MANUFACTURE OF PHENOL FORMALDEHYDE RESINA PROJECT REPORT Submitted by URMILA.K (41502203018) VARUN RATHI (41502203019) in partial fulfillment for the award of the degree of BACHELOR OF ENGINEERING in CHEMICAL ENGINEERING S.R.M ENGINEERING COLLEGE, KANCHEEPURAM ANNA UNIVERSITY:: CHENNAI 600 025 MAY 2006 i ANNA UNIVERSITY: CHENNAI BONAFIDE CERTIFICATE Certified that this project report “MANUFACTURE OF PHENOL FORMALDEHYDE RESIN” Is the bonafide work of “URMILA.K (41502203018) and VARUN RATHI (41502203019)” who carried out the project work under my supervision. SIGNATURE SIGNATURE Dr.R.KARTHIKEYAN HEAD OF THE DEPARTMENT Dr.R.KARTHIKEYAN Professor and Head & Dr.B.S.M. KUMAR Professor CHEMICAL ENGNEERING ENGINEERING S.R.M.Engineering College Kattankulathur-603203 Kancheepuram District CHEMICAL S.R.M.Engineering College Kattankulathur-603203 Kancheepuram District ii ACKNOWLEDGEMENT It is pleasure and privilege for us to present this project report, before which we would like to thank all those who supported and guided us at the various stages of this project. We express our sincere thanks to our guides DR.R. Karthikeyan B.E., Ph.D, Professor and Head of the Department of Chemical Engineering , and Dr.B.S.M.Kumar, M.sc., M.Tech.,Ph.D., Professor, Department of Chemical Engineering, S.R.M Engineering College, for their outstanding guidance, constant encouragement and support, apart from their ideas and approach which has helped us complete this project . We would like to mention special thanks to Dr.V.E.Annamalai, Dr.I.A.P.S Murthy, of Carborundum Universal Ltd., For giving us opportunity in gaining practical knowledge in recent industry. We would like to thank all the staff members of our department for their endless suggestions and guidance towards the completion of this project. ABSTRACT Phenol-formaldehyde resins belong to the class of thermo set resins. These are known for their outstanding heat resistance. PF resins are of two types-resoles and novolaks – depending on the phenol-formaldehyde ratio. They can be manufactured in both liquid and powder form. The raw materials which are charged in the reactor at room temperature undergo an exothermic reaction for two hours. Continuous vacuum distillation takes place for about 6 hours , till the required viscosity is attained. Thus the phenol formaldehyde resin, of resole type is manufactured, as proposed . iii TABLE OF CONTENTS CHAPTERS TITLE ABSTRACT LIST OF TABLES LIST OF FIGURES LIST OF SYMBOLS PAGE NO. iv vii viii ix 1 2 INTRODUCTION PROPERTIES 2.1 PHYSICAL PROPERTIES 2.2 CHEMICAL PROPERTIES 1 3 3 4 6 8 10 12 16 22 26 29 40 42 52 60 64 65 66 3 4 5 6 7 8 9 10 11 12 13 14 APPLICATION LITERATURE SURVEY 4.1 PROCESS SELECTION PROCESS DESCRIPTION 5.1 EFFLUENT TREATMENT MATERIAL BALANCE ENERGY BALANCE DESIGN PROCESS CONTROL PLANT LAYOUT COST ESTIMATION SAFETY STORAGE AND TRANSPORTATION CONCLUSION BIBLOGRAPHY iv LIST OF TABLES TABLE NUMBER 2.1 5.1 7.1 8.1 11.1 11.2 11.3 11.4 DESCRIPTION Physical properties Viscosity test calculation of heat content Heat transfer data Delivered cost of equipments Direct cost factor Indirect cost factor Auxillary cost factor LIST OF FIGURES PAGE NO. 3 13 26 34 52 53 53 54 FIGURE 5.1 FIGURE 5.2 FIGURE 6.1 FIGURE 6.2 FIGURE 7.1 FIGURE 7.2 FIGURE 10.1 FLOW SHEET FLOW SHEET REACTOR BALANCE CONDENSER BALANCE ENERGY BALANCE FOR A REACTOR ENERGY BALANCE FOR A CONDENSER PLANT LAYOUT 15 21 22 24 26 28 51 LIST OF SYMBOLS A D,d L Area(m2) Diameter(m) Length (m) v H m Nu n P Pr Re V T U Cp K f tsk W Cv GREEK LETTERS ∆T µ λ ρ Height (m) Mass (kg) Nusselt number Number of tubes Pressure Prandtle number Reynolds nymber Volume Temperature Overall heat transfer Coefficient (W/m2ºC) Specific heat capacity (KJ/KgK) Thermal conductivity (W/Mk) Shear stress Skirt thickness (mm) Weight of the reactor (N) Correction factor Temperature difference(ºC) viscosity of liquid Latent heat of vapourisation (KJ/Kg) vi . horn and celluloid. Phenolic resins mixed with fillers could be hardened in a press or autoclave. infusible products being obtained only if the formaldehyde was used in excess. Even from his first patent application of feb 18. it was clear that baekland . Henschke granted a patent to him in the USA vii . preferably ammonia.1.INTRODUCTION HISTORY Leo H. According to a patent application by lebach in February 1907 insoluble and infusible condensation products. under pressure at temperature below 100 * c in a considerably short time and without the formation of blisters. According to the first bakelite patent phenol and formaldehyde. economic of molded parts are not yet possible. So that when bakelite started with phenolic resins the following were already know. useful as plastic materials. However . These may be permanently fusible and soluble in organic solvents or heat curable depending upon the preparation conditions. more than his predecessors was fully aware of the value of the phenolic resins. ebonite. Soon afterwards he recommended the impregnation of the cellulosic fibers with liquid phenolic resins. can be mixed with fillers and under the influence of heart shaped in molds into solid parts. acid catalyzed resins were being used at this stage. In the same year bakeland also patented a process for the preparation of phenolic resins using alkaline catalyst. The “heat and pressure” patent became the turning point . NaOH and Na2CO3. These are colorable . indicating clearly the importance of economic processing techniques for market acceptance. 1907. Phenolic resins were already being sold as substitutes for shellac.Bakeland applied for his famous “heat and pressure” patent for the processing of phenol formaldehyde resins. which was called bakelistor. The impregnation of the fibrous material can be improved by application of vacuum and pressure. Phenols and formaldehyde are converted to resinous products in the presence of acidic and alkaline catalysts. catalyst and fibrous cellulosic material were reacted at elevated temperature. This technique made possible the worldwide application of the first wholly synthetic polymer material. could be obtained if phenol is reacted with surplus formaldehyde using neutral or basic salts as catalysts. 0.59. Ultimate Elongation at Break Tensile Modulus Flexural Modulus Flexural Yield Strength Compressive Yield Strength Poisson's Ratio Charpy Impact.2 J/cm² viii .0065 cm/cm 75 .7 .0. PROPERTIES 2.0. Rockwell E Tensile Strength.13 GPa 7.95.1 Physical properties Physical Properties Density Apparent Bulk Density Water Absorption Linear Mold Shrinkage Hardness.1.2 .8.36 .9 % 7.6 MPa 187. More than 2/3 of all phenolic resins are used in these three fields.5 . molding and insulation compounds. that resin manufacture was described for the first time just as it is carried out today. however.003 . But also all classic application established by bakeland could maintain their position. the most important fields of application are the wood industry.3 GPa 80. ⇒ The reaction is performed in a closed vessel with a reflux condenser to prevent loss of volatile material.19 .1 .0. ⇒ The reaction is interrupted when the desire viscosity is obtained. which is still soluble in alcohols is obtained.68 g/cc 0.5 MPa 0.36 0. Today.64 . It was in this patent.0.83 50.but not in Germany because of the lack of inventive steps considering previous publications. 2.7 MPa 0.07 .22 .51 g/cc 0. Notched Metric 1.198. ⇒ Distillation is performed in a vacuum and can be continued until a solid product.9.39 .54 % 0. 2)ACTION OF HEAT The base catalyzed reaction of phenol with formaldehyde produces Intermediates which condense into branched polymers (resoles) at temperatures of between 60 and 100 ‘C .7 kV/mm 0. 