No. Title Page

1. Introduction to Chlorobenzene

2. Process Description & Process Analysis

3. Plant Location & Site Selection

4. Process Flow Diagram (PFD)

5. Workbook

6. Material & Energy Balance

7. Pinch Calculation

8. Major Equipment Design

Piping & Instrumentation Diagram (P&ID)

9. Plant Layout

10. Capital & Manufacturing Cost

11. Hazard Analysis (Environmental Considerations)

12. References

13. Appendices

Table of Content

Introduction to Chlorobenzene

Chlorobenzene is an aromatic organic compound with the chemical formula C6H5Cl. It is made

from chlorine and benzene trough chlorination process. It is a colorless volatile flammable liquid

with an almond odor and used as a solvent and in the production of phenol and DDT and other

organic compounds.

As a group, chlorobenzenes are much less reactive than the corresponding chlorinated

derivatives of alkyl compounds and are similar in reactivity to the vinyl halides. They are very

stable to nucleophilic attack due to resonance in the molecule resulting in a shortening of the

carbon-chlorine bond distance and an increase in bond strength.

Chlorobenzenes are not attacked by air, moisture, or light. at room temperature and pressure.

Chlorobenzenes also are not affected by steam, prolonged boiling with aqueous or alcoholic

ammonia, other alkalis, hydrochloric acid, or dilute sulfuric acid. To form phenols, hydrolysis

takes place at elevated temperatures in the presence of a catalyst.

Hot concentrated sulfuric acid attack chlorobenzenes to form chlorobenzene-p-sulfonic acid.

Nitric acid will react with chlorobenzenes at the meta- and parapositions on the ring to form

chloronitrobenzenes at -30°C to 0°C (-22°C to 32°F). At higher temperatures, the nitration will

either proceed further to form a dinitrochloro-compound, chloronitrophenol, or a nitrophenol.1

Chlorobenzenes are attacked by electrophilic agents. Para- is predominantly substitution for

monochlorobenzene with some ortho-substitution. Electrophilic substitution might be resisted by

the higher chlorinated benzenes but can be substituted under extreme conditions.

Some free radical reactions undergo on Chlorobenzenes. Formation of organometallic

compounds (grignards, aryl-lithium compounds) provides a useful route to many organic

intermediates. Photochemical transformations occur on irradiation of chlorinated benzenes,

which are much less stable to radiation than benzene. When subjected to ultraviolet irradiation or

pulse hydrolysis in solution, chlorobenzenes may polymerize to biphenyls, chloronaphthalenes,

or more complex products. The ability of chlorobenzenes to undergo wide varieties of chemical

reactions makes chlorinated benzenes useful as reactants in numerous commercial processes to

produce varied products. All chlorinated derivatives of benzene are soluble in lipids. Partition

coefficient data for chlorobenzenes show an increase in partition coefficient with an increase in

the degree of chlorination. In general, a positive correlation exists between partition coefficient

and degree of bioaccumulation.

Identification

Chlorobenzene identification in the commercial industry is listed as below in Table 1.2:

Chemical Name Chlorobenzene

Molecular Structure

Synonyms Monochlorobenzene, Chlorobenzol, Phenyl

chloride, Benzene chloride

IUPAC Name Chlorobenzene

Classification Aryl halides

UN Identification Number UN1134

Hazardous Waste ID No. D001, U037, D021

Formula C6H5Cl

Codes/Label Flammable Class 3

The physical and chemical properties of chlorobenzene can be concluded in the Table 1.1.

Properties Value

Molecular Weight 112.56 G

Normal Freezing Point -45.58 °C

Vapor Pressure 1.17 kPa

Normal Boiling Point, 131.69 °C

Liquid Density 1.11 g/cm3

Reference temperature for liquid

Density

20 °C

Uses

Chlorobenzene is usually used as a solvent for pesticide formulations, diisocyanate manufacture,

and degreasing automobile parts and for the production of nitrochlorobenzene. Furthermore,

chlorobenzene can be used as intermediate in the phenol and dichlorodiphenyltrichloroethane

(DDT) production.

Health

The United States Environmental Protection Agency (EPA) stated that the exposure of the

chlorobenzene to human being appears to be primarily occupational. EPA has listed some

information on the health hazard information of chlorobenzene.

Acute Effects:

Acute exposure to chlorobenzene may cause redness and inflammation of the eyes and eyelids,

runny nose, sore throat, redness and irritation of the skin, headache, dizziness, drowsiness,

incoherence, ataxia, and loss of consciousness. Furthermore, it also may cause twitching of the

extremities, deep and rapid respiration, and irregular heartbeat. Respiratory arrest may follow.

1. A child who ingested chlorobenzene became unconscious and cyanotic and had muscle

spasms but recovered completely.

2. Acute inhalation exposure of animals to chlorobenzene produced narcosis, restlessness,

tremors, and muscle spasms.

3. Acute animal tests in rats, mice, rabbits, and guinea pigs have demonstrated

chlorobenzene to have low acute toxicity by inhalation and moderate acute toxicity from

oral exposure.

Chronic Effects (Non-cancer):

Long term exposure to chlorobenzene may cause chronic central nervous system (CNS)

depressions which are headache, dizziness, and somnolence. Based on effects seen in animals,

chronic exposure may cause elevated liver enzymes, enlarged and tender liver, and blood, pus, or

protein in the urine. Prolonged or repeated skin contact may cause skin burns.

1. Chronic exposure of humans to chlorobenzene affects the CNS. Signs of neurotoxicity

include numbness, cyanosis, hyperesthesia (increased sensation), and muscle spasms.

2. Headaches and irritation of the mucosa of the upper respiratory tract and eyes have also

been reported in humans chronically exposed via inhalation.

3. The CNS, liver, and kidneys have been affected in animals chronically exposed to

chlorobenzene by inhalation.

4. Chronic ingestion of chlorobenzene has resulted in damage to the kidneys and liver in

animals.

5. EPA has calculated a provisional Reference Concentration (RfC) of 0.02 milligrams per

cubic meter (mg/m3) for chlorobenzene based on kidney and liver effects in rats. The

RfC is an estimate (with uncertainty spanning perhaps an order of magnitude) of a

continuous inhalation exposure to the human population (including sensitive subgroups),

that is likely to be without appreciable risk of deleterious noncancer effects during a

lifetime. It is not a direct esimator of risk but rather a reference point to gauge the

potential effects. At exposures increasingly greater than the RfC, the potential for adverse

health effects increases. Lifetime exposure above the RfC does not imply that an adverse

health effect would necessarily occur. The provisional RfC is a value that has had some

form of Agency review, but it does not appear on IRIS.

6. The Reference Dose (RfD) for chlorobenzene is 0.02 milligrams per kilogram body

weight per day (mg/kg/d) based on histopathologic changes in the liver in dogs.

7. EPA has medium confidence in the study on which the RfD was based because it

provided both a no-observed-adverse-effect level (NOAEL) and a lowest-observed-

adverse-effect level (LOAEL) and incorporated several biochemical and biological

endpoints; medium confidence in the database because several subchronic, chronic,

developmental, and reproductive toxicity studies provide supportive data, but they did not

give a complete assessment of toxicity; and, consequently, medium confidence in the

RfD.

Reproductive/Developmental Effects:

1. No information is available on the reproductive or developmental effects of

chlorobenzene in humans.

2. Chronic inhalation exposure of rats to chlorobenzene did not adversely affect

reproductive performance or fertility. However, a slight increase in the incidence of

degenerative testicular changes was observed.

3. Chlorobenzene does not appear to be a developmental toxicant and did not produce

structural malformations in rats and rabbits acutely exposed via inhalation.

Cancer Risk:

1. No information is available on the carcinogenic effects of chlorobenzene in humans.

2. In a National Toxicology Program (NTP) study of rats and mice exposed to

chlorobenzene via gavage (experimentally placing the chemical in the stomach), an

increased incidence of neoplastic nodules of the liver in high dose male rats was

observed, but not in female rats or male or female mice.

3. EPA has classified chlorobenzene as a Group D, not classifiable as to human

carcinogenicity.

Handling

A worker who handles chlorobenzene should wear protective clothing such as gloves, boots,

aprons, and gauntlets to prevent skin contact with chlorobenzene. Eyewash fountains and

emergency showers should be available within the immediate work area whenever the potential

exists for eye or skin contact with chlorobenzene. Contact lenses should not be worn if the

potential exists for chlorobenzene exposure.

Use of respirator also should be considered for handling the chlorobenzene. Good industrial

hygiene practice requires that engineering controls be used to reduce workplace concentrations

of hazardous materials to the prescribed exposure limit. Respirators must be worn if the ambient

concentration of chlorobenzene exceeds prescribed exposure limits.

Spill and leaks

In the event of spill or leak involving chlorobenzene, persons not wearing protective equipment

and clothing should be restricted from contaminated areas until cleanup is complete. The

following steps should be undertaken following a spill or leak:

1. Do not touch the spilled material.

2. Notify safety personnel.

3. Remove all sources of heat and ignition.

4. Ventilate potentially explosive atmospheres.

5. Water spray may be used to reduce vapors, but the spray may not prevent ignition in

closed places.

6. For small dry spills, use a clean non-sparking shovel and gently place the material into a

clean, dry container, cover and remove the container from the spill area.

7. For small liquid spills, absorb with sand or other non-combustible absorbent material and

place into closed container for later disposal.

8. For large liquid spills, build dikes far ahead of the spill to contain the chlorobenzene for

later reclamation or disposal.

Storage

Chlorobenzene should be stored in a cool, dry, well-ventilated area in tightly sealed

containers that are labeled in accordance with OSHA’s hazard communication standard (29 CFR

1910.1200). Outside or detached storage is preferred. Inside storage should be in a standard

flammable liquid storage room. Containers of chlorobenzene should be protected from physical

damage and should be stored separately from oxidizers, dimethyl sulfoxide, silver perchlorate,

other incompatible material, heat, sparks, and open flame. Only non-sparking tools may be used

to handle chlrobenzene. To prevent static sparks, containers should be grounded and bonded for

transfers. Because containers that formerly contained chlorobenzene may still hold product

residues, they should be handled appropriately.

Market Analysis of ChlorobenzeneDemand and consumption pattern

Only three of many possible products resulting from the chlorination of benzene continue to have

any large-volume applications—monochlorobenzene, o-dichlorobenzene and p-dichlorobenzene

—and they are the major focus of this report. These three products combined account for as

much as 92–96% of the total chlorobenzenes market. Other chlorobenzenes that have

commercial applications but are not produced on a large scale include m-dichlorobenzene,

trichlorobenzenes, tetrachlorobenzenes and hexachlorobenzene. Market information on these

products is included in the report where available.

The following pie chart shows consumption of chlorobenzenes in the major regions:

Monochlorobenzene accounts for nearly 73% of total chlorobenzene consumption. China is the

world's largest manufacturer and consumer, accounting for nearly 82% of total consumption in

the four major regions shown below. Monochlorobenzene represents about 70% of

chlorobenzene consumption in Western Europe, and 52% of consumption in the United States,

but only 10% in Japan, where p-dichlorobenzene is a larger factor than in the other regions.

Nitrochlorobenzene is the most significant end use for monochlorobenzene. Nitrochlorobenzenes

are consumed as intermediates in the manufacture of dyes and pigments, rubber-processing

chemicals, pesticides (e.g., parathion and carbofuran), pharmaceuticals (e.g., acetaminophen) and

other organic chemicals. Monochlorobenzene has been used for the synthesis of diphenyl ether

(also known as diphenyl oxide or DPO) and is increasing in demand for sulfone polymers.

o-Dichlorobenzene is a chemical intermediate consumed mostly for 3,4-dichloroaniline in the

United States, South America and Western Europe and as an herbicide intermediate in Japan.

Worldwide, p-dichlorobenzene is used primarily as a raw material for polyphenylene sulfide

(PPS) resins, for deodorant blocks for indoor air, and for moth control. Polyphenylene sulfide is

a growing high-performance polymer that is produced only in the United States, Japan and

China. PPS resin production has increased rapidly both in the United States and Japan over the

past five years and has become significant in China since 2010. PPS production is projected to

continue to grow over the next five years, with additional capacity planned in China and the

Republic of Korea. There are no producers of PPS resins in Western Europe.

The gradual shift in global demand away from industrialized regions and further into developing

countries has resulted in a buildup of new chlorobenzene capacity in Asia. China is the world's

most diverse market and home to four of the world's five largest producers. It also accounts for

an estimated 68–75% of global capacity.

With the exception of high-performance polymers, the markets for chlorobenzenes are mature.

Demand for chlorobenzenes in more industrialized regions has been on a decline for the past few

decades as a result of the substitution of alternative chemistry in the production of such products

as phenol, rubber chemicals and moth control agents. Growing environmental concern over

usage in herbicides and solvents has additionally contributed to the slow decline. However,

strong growth in China and growing global demand for p-dichlorobenzene have since stabilized

this trend, resulting in a moderate, average growth rate of 4% per year for the forecast period.

Future Demand for Chlorobenzene

The capacity of chlorobenzene in China reached 320 000 t/a at the end of 2003, accounting for

50% of the world total. The output of chlorobenzene in China was around 260 000 tons in 2003.

Chlorobenzene is mainly used to produce o- and pnitrochlorobenzene, 2,4-dinitrochlorobenzene

and diphenyl ether. It is also used in the synthesis of solvents, pesticides and dyestuffs. The

consumption composition of chlorobenzene in 2003 was 73.8% for o- and p-nitrochlorobenzene,

10% for 2,4-dinitrochlorobenzene, 1.7% for diphenyl ether and 14.5% for others. The import and

export amounts of chlorobenzene in China are fairly small. The export amount was estimated to

be 3 000 tons in 2003. The competition in chlorobenzene and major downstream products is

mainly between domestic producers rather than from foreign products. Furthermore, the

consumption of chlorobenzene in other sectors is also relatively stable, mainly determined by o -

a n d p – nitrochlorobenzene production. With the rapid capacity expansion, the production cost

of o- and p-nitrochlorobenzene in China has consistently fallen. Foreign countries have slowed

down the development of o- and p-nitrochlorobenzene production and mainly depended on the

import of downstream fine chemicals derived from o- and p-nitrochlorobenzene such as

dyestuffs, pigments, pharmaceuticals and pesticides from China. The export of o- and p-

nitrochlorobenzene has therefore been promoted. Chlorobenzene will still experience brisk

production and sales in China in 2004 and there will be a supply shortage in some areas. If there

are no drastic fluctuations in raw material supply, however, the price of chlorobenzene will be

kept stable.

