PROJECT ON NITROBENZENE
1
ACKNOWLEDGEMENT
We here by place our sincere thanks to Dr.R.KARHIKEYAN, Head of the Department of Chemical Engineering , S.R.M Engineering College affiliated to S.R.M University and the faculty members of Chemical Engineering Department for their full hearted co-operation and encouragement for the successful completion of this project. We extend out thanks to Project guide D.BALAJI for the Motivation, encouragement and guidance provided by him. We would also like to extend our thanks to each and everyone who have helped us in completing this project successfully.
2
ABSTRACT
The project deals extensively with the manufacture of nitrobenzene from mixed acid and benzene .Since the demand for aniline has been increasing day by day manufacture of benzene is more important. Nitrobenzene is obtained by treating mixed acid and benzene. A detailed process flow sheet, material balance, energy balance, have been done. A detailed design of equipments, cost estimation of plant, plant layout and safety aspects have been discussed.
3
CONTENTS
Chapter No
Topic
Page NO.
1.
INTRODUCTION
5
2.
PHYSICAL PROPERTIES
7
3.
CHEMICAL PROPERTIES
9
4.
USES
12
5.
PROCESS DESCRIPTION
14
6.
MATERIAL BALANCE
19
7.
ENERGY BALANCE
25
8.
REACTOR DESIGN
29
9.
DISTILLATION COLUMN DESIGN
35
10.
COST ESTIMATION
44
11.
HEALTH AND SAFTEY FACTORS
51
12.
PLANT LAYOUT
55
13
CONCLUSION
62
14.
BIBLIOGRAPHY
64
4
1.INTRODUCTION
5
1.CHAPTER
Nitrobenzene was first synthesized in 1834 by treating Benzene with Fuming Nitric Acid, and it was produced commercially in England in 1856. The relative case of aromatic nitration has contributed significantly to the large and varied industrial application of nitrobenzene and its derivative.
Nitrobenzene (oil of Mir bane) is a pale yellow liquid with an odor of bitter almonds. Depending upon the compound impurity , its color varies from pale yellow to yellowish brown. Nitrobenzene is one of the important raw materials for the dye manufacture and most nitrobenzene produced is used directly or indirectly in dye manufacture. It is manufactured on large scale only by aniline manufactures. Ref[1]
6
2.PHYSICAL PROPERTIES
7
2.CHAPTER 2.Physical Properties of Nitrobenzene :ref[4] Molecular Weight
123.11
Boiling Point
210 - 211 °C
Melting Point
6 °C
Flash Point
88 °C (closed cup)
Vapor Density
4.3 (air = 1)
Vapor Pressure
1 mm Hg at 44.4 °C
Density/Specific Gravity
1.205 at 15/4 °C (water = 1)
Log Octanol/Water Partition Coefficient
1.85
Henry's Law Constant
2.44 x 105 atm-m3/mole
Conversion Factor
1 ppm = 5.04 mg/m3
8
3.CHEMICAL PROPERTIES
9
3.CHAPTER CHEMICAL PROPERTIES 1.
Nitrobenzene reactions involve substitution on the aromatic ring and reactions involving the nitro group.
2.
Under electrophilic conditions, the substitution occurs at a slower rate than for benzene and the nitro group promotes met substitution
3.
Nitrobenzene can undergo halogination,sulfonation and nitration, but it does not undergo Friedel-crafts reactions.
4.
Under nucleophilic conditions, the nitro group promotes ortho and para substitution.
5.
The reaction of nitro group to yield aniline is the most commercially important reaction of nitrobenzene.
6.
Depending on the conditions, the reduction of nitrobenzene can lead to a variety of products.
