Design Report-CP409

Production of Aspirin and salicylic acid using Phenol and

NaoH

The Final Report Submitted to the Department of

Chemical and Process Engineering

In partial fulfillment of the requirements of the Bachelor of Science of

Engineering Degree Programme

Name of the Student : Rodrigo K.A.R.N.

Registration Number : E/15/308
Project Advisor : Dr. Aruna Manipura
Project Supervisor : Miss. Nadeeshani Bandara
Date of Submission : 19/03/2021
 Content
Declaration
List of Figures
List of Tables
List of Abbreviations and notations
Chapter 1 INTRODUCTION
1.1 Introduction to design project
1.2 Objectives
1.3 Specific goals
1.4 Introduction to tray dryer
1.5 Mass balance
Chapter 2 CHEMICAL ENGINEERING DESIGN
2.1 Introduction
2.2 Basic dimension calculation
2.2.1 Design data
2.1.2 Seizing of the chamber
2.1.3 Summary

Chapter 3 MATERIAL SELECTION

3.1 Introduction
3.2 Material type

Chapter 4 MECHANICAL ENGINEERING DESIGN

4.1 Introduction
4.2 Thickness calculation of the plate
4.3 Insulation
4.4 Welding design

Chapter 5 CIVIL ENGINEERING DESIGN

5.1 Introduction
5.2 Nut and bolt design
5.3 Colum design
5.4 Buckling design

Chapter 6 COST ANALYSIS

6.1 Introduction
6.2 Historical method

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 6.3 Factorial method
6.4 Operational cost
6.5 Direct Production Cost

Chapter 7 SAFETY ANALYSIS

7.1 Introduction
7.2 HAZOP analysis of process

Chapter 8 AUXILIARY EQUIPMENT DESIGN

8.1 Introduction
8.2 Blower selection
8.3 Blower properties

Chapter 9 ENVIRONMENTAL, SOCIAL AND ECONOMIC IMPACT OF

THE PROJECT
9.1 Introduction
9.2 Social and Economic Impact
9.3 Environmental Impact

References

APPENDIX A : P&ID for the tray dryer

3
 Declaration
I declare that this report does not contain any material previously submitted for any other
degree or diploma to the best of our knowledge. It does not contain any material previously
published or written by other persons or group of persons except where due references are
made. This report does not submitted by any other persons before.

Rodrigo K.A.R.N.

4
 List of Figures
Figure 1.4.1 Classification of dryers based on method of operation
Figure 1.4.2 Classification of dryers based on physical form of feed
Figure 1.5.1 Mass flow through the dryer
Figure 2.2.2.1 Batch tray through the dryer
Figure 3.2.1 Thermal conductivity variation of materials
Figure 3.2.2 Unit cost variation of materials
Figure 4.2.1 Typical design stress for plate
Figure 4.3.1 Insulation R values for fiber mat
Figure 4.4.1 Types of joints (Oxlev et al,2013)
Figure 5.2.1 Flange ring design (Coulson and Richardson,vol 6)
Figure 5.2.2 Base Plate schedule.
Figure 5.2.3 Equation for area of one bolt
Figure 5.3.1 Shapes of tubes
Figure 6.2.1 Variation of CEPCI ratio with time
Figure 6.3.1 The typical factors for estimation of project fixed capital cost
Figure 6.3.2 LKR to USD exchange rate
Figure 6.4.1 Summary of production cost
Figure 8.1.1 Equipment layout
Figure 8.2.1 Different type of air blowers
Figure 8.2.2 Different type of impellers
Figure 9.2.1 Working population of Biyagama based on the age
Figure 9.2.2 Employment statistic of EPZ enterprise

5
 List of tables
Table 1.5.1 Operation conditions through a one drying cycle
Table 2.2.1.1 CP408 previous calculation data
Table 2.2.3.1 Summary of design details
Table 5.4.1 Summary of civil engineering design
Table 6.2.1 CEPCI ratios
Table 7.2.1 HAZOP analysis of process
Table 8.3.1 Inlet air properties
Table 8.3.2 Blower equations
Table 8.3.3 Outlet air properties

