CHAPTER 1.0 INTRODUCTION
1
BACKGROUND
Zimbabwe imports all of its petroleum which is then refined to produce various petroleum products like petrol and diesel oil. Despite government’s support for the use of unleaded and leaded petrol which is a health hazard. The use of petrol without fuel oxygenate poses an environmental environmental threat, threat, xygenates help petrol burn more completely completely,, reducing emissions emissions from motor vehicles! vehicles! dilutes or displaces displaces gasoline components such as aromatics aromatics "e.g., benzene# benzene# and sulphur! sulphur! and optimizes optimizes the oxidation oxidation during combustion combustion and they help raise the oxygen content of petrol. ur group proposes the use of methyl tertiary$butyl ether "%T&'# as an alternative petrol additive(oxygenates to lead and other additives hence the need for a feasibility study on the production of %T&' production in Zimbabwe. %T&' fuel blends are likely to have substantial air )uality benefits. *se of %T&' decreases gasoline overall cancer potential by displacing more potent carcinogenic materials in gasoline. %T&' is approximately seven times less potent than benzene and twenty five times less potent than +, $butadiene, toxic components found in gasoline and motor vehicle emissions. -eleases of petrol containing either %T&' or lead could have an impact on some drinking water sources, although the impacts associated with %T&' tend to relate to aesthetics "i.e. Taste and odor#, whereas the impacts associated with lead generally relate to health risk. 2
USES USES AND IMP IMPOR ORT TANCE NCE OF MTBE MTBE MTBE is an octane enance! tat "!e#ents en$ines %!o& 'noc'in$
%T&' is used extensively as a fuel additive in petrol blending •
%T&'$petrol blend is eco$friendly so it is better to use it and reduce pollution.
•
%T&'$etrol blends are compatible with most cars
•
%T&' is also used as a chemical intermediate to produce high purity isobutylene
•
/igh purity %T&' is being used as a process reaction solvent in the pharmaceuticals industry
•
%inor use patterns are use as chromatographic eluent and use as a therapeutic agent for in vivo dissolution of cholesterol gallstones in humans 1|Page
A(TERNATI)ES A(TERNATI)ES FOR MTBE •
'T&' "'thyl tertiary butyl ether#, T0%' "Tert amyl methyl ether#, D1'"Di isopropyl ether. These are all ethers like %T&'. There is no field data available due to limited use of them. A*'a*+te A*'a*+tes, s,
these are a mixture of high octane, low vapor pressure compounds that are
produced from crude cr ude oil through a catalytic ca talytic cracking process. They have low solubility in water and are likely not to pose the same risks to water resources. They also increase price of reformulated gasoline. A!o&atics- tese are high in octane and may cause health risks i.e carcinogens, lower potency central nervous system and liver toxicants. (ea -tetrahedral lead is used to reduce engine knocking, boost octane rating and help with wear and tear on valve seats within the motor. 2ead tends to clog up catalytic converters making them inoperable. 1t is poisonous to humans. /
PROB PROB(E (EM M ST STATEMEN EMENT T
3urrently there is no local production of %T&' in Zimbabwe! the country is using lead ,'T&', as a fuel additive. 4evertheless, there has been a public outcry re5ecting the use of lead with problems emanating from it being poisonous to human health. 6e seek to investigate the technical and economic feasibility of producing %T&' in Zimbabwe.
USTIFICATION •
%T&' production is cheaper since the raw materials are locally available
•
1n 0frica there is no production of %T&', the proposal of a cost effective %T&' production process will go a long way in alleviating 0frica’s 0frica’s energy challenges.
•
The country can export excess %T&' to other 0frican countries.
•
0vailab 0vailability ility of %T&' can go a long way in solving solving environmental problems problems associated associated with the widespread use of leaded and unleaded petrol.
RESEARCH FOCUS
This study was conducted to find a technical and economic feasible process for the production of %T&' in Zimbabwe from locally available raw materials that will account for maximum 2|Page
A(TERNATI)ES A(TERNATI)ES FOR MTBE •
'T&' "'thyl tertiary butyl ether#, T0%' "Tert amyl methyl ether#, D1'"Di isopropyl ether. These are all ethers like %T&'. There is no field data available due to limited use of them. A*'a*+te A*'a*+tes, s,
these are a mixture of high octane, low vapor pressure compounds that are
produced from crude cr ude oil through a catalytic ca talytic cracking process. They have low solubility in water and are likely not to pose the same risks to water resources. They also increase price of reformulated gasoline. A!o&atics- tese are high in octane and may cause health risks i.e carcinogens, lower potency central nervous system and liver toxicants. (ea -tetrahedral lead is used to reduce engine knocking, boost octane rating and help with wear and tear on valve seats within the motor. 2ead tends to clog up catalytic converters making them inoperable. 1t is poisonous to humans. /
PROB PROB(E (EM M ST STATEMEN EMENT T
3urrently there is no local production of %T&' in Zimbabwe! the country is using lead ,'T&', as a fuel additive. 4evertheless, there has been a public outcry re5ecting the use of lead with problems emanating from it being poisonous to human health. 6e seek to investigate the technical and economic feasibility of producing %T&' in Zimbabwe.
USTIFICATION •
%T&' production is cheaper since the raw materials are locally available
•
1n 0frica there is no production of %T&', the proposal of a cost effective %T&' production process will go a long way in alleviating 0frica’s 0frica’s energy challenges.
•
The country can export excess %T&' to other 0frican countries.
•
0vailab 0vailability ility of %T&' can go a long way in solving solving environmental problems problems associated associated with the widespread use of leaded and unleaded petrol.
RESEARCH FOCUS
This study was conducted to find a technical and economic feasible process for the production of %T&' in Zimbabwe from locally available raw materials that will account for maximum 2|Page
production and better )uality. The pro5ect aims to find a process that is energy$efficient and affordable technology in the production of %T&' and increase its market potential. 3
5
RESE RESEAR ARCH CH 4UE 4UES STIONS IONS •
1s the process cost effective7
•
1s the process environmentally friendly7
•
0re the products environmentally friendly7
•
/ow can Zimbabweans benefit from %T&'7
•
/ow does %T&' production in Zimbabwe affect its economy7
SCOPE
The pro5ect will focus on effect of pressure, temperature and catalyst on the production of %T&' and conversion of isobutylene. The results from the experiments will be used to design the process and the e)uipment used for the production process. 6
STU ST UD7 H7P H7POTHE HESI SIS S
/8$1t is feasible to produce %T&' in Zimbabwe /8$1t is technically and economically feasible to produce %T&' /+$1t is not feasible to produce %T&' in Zimbabwe /+$1t is not technically and economically feasible to produce %T&' 8
PRO PROEC ECT T OB OBE ECT CTI) I)ES ES •
To design a process that is economically and technically feasible.
