Production of 1 tetradecene at 100 tons per year

PRODUCTION OF 1-TETRADECENE AT 100 TONS

PER YEAR

Submitted in partial fulfilment of the requirements for the award of

Bachelor of Technology degree in

Chemical Engineering

By

AMAN KUMAR (3119109)

HAZARI AKASH KHATRI (3119133)

DEPARTMENT OF CHEMICAL ENGINEERING

FACULTY OF BIO & CHEMICAL ENGINEERING SATHYABAMA UNIVERSITY

JEPPIAAR NAGAR, RAJIV GANDHI SALAI,

CHENNAI – 600119. TAMILNADU

MARCH 2015

DEPARTMENT OF CHEMICAL ENGINEERING

BONAFIDE CERTIFICATE

This is to certify that this Project Report is the bonafide work of Aman Kumar (Reg. no.

3119109) and Hazari Akash Khatri (Reg. No. 3119133) who carried out the project

entitled “Production of 1-Tetradecene at 100 tons per year” under my supervision from

September 2014 to March 2015.

Internal Guide

Mr. D. VENKATESAN, M.Tech.,(Ph.D).

Head of the Department

Dr. D JOSHUA AMARNATH, M.Tech., MBA., Ph.D.

Submitted for Viva voce Examination held on_____________________2015

Internal Examiner External Examiner

DECLARATION

We, AMAN KUMAR (Reg. No. 3119109) and HAZARI AKASH KHATRI (Reg.

No.3119133) hereby declare that the Project Report entitled “Production of 1-

Tetradecene at 100 tons per year” done by us under the guidance of Mr. D.

VENKATESAN, M.Tech.,(Ph.D). at Sathyabama University Chennai is submitted in

partial fulfilment of the requirements for the award of Bachelor of Technology degree in

Chemical Engineering.

1.

2.

DATE : SIGNATURE OF THE CANDIDATES

PLACE : CHENNAI

ACKNOWLEDGEMENT

First and foremost we would like to thank Col. Dr. JEPPIAAR, M.A., B.L., Ph.D. for his

whole hearted encouragement.

Our special thanks to the Directors, Dr. MARIE JOHNSON, B.E., M.B.A., M.Phil., Ph.D.

and Dr. MARIAZEENA JOHNSON, B.E., M.B.A., M.Phil., Ph.D. and hearty thanks to

our Vice Chancellor Dr. B. SHEELA RANI, M.S (By Research)., Ph.D. for providing us

the necessary facilities for the completion of our project and Controller of Examinations

Dr. K.V.NARAYANAN., Ph.D. for their constant support and endorsement.

We are also thankful to Dr. ANIMA NANDA, M.SC., Ph.D., SNRS. Faculty Head of Bio

and Chemical Engineering and Dr. D.JOSHUA AMARNATH, M.B.A., M.Tech., Ph.D.

Head of the Department of Chemical Engineering (Administration and Research),

Sathyabama University for their support and encouragement for the completion of the

work.

We express our sincere gratitude and heartfelt thanks to our internal guide Mr. D.

VENKATESAN, M.Tech., (Ph.D). Asst. Professor of Department of Chemical

Engineering for his constant support and encouragement for the completion of the project.

We also thank the other Teaching and Non-Teaching staffs of the Department of

Chemical Engineering, friends and family for their concern in making this project

successful.

ABSTRACT

The purpose of the project is to study the production of 1-Tetradecene through processing

and refining process method and to perform energy balance, material balance and design

the equipments involved in this process. We used chemcad chemstation software for

process simulation and determining the phase envelope graph. We created a component,

1-octacosene in component database of chemcad simulation software.

CONTENTS

CHAPTER NO. TITLE PAGE NO.

LIST OF TABLES i

LIST OF FIGURES i

LIST OF ABBREVIATIONS AND SYMBOLS ii

1 INTRODUCTION 1

1.1 Chemical reaction 1

1.2 Chemical properties 2

1.3 Physical properties 2

1.4 Application of 1-tetradecene 2

1.4.1. Paints 2

1.4.2. Varnishes 2

1.4.3. Surfactants 2

1.4.4. Detergent and soaps 3

2 AIM AND SCOPE 4

3 METHOD OF PRODUCTION 5

3.1 Processing and refining of oil. 5

3.1.1. Process description. 5

3.2 Equipments. 6

3.2.1. Mixer 6

3.2.2. Furnace 6

3.2.3. Reactor 6

3.2.4. Heat exchanger 1 6

3.2.5. Filter 6


3.2.7. Distillation column 1 6


3.2.9. Distillation column 2 7



4 MATERIAL BALANCE 8

4.1 Mixer 8

4.2 Reactor 8

4.3 Filter 9

4.4 Distillation column 1 10


4.6 Overall mass balance 11

5 ENERGY BALANCE 13

5.1 Mixer 13

5.2 Furnace 14

5.3 Reactor 14

5.4 Heat exchanger 1 15







5.11 Overall energy balance 21

6 EQUIPMENT DESIGN 23

6.1 Design for heat exchanger 2 23

6.2 Reactor 24

7 ECONOMIC ANALYSIS 25

7.1 Equipment purchased cost 25

7.2 Direct fixed cost 25

7.3 Indirect fixed cost 26

7.4 Working capital 26

7.5 Total fixed capital investment 26

7.6 Variable cost 26

7.6.1 Direct production cost 26

7.7 Utilities 26

7.8 Operating cost 27

7.9 Depreciation 28

7.10 General expenses 28

7.11 Total variable cost 29

7.12 Total investment 29

7.13 Product value 29

7.14 Profit estimation 29

7.15 Payback period 29

8 PLANT LOCATION AND LAYOUT 30

8.1 Plant location 30

8.1.1. General location of factory 30

8.1.2. The selection of actual site 31

8.2 Plant layout 31

8.2.1 Construction and operation cost 32

8.2.2 The process requirements 32

8.2.3 Convenience of operation 32

8.2.4 Convenience of maintenance 32

8.2.5 Safety 32

8.2.6 Future expansion 32

8.2.7 Modular construction 33

9 SIMULATION 35

9.1 Simulation software used 35

9.1.1. Chemcad hint 35

9.2 Simulation report 36

9.2.1. Simulation flow summaries 36

9.2.2. Mass and energy balance 38

9.2.3. Graph from chemcad 39

10 PROCESS SAFETY AND HEALTH ASPECTS 40

10.1 Material data sheet 40

10.2 Possible hazard 40

10.3 First aid measure 40

10.4 Firefighting measures 41

10.5 Accidental release measure 41

10.6 Handling 42

10.7 Storage 42

10.8 Exposure control and personal protection 42

10.9 General safety and hygiene measure 42

10.9.1 Disposal consideration 42

11 CONCLUSION 43

REFERENCES

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1.7 Purchased cost in lakhs 25

