TABLE OF CONTENTS

PAGE

DECLARATION CERTIFICATION LIST OF TABLES LIST OF FIGURES TABLE OF CONTENTS LIST OF NOMENCLATURES ACKNOWLEDGMENT ABSTRACT

ii iii iv v vi viii x xi

CHAPTER 1

INTRODUCTION

1.1.

PROCESS BACKGROUND 1.1.1 The Uses of 2-Ethylhexyl Acrylate

1.2

AVAILABLE PROCESS 1.2.1 Esterification Process 1.2.1.1 Reaction Mechanism 1.2.1.2 Side reaction 1.2.2 General Process Description

1.3

ALTERNATIVE METHOD 1.3.1 1.3.2 1.3.3 1.3.4 Batchwise Esterification Continuous Esterification Cascade Esterification Equilibrium Limited Reaction

10

1.4

PROCESS SELECTION AND METHOD COMPARISON 20

1.5

RAW MATERIAL SELECTION 1.5.1 1.5.2 1.5.3 1.5.4 Acrylic Acid 2-Ethylhexanol DBSA PTZ, Hydroquinone, HMME

26

CHAPTER 2

MARKET ANALYSIS

2.1.

INTRODUCTION 2.1.1. Chemical Demand 2.2.2. Industry 2.2.3. COFs

32

2.2.

SUPPLY AND DEMAND OF 2-EHA 2.2.1. Global 2.2.2. Malaysia 2.2.2.1. BASF Malaysia 2.2.2.2. Branches 2.2.2.3. Sales 2.2.3. Acrylic acid production 2.2.4. Local demand for 2-EHA 2.2.5. Forecast 2-EHA

34

2.3.

AN OVERVIEW ON RAW MATERIALS 2.3.1. Acrylic Acid (AA) 2.3.1.1. Demand for AA 2.3.1.2. Demand for AA 2.3.2. 2-Ethylhexanol (2-EH) 2.3.2.1. Demand for 2-EH 2.3.2.2. Supplier for 2-EH 2.3.3. Catalyst 2.3.3.1. DBSA supply/demand 2.3.3.2. Producer/Suppliers for DBSA

41

2.4.

MARKET PRICE ANALYSIS 2.4.1. Price of 2-EHA 2.4.2. Price of AA 2.4.3. Price of 2-EH 2.4.4. Price of DBSA

50

2.5.

BREAK EVEN ANALYSIS 2.5.1. 2.5.2. Introduction Process economics and estimation

53

2.5.3. Total Capital investment 2.5.3.1. Fixed Capital Investment (FCI) 2.5.3.2. Operating cost 2.5.3.3. Start-up cost 2.5.4. Total Cost (TC)

2.5.5. Total Revenue 2.5.6. 2.5.7. Break Even Point Calculation of Break Even Analysis 2.5.7.1. Estimation of Total Operating cost 2.5.7.1.1. Cost of Raw Materials, CRM 2.5.7.1.2. Cost of Utilities, CUT 2.5.7.1.3. Equipment prices 2.5.7.2. Estimation of Fixed Capital Investment 2.5.7.3. Total Direct Manufacturing Cost (DMC) 2.5.7.3.1. Operating Labor 2.5.7.4. Total Fixed Manufacturing Cost (FMC) 2.5.7.5. Total General Expenses (GE) 2.5.8. Total Investment

2.5.9. Breakeven Point 2.5.9.1. Calculation of Payback Period, PBP

2.6.

CONCLUSION

74

CHAPTER 3

PLANT LOCATION AND SITE SELECTION

3.1.

INTRODUCTION

75

3.2

SELECTION CRITERIA 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 3.2.9 Marketing Area Raw Material Transportation Availability of Labor Utilities Environmental Impact and Effluent Disposal Local Community Plant Consideration Land Climate

75

3.2.10 Political and Strategic Consideration

3.3

SITE LOCATION SUGGESTED 3.3.1 Description of Suggested Location 3.3.1.1 Tanjung Langsat 3.3.1.2 Teluk Kalung 3.3.1.3 Pulau Indah

80

3.4

SITE LOCATION SELECTED

CHAPTER 4

ENVIRONMENTAL AND SAFETY CONSIDERATIONS

4.1

ENVIRONMENTAL CONSIDERATION 4.1.1 4.1.2 4.1.3 Introduction Environmental exposure Laws and regulations 4.1.3.1 Environmental Quality (clean air) 4.1.3.2 EIA

99

4.1.3.3 Environmental Quality (Industrial Effluent) 4.1.4 Wastewater treatment

4.1.4.1 Wastewater discharge regulation 4.1.5 Air treatment

4.2

SAFETY CONSIDERATION 4.2.1 4.2.2 INTRODUCTION Introduction to Occupational Risk Assessment 4.2.3 Safety Considerations on Chemicals 4.2.3.1 Chemical storage 4.2.3.2 Exposure to chemical 4.2.4 Leaking prevention and safety procedure 4.2.4.1 Leaking protective equipment 4.2.4.2 Leak detector 4.2.5 Safety consideration at plant site 4.2.5.1 Emergency planning 4.2.6 Fire prevention and safety 4.2.6.1 Fire extinguishers 4.2.6.2 Fire detector 4.2.6.3 Fire alarm 4.2.7 Unit evacuation alarm 4.2.7.1 Total plant evacuation 4.2.8 4.2.9 Personal protective equipment Material safety data sheet

107

4.3

STARTUP AND SHUTDOWN PROCEDURE 4.3.1 4.3.2 Startup Shutdown

130

4.4

HAZOP 4.4.1 4.4.2 4.4.3 HAZOP study on heat exchanger HAZOP study on reactor HAZOP study on distillation column

133

CHAPTER 5

MASS BALANCE

5.1

INTRODUCTION

145

5.2

SAMPLE CALCULATION 5.2.1 Mass Balance around 2nd Distillation Column 5.2.2 Mass Balance around 1st Distillation Column 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 Mass Balance around Mixer Mass Balance around TEE-100 Mass Balance around Decanter Mass Balance around Reactor Overall Mass Balance

146

CHAPTER 6

ENERGY BALANCE

6.1

INTRODUCTION

166

6.2

ENERGY BALANCE 6.2.1 Balance at each equipment 6.2.1.1 E-101 6.2.1.2 E-102 6.2.1.3 E-107 6.2.1.4 Reactor 6.2.1.5 T-101 6.2.1.6 T-102 6.2.1.7 Decanter

168

CHAPTER 7

HYSIS 7.1 HYSIS SIMULATION 199

REFERENCES

APPENDIX B APPENDIX C APPENDIX D APPENDIX E

LIST OF NOMENCLATURES

AA 2-EH 2-EHA DBSA GDP DOP PVC BEP FMC DMC GE FCI COM COMd PBP Cp Hv Hf H Tref C K Q Hr

Acrylic acid 2-Ethylhexanol 2-Ethylhexyl acrylate Dodecylbenzenesulfonic acid Growth domestic product di-octyl phthalate polyvinyl chloride Breakeven point Fixed manufacturing cost Direct manufacturing cost General Expenses Fixed capital investment Cost of manufacturing without depreciation Cost of manufacturing with depreciation Payback period Heat capacity Enthalpy of vapour Enthalpy of fluid Enthalpy of difference Reference temperature Celcius Kelvin Heat Hour