6
 CHAPTER 1
INTRODUCTION

1.1. Introduction to design project

The design project is titled “Production of Aspirin and Salicylic acid using Phenol and NaOH”.
Aspirin is the generic name of Acetyl salicylic acid, which was originally used as an analgesic
and fever reducing agent. Later, research has found that aspirin reduces the likelihood of strokes,
reduces the likelihood of heart attacks, reduces the complications of a stroke or heart attack when
administered after the cardiovascular incident, and reduces the likelihood of a second heart attack
(Handal-Vega et al., 2001). With minimal side effects upon administration, aspirin continues to
be the longest-selling drug on the market, since its introduction in 1899.
In 1823, the active ingredient within willow tree bark, which was traditionally used to treat pains,
fevers, and rheumatic fevers, was isolated and named as Salicin. Later, salicylic acid was created
from salicin and it was found that salicylic acid was effective as a pain reliever, but it irritated
the gut. Finally, in 1897, Hoffman, a scientist from Bayer, synthesized aspirin from salicylic acid
by treating it with acetic acid anhydride (Roy, 2011). In the modern age, salicylic acid is used in
the synthesis of aspirin and other pharmaceutical products. Technical grade salicylic acid is used
as an intermediate in the production of agrochemical products, dyes, and colourants, as well as in
the rubber industry and in the manufacture of phenolic resins (Boullard et al., 2000). And
although it can cause irritation upon ingestion, it can be safely used to treat skin conditions.
There are many starting points for the synthesis of salicylic acid, however, this project is focused
on using Phenol (C6H5OH) and NaOH as the starting raw materials. The synthesis of salicylic
acid (HOC6H4COOH) is based on the Kolbe-Schmitt reaction mechanism which is as follows
(Abounassif et al., 1994).

C6H5OH + NaOH → C6H5ONa + H2O

C6H5ONa + CO2 → HOC6H4COONa

2HOC6H4COONa + H2SO4 → 2HOC6H4COOH + Na2SO4

And the reaction for the conversion of salicylic acid and acetic anhydride into aspirin and acetic
acid is as follows.

HOC6H4COOH + (CH3CO)2O → CH3COOC6H4COOH + CH3COOH

Most drugs become obsolete after being on the market for a couple of decades due to the
availability of newer and better drugs, but aspirin despite being more than 100 years old is still
being widely used today. Therefore, it is worthwhile considering the production of aspirin in a
manufacturing plant based in Sri Lanka.

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1.2. Objectives
Design of the Tray dryer consists of Chemical engineering design including detailed
equipment sizing, material selection, insulation and Mechanical and Civil engineering design
calculations including force analysis and support designs.

1.3. Specific goals

1) To get knowledge on Chemical Engineering design of tray dryer.
2) To get knowledge on Civil & Mechanical Engineering components of tray dryer.

1.4. Introduction to Tray dryer

In Asprin synthesis process Salicylic acid is produced and It is mixed with some amount of
moisture. It should put in to the dryer at ambient temperature then heated air stream at 70 to 60
0
C is went parallel to the salicilyic acid solid layer. Then the moisture content of Salicylic acid is
decreased 0.5% to 0.2% and also some amount of salicylic acid is loosed. (boullard2000,
Chemical_Engineering._Vol._6 Coulson & Richardson)
To select a suitable dryer should be looked in to drying classifications.

Figure 1.4.1: Classification of Dryers Based On Method of Operation

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Figure 1.4.2: Classification of Dryers Based on Physical Form of Feed

according to above classifications and considering batch process, Convectional heat transfer and
crystalline solid phase can be selected the tray dryer as the suitable dryer.
When designing a tray dryer there are 6 major components to design,
(1) Drying chamber
(2) Trays
(3) Heat source(Heater)
(4) Temperature and humidity sensors
Control Panel
(5) Strain gauge weight sensors
(6) Moisture air outlet fan

1.5 Mass balance

Figure 1.5.1: Mass flow through the dryer

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Table 1.5.1: Operation conditions through a one drying cycle

S-120 S-121 S-122 S-123

Salicylic acid (kg) 31.63 31.56
Liquid (kg) 0.49 0.19
Air (kg h-1) 5 5 5.000014
Total (kg) 32.11 31.76
Temperature (0C) 25 70 60 25
Pressure (0C) 1.1 1.1 1.1 1.1

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 CHAPTER 2
CHEMICAL ENGINEERING DESIGN

2.1 Introduction
This chapter includes the design of tray dryer according to standard Specifications and codes.

2.2 Basic dimension calculation

2.2.1 Design data

Table 2: CP408 previous calculation data

Heat tranfer coefficient, Wm-2K-1 (h) 1.243

Mass of air flow rate, kgm-2s-1 (G) 1.558
Total drying area, m2 (A) 3.208
Air flow rate, kgs-1 (mg) 5
Specific heat capacity, kJkg-1K-1, (Cs) 1.038
Inlet air temp, 0C, (Tin) 70
Outlet air temp, 0C, (Tout) 60
Temp of the solid, 0C, (Ts) 25
Latent Heat, J, (L) 2437.2

