Proyecto mtbe indonesia

PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR

MEMBER OF GROUP AND SUPERVISORS

1


ACKNOWLEDGEMENT

First and foremost, thank you to Allah S.W.T for giving us the strength to finish up this
project report. Without Your Willingness we would not be able to complete this project.
It would be impossible to acknowledge adequately all the people who have been
influential, directly or indirectly in forming this project.
We would like to take this opportunity to express our deepest gratitude to our
supervisors, Encik Mohd Imran Bin Zainuddin and Puan Sunita Binti Jobli who has
given us his constant encouragement constructive advises and his patient in
monitoring our progress in this project.
Our appreciation and special thanks goes, Puan Hasnora Binti Jafri, Puan Junaidah
Binti Jai, Encik Aziz Bin Ishak for supplying the valuable information and guidance for
this project.
We greatly indebted to Encik Napis Bin Sudin for his cooperation and willingness to be
interviewed and for provide us with invaluable information and for his resourcefulness
in gathering material.
Special thanks owe to Puan Masni Bt Ahmad for her willingness to be interviewed and
for the painstaking care she has shown in assisting us throughout the project.
We also would like to express our appreciation to the Malaysia Industrial Development
Authority (MIDA), Pusat Informasi Sirim Berhad, Petronas Resource Center, Jabatan
Perangkaan Malaysia and Tiram Kimia Sdn.Bhd. (Kuala Lumpur) for their generous
supply of relevant documents and material needed research.
Last but not least to all my lecturers, family, friends and collegues for their
encouragement and kind support when we need it most.

2


ABSTRACT

The purpose for this MTBE or Methyl tertiary Butyl Ether plant is to produce 300,000
metric tonne/year. MTBE is the simplest and most cost effective oxygenate to produce,
transport and deliver to customers. The additive works by changing the oxygenate /
fuel ratio so that gasoline burns cleaner, reducing exhaust emissions of carbon
monoxide, hydrocarbons, oxides of nitrogen, fine particulates and toxic. Two units will
be considered which are the fluidizations, (Snamprogetti) Unit and the Etherification
Unit. The raw materials used are isobutane, methanol, and water as feedstock. In
addition, two types of catalysts are chromia alumina catalyzed compound in
Snamprogetti Unit, while sulphonic ion exchanged resin catalyzed is used in the MTBE
reactor. A good deal of catalyst has been devoted to improve the activity, selectivity,
and the lifetime of the catalysts.
In the Design Project 2, we emphasize in the individual chemical and mechanical
designs for selected equipments in the plant. The chosen equipments are Catalytic
Cracking Reactor, Multitubular Fixed Bed Reactor, MTBE Distillation Column, LiquidLiquid Extraction Column and Heat Exchanger.
Design Project 2 also includes Process Control, Safety, Economic Evaluation, Process
Integration and as well as Waste Treatment, which are considered as group works.

3


CONTENTS

TITLE

PAGE

DECLARATION

II

CERTIFICATION

III

ACKNOWLEDGEMENT

V

ABSTRACT

VI

LIST OF TABLES
LIST OF FIGURES
LIST OF NOMENCLATURES

REPORT 1
CHAPTER 1 PROCESS BACKGROUND AND INTRODUCTION
1.1 Introduction
1.2 Historical Review of MTBE Production Process
1.2.1 UOP Oleflex Process
1.2.2 Philips Star Process
1.2.3 ABB Lummus Catofin Process
1.2.4 Snmprogetti Yartsingtez FBD Process

1
2
3
3
3
4

CHAPTER 2 PROCESS SELECTION
2.1
2.2

Method Consioderation
Detailed Process Description
2.2.1 Snaprogetti Yarsingtez fbd Process
2.2.2 MTBE Unit
2.2.3 Distillation Column Unit
2.2.4 Liquid-Liquid Extraction Unit

5
7
7
8
8
9

CHAPTER 3 ECONOMIC SURVEY
3.1
3.2
3.3

3.4

Market Survey
3.1.1 World Market
Asia Market
Demand
Production Capacity

10
10
11
11
14

4


3.5
3.6

3.7

Supply
Market Price
3.6.1 Methanol
3.6.2 Isobutane
3.6.3 Catalyst
3.6.4 Conclusion
Economic Analysis
3.7.1 Break Even Analysis
3.7.2 Data Calculation1

14
15
15
16
16
16
17
17
20

CHAPTER 4 PLANT LOCATIONS & SITE SELECTION
4.1
4.2

4.3

4.4

Plant Location
24
General Consideration On the site Selection
24
4.2.1 Location with Respect To Marketing Area 25
4.2.2 Raw Material supply
25
4.2.3 Transport Facilities
25
4.2.4 Availability Of Labor
25
4.2.5 Availability Of Utilities
26
4.2.6 Environmental Impact and Effluent Disposal 26
4.2.7 Local Community Considerations
26
4.2.8 Land (Site Consideration)
26
4.2.9 Political and Strategic Consideration
27
Overview on Prospective Locations
27
4.3.1 Teluk Kalong
28
4.3.2 Tanjung Langsat
28
4.3.3 Bintulu
29
Conclusion
33

CHAPTER 5 ENVIRONMENTAL CONSIDERATION
5.1
5.2
5.3

Introduction
Stack gas
5.2.1 Gas Emission treatment
Wastewater Treatment
5.3.1 Wastewater characteristic
5.3.1a) Priority pollutants
5.3.1b) Organic
5.3.1c) Inorganic
5.3.1d) pH and Alkalinity
5.3.1e) Temperature
5.3.2 Liquid waste treatment
5.3.2a) Equalization treatment
5.3.2b) Solid waste treatment
5.3.3 Waste Minimization

34
35
35
35
35
36
36
37
37
38
38
38
39
41

5


CHAPTER 6 SAFETY CONSIDERATION
6.1
6.2

6.3

Introduction
42
Material Safety Data Sheet
43
6.2.1 Isobutane
43
6.2.1.1 Product Information
43
Physical & Chemical Properties
43
6.2.1.2 Immediate Health Effects
44
6.2.1.3 First Aid Measure
44
6.2.2 N-Butane
44
6.2.2.1 Handling and Storage
45
6.2.3 Methanol
45
6.2.4 MTBE
46
6.2.4.1 Physical State and Appearance46
6.2.4.2 Physical Dangers
46
6.2.4.3 Chemical Dangers
47
6.2.4.4 Inhalation Risks
47
6.2.5 TBA
47
6.2.5.1 Recognition
48
6.2.5.2 Evaluation
48
6.2.5.3 Controls
48
Hazard Identification & Emergency Safety & Health Risk 49

CHAPTER 7 MASS BALANCE
7.1
7.2
7.3
7.4

7.5
7.6

7.7
7.8
7.9

Snamprogetti -Yarsingtez FBD Unit
Separator
Mixer
MTBE Reactor
7.4.1 1st Reaction in rector
7.4.2 2nd Reaction in reactor
7.4.3 3rd Reaction in reactor
7.4.4 Overall reaction
Distillation Column
Liquid Extraction Column
Distillation Column
Overall reaction system; flow diagram
Scales Up Factor

51
53
53
54
55
56
57
58
59
60
61
62
63

CHAPTER 8 ENERGY BALANCES
8.1
8.2

Energy Equation
Energy balance: Sample of calculation
8.2.1 Pump 1
8.2.2 Cooler 1
8.2.3 Separator
8.2.4 MTBE Reactor
8.2.5 Pump 2

64
65
73
75
76
78
79

6


8.2.6
8.2.7
8.2.8
8.2.9
8.2.10
8.2.11
8.2.12
8.2.13
8.2.14
8.2.15
8.2.16

Mixer
Expander 1
Cooler 1
Distillation Column 1
Cooler 2
Pump 3
Extraction Column
Pump 4
Pump 5
Distillation Column 2
Cooler 3

CHAPTER 9 HYSYS

80
81
82
84
86
87
88
89
91
92
93

95

APPENDICES

REPORT 2
CONTENTS
PAGE

CHAPTER 1 CHEMICAL DESIGN AND MECHANICAL DESIGN
SECTION 1 CATALYTIC CRACKING DESIGN

2.2

1.1
Introduction
1.2
Estimation of Cost Diameter of Reactor
1.3
Calculation of TDH Height
1.4
Minimum Fluidization Velocity
1.5
Calculation for Terminal Velocity
1.6
Find the Value Kih
1.7
Find the value Eo
1.8
Calculation of Solid Loading
1.9
Calculation for Holding Time
1.10 Calculation for Pressure Drop
1.11 Determine the Direction and Flowrate
1.12 Design of Cyclone
1.13 Calculation for Mechanical Design
Mechanical Design
2.2.1
Introduction
2.2.2
Design stress
2.2.3
Welded Joint Efficiency

1
3
4
4
5
8
9
10
12
14
15
17
21
58
59
59

7


2.2.4
2.2.5
2.2.6
2.2.7
2.2.7.1

2.2.8
2.2.9
2.2.10
2.2.11
2.2.12
2.2.13
2.2.14
2.2.15
2.2.16
2.2.17
2.2.18
2.2.19
2.2.20
2.2.21

Corrosion allowance
Minimum thickness of cylindrical section of shell
Minimum thickness of domed head
Loading stress
Dead weight load
1.2.7.1
Dead Weight of Vessel
1.2.7.2
Weight of the Tubes
1.2.7.3
Weight of Insulation
1.2.7.4
Weight of Catalyst
1.2.7.5
Total Weight
1.2.7.6
Wind Loading
1.2.7.7
Analysis of Stresses
Dead Weight Stress
Bending Stress
Radial Stress
Check Elastic Stability
Vessel Support
Skirt Thickness
Height of the Skirt
Bending Stress at Base of the Skirt
Bending Stress in the Skirt
Base Ring and Anchor Bolt Design
Compensation for Opening and Branches
Compensation for Other Nozzles
Bolted Flange Joint
2.2.20.1
Type of Flanges Selected
2.2.20.2
Gasket
Flange face

SECTION 3
3.1
3.2
3.3

3.4

59
59
60
61
61
61
62
62
63
63
63
64
65
65
66
67
68
68
69
70
70
71
73
74
74
74
75
75

MTBE DISTILLATION COLUMN

Introduction
Selection f Construction Material
Chemical Design
3.3.1 Determine the Number of Plate
3.3.2 Determination of Number of Plate
3.3.3 Physical Properties
3.3.4 Determination of Column Diameter
3.3.5 Liquid Flow Arrangements
3.3.7 Plate Layout
3.3.8 Entrainment Evaluation
3.3.9 Weeping Rate Evaluation
3.3.13 Number of Holes
3.3.14 Column size
Mechanical Design
3.4.1 Material construction
3.4.2 Vessel Thickness
3.4.3 Heads and closure
3.4.4 Total Column Weight

78
79
79
81
88
89
89
90
91
91
94
95
96
98
98
99

8


3.5

3.4.5 Wind Loads
3.4.6 Stiffness Ring
Vessel Support Design

SECTION 4
4.1
4.2

4.3

5.1
5.2

5.3

DESIGN OF LIQUID-LIQUID EXTRACTION COLUMN

Introduction
Chemical Design
4.2.1 Choice of Solvent
4.2.2 Estimation the Physical Properties
4.2.3 Determination the Number of Stage
4.2.4 Sizing of Sieve Tray
4.2.5 Number of Holes
4.2.6 Column Parameter
4.2.7 Weeping Evaluation
Mechanical Design
4.3.1 Material Construction
4.3.2 Vessel Thickness
4.3.3 Design of Domed Ends
4.3.4 Column Weight
4.3.4.1 Dead Weight of Vessel
4.3.4.2 Weight of Plate
4.3.4.3 Weight of Insulation
4.3.4.4 Total weight
4.3.4.5 Wind Loading
4.3.5 Analysis of Stress
4.3.5. 1 Longitudinal & Circumferential Pressure Stress
4.3.5.2 Dead weight
4.3.5.3 Bending Stress
4.3.5.4 Buckling
4.3.6 Vessel Support Design
4.3.6.1 Skirt Support
4.3.6.2 Base Ring and Anchor
4.3.7 Piping Sizing

SECTION 5

100
100
100

103
104
104
104
105
107
107
107
108
110
111
111
112
112
113
113
113
114
114
115
115
115
115
116
117
117
119
122

