PROJECT

ON

NITROBENZENE

1
 ACKNOWLEDGEMENT

We here by place our sincere thanks to Dr.R.KARHIKEYAN, Head of the

Department of Chemical Engineering , S.R.M Engineering College affiliated to

S.R.M University and the faculty members of Chemical Engineering Department for

their full hearted co-operation and encouragement for the successful completion of

this project.

We extend out thanks to Project guide D.BALAJI for the Motivation,

encouragement and guidance provided by him. We would also like to extend our

thanks to each and everyone who have helped us in completing this project

successfully.

2
 ABSTRACT

The project deals extensively with the manufacture of nitrobenzene from mixed acid

and benzene .Since the demand for aniline has been increasing day by day

manufacture of benzene is more important. Nitrobenzene is obtained by treating

mixed acid and benzene. A detailed process flow sheet, material balance, energy

balance, have been done. A detailed design of equipments, cost estimation of plant,

plant layout and safety aspects have been discussed.

3
 CONTENTS

Chapter No Topic Page NO.

1. INTRODUCTION 5

2. PHYSICAL PROPERTIES 7

3. CHEMICAL PROPERTIES 9

4. USES 12

5. PROCESS DESCRIPTION 14

6. MATERIAL BALANCE 19

7. ENERGY BALANCE 25

8. REACTOR DESIGN 29

9. DISTILLATION COLUMN DESIGN 35

10. COST ESTIMATION 44

11. HEALTH AND SAFTEY FACTORS 51

12. PLANT LAYOUT 55

13 CONCLUSION 62

14. BIBLIOGRAPHY 64

4
1.INTRODUCTION

5
 1.CHAPTER

Nitrobenzene was first synthesized in 1834 by treating Benzene with Fuming

Nitric Acid, and it was produced commercially in England in 1856. The relative case
of aromatic nitration has contributed significantly to the large and varied industrial
application of nitrobenzene and its derivative.

Nitrobenzene (oil of Mir bane) is a pale yellow liquid with an odor of bitter
almonds. Depending upon the compound impurity , its color varies from pale yellow
to yellowish brown. Nitrobenzene is one of the important raw materials for the dye
manufacture and most nitrobenzene produced is used directly or indirectly in dye
manufacture. It is manufactured on large scale only by aniline manufactures. Ref[1]

6
2.PHYSICAL PROPERTIES

7
 2.CHAPTER

2.Physical Properties of Nitrobenzene :ref[4]

Molecular Weight 123.11

Boiling Point 210 - 211 °C

Melting Point 6 °C

Flash Point 88 °C (closed cup)

Vapor Density 4.3 (air = 1)

Vapor Pressure 1 mm Hg at 44.4 °C

Density/Specific Gravity 1.205 at 15/4 °C (water = 1)

Log Octanol/Water Partition Coefficient 1.85

Henry's Law Constant 2.44 x 105 atm-m3/mole

Conversion Factor 1 ppm = 5.04 mg/m3

8
3.CHEMICAL PROPERTIES

9
 3.CHAPTER

CHEMICAL PROPERTIES

1. Nitrobenzene reactions involve substitution on the aromatic ring and reactions

involving the nitro group.

2. Under electrophilic conditions, the substitution occurs at a slower rate than for
benzene and the nitro group promotes met substitution

3. Nitrobenzene can undergo halogination,sulfonation and nitration, but it does

not undergo Friedel-crafts reactions.

4. Under nucleophilic conditions, the nitro group promotes ortho and para
substitution.

5. The reaction of nitro group to yield aniline is the most commercially important
reaction of nitrobenzene.

6. Depending on the conditions, the reduction of nitrobenzene can lead to a

variety of products.

10
Reduction Products Of Nitrobenzene

Reagent Product

Fe,Zn or Sn+HCl Aniline

H2+metal catalyst+ heat

(gas phase or solution) Aniline

SnCl2+acetic acid Aniline

Zn+NaOH Hydrazobenzene, azobenzene

Zn + H2O N-Phenylhydroxylamine Azoxybenzene

Na3ASO3 Azoxybenzene

LiAIH4 Azobenzene

Na2S2O3 + Na3PO4 Sodium Phenylsulfamate,C6H5NHSO3NA

11
4.USES

12
 4.CHAPTER

The largest end use of nitrobenzene is in the production of aniline.approximtely

95-98% of nitrobenzene is converted to aniline the demand for nitrobenzene
fluctuates with the demand for aniline production grew at an average annual rate of
almost 5% from 1984 to1988 but dropped by over 4% during the 1989-1990
economic downturn. For 1990,96% of the 532972 metric tons of nitrobenzene left
were used to produce variety of other products, such as para-aminiphenol and
nigrosine dyes. The U.S. producers of PAP are MALLINCHRODT,INC., RHONE-
POULENC, and Hoechst cleanse with combined production capacities >35000 metric
tons. Mallinckrodt is the largest producer, with over 50% of capacity PAP primarily is
used as an intermediate for acetaminophen. Ref[4]

