not been submitted to any other
University or Institute for the award of any other degree.
Head of the Department Project Guide
Dr. B. Bala Krishna Mr. P.Anil Kumar

Head Lecturer
Dept. of PE & PCE Dept. of PE & PCE
UCEK(A) UCEK(A)
J.N.T. University J.N.T. University
Kakinada-533003 Kakinada-533003
Project Supervisor
Prof. K. V. Rao
Programme Director
Dept. of PE & PCE
UCEK(A)
J.N.T. University
Kakinada-533003
ACKNOWLEDGEMENTS
I would like to express our sincere gratitude to the project guide, Mr. P.Anil Kumar,
Lecturer, Department of Petroleum Engineering & Petrochemical Engineering, University
College of Engineering (A), Jawaharlal Nehru Technological University, Kakinada, for his
timely cooperation and valuable suggestions while carrying out the project. It is his kindness that
made me learn more from him.
I would like to express our thanks to Prof K.V.Rao, Programme Director, Department
of Petroleum Engineering & Petrochemical Engineering, University College of Engineering (A),
Jawaharlal Nehru Technological University, Kakinada, for their guidance given to me to finish
this project successfully.
I would like to acknowledge gratitude to Prof. K.Padma Raju, Principal,UCEK(A)

and Dr. B.Bala Krishna, Professor and Head of the Department, Department of Petroleum
Engineering & Petrochemical Engineering, University College of Engineering (A), Jawaharlal
Nehru Technological University, Kakinada, for providing good environment and better
infrastructural facilities.
I also like to thank all my friends and well-wishers for their warm and willing
assistance.
T.Prudhvi Raj (10021A2512)

CONTENTS
ABSTRACT i
LIST OF FIGURES ii
LIST OF TABLES iii
NOMENCLATURE iv
1. INTRODUCTION 1
1.1. INTRODUCTION 2
1.2. GLOBAL SCENARIO 3
1.3. INDIAN MARKET 6
2. PHYSICAL AND CHEMICAL PROPERTIES AND USES 7
2.1. PHYSICAL PROPERTIES 8
2.2. CHEMICAL PROPERTIES 10
2.3. USES OF METHANOL 11
3. DIFFERENT PROCESSES FOR MANUFATURE OF ACETIC ACID 14
3.1 ANAEROBIC FERMENTATION 15
3.2 THE DIRECT OXIDATION OF N-BUTANE 16
3.3. ACETALDEHYDE OXIDATION 17
4. PROCESS SELECTION 20
4.1 THE SELECTED PROCESS 21
4.2 ADVANTAGES OF SELECTED PROCESS 24
5. PROCESS DESCRIPTION 25
6. MATERIAL BALANCES 29
6.1 INTRODUCTION 30
6.2 MATERIAL BALANCE FOR ACETIC ACID PURIFICATION COLUMN 30
6.3 FOR THE LIGHT END DISTILLATION COLUMN (DC-1) 33
6.4 MATERIAL BALANCE FOR REACTOR 34
7. ENERGY BALANCES 35
7.1INTRODUCTION 36
7.2 ENTHALPY BALANCE FOR REACTOR 37
7.3 ENTHALPY BALANCE FOR LIGHT END DISTILLATION COLUMN 44
7.4. ENERGY BALANCE FOR DISTILLATION COLUMN-2 48
7.5 CALCULATION OF COOLING WATER REQUIREMENT 52
7.6 CALCULATION OF STEAM REQUIREMENT 53
8. EQUIPMENT DESIGN 54
8.1 AVERAGE MOLECULAR WEIGHT CALCULATION 55
8.2 NUMBER OF STAGES CALCULATIONS FOR DC-I 56
8.3 INTERNAL DESIGN ESTIMATION 58
8.4 LIQUID FLOW PATTERN 61
8.5 PROVISIONAL PLATE DESIGN 61
8.6 CROSS CHECK 62
8.7 PLATE PRESSURE DROP 63
8.8 DOWN COMER LIQUID BACKUP 65
8.9 CHECK TO AVOID FLOODING 65
8.10 CHECK ENTRAINMENT 66
8.11 TRIAL LAYOUT 66
8.12 CHOOSING DOMEDHEAD AND CALCULATING ITS THICKNESS 68
8.13 STAGES CALCULATION FOR LIGHT END DISTILLATION COLUMN 69
8.14 SHELL THICKNESS 71
8.15. CONDENSER DESIGN 72
8.16. REBOILER DESIGN 77
9. SIMULATION USING UNISIM DESIGN SUITE 80
10. MATERIALS OF CONSTRUCTION 94
11. SAFETY, HEALTH AND ENVIRONMENT ASPECTS 97

12. PLANT LOCATION 113
13. PLANT LAYOUT 116
14. COST ESTIMATION 120
BIBLIOGRAPHY 127
ABSTRACT– Plant design for manufacturing acetic acid
Acetic acid has a place in organic processes comparable to sulfuric acid in the mineral chemical
industries and its movements mirror the industry.
Methanol carbonylation has become the technology of choice in the world market. Production
from synthesis gas is increasing and the development of alternative raw materials is under
serious consideration. Research on fermentative routes to glacial acetic acid is also being
pursued.
The main objective of the project is to discuss the design of a chemical plant for manufacture of
acetic acid, this project will shows the industrialized processes employed in manufacturing of the
acetic acid.
The objective of the development of new acetic acid processes has been to reduce raw material
consumption, energy requirements, and investment costs. Significant cost advantages resulted
from the use of carbon monoxide and of low-priced methanol as feedstock’s. At present,
industrial processes (commercial process) for the production of acetic acid is dominated by
methanol carbonylation route.
This is the basic and outlined scope of the project that is needed to be carried out:
Constructing a process flow diagram of the entire process

Calculating mass and energy balances
Equipment design and sizing
Industry safety and hazard management
Plant location
Plant layout plans
Project investment and costs
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LIST OF FIGURES PAGE NO.
Fig 1.1. Acetic acid global demand 3
Fig 1.2. Acetic acid supply 3
Fig 1.3. Global acetic acid consumption 4
Fig 1.4. Acetic acid capacities 5
Fig.1.5. Global acetic acid derivatives 5
Fig 1.6. Acetic acid supply and demand 5
Fig 3.1. Flow sheet for acetaldehyde oxidation 18
Fig 5.1. Flow sheet for methanol carbonylation 19
Fig 6.1. Material balance for Distillation column – II 31
Fig 6.2. Material Balance for Distillation column-I 33
Fig 6.3. Reactor material balance 34
Fig 8.1 Equilibrium stages for Distillation column 57
Fig 8.2. Graph for to estimate Capacity Factor 59
Fig 8.3. Graph for estimating Flow pattern 61
Fig 8.4. Weep Point correlation 63
Fig 8.5. Discharge coefficient for gas flow through sieve plates 64
Fig 8.6. Graph for Fractional entrainment 66
Fig 8.7. Relation between weir length , chord height and angle subtended by weir 67
length
Fig.8.8.Ft parameter versus S correlation 73
Fig.8.9. Shell bundle clearance 75
Fig.8.10. Shell-side friction factors, segmental baffles 76
Fig.8.11. Tube-side friction factors 77
Fig.8.11. Tube-side friction factors 82
Fig 13.1. Plant Layout 119
LIST OF TABLES PAGE NO
Table 6.1. Material balance for Distillation column – 2 31
Table 6.2. Material balance for distillation column – I 34
Table 6.3. Material balance for Reactor 34
Table 7.1. A,B,C,D & E constant values for different components 36
Table 7.2. Enthalpy balance for feed out from CSTR 40
Table 7.3. Energy balance for Distillation column – 1 44
Table 7.4. Enthalpy balance for overhead stream 45
Table 7.5. Enthalpy balance for bottom stream 47
Table 7.6. Energy balance for feed stream 49
Table 7.7. Energy balance for the overhead stream 50
Table 7.8. Energy balance for the bottom stream 51
Table 8.1.equilibrium data for distillation column -II 57
Table 8.2. calculations for Relative volatility 70
Table 14.1. Total direct costs 122
Table 14.2. Total indirect costs 123
Table 14.3. Total fixed costs 124
Table 14.4. Total direct product costs 125
Table 14.5.Total general expenses 126
NOMENCLATURE
a,at,as Flow area in general, for tube side, and for shell side,
respectively
B Rate of Bottom Product
B’ Baffle spacing
Cp Specific heat
C’ Clearance between tubes
D Diameter
De Equivalent diameter
dp,dt Diameter of particle & tube respectively
D Rate of Distillate Product
F Rate of feed
ID Inner Diameter
jH Heat transfer factor, dimensionless
k Thermal conductivity
L Length
Nt Number of tubes
ni Molar flow rate of component i
OD Outer Diameter
P Pressure
ΔP Pressure drop
PT Tube pitch
Q Heat flow Rate
Qc Condenser heat duty
Qr Reboiler Duty
Rd Dirt Factor
ΔT Temperature Difference
U,Uc,Ud Overall heat transfer coefficient, clean coefficient, design
coefficient
V Vapor Flow Rate in Rectifying Section
Xf Composition of Feed
Xb Composition of Bottom product
Xd Composition of Distillate
v Latent Heat of Vaporization
 Viscosity Ratio ( w)
 Viscosity
w Viscosity at the tube wall
 Density
 Voidage
CHAPTER - I
INTRODUCTION
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1.1. Introduction:
Acetic acid is an important commodity used in chemical industries, with about 9 million tons of
world demands per year. The primary use of this chemical is in the manufacture of
assorted acetate esters, fungicide, organic compounds, organic solvents and the preparation
of pharmaceuticals, cellulose acetate that is important in making film and plastic wares,
perfumes and synthetic fiber.
Acetic acid (CH3COOH), is a corrosive organic acid having a
Sharp odor,
Burning taste, and
Pernicious blistering properties.
It is found in ocean water, oilfield brines, rain, and at trace concentrations in many plant and
animal liquids. It is central to all biological energy pathways. Fermentation of fruit and vegetable
juices yields 2–12% acetic acid solutions, usually called vinegar (qv). Any sugar-containing sap
or juice can be transformed by bacterial or fungal processes to dilute acetic acid.
Theophrastus (272–287 BC) studied the utilization of acetic acid to make white lead and Andreas
Libavius (AD 1540–1600) distinguished the properties of vinegar from those of ice like (glacial)
acetic acid obtained by dry distillation of copper acetate or similar heavy metal acetates.
Lavoisier believed he could distinguish acetic acid from acetous acid, the hypothetical acid of
vinegar, which he thought was converted into acetic acid by oxidation. Uses include the
manufacture of vinyl acetate and acetic anhydride. Vinyl acetate is used to make latex emulsion
resins for paints, adhesives, paper coatings, and textile finishing agents. Acetic anhydride is used
in making cellulose acetate fibers, cigarette filter tow, and cellulosic plastics.
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1.2 GLOBAL SCENARIO:
A market study on glacial acetic acid discloses a large gap between its demand and
supply. The production of acetic acid is sound globally but recent data shows a
decreasing producing capacity of Asia worldwide. Most of Acetic acid produced in Asia is
consumed internally and the excess is being imported due to its cheapness in the process
involved.
Fig 1.1. Acetic acid global demand
Fig 1.2. Acetic acid supply
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A comparison of the demand and supply chart from the 2013 data supports the fact that with the
demand of 12%, Europe producers are able to supply only 8% of it. The rest of the demand is
being imported from producers from other continents.
A study of world consumption of acetic acid in the year 2009 also reveals similar facts
with china being the greatest consumer of acetic acid in the market and united states
being the second most consumer.
Fig 1.3. Global acetic acid consumption
In a recent study, total worldwide production of virgin acetic acid is estimated at

5MMTPA (million metric tons per year), approximately half of which is produced in the
United States. European production stands at approximately 1 MTA and is declining,
and 0.7 MT is produced in Japan. Another 1.5 MT are recycled each year, bringing the
total world market to 6.5 MTA. The two biggest producers of virgin acetic acid are
Celanese and BP Chemicals. Other major producers include Millennium Chemicals,
Sterling Chemicals, Samsung, Eastman, and Svensk Etanolkemi. Of the total global acetic
acid capacity (virgin acid), 44% is in China, followed by 21% for the rest of Asia, 19% in
the United States and 6% in Western Europe. These regions make up 90% of total world
capacity.
1.2.1 CAPACITY OF ACETIC ACID: This section describes about the capacities and acetic
acid derivatives production world wide
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Fig 1.4. Acetic acid capacities
Fig.1.5. Global acetic acid derivatives
Fig 1.6 acetic acid supply and demand
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1.3 INDIAN MARKET:
With Asia’s growing contribution to the global chemical industry, India emerges as one
of the focus destinations for chemical companies worldwide. With the current size of
$108 billion, the Indian chemical industry accounts for approximately 7% of Indian GDP.
Share of industry in national exports is around 11%. In terms of volume, India is the third-
largest producer of chemicals in Asia, after China and Japan. Despite its large size and
significant GDP contribution, India chemicals industry represents only around 3% of global
chemicals.
The Indian chemical industry could grow at 11% P.A. To reach size of $224 billion by 2017.
The demand for organic chemicals in India has been increasing at nearly 6.5% during
this period and has reached the level of 2.8 million tons. The domestic supply has
however grown at a slower pace resulting in gradual widening of demand supply gap
which was primarily bridged through imports.
Acetic Acid is primarily used for production of Purified terepthalic acid (PTA), Vinyl acetate
monomer (VAM), and acetic anhydride and acetate esters. In India, production of acetic acid
is primarily based on alcohol and its demand has grown at 10% during XI th Five Year
Plan period. At present the consumption is estimated to be 0.6 million tons which would
reach nearly 1.0 million tons by end of XII th Five Year Plan period (2012-2017). The
demand growth is primarily driven by end use demand from PTA which is basic raw
material for polyester and fiber. There is substantial incremental capacity of PTA, driving
demand for acetic acid in this segment.
Acetic acid is primarily produced through alcohol or methanol route. Alcohol route in Indian
context is gradually becoming unviable due to high prices and limited availability of this
feedstock. At present bulk of acetic acid is imported with domestic production accounting for
less than 30% of demand.
Amongst the six major organic chemicals produced in India Acetic Acid contribute to
nearly 2/3rd of Indian basic organic chemical industry. The balance 1/3rd of the organic
chemical consumption in the country is accounted for by other wide variety of chemicals.
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CHAPTER - II
PHYSICAL & CHEMICAL

PROPERTIES AND USES
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2.1 PHYSICAL PROPERTIES:
Acetic acid is a clear, colorless, corrosive liquid that has a pungent odor and is a dangerous
vesicant. It has pungent vinegar like odor. The detectable odor is as low as 1 ppm. The liquid is
usually available as glacial acetic acid with less than 1 Wt % water and over 98 % purity.
Besides water, the acid contains traces of impurities such as acetaldehyde, oxidized substances,
iron, and chlorides. Occasionally, the acid may be colored due to the presence of ethyl
acetoacetate. The acetate is easily mistaken for formic acid because it reduces mercuric chloride.
Traces of mercury may cause extensive corrosion by reaction with aluminum. Aluminum is a
common material for containers to ship the acid .Glacial acetic acid is very hydroscopic. The
presence of 0.1 Wt % water lowers the freezing point significantly. Acetic acid forms azeotropes
with many common solvents, such as benzene, pyridine, and dioxane. Acetic acid is miscible
with water, ethanol, acetone, benzene, ether, and carbon tetrachloride. However, it is not soluble
in CS2.The presence of acetaldehyde or formic acid is commonly revealed by permanganate
tests.
• Though the molecular weight of acetic acid is 60.05, its apparent molecular weight
varies with both temperature and the other associating substances present.
• It is miscible in all proportions with water, ethanol and ether.
• It is an excellent solvent for organic compounds.
• A zero dipole moment for unsymmetrical acetic acid structure(is explained by the formation
of symmetric dimmers via hydrogen bonding in which the dipole moments cancel).
• No high dissociation ionic species in acetic acid solution.
• Possesses relatively low basicity or proton affinity.
• Has a very strong leveling effect on bases and solvolyzes all strong bases to acetate ion,
CH3COO- .
The physical properties are
1. Melting point : 16.635 0.002 0C
2. Boiling point : 117.870C
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3. Vapor pressure :
4. Thermal conductivity : 0.158 W/m2 0C at 200C
5. Heat of melting : 207.1 J/g
6. Heat of vaporization : 394.5J/g at boiling point
7. Specific heat of vapor : 5.029 J/g 0K at 1240C
8. Density : 1.04938 g/ml at 200C
9. Refractive index,ηd : 1.36965
10. Specific heat of solid : 0.837 J/g 0K at 1000K
11. Critical pressure : 57.856 KPa (571.1 atm)
12. Critical temperature : 321.60C
13. Magnetic susceptibility
Solid : 32.05 10-6 cm3/mol
Liquid : 31.80 10-6 cm3/mol
14. Dielectric constant
Solid : 2.665 at -10.00C
Liquid : 6.710 at 20.00C
15. Surface tension : 27.57 N/m or Dyne/cm at 20.10C
16. Flash point, open cup : 570C
17. Auto ignition point : 465 0C
18. Lower limit of flammability : 400C
: 5.4 vol% at 1000C
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2.2 CHEMICAL PROPERTIES:
Many useful materials are made from acetic acid. Acetate esters are formed by reaction of olefins
or alcohols with acetic acid. Acetic acid is also used in the preparation of pharmaceuticals.
Aspirin (acetylsalicylic acid) is formed by the reaction between acetic acid and salicylic acid.
This esterification reaction is reversible, however, and the presence of water can lead to
hydrolysis of the aspirin. Thus, an anhydrous (“without water”) reagent could lead to better
yields of product.
Acetic anhydride can by prepared by the dehydration of acetic acid at 800OC.
Alternatively, the reaction between the acid chloride and a salt of acetic acid (e.g. sodium
acetate) yields acetic anhydride and a salt.
2.2.1 Reactions with inorganic compounds
Acetic acid is mildly corrosive to metals including iron, magnesium, and zinc, forming hydrogen
gas and salts called acetates:
Mg + 2CH3COOH → (CH3COO)2Mg + H2
Because aluminium forms a passivizing acid-resistant film of aluminium oxide, aluminium tanks
are used to transport acetic acid. Metal acetates can also be prepared from acetic acid and an
appropriate base, as in the popular "baking soda + vinegar" reaction:
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NaHCO3 + CH3COOH → CH3COONa + CO2 + H2O
2.2.2 Decomposition Reactions:
Minute traces of acetic anhydride are formed when very dry acetic acid is distilled. Without a
catalyst, equilibrium is reached after 7 hrs of boiling, but a trace of acid catalyst produces
equilibrium in 20 min.
Thermolysis of acetic acid occurs at 442OC and 101.3 KPa (1 atm), leading by parallel pathways
to methane and carbon dioxide, and to ketene and water. Both reactions have great industrial
significance.
2.2.3 Acid–Base Chemistry:
Acetic acid dissociates in water, pKa=4.76 at 25OC. It is a mild acid that can be used for analysis
of bases too weak to detect in water. It readily neutralizes the ordinary hydroxides of the alkali
metals and the alkaline earths to form the corresponding acetates. Other acids exhibit very
powerful, super acid properties in acetic acid solutions and are thus useful catalysts for
esterification of olefins and alcohols.
Nitration conducted in acetic acid solvent are affected because of the formation of the nitronium
ion, (NO2+) Hexamethylenetetramine may be nitrated in acetic acid solvent to yield the explosive
cyclotrimethylenetrinitramine , also known as cyclonit or RDX.
2.2.4 Acetylation Reactions:

Alcohols may be acetylated without catalysts by using a large excess of acetic acid.
2.3 USES OF ACETIC ACID:

2.3.1 The various areas where acetic acid has its wide use are
• Over 60% of acetic acid produced goes into polymers derived from either Vinyl acetate (vinyl
esters) or cellulose (cellulose esters).
• Most of poly (vinyl acetate) is used in paints and coatings or used for making poly (vinyl
alcohol) and plastics.
• Also, cellulose acetate is used to produce acetate fibers.
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• Acetic acid and acetate esters are used extensively as solvents and in organic
Synthesis.
• In the production of white lead and chrome yellow pigments, it is used to make lead available
in a soluble form for further reaction to give basic lead carbonate and lead chromate.
• Also used to provide the necessary acidity in the number of processes carried out in an
aqueous media.
• Used in the mordanting process and in dyeing of wool in textile industry.
• Used as a coagulant for rubber latex in manufacture of elastic thread, as a component
of photographic stopping and fixing baths and as a laundry sour.
• Also used in electroplating, engraving and in the processing offish glue.
• Dilute acetic acid functions either or both as a preservative and flavoring agent in food
stuffs such as pickled vegetables, condiments, jellies and confectionery.
• RDX - The high explosive cyclotrimethylenetrinitramine is furnished on nitration of
hexamethylenetetramine with acetic acid.
• Also, lower alkyl esters such as methanol, ethanol, isopropanol and butanol are widely
used as solvents for lacquers and adhesives. Other esters form basis for synthetic flavors for
perfumes and bornyl acetate in the manufacture of synthetic camphor.
2.3.2 Acetic acid is mainly utilized in the manufacture of the following products:
1. Acetic anhydride: Acetic anhydride is a very versatile product. It is a part of the

manufacturing of Cellulose acetate fiber, Plastics, Vinyl acetate monomer etc. The
pharmaceutical industry uses acetic anhydride as a dehydration agent. The dye industry also uses
it for manufacturing dyes and dye intermediates. Ordinance factories use it in the manufacture of
explosives. Perfumes are also made by the use of acetic anhydride. Aspirin, Paracetamol and
other antibiotics are also made by using acetic anhydride.
2. Vinyl acetate: Vinyl acetate is a basic raw material for Poly vinyl acetate and Poly vinyl
alcohol. Vinyl acetate monomer is used in the manufacture of latex paint, paper coatings,
adhesives and textile finishing.
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3. Cellulose acetate: Cellulose acetate is an important constituent of thermoplastics and fibers.
The textile industry uses cellulose acetate widely for the production of cellulose acetate fiber.
The other uses of Cellulose acetate are the production of film, plastic sheets and the formulation
of liquor.
4. Monochloro acetic acid: Monochloro acetic acid [MCA] is used extensively in the
manufacture of Herbicides, Preservatives, Bacteriostat and Glycine. Mainly it is used in the
manufacture of Carboxy methyl cellulose which is a gummy and strong adhesive powder used in
drilling for oil. MCA is also used for producing laboratory chemicals like EDTA and 2 4 D
Thioglucolicacid.
5. Purified Terepthalic acid [PTA]: · Acetic acid finds use in the manufacture of PTA as a
solvent. PTA is an alternative raw material for polyester fiber manufacture instead of Dimethyl
terephthalate [DMT]
6. Food Additives [vinegar]: Acetic acid is widely used in the form of vinegar as a food
additive. As vinegar it is used for the preservation of food and also to impart a sour taste to
certain preparations.
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CHAPTER - III
DIFFERENT MANUFACTURING
PROCESSES
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The 99.8% pure acetic acid, sold in the name of glacial acetic acid can be manufactured
by various processes. Each process is discussed in detail in the following sections.
Different processes employed for manufacture of acetic acid:
There are mainly three processes that produce acetic acid. They are
Acetaldehyde Oxidation
Methanol Carbonylation
Anaerobic fermentation
Butane–Naphtha Catalytic Liquid-Phase Oxidation
While in the Indian scenario acetaldehyde oxidation process takes the majority of acetic acid
production. Alcohol is used to obtain Acetaldehyde (Alcohol is obtained by the fermentation and
distillation of Molasses).
Acetic acid is produced by this route using a two-step process.
i. Oxidation of alcohol to Acetaldehyde:
C2H5OH +½O2 → CH3CHO + H2O
ii. Oxidation of Acetaldehyde to Acetic acid:
CH3CHO +½O2→ CH3COOH
3.1 ANAEROBIC FERMENTATION:
Species of anaerobic bacteria Species of anaerobic bacteria, including members of the genus
Clostridium or Acetobacterium can convert sugars to acetic acid directly, without using
ethanol as an intermediate. The overall chemical reaction conducted by these bacteria may be
represented as:
C6H12O6 → 3CH3COOH
These acetogenic bacteria produce acetic acid from one-carbon compounds, including methanol,
carbon monoxide, or a mixture of carbon dioxide and hydrogen:
2CO2 + 4H2 → CH3COOH + 2H2O
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This ability of Clostridium to utilize sugars directly, or to produce acetic acid from less costly
inputs, means that these bacteria could potentially produce acetic acid more efficiently
than ethanol-oxidizers like Acetobacterium .
However, Clostridium bacteria are less acid-tolerant than Acetobacter. Even the most acid-
tolerant Clostridium strains can produce vinegar of only a few per cent acetic acid,
compared to Acetobacter strains that can produce vinegar of up to 20% acetic acid. At
present, it remains more cost-effective to produce vinegar using Acetobacter than to produce
it using Clostridium and then concentrate it. As a result, although acetogenic bacteria have
been known since 1940, their industrial use remains confined to a few niche applications.
3.2 THE DIRECT OXIDATION OF N-BUTANE:
Oxidation of n-butane in the liquid phase is through Chemische Werke Huls process.
This reaction can be carried out in three different ways as shown below:
i. A vapor phase non-catalytic reaction at 350 to 4000C and 5-10 atm.pressure.
ii. A liquid phase non-catalytic reaction at 160-1800C and 45-10 atm.pressure.
iii. A liquid phase homogenous catalytic reaction at 160-1800C and 45-55 atm. pressure.
½ C4H10 + O2 → CH3COOH + H2O
The production of acetic acid by acetaldehyde oxidation has an extensive patent literature. It has
been in commercial operation since 1911 in Germany and 1920 in the US.
Even in many processes acetaldehyde is essentially an intermediate in the production of acetic

acid and the four common main routes to acetaldehyde are:
i) The vapor-phase dehydrogenation or partial oxidation of ethyl alcohol
ii) The liquid-phase hydration of acetylene
iii) The high-temperature oxidation of saturated hydrocarbons
IV) The liquid-phase oxidation of ethylene.
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3.3. ACETALDEHYDE OXIDATION:
The continuous oxidation of acetaldehyde in the liquid phase is generally carried out by using air
or oxygen in the presence of catalyst manganese acetate. The reaction mixture containing
acetaldehyde diluted with crude acid and manganese acetate solution is circulated upward
through the oxidation tower.
CH3CHO +½O2→ CH3COOH
Reaction conditions when air is used are 55-65°C at 70-75 psi (about 5 atm); and when air is
used oxygen is used, 70-80°C at a pressure sufficient to keep the acetaldehyde liquid.
The reaction mixture is drawn off the top of the distillation tower and is diluted continuously in
as many as 3 distillation columns. Now, crude acid is fed into the top of the distillation column
and other volatile components are withdrawn overhead while a residue containing manganese
acetate is removed at the bottom. A low boiling fore –run is taken off overhead in the second
column and 99.6 - 99.8% pure acetic acid is taken off just above the reboiler.
The mechanism can be described in the following manner
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In Hoechst Process, the oxidation is usually done with oxygen, which operates
continuously at 50-70oC in the oxidations towers of stainless steel (bubble columns) with
acetic acid as solvent. Temperatures of at least 50oC are necessary to achieve an adequate
decomposition of peroxide and thus a sufficient rate of oxidation. The heat of reaction is
removed by circulating the oxidation mixture through a cooling system. Careful
temperature control limits the oxidative decomposition of acetic acid to formic acid,
CO2, and small amounts of CO and H2O. Acetic acid selectivity reaches 95-97%.
Besides CO2 and formic acid, the byproducts include methyl acetate, methanol, methyl
formate, and formaldehyde, which are separated by distillation.
19 | P a g e
CHAPTER - IV
PROCESS SELECTION
20 | P a g e
4.1 THE SELECTED PROCESS: Methanol Carbonylation route
Undoubtedly the methanol carbonylation route has a much greater production when compared to
any other processes i.e. it holds 75% of the world’s acetic acid production technologies.
Production of Acetic acid by carbonylation of methanol used to be done by a process

named as Monsanto process where Rhodium catalyst was used as an active catalyst with
iodide of metals such as lithium. The process was carried at 50-60 bar pressure and at a
temperature of 150 to 200oC giving a high selectivity of 99% based on the methanol feed. But
B.P chemicals came up with a process named as Cativa that used Iridium catalyst with
Hydrogen iodide as the active catalyst in the system.
Henry Drefyus at British Celanese developed a methanol carbonylation pilot plant as early as
1925. However, a lack of practical materials that could contain the corrosive reaction mixture at
the high pressures needed (200 atm or more) discouraged commercialization of these routes. The
first commercial methanol carbonylation process, which used a cobalt catalyst, was developed by
German chemical company BASF in 1963. In 1968, a rhodium-based catalyst (cis−
[Rh(CO)2I2]−) was discovered that could operate efficiently at lower pressure with almost no by-
products. The first plant using this catalyst was built by US chemical company Monsanto
Company in 1970, and rhodium-catalyzed methanol carbonylation became the dominant method
of acetic acid production. In the late 1990s, the chemicals company BP Chemicals
commercialized the Cativa catalyst ([Ir(CO)2I2]−), which is promoted by ruthenium. This iridium
catalyzed process is greener and more efficient and has largely supplanted the Monsanto process,
often in the same production plants.
4.1.1 This overcame many limitations of the Monsanto process as
• Lower water concentration was obtained in the product compared to Monsanto process.
• The process now could be carried at a comparatively lesser pressure and

temperature.
• The number of distillation units was reduced.
• Iridium is cheaper than Rhodium, hence reducing the cost of production to a large extent.
The Cativa Process is carried 30-40 bar pressure and at a temperature of 150-180oC
giving a high selectivity of 99%(based on the methanol feed).

21 | P a g e
The reactions are:
Main reaction:
CH3OH + CO → CH3COOH ∆H= -138kJ/mol
Side Reactions:
CH3OH + CO → C2H5COOH
CH3COOH + CH3OH → CH3COOCH3
The process involves iodomethane as an intermediate, and occurs in three steps. A catalyst,
usually a metal complex, is needed for the carbonylation (step 2).
CH3OH + HI → CH3I + H2O
CH3I + CO → CH3COI
CH3COI + H2O → CH3COOH + HI
By altering the process conditions, acetic anhydride may also be produced on the same plant.
Because both methanol and carbon monoxide are commodity raw materials, methanol
carbonylation long appeared to be an attractive method for acetic acid production.
The use of other less expensive catalyst such as nickel, palladium, and ruthenium in
homogeneous systems has also been investigated. In 1996, BP Amoco commercialized the
iridium-based Cativa technology, which operates with reactor water levels that are comparable to
the improved Monsanto process. The new catalyst is most effective when used in combination
with lithium and ruthenium.
The Cativa technology is installed in Sterling’s Texas City acetic acid plant, which has a capacity
of 990 million lb/yr (450,000 t/yr)
22 | P a g e
This is the catalytic cycle for the carbonylation of methanol using iridium as the catalyst
23 | P a g e
4.2. ADVANTAGES OF SELECTED PROCESS:
The selected process has following advantages over other processes:
• The selectivity of Cativa process is 99% as compared to the 90% of acetaldehyde oxidation and
even lesser in other processes.
• The operation is cheaper than other processes.
• The methanol used as the feed is comparatively cheaper than the feed in other processes.
• Fermentation process which also seems viable in terms of operation involves a greater
upstream and downstream cost for sterilization of equipment to provide an environment for
microbial growth.
• The liquid phase reaction is easy to control.
24 | P a g e
CHAPTER - V
PROCESS DETAILS
25 | P a g e
5.1 PROCESS DETAILS:
The carbonylation process of methanol is carried out in a continuous stirred tank reactor.
The methanol and carbon monoxide is fed to the reactor from the bottom as feed. The
carbon monoxide is compressed in a compressor to 30 bar before inlet to the reactor to
ensure the reaction is occurs in the liquid phase. The reaction is highly exothermic and
hence a cooling jacket is provided outside the reactor to ensure that the proper
temperature of 150oC is maintained in the reactor. The initial heat required to ignite the
reaction is mainly rough age of steam through the jacket. As the reaction starts, the heat of
reaction is used to continue the reaction and excess heat is removed.
The following will be the process flow diagram for methanol carbonylation route.
The unreacted gases are vented out through a scrubber which also works as a preheater
for a part of methanol feed. A part of methanol feed is preheated from ambient
temperature to 60oC as it comes out of the scrubber Another work that is performed by
the side stream is the stripping of entrained liquid in the vent gases and it also ensures
that the loss of product with these gases is minimal. The vent gases generally exit the
scrubber at 50oC to the atmosphere.
26 | P a g e
27 | P a g e
The product stream from the CSTR, is rich in acetic acid and containing small
concentrations of methanol, by-product propionic acid and water is made to pass through
the throttling valve to the flash tank where the product is flashed to a reduced pressure
of 1 atm. The product from the flash tank is fed to the light end distillation column at a
temperature of 52oC. A recycle stream is pumped from the bottom of the flash tank back
to the CSTR.
In the light end distillation column the feed containing acetic acid, water, propionic acid,
methanol and methyl acetate is distilled to separate light ends (methyl acetate and
methanol) from the bottom stream containing acetic acid, propionic acid and little
concentration of water. The acetic acid is generally 87.6 % by wt. which is further purified
in the acid purification unit to obtain the required product. The feed stream enters at a
temperature of about 52oC and the bottom stream leaves the end column at a temperature of
97oC. In the acid purification unit, the stream enters at a temperature of 97oC. The higher boiling
component propionic acid is obtained from the bottom of the distillation tower where a
temperature of 123oC is maintained. Glacial Acetic acid (99.8% by wt.) is obtained from the
top of the distillation tower, maintained at 118oC.
28 | P a g e
CHAPTER - VI
MATERIAL BALANCE
29 | P a g e
6.1. INTRODUCTION:-
Material balance is the basis of process design. A material balance taken on complete process
determines the quantities of material required and the products produced. Balance over
individual process unit sets the process stream flows and compositions.
Material balances are also useful tool for study of plant operation and trouble shooting.
They can be used to check the performance against design to check instrument calibration
and to locate the source of material loss.
From literature, selectivity to acetic acid = 99% (based on Methanol Route).
Yield of Acetic Acid = 90%
Basis: 100 ton per day of Glacial Acetic Acid (product)
It is known that 99.8% acetic acid by weight is to be obtained as the overhead product.
Assumed capacity of the plant = 100 TPD
= 33400 TPA
Because the total working hours for a plant under operation per a year are 8000 hours so 334
days.
6.2. MATERIAL BALANCE FOR ACETIC ACID PURIFICATION COLUMN (DC-II):
Hence for the 2nd distillation column (acetic acid purification column) the following data is
known
We have, XD = 0.998, XB = 0.00085, XF = 0.876 (all in Wt %)
And D = 100 TPD
= 4166.67 kg/hr of Acetic acid.
Taking wt. per hour basis of acetic acid,
( – )
B= ( – )
= 4166.67 × (0.876-0.998) / (0.00085-0.876)
30 | P a g e
= 580.853 kg
Thus, F = D + B = 4747.523 kg.
Hence, the weight and wt. fraction can be arranged for DC-II in the table as:
Fig 6.1. Material balance for Distillation column – II
The composition for the above components can be known from the tables
Table 6.1. Material balance for Distillation column – 2
COMPONENTS FEED FEED (wt) BOTTOM BOTTOM(wt) overhead Overhead

(wt %) in kg (wt %) in kg
H2O 0.376 17.835 1.7209 9.996 8.39 0.02
CH3COOH 87.6 4158.828 - - 4158.33 0.998
C2H5COOH 12.024 570.857 98.279 570.857 - -
TOTAL 100 4747.523 100 580.853 4166.72 100
Now, as assumed remaining methanol is converted to methyl acetate during the throttling
operation. Hence the amount of acetic acid remains constant and can be used to find the moles
(and thus the wt.) of methanol to be used.
Main Reactions:
CH₃OH + CO CH₃COOH
31 | P a g e
Side Reactions:
CH₃OH + ½ CO C2H5COOH
CH₃OH + CH₃COOH CH₃COOCH

Let the moles of methanol taken be x Kmol.
Also, yield = conversion × selectivity
∴ We have conversion = 90.91%.
Taking mole balance on the reactor itself, we have:
CH₃OH + CO CH₃COOH
x Kmoles of MeOH + x Kmoles of CO 0.9091×x Kmoles of AA
unreacted MeOH = (1-.9091) × x = 0.0909 × x kmoles
Hence, this methanol is used in production of methyl acetate in the flash tank during the
throttling process. But it is known that we obtain 1000 ppm of methanol from the tank output.
Thus,
Methanol consumed in flash tank = 0.0909 × x – 0.001 × x = 0.0899 × x kmoles
CH₃OH + CH₃COOH CH₃COOCH₃ + H2O

0.0899 × x kmoles of reactants 0.0899 × x kmoles of products
∴ Total CH3COOH to light end distillation feed = 0.9091 × x – 0.0899 × x
= 0.8192 × x Kmoles
But, the kmoles of Acetic acid in the flash tank output = 69.28 Kmoles
Hence, actual methanol requirement = 69.28/0.8192
= 84.57 Kmoles
Also, total water is produced in propionic acid and methyl acetate reaction.
∴ Total water produced = 0.01× 0.9091 × 84.57 + 0.0899 × 84.57
= 8.37 Kmoles
32 | P a g e
Total water in light end distillation column feed = 9.13 Kmoles
Carbon monoxide is taken 7.2%in excess than the methanol feed.
∴ Moles of carbon monoxide = 107.2% × 84.57 = 90.66 Kmoles
CO is the excess reagent and Methanol is the limiting reagent.
Considering overall material balance assuming the reactor, scrubber and flash tank as a
complete system we have,
Mass of gas in vent = Mass of methanol in + Mass of carbon monoxide in
– Mass of feed in light end distillation column
Mass of vent from scrubber = 2709.6228 + 2538.48 – 4945.73
= 296.56 kg
Also, 20% in excess promoter, i.e. Hydrogen Iodide and Iridium Catalyst is assumed to be used
in the reactor.
Hence, weight of catalyst = 20% excess of feed methanol
= 12981.36 Kg = 12.98 Tons
This catalyst is recycled back to the reactor from the flash tank and hence is not required to be
fed again and again.
6.3. MATERIAL BALANCE FOR THE LIGHT END DISTILLATION COLUMN (DC-I):
Fig 6.2. Material Balance for Distillation column-I
33 | P a g e
Table 6.2. Material balance for distillation column – I
Compone Feed Feed Feed Bottom Botto Botto Overhe Overhe Overhe
nts weight Wt Kmol Wt m m ad Wt ad Wt% ad
(Kg/hr) % es (Kg/hr) Wt% Kmol (Kg/hr) Kmoles
es
Acetic 4158.8 84 69.26 4158.8 87.6 69.25 - - -
acid 3 3 6
Water 163.45 3.30 9.08 17.835 0.376 0.990 145.62 71 8.09
56 1 6 8
Methanol 1.7133 0.03 0.053 - - - 1.7133 0.839 0.0535
4
Propionic 570.85 11.5 7.714 570.85 12.02 7.71
acid 7 2 7 4
Methyl 56.88 1.14 0.77 - - - 56.88 27.8 0.7686
acetate 8
Total 4951.7 100 86.87 4747.5 100 77.96 204.217 100 8.912
3 23
6.4. MATERIAL BALANCE FOR REACTOR:
Fig 6.3. Reactor material balance
Table 6.3. Material balance for Reactor