2.7 Salary Distribution 27

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1.3 Process Flow Diagram 5

1.8 Plant layout 34

LIST OF ABBREVIATIONS AND SYMBOLS

ACO Acetylated castor oil.

AA Acetic acid.

DO Drying oil (1-Tetradecene).

TPC Total purchased cost.

TDFC Total Direct fixed cost.

TIFC Total indirect fixed cost.

WC Working capital.

TFCI Total fixed capital investment.

OC Operating cost.

TVC Total variable cost.

TI Total investment.

PAT Profit after tax.

Y 1-Tetradecene in recycle stream.

Z Acetylated castor oil in recycle stream.

M Molar flow rate. (kmol/hr.).

Cp Specific heat capacity (kj/kmol. k).

∆t Temperature difference (°C).

Q Energy (kj/hr.).

Thi Hot water inlet temperature (°C).

Tho Hot water outlet temperature (°C).

TCo Cold water outlet temperature (°C).

TCi Cold water inlet temperature (°C).

hi Heat transfer coefficient at inner surface (W/ m2 k).

ho Heat transfer coefficient at outer surface (W/ m2 k).

Ki Inner thermal conductivity (W/m k).

Nu Nusselt number.

A Area (m2).

U Overall heat transfer coefficient (W/ m2 k).

Ds Shell diameter (m).

1. INTRODUCTION

1-tetradecene commonly called poly alpha olefins (PAOs) is used to improve the

polymer’s properties, such as softness and flexibility, is an unsaturated fatty oil which is

either natural or synthetic, when it is applied as thin coating it absorb atmospheric oxygen

and polymerize forming a tough elastic layer. These oils harden and become completely

dry after being exposed to air over a period of time. Some synonyms of 1-Tetradecene

are Tetradecenen1, Tetradecylene C14 alpha olefin, Alpha Tetradecene, Tetradec-1-ene.

It is a type of drying oils which are additives to products like paint and varnish to aid the

drying process when these products are coated on a surface. Some commonly used

drying oils include linseed oil, Tung oil, poppy seed oil, perilla oil, and walnut oil. Their

use has declined over the past several decades, as they have been replaced by alkyd

resins and other binders.

Drying oils consist of glycerol tri-esters of fatty acids. These esters are characterized by

high levels of polyunsaturated fatty acids, especially alpha-linolenic acid. One common

measure of the “siccative” (drying) property of oils is iodine number, which is an indicator

of the number of double bonds in the oil. Oils with an iodine number greater than 130 are

considered drying, those with an iodine number of 115-130 are semi-drying, and those

with an iodine number of less than 115 are nondrying.

1.1 CHEMICAL REACTION

The raw material is acetylated castor oil, which we will model as palmitic acid

(C15H31COOH). The primary reaction is one in which the acetylated castor oil is

thermally cracked to the drying oil (which we will model as tetradecene, C14H28) and

acetic acid (CH3COOH). There is an undesired reaction in which the drying oil dimerizes

to form a gum, which we will model as C28H56.

C15H31COOH (g) → CH3COOH (g) + C14H28 (l) (1)

ACO AA DO

2C14H28 (l) → C28H56 (2)

DO GUM

1.2 CHEMICAL PROPERTIES

Insoluble in water.

Can develop heat spontaneously in the air.

Reacts with acids to liberate heat along with alcohols and acids.

Flammable hydrogen is generated by mixing with alkali metals and hydrides.

1.3 PHYSICAL PROPERTIES

Boiling Point: 312°C at 760.0 mm Hg

Melting Point: -12° C

Specific Gravity: 0.96

Water Solubility: less than 1 mg/ml at 20° C

Flash Point: 230 ° C

Density 0.95 g / cm3.

Auto ignition Temperature: 550 ° C

1.4 APPLICATION OF 1-TETRADECENE

1.4.1 Paints:

In automotive Industry.

For painting Industrial Appliances or equipments.

In pigments.

1.4.1 Varnishes:

For better Protection of surface..

Highly inflammable.

1.4.2 Surfactants:

Stability.

Adhesive industry.

1.4.3 Detergents and soaps:

Metallic soap.

Presence of iodine.

2. AIM & SCOPE

To do a preliminary analysis to determine the feasibility of constructing a chemical

plant to manufacture 100 tons/year of 1-Tetradecene. A facility is to be designed to

manufacture 100 metric tons/year of 1-Tetradecene from acetylated castor oil (ACO).

Both of these compounds are mixtures. However, for simulation purposes, acetylated

castor oil is modeled as palmitic (hexadecanoic) acid (C15H31COOH) and 1-tetradecene

(C14H28) is the drying oil. In an undesired side reaction, a gum can be formed, which is

modeled as 1-octacosene (C28H56).

According to a recent survey report, In coming years the need of 1-tetradecene (drying

oil) is going to increase with huge increment. It is used in all automotive industries and

chemical industries as well.

.

3. METHOD OF PRODUCTION

3.1 PROCESSING AND REFINING

Fig.1.3: Process Flow Diagram.

3.1.1 Process description

The process is shown in Figure 3.1. The acetylated castor oil (ACO) feed is mixed

with recycled ACO and passed through a vessel that helps maintain constant flow

downstream of the mixing point. The ACO stream is then heated to the required reactor

temperature in a fired heater (furnace). The hot ACO stream is fed to the reactor, where

the reaction proceeds. In the reactor, reactions in Equations. (1) and (2) occur. The

reactor effluent is quenched to 175°C in HX1, using cooling water. In FILTER, the gum is

filtered out, and the filtrate is fed to a distillation column, DC-1, where the unreacted ACO

is recycled. The top product of DC-1 is fed to a second distillation column DC-2, which

purifies the AA and DO. More details on distillation columns and the associated heat

exchangers are presented later.

