eRep-Mini Design Project - Production of Methanol, BSc

FACULTY OF CHEMICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA

TITLE:

MINI DESIGN PROJECT

(PRODUCTION OF METHANOL)

PREPARED BY:

AHMAD SHAHRUL AZROI B CHE RANI 2008403464

AFIFAH BT DZULKIFLI 2008403564

BALQIS BT ZAINAL ABIDIN 2008403518

MOHD FAREED B MOHD RASHIDI 2008403446

MOHAMAD ASYRAF B PAHMI 2008403542

MUHAMMAD ARIF B CHE RAHI 2008403562

NOOR HAYATI BT KAMARUDIN 2008403494

NOOR ELYZAWERNI BT SALIM 2008403532

NOR SURAYA BT MOHD KAMILAN 2008403488

DATE OF SUBMISSION:

5TH

APRIL 2011

NAME OF LECTURER:

EN. AMMAR BIN MOHD AKHIR

TABLE OF CONTENT

INTRODUCTION

PART 1

1.0 History and General Information On Methanol 15

1.1 History 15

1.1.1 Methanol 16

1.1.2 Production of Methanol Synthesis 8

1.2 General Description 19

1.3 Usage 20

PART 2

2.0 Process in Producing Methanol 25

2.1 Process Selected and Selection Criteria

2.2 Process Description

2.3 Input and Output Structure 26

2.3.1 Overall 29

2.3.2 Conversion Reactor (Crv-100) 33

2.3.3 Conversion Reactor (Crv-102) 36

PART 3

3.0 Market Analysis 42

3.1 List of Equipment Supplier 42

PART 4

4.0 Site selection 49

4.1 Potential Site Location 49

4.2 Transport 49

4.3 Availability of Labor 50

4.4 Utilities and Facilities 50

4.5 Land 51

4.6 Climate 51

PART 5

5.0 Material safety data sheets 62

5.1 Methanol 62

5.1.1 Product identification 62

5.1.2 Hazards Identification 62

5.1.3 First Aid Measures 63

5.1.4 Fire fighting measure 63

5.1.5 Accidental Release Measure 64

5.1.6 Storage and Handling 64

5.1.7 Exposure Controls / Personal Protection 64

5.1.8 Physical and Chemical Properties 65

5.1.9 Stability and Reactivity Data 65

5.1.10 Toxicological Information 66

5.1.11 Ecological Information 66

5.1.12 Disposal Consideration 66

5.2 Methane












5.2.12 Disposal Consideration

5.3 Carbon Monoxide












5.3.12 Disposal Consideration 78

5.4 Carbon Dioxide













5.5 Water













5.6 Hydrogen













PART 6

6.0 Environmental analysis 113

6.1 Project activity and data 118

6.1.1 Faith and Transport 119

6.2 Environmental Monitoring 120

6.3 Human and Aquatic Toxicity

PART 7

7.0 Mass Balance

7.1 Mass Balance of Mixer 130

7.2 Mass Balance of Reforming Reactor

7.3 Mass balance of Reactor and Seperator

PART 8

8.0 Energy balance 152

PART 9

9.0 Pinch temperature analysis 192

PART 10

10.0 Conclusion 196

PART 11

11.0 References 198

Introduction

The annual production of methanol exceeds 40 million tons and continues to grow by 4%

per year. Methanol has traditionally been used as feed for production of a range of chemicals

including acetic acid and formaldehyde. In recent years methanol has also been used for other

markets such as production of DME (Di-methyl-ether) and olefins by the so-called methanol-to-

olefins process (MTO) or as blend stock for motor fuels.

The production of methanol from coal is increasing in locations where natural gas is not

available or expensive. However, most methanol are produced from natural gas. Several new

plants have been constructed in areas where natural gas is available and cheap such as in the

Middle East. There is little doubt that (cheap) natural gas will remain the predominant feed for

methanol production for many years to come.

The capacity of methanol plants has increased significantly only during the last decade.

In 1996 a world scale methanol plant with a capacity of 2500 MTPD was started up in

Tjeldbergodden, Norway [1]. Today several plants are in operation with the double of this

capacity e.g. [2].

Plants with capacities of 10,000 MTPD or more are considered and planned for example

for the production of methanol for the MTO process [3]. Given the substantial investment in such

large scale plants there is considerable incentive to maximize single line capacity to take

advantage of economy of scale. This design project will describes the state of the art methanol

synthesis technology with focus on very large plants with a capacity of 00000 MTPD or more.

All commercial methanol technologies feature three process sections and a utility section

as listed below:

Synthesis gas preparation (reforming)

Methanol synthesis

Methanol purification

Utilities

In the design of a methanol plant the three process sections may be considered

independently, and the technology may be selected and optimized separately for each section.

The normal criteria for the selection of technology are capital cost and plant efficiency. The

synthesis gas preparation and compression typically accounts for about 60% of the investment,

and almost all energy is consumed in this process section. Therefore, the selection of reforming

technology is of paramount importance, regardless of the site.

Methanol synthesis gas is characterized by the stoichiometric ratio (H2 CO2) / (CO +

CO2), often referred to as the module M. A module of 2 defines a stoichiometric synthesis gas

for formation of methanol. Other important properties of the synthesis gas are the CO to CO2

ratio and the concentration of inert. A high CO to CO2 ratio will increase the reaction rate and

the achievable per pass conversion. In addition, the formation of water will decrease, reducing

the catalyst deactivation rate. High concentration of inerts will lower the partial pressure of the

active reactants. Inert in the methanol synthesis are typically methane, argon and nitrogen.

A comprehensive survey of methanol production technology is given in [4]. In the

following a brief description is given covering technologies available for the three process

sections.

PART 1

1.0 History and General Information on Methanol

1.1 History

1.1.1 Methanol

In their embalming process, the ancient Egyptians used a mixture of

substances, including methanol, which they obtained from the pyrolysis of

wood. Pure methanol, however, was first isolated in 1661 by Robert Boyle,

when he produced it via the distillation of boxwood. It later became known as

pyroxylic spirit. In 1834, the French chemists Jean-Baptiste Dumas and

Eugene Peligot determined its elemental composition.

They also introduced the word methylene to organic chemistry, forming it

from Greek methy = "wine" + hl = wood (patch of trees). Its intended origin

was "alcohol made from wood (substance)", but it has Greek language errors:

wrong Greek word used for the French word bois = "wood"; wrong Greek

word combining order influenced by French usage.[dubious discuss]

The term

"methyl" was derived in about 1840 by back- formation from methylene,

and was then applied to describe "methyl alcohol." This was shortened to

"methanol" in 1892 by the International Conference on Chemical

Nomenclature. The suffix -yl used in organic chemistry to form names of

carbon groups, was extracted from the word "methyl."

In 1923 the German chemists Alwin Mittasch and Mathias Pier, working

for BASF, developed a means to convert synthesis gas (a mixture of carbon

monoxide, carbon dioxide, and hydrogen) into methanol. A patent was filed

Jan 12 1926 (reference no. 1,569,775). This process used a chromium and

manganese oxide catalyst, and required extremely vigorous conditions

pressures ranging from 50 to 220 atm, and temperatures up to 450 C. Modern

methanol production has been made more efficient through use of catalysts

(commonly copper) capable of operating at lower pressures, the modern low

pressure methanol (LPM) was developed by ICI in the late 1960s with the

technology now owned[citation needed]

by Johnson Matthey who is a leading

licensor of methanol technology.

The use of methanol as a motor fuel received attention during the oil crises

of the 1970s due to its availability, low cost, and environmental benefits. By

the mid-1990s, over 20,000 methanol "flexible fuel vehicles" capable of

operating on methanol or gasoline were introduced in the U.S. In addition,

low levels of methanol were blending in gasoline fuels sold in Europe during

much of the 1980s and early-1990s. Automakers stopped building methanol

FFVs by the late-1990s, switching their attention to ethanol fueled vehicles.

While the Methanol FFV program was a technical success, rising methanol

pricing in the mid- to late-1990s during a period of slumping gasoline pump

prices diminished the interest in methanol fuels. Additionally, methanol is

highly corrosive to rubber and many synthetic polymers used in the

automotive industry, whereas ethanol is not.[5]

In 2006 astronomers using the MERLIN array of radio telescopes at

Jodrell Bank Observatory discovered a large cloud of methanol in space, 288

billion miles across.[6][7]

1.1.2 The Production of Methanol Synthesis

Supp (1990) and Olah et al. (2006) present good overviews on the

characteristics of methanol and its production methods. This section is largely

based on these reference books. Another source may be found at wikipedia.

