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DESIGN OF A PLANT TO PRODUCE 20,000 TONNES PER
ANNUM OF ACRYLONITRILE
BY
OBAJI NW ANI OKIKE
, 2004/18525EH
A I'ROJECT SUBMITTED TO THE
DEPARTMENT OF CHEMICAL'ENGINEERING
SCHOOL OF ENGINEERING AND ENGINEERING TECHNOLOGY,
FEDERAL'UNIVERSITY OF TECHNOLOGY MINNA,
NIGER STATE
IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE -' ," ,.~ ,
AWARD OF BACHELOR OF ENGINEERING (B.ENG) IN CHEMICAL
ENGINEERING *
, DECEMBEI~, 2009
DECLARATION
I Obaji Nwani Okike with Registration Number 2004118525EH declare that this Design
project is my original and has not been presented elsewhere to the best of my knowledge.
Student Signature Date
ii
CERTIFICATION
This project has been examined and certified under the supervision of Engr. Habibu
Uthman on behalf of Chemical Engineering Department, Federal University of Technology
Minna to be adequate in scope and in quality as a meeting part of the partial fulfilment of the
requirement for the award of bachelor of Engineering (B.Eng) in Chemical Engineering .
.. ~ .......... .. ~QJI c>1! '2 t5{ 0 ............. / .......................... .
Engr. Habibu Utlunan Date
Project Supervisor
........................................ .........................................
(
Dr. 1. O. Okafor Date
Head of Department
........................................ ............................................
External Supervisor . Date
iii
DEDICATION
This Design project is specially dedicated to the Almighty God for being my strength,
defender, provider and supporter throughout my course of study. I travelled severally to places
far and near within this period and in all he saw me through. Praise be to his Holy name. ) '
HALLELUYAH!!!!!!!!!!! !!!
I also dedicate this project to my loving parents Chief Okaji and Mrs. Okike Obaji for
their care, love, support and prayers in the course of this programme. You are priceless and
incomparable.
iv
ACKNOWLEDGEMENT
A saying says "Tough times never lack but tough people do". I bless the Almighty God for
giving me the determination, opportunity, strength and the grace to be part of this great institute and
for sparing my life to cope with the struggle, risk and rigorous pain during my academic pursuit. The
Almighty God saw me through thick and thin. Thanks a million times my heav~nly father. Glory be
to your HolyNAME forever. Amen.
An adage says "A tree cannot make a forest" which is explicitly true. This project was
successfully completed as a result of the collective efforts of many of whom lowe a debt of
gratitude.
I must express my sincere gratitude to my amiable and ever supporting supervisor, Engineer
Habibu Uthman for Supervising and guiding me through out the course of this project to make it a
successful one.
My sincere and warm gratitude also extend to all members of my family, Mr., Kingsley Obaji
Okike, Mrs. Nnennaya Obasi, Mrs. Confidence Godwin, Mrs. Jennifer Okoronkwo, Miss Uzoma
Okike Obaji, Miss Joy Obaji, Miss Ijeoma Okike, Miss Ngozi Okike" Miss Chinonyerem, Master 1.
Ogbonnaya Okike Obaji for all their prayers, moral and financial supports through out my course of
study. You are too wonderful to me.
A very big THANK You to all my dear and Loving friends who stood my me in the tough
and difficult times, Olalekan .T. Fakuade, Damilare Oladiji, Femi Owolabi, Chimankpam
Onwuchekwa, Chidi Anunobi, Pastor and Pastor Mrs. Okechukwu Okoro, Mr. and Mrs. Ogbonnaya
Obaji. Thank you for your prayers and support. I LOVE U ALL
My gratitude and thanks also go to all the Lecturers in Chemical Engineering Department
that has in one way or the other impacted me greatly with knowleqge; Dr J. C. OkafoI', Engr Dim
Paul, Engr Umaru, Engr Manasseh, Engr Mrs Muyibat, Engr. Mrs Olugbenga, Engr Aboje, Mallam
Sidi, Mr. Dikko. Thank you all for making me what I have become today. I pray that all your
children will be very great in life. God bless you all.
v
. :~.