2.2.2 Seizing of the chamber

Tray area calculation

ℎ = 𝛼𝐽0.78
Perrys_Chemical_Engineers_Handbook_8thEd

h = Heat-transfer coefficient, 𝑊𝑚−2 𝐾 −1

J = Gas mass flux, 𝑘𝑔𝑚−2 𝑠 −1
α = Plates open areas equal to 2 to 3 percent of the total heat-transfer area

h = 1.243 𝑊𝑚−2 𝐾 −1 (CP 408 calculations)

α = 0.02

Calculated

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J = 1.321 𝑘𝑔𝑚−2 𝑠 −1

8.8𝐽0.8
h =
𝐷𝑐 0.2
Perrys_Chemical_Engineers_Handbook_8thEd

Dc = equivalent diameter (4 times the cross-sectional area divided by the perimeter of the
flow channel), 𝑚

Calculated
Dc = Length of the tray, 𝑚
a = Length of the tray, 𝑚
a = 0.896 m

Trays may be rectangular or square. Tray area varies from 0.5 to 1 m2

a2 = Tray area, m2

Calculated for square trays

a2 = 0.802 m2

Total trays
𝐴
𝑁=
𝑎2
N = Total trays
A = Total drying area, m2

A = 3.208 m2 (CP 408 calculations)

Calculated
N = 4

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Drying Chamber height

𝐻𝑐 = 𝑁. 𝐻𝑡 + 𝑁. 𝑇𝑡 + (𝑁 − 1). 𝑆𝑡 + 𝐻ℎ𝑠 + 𝐻𝑏𝑠

Perrys_Chemical_Engineers_Handbook_8thEd

Hc = Drying chamber height, m

Ht = Height of the trays, m
Tt = Tray thickness, m
St = Space between the trays, m
Hhs = Head spaces of the dryer, m
Hbs = Bottom spaces of the dryer, m

The depth of feed materials should be varies from 1 to 5 cm.. Trays are stacked in, there should
be a clearance of not less than 4 cm between the material in one tray and the bottom of the tray
immediately above.
Ht = 0.05 m
Tt = 0.005 m
St = 0.1 m
Hhs = 0.12 m
Hbs = 0.17 m

Calculated
Hc = 0.81 m

Figure 2.2.2.1: Batch tray dryer((Devahastin,2000)

2.2.3 Summary
Table 1 depicts the summary of design details

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 Table 2.2.3.1 Summary of design details

Notation Parameter Value

a Length of a tray 0.9 m
a2 A tray area 0.8 m2
N Total number of trays 4
Hc Drying chamber height 0.81 m

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 CHAPTER 3
MATERIAL SELECTION

3.1 Introduction
Material selection of the tray dryer is very important factor which effect safety and economic
feasibility of the design. The most important characteristics to be considered when selecting a
material are:
1. Mechanical properties
2. Corrosion resistance
3. Ease of fabrication: forming, welding, and casting
4. Availability in standard sizes plates, sections, tubes
5. Cost

3.2 Material types

The most common material type uses to design tray dryer are steel. A wide range of steels are
available, with metal compositions to give the properties required for specific applications. They
can be divided into four broad classes.
1. Carbon steel
Carbon steel is a special type of steel that, as the name suggests, has a higher
concentration of carbon than other types of steel. Most types of steel have a relatively
low carbon content of about 0.05% to 0.3%. In comparison, carbon steel has
a carbon content of up to 2.5%

2. Alloy steel
Alloy steel is a type of steel alloyed with several elements such as molybdenum,
manganese, nickel, chromium, vanadium, silicon, and boron.
These alloying elements are added to increase strength, hardness, wear resistance, and
toughness. The amounts of alloying elements may vary between 1 and 50%.

3. Stainless steel
Stainless steels are steels containing at least 10.5% chromium, less than 1.2% carbon and
other alloying elements. Stainless steel's corrosion resistance and mechanical properties
can be further enhanced by adding other elements, such as nickel, molybdenum, titanium,
niobium, manganese, etc

4. Tool steel

15
 Tool steels are a family carbon and alloy steels having distinct characteristics such as
hardness, wear resistance, toughness, and resistance to softening at elevated
temperatures. Tool steels comprise carbide-forming elements such as chromium,
vanadium, molybdenum and tungsten in different combinations.