10
Reduction Products Of Nitrobenzene Reagent
Product
Fe,Zn or Sn+HCl
Aniline
H2+metal catalyst+ heat (gas phase or solution)
Aniline
SnCl2+acetic acid
Aniline
Zn+NaOH
Hydrazobenzene, azobenzene
Zn + H2O
N-Phenylhydroxylamine Azoxybenzene
Na3ASO3
Azoxybenzene
LiAIH4
Azobenzene
Na2S2O3 + Na3PO4
Sodium Phenylsulfamate,C6H5NHSO3NA
11
4.USES
12
4.CHAPTER
The largest end use of nitrobenzene is in the production of aniline.approximtely 95-98% of nitrobenzene is converted to aniline the demand for nitrobenzene fluctuates with the demand for aniline production grew at an average annual rate of almost 5% from 1984 to1988 but dropped by over 4% during the 1989-1990 economic downturn. For 1990,96% of the 532972 metric tons of nitrobenzene left were used to produce variety of other products, such as para-aminiphenol and nigrosine dyes. The U.S. producers of PAP are MALLINCHRODT,INC., RHONEPOULENC, and Hoechst cleanse with combined production capacities >35000 metric tons. Mallinckrodt is the largest producer, with over 50% of capacity PAP primarily is used as an intermediate for acetaminophen. Ref[4]
13
5.PROCESS DESCRIPTION
14
5.CHAPTER Nitrobenzene is prepared by direct nitration of benzene, using a nitric acid-sulphuric acid mixture. The reaction vessel or nitrator is a specially built cast-iron or steel kettle fitted with an efficient agitator. The kettle is jacketed and generally contains internal cooling coils for proper control of the exothermic reaction. Nitrobenzene can be produced by either a batch or a continuous process with a typical batch, the reactor is charged with benzene, and the nitrating acid (5660% H2SO4,27-32wt% HNO3 and 8-17%wt% H2O) is added slowly below the surface of the benzene. The temperature of the mixture is maintained at 55-55°C by adjusting the feed rate of the mixed acid and the amount of cooling. the temperature can be raised to 90°C towards the end of the reaction to promote completion of reaction. The reaction mixture is fed into separator where the spent acid settles to the bottom and is drawn off to be refortified. The crude nitrobenzene is drawn from the top to the separator and washed in several steps. depending on the desired purity of the nitrobenzene the product can be distilled. Usually a slight excess of the benzene is used to ensure that little or no nitric acid remains in spent acid. Yield is about 98%. Because of a continuous nitration process generally offers lower capital cost and more efficient labor usage than a batch, most if not all of the nitrobenzene produce use continuous process. Benzene nitrating acid (56-65 wt% H2SO4,20-26%HNO3 & 15-18wt% water) are fed into the nitrator, which can be a stirred cylindrical reactor with internal cooling coils and external heat exchangers or cascade of such reactors. The nitator also can be designed as a tubular reactor e.g. tube and shell heat exchangers with appropriate cooling coils involving turbulent flow. Generally, with a tubular reactor the reaction mixture is pumped through the reactor cycle loop and a portion of the mixture is withdrawn and fed into the separator.
15
A slight excess of benzene usually is fed into the nitrator to ensure that the nitric acids in the nitrating mixture is consumed to maximum possible extent and to minimize the formation of di-nitrobenzene. the temperature of the nitrator is maintained at 50-100°C by varying the amount of cooling. The reaction mixture flows from the nitrator into separator are centrifuged here is separated into two phases. The aqueous phase or spent acid is drawn from the bottom and concentrated in a sulfuric acid reconcentrated step or recycled to the nitrator where it is mixed with nitric and sulfuric acid immediately prior to being fed into the nitrator. The
crude nitrobenzene is washed and distilled to remove water and
benzene and if required nitrobenzene can be refined by vacuum distillation. ref[3]
SPECIFICATION AND TEST METHODS Specification and test Methods: Specification for double-distilled nitrobenzene are give in table below, Property
Value
Purity ,%
> 99.8
Color
Clear, light yellow to brown
Freezing Point, 0C
> 5.13
Distillation range (First drop), 0C
> 207
Dry point 0C
212
Moisture,%
<0.1
Acidity As nitric acid, %
<0.001
16
Several qualitative spot tests are applicable to nitrobenzene and depend on characteristic color developed by its reaction with certain reagent. In general, calorimetric methods are subject to interferences from aromatic nitro compounds. Certain colorimetric methods are based on the nitration of nitrobenzene to mnitrobenzene and subsequent determination by the generation of a red-violet color with acetone and alkali. A general micrometric method for the determination of aromatic nitro compounds is based on reduction with titanium(lll) sulfate or chloride in acidic solution followed by back titration of excess titanium (lll) ions with a standard ferric alum solution. Now days most modern techniques use instrumental methods such as gas chromatography and high pressure liquid chromatography.