•
To make an affordable and cheap fuel additive of which %T&' is cheap. To make a petrol blend with a long shelf life. %T&'$ petrol blend has a shelf life of several years To make a petrol blend that is environmentally friendly
CHAPTER 2.0, (ITERATURE RE)IE9
3|Page
3urr 3urren entl tlyy ther theree is no local ocal prod produc ucti tion on of %T&' %T&' "%et "%ethy hyll terti ertiar aryy$&ut $&utyyl ethe ether# r# in Zimbabwe.%T&' is being produced in countries such as 3hina, 9audi 0rabia, %alaysia and 9ingapore. %ethyl tertiary butyl ether "%T&'# is produced by reacting isobutene with methanol over a catalyst bed in the li)uid phase under mild temperature and pressure "3ollignon, +::;#. 1sobutene can be obtained from stream cracker raffinate or by the dehydrogenation of isobutene from refineries. 'ther in general is a compound containing an oxygen atom bonded to two carbon atoms. 1n %T&' one carbon atom is that of a methyl group < 3/ and the other is the central atom of a tertiary butyl group, $3 "3/##. 0t room temperature, %T&' is a volatile, flammable, colorless li)uid with a distinctive odor. 1t is miscible with water but at high concentrations it will form an air$vapor explosive mixture above the water, which can ignite by sparks or contact with hot surfaces.%T&' has good blending properties and about :=> of its output is is used in gasoline as an octane booster and an oxygenate "providing oxygen for cleaner combustion and reduced carbon monoxide emissions#. 1t is also used to produce pure isobutene from 3? streams by reversing its formation reaction. 1t is a good solvent and extractant. "3asebook@?, -ev +.%ethyl Tertiary Tertiary &utyl 'ther "%T&'# lant. %arch +::=# Table Table + hysical h ysical properties of %T&' 3hemical formula xygen content %olecular structure hysi hysica call stat statee "at norm normal al temp tempera eratu ture re and
3=/+A +B.A wt.> "3/#?3 3olorless li)uid
pressure# &oiling point %elting point Clash point 0uto ignition temperature Clammable limits in air -elative density Eapor pressure -eactive index 3olor
==.Ac $+8B.;o3 8o3 ?A=o3 +.= < B.=> 8.?8=g(ml at A8o3 A?= mm /g at A=o3 +.;:8 3olorless
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Cigure +F %T&' structure 2.1 METHODS USED FOR THE PRODUCTION OF MTBE
There are nine methods of producing %T&' implemented under license as the followingF + A ? = ; B :
*$leflex rocess hillips 'therification rocess 0&& 2ummus 3atofin rocess 9namprogetti rocess. 9tandard "/uls# process 'T/'-%0G process "by /uls 0H and *# -efinery or etrochemical plants %erchant plants Tertiary &utyl 0lcohol
2.1.1 UOP:O*e%*e; P!ocess
The *$leflex process uses multiple side$by$side, radial flow, and moving$bed reactors connected in series. reheated feed and interstage heaters supply the heat of reaction. The reaction is carried out over platinum supported on alumina, under near isothermal 3onditions. The catalyst system employs *Is 3ontinuous 3atalyst -egeneration "33-# technology. The bed of catalyst slowly flows concurrently with the reactants and is removed from the last reactor and regenerated in a separate section. The reconditioned catalyst is then returned to the top of the first reactor. The typical processes involved are the deisobutenization, the isomerization and the dehydrogenation process that has been commercial in %alaysia. "Juintain,A8+# 2.1.2 Pi**i"s Ete!i%ication "!ocess <=+ Pi*i"s Pet!o*e>& Co.?
This process uses olefins "i.e. isoamylene and isobutylene# to react with methanol over acidic1on$exchange resin. %ixed olefins from a fluid catalytic cracking unit "C33*# or steam 5|Page
3racker, along with fresh alcohol are fed to the reactor section. The reactor operation is li)uid phase at mild temperature and pressure. 1n case of %T&', high purity %T&' is removed as a bottom product from the fractionator and all the unreacted methanol is taken overhead. The overhead product is then stripped of methanol in an extractor using water. The extract is sent to the fractionator, while the denuded water is returned to the methanol extractor. "Juintain,A8+# 2.1./ ABB (a&&>s Cato%in P!ocess
The 0&& 2ummus 3atofin rocess uses a relatively inexpensive and durable 3hromium oxide< alumina as catalyst for the dehydrogenation process. This catalyst can be easily and rapidly regenerated under severe conditions without loss in activity. Dehydrogenation is carried out in the gas phase over fixed beds. &ecause the catalyst cokes up rapidly, five reactors are typically used. Two are on stream, while two are being regenerated and one is being purged. The reactors are cycled between the reaction and the reheat(regeneration modes, and the thermal inertia of the catalyst controls the cycle time, which is typically less than +8 minutes. The chromium catalyst is reduced from 3r;K to 3rK during the dehydrogenation cycle. The raw materials used to produce %T&' by using this method are butanes, hydrogen and as well as recycled isobutene from the system itself. 1n this process, there is an isostripper column, which separates the heavies, and the light ends from which then could produce %T&'."/utchings,+::A# 2.1. Sna&"!o$etti P!ocess
9imilar to hilips 'therification rocess, ethers are produced by the addition of alcohol to reactive olefins in the presence of an ion exchange resin at mild temperature and pressure. The feed passes through two reactors in series < an isothermal tubular reactor and an adiabatic drum reactor. The second reactor effluent goes to the product fractionation tower where the ether product leaves the bottom stream and hydrocarbon is recovered overhead. 1n the %T&' process, methanol in the overhead stream is extracted with water in the water removal tower. The extract from the bottom enters the methanol$water fractionator, while the water overhead is recycled to reactor feed. "Juintain,A8+# 2.1. Stana! *s? P!ocess
6|Page
The key feature of this process is the fixed bed %T&' reactor used prior to the azeotropic distillation column .3onversions of isobutylene to %T&' are in the range B=$:=>.1n many plants two reactors are used in tandem, along with recycle in order to increase the overall conversion closer to ::>."Juintain,A8+# 2.1.3 ETHERMA@ P!ocess
This process which uses reactive distillation technology is developed by combined expertise of /uls 0H and *. The feed consists of methanol and hydrocarbon streams containing reactive tertiary olefins such as isoamylene and isobutylene. -eaction takes place over an acidic ion exchange resin at mild temperature and moderate pressure. 1n the %T&' case, feed first passes through an optional water wash system to remove the resin contaminants. The ma5ority of the reaction is carried out in a simple fixed$bed reactor. The reactor effluent feeds the reactive distillation column containing a proprietary packing where simultaneous reaction of the remaining isobutylene and distillation occur. verhead from the reactive distillation column is routed to methanol recovery, a simple counter current extraction column using water, and a methanol$water distillation column. The recovered methanol is recycled to the reactor section. /ydrocarbon raffinate is typically sent to a downstream alkylation or oligomerization unit. "Juintain,A8+# Re%ine!+ o! Pet!oce&ica*
1sobutylene produced is a by product in refinery catalytic crackers and in petrochemical ethylene plants, is reacted with methanol to produce %T&'. Me!cant "*ants
4ormal butane is isomerized to isobutene, the isobutene is dehydrogenated to isobutylene and then combined with methanol to produce %T&'. TBA P*ants
Tertiary butyl alcohol is a byproduct of propylene oxide production process. The T&0 is reacted with methanol to produce %T&'.