When selecting the best material cost, thermal conductivity and corrosion resistence must also take
into consideration. The following figure shows the basic cost and thermal conductivity of the most
common used materials.

Figure 3.2.1: Thermal conductivity variation of

materials

Figure 3.2.2: Unit cost variation of materials

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Carbon Steel is in lowest unit cost and lowest thermal conductivity region and also it is extremely
resistant to chemicals and has a high resistance to corrosion. Considering these features which are
suitable for the dryer, Carbon Steel is selected as the construction material

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 CHAPTER 4
MECHANICAL ENGINEERING DESIGN

4.1 Introduction
In this chapter thickness calculation of the Tray dryer and insulation are calculated. All the
calculations are done according to the given standards.

4.2 Thickness calculation of the plate

Figure 4.2.1: Typical design stresses for plate

Metal walls are constructed using carbon steel. Design stress at drying operating temperature (60
to 70 0C) is nearly to 129.67 N mm-2

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 f = Design stress, N mm-2

Calculated
f = 129.67 N mm-2

A general equation for the thickness of a flat plate required to resist a given pressure load can be
written in the form.

𝑃
t = CD√
𝑓

Coulson Richardson's Chemical Engineering Vol.6 Chemical Engineering Design 4th

Edition
The limiting value of C can be obtained from equations Taking Poisson’s ratio as 0.3, a typical
value for steels, then if the plate can be taken as completely rigid C = 0.43, and if it is essentially
free to rotate C = 0.56.
t = Plate thickness, m
C = A constant, which depends on the Plate stability
D = The effective plate diameter, m
P = Inlet pressure, Pa
f = the maximum allowable stress (the design stress), Pa

C = 0.43
D = 0.896 m
P = 1.1×105 Pa
f = 1.35×108 Pa

Calculated
t = 0.011 m

Corrosion allowance
The “corrosion allowance” is the additional thickness of metal added to allow for material lost by
corrosion and erosion, or scaling. The allowance to be used should be agreed between the
customer and manufacturer. Corrosion is a complex phenomenon, and it is not possible to give
specific rules for the estimation of the corrosion allowance required for all circumstances. The
allowance should be based on experience with the material of construction under similar service
conditions to those for the proposed design. For carbon and low-alloy steels, where severe
corrosion is not expected, a minimum allowance of 2.0 mm should be used; where more severe
conditions are anticipated this should be increased to 4.0 mm. Most design codes and standards
specify a minimum allowance of 1.0 mm.
Selected corrosion allowance is 0.002 m

Total thickness = Calculated thickness + Corrosion allowance

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 = 0.011 + 0.002
= 0.013 m

4.3 Insulation
The most common insulation type uses to design tray dryer are fiber glass. A wide range of fiber
glass are available, with metal compositions to give the properties required for specific
applications. They can be divided into four broad classes.
1. Tow
When fiberglass is in the form of tow or roving, it exhibits the highest number of
properties that are achievable. Fiberglass in this form is supplied on spools that can be
unrolled and cut as needed or fed into filament winders. The fibers of the fiberglass must
remain in tension to retain their mechanical properties.
2. Veil mats
Fiberglass, in the form of veil mats, has continuous strands of fibers that have been
arranged in thin piles, looped randomly. Veil mats have a consistency similar to that of a
tissue paper. They are not intended for any structural applications. However, they have
some very important uses. They can be placed in the mold that is placed directly behind
the surface coat to minimize the print through of heavier reinforcing cloths. Moreover, this
outer layer – that is quite thin – also allows surface sanding of the finished parts without
cutting into the reinforcing fabric that lies below.
The second very important use that veil mats have is that they are used with sandwich
cores. They are placed over the core directly in order to maintain the ideal (maximum)
bond-line thickness. Veil mats can also keep the excess resin from falling into the cells of
honeycomb cores in case a vacuum is not used.
3. Woven fabrics
Woven fabrics are fairly strong reinforcements. The fibers in woven fabrics are oriented in
two directions and are bundled into yarns. The resulting fabrics are, therefore, stronger .
4. Chopped strand mat
The length of fibers in this form of fiberglass is 3 to 4 inches. Unlike woven fabrics, the
fibers in chopped strand mats are arranged randomly, without any fixed
orientation. Fiberglass in this form is not very strong because the length of fibers is quite
short. However, fiberglass that comes in this form is the least expensive, and that is why it
is also the most commonly used. Due to the random orientation of fibers, the print through
of gels coats is effectively hidden.