17
PROCESS FLOW DIAGRAM
18
6.Material Balance
19
6.CHAPTER Individual Material Balance for Mixed Acid Reaction Involved H2SO4 + HNO3 Mol.wt
98
HNO3 (H2SO4)
63
161
Basis : 1 Ton of Mixed acid
H2SO4 600 Kg 1000 Kg of Mixed Acid
Mixer HNO3 400 Kg Where, H2SO4
= Wt / Mol.wt = 600/98 = 6.1224 no of moles
HNO3
= Wt / Mol.wt = 400 /63 = 6.349 no of moles
Mixed acid = Wt/Mol.wt = 1000/161 = 6.2111 no of moles Where, Mass In
= Mass of HNO3 + Mass of H2SO4
20
= 400 + 600 =
Mass Out
1000 Kg
= Mass of HNO3(H2SO4) = 1000 Kg
Mass In = Mass Out
Nitration: Reaction Involved: C6H6 + HNO3(H2SO4) Mol.Wt 78
C6H5NO2 + H2O + H2SO4
161
123
18
98
C6H6 650 Kg HNO3(H2SO4)
C6H5NO2 840.84 Kg Nitration
1000 Kg
H2O 129.36 Kg H2SO4
646.8 Kg
Unreacted C6H6 13Kg UnreactedHNO3(H2SO4) 20 Kg
C6H6
=
Wt /Mol.wt
= 650 /78 = 8.333 no of Moles HNO23(H2SO4) = Wt / Mol.wt
21
= 1000 /161 = 6.2111
C6H5NO2 : Wt %
= 51% of C6H5NO2 = 50.96 /100* 1650 = 840.84 Kg
No of Moles = 840.84 /123 =
6.836 Moles
H2SO4 : Wt %
= 39.2 % of H2SO4 = 39.2 / 100* 1650 = 646.8 Kg
No of Moles = 646.8 /98 = 6.6 Moles H2O : Wt %
= 7.84% of Moles = 7.84/100 *1650 = 129.36 Kg
No of Moles = 129.36 Kg /18 = 7.18 Moles. Unreacted of C6H6 2%: = Wt / Mol.wt
=
2 / 100 * 650 = 13 Kg
= Wt / Mol.wt =
2 /100 * 1000 = 20 Kg
Unreacted of HNO3(H2SO4) 2%:
Mass In
= Mass of HNO3(H2SO4) + Mass of C6H6
22
= 1000 + 650
= 1650 Kg
Mass Out = Mass of C6H5NO2 + Mass of H2O + Mass of H2SO4 + Mass of Unreacted C6H6 + Mass of Unreacted HNO3(H2SO4) = 840.84 + 646.8 + 129.36 + 13+ 20 Mass Out = 1650 Kg
Mass In = Mass Out
Material Balance in Separator ;
C6H5NO2 840.84 Kg UnreactedC6H6 13Kg
C6H5NO2 840.84 Kg
Separator
H2O129.36Kg
H2O129.36 Kg
H2SO4646.8 Kg
H2SO646.8 Kg
UnreactedC6H613Kg UnreacteHNO3(H2SO4)20Kg UnreacteHNO3(H2SO4)20Kg
Mass In
= Mass of C6H5NO2 + Mass of H2O + Mass of H2SO4 + Mass of Unreacted C6H6 + Mass of Unreacted HNO3(H2SO4)
Mass In
= 840.84 + 646.8 + 129.36 + 13+ 20 = 1650 Kg
Mass Out = 1650 Kg
Mass In = Mass Out
23
Material Balance for Distillation Column: Unreacted C6H6 13Kg
C6H5NO2 840.84 Kg Unreacted C6H6 13Kg
D I S T I L L C6H5NO2 840.84 Kg
Mass In
= Mass of C6H5NO2 + Unreacted of C6H6 = 840.84 + 13 = 853.84 Kg
Mass Out
= Mass of C6H5NO2 + Mass of unreacted of C6H6 = 840.84 + 13 = 853.84 Kg
Mass In = Mass Out
24
7.ENERGY BALANCE
25
7.CHAPTER Individual Energy Balance for Mixed Acid: Reaction Involved: H2SO4 + HNO3 Temp 0C Cp(KJ/Kg k)
HNO3(H2SO4)
30
30
55
1.402
2.013
1.641
Cp of HNO3 (H2SO4) ; Cp of mix
=
{ Mass fraction of H2S04 * Cp H2S04} + {Mass fraction of HNO H2S03 * Cp HNO3}
=
{(600/1000) * 1.402} + {(400/1000) * 2.013}
Cp of Mix
=
1.6464 KJ / Kg k
ΔH Reaction
= (ΔHF) Product – (ΔHF) Reactant
(ΔHF) reactant
= (ΔHF) H2SO4 + (ΔHF) HNO3
(ΔHF) H2SO4
= -193.69 Kcal /Mol at 25 0 C. ref[2] = -8269.377 KJ/Kg = - 8269.377*600
(ΔHF) H2SO4
= - 4.9616*106 KJ
(ΔHF) HNO3
