A PROJECT REPORT ON “ALKYL ARYL SULFONATE”

SVNIT PROJECT ChED Page 1
A PROJECT REPORT
ON
“ALKYL ARYL SULFONATE”
Submitted in partial fulfillment of the requirement for the
Degree of Bachelor of Technology
---------- Submitted-----------
By
Govind Kumar Patel (Roll No: U10CH002)
Kavaiya Ashish Rajeshkumar (Roll No: U10CH010)
B. TECH. IV (Chemical) 8th
Semester
Guided by
Dr. Z.V.P. Murthy
Professor, ChED
(May - 2014)
CHEMICAL ENGINEERING DEPARTMENT
Sardar Vallabhbhai National Institute of Technology
Surat-395007, Gujarat, INDIA

Sardar Vallabhbhai National Institute of Technology
Surat-395007, Gujarat, INDIA
CHEMICAL ENGINEERING DEPARTMENT
CERTIFICATE
This is to certify that the B. Tech. IV (8th
Semester) Project Report entitled “Alkyl
Aryl Sulfonate” submitted by Candidate GOVIND KUMAR PATEL (Roll No:U10CH002) &
KAVAIYA ASHISH RAJESHKUMAR (Roll No: U10CH010) & in the partial fulfillment of
the requirement for the award of degree B. Tech. in CHEMICAL Engineering.
We have successfully and satisfactorily completed his Project Exam in all respect. We, certify
that the work is comprehensive, complete and fit for evaluation.
Dr. Jigisha Kamal Parikh
(Associate Professor)
Head of the Deptt., ChED

DEPARTMENT OF CHEMICAL ENGINEERING
S. V. NationalInstitute of Technology, Surat
Govind Kumar Patel & Kavaiya Ashish Rajshkumar, registered in Chemical Engineering
Department of S.V.N.I.T. Surat having Roll No. U10CH002, U10CH010 has successfully
presented his Project on 13/04/14 at 3:00 P.M. The Project is presented before the following
members of the Committee.
The Project entitled “Alkyl Aryl Sulfonate” is submitted to the Head (ChED) along with this
certificate.
(Dr.Z.V.P. Murthy)
Project Co-ordiantor
Sign Date
1) Examiner-1 _________ ___________ _________
2) Examiner-2 _________ ___________ _________
3) Examiner-3 _________ ___________ _________
Place: Surat
Date: 13/4/14

--------------------- Acknowledgement ----------------------
This project is done as a semester project, as a part of course titled “Alkyl Aryl Sulfonate”. We
are really thankful to our course instructor Dr .Z.V.P. Murthy, Professor, Department of
Chemical Engineering, Sardar Vallabhbhai National Institute of Technology, Surat, for his
invaluable guidance and assistance, without which the accomplishment of the task would have
never been possible. We also thank him for giving this opportunity to explore into the real world
and realize the importance of ‘Alkyl Aryl Sulfonate’, without which a society can never
progress.
Govind Kumar Patel
(U10CH002)
Kavaiya Ashish Rajeshkumar
(U10CH010)

CONTENTS
I ACKNOWLEDGEMENT 4
II CONTENTS 5
INDEX PAGE
NO.
1. Introduction 8
1.1 Uses of Alkyl Aryl Sulfonate 9
1.2 Properties 10
2. Demand and Supply 11
3. Process Selection 13
3.1 Various Processes 13
3.2 Process Description 13
4. Material Balance 15
4.1 Assumptions 15
4.2 Reactions 15
4.3 Sulfonator 16
4.4 Separator 17
4.5 Neutraliser 18
4.6 Dryer 19
5. Energy Balance 20
5.1 Assumption 20
5.2 Sulfonator 20
5.3 Dryer 21
6.Thermodynamics and Kinetics 24
6.1 Kinetics Data 24
6.2 Thermodynamics Data 25
7. Process Design & Mechanical 27
7.1 Reactor (Major Equipment) 27

7.1.1 Process Design 27
7.1.2 Mechanical Design 30
7 .2 Shell & Tube Heat Exchanger (Minor Equipment) 38
7.2.1 Process Design 38
7.2.2 Mechanical Design 44
7.3 Storage Tank (Minor Equipment) 52
8. INSTRUMENTATION AND CONTROL 57
9. Plant location 62
10. Plant Layout 66
11. Cost Estimation 70
11.1 Estimation of Total Capital Investment 70
11.2 Estimation of Total Product Cost 72
12. Safety Issues 75
12.1Material Safety Data Sheet for Raw materials 76
12.1.1 Alkyl Aryl Sulfonate 76
12.1.2. SULFURIC ACID 79
12.1.3. Linear Alkylbenzene 83
Conclusion 88
Reference 89

----------------------LIST OF FIGURES --------------------
Figures Reference
Figure
Number
Name Page
No.
5.1 Qualitative Flow Diagram for the Manufacture of Alkyl Aryl Sulfonate 23
8.1 P&I Flow Diagram for the Manufacture of Alkyl Aryl Sulfonate 61
10.1 Master Plot of Plant 68
10.2 Chemical Processing Area 69

Chapter 1 INTRODUCTION
Alkyl aryl sulfonates were introduced in 1950’s. Today, alkyl aryl sulfonates are the largest class
of synthetic detergents. Alkyl aryl sulfonate is used as surfactant material for the detergents.
These alkyl aryl sulfonates hold the first place in world markets on account of their excellent
properties and relatively low cost of production. Because of their low price this group is
extensively used in both the home and industry. Their stability and soil suspending power is not
as good as sulfated fatty alcohols. But by adding sodium carboxymethyl cellulose the suspending
power can be increased. Alkyl aryl sulfonates come under the type anionic surfactants. These
sulfonates ionize in water to give a negatively charged organic ion.
The surfactants of synthetic detergents perform the primary cleaning and sundering of the
washing action.
The cleaning process consists of
 thoroughly wetting the dirt and the surface of the article being washed with the soap or
detergent solution.
 Removing the dirt from the surface &
 Maintaining the dirt is a stable solution or suspension.
This alkyl aryl sulfonate accounts for some 40 percent of all detergents used throughout the
world. The main source of alkyl aryl sulfonate is the petroleum industry. As the name implies
there products are based on aromatic compounds combined with an aliphatic chain bound to the
aromatic nucleus.
The aromatic nucleus is usually benzene, but occasionally it is naphthalene, toluene, xylene or
even phenol. Carbon atom in R may vary from 12-16 for alkyl aryl sulfonates. Until the mid
1960, this largest of synthetic surfactant class was most prominently represented by
Tetrapropylene Benzene Sulfonate(TPS). It was found that branched chain present in TPS
prevents the compound from undergoing efficient biodegradation.:thus ,means were developed to

replace it by more biodegradable straight chain derivaties. Thus linear alkylbenzene sulfonate
was developed which showed the effective performance.
The manufacture of alkyl aryl sulfonates by sulfonizing and neutralizing the alkylates is easily
handled by soap makers who with to enter the field of synthetic detergents and to make special
mixtures for selected application.
1.1 Uses of Alkyl Aryl Sulfonates:
Alkyl aryl sulfonates are used in different fields because of their effective performance. Apart
from its effective performance it has very interesting foaming characteristics, which are of great
significance to its use in detergents. They are used for home laundering, household and industrial
washing operations, textile washing, bleaching and degreasing treatments, home-dish washing
and for cleaning, dairy apparatus and installations.
As a result of its high solubility it is employed in formulations for liquid detergents. They are
recommended in liquid form for cleaning painted surfaces to remove dirt without affecting the
luster , as well as for cleaning automobiles to restore brilliancy to surfaces soiled by the weather.
They are also used for treating pigments in making water colors and for finishing paper, as
additives for cement, as well as wetting and spreading insecticides and herbicides and to improve
their penetration. They can also be used in mixtures with sodium bisulfate or with alkaline
builders in compounding industrial cleaning agents. In addition, the surface activities of these
compounds makes them suitable in the treatment of ores, as collectors and forming agents and in
the paper industry for making ground wood for mechanical pulp, separation of fibres, bleaching
and rinsing.

1.2 Properties:
Chemical Name Alkyl Aryl Sulfonates
Synonyms Benzene Sulfonic Acid,
Sodium Alkyl Aryl Sulfonate,
sodium salts
Formula C12H25C6H4SO3Na
Molecular Weight (g/mol) 348
Viscosity, 25°C (77°F) 0.0045(Pa-sec)
PH 7-10.5
Apparent Density >0.18 g/ml
Surface tension of 0.1% Active material (N/m) 0.03
Ionic nature Anionic
Appearance of sol at 20 0
C Clear liquid
Ultraviolet absorption max (m) 225
Electrolytic dissociation yes
Chromatogram Emerald green (Turquoise)
Saybolt color of the alkyl aryl sulfonate +26
Primary biodegradation OECD confirmatory test
%MBAS/BiAS/DAS removal
90 - 95
Foam Height of 0.1% Active Material Solution
Initial Final (after 5 min)
(cm) (cm)
18 17
Formula of Alkyl Aryl Sulfonates :

Chapter 2 Demand and Supply Data
The largest end use market for surfactants is as household cleaning detergents. These are
typically formulated cleaners based on linear alkylbenzene sulfonate (LAS) made from
petroleum feedstocks – benezene, kerosene and n-paraffins. The largest producers are Procter &
Gamble, Unilever and Colgate Palmolive. These “household cleaning” products are comprised of
large volume, lower priced laundry and dishwashing detergent commodity products that account
for roughly one-half of the U.S. surfactant market. The rest of the U.S. surfactant market
involves “Specialty Surfactants”. The portion of these that are higher-priced, low-volume
products used in a broad range of industrial and personal care market applications is estimated at
2 billion pounds, or 26% of the total US surfactant market.
U.S. SURFACTANT MARKE 2011
DEMAND
MARKET SEGMENT MILLION POUNDS
Key Markets
Household Detergents 3,500
Personal Care 800
Industrial & Institutional Cleaners 490
Food Processing 405
Oilfield Chemicals 385
Agricultural Chemicals 270
Textiles 200
Emulsion Polymerization (Plastics) 200
Paints & Coatings 200
Construction 100
6,550

Other Markets
Lubricant and Fuel Additives 615
Metal Working 150
Mining Chemicals 100
Pulp & Paper 75
Leather Processing 30
Other 195
1165
Total 7,715
SURFACTANT DEMAND & MARKET GROWTH
SURFACTANT TYPE MILLION POUNDS MARKET GROWTH
Anionics 135 2.0%
Nonionics 100 1.0%
Cationics & Amphoterics 150 4.0%
TOTAL 385 3.4%