13
5.PROCESS DESCRIPTION

14
 5.CHAPTER

Nitrobenzene is prepared by direct nitration of benzene, using a nitric acid-sulphuric

acid mixture. The reaction vessel or nitrator is a specially built cast-iron or steel
kettle fitted with an efficient agitator. The kettle is jacketed and generally contains
internal cooling coils for proper control of the exothermic reaction.

Nitrobenzene can be produced by either a batch or a continuous process

with a typical batch, the reactor is charged with benzene, and the nitrating acid (56-
60% H2SO4,27-32wt% HNO3 and 8-17%wt% H2O) is added slowly below the
surface of the benzene. The temperature of the mixture is maintained at 55-55°C by
adjusting the feed rate of the mixed acid and the amount of cooling. the temperature
can be raised to 90°C towards the end of the reaction to promote completion of
reaction. The reaction mixture is fed into separator where the spent acid settles to the
bottom and is drawn off to be refortified. The crude nitrobenzene is drawn from the
top to the separator and washed in several steps. depending on the desired purity of
the nitrobenzene the product can be distilled. Usually a slight excess of the benzene is
used to ensure that little or no nitric acid remains in spent acid. Yield is about 98%.

Because of a continuous nitration process generally offers lower capital cost and more
efficient labor usage than a batch, most if not all of the nitrobenzene produce use
continuous process.

Benzene nitrating acid (56-65 wt% H2SO4,20-26%HNO3 & 15-18wt%

water) are fed into the nitrator, which can be a stirred cylindrical reactor with internal
cooling coils and external heat exchangers or cascade of such reactors.

The nitator also can be designed as a tubular reactor e.g. tube and shell
heat exchangers with appropriate cooling coils involving turbulent flow. Generally,
with a tubular reactor the reaction mixture is pumped through the reactor cycle loop
and a portion of the mixture is withdrawn and fed into the separator.

15
 A slight excess of benzene usually is fed into the nitrator to ensure that
the nitric acids in the nitrating mixture is consumed to maximum possible extent and
to minimize the formation of di-nitrobenzene. the temperature of the nitrator is
maintained at 50-100°C by varying the amount of cooling.

The reaction mixture flows from the nitrator into separator are
centrifuged here is separated into two phases. The aqueous phase or spent acid is
drawn from the bottom and concentrated in a sulfuric acid reconcentrated step or
recycled to the nitrator where it is mixed with nitric and sulfuric acid immediately
prior to being fed into the nitrator.

The crude nitrobenzene is washed and distilled to remove water and

benzene and if required nitrobenzene can be refined by vacuum distillation. ref[3]

SPECIFICATION AND TEST METHODS

Specification and test Methods:

Specification for double-distilled nitrobenzene are give in table below,

Property Value

Purity ,% > 99.8

Color Clear, light yellow to brown

Freezing Point, 0C > 5.13

Distillation range (First drop), 0C > 207

Dry point 0C 212

Moisture,% <0.1

Acidity As nitric acid, % <0.001

16
 Several qualitative spot tests are applicable to nitrobenzene and depend on
characteristic color developed by its reaction with certain reagent. In general,
calorimetric methods are subject to interferences from aromatic nitro compounds.
Certain colorimetric methods are based on the nitration of nitrobenzene to m-
nitrobenzene and subsequent determination by the generation of a red-violet color
with acetone and alkali. A general micrometric method for the determination of
aromatic nitro compounds is based on reduction with titanium(lll) sulfate or chloride
in acidic solution followed by back titration of excess titanium (lll) ions with a
standard ferric alum solution. Now days most modern techniques use instrumental
methods such as gas chromatography and high pressure liquid chromatography.