3.2 EQUIPEMENTS

3.2.1 Mixer

It is the place where feed ACO and recycle stream mix.

3.2.2 Furnace

The fired heater heats feed to the reaction temperature. Energy is provided by

burning natural gas (CH4). The lower heating value should be used to determine the cost

of the required natural gas.

3.2.3 Reactor

It is a kinetic reactor with 90% conversion. This is where the reactions in Equation

(1) and (2) occur.

3.2.4 Heat exchanger (HX1)

It is a shell and tube heat exchanger. It is where the high temperature fluid from

reactor quenched to lower temperature.

3.2.5 Filter

In the filter, all gum is removed in Stream 7, all AA, ACO, and 1-Tetradecene go to

Stream 6.

3.2.6 Heat exchanger 5 (HX5)

The filtered high temperature gum is cooled to lower temperature here.

3.2.7 Distillation column 1 (DC-1)

In DC-1, all AA in Stream 6 goes to Stream 9, all ACO in Stream 6 goes to Stream

8 and 99% of 1-Tetradecene in Stream 6 goes to Stream 9. The column pressure is

determined by the constraint that the bottom of the column may not exceed 350°C, to

avoid additional reaction at the bottom of the column that may form gum.

3.2.8 Heat exchanger 2(HX2)

Here, the high temperature (344°C) recycling fluid is cooled at lower temperature

(170°C).

3.2.9 Distillation column (DC-2)

Here, 99% of AA in Stream 9 goes to Stream 10, and 99% of 1-Tetradecene in

Stream 9 goes to Stream 12. This column operates at atmospheric pressure.


Here, 99% of AA from stream 10 is cooled to 25°C.


Here, 99% of 1-Tetradecene from stream 12 is cooled to 25°C.

4. MATERIAL BALANCE

Assumptions: 1. feed (ACO) = 99% pure.

2. 10% 1-Tetradecene converts into gum

3. 1 year = 330 days

Production rate. = 100 tonne/year of 1-Tetradecene

= (100x1000) / (330x24)

= 12.6264 kg/hr.

Feed required. = 148.2228 tonne/year (ACO).

= (148.2228x1000) / (330x24)

= 18.715 kg/hr.

4.1 MIXER

4.1.1 Material IN:

Feed ACO = 99% pure.

= 0.99x18.715 kg/hr.

= 18.52785 kg/hr.

Recycle fluid = 10% ACO + 1% 1-Tetradecene.

= 2.05865 + 0.128823 kg/hr.

= 2.087473 kg/hr.

Total IN = 20.7153 kg/hr.

4.1.2 Material OUT:

ACO = (18.52785 + 2.05865) kg/hr.

= 20.5865 kg/hr.

1-Tetradecene = 0.128823 kg/hr.

Total OUT = 20.7153 kg/hr.

4.2 REACTOR

4.2.1 Material IN:

ACO from Mixer = 20.5865 kg/hr.

1-Tetradecene from Mixer = .0128823 kg/hr.

Total IN = 20.7153 kg/hr.

4.2.2 Material OUT:

ACO = 10% (18.52785 + Z) kg/hr.

“Z” is the recycled ACO = 2.05865 kg/hr.

= 0.1 x 20.5865 kg/hr.

=2.05865 kg/hr.

1-tetradecene = 90% [Y + (196/256) (0.9{18.52785 + Z)}]

“Y” is the recycling 1-Tetradecene = 0.128823 kg/hr.

=12.88278 kg/hr.

Acetic acid = (60/256) {0.9(18.52785 + Z)}

= 4.34246 kg/hr.

GUM = 10% [Y + (196/256) {0.9(18.52785 + Z)}]

=1.43142 kg/hr.

Total OUT = 20.1531 kg/hr.

4.3 FILTER

4.3.1 Material IN:

ACO = 10% (18.52785 + Z) kg/hr.

“Z” is the recycled ACO = 2.05865 kg/hr.

= 0.1 x 20.5865 kg/hr.

=2.05865 kg/hr.

1-tetradecene = 90% [Y + (196/256) (0.9{18.52785 + Z)}]

=12.88278 kg/hr.

Acetic Acid = (60/256) {0.9(18.52785 + Z)}

= 4.34246 kg/hr.

GUM = 10% [Y + (196/256) {0.9(18.52785 + Z)}]

=1.43142 kg/hr.

Total material IN = 20.1531 kg/hr.

4.3.2 MATERIAL OUT 1:

GUM = 10% [Y + (196/256) {0.9(18.52785 + Z)}]

= 1.43142 kg/hr.

4.3.3 Material OUT 2:

ACO = 10% (18.52785 + Z) kg/hr.

= 0.1 x 20.5865 kg/hr.

=2.05865 kg/hr.

1-tetradecene = 90% [Y + (196/256) (0.9{18.52785 + Z)}]

=12.88278 kg/hr.

Acetic Acid = (60/256) {0.9(18.52785 + Z)}

= 4.34246 kg/hr.

4.4 DISTILLATION COLUMN 1 (DC-1)

4.4.1 Material IN:

ACO = 10% (18.52785 + Z) kg/hr.

= 0.1 x 20.5865 kg/hr.

=2.05865 kg/hr.

1-Tetradecene = 90% [Y + (196/256) (0.9{18.52785 + Z)}]

=12.88278 kg/hr.

Acetic Acid = (60/256) {0.9(18.52785 + Z)}

= 4.34246 kg/hr.


Acetic Acid = (60/256) {0.9(18.52785 + Z)}

= 4.34246 kg/hr.

1-Tetredecene = 99% [0.9{Y + (196/256) (0.9(1.52785 + Z))}]

= 12.75395 kg/hr.

4.4.3 Material OUT 2 (Recycle):

ACO = 10% (18.52785 + Z) kg/hr.

