Dimethyl Aniline

7/31/2019 Dimethyl Aniline

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MANUFACTURE OF DMA

MGMs College of Engineering & Technology Kamothe, Navi Mumbai (2011-12). Page 2

Table of Contents

CHAPTER 1: INTRODUCTION 5

1.1 DIMETHYLANILINE 6

1.2 HISTORY 8

CHAPTER 2: PHYSICAL AND CHEMICAL PROPERTIES 9

2.1 CHEMICAL AND PHYSICAL DATA 10

CHAPTER 3: MATERIAL SAFETY AND DATA SHEET 12

3.1 MSDS 13

CHAPTER 4: APPLICATION 20

4.1 APPLICATION 21

CHAPTER 5: MANUFACTURING PROCESS 23

5.1 PROCESSES 24

CHAPTER 6: PROCESS DESCRIPTION 25

6.1 RAW MATERIALS 26

6.2 DETAILS OF SELECTED PROCESS 27

6.3 PROCESS FLOW DIAGRAM 32

CHAPTER 7: MATERIAL BALANCE 34

7.1 MATERIAL BALANCE 35

CHAPTER 8: ENERGY BALANCE 39

CHAPTER 9: EQUIPMENT DESIGN 41

9.1 HEAT EXCHANGER 42

9.2 DISTILLATION COLUMN 48

CHAPTER 10: PLANT LAYOUT 55

CHAPTER 11: HAZOP STUDY 58

CHAPTER 12: PROJECT COST ESTIMATION 62

CHAPTER 13: CONCLUSION AND REFERENCES


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CHAPTER 1

INTRODUCTION


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1.1 Introduction Of Dimethylaniline

N,N-Dimethylaniline (DMA) is an organic chemical compound, a substituted derivative of

aniline. It consists of a tertiary amine, featuring dimethylamino group attached to a phenyl group.This oily liquid is colourless when pure, but commercial samples are often yellow. It is an

important precursor to dyes such as Crystal violet.

N, N- Dimethylaniline is used as an intermediate

in the manufacture of dyes and other products and

as a solvent for special purposes, a rubber

vulcanizing agent and a stabilizer. It has been

detected in ambient water and soil in the vicinity

of industrial facilities N, N-Dimethylaniline can

be detected in air by adsorption on silica gel,

desorption with ethanol and analysis by gas

chromatography and flame ionization detection.

The limit of detection is 10 l1g/sample Amines

can be liberated during the manufacture of rubber,

especially by vulcanization and by other thermal

degradations. A method was described for the

determination of free aromatic amines.

Including N,N-dimethylaniline, using high-temperature glass-capillary gas chromatography and

nitrogen-selective detection (thermionic specific detector), with detection limits of 10-20 pg.


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A

BRIEF

HISTORY


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1.2 HISTORY

DMA was first reported in 1850 by A. W. Hofmann, who prepared it by heating aniline and

iodomethane:C6H5NH2 + 2 CH3I C6H5N(CH3)2 + 2 HI

DMA is produced industrially by alkylation of aniline with methanol in the presence of an acid

catalyst:

C6H5NH2 + 2 CH3OH C6H5N(CH3)2 + 2 H2O

Similarly, it is also prepared using dimethyl ether as the methylating agent.

Dimethylaniline undergoes many of the reactions expected for an aniline, being

weakly basic and reactive toward electrophiles. N, N-Dimethylaniline is produced commercially

by heating aniline at 300C with

Methanol in the presence of a catalyst at high pressure; sulfuric acid, phosphoric acid or

Alumina can be used as the catalyst (Northcott, 1978; Rosenwald, 1978; Budavari, 1989).

N, N- Dimethylanilne is produced by one company each in France, Germany, Hungary,Korea,

Spain and the USA, by two companies in Japan and The United Kingdom and by four companies

in India (Chemical Information Services, 1991).
http://en.wikipedia.org/wiki/Iodomethanehttp://en.wikipedia.org/wiki/Hydrogen_iodidehttp://en.wikipedia.org/wiki/Alkylationhttp://en.wikipedia.org/wiki/Methanolhttp://en.wikipedia.org/wiki/Methanolhttp://en.wikipedia.org/wiki/Methanolhttp://en.wikipedia.org/wiki/Methanolhttp://en.wikipedia.org/wiki/Dimethyl_etherhttp://en.wikipedia.org/wiki/Dimethyl_etherhttp://en.wikipedia.org/wiki/Methanolhttp://en.wikipedia.org/wiki/Methanolhttp://en.wikipedia.org/wiki/Alkylationhttp://en.wikipedia.org/wiki/Hydrogen_iodidehttp://en.wikipedia.org/wiki/Iodomethane


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CHAPTER 2

PHYSICAL

AND

CHEMICAL

PROPERTIES


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2.1Chemical and physical data

N,N-Dimethylaniline (DMA) is colourless or pale yellow to brown, oily liquid with

characteristic amine-like odor. DMA is less dense than water and insoluble in water. Freelysoluble in alcohol, acetone, benzene, chloroform, diethyl ether, ethanol and acid solution. Stable

under ordinary conditions of use and storage. Combustible. DMA is a weak base incompatible

with strong oxidizing agents, strong acids, acid chlorides, acid anhydrides, chloroformates,

halogens. It emits toxic fumes of nitriogen oxides, carbon oxides, and aniline when heated to

decomposition. (C8H11N) MoL. wt: 121.18.

Synonyms, structural and molecular data

Chem. Abstr. Sem Reg. No.: 121-69-7

Chem. Abstr. Name: N,N- Dimethyl benzenamine

IUPAC Systematic Name: N,N-Dimethylaniline

Synonyms: (Dimethylamino )benzene; N,N-dimethylaminobenzene; dimethylanilne;

dimethylphenylamine; N,N-dimethylphenylamine

Chemical and physical properties

(a) Description: Yellowish to brownish oily liquid (Sax & Lewis, 1987)

(b) Boiling-point: 192-194 C (ElIer, 1985; Lide, 1991)

(c) Melting-point: 2-2.45 C (ElIer, 1985; Lide, 1991)

(d) Density: 0.956 g/ml at 20C (Eller, 1985)

(e) Refractive Index: 1.5580

(f) Spectroscopy data: Infrared, ultraviolet and nuclear magnetic resonance spectral data have

been reported (Sadtler Research Laboratories, 1980; Pouchert, 1981, 11983; US Nation9al

Toxicology 9Pro 1)gram., 1989; Sadtler .Research Laboratories, if Solubilty: Insoluble in water


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(2-14 g/l at 25C). Since N,N-dimethyl aniline is a basic compound, its solubility is dependent

on the pH of the aqueous medium: its solubility in water at pH ).