17
PROCESS FLOW DIAGRAM

18
6.Material Balance

19
 6.CHAPTER

Individual Material Balance for Mixed Acid

Reaction Involved

H2SO4 + HNO3 HNO3 (H2SO4)

Mol.wt 98 63 161

Basis :

1 Ton of Mixed acid

H2SO4 600 Kg

1000 Kg of Mixed Acid

Mixer

HNO3 400 Kg

Where,

H2SO4 = Wt / Mol.wt

= 600/98 = 6.1224 no of moles

HNO3 = Wt / Mol.wt

= 400 /63 = 6.349 no of moles

Mixed acid = Wt/Mol.wt

= 1000/161 = 6.2111 no of moles

Where,

Mass In = Mass of HNO3 + Mass of H2SO4

20
 = 400 + 600 = 1000 Kg

Mass Out = Mass of HNO3(H2SO4)

= 1000 Kg

Mass In = Mass Out

Nitration:

Reaction Involved:

C6H6 + HNO3(H2SO4) C6H5NO2 + H2O + H2SO4

Mol.Wt 78 161 123 18 98

C6H6 650 Kg

HNO3(H2SO4) C6H5NO2 840.84 Kg

Nitration
1000 Kg H2O 129.36 Kg

H2SO4 646.8 Kg

Unreacted C6H6 13Kg

UnreactedHNO3(H2SO4) 20 Kg

C6H6 = Wt /Mol.wt

= 650 /78 = 8.333 no of Moles

HNO23(H2SO4) = Wt / Mol.wt

21
 = 1000 /161 = 6.2111

C6H5NO2 :

Wt % = 51% of C6H5NO2

= 50.96 /100* 1650 = 840.84 Kg

No of Moles = 840.84 /123

= 6.836 Moles

H2SO4 :

Wt % = 39.2 % of H2SO4

= 39.2 / 100* 1650 = 646.8 Kg

No of Moles = 646.8 /98

= 6.6 Moles

H2O :

Wt % = 7.84% of Moles

= 7.84/100 *1650 = 129.36 Kg

No of Moles = 129.36 Kg /18 = 7.18 Moles.

Unreacted of C6H6 2%:

= Wt / Mol.wt = 2 / 100 * 650 = 13 Kg

Unreacted of HNO3(H2SO4) 2%:

= Wt / Mol.wt = 2 /100 * 1000 = 20 Kg

Mass In = Mass of HNO3(H2SO4) + Mass of C6H6

22
 = 1000 + 650 = 1650 Kg

Mass Out = Mass of C6H5NO2 + Mass of H2O + Mass of H2SO4 +

Mass of Unreacted C6H6 + Mass of Unreacted HNO3(H2SO4)

= 840.84 + 646.8 + 129.36 + 13+ 20

Mass Out = 1650 Kg

Mass In = Mass Out

Material Balance in Separator ; C6H5NO2 840.84 Kg

UnreactedC6H6 13Kg

C6H5NO2 840.84 Kg
Separator
H2O129.36Kg H2O129.36 Kg
H2SO4646.8 Kg H2SO646.8 Kg

UnreactedC6H613Kg
UnreacteHNO3(H2SO4)20Kg
UnreacteHNO3(H2SO4)20Kg

Mass In = Mass of C6H5NO2 + Mass of H2O + Mass of H2SO4 +

Mass of Unreacted C6H6 + Mass of Unreacted HNO3(H2SO4)

Mass In = 840.84 + 646.8 + 129.36 + 13+ 20 = 1650 Kg

Mass Out = 1650 Kg

Mass In = Mass Out

23
Material Balance for Distillation Column:

Unreacted C6H6 13Kg

D
C6H5NO2 840.84 Kg I
S
Unreacted C6H6 13Kg T
I
L
L

C6H5NO2 840.84 Kg

Mass In = Mass of C6H5NO2 + Unreacted of C6H6

= 840.84 + 13 = 853.84 Kg

Mass Out = Mass of C6H5NO2 + Mass of unreacted of C6H6

= 840.84 + 13 = 853.84 Kg

Mass In = Mass Out

24
7.ENERGY BALANCE

25
 7.CHAPTER

Individual Energy Balance for Mixed Acid:

Reaction Involved:

H2SO4 + HNO3 HNO3(H2SO4)

Temp 0C 30 30 55

Cp(KJ/Kg k) 1.402 2.013 1.641

Cp of HNO3 (H2SO4) ;

Cp of mix = { Mass fraction of H2S04 * Cp H2S04} +

{Mass fraction of HNO H2S03 * Cp HNO3}

= {(600/1000) * 1.402} + {(400/1000) * 2.013}

Cp of Mix = 1.6464 KJ / Kg k

ΔH Reaction = (ΔHF) Product – (ΔHF) Reactant

(ΔHF) reactant = (ΔHF) H2SO4 + (ΔHF) HNO3

(ΔHF) H2SO4 = -193.69 Kcal /Mol at 25 0 C. ref[2]

= -8269.377 KJ/Kg

= - 8269.377*600

(ΔHF) H2SO4 = - 4.9616*106 KJ

(ΔHF) HNO3 = -41.35 KCal / Mol at 25 0 C. ref[3]

