A Project Report On

Conversion of Naphtha into valuable Petrochemical Feedstock: Catalytic Reforming

By
1. Saurabh Shamkuwar 2. Sriket Baheti 3. T. Vinay Kr. Reddy

Under the Guidance of Dr. Vivek Kumar Assistant Professor, I.I.T ROORKEE

IDD Process Engineering With MBA

INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

CONTENT

Certificate.................................................................... Acknowledgement.................................................... Problem Statement.................................................... Executive Summary.................................................. Introduction............................................................... About Naphtha......................................................... Steam Cracking......................................................... Catalytic Reforming.................................................. Selecting the Route................................................. Process Flow.............................................................. Feed Pretreatment..................................................... Main Reactor Design................................................ Instrumentation........................................................ Feed and Product Storage........................................ Utilities....................................................................... Safety Features.......................................................... Plant Layout............................................................... Economic Analysis.................................................... Bibliography...............................................................

CERTIFICATE

This is to certify that the project titled Conversion of Naphtha into valuable Petrochemical Feedstock: Catalytic Reforming is a record of analysis of work carried out under my guidance by Mr. Saurabh Shamkuwar, Mr. Sriket Baheti, Mr. T. Vinay Kr. Reddy.

(Dr. Vivek Kumar) Assistant Professor

Dated 11 / 05 / 2011

Place : Department of Paper Technology, I.I.T. ROORKEE (SAHARANPUR CAMPUS)

ACKNOWLEDGEMENT
When one is so closely involved with an organization for a period of over four years, it becomes a monumental task to try to acknowledge all the people who have influenced you in various different ways. However, it also becomes imperative, due to the valuable contributions that they make towards your life and work, to attempt to perform this task right at the beginning. We express our deep sense of gratitude towards our guide Dr. Vivek Kumar for his extreme help and support in spite of his busy and hectic schedule and making this project a success. We are also deeply indebted to Prof. (Dr.) A. K. Ray for extending his help in time of need in the form of valuable material and information. Last but not the least; we are also thankful to the library staff for the cooperating with us to make this a successful venture.

(Saurabh Shamkuwar)

(Sriket Baheti)

(T. Vinay Kr. Reddy)

PROBLEM STATEMENT
A Refinery has about 200,000 MT of surplus naphtha; it is considering the disposal of this product by converting it into petrochemical feedstock. Feasibility study with the complete design of the proposed scheme covering: Selection of alternatives routes such as production of BTX or, olefins Process flow of the complete process which is selected Feed pretreatment section Main reactor with instrumentation with control strategy Product separation and purification sections Feed and Product Tankage (MOC and sizes) Utility requirement Safety features The report shall include: Comparison of the two alternative routes of conversion viz. Steam Cracking (Olefin Production) and Catalytic Reforming (Aromatics Production). Selection of the process and complete design of the process along with product separation and purification sections, utility requirements, safety features and economic analysis. Material and energy balance for the reactor shall be achieved and major process parameters will be calculated. Input Parameter: Surplus Naphtha: 200,000 MT annually.

EXECUTIVE SUMMARY
In this project, our main purpose was to design a route for conversion of surplus Naphtha from a refinery into valuable Petrochemical Feedstock like Olefins or Aromatics. A surplus Naphtha feed of 200,000 MT has been given as the input parameter. The choice was made between Steam Cracking and Catalytic Reforming. We selected Catalytic Reforming primarily because of growing demand of reformer products and on the basis of preliminary cost estimation. After a discussion on the complete process flow and the feed pre-treatment section, the design of the main reactor was accomplished along with the various process parameters and conversion efficiency. A detailed mass-energy balance was carried out to calculate the mass flow rates and the utility requirements. Also the variation of parameters like molar flow, coke formation, temperature in the reactors as an effect of variation in catalyst (%) or with time were studied. Various control measures and strategies were suggested to overcome operational difficulties for efficient operation of the plant. The product separation techniques from the reformate and purification section have been discussed thereon. The sizes and the material of construction that will be required to store the feed and the products have been determined. For a proper accident-free operation of any plant, it is required to understand the potential effects of the materials that are being handled in the plant. Thus, the hazards and associated risk from the specific compounds that are handled in this plant have been discussed in detail. After discussing the proposed plant layout, the entire economics of the plant has also been evaluated. All the modelling and simulations were done using ASPEN while MATLAB was used for solution of complex rate equations.

INTRODUCTION
The petrochemical industry in India has been one of the fastest growing industries in the country. Since the beginning, the Indian petrochemical industry has shown an enviable rate of growth. This industry also has immense importance in the growth of economy of the country and the growth and development of manufacturing industry as well. It provides the foundation for manufacturing industries like construction, packaging, pharmaceuticals, agriculture, textiles etc. This industry is divided into 3 basic petrochemicals such as olefins (ethane, propane, and aromatic compounds such as benzene, toluene, intermediate petrochemicals, end products (polymers), synthetic fibres, and synthetic rubber. The Present Scenario Presently India has three gas-based and three naphtha-based cracker complexes with a combined annual capacity of 2.9 MMT of ethylene. Besides this, there are also 4 aromatic complexes with a capacity of 2.9 MMT of Xylenes (1). Basic chemicals such as ethylene, propylene, and other light olefins are currently manufactured mainly from naphtha by thermal cracking, i.e., socalled steam cracking. Steam Cracking involves much severe operations with temperatures ranging from 8150C to 9500C. Catalytic reforming is a process whereby light petroleum distillates (naphtha) are contacted with a platinumcontaining catalyst at elevated temperatures and hydrogen pressures ranging from 345 to 3,450 kPa (50500 psig) for the purpose of raising the octane number of the hydrocarbon feed stream. The low octane, paraffin-rich naphtha feed is converted to a high-octane liquid product that is rich in aromatic compounds. Hydrogen and other light hydrocarbons are also produced as reaction by-products. In addition to the use of reformate as a blending component of motor fuels, it is also a primary source of aromatics used in the petrochemical industry. The major Indian companies in this sector are: Reliance Industries Limited Gas Authority of India Limited Indian Petrochemicals Corporation Limited

 National Organic Chemical Industries Ltd. (NOCIL), Mumbai. National Aromatics and Petrochemicals Co., T.N. Indian Oil Corp. Ltd., Panipat. Indo Rama Synthetics Limited, Nagpur.

Schematic representation of Indian Petrochemical Industries.

(1) Source: Petrochemical Statistics, 2004.

ABOUT NAPHTHA
Naphtha is a group of hydrocarbons including light or medium oils. It is a cut covering the end of the motor spirit and the beginning of the kerosene range. Naphtha is a complex mixture of parafns, naphthenes, and aromatics in the C5C12 range along with some sulfur, and small amounts of nitrogen, and distils from crude petroleum oil in a wide boiling range with initial boiling point (I.B.P) of about 350C and end boiling point (E.B.P.) of about 2100C. Based on the type of crude oil (paraffinic, naphthenic, or aromatic-base oil), and the initial and end boiling points of the products' fractions petroleum refining can produce various cuts of naphthas that contain various quantities of Paraffinic, naphthenic and aromatic hydrocarbons. Usually, naphtha is classified as full range and narrow cuts, and the later may be subdivided into light naphtha [distilling between 350C and 700C], medium naphtha [distilling between 700C and 1250C], and heavy naphtha [distilling between 1250C and 2100C). Naphtha is characterized as lean (high paraffin content) or rich (low paraffin content). The rich naphtha with higher proportion of naphthene content is easier to process in the platforming unit and achieves a greater volumetric yield of reformate than does a lean charge. Petroleum Naphtha is by far the most popular feedstock for aromatics production. A detailed component breakdown of a typical Naphtha feed as given by gas chromatographic analysis is as shown: Table 1: Typical composition of naphtha(2):
Concentration (wt%) Aromatics: Benzene Toluene Ethylbenzene p-Xylene m-Xylene o-Xylene C9+ Aromatics Total Aromatics Total Olefins Paraffins and Naphthenes Propane Isobutane n-Butane 1.45 4.06 0.52 0.92 2.75 0.87 3.31 13.88 0.11 0.79 1.28 3.43

Isopentane n-Pentane Cyclopentane C6 Isoparaffins n-Hexane Methylcyclopentane Cyclohexane C7 Isoparaffins n-Heptane C7 Cyclopentanes Methylcyclohexane C8 Isoparaffins n-Octane C8 Cyclopentanes C8 Cyclohexanes C11 Paraffins C9 Naphthenes C9 Paraffins C10 Naphthenes C10 Paraffins C11 Naphthenes C12 P +N > 200 P +N Total Paraffins Total Naphthenes

5.62 6.19 0.64 6 5.3 2.58 3.26 4.55 4.65 2.77 7.57 4.24 3.43 1.52 5.23 0.53 3.63 5.93 1.66 3.41 1.04 0 0 55.35 30.7

The distribution of paraffins (P), olefins (O), naphthenes (N), and aromatics (A) in the naphtha determines the richness of the feedstock. Table 2: Typical Characteristics of Naphtha feed available in India(3):
Bombay High Site Ankleshwar Bombay High + N-Gujarat Boiling Range, 0C 110-131 110-134 108-136 Naphtha Feed at IOC Panipat 87-149.6

Paraffins, wt. %

48.7

34.6

35.7

48.9

Naphthenes, wt. %

41.1

34.0

37.0

26.26

Aromatics, wt. %

10.2

31.4

27.3

24.84

(2) Source: Catalytic Naphtha Reforming: Science and Technology, edited by George J. Antos,

Abdullah M. Aitani, and Jose M. Parera B, 2nd Edition. (3) Source: Petrochemical Process Technology, I D Mall, 1 st Edition.

STEAM CRACKING
Steam cracking typically refers to all processes inside the battery limits of a steam cracker. A typical steam cracker comprises the following three sections: pyrolysis (A), primary fractionation (B) and product recovery/separation (C).