7|Page
2.2 PROCESS SE(ECTION
9uitable process, which is gives a lot of profit and less problem is an important in order to determine the feasibility of the pro5ect. This section will briefly discuss the best process selected based on a few criteria. 1t covers general consideration, detailed consideration for process selection and conclusion on the process selection. hillips 'therification process "by hilips etroleum 3o.# process will be chosen as the method to produce %T&'. 2.2.1 PROCESS DESCRIPTION
%T&' is manufactured by catalytically reacting methanol and isobutylene in a fixed bed reactor at a moderator pressure and temperature. The reaction is reversible and exothermic, and is carried out in the li)uid phase over a fixed bed of sulphonated ion$exchange resin$type catalyst. 1t is highly selective since methanol reacts prefentially with the isobutylene in the mixed butenes "Juintain, A8+#.1n this %T&' process, an isobutylene$rich mixed 3? stream is mixed with fresh methanol and a small amount of recycle methanol and fed to the reactor section. The reactor is cooled to prolong catalyst life and to minimize the undesirable side reactions such as the dimerization of isobutylene "/utchings,+::A#. Temperatures below :?o3 are recommended. The reactor is adiabatic, and the reaction is exothermic. Therefore, the heat generated by the reaction raises the temperature of the exit stream. The exit temperature is a function of the conversion. The reaction must be run at a pressure and temperature to ensure that all components remain in the li)uid phase in the reactor. %ethanol must be present in the reactor feed at a minimum A88> excess
to
suppress
undesired
side
reactions
that
produce
undesired
products.
"3ollignon,+::;#.The hilips 'therification process uses three distillator but for our process design we will employ two fractional distillators due to the replacement of mixed butenes with 5ust isobutylene in the process, thus saving money. 1n the original etherification process, methanol is recycled to the reactor feed whilst butenes and the unreacted methanol are treated as waste.1n our process design we recycle both the unreacted methanol and isobutylene, thus maximizing on raw materials and profits. Ce&ica* Reaction
The reaction is facilitated by a sulphonated ion$exchange resin catalyst. The reaction isF 8|Page
→"CH , # , C − O − CH , CH ,OH + "CH , # A C = CH A ←
2.2.2 AD)ANTAGES OF THE PROCESS
%ore detailed reasons for the selection of this process areF •
/igh conversion "greater than :B ># with few by$products compared to other process The process operates under low pressure and has a low pressure drop and this means that
•
the fluidized bed is physically not harmful to anyone. 0s the Temperature is not high! this means that the process is not as dangerous as other
•
high temperature$operated process. /igher per pass conversion and at least +$A> higher catalyst selectivity as a result of
•
•
lowest operating pressure and temperature. 4o catalyst losses.
2.2./ PROCESS E4UIPMENT 1
Reacto!
9everal reactor types may be considered for use in this process such asF • • •
0n adiabatic, packed bed reactor 0n Lisothermal,M packed bed reactor 0 packed bed reactor with heat exchange
Cor our process we are going to use an adiabatic packed bed reactorF 0 packed bed reactor consists of a vessel containing one or several tubes of packed catalyst particles in a fixed, non$mobile bed "-ase, +::8#. acked bed reactors are an economical choice in large scale production. This is due to the fact that they can operate nearly continuously due to the long catalyst life! which leads to savings in annual costs and shutdown costs. -eactors with a single adiabatic bed are traditionally used in either exothermic or endothermic reactions. /owever, they are primarily used for exothermic reactions in industrial practice "9atterfield, +::;#. This type of adiabatic reactor is the least expensive to produce and is used as often as is practical. %aintaining an adiabatic state conserves energy and can result in large savings for a company. 0 packed bed reactor with adiabatic beds in series is used for high conversion reactions with no heat transfer to the environment. ther advantages for using an adiabatic packed bed reactor are /igher conversion per unit mass of catalyst than other catalytic reactors, 9|Page
2ow operating cost, 3ontinuous operation, 4o moving parts to wear out, 3atalyst stays in the reactor, -eaction mixture(catalyst separation is easy.
2
Disti**ation Co*>&ns
Batc Co*>&ns
1n batch operation, the feed to the column is introduced batch$wise. That is, the column is charged with a IbatchI and then the distillation process is carried out. 6hen the desired task is achieved, a next batch of feed is introduced.
Contin>o>s Co*>&ns
1n contrast, continuous columns process a continuous feed stream. 4o interruptions occur unless there is a problem with the column or surrounding process units. They are capable of handling high throughputs. ur process will use a continuous tray type column where trays of various designs are used to hold up the li)uid to provide better contact between vapor and li)uid, hence better separation. The process will therefore use a fractional distillater which is the most common form of separation technology used in petroleum refineries, petrochemical and chemical plants, natural gas processing and cryogenic air separation plants. 1n most cases, the distillation is operated at a continuous steady state. 4ew feed is always being added to the distillation column and products are always being removed. *nless the process is disturbed due to changes in feed, heat, ambient temperature, or condensing, the amount of feed being added and the amount of product being removed are normally e)ual. This is known as continuous, steady$state fractional distillation. The advantages of using a plate column areF %ost cost efficient distillation column for diameters greater than 8.; m,the li)uid(vapor contact in the cross$flow of plate columns is more effective than the countercurrent$flow in packed columns, 3ooling coils can easily be added to the plate column"cryogenic applications#,3an handle high li)uid flow rates cost$ effectively. "encyclopedia.che.engin.umich.edu(ages(9eparations3hemical(Distillation3olumns(Distillatio 10 | P a g e
n3olumns.html# /
Heat E;can$e!s
There are types of heat exchangers namelyF 9hell and tube heat exchanger late heat exchanger 0diabatic wheel heat exchanger • • •
The process will use a shell and tube heat exchanger, 9hell and tube heat exchangers are comprised of multiple tubes through which li)uid flows. The tubes are divided into two setsF the first set contains the li)uid to be heated or cooled. The second set contains the li)uid responsible for triggering the heat exchange, and either removes heat from the first set of tubes by absorbing and transmitting heat awayNin essence, cooling the li)uidNor warms the set by transmitting its own heat to the li)uid inside. 6hen designing this type of exchanger, care must be taken in determining the correct tube wall thickness as well as tube diameter, to allow optimum heat exchange. "-. 9hankar 9ubramanian. 9hell$and$Tube /eat 'xchangers# A#anta$es
/ere are the main advantages of shell$and$tube heat exchangerF • • •
The pressures and pressure drops can be varied over a wide range. Thermal stresses can be accommodated inexpensively. There is substantial flexibility regarding materials of construction to accommodate corrosion and other concerns. The shell and the tubes can be made of different
•
•
materials. 'xtended heat transfer surfaces "fins# can be used to enhance heat transfer. 3leaning and repair are relatively straightforward, because the e)uipment can be dismantled for this purpose." httpF((www.thomasnet.com(articles(process$ e)uipment(heat$exchanger$types#
P>&"s
11 | P a g e
C*assi%ication o% P>&"s
umps used in process industries may be broadly classified in two main typesF O O
Dynamic "Pinetic#, and ositive$displacement.