= - 2749.165 KJ/ Kg

= - 2749.165 * 400

(ΔHF) HNO3 = -1.0996 * 106 KJ

26
(ΔHF) reactant = (-4.9616- 1.0996) * 106 KJ

= - 6.0612 * 106 KJ

(ΔHF) Product = - 236.619 K Cal/ Mol

= - 6149.155 KJ/ Kg

= - 6149.155 * 1000

= - 6.149 * 106 KJ

(ΔHF) reaction = (- 6.149 + 6.0612) * 106 KJ

= -0.088 KJ

Energy In = (m.cp.dt) HNO3 + (m.cp.dt) H2SO4

= [400 * 2.013 *(30-25)] + [1000 * 1.402(30-25)]

= 8232 KJ

Energy Out = (m.cp.dt) Product + ΔH reaction

= 1000 * 1.641 *(55-25) -0.088 * 106

= 8636.1 KJ

27
Overall Energy Balance:

Reaction Involved:

C6H6 + HNO3(H2SO4) C6H5NO2 + H2O(H2SO4)

Temp 0C 30 55 95 95

Cp(KJ/Kg K) 1.769 1.641 1.528 1.97

Energy In = (m.cp.dt)C6H5NO2 + (m.cp.dt) mix acid

= (650 * 1.769 * 55) + (1000 * 1.641 *30)

= 112471.75 KJ

Energy Out = (m.cp.dt)C6H5NO2 + (m.cp.dt) H2O(H2SO4) +

(m.cp.dt) unreacted C6H6 + (m.cp.dt) unreacted mix acid + ΔHrxn

= [840.84 * 1.528 *(95-55)] + [776.16 * 1.97(95-25)] +

[13 * 1.769 *(95-25)] + [20 * 1.641 * (95-25)] – 1510080.0

= 113251.79 KJ

Energy In = Energy Out

28
8.Design For Reactor

29
 12.CHAPTER

Ideal steady state operation is carried out :

We know that for a 2nd order reaction,

V XA
______ = _______
FAO -rA

(or)

V /VO = XA/ KCAO(1-XA)2

Where,

Vo = Feed rate,

CAo = Moles of A/VOL of fluid

XA = Conversion (98%)

We know that K is const = 1.412 Lit/min.mol . ref[2]

Volume of C6H6 = volume of C6H6/ Density of C6H6

= 650 /876 = 742.0L

Volume of HN03 = Volume of HNO3 / Density of HNO3

= 400/ 1504 = 265.9L

Volume of H2SO4 = Volume of H2SO4/ Density of H2SO4

= 600 / 1834 = 327.2L

30
Total Volume = 445.03 l/day = 445.03/24 = 18.54 l/hr = 18.54 / 60 = 0.309 l/min

= 18.54/ 3600 = 5.15*10-3

= 0.00515 l/sec.

CAO = No of Moles/ Total Volume

= 6.122/0.0052 =1177.31/60 = 19.62 Mol/Lit

CAO = 19.62 Mol/Lit

τ = V /VO = XA* CA / K *CAO*(1-XA)2

τ = V / VO = 0.98 * 0.309/ 1.412*19.62*(1-0.98)2 = 27.33 Litres

Vol of the reaction = 27.33 Lit

= 0.02733 m3

We know that,

π /4 D2 H = 0.027

π * D2 = 0.027*4

D = 0.185 m3

π/4* (0.185)2 H = 0.027

H = 0.027 * 4 * 1 /π*0.1852

H = 1.019 m3

31
We know that ,

Thickness of vessel t = P*D /2FN-P

Operating Pressure = 3 atm

Design Pressure P = 3+15% = 3.15 atm = 3.15*1.01325 bars*105 N/m2

Design Presure = 319173.75 N/m3

Shear Stress , if = yield stress /2

We know that

Yield stress = 207*106 ref[5]

Shear Stress = 207*106 / 2

Shear Stress = 103*106 w/m3

We know that

h—welding efficiency =0.85 ref[5]

Thickness of vessel t = P*D /2FN-P

= 319173.75*09 / (2*103*106*0.85)-319173.75

t = 1.64*10-3m

Thickness of vessel = 1.64 mm

32
 DESIGN SUMMARY

Volume of the reactor = 2.77 m3

Diameter of the reactor = 0.185 m3

Height of the reactor = 1.019 m3

Thickness of vessel = 1.64 mm

33
REACTOR

34
9.DISTILLATION COLUMN

35
 9.CHAPTER

Basis ; 1 hour of operation.

Feed F = Volume of feed = 35.576 Kg/hr.

Distillate D = Volume of distillate = 0.5416 Kg/hr.

Bottom Product B = Volume of bottom = 35.03 Kg/hr.

