List of Tables, Figures, Nomenclatures

i

LIST OF TABLES

TABLE TITLE PAGE

1.1 Physical and Chemical Properties of Butyl Acetate 1

1.2 The Activity for Different Catalyst in the Esterification

Reaction of Acetic Acid and Butanol at 75°C.

9

1.3 Summary of the Comparison between Four Processes 19

1.4 Major Global n-Butyl Acetate Capacity, ’000 tonnes per year 22

1.5 Global Raw Material and Product Price 25

1.6 Specification of Optimal Integrated Petrochemical Complex 26

1.7 Summary of the Estimated Cost of Designing, Purchasing,

and Installing a Complete Continuous Ester Unit

34

1.8 Summary of Estimation of Indirect Cost 35

1.9 Summary of Raw Materials Cost 37

1.10 Summary of Utilities Cost 37

1.11 Summary of Calculation on Cost of Operating Labor 38

1.12 The Number of None Particulate Processing Steps and

Handing Steps, Nnp

38

1.13 Summary of Production Costs 40

1.14 Summary of TR, VC, FC and TC Values 41

1.15 Cash Flow ROROI Payback Period 43

1.16 Nondiscounted After Tax Cash Flows 44

1.17 Site Selection Comparisons 61

1.18 Weightage for Site Selection 64

2.1 Stream Table 80

2.2 Overall Plant Mass Balance 83

2.3 Major Equipments Mass Balance 83

2.4 Heat Capacity Constant for Liquid Phase 86

2.5 Heat Capacity Constant for Gas phase 86

2.6 Heat of Formation and Heat of Vaporization 86

2.7 Inlet-Outlet Enthalpy Table for Reactor 94

2.8 Inlet-Outlet Enthalpy Table for Esterification Column 103

2.9 Inlet-Outlet Enthalpy Table for Refining Column 112

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2.10 Comparison of Inlet-Outlet Enthalpy from Calculation and

HYSYS

112

3.0 Streams process data to be used in pinch analysis 116

3.1 CP for streams 117

3.2 Typical ∆Tmin values for various types of processes 119

3.3 Typical ∆Tmin values for process-utility matches 120

3.4 Shifted temperatures for the data from Table 9.0 121

3.5 Ranked order of interval temperatures 122

3.6 The temperature interval heat balance 123

3.7 Compare and contrast the utilities before and after heat

integration

129

4.1 Process and instrumentation diagram description 139

4.2 Control system for reactor (R-100) 141

4.3 Control system for esterification column (T-100) 143

4.4 Control system for refining column (T-101) 145

4.5 Control system for heater (E-100) 147

4.6 Control system for cooler (E-101) 148




4.10 Control system for compressor (C-100) 152

4.11 Control system for compressor (C-101) 153

4.12 Control system for pump (P-100) 154



4.15 Control system for decanter (V-100) 156

5.1.1 Molecular weight for each reactants and products 161

5.1.2 Condition at stream inlet and outlet of the reactor 161

5.1.3 Table of composition of each component before and after

reaction

163

5.1.4 Summary of chemical design of R-100 181

5.2.1 Properties of inlet and outlet process stream of E-100. 182

5.2.2 Classification of stream for shell and tube side of E-100. 183

5.2.3 Selection on type of heat exchanger. 183

5.2.4 Selection on tube characteristics 184

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5.2.5 Allowable pressure drop for shell and tube side. 185

5.2.6 Physical properties of stream 5 and steam. 185

5.2.7 Temperature for each stream. 186

5.2.8 Summary of chemical design of E-100. 193

5.3.1 Specification of distillation column T-100 194

5.3.2 Antoine's coefficient 198

5.3.3 Trial and error for bubble point calculation, feed 198

5.3.4 Trial and error for dew point calculation, top 199

5.3.5 Trial and error for bubble point calculation, bottom 199

5.3.6 Equilibrium constants calculation, feed 200

5.3.7 Equilibrium constants calculation, top 200

5.3.8 Equilibrium constants calculation, bottom 200

5.3.9 Relative volatility calculation, feed 201

5.3.10 Relative volatility calculation, top 201

5.3.11 Relative volatility calculation, bottom 202

5.3.12 Average relative volatility calculation 202

5.3.13 Feed specifications 204

5.3.14 Calculation of θ value 205

5.3.15 Calculation of value 205

5.3.16 Data of the column for using Winn’s method 206

5.3.17 Tabulated data of μa calculation 208

5.3.18 Properties of the inlet and outlet streams 209

5.3.19 Summary of chemical design of T-100 225

5.4.1 Common types of packing criteria 227

5.4.2 Properties of feed, overhead and bottom products 231

5.4.3 Summary of chemical design values 238

5.5.1 The advantages and disadvantages of each type of heat

exchanger

241

5.5.2 Basis design procedure of heat exchanger 242

5.5.3 Selection dimensions for tubes 246

5.5.4 Physical properties in shell and tube side 248

5.5.5 Summary of chemical design of E-101 261

6.1.1 Summary of mechanical design of R-100 297

6.2.1 Design pressure and temperature for shell and tube, taking

safety factor as 10%

299

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6.2.2 Types of materials selected for construction for shell and

tube.

