EXECUTIVE SUMMARY

CHAPTER 3: CHEMICAL AND MECHANICAL DESIGN

3.1 REACTOR
SPECIFICATION CHEMICAL DESIGN SHEET
Name: NUR HAMIZAH BT MUSA ID. No: 2013454224
IDENTIFICATION
Item Distillation Column (R-101)
Type Fixed Bed Reactor
PURPOSE
-To allow the reaction of 1,4 butanediol with catalyst to produce Tetrahydrofuran
Reactor DESIGN
Volume of Reactor 26.79 m3
Length of reactor 8m
Diameter of Reactor 2m
Residence time 148 minute
Volume of Catalyst 13.39 m3
Weight of Catalyst 14193 kg
Mass of cooling water 412.2 kg/s
Diameter of Tube 50mm
Wall thickness 0.002
Number of Tubes 323
Tube pitch 0.0625
Tube arrangement triangular
Pressure drop in Tube - side 0.33kPa
Bundle Diameter 1.26.
Baffles 8
Tubes in Center Row 21
Pressure Drop of Shell side 43.3 kPa

SPECIFICATION MECHANICAL DESIGN SHEET

NAME: NUR HAMIZAH BT MUSA ID. NO: 2013454224
Reactor
Operating Pressure (Po) 4.8bar
Design Pressure (PI) 0.5N/mm2
Operating Temperature 120
Design Temperature 132
Design Stress 157 N/mm2
HEAD AND CLOSURE
Type Torispherical Head
Joint Factor (J) 1
Minimum Thickness (e) 8 mm
COLUMN WEIGHT
Dead Weight of Vessel (W v) 0.4264 kN
Weight of Insulation (W i) 9.62 kN
Weight of tube (W t) 122.528 kN
Weight of catalyst (W cat) 139.237 kN
Total Weight (W t) 587.21 kN
Bending Moment (Mx) 88426.88 Nm
Insulation Material Mineral Wool
Insulation Thickness 75 mm
SKIRT SUPPORT
Type of Support Straight Cylindrical Skirt
Material of Construction Plain Carbon Steel
Youngs Modulus 200000 N/mm2
Bending Moment (Ms) 167.16 kN/m
Weight of Skirt 245.09 kN
Skirt Thickness (ts) 8 mm
Skirt Height (Hs) 3m
BASE RING ANCHOR BOLTS
No. of Bolt Required 12
Bolt Area (Ab) 198.5 mm2
Bolt Root Diameter 15.9 mm
Type M24
Base Thickness (tb) 29 mm
FLANGES DESIGN
Feed Inlet:
Nominal Size 40 mm
Bolting Type M12
Top Outlet:
Nominal Size 40 mm
Bolting Type M12
Bottom Outlet:
Nominal Size 500 mm
Bolting Type M20

3.2 DISTILLATION COLUMN (T-101)

SPECIFICATION CHEMICAL DESIGN SHEET
NAME: PUTERI FAZIRAAMIRA BINTI ISMAIL ID. NO: 2013472312
IDENTIFICATION
Item Distillation Column (T-101)
Type Plate/Tray
PURPOSE
-To separate 1,4-butanediol (BDO) from the mixture of tetrahydrofuran (THF) and
water
-To recycle unreacted 1,4-butanediol (BDO) to feed stream
COLUMN DESIGN
Tray Spacing 0.51 m
Internal Column Diameter (Dc) 2m
Area of Column (Ac) 3.14 m
Thickness of Column 5 mm
Number of Tray 30
Material of Tray and Column Carbon Steel
Bubble Temperature 134
Dew Temperature 111.8
Minimum Tray 22
Feed Location Stage 12
Efficiency Plate 74.07 %
PLATE DESIGN
Type Sieve Plate
Plate Thickness 16 mm
Total Plate Pressure Drop 88.46 mm liquid
Down Comer Area (Ad) 0.38 m2
Net Area (An) 2.77 m2
Active Area (Aa) 2.39 m2
Hole Area (Ah) 0.24 m2
No. of Hole per Plate 12159 units
WEIR DESIGN
Weir Length (Iw) 1.54 m
Weir Height (hw) 50 mm
Maximum Weir Liquid Crest (how) 57.4187 mm
Minimum Weir Liquid Crest (how) 7.4187 mm
WEEP POINT
Minimum (Uh) 6.12 m/s
Actual (Uh) 6.595 m/s
RESIDENCE TIME = 11.18 s
PERFORATED AREA = 2.10 m2