Xf = unreacted of benzene /mol.wt / (Unrect/mol) + (prod/mol.wt)

= 2/78 / (2/78) + (98/123) = 0.036

Xd = nitrobenzene /mol.wt / (nitroben/mol) + (prod/mol.wt)

= 100/78 / (100/78) + (0/123) = 1

Xb = Unrectbenz/mol.wt / (unrectbenz/mol) + (nitrobenzene/mol)

= 0/78 / (0/78) + (100/123) = 0

Average Molecular weight of feed

= 123*0.98+78*(1-0.98) = 122.1

Feed rate = 35.576 /122.1

= 0.29 Kg mole / hr

Also,

Fxf = Dxd + Bxb

From above,

D = Fx xf-xb / xd-xb . ref[2]

= 0.29*(0.03-0/1-0)

D = 0.0087 Kg mole/hr

36
 B = 0.29-0.0087 = 0.2813 Kg mole/hr.

Slope of q-line ;

We know that q = Hg-Hf / Hg-Hl

q=1

slope of q-line:

slope of q-line = q/q-1

= 1/1-1

Tan-1(α) = 0

q line is st.line

Xd / Rm+1 = 0.05

Rm+1 = 1/0.05

Rm+1 = 20

Rm = 19

R = 1.2 Rm

R = 22.8 ∼ 23

Xd = 1 = 0.042

Rm+1 23+1

37
From Mc-cabe Thile Graph

X 0 0.01 0.02 0.03 0.045 0.07 0.10 0.155 0.20 0.30

Y 0 0.03 0.485 0.63 0.74 0.82 0.88 0.92 0.94 0.964

Ideal Plate = 16 (From Graph)

Actual Plate = Ideal/n = 16/0.6

Actual Plate = 26.66

Height:

Plate Spacing = 450 mm = 0.45m

Ht = (Actual Plate-1)*0.45 + 2(0.45)

= 12.45m

Diameter :

Vap rate = v = D(R+1)

= 0.0087(23+1)

n = 0.21 Kg moles/hr

Top Column :

Vol.rate = nRT/P

= 0.21*8.314*103*(82+273)/ 1.01325*105 = 6.1170 m3/hr

Vol rate = 1.7*10-3 m3/sec

Velocity = 1 m/sec

38
 Area = Vol rate / Velocity

= 1.7*10-3 /1 = 1.7*10-3 m2

Area = π D2 /4

D2 = 4A /π ; D = √4A /π

D = 0.047 m

Bottom column:

Vol.rate = nRT/P

= 0.21*8.314*103*(210+273)/ 1.01325*105 = 8.32 m3/hr

Area = Vol .rate / Velocity

Velocity = 1 m/sec

Area = 2.31*10-3 m2

A = π D2 / 4

D2 = 4a /π ; D = √4A/π

D = 0.054 m

Both diameters are approximately same ,

we choose the larger diameter (i.e) bottom diameter

Bottom diameter D= 0.054 m

39
 DESIGN SUMMARY

Ideal plate = 16.00

Actual Plates = 26.66

Column Height = 12.45m

Column Diameter = 0.054 m

40
DISTILLATION COLUMN

41
TOPSIDE

42
BOTTOM SIDE

43
10.COST ESTIMATION

44
 10.CHAPTER

Cost of a Kg of Nitrobenzene in Market = 35 Rs

The Capacities of Plant is 840.84 Kg/day for 1 year = 29429.4

Gross `sales for 1 year or Total income = Rs.87*106

Estimation of capital investment cost Turnover = Gross Annual Sales

Fixed Capital

For Chemical Industries Turn Over ratio = 1

Therefore gross annual sales = Fixed Capital Investment

Therefore Fixed capital Investment = Rs.30.87*106

1. DIRECT COST

It is taken as 70% of fixed capital investment

Hence direct cost = 0.7 * 30.87* 106 = Rs 21.6*106

The cost involved in direct costs are

Equipment and installation + instrumentation = piping + electrical + insulation+

Paintings which amount for 50% of the fixed capital

1. Equipment cost is 24% of fixed capital cost = Rs.7.4 * 106

2.Installation and painting is 40% of delivered equipment cost = Rs3*106

3.Instrumentation and control and installation cost = 10% of delivered equipment

cost this cost is equal to Rs7.4*106

4.Piping and installation cost is 25% of the delivered cost = Rs1.85*106

5.Electrical and installation cost Rs 33.33% of the delivered cost.

