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7/30/2019 Manufacture of NaphthalenMANUFACTURE OF NAPHTHALENE

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MANUFACTURE OF NAPHTHALENE


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Plant Safety

Introduction

The significance of Safety & Health in chemical industries has been a vital issue

in achieving productivity and an edge in the competitive world. All applicable

laws and regulations on environmental protection or plant and industrial safety

must be fully complied with.

Compliance with all legislation to protect human beings and the environment is

one of the companys basic tenets for both legal and ethical reasons. This applies

to our products as well as to our processes.

Areas of Concern

Dangerous Materials

i)Explosives ii) Gases iii) Inflammable Liquids iv) Inflammable Solids v)

Oxidising substances vi) Toxic and Infectious substances vii)Radio Active

Substances viii)Corrosive Substances ix)Miscellaneous Dangerous Substances

Hazards Of Pressure Vessels

1.Leakage or Bursting of Pressure Vessels 2.Design defects 3.Failure of Relief

Systems 4.Lack of hydraulic testing. 5. Lack of Proper Instrumentation or

Instrumentation Failure 6.Lack of N.D.Tests 7.Corrosion of Vessels. 8. Lack of

routine inspections 9. Attempt of Pneumatic testing

Hazardous Chemical Reactions

Understanding about the behaviours of reactions and adopting precautionary and

emergency measures.

Hazards of Unit operations

Understanding the hazards inherent in each unit operation and adopting

precautionary and emergency measures

Heat Transfer Surface fouling and leakage, Miscalculation in scaling, Mixing of fl

Size Reduction Dust explosions, Dust release etc.


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Flammable Gases, Vapours And Dust Hazards

Identification of potential areas, where possibility of flammable mixtureare possible.

Efforts to avoid hazardous mixtures, by inert gas purging and othermethods.

Declaring hazard zones and providing flame proof electrical fittings andequipments.

Providing Explosion Vents in spaces with possibility of air-vapourmixtures.

Explosive meter testing. Providing adequate fire control devices. Providing arrangements to avoid static sparks. Etc.

Health Hazards

Identification of potential health hazards. Assessment of levels of physical and chemical health hazards. Control of hazards by various techniques Adequate awareness among the workers. Periodic medical examination of the workers. Personal protection for occasional exposures. Proper hygiene and decontamination facilities. etc.

Entry into Confined Spaces

1.Oxygen Deficiency 2. Toxic Contamination 3. Flammable

Environment4.Possibility of Electrocutions through electric

equipments5.Possibility of Toxic gas generation during the work 6.Lack of

Ventilation 7.Difficulty in welfare monitoring 8.Failure to escape on emergency

9.Combustible Substances

Hazards Due To Corrosion

Weakening and falling of structures and sheds. Falling of workers from height due to breaking of raised platforms, hand

rails, toe boards, stairs and ladders.


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Spills and toxic releases from pipelines due to corrosion. Leakages and bursting of vessels due to corrosion. Corrosion monitoring and control. Testing and inspection of vessels and structures to ensure safety.

Hazards Due To Instrument Failures

Absence of fail safety instruments. Lack of interlocks and trip systems. Human failures in manual and semi automatic operations. Need for safety analysis of the instrumentation systems

General Safety Rules

Smoking is not allowed in any part of the refinery area except in smokingbooths.

Use of PPE is mandatory in the plant area. Before entering deposit all the matches, lighter or any other spark

producing device.

Only DCP or CO2 extinguishers are to be used in cause of a fire aroundelectrical equipment.

Never enter work area without safety helmet. When dangerous or unsafe condition is observed report to the supervisor

or fire and safety division.

Job area should be cleaned as soon as job is completed. Always use walkways instead of shortcuts. All stairways, platforms and walkways must be kept clean at all times. Compressed air must not be used except for process and system

requirements.

Never look directly into the arc produced while welding without propereye protection.

Defective equipment of any kind should not be used. Keep the access to fire fighting equipment free of obstructions as these are

required to be used in emergencies.

Polyester or nylon clothing should not be worn while on duty as thesecreate hazards of static charge.


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Protruding nails should be pulled out or bent over. Goggles or shields must be used when working under any circumstances

when there are possible eye hazards.

All stairways, platforms and walkways must be kept clean at all times. Compressed air must not be used except for process and system

requirements.

Never look directly into the arc produced while welding without propereye protection.

Defective equipment of any kind should not be used. Keep the access to fire fighting equipment free of obstructions as these are

required to be used in emergencies.

Polyester or nylon clothing should not be worn while on duty as thesecreate hazards of static charge.

Protruding nails should be pulled out or bent over. Goggles or shields must be used when working under any circumstances

when there are possible eye hazards.

When working around moving machinery the wearing of loose clothingsuch as lunges, dhoti etc are strictly prohibited.

Vehicles of all types must be equipped with approved type of spark arrestsand muffler system before entering in the production area.

Protective valve caps must be placed on all gas cylinders except when inuse.

Do not enter into enclosed places without strictly observing the definedprecautions.

Do not touch hot pipes without wearing suitable protective clothing. Wear ear protection in areas of high noise levels.


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Safety Signs


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Plant Layout

Introduction

A plant layout study is an engineering study used to analyze different physical

configurations for an manufacturing plant. It is also known as Facilities Planning

and Layout.

A suitable site must be found for a new project, and the site and equipment layout

planned. Provision must be made for the ancillary buildings and services needed

for plant operation and for the environmentally acceptable disposal of effluent.