HEAT EXCHANGER DESIGN

Introduction
5.1.1 Designing the heater
Chemical Design
5.2.1 Physical Properties of the Stream
5.2.2 The Calculation
5.2.3 Number of Tubes Calculation
5.2.4 Bundle and Shell Diameter
5.2.5 Tube Side Coefficient
5.2.6 Shell Side Coefficient
5.2.7 Overall Heat Transfer Coefficient
5.2.8 Tube Side Pressure Drop
5.2.9 Shell Side pressure Drop
Mechanical Design
5.3.1 Design Pressure

127
129
130
130
131
133
134
135
137
139
140
140
142
142

9


5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
5.3.7
5.3.8
5.39
5.3.10
5.3.11
5.3.12
5.3.13
5.3.14
5.3.15

Design Temperature
Material of Construction
Exchanger Type
Minimum Thickness
Longitudinal Stress
Circumferential Stress
Minimum Thickness of Tube wall
Minimum Thickness of Head and Closure
Minimum Thickness of the Channel Cover
Design Load
Pipe Size Selection for the Nozzle
Standard Flanges
Design Of Saddles
Baffles

142
142
143
143
144
144
144
145
146
147
150
150
152
152

CHAPTER 2 PROCESS CONTROL AND INSTRUMENTATION
2.1
2.2
2.3

Introduction
Objective of control
Control system design sheet
2.3.1 Heat Exchanger
2.3.2 Catalytic cracking fluidized bed reactor
2.3.3 Compressor
2.3.4 Condenser
2.3.5 Separator
2.3.6 Fixed bed reactor
2.3.7 Distillation Column
2.3.8 Liquid -liquid extraction Column
2.3.9 Distillation Column
2.3.10 Mixer
2.3.11 Expander

154
155
156
156
157
158
159
160
161
162
163
164
165
166

CHAPTER 3 SAFETY CONSIDERATION
3.1
3.2
3.3

3.4

Introduction
Hazard and Operability Study
Plant Start Up and Shut Down Procedure
3.3.1 Normal Start Up and Shut Down the Plant
3.3.1.1 Operating Limits
3.3.1.2 Transient Operating and Process Dynamic
3.3.1.3 Added Materials
3.3.1.4 Hot Standby
3.3.1.5 Emergency Shut Down
3.3.2 Start up and Shut down Procedure for the main
Equipment
3.3.2.1 Reactor
3.3.2.2 Distillation Column
3.3.2.3 Liquid-Liquid Extraction Column
3.3.2.4 Heat Exchanger
Emergency Response Plan (ERP)

167
168
170
171
171
172
172
172
172
172
172
173
174
175
175

10


3.5

3.4.1 Emergency Response Procedures
3.4.2 Evacuation Procedures
3.4.3 Fires
3.4.4 Explosion, Line Rupture or Serious Leak
3.4.5 Other Emergencies
Plant Layout

176
176
177
177
177
178

CHAPTER 4 ECONOMIC EVALUATION
4.1
4.2
4.3

4.4

Introduction
Cost Estimation
Profitability Analysis
4.3.1 Discounted Cash flow
4.3.2 Net Present Value
4.3.3 Cumulative Cash flow Diagram
4.3.4 Rate of Return
4.3.5 Sensitivity Analysis
4.3.6 Payback Period
Conclusion

184
187
199
199
202
203
204
205
206
208

CHAPTER 5 PROCESS INTEGRATION AND PINCH TECHNOLOGY
5.1
5.2
5.3
5.4
5.5

Introduction
Pinch Technology
The Problem Table Method
The Heat Exchanger Network
Minimum number of exchangers

209
209
210
214
216

CHAPTER 6 WASTE TREATMENT
6.1
6.2
6.3
6.4
6.5
6.6

Introduction
Wastewater Treatment
Wastewater Treatment Plant Design
Sludge Treatment
Waste Treatment Plant Layout
Absorption tank using granular activated carbon
6.6.1 Analysis of the absorption process
6.6.2 Breakthrough Absorption capacity

220
221
224
229
230
231
232
233

APPENDICES

11


LIST OF TABLES OF DESIGN I

TABLE

TITLE

1.1

The Physical and Chemical Properties of MTBE

2.1

PAGE
2

The Comparison of the UOP Oleflex, Philips Star
SP-Isoether FBD Process

6

3.1

Trade Balance of MTBE in Asia and Pacific

12

3.2

MTBE Balances for Asia and Pacific

13

3.3

Production, Import, Export & Consumption in Europe in
Year 2000

14

3.4

Supplies MTBE Plant in Asia & Pacific

15

3.5

Standard Price for Isobutane

16

3.6

Cost of Producing MTBE 500000 tonne/year

18

3.7

Value in US Dollar Converted to RM

20

3.8

Value in US Dollar Converted to RM per tonne

20

3.9

Data Calculation by using Microsoft Excel in RM

23

4.1

The Comparison of the Potential Site Location

30

4.2

The Comparison of Location in term of Weightage Study

31

4.3

The Electricity Tariffs (Industrial Tariff) for Peninsular
Malaysia and Sarawak

33

12


LIST OF TABLES OF DESIGN II

TABLE

TITLE

PAGE

Chapter 1
Section 1
1.1

Calculation for Terminal Velocity in Different Size of dp.

8

1.2

Correlation of Three Investigators

10

1.3

Data Calculation to Find Solid Loading

12

1.4

Summary of Mechanical Design

40

3.1

The Composition in Feed Stream

80

3.2

The Composition in Top Stream

80

3.3

The Composition in Bottom Stream

80

3.4

The Average Relative Volatility,

3.5

The Non-key Flow of the Top Stream

82

3.6

The Non-key Flow of the Bottom Stream

83

3.7

MTBE Equilibrium Curve

85

3.8

Provisional Plate Design Specification

97

3.9

Summarized Results of Mechanical Design

101

3.10

Design Specification of the Support Skirt

102

4.1

Provisional Plate Design Specification

106

4.2

Summary of the Mechanical Design

118

4.3

Stress Analysis for Liquid-Liquid Extraction Column

119

4.4

Design Specification of the Support Skirt

119

4.5

Piping Sizing for Liquid-liquid Extraction Column

120

Section 3

α

82

Section 4

Section 5
5.1

Properties of Raw Material (Isobutane and N-butane)
and Steam for (E100)

5.2

130

Summary of Chemical Design For
Heat Exchanger In Series

5.3

141

By taking D = 100 mm, the selected tube nozzle

149

13


TABLE

TITLE

PAGE

5.4

By taking D = 500 mm, the selected tube nozzle is:

149

5.5

Standard Flange for Inlet isobutene

150

5.6

Standard Flange for Outlet isobutene

151

5.7

Standard Flange for Inlet Steam

151

5.8

Standard Flange for Outlet Steam

151

5.9

Using Ds = 600mm, the Standard Steel Saddles
for Vessels up to 1.2m

5.10

152

Summary of Mechanical Design For
Heat Exchanger in Series

153

2.1

Parameter at Heat Exchanger

151

2.2

Parameter at Catalytic Cracking Fluidized Bed Reactor

152

2.3

Parameter at Compressor

153

2.4

Parameter at Condenser

154

2.5

Parameter at Separator

154

2.6

Parameter at Fixed Bed Reactor

155

2.7

Parameter at MTBE Distillation Column

156

2.8

Parameter at Liquid-liquid Extraction Column

157

2.9

Parameter at Distillation Column

158

2.10

Parameter at Mixer

159

2.11

Parameter for Expander

160

Important Features in a HAZOP Study

170

4.1

Labor Cost

189

4.2

Estimation Cost of Purchase Equipment

197-198

4.3

Annual Cash flow Before Tax

200

4.4

Annual Cash flow After Tax

201

4.5

Present Worth Value

202

Chapter 2

Chapter 3
3.1
Chapter 4

14


4.6

After Tax Cumulative Cash Flow

TABLE

203

TITLE

PAGE

4.7

Present Value (RM) When i = 30% & i = 40%

204

4.8

Future Value (RM) When MARR = 15%

205

4.9

Simple Payback Period

206

4.10

The Interpolation Simple Payback Period

206

4.11

Discounted Payback Period

207

4.12

The Interpolation Discounted Payback Period

207

5.1

Shows the process data for each stream.

210

5.2

Interval Temperature for ΔTmin = 10oC

211

5.3

Ranked order of interval temperature

212

5.4

Problem Table

213

Chapter 5

Chapter 6
6.1

Parameter Limits for Wastewater and Effluent under the Environmental Quality
Act 1974

6.2

208

Functions of Pumps in the Waste Treatment Plant

215

15


LIST OF FIGURES OF DESIGN I

FIGURE
3.1

TITLE

PAGE

MTBE’s Role in US Gasoline grew rapidly
Through 1995

10

3.2

World MTBE Demand (1998-2010) – Mod Scenario

11

3.3

MTBE supply & Demand Asia and Pacific

13

3.4

Breakeven Analysis Chart Calculated by using Excel

19

5.1
.

Functional Elements in a Solid-Waste Treatment System

40

16


LIST OF FIGURES OF DESIGN II

FIGURE

TITLE

PAGE

Chapter 1
Section 1
1.1

Illustration Diagram of the Reactor

2

1.2

CDRe2 and CD/Re vs. Reynolds Number

6

Analysis of Stresses

67

3.1

MTBE Distillation Column

78

3.2

McCabe-Thiele Diagram

86

5.1

Heat Exchanger in Series for the Heating Process

129

5.2

Steel Pipe Nozzle

149

5.3

Standard Flange

150

2.1

Control Scheme for the Heat Exchanger

156

2.2

Control Scheme for Catalytic Cracking

Section 2
2.1
Section 3

Section 5

Chapter 2

Fluidized Bed Reactor

157

2.3

Control Scheme for the Compressor

158

2.4

Control Scheme for the Condenser

159

2.5

Control Scheme for the Separator

160

2.6

Control Scheme for the Fixed Bed Reactor

161

2.7

Control Scheme for the MTBE Distillation Column

162

2.8

Control Scheme for the Liquid-liquid Extraction Column

163

2.9

Control Scheme for the Distillation Column

164

2.10

Control Scheme for the Mixer

165

2.11

Control Scheme for the Expander

166

17


FIGURE

TITLE

PAGE

Chapter 3
3.1

Methyl tert-Butyl Ether (MTBE) Plant Layout

180

3.2

Methyl tert-Butyl Ether (MTBE) Plant Evacuation Routes

181

3.3

PID before HAZOP

182

3.4

PID after HAZOP

183

Cumulative Cash Flow (RM) Versus Year

203

5.1

Diagrammatically representation of process stream

210

5.2

Intervals and streams

211

5.3

Heat Cascade

212

5.4

Grid for 4 stream problem

213

5.5

Grid for 4 Stream Problem

214

5.6

Proposed Heat Exchanger Network

216

6.1

The Sludge Treatment System

229

6.2

Waste Treatment Plant Layout

231

Chapter 4
4.1
Chapter 5

Chapter6

18


Ar

-

Archimedes number

a

-

acceleration

B

-

settling chamber longitudinal cross-sectional area

b

-

dimension

C

-

constant

CD

-

drag coefficient

c

-

concentration

D

-

system diameter

d

-

particle diameter

de

-

effective fiber diameter

E,

-

field intensity

F

-

cross-sectional area

Pr

-

Fronde number

g

-

gravitational acceleration

H

-

height

K

-

precipitation constant ,

A

-

Cross sectional area of catalytic reactor

Aor

-

Area of orifice

C Ag

-

Concentration of gas reactant

CD

-

Drag coefficient

d Bv

-

Diameter of bubble in the bed

dp

-

Particle diameter

D

-

Diffusivity

Dt

-

Diameter of catalytic reactor

e

-

Thickness

E

-

Activation energy

19


FBo

-

Mass flow of coal to the catalytic reactor

FC

-

Fixed carbon mass fraction

Hbed

-

Height of bed

Hh

-

Height of Catalytic reactor

J

-

Joint factor

k”