SPECIFICATION MECHANICAL DESIGN SHEET

NAME: PUTERI FAZIRAAMIRA BINTI ISMAIL ID. NO: 2013472312
PRESSURE VESSEL
Operating Pressure (Po) 4.6 bar
Design Pressure (PI) 0.5126 N/mm2
Operating Temperature 100
Design Temperature 110
Column Height 18 m
Design Stress 125 N/mm2
Tensile Strength 360 N/mm2
HEAD AND CLOSURE
Type Torispherical Head
Joint Factor (J) 1
Minimum Thickness (e) 16 mm
COLUMN WEIGHT
Dead Weight of Vessel (W v) 152.62 kN
Weight of Insulation (W i) 7.26 kN
Weight of Plate (W p) 113.11 kN
Weight of Ladder (W L) 6.48 kN
Total Weight (W t) 279.47 kN
Bending Moment (Mx) 469272 Nm
Insulation Material Mineral Wool
Insulation Thickness 50 mm
SKIRT SUPPORT
Type of Support Straight Cylindrical Skirt
Material of Construction Plain Carbon Steel
Youngs Modulus 200000 N/mm2
Bending Moment (Ms) 638.73 kN/m
Weight of Skirt 563.88 kN
Skirt Thickness (ts) 16 mm
Skirt Height (Hs) 3m
BASE RING ANCHOR BOLTS
No. of Bolt Required 12
Bolt Area (Ab) 588 mm2
Bolt Root Diameter 27.36 mm
Type M36
Base Thickness (tb) 25 mm
FLANGES DESIGN
Feed Inlet:
Nominal Size 40 mm
Bolting Type M12
Top Outlet:
Nominal Size 300 mm
Bolting Type M20
Bottom Outlet:
Nominal Size 20 mm
Bolting Type M10
Manhole:
Nominal Size 1200 mm
Bolting Type M30

3.3 DISTILLATION COLUMN (T-102)

SPECIFICATION CHEMICAL DESIGN SHEET
NAME: SITI NOR ROUDAH BT HAIRUL ANUAR ID NO: 2012462554
IDENTIFICATION
Item Distillation Column (T-102)
Type Plate/Tray
 PURPOSE
To separate the mixture of Tetrahydrofuan (THF) and Water in order to remove water
from the mixture
CHEMICAL DESIGN
Minimum reflux rate 0.8374
Reflux rate 1.1831
Actual number of stages 59 stages
Feed point location 29th stages
Plate spacing 0.50 m
Column diameter, 1.57 m
Column height, H 34 m
Liquid flow arrangement cross flow (single pass)
Number of holes (Tray) 6915 units

