Full Repot

INTRODUCTION
Maleic anhydride is a chemical intermediate that is used to produce resins, surface coatings,
lubricant additives, and agricultural chemicals. The compound’s chemical formula is
C2H2(CO)2O and is the acid anhydride of maleic acid. In its pure state, the compound
colorless or white solid with an acrid odor. Maleic anhydride was traditionally manufactured by
the oxidation of benzene or other aromatic compounds. As of 2006, only a few smaller plants
continue to use benzene; due to rising benzene prices, most maleic anhydride plants now use n-
butane as a feedstock.
In 1995, global production of maleic anhydride was estimated at 1.8 billion pounds, with an
estimated value of $700 million. Over the last five years, world consumption has increased at an
average annual rate of 5.8%, with the fastest growth occurring in Asia, where it is used as an
intermediate for production of 1,4-butanediol.
CHEMICAL REACTIONS
The raw material is benzene. The primary reaction is one in which benzene is partially oxidized
to form maleic anhydride (Equation 1). There are three undesired side reactions, the subsequent
combustion of maleic anhydride (Equation 2), the complete combustion of benzene (Equation 3),
the formation of the by-product , quinone (Equation 4).
C6H6 (g) + 4.5O2 (g) → C4H2O3(g) + 2CO2(g) + 2H2O(g) (1) benzene maleic
anhydride
C6H6 (g) + 7.5O2 (g) → 6CO2 (g) +3H2O (g) (2) benzene
C4H2O3 (g)+ 3O2(g) →4CO2 (g)+ H2O (g) (3) Maleic anhydride
C6H6 (g) + 1.5O2 (g) → C6H4O2(g) + H2O(g) (4) Benzene quinone
PROCESS DESCRIPTION
Maleic anhydride is a white crystalline solid which widely used in food, oil, electronic and
polymer industry. It can be produce by the oxidation of benzene, n-butane or other aromatic
compounds. However, the production of Maleic Anhydride for this project only focuses on the
oxidation of Benzene which acts as limiting reactant. Oxidation process is a chemical between
two substances in which one substance is oxidized. It occurs when the oxidation state of a
molecule, atom or ion increased. Benzene was oxidized to form Maleic anhydride with some
carbon dioxide and water. The reactions are shown below:
C6H6 + 4.5O2 C4H2O3 + 2CO2 + 2H2O
The process flow diagram for the Maleic Anhydride production is shown in Figure 2.3.
The reactor choose in this study is PFR(R-1) as PFR has the ability to convert highest conversion
of benzene into Meleic Anhydride. Initially, Benzene inlet has been heated to change the phase
from liquid to gases phase. The benzene then mix with air to before it continues to react in the
PFR. The process rate constant was given as shown below:
k1 =
The reacted compound was then proceed to feed into the gas absorber (Absorber
Column) to further separate the unwanted gas with Maleic Anhydride. The solvent used in this
column is dibutyl phthalate which change the Maleic Anhydride phase from gases to liquid. The
reaction of the Maleic Anhydride with water creates another chemical compound which is
Maleic Acid. About 95% water was converting forming the Maleic Acid. The process was then
continues entering the distillation column to separate the solvent with other chemical compound.
Overhead product of the distillation column consist of 85% Maleic Anhydride with a few
nitrogen and oxygen. The bottom product of the distillation was which Dibutyl phthalate was
recycle back to solvent inlet stream to be used in next reaction.
PROCESS SELECTION
In every process, the selection process is required and very important to run a chemical plant
reaction. In this process, Maleic Anhydride is a desired product and there are a few processes
that available in order to achieve the desired product. First of all, the first step to run the reaction
is by choosing the good and right raw material. The main raw material that plays a big role in
this process is benzene. From study, the industry had widely used either benzene or n-butane, but
most of the time, the industry is much preferable toward n-butane. This is because, n-butane
process is considered to more advantages in term of health, safety and economics.
According Lonza group, a chemical company, benzene route is competitive in low cost
revamps and medium-size plants. However, when the cost of benzene is high, this route is
much less attractive.
Instead of that, most of companies are using the packed bed reactor or fluid bed
process rather than shell and tube vertical design reactor in production of Maleic
Anhydride because it have advantages over the fixed bed route, such as lower air -to-
hydrocarbon concentration in the feedstock and no need for premixing, but has
disadvantages including abrasion of the catalyst, conversion rates and by-product
formation. While shell and tube with the presence of catalyst is good for conducting gas
phase chemical reactions and best suits if heat transfer play important role in the chemical
reaction conversion. However, shell and tube are not so good for liquid reactions. As a nutshell,
the importance in process selectivity is the efficiency, effect of the material and the cost required
to run the process.
OBJECTIVES
The purpose of this project is to do a preliminary analysis to determine the feasibility of

constructing a chemical plant to manufacture 58,940 ton/year maleic anhydride. The raw
material is benzene. From the World Maleic Anhydride Supply & Demand By Region graph in
the appendices, we get the the value of production of maleic anhydride which is 58940 tonne /
year for 2016.
The goal of this project is to design a grass roots facility that is capable of producing 58,940
million pounds of maleic anhydride per year from n-butane.
Our job is to analyze a simplified maleic anhydride production process, to suggest profitable
operating conditions, and to write a final report summarizing our findings.
.
MARKET ANALYSIS
The Maleic Anhydride Market in asia from year had incease from year 2001 to 2015 had
grow smoothly and in the year 2016, they had reach about 800 to 1300 Metric Tons.10 The
production of Maleic Anhydride fro asia region by 2014 is about 56%, and the consumption is
about 13.6% and the capacity is about14%. These record can be referring in the appendices.10
According to the Maleic Anhydride Market’ Book, the global Maleic Anhydride
production market is projected to grow at smooth and fascinating pace of 6.6%, from USD 4.72
million to USD 6.5 million metric tons, during the forecast period.10 The total capital investment
is estimated to build a plant producing 60,000 metric ton (m.t.) per year of maleic anhydride in
the U.S. is about $150 million.10 The capital investment presented includes the total fixed capital,
working capital and additional capital requirements and yet, the production cost is estimated at
about $830/m.t. of Maleic anhydride.
PROCESS FLOW DIAGRAM
MASS AND ENERGY BALANCE
Because its per year, so assume the production of maleic anhydride in one year which means
353 days.
Mass Balance
Basis operation: 353 days/year of operation
Based on PFD and the stream table, the production of maleic anhydride at stream 13,
5194 𝑘𝑔 1 tonne 24 ℎ𝑟 353 𝑑𝑎𝑦𝑠 𝑡𝑜𝑛𝑛𝑒

Original capacity: x 1000 𝑘𝑔 x 1 𝑑𝑎𝑦 x = 44003.568
ℎ𝑟 1 𝑦𝑒𝑎𝑟 𝑦𝑒𝑎𝑟
𝑡𝑜𝑛𝑛𝑒
To increase the capacity product to 58940 , capacity ratio:
𝑦𝑒𝑎𝑟
58940.00
Ratio: = 44003.568 = 1.34
𝑡𝑜𝑛𝑛𝑒
Total mass and mole required for 58940.00 :
𝑦𝑒𝑎𝑟
𝑡𝑜𝑛𝑛𝑒 1 𝑦𝑒𝑎𝑟 1000 𝑘𝑔 1 𝑑𝑎𝑦 𝑘𝑔

Total mass required = 58940.00 × × 1 𝑡𝑜𝑛𝑛𝑒 × 24 ℎ𝑜𝑢𝑟𝑠 = 6957.03 ℎ𝑟
𝑦𝑒𝑎𝑟 353 𝑑𝑎𝑦𝑠
𝑘𝑔 1 𝑘𝑚𝑜𝑙 𝑘𝑚𝑜𝑙
Total mole required = 6957.03 ℎ𝑟 x 98.06 = 70.95
𝑘𝑔 ℎ𝑟
Molecular weight for every component:
Component Molecular weight (kg/kmol)
Maleic anhydride 98.06
Dibutyl phthalate 278.34
Nitrogen 14
Water 18
Oxygen 16
Benzene 78.11
(1,4-Benzoquinone)Quinone 108.095
Carbon dioxide 44
Maleic acid 116.072
Sodium nitrite 69
Sodium nitrate 84.9947
We double the mass and mole flowrate, include the component flowrates. So the new stream
table as below:
Stream Number 1 2 3 4 5 6 7 8
Temperature (°C) 30 30 30 30 170 460 608 270
Pressure (kPa) 101 101 280 101 250 235 220 215
Total kg/h 6608 6608 6608 160980 160980 167588 167588 167588
Total kmol/h 84.6 84.6 84.6 5580 5580 5664.6 5650.4 5650.4
Component Flowrates (Kmol/h)
Maleic anhydride 0.0 0.0 0.0 0.0 0.0 0.0 52.6 52.6
Dibutyl phthalate 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Nitrogen 0.0 0.0 0.0 4410 4410 4410 4410 4410
Water 0.0 0.0 0.0 0.0 0.0 0.0 183 183

Oxygen 0.0 0.0 0.0 1170 1170 1170 740.4 740.4
Benzene 84.6 84.6 84.6 0.0 0.0 84.6 5.2 5.2
Quinone 0.0 0.0 0.0 0.0 0.0 0.0 1.4 1.4
Carbon dioxide 0.0 0.0 0.0 0.0 0.0 0.0 258 258
Maleic acid 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Sodium nitrite 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Sodium nitrate 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Stream Number 9 10 11 12 13 14 15 16
Temperature (°C) 330 320 194 84 195 330 419 562
Pressure (kPa) 82 100 82 75 80 82 200 200
Total kg/h 278383.2 61.2 283732 162450 5194 278538 783850 783850
Total kmol/h 1000.2 0.2 1052.4 5595.8 52.4 1000 10000 10000
Component Flowrates (Kmol/h)
Maleic anhydride 0.0 0.0 9.6 1.0 49.6 0.0 0.0 0.0
Dibutyl phthalate 1000.2 0.2 1000 0.0 0.0 1000 0.0 0.0
Nitrogen 0.0 0.0 0.0 4410 0.0 0.0 0.0 0.0
Water 0.0 0.0 0.0 183 0.0 0.0 0.0 0.0
Oxygen 0.0 0.0 0.0 740.4 0.0 0.0 0.0 0.0
Benzene 0.0 0.0 0.0 5.2 0.0 0.0 0.0 0.0

Quinone 0.0 0.0 0.8 0.8 0.8 0.0 0.0 0.0
Carbon dioxide 0.0 0.0 0.0 258 0.0 0.0 0.0 0.0
Maleic acid 0.0 0.0 2.0 0.0 2.0 0.01 0.0 0.0
Sodium nitrite 0.0 0.0 0.0 0.0 0.0 0.0 4131.2 4131.2
Sodium nitrate 0.0 0.0 0.0 0.0 0.0 0.0 5868.8 5868.8
V-601
Stream 1 V-601 Stream 2
Stream 1
𝑘𝑔 𝑘𝑔
Mass of stream: 6608 ℎ𝑟 x 1.34 = 8854.72 ℎ𝑟
𝑘𝑚𝑜𝑙 𝑘𝑚𝑜𝑙
Mole flowrate of benzene: 84.6 x 1.34 = 113.364
ℎ𝑟 ℎ𝑟
𝑘𝑚𝑜𝑙
Total mole flowrate: 113.364 ℎ𝑟
Stream 2
𝑘𝑔 𝑘𝑔
ℎ𝑟 ℎ𝑟
𝑘𝑚𝑜𝑙
Total mole flowrate: 113.364 ℎ𝑟
Stream Number Stream 1 (in) Stream 2 (out)
Mass flow rate (kg/hr) 8854.72 8854.72
Mole flow rate (kmol/hr) 113.364 113.364
Component flow rates (kmol/h)
Maleic anhydride 0.00 0.00
Dibutyl phthalate 0.00 0.00
Nitrogen 0.00 0.00
Water 0.00 0.00
Oxygen 0.00 0.00
Benzene 113.364 113.364
(1,4-Benzoquinone)Quinone 0.00 0.00
Carbon dioxide 0.00 0.00
Maleic acid 0.00 0.00
Sodium nitrite 0.00 0.00
Sodium nitrate 0.00 0.00
Overall Mass Balance
S1 = S2
𝑘𝑔 𝑘𝑔
8854.72 = 8854.72 ℎ𝑟
ℎ𝑟
Input = Output
𝒌𝒈 𝒌𝒈
8854.72 𝒉𝒓 = 8854.72 𝒉𝒓
For R-601
Stream 6 Stream 7
R-601
Stream 15 Stream 16
Stream 6
𝑘𝑔 𝑘𝑔
Mass of stream: 167588 x 1.34 = 224567.92 ℎ𝑟
ℎ𝑟
Mole flowrate of nitrogen: 4410 x 1.34 = 5909.4
ℎ𝑟 ℎ𝑟
Mole flowrate of oxygen: 1170 x 1.34 = 1567.8
ℎ𝑟 ℎ𝑟
Mole flowrate of benzene: 84.6 x 1.34 =113.364
ℎ𝑟 ℎ𝑟
𝑘𝑚𝑜𝑙
Total mole flowrate: 5909.4 + 1567.8 + 113.364 = 7590.564 ℎ𝑟
Stream 15
𝑘𝑔 𝑘𝑔
Mass of stream: 783850 ℎ𝑟 x 1.34 = 1050359 ℎ𝑟
Mole flowrate of sodium nitrite: 4131.2 x 1.34 = 5535.808
ℎ𝑟 ℎ𝑟
Mole flowrate of sodium nitrate: 5868.8 x 1.34 = 7864.192
ℎ𝑟 ℎ𝑟
𝑘𝑚𝑜𝑙
Total mole flowrate: 5535.808 + 7864.192 = 13400 ℎ𝑟
Stream 7
𝑘𝑔 𝑘𝑔
Mole flowrate of maleic anhydride : 52.6 x 1.34 = 70.484
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
Mole flowrate of water : 183 x 1.34 = 245.22
ℎ𝑟 ℎ𝑟
Mole flowrate of oxygen: 740.4 x 1.34 = 992.136
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
Mole flowrate of quinone: 1.4 x 1.34 = 1.876
ℎ𝑟 ℎ𝑟
Mole flowrate of carbon dioxide: 258 x 1.34 = 345.72
ℎ𝑟 ℎ𝑟
𝑘𝑚𝑜𝑙
Total mole flowrate: 70.484 + 5909.4 + 245.22+992.136+6.968+1.876+345.72 = 7571.804 ℎ𝑟
Stream 16
𝑘𝑔 𝑘𝑔
Mole flowrate of sodium nitrite: 4131.2 x 1.34 = 5535.808
ℎ𝑟 ℎ𝑟
Mole flowrate of sodium nitrate: 5868.8 x 1.34 = 7864.192
ℎ𝑟 ℎ𝑟
𝑘𝑚𝑜𝑙
Total mole flowrate: 5535.808 + 7864.192 =13400 ℎ𝑟
Stream Number Stream 6 (in) Stream 15 (in) Stream 7 (out) Stream 16 (out)
Mass flow rate (kg/hr) 224567.92 1050359 224567.92 1050359
Mole flow rate (kmol/hr) 7590.564 13400 7571.804 13400
Component flow rates