-

Reaction rate constant

k

-

Reaction rate constant

K eq

-

Equilibrium constant

L

-

Height above the bed

n

-

Total no of orifice

N

-

No of holes in 1 m2 area

Nor

-

No of orifice in 1 m2 area

PCO , PH 2 O

-

Pi

Design stress

-

Partial pressure

rC , rS -

Rate of reaction

R

-

Ideal gas constant

Ret

-

Reynolds number

Rp

-

Radius of particle

t

-

Total holding time

T

-

Temperature

Uo

-

Superficial gas velocity

Umf

-

Minimum fluidization velocity

Ut

-

Terminal velocity

VBed

-

Volume of bed

WBed

-

Weight of coal in bed

WC

-

Total mass of carbon

X

-

Conversion factor

α

-

Fitting parameter (for this design is 0.21)

β

-

Fitting parameter (for this design is 0.66)

ρg

-

Gas density

ρB

-

Molar density

ρs

-

Bulk density of catalyst

ρp

-

Particle density

20


µg

-

Gas viscosity

τ

-

Time for complete conversion of reactant particle

∆
p

-

Pressure drop

E

-

total elutriation rate of particles

Ef

-

frictional force of particles

Ei

-

entrainment rate of panicle size i

Ei∞

-

elutriation rate of particle size i

Eo

-

total entrainment rate at bed surface

E∞

-

total elutriation rate of particles

g

-

gravitational acceleration constant

gc

-

gravitational conversion constant, m kg/s2 kg -force

Gi

-

solids flow rate

h

-

height above dense bed surface

Rep

-

particle Reynolds Number = ρ g (U o − U ts ) d p / µ

Ret

-

dpU ρ / µ
g

t

-

time

Umf

-

minimum fluidization velocity

Uo

-

superficial gas velocity

Usi

-

solid velocity (upward)

Us

-

single particle terminal velocity of particle size i

W

-

weight fraction of bed

Ws

-

weight of solid particles in verlical pipe having length h

Xi

-

weight fraction of particle size i in bed

Greek Symbols

ε

-

voidage in freeboard

21


εi

-

voidage in freeboard for system having only particle size i

λ

-

solid friciion coefficient

ρg

-

gas density

ρp

-

particle density

22


CHAPTER 1

PROCESS BACKGROUND AND INTRODUCTION

1.1

INTRODUCTION

Methyl tertiary butyl ether (MTBE) is produced by reacting isobutene with methanol
over a catalyst bed in the liquid phase under mild temperature and pressure. Isobutene
can be obtained from stream cracker raffinate or by the dehydrogenation of isobutane
from refineries. Ether in general is a compound containing an oxygen atom bonded to
two carbon atoms.
In MTBE one carbon atom is that of a methyl group – CH3 and the other is the central
atom of a tertiary butyl group, -C (CH3)). At room temperature, MTBE is a volatile,
flammable, colorless liquid with a distinctive odour. It is miscible with water but at high
concentrations it will form an air-vapour explosive mixture above the water, which can
ignite by sparks or contact with hot surfaces.
MTBE has good blending properties and about 95% of its output is used in gasoline as
an octane booster and an oxygenate (providing oxygen for cleaner combustion and
reduced carbon monoxide emissions). It is also used to produce pure isobutene from
C4 streams by reversing its formation reaction. It is a good solvent and extractant.

Table 1.1: The Physical and chemical properties of MTBE

23


Chemical formula
Molecular structure
Oxygen content
Physical state (at normal

C5H12O
(CH3)4CO
18.2 wt%
Colorless liquid

temperature and pressure)
Boiling point
Melting point
Flash point
Autoignition temperature
Flammable limits in air
Relative density
Vapour pressure
Reactive index
Color
Water solubility

55.2oC
-108.6 oC
30 oC
425 oC
1.5 – 8.5%
0.7405g/ml at 20 oC
245 mm Hg at 25 oC
1.3690 at oC
Colorless
42000mg/l at 25 oC (<10% in
water, miscible with ethanol and

Partition coefficient noctanol/water (log10)
Henry’s Law Constant

1.2

diethyl ether)
1.06
65.4 Pa/m3/mol

HISTORICAL REVIEW OF MTBE PRODUCTION PROCESS

The MTBE plants actually consist of six units: Isomerization Unit (including
deisobutanizer), Dehydrogenation Unit, MTBE Unit, Methanol Recovery Unit,
Oxygenate Removal Unit and Olefin Saturation Unit. A common offsite utility system
will be incorporated to distribute the required utilities to each unit. There are four
method of producing MTBE implemented under license as the following:
1. UOP-Oleflex Process
2. Phillips STAR Process
3. ABB Lummus Catofin Process
4. Snamprogetti-Yarsingtez FBD (SP-Isoether) Process.
1.2.1

UOP-Oleflex Process

24


The UOP-Oleflex process uses multiple side-by-side, radial flow, moving-bed reactors
connected in series. Preheated feed and interstage heaters supply the heat of reaction.
The reaction is carried out over platinum supported on alumina, under near isothermal
conditions. The catalyst system employs UOP's Continuous Catalyst Regeneration
(CCR) technology. The bed of catalyst slowly flows concurrently with the reactants and
is removed from the last reactor and regenerated in a separate section. The
reconditioned catalyst is then returned to the top of the first reactor.
processes

involved

are

the

deisobutenization,

the

isomerisation

The typical
and

the

dehydrogenation process that has been commercial in Malaysia.
1.2.2

Philips Star Process

The second one is the Philips Steam Active Reforming (STAR) Process. The Phillips
Steam Active Reforming (STAR) Process uses a noble metal-promoted zinc aluminate
spinel catalyst in a fixed-bed reactor. The reaction is carried out with steam in tubes
that are packed with catalyst and located in a furnace. The catalyst is a solid,
particulate noble metal. Steam is added to the hydrocarbon feed to provide heat to the
endothermic reaction, to suppress coke formation, and to increase the equilibrium
conversion by lowering partial pressures of hydrogen and propane.
1.2.3

ABB Lummus Catofin Process

The ABB Lummus Catofin Process uses a relatively inexpensive and durable
chromium oxide–alumina as catalyst. This catalyst can be easily and rapidly
regenerated under severe conditions without loss in activity. Dehydrogenation is
carried out in the gas phase over fixed beds. Because the catalyst cokes up rapidly,
five reactors are typically used. Two are on stream, while two are being regenerated
and one is being purged. The reactors are cycled between the reaction and the
reheat/regeneration modes, and the thermal inertia of the catalyst controls the cycle
time, which is typically less than 10 minutes. The chromium catalyst is reduced from
Cr6+ to Cr3+ during the dehydrogenation cycle. The raw materials used to produce
MTBE by using this method are butanes, hydrogen and as well as recycled isobutene
from the system itself. In this process, there is an isostripper column, which separates
the heavies, and the light ends from which then could produce MTBE.

25


1.2.4

Snamprogetti-Yartsingtez FBD (SP-Isoether)

The Snamprogetti-Yarsingtez SP-Isoether (FBD) Process uses a chromium catalyst in
equipment, which is the fluidized bed that resembles conventional fluidized catalytic
cracking technology used in the oil refinery. The catalyst is recirculated from the
reactor to the regeneration section on a 30–60-min cycle. The process operates under
low pressure and has a low-pressure drop and uniform temperature profile.
Snamprogetti has been presenting and marketing their hydrogenation technology,
ISOETHER 100, since 1997. This process is to be used to convert MTBE units by
utilizing Snamprogetti’s MTBE Water Cooled Tubular Reactor Technology. In this SPIsoether Process, the products are MTBE and isooctagenas (iso octane gas). In this
SP-Isoether Process the catalyst used in the isoetherification reactor is the same as
those other typical processes, which is Platinum. (Please refer Appendix A – Figure
1.3).
Four method processes of the MTBE above are favorable among the
petrochemical firms.

CHAPTER 2

PROCESS SELECTION

26


Suitable process, which is gives a lot of profit and less problem is an important in order
to determinant for the success of a plant. This chapter will briefly discuss the best
process selected based on a few criteria. It covers general consideration, detailed
consideration for process selection and conclusion on the process selection.

2.1

METHOD CONSIDERATION.

From the processes mentioned earlier, there are many ways to produce MTBE. It is
essential to choose the best method that will be used to produce MTBE. The selection
of the method must consider the safety of the plant, minimum waste or by product
generated, efficient and economical. Snamprogetti-Yarsingtez SP- Isoether FBD
process will be chosen as the method to produce MTBE. More detailed reasons for the
selection of this process are: High conversion (greater than 98 %) with few by-products
compared to other process. From the economy aspect,Snamprogetti-Yarsingtez FBD
Process can reduce the cost of setting up the plant as it can be implied in any of typical
MTBE-produced plant, known as “Financial Safety Net”.(When an MTBE plant faces an
oversupplied MTBE market, Isoether makes it possible to switch production from
MTBE to a superior Alkylate.). As for the safety aspects of the plant, as the
Snamprogetti-Yarsingtez FBD is a safe process as it just use the fluidize bed to the
process of producing MTBE. The process operates under low pressure and has a lowpressure drop and this means that the fluidized bed is physically not harmful to anyone.
As for the temperature, it operates under uniform temperature profile. As the
temperature is not high, this means that the process is not as dangerous as other hightemperature-operated process. But, precautions should be taken seriously all the time,
as we do not know when an accident could happen even in the safest place. As for the
waste by using the Snamprogetti-Yarsingtez FBD Process, the product of the process
is only MTBE and other effluent and as well as flue gas which are not harmful to the
environment.
Table 1.1 The comparison of the UOP-Oleflex, Philips Star, ABB Lummus Catofin and
Snamprogetti- Yartsingtez SP-Isoether FBD process.

27


Method and

UOP-Oleflex

STAR Philip

ABB Lummus

Snamprogetti-

Consideration

Process

process

Process

Yarsingtez FBD

Investment cost

Investment cost

Lower capital

process
Reduce the cost

is very modest

were evaluated

investment

of setting up the

Economic

for 700 BPSD

plant as it can be

Consideration

(650tonne/day)

implied in any of

feed capacity

typical MTBE-

97-99%

98%

99 .99%

produced
Greater than 98%

1. Higher per

1. The Stabilized

1.CD Tech

1.Environmental

pass

Product Is Near

Efficiently Uses

Friendly

conversion and

Equilibrium

The Heat

2.”Financial

at least 1-2%

Mixture Of

Released By An

Safety Net”.

higher catalyst

Isobutane.

Exothermic

(When an MTBE

selectivity as a

2.The Light-End

Reaction.

plant faces an

result of lowest

Yield Fr. Cracker

2.Conducting 2

oversupplied

operating

Is Less Than 1

Unit Operations

MTBE market,

pressure and

Wt% Butane

In 1 Equipment

Isoether makes it

temperature.

Efficiency

Feed

(Isobutylene
Selectivity)
Advantages

possible to switch

2. No catalyst

production from

losses.

MTBE to a
superior Alkylate.)

Disadvantages

1. Less

1. Much heat is

1. The Reaction

1. Not widely

efficiencies

needed as

Must Take Place

practiced in

furnace is used.

In The Liquid

industry, as it

Phase –Catalyst

needs thorough

Must Remain

research to

Completely

implement it.