SPECIFICATION MECHANICAL DESIGN SHEET

NAME: SITI NOR ROUDAH BT HAIRUL ANUAR ID NO: 2012462554
PRESSURE VESSEL
Operating pressure, 2 bar
Design pressure, 0.22 N/2
Operating temperature, 403.21K
HEADS AND CLOSURE
Types Ellipsoidal head
Crown Radius, = 1.57 m
Knuckle Radius, = 6% 0.0942 m
Joint Factor, J 1
Minimum thickness head, e 2 mm
COLUMN WEIGHT
Dead weight of vessel, 92.03 kN
Weight of plate, 2.33 kN
Weight of 59 plates, 137.47 kN
Weight of insulation, 32.09kN
Total weight 261.59 kN
Wind speed, 160 km/h
Wind pressure, 1.28 x 106 kN/ 2
Bending moment, 1281.4 kN/m
3.4 HEAT EXCHANGER (HE-3)
SPECIFICATION CHEMICAL DESIGN SHEET
NAME: NUR AMALINA BINTI MOHD ASRI ID. No: 2013420168
IDENTIFICATION
Item Heat Exchanger (HE-3)
Fixed Tube - Shell and Tube Heat
Type Exchanger (1 shell pass, 2 tubes
passes)
PURPOSE: To transfer heat from one fluid to another. To reduce the
temperature of hot fluid in tube-side.
CHEMICAL DESIGN
BUNDLE AND SHELL DIAMETER CALCULATION
Bundle diameter, Db 0.1224 m
Shell clearance 0.0122 m
Shell diameter, Ds 0.1346 m
TUBE SIDE COEFFICIENT,hi
Area 3.22 m
Number of tube,Nt 8
For 2 passes, tube per pass 4
Tube cross sectional area 0.39 m
Area per pass 0.00152 m
Volumetric flow 0.0029 m3/s
Tube side velocity,ut 1.91 m/s
Re 110872.74
Jh 2.75 x 10-3
Pr 5.87
L/di 277.27
Nu 546.77
Hi 2744.66 W/m2C
SHELL SIDE COEFFICIENT,hs
Baffle spacing,IB 0.04 m
Tube pitch, pt 0.032 m
Flow area,AS 0.00112 m
Shell side equibalent 0.0187 m
diameter,de
Volumetric flow,V 0.0030 m3/s
Shell side velocity,us 2.695 m/s
Re 1022.38
jh 1.74 x 10-2
Pr 646.14
hs 1646.31 W/m2C
OVERALL HEAT TRANSFER COEFFICIENT, U0

kw= 16 W/m2C
hid =5000 W/m2C
hod =5000 W/m2C
Uo = 635.71 W/m2C
Uo assume 500 W/m2C
Percentage value 27.14%
Pressure drop
Pt = 15.37 kPa
Ps = 18.65 kPa

SPECIFICATION MECHANICAL DESIGN SHEET

NAME: NUR AMALINA BINTI MOHD ASRI ID. No: 2013420168
PRESSURE VESSEL
Shell
Design Pressure 5.5 bar
Design Temperature 102.3C
Wall Thickness 3 mm
Material of Construction Carbon Steel
Design Stress 125 N/mm2
Shell Diameter 134.6 mm
Shell Length 4880 mm
No. of Passes 1
Baffles
Baffles Diameter 133 mm
Baffle Length 100.95 mm
Baffle Spacing 40 mm
No. of Baffles 35
 Tube
Design Pressure 2.53 bar
Design Temperature 113.3C
Inner Diameter 22 mm
Outer Diameter 25.4 mm
Length 4880 mm
Design Stress 130 N/mm2
No. of Tubes 8
No. of Passes 2
HEAD AND CLOSURE
Type Torispherical Head
Joint Factor (J) 1
Minimum Thickness (e) 3 mm
Length 33.65 mm
Type Flat Closure
Joint Factor (J) 1
Minimum Thickness (e) 3 mm
Length 33.65 mm
WEIGHT
Dead Weight of Vessel (W v) 548.50 N
Weight of Tube (W t) 1589.37 N
Weight of Insulation (W i) 184.22 N
Weight of Shell Fluid (W shell fluid) 686.83 N
Weight of Tube (W tube fluid) 40.65 N
Total Weight (W t) 3049.57 N
Insulation Material Mineral Wool
Insulation Thickness 70 mm
SADDLE SUPPORT
Bolt Diameter 20
Bolt Holes 25
Max. Weight 35kN
NOZZLES
Shell Nozzle Diameter 40.90 mm
Tube Nozzle Diameter 34.42 mm
FLANGES
Type Welding Neck
Tube Bolting Type M10
Tube Flange Diameter 100 mm
Shell Bolting Type M12
Shell Flange Diameter 120 mm

