Final Review PDF

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DESIGN OF DDT MANUFACTURING PLANT
SUBMITTED BY
K CHAITANYA MOULI SUDHANSHU KUMAR
102112032 102112063
CHEMICAL ENGINEERING CHEMICAL ENGINEERING
NIT – TRICHY NIT - TRICHY
UNDER THE GUIDANCE OF:
Dr.G.ARTHANAREESWARAN
ASSOCIATE PROFESSOR, CHEMICAL ENGINEERING
NATIONAL INSTITUTE OF TECHNOLOGY – TRICHY
DATE OF SUBMISSION: 18-04-2016

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DESIGN OF DDT MANUFACTURING PLANT
A thesis submitted in partial fulfilment of the requirements for
the award of the degree of
B.Tech
in
Chemical Engineering
By
K CHAITANYA MOULI (102112032)
SUDHANSHU KUMAR (102112063)
DEPARTMENT OF CHEMICAL ENGINEERING
NATIONAL INSTITUTE OF TECHNOLOGY
TIRUCHIRAPALLI – 620015
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BONAFIDE CERTIFICATE
This is to certify that the project titled Design of DDT Manufacturing Plant is
a bonafide record of the work done by
K CHAITANYA MOULI (102112032)
SUDHANSHU KUMAR (102112063)
in partial fulfilment of the requirements for the award of the degree of Bachelor of
Technology in Chemical Engineering of the NATIONAL INSTITUTE OF
TECHNOLOGY, TIRUCHIRAPALLI, during the year 2015 – 2016.
Dr.G.Arthanareeswaran Dr.Sivashanmugam
Project Guide Professor
Associate Professor Head of Department
Department of Chemical Engineering Department of Chemical Engineering
Project Viva-Voce held on ___________________
Internal Examiner External Examiner

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ABSTRACT
DDT, also known as (Di chloro Di phenyl Tri chloro ethane), is one of the insecticides
used for the eradication of malaria in the areas which are severely infected. Its
utilisation is increasing and due to this, several methods are being developed for
producing DDT with the best output while also taking the feasibility aspect into
consideration.
This project deals with studying the various DDT manufacturing processes and
subsequently conducting mass and energy balances, designing the required equipment
and depicting a plant layout of the best available process.
A basis of 6000 tons/year of production is taken for all the calculations, which is
annual production of DDT in India. DDT production using Monochloro Benzene is
chosen as the best alternative considering all the advantages of this process. Design of
reactor, dryer, crystalliser and filter is carried out. Safety and pollution control of this
plant is also suggested.
Thus this thesis lays the foundation to construct the plant, conduct a pilot run and
commission the plant operations.
Keywords: DDT, Chloral, Equipment design

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ACKNOWLEDMENTS
We would like to thank all the people whose valuable guidance, suggestions, and
cooperation helped us to complete the project.
We wish to express our sincere gratitude to our guide Dr.G.Arthanareeswaran,

Associate Profesor, Department of Chemical Engineering, National Institute of
Technology, Tiruchirapalli, for his invaluable knowledge, guidance and support on
this endeavour. Initial discussions about the selection of project and the way to
proceed were so helpful.
We would like to thank our Project Co-ordinator Dr.N.Samsudeen, Assistant

Professor, Department of Chemical Engineering, National Institute of Technology,
Tiruchirapalli for his kind support and guidance.
We also like to thank our Head of the Department Dr.P.Sivashanmugam, Department

of Chemical Engineering, National Institute of Technology, Tiruchirapalli, for giving
us this wonderful opportunity, which was a great learning experience and will go a
long way in shaping up our careers.
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TABLE OF CONTENTS
Title Page no.
ABSTRACT i
ACKNOWLEDGEMENT ii
TABLE OF CONTENTS iii
LIST OF TABLES vi
LIST OF FIGURES vii
LIST OF SYMBOLS viii
CHAPTER 1 INTRODUCTION
1.1 Objective of the project 1

1.2 Outline 1
1.3 History 1
CHAPTER 2 PROPERTIES AND USES
2.1 Chemical Properties 3
2.2 Physical Properties 3
2.3 Applications 3
CHAPTER 3 MANUFACTURING PROCESSES
3.1 Monochloro Benzene process 4
3.2 products - chloral 4
3.3 Flow Sheet 5

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CHAPTER 4 PROCESS SELECTION AND DESCRIPTION
4.1 Process Selection 6
4.2 Process description 6
CHAPTER 5 MATERIAL BALANCES
5.1 Basis 8
5.2 Dryer 8
5.3 Distillation column 9
5.4 Reactor 10
CHAPTER 6 ENERGY BALANCES
6.1 Dryer 11
6.2 Reactor 12
6.3 Distillation column 13
6.4 Detailed flow sheet 14
CHAPTER 7 DESIGN OF EQUIPMENT
7.1 Process Design of Distillation column 15
7.1.1 compostions 15
7.1.2 Tray Tower design 16
7.1.2.1 Column diameter 16
7.1.2.2 Plate pressure drop 20
7.1.2.3 Down commer design 21
7.1.2.4 Trail layout 22

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7.1.2.5 Perforated area 23
7.1.2.6 Number of holes 23
7.1.2.7 Plate specification 24
7.2 Design of Dryer 24
7.2.1 Mechanical design of dryer 25
7.3 Design of Reactor 28
CHAPTER 8 SAFETY AND HEALTH ASPECTS
8.1 Safety by HAZOP analysis 32
CHAPTER 9 PLANT LOCATION AND LAYOUT
9.1 Site consideration and plant layout 37
9.2 Plant layout 39
CHAPTER 10 COST ESTIMATION AND ECONOMICS
10.1 Chemical Engineering Plant Cost Index 41
10.2 Estimation of Capital Investment Cost 41
10.3 Estimation of Total Product Cost 43
10.4 Break Even Analysis 47
APPENDIX 1 REFERENCES 48

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LIST OF TABLES
8.1 Purpose of each equipment
8.2 Identification of hazards and their causes
LIST OF FIGURES
3.3 Flow Sheet
6.2 Detailed flow sheet
8.1 Node Selection
LIST OF SYMBOLS
Water input to dryer K
Moisture to be removed from dryer m
Weight of water vapour contained in saturated air at a temperature t0 of H0
entry air to the heater (ambient temperature) in kg/1000 kg
Weight of water vapour contained in saturated air at the temperature t1 of H1
exit from the dryer in kg/1000 kg\
Volume of air required in dryer V
Input to washer Z1
Input to filter A1
Amount of acetic anhydride in input to reactor B
The heat necessary to evaporate the water contained in the DDT in dryer q2
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Heat absorbed in filter Q1
Heat liberated in crystalliser Q2
Heat absorbed in reactor Q3
Diameter of crystalliser D1
Height of crystalliser H2
Diameter of impeller D2
Thickness of Impeller t2
Baffle height H3
Baffle width W1
Power Number Np
Power P
Total heat required Qt
Logarithmic temperature difference ΔTm
The amount of air required ma
Mass velocity of air Ga
Area of dryer Ad
Internal diameter of dryer Dd
External diameter of dryer Dd2
Volumetric heat transfer coefficient Ud
Volume of the dryer Vd
Length of dryer Ld
Number of flights Nd
Density of mild steel þm
Volume of mild steel Vm
Maximum bending moment M
Maximum permissible stress fm

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Section modulus Z
Thickness of dryer td
Diameter of reactor Di
Permissible shear stress in shaft fs
Stuffing box permissible shear stress ft
Design pressure of reactor Pi
Shell thickness ts
Joint Efficiency J
Corrosion allowance C
Design pressure for Jacket Pj
Thickness of Jacket tj
Diameter of Jacket dj
Head thickness dh
Knuckle diameter Dk
Averaged rated torque on agitator Tc
Maximum torque Tm
Speed of Agitator N
Equivalent Bending Moment Me
Stress due to equivalent Bending Moment f
Diameter of shaft d
Length of shaft l
Width of key b
Thickness of key tk
Length of key k
Internal diameter of stuffing box bi
Load on gland F
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Force per bolt Fb
Production quantity II Q1
Production quantity II Q2
Cost of plant with production Q1 C1
Cost of plant with production Q2 C2
Fixed Capital Investment FCI
Purchased Equipment Cost PEC
Total Capital Investment TCI
Total Product Charge TPC
Operating Labor OL
Direct Supervisory and Clerical Labor DS & CL
Maintenance and Repairs M&R
Break Even Production Rate n

