B.E Project

1. Prepared by:
-Isha Shah
-Bhavik Sheth
-Aliasgar Mandsaurwala

2.  Product Name: Acetonitrile
 Molecular formula: CH3CN
 Synonyms: Cyanomethane, ethyl nitrile, methyl cyanide, ethane nitrile,
methane carbonitrile, AN, ethanonitrile
 Acetonitrile is a liquid at room temperature and has an ether-like odor.
 Acetonitrile is miscible with water, methanol, methyl acetate, acetone, ether,
chloroform, carbon tetrachloride, and many saturated and unsaturated
hydrocarbons. It is immiscible with many saturated hydrocarbons (petroleum
fractions).
 It has a convenient liquid range and a high dielectric constant of 38.8. With
a dipole moment of 3.92 D, acetonitrile dissolves a wide range of ionic and
nonpolar compounds and is useful as a mobile phase in HPLC and LC-MS The
N-C-C skeleton is linear with a short C-N distance of 1.16 Å.

3.  Molecular weight: 41.05
 Boiling point: 81.60°C
 Vapor pressure: 88.8 Torr at 25°C
 Freezing point: -43.8°C
 Refractive index: 1.3441 at 20°C
 Density: 0.7822 g/mL (6.527 lb/gal) at 20°C
0.7766 g/mL (6.481 lb/gal) at 25°C
 Solubility in water: Miscible in all proportions
 Appearance: Colorless liquid

4.  Acetonitrile is very soluble in water.
 It mixes with most organic solvents, e.g. alcohols, esters, acetone, ether, benzene,
chloroform, carbon tetrachloride and many unsaturated hydrocarbons.
 Acetonitrile does not mix with petroleum ether and many saturated hydrocarbons.
 Acetonitrile is incompatible with water, acids, bases, oleum, perchlorates, nitrating agents,
reducing agents and alkali metals.
 Acetonitrile decomposes on contact with acids, water and steam, producing toxic fumes
and flammable vapour.
 Acetonitrile reacts with strong oxidants such as nitric acid, chromic acid and sodium
peroxide, causing fire and explosion hazards.
 Acetonitrile forms toxic fumes of hydrogen cyanide and nitrogen oxides on combustion. It
attacks some forms of plastics, rubber and coatings.
 Reactivity Profile
Acetonitrile decomposes when heated to produce deadly toxic hydrogen cyanide gas and
oxides of nitrogen. Strongly reactive. May react vigorously with strong oxidizing reagents,
sulfuric acid, chlorosulfonic acid, sulfur trioxide, perchlorates, nitrating reagents, and nitric
acid.

5.  1. As a chemical intermediate in pesticide manufacturing.
 2. Solvent for both inorganic and organic compounds;
 3. Starting material for the production of acetophenone, alpha-
naphthalenacetic acid, thiamine, and acetamidine.
 4. In the production of acrylic fibers;
 5. In pharmaceuticals,
 6. extraction solvent for butadiene.
 7. Its ultraviolet transparency UV cutoff, low viscosity and low chemical
reactivity make it a popular choice for high-performance liquid
chromatography (HPLC).
 8. Acetonitrile plays a significant role as the dominant solvent used in the
manufacture of DNA oligonucleotides from monomers.
 9. Industrially, it is used as a solvent for the manufacture of photographic
film.

6.  Indian Scenario
 World Scenario
 Export data: India exported ACETONITRILE worth USD
1762162 with total quantity of 6000 tonne per annum.
 Import data: India imported ACETONITRILE ORGANIC
CHEMICAL worth USD 185250 with total quantity of 2000
tonne per annum
 As compared to the 2000 tonne/annum of acetonitrile imported,
6000 tonne/annum is exported. Since the export of acetonitrile
exceeds its imports we see that a part of the demand for
acetonitrile in the international market is met by India. Hence our
decision to manufacture a safe amount of 3200 tonne/annum of
acetonitrile when there is a deficit of 4000 tonne/annum.