D+na&ic P>&"s
Dynamic "kinetic# pumps such as centrifugal pumps are pumps in which energy is imparted to the pumped li)uid by means of a moving 1mpeller or ropeller rotating on a shaft. The kinetic energy imparted to the fluid in terms of velocity by the moving impeller is converted to pressure as the li)uid leaves the 1mpeller and moves through a stationary volute or diffuser casing. "httpF((www.pumpscout.com(all$pump$types# Positi#e:is"*ace&ent P>&"s
ositive$displacement pumps are those pumps in which energy is imparted to li)uid in a fixed displacement volume such as a casing or cylinder by the rotating motion of gears, screws or vanes, by reciprocating pistons or by plunger." httpF((www.pumpscout.com(all$ pump$types# The process will use centrifugal pumps, which are often the best choice for low viscosity "thin# li)uids "%T&' and isobutylene# and high flow rates. The pump uses one or more impellers that attach to and rotates with the shaft. The rotation of the impeller creates energy that moves li)uid through the pump and pressurizes the li)uid to move it through the piping system. "httpF((www.energymanagertraining.com(Qournal(A?8:A88=(9electionofumpsforrocess1ndu stries.pdf#
Cor experimental design in research methodology the mixed butanes stream is replaced by a stream of pure isobutylene to react with the methanol. The feed components have been altered therefore the hilips etherification process has to be modified in the process design chapter in order for it to align with our experimental design and results in the following two chapters.
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CHAPTER /.0, RESEARCH METHODO(OG7
/.1 DATA CO((ECTING METHODS AND SOURCES
• • • •
1nternet 'xperimental results 3onsultation of expert engineers 3hemical engineering 5ournals 13 | P a g e
• •
-elevant chemical engineering textbooks 1nterviews
/.2 RESEARCH OBECTI)ES • • • • • • •
To find a way to minimize %T&' production costs in Zimbabwe 1nformation on problems encountered during %T&' production /ow to increase the conversion of the process To find out the amounts of the reactants needed To find out limitations of the process using a single reactor To find out limitations of the process using a non$reactive fractional distillator To find out the standards re)uired for the methanol )uality and compare to our local methanol )uality
/./ INTER)IE9S
6e visited some industries in the petrochemicals sector and carried out interviews to find out information about! • •
0mount of methanol produced per day 0mount of isobutylene and mixed butenes available and how much can be imported
/. E@PERIMENTA( P(AN
9everal experiments were carried out in order to determine the )uality or purity of methanol obtained from 43 Distillers, the amount of %T&' obtained per kilogram of methanol and isobutylene, the composition of the product obtained from the reaction of methanol and isobutylene and also the conditions under which a high yield of %T&' is produced. Curthermore, finding a rough estimate of the cost for producing %T&' at a low scale then scaling it up to industrial level. The experiments carried out wereF •
'xperiment to determine the amount of %T&' produced from one kilogram of methanol and one kilogram of isobutylene.
14 | P a g e
•
/ow the yield of %T&' changes with change in temperature, amount of catalyst and
•
change in pressure. 'xperiment to determine the purity of methanol
0fter obtaining the product from the reaction of methanol and isobutylene the following tests were to be done • •
Qones oxidation test for alcohols 1odine test for ethers
/..1 E@PERIMENTA( PROCEDURE
1
3atalytic reactionF %ethanol was obtained from 43 distillers and isobutylene from %asasa chemical suppliers. 8. = grams of sulphonated ion exchange resin catalyst was incorporated into the fixed bed. =8 grams of methanol feed and A= grams "?A.= cm# of isobutylene feed were put into the reaction vessel using a syringe pump and sealed. The experiment was carried out in a stainless steel fixed bed reactor containing a magnetic stirrer at 8 bars and :8o3 over a period of A hrs. Note density of isobutylene =
11
0.5879g/cm3
Cractional distillationF The product stream from the catalytic reaction was put into a
fractional distillatory to separate %T&' and the unreacted methanol. The boiling point for %T&' is ==.Ao3.The boiling point for methanol is ;?. o3 and the boiling point of isobutylene is $;.:o3.9o as the %T&' reached its boiling point it turned into vapor and condensed in the condenser and then collected as product. /ence what remained in the distillation column was collected. /..2 TESTING FOR THE PURIT7 OF METHANO(
0im Determining the purity of methanol 0pparatus &eaker, methanol and hydrometer rocedure • •
A=8ml of methanol were placed in a beaker 0 hydrometer was placed inside the beaker such that it floated on the methanol
15 | P a g e
/../ ONES O@IDATION TEST FOR A(COHO(S
0im To test for the presence of methanol in the product -eagents 3hromium trioxide, condensate 3onditions Temperature of A=o3 0pparatus Test tube, dropper rocedure • • •
0 small sample of the condensate was put into the test tube two drops of chromium trioxide were added The tube was observed for an immediate "A$= sec# color change
/.. E@PERIMENT, IODINE TEST FOR ETHERS
0im To test for the presence of %T&' in the product -eagents otassium iodide, condensate 3onditions Temperature of A=o3 0pparatus Test tube, dropper rocedure •
0)ueous otassium iodide solution was added into the test tube containing a sample of the product and observed 16 | P a g e
CHAPTER .0, RESU(TS AND ANA(7SIS
.1
RESU(TS
FOR
THE
CATA(7TIC
AND
FRACTIONA(
DISTI((ATION
E@PERIMENT
Table A -esults for the catalytic and fractional distillation experiment 'xperiment + A ? = ;
ressure"bars# A8 A8 A8 A8 A8 A8
Temperature"o3#
%ass
%ass
left
in
=8 8 :8 +88 ++8 +=8
collected"g# ?.B ?:.+ =+. =8.?= ?;.B: ?8.=
distillation flask AA.=; A+.= A8.:? AA.+8 A+.; A8.; 17 | P a g e
A8
A88
=.:B
+:.==
Table > conversion of isobutylene Temperature"o3# =8 8 :8 +88 ++8 +=8 A88
> conversion B+.; B.;B :8.;B :8.A8 .88 ?=.;B AA.+A
18 | P a g e
Cigure A graph of > isobutylene conversion against temperature .2 DISCUSSION OF RESU(TS
*sing experiment number with the highest > conversion for isobutylene =+.g of product was condensed and collected, A8.:?g was left in the fractional distillatory. /ence composition of collected product and the remainder must be determined and the percentage conversion of isobutylene the limiting reactant. %T&' was condensed and collected. 'xpected amount of product in fractional distillatory R mass of feed $ mass of collected product 5$:1.5/$2/.25$
