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MANUFACTURE OF NAPHTHALENE
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Plant Safety
Introduction
The significance of Safety & Health in chemical industries has been a vital issue
in achieving productivity and an edge in the competitive world. All applicable
laws and regulations on environmental protection or plant and industrial safety
must be fully complied with.
Compliance with all legislation to protect human beings and the environment is
one of the companys basic tenets for both legal and ethical reasons. This applies
to our products as well as to our processes.
Areas of Concern
Dangerous Materials
i)Explosives ii) Gases iii) Inflammable Liquids iv) Inflammable Solids v)
Oxidising substances vi) Toxic and Infectious substances vii)Radio Active
Substances viii)Corrosive Substances ix)Miscellaneous Dangerous Substances
Hazards Of Pressure Vessels
1.Leakage or Bursting of Pressure Vessels 2.Design defects 3.Failure of Relief
Systems 4.Lack of hydraulic testing. 5. Lack of Proper Instrumentation or
Instrumentation Failure 6.Lack of N.D.Tests 7.Corrosion of Vessels. 8. Lack of
routine inspections 9. Attempt of Pneumatic testing
Hazardous Chemical Reactions
Understanding about the behaviours of reactions and adopting precautionary and
emergency measures.
Hazards of Unit operations
Understanding the hazards inherent in each unit operation and adopting
precautionary and emergency measures
Heat Transfer Surface fouling and leakage, Miscalculation in scaling, Mixing of fl
Size Reduction Dust explosions, Dust release etc.
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Flammable Gases, Vapours And Dust Hazards
Identification of potential areas, where possibility of flammable mixtureare possible.
Efforts to avoid hazardous mixtures, by inert gas purging and othermethods.
Declaring hazard zones and providing flame proof electrical fittings andequipments.
Providing Explosion Vents in spaces with possibility of air-vapourmixtures.
Explosive meter testing. Providing adequate fire control devices. Providing arrangements to avoid static sparks. Etc.
Health Hazards
Identification of potential health hazards. Assessment of levels of physical and chemical health hazards. Control of hazards by various techniques Adequate awareness among the workers. Periodic medical examination of the workers. Personal protection for occasional exposures. Proper hygiene and decontamination facilities. etc.
Entry into Confined Spaces
1.Oxygen Deficiency 2. Toxic Contamination 3. Flammable
Environment4.Possibility of Electrocutions through electric
equipments5.Possibility of Toxic gas generation during the work 6.Lack of
Ventilation 7.Difficulty in welfare monitoring 8.Failure to escape on emergency
9.Combustible Substances
Hazards Due To Corrosion
Weakening and falling of structures and sheds. Falling of workers from height due to breaking of raised platforms, hand
rails, toe boards, stairs and ladders.
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Spills and toxic releases from pipelines due to corrosion. Leakages and bursting of vessels due to corrosion. Corrosion monitoring and control. Testing and inspection of vessels and structures to ensure safety.
Hazards Due To Instrument Failures
Absence of fail safety instruments. Lack of interlocks and trip systems. Human failures in manual and semi automatic operations. Need for safety analysis of the instrumentation systems
General Safety Rules
Smoking is not allowed in any part of the refinery area except in smokingbooths.
Use of PPE is mandatory in the plant area. Before entering deposit all the matches, lighter or any other spark
producing device.
Only DCP or CO2 extinguishers are to be used in cause of a fire aroundelectrical equipment.
Never enter work area without safety helmet. When dangerous or unsafe condition is observed report to the supervisor
or fire and safety division.
Job area should be cleaned as soon as job is completed. Always use walkways instead of shortcuts. All stairways, platforms and walkways must be kept clean at all times. Compressed air must not be used except for process and system
requirements.
Never look directly into the arc produced while welding without propereye protection.
Defective equipment of any kind should not be used. Keep the access to fire fighting equipment free of obstructions as these are
required to be used in emergencies.
Polyester or nylon clothing should not be worn while on duty as thesecreate hazards of static charge.
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Protruding nails should be pulled out or bent over. Goggles or shields must be used when working under any circumstances
when there are possible eye hazards.
All stairways, platforms and walkways must be kept clean at all times. Compressed air must not be used except for process and system
requirements.
Never look directly into the arc produced while welding without propereye protection.
Defective equipment of any kind should not be used. Keep the access to fire fighting equipment free of obstructions as these are
required to be used in emergencies.
Polyester or nylon clothing should not be worn while on duty as thesecreate hazards of static charge.
Protruding nails should be pulled out or bent over. Goggles or shields must be used when working under any circumstances
when there are possible eye hazards.
When working around moving machinery the wearing of loose clothingsuch as lunges, dhoti etc are strictly prohibited.
Vehicles of all types must be equipped with approved type of spark arrestsand muffler system before entering in the production area.
Protective valve caps must be placed on all gas cylinders except when inuse.
Do not enter into enclosed places without strictly observing the definedprecautions.
Do not touch hot pipes without wearing suitable protective clothing. Wear ear protection in areas of high noise levels.
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Safety Signs
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Plant Layout
Introduction
A plant layout study is an engineering study used to analyze different physical
configurations for an manufacturing plant. It is also known as Facilities Planning
and Layout.
A suitable site must be found for a new project, and the site and equipment layout
planned. Provision must be made for the ancillary buildings and services needed
for plant operation and for the environmentally acceptable disposal of effluent.