Component Kmoles Wt (Kg/hr) Wt %
Methanol 7.6028 243.3 4.92
Water 1.527 27.486 0.55
Acetic acid 76.88 4616.644 93.37
Propionic acid 0.77 56.98 1.1
Total 86.78 4944.41 100
34 | P a g e
CHAPTER - VII
ENERGY BALANCE
35 | P a g e
7.1. INTRODUCTION:
In the process design energy balances are made to determine the energy requirements of the
processes: the heating, cooling and power required in the plant operation an energy audit on plant
will show the pattern of energy usage and suggest the areas for energy conservation & solving.
General equation for conservation of energy:
Energy out = Energy in + generation – consumption - accumulation
The process is considered as perfectly steady state and accumulation of both mass and energy
will be zero.
General form for heat capacity of a particular compound will be
= A + B×T + C×T2 and
ΔHi = ∫
298 K is the reference temperature or datum temperature.
Where n is the number of moles of the particular component
TR is the temperature required.
Table 7.1. A,B,C,D & E constant values for different components

A B C D E
Methanol 105800 -320.48 0.9397 - -
Carbon 65.249 28723 -847.39 1959.6
monoxide
Acetic acid 139640 -320.48 0.8985 - -
Water 276370 -2090.1 8.125 -0.014116 9.37×10-6
Propionic acid 213660 -702.7 1.6605 - -

Methyl acetate 61260 270.9 - - -
36 | P a g e
7.2. ENTHALPY BALANCE FOR REACTOR:
Specific heat of methanol entering at 30oC will be
(Methanol) = 105800 + (-362.23×T) + 0.9397 × T2
And ΔHi at 300C =∫
= ∫ ( )
n =
= 84.55 Kmole/hr
Now =∫ ( )
Which is equal to 7536.23 KJ/Kg
∴ Specific Enthalpy of methanol at 30⁰C = 7536.23 KJ/Kg
Now specific heat of Carbon monoxide entering at 30oC will be
(Carbon monoxide) = ( ) ( ) ( )
And ΔHi at 300C = ∫
= ∫ ( ) ( ) ( )
n = 2538.48 / 28
= 90.66 Kmoles/hr
Now =∫ ( ) ( ) ( )
Which is equal to 3941.28 KJ/Kg .
∴ Specific enthalpy of carbon monoxide = 3941.28 KJ/Kg
Now calculating the total enthalpy of the streams
1. Methanol stream entering at 30⁰C
37 | P a g e
Methanol steam rate =2709.62 Kg/hr
Specific Enthalpy of methanol at 30⁰C = 7536.23 KJ/Kg
Water stream rate =13.68 Kmole/hr
Enthalpy of water =15856.5 KJ/Kmole
Total enthalpy for the stream = Enthalpy of methanol +Enthalpy of water
= (2709.62×7536.23)+(13.68×15856.5)
= 20637236.54 KJ/hr
2. Carbon monoxide stream entering at 30⁰C
Carbon monoxide stream rate = 2538.48 Kg/hr
Specific enthalpy of carbon monoxide = 3941.28 KJ/Kg
Enthalpy of Carbon monoxide stream = 2538.48 × 3941.28
= 10008604.61 KJ/hr
Now we perform the total enthalpy calculations for the feed output from the CSTR at
150oC
Now so the equation will be
(Acetic acid) = 139640 + (-320.48 ×T) + (0.8985 × T2 )
=n×∫ ( ) ( )
n = 4158.83 / 60.05
= 69.256 Kmoles/hr
Now =∫ ( ) ( )
This will be equal to 7698.63 KJ/Kg
38 | P a g e
Specific heat of Propionic acid leaving at 150oC will be
(Propionic acid) = 213660 + (-702.7 × T) + (1.6605 × T2)
And ΔHi at 150oC = ∫
=n×∫ ( ) ( )
n = 570.857 / 74.09
= 7.7049 Kmoles/hr
Now =∫ ( ) ( )
(water) = 276370 + (-2090.1 × T) + (8.125×T2) + (-0.014116×T3) + (9.37×10-6 × T4)
=n× ∫ ( ) ( )
( ) ( )
n = 163.4556 / 18
= 9.13 Kmoles/hr
Now
=∫ ( ) ( )
( ) ( )
Specific heat of methanol leaving at 150oC will be
(Methanol) = 105800 + (-362.23×T) + 0.9397 × T2
And ΔHi at 150oC =∫
39 | P a g e
=n×∫ ( ) ( )
n = 1.7133 / (32.045)
= 0.0534 Kmole/hr
Now =∫ ( ) ( )
Table 7.2. Enthalpy balance for feed out from CSTR

Component Specific enthalpy (KJ/kg) Kg/hr KJ/hr
Acetic acid 7698.63 4158.83 32017293.4
Propionic acid 6534.98 570.857 3730539.078
Methanol 7072.02 1.7133 12116.492
Water 15349.07 163.4556 2508891.446
Total 4894.856 38268840.42
Total gases (vent) out of the scrubber:
Mass of the vent gases out of the scrubber = 296.56 Kg/hr
Enthalpy of vent gases =3942.82 KJ/Kg
Enthalpy of total gases out of the scrubber = (296.56×3942.82) KJ/hr
= 1168825.997 KJ/hr
Heat gained by methanol stream
We know that heat of reaction ∆H = -138KJ/mole
= -138×103 KJ/Kmole
Flow rate of acetic acid = 76.88 Kmole/hr
Rate of heat required to start the reaction = -138×103 ×76.88
= 10609440 KJ/hr
40 | P a g e
Making overall energy balance for reactor:-
Energy in + Energy generated = Energy out + Energy accumulated
Energy accumulated = Energy in + Energy generated - Energy out
Energy in = Enthalpy of methanol stream + Enthalpy of CO stream
= 20637236.45 + 10008604.67
= 30645841.12 KJ/hr
Energy generated = Heat required to start the reaction = 10609440 KJ/hr
Energy out = 38268840.44 + Enthalpy of total gases out of the
Scrubber
=38268840.44 +1168825.997
=39437666.42 KJ/hr
Energy accumulated = 30645841.12 + 10609440 - 39437666.42
= 1817614.7 KJ/hr
We have to assume any random temperature for cooling water which is less than the ambience
So cooling water is at 17⁰C and leaves the reactor at 80⁰C.
Heat gained by cooling water = heat accumulated in the reactor
Heat gained by cooling water = mass of cooling water × Cp of water × T
Specific heat of water, = 4.18 KJ/Kg K
∆T = (80-17) ⁰C = 63⁰K
Mass of cooling water required by reactor = Energy accumulated in reactor / (4.18×(80-17))
= 1817614.7 / (4.18×63)
= 6902.16 Kg/hr
41 | P a g e
Specific heat of methanol entering at 52oC will be
(Methanol) = 105800 + (-362.23×T) + 0.9397 × T2
= n× ∫ ( ) ( )
Now =∫ ( ) ( )
Specific heat of Propionic acid entering at 52oC will be
=n × ∫ ( ) ( )
n = 570.857 / 74.09
= 7.7049 Kmoles/hr
Now =∫ ( ) ( )
Now specific heat of Acetic acid entering at 52oC will be
(Acetic acid) = 139640 + (-320.48 ×T) + (0.8985 × T2)
=n × ∫ ( ) ( )
n = 4158.83 / 60.05
= 69.256 Kmoles/hr
42 | P a g e
Now =∫ ( ) ( )
Specific heat of water entering at 52oC will be
(water) = 276370 + (-2090.1 × T) + (8.125×T2) + (-0.014116×T3) + (9.37×10-6 × T4)
=n×∫ ( ) ( )
( ) ( )
n = 163.4556 Kg/hr / 18
= 9.13 Kmoles/hr
Now = ∫ ( ) ( )
( ) ( )
Now specific heat of methyl acetate entering at 52oC will be
(Methyl acetate) = 61260 + (270.9 × T)
=n×∫ ( )
n = 56.88 / 74.09
= 0.7677 Kmoles/hr
Now =∫ ( )
43 | P a g e
7.3. ENTHALPY BALANCE FOR LIGHT END DISTILLATION COLUMN (DC-1):-
Table 7.3. Energy balance for Distillation column – 1
Component Feed (Kg/hr) Specific Enthalpy (KJ/hr)

(KJ/Kg) @ 52⁰C
Propionic acid 570.857 692.89 395541.1067
Acetic acid 4158.83 644.82 2681613.584
Water 163.4556 2211.05 361408.5
Methanol 1.7133 810.77 1389.0922
Methyl acetate 56.88 461.89 26272.3032
Total 4951.736 3466224.586
Now specific heat of methyl acetate leaving at 62oC will be
(Methyl acetate) = 61260 + (270.9 × T)
=n×∫
=n×∫ ( )
n = 56.88 / 74.09
= 0.7677 Kmoles/hr
Now =∫ ( )
water) = 276370 + (-2090.1 × T) + (8.125×T2) + (-0.014116×T3) + (9.37×10-6 × T4)
44 | P a g e
=n×∫ ( ) ( )
( ) ( )
n = 163.4556 / 18
= 9.13 Kmoles/hr
Now = ∫ ( ) ( )
( ) ( )
This will be equal to 2264 KJ/Kg
Specific heat of methanol at 620C
Cp(Methanol) = 105800 + (-362.23×T) + 0.9397 × T2
=n×∫ ( ) ( )
Now =∫ ( ) ( )
This is equal to 838.35 KJ/Kg.
Enthalpy balance for overhead stream:
Table 7.4. Enthalpy balance for overhead stream
Component Overhead Kg/hr Enthalpy @62⁰C KJ/Kg KJ/hr
Water 145.62 2264 329683.68
Methanol 1.7133 838.35 1436.345
Methyl acetate 56.88 482.23 27429.2424
Total 204.213 358549.2674
=n×∫ ( ) ( )
45 | P a g e
n = 570.857 / 74.09
= 7.7049 Kmoles/hr
Now =∫ ( ) ( )
(Acetic acid) = 139640 + (-320.48 ×T) + (0.8985 × T2 )
=n×∫
=n×∫ ( ) ( )
n = 4158.83 Kg/hr / 60.05
= 69.256 Kmoles/hr
Now =∫ ( ) ( )
Specific heat of water leaving at 97oC will be
(water) = 276370 + (-2090.1 × T) + (8.125×T2) + (-0.014116×T3) + (9.37×10-6 × T4)
=n×∫ ( ) ( )
( ) ( )
n = 163.4556 / 18
= 9.13 Kmoles/hr
Now = ∫ ( ) ( )
( ) ( )
46 | P a g e
Table 7.5. Enthalpy balance for bottom stream
Component Bottom Kg/hr Enthalpy @97⁰C KJ/hr
KJ/Kg
Propionic acid 570.857 796.32 454584.8462
Acetic acid 4158.83 747.32 3107976.836
Water 17.8356 2399.71 42800.26768
Total 4747.523 3605361.95
Calculation for cooling water requirement:
Amount of cooling water used by condenser = Mass of vapor being condensed × Specific
enthalpy of water
= Heat accumulated in the overhead stream
Amount of cooling water used by condenser = mass of cooling water×specific heat of water ×∆T
Mass of cooling water × Specific heat of water ×∆T=Heat accumulated in the overhead stream
m× (4.18× (25-17)) = 358549.2674KJ/hr
m = 358549.2674 / (4.18× (25-17))
= 10722.16 Kg/hr
Overall energy balance over DC-I:
Feed enthalpy + Enthalpy of steam = Overhead enthalpy + Bottom enthalpy
Total enthalpy of steam = Overhead enthalpy + Bottom enthalpy - Feed enthalpy
= 358549.2674 + 3605361.95 – 3466224.586
= 497686.631 KJ/hr
If there are losses for example let us assume it as 5%
Steam should provide energy = (1+0.05) × 497686.631 = 522570.96 KJ/hr
Steam entering at 120⁰C and leaving at 100⁰C as saturated liquid
Amount of steam used = Mass of steam × Specific heat of water at 100⁰C×∆T

47 | P a g e
mass of steam × specific heat of water at 100⁰C×∆T = energy provided by steam
mass of steam × 4.22 × (120-100) = 522570.96 KJ/hr
mass of steam = 522570.96 / (4.22 × (120-100))
= 6191.6 Kg/hr
7.4. ENERGY BALANCE FOR DISTILLATION COLUMN-II:
Specific heat of Propionic acid entering at 97oC will be
=n×∫ ( ) ( )
n = 570.857 / 74.09
= 7.7049 Kmoles/hr
Now =∫ ( ) ( )
Now specific heat of Acetic acid entering at 97oC will be
(Acetic acid) = 139640 + (-320.48 ×T) + (0.8985 × T2 )
=n×∫ ( ) ( )
n = 4158.83 / 60.05
= 69.256 Kmoles/hr
Now =∫ ( ) ( )
48 | P a g e
Specific heat of water entering at 97oC will be
(water) = 276370 + (-2090.1 × T) + (8.125×T2) + (-0.014116×T3) + (9.37×10-6 × T4)
=n×∫ ( ) ( )
( ) ( )
Now = ∫ ( ) ( )
( ) ( )
Enthalpy balance about Distillation Column-II :
Table 7.6. Energy balance for feed stream

component feed (Kg/hr) Enthalpy @97⁰C KJ/hr
(KJ/Kg)
Propionic acid 570.857 796.32 454584.8462
Acetic acid 4158.83 747.32 3107976.836
Water 17.8356 2399.71 42800.26768
Total 4747.523 3605361.95
Now specific heat of Acetic acid leaving at 118oC will be
(Acetic acid) = 139640 + (-320.48 ×T) + (0.8985 × T2 )
And ΔHi at 118 oC = ∫
=n×∫ ( ) ( )
Now =∫ ( ) ( )
This will be equal to 47980.18 KJ/ Kmole
(water) = 276370 + (-2090.1 × T) + (8.125×T2) + (-0.014116×T3) + (9.37×10-6 × T4)
49 | P a g e
And ΔHi at 1180C= ∫
=n×∫ ( ) ( )
( ) ( )
Now = ∫ ( ) ( )
( ) ( )
This will be equal to 44131.17 KJ/Kmole .
(Acetic acid) = 139640 + (-320.48 ×T) + (0.8985 × T2 )
= n× ∫ ( ) (
Now =∫ ( ) (
OVERHEAD STREAM SUMMARY :
Table 7.7. Energy balance for the overhead stream

Component Overhead Kmole/hr Enthalpy @ 1180C KJ/hr
KJ/Kmole
Acetic acid 69.2477 47980.18 3322517.11
Water 0.4627 44131.17 20419.492
Total 69.71 3342936.603
=n×∫ ( ) (
50 | P a g e
Now =∫ ( ) ( )
(water) = 276370 + (-2090.1 × T) + (8.125×T2) + (-0.014116×T3) + (9.37×10-6 × T4)
=n×∫ ( ) ( )
( ) ( )
Now = ∫ ( ) ( )
( ) ( )
(Acetic acid) = 139640 + (-320.48 ×T) + (0.8985 × T2 )
And ΔHi =∫
= n× ∫ ( ) ( )
Now =∫ ( ) ( )
BOTTOM STREAM SUMMARY:
Table 7.8 Energy balance for the bottom stream

Component Bottom (Kmole/hr) Enthalpy @ 1230C (KJ/hr)
(KJ/Kmole)
Propionic acid 7.7133 63883.9 492819.57
Acetic acid 0.0096 48742.8 467.93
Water 0.52456 45214.0 25021.4276
Total 8.269 518308.93
51 | P a g e
Heat Capacity summary of all Compounds, Cp Value in J/kmol.K
(Acetic acid) = 139640 + (-320.48 ×T) + 0.8985 × T2
(Methanol) = 105800 + (-362.23×T) + 0.9397 × T2
(Carbon monoxide) = 65.249 + (28723 × T) + (-847.39 × T2 ) + (1959.6 × T3)
(Water) = 276370+(-2090.1 × T) + (8.125×T2) + (-0.014116×T3) + (9.37×10-6 ×T4)
(Methyl acetate) = 61260 + (270.9 × T)
7.5 CALCULATION OF COOLING WATER REQUIREMENT:
Amount of cooling water used by condenser = m ×4.18 × (25-17)
= Mass of vapor condensed × Specific enthalpy of

vapor
= 69.71 × 1225.632
=85438.806 KJ/hr
m ×4.18 × (25-17) = 85438.806 KJ/hr
m = 85438.806 / (4.18 × (25-17))
=2554.98 Kg
Steam requirement for DC-II:-
Overall energy balance for DC-II:
Enthalpy of feed + Steam enthalpy = Overhead enthalpy + Bottom enthalpy
Total enthalpy of steam = Overhead enthalpy + Bottom enthalpy - Enthalpy of feed
= 3342936.603 + 518308.93 – 3605360.83
= 255416.773 KJ/hr
If there are losses for example let us assume it as 5%

52 | P a g e
Steam should provide energy = (1+0.05) ×255416.773 =268187.6117 KJ/hr
Steam entering at 120⁰C and leaving at 100⁰C as saturated liquid
Amount of steam used = Mass of steam × Specific heat of water at 100⁰C× ∆T
Mass of steam × specific heat of water at 100⁰C×∆T = energy provided by steam
Mass of steam × 4.22 × (120-100) = 268187.6117 KJ/hr
Mass of steam = 268187.6117 / (4.22 × (120-100))
Mass of steam = 3177.578 Kg/hr
Total steam and total cooling water requirement:-
Now evaluating total cooling water requirement
Total cooling water requirement = Cooling water in reactor + Cooling water in DC-I
+ Cooling water in DC-II
Cooling water in reactor = 6902.16 Kg/hr
Cooling water in DC-I = 10722.16 Kg/hr
Cooling water in DC-II = 2554.98 Kg/hr
Total cooling water requirement = 6902.16 + 10722.16 + 2554.98
= 20179.3 Kg/hr
= 484.303 TPD
7.6 CALCULATION OF STEAM REQUIREMENT:
Total steam requirement = Steam in DC-I + Steam in DC-II
Steam in DC-I = 6191.6 Kg/hr
Steam in DC-II = 3177.578 Kg/hr
Total steam requirement = 6191.6 + 3177.578
= 9369.178 Kg/hr = 224.86 TPD

