The heat exchanger CONDEN-2 has a heat duty of 1,011,451.6 kW. Using a cost factor of $20,000/MW, the estimated cost is $20,234,032. The preferred location for the plant is in Mumbai based on factors such as proximity to markets, raw material supply, labor availability, and infrastructure.

2. 11
WA SHER
A CIDS
MIXER-2
BENZENE
STREAM-5 B21
STREAM-0
B19
STREAM-1 STREAM-3
WA TER1
1 DISTIL-1
B1
PRODUCT1 PRODUCT2
NITMIXER
CONDEN-2

3.  Aspen results:
 Stages = 7
 Reflux Ratio = 5
 Feed Stage = 4

4. Liquid Flow Rate L=R*D 3.647 kg/s
Vapor Flow Rate V=(1+R)*D 4.376 kg/s
Liquid Vapor Flow Factor 0.913
Flooding Velocity 0.022 m/s
Operating Velocity 0.018 m/sec
 Diameter-Rectifying = 18.896 m

5. Liquid Flow Rate L’=L+F 3.647 kg/s
Vapor Flow Rate V’=V 4.376 kg/s
Liquid Vapor Flow Factor 0.913
Flooding Velocity 0.022 m/s
Operating Velocity 0.018 m/sec
 Diameter-Stripping = 18.504 m

6.  Inner Diameter of Distillation Column = Max(Diameter-Rectifying,
Diameter-Stripping)
 Inner Diameter = 18.896 m
 Height = (7x0.3 + 2x0.3 + 7x0.1) = 3.4 m

7. • Cylindrical Portion:
• Sa= Sy/3 => 143.33MPa
• Operating pressure = 1 atm
• Design Pressure = P = max {operating pressure + 2 bar, 1.1*
operating pressure} = 3 atm
•
• From Distillation Column design, we have inner diameter =
Di = 18.896 m
• Regulation thickness
• Where P = Design Pressure
• E = Weld joint Efficiency = 0.85
•
• We get Tregulation = tR= 23.3 mm
• Taking corrosion allowance = ε = 3 mm for 20 years
• And mill tolerance = m = (+ or -) 12.5 %
• We get required thickness
• = 30 mm
• Outer Diameter = 18.926 m
• Next Available = 3/8 inch

8.  Ellipsoidal Portion:
• Sa= Sy/3 => 143.33MPa
• Operating pressure = 1 atm
• Design Pressure = P = max {operating pressure + 2 bar, 1.1* operating pressure} = 3 atm
•
• From Distillation Column design, we have inner diameter = D i = 18.896 m
• Regulation thickness
• Where P = Design Pressure
• E = Weld joint Efficiency = 0.85
• t = P*Di/ ((Sa*E+ 0.9*P) +P)
• We get Tregulation = tR= 46.3 mm
• Taking corrosion allowance = ε = 3 mm for 20 years
• And mill tolerance = m = (+ or -) 12.5 %
• We get required thickness = 56.4 mm
• Outer Diameter = 18.952 m
• Next Available = 3/8 inch
• Outer Diameter = 28.125 m

9. Stages 7
Reflux Ratio 5
Feed Stage 4
Inner Diameter 18.896 m
Outer Diameter 18.934 m
Height 3.4 m

10. • Ea = (-283.88s+263.37)x103 J/mol
• ko= exp(166.64s2-254.36s+113.79)
• H2SO4 wt. % = 0.6 = s
• K = ko exp(-Ea/RT)
• K = 1.418x10-6 m3/mol.sec
• Rate = KxCbenzenexCnitric acid
• Cbenzene = 3.439x103 mol/m3
• Cnitric acid = 5.079x103 mol/m3
• Rate = 24.768 mol/m3.sec

11. • Cbenzene,o/Cbenzene = 1/(1+KτCnitric acid)
• τ= 6873.77 sec = 1.9 hr
• τ= Cbenzene,oxV/Fao
• V=58.453 m3
• R=1.669 m
• H= 6.677 m

12. • Sa = 520/3 = 143.33 MPa
• Volume of CSTR = 58.453 m3
• Height of reactor=2* Diameter of Reactor (D)
• Baffle width=D/10
• For the impeller
• Impeller Diameter Di=D/3
• D1=Di/5
• D2=Di/4
• Choosing Reactor Diameter D=3.338 m
• H=6.676 m
• Baffle width=0.3338 m
• Di=1.113 m
• D1=0.223 m
• D2=0.278 m

13. • Sa= Sy/3 => 143.33MPa
• Operating pressure = 1 atm
• Design Pressure = P = max {operating pressure
+ 2 bar, 1.1* operating pressure} = 3 atm
• Where P = Design Pressure
• E = Weld joint Efficiency = 0.85
• We get Tregulation = tR=4.116 mm
• Taking corrosion allowance = ε = 3 mm for 20
years
• And mill tolerance = m = (+ or -) 12.5 %
• Required thickness= 8.133 mm
• Next available commercial thickness = 3/8 inch
= 9.375 mm
• Outer Diameter = 3.348 m
• Thickness for ellipsoidal portion = 12.779 mm
• Next Available thickness = 3/8 inch = 18.75 mm