20
 There isn’t any movement in the dryer and need as well as least expensive insulation.
Then the Chopped strand mat is the most suitable insulation method and also the
insulation thickness must be grater than 50 mm.
There are different type of chopped strand mat thickness According to the R values,
Suitable thickness can be selected.

Figure 4.3.1: Insulation R values for fiber mat

R19 fiber mat is the most suitable insulation phase. Its thickness is 139 mm and its grater
the approved value of 50 mm and also there are two types of length sizes then a suitable
length size can be selected within a minimum cost.

4.4 Welding design

The strength of a welded joint will depend on the type of joint and the quality of the
welding. Tungsten Inert Gas (TIG) welding is the most commonly used for the carbon-steel
welding processes. This welding process creates a low heat input. This welding type is an arc
welding process. In here, weld is applied with a non-consumable tungsten electrode. In here, type
of joint is selected as single-weld butt joint with bonding strips. Double-welded butt is applied,
when radiation materials are using. [Owler et al., 2013]. Figure 4.1 shows the type of joints.

21
Figure 4.4.1: Types of joints [Owler et al., 2013]

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 CHAPTER 5
CIVIL ENGINEERING DESIGN

5.1 Introduction

Firstly, nut and bolt are designed to fix the tray dryer on the ground surface. Required
standard bolt diameter size is calculated in the nut and bolt design part. Then, buckling design is
done. Critical force is calculated and compared with affected force in the buckling design part.

5.2 Nut and bolt design

Firstly, type of base flange is assumed as double plate with gusset. This type can be bearing
the high total weight well. Safety factor is assumed as additional 10% of the total weight. Figure
5.1.1 shows the flange ring designs.

Figure 5.2.1: Flange ring designs [Coulson and Richardson, Vol 6]

Then, data of weight of the tray dryer and weight of the load are obtained. Next, total
weight with the safety factor and force are calculated.

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Weight of the Tray dryer (W1) = 463.04 kg

Weight of the load (W2) = 57.92 kg

Total weight with the safety factor (W) = (W1 + W2) × 1.1

W = (463.04 + 57.92)𝑘𝑔 × 1.1

W = 573.06 kg

Force (F) = Total weight × 9.81

F = 573.06 𝑘𝑔 × 9.81 𝑚𝑠 −2

F = 5.62 kN

Then, data of length of the diagonal and average wind pressure are obtained. Next, wind loading
is calculated.

Length of the diagonal = 4.53 m

Average wind pressure = 1280 Nm−2 [ Coulson and Richardson, Vol 6]

Wind loading (W) = Average wind pressure × Length

W = 1280 Nm−2 × 8.5 m

W = 11.5 kNm

Then, size of the base plate is assumed. Size of base plate is taken as 5 inch to 5 inch. Next,
base plate area is calculated. Figure 5.2 shows the base plate schedule.

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 Figure 5.2.2: Base plate schedule

Size of the base plate = 0.125 m

Base plate area (A) = Length × Width

A = 0.125 m × 0.125 m

A = 0.01 𝑚2

A = 0.01 𝑚2

Then, bending moment at the base is calculated.

Bending moment at the base (B) = Wind loading × Length × Length

B = 1280 Nm−1 × 0.896 m × 0.896 m

B = 1.16 kNm

There are four bases at four corners and four bolts in one base. Then, number of bolts are 16.
Maximum allowable bolt stress is 125 N/mm2. Then, area of one bolt is calculated by using figure
5.2.3 Bolt circle diameter is selected as 0.12 m to bear the high total weight.

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Figure 5.2.3: Equation for area of one bolt

Area of the one bolt = 16.46𝑚𝑚2

Finally, diameter of the bolt is calculated and standard bolt size available in industry are obtained.

4×A 0.5
Diameter of the bolt (D*) =( )
π

4×16.46 mm2 0.5

D* =( )
π

D* = 1.83 inch

Standard available size = 2 inch

5.3 Column Design

Design material = Stainless steel

Shape of the Column = Square tube (Assumed)

Beam bolt circle diameter Db = 0.12 m (Assumed)

Therefore, size of the column should be greater than 0.12 m.
Standard column size is 76mm * 76mm
Figure 5.3.1 shows the shapes of tubes.

26
 Figure 5.3.1: Shapes of tubes

Maximum allowable stress = 1.25 × 105 kNm2

Force affected to the one column = 14.05 kN

5.4 Buckling design

Firstly, data of elastic modulus of stainless steel is taken. Then, moment of inertia is calculated.

