project on nitrobenzene

8/14/2019 project on nitrobenzene

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PROJECT

ON

NITROBENZENE

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ACKNOWLEDGEMENT

We here by place our sincere thanks to Dr.R.KARHIKEYAN, Head of the

Department of Chemical Engineering , S.R.M Engineering College affiliated to

S.R.M University and the faculty members of Chemical Engineering Department for

their full hearted co-operation and encouragement for the successful completion of

this project.

We extend out thanks to Project guide D.BALAJI for the Motivation,

encouragement and guidance provided by him. We would also like to extend our

thanks to each and everyone who have helped us in completing this project

successfully.

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ABSTRACT

The project deals extensively with the manufacture of nitrobenzene from mixed acid

and benzene .Since the demand for aniline has been increasing day by day

manufacture of benzene is more important. Nitrobenzene is obtained by treating

mixed acid and benzene. A detailed process flow sheet, material balance, energy

balance, have been done. A detailed design of equipments, cost estimation of plant,

plant layout and safety aspects have been discussed.

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CONTENTS

Chapter No Topic Page NO.

1. INTRODUCTION 5

2. PHYSICAL PROPERTIES 7

3. CHEMICAL PROPERTIES 9

4. USES 12

5. PROCESS DESCRIPTION 14

6. MATERIAL BALANCE 19

7. ENERGY BALANCE 25

8. REACTOR DESIGN 29

9. DISTILLATION COLUMN DESIGN 35

10. COST ESTIMATION 44

11. HEALTH AND SAFTEY FACTORS 51

12. PLANT LAYOUT 55

13 CONCLUSION 62

14. BIBLIOGRAPHY 64

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1.INTRODUCTION

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1.CHAPTER

Nitrobenzene was first synthesized in 1834 by treating Benzene with Fuming

Nitric Acid, and it was produced commercially in England in 1856. The relative case

of aromatic nitration has contributed significantly to the large and varied industrial

application of nitrobenzene and its derivative.

Nitrobenzene (oil of Mir bane) is a pale yellow liquid with an odor of bitter

almonds. Depending upon the compound impurity , its color varies from pale yellow

to yellowish brown. Nitrobenzene is one of the important raw materials for the dye

manufacture and most nitrobenzene produced is used directly or indirectly in dye

manufacture. It is manufactured on large scale only by aniline manufactures. Ref[1]

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2.CHAPTER

2.Physical Propert ies of Nitrobenzene :ref[4]

Molecular Weight 123.11

Boiling Point 210 - 211 C

Melting Point 6 C

Flash Point 88 C (closed cup)

Vapor Density 4.3 (air = 1)

Vapor Pressure 1 mm Hg at 44.4 C

Density/Specific Gravity 1.205 at 15/4 C (water = 1)

Log Octanol/Water Partition Coefficient 1.85

Henry's Law Constant 2.44 x 105 atm-m3/mole

Conversion Factor 1 ppm = 5.04 mg/m3

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3.CHEMICAL PROPERTIES

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Reduction Products Of Nitrobenzene

Reagent Product

Fe,Zn or Sn+HCl Aniline

H2+metal catalyst+ heat

(gas phase or solution) Aniline

SnCl2+acetic acid Aniline

Zn+NaOH Hydrazobenzene, azobenzene

Zn + H2O N-Phenylhydroxylamine Azoxybenzene

Na3ASO3 Azoxybenzene

LiAIH4 Azobenzene

Na2S2O3 + Na3PO4 Sodium Phenylsulfamate,C6H5NHSO3NA

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4.USES

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4.CHAPTER

The largest end use of nitrobenzene is in the production of aniline.approximtely

95-98% of nitrobenzene is converted to aniline the demand for nitrobenzene

fluctuates with the demand for aniline production grew at an average annual rate of

almost 5% from 1984 to1988 but dropped by over 4% during the 1989-1990

economic downturn. For 1990,96% of the 532972 metric tons of nitrobenzene left

were used to produce variety of other products, such as para-aminiphenol and

nigrosine dyes. The U.S. producers of PAP are MALLINCHRODT,INC., RHONE-

POULENC, and Hoechst cleanse with combined production capacities >35000 metric

tons. Mallinckrodt is the largest producer, with over 50% of capacity PAP primarily is

used as an intermediate for acetaminophen. Ref[4]

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5.PROCESS DESCRIPTION

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5.CHAPTER

Nitrobenzene is prepared by direct nitration of benzene, using a nitric acid-sulphuric

acid mixture. The reaction vessel or nitrator is a specially built cast-iron or steel

kettle fitted with an efficient agitator. The kettle is jacketed and generally contains

internal cooling coils for proper control of the exothermic reaction.

