2019 Plant Design and Economics-Phthalic Anhydride Design Report (Very Good PFD)

CPE604
PLANT DESIGN AND ECONOMICS
SHINKA SDN BHD

PRODUCTION OF PHTHALIC ANHYDRIDE
Lecturer
AMMAR BIN MOHD AKHIR
Team Members
Muhammad Qayyum bin Shahimi (2019653646)
Nabilah Huda binti Hasmalsah (2019801684)
Hanis Syazana binti Khairil Azli (2019630676)
Nurin Syafiqah binti Abdul Tahir (2019602032)
Syazwani binti Mohd Joneidi (2019695424)
Nurul Aqilah Fakhira Binti Mohd Zukri (2019814692)
Nurulsyazwani binti Erizon (2019461876)
Syazana binti Mahiyud-din (2019455318)
EH2205I
Table of Contents
Page
1.0 PROCESS BACKGROUND & SELECTION 4
1.1 History & General Information of Phthalic Anhydride 5

1.1.1 Phthalic Anhydride 5
1.2 Process Selection 6
1.2.1 Production of Phthalic Anhydride using Partial Oxidation Process 8
1.2.2 Production of Phthalic Anhydride using Thermal Dehydration Process 10
1.2.3 Production of Phthalic Anhydride using Bio-renewable Process 11
1.3 Process Flow Diagram & Parameter Table 12
1.3.1 Partial Oxidation Process 12
1.3.2 Thermal Dehydration Process 13
1.3.3 Bio-renewable Process 14
1.4 Profit Margin 16
1.4.1 Profit Margin for Partial Oxidation Process from O-xylene 16
1.4.2 Profit Margin for Thermal Dehydration Process from Phthalic Acid 17
1.4.3 Profit Margin for Bio-renewable Process from Corn Stover 18
2.0 SITE SELECTION 20
2.1 Tanjung Langsat Industrial Complex, Johor 22

2.1.1 Land Estimation and Topography 22
2.1.2 Resource Availability (Energy and Water Supply) 23
2.1.3 Transportation Facilities 24
2.1.4 Waste Disposal Management 24
2.1.5 Market Accessibility 25
2.1.6 Labour Supply 25
2.2 Kerteh Industrial Estate, Terengganu 26
2.2.1 Land Estimation and Topography 26
2.2.3 Transportation Facilities 27
2.3 Gebeng Industrial Estate, Pahang 30
2.3.1 Land estimation and topography 30
2.3.3 Transportation facilities 32
3.0 MARKET ANALYSIS 36
3.1 Market of Raw Material and Product 37

3.1.1 Market of O-xylene 37
i
3.1.2 Market of Phthalic Anhydride 38
3.2 Supply of Raw Material and Product 40
3.2.1 Supply of O-xylene 40
3.2.2 Supply of Phthalic Anhydride 41
3.3 Demand of Raw Material and Product 42
3.3.1 Demand of O-xylene 42
3.3.2 Demand of Phthalic Anhydride 43
4.0 MASS BALANCE 45
4.1 Process Flow Diagram 45

4.2 Stream Table 46
4.3 Reactor (R-701) 47
4.4 Switch Condenser 54
4.5 Distillation Column 58
4.5.1 Distillation Column 1 58
4.6 Overall Mass Balance 62
4.7 Overall Conversion 64
4.7.1 O-xylene 64
4.7.2 Air (O2 and N2) 65
5.0 ENERGY BALANCE 66
5.1 Reactor (R-701) 67

5.2 Switch Condenser 75
5.3 Distillation Column 81
5.4 Heat Exchanger 86
5.4.1 Air Furnace 86
5.4.2 O-xylene Pre-Heater 89
5.5 Pump 92
5.6 Compressor 93
6.0 EQUIPMENT DESIGN 94
6.1 Heuristic of Equipment 95

6.1.1 Heuristic for Reactor (R-701) 95
6.1.2 Heuristic for Switch Condenser (SC-701) 98
6.1.3 Heuristic for Distillation Column 1 (T-701) 98
6.1.4 Heuristic for Distillation Column 2 (T-702) 104
6.1.5 Heuristic for Air Furnace (H-701) 108
6.2.1 Heuristic for o-Xylene Pre-Heater (E-701) 110
ii
7.0 ECONOMIC ANALYSIS 113
7.1 Cost of Equipment 114

7.1.1 Cost of Reactor (R-701) 114
7.1.2 Cost of Switch Condenser (SC-701) 115
7.1.3 Cost of Distillation Column 1 (T-701) 116
7.1.4 Cost of Distillation Column 2 (T-702) 118
7.1.5 Cost of Air Furnace (H-701) 120
7.1.6 Cost of Pre-Heater (E-701) 122
7.2 Summary of Bare Module of Equipment Cost 124
7.3 Total Module Cost and Fixed Capital Investment (FCI) 124
7.4 Cost of Raw Material 125
7.5 Cost of Operating Labour 126
7.6 Cost of Utility 127
7.7 Cost of Manufacturing 132
7.7.1 Estimating Manufacturing Cost 132
7.7.2 Direct Manufacturing Cost 132
7.7.3 Fixed Manufacturing Cost 133
7.7.4 General Manufacturing Cost 133
7.7.5 Overall Manufacturing Cost 134
7.7.6 Working Capital 134
8.0 PROFITABILITY ANALYSIS 135
8.1 Summary of Cost of Manufacturing 136

8.2 Cash Flow Analysis 138
9.0 REREFENCES 141
10.0 APPENDIX 143
iii
1.0 PROCESS
BACKGROUND AND
SELECTION
4
1.0 PROCESS BACKGROUND & SELECTION
1.1 History & General Information of Phthalic Anhydride

1.1.1 Phthalic Anhydride
Phthalic anhydride is the natural compound with chemical formula of C6H4(CO)2O or also
C8H4O3. Phthalic anhydride appears as a colourless to white lustrous solid in the form of
needles with a mild distinctive odour. It is the anhydride of phthalic corrosive. Phthalic
anhydride is a key business type of phthalic corrosive. It was the principal anhydride of a
dicarboxylic corrosive to be utilized monetarily. In 2000, the overall creation volume was
assessed to be around 3 million tons for each year.
Truly, phthalic anhydride was first delivered by the oxidation of naphthalene in

amassed sulphuric corrosive within the sight of mercury sulphate. This course was later
supplanted by the synergist fume stage oxidation of naphthalene in air within the sight of a
vanadium oxide impetus. Naphthalene as feedstock of phthalic anhydride creation has slowly
been supplanted by o-xylene all through the previous 50 years. In America, about 55% of the
0.9 billion pounds for each time of phthalic anhydride creation is gotten by oxidizing o-xylene
because of the way that o-xylene speaks to less expensive crude material and on a weight
premise yields to some degree more item (about 1.0 lb of phthalic anhydride/1.0 lb of xylene
versus 0.97 lb phthalic anhydride/1.0 lb of naphthalene), it is normal that all future plants will
be intended to utilize xylene feed.
Sadly, phthalic anhydride adds to negative impacts towards Mother’s Earth. The
phthalic anhydride industry has been concentrated to decide the degree of air contamination
coming about because of the tasks of different plants and cycle industries. The primary goal of
this examination being led is to furnish the Environmental Protection Agency with a segment
of the fundamental information needed so as to arrive at a choice on the need to declare air
emanation norms for the business.
5
1.2 Process Selection
Table 1.1. Summary of the processes available to produce Phthalic Anhydride.
Processes
Criteria Thermal
Oxidation Bio-renewable
Dehydration
- 245 - 400
Temperature
- 340 - 385
Operated 180 - 275 48 - 319.85
- 360 - 390
(°C)
- 330 - 480
101.325 kPa down to
5.3329 kPa
Pressure
(preferably in the
Operated 100 - 300 101.325 - 770.07
range of from 33.3306
(kPa)
kPa down to 9.99918
kPa)
- Oxygen - Corn stover
Raw Material - O-xylene/ Ortho- Phthalic acid - Sulphuric Acid
xylene - Ammonia
Raw Material All over Peninsular
Imported from China Imported from China
Availability Malaysia
- Vanadium Oxide
promoted with
- Vanadium oxide
alumina
accompanied by
- Vanadyl
Catalyst titanium oxide No catalyst required
acetylacetonate
- Vanadia-titania
- Pd-Li alumina
pellets or rings.
promoted with
cesium carbonate.
94% - 96% yields
Amount of 20,000 to 80,000 (obtained from 50,000 to 62,000
Yields tonnes/year recovery process of tonnes/year
partial oxidation)
Profit Margin $ 7 602.21 $ 5 006.45 $ 10 941.44
6
Table 1.2. Table of scores for the scoring method to choose the process.
Score
Selection
criteria Thermal
Partial Oxidation Bio-renewable
Dehydration
Temperature
Operated (°C) 2 3 2
Pressure
3 2 1
Operated (kPa)
Raw Material 4 2 3
Raw Material
Availability 3 2 4
Catalyst 2 4 2
Amount of
4 3 3
Yields
Profit Margin 3 2 4
Total score 21 168 19

*1: very bad, 2: bad, 3: moderate, 4: good, 5: excellent
7
1.2.1 Production of Phthalic Anhydride using Partial Oxidation Process
Typically, phthalic anhydride commonly being synthesized by using oxygenation process.

However, the feedstock in producing phthalic anhydride may be varied. The most common
feedstock used in current production phthalic anhydride is o-xylene. Traditionally, naphthalene
was used by the industry in order to produce phthalic anhydride but as time went by, most
petrochemical industries decided to choose ortho-xylene as feedstock in manufactured phthalic
anhydride. Since o-xylene is a cheaper raw material and produces far more goods on a weight
basis (about 1.0 lb. PAN/lb. xylene versus 0.97 lb. PAN/lb. naphthalene, it is predicted that o-
xylene feed will be used in all future plants.
The process begins in streamline 1 whereby air (mainly oxygen) being compressed to
a centrifugal compressor with a pressure of 220 kPa and being preheated in a heater at
temperature 245°C using a high steam heat exchanger. O-xylene in streamline 2 with 99%
purity being heated in heat exchanger at temperature of 144°C- 245°C. The oxygen and o-
xylene from streamline 5 and 6 meet and enter a packed bed reactor where reaction takes place.
The inlet temperature of the reactor is 245°C at 200 kPa. The following in Figure 1.1, it shows
the reactions that take place inside the packed bed reactor.
Figure 1.1. The reactions that take place inside the packed bed reactor.
8
Ortho-xylene or also known as o-xylene reacts with oxygen under the oxidation process
to produce phthalic anhydride. Besides direct oxidation of o-xylene and oxygen, there's a side
reaction involved in this process whereby o-xylene and oxygen react together to form maleic
anhydride and water as by-product alongside carbon dioxide gas. These various by-products
later needed to be separated from the main product in order to achieve high purity of phthalic
anhydride. The reactor is supplied with a catalyst known as vanadium oxide alongside titanium-
oxide as a promoter. A molten salt is used to remove generated heat and fed to a steam
generator, where high pressure steam is produced and utilized in the plant. The temperature
effluent of reactor is 353°C with outlet pressure of 130 kPa which the proposed temperature is
slightly higher because it is said to be optimum temperature in producing more phthalic
anhydride in this process.
The product gas stream is cooled downstream of the reactor in several steps and finally
guided via switch condensers. The switch condensers are specially designed heat exchangers,
which can be heated or cooled, constructed as finned tube packages. In achieving high overall
PA yields, this is the next critical unit process as its complete sublimation from the commodity
stream is obtained only in optimised systems. The temperature of yields brought down to 140
at pressure of 100 kPa. Some of the unreacted oxygen may be recycled from streamline 12 until
streamline 3. The air waste produced (carbon dioxide) later being brought to air waste
streamline for further treatment in a scrubber before it being released. However, phthalic
anhydride still consists of other by products such as maleic anhydride and water during
occurrence reactions in the reactor. Hence, it needs to be separated using a distillation column.
The first continuous distillation column is used to separate maleic anhydride from
phthalic anhydride. It is expected that maleic anhydride will be a top product and the heavy
products will flow down as a bottom product. The first continuous distillation column is
suggested to operate at temperature of 230°C and pressure of 100 kPa. Since there’s still
impurities existing from phthalic anhydride such as water, unreacted o-xylene and unreacted
maleic anhydride, therefore there’s dire need to introduce a second continuous distillation
column as another separator equipment in this process. The expected product that may be
produced at the overhead should be 99% purity of phthalic anhydride and the bottom product
should be heavy impurities that later will be treated as waste of this process. The operating
temperature for the second continuous distillation column is 295°C at pressure of 50 kPa.
According to literature review, the production of phthalic anhydride may be achieved around
20,000 to 80,000 tonnes/year.
9
1.2.2 Production of Phthalic Anhydride using Thermal Dehydration Process
Another way to synthesize phthalic anhydride is by using thermal dehydration process.

Thermal dehydration or thermal drying can be defined as a method for dehydration of moist
products based on the evaporation of moisture by heating (Neikov, 2019). This process is
generally the continuation of the previously mentioned process but taking only the pre-
treatment parts.
In this process, the required raw material is phthalic acid. The raw material will be
bought instead of producing itself as it will be more cost saving. Thus, the production of the
feedstock requires another operation unit which will affect the maintenance cost. There are
several companies that produce phthalic acids as feedstock. However, there are no local
companies that produce this acid on a large scale. Therefore, the raw material has to be
imported to produce phthalic anhydride. These are the major phthalic acid feedstock producers
worldwide especially South east Asia.
• BASF SE • UPC Technology Corporation
• Sandung Qilu • Guandong Chunda Chemical Industry
• KLJ Group • Evonik Industries AG
• ExxonMobil Chemical • LG Chem
• Aekyung petrochemical
Figure 1.2. Market share of Phthalic acid by Region from 2018 to 2027 (source: Reports and Data).
10
Phthalic acid comprises the oxidation of naphthalene to phthalic anhydride. Phthalic
acids are commonly used for the manufacturing of plastics products. However, the demand of
this chemical is very low in North America and Europe. Figure 1.2 shows the market share of
phthalic acid from 2018 to 2027. Based on this figure, North America and Europe are
forecasted to have a slight increment in 2021 and 2027. On the other hand, Asia Pacific has the
largest market share which dominates the packaging in the food and beverage sector and textile
industries in India and China.
1.2.3 Production of Phthalic Anhydride using Bio-renewable Process
Phthalic anhydride is usually produced using coal-tar naphthalene oxidation process. It was
obtained from o-xylene which can be separated from mixtures of xylenes that contain roughly
one third o-xylene and two thirds p-xylene. The manufacturing costs of the feedstocks are
necessarily linked to fossil price fluctuation. In order to maintain, a renewable process is highly
encouraged as a step towards bio-based production. The development of chemicals
manufactured from renewables (i.e. bio-based chemicals) has been receiving an increasing
interest not only due to environmental policies (at both national and international levels) but
also due to initiatives of private companies (like Cargill and BASF) (Golden & Handeld, 2014).
In contrast to environmentally unfriendly petroleum starting materials, bio-renewable

platforms are made of materials derived from living things like plants, algae, microbes, and
animals in general term called biomass. According to lead scientist professor Hal Alper, from
the McKetta Department of Chemical Engineering, biorenewables give a ‘greener label to
products as well as a cleaner and more precise conversion that is enantiomerically pure’.
The main raw material required in such a process is corn stover. Firstly, the biomass is
treated with a co-current dilute-acid pretreatment to make the hemicellulose sugars and the
cellulose available for subsequent reactions. Ammonia-based conditioning is used for the
hydrolyzate pH neutralisation (Sara & Charles, 2015). The availability of the raw material
especially corn stover can be purchased from all over peninsular Malaysia because corn is a
common crop to be harvested. After its cobs have been harvested, the stover still remains a
good source of nutrients for the process.
11
1.3 Process Flow Diagram & Parameter Table
In this section, for each of the processes, the Process Flow Diagram (PFD) and the parameter
table which consists of temperature and pressure are explained.
1.3.1 Partial Oxidation Process
Figure 1.3. A process flow diagram of the Oxidation process to produce Phthalic Anhydride.
Table 1.3. The equipment used in the Oxidation process to produce Phthalic Anhydride.
No. Equipment Tagging Code Temperature Operated (oC) Pressure Operated (kPa)
1. Centrifugal Compressor C-701 25 220
2. Air Heater H-701 25-245 220
3. Heat Exchanger E-701 25-245 290
4. Packed Bed Reactor R-701 245-353 200-130
5. Switch Condenser SC-701 140 100
6. Distillation Column 1 T-701 230 100
7. Distillation Column 2 T-702 295 50
12
1.3.2 Thermal Dehydration Process
Figure 1.4. Thermal Dehydration Process Flow Diagram.
Table 1.4. Summary of the process descriptions.
Temperature Pressure
Equipment Description
Operated (°C) Operated (kPa)
Rapid dehydration of phthalic acid to its
Pre-treatment 200 – 230 27.9977 – 30.6641
anhydride.
Stripper Methyl benzoate is used to remove water
215 19.9984
Column vapour from the mixture.
Removal of phthalide, benzoic acid, o-
Refining
toluic acid, 2-carboxybenzaldehyde, 220 – 275 13.17225
Column
bromine.
13
1.3.3 Bio-renewable Process
Figure 1.5. The process flow diagram of the production of Phthalic Anhydride from corn stover.
Table 1.5. The summary of the process on the selected reaction region in the system.
Operating Operating
Equipment Temperature Pressure Chemical equation involved
(℃) (atm)
Steam
M1 100 7 Cellulose → Cellulose
Pretreatment Process:
H2 SO4
M2 158 5.7
Cellulose + H2 O → Glucose + Xylan
H2 SO4
Xylan + H2 O → Xylose
Neutralization process:
M3 77.1 5.7
H2 SO4 + 2NH3 → (NH4 + )2 SO4 2−
Reacidification process:
M4 77.4 3.4
H2 SO4 + 2NH3 → (NH4 + )2 SO4 2−
H2 SO4
R1 168.5 7.6 Xylose → Furfural + 3H2 O
Oxidation process:
Furfural + 0.5O2 → Furan + CO2
Furan + 0.5O2 → Furanone
R2 319.85 1.1 Furanone + O2 → MA + H2 O
MA= Maleic Acid
Catalyst used is Vanadium Oxide promoted with alumina
(VOx /Al2 O3 )
Vapor-phase decarbonylation:
Furfural + O2 → Furan + CO
Furfural + H2 → Furfuryl alcohol
R3 310 1 Furan + 2H2 → THF
Catalyst used is Pd-Li alumina promoted with cesium
carbonate.
THF= tetrahydrofuran
14
Saccharification process:
R4 48 1
Cellulose + H2 O → Glucose
Isomerisation process:
R5 60 1
Glucose → Fructose
Fructose → HMF + 3H2 O
R6 179.85 1
MIBK as extractive agent
Oxidation process:
HMF + 2O2 → MA + 2CH2 O2
R7 90 1
HMF + 3O2 → MAc + 2CO2 + H2 O
Catalyst used Vanadyl acetylacetonate, VO(acc)2
Furan + MA → PA + H2 O
R8 25 1.5
PA + H2 O → PAc
Table 1.6. The summary of the process on the separation system.
Recovery Separation Temperature operating (overhead Pressure operating

system system bottom) (℃) (atm)
T1 97.63, 101.4 1
Recovery T2 99.63, 161.35 1
T3 100.04, 101.03 1.04
SC1 25.14, 31.02 1
T4 96.56, 128.98 2.04
Recovery 1
T5 38.94, 51.68 0.23
T6 122.95, 130.31 4.08
SC2 26.77, 44.55 1
Recovery 2
T7 75.52, 142.55 3.8
E1 24.85, 24.85 1
E2 15, 15 1.3
Recovery 3 E3 25, 25 1
T8 76.24, 181.7 0.08
T9 137.10, 143.94 0.013
T10 13.10, 71.10 0.008
T11 76.74, 146.52 0.01
Recovery 4
T12 139.52, 179.75 6.5
T13 41.69, 56.33 0.1
Where,
M: Mixer, R: reactor, T= Tower, SC= Scrubber, E= Extractor.
15
1.4 Profit Margin
In order to calculate the profit margin, the prices of each raw material from each process must
be determined first. The sale price of the product which is Phthalic Anhydride must also be
determined. The prices are as follow:
Table 1.7. The summary prices of the raw materials and product in each of the process.
Name Price ($/tonne)

Oxidation Thermal Dehydration Bio-renewable
Raw Materials
O-xylene $ 682.90 - -
Phthalic Acid - $ 592.60 -
Corn stover - - $ 50.00
H2SO4 - - $ 150.00
NH3 - - $ 300.00
Product
Phthalic Anhydride $ 1,002.83
1.4.1 Profit Margin for Partial Oxidation Process from O-xylene
From gas-phase catalytic oxidation process in producing phthalic anhydride, the following
prices for raw material and product are found to be:
Molecular weight (MW):

O-Xylene = 106.16 kg/kmol Phthalic Anhydride = 148.10 kg/kmol
By using 100 kmol of O-Xylene as a feed basis,

Cost of Raw Material = Feed basis × Molecular Weight × Cost of material per tonne
𝑘𝑔 $ 682.90 1 𝑡𝑜𝑛𝑛𝑒
Cost of O-Xylene = 100 kmol (106.16𝑘𝑚𝑜𝑙)( )(1000 𝑘𝑔)
𝑡𝑜𝑛𝑛𝑒
= $ 7,249.69
Cost of Product = Feed basis × Molecular Weight × Cost of product per tonne
𝑘𝑔 $ 1 002.83 1 𝑡𝑜𝑛𝑛𝑒
Cost of PA = 100 kmol (148.10𝑘𝑚𝑜𝑙) ( ) (1000 𝑘𝑔)
= $ 14,851.90
Profit Margin = Total Cost of Product - Total Cost of Raw Material

= $ 14,851.90 - $ 7,249.69
= $ 7,602.21
16
1.4.2 Profit Margin for Thermal Dehydration Process from Phthalic Acid
From liquid-phase thermal dehydration process in producing phthalic anhydride, the following
prices for raw material and product are found to be:
Molecular weight (MW):

Phthalic Acid = 166.14 kg/kmol Phthalic Anhydride = 148.10 kg/kmol
By using 100 kmol of Phthalic Acid as feed basis,
Cost of Raw Material = Feed basis × Molecular Weight × Cost of material per tonne
𝑘𝑔 $ 592.60 1 𝑡𝑜𝑛𝑛𝑒
Cost of Phthalic Acid =100𝑘𝑚𝑜𝑙 (166.14 𝑘𝑚𝑜𝑙) ( ) (1000 𝑘𝑔)
= $ 9 845.46
Cost of Product = Feed basis × Molecular Weight × Cost of product per tonne
𝑘𝑔 $ 1002.83 1 𝑡𝑜𝑛𝑛𝑒
Cost of PA = 100𝑘𝑚𝑜𝑙 (148.10 𝑘𝑚𝑜𝑙) ( ) (1000 𝑘𝑔)
= $ 14 767.62

= $ 14 767.62 - $ 9 845.46
= $ 5 006.45
17
1.4.3 Profit Margin for Bio-renewable Process from Corn Stover
Based on the article written by Sara Giarola (2015), a bio-renewable process can be done using
corn stover as the main raw material. Two other raw materials are used as pre-treatment which
are Sulphuric Acid, H2SO4 and Ammonia, NH3. The cost for the corn stover is based on the
paper by Edwards W. et al. (2015). As for the other two materials and the product, the prices
are based on the current market value on Alibaba website.
In order to calculate the cost of biomass per feed as a basis, the mass composition must be
determined. Table 1.7 is based on the article by Sara Giarola (2015).
Table 1.8. The mass composition of the biomass.
Molecular weight
Component Mass fraction (dry basis)
(kg/kmol)
cellulose 0.3895 162.1406
galactan 0.0159 1182.00
mannan 0.0069 666.60
xylan 0.2831 166.13
arabinan 0.0476 500.50
lignin 0.1346 1513.60
acetate 0.0635 59.04
protein 0.01 22.00
ash 0.0489 75.9296
By using 100 kmol of biomass (corn stover) as a feed basis, the total cost of raw
materials and product can then be determined.
Cost of biomass = [(100 × 0.3895) kmol × 162.1406 kg/kmol × $ 50/tonne ×

1 tonne/1000 kg] +
[(100 × 0.0159) kmol × 1182.00 kg/kmol × $ 50/tonne ×
1 tonne/100 kg] +
1 tonne/1000 kg] +
1 tonne/1000 kg] +
1 tonne/1000 kg] +
18
1 tonne/1000 kg] +
1 tonne/1000 kg] +
[(100 × 0.01) kmol × 22.00 kg/kmol × $ 50/tonne × 1 tonne/1000 kg] +
1 tonne/1000 kg]
= $ 315.77 + $ 93.97 + $ 23.00 + $ 235.16 + $ 119.12 + $ 1018.65 +
$ 18.75 + $ 1.10 + $ 18.56
= $ 1844.08
Cost of H2SO4 = 100 kmol × 98.079 kg/kmol × $ 150/tonne × 1 tonne/1000 kg

= $ 1471.19
Cost of NH3 = 100 kmol × 17.031 kg/kmol × $ 300/tonne × 1 tonne/1000 kg

= $ 510.93
Cost of raw material = Cost of Biomass + Cost of H2SO4 cost + Cost of NH3
= $ 1844.08 + $ 1471.19 + $ 510.93
= $ 3826.2
Cost of product = 100 kmol × 148.10 kg/kmol × $ 1002.83/tonne × 1 tonne/1000 kg
= $ 14 851.91
After calculating both values of raw material and product, then the profit margin can be
calculated.