Pyrolysis section: This is the heart of a steam cracker. Naphtha first enters the convection section (where a series of heat exchangers are located) of a pyrolysis furnace and is preheated to 650oC. Then, it is vaporized with superheated steam and is passed into long (12-25 meters), narrow (25-125 mm) tubes, which are made of chromium nickels alloys. Pyrolysis mainly takes place in the radiant section of the furnace where tubes are externally heated to 750-900oC (up to 1100oC) by fuel oil or gas fired burners. Depending on the severity, naphtha is cracked into smaller molecules via free-radical mechanism in the absence of catalysts. After leaving the furnace, the hot gas mixture is subsequently quenched in the transfer line exchangers (TLE) to 550650oC (or sometimes lower to 400oC). TLE will then be followed by a series of heat exchangers and temperatures could drop down to 300oC.

Primary fractionation: Primary fractionation applies to naphtha and gas oil feed only. In the primary fractionation section, gasoline and fuel oil streams (rich in aromatics) are condensed out and fractionated. While this liquid fraction is extracted, the gaseous fraction is de-superheated in the quench tower by a circulating oil or water stream. The gaseous fraction is then passed through four or five stages of gas compression (temperatures at 15-100oC), cooling and final cleanup to remove acid gases, carbon dioxide and water. Most of the dilution water steams are condensed, recovered and recycled. Fuel oil and BTX (aromatic gasoline which contains benzene, toluene and xylene) are products from this section. Product recovery and fractionation: It is essentially a separation process through distillation, refrigeration and extraction. Equipment includes chilling trains (chilling and refrigeration) and fractionation towers (demethanizer, deethanizer and the rest in Figure 1). De-methanization requires very low temperatures (e.g. 114oC). C2 (ethylene and ethane)

separation often requires large distillation columns (splitters) with 120 to 180 trays and high reflux ratios. Undesired acetylene will be removed through catalytic hydrogenation or extractive distillation. Similarly, in a C3 splitter, C3 (propane and propylene) are re-boiled with quench water at 80oC and separated. Ethylene and propylene refrigeration systems could be operated at low temperatures (within the range of 10oC and 150oC) for cooling and high pressure (200-450 psia) for compression. Butadiene, other C4 and aromatic gasoline are separated in the end. The total products yields from naphtha cracking differ depending on the paraffin and aromatic content of naphtha (full range, light, etc.) and severities (high, moderate and low). Schematically, this process can be shown as:

Figure 1: Schematic representation of Steam Cracking of Naphtha.

CATALYTIC REFORMING
Catalytic reforming is a chemical process used to convert petroleum refinery naphtha, typically having low octane ratings, into high-octane liquid products called reformates which are components of high-octane gasoline (also known as petrol). Basically, the process re-arranges or re-structures the hydrocarbon molecules in the naphtha feedstock as well as breaking some of the molecules into smaller molecules. The overall effect is that the product reformate contains hydrocarbons with more complex molecular shapes having higher octane values than the hydrocarbons in the naphtha feedstock. In so doing, the process separates hydrogen atoms from the hydrocarbon molecules and produces very significant amounts of by-product hydrogen gas for use in a number of the other processes involved in a modern petroleum refinery. Other by-products are small amounts of methane, ethane, propane and butanes. Main products of catalytic naphtha reforming are: Aromatic hydrocarbons: i. ii. iii. iv. Benzene Toluene Xylene Ethyl benzene

Reactions Involves: There are a good many chemical reactions that occur in the catalytic reforming process, all of which occur in the presence of a catalyst and a high partial pressure of hydrogen. Depending upon the type or version of catalytic reforming used as well as the desired reaction severity, the reaction conditions range from temperatures of about 495 to 525 C and from pressures of about 5 to 45 atm. Dehydrogenation: The conversion of naphthenes to aromatics is the primary naphthene reaction and the most rapid of all the general reactions. The overall conversion is a measure of reformer severity, but in typical unit, 90-80 percent of most naphthenes are dehydrogenated. The dehydrogenation of naphthenes

to convert them into aromatics as

exemplified

in the conversion

methylcyclohexane (a naphthene) to toluene (an aromatic), as shown below

Isomerization: The isomerization of normal paraffins to isoparaffins as exemplified in the conversion of normal octane to 2,5-Dimethylhexane (an isoparaffin), as shown below:

Dehydrocyclization: The dehydrogenation and aromatization of paraffins to aromatics (commonly called dehydrocyclization) as exemplified in the conversion of normal heptane to toluene, as shown below:

Hydrocracking: The hydrocracking of paraffins into smaller molecules as exemplified by the cracking of normal heptane into isopentane and ethane, as shown below:

Hydrodealkylation: Hydrodealkylation of both naphthenes and aromatics to respective homologues of lower carbon number occur in the reforming process and are favoured by high temperature, low pressure and low space velocity. These reactions are endothermic, and result in loss in reformate yield. The effluent from the last reactor is cooled and split into vapour and liquid products in a separator. The vapour phase is rich in hydrogen gas. The liquid portion is sent for further separation and aromatics recovery.
Schematic process diagram of continuous catalytic reforming process:

SELECTING THE ROUTE

Of the two alternatives discussed above, Catalytic Reforming was chosen as the route for converting surplus Naphtha into petrochemical feedstock. This selection was based on the estimated capital investments involved in both the processes and the revenue that can be generated from such a facility. Before we discuss the estimation, let us have a look at some facts that also stress upon selection of Reforming as the desirable route.

Reforming process converts naphtha into High-Octane blending stock which is used as an additive to gasoline derived from crude oil to raise its Octane Number (RON and MON), which is a measure of its antiknock quality, so that it can meet the stringent EU Gasoline Specification.

Table : Comparing Octane Numbers of Aromatics with paraffins.

For production of olefins, lighter feedstocks (e.g. Ethane) results in fewer by-products and thus are preferred over heavy liquid feedstock (e.g. Naphtha) which in contrast results in a variety of by-products (e.g. butylenes and aromatics) because of a large number of side-reactions. This is more pronounced by looking at the global pattern of feedstock for Ethylene production.

Figure : Global feedstock pattern for Ethylene production.

* Source: SRI Consulting, Chemical Industry News, March 2004.

The feedstock properties greatly affect the reformate yield and aromatic content of reformate. N+A(where N is naphthenes percent, A is aromatics percent) values of available Naphtha feedstock are commonly used to judge the reformer yield. A plot can be shown as:

Figure : Variation of reformer yield with N+A value of feedstock.

Also, from Table 2, it can be seen that average naphtha feed available in India is more favourable for aromatics production.

The production and consumption pattern for both olefins and aromatics is as shown:

Figure : Production-Consumption pattern for Olefins and BTX*.

*Source: Petrochemical Statistics 2004(i), petrochemical Statistics at a Glance-Group: Aromatics Chemical industrial News, April 2004, pg. 42

Preliminary cost estimation justifies our selection.

As per market prices of BTX and olefins on January 11, 2011***, a preliminary estimation of the sales revenue generated from each plant considering sale of BTX and olefins only and assuming same variable costs, shows that: Revenue generated for a cracker= 672 crore/annum Revenue generated for reformer= 826.36 crore/annum Thus for a plant capacity of 200,000 TPA, the capital investment for reformer unit is lesser than a cracker unit. Also comparison of revenues generated, on an assumption that the cost of production and value of by-products are same, reveals that reformer can be easily preferred over cracker.

*Source: Petrochemical Process Technology, I. D. Mall, Macmillan, 2008. **Fixed Investment at capacity C1= ( ***Source: chemical weekly Jan 18, 2011. )0.6 X Fixed Investment at capacity C0

PROCESS FLOW

FEED PRETREATMENT
Feed hydrotreating is used to reduce feedstock contaminants to acceptable levels. Common poisons for reforming catalysts that are found in naphtha are sulfur, nitrogen, and oxygen compounds. Removing these requires breaking of a carbon-sulfur, -nitrogen or -oxygen bond and formation of hydrogen sulfide, ammonia, or water, respectively. Hydrotreaters will also remove olefins and metal contaminants. Sulphur is found in the naphtha feed as:

This two staged process including a reactor and a stripper can be schematically represented as:

Process Objective: To remove contaminants (sulfur, nitrogen, metals) and saturate olefins and aromatics to produce a clean product for further processing or finished product sales.

Primary Process Technique: Hydrogenation occurs in a fixed catalyst bed to improve H/HC ratios and to remove sulfur, nitrogen, and metals.

Process steps: Feed is preheated using the reactor effluent

Hydrogen is combined with the feed and heated to the desired hydrotreating temperature using a fired heater. Feed and hydrogen pass downward in a hydrogenation reactor packed with various types of catalyst depending upon reactions desired. Reactor effluent is cooled and enters the high pressure separator which separates the liquid hydrocarbon from the hydrogen/hydrogen sulfide/ ammonia gas. Acid gases are absorbed from the hydrogen in the amine absorber. Hydrogen, minus purges, is recycled with make-up hydrogen. Further separation of LPG gases occurs in the low pressure separator prior to sending the hydrocarbon liquids to fractionation. With the process conditions as: Pressure: 600psig; H/HC ratio: 3000 scf/bbl = 0.513m3/L of feed; LHSV: 1.0; Catalyst: Co-Mo Oxides on alumina; The output from the hydrotreater unit was calculated as: Naphtha Feed 0.7 71 100 100 Output 370 400 0.006 <1 79.3 78.1

Stage 1 Temp. (0C) Stage 2 Temp. (0C) Product Analysis Sulphur, wt% Nitrogen, ppm Vol % Wt %

MAIN REACTOR DESIGN

The Catalytic Reforming process is assumed to have three reactors in series with varying sizes. These form a continuously regenerating system where the catalyst flows in a direction opposite to the feed. Hydrotreated feed is first heated to a desired temperature and then is made to pass through the first reactor. The output feed from one of the reactors has to be pre-heated again before feeding it to the next reactor owing to the endothermic nature of reactions taking place.