45
6.Building , Process and Auxiliary

This cost is 39.1667 of the purchased equipment cost

this cost is equal to 391667*7.4*106 = Rs289*106

7.Service Facilities and yard improvement is 40% of the delivered equipment cost

this cost is equal to 0.4*7.4*106 = 2.96*106

8. Load cost is 1% of fixed capital

this cost is equal to 0.001*30.87*106 = Rs 30.87*106

2.INDIRECT COST:

This is expenses which are not included with material and labor of actual

installation of complete facilities

this cost is equal to 0.3*30.87*106 = Rs6.174*106

a) engineering are supervision : this cost is 20% of the fixed capital investment

this cost is equal to 0.2*30.87*106

b) Construction expenses and contractor fees. this cost is 10% of direct cost

This cost is equal 0.1*21.6*106 = Rs2.16*106

c) Contingency : This cost in 5% of the capital

This cost is equal to 0.5*30.87*106 = Rs1.544*106

46
Working Capital:

In 20% of total capital investment total capital investment = fixed cap+ Working cap

=30.87*106+0.8(Total cost investment)

total capital capital investment = 30.87 *106/0.8 = Rs 38.58*106

Working Capital = 38.58*106-30.87*106 = Rs 7.71*106

Estimation of Total Product Cost

Total annual income = Rs.30.87*106

Total Grass Earnings = 10% of total annual incomes

= 0.1*30.87*106 = Rs3.08*106

Product Cost = Total annual Gross earnings income

=30.87*106-3.08*106 = Rs 27.79*106

Total Product Cost = Direct Production Fixed + Charge Plant + Overhead

DIRECT PRODUCTION COST

It is 60% of total product cost the

Direct Production cost is equal to = 0.6*27.79*106

1. Raw Material : It is 20% of total product

cost the cost of raw material is = 27.79*106 = Rs.5.56*106

2. Operating Labor is 15% of the total product cost

The cost of operating labor is = 0.15*27.79*106 = 4.168*106

47
3. Direct supervisory and clinical labor is 20% of operating labour.

The cost of direct supervisory and clinical labor is = .15*27.79*106= Rs.5.56*106

= Rs4.168*106= Rs.5.56*106

4. Utilities : In 15% of total Product cost

The cost of utilities is = 0.15*27.79*106 = Rs4.168*106

5. Maintenance and Repairs : it is 3.6% of fixed capital investment

The cost of maintenance = 0.0036*30.87*106

6. Operating Supplies : it is 0.5% of the fixed capital investment

The cost of operating supplies is = 0.005*30.87*106

7. Laboratory Charge is 6.6667% of the operating labor cost

The cost of Laboratory Charges is = 0.6667*4.168*106 = Rs 0.281681*106

8. Patents and Royalties : it is 1.45% of the fixed capital cost

the cost of patents and royalties is = 0.0145*30.87*106 = Rs.447675.00

9. Fixed charge : it is 20% of total product cost.

The cost of fixed charges is = Rs 5.56*106

DEPRECIATION

Depreciation for building is 3% of land cost

= 0.03*30.87*105

Total depreciation value = Rs0.93*106

48
3. INSURANCE

This is 1 % of the fixed capital investment

The insurance value = 0.01*30.87*106 = Rs 308700

4. Rent : This is 3.0555% of total product cost

Rent value = 0.030555*27.79*106 = Rs.849123.45

C) Plant overheads : The includes cost for following general plant upkeep and

Overheads payroll, overhead packaging, medical services safety and protection,

Restaurants, recreation salvage, laboratories and storage facilities. This cost is 5%

of total product cost plant overhead is equal to = 0.05*27.79*106 = Rs 1389500.00

ll GENERAL EXPENSES:

a) Administrative cost:

Includes cost for executive officer, clinical wage, legal fees, office

Supplies and communication. This cost is 5% of the total product cost

Administrative cost = 0.005*27.79*106 = Rs.1389500.00

b) Distribution and selling cost:

Includes cost for sales offices, sales man shopping and advertising

This cost is 7 of the total product cost

Distribution and selling cost = 0.07*27.79*106 = Rs. 1945300.00

49
c) Research and development

This cost is 1% of total product cost. Research and

Development cost = 0.01*27.79*106 = Rs 277900.00

D) Gross earning cost: it is the net profit obtained after deduction of tax from
gross earning

Gross earning cost = 60%

Net profit = Rs 1.848*106

d) Pay back period: with interest charge

Pay back = Depreciable fixed capital investment

Average profit/year-Average depreciation/year

= (30.87-3.08)*106 /(1.846+3.08)*106

= 5.612 years

Pay back = 5years 233 days ref[2]