1t was expected that A.Ag would remain in the fractional distillatory but only A8.:? g was obtained. A&o>nt o% "!o>ct tat e#a"o!ate R &ass o% e;"ecte "!o>ct in %!actiona* isti**ato!+
$
act>a* &ass o% "!o>ct tat !e&aine in %!actiona* isti**ato!+
2/.25$:20.8$2.//$
9ince isobutylene has a boiling point of $;.:o3 it was concluded that A.g of isobutylene evaporated. Mass o% iso=>t+*ene tat !eacte &ass o% iso=>t+*ene %ee : &ass o% e#a"o!ate "!o>ct
R 2$ 2.//$ 22.35$ con#e!sion o% iso=>t+*ene <&ass o% !eacte iso=>t+*ene&ass o% iso=>t+*ene %ee?100 <22.352.00?100 80.36
34D'490T' 0402S919 1f AA.;g of isobutylene reacted then AA.;g of methanol reacted to produce ?=.?g of %T&'. 19 | P a g e
co&"osition o% MTBE in conensate <&ass o% &t=e "!o>ce&ass o% conensate?100 <./$1.5/$?100 66 Te!e%o!e co&"osition o% &etano* in conensate 12
D19T1220T-S -D*3T 0402S919 1f methanol fed is :?> pure then the remaining ;> is water 0mount of water in methanol feed R 8.8;=8g R g 0mount of methanol in feed R ?g Therefore amount of methanol that remained in the fractional distillatory R mass of distillatory product < mass of water in feed R A8.:? < R +.:?g > composition of methanol R "mass of methanol(mass of product#+88 R "+.:?(A8.:?#+88 R B;> > composition of water R +?> ./ RESU(TS FOR (ABORATOR7 TESTS CARRIED OUT
?..+ Test %o! &etano* ">!it+ R esults
The specific gravity of methanol was found to be 8.B8B Therefore methanol purityR+$specific gravity of sample(+$specific gravity of pure methanol %ethanol purityR+$8.B8B(+$8.:+
R8.+:;A(8.A8BR8.:?
R8.:?+88> %ethanol purityR:?>
The sample of therefore contains :?> methanol and ;> water, this water should be accounted for in mass and energy balance in the following chapter ?..A Test %o! a*coo* -esults
20 | P a g e
Cormation of an opa)ue suspension with a green to blue after two drops of chromium trioxide was observed color was observed. This implies that a primary alcohol is present in our product. /ence we can conclude that methanol is present in our product since it was fed in excess. ?.. Test %o! ete! -esults Cormation of a tan solution after drops of potassium iodide was observed. This implies that ether is present in our product. /ence we can conclude that %T&' which is a ma5or constituent of our product is present in the product obtained
CHAPTER .0 PROCESS DESIGN .1 PROCESS F(O9 DIAGRAM
Cigure F rocess Clow Diagram
21 | P a g e
PROCESS INFORMATION
'$+ %ethanol storage tank '$ %T&' reactor '$? distillation column for separation of methanol, isobutylene and methanol 22 | P a g e
'$= distillation column for separation of methanol, isobutylene and water '$A 1sobutylene storage tank '$+8 %T&' storage tank 9tream + %ethanol$isobutylene feed stream 9tream 9tream contains %T&', excess methanol and unreacted isobutylene 9tream 9tream contains BB>wt %T&' and +A>wt methanol 9tream ? 9tream contains >wt methanol, +>wt water and +8>wt isobutylene 9tream ; %ethanol and isobutylene recycle stream 9tream = 6aste water stream .2 PROCESS DESCRIPTION
%ethanol and isobutylene are fed into the %T&' reactor, %T&' is produced and excess methanol and isobutylene remains. The excess reactants and the product are separated in the distillation column '$? and a stream which contains BB>wt %T&' and +A>wt methanol is collected as product. The overhead stream from column '$? which contains >wt methanol, +>wt water and +8>wt isobutylene is fed into distillation column '$= were methanol and isobutylene are recycled while the water is collected as waste.
./ MASS BA(ANCE
=..+ %T&' -'03T- Basis !00"mol/#$. Combined feed to t#e $eacto$
23 | P a g e
8.=:B 3=/+A 100Kmol/hr
8.?: 3//
.
8.8+ 3?/B
8.; 3//
Cigure =F %T&' reactor material balance =..A D19T1220T- '$
A.AAkmol(hr. /A .8Bkmol(hr. 3?/B A;.;:kmo(hr.
=:.B?kmol(hr. 3=/+A ?.B;kmol(hr. 3// .8Bkmol(hr. 3?/B A.AAkmol(hr. /A
24 | P a g e
=:.B?kmol(hr. 3=/+A B.+;kmol(hr. 3//
Cigure ;F '$? material balance
=.. D19T1220T- '$=
A;.;:kmo(hr.3// .8Bkmol(hr.3?/B
A.AAkmol(hr. /A .8Bkmol(hr.3?/B
/A Cigure F '$= material balance
A.AAkmo(hr.
25 | P a g e
3023*20T149 MTBE Reacto!
Crom experimental results isobutylene overall conversion is :8.;B> therefore number of moles of isobutylene that reacted areF 8.:8;B8.+88 R A:.:Akmol(hr. Table ?F %T&' reactor stoichiometric balances %oles 9toichiometric moles 0ctual moles -eacted moles *nreacted moles
CH/OH <'&o*!.?
CH6<'&o*!.?
; + A A:.:A .8B
+ + A:.:A .8B
%oles of %T&' produced R +88kmol(hr. < ".8BK .8B# kmol(hr. R =:.B?kmol(hr. 14*T R *T*T >%T&' R =:.B?(+88+88 R =:.B> >3// K /A R .8B(+88+88 R .+> >3?/B R .8B(+88+88 R .+> >6ater in product stream R 8.8;.8B R A.AA(+88+88 R A.A> Therefore mass of methanol in product R .8B< A.AA R ?.B;kmol(hr. Disti**ato!+ E: Metano* =a*ance
Crom experimental results 1f 9tream composition is BB>wt %T&' and +A>wt 3// then 1f BB>wt R =:.B?kmol(hr. 3=/+A then +A> 3// R x &y simple proportion, moles of 3// in 9tream R +A(BB=:.B? R B.+;kmol(hr. %oles of methanol in 9tream ? R ?.B= < B.+; R A;.;:kmol(hr. 26 | P a g e
. ENERG7 BA(ANCE
The e)uation that we used to calculate the power J or 6 at each e)uipment isF J < 6 R U/-K "$U/in# K "U/out# K "UP'# K "U'# To calculate U/, first we need to find the 3p values for every component in each of the 9tream. To find the 3p values, we need to use this e)uation to find the values of 3p 3p R a K bT K cTA K dT The values of a, b, c and d are taken from 0ppendix D, 3oulson and -ichardson 3hemical 'ngineering, Eolume ;. 1f the temperature and pressure is more than the critical temperature and pressure of the component, we need to find the "3p< 3po# for that specific component. &ut as for all of our temperatures and pressures none of them exceed the critical temperature and pressure! we need not to find the "3p< 3po# To find the value of U/, we use this e)uationF U/ R
V
3pdT x "n#
TA T+
9hould there is any reaction in the process! we need also to find the values of U/- which takes place in the e)uipment. The e)uation, which we used to find U/- isF U/-R "UWC product$ UWC reactant# x n ..1 MTBE REACTOR
27 | P a g e
T R :?o3,
T R +8+o3,
R A888ka
R A888ka
Cigure +8F %T&' reactor energy balance Table =F 9tream A 9ubstance
Clow
rates /f
3// 3?/B
"kmol(hr.# ;
To
T
/
kQ(kmol $AB;88 $+;B8
P A:B A:B
P ; ;
kQ(hr. ;8:?88 ??B8 X/ R:=ABB 8
Table ;F 9tream 9ubstance
4
/f
To
T
/
3// 3?/B 3=/+A /A
kmol(hr. ?.:8 .+8 =:.B? A.A8
kQ(kmol. $AB;88 $+;B8 $AA=8 $A?A888
P A:B A:B A:B A:B
P ? ? ? ?