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CHAPTER 1
INTRODUCTION
1.1 Objective:
To design a DDT manufacturing plant with a capacity of 6000 tonnes/yr, which
includes material and energy balances, design of equipment like reactor, dryer,
condensor, and suggestion of plant location and layout along with safety measures.
1.2 Outline:
1. DDT is an abbreviation for p,p-dichlorodiphenyltrichloroethane.
2. DDT is an insecticide used to control insect-borne diseases.
3. Dichlorodiphenyltrichloroethane is an organochlorine contact insecticide that
kills by acting as nerve poison.
4. First synthesized in 1874, DDT’s insecticidal action was discovered by the
swiss chemist Paul Hermann Muller in 1939.
5. DDT was orginally used during world war II to control typhus which was
spread by the body louse.
6. After the war DDT was made available for use as an agricultural insecticide
and its production and use duly increased.
7. Farmers used DDT on a variety of food crops worlwide. DDT was also used in
buildings for pest control.
1.4 History:
DDT is the best-known of several chlorine-containing pesticides used in the

1940s and 1950s. With pyrethrum in short supply, DDT was used extensively
during World War II by the Allies to control the insect vectors of typhus –
nearly eliminating the disease in many parts ofEurope. In the South Pacific, it
was sprayed aerially for malaria and dengue fever control with spectacular
effects. While DDT's chemical and insecticidal properties were important
factors in these victories, advances in application equipment coupled with
competent organization and sufficient manpower were also crucial to the
success of these programs.SINCE early in 1944, when insecticidal products
containing D.D.T. were first put on the market in Denmark, a great proportion
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of the available D.D.T has been used for fly control on our farms. The
commonest practice has been to spray the inside of cowsheds, pigsties, etc.,
with a water suspension or emulsion, usually containing not more than
0·05–0·1 per cent D.D.T., at the rate of about 0·1–0·2 gm. D.D.T. per sq.
metre. The spraying must be carefully done. This dosage may seem rather
small ; but in the first year or two it worked well in most places, and many
farmers were able to keep their farm buildings free from flies by spraying two
or three times a year.
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CHAPTER 2
PROPERTIES AND USES
2.1 Chemical Properties:

DDT has been conceivable form including solutions in xylene or petroleum distillates,
emulsifiable concentrates water- wettable powders, granules, aerosols, smoke candles
and charges for vaporizers and lotions.DDT is moderately to slightly toxic to
mammals.DDT is very fat soluble and is therefore found in fatty foods such as meat
and diary products.DDT is an organochlorine similar in structure to the insecticide
methoxychlor and the acaricide dicofol.The reason why DDT was so widely used was
because it is effective relatively inexpensive to manufacture and lasts for a long time
in the environment.Under simulated atmospheric conditions DDT decompose to form
carbon dioxide and hydrochloric acid. DDT is soluble in organic solvents like
Benzene, cyclohexanone, chloroform, petroleum solvents, ethanol. It is highly
insoluble in water.
2.2 Physical Properties:
DDT is colorless crystalline tasteless and almost ordorless oganochloride, with
a melting point of 108.5-109oc and its vapour pressure is 2.53 * 10^-5 pa (1.9 * 10^-7
mm HG) at 20 c.
Its acid dissociation constant is 3.5 at 25 °C (77 °F).
2.3 Applications
DDT was made available to farmers as an agricultural insecticide[9] and played a role
in the final elimination of malaria in Europe and North America. DDT was less
effective in tropical regions due to the continuous life cycle of mosquitoes and poor
infrastructure. It was not applied at all insub-Saharan Africa due to these perceived
difficulties
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CHAPTER 3
MANUFACTURING PROCESSES
3.1 Monochloro Benzene
Monochlorobenzene + Chloral → DDT + H2O
3.2 Products – chloral
The following reaction scheme provides an insight of this process. Therefore, to

prepare DDT, first we need to prepare Chloral and purify it to the highest standard.
Chloral is prepared by first forming chloral hydrate using chlorination of benzene
route. Then chloral hydrate is allowed to distill in the presence of sulphuric acid which
dessicates the chloral hydrate to chloral. Dry chlorine is first absorbed into ethanol at
room temperature conditions. In this process, the alcohol turns to a syrupy fluid. The
operation occurs in a chlorination tank which produces chloral hydrate and HCl. From
the chlorination tank, HCl is separated by using partial condenser. The uncondensible
HCl is sent for gas recovery using scrubbing. The liquid stream from the partial
condenser is sent back to the chlorinator The condensate from the chlorination tank is
sent to a still, where distillation is facilitated in the presence of sulphuric acid which
acts as a dessicant. Eventually, the still is operated at high temperature and for this
purpose, steam is used for heating purposes. To control the operation, cooling water is
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also circulated in the jacket, as chloral hydrate conversion to chloral is a sensitive

reaction.
3.3 Flow Sheet
Figure 3.3 Flow sheet

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CHAPTER 4
PROCESS SELECTION AND DESCRIPTION
3.1 Process Selection:

Advantages:
1) Relatively cheap and large scale production is viable.

2) Good yield (around 95%).
3) Easy extraction of DDT after the reaction by crystallisation.
3.2 Process Description:
● DDT is produced by a reaction between monochlorobenzene and chloral in the

presence of Oleum as catalyst.
● Monochlorobenzene + Chloral → DDT + H2O
● Therefore, to prepare DDT, first we need to prepare Chloral and purify it to
the highest standard.
● Chloral is prepared by first forming chloral hydrate using chlorination of
benzene route.
● The reaction for chloral is presented as
● 4 Cl2 + C2H 5OH + H2O → Cl2 CCH(OH)2+ 5 HCl
● Then chloral hydrate is allowed to distill in the presence of sulphuric acid
which dessicates the chloral hydrate to chloral.
● In the process technology, we first discuss the process technology of chloral
which is an important ingredient.
● Dry chlorine is first absorbed into ethanol at room temperature conditions. In
this process, the alcohol turns to a syrupy fluid. The operation occurs in a
chlorination tank which produces chloral hydrate and HCl.
● From the chlorination tank, HCl is separated by using partial condenser. The
uncondensible HCl is sent for gas recovery using scrubbing. The liquid stream
from the partial condenser is sent back to the chlorinator.
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● The condensate from the chlorination tank is sent to a still, where distillation
is facilitated in the presence of sulphuric acid which acts as a dessicant.
Eventually, the still is operated at high temperature and for this purpose, steam
is used for heating purposes. To control the operation, cooling water is also
circulated in the jacket, as chloral hydrate conversion to chloral is a sensitive
reaction.
● After the reaction, the batch still produces the waste acid as a product at the
bottom and the clear chloral liquid at the top along with the vent gases.
● Eventually chloral is treated with lime to remove dissolved acidic impurities.
● The purified crude chloral is further sent to distillation in another still to
remove chloral hydrates present in the stream. Therefore the second distillation
unit is also operated in the presence of H2SO4 . Vapors released during this
step (from the partial condenser) are sent to the vent scrubber.
● Eventually, chloral is produced from the distillation unit and chloral hydrate is
recycled back to the chloral hydrate converter to chloral.
● To manufacture DDT, purified chloral, monochlorobenzene, oleum are
allowed to enter the DDT condensation unit.
● After condensation, the organic layer and spent acid are withdrawn. The
organic layer consists of DDT and monochlorobenzene. This is first
neutralized with soda ash.
● After reaction, the organic layer is sent to a dryer where the vapors generated
from dryer enter a total condenser followed with gravity settling separator. The
gravity settling unit separates monochlorobenzene from other organic
impurities. The monochlorobenzene is recycled back to the condensation unit
that is meant for preparing the DDT.
● The Dryer produces DDT powder which is sent for casting/pelletization
process to obtain the DDT in either flakes or in pellets for sale.
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CHAPTER 5
MATERIAL BALANCES
5.1 Basis: Annual Production :

6000 tons/year = (6000*1000) /(365*24)
= 684.9 kg/hr
Basis : 1hr
1 hr of operation is used for calculations.
5.2 Dryer:
With a dryer, the moisture content may be reduced to between 0.2 and 0.5%.
Drying by contact with hot air involves heating the air, to increase the capacity for
absorbing water and bringing it into intimate contact with the DDT from which it
evaporates the moisture.
Assume that the final moisture content is 0.2%.
Weight of output is 684.9 kg as calculated before.
Therefore final sugar produced = 684.9 * (1 – 0.002) = 683.5275 kg
moisture content in the final product is 684.9 - 683.5275 = 1.3725 kg
Assume mositure to be removed is 98%
Thus moisture to be removed = 68.625 kg
There are two possible methods of circulation of air and sugar.
i.e. parallel flow and countercurrent flow.
For safety, the calculation is based on most unfavourable condition, i.e. it is assumed
that
the ambient air is saturated. On the other hand, the air leaving a dryer is generally not
saturated; it is assumed that in case of countercurrent flow, it has absorbed only
twothirds
of the quantity of water that it could have absorbed if it had left in a saturated
condition.
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We have then, in the case of countercurrent condition,