Methanol has a history extending back to about 1661, when Boyle

succeeded for the first time in recovering methanol from crude wood vinegar.

The component was re-discovered in 1822 by Taylor, after which in 1835 Von

Liebig succeeded in clarifying the chemical structure of methanol. In the

hundred years following this, methanol was recovered to an increasing degree

as wood alcohol by distilling wood.

In 1923, Mittasch and his staff succeeded in first producing methanol from

carbon monoxide and hydrogen (synthesis gas or syngas) using a catalyst.

Methanol was recovered together with a whole series of other components

containing oxygen, and the catalyst only had very short cycle times. Patart

then described a methanol synthesis process using hydrogenation active

metals, and metal oxides stated to be the catalyst. This led to a first

commercial plant. This process required vigorous conditionspressures

ranging from 3001000 atm, and temperatures of about 400 C. Modern

methanol production has been made more efficient through use of catalysts

(commonly containing copper) capable of operating at lower pressures.

At the beginning of the thirties, a series of commercial plants went into

operation in the USA, with capacities per plant of 100 to 500 tons/day, using

chromic acid activated zinc oxide catalyst. As early as 1935, it was recognized

that copper-based catalysts provided considerable advantages for methanol

synthesis, permitting considerably lower pressures and, above all, lower

temperatures. But these catalysts were extremely sensitive to sulphur

components. After development of suitable syngas purification systems,

mainly to remove sulphur, the first Low-Pressure Methanol process was

brought onto the market by Imperial Chemical Industries Ltd (ICI), Great

Britain. At that time, Lurgi Gesellschaft fr Wrme und Chemoteknik from

Germany also developed a low-pressure methanol process, which, contrary to

the ICI quench reactor, applied a tubular reactor cooled with boiling water.

Most of the methanol plants in the last 20 years operate according to the ICI

or Lurgi processes, while numerous high-pressure units have been converted

to the low-pressure system in the second half of the last century.

1.2 General Description

Methanol is also known as methyl alcohol, wood alcohol, wood naphtha or wood

spirits. It is a chemical with formula CH3OH. It is the simplest alcohol, and has a

characteristic of light, volatile, colorless, flammable, liquid with a distinctive odor

that is very similar to but slightly sweeter than ethanol. Methanol can be used as an

antifreeze, solvent fuel and also as a denaturant for ethanol as it is a polar liquid at

room temperature. In anaerobic metabolism of many varieties of bacteria and in

ubiquitos condition, methanol produced naturally. Therefore, that is why there are

small amount of methanol vapour in the atmosphere. In atmosphere, Methanol burns

in air forming carbon dioxide and water:

2 CH3OH + 3 O2 2 CO2 + 4 H2O

Methanol flame is almost colorless in bright sunlight because of its toxic properties.

Methanol

1.3 Usage

The three largest derivatives of methanol are formaldehyde, methyl tertiary butyl

ether (MTBE) and acetic acid. However, methanol is seeing growing demand in fuel

application such as dimethyl ether (DME), biodiesel and direct blending into

gasoline.

Formaldehyde is used mainly to make amino and phenolic resins which are

employed in the manufacture of wood-based products such as panels, flooring and

furniture.

The main use for MTBE is an octane booster and oxygenate in gasoline.

However, it has been phased out following its contamination of underground water

supplies and the removal of the oxygenate mandate and liability protection. MTBE

will continue to be vital for fuel quality and cleaner emissions. As countries look to

remove sulphur and lead and reduce aromatic content in the gasoline pool, MTBE

will make a significant contribution to improve fuel quality.

Acetic acid has a number of outlets of which the two largest are vinyl acetate

monomer and purified terephtalic acid. Global demand for acetic acid has been

growing at a steady 4%/ year with PTA sector growth at double this rate driven by

polyester demand. In the area of petrochemical feedstocks, there has been

considerable interest in methanol-to-olefins(MTO) and methanol-to-propylene(MTP)

technologies with projects underway in China. The first MTO units in China were

started up in August 2010.

Methanol is also used for the basis of many other chemical products:

- The largest solvent use for methanol is as a component of windscreen wash

antifreeze. It can also be used to extract, wash, dry and crystallise pharmaceutical

and agricultural chemicals.

- Methlamines are used as intermediates in a range of speciality chemicals with

applications in water treatment chemicals, shampoos, liquid detergents and animal

feeds.

- Methyl methacrylate is employed in the production of acrylic polymers.

- Dimethyl terephthalate is used to make polysters although PTA is preferred

feedstock.

- Methanol and sodium chlorate are used to produce chlorine dioxide, a bleaching

agent for the pulp and paper industry.

- Glycol esthers are solvents used in acrylic coatings and newer high-solids and

waterborne coatings.

- Methyl mercaptan is used an intermediate in the production of DL-methionine, an

amino acid supplement in animal feeds.

Fuel uses to grow:

The use of methanol in fuel applications is expected to have a big impact on

future demand. Methanol can be used in biodiesel plants have been built, there has

been uncertainty in the biodiesel industry. Methanol is increasingly being used to

make DME , which can be employed as an alternative to diesel, a supplement to

liquiefied petroleum gas (LPG) and in power generation. The largest DME market in

China where it is blended into LPG. The DME industry in China is suffering from

capacity.

PART 2

2.0 Process in Producing Methanol

2.1 Process Selected and Selection Criteria

This section will explain the reason why the selected process has been chosen and

the disadvantages of the unselected processes.

Nowadays, there are several ways of producing methanol (CH3OH) in this world.

All of the processes have their own advantages and disadvantages. It is important to

choose the most efficient process in order to have a good and almost perfect

production of methanol. Here are the lists of the processes or step in producing the

methanol.

1. Synthesis Gas

2. Synthesis Methanol

3. Catalytic Conversion of Methanol

4. Methyl Alcohol

For this mini design project, we have decided to choose synthesis gas process for

producing the methanol. The synthesis gas is so far the best way in producing

methanol because it has more advantages compared to the other processes and it is

also being used commercially by many plants worldwide. Most methanols are

produced using either a high-pressure process or a low-pressure process. In the high-

pressure process (above 275 bars), synthesis gas is made by reforming natural gas and

forming carbon dioxide to balance the excess hydrogen by the equation

CO2 + 3H2 CH3OH + H2O

This, in effect, produces more methanols. In the low-pressure (50 to 100 bars)

methanol processes, the excess hydrogen is purged from synthesis loop and is not

used to produce methanol. In this method, a large reformer must be built in order to

produce the equivalent amount of methanol. Commercially available cu-ZnO-Al2O3

catalyst permits production of the desired product with high selectivity. The main

advantages of the low-pressure process are lower investment and production cost,

improved operational reliability and greater flexibility in the choice of plant size.

Stand-alone Auto Thermal Reforming (ATR) at low steam to carbon (S/C) ratio is the

preferred technology for large scale plants by maximizing the single line capacity and

minimizing the investment. The ATR produces a synthesis gas well suited for

production of both fuel grade and high purity methanol.

Here are the disadvantages of the other processes that have not been selected.

a) Synthesis Methanol

Synthesis methanol will produced three unwanted reaction which need a

further consideration and eventually will cause a high capital cost. Under this

reaction, CO will reacts with the walls of the reactor and produces iron

carbonyl which deposits on the catalyst and accelerates its deactivation which

is not good for a plant. This and the other disadvantages of the high pressure

operation led to the development of the low pressure process using copper as a

component of the catalyst.

b) Catalytic Conversion of Methanol

For catalytic conversion of methanol, there are too many flaws and

disadvantages that lead to the inefficient production. By using this process to

produce methanol, it will eventually produce several by-product which is

paraffins, olefins and aromatics. The extra separation or procedure needed to

set up to in order to deal with undesired by-product. Olefins are intermediates

in the conversion of methanol to aromatic hydrocarbons over zeolite. This

process is basically focusing on how to increase the olefin production instead

of methanol.

c) Methyl Alcohol

Basically methyl alcohol was produced from synthesis gas and it is also

obtained by the oxidation of methane using natural gas as the feedstock.

However, by using this process, only 60 percent of methanol produced which

the natural gas not fully converted. This means this process are quite similar

with synthesis gas but the fact that it is not being practiced by many company

in this world is a major disadvantage. This process also not focusing on

producing methanol but it is mainly on the production of methyl alcohol.

However methanol can be produced by purified with distillation.

2.2 Process Descriptions

Autothermal reforming (ATR) features a stand-alone, oxygen-fired reformer.