= $ 14 851.91 - $ 3 826.2
= $ 11 025.71
19
2.0 SITE
SELECTION
20
2.0 SITE SELECTION
Below is the scoring table which is used in determining the best location for the plant using the
scoring method.
Table 2.1. The scoring method for each site location.
Score
Selection criteria Tanjung Langsat Kerteh Industrial Gebeng Industrial

Industrial Complex Estate Estate
Land estimation
4 3 4
and topography
Raw material
2 2 2
availability
Resource
availability (energy 3 3 3
and water supply)
Transportation
4 3 5
facilities
Waste disposal
4 4 4
management
Market accessibility 3 2 4
Environmental
impact (gas 3 3 3
emission)
Labor supply 3 3 3
Total score 26 23 28
*1: very bad, 2: bad, 3: moderate, 4: good, 5: excellent
As for these two criteria in choosing the best location of the plant, they are the same for
all three locations. The two criteria are environmental impact (gas emission) and raw material
availability.
21
Environmental Impact (Gas Emission)
The phthalic anhydride plant produces wastes in gas form which is mainly carbon dioxide,
However, the gas waste ought to be disposed of in a safe manner to avoid any air pollution.
Therefore, for the controlled waste, the company itself will deal with the waste or effluent
earlier than it can be disposed of in the atmosphere by installing an air scrubber to filter the air.
Therefore, this criterion does not differ in any location of the plant.
Raw Material Availability
The company uses o-xylene and air supply as raw material in phthalic anhydride production.
O-xylene material is shipped from China while air supply is provided by GAS Malaysia Berhad
and is available around Peninsular of Malaysia. Therefore, this criterion is the same for all three
locations.
2.1 Tanjung Langsat Industrial Complex, Johor

2.1.1 Land Estimation and Topography
Tanjung Langsat Industrial Complex (TLIC) is located just beside Pasir Gudang Industrial Park
and is specifically designated for heavy industries. TLIC spans a total area of 4,835 acres and
is the newer modern and integrated industrial park fully equipped with 6 business enablers:
Free Commercial Zone (FCZ), warehouses and marine supply base, Palm Oil Industrial Cluster
(POIC), Johor Skills Development Centre (PUSPATRI), centralised worker’s hostel and port
facilities of Tanjung Langsat Port Terminal (TLPT).
As for the topography, the physical area of TLIC is mainly flat surfaces and near to a
port which is TLPT. This shows that to build a plant in this area, there will be no extra cost for
high terrain. Hence, this location satisfies the consideration for a flat area.
22
Figure 2.1. An aerial view of the Tanjung Langsat Industrial Complex.
2.1.2 Resource Availability (Energy and Water Supply)
The utilities such as electricity and water supply at TLIC are available and are expected to be
sufficient for a big plant. Near TLIC, there is YTL Sultan Iskandar Power Plant at Pasir Gudang
which can be the source of power supply for the plant. It is said that the power plant had a
capacity of 390 MW. Tenaga Nasional Berhad (TNB) is a joint company with YTL, hence the
electricity tariff is the same as in other Malaysia states. The rates can be seen in the table below.
Table 2.2. The electricity tariff rates by TNB.

Tariff Category Rates (RM/kW)
Tariff D (Low Voltage
Industrial Tariff)
For all kWh
0.29
The minimum monthly charge
is RM7.20
Tariff E1 (Medium Voltage For each kilowatt of maximum demand per
19.50
General Industrial Tariff) month
The minimum monthly charge For all kWh 0.222

is RM600.00
24.40
For each kilowatt of maximum demand
Tariff E2 (Medium Voltage
per month during the peak period
Peak/Off-Peak Industrial Tariff)
For all kWh during the peak period 0.234
The minimum monthly charge
is RM600.00
For all kWh during the off-peak period 0.144
23
As Tanjung Langsat Port (TLP) is one of the facilities provided in TLIC, the plant can
obtain water supply easily from TLP Terminal Sdn Bhd. It is a facility to supply fresh water to
vessels and via pipeline as well. The supply of fresh water is RM 9.50 per metric ton or part
thereof as stated in Johor Port tariffs and rates.
2.1.3 Transportation Facilities
TLP is a part of TLIC which it can provide the transportation facilities the plant needs. It also
provides oil, gas & energy initiatives under Tanjung Langsat Petroleum Terminal - Storage and
Trading of Petroleum Products and Tanjung Langsat Petroleum Support Service Hub-Logistic
service provider for offshore petroleum's exploration and production activities. Hence,
equipment and chemicals imported from overseas can be accessed easily as TLP is very near
to TLIC. Apart from that, TLIC has easy access to these highways which are Senai-Desaru
Highway, Tanjung Langsat Highway, Pasir Gudang Highway and Eastern Dispersal Link
Expressway, thus anything that the plant produces can be allocated nationally.
2.1.4 Waste Disposal Management
Around Pasir Gudang, Johor, there is one Recycling and Recovery facility which is named
CHEMALAYA Sdn Bhd. The company is a scheduled waste solutions provider dealing with
Scheduled Wastes, all kinds of ferrous wastes, non-ferrous metal wastes, and industrial wastes.
Hence, as for the waste disposal especially wastewater treatment plant sludge, there is a facility
which can take care of that. The table below shows the examples of scheduled waste which the
company accepts.
Table 2.3. Examples of scheduled waste that CHEMALAYA Sdn Bhd handles.
Waste code Name of scheduled waste

SW 110 Stamping Metal with Coating
SW 204 Wastewater Treatment Plant Sludge
SW 305 Spent Lubricant Oil
SW 306 Spent Hydraulic Oil
24
2.1.5 Market Accessibility
As to access the markets in both TLIC and nationally, the plant must be very useful in supplying
Phthalic Anhydride as the raw material or as the intermediate for the end product. Dyes,
plasticisers, and resins are made from ortho-xylene which Phthalic Anhydride is a significant
application of ortho-xylene. It is used to manufacture plasticizers that are mainly used in the
construction of industrial and automotive industries. Hence, there are several industries that
might need Phthalic Anhydride as their raw material. The table below shows the industry with
such need.
Table 2.4. The companies that might need Phthalic Anhydride as raw material.
Company name Address Production
Eternal Materials PTD 5044, Jalan Rumbia 2, Tanjung Langsat Resins

(Malaysia) Sdn. Bhd. Industrial Estate, Mukim Sungai Tiram, 81700
Pasir Gudang, Johor
Polynt Composites PLO 45, Jalan Keluli, Kawasan Perindustrian Plasticisers

Malaysia Sdn. Bhd. Pasir Gudang, 81700 Pasir Gudang, Johor
LOTTE CHEMICAL PLO 8, Tanjung Langsat, Industrial Estate, 81700 Plasticisers

TITAN (M) Sdn. Bhd. Pasir Gudang, Johor
Moreover, in Malaysia, there is still no Phthalic Anhydride producing company. The

examples of companies which produce Phthalic Anhydride are PC Company, BASF, Nan Ya
Plastics Corp., and ExxonMobil Chemical which are located in China. Thus, this plant can
enter the market without similar chemical type competition.
2.1.6 Labour Supply
Based on the Department of Statistics Malaysia, Johor has the third highest number of
populations. Thus, this makes the labour supply sufficient for the plant to be operated at full
capacity. On top of that, there are several institutions that may provide skilful and
knowledgeable workforce. The table below shows the institutes around TLIC.
Table 2.5. The institutions available around TLIC.
Location Institution name

Pasir Gudang Universiti Teknologi MARA
Skudai Universiti Teknologi Malaysia
Pasir Gudang Politeknik Sultan Ibrahim
Batu Pahat Universiti Tun Hussein Onn
25
2.2 Kerteh Industrial Estate, Terengganu
2.2.1 Land Estimation and Topography
Previously a silent fishing community or village, Kerteh has now changed into a petrochemical
center. It houses the PETRONAS Petrochemical Integrated Complex (PPIC) that connects the
whole variety of the oil and gas value chain commencement from upstream survey or
exploration and manufacture to the final phase of petrochemical manufacturing. Kerteh
Industrial area is situated 35 kilometers from Kemaman town. The selling price is RM 5.57 per
square feet. The kind of industry progress in this area is chemical and petrochemical based
industry.
Figure 7. The location of Kerteh Industrial Estate of Terengganu.
26
Meanwhile, in terms of utilities such as water supply and electricity, this area is provided with
water from Terengganu Waterworks Department capacity of some 75.3 million gallons per
day. The suppliers for electricity are the Paka Power Plant which was around 900 megawatts,
IPP YTL Power Generation Sdn. Bhd. about 600 megawatts and Tasik Kenyir Hydroelectric
Power around 400 megawatts. As for the electricity tariff, it can be seen in Table 2.2 from the
previous section.
Table 2.6. Water tariff in Terengganu.
Type Charge every m3 (RM) Minimum charge (RM)

Industrial 1.15 0.36
Minimum charge 50.00 15.63
Commercial
Less than 70 m3 0.95 0.30
More than 70 m3 1.15 0.36
Minimum charge 15.00 4.69
2.2.3 Transportation Facilities
Road and Highways
Terengganu has developed very well with a structured network of roads and highways which
link major towns, airports, seaports and industrial areas. Recently, Terengganu has successfully
built 1,071 federal roads and 1600 km state roads. The east coast highway which is near to the
area makes it easy for transportation of materials, equipment and machinery from Kuala
Lumpur.
Table 2.7. Cargo trucking charges to and from Kuala Lumpur International Airport.
Cargo trucking charges to and from Kuala Lumpur International Airport
(Kerteh rates)
1 tonner RM 800
3 tonners RM 900
10 tonners RM 1400
Table 2.8. Road tolls, Haulage rates and Fuel Adjustment Factor (FAF).
Road tolls, Haulage rates and Fuel Adjustment Factor (FAF)

Road tolls RM 197.80
FAF (16.7% period from Dec 2016) 464.59
Haulage Rates 20' & 40' 2,782.00
Total: RM 3444.39
27
Seaport
Kerteh comprises two well-known ports called the Kerteh Port and Kuantan port which
centralizes in tankage facilities, for container and bulk liquid port. This would be a cheaper
option for the company to order raw material which is o-xylene from India compared to air
freight shipment. This is because from cost consideration, an air freight shipment is
considerably more expensive than the same volume of sea freight cargo. This is mainly due to
the capacity available on a plane, the higher fuel consumption and operational costs of a plane.
Due to the volume of cargo a ship can carry at once, as compared to an aircraft, the freight cost
by sea freight is much cheaper than air.
Kerteh is one of an industrial estate that employs an integrated environmentally friendly waste-
management from the industrial waste. Therefore, the company scheduled a waste management
company which is provided by NRS Waste Management Sdn Bhd at Teluk Kalong Industrial
Estate.
Table 2.9. The company name and address.
Company Name Address

NRS Waste Management Sdn Bhd PT 7460, Kawasan Perindustrian Telok Kalong, 24000
Kemaman, Terengganu
Figure 2.2. Flowchart of NRS waste management company handling waste disposal.
28
Table 2.10. Petrochemical markets in Kerteh.
Petrochemical
Facilities & Infrastructures Products
Zones
Kerteh, ● Gas processing plants ● Praxylene

Terengganu ● Peninsular Gas Utilisation (PGU) ● Benzene
project ● Ammonia
● Centralised utility facilities ● Acetic Acid
● Institut Teknologi Petroleum ● Ethylene
PETRONAS (INSTEP ● Polyethylene
● Kerteh Port ● Ethanolamines
● Kuantan Port ● Ethoxylates
● Glycol Ethers
● Butanol
● Butyl Acetate
● Ethylene Oxide
● Ethylene Glycol
● Low Density Polyethylene
● Vinyl Chloride Monomer
● Polyvinyl Chloride
From the table above, the market for phthalic anhydride is not available in Kerteh. Therefore,
producing phthalic anhydride in Kertih might be very advantageous since there is no
competition with other companies.
Moreover, the major end-use markets of phthalic anhydride include phthalate

plasticizers, polyester resins, and alkyd resins for coating applications. Other uses include the
manufacture of dye intermediates and pigments, polyester polyols and flame-retardants.
However, in Kerteh industrial estates majority of the plants are refining plants and
petrochemicals instead of plasticizer or Polyvinyl chloride (PVC). Therefore, the company
might need to sell it outside of the state or exports globally.
Table 2.11. The company that produces plasticizer and PVC.
Company Name Company address Production

Kao Plasticizer Central Industrial Corporation Berhad, Lorong Perusahaan 1,
Plasticizer
(M) Sdn. Bhd. Kawasan Perusahaan Perai, 13600 Perai, Penang
51-13-C, Menara BHL,
Eagle Chemicals Polyvinyl chloride
Jalan Sultan Ahmad Shah,
Sdn Bhd (PVC)
10050 Georgetown, Penang, Malaysia.
29
2.2.6 Labour Supply
Here in Kerteh, there are few programs that have been introduced by the Malaysian government
in creating workforce and manpower that are ready for challenges in industries. One of the
programs include a training centre which is Institut Teknologi Petroleum Petronas (INSTEP).
Besides that, there are other related programmes which are included Petronas Training
Institute, TATI or Terengganu Advanced Technical Institute, TSTC or Terengganu Safety
Training Centre and TPTTC or Terengganu Plastic Technology Training Centre are such
institutes that provides the training center in order to give training more knowledge for labours
about the plant.
2.3 Gebeng Industrial Estate, Pahang
2.3.1 Land estimation and topography
The Gebeng Industrial Estate offers a comprehensive chemical and petrochemical

manufacturing facility for investors. The Gebeng bypass, which eases traffic flow from the
industrial estate to Kuantan Port, links Kuala Lumpur and Kuantan directly via the East Coast
Highway. This route provides cost effective and convenient means of transportation enabling
more efficient transfer of freight and raw materials locally as well as for international channels.
Gebeng Industrial area is situated 25 kilometers from Kuantan. The selling price is RM18.00
per square feet (Industrial Lot - Ready Land).
Figure 2.3. The location of Gebeng Industrial Estate.
30
Figure 2.4. Gebeng Industrial Estate map.
The water supply in Gebeng Industrial Estate is supplied from the Semambu Water Treatment
Plant. The current capacity of water supply is 2MG/D. However,the Government of Pahang is
committed to ensuring an efficient water supply in Gebeng. Therefore, the steps that have been
taken are:
● Increase of water supply to 64 MG/D

● Building of a new 200 acre dam in Sungai Lembing, Kuantan
● Building of new pipes and water tanks in Gebeng Industrial Estate
The main electricity supplier in Gebeng Industrial Estate is Tenaga Nasional Berhad (TNB).
The electricity supply provided by TNB for Phase I and II is supported by its 132/11kV main
intake and for Phase III, two sources of electricity supply are available which are:
● Centralised Utility Facilities (CUF)

● 12/275kV main intake
31
2.3.3 Transportation facilities
Road and Highways
Gebeng is built with a structured road and highways networks which connect with towns and
the industrial area which makes the accessibility to Gebeng Industrial Estate excellent. The
East Coast Highway which links Kuantan and Kuala Lumpur has an estimated travel time of
just 2 hours. This short period of time makes it easier for transporting equipment and any other
material from Kuala Lumpur areas.
Table 2.12. The Cargo trucking charges
Cargo trucking charges to and from Kuala Lumpur International Airport

(Gebeng rates)
1 tonne RM 700
3 tonne RM 800
10 tonne RM 1200
Table 2.13. The Road tolls, Haulage rates and Fuel Adjustment.
Road tolls, Haulage rates and Fuel Adjustment Factor (FAF)
Road tolls RM 197.80
FAF (16.7% period from Dec 2016) RM 404.47
Haulage Rates 20' & 40' RM 2,422.00
Total: RM 3024.27
Seaports and Railways
In addition, a railway link connects the integrated petrochemical complex in Kerteh

(Terengganu) to Gebeng and Kuantan Port. This railway link further strengthens the chemical
and petrochemical linkage between Gebeng and other industrial centers thus ensures safe
transport as compared to transportation of dangerous goods by road.
32
Good waste management is one of the important factors to maintain a friendly environment in
industrial areas. Therefore, in maintaining a stable waste management the company scheduled
a waste management company near Gebeng area.
Table 2.14. Waste disposal management company near Gebeng area.
Company Name Address

Green Verse Sdn.Bhd Lot 4, Jalan Gebeng 1/5, Kawasan Perindustrian
Gebeng, 26080 Kuantan, Pahang, Malaysia.
Figure 2.5. A flowchart of Green Verse Sdn Bhd handling waste disposal.
33
Table 2.15. Table shows that products of petrochemical plants in Gebeng.
Petrochemical Zones Products
1. Acrylic Acid and Esters 9. Polyester Copolymers

2. Syngas 10. Purified Teerephtahlic Acid
3. Butyl Acrylate 11. Dispersion Polyvinyl Chloride
4. Oxo-alcohols 12. Methyl Methacrylates Copolymers
Gebeng, Pahang 5. Phthalic Anhydride and 13. MTBE
Plasticizers 14. Propylene
6. Butanediol 15. Polyacetals
7. Tetrahydrofurane 16. Polypropylene
8. Gamma-butyrolastone 17. Polybtylene Terephthalate (PBT)
From the table above shows that there is phthalic anhydride supply is available in Gebeng.
Therefore, competition in marketing phthalic anhydride is predicted.
Table 2.16. The company that involves in producing phthalic anhydride.
Company Name Company Addresses Estimated Production

BASF Petronas Kuantan Integrated ● Oxo Alcohols (250,000t/yr)
Chemicals Sdn Bhd Chemical Site, Jalan ● Phthalic Acid, Phthalic
Gebeng 2/1, Kawasan Anhydride (40,000t/yr)
Perindustrian Gebeng, ● Softening Agents
26080 Kuantan, Pahang. (100,000t/yr)
Major end-use markets of phthalic anhydride include phthalate plasticizers, polyester resins,
and alkyd resins for coating applications. Gebeng industrial estate is not only oil and gas based
but also in plasticizer and latex coating based. Therefore, there are market availability in
Gebeng which is an easier and cheaper way to transport our product to other companies.
Table 2.17. the companies that produce plasticizer and polyester resin.
Company Name Company Addresses Production
UPC Chemicals (Malaysia) Lot 140, Jalan Gebeng 2/1, Kawasan Perindustrian Plasticizer
Sdn. Bhd. Gebeng, 26080 Kuantan, Pahang, Malaysia
Eastman Chemical Lot 118, 119, Jalan Gebeng 2/4, Gebeng Industrial Polyester resin
(Malaysia) Sdn. Bhd. Estate, 26080 Kuantan, Pahang
Malaysia
34
2.3.6 Labour Supply
Skilled and knowledgeable workforce in Pahang is abundant. There are several institutions in
Pahang which provide ample supply of labour such as:
● Industrial Training Institute, Gebeng

● MARA Skills Training Institute, Pekan
● Pahang Skills And Development Centre
● IKIP (Pahang International Colleges), Kuantan
● UMP (University Malaysia Pahang)
● International Islamic University Malaysia (IIUM)
35
3.0 MARKET
ANALYSIS
36
3.0 MARKET ANALYSIS
3.1 Market of Raw Material and Product