7.  1. The BP (Distillers)-Ugine process.
 2. Societa Nazionale Metanodotti (SNAM) Process
 3. Montedison Process
 4. Acetonitrile manufacture by ammoxidation of
propylene (SOHIO Process)

8.  The manufacturing of acrylonitrile by ammoxidation of propene remains
highly.
 Competitive because of the high performance achieved with the modern
catalysts based on molybdenum/antimonium oxides.
 The conversion of propene is practically complete, while the ammonia and
oxygen are used in amounts close to stoichiometry.
 Fluid - bed - reactor technology allows short reaction times and very high
heat - transfer coefficients to be achieved, by preserving safety despite the
potential explosive reaction mixture and very high exothermic effect. The
separation of acetonitrile from acetonitrile by extractive distillation with
water can be done in a more efficient two - column heat integrated setup.
 The separation of acrylonitrile from water, which is hindered by the
existence of an azeotrope, can actually take advantage of the large
immiscibility gap. Valuable byproducts, such as HCN and acetonitrile can
be efficiently separated. Chemical conversion can solve the separation of
difficult impurities, such as acroleine.

9.  About 90% of the worldwide acrylonitrile (AN) is manufactured today by the
ammoxidation of propene.
 Highly exothermal ( Δ H = − 123 kcal/mol)
 Temperatures of 300 – 500 ° C
 Pressures of 1.5–3 bar in fluid bed or fixed bed reactors.
 The first commercial plant built by Sohio (now BP International) used a catalyst
based on Bi2O3.MoO3.
 Numerous chemical formulations have been patented. The catalyst should be
multifunctional and possess redox properties.
 The most commonly employed contain molybdenum or antimonium oxides mixed
with transition metals, such as Fe, Ni, Co and V, activated by alkali and rare earth
elements.
 yield in acrylonitrile of 80 – 82%, mainly because of losses in propene by
combustion.
 Significant amounts of highly toxic species form, such as HCN, acetonitrile (ACN)
and heavy nitriles. Their removal from aqueous mixtures is difficult, as reflected in
elevated water treatment and energy costs.

10.  CH2=CH-CH3 + NH3 + 3/2O2 → CH2= CH - CN (AN) + 3H2O Conversion= 0.801
 2CH2=CH-CH3 + 3NH3 + 3/2O2 → 3 CH3- CN (ACN) + 3H2O Conversion=
0.021
 CH2=CH-CH3 + 3NH3 + 3O2 → 3HCN + 6H2O Conversion= 0.027
 CH2=CH-CH3 + 9/2O2 → CH2= 3 CO2+ 3H2O Conversion= 0.107
 CH2=CH-CH3 + O2 → CH2= CH2=CH-CHO (ACR)+ H2O Conversion= 0.027
 CH2=CH - CN + HCN → NC-CH 2-CH2-CN (Dinitrile Succinate) Conversion=
0.005
 CH2=CH - CHO + HCN → NC-CH 2-CH2-CHO ( propion- cyanhydrine)

11.  BASIS: 96000 tonne/annum of acrylonitrile produced.

 96000 tonne/year = 12500 kg/hr ( considering 320
days )
 = 235.849 kmol/ hr of acrylonitrile.
 We get propylene fed= 363.183 kmol/hr
 Yield of Acrylonitrile = 81%
 Conversion = 80.10%
 propylene fed = 363.183
 Acetonitrile Produced =10.70495642
 Feed Ratio = Propene : Ammonia : Air
 1:1.2:9.5

12. Input for Reactor
Components Weight Weight % Moles Mole %
Propylene 15253.686 12.5 363.183 8.5
Air 96606.678 81.4 3450.2385 81.2
Ammonia 7408.9332 6.1 435.8196 10.3
Total 119269.297 100 4249.2411 100
output for reactor
Component Amount Molecular
Weight
Amount2 Mole %
Propylene 6.174 42 259.308 0.138
Oxygen 28.14 32 900.48 0.629
Nitrogen 2760.184 28 77285.152 61.8
Ammonia 104.052 17 1768.884 2.33
carbon dioxide 116.58 44 5129.52 2.6
HCN 29.42 27 794.34 0.66
AN 290.89 53.1 15446.259 6.5
Acrolein 9.81 56.1 550.341 0.219
Acetonitrile 11.43 41.1 469.773 0.256
Water 1112.22 18 20019.96 24.88
Total 119269.297
Reactor inlet = reactor outlet = 119269.297