Plant layout refers to the arrangement of physical facilities such as machinery,

equipment, furniture etc. within the factory building in such a manner so as to

have quickest flow of material at the lowest cost and with the least amount of

handling in processing the product from the receipt of material to the shipment of

the finished product.

Factors affecting plant layout

While deciding a factory or unit or establishment or store, we should keep the

following factors in mind:

1) Location with respect to the market area.

2) Raw material supply.

3) Transport facility.

4) Availability of labour.

5) Availability of utilities: water, fuel, power.

6) Availability of suitable land.

7) Environmental impact and effluent disposal.

8) Local community considerations.

9) Climate.

10) Political and strategic considerations.


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Cost Estimation

Estimation of total capital investment

The total investment I involves :-

Fixed investment in process area IF

Investment in auxiliary services IA

Investment in working capital IW

i.e. I = IF + IA + IW

The approximate cost of various equipments used in the proposed plant are:-

Equipment No. Cost ( Rs. Lakh)

Gas Stripper 1 360

Hear Exchanger 2 300

Reactor 1 150


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Equipment Nos. Cost (Rs. Lak

Furnace 1 120

Separator 1 200

Fractionator 1 350

Miscellaneous 1 700

Direct Cost Factors

Items Cost (Rs. Lakh)

Purchased equipment cost 250

Equipment installation 80

Insulation 60

Instrumentation 300


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Total Direct Cost = ((Equipment Cost)*(Direct Cost Factor))/100

= (3160*945)/100

= Rs. 20601 Lakh

Indirect Cost Factors

Indirect cost = ((Direct cost)*(Indirect cost factor))/100

= (20601*156)/100

= Rs. 32137.56 Lakh

Total fixed investment IF = Total direct cost + Indirect cost

= 20601 + 32137.56

= Rs. 52738.56 Lakh


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Auxiliary Investment

Items such as steam generators, fuel stations & fire protection facilities are

commonly stationed outside the process area & serve the system under

consideration.

Items % of total installed cost

Investment total fixed 100

Auxiliary building 5

Water supply 2

Electric main substation 1.5

Process waste system 1

Raw material storage 1

Fire protection 0.7

Roads 0.5

Sanitary & waste disposal 0.2


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Auxiliary cost (IA) = ((Total fixed investment)*(Auxiliary cost factor))/100

= (52738.56*112.3)/100

= Rs. 59225.4 Lakh

Total installed cost = Total fixed investment + Auxiliary cost

= 52738.56+59225.4

= Rs. 111963.96 Lakh

Working Capital

This is the capital fixed up in the interest of the system in the form of ready cash

to meet operating expenses, inventories of raw materials & the products. The

working capital may conveniently be assumed as 15% of total investment made

in plant.

Working capital =111963.96*15/100

= Rs. 16794.59 Lakh

Total capital investment = Total installed Cost + Working capital

= Rs. 128758.55 Lakh

Estimation of manufacturing cost

The manufacturing cost can be divided into three items

a) Proportional to total investmentb) Anticipated production ratec) Labor requirement

Proportional to total investment

This includes the factors which are independent of the production rate &

proportional to the fixed investments such as :-

Maintenance Property tax Insurance Safety expense General services Administrative services


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This can be taken as 15% per year of total installed cost

i.e. 52738.56*15/100

= Rs. 7910.784 Lakh

Anticipated production rate

The factors proportional to production rate are :-

Raw material cost Utilities cost Maintenance cost Chemical, warehouse and shipping

Assuming that the cost proportional to production rate is nearly 60% of the total

capital investment.

i.e. 128758.55*60/100

= Rs. 77255.13 Lakh

Labor Requirement

The manufacturing cost proportional to labor might amount to 10% of total

manufacturing cost.

i.e. (7910.784+ 77255.13)*10/100

= Rs. 8516.59 Lakh

Total Manufacturing cost = 7910.78 + 77255.13 + 8516.59

= Rs. 93682.5Lakh

Sale price fixation

Rs. 80/Kg.

Profitability analysis

Total sales income = 80*2000

= Rs. 160000 Lakh

Depreciation

Using sinking fund method.

R = (V-Vs)(i/((1+i)^n-1))

R = Uniform annual payment at the end of each year

V = Installed cost of plant

Vs = Salvage value of plant after n years

n = Life period (Assumed to be 15 years)


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i = Annual interest rate (taken as 15%)

R = (11963.96-0)(0.15/((1+0.15)^15-1))

= 162296.39*0.021

= Rs. 251.24 Lakh

Gross profit

Gross profit = Net income from annual salesAnnual manufacturing cost

= 16000093682.5

= Rs. 66317.5 Lakh

Net profit rate

It is defined as the expected annual return on investment after deducting

depreciation and taxes. Tax rate is assumed to be 40%

Net Profit = Gross profitDepreciation(Gross Profit*Tax rate)

= 66317.5251.24(66317.5*40/100)

= 20795.119681.33

= Rs. 39539.26 Lakh

Annual rate of return

Annual percent return on the total initial investment after income taxes = (Net

profit/Total installed cost)*100

= (39539.26/111963.96)*100

= 35.31%

Payout period

Payout period = Total installed cost/(Depreciation + Net profit)

= 111963.96/(251.24 + 39539.26)

= 2.813 years

References

Plant Design and Economics for Chemical Engineers

Author: Max Peters, Klaus Timmerhaus, Ronald West

manufacture of naphthalenmanufacture of naphthalene

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