= 0.1 x 20.5865 kg/hr.

=2.05865 kg/hr.

1-Tetradecene = 1% of [0.99(0.9) {Y + (196/256) (0.90(1.52785 + Z))}]

= 0.128823 kg/hr.

Total material OUT = 19.28389 kg/hr.


4.5.1 Material IN:

Acetic Acid = (60/256) {0.9(18.52785 + Z)}

= 4.34246 kg/hr.

1-Tetredecene = 99% [0.9{Y + (196/256) (0.9(1.52785 + Z))}]

= 12.75395 kg/hr.

Total material IN = 17.09641 kg/hr.


Acetic Acid = 99% of [60/256{0.9(18.52785 + Z)}]

= 4.299 kg/hr.

1-Tetradecene = 1% of [0.99(0.9) {Y + 196/256(0.90(18.52785 + Z))}]

= 0.127539 kg/hr.


1-Tetradecene = 99% of [0.99x0.9{Y + 196/256(0.9(18.52785 + Z))}]

= 12.6264 kg/hr.

Acetic Acid = 1% of [0.99x0.9{Y + 196/256(0.90(18.52785 + Z))}]

= 0.04342 kg/hr.

4.6 OVERALL MATERIAL BALANCE

4.6.1 Material IN:

Feed ACO = 18.52685 kg/hr.

4.6.2 Material OUT 1 (99 % AA):

Acetic Acid = 99% of [60/256{0.9(18.52785 + Z)}]

= 4.299 kg/hr.

1-Tetradecene = 1% of [0.99(0.9) {Y + 196/256(0.90(18.52785 + Z))}]

= 0.127539 kg/hr.

4.6.3 Material OUT 2 (99% DO):

1-Tetradecene = 99% of [0.99x0.9{Y + 196/256(0.9(18.52785 + Z))}]

= 12.6264 kg/hr.

Acetic Acid = 1% of [0.99x0.9{Y + 196/256(0.90(18.52785 + Z))}]

= 0.04342 kg/hr.

4.6.4 Material OUT 3 (GUM):

GUM = 10% [Y + (196/256) {0.9(18.52785 + Z)}]

= 1.43142 kg/hr.

Total IN = Total OUT = 18.5268 kg/hr.

5. ENERGY BALANCE

5.1 MIXER

Q = mCp∆t

Where, m → molar flow rate.

Cp → specific heat capacity.

∆t → temperature difference

5.1.1 Energy IN:

Inlet temperature = 25°C = 298 K

Feed ACO molar flow rate = 0.07273744 kmol/hr.

Recycle ACO molar flow rate = 8.0416 x10-3 kmol /hr.

Recycle DO molar flow rate = 6.5726 x 10-4 kmol/hr.

Now,

Feed ACO IN = 0.07273744 x 482.7923 x 298

= 10412.6593 kj/hr.

Recycle ACO IN = 8.0416 x10-3. x 731.38 x 443

= 2605.505 kj/hr.

1-Tetradecene = 6.5728 x 10-4 x 518.6092 x 443

= 151.0071 kj/hr.

Heat added = 322.6795 kj/hr.

Total IN = 13491.844 kj/hr.

5.1.2 Energy OUT:

Outlet temperature = 44.55°C = 317.55 K

ACO = 0.080416 x 524.7913 x 317.55

= 13401.02 kj/hr.

1-Tetradecene = 6.5726 x 10-4 x 435.1672 x 317.55

= 90.82 kj/hr.

Total OUT = 13491.844 kj/hr.

5.2 FURNACE

5.2.1 Energy IN:

Inlet temperature = 24.55°C = 317.55 K

ACO = 0.80416 X 524.7913 X 317.55

= 13401.02 kj/hr.

1-Tetradecene = 6.5726 x 10-4 x 435.1672 x 317.55

= 90.82 kj/hr.



5.2.2 Energy OUT:

Outlet temperature = 380°C = 653 K

ACO = 0.080416 x 833.7652 x 653

= 43782.3847 kj/hr.

1-Tetradecene = 6.5726 x 10-4 x 569.5721 x 653

= 244.455 kj/hr.


5.3 REACTOR

5.3.1 Energy IN:


ACO = 0.080416 x 833.7652 x 653

= 43782.3847 kj/hr.

1-Tetradecene = 6.5726 x 10-4 x 569.5721 x 653

= 244.455 kj/hr.


5.3.2 Energy OUT:


ACO = 8.0416 x10-3 800.7286 X 515.4797

= 3319.2448 kj/hr.

1-Tetradecene = 0.065728 x 572.6126 x 515.4797

= 19401.07604 kj/hr.

GUM = 3.65158 x 10-3 x1054.2273 x 515.4797

= 1984.388 kj/hr.

Acetic Acid = 0.07237 x 212.9389 x 515.4797

= 7944.2148 kj/hr.

Heat removed = 11377.9165 kj/hr


5.4 HEAT EXCHANGER 1 (HX1)

5.4.1 Energy IN:


ACO = 8.0416 x 10-3 x 800.7286 X 515.4797

= 3319.2448 kj/hr.

1-Tetradecene = 0.065728 x 572.6126 x 515.4797

= 19401.07604 kj/hr.

GUM = 3.65158 x 10-3 x 1054.2273 x 515.4797

= 1984.388 kj/hr.

Acetic Acid = 0.07237 x 212.9389 x 515.4797

= 7944.2148 kj/hr.

Total IN = 44026.8397 kj/hr.

5.4.2 Energy OUT:


ACO = 8.0416 x 10-3 x 737.4030 x 448

= 2656.595184 kj/hr.

DO = 0.065728 x 522.1091 x 448

= 15374.0997 kj/hr.

GUM = 3.65158 x 10-3 x 950.9961 x 448

= 1555.7419 kj/hr.

Acetic Acid = 0.07237 x 176.1734 x 448

= 5712.85169 kj/hr.

Heat removed = 4030.661 kj/hr.



5.5.1 Energy IN:


ACO = 8.0416 x 10-3 x 737.4030 x 448

= 2656.595184 kj/hr.

DO = 0.065728 x 522.1091 x 448

= 15374.0997 kj/hr.