= -41.35 KCal / Mol at 25 0 C. ref[3] = - 2749.165 KJ/ Kg = - 2749.165 * 400
(ΔHF) HNO3 = -1.0996 * 106 KJ
26
(ΔHF) reactant = (-4.9616- 1.0996) * 106 KJ = - 6.0612 * 106 KJ (ΔHF) Product = - 236.619 K Cal/ Mol = - 6149.155 KJ/ Kg = - 6149.155 * 1000 = - 6.149 * 106 KJ (ΔHF) reaction = (- 6.149 + 6.0612) * 106 KJ = -0.088 KJ Energy In = (m.cp.dt) HNO3 + (m.cp.dt) H2SO4 = [400 * 2.013 *(30-25)] + [1000 * 1.402(30-25)] = 8232 KJ Energy Out = (m.cp.dt) Product + ΔH reaction = 1000 * 1.641 *(55-25) -0.088 * 106 = 8636.1 KJ
27
Overall Energy Balance: Reaction Involved: C6H6 + HNO3(H2SO4) Temp 0C Cp(KJ/Kg K) Energy In
C6H5NO2 + H2O(H2SO4)
30
55
95
1.769
1.641
1.528
95 1.97
= (m.cp.dt)C6H5NO2 + (m.cp.dt) mix acid = (650 * 1.769 * 55) + (1000 * 1.641 *30) = 112471.75 KJ
Energy Out = (m.cp.dt)C6H5NO2 + (m.cp.dt) H2O(H2SO4) + (m.cp.dt) unreacted C6H6 + (m.cp.dt) unreacted mix acid + ΔHrxn = [840.84 * 1.528 *(95-55)] + [776.16 * 1.97(95-25)] + [13 * 1.769 *(95-25)] + [20 * 1.641 * (95-25)] – 1510080.0 = 113251.79 KJ
Energy In = Energy Out
28
8.Design For Reactor
29
12.CHAPTER Ideal steady state operation is carried out : We know that for a 2nd order reaction,
V ______ FAO
=
XA _______ -rA
(or) V /VO
=
XA/ KCAO(1-XA)2
Where, Vo
=
Feed rate,
CAo
=
Moles of A/VOL of fluid
XA
=
Conversion (98%)
We know that K is const = 1.412 Lit/min.mol . ref[2] Volume of C6H6
Volume of HN03
=
volume of C6H6/ Density of C6H6
=
650 /876 = 742.0L
=
Volume of HNO3 / Density of HNO3
=
400/ 1504 = 265.9L
Volume of H2SO4 = Volume of H2SO4/ Density of H2SO4 =
600 / 1834 = 327.2L
30
Total Volume
= 445.03 l/day = 445.03/24 = 18.54 l/hr = 18.54 / 60 = 0.309 l/min = 18.54/ 3600 = 5.15*10-3 = 0.00515 l/sec.
CAO
= =
CAO
No of Moles/ Total Volume 6.122/0.0052
=1177.31/60 = 19.62 Mol/Lit
= 19.62 Mol/Lit
τ
= V /VO
= XA* CA / K *CAO*(1-XA)2
τ
=
=
V / VO
Vol of the reaction
0.98 * 0.309/ 1.412*19.62*(1-0.98)2 =
= 27.33 Lit =
0.02733 m3
We know that, π /4 D2 H = 0.027 π * D2
= 0.027*4
D
= 0.185 m3
π/4* (0.185)2 H = 0.027 H
=
0.027 * 4 * 1 /π*0.1852
H
=
1.019 m3
31
27.33 Litres
We know that , Thickness of vessel
t = P*D /2FN-P
Operating Pressure Design Pressure
P
= 3+15% = 3.15 atm = 3.15*1.01325 bars*105 N/m2 = 319173.75 N/m3
Design Presure Shear Stress ,
= 3 atm
if
= yield stress /2
We know that Yield stress
= 207*106 ref[5]
Shear Stress
= 207*106 / 2
Shear Stress
= 103*106 w/m3
We know that h—welding efficiency =0.85 ref[5] Thickness of vessel
t = P*D /2FN-P = 319173.75*09 / (2*103*106*0.85)-319173.75 t = 1.64*10-3m
Thickness of vessel
= 1.64 mm
32
DESIGN SUMMARY
Volume of the reactor
=
2.77 m3
Diameter of the reactor
=
0.185 m3
Height of the reactor
=
1.019 m3
Thickness of vessel
=
1.64 mm
33
REACTOR
34
9.DISTILLATION COLUMN
35
9.CHAPTER Basis ; 1 hour of operation. Feed
F
=
Volume of feed
= 35.576 Kg/hr.
Distillate
D
= Volume of distillate = 0.5416 Kg/hr.
Bottom Product B = Volume of bottom Xf
= 35.03
Kg/hr.