(kmol/h)
Maleic anhydride 0.00 0.00 70.484 0.00
Dibutyl phthalate 0.00 0.00 0.00 0.00
Nitrogen 5909.4 0.00 5909.4 0.00
Water 0.00 0.00 245.22 0.00
Oxygen 1567.8 0.00 992.136 0.00
Benzene 113.364 0.00 6.968 0.00
(1,4-Benzoquinone)Quinone 0.00 0.00 1.876 0.00
Carbon dioxide 0.00 0.00 345.72 0.00
Maleic acid 0.00 0.00 0.00 0.00
Sodium nitrite 0.00 5535.808 0.00 5535.808
Sodium nitrate 0.00 7864.192 0.00 7864.192
Input = Output
S6 + S15 = S7 + S16
𝑘𝑔 𝑘𝑔 𝑘𝑔 𝑘𝑔
224567.92 ℎ𝑟 + 1050359 ℎ𝑟 = 224567.92 ℎ𝑟 + 1050359 ℎ𝑟
𝑘𝑔 𝑘𝑔
1274926.92 ℎ𝑟 = 1274926.92 ℎ𝑟
C-601
Stream 4
C-601
Stream 5
Stream 4
𝑘𝑔 𝑘𝑔
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
𝑘𝑚𝑜𝑙
Total mole flowrate: 5909.4 + 1567.8 = 7477.2 ℎ𝑟
Stream 5
𝑘𝑔 𝑘𝑔
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
𝑘𝑚𝑜𝑙
Total mole flowrate: 5909.4 + 1567.8 = 7477.2 ℎ𝑟
Stream Number Stream (in) Stream 5 (out)
Nitrogen 5909.4 5909.4
Oxygen 1567.8 1567.8
S4 = S5
Input = Output
𝑘𝑔 𝑘𝑔
215713.2 ℎ𝑟 = 215713.2 ℎ𝑟
V-602
Stream 9
𝑘𝑔 𝑘𝑔
Mass of stream: 278383.2 ℎ𝑟 x 1.34 = 373033.488 ℎ𝑟
Mole flowrate of dibutyl phthalate: 1000.2 x 1.34 = 1340.268
ℎ𝑟 ℎ𝑟
𝑘𝑚𝑜𝑙
Total mole flowrate = 1340.268 ℎ𝑟
Stream 12
𝑘𝑔 𝑘𝑔
Mole flowrate of maleic anhydride: 1.0 x 1.34 = 1.34
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
Mole flowrate of water: 183 x 1.34 = 245.22
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
Total mole flowrate: 1.34 + 5909.4 + 245.22 + 992.136 + 6.968 + 1.072 +345.72 = 7501.856
𝑘𝑚𝑜𝑙
ℎ𝑟
Mass flow rate (kg/hr) 373033.488 217683

(kmol/h)
Nitrogen 0.00 5909.4
Water 0.00 245.22
Oxygen 0.00 992.136
Benzene 0.00 6.968
S9 = S12
Input = Output
𝑘𝑔 𝑘𝑔
373033.488 ℎ𝑟 = 217683 ℎ𝑟
- There are some of flow rate accumulate in the vessel, so the mass balance is not balance
for inlet and outlet stream for V 602
V-603
Stream 11
𝑘𝑔 𝑘𝑔
ℎ𝑟 ℎ𝑟
Mole flowrate of dibutyl phthalate: 1000.0 x 1.34 = 1340
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
Mole flowrate of maleic acid: 2.0 x 1.34 = 2.68
ℎ𝑟 ℎ𝑟
𝑘𝑚𝑜𝑙
Total mole flowrate: 12.864 + 1340+ 1.072 + 2.68 = 1356.616 ℎ𝑟
Stream 13
𝑘𝑔 𝑘𝑔
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
𝑘𝑚𝑜𝑙

(kmol/h)
Dibutyl phthalate 1340 0.00
Nitrogen 0.00 0.00
Water 0.00 0.00
Oxygen 0.00 0.00
Benzene 0.00 0.00

S11 = S13
𝑘𝑔 𝑘𝑔
380200.88 ℎ𝑟 = 6959.96 ℎ𝑟
for inlet and outlet stream for V 603
T-601
Stream 8
Stream 11
T-601
Stream 9 Stream 12
am 9 8
Stream
𝑘𝑔 𝑘𝑔
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
Total mole flowrate: 70.484 + 5909.4 + 245.22 + 992.136 + 6.968 + 1.876 +345.72
𝑘𝑚𝑜𝑙
= 7571.804 ℎ𝑟
Stream 9
𝑘𝑔 𝑘𝑔
Mass of stream: 278383.2 ℎ𝑟 x 1.34 = 373033.488 ℎ𝑟
Mole flowrate of dibutyl phathalate: 1000.2 x 1.34 = 1340.268
ℎ𝑟 ℎ𝑟
𝑘𝑚𝑜𝑙
Total mole flowrate = 1340.268 ℎ𝑟
Stream 11
𝑘𝑔 𝑘𝑔
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
Mole flowrate of quinone: 0.8 x 1.34 =1.072
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
𝑘𝑚𝑜𝑙
Total mole flowrate: 12.864 + 1340+ 1.072 + 2.68 = 1356.616 ℎ𝑟
Stream 12
𝑘𝑔 𝑘𝑔
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
Mole flowrate of quinone: 0.8 x 1.34 =1.072
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
Total mole flowrate: 1.34 + 5909.4 + 245.22 + 992.136 + 6.968 + 1.072 +345.72 = 7501.856
𝑘𝑚𝑜𝑙
ℎ𝑟
Stream Number Stream 8 (in) Stream 9(in) Stream 11 (out) Stream 12 (out)
Mass flow rate 224567.92 373033.488 380200.88 217683

(kg/hr)
Mole flow rate 7571.804 1340.268 1356.616 7501.856

(kmol/hr)
Component flow
rates (kmol/h)
Maleic anhydride 70.484 0.00 12.864 1.34
Dibutyl phthalate 0.00 1340.268 1340 0.00
Nitrogen 5909.4 0.00 0.00 5909.4
Water 245.22 0.00 0.00 245.22
Oxygen 992.136 0.00 0.00 992.136
Benzene 6.968 0.00 0.00 6.968

Quinone 1.876 0.00 1.072 1.072
Carbon dioxide 345.72 0.00 0.00 345.72
Maleic acid 0.00 0.00 2.68 0.00
S8 + S9 = S11 + S12
𝑘𝑔 𝑘𝑔 𝑘𝑔 𝑘𝑔
224567.92 ℎ𝑟 + 373033.488 ℎ𝑟 = 380200.88 ℎ𝑟 + 217683 ℎ𝑟
Input = Output
𝑘𝑔 𝑘𝑔
597601.408 ℎ𝑟 = 597883.88 ℎ𝑟
for inlet and outlet stream for T 601
-
T-602
Stream 13
Stream 11
T-602
Stream 14
Stream 11
𝑘𝑔 𝑘𝑔
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
𝑘𝑚𝑜𝑙
Total mole flowrate: 12.864 + 1340 + 1.072 + 2.68 = 1356.616 ℎ𝑟
Stream 13
𝑘𝑔 𝑘𝑔
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
Mole flowrate of maleic acid: 2.0 x 1.34 =2.68
ℎ𝑟 ℎ𝑟
𝑘𝑚𝑜𝑙
Stream 14
𝑘𝑔 𝑘𝑔
ℎ𝑟 ℎ𝑟
ℎ𝑟 ℎ𝑟
𝑘𝑚𝑜𝑙
Total mole flowrate: 1340+ 0.0134 = 1340.0134 ℎ𝑟
Stream Number Stream 11 (in) Stream 13 (out) Stream 14 (out)
Mass flow rate (kg/hr) 380200.88 6959.96 373240.92
Mole flow rate 1356.616 70.216 1340.0134

(kmol/hr)
Component flow
rates (kmol/h)
Maleic anhydride 12.864 69.936 0.00
Dibutyl phthalate 1340 0.00 1340
quinone 1.072 1.128 0.00
maleic acid 2.68 2.82 0.0134
S11 = S13 + S14
𝑘𝑔 𝑘𝑔 𝑘𝑔
380200.88 ℎ𝑟 = 6959.96 ℎ𝑟 + 373240.92 ℎ𝑟
Input = Output
𝑘𝑔 𝑘𝑔
380200.88 ℎ𝑟 = 380200.88 ℎ𝑟
Production of ethylbenzene in stream 13 after scale up is:
𝑘𝑔
Mass flow rate: 6959.96 ℎ𝑟
𝑘𝑚𝑜𝑙
Mole flow rate: 70.216 ℎ𝑟
So, the process of production of maleic anhydride is achieved the production rate for a year
which is:
𝑘𝑔
Mass flow rate: 6957.03 (58,940 tonne/year)
ℎ𝑟
𝑘𝑚𝑜𝑙
Mole flow rate: 70.95 ℎ𝑟
Plant production after scale up (> Production rate per year

high)
Mole flow rate 70.216 70.95

(kmol/hr)
Thus, the plant production of ethylbenzene is valid.
Energy Balance
Energy balances are calculated in order to determine the energy value needed in some
processes such as heating, cooling or reaction. Some assumptions are made to produce the
energy balance calculations. Common equations and formula regarding energy balance are also
included in the calculations.
Assumption:
 Open system
 Steady state
 Kinetic and potential energy negligible
 No shaft work
 No leakage in the vessels and piping used in the system
 Pure reactant is used
General energy balance equation:
Output = input + generation – consumption – accumulation
Energy balance formula
Denotation Formula
Heat capacity,Cp (KJ/mol.0C) a+ bT + cT2 + dT3
Error percentage (%) Estimate−actual

% error = ( ) (100)
Actual
Molecular weight for every component:
Component Molecular weight (kg/kmol)
Maleic anhydride 98.06
Dibutyl phthalate 278.34
Nitrogen 14
Water 18
Oxygen 16
Benzene 78.11
(1,4-Benzoquinone)Quinone 108.095
Heat capacity of compound:
References : http://booksite.elsevier.com/9780750683661/Appendix_C.pdf
Compounds Cp = a + bT + cT2 + dT3 + eT4 (kJ/kmol.oC)
Maleic anhydride
C4H2O3
cis-Butenedioic
anhydride
2,5-Furanedione
Maleic acid
anhydride
Toxilic anhydride
Dibutyl phthalate
Di-n-butyl phthalate
Butyl phthalate
n-Butyl phthalate
1,2-
Benzenedicarboxylic
acid dibutyl ester
Nitrogen 29.342 -3.5395x10-3T+(2.9197x10-4)T2+(1.0076x10-5 )T3+

(2.5935x10-13)T4 (for gas)
76.452 -3.5226x10-1T-(2.6690x10-3)T2+(5.0057x10-5 )T3
(for liquid)
Water 33.933 -8.4186x10-3T+(2.9906x10-5)T2-(1.7825x10-8)T3+ (3.6934x10-

12
)T4 (for gas)
92.053 -3.9953x10-2T-(2.1103x10-4)T2+(5.3469x10-7 )T3
(for liquid)
Oxygen 29.526-8.8999x10-3T+(3.8083x10-5)T2-(3.2629x10-8 )T3+ (8.8607x10-

12
)T4 (for gas)
46.432+3.9506x10-1T-(7.0522x10-3)T2+(3.9897x10-5 )T3
(for liquid)
Benzene -31.368 +4.7460x10-1T-(3.1137x10-4)T2+(8.5237x10-8)T3-

(5.0524x10-12)T4 (for gas)
-31.663 +1.3043T-(3.6078x10-3)T2+(3.8243x10-6 )T3

(for liquid)
Quinone
(1,4-Benzoquinone)
p-benzoquinone; p-
quinone
Carbon dioxide 27.437 +4.2315x10-2T-(1.9555x10-5)T2+(3.9968x10-9)T3- (2.9872x10-
13
)T4 (for gas)
-338.956 +2.2796T-(2.3279x10-2)T2+(3.5980x10-5 )T3
(for liquid)
Maleic acid
Sodium nitrite
Sodium nitrate
Heat of combustion
Compounds H0 combustion (KJ/mol)

Maleic Anhydride -1339
Benzene (gas) -3267.6
Heat of formation
Compounds H0 formation (KJ/mol)
Maleic Anhydride -470.41
Quinone -184.5
Energy Balance Calculation
FOR E-601
T = 30oC T = 116.2oC
E-601
Stream 3 Stream 3’
Inlet stream
Vapor fraction: 0.00
T = 30oC
CpBenzene (liquid) = -31.663 +1.3043T-(3.6078x10-3)T2+(3.8243x10-6 )T3

= 4.322 KJ/mol. oC
Power ,Q = mCp TT
= (84.6)(4.322)(30)
= 10969.236 MWh
Outlet stream
T = 116.2oC
CpBenzene (gas) = -31.368 +4.7460x10-1T-(3.1137x10-4)T2+(8.5237x10-8)T3 - (5.0524x10-12)T4
= 19.710 KJ/mol. oC
Power ,Q = mCp TT
= (84.6)(19.710)(116.2)
= 193759.550 MWh
Cpaverage= (in + out)/2
= (4.322 + 19.710 )/2 KJ/mol. oC
= 12.016 KJ/mol. oC
QTotal = Qout – Qin
= 193759.550 - 10969.236 MWh
= 182790.314 MWh
H-601
T = oC T = 460oC
H-601
Stream 3’ Stream 6
Inlet stream
Outlet of E-601( from hysys)+ Stream 5= Inlet
By using Gay-Lussac’s Law:
P1 P2
=
T1 T2
At outlet E-601:
279.7 250
=
116.2 T2
T2 = 103.86 oC
Stream 5
T = 170 oC
Composition:
component 5580
Nitrogen: = = 0.79
mole 116.2
component 1170
Oxygen: = = 0.21
mole 5580
CpNitrogen (gas) = 29.342 -3.5395x10-3T+ (2.9197x10-4)T2+(1.0076x10-5 )T3+ (2.5935x10-13)T4
= 86.681 KJ/mol.oC
CpOxygen (gas) = 29.526-8.8999x10-3T+ (3.8083x10-5)T2-(3.2629x10-8 )T3+ (8.8607x10-12)T4
= 28.961 KJ/mol. oC
CpTotal = ∑ xi Cpi
= (0.79 × 86.681) + (0.21 × 28.961)
= 74.560 KJ/mol. oC
Power,Q = mCp T
T
= (5580)( 74.560)(170)
= 7.1 ×107 MWh
Outlet E-601
T=103.86oC
CpBenzene (gas) = -31.368 +4.7460x10-1T-(3.1137x10-4)T2+(8.5237x10-8)T3 - (5.0524x10-12)T4
= 14.486 KJ/mol. oC
Power ,Q = mCp TT
= (84.6)(14.486)(103.86)
= 127282.050 MWh
Outlet stream
T = 460 oC
Composition:
component 4410
Nitrogen: = = 0.78
mole 5664.6
component 1170
Oxygen: = 5664.6 = 0.21
mole
component 84.6
Benzene: = 5664.6 = 0.01
mole
CpNitrogen (gas) = 29.342 -3.5395x10-3T+(2.9197x10-4)T2+(1.0076x10-5 )T3+ (2.5935x10-13)T4
= 1070.265 KJ/mol. oC
= 37.063 KJ/mol. oC
CpBenzene (gas) = -31.368 +4.7460x10-1T-(3.1137x10-4)T2+(8.5237x10-8)T3- (5.0524x10-12)T4
= 116.649 KJ/mol. oC
= (0.78 × 1070.265) + (0.21 × 37.063) + (0.01 × 116.649)
= 843.756 KJ/mol. oC
Power ,Q = mCp TT
= (5664.6)( 843.756)(460)
= 2.2× 109 MWh
= 2.2× 109 – (7.1 ×107 + 127282.050)
= 2.1× 109 MWh
E-603
T = 608oC T = 270oC
E-603
Stream 7 Stream 8
Inlet stream
Vapor fraction =1.00
Composition:
component 52.6
Maleic anhydride: = = 0.01
mole 5650.4
component 4410
Nitrogen: = 5650.4 = 0.78
mole
component 183
Water: = = 0.03
mole 5650.4
component 740.4
Oxygen: = 5650.4 = 0.13
mole
component 5.2
Benzene: = = 0.00
mole 5650.4
component 1.4
Quinone: = 5650.4 = 0.00
mole
component 258
Carbon dioxide: = = 0.05
mole 5650.4
CpMaleic anhydride(gas) = 0.1681 KJ/mol. oC
= 2399.795KJ/mol. oC
CpWater (gas) = 33.933 -8.4186x10-3T+(2.9906x10-5)T2-(1.7825x10-8)T3+ (3.6934x10-12)T4
= 36.368 KJ/mol. oC
= 32.07 KJ/mol. oC
= 160.555KJ/mol. oC
CpQuinone (gas) = 0.3466 KJ/mol. oC