kQ(hr. =+A88 =;8 ;8:8 ;.+8 X/ R+8;;8
9tream A X/r R ;"$AB;88# K "$+;B8# R$?AB;.?k6 9tream X/r R ?.:"$AB;88# K .+8"$+;B8# K =:.B?"$AA=8# KA.A8"$A?A888# R $8B.::k6
28 | P a g e
'nergy balance J $ 6 R X/r K X/out $ X/in K P' K' P' R 8 ' R 8 / R X/r K X/out $ X/in X/r. R X/r. "products# $ X/r. "reactants# X/r. R $8B.::$"$?AB;.?# R $ A:.;=k6 / R "$A:.;=# K A:=.B$"A;?.;:# / R $A;;.:;k6 / R J R $A;;.:;k6 ..2 DISTI((ATOR E:
T R =.o3 R 8=ka
T R ;?.=o3 R ?=8ka
29 | P a g e
R ?88Pa T R +8.o3 Cigure ++F '$? energy balance
Table F 9tream 9ubstance
4
/f
To
Tf
/
3=/+A
kmol(hr. =:.B?
kQ(kmol $AA=8
P A:B
P .=
kQ(hr. +8
3//
?.:8
$AB;88
A:B
.=
+B88
3?/B
.+8
$+;B8
A:B
.=
AB+;8
/A
A.A8
$AB=B?8
A:B
.=
+=8 X/ R =?AB8
Table BF 9tream 9ubstance
4
/f
To
T
/
3=/+A 3//
kmol(hr. =:.B? B.+;
kQ(kmol. $AA=8 $AB;88
P A:B A:B
P ;. ;.
kQ(hr. ;:A==8 B?A8 X/ RA8
/f
To
T
/
Table :F 9tream ? 9ubstance
4
30 | P a g e
3// 3?/B /A
kmol(hr. A;.;: .8B A.AA
kQ(kmol $AB;88 $+;B8 $AB=B?8
P A:B A:B A:B
P A;. A;. A;.
kQ(hr. :;:B8 +AB8 AAB8 X/ R ++A+8
'nergy balance J $ 6 R X/r K X/out $ X/in K P' K' 6R8 X/rR8 'R8 P'R8 J R X/out $ X/in J R "A+=.:+ K +.+=#$"+=8.# J R :;.A:k6 ../ DISTI((ATOR E:
T R =.o3 R +88ka
31 | P a g e
T R ?8o3 R +88ka
T R 8o3 R +88ka
Cigure +AF '$= energy balance Table +8F 9tream ? 9ubstance
4
/f
To
T
/
3// 3?/B /A
kmol(/r. A;.;: .8B A.AA
kQ(kmol $AB;88 $+;B8 $ABB?8
P A:B A:B A:B
P + + +
kQ(hr. =8:=8 ;8 AB=8 X/ R ;8+8
Table ++F 9tream ; 9ubstance
4
/f
To
T
/
3?/B 3//
kmol(hr. .8B A;.;:
kQ(kmol $+;B8 $AB;88
P A:B A:B
P A; A;
kQ(hr. ;8 :=:8 X/ R +8A88 32 | P a g e
Table +F 9tream = 9ubstance
4
/f
To
Tf
/
/A
kmol(hr. A.AA
kQ(kmol $ABB?8
P A:B
P 8
kQ(hr. ?88
'nergy balance J $ 6 R X/r K X/out $ X/in K P' K' 6R8 X/rR8 'R8 P'R8 J R X/out $ X/in J R "+.BB K A;.;=K8.++#$+;.+ J R ++.:k6 .. Ene!$+ =a*ance a!o>n "!eeate! E:3
9tream +
9tream A
Table +?F 9tream + 9ubstance
Clow
rates /f
3// 3?/B
"kmol(hr.# ;
kQ(kmol $AB;88 $+;B8
To
T
/
P A:B A:B
P A:B :B
kQ(hr. 8 8 X/ R 8
Table +=F 9tream A 33 | P a g e
9ubstance
Clow
rates /f
3// 3?/B
"kmol(hr.# ;
kQ(kmol $AB;88 $+;B8
To
T
/
P A:B A:B
P ; ;
kQ(hr. ;8:?88 ??B8 X/ R:=ABB 8
J R X/out $ X/in J R A?;.;: < 8 J R A?;.;: k6
. SAFET7 HEA(TH AND EN)IRONMENTA( ANA(7SIS
Cor years, those employed in the chemical industry have known that the safe operation of 3hemical plant is essential to the industry’s continued ability to survive. The human, olitical and financial costs of having accidents are 5ust too high for the chemical industry to not exhibit excellence in their efforts to operate plants in safe and environmentally responsible ways. The chemical industry has an outstanding record in both transportation safety and the safe operations of its processes. That effort has resulted in a dramatic and steady decline in releases and waste produced at chemical sites. 0ctions that should be taken to avoid serious chemical plant accidents are as followsF +. 1n most cases involving large volumes of highly hazardous chemicals, excess flow valves are in place that would stop a rapid flow of the chemicals. A. 6hen highly hazardous chemicals are involved, processes have fixed protection, as well as trained emergency response teams that could handle the incident. . 0ppropriate reaction control or inhibiting systems are in place to interrupt runaway reactions if cooling, heating and pressure relief are not considered ade)uate. ?. 3ontrol systems are designed to detect heat or pressure of a chemical reaction and to control that reaction. =. 6ork more closely with local and state law enforcement groups. 34 | P a g e
..1 ISOBUT7(ENE
$ 3olorless li)uefied gas, odorless. $ Clammable gas. %ay cause flash fire $ 3ontents under pressure $ Detection of leak via sense of smell may not be possible if odorant has degraded $ 3ontact with li)uefied gas can cause frostbite $ 2i)uid can cause eye and skin in5ury $ -educes oxygen available for breathing P+sica* an Ce&ica* P!o"e!ties
0ppearance and odorF
colorless li)uefied gas, odorless.