The autothermal reformer design features a burner, a combustion zone, and a catalyst

bed in a refractory lined pressure vessel as shown in Figure 3

Figure 3. Autothermal Reformer

The burner provides mixing of the feed and the oxidant. In the combustion zone,

the feed and oxygen react by sub-stoichiometric combustion in a turbulent diffusion

flame. The catalyst bed brings the steam reforming and shift conversion reactions to

equilibrium in the synthesis gas and destroys soot precursors, so that the operation of

the ATR is soot-free. The catalyst loading is optimized with respect to activity and

particle shape and size to ensure low pressure drop and compact reactor design.

The synthesis gas produced by autothermal reforming is rich in carbon monoxide,

resulting in high reactivity of the gas. The synthesis gas has a module of 1.7 to 1.8

and is thus deficient in hydrogen. The module must be adjusted to a value of about 2

before the synthesis gas is suitable for methanol production. The adjustment can be

done either by removing carbon dioxide from the synthesis gas or by recovering

hydrogen from the synthesis loop purge gas and recycling the recovered hydrogen to

the synthesis gas [6]. When the adjustment is done by CO2 removal, a synthesis gas

with very high CO/CO2 ratio is produced. This gas resembles the synthesis gas in

methanol plants based on coal gasification. Several synthesis units based on gas

produced from coal are in operation, this proves the feasibility of methanol synthesis

from very aggressive synthesis gas. Adjustment by hydrogen recovery can be done

either by a membrane or a PSA unit. Both concepts are well proven in the industry.

The synthesis gas produced by this type of module adjustment is less aggressive and

may be preferred for production of high purity methanol.

Methanol Synthesis and Purification

In the methanol synthesis conversion of synthesis gas into raw methanol takes

place. Raw methanol is a mixture of methanol, a small amount of water, dissolved

gases, and traces of by-products.

The methanol synthesis catalyst and process are highly selective. A selectivity of

99.9% is not uncommon. This is remarkable when it is considered that the by-

products are thermodynamically more favored than methanol. Typical byproducts

include DME, higher alcohols, other oxygenates and minor amounts of acids and

aldehydes.

The conversion of hydrogen and carbon oxides to methanol is described by the

following reactions:

CO2 + 3 H2 CH3OH + H2O (-H298K, 50Bar = 40.9 kJ/mol) (1)

CO + 2 H2 CH3OH (-H298K, 50Bar = 90.7 kJ/mol) (2)

CO2 + H2 CO + H2O (-H298K, 50Bar = 49.8 kJ/mol) (3)

The methanol synthesis is exothermic and the maximum conversion is obtained at

low temperature and high pressure. Thermodynamics, reaction mechanism, kinetics,

and catalyst properties are discussed in [9].

A challenge in the design of a methanol synthesis is to remove the heat of reaction

efficiently and economically - i.e. at high temperature - and at the same time to

equilibrate the synthesis reaction at low temperature, ensuring high conversion per

pass.

Different designs of methanol synthesis reactors have been used:

Quench reactor

Adiabatic reactors in series

Boiling water reactors (BWR)

A quench reactor consists of a number of adiabatic catalyst beds installed in

series in one pressure shell. In practice, up to five catalyst beds have been used. The

reactor feed is split into several fractions and distributed to the synthesis reactor

between the individual catalyst beds. The quench reactor design is today considered

obsolete and not suitable for large capacity plants.

A synthesis loop with adiabatic reactors normally comprises a number (2-4) of

fixed bed reactors placed in series with cooling between the reactors. The cooling

may be by preheat of high pressure boiler feed water, generation of medium pressure

steam, and/or by preheat of feed to the first reactor.

The adiabatic reactor system features good economy of scale. Mechanical

simplicity contributes to low investment cost. The design can be scaled up to single-

line capacities of 10,000 MTPD or more.

The BWR is in principle a shell and tube heat exchanger with catalyst on the tube

side. Cooling of the reactor is provided by circulating boiling water on the shell side.

By controlling the pressure of the circulating boiling water the reaction temperature is

controlled and optimized. The steam produced may be used as process steam, either

direct or via a falling film saturator.

The isothermal nature of the BWR gives a high conversion compared to the

amount of catalyst installed. However, to ensure a proper reaction rate the reactor will

operate at intermediate temperatures - say between 240C and 260C - and

consequently the recycle ratio may still be significant.

Complex mechanical design of the BWR results in relatively high investment cost

and limits the maximum size of the reactors. Thus, for very large scale plants several

boiling water reactors must be installed in parallel.

An adiabatic catalyst bed may be installed before the cooled part of the BWR

either in a separate vessel or preferably on top of the upper tube sheet. One effect of

the adiabatic catalyst bed is to rapidly increase the inlet temperature to the boiling

water part. This ensures optimum use of this relatively expensive unit, as the tubes are

now used only for removal of reaction heat, not for preheat of the feed gas. This is

illustrated in Figure 5, which compares the operating lines in identical service for

BWRs with and without adiabatic top layer.

Figure 5: Temperature and methanol concentration profiles in BWR reactors with and without

adiabatic top layer

The installation of the adiabatic top layer in the BWR reduces the total catalyst

volume and the cost of the synthesis reactor by about 15-25%. The maximum

capacity of one reactor may increase by about 20%.

A boiling water reactor with adiabatic top layer will be installed in a 1000 MTPD

methanol plant in China.

The last section of the plant is purification of the raw methanol. The design of this

unit depends on the desired end product. Grade AA methanol requires removal of

essentially all water and byproducts while the requirements for fuel grade methanol

are more relaxed. In all cases the purification can be handled by 1-3 columns, where

the first is a stabilizer for removal of dissolved gases.

2.3 Input and Output Structure

2.3.1 Overall

2.3.2 Conversion Reactor (CRV-100)


Fliq =0 lb/hr

T=662F

P=435.1 psia

Fwater =7.943x104 lb/hr

T=1562F

P=435.1 psia

XH20 = 1

F1= 7.074x104

lb/hr

T=1562 F

P=435.1 psia

CH4 =1


11,4 =0

11,2 = 0.0011

11, = 0

11,2 = 0.0002

11,3 =0.9987

10,4 = 0.0009

10,2 = 0.0001

10, = 0

10,2 = 0.8593

10,3 =0.1398

F11 =0 lb/hr

T=127.6F

P=14.7 psia

F10= 3.722x106 lb/hr

T=127.6 F

P=14.7 psia

F9= 3.722x106 lb/hr

T=88.41 F

P=14.7 psia

9,4 = 0.0008

9,2 = 0.0001

9, = 0.0073

9,2 = 0.8613

9,3 =0.1305

PART 3

3.0 Market Analysis

3.1 Supply and Demand

The objective of market analysis is to provide the pleasant appearance of methanol

market. It is also important to provide opportunities for the world market which it can be

categorize into two categories. The first categories is to attract many investors to invest in

the plant that is going to be build and the second one is to provide the a wide range of

possible site to market for the products and also to find the potential target client to market

their products.

There are few countries that produce methanol in the world. The country that produces

larger scale of methanol is The United States of America and China. The demand of

methanol especially in Asia countries such China is expected to increase as well as for the

demand for the world. From late August 2010, in just two months, the domestic Methanol

Market prices rose about 50%. At present, East and South China methanol market prices

rose or as high as 50% to 53%.

Methanol is widely consumed by many countries around the world. Hence, there is no

surprising to know that many countries imported methanol for domestic used such as

Malaysia, Thailand and many more.

3.2 Economic data

3.2.1 Raw Material Cost Estimation

The production is to achieve 387260 metric tonnes per annum. The raw

materials used are:

Raw material Cost estimation per year (RM)

Natural gas 207633

Water 6472200

The cost estimation of raw material:

= 207633+6472200 = RM 6679833

3.2.2 Equipment Cost Estimation

Equipment Quantity Cost per unit(RM)

Reactor 2 683009

Heat Exchanger 7 35000

Separator 2 233463

Mixer 1 711295

Vessel 3 7497

Compressor 1 293000

Pump 1 8690

The cost estimation of equipment:

= (2x 683009) + (7 x 35000 ) + (2 x 233463) + (1x711295) + (3 x 7497) +

(1x 293000) + (1x8690)

= RM 3113420

3.2.3 Operating Labor Cost Estimation

2

0 5

NOL = Number of operating labour operating per shift.

P2 = Particulate processing steps.

Nnp = Non-particulate processing steps.

Equipment Quantity Nnp

Reactor 2 2

Distillation column 2 2

Heat Exchanger 7 7

Separator 2 2

Compressor 3 3

Condenser 1 1

Total 17

A single operator will work on average of 49 weeks per year (3 weeks work

off) with 8 hours per shift and 5 shift per week.

