Preliminary Report Completed

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KKEK4281 DESIGN PROJECT
SEMESTER 1, SESSION 2015/2016
FEASIBILITY REPORT
G6 Synthesis of Highly Reactive Polyisobutylene (HR-PIB) Using BF
3
/methanol-alumina Catalyst System in Fixed Bed Reactor
Group Facilitator
Prof. Dr. Wan Mohd Ashri Bin Wan Daud
Group Members
How Seow Wah KEK120011 Ahmad Farid Bin Yahaya KEK120002 Khor Suet Fenn KEK120016  Nurshafikah Binti Abdul Rahim KEK110043 Aravend A/L Kumaresan KEK120004
 Submission Date
29 October 2015
 
 
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Acknowledgement
Hereby, our group would like to express our highest gratitude to everyone who has provided us guidance and supervisions throughout the composure of this feasibility report.
 
Prof. Dr. Wan Mohd Ashri WAN DAUD
(Group Facilitator)
 
Thank you for your guidance and advices on the progress of our group on weekly basis, we are really grateful for your assistance in answering our doubts so far.
 
Dr. Nur Awanis HASHIM / Professor Ir. Dr. Mohd Azlan HUSSAIN
(Course Coordinators)
 
We are thankful for your relentless effort in coordinating the project and groups to ensure all the groups are on the right track. Special thanks for arranging various industrial talks to widen our horizon in chemical industries.
 
Friends and family members
Our heartfelt gratitude to all of our friends and family members for their mental support and assistance, especially to all of our course mates for your encouragements despite being in different groups.
 
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Table of Contents No. Items Page
Acknowledgement i Table of Contents ii List of Figures and Tables iii 1.0 Identification of Raw Materials and Products 1.1
 
Brief Introduction of Highly Reactive Polyisobutylene (HR-PIB) 1.2
 
Raw Materials Considered 1.2.1
 
Isobutane 1.2.2
 
C
4
-Raffinate 1.2.3
 
Pure Isobutylene 1 1 1 1 1 1 2.0 Identification of Process Routes 2.1 Cationic Polymerization 2.2 Selection of Raw Material 2.3 Selection of Catalyst 2.4 Selection of Reactor 2 2 2 2 3 3.0 Market Survey 3.1 Latest Industrial Development 3.2 Demand of HR-PIB 3.3 Applications 3.4 Capacity 4 4 4 4 4 4.0 Preliminary Economic Analysis 4.1 Capital Cost 4.2 Production Cost 4.3 Estimated of Generated Revenue 4.4 Cash Flow Analysis 4.5 Payback Period and ROI 5 5 5 5 6 6 5.0 Location 5.1 The Plant Location Survey 7 7 6.0 Safety Considerations 6.1 Location 6.2 Raw Material (Isobutylene) 6.3 Processes 6.4 Product (HR-PIB) 6.5 Hazard Mitigation Methods 8 8 8 8 8 9 7.0 Environmental Considerations 9 8.0 Novelty 10 9.0 References R1 Appendix A1
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List of Figures and Tables Items Page
 Figure 1: The scores for each location based on the 11 criteria
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 Figure A1: Cationic polymerization of isobutylene
 A1
 Figure A2: The cash flow analysis in 20 years with and without interest 
 A8
 Figure A3: Preliminary process flow diagram (PFD) of the proposed HR-PIB plant with operating parameters of major equipment 
 A12
Table 1: Countries with major HR-PIB producers
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Table 2: Comparison of cumulative cash flow with and without interest rate
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Table 3: Summary of economic feasibility study of HR-PIB plant 
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Table A1: Comparison between raw materials
A2
Table A2: Comparison between catalysts
A3
Table A3: Comparison between loop reactor and fixed bed reactor
A4
Table A4: Inside battery-limits (ISBL) equipment (inclusive of delivery cost)
A5
Table A5: Total Fixed Capital Investment Preliminary Estimation (Peters and Timmerhaus Method)
A5
Table A6: Consumables and utilities
A6
Table A7: Total estimation of production cost
A6
Table A8: Estimated Annual Revenue
A7
Table A9: Cash flow analysis with cumulative for with and without interest rate
A7
Table A10: Comparison of three candidate locations with the assessing criteria
A9
Table A11: Preliminary mass balance of the proposed HR-PIB plant at 50 kMT (equivalent to 6315 kg/h)
A11
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