Process description
It can be observed that the total aromatics content increases as the feedstock pass through the unit, where the total aromatics content increases quickly in the former two reactors and slowly in the latter two reactors. The total naphthenes content decreases as the feedstock passes through each unit, declines rapidly in the former two reactors, and approaches a very low steady-state value after the second reactor; the final conversion of naphthenes is very close to 100%. The main reaction, which is dehydrogenation of naphthenes, occurs fast in the former two reactors, which results in rapid increase of aromatics and decrease of naphthenes. The major reforming reactions in the first two reactors are highly endothermic, which leads to rapid temperature drop. The cracking and dehydrocyclization reactions are weakened due to rapid temperature decline. The major reforming reactions in the latter two reactors are cracking, dehydrocyclization, and so on.

Modelling of reactions The naphtha feed is very complex consisting of several hundred components and each of them undergoes various reactions. A detailed model considering all the components and reactions is very complex and hence a proper lumping of the components by carbon number based on similar properties and kinetic behaviour would be more convenient. In this work a 10 lump model is considered. Naphtha feed composition is given below

Component Paraffins C6 C7 C8+ Napthenes C6 C7 C8+ Aromatics C6 C7

(% mass)

0.17 5.36 35.01

1.05 12.33 27.85

0.15 4.88

C8

13.2

In this model naphtha is divided into 10 lumps as shown below Carbon Number C8+ C7 C6 C5Paraffins Paraffin(n-octane) n-heptane n-hexane n-pentane Naphthenes cyclooctane cycloheptane cyclohexane Aromatics ethylbenzene toulene benzene

Reactions considered in the model: ( n =6,7,8) Dehydrogenation:

Ring Expansion:

Hydro Cracking:

Hydrodealkylation:

Knowing the constants, these equations were solved using MATlab. Following are some snippets of the program:

For the ease of modelling, axial flow in the reactors is neglected and the reactors are considered as plug flow reactors. Catalyst used in the reactor : Pt/Sn-Al2O3 Size and shape: Spherical-1.8 mm diameter Particle density: 690 kg/m3 Particle porosity: 0.6 Total catalyst: 6000 Kg

Distribution of catalyst among the reactors:

Reactor-I Amt of catalyst(kg) Void space Diameter(cm) 1000 0.3 3 Reactor-II 1500 0.3 3 Reactor-III 3500 0.3 3

Length(m) No. of tubes

7.32 400

7.32 600

7.32 980

Design of Catalytic reformer:

Components Parafins C5 C6 C7 C8 Naphthenes C6 C7 C8 Aromatics Benzene Toluene Ethyl benzene Hydrogen

Stream 1 (8) (% mass) 6 5 5.5 28.84 0.7 8.12 15.04 0.4 0.6 23.2 1.2

Stream2 (14)(% mass) 10 6.56 6 15 1 1.26 4 0.8 12 41.4 2

Stream3 (17)(% mass) 12.6 8.285 6.820 4.54 0.08 0.3 0.68 1.2 16 46.2 2.7

Heat Requirements for the reactor:

Heater B4 B7 B2 B6 Inlet temperature (0c) 450 468 478 30 Outlet temperature(0c) 490 490 30 200 Heat required (MJ/hr) 4295.56 1901.69 -1605110 451699

SEPARATION UNITS:

Flash drum:

Feed from Catalytic reformer is further processed to recover hydrogen and light ends. A flash drum is used to separate hydrogen from the output stream which is sent into flash drum at 30 0C and 19 bar pressure. Pressure in the flash drum is reduced which results in the separation of hydrogen from the product stream. Components Paraffin C5 C6 C7 C8 Naphthenes C6 C7 C8 Aromatics Benzene Toluene Ethyl benzene Hydrogen Stream 5 (% mole) Stream 2 (% mass) Stream 13 (% mass) 0.07 0.041 0.03 0.017 4*10-4 1.2*10-3 2.6*10-3 6.43*10-3 0.075 0.186 0.568 0.218 0.046 0.011 0.0025 2.54*10-4 2.96*10-3 1.13*10-4 4.25*10-3 0.015 0.0178 0.683 0.125 0.086 0.0721 0.048 8.40*10-4 3.18*10-3 7.23*10-3 0.012 0.147 0.496 2.23*10-5

Separation of Lower ends:

Components Parafins C5 C6 C7 C8 Naphthenes C6 C7 C8 Aromatics Benzene Toluene Ethyl benzene Hydrogen

Stream 3 (% mass) Stream 6 (% mass) 0.88 0.12 0.012 0.08 0.08 0.054 9.17x10^-4 0.0035 0.0081 0.014 0.19 0.56

Distillation column specifications: Temperature ( 0C)(inlet) Pressure (bar) No. of trays Feed Tray 200 15 19 11

X-axis: Mole fraction Y-axis: stages

Figure : Variation of N-pentane along the column.

Figure : Temperature variation along the column Condenser:

Temperature( 0C)

150

Pressure (bar)

15

Heat Duty(MJ/hr)

-2163.4

Separation of Non Aromatics:

First step in processing of aromatics is the separation of aromatics from nonaromatics. As the boiling point of non-aromatics is very close to aromatics, separation by conventional fractionation is not possible. Most widely used technology combines liquid-liquid extraction and extractive distillation. The molecules of aromatic hydrocarbon are much more polarizable because of their electrons than those of alkanes and cycloalkanes and thus they are soluble in variety of solvent. In the liquid-liquid extraction process, the hydrocarbon feed from reforming process flows into the lower section of liquid-liquid extraction column. The solvent extracts aromatics and some non-aromatics from extraction column bottom. It is then fed to the extractive distillation column for separation of non-aromatics from the solvent and aromatics. Aromatics and the solvents are separated in the solvent recovery section. The recovered solvent is routed back to the extractor column. The solvent from non-aromatics fraction is also recovered in a water wash extraction operation. A fundamental of liquid-liquid extraction is that solvent exhibits selectivity favouring lower boiling components more than high boiling components. Selectivity favours the hydro carbon species according to the functional group; aromatics > naphthenes > olefins > paraffins. The various individual extractors could be divided into gravity separated and centrifugal separated type. Basic consideration in the selection of solvents are : polarity of the solvents, polarity of the hydrocarbons, solvents selectivity, recoverability of solvent, density difference between disperse and continuous phase, viscosity, melting point, interfacial tension, corrosion, toxicity, thermal and chemical stability and low miscibility with feed solution. In the extractive distillation for separating the closed boiling components, a solvent is used which alters the volatility between constituents in the organic mixture. In the extractive distillation, non-aromatics are separated as top products and bottom products containing aromatics and solvent, which are separated in the solvent recovery column. The solvent used in polar component having a higher boiling point than the mixture to be separated.

Various solvents used in extraction of aromatics are given in the following table:

Separation of Aromatics:
After removal of non-aromatics, aromatics are separated into benzene, toulene, ethyl benzene. In the first stage benzene is separated and in second stage toulene is separated from ethyl benzene which has higher boiling point. Distillation columns are installed to separate aromatics into respective fractions.

Fig. a In the above figure it is shown two distillation columns are employed to separate aromatics into respective fractions. In the first column feed sent into the distillation column to separate benzene (top product) of 95% purity is obtained. Bottom product is sent into a column through a heat exchanger which cools the bottom product and sends to distillation column where toulene (95% purity) and ethyl benzene (95% purity) are separated. Feed composition: Component Benzene Toulene Ethyl Benzene % mole 0.023 0.276 0.7

Top product (stream 8 in Fig. a) Component Benzene % Mole 0.93

Toulene Ethyl Benzene

0.69 0.01

Bottom product (stream 15 in fig. a) Component Benzene Toulene Ethyl Benzene %Mole 0.0019 0.28 0.71

Fig. b Variation of benzene along the column (%mole fraction) From the fig it can be construed that product purity of benzene is 95%.

Distillation column (B7 in fig. a): Bottom from B5 is cooled to 323K and sent into distillation column. Column specifications are given below

Temperature(inlet) Pressure(bar)

323K 10

No of trays Feed plate Composition of Top and bottom products: Component Toulene Ethyl benzene Stream 11(top product) (%mole) 0.95 0.05

29 14

Stream 12(bottom product) (%mole) 0.05 0.95

Fig. c Above figure shows the variation of toluene and ethyl benzene along the stages of column.

Energy Requirements in catalytic reformer Plant: Flash Drum unit: Heat Exchanger B2 B6 Heat required (MJ/hr) -37866.7 10656.1981

Lower End separating unit: Heat Exchanger Condenser Reboiler Heat Required(MJ/hr) -2163.4112 4224

Aromatics Separation Unit: Heat Exchanger Condenser of B5 Reboiler of B5 B8 Condenser of B7 Reboiler of B7 Heat Required(MJ/hr) -361.87741 7437.55086 -6989.5047 -4124.2305 11206.079

Reformer Reactors: Heater B4 B7 B2 Inlet temperature (0c) 450 468 478 Outlet temperature(0c) 490 490 30 Heat required (MJ/hr) 4295.56 1901.69 -1605110

Mass Balance of Catalytic reformer:

Reformer Reactors:

Reactor system. 1 (RI, RII, RII) 2

Input Feed (stream 1) Component Hexane Heptane Octane C6naphthenes C7naphthenes C8naphthenes Benzene Toulene Ethyl benzene Mass flow rate (kg/hr) 42.925 1353.4 8840 265.125 3113.325 7032.125 37.875 1232.2 3333

Output stream: Component C5- fractions(pentane) Hexane Heptane Octane C6naphthenes C7napthenes C8naphthenes Benzene Toulene Ethyl benzene Hydrogen Mass flow rate( kg/hr) 3181.5 2092 1722 1466.35 20.2 75.75 171.7 303 4040 11665.5 681.75

Flash Drum:
In this stage hydrogen is separated from product stream:

Flash Drum

Component C5-(pentane) Hexane Heptane Octane C6naphthenes C7naphthenes C8naphthenes Benzene Toulene Ethyl Benzene Hydrogen

Stream 3(kg/hr) 216 45.58 11.8 2.508 0.252 0.294 0.112 4.212 17.48 17.102 676.5

Stream 4(kg/hr) 2961.8664 2044.048 1708.4 1142.622 19.908 75.46 171.36 298.662 4020.216 11766.36 0.5288

Separation of Lower ends:

4 Distillation 5

In this stage C5- compounds are separated.