Acetic Acid = 0.07237 x 176.1734 x 448

= 5712.85169 kj/hr.

Total IN = 23748.9897 kj/hr.

5.5.2 Energy OUT 1: (To DC-2)


Acetic Acid = 8.0416 x 10-3 x 838.0175 x 413.7126

= 4157.9647 kj/hr.

1-Tetradecene = 0.065071 x 498.2966 x 140.7126

= 13414.5253 kj/hr.

Total IN = 23748.9897 kj/hr.

5.5.3 Energy OUT 2: (To recycle)


ACO = 8.0416 x 10-3 x 838.0175 x 617

= 4157.9646 kj/hr.

1-Tetradecene = 6.5728 x 10-4 x 550.6767 x 617

= 223.32375 kj/hr.

Heat removed = 1150.2299

Total heat = 23748.9897 kj/hr.

5.6 HEAT EXCHANGER 2 (HX2)

5.6.1 Energy IN:


ACO = 8.0416 x 10-3 x 838.0175 x 617

= 4157.9646 kj/hr.

1-Tetradecene = 6.5728 x 10-4 x 550.6767 x 617

= 223.32375 kj/hr.

Total IN = 4381.288 kj/hr

5.6.2 Energy OUT:


ACO = 8.0416 x 10-3 x 731.3845 x 443

= 2605.5057 kj/hr.

1-Tetradecene = 6.5728 x 10-4 x 518.6092 x 443

= 151.0071 kj/hr.


Total out = 4381.288 kj/hr.


5.7.1 Energy IN:


Acetic Acid = 8.0416 x 10-3 x 838.0175 x 413.7126

= 4157.9647 kj/hr.

1-Tetradecene = 0.065071 x 498.2966 x 140.7126

= 13414.5253 kj/hr.


Total IN = 24284.9978 kj/hr.

5.7.2 Energy OUT 1: (99% AA)


Acetic Acid = 0.07165 x 154.6505 x 398.9374

= 4420.5089 kj/hr.

1-Tetradecene = 6.50709 x 10-4 x 488.3529 x 398.9374

= 126.4747 kj/hr.

5.7.3 Energy OUT 2: (99% 1-Tetradecene)


1-Tetradecene = 0.06442 x 581.1498 x 525

=19654.9013 kj/hr.

Acetic Acid = 7.2366 x 10-4 x 218.761 x 525

= 83.112 kj/hr.


5.8 HEAT EXCHANGER 3 (HX3): DO

5.8.1 Energy IN:


1-Tetradecene = 0.06442 x 581.1498 x 525

=19654.9013 kj/hr.

Acetic Acid = 7.2366 x 10-4 x 218.761 x 525

= 83.112 kj/hr.

Total IN = 19738.01334 kj/hr.

5.8.2 Energy OUT:


1-Tetradecene = 0.06442 x 422.5414 x 298

= 8111.646 kj/hr.

Acetic Acid = 7.2366 x 10-4 x 123.8382 x 298

= 26.7060 kj/hr.



5.9 HEAT EXCHANGER 4: (AA)

5.9.1 Energy IN:


Acetic Acid = 0.07165 x 154.6505 x 398.9374

= 4420.5089 kj/hr.

1-Tetradecene = 6.50709 x 10-4 x 488.3529 x 398.9374

= 126.4747 kj/hr

5.9.2 Energy OUT:


Acetic Acid = 0.7165 x 123.8382 x 298

= 2644.156 kj/hr.

1-Tetradecene = 6.507 x 10-4 x 422.5414 x 298

= 81.93 kj/hr.


Total energy OUT = 4546.9836 kj/hr.

5.10 HEAT EXCHANGER 5: GUM

5.10.1 Energy IN:


GUM = 3.65158 x 10-3 x 950.9961 x 448

= 1555.7419 kj/hr.

5.10.2 Energy OUT:


GUM = 3.65158 x 10-3 x 691.4135 x 298

= 752.3763 kj/hr.


Total energy out = 1555.7426 kj/hr.

5.11 OVERALL ENERGY BALANCE

5.11.1 Energy IN:

Feed ACO = 0.07310 x 482.7923 x 298

= 10517.8377 kj/hr.

Total IN = 10517.8377 kj/hr.

5.11.2 Energy OUT 1: (99% AA)


Acetic Acid = 0.7165 x 123.8382 x 298

= 2644.156 kj/hr.

1-Tetradecene = 6.507 x 10-4 x 422.5414 x 298

= 81.93 kj/hr.



5.11.3 Energy OUT 2: (99% 1-Tetradecene)

1-Tetradecene = 0.06442 x 422.5414 x 298

= 8111.646 kj/hr.

Acetic Acid = 7.2366 x 10-4 x 123.8382 x 298

= 26.7060 kj/hr.



5.11.4 Energy OUT 3: (Gum)

GUM = 3.65158 x 10-3 x 691.4135 x 298

= 752.3763 kj/hr.



Total overall heat removed = -14223.9249 kj/hr.

Total overall OUT = 25340.73954 kj/hr.

Total IN = Total OUT = 10517.8733 kj/hr.

6. EQUIPEMENT DESIGN

6.1 DESIGN FOR HEAT EXCHANGER 2 (HX2):

Heat, Q = 4381.288 KJ/hr.

Note: 1 KJ =2.777 x 10-4 kW

= 1.219 kW

Logarithmic mean temp. diff., ∆Tlm

= (Thi - TCo) – (Tho - Ci)

Ln. (Thi - TCo)

(Tho - TCi)

Thi = 345°C

Tho = 170°C

TCo = 160°C

TCi = 90°C

= 125.249°C

NOTE:

Nu = hidi / ki = 3.66 [ from O. Levenspiel, Engineering Flow and Heat Exchange second

edition, Plenum, New York, 1998, Equation (9.23), p 177.]

di = 22.91 mm = 0.02291 m

Using an average thermal conductivity, ki of 0.1207 W/mk, we get

hi = 3.66ki/di = (3.66)(0.1207)/(0.02291) = 19.3 W/ m2k

Heat transfer coefficient, hi = 19.3 w/ m2k

Assuming fouling factor = 500 w/m2k and ignoring outside heat transfer coefficient.