Cpcarbon dioxide (gas) = 27.437 +4.2315x10-2T-(1.9555x10-5)T2+(3.9968x10-9)T3
- (2.9872x10-13)T4
= 46.793 KJ/mol. oC
= (0.01× 0.1681) + (0.78× 2399.795) + (0.03× 36.368) + (0.13 × 32.07)
+ (0.00 × 160.555) + (0.00 × 0.3466) + (0.05 × 46.793)
= 1879.441 KJ/mol. oC
Power ,Q = mCp T T
= (5650.4)( 1879.441)(608)
= 6.5×109MWh
Outlet stream
Vapor fraction =1.00
Composition:
component 52.6
Maleic anhydride: = = 0.01
mole 5650.4
component 4410
Nitrogen: = 5650.4 = 0.78
mole
component 183
Water: = = 0.03
mole 5650.4
component 740.4
Oxygen: = 5650.4 = 0.13
mole
component 5.2
Benzene: = = 0.00
mole 5650.4
component 1.4
Quinone: = 5650.4 = 0.00
mole
component 258
Carbon dioxide: = = 0.05
mole 5650.4
CpMaleic anhydride(gas) = 0.13301 KJ/mol. oC
= 247.998 KJ/mol. oC
CpWater (gas) = 33.933 -8.4186x10-3T+(2.9906x10-5)T2-(1.7825x10-8)T3+ (3.6934x10-12)T4
= 33.509 KJ/mol. oC
= 29.304 KJ/mol. oC
= 75.725 KJ/mol. oC
CpQuinone (gas) = 0.2223 KJ/mol. oC
Cpcarbon dioxide (gas) = 27.437 +4.2315x10-2T-(1.9555x10-5)T2+(3.9968x10-9)T3- (2.9872x10-13)T4
= 37.513 KJ/mol. oC
= (0.01× 0.13301) + (0.78× 247.998) + (0.03× 33.509) + (0.13 × 29.304)
+ (0.00 × 75.725) + (0.00 × 0.2223) + (0.05 × 37.513)
= 200.130 KJ/mol. oC
Cpaverage= (in + out)/2
= (1879.441 +200.130 )/2
= 1039.786 KJ/mol. oC
Power ,Q = mCp T T
= (5664.6)( 843.756)(460)
= 2.2× 109 MWh
= 193759.550 - 10969.236 MWh
= 182790.314 MWh
T-601
Stream 8
Stream 11
T-601
Stream 9 Stream 12
am 9
Inlet balance
Stream 8 9
Flow rate, m(mol/hr) 5650400 1000200
Temperature (oC) 270 330
Composition Cp(KJ/mol. oC) Composition Cp(KJ/mol. oC)
Maleic anhydride 0.009 0.13301 0 -
Dibutyl phalate 0.00 0.00 1 0.6409
Nitrogen 0.780 247.998 0.00 -

Water 0.032 33.509 0.00 -
Oxygen 0.131 29.304 0.00 -
Benzene 0.00092 75.725 0.00 -
Quinone 0.00025 0.2223 0.00 -
Carbon dioxide 0.04566 37.513 0.00 -
Maleic acid 0.00 0.00 0.00 -
Total CP 200.130 0.6409
Energy,Q 182790.314 6410.282
189200.596
Total Q (MW)
Outlet balance
Stream 11 12
Flow rate, m(mol/hr) 1052400 5595800
Temperature (oC) 194 84
Composition Cp(KJ/mol. oC) Composition Cp(KJ/mol. oC)
Maleic anhydride 0.01 0.12227 0 0.10129
Dibutyl phalate 0.95 0.56735 1 -
Nitrogen 0.00 - 0.00 0.02922
Water 0.00 - 0.00 0.03409
Oxygen 0.00 - 0.00 0.03003

Benzene 0.00 - 0.00 0.10001
Quinone 0.00 0.19439 0.00 0.15395
Carbon dioxide 0.04566 - 0.00 0.03945
Maleic acid 0.00 0.12227 0.00 -
Total CP 0.54525 0.03006
Energy,Q 1113421.895 140720.276
1254142.171
Total Q (MW)
= 1254142.171- 189200.596MWh
= 1064941.575 MWh
FOR V-601
T= 30 oC T= 30 0C
Mass flow rate (kg/hr) 6608 6608

Nitrogen 0.00 0.00
Water 0.00 0.00
Oxygen 0.00 0.00
Benzene 84.6 84.6
Tref = 25 oC , all stream liquid phase,
Mole fraction at stream 1:
Benzene: 84.6 / 84.6 = 1.0
ℎ𝑟 ℎ𝑟
30
Cp,benzene=∫25 -31.663 +1.3043T-(3.6078x10-3)T2+(3.8243x10-6 )T3
= 4.322 – ( –1.251)
= 5.573 kJ/kmol . oC
Cp1,mix = ∑ xiCpi
Mole fraction at stream 2:
Benzene: 84.6 / 84.6 = 1.0
ℎ𝑟 ℎ𝑟
30
Cp,benzene = ∫25 -31.663 +1.3043T-(3.6078x10-3)T2+(3.8243x10-6 )T3
= 4.322 – (–1.251)
Cp2,mix = ∑ xiCpi
∆H = Hout - Hin
∆H = mCp2,mix∆T – mCp1,mix∆T
= (84.6 x 5.573 x (30-25)) – (84.6 x 5.573 x (30-25))
= 0 kJ/hr
FOR R – 601
T = 460 oC T = 608 oC
Stream 6 Stream 7
o
R-601
T = 419 C T = 562 oC
Stream 15 Stream 16
Stream Number Stream 6 (in) Stream 15 (in) Stream 7 (out) Stream 16 (out)
Mass flow rate (kg/hr) 167588 783850 167588 783850

Mole flow rate 5664.6 10000 5650.4 10000
(kmol/hr)
Component flow
rates (kmol/h)
Nitrogen 4410 0.00 6218.1 0.00
Oxygen 1170 0.00 1649.7 0.00
Benzene 84.6 0.00 119.286 0.00
Sodium nitrite 0.00 4131.2 0.00 5824.992
Sodium nitrate 0.00 5868.8 0.00 8275.008
Overall reaction
C6H6 (g) + 4.5O2 (g) → C4H2O3(g) + 2CO2(g) + 2H2O(g)
benzene maleic anhydride
∆𝐻𝑟 ° = ∑𝑖 𝑣 ∆𝐻ofio = ∑𝑝𝑟𝑜𝑑𝑢𝑐𝑡|𝑣𝑖 | ∆Ȟ fio - ∑𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡|𝑣𝑖 | ∆Ȟ fio
Heat formation of compound1:
Compund Heat of Formation, ∆Hf at Tref = 25 oC
Benzene 82.93 kJ/kmol
Oxygen 0
Maleic anhydride 469.445 kJ/kmol
1
http://www.gridgit.com/post_standard-heat-of-formation-chart_508361/
booksite.elsevier.com/9780080966595/.../Appendix_C_searchable_spreadsheet.xls
http://www.bartek.ca/pdfs/PhysicalMaleic/Maleic%20Anhy.%20Tech%20Data%20Sheet.pdf
Carbon dioxide -393.52 kJ/kmol
Water -241.82 kJ/kmol
Inlet
T = 460 oC
Composition:
component 84.6
Benzene: = = 0.01
mole 5664.6
component 4410
Nitrogen: = 5664.6 = 0.78
mole
component 183
Oxygen : = = 0.03
mole 5664.6
CpBenzene (liquid) = -31.663 +1.3043T-(3.6078x10-3)T2+(3.8243x10-6 )T3

= 178.147 KJ/mol. oC
Cpnitrogen (liquid) = 76.452 -3.5226x10-1T-(2.6690x10-3)T2+(5.0057x10-5 )T3
= -2.6 × 105 KJ/mol. oC
Cpoxygen (liquid) = 46.432+3.9506x10-1T-(7.0522x10-3)T2+(3.9897x10-5 )T3
= 2.6 × 103 KJ/mol. oC
= (0.01× 178.147 ) + (0.78 × −2.6 × 105 )+ (0.03× 2.6 × 103)
= -2.0 × 105 KJ/mol. oC
Power ,Q = mCp T T
= (5664.6)( -2.0 × 105)(460)
= -5.2× 1011MWh
Outlet
T = 608 oC
Composition:
component 5.2
Benzene: = 5650.4 = 0.00
mole
component 4410
Nitrogen: = 5650.4 = 0.78
mole
component 740.4
Oxygen: = = 0.13
mole 5650.45664.6
component 52.6
Maleic anhydride: = 5650.4 = 0.01
mole
component 183
Water : = 5650.4 = 0.03
mole
component 1.4
Quinone: = = 0.00
mole 5650.4
component 258
Carbon dioxide: = 5650.4 = 0.05
mole
Cpbenzene = -31.663 +1.3043T-(3.6078x10-3)T2+(3.8243x10-6 )T3

= 3.2× 102 KJ/mol. oC
Cpnitrogen= 76.452 -3.5226x10-1T-(2.6690x10-3)T2+(5.0057x10-5 )T3
= 9.9× 103 KJ/mol. oC
Cpoxygen= 46.432+3.9506x10-1T-(7.0522x10-3)T2+(3.9897x10-5 )T3
= 6.7× 103 KJ/mol. oC
Cpmaleic anhydride = 0.1681 KJ/mol. oC

Cpwater = 92.053 -3.9953x10-2T-(2.1103x10-4)T2+(5.3469x10-7 )T3
= 1.1× 102 KJ/mol. oC
Cpquinone = 0.3466 KJ/mol. oC
Cpcarbon dioxide= -338.956 +2.2796T-(2.3279x10-2)T2+(3.5980x10-5 )T3
= 5.6× 102 KJ/mol. oC
= (0.00×3.2× 102) + (0.78×9.9× 103) + (0.13×6.7× 103) + (0.01×0.1681)+ (0.03×1.1×

102 )+ (0.00× 0.3466 )+ (0.03×5.6× 102)
= 8.6× 103 KJ/mol. oC
Power ,Q = mCp T T
= (5664.6)( 8.6× 103)(608)
= 3.0× 1010 MWh
Heat of reaction
Overall reaction
C6H6 (g) + 4.5O2 (g) → C4H2O3(g) + 2CO2(g) + 2H2O(g)
benzene maleic anhydride
∆𝐻𝐻 ° = ∑𝐻 𝐻 ∆𝐻ofio = ∑𝐻𝐻𝐻𝐻𝐻𝐻𝐻|𝐻𝐻 | ∆Ȟ fio - ∑𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻|𝐻𝐻 | ∆Ȟ fio
Heat formation of compound:
Compund Heat of Formation, ∆Hf at Tref = 25 oC
Benzene 82.93 kJ/kmol
Oxygen 0
Maleic anhydride 469.445 kJ/kmol
Carbon dioxide -393.52 kJ/kmol
Water -241.82 kJ/kmol
References ;
http://www.gridgit.com/post_standard-heat-of-formation-chart_508361/
booksite.elsevier.com/9780080966595/.../Appendix_C_searchable_spreadsheet.xls
http://www.bartek.ca/pdfs/PhysicalMaleic/Maleic%20Anhy.%20Tech%20Data%20Sheet.pdf
∆𝐻𝐻 ° = [469.445 +2(-393.52 ) + 2(-241.82)] - 82.93 + 0
= -801.235 – 82.93
= -884.165 kJ/kmol (exothermic)
= 3.0× 1010 - (-5.2× 1011)MWh
= 5.5× 1011MWh
HEAT INTEGRATION
The term of “Pinch technology” was introduced to represent a new set of thermodynamically
based on methods that guarantee minimum energy levels in design of heat exchanger networks.
Over the last two decades it has emerged as an unconventional development in process design
and energy conversation. The term “pinch technology” is often used to represent the application
of the tools and algorithm of Pinch technology for studying industrial processes. Development of
the rigorous software programs like Aspen PinchTM have proved to be very useful in pinch
analysis of complex industrial process with speed and effieciency (Linnhoff and Vredeveld,
1984).
Pinch analysis is used to identify energy cost and heat exchanger network capital cost targers for
a proces and recognizing the pinch point. The procedure first predicts, ahead of design, the
minimum requirements of external energy, network area and the number of units for a given
process at the pinch point. Next a heat exchanger network design tha satisfies these target is
synthesized. Finally the network is optimized by comparing energy cost and capital cost of the
network so that the total annual cost is minimized. Thus, the prime objective of pinch technology
analysis is to achieve financial savings by better process heat integration (maximizing process to
processs heat recovery and reducing the external utility loads (Linnhoff and G.T.Polley, June
1988).
Table Heat Exchanger Details
Heat exchanger Tin (oC) Tout (oC)
E-601 Stream 3 = 30 116
E-603 Stream 7=608 Stream 8=270

Table of hot and cold stream
Stream Hot/Cold ṁCp Tin (oC) Tout(oC)
1 cold 79 401.7 30 116
Hot
2 174 255 656.2 608 270
Temperature interval diagram
HOT COLD
Stream 1 2 Q(kW)
ṁCp 79 401.7 174 255 656.2
°C °C
608 588
A 26.83x106
270 250
B 0.00
136 116
C -14.99x109
50 30
Q = -14.96x109 kW
Since there is no pinch temperature can be obtained from the interval diagram, thus the heat
integration cannot be performed. This may be due to only two heat exchangers involved
therefore the temperature interval diagram has less temperature which consequently does not
have any overlap between the cold and hot water stream. From the observation, the more heat
exchanger involve, the pinch technology can be applied very well. Since there is no pinch
temperature identified, thus we cannot proceed with the pinch technology. In order to conduct
the pinch technology, more heat exchanger such as heater and cooler must be added to the
system.
PRELIMINARY DESIGN OF EQUIPMENT-HEURISTIC
*All the heuristics done is taking from reference.1
R-601
Shell-and-tube vertical design
Stainless steel
L = 7.0 m D2
D = 3.8 m
12,100 1- in diameter, 6.4 m length catalystfilled tubes
Design pressure = 300kPa
Pav = 2.14 barg

𝐻𝐻²𝐻
Volume of tube = 4
𝐻(0.0254)2 (6.4)
= × 12100
4
= 39 tubes
𝐻𝐻²𝐻
Volume of shell = 4
𝐻(3.8)2 (7.0)
= 4
= 79 tubes
Volume of reactor = 79 – 39
= 40 m3
Follow the rule for unmixed system.
We choose L/D = 10 (Based on plug flow consideration)
𝐻(𝐻)2 (10𝐻)
40 m3 = , D= 1.7205 m
4
-ri = kiCbenzene or -r3 =k3Cmaleicanhydride
K1 =7.7 ×106 exp(-25143/RT)
K2 =6.31 ×107 exp(-29850/RT)
K3 =2.33 ×104 exp(-21429/RT)
K4 =7.20 ×105 exp(-27149/RT)
For 1st reaction,
–r1 = k1Cbenzene
From the first chemical reaction and according to the stream table, the benzene enter the reactor
at stream 6 and produce the maleic anhydride, carbon dioxide and water at stream 7.
Calculation:
Stream 6:
𝐻.𝐻𝐻𝐻 1𝐻3 𝐻𝐻𝐻 10−5 𝐻3 .𝐻𝐻𝐻
T= 733.15k, R=0.08205 𝐻𝐻𝐻𝐻.𝐻 × 1000𝐻 × 1.013 𝐻𝐻𝐻 = 8.311 × 𝐻𝐻𝐻𝐻.𝐻
84.6𝐻𝐻𝐻𝐻 876𝐻𝐻 ℎ𝐻
Cbenzene = × × 167588𝐻𝐻= 0.4422kmol/m3
ℎ𝐻 𝐻3
K1 =7.7 ×106 exp(-25143/(8.311)(733.15))= 124285.2018m3/m3.s
–r1 = (124285.2018m3/m3.s)( 0.4422kmol/m3)= 54958.92Kmol/m3.s
For 2nd reaction,
–r2 = k2Cbenzene
Calculation:
Stream 6:

ℎ𝐻 𝐻3
K2 =6.31 ×107 exp(-29850/(8.311)(733.15))= 470398.4545m3/m3.s
–r2 = (470398.4545m3/m3.s)( 0.4422kmol/m3)= 208010.1966 Kmol/m3.s
For 3rd reaction,
–r3 = k3Cmaleic anhydride
Calculation:
Stream 7:

𝐻𝐻𝐻𝐻 1480𝐻𝐻 ℎ𝐻
Cmaleic anhydride = 52.6 × × 167588𝐻𝐻= 0.465kmol/m3
ℎ𝐻 𝐻3
K3 =2.33 ×104 exp(-21429/(8.311)(881.15))= 1248.93m3/m3.s

–r3 = (1248.93m3/m3.s)( 0.465kmol/m3)= 580 Kmol/m3.s
For 4th reaction,
–r4 = k4Cbenzene
Calculation:
Stream 6:

T= 733.15k, R=0.08205 × × 1.013 = 8.311 ×
𝐻𝐻𝐻𝐻.𝐻 1000𝐻 𝐻𝐻𝐻 𝐻𝐻𝐻𝐻.𝐻
ℎ𝐻 𝐻3
K4 =7.20 ×105 exp(-27149/(8.311)(733.15))= 8361.48m3/m3.s
–r4 = (8361.48m3/m3.s)( 0.4422kmol/m3)= 3697.447Kmol/m3.s
TOWER, T-601
From table 11.13, the following heuristic was

Rule 5 : optimum reflux in the range of 1.2 -1.5Rmin
Rule 6 : Optimum number of stages approximately 2Nmin
Rule 7 :Nmin= ln{x/(1-x)ovhd/[x(1-x)bot]} / ln α
Rule 8 :Rmin= {F/D}/(α – 1)
Rule 9 : Use safety factor of 10% on number of trays
Rule 14 :Lmax= 53 m and L/D <30
From table 11.14, the following heuristic was

Rule 2 :Fs= μρv0.5 = 1.2  1.5 m/s (kg/m3)0.5
Rule 3 :ΔPtray = 0.007 bar
Rule 4 : ϵtray = 10 – 20 %
XOVERHEAD = 0.79
XBOTTOM = 0.0001976
αoverhead =2738.68
αbottom = 6.21x10-3
αaverage = (αoverhead X αbottom )0.5
= 4.12
Nmin= ln{0.79(1-0.79)ovhd/[0.0001976(1-0.0001976)bot]} / ln 4.12
= 6.9597
From the heuristic, when the feed is enter at the bubble point, the following equation was used
Rmin = {F/D}/(α – 1)
= ((5650.6 + 1000.2)/ 5598.4) / (4.12-1)
= 0.3808
Range R = (1.2  1.5) Rmin

= 0.456 0.57
Ntheorithical= 2(Nmin) = 2(6.9597) = 13.9194
Nactual= Ntheorithical/ ϵ
= 13.9194 / 0.5 x 1.1 =31 stage
ρv= 0.7454 kg/m3
μ = [ 1.2 1.5 ] / (0.7454)0.5 = 1.3899  1.737
Stream top
V = 106443.725 m3/h = 29.568 m3/s
D = [4v / μ]0.5 = [4(29.568) / (1.3899  1.737)]0.5 = 5.2044  4.655 m

L/D = 10/4.2 = 2.38 <30
From Table B.5.3 From Heuristic
Tower Diameter 4.2m 5.2044  4.655 m
Reflux 0.189 0.456 0.57
No of tray 42 31
efficiency 50% 1020%
Assume cylindricalvvessel:
From the calculation above :
D = 5.2 m
H= 10 m
Volume = ∏D2L/4
Volume = ( ∏x 5.22 x 10 ) / 4
= 212.37 m3
It is suggest that the dimension is 10% higher from the operating dimension.
Design D= 1.1 x 5.2= 5.5 ~ 6 m
Design H= 1.1 x 10= 11 m
Suggested design and dimension:
H= 11 m
D= 6 m
The maximum capable capacity:
= 331.018 m3
TOWER T-602
Based on the Table 11.13 of the Analysis, Synthesis and Design of Chemical Processes, there are
some rules that need to take account in order to do the heuristics for a tower. These rules are as
follow:
Rule 5 : Optimum reflux in the range of 1.2 -1.5Rmin

Rule 6 : Optimum number of stages approximately 2Nmin
Rule 7 :Nmin= ln{x/(1-x)ovhd/[x(1-x)bot]} / ln α
Rule 8 :Rmin= {F/D}/(α – 1)
Rule 9 : Use safety factor of 10% on number of trays
Rule 14 :Lmax= 53 m and L/D <30
On the other hand, there are also rules that must obey in doing the heuristics for trays. The rules
taken from table 11.14 of the same book are as follow:
1. 𝐻𝐻𝐻 = (𝐻𝐻𝐻ℎ𝐻 ∙ 𝐻𝐻𝐻𝐻) 0.5 ; ovhd = overhead
btm = bottom
𝐻𝐻𝐻𝐻
𝐻𝐻𝐻ℎ𝐻 = 𝐻1𝐻𝐻𝐻 @ 𝐻𝐻𝐻ℎ𝐻 ; 1 = light key component (MA)
2
2 = heavy key component (DP)
𝐻𝐻𝐻𝐻
𝐻𝐻𝐻𝐻 = 𝐻1𝐻𝐻𝐻 @ 𝐻𝐻𝐻𝐻 ; 1 = light key component (MA)
2
2 = heavy key component (DP)

The table below contain the parameters for Antoinne equation.
𝐻
log10 𝐻 = 𝐻 − ; 𝐻 (𝐻𝐻𝐻𝐻); 𝐻(𝐻)
𝐻+𝐻
Component A B C Temperature range
Maleic 16.2747 3765.65 -82.15 79°C – 243°C

Anhydride
Dibutyl 16.9539 4852.47 -138.10 196°C – 384°C

Phthalate
At Tovhd At Tbtm
3765.65 3765.65
log10 𝐻𝐻𝐻 = 16.2747 − log10 𝐻𝐻𝐻 = 16.2747 −
(195 + 273) − 82.15 (330 + 273) − 82.15
PMA = 26.03 mmHg × 133.32 PMA = 23.50 mmHg × 133.32
= 3.47 kPa = 3.13 kPa
log10 𝐻𝐻𝐻 = 16.9539 log10 𝐻𝐻𝐻 = 16.9539

4852.47 4852.47
− −
(195 + 273) − 138.10 (330 + 273) − 138.10
PDP = 9.44 mmHg × 133.32 PDP = 6.52 mmHg × 133.32
= 1.26 kPa = 0.87 kPa
𝐻𝐻𝐻𝐻
𝐻𝐻 3.47 𝐻𝐻𝐻 𝐻𝐻𝐻𝐻
𝐻𝐻 3.13 𝐻𝐻𝐻
𝐻𝐻𝐻ℎ𝐻 = 𝐻𝐻𝐻 = = 2.754 𝐻𝐻𝐻𝐻 = 𝐻𝐻𝐻 = = 3.598
𝐻𝐻𝐻 1.26 kPa 𝐻𝐻𝐻 0.87 kPa
∴ 𝐻𝐻𝐻 = (2.754 × 3.598)0.5 = 3.148
𝐻𝐻𝐻𝐻
𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻
2. 𝐻𝐻𝐻𝐻 = ; feed at stream 11 (inlet of tower)
𝐻𝐻𝐻 −1
distillate at stream 13 (overhead product)
1012.4 𝐻𝐻𝐻𝐻𝐻/ℎ
52.4 𝐻𝐻𝐻𝐻𝐻/ℎ
𝐻𝐻𝐻𝐻 = = 8.995
3.148 − 1
3. 𝐻 = (1.2 → 1.5 )𝐻𝐻𝐻𝐻 = (1.2 → 1.5 )8.995 = 10.794 → 13.493
𝐻
( )𝐻𝐻ℎ𝐻
ln[ 1−𝐻
𝐻 ]
( )
1−𝐻 𝐻𝐻𝐻 49.5 𝐻𝐻𝐻𝐻𝐻/ℎ
4. 𝐻𝐻𝐻𝐻 = ; 𝐻𝐻𝐻ℎ𝐻 = = 0.945
ln 𝐻𝐻𝐻 52.4 𝐻𝐻𝐻𝐻𝐻/ℎ
0.1 𝐻𝐻𝐻𝑙𝐻/ℎ
𝐻𝐻𝐻𝐻 = 1000.01 𝐻𝐻𝐻𝐻𝐻/ℎ
= 0.10 × 10−3
0.945
( )
1−0.945 𝐻𝐻ℎ𝐻
ln[ −3 ]
0.10×10
( )𝐻𝐻𝐻
1−0.10×10−3
𝐻𝐻𝐻𝐻 = = 10.48
ln 3.148
5. 𝐻𝐻ℎ𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 = 2𝐻𝐻𝐻𝐻 = 2(10.48) = 20.96

𝐻𝐻ℎ𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻
6. 𝐻𝐻𝐻𝐻𝐻𝐻𝐻 = × (1 + 0.1) ; 𝐻𝐻𝐻𝐻𝐻 = 60% =
𝐻𝐻𝐻𝐻𝐻
0.6 (𝐻𝐻𝐻 𝐻𝐻𝐻𝐻𝐻𝐻𝐻 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻)
20.96
𝐻𝐻𝐻𝐻𝐻𝐻𝐻 = × (1.1) = 38.427 ≅ 39 𝐻𝐻𝐻𝐻𝐻 𝐻𝐻𝐻𝐻𝐻
0.6
7. 𝐻 = ( 𝐻𝐻𝐻𝐻 𝐻𝐻𝐻𝐻𝐻𝐻𝐻 × 𝐻𝐻𝐻𝐻𝐻𝐻𝐻 ) + 3 𝐻 = ( 0.6 𝐻 × 38.427) + 3 𝐻 =

26.056 𝐻
𝐻𝐻
8. 𝐻𝐻 = 𝐻𝐻0.5
𝐻 = 1.2 → 1.5 ; 𝐻𝐻 = 3.38 (𝐻𝐻)
𝐻3
1.2 → 1.5 1.2 → 1.5 𝐻

𝐻= = = 0.653 → 0.816
𝐻0.5
𝐻 3.38 0.5 𝐻
𝐻̇
9. 𝐻 = ; 𝐻̇ =
𝐻𝐻
𝐻𝐻
5194 (𝐻𝐻𝐻𝐻ℎ𝐻𝐻𝐻 𝐻𝐻𝐻𝐻𝐻 𝐻𝐻𝐻𝐻 𝐻𝐻𝐻𝐻)
ℎ
𝐻𝐻
5194 ℎ 𝐻3
𝐻= = 0.4269
𝐻𝐻 3600 𝐻 𝐻
3.38 3 × 1 ℎ
𝐻
4𝐻
10. 𝐻 = 𝐻𝐻
𝐻3
4(0.4269 𝐻 )
𝐻= 𝐻 = 0.832 → 0.666 𝐻
𝐻(0.653 → 0.816 𝐻)
0.832 𝐻 + 0.666 𝐻
𝐻𝐻𝐻 = = 0.749 𝐻
2
The value of Dav and height is then being used to calculate the cost of this tower.
𝐻 26.056 𝐻
11. = = 34.79
𝐻 0.749 𝐻
The value of L/D obtained from heuristics is slightly higher than the desired value which is 30.
This may be due to some errors during calculation that had done.
The differences of the actual number of tray, height and diameter of the tower are as follow:
Table B.5.3 Heuristics
Number of tray 42 39
Tray efficiency 65% 60%
Reflux ratio 1.24 10.794 → 13.493
Height 18 m 26.056 m
Diameter 1.05 m 0.832 m → 0.666 m

HEAT EXCHANGER E-601
- Heuristics for heater using Table 11.11
Rule 1 : Assume conservative estimate set F = 0.9 for shell and tube exchanger with no phase
change. Q = UAF∆Tlm
Data from pfd :-
Q = 151000 W
t1(Fluid in) = 32°C
t2(Fluid out) = 116°C
Rule 6 : Minimum temperature approach, ∆T = 10°C
Rule 7 : Neglect because heater using lps(low pressurized steam)
Rule 8 : U =280 W/m2.°C because liquid to liquid
Hence, find ∆Tlm
t1(Fluid in) = 32°C T1(lps in)= 130°C
t2(Fluid out) = 116°C T2(lps out) = 120°C
∆Tlm= [(130-116)-(120-32)]/ln[(130-116)/(120-32)]
= 40.26°C
Find A from Q formula
A = (151128.8211 W)/ (280W/m2.°C)(0.9)(40.26°C)
= 14.88 m2
Thus, Our Area in pfd is 14.60 m2 and it is almost similar with the heuristic area and use floating
head, stainless steel heater.
- For sizing, area of E-1 must be use in order to get Diameter, D and Length, L
A = 2𝐻𝐻𝐻, where radius, r = D/2 and L = 2D
𝐻
A = 2𝐻 ( 2 ) (2𝐻)
= 2𝐻𝐻^2
14.6 m2 = 2𝐻𝐻^2
D = 1.52 m
and, L = 2D
= 2(1.52 m) = 3.05 m
𝐻𝐻²𝐻
Thus, Volume (V) = 4
𝐻(1.52)2 (3.05)
=
4
= 5.53 m3
Data from pfd :-
Q = 4053000 W
t1(Fluid in) = 153.4°C
Rule 6 : Minimum temperature approach, ∆T = 10°C

Rule 7 : Neglect because heater using hps(high pressurized steam)
Rule 8 : U =30 W/m2.°C because gas to gas
Hence, find ∆Tlm
t1(Fluid in) =153.4°C T1(hps in)= 400°C
t2(Fluid out) = 170°C T2(hps out) = 390°C
∆Tlm= [(400-170)-(390-153.4)]/ln[(400-170)/(390-153.4)]
= 233.28°C
A = (405313.3921 W)/ (30W/m2.°C)(0.9)(233.28°C)
= 64.35 m2
Thus, Our Area in pfd is 61.6 m2 and it is almost similar with the heuristic area and install
floating head, stainless steel heater.
- Based on area, find sizing which is the diameter, length and volume.
𝐻
A = 2𝐻 ( 2 ) (2𝐻)
= 2𝐻𝐻^2
64.3501 m2 = 2𝐻𝐻^2
D = 3.2 m
and, L = 2D
= 2(3.2 m) = 6.4 m
𝐻𝐻²𝐻
𝐻(3.2)2 (6.4)
= = 51.47 m3
4
Data from pfd :-
Q = 21516000 W
t1(Fluid in) = 924.1°C
Rule 6 : Neglect due to minimum temperature approach, ∆T = 100°C not equal to 10°C
Rule 7 : Neglect because heater using hps(high pressurized steam)
Rule 8 : U =30 W/m2.°C because gas to gas
Hence, find ∆Tlm
t1(Fluid in) =924.1°C T1(hps in)= 1000°C
t2(Fluid out) = 130°C T2(hps out) = 1100°C
∆Tlm= [(1000-130)-(1100-924.1)]/ln[(1000-130)/(1100-924.1)]
= 434.25°C
A = (21516569.8715 W)/ (30W/m2.°C)(0.9)(434.25°C)
= 1835.14 m2
Thus, Our Area in pfd is1760 m2 and it is almost similar with the heuristic area and use floating
head, stainless steel.
- Based on area, find sizing which is the diameter, length and volume.
𝐻
A = 2𝐻 ( 2 ) (2𝐻)
= 2𝐻𝐻^2
1835.14 m2 = 2𝐻𝐻^2
D = 17.09 m
and, L = 2D
= 2(17.09 m) = 34.18 m
𝐻𝐻²𝐻
𝐻(17.09)2 (34.18)
= 4
= 7840.54 m3
PUMP 601
Pressure: 101 kPa (1.01 bar)