Nitrobenzene can be produced by either a batch or a continuous process

with a typical batch, the reactor is charged with benzene, and the nitrating acid (56-

60% H2SO4,27-32wt% HNO3 and 8-17%wt% H2O) is added slowly below the

surface of the benzene. The temperature of the mixture is maintained at 55-55C by

adjusting the feed rate of the mixed acid and the amount of cooling. the temperaturecan be raised to 90C towards the end of the reaction to promote completion of

reaction. The reaction mixture is fed into separator where the spent acid settles to the

bottom and is drawn off to be refortified. The crude nitrobenzene is drawn from the

top to the separator and washed in several steps. depending on the desired purity of

the nitrobenzene the product can be distilled. Usually a slight excess of the benzene is

used to ensure that little or no nitric acid remains in spent acid. Yield is about 98%.

Because of a continuous nitration process generally offers lower capital cost and more

efficient labor usage than a batch, most if not all of the nitrobenzene produce use

continuous process.

Benzene nitrating acid (56-65 wt% H2SO4,20-26%HNO3 & 15-18wt%

water) are fed into the nitrator, which can be a stirred cylindrical reactor with internal

cooling coils and external heat exchangers or cascade of such reactors.

The nitator also can be designed as a tubular reactor e.g. tube and shell

heat exchangers with appropriate cooling coils involving turbulent flow. Generally,

with a tubular reactor the reaction mixture is pumped through the reactor cycle loop

and a portion of the mixture is withdrawn and fed into the separator.

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A slight excess of benzene usually is fed into the nitrator to ensure that

the nitric acids in the nitrating mixture is consumed to maximum possible extent and

to minimize the formation of di-nitrobenzene. the temperature of the nitrator is

maintained at 50-100C by varying the amount of cooling.

The reaction mixture flows from the nitrator into separator are

centrifuged here is separated into two phases. The aqueous phase or spent acid is

drawn from the bottom and concentrated in a sulfuric acid reconcentrated step or

recycled to the nitrator where it is mixed with nitric and sulfuric acid immediately

prior to being fed into the nitrator.

The crude nitrobenzene is washed and distilled to remove water and

benzene and if required nitrobenzene can be refined by vacuum distillation. ref[3]

SPECIFICATION AND TEST METHODS

Specification and test Methods:

Specification for double-distilled nitrobenzene are give in table below,

Property Value

Purity ,% > 99.8

Color Clear, light yellow to brown

Freezing Point, 0C > 5.13

Distillation range (First drop), 0C > 207

Dry point 0C 212

Moisture,%


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Several qualitative spot tests are applicable to nitrobenzene and depend oncharacteristic color developed by its reaction with certain reagent. In general,

calorimetric methods are subject to interferences from aromatic nitro compounds.

Certain colorimetric methods are based on the nitration of nitrobenzene to m-

nitrobenzene and subsequent determination by the generation of a red-violet color

with acetone and alkali. A general micrometric method for the determination of

aromatic nitro compounds is based on reduction with titanium(lll) sulfate or chloride

in acidic solution followed by back titration of excess titanium (lll) ions with a

standard ferric alum solution. Now days most modern techniques use instrumental

methods such as gas chromatography and high pressure liquid chromatography.

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PROCESS FLOW DIAGRAM

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6.Material Balance

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6.CHAPTER

Individual Material Balance for Mixed Acid

Reaction Involved

H2SO4+ HNO3 HNO3(H2SO4)

Mol.wt 98 63 161

Basis :

1 Ton of Mixed acid

H2SO4600 Kg

1000 Kg of Mixed Acid

HNO3 400 Kg

Mixer

Where,

H2SO4 = Wt / Mol.wt

= 600/98 = 6.1224 no of moles

HNO3 = Wt / Mol.wt

= 400 /63 = 6.349 no of moles

Mixed acid = Wt/Mol.wt

= 1000/161 = 6.2111 no of moles

Where,

Mass In = Mass of HNO3+ Mass of H

2SO

4

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= 400 + 600 = 1000 Kg

Mass Out = Mass of HNO3(H2SO4)

= 1000 Kg

Mass In = Mass Out

Nitration:

Reaction Involved:

C6H6+ HNO3(H2SO4) C6H5NO2 + H2O + H2SO4

Mol.Wt 78 161 123 18 98

C6H

6 650 Kg

HNO3(H2SO4) C6H5NO2 840.84 Kg

1000 Kg H2O 129.36 Kg

H2SO4 646.8 Kg

Nitration

Unreacted C6H6 13Kg

UnreactedHNO3(H2SO4) 20 Kg

C6H6 = Wt /Mol.wt

= 650 /78 = 8.333 no of Moles

HNO23(H2SO4) = Wt / Mol.wt

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= 1000 /161 = 6.2111

C6H5NO2:

Wt % = 51% of C6H5NO2

= 50.96 /100* 1650 = 840.84 Kg

No of Moles = 840.84 /123

= 6.836 Moles

H2SO4:

Wt % = 39.2 % of H2SO4

= 39.2 / 100* 1650 = 646.8 Kg

No of Moles = 646.8 /98

= 6.6 Moles

H2O :

Wt % = 7.84% of Moles

= 7.84/100 *1650 = 129.36 Kg

No of Moles = 129.36 Kg /18 = 7.18 Moles.

Unreacted of C6H62%:

= Wt / Mol.wt = 2 / 100 * 650 = 13 Kg

Unreacted of HNO3(H2SO4) 2%:

= Wt / Mol.wt = 2 /100 * 1000 = 20 Kg

Mass In = Mass of HNO3(H2SO4) + Mass of C6H6

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= 1000 + 650 = 1650 Kg

Mass Out = Mass of C6H5NO2+ Mass of H2O + Mass of H2SO4+

Mass of Unreacted C6H6+ Mass of Unreacted HNO3(H2SO4)

= 840.84 + 646.8 + 129.36 + 13+ 20

Mass Out = 1650 Kg

Mass In = Mass Out

Material Balance in Separator ; C6H5NO2 840.84 Kg

UnreactedC6H6 13Kg

C6H5NO2 840.84 Kg

H2O129.36Kg H2O129.36 Kg

H2SO4646.8 Kg H2SO646.8 Kg

Separator

UnreactedC6H613Kg

UnreacteHNO3(H2SO4)20Kg

UnreacteHNO3(H2SO4)20Kg

Mass In = Mass of C6H5NO2+ Mass of H2O + Mass of H2SO4+

Mass of Unreacted C6H6+ Mass of Unreacted HNO3(H2SO4)

Mass In = 840.84 + 646.8 + 129.36 + 13+ 20 = 1650 Kg

Mass Out = 1650 Kg

Mass In = Mass Out

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Material Balance for Distillation Column:

Unreacted C6H6 13Kg

C6H5NO2 840.84 Kg

Unreacted C6H6 13Kg

C6H5NO2 840.84 Kg

DISTIL

Mass In = Mass of C6H5NO2+ Unreacted of C6H6

= 840.84 + 13 = 853.84 Kg

Mass Out = Mass of C6H5NO2+ Mass of unreacted of C6H6

= 840.84 + 13 = 853.84 Kg

Mass In = Mass Out

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7.ENERGY BALANCE

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7.CHAPTER

Individual Energy Balance for Mixed Acid:

Reaction Involved:

H2SO4 + HNO3 HNO3(H2SO4)

Temp 0C 30 30 55

Cp(KJ/Kg k) 1.402 2.013 1.641

Cp of HNO3 (H2SO4) ;

Cp of mix = { Mass fraction of H2S04* Cp H2S04} +

{Mass fraction of HNO H2S03* Cp HNO3}

= {(600/1000) * 1.402} + {(400/1000) * 2.013}

Cp of Mix = 1.6464 KJ / Kg k

H Reaction = (HF) Product (HF) Reactant

(HF) reactant = (HF) H2SO4+ (HF) HNO3

(HF) H2SO4 = -193.69 Kcal /Mol at 250 C. ref[2]

= -8269.377 KJ/Kg

= - 8269.377*600

(HF) H2SO4 = - 4.9616*106KJ

(HF) HNO3 = -41.35 KCal / Mol at 250 C. ref[3]

= - 2749.165 KJ/ Kg

= - 2749.165 * 400

(HF) HNO3 = -1.0996 * 106KJ

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Overall Energy Balance:

Reaction Involved:

C6H6+ HNO3(H2SO4) C6H5NO2+ H2O(H2SO4)

Temp 0C 30 55 95 95

Cp(KJ/Kg K) 1.769 1.641 1.528 1.97

Energy In = (m.cp.dt)C6H5NO2+ (m.cp.dt) mix acid

= (650 * 1.769 * 55) + (1000 * 1.641 *30)