Process Description & Process AnalysisContinuous process

Batch process

Raschig process

1. Direct chlorination (Continuous process)

C6H6 + Cl2 C6H5Cl + HCl

C6H6 + Cl2 C6H5Cl + HCl

The process begins with a series of small, externally cooled cast iron or steel vessels

containing the catalyst (which may consist of Rashig ring of iron or iron wire). The catalyst used

is usually Ferric chloride. This can be added as solution in benzene. Chlorine is supplied into

each vessel through suitably positioned inlets to maintain a large benzene-to-chorine reaction at

all points along the reaction stream. The temperature is maintained about 20℃ to 40℃ for this

reaction in order to minimize the production of dichlorobezene which occur at higher

temperature. Besides, this range of temperature is the best temperature for production of large

amount of monochlorobenzene. This process will produce large amount of monochlorobenzene

and small amount of dichlorobenzene. The feed, which are liquid benzene and gaseous chlorine

are at temperature 25℃ and atmospheric pressure then fed to the reactor which operates at 2.4

bars.

The reaction is exothermic process. Cooling process is required to maintain the

temperature at 40℃ . 90% of the HCl formed is first cooled to condense impurities (benzene and

chlorinated product) and then it is scrubbed in a scrubber using refrigerated chlorobenzene. The

crude chlorobenzene stream leaving reactor is washed with NaOH solution (20wt%) in order to

maintained slightly alkaline to protect downstream equipment from corrosion) in a pre-

neutralizer. The product stream is free from HCl. Then, the product is fed to a Benzene Recovery

Column (distillation column). Here, the bottom is almost slightly 100% pure chlorobenzene. The

top contain 98% by weight of benzene and 2% chlorobenzene. All the benzene is recycled to the

benzene storage via a purifier. From purifier the monochlorobenzene is sent to the refrigeration

system. The bottom contains monochlorobenzene and dichlorobenzene. This bottom product is

fed to the chlorobenzene column that may be contain 12-25 trays which operated at 3-7 lb/in2

abs. The temperature may be 100℃-200℃. The distillate has purity of 99% monochlorobenzene

while bottom has purity of 97% dichlorobenzene.

This reaction will produce HCI as the side product. All the desired product and undesired

product are then fed to the Benzene Recovery Column (distillation column). The advantages of

continuous process are, it produce higher amount of monochlorobenzene which is 95%

conversion and the process also operate at lower temperature.

2. Batch processIn the batch process, benzene is contained in a deep, iron or mild steel vessel lined with

lead cooling coils. The catalyst that usually used for this process is FeCl3, is added in a benzene

solution. Chlorine is fed to into bottom of the chlorinator through a lead covered at temperature

45℃in order to minimize the formation of dichlorobenzene. Then the crude chlorobenzene

stream and HCl stream are collected and treated in the purification and recovery process.

For another type of batch process is describe by Faith, Keyes, and Clark’s Industrial

Chemicals. The chlorine is bubbled into a cast iron or steel tank containing dry benzene with on

percent of its own weight of iron filings. The temperature is maintained at 40°C to 60°C (104°F

to 140°F) until density studies indicate that all benzene is chlorinated. Then, the temperature is

raised to between 55°C and 60°C (131°F to 140°F) for six hours until the density raises to

1.280g/cm3 (79.91 lb/ft3). The same methods of chlorobenzene purification and HCl recovery in

batch form are then employed. At 100% chlorination, the products are 80% of

monochlorobenzene, 15 % of p-dichlorobenzene, and 5% of o-dichlorobenzene.

3. Hooker/ Raschiq Process

C6H6 + HCl + ½ O2 (AIR) C6H5Cl + H2O

C6H5Cl + H2O C6H5OH + HCl

This process is conducted at elevated temperature which is in the range of 230 to 270 ℃.

This process involve the reaction between benzene and mixture of hydrochloric acid gas and air

in the presence of an oxychlorination catalyst. This catalyst consists of copper and iron chlorides

on an inert support. Once-through conversion for this process is limited (10 – 15 percent ) to

prevent the excessive formation of polychlorobenzene. The catalyst is put in the beds to prevent

damage since this process is exothermic process. In order to control the overall temperature, the

benzene is injected at lower temperature. This process is then followed by purification of

monochlorobenzene which can be done by fed the product from the reactor into the distillation

column which is known as brick-lined column.

The top stream of this column contain water/benzene azeotrope while at the bottom are

1/1 mixture of benzene and chlorobenzenes. The top product which is benzene and water is

recycled back into the reactor while the bottom products which are benzene and chlorobenzene is

neutralized with caustic soda, washed with water and distillate in two columns to separate the

dichlorobenzene, monochlorobenzene and benzene. Then the process is followed by hydrolysis

of the monochlorobenzene by steam in the presence of tricalcium phosphate or silica gel base

catalyst which can be reactivated periodically to reduce carbon deposited. The formation of

dichlorobenzene in the oxychlorination reaction and the polyphenols in the hydrolysis process

reduce the yield.

The process contains a few disadvantages. The high temperature in the process favours

high combustion rates of benzene which cause the reaction uncontrollable. Compare to the other

process, this process produce high cost of vapour phase chlorination process which make it

become uneconomical process for the production of monochlorobenzene. This process also can

only produce small amount of chlorobenzene since this once-through conversion is limited.

Comparison between the three process

PROCESS RASCHIQ PROCESS CONTINUOUS

Raw Material Benzene

Hydrochloric acid

Oxygen (air)

Benzene

Chlorine

Reaction Conditions Temperature at range 220 ℃ - 260℃ and in gas-phase

Temperature at range 20℃ -

40℃ and in liquid -phase

Reactor Fixed-Bed Reactor Continuous Stirrer Tank

Reactor

Catalyst Copper and iron chloride Ferric chloride

Advantages Large economic

advantages because

HCl produce in the

hydrolysis of

chlorobenzene can be

used for the

oxychlorination of

benzene.

Economy in steam

and cooling required

for evaporating and

condensing the

benzene.

Less purification

operations.

Lower operating

labor

Simple operation

liquid phase

High conversion of

benzene (95%)

High production of

monochlorobenzene

Produce less by

products only

small amount of

dichlorobenzene.

Disadvantages Produce many by-

products

High cost of

dichlorobenzene,

trichlorobenzene,

tetrachlorobenzene

and others.

The benzene

conversion is

limited,10-15%.

The reaction is

uncontrollable

because of the high

temperature.

High cost of vapour

phase chlorination

process.

Has large investment

for corrosion-

resistants

hydrochloric acid is

highly corrosive

equipments

Required special

material of

construction for very

low temperature.

PROCESS BATCH

Raw Material Benzene

Chlorine

Reaction Conditions Temperature at range of 40℃ - 60℃ and in

liquid-phase

Reactor Batch Reactor

Catalyst Ferric chloride

Advantages High production of

monochlorobenzene compare raschiq

process.

Low cost of factory equipment

because of the simple design of batch

reactor.

Reaction it easy to control due to low

temperature.

Disadvantages Lower conversion compare to

continuous (80%).

Produce higher amount of by-

products dichlorobenzene

Only can produce small scale

production.

Require strict scheduling and control.

Higher operating labor costs due to

equipment cleaning and preparation

time.

Many people need to operate the

process.

PROCESS SELECTION

Based on the review and screening, the most suitable process for the production of the

monochlorobenzene is by continuous process. The process was selected because it is more

beneficial compare to batch process and Raschig process. The selection is based on a few

important criteria that need to be considering in this process. One of the criteria is continuous

process can give higher conversion of monochlorobenzene which is 95% conversion. Besides,

the temperature used for this process is only between 20℃- 40℃ . At this low temperature, the

operating cost can be reduced because it does not required heating process. Furthermore it is easy

to handle the reaction at low temperature and this range of the temperature is the best

temperature to produce high amount of the monochlorobenzene. Furthermore, the continuous

process also produce high amount of monochlorobenzene and small amount of dichlorobenzene

compared to the other two processes that produce dichlorobenzene, tri-chlorobenzene, penta-

chlorobenzene and also tetra-chlorobenzene. Another criteria is, for this process the benzene that

been used is in liquid phase which is cheaper compared if we used benzene in vapor phase.

Therefore, it indirectly can reduce the operating cost. Other than that, the continuous process

only need a bit of workforce. So, only a few workers need to be hired and it indirectly also can

reduce the labor cost.

Review of the process production of monochlorobenzene from benzene and chlorine (from question)

Liquid benzene (which must contain less than 30 ppm by weight of water) is fed into a

reactor system consisting of two continuous stirred tanks operating in series at 2.4 bar. Gaseous

chlorine is fed in parallel to both tanks. Ferric chloride acts as an catalyst produce in situ by the

action of the hydrogen chloride on mild steel. Cooling is required to maintain the operating

temperature at 328K. The hydrogen chloride gas leaving the reactor is first cooled to condense

most of the organic impurities. It then passes to an activated carbon adsorber where the final

traces of the impurity are removed before it leaves the plant for use elsewhere.

The crude liquid chlorobenzenes stream leaving the second reactor is washed with water

and caustic soda solution to remove all the dissolved hydrogen chloride. The product recovery

system consists of two distillation columns in series. In the first column (the “benzene column”)

unreacted benzene is recovered as top product and recycled. In the second (the “chlorobenzene

column”) the mono- and dichloro-benzenes are separated. The recovered benzene from the first

column is mixed with the raw benzene feed, and this combined stream is fed to a distillation

column (the “drying column”) where water is removed as overhead. The benzene stream from

the bottom of the drying column is fed to the reaction system.

Plant Location & Site SelectionIt is important to have a proper selection of the location of the plant. The geographical location

of the plant could give a very strong influence to the success of the plant/industry itself. During

the selection of the site of the plant, it is crucial to always keep in mind the objectives of the

company. This will lead to a very careful considerations on the various factors that could make

the plant to give a big contributions towards its working environment and thus, making it into an

economically viable unit.

Any mistakes in selecting the plant location could lead to undesired situations or problems to

occur, such as; a higher cost and investment, the difficulties in both marketing and transporting

of the products, dissatisfaction of the employees and customers, as well as interruptions in the

production process and an excessive wastage. Therefore, a complete survey of both the

advantages and disadvantages of the various areas should be made prior to selecting the final

site/location of the plant. The following are the list of the factors that should be taken into

considerations during the selection of the site of the plant:

1. Location, with respect to the marketing area

2. Raw material supply

3. Transport facilities

4. Availability of labour

5. Availability of utilities

6. Availability of suitable land

7. Environmental impact (including the waste/effluent disposal)

8. Local community considerations

9. Climate

10. Political and strategic considerations

Other than those listed above, the room for expansion and safe living conditions of the operating

plant are also important in the site selection. The following are the details on how the above

factors affect the site selection of the plant.

1. Location with Respect to Marketing Area

The cost of an industrial land depends on few factors such as the physical characteristic of the

land, market economic conditions and most of all its location, with respect to the marketing area.

The price of the land site should be as economical as possible to reduce the total investment and

construction cost of the plant. It is important to choose the lowest reasonable land price, with

good storage and handling infrastructures. The price of the land can be referred to the real estate

agency. For materials that are produced in large or bulk quantities, it is important that the

proposed plant site should be located as close to the primary market so that the cost of

transportation can be maximized. Other considerations include the demand of the product within

the area and the availability of the raw materials suppliers should also be taken.

2. Raw Material Supply

This is one of the most important factors taken into consideration whenever a selection of plant

location/site is made. The nearness of the source of the raw materials for the production of

Chlorobenzene (which are benzene and chlorine) has to be considered since this will influence

both the transportation and storage charges of the raw materials. This is very important

especially if large volumes of raw materials are needed for the Chlorobenzene production

process. The nearer the source of the raw materials could reduce the transportation and storage

charges. Attention should also be given to the price as well as the purity of the raw materials

themselves.

3. Transport Facilities

They are three forms of major transport facilities, which are the road network (land-port), seaport

and airport. A plant site should be close to at least two of this major form of transport in order to

boost the import-export activities. Land-port can be connected via road or railway. Road

transport using lorry, etc. is suitable for local distribution from a central warehouse while rail

transport using the train is used for long-distance transport of bulk chemical because is cheaper.

Good road linkage will aid in the selling of product to local customer. Seaport facilities is

connected via waterway such as canal, river and sea; using tankers that is usually practiced if

involving import and exportation of product and raw materials with other country. Meanwhile,

air transport using the airplane, helicopter, etc. is convenient and efficient for the movement of

personnel and essential equipment and supplies. Transportation factor also important in case of

emergency such as an accident at the plant site for example fire at the workplace. Good road

linkage from the site to the nearest fire station can prevent further property damage if this kind of

accident happens.

4. Availability of Labour

This factor has been in the top 10 list (ranked by the Area Development Corporate Survey) of the

important factors in site selection. The location of the plant should have sufficient available

labors to be employed. Labors are needed for the construction as well as for running the plant.

The availability of both the skilled and semi-skilled labors will lead to the efficiency of the

operating plant itself. For example, when a large amount of money is invested by a plant, the

needs of the skilled labors become very important in order to ensure the operations in the plant

could run smoothly. Also, skilled labors such as the electricians and pipe fitters are important in

the maintenance of the plant. Unskilled labors however are important as well for training in

operating the plant.

5. Availability of Services such as Utilities, Water, Fuel, Power

Water, electricity and fuel are very important factors in site selection to ensure the plant can be

operated smoothly. Nearness to the available power facility will reduce the plant operation cost.

Most chemical processes required a large quantity of water for cooling process and general use.