Chapter 3 Process Selection
3.1 Various processes:
In early Time alkyl benzene derived from propylene tetramer had been the work-horse of the
detergent industry. Detergents derived from PT benzene caused Considerable difficulties in
sewage systems. The bacterial flora normally present in sewage was unable to cope with the
steadily increasing amounts of detergents based on PT benzene present in town effluent. Huge
manses of foam formed on top of sewage plants. This detergents form not only caused aesthetic
problems in rivers and in town water, but also presented biological degradation of other sewage
components from causing health hazards. Later this PT chain was replaced by a straight chain
paraffinic or olefinic hydrocarbon which in sewage was attacked and destroyed much more
quickly by bacterial flora. In the process linear alkyl benzene is taken as raw material. The
detergents produced from these are “biologically soft”. Sulfonation can be carried out using
oleum, liquid sulphur trioxide, sulphamic acid. Sulphamic acid is only suitable for detergent raw
materials where an OH group is present. Sulfonation using sulphur trioxide is high cost process.
Also availability and maintenance or handling of sulphur trioxide is difficult. In the process
oleum is taken. Oleum sulfonation is mainly used for the sulfonation of alkyl benzene. This
process is cheaper comparing to other and commonly used in detergent industry.
3.2 Process description:
In the process alkyl benzene [C12H25C6H5] which has straight chain hydrocarbons (straight chain
- olefine) is taken as the raw material. (LAB) The alkyl benzenes are mobile liquids which can
readily be transported to the detergent manufacturer, in drums or in bulk. 20% oleum is used for
the sulfonation. Oleum can be handled in mild steel. This process is carried out as continuous
operation. It is necessary to use a large excess of acid (1.1 times AB) to maintain a sufficiently

high acid concentration to carry the reaction near enough to completion, cooling is necessary to
keep the temperature of the reaction mixture at 30C. This is done using an heat exchanger.
Alkyl benzene is fed continuously to the sulfonator. Sulfonation product is recirculated through
the heat exchanger by a centrifugal pump. Sulfonation kettle is equipped with a mixer or agitator.
Oleum is charged at the pump inlet. The reaction product is continuously bled off to the digestor.
Digestor is used to ensure the completion of the reaction. At this point the concentration of
sulphuric acid has deceased. Approximately 98 percent of the hydrocarbon charged in
sulfonated. Both sulfonator and digestor are maintained at 30C.
Next acid mixture is diluted with water in the separator.In the separator it is usual to add 10% of
water to the acid reaction mixture. Layer separation occurs. Care must be taken to avoid the
development of high a temperature as the water is added. A lower layer of black H2SO4 and an
upper layer of sulphonic acid, which contains at about 5-6% H2SO4 separate. The spent acid
whose concentration is around 78% is removed. It can be removed continuously by means of
centrifugal pump. Disposal of the spent acid may present problems. Sometimes it is neutralized
with caustic soda, or sodium carbonate to produce a sodium sulphate which is useful in some
NSD powder slurries. Product loss by solution in the spent acid is negligible. The sulfuric acid is
neutralized with 20% caustic soda solution to a pH of 7.5-8 at a temperature of about 55C.
Neutralization of acid reaction mixture gives slurry containing sodium sulphate and sodium
sulfonate.Since the reaction is exothermic neutralizer requires some form of jacketed cooling.
The slurry from the neutraliser is passed into the spray drier. Droplets of liquid are brought into
contact with hot gas in some form of chamber, where they dry rapidly to produce a powder. The
powder from the drier contains 80-85% of active surfactant, the rest being sodium sulphate and
water. This material has then only to be diluted to obtain liquid products etc. or be mixed with
suitable builders to provide products ready to be marketed.

Chapter 4 MATERIAL BALANCE
Fig 4.1 Block Diagarm of Alkyl Aryl Sulfonate
( a=Pump, b=Heat Exchanger, c=Sulfonator (CSTR), d=Separator, e= Neutralizer, f=Spray
Dryer, AB = Alkyl benzene,Product= Alkyl Aryl Sulfonate )
4.1 Assumptions:
1. No sulfonic acid passes into the spent acid.
2. Sulphuric acid left in the sulfonic acid has the same strength as the spent acid.
3. Sodium sulfonate product is 85% active.
4. Ratio of oleum to alkylate is 1.1
5. Possible side reactions are neglected.
4.2 Reactions:
C12H25C6H5 + H2SO4.SO3 C12H25C6H4SO3 H + H2SO4 -------------- (1)
C12H25C6H4SO3H + NaOH C12H25C6H4SO3Na + H2O -----------------(2)
a
C
db e f
20% Oleum
AB
H20 NaOH
Product

H2SO4 + 2NaOH Na2SO4 + 2H2O -----------------------------------------(3)
Product: 2, 50,000 kg/day.
With 85% active = 2, 12,500 kg/day
= 8854.2 kg/hr.
Amount of alkyl aryl sulfonic acid produced =8854.2(326/348)
=8294.4kg/hr.
4.3 Sulfonator:
Consider reaction
C12H25C6H5 + H2SO4.SO3 C12H25C6H4SO3H + H2SO4
Basis: 8294.4 kg/hr of sulfonic acid.
Amont of alkyl benzene = 8294.4(246/326)
= 6258.97 kg/hr
= 25.44 kmole/hr
Conversion is 98%
Alkyl benzene = 25.96 kmoles / hr
= 6386.7 kg/hr.
Oleum taken(in practice) = 1.1 x 6386.7
= 7025.38 kg/hr
SO3 required = 8294.42 (80/326)
= 2035.4 kg/hr

[1 kg of 20% oleum contains 0.2 kg of SO3 & 0.8 kg of H2SO4.
i.e. 0.8(80/98)+0.2=0.853 kg of SO3 , 0.8 (18/98) = 0.147 kg of H2O]
Water associated = 366.56 kg
Total theoretical oleum required = 2402 kg/hr.
Oleum taken contains 5992.6 kg of SO3 and 1032.73 kg of H2O
Excess SO3 = 3957.2 kg
H2SO4 formed = 3957.2 ( 98/80)
= 4847.88 kg/hr
Additional water = 1032.7 - (3957.2 x 18/80)
= 142.36kg
Concentration of H2SO4 = 97.15%
Unreacted alkyl benzene = 6386.7 x 0.02
= 127.7kg/hr
4.4 Separator :
Total reaction mixture = 13412.1 kg/hr
10% of water = 1341.2 kg/hr
Total mixture = Total reaction mixture +10% of water
=14753.3 kg/hr
Concentration of H2SO4 = 76.6%
Sulfonic acid layer contains 5-6% of H2SO4.
Let us take 5.5%
i.e. 5.5/0.766 = 7.2% of 76.6% sulfuric acid

H2SO4 in sulfonic acid layer = 8294.4 x 7.2/92.8
= 643.5 kg/hr
Total acid mixture = 8937.95 kg/hr
Amount of spent acid = 5815.35 kg/hr
H2SO4(76.6%) present in the sulfonic acid layer contains 492.9 kg H2SO4 & 150.6 kg
H2O
4.5 Neutraliser:
Consider reaction (1)
H2SO4 + 2NaOH Na2SO4 + 2H2O
20% NaOH is added into the neutraliser.
Na2SO4 formed = 492.94 x 142/98
= 714.3 kg/hr.
NaOH required = 492.44 x 80/98
= 402.4 kg
H2O associated = 1609.6 kg
Total 20% NaOH = 2012 kg/hr
H2O produced=181.1kg/hr
Consider reaction (2)
H2SO4 + 2NaOH Na2SO4 + 2H2O
NaOH required = 1017.7 kg
H2O associated = 4070.88 kg
Total 20% NaOH = 5088.6 kg/hr
H2O produced = 457.97 kg/hr

Total amount of water = 4528.8 kg
Total amount of water present in the neutralizer = 6470.12 kg/hr
Product from the neutralizer contains 42% water .
4.6 Dryer:
Product from the dryer contains 8854.2 kg of Alkyl Aryl Sulfonate, 714.258 kg of sodium
Sulfate and rest water (8%).
Total amount of water evaporated = 5621.9 kg/hr.

Chapter 5 ENERGY BALANCE
5.1 Assumption:
1. Heat of dilution of oleum is neglected
5.2 Sulfonator:
Temperature of the reactor = 30 0
C
General Heat balance:
Heat Input + Heat of reaction = Heat output + Q
Specific Heat:
1. Specific Heat of Alkyl benzene = 3.536KJ/KgK
2. Specific Heat of Oleum = 1.403 KJ/KgK
3. Specific Heat of alkyl benzene sulfonic acid = 3.057 KJ/kgK
4. Specific Heat of sulfuric acid (98%) = 1.415 KJ/kgK
Heat of Formation:
1. Heat of Formation of alkyl benzene = -13.508 Kcal/mole
2. Heat of Formation of sulfuric acid = -192 Kcal/mole
3. Heat of Formation of alkyl benzene sulfuric acid = - 8.908 Kcal/mole
4. Heat of Formation of oleum = -163.46 Kcal/mole
Taking reference temperature 00
C
Input :- Entering temp = 28 0
C
Mass flow rates:
1. Alkyl benzene =1.77 kg/sec
2. Oleum =1.95 kg/sec

Output :- Leaving temp = 30 0
C
Mass flow rates:
1. ABS – 2.304 Kg/sec
2. H2SO4 – 1.34 kg/sec
Heat input = ( mCpt) AB+(mCpt)oleum
= 175.64 + 76.6
= 250.95 KJ/sec
Heat of formation at 25C for the reaction(1) = 23.38 Kcal/mole
Heat generated in the reactor = 23.38 x 4.18 x 7.2
= 703.85 KJ/sec
Heat output = (mCpt)ABS+(mCpt)H2SO4
= 210.9 + 87.16
= 270.75 KJ/sec
Q = 250.95+703.85 – 270
= 684.8 KJ/sec
[Heat transferred to the cooling medium]
5.3 Dryer:
Assume inlet gas temperature = 300 0
C
Standard m3
of air per tonne of powder made from slurry containing 42% water for 300 0
C is
12,500
Outlet gas temperature = 100 0
C
Properties:
The density of the gas at 100 0
C is 0.94 Kg/m3
The specific heat of air is 0.24 Kg cal/Kg0
C
Gas temperature after admixture with 10% cold air = 2720
C