= 112471.75 KJ

Energy Out = (m.cp.dt)C6H5NO2+ (m.cp.dt) H2O(H2SO4) +

(m.cp.dt) unreacted C6H6+ (m.cp.dt) unreacted mix acid + Hrxn

= [840.84 * 1.528 *(95-55)] + [776.16 * 1.97(95-25)] +

[13 * 1.769 *(95-25)] + [20 * 1.641 * (95-25)] 1510080.0

= 113251.79 KJ

Energy In = Energy Out

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8.Design For Reactor

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12.CHAPTER

Ideal steady state operation is carried out :

We know that for a 2nd

order reaction,

V XA______ = _______FAO -rA

(or)

V /VO = XA/ KCAO(1-XA)2

Where,

Vo = Feed rate,

CAo = Moles of A/VOL of fluid

XA = Conversion (98%)

We know that K is const = 1.412 Lit/min.mol . ref[2]

Volume of C6H6 = volume of C6H6/ Density of C6H6

= 650 /876 = 742.0L

Volume of HN03 = Volume of HNO3 / Density of HNO3

= 400/ 1504 = 265.9L

Volume of H2SO4 = Volume of H2SO4/ Density of H2SO4

= 600 / 1834 = 327.2L

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Total Volume = 445.03 l/day = 445.03/24 = 18.54 l/hr = 18.54 / 60 = 0.309 l/min

= 18.54/ 3600 = 5.15*10-3

= 0.00515 l/sec.

CAO = No of Moles/ Total Volume

= 6.122/0.0052 =1177.31/60 = 19.62 Mol/Lit

CAO = 19.62 Mol/Lit

= V /VO = XA* CA / K *CAO*(1-XA)2

= V / VO = 0.98 * 0.309/ 1.412*19.62*(1-0.98)2 = 27.33 Litres

Vol of the reaction = 27.33 Lit

= 0.02733 m3

We know that,

/4 D2 H = 0.027

* D2 = 0.027*4

D = 0.185 m3

/4* (0.185)2 H = 0.027

H = 0.027 * 4 * 1 /*0.18522

HH == 11..001199mm33

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32

WWeekknnoowwtthhaatt,,

TThhiicckknneessssooffvveesssseell tt == PP**DD//22FFNN--PP

OOppeerraattiinnggPPrreessssuurree == 33aattmm

DDeessiiggnnPPrreessssuurree PP == 33++1155%%== 33..1155aattmm== 33..1155**11..0011332255bbaarrss**110055NN//mm22

DDeessiiggnn PPrreessuurree == 331199117733..7755 NN//mm33

SShheeaarrSSttrreessss,, iiff == yyiieellddssttrreessss //22

We know that

Yield stress = 207*106 ref[5]

SShheeaarrSSttrreessss == 220077**11006//22

SShheeaarrSSttrreessss == 110033**110066 ww//mm33

WWeekknnoowwtthhaatt

hhwweellddiinnggeeffffiicciieennccyy ==00..8855 rreeff[[55]]

TThhiicckknneessssooffvveesssseell tt == PP**DD//22FFNN--PP

== 331199117733..7755**0099//((22**110033**110066**00..8855))--331199117733..7755

tt == 11..6644**1100--33mm

TThhiicckknneessssooffvveesssseell == 11..6644mmmm


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DESIGN SUMMARY

Volume of the reactor = 2.77 m3

Diameter of the reactor = 0.185 m3

Height of the reactor = 1.019 m3

Thickness of vessel = 1.64 mm

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REACTOR

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9.DISTILLATION COLUMN

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9.CHAPTER

Basis; 1 hour of operation.

Feed F = Volume of feed = 35.576 Kg/hr.

Distillate D = Volume of distillate = 0.5416 Kg/hr.

Bottom Product B = Volume of bottom = 35.03 Kg/hr.

Xf = unreacted of benzene /mol.wt / (Unrect/mol) + (prod/mol.wt)

= 2/78 / (2/78) + (98/123) = 0.036

Xd = nitrobenzene /mol.wt / (nitroben/mol) + (prod/mol.wt)

= 100/78 / (100/78) + (0/123) = 1

Xb = Unrectbenz/mol.wt / (unrectbenz/mol) + (nitrobenzene/mol)

= 0/78 / (0/78) + (100/123) = 0

Average Molecular weight of feed

= 123*0.98+78*(1-0.98) = 122.1

Feed rate = 35.576 /122.1

= 0.29 Kg mole / hr

Also,

Fxf = Dxd + Bxb

From above,

D = Fx xf-xb / xd-xb . ref[2]

= 0.29*(0.03-0/1-0)

D = 0.0087 Kg mole/hr

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B = 0.29-0.0087 = 0.2813 Kg mole/hr.