Wetted.
2.The Reaction
Cannot Be Overly

28


Endothermic

2.2.1

DETAILED PROCESS DESCRIPTION

2.2.2

Snamprogetti-Yartsingtez SP-Isoether (FBD) Process

The Snamprogetti-Yarsingtez SP-Isoether (FBD) Process uses a chromium catalyst in
equipment, which is the fluidized bed that resembles conventional fluidized catalytic
cracking technology used in the oil refinery with 65% isobutane (i-C4H10) conversion to
produce isobutene.
Dehydrogenation reaction that occur in this process:
iC4H10

iC4H8 + H2

The main feature of this process is that the catalyst filled annuli are connected in such a way
that small, discrete amounts of catalyst can be withdrawn from the bottom of a reactor,
and sent to the top of the reactor. Catalyst withdrawn from the bottom of the reactor is
sent to a separate regeneration section for regeneration prior to being sent to the top of
the reactor. The catalyst is recirculated from the reactor to the regeneration section on
a 30–60-min cycle. The reactor and regeneration sections are totally independent of
each other. The regeneration section can be stopped, even for several days, without
interrupting the dehydrogenation process in the reactor section. The vaporized
isobutane is fed along with fresh catalyst to the first, called reactor, and the spent
catalyst is separated from the products and sent to the regenerator, where air (O 2) is
added to oxidize the carbon. The reactor cracks the isobutane and forms coke on the
catalyst. Then in the regenerator the coke is burned off and the catalyst is sent back
into the reactor. The “magic” of this process is that the reactor-regenerator combination
solves both the heat management and coking problems simultaneously. Burning off the
coke is strongly exothermic, and this reaction in the regenerator supplies the heat
(carried with the hot regenerated catalyst particles) for the endothermic cracking
reactions in the reactor.
The process operates under low pressure and has a low-pressure drop and
uniform temperature profile. Products that have been produced from this unit are

29


isobutene. Isobutene available in the C4 stream from the Snamprogetti-Yarsintez FBD
unit will be combining with methanol, which is sourced from the Sabah Gas Industries
methanol plant in Labuan to produce, fuel-grade MTBE with a high-octane value in the
MTBE unit.
2.2.3

MTBE Unit

The MTBE unit includes two sections such as the main reaction section and the
finishing reaction. In the main reaction section, 98% conversions of isobutene occurs
mainly in the main reactor which are designed to provide the mechanical ands thermal
conditions required by the expanded catalyst bid technology.
Reactions occur in this unit are:

1.

iC4H8 (isobutene) + CH3OH (methanol)

2.

CH3OH + CH3OH

(CH3)2O + H2O (DME)

3.

iC4H8 + H2O

C4H10O (TBA)

C5H12O (MTBE)

The reactor is operated in an up-flow direction with an external liquid recycle to
remove the heat of reaction and to control the expansion of the catalyst bed. This
selective reaction of methanol with isobutene is conducted in liquid phase at moderate
temperature on an ion exchange resin type catalyst. The expansion of the catalyst bed
in the reactor is ensured by pump around circulation loop with a cooling water cooler to
control the reactor feed temperature to remove the heat of reaction. Resin traps on top
of each reactor to trap resin in case of carryover with the liquid. In the finishing reactor
section, isobutene final conversion is achieved in a catalytic column where reaction
and distillation are performed simultaneously.

2.2.4

Distillation Column Unit

30


This column includes a separation column yielding MTBE product at the bottom and
(isobutene, isobutene, normal butane, water and DME) with methanol entrained by
azeotropy at the top. The reaction section bed is contained in the upper part of this
column. An excess of methanol is maintained corresponding to the amount leaving the
tower in the azeotrope. The required methanol is passed through guard beds and
filtered prior to being charged to the catalytic column to achieve final conversion.
Bottom MTBE product and the other by-product such as TBA, DME is sent to rundown
tanks under level control after cooling in feed/bottom exchanger and trim cooler.
The overhead of the column is condensed in the air-cooled condenser under
pressure control. One part of the liquid is sent to the column as reflux and the other
part to the liquid-liquid extraction unit after cooling.
2.2.5

Liquid-Liquid Extraction Unit

In this unit methanol will extract from the isobutene, isobutene, normal butane to
produce C4 raffinate from the overhead of the column and at the bottom, methanol and
water are produced. C4 raffinate from this unit we decided to sell to the Korea.

CHAPTER 3

ECONOMIC SURVEY

31


3.1 MARKET SURVEY
3.1.1

World Market

The MTBE market has been in strong continuous growth since 1992. For instance, the
1998 world consumption was approximately 19.5 million tonnes, about double that of
1992, representing an annual growth rate of about 12%. Present trends indicate a mild
growth in 2000, up to 20 million tonnes, with US consumption slightly declining and
other parts of the world growing (EEA 2000). The MTBE’s role in U.S. gasoline grew
rapidly through 1995 given away in figure 3.1.

Figure 3.1 MTBE’s role in U.S. gasoline grew rapidly through 1995
(Sources: Local Issues, Global Implications)

3.2 ASIA MARKET

Most Asia countries such as South Korea, Japan, Hong Kong, Taiwan, China, Malaysia,
Singapore, Philippines and Thailand, have already phased lead out of their gasoline pool
and are replacing it with oxygenates such as MTBE. Due to MTBE’s relative ease in
blending into gasoline, easy transportation and storage, as well as relatively cheap and
abundant supply, MTBE is the most widly use oxygenate in Asia.
However, the use of MTBE in gasoline blending is not mandatory for countries
like South Korea and Thailand. South Korea, for instance, requires a 1.3% - 2.3%
32


oxygenate content in gasoline during the winter, compared to a minimum of 0.5% for
the summer. In other Asian Countries, MTBE is mainly use as an octane booster to
replace lead. (source: features mtbe asias.html).

3.3 DEMAND
World demand of MTBE mod scenario is about 4.1 mil ton per annum consumption in
US West Coast at stake due to the legislation from 1998 to 2010. It has as an impact
on 80% of PETRONAS MTBE exports to the US. This mod scenario is representing in
figure 3.2.

Figure 3.2: World MTBE demand (1998-2010) – mod scenario
(Sources: Petronas’s Library Kuala Lumpur City Center (KLCC)
U.S. demand is about 250,000b/d, dominates MTBE consumption. Most MTBE
is used to comply with mandated oxygen content rules for gasoline supplied to either
RFG or wintertime carbon monoxide areas. A small amount may be utilized for octane
enhancement.
In Europe, MTBE demand is estimated about 60,000 b/d. MTBE use in Europe
is essentially confined to Octane enhancement, and about 6,000 b/d is exported to the
United States. Eastern Europe currently consumed about 10,000 b/d of MTBE.

In Asia, demand for MTBE in this region is expected to grow at much more
rapid rate than elsewhere in the world. The rate will taper off late in decade from about
12% per year to about 8% by the turn of the century, since the early rapid growth has
33


been fed by the lead phase down which should be nearly complete by 2000. Throughout
the period, the region will be a net importer of MTBE, mostly obtained from the Middle
East. The trade balance of MTBE in Asia and Pacific is expected to be in table 3.1.
(Sources: MTBE annual Report)
Table 3.1 Trade Balance of MTBE in Asia and Pacific

Capacities listed are the average available during the year. Details for 1995 and 1999
of MTBE Balance for Asia and Pacific are shown in table 3.2. These data are also
shown graphically in figure 3.3 which indicate for MTBE supply and demand Asia and
Pacific. (Sources: MTBE annual Report)

Table 3.2: MTBE Balance for Asia and Pacific

34


MTBE supply and demand
Asia and Pacific

Figure 3.3: MTBE supply and demand Asia and Pacific
Demand for MTBE expected to be marginally firmer in the near future as Asian
Countries such as Indonesia and India are working totally phase out lead from their
gasoline pool. Supply on other hand is expected to remain abundant, as Asia is able to
produce about 3 million Mt/yr of MTBE for its Captive consumption. In addition to this,
Asia attracts a regular supply of about 500,000 ton/yr of MTBE from Middle Eastern
and Europe sources.(Reference: features mtbe asias.html).

35


3.4 PRODUCTION CAPACITY

Commercial production of MTBE started in Europe in 1973 and in the US in 1979. Total
worldwide production capacity in 1998 was 23.5 million tones and the actual production
was 18 million tones
The annual production volume of MTBE in the year 2000 in the Europe was
2,844,000 tons. About 129,000 tonnes was imported and about 479 000 tonnes were
exported outside the Europe in the year 2000 ((Dewitt & Company Inc. 2002). The
majority of the exported volume (> 83%) was exported to USA and Canada. The
majority of exported volume (> 80%) was transported as non-blended MTBE and
minority as a component of petrol (blended). The annual consumption of MTBE within
the Europe was hence 2,495,000 tons in the year 2000 (see table below). For the future
no substantial increase in MTBE usage is expected. (Dewitt & Company Inc. 2002).
Table 3.3: Production, import, export and consumption in Europe in year 2000
(tonnes/year) souces: (Dewitt & Company Inc. 2002).
Production
2 844 000

Import into Europe
129 000

Export outside Europe
479 000

Consumption
2 495 000

The world's MTBE industry today is operating at about 80% of capacity. The US
is by far the largest market, having about 43% of the production capacity but
consuming 63% of total global output. On stability, the Middle East is the swing
producer, exporting more than 50,000 bbl/day to the US and elsewhere.

3.5

SUPPLY

DeWitt’s Company estimates for local production of MTBE a summarized in table 3.4.
Most of plants unit are refinery-based units taking isobutylene from FCCU units, or as
Raffinate I from olefins plants. Since olefin plants in the region a mostly naphthabased, they produce significant quantities of C4 olefins for this purpose. There is one
butane-based plant in Malaysia. Table 3.4 also shown for MTBE plants suppliers to
Asia and Pacific.

36


Table 3.4 Suppliers MTBE plant in Asia and Pacific

3.6 MARKET PRICE
3.6.1

Methanol

Price of methanol, as feedstock in Asia is $240 - $280 /ton. While in Europe, the prices
is $265 - $270 / ton free on board (fob) Rotterdam. In U.S. the price of methanol is 76
cts – 77cts/ gal in fob.
Global Methanol demand is expected to increase to 3.5 % per year over the
next 5 years, compared to 1.0% - 1.5% growth in 2002 and 2003. Those lower growth
rates are attributable to the phase-out of Methyl tert-butyl ether (MTBE) as oxygenate
in gasoline in California, and slower economic growth in China caused by SARS.
Methanol growth in China is forecast at 7% - 8.5% per year, fueled by formaldehyde
and acetic acid demand. (Chemicals Week)

3.6.2

Isobutane

Standard price for isobutene is stated by followed:

37


Table 3.5 : Standard price for isobutane
Grade

Purity

Grade 4.0

99.99%

Grade 3.0

99.9%

Instrument

99.5%

3.6.3

Cylinder Size
LP30
LP15
LP05
LP01
1/2 Ton
LP30
LP15
LP05
LP01
1 Ton
LP30
LP15
LP05
LP01

Volume
lbs
117
60
23
6
490
117
60
23
6
490
117
60
23
6

Price per Cylinder
RM900.00
RM600.00
RM370.00
RM200.00
RM1225.00
RM380.00
RM240.00
RM170.00
RM100.00
RM890.00
RM293.00
RM185.00
RM100.00
RM75.00

Catalyst

Price of Chromia catalyst Compound – USD60 000/Rottedam (Rdam) from the existing
plant. (En Mohd. Napis, from MTBE plant, Gebeng )
3.6.4

Conclusion

Our company will import the methanol and isobutane as feedstock, from Petronas
Malaysia and United State (US) respectively. Methanol feedstock will be supplied from
Gurun, Kedah production capacity of 66,000 ton/year. For the second feedstock,
isobutane (instrument grade) will be supplied by Chevron Phillips Chemical Company
LP, 10001 Six Pines Drive, The Woodlands, Texas, US by shipping method.
MTBE is suitable as a gasoline additive which simultaneously increases the
octane rating of the fuel and adds oxygen which promotes cleaner burning. When used
in place of lead-based octane enhancers, dual environmental benefits are realized, a
reduction in atmospheric lead concentrations and reduced emissions of carbon
monoxide and other smog forming chemicals. Since the 1970s, the worldwide

38


consumption of MTBE has increased significantly and many new facilities have been
constructed to support the growing market (Kirschner, 1996; Riddle, 1996).
MTBE production will increase in future in Asia, Asia Pacific, Middle East and
Europe even though MTBE is banned in California but not in the entire nation of the
United States.

3.7

ECONOMIC ANALYSIS

An economic analysis used to smooth the progress of based on existing plant. This
analysis is important to ensure that the chemical plants converge and the economics is
satisfactory before the plant operate. All the data taken from MTBE Annual 1994,
DeWitt & Company

Incorporated, 16800 Greenpoint Park, Suite 120 N, Houston,

Texas, that given by Petronas Library, KLCC.
3.7.1

Break-Even Analysis

When chemical engineers determine outlay for any type commercial process, they
want these costs to be enough accuracy to provide reliable decision. To accomplish
this, they must have a complete understanding of the many factors that can affect
costs. Break-even analysis is important to ensure that the plant can give profit before
the plant can run.
The objective of break even analysis is to find the point, in dollars or in ringgits
and units, at which costs equal revenues. This point is the break even point. Break
even analysis requires an estimation of fixed costs, variable costs and revenue.
Fixed costs are costs that continue even if no units are produced. Examples
include depreciation, taxes, debt, and mortgage payments. Variable costs are those
that vary with the volume units produced. The major components of variable costs are
labor and materials. However, others cost, such as the portion of the utilities that varies
with volume, are also variable cost. The different between selling price and variable
cost is contribution. Only when total contribution exceeds total fixed cost will there be
profit.