3.1.1 Market of O-xylene
During the forecast period of 2019-2024, the worldwide ortho-xylene market is projected to
record a CAGR of over 4.2 percent. The growing demand for technological innovation in
nations for the ortho-xylene market as an intermediate for the production of PVC and the
extensive use of ortho-xylene in paints and adhesive production are the key factors driving
market studies (Research and Markets, 2019). Largest market of o-xylene produced is
consumed for preparation of phthalic anhydride, which is then being used in polyester resins
production, bactericides, soybean herbicides, lube oil additives and other applications (Mordor
Intelligence, 2019).
Figure 3.1. Ortho-Xylene Market Value, 2016-2021 in & Million (source: Industry ARC Analysis and Expert
Insights).
Due to the rising demand and use of ortho xylene in the cosmetics industry, Asia-Pacific
dominated the market for ortho xylene globally in 2015 with the highest market share. North
America and Europe is followed by the Asia-Pacific region as the second and third largest
regional markets for o-xylene. However, o-xylene consumption in the automotive, aerospace,
aviation and other sectors in the area is expected to be the fastest growing regional segment,
especially in major economies such as India, China, Japan and South Korea.
Due to the rising demand for o-xylene in automotive, paint & coatings, and other
industries, North American regions such as United States, Canada, and Mexico are growing
significantly. The European market has seen impressive market growth in countries such as the
United Kingdom, Italy, Germany and France, due to the rising use of o-xylene in the
construction industry. Due to the increasing consumption of o-xylene in the healthcare,
automotive and other sectors, the Middle East & Africa region is expected to experience
significant market growth (Research and Markets, 2019).
37
3.1.2 Market of Phthalic Anhydride
The global Phthalic Anhydride market was valued at USD 7.9 Billion in 2018 and is projected
to reach USD 11.8 Billion by 2026, growing at a CAGR of 5.03% from 2019 to 2026, according
to a new report by Verified Market Research. The largest markets for phthalic anhydride are
phthalate plasticizers, unsaturated polyester resins, and alkyd resins for surface coatings.
Commercial phthalic anhydride is 99.8–99.9% pure and is available in two forms—flake and
molten. Most worldwide consumption of phthalic anhydride is molten (IHS Markit, 2020).
Figure 3.2. Global Phthalic Anhydride market including volume of phthalic anhydride from year 2011
until 2019 (source: Market Transparency Research).
The Global Phthalic Anhydride Market has been segmented on the basis of Derivative,
Application, End-Use Industry, and Region. On the basis of derivative, the global market is
classified into phthalate esters, phthalimide, phthalein, phenolphthalein, and others. The
phthalate esters segment is the dominating segment with a value of USD 3,909 million in 2018.
Based on Application, the market has been segmented into plasticizers, unsaturated polyester
resin, alkyd resin, flame retardants, dyes and pigments, and others. The plasticizers segment
held the largest market share of around 50% in 2018. By End-Use Industry, the market is
categorized into building & construction, automotive, electrical & electronics, healthcare,
agriculture, and others. The building & construction segment is projected to exhibit a CAGR
of 4.6% during the forecast period (Market Research Future, 2020).
38
Figure 3.3. Global Percentage Phthalic Anhydride Market Share, by Region in 2018 (source: MRFR
Analysis).
The Global Phthalic Anhydride Market has been studied across five regions. The
market in Asia-Pacific for countries such as Malaysia, China, Japan, South Korea, Taiwan and
India held the largest market share of over 60% in 2018, with a market value of around USD
3,439 Million. The high growth in this region can be attributed to the rapid industrialization
and urbanization in growth-centric countries such as India, South Korea, and Malaysia. For
instance, the implementation of the ‘Make in India’ initiative with a target of Net Zero Imports
by 2020 is expected to boost the manufacturing sector (Market Research Future, 2020).
The second-largest market share for phthalic anhydride is in the European market for
such in Germany, United Kingdom, Italy, Russia, France and Spain is likely to witness
significant growth on account of the high demand for PVC in automobile manufacturing.
Demand for most of the downstream markets of phthalic anhydride is greatly influenced by
general economic conditions. As a result, consumption of phthalic anhydride largely follows
the patterns of the leading world economies. Consumption of phthalic anhydride depends
heavily on construction or remodelling activity, automobile production, and original equipment
manufacturing.
39
3.2 Supply of Raw Material and Product
3.2.1 Supply of O-xylene
Global annual production capacity of o-xylene is at over 4.76 million tonnes in 2013. APAC
captures almost 60% share of the entire o-xylene capacity worldwide. The three Asian
countries – China, South Korea and Taiwan – together account for nearly 42% of the global
installed o-xylene capacity.
Figure 3.4. Global o-xylene capacity broken down by region, 2013.
From 2004 to 2007, the worldwide o-xylene production grew by around 3% on a yearly
basis. It declined due to the global economic crisis by 0.5% and 1.5% in 2008 and 2009,
respectively. In 2010, the performance of the industry improved, but the growth rates failed to
reach the pre-crisis level. In 2012, o-xylene production grew by 1.6% year over year and
climbed to about 3.5 million tonnes. The increment in o-xylene production led to an increase
in o-xylene suppliers.
APAC and Europe are the leading regional o-xylene producers. China, Taiwan, the
USA, South Korea and Germany are the top five countries in terms of o-xylene production,
together contributing more than 55% of the global production volume. Royal Dutch Shell,
Reliance Industries, China Petroleum & Chemical Corp, ExxonMobil Corp, SINOPEC,
Formosa Chemicals and Fibre Corp, KP Chemical, SK Energy, Flint Hills Resources LP,
Polimeri Europa, Lyondell-Citgo Refining LP, Nouri Petrochemical Co and Braskem SA are
amid the top players in the global o-xylene marketplace. While, Evergreen Engineering,
Resources and Element Chemical Sdn Bhd., Global Market Sdn Bhd. and etc are the o-xylene
manufacturers and wholesalers in Malaysia and many more in Asia region.
40
3.2.2 Supply of Phthalic Anhydride
The growth rates of the world development of phthalic anhydride (PA) decreased during the
recession years (2008-2009). However, the situation in the overall PA market has started to
improve since 2010, mainly due to the continuously growing demand from the end-use
segments. Global PA supplies increased by 200,000 tonnes in 2013 compared to 2012, hitting
4.05 million tonnes.
Figure 3.5. Phthalic Anhydride: structure of the global production by country, 2013 (source
Merchant Research & Consulting, Ltd)
The APAC field has called for the largest chunk of the world's PA production volume
as of 2013; the PA output volume was over 2.5 million tonnes. Europe was accompanied by it.
In 2013, China, the US, South Korea, India and Taiwan, the top five PA producing countries,
accounted for a 62.3 percent share of the overall PA production volume in the world.
The leading companies involved in the global PA market are PC Company, BASF, Nan
Ya Plastics Corp, ExxonMobil Chemical, Aekyung Petrochemical, Shandong Hongxin
Chemical, Thirumalai Chemicals, Petrowidada PT, Tianjin Taisen Chemical Industry (Group),
Henan Qingan Chemical High Technology, IG Petrochemicals and Nippon Steel & Sumikin
Chemical.
41
3.3 Demand of Raw Material and Product
3.3.1 Demand of O-xylene
The growing demand for dyes, plasticizers and resins has led to a strong rise in the ortho-xylene
industry. Phthalic anhydride (a significant application of ortho-xylene) is used to manufacture
plasticizers that are mainly used in the construction of industrial and automotive industries.
The main end-users of phthalic anhydrides are unsaturated polyester resins and phthalates,
which indicate substantial growth potential in the near future. Due to the increase in growth of
phthalic anhydride demand, the demand of ortho-xylene is expected to increase. Figure x below
shows the world consumption of ortho-xylene in the year 2019.
Figure 3.6. World Consumption of Ortho-xylene in 2019 (source: HIS Market).
42
3.3.2 Demand of Phthalic Anhydride
The demand of phthalic anhydride for most of the downstream market is highly influenced by
the general economic conditions. Therefore, the patterns of the leading world economies
largely impact the consumption of this product. Phthalic anhydride demand depends heavily
on the remodelling/construction activity, automobile production and manufacturing of original
equipment. Figure 3 shows the world consumption of phthalic anhydride in 2019.
Figure 3.7. World Consumption of Phthalic Anhydride in 2019 (source: IHS Market)
Western Europe and Asia which is mainly China and India will be leading the volume
growth of phthalic anhydride for plasticizers, the growth of the economy in Asia will increase
the domestic demand for phthalic anhydride. Consumption of phthalic anhydride for
plasticizers in North American is expected to decrease 0.4% per year during 2019 to 2024.
Concern in environmental and chemical replacement that leads to the major reason for the
lower consumption. On the other side, consumption of phthalic anhydride for the production
of polyester resin products is forecasted to increase moderately in 2019 to 2024 but it will be
varied according to region. The Asian markets are forecasted to have an increment in the
growth demand especially China, India and Southeast Asia. However, the demand is forecasted
to be decreasing in Japan.
43
4.0 MASS
BALANCE
44
4.0 MASS BALANCE
4.1 Process Flow Diagram
45
4.2 Stream Table
Definitions of the abbreviations used in the calculations are listed below.

O2: oxygen (O2), N2: nitrogen (N2), xy: o-xylene (C8H10), PA: phthalic anhydride (C8H4O3), MA: maleic anhydride (C4H2O3), CO2: carbon dioxide
(CO2), H2O: water (H2O)
Stream no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Flow rate
29608.12 5847.07 5847.07 29608.12 29608.12 5847.07 35332.51 35326.23 27971.31 7354.92 279.71 27691.60 1697.463 5657.458 5651.801 5.6567
(kg/hr)
O2 0.21 - - 0.21 0.21 - 0.195 0.0002 0.00025 - 0.00025 0.00025 - - - -
N2 0.79 - - 0.79 0.79 - 0.64 0.64 0.8083 - 0.8083 0.8083 - - - -
xy - 1 1 - - 1 0.165 0.0099 - 0.0476 - - 0.2062 - - -
PA - - - - - - - 0.1616 - 0.7762 - - 0.0335 0.999 0.999 0.001
MA - - - - - - - 0.0367 - 0.1763 - - 0.7604 0.001 0.999
CO2 - - - - - - - 0.0658 0.0831 - 0.0831 0.0831 - 0.001 - -
H2O - - - - - - - 0.0858 0.1084 - 0.1083 0.1083 - - - -
SUM 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
46
4.3 Reactor (R-701)
The mixed reactants prepared entered through stream 7 to reactor R-701 at the inlet temperature
of 245°C and 200 kPa and the product emerged at the temperature of 353°C and 130kPa. The
reaction takes place inside the reactor in vapour phase. There are 2 reactions that took place in
the reactor, the main reaction which produce the main product, phthalic anhydride, while the
side reaction producing the side product maleic anhydride. The reactants entered were o-
xylene, oxygen and nitrogen reacted and produced products such phthalic anhydride, water,
maleic anhydride, carbon dioxide, nitrogen gas, oxygen, and some unreacted o-xylene in
stream 8. The nitrogen component acted as an inert because the amount of nitrogen gas fed,
and the exit amount was the same. The reactants and the products than emerged in vapour
phase, and flow through stream 8, into the switch condenser to undergo further process. The
following were the operation condition for reactor R-701:
1. Temperature operating 245°C - 353°C

2. Pressure operating 200 kPa – 130 kPa
Reaction 1 : C8H10 + 3 O2 → C8H4O3 + 3 H2O

Reaction 2 : C8H10 + 15/2 O2 → C4H2O3 + 4 CO2 + 4 H2O
47
Inlet Outlet
Substance
Composition Flow rate (kg/hr) Composition Flow rate (kg/hr)
xy 0.165 5847.07 0.0099 350.82
O2 0.195 6870.4 0.0002 7.07
N2 0.64 22615.04 0.64 22615.04
PA - - 0.1616 5707.76
H2O - - 0.0858 3032.28
MA - - 0.0367 1295.37
CO2 - - 0.0658 2324.96
Total 1 35 332.51 1 35 326.23
Material Balance (Reaction 1)

Phthalic Anhydride
Assume 50 000 tonnes/year is produced in the plant.
𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑃𝐴 = 5707.76 𝑘𝑔/ℎ𝑟

𝑚𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑃𝐴 = 38.54 𝑘𝑚𝑜𝑙/ℎ𝑟
Reacted O-xylene
Based on stoichiometric reaction, 1 mol of O-xylene is required to react with oxygen to produce
1 mol of Phthalic Anhydride.
1 𝑚𝑜𝑙 𝑜𝑥𝑦𝑙𝑒𝑛𝑒 ∶ 1 𝑚𝑜𝑙 𝑃𝐴
Thus,
𝑀𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑟𝑒𝑎𝑐𝑡𝑒𝑑 𝑜𝑥𝑦𝑙𝑒𝑛𝑒 = 38.54 𝑘𝑚𝑜𝑙/ℎ𝑟
Since,
𝑀𝑊𝑜𝑥𝑦𝑙𝑒𝑛𝑒 = 106.2 𝑘𝑔/𝑘𝑚𝑜𝑙
𝑘𝑚𝑜𝑙 𝑘𝑔
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 = 38.54 × 106.2
ℎ𝑟 𝑘𝑚𝑜𝑙
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑟𝑒𝑎𝑐𝑡𝑒𝑑 𝑜𝑥𝑦𝑙𝑒𝑛𝑒 = 4092.95 𝑘𝑔/ℎ𝑟
48
Unreacted O-xylene
Fractional conversion o-xylene to PA = 70%
𝑟𝑒𝑎𝑐𝑡𝑒𝑑 𝑜𝑥𝑦𝑙𝑒𝑛𝑒
𝑜𝑥𝑦𝑙𝑒𝑛𝑒 𝑓𝑒𝑒𝑑𝑠𝑡𝑜𝑐𝑘 =
𝑓𝑟𝑎𝑐. 𝑐𝑜𝑛𝑣𝑒𝑟𝑠𝑖𝑜𝑛
4092.95 𝑘𝑔/ℎ𝑟
=
0.7
𝑂𝑥𝑦𝑙𝑒𝑛𝑒 𝑓𝑒𝑒𝑑𝑠𝑡𝑜𝑐𝑘 = 5847.07 𝑘𝑔/ℎ𝑟 = 55.06 𝑘𝑚𝑜𝑙/ℎ𝑟
Thus, 𝑈𝑛𝑟𝑒𝑎𝑐𝑡𝑒𝑑 𝑜𝑥𝑦𝑙𝑒𝑛𝑒 = 𝑂𝑥𝑦𝑙𝑒𝑛𝑒 𝑓𝑒𝑒𝑑𝑠𝑡𝑜𝑐𝑘 − 𝑅𝑒𝑎𝑐𝑡𝑒𝑑 𝑜𝑥𝑦𝑙𝑒𝑛𝑒

= 5847.07 𝑘𝑔/ℎ𝑟 − 4092.95 𝑘𝑔/ℎ𝑟
= 1754.12 𝑘𝑔/ℎ𝑟
Oxygen
Based on stoichiometric reaction, the ratio of reactants, o-xylene and oxygen is
1 𝑚𝑜𝑙 𝑜𝑥𝑦𝑙𝑒𝑛𝑒 ∶ 3 𝑚𝑜𝑙 𝑜𝑥𝑦𝑔𝑒𝑛
Thus, 𝑀𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑜𝑥𝑦𝑔𝑒𝑛 = 3 × 38.54 𝑘𝑚𝑜𝑙/ℎ𝑟 = 115.62 𝑘𝑚𝑜𝑙/ℎ𝑟
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 = 115.62 × 32 = 3699.84 𝑘𝑔/ℎ𝑟
In air composition, Oxygen = 21% and Nitrogen = 79%,

𝑂𝑥𝑦𝑔𝑒𝑛 115.62 𝑘𝑚𝑜𝑙/ℎ𝑟
𝐴𝑖𝑟 = = = 550.57 𝑘𝑚𝑜𝑙/ℎ𝑟
0.21 0.21
Nitrogen
𝑁𝑖𝑡𝑟𝑜𝑔𝑒𝑛 = 𝐴𝑖𝑟 − 𝑂𝑥𝑦𝑔𝑒𝑛
𝑘𝑚𝑜𝑙
= 550.57 − 115.62
ℎ𝑟
= 434.95 𝑘𝑚𝑜𝑙/ℎ𝑟
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑛𝑖𝑡𝑟𝑜𝑔𝑒𝑛 = 434.95 × 28 = 12178.6 𝑘𝑔/ℎ𝑟
Water
1 𝑚𝑜𝑙 𝑜𝑥𝑦𝑙𝑒𝑛𝑒 ∶ 3 𝑚𝑜𝑙 𝑤𝑎𝑡𝑒𝑟
𝑀𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 = 3 × 38.54 𝑘𝑚𝑜𝑙/ℎ𝑟 = 115.62 𝑘𝑚𝑜𝑙/ℎ𝑟
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 = 115.62 × 18 = 2081.16 𝑘𝑔/ℎ𝑟
49
Material Balance for Side Reaction
1. Assume 80% of unreacted o-xylene from reaction 1 is reacted with oxygen to form
maleic anhydride.
2. 20% of unreacted o-xylene from reaction 1 is unreacted in reaction 2 and leaving the
reactor.
Reacted O-xylene
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑟𝑒𝑎𝑐𝑡𝑒𝑑 𝑜𝑥𝑦𝑙𝑒𝑛𝑒 = 0.8 × 1754.12 𝑘𝑔/ℎ𝑟 = 1403.30 𝑘𝑔/ℎ𝑟
𝑘𝑔 𝑘𝑚𝑜𝑙
𝑀𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑟𝑒𝑎𝑐𝑡𝑒𝑑 𝑜𝑥𝑦𝑙𝑒𝑛𝑒 = 1403.30 × = 13.21 𝑘𝑚𝑜𝑙/ℎ𝑟
ℎ𝑟 106.2 𝑘𝑔
Unreacted O-xylene
𝑈𝑛𝑟𝑒𝑎𝑐𝑡𝑒𝑑 𝑜𝑥𝑦𝑙𝑒𝑛𝑒 𝑙𝑒𝑎𝑣𝑖𝑛𝑔 𝑡ℎ𝑒 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 = 0.2 × 1754.12 𝑘𝑔/ℎ𝑟 = 350.82 𝑘𝑔/ℎ𝑟
Oxygen
Based on stoichiometric reaction,
1 𝑚𝑜𝑙 𝑜𝑥𝑦𝑙𝑒𝑛𝑒 ∶ 71/2 𝑚𝑜𝑙 𝑜𝑥𝑦𝑔𝑒𝑛
Thus,
𝑀𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑜𝑥𝑦𝑔𝑒𝑛 = 71/2 × 13.21 𝑘𝑚𝑜𝑙/ℎ𝑟 = 99.08 𝑘𝑚𝑜𝑙/ℎ𝑟
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 = 99.08 × 32 = 3170.56 𝑘𝑔/ℎ𝑟
In air composition, Oxygen = 21% and Nitrogen = 79%,

𝑂𝑥𝑦𝑔𝑒𝑛 99.08 𝑘𝑚𝑜𝑙/ℎ𝑟
𝐴𝑖𝑟 = = = 471.81 𝑘𝑚𝑜𝑙/ℎ𝑟
0.21 0.21
Nitrogen
𝑁𝑖𝑡𝑟𝑜𝑔𝑒𝑛 = 𝐴𝑖𝑟 − 𝑂𝑥𝑦𝑔𝑒𝑛
= 471.81 − 99.08 𝑘𝑚𝑜𝑙/ℎ𝑟
𝑀𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑛𝑖𝑡𝑟𝑜𝑔𝑒𝑛 = 372.73 𝑘𝑚𝑜𝑙/ℎ𝑟

𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑛𝑖𝑡𝑟𝑜𝑔𝑒𝑛 = 372.73 × 28 = 10436.44 𝑘𝑔/ℎ𝑟
50
Maleic Anhydride (MA)
1 𝑚𝑜𝑙 𝑜𝑥𝑦𝑙𝑒𝑛𝑒 ∶ 1 𝑚𝑜𝑙 𝑀𝐴
Thus,
𝑀𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑀𝐴 = 13.21 𝑘𝑚𝑜𝑙/ℎ𝑟
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑀𝐴 = 13.21 × 98.06 = 1295.37 𝑘𝑔/ℎ𝑟
Water
1 𝑚𝑜𝑙 𝑜𝑥𝑦𝑙𝑒𝑛𝑒 = 4 𝑚𝑜𝑙 𝑤𝑎𝑡𝑒𝑟
𝑀𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 = 4 × 13.21 𝑘𝑚𝑜𝑙/ℎ𝑟 = 52.84 𝑘𝑚𝑜𝑙/ℎ𝑟
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 = 52.84 × 18 = 951.12 𝑘𝑔/ℎ𝑟
Carbon Dioxide
1 𝑚𝑜𝑙 𝑜𝑥𝑦𝑙𝑒𝑛𝑒 = 4 𝑚𝑜𝑙 𝑤𝑎𝑡𝑒𝑟
𝑀𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 CO2 = 4 × 13.21 𝑘𝑚𝑜𝑙/ℎ𝑟 = 52.84 𝑘𝑚𝑜𝑙/ℎ𝑟
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 CO2 = 52.84 × 44 = 2324.96 𝑘𝑔/ℎ𝑟
51
Reaction 1 Balance
In:
𝑘𝑔 𝑘𝑔
𝑜 − 𝑥𝑦𝑙𝑒𝑛𝑒 + 𝑜𝑥𝑦𝑔𝑒𝑛 = 4092.95 + 3699.84
ℎ𝑟 ℎ𝑟
= 7792.79 𝑘𝑔/ℎ𝑟
𝑘𝑔 𝑘𝑔
Out: 𝑝ℎ𝑡ℎ𝑎𝑙𝑖𝑐 𝑎𝑛ℎ𝑦𝑑𝑟𝑖𝑑𝑒 + 𝑤𝑎𝑡𝑒𝑟 = 5707.76 ℎ𝑟 + 2081.16 ℎ𝑟
= 7788.92 𝑘𝑔/ℎ𝑟
Reaction 2 Balance
In:
𝑜𝑥𝑦𝑙𝑒𝑛𝑒 + 𝑜𝑥𝑦𝑔𝑒𝑛 = 3170.56 𝑘𝑔/ℎ𝑟 + 1403.30 𝑘𝑔/ℎ𝑟
= 4573.86 𝑘𝑔/ℎ𝑟
Out: 𝑚𝑎𝑙𝑒𝑖𝑐 𝑎𝑛ℎ𝑦𝑑𝑟𝑖𝑑𝑒 + 𝑤𝑎𝑡𝑒𝑟 + 𝐶𝑂2 = 1295.37 𝑘𝑔/ℎ𝑟 + 951.12 𝑘𝑔/ℎ𝑟 + 2324.96 𝑘𝑔/ℎ𝑟
= 4571.45 𝑘𝑔/ℎ𝑟
General Reaction Balance:
𝐼𝑛𝑙𝑒𝑡 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 1 + 𝑖𝑛𝑙𝑒𝑡 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 2 = 7792.79 𝑘𝑔/ℎ𝑟 + 4573.86 𝑘𝑔/ℎ𝑟
= 12366.65 𝑘𝑔/ℎ𝑟
𝑂𝑢𝑡𝑙𝑒𝑡 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 1 + 𝑂𝑢𝑡𝑙𝑒𝑡 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 2 = 7788.92 𝑘𝑔/ℎ𝑟 + 4571.45 𝑘𝑔/ℎ𝑟

= 12360.37 𝑘𝑔/ℎ𝑟
Total Water Leaving Reactor
𝑇𝑜𝑡𝑎𝑙 𝑤𝑎𝑡𝑒𝑟 = 𝑤𝑎𝑡𝑒𝑟𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 1 + 𝑤𝑎𝑡𝑒𝑟𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 2
= 2081.16 𝑘𝑔/ℎ𝑟 + 951.12𝑘𝑔/ℎ𝑟
= 3032.28 𝑘𝑔/ℎ𝑟
Total O-xylene Consumed

𝑇𝑜𝑡𝑎𝑙 𝑂𝑥𝑦𝑙𝑒𝑛𝑒 𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑 = 𝑜𝑥𝑦𝑙𝑒𝑛𝑒𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 1 + 𝑜𝑥𝑦𝑙𝑒𝑛𝑒𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 2
= 4092.95 𝑘𝑔/ℎ𝑟 + 1403.30𝑘𝑔/ℎ𝑟
= 5496.25 𝑘𝑔/ℎ𝑟
Total Oxygen Entering Reactor

𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑜𝑥𝑦𝑔𝑒𝑛 = 𝑜𝑥𝑦𝑔𝑒𝑛𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 1 + 𝑜𝑥𝑦𝑔𝑒𝑛𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 2
= 3699.84 𝑘𝑔/ℎ𝑟 + 3170.56𝑘𝑔/ℎ𝑟
= 6870.4 𝑘𝑔/ℎ𝑟
52
Total Nitrogen Entering Reactor
𝐸𝑛𝑡𝑒𝑟𝑖𝑛𝑔 𝑛𝑖𝑡𝑟𝑜𝑔𝑒𝑛 = 𝐿𝑒𝑎𝑣𝑖𝑛𝑔 𝑛𝑖𝑡𝑟𝑜𝑔𝑒𝑛
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑛𝑖𝑡𝑟𝑜𝑔𝑒𝑛 = 𝑛𝑖𝑡𝑟𝑜𝑔𝑒𝑛𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 1 + 𝑛𝑖𝑡𝑟𝑜𝑔𝑒𝑛𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 2

= 12178.6 𝑘𝑔/ℎ𝑟 + 10436.44 𝑘𝑔/ℎ𝑟
= 22615.04 𝑘𝑔/ℎ𝑟
Unreacted O-xylene
𝑇𝑜𝑡𝑎𝑙 𝑈𝑛𝑟𝑒𝑎𝑐𝑡𝑒𝑑 𝑜𝑥𝑦𝑙𝑒𝑛𝑒 = 350.82 𝑘𝑔/ℎ𝑟
Air Feedstock
𝑇𝑜𝑡𝑎𝑙 𝑎𝑖𝑟 𝑓𝑒𝑒𝑑𝑠𝑡𝑜𝑐𝑘 = 𝑎𝑖𝑟𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 1 + 𝑎𝑖𝑟𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 2
= 550.57 𝑘𝑚𝑜𝑙/ℎ𝑟 + 471.81 𝑘𝑚𝑜𝑙/ℎ𝑟
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑎𝑖𝑟 𝑓𝑒𝑒𝑑𝑠𝑡𝑜𝑐𝑘 = 1022.38 × 28.96 = 29608.12 𝑘𝑔/ℎ𝑟
Inlet Reactor
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑒𝑛𝑡𝑒𝑟𝑖𝑛𝑔 𝑟𝑒𝑎𝑐𝑡𝑜𝑟
= 𝑜𝑥𝑦𝑔𝑒𝑛𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 1 + 𝑜𝑥𝑦𝑙𝑒𝑛𝑒 𝑓𝑒𝑒𝑑𝑠𝑡𝑜𝑐𝑘 + 𝑜𝑥𝑦𝑔𝑒𝑛𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 2 + 𝑛𝑖𝑡𝑟𝑜𝑔𝑒𝑛
= 3699.84 + 5847.07 + 3170.56 + 22615.04 𝑘𝑔/ℎ𝑟
= 35 332.51 𝑘𝑔/ℎ𝑟
Outlet Reactor
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑙𝑒𝑎𝑣𝑖𝑛𝑔 𝑟𝑒𝑎𝑐𝑡𝑜𝑟
= 𝑃𝐴𝑟𝑥𝑛 1 + 𝑇𝑜𝑡𝑎𝑙 𝑤𝑎𝑡𝑒𝑟 + 𝑀𝐴𝑟𝑥𝑛 2 + 𝐶𝑂2 𝑟𝑥𝑛2 + 𝑈𝑛𝑟𝑒𝑎𝑐𝑡𝑒𝑑 𝑜𝑥𝑦𝑙𝑒𝑛𝑒 + 𝑛𝑖𝑡𝑟𝑜𝑔𝑒𝑛
= 5707.76 + 3032.28 + 1295.37 + 2324.96 + 350.82 + 22615.04 𝑘𝑔/ℎ𝑟

= 35 326.23 𝑘𝑔/ℎ𝑟
53
4.4 Switch Condenser
The effluents from a reactor entered switched condenser SC-701 at inlet temperature of 165°C
and outlet temperature of 140°C. The effluents needed to be condensed as preparation before
entering the separation section. It is also crucial to condensed components in stream 8 because
some of the components will experience changes in phase. Those components that remain as
gaseous phase will be condensed and entered to stream 9 which will later be recycled. The
remaining components which are physically in liquid phase will enter stream 10 for separation
purposes. Few assumptions need to be considered about the usage of switch condenser. The
following were the assumptions made:
1. 100% material recovery

1. Temperature operating from inlet < 180°C
2. Pressure operating is 100 kPa
54
Inlet Outlet (Upper Stream) Outlet (Bottom Stream)
Substance Flow rate Flow rate Flow rate
Composition Composition Composition
(kg/hr) (kg/hr) (kg/hr)
O2 0.0002 7.0652 0.00025 6.9928 - -
N2 0.64 22608.7872 0.8083 22609.2089 - -
xy 0.0099 349.7297 - - 0.0476 350.0942
PA 0.1616 5708.7188 - - 0.7762 5708.8898
MA 0.0367 1296.4726 - - 0.1763 1296.6726
CO2 0.0658 2324.4659 0.0831 2324.4158 - -
H 2O 0.0858 3030.9905 0.1084 3032.0899 - -
Total 35326.23 27971.3088 7354.9211
Overall Mass Balance:

𝑘𝑔 𝑘𝑔 𝑘𝑔
35,326.23 =A +B ….[1]
ℎ ℎ ℎ
Inlet Mass Flowrates:

O2 ;
𝑘𝑔
35,326.23 x 0.0002 = 7.0652 ℎ
N2;
𝑘𝑔
35,326.23 x 0.64 = 22608.7872 ℎ
CO2;
𝑘𝑔
35,326.23 x 0.0658 = 2324.4659 ℎ
H2O;
𝑘𝑔
35,326.23 x 0.0858 = 3030.9905 ℎ
Phthalic Anhydride;
𝑘𝑔
35,326.23 x 0.1616 = 5708.7188 ℎ
Maleic Anhydride;
𝑘𝑔
35,326.23 x 0.0367 = 1296.4726 ℎ
O-xylene;
𝑘𝑔
35,326.23 x 0.0099 = 349.7297 ℎ
55
Outlet Mass Flowrates at Upper:
Since it is 100% recovery:
A = 7.0652 + 22 608.7872 + 2324.4659 + 3030.9905

𝑘𝑔
A = 27,971.3088 … [2]
ℎ
To get compositions for outlet at upper:
O2 ;
7.0652
= 2.529 x 10-4
27971.3088
N2 ;
22608.7872
= 0.8083
27971.3088
CO2;
2324.4659
= 0.0831
27971.3088
H2O;
3030.9905
= 0.1084
27971.3088
56
Outlet Mass Flowrates at Bottom:
Substitute 2 into 1:-
B = 35,326.23 - 27,971.3088
𝑘𝑔
B = 7, 354.921 ℎ
To get compositions of outlet at bottom:
Phthalic Anhydride;
5708.7188
= 0.7762
7354.921
Maleic Anhydride;
1296.4726
= 0.1763
7354.921
O-Xylene:
349.7297
= 0.0476
7354.921
57
4.5 Distillation Column
4.5.1 Distillation Column 1
The contents of stream 10 which consists of phthalic anhydride, maleic anhydride and o-xylene
enter the first distillation column, T-701 at the temperature of 140℃. In this distillation column,
the small amount of reaming unreacted o-xylene will be separated and enter stream 13 at 230℃.
This is because, there will be 0% purity of o-xylene in stream 14 with the temperature of 230℃
as preparation before entering second distillation column, T-702. Moreover, all these
components are in liquid phase.
Assumptions:
1. The recovery of phthalic anhydride at bottom is 99%.
2. Bottom composition (99.9% purity of phthalic anhydride): 99.9% of phthalic
anhydride, 1% of maleic anhydride and 0% o-xylene separated from stream 10.
58
Inlet Outlet
Substance Flowrate Composition Component Flowrate Composition
(kg/h) (kg/h)
Phthalic 5708.8898 07762 Distillate
Anhydride Phthalic 56.865 0.0335
(𝐶8 𝐻4 𝑂3 ) Anhydride
(𝐶8 𝐻4 𝑂3 )
Maleic 1296.6726 0.1763 Maleic 1290.7509 0.7604
Anhydride Anhydride
(𝐶4 𝐻2 𝑂3 ) (𝐶4 𝐻2 𝑂3 )
O-xylene 350.0942 0.0476 O-xylene 350.0169 0.2062
𝐶8 𝐻10 𝐶8 𝐻10
Total 7354.9211 1.0001 Total 1697.463 1.0001
Bottom
Phthalic 5651.8005 0.999
Anhydride
(𝐶8 𝐻4 𝑂3 )
Maleic 5.6575 0.001
Anhydride
(𝐶4 𝐻2 𝑂3 )
O-xylene 0.0000 0.000
𝐶8 𝐻10
Total 5657.458 1.0000
Table 4.5.1: Table shows the inlet-outlet table for compositions and mass flowrates for each of
components in distillation column.
Bottom mass flow rate
𝑓𝑟𝑒𝑐,𝐵 ( F)(𝑛1 ) (0.99)(7354.9211)(0.7762)
B= =
𝑛7 0.999
= 5657.4583 kg/h
Inlet = outlet mass flowrate
F= B + D
7354.9211 = 5657.4583 + D
D = 1697.4627kg/h
Phthalic Anhydride
7354.9211 (0.7762) = 1697.4627 (𝑛4 ) + 5657.4583 (0.999)
𝑛4 = 0.0335
Maleic Anhydride
7354.9211 (0.1763) = 1697.4627 (𝑛5 ) + 5657.4583 (0.001)
𝑛5 = 0.7604
O-xylene
7354.9211 (0.0476) = 1697.4627 (𝑛6 ) + 5657.4583 (0)
𝑛6 = 0.2062
59
In this second unit of distillation column, 99.9% and 0.01% composition of phthalic anhydride
and maleic anhydride respectively enter the column as feed at temperature of 230℃. Main
objective for this column is to achieve 99% purity for both phthalic anhydride and maleic
anhydride. Both products leave the column at 295℃.
Assumptions:
1. The recovery Phthalic Anhydride at top is 99%
2. Bottom composition (99.9% purity of maleic anhydride): 99.9% of maleic anhydride, 1% of
phthalic anhydride.
60
Inlet Outlet
Substance Flowrate Composition Component Flowrate Composition
(kg/h) (kg/h)
Phthalic 5651.8005 0.999 Distillate
Anhydride Phthalic 5595.283 0.99
(𝐶8 𝐻4 𝑂3 ) Anhydride
(𝐶8 𝐻4 𝑂3 )
Maleic 5.6575 0.001 Maleic 56.518 0.01
Anhydride Anhydride
(𝐶4 𝐻2 𝑂3 ) (𝐶4 𝐻2 𝑂3 )
O-xylene 0.000 0.000 O-xylene - -
𝐶8 𝐻10 𝐶8 𝐻10
Total 5657.458 1.0000 Total 5651.801 1.000
Bottom
Phthalic 0.0567 0.01
Anhydride
(𝐶8 𝐻4 𝑂3 )
Maleic 5.600 0.99
Anhydride
(𝐶4 𝐻2 𝑂3 )
O-xylene - -
𝐶8 𝐻10
Total 5.6567 1.0000
Table 4.5.2. Table shows the inlet-outlet table for compositions and mass flowrates for each components in
distillation column
Top mass flow rate
𝑓𝑟𝑒𝑐,𝐷 ( F)(𝑛7 ) (0.99)(5657.458)(0.999)
B= =
𝑛10 0.99
= 5651.801 kg/h
Bottom mass flow rate
F= B + D
5657.458 = B - 5651.801
B = 5.6567 kg/h
Top Molar Flowrate
Phthalic Anhydride
(0.99) (5651.801) = 5595.283 kg/h
Maleic Anhydride
(0.01) (5651.801) = 56.518 kg/h
Bottom Molar Flowrate
Phthalic Anhydride
(0.01) (5.657) = 0.0567 kg/h
Maleic Anhydride
(0.99) (5.657) = 5.600 kg/h
61
4.6 Overall Mass Balance
n4 CO2, n5
H2O
n1 O2, n2 N2 n6 PA
Overall
n3 xy mass n7 MA
balance
Degree of freedom (DOF) analysis for the overall system:

1. Unknowns : +7 (n1, n2, n3, n4, n5, n6, n7)
2. Independent atomic species : -3 (C, H, O)
3. Independent nonreactive molecular species : -1 (N2)
4. Specifications/assumptions : -3
Recovery of PA: 99%
Recovery of MA: 100%
Conversion of main reaction: 70%
DOF:
7 – 3 – 1 – 3 = 0 (Mass balance can be solved)
Basis:
50 000 tonne/year of 99% PA with 1% MA
Component O2 N2 xy PA MA CO2 H2O
Molecular weight 31.999 28.014 106.16 148.11 98.06 44.009 18.015
(kg/kmol)
Based on the specifications/assumptions,

n6 = (0.99) (50000 tonne/year) (1000 kg/tonne) / (8760 hr/year)
= 5650.68 kg/hr
n7 = (0.01) (50000 tonne/year) (1000 kg/tonne) / (8760 hr/year)
= 57.08 kg/hr
Conversion,
50000 tonne/year = 5707.76 kg/hr = 38.54 kmol/hr
Since 1 mol xy : 1 mol PA, thus o-xylene is 38.54 kmol/hr.

Calculating the mass flowrate of o-xylene,
38.54 × 106.2 = 4092.95 kg/hr
62
Since the conversion of main reaction is 70%,
n3 = 4092.95 / 0.7 = 5847.07 kg/hr
Atomic species balance

Input = Output
O2 + N2 + C8H10 (o-xylene) = C8H4O3 (PA) + C4H2O3 (MA) + CO2 + H2O
C balance
0(n1) + 0(n2) + 8(n3) = 8(n6) + 4(n7) + 1(n4) + 0(n5)
8(5847.07) = 8(5650.68) + 4(57.08) + n4
n4 = 1342.80 kg/hr
H balance
0(n1) + 0(n2) + 10(n3) = 4(n6) + 2(n7) + 0(n4) + 2(n5)
10(5847.07) = 4(5650.68) + 2(57.08) + 2n5
n5 = 17876.91 kg/hr
O balance
2(n1) + 0(n2) + 0(n3) = 3(n6) + 3(n7) + 2(n4) + 1(n5)
2n1 = 3(5650.68) + 3(57.08) + 2(1342.80) + 1(17876.91)
n1 = 18842.90 kg/hr
Since in air the composition of O2 and N2 are 21% and 79%, respectively,
0.21 / 18842.90 = 0.79 / n2
n2 = 70885.20 kg/hr
Inlet Outlet
Substance
Flowrate (kg/hr) Mol fraction Flowrate (kg/hr) Mol fraction
O2 18842.90 0.197 - -
N2 70885.20 0.742 70885.20 0.7398
xy 5847.07 0.061 - -
PA - - 5650.68 0.0590
MA - - 57.08 0.0006
CO2 - - 1342.80 0.0140
H2O - - 17876.91 0.1866
Total 95575.17 1 95812.67 1
63
4.7 Overall Conversion
4.7.1 O-xylene
reactant consumed in reaction

Single pass conversion =
reactant fed to reactor
From Stream 7, O-xylene inlet is 5847.07 kg/hr

From Stream 10, O-xylene outlet is 3030.99 kg/hr
kg kg
5847.07 − 3030.99
Single pass conversion = hr hr
kg
5847.07
hr
= 0.482 or 48.2%
reactant consumed in process

Overall conversion =
reactant fed to reactor
From Stream 2, O-xylene inlet is 5847.07 kg/hr

kg kg
5847.07 − 350.02
Overall conversion = hr hr
kg
5847.07
hr
= 0.940 or 94%
The single pass conversion shows the amount of O-xylene is converted to Phthalic Anhydride.
The lower the single-pass conversion, the higher the recycle required, assuming the unreacted
O-xylene will be separated and recycled. Generally, the single pass conversion will affect the
equipment size and utility flows since both of these are related to the amount of recycle.
However, the cost of raw material remains unchanged significantly if the O-xylene is assumed
to be separated and recycled.
The overall conversion shows the fraction of O-xylene in the feed to the process which
is at Stream 2 that is converted to products. For the partial oxidation process, the fraction
obtained is high which is 94%. The high overall conversion is common for chemical processes
and indicates that the unreacted raw materials are not being lost from the process.
64
4.7.2 Air (O2 and N2)
Single pass conversion of Air (O2 and N2)
From Stream 7, Air inlet is 29502.64 kg/hr

From Stream 9, Air outlet is 22615.86 kg/hr
kg kg
29502.64 − 22615.86
Single pass conversion = hr hr
kg
29502.64
hr
= 0.233 or 23.3%
Overall conversion of Air
From Stream 2, Air inlet is 29608.12 kg/hr

kg kg
29608.12 − 30.31
Overall conversion = hr hr
kg
29608.12
hr
= 0.998 or 99.8%
The single-pass conversion is kept low because the oxygen is required everywhere in reactor
so as to avoid or reduce coking of the catalyst. 99% of the inlet air is recycled and purged after
the reaction. Therefore, the overall conversion is high due to the high amount of recycled air.
Thus, the high overall conversion of air indicates the high usage of the raw material.
65
5.0 ENERGY
BALANCE
66
5.0 ENERGY BALANCE
5.1 Reactor (R-701)
Reference States:
• O2, N2, CO2 at (25°C, vapour, 1 atm)
• C8H10, C8H4O3, C4H2O3, H20 (at 25°C, liquid, 1 atm)
*Assume there is no effect in pressure.
Table 5.1-1 Enthalpy Table

Inlet Outlet
Substance 𝑛̇ (kmol/hr) ̂ (kJ/kmol)
𝐻 𝑛̇ (kmol/hr) ̂ (kJ/kmol)
𝐻
C8H10 55.06 ̂1 = 83212.2908
𝐻 3.31 ̂4 = 97617.8217
𝐻
O2 214.7 ̂2 = 6717.35
𝐻 0.22 ̂5 = 10145.8997
𝐻
N2 807.68 ̂3 = 6470.749
𝐻 807.68 ̂6 = 9721.0586
𝐻
C8H4O3 - - 38.54 ̂7 = -1007786.829
𝐻
H20 - - 168.46 ̂8 = 4935110.734
𝐻
CO2 - - 52.84 ̂9 = -772925.9917
𝐻
C4H2O3 - - 13.21 ̂10 = 10230374.4
𝐻
67
Overall Energy Balance
𝑄̇ + 𝑊̇ = ∆𝐻̇ + ∆𝐸𝑘 + ∆𝐸𝑝
𝑄̇ = ∆𝐻̇
• Using Heat of Formation
∆𝐻̇ = ∑ 𝑛̇ 𝐻
̂ − ∑ 𝑛̇ 𝐻
̂
𝑜𝑢𝑡 𝑖𝑛
∆𝐻 = ∆𝐻𝑓𝑜 + ∆𝐻𝑖 𝑠𝑡𝑎𝑡𝑒

Inlet Stream (Stream 7)
C8H10 (at 25°C, liquid, 101.325 kPa) to C8H10 (at 245°C, vapour, 200 kPa)
• Ref: C8H10 (at 25°C, liquid, 1 atm)

𝐻𝑓𝑜 (𝑙) = −24440 𝑘𝐽/𝑘𝑚𝑜𝑙
𝐻𝑓𝑜 (𝑣) = −18990 𝑘𝐽/𝑘𝑚𝑜𝑙
̂ 𝟏 = 𝑯𝟏𝒂 + 𝑯𝟏𝒃 + 𝑯𝟏𝒄 + 𝑯𝟏𝒅

𝑯
𝐻1𝑎 = 𝐻𝑓𝑜 + ∆𝐻𝑖 𝑠𝑡𝑎𝑡𝑒
144
𝐻1𝑎 = −24440 + ∫ 41.69 + 7.773 × 10−2 𝑇

25
𝐻1𝑎 = −412.443 𝑘𝐽/𝑘𝑚𝑜𝑙
𝐻1𝑏 = ∆𝐻𝑣
𝐻1𝑏 = 36820 𝑘𝐽/𝑘𝑚𝑜𝑙
𝐻1𝑐 = 𝐻𝑓𝑜 + ∆𝐻𝑖 𝑠𝑡𝑎𝑡𝑒

245
𝐻1𝑐 = 18990 + ∫ (−15.851) + (59.62 × 10−2 )𝑇 − (3.443 × 10−4 )𝑇 2 + (75.279 × 10−9 )𝑇 3

144
𝐻1𝑐 = 27815.7338 𝑘𝐽/𝑘𝑚𝑜𝑙
𝐻1𝑑 = 𝐻𝑓𝑜 + ∆𝐻𝑖 𝑠𝑡𝑎𝑡𝑒

𝐻1𝑑 = 18990 𝑘𝐽/𝑘𝑚𝑜𝑙 + 0
𝐻1𝑑 = 18990 𝑘𝐽/𝑘𝑚𝑜𝑙
̂ 𝟏 = 𝑯𝟏𝒂 + 𝑯𝟏𝒃 + 𝑯𝟏𝒄 + 𝑯𝟏𝒅

𝑯
̂ 𝟏 = −412.443 + 36820 + 27815.7338 + 18990
𝑯
̂ 𝟏 = 83212.2908 𝑘𝐽/𝑘𝑚𝑜𝑙
𝑯
O2 (at 25°C, vapour, 101.325 kPa) to O2 (at 245°C, vapour, 200 kPa)
68
• Ref: O2 (at 25°C, vapour, 1 atm)
𝐻𝑓𝑜 = 0 𝑘𝐽/𝑘𝑚𝑜𝑙
̂ 𝟐 = 𝑯𝟐𝒂 + 𝑯𝟐𝒃
𝑯
245
𝐻2𝑎 = 0 + ∫ 29.10 × 10−3 + 1.158 × 10−5 T – 0.6076 × 10−8 𝑇 2 + 1.311 × 10−12 T 3

25
𝐻2𝑎 = 6717.35 𝑘𝐽/𝑘𝑚𝑜𝑙
̂ 𝟐 = 𝑯𝟐𝒂 + 𝑯𝟐𝒃
𝑯
̂ 𝟐 = 6717.35 + 0
𝑯
̂ 𝟐 = 6717.35 𝑘𝐽/𝑘𝑚𝑜𝑙
𝑯
N2 (at 25°C, vapour, 101.325 kPa) to N2 (at 245°C, vapour, 200 kPa)
• Ref: N2 (at 25°C, vapour, 1 atm)

̂ 𝟑 = 𝑯𝟑𝒂 + 𝑯𝟑𝒃
𝑯
245
𝐻3𝑎 = 0 + ∫ 29.00 × 10−3 + 0.2199 × 10−5 T + 0.5723 × 10−8 𝑇 2 − 2.871 × 10−12 T 3