14.  Steam at 63.5 oC
 k= 0.682 J/m.sec.K
 ρ = 960 kg/m3
 μ = 0.28 x 10-3 Pa.sec
 Cp = 4.2164 KJ/Kg.K
 RPM = 240
 NRe = 283147.2
 Di= 0.0381 m (inner diameter of
tube)
 h = 33059.391 W/m2.K
 Q = 50917851.34 W
 n = 150
 Q/n = 339452.3423 W/Tube

15.  Feed rate = 881 TPD = 44037.9063 kg/hr = 12.233 kg/sec
 ρ = 1438.55 kg/m3
 Assuming velocity to be 0.018 m/s
 Area of nozzle is given by m/(v*ρ)
 Where m= mass flow rate
 v= velocity
 Area = 0.472 m2
 Hence diameter of nozzle is 0.775 m=77.5 cm
 Thickness of the nozzle:
 t= P*Di/ ((Sa*E+ 0.4*P) +P)
 =1.9 mm
 Considering corrosion allowance = 3 mm
 Mill tolerance = 12.5%
 We get a thickness of 5.6 mm

16. Inner Diameter 3.338 m
Outer Diameter 3.348 m
HCalculated 6.676 m
HActual 8.903 m
Impeller Diameter 1.113 m
Heating Jacket:
Inner Diameter (Tube) 0.0381 m
Outer Diameter (Tube) 0.0444 m
n (number of tubes inside) 150
RPM (of agitator) 240

17.  We know that m*Cp*∆T = Q  For the tube side, we have
 Here n=3, m =3.29 Kg/sec and water enters  Re = 4*ṁ / π* Di* μ
at 18.1 0C  Where μ = 0.467*10-3 N.S/m 2
 Q = 9.9429 x 105 W  We get Re = 99706.378 (turbulent regime)
 For a heat exchanger, we have  Using the relationship Dittus -Boelter
 U*A* ΔTm= Q/n relationship
 FT = 0.85 (Complex Flow) (1-2 pass  Nu = 0.023*Re0.8 * Pr0.4 where Pr = 3.65 (Since
exchanger) water)
 A = π *Di*L  We get Nu=385.144
 We have taken Di = 0.09 m (Schedule 40 –  Nu= hi*Di/k
Pipe Size of 3.55 inches)  k=0.58 W/m*K for water
 ΔTLMTD = (ΔT1 - ΔT2) / ln (ΔT1 / ΔT2)  Therefore hi comes out to be= 2482.039
 ΔT1 = 113.0030C, W/m2K.-
 ΔT2 = 27 0C Substituting the values of ΔT1,  We can assume the outer surface convection
ΔT2 in Eq(2) we get resistance ( = 164.702 W/m2K ) and tube wall
conduction resistance ( = 8.195x10-5 W/m2K )
 ΔTlmtd = 60.076 K, ΔTm =FTx ΔTlmtd = 51.065 K, as small and hence neglect them. Therefore U
Substituting ΔTm, we get = hi
 U*L = 11477.468 W/K  Therefore L = 4.624 m
 Di = 3.55 inch
 Do= 4 inch

18. • A triangular pattern produces high
turbulence and therefore a high
heat-transfer coefficient. However,
at the typical tube pitch of 1.25
times the tube O.D., it does not
permit mechanical cleaning of
tubes, since access lanes are not
available.
• We have chosen a triangular tube
arrangement pattern.
• The recommended tube pitch is
1.25 times the tube outside
diameter.[Coulson and
Richardson] .Therefore
• Tube pitch= 13 cm

19.  Shell Side :-
 Di = 76 cm = .76 m
 Tube Pitch = 13 cm
 Diameter of baffle, Ds = 40 cm = 0.4
m
 Baffle Pitch = 30 cm
 Baffle Design:

20. • Sa= Sy/3 => 143.33MPa
• Operating pressure = 1 atm
• Design Pressure = P = max {operating pressure + 2 bar, 1.1*
operating pressure} = 3 atm
• From Heat exchanger design, we have shell inner diameter
= Di = 0.76 m
• Regulation thickness
• Where P = Design Pressure
• E = Weld joint Efficiency = 0.85
•
• We get Tregulation = tR= 0.888 mm
• Taking corrosion allowance = ε = 3 mm for 20 years
• And mill tolerance = m = (+ or -) 12.5 %
• We get required thickness
• = 4.443 mm
• Outer Diameter = 0.765 m
• Next Available = 3/8 inch
• Outer Diameter = 0.770 m
• Thickness for ellipsoidal portion = 3.431 mm
• Next Available thickness = same as cylindrical part