h.F
4a
Eapor pressureF
A psia Y .B c
Eapor density "airR+#F
A.+
&oiling pointF
$+A[c "+8.?[f#
9olubilityF
negligible
ercent volatileF
+88 > volume
9pecific gravityF
8.=;? Y +=.; c
'vaporation rateF
\+
I&&eiate Hea*t E%%ects, E+eF &ecause the
li)uid product evaporates )uickly, it can have a severe chilling effect on eyes
and can cause local freezing of tissues "frostbite#. 9ymptoms may include pain, tearing, reddening, swelling and impaired vision. S'inF
&ecause the li)uid product evaporates )uickly, it can have a severe chilling effect on skin
and can cause local freezing of tissues "frostbite#. 9ymptoms may include pain, itching, discoloration, swelling, and blistering. 4ot expected to be harmful to internal organs if absorbed through the skin. In$estion F %aterial is a gas and cannot usually be swallowed.
35 | P a g e
Ina*ation F
This material can act as a simple asphyxiate by displacement of air.
9ymptoms of asphyxiation may include rapid breathing, in coordination, rapid fatigue, excessive salivation, disorientation, headache, nausea, and vomiting. 3onvulsions, loss of consciousness, coma, and(or death may occur if exposure to high concentrations continues. Fi!st Ai Meas>!es E+eF
Clush eyes with water immediately while holding the eyelids open. -emove contact
lenses, if worn, after initial flushing, and continue flushing for at least += minutes. Het immediate medical attention. S'in, 9kin
contact with the li)uid may result in frostbite and burns. 9oak contact area in tepid
water to alleviate the immediate effects and get medical attention. In$estion,
4o specific first aid measures are re)uired because this material is a gas and cannot
usually be swallowed. Ina*ation,
Cor emergencies, wear a nose approved air$supplying respirator. %ove the exposed
person to fresh air. 1f not breathing, give artificial respiration. 1f breathing is difficult, give oxygen. Het immediate medical attention. ..2 METHANO(
%ethanol synonyms with %ethyl alcohol and in chemical family alcohol with the formula 3//. %ethanol is a clear, colorless, mobile, volatile, flammable li)uid and it’s soluble in water, alcohol and ether. P+sica* an Ce&ica* "!o"e!ties
hysical stateF
li)uid
&oiling ointF
;?.o3
Eapor ressure
"A8o3#F +AB mb
Eapor Density "airR+#F
+.++
9olubility in water, >wtF
full
9pecific HravityF
8.:A g(cm
0ppearance and odorF
li)uid$colorless$odor specific
36 | P a g e
Fi!e an E;"*osion Haa! ata F
Clash pointF closed cupF
+Ao3
Clammable limits, > volF
2elF ;, *elF ;.=
'xtinguishing mediaF
Coam < 3A
9pecial firefightingF
0void contact with oxidizing materials
*nusual fire and explosionF
%oderate
Reacti#it+ Data
9tabilityF
%edium
3onditions to avoidF
xidizing materials
1ncompatibilityF
9ulfo$chromic mixtures
S"ecia* P!eca>tions
recaution to be taken in handling and storing %ethanolF store in iron or steel 3ontainers or tanks. 9mall )uantities can be stored in reinforced glass containers. ../ MTBE
%T&' is chemically stable! it does not polymerize, nor will decompose under normal conditions of temperature and pressure. *nlike most ether, %T&' does not tend to form peroxides "auto$ oxidize#. The physical state of %T&' is that %T&' is in the form of li)uid at room temperature "A=o3#. 1t is a colorless li)uid with the billing point at ==.A o3. The freezing point of %T&' is < +8B.;o3 <+;.=o3. The density of %T&' at A=o3 is =g(cm. P+sica* an$e!s
%T&' is non$reactive. 1t does not react with air, water, or common materials of construction. The reactivity of %T&' with oxidizing materials is probably low. /owever, without definitive information, it should be assumed that %T&' reacts with strong oxidizers, including peroxides. Ce&ica* an$e!s
%T&' is highly flammable and combustible when exposed to heat or flame or spark, and it is a moderate fire risk. Eapors may form explosive mixtures with air. 1t is unstable in acid solutions. 37 | P a g e
Cire may produce irritating, corrosive or toxic gases. -unoff from fire control may contain %T&' and its combustion products. Ina*ation !is'
2ike other ethers, inhalation of high levels of %T&' by animals or humans results in the depression of the central nervous system. 9ymptoms observe red in rats exposed to ?888 or B888 ppm in air included labored respiration, ataxia, decreased muscle tone, abnormal gait, impaired treadmill performance, and decreased grip strength. These symptoms were no longer evident ; hours after exposure ceased. 0 lower level of %T&', B88ppm did not produce apparent effects "Daughtrey et al., +::#. 0 number of investigations have been conducted to examine the self$ reported acute %T&' in gasoline vapors during use by consumers. This research includes both epidemiological studies and studies involving controlled exposure of volunteers to %T&' at concentrations similar to those encountered in refueling an automobile "-eviewed in *9'0, +::, and 3alifornia '0, +::B#. 1n general, the studies involving controlled human exposures in chambers to levels of %T&' similar to those experienced during refueling and driving an automobile have not shown effects of %T&' on physical symptoms "e.g. irritation#, mood, or performance based tests of neurobehavioral function. . .. EN)IRONMENTA( CONSDIDERATIONS
4owadays, environmental issues become very important. &esides this, a good waste treatment system is also important in order to reduce and minimize environmental pollutants. The chemical waste in the form of solid, li)uid and gases must be treated before being discharged into sewage, drain and atmospheres. 0ny chemical plant to be set up in Zimbabwe must follow the rules and regulations under the 'nvironmental %anagement 0ct "3hap A8FA# 9ection +?8 as read with 9tatutory 1nstrument +8 of A88 "/azardous 6aste %anagement#, is the legislation that regulates handling of hazardous waste, and are the legal instrument used to manage hazardous waste in the country. *nder these regulations, no person shall generate, store, sell, transport, use, recycle, discharge or dispose of hazardous waste to the environment except under a licence from the 'nvironmental %anagement 0gency "'%0#. 38 | P a g e
The plant owner or waste generator must ensure that waste generated is disposed appropriately to prevent environmental pollution. The proper and suitable methods should be implemented in dealing with the waste disposal. %T&' plant is not excluded from these regulations. 0s our plant produces %T&' which is not hazardous to the environment and humans if safety measures are taken into consideration. These environmental considerations depend on the location of our plant.