Thus, the plant needs to be located near to the source of water of suitable quality which is usually

near to coastal (sea) area or lake. Other source for this process water may come from a river,

deep wells, and reservoirs or even purchased from a local authority. Electrical power is a must at

all sites, without electrical power, the plant might be shut down. Therefore the availability of

power plants near to the plant site is very important. Stable and uninterrupted power of required

magnitude, without fluctuations in voltage and frequency is important for the successful

operation of the plant. Other than that, a reasonably competitive priced fuel is important for

steam and power generation.

6. Availability of Suitable Land

It is important to first examine carefully the characteristics of the proposed plant site. This means

that the topography of the tract of land and the structure of the soil has to be considered and

examined very well. It should be noted that either the land or the soil of the proposed site could

affect the cost of the construction. The characteristic of the land that is considered as the most

suitable for the construction of a new plant is for it to be flat, well drained and having suitable

load-bearing characteristics. Even though there is no immediate expansion is, it is best for a new

plant to be constructed at a location with an additional space (for future changes).

7. Environmental Impact, Including Effluent Disposal

A plant site needs a smooth operation to maximize the production but in the same time release

the minimum amount of waste or effluent so that cause less impact to the environment. For

example, constructing a site next to sea coastal may be convenient for cooling water supply but it

will cause harm to the local aquatic ecosystem in the water through excessive withdrawals or

thermal pollution (from discharges of hot cooling water). All industrial processes will produce

waste products. The site selected must have efficient disposal system such as drainage and

dumping site. Disposal of toxic and harmful effluent need to follow the local regulations, and

during the site survey, appropriate authorities need to be consulted to determine the standards

that must be met.

8. Local Community Considerations

The proposed plant site should also consider the opinions of the community nearby the location

of the plant. The proposed site should be accepted by the local community. It must be ensured

that the plant that is going to be constructed at the proposed site will not cause any risks to the

local community nearby. The health hazards should be kept at its minimum with all the safety

precautions taken as one of the priority in the construction of the plant.

9. Climate

The characteristics features of the climate of Malaysia are uniform temperature, high humidity

and copious rainfall with winds that are generally light. A suitable climate can ensure the plant to

operate smoothly and productively. Some natural disaster such as flood, earthquake, typhoon,

etc. that occur at the plant location may increase the cost of operation. Thus, careful site

consideration needs to be taken to avoid choosing site with adverse climatic conditions. In

Malaysia, cases where major disasters such as earthquake or typhoon occur very little; the

weather condition is influenced by the Northeast and Southwest monsoon. The Southwest

monsoon season usually occur in end of May to September with wind flow is generally light

below 15 knots. Meanwhile, the Northwest monsoon occurs in early November to March with

wind speed ranging from 10 to 20 knots. During the two inter-monsoon seasons, the winds are

generally light and variable. Stronger structure need to be built at locations subject to high winds.

Annual rainfall in Malaysia is found to be around 2500 mm per year. Rain falls most heavily

during the monsoon season, which is from the end of September to early January for East

Malaysia and December to March for West Malaysia. Malaysia is a tropical country that has a

daily temperature that varies around 25 to 27 degrees Celsius. The maximum is about 32oC,

while the minimum is about 21oC daily. Highest humidity is achieved during the night and dawn,

while the relative humidity value drops to minimum around midday where bright sunlight

appears.

10. Political & Strategic Considerations

Subsidies and concessions from the government are provided for industries located in certain

notified areas. Those areas are the ones that have been declared as industrially backward where

low wages, cheap power and tax concessions are offered by the government.

The Several Strategic Locations as the Site For The Manufacture Of Chlorobenzene

In order to find the most suitable site location for the production of Chlorobenzene (with

20000KMT/year of Mono-Chlorobenzene and not less than 2000KMT/year of Di-

Chlorobenzene), all the 10 factors stated previously has been considered during the survey of

several possible sites. The three main sites that have been considered are as listed below:

i. Tanjung Langsat, Johor

ii. Gebeng Industrial Estate, Pahang

iii. Kerteh Industrial Park, Terengganu

Tanjung Langsat Industrial Complex, Johor

Iskandar Malaysia which is a development corridor conducted in the southern part of Johor. It is

also known as the South Johor Economic Region (SJER). One of the main components of

Iskandar Malaysia is as the centre of industrial and manufacturing activities which covers up to

31,132 hector of Pasir Gudang region. The Major Economic Zone D includes the Pasir Gudang

Port, Pasir Gudang Industrial Park, Tanjung Langsat Port as well as the Tanjung Langsat

Industrial Complex.

It is located for about 48km in eastern of Johor Bahru and 8km from the Pasir Gudang industrial

area with population of around 100,000 people. One of the main economic activities of Pasir

Gudang involves chemicals, oleo chemicals, biofuels and etc. The Tanjung langsat Industrial

Complex symbolizes the continuation of the existence of the industrial area of Pasir Gudang and

it covers an area of 4,198.52 acres which is reserved for light, medium, and heavy industries. On

the other hand, the Tanjung Langsat Industrial Park which covers up to 3764 acres of land has

been one of the most successful industrial estates in Malaysia with a tank farm facility being

developed for the chemical storage.

This location has good connectivity in terms of the transport facilities. It currently is connected

by the four-lane Pasir Gudang Highway, a trunk road and a railway line to Johor Bahru. This

would therefore ease the transportation process of raw materials (chlorine and benzene) since the

supplier of these raw materials are also available in Johor Bahru (HG Chemicals Technology

Sdn. Bhd.) which is only 48km away from Tanjung Langsat. Other than that, the Senai-Desaru

Expressway makes it possible for the traffic from the north of Johor Bahru to have an easy

access to the Tanjung Langsat Industrial Complex through the 5km four-lane dual carriage road

that links Tanjung Langsat to the expressway. Also, this location has seaport nearby (Tanjung

Langsat Port that is located adjacent to the 4,000 acres of the industrial land) which would make

it easier for the import and export activity of the Chlorobenzene product. Tanjung Langsat Port is

designed especially to handle the bulk cargo (LPG and hazardous chemicals). Other than that,

Senai Airport is also available for personal businesses.

The available area for the industrial activities in Tanjung Langsat is about 2709.94 acres with the

price ranging from RM12 – RM14 per square feet (for a 30yr + 30yr lease period). In terms of

the available utilities, the current water supply by the Syarikat Air Johor Holdings Bhd (SAJH)

to the industrial areas in Iskandar Malaysia is adequate. On the other hand, natural gas is used for

the power generation in Malaysia with 24% of the NG being used in heavy industries whereas

4% is used in the housing, commercial and other industrial areas. Supply of NG is made by the

Petronas Gas Bhd via pipelines to the factories.

In reference to Ramli, Abdul Rahim (2007), the environmental impact of the industrial activities

in the Tanjung Langsat area has showed that the industrial development had given positive

impacts to the local community in terms of their income, infrastructure as well as public

facilities. However, it also creates negative impacts such as pollution of air & water and

limitation of area for fishing activities around the Tanjung Langsat. Next, considering the

climatic factor, as stated earlier, a suitable climate can ensure the plant to operate smoothly and

productively. Natural disasters that occur at the plant location may increase the cost of operation.

Thus, it is important to avoid choosing site with adverse climatic conditions. The possibilities of

the occurrence of natural disasters in Malaysia are very low. Thus, it could be concluded here

that in terms of climatic factor, Tanjung Langsat is also suitable for the site location. Next, the

rapid development of the industry in the Pasir Gudang Tanjung Langsat has led to the shortage of

manpower or labor to carry out all the operations in the plant. Though some industries have

implemented the automated systems, but the need of manpower is still high.

Lastly, it is important to have the targeted marketing area as close as possible to the site location.

Chlorobenzene is used mostly in the manufacture of pesticides, dyes, and rubber. Thus, it is

important to have the site close to the manufacturer of these three materials. In Johor, there are

few rubber industries which are located at Skudai, Johor Bahru which are LekSeng Rubber

Industries and N.K. Rubber (M) SDN. BHD.

Gebeng Industrial Estate, Pahang

Gebeng Industrial Estate (GIE) has developed rapidly over the past 20 years where it first started

in early 90s by the Pahang State Development Corporation (PSDC). GIE is located in Kuantan,

Pahang, Malaysia which consist of four development phases that have about 8600 hectares of

land and is a world-class petrochemical and chemical industrial zone. It is located 25 km from

Kuantan Town and 250 km from Kuala Lumpur; and is strategically located only 5 km from the

Kuantan Port. GIE also offers a wide variety of facilities for the investors. For example, the

Gebeng bypass that links Kuala Lumpur and Kuantan directly via the East Coast Highway which

eases the trafiic flow from the industrial estate to Kuantan Port. Pahang State Government has

continuously upgrading the infrastructures around the area mainly its transportation facilities. For

example, the railway link that connects Kuantan Port-Gebeng-Kerteh to ensure the import and

export activities runs smoothly.

1. Location, with respect to the marketing area

Distance from nearest town :

o 25 km from Kuantan town

o 250 km from Kuala Lumpur city

- Using land transport is 2 hours drive and by air is 45 minutes.

Distance from nearest port :

o 5 km from Kuantan Port

- This is very strategic; close proximity to the port save the logistics costs

and promotes imports-exports activities.

Market Demand:

o Chlorobenzene is widely used in pesticide business. Within the Pahang State

itself, there are many pesticide or pest control company that required

chlorobenzene for its production, for example:

- Rentokil Pest Control Kuantan, BINS Pest Control, Kilpest (Pahang) Sdn

Bhd, Prima Pest Control & Services, etc. which is all located in Kuantan,

Pahang.

o Chlorobenzene also used in synthesis of rubber for example in manufacturing of

tire and furniture. There are a lot of tires and rubber-based furniture company in

area near to Gebeng such as Uts Tyre Service (Kuantan) Sdn Bhd and TWINS

Furniture Manufacture.

o Other than that, chlorobenzene also involve in the production of herbicide that

widely used to kill weed. Weed killer is popular among farmers and also

landscape designer.

2. Raw material supply

The raw materials needed for production of chlorobenzene are chlorine and benzene.

There are many suppliers for benzene near to Gebeng, for example PETRONAS

Chemicals Group Berhad (PCG) which is located at Gebeng too. Since Gebeng Industrial

Estate is located near to Kuantan Port, the availability of raw materials should not be a

problem as it can be exported from outside of Gebeng.

3. Transport facilities

a) Road facilities:

i. Highway

- East Coast Highway that links Kuantan and Kuala Lumpur which is only 2

hours drive away.

- Gebeng Bypass Road is being planned to further enhance the traffic flow

between the main road and Gebeng.

- Kuantan Bypass Road will be widened to eased the traffic congestion.

- Federal Road (Kuantan-Kerteh-Kuala Terengganu)

- Federal Road (Kuantan-Segamat)

- Federal Road (Kuantan-Karak-Kuala Lumpur)

ii. Railway

- Have a railway link that connects the integrated petrochemical complex in

Kerteh (Terengganu) to Gebeng and Kuantan Port. This railway link has

strengthen the chemical and petrochemical linkage between Gebeng and other

industrial centers by which it ensures a much more safer form of transporting

dangerous goods by train rather than by road.

b) Airport facilities:

- The nearby airport to Gebeng is the Kuantan Airport. Since airport transportation

is used to ease the movement of personnel and essential equipment and supplies

from Gebeng to other places, Kerteh Airport and Kuala Lumpur International

Airport (KLIA) also available for this purpose.

c) Seaport facilities:

- The main seaport facility in Gebeng is Kuantan Port which is only located 5 km

from the industrial estate. (*More details about Kuantan Port are described in

latter section.)

- Other seaports that connect with Kuantan Port are Kemaman Port and Kerteh

Minor Port for better transport of goods for import and exports activities.

4. Availability of labour

Labors, of both the skilled and semi-skilled labors are needed for the construction as well

as for running the plant. Training institution with customized courses are available such

as:

- Universiti Teknologi Malaysia, Indera Mahkota

- Institut Latihan Perindustrian

- Politeknik Sultan Ahmad Shah (POLISAS)

- Institut Kemajuan Ikhtisas Pahang (IKIP)

5. Availability of utilities

a) Electricity

The main electricity supplier in Gebeng Industrial Estate is Tenaga Nasional Berhad

(TNB) which supply 132/11 kV main intake for Phase I and II; and for Phase III,

there are two sources of electricity available which are Centralized Utility Facilities

(CUF) and 12/275 kV main intake.

Other sources of electricity may be from the nearest electric generators which are:

- Paka Power Plant

- IPP YTL Power Generation Sdn. Bhd.

- Tasik Kenyir Hydro-Electric

b) Water Supply

The main water supply in Gebeng Industrial Estate is from the Semambu Water

Treatment Plant with capacity of 2 MG/D.

Others are from the reservoirs at Bukit Penggorak with capacity of 2 MG/D and 1.5

MG/D; and reservoirs at Bukit Merah with capacity of 0.5 MG/D and 1.0 MG/D.

Government of Pahang have taken few steps in order to ensure efficient water supply

in Gebeng which are:

i. Increase the water supply to 64 MG/D

ii. Building of a new 200 acres dam in Sungai Lembing, Kuantan

iii. Building of new pipes and water tanks in Gebend Industrial Estate

c) Natural gas utility

The current natural gas suppliers for Gebeng Industrial Estate are Gas Malaysia and

Petronas Gas Berhad which supply gases within the estate to fulfil the tremendous

demand for existing and further petrochemical projects in the area.

Other than that, availability of natural gases, Butane and Propane are supplied by the

Peninsular Gas Utilization Network (PGU).

d) Telecommunications

Telecommunication services such as Integrated Systems Digital Network (ISDN),

digital line, MAYPAC, Internet and video conferencing in Gebeng is supplied by the

Telekom Malaysia.

e) Fire Fighting facilities

As one of the most developed industrial estate in the nation with various kinds of

plant, factory, buildings, etc., Gebeng Industrial Estate is built near to the Pahang Fire

and Rescue Department in order to handle any emergencies. In addition, near to

Gebeng area is also the Petronas Centralized Emergency Facilities. Both of these

stations are equipped with HAZMAT (hazardous material) facilities.