Overall heat transfer coefficient. U = 1/hi + 1/ ho

= 18.528 W/m2k

Q = UA ∆t.

Where, Q = heat

A = Area.

∆t = temperature difference.

Therefore, Area, A = 0.1648 m2

Now, assuming no. of tubes = 10

Therefore, Area / tube = nπdl

= 10 x π x 0.02291 x 0.20

= 0.02193 m2

Therefore, tube needed = Area / Area per tube.

= 9.017

No. of tubes = 9.017 ≈ 9

Pitch2 = π x ds2 /4 x n

Where, ds = shell diameter.

Pitch = Area per tube / no. of tubes.

= 0.00243667 m

Ds = √( 4 x 9 x (0.00243667) / π)

= 0.1671 m = 6.57 inch.

6.2 REACTOR

We used an plug flow reactor.

PFR consideration L/D = 10 m {from do12 ,author-Joe Shaeiwitz,

. Article no.- ChE 182 }

Volume = 0.01968 m3 {from Chemcad simulation}

V = π x (d2 /4) x l

V = π x (d2 /4) x 10D

D3 = 2.505 x 10-3

D = 0.1358 m

Therefore, L = 1.358 m

Diameter = 0.1358 m

Length = 1.358 m

7. ECONOMIC ANALYSIS

7.1 EQUIPMENT PURCHASED COST

Table 1.7 Purchased cost in lakhs.

EQUIPMENT COST IN LAKHS

REACTOR 5.90

FURNACE 2.56

HEAT EXCHANGER 2.0

DISTILLATION COLUMNS 10

PUMPS 1.40

FILTER 1.80

MIXER 3.0

Total purchased cost (TPC) = 26.66 lakhs

7.2 DIRECT FIXED COST

Equipment installation cost = 20% of PEC

= 5.332 lakhs

Instrumentation and process control = 15% of PEC

= 3.999 lakhs

Electrical equipment cost = 2 lakhs

Land cost = 5 lakhs

Building cost = 3 lakhs

Piping cost = 3 lakhs

Total Direct fixed cost (TDFC) = 22.331 lakh

7.3 INDIRECT FIXED COST

Engineering and supervision = 30% of TPC

= 7.998 lakhs

Contingency = 8% of DFC

= 1.78648 lakhs

Construction expenses = 5 lakhs

Total indirect fixed cost (TIFC) = 14.7845 lakhs

7.4 WORKING CAPITAL (WC)

WC = 5% of (TPC + DFC + TIFC)

= 3.1887 lakhs

7.5 TOTAL FIXED CAPITAL INVESTMENT (TFCI)

TFCI = TPC + DFC + IFC + WC

= 6.997 lakhs

7.6 VARIABLE COST

7.6.1 Manufacturing cost (Direct Production Cost)

Raw material = ACO

Requirement = 148.2228 tons/year

Rate = 60 Rupees/kg

Total cost = 88.93368 lakhs

7.7: UTILITIES

Cooling water = 2386.4 ton/year

= 3.999 rupees per ton/year

Therefore, cost = .09500 lakhs

Fuel = 28.4517 SCF / hr. = 0.03 GJ/hr.

Cost = 1017 rupees /GJ.

Therefore, fuel cost =2.416 lakhs

Electricity required = 50 ton/year

Rate = 1.25 rupees tons/year

Electricity cost = 0.00185 lakhs

Total utilities cost = 2.51285 lakhs

7.8 OPERATING COST (OC)

Table: 2.7 Salary Distribution

LABOUR

NO.

SALARY PER MONTH

PER LABOUR

SALARY PER ANNUM(LAKHS)

CHIEF EXECUTIVE 2 25000 6.0

WORKERS MANAGER 2 15000 3.6

ASSISTANT MANAGER 3 12000 4.32

SUPERVISOR 6 10000 7.20

SKILLED LABOUR 10 3000 3.60

UNSKILLED LABOUR 15 1500 2.70

Total operating cost = 27.42 lakhs

Maintenance cost per annum = 1.5 lakhs

Supervision & labour cost = 5% of OC

=1.371 lakhs

7.9 DEPRICIATION

Plant life = 10 years

Salvage = 10% of TPC

= 2.666 lakhs

Straight line depreciation = Total Purchased Cost – Salvage / Plant life

= 26.66 – 2.666

10

= 2.399 lakhs

Building = 3% of initial building construction

= 0.09 lakhs

Total depreciation = 2.489 lakhs

Local tax = 3% of TFCI

= 2.01 lakhs

Insurance = 0.67 lakhs

Plant overhead = 50% of (OC + Maintenance + Supervision)

= 15.1455 lakhs

7.10 GENERAL EXPENSES

Admin cost = 1.5 lakhs

Distribution & marketing cost = 100 lakhs

R & D cost = 5% of OC

= 1.371 lakhs

Total general cost = 102.861 lakhs

7.11 TOTAL VARIABLE COST (TVC)

TVC = manufacturing cost + utilities + labour cost

= 121.7375 lakhs

7.12 TOTAL INVESTMENT (TI)

TI = TVC + TFCI +TAXES

= 203.847 lakhs

7.13: PRODUCT VALUE:

Product sales price (1-tetradecene) = 101 rupees /kg

Product cost = 101 lakhs

Product sales price (AA) = 3000$/ton

AA formed = 34391.9664 kg/year

Product cost = 61.91633 lakhs

Total product value = 162.916339 lakhs

7.13 PROFIT ESTIMATION

Profit before tax = total earning - TVC + depreciation

= 43.6679 lakhs

Tax rate = 40 %

Profit after tax (PAT) = 26.2 lakhs

7.14 PAY BACK PERIOD

PBP = TI/PAT

= 7.78 years

8. PLANT LOCATION AND LAYOUT

8.1 PLANT LOCATION

The important part in the setting of a factory is to select a suitable site or location to house

the factory because an inappropriate selection of location would end the activity of the

plant no matter how efficient the equipment, management etc are. The problem can be

divided in to two main parts:

General location of the factory

The selection of particular site

For the general location of the factory following factors must be considered:

The Raw materials should be easily available at comparatively low cost and at

low freight charges.