39


Another element in break-even analysis is the revenue function. From the
graph, revenue begins at the origin and proceeds upward to the right, increasing by
selling price of each unit. Where the revenue function crosses the total cost line (the
sum of fixed and variable costs), is the break even point, with a profit corridor to the
right and a loss corridors to the left.
Table 3.6: Cost of producing MTBE 500,000 ton/year
(Sources: DeWitt & Company Incorporated, Annual Report)

Table 3.6 showed that the cost of production of MTBE based on existing plant
producing 500,000 ton/year. From table 3.6, given data, break-even analysis can be
calculated to know the break-even point figure. Figure below indicate that break-even
chart, where it has been calculated by using excel that shown in table 3.8 and based
on the data given from table 3.6.

40


Figure 3.4 : Break even analysis chart calculated by using excel.
From the break even chart figure above, the value of break-even point at the
existing capacity of 500,000 ton/year is 185,629.85 tons in units and RM
244,679,817.14 in Ringgit Malaysia (RM). This value indicates the minimum units and
values needed to be sold. The given capacity of 500,000 tons/year can give profit to
the company. The margin of safety (MOS) calculated from the graph, which is
314,370.15 tons and RM414,373,182.86. Margin of safety (MOS) in percentage of
sales is 62.87%. The sale is allowed to drop about 62.87% before the company will
incurred a loss.
In other word, at selling 300,000 tons/year capacity will also give profit to our
company. The margin of safety from the graph for 300,000 ton/year calculated is
114,370.15 tons and RM150,751,982.86. The margin of safety (MOS) as percentage of
sales is 38.12%. The sale is allowed to drop about 38.12% before the company will
incurred a loss. All the data calculation is shown in the next section.

41


3.7.2

Data Calculation

All the data based on 500,000 tons/year producing MTBE from existing plant.
Table 3.7 Values in USD converted to RM
(Sources: Data collected from table 3.6)
Total revenue, TR
Total variable cost, TVC
Total fixed cost, TFC

RM 659,053,000.00
RM 504,754,000.00
RM 57,285,000.00

Total Revenue (TR), MTBE (500,000 ton),
TR

= Quantity of MTBE X Price of MTBE
= QMTBE X PMTBE
= 500,000 tons X USD346.87 X 3.8
= RM 659,053,000

Total cost
TC

= total fixed cost + total variable cost
= TFC + TVC

Where,
Total fixed cost

= 500,000 ton X USD30.13 X 3.8
= RM 57,285,000.00

Total variable cost

= 500,000 ton X USD (226.4 + 39.26) X 3.8
= RM 504,754,000.00

∴ Total cost, TC

= RM57,285,000.00 + RM 504,754,000.00
= RM 562,039,000.00

Tables 3.7 represent cost per unit ton converted into Ringgit Malaysia (RM), taking
data’s directly from the table 3.6.
Table 3.8 Values in USD converted to RM per ton
(Sources: Data collected from table 3.6)
Revenue (RM) per ton
RM1,318.00
Variable cost (RM) per ton
RM 1,009.51
Fixed cost (RM) per ton
RM114.57
Break-even point in ton can be calculated based on formula equation, which given by
follow:

42


Break-even point, BEP (tons)

= Total Fixed cost
Contribution/ton

where,
Contribution/ton

= revenue / ton - variable cost / ton

∴ BEP (tons) =

______RM 57,285,000.00_____
(RM1, 318.00 - RM 1,009.51)

=

185,629.85 tons (the minimum capacity)

Next, Break-even point in RM can be calculated based on formula equation, which
given by follow:
∴ BEP (RM)

=

Break-even point, BEP (tons) X revenue / ton

=

185,629.85 tons X RM1, 318.00

=

RM 244,679,817.14

Beside that, margin of safety and percentage of sale can be calculated as follows:
For 500,000 ton/year production,
∴ Margin of safety (MOS) in units = Budgeted sale (units) - BEP (units)
= 500,000 tons - 185,629.85 tons
= 314,370.15 tons
∴ Margin of safety (MOS) in RM = Budgeted sale (RM) - BEP (RM)
= RM 659,053,000.00 - RM 244,679,817.14
= RM 414,373,182.86
∴ Margin of safety (MOS) as percentage of sales = MOS (RM) x 100%
Sales(RM)
= RM 414,373,182.86 x 100%
RM 659,053,000
= 62.87%

43


For 300,000 ton/year production,
∴ Margin of safety (MOS) in units = Budgeted sale (units) - BEP (units)
= 300,000 tons - 185,629.85 tons
=

114,370.15 tons

∴ Margin of safety (MOS) in RM = Budgeted sale (RM) - BEP (RM)
= RM 395,431,800 - RM 244,679,817.14
= RM 150,751,982.86
∴ Margin of safety (MOS) as percentage of sales = MOS (RM) x 100%
Sales(RM)
= RM150,751,982.86 x 100%
RM 395,431,800
= 38.12%
Table 3.9 shown that the calculation of break-even point by using excel.

Table 3.9: Data calculation by using excel in RM
(Sources: Data taking from table 3.7)

44


CAPACITY

TFC1

0

57,285,000.00

10000

57,285,000.00

20000

TVC1
0

TR1

TC1

0

57,285,000.00

10,095,080.00

13,181,060

67,380,080.00

57,285,000.00

20,190,160.00

26,362,120

77,475,160.00

40000

57,285,000.00

40,380,320.00

52,724,240

97,665,320.00

60000

57,285,000.00

60,570,480.00

79,086,360

117,855,480.00

80000

57,285,000.00

80,760,640.00

105,448,480

138,045,640.00

100000

57,285,000.00

100,950,800.00

131,810,600

158,235,800.00

120000

57,285,000.00

121,140,960.00

158,172,720

178,425,960.00

140000

57,285,000.00

141,331,120.00

184,534,840

198,616,120.00

160000

57,285,000.00

161,521,280.00

210,896,960

218,806,280.00

180000

57,285,000.00

181,711,440.00

237,259,080

238,996,440.00

200000

57,285,000.00

201,901,600.00

263,621,200

259,186,600.00

220000

57,285,000.00

222,091,760.00

289,983,320

279,376,760.00

240000

57,285,000.00

242,281,920.00

316,345,440

299,566,920.00

260000

57,285,000.00

262,472,080.00

342,707,560

319,757,080.00

280000

57,285,000.00

282,662,240.00

369,069,680

339,947,240.00

300000

57,285,000.00

302,852,400.00

395,431,800

360,137,400.00

320000

57,285,000.00

323,042,560.00

421,793,920

380,327,560.00

340000

57,285,000.00

343,232,720.00

448,156,040

400,517,720.00

360000

57,285,000.00

363,422,880.00

474,518,160

420,707,880.00

380000

57,285,000.00

383,613,040.00

500,880,280

440,898,040.00

400000

57,285,000.00

403,803,200.00

527,242,400

461,088,200.00

420000

57,285,000.00

423,993,360.00

553,604,520

481,278,360.00

440000

57,285,000.00

444,183,520.00

579,966,640

501,468,520.00

460000

57,285,000.00

464,373,680.00

606,328,760

521,658,680.00

480000

57,285,000.00

484,563,840.00

632,690,880

541,848,840.00

500000

57,285,000.00

504,754,000.00

659,053,000

562,039,000.00

CHAPTER 4

45


PLANT LOCATIONS AND SITE SELECTION

4.1

PLANT LOCATION

The location of the plant can have a crucial effect on the profitability of a project and the
scope for future expansion. Many factors must be considered when selecting a suitable
site. A good location is required to optimise the production of the plant. It is important to
know that, not all Malaysian industrial park caters the need of a chemical plant. Also not
all industrial park allows the building of chemical plants. Our industrial parks are divided
into categories such as: 1. Light industrial
2. Medium industrial
3. Heavy industrial
4. General industrial
5. Hi-tech industrial

4.2

GENERAL CONSIDERATION ON THE SITE SELECTION

All the information about plant locations are based on the data gathered from the
Malaysian Industrial Development Authority (MIDA). And we refer detail information on
important factors that need to be considered in the site selection. In the process of
selecting the location, we did some evaluation. Among the principle factors considered
are:

4.2.1

Location With Respect To Marketing Area

For materil that are produced in bulk quantities, such as cement, fertilizer, raw material
of petrochemical product, where the cost of product per tone is relatively low and the
cost of transport a significant fraction of the sales price, the plant must located close to
the primary market. This consideration will be less important for low volume production,
high priced products; such as pharmaceuticals, plastisizer and etc. in an international

46


market, there may be an advantage to be gained by locating the plant within an area
with preferential tariff agreement.
4.2.2

Raw Material Supply

The availability and price of suitable raw materials will often determine the site location.
Plant producing bulk chemicals are best located close to the source of the major raw
material, where this is also close to the marketing area.
4.2.3

Transport Facilities

The transport of materials and products to and from the plant will be an overriding
consideration in site selection. If practicable, a site that we are consider that close to at
least two major forms of transport: road, rail, waterway or a sea port. Road transport
being increasing used, and is suitable for local distribution from central warehouse. Rail
transport will be cheaper for the long distance transport of bulk chemicals
.

Air transport is convenient and efficient for the movement of personnel and

essential equipment and supplies and the proximity of the site to a major airport also
considered.
4.2.4

Availability of Labour

Labour that will be needed for construction of the plant and its operation. Skilled
construction workers will usually be brought in from outside the site area, but there
should be an adequate pool of unskilled labour available locally and labour suitable for
training to operate the plant. Skill tradesman will be needed for plant maintenance.
Local trade union customs and restrictive practices will have to be considered when
assessing the availability and suitability of the local labour for requirement and training
.
4.2.5

Availability of Utilities

47


Chemical processes invariably require large quantities of water for cooling and general
process used and the plant must be located near a source of water of suitable quality.
Process water may be drawn from a river, wells or purchased from a local authority.
At some site, the cooling water required can be taken from a river or lake or
from the sea; at other locations cooling towers will be needed.
Electrical power will be needed at all sites. Electrochemical processes that
required large quantities of power: for example, aluminium smelters need to be located
close to a cheap source of power. A competitively priced fuel must be available onsite
for steam and power generation.
4.2.6

Environmental Impact and Effluent Disposal

All industrial processes produce waste products and full consideration must be given to
the difficulties and cost of their disposal. The disposal of toxic and harmful effluents will
be covered by local regulations and the appropriate authorities must be consulted
during the initial site survey to determine the standards that must be met.
An environmental impact assessment should be made for each new project or
major modification of addition to an existing process.
4.2.7

Local Community Considerations

The proposed plant must fit in with and be acceptable to the local community. Full
consideration must be given to the safe location of the plant so that it does not impose
a significant additional risk to the community.
On a new side, the local community must be able to provide adequate facilities
for the plant personnel: schools, banks, housing and recreational and cultural facilities.
4.2.8

Land (site consideration)

48


Sufficient suitable land must be available for the proposed plant for future expansion.
The land should ideally be flat, well drained suitable load-bearing characteristics. A full
site evaluation should be made to determine the need for piling or other special
foundations.
4.2.9

Political and Strategic Considerations

Capital grants, tax concessions and other inducements are often given by government
to direct new investment to preferred locations such as areas of high unemployment.
The availability of such grants can be the overriding factor in site selection.

4.3 OVERVIEW ON PROSPECTIVE LOCATIONS
Our process is a petrochemical base process; therefore we choose to locate our plant in a
petrochemical complex. The reason is quite simple; a petrochemical complex could
simplify the formation and the maintenance of a chemical plant. It could also cut the daily
operation cost and saving us the hassle of transportation.
In Malaysia there are only three such places, known as the Integrated
Petrochemical Complexes. These complexes are situated in each of the site below:
1. Telok Kalong Industrial Park.
2. Tanjung Langsat Industrial Park.
3. Bintulu Industrial Park.
Other than the above factors, the capacity of plant was also taken into consideration in
determining the suitability of site. Plant capacity will determine how big the space required
to build the plant and the storage area and also the mode of transportation to be use.
The manufacture of MTBE is classified as a petrochemical project. Several
locations of industrial area particular at Teluk Kalong Industrial Area in Terengganu,
Tanjung Langsat Industrial Area in Johor and Bintulu Industrial Area, Sarawak that we are
refer for location.

