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MANUFACTURE OF CELLULOSE ACETATE

​(Capacity-11000 tons/year)
Project report submitted in partial fulfilment of the requirements for the degree of
Bachelor of Technology in Chemical Engineering
By
K.MADHAVI
160114802308
​UNDER THE GUIDANCE OF

NLN REDDY
ASSOCIATE PROFESSOR

CHAITANYA BHARATHI INSTITUTE OF TECHNOLOGY

DEPARTMENT OF CHEMICAL ENGINERRING
( Affilated to Osmania University)
Hyderabad-500075

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PLANT LOCATION AND LAYOUT

PLANT LOCATION:
For majority of case, the primary reason for a plant location study is to find a site at
which a plant can produce highest return on investment capital. The nature of the
process of production often narrows the potential site to a relatively few possible
areas. If it is not so carefully engineered during research and development stages
can be wiped out. Optimum location, the plant may even be inoperable. Eventually
a new site must be chosen which fits all the requirements; this involves plan, strain,
and additionally expenditure of funds.
Some of the important factors that are to be considered are:
Raw material:
Probably the location of the raw material of an industry contributes more towards
the choice of plant of site than any other factor. In most chemical operation load
delivery cost of raw material. Must weigh up against other operating costs. This is
especially noticeable in those industries in which the raw materials. Is in
expansible and bulky and is more compact and obtains a high bulk value during the
process of manufacture. The supply of basic raw materials. Should be controlled
directly by user. Physical distance is not the only controlling factor in source of
raw material, for purchasing price and buying expense, base point. Procuring,
reserve stock and liability of supply are also determinants.
Market and transportation:
The existence of transportation facilities, as given to many of the greatest tract
centers of the world. A location should be chosen if possible which has several
competing railroads and road ways in order that the competition will help to
maintain low rates and give better service. Often times, a location is selected
outside the city in order to have a rail road sliding available thus eliminate trucking
cost to freight yards from expensive cost of transportation. We ensure that the
product has ready market at a chosen distance from the plant site so that the

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transportation will not become a big problem. Also we will have to see that the
project has ready market. So that there will be demand throughout the year.

Climate:
The plant site should at the place, where the climate is mild. Excessive cold, torrid
heat and excessive humidity should not be present where the plant is situated. This
will reduce the productivity part of their work man. Also extreme conditions are
present, and then AC and other facilities will increase the expenditure.
Power supply:
The chemical industries are the largest users of electric power requirement among
industries today, because the modern is for extreme flexibility, that sometimes on
the side of to many industry drives. Power for chemical industries is primarily from
coal, water and oil. These fuels supply the most flexible and economical source, as
much as they provide for generation of steam both for processing and electricity
production. The plant should establish near a hydrolic power generation project.
Water supply:
Water for industrial purposes can be obtained from one of the general sources. The
plant main source of water is municipal supply. If the demands for water is large,
is economical for the industry to supply its own water such may be obtained from
dried well, rivers, lakes and other impounded supplied. Before a company enters
upon any project, it must ensure itself of a sufficient supply of water for all
industrial, sanitary and fire demands, both present and future. Data on temperature
of water a maximum, minimum an average rainfall can be obtained from
government. Agencies, if surface water is to be impounded or the data on stream
flow of rivers can be acquired likewise. If wells are to be relied on, geologist and
practical well drillers should be consulted.
Labour:
A certain careful study of a cheap labour should be made. Factors to be considered
in labour studies are supply, kind, diversity, intelligence, wage sales, regulation,
efficiency, and cost. The success of many organizations depend upon the means by
which its labour gets to and from their work. A cheap site may have to be chosen

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but lack of attention to the housing facilities should be avoided. If the labours come
from a long distance, they will be tired by the times they come to the point. Also
technical skills should be given due to importance.