2. thermoset cure is a kinetically controlled process while after vitrification it is a diffusion-controlled process and the reaction rate decreases dramatically. Thermo set cure usually involves polymerization and cross linking.054 80 .13. infusible.2 . It marks the transition between the liquid and gel state. Air Flammability. Before gelation. UL94 4. linear 20°C Maximum Service Temperature.032 .2 . and water resistant. An investigation of ix . Vitrification marks the transition from a liquid or rubber to a glass. Gelation occurs when a three dimensional network structure with infinite viscosity is formed. Understanding adhesive cure behavior and its dependence on the temperature and chemical conversion is important for predicting processing windows and the properties of cured bond lines. scratch resistant.205 °C HB Phenol formaldehyde resin is hard.150 sec 175 V 53 µm/m-°C 182 .58139e+013 ohm-cm 5.5.0. Vitrification occurs when the glass transition temperature of the thermosetting (pf) material rises and equals the cure temperature.2 Chemical Properties 1) Overview of PF Cure Cure behavior is one of the most important characteristics of thermosetting adhesives.9 10.Electrical Resistivity Dielectric Constant Dielectric Strength Dissipation Factor Arc Resistance Comparative Tracking Index CTE. as it passes through two stages: gelation and vitrification.14e+012 3. rods and tubes for hundreds of industrial applications in the electronics. 3. electrical plugs and switches. Major use categories of phenolic resins are. while CH4 which is the major volatile product from the thermal degradation of the resin. APPLICATIONS Phenolics are little used in general consumer products today due to the cost and complexity of production and their brittle nature. is evident only at temperatures above 550° C. such as molded disc brake cylinders. Micarta is produced in sheets. 7) Flammability: Phenol formaldehyde is generally un flammable. Molding materials. 5) Toxicity : Oral LD50 : 9200 mg/kg (rat) 6) Ecological effects: Can be separated mechanically in water treatment plants. He Concluded that the primary degradation pathway for PF resins is oxidative in nature even in an oxygen deficient atmosphere and that thermal processes only begin to compete at higher temperatures. saucepan handles. An exception to the overall decline is the use in small precision-shaped components where their specific properties are required. Bakelite is manufactured under various commercial brand names such as Micarta. Today. and electrical iron parts. salts and many organic solvents. power generation and aerospace industries. No decomposition at ordinary temperatures. The discovery by bakeland that wood flour compounded with phenolic resins could be molded under heat and pressure to give a strong x .The degradation properties of PF resins was conducted by Cordey . 4) Stability: Phenol formaldehyde is very stable. 3) Action of acids: Phenol formaldehyde is resistant to non-oxidizing acids. The presence of CO is first detected at about 350 ‘C. The major categories are automotive brake linings. was the start of phenolic resin industry. power derricks. Liquid one step resins and solvent solutions of one step resins are used to make laminated structures. Bonded abrasives. Laminates. Resins used as the sole reactive ingredient are alkaline catalyzed one step phenol formaldehyde resin. and inorganic fibers for insulation. Foundry use. Coated abrasives. Phenolic resins are used in coatings both as the sole film former and to fortify drying oils. BONDING RESINS: This market area includes the use of phenolic resins to bond friction materials. Phenolic resins have replaced hide glue for industrial grades of “sand paper” where heat is generated in dry grinding or where water-cooling is required. wood particles. Coatings. xi . Two general classes are recognized: Industrial and decorative. but a wide variety of other products are made. About half of oil grinding wheel tonnage is resin bonded. the phenolic resins being used almost exclusively.g. abrasives. Phenolic resins are used to bond glass and rock wool fibers for thermal and acoustic insulation.heat resistant part that would not crack or split apart on aging. Friction materials. Phenol formaldehyde resins for plywood glues are alkaline – catalyzed liquid one step resins. Plywood. and automatic –transmission discs. Resins have replaced the various ceramic bonds because resinoid wheels can withstand more mechanical and thermal shock. Insulation. Phenol Formaldehyde resins is the principal bonding agent for the asbestos used in friction materials. e. and rail road cars. brakes for oil well drilling rigs. clutch facings. Phenolic resins are employed in several metal casting applications. PF resins were first introduced as binders for particleboard and plywood in the mid 1930’s. adhesives. Almost all PF resins currently used in wood bonding applications are resoles. especially for exterior applications. coatings. Resoles and novolaks are inherently different: resoles are heat curable while novolaks require addition of a cross linking agent such as hexamethylenetetramine (HMTA) to cure. For most novolaks. It has become one of the most widely utilized synthetic polymers since Baekeland developed a commercial manufacturing process in 1907. are currently used as binders for the manufacture of an important structural wood panel. in either a liquid or a spray-dried form. this additional step results in slower cure rates and lower cross linking than resoles . two classes of PF resin can be synthesized: resoles (resols) and novolaks (novolacs). weather resistance.e. oriented strand board (OSB). F/P<1). Resoles are synthesized under basic conditions with excess formaldehyde (i. Compared to polymeric diphenylmethane diisocyanate (PMDI).78 million metric tons of resin solids consumed in the North American wood products industry. xii . PF resoles have the advantage of low cost. the only other binder currently used in OSB manufacturing in North America. In 1998.e. PF resoles.4. etc. F/P>1). PF resins comprised approximately 32 percent of the total 1. LITERATURE SURVEY Phenol-formaldehyde (PF) Overview Phenol-formaldehyde (PF) resin was the first wholly synthetic polymer to be commercialized (1). chemical resistance and dimensional stability. novolaks are synthesized under acidic conditions with excess phenol (i. PF resoles are desirable for exterior applications due to their rigidity. paper impregnates. Phenol-formaldehyde resin can be tailored to different properties suitable for various applications such as molding compounds. they have since become one of the most important thermosetting adhesives in the wood composites industry. By varying the catalyst type and the formaldehyde (F) and phenol (P) molar ratio. good thermal stability and reasonably fast cure. The polymeric form of formaldehyde. Formaldehyde is often used in the form of an aqueous solution during commercial production of PF resoles. An alkaline catalyst is added to initiate the reaction. Para formaldehyde. 