A = (100 × m) ÷ {(2 ÷ 3) × (H1 – H0)} = (1500 × m) ÷ (H1 – H0)
Where A – weight of air to be passed through dryer (kg/hr)
m – moisture to be removed (kg/hr)
H0 – weight of water vapour contained in saturated air at a temperature t0 of entry
air to the heater (ambient temperature) in kg/1000 kg
Taking ambient temperature as 30oC.
H0 = 26 kg water/1000 kg saturated air
H1 – weight of water vapour contained in saturated air at the temperature t1 of exit
From the dryer in kg/1000 kg
The temperature of air leaving the dryer is in between the 45 – 52oC.
Assuming it as 50oC.
H1 = 85 kg water/1000 kg saturated air
Therefore A = (1500 × 68.625) ÷ (85 – 26) = 1709.739 kg
Thus weight of air to be passed through the dryer = A = 1709.739 kg
Hence volume of air required = V = A ÷ (a0 + e0)
a0 = density of air at t0 = 1.12 kg/m3
e0 = weight of vapour contained in saturated air at t0 = 0.03 kg/m3
Therefore V = 1709.739 ÷ (1.12 + 0.03) = 1486.72 m3/hr
5.3 Distillation :
From the information collected we take 85% of feed is distilled out
and from the calculations done in the reactors material balance we get that chloral
content is 315.72 kg
suppose distillate be D , feed be F , residue be W
Assume Xd as 0.95
0.95*D = 315.72 kg
D = 332.33 kg
0.85*F = 332.33
F = 390.984 kg
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from equation F = D + W , W=F-D

W = 390.984 - 332.33 = 58.654 kg
from this we can deduce that in distillate 0.95*D is chloral ie 315.72 kg
and remaining is chloralhydrate ie 16.61 kg
and in residue 0.05 is chloralhydrate ie 2.93 kg and remaining is water ie 55.72 kg
5.4 Reactor:
To manufacture DDT, purified chloral, monochlorobenzene, oleum are allowed to
enter the DDT condensation unit.
Assume there is 90 % conversion in the reactor so using the chemical reaction we can
get the materials mass used in the reactor.
2C6H5Cl + C2HCl3O → C14H9Cl5 + H2O

Molecular weight of DDT is 354.49 g . So gmole of DDT produced is
683.5275/354.49 = 1.928 kmol.
Molecular weight of monochlorobenzene is 112.56 g
weight of monochlorobenzene required is 1.928*112.56*2 = 434.033 kg
as there is only 90 % conversion so actual mass of monochlorobenzene = 434.033/0.9
= 482.254 kg
Molecular weight of chloral is 147.38 g
weight of chloral required is 147.38 * 1.928 = 284.158 kg
again here considering 90 % conversion actual mass of chloral entering the reactor is
284.158/0.9 = 315.72 kg
Here soda ash is used for neutralization of DDT Assuming the moles of soda ash used
is 1.6 kmol ie 170 kg
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CHAPTER 6
ENERGY BALANCES
6.1 Dryer:
DRYER
To calculate the heating surface of air heater:
The air heater generally consists of tubes, which are supplied with steam at about 5
kg/cm2. The condensate leaves at bottom.
The heating surface of this small heat exchanger will be given by
A = Q ÷ [U × {T – (t1 + t0)/2}]
Where A – heating surface of air heater (m2)
Q – quantity of heat to be transmitted in kcal/hr
U – heat transfer coefficient in kcal/(m2hroC)
T – temperature of saturated steam employed in o C.
t0 – temperature of cold air entering = 30oC
t1 – temperature of hot air leaving = 50oC
Assume steam is available at 5 kg/cm2 i.e. 490.5 kPa
Therefore T = 152oC (from steam table)
U = 10 kcal/(m2hroC)
The quantity of heat Q to be transferred is calculated from the fact that it consists of
three
principle terms.
(I) The heat necessary to heat the weight of air is given by
q1 = M × C × (t1 – t0)
M = amount of air entering = 1709.739 kg/hr
C = specific heat of air = 0.24 kcal/kgoK
Therefore q1 = 1709.734 × 0.24 × (50 – 30) = 8206.74 kcal/hr
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(II) The heat necessary to evaporate the water contained in the sugar is given by
q2 = m × [607 + 0.3 × t1 – t0]
m = amount of water evaporated = 67.24 kg/hr
Thus q2 =
67.24 × [607 + 0.3 × 50 – 30]
= 41224.09 kcal/hr
The quantity q2 of heat correspond to that given up by the hot air between T| reached
at
the outlet from the air heater and t1, which has not been included in q1.
(III) The heat necessary to heat the vapour contained in the weight M of air, assumed
saturated is given by
q3 = M × H0 × C| × (t1 – t0)
C | = specific heat of vapour = 0.475 kcal/kgoK
H0 = it is expressed as kg of water per kg of air = 0.026
Therefore q3 = 1709.739 × 0.026 × 0.475 × (50 – 30)
= 422.305 kcal/hr
The heat lost to ambient air is taken into account by writing the expression for Q as
follows:
Q = 1.25 × (q1 + q2 + q3)
= 1.25 × (8206.74 + 41224.09 + 422.305)
= 62316.434 kcal/hr
Therefore heating surface of heat exchanger will be
A = 62316.434 ÷ [10 × {152 – (30 + 50)/2}]
= 55.63 m2
The steam consumption will be
ms = Q ÷ L
L = latent heat of steam used = 500 kcal/kg
ms = steam consumption for air heater (kg/hr)
Therefore ms = 62316.434 ÷ 500 = 124.6 kg/hr
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6.2 Reactor :
In the reactor the heat of reaction is calculated by using the below equation
ΔH = ΔHPRODUCTS - ΔHREACTANTS
The reactor temperature is assumed as 400oc. Reference temperature is taken as 0oc .
ΔHPRODUCTS = HDDT + HMCB
HDDT = M*CP*(T1 - T2)
Specific heat capacity of DDT in vapor is 0.19 cal/g
= 683.5275*1000*0.19*400 = 519408090 cal
HMCB = M*CP*(T1 - T2)
Specific heat capacity of monochlorobenzene in vapor is 0.215 cal/g
= 48.25*1000*0.215*400 = 4149500 cal
ΔHREACTANTS = HMCB + HCHLORAL
HMCB = M*CP*(T1 - T2)
Specific heat capacity of monochlorobenzene in liquid is 0.311 cal/g
= 482.254*1000*0.311*400 = 59992397.6 cal
HCHLORAL = M*CP*(T1 - T2)
Specific heat capacity of chloral in liquid is 0.47 cal/g
= 315.72*1000*0.47*400 = 59355360 cal
ΔH = ΔHPRODUCTS - ΔHREACTANTS
ΔH= 56097590 - 119347757.6 = -63250.1 kcal
6.3 Distillation:
The temperature assumed in distillation column is 95oc.

let the reference temperature be 0oc
Feed is saturated liquid.
Feed contains chloral hydrate
Specific heat of chloral hydrate in liquid is 0.753 cal/g
HF =
M*CP*(T1 -
T2)
HF = 390.984*1000*0.753*95 = 27969040.44 cal

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This is enthalpy of feed stream.

HD = M1*CP1*(T1 - T2) + M2*CP2*(T1 - T2)
Distillate contains chloral hydrate and chloral.
Specific heat of chloral in liquid is 0.47 cal/g
HD = 315.72*1000*0.47*95 + 16.61*1000*0.753*95 = 15285094.35 cal
This is enthalpy of distillate stream.
HW = M1*CP1*(T1 - T2) + M2*CP2*(T1 - T2)

Residue contains water and chloral hydrate.
Specific heat of water in liquid is 1 cal/g
HW = 2.93*1000*0.753*95 + 55.7223*1000*1*95 = 5503216.05 cal
6.5 Detailed flow sheet:

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Figure 6.2 Detailed flow sheet
CHAPTER 7
DESIGN OF EQUIPMENTS
7.1 Process design of distillation column:
7.1.1 compositions
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Composition of feed
Feed flow rate = 2.363 Kmol/hr
Composition of Distillate
Chloral = 2.14 kmol/hr
Chloral hydrate = 0.1 kmol/hr
Composition of Residue
Chloral hydrate = 0.177 kmol/hr
water = 3.095 kmol/hr
Using Material Balance
from equation F=D+W ,
W=F-D
W = 390.984 - 332.33 = 58.654 kg
the tower is designed as binary distillation column
Minimum Reflux ratio (Rm) = 0.87
Operating Reflux ratio (Ropt) = 1.305
L = D*Ropt
= 332.33*1.305
= 433.6 Kmol/hr
G =L+D
= 433.6 + 332.33
= 766.02 Kmol/hr
L = L + qF
= 766.02 + 2.363
= 768.38 Kmol/hr
G = G + (q -1)F
= 766.02 Kmol/hr
Molecular weight of feed = 165.4 kg/kmol
7.1.2 Tray tower design