7 is lower than that in water of pH .: 5. The data on aqueous solubility reported in the literature

thus vary widely (US Environmental Protection Agency, 1986). Soluble in acetone, benzene,

chloroform, diethyl ether and ethanol (Amoore & Hautala, 1983; Dragun & Hellng, 1985; Sax &

Lewis, 1987; Lide, 1991)

(g) Volatility: Vapour pressure, 1 mm Hg (133 Pal at 29.5 C (Lide, 1991)

(h) Stability: Slowly oxidizes and darkens in air; can react with nitrous acid to form ring-

substituted nitroso compounds (US Environmental Protection Agency, 1986)

(i) Octanol/water partition coeffcient (P): 2.31 (Hansch & Leo, 1979)

(j) Conversion factor: mg/m3 = 4.95 x ppm1.

TRANSPORTATION

PACKING: 180 Kg in Drum

HAZARD CLASS: 6.1 (Packing group: II)

UN NO.: 2253


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CHAPTER 3

MATERIAL

SAFETY

DATA

SHEET

(M.S.D.S.)


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3.1 Material Saftey And Data Sheet

Section 1: Chemical Product and Company Identification

Product Name: N,N-DimethylanilineCatalog Codes: SLD3868

CAS#: 121-69-7

RTECS: BX4725000

TSCA: TSCA 8(b) inventory: N,N-Dimethylaniline

CI#: Not available.

Synonym: Xylidine

Chemical Formula: C8H11N

Section 2: Composition and Information on Ingredients

Composition:

Name CAS # % by Weight

{N,N-}Dimethylaniline 121-69-7 100

Toxicological Data on Ingredients: N,N-Dimethylaniline: ORAL (LD50): Acute: 1410 mg/kg

[Rat]. DERMAL (LD50): Acute:1770 mg/kg.

Section 3: Hazards Identification

Potential Acute Health Effects:

Very hazardous in case of ingestion. Hazardous in case of skin contact (irritant, permeator), ofeye contact (irritant), of inhalation.

Potential Chronic Health Effects:

Hazardous in case of skin contact (irritant, permeator), of eye contact (irritant), of inhalation.


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CARCINOGENIC EFFECTS: Not available.

MUTAGENIC EFFECTS: Not available.

TERATOGENIC EFFECTS: Not available.

DEVELOPMENTAL TOXICITY: The substance is toxic to blood, kidneys, liver. Repeated or

prolonged exposure to the substance can produce target organs damage

Section 4: First Aid Measures

Eye Contact: Check for and remove any contact lenses. Immediately flush eyes with running

water for at least 15 minutes, keeping eyelids open. Cold water may be used. Do not use an eye

ointment. Seek medical attention.

Skin Contact: After contact with skin, wash immediately with plenty of water. Gently and

thoroughly wash the contaminated skin with running water and non-abrasive soap. Be

particularly careful to clean folds, crevices, creases and groin. Cold water may be used. Cover

the irritated skin with an emollient. If irritation persists, seek medical attention. Wash

contaminated clothing before reusing.

Serious Skin Contact: Wash with a disinfectant soap and cover the contaminated skin with an

anti-bacterial cream. Seek immediate medical attention.

Inhalation:

Allow the victim to rest in a well ventilated area. Seek immediate medical attention.

Serious Inhalation: Evacuate the victim to a safe area as soon as possible. Loosen tight clothing

such as a collar, tie, belt or waistband. If breathing is difficult, administer oxygen. If the victim is

not breathing, perform mouth-to-mouth resuscitation. Seek medical attention.


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Ingestion: Do not induce vomiting. Examine the lips and mouth to ascertain whether the tissues

are damaged, a possible indication that the toxic material was ingested; the absence of such

signs, however, is not conclusive. Loosen tight clothing such as a collar, tie, belt or waistband. If

the victim is not breathing, perform mouth-to-mouth resuscitation. Seek immediate medical

attention.

Serious Ingestion: Not available.

Section 5: Fire and Explosion Data

Flammability of the Product: Combustible.

Auto-Ignition Temperature: 371C (699.8F)

Flash Points: CLOSED CUP: 63C (145.4F).

Flammable Limits: LOWER: 1.1%

Products of Combustion: These products are carbon oxides (CO, CO2).

Fire Hazards in Presence of Various Substances: Not available.

Explosion Hazards in Presence of Various Substances:

Risks of explosion of the product in presence of mechanical impact: Not available. Risks of

explosion of the product in presence of static discharge: Not available.

Fire Fighting Media and Instructions:

SMALL FIRE: Use DRY chemical powder. LARGE FIRE: Use water spray, fog or foam. Do

not use water jet.


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Special Remarks on Fire Hazards: Not available.

Special Remarks on Explosion Hazards: Not available.

Section 6: Accidental Release Measures

Small Spill: Dilute with water and mop up, or absorb with an inert dry material and place in an

appropriate waste disposal container.

Large Spill: Combustible material. Keep away from heat. Keep away from sources of ignition.

Stop leak if without risk. Be careful that the product is not present at a concentration level above

TLV. Check TLV on the MSDS and with local authorities.

Section 7: Handling and Storage

Precautions: Keep away from heat. Keep away from sources of ignition. Ground all equipment

containing material. Do not ingest. Do not breathe gas/fumes/ vapour/spray. Wear suitable

protective clothing In case of insufficient ventilation, wear suitable respiratory equipment If

ingested, seek medical advice immediately and show the container or the label. Avoid contact

with skin and eyes

Storage: Flammable materials should be stored in a separate safety storage cabinet or room.

Keep away from heat. Keep away from sources of ignition. Keep container tightly closed. Keep

in a cool, well-ventilated place. Ground all equipment containing material. Keep container dry.