299

6.2.3 Design stress for shell and tube, taking safety factor as 10% 300

6.2.4 Specification for tube side (based on chemical design) 303

6.2.5 Specification for shell side (based on chemical design) 304

6.2.6 Total weight loads of E-100 310

6.2.7 Summary for mechanical design of E-100 312

6.3.1 Material of construction details 313

6.3.2 Welded joint efficiency 314

6.3.3 Insulating material specifications 319

6.3.4 Straight cylindrical skirt specifications 328

6.3.5 Data obtained from Hysys to calculate pipe diameter 334

6.3.6 Flanges Dimensions 335

6.3.7 Summary of mechanical design values 336

6.4.1 Details of material of construction 338

6.4.2 Summary of mechanical design of T-101 359

6.5.1 Design pressure of shell and tube 361

6.5.2 Design temperature of shell and tube 362

6.5.3 Design stress for material construction 364

6.5.4 Selection of heat and closure 366

6.5.5 Properties of shell side 373

6.5.6 Properties of pipe of shell side 373

6.5.7 Properties of tube side 374

6.5.8 Properties of pipe of tube side 374

6.5.9 Dimensions of flanged for nozzle 375

6.5.10 Dimensions for saddle support 377

6.5.11 Summary of mechanical design of E-101 378

10.1 Concentration of acetic acid 396

10.2 Summary of wastewater treatment plant 414

8.1 Estimation cost of purchased equipment 419

8.2 Calculation of Total Capital Investment 421

8.3 Labor Cost 432

8.4 Cost of Raw Material 437

8.5 Annual Cash Flow before tax 441

8.6 Depreciation Schedule for MACRS method 442

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8.7 Annual cash flow after tax 443

8.8 Present worth value 445

8.9 After Tax Cumulative Cash Flow 446

8.10 Present value (RM) when i=30% and i=40% 448

8.11 Future worth (RM) when MARR = 15% 449

8.12 Simple Payback Period 451

8.13 Discounted Payback Period 452

9.1 Lists the EU Classification of Acetic Acid Solutions 461

9.2 Example of HAZOP Analysis 476

9.3 Types of emergencies in a plant 482

9.4 Guide words, meaning and example of deviation 493

9.5 Deviation and some typical causes 494

9.6 HAZOP study on reactor (R-100) 495

9.7 HAZOP study on heat exchanger (E-101) 497

9.8 HAZOP study on distillation column (T-100) 499

9.9 HAZOP study on distillation column (T-101) 501

9.10 HAZOP study on heater (E-100) 503

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LIST OF FIGURES

FIGURE TITLE PAGE

1.1 Block Flow Diagram for Conventional Esterification

Process

10

1.2 Block Flow Diagram for Esterification by Reactive

Distillation Process

12

1.3 Block Flow Diagram for Conventional Transesterification

Process

14

1.4 Block Flow Diagram for Transesterification by Reactive

Distillation Process

16

1.5 World Consumption of Butyl Acetate 21

1.6 Graph of Butyl Acetate And Butanol Price 23

1.7 Malaysia Import and Export of n-Butyl Acetate in Year

2007-2009 (Quantity, kg)

27

1.8 Malaysia Import and Export of n-Butyl Acetate for Mid-

Term Year 2008-2010 (Quantity, kg)

27

1.9 Average Pricing of n-Butyl Acetate for Import, Year 2007-

2009

28

1.10 Average Pricing of Butyl Acetate for Import, Mid-Term

Year 2008-2010

29

1.11 Average Pricing of n-Butyl Acetate for Export, Year 2007

2009

30

1.12 Average Pricing of n-Butyl Acetate for Export, Mid-Term

Year 2008-2010

30

1.13 Graphical Breakeven Point 42

1.14 Graph of Cumulative Cash Flow versus End of Year 45

1.15 Location of Gebeng (Phase IV) 68

1.16 Transport Facilities Connecting Gebeng 69

3.0 Composite curve 118

3.1 Cascade surplus heat from high to low temperature 123

3.2 Grid diagram 125

3.3 Grid representation of process streams 126

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3.4 Network design below pinch 128