Water evaporated to produce 1 tonne of powder = 540 Kg.
12500 m3
gas/tonne powder, equivalent to 12,5000 x 0.94
= 11750 Kg gas / tonne powder.
Reference temperature = 200
C
Heat in = 11750 x ( 272 – 20) x 0.24
= 711000 Kg cal / tonne powder.
Heat out [ in Kcal / tonne powder]
Latent heat required = 540x550
= 297000
Radiation and convection losses, Say 5% of input
= 35000
In gas exhausted from the tower
=11750 x (100 – 20) x 0.24 = 226000
Errors ( by difference) = 1,74,500(24.5%)
Total=7,11,000

Fig 5.1 Qualitative Flow Diagram for the Manufacture of Alkyl Aryl Sulfonate
Mass Flow Rate (Kg/h)
Component 1 2 3 4 5 6 7 8 9 10 11
LAB 6387 6387 - 128 - - - - - - -
Oleum - - 2402 - - - - - - - -
Sulfonic acid - - - 8294 - - 8294 - - - -
H2SO4 - - - 4848 - - - - - - -
H2O - - - 142 1341 5815 151 - 6470 5622 848
NAOH - - - - - - - 5089 - - -
Na2SO4 - - - - - - - - 714 - 714
AAS - - - - - - - - 8854 - 8854
Total Flow Rate 6387 6387 2402 13412 1341 5815 8445 5089 16039 5622 10417
Temperature (0
C) 108 28 30 30 30 30 30 30 55 100 30
Pressure(atm) 1 1 1 1 1 1 1 1 1 1 1

Chapter 6 Thermodynamics and Kinetics
6.1 Kinetics Data
LAS is obtained by reacting LAB with the SO3 functional group in a one to one ratio, thus resulting in a
molecule capable of reducing the surface tension between two nonmiscible phase.
There are many sources of SO3 ;H2SO4 ,oleum, pure gaseous SO3, chlorosulfonic acid, and
sulfamic acid ; how ever, the basic path leading to LAS formation is essentially the same as outlined in
the reactions.
Reaction Mechanism:

The reaction between SO3 and the aromatic substrate is an electrophilic substitution reaction of the
second order, and in the specific case of LAB, this reaction proceeds in accordance with the mechanism
shown in the above reactions.
When sulfonating LAB, the reaction is extended to the by-product in the LAB raw material;
consequently, branched alkylates, DATs, and diphenylalkanes undergo sulfonation too, although each
with a different speed.
so
SO3 reaction with LAB by- products
The control of the preceding outlined reaction is the key point to ensure the production of LAS having
the best quality. Therefore, specific operating conditions should be properly set up to minimize the side
reactions negatively affecting both the conversionyield and product quality.
6.2 Thermodynamics Data
Specific Heat:
 Specific Heat of Alkyl benzene = 3.536KJ/KgK
 Specific Heat of Oleum = 1.403 KJ/KgK
 Specific Heat of alkyl benzene sulfonic acid = 3.057 KJ/kgK
 Specific Heat of sulfuric acid (98%) = 1.415 KJ/kgK

Heat of Formation:
 Heat of Formation of alkyl benzene = -13.508 Kcal/mole
 Heat of Formation of sulfuric acid = -192 Kcal/mole
 Heat of Formation of alkyl benzene sulfuric acid = - 8.908 Kcal/mole
 Heat of Formation of oleum = -163.46 Kcal/mole
Taking reference temperature 00
C

Chapter 7 PROCESS DESIGN & MECHANICAL DESIGN
7.1 REACTOR (Major equipment):
7.1.1 Process Design
Sulfonator is a continuous stirred tank reactor.
It is assumed that reaction takes place only in the reactor.
The reaction is given by
Alkyl benzene + oleum --> alkyl benzene sulfonic acid + sulfuric acid
Since oleum is used in large amount the reaction is pseudo first order.
The rate of the reaction is given by
(-rA)=CA[2667(XA- ½ Xw + ¼ XS) -9.329 +5349/T ]
Where
XA - mole fraction of H2SO4
Xw - mole fraction of water
Xs - mole fraction of alkyl aryl sulfonic acid
T - abs temp
CA – concentration of alkyl aryl sulfonic acid (moles / lit)
(-rA) - rate (moles /hr/lit)
XA - 0.598
XS - 0.307
XW - 0.095
T - 303 K
Density of oleum = 1830 kg/m3
Density of alkyl benzene = 840 kg/m3
Flowrate of oleum=7029.4kg/hr
Flowrate of alkyl benzene=6386.7kg/hr
Total volumetric feed rate = (6386.7 / 840) + (7029.4 / 1830)
v0 = 11.44 m3
/hr
Initial concentration of alkyl benzene =CA0 = F/v
F = molar flow rate (input)
=25960 moles / hr

v =volumetric flow rate
= 7.60 m3
/hr
CAo = 25960 / 7.6
= 3451.1 moles /m3
= 3.4 mole /lit
Assuming constant density system,
CA = CAo (1-XA)
CA –Final concentration
Conversion, XA = 98%
CA = 3.4(1-0.98)
=0.068 moles / lit.
For different concentration, rate is found & Graph of (-1/rA) vs CA is plotted.
Table:
CA(moles/lit) (-rA)(moles/hr/lit) (-1/rA)(* 10-2
)
3.4 303.3 0.33
3.07 270 0.37
2.75 243.3 0.411
2.44 212.8 0.47
2.07 181.8 0.55
1.74 153.8 0.65
1.4 123.5 0.81
0.70 66.7 1.0
0.402 35.7 2.8
0.068 5.99 16.7
From the graph of (-1/rA) vs CA
Area under the curve = 0.7
Residence time, = 0.7 hr

Volume of the reactor, V = v0 * 
= 11.44 * 0.7
= 8 m3
(d2
/ 4) * l = V Where
d-Dia of the reactor
l-Height of the reactor
By taking (l/d) =2
V=(d2
/4)*2d
Dia of the reactor, d = 1.72 m
Height of the reactor, l = 3.44 m

7.1.2 Mechanical Design
Vessel shell internal diameter – 1.72m
Internal pressure – 2.04 Kg/cm2
Design pressure – 2.44 Kg/ cm2
(20% more than Internal Pressure)
Material – openhearth steel (IS-2002) Allowable stress – 980 Kg/cm2
Shell thickness:
ts = P * Di/(2*f*J –P)
J = Joint efficiency factor
= 0.85
ts = (2.44 * 1720)/(2 * 0.85 * 980 – 2.44)
= 2.52 mm
Use 4 mm thickness including corrosion allowance
Agitator:
Diameter of agitator – 525 mm (Da) Speed (maximum) – 200 rpm
Overhang of agitator shaft between bearing and agitator – 1300 mm (l) Agitator blades – 6 (n)
Width of the blade – 75 mm (w) Thickness of blade – 8 mm (t)
Shaft material – commercial cold rolled steel
Permissible shear stress in shaft – 550 Kg/cm2
Elastic limit in tension – 2460 Kg/cm2
Modulus of elasticity – 19.5 * 105
Kg/cm2
(E)
Permissible stress for key (carbon steel) Shear – 630 Kg/cm2
Crushing – 1300 Kg/cm
2
Stuffing box (carbon steel) - 950 Kg/cm2
Studs and bolts (hot rolled carbon stee l) Permissible stress – 587 Kg/cm2
It is assumed that vessel geometry conforms to the standard tank configuration
Re = da2 /= 1.4 * 103 * 200/60 * (500/1000)2/1.7 * 10-2
= 683.52 * 102
> 10,000
From power curve, Np = 6
Power, P = NP * N3
*Da5
/(gc * 75)

= (6 * 1.4 * 103
*(200/60)3)
* (500/1000)5
) / (9.81 * 75)
= 13.22 hp
Gland losses (10%) – 1.322 hp
Power input = 13.22 + 1.3 = 14.52 hp
Transmission system losses (20%) = 14.52 * 0.2
= 2.904 hp
Total hp = 14.52 + 2.904 = 17.42
This will be taken as 18.5 hp to allow for fitting losses
Shaft design
Continuous average rated torque on the agitator shaft, Tc= (hp * 75 * 60)/ (2  N)
= (18.5 * 75 * 60)/ (2  * 200)
= 66.25 Kg m
Polar modulus of the shaft, Zp = Tm/fs
Tm = 1.5 Tc
fs – shear stress – 550 kg/cm2
Zp = (1.5 * 66.25 * 100) /550
= 18.07 cm3
d3
/16 = 18.07
d = 4.5 cm
Diameter of shaft = 5 cm
Force, Fm = Tm /0.75Rb
Rb – Radius of blade
Fm = (1.5 * 66.25 * 100) / (0.75 * 25)
= 530 Kg
Maximum bending momentum
M = Fm * l
= 530 * 1.3
= 689 Kg-m

=692.5 Kg .m
The stress due to equivalent bending
f = Mc/Z
Z = (5)3
/32 (Modulus of reaction of the shaft cross section)
=12.27
f = (692.5 * 100)/12.27
= 5642.9 kg/cm2
Stress f is higher than the permissible elastic limit (2460 Kg/Cm2
). Therefore use a 7 cm
diameter shaft for which the stress will be
f = 2056 Kg/cm
2
Deflection of shaft,  = (W * l3)
/ (3*E*I) [W = Fm]
= (130)3
x 530/3 x 19.5 x 105
x  x 74
/64
= 1.69cm
Critical speed , Nc = (4.987 x 60) / (
= 230.16rpm
Since actual shaft speed is 200 rpm which is 87% of the critical speed it is necessary to
increase the value of critical speed by decreasing the deflection.
Choose therefore a 8cm dia shaft.
Then,
 = 1.00 cm
Nc = 60 x 4.987/ 1.00 = 300 rpm
Actual speed is 66.6 % of the critical speed

Blade design:
F = (maximum torque)/ (t * w2
/ n)
= 99.375 / (0.8 x 7.52
/6)
= 132.5 Kg/cm2
Stress is well within the limit
Hub and key design:
Hub diameter of agitator = 2 x shaft diameter
= 16 cm
Length of the hub = 2.5 x 8 = 20 cm
Length of key = 1.5 x shaft dia = 12 cm
Tmax/ (d/2 )= l*b*fs = (l*t/2)*fc = 99.25 x 100/(8/2)
fs- shear stress in key
fc – stress in crushing of key
12 x b x 650 = 12 x t/2 x 1300 = 2481.25
b = 3.18 mm
t = 3.18 mm
Use 4mm x 4mm x 12 cm key
Stuffing box and gland:
b = d +d
= 8 + 8 = 10.28 cm
Permissible stress in the material of stuffing box, t = Pb /(2*f) + C
t = (2.44 x 10.28 x 10 /2 x 950) + 6
= 6.13mm
a = b + 2t
= 10.28 + 2 x 0.613
= 11.51 cm
Load on gland,

