CHLOROBENZENE

MANUFACTURING
PLANT

PROJECT COORDINATORS :

 SIR SHAKEEL MANERI

 SIR MOHAIB RAZA KAZMI

GROUP MEMBERS SEAT # CONTRIBUTION

M.SHERAZ EP#1642041 CHAPTER # 3&4
H.M JAHANZAIB EP#1642018 CHAPTER # 6&8
NAYYER AHMED EP#1642049 CHAPTER # 01
SALMAN KHAN EP#1642038 CHAPTER # 2,5&7
SYED TALHA NAQVI EP#1642061 CHAPTER # 08

1
 PAGE
LIST NO
ACKNOWLEDGEMENT 1

CHAPTER # 01 : INTRODUCTION
1.1 INTRODUCTION TO CHLOROBENZENE 5
1.2 APPLICATION OF CHLOROBENZENE 7
1.3 STORAGE 9
1.4 MARKET ANALYSIS OF CHLOROBENZENE 9
1.5 PROCESS DISCRIPTION 11

CHAPTER # 02 : PROCESS SYNTHESIS AND FLOW SHEETING

2.1 INPUT AND OUTPUT DIAGRAM 16
2.2 FUNCTIONAL DIAGRAM 17
2.3 OPERATIONAL DIAGRAM 18
2.4 PROCESS FLOWSHEET WITH DETAILS 19

CHAPTER # 03 : MATERIAL BALANCE

3.1 SPECIFICATIONS 20
3.2 MATERIAL BALANCE ON REACTOR 21
3.3 MATERIAL BALANCE ON NEUTRALIZATION TANK 25
3.4 MATERIAL BALANCE ON DISTILLED COLUMN 28

CHAPTER # 04 : ENERGY BALANCE

4.1 ENERGY BALANCE ON REACTOR 29
4.2 ENERGY BALANCE ON NEUTRALIZATION TANK 32
4.3 ENERGY BALANCE ON DISTILLED COLUMN 35

CHAPTER # 05 : PIPING AND INSTRUMENTATION DIAGRAM

5.1 PIPING AND INSTRUMENTATION DIAGRAM 37

CHAPTER # 06 : SITE SELECTION AND PLANT LAYOUT

FACTORS AFFECTING DESIGN OF PLANT
6.1 LOCATION 38
2
6.2 SELECTED SITE 40
6.3 PLANT LAYOUT WITH ITS SIGNIFICANCE 41

CHAPTER # 07 : ECONOMIC ANALYSIS

7.1 INTRODUCTION 43
7.2 TOTAL CAPITAL INVESTMENT 44
TOTAL PRODUCTION AND MANUFACTURING
7.3 COST 45
7.4 COST OF PROJECT 47
7.5 COST OF PRODUCT 47
7.6 PROFIT ANALYSIS 47
7.7 BREAK EVEN POINT 48

CHAPTER # 08 : SAFETY, HAZARDS AND OPERATIBILITY STUDY

8.1 PLANT SAFETY 49
8.2 GENERAL STORAGE AND HANDLING 52
8.3 WORKPLACE EXPOSURE LIMITS 52
8.4 HAZARD 53
8.5 WASTE WATER TREATMENT 59

CHAPTER # 09 : CONCLUSIONS AND RECOMMENDATIONS

9.1 CONCLUSIONS AND RECOMMENDATIONS 60

3
ACKNOWLEDGEMENT

Firstly, we bow our head to Almighty Allah for giving us the ability to complete this
project report.

We would like to express our deepest appreciation and thanks to all those who
provided us the power and possibility to complete this report.

A special thanks to our awesome lecturer who is SIR MOHAIB RAZA KAZMI & SIR
SHAKEEL MANERI for the support, motivation and immense knowledge. His guidance
helped us very much in every step of report writing. Apart from that, we also gain so
many knowledge about industry so that we can be more prepared for our future.

We are also thankful to our helpful team mates that always support each other to
complete this project. We all worked together to give the best of our project.

We are so much thankful to our parents for giving encouragement, enthusiasm and
invaluable assistance to us. Without all this, we might not be able to complete this
report properly.

4
 CHAPTER # 1
INTRODUCTION

Q: WHY WE SELECT THIS TOPIC SPECIFICALLY??

ANS: We select this topic because of the increase in consumption rate around
the world and Not a single company produces Chlorobenzene in our country and the
most important thing is when we import Chlorobenzene we have faced a lot of
challenges and by our economic analysis in chapter 7 it is found an exceptional cost
difference we import or we produces by own. In the end we have come to conclusion
that we produce an economical product according to our economic analysis that’s why
we select Chlorobenzene topic.
1.1 INTRODUCTION TO CHLOROBENZENE:

Chlorobenzene is classified as an aromatic compound with the chemical formula i.e.

C6H5Cl. It is made from chlorine and benzene through chlorination process. It is found
as a colorless, volatile, flammable liquid with an almond odor. It is mainly used as a
solvent and also for the production of phenol and DDT and other organic compounds.
Chlorobenzenes are not affected by air, moisture, or light at room temperature and
pressure but some free radical reactions undergo on Chlorobenzenes.
Chlorobenzenes may undergo wide varieties of chemical reactions make chlorinated
benzenes applicable as reactants in number of commercial processes to yield various
products.

5
IDENTIFICATION:
Chlorobenzene identification in the commercial industry is listed as below in
CHEMICAL NAME CHLOROBENZENE
Molecular Structure

Synonyms Monochlorobenzene, Chlorobenzol,

Phenyl chloride, Benzene chloride
IUPAC Name Chlorobenzene
Classification Aryl halides

Formula C6H5Cl

PHYSICAL & CHEMICAL PROPERTIES:

PROPERTIES VALUE
Molecular Weight 112.56
Normal Freezing Point -45.58 °C
Vapor Pressure 1.17 kPa
Normal Boiling Point, 131.69 °C
Liquid Density 1.11 g/cm3
Reference temperature for liquid 20 °C
Density

1.2 APPLICATION OF CHLOROBENZENE:

The significant use of chlorobenzene is as an intermediate in the production of
commodities such as herbicides, dyestuffs and rubber. Chlorobenzene is also used as
a high-boiling solvent in the industrial application as well as in the laboratory.
Chlorobenzene once was used in the manufacture of certain pesticides, most notably

6
DDT by the reaction of chloral (trichloroacetaldehyde), but this application has been
rejected with the diminished use of DDT. Other applications include:
* It is used as a fiber swelling agent and dye carrier in textile processing.
* It is used as a tar and grease remover in cleaning and degreasing operations.
* It is also used as a heat-transfer medium.
At one time, chlorobenzene was mainly used for the manufacture of phenol.

C6H5Cl + NaOH → C6H5OH + NaCl

The reaction also contains a byproduct of salt. The reaction is known as the Dow
process. It is carried out at 350 °C, using fused sodium hydroxide without solvent.

 HEALTH:
Environmental Protection Agency (EPA) declared that the exposure of the
chlorobenzene to human being seems to be primarily occupational. There are some
information on the health hazard information of chlorobenzene by EPA.

 ACUTE EFFECTS:
The acute effects of chlorobenzene may be considered as redness and inflammation
of the eye, runny nose, sore throat, redness and irritation of the skin, headache,
dizziness, incoherence and loss of consciousness.

 CHRONIC EFFECTS (Non-cancer):

Chlorobenzene's long-term exposure may cause Chronic Central Nervous System
(CNS) depressions which are headache, dizziness, and somnolence. The chronic
exposure found in animals are elevated liver enzymes, enlarged and tender liver, and
blood, pus, or protein in the urine. Prolonged contact with skin may cause skin burns.
Reproductive/Developmental Effects:
1. No information is found on the reproductive or developmental effects of
chlorobenzene in humans.

7
2. Chronic inhalation exposure of rats to chlorobenzene did not negatively affect
on reproductive performance or fertility. However, a slight increment in the
incidence of degenerative testicular changes was found.

 CANCER RISK:
1. There is no information present on the carcinogenic effects of chlorobenzene in
humans.
2. In a National Toxicology Program (NTP) study of rats and mice exposed to
chlorobenzene via gavage (the experiment of placing the chemical in the
stomach), an increased incidence of neoplastic nodules of the liver in high dose
male rats was observed, but not in female rats, also not in male or female mice.
3. EPA has classified chlorobenzene as a Group D, not classifiable as to human
carcinogenicity.

 SAFETY:
1. Spilled material should not be touched.
2. Safety personnel should be notified.
3. Eliminate all sources of heat and ignition.
4. Ventilate potentially explosive atmospheres.
5. Water spray may be used to reduce vapors, but the spray cannot prevent
ignition in closed places.
6. For small dry spills, use a clean, non-sparking shovel and gently place the
material into a clean, dry container, cover and remove the container from the
spill area.
7. For small liquid spills, absorb with sand or other non-combustible absorbent
material and place into closed container for later disposal.
8. For large liquid spills, build dikes far ahead of the spill to contain the
chlorobenzene for later reclamation or disposal.

8
1.3 STORAGE:
Storage of chlorobenzene should be placed in a cool and dry area with tightly
sealed containers. Chlorobenzene's containers must be protected from physical
damage and stored separately from dimethyl sulfoxide, oxidizers, heat, sparks and
open flame. There should be non-sparking tools may be used to handle
chlorobenzene. To prevent static sparks, containers should be grounded and bonded
for transfers because containers that formerly contained chlorobenzene may hold
product residues, they should be handled appropriately.

1.4 MARKET ANNALYSIS OF CHLOROBENZENE

DEMAND AND CONSUMPTION PATTERN:
There are three out of many possible products resulting from the chlorination of
benzene continue to have large-volume applications—monochlorobenzene, o-
dichlorobenzene and p-dichlorobenzene. These three products combined account for
as much as 92–96% of the total chlorobenzenes market. Other chlorobenzenes also
have commercial applications but are not produced on a large scale including m-
dichlorobenzene, trichlorobenzenes, tetrachlorobenzenes and hexachlorobenzene.
Market information on these products is included in the report where they are
available:
The following pie chart shows consumption of chlorobenzenes in the major regions:
Co n s u mp t io n o f c h lo ro b en z en e b y maj o r regio n 2016

6%1%
7%

16%

70%

CHINA UNITED STATES JAPAN EUROPE PAKISTAN

Monochlorobenzene accounts for nearly 70% of total chlorobenzene consumption.

China is the world's largest manufacturer and consumer, accounting for nearly 82%
of total consumption in the four major regions shown below. Monochlorobenzene
9
represents about 70% of chlorobenzene consumption in Western Europe, and 52% of
consumption in the United States, but only 10% in Japan and India , and 2 or less than
2% in PAKISTAN , where p-dichlorobenzene is a larger factor than in the other
regions.

FUTURE DEMAND FOR CHLOROBENZENE:

Global chlorobenzene market is estimated to reach $2942 million by 2024 growing at
a CAGR of 5.8% from 2016 to 2024. In terms of volume the market was valued at 1579
kilo tons in 2016 and expected to reach 2201 kilo tons by 2024 at a CAGR of 4.2%
from 2016- 2024.

2015 2016 2017 2018 2019 2020 2021 2022 2023 2024

1.5 PROCESS DISCRIPTION:

Global chlorobenzene market size and forecast 2015-2024
(US$ Million)
 Continuous process us

1.5 PROCESS DISCRIPTI0N:

 Batch process
 Raschig process

DIRECT CHLORINATION (CONTINIOUS PROCESS)

C6H6 + Cl2 C6H5Cl + HCl

C6H6 + Cl2 C6H5Cl + HCl

The process begins with a series of small, externally cooled cast iron or steel
vessels containing the catalyst (which may consist of Rashig ring of iron or iron wire).
The catalyst used is usually Ferric chloride. This can be added as solution in benzene.
Chlorine is supplied into each vessel through suitably positioned inlets to maintain a
large benzene-to-chorine reaction at all points along the reaction stream. The
temperature is maintained about 20℃ to 40℃ for this reaction in order to minimize

10
the production of dichlorobezene which occur at higher temperature. Besides, this
range of temperature is the best temperature for production of large amount of
monochlorobenzene. This process will produce large amount of monochlorobenzene
and small amount of dichlorobenzene. The feed, which are liquid benzene and
gaseous chlorine are at temperature 25℃ and atmospheric pressure then fed to the
reactor which operates at 2.4 bars.
The reaction is exothermic process. Cooling process is required to maintain the
temperature at 40℃. 90% of the HCl formed is first cooled to condense impurities
(benzene and chlorinated product) and then it is scrubbed in a scrubber using
refrigerated chlorobenzene. The crude chlorobenzene stream leaving reactor is
washed with NaOH solution (20wt%) in order to maintained slightly alkaline to
protect downstream equipment from corrosion) in a pre-neutralizer. The product
stream is free from HCl. Then, the product is fed to a Benzene Recovery Column
(distillation column). Here, the bottom is almost slightly 100% pure chlorobenzene.
The top contains 98% by weight of benzene and 2% chlorobenzene. All the benzene
is recycled to the benzene storage via a purifier. From purifier the
monochlorobenzene is sent to the refrigeration system. The bottom contains
monochlorobenzene and dichlorobenzene. This bottom product is fed to the
chlorobenzene column that may be contain 12-25 trays which operated at 3-7 lb/in2
abs. The temperature may be 100℃-200℃. The distillate has purity of 99%
monochlorobenzene while bottom has purity of 97% dichlorobenzene.
This reaction will produce HCI as the side product. All the desired product and
undesired product are then fed to the Benzene Recovery Column (distillation column).
The advantages of continuous process are, it produces higher amount of
monochlorobenzene which is 95% conversion and the process also operate at lower
temperature.

11
COMPARISION B/W THREE PROCESS:
PROCESS RASCHIQ PROCESS CONTINUOUS

Raw Material  Benzene  Benzene

 Hydrochloric acid  Chlorine
 Oxygen (air)
Reaction Conditions Temperature at range Temperature at range
220 ℃ - 260℃ and in gas- 20℃ - 40℃ and in liquid -
phase phase
Reactor Fixed-Bed Reactor Continuous Stirrer Tank
Reactor
Catalyst Copper and iron chloride Ferric chloride

Advantages  Large economic  Lower operating

advantages labor
because HCl  Simple operation 
produce in the liquid phase
hydrolysis of  High conversion of
chlorobenzene can benzene (95%)
be used for the  High production of
oxychlorination of monochlorobenzene
benzene.  Produce less by
 Economy in steam products  only
and cooling small amount of
required for dichlorobenzene.
evaporating and
condensing the
benzene.
 Less purification
operations.
Disadvantages  Produce many by-  High cost of
products  equipments
dichlorobenzene,  Required special
trichlorobenzene, material of
tetrachlorobenzene construction for
and others. very low
temperature.
12
  The benzene
conversion is
limited,10-15%.

 The reaction is
uncontrollable
because of the high
temperature.
 High cost of vapour
phase chlorination
process.
 Has large
investment for
corrosion-
resistants 
hydrochloric acid is
highly corrosive

PROCESS BATCH

Raw Material  Benzene

 Chlorine
Reaction Conditions Temperature at range of 40℃ - 60℃
and in liquid-phase

Reactor Batch Reactor

Catalyst Ferric chloride

Advantages  High production of

monochlorobenzene compare
raschiq process.
 Low cost of factory equipment
because of the simple design of
batch reactor.

13
  Reaction it easy to control due
to low temperature.
Disadvantages  Lower conversion compare to
continuous (80%).
 Produce higher amount of by-
products  dichlorobenzene
 Only can produce small scale
production.
 Require strict scheduling and
control.
 Higher operating labor costs
due to equipment cleaning and
preparation time.
 Many people need to operate
the process.

CHAPTER # 2
PROCESS SYNTHESIS AND FLOW SHEETING
 INPUT AND OUTPUT DIAGRAM:
I/O Diagram provides the material streams entering and exiting the process.
To represent the inputs and outputs, we are using arrows entering and exiting a
process box.

 FUNCTIONAL DIAGRAM :
It is a block diagram and describes the interrelationships and functions of a process.
Input and output elements of a block are connected with lines and indicate all the
relationships of the blocks. Each reactor output streams enters a separate box that
produces a recycle to the reactor

 OPERATIONAL DIAGRAM :
Operational diagram is a diagram that describes the operations involved in the
production of a product and the technology that we are using in the process. This
diagram requires extensive information and understanding of the technologies.

14
Ranges of temperature, pressure, heat transfer all are estimated and examine the
separation and purifications technique.
In this operational diagram Input and output materials of a block is represented by
lines.

 PROCESS FLOWSHEET WITH DETAILS:

Process flowsheet is a diagram which is used to indicate the general flow of plant
processes and equipment. It is a picture of the separate steps of a process in sequential
order. The another term used for a process flowsheet is a PFD. It displays the major
equipment and doesn’t show minor details such as piping details and designations.
Process flowsheet includes:
 Major equipment items
 Piping
 Operational data (pressure, temperature, mass flow rate, etc.)
 Connections with other systems
 Recycle streams

2.1 INPUT & OUPUT DIAGRAM

Benzene Chlorobenzene

Chlorine Hydrochloric Acid

PROCESS
FeCl2 Dichlorobenzene

NaOH

15
2.2 FUNCTIONAL DIAGRAM
Recycle FeCl3

HCL OUT

FeCL3

CL2

BENZENE DERIVATIVE
Liquid Liquid
Benzene Ch0rination with bi product separation

Benzene recycle

20% Na0H
Purification Neutralization

waste

Mono chlorobenzene &

dichlorobenzene

Liquid iquid chlorobenzene product

separation

Di chlorobenzene

16
2.3 OPERATIONAL DIAGRAM

Recycle Benzene Cl2 FeCl3

Water out Q FeCl3 Recycle

Benzene Purifier Pure Benzene Chlorinator

Benzene derivative Q

HCl out
Liquid -Liquid Separator

Benzene derivative without by product

20% NaOH

Benzene derivative
Liquid -liquid separator Neutralizer

Chloro & dichloro benzene

Waste

Liquid -Liquid Separator

CHLOROBENZENE PRODUCT

Di chloro-benzene

17
2.4 PROCESS DIAGRAM

18
 CHAPTER # 3
MATERIAL BALANCE

3.1 SPECIFICATIONS :
Daily Production Plan =100 tons/day
COMPOSITION OF FINAL PRODUCT:
CHLOROBENZENE = 100 Kg/day

OVERALL REACTION INVOLVED IN THE PROCESS:

C6H6 + CL2 C6H5CL + HCL
78gm 70gm 112gm 36 gm

STOICHIOMETRIC CALCULATION:
On the basis of molecular wt:

S.NO CHEMICALS INPUT OUTPUT

1 Benzene 78 0
2 Chlorine 70 0
3 Chlorobenzene 0 112
4 HCL 0 36

Total = 148 Total = 148

Benzene Chlorobenzene
78gm 112gm

𝟏𝟏𝟐
1Kg = 𝟏. 𝟒𝟑𝟓𝟗 𝐤𝐠
𝟕𝟖

Chlorine Chlorobenzene
70 gm 112gm
𝟏𝟏𝟐
1Kg = 𝟏. 𝟔 𝐤𝐠
𝟕𝟎

19
Hence limiting reactant is benzene but to keep the reaction in forward direction
we use chlorine in excess because benzene is expensive as compared to
chlorine.

Because of excess use of chlorine about 50 %

= 50% × 1.6
= 0.8 kg
Total chlorine used = 1.6 + 0.8
Total chlorine used = 2.4 Kg

BASIS:
100 kg of chlorobenzene produces per day.

3.2 MATERIAL BALANCE ON REACTOR

Benzene Chlorobenzene
CHLORINATION
Chlorine Hydrochloric Acid
REACTOR
FeCl3 Dichlorobenzene

FEED MASS FLOWRATE:

 CHLORINE :
Chlorobenzene Chlorine
112gm 70gm
100kg/day 70×100
112
100kg/day 62.5 kg/day

 We used Cl2 in excess = 50%

Amount of Cl2 in excess = 50×62.5
100
Amount of Cl2 in excess = 31.25 kg/day
Total amount of Cl2 used = 62.5 + 31.25
Total amount of Cl2 used = 93.75 kg/day
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Assume 95% conversion:

62.5
Amount of chlorine actually required =
0.95
Amount of actually required = 66.053 kg/day
Total amount of chlorine actually required = 66.053 + 31.25
Total amount of chlorine actually required = 97.3026 kg/day

UNREACTED :
Chlorine unreacted = 97.3026 – 62.5
Chlorine unreacted = 34.803 kg / day

 BENZENE:
Chlorobenzene Benzene
112 gm 78 gm
100kg/day 78*100
112
100kg/day 69.6428 kg/day

Assume 95% conversion:

Amount of benzene required = 69.6428
0.95
Amount of benzene actually required = 73.308 kg/day

UNREACTED :
Benzene unreacted = 73.308 – 69.6428
Benzene unreacted = 3.6652 kg/ day

PRODUCT MASS FLOWRATE:

 HCL
Chlorobenzene HCL
112gm 36gm
100kg/day 36×100
112
100kg/day 32.143 kg/day

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  DI-CHLOROBENZENE:
Assume that 2% of unreacted benzene produce dichlorobenzene
C6H6 + 2CL2 C6H4CL2 + 2HCL
78gm 140gm 146gm 72 gm

Benzene Dichlorobenzene
78gm 146gm
3.6652 kg 6.8605 kg/day
As 2% benzene used:
2% unreacted benzene produce 6.8605*0.02 = 0.137204

INPUT

CHEMICALS FLOWRATE MASS FRACTION

kg/day %

FEED

Benzene 73.308 41.77

Chlorine 97.3026 55.4397
FeCl2 5 2.849
TOTAL 175.5106 100

OUTPUT

CHEMICALS FLOWRATE MASS FRACTION

kg/day %

CATALYST
22
 FeCl2 5 2.849

UNREACTED

Benzene 3.592 2.0466

Chlorine 34.803 19.829

PRODUCTS

Chlorobenzene 100 75.597

HCL 32.143 24.299

Dichlorobenzene 0.137204 0.104

TOTAL 132.280 100

3.3 MATERIAL BALANCE ON NEUTRALIZATION TANK

20% NaOH solution NaCl

NEUTRALIZATION
HCL Isoamyl alcohol H2 O
TANK

NaOH + HCL NaCl + H 2O

40gm 36gm 58 gm 18gm
23
FEED MASS FLOWRATE:
 SODIUM HYDROXIDE
HCL NaOH
36 gm. 40gm
32.143 kg/day 40×32.143
36
32.143 kg/day 35.7111 kg/day
Assume 95% conversion of salt NaOH :
NaOH actually required = 35.7111
0.95
NaOH actually required = 37.5906 kg/daY
UNREACTED :
NaOH unreacted = 79.452 – 75.479
NaOH unreacted = 3.973 kg/day

20% sodium hydroxide solution is used.

For 37.5906 kg, add 187.953 kg water to make it 20% sodium Hydroxide solution.
37.5906 = 20%
187.953

 WATER:
HCL water
36gm. 18gm
32.143kg/day. 18×32.143
36
32.143kg/day. 16.0715 kg/day

 NaCl:
HCL sodium chloride
36gm 58gm
𝟓𝟖×𝟑𝟐.𝟏𝟒𝟑
32.143kg/day
𝟑𝟔
32.143kg/day 51.785944 kg/da

24
 INPUT

CHEMICALS FLOWRATE MASS FRACTION

kg/day

FEED
HCL 32.143 8.112
NaOH solution (20%) 37.5906+187.953 56.924

CHLORINATED
REACTOR
PRODUCTS
Chlorobenzene 100 25.239
Dichlorobenzene 0.137204 0.035
Benzene 3.592 0.906
Chlorine 34.803 8.784

TOTAL 396.2188 100

25
 OUTPUT

CHEMICALS FLOWRATE MASS FRACTION

kg/day

PRODUCTS
Sodium Chloride 51.785944 22.536
Water 16.0715 0.0006

CHLORINATED
REACTOR
PRODUCTS
Chlorobenzene 100 43.518
Dichlorobenzene 23.538 10.243

UNREACTED
benzene 3.592 1.563
Chlorine 34.803 15.145

TOTAL 229.7904 100

26
 3.4 MATERIAL BALANCE ON DISTILLATION COLUMN

TOP PRODUCTS
 BENZENE

FEED
 BENZENE
 CHLOROBENZENE
 DICHLOROBENZENE

BOTTOM PRODUCTS
 CHLOROBENZENE
 DICHLOROBENZENE

The input of distilled column is same as output of the reactor because all the mixture
comes in the distilled column

CHEMICALS INPUT OUTPUT

BENZENE 3.592 3.592

CHLOROBENZENE 100 100

DICHLOROBENZENE 23.538 23.538

CHAPTER # 4
ENERGY BALANCE
 Reference temperature = 25 °C
 Side reactions and energy losses are neglected
27
4.1 ENERGY BALANCE ON REACTOR

C6H6, CL2 25°C CHLORINATION

20 °C 40 °C C6H5CL, HCL
REACTORS C6H4CL2

OVERALL REACTION:
C6H6 + C6H5CL + 2CL2 C6H5CL + 2HCL + C6H4CL2
 CHLORINE :
ΔfH = 0 KJ /mol

 BENZENE :
ΔfH = 49.080 KJ / mol

 CHLOROBENZENE :
ΔfH = 11.5 KJ/ mol

DICHLOROBENZENE :
ΔfH = -42.3 KJ/ mol

 HYDROCHLORIC ACID:
ΔfH = -92.307 KJ / mol

HEAT OF REACTION:
ΔHr0 = Product – Reactant
= (-42.3-2x92.307+11.5)-(49.080+11.5+0)
ΔHr0= -275.994 KJ/mol
Chlorobenzene produced / formed per day = 100 kg / day
= 100
112
= 0.8928571 Kmole / day
Chlorobenzene produced / formed per day = 8.928 ×10 2 mole / day
28
HEAT RELEASED:
As this is exothermic reaction, heat released from the system is

= Δ Hr × moles produced
= -275.994 x 8.928 ×102
Heat released from the system = -245.435 KJ/day
Heat consumed for 0.8928 Kmole / day of chlorobenzene = -245.435 x 103
J / day
According to literature, this reaction is exothermic in nature, we firstly find its heat of
Reaction.
Reference C6H6, Cl2, HCl and MCB at 298 K
min Hin mout Hout
COMPONENTS (kg) (kJ/kmol) (kmol/hr) (kJ/kmol)
C6H6 73.308 H1 3.592 H3
Cl2 97.3026 H2 34.803 H4
HCl - - 32.143 H5
MCB - - 100 H6
DCB - - 0.137204 H7

H1= (Cp313 – Cp298 )

= 142.96 -136
H1 = 6.92 kJ/kmol
𝟑𝟏𝟑
H2 = ∫𝟐𝟗𝟖 𝟑𝟑. 𝟔 × 𝟏𝟎−𝟑 + 𝟏. 𝟑𝟔𝟕 × 𝟏𝟎−𝟓 𝑻 − 𝟏. 𝟔𝟎𝟕 × 𝟏𝟎−𝟖 𝑻𝟐 + 𝟔. 𝟒𝟕𝟑 ×
𝟏𝟎−𝟏𝟐 𝑻𝟑 𝒅𝑻
H2 = 1.0992 kJ/kmol

H3 = H 1
H3 = 6.92 kJ/kmol

H4 = H 2
H4 = 1.0992 kJ/kmol

𝟑𝟏𝟑
H5 = ∫𝟐𝟗𝟖 𝟐𝟗. 𝟏𝟑 × 𝟏𝟎−𝟑 − 𝟎. 𝟏𝟑𝟒𝟏 × 𝟏𝟎−𝟓 𝑻 + 𝟎. 𝟗𝟕𝟏𝟓 × 𝟏𝟎−𝟖 𝑻𝟐 − 𝟒. 𝟑𝟑𝟓 ×
𝟏𝟎−𝟏𝟐 𝑻𝟑 𝒅𝑻
H5 = 0.879 kJ/kmol

29
H6 = (Cp313 – Cp298 )
= 157.19 – 152
H6 = 5.19 kJ/kmol

H7 = (Cp313 – Cp298 )
= 142-138.5
H7 = 3.5 kJ/kmol

∆𝑯 = 𝒎∆𝑯𝒓 ° + ∑ 𝒏𝒐𝒖𝒕 𝑯𝒐𝒖𝒕 − ∑ 𝒏𝒊𝒏 𝑯𝒊𝒏

= (𝟕𝟑. 𝟑𝟎𝟖 − 𝟑. 𝟓𝟗𝟐) × (−𝟐𝟕𝟓. 𝟗𝟗𝟒) 𝒌𝑱/𝒎𝒐𝒍) +
(𝟑. 𝟓𝟗𝟐 ×6.92)+(34.803×1.0992)+(32.143 ×0.879) +(100×5.19)) – (
(𝟑. 𝟓𝟗𝟐 ×6.92)+( 97.3026× 1.0992))

∆𝑯 = −𝟏𝟗. 𝟐𝟒𝟏𝟐 × 𝟏𝟎𝟑 + 𝟒𝟕𝟖. 𝟓𝟓𝟒𝟏

∆𝑯 = −𝟏𝟖𝟕𝟔𝟐. 𝟔𝟒𝟓𝟗 kJ/hr

𝑸 + 𝑾𝒔 = ∆𝑯 + ∆𝑬𝒌 + ∆𝑬𝒑

Where Ws,ΔEp and ΔEk are equal to zero

𝑸 = ∆𝑯
Q = −𝟏𝟖𝟕𝟔𝟐. 𝟔𝟒𝟓𝟗 kJ/hr

4.2 ENERGY BALANCE ON NEUTRALIZATION TANK

NEUTRALIZATION
40 °C 80 °C
TANK
NaOH, HCl, NaCl, H₂O
C6H5CL, C6H4CL2 , C6H5CL, C6H4CL2

NaOH + HCl NaCl + H₂O

30
According to literature, this reaction is exothermic in nature, we firstly find its heat of
Reaction.
Heat of formation of the reactants and products given in the equation are :
HCL :
ΔfH = -92.307 KJ / mol

NaOH :
ΔfH = -469.2 KJ / mol

NaCL :
ΔfH = 787 KJ/ mol

WATER :
ΔfH = - 292.740 KJ /mol

HEAT OF REACTION :
ΔHr = (1) (787 ) + (1) ( -292.740 ) – (1) (- 469.2 ) – (1) ( -92.307 )
ΔHr = 1055.767 KJ/mol
Sodium chloride produced / formed per day = 51.786 kg / day
= 51.786
58
= 0.89286 Kmole / day
Sodium chloride produced / formed per day = 8.9286 × 10 2 mole / day
HEAT RELEASED :
As this is exothermic reaction, heat released from the system is
= Δ Hr × mols produced
= 1055.767 × 8.9286 × 102
Heat released from the system = 942.654 x 103 KJ / day
Heat released for 0.89286 Kmole / day of sodium chloride = 942.654× 10⁶ J /
day

HEAT OF FEED Q (feed ) OR Q (input) :

Taking base temperature 25 °C and Cp remains constant over temperature rise from
250C To 400C

 HYDROGEN CHLORIDE :
Q = mCpΔT
31
Q = 32.143 × 10³ × 3.312 × (313.15 – 298.15)
36
Q = 47.036 × 10³ J / day

 Sodium hydroxide:
Q = mCpΔT
Q = 225.5436 × 10³ × 7.177 × ( 313.15 – 298.15 )
40
Q = 607.0224× 10³ J / day

 Benzene:
Q = mCpΔT
Q = 3.592 × 10.259/78 x ( 313.15 - 298.15 )
Q = 7.0866 × 103 J / day

 CHLORINE :
Q= (34.803 × 1000)/70 × 4.082 × ( 313.15 – 298.15 )
Q = 30.4426 × 103 J / day

 CHLOROBENZENE :
Q = mCpΔT
Q = 100 × 1000/112 × 18.240 × (313.15 – 298.15)
Q = 244.2857 × 10³ J / day

Q (FEED ) OR Q (INPUT) :
Q (feed) =47.036 × 10³ +607.0224× 10³+7.0866 × 10+ 30.4426 × 103+ 244.2857×10³
Q (feed) = 938.29786 x 103J / day

HEAT OF PRODUCT ( Q (PTODUCTS) OR Q (OUTPUT) ):

 SODIUM CHLORIDE :
Q = mCpΔT
Q = (53.785x1000)/58 × 6.111 × (353.15-313.15)
Q = 218.2509 × 10³ J / day

 CHLOROBENZENE :
Q = mCpΔT

32
Q = (100 × 1000)/112 × 18.240 × ( 55 )
Q = 1651.4285 × 103 J / day

 DICHLOROBENZENE :
Q = mCpΔT
Q = (23.538 × 172 × 1000)/146 × ( 55 )
Q = 110.918 × 103 J / day

 WATER :
Q = mCpΔT
Q = 16,0715 × 9.069 × 1000/18 × ( 40 )
Q = 323.894 × 103 J / day

 BENZENE:
Q = mCpΔT
Q = 3.592 × 10.259/78 x ( 313.15 - 298.15 )
Q = 7.0866 × 103 J / day

Q (PRODUCTS) OR Q (OUTPUT) :
Q (Product) =218.2509 × 10³+1651.4285 × 103 + 110.918 × 103+ 323.894 × 103 +
7.0866 × 103
Q (Product) = 1311.5776 × 103 J / day

HEAT BALANCE:
Q = OUTPUT - INPUT - RELEASED
Q = Q (products) - Q (feed) - released
Q = 1311.5776 × 103 - 938.29786 × 103 - 942.654× 103
Q = -569.37426 × 103 J / day

33
 4.3 ENERGY BALANCE ON DISTILLED COLUMN

TOP PRODUCTS
 BENZENE
FEED
 BENZENE
 CHLOROBENZENE
 DICHLOROBENZENE

BOTTOM PRODUCTS
 CHLOROBENZENE
 DICHLOROBENZENE

HEAT OF FEED ( Q (feed ) OR Q (input) ) :

Input = 1311.5776 × 103 J / day
 This distillation column is liquid-liquid separation column.
 There is no heat loss in the surrounding.
 No reaction is occurring inside the distillation column.
The Enthalpy Change equation for inlet is:
𝟑𝟏𝟑.𝟏𝟓
Inlet Ĥin =∫𝟐𝟗𝟖 𝑪𝒑 (𝒍) 𝒅𝒕
Reference
Flowrate Temp ΔĤ ΔHi
COMPONENTS Phase Temp
(kg/day) (K) (kJ/mol) (kJ/day)
(K)
BENZENE l 3.592 298 353 0.552x106 7.0866
CHLOROBENZENE l 100 298 353 184.959x106 1651.4285
DICHLOROBENZENE l 23.538 298 353 16.194x106 110.918

34
HEAT OF PRODUCTS (Q (products) OR Q (output )):

 BOTTOM PRODUCTS :
𝟑𝟗𝟖
Downstream outlet Ĥout =∫𝟐𝟗𝟖 𝑪𝒑 (𝒍) 𝒅𝒕
Reference
Flowrate Temp ΔĤ ΔHi
COMPONENTS Phase Temp
(kg/day) (K) (kJ/mol) (kJ/day)
(K)
CHLOROBENZENE l 100 298 398 182400 1628.571
DICHLOROBENZENE l 23.538 298 398 404853.62 2772.969

 TOP PRODUCTS :

𝟒𝟗𝟖
Upstream outlet Ĥout =∫𝟐𝟗𝟖 𝑪𝒑 (𝒈) 𝒅𝒕
COMPONENT Phase Flowrate Reference Temp ΔĤ ΔHi
(kg/day) Temp (K) (kJ/mol) (kJ/day)
(K)
BENZENE g 3.592 298 498 7370.065 94.488

35
 CHAPTER # 5
5.1 PIPING & INSTRUMENTATION (P&ID)
DIAGRAM

36
 CHAPTER # 6
SITE SELECTION & PLANT LAYOUT
6.1 FACTORS AFFECTING DESIGN OF PLANT LOCATION AND
SITES:
CHOICE OF LOCATION & SITE SELECTION:
It is important to have a proper selection of the location of the plant. Geographical
location of plant could give a strong influence to the success of plant/Industry.
Any Mistakes while selecting Plant Location could leads to undesired situations or
problems occur, such as;
Higher cost and Investment, difficulties in marketing and transporting of the products,
dissatisfaction of the employees and customers, as well as interruptions in the
production process.
The following Factors that should be taken into considerations during the selection of
the site of the plant are;

1. INTEGRATION WITH OTHER GROUP OF COMPANIES:

This is most important factor which reduces capital cost.i.e; the new factory is located
near the factory that their works are integrated means both utilize same raw materials
or making same products.

2. AVAILABILITY OF LABOUR:
While Selection of site there must be need of both skilled and unskilled labour. The
Choice has to be made in between location where a large number of unskilled labour
and skilled labour exist but not readily available. When we go with unskilled labor
there must be need of new skills training which is not easy for them. So, the care must
be taken while selecting site.

3. AVAILABILITY OF HOUSING:
When the recruitment of staff other than locally the good housing can assist the
attractive staff which decline their interest towards the Company.

4. AVAILABILITY OF AMUNITIES:
The Availability of Amenities of Shops, banks, restaurants, Mosque these are often
attracts the good staff outside the factory.

5. AVAILABILITY OF TRANSPORT:
37
The heavy transport (i.e: Truck) for transporting the bulky material and other heavy
parts may help in transporting from one place to another thing is to be remembered
that the location must be near to sea or large airfield for Large scale exports.
Other Transport facilities (i.e; good pick and drop service availability which attracts
staff)

6. AVAILABILITY OF MATERIAL:
The location of the factory near to the main supplier reduces cost and also helps to go
readily and discuss the technical and delivery problems regarding materials and solve
the problems early.

7. AVAILABILITY OF SERVICES:
Gas, electricity, water, drainage, disposal of waste these are the basic services.

8. SUITABILITY LAND & CLIMATE:

Land and climate both are the key factors that can effect your plant processing. The
main thing is to be consider while selecting proper land that it must with stand with
the heavy structure(i.e; the new technologies of building plant structure can apply on
any type of land. Climate must be supportive, high humidity and temperature that
effects the whole pant structure.

9. ROOM FOR EXPANSION:

Room for expansion is also available to fulfill future demands in future there is need
to expand a plant according to the requirements

10. SAFETY REQUIREMENTS:

Safety of surrounding is most important while installing plant. If the processing and
production of plant produces harmful things then this type of plant must located at
remote areas.

11. SITE COST:

The most important factor ever is site cost. Although it important not for short term
gain but it has importance for long term plans.

12. POLITICAL SITUATION:

Good relationship with the local politicians on your plant location surrounding. Also
have some know how of local laws can assist in taking decisions
38
13. SPECIAL GRANTS:
Special grants like low interest loans ,rent inducement ,these are the schemes
offered by Govt and other local authorities which can help to run plant effectively.

6.2 CHOICE OF A PARTICULAR SITE

After selecting area for the plant next step is to select a Particular site in this area.
While selecting a site the owner must consider technical, commercial and financial
aspects to make maximum advantages.
Important point should be considered while selecting a particular site are;
 ECOLOGY & POLLUTION: Site must be located away from population and also
away from
 WASTE DISPOSAL: Site must be located where a suitable waste disposal facility.
 SIZE OF LAND: Site must have room for expansion for future consequences
 TRANSPORTATION FACILITIES: While selecting particular site must have a
local transport availibilty
 SUPPORTING INDUSTRIES: If New industry located where the other industry is
already placed and utilize same raw materials than their work is integrated
which reduces new industry’s capital cost.
RESEARCH ON LOCATION ECONOMICS FOR
CHLOROBENZENE
S.NO FACTORS KARACHI KARACHI
(PORT QASIM) (LANDHI ZONE)
1. Rent Rs.175,000 (2500 Sq.ft)Rs.200,000 (2500 Sq.ft)
2. Labour Rs.1137500 Rs.1137500
3. Freight Charges Rs.700000 Rs.700000
4. Power Rs.50000 Rs.50000
5. Total Operating Cost Rs.20622500 Rs.2350000
6. Transportation Company Tansport(Good) Company Transport
facilities Local Transport (Poor) (depend)
Local Transport
(Adequate)
7. Wastage disposal Landfill and Sea both Landfill and Sea both
available available
8. Ecology & pollution Less affected(far away More affected
from population)
9. Supporting industries Available Available
10. Reference Zameen.com Zameen.com

39
CONCLUSION:
On the basis of operating Cost PORT QASIM appear the best LOCATION.

6.3 PLANT LAYOUT SIGNIFICANCE

Plant layout plays a significant role in Plant processing which are given below:
1. We can save time period and minimize all expenses of Production.
2. All Operations with respect to Production are completed on specific time.
3. All Operations with respect to Production Performed on Systematic Way.
4. Flow of production in a good rhythm.
5. Effective layout minimizes the expenses at high standard.
6. Easily access of raw material towards plant.
7. Provides all basic needs of staff and labour.
8. Minimize Hazards which can affect the whole plant.
9. Easily excess of staff with labour without any delay.

LAYOUT FOR CHLOROBENZENE

PLANTATION

HOUSING ADMINISTRATIO ENTRAN

WARE CANTE INDO
FOR OR N BUILDING CE
HOUSE EN
employs
PARKING

ROOM WASTE
TESTING CONFEREN TRAINING
FOR TREATME
NT PLANT
LAB CE ROOM CENTER
EXPANSI
PLANTATION

PLANTATION

RAW POWE
PRODUCTION AREA MATERIAL R
PLANT
GARD
EMER GEN C EN
EXTR Y FIRE HOUSE DISPENSA
A EXIST RY

ROOM FOR EXPANSION PRAYER

AREA

40
PLANTATION
 CHAPTER # 7
ECONOMIC ANALYSIS

7.1 INTRODUCTION:
This chapter involves the cost estimation of the product i.e. ISO AMYL ACETATE.
Costing is the process of calculating the production cost, which fall into two sectors:
 Total capital investment (Capital Cost)
 Total production cost (Operating Cost)

TOTAL CAPITAL INVESTMENT:

It supplies all the fundamental and necessary manufacturing of the plant. It is the one
time investment, for example: equipments, installations, land etc. It is divided into two
categories:
FIXED CAPITAL INVESTMENT (FCI) :
It involves all plant facilities and sub divided into two categories:
 Direct cost
 Indirect cost
WORKING CAPITAL INVESTMENT (WCI):
It is the investment which is responsible for the working of the plant.
The formula for the Total capital investment is mentioned below:
TCI = FCI +WCI
TOTAL PRODUCTION COST:
This cost include all the expenses that are required to run an industry. It is also called
operating cost which split into two sectors:
 Fixed cost
 Variable cost
Lastly the profit of the product is analyzed by different methods.

BREAK EVEN ANALYSIS:

 In economics, business and categorically in cost accounting is the point where
the total cost and total revenue are equal. i.e. there is no loss or gain.
 Any firm which wants to make exceptional profit must find their break point.
FORMULA:
BEP = FIXED COST/ (SALE COST PER UNIT- VARAIBLE COST PER UNIT)
COST OF THE EQUIPMENTS:

41
 S.NO EQUIPMENT QUANTITY UNIT COST TOTAL COST
(PKR) (PKR)
1- Reactor 02 15500000 3100000
2- Distillation Column 03 5560000 16680000
3- Neutralization tank 01 1005000 1005000
4- Pumps 02 1057592 2115184
5- Heat Exxchanger 04 1500000 6000000
6- Storage Tank 01 309820 309820
8- Stripper 01 3500000 3500000
9- Condenser 06 17000 108000
Total Rs.25550004

7.2 TOTAL CAPITAL INVESTMENT (CAPITAL COST)

FIXED CAPITAL INVESTMENT :
FCI= Direct Cost + Indirect Cost

a. DIRECT COST:

S.NO COMPONENTS %AGE OF EQUIPMENT TOTAL COST

(PKR)
1- Purchased Euipment 100% 25550004
2- Installation 47% 12008502
3- Piping 66% 16863003
4- Instrumentation 36% 9198001.4
5- Electrical 11% 2810500.4
6- Building 18% 4599000.7
7- Yard Improvement 10% 2555000.4
8- Land 8% 2044000.3
9- Service Facilities 70% 17885003
Total Rs. 93513015

42
 b. INDIRECT COSTt:

S.N COMPONENTS %AGE OF EQUIPMENT TOTAL COST

O (PKR)
1- Design & Engineering 33% 8431501.3
2- Construction 41% 10475502
3- Contractor's fees 22% 5621000.9
4- Contingency 44% 11242002
Total Rs. 71540012

 FIXED CAPITAL INVESTMENT=D+I

FCI = 93513015 + 71540012
FCI = 165053027 PKR

WORKING CAPITAL INVESTMENT:

WCI = 10% FCI
WCI = 16505302.7 PKR

TOTAL CAPITAL INVESTMENT :

TCI = FCI+WCI
TCI = 165053027 + 16505302.7
TCI = 181558329.7 PKR

7.3 TOTAL PRODUCTION COST:

 COST OF RAW MATERIAL
Assume plant will run 300 days in a year
RAW COST COST
MATERIAL (Rs/kg) (kg/year)
Benzene Rs.160 Rs.3518784
Chlorine Rs.62.3466 Rs.13665800
FeCl3 Rs.202.6265 Rs.303939.87
20%,NaoH Rs.22.63 Rs.1531215.5
Total Rs 19019739

43
a-VARIABLE COST:

COMPONENTS COST
(pkr)
Raw material Rs 19019739
Miscellaneous material 10% of maintenance Rs 825265.135
cost
Utilities 12%FCI Rs 19806363.24
Total Rs 39651367.38

b-FIXED COST: TPC=FCI

COMPONENTS COST
(pkr)
Maintenance Cost 5% of FCI Rs 8252651.35
Operating labour 15% of TPC Rs 8800665.956
Supervision 15% of TPC Rs 8800665.956
Plant over head 50% of operating Rs 4400332.978
labour
Laboratory 20% of operating Rs 1760133.191
labour
Capital charges 15% of FCI Rs 8252651.35
Insurance 1% of FCI Rs 1650530.27
Local taxes 2% of FCI Rs 3301060.54
Royalities 1% of FCI Rs 1650530.27
Total Rs 46869221.88

c- GENERAL EXPENSES (TGE):

S.NO COMPONENTS COST (PKR)
1- Distribution and selling 15% of TPC Rs. 8800665.956
2- Financing 5% of TCI Rs. 9077916.485
3- Administration Cost 5% of TPC Rs. 24757954.05
TOTAL Rs. 42636536.49

44
TOTAL MANUFACTURING COST:
TMC= a +b = 86520589.26 PKR
TOTAL PRODUCTION COST:
TPC= a+ b+ c= 129157125.8 PKR

7.4 COST OF PROJECT:

COST OF PROJECT= TCI+ TMC +TGE
COST OF PROJECT = 139194470.9 +435711326.8 +32267809.1
COST OF PROJECT = 607173606.8 PKR

7.5 COST OF PRODUCT:

S.NO MARKET PRODUCT PRICE
VALUE PER PER PER PER PER Kg
DAY YEAR YEAR Kg (PKR)
(Kg) (Kg) (TON) ($)
1- Chlorobenzene 100 30000 30 17.67 2739.818

 COST OF PRODUCT IN MARKET = 30000 * 3000

= 90000000 PKR/ Ton
 OUR PRODUCT COST = 86520589.26/30000
= 2884.019 PKR/Kg
= 2739.818 PKR/ Kg (after ±5% approximation)
= 30000 X 2739.818
= 82194540.54 PKR/ Ton

7.6 PROFIT ANALYSIS :

GROSS PROFIT = TOTAL INCOME-TOTAL PRODUCTION COST
= 82194540.54 - 129157125.8
GROSS PROFIT = 46962585.26 PKR/year

PAYOUT PERIOD :
PAYOUT PERIOD = FCI/ (GP/2+Dep)
= 129157125.8 / (46962585.26 /2 + 12915712.58)
PAYOUT PERIOD = 1.1 years

45
RATE OF RETURN
RATE OF RETURN (Before tax) = PROFIT/ (FCI/2+WCI) * 100
= 46962585.26/ (129157125.8 /2 + 16505302.7 ) *100
RATE OF RETURN (Before tax) = 300 %

7.7 BREAK EVEN POINT :

BEP = FIXED COST/ (SALE COST PER UNIT- VARAIBLE COST PER UNIT)
Fixed Cost = Rs 46869221.88
Variable Cost = Rs 39651367.38
Variable Cost per unit = 39651367.38/30000
= 1321.712 PKR/unit
Selling Cost = 82194540.54 PKR
Selling Cost pkr /unit = 82194540.54/ 30000
= 2884.019 PKR
Break-even point = 46869221.88/ (2884.019 -1321.712)
Break-even point = 30,000 UNITS

BREAK EVEN POINT GRAPH

CONCLUSION:
According to economic analysis we have come to conclusion that we produce an
economical Chlorobenzene. As compare to the price at which we import. There is a
difference of 200 Rs approx. per kg cost as compared to import cost. Our analysis is
fulfill all the requirements for installation of new plant and better to produce e by
own.

46
REFERENCE:
Equipment cost and raw material cost from Ali Baba and anlaysis method
followed by engineering economics and perry handbook

CHAPTER # 8
SAFETY, HAZARDS AND OPERATIBILITY STUDY
8.1 PLANT SAFETY :
Feeling safe is an important aspect of life. A safe house ,a safe job ,a safe environment
and a safe house etc. are things everyone desire. Plant safety is the maintenance of
plant and the arrangement in the factory or industry for ensuring safety, absence of
risk and worker can works without any fear. Instruction, training and safety
awareness are necessary to ensure the health of all workers at plant..

OBJECTIVES OF PLANT SAFETY :

 To eliminate fire accident in the plant by reducing the fire hazard.
 To educate all members of the organization before they start operating equipment.
 To enhance employee's confidence by promoting safe and good place of working.
 To prevent loss of worker's life caused by accident.
 Should be stocked with an assortment of first aid facilities
 Should be sure that the safety of the workers isn't jeopardized
 Should proper disposal of waste of plant.

IMPORTANT FACTORS IN SAFETY OF PLANT :

1. PLANT DESIGN AND LOCATION :

The first and important feature that plant must be built in a safe side and location.
Plant site save from natural disaster such as floods, earthquakes.

2. CHEMICAL HAZARDS :
Many chemicals are explosive, toxic, and poisonous so their proper handling is
necessary. All hazardous chemicals should be stored in minimum quantity as possible.
There are three main hazards i.e. fire ,explosion and release of toxic chemicals.

47
 CHLOROBENZENE :
Chlorobenzene is an irritant to the eyes must be stored in appropriate storage
conditions. It is a flammable liquid or vapor, vapor may cause flash or fire. It is
hazardous to inhale and also it cause skin irritation.

 HYDROCHLORIC ACID :
Hydrochloric acid is highly acidic and damaging if inhaled. Store the acid in smaller
and easier to handle bottles.

 SODIUM HYDROXIDE :
Sodium hydroxide is generally not harmful chemical but cause coughing and sneezing
if a high concentration of dust has been inhaled, also it can cause the corrosion.

3. AWARENESS OF EQUIPMENTS :
Workers must be properly trained on any plant equipment or machinery . No
employee should ever All be allowed to operated equipment without instruction. It
should include proper operation as well as how to check that everything is working
as it should.

4. UNRESTRICTED ACCESS :
Work sites should only be open to the trained people and pay to be there. Family
members and employees of other department should not be allowed to the working
area. It is necessary to limit access with locked gates and doors.

5. SAFETY ISSUES :
Safety training is essential when working in plant. Employees must be aware of all
safety procedures. Safety raining should occur periodically to reduces the risk of
accident.

 EYES SAFETY :
It is important to covered your eyes all the times by wearing gas proof goggles and
flush eyes with plenty of water and consult medical treatment if irritation occurs
otherwise any injury to the eye can cause permanent eye damage.

48
 SAFETY SHOES:
Open toed shoes are not allow in the work place due to safety issue because possible
drop of the equipment.

 HEAD PROTECTION:
Your head must be covered with insulated protected helmet.

6. PROPER DISPOSAL OF WASTAGE :

Everyone wants to visit that are clean, fresh and healthy. Bad waste management can
cause land and air pollution that effects respiratory and lungs problem. There should
be enough containers to hold all waste it properly until it is removed. Waste chemicals
should be stored away from process area and disposed off .

7. AIR FLOW:
In a work place, proper ventilation is used to control exposure to airborne
contaminant. it is commonly used to remove contaminants such as dust, harmful
fumes and vapors in order to provide a healthy working environment. Ventilation can
be accomplished by natural or mechanical.

8.2 HANDLING AND STORAGE :

GENERAL HANDLING PROCEDURE :
 Wear protective rubber gloves and clothing when risk of over exposure occurs.
 Avoid physical damage or leakage to container.
 Work clothes should be washed separately.
 Do not eat, drink and smoking, when handling.
 Keep hands free of oil and grease while handling.
 Always wash your hand after using any hazardous material.
 Keep container securely sealed when not in use.
 Floor must be cleaned properly. There must not be chemical spills on the working
floor.
GENERAL REQUIREMENTS FOR STORAGE :
 Corrosive chemicals store in protective shelves and cabinet.
 Toxic materials are store in ventilated, dry and cool area.
 Do not store strong acid and alkalis together.
 Combustible chemicals must be stored in fireproof cupboard and shelves.
 Refrigerators is used for storage of chemicals must be of such a type that is
specially made for this purpose.
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STORAGE AND HANDLING FOR CHLOROBENZENE :
i. Prior to working with chlorobenzene, you should be trained on its proper
storage.
ii. Store the chlorobenzene in a tightly closed and sealed containers, in well
ventilated area away from combustibles.
iii. Chlorobenzene containers should be protected from physical damage and
source of ignition such as smoking, open flame are prohibited.
iv. Chlorobenzene should be stored separately from nitrates, strong oxidizers,
strong acids and strong bases. The federal OSHA Hazard Communication
STANDARD 1910.1200 required information about labeling of chlorobenzene's
containers.

8.3 WORKPLACE EXPOSURE LIMITS :

Exposure to chlorobenzene can occur when breathed in and through eye or skin
contact. High exposure can cause dizziness, fatigue and may cause you pass out.
Limits and regulations for exposure to chlorobenzene are given by different
authorities are given below:
 OSHA (Occupational Safety and Health Administration) :
The legal airborne permissible exposure limit (PEL) for chlorobenzene is 75 ppm
(350mg/m3) as an 8-hour time-weighted average (TWA) concentration.

 NIOSH (National Institute for Occupational Safety and Health) :

The (NIOSH) recommended airborne exposure limit (REL) for chlorobenzene of 75
ppm (350mg/m3) as a (TWA) for up to a 10-hour workday.

 ACGIH(American Conference of Governmental Insdustrial Hygienists ) :

The recommended threshold limit value (TLV) of chlorobenzene is of 100 ppm as a
(TWA) for a normal 8-hour work day.

8.4 HAZARD :
‘It is a potential source of harm or adverse health effect on a person or persons’.
Hazards to be found in every workplace, but how do we recognize which ones have
the most potential to wickedness us? By identifying hazards at our workplace, we will
be better prepared to control or eliminate them and to prevent accidents which cause
injuries and property damage.

50
A basic step in any safety protocol is to conduct a hazard assessment of environments
and equipment’s of all workplaces.
There are six main categories of workplace hazards as follow:
1. Safety hazards
2. Biological hazards
3. Physical hazards
4. Ergonomic hazards
5. Chemical hazards
6. Work organization hazards
1. SAFETY HAZARDS :
It is defined as the unsafe working conditions that can cause death, injury and illness.
It is the most common workplace hazard. It includes

 Anything that can cause falls such as working from heights, including ladders,
roofs, or any raised work area.
 Unguarded machinery and moving machinery parts that a worker can accidentally
touch.

2. BIOLOGICAL HAZARDS:
It includes blood and other body fluids, Fungi/mold, Bacteria and viruses, Plants,
Insect bites, Animal and bird droppings.

3. PHYSICAL HAZARDS :
It includes:
 Radiation
 High exposure to sunlight/ultraviolet rays
 Temperature extremes – hot and cold
 Constant loud noise

4. ERGONOMIC HAZARDS :
It occurs when the type of work, working conditions and body positions put strain on
your body. They are the hardest to recognize since you don’t always immediately
notice the strain and pain on your body. It includes;
 Repeating the same movements over and over.
 Vibration
 Having to use too much force, especially if you have to do it frequently.

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5. CHEMICAL HAZARDS:
Chemical hazards include Flammable materials, Vapors and fumes and gases. When a
worker is exposed to any chemical preparation in the workplace in any form such as
solid, liquid or gas then some Peoples/ workers who are working in industries are
more sensitive to chemicals, even common solutions and chemicals can cause skin
irritation, illness or breathing problems.

6. WORK ORGANIZATION HAZARDS :

These are the hazards associated with workplace and these hazards cause stress and
strain too. It includes workload demands, workplace violence, lack of control and/or
respect, etc.

HAZARD PICTOGRAMS:

FLAMMABLE
SYMBOL: FLAME

ACUTE TOXICITY
SYMBOL: SKULL AND
CROSS BONES

OXIDISING
SYMBOL: FLAME
OVER CIRCLE

HAZARDOUS TO THE
ENVIRONMENT
SYMBOL: DEAD TREE
AND FISH

52
 SERIOUS HEALTH
HAZARD
SYMBOL: HEALTH
HAZARD

SAFETY HAZARDS & OPERABILITY STUDY

In chlorobenzene Production the Effluent we get from two stages in production
processing which are :Benzene Purifier & Neutralizer.

WASTE FROM BENZENE PURIFIER:

The effluent we get from benzene purifier is contaminated benzene with water that
contain less then 0.1% of Benzene but it has an adverse effect on environment
because even it is in much less amount in containment water because benzene is
Volatile liquid and cancerous to human health also an adverse effect on ecology.

METHOD FOR REMOVAL OF BENZENE FROM WATER:

Now the challenge has come to remove even a small amount of benzene from water
the best choice is to utilize Scrubber, steam stripper, Bio treatment method &
activated carbon Adsorber.
The Economical methods for removal of benzene from water are:
1. ACTIVATED CARBON ADSORBER:
Carbon bed containing Adsorber utilize most because of its porous structure it
absorbs effectively VOC which is benzene here .the most important thing to use
Carbon Adsorber because we can activate carbon and utilize again for further
treatment.

2. BIO TREATMENT METHOD:

Bio filtration containing various processes(bio-trickling filters, bio scrubber and new
technology bio-membrane bio-Reactor.

3. BIO MEMBRANE BIO-REACTOR:

This is the new technology and using widely. bio treatment methods reduce operating
cost. Because of a membrane which is made up of lipids and phospholipids this is
53
permeable to water and impermeable to benzene and suspended solid work on a high
standard. The main advantage of using bio reactor is eco-friendly and economical, can
utilize again and again.

4. WASTE WATER FROM NEUTRALIZER:

Effleunt from Neutralizer containing a sludge which is NaCl salt and in both dissolved
and suspended from we utilize the methods here both physical and chemical methods
because the we can separate undissolved solid by adapted filtration process of new
technology and the methods for chemical separation needed works on coagulation
and flocculation because the suspended solids are extremely small in size we utilize
some chemicals here

5. PHYSICAL METHOD TREATMENT:

Utilize a filtration process here to remove most of the solids which is in large amount
I.e; Nacl ,so we use a Filtration assembly here which Bio-membrane bio treatment is
preferable because of its effective results and economical aspects.

6. USING AN ION-EXCHANGE:(MIXED BED RESIN)

Easy and most economical method is Ion Exchange Column which is effectively
Absorb. A mix bed resin consists of Strong Acid Cation (8% crosslink) in (H+) form
and Strong Base Anion in (OH-).
an exchanger is charged with Ca(OH)2 so the Effluent containing Nacl can effectively
exchange their ions and separate easily and also regenerate easily.

Chemical Methods:
 COAGULATION & FLOCULATION:
The colloids are removed by coagulation which neutralize the –ve charge of
suspended particles. To encourage particles and forms micro flocs.
Common Coagulant:
Is Alum which is widely use because it is cheap and easily available.
Pre-polymerized:
In organic coagulants have been used due to their availability such as PACI(polyalum
chloride) and ACH(Aluminum chloralhydrate). When added in a effluent it dissociates
in to ions I.e; Fe+3,Al+3,Na+2) forms their hydrates I.e;Na(OH)2.
Flocculation:
A physically agitation required here after addition of coagulants then send for
sedimentation.in a sedimentation tank now it is free for separate.
54
 COST ESTIMATION FOR WASTE TREATMENT PLANT
INSTRUMENTS COST(Rs)

Clarifier tank 185,805

Coagulation tank 465,125
Ion Exchanger 45000
Bio-Reactor 630000
Coagulant(Alum) 40/kg
TOTAL Rs. 1325970

DIRECT COST:
COMPONENTS % OF EQUIPMENT TOTAL COST(pkr)

Purchased Euipment 100% 1325970

Installation 47% 623205.9
Piping 66% 875140.2
Instrumentation 36% 477349.2
Electrical 11% 145856.7
Land 8% 106077.6
Service Facilities 70% 928179
Total Rs. 4481778.6

INDIRECT COSTt:
COMPONENTS % OF EQUIPMENT TOTAL COST(pkr)

Design & Engineering 33% 437570.1

Construction 41% 543647.7
Total Rs. 981217.8

F.I = DC + IC
= 4481778.6 + 981217.8
F.I = Rs. 5462996.4
When we installed waste water treatment plant then we have required to invest an
amount which is Rs. 5462996.4

55
8.5 WASTE WATER TREATMENT DESIGN FOR CHLOBENZENE PLANT

WASTE TREATMENT WASTE TREATMENT SYSTEM FROM NEUTRALIZER EFFLUENT

SYSTEM FROM
PURIFIER EFFLUENT

Water + benzene Microbes Coagulant Colloidal particles

ADSORBER BIOREACTOR COAGULATOR CLARIFIER

Benzene free Water

Sediment Free Water SEDIMENTATION

TANK

Sediment

56
 CHAPTER # 9
CONCLUSION & RECOMENDATION

9.1 SUMMERY & CONCLUSION:

1. MCB production process has a promising future.
2. Optimization of absorption column lead to a decrease in the recycle ratio of MCB
and increasing separation efficiency.
3. Optimization of distillation column sequence had led to choosing the sequence
with the lower EAOC and vapor load.
4. The greatest contributor to the fix model cost is the heat exchanger network
confirming the importance of heat integration.
5. On Economic analysis, we have come to conclusion that we should make it by
own resources. A huge cost difference is been found in between when we are
going to Import chlorobenzene and when we are going to produce
chlorobenzene by own in our country.
6. It is found in Market survey that the whole chlorobenzene is imported in our
country i.e; Not a single Production unit is been found so we have to install a
production unit in our country.
7. On Analyses of Site location, we have come to conclusion that We can move our
plant according to requirements but most important is to move early as soon as
possible. Take an initiative as quick as possible before facing any huge amount
of loss. We select the port qasim site because it is near to sea port and far away
from Population that’s a good sign to save human beings by its effect.
8. Effluent treatment is also played an important role in between to save chemicals
and discharge treated effluent in rivers, air and land fill according to the NEQS
And WHO Standards. Here we suggest the effluent treatment system which has
described the optimized treatment process in chapter 8.

57
RECOMMENDATIONS:
 It is recommended to investigate further possible process intensifications.
 It is recommended to further optimize the minimum approach temperature. i.e;
Utilize heat exchangers coil inside the vessels to fulfil temperature sensitivity
demand. It saves additional cost of extra heat exchangers utilization.
 It is highly recommended to install plant inside the country because when we
going to import chlorobenzene, we face many challenges (like delay of order
and any incident regarding shipment). more importantly we are facing a lot of
extra charges which increases total production cost.
 Also recommended to treat waste water by adapting new techniques i.e; utilize
bio reactors by using microbes as a catalyst to make Environment friendly.

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