3.5 COOLER (E-105)

SPECIFICATION CHEMICAL DESIGN SHEET
NAME: NUR AINUL BASYIRAH BT ABU BAKAR ID. NO: 2012240324
Parameters Value (SI unit)
Process Condition
Heat Load ,Q 16.935 kW
Overall heat transfer coefficient, U0 354.14 W/m2C
Heat Transfer Area, m2 41.59 m2
Tlm 194.78C
Tm 190.88C
Shell Side
Inlet Temperature, T1 165C
Outlet Temperature, T2 25C
Flow rate 95.04 kg/hr
Shell side velocity 0.0416 m/s
Diameter of shell 0.1313 m
Bundle Diameter 0.0963 m
Equivalent Diameter 0.0142 m
Shell Passes 2
Heat Transfer Coefficient 1263.28 W/m2C
Pressure drop 0.695 kPa
Tube Side
Inlet Temperature, t1 15C
Outlet temperature, t2 40C
Flow rate 0.1621 kg/s
Tube velocity 0.2019 m/s
Tube length 5m
Outer diameter 2010-3 m
Inner diameter 1510-3m
Birmingham Wire Gage 16 W/m2C
Tube pitch 0.025 m
Number of tubes 8 tubes
Heat transfer coefficient, 786.92 W/m2C
Pressure drop 1.485 kPa

SPECIFICATION MECHANICAL DESIGN SHEET

NAME: NUR AINUL BASYIRAH BT ABU BAKAR ID. NO: 2012240324
Parameter Specification
Design Pressure 0.77 N/mm2
Design Temperature 165C
Material of Construction Stainless Steel 316 for both shell and tube side
Design Stress 130.5 N/mm2
Minimum Thickness 5.181 mm
Type of Head Ellipsoidal Head
Total Dead Weight Load 2.424 kN

CHAPTER 4: PROCESS CONTROL & INSTRUMENTION

All processing chemical plant are subject to disturbances that can change the operating
conditions, compositions and also physical properties of the streams. Thus, chemical
plants are implemented with numerous amounts of instrumentation and automatic control
equipment in order to minimize the disturbance effects that could cause accident happen
in the future.

There are three common types of process control which are:

1. Feedforward control - A method of control based on process model: mass and energy
balances.
2. Feedback control - Outcome of an action is fed back to the controller for corrective
action.
3. Cascade control - The inner loop controller obtains its set point from the outer loop
controller.

There are several individual process variables that need to be considered in process
control which are temperture, pressure, level of liquid, flow rate, composition and flow
ratio.
INSTRUMENT AND CONTROL ELEMENTS SYMBOLS
 Table 4.1: Instrument Symbols
Symbol Description

Level Controller

Level Indicator

Pressure Gauge

Temperature Gauge

Temperature Indicator

Temperature Controller

Table 4.2: Instrument Line Symbols

Symbol Description

Carbon Steel Piping

Pneumatic Signal

Table 4.3: Control Element Symbols

Symbol Description

Pressure safety valve / Pressure relief

valve
Normally open
Manual valve
Normally close
Manual valve

Check valve

Control valve
CONTROL SYSTEM DESIGN SHEET FOR DESIGN EQUIPMENT
4.5.1 Reactor (R-101)

Figure 4.4: Control System for Reactor (R-101)

Table 4.4: Summary Control System for Reactor (R-101)

Controlled Measured variable Manipulated Disturbance Type of
variable variable Control

Feed rate to Pressure of the reactor Adjust feed rate of Variation of Feedback
the reactor vessel heat transfer reactor control
medium which is temperature
the cooling water
Level of liquid Pressure gauge is used Open valve at Reactor Feedback
in the reactor to measure the outlet stream of the over flow control
pressure of the reactor reactor to adjust
vessel. Level indicator the level of liquid in
is used to measure the the reactor and
level of liquid inside the pressure relief
reactor. valve is being
opened.
Pressure of Pressure gauge is used Pressure relief Overpressu Feedback
reactor to measure the valve is opened. re of reactor control
pressure of the reactor
vessel.

Distillation Column 1 (T-101) and Distillation Column 2 (T-102)

 Figure 4.5: Control System for Distillation Column 1 (T-101)

Figure 4.6: Control System for Distillation Column 2 (T-102)

Table 4.5: Summary Control System for Distillation Column 1 and 2 (T-101 and T-102)
Controlled Measured Manipulated variable Disturbance Type of
variable variable Control

Temperature Temperature Regulating the amount of Variation of Feedback

of the heat at the heat transfer surface pressure at the control
transfer product top exposed to contact with upper section
medium stream condensing vapor by of the column.
adjusting the flow of the
heat transfer medium of
the condenser.
Flow rate of Level of Adjusting the level of Temperature Cascade
the bottom liquid in the liquid in the reboiler by of reboiler control
product reboiler. adjusting the flow rate at supply.
stream of the bottom product
column