PLANT LAYOUT:
Factors in planning layout:
1. Future expansion
2. Economic distribution of service water, steam power and gas.
3. Weather conditions.
4. Safety conditions.
5. Building code requirements.
6. Waste disposal problems.
7. Sensible use of floor and elevation space.
Method of planning Lay out:​ Unit area Concept:
The basic blocks with which to build an arrangement for plot plans are often used
in the unit area concept. The method of planning is particularly well adapted to
large plant layout. Unit area are often delineated by means of distinct process
phases and operational procedures, by reason of contaminations, and safety
requirements. Thus the delineation of the shape and extend of unit area and the
interrelation of each area in a master plot plan is one of the first tasks of planning
layout.
Principles of Planning Layout: ​Storang layout
Storage facilities for few materials and intermediate and finished product may be
located in isolated areas or in adjoining areas. Hazardous materials become a
decided disturbances to life and property when stored in large quantities and should
consequently be isolated. Storage in adjoining area, to reduce materials handling
may introduce an odstacle towards future expansion of the plant. Arrange storage
of materials so as to facilitate or simply handling is above point to be considered in
design. Where it is possible to pump a single material to an elevation so that
subsequent handling can be reduced. Liquids can be stored in small containers,
barrels, horizontal or vertical tanks either indoors or outdoors.

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Equipment Layouy:
In making a layout simple space should be assigned to each piece of equipment,
accessibility is an important factor for maintenance. It is extremely poor economy
to fit the arrangement layout too closely into a building. A slightly larger that
appears will necessary coat little more than one that is covered. The extra cost will
indeed be small in comparision with the penalities that will be extracted in order to
on out kind the building must be expanded. The relative levels of several pieces of
equipment and their accessories determine their placement. Although gravity flow
is usually preferable, it is not all together necessary because liquids can be
transported by blowing pumping, solids by mechanical transportation involve the
cost of necessary eqyipment and the cost of operating and maintenance but
material should located near access area. When struts or hoists can be placed for
pulling and replaced tube bundles, space should be provided for repair and
replacement equipment such as cranes and forked truck.
Safety:
A great deal of planning is governed by local and national safety and fire code
requirements, fire protection reserivors, sprinkles in building, explosive barriers
and directional routing of explosion forces to clear areas and dikes for combustible
product storage tanks must be incorporated to protect cost by plant investment and
reduce insurance rates.
Floor spaces:
This may or may not factor in the design of the plant. The value of plant is a
considerable item. Proper consideration is given to the line flow of materials, acess
of equipment, space to permit working on parts of equipment that needed
frangment service and safety and comfort of the operation.
Utility services:
Proper placement of each of the services like waste, steam and powder etc; aids in
the case of operation order lines and reduction in costs of maintenance. No pipes
should be laid on the floor or the between the floor and the server feet level, where
the operator must pass or work.
Buildings:

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The buildings should be build around the process being made to fit buildings of
connections design. Proper design must be done for disposal of waste liquors,
fumes, dust, gases and ventilation.

PLANT LAYOUT

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PLANT ECONOMICS
Cost estimation:
S.No. Equipment Units required Cost per unit Total cost in
in Lakhs Lakhs
1 Acetylator 1 55,00,000 55,00,000

2 Distillation 1 15,00,000 15,00,000

column
3 Aging tank 1 9,00,000 9,00,000

4 Precipitation 2 8,50,000 17,00,000

tanks
5 Drier 2 6,00,000 6,00,000

6 Pumps 6 60,000 3,60,000

7 Storage tanks 6 2,50,000 15,00,000

8 Extruder 1 2,50,000 15,00,000

9 Heat 1 8,30,000 8,30,000

exchanger
10 Extractor 1 6,20,000 6,20,000

11 Wash tank 1 80,000 80,000

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12 settler 1 1,50,000 1,50,000

Total purchased equipment cost(TES) = Rs. 1,87,40,000

Assuming minor equipment cost = 10% of major equipment cost = Rs.18,74,000
Total equipment purchased = Rs. 2,06,14,000

S.No. ITEM Larger factor Amount in Rs.

1 Purchased equipment 1.0 2,06,14,000

2 Equipment Installation 0.57 1,17,49,980
3 Instrumentation and control 0.24 49,47,360
4 Piping Installation 0.31 63,90,340
5 Electrical Installation 0.21 43,28,940
6 Building Services 0.43 88,64,020
7 Site separation 0.16 32,98,240
8 Service facilities 0.55 1,13,37,700
9 Land 076 1,56,66,640

Total investment cost(TIC) : Rs. 8,71,97,220

Direct costs:
Engineering supervision 0.32 65,96,480
Construction Expenses 0.34 70,08,760
Total Direct and Indirect costs = Rs. 10,08,02,460
Other costs: contingency (10% of total costs) = Rs. 1,00,80,246

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Contraction fee (5% of total costs) = Rs. 5,04,012

Fixed capital investment(FCC): Rs. 11,13,86,718
Working Capital (WC):
S.No Material Amount in Cost in Rs./Kg Total cost/year
tons/year in Rs.