25
𝐻3𝑎 = 6470.749 𝑘𝐽/𝑘𝑚𝑜𝑙
̂ 𝟑 = 𝑯𝟑𝒂 + 𝑯𝟑𝒃
𝑯
̂ 𝟑 = 6470.749 + 0
𝑯
̂ 𝟑 = 6470.749 𝑘𝐽/𝑘𝑚𝑜𝑙
𝑯
69
Outlet Stream (Stream 8)
C8H10 (at 25°C, liquid, 101.325 kPa) to C8H10 (at 353°C, vapour, 130 kPa)
• Ref: C8H10 (at 25°C, liquid, 1 atm)

̂ 𝟒 = 𝑯𝟒𝒂 + 𝑯𝟒𝒃 + 𝑯𝟒𝒄 + 𝑯𝟒𝒅

𝑯
144
𝐻4𝑎 = −24440 + ∫ 41.69 + 7.773 × 10−2 𝑇

25
𝐻4𝑎 = −412.443 𝑘𝐽/𝑘𝑚𝑜𝑙

353
𝐻4𝑐 = 18990 + ∫ (−15.851) + (59.62 × 10−2 )𝑇 − (3.443 × 10−4 )𝑇 2 + (75.279 × 10−9 )𝑇 3

144
𝐻4𝑐 = 42220.2647 𝑘𝐽/𝑘𝑚𝑜𝑙

𝐻4𝑑 = 18990 𝑘𝐽/𝑘𝑚𝑜𝑙 + 0
̂ 𝟒 = 𝑯𝟒𝒂 + 𝑯𝟒𝒃 + 𝑯𝟒𝒄 + 𝑯𝟒𝒅

𝑯
̂ 𝟒 = −412.443 + 36820 + 42220.2647 + 18990
𝑯
̂ 𝟒 = 97617.8217 𝑘𝐽/𝑘𝑚𝑜𝑙
𝑯
O2 (at 25°C, vapour, 101.325 kPa) to O2 (at 353°C, vapour, 130 kPa)
• Ref: O2 (at 25°C, vapour, 1 atm)

̂ 𝟓 = 𝑯𝟓𝒂 + 𝑯𝟓𝒃
𝑯
70
353
𝐻5𝑎 = 0 + ∫ 29.10 × 10−3 + 1.158 × 10−5 T – 0.6076 × 10−8 𝑇 2 + 1.311 × 10−12 T 3

25
𝐻5𝑎 = 10 145.8997 𝑘𝐽/𝑘𝑚𝑜𝑙
𝐻5𝑏 = 𝐻𝑓𝑜 + ∆𝐻𝑖 𝑠𝑡𝑎𝑡𝑒

̂ 𝟓 = 𝑯𝟓𝒂 + 𝑯𝟓𝒃
𝑯
̂ 𝟓 = 10145.8997 + 0
𝑯
̂
𝑯𝟓 = 10145.8997 𝑘𝐽/𝑘𝑚𝑜𝑙
N2 (at 25°C, vapour, 101.325 kPa) to N2 (at 353°C, vapour, 130 kPa)
• Ref: N2 (at 25°C, vapour, 1 atm)

̂ 𝟔 = 𝑯𝟔𝒂 + 𝑯𝟔𝒃
𝑯
353
𝐻6𝑎 = 0 + ∫ 29.00 × 10−3 + 0.2199 × 10−5 T + 0.5723 × 10−8 𝑇 2 − 2.871 × 10−12 T 3

25
𝐻6𝑎 = 9 721.0586 𝑘𝐽/𝑘𝑚𝑜𝑙

̂ 𝟔 = 𝑯𝟔𝒂 + 𝑯𝟔𝒃
𝑯
̂ 𝟔 = 9721.0586 + 0
𝑯
̂ 𝟔 = 9721.0586 𝑘𝐽/𝑘𝑚𝑜𝑙
𝑯
C8H4O3 (at 25°C, liquid, 101.325 kPa) to C8H4O3 (at 353°C, vapour, 130 kPa)
• Ref: C8H4O3 (at 25°C, liquid, 1 atm)

𝐻𝑓𝑜 = −371790 𝑘𝐽/𝑘𝑚𝑜𝑙
̂ 𝟕 = 𝑯𝟕𝒂 + 𝑯𝟕𝒃 + 𝑯𝟕𝒄 + 𝑯𝟕𝒅
𝑯
71
295
𝐻7𝑎 = −371790 + ∫ 41.69 + 7.773 × 10−2 𝑇

25
𝐻7𝑎 = −310 644.0366 𝑘𝐽/𝑘𝑚𝑜𝑙

353
𝐻7𝑐 = −371790 + ∫ (−4.455) + (65.398 × 10−2 )𝑇 − (4.283 × 10−4 )𝑇 2

295
+ (10.094 × 10−8 )𝑇 3
𝐻7𝑐 = −362172.792 𝑘𝐽/𝑘𝑚𝑜𝑙

𝐻7𝑑 = −371790 𝑘𝐽/𝑘𝑚𝑜𝑙 + 0
𝐻7𝑑 = −371790 𝑘𝐽/𝑘𝑚𝑜𝑙
̂ 𝟕 = 𝑯𝟕𝒂 + 𝑯𝟕𝒃 + 𝑯𝟕𝒄 + 𝑯𝟕𝒅

𝑯
̂ 𝟕 = −310644.0366 + 36820 − 362172.792 − 371790
𝑯
̂ 𝟕 = −1 007 786.829 𝑘𝐽/𝑘𝑚𝑜𝑙
𝑯
H2O (at 25°C, liquid, 101.325 kPa) to H2O (at 353°C, vapour, 130 kPa)
• Ref: H20 (at 25°C, liquid, 1 atm)

̂ 𝟖 = 𝑯𝟖𝒂 + 𝑯𝟖𝒃 + 𝑯𝟖𝒄 + 𝑯𝟖𝒅

𝑯
100
𝐻8𝑎 = −285840 + ∫ 75.4

25
𝐻8𝑎 = 5369160 𝑘𝐽/𝑘𝑚𝑜𝑙
𝐻8𝑏 = 40 656 𝑘𝐽/𝑘𝑚𝑜𝑙
72
353
𝐻8𝑐 = −241830 + ∫ (33.46 × 10−3 ) + (0.6880 × 10−5 )𝑇 + (0.7604 × 10−8 )𝑇 2

100
− (3.593 × 10−12 )𝑇 3
𝐻8𝑐 = −232 875.266 𝑘𝐽/𝑘𝑚𝑜𝑙

𝐻8𝑑 = −241830 𝑘𝐽/𝑘𝑚𝑜𝑙 + 0
𝐻8𝑑 = −241 830 𝑘𝐽/𝑘𝑚𝑜𝑙
̂ 𝟖 = 𝑯𝟖𝒂 + 𝑯𝟖𝒃 + 𝑯𝟖𝒄 + 𝑯𝟖𝒅

𝑯
̂ 𝟖 = −5369160 + 40 656 − 232875.266 − 241830
𝑯
̂ 𝟖 = 4 935 110.734 𝑘𝐽/𝑘𝑚𝑜𝑙
𝑯
CO2 (at 25°C, vapour, 101.325 kPa) to CO2 (at 353°C, vapour, 130 kPa)
• Ref: CO2 (at 25°C, vapour, 1 atm)

𝐻𝑓𝑜 = −393500 𝑘𝐽/𝑘𝑚𝑜𝑙
̂ 𝟗 = 𝑯𝟗𝒂 + 𝑯𝟗𝒃
𝑯
𝐻9𝑎 = −393500
353
+ ∫ 36.11 × 10−3 + 4.233 × 10−5 T − 2.887 × 10−8 𝑇 2

25
+ 7.464 × 10−12 T 3
𝐻9𝑎 = −379425.9917 𝑘𝐽/𝑘𝑚𝑜𝑙

𝐻9𝑏 = −393500 𝑘𝐽/𝑘𝑚𝑜𝑙
̂ 𝟗 = 𝑯𝟑𝒂 + 𝑯𝟑𝒃
𝑯
̂ 𝟗 = −379425.9917 − 393500
𝑯
̂ 𝟗 = −772 925.9917 𝑘𝐽/𝑘𝑚𝑜𝑙
𝑯
C4H2O3 (at 25°C, liquid, 101.325 kPa) to C4H2O3 (at 353°C, vapour, 130 kPa)
• Ref: C4H2O3 (at 25°C, liquid, 1 atm)
̂ 𝟏𝟎 = 𝑯𝟏𝟎𝒂 + 𝑯𝟏𝟎𝒃 + 𝑯𝟏𝟎𝒄 + 𝑯𝟏𝟎𝒅
𝑯
73
202
𝐻10𝑎 = 0 + ∫ 41.69 + 7.773 × 10−2 𝑇

25
𝐻10𝑎 = 37407.8336 𝑘𝐽/𝑘𝑚𝑜𝑙

353
𝐻10𝑐 = 0 + ∫ (−13.075) + (34.847 × 10−2 )𝑇 − (2.184 × 10−4 )𝑇 2 + (48.399 × 10−9 )𝑇 3

202
𝐻10𝑐 = 10 192 966.57𝑘𝐽/𝑘𝑚𝑜𝑙

̂ 𝟏𝟎 = 𝑯𝟏𝟎𝒂 + 𝑯𝟏𝟎𝒃 + 𝑯𝟏𝟎𝒄 + 𝑯𝟏𝟎𝒅

𝑯
̂ 𝟏𝟎 = 37407.8336 + 0 + 10 192 966.57 + 0
𝑯
̂ 𝟏𝟎 = 10 230 374.4 𝑘𝐽/𝑘𝑚𝑜𝑙
𝑯
Thus,
𝑄 = ∆𝐻̇ = ∑ 𝑛̇ 𝐻
̂ − ∑ 𝑛̇ 𝐻
̂
𝑜𝑢𝑡 𝑖𝑛
𝑄 = 895 007 338 − 11 250 178.33 𝑘𝐽/ℎ𝑟

𝑘𝐽 1ℎ𝑟
𝑄 = 883 757 159.6 ×
ℎ𝑟 3600𝑠
𝑄 = 245 488.1 𝑘𝑊
74
5.2 Switch Condenser
Reference State: O2(v) , N2(v) , C8H10(v), CO2(v), H2O(v), C8H4O3(l), C4H2O3(l) at 25°C and 1atm
Components Inlet Outlet (Upper Stream) Outlet (Bottom Stream)
Flow rate Flow rate Flow rate
Composition Composition Composition
(kg/hr) (kg/hr) (kg/hr)
O2 0.0002 7.0652 0.00025 6.9928 - -
N2 0.64 22608.7872 0.8083 22609.2089 - -
C8H10 0.0099 349.7297 - - 0.0476 350.0942
C8H4O3 0.1616 5708.7188 - - 0.7762 5708.8898
C4H2O3 0.0367 1296.4726 - - 0.1763 1296.6726
CO2 0.0658 2324.4659 0.0831 2324.4158 - -
H2O 0.0858 3030.9905 0.1084 3032.0899 - -
Total 35326.23 27971.3088 7354.9211
Table 5.2: Table shows the inlet-outlet enthalpy table for each of components in switch condenser
75
Inlet Stream
O from 25 C to 165 C, P=1 atm:
2 (v)
o o
C =2516529.10 x 10 T + 0.5723 x 10 T - 2.871 x 10 T dT

p
-3 -5 2 -12 3
C = 4080.3352 (kJ/mol. C)
p
o
4080.3352 kJ 0.001mol
mol.OC 1kmol
H = 4.0803 (kJ/kmol. C)
1
o
N from 25 C to 165 C, P=1 atm:

2 (v)
o o
165
C =∫25 29.00 + 0.2199 x 10 -3 T + 0.5723 x 10 T - 2.871 x 10 T dT
p
-5 2 -12 3
C = 4071.46381 kJ/mol. C
p
o
4071.46381 kJ 0.001mol
mol.OC 1kmol
H = 4.0715 (kJ/kmol. C)
2
o
CH
8 10 (v) from 25 C to 165 C, P=1 atm:
o o
165
C = ∫25 −15.851 +59.620 x 10-2T – 3.443 x 10-4 T-2+ 1.798 x 10-9 T3 dT
p
C = 5210.5083 (kJ/mol. C)
p
o
5210.5083 cal 0.001 mol
mol.OC 1kmol
H = 5.2106 kJ/kmol. C
3
o
76
C8H4O3(l) from 25 C to 165 C, P=1 atm:
o o
165
Cp= ∫25 −1.064 + 1.562 x 10-1 T -1.023 x 10-5 T2 + 2.411 x 10-9 T3 dT
Cp = 1957.8875 （cal/moloC）
1957.8875 cal 1 kcal 1kJ 0.001mol
mol.OC 1000 cal 0.239006kcal 1kmol
H4 = 0.00819 (kJ/kmoloC)
C4H2O3(l) from 25oC to 165oC, P=1 atm:

165
Cp = ∫25 −3.213 + 0.823 x 10-1 T – 5.217 x 10-5 T2 + 1.156 x 10-7T3 dT
Cp = 600.9331 (cal/mol.oC)
600.9331 cal 1 kcal 1kJ 0.001mol
H5 = 0.00251 (kJ/kmol.oC)
CO2 from 25 C to 165 C, P=1 atm:

(v)
o o
165
Cp = ∫25 −36.11 + 4.233 x 10-3T – 2.887 x 10-5-T2 + 7.464 x 10-12T3 dT
Cp = 5068.6214 (kJ/mol.oC)
5068.6214 kJ 0.001mol
mol.OC 1kmol
H6 = 5.069 (kJ/kmol.oC)
H2O from 25 C to 165 C, P=1 atm:

(v)
o o
165
Cp = ∫25 33.46 + 0.6880 x 10-3 T + 0.7604 x 10-5 T2 – 3.593 x 10-12 T3 dT
Cp = 4704.8962 (kJ/mol.oC)
77
4704.8962 kJ 0.001mol
mol.OC 1kmol
H7 = 4.705 (kJ/kmol.oC)
Outlet Stream (Upper)
O from 165 C to 140 C, P=1 atm:

2 (v)
o o
140
C =∫165 29.10 + 1.158 x 10-3T – 0.6076 x 10 T + 1.311 x 10 T dT
p
-5 2 -12 3
C = -728.3744 (kJ/mol. C)
p
O
-728.3744 kJ 0.001mol
mol.OC 1kmol
H = -0.7284 (kJ/kmol. C)
8
O
N from 165 C to 140 C, P=1 atm:

2 (v)
o o
140
Cp = ∫165 29.00 + 0.2199 x 10-3T – 0.5723 x 10-5T2 – 2.871 x 10-12T3 Dt
Cp = -722.5033 (kJ/mol.oC)
-722.5033 kJ 0.001mol
mol.OC 1kmol
H9 = -0.7225 (kJ/kmol.oC)
CO from 165 C to 140 C, P=1 atm:

2 (v)
o o
140
Cp = ∫165 36.11 + 4.233 x 10-3T – 2.887 x 10-5-T2 + 7.464 x 10-12T3 dT
Cp = -902.0662 (kJ/mol.oC)
78
-902.0662 kJ 0.001mol
mol.OC 1kmol
H10 = -0.9021 (kJ/kmol.oC)
H2O from 165 C to 140 C, P=1 atm:

(v)
o o
140
Cp = ∫165 33.46 + 0.6880 x 10-3 T + 0.7604 x 10-5 T2 – 3.593 x 10-12 T3 dT
Cp = -843.5536 (kJ/mol.oC)
-843.5536 kJ 0.001mol
mol.OC 1kmol
H11 = -0.8436 (kJ/kmol.oC)
Outlet Stream (Bottom):
CH
8 10 (v) from 165 C to 140 C, P=1 atm:
o o
140
C = ∫165 −3.786 +1.424 x 10-1T – 8.224 x 10-5 T-2+ 1.798 x 10-7 T3 dT
p
Cp = -416.3770 (cal/mol.oC)
-416.3770 cal 1 kcal 1kJ 0.001mol
mol. C
O
1000 cal 0.239006kcal 1kmol
Ha = -0.001742 (kJ/kmol.oC)
Hv = Hb = 36.82 kJ/mol
36.82 kJ 0.001mol
mol. C
O
1kmol
79
Hv=Hb = 0.03682 (kJ/kmol.oC)
H12 = Ha + Hb
H12 = -0.001742 + 0.03682
H12 = 0.03508 (kJ/kmol.oC)
C8H4O3(l) from 165 C to 140 C, P=1 atm:

o o
140
Cp= ∫165 −1.064 + 1.562 x 10-1 T -1.023 x 10-5 T2 + 2.411 x 10-9 T3 dT
Cp = -563.1666 (cal/moloC）
-563.1666 cal 1 kcal 1kJ 0.001mol
H13 = -0.002356 (kJ/kmoloC)
C4H2O3(l) from 165oC to 140oC, P=1 atm:

165
Cp = ∫25 −3.213 + 0.823 x 10-1 T – 5.217 x 10-5 T2 + 1.156 x 10-7T3 dT
Cp = -213.3623 (cal/mol.oC)
-213.3623 cal 1 kcal 1kJ 0.001mol
H14 = -0.000893 (kJ/kmol.oC)
To obtain the amount of heat released by SC-701:
Q=ΣnoutHout – ΣninHin
Q =-772.7507-4362.9203
Q =-5135.67 kJ/h
-5135.67 kJ 1h
h 3600s
Q = -1.4266 kJ/s ~ -1.4266kW
80
5.3 Distillation Column
Reference state: all liquid substance at 45℃, 1 atm

Substance Input Output
𝑛𝑖 𝐻𝑖𝑛 𝑛𝑜𝑢𝑡 𝐻𝑜𝑢𝑡
(kmol/h) (kJ/kmol) (kmol/h) (kJ/kmol)
Phthalic Anhydride, 38.5624 - 38.5460 𝐻1 = 211113.738
(𝐶8 𝐻4 𝑂3 ) Liq
Maleic Anhydride 13.2233 - - -
O-xylene (𝐶8 𝐻10) Liq 3.2978 - - -
Maleic Anhydride - - 13.2206 𝐻2 = 28525.4446

(𝐶4 𝐻2 𝑂3 ) Vap
O-xylene - - 3.2971 𝐻3 = 7220365
(𝐶8 𝐻10) Vap
∑ 𝑛𝐻𝑖𝑛 = 0 kJ/s ∑ 𝑛𝐻𝑜𝑢𝑡 = 32320980.7 kJ/hr
Table 5.3.1: Table shows the inlet-outlet enthalpy table for each of components in distillation column
81
𝐇𝟏
𝑃𝐴(𝑙) from 140℃ to 230℃, P =1 atm
230
Cp = ∫140 41.69 + 7.773 × 10−2 𝑇𝑑𝑇
= 5046.305 (cal/mol.℃)
5046.305 cal 4.184 k J 1000 mol
mol 1000 cal kmol
𝐻1 = 211113.738 kJ/kmol
𝐇𝟐
𝑀𝐴(𝑙) from 140℃ to 230℃, P =1 atm
202
Cp = ∫140 41.69 + 7.773 × 10−2 𝑇𝑑𝑇
= 3408.8734 (cal/mol.℃)
3408.8734 cal 4.184 k J 1000 mol
mol 1000 cal kmol
𝐻2𝑎 = 14262.72kJ/kmol
230
Cp = ∫202 −13.075 + 34.843 × 10−2 𝑇 − 2.184 × 10−4 𝑇 2 + 48.399 × 10−9 𝑇 3 𝑑𝑇
= 1469.4506 kJ/mol
𝐻2𝑏 = 14968450 kJ/kmol
∆𝐻𝑣 = 0
𝐻2 = 14262.72 + 14968450 + 0 = 28525.4446 kJ/kmol
82
𝐇𝟑
𝑂 𝑥𝑦𝑙(𝑙) from 140℃ to 230℃, P =1 atm
144
Cp = ∫140 41.69 + 7.773 × 10−2 𝑇𝑑𝑇
= 210.9106 (cal/mol.℃)
210.9106 cal 4.184 k J 1000 mol
mol 1000 cal kmol
𝐻3𝑎 = 882.440 kJ/kmol

230
Cp = ∫202 −15.851 + 59.62 × 10−2 𝑇 − 3.44 × 10−4 𝑇 2 + 75.279 × 10−9 𝑇 3 𝑑𝑇
= 7215.801 kJ/mol
𝐻3𝑏 = 14968450 kJ/kmol
∆𝐻𝑣 = 3682 kJ/kmol
𝐻3 = 882.440 + 14968450 + 3682 = 7220365.44 kJ/kmol
𝑄 = ∆𝐻 = ∑ 𝑛𝐻𝑜𝑢𝑡 − ∑ 𝑛𝐻𝑖𝑛
= 32320980.7 kJ/hr - 0 kJ/hr
= 8978.0497 kJ/s or kW
83
Reference state: 𝐶8 𝐻4 𝑂3 (l) and 𝐶4 𝐻2 𝑂3 (v) at 230℃, 1 atm