13. composition of gas stream entering Reactor 2
Component Amount
Molecular
Weight Amount2 Mole %
Propylene 6.174 42 259.308 0.138
Oxygen 28.14 32 900.48 0.629
Nitrogen 2760.184 28 77285.152 61.8
Ammonia 104.052 17 1768.884 2.33
carbon dioxide 116.58 44 5129.52 2.6
HCN 29.42 27 794.34 0.66
AN 290.89 53.1 15446.259 6.5
Acrolein 9.81 56.1 550.341 0.219
Acetonitrile 11.43 41.1 469.773 0.256
Water 1112.22 18 20019.96 24.88
Total 119269.297
composition of Quenching media 30% sulphuric acid
component
Amount
Kmoles Molecular Wt Amount in kg Mol %
Water 794.058 18 14298.893 92.7
Sulphuric Acid 62.531 98 6128.0977 7.3
Total Amount of Quenching Media = 20426.9907kg/hr
Total input= 119269.297 + 20426.9907 139696.288kg/h

14. composition of Components leaving at the top
component Amount Kmoles Molecular Wt Amount in kg Mol %
Propene 6.174 42 259.308 0.19
oxygen 28.14 32 900.48 0.85
nitrogen 2760.184 28 77285.152 83.8
co2 116.58 44 5129.52 3.54
HCN 29.1258 27 786.3966 0.88
AN 287.9811 53.1 15291.7964 8.74
Acrolein 9.7119 56.1 544.83759 0.29
Acetonitrile 11.3157 41.1 465.07527 0.34
water 44.03 18 16779.734 1.34
total amount of gaseous component leaving = 117442.3kg/hr
composition of components leaving at the bottom
component Amount Kmoles Molecular Wt Amount in kg Mol %
HCN 0.2942 27 7.9434 0.032
sulphuric acid 10.425 98 1021.65 1.2
ammonium sulphate 51.22 132 6761.04 6.06
AN 2.9089 53.1 154.46259 0.39
Acrolein 0.0981 56.1 5.50341 0.012
Acetonitrile 0.1143 41.1 4.69773 0.013
water 794.372 18 14298.696 92.34
total amount of components leaving at the bottom = 22253.9931kg/hr
total output = 117442.3 + 22253.9931 = 139696.288kg/hr

15. composition of components entering Decanter
component Amount Kmoles Molecular Wt Amount in kg Mol %
Propene 6.174 42 259.308 0.17
oxygen 28.14 32 900.48 0.8
nitrogen 2760.184 28 77285.152 76.94
co2 116.58 44 5129.52 5.11
HCN 29.1258 27 786.3966 0.7
AN 287.9811 53.1 15291.7964 7.61
Acrolein 9.7119 56.1 544.83759 0.27
Acetonitrile 11.3157 41.1 465.07527 0.23
water 932.207 18 16779.734 8
total amount of components entering= 117442.3

16. Composition of components leaving at the top of decanter
component Amount Kmoles Molecular Wt Amount in kg Mol %
Propene 6.174 42 259.308 0.19
oxygen 28.14 32 900.48 0.85
nitrogen 2760.184 28 77285.152 83.8
co2 116.58 44 5129.52 3.54
HCN 26.222 27 707.994 0.88
AN 143.99 53.1 7645.869 8.74
Acrolein 4.85 56.1 272.085 0.29
Acetonitrile 5.6525 41.1 232.31775 0.34
water 445.1494 18 8012.6892 1.34
total amount of components leaving at top = 100445.415
composition of components leaving at the bottom of decanter
component Amount Kmoles Molecular Wt Amount in kg Mol %
Propene 0 42 0 0
oxygen 0 32 0 0
nitrogen 0 28 0 0
co2 0 44 0 0
HCN 2.9038 27 78.4026 0.04
AN 143.9911 53.1 7645.92741 22.34
Acrolein 4.8619 56.1 272.75259 0.754
Acetonitrile 5.6632 41.1 232.75752 0.878
water 487.058 18 8767.044 75.57
total amount of components leaving top of decanter= 16996.8841
total output = 100445.415 + 16996.8841 = 117442.299