49


4.3.1

Teluk Kalong

Teluk Kalong Industrial Estate located 9.6 km from Kemaman. Total area available
167.46 hectares. The price of land in ranges RM 0.46 to RM 4.18 per Feet Square.
This area is proposed for petrochemical and heavy industry petrochemical.
The Electricity is generated at the following station. Total generation capacity is
900 MW. Local consumption is less than 1/3. No major breakdown, low frequency of
interruption. Water most plentiful with surplus capacity. Water supply capacity at
various treatment plants total 331000-meter cube per day, with planned upgrading for
additional requirement. Kenyir Lake with 39000 hectares of water with 134 metre
average depth, make Terengganu a potential export of water middle East. Water
supply is in Bukit Shah. Water tariffs (industrial) are RM1.15 metre cube. The raw
materials supplier of isobutene is availability from Chevron Philips Chemical Company
LP, United State and methanol is availability from Petronas Malaysia, Labuan.
1.
•

Airport facilities
Terengganu major industrial locations are serve by 3 airports
- Kuantan
- Kerteh
- Kuala Teregganu

•
2.
•
4.3.2

Kuala Teregganu
Port Facilities
Kemaman Port, Kerteh Port and Kuantan Port
Tanjung Langsat Industrial Park

Tanjung Langsat is designed as hub for heavy/medium industries with all the
necessary infrastructure and service facilities. 91.43 km distance from Johor Baharu.
The infrastructure works such as the Pasir Gudang – Segamat Highway. Sungai
Johore Bridge and dedicated Port in Tanjung Langsat. Tanjung Langsat Industrial
Complex is a sprawling area just a stone’s through from Pasir Gudang Industrial Area.
A total hectare still available is 1,085.95. Selling price is RM8 to RM22 square feet. In
term of seaport two seaports are currently being constructed at Tanjung Pelepas,

50


located 40 km west of Johore Baharu city and Tanjung Langsat located 10 km east of
the Johore Port. Tenaga Nasianal Berhad (TNB) provides electricity.
Two airports in the 50km radius. There is the Sultan Ismail International Airport
(common known locally as Senai Airport) in Johore Baharu and the Changi
International Airport in Singapore. The Sultan Ismail International Airport, which is
located about 30km to the north west of JB city, is currently being expended and
upgrades to become the regional airport for southern peninsular Malaysia.
4.3.3

Bintulu

The distance from nearest town is 224.29 km from Sibu. Type of industries is light and
medium petrochemical. Area available is 77 hectares. Selling price RM2.5 to RM10 per
feet square. Electricity supplies by Sarawak Electricity Supply Cooperation (SESCO).
•

Airport facilities - Bintulu Airport

•

Port Facilities - Bintulu Port

51


Table 4.1 The Comparison of The Potential Site Location:
Teluk Kalong
Industrial Park

Tanjung Langsat
Industrial Park

Bintulu Industrial
Park

9.6 km from Kemaman

91.43 km from Johor
Baharu

224.29 km from Sibu

Types of
Industry

Isobutane from US and
methanol from Labuan
Petrochemical and heavy
industry

Petrochemical light and
medium

Petrochemical light and
medium

Area Available

167.46 hectares

1085.98 hectares

77 hectares

RM 0.46 - 4.18

RM 8.00 - 22.00

RM 2.50 - 10.00

Electricity
Supply

Tenaga National Berhad

Tenaga National Berhad

Sarawak Electrycity
Supply Cooperation
(SESCO)

Water Supply

Bukit Shah Water
Treatment

Road Facilities

Kuala TerengganuKuantan-Kuala LumpurKuala Terengganu-KertehTeluk Kalong-KuantanKuala Lumpur

Distance from
the nearest town
Raw Material

Land Price
2

(RM/ft )

Airport Facilities
Port Facilities
Water Tariffs
3

(RM/m )

Kuala Terengganu Airport
Kerteh Airport
Kemaman Port,
Kerteh Port
Kuantan Port
RM 1.15

Syarikat Air Johor and
Logi Air Sg. Layang

Syarikat Air Sarawak

North-South Highway
from Bukit Kayu Hitam to
Singapore-

Major Road : Bintulu Sibu and Bintulu - Miri

Senai International
Airport

Bintulu Airport

Pasir Gudang Port

Bintulu Port

RM 1.68 (0-20 m 3)
RM2.24 (more than
20 m 3)

RM 0.95 (0 -25 m 3)
RM1.20 (more than
25 m 3)

(Source: MIDA)

A few proposed plant sites were narrowed down based on the above factors (table 4.2).
Table 4.2 is a summary of location and factors being considered. After detailed study of

52


the factors, each was given weightage and was estimated. The result tabulated in table
4.2 for the purpose of comparison.

Table 4.2 The Comparison of Location in term of Weightage Study

Weightage

Telok Kalong
Industrial
Area

Tanjung
Langsat
Industrial
Area

Bintulu
Industrial Area

Marketing Area

10

8

7

7

Raw Material

10

8

9

9

Transport

10

8

7

6

Availabillity of
Labour

10

8

8

7

Utilities

10

8

9

7

Total Land
Available

10

8

9

8

Climate

10

9

9

9

Price of Land

10

9

5

7

Local
Community
Consideration

10

6

8

9

Incentives

10

8

8

8

TOTAL

100

80

79

77

∴ 0 to 10 with 10 is the best

Table 4.3 The Electricity Tariffs (Industrial Tariff) for Peninsular Malaysia and Sarawak

53


Tariff
Peninsular
Malaysia

Tariff D (Low Voltage, and less than 6.6
supply) for all consumptions

Cost per kWh
kV

Tariff E1 (Medium Voltage General, 6.6 kV - 66 kV
supply) for all consumptions. For each kW of maximum
demand per month: RM 17.30

25.8
19.8.

Tariff E2 (Medium Voltage Peak/Off-Peak, 6.6 kV 66kV supply)
Peak period (0800-2200 hours),

20.8

Off-Peak period (2200-0800 hours).

12.8

For each kW of maximum demand per month during
peak period: RM21.70
Tariff E3 (High Voltage Peak/Off-Peak, more than 132
kV supply)
Peak period (0800 -2200 hours),
Off-Peak period (2200 - 0800) hours).
peak period: RM 20.80

Sarawak

Tariff 11
1st 100kWh
In excess of 100kWh to 3000 kWh
In excess of 3000 kWh
Minimum charge per month: RM 10.00
Tariff 12
All units

17.8
10.8

40
30
21

17

For each kW of maximum demand per month: RM12.00
Minimum charge : RM 12.00 per kW x billing demand
Tariff 13 (Peak/Off-Peak)
Peak period ( 0700 - 2400 hours)
Off-Peak period ( 0000 - 0700 hours)
peak period: RM20.00
Minimum charge: RM 20.00 per kW x billing demand.

17
10

(Source: MIDA)

54


4.4

CONCLUSION

Based on the factor weightage studied, it can be concluded that Telok Kalong Industrial
Estate is the most suitable and practical location to choose as a site for MTBE plant.
The philosophy of in situ consumption of much of the production MTBE,
together with remaining product aimed directly at the export market and also makes the
need for port facilities of paramount importance. The Tanjung Langsat and Bintulu
Industrial Area are not impressive for MTBE plant. There are many other reasons
influences our decision including:
•

Nearest of the Kuantan Port, Kemaman Port and Kerteh Port facilities is more

convenient and economically for export and import purposes.
•

Excellent and consistent support from bulky oil, gas and chemical supplier from

Kerteh.
Constantly upgrading existing and developing new infrastructure, facilities and supporting
industries. These include the construction of roads; to increase accessibility to and from
the estates are scheduled.

55


CHAPTER 5

ENVIRONMENTAL CONSIDERATION

5.1

INTRODUCTION

Nowadays, environmental issues become very important. Besides this, a good waste
treatment system is also important in order to reduce and minimize
environmental pollutants. The chemical waste in the form of solid, liquid and
gases must be treated before being discharged into sewage, drain and
atmospheres.
Any chemical plant to be set up in Malaysia must follow the rules and
regulations under the Department of Environment (DOE) Malaysia, which includes the
Environmental Quality Act 1974. Under Environmental Quality Act (Sewage and
Industrial Effluents) Regulation 1979 and Environment Quality Act (Clean Air) 1978.
The plant owner or waste generator must ensure that waste generated disposed
appropriately to prevent environmental pollution. The proper and suitable methods
should be implemented in dealing with the waste disposal. Kualiti Alam Sdn. Bhd is
one of the licensed contractors specialized in the industrial waste disposal in Malaysia.
MTBE plant is not excluded from these regulations. As our plant produces
MTBE and other byproducts like raffinate but generally they are not hazardous to the
environment and human if safety measures are taken into consideration. These
environmental considerations depend on the location of our plant. The plant will follow
the Standard B of water quality measurement and also need some waste treatment
facilities to minimize the pollution from our plant.

56


STACK GASES
Gas Emission Treatment
Direct flame combustion was used to burn the excess gas. Flare is usually open ended
combustion unit. Therefore, the combustion process will be controlled by flow
rate of gases mixture to prevent incomplete combustion.
Another treatment is thermal combustion. It is an incinerator used in the cases
where the concentration of combustible gases is too low to make direct flame
incineration insufficient condition. The temperature of operation depends upon the type
of pollutant in waste gas. Thermal combustion must be carefully designed to provide
safe, efficient operation and to prevent incomplete combustion. Time, temperature, and
oxygen must be carefully monitored. (Howard et. al 1985)
Stack gas means the product of combustion process usually occur at machine or
generator. It is usually the fuels used occurred in the complete combustion
process, but it produced unwanted gas such as carbon monoxide, sulphur oxide
and other gases.
In our MTBE plant, the stack gases is only Hydrogen and it is stored in a
special tank before being sold to interested company at market price.

5.3
5.3.1

WASTEWATER TREATMENT
Wastewater Characteristics

Wastewater characteristics vary widely from industry to industry. Obviously, the
specific characteristics will affect the treatment techniques chosen for use in meeting
discharge requirements. Because of the large number of pollutant substances,
wastewater characteristics are not usually considered on a substance-by-substance
basis. Rather, substances of similar pollution effects are grouped together into classes
of pollutants or characteristics are indicated below.
5.3.1(a) Priority Pollutants

57


Recently, greatest concern has been for this class of substances for the reasons given
previously. These materials are treated on an individual-substance basis for regulatory
control. Thus each industry could receive a discharge permit that lists an acceptable
level for each priority pollutant.
5.3.1(b) Organics
The organic composition of industrial wastes varies widely, primarily due to the
different raw materials used by each specific industry. These organics include proteins,
carbohydrates, fats and oils, petrochemicals, solvents, pharmaceutical, small and large
molecules, solids, and liquids. Another compilation is that a typical industry produces
many diverse waste streams. Good practice is to conduct a material balance
throughout an entire production facility. This survey should include a flow diagram,
location and sizes of piping, tanks, and flow volumes, as well as an analysis of each
stream.
An important measure of the waste organic strength is the 5-day biochemical
oxygen demand (BOD5). As this test measures the demand for oxygen in the water
environment caused by organics released by industry and municipalities, it has been
the primary parameter in determining the strength and effects of a pollutant. This test
determines the oxygen demand of a waste exposed to biological organisms (controlled
seed) for an incubation period of five days. Usually this demand is caused by
degradation of organics according to the following simplified equation, but reduced
inorganics in some industries may also cause demand (i.e., Fe2+, S2- and SO32-).
Organic waste + O2

CO2 +H2O

In general, low-molecular-weight water-soluble organics are biodegraded
readily. As organic complexity increases, solubility and biodegrability decrease. Soluble
organics are metabolized more easily than insoluble organics. Complex carbohydrates,
proteins and fats and oils must be hydrolyzed to simple sugars, aminos, and other
organics acids prior to metabolism. Petrochemicals, pulp and paper, slaughterhouse,