4. After 2 hours of reaction continuous distillation takes place for 6 hours . which allows resoles to be synthesized with a high degree of advancement for fast curing. Phenol formaldehyde resin is been manufactured . while maintaining good process ability. The most commonly used catalyst in commercial resole preparation is sodium hydroxide (NaOH). Phenol and formaldehyde are charged into the kettle in specified quantaties. Importance of process selection has been the key tool for many of the manufacturing units. The two process are explained in brief below. Manufacture of phenol formaldehyde resin using alkaline catalyst. quality and within the cost to be produced.PF Resole Synthesis PF Resoles are polycondensation products of phenol (P) and formaldehyde (F) in an alkaline aqueous medium with excess formaldehyde. is rarely used in industrial processes due to its high cost. PF resoles used as wood binders are typically synthesized under 100oC with a formaldehyde/phenol (F/P) ratio of 2 to 1 .1 PROCESS SELECTION Process selection is an important criteria for any manufacturing unit. sodium hydroxide also improves the solubility of PF resoles in aqueous solution. Depending on the application of resin the required process can be chosen. The applications of the product defines the condition and changes required for manufacturing. Besides its catalytic effect. This selection gives direction to obtain the required product with high efficiency . The kettle is kept under continuous agitation. PF resins are manufactured in batch process. mainly by two process. Once the xiii . Exotherms are controlled and cooking temperature is maintained by circulating cooling water and by cooling oil within the pipe and the outer jacket respectively. The whole manufacturing process takes place under vaccum. vaccum is applied when temperature reaches to 120-150ºC. PROCESS DESCRIPTION This is a batch process.the acid catalyst is then added and the batch is tested for pH. sodium hydroxide. Vacuum is first created in the reactor kettle. Reactor consists of an outer jacket and a coil around its circumference. After charging phenol. It is mixed with necessary amount of water. Now. 5. formaldehyde is charged into the kettle. When the resin is completed . After achieving the viscosity/water tolerance . which is the catalyst. The molar ratio of phenol to formaldehyde is of 1:1. after the entire charging section is complete. condenser valve is opened. and then charging of phenol is done. The outer jacket carries the cooling oil for the first two hours of the reaction and the cooling water is circulated in the coil within the reactor for the same time. then the contents are discharged into specific containers. Phenol and formaldehyde are taken from the raw material storage room.steam heat is applied to raise the temperature . vaccum distillation is stopped and the reactor is cooled to below 40ºC. The product is kept in a cold room at below 10ºC till the time of dispatch.distillation starts heating oil is circulated in place of cooling oil. Before adding phenol. In a typical reaction reaction cycle molten phenol at 60-65ºC and warm 37-40% formaldehyde are charged to the kettle from weigh tanks. which takes place for about eight hours. is added.at the end of reflux period the condensate is re routed to a reciever and the water is distilled from the kettle.5. Now. Charging of raw materials in the reactor kettle takes place at 30°C. vacuum pressure is created and cooling water supply is started. Manufacture of phenol formaldehyde resin using acid catalyst Novolak resins are ordinarily manufactured by batch process in a jacketed acid resistant stainless steel kettles equipped with shell and tube vapour condensers and heavy duty achor or turbine blade agitator. As the stirring continuously takes place. the reaction temperature increases to about 102º C. Agitation is started and is continuous throughout the cycle.this heating is necessary for 3-6 hours. the reaction xiv . it is discharged .melting point or solution viscosity is used to test the sample for checking its completion. This is xv . thereby changing the phase of vapour to liquid and directing it towards the distillation receiver. the reaction continues for about 2 hours at the same temperature. as the reaction continues. The extent of the reaction or amount reacted is tested by WATER TOLERANCE TEST also known as GEL TIME TEST. The cooling oil and cooling water helps to control the reaction temperature at about 60-70ºC. after two hours of reaction.being an exothermic one.70°C. the reactor behaves as a distillation column and continuous condensation takes place. Distillation continues for about 6 hours at about 60 . Cooling is cut off and hot water and oil is circulated through the coils and outer jacket respectively. STEP: 1 C6H5OH + 2CH2O → C8H10 O3 STEP: 2 2n C8 H10O3 → [C8H8O2] n + n H2O OVERALL REACTION 2n C6H5OH + 4nCH2O → n C8H7O2Na + n H2O {naoh} Now. The distilled water is collected in the receiver. Condensation takes place in the condenser. Now. The viscosity check is done in FORKED VISCOMETER. The water tolerance reduces from infinity to 600. the resin is checked for its viscosity periodically. As the condensation takes place. This is taken and stored in the PVC containers and is stored in cool room at temperatures below 15°C. xvi . which contains some amount of phenol goes to the EFFLUENT TREATMENT PLANT. Thus semi solid resin. may be applied to sheets for subsequent lamination. The water from the distillation receiver tank. the distillation is stopped and the discharging is done at about 40-55°C. which may be dissolved in organic solvents such as alcohols and used as varnish or coating or it. TABLE NO 5. the viscosity of resin is measured as 3000 cpi from BROOKFIELD VISCOMETER.one of the widely used viscometer known for its accuracy and efficiency. The following table shows the values of the viscosity test. The discharged phenol formaldehyde resole contains about 20% water.1 TIME 15 SEC SAMPLE FIRST SAMPLE SECOND SAMPLE THIRD SAMPLE FOURTH SAMPLE 25 SEC 37 SEC 54 SEC Finally. 1 .1 15 xvii DISTILATION RECEIVER VACUUM TANK ETP RESIN RECEIVER 5.RAW MATERIAL 1 RAW MATERIAL 2 CO BALANCE ND EN SE R REACTOR WITH AGITATOR FIGURE 5. the equalisation tank is designed to hold 24 hours retention of effluent. the organic matter is degraded by aerobic micro organisms. Higher animals such as norms insects. shine longer. BIO FILTER A population of micro-organism attached to the filter media degrades the organic matters in the waste water.lime and polyelectrolyte solutions are added. anaerobic and facultative bacteria .organisms grow . xviii . PROCESS MICROBIOLOGY AND ANALYSIS The biological community in the filter consists primarly of protests including aerobic .The liquid then washes the slime of media and the new slime layer is called SLOUGHING and is primarly a function of organic and hydraulic loading on the filter. the thickness of the slime layer increases and the diffused oxygen is consumed before it can penetrate the full depth of the biological slime layer. larve and snails are also present .fungi. As the micro. Oil is separated by belt oil and skimmer mechanism .1 PROCESS DESCRIPTION OF EFFLUENT TREATMENT SCREENING AND EQUALISATON The effluent is screened in the bar screen and taken to the equalisation tank where the flow and parameters are equalised. As a result of having no external organic source available for cell carbon . as the slime layer increases in thickness the adsorbed organic matter is metabolised before it can reach the microorganisms near the media surface.algae and protozoa. the microorganisms near the media surface enter into an endogenous phase of growth and loose their ability to cling to the media surface. In the outer positions of the biological slime layer . Thus anaerobic environment is established at the surface of the media.5. The reacted effluent is allowed settled and the clear effluent is taken on furthur treatment to bio filter and where as a setteled sludge is applied on the sludge drying beds for disposal. CHEMICAL TREATMENT Then the equalised and neuralised effluent is pumped to the reaction cum settling tank where alum.The hydraulic loading accounts for the sheer velocities and the organic loading accounts for the rate of metabolism in the shine layer. Organic matter from liquid is adsorbed on to the biological film or. a portion of the organic material is synthesised into new cells. Suface aerators are provided to supply oxygen to the microorganisms . AEROBIC PROCESS The clear overflow of grvitates to the aeration tank for biological degradaiton. Fungi present are also responsible for the waste stabilization but their contribution is usually important only under low pH Conditions or. The main problem encountered is the design of bio filter is the dtermination of macimum organic material that can be applied to the filter before oxygen becomes a limiting variable. to completely mixed conditions. xix . Two stage bio filter is the envisaged for the treatment process. biological treatment system characterized by a suspension of aerobic microorganisms maintained in a realtively homogenious by mixing and turbulence induced in conjuction of aeration process. “ ACTIVATED SLUDGE “ describes a continous flow . A single stage extended aeration activated sludge system has been adopted for treatment of organics. During the oxidation process . The mixed liquor flows from the aeration tank to settling tank where the activated sludge is settled. the excess sludge is wasted. A part of the synthesised cells then undergo auto oxidation ( self oxidation or endogenous respiration) in the Aeration Tank. The aerobic micoorganisms degrade the solube and suspended organics in the effluent. Basically the Activated Sludge Process uses aerobic mocrorganisms in suspension to oxidise soluble and colloidal organics in the presence of molecular oxygen. In predicting the performance of bio filter the organic and hydraulic loading and the degree of purification required are the most important factors to be considered. A portion of the settled sludge is returned to aeration tank to maintain proper microorganisms (MLSS) concentration in aeration tank to permit rapid bio – degradation of organic matter . Waste water is received in aeration tank where aerobic microorganism is maintained in suspension. the protozoan are predominating of ciliate group and their function is to control the bacteria population.Facultative bacteria are the predominating microorganisms in the bio filter. The process of ACTIVATED SLUDGE PROCESS is to remove organics that ecape from the primary treatment. with certain induatrial wastes . Oxygen is required to support the synthesis and endogenous respiration reactions. a generalised kinetic model of the bio filter is very difficult to develop. Due to the unstable characteristics of the biological slime layer and the unpredictable hydraulic characteristics . The overflow from the aeration tank shall be settled in in secondary settling tank. The aerobic microbes are capable of utilising about 65-70% of the nitrogen in the feed. which only comprises of biological solids is rich in nitrogen and phosphorus. The overflow ffrom the aeration tank will contain a high concentration of solids. Nitrogen being avaliable in the form of Ammonia would be readily utilised by the microbes. In addition to the oxygen requirements the aerobic microbes require macro nutrients. The aeration tanks would be equiped with diffused aeration system to transfer oxygen to sustain the activity of microbes. A secondary clarifier helps in separating the microbes from the liquid stream to produce a high quality effluent . required oxygen necessary to sustain the activity of the microrganisms. the secondary clarifier also aids in maintaining a thick undeflow sludge concentrtion . SLUDGE TREATMENT AND DISPOSAL The sludge from the waste activated sludge from the extended aeration activated sludge plands shall be drained to sludge drying beds to dewater the sludge. nitrogen and phosphorus to sustain the microbial activity. The overflow from the secondary settling tanks shall be collected in a treated effulent sump to be taken up for furthur treatment and disposal. since this sludge.Sufficient numbers of aerators shall be installed in the aeration tank to transfer . crucial to the effective operation of the activated sludge process. The sludge drained to the sludge drying beds shall be allowed to dry for a period of about 7 days. The filtrate from the sludge drying beds shall be taken up for furthur treatment and disposal. Pressure land filter comprises of a mild steel pressure vessel containing the media. The solids settled in the primary settling tanks following neutralisation treatment shall be dried to the sludge drying beds and stored for safe land fillings. A portion of the settled sludge shall be recycled to maintain the desired mixed liquor suspended solids in the aeration tank. TERITARY TREATMENT PLANT After secondary clarifiaction the efluent is subject to filtration followed by activated carbon filtration. provided externally with valves and piping to direct and control flow of water during xx . Phosphorus on the other has to be supplemented with phosphorus salts. The dried sludge would be scrapped from the sludge drying beds and used as manure. The media is supported by layers of crushed gravel and graded pebbles of specific sizes. Filtered water leaves the filter uniformly by means of a bottom collecting system which also serves to distribute evenly the flow of water used to xlean the filter. After filtration the water is passed throught activated carbon filter for odour removal also excess chlorine removal. The internal syrface of sand media filter is painted with anti corrsosive bituminous paint. And inlet distributor in the form of inverted bell-mouth funnel directs the inflow of raw water upwards towards thew top dished ends to ensure even distributon across the surface area of filter beds. Activated carbon filter comprises of a mild steel pressure vessel containing the media. The bottom collecting system is either a false bottom type or either a header with perforated laterals depending on the type of filter and diameters. xxi .treatment and for cleaning. The media is supported by layers of crushed gravel and graded pebbles of specific sizes. provided externally with valves and piping direct and control flow of water during treatment for cleaning. flash mixer sludge Recycle tank Bio Filter .FLOW SHEET Raw Effluent Bar Screen FeSO4.2 Aeration tank Settling Tank Collection Tank Dual Media Filter Sludge Filtrate to recycle tank Fig 5.2 flow sheet xxii .1 Bio Filter .Lime Raw effluent collection tank Batch settler . 2% Reactant side : Resin Resin = 1413kg Unreacted phenol = 94kg Unreacted CH2O= 60kg Unreacted water= 1164 kg Reactor xxiii . MATERIAL BALANCE STEP: 1 C6H5OH + 2CH2O → C8H10 O3 STEP: 2 2n C8 H10O3 → [C8H8O2] n + n H2O OVERALL REACTION 2n C6H5OH + 4nCH2O → n C8H7O2Na + n H2O {naoh} Material balance for the reactor Basis: 1000 kg of phenol input.6.1 REACTOR BALANCE Phenol = 1000kg CH2O solution = 1704 CH2O = 37% H2O = 63% NaOH solution = 132kg NaOH = 31.8% H2O = 68. Molecular weight of resin: 295 Molar ratio of phenol to formaldehyde = 1:2 FIG 6. 45*18*10.Total amount of phenol added = 1000kg Mole basis = 1000/94 = 10.37 = 1704kg amount of water in formalin solution NaOH catalyst solution : 10% of phenol in kmoles NaOH =42kg Water content in NaOH =90kg Total amount of reactant water = 1074+90 = 1164 kg total weight of reactant Product ( 90% conversion) Total resin = 295*. formalin solution contains 37% of formaldehyde amount of formalin solution = 630 kg = 630 /.05 kmoles = 1.5 = 1413 kg total reaction water = .5 kmoles Total amount of formalin solution added in mole basis = 21kmoles Total amount of formalin solution added by weight = 21*30 = 630 kg.17 kg water from NaOH = 1.5 = 86.45*10.9 kg total unreacted water = 1164 kg total unreacted formaldehyde =30*2 = 60 kg total unreacted phenol total weight of the product reactor outlet: unreacted phenol: 1kmole = 94 kg = 94 kg = 2836 kg = 2836 kg = 1704-630 = 1074kg xxiv .05*18 = 18. 8)+94+60 =1169kg condenser balance is given as: feed = vapour + liquid 2836 = 1667 + 1169 =2836kg.2=254kg therefore. xxv . total liquid resin =254+1413 =1667kg total amount of vapour coming out =(1269*0.2 CONDENSER BALANCE Total feed entering the condenser = 2836 kg Total amount of water in the mixture=1269kg 20% of water remains in the resin product=1269*0.unreacted formaldehyde: 2 kmoles = 60kg total unreacted water : 1269kg total resin produced : 1413kg Material balance for condenser Resin+ water = 2836 kg CONDENSER Total distillate = 1169kg Resin = 1667kg FIG 6. Cp MCp∆ T Phenol Formaldehyde Resin Water at 55 C 1000 1704 2836 200 2.8 - Standard heat of reaction: xxvi .5 117126. ENERGY BALANCE Energy balance for the reactor Phenol = 1000kg CH2O solution = 1704 NaOH solution = 132kg (30ºC) ISOTHERMAL REACTOR Resin = 1413kg Unreacted phenol = 94kg (60ºC) Unreacted CH2O= 60kg Unreacted water= 1164 kg (60ºC) FIG 7.175 11700 4262.5 1.1 Amount of water circulated in the reactor =200 kg DATA TABLE 7.1: Compound Mass .kg Specific heat capacity.7.34 0.18 4. 70*(70-20))+(200*4.2 xxvii .05+117126.5 =15962.∆H (reactants)=( mCp∆ T)phenol+ (mCp∆ T)formaldehyde =(1000*2.35 Mass of oil to be circulated: ∆H m =(∑∆H) oil+(∑∆H) water = 848 101325.5 = 101327.(∑∆H) reactants = 163.5*5) =11700+4262.8-15962.35 = (m*1.8 ∆H =∆H°+ (∑∆H) products .18*2836) = 117126.34*5)+(1705*0.175*(60-25)) Mass of oil circulated in the reactor is: 848 kg CONDENSER: H2O (20ºC) Vapour (60ºC) H2O (60ºC) H2O(60ºC) Fig 7.5 ∆H (products)=( mCp∆ T)products = ((60-25)*1. 6 kg 8.41 kg/m3 To find the volume of the vessel : Volume to be handled = m/ρ = 2836*8/957.3Kg/m3 1056.5 957. DESIGN OF EQUIPMENTS REACTOR Data required for design of reactor: Density of formaldehyde Density of phenol Density of water Mass flow rate of the reactants : Hours of operation H/D ratio Average density : : : : : : : 815.93kg/m3 1000 kg/m3 2836 kg/batch 8 hours 1.69 m3/batch xxviii . mass of cooling water in the condenser = 18.182 kj/kgºC ∆T= 35º C mλ m = mCp∆ T = 18835.41 =23.4 = m*4.182 Therefore.4 kj/kg Cp of water = 4.835.6 kg 1169*2858.Enthalpy balance: mλ = mCp∆ T Mass of vapour =1169 kg λ at 60ºC = 2358. 12m tube peripheral speed = 225 m/min therefore.059 m3/batch total volume = volume of the cylindrical portion V = (πD2 H)/ 4 = 26.6 Density of water: 1000kg/m3 Density of resin : 1.8m Peripheral speed : 200-250 m/min Viscosity of resin: 3010-3 kg/ms Specific gravity of resin:1.69*(10/100))+23.4(Dt) = 0.8 m H = 1.69 = 26.4*2.8m .8 =1.Da :30-50% Dt Diameter of the tank.2 m The diameter of the vessel is 2. πDaN=225 xxix .To find the volume of reaction vessel: Assuming 10% excess volume Volume = (23.059 D = π D2 (1.6*1000 = 1600 kg/m3 tube turbine diameter = 0.5}1/3 = 2.Dt: 2. AGITATOR Type : turbine type Turbine diameter.5*2.2m.5D = 1.5D)/4 π D3 *1.8 = 4.5/4 = {(26.059*4)/ π *1. Height of the reactor is 4. 1/10.284 HP To calculate diameter of shaft: P= 2 π NT/75 .38 HP = (1.988 2053. Np Np P Power consumption = 6 = ρgc / ρN 3 Da5 = = = = Then actual power requirement is.225/( π*1.856*1.5 = 49. . .125 )/9. .321. Take 1/15 as the ratio of the reduction gear. . P max = P*1.856 HP Power at the start.12 = 1.1/15……. .(1) Torque T is given by. . .6 Now take transmission and other losses as 20%.988/75 27.12)=N N=64 rpm Consider the ratio of the reduction gear available 1/5.063*1.2 m/s now.8 2053.2 = 32. Nre V = DVρ/µ = N*D = (64/60)*1. Therefore speed of the motor = 64/(1/15) = 960 rpm Power consumption: Reynolds number. . . . .12*1.5 = 32.38*1. T = π*Dsh3 Fsh/16 (6*1600*1. . = 27. . .194*160)/30*10-3 = 71. xxx . Nre From Np vs Nre graph. 25 L =0. N .28m Width of the blade : 0.33 S3 =0.1 J = 0.2 W = .224m xxxi .0267m Shape factors: S1 = 0.motor speed N = 960/60 = 16 rps from (1) T = P*75/ (2* π*N) = (49.224m S5 = J/Dt = 0.78 T = π* Dsh3 *Fsh/16 Dsh3 = 36.diameter of the shaft Fsh .284*75)/(2* π*16) = 36.12m Length of the blade : 0.224m W=0.Dsh .1 S6=1.28m S4 = W/Da =0.33 S2 = 0.12 = 0.1*2.0 S3=L/Da=0.28m Thickness of the blade : 0.2*1.78*16/π*9800000 Dsh = 0.shear stress of the shaft.2 S5=0.28m Agitator dimensions Diameter of the turbine: 1.12 =.25*1.8 = 0.25 S4=0. 6kg/hr =3139.025m Length of the condenser = 4m DATA TABLE 8.1 HEAT TRANSFER PROPERTIES Sl no.0225 m =0. λs LMTD = ∆T1-∆T2/ ln(∆T1/ ∆T2) =(5-30)/ln(5/30) =13.1 SHELL AND TUBE HEAT EXCHANGER Tube side .916 2354 kj/kg Volumetric flow rate = mass flow rate/density of water .49*10-6 kg/m sec 22. 1.Diameter of the shaft: 0. 4.16 VAPOUR at 60ºC 1. 2. PROPERTY Specific heat capacity . Pr Latent heat of vaporization.cooling water Shell side .026m HEAT EXCHANGER 1.K Prandtl number. 5.95 Mass of cooling water =18835kg Per hour operation Mass flow rate =18835/6 = 3139.179 kj/kg k 631*10-6 kg/m sec 634*10-3 w/m k 4.5ºC 4.Do =0.Cp Viscosity. µ Thermal conductivity .vapour Water inlet temperature = 30ºC Water outlet temperature = 55ºC Vapour inlet temperature = 60ºC Vapour outlet temperature = 60ºC Mass of the steam entering = 1169 kg Inside diameter .0*10-3 w/m k 0.6/1000 xxxii WATER at 42. 3.920 kj/kg k 1.Di Out side diameter. 4 =0.11 Prandtl number.35 w/ m2 ºC Heat lost by steam = heat gained by cooling water Q= m Cp ∆T =1169*4. Pr Nusselt number .11) 0. Nu = 4.175 Nu Hi = Hi D/K =9557.16)0.023*(Nre)0. Ho= 8518.02252 *3600 ) = 2.19*1000/(631*10-6) =79.023*(79.186 kj /hr m2 ºC Shell side steam coefficient.1396 m3/ hr velocity = volumetric flow rate/ area =3.675.19 m/sec Reynolds number.53 U = 1/{ (1/Hi)*(Do/Di) + ln(Ro/Ri)*(Ro/k) + 1/Ho} = 3847.16 = 0.=3.4 =339.72 Q = UA ∆T A = 146557. Number of tubes = 24 xxxiii .675.8 (Pr)0.179*30 =146557.72*5) = 7.617 m2 A = πDoLN N = 24 TUBES. Nre = DVρ/µ = 0.53/(3847.8 (4.139*4/ (π*0.0225*. SKIRT SUPPORT To know the weight of the reactor: Wv = 240CvDm(Hv+ 0.08 = 70.48*103 / Tsk Permissible tensile stress of the material = 61.42*106/Tsk Maximum tensile stress in the skirt support ft = fsb.2*1000*9.08 Dm = 2.28.fdw = 11.8)*3*10-3 = 14.7*103*5.08 = 2/3*253.42*106/Tsk .8Dm)t Assume thicknes of vessel to be 3mm.39*106 / tsk xxxiv .02 KN Approximate weight =п * 2.71*103 KN (a) stress due to dead weight fdw = ЄW/ п Dsk Tsk = 28.35*103 Nm Stress due to seismic load fsb = 4*Msb*1000/п*Ds*Tsk = 4*70.81 = 253.7*103 KN total weight = 14.8(4.7*103 = 253.48*103 / Tsk Assume height of the skirt = 1m Msb = 2/3 * ЄW*Ht*0.2m Wv = 240*1.2*0.2+0.08*2.8m H v = 4.3 * 106 N/m2 ft = 11.8*2.8 2*4. Cv = 1.82*Tsk = 11.02+253.35*103*1000/п*2. 61mm actual width = Lb + tsk + 50 = 127.tsk = 185mm Maximum compressive stress in the skirt fc = fsb + fdw = 11.8 + 1402000/п*2.95 KN/nm taking the bearing pressure as 5 n/mm2 Lb = fb/fc = 638.9 mm2 total compressive load on the base ring is given by fb = 4*Ms/п Ds2 + W/ п Ds = 4*3919000/п 2.27+50 = 315.8*2.42*106/Tsk +28.5 no of bolts = 12 take bolt design stress = 125 N/mm2 Ms = 3919 KNm take W = operating value = 14.02*103) = 4740.2m No of bolts = 2200п/600 = 11.2) – 14.06 KN fb = maximum allowable bolt stress = (1/125*106*12)(4*3919/(2. tsk = 138.61+138.88 mm Lb = fb/fc’ Area of cross section Ab = 1/Nb*fb ( 4*Ms/Db – W) = 82.2 N/mm2 xxxv .48*103 / tsk Permissible compressive stress of the material Therefore.8 = 638.05/5 = 127.27 mm Design of the skirt bearing plate Approximate bolt circle diameter = 2. Reflux cooling is limited until the reaction mass reaches the boiling point of the liquid and cannot control exotherms that begin while the reaction temperature is below the liquid’s boiling point.fc’ = 638. PROCESS CONTROL Temperature control .61 mm = 185 mm Area of cross section = 4740. xxxvi .Frequently.61 = 5 N/mm2 Tb = LbҐ(3*fc’/fb) Tb = 19. the mass flow rate. Facilities should evaluate capacity of cooling system with respect to controlling unexpected exotherms. but has several limitations to Control unexpected exotherms.9 mm2 9. The increased heat load on the condenser results in only partial condensation and reflux of water. Addition of raw materials . Condensation cooling of reflux is commonly used to cool exothermic reactions that generate vapor as a byproduct.56 mm bolt circle diameter = 2. the reaction rate is controlled by the addition rate of one reactant or the catalyst and should be determined based on chemistry studies.56 mm bearing length Skirt thickness = 127. and the inlet temperature in the overhead condenser. As a runaway reaction proceeds.05/127. the increased generation rate of vapor increases the vapor velocity.The capability of the cooling system to remove the heat generated by the reaction is critical to the safe operation of an exothermic process.2m bearing thickness = 19. nominal 37% grade should contain 36. SOP’s must be understandable. 181. interlocks. and loss of agitation. and kept up-to-date. consideration must be given to human factors to ensure reliability. Employees must be trained on the SOP’s and mechanisms set up to ensure that SOP’s are followed at all times. especially if an administrative control is the Sole layer of protection. are used as a safeguard against process deviation and accidental release. Phenol is generally USP grade.2% CH2O and 1% methanol wax. Humans make mistakes. 1. periodically reviewed. Processes. preventive measures should be considered to minimize the likelihood of human error.9º C min . Administrative controls.8% . under. is monitored for assay by the hydroxylamine hydrochloric test. 40. Formaldehyde. bp. such as training and standard operating procedures. for example.If administrative controls. and sp gravity . Specifications for phenol include fp .or overcharging. For manual operations.37.0563 (45/20ºC) .Facilities must pay attention to the order of ingredients. the addition rates. xxxvii . equipment and procedures must be designed with potential for human error in mind. also USP grade. QUALITY CONTROL Quality control of phenolic resins begins with control of the raw materials.8ºC min . The consequences of deviation from SOP’s must be well understood by all employees. the consequences of a human error should not lead to a catastrophic release. Marketing area xxxviii .Political and strategic considerations 1. Transport facilities 4. Availability of suitable land 7.10. Plant location and site selection should be made before the plant layout. Environmental impact and effluent disposal 8. PLANT LAYOUT INTRODUCTION The economic construction and efficient operation of a process unit will depend upon how well the plant and equipment specified on the process flow sheet is laid out and on the profitability of the project with it scope for future expansion. Availability of utilities 6. Raw material supply 3. Plant location and site selection: The location of the plant has a crucial effect on the profitability of the project. Location. Local community considerations 8. The important factors that are to be considered while selecting a site are: 1. Climate 9. Availability of labour 5. with respect to market area 2. 3. but there should be an adequate pool of unskilled labours available locally. mineral acids. For the production of formaldehyde the site should be preferably near a methanol plant. . This consideration will be less important for low volume production. Skilled tradesman will be needed for plant maintenance. Skilled construction workers will usually be brought in from outside the site area.For materials that are produced in bulk quantities. Plants producing bulk chemicals are best located close to the source of major raw material. the plant should be located close to the primary product. 2. Local trade union customs and restrictive practices will have to be considered when assessing the availability and suitability of the local labour for recruitment and training. The disposal of toxic and harmful effluents will be xxxix . Raw materials The availability and price of suitable raw materials will often determine the site location. Environmental impact and effluent disposal All industrial processes produce waste products. and fertilizers where the cost of product per tone is relatively low and the cost of transport a significant fraction of the sales price. such as pharmaceutical. high priced products. Transport Transport of raw materials and products is an important factor to be Considered. and labour suitable for training to operate the plant. 4. and full consideration must be given to the difficulties and cost of their disposal. 5. such as cement. Transport of products can be in any of the four modes of Transport. Availability of labour Labour will be needed for construction of the plant and its operation. where this is also close to the marketing area. The availability of such grants can be overriding consideration in the site selection. It involves placing of equipment so that the following are minimized: The various units that should be laid out include: 1. The land should ideally be flat. well drained and have suitable load-bearing characteristics full site evaluation should be made to determine the need for piling or other special foundations. Political and strategic considerations Capital grants . Main processing unit xl .covered by the local regulations and the appropriate authorities must be consulted during the initial survey to determine the standards that must be met. 9. tax concessions and other inducements are often given by governments to direct new investment to preferred locations such as areas of high unemployment. Climate Adverse climatic conditions. is completed. Abnormally low temperatures will require the provision of additional insulation and special heating for equipment and pipe runs. at a site will increase costs. Full consideration must be given to the safe location of the plant so that it does not impose a significant additional risk to the community on a new site. Local community consideration The proposed plant must fit n with and be acceptable to the local community. Land Sufficient suitable land must be available for the proposed plant and for future expansion. After considering the location of the site the plant layout. the local community must be able to provide adequate facilities for the plant personnel. 7. 6. 8. boilers. and refrigeration. power.) Grouped layout 2. compressed air.2. such as medical centers 10. Maintenance workshops 4. 5. Offices for general administration 9. This provides for ease of operation and switching from one unit to another. Fire stations and other emergency services 6. Utilities: steam.) Flow line layout Grouped layout Grouped layout places all similar pieces of equipment adjacent. Canteens and other amenity buildings.Car parks 1. Processing area Processing area also known as plant area is the main part of the plant where the actual production takes place. Effluent disposal plant 8. Laboratories for process control. There are two ways of laying out the processing area 1. Storage for raw materials and products 3. This is suitable for all plants. generation. 7. Flow line layout xli . This is used mainly for. a site should be selected that is close to at least two major forms of transport: road. No roads should be a dead end. All major traffic should be kept away from the processing areas. Laboratories Quality control laboratories are a necessary part of any plant and must be included in all cost estimates. This means that there should be a road around the perimeter of the site. plant offices. waterway or a seaport. which locates all the equipment in the order in which it occurs on the flow sheet. and for clearing and storing laboratory sampling and testing containers. 4. Road area also used for fire fighting equipment and other emergency vehicles and for maintenance equipment.Flow line layout uses the line system. If practicable. Adequate space must be provided in them for performing all tests. liquids are stored in small containers or in a pile on the ground. 3. rail. It is wise to locate all loading and unloading facilities as well as. Road transport is being increasingly used and is suitable for local distribution. Rail transport will be cheaper for long distance transport of bulk chemicals. Storage house The main stage areas should be placed between the loading and unloading facilities and the process they serve. The amount of space required for storage is determined from how much is to be stored in what containers. xlii .small volume products. Transport The transport of materials and products to and from the plant will be an overriding consideration in site selection. 2. In raw material storage. This minimizes the length of transfer lines and therefore reduces the energy needed to transport materials. personnel facilities near the main road to minimize traffic congestion within the plant and to reduce danger. Automatic storage and retrieving equipment can be substantially cut down storage. Steam for process heating: The steam for process heating is usually generated in water tube boilers using the most economical fuel available. Water for general use. The process temperature can be obtained with low-pressure steam. The cooling water required can be taken from a river or lake or from the sea. Steam for process heating. Electricity: Electrical power will be needed at all the sites. Transformers will be used to step down the supply voltage to the voltages used on the purpose. A competitively priced fuel must be available on site for steam generation. xliii . Cooling water: Chemical processes invariably require large quantities of water for cooling. These services will normally be supplied from a central site facility and will include: Electricity. Administration offices in which a relatively large number of people working should be located well from potentially hazardous process. process water may be drawn from river from wells or purchased from a local authority. Offices: The location of this building should be arranged so as to minimize the time spent by personnel in traveling between buildings. Cooling water. Inert gas supplies.5. Utilities The word "Utilities" is now generally used for ancillary services needed in the operation of any production process. Water for general use: Water is needed in large quantities for general purpose and the plant must be located near the sources of water of suitable quality. Electrochemical processes that require large quantities of power need to be located close to a cheap source of power. Medical facilities: Medical facilities should be provided with at least basic facilities giving first aid to the injured workers. The layout of the plant can be made effective by: 1) Adopting the shortest run of connecting pipe between equipments and the least amount of structural steel work and thereby reducing the cost. 2. Provision must be made for the environmentally acceptable disposal of effluent. Locating the vessels that require frequent replacement of packing or catalyst outside the building 4. xliv . Fire station: Fire station should be located adjacent to the plant area. Equipment that need frequent operator attention should be located convenient to control rooms. so that in case of fire or emergency. the service can be put into action. Convenient location of the equipment so that it can be tied with any future expansion of the process. 3. Providing at least two escape routes for operators from each level in process buildings.Canteen: Canteen should be spacious and large enough for the workers with good and hygienic food. 5. FINISHED PRODUCT COLD STORAGE EXTENSION AREA SCRAP YARD ETP PROCESSING AREA C A N T E E N W O R K S H O P FIRE STATION SAFETY & HEALTH CARE DEPARTMEN T ADMINISTRATIVE OFFICE PARKING AREA SECURITY OFFICE ENTRY EXIT FIGURE 10.1 51 11. COST ESTIMATION xlv . 2 DIRECT COST FACTOR S.1 S. IA. This is the investment in all processing equipment within the processing area. IF.. IF. IW.No 1 2 3 Items Delivered cost of major equipments Equipment installation Insulation Direct cost factor 50 15 15 xlvi .e. C. The capital investment in the auxiliary services. Fixed capital investment in the process area.ESTIMATION OF THE TOTAL CAPITAL INVESTMENT The total capital investment “I” involves the following: A. B. The capital investment as working capital. IF = Direct plant cost + Indirect plant cost. FIXED CAPITAL INVESTMENT IN THE PROCESS AREA. i.No. The fixed capital investment in the process area. I = IF + IA + IW A. The approximate delivered cost of major equipments used in the proposed manufacturing plant are furnished below: DATA TABLE 11. 1 2 3 4 5 6 7 8 9 10 11 12 Equipment Reactor Condenser Distillate collection tank Storage tank-phenol Storage tankformaldehyde Storage tank-resin Bio filters Storage tanks.ETP Flash mixer Vacuum tank Cooling tower Miscellaneous TOTAL Units 1 1 1 1 1 1 3 5 1 1 1 Cost in lakhs/unit 30 20 10 10 10 10 15 10 10 10 20 Cost (in lakhs Rs) 30 20 10 10 10 10 45 50 10 10 20 125 350 CALCULATION OF FIXED CAPITAL INVESTMENT 1) Direct cost factor: DATA TANLE 11. Such items as steam generators. THE CAPITAL INVESTMENT IN THE AUXILLARY SERVICES. Engineering fee Contingency Total indirect cost factor Indirect cost factor 30 13 13 56 Indirect plant cost = (Direct plant cost)(Total indirect cost factor) / 100 = (630 * 56) / 100 = 352.8 lakhs B. DATA TABLE 11. IA. IF = Direct + Indirect plant cost = 630 + 352.4 5 6 7 8 9 Instrumentation Piping Land & building Foundation Electrical Clean up Total direct cost factor 15 25 30 10 15 5 180 Direct plant cost = (Delivered cost of major equipments)(Total direct cost factor) / 100 Direct plant cost = (350 * 180) / 100 = 630 lakhs 2) Indirect cost factor: DATA TABLE 11.No.8 lakhs Fixed capital investment in the process area.3 INDIRECT COST FACTOR S. fuel stations and fire protection facilities are commonly stationed outside the process area and serve the system under consideration.8 = 982.4 AUXILLARY COST FACTOR xlvii . 1 2 3 Item Overhead contractor etc. 8 + 194. The working capital may be assumed as 15% of the total capital investment made in the plant ( I ).2 0.5 1 1 0.5 0.8 = 1298.S.8 = 1103.75lakhs Total capital investment I = IF+ IA+ IW = 982.8+120. inventories of raw materials and products. IW. Capital investment as working capital.75+ 120. This is the capital invested in the form of cash to meet day-to-day operational expenses. 1 2 3 4 5 6 7 8 9 10 Items Auxiliary buildings Water supply Electric Main Sub station Process waste system Raw material storage Fire protection system Roads Sanitary and waste disposal Communication Yard and fence lighting Total Auxiliary services cost factor 5 2 1.No.8 + 120.2 12.2 0. IW = ((982.6* 15) / 85 = 194.6 lakhs C.35lakhs xlviii .3 Capital investment in the auxiliary services = (Fixed capital investment in process area)*( Auxillary services cost factor) / 100 = (982.8* 12.8 lakhs Installed cost = Fixed capital investment in the process area + Capital Investment in the auxiliary services = 982. THE CAPITAL INVESTMENT AS WORKING CAPITAL.7 0.8)* 15)/85 = (1103.3) / 100 = 120. COST PROPORTIONAL TO PRODUCTION RATE The factors proportional to production rate are Raw material costs Utilities cost – power. laboratory.6* 15) / 100 = 165. Cost Proportional to total investment B. Steam. as follows: A. COST PROPORTIONAL TO TOTAL INVESTMENT This includes the factors. warehouse. security and first aid General services. Maintenance cost Chemical. Administrative services For this purpose we shall charge 15% of the installed cost of the plant = (Installed cost * 15) / 100 = (1103. shipping expenses xlix . roads. etc.ESTIMATION OF MANUFACTURING COST The manufacturing cost may be divided into three items. Cost proportional to labour requirement A. fuel. etc. Cost proportional to production rate C. water. which are independent of production rate and proportional to the fixed investment such as Maintenance-labour and material Property taxes Insurance Safety expenses Protection.54 lakhs B. 9) = 104.5 lakhs SALES PRICE OF PRODUCT Market price of Production rate Total sales income = Rs.54 + 779. manufacturing cost = (165.01)*(0.Assuming that the cost proportional to production rate is nearly 60% of total capital investment.1) / (0. 