F = (/4) * p *(b2
– d2
)
= (/4)(10.282
– 82
)2.44
= 79.87 Kg
Size of the stud:
F = (d0
2
/4)* n*f
n – no of stud = 4
f – Permissible stress for stud
=587 Kg/cm2
d0
2
= 0.043 cm
d0 = 0.658mm
Minimum stud diameter – 15 mm
Flange thickness = 1.75 x 15
= 27.25=30mm
Coupling: -
A clamp coupling of cast iron is used
Force per bolt = 2 * Tmax /(x n/2)
No of bolts ,n= 8
 - coffecient of friction = 0.25
Force = (2 x 99.25 x 100) / ( x 0.25 x 8 x (8/2))
= 789.7 kg
Area of bolt = 789.7/587
= 1.35cm2
Diameter of bolt = (1.35 x 4)/
= 1.65mm
Overall diameter of coupling= 2 x shaft dia
= 16cm
Support Design:
Bracket or lug support is designed. Diameter of reactor = 1.72 m Height of Reactor = 3.44 m
Clearance from vessel bottom to foundation – 1.0m

Wind pressure – 128.5 kg/m2
Number of brackets – 4
Diameter of anchor bolt circle – 1.9 m (Db) Height of bracket from foundation = 1.8 m
Permissible stresses for structural steel (IS-800)
Tension – 1400 Kg/cm2
Compression – 1233 kg/cm2
Binding – 1575 Kg/cm2
Permissible bearing pressure for concrete – 35 Kg/cm2
Weight of the vessel with contents = 10000 Kg.
Maximum compressive load:
Wind pressure, Pw = k*p*h.Do
k- Coefficient depending on the shape factor
= 0.7
Pw = 0.7 x 128.5 x 3.44 x 1.72
= 532.2 Kg.
Maximum total compressive load in the support is
P=
4*Pw*(H F)

w
N*D*b n
H – Height of the vessel above the foundation
F – Vessel clearance from foundation to vessel bottom.
W – Maximum weight of the vessel
n = number of brackets
P 
4x 532.2(4.440 1)

10000
4x1.9 4
= 3463.5 Kg.

Bracket:
(a)Base plate:
Suitable base plate size, a = 140 mm
B = 150 mm
Average pressure on the plate, Pav = P/(aB)
Pav = (3463)/(14x15) = 16.5 Kg/cm2
Maximum stress in a rectangular plate subjected to a pressure Pav and fixed at the edges is given
by
f 1575Kg /cm
2
(Given)
T1 = 8.7 mm
Use a 9 mm thick plate.
(b) Web plate.
Bending moment of each plate =
P (Dim  D)
x 100
2 2

(3463 )(1.9  1.72)
4
 15583 .5Kg.cm
Stress at the edge , f = (15583.5 *1) / (T2 *14 * 14*0.707)
=112.5/T2
For f = 1575, T2 = 7 mm

Column support for bracket:
It is proposed to use a channel section as column. The size chosen is ISMC 150.
Size – 150 x 75
Area of cross section – 20 .88 cm2
Modulus of section – 19.4 cm3
Radius of gyration, r– 2.21 cm
Weight – 16.4 Kg/m
Height from foundation, l=1.8m
Equivalent length for fixed ends le=1/2
= 0.9 m
Slenderness ratio=0.9*100/2.21=4
For the load acting accentric on a short column, the maximum combined bending and direct
stress is given by
w = Load on column
A – Area of cross section
E – Eccentricity
Z – Modulus of section of cross – section
N – Number of columns
f=[3463/(20.88*1)] + [3463*4.5/(1*19.4)]
 969Kg / cm,2
Channel selected is satisfactory.
Base plate for column:
Size of the column 150 x 75
It is assumed that the base plate extends 25 mm on either side of channel
Side B – 0.8 x 75 + 2 x 20=100mm
Side C – 0.95 x 150 + 2 x 20 = 182.5 mm

Bearing pressure, Pb = (3463/4) x (1/10x18.25)
= 4.74 Kg/cm2
This is less than the permissible bearing pressure for concrete.
Stress is the plate,
For f = 1575 Kg/cm2
t = 2.33 mm
It is usual to select a plate 4 to 6 mm thick.
7.2 HEAT EXCHANGER:(Minor equipment)
7.2.1 Process Design
Total amount of heat to be removed, Q = 684.8 KJ/sec
Hot fluid - Mixture of reaction product & oleum
Cold fluid – water
Q = m*Cp*t
Mass flow rate of liquid mixture, m = 3.72 Kg/sec
Specific heat of liquid mixture, Cp=2.092 KJ/KgK Outlet temp = 30 0
C
t=88 0
C
Inlet temp = 118 0
C
Let inlet temperature of water = 20 0
C & Outlet temperature = 40 0
C
Specific heat of water = 4.18 KJ/KgK
Mass flow rate of water = 684.8 /( 4.18 * 20)
= 8.2 kg/hr
Routing of fluids:
Water which has the high flow rate is taken in tube side.

Liquid mixture which has viscosity higher than water is taken in shell side.
LMTD:
Liquid mixture Water t
118 0
C 40 0
C 78 0
C
30 0
C 20 0
C 10 0
C
LMTD = (78-10)/ln(78/10) = 33.10
For R = 4.4 and S = 0.19
FT = 0.76 (LMTD)cor=0.76*33.10 = 25.16
Heat transfer area:
U = 750 W/m2K.
Area = Q / (LMTD * U)
= (684.8 * 103
) / (750 * 25.16)
= 36.29 m2
Length = 10ft = 3.054 m
Let us take
¾” O.D. tubes , 12 BWG gauge
Do = 19.05 mm
Di = 13.25 mm
External surface per m length = 0.05948 m

Heat transfer area = 0.05948 (3.054 - 50 * 10-3
) [ 50mm allowance]
= 0.179 m2
per tube
Number of tubes = 36.29 / 0.179 = 202
Choosing TEMA L or M type:
208 tubes (Nt) , 4 passes (Np) , one shell pass.
Shell ID= 438mm, pitch = 1 inch (triangular)
Corrected area = 0.179 * 208
= 37.23 m2
Corrected U = (684.8 * 103
)/ (37.23 * 25.16)
= 731 W/m2
K
Fluid velocities:
Tube side - water
Properties: Specific heat = 4.18 kJ/kg k
Density = 996 kg/m3
Viscosity = 0.85 cP
Thermal conductivity = 0.61 W/mK
Flow area, at =(( * (Di)2)/4) * (Nt/Np)
=((13.25 * 10-3)2 /4)* (208/4)
= 7.35 * 10-3 m2
Velocity ,Vt= mass flow rate / (density * area)
= 8.2 / (996 * 7.35 * 10-3)
= 1.23 m/sec
Shell side – Liquid mixture
Properties - Density - 1238 kg/m3
Specific heat - 2.093 KJ/kg K Viscosity - 1.5 cP
Thermal conductivity - 0.176 W/mK
Cross flow area at center of the shell, Sm = ((Pt - Do) Ls) (Ds / Pt) Do
= 19.02 mm

Pt = 1 inch
Ds=Shell ID
Ls = Baffle pitch=0.2 Ds = 0.2 * 0.438 = 0.0876 m
Number of baffles = (L/Ls)-1
= (3.054/ (0.2 * 0.438)) -1
= 30
Sm = ((25.4-19.02) * 0.438 * 0.2 * 0.438) / 25.4
=9.6 * 10-3 m2
Velocity , Vs= 3.72 / (1238 * 9.6 * 10-3)
=0.31m/sec
Heat transfer coefficients:
Tube side:
Re = (Vt * Di*)/
= (13.25 * 10-3
* 1.23 * 996) / (0.85 * 10-3
)
= 20,184
Pr = Cp*/K
= (0.85 * 4.18) / 0.61
= 5.82.
Nu = 0.023(Re) 0.8
(Pr) 0.4
= 129.33
hi = (129.33 * 0.61)/(13.25 * 10-3
)
=5954 W/m2
K Shell side:
Re = (Vs*Do) /
= (0.31 * 19.05 * 10-3
* 1238) / (1.5 * 10-3
)
=4968.3
Pr = Cp /K
= (1.5 * 2.093) / 0.176
= 15.07
jH = 10-2
Nu = 10-2
* 4968.3 * (15.07)1/3

= 122.76
ho =(0.176 * 122.76)/ 0.01905
= 1134.19 W/m2
K
Overall heat transfer coefficient:
(1/Uod) = (1/ho) + (Do/Di)*(1/hi) + (Do*ln(Do/Di))/2Kw (clean) Kw = 50
1/Uod=1.16 * 10
-3
1/Uod = 1.16 * 10-3
+ 2 * 10-4
(dirt)
Uod = 735 W/m2
K
Pressure drop:
Tube side:
Re = 20184
f = 0.079 (20.184)-0.25
= 6.63*10-3
PL= (4f*L*Vt
2
g) / (2*g*Di)
= (2 * 6.63 * 0.001 * 3.054 * 1.2 *1.2 *996)/0.01325
=4192 N/m2
PE=2.5(Vt
2
/2)
=1798.8 N/m2
(P)total = Np(PL+PE)
= 4(4192 +1792.8)
=23.93 KPa
Shell side:
Cross flow zones:
Pc= (fk*b*W2
*Nc / Sm
2
) * (w/b) 0.14
b=2*10-3
fk=0.08
W=3.72kg/sec
Sm=9.6 * 10-3

Nc :- No. of tube rows crossed in each cross flow region.
Pp :- Pitch parallel to flow
= 22
lc = Baffle cut =25% of Ds
= 438(1-2(0.25 * 0.438)/0.438))/22
= 9.95 = 10
Pc=0.002*(3.72)
2
*0.08*10/(1238*(0.0096)
2
)
= 0.194 Kpa
End Zones:
Pe  Pc* 1+
Naw
Nc
Naw = No. of effective cross flow rows in each window
=0.8 * lc/Pp
=0.8 * 0.25 * 438 /22
=3.98 = 4
Pe=0.194(1+4/10)
=0.27KPa
Window zones: Pw= (b* W2
*(2+0.6*Naw))/(Sm*Sw) b
=5 * 10-4
Sw :-area for flow through window
Sw = Swg - Swt
Swg = Cross window area
Swt = area occupied by the tubes
Swt = Nt /8*(1-Fc)* Do
2
=208/8[(1-0.7)* (19.05*10-3
)2
=8.89*10-3