= unreacted of benzene /mol.wt / (Unrect/mol) + (prod/mol.wt) = 2/78 / (2/78) + (98/123) = 0.036
Xd
=
nitrobenzene /mol.wt / (nitroben/mol) + (prod/mol.wt)
= 100/78 / (100/78) + (0/123) = Xb
1
= Unrectbenz/mol.wt / (unrectbenz/mol) + (nitrobenzene/mol) = 0/78 / (0/78) + (100/123)
= 0
Average Molecular weight of feed = 123*0.98+78*(1-0.98) = Feed rate
122.1
= 35.576 /122.1 = 0.29 Kg mole / hr
Also, Fxf = Dxd + Bxb From above, D = Fx xf-xb / xd-xb . ref[2] = 0.29*(0.03-0/1-0) D = 0.0087 Kg mole/hr
36
B = 0.29-0.0087 = 0.2813 Kg mole/hr. Slope of q-line ; We know that q = Hg-Hf / Hg-Hl q=1 slope of q-line: slope of q-line = q/q-1 = 1/1-1 Tan-1(α) = 0 q line is st.line Xd / Rm+1
= 0.05
Rm+1 = 1/0.05 Rm+1 = 20 Rm
= 19
R
= 1.2 Rm
R
= 22.8 ∼ 23
Xd
=
Rm+1
1
= 0.042
23+1
37
From Mc-cabe Thile Graph X
0 0.01 0.02 0.03 0.045 0.07 0.10 0.155 0.20 0.30
Y
0 0.03 0.485 0.63 0.74 0.82 0.88 0.92 0.94 0.964 Ideal Plate
=
16 (From Graph)
Actual Plate =
Ideal/n
Actual Plate =
26.66
=
16/0.6
Height: Plate Spacing Ht
= 450 mm = 0.45m
= (Actual Plate-1)*0.45 + 2(0.45) = 12.45m
Diameter : Vap rate
= v = D(R+1) = 0.0087(23+1) n = 0.21 Kg moles/hr
Top Column : Vol.rate
= nRT/P = 0.21*8.314*103*(82+273)/ 1.01325*105 = 6.1170 m3/hr
Vol rate
= 1.7*10-3 m3/sec
Velocity
= 1 m/sec
38
Area
= Vol rate / Velocity = 1.7*10-3 /1
Area
= 1.7*10-3 m2
= π D2 /4
D2 = 4A /π ;
D = √4A /π
D = 0.047 m Bottom column: Vol.rate
= nRT/P = 0.21*8.314*103*(210+273)/ 1.01325*105 = 8.32 m3/hr
Area
= Vol .rate / Velocity
Velocity
= 1 m/sec
Area
= 2.31*10-3 m2
A
= π D2 / 4
D2 = 4a /π ; D = √4A/π D = 0.054 m Both diameters are approximately same , we choose the larger diameter (i.e) bottom diameter Bottom diameter D= 0.054 m
39
DESIGN SUMMARY
Ideal plate
=
16.00
Actual Plates
=
26.66
Column Height
=
12.45m
Column Diameter
=
0.054 m
40
DISTILLATION COLUMN
41
TOPSIDE
42
BOTTOM SIDE
43
10.COST ESTIMATION
44
10.CHAPTER Cost of a Kg of Nitrobenzene in Market
= 35 Rs
The Capacities of Plant is 840.84 Kg/day for 1 year
= 29429.4
Gross `sales for 1 year or Total income
= Rs.87*106
Estimation of capital investment cost Turnover
= Gross Annual Sales Fixed Capital
For Chemical Industries Turn Over ratio
= 1
Therefore gross annual sales
= Fixed Capital Investment
Therefore Fixed capital Investment
= Rs.30.87*106
1. DIRECT COST It is taken as 70% of fixed capital investment Hence direct cost
= 0.7 * 30.87* 106 = Rs 21.6*106
The cost involved in direct costs are Equipment and installation + instrumentation = piping + electrical + insulation+ Paintings which amount for 50% of the fixed capital 1. Equipment cost is 24% of fixed capital cost = Rs.7.4 * 106 2.Installation and painting is 40% of delivered equipment cost = Rs3*106 3.Instrumentation and control and installation cost = 10% of delivered equipment cost this cost is equal to Rs7.4*106 4.Piping and installation cost is 25% of the delivered cost = Rs1.85*106 5.Electrical and installation cost Rs 33.33% of the delivered cost. 45
6.Building , Process and Auxiliary This cost is 39.1667 of the purchased equipment cost this cost is equal to 391667*7.4*106 = Rs289*106 7.Service Facilities and yard improvement is 40% of the delivered equipment cost this cost is equal to 0.4*7.4*106 = 2.96*106 8. Load cost is 1% of fixed capital this cost is equal to 0.001*30.87*106 = Rs 30.87*106
2.INDIRECT COST: This is expenses which are not included with material and labor of actual installation of complete facilities this cost is equal to 0.3*30.87*106 = Rs6.174*106 a) engineering are supervision : this cost is 20% of the fixed capital investment this cost is equal to 0.2*30.87*106 b) Construction expenses and contractor fees. this cost is 10% of direct cost This cost is equal 0.1*21.6*106 = Rs2.16*106 c) Contingency : This cost in 5% of the capital This cost is equal to 0.5*30.87*106 = Rs1.544*106
46