Component C5-(pentane) Hexane Heptane Octane C6naphthenes C7napthenes C8naphthenes Benzene Toulene Ethyl Benzene Hydrogen

Stream-5(kg/hr) 2723.328 344.688 1.5 -

Stream-6(kg/hr) 216.288 1697.038 1705 1141.368 19.968 75.362 171.136 299.91 4015.432 11753.174 -

Liquid-Liquid extraction:

6 Extraction

Component C5-(pentane) Hexane Heptane Octane C6naphthenes C7naphthenes C8naphthenes Benzene Toulene Ethyl benzene

Stream-7(kg/hr) 216.288 1697.038 1705 1141.368 19.968 75.362 179.136 -

Stream-8(kg/hr) 299.91 4015.432 11753.174

Separation of Aromatics
In stage-I a distillation column is used to separate benzene from toulene and Ethyl Benzene.
8 Stage-I 9

10

Component Benzene Toulene Ethyl benzene

Stream-9(kg/hr) 265.746 26.864 0.212

Stream-10(kg/hr) 22.854 3988.568 11752.962

10

11 Stage-II
10

12

Component Benzene Toulene Ethyl Benzene

Stream-11(kg/hr) 22.854 3443.928 240.832

Stream-12(kg/hr) 544.64 11512.13

INSTRUMENTATION
The regulatory control system in a commercial reformer allows the unit operators to convert the operating plan developed by management into the conversion of naphtha to reformate, LPG, and hydrogen. Typically, the management operating plan will tell the operators to run a certain feedstock, at a certain rate, and at a certain processing severity. This plan has to be integrated with safety policies, efficiency guidelines, environmental regulations, and the units physical limitations, and then transformed into control terms of flow rates, temperatures, and pressures. Regulatory Controls in a Catalytic Reformer: The regulatory control system is used to control the conversion of naphtha to reformate with the required product properties and recovery, and to meet defined mechanical constraints such as heater excess air. Typically the reformate properties are research octane (RON) and vapor pressure (RVP).

Table: Fundamental Control Systems Only the key closed-loop controllers are shown and are represented by flags at their feedback sensor location. For simplicity, level controllers have not been included because they are not pertinent to the control of the operation of the process.

Figure : Simplified Instrumentation Diagram: Catalytic Reformer

Table lists the primary operating objectives of a catalytic reformer (control variables) and the controllers used to meet the processing objectives (manipulated variables).

Table : Basic Regulatory Control: Typical Operating Variables.

RON, or an alternate conversion target, is maintained by adjusting the reactor temperature controller set points. In conventional operations, the control is open loop. The operators make adjustments based on feedback from laboratory analyses or to account for process disturbances such as changes in feed rate. In an APC application, the set points are adjusted automatically based on on-line measurement or inference of severity. Temperature controllers adjusting the fuel to the fired heater preceding each reactor maintain the reactor temperatures. Quite often the temperature

controller is cascaded to either a pressure controller or a flow controller on the fuel source. Some applications use on-line measured fuel gas heating value compensation to the fuel controller to alleviate disturbances. Heater outlet temperature set points are commonly adjusted simultaneously and to approximately the same value. The driver for varying hydrogen recycle is its effect on coke production. Units in an unconstrained coke operation are run to a specified hydrogen-tohydrocarbon ratio in an attempt to control the rate of coke laydown to an acceptable rate. Those units that are coke make-constrained maximize hydrogen recycle to the limits of the instrumentation or process equipment, with equipment constraints being the most common limit. The type of compressor and associated driver usually determines the instrumentation used for hydrogen recycle gas control. Depending on the design requirements, aspects of the various systems may be incorporated into an integrated design. The reformer feed rate is usually specified by the refiners planning department. To reduce the impact of moisture absorbed in stored feed on the catalyst, reformer feed control systems are designed to maximize feed coming directly from the hydrotreater and still be on flow control. If the bottom of the hydrotreater stripper is adequately sized, the flow to the reformer can be on flow control, and the surge volume of the hydrotreater stripper is maintained by adjusting the feed rate to the hydrotreater as shown in Figure a.

Figure : Reformer feed diagrams

In this configuration, all of the reformer feed comes directly from the hydrotreater. A common feed line-up is presented in Figure b. A small part of the treated naphtha from the hydrotreater goes to storage, the bulk goes to the reformer, and the reformer feed rate is maintained by a slip stream from storage. The reformer feed tank serves as a surge drum between the hydrotreater unit and the reformer. Heater excess air and firebox pressure are controlled simultaneously with the air registers and the stack damper(s). Closed-loop controllers must be designed in such a manner that disturbances in the unit operation that (1) increase the firing rate are used as feed forwards to open the damper prior to additional fuel being added to the system, and those that (2) decrease the firing rate are not used as feed forwards to close the damper prior to the reduction in fuel rate. The burner manufacturer specifies minimal excess air rates. Recommended control schemes for fired heater excess air and firebox pressure controls are outlined in API RP-560. In most regulatory control systems on catalytic reformers, the damper position and registrars are in open-loop control with the operators making the required adjustments to meet both operating objectives and safe operation. This is done with either manually operated devices such as a chain wheel drive on a damper or a hydraulic positioner. The reactor system pressure is simply controlled by a pressure controller on the product separator or on the product separator vent line. The excess hydrogen produced in the dehydrogenation reactions is vented to fuel or, more commonly, to a hydrogen header. In most reformer complexes the product separator pressure is set by the design and cannot be varied significantly due to a combination of factors, including feed pump head, compressor constraint issues, valve and pipe sizes, relief valve settings, stabilizer pressure, and downstream unit pressures. Product separator temperature is usually not directly controlled. Tight control of the product separator temperature is normally not critical to the unit operation or equipment safety. Some units have temperature controllers adjusting the fin fan speed or louver positions. Stabilizer pressure is maintained using a traditional pressure controller venting the off gas either to fuel or to a light-ends recovery unit. Maintaining system pressure is critical to maintaining proper separation in the stabilizer between the designated light and heavy keys in the tower. In most reformer

complexes the stabilizer pressure is set by the design and cannot be varied due to a combination of mechanical limits. RVP is typically maintained by adjusting the bottoms temperature of the stabilizer tower and using laboratory feedback. The best point for temperature measurement to control RVP is approximately three trays from the bottom of the tower. The third tray also offers the best location for the temperature measurement used in an inferred RVP calculation. The stabilizer reflux rate is typically set to meet one of four specifications: (1) A defined reflux rate; (2) A reflux-to-distillate ratio (reflux-to-feed is occasionally specified); (3) The tower overhead temperature; The control of a defined reflux rate is accomplished using a standard flow controller on the reflux line. Because the liquid distillate off the stabilizer overhead receiver is on level control, the calculated reflux ratio used in refluxto-distillate control uses a weighted average distillate rate in the denominator. (The calculation of the reflux-to feed ratio uses the same type of weighted average feed rate because the stabilizer feed is on level control from the product separator.) The use of reflux to control the tower overhead temperature is normally done by cascading the overhead temperature to a reflux flow controller. Changes in feed composition or unit severity can cause the stabilizer overhead composition to vary to the degree that the tower overhead temperature cannot be maintained without wild swings in the reflux rate. It is recommended that tower overhead temperature control be integrated with some form of overhead liquid composition control. Control of the stabilizer liquid composition is secondary to control of the reformate RVP. Also, the lag time and TSS for changes in the stabilizer overhead liquid composition due to changes in reflux are beyond the capabilities of a PID controller. Controlling the heavy key in the stabilizer overhead liquid requires the use of on-line analysis or laboratory analysis for feedback, both of which have a delay in feedback to the control function. Because of these issues, an intermediate controller is used, and the heavy key composition specification is implemented subordinate to the reformate RVP specification. Typical intermediate controllers are reflux-to-distillate ratio or tower overhead temperature, both of which have been discussed. In either option, both the tower overhead and bottoms are ultimately on composition control, which is a difficult control problem given the number of degrees of freedom and their limited range of operation.

FEED AND PRODUCT TANKAGE

Storage of liquid materials is most commonly accomplished in industrial plants by the use of cylindrical, spherical or rectangular tanks. These tanks may be constructed of wood, concrete, fiber-reinforced plastic, or metals. The last is the most common material of construction due to its lesser cost and ease of fabrication. Both our feed (naphtha) and the products (Benzene, Toluene and Xylene) are liquids at ambient temperature. As some of these, chemicals are toxic and highly inflammable in nature; special care needs to be taken so as to avoid any leakage from the storage vessels. This forces every process design engineer to search for a more dependable, more corrosion resistant material of construction for design of the storage vessels. Material Selection: While selecting material, one has to consider two facts: 1) Storage conditions; 2) Properties of engineering material. Among the storage conditions, one has to consider: a) Medium (liquid or gas), b) Temperature, c) Chemical composition, pH, d) Loading of equipment (additional stress due to loading), e) Whether pressure or vacuum has to be applied, f) If the media is stationary or moving. Properties of Material: Strength, tensile strength or yield strength are main properties on which design stress is based for applications where creep is immaterial. For a given pressure/load, this also defines the thickness of the sheet used to make equipment. Creep: At higher temperature, materials fail due to creep. Fatigue: Fatigue limit is the maximum allowable stress at which material can sustain infinite number of stress cycles.