Swg = 38 in2
= 0.0245 m2
Sw=0.0156m2

Pw = (5*E*3.722
*[2+0.6*4])/ (0.0156*1238*9.96*E-3
)
=0.1675 KPa
(P)total = 2 * Pe + (Nb-1)*Pc + Nb *(Pw)
= 2*0.27 + (34-1)*0.194 + 34 * 0.16
= 12.86 KPa
7.2.2 MECHANICAL DESIGN
Shell side:
Material –carbon steel
Working pressure –0.1N/mm2
Design pressure –0.11N/mm2
Permissible stress for carbon steel –95 N/mm2
Dia of shell=438mm
Tube side:
Working pressure=0.5N/mm2
Design pressure=0.55N/mm2
Shell thickness:
ts = PD/2fJ+P =
=0.33mm
Minimum thickness of shell must be 6.3 mm
Including corrosion allowance, ts = 8mm.
Head thickness:Shallow dished & torispherical head
th =
Rc –crown radius
W –stress intensification factor

W=
Rc = 6%Rk
W=
J=1
th =
=0.45 mm
Use thickness as same for shell i.e. 8 mm
Transeverse baffles:
Baffle spacing = 0.2 x 438 = 87.6 mm
Thickness of baffles = 6 mm
Tie rods and spaces:
Diameter of tie rod = 10 mm
Number of tie rods = 6
Flanges:
Shell thickness = go = 8 mm
Flange material –IS: 2004 –1962 class 2
Gasket material –asbestos composition
Bolting steel = 5% Cr Mo steel
Allowable stress of flange material –100 MN / m2
Allowable stress of bolting material,Sg –138 MN/m2
Outside dia = B=438+(2x8)
= 454 mm
Gasket width:
m –gasket factor –2.75

y –min design seating stress –25.5 MN/m2
Gasket thickness = 1.6 mm
=1.002
Let di of the gasket equal 464 mm [ 10 mm greater than shell dia]
do = 0.464 x 1.002
= 0.4649m
Mean gasket width= (0.4649 –0.464)/2
= 5 x 10-4
Taking gasket width of 12 mm,
do = 0.488 m
Basic gasket seating width, bo= 5mm
Diameter of location of gasket load reaction is,
G = di+N
= 0.464+0.012
= 0.476m
Estimation of bolt loads:
Load due to design pressure:
=
=0.0196MN
Load to keep joint tight under operation
Hp = πG(26)mp
=πx 0.476 x 2 x 5 x 10-3
x 2.75 x 0.11
= 4.52 x10-3
MN
Total operating load, Wo = H+Hp
= 0.024MN

Load to seat gasket under bolting up condition
Wg = πGby
= πx 0.476 x 0.005 x 25.5
= 0.1906 MN
∴Controlling load = 0.1906 MN
Minimum bolting area=Am=Wg/Sg
=0.1906/138
= 1.38 x 10-3m2
Take Bolt size –M 18 x 2
Actual number of bolts –44
R = 0.027m
g1= go/0.707 = 1.415 go for weld leg
go = 8mm
Bolt circle diameter,C = B +2(g1+R)
=0.454+2(1.415x0.008+0.027)
=0.5306 m
Using 66 mm bolt spacing,
C=44 x 0.066 / π
= 0.9243 m
∴Bolt circle diameter, C = 0.93 m
Flange outside diameter
A = C+ bolt diameter + 0.02 m (minimum)
= 0.93 + 0.018 + 0.02
= 0.968 = 0.97m
Check of gasket width
=50.43< 2y

It is satisfied
Flange moment computation:
For operating condition:
Wo=W1+W2+W3
W1= π(B2
/4)P
=π/4(0.454)2
0.11
=0.0178
W2= H-W1
= 0.0196 –0.0178
= 1.79 x 10-3
W3= Wo-H = Hp (gasket load)
= 4.52 x 10-3
MN
Total flange moment, Mo=W1a1+W2a2+W3a3
Mo = 5.68 x 10-3
For bolting up condition
Mg = W. a3
W = (Am +Ab)/(2). Sg
Ab =area of bolt
= 44 x 1.56 x 10-4
= 6.76 x 10-3
m2
Am = Minimum bolt area
=1.38 x 10-3
m2

Sg=138N/mm2
W = 0.562 MN
a3=0.23
Mg = 0.1275 MN-m
Mg is controlling momen
Flange thickness:
t2
=(MCfY)/(BSt)=(MCfY/BSfo)
K=(A/B)
=(0.97/0.454)
=2.13
Assume Cf=1
From the graph ,Y=3
M=0.1275MN-m
St=Allowable stress
=100MN/m2
t2
=(0.1275 x 3)/(0.454 x 100)
=0.0008
t=0.029m
Tube sheet thickness:
=18.07mm
tts= 21 mm including corrosion allowance

Channel and channel cover:
=19mm
th= 22mm including corrosion allowance.
Nozzle:
Thickness of nozzle = PD/2fJ-P
Inlet & outlet dia –100 mm
Vent –50 mm
Drain –50 mm
Opening for relief value –75 mm
=0.293mm
Corrosion allowance 3 mm
tn = 4 mm
Considering the size of the nozzle & the pressure rating, it is necessary to provide for a
reinforcing pad on the channel cover.
Area required to be compensated for each nozzle
A = d x th= 100 x 22 = 2200 mm2
Saddle Support:
Material- low carbon steel
Diameter = 454 mm
Length of the shell, L = 3.054 m
Knuckle radius = 6% of diameter
= 27.24 mm
Total depth of head

=
=
H=78.63mm
Weight of vessel & contents, W = 11943 kg.
Distance of saddle center line from shell end,
A = 0.5 x R = 113.5 mm
Longitudianl bending moments:
Q = Load carried by each symmetrical support
=
=
=18843.1Kg
M1 =12.778Kg.m
M2 = 10218Kg.m
Stresses in shell at the saddle
1.At the topmost fibre of the cross section.
f1 = k1 =1
t= thickness of the shell
f1=
=0.9865Kg/cm2
2.At the bottom most fibre of the cross –section

f2 =
f2=0.9865Kg/cm2
Stresses are well within the permissible values.
Stresses in the shell at mid –span:
The stress at the span is ,
f3 =
=
=789.46 Kg/cm2
Axial stress is the shell due to internal pressure :
fp=
=15.34Kg/cm2
f3+fp= 804.80kg/cm2
Stresses are well within the permissible values.
6.3 Storage Tank (Minor equipment)
Production of Alkyl Aryl Sulfonate is 250000 kg/day.
Design For storage Capacity per tank is 31250 Kg/day.
So that number of storage tank is 8.
Volume of the storage tank: 350 m3
Volume of shell
V = π D2
H
4
We have D: H = 8:3
So, D = 8 H
3

V = π x 8 H 2
H
4 3
350 = π x 64 x H3
4 9
H=3.97
 4 m
D = 10.59 m.
≈11 m
8.2.2 Thickness of shell:
ts = PD + CA
2fJ
Where, P = (H – 0.3) x ρ fluid x g / gc
= (4 – 0.3) x 1450 x 10
= 53650 N/ m2
=0.053650 N/ mm2
f (allowable stress) = 142 N / mm2
C.A. (corrosion allowance) = 0 mm
J (joint efficiency) = 0.85
So, ts = 0.053650 x 11,000
2 x142 x 0.85
= 2.44 mm
≈5 mm
Minimum shell thickness is 5 mm.
So, ts = 5 mm.

Calculation for No. of plates:
No. of horizontal plates = nH = π d
L + 2x10-3
= π x 11
6 + 2x10-3
= 5.75
≈6
No. of vertical plates = nv = H + 2x10-3
W + 2x10-3
= 4 + 2x10-3
1.5 + 2x10-3
= 3.103
≈5 plates
Total no. of plates = ns = nH x nv
= 6 x 5
= 30 plates
Bottom design
Base dia. Db = Ds + 2 ts + 2 x welding thickness + (2 x 0.00254)
= 11 + (2 x0.005) +(2 x0.002) + (0.050)
= 11.01908 m
No. of Base plates = N = (π / 4) Db
2
L x W
= (π / 4) x (11.01908)2
6 x 1.5
= 10.5905
= 12.0 plates
Conical roof design
Assuming that self-supporting type conical roof can be used.
Thickness of salt supporting roof:

Take tr = 20 mm
Pr = dead load + live load
= 1250 + (tr x ρ moc x g/gc)
= 1250 + (0.020 x 7750 x 10)
= 2800 N / mm2
= 2.8 x 10-3
Sin θ = Pr D
0.204 x E tr
Sin θ = [0.00125+(20 x 7750 x 10-9
x 10)] 1/2
x 11019/20
0.204 x 1.9 x 105
Sin θ= 0.147
Tan θ= 0.1532 <0.2
Assume tr= 14 mm
Sin θ= 0.194
Tan θ= 0.1967< 0.2
So, Design is Safe for tr= 14 mm.
A1= P* D2
* Cot θ
8*f
=[0.00125+(14*7750*10-9
*10)]*(11*103
)2
*{1/0.1967}
8 *142
A1= 587.52 mm2
A2= Ac+As+Ar
Ac = 65*65
= 4225 mm2

As = 1.5 tr*(R* tr)1/2
R=D/2=11019/2=5509.5
= 1.5 * 5*(5509.5*5)1/2
=1244.80 mm2
Ar= 0.75* tr * (r * tr)1/2
r= D/2
Sin θ
= 5509.5
0.194
=28399.48
Ar = 0.75* 5*(28399.5 * 5)1/2
= 1413.09 mm2
A2 = 4225 + 1244.80 + 1413.09
= 6882.89 mm2
A 2 > A1
So, Design is safe.

