A report on Economic Feasibility for a chemical Process.(For details on Appendices,contact me!)
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The cumene production project analysis indicates economic feasibility with a pay-back period of approximately 7 years. Equipment sizes and cost estimations have been calculated, resulting in total capital costs of $2,300,612.13 and a profit of $1,110.00/hr, making the operation viable. Safety considerations are integrated into the design to minimize risks, including low-pressure steam use and strategic placement of equipment.
A report on Economic Feasibility for a chemical Process.(For details on Appendices,contact me!)
- 1. 1 P a g e 0 | 5 CUMENE PRODUCTION REPORT ON ECONOMIC FEASIBILITY AND SAFETY PROJECT WORK -II PROCESS ANALYSIS AND SIMULATION| CL424 SEMESTER II, 2015-16 IIT GANDHINAGAR BY, PARAG PATIL|15310003
- 2. PAGE 1 INDEX Sr.No Topic Page No 1 Summary of Process and Work 1 2 Sizes of process equipments 2 3 Cost Estimation: Capex, Opex and Profit 4 Safety considerations in design
- 3. PAGE 2 1. SUMMARY OF PROCESS AND WORK As per the analysis carried out, the process is economically feasible,as it is having a pay-back period of 7 years (approx), (Assuming full year of work as discussed in APPENDIX) As per the problem statement ,a process of cumene production from a waste-water stream is suppose to be simulated in ASPENPLUS using NRTL-RK method. The CONSTRAINS for my work were as follows: Sr.No. Constrain Required Value Achieved Value 1 Cumene Conversion in Product stream 0.997(Roll Number Specific) 0.999 2 Exit Temperature of Cold-Out stream 97 0F(Roll Number Specific) 97 0F 3 Waste- Gas Stream, Max flow 37lbmol/hr(As per PCB rule) 36.980lbmol/Hr Beside this , a profit was to be maximixed with the Optimization tool in ASPEN.The Costs for the streams were provided and Utility-Cost was taken from Turton et al(2009). Maximization of the profit is done with using following parameters: 1. Using refrigerent with low cost (As stated in APPENDIX) 2. Using steam at lower pressure of 5kg/cm2(g) 3. Using Aspen tool of optimization by varying Reflux Ratios and length of the reactor (to reduce CAPEX). The safety is also considered while designing the process,discussed later on
- 4. PAGE 3 2. SIZES OF PROCESS EQUIPMENTS The sizes of all the equipments were calculated with mass balances, rule of thumbs (Like L/D=4,rule)and standard procedures given in the reference to Systematic Methods of Chemical Process Design by L.T.Beigler et al,1997. Following are the equipments with their sizes Sr.No. Equipment Size/Area Diameter Height 1 Flash-Tank (vertical) 1.7m 6.8m 2 Cooler (Heat Exchanger) 6.40m2 3 Pre-Heater 4.18m2 4 Plug-Flow Reactor 0.365m 5.18m 5 BZ-Column(D-01) 4.91m 20.478m 6 Cum-Col(D-02) 3.650m 12.858m Following major equipments were not considered for sizing, however the cost estimation for operation is considered for them 1. Reboilers and Condensors for distillation columns 2. mixing equipments As it is assumed that these equipments will be in-sourced and since the costing based on this is prelimanary, the effect will be adjusted within the assumed range of cost-variation of ±40%.
- 5. PAGE 4 3. COST ESTIMATION:CAPEX,OPEX & PROFIT Following cost estimation is done with the help of above sizing and the costs given in the problem statement as well as the utility costs taken from Turton et al,2009.The cost index of 5.22 is asumed for the year of 2016, and the procedure for the cositng is taken from Systematic Methods of Chemical Process Design by L.T.Beigler et al,1997. Following is the Capex for the simulated process in Aspen Sr. No. Equipment Cost in Dollars 1 Flash tank 40277.2999 2 BZ-Column 1267288.817 3 Cum-Column 636700.3791 4 Cooler 3045.1067 5 Pre-Heater 2684.385657 6 Reactor 4536.090918 7 Tray Stack for BZ-Column 82926.00991 8 Tray Stack for Cumene Column 263154.0378 Total Capital Cost 2300612.127 The Opex is first done on hourly basis, which is further extended to year to calculate the payback period for the whole process.I have assumed the Refrigeration and steam for cooling/(chilling) and Heating respectively. The selling prizes and cost for Raw material,utility is also tabulated as follows: Cooling/Chilling cost for refrigeration $276.14/Hr Steam Cost for heating $366/Hr Cumene (Production) $6456.88/Hr Propylene (Raw Material) $5024/Hr The Profit we can make from this process comes out to be $1110.0/Hr, which is sufficient to pay back the whole Capex in 4.5 years (approximatly).
- 6. PAGE 5 4. SAFETY CONSIDERATIONS IN DESIGN The process is designed by keeping safety considerations in mind.Some of them are as follows 1. The steam is utilized but with low pressure (6kg/cm2(g)), So the person coming in contact with it will have to face less trauma. 2. The process water is avoided and instead taken refrigeration system into account so that the temperature in the pipeline of cooling will remain within 5-12.5 degreeC. 3. Overall process pressure is well within 20psig, hence the explosion chance is quite less. While preparing layout and designing the plant, a care should be taken to avoid the accidents as follows: 1. Boiler section can be kept sufficiently away from the process area 2. The cumene reactor and distillation column will safely kept away from rest of the plant with equipped fire extenguishers as it is highly flammable (MSDS of Cumene is in APPENDIX),rating pf health safety is 3 on the diamond Apart from design aspects of safety the plant personnel can be briefed with the possible hazards of the chemicals and process to avoid the accidents.