Slope of q-line ;

We know that q = Hg-Hf / Hg-Hl

q=1

slope of q-line:

slope of q-line = q/q-1

= 1/1-1

Tan-1() = 0

q line is st.line

Xd / Rm+1 = 0.05

Rm+1 = 1/0.05

Rm+1 = 20

Rm = 19

R = 1.2 Rm

R = 22.8 23

Xd = 1 = 0.042

Rm+1 23+1

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From Mc-cabe Thile Graph

X 0 0.01 0.02 0.03 0.045 0.07 0.10 0.155 0.20 0.30

Y 0 0.03 0.485 0.63 0.74 0.82 0.88 0.92 0.94 0.964

Ideal Plate = 16 (From Graph)

Actual Plate = Ideal/n = 16/0.6

Actual Plate = 26.66

Height:

Plate Spacing = 450 mm = 0.45m

Ht = (Actual Plate-1)*0.45 + 2(0.45)

= 12.45m

Diameter :

Vap rate = v = D(R+1)

= 0.0087(23+1)

n = 0.21 Kg moles/hr

Top Column :

Vol.rate = nRT/P

= 0.21*8.314*103*(82+273)/ 1.01325*105 = 6.1170 m3/hr

Vol rate = 1.7*10-3 m3/sec

Velocity = 1 m/sec

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Area = Vol rate / Velocity

= 1.7*10-3 /1 = 1.7*10-3 m2

Area = D2

/4

D2 = 4A / ; D = 4A /

D = 0.047 m

Bottom column:

Vol.rate = nRT/P

= 0.21*8.314*103*(210+273)/ 1.01325*105 = 8.32 m3/hr

Area = Vol .rate / Velocity

Velocity = 1 m/sec

Area = 2.31*10-3 m2

A = D2

/ 4

D2= 4a /; D = 4A/

D = 0.054 m

Both diameters are approximately same ,

we choose the larger diameter (i.e) bottom diameter

Bottom diameter D= 0.054 m

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DESIGN SUMMARY

Ideal plate = 16.00

Actual Plates = 26.66

Column Height = 12.45m

Column Diameter = 0.054 m

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DISTILLATION COLUMN

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TOPSIDE

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BOTTOM SIDE

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10.COST ESTIMATION

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10.CHAPTER

Cost of a Kg of Nitrobenzene in Market = 35 Rs

The Capacities of Plant is 840.84 Kg/day for 1 year = 29429.4

Gross `sales for 1 year or Total income = Rs.87*106

Estimation of capital investment cost Turnover = Gross Annual Sales

Fixed Capital

For Chemical Industries Turn Over ratio = 1

Therefore gross annual sales = Fixed Capital Investment

Therefore Fixed capital Investment = Rs.30.87*106

1. DIRECT COST

It is taken as 70% of fixed capital investment

Hence direct cost = 0.7 * 30.87* 106 = Rs 21.6*106

The cost involved in direct costs are

Equipment and installation + instrumentation = piping + electrical + insulation+

Paintings which amount for 50% of the fixed capital

1. Equipment cost is 24% of fixed capital cost = Rs.7.4 * 106

2.Installation and painting is 40% of delivered equipment cost = Rs3*106

3.Instrumentation and control and installation cost = 10% of delivered equipment

cost this cost is equal to Rs7.4*106

4.Piping and installation cost is 25% of the delivered cost = Rs1.85*106

5.Electrical and installation cost Rs 33.33% of the delivered cost.

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6.Building , Process and Auxiliary

This cost is 39.1667 of the purchased equipment cost

this cost is equal to 391667*7.4*10

6

= Rs289*10

6

7.Service Facilities and yard improvement is 40% of the delivered equipment cost

this cost is equal to 0.4*7.4*106= 2.96*106

8. Load cost is 1% of fixed capital

this cost is equal to 0.001*30.87*106= Rs 30.87*106

2.INDIRECT COST:

This is expenses which are not included with material and labor of actual

installation of complete facilities

this cost is equal to 0.3*30.87*106= Rs6.174*106

a) engineering are supervision: this cost is 20% of the fixed capital investment

this cost is equal to 0.2*30.87*106

b) Construction expenses and contractor fees. this cost is 10% of direct cost

This cost is equal 0.1*21.6*106= Rs2.16*106

c) Contingency : This cost in 5% of the capital

This cost is equal to 0.5*30.87*106= Rs1.544*106

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Working Capital:

In 20% of total capital investment total capital investment = fixed cap+ Working cap

=30.87*10

6

+0.8(Total cost investment)

total capital capital investment = 30.87 *106/0.8 = Rs 38.58*106

Working Capital = 38.58*106-30.87*106 = Rs 7.71*106

Estimation of Total Product Cost

Total annual income = Rs.30.87*106

Total Grass Earnings = 10% of total annual incomes

= 0.1*30.87*106 = Rs3.08*106

Product Cost = Total annual Gross earnings income

=30.87*106-3.08*106 = Rs 27.79*106

Total Product Cost = Direct Production Fixed + Charge Plant + Overhead

DIRECT PRODUCTION COST

It is 60% of total product cost the

Direct Production cost is equal to = 0.6*27.79*106

1. Raw Material: It is 20% of total product

cost the cost of raw material is = 27.79*106 = Rs.5.56*106

2. Operating Laboris 15% of the total product cost

The cost of operating labor is = 0.15*27.79*106 = 4.168*106

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3. Direct supervisory and clinical laboris 20% of operating labour.

The cost of direct supervisory and clinical labor is = .15*27.79*106= Rs.5.56*106

= Rs4.168*10

6

= Rs.5.56*10

6

4. Utilities: In 15% of total Product cost

The cost of utilities is = 0.15*27.79*106= Rs4.168*106

5. Maintenance and Repairs: it is 3.6% of fixed capital investment

The cost of maintenance = 0.0036*30.87*106

6. Operating Supplies: it is 0.5% of the fixed capital investment

The cost of operating supplies is = 0.005*30.87*106

7. Laboratory Chargeis 6.6667% of the operating labor cost

The cost of Laboratory Charges is = 0.6667*4.168*106 = Rs 0.281681*106

8. Patents and Royalties: it is 1.45% of the fixed capital cost

the cost of patents and royalties is = 0.0145*30.87*106= Rs.447675.00

9. Fixed charge: it is 20% of total product cost.

The cost of fixed charges is = Rs 5.56*106

DEPRECIATION

Depreciation for building is 3% of land cost

= 0.03*30.87*105

Total depreciation value = Rs0.93*106

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3. INSURANCE

This is 1 % of the fixed capital investment

The insurance value = 0.01*30.87*106

= Rs 308700

4. Rent: This is 3.0555% of total product cost

Rent value = 0.030555*27.79*106 = Rs.849123.45

C) Plant overheads: The includes cost for following general plant upkeep and

Overheads payroll, overhead packaging, medical services safety and protection,

Restaurants, recreation salvage, laboratories and storage facilities. This cost is 5%

of total product cost plant overhead is equal to = 0.05*27.79*106 = Rs 1389500.00

ll GENERAL EXPENSES:

a) Administrative cost:

Includes cost for executive officer, clinical wage, legal fees, office

Supplies and communication. This cost is 5% of the total product cost

Administrative cost = 0.005*27.79*106= Rs.1389500.00

b) Distribution and selling cost:

Includes cost for sales offices, sales man shopping and advertising

This cost is 7 of the total product cost

Distribution and selling cost = 0.07*27.79*106= Rs. 1945300.00

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c) Research and development

This cost is 1% of total product cost. Research and

Development cost = 0.01*27.79*10

6

= Rs 277900.00

D) Gross earning cost: it is the net profit obtained after deduction of tax from

gross earning

Gross earning cost = 60%

Net profit = Rs 1.848*106

d) Pay back period: with interest charge

Pay back = Depreciable fixed capital investment

Average profit/year-Average depreciation/year

= (30.87-3.08)*106 /(1.846+3.08)*106

= 5.612 years

Pay back = 5years 233 days ref[2]

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11.HEALTH AND SAFTEY FACTORS

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11.CHAPTER

Nitrobenzene is a very toxic substance the maximum allowable concentration

for nitrobenzene is 1ppm or 5 mg/m.It is readily absorbed by contact with skin and

by inhalation of vapor, If a worker was exposed for 8 hours to 1ppm nitrobenzene in

the working atmosphere, about 25mg of nitrobenzene would be absorbed, of which

about one-third would be by skin absorption and the remainder by inhalation . The

primary effect of nitrobenzene is the conversion of hemoglobin to met hemoglobin;

thus the conversion eliminates hemoglobin from the oxygen-transport cycle.

