DESIGN OF MALEIC ANHYDRIDE (MAN) PRODUCTION PLANT GROUP 4 AFIQ NOOR BIN TUAH 11857 MOHD FADHLI BIN SAYUTTI 12012 CHE MUHAMMAD BUKHARI BIN CHE MOHD RAZALI 11908 CHE FATIN HUMAIRA BINTI CHE YUSUF 11907 NUR HANIE BINTI ZAMRI 1 PLANT DESIGN I (CBB 4013) INTERIM ORAL PRESENTATION SEMESTER MAY 2012
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DESIGN OF MALEIC ANHYDRIDE (MAN) PRODUCTION PLANT GROUP 4 AFIQ NOOR BIN TUAH 11857 MOHD FADHLI BIN SAYUTTI 12012 CHE MUHAMMAD BUKHARI BIN CHE MOHD RAZALI.
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DESIGN OF MALEIC ANHYDRIDE (MAN)
PRODUCTION PLANT
GROUP 4AFIQ NOOR BIN TUAH 11857MOHD FADHLI BIN SAYUTTI 12012CHE MUHAMMAD BUKHARI BIN CHE MOHD RAZALI 11908CHE FATIN HUMAIRA BINTI CHE YUSUF 11907NUR HANIE BINTI ZAMRI 12140
1
PLANT DESIGN I (CBB 4013)INTERIM ORAL PRESENTATION
1. Location with respect to the marketing area2. Raw material supply3. Transport facilities4. Availability of labor5. Availability of utilities: water, fuel, power6. Availability of suitable land7. Environmental impact & effluent disposal8. Local community considerations9. Climate10. Political and strategic considerations
SITE LOCATION: Criteria
Raw Materials
Butane Imported GPP, PGB
Utilities Power Sultan Iskandar Power Station
Paka Power Plant
Water Johor Waterworks Department, Loji Air Sungai Layang, Syarikat Air Johor
Terengganu Waterworks Department, Bukit Sah, Sg Cherol, Seberang Tayor, Kemasik
N/A Stable but acts as oxidizing agent at elevated temperature of 435 0C
800 ppm
n- Butane 430.0 -60.0 1.8 8.4 N/A 658 g/m3/4hr
Rat
N/A Stable but acts as oxidizing agent at elevated temperature of 435 0C
800 ppm
IDENTIFICATION OF HAZARD
Maleic Anhydride
447 110 1.4 1.7 1030mg/kg
Rat
N/A
2620mg/kg
Rabbit
Stable except when in contact with water. Reacts violently with amines, alkali metal ions and bases.
0.25 ppm (8 hours)
Carbon Dioxide
None None None None N/A 2000 ppm
Human
N/A Stable under normal condition
5000 ppm
Chemicals Flammability Toxicity Reactivity
Exposure Standard
Auto-ignition Temp oC
Flash
Point oC
LEL
(%)
UEL
(%)
Oral (LD50) Inhalation (LC50)
Dermal
(LD50)
TWA
IDENTIFICATION OF HAZARD
• Human Exposure i. Workers are exposed to mixture of acid anhydridesii. An individual showed an acute asthmatic reaction
after exposure to dust containing maleic anhydride (Lee et al., 1991).
iii. Human exposed to maleic anhydride showed respiratory tract and eye irritation at concentrations of 0.25 to 0.38 ppm (1 to 1.6 mg/m3) maleic anhydride (Grigor’eva, 1964).
iv. maleic anhydride is a severe irritant to the eyes, skin and respiratory tract which can, upon exposure, produce intense burning sensations in the eyes and throat with coughing and vomiting.
IDENTIFICATION OF HAZARD
Personal Protection for Exposure Control
• To control or even avoid the exposure of those chemicals
• Wearing eye/face protection to avoid eye contact with the chemicals.