Keep in a cool place.

Section 8: Exposure Controls/Personal Protection

Engineering Controls: Provide exhaust ventilation or other engineering controls to keep the

airborne concentrations of vapors below their respective threshold limit value. Ensure that

eyewash stations and safety showers are proximal to the work-station location.


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Personal Protection: Splash goggles. Lab coat. Vapor respirator. Be sure to use an

approved/certified respirator or equivalent. Gloves.

Personal Protection in Case of a Large Spill: Splash goggles. Full suit. Vapor respirator.

Boots. Gloves. A self contained breathing apparatus should be used to avoid inhalation of the

product. Suggested protective clothing might not be sufficient; consult a specialist BEFORE

handling this product.

Exposure Limits:

TWA: 5 CEIL: 10 (ppm) from ACGIH (TLV) TWA: 25 CEIL: 50 (mg/m3) from ACGIHConsult

local authorities for acceptable exposure limits

Section 9: Toxicological Information

Routes of Entry: Dermal contact. Eye contact. Inhalation. Ingestion.

Toxicity to Animals: Acute oral toxicity (LD50): 1410 mg/kg [Rat]. Acute dermal toxicity

(LD50): 1770 mg/kg [Rabbit].

Chronic Effects on Humans: The substance is toxic to blood, kidneys, liver.

Other Toxic Effects on Humans: Very hazardous in case of ingestion. Hazardous in case of

skin contact (irritant, permeator), of inhalation.

Special Remarks on Toxicity to Animals: Not available.

Special Remarks on Chronic Effects on Humans: Not available.

Special Remarks on other Toxic Effects on Humans: Not available.

Section 10: Ecological Information

Ecotoxicity: Not available.


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BOD and COD: Not available.

Products of Biodegradation:

Possibly hazardous short term degradation products are not likely. However, long term

degradation products may arise.

Toxicity of the Products of Biodegradation: The products of degradation are more toxic.

Special Remarks on the Products of Biodegradation: Not available.

Section 11: Disposal Considerations

Waste Disposal:

Section 11: Transport Information

DOT Classification: CLASS 6.1: Poisonous material.

Identification: N,N-Dimethylaniline : UN2253 PG: II

Special Provisions for Transport: Not available.

Section 12: Other Regulatory Information

Federal and State Regulations: Pennsylvania RTK: N, N-Dimethylaniline Massachusetts RTK:

N,N-Dimethylaniline TSCA 8(b) inventory: N,N-Dimethylaniline SARA 313 toxic chemical

notification and release reporting: N,N-Dimethylaniline CERCLA: Hazardous substances.:

N,NDimethylaniline

Other Regulations: OSHA: Hazardous by definition of Hazard Communication Standard


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(29 CFR 1910.1200).

Other Classifications:

WHMIS (Canada): CLASS B-3: Combustible liquid with a flash point between 37.8C (100F)

and 93.3C (200F). CLASS D-1A: Material causing

Immediate and serious toxic effects (VERY TOXIC). CLASS D-2B: Material causing other

toxic effects (TOXIC).

DSCL (EEC):R21/22- Harmful in contact with skin and if swallowed. R36/38- Irritating to eyes

and skin.

HMIS (U.S.A.):

Health Hazard: 3

Fire Hazard: 2

Reactivity: 0

Personal Protection: h

National Fire Protection Association (U.S.A.):

Health: 3

Flammability: 2

Reactivity: 0

Specific hazard:

Protective Equipment:

Gloves. Lab coat. Vapor respirator. Be sure to use an approved/certified respirator or equivalent.

Wear appropriate respirator when ventilation is inadequate. Splash goggles.


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CHAPTER 4

APPLICATIONS


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4.1 Applications

DYES

N, N-Dimethylaniline is used in the manufacture of Michler's ketone which is a chemicalintermediate used in the synthesis of many dyes and pigments, particularly auramine derivatives.

These pigments are used to dye paper, textiles, and leather. The main types of the dyes that can

be manufactured from DMA are alkali light yellow, alkali purple 5BN, alkali light green, alkali

turquoise blue, bright red 5 GN, bright blue. DMA is a key precursor to commercially important

triarylmethane dyes such as Malachite green or Crystal (Gentian) violet used as a histological

stain and in Gram's method of classifying bacteria.

PROMOTERS

DMA serves as a promoter in the curing of polyester and vinyl ester resins. This compound can

be used on its own with benzoyl peroxide (BPO) type catalysts or in combination with cobalt 6%

promoters with methyl ethyl ketone(MEKP) type catalysts. These systems give rapid cure at

room temperature. DMA helps the catalyst to start the chemical reaction. Promoters must never

be mixed directly with catalyst since a violent explosive reaction results.

STABILISERS

DMA is used as a stabilizer for colorimetric peroxidase determination.

FRAGRANCE

N,N-Dimethylaniline is used as an intermediate to manufacture vanillin .

PHARMA

DMA is used to manufacture cephalosporin V, madribon, sulphormethoxine and flucytosine in

medical industry. It is used as an acid scavenger in the synthesis of penicillins and

cephalosporins and has been reported as a contaminant of commercial preparations of those

antibiotics at levels of up to 1500 ppm.


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Other Uses:

Specialty industrial solvent and rubber vulcanizing agent.

Reagent in chemical synthesis.

Catalytic hardener in certain fibreglass resins.

N,N-Dimethylaniline is used as an intermediate in the manufacture of dyes, Michler's

ketone and vanilin. It is also used as a specialty industrial solvent, a rubber vulcanizing agent

(see IARC, 1982b, 1987b), a stabilizer and an acid scavenger


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CHAPTER 5

MANUFATURING

PROCESSES


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1] BY ALKYLATION OF ANILINE:

REACTION:

C6H5NH2 + 2CH3OH C6H5N(CH3)2 + 2H2O

Thus, aniline, with a considerable excess of methyl alcohol and a catalytic amount of sulfuric

acid, is heated in an autoclave at about 200 oC for 5 or 6 hours at a high reaction pressure we get

dimethylaniline . Vacuum distillation is used for purification.