Alliance between Government agencies and private manufactures in Gebeng has set

up a voluntary crisis management organization called the Gebeng Emergency Mutual

Aid (GEMA) which is to execute proactive action and offer expert services to

overcome emergencies situation.

f) Piperack link

Centralized Tankage Facilities which is located at Kuantan Port links Gebeng and

Kuantan Port with a common piperack / pipeline network to transport gases.

6. Availability of suitable land

The preferable type of industrial activities in Gebeng Industrial Estate is chemical,

petrochemical and general.

The land / site available are originated from the State Land.

There are four development phases available in Gebeng Industrial Estate, which is very

convenient for additional space needed for future changes such as expansion of plant and

so on. They are Gebeng Phase I with space 700 acres (283.28 hectares), Gebeng Phase II

with 1400 acres (566.57 hectares), Gebeng Phase III with 2500 acres (1,011.73 hectares)

and Gebeng Phase IV with 4000 acres (1,618.76 hectares).

Land price (RM psf) : (Note: Price change without notice)

- RM16.00 per square feet  (Industrial Lot Ready Land)

- RM20.00 per square feet (Small Medium Enterprise- SME

Lot 129 Complete with infrastructure)

- RM12.00 per square feet  (Raw Land)

The leasehold for the site is 99 years upon the issuance of titles.

Total Planned Area is about 2468.60 hectares, Total Land Developed around 2408.08

hectares; and the Total Land Available is 1,528.5 hectares.

Quit Rent per Annum (RM) is subjected to RM15.00 for every 100 m2 portion of it for

the first 2 hectares and RM10.00 for every 100 m2 or portion of it subject to a minimal

taxation of RM150.00 per ownership.

The Annual Assessment is 7% of the property / land value.

Kerteh Industrial Park, Terengganu

Kerteh also known as Kertih, is a town in the district of Kemaman in southern Terengganu,

Malaysia. Kerteh is the base of operations for Petronas in Terengganu, overseeing the oil

platform operations off the state's coast as well as petrochemicals production and crude oil

refining in nearby Paka.

Terengganu is known with its industrial land being the cheapest among the other lands in

Malaysia. It ranges from RM0.18 – RM5.60 per square foot. Other states land price usually

ranging from as low as RM2.00 – RM4.50 psf to as high as RM18.00 – RM22.00 psf. The land

price in Kerteh Industrial Area is ranging from RM9 - RM14 psf. While for land with ready-built

factories with pre-installed facilities like broadband, water and power, which reduces the time

required to get a project off the ground is ranging from RM45 - RM60 per square meter.

As for the utilities supply, the Centralized Utility Facility (CUF) which is located in Kerteh

operates independently of the national grid. CUF supplies wide range of industrial utilities to the

selected industrial area. This includes the electricity, steam, industrial gases as well as other by-

products (de-mineralized water, raw water, cooling water, effluent treatment and etc.). Since

power is generated by CUF from natural gas. Thus, it is less prone to lighting and power surges

in the grid, and therefore making it an efficient source of utilities. The availability of this facility

allows the Kerteh industrial area to save up to 20% of its operating and investment costs since

they do not need to build any extra infrastructure to generate utilities.

In terms of closeness of the plant with the targeted markets, for the Kerteh Industrial Park, this

location is quite close with the Mardec Processing Sdn. Bhd. (MPSB) Kuala Berang Factory

which manufactures rubber (one of the product in which the process of the production uses

chlorobenzene). The distance between Kerteh and Kuala Berang is about 108km difference.

Another targeted market is the manufacturer of pesticide which is the Felda Agricultural Services

Sdn Bhd located Kuala Lumpur. The distance between Kerteh and Kuala Lumpur is about

326km difference.

One of the raw materials suppliers that provide benzene for production of chlorobenzene in

Kerteh Industrial Park is Aromatics Malaysia Sdn Bhd in conjunction with PETRONAS, MJPX

Co. Ltd. that was built in July 2000. It has a capacity of 188,000 tonnes per annum (tpa)

Benzene. Meanwhile, liquid chlorine may be supplied by Malay-Sino Chemical Industrial Sdn

Bhd which is located in Kemaman Terengganu. This somehow increases the transportation cost

of raw materials since raw materials are obtained from two different suppliers.

As a developed town, Kerteh is equipped with a good transportation facility. As for road

facilities, Kerteh Industrial Area is located within the East Coast Industrial Corridor (ECIC) of

Pennisular Malaysia and also Kerteh-Kuantan Port Railway Line is available for transportation

of goods via train. The railway is 77 km is a single-track line that links Kerteh Petrochemical

Complex in Terengganu with Kuantan Port in Pahang with a direct connection to Gebeng

Industrial Estate. East Coast Expressway is the highway that connects Kerteh, Terengganu with

Kuala Lumpur. As in terms of airport facility, Kerteh Airport is available, that is only 3.54 km to

Kerteh town center. This airport is owned and operated by Petroleum Nasional Berhad

(Petronas), and was built to serve the purpose of airlifting its employees and ExxonMobil

employees to their various oil platforms located 100–200 km offshore South China Sea. Other

than that, this airport is also used to transport Petronas and ExxonMobil employee from Kerteh

to Sultan Abdul Aziz Shah Airport, Subang near to Kuala Lumpur. As for seaport facility, Kertih

Port Marine Terminal which is operated by Petronas Penapisan Sdn Bhd is available in the South

China Sea. The supporting Kerteh marine facilities include six berths that can accommodate

chemical tankers of up to 40,000 tonnes. Another port is the Kemaman Port which is situated

only 7 km from Kerteh, about 9 minutes of travel via road.

Comparison Among The Possible Sites (Using Concept Screening & Scoring)

For the concept screening of the potential sites, only five main criterions are considered and

evaluated. The criterions are as follow:

Criterion Alternatives

1 (Gebeng) 2 (Reference:Kertih) 3 (Tanjung Langsat)

1 Kuantan Town(25 km)

Kuala Lumpur(250 km)

Targeted markets are mainly located in Kuantan, Pahang

+

Kuala Berang (108km) Kuala Lumpur (326km)

0

Targeted markets are located in Skudai, Johor

+2 Benzene supplied from

PETRONAS Chemicals Group Berhad (PCG) in Gebeng itself.

--

2 suppliers: Kemaman, 41.9km and in Kerteh

Increase in transportation cost

0

48km from Tanjung Langsat

+

3 East Coast Highway Gebeng Bypass Road Kuantan Bypass Road Federal Road Kerteh-Kuantan Port

Railway Line Kuantan Airport Kuantan Port

+

Kerteh-Kuantan Port Railway Line

East Coast Expressway Kerteh Airport Kertih Port Marine

Terminal

0

Four-lane Pasir Gudang Highway, a trunk road and a railway line

Senai-Desaru Expressway

Tanjung Langsat Port Senai Airport

+

4 Centralized Utility Facility (CUF)

Centralised Tankage Facilities

+

Centralized Utility Facility (CUF)

0

SAJH (water supply) Petronas Gas Bhd.

(power supply)

05 RM12 – RM16

-- RM 9 – RM 14

0 RM 12 - RM14

--Total 2 0 2

Rank 1 3 1

Where the criterion are as follow:

1 = Location, with respect to the marketing area

2 = Raw material supply

3 = Transport facilities

4 = Availability of utilities

5 = Availability of suitable land

Based on the concept scoring, both proposed sites which are in Gebeng Industrial Estate, Pahang

and Tanjung Langsat Industrial Complex, Johor has a higher ranking than the reference site in

Kerteh Industrial Area, Terengganu. Therefore, both proposed sites are further judged in the

concept scoring as shown below.

Criterion Weight

Alternatives

1 3

1 35% 5 4

2 25% 2 4

3 15% 5 4

4 20% 5 3

5 5% 2 2

Total Score 4.10 3.70

Rank 1 2

By comparing both proposed sites that have passed the concept scoring, it was found that the

best alternative is the one with the highest score which is the Gebeng Industrial Estate with total

score of 4.10 against Tanjung Langsat Industrial Complex with total score of 3.70. Thus, Gebeng

Industrial Estate has been chosen as the site location for the production of Chlorobenzene.

Process Flow Diagram (PFD) PFD for the production of Chlorobenzene

WorkbookHeat and Material Balance Table

Stream ID B--OUT B-1 B-2 B-FEE D B-IN CL2-FE ED CL2-OUT COND-OUT DIST-1 DIST-2 HCL-OUT MIX-OUT R1-OUT R2-OUT RECYCLE SPLIT-1 SPLIT-2 W-OUT

From SEP1 SEP3 DC1 HE ATE R HEATE R2 CONDNSER SEP2 DC1 SEP2 MIXER REACT OR1 REACT OR2 SEP3 SPLITE R SPLITE R SEP1

To HEATE R DC1 MIXER RE ACT OR1 HEATE R2 SPLITE R SEP2 SEP3 SEP1 REACT OR2 CONDNSER MIXER REACT OR1 REACT OR2

Phase LIQUID LIQUID LIQUID LIQUID VAPOR VAPOR VAPOR MIXED LIQUID LIQUID VAPOR LIQUID MIXED MIXED VAPOR VAPOR VAPOR LIQUID

Substream: MIXED

Mole Flow lbmol/hr

C6H6 70.21297 0.0 0.0 62.34210 70.21297 0.0 0.0 7. 870874 7. 870874 0.0 0.0 70.21297 41.42565 7. 870874 7. 870874 0.0 0.0 0.0

CL2 0.0 0.0 0.0 0.0 0.0 139.0676 139.0676 73.01193 0.0 0.0 73.01193 0.0 40.74648 73.01193 0.0 69.53380 69.53380 0.0

HCL 0.0 0.0 0.0 0.0 0.0 0.0 0.0 66.05566 0.0 0.0 66.05566 0.0 28.78732 66.05566 0.0 0.0 0.0 0.0

C6H5CL 0.0 58.62853 . 0165002 0.0 0.0 0.0 0.0 58.62853 58.62853 58.61203 0.0 0.0 28.78732 58.62853 0.0 0.0 0.0 0.0

P-DIC-01 0.0 3. 713564 3. 555722 0.0 0.0 0.0 0.0 3. 713564 3. 713564 . 1578421 0.0 0.0 0.0 3. 713564 0.0 0.0 0.0 0.0

H2O 0.0 0.0 0.0 . 3132769 0.0 0.0 0.0 0.0 0.0 0.0 0.0 . 3132769 0.0 0.0 0.0 0.0 0.0 . 3132769

Total Flow lbmol/hr 70.21297 62.34210 3. 572202 62.65538 70.21297 139.0676 139.0676 209.2806 70.21297 58.76990 139.0676 70.52625 139.7468 209.2806 7. 870874 69.53380 69.53380 . 3132769

Total Flow lb/hr 5484.591 7145.040 524.5567 4875.412 5484.591 9860.644 9860.644 15345.23 7759.862 6620.482 7585.372 5490.235 10414.91 15345.23 614.8226 4930.322 4930.322 5. 643771

Total Flow cuft/hr 104.9297 109.3135 7. 829402 89.47071 33431.60 53581.76 60176.79 87193.84 121.4675 110.9598 65951.02 104.9700 12598.08 24653.12 3648.030 30088.40 30088.40 . 0941140

Temperature F 138.0930 184.7300 384.5992 76.73000 201.0930 67.73000 130.7300 184.7300 184.7300 306.0184 184.7300 138.0930 130.7300 130.7300 184.7300 130.7300 130.7300 138.0930

Pressure psia 14.50377 14.50377 24.65642 14.50377 14.50377 14.50377 14.50377 14.50377 14.50377 24.65642 14.50377 14.50377 34.80906 34.80906 14.50377 14.50377 14.50377 14.50377

Vapor Frac 0.0 0.0 0.0 0.0 1. 000000 1. 000000 1. 000000 . 8830702 0.0 0.0 1. 000000 0.0 . 5022436 . 6563256 1. 000000 1. 000000 1. 000000 0.0

Liquid Frac 1. 000000 1. 000000 1. 000000 1. 000000 0.0 0.0 0.0 . 1169298 1. 000000 1. 000000 0.0 1. 000000 . 4977564 . 3436744 0.0 0.0 0.0 1. 000000

Solid Frac 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

Enthalpy Btu/lbmol 23377.86 7694.139 3344.977 20857.45 38298.11 -108.7071 410.5660 -5323.835 9618.068 13315.22 -18048.10 22758.96 632.5283 -9539.589 37895.68 410.5660 410.5660 -1.2252E +5

Enthalpy Btu/lb 299.2802 67.13311 22.77911 268.0454 490.2871 -1. 533129 5. 790335 -72.60725 87.02643 118.1989 -330.8876 292.3561 8. 487232 -130.1023 485.1353 5. 790335 5. 790335 -6800.626

Enthalpy Btu/hr 1.64143E+6 4.79669E+5 11948.94 1.30683E+6 2.68902E+6 -15117.63 57096.43 -1.1142E +6 6.75313E+5 7.82534E+5 -2.5099E +6 1.60510E+6 88393.78 -1.9965E +6 2.98272E+5 28548.22 28548.22 -38381.17

Entropy Btu/lbmol-R -56.41256 -55.26235 -49.08018 -59.44399 -32.88386 -. 1537557 .7762084 -9. 876595 -54.42879 -48.51741 3. 913583 -56.24713 -26.65722 -17.91827 -33.50052 . 7762084 . 7762084 -38.00291

Entropy Btu/lb-R -.7221858 -. 4821766 -. 3342333 -. 7639324 -. 4209746 -2.1685E -3 .0109471 -. 1346985 -. 4924839 -. 4306881 .0717502 -. 7225372 -. 3576852 -. 2443720 -. 4288690 . 0109471 . 0109471 -2. 109482

Densi ty lbmol/cuft . 6691428 . 5703057 . 4562548 . 7002893 2.10020E-3 2.59543E-3 2.31098E-3 2.40018E-3 . 5780390 . 5296502 2.10865E-3 . 6718707 . 0110927 8.48901E-3 2.15757E-3 2.31098E-3 2.31098E-3 3. 328696

Densi ty lb/cuft 52.26918 65.36284 66.99831 54.49171 . 1640541 . 1840299 .1638612 . 1759899 63.88425 59.66557 .1150152 52.30290 . 8267063 . 6224461 . 1685355 . 1638612 . 1638612 59.96739

Average MW 78.11364 114.6102 146.8441 77.81315 78.11364 70.90540 70.90540 73.32374 110.5189 112.6509 54.54450 77.84668 74.52704 73.32374 78.11364 70.90540 70.90540 18.01528

Liq Vol 60F cuft/hr 99.54653 102.8150 6. 490596 88.47795 99.54653 113.3212 113.3212 230.1390 113.9742 96.32442 116.1649 99.63711 163.8012 230.1390 11.15917 56.66059 56.66059 . 0905787

Cl2 = 69.53380 lbmol/hr

o B = 0.2964 0 Cl2 = 0.2916 o HCl= 0.2060 o MCB = 0.2060

B = 1

tot = 139.7468 lbmol/hr

tot = 70.21297 lbmol/hr

R1

SPLIT-1

B-IN R1-OUT

Material Balance

Basis being used: 330 days/year of operation.