From Mccabe-Thiele diagram
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Number of stages = 11
Assume column efficiency= 50%
(11−1)
Number of real stages = 0.5
= 20
Plate spacing = 900 mm
Hole diameter =5 mm
Hole pitch =15 mm
Tray thickness =3 mm
7.1.2.1 Column Diameter

ρV
L
FLG top = G
√ ρL
L = liquid mass ow-rate, kg/s,

G = vapor mass ow-rate, kg/s.
√
106606.082 841.5
= 188301.129 3.195
= 0.035
ρV
√
L
FLG bottom = G ρL
L = liquid mass ow-rate, kg/s,
G = vapor mass ow-rate, kg/s.
= 311920.077
221770.027 √ 826
3.34
= 0.0894
From Figure 11.27 in Coulson&Richardson (K1 vs FLG graph using plate spacing as
parameter)
Top K1 = 0.12

Base K1 = 0.11
(K1 is
a constant used to find flooding velocity)
Corrections for surface tensions
σ 0.2
Top K1 = K 1 [ 0.02 ]
0.2
= 0.12[ 0.01729
0.02
]
30
= 0.1165
σ 0.2
Base K1 = K 1 [ 0.02 ]
0.2
= 0.11[ 0.0175
0.02
]
= 0.0976
ρL −ρV
Top uf = K 1 √ ρV
uf = ooding vapor velocity, m/s
√
841.5−3.195
= 0.1165 3.195
= 1.682 m/s
ρL −ρV
Bottom uf = K 1 √ ρV
√
826−3.34
= 0.0976 3.34
= 1.386 m/s
Design for 85 percent ooding at maximum ow rate base
Top uˆv = 0.85* uf
= 0.85*1.682
= 1.4297 m/s
Base uˆv = 0.85* uf
= 0.85*1.386
= 1.1526 m/s
Maximum volumetric ow-rate
G*M ol wt
Base = ρV *3600
1469.61*150.904
= 3.34*3600
= 18.44 m3/s
G*M ol wt
Top = ρV *3600
1469.61*128.130
= 3.195*3600
= 16.37 m3/s
Net area required
M ax volumetric f low rate base
Bottom = Base uˆv .
18.44
= 1.1526
= 15.99 m2
31
M ax volumetric f low rate top

Top = top uˆv .
16.37
= 1.4297
= 11.45 m2
Column diameter
√
bottom area*4
Base = π
√
15.99*4
= π
= 4.512 m
√
top area*4
Top = π
√
11.45*4
= π
= 3.818 m
Use same diameter above and below feed, reducing the perforated area for plates
above the feed.
Assume single pass plate to be used
Provisional plate design
Column diameter Dc = 4.512 m
Column area Ac = 15.99 m2
Downcomer area Ad = 0.12* Ac
= 0.12*15.99
= 1.9188 m2 at 12% percent
Net area An = Ac - Ad
= 15.99 – 1.9188
= 14.0712 m2
Active area Aa = Ac - 2Ad
= 15.99 – 2*1.9188
= 12.1524
Hole area Ah = 10% of Active area Aa
= 0.1*12.1524
= 1.21524
Weir length lw = 0.76*4.512
32
= 3.42912 m2
Assume weir height hw = 50 mm
Check weeping
L*M ol wt
Maximum liquid rate = 3600
2067.01*150.904
Lw = 3600
= 86.64 kg/s
At 70 per cent turn-down
Minimum liquid rate = 0.7* Maximum liquid rate
= 0.7*86.64
= 60.648 kg/s
2
Maximum how = 750[ ρLwlw ] 3
L
Lw = liquid flow rate, kg/s

lw = weir length, m
how = weir crest, mm liquid
2
= 750[ 82686.64
3.42912
]3
*
= 73.35 mm
2
Minimum how = 750[ ρLwlw ] 3
L
2
= 750[ 82660.648
3.42912
]3
*
= 57.831 mm
at minimum rate hw + how = 50 + 57.831
= 107.831 mm
From Figure 11.30 in Coulson & Richardson
K2 = 31.2
Where K2 is a constant dependent on the depth of clear liquid on the plate obtained
from Figure 11.30.
The minimum design vapor velocity is given by
[K 2 −0.90(25.4−dh )]
ǔh (min) = (ρV )0.5
ǔh is the minimum vapour velocity through the holes(based on the hole area), m/s
dh = hole diameter
33
[31.2−0.90(25.4−5)]
=
(3.34)0.5
= 7.025 m/s
M inimum vapor rate
Actual minimum vapor velocity = Ah
0.7*18.44
= 1.21524
= 10.622 m/s
So minimum operating rate will be well above weep point.
7.1.2.2 Plate pressure drop

Dry plate drop
Maximum vapor velocity through holes
uˆh = M aximum vapor f low rate
Ah
18.44
= 1.21524
= 15.173 m/s
3
For (plate thickness/hole diameter)= 5
Ah Ah
≅
Ap Aa
= 0.1
From fig 11.34 in Coulson & Richardson

C0 = 0.74
where the orice coefcient C0 is a function of the plate thickness, hole diameter, and
the hole to perforated area ratio.
u 2 ρV
hd = 51[ Cho ] ρL
2 3.34
= 51[ 15.173
0.74
] 826
= 86.699 mm liquid
Residual head
12500
hr = ρL
12500
= 826
= 15.133 mm liquid
Total pressure drop
ht = hd +
(hw+how) + hr
= 86.699 + (50+73.35) +15.133

= 225.182 mm
34
7.1.2.3 Downcomer design

Downcomer pressure loss
Take hap = hw - 10
= 50 – 10
= 40 mm
Where hap is height of the bottom edge of the apron above the plate
Area under apron Aap = hap lw
Where Aap is
the clearance area under the downcomer
= 0.04*3.42912
= 0.1371 m2
As this is less than Ad use
Aap in
the below equation for the head loss in the
downcomer
L 2
hdc = 166 [ ρ wd
Am
]
L
hdc is
the head loss in the downcomer, mm
Lwd is liquid ow rate in downcomer, kg/s
Am is either the downcomer area Ad or the clearance area under the downcomer Aap;
whichever is the smaller, m2
2
= 166 [ 82686.64
0.1371
]
*
= 97.165 mm
Downcomer backup is given by
hb = hdc + (hw+how) + ht
hb is downcomer back-up, measured from plate surface, mm,
hdc is head loss in the downcomer, mm.
= 97.165 + (50 + 73.35) + 225.182
= 445.697 mm
If hdc< 0.5*(plate spacing + weir height)
Then only the plate spacing assumed is acceptable
= 0.44569 < 0.5*(0.9 + 0.05)
= 0.44569 < 0.475
So plate spacing is acceptable
35
Check residence time

Ad hb ρL
tr = Lwd
tr = Residence time

1.9188*0.44569*826
= 86.64
= 8.153 s
As tr > 3 s (Satisfactory)
Check entrainment
M aximum vapor f low rate
uv = An
18.44
= 14.0712
= 1.3105 m/s
uv
Percent flooding = uf
1.3105
= 1.356
= 0.966
FLG bottom = 0.0894
From figure 11.29 in Coulson & Richardson
Entrainment value ψ = 0.087 (< 0.1)
As the per cent ooding is well above the design gure of 85, the column diameter
could be increased, but this would decrease the pressure drop.
7.1.2.4 Trial layout

Use cartridge-type construction. Allow 50 mm unperforated strip round plate edge; 50
mm wide calming zones
7.1.2.5 Perforated area

lw 3.42912
From Figure 11.32 in CR-6, at Dc
= 4.518
= 0.76
ϴc = 990
angle subtended by the edge of the plate
= 1800 - 990
= 810
36
(4.518−0.05) 81
mean length, unperforated edge strips = 1 *π* 180
= 6.316 m
area of unperforated edge strips = 0.05*6.316
= 0.3158 m2
mean length of calming zone, approx. = weir length + width of unperforated strip
= 3.42912 + 0.05
= 3.47912 m
area of calming zones = 2*(3.47912*0.05)
= 0.34791 m2
total area for perforations, Ap = Aa - area of unperforated edge strips - area of calming
zones
= 12.1524 – 0.3158 – 0.34791
= 11.4886 m2
Ah 1.21524
Ap
= 11.4886
= 0.105
lP
Figure 11.33 in CR-6 dh
= 2.9; satisfactory, within 2.5 to 4.0
7.1.2.6 Number of holes