Working Capital: In 20% of total capital investment total capital investment = fixed cap+ Working cap =30.87*106+0.8(Total cost investment) total capital capital investment = 30.87 *106/0.8 = Rs 38.58*106 Working Capital = 38.58*106-30.87*106 = Rs 7.71*106 Estimation of Total Product Cost Total annual income = Rs.30.87*106 Total Grass Earnings = 10% of total annual incomes = 0.1*30.87*106 = Rs3.08*106 Product Cost
= Total annual Gross earnings income =30.87*106-3.08*106 = Rs 27.79*106
Total Product Cost = Direct Production Fixed + Charge Plant + Overhead DIRECT PRODUCTION COST It is 60% of total product cost the Direct Production cost is equal to = 0.6*27.79*106 1. Raw Material : It is 20% of total product cost the cost of raw material is = 27.79*106 = Rs.5.56*106 2. Operating Labor is 15% of the total product cost The cost of operating labor is = 0.15*27.79*106 = 4.168*106
47
3. Direct supervisory and clinical labor is 20% of operating labour. The cost of direct supervisory and clinical labor is = .15*27.79*106= Rs.5.56*106 = Rs4.168*106= Rs.5.56*106 4. Utilities : In 15% of total Product cost The cost of utilities is = 0.15*27.79*106 = Rs4.168*106 5. Maintenance and Repairs : it is 3.6% of fixed capital investment The cost of maintenance = 0.0036*30.87*106 6. Operating Supplies : it is 0.5% of the fixed capital investment The cost of operating supplies is = 0.005*30.87*106 7. Laboratory Charge is 6.6667% of the operating labor cost The cost of Laboratory Charges is = 0.6667*4.168*106 = Rs 0.281681*106 8. Patents and Royalties : it is 1.45% of the fixed capital cost the cost of patents and royalties is = 0.0145*30.87*106 = Rs.447675.00 9. Fixed charge : it is 20% of total product cost. The cost of fixed charges is
= Rs 5.56*106
DEPRECIATION Depreciation for building is 3% of land cost = 0.03*30.87*105 Total depreciation value = Rs0.93*106
48
3. INSURANCE This is 1 % of the fixed capital investment The insurance value = 0.01*30.87*106 = Rs 308700 4. Rent : This is 3.0555% of total product cost Rent value = 0.030555*27.79*106 = Rs.849123.45 C) Plant overheads : The includes cost for following general plant upkeep and Overheads payroll, overhead packaging, medical services safety and protection, Restaurants, recreation salvage, laboratories and storage facilities. This cost is 5% of total product cost plant overhead is equal to = 0.05*27.79*106 = Rs 1389500.00
ll GENERAL EXPENSES: a) Administrative cost: Includes cost for executive officer, clinical wage, legal fees, office Supplies and communication. This cost is 5% of the total product cost Administrative cost = 0.005*27.79*106 = Rs.1389500.00 b) Distribution and selling cost: Includes cost for sales offices, sales man shopping and advertising This cost is 7 of the total product cost Distribution and selling cost
= 0.07*27.79*106 = Rs. 1945300.00
49
c) Research and development This cost is 1% of total product cost. Research and Development cost
= 0.01*27.79*106 = Rs 277900.00
D) Gross earning cost: it is the net profit obtained after deduction of tax from gross earning Gross earning cost = 60% Net profit
= Rs 1.848*106
d) Pay back period: with interest charge Pay back = Depreciable fixed capital investment Average profit/year-Average depreciation/year = (30.87-3.08)*106 /(1.846+3.08)*106 = 5.612 years Pay back = 5years 233 days ref[2]
50
11.HEALTH AND SAFTEY FACTORS
51
11.CHAPTER Nitrobenzene is a very toxic substance the maximum allowable concentration for nitrobenzene is 1ppm or 5 mg/m³.It is readily absorbed by contact with skin and by inhalation of vapor, If a worker was exposed for 8 hours to 1ppm nitrobenzene in the working atmosphere, about 25mg of nitrobenzene would be absorbed, of which about one-third would be by skin absorption and the remainder by inhalation . The primary effect of nitrobenzene is the conversion of hemoglobin to met hemoglobin; thus the conversion eliminates hemoglobin from the oxygen-transport
cycle.