Flowrate: 6608 kg/hr
Component (kmol/hr) :
Benzene: 84 kmol/hr
Density: 876 kg/m3 (density of benzene)
Rule 1: Power (kW)= 1.67[Flow(m3/min)][ ∆P (bar)]/ɛ
𝐻𝐻 1ℎ 𝐻3
Flow= 6608 × 60𝐻𝐻𝐻 × 876𝐻𝐻 = 0.126 m3/min
ℎ
Fluid pumping power = 1.67 x 0.126 x (3-1.01) bar

= 0.4187 kW
0.4187𝐻𝐻
Power Shaft = = 0.64𝐻𝐻
0.65
0.64kW compared to the actual power shaft of 0.6kW from equipment summary.
PUMP 605
Stream 13
Pressure: 80 kPa (0.8 bar)

Flowrate: 5194 kg/hr
Component (kmol/hr) :
Maleic Anhydride ,A : 49.6
Quinone, B: 0.8
Maleic Acid, C: 2.0
Density of mixture:
= 𝐻𝐻𝐻𝐻 + 𝐻𝐻𝐻𝐻 + 𝐻𝐻𝑥𝐻
xA= 49.6/52.4 = 0.9466, 𝐻𝐻 = 1480
xB= 0.8/52.4 = 0.0153, 𝐻𝐻 = 1320
xC= 2.0/52.4 = 0.038, 𝐻𝐻 = 1590
Density of mixture = 1480(0.9466) + 1320(0.0153) + 1590(0.038) = 1481.584Kg/m3
Rule 1: Power (kW)= 1.67[Flow(m3/min)][ ∆P (bar)]/ɛ
𝐻𝐻 1ℎ 𝐻3
Flow= 5194 × 60𝑚𝐻𝐻 × 1481.584 = 0.0584 m3/min
ℎ
Fluid pumping power = 1.67 x 0.0584 x (4-0.8) bar
= 0.312 kW
0.312𝐻𝐻
Power Shaft = = 0.48𝐻𝐻
0.65
0.48kW compared to the actual power shaft of 1.4kW from equipment summary.
V-601
Stream 1 Stream 2
V-601
P= 1.01 bar
Temperature= 30oC
P= 1.01 bar
Mass flowrate: 6608kg/hr
Temperature= 30oC
Mass flowrate: 6608kg/hr Component:
Benzene : 84.6kmol/hr
Component:
Benzene : 84.6kmol/hr
Density: 876kg/m3
(benzene)
Density: 876kg/m3
(benzene)
Rule 2: Liquid drum are usually horizontal
Rule 4; optimum ratio of length to diameter = 3, but the range 2.5 to 5 is common.
Rule 6: In drum feeding a furnace, 30 min for half-full reflux drum allowed.
Rule 8: Liquid-liquid separation are designed for settling velocity of 0.085-0.127 cm/s (2-
3in/min)
ṁ = u𝐻𝐻, u=0.106cm/s (rule 8)
𝐻𝐻2
ṁ = u𝐻 , 𝐻in=𝐻out= 876kg/m3
4
kg
4ṁ 4(6608 )
h
D= √𝐻𝐻inπ = √0.106𝐻𝐻 1m 876kg 3600s = 5.02m
×( )( 3 )×( )π
𝐻 1000cm m 1h
6608𝐻𝐻 1ℎ 1𝐻3
30 min liq flow (Rule 6)= (30min)× ( ) × (60𝐻𝐻𝐻) × (876𝐻𝐻)= 3.77169m3
ℎ
The volume of liquid = 0.5L𝐻D2/4 = 3.77169m3
9.896L = 3.77169m3
L= 0.38m
(5.02)2
Volume= π( )(0.38)= 7.52m3
4
COST CALCULATION
The annual value of Chemical Engineering Plant Cost Index (CEPCI) calculated for 2016 at
556.8 where it is rather smaller than the annual value for 2014 which at 576.1.
THE CBM AND C0BM OF ALL EQUIPMENTS
Bare module cost
Bare module cost is cost calculated totally based on equipment used in this process. Stream
summary and equipment summary are needed to continue this step. From the PFD, there are 13
equipments used consist of pump, heater, compressor, tower, reactor and mixer. Each equipment
cost will be calculated based on 3 factors:
 The specific equipment type

 The specific system pressure
 The specific materials of construction
𝐻𝐻𝐻 = 𝐻𝐻 °[𝐻1 + 𝐻2 𝐻𝐻 𝐻𝐻 ]
*All the formulas and parameters is taking from the reference.1

R-601
R-601
𝐻(𝐻)2 (10𝐻)
40 m3 = , D= 1.7205 m
4
Bare module for reactor (Jacketed nonagitator)
CBM = Cp0FBM
For the purchase cost Cp0,
Log10 Cp0 = K1+K2log10(A)+K3[log10(A)]2 ( Table A.1)
K1 = 3.496
K2 = 0.7235
K3 = 0.0025
Log10 Cp0 = 3.3496 +0.7235log10 (40) + 0.0025 [log10 (40)] 2
Cp0 = $ 32742.12742
CBM = Cp0FBM= Cp0(B1+B2FpFm)

(3.14)1.7205
Fp=( 2(850−0.6(3.14)) + 0.00315)/0.0063
Fp= 1.057
Fm= 3.1 (use process vessel)
CBM = Cp0FBM= Cp0(B1+B2FpFm), B1=2.25 , B2= 1.82
= $ 32742.127(2.25+1.82(1.057)(3.1))
=$ 268930.54
CoBM = Cp0FBM= Cp0(B1+B2FpFm), B1=2.25 , B2= 1.82,
Fp@ p is 1.5barg = 0.954, Fm= 1
= $ 32742.127(2.25+1.82(0.954)(1))
=$ 130519.286
Therefore,
Recent CEPCI on early March 2016 = 556.8
𝑪𝑪𝑪(𝑪𝑪𝑪𝑪) = $ 268930.54 (556.8/394)
= $ 380052.09
CoBM (2016) = $ 130519.286 (556.8/394)
= $ 184449.59
Tower, T-601
 Stainless steel
 14 sieve trays
 Length = 10m
 Diameter = 5.2m
 Pgauge = Pabs - Patm
= 110kpa - 101.3kpa
= 8.7 kpa
 Pbargauge = 0.087 bar
FOR THE TOWER:
A = Volume = πD2L/4
=[π(5.2)2(10)]/4
= 212.37m3
Based on Table A.1,
K1 = 3.4974
K2 = 0.4485
K3 = 0.1074
Thus,
log10C0P = K1+K2log10(A)+K3[log10(A)]2
log10C0p (2001)= 3.4974+(0.4485)log(212.37)+(0.1074)[log(212.37)]2
C0p (2001) = 161,305.85
C0p (2016) = 161,305.85 x (556.8/394)
= 227,957.02
From table A.4,
B1= 2.25
B2= 1.82
To find Fp :
( P  1) D
 0.00315
2(850  0.6( P  1))
0.0063
(0.087  1)( 5.2)

 0.00315
= 2 (850  0 .6( 0. 087  1))
0.0063
= 1.028
To find FM :
From Table A.3 , identification number for stainless steel vertical vessel = 20 ; from Figure A.8,
FM = 3.11
Thus,
CBM (2016) = C0p (B1 + B2FmFp)
CBM = 227,957.02( 2.25 + (1.82 x 3.11 x 1.028))
CBM =＄ 1,839,537.65
FOR THE TRAYS:
Tray area =πD2/4
= π(5.22)/4
=21.23m2
Based on Table A.1,
K1 = 2.9949
K2 = 0.4465
K3 = 0.3961
Thus,
log10C0p (2001)=2.9949+(0.4465)log(21.23)+(0.3961)[log(21.23)]2
C0p (2001)= 19, 267.908
C0p (2016) =19, 267.908x (556.8/394)
=27,229.37
N = 31 thus
fq = 1
To find FM :
From Table A.6 , identification number for stainless steel = 61 ; from Figure A.19, FBM = 1.83
CBM = CpNFBMfq
=＄1544722.136
Thus,
CBMtrays+tower = ＄1544722.136 + ＄ 1,839,537.65
= ＄ 3384259.79
TO FIND Cbm0
FOR THE TOWER:
Pressure : 1.5 barg
MOC : Carbon Steel
C0p (2016) = 126,091.23
From table A.4,
B1= 2.25
B2= 1.82
To find Fp :
( P  1) D
 0.00315
2(850  0.6( P  1))
0.0063
(1.5  1)( 5.2)

 0.00315
= 2 (850  0 . 6(1.5  1))
0.0063
Fp = 1.72
To find FM :
From Table A.3 , identification number for stainless steel vertical vessel = 18 ; from Figure A.8,
FM = 1
Thus,
CBM (2016) = C0p (B1 + B2FmFp)

CBM0 =227,957.02 ( 2.25 +(1.82x1x1.72))
CBM0 = ＄ 1226499.95
FOR THE TRAYS:
Tray area =πD2/4
= π(5.22)/4
=21.23m2
Based on Table A.1,
K1 = 2.9949
K2 = 0.4465
K3 = 0.3961
Thus,
log10C0p (2001)=2.9949+(0.4465)log(21.23)+(0.3961)[log(21.23)]2
C0p (2001)= 19 267.91
C0p (2016) = 19 267.91 x (556.8/394)
= 27229.36
N = 31 , fq = 1
To find FM :
From Table A.6 , identification number for carbon steel = 60 ; from Figure A.19, FBM = 1
CBM0 = CpNFBMfq
=＄ 844110.456
CBM0trays+tower = ＄844110.456 +＄ 1226499.95
=＄ 2070610.41
TOWER T-602
D = 0.749m Material = Stainless Steel
H = 26.056 m Pressure Column = 110 kPa
Pgage = Pabsolute – Patmosphere = ( 110 kPa – 101.3 kPa )/100 = 0.087 barg
𝐻𝐻2 𝐻 𝐻(0.749 𝐻)2 (26.056 𝐻)

𝐻𝐻𝐻𝐻𝐻𝐻, 𝐻= = = 15.328 𝐻3
4 4
(2001)
log10 𝐻0𝐻 = 𝐻1 + 𝐻2 log10 𝐻 + 𝐻3 (log10 𝐻)2 ; A = volume of the tower
K1 = 3.4979
K2 = 0.4485
K3 = 0.1074
log10 𝐻0𝐻 = 3.4979 + 0.4485(log10 15.328) + 0.1074(log10 15.328)2
log10 𝐻0𝐻 = 4.181
∴ 𝐻0𝐻 = 15 170.504
𝐻𝐻𝐻 = 𝐻0𝐻 𝐻𝐻𝐻 = 𝐻0𝐻 (𝐻1 + 𝐻2 𝐻𝐻 𝐻𝐻 ) ; B1 = 2.25
B2 = 1.82
FM = 3.1
(𝐻+1)𝐻
+0.00315
2[850−0.6(𝐻+1)]
𝐻𝐻 =
0.0063
(0.087+1)(0.749)
+0.00315
2[850−0.6(0.087+1)]
𝐻𝐻 = = 0.5706
0.0063
𝐻𝐻𝐻 = 15 170.504[2.25 + (1.82)(3.1)(0.5706)] = $82 972.42
𝐻0𝐻𝐻 → 𝐻𝐻𝐻𝐻 𝐻𝐻 𝐻𝐻𝐻𝐻 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻; 𝐻 = 1.5 𝐻𝐻𝐻𝐻 & 𝐻𝐻𝐻𝐻𝐻𝐻 𝐻𝐻𝐻𝐻𝐻.
(1.5 + 1)(0.749)
+ 0.00315
2[850 − 0.6(1.5 + 1)]
𝐻𝐻 = = 0.640
0.0063
𝐻0𝐻𝐻 = 15 170.504 [2.25 + (1.82)(1.00)(0.640)] = $51 804.24
(2016)
556.8
𝐻𝐻𝐻 ′11 = 𝐻𝐻𝐻 ′01 ( )
394
556.8
𝐻𝐻𝐻 ′11 = $82 972.42 ( ) = $117 256.46
394
556.8
𝐻0𝐻𝐻 ′11 = 𝐻0𝐻𝐻 ′01 ( )
394
556.8
𝐻0𝐻𝐻 ′11 = $51 804.24 ( ) = $73 209.65
394
CBM & CBM0 OF SIEVE TRAYS
D = 0.749m Material = Stainless Steel
Number of tray = 39 sieve trays
𝐻𝐻2 𝐻(0.749)2
𝐻𝐻𝐻𝐻, 𝐻= = = 0.441 𝐻2
4 4
(2001)
log10 𝐻0𝐻 = 𝐻1 + 𝐻2 log10 𝐻 + 𝐻3 (log10 𝐻)2 ; A = area of the sieve tray
K1 = 2.9949
K2 = 0.4465
K3 = 0.3961
log10 𝐻0𝐻 = 2.9949 + 0.4465 (log10 0.441) + 0.3961(log10 0.441)2
log10 𝐻0𝐻 = 2.886
𝐻0𝐻 = 769.130
𝐻𝐻𝐻 = 𝐻0𝐻 𝐻𝐻𝐻𝐻 𝐻𝐻 ; N = 39
FBM = 1.8
Fq = 1.0 , for N≥20
∴ 𝐻𝐻𝐻 = (769.130)(39)(1.8)(1.0) = $53 992.93
𝐻0𝐻𝐻 → 𝐻𝐻𝐻𝐻 𝐻𝐻 𝐻𝐻𝐻𝐻 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻; 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 = 𝐻𝐻𝐻𝐻𝐻𝐻 𝐻𝐻𝐻𝐻𝑙
𝐻0𝐻𝐻 = 𝐻0𝐻 𝐻𝐻𝐻𝐻 𝐻𝐻 ; N = 39
FBM = 1.0
Fq = 1.0 , for N≥20
𝐻0𝐻𝐻 = (769.130)(39)(1.0)(1.0) = $29 996.07
(2016)
556.8
𝐻𝐻𝐻 ′11 = 𝐻𝐻𝐻 ′01 ( )
394
556.8
𝐻𝐻𝐻 ′11 = $53 992.93 ( ) = $76 302.70
394
556.8
𝐻0𝐻𝐻 ′11 = 𝐻0𝐻𝐻 ′01 ( )
394
556.8
𝐻0𝐻𝐻 ′11 = $29 996.07 ( ) = $42 390.38
394
V-601
Volume= 7.52m3 P= 1.01 bar

Temperature= 30oC Mass flowrate: 6608kg/hr
Component:
Benzene : 84.6kmol/hr Density: 876kg/m3 (benzene)
Horizontal Carbon steel
K1 = 3.5565
K2 = 0.3776
K3 = 0.0905
Log10 Cp0 = 3.5565+0.3776log10 (7.52) + 0.0905 [log10 (7.52)] 2
Cp0 = $ 9054.03

(2.01)5.02
Fpvessel=( 2(850−0.6(2.01)) + 0.00315)/0.0063
= 1.443
Fm= 1 (Table A.3 + Figure A.18)
B1=1.49 , B2= 1.52
CBM (2001) = Cp0FBM= Cp0(B1+B2FpFm)
= $ 9045.03(1.49+1.52(1.443)(1))
=$ 33349.252
Therefore,
𝑪𝑪𝑪(𝑪𝑪𝑪𝑪) =$ 33349.252 (556.8/394)
= $ 47129.09521
MOC: carbon steel, P< 5 barg
Thus, CBM(2016) = CoBM (2016)=$ 47129.09521
V-602
Volume= 200m3 P= 1.01 bar

D= 4.4m, L= 13.2 m
Component:
Volume (new) = 200m3×2= 400m3
400(4)
D= √𝐻×(13.2) , fixed the value of Length.
D= 6.212 m
K1 = 3.5565
K2 = 0.3776
K3 = 0.0905
Log10 Cp0 = 3.5565+0.3776log10 (400) + 0.0905 [log10 (400)] 2
Cp0 = $ 141836.3899
B1=1.49 , B2= 1.52