Heat Exchanger (HE-3) and Cooler (E-105)

Figure 4.7: Control System for Heat Exchanger 3 (HE-3)

 Figure 4.7: Control System for Cooler (E-105)

Summary Control System for Heat Exchanger (HE-3) and Cooler (E-105)
Controlled Measured Manipulated Disturbance Type of
variable variable variable Control

Temperature Temperature Flow rate of Variation of Feedback

of process indicator is heat transfer temperature control
fluid (tube- used to medium outlet process
side) measure the (Shell-side) is fluid (tube-
outlet adjusted. side)
temperature of
the tube-side
heat
exchanger
(process fluid).
CHAPTER 5: PROCESS INTEGRATION

Figure 5.5 Heat exchanger network (HEN) diagram and network for below pinch
 Table 1: Comparison of Heat Duty before and after Heat Integration
Before heat integration After heat integration Percent saving
No of heat
0 3
exchanger
Hot utility, kW 780.655 0 100%
Cold utility,
3199.177 2428.572 25%
kW
Total utility,
3979.832 2428.572 39%
kW
Cost utility,
357497 286061 20%
(USD)
Payback
2 years 1 year
period

CHAPTER 6: ENVIRONMENT, WASTE PREVENTION AND TREATMENT

Figure 6.1 show the process flow diagram of wastewater treatment for production of
tetrahydrofuran. The treatment is divided into three stages which are preliminary, primary
and secondary treatment. For preliminary and primary treatment, there are the screening
and grit removal process. The secondary treatment consists of pH adjustment tank,
oxidation tank, flocculation tank, sedimentation tank, neutralization tank and disinfection
tank.

Figure 6.1: Process Flow Diagram of Wastewater Treatment

CHAPTER 7:ECONOMIC ANALYSIS

Economic analysis is the evaluation of operating costs and capital costs that associated with
the construction and operating of chemical process. The plant for the production of
tetrahydrofuran is located at Pune, India and the plant is estimated to operate within 10
years. The plant is also expected to operate for 344 days per year due to plant shut-down for
maintenances. In this process, the raw material used to produce 60,000 metric tonnes of
tetrahydrofuran per year is 1,4 Butanediol and the catalyst used is Zirconium Sulphate.
Major equipment that involve in this process is reactor, distillation column and also cooler.
There are several steps involves in economic analysis which are purchase cost, capital cost,
cost of manufacturing and cash flow diagram.

Total Bare Module Costs, CTMB

Equipment Cost (USD) Cost (USD)

Pump 3 20858 62574
Cooler 6 835952 5015712
Reactor 1 146919 146919
Heat Exchanger 3 336031 1,008093
Tower
Distillation column 3 902819 2708457

Mixer 2 30251 60502

9,002257
Total Bare Module Cost, (CTMB)

Total Module Costs, CTM

Cost (USD)
Contingency cost 0.15CTMB 1,350338
Fees cost 0.03CTMB 270067
Total module cost (CTM = CTMB+CCont+CFee) 10,622662

Grassroots Cost, CGR

Cost Cost (USD)
Side-development cost (Cside) 0.25CTM 2,655665
Auxiliary building cost (CAux) 0.05CTM 531138
Off-site and utilities (COff) 0.2 CTM 2,124532
Cside+CAux+COff 0.5CTM 5,311331
Grassroot cost (CGRC = Cside+CAux+COff+ CTM) 15,933993

Working Capital Investment = 0.15 FCI

= (0.15) (USD 15,933993)
= USD 2390098
Total Capital Investment = Fixed Capital Investment + Working Capital Investment
= USD 15,933993 + USD 2,390098
= USD 18, 324091
Cost of Manufacturing
CRM (Raw Materials Costs) $ 168,152,116

CUT (Cost of Utilities) $ 286,061

COL (Cost of Operating Labor) $ 279,960

CWT (Cost of Waste Management) $ 520974

= 0.280() + 2.73 + 1.23( + + )