53 | P a g e
CHAPTER - VIII
EQUIPEMENT DESIGN
54 | P a g e
8.1. AVERAGE MOLECULAR WEIGHT CALCULATION:-
From material balance we have
Feed to the DC-II = 4158.828 Kg/hr of acetic acid + 17.83576 Kg/hr
of water + 570.857 Kg/hr of Propionic acid
= 4747.521 Kg/hr
Top product from DC-II = 99.8% purity of acetic acid
Bottom product from DC-II = 98.279% purity of propionic acid
Feed:-
Total flow = 4747.521 Kg/hr
Molefraction of acetic acid in feed = 4158.828/4747.521
= 0.876
Average molecular weight calculation:
Total no of feed moles = 77.961 Kmoles/hr
Average molecular weight = 4747.521 / 77.961
= 60.895 Kg/Kmole
Distillate:-
Total flow rate of distillate = 4166.67 Kg/hr
Mole fraction of acetic acid in distillate = 0.998
Average molecular weight calculation
Total moles of distillate = 69.2478 + 0.46278
= 69.7105 Kmole/hr
Average molecular weight of distillate = 4166.67 /69.7105
= 59.7709 Kg/Kmole
Bottom:
Total bottom flow rate = 580.853 Kg/hr
Mole fraction of acetic acid = 0.001
Average molecular weight = 580.853 / total moles
Total moles = 8.269 Kmole/hr
Average molecular weight = 580.853 / 8.269

= 70.24 Kg/Kmole
55 | P a g e
8.2. Number of stages calculations for DC-2:
Firstly, we need to know relative volatility
We have following data for DC-2 from material balance
XD=0.998, XF=0.876, XB=0.001
Calculation of relative volatility:
We need to calculate the vapor pressures of acetic acid and propionic acid at 370K
Vapor pressure for acetic acid:
From perry’s handbook we have values of acetic acid
()
C1=53.27,C2=-6304.5,C3=-4.2985,C4=8.8865×10-18,C5=6
As T = 370K lnP = 53.27 – 17.039-25.4192 +0.0228
P = 10.8346
P = e10.8346
P = 50746.62 KPa
Vapor pressure calculation for propionic acid
From perry’s handbook
lnP = C1 + (C2/T) + C3 lnT + C4 × TC5
Values for propionic acid are

C1=54.552,C2=-7149.4,C3=-4.2769,C4=1.1843×10-18,C5=6
ln P = 54.552-19.322-25.29146+0.00303
ln P = 9.941
P = e9.941
P = 20776.33Kpa
α = vapor pressure of acetic acid at 370K /vapor pressure of propionic acid at 370K
α = 50746.62/20776.33
α =2.4425
We know that y = (α×x)/(1+( α-1)×x)
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y = (2.4425×x)/(1+1.4425×x)
Form the above expression we have the following equilibrium data
Table 8.1.equilibrium data for distillation column -II
x 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Y 0 0.213 0.379 0.511 0.619 0.709 0.785 0.8507 0.9071 0.9564 1
As it is saturated liquid q=1

Now Rmin is calculated in the following way
Rmin=(1/ α)((XD/XF)-( α×(1-XD)/(1-XF))
Hence by substituting the values of α, XD, XF
We have Rmin=0.45030.
Now R = 1.5×Rmin
R = 0.67545
Now by giving equilibrium data and conditions in the excel VBA Macros
we obtain the following curve
Fig 8.1 Equilibrium stages for Distillation column
57 | P a g e
Number of stages =15
From the above curve
Slope of the rectifying section line = 0.719
Slope of the stripping section line =1.041
Assuming 80% efficiency
Number of real stages =15/0.8=19
8.3. INTERNAL DESIGN ESTIMATION:
Total feed moles = 77.961Kmoles/hr
Top product vapor rate V = D×(R+1)
= 69.7105×(0.67545+1)
= 116.8Kmole/hr
Liquid rate = V×slope of the rectifying section
= 116.8×0.719
= 84Kmole/hr
Bottom product B = 8.269Kmole/hr
Slope of the stripping section =L’/V’ =1.041
V’ =L’-B
L’ =1.041×V’
V’ =1.041×V’-B
B =0.041×V’
0.041×V’ =8.269Kmole/hr
V’ =201.683Kmole/hr
L’ =1.041×201.683
L’ =209.951Kmole/hr
Top section:
Top densities form perry’s hand book
𝜌V =3.038Kg/m3 ,
𝜌L =934.36Kg/m³
Surface tension, σtop =27×10-3N/m
Bottom section:
𝜌V =3.119Kg/m³ ,
𝜌L =905.246Kg/m³
58 | P a g e
Surface tension, σbottom =32.3×10-3N/m
Calculation of flooding velocity:
Uflood = k×√
k = Csb×(σ/20)0.2
FLV = (L/V)×( 𝜌V/ 𝜌L)0.5
Now FLV,bottom = 1.041×(3.119/905.346)0.5
= 0.0611
FLV,top = 0.719×(3.038/934.36)0.5
= 0.041
Now estimating the capacity factor From the Graph
Fig 8.2. Graph for to estimate Capacity Factor
Csb,Top=0.36
Csb,Bottom=0.35
General plate spacing would be 24inch
Now
Ktop = Csb,top× (σtop/20)0.2
= 0.09602
59 | P a g e
Kbottom = Csb,bottom×( σbottom/20)0.2
= 0.09676
Uflood,top = Ktop×√
=1.6811m/s
Uflood,bottom = Kbottom×√
= 1.645m/s
Let us assume that we are designing for 85% flooding at maximum vapor flow rate
Uflood,bottom =1.645×0.85 = 1.4m/s
Uflood,top =1.6811×0.85 = 1.43m/s
Maximum volumetric flow rate
Bottom, Qv = bottom vapor flow rate × average molecular weight of bottom/ (𝜌vbottom×3600)
=201.683Kmole/hr×70.24Kg/Kmole / (3.119 Kg/m³ × 3600)
=1.2616m³/s
Top,Qv = 116.8Kmol/hr×59.77Kg/Kmol / (3.119Kg/m³ × 3600)
= 0.62m³/s
Net area required bottom(base) = Qvbottom / Uflood,bottom
= 1.2616m³/s / 1.645m/s=0.7669m²
Net area required for top = Qvtop/Uflood,top
= 0.62 m³/s / 1.6811m/s=0.368m²
Downcomer area is equal to 12% of the total area
Column cross section area
Base= 0.7669 / 0.88 = 0.8714m²
Top = 0.368 / 0.88 = 0.418m²
Column diameter:
Base = √
= 1.0535m
Top =√
= 0.737m
So we take column diameter as 1.0535m
60 | P a g e
8.4. LIQUID FLOW PATTERN:
This is determined by two parameters
1. Maximum liquid flow rate
2. Column diameter
Maximum liquid flow rate = 84Kmol/hr×59.77/(934.6×3600)
= 1.492×10-3m/s
And we know column diameter =1.0535m

From fig 11.28 vol6
Fig 8.3. graph for estimating Flow pattern

We have the flow to be cross flow single pass.
So single pass tray can be selected.
8.5. PROVISIONAL PLATE DESIGN
Column diameter Dt = 1.0535m
Column area = 0.8714m²
61 | P a g e
Down comer area = 12% of the total area = 0.104568m²
Net area = Ac-Ad = 0.8714-0.10456 = 0.77m²
Active area ,Aa = Ac-2×Ad = 0.8714-0.209136 = 0.66226m²
Hole area ,Ah = taking 10% of the active area
Hole area = 0.1×0.66226
= 0.066226m²
Weir length is generally 76% of the column diameter
=0.76×1.0535 = 0.8m
Since column operating at pressure above atmospheric pressure
Weir height = 50mm
Plate thickness = 5mm
8.6. CROSS CHECK:
Maximum liquid rate =84 ×59.77 / 3600
=1.394Kg/s
Minimum liquid rate at 70% turn down = 0.7×1.394 Kg/s
= 0.976Kg/s
Height of liquid crest over the wear
(How)max = 0.75×(1.394/(934.6×weir length))(2/3)
= 0.75×(0.7756/(934.6×0.8)2/3
= 11.363mm
Clear liquid height =11.363mm
(How)min = 0.75×(.976/(934.36×0.8))(2/3)
= 8.96mm
Clear liquid height
At minimum flow rate,dh
Hw +(How)min = 50 + 8.96
= 58.96mm liquid
62 | P a g e
Fig 8.4. Weep Point correlation
From graph Kw=30.4

Ūh = ((Kw-0.90×(25.4-dh))/( 𝜌V)(1/2))
= (30.4-0.90×(25.4-5))/(3.038)(1/2)
= 6.907m/s
Actual minimum vapor velocity = minimum vapor flow rate/hole area
= 1.2616m³/s×0.7/0.066226 (70% turndown)
= 13.335m/s
Thus,the minimum operating pressure(13.335m/s) lies well above the weep point(i.e.when vapor
velocity is 7.252m/s)
Therefore,our design is safe from operating point of view
8.7. PLATE PRESSURE DROP:-
The total plate pressure drop is given by
ht = h d + h l + h r
Dry plate drop
hd = K1 + K2× (Vgh)² ×(𝜌V/ 𝜌L)
For sieve plate ,K1=0 & K2= (58.85×10-3)/Cv²
Discharge coefficient Cv =plate thickness/hole diameter = 5/5 = 1
63 | P a g e
Fig 8.5. Discharge coefficient for gas flow through sieve plates
Form fig Cv = 0.84

Velocity through holes
Vgh = 1.2626m³/s/0.06626
= 19.05m/s
hd = K1+ K2× Vgh² × (𝜌V/ 𝜌L)
Pressure drop due to static head

hl = hw + (how)max
= 50 + 11.363mm
= 61.363mm
Residual height hr = 12.5/ 𝜌L
= 12.5×10³/934.36
= 13.374mm
The total pressure drop
Dry plate drop
hd = 51×(Uh/C0)² ×(𝜌V/ 𝜌L)
= 85.28mm liquid
ht = h d + h l + hr
64 | P a g e
= 85.28 + 61.363 + 13.374mm
= 160.014mm
8.8. DOWN COMER LIQUID BACKUP
The down comer and plate spacing must be such that the level of the liquid and froth in the down
comer is well below the top of the outlet weir on the plate above. if the level rises above the
outlet weir the column will flood
In terms of clear liquid the down comer backup is given by
hb = hw + how + ht + hdc
hdc = 166×(Lwd/( 𝜌L×Am)²
Aap = hap×Lw
Hap=height of the lower edge of the apron above tray
hap = hw-(5 or 10)
= 50-10
= 40mm
(this height is normally set at 5 to 10mm below the outlet weir height)
Aap = hap×Lw
Lw=weir length
Aap = 40mm×0.8=0.032m²
As Aap<Ad
hdc = 166×(1.394/(934.36×0.104568))²
= 33.8mm
hb = 255.177mm clear liquid
8.9. CHECK TO AVOID FLOODING
hb < 1/2(plate spacing +weir height)
hb < 1/2(609.6+50) =329.8mm
hb=255.177mm < 329.8mm
This is obvious
Since hb<329.8mm,there will be no flooding at specified operating condition that tray spacing is
acceptable
Tr = Ad×hb× 𝜌L/Lwd
= 0.104568×255.177×10-3×934.36/1.394Kg/s
= 17s
As residence time is greater than 3 secs therefore it is satisfactory
65 | P a g e
8.10. CHECK ENTRAINMENT:
Percent flooding = Uv/Uf
= 1.40m/s/1.682m/s
= 0.826
Fig 8.6. Graph for Fractional entrainment
The percent of flooding is 82.6% and flow parameter at the bottom of distillation column is FLV
= 0.0611. From the above graph Figure by using the above two parameters, the fractional
Entrainment is found out to be ᵠ = 0.058 which is well below the value = 0.1
Therefore our design is acceptable.

Hence the achieved flooding is less than flooding at maximum flow rate (85%) our design is
correct.
8.11. TRIAL LAYOUT:
We are considering sectional construction plates Allowing 125 mm unperforated strip round
plate and 125 mm wide calming zone
66 | P a g e
From Figure below, at Lw/Dc =0.8/1.0535 = 0.76
Φ=99o
Angle subtended by the edge of the plate will be 180 -99 = 810
Mean length, unperforated edge strips = (column dia – 125mm)×3.14×(angle subtended by
edge/1800)
= (1.0535 – 125×10-3 ) × 3.14 × (81/180)
= 1.312 m
Area of unperforated edge strips = (125×10-3 × 1.312) m2
= 0.164 m2
Mean length of calming zone = weir length × width of unperforated strip

= 0.8 m + (125×10-3) m
= 0.925 m
Area of calming zones = 0.925 × (125×10-3) m2
= 0.1156 m2
Total area for perforations, Ap = (Aa) – (area of edge strips) – (calming zone area)
= 0.66226 m2 – 0.164 m2 - 0.1156 m2
= 0.38266 m2
Ah/Ap = 0.06626 m2 / 0.38266 m2
= 0.173
Fig 8.7. Relation between weir length , chord height and angle subtended by weir length
67 | P a g e
Number of holes
Area of one hole = 1.964×10-5 m2
Number of hole = 0.066226/1.964×10-5
= 3375
Design pressure =1atm =1.01325 bar
= 0.101325N/mm
Design pressure, take as 10 per cent above operating pressure
Therefore design pressure =0.101325×1.1 = 0.1114575 N/mm
Typical design stress =145 N/mm2
Cylindrical section:
e = (0.1114575×1.98×103)/((2×145)-(0.1114575)) = 0.76mm
Say 1mm
8.12 CHOOSING DOMEDHEAD AND CALCULATING ITS THICKNESS:

1. Try a standard dish head(torisphere)
Crown radius Rc =Di =1.0535 m
Knuckle radius Rk =0.06×1.0535 = 0.06321 m
Assuming joint efficiency, J=1
() ( √ )
Cs = 1.7706
( )
e = 1.3 mm
∴ Thickness of the torispherical head e = 1.3 mm
Trying standard ellipsoidal head, major to minor axes ratio =2:1
∴ Thickness of ellipsoidal head, e = 0.76(Say 1mm)
Hence we have ellipsoidal head as probably the most economical.

∴ Taking same thickness as wall 1 mm.
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8.13. STAGES CALCULATION FOR LIGHT END DISTILLATION COLUMN (DC-1):
This calculation is done by FUG shortcut method (Fenskey,Underwood,Gilliland)
We need to know the relative volatilities of the components.so we need to calculate the
component vapor pressures.
Antoine equation ln P =A- (B/(T+C))
From Coulson and Richardson volume 6,
We have the following data of A,B,C
Acetic acid :
A= 16.808,B= 3405.57,C= -56.34
Propionic acid:
A= 17.3789,B= 3723.42,C= -67.48
Methyl acetate:
A= 16.1295,B= 2601.92,C= -56.15
Water:
A= 18.3036,B= 3816.44,C= -46.13
Methanol:
A= 18.5875,B= 3626.55,C= -34.29
Now calculating the pressures for the components at temperature 325K
ln = A- (B/(T+C))
= 16.808 – (3405.57/(325-56.34))
=4.1319
=62.33 mmHg
ln = A- (B/(T+C))
= 17.3789 – (3723.42/(325-67.48))
= 2.9201
=18.5438 mmHg
ln = A- (B/(T+C))
= 16.1295 – (2601.92/(325-56.15))
= 6.4515
=633.676 mmHg
= A- (B/(T+C))
= 18.3036 – (3816.44/(325-46.13))
69 | P a g e
= 4.6182
=101.314 mmHg
ln = A- (B/(T+C))
= 18.5875 – (3626.55/(325-34.29))
= 451.55mmHg
Calculation of relative volatilities:

We assume that water is the light key component (LK) and methyl acetate as heavy key
component (HK)
αi = Pi/PHK
= 18.5438/633.676
= 0.02926
= 62.3/633.676
= 0.0983
= 101.314/633.676
= 0.15988
= 451.55/633.676
= 0.7125
= 633.676/633.676
=1
Table 8.2. calculations for Relative volatility
Components XF XD XB α
C2H5COOH 0.115 0 0.12 0.02926

CH3COOH 0.84 0 0.876 0.983
H2O 0.033 0.713 0.003756 0.15988
CH3OH 0.000346 0.00839 0 0.7125
CH3COOCH3 0.01148 0.278 0 1
1- Gilliland equation:
( )
70 | P a g e
2- Fenske equation:
( )
( )
3- Underwood equation:
( )
Where θ: is a relative volatility lies between the relative volatility of light and heavy
components
substituting α ,XF, and q=1 (saturated liquid)
we have the equation

0.103×θ4 – (0.18531× θ3 ) +0.09732 ×θ2 + 0.01244× θ – 0.0005 = 0
By solving we get θ = 0.0324
Rmin = 0.19
R = 1.5×Rmin
= 0.285
( )
( )
Nmin= 14
( )
By substituting above all values we have N= 25 stages

9.14. SHELL THICKNESS:
For thickness we must follow the following configuration
1. Design pressure=1.1×operating pressure
2. Permissible tensile stress, F= 145 N/mm²
3. Joint efficiency factor, j= 1(for shell)
4. Inner diameter, Di=0.7721m
5. Corrosion allowance C=1.5m
71 | P a g e
Shell thickness is given by
tS = (145 × 772.1) / ((2×145×1) – 145) + 1.5
= 77.2 mm
9.15. CONDENSER DESIGN:

The molar flow rate of vapor into the condenser of a purification column is
V = 69.77 Kmol /hr
Entering temperature of the condensate = 1180C = 391 K
Leaving temperature of the condensate = 600C = 333 K
The enthalpy of the vapor = 47980.18 kJ/kmol
The enthalpy of the condensate = 39870.16 kJ/kmol
Entering temperature of the cooling water = 170C = 290 K
Leaving temperature of the cooling water = 700C = 343 K
Standard plant requires the tubes of each having outer diameter 20 m.m and inner diameter
16.8 m.m and tube length of 4.88 m long made of admiralty brass
Thermal condition of vapor: Totally condensed and no sub-cooling occurs.
Here only the thermal design of the condenser is considered.
The physical properties of the mixture will be taken as mean of those for Acetic acid
(M.W=60.05) and propionic acid (M.W=74.09) at the average temperature.
Heat transferred from vapor = 69.77 × (47980.18 – 39870.16) / 3600
= 157.91 KW
Assume the overall heat coefficient = 75 W/m2 K
as it is light organics-water system the overall heat transfer coefficient lies in the range of
75-150 W/m2 K
Mean temperature difference:

The condensation range is small and the change in the saturation temperature will be linear. So
the corrected logarithmic mean temperature is used.
R = ( TH.in – TH.out ) / ( Tw.out – Tw.in )
= ( 118-60 ) / ( 70-17 ) = 1.094

S = ( Tw.out – Tw.in ) / ( TH.in – Tw.in)
= ( 70-17 ) / ( 118-17 ) = 0.52

Take a horizontal exchanger with condensation in the shell, four tube passes. For one shell and
four tube passes Ft = 0.75 from the below Figure.
72 | P a g e
Fig.8.8.Ft parameter versus S correlation
ΔTlh = (( 118-60 ) - ( 70-17 )) / ln (( 118-60 ) /( 70-17 ))
= 45.45420C
ΔTm = 0.7 × 45.4542 = 34.090C
Trial area = 157.91 ×1000/ 75 ×34.09

= 61.66 m2
Surface area of one tube = π × 20 × 10-3 × 4.88

= 0.305m2
Number of tubes = 61.76 / 0.305 = 203

Using square pitch = Pt = 1.25 × 20 = 25 m.m
Tube bundle diameter = Db = d0 (Nt / K1)/n1
K1 for 4 pass and square pitch is 0.158 and n1 is 2.263
Db = 20 (1.512 / 0.158 )1/2.263
= 1,148 m.m
Number of tubes in the center row = Nr = Db / Pt = 1148 / 25 = 46
Shell-side coefficient:
Estimate tube wall temperature by assuming the condensing heat transfer coefficient as
150 W/m2 0K
Shell side mean temperature = (118 + 60) / 2 = 890C
Tube side mean temperature = (17 + 70) / 2 = 43.50C
Balancing the heat energy on both sides