(2.01)6.212
Fpvessel=( 2(850−0.6(2.01)) + 0.00315)/0.0063
= 1.72
Fm=3.1(Table A.3 + Figure A.18)
= $ 141836.3899(1.49+1.52(1.72)(3.1))
=$ 1360869.1
Therefore,
𝑪𝑪𝑪(𝑪𝑪𝑪𝑪) =$ 1360869.1(556.8/394)
= $ 1923177.449
MOC: carbon steel, Fp=1.5
Fpvessel=1.53
CoBM(2001) = Cp0FBM= Cp0(B1+B2FpFm), B1=1.49 , B2= 1.52
= $ 141836.3899(1.49+1.52(1.53)(1))
=$ 541190.9293
CoBM(2016) =$ 541190.9293 (556.8/394)
=$ 764809.9224
V-603
Volume= 5.76m3 P= 1.01 bar

D= 1.3m, L= 3.9 m
Component:
Volume (new) = 5.76m3×2= 10.352m3
10.352(4)
D= √ 𝐻×(3.9) , fixed the value of Length.
D= 1.84 m
K1 = 3.5565
K2 = 0.3776
K3 = 0.0905
Log10 Cp0 = 3.5565+0.3776log10 (10.352) + 0.0905 [log10 (10.352)] 2
Cp0 = $ 10789.79

(2.1)1.84
Fpvessel=( 2(850−0.6(2.1)) + 0.00315)/0.0063
= 0.86
B1=1.49 , B2= 1.52
= $ 10789.79 (1.49+1.52(0.86)(3.1))
=$ 59800.47
Therefore,
𝑪𝑪𝑪(𝑪𝑪𝑪𝑪) =$ 59800.47(556.8/394)
= $ 84509.90
MOC: carbon steel, Fp=1.5
Fpvessel=1.53
CoBM(2001) = Cp0FBM= Cp0(B1+B2FpFm
= $ 10789.79 (1.49+1.52(0.804)(1))
=$ 29262.77366
CoBM(2016) =$ 29262.77366 (556.8/394)
=$ 41354.092
Bare module cost (E-601)
1. Find Cp°/A by using Figure A.5

Cp°/A = 3000
Cp° = 3000A
Cp° = 3000(14.88)
Cp° = 44640
2. Find B1 and B2 at table A.4
𝐻1 = 1.63 𝐻2 = 1.66
3. Find FP using equation A.3 and table A.2
log 𝐻𝐻 = 𝐻1 + 𝐻2 log(𝐻) + 𝐻3 [log 𝐻]2

Pressure, P = 4.98 barg
log 𝐻𝐻 = 0 + 0 log(4.98) + 0[log 4.98]2
𝐻𝐻 = 1
4. Find FM using figure A.18and table A.3
Based on table FM= 2.7

5. Find CBM
𝐻𝐻𝐻 = $44640[1.63 + (1.66)(1)(2.7)]
𝐻𝐻𝐻(2001) = $272839.68
556.8
𝐻𝐻𝐻(2016) = $272839.68 ×
394
𝐻𝐻𝐻(2016) = $385576.48

Cp°/A = 350
Cp° = 350A
Cp° = 350(64.35)
Cp° = 22522.5
𝐻1 = 1.63 𝐻2 = 1.66

log 𝐻𝐻 = 0.03881 − 0.11272 log(39.98) + 0.08183[log 39.98]2
𝐻𝐻 = 1.17

5. Find CBM
𝐻𝐻𝐻 = $22522.5[1.63 + (1.66)(1.17)(2.7)]
𝐻𝐻𝐻(2001) = $154818.31
556.8
𝐻𝐻𝐻(2016) = $154818.31 ×
394
𝐻𝐻𝐻(2016) = $218788.93

Cp°/A = 125
Cp° = 125A
Cp° = 125(1835.14)
Cp° = 229392.5
𝐻1 = 1.63 𝐻2 = 1.66

log 𝐻𝐻 = 0.03881 − 0.11272 log(39.98) + 0.08183[log 39.98]2
𝐻𝐻 = 1.17
5. Find CBM
𝐻𝐻𝐻 = $229392.5[1.63 + (1.66)(1.17)(2.7)]
𝐻𝐻𝐻(2001) = $1574536.36
556.8
𝐻𝐻𝐻(2016) = 1574536.36 ×
394
𝐻𝐻𝐻(2016) = $2225131.58

Cp°/A = 63
Cp° = 63A
Cp° = 63(1100)
Cp° = 69300
𝐻1 = 1.63 𝐻2 = 1.66

log 𝐻𝐻 = 0 + 0 log(0.98) + 0[log 0.98]2
𝐻𝐻 = 1

5. Find CBM
𝐻𝐻𝐻 = $69300[1.63 + (1.66)(1)(2.7)]
𝐻𝐻𝐻(2001) = $422868.60
556.8
𝐻𝐻𝐻(2016) = $422868.60 ×
394
𝐻𝐻𝐻(2016) = $597597.05

Cp°/A = 210
Cp° = 210A
Cp° = 210(135)
Cp° = 28350
𝐻1 = 1.63 𝐻2 = 1.66

log 𝐻𝐻 = 0.03881 − 0.11272 log(39.98) + 0.08183[log 39.98]2
𝐻𝐻 = 1.17

5. Find CBM
𝐻𝐻𝐻 = $28350[1.63 + (1.66)(1.17)(2.7)]
𝐻𝐻𝐻(2001) = $187221.70
556.8
𝐻𝐻𝐻(2016) = 187221.70 ×
394
𝐻𝐻𝐻(2016) = $264581.32

Cp°/A = 1800
Cp° = 1800A
Cp° = 1800(12)
Cp° = 21600
𝐻1 = 1.63 𝐻2 = 1.66

log 𝐻𝐻 = 0 + 0 log(0.98) + 0[log 0.98]2
𝐻𝐻 = 1

5. Find CBM
𝐻𝐻𝐻 = $21600[1.63 + (1.66)(1)(2.7)]

𝐻𝐻𝐻(2001) = $132019.20
556.8
𝐻𝐻𝐻(2016) = $132019.20 ×
394
𝐻𝐻𝐻(2016) = $186569.27

Cp°/A = 197
Cp° = 197A
Cp° = 197(195)
Cp° = 38415
𝐻1 = 1.63 𝐻2 = 1.66

log 𝐻𝐻 = 0.03881 − 0.11272 log(39.98) + 0.08183[log 39.98]2
𝐻𝐻 = 1.17

5. Find CBM
𝐻𝐻𝐻 = $38415[1.63 + (1.66)(1.17)(2.7)]
𝐻𝐻𝐻(2001) = $264062.41
556.8
𝐻𝐻𝐻(2016) = 264062.41 ×
394
𝐻𝐻𝐻(2016) = $373172.45
Bare module cost at base condition (E-601)

Cp°/A = 3000
Cp° = 3000A
Cp° = 3000(14.88)
Cp° = 44640
𝐻1 = 1.63 𝐻2 = 1.66

Pressure, P = 1 barg
log 𝐻𝐻 = 0 + 0 log(1) + 0[log 1]2
𝐻𝐻 = 1
Based on table FM= 1

5. Find CBM
𝐻°𝐻𝐻 = 𝐻𝐻 °[𝐻1 + 𝐻2 𝐻𝐻 𝐻𝐻 ]
𝐻°𝐻𝐻 = $44640[1.63 + (1.66)(1)(1)]
𝐻°𝐻𝐻(2001) = $146865.6
556.8
𝐻°𝐻𝐻(2016) = $146865.6 ×
394
𝐻°𝐻𝐻(2016) = $207550.17

Cp°/A = 350
Cp° = 350A
Cp° = 350(64.35)
Cp° = 22522.5
𝐻1 = 1.63 𝐻2 = 1.66

log 𝐻𝐻 = 0 + 0 log(1) + 0[log 1]2
𝐻𝐻 = 1

5. Find CBM
𝐻°𝐻𝐻 = $22522.5[1.63 + (1.66)(1)(1)]
𝐻°𝐻𝐻(2001) = $74099.03
556.8
𝐻°𝐻𝐻(2016) = $74099.003 ×
394
𝐻°𝐻𝐻(2016) = $104716.60

Cp°/A = 125
Cp° = 125A
Cp° = 125(1835.14)
Cp° = 229392.5
𝐻1 = 1.63 𝐻2 = 1.66

log 𝐻𝐻 = 0 + 0 log(1) + 0[log 1]2
𝐻𝐻 = 1

5. Find CBM
𝐻°𝐻𝐻 = $229392.5[1.63 + (1.66)(1)(1)]
𝐻°𝐻𝐻(2001) = $754701.33
556.8
𝐻°𝐻𝐻(2016) = $754701.33 ×
394
𝐻°𝐻𝐻(2016) = $1066542.38

Cp°/A = 63
Cp° = 63A
Cp° = 63(1100)
Cp° = 69300
𝐻1 = 1.63 𝐻2 = 1.66

log 𝐻𝐻 = 0 + 0 log(1) + 0[log 1]2
𝐻𝐻 = 1

5. Find CBM
𝐻°𝐻𝐻 = $69300[1.63 + (1.66)(1)(1)]
𝐻°𝐻𝐻(2001) = $221997
556.8
𝐻°𝐻𝐻(2016) = $221997 ×
394
𝐻°𝐻𝐻(2016) = $322204.90

Cp°/A = 210
Cp° = 210A
Cp° = 210(135)
Cp° = 28350
𝐻1 = 1.63 𝐻2 = 1.66

log 𝐻𝐻 = 0 + 0 log(1) + 0[log 1]2
𝐻𝐻 = 1

5. Find CBM
𝐻°𝐻𝐻 = $28350[1.63 + (1.66)(1)(1)]
𝐻°𝐻𝐻(2001) = $93271.50
556.8
𝐻°𝐻𝐻(2016) = $93271.50 ×
394
𝐻°𝐻𝐻(2016) = $131811.10

Cp°/A = 1800
Cp° = 1800A
Cp° = 1800(12)
Cp° = 21600
𝐻1 = 1.63 𝐻2 = 1.66

log 𝐻𝐻 = 0 + 0 log(1) + 0[log 1]2
𝐻𝐻 = 1

5. Find CBM
𝐻°𝐻𝐻 = $21600[1.63 + (1.66)(1)(1)]
𝐻°𝐻𝐻(2001) = $71064
556.8
𝐻°𝐻𝐻(2016) = $71064 ×
394
𝐻°𝐻𝐻(2016) = $100427.50

Cp°/A = 197
Cp° = 197A
Cp° = 197(195)
Cp° = 38415
𝐻1 = 1.63 𝐻2 = 1.66

log 𝐻𝐻 = 0 + 0 log(1) + 0[log 1]2
𝐻𝐻 = 1

5. Find CBM
𝐻°𝐻𝐻 = $38415[1.63 + (1.66)(1)(1)]
𝐻°𝐻𝐻(2001) = $126385.35
556.8
𝐻°𝐻𝐻(2016) = $126385.35 ×
394
𝐻°𝐻𝐻(2016) = $178607.52
P-601
Power Shaft =0.64kW P= 1.01

Carbon steel Centrifugal
K1 = 3.3892
K2 = 0.0536
K3 = 0.1538
Log10 Cp0 = 3.3892+0.0536log10 (0.64) + 0.1538 [log10 (0.64)] 2
Cp0 = $ 2424.314
Fp=1
CBM = Cp0FBM= Cp0(B1+B2FpFm), B1=1.89 , B2= 1.35
= $ 2424.314 (1.89+1.35(1)(1.6))
=$ 9818.472
Therefore,

𝑪𝑪𝑪(𝑪𝑪𝑪𝑪) =$ 9818.472 (556.8/394)
= $ 13875.445
MOC: carbon steel, P< 5 barg
Thus, CBM(2016) = CoBM(2016) = $ 13875.445
P-602
Power Shaft =7.6kW P= 3 bar

stainless steel Centrifugal
B1=1.89 , B2=1.35
K1 = 3.3892
K2 = 0.0536
K3 = 0.1538
Log10 Cp0 = 3.3892+0.0536log10 (7.6) + 0.1538 [log10 (7.6)]2
Cp0 = $ 3595.2961
For Calculating the CBM For Calculating the CoBM
FM= 2.3 FM= 1.6
Fp= 1 Fp= 1

CoBM(2016)= Cp0FBM= Cp0(B1+B2FpFm)
= $ 3595.2961(1.89+1.35(1)(2.3))
= $ 3595.2961(1.89+1.35(1)(1.6))
=$ 17958.50402 =$ 14560.94921
Therefore, Therefore,
CoBM(2016) =$ 14560.94921 (556.8/394)
= $ 20577.504
𝑪𝑪𝑪(𝑪𝑪𝑪𝑪) =$ 17958.50402 (556.8/394)
= $ 25378.92142
P-603

stainless steel Reciprocating
B1=1.89 , B2=1.35
K1 = 3.8696
K2 = 0.3161
K3 = 0.1220
Log10 Cp0 = 3.8696+0.3161log10 (0.2) + 0.1220 [log10 (0.2)]2
Cp0 = $ 5108.105
FM= 2.35 FM= 1.45
Fp= 1 Fp= 1

= $ 5108.105 (1.89+1.35(1)(2.35))
= $ 5108.105 (1.89+1.35(1)(1.45))
=$ 25859.78156 =$ 19653.43399
Recent CEPCI on early March 2016 = 556.8 Recent CEPCI on early March 2016 = 556.8
CoBM(2016) =$ 19653.43399 (556.8/394)
= $ 27774.193
𝑪𝑪𝑪(𝑪𝑪𝑪𝑪) =$ 25859.78156 (556.8/394)
= $ 36544.99
P-604

B1=1.89 , B2=1.35
K1 = 3.3892
K2 = 0.0536
K3 = 0.1538
Log10 Cp0 = 3.3892+0.0536log10 (13.5kW) + 0.1538 [log10 (13.5kW)]2
Cp0 = 4428.83
FM= 2.25 FM= 1.6
Fp= 1 Fp= 1

= $ 4428.83 (1.89+1.35(1)(2.25))
= $ 4428.83 (1.89+1.35(1)(1.6))
=$ 21823.05983 =$ 17936.7615
CoBM(2016) =$ 17936.7615 (556.8/394)

𝑪𝑪𝑪(𝑪𝑪𝑪𝑪) =$ 21823.05983(556.8/394)
= $ 25348.194
= $ 30840.30383
P-605
Power Shaft =0.48kW P= 0.8 bar

B1=1.89 , B2=1.35
K1 = 3.3892
K2 = 0.0536
K3 = 0.1538
Cp0 = $2441.97791
FM= 2.3 FM= 1.6
Fp= 1 Fp= 1

= $ 2441.97791(1.89+1.35(1)(2.3))
= $ 2441.97(1.89+1.35(1)(1.6))
=$ 12197.64 =$ 9889.9785
CoBM(2016) =$ 9889.9785 (556.8/394)

𝑪𝑪𝑪(𝑪𝑪𝑪𝑪) =$ 12197.64 (556.8/394)
= $ 13976.498
= $ 17237.68
P-606
Power Shaft =4.8kW P= 1.5bar