In which, it is required to produce 50000 metric tonne/year of monochlorobenzene (MCB)

with not less than 2000 metric tonne/year of dichlorobenzene (DCB).

Balance Around Reactors

The reaction that occurred around the reactor is as follow:

Reaction 1 : C6H6 + Cl2 → C6H5Cl + HCl

Reaction 2 : C6H5Cl + Cl2 → C6H4Cl2 + HCl

The balance around Reactor 1:

Inlet streams:

B-IN = 1 ×70.21297 lbmolhr

=70.21297 lbmolhr B

SPLIT-1 = 1 ×69.53380 lbmolhr

=69.53380 lbmolhr Cl2

Components in outlet R1-OUT stream:

B = 0.2964 × 139.7468 lbmolhr

=41.42 lbmolhr

Cl2 = 0.2916 ×139.7468 lbmolhr

=40.75 lbmolhr

HCl = 0.2060 ×139.7468 lbmolhr

=28.79 lbmolhr

MCB = 0.2060 ×139.7468 lbmolhr

=28.79 lbmolhr

Cl2 = 69.53380 lbmol/hr

B = 0.0376 Cl2 = 0.3489 HCl= 0.3156 MCB = 0.2801 DCB = 0.0177

B = 0.2964 Cl2 = 0.2916 HCl= 0.2060 MCB = 0.2060

tot = 209.2806 lbmol/hrtot = 139.7468 lbmol/hr R2

SPLIT-2

R1-OUT R2-OUT

The balance around Reactor 2:

Inlet streams:

For stream R1-OUT

= 0.2964 × 139.7468 lbmolhr

=41.42 lbmolhr B

= 0.2916 ×139.7468 lbmolhr

=40.75 lbmolhr Cl2

= 0.2060 ×139.7468 lbmolhr

=28.79 lbmolhr HCl

= 0.2060 ×139.7468 lbmolhr

=28.79 lbmolhr MCB

For stream SPLIT-2

= 1 ×69.53380 lbmolhr

=69.53380 lbmolhr Cl2

Components in outlet R2-OUT stream:

B = 0.0376 ×209.2806 lbmolhr

=7.87 lbmolhr

Cl2 = 0.3489 ×209.2806 lbmolhr

=73.02 lbmolhr

HCl = 0.3156 ×209.2806 lbmolhr

=66.05 lbmolhr

MCB = 0.2801 ×209.2806 lbmolhr

=58.62 lbmolhr

DCB = 0.0177 ×209.2806 lbmolhr

=3.70 lbmolhr

B = 0.9956 H2O= 0.0044

tot = 70.52625 lbmol/hr

H2O = 1

tot = 0.3132769 lbmol/hr

tot = 70.21297 lbmol/hr B = 1

Sep1

B-OUT

W-OUT

MIX-OUT

Balance around Separator & DC The balance around the first separator 1:

Assumption is that all the water contained in the liquid benzene fed to the inlet stream of this

separator goes to the top stream of the separator:

Balance for each component is as follow:

B: inlet = outlet

0.9956 ×70.52625 lbmolhr

=1×70.21297 lbmolhr

70.215935 lbmol

hr ≈ 70.21297 lbmol

hr

H2O: inlet = outlet

0.0044 × 70.52625 lbmolhr

=1× 0.3132769 lbmolhr

0.3103155 lbmol

hr ≈ 0.3132769 lbmol

hr

The balance around the separator 2:

B = 0.0376 Cl2 = 0.3489 HCl= 0.3156 MCB = 0.2801 DCB = 0.0177

tot = 209.2806 lbmol/hr

B = 0.1121 MCB = 0.8350 DCB = 0.0529

tot = 70.21297 lbmol/hr

tot = 139.0676 lbmol/hr

HCl= 0.4750 Cl2 = 0.5250

Sep 2

HCL-OUT

DIST-1

COND-OUT

Where hydrochloric acid and chlorine are removed in this step:

Balance for each component is as follow:

B: inlet = outlet

0.0376 ×209.2806 lbmolhr

=0.1121×70.21297 lbmolhr

7.86895 lbmol

hr ≈ 7.87087 lbmol

hr

Cl2: inlet = outlet

0.3489 ×209.2806 lbmolhr

=0.5250× 139.0676 lbmolhr

73.01800 lbmol

hr ≈ 73.01049 lbmol

hr

HCl: inlet = outlet

0.3156 ×209.2806 lbmolhr

=0.4750× 139.0676 lbmolhr

66.04896 lbmol

hr ≈ 66.05711 lbmol

hr

MCB: inlet = outlet

0.2801 ×209.2806 lbmolhr

=0.8350 ×70.21297 lbmolhr

58.61950 lbmol

hr ≈ 58.62783 lbmol

hr DCB: inlet = oulet

0.0177 ×209.2806 lbmolhr

=0.0529× 70.21297 lbmolhr

3.70427 lbmol

hr ≈ 3.71427 lbmol

hr

B = 0.1121 MCB = 0.8350 DCB = 0.0529

tot = 70.21297 lbmol/hr

tot = 7.870874 lbmol/hr

tot = 62.34210 lbmol/hr

MCB= 0.9404 DCB = 0.0596

Sep. 3

B= 1

B-1

RECYCLE

DIST-1

The balance around the separator 3:

Assumption is that all the benzene remained in the inlet stream of the separator goes to the

top stream of this unit and is recycled back together with the feed:

Balance for each component is as follow:

B: inlet = outlet

0.1121×70.21297 lbmolhr

=1×7.870874 lbmolhr

7.87087 lbmol

hr ¿ 7.87084 lbmol

hr

MCB: inlet = outlet

0.8350 ×70.21297 lbmolhr

=0.9404 ×62.34210 lbmolhr

58.62783 lbmol

hr ≈ 58.62651lbmol

hr DCB: inlet = oulet

0.0529 ×70.21297 lbmolhr

=0.0596× 62.34210 lbmolhr

3.71427lbmol

hr ≈ 3.71559 lbmol

hr

MCB= 0.9404 DCB = 0.0596

tot = 62.34210 lbmol/hr

MCB= 0.997 DCB = 0.003

tot = 58.76990 lbmol/hr

tot = 3.572202 lbmol/hr

MCB= 0.0046 DCB = 0.9954

DistillationColumn

B-2

DIST-2

B-1

The balance around the Chlorobenzene column:

Based on the process description, it is required to produce product with 99.7 wt% of MCB

and 99.6 wt% of DCB:

Balance for each component is as follow:

MCB: inlet = outlet

0.9404 × 62.34210 lbmolhr

=(0.997 × 58.76990+0.0046 ×3.572202) lbmolh r

58.62651lbmol

hr ≈ 58.61002 lbmol

hr DCB: inlet = oulet

0.0596 ×62.34210 lbmolhr

=(0.003 ×58.76990+0.9954 ×3.572202) lbmolhr

3.71559lbmol

hr ≈ 3.73208 lbmol

hr

tot = 7.870874 lbmol/hr

B = 1

tot = 62.65538 lbmol/hr

B = 0.995 H2O = 0.005

tot = 70.52625 lbmol/hr

B = 0.9956 H2O= 0.0044

MIX-OUT

B-FEED

RECYCLE

Balance around Heat Exchangers & Mixer/Splitter Balance around Mixer

Balance for each component:

B: inlet = outlet

(0.995 ×62.65538+1×7.870874) lbmolhr

=0.9956× 70.52625 lbmolhr

70.21298 lbmol

hr ≈ 70.21593 lbmol

hr

H2O: inlet = outlet

0.005 ×62.65538 lbmolhr

=0.0044 ×70.52625 lbmolhr

0.31328 lbmol

hr ≈ 0.31032 lbmol

hr

Cl2 = 69.53380 lbmol/hr

Cl2 = 69.53380 lbmol/hr

tot Cl2 = 139.0676 lbmol/hr

CL2-OUT

SPLIT-2

SPLIT-1

Balance around the Splitter

Balance for each component:

Cl2 : inlet = outlet

1 ×139.0676 lbmolh r

=(1× 69.53380+1× 69.53380) lbmolh r

139.0676 lbmol

hr ≈ 139.0676 lbmolhr

tot = 70.21297 lbmol/hr

B = 1

tot = 70.21297 lbmol/hr

B = 1

B-INB-OUT

Cl2 = 69.53380 lbmol/hr Cl2 = 69.53380 lbmol/hr

CL2-OUTCL2-FEED

Balance around the HEATER:

B : inlet = outlet

1 ×70.21297 lbmolhr

=1×70.21297 lbmolh r

70.21297 lbmol

hr ≈ 70.21297 lbmolhr

Balance around the HEATER2:

B : inlet = outlet

1 ×69.53380 lbmolh r

=1 ×69.53380 lbmolh r

69.53380 lbmol

hr ≈ 69.53380 lbmolh r

tot = 209.2806 lbmol/hr

B = 0.0376 Cl2 = 0.3489 HCl= 0.3156 MCB = 0.2801 DCB = 0.0177

B = 0.0376 Cl2 = 0.3489 HCl= 0.3156 MCB = 0.2801 DCB = 0.0177

tot = 209.2806 lbmol/hr

COND-OUTR2-OUT

Balance around CONDENSER:

Balance for each component:

B: inlet = outlet

0.0376 ×209.2806 lbmolhr

=0.0376 ×209.2806 lbmolhr

7.86895 lbmol

hr ≈ 7.86895 lbmol

hr Cl2: inlet = outlet

0.3489 ×209.2806 lbmolhr

=0.3489× 209.2806 lbmolhr

73.01800 lbmol

hr ≈ 73.01800 lbmol

hr HCl: inlet = outlet

0.3156 ×209.2806 lbmolhr

=0.3156 ×209.2806 lbmolhr

66.04896 lbmol

hr ≈ 66.04896 lbmol

hr MCB: inlet = outlet

0.2801 ×209.2806 lbmolhr

=0.2801 ×209.2806 lbmolhr

58.61950 lbmol

hr ≈ 58.61950 lbmol

hr DCB: inlet = outlet

0.0177 ×209.2806 lbmolhr

=0.0177 ×209.2806 lbmolhr

3.70427 lbmol

hr ≈ 3.70427 lbmol

hr

Energy Balance

Energy Balance For Reactors Energy Balance for reactor 1:

Overall chemical equation

C6H6 + C6H5Cl + 2Cl2 C6H5Cl + 2HCl + C6H4Cl2

∆ H r°=(7.5+2 (−92310 )+ (−42 ) )−(49+7.5+0 )

= -184711 kJ/kmol

ε=31.85−18.79

= 13.06 kmol/hr

∆ H=ε ∆ H r°

= 13. 06 kmol/hr X (-184711 kJ/kmol)

= −2.41 ×106 kJ /hr

Cl2 = 31.54 kmol/hr

T=328K Total= 63.39 kmol/hr

C6H6=31.85 kmol/hr 0.2964 C6H6

0.2916 Cl2 T=328K0.2060 HCl0.2060 MCB

Reference C6H6, Cl2, HCl and MCB at 298℃Component nin (kmol/hr) Hin (kJ/kmol) nout (kmol/hr) Hout(kJ/kmol)

C6H6 31.85 H1 18.79 H3

Cl2 31.54 H2 18.48 H4

HCl - - 13.06 H5

MCB - - 13.06 H6

H1= (Cp328 – Cp298 ) = 142.96 -136 = 6.92 kJ/kmol

H2 = ∫298

328

33.6 ×10−3+1.367 ×10−5T−1.607 × 10−8 T2+6.473 ×10−12T 3dT

= 11.59 – 10.49

= 1.0992 kJ/kmol

H3= H1 = 6.92 kJ/kmol

H4 = H2

= 1.0992 kJ/kmol

H5 = ∫298

328

29.13× 10−3−0.1341× 10−5T +0.9715 ×10−8T 2−4.335× 10−12T 3 dT

= 0.879 kJ/kmol

H6 = (Cp328 – Cp298 ) = 157.19 – 152 = 5.19 kJ/kmol

∆ H=ε ∆ H r°+∑ nout H out−∑ n¿ H ¿

= −2.41 ×106 kJhr

+¿(18.79×6.92)+(18.48×1.0992)+(13.06 ×0.879) +(13.06×5.19)) –

( (31.85×6.92)+(31.54 ×1.0992))

= −2.41 ×106+¿229.60 – 255.07)= −2.41 ×106- 25.47= −2410025.47 kJ/hr

Q+W s=∆ H +∆ Ek+∆ Ep

Where W s ,∆ Ek∧∆ E p are equal¿ zero

Q=∆ H = −2410025.47 kJ/hr

Energy Balance for reactor 2:

Cl2 = 31.54 kmol/hr Total= 94.93 kmol/hr

Total= 63.39 kmol/hr

0.2964 C6H6 0.0376 C6H6

0.2916 Cl2 T=328K 0.3489 Cl20.2060 HCl 0.3156 HCl0.2060 MCB 0.2801 MCB

0.0177 DCB

Reference C6H6, Cl2, HCl and MCB at 298℃Component nin (kmol/hr) Hin (kJ/kmol) nout (kmol/hr) Hout(kJ/kmol)

C6H6 18.79 H1 3.57 H5

Cl2 50.02 H2 33.12 H6

HCl 13.06 H3 29.96 H7

MCB 13.06 H4 26.59 H8

DCB - - 1.68 H9

H1 =(Cp328 – Cp298 ) = 142.96 -136 = 6.92 kJ/kmol

H2 = ∫298

328

33.6 ×10−3+1.367 ×10−5T−1.607 × 10−8 T2+6.473 ×10−12T 3dT

= 11.59 – 10.49

= 1.0992 kJ/kmol

H3 = ∫298

328

29.13× 10−3−0.1341× 10−5T +0.9715 ×10−8T 2−4.335× 10−12T 3 dT

= 0.879 kJ/kmol

H4 = (Cp328 – Cp298 )

= 157.19 – 152 = 5.19 kJ/kmol

H5 = H1

= 6.92 kJ/kmol

H6=H2

= 1.0992 kJ/kmol

H7 = H3

= 0.879 kJ/kmol

H8 = H4

= 5.19 kJ/kmol

H9 = (Cp328 – Cp298 ) = 111.35 – 0 = 111.35 kJ/kmol

ε=18.79−3.57 = 15.22 kmol/hr

∆ H r°=(7.5+2 (−92310 )+ (−42 ) )−(49+7.5+0 )

= -184711 kJ/kmol

∆ H=ε ∆ H r°+∑ nout H out−∑ n¿ H ¿

= −2.81 ×106 kJhr

+¿(3.57×6.92)+(33.12×1.0992)+(29.96 ×0.879) +(26.59×5.19) +

(1.68×111.35) ) – ( (18.79×6.92)+(50.02 ×1.0992)+ (13.06× 0.879)+(13.06×5.19))

= −2.81 ×106+¿148.24 = -2809851.76 kJ/hr

Q+W s=∆ H +∆ Ek+∆ Ep

Where W s ,∆ Ek∧∆ E p are equal¿ zero

Q=∆ H = −2809851.76 kJ/hr

Energy Balance for DC

Energy Balance for Distillation Column

F 10 =129.7 kmol/h

0.9954 DME0.0046 CH3OH0 H2O

Total = F 9 =328.23 kmol/h

0.3976 DME0.1976 CH3OH0.4048 H2O

Reference MCB and DCB at 298KComponent nin (kmol/hr) Hin (kJ/kmol) nout (kmol/hr) Hout(kJ/kmol)

Feed DME 129.1 H1 - -

Feed CH3OH 64.9 H2 - -

Feed Water 132.9 H3 - -Distillate DME - - 1.4 H4

Distillate CH3OH - - 0.6 H5

Bottom DME - - 1.4 H6

Bottom CH3OH - - 64.3 H7

Bottom Water - - 132.9 H8

Cp at 298K :MCB = 152 kJ/kmolDCB = 0 kJ/kmol

F 11 =198.6 kmol/h

0.0071 DME0.3238 CH3OH0.6692 H2O

H1 = Cp298 – Cp298

= 0 kJ/kmol

H2 = Cp298 – Cp298

= 0 kJ/kmol

H3 = Cp425.4 – Cp298

Value Cp425.4 by interpolation:

T Cp400 170

425.4 X450 181

X= 175.588 kJ/kmol

H3 = 175.588 – 152 = 23.588 kJ/kmol

H4 = Cp425.4 – Cp298

Value Cp425.4 by interpolation:T Cp

400 238425.4 X450 296

X= 267.464 kJ/kmol H4 = 267.464 – 0 = 267.464 kJ/kmol

H5 = Cp468.92 – Cp298

Value Cp468.92 by interpolation:T Cp

450 181468.92 X

500 192X= 185.162 kJ/kmol

H5 = 185.162 – 152 = 33.162 kJ/kmol

H6 = Cp468.92 – Cp298

Value Cp468.92 by interpolation:T Cp

450 296468.92 X

500 366X= 322.488 kJ/kmol

H6 = 322.488 – 0 = 322.488 kJ/kmol

∆ H=∑ nout Hout−∑ n¿ H ¿

= ((26.58 ×23.588) + (0.08 ×267.464 ¿+¿ 0.007×33.162)+( 1.61×322.488 ¿¿−0

= 1167.8 kJ/hr

Q+W s=∆ H +∆ Ek+∆ Ep

Where W s ,∆ Ek∧∆ E p are equal¿ zero

Q=∆ H = 1167.8 kJ/hr

Pinch Calculation

Table of data:

Stream Condition mCp (kW/K) Tin (K) Tout (K)

3 Hot 1.03 328 298

1 Cold 1.23 293 328

2 Cold 4.034 x 10-6 293 328

Step 1: The minimum approach temperature is chosen to be 10℃

Step 2: The Temperature Interval Diagram

Stream 3 1 2∑ mC p ∆TmC p 1.03 1.23 4.034 ×10−6 kW/K (kW)65°C (338 K) ___________________________________________ 55°C (328K)

-12.355°C (328K) ___________________________________________ 45°C (318K)

-5.0030°C (303K) ___________________________________________ 20°C (293K)

5.1525°C (298K) ___________________________________________ 15°C (288K) _____

-12.15

B

C

A

Step 3: The Cascade Diagram

Tpinch -------------------------------------------------------------------------------------------------- Tpinch

Tpinch --------------------------------------------------------------------------------------------------- Tpinch

Step 4: The Calculation for Minimum Number of Heat Exchanger

i. Above the Pinch

Since there are two arrows, thus minimum number of heat exchanger above the pinch is two. Nmin,a = 2.

HO

T U

TIL

ITY

CO

LD

UT

ILIT

Y

A-12.30

B-5.00

A5.15

QH = 12.30

QH = 5.00

QH = 5.15

H.U17.3

143.05

21.4119×10−4

325.75

17.3 25.75

Stream

328

318

293303

328

338

p 1.03 1.23 4.034 x 10-6

3 1 2

1 1

HUU

Q1 = 25.75

QHU = 17.3

328 313.9

327.97

ii. Below the Pinch

Since there is only one arrow, thus minimum number of heat exchanger below the pinch is one. Nmin,b = 1.

Step 5: Design of the heat exchanger network

Above The Pinch

The calculation for change in temperature:

For stream 3: ∆ T= Q˙mC p

=25.751.03

=25

For stream 1: ∆ T= Q˙mC p

=25.751.23

=20.9

For Hot Utility: ∆ T= Q˙mC p

=17.31.23

=14.07

35.15

C.U5.15

5.15

Stream

293

288298

303

p 1.03 1.23 4.034 x 10-6

3 1 2

CU QCU = 5.15

298

293

Below The Pinch

The calculation for change in temperature:

For stream 3: ∆ T= Q˙mC p

=5.151.03

=5

For Cold Utility: ∆ T= Q˙mC p

=5.151.03

=5

Major Equipment Design The Distillation Column (Chlorobenzene Column):

inside diameter : 0.94 m

height of top disengaging section: 0.3 m

height of bottom separation section: 0.4 m

Design pressure: 1.7bar

The vessel is subjected to external pressure of :0.5405 kgf/cm2

Design temperature: 25℃ Shell material: carbon steel(sp. Gr.=7.7) (IS:2002-1962, GRADE I)

Permissible tensile stress: 950 kgf/cm2

Insulation material: asbestos

Density of insulation: 2700 kg/m3

Insulation thickness: 50 mm

Down comer plate material: stainless steel(sp. Gr.: 7.8)

The shell thickness calculation:

Assuming first that the thickness of the shell is 6mm

By using a stiffener channel of C-60, 18x4, of CSA=18 in2

With Wt =51.9 lb/ft

The data needed for the calculation of allowable P:

Do = 0.952 m

L = 0.305 m

B = 13100

Therefore; L

D0 =

0.305 m0.952 m = 0.3204

Thus, P allowable?

Pallowable = B

14.22×( Do

t )1.7 bar =

13100

14.22×( 0.952t

)

t = 1.757 x 10-3m = 1.757mm

From the calculated value above, it shows that the thickness assumed (6mm) is allowable

under the operating condition. Taking into consideration the corrosion correction of 2mm,

therefore the thickness becomes: 6 + 2 = 8mm.

Piping & Instrumentation Diagram (P&ID)

Plant LayoutThe 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. Plant layout for the plant will

consist of the process units involved, which is located in the main plant and other auxiliary

buildings. The layout, which refers to each department, must be arranged in order to

maximize efficiency and minimize the cost of ownership and plant operating; and also to

minimize the time spent by personnel in travelling between buildings.

The principal factors to be considered when designing the plant 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

Other than the lists above, it is also advisable to check up the insurance regulations from the

view of getting the best coverage at minimum cost for plant building and inventory. The

auxiliary buildings and services required on site, in addition to the main processing units

(buildings), will include:

i. Storages for raw material and products : Tank farms and Ware house

ii. Maintenance workshops.

iii. Store for maintenance and operating supplies.

iv. Control room.

v. Laboratories for process control.

vi. Fire stations and other emergency services.

vii. Utilities: steam boilers, compressed air, power generation, transformer station.

viii. Effluent disposal plant.

ix. Offices for general administration.

x. Canteens, surau and other amenity buildings, such as medical centres.

xi. Car parks.

xii. Guard house / security posts.

1. Costs

- The cost required to build a plant need to be kept at possible minimum value

so that less modal will be used and more profits will be generated. The cost of

construction can be minimized by choosing a land site with cheapest price but has a

good facilities and utilities provided. Other than that, the layout needs to have the

shortest run of connecting pipes between all equipment and also least amount of

structural steel work. However, this will not necessarily be the best arrangement for

operation and maintenance. In plant layout, economic is considered mainly with

steelwork, concrete, piping and electric cabling.

2. Process Requirement

- All the required equipment need to be placed properly and strategically so that

can achieves smooth flow for transportation from raw materials to final product

storage. The installation of the auxiliaries also need to be placed in such was so that it

will occupy the least space. Process units are normally spaced at least 30 meters apart.

Administration offices and laboratories, in which a relatively large number people

will be working, should be located well away from potentially hazardous process

control rooms. The siting of the main process units will determine the layout of the

plant roads, pipes, alleys and drains. Access roads will also be constructed for

operation and maintenance purpose. Utility building should be sited to give the most

economical run of the processing units. The main storage areas should be placed

between the loading and unloading facilities and the process units they serve. Storage

tanks containing hazardous materials should be sited at a safe distance from other

buildings which is at least 70 meter from site boundary.

3. Operation

- Any equipment that required frequent operation should be located near to the

control room so that easier for the operators to monitor the operation. All valves,

sample points, and instruments should be located at convenient position and height.

The working space and headroom must be sufficient to allow easy access to

equipment. Since some of the equipment might need replacement if some parts is

broken, thus sufficient space must be provided to allow access for lifting the

equipment.

4. Maintenance

- All equipment needs to be prepared with maintenance facilities so that if any

problems arise during the process, the source of problem will be detected and solved

at a fast rate. 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.

5. Safety

- Since most chemicals are hazardous and have the potential to explode in

wrong condition, blast walls may need to be built in order to separate potentially

hazardous equipment and thus confine the effects of an explosion. Other than that, at

least two escape routes for operator must be provided from each level in the process

building and assembly point need to be built at an easy access and the emergency

route need to be stated clearly.

6. 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,

and service pipes should be over-sized to allow for future requirements. Free space for

plant expansion is important so that if the production rate need to be increased, more

equipment should be added to the plant, thus free space will allow future expansion to

be able to accommodate the equipment required. This expansion space is also very

important because the additions of equipment and pipes can be erected and tested with

the minimum interference to plant operations.

Plant Layout Description

As mentioned in the site selection section, the plant was decided to be built in Gebeng

Industrial Estate, Kuantan, Pahang that was estimated to cover about 10 hectares of industrial

lot ready land with price of RM16.00 per square feet.

Gebeng is located in Pahang in the East coast of Malaysia. Every year Pahang experiencing

Northeast Monsoon that brings rain and wind. Thus, the structure of the plant is placed in

upwind direction. The buildings need to be placed in such that the wind will not affect the

plant and brings any inconvenience. Strategic placement of the buildings relative to wind

direction can assist to cool down process equipment during the process.

By referring to the plant layout provided in the following figure, administration building is

the main and most visited building for many purposes in a plant. It should be located on the

public and safe side of security point and as close as possible to main entrance.

Administration offices and laboratories, in which a relatively large number of people will be

working, are located well an away from potentially hazardous process which is the main

processing plant. Stores for maintenance and operating supplies was placed near to the

administration buildings so that the staff will have easy access to the service.

There is a bottom expansion just below the main process plant and near to the waste

treatment plant. This free space is provided to be used for the placement of new equipment

and pipes in the future just in case the plant needs to be expanded. The waste treatment plant

will enable the direct transport of waste stream produced by the separation units. There is also

a pond that is placed next to the waste treatment plant.

Waste treatment plant, utilities plant and tank farm were placed near to the main process

plant. This placement also reduces the distance and length of supply pipes used in the

transporting process of raw materials, waste, and utilities to or from the plant area, making it

cost effective. Beside it, it should be beside a road which will make it easier for loading and

unloading of materials.

Control room was placed near to the main processing plant so that easier for the operators to

monitor the operation of the plant because if the is malfunction in any of the operating

process, troops can be send to the site immediately.

Maintenance workshops and others that did not link to process materials should be located

together at the safe area and within easy access to process units. Direct access should be

provided for traffic purposes, which if possible should not pass through any process area.

There is also a loading area placed for transport of goods and raw materials where only the

lorries and other form of transport to transfer these materials allowed entering the area.

Canteen and surau (prayer room) are also provided for the convenience of the staffs and were

placed near to the administration and maintenance workshop buildings because it is one of

the most used workplace and it is a must to have easy access to these places. These buildings

should be located in a safe area within a short distance of the main concentration of workers.