Usually a chemical plant is operate 24 hours so it requires 3 shifts per day.

(49 weeks/year) x (5 shifts/week) = 245 shifts / year.

(330 days/year) x (3 shifts/day) = 990 shifts/year.

(990 shifts/year) x (operator.year/245 shifts) = 4 operators.

2

0 5

2 0 5

Number of operator needed:

(3.19) x 4 =13 operator

For all equipment:

Cost of operating labour per year:

(RM 2/hour.operator) x (8 hours/day) x ( 330 days/ year) x (13 operator)

= RM 68640/ year

3.2.4 Land Cost Estimation

By considering the plant site and extra site for future build up, the

estimation of land to buy is 3.5 acres which is approximate 14164 m2.

Figure: Plant estimation

Price per meter square of land 2

73.27

m

RM

Land cost

72.39276773.27141642

2 RMm

RMm

120 m

100 m

3.2.5 Utilities Cost Estimation

Estimated service requirement:

Steam : 2000 kg/hr

Cooling water : 1000 kg/hr

Electrical power : 10000 kW/d 0.59DOLLAR MW/h 2.5fen/ kw/h

Steam

year

RM

kg

tonne

hour

kg

year

hours

tonne

RM 1608

1000

12000804010.0

Cooling water

year

RM

kg

tonne

hour

kg

year

hours

tonne

RM 8.155332

1000

12000804066.9

Electrical power

year

RM

hours

day

day

kW

year

hours

kW

RM 4.99240

24

123000804001288.0

Total utilities cost

year

RM

year

RM

year

RM

year

RM 20.2561814.992408.1553321608

3.2.6 Estimation of Fixed Capital Cost, Working Capital Cost, and

Variables Cost

Description Cost

(RM)

Land 392767.72

Raw Material 6679833

Utilities 256181.20

Labor 68640

Equipment 3113420

Engineering &

Supervision 2500000

Construction expenses 2550000

Contractors Fee 1500000

Maintenance 1500000

Installation 5000000

Building 1000000

Total 24560842

Product profit estimation:

(143333 kg/hr) x (24 hr/d) x (335 d/y) / (RM 0.80 /kg) = RM 1440496650

Gross profit:

RM 1440496650 RM 24560842 = RM 1,415,935,808

Net Present Value Data

Discounted Payback Period Data

Cumulative Cash Position Data

Rate of Return On Investment Data

Payback Period Data

3.3 List of Equipments Supplier:

a) Shanghai Ger-Tech Compressor Co., Ltd.

Centrifugal Air Compressor

Quick Details

Place of Origin: Shanghai

China (Mainland) Brand Name: Ger-Tech Model Number: SM-2075

Type: Centrifugal Configuration: Stationary Power Source: DC Power or

AC Power

Lubrication Style: Oil-free Mute: No Atmospheric

Pressure:: 1.013 bar A

Relative Humidity:: 80%

Packaging & Delivery

Packaging

Detail:

WOODEN CASE; DIMENSION: 2115 mm x 1455 mm x 1831

mm

Delivery Detail IN STORE OR 6~10 MONTHS

Specifications

New Technologies applied to Micro-TM.

Performance Enhancement, Safe and Easy.

Versatile Controller.

Long lifetime.

Advantages:

Advanced technology assures the best performance in its components.

High-performance turbo air compressor utilizes modern aircraft enginer

technology.

It is safe and easy to operate our products.

It has versatile controller, and intellect control system.

New technologies are applied to Micro-TM.

Technical specification:

Air compressor capacity: 800~1600 m3/ hr

Air compressor discharge pressure: 6~10 bar A

Air compressor intake pressure: 0.983 bar A

Air feeding temperature: 35C

Motor power: 175 HP

Dimension: 2100 mm x 1440 mm x 1816 mm

Weight: 2500 kg

Cooling water temperature: 32C

Protection Level: IP 55

b) Shandong Qingneng Power Co., Ltd.

Back Pressure Steam Turbine (B6-4.90/0.981)

Product Details:

Model NO.: B6-4.90/0.981

Standard: 4380&Times;2805&Times;2615

Trademark: QNP

Origin: China(Main Land)

Power(Mw): 6

Rated Speed: 3000r/Min

Steam

Rate(Kg/Kw.

H):

13

Exhaust

Pressure(Mpa): 0.981

Weight(T): 21.2

Press(Mpa): 4.9

Temp: 435

Flow(T/H): 78.15

Export Markets:

North America, South America,

Eastern Europe, Southeast Asia,

Africa, Oceania, Mid East, Eastern

Asia, Western Europe

Product Description

Single-stage and multistage are all fittings selection.

Power is between 100KW to 100MW, it can meet the needs of various industries

and conditions uses.

Operating reliably and it is easy to operate.

Single-stage has a simple structure, therefore it is convenient to install and the

adaptability is well.

Adopt DEH or full hydraulic governing system.

Protective system with complete functions.

c) Yueyang City Zhongda Mechanical & Electrical Co., Ltd.

Shell & Tube Heat Exchanger

Product Details:

Place of Origin Hunan, China (Mainland)

Brand Name Fulida

Model Number ZD-A003

Type Fin Tube

Application Heater Parts

Certification ISO9001

Eco-friendly Yes

Patent product Yes

Maximum Working Pressure 60pa

Product Description:

The high Thermal Capacity with strong adaptability.

High quality , reasonable price

Unique quality

High effect Heat exchanger, the structure is simple, easy install, maintenance

is convenient; Product technology is advanced, quality is stable.

Model Power Air

flow (m3/h)

Output

static

pressure(Pa)

Temperature

efficiency(%)

Enthalpy

efficiency Rated

power

(W)

Noise dB(A)* Chill

room

Warm

room

ALH-

30BX3

220 /50Hz

300 60 70-82 54-

59 73-81 130 28

ALH-

35BX3

350 75 78-80 53-

57 72-79 180 31

ALH-

50BX3

500 80 65-76 52-

57 71-78 240 33

PART 4

4.0 Site Selection

4.1 Potential Site Location

Several sites in China have been taken into consideration. These locations are

industrial site for various kinds of industries. These sites are located close to the

source of raw materials and also close to major forms of transport, which are road,

rail, sea ports and airports.

Xu Dong Da Jie 303

Xu Dong Da Jie 303 is located at Wuchang District in Wuhan City. Wuhan

City is a major transportation hub, with dozens of railways, roads and

expressways passing through the city. Wuchang was one of the three cities that

merged into modern-day Wuhan, the capital of the Hubei province, China. It

stood on the right (south-eastern) bank of the Yangtze River, opposite the mouth

of the Han River. The historic center of Wuchang lies within the

modern Wuchang District, which has an area of 82.4 square kilometers and a

population of 1,003,400.

Xu Dong Da Jie is located 11.2 km from Wuhan Port and only takes 18

minutes to reach there. Wuhan Port is located centrally between Beijing

and Guangzhou (Canton) and between Shanghai and Chongging, it is called the

thoroughfare of nine provinces. It is an important hub for transportation, with

many roads and railways meeting here. Wuhan Tianhe International Airport

situated 19.2 km from the port. Furthermore, the chosen location is located

27.5km from Xian Xilan Natural Gas Co.Ltd Hubei Branch which was the main

supplier for the methanols plant.

Xu Dong Da Jie is the most potential location for plant site because it is

located in the Wuhan City which is an important center for economy, trade,

finance, transportation, information technology, and education in Central China.

Wuhan has currently attracted about 50 French companies, representing over one

third of French investment in China, and the highest level of French investment in

any Chinese city. Therefore it is easier for our plant to develop and enter Frenchs

market.

Distance from:

Wuhan port : 11.2km

Xian Xilan Natural Gas Co.Ltd Hubei Branch : 27.5 km

Zhongnan Hospital of Wuhan University: 3 km

Bank of China 24-hour Self- service Bank : 4.4 km

4.2 Transport

The location Xu Dong Da Jie 303 is convenient and efficient because of easy

access to the rest of the world due to its closeness to the international shipping

lane and its connectivity with other modes of transport. Designation of Wuhan

Port as the most important port in the Wuhan City with an area of more than

70,000 sq km will become a convenient logistics hub of the Yangtze River and

Central China, a modern base for a variety of industries and an ecologically

friendly home for urban dwellers by 2020. The aim in china of making the Wuhan

Port the largest port in Asia make it more accessible and vibrant place in the near

future.

4.3 Availability of Labor

The current population estimation for Wuchang is 1,003,400 people. It is clear

that it will be plenty of labors available in that area. The forecasted benefits are

increase in business and employment opportunities.