1 Wood pulp 8400 10.52 8,83,68,000

2 Acetic 14511 90 1,54,17,78,000
Anhydride
Total Raw Material Cost(RMC) = Rs. 1,54,17,78,000

Utility Cost(UC):
Power = Rs.4,00,000
Steam = Rs.2,00,000
Water = Rs.2,00,000
Total Utility Cost(US) = Rs.8,00,000
Labour &​ ​Supervision Cost:
S.No Man Power Members Salary/monthly/member Salary/year
required in Rs.
1 Plant manager 1 70,000 70,000

2 Shift manager 9 50,000 4,50,000

3 Sales executive 5 45,000 2,25,000

4 Chemical engineer 2 45,000 90,000

5 Chemist 6 40,000 2,40,000

6 Plant operator 10 30,000 3,00,000

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7 Accountant 4 30,000 3,00,000

8 Clerk 8 20,000 1,60,000

9 Watchman 7 15,000 1,05,000

10 Unskilled labors 25 8000 2,00,000

Labour and supervision cost(LSC): Rs.21,40,000

Working Capital(WC): RMC+UC+LSC = Rs.1,54,47,18,000
Total Capital Investment(TCI)=FCC+WC = Rs.165,61,04,718

ESTIMATION OF TOTAL PRODUCTION COST:

1. Manufacturing cost = direct production cost + fixed charges
DIRECT PRODUCTION COSTS(DPC):
1. Maintenance Cost(MC) = 6% of FCC = Rs.66,83,204
DPC = RMC + LSC + UC + MC = Rs.1,55,14,01,204
FIXED CHARGES(FC):
Depreciation(D) = 10% of FCC = 1,11,38,672
Local taxes(T) = 3% of FCC = 33,41,602
Insurance(I) = 1% of FCC = 11,13,868
Rent(R) = 10% of FCC = 1,11,38,672
FC = D+T+I+R = 2,67,32,814
Total manufacturing cost(TMC) = DPC+FC = Rs.157,81,34,018
2. GENERAL EXPENSES
Administration Cost(AC) = 15% of LSC = Rs. 3,21,000

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Interest Cost(IC) = 5% of TMC = Rs.7,89,06,701

GE = AC+IC = Rs.7,92,27,701
Total product cost(TPC) = TMC+GE = Rs.165,73,61,718
Annual cost(AC):
Variable cost(VC)
Mislennious material cost (MMC) = 10% of TMC = 15,78,13,402
VC = MMC+RMC+UC
= Rs.170,03,91,402
AC = TIC+VC
=Rs.178,21,88,622

Gross profit(GP):
Annual sales: Rs.250/kg
=Rs.250,00,00,000
Gross Profit = Annual sales-Total Product
= 84,26,38,282
Net Profit = Gross Profit – Taxes
= 83,92,96,680
Pay Out time(POP): TCI/NP+D
= 3 years
Rate of Return = Np/TCI*100
= 33.4%
Break Even Point = FCC/(FCC+Np)*100 = 36.6%

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SAFETY HEALTH AND ENVIRONMENT

Safety and Handling of Materials:

Safety is one of the measures to be taken in industry. The safety and
handling measures upon particular materials and process of particular industry. If
the reactions are highly corrosive in nature, then corrosive in nature, then reaction
block should be represented by corrosive block. Type of hazards presented by
chemical in corrosive block are divided into two categories:
1. Toxic and corrosive hazards.
There are hazards to human health where a chemical can come in contact
with the human body. Depending upon the chemical nature of contact the
harmful effect may be localized on the outside surface of body. Safety of
person working in chemical industry is very much important. For eye
protection UV example glasses and goggles are provided. For good
respiration, poly air mask, chemical catridges and self contained breathing
apparatus used. A wind sock is a must which shows the direction of wind
and guides te people to run opposite to it in case of major accidents.

2. Fire arising(or) involving chemicals.

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In chemical industry, majority of accidents are associated with fire only.