Toughness: Toughness is ability to withstand impact and is related to ductility. A tough material has lesser chance of stress concentration. Hardness: Required for abrasion resistance, a harder material is better. Density: A given weight of lighter material will give a thicker surface, which can obviously undertake higher pressure/load. Corrosion resistance: Resistance of material against corrosion can be considered as an important material characteristic. Corrosion rates can be varied by the level of contamination in the feed or the product. A corrosion allowance of 3mm for a life of 10 years is generally taken into account for mildly corrosive substances. In case of a naphtha reformer, the Material of Construction has been listed for the feed, the intermediate (reformate) and the products (Benzene, Toluene and Xylene) after referring to their Material Safety Data Sheets. Feed (Naphtha).................................................................Carbon Steel Intermediates....................................................................Carbon Steel Benzene.............................................................Carbon Steel/ SS-304H Toluene..............................................................................Carbon Steel Mixed Xylene....................................................Carbon Steel/ SS-304H As all the above mentioned compounds are mostly stable under confined conditions, thus the life of the vessels will only be affected by the contaminants in them. The other by-products include H2 gas, which is recycled or sent to other units, and light ends and fuel gas, which are used with the other units as fuel, and hence need not be stored in vessels. All the bulk storage tanks should be stored in a diked (bunded) wellventilated area, away from sunlight, ignition sources and other sources of heat. The tanks should be stored in a ventilated area away from incompatible sources.

Size of Tankage: As with storage for continuous processes, storage tanks for liquids should not be designed to operate with less that 10% inventory at the minimum or more than 90% full at the maximum. The amount of feed, product and intermediate storage will depend on the Lead time which is defined as the time that is taken to realize an order for the feed and the products, together with operability, control and safety considerations. Assuming a lead time of 1 days for supply of naphtha, 1) For feed storage: Required Feed Rate = 918.3 m3/day, For continuous operations, we will have to maintain a stock of at least 1 days, thus, stock of feed = 918.3 m3, The tank should be filled to a maximum of 90%, Thus, tank capacity = 1020.4 m3 For minimum cost, H/D ratio should be 1, Thus, the dimension of the tank is: (Dia. X Height) = 11 m X 11 m. 2) For Benzene Storage, the lead time can be considered to be 7 days: Product formation Rate = 9.1 m3/day, For continuous operations, we will have to maintain a stock of at least 3 days, thus, stock of feed = 27.3 m3, The tank should be filled to a maximum of 90%, Thus, tank capacity = 30.4 m3 For minimum cost, H/D ratio should be 1, Thus, the dimension of the tank is: (Dia. X Height) = 3.5 m X 3.5 m. 3) For Toluene Storage, the lead time can be considered to be 3 days due to its demand: Product formation Rate = 118.1 m3/day, For continuous operations, we will have to maintain a stock of at least 3 days, thus, stock of feed = 354.3 m3, The tank should be filled to a maximum of 90%, Thus, tank capacity = 394 m3 For minimum cost, H/D ratio should be 1, Thus, the dimension of the tank is: (Dia. X Height) = 8 m X 8 m.

4) For Xylene Storage, the lead time can be considered to be 3 days due to its demand: Product formation Rate = 333.12 m3/day, For continuous operations, we will have to maintain a stock of at least 3 days, thus, stock of feed = 1000 m3, The tank should be filled to a maximum of 90%, Thus, tank capacity = 1110 m3 For minimum cost, H/D ratio should be 1, Thus, the dimension of the tank is: (Dia. X Height) = 11.3 m X 11.3 m.

UTILITIES
The word Utilities is now generally used for the ancillary services needed in the operation of any production process. These services will normally be supplied from a central site facility; and will include: 1. Electricity. 2. Steam, for process heating. 3. Cooling water. 4. Water for general use. 5. Demineralised water. 6. Compressed air. 7. Inert-gas supplies. 8. Refrigeration. 9. Effluent disposal facilities.

Electricity
The power required for electrochemical processes; motor drives, lighting, and general use, may be generated on site, but will more usually be purchased from the local supply company (the national grid system in the UK). The economics of power generation on site are discussed by Caudle (1975). The voltage at which the supply is taken or generated will depend on the demand. For a large site the supply will be taken at a very high voltage, typically 11,000 or 33,000 V. Transformers will be used to step down the supply voltage to the voltages used on the site. In the United Kingdom a three-phase 415-V system is used for general industrial purposes, and 240-V single-phase for lighting and other low-power requirements. If a number of large motors are used, a supply at an intermediate high voltage will also be provided, typically 6000 or 11,000 V. A detailed account of the factors to be considered when designing electrical distribution systems for chemical process plants, and the equipment used (transformers, switch gear and cables), is given by Silverman (1964).

Steam
The steam for process heating is usually generated in water tube boilers; using the most economical fuel available. The process temperatures required can usually be obtained with low-pressure steam, typically 2.5 bar (25 psig), and steam is distributed at a relatively low mains pressure, typically around 8 bar (100 psig). Higher steam pressures, or proprietary heat-transfer fluids, such as

Dowtherm (see Conant and Seifert, 1963), will be needed for high process temperatures. The generation, distribution and utilization of steam for process heating in the manufacturing industries is discussed in detail by Lyle (1963).

Combined heat and power (co-generation)

The energy costs on a large site can be reduced if the electrical power required is generated on site and the exhaust steam from the turbines used for process heating. The overall thermal efficiency of such systems can be in the range 70 to 80 per cent; compared with the 30 to 40 per cent obtained from a conventional power station, where the heat in the exhaust steam is wasted in the condenser. Whether a combined heat and power system scheme is worth considering for a particular site will depend on the size of the site, the cost of fuel, the balance between the power and heating demands; and particularly on the availability of, and cost of, standby supplies and the price paid for any surplus power electricity generated. The economics of combined heat and power schemes for chemical process plant sites in the United Kingdom is discussed by Grant (1979). On any site it is always worthwhile considering driving large compressors or pumps with steam turbines and using the exhaust steam for local process heating.

Cooling water
Natural and forced-draft cooling towers are generally used to provide the cooling water required on a site; unless water can be drawn from a convenient river or lake in sufficient quantity. Sea water, or brackish water, can be used at coastal sites, but if used directly will necessitate the use of more expensive materials of construction for heat exchanger.

Water for general use

The water required for general purposes on a site will usually be taken from the local mains supply, unless a cheaper source of suitable quality water is available from a river, lake or well.

Demineralised water
Demineralised water, from which all the minerals have been removed by ionexchange, is used where pure water is needed for process use, and as boiler feed-water. Mixed and multiple-bed ion-exchange units are used; one resin converting the cations to hydrogen and the other removing the acid radicals. Water with less than 1 part per million of dissolved solids can be produced.

Refrigeration
Refrigeration will be needed for processes that require temperatures below those that can be economically obtained with cooling water. For temperatures down to around 100C chilled water can be used. Vapour compression machines are normally used.

Compressed air
Compressed air will be needed for general use, and for the pneumatic controllers that are usually used for chemical process plant control. Air is normally distributed at a mains pressure of 6 bar (100 psig). Rotary and reciprocating single-stage or two-stage compressors are used. Instrument air must be dry and clean (free from oil).

Inert gases
Where large quantities of inert gas are required for the inert blanketing of tanks and for purging this will usually be supplied from a central facility. Nitrogen is normally used, and is manufactured on site in an air liquefaction plant, or purchased as liquid in tankers.

Effluent disposal
Facilities will be required at all sites for the disposal of waste materials without creating a public nuisance.

SAFETY FEATURES
An unsafe act or a mechanical/physical hazard causes accidents and lead to injury or even death. Such an act is caused by fault occurring in the setup of environment. For any industry to be successful, it has become essential to identify the Hazards, to assess the associated risks and to bring the risks to tolerable level. Recognizing this, efforts need to be made for controlling the risks which are arising from various hazards such that loss to human life and property is negligible or zero. Accidents are caused are also caused by human error and such unsafe practices can result in any of the following: A. Injury: a. Reportable disabling injury b. Permanent practical injury c. Permanent disability d. Temporary disability B. Dangerous Occurrence------- No injury Continuous best efforts to identify the hazards and to bring the risk levels to tolerable level in the organization are recognised by several Government and safety regulating bodies. Regarding our Catalytic naphtha reformer we have classified the safety measures broadly on the basis of the different substances/chemicals involves in the reforming reactions. Apart from this, the hazards and safety requirements corresponding to equipments and plant setup are mentioned in the equipment detail and plant layout section itself. From every point of view these hazards are liabilities and safety instructions must be followed to avoid shut down and reduce the loss of man hours. Chemical in any form can be safely stored and used if physical and hazardous properties are fully understood and necessary precautions are observed. Following are the hazard and safety specifications for the chemicals involved in the reforming reactions: NAPHTHA: HAZARDS IDENTIFICATION: Appearance and Odor: Clear liquid, with motor spirit odor Acute:

Swallowed harmful; May cause lung damage if swallowed Eye- mildly irritating to eyes Skin irritating to skin; will cause redness and inflammation Inhaled inhalation may cause irritation to the respiratory system. Prolonged exposure to vapors may cause somnolence and narcosis Chronic: Prolonged and repeated skin contact may cause dermatitis due FIRST AID MEASURES Inhalation: Remove affected person from contaminated area to fresh air. If not breathing, apply artificial respiration and seek urgent medical advice. Skin Contact: Remove contaminated clothing. Immediately flush skin with large amounts of water for at least 15 minutes, followed with soap and water if available. Eye Contact: Flush eye with plenty of water for 20 minutes. If irritation occurs, seek medical advice. Ingestion: In the unlikely event of ingestion, obtain medical attention immediately. Do not induce vomiting. If vomiting occurs, keep head below hips to prevent aspiration FIRE FIGHTING MEASURES Fire hazards: Product is highly flammable. Isolate from sources of heat, naked flames, sparks and oxidizing materials. Take precautions against discharges of static electricity. Earth and bond all process equipment including tanks and drums. Ensure ventilation is adequate to prevent build up of explosive atmosphere. Hazardous combustion products include combustion products such as oxides of carbon. Extinguishing Media : Use foam, water spray or fog. CO2, dry chemical powder or sand may be used for small fires only. Do not use water in a jet. Protective Equipment for Firefighters: Wear full protective clothing and selfcontained breathing apparatus when approaching fire in a confined space. Additional Advice: Keep adjacent storage tanks, pipelines and fire exposed surfaces cool by spraying with water. Shut off supply if safe to do so and remove sources of re-ignition. Vapor/air mixtures may ignite explosively and flashback along the vapor trail may occur. Contain residual material at affected sites to prevent material from entering sewers, ditches and waterways. ACCIDENTAL RELEASE MEASURES Protective measures: Wear appropriate personal protective equipment. Extinguish or remove all sources of ignition and stop leak if safe to do so.

