cumene to phenol

A Report on

Production of Phenol from 99.9% pure Cumene from Naptha Cracker Production of 99.9% pure Bisphenol A from 99.9% pure Phenol February-14-2015

Major Project Report Submitted by

Virender Pratap Singh

Department of Chemical Engineering

IIT Roorkee

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Index

1. Material and Energy Balance

1.1 Material Balance

1.2 Energy Balance

2. Environmental Protection & Energy Conservation

2.1 Air Pollution

2.2 Liquid Effluents

2.3 Solids disposal

2.4 Noise Pollution

2.5 Energy conservation

3. Organizational Structure and Manpower Requirement

3.1 Organizational Principles and Basics

3.2 Hierarchy

3.3 Manpower Requirement

4. SITE SELECTION & PROJECT LAYOUT

4.1 Plant Location

4.2 Plant Layout

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1. MATERIAL AND ENERGY BALANCE

1.1 Material Balance

BASIS: 24133 kg/hr production of phenol

1.1.1 Overall reactions:

1. Oxidation of Cumene:

NaOH

C6H5CH(CH3)2 + O2 C6H5C (CH3)2OOH

(120) (32) (152)

2. Decomposition of Cumene hydroperoxide:

C6H5C (CH3)2OOH + H2S04 C6H5OH + CH3COCH3

(152) (94) (58)

1.1.2 Molecular weights of components:

Cumene (Isopropyl benzene) = 120 kg moles

Cumene Hydroperoxide = 152 kg moles

Oxygen = 32 kg moles

Phenol = 94 kg moles

Acetone = 58 kg moles

Mass of inlet of Cumene and oxygen = 120+32=152 kg moles

Mass of outlet of phenol and acetone = 94+52= 152 kg moles

INLET = OUTLET

1.1.3 Feed:

Cumene = 1650 kg (For 1000 kg of Phenol)

Required oxygen = 440 kg

1 kg of air contains 0.23 kg of O2

X kg of air contains 440 kg of O2

Amount of air supplied = 1913 kg of air

25% excess air supplied = 478 kg of air

Actual amount of air supplied = 2319 kg of air

1.1.4 Balances:

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OXIDIZER:

COMPONENTS INLET kg/hr OUTLET kg/hr

Cumene 39552.975 10020.087

Air 57315.8565 ---

Cumene hydroperoxide ---- 40080.348

Off gases ---- 46768.3965

Total 96868.8315 96868.8315

ACIDIFIER:


Cumene hydroperoxide 40080.348 10022.48415

Cumene 10020.087 ---

Cleavage --- 40089.9366

H2SO4 11.98575 ---

Total 50112.42075 50112.42075

SEPARATOR:



Carryover Cleavage --- 1002.0087

Cleavage 10022.48415 39087.9279

Total 50112.42075 50112.42075

WASH TOWER:


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Cleavage 39087.9279 ---

Water 575.316 ---

Acid free Cleavage --- 38968.0704

Acidified wash water --- 695.1735

Total 39663.2439 39663.2439

ACETONE COLUMN:

COMPONENTS INLET kg/hr OUTLET kg/hr OVERHEAD

BOTTOM

Cleavage 38968.0704 --- ---

Acetone --- 11956.9842 ---

Carryover cleavage --- 119.8575 ---

Carryover acetone in

residue --- --- 119.8575

Residue --- --- 26771.3712

Total 38968.0704 12076.8417 26891.2287

CUMENE COLUMN:


BOTTOM

Feed 26891.2287 --- ---

Cumene --- 1948.88295 ---

Carryover acetone in

Cumene --- 119.8575 ---

Residue --- --- 24822.48825

Total 26891.2287 2068.74045 24822.48825

- METHYL STYRENE COLUMN:

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BOTTOM

Feed 24822.48825 --- ---

- methyl styrene --- 546.5502 ---

Residue --- --- 24275.93805

Total 24822.48825 546.5502 24275.93805

PHENOL COLUMN:


BOTTOM

Feed 24275.93805 --- ---

Phenol --- 24041.01735 ---

Carryover acetophenone --- 91.0917 ---

Acetophenone --- --- 119.8575

Total 24275.93805 24132.10905 119.8575

The amount product phenol = 24133 kg/hr

Purity of the product phenol = 99.9%

1.2 Energy Balance

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OXIDIZER:

A) Inlet heat@ 70C:

1. Cumene @ 30C

mass 1 39552.975 kg

Cp1 0.415 kcal/kg C

T1 5 C

Q1 82072.42313 Kcal

343473.0908 KJ

2. Air @ 30C

mass 2 57315.8565 kg

Cp2 1.005 KJ/kg C

T2 5 C

Q2 288012.1789 KJ

3. Total heat inlet

Q = Q1+ Q2

Q = 631485.2697 KJ

B) Outlet heat@ 110C:

1. Cumene Hydroperoxide @ 110C

mass 1 40080.348 kg

Cp1 0.45 kcal/kg C

T1 85 C

Q1 1533073.311 Kcal

6415911.807 KJ

2. Cumene @ 110C

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mass 2 10020.087 Kg

Cp2 0.455 kcal/kg C

T2 85 C

Q2 387526.8647 Kcal

1621799.929 KJ

3. Off gases @ 110C

a) Oxygen

mass 3 2636.865 Kg

Cp3 0.936 KJ/kg C

T3 25 C

Q3 61702.641 KJ

b) Nitrogen

mass 4 44131.5315 Kg

Cp4 1.035 KJ/kg C

T4 25 C

Q4 1141903.378 KJ

4. Total heat outlet Q= Q1+ Q2+ Q3+ Q4

Q = 1044923.774 KJ

Heat of reaction of Cumene Hydroperoxide = 736 KJ/kg

For 38171.76kg of Cumene Hydroperoxide = 29499136.13

COMPONENTS INLET HEAT KJ OUTLET HEAT KJ

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Cumene 343473.0908 1621799.929

Air 288012.1789 ---

Cumene hydroperoxide 29499136.13 ---

Cumene hydroperoxide --- 6415911.807

Off gases --- 1203606.019

Heat removed by water --- 19894575

Total 30130621.4 29135892.75

COOLER:

A) Inlet heat @ 110C:

Heat taken by Cumene

Hydroperoxide 6415911.807 KJ

Heat taken by Cumene 1621799.929 KJ

Total Heat 8037711.735 KJ

B) Outlet heat @70C:

1. Cumene hydroperoxide @ 70C:

mass 1 40080.348 kg

Cp1 0.45 kcal/kg C

T1 45 C

Q1 811627.047 Kcal

3396659.192 KJ

2. Cumene @ 70C:

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mass 2 10020.087 kg

Cp2 0.435 kcal/kg C

T2 45 C

Q2 196143.203 Kcal

820859.3047 KJ

3. Total heat outlet

Q= Q1+ Q2

Q = 4217518.496



Cumene 1621799.929 820859.3047


Total 8037711.735 8027810

ACIDIFIER:


Heat taken by Cumene

Hydroperoxide 3396659.192

Heat taken by Cumene 820859.3047

Total Heat

4217518.496

1. H2SO4 @ 30C:

mass 2 11.98575 kg

Cp2 1.44 KJ/kg C

T2 45 C

Q2 776.6766 KJ

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2. Total heat inlet Q = Q1+Q2 = 4218295.173KJ

B) Outlet heat @ 80C:

1. Mass of cleavage = 40089.9366 kg

COMPONENTS MASS kg SPECFIC HEAT KJ/KgC

Phenol 24856.04835 2.29

Acetone 12426.8256 1.481

Cumene 2004.0174 1.842

- methyl styrene 563.33025 1.406

Acetophenone 244.5093 1.97

Q1=((24856.0482.29)+( 12426.8256*1.481)+( 2004.01741.842)+( 536.330251.406)+(

244.50931.97)) (80-25)

Q1= 4415928.283 KJ

2. Cumene hydroperoxide@ 80C:

mass 2 10022.48415 kg

Cp2 0.45 kcal/kg C

T2 55 C

Q2 248056.4827 Kcal

1038116.38 KJ


Q = Q1+Q2 = 5454044.663 KJ

Heat of reaction of cleavage = 2983 KJ/kg

For 38180.9 kg of cleavage =113893624.7

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Cumene Hydroperoxide 3396659.192 1038116.38

Cumene 820859.3047 ---

H2SO4 776.6766 ---

Heat of reaction of

cleavage 113893624.7 ---

Cleavage --- 4415928.283

Heat removed by water --- 112716720.4

Total 118111919.9 118170765.1

SEPARATOR:

A) Inlet heat @80C:

Heat in Cumene


Heat in Cumene 4415928.283

Total 5454044.663


Heat in Cumene


Heat in cleavage 4415928.283

Total heat outlet 5454044.663

WASH TOWER:

A) Inlet heat @80C:

1. Mass of Cleavage =39087.9279 kg

COMPONENTS MASS kg SPECFIC HEAT

KJ/KgC

Phenol 24235.1865 2.29

Acetone 12117.59325 1.481

Cumene 1953.67725 1.842



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Q1= 4305105.725 KJ

2. Water @ 30C

mass 2 575.316 kg

Cp2 4.18 KJ/kg C

T2 5 C

Q2 12024.1044 KJ

3. Total heat inlet Q = Q1+Q2 = 4317129.829


1. Acid free cleavage = 38969.074 kg


Phenol 24158.4777 2.29

Acetone 12076.8417 1.462

Cumene 1948.88295 1.821



Q1=4275595.914 KJ

2. Acidified wash water @ 40C

mass 2 575.316 kg

Cp2 4.18 KJ/kg C

T2 15 C

Q2 36072.3132 KJ

3. Heat taken by carryover cleavage Q3=5201.9KJ

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Q= Q1+Q2+ Q3= 4316869.727 KJ


Cleavage 4305105.725 ---

Water 12024.1044 ---

Acid free cleavage --- 4275595.514

Acidified wash water --- 36072.3132

Carryover cleavage --- 5201.9

Total 4317129.829 4316869.727

HEATER:

A) Inlet heat @75C:

Cleavage

Mass of cleavage = 38968.0704 kg


Phenol 24158.4777 2.29

Acetone 12076.8417 1.462

Cumene 1948.88295 1.821



Q = 4275595.514 KJ


Mass of cleavage = 38968.0704


Phenol 24158.4777 2.29

Acetone 12076.8417 1.509

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Cumene 1948.88295 1.863



Q = 4313660.77 KJ


Cleavage 4275595.514 4313660.77

Heat added by steam 36252.62 ---

Total 4311848.134 4313660.77

ACETONE COLUMN:

A) Inlet heat @90C:

Mass of cleavage =38689.0704 kg


Phenol 24158.4777 2.29

Acetone 12076.8417 1.509

Cumene 1948.88295 1.863



Q = 5097962.728 KJ

B) Outlet heat:

1. Acetone vapours @ 56C

Mass 1 11956.9842 kg

1 212.3 KJ/kg C

Q1 2538467.746 KJ

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2. Cleavage vapours @ 56C

Mass 2 119.8575 kg

2 109.96 KJ/kg C

Q2 13179.5307 KJ

3. Total heat outlet as vapour

= 2551647.276

4. Bottom residue @90C

Mass of residue= 2799.8712 kg


Phenol 24086.5632 2.32

Cumene 1948.88295 1.863



Q3= 2126745.403KJ

5. Carryover acetone @90C

mass 4 119.8575 kg

Cp4 1.509 KJ/kg C

T4 65 C

Q4 11756.22289 KJ


Q = Q1+Q2+ Q3+ Q4

Q =4690148.902 KJ

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Cleavage 5097962.728 ---

Vapour acetone --- 2538467.746

Vapour cleavage --- 13179.5307

Bottom residue --- 2126745.403

Carryover acetone in residue --- 11756.22289

Total 5097962.728 5097954

OVERHEAD ACETONE CONDENSER:



Mass 1 11956.9842 kg

1 212.3 KJ/kg C

Q1 2538467.746 KJ

2. Cleavage vapours @ 56C

Mass 2 119.8575 kg

2 109.96 KJ/kg C

Q2 13179.5307 KJ

3. Total heat inlet as vapour Q = Q1+Q2

Q= 2551647.276

B) Outlet [email protected]:

1. Acetone

mass1 11956.9842 kg

Cp1 1.397 KJ/kg C

T1 25 C

Q1 417597.6732 KJ

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2. Heat produced by Cleavage Q2 = 4837.75 KJ

3. Total heat outlet Q = Q1+Q2

Q = 422435.4232 KJ


Vapour acetone 2538467.746 ---

Vapour cleavage 13179.5307 ---


Condensed acetone --- 417597.6732

Condensed cleavage --- 4837.75

Total 2551647.276 2541652

HEATER:

A) Inlet heat @90C:

1. Mass of residue= 2799.8712 kg


Phenol 24086.5632 2.32

Cumene 1948.88295 1.863



Q1 = 2126745.403 KJ

2. Acetone

mass2 119.8575 kg

Cp2 1.509 KJ/kg C

T2 65 C

Q2 11756.22289 KJ

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3. Total heat inlet Q = Q1+Q2

Q =2138501.626 KJ


1. Mass of residue= 2799..8712 kg


Phenol 24086.5632 2.32

Cumene 1948.88295 1.863



Q1=2126745.403 KJ

2. Acetone

mass2 119.8575 kg

Cp2 1.51 KJ/kg C

T2 70 C

Q2 12668.93775 KJ


Q = Q1+Q2 =2139414.341 KJ


Residue 2126745.403 2126745.403

Carryover acetone 11756.22289 12668.93775

Heat added by steam 869.25 ---

Total 2139370.876 2139414.341

CUMENE COLUMN:

A) Inlet heat @95C:

1. Mass of feed= 2799.8712 kg

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Phenol 24086.5632 2.32

Cumene 1948.88295 1.863



Q1=4253490.806 KJ

2. Acetone

mass2 119.8575 kg

Cp2 1.51 KJ/kg C

T2 70 C

Q2 12668.93775 KJ

3. Total heat inlet

Q = Q1+Q2 = 4266159.744 KJ

B) Outlet heat:

1. Cumene vapours @ 90C

Mass 1 1948.88295 kg

1 343.9 KJ/kg C

Q1 670220.8465 KJ


Mass 2 119.8575 kg

2 212.3 KJ/kg C

Q2 25445.74725 KJ

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3. Residue @ 95C

Mass = 24822.48225 kg


Phenol 24086.5632 2.32

Cumene 1948.88295 1.863


Q3 = 4253490.806 KJ


Q = Q1+Q2+Q3=4949157.4 KJ


Feed 4253490.806 ---

Vapour Cumene --- 670220.8465

Vapour acetone --- 25445.74725

Residue --- 4253490.806

Carryover acetone in feed 12668.93775 ---

Total 4713483 4949157.4

CUMENE VAPOUR CONDENSER:

A) Inlet heat:

1. Cumene vapours @ 90C

Mass 1 1948.88295 kg

1 343.9 KJ/kg C

Q1 670220.8465 KJ

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Mass 2 119.8575 kg

2 212.3 KJ/kg C

Q2 25445.74725 KJ

3. Total heat inlet Q

Q1+Q2 = 695666.5938 KJ

B) Outlet [email protected]:

1. Cumene

mass1 1948.88295 kg

Cp1 1.842 KJ/kg C

T1 55 C

Q1 197441.3317 KJ

2. Acetone

mass1 119.8575 kg

Cp1 1.51 KJ/kg C

T1 55 C

Q1 9954.165375 KJ


Q = Q1+Q2 = 207395.497 KJ


Vapour Cumene 670220.8465 ---

Vapour acetone 25445.74725 ---


Condensed Cumene --- 197441.3317

Condensed acetone --- 9954.165375

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Total 695666.5938 695670.5

Total 662539.6131 662539.621

HEATER:


1. Mass = 24822.48825 kg


Phenol 24086.5632 2.32



Q = 3999336.981 KJ

B) Outlet heat @ 110C:

1. Mass = 24822.48825 kg


Phenol 24086.5632 2.32



Q=4856337.763 KJ


Residue 3999336.981 4856337.763

Heat added by steam 816191 ---

Total 4815527.981 4856337.763

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- METHYL STYRENE COLUMN:


1. Mass 24822.48825 kg


Phenol 24086.5632 2.32



Q=4859961.39 KJ

B) Outlet heat:

1. - methyl styrene vapours @ 100C

Mass 1 546.5502 kg

1 449.1 KJ/kg C

Q1 245455.6948 KJ

2. Residue @110C

Mass = 24275.93805Kg


Phenol 24041.01735 2.32


Q2 = 4780229.093 KJ


Q = Q1+Q2 = 5025681.787 KJ


Residue 4859961.39 ---

Vapour - methyl styrene --- 245455.6948

Bottom residue --- 4780226.093

Total 4859961.39 4859960

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- METHYL STYRENE CONDENSER:

A) Inlet heat:

1. - methyl styrene vapours @ 100C

Mass 1 546.5502 kg

1 449.1 KJ/kg C

Q1 245455.6948 KJ

B) Outlet heat:

1. - methyl styrene condensed @ 95C

mass 1 546.5502 kg

Cp1 1.445 KJ/kg C

T1 70 C

Q1 55283.55273 KJ


Vapour - methyl styrene 245455.6948 ---


Condensed - methyl styrene --- 55283.55273

Total 245455.6948 236399.8527

HEATER:

A) Inlet @110C

1. Mass =24275.93805 kg


Phenol 24041.01735 2.32


25 | P a g e

Q=4780226.093 KJ

B) Outlet @130C

1. Mass =24275.93805 kg


Phenol 24041.01735 2.32


Q=5904985.195KJ


Residue 4780226.093 5904985.173

Heat added by steam 1071199 ---

Total 5851425.093 5904985.173

PHENOL COLUMN:

A) Inlet @130C

1. Mass =24275.93805 kg


Phenol 24041.01735 2.32


Q=5904985.173 KJ

B) Outlet heat

1. Phenol vapours @ 120C

Mass 1 24041.01735 kg

1 296.7 KJ/kg C

Q1 7132969.848 KJ

26 | P a g e

2. Acetophenone vapours @ 120C

Mass 2 91.0917 kg

2 116.1 KJ/kg C

Q2 10575.74637 KJ

3. Bottom acetophenone @130C

mass 3 119.8575 kg

Cp3 1.97 KJ/kg C

T3 105 C

Q3 24792.52388 KJ


Q= Q1+Q2+ Q3= 7168338.118


Feed 7168338.1 ---

Vapour phenol --- 7132969.848

Vapour Acetophenone --- 10575.74637

Acetophenone --- 24792.52388

Total 7168338.1 7168338.118

PHENOL VAPOUR CONDENSER:

A) Inlet heat

1. Phenol vapours @ 120C

Mass 1 24041.01735 kg

1 296.7 KJ/kg C

Q1 7132969.848 KJ

2. Acetophenone vapours @ 120C

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Mass 2 91.0917 kg

2 116.1 KJ/kg C

Q2 10575.74637 KJ

3. Total heat inlet

Q= Q1+Q2=7143545.594 KJ

B) Outlet heat@ 100C

1. Mass = 24132.10905 kg


Phenol 24041.01735 2.32


Q=4196595.818 KJ


Vapour phenol 7132969.848 ---

Vapour Acetophenone 10575.74637 ---


Condensed phenol &

acetophenone --- 4196595.818

Total 7003213 7003213.818

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2. Environmental Protection & Energy conservation 2.1 AIR POLLUTION

In this section, air emissions are characterized by location, effective emission heights, and emission

factors for criteria pollutants and selected pollutants; the hazard potential of each pollutant is

quantified, and the affected population is determined; the national and state emission burdens are

calculated; and the growth factor of the industrys emissions is determined. The data in this section

were obtained through industry cooperation.

SELECTED POLLUTANTS

Compounds identified as potential emissions from the manufacture of acetone and phenol from

cumene are listed in Table 12. A sampling program was undertaken to quantify these compounds

plus others which may not previously have been known to be present.

TABLE 12. SUSPECTED EMISSIONS FROM ACETONE AND PHENOL MANUFACTURE FROM CUMENE

PRIOR TO SAMPLING

Acetaldehyde

Acetic acid

Acetone

-Hydroxyacetone

Diacetone alcohol

Acetophenone

Benzene

Ethylbenzene

n-Propylbenzene

Methyl isobutyl carbinol

Cumene

Cumene hydroperoxide

Dicumyl peroxide

1,1,2, 2Tetramethyll,2diphenylethane

Formaldehyde

Formic acid

2-Methylbenzofuran

Methylgioxal

Heavy tars

2, 6Dimethyl-2, 5heptadiene4-one

l-Hydroxyethyl methyl ketone

Methyl isobutyl ketone

Lactic acid

Methanol

-Methylstyrene

Dimers of -methylstyrene

2-Methyl-3, 4-pentanediol

29 | P a g e

4-Hydroxy-4-methyl- 2-pentanone

Phenol

2,4,6-Tris (2-phenyl-2-propyl)phenol

Toluene

2-Phenyl-2- (4-hydroxyphenyl) propane

TABLE 13. CHARACTERISTICS OF EMISSIONS IDENTIFIED DURING SAMPLING OR REPORTED FROM

ACETONE AND PHENOL PLANTS USING CUMENE PEROXIDATION

TABLE 14. EMISSION SOURCES BY PROCESS TYPE AT A PLANT MANUFACTURING ACETONE AND

PHENOL FROM CUMENE

Process

technology

Emission source

Allied Cumene peroxidation.

Cumene hydroperoxide concentration vent.

Separation column vent.

Acetone concentration column vent.

Cumene column vent.

Methylstyrene column vent.

Refined -methylstyrene column vent.

Phenol column vent.

Acetophenone column vent.

Cumene tank vent.

Acetone tank vent.

Catalyst tank vent.

Acetone transport loading vent.

-Methylstyrene transport loading vent

Phenol transport loading vent.

Acetophenone transport loading vent.

Acetophenone transport loading vent.

Hercules Cumene peroxidation vent.

Cumene hydroperoxide wash vent.

Cumene hydroperoxide concentration vent.

MATERIAL EMITTED HEALTH EFFECTS

Acetaldehyde Local irritant; central nervous system narcotic

Acetone Skin irritant, narcotic in high concentrations

Acetophenone Narcotic in high concentrations

Benzene Carcinogen

Cumene Narcotic ; toxic

Ethyl benzene Skin and mucous membrane irritant

Formaldehyde Irritant ; toxic

methyl styrene Toxic

Naphthalene Moderate irritant

Phenol Toxic & irritant

30 | P a g e

Vent of cuxnene hydroperoxide cleavage and product wash operations

combined.


Acetone column vent.


Dewatering column vent

Hydrogenation column vent

Acetone tank vent

-Methylstyrene tank vent

Phenol tank vent

Buffer tank vent

TABLE 15. EMISSION SOURCES AT A REPRESENTATIVE PLANT MANUFACTURING ACETONE AND

PHENOL FROM CUMENE

1. Cumene Peroxidation Vent

The cumene feed is contacted with air in a reaction vessel to peroxidize the cumene. Air is

continuously introduced and removed. The offgas stream carries vaporized hydrocarbons and

some volatile trace elements. Cumene is recovered from the spent gas for recycle by condensation.

The emission control equipment is the last piece of equipment before the gas is emitted to the

atmosphere. That is, any prior equipment is process equipment, and the control of any material

released to the atmosphere is performed by the last piece of equipment prior to release. For

example, in the Allied process the emission control equipment is the carbon bed system, and in the

Hercules process it is the refrigerated condenser, unless another piece of equipment is added on.

2. Cleavage Section Vents, Combined

The composite emission factors, Table 18, are determined by aggregation of the emission factors

available from sampling and industry communication. These emission factors combine values for

the cumene hydroperoxide concentration vent (Allied process technology) and the cumene

hydroperoxide wash vent, the cumene hydroperoxide concentration vent, and the combined cunene

hydrperoxide cleavage and product wash vent (Hercules process technology).

TABLE 18. AVERAGE EMISSION FACTORS FOR THE CLEAVAGE SECTION

Material emitted g/kg phenol produced

Total nonmethane hydrocarbon 0.17

Acetone 0.0000060

Acetophenone 0.0000044

Benzene 0.000031

2Butanone 0.0000018 0.0000018

2Butenal 0.000000085

tButylbenzene 0.000023

Cumene 0.14

31 | P a g e

Ethylbenzene 0.0000050

Formaldehyde

32 | P a g e

Emissions in the cleavage section are most often controlled by condensation. Absorption and

incineration are also used.

Emissions in the product purification section are controlled by condensation, adsorption,

absorption, and incineration.

Floating roofs are used to control emissions from tanks, particularly acetone and cumene storage

tanks. Condensation, sealed dome roofs, and conservation vents are also used for this purpose, but

not as commonly as floating roofs.

Product transport loading emissions are controlled by absorption or vapor recovery. Not all plants

control this emission source.

The Scope of fugitive emissions and control methods are under study by EPA.

VARIOUS EMISSION CONTROL METHODS IN USE AT CUMENE PEROXIDATION PLANTS

VAPOUR CONDENSATION

Organic compounds can be removed from an air stream by condensation. A vapor will condense

when, at a given temperature, the partial pressure of the compound is equal to or greater than its

vapor pressure. Similarly, if the temperature of a gaseous mixture is reduced to the saturation

temperature (i.e., the temperature at which the vapor pressure equals the partial pressure of one of

the constituents), the material will condense. Thus, either increasing the system pressure or

lowering the temperature can cause condensation. In most air pollution control applications,

decreased temperature is used to condense organic materials, since increased pressure is usually

impractical. Equilibrium partial pressure limits the control of organic emissions by condensation. As

condensation occurs, the partial pressure of material remaining in the gas decreases rapidly,

preventing complete condensation.