In the alkylation of aniline to dimethylaniline by heating aniline and methyl

alcohol, sulfuric acid cannot be used because it will form ether; consequently,hydrochloric acid is

employed, but these conditions are so corrosive that the steel used to resist the pressure must be fitted

with replaceable enameled liners.Thus in presence of Al2O3 as a catalyst is used.

2] BY NITRATION OF BENZENE:

REACTION:

Benzene ring in presence of H2SO4 reacts with nitric acid to give nitrobenzene and water. The

obtained nitrobenzene is subjected to hydrogenation in presence of palladium catalyst and ethanol gives

aniline. And further, aniline on reacting with methyl chloride or chloromethane produces N, N-Dimethyl

aniline.


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CHAPTER 6

PROCESS

DESCRIPTION


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6.1 Raw Materials Used

ANILINE

Aniline, phenylamine or aminobenzene is an organic compound with the formula C6H5NH2.

Consisting of a phenyl group attached to an amino group, aniline is the prototypical aromatic

amine. Being a precursor to many industrial chemicals, its main use is in the manufacture of

precursors to polyurethane. Like most volatile amines, it possesses the somewhat unpleasant

odour of rotten fish. It ignites readily, burning with a smoky flame characteristic of aromatic

compounds. Aniline is colorless, but it slowly oxidizes and resinifies in air, giving a red-brown

tint to aged samples.
http://en.wikipedia.org/wiki/Organic_compoundhttp://en.wikipedia.org/wiki/Chemical_formulahttp://en.wikipedia.org/wiki/Phenyl_grouphttp://en.wikipedia.org/wiki/Amino_grouphttp://en.wikipedia.org/wiki/Polyurethanehttp://en.wikipedia.org/wiki/Organic_oxidationhttp://en.wikipedia.org/wiki/Organic_oxidationhttp://en.wikipedia.org/wiki/Polyurethanehttp://en.wikipedia.org/wiki/Amino_grouphttp://en.wikipedia.org/wiki/Phenyl_grouphttp://en.wikipedia.org/wiki/Chemical_formulahttp://en.wikipedia.org/wiki/Organic_compound


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PROPERTIES OF ANILINE

Molecular formula:C6H5NH2

Molar mass: 93.13 g/mol

Appearance: colorless liquid

Density : 1.0217 g/mL, liquid

Melting point: -6.3 C, 267 K, 21 F

Boiling point: 184.13 C, 457 K, 363 F

Solubility in water:3.6 g/100 mL at 20C

Basicity (pKb): 9.3

Viscosity: 3.71 cP (3.71 mPas at 25 C


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METHANOL

Derived from natural gas, methanol is a hydrocarbon, comprised of carbon, hydrogen and

oxygen. Its chemical formula is CH3OH.

Methanol is an alcohol and is a colorless, neutral, polar and flammable liquid. It is miscible with

water,alcohols, esters and most other organic solvents. It is only slightly soluble in fats and oils.

Detailed physical and chemical properties of methanol are provided in the following pages.

Methanex produces methanol using a catalytic process with natural gas and steam as the

feedstocks. The natural gas is catalytically reformed to carbon oxides and hydrogen. The

resulting synthesis gas mixture is circulated under pressure and moderate temperature in the

presence of a metallic catalyst and converted to crude methanol. The crude methanol is distilled

to yield commercial chemical grade methanol.

Other common names for methanol include methyl alcohol, methyl hydrate, wood spirit, wood

alcohol, and methyl hydroxide.

Methanol is used as a building block for many chemicals and products. Other uses include

windshield washer antifreeze, fuels, waste water treatment and biodiesel production.


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PROPERTIES OF METHANOL

Molecular formula:CH4O

Molar mass : 32.04 g mol1

Appearance: Colorless liquid

Density: 0.7918 g cm3

Melting point: -98--97 C, 175-176 K, -144--143 F

Boiling point: 65 C, 338 K, 149 F

Vapor pressure: 13.02 kPa (at 20 C)

Acidity (pKa): 15.5[2]

Viscosity: 5.9104 Pa s (at 20 C)

Dipole moment: 1.69 D


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6.2 MANUFACTURING OF DIMETHYLANILINE (DMA) BY

ALKYLATION OF ANILINE

A method for the production of dimethylaniline which consist alkylation of aniline withuse of methanol.

First methanol is passed through heat exchanger to rise the temperature to 260 0 C.

Then it is passed to the reactor to convert it into dimethylether gas in presence of alumina(Al2O3)a instead of sulphuric acid as a catalyst , because sulphuric acid is corrossive

towards the reactor vessel.

REACTION:

2CH3OH CH3-O-CH3+H2O

METHANOL DIMETHYLETHER

The effluent from the reactor is passed to ETP and DME gas is passed to autoclave.

Here, it is mixed with aniline at high temperature and high pressure of 540 psi (3.7MPa)about 5 to 6 hours.

REACTION:

CH3-O-CH3+C6H5NH2 C6H5N(CH3)2+H2O

DIMETHYLETHER ANILINE DIMETHYLANILINE

At the end of reaction we get dimethylaniline , which we need to purify.

To purify the mixture from autoclave, it is passed through series of vaccum distillation


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coloumn. Thus, pure dimethylaniline is formed and passed to further processes andstorage.


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6.3 PROCESS FLOW DIAGRAM FOR DIMETHYLANILINE

CHAPTER 6


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CHAPTER 6

MATERIAL

BALANCE


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MATERIAL BALANCE

REACTION 1:

2CH3OH CH3-O-CH3 + H2

2 kmole of Methanol = 1 kmole of Dimethyl ether + 1mole of water

64gm of CH3OH 46gm DME + 18gm H2O

Assume 80% Conversion

Methanol reacted=64 0.8 = 51.2 gm

Unreacted Methanol = 12 .8gm

64gm CH3OH 48gm DME

51.2gm CH3OH x gm DME

x = 36.8gm of DME

REACTION 2:

CH2OCH3 + C6H5NH2 C6H5N(CH3)2 + H2O

1 mol DME+1mol Aniline DMA + 1 mol of water

46gm DME + 93 Aniline 121gm DMA+ 18gm water

46gm DME 93gm Aniline

Therefore ,

36.8gm DME + 74.4Aniline 96.8 gm DMA + 14.4gm H2O

Assume 80% conversion Based on DME

DME reacted = 0.8 36.8 =29.44gm of DME

Therefore DME unreacted = 7.36gm of DME

Aniline req.= 59.52gm of Aniline

DMA produced = 77.44gm = 34.44 kmol/hr


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H2O produced = 11.52gm of water

Feed to Distillation Column

DME = 7.36gm

H2O =11.52gm

DMA =77.44gm=77.44 X 10-3kg


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Basis : 100 tones /day

i.e. 4166.67kg/hr of DMA

34.44kmol/hr

Material balance over reactor:REACTION 1:

2 CH3OH CH3OCH3 + H2O

153.057 kmol/hr Methanol = 110.01kmol/hr of DME

i.e. 4897.824kg/hr of Methanol feed

1692.8kg/hr of DME gas produced

Material balance over autoclave:REACTION 2:

CH3OCH3 + C6H5NH2 C6H5N(CH3)2 + H2O

110.01kmol/hr of DME = 34.44kmol/hr of DMA = 222.54kmol/hr of Aniline = 34.43kmol/hr of

H2O

i.e. Aniline feed = 222.54 93 = 20696.22kg/hr


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Material balance over distillation column:

bdf BxDxFx

BDF

fd

bf

xx

xx

B

D

F = feed flow rate (mol/hr)

D = distillate flow rate (mol/hr)

B = bottom flow rate (mol/hr)

x = mole fraction of corresponding stream

Component In(kg/hr) Top Product

(kg/hr)

Bottom Product

(kg/hr)

DMA 4167.24 41.6724 4125.5676

H2O 619.88 618.0203 1.8597

ANILINE 256.34 253.7766 2.5634

DME 1594.24 1594.24 _

Total 6637.7


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CHAPTER 8

ENERGY

BALANCE


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ENERGY BALANCE

Total feed=4898.24kg

Assume water used 500kg

Reactor 1

mxCpxT=mxCpxT

4898.24x(533-298)x2.51=mx4.187x(573-T)

Q=2889226.864kJ/kg

4896.24x(533-298)x2.51=5000x4.187x(573-T)

T(out) of Water=434.9K

Q=mxCpxT+Mx

=153.057x0.06143x(623-533)+34.4x153.057

=611.367kJ

Req. of steam for the autoclave

Q=mx

611.36=mx1736.2

=3.51kg

aniline=4.838kJ/kmolK

Cp(mix)=Cp(aniline)xmolar mass of aniline+Cp(DME)xmolar mass of DME

=12.115kJ/kmolK

Reactor 2

Q=mxCpxT+Mx

=332.55x12.11x(673-473)+222.5x4.838

=805545.148kJ

Req. of heat for total reactor

Q=mx

805545.148=mX1825.1

=441.37kg/hr


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CHAPTER 9

EQUIPMENT

DESIGN


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9.1 HEAT EXCHANGER

Shell sideMOC: CS

No. of shells: 1

No. of passes: 1

Fluid: liquid

Working pressure: 0.33N/mm2

Design pressure: 0.5N/mm2

Temp. IN: 30oC

Temp OUT: 50oC

Segmental Baffles (25%) with tie rods & spacers

HeadCrown radius: 400mm

Knuckle radius: 40mm

Shell Flange: female facing

Bolts: steel

Nozzles-inlet & outlet-75mm

Vent: 25mm

Drain: 25mm

Opening for relief valve: 50mm

Permissible stress for carbon steel: 95N/mm2

Permissible stress for bolt: 140.6N/mm2


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Tube and tube sheet material: stainless steelNo. of tubes: 54

Outside dia: 12mm

Length: 12m

Pitch (Square): 25mm

Fluid: gas

Working pressure:19N/mm2

Design pressure: 21.5N/mm2

Temp. IN: 150oC

Temp OUT: 55oC

Permissible stress: 100.6N/mm2

Channel and channel coverMOC: CS

Joint: ring facing

Gasket: steel jacketed asbestos

Nozzles-inlet & outlet-75mm

Permissible stress: 95N/mm2


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Shell sideShell Diameter

a=S2T=252=625mm2

an=2x54x625=67500mm2

As=/4xD=an/ =0.7

Ds=(61500x4/0.7x)0.5

=350.4mm

Shell Thicknesst=pDi/(2fJ-p)

=0.5x400/(2x95x0.85-0.5)

=1.24mm

Nozzle (Inlet & Outlet)tn=pDi/(2fJ-p)

=0.5x75/(2x95x0.85-0.5)

=0.23mm

Head Thicknessth= [pRcW/(2fJ)]+c

= [0.5x400x1.54/(2x95x0.85)]+1.5

= 3.4mm


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Flange Thickness (male & female)Go=440mm

Gi=416mm

G=428mm

Gasket width (N)= 24

Basic gasket seating width

bo=N/2=24/2=12

b=2.5x bo0.5

=8.66

Seating stress(Ya)=53.4N/mm2

Gasket factor(m)=3.75

Wm1=bGYa

=x8.66x428x53.40

=6.2x105N

Wm2=x2x8.66x428x3.75x0.5+(/4)x4282x0.5

=1.15x105N

k=1/(0.3+(1.5WmhG/HG))

Wm=6.2x105

hG =48.5

H=71936.6

G=428

k=0.565

tf=G(p/kf)0.5

=428x(0.5/0.565x95)0.5

=41.3mm


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Tube sideThickness of tube

tf=pDo/(2fJ+p)

=(21.5x18)/(2x100.6+21.5)

=1.74mm

Tube sheett=FGx(0.25p/f)

0.5

=1.25x380x(0.25x21.5/100.6)0.5

=109.8mm

Channel and channel coverT=Gc x(kp/f)

0.5

=380x(0.3x21.5/95)

=99.02mm

Flange joint between tube sheet and channel

G=380mm

Ring gasket width=22mm

bo=w/8=22/8=2.75mm

Ya=126.6N/mm2

m=5.5

Wm1=bGYa

=x980x2.75x126.6

=4.16x105N


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Wm2=x2x2.75x380x5.5x21.5+(/4)x3802x21.5