Exposure to nitrobenzene may irritate the skin and eyes. nitrobenzene affects the central
nervous
and
produces
fatigue,
headache,vertigo,vomiting,
general
weakmess,and in some cases unconscious and coma. There generally is a latent period of 1-4 hours before signs or symptoms appear. Nitrobenzene is a powerful met hemoglobin former, and cyanosis appears when the met hemoglobin level reaches 15%. Chronic exposure can lead to spleen and liver damage, jaundice and anemia. Alcohol in any form should not be ingested by the victim of nitrobenzene poisoning for several days after the nitrobenzene poisoning or exposure. Impervious protective clothing should be worn in areas where risk of splash exists. Ordinary work clothes that have been splashed should be worn in areas where risk of splash exists. Ordinary work clothes that have been splashed should be removed immediately, and the skin washed thoroughly with soap and warm water. In areas of high vapor concentrations full face marks with organic-vapor canister or air-supplied respirators should be used. clean work clothing should be worn daily and showering after each shift should be mandatory. With respect to the hazards of fire and explosion, nitrobenzene is classified as a moderate hazard when exposed to heat or flame. Nitrobenzene is classified by the ICCas a classB poisonous liquid. Ref[1]
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ENVIRONMENT EFFECTS First draft prepared by L. Davies, Office of Chemical Safety, Therapeutic Goods Administration, Australian Department of Health and Ageing, Canberra, Australia Published under the joint sponsorship of the United Nations Environment Programmer, the International Labor Organization and the World Health Organization, and produced within the framework of the Inter-Organization Programmer for the Sound Management of Chemicals. The International Programmer on Chemical Safety (IPCS), established in 1980, is a joint venture of the United Nations Environment Programmer (UNEP), the International Labor Organization (ILO) and the World Health Organization (WHO). The overall objectives of the IPCS are to establish the scientific basis for assessment of the risk to human health and the environment from exposure to chemicals, through international peer review processes, as a prerequisite for the promotion of chemical safety, and to provide technical assistance in strengthening national capacities for the sound management of chemicals. The Inter-Organization Programmer for the Sound Management of Chemicals (IOMC) was established in 1995 by UNEP, ILO, the Food and Agriculture Organization of the United Nations, WHO, the United Nations Industrial Development Organization, the United Nations Institute for Training and Research and the Organization for Economic Co-operation and Development (Participating Organizations), following recommendations made by the 1992 UN Conference on Environment and Development to strengthen cooperation and increase coordination in the field of chemical safety. The purpose of the IOMC is to promote coordination of the policies and activities pursued by the Participating Organizations, jointly or separately, to achieve the sound management of chemicals in relation to human health and the environment. Nitrobenzene. (Environmental health criteria ; 230) 1.Nitrobenzenes - toxicity
53
2.Nitrobenzenes - adverse effects 3.Environmental exposure 4.Risk assessment I. International Programmer for Chemical Safety II.Series. ref[1]
HANDLING AND STORAGE TRANSPORTATION Nitrobenzene samplings handling procedures in the united states are described by ASTMP 3436-75.They are classified by the U.S interstate commission (ICC)as a poisonous liquid,classB (regulation 173 347) and as a class 6 poison by united nations as such they must be packaged in ICC specifications contains when shipped by rail, water or highway and all of ICC regulations regarding loading handling and labeling must be followed. nitrobenzene ordinarily is transported in tanks, cars, tank trucks, or metal drums. Carbon steel or cast iron is considered materials of choice for handling nitrobenzene except when decolonization must be kept to minimum. Stainless steel (400 series) is recommended for color critical applications. Nitrobenzene attacks, copper alloys, brass and copper. It is rated on class IIIA combustible liquids (NFPA std no.30) and usually can be handled with little danger of fire. Ref[2]
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12.PLANT LAYOUT
55
15.CHAPTER Plant layout is the functional arrangement of machinery and equipment in a existing plant. Plant layout may be defined as the floor plan for determining and arranging the desired equipment of a plant, in the one best place, to permit the quickest flow of materials at lowest cost and least amount of handling in processing the raw material from the receipt of raw material to the shipment of finished products. The material handling planned in the layout begins at the receiving point , where the material arrives as raw material, then continuous progressively from storage through process, moving the from of worked material from department to department , from machine to machine, the material flows in and out of temporary storage is fed through assembly lines for final assembly. Provision is made for inspection, packaging and storing the material as finished product. Advantages of good plant layout to the workers : •
Reduces the effort of the workers.