B1=1.89 , B2=1.35
K1 = 3.3892
K2 = 0.0536
K3 = 0.1538
Cp0 = $3141.17
For Calculating the CoBM
For Calculating the CBM FM= 1.6
FM= 2.25 Fp= 1
Fp= 1
= $3141.17(1.89+1.35(1)(1.6))
= $ 3141.17(1.89+1.35(1)(2.25))
=$ 12721.7385
=$ 15478.11518
Therefore,
Therefore, Recent CEPCI on early March 2016 = 556.8
Recent CEPCI on early March 2016 = 556.8 CoBM(2016) =$ 12721.7385 (556.8/394)
= $ 17978.335
𝑪𝑪𝑪(𝑪𝑪𝑪𝑪) =$ 15478.11518 (556.8/394)
= $ 21873.64094
FIXED CAPITAL INVESTMENT
An investment is an agreement between two parties, whereby one party, the investor, provide
money to second party, the producer, with the expectation that the producer will return money to
the investor at some future specified date.
Terms used in describing investment are:
P: Principal or Present Value
F: Future Value
n: Years between F and P
Total Capital Investment is referred to funds invested in a firm or enterprise for the purpose of
furthering its business objectives usually made up of two components:
Total Capital Investment = Fixed Capital + Working Capital
Fixed capital is all cost associated with building the plant and working capital is the amount of
capital required to start up the plant and finance the first few month of operation before revenues
from the process start.
All the cost for equipment are as follow.
Equipment CBM(2016) COBM(2016)
C-601 3692844.52 3692844.52
H-601 7000770.58 7000770.58
E-601 385576.48 2057550.1677

E-602 218788.93 104716.60
E-603 225131.582 1066542.38
E-604 672217.3507 322204.8975
E-605 264581.32 131811.0944
E-606 181905.03 97916.81
E-607 373172.45 178607.52
P-601 13875.445 13875.445
P-602 25378.92142 20577.504
P-603 36544.99 27774.193
P-604 30840.30383 25384.195
P-605 17237.68 13976.498
P-606 21873.64094 17978.335
r-601 380052.09 184449.59
T-601 3384259.09 2070610.41
T-602 193559.16 115600.03
V-601 47129.09521 $ 47129.09521
V-602 1923177.449 764809.9224
V-603 84509.90 41354.092

Total : 21103126.80321 17998994.67321
Total module cost:

CTM = 1.18 ∑ni=1 𝐻𝐻𝐻 (2016)=
= 1.18 (21103126.80321) =24901689.628
Grass root cost:
CGR = CTM (2016)+ 0.5∑ni=1 𝐻𝐻𝐻 𝐻 (2016)
=$24901689.628+ $17998994.67321
=$42900684.30
DIRECT COST
COMPONENT RANGE (%) COST

Purchased equipment 25.7 27.5
( 100 ) ×42900684.30 = $11797688.1825
Purchased equipment 10 10
(100) × 42900684.30 = $4290068.43
installation
Instrumentation and controls 5 5

(100) × 42900684.30 = $2031056.38055
(installed)
Piping (installed) 11 11
(100) × 42900684.30 = $4719075.273
Electrical (installed) 6 6
(100) × 42900684.30 = $2574041.058
Buildings (including services) 11 11

(100) × 42900684.30 = $4719075.273
Yard improvements 3.5

3.5
(100) × 42900684.30 = $1501523.9505
Land 14 14
(100)42900684.30 = $6006095.802
Total direct costs $37638624.34955@ $37.64 ×106
INDIRECT COST
COMPONENT RANGE (%) COST

Engineering and supervision 13 13
(100)42900684.30 = $ 5577088.959
Construction expense 9 9
(100)42900684.30 =$ 3861061.587
Contractor’s fee 4 4
(100)42900684.30 = $1716027.372
Contingency 10 10
(100)42900684.30 = $4290068.43
Total Indirect Cost $15444246.348 @ $15.44×106
Total indirect cost + Total direct Cost =53082870.69755
Total Feed Capital Investment, FCIL = 53082870.69755+42900684.30
= $ 95983554.99755@ $ 95.98×106
COST OF MANUFACTURING
Factors affecting the cost of manufacturing (COM), for a chemical Product.
Factor Description of Factor

1.Direct cost Factors that vary with the rate of production
a. Raw materials Costs of chemical feed stocks required by the process.
Flow rates obtained from the PFD.
b. Waste treatment Cost of waste treatment to protect environment.
c. Utilities Costs of utility streams required by process. Includes but not

limited to
a. Fuel gas
b. Electric power
c. Steam(all pressures)
d. Cooling water
e. Process water
f. Boiler feed water
g. Instrument air
h. Inert gas (nitrogen) etc.
i. Refrigeration
Costs of personnel required for plant operations.
Cost of administrative/ engineering and support personnel.
d. Operating labor
e. Direct supervisor and Costs of labor and materials associated with the maintenance.
clerical labor
f. Maintenance and
Costs of miscellaneous supplies that support daily operation
repairs
not considered to be raw materials. Examples include chart
paper, lubricants, miscellaneous chemicals, filters, respirators
and protective clothing for operators, etc.
g. Operating supplies
Costs of routine and special laboratory tests required for

product quality control and troubleshooting.
Costs of using patented or licensed technology.

h. Laboratory charges
i. Patents and royalties
2. Fixed costs Factors not affected by the level of production
a. Depreciation Costs associated with the physical plant (buildings, equipment,

etc.). Legal operating expense for tax purposes.
b. Local taxes and Costs associated with property taxes and liability insurance.
Based on plant location and severity of the process.
Insurance
Catch-all costs associated with operations of auxiliary facilities

c. Plant overhead costs
supporting the manufacturing process. Costs involve payroll
(sometimes referred to and accounting services, fire protection and safety services,
as factory expenses) medical services, cafeteria and any recreation facilities, payroll
overhead and employee benefits, general engineering, etc.
3. General expenses Costs associated with management level and administrative

activities not directly related to the manufacturing process
a. Administration
Costs for administration. Includes salaries, other
costs
administration, buildings, and other related activities.
Costs of sales and marketing required to sell chemical

b. Distribution and
products. Includes salaries and other miscellaneous costs.
selling costs
c. Research and Costs of research activities related to the process and product.
development Includes salaries and funds for research related equipment and
supplies, etc.
1. Utilities costs.
Utilities cost stream required by process. They exchange heat energy (fuel gas, electric power,
steam, cooling water, boiler feed water) in equipment such as heat exchanger and process heater,
or supply work(electric power or steam) to pumps, compressor and other rotating equipment. In
this case, the duty value (GJ/h)can be found by doing heuristic around the equipment. Heater are
the equipment that consumed utilities in our new chemical plant. The equipment and their
utilities cost are provided in Table 4.5.
𝐻𝐻.𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 353
Stream factor, 𝐻𝐻 = 0.967 = = 365
365
A. E-601 Duty is 1.75 GJ/h and cost $13.28 per GJ

𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 = (𝐻)(𝐻𝐻𝐻𝐻𝐻𝐻 )(𝐻) × 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻
𝐻𝐻 $ ℎ 𝐻𝐻𝐻
= 1.75 × 13.28 × 24 × 365 × 0.967
ℎ 𝐻𝐻 𝐻𝐻𝐻 𝐻𝐻𝐻𝐻
= $196,864 × 2
= $393728 𝐻𝐻𝐻 𝐻𝐻𝐻𝐻
B. E-602 Duty is 16.7 GJ/h and cost $13.28 per GJ
= 16.7 × 13.28 × 24 × 365 × 0.967
= $1,878,646.75 × 2
= $3,357,293.5 𝐻𝐻𝐻 𝐻𝐻𝐻𝐻
C. E-602 Duty is 16.7 GJ/h and cost $13.28 per GJ
= 16.7 × 13.28 × 24 × 365 × 0.967
= $1,878,646.75 × 2
= $3,757,293.5 𝐻𝐻𝐻 𝐻𝐻𝐻𝐻
D. E-603 Duty is 31.4 GJ/h and cost $13.28 per GJ
= 31.4 × 13.28 × 24 × 365 × 0.967
= $3,532,305.87× 2
= $ 7,034,611.74 per year
E. E-604 Duty is 86.9 GJ/h and cost $13.28 per GJ
= 86.9 × 13.28 × 24 × 365 × 0.967
= $ 9,775,712.75 × 2
= $ 19,551,425.5 per year
F. E-605 Duty is 19.15 GJ/h and cost $13.28 per GJ
= 19.15 × 13.28 × 24 × 365 × 0.967
= $2,154,256.61× 2
= $ 4,308,513.22
G. E-606 Duty is 3.05 GJ/h and cost $13.28 per GJ
= 3.05 × 13.28 × 24 × 365 × 0.967
= $343106.14 × 2
= $ 686,212.28
Table 4.5: Total Cost of Utilities, CUT.

Equipment Utility Cost Yearly Cost ($)
Heater (E-601) Steam from boiler (LPS) 13.28($/GJ) 393728
Heater (E-602) Steam from boiler (LPS) 13.28 ($/GJ) 3,357,293.5
Heater (E-605) Steam from boiler (LPS) 13.28($/GJ) 4,308,513.22
Heater (E-606) Steam from boiler (LPS) 13.28($/GJ) 686,212.28
Total cost of utilities, CUT = 35,331784.24
= 𝟑𝟑. 𝟑𝟑 ×
𝑪𝑪𝑪
The utility requirements for a process are obtained from material and energy balances then
translated into expected demands natural gas or heating oil for fired heat, steam, electricity,
cooling water, and refrigeration. In addition to the utilities required for heating and cooling, the
process may also need process water and air for applications such as washing, stripping, and
instrument air supply. The cost of utilities can vary widely with the location, with the size of the
service required, with the national and local economy, and even with the season. Generally
utility pricing is regulated and the approved tariffs are readily available from the utility company
or the cognizant regulatory agency
2. Labor cost.
The technique used to estimate operating labor requirements is based on the data obtained using
Alkahayat and Gerrard Method. According to this method, the operating labor requirements for
chemical processing plant is given by equation below2:
Cost of operating labor, COL

NOL = ( 6.29 + 31.7 P2+ 0.23Nnp ) 0.5
NOL : Number of operator shifts

P : Number of processing steps involving particulate solids
Nnp : Number of non-particulate processing steps and includes compression, heating and cooling,
mixing and reaction.
In general, for the processes considered in this text, the value of P is zero, and the value of Nnp is
given by
Nnp = ∑ 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻
Compressors
Towers
Reactors
Heaters
Exchangers
EQUIPMENT THAT NEEDS AN OPERATOR TO OPERATE
Table 1: Equipment that needs an operator to operate
Equipment Type Number of Equipment Nnp
Towers 2 2
2
Richard Turton, R. C. (2013). Analysis, Synthesis, and Design of Chemical Processes. New
Jersey: Pearson Education. (page 202)
Pumps* 6 -
Reactors 1 1
Heaters 1 1
Vessels* 3 -
Exchangers 7 7
Compressor 1 1
Total 12
*Pumps and vessels are not counted in evaluating Nnp in equation above.
NOL = (6.29 + 3.17P2 + 0.23Nnp)0.5
= (6.29 + 3.17(0)2 + 0.23(12))0.5
= 3.00
The value of NOL is the number of operators required to run the process unit per shift. A single
operator works on the average 49 weeks (3weeks time off for vacation and sick leave) a year,
five 8-hour shift a week.
= 49 week/year × 5 shift/week
= 245 shifts per operator/year
Assumption:
A chemical plant operates 24 hours per day. This requires (335 days/year × 3 shift/day) 1005
operating shifts per year. The number of operators needed to provide this number of shifts is
= 1005 shift/year ÷ 245 shifts per operator/year
= 4.1 operators
The operating labor = NOL × 4.1 operators
= 3.00 × 4.1
= 12.3 ≈ 12 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻
To estimate the cost of operating labor, the average hourly wage of an operator is required.
Based on the Chemical Plant Operator Salary in United States3, the hourly rate about $21.12
which is equivalent to RM 94.41.
Labor costs = 12 operator × RM 94.41 × 8 hour per day/operator
= RM 9063.36 per day
The cost of operating labor, COL is equal to the salary given to each of operator yearly which in
this case the yearly salary given is
In one year, COL = RM 9063.36 per day × 335 days/year
= RM 3036225.6 / year (two million ,

eight hundred eighty nine thousand ,
five hundred seventy six)
http://www.investinpahang.gov.my/index.php?rp=comptetitive_wages.pdf
3. Raw material costs.
Raw Material:
 Benzene : stream 1
3
https://www.sokanu.com/careers/power-plant-operator/salary/
o Mass flowrate: 6608kg/h
 Dibutyl phthalate : stream 10

o Mass flowrate: 61.2 kg/h
Price of benzene, according to the ICIS,
Benzene= US$3.45/gal.
The information is retrieved from http://www.icis.com/chemicals/channel-info-chemicals-a-z/
Price of benzene, according to the Adinath Petrochem,
The information is retrieved from http://www.adinathpetro.com/productlist1.asp
Calculation:
𝐻𝐻$ 3.45 𝐻𝐻𝐻 6608𝐻𝐻 24ℎ𝐻𝐻𝐻 353𝐻𝐻𝐻𝐻
1.) Benzene: × 9.11𝐻𝐻 × × × = US$21.20×106/year
𝐻𝐻𝐻 ℎ𝐻𝐻𝐻 1𝐻𝐻𝐻 1𝐻𝐻𝐻𝐻
𝐻𝐻.97 𝐻𝐻$0.015 61.2𝐻𝐻 24ℎ𝐻𝐻𝐻 353𝐻𝐻𝐻𝐻

2.) Dibutyl phthalate = × × × × =
𝐻𝐻 𝐻𝐻 ℎ𝐻𝐻𝐻 1𝐻𝐻𝐻 1𝐻𝐻𝐻𝐻
US$745.397712×103/year
Cost Of Manufacturing of raw material:

= US$745.397712×103/year + US$21.20×106/year
= US$21.95×106/year.
4. Waste treatment cost.
The amount of waste produced must be known in order to determine waste treatment charges,
which depend on material balance. The waste disposal cost depends on the nature of the waste,
as well as whether a commercial or municipal treatment plant can handle it or investment in
onsite waste treatment equipment is needed. When project specific data is available, published
method for estimating the cost of treatment can be used.
REVENUE
MALEIC ANHYDRIDE
𝐻𝐻𝐻𝐻 𝐻𝐻
49.6 × 98.06 = 4863.776 𝐻𝐻/ℎ
ℎ 𝐻𝐻𝐻𝐻
𝐻𝐻 ℎ𝐻 𝐻𝐻𝐻 $1.158
4863.776 × 24 𝐻𝐻𝐻 × 353 𝐻𝐻𝐻𝐻 × = $47.72 per year*
ℎ 𝐻𝐻
MALEIC ACID
𝐻𝐻𝐻𝐻 𝐻𝐻 ℎ𝐻 𝐻𝐻𝐻 2269 𝐻𝐻𝐻𝐻𝐻 $0.015

2.0 × 116.072 𝐻𝐻𝐻𝐻 24 𝐻𝐻𝐻 × 353 𝐻𝐻𝐻𝐻 × × 1 𝐻𝐻𝐻𝐻𝐻 = $67.73 per year*
ℎ 𝐻𝐻
TOTAL REVENUE
Total Revenue, R= $47.72 + $67.73 = $115.45 per year*