73 | P a g e
(89-TW) ×150 = (89-43.5) × 75
TW = 66.250C
Mean temperature condensate = ( 89 + 66.25 ) / 2 = 77.6250C
Physical properties at 77.6250C
μL = 0.55 mNs/m2
ℓL = 934.36 kg/m3
KL = 0.158 W/m0C
Vapor density at mean vapor temperature = ℓV
= (60.05 / 22.4) × (273 / (273 + 89)) ×10

= 20.217 kg/m3
Ґh = WC / L×Nt
= (4166.67 / 3600) × (4.88 ×203)
= 1.17×10-3 kg/s.m
Nr = 2 ×46 / 3 = 30
(hc)b = 0.95 × KL × (ℓL ( ℓL-ℓV ) ×g / μL × Ґh )1/3 ×Nr-1/6
= 0.95 × 0.158 (934.36 × ( 934.36 – 3.038 ) × 9.81)
/ 0.55×10-3×20.217×10-3)-1/3× (30)-1/6
= 162.58 W/m2 0C
Close enough to assumed value of 150 W/m2 0C. So no correction to Tw needed.
Tube-side coefficient:
Tube cross-sectional area = (π/4) × (16.8×10-2)2 × 203 / 4 = 0.0125 m2
Density of water at 43.50C = 993 kg/m3
Tube velocity = (0.71 / 993) × (1 / 0.0125) = 0.0572m/s

Inner heat transfer coefficient = hi = 4200 (1.35 + 0.02t ) Ut0.8 / di0.2
= 4200 (1.35 + 0.02 × 43.5) × 0.05720.8 / 16.80.2
= 437.68 W/m2 0C
Fouling factors: As neither fluid is heavily fouling, use 550 W/m2 0C for each side and
Kw = 30 W/m0C
Overall coefficient:
1/U = 1/162.58 + 1/550 + 20×10-3ln (20/16.8)/2×30 + 20/(16.8×550) + 20/(16.8×437.68)
= 0.012911
U = 77.45 W/m2 0C Close enough to the estimate, firm up design.
Shell-side pressure drop:

74 | P a g e
Use pull through floating head, no need for close clearance.
Select baffle spacing = shell diameter, 45 percent cut
Fig.8.9. Shell bundle clearance

For calculated bundle diameter Db = 1148 m.m the clearance from the above graph Figure 8.9 is
97 m.m
Shell inner diameter = shell bundle diameter + clearance = 1148 + 97 = 1245 m.m
Using kern’s method to make an approximate estimate
Cross-flow area = As = ( Pt – do ) × Ds × lb / Pt
= ( 25-20 ) × 1245 ×1245 ×10-6 / 25 = 0.31 m2
Mass flow rate based on inlet conditions = Gs = (4166.67 / 3600) × (1 / 0.31)

= 3.733 kg/s.m2
Equivalent diameter = de = 1.27( Pt2 – 0.785do2 ) / do

= 1.27( 252 – 0.785×202 ) / 20
= 19.8 m.m
Vapor viscosity = 0.035 mNs/m2
Reynolds number, Re = 3.733 × 19.8 ×10-3 / 0.035×10-3
75 | P a g e
= 21777.3
From this Reynolds number we can calculate shell side friction factors, and segmental baffles
from the below graph in Figure 8.10
Fig.8.10. Shell-side friction factors, segmental baffles

From the above figure, the friction factor = jf = 2.9×10-2
US = GS / ℓV = 3.733 / 3.038 = 1.228 m/s
Take the pressure drop as 40 % of that calculated using the inlet flow, neglect viscosity
correction
ΔPs = 8 × jf ( DS / de ) ( L / lb) ( ℓV × US2 / 2) ( μ /μw )-0.14
= (2/5) × (8 × 2.9 ×10-2) (1245 / 19.8) (4.88 / 1245) (12.87 × (22.6)2 / 2)
= 3.6psi
Negligible, more sophisticated method of calculation not justified.
Tube-side pressure drop:
Viscosity of water = 0.66 mNs/m2
Reynolds number = 0.057×993×16.8×10-3/(0.66×10-3) = 14458.08
76 | P a g e
By using this Reynolds number we can calculate tube side friction factors from the below graph
in Figure 8.11.
Fig.8.11. Tube-side friction factors

From the above graph, the friction factor jf = 4.5×10-3
Neglect viscosity correction factor
ΔPt = Np (8×jf (L/di) (μ/μw)-m + 2.5)×ℓ×Ut2/2
= 4 (8×4.5×10-3(4.88/13.8×10-3) +2.5)×993×0.0572/2
= 7.8 psi
This is an acceptable value.
8.16. REBOILER DESIGN:

Consider a kettle type reboiler is used in purification column
Physical properties of Acetic acid at 1.4070 atm
Vaporization rate of Acetic acid : 201.683 kmol/hr
Boiling point at 1.4070 atm : 117.870C
Latent heat of the stream : 23670 kJ/kmol

Critical pressure (PC) : 571.1 atm
Mean specific heat liquid : 51.463 kJ/kmol0C
77 | P a g e
Calculation of heat loads:
Sensible heat load (maximum) = ( 117.87 - 0) × 51.463 = 6065.94 kJ/kmol
Total heat load = (6065.94 + 23670) ×201.683 / 3600 = 1665.89 KW
For light organics-water mixture, we use steam to vaporize the mixture. The range of overall heat
transfer coefficient is in the range of 100 – 200 W/m2 0C
Assume U = 100 W/ m2 0C
Mean temperature difference:

Steam saturation temperature at 1 atm = 1000C
ΔTm = 117.8 – 100 = 17.80C
Area required (outside) = Total head load / U ×ΔTm

= 1665.8 ×1000 / 100 ×17.8 = 935.89 m2
Select 56 mm of inner diameter and 60 mm of outer diameter plain U-tubes of nominal length =
9.6 m
Number of U-tubes = Area required (outside)/Area of each pipe
= 935.89/ (60×10-3) × 3.14 × 9.6 = 517.46 tubes
Use square pitch arrangement, pitch = 1.5 × tube outer diameter

= 1.5 × 60 = 90 mm
Use mostinski’s equation
Heat flux, based on estimated area = Q = Total heat load / Area (outside)
= 1665.8 / 935.89 = 1.78 KW/m2
Heat coefficient = hnb is given by the equation

hnb = 0.104 (PC)0.69 (Q)0.7 (1.8(P/PC)0.17 + 4×(P /PC)1.2 + 10×(P/PC)10)
P = operating pressure, = 1.4 atm

PC = liquid critical pressure = 571.1 atm
Q = heat flux, W/m2 = 13.88 KW/m2
Hnb = 0.104 × (571.1)0.69 × (1.78 × 103)0.7 × (1.8(1.4/ 571.1)0.17 +

4×(1.4/ 571.1)1.2+10(1.4/ 571.1)10)
= 1018.62 W/m2 0C
Take steam condensing coefficient as 1000 W/m2 0C
Fouling coefficient 300 W/m2 0C and methanol fouling coefficient,essentially clean 500 W/m2 0C
Tube material will be in plain carbon steel = 55 W/m 0C
1/U0 = (1/1018.62) + (1/500) + (60×10-3×ln (60/56) ) / 2×55 + (60/56)×(1/300 + 1/1000)
U0 = 108.6 W/m2 0C
78 | P a g e
This is close enough to original estimate of 100 W/m2 oC for the design to stand.
Myers and Kate give some data on boiling of methanol on banks of tubes. To compare the value
estimate with their values an estimate of the boiling film temperature difference is required.
= (108.6/1018.62) × 17.8 = 1.89770C
Myers data, extrapolated gives a coefficient of around 100 W/m2 0C at a 1.89770C temperature
difference = 4826 W/m2 0C, so the estimated value of 1018.62 W/m2 0C is certainly on the safe
side.
Check maximum allowable heat flux. Use modified Zuber equation.
Surface tension (estimated) = 32.3×10-3 N/m
ℓL = 905.346 kg/m3
ℓV = 3.119 kg/m3
Nt = 518
Qcb = Kb (Pt/Do) (λ) (σg (ℓL - ℓV)× ℓV2)0.25
As square arrangement Kb = 0.44

Qcb = 0.44×(90/60)×(23670) (20.6×10-3× 9.8×(905.346 – 3.119)×(3.119)2)0.25
= 4985.946 W/m2
= 4.985 KW/m2
Applying a factor of 0.7, maximum flux rate should not exceed the value
= 4.985×0.7 = 3.49 KW/m2.
Actual flux of 1.788 KW/m2 is well below maximum allowable flux rate.
79 | P a g e
CHAPTER -IX
SIMULATION USING UNISIM

DESIGN SUITE
80 | P a g e
This chapter includes the study of comparison of handmade calculations and computer
simulated results using UnisimTM design software.
UniSim Design offers a high degree of flexibility because there are multiple ways to accomplish
specific tasks. This flexibility combined with a consistent and logical approach to how these
capabilities are delivered makes UniSim Design an extremely versatile process simulation tool.
The usability of UniSim Design is attributed to the following four key aspects of its design:
• Event Driven operation
•Modular Operations
• Multi-flow sheet Architecture
• Object Oriented Design
The simulation software UnisimTM which is designed by Honeywell is mostly used in many of
the chemical and petro-chemical industries.
UniSim design is the Honeywell’s version of Hysis.
“Fluid Package” is UniSim’s terminology for a collection of data that includes all the
thermodynamic, component, and reaction parameters required to run the model. Select
UNIQUAC as this method provides maximum data for our chemicals.
Having completed the process model we will now take a look at some of the facilities in UniSim
that allow us to generate reports, do additional design tasks, and help with model development.
REPORT:
The following report is being generated from the simulation balance tool
81 | P a g e
Fig.9.1. Flow sheet of simulation of manufacture of acetic acid.
82 | P a g e
1
Case Name: C:\Documents and Settings\Administrator\Desktop\work\prun.usc
2 Company Name Not Available
3 Calgary, Alberta Unit Set: SI

4 CANADA
Date/Time: Wednesday May 21 2014, 12:18:06
5
6
7 Workbook: Case (Main)

8
9
STATUS
10
11 OK
12
Material Streams Fluid Pkg: All
13
14 Name top bottom FEED1 top1 bottom1

15 Vapour Fraction 0.0000 0.0000 0.0000 0.0000 0.0000
16 Temperature (C) 118.0 123.0 52.00 * 62.08 97.03
17 Pressure (kPa) 101.3 157.3 1800 * 101.3 171.0
18 Molar Flow (kgmole/h) 69.712 8.264 86.856 8.910 77.953
19 Mass Flow (kg/h) 4167 580.850 4952 * 204.21 4747.523
20 Liquid Volume Flow (m3/h) 3.982 0.5755 4.754 0.1963 4.178
21 Heat Flow (kJ/h) -3.343e+006 -5.183e+005 -3.466e+006 -3.585e+005 -3.605e+006
22 Name cstr out out methanol CO vout
23 Vapour Fraction 0.0000 0.0000 0.0000 1.0000 1.0000
24 Temperature (C) 150.0 * 150.0 30.00 * 30.00 * 715.9
25 Pressure (kPa) 3000 * 2000 101.3 * 101.3 * 101.3
27 Mass Flow (kg/h) 4895 * 4895 2710 * 2538 * 5248
30 Name lout
31 Vapour Fraction 0.0000
32 Temperature (C) 715.9
33 Pressure (kPa) 101.3
34 Molar Flow (kgmole/h) 0.0000
35 Mass Flow (kg/h) 0.0000
36 Liquid Volume Flow (m3/h) 0.0000
Heat Flow (kJ/h) -0.0000
37
38
Compositions Fluid Pkg: All
39
40 Name top bottom FEED1 top1 bottom1

41 Comp Mole Frac (Methanol) 0.000000 0.000000 0.000616 * 0.005992 0.000000
42 Comp Mole Frac (CO) 0.000000 0.000000 0.000000 * 0.000000 0.000000
43 Comp Mole Frac (C3oicAcid) 0.000615 0.982756 0.088722 * 0.000000 0.098957
44 Comp Mole Frac (M-Acetate) 0.000000 0.000000 0.008840 * 0.086159 0.000000
45 Comp Mole Frac (H2O) 0.001380 0.009796 0.104465 * 0.907860 0.012733
46 Comp Mole Frac (AceticAcid) 0.998005 0.007444 0.797357 * 0.000000 0.888230
47 Name cstr out out methanol CO vout
48 Comp Mole Frac (Methanol) 0.000621 * 0.000621 1.000000 * 0.000000 * 0.078190
49 Comp Mole Frac (CO) 0.000000 * 0.000000 0.000000 * 1.000000 * 0.139828
50 Comp Mole Frac (C3oicAcid) 0.089514 * 0.089514 0.000000 * 0.000000 * 0.000000
51 Comp Mole Frac (M-Acetate) 0.000000 * 0.000000 0.000000 * 0.000000 * 0.000000
52 Comp Mole Frac (H2O) 0.105397 * 0.105397 0.000000 * 0.000000 * 0.000000
53 Comp Mole Frac (AceticAcid) 0.804469 * 0.804469 0.000000 * 0.000000 * 0.781982
54 Name Lout
55 Comp Mole Frac (Methanol) 0.019466
56 Comp Mole Frac (CO) 0.478011
57 Comp Mole Frac (C3oicAcid) 0.000000
58 Comp Mole Frac (M-Acetate) 0.000000
59 Comp Mole Frac (H2O) 0.000000
83 | P a g e
60 Comp Mole Frac (AceticAcid) 0.502523
61
1

4 CANADA
5
6
7 Workbook: Case (Main) (continued)

8
9
Energy Streams Fluid Pkg: All
10
11 Name Qcondenser Qreboiler qc qr

Heat Flow 5.786e+006 5.656e+006
12 (kJ/h) 1.541e+006 2.239e+006
13
Unit Ops
14
15 Operation Name Operation Type Feeds Products Ignored Calc Level

16 bottom1 bottom
17 DC-2 Distillation Qreboiler top No 2500 *
18 Qcondenser
19 FEED1 bottom1
20 DC-1 Distillation qr top1 No 2500 *
21 qc
22 VLV-100 Valve cstr out out No 500.0 *
23 methanol lout
CRV-100 Conversion Reactor CO vout No 500.0 *
24
25
26 Distillation: DC-2
27
28
CONNECTIONS
29
30 Inlet Stream
31 STREAM NAME Stage FROM UNIT OPERATION
32 Qreboiler Reboiler
33 bottom1 7__Main TS Material Stream bottom1
34 Outlet Stream
35 STREAM NAME Stage TO UNIT OPERATION
36 Qcondenser Condenser
Top Condenser
37
Bottom Reboiler
38
39
MONITOR
40
41 Specifications Summary
42 Specified Value Current Value Wt. Error Wt. Tol. Abs. Tol. Active Estimate Used
43 Reflux Ratio 0.675 0.675 -2.904e-006 0.0100 * 0.0100 * On On On
44 Distillate Rate 4167 kg/h * 4167 kg/h -2.476e-006 0.0100 * 1.000 kg/h * On On On
45 Reflux Rate --- 1.042e+004 kg/h --- 0.0100 * 1.000 kg/h * Off On Off
Btms Prod Rate --- 580.85 kg/h --- 0.0100 * 1.000 kg/h * Off On Off
46
47
SPECS
48
49 Column Specification Parameters
50
Reflux Ratio
51
52 Fixed / Ranged: Fixed Primary / Alternate: Primary Lower Bound: --- Upper Bound: ---
Stage: Condenser Flow Basis: Molar Liquid Specification: ---
53
54
Distillate Rate
55
Stream: top @COL1 Flow Basis: Mass
57
84 | P a g e
1


4 CANADA
5
6
7 Distillation: DC-2 (continued)
8
10
Btms Prod Rate
11
Stream: bottom @COL1 Flow Basis: Mass
13
14
SUBCOOLING
15
16 Condenser
17 Degrees of Subcooling ---
Subcool to ---
18
19
20
User Variables
21
CONDITIONS
22
23 Name bottom1 bottom top Qreboiler Qcondenser

24 Vapour 0.0000 0.0000 0.0000 --- ---
25 Temperature (C) 97.038 123.0 118.0 --- ---
26 Pressure (kPa) 170.9758 157.2564 101.3250 --- ---
27 Molar Flow (kgmole/h) 77.9747 8.2649 69.7123 --- ---
28 Mass Flow (kg/h) 4747.525 580.858 4166.7667 --- ---
29 Std Ideal Liq Vol Flow (m3/h) 4.1782 0.5557 3.9818 --- ---
30 Molar Enthalpy (kJ/kgmole) -4.524e+005 -4.736e+005 -4.535e+005 --- ---
31 Molar Entropy (kJ/kgmole-C) 135.5 171.4 121.5 --- ---
Heat Flow (kJ/h) -3.605e+006 -5.183e+005 -3.343e+006 5.6556e+06 5.7856e+06
32
33
PROPERTIES
34
35 Name bottom1 bottom top
36
37
STATUS
38
39 OK
40
41
NOTES
42
43
44
Description
45
46
47 Distillation: DC-1
48
49
CONNECTIONS
50
51 Inlet Stream
52 STREAM NAME Stage FROM UNIT OPERATION
53 qr Reboiler
54 FEED1 13__Main TS
55 Outlet Stream
56 STREAM NAME Stage TO UNIT OPERATION
57 qc Condenser
58 top1 Condenser
59
bottom1 Reboiler Material Stream bottom1
85 | P a g e
60
61
MONITOR
1

4 CANADA
5
6

8
9 Specifications Summary
10 Specified Value Current Value Wt. Error Wt. Tol. Abs. Tol. Active Estimate Used
11 Reflux Ratio 1.785 * 1.785 5.391e-008 0.0100 * 0.0100 * On On On

12 Distillate Rate 16.00 kgmole/h * 16.00 kgmole/h -4.702e-007 0.0100 * 1.000 kgmole/h * On On On
13 Reflux Rate --- 28.56 kgmole/h --- 0.0100 * 1.000 kgmole/h * Off On Off
Btms Prod Rate --- 70.85 kgmole/h --- 0.0100 * 1.000 kgmole/h * Off On Off
14
15
SPECS
16
18
Reflux Ratio
19
21
22
Distillate Rate
23
Stream: top1 @COL2 Flow Basis: Molar
25
26
Reflux Rate
27
29
30
Btms Prod Rate
31
Stream: bottom1 @COL2 Flow Basis: Molar
33
41
CONDITIONS
42
43 Name FEED1 bottom1 top1 qr qc

44 Vapour 0.0000 0.0000 0.0000 --- ---
45 Temperature (C) 52.0000 * 97.03 62.08 --- ---
46 Pressure (kPa) 1800.0000 * 170.9758 101.3250 --- ---
47 Molar Flow (kgmole/h) 86.8547 77.953 8.910 --- ---
48 Mass Flow (kg/h) 4951.7359 * 4747.523 204.21 --- ---
49 Std Ideal Liq Vol Flow (m3/h) 4.7537 4.1782 0.1963 --- ---
50 Molar Enthalpy (kJ/kgmole) -4.423e+005 -4.524e+005 -3.537e+004 --- ---
51 Molar Entropy (kJ/kgmole-C) 107.0 135.5 68.02 --- ---
Heat Flow (kJ/h) -3.466e+006 -3.605e+006 -3.585e+005 2.2389e+06 1.5406e+06
52
53
PROPERTIES
54
55 Name FEED1 bottom1 top1
56
57
STATUS
58
59 OK
1 Case Name: C:\Documents and Settings\Administrator\Desktop\work\prun.usc