Chapter 8 INSTRUMENTATION AND CONTROL
Instruments are provided to monitor the key process variables during plant operation.
They may be incorporated in automatic control loops, or used for manual monitoring of process
operation. They may also be part of an automatic computer data logging system. Instrument
monitoring critical process variables will be fitted with automatic alarm to alert the operators to
critical and hazardous situations.
INSTRUMENTATION AND CONTROL OBJECTIVES
The primary objectives of the designer when specifying instrumentation and control schemes are:
1) Safe plant operation.
a) To keep the process variables within known safe operating limits.
b) To detect the dangerous as they develop and to provide alarms and automatic shut-down
systems.
2) Production rate.
To achieve design product output.
3) Production quality.
To maintain the product composition within the specified quality standards.
4) Cost
To operate at the lowest production cost, commensurate with the other objectives.
TYPICAL CONTROL SYSTEMS:
1) Level control
In any equipment where all interface exists between two phases (liquid-vapor), some means
of maintaining the interface at required level must be provided. This may be incorporated in the
design of the equipment, as is usually done for distillation column or by automatic control of the flow
from the equipment. The control value should be placed on the discharge line of the pump.
2) Pressure control:
Pressure control will be necessary for most systems handling vapor or gas. The method of
control will depend on the nature of the process. For nontoxic and noble gas the pressure is control

by direct venting. For toxic and/or valuable gas the vent should be taken be to a vent recovery system
such as scrubber.
3) Flow control:
Flow control is usually associated with inventory control in a storage tank or other
equipment. There must be a reservoir to take up the changes in flow rate. Flow control is provided
around pumps and compressors running at fixed spaced and supplying a near constant volume output,
a by-pass control would be used
a) Flow control for reciprocating pump.
b) Flow control for a centrifugal compressor or pump.
4) Heat exchangers:
The temperature being controlled by varying the flow of cooling or heating medium. If the
exchange is between two process streams whose flows are fixed, by pass control will have to be used
a) control of fluid stream b) By-pass control.
5) Cascade control:
With this arrangement, the output of one controller is used to adjust the set point of another.
Cascade control can give smoother control insinuation where direst control of the variable would lead
to unstable operation. It is most widely used for distillation column.
6) Ratio Control:
Ratio control is used to maintain two flows at a constant ratio, for example, reactor feeds .
ALARMS , SAFETY TRIPS AND INTERLOCKS:
Alarms are used to alert operators of serious and potentially hazardous deviations from
process condition. Key instrument are fitted with switches and relays to operate available and visual
alarms on control panels and anniciation panels. Where delays, or lack of response, by the operator
lead to rapid development of hazardous situation, the instrument should be fitted with a trip system to

take action automatically to avert the hazard, such as shutting down pumps, closing valves, operating
emergency systems.
The basic components of automatic trip system are:
1. Sensor to monitor the control variable and provide an output signal when a present value is
exceeded.
2. A link to transfer the signal to actuator, usually consisting of system of pneumatic or electrical
relays.
3. An actuator to carry out the required action, close or open a value, switch or a monitor.
All the streams used in the plant other than reactants come under the head of utility. These are many
streams which are being used by chlorosulfonated polyethylene pant as utility via stream for heating
purpose, nitrogen stream used as inert. Instrument air used for the operation of valves etc.
Process and instrument symbols

Instrument symbols for different equipments

Fig 8.1 P&I Flow Diagram for the Manufacture of Alkyl Aryl Sulfonate
NaOH
H2O

Chapter 9 Plant location
The geographical location of the final plant can have strong influence on the success of an
industrial venture. Considerable care must be exercised in selecting the plant site, and many
different factors must be considered. Primarily, the plant should be located where the minimum
cost of production and distribution can be obtained, but other factors, such as room for expansion
and safe living conditions for plant operation as well as the surrounding community, are also
important.
A general consensus as to the plant location should be obtained before a design project reaches
the detailed estimate stage, and a firm location should be established upon completion of the
detailed-estimate design. The choice of the final site should first be based on a complete survey
of the advantages and disadvantages of various geographical areas and, ultimately, on the
advantages and disadvantages of available real estate.
The following factors should be considered in selecting a plant site:
1. Raw materials availability
2. Markets
3. Energy availability
4. Climate
5. Transportation facilities
6. Water supply
7. Waste disposal
8. Labor supply
9. Taxation and legal restrictions
10. Site characteristics
11. Flood and fire protection
12. Community factors
 Raw materials availability: The source of raw materials is one of the most important factors
influencing the selection of a plant site. This is particularly true if large volumes of raw
materials are consumed, because location near the raw-materials source permits considerable
reduction in transportation and storage charges. Attention should be given to the purchased
price of the raw materials, distance from the source of supply, freight or transportation

expenses, availability and reliability of supply, purity of the raw materials, and storage
requirements.
 Markets: The location of markets or intermediate distribution centers affects the cost of
product distribution and the time required for shipping. Proximity to the major markets is an
important consideration in the selection of a plant site, because the buyer usually finds it
advantageous to purchase from nearby sources. It should be noted that markets are needed
for by-products as well as for major final products.
 Energy availability: Power and steam requirements are high in most industrial plants, and
fuel is ordinarily required to supply these utilities. Consequently, power and fuel can be
combined as one major factor in the choice of a plant site. Electrolytic processes require a
cheap source of electricity, and plants using electrolytic processes are often located near large
hydroelectric installations. If the plant requires large quantities of coal or oil, location near a
source of fuel supply may be essential for economic operation. The local cost of power can
help determine whether power should be purchased or self-generated.
 Climate: If the plant is located in a cold climate, costs may be increased by the necessity for
construction of protective shelters around the process equipment, and special cooling towers
or air-conditioning equipment may be required if the prevailing temperatures are high.
Excessive humidity or extremes of hot or cold weather can have a serious effect on the
economic operation of a plant, and these factors should be examined when selecting a plant
site.
 Transportation facilities: Water, railroads, and highways are the common means of
transportation used by major industrial concerns. The kind and amount of products and raw
materials determine the most suitable type of transportation facilities. In any case, careful
attention should be given to local freight rates and existing railroad lines. The proximity to
railroad centers and the possibility of canal, river, lake, or ocean transport must be
considered: Motor trucking facilities are widely used and can serve as a useful supplement to
rail and water facilities. If possible, the plant site should have access to all three types of
transportation, and, certainly, at least two types should be available.
There is usually need for convenient air and rail transportation facilities between the plant
and the main company headquarters, and effective transportation facilities for the plant
personnel are necessary.
 Water supply: The process industries use large quantities of water for cooling, washing,
steam generation, and as a raw material. The plant, therefore, must be located where a
dependable supply of water is available. A large river or lake is preferable, although deep
wells or artesian wells may be satisfactory if the amount of water required is not too great.

 The level of the existing water table can be checked by consulting the state geological
survey, and information on the constancy of the water table and the year-round capacity
of local rivers or lakes should be obtained.
 If the water supply shows seasonal fluctuations, it may be desirable to construct a
reservoir or to drill several standby wells.
 The temperature, mineral content, silt or sand content, bacteriological content, and cost
for supply and purification treatment must also be considered when choosing a water
supply.
 Waste disposal: In recent years, many legal restrictions have been placed on the methods
for disposing of waste materials from the process industries. The site selected for a plant
should have adequate capacity and facilities for correct waste disposal. Even though a
given area has minimal restrictions on pollution, it should not be assumed that this
condition will continue to exist. In choosing a plant site, the permissible tolerance levels
for various methods of waste disposal should be considered carefully, and attention
should be given to potential requirements for additional waste-treatment facilities.
 Labor supply: The type and supply of labor available in the vicinity of a proposed plant
site must be examined. Consideration should be given to prevailing pay scales,
restrictions on number of hours worked per week, competing industries that can cause
dissatisfaction or high turnover rates among the workers, and variations in the skill and
productivity of the workers.
 Taxation and legal restrictions: State and local tax rates on property income,
unemployment insurance, and similar items vary from one location to another. Similarly,
local regulations on zoning, building codes, nuisance aspects, and transportation facilities
can have a major influence on the final choice of a plant site. In fact, zoning difficulties
and obtaining the many required permits can often be much more important in terms of
cost and time delays than many of the factors discussed in the preceding sections.
 Site characteristics: The characteristics of the land at a proposed plant site should be
examined carefully. The topography of the tract of land and’ the soil structure must be
considered, since either or both may have a pronounced effect on construction costs. The
cost of the land is important, as well as local building costs and living conditions. Future
changes may make it desirable or necessary to expand the plant facilities. Therefore, even
though no immediate expansion is planned, a new plant should be constructed at a
location where additional space is available.

 Flood and fire protection: Many industrial plants are located along rivers or near large
bodies of water, and there are risks of flood or hurricane damage. Before selecting a plant
site, the regional history of natural events of this type should be examined and the
consequences of such occurrences considered. Protection from losses by fire is another
important factor in selecting a plant location. In case of a major fire, assistance from
outside fire departments should be available. Fire hazards in the immediate area
surrounding the plant site must not be overlooked.

Chapter 10 Plant Layout
A chemical plant should essentially contain the following units.
 Storage area for raw materials and products.
 Maintenance workshop
 Stores for maintenance and operating supplie
 Laboratories
 Fire Station and Security
 Utilities (Distillation column, boiler, reactor, etc)
 Effluent Disposal plant
 Offices for general administration
 Canteens, medical center, etc.
 Parking Lot
The economic construction and efficient operation of a process unit will depend on how well
the plant and equipment specified on the process sheet is laid out.
The principle factors that have to be considered are:
 Economic Considerations
 The Process Requirements
 Convenience of operation
 Convenience of maintenance
 Safety
 Future Expansion
Costs:
The Cost of construction can be minimized by adopting a layout that gives the shortest run of
connecting pipe between equipment and the least amount of structural steel work.
Process Requirements:
The height and the distance between the equipments are sometimes dictated by the process
taking place. For example it is necessary to elevate the base of columns to provide the
necessary net positive suction head to the pump. Gravity can be used in some cases. By
elevating a component the service of a pump can be avoided.

Operation:
Equipment that needs to have frequent operator attention should be located convenient to the
control room. Valves, sample points and instruments should be located at convenient
positions and heights.
Maintenance:
Heat exchangers need to be sited so that the tube bundle can be easily withdrawn for cleaning
and tube replacement. Vessels that require replacement of catalyst or packing should be
located on the outside the building. Equipments that require constant dismantling should be
under cover.
Safety:
Cooling towers should be situated so that under the prevailing wind conditions the plume of
condensate spray drifts away from the plant area and adjacent properties. The hazardous
chemicals should be handled away from the place where relatively large number of people
work.
Plant expansion:
Equipment should be located so that it can be conveniently tied in with any future expansion
of the process. Space should be left on pipe alleys for future needs and service pipes
oversized to allow future requirements.

Fig 10.1 Master Plot of Plant

Fig 10.2 Chemical Processing Area

Chapter11 CostEstimation
Fixed capital investment = $ 3228500 (year 1999)
Capacity at that year, Q1 = 6.795 x 103 tons / yr.
C2=C1 (Q2/Q1) n
n=0.6
Considering 300 days,
Given capacity, Q2=75000 tons/yr
C2 = 3228500(75000/6795)0.6
= 13.64 x 106$
= 654.6 x 106Rs
Cost index in the year 1999 = 230
Cost index is the year 2012 = 402 n – fixed capital investment
n2= n1 (C2/C1)
=654.6 x 106(402/230)
= 1144x106 Rs.
Fixed capital investment for 75000 tons / yr capacity
= 1144 x 106
Rs
11.1 Estimation of total capital investment:
I. Direct cost:
A. Equipment, installation, piping etc.
1. Purchased equipment (30% of fixed capital investment)
= 0.3 x 1144 x 106
= 343.2 x 106
Rs.
2. Installation, including insulation and painting
(30% of purchased equipment)
= 0.3 x 343.2 x 106
= 102.96 x 106
Rs.