*All the values is in x106
LAND COST
The land that is chosen to build this chemical plant is located at Pulau Indah, Port Klang in
Selangor. 17To be exact, this land is located in Pulau Indah Industrial Park, Port Klang, Selangor.
The size of this land is at about 20.11 acres which is enough to build the plant for production of
maleic anhydride and it is also enough to make expansion in future.17 The price of this 20.11
acres including GST is RM 36 795 150.00 which is equivalent to $8.21 x 106.17
This location is one of the strategic area for chemical industry since this area has been reserved
for industrial area and it is ideal location for cost savings as well as high returns.18 Pulau Indah
Industrial Park (PIIP) has attracted many investors including giant investors such as Central
Sugar Refinery Sdn. Bhd. (CSR) and Federal Flour Mill Berhad (FFM).18
Many big companies are attracted to invest to the PIIP since it has providing innovative
industrial solutions. This including the complete infrastructure and tariff such as electricity,
telecommunication, enough water supply and sewage and water treatment. 18
The electricity supplied to this area are from three power stations which are Connaught Bridge in
Klang, Kapar Power Station in Kapar and Putrajaya Power Station in Serdang.18 These three
power stations has contribute at about 3 877 Mega Watt to the total installed capacity of
Malaysia which at 19 723 Mega Watt. The total current capacity in Pulau Indah is 275/132 Kilo
Volt with transformer capacity at 11/0.433 Kilo Volt and main distributor substation at 33/11
Kilo Volt.18
The telecommunication facility has a very good coverage where the Pulau Indah’s
telecommunication network provides unlimited broadband internet access with high speed
connectivity. 18 This excellent facility can fulfill all broadband application such as web hosting,
18
video streaming, e-commerce and many other online needs. The speed of internet access
become one of the most important thing and need due to borderless world.
The water for Pulau Indah Industrial Park or PIIP is supplied by a few dams in Selangor
including Semenyih dam and Sungai Selangor dam. 18 The total water capacity demand in Pulau
Indah is at about 20 million gallons per day. 18 The demand is rather small than the capacity that
can be supplied by both dams where the Semenyih dam can generate at about 140 million gallons
18
per day. Meanwhile at about 400 million gallons per day can be generated when the water
scheme in Sungai Selangor is combined with other major damns. 18 The total capacity of water
generated are expected to reach as high as 1900 gallons per day. 18 Thus, the dam in Selangor can
supply more than enough of the water capacity needed by the PIIP.
The PIIP is built with sewage and waste treatment facility. One of the facility regarding the
sewage treatment is a built of flood retention pond which acts as a run-off basin. 18 The pond
handles a quick influx of water and catches large amounts of surface run-off in order to minimize
the effects of large rains and flooding. 18
WORKING CAPITAL
Working Capital = 0.2 ×$95.98× 106 = $19196710.99951@ 19.20×106
SALVAGE VALUE
Salvage value is the estimated value that the owner is paid when the item is sold at the end of its
useful life. The value is used to determine annual depreciation in the accounting records, and
salvage value is used to calculate depreciation expense on the tax return.
PROFITABILITY ANALYSIS
NON-DISCOUNTED CASH FLOW
A loan transaction starts with a positive cash flow when the loan is received - and continuous
with negative cash flows for the pay offs.
Payback period (PBP)
Payback period also known by a variety of other name, such as payout period, payoff period and
cash recovery period.
PBP = Time required, after start-up, to recover the fixed capital investment for the project
The shorter the payback period, the more profitable the project.
Cumulative cash position (CCP)

Cumulative cash position is simply the worth of the project at the end of life.
Cumulative cash ratio (CCR)
𝐻𝐻𝐻 𝐻𝐻 𝐻𝐻𝐻 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 𝐻𝐻𝐻ℎ 𝐻𝐻𝐻𝐻𝐻

𝐻𝐻𝐻 = 𝐻𝐻𝐻 𝐻𝐻 𝐻𝐻𝐻 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 𝐻𝐻𝐻ℎ 𝐻𝐻𝐻𝐻𝑠
Rate of return on investment (ROROI)
The rate of return on investment (ROROI) represents the non-discounted rate at which money is
made from our fixed capital investment.
𝐻𝐻𝐻𝐻𝐻𝐻𝐻 𝐻𝐻𝐻𝐻𝐻𝐻 𝐻𝐻𝐻 𝐻𝐻𝐻𝐻𝐻𝐻 1

𝐻𝐻𝐻𝐻𝐻 = 𝐻𝐻𝐻𝐻𝐻 𝐻𝐻𝐻𝐻𝐻𝐻𝐻 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 (𝐻𝐻𝐻 −𝐻
𝐻)
*all values in $ million :
Cost of land, L = $ 8.21
Total fixed capital investment year 1 = $40
Fixed capital investment year 2 = $25.34
Plant start-up at end of year 2
Working capital = $19.20 at end of year 2
Yearly sales revenue (after start up ), R = $ 115.45
Cost of manufacturing excluding depreciation allowance (after start up) ,COMd = $84.19 x 106
Taxation rate19, t = 20%

Salvage value of plant, S = $0.00
Depreciation : Use 5 years MACRS
Assume a project life 20 years
Non-discounted After Tax Cash Flow (All numbers in $106)
End Investmen dk FCIL-∑dk R COMd After Cash Cumulative

of t tax flow cash flow
year profit
0 (8.21) - 95.984 - - - (8.21) (8.21)
1 (60.00) - 95.984 - - - (60.00) (68.21)
2 (35.98)+ - 95.984 - - - (55.18) (123.39)
(19.20)
=(55.18)
3 - 19.1968 76.7872 115.45 84.19 28.85 28.85 (94.54)
4 - 30.7149 46.0671 115.45 84.19 31.15 31.15 (63.39)
5 - 18.4289 27.6382 115.45 84.19 28.69 28.69 (34.7)
6 - 11.0573 16.5809 115.45 84.19 27.22 27.22 (7.48)
7 - 11.0573 5.5286 115.45 84.19 27.22 27.22 19.74
8 - 5.5286 0.000 115.45 84.19 26.11 26.10 45.84
9 - - 0.000 115.45 84.19 25.00 25.00 70.84

10 - - 0.000 115.45 84.19 25.00 25.00 95.84
11 - - 0.000 115.45 84.19 25.00 25.00 120.84
12 - - 0.000 115.45 84.19 25.00 25.00 145.84
13 - - 0.000 115.45 84.19 25.00 25.00 170.84
14 - - 0.000 115.45 84.19 25.00 25.00 195.84
15 - - 0.000 115.45 84.19 25.00 25.00 220.84
16 - 0.000 115.45 84.19 25.00 25.00 245.84
17 - - 0.000 115.45 84.19 25.00 25.00 270.84
18 - - 0.000 115.45 84.19 25.00 25.00 295.84
19 - - 0.000 115.45 84.19 25.00 25.00 320.84
20 - - 0.000 115.45 84.19 25.00 25.00 345.84
21 - - 0.000 115.45 84.19 25.00 25.00 370.84
22 19.20 + - 0.000 115.45 84.19 25.00 52.41 423.25

8.21
= 27.41
Payback period = 5.2-2 = 3.2 years
Cumulative Cash Position (CCP)= $423.25 x 106

Cumulative Cash Ratio (CCR) = ∑positive cash flow / ∑negative cash flow
= 546.64 / 123.39
= 4.43
Rate of return on investment (ROROI ) = (28.85 +31.15 + 28.69……+25.00) /20 /95.984 - (1/20)
= 0.22 or 22.04% per year

DISCOUNTED CASH FLOW
There are a few profitability criteria that should be analyze which including the discounted
payback period, net present value, present value ratio and discounted cash flow rate of return.
These criteria are divided into two types of criterion which are time criterion and cash criterion.
For the time criterion which is discounted payback period is the time required for a plant to
recover back the fixed capital investment FCIL and a project with the shortest discounted
payback period is the most desirable.
There are two types of cash criterion which are net present value (NPV) and present value ratio
(PVR). The value of NPV is taking from the cumulative discounted cash flow at end of the
project life meanwhile the PVR is the ratio of present value of all positive cash flow to the
present value of all negative cash flow. The NPV is totally dependable on the level of fixed
capital investment therefore a better criterion to compare the project with different investment is
the PVR criterion. From the PVR, if it give the greater value than the unity, thus the project can
be said profitable but if it less than the unity it shows that the project is unprofitable.
DISCOUNTED CASH FLOW = Fn / (1+i)n
DISCOUNTED CASH FLOWS (ALL NUMBERS IN MILLION OF $106)
END OF YEAR NON- DISCOUNTED CUMULATIVE

DISCOUNTED CASH FLOW DISCOUNTED
CASH FLOW CASH FLOW
0 (8.21) (8.21) (8.210)
1 (60.00) (58.25) (66.46)
2 (55.18) (52.01) (118.47)
3 28.85 26.40 (92.07)
4 31.15 27.68 (64.39)
5 28.69 24.75 (39.64)

6 27.22 22.79 (16.85)
7 27.22 22.13 5.28
8 26.10 20.60 25.88
9 25.00 19.16 45.04
10 25.00 18.60 64.64
11 25.00 18.06 81.70
12 25.00 17.53 99.23
13 25.00 17.02 116.25
14 25.00 16.53 132.78
15 25.00 16.04 148.82
16 25.00 15.58 164.4
17 25.00 15.13 179.53
18 25.00 14.68 194.21
19 25.00 14.25 208.46
20 25.00 39.25 247.71
21 25.00 64.25 311.96
22 52.41 116.66 428.62

500
Cumulative Cash flow diagram for discounted
400 after tax cash flows
300
200
Series1
100
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
-100
-200
Discounted payback period = 5.5-2
= 3.5 years
Net present value (NPV) = 428.62 x 106
Present value ratio (PVR) = 4.67
END OF YEAR NON- DISCOUNTED CUMULATIVE

DISCOUNTED CASH FLOW DISCOUNTED
CASH FLOW RATE
0 (8.21) (8.21) (8.21)

1 (60.00) (44.44) (52.62)
2 (55.18) (30.28) (82.93)
3 28.85 11.73 (71.2)
4 31.15 9.38 (61.82)
5 28.69 6.39 (55.43)
6 27.22 4.4966 (50.93)
7 27.22 3.33 (47.60)
8 26.10 2.37 (45.23)
9 25.00 1.68 (43.55)
10 25.00 1.24 (42.31)
11 25.00 0.92 (41.40)
12 25.00 0.68 (40.71)
13 25.00 0.51 (40.20)
14 25.00 0.374 (39.83)
15 25.00 0.28 (39.55)
16 25.00 0.21 (39.34)
17 25.00 0.152 (39.19)
18 25.00 0.11 (39.08)
19 25.00 0.08 (38.997)
20 25.00 0.06 (38.937)

21 25.00 0.045 (38.892)
22 52.41 0.0034 (-38.8694)
To find DCFROR :
Discounted rate
Discounted cash flow rate of return (DCFROR) is the interest rate at which all the cash flow
must be discounted in order for the net present value, NPV of the project to be equal to zero.
Therefore, when NPV is equal to zero, the DCFROR value is 32.2%and shown below:
Table : Interest rate when NPV is zero
Interest Rate, i NPV (RM Miliion)
0.03 428.62
X 0.00
0.35 -38.8694
𝐻𝑥 − 0.03 0 − 428.62
=
0.35 − 0.03 −38.8694 − 428.62
𝑥 = 32.2%
COMPARISM BETWEEN DCFROR WITH THE INTERNAL INTEREST RATE
From the DCFROR obtained in the discounted cash flow, the value obtained is as much as 32.2%
which is slightly higher than 3% from the internal interest rate in 2016. The difference is at about
29.8% where the DCFROR is higher than the current internal interest rate, thus the project is
profitable to proceed.
COMPARISM BETWEEN NON-DISCOUNTED AND DISCOUNTED CASH FLOW
The rate of return on investment (ROROI) is calculated in the part of non-discounted cash flow
meanwhile the discounted cash flow rate of return (DCFROR) is calculated in the discounted
cash flow. The value of ROROI obtained is at 22.04% per year but the value of DCFROR
obtained is at 32.3% which is slightly higher than the ROROI. Thus it can be concluded that the
discounted cash flow is more profitable than the non-discounted cash flow.
CONCLUSION
The aim of the project is to make a preliminary design plant for production of maleic anhydride
that includes the economic analysis. As the conclusion, the payback period for non discounted
cash flow within 20 years is 3.2 years . This is because the selling price of maleic anhydride and
maleic acid, thus make the revenue is moderate amount which is $115.45x10^6, giving
cumulative ratio (CCR) of 4.43 and return of rate on investment (ROROI) is 22.04% per year.
However, it is a little bit longer for discounted payback period within 3.5 years because the
payment to the bank is increasing year by year as the give interest rate each year 3%. The
present value ratio (PVR) is 4.607 with DCFROR of 32.2%. The project depends on a good and
stable price of maleic anhydride and the variation in utility price had minimum effect on the
payback time.
REFERENCES
1. Turton R., Bailie R. C., Whitting W. B., Shaeiwitz J. A., Bhattacharyya D. (2013).
Analysis, Synthesis, and Design of Chemical Processes. Pearson Education.
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anhydride-ma-production-and-manufacturing-process/
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chain-world-market-overview
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anhydride-market-industry?gclid=CNKh2O3wgdECFcIQaAodAgoL2A
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n
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park-port-klang-land-for-sale-by-hata-teo
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AQHGov7T
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25.
APPENDICES
1. The pie chart of the demand and supply over the world in 2014.
2. The graph on the demand and supply of the maleic anhydride in 2014.

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What are the main reactions involved in the production of maleic anhydride?

What are the main reactions involved in the production of maleic anhydride?

What are the main steps in the production process of maleic anhydride?

What are the main steps in the production process of maleic anhydride?

INTRODUCTION

C6H6 + 4.5O2 C4H2O3 + 2CO2 + 2H2O

The purpose of this project is to do a preliminary analysis to determine the feasibility of

Basis operation: 353 days/year of operation

5194 𝑘𝑔 1 tonne 24 ℎ𝑟 353 𝑑𝑎𝑦𝑠 𝑡𝑜𝑛𝑛𝑒

𝑡𝑜𝑛𝑛𝑒 1 𝑦𝑒𝑎𝑟 1000 𝑘𝑔 1 𝑑𝑎𝑦 𝑘𝑔

Molecular weight for every component:

Component Molecular weight (kg/kmol)

Maleic anhydride 98.06

Dibutyl phthalate 278.34

Maleic acid 116.072

Sodium nitrate 84.9947

Temperature (°C) 30 30 30 30 170 460 608 270

Component Flowrates (Kmol/h)

Nitrogen 0.0 0.0 0.0 4410 4410 4410 4410 4410

Water 0.0 0.0 0.0 0.0 0.0 0.0 183 183

Benzene 84.6 84.6 84.6 0.0 0.0 84.6 5.2 5.2

Quinone 0.0 0.0 0.0 0.0 0.0 0.0 1.4 1.4

Temperature (°C) 330 320 194 84 195 330 419 562

Pressure (kPa) 82 100 82 75 80 82 200 200

Component Flowrates (Kmol/h)

Nitrogen 0.0 0.0 0.0 4410 0.0 0.0 0.0 0.0

Water 0.0 0.0 0.0 183 0.0 0.0 0.0 0.0

Oxygen 0.0 0.0 0.0 740.4 0.0 0.0 0.0 0.0

Benzene 0.0 0.0 0.0 5.2 0.0 0.0 0.0 0.0

Stream 1 V-601 Stream 2

Mass flow rate (kg/hr) 8854.72 8854.72

Mole flow rate (kmol/hr) 113.364 113.364

Component flow rates (kmol/h)

Maleic anhydride 0.00 0.00

Dibutyl phthalate 0.00 0.00

Nitrogen 0.00 0.00

Water 0.00 0.00

Oxygen 0.00 0.00

Benzene 113.364 113.364

(1,4-Benzoquinone)Quinone 0.00 0.00

Carbon dioxide 0.00 0.00

Maleic acid 0.00 0.00

Sodium nitrite 0.00 0.00

Sodium nitrate 0.00 0.00

Overall Mass Balance

Mass flow rate (kg/hr) 224567.92 1050359 224567.92 1050359

Mole flow rate (kmol/hr) 7590.564 13400 7571.804 13400

Component flow rates

Maleic anhydride 0.00 0.00 70.484 0.00

Dibutyl phthalate 0.00 0.00 0.00 0.00

Nitrogen 5909.4 0.00 5909.4 0.00

Water 0.00 0.00 245.22 0.00

Oxygen 1567.8 0.00 992.136 0.00

Benzene 113.364 0.00 6.968 0.00

(1,4-Benzoquinone)Quinone 0.00 0.00 1.876 0.00

Carbon dioxide 0.00 0.00 345.72 0.00

Maleic acid 0.00 0.00 0.00 0.00

Sodium nitrite 0.00 5535.808 0.00 5535.808

Sodium nitrate 0.00 7864.192 0.00 7864.192