Area of one hole = 1.964*10-5 m2
1.21524
Number of holes = 1.964*10−5
= 61875
7.1.2.7 Plate specification

Plate No = 1
Turn-down = 70 percent max rate
Plate I.D = 4.518 m
Plate material = Mild steel
Hole size = 5 mm
37
Downcomer material = Mild steel

Hole pitch = 15 mm
Plate spacing = 0.9 m
Plate thickness = 3 mm
Active holes = 1935
Plate pressure drop = 225.182 mm liquid
7.2 Design of Dryer:
Drying rate = 4.81 kg/m2 hr
Heat required raising product to discharge temperature = 3.66 x 184.05 x (80-25)
= 37049.265 kJ/ hr
Heat required for removing water = 3.1 x (4.187 x (80-25) + 125.4)
= 1102.6 kJ/ hr
Hence Total heat required (Qt) = 37049.265 + 1102.6
= 38151.865 kJ/ hr
(150−80) – (85−25)
Logarithmic temperature difference, ΔTm = ln (70 ÷60)
= 64.87 o C
The amount of air required, ma = Qt ÷

(Cpa x ΔTa)
38151.865
= (1.013 x (150 – 85))
= 579.42 kg/hr
Let the mass flow per hour (mass velocity) of air be Ga = 200 kg/m2 hr
Hence Area of dryer, Ad = ma ÷ Ga
= 579.42 ÷ 200
38
= 2.90 m2
Therefore Diameter of dryer, Dd = √(2.90 x 4)÷π

= 1.922 m
Volumetric heat transfer coefficient, Ud = (244.7 x Ga0.16) ÷ Dd
= (244.7 x 2000.16) ÷ 1.922
= 297.2 kJ/ hrm3oC
Volume of the dryer Vd = Qt ÷ (Ud x ΔTm)
38151.865
= (297.2 x 64.87)
= 42.08 m3
Therefore length of dryer, Ld = (4 x Vd) ÷ (π x Dd2)
= (4 x 42.08) ÷ (π x 1.9222)
= 14.5 m
7.2.1 Mechanical Design of dryer
1. Flight Design:
Number of flights Nd = 3 x Dd (in feet)
= 3 x 1.922 x 3.2808
= 18.92
Hence 19 flights are used.
Radial height = Dd ÷ 8
= 1.922 ÷ 8
= 0.24025
2. Thickness of dryer:
Let td be the thickness of dryer. Mild steel can be used as material of construction to
withstand temperature up to 200 o C.
39
Density of mild steel þm = 7688.86 kg/m3

Dd2 – Dd = td
Volume of mild steel Vm = ((π x Dd22/4) – (π x Dd2/4)) x L
= π x Dd x Ld x td
Weight of dryer = π x 1.922 x 14.5 x td x 7688.86
= 673183.1 x td
Assume hold up 0.2
Volume of material in dryer = (π x Dd2 x Ld x 0.2) ÷ 4
= (π x 1.9222 x 14.5 x 0.2) ÷ 4
= 8.414 m3
Average density earlier calculated was 1040 kg/m3
Hence Weight of material = 8.414 x 1040
= 8750.56 kg
Maximum bending moment M = (W x Ld) ÷ 8
= ((673183.1td + 8750.5) x 14.5) ÷ 8
= 1220144.37td + 15860.28
Bending moment M = fm x Z
Where fm is maximum permissible stress and Z is section modulus.
Z = π x (Dd24 – Dd4) ÷ (32 x Dd2)
= 0.785td3 + 12.59td2 + 67.31td
fm = 17576.7 kg/m2
Hence 1220144.37td + 15860.28 = 17576.7 x (0.785td3 + 12.59td2 + 67.31td)
Solving we get td = 35 mm
Thickness of dryer = 35 mm
3. BHP to drive the dryer:
(nd x ((4.75 x Dd x W ) + (0.1925 D x W ) + (0.33 x W )))
BHP = 100000
nd = 3 rpm
W = (673183.1 x 0.035) + 8750.5
= 32311.91 kg
Dd = 1.922 m = 6.3058 ft
D = Dd + 2
40
= 6.3058 + 2
= 8.3058 ft
(3 x ((4.75 x 6.3058 x 32311.91) + (0.1925 x 8.3058 x 32311.91) + (0.33 x 32311.91)))
BHP = 100000
= 30.904 BHP
4. Horse power of Blower:

Atmospheric air temperature = 30 o C
Humidity = 0.002 kg water/ kg dry air
Quantity of air handled = 579.42 kg/hr
= 9.657 kg/min
Volume of air = (9.657 x 22.4 x 303) ÷ (29 x 298)
= 7.584 m3/ min
= 267.83 ft3/ min
Horse power = (0.000157 x Q1 x developed head

in inch)
= (0.00157 x 267.83 x 10)
= 4.205 hp
5. Diameter of inlet and outlet

At inlet temperature 150 o C, volume of air handled = (7.584 x 423) ÷ 303
= 10.587 m3/ min
= 0.176 m3/ s
Assume air velocity = 10 m/s
Cross sectional area of pipe = 0.176/10
= 0.0176 m2

Diameter of inlet pipe = ((0.0176 x 4) ÷ π) 0.5
= 0.15 m
41
At outlet conditions, volume of air = (7.584 x 358) ÷ 303
= 8.96 m3/ min
= 0.15 m3/ s
Cross section of outlet pipe = 0.015 m2

Diameter of outlet pipe = ((0.015 x 4) ÷ π) 0.5
= 0.138 m
7.3 Design of Reactor:
Hot fluid enters at 380.12 K and leaves at 380.12 K

Cold fluid enters at 298 K and leaves at 313 K.
(Vapor) F
F = 1.928 Kg/s (liq.)
Cooling
Condensation occurs at isothermal condition, correction factor Ft =1.
Assume feed is saturated vapor at 380.12 K
λ =Latent Heat =324.86 KJ/Kg
Vapor flow rate = 1.928 Kg/s
Heat load =mλ=1.928 x 324.86=367 x 103 J\sec
Properties are evaluated for cold fluid water
μ = Viscosity = 1 CP
ρ = Density = 1000 kg/m3.
cp = Heat capacity =4.187 KJ/kg K
k = 0.578 W/m K
Using this,
Mass of process water required = 5.849 kg/s.
The range of U for organic solvent and water is (289.3 to 567.8 w\m2k )
Assuming counter current operation ΔTln = 74.36
42
Assuming U heat transfer coefficient = 300 W/m2K

A = Q /U (ΔTln) = ( 367.38x103 )\300x74.36 =16.468 m2.
Assuming length of pipe to be 10 ft. and we take 3/4 inch O.D.,16 BWG tube,
I.D. of tube = 0.01574 m
External area = 0.05987 m2\m
Nt =16.468 \ 0.05487 x 3.048 = 90.19
From Perry for 1-4 TEMA P or S for 3/4 inch OD on 15/16 inch Triangular pitch
Nt = 106 for Shell diameter = 0.337 m.
So corrected area = 19.34 m2.
Corrected U = 254.59 W/m2K
Flow area = 3.14/4 x 0.015742 = 194.7 x 10-6 m 2 /tube.
at = 106 x 194.7 x10-6 /4 = 5.156 x 10-9 m 2 /pass
Gt = 5.589/5.156 x 10-9 = 1134.20 kg/m 2 s
velocity =1134.2/1000
=1.134 m\sec
Therefore the velocity is above the minimum value.
Tube side heat transfer coefficient:
Prandtl number ( NPr ) = (cp μ)\k = 7.24
Reynolds’s number ( NRe) =(Divρ)\μ = 17858.23
For turbulent conditions Dittus Boelter equation.
hi de/k = 0.023 ( NRe )0.8 ( NPr )0.33
hi = 4091.04 W/m2K
FILM TRANSFER COEFFICIENT
Shell side – Distillate

Temp. of wall= 69.75 deg C
Film temp. = 88.375 deg C or 361.37 K
Property of condensing vapor at this temp.
ρ = 1050 kg/m3
k = 0.115 W/mK
μ = 0.0004 Pas.
43
Cp= 1.549 KJ/kg K

Reynold’s number ( NRe ) = (4 x Mass flow rate of condensate)/ (μ x Nt2/3 x Length
of the tube)
= 168.97

hs = 1.151 [ ]1/3 [NRe ] -1/3
hs =1279.27 W/m2K
the dirt factor = 5.283x10-4 W/m2K
Overall heat transfer cofficient :
1\U = (Do\Di) x 1\hi + 1\ hs + 5.283x10-4
U = 622.79 W/m2K
Calculated U = 622.79 W/m2K assuming U= 300 W/m2K
∴ Design is okay.
PRESSURE DROP CALCULATION
TUBE SIDE
NRe = 17858.23
f = 0.079 ( NRe )-1/4 = 6.833 x 10-3
H = (4 x f x v2 x L )\(2gD)
= 03.378
P = ρgH
= 3.378 kN\ m2
ΔP = (2.5ρ v2)\2
=1.596 kN\ m2
ΔP Total = 4(1.596+3.378)
=19.896 kN\ m2
which is very less than permissible, therefore design is okay
SHELL SIDE
TVapour =380.12 K
δm = (p1- D)ls Ds \ p1
44
here ,
p1 = pitch =23.81 mm
ls = 0.89 Ds = 300 mm
Ds = shell diameter = 337 mm
δm =0.021 m2
PRESSURE DROP CALCULATION
End zones Δpe ,two end zones.