= 0.280($15,933993) + 2.73($279960) + 1.23($286061 + 520974 + $168152116)
= USD 213,045564
The total of manufacturing cost without depreciation,
= 0.180 () + 2.73 + 1.23( + + )
= 0.180 ($15933993) + 2.73($279960) + 1.23($286061 + 520974 + $168152116)
= USD 211,452165

Cost of Land $ 5,999,083

Revenue from Sales $ 140,993,514

Taxation Rate 40%

Annual Interest Rate 6.75%

Working Capital = (0.15FCI) $ 2,390098

FCI $ 15,933993

FCIL = (FCI - Cost of Land) $ 9,934910

Fixed Capital Investment of end Year 1 (50% of FCI) $7,966996

Fixed Capital Investment of end year 2 ( 50% of FCI + Working

Capital 10,357094

Economic Information

Cash Flow Diagram

Cash Flow Diagram

70.0

60.0
Project Value (millions of dollars)

50.0

40.0

30.0

20.0

10.0

0.0

-10.0

-20.0

-30.0
-1 0 1 2 3 4 5 6 7 8 9 10 11 12 13
Project Life (Years)
 CHAPTER 8: PLANT AND SAFETY LAYOUT

Cash Flow Cash Flow Cumulative Cash Flow Cumulative Cash Flow
Year Investment dk FCIL-Sdk R COMd (R-COMd-dk )*(1-t)+dk (Non-discounted) (discounted) (discounted) (Non-discounted)
0 6.00 9.93 (6.00) (6.00) (6.00) (6.00)
1 4.97 9.93 (4.97) (4.65) (10.65) (10.97)
2 7.36 9.93 (7.36) (6.46) (17.11) (18.32)
3 0.99 8.94 140.99 122.70 11.37 11.37 9.35 (7.76) (6.95)
4 0.99 7.95 140.99 122.70 11.37 11.37 8.76 1.00 4.42
5 0.99 6.95 140.99 122.70 11.37 11.37 8.20 9.20 15.80
6 0.99 5.96 140.99 122.70 11.37 11.37 7.69 16.89 27.17
7 0.99 4.97 140.99 122.70 11.37 11.37 7.20 24.09 38.54
8 0.99 3.97 140.99 122.70 11.37 11.37 6.74 30.83 49.91
9 0.99 2.98 140.99 122.70 11.37 11.37 6.32 37.15 61.29
10 0.99 1.99 140.99 122.70 11.37 11.37 5.92 43.07 72.66
11 0.99 0.99 140.99 122.70 11.37 11.37 5.54 48.61 84.03
12 0.99 - 140.99 122.70 11.37 19.76 9.02 57.64 103.80
Safety study is the most important element in preparation of chemical production plant.
Safety features in this topic including the Standard Operability Procedure (SOP) for every
critical equipment such as reactor, distillation column and heat exchanger in order to
manage the equipment. Managing equipment in a chemical production plant is very
important because incorrect way to do start-up and shut-down procedure for each equipment
can lead to damage of the equipment and even worse can cause explosion. Other than
SOP, HAZOP or Hazards and Operability Studies prepared to identify hazard in chemical
process facility. HAZOP is being create to reduce the potential accident that can happen in a
plant and to give early awareness about the possible hazard that might happened. Thus,
each personnel in the plant will be more careful in handling equipment and chemicals at the
work place area. Safety plant layout is one of the preliminary steps in building a production
plant. All the position of the office, production plant, waste water treatment plant and also
facilities that have in the production plant such as workshop must be placed nicely and
accordingly. Nice position of each element in the production plant can gives good
environment surrounding for each personnel. Despite the good environment, nice and
accordingly position in the plant can reduce damage of equipment and injuries for each
workers if any accident happen. To prevent all of the injuries that happened from the
possible accident, route for emergency response plant has been create and also the
assembly point for each workers to gather during emergency. Safety studies is very
important and cannot be treated flippantly. Neglecting the importance of safety
implementation is similar with putting yourself in danger.
Assembly
cha Point Parking

Office

Future Expansion Changing Prayer

Cafe
room Room

Control Room Toilet

Technical
Room

Production plant

Firefighting
room

Raw Workshop
Product Waste
material
storage storage
storage

Waste water treatment Laboratory Loading bay