17. composition of components in gaseous feed
component
Amount
Kmoles Molecular Wt Amount in kg Mol %
Propene 6.174 42 259.308 0.19
oxygen 28.14 32 900.48 0.85
nitrogen 2760.184 28 77285.152 83.8
co2 116.58 44 5129.52 3.54
HCN 26.222 27 707.994 0.88
AN 143.99 53.1 7645.869 8.74
Acrolein 4.85 56.1 272.085 0.29
Acetonitrile 5.6525 41.1 232.31775 0.34
water 445.1494 18 8012.6892 1.34
total amount of
components entering the
absorber= 100445.415
total amount of water entering the absorber 96337.9494kg/hr
total input = 100445.415 + 96337.9494=196783.3644 kg/hr

18. composition of components leaving at the top
component Amount Kmoles Molecular Wt Amount in kg Mol %
Propene 6.174 42 259.308 0.2
oxygen 28.14 32 900.48 0.94
nitrogen 2760.184 28 77285.152 92.76
co2 116.58 44 5129.52 3.92
AN 0.7156 53.1 37.99836 0.02
Acrolein 2.927 56.1 164.2047 0.1
water 61.4518 18 1106.1324 2.06
total amount of components leaving as off gases= 84882.7955
composition of components leaving at the bottom
component Amount Kmoles Molecular Wt Amount in kg Mol %
HCN 26.222 27 707.994 0.44
AN 143.2636 53.1 7607.29716 2.42
Acrolein 1.9229 56.1 107.87469 0.03
Acetonitrile 5.6525 41.1 232.31775 0.1
water 5736.1079 18 103249.942 97
total amount of components leaving at the bottom= 111905.426
total output= 84882.7955 + 111905.426 = 196788.4

19. composition of components entering at stripping section from decanter and absorber
component
Amount
Kmoles
Molecular
Wt
Amount in
kg Mol %
HCN 29.1238 27 786.3426 0.4441
AN 287.1746 53.1 15248.9713 4.379
Acrolein 6.7848 56.1 380.62728 0.103
Acetonitrile 11.3157 41.1 465.07527 0.1725
water 6223.165 18 112016.97 94.9
total amount entering= 128897.986kg/h

20. composition of components leaving stripping section at top
component Amount Kmoles Molecular Wt Amount in kg Mol %
HCN 28.7534296 27 776.3426 8.67310651
AN 244.0984 53.1 12961.625 73.6284241
Acrolein 5.1203 56.1 287.25 1.54445756
Acetonitrile 11.1973 41.1 460.211 3.37748856
water 42.358 18 762.44 12.7767522
total components leaving at top= 15247.8686kg/h
composition of components leaving stripping section at bottom
component Amount Kmoles Molecular Wt Amount in kg Mol %
HCN 0.3704 27 10.0008 0.00559007
AN 43.0762 53.1 2287.34622 0.69187189
Acrolein 1.6645 56.1 93.37845 0.0267345
Acetonitrile 0.1184 41.1 4.86624 0.00190169
water 6180.807 18 111254.526 99.2735347
total components leaving stripping section at bottom = 113650.118kg/h
total output = 15247.8686+113650.118= 128897.986

21. Raw AN
HCN, AN, Acrolein, Acetonitrile
HCN, AN, Acrolein, Acetonitrile,
Water.
Compositipn of components entering C1-A
component
Amount
Kmoles Molecular Wt Amount in kg Mol %
HCN 28.7534296 27 776.3426 8.67310651
AN 244.0984 53.1 12961.625 73.6284241
Acrolein 5.1203 56.1 287.25 1.54445756
Acetonitrile 11.1973 41.1 460.211 3.37748856
water 42.358 18 762.44 12.7767522
total components entering
= 15247.8686kg/h

22. composition of components leaving at top
component Amount Kmoles Molecular Wt Amount in kg Mol %
HCN 28.552 27 770.904 8.77544817
AN 239.21 53.1 12702.051 73.5211178
Acrolein 5.1203 56.1 287.24883 1.57369357
Acetonitrile 10.97 41.1 450.867 3.37156386
water 41.51 18 747.18 12.7578501
total components leaving at top= 14958.2508kg/h
composition of components leaving at bottom
component Amount Kmoles Molecular Wt Amount in kg Mol %
HCN 0.201 27 5.427 0.06062909
AN 4.8884 53.1 259.57404 1.47450859
Acrolein 0 56.1 0 0
Acetonitrile 0.2273 41.1 9.34203 0.06856145
water 0.848 18 15.264 0.25578842
total components leaving at bottom= 289.60707kg/h
total output= 15247.857kg/h