4.4 Utilities and Facilities

Infrastructural facilities such as road accesses, electricity supply, water

supply, gas supply and telecommunications are readily available at Xu Dong Da

Jie 303. There also have availability of ancillary services and facilities such as

banking, hospital and fresh water supply.

In CNY In MYR

Cooling water : 21yuan/m3

RM 9.72/m3

Electrical power : 2.5fen kW/h RM 0.12 kW/hr

4.5 Land

Sufficient suitable land must be available for the proposed plant and for future

expansion. The land should be ideally flat, well drained and have suitable load

bearing characteristics. A full site evaluation should be made to determine the

need for piling or other special foundations. Particular care must be taken when

building plants on reclaimed land near the ocean in earthquake zones because of

the poor seismic character of such land.

Plants location:

Xu Dong Da Jie 303

Source: Google maps (Satellite view)

Source: Google maps (Map view)

Location from Xian Xilan Natural Gas Co. Ltd Hubei Branch (A) to Site Plant (B)

27.5 km (40 mins)

Location from Site Plant (B) to Wuhan Port (A)

11.2 km (18 mins)

Location from Site Plant(B) to Bank of China 24-hour Self- Service Bank(A)

4.4 km (7.07 mins)

Location from plant site(B) to Zhongnan Hospital of Wuhan University (A)

3.0 km (5 mins)

Land Cost Estimation

By considering the plant site and extra site for future build up, the estimation of

land to buy is 3.5 acres which is approximate 14164 m2.

Figure: Plant estimation

4.6 Climate

Adverse climatic conditions at a site will increase cost. Abnormally low

temperatures require the provision of additional insulation and special heating for

equipment and pipe runs. Stronger structures are needed at locations subject to

high wind, snow or earthquakes.

Wuhan's climate is humid subtropical with abundant rainfall and four

distinctive seasons. Wuhan is known for its oppressively humid summers, when

dew points can often reach 26 C (79 F) or more. Because of its hot summer

weather, Wuhan is commonly known as one of the Three Furnaces of China,

along with Nanjing and Chongqing. Spring and autumn are generally mild, while

winter is cool with occasional snow. In the recent thirty years, the average annual

rainfall is 1269 mm, mainly from June to August; annual temperature is 15.8-

17.5, annual frost free period lasts 211 to 272 days and annual sunlight duration

120 m

100 m

is 1810 to 2100 hours. Extreme temperatures have ranged from 18.1 C (1 F)

to 42.0 C (108 F).

Recently according to the China Earthquake Network Center a strong

earthquake with a 7.2 magnitude, struck eastern Burma (20.8 Degrees North and

99.8 Degrees East) at 21:55 on March 24 (Beijing Time), Tremors were felt in

many parts of Yunnan Province. Because the epicenter was very close to the

borders between Burma and China, people in some areas of Yunnan felt strong

tremors.

From March 31st to April 3rd

2011, a strong cold air will sweep across eastern

parts of China, Inner Mongolia, north and northeast China, areas north of the

Yellow River and Huai River, Jianghan Area and other areas which is nearby

Wuhan City, causing a substantial drop in temperature (an average drop of 8

10 and 1214 in some areas). Moreover, a moderate gale will sweep over

eastern Inner Mongolia, northeast China, north China and other places.

PART 5

5.0 MATERIAL SAFETY DATA SHEET

5.1 METHANOL

5.1.1 PRODUCT IDENTIFICATION

Product Name: Methanol

Formula: CH3OH

Synonyms or Generic ID for Methanol: Carbinol; Methyl alcohol; Methyl

hydroxide;

Monohydroxymethane; Wood alcohol; Wood naptha; Wood spirits;

Columbian spirits; Methanol

5.1.2 HAZARD IDENTIFICATION

1. Appearance: Colorless liquid, Flash Point: 12C, 53.6F.

2. Danger! Poison! May be fatal or cause blindness if swallowed. Vapor

harmful.

3. Flammable liquid and vapour: Harmful if swallowed, inhaled, or

absorbed through the skin. Causes eye, skin, and respiratory tract irritation.

May cause central nervous system depression. Cannot be made non-

poisonous.

4. Target Organs: Eyes, nervous system, optic nerve.

5. Potential Health Effects:

Eye: May cause painful sensitization to light. Methanol is a mild to

moderate eye irritant. Inhalation, ingestion or skin absorption of methanol

can cause significant disturbance in vision, including blindness.

Skin: Causes moderate skin irritation. May be absorbed through the skin

in harmful amounts. Prolonged and or repeated contact may cause

defatting of skin and dermatitis. Methanol can be absorbed through the

skin, producing systemic effects that include visual disturbances.

Ingestion: May be fatal or cause blindness if swallowed. Aspiration

hazard. Cannot be made nonpoisonous. May cause gastrointestinal

irritation with nausea, vomiting and diarrhea. May cause systematic

toxicity with acidosis. May cause central nervous system depression,

characterized by excitement, followed by headache, dizziness, drowsiness,

and nausea. Advanced stages may cause collapse, unconsciousness, coma,

and possible death due to failed respiratory failure. May cause

cardiopulmonary system effects.

Inhalation: Methanol is toxic and can very readily form extremely high

vapour concentrations at room temperature. Inhalation is the most

common route of occupational exposure. At first, methanol causes CNS

depression with nausea, headache, vomiting, dizziness and incoordination.

A time period with no obvious symptoms follows (typically 8-24 hrs).

This latent period is followed by metabolic acidosis and severe visual

effects which may include reduced reactivity and/or increased sensitivity

to light, blurred, doubt and/or snowy vision, and blindness. Depending on

the severity of exposure and the promptness of treatment, survivors may

recover completely or may have permanent blindness, vision disturbances

and/or nervous system effects.

Chronic: Prolonged or repeated skin contact may cause dermatitis.

Chronic exposure may cause effects similar to those of acute

exposure. Methanol is only very slowly eliminated from the body.

Because of this slow elimination, methanol should be regarded as a

cumulative poison. Though a single exposure may cause no effect, daily

exposures may result in the accumulation of a harmful amount. Methanol

has produced fetotoxicity in rats and teratogenicity in mice exposed by

inhalation to high concentrations that did not produce significant maternal

toxicity.

5.1.3 FIRST AID MEASURES

1. Eyes: In case of contact, immediately flush eyes with plenty of water for a t

least 15 minutes. Get medical aid.

2. Skin: In case of contact, immediately flush skin with plenty of water for at

least 15 minutes while removing contaminated clothing and shoes. Get

medical aid immediately. Wash clothing before reuse.

3. Ingestion: Potential for aspiration if swallowed. Get medical aid

immediately. Do not induce vomiting unless directed to do so by medical

personnel. Never give anything by mouth to an unconscious person. If

vomiting occurs naturally, have victim lean forward.

4. Inhalation: If inhaled, remove to fresh air. If not breathing, give artificial

respiration. If breathing is difficult, give oxygen. Get medical aid.

5. Notes to Physician: Effects may be delayed.

6. Antidote: Ethanol may inhibit methanol metabolism.

5.1.4 FIRE FIGHTING MEASURES

FLASH POINT: AUTOIGNITION FLAMMABLE RANGE:

12 deg C ( 53.60 deg F)) 455 deg C ( 851.00 deg F)) 6.0 vol %- 31.00 vol %

1. General Information: Ethanol may inhibit methanol metabolism. 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. Water may be ineffective. Material is lighter than water and

a fire may be spread by the use of water. Vapors are heavier than air and

may travel to a source of ignition and flash back. Vapors can spread along

the ground and collect in low or confined areas.

2. Extinguishing Media: For small fires, use dry chemical, carbon dioxide,

water spray or alcohol-resistant foam. Water may be ineffective. For large

fires, use water spray, fog or alcohol-resistant foam. Do NOT use straight

streams of water.

5.1.5 ACCIDENTAL RELEASE MEASURES

1. Spills/Leaks: Use water spray to disperse the gas/vapor. Remove all sources

of ignition. Absorb spill using an absorbent, non-combustible material such

as earth, sand, or vermiculite. Do not use combustible materials such as

sawdust. Use a spark-proof tool. Provide ventilation. A vapor suppressing

foam may be used to reduce vapors. Water spray may reduce vapor but may

not prevent ignition in closed spaces

5.1.6 STORAGE AND HANDLING

1. HANDLING: Wash thoroughly after handling. Remove contaminated

clothing and wash before reuse. Ground and bond containers when

transferring material. Use spark-proof tools and explosion proof equipment.

