PRESENTATION ON
PLANT DESIGN FOR
A 350 TONNE PER DAY
PHTHALIC ANHYDRIDE PLANT
ACKNOWLEDGEMENT
We express our sincere thanks to our guide Prof. (Dr.) Swami Vedajnananda for
his inspiring guidance and sharing his experience and for his exemplary
perseverance and hospitality.
We sincerely acknowledge him for extending his valuable guidance, support for
literature, critical reviews of reports and above all the moral support he had
provided to us during this project.
INDEX
SECTION : 1 (PROBLEM STATEMENT)
SECTION : 2 (SUPPLY DEMAND ASPECT)
SECTION : 3 (SCHEMATIC FLOWSHEET OF THE PROCESS)
SECTION : 4 (MATERIAL BALANCE)
SECTION : 5 (ENERGY BALANCE)
SECTION : 6
SECTION : 7
SECTION : 8
SECTION : 1
PROBLEM STATEMENT
It is required to design a plant producing 350 tons/day of phthalic
anhydride(C8H4O3) from the oxidation of o-xylene in the presence of a
catalyst usually vanadium/titanium pent-oxide supported on ceramic
and silicon carbide.
The reactions involved in the process are as follows:
C8H10 + 3O2 → C8H4O3+3H2O (MAIN REACTION)
C8H10 + 7.5O2 → C4H2O3 + 4H2O + 4CO2 (SIDE REACTION)
C8H10 + O2 → 8CO2+5H2O (SIDE REACTION)
All the reactions are highly exothermic. The main reaction has a conversion
of 70%, while side reactions 1 and 2 have conversions 7% and 5%
respectively. A fixed bed reactor running at 1-3 bar pressure and 300-
400ºC is to be used.
Relevant properties are listed in the following table.
RELEVANT PHYSICAL AND CHEMICAL PROPERTIES:
Material Formula Mol. Wt. B.P.(ºc) M.P.(ºc) ΔHv (kJ/mol)
O-Xylene C8H10 106.17 144.4 -24 36.24
Phthalic Acid C8H6O4 166.13 --- 210 ---
Phthalic Anhydride C8H4O3 148.12 284 131-134 52.1
Maleic Anhydride C4H2O3 98.06 202 52.8 49.1
Vanadium Pent V2O5 181.88 1750 670 ---
oxide
Water H2O 18.02 100 0 40.66
Air --- 28.85 -194.5 --- ---
Nitrogen N2 28 -195.80 -210 5.57
Oxygen O2 32 -182.96 -218.79 6.82
Hydrogen H2 2.02 -252.7 --- 0.90
Carbon Monoxide CO 28.01 -191.5 -205.02 6
Carbon Dioxide CO2 44.01 -56.6 -78.5 16.4
SECTION : 2
SUPPLY DEMAND ASPECT
PAN End Uses Mainly Include It’s Role As A Phthalate Plasticizer And Alkyd Resin While Smaller Volume Applications Include Pigments, Dyes, Sweeteners And Flame Retardants.
Strong Global Demand For Phthalate Plasticizers Is A Major Driver For The Growing Consumption Of PAN.
Asia Pacific Region Is The Major Producer Of PAN.
At Present Asia Accounts For Over 61% Of The Global Consumption.
As Far As India Is Concerned, Here The Market Size Of PAN Has Been Growing At About 7.9% Annually, Which Is Expected To Grow Further Given Government Of India’s Thrust On Infrastructure.
Currently China Is The Largest Producer Of O-xylene In The World.
SECTION : 3
SCHEMATIC FLOWSHEET
OF THE PROCESS
SECTION : 4
MATERIAL BALANCE
Basis of calculation: 100kmol/hr. of o-xylene.
INFORMATION FROM PROBLEM STATEMENT:
Conversion of:
1st reaction:70%
2nd reaction:5%
3rd reaction:7%
Required phthalic anhydride (pan) production: 350 tpd.
Explosion limit of o-xylene: (<1%) & (>6%)
Reactor conditions: 300-400ºC temperature, 1-3 bar pressure
Switch condenser conditions: 1.7-2 bar pressure, <180ºC temperature
Bottoms composition of distillation column 1(D1):
XPAN= 0.999, XMAN= 0.001
Amount Of O-Xylene In Fresh Feed:
Assumptions: fresh and recycled o-xylene are 100% pure.
Overall balance: (nre + nfr=n1)
(n1= 100kmol/hr. chosen, nre = 100*(1- .7- .05- .07) = 18 kmol/hr.)
nfr = 100-18=82 kmol/hr.
MATERIAL BALANCE
AROUND
MIXING POINT
MATERIAL BALANCE
AROUND
REACTOR
MATERIAL BALANCE AROUND SWITCH CONDENSER
• Assumptions:
All the water vapor, carbon dioxide, nitrogen is
separated and exits the condenser in the top stream.
MATERIAL BALANCE OF FIRST DISTILLATIONCOLUMN (D1):
Assumptions:
Light key component iso-xylene.
Heavy key component is phthalic
anhydride.
Constant molar flow
Purity of phthalic anhydride at
bottoms is 99.9%.
The recovery of phthalic
anhydride is 99%.
All the xylene goes into the top
stream.
MATERIAL BALANCE OF FIRST DISTILLATIONCOLUMN (D2):
Assumptions :
recovery of Phthalic Anhydride
at bottom is 100%.Recovery of
Maleic Anhydride in bottom is
99%.
Recovery of O-Xylene in bottom
is 0%.
SECTION : 5
ENERGY BALANCE
ENERGY BALANCE FOR REACTORS :
• EQUATIONS USED WERE :
FOR GASES: CP=a+bT+Ct^2+dT^3
FOR ORGANIC LIQUIDS: CP=174.26+32.49*10-2T (T is in Kelvin)
ENERGY BALANCE FOR DISTILLATION COLUMN :
• ASSUMPTIONS:
Reflux ratio(L/D)=1.3
Raoult's law: P=Xi*Pi sat is applicable.
• EQUATIONS USED:
Antoine’s equation: Pisat= e(A- B/(T-C))
Heat capacity for vapor: CP= a+b^T+cT^2+dT^3
Heat capacity for organic liquid:
CP= 174.26+0.3249*T (All T’s are in Kelvin)
ENERGY BALANCE AROUND MIXING POINT
Mixing Point Of
Fresh And Recycled O-
Xylene:
Mixing Point Of
O-Xylene And Air:
SECTION : 6
PLANT LAYOUT
The Main Goal Of Plant Layout Is To Design A Physical Arrangement That
Most Economically Meets The Desired Output-quantity And Quality.
The Main Points To Be Taken Care While Designing A Plant Layout Are:
1) Suitable And Efficient Utilization Of Available Floor Space.
2) Ensures That Work Takings From One Point To Another Point Without
Interruption.
3) Shrinks Material Handling Costs.
4) Provides Enough Production Capacity.
5) Reduces Hazards To Personnel.
6) Provides Volume And Product Flexibility.
7) Provides Ease Of Supervision And Control. The Plant Area Is Mainly
Divided Into 3sections:
A) Feed Preparation Zone
B) Reaction Zone
C) Separation Zone
1. MAIN GATE
2. ADMIN BUILDING.
3. SECURITY & SAFETY DEPARTMENT.
4. PARKING.
5. LABORATORY.
6. STORES.
7. EMERGENCY WATER.
8. FIR STATION.
9. RESTAURANT.
10. CLINIC.
11. YARD FOR PLANT.
12. WASTEWATER TREATMENT.
13. WORKSHOP.
14. CONTROL ROOM OFFICE.
15. TANK FARM.
16. PLANT AREA.
17. PLANT UTILITIES.
18. FLARE.
FIGURE SHOWING THE ENTIRE LAYOUT OF THE PLANT
SECTION : 7
HAZARD & SAFETY
PRECAUTIONS
PHTHALIC ANHYDRIDE :
PRECAUTIONS :
Keep container dry and locked up.
Keep phthalic anhydride away from heat.
EXPOSURE:
Phthalic anhydride is harmful if swallowed. In presence of moisture,
possible burns, causes serious eye damage, eye irritation damage to conjunctiva
and cornea. Dust may be irritating to the respiratory tract .Also it may cause
asthma or allergic skin reactions.
STORAGE :
Do not store it above 250⁰C . Keep container tightly closed, cool and well
ventilated area.
REACTIVITY :
Phthalic anhydride is reactive with oxidizing agents. It is slightly reactive
with moisture and incompatible with nitric acid (HNO3), Sodium nitrate (NaNO2)
and copper oxide (CU2O).
O-XYLENE :
PRECAUTIONS :
Keep container dry and locked up.
Keep IT away from heat.
EXPOSURE:
O-Xylene Would Irritate The Respiratory Tract , Skin ,Eye And Leads To
Central Nervous System Depression .Its Vapor May Cause Flash Fire .The Health
Effect May Include Low Body Temperature ,Lung Congestion ,Visual Disturbance
,Vomiting ,Ringing In The Ears, Coma And Kidney Damage.
STORAGE :
Store O-xylene outside or in a separate building .Keep it separated
from incompatible substance .It should be protected from physical damage.
REACTIVITY :
O-xylene is stable at normal temperature and pressure .Avoid heat,
flames, sparks and other source of ignition .Explosion may occur if containers
exposed to heat .Keep it out of water supplies and sewers .
MALEIC ANHYDRIDE :
PRECAUTIONS :
Keep container dry and locked up.
Keep IT away from heat.
EXPOSURE:
Maleic anhydride is hazardous in case of ingestion .It irritates the skin
and eye when exposing to Maleic anhydride . Severe over exposure can make lung
damage, choking, unconsciousness or even death.
STORAGE :
Keep container dry and cool .Ground all equipment containing
material .Corrosive materials should not be stored in a separate safety storage
cabinet or room.
REACTIVITY :
Maleic anhydride is reactive with oxidizing agents, reducing agents,
acids and moisture .It is slightly reactive with metals and alkalis. It might
decompose when exposing it to moist air or water.
CONCLUSION
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