21.  Taking the nozzle to be a pipe of 4
Nominal Bore and 40 Schedule pipe and
the nozzle to be of flush type, we get
 4 NB= 4 inch =114.3 mm
 Sch 40 = 0.237 inch thickness = 6.0198
mm
 Therefore inner diameter = 102.26 mm
 Taking a corrosion allowance of 3 mm
and a mill tolerance of 12.5 %, we get
regulation thickness t = 3.57 mm

22.  1-2 pass exchanger
 Counter-current flow of fluids
 Cold water flows through the tube and the product flows through the shell
Number of Tubes 3
Length of Tubes 4.624 m
Shell Inner Diameter 0.760 m
Shell Outer Diameter 0.770 m
Tube Pitch 13 cm
Baffle Pitch 30 cm
Diameter of Baffle 40 cm

23.  Relative Gain Method (RGA)
 For a multivariable process, one input (u1) can be changed in a step-
wise fashion (Δu1) while holding the other inputs constant. The
responses are then measured.
 G is the steady state gain matrix and ⊗ denotes the Schur product.

24. • Manipulated Variables:
– Reflux Ratio, R
– Distillate Rate, D
– Reboiler Duty, Qr
– Bottoms Rate, B
• Controlled Variables:
– Concentration in bottom, xB
– Concentration in distillate, xD
• Original Values of the variables before
manipulations: Reflux Ratio 0.025
Distillate Rate 125 kmol/hr
Reboiler Duty 2496.96217 KW
Bottoms Rate 103.1601 kmol/hr
xD 0.964228
xB 0.999444552

25.  R, Qr pairing :  D, Qr pairing :
1.750839 -0.750839 1.220769 -0.22077
-0.75084 1.7508386 -0.22077 1.220769
 R, B pairing :  D, B pairing:
0.966828 0.033172 0.985738 0.014262
0.033172 0.966828 0.014262 0.985738

26. • λi,j = 1 – ideal means open loop and
closed loop gain between yi and ui are
identical
• 0 < λi,j < 1 also preferred
0.966828 0.033172
• λi,j > 1 - less preferred but allowable
• λi,j < 0 – Avoid means open loop gain
and closed loop gain between yi and ui 0.033172 0.966828
have different signs.
• λi,j represents the element of the
relative gain matrix.
• Preferred : R, B pairing
– Bottoms rate to regulate
composition of the bottom stream.
– Reflux Rate to regulate composition
of the distillate stream.

27. • Factors affecting location:
– 1. Location of the plant relative to marketing area
– 2. Raw material supply
– 3. Transport facilities
– 4. Availability of labor
– 5. Availability of utilities: water, fuel, power
– 6. Availability of suitable land
– 7. Environmental impact and effluent disposal
– 8. Local community considerations
– 9. Climate
– 10. Political and strategic considerations
• Preferred site location to be in Mumbai.

29. Heat Duty (IN KW) Cost P Type Cost
facto
r
Heat CONDEN-2 1011451.6 1011.4516 20000 1 1 20000
Exchanger
CONDENSER DISTIL-1 9713979.8 9713.9798 77714.3555 1 1 77714.3555
REBOILER DISTIL-1 10605461.1 10605.4611 81918.24989 1 1.3 81918.24989
Total cost (in $) 179632.6054
Total cost (in 8083467.244
Rs)
Total cost (in 80.83467244
lakhs)
Distillation Column Purchased Equipment Cost in $ Price in lakhs
DISTIL-1 387847.74 174.532
Reactors Size Unit (m3) Purchased Equipment Cost Price in lakhs
REACTOR 311.644 149126.4801 67.10691603
Size Purchased Equipment Price in lakhs
Cost
washer 15 m3 22405.65 10.0825425
decanter 15 m3 22405.65 10.0825425

30.  Total Equipment Cost (base of 1993) in Rupees
= 37690197.21
 Equipment Costs after Inflation (6 %) Rupees =
39951609.04
 Total Delivered Equipment Cost (TDEC) =
Rs. 399.5160904 Lakh

31. Component Cost ( lakh  Total capital investment = Total
rupees)
Fixed Cost + Working Capital
Total delivered equipment cost (TDEC)
399.51609
Installation (estimated as 40% of TDEC) 0.04
Where Working Capital is
Piping (estimated as 70 % of TDEC) 0.7