Fire is caused by combination of heat, oxygen and fuel. By removing any
one of below fire can be avoided.
a) Starvation – By removing fuel
b) Cooling effect – Elimination heat from spraying water.
c) Blanketing – Suppressing supply of oxygen and fire. In industries, fire
accidents are controlled by blanketing methods.
Fires are classified as 3 types
Class 1 fire: this is caused when material like cotton, wood, paper etc, catch fire.
The type of extinguisher used is called as soda type.
Class 2 fire​: this is caused by chemicals like oil, Toluene, Benzene etc. foam type
of extinguisher is used for contolling this type of fire. Usually, the extinguisher
consists of chemicals like NaHCO, and the foaming agent is animal fat. This
usually has the blanketing effect i.e., the foam spreads over chemical and thus
stops its contact with air and hence the fire is controlled.
Class 3 fire​: These are usually electric fire. When it is an electric fire, then all the
mains should be switched off. To put off such type of fires, we should use mainly
use sand and granite powder. Co​2 also be used. Hallam (a small type of
extinguisher) is used to stop the fire and thus reduces the effect of fire. Fire
accidents can be avoided in the industry if proper care is taken by people working
in the site. If they have any doubts, they should get them cleared immediately. In
this fire accidents can be avoided.
Onsite emergency plans:
Emergency plans needed to be thought by all concerned and will involve many
meetings and discussions. To effective in action, these plans need to be rehearsed.
In case of leaks/fires in different occasions, the following measures have to be
taken.
Action plan in case of leaks/minor fires:
❖ Tankers leakage inside the plant
a. Immediately close the valve or fix the security cap.
b. Operate fire extinguisher and blanket the fire.
c. Pour sand blanket on the fire.

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After the fire is distinguished, fix the security cap and cool the drum tank.
1. Minor leaks in the pipes:
a. Try to close the control valves of upstream and downstream of leaky part.
b. Depending on situation, open the line into storage vessel having low
pressure thereby reducing the pressure in the pipe lines and also reducing
the contents escaping to atmosphere.
2. Major leaking leading to fire:
a. Close the control valve on either side.
b. Surround the leak with sand filled gunny bags.
c. Fight fire and bring the same under control.
3. Action plan for electric fire:
a. Cut off power supply by pressing the emergency switch.

Safety systems recommended:

● Housekeeping to be followed. All waste materials to be disposal to separate
place.
● Work permit system to be adopted and make safe maintenance and repairs.
● Display of work procedures at each stage of work shop.
● Fire fighting systems to be improved and all concerned to be trained.
● Medical and first aid systems are to be available in all shifts.

RISK CONTROL MEASURES:

General chemical poisoning:
The three ways of chemical poisoning are:
1. Ingestion by mouth
2. Inhalation by nose
3. Penetration by skin contact.
Ingestion: The possibility in Ingestion is through contaminated food, drink,
chewing or smoking in presence of chemicals. At the work spot, no one should be
allowed to take food or drink. After working hours and also during lunch and

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dinner time in the plant, all the employees should clean their hands well before
consuming food.
Inhalation: The vapors, fumes or dust of the chemicals may enter into the lungs by
breathing. In the process of breathing, some of the chemicals may get deposited on
the kin or the nose, throat, lungs etc and cause ill health.
Skin Penetration: Chemicals can be entering the body through the skin pore spaces.
The chemicals penetrates into the skin and causes ill health like Dermatitis and
sometimes reach the blood stream and create serious health problems.
UTILITIES:
There are different types of utilites, which are essential for running a chemical
industry.
They are as follows:
1. Boiler
2. Refrigeration plant
3. Air compressor
4. Vacuum pump

Boiler:
1. Steam pressure of around 10kgf/cm​2​ is to be maintained.
2. C-grade cost can be used for the production of stream.
Refrigeration plant:
1. Brine solution is to be maintained at 10​0​C.
2. CaCl​2​ may be used as anti freezing element.
Power:
1. The transformer used is a step down transformer which steps down voltage
from 11KV to 440V.
2. Disel is used as fuel to the generators.
Vacuum pump:
1. Water ejector are used.
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2. Capacity of vacuum pump is 10HP.

DM water plant:
1. Ion exchanger is used for purification of water.
2. HCl is used as anionic exchanger and NaOH is used as cationic exchanger.

BIBLOGRAPHY:
1. Chemical Process Safety by Sanders R.E.
2. Process Engg Economics by Schweyer.
3.

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