Plant layout refers to the arrangement of physical facilities such as machinery,
equipment, furniture etc. within the factory building in such a manner so as to
have quickest flow of material at the lowest cost and with the least amount of
handling in processing the product from the receipt of material to the shipment of
the finished product.
Factors affecting plant layout
While deciding a factory or unit or establishment or store, we should keep the
following factors in mind:
1) Location with respect to the market area.
2) Raw material supply.
3) Transport facility.
4) Availability of labour.
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.
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Cost Estimation
Estimation of total capital investment
The total investment I involves :-
Fixed investment in process area IF
Investment in auxiliary services IA
Investment in working capital IW
i.e. I = IF + IA + IW
The approximate cost of various equipments used in the proposed plant are:-
Equipment No. Cost ( Rs. Lakh)
Gas Stripper 1 360
Hear Exchanger 2 300
Reactor 1 150
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Equipment Nos. Cost (Rs. Lak
Furnace 1 120
Separator 1 200
Fractionator 1 350
Miscellaneous 1 700
Direct Cost Factors
Items Cost (Rs. Lakh)
Purchased equipment cost 250
Equipment installation 80
Insulation 60
Instrumentation 300
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Total Direct Cost = ((Equipment Cost)*(Direct Cost Factor))/100
= (3160*945)/100
= Rs. 20601 Lakh
Indirect Cost Factors
Indirect cost = ((Direct cost)*(Indirect cost factor))/100
= (20601*156)/100
= Rs. 32137.56 Lakh
Total fixed investment IF = Total direct cost + Indirect cost
= 20601 + 32137.56
= Rs. 52738.56 Lakh
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Auxiliary Investment
Items such as steam generators, fuel stations & fire protection facilities are
commonly stationed outside the process area & serve the system under
consideration.
Items % of total installed cost
Investment total fixed 100
Auxiliary building 5
Water supply 2
Electric main substation 1.5
Process waste system 1
Raw material storage 1
Fire protection 0.7
Roads 0.5
Sanitary & waste disposal 0.2
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Auxiliary cost (IA) = ((Total fixed investment)*(Auxiliary cost factor))/100
= (52738.56*112.3)/100
= Rs. 59225.4 Lakh
Total installed cost = Total fixed investment + Auxiliary cost
= 52738.56+59225.4
= Rs. 111963.96 Lakh
Working Capital
This is the capital fixed up in the interest of the system in the form of ready cash
to meet operating expenses, inventories of raw materials & the products. The
working capital may conveniently be assumed as 15% of total investment made
in plant.
Working capital =111963.96*15/100
= Rs. 16794.59 Lakh
Total capital investment = Total installed Cost + Working capital
= Rs. 128758.55 Lakh
Estimation of manufacturing cost
The manufacturing cost can be divided into three items
a) Proportional to total investmentb) Anticipated production ratec) Labor requirement
Proportional to total investment
This includes the factors which are independent of the production rate &
proportional to the fixed investments such as :-
Maintenance Property tax Insurance Safety expense General services Administrative services
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This can be taken as 15% per year of total installed cost
i.e. 52738.56*15/100
= Rs. 7910.784 Lakh
Anticipated production rate
The factors proportional to production rate are :-
Raw material cost Utilities cost Maintenance cost Chemical, warehouse and shipping
Assuming that the cost proportional to production rate is nearly 60% of the total
capital investment.
i.e. 128758.55*60/100
= Rs. 77255.13 Lakh
Labor Requirement
The manufacturing cost proportional to labor might amount to 10% of total
manufacturing cost.
i.e. (7910.784+ 77255.13)*10/100
= Rs. 8516.59 Lakh
Total Manufacturing cost = 7910.78 + 77255.13 + 8516.59
= Rs. 93682.5Lakh
Sale price fixation
Rs. 80/Kg.
Profitability analysis
Total sales income = 80*2000
= Rs. 160000 Lakh
Depreciation
Using sinking fund method.
R = (V-Vs)(i/((1+i)^n-1))
R = Uniform annual payment at the end of each year
V = Installed cost of plant
Vs = Salvage value of plant after n years
n = Life period (Assumed to be 15 years)
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i = Annual interest rate (taken as 15%)
R = (11963.96-0)(0.15/((1+0.15)^15-1))
= 162296.39*0.021
= Rs. 251.24 Lakh
Gross profit
Gross profit = Net income from annual salesAnnual manufacturing cost
= 16000093682.5
= Rs. 66317.5 Lakh
Net profit rate
It is defined as the expected annual return on investment after deducting
depreciation and taxes. Tax rate is assumed to be 40%
Net Profit = Gross profitDepreciation(Gross Profit*Tax rate)
= 66317.5251.24(66317.5*40/100)
= 20795.119681.33
= Rs. 39539.26 Lakh
Annual rate of return
Annual percent return on the total initial investment after income taxes = (Net
profit/Total installed cost)*100
= (39539.26/111963.96)*100
= 35.31%
Payout period
Payout period = Total installed cost/(Depreciation + Net profit)
= 111963.96/(251.24 + 39539.26)
= 2.813 years
References
Plant Design and Economics for Chemical Engineers
Author: Max Peters, Klaus Timmerhaus, Ronald West