ACTIVATED CARBON ADSORPTION

Adsorption is a phenomenon in which molecules become attached to the surface of a solid. The

process is highly selective, and a given adsorbent, or adsorbing agent, will adsorb only certain types

of molecules. The material adhering to the adsorbent is called the adsorbate. Adsorption involves

three steps.

First, the adsorbent comes in contact with the stream containing the adsorbate, and separation due

to adsorption results. Next, the unadsorbed portion of the stream is separated from the adsorbent.

Finally, the adsorbent is regenerated by removing the adsorbate.

Activated carbon is the most suitable adsorbent for organic vapors. Carbon adsorbs 95% to 98% of

all organic vapor from air at ambient temperature regardless of variations in concentration and

humidity given a sufficient quantity of carbon. The adsorption of a mixture of organic vapors in air

by carbon is not uniform, however, higher boiling point components are preferentially adsorbed.

When a contaminated gas stream is passed over an activated carbon bed, the organic vapor is

adsorbed and the purified stream passes through. Initially, adsorption is rapid and complete, but as

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the carbon bed approaches its capacity to retain vapor, traces of vapor appear in the exit air. This is

the breakpoint of the activated carbon. If gas flow is continued, additional amounts Of Organic

material are adsorbed, but at a decreasing rate.

SOLVENT ABSORPTION

Absorption is a process for removing one or more soluble component from a gas mixture by

dissolving them in a solvent. Absorption equipment is designed to insure maximum contact

between the gas and the liquid solvent to permit interphase diffusion between the materials.

Absorption rate is affected by factors such as the solubility of gas in the particular solvent and the

degree of chemical reaction; however, the most important factor is the solvent surface exposed.

A vent gas scrubber-cooler system used on a cumene peroxidation vent is illustrated in figure. In this

system off gases are scrubbed in a tray tower to absorb hydrocarbons into the scrubbing liquid,

which is an aqueous Na2CO3 solution. Some of the scrubbing liquid is sent to the oxidation section,

and some is recycled through the scrubber with makeup solution. The scrubbed gas is cooled,

condensate is removed and sent to the oxidation section, and the gas is released to the atmosphere.

INCINERATION

Complete combustion of the hydrocarbons present in the emissions from a cumene peroxidation

phenol plant produces carbon dioxide and water. NOx may be produced depending on the method

of combustion the temperature. SOx production depends on the sulphur content of the auxiliary

fuel, if any. The types of incinerators (i.e., direct flame afterburners, catalytic after burners, or flares),

used to combust hydrocarbons at plants manufacturing acetone and phenol from cumene were not

reported.

STORAGE TANKS

Six kinds of evaporation loss from storage of organic materials occur: breathing, standing storage,

filling, emptying, wetting, boiling. Vapors expelled from a tank because of thermal expansion,

barometric expansion, or additional vaporization are breathing losses. Vapor loss from such areas

as seals, hatches, other openings (but not due to breathing or level changes) constitute standing

storage loss. Vapors expelled from a tank is filled constitute filling loss. Vapors expelled from tank

during emptying (due to the fact that vaporization occurs slowly, air enters to equalize pressure,

vaporization stabilizes, and there is excess vapor in the tank) are emptying loss. Wetting loss is the

vaporization of liquid from wetted exposed wall in a floating roof tank when the roof is lowered.

Vapors expelled because of boiling are boiling loss.

FLOATING ROOF TANKS

Floating roof tanks are of various designs but the basic concept is that the roof floats on the surface

of the stored material. A seal provides intimate contact between the roof and the tank wall. These

tanks reduce breathing and filling losses by reducing the space available for vapor accumulation.

Wetting losses are small and not a problem.

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SEALED DOME ROOF TANKS

This type of tank can withstand relatively large pressure variations without incurring a loss. There is

little or no breathing loss. Filling loss will depend on the tank design.

CONSERVATION VENT FOR TANKS

The conservation vent is a device to inhibit evaporation loss while protecting the tank from possible

damage due to under pressure or overpressure. The vent has two set points, an upper a lower

pressure. If the pressure is outside this range the vent opens to allow pressure equalization with the

atmosphere. This reduces evaporation losses.

VAPOR RECOVERY SYSTEM ON PRODUCT LOADING FACILITIES

This control device collects the vapors produced from product loading and disposes of them by one

of the control methods previously described, such as condensation, adsorption, etc. Vapor recovery

is a general term for emission control practices.

2.2 Liquid effluents

Acetophenone

Acetophenone is a colorless liquid with a sweet, pungent odor that is sparingly soluble (0.55 wt % at

20C) in water. Acetophenone is used as a chemical Intermediate for resins, pharmaceuticals,

corrosion Inhibitors and dyestuffs; as a solvent for gums, resin dyestuffs and highmelting aromatic

chemicals; as a polymerization catalyst and photosensitizer. In organic synthesis; as a flavoring agent

for tobacco and in perfumery. If acetophenone is released to water, microbial degradation and

volatilization are expected to be the major environmental fate and transport processes.

Biodegradation studies have shown that acetophenone is significantly biodegradable. The

volatilization halflife from a river 1m deep flowing at 1 m/sec with a wind velocity of 3 m/sec was

estimated to be 3.7 days. Hydrolysis, oxidation, adsorption to sediments and bioconcentration are not

expected to be significant. When acetophenone is released to the ambient atmosphere, reaction with

photochemical)yproduced hydroxyl radicals is expected to be the dominant removal mechanism;

the halflife for this reaction has been estimated to be 2 days (U.S. EPA. 1981). In the atmosphere,

acetophenone will exist almost entirely in the vapor phase.

If acetophenone is released to soil, microbial degradation is likely to be

the major degradation process. Based on various adsorption studies

acetophenone is expected to be mobile in soil and susceptible to significant leaching. Acetophenone

is also expected to evaporate from dry soil surfaces. Acetophenone occurs naturally. In varius plant

oils, in the buds of balsam poplar and In Concord grapes (Dorsky et al., 1963; NIcholas, 1973). It has

been detected in drinking waters, surface waters, groundwaters and waste effluent waters. The

presence of acetophenone in environmental waters is most likely the result of discharges from

industrial sources. Metabolism and toxicity data indicate that acetophenone is absorbed by both

gastrointestinal and respiratory tracts. Studies using rabbits indicate that acetophenone Is

metabolized to ()1phenylethanol, which is excreted in the urine as glucuronide and sulfate

conjugates.

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Health Hazard Information

Acute Effects:

Acute exposure of humans to acetophenone vapor may produce skin irritation and

transient corneal injury. One study noted a decrease in light sensitivity in exposed

humans.

Acute oral exposure has been observed to cause hypnotic or sedative effects,

hematological effects, and a weakened pulse in humans.

Congestion of the lungs, kidneys, and liver were reported in rats acutely exposed to

high levels of acetophenone via inhalation.

Tests involving acute exposure of rats, mice, and rabbits have demonstrated

acetophenone to have moderate acute toxicity from oral or dermal exposure.

Reproductive/Developmental Effects:

No information is available on the reproductive or developmental effects of

acetophenone in humans.

In one study of pregnant rats exposed dermally, no effects on reproduction or

development were noted.

Cancer Risk:

No information is available on the carcinogenic effects of acetophenone in humans or

animals.

EPA has classified acetophenone as a Group D, not classifiable as to human

carcinogenicity.

Potential Health Effects

Inhalation:

May cause irritation to the respiratory tract; symptoms may include sore throat, coughing,

headache, and dizziness. Higher concentrations may cause narcosis.

Ingestion:

May cause sore throat, abdominal pain, nausea, coughing, headache, dizziness, anesthetic

effects, and central nervous system effects.

Skin Contact:

May cause irritation with redness and pain.

Eye Contact:

May cause severe irritation, redness, pain, and transient corneal injury.

Chronic Exposure:

Prolonged or repeated skin exposure may cause dermatitis.

Aggravation of Pre-existing Conditions:

No information found.

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First Aid Measures

Inhalation:

Remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give

oxygen. Call a physician.

Ingestion:

Induce vomiting immediately as directed by medical personnel. Never give anything by

mouth to an unconscious person. Call a physician.

Skin Contact:

In case of contact, immediately flush skin with plenty of water for at least 15 minutes.

Remove contaminated clothing and shoes. Wash clothing before reuse. Call a physician.

Eye Contact:

Immediately flush eyes with plenty of water for at least 15 minutes, lifting lower and upper

eyelids occasionally. Get medical attention immediately.

Fire Fighting Measures

As in any fire, wear a self-contained breathing apparatus in pressure-demand, MSHA/NIOSH

(approved or equivalent), and full protective gear. During a fire, irritating and highly toxic gases may

be generated by thermal decomposition or combustion. Use water spray to keep fire-exposed

containers cool. Combustible liquid and vapor.