86 | P a g e

4 CANADA
5
6
8
9
10
NOTES
11
12
Description
13
14
15 Valve: VLV-100
16
17
18
CONNECTIONS
19
Inlet Stream
20
21 STREAM NAME FROM UNIT OPERATION
22 cstr out
23
Outlet Stream
24
25 STREAM NAME TO UNIT OPERATION

26 out
27
28
PARAMETERS
29
Physical Properties
30
31 Pressure Drop: 1000 kPa *
32
33
User Variables
34
CONDITIONS
35
36 Name cstr out out

37 Vapour 0.0000 0.0000
38 Temperature (C) 150.0000 * 150.0107
39 Pressure (kPa) 3000.0000 * 2000.0000
40 Molar Flow (kgmole/h) 86.0868 86.0868
41 Mass Flow (kg/h) 4894.8559 * 4894.8559
42 Std Ideal Liq Vol Flow (m3/h) 4.6932 4.6932
43 Molar Enthalpy (kJ/kgmole) -4.322e+005 -4.322e+005
44 Molar Entropy (kJ/kgmole-C) 152.9 149.9
45 Heat Flow (kJ/h) -3.7205e+07 -3.7205e+07
46
PROPERTIES
47
48 Name cstr out out
49
50
STATUS
51
52 OK
87 | P a g e
1


4 CANADA
5
6
7 Conversion Reactor: CRV-100

8
9
10
CONNECTIONS
11
Inlet Stream Connections
12
13 Stream Name From Unit Operation
14 methanol
15 CO
16
Outlet Stream Connections
17
18 Stream Name To Unit Operation

19 vout
20 lout
21
Energy Stream Connections
22
24
25
26
PARAMETERS
27 Physical Parameters Optional Heat Transfer: Heating
28 Delta P Vessel Volume Duty Energy Stream
29 0.0000 kPa --- 0.0000 kJ/h
30
31
User Variables
32
CONDITIONS
33
34 Name methanol CO lout vout

35 Vapour 0.0000 1.0000 0.0000 1.0000
36 Temperature (C) 30.0000 * 30.0000 * 715.9276 715.9276
37 Pressure (kPa) 101.3250 * 101.3250 * 101.3250 101.3250
38 Molar Flow (kgmole/h) 84.5649 90.6247 0.0000 98.3117
39 Mass Flow (kg/h) 2709.6200 * 2538.4800 * 0.0000 5248.0154
40 Std Ideal Liq Vol Flow (m3/h) 3.4052 3.1755 0.0000 5.1818
41 Molar Enthalpy (kJ/kgmole) -2.389e+005 -1.104e+005 -2.347e+005 -3.073e+005
42 Molar Entropy (kJ/kgmole-C) 50.71 198.0 254.4 273.7
43
Heat Flow (kJ/h) -2.0199e+07 -1.0009e+07 -0.0000e-01 -3.0208e+07
44
PROPERTIES
45
47
48
STATUS
49
50 OK
57
58 Conversion Reactor: CRV-100
88 | P a g e
1
1 Case Name:Case Name:
C:\Documents and Settings\Administrator\Desktop\work\prun.uscC:\Documents and
2 Company Name Not Available Settings\Administrator\Desktop\work\prun.usc

4 CANADA
5
6
7 Conversion Reactor: CRV-100 (continued)
8
9
CONNECTIONS
10
11 Inlet Stream Connections
13 methanol
14 CO
15
Outlet Stream Connections
16
17 Stream Name To Unit Operation
18 vout
19 lout
20
Energy Stream Connections
21
23
24
25
PARAMETERS
26 Physical Parameters Optional Heat Transfer: Heating
27 Delta P Vessel Volume Duty Energy Stream
28 0.0000 kPa --- 0.0000 kJ/h
29
30
User Variables
31
REACTION DETAILS
32
33 Reaction: Rxn-1
34 Component Mole Weight Stoichiometric Coeff.
35 Methanol 32.04 -1.000 *

36 CO 28.01 -1.000 *
AceticAcid 60.05 1.000 *
37
38
39
40
REACTION RESULTS FOR : Global Rxn Set
41
42
Extents
43 Name Rank Specified Use Default Actual Base Reaction Extent
44 % Conversion % Conversion Component (kgmole/h)
45 Rxn-1 0 90.91 Yes 90.91 Methanol 76.88
46
47
Balance
48 Components Total Inflow Total Reaction Total Outflow
49 (kgmole/h) (kgmole/h) (kgmole/h)
50 Methanol 84.56 -76.88 7.687
51 CO 90.62 -76.88 13.75
52 C3oicAcid 0.0000 0.0000 0.0000
53 M-Acetate 0.0000 0.0000 0.0000
54 H2O 0.0000 0.0000 0.0000
AceticAcid 0.0000 76.88 76.88
55
89 | P a g e

4 CANADA
5
6
8
9
10
User Variables
11
REACTION DETAILS
12
13 Reaction: Rxn-1
14 Component Mole Weight Stoichiometric Coeff.
15 Methanol 32.04 -1.000 *

16 CO 28.01 -1.000 *
AceticAcid 60.05 1.000 *
17
18
19
20
REACTION RESULTS FOR : Global Rxn Set
21
22
Extents
23 Name Rank Specified Use Default Actual Base Reaction Extent
24 % Conversion % Conversion Component (kgmole/h)
25 Rxn-1 0 90.91 Yes 90.91 Methanol 76.88
26
27
Balance
28 Components Total Inflow Total Reaction Total Outflow
29 (kgmole/h) (kgmole/h) (kgmole/h)
30 Methanol 84.56 -76.88 7.687

31 CO 90.62 -76.88 13.75
32 C3oicAcid 0.0000 0.0000 0.0000
33 M-Acetate 0.0000 0.0000 0.0000
34 H2O 0.0000 0.0000 0.0000
AceticAcid 0.0000 76.88 76.88
35
36
37
RATING
38
Sizing
39
40 Cylinder Vertical Reactor has a Boot: No
Height
41 Volume --- Diameter --- ---
42
Nozzles
43
44 Base Elevation Relative to Ground Level 0.0000 m Diameter --- Height ---
45 methanol CO vout
46 Diameter (m) 0.0500 0.0500 0.0500
47 Elevation (Base) (m) 0.0000 0.0000 0.0000
48 Elevation (Ground) (m) 0.0000 0.0000 0.0000
49 Elevation (% of Height) (%) --- --- ---
50 lout
51 Diameter (m) 0.0500
52 Elevation (Base) (m) 0.0000
53 Elevation (Ground) (m) 0.0000
Elevation (% of Height) (%) ---
54
55
CONDITIONS
56

58 Vapour 0.0000 1.0000 0.0000 1.0000
59 Temperature (C) 30.0000 * 30.0000 * 715.9276 715.9276
60 Pressure (kPa) 101.3250 * 101.3250 * 101.3250 101.3250
61 Molar Flow (kgmole/h) 84.5649 90.6247 0.0000 98.3117
90 | P a g e
62 Mass Flow (kg/h) 2709.6200 * 2538.4800 * 0.0000 5248.0154
63 Honeywell International Inc. UniSim Design (R410 Build 17061) Page 10 of 13


4 CANADA
5
6
8
9
CONDITIONS
10
11 Std Ideal Liq Vol Flow (m3/h) 3.4052 3.1755 0.0000 5.1818
12 Molar Enthalpy (kJ/kgmole) -2.389e+005 -1.104e+005 -2.347e+005 -3.073e+005
13 Molar Entropy (kJ/kgmole-C) 50.71 198.0 254.4 273.7
Heat Flow (kJ/h) -2.0199e+07 -1.0009e+07 -0.0000e-01 -3.0208e+07
14
53
54
55
Workbook: DC-1 (COL2)
56
STATUS
57
58 OK


4 CANADA
5
6
7 Workbook: DC-1 (COL2) (continued)
8
9
10
11 Name Reflux @COL2 To Condenser @COL Boilup @COL2 To Reboiler @COL2 top1 @COL2
12 Vapour Fraction 0.0000 1.0000 1.0000 0.0000 0.0000
13 Temperature (C) 90.58 102.3 137.8 137.1 62.08
14 Pressure (kPa) 101.3 101.3 171.0 171.0 101.3
16 Mass Flow (kg/h) 1052 1641 5777 1.014e+004 204.21
19 Name bottom1 @COL2 FEED1 @COL2
20 Vapour Fraction 0.0000 0.0000
21 Temperature (C) 97.03 52.00
22 Pressure (kPa) 171.0 1800
24 Mass Flow (kg/h) 4747.523 4952
25 Liquid Volume Flow (m3/h) 4.178 4.754
Heat Flow (kJ/h) -3.605e+006 -3.466e+006
26
27
28
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29 Name Reflux @COL2 To Condenser @COL Boilup @COL2 To Reboiler @COL2 top1 @COL2
30 Comp Mole Frac (Methanol) 0.003342 0.003342 0.000000 0.000000 0.005992
31 Comp Mole Frac (CO) 0.000000 0.000000 0.000000 0.000000 0.000000
32 Comp Mole Frac (C3oicAcid) 0.000000 0.000000 0.052903 0.076757 0.000000
33 Comp Mole Frac (M-Acetate) 0.047989 0.047989 0.000000 0.000000 0.086159
34 Comp Mole Frac (H2O) 0.566490 0.566490 0.000397 0.000284 0.907860
35 Comp Mole Frac (AceticAcid) 0.382179 0.382179 0.946700 0.922959 0.000000
36 Name bottom1 @COL2 FEED1 @COL2
37 Comp Mole Frac (Methanol) 0.000000 0.000616
38 Comp Mole Frac (CO) 0.000000 0.000000
39 Comp Mole Frac (C3oicAcid) 0.098957 0.088722
40 Comp Mole Frac (M-Acetate) 0.000000 0.008840
41 Comp Mole Frac (H2O) 0.012733 0.104465
Comp Mole Frac (AceticAcid) 0.888230 0.797357
42
43
44
45 Name qc @COL2 qr @COL2

Heat Flow 1.541e+006 2.239e+006
46 (kJ/h)
47
Unit Ops
48

50 To Reboiler @COL2 bottom1 @COL2
Reboiler @COL2 Reboiler No 500.0 *
51 qr @COL2 Boilup @COL2
52 Reflux @COL2 To Reboiler @COL2
53 Main TS @COL2 Tray Section Boilup @COL2 To Condenser @COL2 No 500.0 *
54 FEED1 @COL2
55 To Condenser @COL2 top1 @COL2
56 Condenser @COL2 Total Condenser qc @COL2 Reflux @COL2 No 500.0 *
qc @COL2
57
1

4 CANADA
5
6
7 Workbook: DC-2 (COL1)
8
9
STATUS
10
11 OK
12
13
14 Name Reflux @COL1 To Condenser @COL Boilup @COL1 To Reboiler @COL1 top @COL1
15 Vapour Fraction 0.0000 1.0000 1.0000 0.0000 0.0000
16 Temperature (C) 119.2 121.0 155.5 155.4 118.0
17 Pressure (kPa) 101.3 101.3 157.3 157.3 101.3
19 Mass Flow (kg/h) 1.042e+004 1.458e+004 1.299e+004 1.319e+004 4167
22 Name bottom @COL1 bottom1 @COL1
23 Vapour Fraction 0.0000 0.0000
24 Temperature (C) 123.0 97.03
25 Pressure (kPa) 157.3 171.0
27 Mass Flow (kg/h) 580.850 4747.523
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28 Liquid Volume Flow (m3/h) 0.5755 4.178
Heat Flow (kJ/h) -5.183e+005 -3.605e+006
29
30
31
32 Name Reflux @COL1 To Condenser @COL Boilup @COL1 To Reboiler @COL1 top @COL1
33 Comp Mole Frac (Methanol) 0.000000 0.000000 0.000000 0.000000 0.000000
34 Comp Mole Frac (CO) 0.000000 0.000000 0.000000 0.000000 0.000000
35 Comp Mole Frac (C3oicAcid) 0.074427 0.074427 0.987706 0.987778 0.000615
36 Comp Mole Frac (M-Acetate) 0.000000 0.000000 0.000000 0.000000 0.000000
37 Comp Mole Frac (H2O) 0.000138 0.000138 0.000000 0.000000 0.001380
38 Comp Mole Frac (AceticAcid) 0.925435 0.925435 0.012294 0.012222 0.998005
39 Name bottom @COL1 bottom1 @COL1
40 Comp Mole Frac (Methanol) 0.000000 0.000000
41 Comp Mole Frac (CO) 0.000000 0.000000
42 Comp Mole Frac (C3oicAcid) 0.982756 0.098957
43 Comp Mole Frac (M-Acetate) 0.000000 0.000000
44 Comp Mole Frac (H2O) 0.009796 0.012733
Comp Mole Frac (AceticAcid) 0.007444 0.888230
45
46
47
48 Name Qcondenser @COL1 Qreboiler @COL1

Heat Flow 5.786e+006 5.656e+006
49 (kJ/h)
50
Unit Ops
51

53 To Reboiler @COL1 bottom @COL1
Reboiler @COL1 Reboiler No 500.0 *
54 Qreboiler @COL1 Boilup @COL1
55 Reflux @COL1 To Reboiler @COL1
56 Main TS @COL1 Tray Section Boilup @COL1 To Condenser @COL1 No 500.0 *
57 bottom1 @COL1
58 To Condenser @COL1 top @COL1
59 Condenser @COL1 Total Condenser Qcondenser @COL1 Reflux @COL1 No 500.0 *
Qcondenser @COL1
60
61
62
63 Honeywell International Inc. UniSim Design (R410 Build 17061) Page 13 of 13
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CHAPTER - X
MATERIALS OF CONSTRUCTION
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10.1 MATERIALS OF CONSTRUCTION
Materials of construction may be divided into two general classifications of metals and non-
metals.
10.1.1 Metals
Pure metals and metallic alloys are included under this classification. Some commonly used
metals are discussed in the following section.
Iron and steel
Although many materials have greater corrosion resistance than iron and steel, cost aspects
favour the use of iron and steel. As a result, they are often used as materials of construction when
it is known that some corrosion will occur. In general, cast iron and carbon steel exhibit about
the same corrosion resistance. They are not suitable with dilute acids, but can be used with strong
acids, since a protective coating composed of corrosion products forms on the metal surface.
Carbon steel plates for reactor vessels are a good example. This application generally requires a
minimum level of mechanical properties, weldability, formability, and toughness as well as some
assurance that these properties will be uniform throughout.
Stainless steel
There are more than 100 different types of stainless steels. These materials are high chromium or
high nickel-chromium alloys of iron containing small amounts of other essential constituents.
They have excellent corrosion-resistance and heat resistance properties. The addition of
molybdenum to the alloy increases the corrosion resistance and high – temperature strength.
If nickel is not included, the low –temperature brittleness of the material is increased and the
ductility and pit type corrosion resistance are reduced. The presence of chromium in the alloy
gives resistance to oxidizing agents.
Aluminium
The lightness and relative ease of fabrication of aluminium and its alloys are factors favouring
the use of these materials. Aluminium resists attack by acids because a surface film of inert
hydrated by aluminium oxide is formed. This film adheres to the surface and offers good
protection unless materials, which can remove the oxide, such as halogen acids or alkalis, are
present.
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10.1.2 Non-metals
Plastics
In comparison with metallic materials, the use of plastics is limited to relatively moderate
temperature and pressures. Generally, plastics have excellent resistance to weak mineral acids
and are unaffected by inorganic salt solutions-areas where metals are not entirely suitable. One
of the most chemical resistant plastics commercially available today is tetrefluoroethylene. This
thermoplastic is practically unaffected by all alkalis and acids except fluorine and chlorine gas at
elevated temperatures and molten metals.
Epoxies reinforced with fiberglass have very high strengths and resistance to heat. Chemical
resistance of the epoxy resin is excellent in non-oxidizing and weak acids not good against
strong acids.
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CHAPTER - XI
SAFETY, HEALTH AND

ENVIRONMENT ASPECTS
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INTRODUCTION
This chapter includes the study of various safety, health and environmental actors along with the
material safety data sheets (MSDS) of methanol, carbon monoxide, propionic acid and acetic
acid.
The goal of chemical plant is not only to produce the chemicals, but to produce
them safely. In the plant’s chain of processes and operations, loss of control anywhere can lead
to accidents and then losses of life and property from hazards. Attempts should be made to
prevent troubles from the inspection while designing, fabricating and operating.
Safety generally involves:
1. Identification and assessments of the hazards
2. Control of hazards
3. Control of the process by provision of automatic control system, interlocks, alarm trips, etc.
4. Limitation of the loss, by press relief, plant layout, etc...
11.1. Potential health effects:-
Inhalation:
Inhalation of concentrated vapors may cause serious damage to the lining of the nose, throat, and
lungs. Breathing difficulties may occur. Neither odor nor degree of irritation are adequate to
indicate vapor concentration.
Ingestion:
Swallowing can cause severe injury leading to death. Symptoms include sore throat, vomiting,
and diarrhea. Ingestion of as little as 1.0 ml has resulted in perforation of the esophagus.
Skin Contact:
Contact with concentrated solution may cause serious damage to the skin. Effects may include
redness, pain, skin burns.High vapor concentrations may cause skin sensitization.
Eye Contact:
Eye contact with concentrated solutions may cause severe eye damage followed by loss of sight.
Exposure to vapor may cause intense watering and irritation to eyes.
Chronic Exposure:
Repeated or prolonged exposures may cause darkening of the skin, erosion of exposed front
teeth, and chronic inflammation of the nose, throat, and bronchial tubes.
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Aggravation of Pre-existing Conditions:
Persons with pre-existing skin disorders or eye problems, or impaired respiratory function may
be more susceptible to the effects of the substance
11.2. First aid measures:-

Eye Contact:
Check for and remove any contact lenses. In case of contact, immediately flush eyes with plenty
of water for at least 15 minutes. Cold water may be used. Get medical attention immediately.
Skin Contact:
In case of contact, immediately flush skin with plenty of water for at least 15 minutes while
removing contaminated clothing and shoes. Cover the irritated skin with an emollient. Cold
water may be used.Wash clothing before reuse. Thoroughly clean shoes before reuse. Get
medical attention immediately.
Serious Skin Contact:
Wash with a disinfectant soap and cover the contaminated skin with an anti-bacterial cream.
Seek immediate medical attention.
Inhalation:
If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult,
give oxygen. Get medical attention immediately.
Serious Inhalation:
Evacuate the victim to a safe area as soon as possible. Loosen tight clothing such as a collar, tie,
belt or waistband. If breathing is difficult, administer oxygen. If the victim is not breathing,
perform mouth-to-mouth resuscitation.
WARNING: It may be hazardous to the person providing aid to give mouth-to-mouth
resuscitation when the inhaled material is toxic, infectious or corrosive. Seek immediate medical
attention.
Ingestion:
Do not induce vomiting unless directed to do so by medical personnel. Never give anything by
mouth to an unconscious person.do not permit the victim to drink milk or carbonated bevarages.
Loosen tight clothing such as a collar, tie, belt or waistband. Get medical attention if symptoms
appear.
Safety precautions:
 All personnel must be aware of the hazardous properties of methanol, and exercise
caution to avoid contact with it.
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 At all times, avoid prolonged or repeated breathing of methanol vapors.
 Proper ventilation is required to ensure safe working conditions. The type of ventilation
will depend upon such factors as dead air spaces, temperature, convection currents and
wind direction and must be considered when determining equipment location, type and
capacity.
 If mechanical ventilation is used, spark-proof fans should be implemented
11.3. Fire safety:

Acetic acid is defined by the National Fire Protection Association (NFPA) and the
Occupational Safety and Health Administration (OSHA) in the USA as a class 2 flammable
liquid. Acetic acid has flash point 39⁰C (102.2⁰F) in closed cup, 43⁰C (109⁰F) in open cup. Flash
point is defined as the minimum temperature at which the vapor pressure of a liquid is sufficient
to form an ignitable mixture with air near the surface of the liquid. When ambient temperature is
less than the flash point, the fire hazard is reduced.
The lower explosive limit (LEL) of a flammable liquid is defined as the minimum
concentration of the vapor in air for which a flame can propagate. Acetic acid LEL is 4% by
volume.
The upper explosive limit (UEL) of a flammable liquid is defined as the maximum
concentration of the vapor in air for which a flame can propagate. The methanol UEL is 16% by
volume.
The auto ignition temperature of a substance is the minimum temperature required for
self-sustained combustion in the absence of an external ignition source. Acetic acid has an auto
ignition temperature of 463⁰C (867⁰F).
Explosion:
Above flash point, vapor-air mixtures are explosive within flammable limits noted above. Vapors
can flow along surfaces to distant ignition source and flash back. Contact with strong oxidizers
may cause fire. Reacts with most metals to produce hydrogen gas, which can form an explosive
mixture with air.
Safety precautions:
The low flash point and wide explosive range require facilities to exercise caution when handling
acetic acid.
1. Smoking must be prohibited.
100 | P a g e
2. Vehicle access should be strictly controlled.
3. Ventilation must be sufficient to cope with the maximum expected vapor levels in buildings
4. Storage tank vents to atmosphere should be sized for fire-heated emergency vapor release.
5. Dry chemical extinguishers should be accessible for small fires. An adequate supply of hand
held and types should be available.
6. Hydrants should be strategically placed with adequate hoses.
7. Small spills should be remediated with sand, earth or other non-combustible absorbent
material, and the area then flushed with water. Larger spills should be diluted with water and
diked for later exposal.
Firefighting techniques:
Flammable liquid, soluble or dispersed in water. For small fire Use DRY chemical powder. For
large fire use alcohol foam, water spray or fog. Cool containing vessels with water jet in order to
prevent pressure build-up, auto ignition or explosion.
11.4. Accidental release measures:

Small Spill:
Dilute with water and mop up, or absorb with an inert dry material and place in an appropriate
waste disposal container. If necessary: Neutralize the residue with a dilute solution of sodium
carbonate.
Large Spill:
Flammable liquid. Corrosive liquid. Keep away from heat. Keep away from sources of ignition.
Stop leak if without risk. If the product is in its solid form: Use a shovel to put the material into a
convenient waste disposal container. If the product is in its liquid form: Absorb with dry earth,
sand or other non-combustible material. Do not get water inside container. Absorb with an inert
material and put the spilled material in an appropriate waste disposal. Do not touch spilled
material. Use water spray curtain to divert vapor drift. Prevent entry into sewers, basements or
confined areas; dike if needed. Call for assistance on disposal. Neutralize the residue with a
dilute solution of sodium carbonate. Be careful that the product is not present at a concentration
level above TLV. Check TLV on the MSDS and with local authorities.
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Waste disposal method:
Burn in a chemical incinerator equipped with an after burner and scrubber. According to all
applicable regulations. Avoid run-off.
Spill prevention program:
An effective spill prevention program will include engineering controls, training and
procedures, and spill response planning.
Effective engineering controls include overfill alarms, secondary containment for tanks,
such as dikes or bunds to contain large spills, and hydrocarbon detectors within dikes. Workers
must be trained to handle methanol in a safe manner. Systems and procedures that protect the
employees, the plant and the environment should be implemented.
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11.5 MATERIAL SAFETY AND DATA SHEET
11.5.1. Product Identification

Synonyms : Acetic acid, methane carboxylic acid; ethanoic acid
CAS No. : 64-19-7
Molecular Weight : 60.05
Chemical Formula : CH₃COOH
11.5.2. Hazard identification:
Overview : POISON! DANGER! Corrosive liquid and mist cause severe burns to all
body tissue may be fatal if swallowed. Harmful if inhaled. Inhalation

may cause lung and tooth damage. Flammable liquid and vapor.
Potential health effects:
Inhalation:
Inhalation of concentrated vapors may cause serious damage to the lining of the nose, throat, and
lungs. Breathing difficulties may occur. Neither odor nor degree of irritation are adequate to
indicate vapor concentration.
Ingestion:
Swallowing can cause severe injury leading to death. Symptoms include sore throat, vomiting,
and diarrhea. Ingestion of as little as 1.0 ml has resulted in perforation of the esophagus.
Skin Contact:
Contact with concentrated solution may cause serious damage to the skin. Effects may include
redness, pain, skin burns. High vapor concentrations may cause skin sensitization.
Eye Contact:
Eye contact with concentrated solutions may cause severe eye damage followed by loss of sight.
Exposure to vapor may cause intense watering and irritation to eyes.
Chronic Exposure:
Repeated or prolonged exposures may cause darkening of the skin, erosion of exposed front
teeth, and chronic inflammation of the nose, throat, and bronchial tubes.
Aggravation of Pre-existing Conditions:
Persons with pre-existing skin disorders or eye problems, or impaired respiratory function may
be more susceptible to the effects of the substance.
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11.5.3 First aid methods:
Inhalation:
Remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give
oxygen. Call a physician.
Ingestion:
DO NOT INDUCE VOMITING! Give large quantities of water or milk if available. Never give
anything by mouth to an unconscious person. Get medical attention immediately.
Skin Contact:
In case of contact, immediately flush skin with plenty of water for at least 15 minutes while
removing contaminated clothing and shoes. Wash clothing before reuse. Call a physician.
Eye Contact:
Immediately flush eyes with plenty of water for at least 15 minutes, lifting lower and upper
eyelids occasionally. Get medical attention immediately.
11.5.4 Firefighting measures:

Flammability of the Product : Flammable.
Auto-Ignition Temperature : 463°C (865.4°F)
Flash Points : CLOSED CUP: 39°C (102.2°F). OPEN CUP: 43°C
(109.4°F).
Flammable Limits : LOWER: 4% UPPER: 19.9%
Products of Combustion : These products are carbon oxides (CO, CO2).
Fire Hazards in Presence of Various Substances:
Flammable in presence of open flames and sparks, of heat. Slightly flammable to flammable in
presence of oxidizing materials, of metals.
Explosion Hazards in Presence of Various Substances:
Risks of explosion of the product in presence of mechanical impact: Not available. Risks of
explosion of the product in presence of static discharge: Not available. Slightly explosive in
presence of oxidizing materials.
Fire Fighting Media and Instructions:
Flammable liquid, soluble or dispersed in water. SMALL FIRE: Use DRY chemical powder.
LARGE FIRE: Use alcohol foam, water spray or fog. Cool containing vessels with water jet in
order to prevent pressure build-up, auto ignition or explosion.
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Special Remarks on Fire Hazards: Reacts with metals to produces flammable hydrogen gas. It
will ignite on contact with potassium-tert-butoxide. A mixture of ammonium nitrate and acetic
acid ignites when warmed, especially if warmed.
Special Remarks on Explosion Hazards:
Acetic acid vapors may form explosive mixtures with air. Reactions between acetic acid and the
following materials are potentially explosive: 5-azidotetrazole, bromine pentafluoride, chromium
trioxide, hydrogen peroxide, potassium permanganate, sodium peroxide, and phorphorus
trichloride. Dilute acetic acid and dilute hydrogen can undergo an exothermic reaction if heated,
forming per acetic acid which is explosive at 110 degrees C. Reaction between chlorine
trifluoride and acetic acid is very violent, sometimes explosive.
11.5.5 Accidental Release Measures
Ventilate area of leak or spill. Remove all sources of ignition. Wear appropriate personal
protective equipment. Isolate hazard area. Keep unnecessary and unprotected personnel from
entering. Use water spray to dilute spill to a nonflammable mixture. Contain and recover liquid
when possible. Collect liquid in an appropriate container or absorb with an inert material (e. g.,
vermiculite, dry sand, earth), and place in a chemical waste container. Use non-sparking tools
and equipment. Do not use combustible materials, such as saw dust. Do not flush to sewer.
11.5.6 Handling and storage:
Handling:
This material is a corrosive, combustible liquid. Inspect containers for damage or leaks before
handling. Immediately report leaks, spills or failures of the engineering controls. Avoid all
ignition sources. Use in the smallest possible amounts, in a well – ventilated area, separate from
the storage area. Avoid generating vapors or mists. Prevent the release of vapors or mists into the
air. Do not use with incompatible materials .never return contemned material to its original
container. Keep containers tightly closed when not in use/empty containers may contain residues
.never add water to a corrosive. Always add corrosives to cold water. Never perform any
welding, cutting, soldering, drillings or other hot work on empty vessel, containers or piping
until all liquid and vapors have been cleared.
Storage:
Store in a segregated and approved area. Keep container in a cool, well-ventilated area. Keep
container tightly closed and sealed until ready for use. Avoid all possible sources of ignition
(spark or flame).
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11.6 MATERIAL SAFETY DATA SHEET FOR METHANOL
11.6.1. Product and supplier identification
Product name: Methanol.
Recommended use: solvent, fuel, feed stock.
Restrictions on use: Do not use in a confined area without proper ventilation. Contact lenses may
cause further damage in case of splash into eye. Avoid use near heat, flames, sparks and other
sources of ignition.
Product: methanol (CH3OH).
Synonyms: methyl alcohol, methyl hydrate, wood spirit, methyl hydroxide.
Company identification: Methanex Corporation.
Importer: Methanex Methanol Company.
11.6.2. Hazards and identification
Classification: Flammable liquid, category 1, Acute toxic category1×,Reproductive toxicity 1B,

Specific target organ toxicity.
Hazard Communication: DANGER! Extremely flammable liquid and vapor.May cause damage
to eyes and central nervous system if ingested or inhaled.
Flammable liquid and vapor: Burns with a clean, clear flame, which is almost invisible in
daylight, or a light blue flame. Can decompose at high temperatures forming carbon monoxide
and formaldehyde. Confined space toxicity hazard. Mild central nervous system depressant
following inhalation, skin absorption or ingestion. May cause headache, nausea, dizziness,
drowsiness, and un-coordination. Severe vision effects, including increased sensitivity to light,
blurred vision, and blindness may develop following an 8-24 hour symptom-free period. Coma
and death may result.
Irritant: Causes eye irritation. Aspiration hazard. Swallowing or vomiting of the liquid may result
in aspiration (breathing) into the lungs.
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11.6.3. First aid measures
Note: Emergency assistance may also be available from the local poison control center.
Eye Contact: Remove contact lenses if worn. In case of contact, immediately flush eyes with
plenty of clean running water for at least 15 minutes, lifting the upper and lower eyelids
occasionally. Obtain medical attention
Skin Contact: In case of contact, remove contaminated clothing. In a shower, wash affected areas
with soap and water for at least 15 minutes. Seek medical attention if irritation occurs or persists.
Wash clothing before reuse. Prolonged contact with methanol may defat skin tissue, resulting in
drying and cracking.
Inhalation: Remove to fresh air, restore breathing if necessary. Obtain medical attention.
Ingestion: Swallowing methanol is potentially life threatening. Onset of symptoms may be

delayed for 18 to 24 hours after digestion. If conscious and medical aid is not immediately
available, do not induce vomiting. In actual or suspected cases of ingestion, transport to medical
facility immediately.
Ethanol significantly decreases the toxicity of methanol because it competes for the same
metabolic enzymes, and has been used to treat methanol poisoning.
11.6.4. Fire Fighting Measures
Unsuitable Extinguishing Media: General purpose synthetic foams or protein foams may work,
but much less effectively. Water may be effective for cooling, but may not be effective for
extinguishing a fire because it may not cool methanol below its flash point.
Specific Hazards: Methanol vapors may burn with an invisible flame. During a fire, carbon
monoxide, carbon dioxide and toxic gases such as formaldehyde may be generated. Vapors can
accumulate in confined spaces resulting in a toxicity and flammability hazard. Closed containers
may rupture violently and suddenly release large quantities of methanol when exposed to fire or
excessive heat for a sufficient period of time. Vapors are slightly heavier than air and may travel
long distances toward sources of ignition.
Fire Fighting Instructions: Methanol burns with a clean clear flame that is almost invisible in
daylight. Stay upwind! Isolate and restrict area access. Concentrations of greater that 25%
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methanol in water can be ignited. Use fine water spray or fog to control fire spread and cool
adjacent structures or containers. Contain fire control water for later disposal. Fire fighters must
wear full face, positive pressure, self-contained breathing apparatus or airline and appropriate
protective firefighting clothing as per NFPA. Note that methanol fires may require proximity
suits. Take care not to walk through any spilled chemical.
11.6.5. Accidental Release Measures
Small Spill: Dilute with water and mop up, or absorb with an inert dry material and place in an
appropriate waste disposal container.
Large Spill: Flammable liquid. Poisonous liquid. Keep away from heat. Keep away from sources
of ignition. Stop leak if without risk. Absorb with dry earth, sand or other non-combustible
material. Do not get water inside container. Do not touch spilled material. Use water spray to
reduce vapors. Prevent entry into sewers, basements or confined areas; dike if needed. Call for
assistance on disposal. Be careful that the product is not present at a concentration level above
TLV. Check TLV on the MSDS and with local authorities.
Environmental Precautions: Biodegrades easily in water. Methanol in fresh or salt water may
have serious effects on aquatic life. A study on methanol’s toxic effects on sewage sludge
bacteria reported little effect on digestion at 0.1% while 0.5% methanol retarded digestion.
Methanol will be broken down to carbon dioxide and water.
11.6.6. Handling and Storage
Precautions for Handling: No smoking or open flame in storage, use or handling areas. Use
explosion proof electrical equipment. Ensure proper electrical grounding procedures are in place.
Storage: Store in totally enclosed equipment, designed to avoid ignition and human contact.
Tanks must be grounded, vented, and should have vapor emission controls. Tanks must be diked
as per NFPA or API Standards. A flammable mixture of methanol vapor and air is possible
inside a storage tank or transportation tank, and handlers should take appropriate precautions to
reduce the risk of ignition. Handlers must eliminate ignition sources or purge the tank with an
inert gas such as nitrogen. All equipment must be grounded - bonded when transferring product
in order to avoid static discharge from the equipment, and subsequent possible fire. Avoid
storage with incompatible materials. Anhydrous methanol is non-corrosive to most metals at
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ambient temperatures except for lead, nickel, Monel, cast iron and high silicon iron. Coatings of
copper (or copper alloys), zinc (including galvanized steel), or aluminium are unsuitable for
storage. These materials may be attacked slowly by the methanol. Storage tanks of welded
construction are normally satisfactory. They should be designed and built in conformance with
good engineering practice for the material being stored. While plastics can be used for short term
storage, they are generally not recommended for long-term storage due to deterioration effects
and the subsequent risk of contamination.
Corrosion rates for several construction materials:
<0.508 mm/year: Cast iron, Monel, lead, nickel
<0.051 mm/year: High silicon iron
Some attack: Polyethylene
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11.7 MATERIAL SAFETY DATA SHEET FOR CARBON MONOXIDE
11.7.1. Chemical product and company identification
Product name: Carbon Monoxide
Synonym: Carbon oxide (CO), Exhaust Gas, Flue gas, Carbonic oxide, Carbon oxide, Carbone,
Carbonio.
Product use: Synthetic/Analytical chemistry.
Supplier: AIR GAS INC., on behalf of its subsidiaries
11.7.2. Hazards identification
Physical state: Gas (colorless gas, may be a liquid at low temperature or high pressure)
Emergency overview: Keep away from heat, sparks and flame. Do not puncture or incinerate
container. Avoid breathing gas. May cause target organ damage, based on animal data. Use only
with adequate ventilation. Keep container closed. Contact with rapidly expanding gases can
cause frostbite.
Target organs: May cause damage to the following organs: blood, lungs, the nervous system,
heart, cardiovascular system, central nervous system (CNS).
Routes of entry: Inhalation
Potential acute health effects:
Eyes: Contact with rapidly expanding gas may cause burns or frostbite.
Skin: Contact with rapidly expanding gas may cause burns or frostbite.
Inhalation: Toxic by inhalation.
Ingestion: Ingestion is not a normal route of exposure for gases.
11.7.3. First aid measures
No action shall be taken involving any personal risk or without suitable training. If it is suspected
that fumes are still present, the rescuer should wear an appropriate mask or self-contained
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breathing apparatus. It may be dangerous to the person providing aid to give mouth-to-mouth
resuscitation.
Eye contact: Check for and remove any contact lenses. Immediately flush eyes with plenty of
water for at least 15 minutes, occasionally lifting the upper and lower eyelids. Get medical
attention immediately.
Skin contact: In case of contact, immediately flush skin with plenty of water for at least 15
minutes while removing contaminated clothing and shoes. To avoid the risk of static discharges
and gas ignition, soak contaminated clothing thoroughly with water before removing it. Wash
clothing before reuse. Clean shoes thoroughly before reuse. Get medical attention immediately.
Frostbite: Try to warm up the frozen tissues and seek medical attention.
Inhalation: Move exposed person to fresh air. If not breathing, if breathing is irregular or if
respiratory arrest occurs, provide artificial respiration or oxygen by trained personnel. Loosen
tight clothing such as a collar, tie, belt or waistband. Get medical attention immediately.
11.7.4. Fire-fighting measures
Flammability of the product: Flammable.
Auto-ignition temperature: 605°C (1121°F)
Flammable limits: Lower: 12.5% Upper: 74.2%
Products of combustion: Decomposition products may include the following materials:
CO, CO2
Fire hazards in the presence: Extremely flammable in the presence of following materials of
various substances open flames, sparks and static discharge and oxidizing materials.
Fire-fighting media: In case of fire, use water spray (fog), foam or dry chemical.
In case of fire, allow gas to burn if flow cannot be shut off immediately. Apply water from a safe
distance to cool container and protect surrounding area. If involved in fire, shut off flow
immediately if it can be done without risk.
111 | P a g e
11.7.5. Accidental release measures
Personal precautions: Immediately contact emergency personnel. Keep unnecessary personnel