,I
ABSTRACT
This project work was carried out to design a plant to produce 20,000 tonne/annum of
Acrylonitrile using propylene and ammonia as the raw material with bismuthmolybdate as
catalyst: The detailed design work like the material and energy balance was done with the aid of
computer aided design(CAD) software like:HYSYS alld MATHCAD. The major units in the < " ' ~ • , ••
plal~t are; ,Fluidized bed Reactor, Absorber, and Distillation unit. The, design of the major
equipment undertaken is the reactor, having a diameter of 4. \ 55m, and height of 5.006m: safety
control, environmental impact assessment"plant location' and site layout were also carried out. , • /1 • ".
Standard Co,~t esti~ationwascarried out using detailed factorial method and this gives the total
capital investment cost to be 198million Naira needed to generate a net 'profit of 314 million
Naira within a pay back period of app1ioximately'six(6) years for a plant life of 15 years. And the " ~ -.". .
pay ba,ck rate.is 22.56%~ Herl~e, the project was concluded to lJeecon~micallyviable .
. , ;
.~ , . , , ..... ,
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vi
TABLE OF CONTENT
CHAPTER ONE .............................................................. 1
1.0 INTRODUCTION
<:1I~~1r~lt ~() ............................................................ ~3
2.0 LITERA TURE REVIEW
2.1 Uses and Consumption of Acrylonitrile
2.2 Sohio Production Processes
2.3 Detailed Description with Control Operation
CHAPTER THREE ........................................ ·.············ ... 1 0
3.0 MATERIAL BALANCE
<:~J»1r~1tJ?()1Jlt ••..••......•.•••••..••..•••••.••••••••••••• .••••.•..••... 64
4.0 ENERGY BALANCE CALCULATION
<:HA~TEll ]!~ •••••••••••••••••••••••••••••••••••••••••••••••••••• •••••••• 82
5.0 FLOW SHEET OF THE PROCESS
<:HA~1[1C1t SJ)( •••••••.• ~ •••••.••••••••••••••••••••.•••••••.•• ·• •• · •••••..••• 83
6.0 EQUIPMENT DESIGN
6.1 Design of a Fluidized bed Reactor
6.2 Absorber Sizing
6.:,) Acrylonitrile Recovery Column Design
, 6.4 Acetonitrile Recovery Column Design
6.5 Design of Light Column
6.6 Design of Product Column
CHAPTER SEVEN ........ · ..................... e •••••••• e ................. 138
7.0. EQUIPMENT OPTJMIZA, TION
7.1 Optimization of the Fluidized Bed Reactor
CHAPTER EIGHT ., ..................... " ........................................ 143
8.0 SAFETY AND QUALITY CONTROL
8.1 Safety control
8.2 Quality Control measure
8.3 General Process Safety Managenement
CHAPTER NINE ............................................................. 156
9.0 PROCESS CONTROL AND INSTRUMENTATIO
CHAPTER TEN ......................................................... e •••• 168
10.0 ENVIRONMENTAL ACCEPTABILITY
CHAPTER ELEVEN ..................................................... ,,0.172
11.0 START UP AND SHUT DOWN PROCEDURE
CHAPTER TWELVE ........................................................ 17S
12.0 SITE FOR PLANT LOCATION
CHAPTER THIRTEEN ...................................................... 184
13.0 COST ESTIMATION AND ECONOMIC ANALYSIS OF PLANT
CHAPTER FOURTEEN .......................... e •••••••••••••••••••• 111 ....... 196
14.0 CONCLUSION AND RECOMMENDATION
14.1 CONCLUSION AND RECOMMENDATION
APPEND IX .......................... " ................................... 111 •••••• ".198
REFERENCE ......... It •••••••••••••••••••••••• 0 .......... • ' ••••••••• ' •• Co •••• 0 ••••• 205
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