The surrounding should be attractive and relaxing for workers to release some stress from

hectic workloads.

For quality control of products, a plant needs a laboratory to inspect the products produced.

Work laboratories should be located at a safe area near the administration building where

most facilities are completed. Clinic is placed next to the laboratory to handle any emergency

case caused by chemicals. Fire house to handle emergency cases for example fire or

explosion of the plant is built near to the main processing plant.

Sufficient car parks facilities also provided for the convenience of the staff and personnel or

visitors to park their vehicles. Car parks are placed near to the main entrance to prevent any

unwanted hazard to the properties.

Guard houses or security post were placed at both entrances to the plant to monitor the flow

of in and out to the plant itself. There were three assembly point placed near to every section

of the plant so that in case of emergency, all the people in the site can be evacuated at faster

rate to these safer places.

Other than those mentioned above, free lands also available at the plant layout for future

needs. Trees also will be planted in the site to absorb the emission of carbon dioxide gases

and also to make the site pleasant to the eye. There is no smoking area provided in this plant

layout since chlorobenzene is volatile and explosive to ignition of fire, thus for safety of the

plant and all personnel, smoking in the plant area are strictly prohibited. Access road will be

needed to each building for construction and for operation and maintenance.

General Safety Procedures

For a new plant, it is very important to have sufficient site medical, fire and security services.

For ensuring safety, health and welfare of all workers at the plant, Occupational Safety and

Health Act (OSHA) was enacted. All contractors, employees and agents must tolerate and

understand the Site Safety Rules & Regulations before starting any work. Work cannot begin

until a complete site safety induction has been carried out. Safety is the most pressing issue

when being evaluated in a chemical plant. It must be made the highest priority as compared

to other factors such as profit. Prevention wills the best means of containing risk and danger.

The plant risk reduction must be followed as strictly as possible to ensure all precautions are

taken.

Some general manuals that should be followed to ensure the safety in work field and work

force are listed below:

1. Each employee is expected to know and observe all plant safety procedure. All

injuries, no matter how light, must be reported to the immediate Supervisor. This is to

ensure the protection of each worker and assure that proper records of the accidents

are made.

2. All employees are responsible for their colleagues and of their own. Broken

equipment, unsafe conditions and unsafe practices must be reported to Supervisor as

soon as discovered.

3. There shall be no smoking at any time within the plant area since most of the

chemicals are volatile. Matches or lighters shall not be carried into the plant and must

be left in locker rooms.

4. It is mandatory that all workers at the plant area to wear hard hats and safety glasses

all the time. In some plant area, other protection may be required such as hearing

protection. Person who do not wear this safety equipment are prohibited to enter the

plant area.

5. Possession or use of liquor and illegal drugs is not permitted on the plant premises.

Anyone under the influenced of either will is strictly prohibited from entering the

premises.

6. Visitor must apply permission at the main office or at the security post, sign a release,

and be instructed of plant safety rules before they are allowed to enter the plant.

Visitor will not be taken into the plant areas that are experiencing production

problems. Any visitors who do not possess the temporary entering pass cannot be

around the plant site.

7. All workers must know how to use all types of fire extinguishers, fire hoses, fire

blankets, and other personal protective equipment. (e.g. water must not be used on

fires around the electrical equipment since water is a conductor that may result an

electrocution of people).

8.

Figure 1: Plant Layout

Economic Analysis

Estimation of Capital CostGenerally, capital cost estimating has five classifications:

1. Order of magnitude Estimate also known as Ratio or Feasibility2. Study Estimate, also known as Major equipment or Factored3. Preliminary Design Estimate, also known as Scope4. Definitive Estimate, also known as Project Control5. Detailed Estimate, also known as Firm or Contractor’s

This five classifications roughly correspond to the five classes of estimate defined in the AACE Recommended Practice No. 17R-97[4]. This part will discuss on Preliminary Design Estimate which is Class 3. For the cost estimation of a chemical plant, a Class 3 estimate is typically +10% to -40% accurate. This means by doing such an estimate, the true cost of building the plant would likely be in the range of 0.1 higher than and 0.4 lower than the estimated price.

If greater accuracy is required in the capital cost estimate, then more money and time must be expended in conducting the estimate.

Estimation Of Purchased Equipment CostsThe purchased cost and an attribute of the equipment are the most common simple relationship related to units of capacity and it is given by

Ca

Cb=( Aa

Ab)

n

Where: A = Equipment cost attribute

C = Purchased cost

N = Cost exponent

Subscripts : a refers to equipment with the required attribute

b refers to equipment with the base attribute

Effect of Time on Purchased Equipment Cost

The cost of equipments are depend on past records or published correlations for price information, it is essential to be able to update these costs to take into account changing economic conditions(inflation). This can be achieved by using the following expression:

C2 = C1( I2

I1)

Where: C= Purchased cost I =Cost Index

Subcripts: 1 refers to base time when cost is known 2 refers to time when cost is desired

Calculation for Cost of Equipments

log10 Cp0= K1 + K2 log10 A + K3 (log10 A)2

The value of K1,K2, and K3 can be obtained from Table A.1 and A is the capacity of the

equipment.

FBM= B1 + B2FMFP

B1 and B2 can be obtained from Table A.4

FM can be obtained by referring the Table A.3 for the identification number for the material and

then refer the material factor at Figure A.8

FP can be obtained by two methods which are

1. For process vessel,

FP,vessel = ( P+1 ) D

2 [850−0.6(P+1)]+0.00315

0.0063

2. For other equipment

Log10 FP = C1 + C2log10P + C3(log10P)2

Value of C1,C2, and C3 can be obtained from the Table A.2 and P is the unit pressure of

bar gauge or barg.

CBM = CPOFBM

Sample of Calculations

Calculations for heater:

Characteristics:

2 units of heater with different types H1 Duty = 1307 kW

H2 Duty = 1501 kW Type = H1 - Steam boiler heater and H2 - Hot water heater Type = Carbon Steel Identification Number = 53

Based on the Figure A.4, C pH 1o = 196 $/kW and C pH2

o = 48.2$/kW

Based on Figure A.19, FBMH1 = FBMH2 = 2.1

Hence,

CBMH1 = C pH 1o FBMH1

= (196 $/kW)(1307 kW)(2.1)

= $538120

CBMH2 = C pH 2o FBMH2

= (48.2 $/kW)( 1501 kW)(2.1)

= $152097

Thus,

$H1(2013) = $538120(564.7397 )

= $765431.65 = RM 2,518270.12

$H2(2013) = $152097(564.7397 )

= $216, 345.53 = RM 711, 776.80

Calculations for reactor:

Characteristics:

Two reactors with same type

Length = 8 , diameter = 4m

Volume of tower = 100 m3

Type = carbon steel

Log10C po = 3.4974 + 0.4485log10(100) + 0.1074[log10(100)]2

C ptowero = $66680.68

$tower(2013) = $66680.68 (564.7397 )

= $94847.80

Based on Table A.4, B1 = 2.25, B2 = 1.82

Fpvessels = (2.4+1 ) 4

2[850−0.6 (3.4 )]+ 0.00315

0.0063

= 1.77

FBM = 2.25 + 1.82(1.77)(1)

= 5.47

CBM = ($94847.80)(5.47)

= $519,450.21

Thus,

$REACTOR(2013) = $519,450.21 (564.7397 )

= $738875.40 = RM 2,430,900.00

For two reactors = RM 4,861,800.00

Calculations for separator

3 units

Characteristic = Flash distillation

Diameter = 1.8 m

Height = 5 m

Volume = 50.89 m3

log10 Cp = 3.4974 + 0.4485 (log10 50.89) + 0.1074 (log10 50.89)2

Cp0= $37644.95

Fpvessels = (1+1 )1.8

2[850−0.6 (1+1 )]+ 0.00315

0.0063 = 0.5021

FP = 0.84

Based on Table A.4, B1 = 2.25, B2 = 1.82 and FM = 1.0 (carbon steel)

FBM = 2.25 + 1.82(0.84)(1)

= 3.779

CBM = ($37644.95)(3.779)

= $142252.74

$SEP(2013) = $142252.74(564.7397 )

= $202342.87 = RM 605,708.00

Calculation for storage tank

Characteristics:

4 units of different types of storage tanks:

Dimensions for benzene, Length=10 , Diameter= 4.8 For 3 days storage,Volume = 182 m3

Type = floating roof

Log10C po = 5.9567 – 0.7587log10(182) + 0.1749[log10(182)]2

C ptowero = $136571.32

$tower(2013) = $136,571.32 (564.7397 )

= $194,261.52 = RM 639,120.00

Dimension for chlorine, Length =10m , Diameter =4.8m Volume = 182m3

Type = fixed roof

Log10C po = 4.8509 – 0.3973log10(182) + 0.1445[log10(182)]2

C ptowero = $49,098.53

$tower(2013) = $49,098.53 (564.7397 )

= $69,838.64 = RM 229,769.00

Dimesion for chlorobenzene, Dimensions , Diameter = 4.4 m, Length = 10 Volume for storage 3 days of = 150 m3

Type= floating roof

Log10C po = 5.9567 – 0.7587log10(150) + 0.1749[log10(150)]2

C ptowero = $136,118.24

$tower(2013) = $136,118.24 (564.7397 )

= $193,617.05 = RM 637,000.00

Dimension for Dichlorobenzene, Dimensions = , Diameter = 2m, Length = 5 m Volume = 15 m3

Type = floating roof

Log10C po = 5.9567 – 0.7587log10(15) + 0.1749[log10(15)]2

C ptowero = $39,810.70

$tower(2013) = $39,810.70 (564.7397 )

= $56,627.49 = RM 186,304.00

Calculation for distillation column One unit of distillation column

Dimensions, Diameter = 3m, Length = 30m

Volume = 212.1 m3

Log10C po = 3.4974 + 0.4485log10(212.1) + 0.1074[log10(212.1)]2

C ptowero = $132500

C ptowero (2013) = $132500 (564.7/397)

= $188,470.40

Based on Table A.4, B1 = 2.25, B2 = 1.82

Fpvessels = (1.7+1 )3

2[850−0.6 (1.7+1 )]+ 0.00315

0.0063

= 1.26

Hence,

FBM = 2.25 + 1.82(1.26)(1)

= 4.54

CBM = ($188470.40)(4.54)

= $856,258.72

Tray tower area = 7.0686 m3

Log10C ptrayo = 2.9949 + 0.4465log10(7.0686) + 0.3961[log10(7.0686)]2

C ptrayo = $4570

C ptrayo (2013) = $4570(564.7/397)

= $6,500.45

Thus,

CBMtray = CpNFBMfq

= ($6500.45)(24)(1)(1.0)

= $156010.82

CBM,tower + trays = $856,258.72 + $156010.82

= $1,012,269.54

$DC(2013) = $1012269.54(564.7397 )

= $1,439,870.55 = RM4,737,174.00

Equipment identification No. Actual bare module cost, CaBM 00 (RM)

Heater H1 2,518,270.00

H2 711,776.00

Cooler CO1 417,463.00

Separator S1 605,708.00

S2 605,708.00

S3 605,708.00

Reactor R1 2,430,900.00

R2 2,430,900.00

Distillation column D1 4,737174.00

Tank T1 639,120.00

T2 229,769.00

T3 637,000.00

T4 186,304.00

Total bare module cost, CBM (RM) 16,755,800.00

CTM=1.18∑i=1

n

CBM❑

= 1.18 x (RM16,755,800.00)

= RM 19,771,844.00

Grass roof capital cost, (GRC) = RM28,493,713.00

Table: Estimation of fixed and total capital investment cost

Range Cost (RM)

Direct cost

Onsite

Purchased equipment cost 12% GRC 3,419,245

Instrumentation and control 6% GRC 1709622.80

Piping (installed) 15% GRC 4274056.95

Electrical and material (installed) 3% GRC 854795.20

Offsite

Building 8% GRC 2279497.04

Yard improvements 1% GRC 284937.13

Service facilities 5% GRC 1424685.65

Land 2% GRC 569874.26

Total 14,816,714.03

Indirect cost

Engineering and supervision 3% GRC 854795.20

Construction expenses 6% GRC 1709622.80

Contractor’s fee 1% GRC 284937.13

Contingency 8% GRC 2279497.04

Total 5,128,852.17

Fixed Capital Investment (FCI) TOTAL + GRC 48,439,279.20

Manufacturing Cost

Factors affecting the cost of manufacturing (COM), for a chemical Product

Factor Description of Factor1.Direct cost

A. Raw materials

B. Waste treatment

C. Utilities

D. Operating labor

E.Direct supervisor and clerical laborF.Maintenance and repairs

G. Operating supplies

H. Laboratory charges

I. Patents and royalties

Factors that vary with the rate of productionCosts of chemical feed stocks required by the process.Flowrates obtained from the PFD

Cost of waste treatment to protect environment

Costs of utility streams required by process. Includes but not limited to:

a. Fuel gasb. Electric powerc. Steam(all pressures)d. Cooling watere. Process waterf. Boiler feed waterg. Instrument airh. Inert gas (nitrogen) etc.i. Refrigeration

Costs of personnel required for plant operations

Cost of administrative/ engineering and support personnel

Costs of labor and materials associated with the maintenance

Costs of miscellaneous supplies that support daily operation not considered to be raw materials. Examples include chart paper, lubricants, miscellaneous chemicals, filters, respirators and protective clothing for operators, etc.

Costs of routine and special laboratory tests required for product quality control and troubleshooting.

Costs of using patented or licensed technology.

2. Fixed costsA. Depreciation

B. Local taxes and Insurance

Factors not affected by the level of productionCosts associated with the physical plant (buildings, equipment, etc.). Legal operating expense for tax purposes.

Costs associated with property taxes and liability insurance. Based on plant location and severity of the process.

C. Plant overhead costs (sometimes referred to as factory expenses)

Catch-all costs associated with operations of auxiliary facilities supporting the manufacturing process. Costs involve payroll and accounting services, fire protection and safety services, medical services, cafeteria and any recreation facilities, payroll overhead and employee benefits, general engineering, etc.