3. Instrumentation and controls, installed (10% of purchased equipment)
= 0.1 x 343.2 x 106
= 34.32 x 106
Rs.
4. Piping, installed (20% of purchased equipment)
= 0.2 x 343.2 x 106
= 68.64 x 106
Rs.
5. Electrical, installed (15% of purchased equipment)
= 0.15 x 4343.2 x 106
= 51.48 x 106
Rs.
B. Buildings (20% of purchased equipment cost )
= 0.2 x 343.2 x 106
= 68.64 x 106
Rs.
C. Service facilities and yard improvements: (60% of purchased equipment)
= 0.6 x 343.2 x 106
= 205.92 x 106
Rs.
D. Land (5% of purchased equipment)
= 17.1 x 106
Rs.
Direct cost = 893.32 x 106
Rs.
II. Indirect cost:-
1. Engineering and supervision ( 10% of direct cost)
=89.23 x 106
Rs.
2. Construction expense and contractor’s fee
(11% of direct cost)
= 93.85 x 106
Rs.
3. Contingency (6% of fixed capital investment)

= 0.06 x 1144 x 106
= 68.64 x 106
Rs
Indirect cost = 251.7 x 106
Rs.
Total capital investment = fixed capital investment + working capital
Let working capital = 15% of total capital investment
Fixed capital investment = 1144 x 106
Rs. Total capital investment = 1345 x 106
Rs.
11.2 Estimation of total product cost:
I. Manufacturing cost
A. Fixed charges:
1. Depreciation (10% of fixed capital investment + 2% of building)
= 114.4 x 106
+ 1.37 x 106
= 116 x 106
Rs.
2. Local taxes (3% of fixed capital investment)
= 34.32x 106
Rs.
3. Insurance ( 0.8% of fixed capital investment )
= 9.15 x 106
Rs.
Fixed charges = 159.5 x 106
Rs.
Let fixed charge be 15% of total product cost
Total product cost
= 159.5 x 106
/0.15
= 1063.14 x 106
Rs
B. Direct production cost:
1. Raw materials (15% of total product cost)
= 159.45 x 106
Rs.

2. Operating labor (11% of total product cost)
= 116.93 x 106
Rs.
3. Direct supervisory and clericallabor (15% of operating labor)
=17.53 x 106
Rs.
4. Utilities (15% of total product cost)
= 159.45 x 106
Rs.
5 .Maintenance and repairs (5% of fixed capital investment)
= 57.2 x 106
Rs.
6. Operating supplies [15% of maintenance and repairs)
= 8.58 x 106
Rs
7. Laboratory charges (15% of operating labor)
= 17.53 x 106
Rs.
8. Patents and royalties (3% of total product cost)
= 31.89 x 106
Rs.
C. Plant overhead costs (5% of total product cost)
= 53.16 x 106
Rs.
I. Manufacturing cost = Fixed charges + direct production cost + plant overhead cost
= 780.3 x 106
Rs.
II. General Expenses:
A. Administrative costs (5% of total product cost)
= 53.15 x 106
Rs.
B. Distribution and selling costs (14% of total product cost )
=148.82 x 106
.Rs
C. Research and development costs (5% of total product cost)
= 53.15 x 106
Rs.

D. Financing (2% of total capital investment)
=26.9 x 106
Rs.
General expenses = 282.7 x 106
Rs.
Total product cost = manufacturing cost + general expenses
= 1063 x 106
Rs.
Cost of the product = (1063 x 106
)/ (75000 x106
)
= 14 Rs/Kg
With a profit margin of 20% = 1.2 x 14
= 17 Rs/Kg
Gross annual earning = 17x75000 x 103
(GAE) = 1275 x 106
Rs.
Net annual earnings = GAE – Income tax
Income tax = 40% of GAE
Net annual earnings = 765 x 106
Rs
Payback period = (total capital investment) / (net annual earnings)
= 1345 x 106
765 x 106
= 1.758 years
Rate of return = (net annual earnings) / (fixed capital investment)
765 x 210
6
x 100
=
1144x106
= 66.8%

Chapter 12 Safety Issues
Linear alkyl benzene sulfonates are accepted as adequately biodegradable. These are bio
‘soft’ surfactants. But they are not broken down as readily and completely as soaps and other
surfactants derived from fats or synthesized to contain a completely unbranched chain with an
even number of carbon atoms and no benzene ring. Years of systematic monitoring of sewage
treatment plants and rivers has shown that in general the residual concentration of surfactants in
streams is extremely small Biodegradation in sewage treatment plant models show
Primary biodegradation.
OECD confirmatory test 90-95
% MBAS/BiAS/DAS removal
Ultimate biodegreadation
Coupled units test, 73±6 (C)
% C/COD/ removal
Highly biodegradable anionic surfactants allowed by the law are of only
marginal toxicity to fish. It is shown that toxicity is inversely proportionate to biodegradability.
Toxicity data of alkyl benzene sulfonate.
(mg/l)
LC50(fishes) 3-10
LC50 (daphniae) 8-50
NOEC (algae, growth inhibition) 30-300
For anionic surfactants the length of the alkyl chain has been found to be closely related to skin
irritability. Straight chain or linear alkyl benzene sulfonate show weak effects to skin since they
are bio soft.
 In general design work, the magnitudes of safety factors are dictated by economic or
market considerations, the accuracy of the design data and calculations, potential changes
in the operating performance, background information available on the overall process,
and the amount of conservatism used in developing the individual components of the
design.

 Each safety factor must be chosen on basis of the existing conditions, and the chemical
engineer should not hesitate to use a safety factor of zero if the situation warrants it.
12.1Material Safety Data Sheet for Raw materials
12.1.1 Alkyl Aryl Sulfonate
1. CHEMICAL PRODUCT
 Product Name: Alkyl Aryl Sulfonate
 Chemical Family: Anionic surfactant
2. COMPOSITION/INFORMATION ON INGREDIENTS
Chemical Name Amount CAS Number
SODIUM SULFATE < 1.0 % 7757-82-6
ALKYL ARYL SULFONATE 1.0 - 4.0 % N/A
HAZARDS DISCLOSURE
This product contains hazardous materials as defined by the OSHA Hazard Communication
Standard 29 CFR 1910.1200.
As defined under Sara 311 and 312, this product contains materials that are acute hazards.
3. HAZARDS IDENTIFICATION
POTENTIAL HEALTH EFFECTS
 EYE:
Can cause severe eye irritation.
 SKIN:
May cause skin irritation.
 INHALATION:
Causes respiratory tract irritation.
 INGESTION:
Ingestion is not considered a potential route of exposure.

 SIGNS AND SYMPTOMS OF EXPOSURE:
Undue drowsiness.
 REPRODUCTIVE HAZARDS:
None.
 CARCINOGENICITY INFORMATION:
Suspect cancer hazard (contains material which) may cause cancer.
 MEDICAL CONDITIONS AGRAVATED BY EXPOSURE:
Rated as a primary fatiguing agent and occular irritant.
4. FIRST AID MEASURES
 EYE CONTACT FIRST AID:
Immediately flush eyes with plenty of water.
 SKIN CONTACT FIRST AID:
Wash skin with soap and water.
If cool wax contacts skin, wash with warm soapy water.
 INHALATION FIRST AID:
Contact a physician.
 INGESTION FIRST AID:
Do not induce vomitting.
5. FIRE FIGHTING MEASURES
 FLAMMABLE PROPERTIES
COC Flash Point: N/A
Autoignition Temperature: N/A
 FLAMMABLE LIMITS IN AIR
LEL: N/A
UEL: N/A
 FLAMMABLE PROPERTIES:

Not Flammable under normal conditions.
 EXTINGUISHING MEDIA:
Non-flammable.
 FIRE & EXPLOSION HAZARDS:
None.
 FIRE FIGHTING INSTRUCTIONS:
None.
 COMBUSTION PRODUCTS:
None.
6. ACCIDENTAL RELEASE MEASURES
 LARGE SPILLS PROCEDURE:
Sweep up and rinse with water.
Wear respirator and protective clothing as appropriate. Shut off source of leak.
Dike & contain. Allow wax to cool and remove as solid.
 SMALL SPILLS PROCEDURE:
Same as large spill.
7. HANDLING AND STORAGE
 STORAGE PRECAUTIONS:
Store in a dry place.
8. EXPOSURE CONTROLS / PERSONAL PROTECTION
 EYE / FACE PROTECTION REQUIREMENTS:
Use safety glasses.
 SKIN PROTECTION REQUIREMENTS:
Not required.
 RESPIRATORY PROTECTION REQUIREMENTS:

Not required.
 MISCELLANEOUS:
Use local ventillation.
 EXPOSURE GUIDELINES:
No Information Available.
10. STABILITY
 STABILITY:
Stable.
11. TOXICOLOGICAL INFORMATION
No information available.
12. DISPOSAL CONSIDERATIONS
 WASTE DISPOSAL:
Dispose of waste material in accordance with all local, state/provincial,
and national requirements. Material is biodegradable.
12.1.2. SULFURIC ACID
Name: Sulfuric acid
Synonyms: Hydrogen Sulfate, Oil of Vitriol, Vitriol Brown Oil, Matting Acid, Battery Acid
1.Hazards Identification
EMERGENCY OVERVIEW
Appearance: colorless to brown.
Danger Harmful if inhaled. Corrosive. Hygroscopic. Causes digestive and respiratory tract
burns. Causes digestive and respiratory tract irritation. Causes severe eye and skin irritation and
burns. Target Organs: None known.

2.Potential Health Effects
Eye:
May cause irreversible eye injury. Causes eye irritation and burns.
Skin:
Causes severe skin irritation and burns.
Ingestion:
Causes gastrointestinal tract burns.
Inhalation:
Harmful if inhaled. May cause severe irritation of the respiratory tract with sore throat, coughing,
shortness of breath and delayed lung edema. Causes chemical burns to the respiratory tract.
Chronic:
Prolonged or repeated skin contact may cause dermatitis. Prolonged or repeated inhalation may
cause nosebleeds, nasal congestion, erosion of the teeth, perforation of the nasal septum, chest
pain and bronchitis. Prolonged or repeated eye contact may cause conjunctivitis.
3.First Aid Measures
Eyes:
Get medical aid immediately. Do NOT allow victim to rub or keep eyes closed. Extensive
irrigation is required (at least 30 minutes).
Skin:
Get medical aid immediately. Flush skin with plenty of soap and water for at least 15 minutes
while removing contaminated clothing and shoes. SPEEDY ACTION IS CRITICAL!
Ingestion:
Do NOT induce vomiting. If victim is conscious and alert, give 2-4 cupfuls of milk or water.
Never give anything by mouth to an unconscious person. Get medical aid immediately.
Inhalation:
Get medical aid immediately. Remove from exposure to fresh air immediately. If breathing is
difficult, give oxygen.