Substance Input Output
𝑛𝑖 𝐻𝑖𝑛 𝑛𝑜𝑢𝑡 𝐻𝑜𝑢𝑡
(kmol/h) (kJ/kmol) (kmol/h) (kJ/kmol)
Phthalic 36.1620 - - -
Anhydride,
Maleic 0.0577 - 0.0571 𝐻1 = 16.742
Anhydride
Phthalic - - 37.780 𝐻2 = 16887.118
Anhydride
∑ 𝑛𝐻𝑖𝑛 = 0 kJ/s ∑ 𝑛𝐻𝑜𝑢𝑡 = 6380556.274 kJ/hr
Table 5.3.2: Table shows the inlet-outlet enthalpy table for each of components in distillation column 2
84
𝐻1
𝑀𝐴(𝑉) from 230℃, P=1 atm to 𝑀𝐴(𝑉) 295℃, P =0.5 atm
295
Cp = ∫230 41.69 + 7.773 × 10−2 𝑇𝑑𝑇
= 4036.118 (cal/mol.℃)
4036.118 cal 4.184 k J 1000 mol
mol 1000 cal kmol
𝐻1 = 16.742 kJ/kmol
𝐻2
𝑃𝐴(𝑙) from 230℃, P=1atm to𝑃𝐴(𝑣) 295℃, P =0.5 atm
295
Cp = ∫230 41.69 + 7.773 × 10−2 𝑇𝑑𝑇
= 4036.118 (cal/mol.℃)
4036.118 cal 4.184 k J 1000 mol
mol 1000 cal kmol
𝐻2 = 16887.118 kJ/kmol
𝑄 = ∆𝐻 = ∑ 𝑛𝐻𝑜𝑢𝑡 − ∑ 𝑛𝐻𝑖𝑛
= 6380556.274kJ/hr - 0 kJ/hr
= 6380556.274 kJ/s or kW
85
5.4 Heat Exchanger
5.4.1 Air Furnace
Reference: O2, N2, 25℃, 1 atm, vapour phase
Component nin (kmol/hr) Ĥin (kJ/kmol) nout (kmol/h) Ĥout (kJ/kmol)
O2 214.6998 Ĥ1 214.6998 Ĥ3
N2 807.6802 Ĥ2 807.6802 Ĥ4
Inlet Stream:
Ĥ1: O2 (25℃, 1 atm, vapour phase) → O2 (25℃, 220 kPa, vapour phase)
Ĥ1 = ΔP = 0 kJ/kmol
Ĥ2: N2 (25℃, 1 atm, vapour phase) → N2 (25℃, 220 kPa, vapour phase)
86
Outlet Stream:
Ĥ3:
O2 (25℃, 1 atm, vapour phase) → O2 (245℃, 220 kPa, vapour phase)
Ĥ3a ↘ ΔT = ∫ Cp(Oxygen) dT Ĥ3b ↗ ΔP = 0 kJ/kmol
O2 (245℃, 1 atm, vapour phase)
Ĥ3a = ∫Cp(Oxygen)dT
245
=∫ (29.10 × 10−3 ) + (1.158 × 10−5 )𝑇 + (−0.6076 × 10−8 )𝑇 2 + (1.311 × 10−12 )𝑇 3 𝑑𝑇
25
= 6.71735 kJ/kmol
Ĥ3 = Ĥ3a + Ĥ3b
= 6.71735 + 0
= 6.71735 kJ/kmol
87
Ĥ4:
N2 (25℃, 1 atm, vapour phase) → N2 (245℃, 220 kPa, vapour phase)
Ĥ4a ↘ ΔT = ∫Cp (Nitrogen)dT Ĥ4b ↗ ΔP = 0 kJ/kmol
N2 (245℃, 1 atm, vapour phase)
Ĥ4a = ∫Cp(Nitrogen)dT
245
=∫ (29.00 × 10−3 ) + (0.2199 × 10−5 )𝑇 + (0.5723 × 10−8 )𝑇 2 + (−2.871 × 10−12 )𝑇 3 𝑑𝑇
25
= 6.47075 kJ/kmol
Ĥ4 = Ĥ4a + Ĥ4b
= 6.47075 + 0
= 6.47075 kJ/kmol
𝑄 = 𝛥𝐻
= ∑𝑜𝑢𝑡𝑙𝑒𝑡 𝑛𝑖Ĥ𝑖 − ∑𝑖𝑛𝑙𝑒𝑡 𝑛𝑖Ĥ𝑖
𝑄 = ⦗(214.6998)(𝟔. 𝟕𝟏𝟕𝟑𝟓) + (807.6802)(6.47075)⦘ − ⦗(214.6998)(0) + (807.6802)(0)⦘
= 6668.5104 kJ/hr × 1 hr/3600 s
= 1.852364 kJ/s
= 1.852364 kW
88
5.4.2 O-xylene Pre-Heater
Reference: C8H10, 25℃, 1 atm, liquid phase

Component nin (kmol/hr) Ĥin (kJ/kmol) nout (kmol/h) Ĥout (kJ/kmol)
C8H10 55.06 Ĥ1 55.06 Ĥ2
Inlet Stream:
Ĥ1: C8H10 (25℃, 1 atm, liquid phase) → C8H10 (25℃, 290 kPa, liquid phase)
89
Outlet Stream:
Ĥ2:
C8H10 (25℃, 1 atm, liquid phase) → C8H10 (245℃, 290 kPa, vapour phase)
Ĥ2a ↓ ΔT = ∫Cp(o-xylene)dT
C8H10 (144.42℃, 1 atm, liquid phase) Ĥ2d ↑ ΔP = 0 kJ/kmol
Ĥ2b ↓ Δphase = ΔĤv (from Table B1)
C8H10 (144.42℃, 1 atm, vapour phase) → C8H10 (245℃, 1 atm, vapour phase)
Ĥ2c : ΔT = ∫Cp(o-xylene)dT
Ĥ2a = ∫Cp(o-xylene)dT
144.42
=∫ (41.69) + (7.773 × 10−2 )𝑇 𝑑𝑇
25
= 5764 cal/mol × 1000 mol/kmol × 4.148 J/cal × 0.001 kJ/J
= 23912.9785 kJ/kmol
Ĥ2b = ΔĤv
= 36.82 kJ/mol (from Table B.1) × 1000 mol/kmol
= 36820 kJ/kmol
90
Ĥ2c = ∫Cp(o-xylene)dT
245
=∫ (−15.851) + (59.620 × 10−2 )𝑇 + (−3.443 × 10−4 )𝑇 2 + (75.279 × 10−8 )𝑇 3 𝑑𝑇
144.42
= 8799.1929 kJ/kmol
Ĥ2d = ΔP = 0 kJ/kmol
Ĥ2 = Ĥ2a + Ĥ2b + Ĥ2c + Ĥ2d
= 23912.9785 + 36820 + 8799.1929 + 0
= 69532.1715 kJ/kmol
𝑄 = 𝛥𝐻
= ∑𝑜𝑢𝑡𝑙𝑒𝑡 𝑛𝑖Ĥ𝑖 − ∑𝑖𝑛𝑙𝑒𝑡 𝑛𝑖Ĥ𝑖
𝑄 = ⦗(55.06)( 69532.1715)⦘ − ⦗(55.06)(0)⦘
= 3828441.36 kJ/hr × 1 hr/3600 s
= 1063.4559 kJ/s or 1063.4559 kW
91
5.5 Pump
ΔH1 T=245°C
P=1.97
T=25° atm
C
P=1
Energy balance for Pump 1:atm
ΔH = ∑ 𝑛𝑖 (ΔȞ𝑡 ) − ∑ 𝑛𝑖 (ΔȞ𝑡 )
𝑜𝑢𝑡𝑙𝑒𝑡 𝑖𝑛𝑙𝑒𝑡
Reference state: C8H10 (g, 25°C, 1 atm)

Inlet Outlet
Substances
nin (kmol/h) Ȟin (kJ/h) nout (kmol/h) Ȟout (kJ/h)
O-xylene(C8H10) 55.06 H1 55.06 H2
Inlet:
𝒌𝑱
Δ𝐻1 = ∑𝑖𝑛𝑙𝑒𝑡 𝑛𝑖 (ΔȞ𝑡 ) = 𝟎 (since the stream in reference condition)
𝒉
Outlet:
𝒌𝑱
Δ𝐻2 = ∑𝑜𝑢𝑡𝑙𝑒𝑡 𝑛𝑖 (ΔȞ𝑡 ) = 𝟎 (Heat changes from pressure differences was neglected)
𝒉
ΔH = ∑𝑜𝑢𝑡𝑙𝑒𝑡 𝑛𝑖 (ΔȞ𝑡 ) − ∑𝑖𝑛𝑙𝑒𝑡 𝑛𝑖 (ΔȞ𝑡 ) = 0 𝑘𝑊 (Power for Pump 1)
92
5.6 Compressor
ΔH3 ΔH4
T=25° T=245°C
C P=2.17
P=1 atm
atm
Energy balance for Compressor 1:
ΔH = ∑ 𝑛𝑖 (ΔȞ𝑡 ) − ∑ 𝑛𝑖 (ΔȞ𝑡 )
𝑜𝑢𝑡𝑙𝑒𝑡 𝑖𝑛𝑙𝑒𝑡
Reference state: O2, N2 (g, 25°C, 1 atm)

Inlet Outlet
Substances
nin (kmol/h) Ȟin (kJ/h) nout (kmol/h) Ȟout (kJ/h)
Oxygen (O2) 429.4 H3a 429.4 H4a
Nitrogen (N2) 1615.36 H3b 1615.36 H4b
Inlet:
𝒌𝑱
Δ𝐻3 = ∑𝑖𝑛𝑙𝑒𝑡 𝑛𝑖 (ΔȞ𝑡 ) = 𝟎 (Since the stream in reference condition)
𝒉
Outlet:
𝒌𝑱
Δ𝐻4 = ∑𝑜𝑢𝑡𝑙𝑒𝑡 𝑛𝑖 (ΔȞ𝑡 ) = 𝟎 (Heat changes from pressure differences was neglected)
𝒉
ΔH = ∑𝑜𝑢𝑡𝑙𝑒𝑡 𝑛𝑖 (ΔȞ𝑡 ) − ∑𝑖𝑛𝑙𝑒𝑡 𝑛𝑖 (ΔȞ𝑡 ) = 0 𝑘𝑊 (Power for Compressor 1)
93
6.0 EQUIPMENT
DESIGN
94
6.0 EQUIPMENT DESIGN
6.1 Heuristic of Equipment

6.1.1 Heuristic for Reactor (R-701)
Referring to the data from stream table and material balance:

No. of stream 7, 8
Flowrate Stream 7 (kg/hr) 35332.51
Flowrate Stream 8 (kg/hr) 35326.23
Density of o-xylene (kg/m3) 880
Density of oxygen (kg/m3) 1.4290
Density of nitrogen (kg/m3) 1.2506
Density of phathalic anhydride (kg/m3) 1530
Density of maleic anhydride (kg/m3) 1480
Density of water (kg/m3) 997
Density of carbon dioxide (kg/m3) 1.93
95
Residence time for our reaction takes up until 0.5 to 50 seconds. (United States Patent No.
3431284, 1965)
Rule 5 (Table 11.17)
Inlet Stream:
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒 (𝑠𝑡𝑟𝑒𝑎𝑚 8)
kg
35326.23
= hr
(880 × 0.0099) + (1.4290 × 0.0002) + (1.2506 × 0.64) + (1530 × 0.1616) + (1480 × 0.0367) + (997 × 0.0858) + (1.93 × 0.0658)
𝑚3 𝑚3 𝑚3
= 101.92 ℎ𝑟
= 1.6987 𝑚𝑖𝑛 = 0.0282 𝑠𝑒𝑐
Outlet Stream:
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒 (𝑠𝑡𝑟𝑒𝑎𝑚 8)
kg
35326.23
= hr
(880 × 0.0099) + (1.4290 × 0.0002) + (1.2506 × 0.64) + (1530 × 0.1616) + (1480 × 0.0367) + (997 × 0.0858) + (1.93 × 0.0658)
𝑚3 𝑚3 𝑚3
= 101.92 = 1.6987 = 0.0282
ℎ𝑟 𝑚𝑖𝑛 𝑠𝑒𝑐
Volume of the Reactor (R-701):
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 (𝑚3 )

𝑀𝑒𝑎𝑛 𝑅𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 𝑇𝑖𝑚𝑒 =
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝐸𝑛𝑡𝑒𝑟𝑖𝑛𝑔 𝑡ℎ𝑒 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 (𝑚3 /𝑚𝑖𝑛)
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 (𝑚3 )

50 𝑠𝑒𝑐𝑜𝑛𝑑𝑠 =
0.0671 (𝑚3 /𝑠𝑒𝑐)
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 (𝑅 − 701) = 3.4 𝑚3
96
Rule 3 ( Table 11.17)
The Diameter of the Stirred Tank Reactor (R-701):

- Liquid level is equal to the tank diameter, (𝐻𝐿𝑖𝑞𝑢𝑖𝑑 = 𝐷 𝑇𝑎𝑛𝑘 )
𝜋𝐷 2 (𝐷)
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 =
4
𝜋𝐷 2 (𝐷)
3.4 𝑚3 =
4
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 (𝑅 − 701) = 1.63 𝑚
In order to achieve the optimum proportions of stirred tank reactor (R-701), we take
that the level of liquid in the tank is equal to the diameter of the tank. Thus, it gives us the value
of 1.63m.

Power input to a homogenous reaction stirred tank reactor is 0.1 kW/m3 but three times
this amount when heat is to be transferred.

The effect of temperature on chemical reaction rate is to double the rate every 10°C.

The rate of reaction in a heterogeneous system is more often controlled by the rate of heat
or mass transfer than by the chemical reaction kinetics.
97
6.1.2 Heuristic for Switch Condenser (SC-701)
Referring to the data from stream table and material balance:

Compound Molecular Weight (MW), kg/kmol Density 𝜌, kg/m3
O’xylene (C8H10) 106.16 880
Oxygen (O2) 28.014 1.4290
Nitrogen (N2) 31.999 1.2506
Phthalic Anhydride (C8H4O3) 148.1 1530
Maleic Anhydride (C4H2O3) 98.06 1480
Water (H2O) 18.015 997
Carbon Dioxide (CO2) 44.009 1.93
The process operating conditions:

Temperature Inlet 353°C Pressure Inlet 130 kPa
Temperature Outlet 140°C Pressure Outlet 100 kPa
Cooling Water Inlet 30 °C Cooling Water Outlet 40 °C
98
From Table 11.11
Rule 3:
Tube side is for corrosive, fouling, scaling and high pressure fluids.
Rule 4:
Shell side is for viscous and condensing fluids
Rule 6:
Minimum temperature approach is 10°C (20°F) for fluids.
Rule 7:
Cooling water inlet is 30°C, maximum outlet 45°C
Rule 9:
Double pipe exchanger is competitive at duties requiring 9.3-18.6 m2
1. Use double pipe heat exchanger.

2. The effect of low partial pressure of phthalic anhydride in the stream, makes it desublimates
the gas phase into solid phase rather than condenses.
The switch condenser desublimates the vapor phase oxidation product using the cold
condenser oil, and then melts off the solid phase crude phthalic anhydride product using hot
condenser oil heated with steam. Both the hot condenser oil and cold condenser oil are pumped
through a multiple valve and piping arrangement into the switch condensers equipped with
horizontally disposed finned heat exchanger tubes.
3. There are three such devices, one operating in desublimation mode, one operating in melting
mode, and one on standby.
4. The net result is a liquid stream containing the condensable (o-xylene, phthalic anhydride &
maleic anhydride), and a vapor stream containing water and the non-condensable.
5. Indicate operation at any scale is possible as long as the pressure of Stream 10 remains within
10% of current operating conditions, and as long as the relative composition of the
condensables (o-xylene, phthalic anhydride & maleic anhydride) remains approximately
constant.
99
6.1.3 Heuristic for Distillation Column 1 (T-701)
Constant for Antoine’s Equation:
Component A B C
Maleic Anhydride 16.2747 3765.65 -82.15
Phthalic Anhydride 15.9984 4467.01 -83.15
Table 6.1.3 : Coulson and Richardson’s Chemical Engineering: Appendix C
Distillation column 1 is used for separating Maleic Anhydride. Thus, it is also known as Maleic
Anhydride column.
Relative volatility
𝑃1𝑠𝑎𝑡
𝛼𝑎𝑣𝑔 =
𝑃2𝑠𝑎𝑡
For multi-component system, the relative volatility is as follows:
𝛼𝑎𝑣𝑔 = 3√𝛼𝐹𝑖𝑗 𝛼𝐵𝑖𝑗 𝛼𝐷𝑖𝑗
In order to find the vapor pressure of each component, Antoine equation is used as below:
𝐵
𝑙𝑛𝑃(𝑚𝑚𝐻𝑔) = 𝐴 −
𝑇(𝐾) + 𝐶
For Feed
Vapor pressure of Maleic Anhydride at 140˚C, P1sat:

3765.65
𝑙𝑛𝑃1𝑠𝑎𝑡 = 16.2747 −
413.15 + (−82.15)
𝑃1𝑠𝑎𝑡 = 134.0367 𝑚𝑚𝐻𝑔
𝑃1𝑠𝑎𝑡 = 0.1764 𝑎𝑡𝑚
Vapor pressure of Phthalic Anhydride at 140˚C, P2sat:
4467.01
𝑙𝑛𝑃2𝑠𝑎𝑡 = 15.9984 −
413.15 + (−83.15)
𝑃2𝑠𝑎𝑡 = 11.7283 𝑚𝑚𝐻𝑔
𝑃2𝑠𝑎𝑡 = 0.0154 𝑎𝑡𝑚
100
Relative volatility for feed:
0.1764 𝑎𝑡𝑚
𝛼𝐹𝑖𝑗 =
0.0154 𝑎𝑡𝑚
𝛼𝐹𝑖𝑗 = 11.4308
For Distillate

3765.65
𝑙𝑛𝑃1𝑠𝑎𝑡 = 16.2747 −
503.15 + (−82.15)
𝑃1𝑠𝑎𝑡 = 1525.6307 𝑚𝑚𝐻𝑔
𝑃1𝑠𝑎𝑡 = 2.0074 𝑎𝑡𝑚

4467.01
𝑙𝑛𝑃2𝑠𝑎𝑡 = 15.9984 −
503.15 + (−83.15)
𝑃2𝑠𝑎𝑡 = 213.2920 𝑚𝑚𝐻𝑔
𝑃2𝑠𝑎𝑡 = 0.2806 𝑎𝑡𝑚

2.0074 𝑎𝑡𝑚
𝛼𝐵𝑖𝑗 =
0.2806 𝑎𝑡𝑚
𝛼𝐷𝑖𝑗 = 7.1540
For Bottom
The relative volatility of the bottom part of the column is same as the distillate because its
temperature condition is same which is 100˚C. Thus,
𝛼𝐵𝑖𝑗 = 𝛼𝐷𝑖𝑗 = 7.1540

The average volatility is:
3
𝛼𝑎𝑣𝑔 = √(11.4308)(7.1540)(7.1540)
𝛼𝑎𝑣𝑔 = 8.3636
101
Rule 7 (Table 11.13) : The minimum number of trays with Fenske-Underwood equation.
For multi-component system using Fenske equation:
(𝑋𝐷𝑖 /𝑋𝐵𝑖 )
𝑙𝑛 [ ]
(𝑋𝐷𝑗 /𝑋𝐵𝑗 )
𝑁𝑚𝑖𝑛 = −1
𝑙𝑛 𝛼
(0.7604/0.001)
𝑙𝑛 [ ]
(0.0335/0.999)
𝑙𝑛 8.3636
𝑁𝑚𝑖𝑛 = 5.7855
Rule 6 (Table 11.13) : The optimum number of theoretical trays is near 2Nmin
𝑁𝑜𝑝𝑡 = 2𝑁𝑚𝑖𝑛 = 11.5711
Rule 9 (Table 11.13) : A safety factor of 10% on number of trays
2𝑁𝑚𝑖𝑛 (1 + 0.1)
𝑁𝑎𝑐𝑡𝑢𝑎𝑙 =
𝜀
11.5711(1 + 0.1)
0.85
𝑁𝑎𝑐𝑡𝑢𝑎𝑙 = 14.9744
Rule 4 (Table 11.14) : Tray efficiencies for distillation of light hydrocarbons and aq. Solution
𝜀 = 60 → 90%
It is assumed that the tray efficiencies is 𝛆 = 𝟖𝟓%
Rule 8 (Table 11.13) : Minimum reflux at bubble point
(𝐹/𝐷) 55.0947/16.844
𝑅𝑚𝑖𝑛 = =
(𝛼 − 1) (8.3636 − 1)
𝑅𝑚𝑖𝑛 = 0.4442
Rule 5 (Table 11.13) : The optimum reflux in the range of 1.2-1.5Rmin
𝑅 = (1.2 → 1.5)𝑅𝑚𝑖𝑛
The optimum reflux is assumed to be 1.2𝐑 𝐦𝐢𝐧
𝑅 = (1.2)𝑅𝑚𝑖𝑛 = (1.2)0.4442
𝑅 = 0.5330
102
𝑚 𝑘𝑔 0.5
Rule 2 (Table 11.14) : Peak efficiency of vapor factor in range 1.2 − 1.5 [𝑚3 ]
𝑠
𝐹𝑠 = 𝑢𝜌𝑣0.5
𝑚 𝑘𝑔 0.5
The efficiency of vapor factor is assumed to be1.35 [𝑚3 ]
𝑠
In order to find the density of the vapor in the distillate, equation below is used:
𝜌 = ∑(𝑋𝑖 𝜌𝑖 )𝑛
For substance at distillate:

Molar Molecular Mass
Mass Density, ρ
Substances flowrate weight flowrate xρ
fraction, x (kg/m3)
(kmol/hr) (kg/kmol) (kg/hr)
Phthalic
0.5643 148.10 56.2620 0.0035 1530 5.3550
Anhydride
Maleic
12.8082 98.06 1277.0637 0.7603 1480 1125.24
Anhydride
O-xylene 3.4732 106.16 346.3053 0.2062 880 181.4560
Total 1312.051
𝜌 = 1312.051 𝑘𝑔/𝑚3
𝐹𝑠 1.35
𝑢= =
𝜌𝑣0.5 1312.050.5
𝑢 = 0.0373 𝑚/𝑠
The diameter, D of the tower is assumed to be 1.2 m
Add spacing for top and bottom vapor and liquid return The tray spacing is
assumed to be 0.3 m.
𝐻 = (𝑡𝑟𝑎𝑦 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 𝑥 𝑁𝑎𝑐𝑡𝑢𝑎𝑙 ) + 3𝑚

𝐻 = (0.3 𝑥 14.9744 ) + 3𝑚
𝐻 = 7.492𝑚
Rule 14 (Table 11.13) : Limit tower height to 53 m or L/D<30
𝐿 7.492𝑚
= = 6.243 < 30
𝐷 1.2𝑚
103
6.1.4 Heuristic for Distillation Column 2 (T-702)
Constant for Antoine’s Equation:
Component A B C
Maleic Anhydride 16.2747 3765.65 -82.15
Phthalic Anhydride 15.9984 4467.01 -83.15
Table 6.1.4 : Coulson and Richardson’s Chemical Engineering: Appendix C
Distillation column 2 is used for separating Phthalic Anhydride. Thus, it is also known as
Phthalic Anhydride column.
Relative volatility
𝑃1𝑠𝑎𝑡
𝛼𝑎𝑣𝑔 =
𝑃2𝑠𝑎𝑡
For multi-component system, the relative volatility is as follows:
𝛼𝑎𝑣𝑔 = 3√𝛼𝐹𝑖𝑗 𝛼𝐵𝑖𝑗 𝛼𝐷𝑖𝑗
In order to find the vapor pressure of each component, Antoine equation is used as below:
𝐵
𝑙𝑛𝑃(𝑚𝑚𝐻𝑔) = 𝐴 −
𝑇(𝐾) + 𝐶
For Feed
4467.01
𝑙𝑛𝑃1𝑠𝑎𝑡 = 15.9984 −
503.15 + (−83.15)
𝑃1𝑠𝑎𝑡 = 213.2920 𝑚𝑚𝐻𝑔
𝑃1𝑠𝑎𝑡 = 0.2806 𝑎𝑡𝑚

3765.65
𝑙𝑛𝑃2𝑠𝑎𝑡 = 16.2747 −
503.15 + (−82.15)
𝑃2𝑠𝑎𝑡 = 1525.6307 𝑚𝑚𝐻𝑔
𝑃2𝑠𝑎𝑡 = 2.0074 𝑎𝑡𝑚
104
0.2806 𝑎𝑡𝑚
𝛼𝐹𝑖𝑗 =
2.0074 𝑎𝑡𝑚
𝛼𝐹𝑖𝑗 = 0.1398
For Distillate