• Proper skin protective equipment such as coveralls or lab coats must be worn to prevent from skin exposure
Catalyst: Divanadyl Pyrophosphate, (VO)2P2O 7 Reason:• The only commercially viable catalyst.• High selectivity to maleic anhydride • Able to selectively activate n -butane during the rate
determining step.• Thermally stable at high temperature
Temperature yield Conversion Selectivity
400 0.561 0.85 0.66
406 0.532 0.888 0.5991
411 0.496 0.83 0.5976
412 0.554 0.918 0.6035
419 0.423 0.873 0.4845
421 0.518 0.888 0.5833
SELECTION OF CATALYST
•400°C
•Based on literature study on optimum operating range
•Safety consideration
Temperature
•170kPa
•Oxidation reaction is not pressure dependent
•Cheaper cost
Pressure
•Molten Salt
•High heat capacity
•Stable at high temperature and not flammable
Heating Medium
•1.7 mol% of N-butane
•LFL and UFL (1.86%-4.61%)
Inlet Feed concentration
•Conversion
: 85%
•Selectivity
: 0.66
•Yield
: 0.561
Conversion, selectivity and yield of Maleic Anhydride
OPERATING PARAMETER
PROCESS SCREENING
LEVEL 1: MODE OF OPERATION
LEVEL 2: INPUT-OUTPUT STRUCTURE
LEVEL 3: REACTOR SYSTEM
LEVEL 4: SEPARATION SYSTEM
Batch Process
• A one-time process, units are designed to start & be stopped frequently once the process is done
Continuous Process (chosen for MAN)• Units are designed to be working continuously & only be
stopped during cleaning or maintenance time
LEVEL 1: MODE OF OPERATION
Why Continuous Process is Chosen?
Production Rate
• Our capacity: 31,375 metric ton/year (bigger than 10 million pound per year/4 535.9237 metric ton per year)
Market Study
• MAN is not seasonable product (widely use in industry in all year long)
• Demand for MAN will continue to grow
Operational Problem
• The plant only involve vapour & liquid phase with no slurry
• The equipment is not periodically started & stopped for cleaning purpose
LEVEL 1: MODE OF OPERATION
A simplified representation of process flow sheet which focuses on raw material feed, products and by-products
Decisions suggested by Douglas:
1. Should we purify the feed stream before they enter the process?2. Should we remove or recycle a reversible by-product? 3. Should we use a gas recycle and purge stream?4. Should we not bother to recover and recycle some reactants?
LEVEL 2: INPUT-OUTPUT STRUCTURE
Type of Reactor Advantages Disadvantages
Fixed-bed reactor High catalytic
conversion Easy to operate
Difficult in temperature control within the reactor
Pay Back Period = 6th yearFuture worth = RM1,900,234,524
CUMULATIVE DISCOUNTED CASH FLOW DIAGRAM
ITEMS PRICE (RM/YEAR)
RAW MATERIAL 66,286,494
PRODUCT 147,462,876
CAPEX 132,114,000.00
OPEX 92,603,095.90
FUTURE WORTH
PAYBACK PERIOD
70
PROFITABILITY ANALYSIS
PROCESS FLOW DIAGRAM(BEFORE
HEAT INTEGRATION)
HEAT INTEGRATION
STREAM DATA
QC = 14697.20 kW Tpinch: 400°C
PROBLEM TABLE ALGORITHM
QC = 14697.20 kW
COMPOSITE CURVE
Process Recovery: 29748.1 kW
GRAND COMPOSITE CURVE
HEAT EXCHANGER NETWORK
Cold utility Hot utility
Before integration (kW) 29743.82 44182.14
After integration (kW) 14697.20 0
Energy saved (kW) 15046.62 44182.14
Percent of energy saved (%) 50.6 100
TOTAL ENERGY SAVING
PROCESS FLOWDIAGRAM
(AFTERHEAT INTEGRATION)
80
PROCESS FLOW DIAGRAM
81
MATERIAL BALANCE TABLE
CONCLUSION
Our design of MAN production plant using n-butane as raw material is feasible with the process route selected & realistic with the demand & market of MAN with the following specifications:i. Plant Site Location: Teluk Kalong Industrial Area, Kemaman,
Terengganuii. Capacity: 30,000 TPAiii. Production Rate: 31,375 TPAiv. Purity: 98%v. Future Worth: RM1,900,234,524vi. Pay Back Period: 6th yearvii. Energy Recovery: 100% Hot Utility, 50% Cold Utility