23. HCN, DNS, PC
AN, Acetonitrile, Water
composition of components entering C1-B
component
Amount
Kmoles Molecular Wt Amount in kg Mol %
HCN 28.552 27 770.904 8.77544817
AN 239.21 53.1 12702.051 73.5211178
Acrolein 5.1203 56.1 287.24883 1.57369357
Acetonitrile 10.97 41.1 450.867 3.37156386
water 41.51 18 747.18 12.7578501
total components entering= 14958.2508kg/h
composition of components leaving at top
component
Amount
Kmoles Molecular Wt Amount in kg Mol %
HCN 18.6231 27 502.8237 65.2906035
dinitrile succinate 4.78 80 382.4 16.7581705
propion cyandhydrine 5.1203 83 424.9849 17.951226
total components leaving at
top= 1310.2086kg/h

24. Composition of components leaving at bottom
component
Amount
Kmoles Molecular Wt Amount in kg Mol %
HCN 0.201 27 5.427 0.06062909
AN 4.8884 53.1 259.57404 1.47450859
Acrolein 0 56.1 0 0
Acetonitrile 0.2273 41.1 9.34203 0.06856145
water 0.848 18 15.264 0.25578842
total components leaving at
bottom= 289.60707kg/h
total output= 15247.857kg/h

25. component Amount
Kmoles
Molecula
r Wt
Amount
in kg
Mol %
HCN 0.201 27 5.427 0.0686348
1
AN 239.318 53.1 12707.785
8
81.719134
7
Acetonitrile 10.9773 41.1 451.16703 3.7483827
3
water 42.358 18 762.444 14.463847
7
Components entering column C2 is mixture of C1-A bottom and C1-
B bottom
Total components entering from column = 13926.8238 kg/hr
Water entering is in the ratio of 10:1 with solvent/mixture
Water entering in column C-2 = 139268.23 kg/hr
Components leaving at top of column C-2
component Amount Kmoles Molecular Wt Amount in kg Mol %
AN 236.924 53.1 12580.6644 99.643733
water 0.8471 18 15.2478 0.35626701
total leaving at top = 12595.9122 kg/h

26. Components entering Decanter 2
component Amount Kmoles Molecular Wt Amount in kg Mol %
AN 236.924 53.1 12580.6644 99.5416255
water 0.8471 18 15.2478 0.35590194
water leaving from decanter 2 to C-2= 15.2478kg/h
water entering from decanter to C-2= 15.2478kg/h
components leaving from middle of C-2
component Amount Kmoles Molecular Wt Amount in kg Mol %
Acetonitrile 10.231 41.1 420.4941 0.02933394
water 34867.46 18 69734.925 99.9706689
total components leaving= 70155.4191kg/h
water leaving from C-2= 69734.927 kg/h
Acrylonitrile entering from decanter 2 to C-4=
component Amount Kmoles Molecular Wt Amount in kg
AN 236.924 53.1 12580.6644
total input in C-2 = 13926.823+139268.23+15.2478= 153210.301kg/h
total output from C-2= 12595.9+70155.4+69734.9+12580.6= 153208.32kg/h

27. Water
Product AN
composition of components entering C-4
component
Amount
Kmoles Molecular Wt Amount in kg Mol %
AN 236.924 53.1 12580.6644 99.78
Water 0.521 18 9.378 0.22
Total input= 12590.04kg/h
composition of components leaving at top
water= 29.3686kg/h
composition of Acrylonitrile leaving from C-4 = 235.97kmol/h
12530.341kg/h
total output= 29.3686 + 12530.341= 12529.7096kg/h

28. Raw ACN
water
composition of Components entering C-3
component
Amount
Kmoles
Molecular
Wt Amount in kgMol %
Acetonitrile 10.231 41.1 420.4941 0.02933394
water 34867.46 18 69734.925 99.9706689
total input= 70155.4191
composition of Acetonitrile leaving from top
component
Amount
Kmoles
Molecular
Wt Amount in kgMol %
Acetonitrile 10.1287 41.1 416.28957 100%
composition of water leaving from bottom
component
Amount
Kmoles
Molecular
Wt Amount in kgMol %
Acetonitrile 0.1023 41.1 4.20453 0.00029331
water 34867.46 18 69734.925 99.9706689
total output= 416.28+4.2045+69743.925= 70155.4191kg/h
Total acetonitrile produced= 10.1287 kmol/h 416.2895 kg/h