3765.65
𝑙𝑛𝑃1𝑠𝑎𝑡 = 16.2747 −
568.15 + (−82.15)
𝑃1𝑠𝑎𝑡 = 5046.4937 𝑚𝑚𝐻𝑔
𝑃1𝑠𝑎𝑡 = 6.6401 𝑎𝑡𝑚

4467.01
𝑙𝑛𝑃2𝑠𝑎𝑡 = 15.9984 −
568.15 + (−83.15)
𝑃2𝑠𝑎𝑡 = 887.1997 𝑚𝑚𝐻𝑔
𝑃2𝑠𝑎𝑡 = 1.1674 𝑎𝑡𝑚

6.6401 𝑎𝑡𝑚
𝛼𝐵𝑖𝑗 =
1.1674 𝑎𝑡𝑚
𝛼𝐷𝑖𝑗 = 5.6881
For Bottom
The relative volatility of the bottom part of the column is same as the distillate because its
temperature condition is same which is 100˚C. Thus,
𝛼𝐵𝑖𝑗 = 𝛼𝐷𝑖𝑗 = 5.6881

The average volatility is:
3
𝛼𝑎𝑣𝑔 = √(13.98)(5.6881)(5.6881)
𝛼𝑎𝑣𝑔 = 7.6762
105
Rule 7 (Table 11.13) : The minimum number of trays with Fenske-Underwood equation.
For multi-component system using Fenske equation:
(𝑋𝐷𝑖 /𝑋𝐵𝑖 )
𝑙𝑛 [ ]
(𝑋𝐷𝑗 /𝑋𝐵𝑗 )
𝑙𝑛 𝛼
(0.999/0.01)
𝑙𝑛 [ ]
(0.001/0.99
𝑙𝑛 8.3636
𝑁𝑚𝑖𝑛 = 5.4154
Rule 6 (Table 11.13) : The optimum number of theoretical trays is near 2Nmin
𝑁𝑜𝑝𝑡 = 2𝑁𝑚𝑖𝑛 = 10.8310
Rule 9 (Table 11.13) : A safety factor of 10% on number of trays
2𝑁𝑚𝑖𝑛 (1 + 0.1)
𝜀
10.8310(1 + 0.1)
0.85
𝑁𝑎𝑐𝑡𝑢𝑎𝑙 = 14.0165
Rule 4 (Table 11.14) : Tray efficiencies for distillation of light hydrocarbons and aq. Solution
𝜀 = 60 → 90%
It is assumed that the tray efficiencies is 𝛆 = 𝟖𝟓%
Rule 8 (Table 11.13) : Minimum reflux at bubble point
(𝐹/𝐷) 36.2197/37.780
𝑅𝑚𝑖𝑛 = =
(𝛼 − 1) (7.6762 − 1)
𝑅𝑚𝑖𝑛 = 0.1436
Rule 5 (Table 11.13) : The optimum reflux in the range of 1.2-1.5Rmin
𝑅 = (1.2 → 1.5)𝑅𝑚𝑖𝑛
The optimum reflux is assumed to be 1.2𝐑 𝐦𝐢𝐧
𝑅 = (1.2)𝑅𝑚𝑖𝑛 = (1.2)0.1436
𝑅 = 0.1723
106
𝑚 𝑘𝑔 0.5
Rule 2 (Table 11.14) : Peak efficiency of vapor factor in range 1.2 − 1.5 [𝑚3 ]
𝑠
𝐹𝑠 = 𝑢𝜌𝑣0.5
𝑚 𝑘𝑔 0.5
The efficiency of vapor factor is assumed to be1.35 [𝑚3 ]
𝑠
In order to find the density of the vapor in the distillate, equation below is used:
𝜌 = ∑(𝑋𝑖 𝜌𝑖 )𝑛
For substance at distillate:

Molar Molecular Mass
Mass Density, ρ
Substances flowrate weight flowrate xρ
fraction, x (kg/m3)
(kmol/hr) (kg/kmol) (kg/hr)
Phthalic
36.1620 148.10 5595.2829 0.99 1530 1514.7
Anhydride
Maleic
0.0577 98.06 56.5180 0.01 1480 14.8
Anhydride
O-xylene - 106.16 - - 880 -
Total 1529.5
𝜌 = 1312.051 𝑘𝑔/𝑚3
𝐹𝑠 1.35
𝑢= =
𝜌𝑣0.5 1529.50.5
𝑢 = 0.0345 𝑚/𝑠
The diameter, D of the tower is assumed to be 1.2 m
Add spacing for top and bottom vapor and liquid return The tray spacing is
assumed to be 0.3 m.
𝐻 = (𝑡𝑟𝑎𝑦 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 𝑥 𝑁𝑎𝑐𝑡𝑢𝑎𝑙 ) + 3𝑚

𝐻 = (0.3 𝑥 14.0165 ) + 3𝑚
𝐻 = 7.2050 𝑚
Rule 14 (Table 11.13) : Limit tower height to 53 m or L/D<30
𝐿 7.2050 𝑚
= = 6.0041 < 30
𝐷 1.2 𝑚
107
6.1.5 Heuristic for Air Furnace (H-701)
The function of Unit H-701 Air Furnace is to prepare and heat the air to reaction temperature.
This unit consists of four identical banks of tubes - currently these are all in operation and are
running in parallel - piping and valving apply to run any or all tube banks in any configuration
(i.e., series, parallel, etc.) - there is a control mechanism which maintains the temperature of
Stream 5 by taking the temperature of Stream 5 and regulating the natural gas and air feed rate.
Referring to the data from stream table and energy balance:

Unit process conditions
Process fluid Air
Fluid flow rate (kg/h) 29608.12
Specific gravity at 27°C 1.000
Molecular weight (kg/kmol) 28.9647
Specific heat at 27°C (kJ/kg. K) 0.718
Inlet conditions
Temperature (°C) 25
Pressure (kPa) 220
3
Fluid density (kg/m ) 1.225
Fluid viscosity (Pa.s) 1.86×10-5
Percentage of weight of vapour 100
Outlet conditions
Pressure (kPa) 220
Flue gas characteristics
Molar heat (kJ/kmol.K) 29.98+3.157×10-3×T
Specific heat(kJ/kg.K) 1.0775+1.1347×10-4×T
Composition (% mol) CO2 (8.234), H2O (15.968), O2
(3.82), N2(71.79), SO2 (0.188)
108
From table 11.11 Heuristics for Heat Exchangers:
Rule 13 (Fired heaters): Approximately equal transfer in the two sections

Radiant rate = 37.6 kW/m (12,000 Btu/hr ft), Convection rate = 12.5 kW/m (4000 Btu/hr ft)
Duty = 6668.64 kJ/hr

= 1.8524 kW
Area of radiant section = (0.5) (1.8524) / (37.6)

= 0.02463 m2
Area of convective section = (0.5) (1.8524) / (12.5)

= 0.074096 m2
109
6.2.1 Heuristic for o-Xylene Pre-Heater (E-701)
The function of Unit E-701 o-Xylene Preheater is to vaporize o-xylene feed to match the
reaction requirement. This unit uses high pressure steam, steam in shell, Q = 3828.4412 MJ/hr.
Referring to the data from stream table and energy balance:

Unit process conditions
Process fluid o-Xylene
Fluid flow rate (kg/h) 5847.07
Specific gravity at 20°C 0.865
Specific heat at 27°C (kJ/kg. K) 1.7615
Inlet conditions
Pressure (kPa) 290
3
Fluid density (kg/m ) 880
Fluid viscosity (Pa.s) 810200
Percentage of weight of vapour 0.0
Outlet conditions
Pressure (kPa) 290
Steam conditions
Inlet Temperature (°C) 300
Outlet Temperature (°C) 30
110
From table 11.6 Heuristics for Process Vessels (Drums):
Rule 3 : Gas-liquid phase separators are usually vertical.

Rule 4 : Optimum ratio of length to diameter = 3, but the range 2.5 to 5 is common.
Rule 5 : Holdup time, 5–10 min for a product feeding another tower.
For our preheater, we decide to assume our diameter is = 1.6, which is the standard diameter
of the evaporator (Course Hero).
Liquid flow = Stream 2 = 5847.07 kg/h, T = 25 °C
𝜌𝐿= density of C8H10

= 880 kg/m3
D = 1.6 m (standard diameter of evaporator)
Volume of liquid = 𝐿𝜋𝐷2/4

= 2.011L m3
10 min liquid flow to ensure all liquid is fully changed into vapour.
Volumetric flowrate = (10min) (60s/min) (5847.07kg/hr)/(880kg/m3)(3600s/hr)

= 1.1074 m3
1.1074 = 2.011 L
L = 0.5507 m
Based on Rule 4, L/D should be in the range of 2.5 to 5:
L/D = 0.5507/1.6
= 0.3442
Because this is out of range, change ratio to 3 as the optimum ratio:

L=3D
= 4.8 m
111
From table 11.11 Heuristics for Heat Exchangers:
Rule 1: F=0.9
Rule 3: Tube side is for corrosive, fouling, scaling, and high-pressure fluids.
Rule 4: Shell side is for viscous and condensing fluids.
Rule 6: Minimum temperature approach= 10oC
Rule 8: Liquid to gas, U= 60 W/m2.℃
Tlm = ((ΔT1)-(ΔT2))/(ln ΔT1/ΔT2)

Tlm = ((300.00 - 245.00)-(30.00 - 25.00))/(ln 55.00/5.00)
Tlm = 20.85℃
From energy balance: Q = 3828.4412 MJ/hr
A = Q/UΔTlmF
= 3828.4412/(60(20.85)(0.9))
= 3.4003 m2
112
7.0 ECONOMIC
ANALYSIS
113
7.0 ECONOMIC ANALYSIS
7.1 Cost of Equipment

7.1.1 Cost of Reactor (R-701)
Volume = 3.4 𝑚3
From table A.1, Reactor Jacketed and Agitated
𝐾1 = 4.1052
𝐾2 = 0.5320
𝐾3 = -0.0005
𝑙𝑜𝑔10 𝐶𝑝° = 𝐾1 + 𝐾2 𝑙𝑜𝑔10 (𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟 ) + 𝐾3 [𝑙𝑜𝑔10 (𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟 )]2

𝑙𝑜𝑔10 𝐶𝑝° = 4.1052 + (0.5320)𝑙𝑜𝑔10 (3.4) + (-0.0005) [𝑙𝑜𝑔10 (3.4)]2
𝑙𝑜𝑔10 𝐶𝑝° = 4.3878
𝐶𝑝° = 24420.74
From table A.7, Reactor Jacketed and Agitated, 𝐹𝐵𝑀 = 4

𝐶𝐵𝑀,2001 = 𝐶𝑝° × 𝐹𝐵𝑀
= 24420.74 × 4
= $ 97 682.95
CEPCI value for year 2001 is 394 while CEPCI value for 2019 is 607.5. Thus,
607.5
𝐶𝐵𝑀,2019 = 97682.95( 394 )
= $ 150 615.21
114
7.1.2 Cost of Switch Condenser (SC-701)
From switch condenser (SC-701) heuristic rule 9, double pipe heat exchanger is competitive at
duties requiring area is 9.3 -18.6 𝑚2 .
To calculate 𝐶𝑝° area must be between 1 -10𝑚2 . Thus, suitable area for this double pipe heat
exchanger is 9.3𝑚2 .
From table A.1, Heat exchanger Double pipe
𝐾1 = 3.3444
𝐾2 = 0.2745
𝐾3 = -0.0472
𝑙𝑜𝑔10 𝐶𝑝° = 𝐾1 + 𝐾2 𝑙𝑜𝑔10 (𝐴𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟 ) + 𝐾3 [𝑙𝑜𝑔10 (𝐴𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟 )]2

𝑙𝑜𝑔10 𝐶𝑝° = 3.3444 + (0.2658)𝑙𝑜𝑔10 (9.3) + (-0.04472) [𝑙𝑜𝑔10 (9.3)]2
𝑙𝑜𝑔10 𝐶𝑝° = 3.5659
𝐶𝑝° = 3680.8622
P = 100 kPa = 1 bar, from table A.2

𝐶1 , 𝐶2, 𝐶3 = 0
𝑙𝑜𝑔10 𝐹𝑝 = 𝐶1 + 𝐶2 𝑙𝑜𝑔10 𝑃 + 𝐶3 (𝑙𝑜𝑔10 𝑃)2
𝑙𝑜𝑔10 𝐹𝑝 = 0
𝐹𝑝 = 1
From Table A.3 identification number is 1.

Based on Figure 10.1 (in Appendix) material factor, Fm =1.
From Table A.4, Heat exchanger double pipe, multiple pipes, scraped wall and spiral tube.
𝐵1 = 1.74
𝐵2 = 1.55
𝐶𝐵𝑀 = 𝐶𝑝° (𝐵1 + 𝐵2 𝐹𝑀 𝐹𝑃 )
𝐶𝐵𝑀 = 3680.6822 (1.74 + 1.55(1)(1))
𝐶𝐵𝑀 = $ 12 109.44
CEPCI value for year 2001 is 394 while CEPCI value for 2019 is 607.5. Thus,
607.5
𝐶𝐵𝑀,2019 = 12 109.44( 394 )
= $ 18 671.29
115
7.1.3 Cost of Distillation Column 1 (T-701)
From Table A1,

K1 2.9949
K2 0.4465
K3 0.3961
Apply formula Log Cpo = K1 + K2 log10(A) + K3 [log10(A)]2 where A is the capacity or size of
the equipment.
Log Cpo = K1 + K2 log10(A) + K3 [log10(A)]2

Log Cpo = 2.9949 + 0.4465 log10(8.4732)+ 0.3961[log10(8.4732)]2
Log Cpo = 3.75046
Cpo = 5629.3727
From Table A-5,

Apply formula CBM = CpoNFBMFq where, N is number of trays, FBM is Bare Module Factor and
Fq is quantity factor for trays.
To find FBM, refers Table A-6 to determine identification number for material factor of sieve
plates,
Identification Equipment Equipment Material of
Number Type Description Construction
60 Trays and demister Sieve and valve Carbon-Steel (CS)
Pads trays
116
Based on Figure 10.2 (in Appendix), FBM is 1.0.
To find Fq when Nact=14.9744<20, apply log10Fq = 0.4771+ 0.08516log10N – 0.3473 (log10N)2

for N<20,
Log10Fq = 0.4771+ 0.08516 log10N – 0.3473 (log10N)2

Log10Fq = 0.4771+0.08516 log10 (14.9744) – 0.3473 [log10 (14.9744)]2
Log10Fq = 0.097414
Fq = 1.2515
CBM = CpoNFBMFq
CBM = (5629.3727) (14.9744) (1.0) (1.2515)
CBM CEPCI (Sept 2001) = $105,497.04
607.5
CBM CEPCI (Mar 2019) = 105,497.04 x 394
CBM CEPCI (Mar 2019) = $162,663.58
117
7.1.4 Cost of Distillation Column 2 (T-702)
From Table A1,

K1 2.9949
K2 0.4465
K3 0.3961
the equipment.

Log Cpo = 2.9949 + 0.4465 log10(8.14866)+ 0.3961[log10(8.14866)]2
Log Cpo = 3.7305
Cpo = 5376.3805
From Table A-5,

Apply formula CBM = CpoNFBMFq where, N is number of trays, FBM is Bare Module Factor and
Fq is quantity factor for trays.
To find FBM, refers Table A-6 to determine identification number for material factor of sieve
plates,

60 Trays and demister Sieve and Carbon-Steel
Pads valve trays (CS)
118
Based on Figure A.19 from Analysis Synthesis and Design Chemical Processes by Richard
Turton et al,
From the figure above, FBM is 1.0.
To find Fq when Nact=14.065<20, apply log10Fq = 0.4771+ 0.08516log10N – 0.3473 (log10N)2

for N<20,
Log10Fq = 0.4771+ 0.08516 log10N – 0.3473 (log10N)2

Log10Fq = 0.4771+0.08516 log10 (14.065) – 0.3473 [log10 (14.065)]2
Log10Fq = 0.11708
Fq = 1.3094
CBM = CpoNFBMFq
CBM = (5376.3805) (14.065) (1.0) (1.3094)
CBM CEPCI (Sept 2001) = $99,015.25
607.5
CBM CEPCI (Mar 2019) = 99,015.25 x 394
CBM CEPCI (Mar 2019) = $152,669.45

119
7.1.5 Cost of Air Furnace (H-701)
Duty (kW), A = 1000 kW

From heuristic, the duty value that we need for air-furnaces is only 1.8524 kW, then 1000 kW
is used as the minimum size value.
From table A.1 for Non Reactive Fired Heater,

K1 7.3488
K2 -1.1666
K3 0.2028
To find Cpo,
the equipment.
Log Cpo = 7.3488 + (-1.1666) log10 (1000) + (0.2028) [log10(1000)]2
Log Cpo = 5.6742
Cpo = 472 280.48
Pressure = 2.2 bar, when P <10 bar
From table A.2 Pressure Factor for Non Reactive Fired Heater,
C1 0
C2 0
C3 0
To find Fp = 0,
Apply formula log10 Fp = C1 + C2 log10(P) + C3 (log10 P)2
log10 Fp = C1 + C2 log10(P) + C3 (log10 P)2
log10 Fp = 0 + (0) log10(2.2) + 0 (log10 2.2)2
log10 Fp = 0
Fp = 1
Apply formula CBM = CpoFBMFPFT where FT is the superheat correction factor for steam boilers
(FT = 1 for other heaters and furnaces).
120
To find FBM, refers Table A-6 to determine identification number for material factor of fired
heater and furnaces,

53 Fired heater and furnaces Tube for furnaces Carbon-Steel (CS)
and non reactive
Turton et al,
From the figure above, FBM is 2.2.
CBM,2001 = CpoFBMFPFT
= (472 280.48) (2.2) (1) (1)
= $ 1 039 017.07
607.5
CBM,2019 = ($ 1 039 017.07) ( 394 )
= $ 1 039 017.07
121
7.1.6 Cost of Pre-Heater (E-701)
Duty (kW), A= 1063.46 kW
From table A.1 for Hot Water Heater,

K1 2.0829
K2 0.9074
K3 -0.0243
To find Cpo,
the equipment.
Log Cpo = 2.0829 + (0.9074) log10 (1063.46) + (-0.0243) [log10(1063.46)]2
Log Cpo = 54.6067
Cpo = 40 432.65
Apply formula CBM = CpoFBM for bare module and material factors for heat exchanger.
To find FBM, refers Table A-6 to determine identification number for material factor of heat
exchanger,
1 Heat exchanger Double pipe, Carbon-steel
multiple pipe shell / Carbon-
steel tube
Turton et al;
122
From the figure above, FM is 1.0.
From table A.4, Heat exchanger double pipe, multiple pipes, scraped wall and spiral tube.
B1 = 1.74
B2 = 1.55
CBM = Cpo (B1 + B2 FM FP )
CBM,2001 = (40 432.65) (1.74 + 1.55(1)(1))

= $ 133 023.42
607.5
CBM,2019 = ($ 133 023) ( 394 )
= $ 205 105.91
123
7.2 Summary of Bare Module of Equipment Cost
Equipment Series
Equipment Type CBM (CEPCI 2001) CBM (CEPCI 2019)
Number
Reactor Jacketed and
R-701 $ 97 682.95 $ 150 615.21
Agitated
Heat Exchanger
SC-701 $ 12 109.44 $ 18 671.29
Double pipe
Trays and demister
T-701 $ 105 497.04 $ 162 663.58
Pads
Trays and demister
T-702 $ 99,015.25 $ 152,669.45
Pads
Non-Reactive Fired
H-701 $ 1 039 017.07 $ 1 602 037.74
Heater
E-701 Hot Water Heater $ 133 023.42 $ 205 105.91
Total $ 1,486,345.17 $ 2,291,763.15
7.3 Total Module Cost and Fixed Capital Investment (FCI)
Fixed Capital Investment (FCI) = Total Module Cost (CTM),

CTM = 1.18 ($ 2,291,763.15)
= $ 2,704,280.52
FCI = $ 2,704,280.52
124
7.4 Cost of Raw Material
Raw Material Cost (CRM) =

Raw Material Flow Rate (kg/h)
O-xylene 5829.86
Air 29502.65
The plant operates for 350 days in a year :
24 ℎ𝑜𝑢𝑟𝑠 350 𝑑𝑎𝑦𝑠 8400 ℎ𝑜𝑢𝑟𝑠

( ) ×( )=
𝑑𝑎𝑦 𝑦𝑒𝑎𝑟 𝑦𝑒𝑎𝑟
Consumption of O-xylene per year :
Price of O-xylene = ($ 682.90/tonne) ×(1 tonne/1000kg)

= $ 0.6829/kg
(5829.86 kg/hr) ×(8400 hr/year) = 48 970 824 kg/year

Cost of O-xylene in a year = (48 970 824 kg/year) ×($ 0.6829/kg)
= $ 33 442 175.71/year
125
7.5 Cost of Operating Labour
A single operator works on average 50 weeks a year with 3 weeks off on 8 hours per shift and
5 shifts per week. Chemical plant will operate for 24 hours. Thus, 3 shifts per day for 350 days.
(50 weeks/year) x (5 shifts/week) = 250 shifts/year
(350 days/year) x (3 shifts/day) = 1050 shifts/year
(1050 shifts/year) x (Operator. year/250 shifts) = 4.2 operators
NOL = (6.29 + 31.7P2 + 0.23Nnp)0.5
NOL = Number of Operating Labor Operating Per Shift
P2 = Particulate Processing Steps
Nnp = Non-particulate processing steps
Equipment Type Number of Equipment Nnp

Compressor 1 1
Exchanger 7 7
Heater/Furnace 1 1
Pumps* 6 -
Reactor 1 1
Tower 2 2
Vessel* 2 -
Total 12
*Pumps and vessels are not counted in evaluating Nnp
Table 1: Number of Equipment
P2 = 0 because there are no particulate processing steps in the process.
NOL = (6.29 + 31.7(0)2 + 0.23(12))0.5
NOL = 3.01
Number of operators required per shift is 3.01
Number of operator needed as operating labor:
3.01 x 4.2 operators = 12.64 (round up 13 operators)
For all equipment, cost of operating labor per year:
(RM10/hour. operator) x (8 hours/day) x (350 days/year) x (13 operator) = $ 88 780/year
126
7.6 Cost of Utility
Utilities expense is the cost during a given time period of using things such as electricity, water,
and heating. Depending on how utilities are used, a company accountant may allocate costs
associated with utility use to various departments. The costs of utilities are directly influenced
by the cost of fuel. Specific difficulties emerge when estimating the cost of fuel, which directly
impacts the price of utilities such as electricity, steam, and thermal fluids.
Electricity Cost
From Table 8.3,

Electric Cost = $0.0674 / kWh
Electrical Cost for the plant to operates 350 days in a year
= $0.0674/𝑘𝑊ℎ × 8400 ℎ/𝑦𝑒𝑎𝑟 = $566.16/𝑘𝑊𝑦
Cooling Water Cost

Estimate the utility cost for producing a circulating cooling water stream using a mechanical
draft cooling tower. Consider a basis of 1 GJ/h of energy removal from the process units. Flow
of cooling water required to remove this energy = 𝑚̇ kg/h.
An energy balance gives,