Extinguishing Media: Use water spray, dry chemical, carbon dioxide, or appropriate foam.

Flash Point: 77 deg C ( 170.60 deg F)

Autoignition Temperature: 570 deg C ( 1,058.00 deg F)

Explosion Limits, Lower:1.1%

Upper: 6.7%

Accidental Release Measures

Ventilate area of leak or spill. Remove all sources of ignition. Wear appropriate personal protective

equipment as specified in Section 8. Isolate hazard area. Keep unnecessary and unprotected

personnel from entering. Contain and recover liquid when possible. Use non-sparking tools and

equipment. Collect liquid in an appropriate container or absorb with an inert material (e. g.,

vermiculite, dry sand, earth), and place in a chemical waste container. Do not use combustible

materials, such as saw dust. Do not flush to sewer! Environmental Regulations require reporting spills

and releases to soil, water and air in excess of reportable quantities.

Handling and Storage

Keep in a tightly closed container, stored in a cool, dry, ventilated area. Protect against physical

damage. Isolate from any source of heat or ignition. Isolate from oxidizing materials. Containers of

this material may be hazardous when empty since they retain product residues (vapors, liquid);

observe all warnings and precautions listed for the product. Keep away from heat and flame. Keep

37 | P a g e

away from sources of ignition. Store in a tightly closed container. Store in a cool, dry, well-ventilated

area away from incompatible substances.

Exposure Controls/Personal Protection

Airborne Exposure Limits:

- Threshold Limit Value (TLV): 10 ppm (TWA)

Ventilation System:

A system of local and/or general exhaust is recommended to keep employee exposures below the

Airborne Exposure Limits. Local exhaust ventilation is generally preferred because it can control the

emissions of the contaminant at its source, preventing dispersion of it into the general work area.

Please refer to the ACGIH document, Industrial Ventilation, A Manual of Recommended Practices,

most recent edition, for details.

Personal Respirators (NIOSH Approved):

If the exposure limit is exceeded, a respirator with an organic vapor cartridge may be worn for up to

ten times the exposure limit. Since this compound has been identified as possibly existing in both

vapor and particulate phase, a dust/mist prefilter is recommended. For emergencies or instances

where the exposure levels are not known, use a positive-pressure, air-supplied respirator.

WARNING: Air-purifying respirators do not protect workers in oxygen-deficient atmospheres.

Skin Protection:

Wear protective gloves and clean body-covering clothing.

Eye Protection:

Use chemical safety goggles and/or a full face shield where splashing is possible. Maintain eye wash

fountain and quick-drench facilities in work area.

Stability:

Stable under ordinary conditions of use and storage.

Hazardous Decomposition Products:

Carbon dioxide and carbon monoxide may form when heated to decomposition.

Hazardous Polymerization:

Will not occur.

Incompatibilities:

Strong oxidizers.

Conditions to Avoid:

Heat, flame, other sources of ignition.

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Maharashtra Pollution Control board Standards under Water Act

The daily quantity of trade effluent from the factory shall not exceed 18 m3.

The daily quantity of sewage effluent from the factory shall not exceed 7 m3.

(i) Trade Effluent Treatment: The applicant shall provide comprehensive treatment system consisting

of Primary / secondary and / or tertiary treatment and is warranted with reference to influent quality

and operate and maintain the same continuously so as to achieve the quality of the treated effluent

to the following standards:

pH Between 5.5 to 9.0

Suspended Solids Not to Exceed 100 mg/l.

BOD Not to Exceed 100 mg/l.

COD Not to Exceed 250 mg/l

Oil & Grease Not to Exceed 10 mg/1.

TDS Not to Exceed 2100 mg/1.

Chlorides Not to Exceed 600 mg/1.

Sulphates Not to Exceed 1000 mg/1.

Chromium Not to Exceed 0.1 mg/l

Total Chromium Not to Exceed 2.0 mg/l

Total metal Not to Exceed 10 mg/l

Iron Not to Exceed 5.0 mg/l

(ii) Trade Effluent Disposal: The treated effluent shall be used in the process to the maximum extent

and remaining shall be used on land for green belt development.

(iii) Sewage Effluent Treatment: The applicant shall provide comprehensive treatment system as is

warranted with reference to influent quality and operate and maintain the same continuously so as

to achieve the quality of treated effluent to the following standards.

(1) Suspended Solids - Not to exceed 100 mg/I.

(2) BOD 3 days 27 C - Not to exceed 100 mg/I.

(iv) Sewage Effluent Disposal: The treated domestic effluent shall be soaked in a soak pit, which shall

be got cleaned periodically. Overflow, if any, shall be used on land for gardening / plantation only.

(v) Non-Hazardous Solid Wastes:

Sr. No. Type of waste Quantity Disposal

1 Slag 158267MT/Yr Landfill

2 Machine returns 10000 MT/Yr By reuse in own sinter

plant

3 Flue Dust 24000 MT/Yr By reuse in own sinter

plant

4 Fly ash 12000 MT/Yr Sale to brick & cement

mfg. & landfill

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(vi) Other conditions: The industry shall monitor effluent quality regularly. The applicant shall comply

with the provisions of the Water (Prevention & Control of Pollution) Class Act, 1977 (to be referred as

Class Act) and Rules there under: The daily water consumption for the following categories is as under:

(i) Domestic -80 CMD

(ii) Industrial Processing CMD

(iii) Industrial Cooling - 3135 CMD

(iv) Agriculture/Gardening - 16 CMD

The applicant shall regularly submit to the Board the returns of water consumption in the prescribed

form and pay the Class as specified under Section 3 of the said Act.

2.3 Solid Waste Disposal

There is no substantial solid waste in the plant; the only solid waste will be dried sludge from the

effluent treatment plant, canteen wastes, worn office equipment and tools, stationery, cleaning rags,

packing boxes, broken pallets and broken office chairs. Solid waste disposal is done by thermal

incineration or by tipping. The design of a solid waste incinerator is difficult to do due to the wide

variety of feed to be disposed. It is important to determine the burning characteristics of the solid

waste material. A major problem with the solid incinerator is fly ash control. Various methods

employed for this purpose ate two-stage combustion, filter baffle and provision of large secondary

chambers where velocities are low and settling takes place. If the fly ash problem is chronic, special

separation devices like electrostatic precipitators can be employed. The flash produced can be used

as a land fill.

2.4 Noise Pollution

The major sources of noise pollution in our plant are:

Pumps

Burners

Electric motors

Valves

Steam Vents

Various equipments noise levels and control measures are listed in the table below:

Equipment Sound level at 3ft(dB) Possible Noise Control

measures

Electric motors 90-110 Acoustically lined fan covers,

enclosures and motor mutes,

absorbent mounts.

Pumps

Vane(Industrial)

Vane(mobile)

Axial position

75-82

84-92

76-85

Acoustically lined fan covers,

enclosures and motor mutes,

absorbent mutes.

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Screw type

Gear

72-78

78-88

Heaters and furnaces 90-110 Acoustic plenums, intake

mufflers, lined/ damped ducts

Valves 80-108 Avoid sonic velocities, limit

pressure drop and mass

flow,and replace with special

low noise valves.

Piping 90-105 Isolation and lagging, in liner

silencers, vibration isolators.

Apart from the listed noise sources, minor sources of the noise pollution may be pipes and hoses

hitting the floor, panels etc. i.e. rattling noises, which can be stabilized with adsorbent mounts. All

the bolts should be tightened to prevent vibration and clatter. Venting of process gas out the

condensers may result in serious noise pollutions. This is due to turbulent mixing of high velocity

gas with the stationary gas. Steam leaks and another common noise problem with the sound level

are reaching sometimes 100 dB at the distance of 25 feet of the leak. All steam leaks should be

timely repaired. Where noise levels cannot be reduced to acceptable levels of a person, ear

protection equipment should be used. The industry shall take adequate measures for control of

noise levels from its own sources within the premises so as to maintain ambient air quality

standard in respect of noise to less than 75 dB(A) during day time and 70 dB(A) during night time.

Day time is reckoned in between 6 a.m. and 10 p.m. and night time is reckoned between 10 p.m.

and 6 a.m.

Maharashtra Pollution Control Board Standards for Noise Pollution:

1) The industry should not cause any nuisance in surrounding area.

2) The industry should monitor stack emissions and ambient air quality regularly.

Conditions for D.G. Set:-

1] Noise from the D.G. Set should be controlled by providing an acoustic enclosure or by treating

the room acoustically.