Exposure to nitrobenzene may irritate the skin and eyes. nitrobenzene affects the

central nervous and produces fatigue, headache,vertigo,vomiting, general

weakmess,and in some cases unconscious and coma. There generally is a latent period

of 1-4 hours before signs or symptoms appear. Nitrobenzene is a powerful met

hemoglobin former, and cyanosis appears when the met hemoglobin level reaches

15%. Chronic exposure can lead to spleen and liver damage, jaundice and anemia.

Alcohol in any form should not be ingested by the victim of nitrobenzene poisoning

for several days after the nitrobenzene poisoning or exposure. Impervious protective

clothing should be worn in areas where risk of splash exists. Ordinary work clothes

that have been splashed should be worn in areas where risk of splash exists.

Ordinary work clothes that have been splashed should be removed immediately, and

the skin washed thoroughly with soap and warm water. In areas of high vapor

concentrations full face marks with organic-vapor canister or air-supplied respirators

should be used. clean work clothing should be worn daily and showering after each

shift should be mandatory.

With respect to the hazards of fire and explosion, nitrobenzene is classified as a

moderate hazard when exposed to heat or flame. Nitrobenzene is classified by the

ICCas a classB poisonous liquid. Ref[1]

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ENVIRONMENT EFFECTS

First draft prepared by L. Davies, Office of Chemical Safety, Therapeutic Goods

Administration, Australian Department of Health and Ageing, Canberra, Australia

Published under the joint sponsorship of the United Nations Environment

Programmer, the International Labor Organization and the World Health

Organization, and produced within the framework of the Inter-Organization

Programmer for the Sound Management of Chemicals.

The International Programmer on Chemical Safety (IPCS), established in 1980, is a

joint venture of the United Nations Environment Programmer (UNEP), the

International Labor Organization (ILO) and the World Health Organization (WHO).

The overall objectives of the IPCS are to establish the scientific basis for assessment

of the risk to human health and the environment from exposure to chemicals, through

international peer review processes, as a prerequisite for the promotion of chemical

safety, and to provide technical assistance in strengthening national capacities for the

sound management of chemicals.

The Inter-Organization Programmer for the Sound Management of Chemicals(IOMC) was established in 1995 by UNEP, ILO, the Food and Agriculture

Organization of the United Nations, WHO, the United Nations Industrial

Development Organization, the United Nations Institute for Training and Research

and the Organization for Economic Co-operation and Development (Participating

Organizations), following recommendations made by the 1992 UN Conference on

Environment and Development to strengthen cooperation and increase coordination in

the field of chemical safety. The purpose of the IOMC is to promote coordination of

the policies and activities pursued by the Participating Organizations, jointly or

separately, to achieve the sound management of chemicals in relation to human health

and the environment.

Nitrobenzene.

(Environmental health criteria ; 230)

1.Nitrobenzenes - toxicity

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2.Nitrobenzenes - adverse effects

3.Environmental exposure

4.Risk assessment I. International Programmer for Chemical Safety II.Series. ref[1]

HANDLING AND STORAGE TRANSPORTATION

Nitrobenzene samplings handling procedures in the united states are

described by ASTMP 3436-75.They are classified by the U.S interstate commission

(ICC)as a poisonous liquid,classB (regulation 173 347) and as a class 6 poison by

united nations as such they must be packaged in ICC specifications contains when

shipped by rail, water or highway and all of ICC regulations regarding loading

handling and labeling must be followed. nitrobenzene ordinarily is transported in

tanks, cars, tank trucks, or metal drums.

Carbon steel or cast iron is considered materials of choice for handling nitrobenzene

except when decolonization must be kept to minimum. Stainless steel (400 series) is

recommended for color critical applications. Nitrobenzene attacks, copper alloys,

brass and copper. It is rated on class IIIA combustible liquids (NFPA std no.30) and

usually can be handled with little danger of fire. Ref[2]

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12.PLANT LAYOUT

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15.CHAPTER

Plant layout is the functional arrangement of machinery and equipment in a

existing plant. Plant layout may be defined as the floor plan for determining and

arranging the desired equipment of a plant, in the one best place, to permit the

quickest flow of materials at lowest cost and least amount of handling in processing

the raw material from the receipt of raw material to the shipment of finished products.

The material handling planned in the layout begins at the receiving point , where the

material arrives as raw material, then continuous progressively from storage through

process, moving the from of worked material from department to department , from

machine to machine, the material flows in and out of temporary storage is fed throughassembly lines for final assembly. Provision is made for inspection, packaging and

storing the material as finished product.