29.  HEAT EXCHANGER 1
 Heats propene to 200 degree celsius
 ( m.Cp.ΔT) propene = (m.Cp.ΔT)steam
 15253.686 * 2.166* (200 – 25) = m*2.142* (40 )
 m= 67482.605 kg/hr
 HEAT EXCHANGER 2
 Heats ammonia to 200 degree celsius
 ( m.Cp.ΔT) ammonia = (m.Cp.ΔT)steam
 7408.9332 * 2.4223* (200 – 25) = m*2.142* (40)
 m= 36655.75 kg/hr

34. component λ Kj/kg Mol %
HCN 1030 8.775448
17
AN 616 73.52111
78
Acrolein 502 1.573693
57
Acetonitrile 729 3.371563
86
water 2270 12.75785
01
total components
leaving at top=

38. Operating Temperature 420 C
Operating pressure 200 kPa
Design temperature 500 C
Design pressure 250 kPa
Diameter 3.28 m
Height 15.13 m
Wall Thickness .0075 m
Material Carbon steel
Volume 129 m3
Pressure Drop 10.3 kPa
Distributor
Type Gas sparger orifice type
Material Nickel
Insulation Ceramic
Catalyst
Size 60 µm
Porosity 50 %
Type Mixed oxide composition
Cooling mechanism
Cooling media Water
Cooling arrangement Coil

39.  Thickness of shell = 4 mm (take 6 mm)
 Tube sheet thickness = 113.114
 Torispherical head thickness = 7.14 mm height =
557.70 mm
 Flange design:
 Effective gasket seating width = b = bo since bo is
less than 6.3 mm)
 Therefore, b = 5 mm
 N (Number of bolts) =
𝐺
25
= 132 bolts
 Therefore, diameter of bolt
 db = 17.85 mm
 Choose M18×2 bolts, 132 in number
 Bolt circle diameter B = 3347.7mm
 Flange thickness = 84.53 mm
 Thickness of nozzle = 0.433 = 5 mm

40.  For system of dowtherm & light organics, the value of Uo
lies in the range of 375-750W/m2 K, so assume.
 Uo= 650 W/m2 K
 For 1 shell and 2 tube passes
 Lmtd = 207.2 K
 R = 1.1428, S = 0.44 Fr = 0.905
 Corrected lmtd = 187.516 K
 Heat transfer area = 230 m^2
 Area of tub e = 0.3679
 No. of tubes = 624
 Tubes/pass = 624/2= 312
 Tube bundle dia = 437.25 mm
 Shell ID = 454 mm
 Shell OD = 470 mm
 Tube heat transfer coefficient (Hi)= 738.65 W/m2.k
 Shell heat transfer coefficient (Ho)= 332.6 W/m2.k
 Overall heat transfer coefficient = 613.68 W/m. k

41.  Shell side: Crown Radius 470 mm
 Nozzles: Inlet and Outlet = 75mm
 Vent = 20 mm
 Drain = 25mm
 Permissible stress for Carbon steel = 95 N/mm2
 Permissible Stress for Bolt material = 142 N/mm2
 Tube side: Outside diameter = 20 mm
 Inside Diameter = 16 mm
 Length = 6 m
 Working pressure = 0.101 N/mm2
 Pitch (Square) = 25mm
 Channel & channel cover: Nozzle = 75 mm
 Permissible Stress = 95 N/mm2
 Gasket: Gasket Factor m = 2.5
 Min. density seating stress Y = 20 N/mm2
 Min. Gasket Width = 10 mm = N


42.  Design of nozzle: shell side nozzle dia =4mm
 Tube side nozzle dia = 4mm
 Shell thickness =0.3235 (take 6mm)
 Torispherical head ho = 80mm
 Torispherical head thickness = 0.4864 (take 8mm)
 FLANGE DESIGN: Mean Gasket Diameter G = 490 mm
 Basic gasket seating width = 5mm
 Bolt dia = 10mm
 Actual bolt area = 8672.565 mm2
 BCD = 528 flange OD= 546mm
 Flange thickness = 10 mm
 Tube sheet thickness = 15 mm
 Channel thickness = 8mm
 Baffle thickness =6mm baffle spacing =235mm
 No. of tie rods = 4
 Diameter of tie rods = 10 mm