Cross flow zones Δpc ,( Nb –1) cross
Window zones Δpw , Nb zones
Δpc =b fk w2 Nc (μw\ μb)
b = 5 x 10-4
w = 1.13 Kg\s
δm = 0.021 m2
Nc = Ds (1 –2(lc\ Ds) )\ Pp
Pp = (1.732\2) p1 mm
= 20.61 mm
lc = 30% of shell dia.
Nc = 6.54
Δpc = 13.1 KN\ m2
Δpw = ( b x ( W)2 (2 +0.6 x Ncw ) )\ (Sw x δm xρ )
Ncw = 0.8 lc \ Pp
= 3.92
Sw = Swg - Swt
Swg = 0.0258 m2
Swt = ( (Nt) ( 1 - Fc )ΠD02)\8
Swt = 4.22 x 10-3 m2
Δpw = 3.57 KN\m2
Δpe = Δpc x 2
= 13.1 x 2
= 26.2 KN\ m2
45
Total pressure drop = 0 +3.57 +26.2

= 29.77 KN\m2
But actual pressure is 40% of this = 11.908 KN\m2
As 11.908 < 14 , so the design is okay.
CHAPTER 8
SAFETY AND HEALTH ASPECTS
8.1 Safety by HAZOP analysis:
A HAZOP is organized by dividing the unit to be analyzed into nodes. A node

represents a section of the process where a significant process change takes place.
46
Steps involved in HAZOP are as follows:
Step 1 : node selection
Node Name Purpose

number
1 Chlorinator tank This tank is supplied by the chlorine and ethyl alchohal
which is converted into chloral hydrate
47
2 Distillation column It is used for the conversion of chloral hydrate into

chloral
3 Chlorinator separator This section is used for the separation of chloral from
waste acid
4 Reactor Used for the conversion of mono chloro benzene and

chloral into DDT
5 Dryer This is used for separation of DDT from sulphuric acid

and others
Step 2: Process Guideword
● Flow Rate
● Pressure
● Temperature
● Level
● Composition
48
Step 3: Identification of hazards and their causes
Table 8.2 - Identification of hazards and their causes
Node Process Guideword Causes Consequences

Variable
1 Flow No Blockage in Decrease in
line, no raw production rate
materials in
storage, feed
pipe rupture,
supply pipe
rupture
More of More amount Reduction of
of opening of reaction
water feed temperature,
valve improper
reaction
Less of Less amount of Increased
opening of temperature,
valve explosion
Temperature Low Cooling water No product
valve obtained due to
malfunction improper
conditions
High Insufficient Runaway
cooling function,
operation catalyst is
destructed
2 Temperature Low Cooling water Crystallization
valve of undesired
malfunction products
49
High Insufficient Required

cooling temperature for
operation crystallization
not available
3 Flow rate No Blockage in No filtration
line, feed pipe
rupture
More of More amount Excessive
of opening of increase in flow
valve rate of feed
which decreases
efficiency of
filter
4 Flow No Blockage in No cleaning of
line, washing impurities
water pipe
rupture
More of More amount Excess moisture
of opening of retained by
valve crystals
Less of Less amount of Improper
opening of cleaning, solid
valve wastes retained
by crystals
5 Flow No Pipe blockage, Operating loss
pump failure
Composition As well as Contaminants Product
entering contamination
50
Step 4: Identification of Safeguards:
1. The facility has been designed and engineered properly based on legal
requirements, design/engineering codes, industry standards and good
engineering practices.
2. The process will not be operated above design rates.
3. All equipment will be well maintained.
4. Appropriate instrument and control system test procedures will be followed.
5. Alarm and shutdown set points will not be set out of range or disconnected to
avoid nuisance trips or other problems.
6. Control valve bypasses will not be used unless the control valve is blocked out.
7. Rupture disks will be monitored.
8. If a double relief valve system is used, at least one will always be in service
when the facility is operating.
9. Inadvertent opening or closing of locked/car sealed valves or blinds during
maintenance are not addressed.
Step 5: Recommendation
1. Install high temperature alarm.

2. Install check valve.
3. Instruct operators on procedures.
4. Check maintenance procedure and schedule.
5. Cleaning of pipes, level control system.
6. Bypass fraction of fluid around each circulation.
51
CHAPTER 9
PLANT LOCATION AND LAYOUT
9.1 SITE CONSIDERATION AND PLANT LAYOUT
The location of the plant can have a crucial effect on the profitability of a project, and
the scope for future expansion. Factors considered while selecting a plant site are:
• Transportation
• Sources and costs of raw materials
• Prospective market for products
• Corporation long range planning
• Water source - quality and quantity
• Special incentive
• Climatic conditions
• Pollution requirements (Waste disposal)
• Utilities - cost, quantity and reliability; fuel - costs, reliability and availability
• Amount of site preparation necessary (site conditions)
• Construction costs • Operating labor
• Taxes
52
• Living conditions
• Corrosion
• Expansion possibilities
• Other factors.
Three factors are usually considered the most important. These are the location of the
markets and raw materials and the type of transportation to be used.
Transportation: The transport of materials and products to and from the plant will be
an overriding consideration in site selection. If practicable, a site should be selected
that is close to at least two major forms of transport: road, rail, and waterway. The
least expensive method of shipping is usually by water; the most expensive is by
truck.
Raw materials: The availability and price of suitable raw materials will often
determine the site location. Salicylic is the major raw material for the manufacture of
DDT, hence the plant can be located near any plant producing salicylic acid. It will
reduce transportation and storage costs.
Location of markets: Consumer products often are delivered in small shipment to a

large number of customers. In an international market, there may be an advantage to
be gained by locating the plant within an area with preferential tariff agreements.
Long Range Corporate Planning: The object of long range planning is to optimize a
whole network of operations instead of each one individually. This means that each
plant site is not considered only for itself and that its chosen location might not be the
one that would be selected if only the economics of the one plant had been considered.
Placing the plants throughout the country allows each plant to be located optimally.
Water: Water is needed by every processing plant for a number of different purposes.
Potable water is needed for drinking and food preparation. The plant site must have an
adequate amount of each type of water at all times of the year.Not only the amount
and quality but the temperature of the water is important.The size of the heat
53
exchanger is inversely proportional to the temperature difference between the cooling

water and the material being cooled.
Climatic Conditions: Adverse climatic conditions at a site will increase costs.

Abnormally low temperatures will require the provision of additional insulation and
special heating for equipment and pipe runs. Stronger structures will be needed at
locations subject to high winds or earthquake.
Pollution and Ecological Factors: All industrial processes produce waste products,
and full consideration must be given to the difficulties and cost of their disposal. The
disposal of toxic and harmful effluents will be covered by local regulations, and the
appropriate authorities must be consulted during the initial site survey to determine the
standards must be met.
Site Conditions: An ideal chemical plant site is above the flood plain, flat, has good
drainage, a high soil- bearing capability, and consists of sufficient land for the
proposed plant and for future expansion.
Availability of labor: Labor will be needed for construction of the plant and its
operation. Skilled construction workers will usually be brought in from outside the
site area, but there should be an adequate pool of unskilled labor available locally; and
labor suitable for training to operate the plant.
Political and Strategic considerations: Capital grants, tax concession and other
inducements are often given by governments to direct new investment to preferred
locations; such as areas of high unemployment.
Local Community Considerations: The proposed plant must fit in with and be
acceptable to the local community. On a new site, the local community must be able
to provide adequate facilities for the plant personnel: Schools, banks, housing and
recreational and cultural facilities.
Corrosion: Once the general area for the plant has been determined, the effect of
neighboring industries should be considered when picking the specific site. Their
presence may indicate an increased corrosion rate.
54
9.2 PLANT LAYOUT: The economic construction and efficient operation of a