3.5 Process Flow Diagram before Heat Integration 130

3.6 Process flow diagram after heat integration 131

4.1 Process control loop 137

4.2 Control system design for reactor (R-100) 141

4.3 Control system design for esterification column (T-100) 144

4.4 Control system design for refining column (T-101) 146

4.5 Control system design for heater (E-100) 147

4.6 Control system design for cooler (E-101) 148




4.10 Control system design for compressor (C-100) 152

4.11 Control system design for compressor (C-101) 153

4.12 Control system design for pump (P-100) 154



4.15 Control system design for decanter (V-100) 156

5.1.1 Schematic design of CSTR 161

5.1.2 Temperature and pressure data of R-100 163

5.1.3 Schematic design of cooling jacket of R-100 169

5.2.1 Model input and output of heater, E-100 182

5.2.2 AES, Channel and removable cover, one pass shell,

floating head with backing device.

184

5.3.1 Configuration of distillation column T-100 194

5.4.1 Configuration of distillation column T-101 231

5.5.1 Design procedure of shell and tube heat exchanger 243

5.5.2 Schematic diagram of shell and tube heat exchanger E-

101

245

5.5.3 E-101 Configuration 245

5.5.4 Triangular tube pattern 246

5.5.5 Heat Exchanger (E-101) 247

6.1.1 Analysis of stresses 285

6.1.2 The resultant principal stresses 288

6.2.1 Welding-neck flanges 305

viii

6.2.2 Single segmental baffles design 306

6.2.3 Standard steel saddles 311

6.3.1 Steel slip-on boss flange for welding 335

6.5.1 Typical standard flange design 376

6.5.2 Design of support saddle 377

10.1 Hierarchy of waste management 384

10.2 Source of liquid waste from butyl acetate plant 387

10.3 Source of gaseous waste from reboiler at stream 11 387

10.4 Gaseous waste treatment process flow 390

10.5 Conventional wastewater treatment system using

activated sludge system

392

10.6 Neutralization tank configuration 397

10.7 Primary settling basin configuration 399

10.8 Activated sludge system 400

10.9 Mixer configuration 403

10.10 Plant layout for the conventional wastewater treatment

system

412

8.1 Cumulative Cash Flow vs. Year 447

9.1 HAZOP Techniques 491

9.2 Plant Layout 511

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LIST OF NOMENCLATURES

Fi Molar flowrate of ith component [kmol/min]

X Conversion -

θi Molar ratio -

T Temperature [oC]

CI Concentration of ith component [kmol/m3]

DT Tank diameter [m]

HT/j Height of tank / Height of jacket [m]

N Rotational speed [rps]

NP Power number -

E Distance between reactor bottom and impeller [m]

D Diameter of one coil [m]

Po Operating power [W]

Q Heat taken/given from the reactor [W]

U0 Overall heat transfer coefficient [W/m2.K]

Dji Inner diameter of jacket [m]

Djo Outer diameter of jacket [m]

G Mass flux [kg/m2.s]

Re Reynolds number -

Vtank Volume of tank [m3]

Vliq Volume of reaction mixture [m3]

dag Agitator diameter [m]

-rA Rate of reaction with respect to component A [kmol/m3min]

k Specific reaction rate -

mi Mass flowrate of ith component [kg/h]

do Outer diameter of coil [m]

di Inner diameter of coil [m]

hi Convective heat transfer coefficient inner fluid [W/m2 .K]

ho Convective heat transfer coefficient outer fluid [W/m2 .K]