2] Industry should provide acoustic enclosure for control of noise. The acoustic enclosure/acoustic

treatment of the room should be designed for minimum 25 dB(A) insertion loss or for meeting the

ambient noise standards, whichever is on higher side. A suitable exhaust muffler with insertion

loss of 25 dB(A) shall also be provided. The measurement of insertion loss will be done at different

points at 0.5 m from acoustic enclosure/room and then average.

3] The industry shall take adequate measures for control of noise levels from its own sources

within the premises in respect of noise to less than 55 dB(A) during day time and 45 dB(A) during

the night time. Day time is reckoned between 6 a.m. to 10 p.m and night time is reckoned between

10 p.m. to 6 a.m.

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4] Industry should make efforts to bring down noise level due to DG set, outside industrial

premises, within ambient noise requirements by proper siting and control measures.

5] Installation of DG Set much be strictly in compliance with recommendations of DG Set

manufacturer.

6] A proper routine and preventive maintenance procedure for DG set should be set and followed

in consultation with the DG manufacturer which would help to prevent noise levels of DG set from

deteriorating with use.

7] D.G. Set shall be operated only in case of power failure.

8] The applicant should not cause any nuisance in the surrounding area due to operation of D.G.

Set.

2.5 Energy Conservation

Chemical plants have always been designed to operate economically due to product competition.

However before 1970, the objectives of building a low cost plant was generally considered more

important than low operating cost. This concept changed due to the oil crisis of 1973 and the

subsequent action at several environment protection agencies in promoting the use of non-low

polluting attention has been paid to such topics such as energy conservation schemes, process

integration, heat exchanger network design, cogeneration etc. This attention is evident by the large

number of books and journals published on these topics in the recent years. The design engineer

must consider appropriate energy conservation schemes that are designed to:

(i) Utilize as much of the energy available within the plant.

(ii) Minimize the energy requirements for the plant.

The energy balances performed for the plant items provide the initial key to identify areas of high

energy availability or demand. An attempt can then be made to utilize excess energy in those areas

where energy must be provided. However, this is not always possible because:

(i) A high energy load may constitute a large volume of liquid at relatively low temperature, exchanging

this energy may require large and expensive equipment.

(ii) This energy source may be distant from the sink and piping and insulating costs may make

utilization uneconomic, sometimes a rearrangement of the plant lay out required.

(iii) The energy source may be corrosive.

Any energy conservation scheme must also consider the costs involved in removing or transferring

the excess energy i.e. capital cost of heat exchangers, piping, valves, pumps, insulation and operating

costs of pumping and maintenance. Energy conservation is only worthwhile if the reduction in energy

costs exceed the cost of implementation. A scheme maybe devised for a plant and then held over until

energy prices make the proposal attractive. This type of forward planning requires that the plant

layout adopted can be easily modified. Energy conservation can be achieved at three levels:

(i) Correct plan and operation and maintenance

42 | P a g e

(ii) Major changes to existing plant and processes.

(iii) New plants and new processes.

The time required to implement energy conservation measures, the capital cost required, and the

potential savings, all increase from level (i) to (iii) above. The cost of downtime for level.(ii) can be

significant, and the level (iii) offers the greatest long term potential for energy conservation. This latter

objective can be achieved either by designing new, energy efficient plants for established process

routes, or adopting new and less energy- intensive process routes. The basic approach towards

conservation of energy should be taken into account:

i. Operational modification

ii. Research and development

iii. Design modification

iv. Insulation

v. Maintenance

vi. Process integration

vii. Process modification

viii. Waste utilization

In the near future all industrial operations that have reacted to the energy crisis must be organized to

institute a systematic approach towards conserving energy in all forms through more efficient

utilization of existing processes and carefully studied reduction of losses and wastes. The following

examples illustrate some application of the basic engineering principles t the design of equipment for

improved energy efficiency.

(i) Plant Operation:

Energy savings can be achieved by good engineering practice and the application of established

principles. These measures may be termed as good housekeeping and include correct plant operation

and regular maintenance. The overall energy savings are usually small and may not be easy to achieve

and significant time may be required for regulate maintenance and checking. However, such

measures do help to establish commitment of a company to a policy of energy conservation.

(ii) Heat Recovery:

Heat recovery is an important and fundamental method of energy conservation. The main limitations

of this method are:

(a) Inadequate scope for using recovered waste heat because it is too low grade for existing heat

requirements, and because the quantity of waste heat available exceeds existing requirements for

low- grade heat.

43 | P a g e

(b) Inadequate heat transfer equipment. Developments and improvements are continuing in design

and operation of different types of heat exchangers including the use of extended heat transfer

surfaces, optimizing heat exchanger networks, heat recovery from waste fuels, heat exchanger fouling

and the use of heat pumps.

(iii) Combined Heat and Power Systems:

Significant energy conservation is achieved by well-established method of combined heat and power

generation. This is often referred to as CHP or COGEN. The heat is usually in the form of intermediate

or low pressure steam and the power as direct mechanical drives or as electricity generated with the

turbo alternators. The choice of system is usually between back pressure steam turbines or gas

turbines with waste heat boilers for the process streams. The amount of power generated is usually

determined by the demand of heat. It is not usually possible to balance exactly the heat and power

loads in a system .The best method of achieving this aim is to generate excess electricity for

subsequent sale, other balancing methods tend to be less efficient. Therefore it is important to

forecast the heat to power ratio accurately at the design stage to avoid large imbalances and reduced

system efficiency.

(iv)Power recovery systems:

A power recovery turbine can recover heat from an exchanger gas and then use this heat to provide

a part of the energy required to drive the shaft of a motor driven process air compressor. Other

examples are the use of the steam turbine drive and a two stage expansion turbine with reheating

between the stages.

A hydraulic turbine can be incorporated on the same shaft as a steam turbine. This arrangement can

be used to provide about 50% of the energy needed to recompress the spent liquor in a high

pressure absorption /low pressure stripping system. Power generation using steam or gas turbine is

now well established; however power recovery by the pressure reduction of process fluids is more

difficult and less common. In general the equipment is not considered to be particularly

reliable.Rankine cycle heat engines have been developed to use relatively low grade waste heat

sources to generate power in the form in the form of electricity or direct drives. They tend to be

used when the heat source would otherwise be completely wasted, the low efficiencies do not

represent a significant disadvantage.

(v) Furnace efficiency

Incorporating an air heater can be more economic than using a hot oil system which is designed for

high level heat only.

(vi) Air cooler v/s water cooler:

Air coolers have higher installed cost but lower operating cost water coolers.

(vii) Low pressure steam:

Energy savings can be achieved by the efficient use of low pressure steam.

(viii) Heat integration:

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Energy can be saved by optimum balance of heat sources and sinks in a process plant so as to

maximize recycling of energy input .thus however has to be done carefully as it leads to loss of

operational independence.

(ix) Thermal insulation:

Owing to the great size of the distillation column large amount of heat is dissipated from the surface

.This necessitates thermal insulation of distillation column reboiler and other piping attached to it so

that minimum heat is dissipated.Multi-layer energy saving insulation should be used which provide

protection from fire, liquid spillage and result in energy savings. Usually, inner insulation layers are

made from alumina silica fibers to reduce the heat loss from the valves and joints to keep the system

heat constant and prevent heat loss.

Instrumentation:

Use of efficient instrumentation in the plant can result in consistent high quality of product and lesser

no. of rejections. In a plant design utmost care must be taken to conserve energy. The reboiler and

the heat exchanger should be set up after a long analysis

Energy conservation in the design of complete process may be achieved in four ways:

(i) Major modifications to the existing plants.

(ii) New plant using an existing process route.

(iii) New process routes and alternative raw materials.

(iv) New processes for new products that are less energy intensive.

Items (i) and (iii) represent short term and medium term energy conservation measures. Item (iv)

requiring the use of new products or processes is more appropriate for new technology in the

chemical industry. Although energy conservation is an obvious objective of all equipment

manufacturers and plant designers, more attention iis necessary in relation to education , training

and the application of new and existing technology to ensure significant medium term and long term

savings.

Energy conservation must be considered at various stages of the project, e.g. feasibility study, process

selection, plant layout, energy balances and in conjunction with the detailed equipment design. If he

energy utilization is not only an afterthought, either unnecessary or costly modifications may be

required to the design work, or the plant may not be economically feasible as it originally appeared.

ENERGY MANAGEMENT:

The high value of energy should be acknowledged in plant operation by treating it as a product with

monetary value than can be sold or traded, just like the chemical product. This should be the basis for

operational policies concerned with the energy management or energy conservation. These duties

can be incorporated by the process engineer. EAM&T is a means to efficient operation in this area,

but there must be a commitment from all operational and managerial personnel to the importance

of these tasks if they are to be successful. The reaction and product recovery areas have been

45 | P a g e

identified as critical units from an energy perspective. Detailed monitoring and targeting should be

established in these areas.