process depend on how well the plant and equipment specified on the process flow
sheet is laid out. The principal factors to be considered are:
• Economic consideration: construction and operating costs.
• The process requirement.
• Convenience of operation.
• Convenience of maintenance
• Safety.
• Future expansion
• Modular construction
Costs: The cost of construction can be minimized by adopting a layout that gives the
shortest run of connecting pipe between equipment, and the least amount of structural
steel works.
Operation: Equipment that needs to have frequent operator attention should be

located convenient to the control room. Valves, sample points and instruments should
be located at convenient positions and heights. Sufficient working space and
headroom must be provided to allow easy access to equipment.
Plant expansion: Equipment should be located so that it can be conveniently tied in

with future expansion of the process.
Modular construction: In recent years there has been a move to assemble sections of
plant at the plant manufacturer’s site. These modules will include the equipment,
structural steel, piping and instrumentation. The modules are then transported to the
plant site, by road or sea.
General consideration: Open, structural steelwork, buildings are normally used for
process equipment; closed buildings are only used for process operations that require
protection from the weather.
55
CHAPTER 10
COST ESTIMATION AND ECONOMICS
Cost of DDT production plant of capacity 980 TPY in 1990 is Rs. 1.875 x 108
Therefore cost of 6000 TPY in 1980 is C1 = C2 x (Q1 ÷ Q2)0.6
= 1.875 x 108 x (6000 ÷ 980)0.6
= Rs. 4.9786 x 108
10.1 Chemical Engineering Plant Cost Index:
Cost Index in 1980 = 110
Cost Index in 2015 = 402
present cost index

Present cost of plant = original cost x past cost index
402
= 4.9786 x 108 x 110
Fixed Capital Investment (FCI) = Rs. 18.19 x 108
10.2 Estimation of Capital Investment Cost:

56
➢ Direct costs: Material and labor involved in actual installation of complete

facility. It is generally 70–85% of fixed capital investment.
o Equipment, installation, instrumentation, piping, electrical, insulation,
painting:
▪ Purchased Equipment Cost (PEC) : 15-40% of FCI
Consider PEC = 25% of FCI
= 0.25 x 18.19 x 108
= Rs. 4.547 x 108
▪ Installation including insulation and painting: 25-55% of PEC
Consider installation cost = 40% of PEC
= 0.4 x 4.547 x 108
= Rs. 1.819 x 108
▪ Instrumentation and controls installed: 6-30% of PEC
Let instrumentation cost = 20% of PEC
= 0.2 x 4.547 x 108
= Rs. 0.9095 x 108
▪ Piping Cost: 10-80% of PEC
Consider piping cost = 40% of PEC
= 0.40 x 4.547 x 108
= Rs. 1.8188 x 108
▪ Electrical Cost: 10-40% of PEC
Consider electrical cost = 25% of PEC
= 0.25 x 4.547 x 108

57
= Rs. 1.1368 x 108
o Buildings and auxiliary: 10-70% of PEC
Consider building and auxiliary = 40% of PEC
= 0.40 x 4.547 x 108
= Rs. 1.819 x 108
o Service Facilities: 40-100% of PEC
Consider service facilities = 60% of PEC
= 0.60 x 4.547 x 108
= Rs. 2.7285 x 108
o Land: 1-2% of FCI or 4-8% of PEC
Consider cost of land = 6% of PEC
= 0.6 x 4.547 x 108
= Rs. 0.2728 x 108
Thus Direct cost = Rs. 15.0519 x 108
➢ Indirect Cost: Expenses which are not directly involved with material and labor
of actual installation of complete facility. It is generally 15-30% of FCI
o Engineering and Supervision: 5-30% of direct costs
Consider engineering cost = 10% of 15.0519 x 108
= Rs. 1.50519 x 108
o Construction Expense and Contractor’s fee: 6-30% of direct costs
Consider construction expense = 10% of direct cost
= 0.1 x 15.0519 x 108

58
= Rs. 1.50519 x 108
o Contingency: 5-15% of FCI
Consider contingency cost = 10% of FCI
= 0.1 x 18.19 x 108
= Rs. 3.638 x 108
Thus Indirect costs = Rs. 6.64838 x 108
➢ Fixed Capital Investment:
Fixed Capital Investment = Direct costs + Indirect costs
= (15.0519 + 6.64838) x 108
= Rs. 21.7 x 108
➢ Working Capital: 10-20% of FCI
Consider working capital = 15% of FCI
= 0.15 x 21.7 x 108
= Rs. 3.255 x 108
➢ Total Capital Investment (TCI) :
Total Capital Investment = Fixed Capital Investment + Working

Capital
= (21.7 + 3.255) x 108
= Rs. 24.955 x 108
10.3 Estimation of Total Product Cost:
➢ Manufacturing Cost: Direct Production cost + Fixed Charges + Plant overhead

cost
o Fixed Charges: 10-20% of total product cost
59
▪ Depreciation: 13% of FCI for machinery and equipment and 2-3%

for buildings. Depreciation = 13% of FCI + 3% of building value
= (0.13 x 21.7 x 108) + (0.03 x 1.819 x 108)
= Rs. 2.8755 x 108
▪ Local Taxes: 1-4% of FCI
Consider local taxes = 3% of FCI
= 0.03 x 21.7 x 108
= Rs. 0.651 x 108
▪ Insurances: 0.4-1% of FCI
Consider insurances = 0.7% of FCI
= 0.007 x 21.7 x 108
= Rs. 0.1519 x 108
▪ Rent: 8-12% of value of rented land and buildings
Consider Rent = 10% of value of rented land and buildings
= 0.1 x ((0.2728 + 1.819) x 108)
= Rs. 2.0918 x 108
Thus Fixed charges = Rs. 5.7702 x 108
o Direct Production Cost:
Fixed charges = 10-20% of total product charges
Consider fixed charges = 15% of total product charges
Total product charges = fixed charges ÷ 15%

60
Total product charges = 5.7702 x 108 ÷ 0.15
Total product charge (TPC) = Rs. 38.468 x 108
▪ Raw materials: 10-50% of TPC
Let cost of raw materials = 25% of TPC
= 0.25 x 7.0126 x 108
= Rs. 8.617 x 108
▪ Operating Labor (OL) : 10-20% of TPC
Consider operating labor = 12% of TPC
= 0.12 x 34.468 x 108
= Rs. 4.1361 x 108
▪ Direct Supervisory and Clerical Labor (DS & CL): 10-25% of

OL
Let DS & CL = 12% of OL
= 0.12 x 4.1361 x 108
= Rs. 0.4963 x 108
▪ Utilities: 10-20% of TPC
Consider cost of utilities = 12% of TPC
= 0.12 x 34.468 x 108
= Rs. 4.1361 x 108
▪ Maintenance and Repairs (M & R): 2-10% of FCI
Consider M & R cost = 5% of FCI

61
= 0.05 x 21.7 x 108
= Rs. 1.085 x 108
▪ Operating Supplies: 10-20% of M & R or 0.5-1% of FCI
Cost of operating supplies = 15% of M & R
= 0.15 x 1.085 x 108
= Rs. 0.1627 x 108
▪ Laboratory charges: 10-20% of OL
Let Laboratory charges = 15% of OL
= 0.15 x 4.1361 x 108
= Rs. 0.6204 x 108
▪ Patents and Royalties: 0-6% of TPC
Let patents and royalties = 4% of TPC
= 0.04 x 38.468 x 108
= Rs. 1.1540 x 108
Thus Direct Production Cost = Rs. 20.4076 x 108
o Plant Overhead Costs: 50-70% of OL, supervision and maintenance. It

includes for the following: general plant upkeep and overhead, payroll
overhead, packaging, medical services, safety and protection, restaurants,
recreation, laboratories and storage facilities.
Consider Plant overhead cost = 60% of OL, DS & CL and M & R
= 0.60 x ((4.1361 + 0.4963 + 1.085) x 108)

62
= Rs. 3.4304 x 108
Thus, Manufacture Cost = Direct Production Cost + Fixed Charges + Plant

Overhead Costs
Manufacture Cost = (38.468 + 5.7702 + 3.4304) x 108
= Rs. 47.6686 x 108
➢ General Expenses: Administrative Costs + Distribution and Selling Costs +