50
11.HEALTH AND SAFTEY FACTORS

51
 11.CHAPTER

Nitrobenzene is a very toxic substance the maximum allowable concentration

for nitrobenzene is 1ppm or 5 mg/m³.It is readily absorbed by contact with skin and
by inhalation of vapor, If a worker was exposed for 8 hours to 1ppm nitrobenzene in
the working atmosphere, about 25mg of nitrobenzene would be absorbed, of which
about one-third would be by skin absorption and the remainder by inhalation . The
primary effect of nitrobenzene is the conversion of hemoglobin to met hemoglobin;
thus the conversion eliminates hemoglobin from the oxygen-transport cycle.
Exposure to nitrobenzene may irritate the skin and eyes. nitrobenzene affects the
central nervous and produces fatigue, headache,vertigo,vomiting, general
weakmess,and in some cases unconscious and coma. There generally is a latent period
of 1-4 hours before signs or symptoms appear. Nitrobenzene is a powerful met
hemoglobin former, and cyanosis appears when the met hemoglobin level reaches
15%. Chronic exposure can lead to spleen and liver damage, jaundice and anemia.
Alcohol in any form should not be ingested by the victim of nitrobenzene poisoning
for several days after the nitrobenzene poisoning or exposure. Impervious protective
clothing should be worn in areas where risk of splash exists. Ordinary work clothes
that have been splashed should be worn in areas where risk of splash exists.

Ordinary work clothes that have been splashed should be removed immediately, and
the skin washed thoroughly with soap and warm water. In areas of high vapor
concentrations full face marks with organic-vapor canister or air-supplied respirators
should be used. clean work clothing should be worn daily and showering after each
shift should be mandatory.

With respect to the hazards of fire and explosion, nitrobenzene is classified as a

moderate hazard when exposed to heat or flame. Nitrobenzene is classified by the
ICCas a classB poisonous liquid. Ref[1]

52
ENVIRONMENT EFFECTS

First draft prepared by L. Davies, Office of Chemical Safety, Therapeutic Goods

Administration, Australian Department of Health and Ageing, Canberra, Australia

Published under the joint sponsorship of the United Nations Environment

Programmer, the International Labor Organization and the World Health
Organization, and produced within the framework of the Inter-Organization
Programmer for the Sound Management of Chemicals.

The International Programmer on Chemical Safety (IPCS), established in 1980, is a

joint venture of the United Nations Environment Programmer (UNEP), the
International Labor Organization (ILO) and the World Health Organization (WHO).
The overall objectives of the IPCS are to establish the scientific basis for assessment
of the risk to human health and the environment from exposure to chemicals, through
international peer review processes, as a prerequisite for the promotion of chemical
safety, and to provide technical assistance in strengthening national capacities for the
sound management of chemicals.

The Inter-Organization Programmer for the Sound Management of Chemicals

(IOMC) was established in 1995 by UNEP, ILO, the Food and Agriculture
Organization of the United Nations, WHO, the United Nations Industrial
Development Organization, the United Nations Institute for Training and Research
and the Organization for Economic Co-operation and Development (Participating
Organizations), following recommendations made by the 1992 UN Conference on
Environment and Development to strengthen cooperation and increase coordination in
the field of chemical safety. The purpose of the IOMC is to promote coordination of
the policies and activities pursued by the Participating Organizations, jointly or
separately, to achieve the sound management of chemicals in relation to human health
and the environment.

Nitrobenzene.

(Environmental health criteria ; 230)

1.Nitrobenzenes - toxicity

53
2.Nitrobenzenes - adverse effects

3.Environmental exposure

4.Risk assessment I. International Programmer for Chemical Safety II.Series. ref[1]

HANDLING AND STORAGE TRANSPORTATION

Nitrobenzene samplings handling procedures in the united states are

described by ASTMP 3436-75.They are classified by the U.S interstate commission
(ICC)as a poisonous liquid,classB (regulation 173 347) and as a class 6 poison by
united nations as such they must be packaged in ICC specifications contains when
shipped by rail, water or highway and all of ICC regulations regarding loading
handling and labeling must be followed. nitrobenzene ordinarily is transported in
tanks, cars, tank trucks, or metal drums.

Carbon steel or cast iron is considered materials of choice for handling nitrobenzene
except when decolonization must be kept to minimum. Stainless steel (400 series) is
recommended for color critical applications. Nitrobenzene attacks, copper alloys,
brass and copper. It is rated on class IIIA combustible liquids (NFPA std no.30) and
usually can be handled with little danger of fire. Ref[2]

54
12.PLANT LAYOUT

55
 15.CHAPTER

Plant layout is the functional arrangement of machinery and equipment in a

existing plant. Plant layout may be defined as the floor plan for determining and
arranging the desired equipment of a plant, in the one best place, to permit the
quickest flow of materials at lowest cost and least amount of handling in processing
the raw material from the receipt of raw material to the shipment of finished products.

The material handling planned in the layout begins at the receiving point , where the
material arrives as raw material, then continuous progressively from storage through
process, moving the from of worked material from department to department , from
machine to machine, the material flows in and out of temporary storage is fed through
assembly lines for final assembly. Provision is made for inspection, packaging and
storing the material as finished product.