•
Reduces the number of handling.
•
Permits working at maximum efficiency.
•
Reduces the number of accidents.
•
Provides basis for higher earnings.
Advantages of a good plant layout in labour cost: •
Increases output per man hour.
•
Reduces number of operators.
•
Loss setup time involved
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Advantages of a good plant lay out in production control: •
Reduces production control expenses
•
Pace production
Fundamental concepts of plant layout : In apprising the advantages of good layout in the light of conditions prevailing in a particular plant ,it is well to bear in mind the following concepts of plant layout. •
Major part of production works is not processing , as is initially suppose but material handling.
•
Then speed of production in the plant is determined primarily by the adequacies of its material handling facilities.
•
A good plant layout is designed to provide the proper facility for material handling.
•
The factory is altered or constructed around the prescribed plant layout.
•
The production efficiency of the plant is determined by the limitations of its layout.
TYPES OF DEPARTMENT •
Processing department.
•
This department performs machining assembly and packaging.
•
Service department.
•
These constitute the facilities provided to keep the processing department in operation without interruption.
•
Administrative department.
57
•
This department administrative sales,engineering,accounting production control, departments etc.
PLANNING THE PROCESSING •
The plant layout engineer should obtain data on building elevation, column spacing, door and conveyors.
•
The conveyors should be placed at reasonable height to mal functioning and waste.
•
The traffic in the plant may be greatly by location store rooms close to the building entrances.
•
In addition to the above vehicular traffic should be separated from pedestrian traffic and the roads should be wider.
PLANNING THE PLANT SERVICE FACILITIES: •
Material received at a plant arrives via the particular forms of transportation which are generally prescribed.
•
Liquids such as chemicals are transported in tank cars, drums or pipelines
•
The receiving department must be well equipped to receive the material in all modes.
•
The design of a receiving involves the following considerations: 1. Space, 2. climate conditions, 3. variety of vehicles
STORE ROOM: •
A store room is the reservoir for raw material.
•
Worked materials, finished products, maintenance supplies etc are kept.
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•
The functional requirements of a store room are: 1. protection to materials 2. handling of the materials 3. control points The above factors also help the layout engineer to design the store room as per requirements.
INSPECTION ROOM: •
The inspection room or quality control room should be located near then production unit, so that the samples from the production plant Can be checked for its quality requirements.
•
The labs should be well equipped and should be properly planned.
WATER STORAGE: •
Water is used in the plant for variety of purposes.
•
A plant must have adequate water supply to crater all these needs.
•
By far the most reliable and effectives means of fire protection is the automatic sprinkler system.
•
The sprinkler system is fitted with a sensitive transducer which lets water up to a height of 15 feet.
•
So the water storage system should be planned out with most more.
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POWER AND LIGHTING SYSTEM: •
Power and lighting systems forms the main part of the plant.
•
The significant features of the power plant operations are, 1. For supplying steam. 2. Providing heat for process operations. 3. supplying power to run motor. 4. providing light to plant. 5. power for surplus use.
PLANNING OF ADMINISTRATIVE BLOCK: •
Location of an administrative block depends upon the geographic location with respect to the plant functions.
•
The general administrative block should have administrative rooms, conference room and vault room storage of documents and records.
•
The employee service facility consists of parking lots, Employment office cafeteria, first aid stations and medical department etc.
ref[6]
60
PLANT LAYOUT
61
13.CONCLUSION
62
13.CHAPTER
The Manufacture of Nitrobenzene has been described in detail. The necessary flow diagram, material and Energy balance for the production of 1 Ton of Nitrobenzene has been worked out in detail. The design aspects are above described in detail. The cost has been estimated .
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14.BIBLIOGRAPHY
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14.CHAPTER
¾ 1. KIRK AND OTHMER, Encyclopedia of Chemical Technology Vol.15. 2nd Ed.Pg:176-190 ¾ 2. ROBERT H .PERRY : PERRY’S Chemical Engineers Hand Book 5th & 6th Ed. Mc Graw Hill international Editions , Pg:642-644 ¾ 3. GEORGE T. AUSTIN : Shreve’s Chemical Process Industries 5th Mc Graw Hill international Editions , Pg:776-778 ¾ 4. BAHL.B.S & ARUN BAHL : A text book of organic Chemistry, 19990,chand , Pg:350-355 ¾ 5. IS CODES : 2825 ; 1969,4503-1967, Pg:5 ¾ 6. JOSHI.M.V: Process Equipment Design 3 rd Ed.Pg :45
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