=32.14x105N

Bolt area= Wm2/f

=22859.2mm2

No. of bolt=38/2.5

=15.2

The bolt diameter=(22859.2x4/x16)0.5

=42.65mm

Flange thicknessk=1/(0.3+(1.5WmhG/HG))

=1.47

Tube sheettf=G(p/kf)

0.5

=145mm

Nozzlestn=pDi/(2fJ-p)

=9.6mm


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9.2 DISTILLATION COLUMN

SHELL:

Diameter (Di ) 1.99 m

Working/Operating Pressure 1.0329 kg/cm2

Design pressure = 1.1Operating Pressure 1.11.0329 = 1.1362 kg/cm2

Working temperature 441 0K

Design temperature 457.8 0K

Shell material - IS: 2002-1962 Grade I Plain Carbon steel

Permissible tensile stress (ft) 950 kg/cm2

Elastic Modulus (E) 1.88105 MN/m2

Insulation material - asbestos

Insulation thickness 2= 50.8 mm

Density of insulation 575 kg/m3

Top disengaging space 0.3 m

Bottom separator space 0.4 m

Weir height 50 mm

Downcomer clearance 25 mm

HEAD - TORISPHERICAL DISHED HEAD:

Material - IS: 2002-1962 Grade I Plain Carbon steel

Allowable tensile stress = 950 kg/cm2

SUPPORT SKIRT:

Height of support 1 m

Material - Carbon Steel


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TRAYS-SIEVE TYPE:

Number of trays = 9

Hole Diameter = 5mm

Number of holes:

Enriching section = 6981

Stripping section = 10726

Tray spacing:

Enriching section: 500 mm

Stripping section: 500 mm

Thickness = 3 mm

SUPPORT FOR TRAY:

Purlins - Channels and Angles

Material - Carbon Steel

Permissible Stress = 1275 kg/cm2

1. Shell minimum thickness:

Considering the vessel as an internal pressure vessel.

ts = ((PDi)/ ((2ftJ)- P)) + C

where ts = thickness of shell, mm

P = design pressure, kg/cm2

Di = diameter of shell, mm

ft = permissible/allowable tensile stress, kg/cm2

C = Corrosion allowance, mm

J = Joint factor


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Considering double welded butt joint with backing strip

J= 85% = 0.85

Thus, ts = ((1.13621990)/ ((29500.85)- 1.1362)) + 3 = 4.556 mm

Taking the thickness of the shell as minimum specified value= 6 mm

2. Head Design- Shallow dished and Torispherical head:

Thickness of head = th = (PRcW)/ (2fJ)

P =internal design pressure, kg/cm2

Rc = crown radius = diameter of shell, mm=1990mm

W=stress intensification factor or stress concentration factor for torispherical head

W= (3 + (Rc/Rk)0.5)

Rk = knuckle radius, which is at least 6% of crown radius, m

Rk = 6% Rc = 0.061990 = 119.4 mm

W= (3 + (Rc/Rk)0.5) = (3 + (1/0.06)0.5) = 1.7706 mm

th = (1.136219901.7706)/ (29500.85) = 2.7538 mm

including corrosion allowance thickness of head is taken as 6 mm

Pressure at which elastic deformation occurs

P (elastic) = 0.366E (t/ Rc)2

= 0.3661.88105 (6/1990)2

= 0.6255 MN/ m2 = 6.3761kg/cm2

The pressure required for elastic deformation, P (elastic)> (Design Pressure)

Hence, the thickness is satisfactory. The thickness of the shell and the head are made

equal for ease of fabrication.

Weight of Head:

Diameter = O.D + (O.D/24) + (2sf) + (2icr/3)


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Where O.D. = Outer diameter of the dish, inch

icr = inside cover radius, inch

sf = straight flange length, inch

From table 5.7 and 5.8 of Brownell and Young

sf =1

icr = 1

Also, O.D.= 1990 mm = 78.35

Diameter = 78.35 + (78.35/24) + (21) + (21/3) =

d = 84.45 = 2144.97 mm

3. Shell thickness at different heights

Axial Tensile Stress due to Pressure:

fap = PDi/4(ts -c) = 1.13621990/4(6 - 3) = 188.38 kg/cm2

This is the same through out the column height.

Compressive stress due Dead Loads:

3.2 a Compressive stress due to Weight of shell up to a distance X meter from top.

fds = weight of shell/cross-section of shell

=(/4)x(Do2- Di

2)xpxX/(/4)x(Do

2- Di

2)

fds=0.85x Xkg/cm2


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3.2 b Compressive stress due to weight of insulation at a height X meter

fd(ins)= Dins tins ins X/ Dm (ts - c)

Where

Dins, tins, ins are diameter, thickness and density of insulation respectively.

Dm = (Dc+ (Dc+2ts))/2

Dins =Dc+2ts+2tins = 199+ (20.6) + (25.08) = 201.216 cm.

Dm = (199+ (199+ (20.6)))/2 = 199.6 cm.

fd(ins) = 201.216 5.08575X/ 199.6 (0.6 - 0.3)= 9815.5 X kg/m

2

3.2c Stress due to the weight of the liquid and tray in the column up to a height X meter

fd, liq. = weight of liquid and tray per unit height X/Dm (ts - c)

The top chamber height is 0.3 m and it does not contain any liquid or tray. Tray spacing is 500

mm.