The market should be near the factory for the quick service to the customers

and easy transportation.

There should be good transport facilities for bringing raw material and sending

finished product.

Skilled and cheap laborers should be available near the plant site.

Availability of power and fuel were very influencing in olden days to day it has

not much effect on plant site.

Climatic and atmospheric conditions are governing factor to several chemical

industries. However, air conditioning systems have changed the situation.

All factories need soft and pure water especially in large quantities.

Availability of Capital.

Social and recreational facilities can be created near the factory site.

Banking facilities are necessary for the factories, which require constant

feeding of the working capital.

Existence of related factories sometimes play very important role in selection

of site.

The factors like local bye laws, taxes, fire protection facilities, post and

telegraph facilities should also be considered.

8.1.2 Selection of actual site:

The most important factors in this division are

Availability of cheap land to build and expand the plant

The cost of leveling the land are providing foundations, subsoil conditions for

foundations and drainage

The cost of bricks, sand, cement, limes, steel and other materials required for

construction.

Facilities for the up keep and general maintenance

Facilities for transport in getting and sending materials

Facilities for housing the workers and if necessary their transport from their place

of residence to work sites.

Cost of laying the water supply, provide sewage and disposal work.

Cost of installation of electricity, gas and other facilities etc.

Any restrictions placed by the planning department or local by laws should be well

studied.

8.2 PLANT LAYOUT

The economic construction and efficient operation of a process unit will depend on

how well the plant an equipment specified on the process flow sheet is laid out the

principal factors considered are :

Economic considerations:

1. Construction and operation costs.

2. The process requirements.

3. Convenience of operation

4. Convenience of maintenance

5. Safety

6. Future expansion

7. Modular construction

8.2.1 Costs:

The cost of construction can be minimized by adopting a layout that gives the shortest

run of connecting pipe between equipments, and at least amount of structural steel work.

However, this will not necessarily be the best arrangement ofr operation and

maintenance.

8.2.2 Process requirement:

An example of the need to take into account process consideration is the need to elevate

the base of column to provide the necessary net positive suction head to a pump or the

operating head for thermo-siphon re-boiler.

8.2.3 Operations:

Equipment that needs to have frequent attention should be located convenient to the

control room. Valves, sample points, and instruments should be located at convenient

positions and heights. Sufficient working space and headroom must be provided to allow

easy access to equipment.

8.2.4 Maintenance:

Heat exchanger 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 places

under cover.

8.2.5 Safety:

Blast walls may be needed to isolate potentially hazardous equipment and confine the

effects of an explosion. At least two escape routes for operators must be provided from

each level in process buildings.

8.2.6 Plant expansion:

Equipment should be located so that it can be conveniently tied in with any future

expansion of eh process. Space should be left on pipe alleys for future needs, and

service pipes over-sized to allow for future requirements.

8.2.7 Modular construction:

In recent years there has been a move to assemble sections of plant at the plant

manufacturer’s site. These modules will include the equipment, structural steel, piping

and instrumentation. The modules are then transported to the plant site, by road or sea.

Advantages:

Improved quality control.

Reduced construction cost.

Less need for skilled labor on site.

Disadvantages:

Higher design cost and more structural steel work.

More flanged construction and possible problem with assembly, on site.

Fig. 1.8 : Plant layout:

9. SIMULATION:

9.1 SIMULATION SOFTWARE USED:

Chemcad Chemstation.

9.1.1 Chemcad hint:

We wanted to simulate this process, it was necessary for us to add gum as a compound

to the chemcad databank. This has been done in chemcad. However, if you save the job

to a zip disk or floppy disk, it will not contain the new component. You must export the file

rather than just saving or copying it for it to contain the new component information.

Therefore, it was beneficial for us to add this component to the databank on our home

computer.

PROCEDURE:

From the Thermophysical menu, click on databank and new component.

In the dialog box that is shown, enter a name for the compound (we used gum),

the molecular weight (392) and the boiling point (431.6°C). Click on group

contribution - Joback. This will use a group contribution method to estimate

properties. Then, click OK.

In the next dialog box, you must put in the correct groups. There is 1 –CH3 group,

25 >CH2 groups, 1 =CH2 group, and 1 =CH– group. Then, click OK.

It will ask you if you want to save this component. Click yes. It will probably assign

it as component number 8001.

If you want to check information or add more information, you can now go to

Thermophysical, databank, view-edit. Then, type in the new component number.

When the next menu list comes up, one thing you can do, for example, is add the chemical

formula for gum or add the correct chemical name under synonyms. However, these are

not necessary to run simulations using this new compound.

Be sure that the new compound, gum, is in your component list for the current

job.

9.2 CHEMCAD REPORT

9.2.1 Simulation flow summaries:

Simulation: 1-tetradecene3A Date: 01/20/2015 Time: 00:08:43

FLOW SUMMARIES:

Stream No. 1 2 3 4

Temp. C 25.0000* 44.5475 380.0000 242.4795

Pres. kPa 110.0000* 230.0000 230.0000 183.0000

Enth MJ/h -59.847 -136.28 -116.01 -116.01

Vapor mole frac. 0.00000 0.00000 0.00000 0.73925

Total kmol/h 0.0723 0.2231 0.2231 0.2928

Total kg/h 18.5278 76.4422 76.4422 76.4421

Total std L m3/h 0.0210 0.0857 0.0857 0.0869

Total std V m3/h 1.62 5.00 5.00 6.56

Flowrates in kg/h

Acetic Acid 0.0000 0.0000 0.0000 4.3408

1-Tetradecene 0.0000 0.2131 0.2131 13.4095

Hexadecanoic Aci 18.5278 20.6044 20.6044 2.0691

1-octacosene 0.0000 55.6247 55.6247 56.6228

Stream No. 5 6 7 8

Temp C 175.0000 175.0000 175.0000 344.0000

Pres kPa 148.0000 136.0000 136.0000 154.7495

Enth MJ/h -121.65 -122.81 -0.0069308 -76.432

Vapor mole frac. 0.35152 0.00000 0.00000 0.00000

Total kmol/h 0.2928 0.2928 0.0000 0.1533

Total kg/h 76.4421 76.4395 0.0027 58.9043

Total std L m3/h 0.0869 0.0869 0.0000 0.0658

Total std V m3/h 6.56 6.56 0.00 3.44

Flow rates in kg/h

Acetic Acid 4.3408 4.3402 0.0006 0.0000

1-Tetradecene 13.4095 13.4077 0.0018 0.2127


1-octacosene 56.6228 56.6228 0.0000 56.6228

Stream No. 9 10 11 12

Temp C 140.7126 125.9374 170.0000 252.0000

Pres. kPa 136.0000 125.0000 129.7495 125.0000

Enth MJ/h -46.769 -31.630 -77.668 -11.265

Vapor mole frac. 0.00000 0.00000 0.00000 0.00000

Total kmol/h 0.1395 0.0715 0.1533 0.0680

Total kg/h 17.5352 4.2943 58.9043 13.2409

Total std L m3/h 0.0211 0.0041 0.0658 0.0170

Total std V m3/h 3.13 1.60 3.44 1.52

Flow rates in kg/h

Acetic Acid 4.3402 4.2943 0.0000 0.0458

1-Tetradecene 13.1950 0.0000 0.2127 13.1950


1-octacosene 0.0000 0.0000 56.6228 0.0000

9.2.2 Mass and Energy balance:

Simulation: dryingoil Date: 01/19/2015 Time: 17:24:26

Overall Mass Balance kmol/h kg/h

Input Output Input Output

Acetic Acid 0.000 0.072 0.000 4.341

1-Tetradecene 0.000 0.067 0.000 13.197


1-octacosene 0.000 0.000 0.000 0.000

Total 0.072 0.139 18.528 17.538

Overall Energy Balance MJ/h

Input Output

Feed Streams -59.8468

Product Streams -51.529

Total Heating 36.478

Total Cooling -28.228

Power Added 0

Power Generated 0

Total -51.5962 -51.5293

9.2.3 Graph from chemcad simulation:

Fig.1.9 : Phase Envelope (stream 7).

10. PROCESS SAFETY AND HEALTH ASPECTS:

10.1 MATERIAL DATA SHEET

10.1.1 Substance Name:

1-TETRADECENE.

10.1.2 Chemical Nature:

Low toxicity.

Less soluble (at 20°C).

.Degrades in soil & water.

10.2 POSSIBLE HAZARDS:

In Animals:

Skin Irritation on inhalation or dosage.

High dosage cause kidney damage.

In humans:

Minimal concern on inhalation.

10.3 FIRST AID MEASURES

10.3.1 General advice:

Move out of dangerous area.

10.3.2 If inhaled:

Keep patient calm, move to fresh air, summon medical help.

10.3.3 On skin contact:

Wash thoroughly with soap and water.

10.3.4 If swallowed:

Keep respiratory tract clear. Do NOT induce vomiting.

Take victim immediately to hospital.

10.3.5 On contact with eyes:

Wash affected eyes for at least 15 minutes under running water with eyelids held

open

Keep eye wide open while rinsing.

10.3.6 On ingestion:

Rinse mouth and then drink plenty of water.

10.4 FIRE FIGHTING MEASURES:

10.4.1 Unsuitable extinguishing media:

Use high volume water jet.

10.4.2 Special protective equipment:

Wear self contained breathing apparatus.

Further information:

Use extinguishing measures that are appropriate to local circumstances.

10.5 ACCIDENTAL REALESE MEASURE:

10.5.1 Personal precautions:

Avoid dust formation.

10.5.2 Environmental precautions:

Do not let product enter drains.

10.5.3 Methods for cleaning up:

Sweep/shovel up.

10.6 HANDLING:

Protection against fire and explosion.

Handle in accordance with good industrial hygiene and safety practice.

10.6.1 Technical protective measures:

Breathing must be protected when large quantities are decanted without local

exhaust ventilation.

Smoking, eating and drinking should be prohibited in the application area.

10.7 STORAGE:

Keep tightly closed in a dry and cool place

.

10.8 EXPOSURE CONTROL AND PERSONAL PROTECTION

Components with workplace control parameters.

Respiratory protection0: if breathable dust is formed

Hand protection: protective gloves

Eye protection: safety glasses.

10.9. GENERAL SAFETY AND HYGIENE MEASURES

The usual precautions for the handling of chemicals must be observed.

Do not breathe dust.

10.9.1 Disposal consideration:

Product must be disposed of by special means, e.g. suitable dumping in

accordance with local regulations.

11. CONCLUSION

Hence we have modified the 1-tetradecene production process using chemcad software.

It can be proved to be higher profitable process. The process overall material balance,

overall energy balance, equipment design is calculated.

REFERENCES:

1. Ashokan K., Chemical process calculation, lecture notes, 1st Edition, Universities

press India pvt. Ltd., 2008.

2. Babu B.V., process plant simulation, 1st Edition, oxford university press, 2004.

3. Bharat Bhatt I. and Shuchen Thakore B., Stoichiometry, 5th Edition, Tata McGraw

Hill, 2010.

4. Deshmukh L.M., Industrial Safety Management, 3rd Edition, Tata McGraw Hill, New

Delhi, 2008.

5. Gupta C.B., Management theory and practice, 14th Edition, Sultan chand, sons,

2009.

6. Levenspiel O., Chemical reaction Engineering, 3rd Edition, McGraw Hill, 1998.

7. Luyben William L., Process Modeling Simulation and Control for Chemical

Engineers, 2nd Edition, McGraw Hill, 1990.

8. Perry R.H., “Chemical Engineer” Handbook, 8th Edition, McGraw-Hill, 2008.

9. Seader J.D., Henley Ernest J., Seperation process principles, 2nd Edition, Wiley

India pvt. Ltd., 2006.

10. Smith J.M., Chemical kinetics and Reactor Design, 2nd Edition, McGraw Hill, 2004.

Production of 1 tetradecene at 100 tons per year

Engineering

Transcript of Production of 1 tetradecene at 100 tons per year