Advantages of good plant layout to the workers :

Reduces the effort of the workers. Reduces the number of handling. Permits working at maximum efficiency. Reduces the number of accidents. Provides basis for higher earnings.

Advantages of a good plant layout in labour cost:

Increases output per man hour. Reduces number of operators. Loss setup time involved

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Advantages of a good plant lay out in production control:

Reduces production control expenses

Pace productionFundamental concepts of plant layout :

In apprising the advantages of good layout in the light of conditions prevailing in a

particular plant ,it is well to bear in mind the following concepts of plant layout.

Major part of production works is not processing , as is initially suppose butmaterial handling.

Then speed of production in the plant is determined primarily by theadequacies of its material handling facilities.

A good plant layout is designed to provide the proper facility for materialhandling.

The factory is altered or constructed around the prescribed plant layout. The production efficiency of the plant is determined by the limitations of its

layout.

TYPES OF DEPARTMENT

Processing department. This department performs machining assembly and packaging. Service department. These constitute the facilities provided to keep the processing

department in operation without interruption.

Administrative department.

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This department administrative sales,engineering,accounting productioncontrol, departments etc.

PLANNING THE PROCESSING

The plant layout engineer should obtain data on building elevation, columnspacing, door and conveyors.

The conveyors should be placed at reasonable height to mal functioning andwaste.

The traffic in the plant may be greatly by location store rooms close to thebuilding entrances.

In addition to the above vehicular traffic should be separated from pedestriantraffic and the roads should be wider.

PLANNING THE PLANT SERVICE FACILITIES:

Material received at a plant arrives via the particular forms of transportationwhich are generally prescribed.

Liquids such as chemicals are transported in tank cars, drums or pipelines The receiving department must be well equipped to receive the material in all

modes.

The design of a receiving involves the following considerations:

1. Space, 2. climate conditions, 3. variety of vehiclesSTORE ROOM:

A store room is the reservoir for raw material. Worked materials, finished products, maintenance supplies etc are kept.

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The functional requirements of a store room are:1. protection to materials

2. handling of the materials3. control pointsThe above factors also help the layout engineer to design the store

room as per requirements.

INSPECTION ROOM:

The inspection room or quality control room should be located near thenproduction unit, so that the samples from the production plant

Can be checked for its quality requirements.

The labs should be well equipped and should be properly planned.WATER STORAGE:

Water is used in the plant for variety of purposes. A plant must have adequate water supply to crater all these needs. By far the most reliable and effectives means of fire protection is the

automatic sprinkler system.

The sprinkler system is fitted with a sensitive transducer which lets water upto a height of 15 feet.

So the water storage system should be planned out with most more.

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POWER AND LIGHTING SYSTEM:

Power and lighting systems forms the main part of the plant.

The significant features of the power plant operations are,1. For supplying steam.2. Providing heat for process operations.3. supplying power to run motor.4. providing light to plant.5. power for surplus use.

PLANNING OF ADMINISTRATIVE BLOCK:

Location of an administrative block depends upon the geographiclocation with respect to the plant functions.

The general administrative block should have administrative rooms,conference room and vault room storage of documents and records.

The employee service facility consists of parking lots,Employment office cafeteria, first aid stations and medical

department etc. ref[6]

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PLANT LAYOUT

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13.CONCLUSION

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13.CHAPTER

The Manufacture of Nitrobenzene has been described in detail. The

necessary flow diagram, material and Energy balance for the production of 1 Ton of

Nitrobenzene has been worked out in detail. The design aspects are above described

in detail. The cost has been estimated .

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14.BIBLIOGRAPHY

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14.CHAPTER

1. KIRK AND OTHMER, Encyclopedia of Chemical Technology Vol.15.2nd Ed.Pg:176-190

2. ROBERT H .PERRY : PERRYS Chemical Engineers Hand Book 5th &6th Ed. Mc Graw Hill international Editions , Pg:642-644

3. GEORGE T. AUSTIN :Shreves Chemical Process Industries 5

th Mc

Graw Hillinternational Editions , Pg:776-778

4. BAHL.B.S & ARUN BAHL : A text book of organic Chemistry,19990,chand , Pg:350-355

5. IS CODES : 2825 ; 1969,4503-1967, Pg:5 6. JOSHI.M.V: Process Equipment Design 3rd Ed.Pg :45

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project on nitrobenzene