Contain residual material at affected sites to prevent material from entering sewers, ditches and waterways. Keep away from heat, naked flames and sparks. Clean Up Methods: For large liquid spills, transfer by mechanical means such as vacuum trucks to a salvage tank. Do not flush away residues with water; retain as contaminated waste. Allow residue to evaporate or soak up with appropriate absorbent material, sand or earth. Remove contaminated soil and dispose safely. HANDLING AND STORAGE General Precautions: Avoid breathing vapors or contact with material. Only use in well ventilated areas. Wash thoroughly after handling. Turn off all battery operated portable electronic devices (cellular phones and pagers). Handling: When using, do not eat or drink. Remove ignition sources, oxidising agents and food stuffs. Avoid sparks. Never siphon by mouth. The vapour is heavier than air, spreads along the ground and distant ignition is possible. Storage: Keep containers closed when not in use. Drums should be packed to a maximum of 3 meters high. Tanks must be specifically designed for use with the product. Bulk storage tanks should be diked (bunded), away from ignition sources and other sources of heat. Product Transfer: Electrostatic charges may be generated during pumping. Electrostatic discharge may cause fire. Ensure electrical continuity by bonding and grounding (earthing) all equipment. Restrict line velocity during pumping in order to avoid generation of electrostatic discharge. Do not use compressed air for filling, discharging or handling. Wait 2 minutes after tank filling (for road tanker vehicles) before opening hatches or manholes. Wait 30 minutes after tank filling (for large storage tanks) before opening hatches or manholes. Recommended Materials: For containers, or container linings use mild steel, stainless steel. Examples of suitable material are: high density polyethylene (HDPE), polypropylene (PP) which has been specifically tested for compatibility with this material. Container Advice: Containers, even those that have been emptied, can contain explosive vapors. Do not cut, drill, grind, weld or perform similar operations on or near containers. EXPOSURE CONTROLS/PERSONAL PROTECTION Exposure Controls: Use sealed systems as far as possible. Where vapors are generated, especially in enclosed area, and natural ventilation is inadequate, provide adequate explosion-proof ventilation to control airborne

concentrations. Local exhaust ventilation recommended. Eye washes and showers for emergency use. Protective Clothing: Chemical resistant gloves/gauntlets, boots, and apron. For spillage clean up use chemical resistant knee length boots. Where risk of splashing or in spillage clean up, use chemical resistant one-piece overall with integral hood, of PVC. Respiratory Protection: Where air-filtering respirators are unsuitable (e.g., airborne concentrations are high, risk of oxygen deficiency, confined space) use appropriate positive pressure breathing apparatus. Where respiratory protective equipment is required, use a full face mask. If air-filtering respirators are suitable for conditions of use, select a filter suitable for combined particulate/organic gases and vapors. Hand Protection: Where hand contact with the product may occur the use of gloves made from Neoprene rubber is recommended. Contaminated gloves should be replaced. Eye Protection: Chemical splash goggles (chemical mono goggles). Monitoring Methods : Monitoring of the concentration of substances in the breathing zone of workers or in the general workplace may be required to confirm compliance with the OEL and adequacy of exposure controls. STABILITY AND REACTIVITY Stability: Stable under normal conditions of use. Conditions to Avoid: Heat, flames, and sparks. Materials to Avoid: Strong oxidizing agents. BENZENE: HAZARDS IDENTIFICATION Potential Acute Health Effects: Very hazardous in case of eye contact (irritant), of inhalation. Hazardous in case of skin contact or ingestion. Inflammation of the eye is characterized by redness, watering, and itching. Potential Chronic Health Effects: CARCINOGENIC EFFECTS: Classified A1 (Confirmed for human.) by ACGIH, 1 (Proven for human.) by IARC. MUTAGENIC EFFECTS: Classified POSSIBLE for human. The substance is toxic to blood, bone marrow, central nervous system (CNS). The substance may be toxic to liver, Urinary System. Repeated or prolonged exposure to the substance can produce target organs damage. FIRST AID MEASURES

Eye Contact: Check for and remove any contact lenses. In case of contact, immediately flush eyes with plenty of water for at least 15 minutes. Cold water may be used. WARM water MUST be used. Get medical attention immediately. Skin Contact: In case of contact, immediately flush skin with plenty of water. Cover the irritated skin with an emollient. Remove contaminated clothing and shoes. Wash clothing before reuse. Thoroughly clean shoes before reuse. Get medical attention. Serious Skin Contact: Wash with a disinfectant soap and cover the contaminated skin with an anti-bacterial cream. Seek immediate medical attention. Inhalation: If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Get medical attention if symptoms appear. 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-tomouth resuscitation. Seek medical attention. Ingestion: Do NOT induce vomiting unless directed to do so by medical personnel. Never give anything by mouth to an unconscious person. If large quantities of this material are swallowed, call a physician immediately. Loosen tight clothing such as a collar, tie, belt or waistband. FIRE AND EXPLOSION DATA Fire Hazards in Presence of Various Substances: Highly flammable in presence of open flames and sparks, of heat. Slightly flammable to flammable in presence of oxidizing materials. Non-flammable in presence of shocks. 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. Explosive in presence of oxidizing materials or acids.

Fire Fighting Media and Instructions: Flammable liquid, soluble or dispersed in water. SMALL FIRE: Use DRY chemical powder. LARGE FIRE: Use alcohol foam, water spray or fog. ACCIDENTAL RELEASE MEASURES Small Spill: Absorb with an inert material and put the spilled material in an appropriate waste disposal.

Large Spill: Flammable liquid. Keep away from heat. Keep away from sources of ignition. Stop leak if without risk. Absorb with DRY earth, sand or other non-combustible material. Do not touch spilled material. Prevent entry into sewers, basements or confined areas; dike if needed. Be careful that the product is not present at a concentration level above TLV. HANDLING AND STORAGE Precautions: Keep locked up.. Keep away from heat. Keep away from sources of ignition. Ground all equipment containing material. Do not ingest. Do not breathe gas/fumes/ vapor/spray. 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. Keep away from incompatibles such as oxidizing agents, acids. Storage: Store in a segregated and approved area. Keep container in a cool, well-ventilated area. Keep container tightly closed and sealed until ready for use. Avoid all possible sources of ignition (spark or flame). 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. 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. STABILITY AND REACTIVITY DATA Stability: The product is stable. Instability Temperature: Not available. Conditions of Instability: Heat, ignition sources, incompatibles. Incompatibility with various substances: Highly reactive with oxidizing agents, acids. Corrosivity: Non-corrosive in presence of glass. TOLUENE: HAZARDS IDENTIFICATION

EYES Moderate to severe irritant. Contact with liquid or vapor may cause irritation. SKIN Moderate to severe irritant. May cause skin irritation with prolonged or repeated contact. Practically nontoxic if absorbed following acute (single) exposure. Liquid may be absorbed through the skin in toxic amounts if large areas of skin are exposed repeatedly. INGESTION The major health threat of ingestion occurs from the danger of aspiration (breathing) of liquid drops into the lungs, particularly from vomiting. Aspiration may result in chemical pneumonia (fluid in the lungs), INHALATION Excessive exposure may cause irritation to the nose, throat, lungs and respiratory tract. Central nervous system (brain) effects may include headache, dizziness, loss of balance and coordination, unconsciousness, coma, respiratory failure, and death. Effects to the liver, kidneys, blood, central nervous system, and the developing foetus have been reported from large, acute (short) and/or repeated or prolonged exposures. MEDICAL CONDITIONS AGGRAVATED BY EXPOSURE Irritation from skin exposure may aggravate existing open wounds, skin disorders, and dermatitis (rash). Chronic respiratory disease, liver or kidney dysfunction, or pre-existing central nervous system disorders may be aggravated by exposure. FIRST-AID MEASURES EYES In case of contact with eyes, immediately flush with clean, low-pressure water for at least 15 min. Hold eyelids open to ensure adequate flushing. Seek medical attention. SKIN Remove contaminated clothing. Wash contaminated areas thoroughly with soap and water or waterless hand cleanser. Obtain medical attention if irritation or redness develops. INGESTION DO NOT INDUCE VOMITING. Do not give liquids. Obtain immediate medical attention. If spontaneous vomiting occurs, lean victim forward to reduce the risk of aspiration. Small amounts of material which enter the mouth should be rinsed out until the taste is dissipated. INHALATION Remove person to fresh air. If person is not breathing, ensure an open airway and provide artificial respiration. If necessary, provide additional oxygen once breathing is restored if trained to do so. Seek medical attention immediately.