CHAPTER 3.0 ECONOMIC ANA(7SIS
;.+ P!icin$ an ist!i=>tion ver the period A888$A8+8 the price of %T&' fluctuated between ]8.: $ ]8.=8(kg.The price has remained essentially stable over the last few years, the price of %T&' in the *90 market is *9D8.?(kg whilst in the 'uropean market the price is *9D8.+(kg. The price fluctuations are mainly caused by crude oil prices. 6e are pro5ecting a selling price of *9D8.=8(kg. ;.A P*ant ca"acit+ 3ommercial production of %T&' started in 'urope in +: and in the *9 in +::. Total 6orldwide production capacity in +::B was A.= million tones and the actual production was +B million tones. The expected production capacity for the pro5ect is ;8 888 tons per annum based on 8 working days. ;8 kg and 8 kg of feed will produce =:B kg of %T&'. ;. O>t*ine o% te "!o>ction sce>*e During the first two years of production, full capacity utilization may not be utilized. This is due to lack of manufacturing and marketing experiences. Thus in the first and second year of production only ;8>$B8> of the plant capacity will be utilized. Then afterwards full capacity can be utilized. ;.? Ra &ate!ia*s
39 | P a g e
Zimbabwe has the largest known reserves of methane in 9outhern 0frica! our pro5ect intends to utilize this abundant natural resource which is lying dormant for the benefit of the nation. This means both methanol and isobutylene can be produced locally from the methane. 0t full capacity the actual raw material re)uirement is ; 888 tons methanol and 888 tons isobutylene at an estimated cost of *9D A? ::8 888. ;.= (an an =>i*in$s The cost of land and buildings is estimated to be *9D 88 888. ;.; (ocation an site The best location is the source of the raw materials to minimize transport costs, therefor the plant can be set up in proximity to the methane reserves. Table +F Cixed assets and fixed costs
FI@ED ASSETS
COST
FI@ED COSTS
<@1000?
2and and &uildings Eehicles 1nstallation labor %T&' reactor Distillation column xA 9torage tanks x iping lant maintenance Total
88 =8 +88 A88 +A8 ?= = = BA=
AMOUNT <@1000?
Depreciation 1nterest Taxes 1nsurance
?B8 A?8 +B8 +A8
Total
+8A8
Table +?F -aw material cost and factory overheads RA9 MATERIA(S
COST
FACTOR7 O)ERHEADS
<@1000?
%ethanol 1sobutylene 3atalyst Total
+;8B8 B:+8 B88 2580
COST <@1000?
9ecurity 'mployee benefits %edical allowance Total
+A8 ;8 ;8 A?8
Table +=F Heneral expenses GENERA( E@PENSES
COST <@1000?
40 | P a g e
0dministrative -esearch and Development 'mployees %arketing Total
A?8 ;8 +A8 ;8 ?B8
;.; Financia* ana*+sis The financial analysis of this pro5ect is based on the data presented in the previous chapters and the following assumptionsF$ 3onstruction
+ year
9ource of finance
=8> e)uity and =8> bank loan
&ank interest
+8> per annum
0ccounts receivables
8 days
-aw materials
8 days
6ork in progress
+ day
3ash in hand
= days
0ccounts payable
8 days
;. Financia* e#a*>ation ;..+ P!o%ita=i*it+ 0ccording to pro5ected income statement, the pro5ect will start generating profit in the first year of operation. 1mportant ratios such as profit to total sales, net profit to e)uity and net profit plus interest on total investment "return on investment# show an increasing trend during the lifetime of the pro5ect. ;..A B!ea' E#en Ana*+sis The break$even point of the pro5ect including cost of finance when it starts to operate at full capacity "year # is estimated by using income statement pro5ection. 9ales R ;8 888 888 kg G ]8.=8(kg R ]8 888 888 41 | P a g e
Total Eariable 3ost R ]A= :8 888 Total Cixed 3ost R ]+ ?8 888
Total 3ost R Total Eariable 3ost K Total Cixed 3ost R ]A= :8 888 K ]+ ?8 888 R ]A= :;? 888 &reak$even point R Cixed cost G +88> 9ales$Eariable 3ost R ]+ ?8 888 G +88> ]8 888 888$]A= :8 888 R ?+.> &-'0P 'E'4 2T 0ssuming a linear relationship between variable costs and production rate the following is realized.
42 | P a g e
8 ]"mill#
9ales income Total costs Eariable costs Cixed costs
+,? 8
?+.
=8
+88
> 30031TS Cigure +F &reak even plot
;.. Ret>!n on In#est&ent -eturn on 1nvestment of the pro5ect R" rofit(total investment capital# G +88> rofit R 9ales < cost of production R ]8 888 $ ]A= :8 888 R ]? A+8 888 -1 R "]? A+8 888(]AB 888 888# G +88> R +=> ;..? Pa+=ac' "e!io The investment cost and income statement pro5ections are used to pro5ect the payback period. 43 | P a g e
ayback R Cixed 3apital 1nvestment( "0nnual rofit K Depreciation# ayback period R ]AB 888 888( "]? A+8 888 K ]?B8 888# R ; years ;..= Econo&ic =ene%its The pro5ect can create employment, improve infrastructure in Zimbabwe, supply the national needs and generate huge amounts of tax revenue for the government. The pro5ect creates an opportunity to put Zimbabwe on the world market.
CHAPTER 5.0 CONC(USION AND RECOMMENDATIONS
.+ 3432*914 %T&' production could the county’s answer to the high dependence of using leaded and unleaded petrol. The production of %T&' using our proposed process is an efficient technology with :8.;B> conversion of isobutylene, the process produces water, an environmentally friendly waste product. .A -'3%%'4D0T149 Crom our analysis it is clear that use of petrol without fuel oxygenate results in emission of flue gasses that pose a danger to the environment. /owever, the implementation of %T&' as a fuel additive will involve the following benefitsF 44 | P a g e
• •
•
9ignificant reduction in air pollution due to the reduction in flue gas emission. 1mprovement of competiveness as %T&' has a lower cost as compared to other additives. Qob creation
2ikewise implementation of this pro5ect will provide for the ever sought for clean solutions. The production of this product also promises huge exports that will turn over the current economic situation in Zimbabwe.
APPENDI@
45 | P a g e
REFERENCES
+. /utchings HQ, 4icolaides 3, 9currell %9. +::A. Developments in the roduction of %ethyltert$&utyl 'ther. 3atalysis Today. +=F p. A$?:. A. %atou) %, Tagawa T, Hoto, 9. +::?. 3ombined rocess for roduction of %ethyl tert$ &utyl 'ther from tert$&utyl 0lcohol and %ethanol. Q. 3hem. 'ng. Qapan A, p.8A$8;. . 3ollignon C, 2onders -, %artens Q0, Qacobs 0, oncelet H. +::;. 2i)uid hase 9ynthesis of %T&' from %ethanol and 1sobutene ver 0cid Zeolites and 0mberlyst$+=. Q. of 3atalysis +BA, p. 8A$+A. ?. 0rmando T. Juitain, 9hunsaku Patoh and %otonobu Hoto. A8+ 9ynthesis of &iomass$ Derived Hasoline Cuel xygenates by %icrowave 1rradiation. 46 | P a g e