Avoid contact with eyes, skin, and clothing. Empty containers retain product

residue, (liquid and/or vapor), and can be dangerous. Keep container tightly

closed. Do not ingest or inhale. Do not pressurize, cut, weld, braze, solder,

drill, grind, or expose empty containers to heat, sparks or open flames. Use

only with

2. STORAGE: Keep away from heat, sparks, and flame. Keep away from

sources of ignition. Store in a cool, dry, well-ventilated area away from

incompatible substances. Flammables-area. Keep containers tightly

5.1.7 EXPOSURE CONTROLS/PERSONAL PROTECTION

1. Engineering Controls: Use explosion-proof ventilation equipment. Facilities

storing or utilizing this material should be equipped with an eyewash facility

and a safety shower. Use adequate general or local exhaust ventilation to

keep airborne concentrations below the permissible exposure limits. OSHA

Vacated PELs: Methanol: 200 ppm TWA; 260 mg/m3 TWA

2. Personal Protective Equipment;

Eyes: Wear chemical splash goggles.

Skin: Wear butyl rubber gloves, apron, and/or clothing

Clothing: Wear appropriate protective clothing to prevent skin exposure.

Respirators: Follow the OSHA respirator regulations found in 29 CFR

1910.134 or European Standard EN 149. Use a NIOSH/MSHA or

European Standard EN 149 approved respirator if exposure limits are

exceeded or if irritation or other symptoms are experienced.

5.1.8 PHYSICAL AND CHEMICAL PROPERTIES

1. Appearance, odor and state: clear, colorless - APHA: 10 max

2. Molecular weight: 32.04

3. Boiling point(1 atm): 64.7 deg C @ 760 mmHg

4. Specific gravity: 7910 g/cm3 @ 20C

5. Freezing point/Melting point: 98C)

6. Vapor pressure(At 200C): 128mm Hg

7. Gas density: 1.11 (Air=1)

8. Solubility in water: miscible

5.1.9 STABILITY AND REACTIVITY

1) Chemical stability: Stable under normal temperatures and pressures

2) Conditions to avoid: High temperatures, ignition sources, confined spaces.

3) Incompability (Materials to Avoid): Oxidizing agents, reducing agents,

acids, alkali metals, potassium, sodium, metals as powders (e.g. hafnium,

raney nickel), acid anhydrides, acid chlorides, powdered aluminum,

powdered magnesium.

4) Hazardous decomposition products: Carbon monoxide, irritating and

toxic fumes and gases, carbon dioxide, formaldehyde.

5) Hazardous polymerization: Will not occur

5.1.10 TOXICOLOGICAL INFORMATION

LD50/LC50:

Draize test, rabbit, eye: 40 mg Moderate;

Draize test, rabbit, eye: 100 mg/24H Moderate;

Draize test, rabbit, skin: 20 mg/24H Moderate;

Inhalation, rabbit: LC50 = 81000 mg/m3/14H;

Inhalation, rat: LC50 = 64000 ppm/4H;

Oral, mouse: LD50 = 7300 mg/kg;

Oral, rabbit: LD50 = 14200 mg/kg;

Oral, rat: LD50 = 5600 mg/kg;

Skin, rabbit: LD50 = 15800 mg/kg;

1. Teratogenicity: There is no human information available. Methanol is

considered to be a potential developmental hazard based on animal data. In

animal experiments, methanol has caused fetotoxic or teratogenic effects

without maternal toxicity.

2. Reproductive Effects: See actual entry in RTECS for complete

information.

3. Mutagenicity: See actual entry in RTECS for complete information.

4. Neurotoxicity: ACGIH cites neuropathy, vision and CNS under TLV basis.

5.1.11 ECOLOGICAL INFORMATION

1. Ecotoxicity: Fish: Fathead Minnow: 29.4 g/L; 96 Hr; LC50

(unspecified)Fish: Goldfish: 250 ppm; 11 Hr; resulted in deathFish:

Rainbow trout: 8000 mg/L; 48 Hr; LC50 (unspecified)Fish: Rainbow trout:

LC50 = 13-68 mg/L; 96 Hr.; 12 degrees CFish: Fathead Minnow: LC50 =

29400 mg/L; 96 Hr.; 25 degrees C, pH 7.63Fish: Rainbow trout: LC50 =

8000 mg/L; 48 Hr.; UnspecifiedBacteria: Phytobacterium phosphoreum:

EC50 = 51,000-320,000 mg/L; 30 minutes; Microtox test No data available.

2. Environmental: Dangerous to aquatic life in high concentrations. Aquatic

toxicity rating: TLm 96>1000 ppm. May be dangerous if it enters water

intakes. Methyl alcohol is expected to biodegrade in soil and water very

rapidly. This product will show high soil mobility and will be degraded from

the ambient atmosphere by the reaction with photochemically produced

hyroxyl radicals with an estimated half-life of 17.8 days. Bioconcentration

factor for fish (golden ide) < 10. Based on a log Kow of -0.77, the BCF

value for methanol can be estimated to be 0.2.

3. Physical: No information available.

4. Other: No information available.

5.1.12 DISPOSAL CONSIDERATIONS

US EPA guidelines for the classification determination are listed in 40 CFR

Parts 261.3. Additionally, waste generators must consult state and local

hazardous waste regulations to ensure complete and accurate

classification.

1. RCRA P-Series: None listed.

2. RCRA U-Series:

CAS# 67-56-1: waste number U154 (Ignitable waste).

5.2 METHANE


Product Name: Methane

Formula: CH4

Chemical name: Methane, Saturated Alphatic Hydrocarbon, Alkane

Synonyms: Methyl Hydride, Marsh Gas, Fire Damp


1. Emergency overview

Methane is a flammable, colorless, odorless, compressed gas packaged in

cylinders under high pressure. It poses an immediate fire and explosion

hazard when mixed with air at concentrations exceeding 5.0%. High

concentrations that can cause rapid suffocation are within the flammable

range and should not be entered.

2. Acute potential health effects:

Route of exposures

Eye contact: No harmful affect.

Ingestion: Not applicable

Inhalation: Methane is nontoxic. It can, however, reduce the amount of

oxygen in the air necessary to support life. Exposure to oxygen-deficient

atmospheres (less than 19.5 %) may produce dizziness, nausea, vomiting,

loss of consciousness, and death. At very low oxygen concentrations (less

than 12 %) unconsciousness and death may occur without warning. It

should be noted that before suffocation could occur, the lower flammable

limit for Methane in air will be exceeded; causing both oxygen deficient and

an explosive atmosphere.

Skin contact: No harmful affect.

3. Potential health effects of repeated exposure:

Route of entry: None

Symtomps: None

Target organs: None

Medical conditions aggravated by exposure: None

Carcinigenicity: Methane is not listed as a carcinogen or potential

carcinogen by NTP, IARC, or OSHA Subpart Z.


1. Eye contact: No treatment necessary.

2. Ingestion: Not applicable

3. Inhalation: Remove person to fresh air. If not breathing, administer

artificial respiration. If breathing is difficult, administer oxygen.

Obtain prompt medical attention.

4. Skin contact: No treatment necessary.

5. Notes to physician: Treatment of overexposure should be directed at the

control of symptoms and the clinical condition.


FLASH POINT: AUTOIGNITION: FLAMMABLE RANGE:

-306 F (-187.8 C) 999 F (537 C) 5.0% - 15%

1. Extinguishing media: Dry chemical, carbon dioxide, or water.

2. Special firefighting instructions: Evacuate all personnel from area. If

possible, without risk, shut off source of methane, then fight fire according

to types of materials burning. Extinguish fire only if gas flow can be

stopped. This will avoid possible accumulation and re-ignition of a

flammable gas mixture. Keep adjacent cylinders cool by spraying with large

amounts of water until the fire burns itself out. Self-contained breathing

apparatus (SCBA) may be required.

3. Unusual fire and hazards explosion: Most cylinders are designed to vent

contents when exposed to elevated temperatures. Pressure in a cylinder can

build up due to heat and it may rupture if pressure relief devices should fail

to function.

4. Hazardous combustion products: Carbon monoxide


Steps to be taken if material released or spilled: Evacuate immediate

area. Eliminate any possible sources of ignition, and provide maximum

explosion-proof ventilation. Use a flammable gas meter (explosimeter)

calibrated for Methane to monitor concentration. Never enter an area where

Methane concentration is greater than 1.0% (which is 20% of the lower

flammable limit). An immediate fire and explosion hazard exists when

atmospheric Methane concentration exceeds 5.0%. Use appropriate

protective equipment (SCBA and fire resistant suit). Shut off source of leak

if possible. Isolate any leaking cylinder. If leak is from container, pressure

relief device or its valve, contact your supplier. If the leak is in the users

system, close the cylinder valve, safely vent the pressure, and purge with an

inert gas before attempting repairs.