43.  Heaviest Key Component = Water
 Light Key Component = AN
 Vapour pressure of both components at avg temperature of the column
i.e 63o C (336K)
 Vapour pressure of water (hk) = 171.4 mmHg
 Vapour pressure of acrolein (lk) = 427.889.84 mmHg
 Relative volatility α lk/hk = 427.889/171.4 = 2.496
 βhk = 1- ξhk = 0.88
 βlk = ξlk =0.73
 No. of trays for top recovery (Nlk) = 11.69 = 12 trays
 No. of trays for bottom recovery (Nhk)= 13.38 = 14 trays
 Nt = Total No. of trays = 12.4 ~ 13
 Taking tray efficiency as 80%
 N = Nt/0.8 = 17 trays
 Calculation of Reflux ratio:
 Reflux ratio for top recovery (Rlk)= 1.09
 Reflux ratio for bottom recovery (Rhk) = 1.187
 Total reflux ratio (Rt) = 0.8*(Rlk) + 0.2*(Rhk) = 1.1094
 L‟ = 1.1094*14958.2508 = 16594.683 kg/hr
 L = 367.4845 kmol/hr
 V‟ = 31552.9338 kg/hr

44. V = 698.7307 kmol/hr
Height of column
Tray stack= 9.6m
Extra feed space = 1.5m
Disengagement space = 3m
Skirt height = 1.5m
Total height = 15.6m
Flv = (L‟/V‟) (ρL/ρv) 0.5= 1.05
Csb = 0.07 ft/sec
Surface tension of water = 60.8 dynes/cm
Surface tension of acrylonitrile = 24.8 dynes/cm
Average surface tension (σ) = 42.8 dynes/cm
Flooding velocity (uf)
uf = Csb*(σ/20)0.2 * [(ρL/ρv) – 1]0.5 = 0.1414 ft/sec
u = 80% of uf
u = 0.1131ft/sec
Diameter of column
V‟ = ρv * u * 0.6 * Л *D2/4
D = 2.131 m

45.  Equipment costing

 Reactor:
 L = 15.13 m = 49.639 ft
 D = 3.28 m = 10.76 ft
 Volume = 129 m3
 𝐶 = 𝐶𝑜 ×
𝐿∝
𝐿𝑜∝
𝐷 𝛽
𝐷𝑜 𝛽
 Co = 1000 $
 Lo = 4 ft
 Do = 3 ft
 α = 0.81
 β = 1.05
 C = 29397.46 $
 Bare module cost (BMC) = C × M.F
 Module factor (M.F) = 4.23
 Update factor (U.F) = present cost index ÷ base cost index
 = 169 ÷ 100
http://www.cea.nic.in/reports/hydro/presentation_cidc_4/presentation_cost_%20indices.pdf
 = 1.69
 BMC = 124351 $
 Updated BMC = U.F × BMC ( M.F – 1 )
 = 678794.80 $ = 4,07,27,688 ₹
 Heat exchanger: = 208186.03 $ = 1,24,91,161.85 ₹
 Distillation column: =5678.4 $ = 3,40,704 ₹

46.  Total purchasing cost of all equipments ( TEC) = Rs.
203193408=Rs.20.31 crores
 Total Direct Costs D = Rs. 546111270 = 54.61 cr
 Total Indirect Costs = I= Rs. 13,00,43,780 = 13 cr
 Fixed Capital investment FCI = DIPC + Contractors
Fee +Contingency + Commission Charge
 =Rs. 78,43,39,857 = 78.43 cr
 Total Working Capital= 1083.67 cr
 Total Production Cost= Rs. 1098.81 cr
 Gross profit (taxable profit): GP = Net annual cash
flow – Total cost of production
 = 694.89 cr
 Payback period=
DC+WCB
NCA
= 1.26 years

47.  To obtain the plant location we had to look at a number of
aspects primarily
  Availability of raw materials
  Industrialized Hub
  Market Demand for the Products
  Transportation and Port Access
  Skilled Workforce
 From the point of view of investement , Pro Industry
Policies and other factors aforesaid BHARUCH ,
GUJARAT would be an ideal location for the plant based
on our preliminary research.