ALTERNATE ENERGY RESOURCES

The fuel resources of the world are fast depleting and there is an urgent need to explore the

possibility of the alternate sources of energy. Although rapid breakthrough has been achieved

in the use of nuclear energy for the distillation of the steam, which in turn is used for the

generation of electricity, it is not used widely due to the lack of the flexibility in its utilization

and because of the non-feasibility of its operation on the smaller scale. Some of the alternate

energy sources being developed nowadays have been briefly discussed below:

Solar energy

Solar energy is the most important form of renewable energy for plant. The energy incident

on the solar panel installed in the roof and other areas of the plants are highly useful in heating

up the water and converting to steam. This is one renewable source of the energy which is

now slowly finding wide acceptance in the process industry. In the process industry it is being

used widely for heating the process water and in some cases for the production of the low

pressure steam. Energy conservation is not only concerned with the process industries but is

also concerned with other small household purposes carried out in the industrial areas. It can

also be used for the heating and providing warm water in the canteen and the other non-

production areas in the process plant.

Energy from biomass conversion

Biomass in todays Chemical Industries is going to play a vital role in the production of energy

as well as in different chemical products. The biomass have been widely used however major

considerations include:

Which raw materials will be needed in the new situation?

How will biomass be processed?

How will feedstock be made available at the appropriate location?

What kind of storage facilities is needed?

How can the production of bio-based bulk chemicals be integrated?

How will products be shipped to the (geographic) area covered by the Port?

Which are the most likely companies to produce new bio-based bulk chemicals?

Two extremes can be envisioned by which the transformation to a biomass based chemical

industry may take place:

1. Biomass will be refined and cracked into the familiar platform chemicals (i.e. ethylene,

propylene, C4-olefines and BTX) and synthesis gas (syngas, a mixture of mainly carbon

monoxide and hydrogen gas). From these one- to six-carbon building blocks, all other

chemicals and materials can be produced. Provided that efficient processes will become

available by which oxygen-rich biomass of a varying composition can be transformed into

basic hydrocarbon building blocks, the big advantage is that the current petrochemicals

46 | P a g e

infrastructure and processes can be used. The fossil feedstock refining companies of today

may then become the biorefineries of tomorrow.

2. A wide range of bio-based building blocks, in which as much of the functionality of biomass

as possible has been retained, become the raw materials from which all other chemicals and

materials are made. Not a few refineries that produce a limited number of platform chemicals

will be present, but a large number of (smaller scale) bio-refineries that produce a whole array

of building blocks.

Between these two extremes lies a whole spectrum of non-exclusive scenarios that are

perhaps more realistic. As a less extreme example of the first scenario: ethylene, one of the

current platform chemicals, can be produced from (bio) ethanol. In fact, the Brazilian company

Braskem and US based Dow Chemical will each start commercial production of polyethylene

from bio-ethanol. Bio-ethanol is currently made from sugar or starch. In the future, it is

expected that ethanol will be made from the more abundant lignocellulosic or woody

biomass.

The Gobar gas concept has found wide acceptance in the rural India. Although bioconversion

technology has been very successful in the waste treatment, the technology to generate

energy for the industrial uses is in early stages of the development. However, this technology

holdsgreat promise as its fundamental advantage is that apart from being a clean source of

the fuel, it is a renewable source of energy.

Ocean thermal energy:

The Ocean energy is one of the contributors in renewable energy. The temperature of the

water in the ocean varies drastically with the depth. The principal here is to run a heat engine

to retract heat energy from ocean by utilizing the difference in temperature of the ocean at

various depths.

This technology is in the very early stages of the development and can only be utilized if the

plant is situated close to the coastlines.

Wind energy:

The unequal heating of the earth by the sun causes winds. This effect is particularly

pronounced in the coastal areas with a difference between the temperature for the land and

the sea. The force of the wind is used to rotate windmills, which are rotating blades to collect

the force of the wind. This mechanical energy produced can be used directly on it can be

converted into electrical energy. These have been used with partial success in the process

industry, mainly to pump water both process water and the water to effluent treatment plants.

47 | P a g e

3. Organizational Structure and Manpower Requirement

3.1 Organizational Principles and Basics

According to one of the prominent scholars, organizations are social units (or human

groupings) deliberately constructed and reconstructed to seek specific goals. (Etzioni, 1964).

Organization is a prescribed pattern of relations among the various tasks and the individuals who

perform the tasks. Organizations are characterized by explicit, common parts which require the co-

ordination of individuals and group efforts towards their attainment. The co-ordination is achieved

by the establishment of vertical and horizontal network of relationships among various components

of the organization. The basic goals of the organization are three-folds:

1. To produce the best quality product at the lowest cost

2. To sell the product to the consumer in a manner that maximizes profit, both in the short as well

as long term.

3. To do these in a manner that is sustainable and is in the interest of the society.

In order to achieve these goals, an effective organizational structure is required both at the

management and operational levels. There are various steps involved in specifying the kind of

organization and the total labour requirement of the plant complex, before beginning the

construction and commissioning of the plant. We briefly take some of the important points.

Consideration of objectives: One should be very clear as to what are the objectives of the

enterprise. Objectives determine the various activities, which need to be performed and the type of

organization, which needs to be built for the purpose.

Grouping of activities into departments: Identify the activities necessary to achieve the objectives

and group the similar or related activities into well-defined groups or departments.

Deciding key departments: Key departments are those which render activities that are essential

for the achievement of goals. These are primary departments; the others exist merely to serve

these.

Determine decision levels: The levels at which all the major and minor decisions in each

department are to be made must be determined. The amount of decentralization and spread of

authority are at the discretion of each firm.

Span of Management: The next step to be taken in designing a structure is the number of sub-

ordinates who will report to each executive.

Coordination mechanism: The whole structure should be like a well-oiled machine, with cohesion

and co-ordination at all levels.

48 | P a g e

Duties of organization and administration:

Principles of work administration and control, labour organization and control, raw material

and their storage

Selection of site, layout of works, building and plants

Problem of internal transport and material handling

Construction work

Proper equipment selection

Minimization of labour

Office administration and finance

Marketing and distribution of products.

There are sixteen principles of organization:

1. Unity of objectives

2. Specialization

3. Coordination

4. Chain of command

5. Authority responsibility

6. Delegation

7. Unity of command

8. Span of Control

9. Balance

10. Communication

11. Efficiency

12. Personal ability

13. Decision making and control by exception

14. Flexibility

15. Departmentalization

16. Goal centered and purposeful activities

But an organization that works well in one type of environment (environment being defined as

combination of markets, customers, producers and technology) may fail in another. The failure may

arise due to contingency factors such as:

1. Task uncertainty, technology and environment

2. Power and conflict

3. Growth and size

Here task uncertainty is the degree to which the task necessary for the performance is unpredictable.

Technology and environment are the sources of unpredictability.

Organizational structure should manage conflict so that it helps the company. It is helpful to

understand the basic determinants of power in an organization and how conflicts are related

49 | P a g e

Organization effectiveness includes the following criteria

1. Organizational efficiencies

2. Adaptability to external changes

3. Satisfaction of individual needs

3.2 Hierarchy

I. Board of Directors

i. Establishes objectives

ii. Overall accountability to stock holders

II. Chief Executive Officer

i. Operates business to accomplish objectives

ii. Accountable to board of directors.

III. Operating management

i. Overall coordination and activities necessary to accomplish objectives

ii. Accountable to CEO

IV. Operating supervision

i. Supervision of non-supervisory employs

ii. Accountable to operating Management

ORGANIZATION HIERARCHY CHART

Keeping the above factors in mind, we have divided the organization of our plant into the following

categories

50 | P a g e

General administration

Production division

Maintenance division

Commercial and inventory division

Human recourses division

Marketing division

Research and development division

A. Finance Sector

When it comes to the overall scope and duties of a finance department, there are many functions to

be fulfilled. For the most part, the duties include all things related to budgeting.

From appropriations to control of expenditure and auditing duties, the finance department of any

given company has an array of duties.

A finance department basically has three main functions:

To provide strategic financial support regarding operational and general business planning

To provide daily financial services functions

To meet and surpass the internal and external needs and financial reporting requirements of

the company at large

The finance department generally focuses on providing relevant information necessary for upper level

management. Such information is crucial in determining how a company can make better financial

decisions.

Services and Duties of a Finance Department

In order to implement these functions, there are a number of services that need to be performed.

For example, the proper preparations of the annual budget as well as compliance of regulatory codes

are both important services of a finance department.

Key Positions in a Finance Department

A finance department is comprised of several key positions that bear the burden of responsibility

when it comes to maintaining the cohesiveness and overall productivity of the department as a unit

of the company.