Dv Diameter vessel m

Di Diameter inlet m

Do Diameter outlet m

x

Do Diameter outlet m

f Design stress N/mm2

g Gravitational acceleration m/s2

J Joint factor -

Lv / Hv Length vessel / Height vessel m

ti`/ e Thickness mm

dnominal Nominal diameter mm

Pi Pressure bar /N/mm2

Q Heat transfer kJ/s

Subscript i Internal -

T Temperature K / °C

V Volume m3

Wi Weight kN

G Flow rate kg/s

ρ Density kg/m3

Eb Distance bottom reactor and blade m

db Diameter blade m

P Power motor kW

T Torque N/mm2

M Bending Moment N/mm2

Stress N/mm2

Fw Wind loading N/mm2

Dm Mean Diameter m

Hs Height skirt m

E Young Modulus N/mm2

A Heat transfer area

Ao Clearance area between bundle and shell

A Tube external surface area

Acs Tube cross-sectional area

At Total flows area

b Effective sealing width of gasket

Cp heat capacity at constant pressure

Cv Factor weight of nozzle

Db Bundle diameter

de Equivalent diameter

xi

Ds Shell diameter

Dh diameter of tube holes in baffles

Dms Mean diameter of vessel

Dmt Mean diameter of tube

do tube outside diameter

di tube inside diameter

es cylindrical shell thickness

eH head thickness

F design stress

Ft Log mean temperature difference correction factor

g Gravitational acceleration

Gt Steam mass flow rate

Gs Shell side mass flow rate per unit area

hv length between tangent lines heat transfer coefficient in condensation

hi Film heat transfer coefficient inside a tube

ho Heat transfer coefficient outside a tube

hod Fouling coefficient on outside of tube

hid Fouling coefficient on inside of tube

hs Shell-side heat transfer coefficient

IB Baffle spacing (pitch)

Iw insulation of mineral wool

J welded joint efficiency

Jh Heat transfer factor

k1 constant value for tube arrangement

k Thermal conductivity

kf Thermal conductivity of fluids

kw Thermal conductivity of tube wall material

L Length of the tube

LMTD Log mean temperature different

Nb number of baffle segmental

Np number of tubes per pass

Nt Number of tubes

n1 constant value for tube arrangement

P Total pressure

pt Tube pitch

xii

∆Pt Tube-side pressure drop

∆Ps Shell-side pressure drop

Q Heat transfer in unit time

T Shell side temperature

T Temperature of surface

T1 Shell-side inlet temperature

T2 Shell-side outlet temperature

∆Tlm Logarithmic mean temperature difference

∆Tm Mean temperature different

t Tube side temperature

t1 Tube-side inlet temperature

t2 Tube –side exit temperature

U Overall heat transfer coefficient

Uo Overall heat transfer coefficient based on tube side area

u fluid velocity

us Shell-side fluid velocity

ut Tube side fluid velocity

Latent heat

Viscosity

Density

w Viscosity at wall temperature

Surface Tension

Pr Prandtl number

Re Reynold number

HK Heavy key component -

LK Light key component -

xi Concentration in liquid phase -

Ki Equilibrium constant -

Psat Saturated pressure kPa

Pt Total pressure kPa

α Relative volatility -

Rm Minimum reflux ratio -

Tb Bubble-point temperature oC

R Reflux ratio -

Minimum number of stages -

xiii

Column efficiency %

Molar average liquid viscosity

Average relative volatility for light key -

VISA Constant of viscosity equation -

VISB Constant of viscosity equation -

L Liquid density kg/m3

V Vapor density kg/m3

RMM Relative Molecular Mass -

MW Molecular Weight -

Vapor velocity m/s

Plate Spacing m

Di Internal diameter m

Dm Mean diameter m

Ds Skirt diameter m

dh Hole diameter mm

e Minimum thickness mm

f Design stress N/mm2

lW Weir length m

J Joint factor -

Mx Bending moment kNm

Ms Bending moment at base skirt kNm

Rc Crown radius m

Rk Knuckle radius m

U Superficial velocity m/s

Uf Flooding vapor velocity m/s

Longitudinal stress N/mm2

Hoop stress N/mm2

t Thickness mm

Dead weight stress N/mm2

Weight of vessel N

Wind loading N/m

Bending stress N/mm2

Bolt area mm2

Number of bolt -

CTC Total Capital Cost

xiv

CFC Fixed Capital Cost

CWC Working Capital Cost

CL Cost of Land

FP Pressure Factor

FM Material Factor

CoP Purchased Cost

FBM Bare Module Cost Factor

CBM Bare Module Equipment Cost for base condition

CoBM Bare Module Equipment Cost for actual condition

A Capacity Size

P Operating Pressure

D Column Diameter

B1, B2 Constant

Fq Quantity Factor for Trays

tvessel Vessel thickness

ξdr Efficiency of drives

CFBT Cash Flow before tax

GI Gross Income

E Expenses

P Initial Investment

S Salvage value

MACRS Modified Accelerated Cost Recovery System

MARR Minimum Attractive Rate of Return

ROR Rate of Return

AW Annual Worth

FW Future Worth

m Mass flow rate kg/s

Cp Mass heat capacity kJ/kg°C

Ts Source temperature °C

Tt Target temparature °C

CP Heat capacity kW/°C

∆Tmin Minimum Temperature Difference °C

Tint Temparature interval °C

Tact Actual temperature °C

∆Tn Internal temperature difference °C

xv

∆Hn heat required in the nth interval kW

∑CPc Sum of the heat capacities of all the cold streams in the kW

interval

∑CPh Sum of the heat capacities of all the hot streams in the kW

interval

QHmin Minimum hot utility kW

QCmin Minimum cold utility kW

List of Tables, Figures, Nomenclatures

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