1. Storage: Store cylinders in a well-ventilated, secure area, protected from the

weather. Cylinders should be stored upright with valve outlet seals and

valve protection caps in place. There should be no sources of ignition. All

electrical equipment should be explosion-proof in the storage areas. Storage

areas must meet National Electrical Codes for class 1 hazardous areas.

Flammable storage areas must be separated from oxygen and other oxidizers

by a minimum distance of 20 ft. or by a barrier of non-combustible material

at least 5 ft. high having a fire resistance rating of at least _ hour. Post No

Smoking or Open Flames signs in the storage or use areas. Do not allow

storage temperature to exceed 125 F (52 C). Storage should be away from

heavily travelled areas and emergency exits. Full and empty cylinders

should be segregated. Use a first-in first-out inventory system to prevent full

containers from being stored for long periods of time.

2. Handling: Do not drag, roll, slide or drop cylinder. Use a suitable hand

truck designed for cylinder movement. Never attempt to lift a cylinder by its

cap. Secure cylinders at all times while in use. Use a pressure reducing

regulator to safely discharge gas from cylinder. Use a check valve to prevent

reverse flow into cylinder. Never apply flame or localized heat directly to

any part of the cylinder. Do not allow any part of the cylinder to exceed 125

F (52C). Use piping and equipment adequately designed to withstand

pressures to be encountered. Once cylinder has been connected to properly

purged and inerted process, open cylinder valve slowly and carefully. If user

experiences any difficulty operating cylinder valve, discontinue use and

contact supplier. Never insert an object (e.g., wrench, screwdriver, etc.) into

valve cap openings. Doing so may damage valve causing a leak to occur.

Use an adjustable strap-wrench to remove over-tight or rusted caps. All

piped systems and associated equipment must be grounded. Electrical

equipment should be non-sparking or explosion-proof.

3. Special precautions: Always store and handle compressed gas cylinders in

accordance with


1. Engineering controls:

-Ventilation: Provide adequate natural or explosion-proof ventilation to

prevent accumulation of gas concentrations above 1.0% Methane (20% of

LEL).

-Respiratory inspections: Emergency Use: Do not enter areas where Methane

concentration is greater than 1.0% (20% of the LEL). Exposure to

concentrations below 1.0% does not require respiratory protection.

-Eye protection: Safety glasses and/or face shield.

-Skin protection: Leather gloves for handling cylinders. Fire resistant suit and

gloves in emergency situations.

-Other protective equipment: Safety shoes are recommended when handling

cylinders.


1. Appearence, odor and state: Colorless, odorless, flammable gas.


3. Boiling point (1 atm): -258.7 F (-161.5 C)

4. Specific gravity (Air = 1): 0.554

5. Freezing point/Melting point: -296. 5 F (-182.5 C)

6. Vapor pressure (At 70 F (21.1 C): Permanent, noncondensable gas.

7. Gas density (At 70 F (21.1 C) and 1 atm: 0.042 lb/ft3

8. Solubility in water (vol/vol): 3.3 ml gas / 100 ml


1. Chemical stability: Stable

2. Condition to avoid: Cylinders should not be exposed to temperatures in

excess of 125 F (52 C).

3. Incompability (Materials to Avoid): Oxygen, Halogens and Oxidizers

4. Reactivity:

A) HAZARDOUS DECOMPOSITION PRODUCTS: None

B) HAZARDOUS POLYMERIZATION: Will not occur


LC50 (Inhalation): Not applicable. Simple asphyxiant.

LD50 (Oral): Not applicable

LD50 (Dermal): Not applicable

Skin corrosivity: Methane is not corrosive to the skin.


1. Aquatic toxicity: Not determined

2. Mobility: Not determined

3. Persistence and Biodegradability: Not determined

4. Potential to accumulate: Not determined

5. Remarks: This product does not contain any Class I or Class II ozone

depleting chemicals.


1. Unused product/empty container: Return container and unused product to

supplier. Do not attempt to dispose of residual or unused quantities.

2. Disposal information: Residual product in the system may be burned if a

suitable burning unit (flair incinerator) is available on site. This shall be

done in accordance with federal, state, and local regulations. Wastes

containing this material may be classified by EPA as hazardous waste by

characteristic (i.e., Ignitability, Corrosivity, Toxicity, Reactivity). Waste

streams must be characterized by the user to meet federal, state, and local

requirements.

5.3 CARBON MONOXIDE


Product Name: Carbon Monoxide

Formula: CO

Synonyms or Generic ID for Methanol: Carbon oxide (CO); CO; Exhaust

Gas; Flue gas; Carbonic oxide; Carbon oxide; Carbone; Carbonio;

Kohlenmonoxid; Kohlenoxyd; Koolmonoxyde; NA 9202; Oxyde de carbone;

UN 1016; Wegla tlenek; Flue gasnide; Carbon monoxide


1. Appearance: Colorless gas [may be liquid at low temperature or high

pressure]

2. Emergency overview : WARNING!

FLAMMABLE GAS.

MAY CAUSE FLASH FIRE.

MAY BE FATAL IF INHALED.

MAY CAUSE TARGET ORGAN DAMAGE,

BASED ON ANIMAL DATA, CONTENTS

UNDER PRESSURE.

Keep away from heat, sparks and flame. Do not

puncture or incinerate container. Avoid breathing

gas. May cause target organ damage, based on

animal data. Use only with adequate ventilation.

Keep container closed. Contact with rapidly

expanding gases can cause frostbite

3. Target organs : May cause damage to the following organs:

blood, lungs, cardiovascular system, central

nervous system (CNS).

4. Route of entry : Inhalation

5. Potential acute health effects

Eyes: Contact with rapidly expanding gas may cause burns or frostbite.

Skin: Contact with rapidly expanding gas may cause burns or frostbite.

Inhalation: Toxic by inhalation.

Ingestion: Ingestion is not a normal route of exposure for gases

6. Potential chronic health effect:

CARCINOGENIC EFFECTS: Not available.

MUTAGENIC EFFECTS: Not available.

TERATOGENIC EFFECTS: Classified 1 by European Union.

7. Medical conditions aggravated by overexposure:

Pre-existing disorders involving any target organs mentioned in this

MSDS as being at risk may be aggravated by over-exposure to this product.


No action shall be taken involving any personal risk or without suitable training.

If it is suspected that fumes are still present, the rescuer should wear an

appropriate mask or self-contained breathing apparatus. It may be dangerous to

the person providing aid to give mouth-to-mouth resuscitation.

1. Eye contact : Check for and remove any contact lenses. Immediately

flush eyes with plenty of water for at least 15 minutes,

occasionally lifting the upper and lower eyelids. Get

medical attention immediately

2. Skin contact : In case of contact, immediately flush skin with plenty of

water for at least 15 minutes while removing

contaminated clothing and shoes. To avoid the risk of

static discharges and gas ignition, soak contaminated

clothing thoroughly with water before removing it.

Wash clothing before reuse. Clean shoes

thoroughly before reuse. Get medical attention

immediately.

3. Frostible : Try to warm up the frozen tissue and seek medical

attention.

4. Inhalation : Move exposed person to fresh air. If not breathing, if

breathing is irregular or if respiratory arrest occurs,

provide artificial respiration or oxygen by trained

personnel. Loosen tight clothing such as a collar, tie, belt

or waistband. Get medical attention immediately.

5. Ingestion : As this product is a gas, refer to the inhalation section.


FLASH POINT: AUTOIGNITION: FLAMMABLE RANGE:

12 deg C ( 53.60 deg F)) 608.89 deg C 12.5 vol %- 74.00 vol %

1. Products of combustion: Decomposition products may include the

following materials: carbon dioxide & carbon monoxide.

2. Fire hazards in presence

of various substances : Extremely flammable in the presence of the

following materials or conditions: open flames, sparks and static discharge

and oxidizing materials.

3. Fire- fighting media & instructions : In case of fire, use water spray

(fog), foam or dry chemical. A safe distance to cool container and protect

surrounding area. If involved in fire, shut off flow immediately if it can be

done without risk. Contain gas under pressure. Flammable gas. In a fire or if

heated, a pressure increase will occur and the container may burst, with the

risk of a subsequent explosion.


1. Personal precautions : Immediately contact emergency personnel. Keep

unnecessary personnel away. Use suitable protective equipment (section 8).

Shut off gas supply if this can be done safely. Isolate area until gas has

dispersed.