Electric Cost = $0.0674 / kWh
Electrical Cost for the plant to operates 350 days in a year
= $0.0674/𝑘𝑊ℎ × 8400 ℎ/𝑦𝑒𝑎𝑟 = $566.16/𝑘𝑊𝑦
Latent heat of water at average temperature of 35°C = 2417 kJ/kg
Amount of water evaporated from tower, Wtower,

𝑚̇𝑐𝑝 ∆𝑇 ⇒ 1 × 109 = (𝑚̇) (4180)(40 − 30)
𝑚̇ = 23 923𝑘𝑔/ℎ
This shows that the amount of water evaporated from tower, Wtower is only [(413.7) (100) /
23,923] = 1.73% of the circulating water flow rate.
127
Typical windage losses from mechanical draft towers are between 0.1% and 0.3% [3,4];
use 0.3%. To calculate the blowdown, the maximum allowable salt (inorganics) concentration
factor, s, of the circulating water compared with the makeup water must be known. The
definition of s is given in the following equation:
𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛 𝑠𝑎𝑙𝑡𝑠 𝑖𝑛 𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟 𝑙𝑜𝑜𝑝

𝑠=
𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛 𝑠𝑎𝑙𝑡𝑠 𝑖𝑛 𝑚𝑎𝑘𝑒𝑢𝑝 𝑤𝑎𝑡𝑒𝑟
𝑠𝑙𝑜𝑜𝑝
𝑠=
𝑠𝑖𝑛
Typical values are between 3 and 7 [3]. Here a value of 5 is assumed. By performing a
water and salt balance on the loop shown in Figure 8.2, and assuming that pure water is
evaporated, the following results are obtained:
WMU = Wtower + Wwind + WBD ---------1
sin WMU = sloop Wwind + sloop WBD --------2
Since sloop = 5 sin ;
𝑠𝑖𝑛 (𝑊𝑡𝑜𝑤𝑒𝑟 + 𝑊𝑤𝑖𝑛𝑑 + 𝑊𝐵𝐷 ) = 𝑠𝑖𝑛 𝑊𝑤𝑖𝑛𝑑 + 𝑠𝑙𝑜𝑜𝑝 𝑊𝐵𝐷
𝑠𝑖𝑛 𝑊𝑡𝑜𝑤𝑒𝑟 + 𝑊𝑤𝑖𝑛𝑑 (𝑠𝑖𝑛 − 𝑠𝑙𝑜𝑜𝑝 ) 𝑠𝑖𝑛 𝑊𝑡𝑜𝑤𝑒𝑟

𝑊𝐵𝐷 = = − 𝑊𝑤𝑖𝑛𝑑
𝑠𝑙𝑜𝑜𝑝 − 𝑠𝑖𝑛 𝑠𝑙𝑜𝑜𝑝 − 𝑠𝑖𝑛
𝑊𝑡𝑜𝑤𝑒𝑟 1.73%
− 𝑊𝑤𝑖𝑛𝑑 = − 0.3% = 0.133%
4 4
𝑊𝑀𝑈 = 1.73 + 0.3 + 0.133 = 2.163% = 517 𝑘𝑔/ℎ
Pressure drop around the cooling water loop is estimated as follows:
ΔPloop = 15 psi (pipe losses) + 5 psi (exchanger losses) + 10 psi (control valve loss) +
8.7 psi of static head (because water must be pumped to top of cooling water tower, estimated
to be 20 ft above pump inlet) = 38.7 psi = 266.7 kPa.
128
Power required for cooling water pumps with a volumetric flow rate 𝑉̇ , assuming an
overall efficiency of 75% and density of water at 35°C as 994 kg/m3, is
1
𝑃𝑢𝑚𝑝 𝑝𝑜𝑤𝑒𝑟 = 𝑉̇ ∆𝑃
𝜀
1 (23,923)
= (266.7) = 2.38𝑘𝑊
0.75 (994)(3600)
Power required for fans: from reference [3], the required surface area in the tower = 0.5
ft2 /gpm (this assumes that the design wet-bulb air temperature is 26.7°C [80°F]). From the
same reference, the fan horsepower per square foot of tower area is 0.041 hp/ft2.
(23923)(2.2048)
𝑃𝑜𝑤𝑒𝑟 𝑓𝑜𝑟 𝑓𝑎𝑛 = (0.5)(0.041)
(60)(8.337)
= 2.16ℎ𝑝 = (2.16)(0.746) = 1.61𝑘𝑊
Using data from Nalco Water [2], the cost of chemicals is $0.0347/1000 kg of makeup
water.
From Table 8.3, using an electricity cost of $0.0674/kWh and a process water cost of
$0.176/1000 kg, the overall cost of the cooling water is given by
Cost of cooling water = cost of electricity + cost of process water + cost of makeup water
Thus,
(517.3)(0.176) (517.3)(0.0347)
𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟 𝑐𝑜𝑠𝑡 = (0.0674)(2.38 + 1.61) + +
1000 1000
= $0.378/ℎ = $0.378/𝐺𝐽
The density of water at 30°C = 996 kg/m3
This gives a cost of circulating cooling water:
= ($0.378) (996) / (23.922)
= $15.7/1000 m3
= $ 208429/year
129
High Pressure Steam Cost
Basis is 1000 kg of HP steam generated at 45.3 bar and 400°C ⇒ H44.barg,400°C = 3205.0 kJ/kg.
𝛥𝐻𝑏𝑓𝑤 − 𝐻𝑃𝑠𝑡𝑒𝑎𝑚 = (3204.3 − 2555.6) 𝑘𝐽/𝑘𝑔 = 648.7 𝑘𝐽/𝑘𝑔 = 0.6487 𝐺𝐽
Let X be the amount of saturated HP steam produced from superheated HP steam; an

enthalpy balance gives,
(1000) (3205) +[X-1000] (2555.6) = X (2762.8)

(3205 − 2555.6)1000
=
(2762.8 − 2555.6)
= 3134.17𝑘𝑔
The source of fuel is assumed to be natural gas that costs $3.16/GJ

The cost of natural gas to produce 1000 kg of sat HP steam assuming a 90% boiler efficiency,
(0.6487)(1000)(3.16)
𝐶𝑜𝑠𝑡 =
(0.9)(3134.17)
= $ 0.76/1000𝑘𝑔
= $61891.69/year
For a basis of 1000 kg of bfw,

Cost of makeup water = $0.177/1000 kg = $536.49/year
Cost of chemicals for treatment = $0.156/1000 kg = $472.83/year
Cost of electricity to pump bfw = $5831.72/year
Treatment costs for circulating boiler feed water =$0.156/1000 kg = $472.83/year
Total cost of MP steam (with power production)
= cost of natural gas + cost to treat circulating water + cost of electricity for air blowers +
cost of makeup bfw + pumping cost for bfw
= $61891.69/year+$536.49/year +$472.83/year +$5831.72/year + $472.83/year
= $69205.57/year
130
Pump Cost
P-701
𝑘𝑔 1ℎ𝑟 1𝑚3
𝐹𝑙𝑜𝑤 = × ×
ℎ𝑟 60𝑚𝑖𝑛 1000𝑘𝑔
5847.07𝑘𝑔 1ℎ𝑟 1𝑚3

= × × = 0.0975𝑚3 /𝑚𝑖𝑛
ℎ𝑟 60𝑚𝑖𝑛 1000𝑘𝑔
The power generated by the pump is as follow,
1.67 × flow (m3/min) × ΔP (bar)

𝑃𝑜𝑤𝑒𝑟(𝑘𝑊) =
𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
1.67 × 0.0975m3/min × 1bar

=
0.65
= 0.2504 kW
Power of all pumps installed:
Equipment Power (kW)

P-701 0.2504
P-702 0.1298
P-703 1.5130
P-704 0.0727
P-705 0.2420
P-706 0.2423
Total 2.45
Therefore, the cost electricity for the pumps are,

Cost of electricity = (2.45kW) (RM 0.44/kWh)
= RM 9443.59
= $2302.31/year
Total Utility Cost, CUt
CUt = Electricity cost + Cooling water cost + HPS cost + Pump cost
=$566.16/year + $208429.60/year + $69205.57/year + $2302.31/year
= $280503.60
131
7.7 Cost of Manufacturing
7.7.1 Estimating Manufacturing Cost
Cost of manufacturing (COM),

COM = 0.28 FCI + 2.73 COL + 1.23 (CUT + CWT + CRM)
COM = 0.28 ($ 2,704,280.50) + 2.73 ($ 49,504) +
1.23 ($ 280,503.60 + $ 202,217.70 + $ 33,442,175.70)
COM = $ 42,618,482.65
Cost of manufacturing without depreciation (COMD),

COMD = 0.180 FCI + 2.73 COL + 1.23 (CUT + CWT + CRM)
COMD = 0.180 ($ 2,704,280.50) + 2.73 ($ 49,504) +
1.23 ($ 280,503.60 + $ 202,217.70 + $ 33,442,175.70)
COMD = $ 42,349,539.70
7.7.2 Direct Manufacturing Cost
No. Cost Item Multiplying Factor Cost

1. Raw Materials CRM $ 33,442,175.70
2. Utilities CUT $ 280,503.60
3. Operating Labour COL $ 49,504.00
Direct Supervisory
4. (0.18) COL $ 8,910.70
and Clerical Labour
Maintenance and
5. (0.06) FCI $ 162,256.80
Repairs
6. Operating Supplies (0.009) FCI $ 24,338.50
7. Laboratory Charges (0.15) COL $ 7,425.60
8. Patent and Royalties (0.03) COM $ 1,278,554.48
Total Direct Manufacturing Cost $ 35,253,669.40
132
7.7.3 Fixed Manufacturing Cost
Fixed manufacturing cost can be understood as such expenditures are independent of

adjustments in the cost of production. They include property taxes, insurance and depreciation,
which, even though the plant is not in operation, are paid at constant rates. The following are
details for fixed manufacturing cost:

1. Depreciation 0.1 FCI $ 270,428.05
2. Local Taxes & Insurance 0.032 FCI $ 86,536.98
3. Plant Overhead Cost 0.078 COL + 0.036 FCI $ 125,746.10
Total Fixed Manufacturing Cost $ 486,711.13
7.7.4 General Manufacturing Cost
General manufacturing costs reflect an overhead burden which is required for the success of
business functions. They include the roles of management, distribution, funding, and analysis.
General expenditures seldom differ with the amount of production. However, if extended
periods of low production levels occur, products such as R&D and distribution and sale costs
can decrease. The following are details of general manufacturing cost:

1. Administration Cost 0.177 COL + 0.009 FCI $ 88,766.52
2. Distribution & Selling Cost 0.11 COM $ 3,877,903.63
3. Research & Development 0.05 COM $ 1,762,683.47
Total Fixed Manufacturing Cost $ 5,729,353.62
133
7.7.5 Overall Manufacturing Cost
Overall Manufacturing Cost = ∑ Direct Manufacturing Cost

+ ∑ Fixed Manufacturing Cost
+ ∑ General Manufacturing Cost
= $ 35,253,669.40 + $ 486,711.13 + $ 5,729,353.62
= $ 41,469,734.15 ~ RM 170,025,910
7.7.6 Working Capital
Working Capital = 0.1 CRM + 0.1 FCI + 0.1COL

= 0.1 (33,422,175.71) + 0.1 (2,704,280.50) + 0.1 (364,000)
= $ 3,651,045.62 ~ RM 14,946,287.04
The FCIL for the Phthalic Anhydride chemical plant is
FCIL = Working Capital + FCI

= 3,651,045.62 + 2,704,280.50
= $ 6,355,326.12 ~ RM 26,016,801.30
134
8.0 PROFITABILITY
ANALYSIS
135
8.0 PROFITABILITY ANALYSIS
In this section, the calculations are made automatically generated using the CAPCOST 2017
Software that is taken from Analysis Synthesis and Design of Chemical Processes 5th Edition
by Professor Richard Turton. In the previous section, all the costs needed for the plant to be
operated such as the cost of equipment, bare module of equipment, total module cost and fixed
capital investment (FCI), cost of raw material, operating labour, utility and manufacturing are
calculated manually. This time, the software is used to estimate and make analysis on the
success of the plant in the business world.
8.1 Summary of Cost of Manufacturing
Figure 8.1. A screen capture of the CAPCOST software on the Materials cost.
Economic Options
Cost of Land $ 7,647,643
Taxation Rate 24%
Economic Options
Annual Interest Rate 10%
Cost of Land $ 7,647,643
Salvage Value 0 custom
Taxation Rate 24%
Working Capital $ 3,651,045 custom
Annual Interest Rate
FCIL $
10% 6,355,326 custom
Salvage Value 0 custom
Total Module Factor 1.18
Working Capital $ 3,651,045 custom
Grass Roots Factor 0.50
FCIL $ 6,355,326 custom
Total Module Factor 1.18
Economic Information Calculated From Given Information
Figure 8.2. A screen capture
GrassofRoots
the CAPCOST
Factor software on the Economic options.
0.50
Revenue From Sales $ 47,029,969 material
CRM (Raw Materials Costs) $ 33,442,175 custom
Economic Information Calculated From Given Information
CUT (Cost of Utilities) $ 280,503 custom
Revenue From Sales $ 47,029,969- material
CWT (Waste Treatment Costs) $ custom
CRM (Raw Materials Costs) $ 33,442,175 custom
COL (Cost of Operating Labor) $ 88,780 custom
CUT (Cost of Utilities) $ 280,503 custom
CWT (Waste Treatment Costs) $ - custom
COL (Cost of Operating Labor) $ 88,780 custom
Figure 8.3. A screen capture of CAPCOST software on the Economic Information.
136
Factors Used in Calculation of Cost of Manufacturing (COM d )
Comd = 0.18*FCIL + 2.76*COL + 1.23*(CUT + CWT + CRM)
Multiplying factor for FCIL 0.18
Multiplying factor for COL 2.76
Facotrs for CUT, CWT, and CRM 1.23
Factors Used in Calculation of Cost of Manufacturing (COM d )
Comd = 0.18*FCIL + 2.76*COL +COM d $
1.23*(CUT + CWT42,867,885
+ CRM)
Multiplying factor for FCIL 0.18
Multiplying
Factors Used infactor for COL of Working
Calculation 2.76Capital
Figure 8.4. A screen capture of CAPCOST software on the Factors Used for Cost of Manufacturing
Facotrs
Factors Used for
Working C UT, C
Capital
in =WT, and
A*C
Calculation RMof+CRM
B*FCI
Cost ofL +Manufacturing
C*C1.23
OL (COM d )
without depreciation.
Comd = 0.18*FCIL + 2.76*COL + 1.23*(CUT A + CWT 0.10
+ CRM)
COM
Multiplying factor for FCIL d B $ 42,867,885
0.18 0.10
Multiplying factor for COL C 2.76 0.10
Facotrs for CUT, CWT, and CRM
Factors Used in Calculation of Working Capital
1.23
Working Capital
Project A*CRM +after
= (Years
Life B*FCI L + C*COL
Startup) 10
COMdA $ 0.10
42,867,885
Construction B period 0.10 2
Factors Used in Calculation of Working C 0.10
Capital
Working Capital = A*C
Distribution RM + B*FCI
of Fixed L + C*C
Capital Investment
OL (must sum to one)
Project Life (Years after
EndStartup)
of year
A One 10 60%
0.10
End of year
B Two 0.10 40%
Construction
End of period
yearC Three 0.102
End of year Four
Distribution of Fixed
Project Life (Years Capital
End
after Investment
of year
Startup) Five (must
10 sum to one)
Figure 8.5 A screen capture of CAPCOST software on the Factors Used for Working Capital.
End of year One 60%
End of year
Construction Two
period 40%
2
End of year Three
EndCapital
Distribution of Fixed of year Four
Investment (must sum to one)
End of year
End of year OneFive 60%
End of year Two 40%
End of year Three
End of year Four
End of year Five
Figure 8.6. A screen capture of CAPCOST software on the Distribution of Fixed Capital Investment.
137
8.2 Cash Flow Analysis
Figure 8.7. The cash flow diagram of the Phthalic Anhydride chemical plant (non-discounted).
The graph shown in Figure 8.7 is taken from a non-discounted project value with 5 years
MACRS depreciation. Based on the graph, the first line going down is because of the cost of
land which is $7,647,642.87 (source: https://www.iproperty.com.my/sale/pasir-
gudang/industrial-land/). The first two years is the duration of construction period, hence the
decreasing in line as can be seen in the graph. On the second year, there is a significant drop
because of Capital cost. Starting from the next year onward, the line shows a steady increment
every year. This can be proven as the period back (non-discounted) is 1 year. As the plant life
is set to 10 years, at the 10th year, the project value peaked at 9.18 million of dollars.
Table 8.1. The discounted and non-discounted profitability criteria.
Discounted Profitability Criterion Non-Discounted Profitability Criterion

Cumulative Cash Position
Net Present Value (millions) 4.41 26.80
(millions)
Discounted Cash Flow Rate of
14.13% Rate of Return on Investment 42.17%
Return
Discounted Payback Period
2.2 Payback Period (years) 1.8
(years)
138
From the discounted profitability criterion perspective, the Net Present Value (NPV) is 4.41
which is in a positive value. This means that the project can be done without losing as much
funds as expected. The Discounted Cash Flow Rate of Return is low which is at 14/13% but
the Discounted Payback Period is only 2.2 years. Although the cash flow is not that good, the
payback period can tackle that problem.
As from the non-discounted criterion perspective, the Cumulative Cash Position (CCP)
is high which is 26.80 million of dollars hence the Rate of Return of Investment (ROROI)
becomes low which is only 42.17%. However, the payback period is only 1.8 years which is
a very short period considering the amount of revenue that has been spent for the project.
In overall, the project of the production of Phthalic Anhydride from o-xylene can be
successfully done despite the low ROROI. This is because the short payback period for both
the discounted and non-discounted profitability criteria. At the final year, the plant is also
expected to have about 10 million dollars of worth. Thus, it is recommended to proceed with
this project.
139
Cash Flow Cash Flow Cumulative Cash Flow Cumulative Cash Flow
Year Investment dk FCIL-Sdk R COMd (R-COMd-dk )*(1-t)+dk
(Non-discounted) (discounted) (discounted) (Non-discounted)
0 7.65 6.36 (7.65) (7.65) (7.65) (7.65)
1 3.81 6.36 (3.81) (3.47) (11.11) (11.46)
2 6.19 6.36 (6.19) (5.12) (16.23) (17.65)
3 1.27 5.08 47.03 42.87 3.47 3.47 2.61 (13.63) (14.19)
4 2.03 3.05 47.03 42.87 3.65 3.65 2.49 (11.13) (10.53)
5 1.22 1.83 47.03 42.87 3.46 3.46 2.15 (8.99) (7.08)
6 0.73 1.10 47.03 42.87 3.34 3.34 1.88 (7.10) (3.74)
7 0.73 0.37 47.03 42.87 3.34 3.34 1.71 (5.39) (0.40)
8 0.37 - 47.03 42.87 3.25 3.25 1.52 (3.87) 2.85
9 - 47.03 42.87 3.16 3.16 1.34 (2.53) 6.01
10 - 47.03 42.87 3.16 3.16 1.22 (1.31) 9.18
11 - 47.03 42.87 3.16 3.16 1.11 (0.20) 12.34
12 - 47.03 42.87 3.16 14.46 4.61 4.41 26.80
Figure 8.8. Discounted and Non-discounted cash flow data .
140
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142
10.0 APPENDIX
Figure 10.1. Material Material Factors for Equipment in Table A.3.
Figure 10.2. Bare Module Factors for Equipment in Table A.6.
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2019 Plant Design and Economics-Phthalic Anhydride Design Report (Very Good PFD)

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CPE604

PLANT DESIGN AND ECONOMICS

SHINKA SDN BHD

1.0 PROCESS BACKGROUND & SELECTION 4

1.1 History & General Information of Phthalic Anhydride 5

2.0 SITE SELECTION 20

2.1 Tanjung Langsat Industrial Complex, Johor 22

3.0 MARKET ANALYSIS 36

3.1 Market of Raw Material and Product 37

4.0 MASS BALANCE 45

4.1 Process Flow Diagram 45

5.0 ENERGY BALANCE 66

5.1 Reactor (R-701) 67

6.0 EQUIPMENT DESIGN 94

6.1 Heuristic of Equipment 95

7.1 Cost of Equipment 114

8.0 PROFITABILITY ANALYSIS 135

8.1 Summary of Cost of Manufacturing 136

9.0 REREFENCES 141

10.0 APPENDIX 143

1.1 History & General Information of Phthalic Anhydride

Truly, phthalic anhydride was first delivered by the oxidation of naphthalene in

Table 1.1. Summary of the processes available to produce Phthalic Anhydride.

Total score 21 168 19

Typically, phthalic anhydride commonly being synthesized by using oxygenation process.

Another way to synthesize phthalic anhydride is by using thermal dehydration process.

1.2.3 Production of Phthalic Anhydride using Bio-renewable Process

In contrast to environmentally unfriendly petroleum starting materials, bio-renewable

1.3.1 Partial Oxidation Process

Figure 1.4. Thermal Dehydration Process Flow Diagram.

Table 1.4. Summary of the process descriptions.

Table 1.6. The summary of the process on the separation system.

Recovery Separation Temperature operating (overhead Pressure operating

Name Price ($/tonne)

1.4.1 Profit Margin for Partial Oxidation Process from O-xylene

Molecular weight (MW):

By using 100 kmol of O-Xylene as a feed basis,

Profit Margin = Total Cost of Product - Total Cost of Raw Material

Molecular weight (MW):

By using 100 kmol of Phthalic Acid as feed basis,

Profit Margin = Total Cost of Product - Total Cost of Raw Material

Table 1.8. The mass composition of the biomass.

Cost of biomass = [(100 × 0.3895) kmol × 162.1406 kg/kmol × $ 50/tonne ×

Cost of H2SO4 = 100 kmol × 98.079 kg/kmol × $ 150/tonne × 1 tonne/1000 kg

Cost of NH3 = 100 kmol × 17.031 kg/kmol × $ 300/tonne × 1 tonne/1000 kg

Profit Margin = Total Cost of Product - Total Cost of Raw Material

Selection criteria Tanjung Langsat Kerteh Industrial Gebeng Industrial

Raw Material Availability

2.1 Tanjung Langsat Industrial Complex, Johor

2.1.2 Resource Availability (Energy and Water Supply)

Table 2.2. The electricity tariff rates by TNB.

The minimum monthly charge For all kWh 0.222

2.1.3 Transportation Facilities

2.1.4 Waste Disposal Management

Waste code Name of scheduled waste

Company name Address Production

Eternal Materials PTD 5044, Jalan Rumbia 2, Tanjung Langsat Resins

Polynt Composites PLO 45, Jalan Keluli, Kawasan Perindustrian Plasticisers

LOTTE CHEMICAL PLO 8, Tanjung Langsat, Industrial Estate, 81700 Plasticisers