away. Use suitable protective equipment. Shut off gas supply if this can be done safely. Isolate
area until gas has dispersed.
Environmental precautions: Avoid dispersal of spilled material and runoff and contact with soil,
waterways, drains and sewers.
Methods for cleaning up: Immediately contact emergency personnel. Stop leak if without risk.
Use spark-proof tools and explosion-proof equipment.
11.7.6. Handling and storage
Handling: Use only with adequate ventilation. Use explosion-proof electrical (ventilating,
lighting and material handling) equipment. High pressure gas. Do not puncture or incinerate
container. Use equipment rated for cylinder pressure. Close valve after each use and when
empty. Keep container closed. Keep away from heat, sparks and flame. To avoid fire, eliminate
ignition sources. Protect cylinders from physical damage; do not drag, roll, slide, or drop. Use a
suitable hand truck for cylinder movement.
Storage: Keep container in a cool, well-ventilated area. Keep container tightly closed and sealed
until ready for use. Avoid all possible sources of ignition (spark or flame). Segregate from
oxidizing materials. Cylinders should be stored upright, with valve protection cap in place, and
firmly secured to prevent falling or being knocked over. Cylinder temperatures should not
exceed 52 °C (125 °F).
112 | P a g e
CHAPTER - XII
PLANT LOCATION
113 | P a g e
PLANT LOCATION
This chapter includes the place where the plant is decided to setup and also checking the
availabilities of all the facilities required for the plant.
The location of the plant can have a crucial effect on the overall profitability of a project, and the
scope for future expansion. Many factors must be considered when selecting a suitable plant site.
The principal factors are:
• Location, with respect to the marketing area
• Raw material supply
• Transport facilities
• Availability of labor
• Availability of suitable land
• Environmental impact and effluent disposal
• Local community consideration
• Climate
• Political and strategic consideration
The Acetic acid synthesis plant can be located in Vijayawada because of its favorable plant
conditions given below:
12.1. RAW MATERIALS:
The main raw material, Methanol is imported from East India Petroleum Limited (EPL)
Vishakhapatnam.
12.2. MARKETS:
Most of the methanol produced is mainly consumed in the present markets for the formation of
di-methyl ether and formaldehyde. Methanol produced here is sent to Aldehydes India limited
located in Haryana for the manufacture of formaldehyde. Otherwise the methanol produced here
is exported to countries like Saudi Arabia and Canada which are largest consumers of methanol
in the world.
114 | P a g e
12.3. ENERGY AVAILABILITY:
Lanco thermal Power Plant is located nearby and two more gas power station is NTPC power
plant, Vijayawada thermal power Station (VTPS).
12.4. TRANSPORTATION FACILITITES:
Vijayawada is well connected by Rail and Road to all states in India. Nearby Gannavaram airport
is being developed to have both domestic and international flights. Air Cargo facilities are also
catching up. The sea port facilities are excellent as it is one of the major ports in India.
12.5. CLIMATE:
The climate present here is moderate hot. Severe conditions of temperature rise or decline do not
exist in this industrial area.
12.6. WATER SUPPLY:
The water requirement for the process plant will be 20179.3Kg/hr. Krishna River waters are
being diverted from Prakasham barrage to the plant. Then, there will not be any shortage for
water.
12.7. WASTE DISPOSAL:
Sewage treatment plant (STP) is present in Vijayawada near Prakasham barrage. It purifies the
waste water from coolers and condensers and releases it to the nearby waters.
12.8. LABOR SUPPLY:
Skilled, semiskilled and unskilled labors are available in Vijayawada. The City of Destiny is a
hub for primary, secondary and higher education.
12.9. TAXATION AND LEGAL RESTRICTIONS:
The tax rules and legalities are favorable to promote industries. The government gives good
subsidies on the raw materials provided for the manufacture of Acetic acid.
12.10. SITE CHARECTERSTICS:
These are good for setting up an industry. The costs are moderate in outskirts of Vijayawada
area.
12.11. FLOOD AND FIRE PROTECTION:
No flood prone area. It is near to the industrial belt and the plant will be constructed taking
preventive measures to fire hazards and fail safe methods in any eventuality.
12.12. COMMUNITY:
All the factors are satisfied to promote community living. Vijayawada area is also known to be
business capital of Andhra Pradesh.
115 | P a g e
CHAPTER - XIII
PLANT LAYOUT
116 | P a g e
PLANT LAYOUT
The economic construction and operation of a process unit will depend on how well the plant
equipment specified on the process flow sheet and laid out.
The principal factors to be considered are:
1. Economic consideration: construction and operation cost.
2. The process requirement
3. Convenience of operation
4. Convenience of maintenance
5. Safety
6. Future expansion
7. Modular construction
COSTS:
The cost of construction can be minimized by adopting a layout that gives shortest run of
connecting pipes between equipment, and adopting the least amount of structural steel work.
However, this will not necessarily be the best arrangement for operation and maintenance.
PROCESS REQUIREMENT:
All the required equipment have to be placed properly within process. Even the installation of the
auxiliaries should be done in such a way that it will occupy the least space.
OPERATION
Equipment that needs to have frequent operation should be located convenient to the control
room. Valves, sample points, and instruments should be located at convenient position and
height. Sufficient working space and headroom must be provided to allow easy access to
equipment.
117 | P a g e
MAINTENANCE
Heat exchangers need to be sited so that the tube bundles can be easily withdrawn for cleaning
and tube replacement. Vessels that require frequent replacement of catalyst or packing should be
located on the outside of buildings. Equipment that requires dismantling for maintenance, such
as compressors and large pumps, should be placed under cover.
SAFETY
Blast walls may be needed to isolate potentially hazardous equipment, and confine the effects of
an explosion. At least two escape routes for operator must be provided from each level in the
process building.
PLANT EXPANSION
Equipment should be located so that it can be conveniently tied in with any future expansion of
the process. Space should be left on pipe alleys for future needs, service pipes over-sized to
allow for future requirements.
MODULAR CONSTRUCTION:
In recent years, there has been a move to assemble sections of the plant at the manufacturer site.
These modules will include the equipment, structural steel, piping and instrumentation. The
modules then transported to the plant site, by road or sea.
118 | P a g e
Fig 13.1. Plant Layout
119 | P a g e
CHAPTER - XIV
COST ESTIMATION
120 | P a g e
COST ESTIMATION
14.1. ESTIMATION OF CAPITAL INVESTMENT COST:

Acetic acid plant size = 100 TPD
Fixed capital investment for 150TPD plant = Rs 1.175
( )
C1 =1.175 108 , S1=150 TPD , S2=100 TPD , n=0.6
( )
C2 = 92126190
Chemical Plant Cost Index for the year 1965 = 126
Chemical Plant Cost Index for the year 2012 = 521.6
Therefore, Cost of plant in 2012 = 92126190.1×
= 92126190×(521.6/126)
= Rs. 38,13,73,180
Therefore, fixed Capital Cost = FCC= Rs. 38,13,73,180
14.2. DETAILED COST ANALYSIS:
All the percentage ranges of calculation are obtained from the standard data book: Plant
design and economics of chemical engineering by Timmerhaus.
14.2.1. Direct costs:
Direct costs included all the below costs such as:
1. Purchased cost
2. Installation cost
3. Instrumentation and controls installation
4. Piping
5. Electrical installation
6. Building process and auxiliaries
7. Service facilities and Yard improvements
8. Land
1. Purchased cost: It contains the equipment cost-15-40% of fixed capital investment
Assume 30% of the fixed capital investment = 0.3 × 38,13,73,180 = Rs.11,44,11,954
2. Installation cost: It include insulation and painting costs-25-55% of purchased cost
Considering 40% of purchased cost = 0.4 × 11,44,11,954= Rs. 4,57,64,781
121 | P a g e
3. Instrumentation and controls cost-6-30% of purchased cost
Considering 13% of purchased cost = 0.13 × 11,44,11,954= Rs. 1,48,73,554
4. Piping installation cost-10-80% of purchased cost
Assume 45% of purchased cost = 0.45 × 11,44,11,954= Rs. 5,14,85,379
5. Electrical cost-10-40% of purchased cost
Assume 15% of purchased cost = 0.15 × 11,44,11,954=Rs. 1,71,61,793
6. Building process and auxiliaries-10-70% of purchased cost
7. Service facilities-40-100% of purchased cost
8. Land-4-8% of purchased cost
Assume 6% of purchased cost = 0.06 × 11,44,11,954= Rs. 6864717
Table 14.1. Total direct costs
Type of cost Amount(Rs.)
Purchased cost 11,44,11,954
Installation cost 4,57,64,781
Instrumentation and controls cost 1,48,73,554
Piping installation cost 5,14,85,379
Electrical cost 1,71,61,793
Building process and auxiliaries 4,57,64,781
Service facilities 8,00,88,367
Land 68,64,717
Total Direct Costs 37,64,15,329
14.2.2. Indirect costs:

Indirect costs include the following costs such as:
1. Engineering supervision
2. Construction expenses
3. Contractor fee
4. Contingency plan
1. Engineering supervision-5-30% of direct costs
Assume 15% of direct costs = 0.15 ×37,64,15,329= Rs. 5,64,62,299
2. Construction expenses-6-30% of direct costs
122 | P a g e
Assume 10% of direct costs = 0.1 × 37,64,15,329= Rs. 3,76,41,532
3. Contractor fee-2-7% of direct costs
Assume 4% of direct cost = 0.04 × 37,64,15,329= Rs. 1,50,56,613
4. Contingency costs-5-15% of present cost
Assume 12% of present cost = 0.12 × 37,64,15,329= Rs. 4,51,69,839
Table 14.2. Total indirect costs
Engineering supervision 5,64,62,299
Construction expenses 3,76,41,532
Contractor fee 1,50,56,613
Contingency costs 4,51,69,839
Total Indirect Costs 1,54,33,02,85
14.2.3. Fixed capital investments:

Fixed capital investments = Direct + Indirect costs = Rs. 53,07,45,614
14.2.4. Working capital:
Working capital = 10-20% of fixed capital investment
Assume 15% of fixed capital investment = 0.15 × 53,07,45,614= Rs. 7,96,11,842
14.2.5. Total capital investment:
Total capital investment = total fixed capital + working capital = Rs. 61,03,57,456
14.3. ESTIMATION OF MANUFACTURING COST:
14.3.1. Fixed costs:
There are mainly four types of fixed costs. They are:
1. Depreciation
2. Local taxes
3. Insurances
4. Rent
1. Depreciation-10% of fixed capital investment for machinery and 3% of building value for
building = 0.1×53,07,45,614 + 0.03×4,57,64,781= Rs. 5,44,47,504
2. Local taxes-3-4% of fixed capital investment
Assume 4% of fixed capital investment = 0.04×53,07,45,614= Rs. 21229824
3. Insurances- 0.4-1% of fixed capital investment
Assume 0.6% of fixed capital investment = 0.006×53,07,45,614= Rs. 3184473
123 | P a g e
4. Rent-8-12% of the rented land and buildings
Assume 10% of building value = 0.1×4,57,64,781= Rs. 45,76,478.168
Fixed charges = 18% of product cost = Total fixed costs = Rs. 83438281 which is summation of
costs present in Table.
Total product cost = Rs. 46,35,46,007
Table 14.3. Total fixed costs
Type of cost Amount (Rs. )
Depreciation 5,44,47,504
Local taxes 2,12,29,824
Insurances 31,84,473
Rent 45,76,478.16
Total fixed costs 8,34,38,281
14.3.2. Direct production costs:

These direct production costs are mainly divided into following categories. They are:
1. Raw materials
2. Operating labor
3. Direct supervisory and electrical labor
4. Utilities
5. Maintenance and repairs
6. Operating supplies
7. Laboratory charges
8. Patents and royalties
1. Raw materials-10-50% of total product cost
Assumed value, 30% of the total product cost = 0.3×46,35,46,007= Rs. 139063802
2. Operating Labor-10-20% of the total product cost
Assume 15% of total product cost = 0.15×46,35,46,007= Rs. 6,95,31,901
3. Direct supervisory and electrical labor-10-25% of operating labor
Assume 12% of operating labor = 0.12×6,95,31,901= Rs. 83,43,828
4. Utilities-10-20% of total production cost
Assume 13% of total production cost = 0.13×46,35,46,007= Rs. 6,02,60,980
5. Maintenance and repairs-2-10% of fixed capital investment
Assume 8% of fixed capital investment = 0.08×53,07,45= Rs. 4,24,59,649
124 | P a g e
6. Operating supplies-10-20% of cost of maintenance and repairs
Assume 15% of maintenance and repairs = 0.15×4,24,59,649= Rs. 63,68,947
7. Laboratory charges-10-20% of operating labor
Assume 15% of operating labor = 0.15×6,95,31,901= Rs. 6, 95, 31,901.091
8. Patents and royalties-2-6% of total product cost
Assume 5% of total product cost = 0.05×46, 35, 46,007= Rs. 2, 31, 77,300
Table 14.4. Total direct product costs
Raw materials 13,90,63,802
Operating labor 6,95,31,901
Direct supervisory and electrical labor 83,43,828
Utilities 6,02,60,980
Maintenance and repairs 4,24,59,649
Operating supplies 63,68,947
Laboratory charges 6,95,31,901
Patents and royalties 2,31,77,300
Total direct product costs 41,87,38,310
14.3.4. Plant overhead costs:

Plant overhead costs-50-70% of operating labor + direct supervisory + Maintenance cost
Assume 60% of total costs = Rs. 9, 25, 22,617
Total manufacturing cost = Fixed costs + Direct production costs + plant overhead costs
= 46, 35, 46,007 + 418738310 + 9,25,22,617
= Rs. 97, 48, 06,935
14.4. GENERAL EXPENSES:
General expenses include various costs in it. They are:
1. Administration costs
2. Distribution costs
3. Research and development costs
1. Administration costs-40-60% of the operating labor cost
Assume 50% of the operating labor cost = 0.5×69531901= Rs. 3, 47, 65,950
2. Distribution cost-2-20% of total product costs
Assume 10% of the total product cost = 0.1×46, 35, 46,007= Rs. 4, 63, 54,600
125 | P a g e
3. Research and development cost-0-5% of total product cost
Assume 3% of the total product cost = 0.03×46, 35, 46,007= Rs. 1, 39, 06,380
Table 14.5.Total general expenses
Administration costs 34765950
Distribution costs 4,63,54,600
Research and development cost 13906380
Total general expenses 9,50,26,931
14.5. TOTAL PRODUCT COST:

Total product cost = Manufacturing cost + general expenses
= 97, 48, 06,935+ 9, 50, 26,931= Rs. 1069833867
Current selling price:
Cost of Acetic acid= Rs. 50 per kg
Total selling price per annum = (100×103) × 334 × 50
= Rs. 1,67,00,00,000 per annum

Gross earnings:
Gross earnings = Total selling price – Total product rate
= 1, 67, 00, 00,000– 1,06,98,33,867

= Rs. 600166132 per annum
Tax:
Assume the local tax rate as 40%
Tax on the gross earnings = 0.4×600166132.976= Rs. 24, 00, 66,453
Net profits:
Net profits = Gross earnings – Tax
= 600166132.976 -240066453.1904= Rs. 36, 00, 99,679

Payback Period:
Payback Period = = 61,03,57,456.477 / 36,00,99,679= 1.69years
Rate of return:
Rate of return = Net profit/Fixed capital investments = 36,00,99,679.7856/53,07,45,614= 67.8%
126 | P a g e
BIBILOGRAPHY
1. Perry’s Chemical Engineering Handbook 8th edition.
2. Unit Operations of Chemical Engineering by McCabe, Smith and Harriott.
3. Coulson & Richardson's chemical engineering volume 6 Chemical Engineering Design by

R.K.Sinnott.
4. Indian Chemical Industry XIIth Five Year Plan (2012-2017).
5. “The Cativa TM Process for the Manufacture of Acetic Acid” By Jane H. Jones, B.P
Chemicals Ltd.
6. United States Patent, Garland et. al. , Processes for the production of Acetic Acid.
7. Process Plant Design and economics by Peter and Timmerhaus.
8. Simulation Software: UNISIM Design suite
9. CEH Marketing Research Report’ ACETIC ACID’ by Kevin Wheeler.
10. G.J. Sunley, D.J. Watson. Catalysis Today 58 (2000) 293 – 307
11. Acetic Acid and Its Derivatives Chemical Industries Agreda, V. H. CRC Press.
12. Handbook on Indian Chemical Industry by Roland Berger strategy consultants
13. Gujarat Narmada Valley Fertilizers Company Limited 34th annual report (2009-2010)
14. Acetic Acid: A Techno-Commercial Profile at http://www.chemicalweekly.com
15. http://www.researchandmarkets.com/reports/1545159/
16. Chemical frontiers December 2008.
17. Applied process design for chemical and petrochemical plants by Ernest E. Ludwig.
18. Applications of the Homogeneous Catalysis in Industry by Prof Philippe Kalck.
19. Process Heat Transfer by D.Q. Kern.
20. Distillation Design by Henry Z.Kister.
127 | P a g e
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Manufacture of Acetic acid through the methanol carbonylation route.

Article in Chemical · May 2014

The user has requested enhancement of the downloaded file.

PLANT DESIGN FOR MANUFACTURING ACETIC ACID

Submitted in partial fulfillment of the requirements for the award of Degree of

BACHELOR OF TECHNOLOGY IN PETROCHEMICAL ENGINEERING

T.PRUDHVI RAJ 10021A2512

Under the esteemed guidance of

DEPARTMENT OF PETROLEUM ENGINEERING & PETROCHEMICAL ENGINEERING

Head of the Department Project Guide

Dr. B. Bala Krishna Mr. P.Anil Kumar

I would like to acknowledge gratitude to Prof. K.Padma Raju, Principal,UCEK(A)

T.Prudhvi Raj (10021A2512)

10. MATERIALS OF CONSTRUCTION 94

11. SAFETY, HEALTH AND ENVIRONMENT ASPECTS 97

Constructing a process flow diagram of the entire process

Acetic acid (CH3COOH), is a corrosive organic acid having a

Fig 1.1. Acetic acid global demand

Fig 1.2. Acetic acid supply

Fig 1.3. Global acetic acid consumption

In a recent study, total worldwide production of virgin acetic acid is estimated at

Fig.1.5. Global acetic acid derivatives

Fig 1.6 acetic acid supply and demand

PHYSICAL & CHEMICAL

• It is miscible in all proportions with water, ethanol and ether.

• It is an excellent solvent for organic compounds.

• No high dissociation ionic species in acetic acid solution.

• Possesses relatively low basicity or proton affinity.

The physical properties are

1. Melting point : 16.635 0.002 0C

2. Boiling point : 117.870C

4. Thermal conductivity : 0.158 W/m2 0C at 200C

5. Heat of melting : 207.1 J/g

6. Heat of vaporization : 394.5J/g at boiling point

7. Specific heat of vapor : 5.029 J/g 0K at 1240C

8. Density : 1.04938 g/ml at 200C

9. Refractive index,ηd : 1.36965

10. Specific heat of solid : 0.837 J/g 0K at 1000K

11. Critical pressure : 57.856 KPa (571.1 atm)

12. Critical temperature : 321.60C

13. Magnetic susceptibility

Solid : 32.05 10-6 cm3/mol

Liquid : 31.80 10-6 cm3/mol

14. Dielectric constant

Solid : 2.665 at -10.00C

Liquid : 6.710 at 20.00C

15. Surface tension : 27.57 N/m or Dyne/cm at 20.10C

16. Flash point, open cup : 570C

17. Auto ignition point : 465 0C

18. Lower limit of flammability : 400C

: 5.4 vol% at 1000C

Acetic anhydride can by prepared by the dehydration of acetic acid at 800OC.

2.2.1 Reactions with inorganic compounds

2.2.2 Decomposition Reactions:

2.2.3 Acid–Base Chemistry:

cyclotrimethylenetrinitramine , also known as cyclonit or RDX.

2.2.4 Acetylation Reactions: