PRELIMINARY DESIGN OF PARAXYLENE PLANT USING SELECTIVE TOLUENE DISPROPORTIONATION PROCESS Preliminary Design Of Paraxylene Plant Using Selective Toluene Disproportionation Process Capacity Of 400,000 Ton/ Year.

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PRELIMINARY DESIGN OF PARAXYLENE PLANT

USING SELECTIVE TOLUENE DISPROPORTIONATION PROCESS CAPACITY OF 400,000 TON/ YEAR

by: Delta Mutiara

D500122006

Supervisor:

1. Dr. Ir. Ahmad M Fuad, M.T. 2. Ir. Herry Purnama, M.T., Ph.D.

CHEMICAL ENGINEERING DEPARTMENT

FACULTY OF ENGINEERING

UNIVERSITAS MUHAMMADIYAH SURAKARTA

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MOTTO

Forgive , Forget , keep learning and continuing growth

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DEDICATION

bismillahirahmanirrahim

I dedicate this work to:

My Heroes, Endang Wulan Sari and Suyono . Thank you for your endless love.

Many thanks for :

My brother n sister “ fantastic Five”Alva Dian Santri, Beta Muhammad Gilang Septian , Gamma Rahma Pratiwi, Meggy Zulkarnaen Muhammad.Thank you for

support anything. You aresecond parent for me.

My cute classmate Aisyah Itsnaini solicheh, Anggie F Asokawati, Aisyah Hanifah, Diah Ayu Anggraeni ,Imala Septi Cahyani , Salam nurdin Aridin, Yulira Kus Rendra. We through all things together for 4 years more .You all are best gift in

my collge life

My patner TPP Listiani thank you for your cooperation ,patience and accomodation :D :D “ finally we made our degree together” :D D

Lecturers and staffs in department chemical Engneering UMS 2012. Thank you so much for support, guidance and encouragment

.Friends in chemical engineering UMS 2012, senior and junior . Thank for sharing experiences and help me so much.

And for everyone who have helped me to finish this final project, i can not mention one by one.

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PREFACE

Alhamdulillahirobbil ‘alamin, praise is merely to Almighty Allah SWT for gracious mercy and blessing, so this final project has been completed.

This report is one of compulsory subjects to pass bachelor degree in

Department of Chemical Engineering, Faculty of Engineering, Universitas

Muhammadiyah Surakarta. In this opportunity author grateful to all those who

helped in completing Final Project Report in particular to:

1. Rois Fatoni, S.T., M.Sc., Ph.D as Chairman of Department Chemical

Engineering, Faculty of Engineering, Universitas Muhammadiyah

Surakarta

2. Dr.Ir. Ahmad M Fuadi, M.T as Supervisor I

3. Ir. Herry Purnama M.T., Ph.D as Supervisor II

4. Lecturers in Chemical Engineering Department, Universitas

Muhammadiyah Surakarta

5. Listiani as my partner in final project

6. Family and friends who have given endorsement and prayer

7. Everyone who has supported

Due to limitations in preparation of this report, author aware that this

report might have some shortcomings. Therefore suggestion and constructive

criticism to improve this report are welcome. Author wish this report will be

useful for all those who concern.

Surakarta, January 2017

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TABLE OF CONTENTS

CHAPTER I INTRODUCTION ... 1

1.1. Background ... 1

1.2.Design capacity ... 2

1.3. Site selection ... 2

1.4.Literature Reviews ... 4

1.4.1. Kinds of process ... 5

1.4.2. use of product ... 7

1.4.3. Physical and chemical properties of raw materials and products ... 8

CHAPTER II PROCESS DESCRIPTION ... 15

2.1.Specification of raw materials and products specification ... 15

2.2.Concept of process ... 16

2.2.1. Background process ... 16

2.2.2. Reaction mechanism ... 17

2.2.3. Kinetics overview ... 19

2.2.4. Thermodynamics review ... 20

2.2.5. Operating condition ... 22

2.3. Process step ... 23

2.3.1.Raw material storage stage... 23

2.3.2.Preparation of raw material stage ... 23

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2.3.4.Separation and purification product stage ... 24

2.3.5.Products storage stage ... 25

2.3.6.Flow chart of process ... 26

2.4. Mass and heat balance ... 28

2.4.1.Mass balance ... 28

2.4.2.Heat balance ... 32

2.5.Plant and process equipment layout ... 35

2.5.1.Plant layout ... 35

2.5.2.Process equipment layout ... 39

CHAPTER III SPECIFICATION OF EQUIPMENTS ... 41

3.1. Main equipment ... 41

3.1.1. Specification of reactor (R-120) ... 41

3.1.2. Specification of distillation tower1 (D-140) ... 42

3.1.3. Specification of distillation tower2 (D-160) ... 42

3.1.4. Specification of crystalizer (E-170) ... 43

3.2. Supporting equipment ... 44

3.2.1. Specification of toluene tank ( F-110) ... 44

3.2.2. Specification of benzene tank (F-150) ... 45

3.2.3. Specification of paraxylene tank (F-190) ... 45

3.2.4. Specification of compressor 1 (G-113) ... 46

3.2.8. Specification of vaporizer (V-121) ... 48

3.2.9. Specification of furnace (Q-116) ... 49

3.2.10. Specification of separator (H-130) ... 49

3.2.11. Specification of condenser 1 (E-143) ... 50

3.2.12. Specification of condenser 2 (E-165) ... 51

3.2.13. Specification of reboiler 1 (E-141) ... 52

3.2.14. Specification of reboiler 2 (E-161) ... 52

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3.2.16. Specification of accumulator 2 (F-166) ... 54

3.2.17. Specification of cooler 1 (E-146) ... 54

3.2.18. Specification of WHB (V-121) ... 55

3.2.19. Specification of expander 1 (G-122)... 56

3.2.20. Specification of condensor 3 (E-123) ... 56

3.2.21. Specification of heat exchanger 1 (E-163)... 57

3.2.22. Specification of heat exchanger 2 (E-164)... 57

3.2.23. Specification of heat centrifuge (H-172) ... 58

3.2.24. Specification of screw conveyor 1 (J-171) ... 59

3.2.25. Specification of screw conveyor 2 (J-173) ... 59

3.2.26. Specification of melter (M-180) ... 60

3.2.27. Specification of pump 1 (L-111) ... 60

CHAPTER IV UTILITIES AND LABORATORIES ... 66

4.1. Process supporting unit ... 66

4.2. Laboratory ... 78

4.3. Health and safety work ... 80

CHAPTER V MANAGEMENT ... 92

5.1.Form of company ... 92

5.2.Organizational structure ... 94

5.3.Duties and authorities ... 95

5.4.Research and development ... 97

5.5.Working hours alocation ... 98

5.6.Status of employees and wage system ... 100

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5.8.Employee’s socialwelfare ... 102

5.9.Production management ... 103

CHAPTER VI ECONOMIC ANALYSIS ... 106

6.1 Equipments’ price approximation ... 110

6.2 Result Calculation ... 112

6.3 Feasibility analysis ... 115

CHAPTER VII CONCLUSION ... 143

BIBLIOGRAPHY

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LIST OF TABLE

Table 1.1 Use of paraxylene in industry ... 9

Table 2.1 Data heat formation at 25°C ... 21

Table 2.2 Data Gibbs Energy at 25°C ... 21

Table 2.3 Mass balancein reactor ... 28

Table 2.4 Mass balance in separator ... 28

Table 2.5 Mass balance in distillation tower I ... 29

Table 2.6 Mass balance in distillation tower II ... 29

Table 2.7 Mass balance in crystalizer ... 30

Table 2.8 Mass balance in centrifuge ... 30

Table 2.9 Mass balance in surround recycle stream ... 31

Table 2.10 Total mass balance ... 31

Table 2.11 Heat balance in vaporizer... 32

Table 2.12 Heat balance in furnace ... 32

Table 2.13 Heat balance in reactor... 33

Table 2.14 Heat balance in distillation towerI ... 33

Table 2.15 Heat balance in distillation tower II ... 34

Table 2.16 Heat balance in separator ... 34

Table 2.17 Heat balance in crystalizer ... 35

Table 2.18 Heat balance in melter ... 35

Table 4.1 Cooling water consumption ... 70

Table 4.2 Water consumption for steam (saturated steam) ... 71

Table 4.3 Water consumption for sanitation ... 71

Table 4.4 Electricity consumption for process equipment ... 74

Table 4.5 Electricity consumption for utility ... 75

Table 4.6 Electricity consumption for lighting ... 76

Table 5.1 Schedule shift group division ... 99

Table 5.2 Position classification, number of employees and salaries ... 101

Table 6.1 Cost Index of equipment ... 110

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Table 6.3 Working capital investment ... 113

Table 6.4 Direct manufacturing cost ... 113

Table 6.5 Indirect manufacturing cost ... 114

Table 6.6 Fixed manufacturing cost ... 114

Table 6.7 General expense ... 114

Table 6.8 Fixed cost (Fa) ... 116

Table 6.9 Variable cost (Va) ... 116

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LIST OF FIGURE

Figure 1.1 Import paraxylene ton/year ... 3

Figure 2.1 Flow chart of quantitative paraxylene plant ... 26

Figure 2.2 Flow chart of qualitative paraxylene plant ... 27

Figure 2.3 Plant layout ... 38

Figure 2.4 Equipment layout ... 40

Figure 4.1 Flow Diagram of water treatment ... 91

Figure 6.1 Chemical engineering cost index ... 111

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ABSTRACT

Paraxylene or 1.4 dimethyl benzene is classified into aromatic compounds. Paraxylene is primarily used as raw material in manufacture of terephthalic acid (TPA) and dimethyl terephthalate (DMT). To meet domestic demand, paraxylene plant is designed with production capacity of 400,000 tons/year. 695,205 tons/year of toluenea and 1,214 tons/year of hydrogen are used as raw material. The plant is planned to establish in Cilegon industrial area, Banten in 2020 with land area 3,800 m2 and hire 166 employees.

The manufacturing of paraxylene through three stages. At raw materials preparation stage, toluene in liquid phase is vaporized in vaporizer. Pressure of toluene and hydrogen gas is increased into 30 atm . Its temperature is also increased into 450°C in furnace. At process stage, 2 moles of toluene are isomerized to 1 mole xylene and 1 mole benzene by catalyst ZSM-5 and hydrogen as support material. The reaction takes place in reactor fixed bed multitube non isothermal adiabatic. At purification product stage, hydrogen, benzene and toluene are separated by separator and distillation process. Paraxylene is separated from xylene by crystallization process to obtain paraxylene crystal of 99% wt. Paraxylene crystall is melted in melter and ready to be marketed. Supporting unit of the plant consist of water supply as much as 968,907 kg/hour which are processed from Ciujung River, provision 296,130,095 kJ/hour of saturated steam, provision 998 kW of electricity, provision 236 liters/hour of diesel fuel, provision 50 m3/hour of instrumentation air and provision 3,252 kg/hour of ammonia.