When you think about the overall structure of the finance department, there are four key point people

that may come to mind:

The finance director

Deputy finance director

Accountant

Finance specialist

51 | P a g e

Finance Director

The finance director is the head of the finance department. This individual will have the supreme

responsibility to ensure that all financial reports are accurate and up to date. The finance director is

tasked with giving a financial forecast for the company and disclosing certain financial information

about the company to the shareholders.

Deputy Finance Director

The deputy finance director is usually responsible for putting together the companys annual budget.

In this position, the deputy finance director will be responsible for developing an overall financial

strategy. Sometimes referred to as the finance manager, the deputy finance director is also

responsible for managing the finance departments team of employees.

Accountant

The next position of importance in the department of finance is the accountant. The accountant is

responsible for handling the accounts payable and accounts receivable.

Accountants also process payroll. Other duties include putting together financial-related documents

such as reports, auditing, and closing out accounting books.

Finance Specialist

The finance specialist basically handles capital investments. This position may also require a bit of

analytical work such as reconciliations, maintaining the general ledger and keeping a close eye on the

funds of the company.

Evolution of the Finance Department

With each passing year the company evolves into an entity that is responsible for increasing the

company (and shareholders value). This shall be done by increasing the number of employees of the

department according to requirement and including other employees like clerical staff and inter-

section commuters.

B. Personnel & Administration department

Human resources is the business administration function responsible for finding, hiring, managing

and retaining employees, and for ensuring that the right employees, in the right numbers, are

deployed throughout the organization to achieve its goals. Human resources are a function that exists

in every business regardless of size, industry or geographic location. In fact, even though small

businesses may not have a formal human resource department or an employee with a title that

includes "human resources," the function is performed when employees are hired, training,

supervised and, hopefully, retained.

Administrators, broadly speaking, engage in a common set of functions to meet the organizations

goals. These "functions" of the administrator were described by Henri Fayol as the 5 elements of

administration" (in italic below).

52 | P a g e

Planning - is deciding in advance what to do, how to do it, when to do it, and who should do it. It maps

the path from where the organization is to where it wants to be. The planning function involves

establishing goals and arranging them in a logical order. Administrators engage in both short-range

and long-range planning.

Organizing - involves identifying responsibilities to be performed, grouping responsibilities into

departments or divisions, and specifying organizational relationships. The purpose is to achieve

coordinated effort among all the elements in the organization (Coordinating).

Organizing must take into account delegation of authority and responsibility and span of control

within supervisory units.

Staffing - means filling job positions with the right people at the right time. It involves determining

staffing needs, writing job descriptions, recruiting and screening people to fill the positions.

Directing (Commanding) - is leading people in a manner that achieves the goals of the organization.

This involves proper allocation of resources and providing an effective support system. Directing

requires exceptional interpersonal skills and the ability to motivate people.

One of the crucial issues in directing is to find the correct balance between emphasis on staff needs

and emphasis on economic production.

Controlling - is a function that evaluates quality in all areas and detects potential or actual deviations

from the organization's plan. This ensures high-quality performance and satisfactory results while

maintaining an orderly and problem-free environment. Controlling includes information

management, measurement of performance, and institution of corrective actions.

Budgeting - exempted from the list above, incorporates most of the administrative functions,

beginning with the implementation of a budget plan through the application of budget controls.

C. Research and development

A research and development department is responsible for innovations in design, products, and style.

This department will be responsible for creating innovative new products to keep the company a step

ahead of the competition. R&D Department will work on improving existing consumer products, and

to explore new ways of producing them.

Often, a Research and Development Department works closely with the Marketing Department. The

Marketing Department studies consumer trends by surveying and researching consumer demands,

purchasing methods, product sales, and the existence and development of technology across the

relevant market. The marketing department gathers all the data, and makes this information available

to the R&D department, which will take action in response to the findings and proceed to keep the

company on top of current market needs.

D. Operations

53 | P a g e

Operations management is an area of management concerned with overseeing, designing, and

redesigning business operations in the production of goods and/or services. It involves the

responsibility of ensuring that business operations are efficient in terms of using as few resources as

needed, and effective in terms of meeting customer requirements. It is concerned with managing the

process that converts inputs (in the forms of materials, labour, and energy) into outputs (in the form

of goods and/or services). The relationship of operations management to senior management in

commercial contexts can be compared to the relationship of line officers the highest-level senior

officers in military science. The highest level officer shapes the strategy and designs it over time, while

the line officer makes tactical decisions in support of carrying out the strategy.

According to the U.S. Department of Education, operations management is the field concerned with

managing and directing the physical and/or technical functions of a firm or organization, particularly

those relating to development, production, and manufacturing.

Operations management programs typically include instruction in principles of general management,

manufacturing and production systems, plant management, equipment maintenance management,

production control, industrial labour relations and skilled trades supervision, strategic manufacturing

policy, systems analysis, productivity analysis and cost control, and materials planning. Management,

including operations management, is like engineering in that it blends art with applied science. People

skills, creativity, rational analysis, and knowledge of technology are all required for success.

E. Product Marketing & Sales

In a manufacturing company the production function may be split into four sub-functions:

Production and planning department

The production and planning department will set standards and targets for each section of the

production process. The quantity and quality of products coming off a production line will be closely

monitored. In businesses focusing on lean production, quality will be monitored by all employees at

every stage of production, rather than at the end as is the case for businesses using a quality control

approach.

Purchasing department

The purchasing department will be responsible for providing the materials, components and

equipment required to keep the production process running smoothly. A vital aspect of this role is

ensuring stocks arrive on time and to the right quality.

Stores department

The stores department will be responsible for stocking all the necessary tools, spares, raw materials

and equipment required to service the manufacturing process. Where sourcing is unreliable, buffer

stocks will need to be kept and the use of computerized stock control systems helps keep stocks at a

minimal but necessary level for production to continue unhindered.

Works Department

54 | P a g e

The works department will be concerned with the manufacture of products. This will include the

maintenance of the production line and other necessary repairs. The works department may also

have responsibility for quality control and inspection.

3.3 Manpower Requirement

Designation Number Required Annual Salary

i

n Qualification

rupees

Lacs/annum

MD/Chairperson 1 40 Engineer cum MBA

with 15 years

experience.

Board Of Directors

Designation Number Required Annual Salary

i

n Qualification

rupees

Lacs/annum

CEO 1 30 Engineer cum MBA

with 10 years

Experience

COO 1 30 Engineer cum MBA

with 10 years

Experience

CFO 1 30 Engineer cum MBA

with 10 years

Experience

55 | P a g e

Operation

Vice President 2 20 Chemical Engineer

(for production) with

10

year experience

Production Engineer 4 12 Chemical Engineer

with 4 year

Experience

Maintenance 4 11 Mechanical Engineer

Engineer with 4 year

experience

Instrumentation 4 8 Instrumentation

Engineer Engineer with 4 year

experience

Shift Engineer 8 5.5 Chemical engineer

with 4 year

Experience

Shift Operator 12 4 Diploma in Chemical

Engineering

Labor(permanent) 12 1 High School

Labor(temporary) Quantity depending High School

upon work required

56 | P a g e

Administration

Vice President 1 15 MBA with 10 year

experience

Manager 1 12 MBA with 6 year

experience

Security Officer 2 5.5 Retired Army or

police

official

Fire & Safety Officer 4 5.5 8 years experience in

fire and safety

management

Medical Officer 2 5.5 MBBS with 4 years

of

experience e

Medical Staff 2 2 Diploma

Public Relation 1 5 Graduate with 5 year

Officer experience in public

relations

57 | P a g e

Finance:

Vice President 1 20 C.A. with 10 years

experience

Manager 1 15 MBA (finance) with

8

years experience

Account Officer 2 10 C.A. with 4 year

experience

Clerical Staff 8 3 B.Com with some or

no experience

Marketing;

Vice President 1 20 MBA (marketing)

with

12 years of

experience

Manager 2 15 MBA (marketing)

with 8 years

Marketing Officer 3 10 MBA (marketing)

with 5 years

experience

58 | P a g e

Research & Development

Vice President 1 20 C.A. with 10 years

experience

Manager 2 15 MBA (finance) with

10

years experience

Research Assistor 3 10 C.A. with 4 year

experience

Clerical Staff 8 3 B.Com with some or

no experience

Total manpower requirement (permanent staff) = 95

This is the number of higher order permanent staff and highly skilled labour. The number of total

employed worker, either skilled or semi-skilled varies with the project being carried out.

59 | P a g e

4. SITE SELECTION & PROJECT LAYOUT

4.1 Plant Location

One of the key features of a transformation system is the efficiency with which the output is

transferred to the recipients. Any consideration of this will include the determination of where to place

the

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cumene to phenol

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