3. General expenses

A. Administration costs

B. Distribution and selling costs

C. Research anddevelopment

Costs associated with management level and administrative activities not directly related to the manufacturing process

Costs for administration. Includes salaries, other administration, buildings, and other related activities.

Costs of sales and marketing required to sell chemical products. Includes salaries and other miscelleaneous costs.

Costs of research activities activities related to the process and product. Includes salaries and funds for research related equipment and supplies, etc.

The equation used to evaluate the cost of manufacture using these costs becomes:

Costs of Manufactures (COM) = Direct Manufacturing Costs (DMC) + Fixed Manufacturing Costs(FMC) + General Expenses (GE)

The cost of manufacturing, COM, can be determined when the following costs are known or can be estimated :

1. Fixed capital investment (FCI) : (CTM or CGR)2. Cost of operating labor (COL)3. Cost of utilities (CUT)4. Cost of waste treatment (CWT)5. Cost of raw materials (CRM)

The table above gives data that are need to calculate to estimate the individual cost items that are identified above. With the exception of the cost of raw materials, waste treatment, utilities, and operating labor all the data need to be calculate by using certain equations. If no other information is avalaible, the midpoint values for each of these ranges is used to estimate the costs involved. Hence, all the summation of the datas for the calculation of manufacturing cost ca be simplified into these equations :

DMC = CRM+ CWT + CUT + 1.33COL + 0.069FCI + 0.03COMFMC = 0.708COL + 0.069FCI + depreciation

GE = 0.177COL + 0.009FCI + 0.16COM

We can obtain the total manufacturing cost by adding these three categories together and solving for the COM and the result is :

COM = 0.280FCI + 2.73COL + 1.23(CRM+ CWT + CUT)

The cost of manufacture without depreciation :COMd = 0.180FCI + 2.73COL + 1.23(CRM+ CWT + CUT)

Cost of operating labor, COL

The technique used to calculate operating labor requirements is based on data obtained from five chemical companies and correlated by Alkayat and Gerrard. According to this method, the equation for the operating labor requirement for a chemical processing plant is given by:

NOL= (6.29 + 3.17P2 + 0.23Nnp)0.5

Where NOL is the number of operators per shift, P is the number of processing step involving the handling of particulate solids, and Nnp is the number of nonparticulate processing steps handling steps includes compression, heating and cooling, mixing, and reaction.

Nnp = ∑ Equipment

Equipment QuantityCompressor

TowerReactorHeater

Exchanger

01223

Total 8

Hence, when Nnp is equal to … , the number of operating labor requirement is

NOL= [6.29+3.17 P 2+0.23(8)]0.5

NOL =2.85

The value of NOL is the number of operators required to run the process unit per shift. A single operator works on the average 49 weeks (3 weeks time off for vacation and sick leave) a year, five 8-hour shift a week.

= 49 week/yr ×5 shift/week

= 245 shifts per operator/year

A chemical plant operates 24 hours per day. This requires (365 days/year × 3 shift/day) 1095 operating shifts per year. The number of operators needed to provide this number of shifts is

= 1095 shift/year ÷ 245 shifts per operator/year

= 4.5 operators

Hence,

the operating labor = NOL × 4.5 operators

=2.85 × 4.5

= 12.8 ≈ 13operator

The cost of operating labor, COL is equal to the salary given to each of operator yearly which in this case the yearly salary given is RM18,000

COL = RM18,000 × 13

=RM 234,000.00

Cost Of UtilitiesUtility Description Cost (RM/GJ) Cost RM/Common

UnitStream

Cooling water

Other water

Caustic soda solution

Waste treatment and disposal (water)

Dry saturated a. 8 barb. 28 bar

Process cooling water: 550C to 200C

High purity water for process use at 20 0C

5 wt % NaOH at 20 0C

Non-hazardous

20.00322.602

1.165

41.717/1000kg45.106/1000kg

48.69/1000m3

1.03/m3

1414.7/tonnes

118.44/tonnes

Production of waste water = 0.142 kmol /hr x 18 kg/kmol = 2.558 kg/hr

= 2.588 kg/hr x 24 hr/day x 365 day/year x 1 tonnes/1000kg

= 22.6709 tonnes/year

Cost for waste water treatment and disposal = 22.6709 tonnes/year x $36/tonnes

= $816.15/year = RM 2,685.15

Raw Material Costs

The cost of raw materials can be estimated by using the current price listed in such publications as the Chemical Market Reporter (CMR) at the middle of 2013.

Chemical Cost (RM/kg) Typical Shipping Capacity or Basis for Price

Benzene

Chlorine

1.3681

0.2156

Barge, Gulf Coast

Railroad tank car

Yearly cost for raw materials = (Mass flow rate of raw materials per year) x (cost, RM/kg)

Yearly cost for benzene = (2216.76 kg/h x 24 x 330) x (1.3681) = RM 24,019,374.90

Yearly cost for chlorine = (0.6212 kg/h x 24 x 330) x (0.2156) = RM 1060.73

Total cost for raw materials, CRM = RM 24,019,374.90 + RM 1060.73

= RM 24,020,435.63

Yearly Cost and Stream Factor

Manufacturing and associated costs are most often reported in terms of RM/yr. The fraction of

time that the plant is operating in a year must be known in oreder to calculate the yearly costs of

raw materials or utilities. This fraction is known as the Stream Factor(SF), where :

Stream Factor (SF) = Number of Days Plant Operates Per Year

365

= 330365 = 0.904

COM = 0.280FCI + 2.73COL + 1.23(CRM+ CWT + CUT)= 0.280(48,439,279.20) + 2.73(234,000.00) +1.23(24,020,435.63 +2,685.15 + 1,738953.39 )

= RM 45,889,169.41COMd = 0.180FCI + 2.73COL + 1.23(CRM+ CWT + CUT)

= 0.180(48,439,279.20) + 2.73(234,000.00) +1.23(24,020,435.63 + 2,685.15 + 1,738953.39) = RM 41,045,241.49

Profitability analysisAssumption

Land: RM 17,222,400.00

Salvage value: RM 10,000000

Taxation rate: $45%

Plant life: 10 years

Non discounted cash flow

Working capital = labor cost + utility cost + raw material cost + waste treatment

Working capital = RM 234,000.00 + RM 1,738953.39 + RM 24,020,435.63 +RM 2,685.15

= RM 25,996.074.17

Total fixed capital investment, FCI: RM 48,439,279.20

END OF

YEAR (K)

INVESTMENTRM

dk

RMFCI L−dk

RMR

RMCOM d

RM ( R−COM−dk ) ×(1−0.45)+d k

RM

CASH FLOW

RM

CUMULATIVE CASH FLOW

RM0 -17222400   -48439279         -129168001 -48439279   -48439279         -484392792 -25996074   -48439279         -259960743   -9687856 -38751423 1316000000 41045241 45889169 694201422 6942014224   -15500569 -23250854 1316000000 41045241 45889169 691585701 691585701

5   -9300342 -13950512 1316000000 41045241 45889169 694375803 694375803

6   -5580205 -8370307 1316000000 41045241 45889169 696049865 6960498657   -5580205 -2790102 1316000000 41045241 45889169 696049865 6960498658   -2790102 0 1316000000 41045241 45889169 697305411 6973054119       1316000000 41045241 45889169 698560957 698560957

10       1316000000 41045241 45889169 698560957 69856095711       1316000000 41045241 45889169 698560957 69856095712 38912874     1317000000 41045241 45889169 699110957 738023831

Payback periodFind the value of $-38912874 in cumulative cash flow

PBP = x−01−0

= −38912874+−25996074−694201422+−25996074

x=0.096 years

Cumulative cash PositionCCP= RM 7012801172Cumulative cash ratio

CCR

¿-1342.2413

ROROI

¿-14.3775Discounted cash flow

END OF YEARNON DISCOUNTED

CASH FLOW$

DISCOUNTED CASH FLOW

$

CUMULATIVE DISCOUNTED CASH

FLOW$

0 -17222400 -17222400 -172224001 -48439279 -44035708 -612581082 -25996074 -21484359 -827424673 694201422 521563803 4388213364 691585701 472362339 9111836755 694375803 431152742 13423364176 696049865 392902003 17352384207 696049865 357183639 2092422059

8 697305411 325298120 24177201799 698560957 296258038 271397821710 698560957 269325489 298330370611 698560957 244841354 322814506012 738023831 235157137 3463302197

Discount rate: 10% p.a

Discounted payback period

Discounted value of land + working capital

¿ 17222400+25,996.074 .171.12

¿ RM 38587923.37

Find the value -RM 38587923.37 in the cumulative cash flow

Discounted payback period

¿ x−01−0

=−38587923.37+82742467438821336+82742467

x=0.08 year

Net present value

NPV= RM 3552745510

Present value ratio

PVR

¿-665.68777Hazard AnalysisHandling and Storage

Chlorobenzene need to be stored in a cool, dry, well-ventilated area in tightly sealed containers

that are labelled according to the OSHA’s hazard communication standard [29 CFR 1910.1200].

Outside or detached storage is highly preferable; however, if inside storage is to be used, the

storage should be in a standard flammable liquids storage room that meet OSHA requirements.

The containers used to store chlorobenzene need to be protected from any possible physical

damage and should be stored separately form oxidizers, dimethyl sulfoxide, silver perchlorate,

other incompatible chemicals, heat, sparks and open flame as cholorobenzene is categorized as

rate 3 flammability which is severe fire hazard. All source of ignition must be eliminated. Thus,

only non-sparking tools can be used to handle chlorobenzene as static electricity and formation

of sparks must be prevented. The optimum temperature condition for the storage of

chlorobenzene is between 16°C and 26°C; and it must be stored away from direct sunlight and

moisture. The containers should also be grounded and bonded together for transfer in order to

prevent static sparks. In addition, the containers previously used to store chlorobenzene need to

be handle or disposed appropriately as it may still hold product residues.

Health Effect

According to Occupational Safety and Health Administration (OSHA), the current permissible

exposure limit for chlorobenzene is 75 ppm (350 mg/m3). The routes for the exposure of

chlorobenzene mainly occur through inhalation, ingestion, and eye or skin contact.

Chlorobenzene also mainly absorbed through the gastrointestinal and respiratory tracts, and

dermal absorption. Chlorobenzene is lipophilic and has a tendency to accumulate in lipid-rich

tissues in animal and humans. The effect of chlorobenzene to animals is irritation, narcosis, liver

and kidney damage. However, fatal effect may occur at high concentration of chlorobenzene. For

humans, if chlorobenzene is exposed at the concentration of 200 ppm, eye and nose irritation will

occur and at high concentration, central nervous system depression will take place. If liquid

chlorobenzene is just briefly in contact with skin, mild irritation occur, however if prolonged or

repeated contact happened, burning of the skin will occur. The toxic effects of chlorobenzene on

humans were exhaustion, nausea, lethargy, headache and irritation to the upper respiratory tract

and eye. Chlorobenzene is considered toxic and many studies conducted have found that the

toxic effect of chlorobenzene on organisms in the environment includes mortality,

immobilization and growth inhibition. The targeted organs for exposure of chlorobenzene are

mainly kidneys and liver.

Environmental Release

Chlorobenzene does not occur naturally. It enters the atmosphere as fugitive emissions from the

pesticide industry and from other industries that use it as a solvent (Howard 1989). Release of

the chemical also occurs during the disposal of industrial wastes (Howard 1989). Concentrations

of chlorobenzene in the atmosphere have typically ranged from < 0.02 ppb for remote areas to

0.8 ppb in cities; the maximum reported value measured was 12 ppb (Howard 1989).

Chlorobenzene is volatile (vapor pressure, 11.7 mm Hg) and slightly soluble in water (466.3

mg/L). The most important transport process for chemical from water and soil is evaporation. If

chlorobenzene is released to moist soil, it will evaporate to the atmosphere; and if it is released to

sandy soil, chlorobenzene will leach into the groundwater. Chlorobenzene will biodegrade very

slow and might not degrade at all and remains in the environment.

If exposed to the air, the half-life of chlorobenzene is to be about 9 days or sometimes 20 to 40

hours under simulated atmospheric conditions. Usually, the chlorobenzene is removed from the

atmosphere through reaction with hydroxyl radicals forming microbiophenyl and photolysis

reaction. When exposed to the water, the chlorobenzene will have a half-life about 0.3 days in a

river, and about 1 to 12 hours in a rapidly flowing stream. Chlorobenzene is removed from the

water through vaporization and biodegradation processes. And if exposed to the soil, it will have

a half-life f 0.3 days is exposed to soil at depth 1 cm and 12.6 days at depth 10 cm. Main removal

of chlorobenzene from the soil surface is through evaporation.

Disposal

Since it is possible for chemicals waste to enter the environment if waste incinerated, land filled

or just drained, it is important to keep them out of municipal waste stream. Since, chlorobenzene

is known as hazardous and toxic chemicals, proper treatment and disposal method need to be

made. The waste disposal facility should be approved by the local authorities; and care should be

taken to ensure the disposal meet the regulatory requirements or local environmental laws.

Chlorobenzene is listed as a hazardous substance, thus the disposal of it is very strict and is

controlled by the federal regulations. Disposal of chlorobenzene into the soil (landfill) is very

restricted, except under specific conditions. It is not suitable for disposal by either landfill or via

local sewers, drains, natural streams or rivers. Wastes containing chlorobenzene may be disposed

by liquid injection, rotary kiln, or fluidized bed incineration. Since chlorobenzene is widely used

as a solvent in many chemical processes and it is a volatile compound, most of the waste is

released to the atmosphere, few wastes were found in wastewater and land. Thus, the air plays a

large role in the environmental transport and degradation of chlorobenzene.

For container disposal, the container must be first drained thoroughly. After draining, it should

be store in a safe place away from sparks and ignition of fire because the residues of

chlorobenzene that still attach to the wall of the container may cause an explosion hazard.

Disposal of container and unused contents must be in accordance to local regulatory

requirements and environmental laws.

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Appendices