Notes to Physician:
Treat symptomatically and supportively.
4. Fire Fighting Measures
General Information:
Wear appropriate protective clothing to prevent contact with skin and eyes. Wear a self-
contained breathing apparatus (SCBA) to prevent contact with thermal decomposition products.
Contact with water can cause violent liberation of heat and splattering of the material.
Extinguishing Media:
Do NOT use water directly on fire. Use water spray to cool fire-exposed containers. Use carbon
dioxide or dry chemical..
Flash Point: 340 deg C ( 644.00 deg F)
5. Accidental Release Measures
General Information: Use proper personal protective equipment.
Spills/Leaks:
Cover with sand, dry lime or soda ash and place in a closed container for disposal.
6. Handling and Storage
Handling:
Wash thoroughly after handling. Remove contaminated clothing and wash before reuse. Use only
in a well ventilated area. Do not get in eyes, on skin, or on clothing. Keep container tightly
closed. Do not ingest or inhale. Do not allow contact with water. Discard contaminated shoes.
Storage:
Keep container closed when not in use. Store in a cool, dry, well-ventilated area away from
incompatible substances. Corrosives area.

7.Exposure Controls/Personal Protection
EngineeringControls:Use adequate general or local exhaust ventilation to keep airborne
concentrations below the permissible exposure limits.
Exposure Limits
Chemical
Name
ACGIH NIOSH OSHA -
Final PELs
Sulfuric
acid
1 mg/m3; 3
mg/m3 STEL
1 mg/m3 TWA; 15
mg/m3 IDLH
1 mg/m3
TWA
8.Personal Protective Equipment
Eyes: Wear appropriate protective eyeglasses or chemical safety goggles as described by
OSHA's eye and face protection regulations in 29 CFR 1910.133 or European Standard EN166.
Skin: Wear appropriate protective gloves to prevent skin exposure.
Clothing: Wear appropriate protective clothing to prevent skin exposure.
9. Physical and Chemical Properties
Appearance: colorless to brown liquid
Odor: Odorless
Molecular Weight: 98.08
Density: 1.8400 g/cm3
Boiling Point: 280 deg C @ 760.00mm Hg
Melting Point: 3 deg C
Vapor Density (Air=1): 1.2 kg/m3
Vapor Pressure (mm Hg): < 0.00120 mm Hg
Evaporation Rate: Slower than ether
MolecularFormula: H2SO4

10. Stability and Reactivity
Chemical Stability:
Stable under normal temperatures and pressures.
Conditions to Avoid:
Contact with water, metals, excess heat, combustible materials,
organic materials.
11. Toxicological Information
Epidemiology:
Workers exposed to industrial sulfuric acid mist showed a statistical increase in laryngeal cancer.
This data suggests a possible relationship between carcinogenisis and inhalation of sulfuric acid
mist..
12.1.3. Linear Alkylbenzene
Name : Linear Alkylbenzen
Synonyms: Benzene C10-C13 alkyl Derivatives / LAB
1.Hazards Identification
Emergency Overview
Appearance: clear, colorless solution
Caution! Corrosive. Causes irritation or burns to eyes, skin, digestive and respiratory tracts. Risk
of serious eye damage. Toxic. Harmful if swallowed.
Target Organs: Eyes, skin, respiratory system, teeth
2.Potential Health Effects
Eye: Causes eye irritation and burns. Eye contact can result in blindness; exposure to mist leads
to watering, irritation.
Skin: Skin contact may result in severe burns, blistering and pain.

Ingestion: May cause severe and permanent damage to the digestive tract. Causes gastrointestinal
tract burns. Vomiting and diarrhea of dark blood may occur; asphyxia from throat swelling.
Stomach and esophagus may become perforated.
Inhalation: May cause severe irritation of the respiratory tract with sore throat, coughing,
shortness of breath, and delayed lung edema. Causes chemical burns to the respiratory tract. At 5
mg/m3 concentrations, nose and throat irritation occurs, with headache, cough, increased
respiratory rate, impairment of lung to ventilate.
Chronic: Delayed symptoms include tight chest, fluid in lungs, cyanosis (blue color),
hypotension, bronchitis or emphysema, tracheobronchitis, dental erosion/discoloration,
pneumonia, gastrointestinal disturbances may occur. Skin irritation/dermatitis, conjunctivitis, and
lacrimation of the eye may occur.
3.First Aid Measures
Eyes: Immediately flush eyes with copious amounts of water for at least 15 minutes, lifting the
upper and lower lids until chemical is gone. Get medical aid immediately.
Skin: Flush with copious amounts of water for at least 15 minutes. Remove contaminated
clothing and shoes. Get medical aid.
Ingestion: Do NOT induce vomiting. Give conscious victim 30 mL (1 ounce) milk of magnesia
and large quantities of water to dilute acid. Get medical aid at once. Never give anything by
mouth to an unconscious person.
Inhalation: Remove to fresh air immediately. If not breathing, give artificial respiration. If
breathing is difficult, give oxygen. Get medical aid at once.
Notes to Physician: Treat symptomatically and supportively.

4.Fire Fighting Measures
General Information: As in any fire, wear a self-contained breathing apparatus in pressure-
demand, MSHA/NIOSH (approved or equivalent), and full protective gear. Contact with metals
may evolve flammable hydrogen gas. Avoid breathing toxic and corrosive vapors. Emits toxic
fumes under fire conditions.
Extinguishing Media: Use extinguishing media most appropriate for the surrounding fire.
Autoignition Temperature:No information found.
Flash Point: No information found.
5.Accidental release measures:
 Person-related safety precautions Wear protective clothing and equipment. Isolate hazard
area. Evacuate all unauthorized personnel not participating in rescue operations from the
area. Avoid entry into danger area. Remove all possible sources of ignition. Stop traffic
and switch off the motors of the engines. Do not smoke and do not handle with naked
flame. Use explosion-proof lamps and non-sparking tools. Avoid contact with the
substance.
 Precautions for protection of the environment: Prevent from further leaks of substance.
Dike flow of spilled material using soil or sandbags to minimize contamination of drains,
surface and ground waters. If Linear Alkyl Benzene has flowed into drains, ponds or
sewage systems, inform appropriate authority.
 Recommended methods for cleaning and disposal: Soak up residues with non-
combustible absorbent material (e.g. sand, earth, vermiculite) and forward for disposal in
closed containers. Dispose off under valid legal waste regulations
6. Handling and storage:
 Handling in accordance with good hygiene and safety procedures, since empty containers
contain residue, follow all hazard warning and precautions.

 Store in a cool, dry and well ventilated area. Store separately from combustible, organic
and oxidizable materials.
7. Exposure control:
Personal protective equipment (PPE) for the protection of eyes, hands and skin corresponding
with the performed labor has to be kept at disposition for the employees. All PPE have to be kept
in disposable state and the damaged or contaminated equipment has to be replaced immediately.
 Eye: Use chemical safety goggles.
 Skin: Wear impervious protective clothing, including boots, gloves and coveralls.
 Respiratory protection: If the exposure limit is exceeded and engineering controls are not
feasible, wear a supplied air, full-face piece respirator, airline hood, or full face piece
self-contained breathing apparatus.
 Environmental exposure controls: Proceed in accordance with valid air and water
legislative regulations.
8.Physical and chemical properties:
General information: Detergent intermediate
Physical State: Liquid
Appearance: Colorless
Odor: Odorless
pH: Not Applicable
Boiling Range: 270 – 320 oC
Flash Pint: 130 oC
Flammability: Not Available
Explosive properties: Not Applicable
Oxidizing properties: Not Available
Freezing Point: 4 oC
Vapor pressure mm Hg @ 20 oC: <0.1
Water Solubility: Negligible
Viscosity: 5- 10 cps @ 20 oC
Vapor Density: 8.4 Specific Gravity: 0.86

9. Stability and reactivity:
Stable. Incompatible with strong oxidizers and No dangerous polymerization.
10. DISPOSAL CONSIDERATIONS
Disposal of product: Disposal is to be performed in compliance with all government regulations.
Do not dispose of via sinks or into immediate environment.
Disposal of packaging: Since empty contaminated containers contain product residue, follow all
hazards warnings and precautions even after container emptied.

CONCLUSION
After studying whole project of Alkyl Aryl Sulfonate(AAS) we have conclude that AAS can be
manufactured by various processes. Raw materials for manufacture of AAS are Linear Alkyl
Benzen and oleum .
Market price of AAS is 17 rupees. From our production of AAS Total product cost is 106.3
Crore Rs/year, Net Profit is 76.5 Crore Rs/year, Pay out period is 1.758 year and Rate of Return
is 66.8 %.
Thus The AAS production process is both Technical and Economically viable.

Reference
1. E. Woollatt, The manufacture of soaps, other industrial detergents and glycerine, Ellis
Horwood limited.
2. G. T. Austin, Shreve’s chemical process industries, fifth edition, International student edition.
3. A. Davidsohn & B.M. Miluidsky, Synthetic detergency, sixth edition, Book center limited.
4. P.H. Groggins, Unit processes in organic synthesis, fifth edition, McGraw Hill book
Company.
5. J.P. Sisley and P.J. Wood, Encydopedia of surface active agents; Vol. I & II; Chemical
publishing company.
6. R. H. Perry, Perry’s Chemical Engineering hand book, sixth edition.
7. “Ullman,” Encyclopedia of industrial chemistry; fifth edition; Volume A8.
8. Octave Levenspiel,Chemical reaction engineering; third edition; John Wiley and Sons.
9. M.V. Joshi, Process equipment design; second edition; MacMillan.
10. B.C. Bhattacharya, Introduction to chemical equipment design; Indian institute of
technology.
11. Max S. Peters & Klaur D. Timmerhaus, Plant design & economics for chemical engineering
; third etition; International student edition.
12. Coulson and Richardson’s Chemical Engineering Design ; second edition; Vol.6.
13. Dwight Rust and Stephen Wildes, “SURFACTANTS A Market Opportunity Study Update
Prepared for the United Soybean Board” December 2008
http://soynewuses.org/wp-content/uploads/pdf/Surfactants%20MOS%20-%20Jan%202009.pdf.

A PROJECT REPORT ON “ALKYL ARYL SULFONATE”

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