Research and Development Costs.
o Administrative Costs: 2-6% of TPC
Let administrative costs = 5% of TPC
= 0.05 x 38.468 x 108
= Rs. 1.9234 x 108
o Distribution and Selling Costs: 2-20% of TPC. It includes costs for sales
offices, salesmen, shipping and advertising.
Let Distribution and Selling Costs = 15% of TPC
= 0.15 x 38.468 x 108
= Rs. 5.7702 x 108
o Research and Development Costs: 5% of TPC
Research and Development Costs = 0.05 x 38.468 x 108
= Rs. 1.9234 x 108
o Financing (Interest): 0-10% of Total Capital Investment
Consider interest = 5% of Total Capital Investment
= 0.05 x 24.955 x 108

63
= Rs. 1.2477 x 108
Thus General Expenses = Rs. 10.8467 x 108
Total Product Cost = Manufacture Cost + General Expenses
= (47.6686 + 10.8647) x 108
= Rs. 58.5333 x 108
➢ Gross Earnings/Income:
Wholesale selling price of DDT per kg = Rs. 1400
Total Income = Selling Price x Quantity manufactured
= 1400 x 5 x 106
= Rs. 70 x 108
Gross Income = Total Income – Total Product Cost
= (70 x 108) – (58.5333 x 108)
= Rs. 11.4667 x 108
Let the tax rate be 45%
Net Profit = Gross Income – Taxes
= 11.4667 x 108 x (1-0.45)
= Rs. 6.306685 x 108
➢ Rate of Return:
N et P rof it
Rate of return = T otal Capital Investment
x 100
= (6.306685 x 108 / 24.955 x 108) x 100
= 25.27%
64
10.4 Break Even Analysis
Annual Direct Production Cost = Rs. 20.4076 x 108
Annual Fixed Charges, overheads and general expenses = Rs.5.7702 x 108
Total annual sales = Rs. 70 x 108
Wholesale selling price per ton = Rs. 1400000
(5.7702 x 108 x 14 x 105)

Direct production cost per ton = 70 x 108
= Rs. 115404 per ton
Let ‘n’ be the break even production rate
Number of tons needed for a break-even point is given as:
(5.7702 x 108) + (115404 x n) = (1400000 x n)
Hence n = 449.184 tons/year
Thus, the break even production rate is 449.184 tons/year or approximately 9% of

the considered plant capacity.
65
APPENDIX 1
REFERENCES
1. Austin, George.T (1999). Shrieve’s Chemical Process Industries (5th Edition).

New Delhi: Tata McGraw-Hill.
2. Perry, Robert H. and Don W. Green (2007). Perry’s Chemical Engineers’
Handbook (8th Edition). New Delhi: McGraw Hill.
3. Anantharaman. N and K.M. Meera Sheriffa Begum (2011). Mass Transfer:
Theory and Practice. New Delhi: PHI Learning Private Limited.
4. Treybal, Robert.E (2012). Mass Transfer Operations (3rd Edition). New Delhi:
Tata McGraw Hill.
5. Anantharaman. N, V. Venkataramani and K.M. Meera Sheriffa Begum (2011).
Process Calculations (2nd Edition). New Delhi: PHI Learning Private Limited.
6. Kirk-Othmer (2004). Encyclopedia of Chemical Technology (5th Edition). New
Delhi: Wiley – Blackwell.
66
7. Peters, Max S, Klaus D. Timmerhaus and Ronald E. West (2004). Plant

Design and Economics for Chemical Engineers (5th Edition). New Delhi:
McGraw Hill.
8. Kern, Donald. Q (2011). Process Heat Transfer. New Delhi: McGraw Hill.
9. Sinnott, R.K. (2003). Coulson and Richardson’s Chemical Engineering
Volume 6 (3rd Edition). London: Butterworth-Heinemann.
10. Brownell, Llyod E. and Edwin H. Young (2013). Process Equipment Design.
New Delhi: Wiley.
E-Resources:
1. http://DDT.com/scripts/pages/en/home.php
2. http://www.drugs.com/DDT.html
3. http://www.nlm.nih.gov/medlineplus/druginfo/meds/a682878.html
4. http://nobelprizes.com/nobel/medicine/DDT.htmlSDG 102 2
5. http://www.chemicalland21.com/lifescience/phar/ACETYLSALICYLIC%20A
CID.htm
6. http://www.medicinenet.com/acetylsalicylic_acid/article.htm
7. http://en.wikipedia.org
8. http://sigmaaldrich.com
9. http://engineeringtoolbox.com

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1

DESIGN OF DDT MANUFACTURING PLANT

K CHAITANYA MOULI SUDHANSHU KUMAR

CHEMICAL ENGINEERING CHEMICAL ENGINEERING

NIT – TRICHY NIT - TRICHY

UNDER THE GUIDANCE OF:

ASSOCIATE PROFESSOR, CHEMICAL ENGINEERING

NATIONAL INSTITUTE OF TECHNOLOGY – TRICHY

DATE OF SUBMISSION: 18-04-2016

DESIGN OF DDT MANUFACTURING PLANT

A thesis submitted in partial fulfilment of the requirements for

the award of the degree of

K CHAITANYA MOULI (102112032)

SUDHANSHU KUMAR (102112063)

DEPARTMENT OF CHEMICAL ENGINEERING

NATIONAL INSTITUTE OF TECHNOLOGY

a bonafide record of the work done by

K CHAITANYA MOULI (102112032)

SUDHANSHU KUMAR (102112063)

Project Guide Professor

Associate Professor Head of Department

Department of Chemical Engineering Department of Chemical Engineering

Project Viva-Voce held on ___________________

Internal Examiner External Examiner

Keywords: DDT, Chloral, Equipment design

We wish to express our sincere gratitude to our guide Dr.G.Arthanareeswaran,

We would like to thank our Project Co-ordinator Dr.N.Samsudeen, Assistant

We also like to thank our Head of the Department Dr.P.Sivashanmugam, Department

Title Page no.

TABLE OF CONTENTS ​iii

LIST OF TABLES ​vi

LIST OF FIGURES ​vii

LIST OF SYMBOLS ​viii

1.1 Objective of the project 1

CHAPTER 2 PROPERTIES AND USES

2.1 Chemical Properties 3

2.2 Physical Properties 3

CHAPTER 3 MANUFACTURING PROCESSES

3.1 Monochloro Benzene process 4

3.2 products - chloral 4

3.3 Flow Sheet 5

CHAPTER 4 PROCESS SELECTION AND DESCRIPTION

4.1 Process Selection 6

4.2 Process description 6

CHAPTER 5 MATERIAL BALANCES

5.3 Distillation column 9

CHAPTER 6 ENERGY BALANCES

6.3 Distillation column 13

6.4 Detailed flow sheet 14

CHAPTER 7 DESIGN OF EQUIPMENT

7.1 Process Design of Distillation column 15

7.1.2 Tray Tower design 16

7.1.2.1 Column diameter 16

7.1.2.2 Plate pressure drop 20

7.1.2.3 Down commer design 21

7.1.2.4 Trail layout 22

7.1.2.5 Perforated area 23

7.1.2.6 Number of holes 23

7.1.2.7 Plate specification 24

7.2 Design of Dryer 24

7.2.1 Mechanical design of dryer 25

7.3 Design of Reactor 28

CHAPTER 8 SAFETY AND HEALTH ASPECTS

TABLE OF CONTENTS iii

LIST OF TABLES vi

LIST OF FIGURES vii

LIST OF SYMBOLS viii

APPENDIX 1 REFERENCES 48

Weight of water vapour contained in saturated air at a temperature t0 of H0

Input to washer Z1

Input to filter A1

Heat absorbed in filter Q1

Heat liberated in crystalliser Q2

Heat absorbed in reactor Q3

Diameter of crystalliser D1

Height of crystalliser H2

Diameter of impeller D2

Thickness of Impeller t2

Baffle height H3

Baffle width W1

Power Number Np

Total heat required Qt

Logarithmic temperature difference ΔTm

The amount of air required ma

Mass velocity of air Ga

Area of dryer Ad

Internal diameter of dryer Dd

External diameter of dryer Dd2

Volumetric heat transfer coefficient Ud

Volume of the dryer Vd

Length of dryer Ld

Number of flights Nd

Density of mild steel þm

Volume of mild steel Vm

Maximum permissible stress fm

Thickness of dryer td

Diameter of reactor Di

Permissible shear stress in shaft fs

Stuffing box permissible shear stress ft

Design pressure of reactor Pi

Shell thickness ts

Design pressure for Jacket Pj

Thickness of Jacket tj

Diameter of Jacket dj

Head thickness dh

Knuckle diameter Dk

Averaged rated torque on agitator Tc

Maximum torque Tm

Equivalent Bending Moment Me

Internal diameter of stuffing box bi

Force per bolt Fb

Production quantity II Q1

Production quantity II Q2

Cost of plant with production Q1 C1

Cost of plant with production Q2 C2