Storages (estimated as 15 % of TDEC) 0.15
Utilities (estimated as 50% of TDEC) 0.5 typically 10-20% of total fixed
Insulation Painting (estimated as 11% of TDEC) 0.11 cost = Rs. 154.3011044 Lakhs
Electricals (estimated as 10% of TDEC) 0.10
Instrumentation (estimated as 20% of TDEC) 0.20
Land Cost(estimated as 8% of TDEC) 0.08  Total capital investment = Rs
Auxiliaries(estimated as 30% of TDEC)
Field Expense(estimated as 43% of TDEC)
0.30
0.43
1182.975134 lakh
2.54
PPC
1014.77087
Engineering and home office(estimated as 40% of TDEC) 0.4
Contractor’s Fees(estimated as 12% of TDEC) 0.12
Contingency(estimated as 10% of TDEC) 0.1
0.62
Total Fixed Capital Cost
1028.67403

32. Maintenance 10% of fixed cost 0.1
Operating labor 3 % of fixed cost 0.03
 Fixed Operating Cost
laboratory costs 1.2 % of operating labor 0.012
Supervision 1% of operating labor 0.01
plant overheads 3% of operating labor 0.03
capital charges 15% of fixed cost 0.15
Insurance 1% of fixed cost 0.01
Local taxes 2% of fixed cost 0.02
Royalties 1% of fixed cost 0.01
0.372
Fixed operating cost (in lakhs rupees)
382.666739
 Variable Operating Cost
Raw materials Tonne/hr tonnes/day tonnes/year $/tonnes Rs/ton Rs/year Lakhs/year
Nitric Acid 9.79735781 235.136587 47027.31748 370 16650 783004836 7830.04836
Benzene 8.06132756 193.471861 38694.37229 330 14850 574611428.5 5746.114285
sulfuric acid 25.4164512 609.994829 121998.9658 65 2925 356846974.8 3568.469748
Total cost - 17144.63239
Nitrobenzene 12.7022422 304.853813 60970.76256 780 35100 2140073766 21400.73766

33.  Total variable Operating cost= 17144.63239 lakh/yr
 Total operating cost =total variable operating cost + total fixed
operating cost
 17144.63239 + 382.666739 = 17527.2991 lakhs/year
 Revenue Generated from Nitrobenzene:
 Revenue generated from sales = Rs. 21400.73766 lakhs /yr

34.  Total investment in fixed capital = Rs. 1028.67403 lakh
 Allowing depreciation for 5 years same amount each year,
 We get annual depreciation = (1028.67403 -0)/5 = Rs. 205.734806 lakhs
 Assuming that the total capital investment is taken as loan @ 10% interest per
annum
 Total loan amount = Rs 1182.97513 lacs
 Taking a loan payback period of 3 years, with an equated yearly installment
of P
 Yearly installment = P = Rs. 588.9486068 lacs
 For balance sheet calculations, revenue and operating cost are estimated to
increase at inflation
 rate of 6%; Income tax is assumed to be 30% of taxable income. The following
formulae are
 used:
 Gross Profit = Income – Outgo
 Taxable income = Income – Outgo – Depreciation – loan interest
 Income tax = 0.3*Taxable income
 Net income after tax = Gross Profit – tax
 Money in hand = Net income – loan interest

35. Lakh Rupees / Year 1 2 3 4 5 6 7 8 9 10
Income from Sales 21400.7377 22684.7819 24045.86883 25488.62096 27017.93822 28639.01452 30357.3554 32178.7967 34109.525 36156.096
operation cost 17144.6324 18173.3103 19263.70895 20419.53149 21644.70338 22943.38558 24319.9887 25779.188 27325.939 28965.496
profit 4256.10527 4511.47159 4782.159881 5069.089474 5373.234843 5695.628933 6037.36667 6399.60867 6783.5852 7190.6003
Interest 118.297513 81.7278631 34.00578873 0 0 0 0 0 0 0
Depriciation 205.734806 205.734806 205.734806 0 0 0 0 0 0 0
Taxable income 3932.07295 4224.00892 4542.419287 5069.089474 5373.234843 5695.628933 6037.36667 6399.60867 6783.5852 7190.6003
tax 1179.62189 1267.20268 1362.725786 1520.726842 1611.970453 1708.68868 1811.21 1919.8826 2035.0756 2157.1801
Principal repayment 365.696499 477.220744 524.9428181 0 0 0 0 0 0 0
profit after tax 2386.75457 2479.5855 2654.750683 3548.362632 3761.26439 3986.940253 4226.15667 4479.72607 4748.5096 5033.4202
Working capital 154.301104 154.301104 154.3011044 154.3011044 154.3011044 154.3011044 154.301104 154.301104 154.3011 154.3011
Net profit 2386.75457 5020.64117 7829.692956 11532.35669 15447.92219 19589.16354 23969.6213 28603.6485 33506.459 38694.181
cash in hand 2541.05567 5174.94227 7983.994061 11686.6578 15602.22329 19743.46465 24123.9224 28757.9496 33660.76 38848.482

36.  Plant Capacity : 60971 TPA of Nitrobenzene
 Purity : 99.95%
 Cash in Hand: Rs. 38848.482 Lakhs after 10 yrs