Average liquid density = 984.67 kg/m3

Liquid and tray weight for X meter

fliq-tray =[2X + 0.4] 3062.97 kg

fd (liq) = Fliq-tray 10/ (Dm (ts - c))

= [2X + 0.4] 3062.97 10/ (1996 (6 - 3))

fd (liq) = 3.26X + 0.653 kg/cm2

3.2d Compressive stress due to attachments such as internals, top head, platforms and ladderup to height X meter

fd (attch.) = weight of attachments per unit height X/Dm (ts - c)

Now total weight up to height X meter = weight of top head + pipes +ladder, etc., Taking the weight

of pipes, ladder and platforms as 25 kg/m = 0.25 kg/cm

Total weight up to height X meter = (170.19+25X) kg


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fd (attch.)= (170.19+25X) 10/ 199 (6 - 3) = 0.907 + 0.133X kg/cm2

Total compressive dead weight stress:

fdx = fds + fins +fd (liq) + fd (attch)

= 0.85X + 0.98155X + [3.26X+0.653] + [0.907 +0.133X]

fdx = 5.225X + 1.559 kg/cm2

4. Tensile stress due to wind load in self supporting vessels:

fwx = Mw /Z

where Mw = bending moment due to wind load = (wind load distance)/2

= 0.7PwDX2/2

Z = modulus for the section for the area of shell

Now Pw = 25 lb/ft2

= 122.06 kg/m2

Bending moment due to wind load

Mwx = 0.7122.061.99X2/2 = 170.03 kg-m

fwx= 1.4122.06X2 /1.99 (6-3) = 3.075X2 kg/cm2

5. Stresses due to Seismic load:fsx = Msx /Dm2 (ts-c)/4

Where bending moment Msx at a distance X meter is given by

Msx = [CWX2/3] [(3H-X)/H2]

Where C = seismic coefficient,

W= total weight of column, kg

H = height of column

Total weight of column = W= CvmDmg (Hv+ (0.8Dm))ts10-3

----- (eqn.

13.75, page 743, Coulson and Richardson 6th

volume)

Where W = total weight of column, excluding the internal fittings like plates, N

Cv = a factor to account for the weight of nozzles, manways, internal

supports, etc.


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= 1.5 for distillation column with several manways, and with plate Support

rings or equivalent fittings

Hv = height or length between tangent lines (length of cylindrical section) g =

gravitational acceleration = 9.81 m/s

2

t = wall thickness

m = density of vessel material, kg/m3

Dm = mean diameter of vessel = Di + (t 10-3

)

= 1.99+ (6 10-3) = 1.996 m

W= 1.585001.9969.81 (4+ (0.81.996))610-3 = 26341.28 N

Trays:The trays are standard sieve plates throughout the column. The plates have 6981

holes in Enriching section and 10726.11 holes in the Stripping section of 5mm

diameter arranged on a 15mm triangular pitch. The trays are supported on purloins.


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CHAPTER 11

PLANT

LAYOUT


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PLANT LAYOUT

A preliminary site layout has been sketched. The layout of the plant is decided keeping the

following factors in mind.

The safety regulation should be followed. There should be minimum possible distance between equipment to facilitate the

transfer of material.

Economic considerations should be taken into account like optimum distributionof equipment and services.

Operational convenience is very important. Possibility for future expansion should be kept in mind. The main cabin room should be located away from the main plant. In order to improve the aesthetic look for the plant, a garden may be provided . It

also helps to maintain better work environment.

The utilities and storage facilities are segregated from the main body of the plant. A separate

gate may be provided in this area. This gate can be used for trucks and tankers carrying the raw

materials, cooling water.

The units in the plant are the main plant, administrative building, utilities, canteen etc. The

vessel should be located close to the entry and exit point of the plant to facilitate loading and un

loading. The fire engines have easy access to all parts of the plant in case of any accidents.

Prevailing the wind conditions should also be considered in the relative locations of equipment.


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CHAPTER 12

HAZOP

STUDY


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HAZOP

(Hazards and operability studies )

The HAZOP study is formal procedure to identify hazards in a chemical process faculty.

The procedure is effective in identifying hazards and is well accepted by the chemical industry.

The basic data is to let the mind go free in a controlled fashion in order to consider all

possible ways that process and operational failures can occur.

Before HAZOP study started , detailed information on the process must be available.

This includes up-to-date process flow diagrams (PFDs), process and instrumentation diagrams

(P & Ids).Detailed equipments specifications, MOC & Mass & energy balances.

Here as far as our project is concerns the main hazards can from reactor itself where the

endothermic reaction is carried out.

HAZOP Study Table For The Reactor

Guide

word

Causes Consequences Action

NO 1. Controlvalve

fails.

2. Controller fails

and

closes

valve.

Temperature in ReactorDecreases.

Temperature in ReactorDecreases.

1. Install a buypassvalve.

2. Put a controllerin critical list.

MORE 1. Controlvalve

fails to

Temperature increases in Reactorrapidly.

Temperature increases in Reactor

1. Instruct operatoron procedure.

2. Instruct operator


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open.

2. Controller fails

and

open

valve.

rapidly. on procedure.

LESS 1. Controlvalve

fails to

respond

&partial

ly open.

2. Partialsteam

source

failure.

Temperature decreases slowly. Temperature decreases slowly.

1. Install bypassvalve.

2. Install backupboiler service.

AS

WELLAS

1. Leak inreactorbody.

2. Pressurein

reactor

less than

pressure

in

jacket.

Dilution of content. Temperature increase evaporation

of content.

1. Install highpressure alarm .

2. Install properrelief valves .

3. Check formaintenance.


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REVE

RSE

1. Reverseflow of

reactant

2. Reverseflow of

product

Failure of coolant source resultingbackflow

Backflow due to back pressure

Use of nonreturn or check

valve in coolant

line

Install hightemperature

alarm to alert

operator

Part of Partial cooling Covered under LESS --------


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CHAPTER 13

PROJECT

COST

ESTIMATION


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COST ESTIMATION

Acceptable plant design must present a process that is capable of operating under conditions,

which will yield profit. Since net profit equal total value minus all expenses, it is essential that

the chemical engineer be aware of the many different types of cost involved in the manufacturing

processes. Capital must allocate for the direct, plant expenses, such as those for raw material,

labor and equipment.

Money is worth hence must be spent where required in a definite foolproof manner. For any

project the cost is of prime importance. The cost estimation is required so as to study about the

financial requirements, so that no future financial crisis should occur, for any project.

Total investment = fixed capital + working capital

FIXED CAPITAL:

A) LAND & BUILDING

Area of building = 1000 m2

No. of building = 5

Therefore plant area = 5 x 1000

= 5000 m2

The cost of plant area = plant area x Rs. 1500/m2

= 5000 x 1500

= 75,00,000 Rs.

Cost per building = area of building x 2000Rs.

= 5000 x 2000

= 1,00,00,000Rs.

Total cost of land = 1,75,00,000Rs.


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B) MACHINARY & EQUIPMENTS:

EOUIPMENT NUMBERS COST IN Rs.