Advantages of good plant layout to the workers :

• Reduces the effort of the workers.

• Reduces the number of handling.

• Permits working at maximum efficiency.

• Reduces the number of accidents.

• Provides basis for higher earnings.

Advantages of a good plant layout in labour cost:

• Increases output per man hour.

• Reduces number of operators.

• Loss setup time involved

56
Advantages of a good plant lay out in production control:

• Reduces production control expenses

• Pace production

Fundamental concepts of plant layout :

In apprising the advantages of good layout in the light of conditions prevailing in a

particular plant ,it is well to bear in mind the following concepts of plant layout.

• Major part of production works is not processing , as is initially suppose but

material handling.

• Then speed of production in the plant is determined primarily by the

adequacies of its material handling facilities.

• A good plant layout is designed to provide the proper facility for material
handling.

• The factory is altered or constructed around the prescribed plant layout.

• The production efficiency of the plant is determined by the limitations of its

layout.

TYPES OF DEPARTMENT

• Processing department.

• This department performs machining assembly and packaging.

• Service department.

• These constitute the facilities provided to keep the processing

department in operation without interruption.

• Administrative department.

57
 • This department administrative sales,engineering,accounting production
control, departments etc.

PLANNING THE PROCESSING

• The plant layout engineer should obtain data on building elevation, column
spacing, door and conveyors.

• The conveyors should be placed at reasonable height to mal functioning and

waste.

• The traffic in the plant may be greatly by location store rooms close to the
building entrances.

• In addition to the above vehicular traffic should be separated from pedestrian

traffic and the roads should be wider.

PLANNING THE PLANT SERVICE FACILITIES:

• Material received at a plant arrives via the particular forms of transportation

which are generally prescribed.

• Liquids such as chemicals are transported in tank cars, drums or pipelines

• The receiving department must be well equipped to receive the material in all
modes.

• The design of a receiving involves the following considerations:

1. Space, 2. climate conditions, 3. variety of vehicles

STORE ROOM:

• A store room is the reservoir for raw material.

• Worked materials, finished products, maintenance supplies etc are kept.

58
 • The functional requirements of a store room are:

1. protection to materials

2. handling of the materials

3. control points

The above factors also help the layout engineer to design the store
room as per requirements.

INSPECTION ROOM:

• The inspection room or quality control room should be located near then
production unit, so that the samples from the production plant

Can be checked for its quality requirements.

• The labs should be well equipped and should be properly planned.

WATER STORAGE:

• Water is used in the plant for variety of purposes.

• A plant must have adequate water supply to crater all these needs.

• By far the most reliable and effectives means of fire protection is the
automatic sprinkler system.

• The sprinkler system is fitted with a sensitive transducer which lets water up
to a height of 15 feet.

• So the water storage system should be planned out with most more.

59
POWER AND LIGHTING SYSTEM:

• Power and lighting systems forms the main part of the plant.

• The significant features of the power plant operations are,

1. For supplying steam.

2. Providing heat for process operations.

3. supplying power to run motor.

4. providing light to plant.

5. power for surplus use.

PLANNING OF ADMINISTRATIVE BLOCK:

• Location of an administrative block depends upon the geographic

location with respect to the plant functions.

• The general administrative block should have administrative rooms,

conference room and vault room storage of documents and records.

• The employee service facility consists of parking lots,

Employment office cafeteria, first aid stations and medical

department etc. ref[6]

60
PLANT LAYOUT

61
13.CONCLUSION

62
 13.CHAPTER

The Manufacture of Nitrobenzene has been described in detail. The

necessary flow diagram, material and Energy balance for the production of 1 Ton of

Nitrobenzene has been worked out in detail. The design aspects are above described

in detail. The cost has been estimated .

63
14.BIBLIOGRAPHY

64
 14.CHAPTER

¾ 1. KIRK AND OTHMER, Encyclopedia of Chemical Technology Vol.15.

2nd Ed.Pg:176-190

¾ 2. ROBERT H .PERRY : PERRY’S Chemical Engineers Hand Book 5th &

6th Ed. Mc Graw Hill international Editions , Pg:642-644

¾ 3. GEORGE T. AUSTIN : Shreve’s Chemical Process Industries 5th Mc

Graw Hill international Editions , Pg:776-778

¾ 4. BAHL.B.S & ARUN BAHL : A text book of organic Chemistry,

19990,chand , Pg:350-355

¾ 5. IS CODES : 2825 ; 1969,4503-1967, Pg:5

¾ 6. JOSHI.M.V: Process Equipment Design 3 rd Ed.Pg :45

65