FIRE AND EXPLOSION HAZARDS Vapors may be ignited rapidly when exposed to heat, spark, open flame or other source of ignition. Flowing product may be ignited by self-generated static electricity. When mixed with air and exposed to an ignition source, flammable vapors can burn in the open or explode in confined spaces. Being heavier than air, vapors may travel long distances to an ignition source and flash back. Runoff to sewer may cause fire or explosion hazard. EXTINGUISHING MEDIA SMALL FIRES: Any extinguisher suitable for Class B fires, dry chemical, CO2, water spray, fire fighting foam, or Halon. XYLENE: HAZARDS IDENTIFICATION Health Hazards: Harmful by inhalation and in contact with skin. Vapours may cause drowsiness and dizziness. Slightly irritating to repiratory system. Irritating to skin. Moderately irritating to eyes. Harmful: may cause lung damage if swallowed. Possibility of organ or organ system damage from prolonged exposure. Target organ(s): Central nervous system (CNS). Auditory system. Safety Hazards: Highly flammable. In use, may form flammable/explosive vapour-air mixture. Electrostatic charges may be generated during pumping. Electrostatic discharge may cause fire. Environmental Hazards: Toxic to aquatic organisms FIRE FIGHTING MEASURES Clear fire area of all non-emergency personnel. Specific Hazards: The vapour is heavier than air, spreads along the ground and distant ignition is possible. Will float and can be reignited on surface water. Carbon monoxide may be evolved if incomplete combustion occurs. Extinguishing Media: Foam, water spray or fog. Dry chemical powder, carbon dioxide, sand or earth may be used for small fires only. Unsuitable Extinguishing Media:: Do not use water in a jet. Protective Equipment for Fire fighters: Wear full protective clothing and selfcontained breathing apparatus. Additional Advice: Keep adjacent containers cool by spraying with water. ACCIDENTAL RELEASE MEASURES

Protective measures: Isolate hazard area and deny entry to unnecessary or unprotected personnel. Stay upwind and keep out of low areas. Shut off leaks, if possible without personal risks. Remove all possible sources of ignition in the surrounding area. Use appropriate containment (of product and fire fighting water) to avoid environmental contamination. Prevent from spreading or entering drains, ditches or rivers by using sand, earth, or other appropriate barriers. Attempt to disperse the vapor or to direct its flow to a safe location for example by using fog sprays. Take precautionary measures against static discharge. Ventilate contaminated area thoroughly. Clean Up Methods: For large liquid spills (> 1 drum), transfer by mechanical means such as vacuum truck to a salvage tank for recovery or safe disposal. Do not flush away residues with water. Retain as contaminated waste. Allow residues to evaporate or soak up with an appropriate absorbent material and dispose of safely. Remove contaminated soil and dispose of safely. HANDLING AND STORAGE General Precautions: Avoid breathing of or contact with material. Only use in well ventilated areas. Wash thoroughly after handling. Handling: Avoid contact with skin, eyes, and clothing. Extinguish any naked flames. Do not smoke. Remove ignition sources. Avoid sparks. Electrostatic charges may be generated during pumping. Electrostatic discharge may cause fire. Ensure electrical continuity by bonding and grounding (earthing) all equipment. Avoid splash filling. Do NOT use compressed air for filling, discharging, or handling operations. Handle and open container with care in a well ventilated area. Storage: Vapours from tanks should not be released to atmosphere. Breathing losses during storage should be controlled by a suitable vapour treatment system. Bulk storage tanks should be diked (bunded) and stored in an area away from sunlight, ignition sources and other sources of heat. Keep away from aerosols, flammables, oxidizing agents, corrosives and from other flammable products which are not harmful or toxic to man or to the environment. The vapour is heavier than air. Beware of accumulation in pits and confined spaces. Storage Temperature: Ambient. Product Transfer: Keep containers closed when not in use. Do not use compressed air for filling, discharging or handling. Recommended Materials: For containers, or container linings use mild steel, stainless steel. Unsuitable Materials: Natural, butyl, neoprene or nitrile rubbers. EXPOSURE CONTROLS/PERSONAL PROTECTION

Additional Information: Skin notation means that significant exposure can also occur by absorption of liquid through the skin and of vapour through the eyes or mucous membranes. Exposure Controls: The level of protection and types of controls necessary will vary depending upon potential exposure conditions. Select controls based on a risk assessment of local circumstances. Appropriate measures include: Adequate ventilation to control airborne concentrations below the exposure guidelines/ limits. Eye washes and showers for emergency use. Personal Protective Equipment: Personal protective equipment (PPE) should meet recommended national standards. Respiratory Protection: If engineering controls do not maintain airborne concentrations to a level which is adequate to protect worker health, select respiratory protection equipment suitable for the specific conditions of use and meeting relevant legislation. Hand Protection: When handling this product, it is recommended to wear chemical resistant gloves. After using gloves, hands should be washed and dried thoroughly. Application of a non-perfumed moisturizer is recommended. Protective Clothing: Chemical resistant gloves/gauntlets. Where risk of splashing or in spillage clean up, use chemical resistant one-piece overall with integral hood. STABILITY AND REACTIVITY Stability: Stable under normal conditions of use. Reacts violently with strong oxidising agents. Conditions to Avoid: Avoid heat, sparks, open flames and other ignition sources. Prevent vapour accumulation. Materials to Avoid: Strong oxidising agents. Hazardous Decomposition Products: Thermal decomposition is highly dependent on conditions. A complex mixture of airborne solids, liquids and gases, including carbon monoxide, carbon dioxide and other organic compounds will be evolved when this material undergoes combustion or thermal or oxidative degradation.

PLANT LAYOUT
The location of the plant can have a crucial effect on the overall profitability of a project, and the scope for future expansion. Many factors must be considered when selecting a suitable plant site. The principal factors are: Location, with respect to the marketing area Raw material supply Transport facilities Availability of labor Availability of suitable land Environmental impact and effluent disposal Local community consideration Climate Political and strategic consideration As for the location of the reformer is concerned, we believe that a location near the BPCL, Bina Refinery in Madhya Pradesh will be the best alternative because that region is still unexplored for petroleum and petrochemical industries and also, this refinery is projected to have a naphtha output of 0.41 MMTPA. Many initiatives have also been taken up by the government to bring about industrial development in this region like setting up of power plants, refineries etc. PLANT LAYOUT The economic construction and operation of a process unit will depend on how well the plant equipment specified on the process flow sheet and laid out. The principal factors to be considered are: 1. Economic consideration: construction and operation cost. 2. The process requirement 3. Convenience of operation 4. convenience of maintenance 5. Safety 6. Future expansion 7. Modular construction

COSTS: The cost of construction can be minimized by adopting a layout that gives shortest run of connecting pipes between equipment, and adopting the least amount of structural steel work. However, this will not necessarily be the best arrangement for operation and maintenance. PROCESS REQUIREMENT: All the required equipments have to be placed properly within process. Even the installation of the auxiliaries should be done in such a way that it will occupy the least space. OPERATION Equipment that needs to have frequent operation should be located convenient to the control room. Valves, sample points, and instruments should be located at convenient position and height. Sufficient working space and headroom must be provided to allow easy access to equipment. MAINTENANCE Heat exchangers need to be sited so that the tube bundles can be easily withdrawn for cleaning and tube replacement. Vessels that require frequent replacement of catalyst or packing should be located on the outside of buildings. Equipment that requires dismantling for maintenance, such as compressors and large pumps, should be placed under cover. SAFETY Blast walls may be needed to isolate potentially hazardous equipment, and confine the effects of an explosion. At least two escape routes for operator must be provided from each level in the process building. PLANT EXPANSION Equipment should be located so that it can be conveniently tied in with any future expansion of the process. Space should be left on pipe alleys for future needs, service pipes oversized to allow for future requirements. MODULAR CONSTRUCTION: In recent years, there has been a move to assemble sections of the plant at the manufacturer site. These modules will include the equipment, structural steel, piping and instrumentation. The modules then transported to the plant site, by road or sea.

SITE LAYOUT:

ENTRY/EXIT

ENTRY/EXIT

ECONOMIC ANALYSIS
Acceptable plant design must present a process that is capable of operating under conditions, which will yield profit. Since net profit equals total value minus all expenses, it is essential to consider 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. Besides direct expenses many others indirect expenses are incurred, and these must be included if a complete analysis of the total cost is to be obtained. Some examples of these indirect expenses are administrative salary, product distribution cost and cost for interplant communication. A capital investment is required for every industrial process and determination of necessary investment is an important part of a plant design process. The total investment for any process consist fixed capital investment for practical equipment and facilities in the plant plus working capital, which must be available to pay salaries, keep raw material and products on hand, and handle other special items requiring the direct cost outline. When the cost for any type of commercial process is to be determined, sufficient accuracy has to be provided for reliable decision. There are many factors affecting investment and production cost. These are: 1. Source of equipment 2. Price fluctuation 3. Company policies 4. Operating and rate of production 5. Governmental policies Before an industrial plant can be put into operation, a large sum of money must be supplied to purchase and install the necessary machinery and equipment. Land and service facilities must be obtained, and the plant must be erected completely with all piping, controls and services. The capital needed to supply the necessary manufacturing and plant facilities is called the fixed-capital investment, while that necessary for the operation of plant is termed the working capital. The sum of the fixed capital investment and the working is known as the total capital investment. Generally, the working capital amounts 10-20% of the total capital investment. Following is the breakdown of the fixed capital investment for a chemical process.