58


brewery, and numerous other industrial wastes containing complex organics have been
satisfactorily treated biologically, but proper testing and evaluation is necessary.
5.3.1(c) Inorganics
The inorganics is most industrial wastes are the direct result or inorganic compounds in
the carriage water. Soft-water sources will have lower inorganics than hard-water or
saltwater sources. However, some industrial wastewaters can contain significant
quantities of inorganics which result from chemical additions during plant operation.
Many food processing wastewaters are high in sodium.
While domestic wastewaters have a balance in organics and inorganics, many
process wastewaters from industry are deficient in specific inorganic compounds.
Biodegration of organic compounds requires adequate nitrogen, phosphorus, iron, and
trace salts. Ammonium salts or nitrate salts can provide the nitrogen, while phosphates
supply the phosphorus.
5.3.1(d) pH and Alkalinity
Wastewaters should have pH values between 6 and 9 for minimum impact on the
environment. Wastewaters with pH values less than 6 will tend to be corrosive as a
result of the excess hydrogen ions. On the other hand, raising the pH above 9 will
cause some of the metal ions to precipitate as carbonates or as hydroxides at higher
pH levels. Alkalinity is important in keeping Ph values at the right levels. Bicarbonate
alkalinity is the primary buffer in wastewaters. It is important to have adequate alkalinity
to neutralize the acid waste components as well as those formed by partial metabolism
or organics.
Many neutral organics such as carbohydrates, aldehydes, ketones, and
alcohols are biodegraded through organics acids which must be neutralized by the
available alkalinity. If alkalinity is inadequate, sodium carbonate is a better form to add
than lime. Lime tends to be hard to control accurately and results in high pH levels and
precipitation of the calcium which forms part of the alkalinity. In a few instances,
sodium bicarbonate may be the best source of alkalinity.

59


5.3.1(e) Temperature
Most industrial wastes tend to be on the warm side. For the most part, temperature is
not a critical issue below 37oC if wastewaters are to receive biological treatment. It is
possible to operate thermophilic biological wastewater-treatment systems up to 65oC
with acclimated microbes. Low-temperature operations in northern climates can result
in very low winter temperatures and slow reaction rates for both biological treatment
systems and chemical treatment systems.
Increased viscosity of wastewaters at low temperatures makes solid separation
more difficult. Increased viscosity of wastewaters at low temperatures makes solid
separation more difficult. Efforts are generally made to keep operating temperatures
between 10 and 30oC if possible.
5.3.2

Liquid Waste Treatment
5.3.2(a) Equalization Treatment

Liquid treatment generally is necessary in any plant. In our plant, we also have liquid
treatment but in general, we only state the general method, as our plant does not
produce any significant liquid waste. In any liquid waste treatment, we need
equalization treatment. The equalization treatment is an initial procedure in liquid waste
treatment. The purpose of equalization is to minimize and control the fluctuation in
liquid waste characteristic. Besides it provides the suitable and optimum condition for
biological and chemical treatment. It also provides adequate damping to minimize the
chemical consumption. The procedure will occur in the equalization tank. The size of
tank and time of equalization process depend on the liquid waste amount.
The Activated Sludge process will be used for this treatment. It is carried out in
Aerobic condition. The main purpose of activated sludge process is to remove soluble
and insoluble organic matter that converted into flocculants microbial suspension and
settable microbial. It also permits the use of gravitational solid liquid separation
technique for the above requirement.
The organic matter where measured in the form of BOD and COD serves as
food and energy source for microbial growth. It converts the pollutant into microbial cell

60


and oxidized end product such as CO2 and H2O by microbial activities. Therefore,
Submersible Aerator as mixing device will supply the oxygen and nutrient into aeration
tank and therefore improves the quality of the liquid. (Howard et. al, 1985)

5.3.2(b)

Solid Waste Treatment

The solid waste treatment will be minimized by regenerating the catalyst. Regeneration
processes depend on the characteristic of catalyst after whole reaction. Licensed
contractor will dispose the solid waste to follow the DOE regulation. By the way,
the scheduled maintenance activities will be implemented.
Dewatering system will be used to solidify and extract the catalyst. Therefore,
clarifier and filter press were used in these treatments. Clarifier is used to clarify any
impurities before going through the filters. The size of equipment depends on the flow
rate and holding time of these processes. Maintenance activities will be scheduled
based on the availability of workers and machines. Skilled and experienced workers
will do the maintenance activities, (Bailed, 1995).

61


Industrial
Process

Waste
Reduction

Waste
Generation
Re-use

Storage
Transfer/
Transport

Processing/
Recovery

Collection

Disposal

Recycling/
Reuse

Figure 5.1 Functional Elements in a Solid-waste Treatment System.
62


5.3.3 Waste Minimization
Waste minimization means the optimization process to minimize the waste come out of
the plant. It will be done by source reduction and recovery of the sources. The source
reduction refers to preventative measured taken to reduce the amount of waste, which
produced in this process. Recovery of the sources is aimed to reuse the excess
methanol to produce the MTBE.
Waste production from the plant could be reduced by implementing these
procedures:
-

Raw material modification,

-

Product reformulation,

-

Process modification,

-

Improvement in operating practices.

The most important is by improving the product yield and this means
minimization of waste generation. It will be accomplished through improvement in
catalyst efficiency and proper maintenance activities.

63


CHAPTER 6

SAFETY CONSIDERATION

6.1

INTRODUCTION

For years, those employed in the chemical industry have known that the safe operation of
chemical plant is essential to the industry’s continued ability to survive. The human,
political and financial costs of having accidents are just too high for the chemical
industry to not exhibit excellence in their efforts to operate plants in safe and
environmentally responsible ways. The chemical industry has an outstanding record in
both transportation safety and the safe operations of its processes. That effort has
resulted in a dramatic and steady decline in releases and waste produced at chemical
sites.

Actions that should be taken to avoid serious chemical plant accidents are as follows:
1. In most cases involving large volumes of highly hazardous chemicals, excess
flow valves are in place that would stop a rapid flow of the chemicals
2. When highly hazardous chemicals are involved, processes have fixed
protection, as well as trained emergency response teams that could handle the
incident.
3.

Appropriate reaction control or inhibiting systems are in place to interrupt
runaway reactions if cooling, heating and pressure relief are not considered
adequate.

4. Control systems are designed to detect heat or pressure of a chemical reaction
and to control that reaction.
5. Work more closely with local and state law enforcement groups.

64


6.2

MATERIAL SAFETY DATA SHEET

6.2.1

Isobutane (Instrument Grade)

Product Number(S): 0001020533, 0001020534, 0001020535, 0001020536
Synonyms: Methylpropane; Iso
Company Identification:
Chevron Phillips Chemical Company Lp
10001 Six Pines Drive
The Woodlands, Tx 77380
6.2.1.1 Product Information:
Msds Requests: (800) 852-5530
Technical Information: (800) 852-5531
Colorless liquefied gas, odorless.
- Flammable gas. May cause flash fire
- Contents under pressure
- Detection of leak via sense of smell may not be possible if odorant has degraded
- Contact with liquefied gas can cause frostbite
- Liquid can cause eye and skin injury
- Reduces oxygen available for breathing
6.2.1.2 Physical And Chemical Properties
Appearance and odor: colorless liquefied gas, odorless.
Ph: na
Vapor pressure: 72 psia @ 37.8 ºc
Vapor density (air=1): 2.1
Boiling point: -12°c (10.4°f)
Solubility: negligible
Percent volatile: 100 % volume
Specific gravity: 0.564 @ 15.6 ºc
Evaporation rate: >1

65


6.2.1.3 Immediate Health Effects:
Eye: Because the liquid product evaporates quickly, it can have a severe chilling effect
on eyes and can cause local freezing of tissues (frostbite). Symptoms may include
pain, tearing, reddening, swelling and impaired vision.
Skin: Because the liquid product evaporates quickly, it can have a severe chilling
effect on skin and can cause local freezing of tissues (frostbite). Symptoms may
include pain, itching, discoloration, swelling, and blistering. Not expected to be harmful
to internal organs if absorbed through the skin.
Ingestion: Material is a gas and cannot usually be swallowed.
Inhalation: This material can act as a simple asphyxiant by displacement of air.
Symptoms of asphyxiation may include rapid breathing, in coordination, rapid fatigue,
excessive salivation, disorientation, headache, nausea, and vomiting.
Convulsions, loss of consciousness, coma, and/or death may occur if exposure to high
concentrations continues.
6.2.1.4 First Aid Measures
Eye: Flush eyes with water immediately while holding the eyelids open. Remove
contact lenses, if worn, after initial flushing, and continue flushing for at least 15
minutes. Get immediate medical attention.
Skin: Skin contact with the liquid may result in frostbite and burns. Soak contact area
in tepid water to alleviate the immediate effects and get medical attention.
Ingestion: No specific first aid measures are required because this material is a gas
and cannot usually be swallowed.
Inhalation: For emergencies, wear a niosh approved air-supplying respirator. Move
the exposed person to fresh air. If not breathing, give artificial respiration. If breathing is
difficult, give oxygen. Get immediate medical attention.
6.2.2

N-Butane

N-Butane synonym with I-Butane, Butane, and Normal Butane is a flammable gas. NButane is heavier than air and may travel considerable distance to an ignition source.

66


N-Butane is listed under the accident prevention provisions of section 112(r) of the
Clean Air Act (CAA) with threshold quantity (TQ) of 10000 pounds.

Physical and Chemical Properties
Parameter

value

Physical state

units

: Gas
o

Vapor pressure at 70 F

: 31

psia

Vapor density at STP

: 2.07

Evaporation point

: not available

Boiling point

: 31.1

o

Freezing point

: -0.5

o

pH

: not available

Solubility

: insoluble

Odor and appearance

: a colourless and odourless gas

Stability

: stable

Condition to avoid

: high temperature

F

C

6.2.2.1 Handling and storage
Protect cylinders from physical damage. Store in cool, dry, well- ventilated area away
from heavily trafficked areas and emergency exits. Do not allow the temperature where
cylinders are stored to exceed 130oF. Cylinders should be stored upright and firmly
secured to prevent falling or being knocked over. Full and empty cylinders should be
segregated. Use a “first in first out” inventory systems to prevent full cylinders from
being stored for excessive periods of time. Never carry a compressed gas cylinder or a
container of a gas in cryogenic liquid form in an enclosed space such as a car trunk,
van or station wagon. A leak cans re4sult in a fire, explosion, asphyxiation or a toxic
exposure.
6.2.3

Methanol

Methanol synonyms with Methyl alcohol and in chemical family alcohol with the
formula CH3OH. Methanol is a clear, colourless, mobile, volatile, flammable liquid and
it’s soluble in water, alcohol and ether.