REACTOR 1 30,00,000

CONDENSER 1 75000

DISTILLATION COLUMN 1 4,00,000

DAY TANK 1 1,00,000

AUTOCLAVE 1 30,00,000

HEAT EXCHANGER 1 2,00,000

PUMPS 4 40,000

TOTAL M/C COST = 68,15,000Rs.

C) OTHER FIXED AMOUNT :

Installation of equipments = 10% of m/c cost = 0.1 x 68,15,000

= 6,81,500 Rs.

Instrumentation and control = 7% of m/c cost = 0.07 x 68,15,000

=4,77,050 Rs.

Piping (ISA approval) = 9% of m/c cost = 0.09 x 68,15,000

= 6,13,350Rs.


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Total cost = equipment cost + (A) + (B) + (C)

= 68,15,000 + 6,81,500 + 4,77,050 + 6,13,350

= 85,86,900Rs.

D) PRELIMINARY & PREVENTIVE EXPENSES:

Training cost = 10,000Rs. Legal expenses =12000 Rs. Marketing expenses = 15000Rs. Production expenses = 10000 Rs. Telephone deposits = 10000Rs. Advertising = 10000 Rs. Electrification deposits = 10000 Rs. Fright & Insurance charges = 25000 Rs. Project report = 10000 Rs. ISO certificates = 25000 Rs. Miscellaneous = 10000 Rs.

TOTAL COST = 1,47,000 Rs.

TOTAL FIXED CAPITAL = 1,75,00,000 + 85,86,900 + 1,47,000

= 2,62,33,900Rs.


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WORKING CAPITAL:A) ADMINISTRATIVE EXPENSES:

Position People required Salary (lakhs./annum)

Total

(lakhs./annum)

General Manager 1 12 12.0

Assistant Manager 2 7 14.0

Engineers 3 3 9.0

Chemists 1 2 2.0

Plant Operators 30 1.5 45.0

Typists 2 0.8 1.6

Clerk 2 1.0 2.0

Accountant 1 1.5 1.5

Receptionist 1 1 1.0

Store Keeper 3 1 3.0

Unskilled workers 20 0.8 0.8

Watchmen 3 0.8 2.4

Drivers 3 0.8 2.4

TOTAL = 96,80,000 RS.


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B) RAW MATERIAL COST:

CHEMICAL QUANTITY(Kg.) RATE PER Kg. TOTAL COST(Rs.)

METHANOL 52,64,304 32 16,84,57,728

ANILINE 34,75,964 25 6,43,13,852

CATALYST 12500 45.75 32,52,000

TOTAL COST 23,27,81,580

C) UTILITIES COST:

UTILITIES COST PER YEAR(IN Lakhs)

ELECTRICITY 15

COOLING WATER 7.5

STEAM 10

TOTAL COST 32.5

TOTAL COST OF WORKING CAPITAL = 23,27,81,580 + 96,80,000 + 32,50,000

= 24,57,11,580Rs.

TOTAL INVESTMENT = FIXED CAPITAL + WORKING CAPITAL

= 2,62,33,900 + 24,57,11,580

= 27,19,45,480Rs.


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SELLING PRICE OF PRODUCT (DMA):

Production per day of DMA = 100tonn = 100000 kg

Cost per kg = 95Rs.

Selling price per annum = 100000 x 95 x 300= 13,50,00,000 Rs.

Net profit = selling pricetotal investment= 28,50,00,000 27,19,45,480

= 1,30,54,520 Rs.

Rate of return = net profit / total investment= 1,30,54,520 / 27,19,45,480

= 0.048

Profit percent = 0.048 x 100= 4.8%

Payback period = Total capital investmentGross profit

=

= 20.83 year

Profit marginAssuming 100% capacity utilization

Profit margin =

100

= 4.83%


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CHAPTER 14

CONCLUSION

&

REFERENCES


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CONCLUSION

This report gives a pre-preliminary feasibility study of a plant manufacturing of Dimethyl

aniline to be set up in India. Alkylation of aniline is the manufacturing process selected which

gives good yield and purity.As a part of this report, the basic Mass Balance, Energy Balance, Process and

Instrumentation, Process Designing was included to give an analysis of the feasibility of the

project.

The estimated cost of the project was found to be Rs. 27.18 Crores. A payback period of

20.83 yrs is expected with a return on investment (ROI) of 4.8 %, assuming 100% capacity

utilization. By seeing the payback period and the profits, it seems that the project is economically

attractive and profitable.

In this analysis several assumptions have been made including that of an ideal market

with all that is produced being sold. Also, product prices have been assumed to remain constant.

To get a clearer picture a detailed feasibility report has to be done. However the

preliminary study does provide sufficient reason to conduct a detailed analysis to come at exact

figures.

This pre-preliminary feasibility report thus calls for and justifies the need for a more

detailed and rigorous analysis of the project in terms of the market demand for the product, the

actual yields from the process and the saleability of the product.


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Bibliography

ROBERT THORNTON MORRISON AND ROBERT NEILSON BOYD,ORGANICCHEMISTRY,SIXTH EDITION.

JAMES G. SPEIGHT, CHEMICAL AND PROCESS DESIGN HANDBOOK. Shreves Chemical process Industries Perrys Chemical Engineers Handbook, Robert H. Perry, Don W. Green 7th Edition. M. V. Joshi & V. V. Mahajani, Process Equipment Design Beigler, Grossman and Westerberg, Systematic Methods of Chemical Process Design. R.K.Sinnott, Coulson & Richardson, Chemical Engineering Design - Volume 6.

Webliography

www.google.com www.wikipedia.com www.britannica.com www.compositesaustralia.com toxnet.nlm.nih.gov ScienceLab.com
http://www.google.com/http://www.google.com/http://www.wikipedia.com/http://www.wikipedia.com/http://www.britannica.com/http://www.britannica.com/http://www.compositesaustralia.com/http://toxnet.nlm.nih.gov/http://toxnet.nlm.nih.gov/http://toxnet.nlm.nih.gov/http://www.compositesaustralia.com/http://www.britannica.com/http://www.wikipedia.com/http://www.google.com/

Documents

Dimethyl Aniline