2. Environmental Precautions : Avoid dispersal of spilled material and

runoff and contact with soil, waterways, drains and sewers.

3. Method for cleaning up: Immediately contact emergency personnel. Stop

leak if without risk. Use spark-proof tools and explosion proof equipment.

Note: see section 1 for emergency contact information and section 13 for

waste disposal.


1. Handling: Use only with adequate ventilation. Use explosion-proof

electrical (ventilating, lighting and material handling) equipment. High

pressure gas. Do not puncture or incinerate container. Use equipment rated

for cylinder pressure. Close valve after each use and when empty. Keep

container closed. Keep away from heat, sparks and flame. To avoid fire,

eliminate ignition sources. Protect cylinders from physical damage; do not

drag, roll, slide, or drop. Use a suitable hand truck for cylinder movement.

2. Storage: Keep container in a cool, well-ventilated area. Keep container

tightly closed and sealed until ready for use. Avoid all possible sources of

ignition (spark or flame). Segregate from oxidizing materials. Cylinders

should be stored upright, with valve protection cap in place, and firmly

secured to prevent falling or being knocked over. Cylinder temperatures

should not exceed 52 C (125 F).


1. Engineering Controls: Use only with adequate ventilation. Use process

enclosures, local exhaust ventilation or other engineering controls to keep

worker exposure to airborne contaminants below any recommended or

statutory limits. The engineering controls also need to keep gas, vapour or

dust concentrations below any lower explosive limits. Use explosion-proof

ventilation equipment.

2. Personal Protective Equipment;

Eyes: Safety eyewear complying with an approved standard should be used

when a risk assessment indicates this is necessary to avoid exposure to

liquid splashes, mists or dusts.

Skin: Personal protective equipment for the body should be selected based

on the task being performed and the risks involved and should be

approved by a specialist before handling this product.

Respirators: Use a properly fitted, air-purifying or air-fed respirator

complying with an approved standard if a risk assessment indicates this is

necessary. Respirator selection must be based on known or anticipated

exposure levels, the hazards of the product and the safe working limits

of the selected respirator

Hands: Chemical-resistant, impervious gloves complying with an approved

standard should be worn at all times when handling chemical products if a

risk assessment indicates this is necessary.

In case of large spill: Self-contained breathing apparatus (SCBA) should be

used to avoid inhalation of the product. Full chemical-resistant suit and

self-contained breathing apparatus should be worn only by trained and

authorized persons.



2. Boiling point : -191.7C (-313.1F)

3. Specific volume: 13.8889 ft3/lb

4. Freezing point/melting point: -198.9C (-326F)

5. Vapor density : 0.97 (Air=1)

6. Gas density: 0.072 lb/ft3

7. Critical tenperature: -140.1C (-220.2F)


1. Chemical stability: Stable under normal temperatures and pressures

2. Incompability (Materials to Avoid): Oxidizing agents

3. Hazardous decomposition products: Under normal conditions of storage

and use, hazardous decomposition products should not be produced.

4. Hazardous polymerization: Will not occur


1. IDLH : 1200 ppm

2. Chronic effects on humans : TERATOGENIC EFFECTS: Classified 1

by European Union. May cause damage to the following organs: blood,

lungs, cardiovascular system, central nervous system (CNS).

3. Other toxic effects on humans: No specific information is available in our

database regarding the other toxic effects of this material to humans.

4. Carcinogenic: no known significant effects or critical hazards

5. Reproductive Effects: No known significant effect or critical hazard.

6. Mutagenicity: No known significant effect or critical hazard.


Aquatic ecotoxicity : Not available.

Products of degradation : carbon oxides (CO, CO2)

Environmental fate : Not available

Environmental hazards : No known significant effects or critical hazards

Toxicity to the environment : Not available


Product removed from the cylinder must be disposed of in accordance with

appropriate Federal, State, local regulation. Return cylinders with residual

product to Airgas, Inc.Do not dispose of locally.

5.4 CARBON DIOXIDE


Material name :Carbon dioxide

Chemical formula: CO2)


Appearance, Odor & State: At room temperature and atmospheric pressure,

carbon dioxide is a colorless, odorless, slightly acidic gas. Carbon Dioxide is

shipped as a liquefied gas under its own vapor pressure.

5.4.3 FIRST AID MEASURE

No action shall be taken involving any personal risk or without suitable

training.If fumes are still suspected to be present, the rescuer should wear an

appropriate mask or a self-contained breathing apparatus. It may be dangerous

to the person providing aid to give mouth-to-mouth resuscitation.

Eye contact : In case of contact, immediately flush eyes with plenty of water

for at least 15 minutes. Get medical attentions immediately.

Skin contact: In case of contact, immediately flush skin with plenty of water.

Remove contaminated clothing and shoes. Wash clothing before

reuse. Thoroughly clean shoes before reuse. Get medical

attention.

Frostbite : Try to warm up the frozen tissues and seek medical attention.

Inhalation : If inhaled, remove to fresh air. If not breathing, give artificial

respiration. If breathing is difficult, give oxygen. Get medical

attention.

5.4.4 FIRE FIGHTING MEASURE

Flammability of the product

Firefighting media and instructions. If involved in fire, shut off flow

immediately if it can be done without risk. Apply water from a safe distance to

cool container and protect surrounding area.No specific hazard.

Special protective equipment for fire-fighters

Fire fighters should wear appropriate protective equipment and self-contained

breathing apparatus (SCBA) with a full face piece operated in positive pressure

mode.

5.4.5 ACCIDENTIAL RELEASE MEASURE

Personal precautions : Immediately contact emergency personnel. Keep

unnecessary personnel away. Use suitable

protective equipment (Section 8). Shut off gas

supply if this can be done safely. Isolate area until

gas has dispersed.

Environmental precautions : Avoid dispersal of spilled material and runoff and

contact with soil, waterways, drains and sewers.


Storage : Keep container tightly closed. Keep container in a cool,

well-ventilated area. Cylinders should be stored upright,

with valve protection cap in place, and firmly secured to

prevent falling or being knocked over. Cylinder temperatures

should not exceed 52 C (125 F).

Handling : Avoid contact with eyes, skin and clothing. Keep container

closed. Use only with adequate ventilation. Do not puncture or

incinerate container. Wash thoroughly after handling. High

pressure gas. Use equipment rated for cylinder pressure. Close

valve after each use and when empty. Protect cylinders from

physical damage; do not drag, roll, slide, or drop. Use a suitable

hand truck for cylinder movement. Never allow any unprotected

part of the body to touch insulated pipes or vessels that contain

cryogenic liquids. Prevent entrapment of liquid in closed

systems or piping without pressure relief devices. Some materials

may become brittle at low temperatures and will easily fracture.


Engineering controls: Use only with adequate ventilation. Use process

enclosures, local exhaust ventilation, or other engineering controls to keep

airborne levels below recommended exposure limits.

Personal protection

Eyes : Safety eyewear complying with an approved standard

should be used when a risk assessment indicates this is

necessary to avoid exposure to liquid splashes, mists or

dusts.

Skin : Personal protective equipment for the body should be

selected based on the task being performed and the risks

involved and should be approved by a specialist before

handling this product.

Respiratory : Use a properly fitted, air-purifying or air-fed respirator

complying with an approved standard if a risk assessment

indicates this is necessary. Respirator selection must be

based on known or anticipated exposure levels, the hazards of the

product and the safe working limits of the selected respirator.

Hand : Chemical-resistant, impervious gloves or gauntlets complying

with an approved standard should be worn at all times when

handling chemical products if a risk assessment indicates this is

necessary.


Molecular weight : 44.01 g/mole

Molecular formula : CO2

Boiling/condensation point : -78.55C (-109.4F)

Melting/freezing point : Sublimation temperature: -78.5C (-

109.3F)

Critical temperature : 30.9C (87.6F)

Vapor pressure : 830 psig

Vapor density : 1.53 (Air = 1)

Physical chemical comments : Not available.


The product is stable.

5.4.10 TOXICOLOGY INFORMATION

Toxicity data

IDLH : 40000 ppm

Chronic effects on humans : Causes damage to the following organs:

lungs, cardiovascular system, skin, eyes,

central nervous system (CNS), eye, lens or

cornea.

Other toxic effects on humans : No specific information is available in our

database regarding the other toxic effects

of this material for humans.

Specific effects

Carcinogenic effects: No known significant effects or critical hazards.

Mutagenic effects: No known significant effects or critical hazards.

Reproduction toxicity: No known significant effects or critical hazards.


Products of degradation : These products are carbon

oxides (CO, CO 2).

Toxicity of the products of biodegradation : The product itself a

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