67


Physical and Chemical properties:
Parameter

value

Physical state

: liquid

Boiling Point

: 64.7oc

Vapor Pressure (20oc)

: 128 mb

Vapor Density (air=1)

: 1.11

Solubility in water ,%wt

: full

Specific Gravity

: 0.792 g/cm3

Appearance and odor

: liquid-colorless-odor specific

Fire and Explosion Hazard data:
Flash point

: closed cup: 12oc

Flammable limits, % vol

: Lel: 6, Uel : 36.5

Extinguishing media

: Foam – CO2 –halogenated agents

Special fire fighting

: Avoid contact with oxidizing materials

Unusual fire and explosion : Moderate
Reactivity Data:
Stability

: Medium

Conditions to avoid

: Oxidizing materials

Incompatibility

: Sulfo-chromic mixtures

Special Precautions
Precaution to be taken in handling and storing Methanol: store in iron or steel
containers or tanks. Small quantities can be stored in reinforced glass containers.
6.2.4

MTBE

6.2.4.1 Physical state, appearance
MTBE is chemically stable; it does not polymerize, nor will decompose under normal
conditions of temperature and pressure. Unlike most ether, MTBE does not tend to
form peroxides (auto-oxidize). The physical state of MTBE is that MTBE is in the form
of liquid at room temperature (25oC). It is a colourless liquid with the billing point at

68


55.2oC 131.4oF. The freezing point of MTBE is –108.6oC –163.5oC. The density of
MTBE at 25oC is 735g/cm3.
6.2.4.2 Physical dangers
MTBE is non-reactive. It does not react with air, water, or common materials of
construction. The reactivity of MTBE with oxidizing materials is probably low. However,
without definitive information, it should be assumed that MTBE reacts with strong
oxidizers, including peroxides.
6.2.4.3 Chemical dangers
MTBE is highly flammable and combustible when exposed to heat or flame or spark,
and it is a moderate fire risk. Vapours may form explosive mixtures with air. It is
unstable in acid solutions. Fire may produce irritating, corrosive or toxic gases. Runoff
from fire control may contain MTBE and its combustion products.
Occupational exposure limits (OELs)
Routes of Exposure
6.2.4.4 Inhalation risk
Like other ethers, inhalation of high levels of MTBE by animals or humans results in the
depression of the central nervous system. Symptoms observe red in rats exposed to
4000 or 8000 ppm in air included labored respiration, ataxia, decreased muscle tone,
abnormal gait, impaired treadmill performance, and decreased grip strength. These
symptoms were no longer evident 6 hours after exposure ceased. A lower level of
MTBE, 800ppm did not produce apparent effects (Daughtrey et al., 1997).
A number of investigations have been conducted to examine the self-reported
acute MTBE in gasoline vapors during use by consumers. This research includes both
epidemiological studies and studies involving controlled exposure of volunteers to
MTBE at concentrations similar to those encountered in refueling an automobile
(Reviewed in USEPA, 1997, and California EPA, 1998). In general, the studies
involving controlled human exposures in chambers to levels of MTBE similar to those
experienced during refueling and driving an automobile have not shown effects of

69


MTBE on physical symptoms (e.g. irritation), mood, or performance based tests of
neurobehavioral function.
6.2.5

TBA (TERT - BUTYL ACOHOL)

CAS Number: 75-65-0
Synonyms:

tert-Butanol
2-methyl-2-propanol
TBA
t-butylhydroxide
1,1-dimethylethanol
trimethylmethanol
trimethylcarbinol

6.2.5.1 Recognition
NIOSH/OSHA Health Guideline. Summarizes pertinent information about for workers
and employers as well as for physicians, industrial hygienists,and other occupational
safety and health professionals who may need such information to conduct effective
occupational safety and health programs.
6.2.5.2 Evaluation

1. Health Hazards. Routes of exposure, summary of toxicology, signs and
symptoms, emergency procedure.

2. Workplace Monitoring and Measurement.
3. Medical Surveillance. Workers who may be exposed to chemical hazards
should be monitored in a systematic program of medical surveillance that is
intended to prevent occupational injury and disease. The program should
include education of employers and workers about work-related hazards,
placement of workers in jobs that do not jeopardize their safety or health, early
detection of adverse health effects, and referral of workers for diagnosis and
treatment.

70


6.2.5.3 Controls

1. Exposure Sources and Control Methods.
2. Personal Hygiene Procedures.
3. Respiratory Protection. Conditions for respirator use, respiratory protection
program.

4. Personal Protective Equipment. Protective clothing should be worn to prevent
any possibility of skin contact. Chemical protective clothing should be selected
on the basis of available performance data, manufacturers' recommendations,
and evaluation of the clothing under actual conditions of use.

5. Emergency Medical Procedures. Material Safety Data Sheets (MSDS's) include
chemical specific information on emergency medical and first aid procedures as
referenced under the OSHA Hazard Communication standard, 29 CFR
1910.1200, (g)(2)(X). This standard requires chemical manufacturers and
importers to obtain or develop an MSDS for each hazardous chemical they
produce or import. Employers shall have an MSDS in the workplace for each
hazardous chemical, which they use.

6. Storage.
7. Spills and Leaks. In the event of a spill or leak, persons not wearing protective
equipment and clothing should be restricted from contaminated areas until
cleanup has been completed.

6.3

HAZARD IDENTIFICATION & EMERGENCY SAFETY & HEALTH RISK
ASSESSMENT

Safety & Health Risks vary with the type of industry & the magnitude of the emergency.
The severity of the risk too will vary with especially where there are chemicals,
combustible gases, potential for fire & explosion etc. These hazards may not only pose
a danger to the health of working in a particular plant but also the adjacent community.
In the event of a major disaster property both within and outside the plant will be
damaged. The real and potential hazards at the work place must be identified and the
Safety & Health Risks that they pose assessed. This will require a close scrutiny of all

71


work place buildings, their design, electrical wiring, transport and storage facilities, the
work processes, workstation design, safe operating procedures, list of chemicals
substances used, their quantity, storage, daily transfer, safe usage and disposal.
MSDS’s of the chemical too have to be studied as regards their toxicity, volatility, and
their potential for a fire and/or explosion and adverse health affects both short term and
long term.
The possible emergencies/disaster in a industry could be:
•

Fire/ explosion

•

Chemical spill

•

Radioactive material spill

•

Biological material spill

•

Personal injury
The best action plan is prevention from an emergency. This is where one has to

work closely with operation personnel to make sure that all operations are safe and
comply with OSH Legislations. All persons at work are aware of the safe procedure
and also follow those procedures. Unfortunately in the real world, mostly human
factors- accident & emergency do occur. This is why emergency response plans have
to be written up, communicated to all concerned and tested for effectiveness.
Depending on the gravity the workplace emergency can be categorized in to Level 1,
Level 2, or Lever 3 emergency.
Level 1 Emergency- the first responder without having to call the disaster
response team or outside help can effectively manage such incident. Examples; a
small fire easily smothered, chemical spill easily contained and cleaned, injury minor
and treated at site by rendering first aid.
Level 2 Emergency - an incident that requires technical assistance from the
disaster response team and may need outside help. Examples; fire that need technical
from trained personnel and specialized equipment spill that can only be properly
contained by specialized equipment.

72


Level 3 Emergency- these are major disaster that are difficult to contain even
with trained personnel and outside help. Examples, spill that cannot be properly
contained or abated even by highly trained team and the use of sophisticated special
equipment. Fire involving toxic material that is too large to control and are to burn. This
may require the evacuation of civilians across jurisdictional boundaries

73


CHAPTER 7

MASS BALANCE

7.1

SNAMPROGETTI UNIT (REACTOR AND REGENERATOR)

Stream S5 = 164.74 kgmole/hr
0.393 C4H8
0.393 H2
0.212 iC4H10
0.002 nC4H10

100 kgmole/hr
0.996 iC4H10
0.004 nC4H10

S2
Given from
MSDS

Assume steady-state system,
Basis = 100 kgmole/hr of S2

74


The fraction at stream S2 acquired from isobutane instrument grade, MSDS.
Reaction occurred in the reactor,
iC4H10

C4H8

+

H2

Flowrate in kgmole/hr of iC4H10 in the feed stream of S2

= 0.996 (100)

= 99.6 kgmole/hr iC4H10
Balanced Based upon the stoichoimetric ratio with 65% conversion of iC4H10 to obtain
C4H8.
Since, 65% conversion in the reactor,
∴ kgmole/hr of C4H8 obtained

= 0.65 (99.6)
= 64.74 kgmole/hr

∴ 35% of iC4H10 unreacted

= 99.6

-

64.74

= 34.86 kgmole/hr
Based upon stoichiometric ratio
(inert)

(unreacted)

n C4H10

+ iC4H10

0.4

C4H8

99.6

H2

64.74

(kgmole/hr)

+

iC4H10

64.74

+ n C4H10

34.86

0.4

(kgmole/hr)

Input
S2

Stream
Component

+

(inert)

MW

Molar flow

Output
S5

Mass flow kg/hr

Molar flow

Mass flow kg/hr

kg/kgmole

kgmole/hr

C4H8

56

-

-

kgmole/hr

64.74

3625.44

H2

2

-

-

64.74

129.4

iC4H10

58

99.6

5776.8

34.86

2021.88

n C4H10
Total

58

0.4

23.2
5800

0.4

23.4
5800

75


7.2

SEPARATOR

1 H2

0.393 C4H8
0.393 H2
0.212 iC4H10

Stream S11 = 100 kgmole/hr

0.002 nC4H10

0.6474 C4H8
0.3486 iC4H10
0.0040 nC4H10

Input
S9

Stream
Component

Output
S10

S11

MW

Molar flow

Mass flow

Molar flow

Mass flow

Molar flow

Mass flow

kg/kgmole

kgmole/hr

kg/hr

kgmole/hr

kg/hr

kgmole/hr

kg/hr

C4H8

56

-

-

-

-

64.74

3625.44

H2

2

-

-

64.74

129.4

64.74

129.4

iC4H10

58

99.6

5776.8

-

-

34.86

2021.88

n C4H10
Total

58

0.4

23.2
5800

-

129.4

0.4

23.4
5670.6

7.3

MIXER

S13 = 64.74kgmole/hr

S14 = 71.62 kgmole/hr

1 CH3OH

0.996 CH3OH
0.004 H2O

S27 = 0.406 kgmole/hr
0.3596 CH3OH
0.6404 H2O

76


Input
Stream
Component

S13
MW

Molar flow

Output
S14

S27

Mass flow

Molar flow

Mass flow

Molar flow

Mass flow

kg/kgmole

kgmole/hr

kg/hr

kgmole/hr

kg/hr

kgmole/hr

kg/hr

CH3OH

32

71.214

2278.848

0.146

4.67

71.36

2283.52

H2O
Total

18

-

2278.848

0.26

4.68
9.356

0.26

4.685
2288.205

7.4

MTBE REACTOR
Assumption : 98% conversion of C4H8 (2% remains unconverted)
Reactions involve in the reactor,

1. C4H8

+

CH3OH

2. 2CH3OH
3. C4H8

+

C5H12O

C2H6O
H2O

+

H2O

C4H10O

Stream S11 = 100 kgmole/hr
0.6474 C4H8
0.3486 iC4H10
0.0040 nC4H10

R
e
ac
to
r

S15

kgmole/hr
C4H8
iC4H10
nC4H10

S14 = 71. 214 kgmole/hr
CH3OH

CH3OH

H2O

C5H12O
C4H10O
C2H6O
H2O

7.4.1

1st REACTION IN REACTOR
C4H8

+

CH3OH

C5H12O

77


kgmole/hr of C4H8 in the stream S11 = 100(0.6474)
=

64.74 kgmole/hr C4H8

Balance based upon stoichiometric ratio with 98% conversion.
CH3OH is classified an excess.
The unreacted of CH3OH (excess) = (71.36 - 64.74)
=

6.62 kgmole/hr

Since 98% conversion in the reactor,
kgmole/hr of C5H12O obtained = 0.98 (64.74)
= 63.44 kgmole/hr C5H12O obtained
From the stoichiometric ratio,
98%

C4H8
64.74

+

CH3OH
71.214

C5H12O +

C4H8

63.44

conv.

+

1.3

CH3OH
7.92

unconverted

kgmole/hr

kgmole/hr

64.74 kgmole/hr
1 C4H8
R
e
ac
to
r

kgmole/hr
C4H8
CH3OH
C5H12O

64.74 kgmole/hr
1 CH3OH

Component

MW

Input
Molar flow
Mass flow

Output
Molar flow
Mass flow

78


C4H8

(kg/kgmole)
56

(kgmole/hr)
64.74

(kg/hr)
3625.44

(kgmole/hr)
1.3

(kg/hr)
72.8

CH3OH

32

71.36

2283.52

7.92

253.44

C5H12O
Total

88

-

5908.96

63.44

5582.72
5908.96

7.4.2

2nd REACTION IN REACTOR

From 2nd reaction, stoichiometric ratio shown below:
Since the ratio between methanol and dimethylether is 2CH3OH : 1C2H6O ,
98% conversion methanol (CH3OH) into dimethylether (C2H6O) = 1.3 (0.98)
2
=

0.637 kgmole/hr

98%

2CH3OH

conv.

7.92

C2H6O +
3.88

H2O

+

2CH3OH

3.88

0.16
unconverted

kgmole/hr

7.92 kgmole/hr
1 CH3OH

kgmole/hr
R
e
ac
to
r

kgmole/hr
CH3OH
C2H6O
H2O

Input

Output

79

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