100/kg =1460000 Kg PA =1460000*100 = 1460 lakhs PROFITABILITY ANALYSIS A. DEPRECIATION According to sinking fund method: R = (V-VS) I / (1+ I)n l .95 lakhs Therefore.54 +779. COST PROPORTIONAL TO LABOUR REQUIREMENT The cost proportional to labour requirement might amount to 10% of total manufacturing cost.01 lakhs C.01+ 104.95) = 1049. Cost proportional to labour requirement = (165. Cost proportional to production rate = (Total capital investment * 60) / 100 = (1298.6) = 779.35 * . 6) = 20. ANNUAL RATE OF RETURN Rate of return = (100*Net profit/Installed cost) = (100*223.1049.6 / (223.15)15-1 = 23.2% E.5*0.48 years li .19-(410.19 lakhs B.5 lakhs C.6 * .11) /1103.5-23. GROSS PROFIT Gross profit = Total sales income .manufacturing cost = 1460 . Tax rate is assumed to be 40%. PAYOUT PERIOD Payout period = Depreciable fixed investment/((profit)+(depreciation)) = 1103.19) = 4.5 =410.11 lakhs D. Net profit = Gross profit-Depreciation-(Gross profit*Tax rate) = 410.R = Uniform annual payments made at the end of each year V = Installed cost of the plant VS = Salvage value of the plant after n years N = life period (assumed to be 15 years) I R = Annual interest rate (taken as 15%) = (1103.15) / (1+0.4) = 223. NET PROFIT It is defined as the annual return on the investment made after deducting depreciation and taxes.11 + 23. For many reasons. ii. This is due in part to the worldwide attention to issues in the chemical industry brought on by several dramatic accidents involving gas releases. Public awareness of these and other accidents has provided a driving force for industry to improve its safety record. Unsafe actions or unsafe mechanical or physical conditions exist only because of faults of a particular person. Improper attitude Lack of knowledge or skill Physical unsuitability Improper mechanical or physical environment lii . iv. which causes or is likely to cause an injury. An accident occurs as a result of unsafe actions or exposure to an unsafe environment. Local and national governments are taking a hard look at safety in the industry as a whole and the chemical industry in particular. There has been an increasing amount of government regulations. SAFETY INTRODUCTION In recent years there has been an increased emphasis on process safety as a result of number of serious accidents.12. iii. Faults of persons are inherited from the environment and reasons for the faults are: i. INDUSTRIAL ACCIDENTS An accident has been defined as an unplanned or unexpected event. It is vital for the future of the chemical industry that process safety has a higher priority in the design and operation of chemical process facilities. major explosions and several environmental accidents. the public often associates chemical industry with environmental and safety problems. These are planning and organizing to: i. iii. HANDLING GUIDELINES 1) Always handle with rubber gloves. it will be seen that the occurrence of an injury is the culmination of a series of events or circumstances that invariably occur in a fused and logical order. even though previous events or circumstances in the sequence are unfavorable. 3) Wear EYE GOGGLES while handling product. Personal factor Hazard factor Unsafe factor Proximate casual factor The solution under the four factors would also lead to two steps. The supervision and management can control the actions of employed persons and so prevent unsafe acts and also guard or remove unsafe conditions. 4) Use a breathing mask while in close proximity to product liii . iv. Prevent unsafe mechanical or physical conditions Prevent unsafe action being committed. ii. 2) Avoid direct skin contact. Knowledge of the factors in the accident sequence guides and assists in selecting the point of attack in prevention work. ii. It permits simplification without sacrifice of effectiveness. The most important point is that unsafe conditions or actions are the immediate cause of accidents. The four factors that converge to cause accidents are: i.ACCIDENT PREVENTION From the foregoing. consult doctor in case of symptoms. 3) Collect contaminated fire fighting water separately.5) Wear an apron while handling product. DO NOT allow product to come in direct contact with clothes 6) Avoid any direct contact with skin. SPILLAGE 1) Spray material with water to prevent air pollution through dispersion of particulate matter. 9) Company should have well equipped medical center. extinguishing powder or water jet is normally used in fires. 3) After skin contact instantly wash with water and soap and rinse thoroughly 4) After eye contact rinse opened eye for several minutes under running water. 2) For large fires water jet or alcohol-resistant foam is used. 8) Every employee inside the factory should wear safety helmet to avoid head injuries. FIRE FIGHTING MEASURES 1) Carbon dioxide. 2) Collect the spilled material using a scrapper. 3) Avoid exposure of spilled material to a direct flame or heat source. FIRST AID MEASURES 1) GENERAL INFORMATION: Instantly remove any clothing soiled by the product. liv . 7) All employees working inside factory should wear safety shoes.it must not enter drains. 2) After inhalation supply fresh air. 5) After swallowing rinse mouth and drink plenty of water. TRANSPORTATION: Phenol formaldehyde resin is stored in air tight containers and is transported from one place to other by: lorries. trucks. ships. The market demand for this resin is always high. 8) The storage area must be designed to avoid direct exposure of the product to the atmosphere. 4) The shelf life for the product which is stored in cold storage room is only 6 months. 14. Today it is used in all common places like wood working industry. abrasives. 3) The storage area must be well insulated from any heat source (direct flame). Storage guidelines 1) The product must be stored in cold storage room. molding and insulation compounds. 5) Advisable to use the product immediately or before 6 months 6) The storage facility must have good ventilation.13. 2) The storage area must be free from moisture. DISPOSAL: After the shelf life period of Phenol formaldehyde resin must be disposed as solid waste disposal techniques outlined by the pollution control board of the local government. STORAGE AND TRANSPORTATION Phenol formaldehyde resin in usually stored in cold storage at about 15 degree Celsius. 9) The containers used for storage should be well sealed containers. CONCLUSION The phenol formaldehyde is the largest used resin in the world. The economic importance of phenolic lv . 7) Clean water must be available in plenty in the vicinity in the event of emergency. Julian C. East-West press .Kern.W. The feasibility of the project and the cost estimation details has also been discussed. McGraw Hill International Edition.Q. Peter Harriott . Khanna Publications.3rd edition. 3rd edition. energy.Knop . “Perry’s Chemical Engineers Hnadbook. “Unit Operations in Chemical Engineering”. Donald . BIBLIOGRAPHY A. mass. “Process Equipment Design “. “Outlines of Chemical Technology”. McGraw Hill.McCabe.Vora. Tata McGraw Hill publication.resins today rather proves that they are irreplaceable in the various engineering fields and distinct areas of daily life.7th edition. B. Dryden’s . This project report deals with the manufacturing process. Warren L.Smith.“Chemistry and Application of Phenolic Resins”.Perry and Don Green.H. “Chemical Engineering”.M. lvi . “Process Heat Transfer”. Robert. 6th volume. “ENCYCLOPEDIA OF CHEMICAL TECHNOLOGY” 4th edition.6th edition. 3rd edition. “Stoichiomtery”.Scheib . International student edition. Coulson and Richardson. balance and design aspects. Joshi and Sharma.I.Bhatt and S. volume 18.4th edition. Kirk and Othmer .
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