DIRECT COST: 1. Purchased equipments 2. Purchased equipment installation 3. Instrumentation and control 4. Piping 5. Electrical equipment and material 6. Building (including services) 7. Yard improvement 8. Land INDIRECT COST: 1. Engineering supervision 2. Construction expenses 3. Contractors fee 4. Contingency Cost TYPES OF CAPITAL COST ESTIMATE: Order of magnitude estimate (ratio estimate) based on similar cost data; probable accuracy of this estimate over 30%. Study estimate based on knowledge of major items of equipment, probable accuracy of this estimate up to 30%. Preliminary estimate (budget authorization estimate scope method): based on sufficient data to permit the estimate to the budget, probable accuracy of this estimate is within 20%. Detailed estimate based on complete engineering drawing, specifications and site survey, probable accuracy of this estimate within 10%. ESTIMATION OF PRESENT PLANT COST The cost of 1MTPA (1X106 tons per annum) Naphtha Reformer in 2003 was Rs. 1280 crore. Using the six-tenths factor rule, the cost of 200,000 TPA Reformer in 2003 will be calculated as: Cost = ( ) X 1280 crore = Rs. 487.34 crore {Source: From Peters, Timmerhaus, West, PLANT DESIGN AND ECONOMICS FOR CHEMICAL ENGINEERS (5th EDITION)}

DETAILED COST ANALYSIS: Direct Costs: (Purchased cost + Installation cost + Instrumentation and controls installation + piping +Electrical installation + building process and auxiliary + service facilities + yard improvement + land) (1) Purchased equipment cost (15 40 % of Fixed Capital Investment). Assume 30% of Fixed Capital Investment = 0.30 * 487.34 crore = Rs. 146.202 crore (2) Installation cost, including insulation and painting (25-55% of purchased cost) Considering 40% of Purchased Cost = 0.40 * 146.202 crore = Rs. 58.48 crore (3) Instrumentation and controls cost (6-30% of Purchased Cost) Considering 13% of Purchased Cost = 0.13 * 146.2 crore = Rs. 19.01 crore (4) Piping installation cost (10-80% of Purchased Cost) Assume 45% of Purchased Cost = 0.45 * 146.2 crore = Rs. 65.8 crore (5) Electrical costs (10-40% of Purchased Cost) Assume 15% of Purchased Cost = 0.15 * 146.2 crore = Rs. 21.93 crore (6) Building, process and auxiliary (10-70% of Purchased Cost) Assume 40% of Purchased Cost = 0.40 * 146.2 crore =Rs. 58.48 crore (7) Service facilities (30-80 % of Purchased Cost) Assume 50% of Purchased Cost = 0.50 * 146.2 crore = Rs. 73.1 crore (8) Yard improvement (10-15% of the Purchased Cost) Considering 12% of the Purchased Cost = 0.12*146.2 crore = Rs. 17.55 crore (9) Land (4-8% of Purchased Cost) Assume 6% of Purchased Cost = 0.06 * 146.2 crore = Rs. 8.78 crore Direct costs = Rs. 469.33 crore

Indirect costs (Engineering supervision+ Construction expenses + Contractor fee + Contingency plan)

1. Engineering and supervision (5-30% of Direct Cost) Assume 15% of Direct Cost = 0.15*469.33 crore = Rs. 70.4 crore 2. Construction expenses and contractors feed(6-30% of Direct Cost) Assume 10% of Direct Cost = 0.10*469.33 = Rs. 46.93 3. Contractor fee (2-7% of the Direct Cost) Assume 4% of the Direct Cost = 0.04*469.33 = Rs. 18.78 crore 4. Contingency costs (5- 15% of Present Cost) Assume 12% of Present Cost = 0.12*469.33 = Rs. 56.32 crore Indirect costs = Rs. 192.43 crore Fixed Capital Investments = Direct + Indirect costs = Rs. 661.76 crore Working Capital (10-20% of Fixed Capital Investment) Assume 15% of Fixed Capital Investment = 0.15*661.76 crore = Rs. 99.264 crore Total Capital Investment = Total Fixed Capital+ Working Capital Investment. = Rs. 761.03 crore ESTIMATION OF MANUFACTURING COST I. Fixed Cost: 1. Depreciation: 10% of Fixed Capital Investment for machinery and 3% of building value = Rs 67.93 crore 2. Local taxes (3-4% of Fixed Capital Investment): Assumed value, 4% of Fixed Capital Investment = Rs. 26.47 crore 3. Insurances (0.4 1 % of Fixed Capital Investment) Assumed value, 0.6% of Fixed Capital Investment = Rs. 3.971 crore 4. Rent (8-12% of the rented land and buildings) Assumed value, 10% of building value = Rs. 66.17 crore Fixed Charges = 18% of Product Cost = Rs. 164.541 crore

Total Product Cost = Rs. 914.12 crore II Direct Production: (1) Raw materials = Available as surplus feed. Raw material cost = Rs. 0 (2) Operating labor (10-20% of Total Product Cost) Assumed value, 15% of Total Product Cost = 0.15*914.12 crore = Rs. 137.12 crore (3) Direct supervisory and electrical labour (10-25% of operating labor) Assumed value, 12% of Operating labour = 0.12*137.12 crore = Rs. 16.45 crore (4) Utilities (10-20% of Total Product Cost) Assumed value, 13% of Total Product Cost = 0.13*914.12 crore= Rs. 118.84 crore (5)Maintenance and repairs (2-10% of Fixed Capital Investment) Assumed value, 8% of Fixed Capital Investment = Rs. 52.94 crore (6)Operating supplies (10-20% of cost of maintenance and repair) Assumed value, 15% = 0.15*52.94 crore = Rs. 7.941 crore (7) Laboratory charges (0-20% of operating labor) Assumed value, 15% of Operating labor = Rs. 20.57 crore (8) Patents and royalties (2-6% of Total Product Cost) Assumed value, 5% of Total Product Cost = Rs. 45.71 crore Direct Production cost = Sum of {(1), (2), (3), (4), (5), (6), (7) and (8)} = Rs. 399.571 crore III Plant overhead costs (50-70% of Operating labour + Direct supervisory + Maintenance Cost) Considering 60%, Overhead Plant Cost = Rs. 123.906 crore Total Manufacturing Cost = I + II +III = Rs. 688.02 crore 2. General Expenses: (Includes administration expenses, distribution prices and also R&D costs)

(A) Administration Cost (40-60% of the Operating Labour Cost) Assuming 50%, the Administration Cost = Rs. 68.56 crore (B) Distribution Cost (2-20% of Total product Cost) Assuming 10% of the Product Cost, cost estimated as = Rs. 91.412 crore (C) Research & development cost: Assuming 3% of the Production Cost = Rs. 27.424 crore General expenses = A +B +C = Rs. 187.34 crore 3. Total product cost = Manufacturing cost + general expenses = Rs. 875.36 crore 4. Current selling price Selling Price of Benzene* = Rs. 59.25/kg Selling Price of Toluene* = Rs. 54.55/kg Selling Price of Xylene* = Rs. 65.00/kg * Source: Chemical Weekly, 26 April, 2011. Selling Price of LPG* = Rs. 360/14.2 kg cylinder Selling Price of paraffinic C6+C7+C8 = 46.2/kg With output rates of: Benzene = 293.15 kg/h Toluene = 3713.38 kg/h Xylene = 12075.784 kg/h LPG = 3069.52 kg/h Paraffins = 4756.0 kg/h With 330 working days in a year, Total annual Sales = Rs. 1031.506 crore 5. Gross earnings = Total selling price Total product cost = Rs. 156.15 crore/annum 6. Tax Assume the local tax rate to be 40%, Tax on the gross earning = 0.4 *156.15 crore = Rs. 62.46 crore 7. Net profits = Gross earnings tax = Rs. 93.69 crore

Rate of return = (Net profit/ fixed capital investment) = 14.16%

Break-even Analysis: Data available: Annual Direct Production Cost = Rs. 399.571 crore Annual Fixed charges, overhead and general expenses = Rs. 475.787 crore Total Annual sales = Rs. 1031.506 crore Weighted Average of the Selling Price of products per ton = Rs. 54474 Direct production cost per ton of polystyrene = (399.571)/ (1031.506/54474) = Rs. 21,101per ton Let n TPA be the break even production rate. Number of tons needed for a break-even point is given by (475.787) + (21,101 n) = (54474n) => n = 142,566 tons/year n = 18 tons/h = 432 TPD Hence, the break-even production rate is 142,566 MTPA or 71.28% of the considered plant capacity.

BIBLIOGRAPHY
The following is a list of books and articles consulted: 1. Speight, James; Chemical and process design handbook. McGraw Hill, 2002. 2. Speight, Handbook of Petroleum Product Analysis, Wiley Interscience, 2005. 3. G. Antos, A. Aitani, Catalytic Naphtha Reforming, 2nd ed. 4. Peters, Max S.; Timmerhaus, Klaus D.; West, Ronald E.; Plant Design an Economics for Chemical Engineers. 5th Ed. 2003 5. Ludwig, Applied process design for chemical and petrochemical plants (VOL. I,II,III). 6. Coughanowr, Process system analysis and Control. 7. Mall, I.D., Petrochemical Process Technology, Macmillan, 2008. 8. SRI Consulting, Chemistry Industry News, March 2004. 9. http://www.landmarks.be/apa/facts.html 10. UOPs official website (http://www.uop.com) 11. Rune Prestvik, Kjell Moljord, Anders Holmen, Compositional Analysis of Naphtha and Reformate. 12. Petrochemical Statistics 2004(c), petrochemical Statistics at a GlanceGroup: Olefins Chemical industries News, April 2004. 13. Perry, Robert H.; Green, Don W.; Perrys Chemical Engineers and book. 7th Ed.McGraw-Hill. New York. 1997. 14. CHEMICAL REACTOR DESIGN FOR PROCESS PLANTS Volume Two: Case Studies and Design Data. 15. R. K. Sinnott, Coulson and Richardsons Chemical Engineering Series, volume- 6, Chemical Equipment Design 3rd Ed., Butter Worth-Heinemann 16. Treybal, Robert E, MASS TRANSFER OPERATIONS. 17. Drydens Outlines of Chemical Technology, 3rd Edtion. 18. Chilton, Cost Engineering In the Process Industries, McGraw Hill, 1960. 19. International Journal of Chemical Reactor Engineering.

20. Padmavathi G., Chaudhuri K. K., Modeling and Simulation of Commercial Catalytic Naphtha Reformers, The Canadian Journal of Chem. Eng.,(1997). 21. www.osha.gov 22. www.bharatpetroleum.com 23. Petrochemical Processes, 2003, Hydrocarbon Processing, March 2003.