Elastic modulus of stainless steel = 1.95 × 108 𝑘𝑁𝑚−2

Moment of inertia (I) = Width × Depth3

I = 76 mm × 51 mm3

I = 8.4 × 10−7 m4

Height of the column is assumed as 1.5 m. Then, critical force on the column is calculated.

π2 ×E×I
Critical force on the column =
l2

Where,

E = Elastic modulus of the stainless steel

27
I = Moment of inertia

L = Height of the column

π2 ×1.95×108 kNm−2 ×8.4×10−7 m4

Critical force on the column (Fc) =
1.5 m×1.5 m

Fc = 718.6 kN

Force that affected to the column = 1.41 kN

Therefore, force that affect to the column is less than critical force on the column.
Table 5.1 shows the summary of civil engineering design.

Table 5.4.1: Summary of Civil Engineering Design

Parameter Value
Type of base flange Double plate with gusset
Safety factor Additional 10% of the total weight
Size of the base plate 0.13 m
Required standard bolt size 2 inches
Force on to the one column 1.41 kN
Critical force on to the one column 718.6 kN

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 CHPTER 6
COST ANALYSIS

6.1 Introduction
When designing a manufacturing facility, cost estimation is extremely important. Use of cost
Approximately, we can get an idea of the cost of the plant. Chemical plants are built for the
purpose Receiving a profit. As a result, before assessing the feasibility of a project, it is
necessary to assess the necessary costs and production costs must be determined. If the estimate
was made before When building a production facility, we can only add the necessary costs. Also,
we may know the average production and operating costs. The appraisal of the cost of the fixed
capital was done in the cost estimate section. This cost can be used to get an idea of how much
the plant is installation will cost. There were operating costs in the manufacturing process. These
costs were measured using estimates of the cost of fixed and working capital. This chapter
estimates the various capital and operating cost components of a tray dryer.

6.2 Historical method

A rough estimate of the capital costs of the project can be obtained by looking at the costs of
previous projects that used the same manufacturing process. This approach can be used to
quickly an estimate of the costs that will be required before the preparation of technological
schemes. Purchase cost Tray dryer in 2004 obtained from Coulson and Richardson Vol 6.
Further, capital costs Tray dryer performance in 2004 is calculated using the following data.

Purchase cost in 2004 (C1) = 7700 USD

According to year 2004,
Drying area (S1) = 6 m2
According to Chemical Engineering Design calculations,
Drying area (S2) = 3.21 m2
C1×S2n
Capital cost in 2004 =
S1n
Where,
n = The value of the index = 0.35
7700×3.210.35
Capital cost in 2025 =
60.35
C2 = 6186.07 USD
The calculated costs and the past cost data values should be corrected for the considered
year of 2025 using the cost escalation (inflation) assessment. The cost correcting CEPCI
(Chemical Engineering’s Plant Cost Index) ratios are given by table 6.1.

29
 Table 6.2.1: CEPCI ratios
Year CEPCI value Year CEPCI value
1990 357.6 2002 395.6
1991 361.3 2003 402
1992 358.2 2004 444.2
1993 359.2 2005 468.2
1994 368.1 2006 499.6
1995 381.1 2007 525.4
1996 381.7 2008 575.4
1997 386.5 2009 521.9
1998 389.5 2010 550.8
1999 390.6 2012 585.7
2000 394.1 2013 584.6
2001 394.3 2014 567.3

Figure 6.2.1 illustrates the variation of CEPI with time. Using figure 6.1 and equation 6.1,
CEPCI value for year 2025 can be predicted. Equation 6.1 is the cost escalation equation which
uses historical data to estimate the cost in a particular year.

Cost in year B×Cost index in year A

Cost in year A = (6.1)
Cost index in year B

CEPCI Value
700

600 y = 4E-19e0.0242x
R² = 0.8934
500

400

300

200

100

0
1985 1990 1995 2000 2005 2010 2015

Figure 6.2.1: Variation of CEPCI ratio with time

CEPCI in 2004 = 444.2

CEPCI in 2025 = 766.76
Capital cost of the tray dryer in 2025 is calculated by using equation 6.1.

30
 6186.07×766.76
Capital cost in 2025 =
444.2
Total equipment cost in 2030 = 10678.14 USD

6.3 Factorial method

The procurement cost of the major equipment items needed for the process is often
calculated as a factor of the equipment cost, and the other costs are estimated as factors of the
equipment cost. The accuracy of this form of calculation will be determined by the stage of the
design at the time the estimate is made, as well as the reliability of the equipment cost data
available.
6.3.1 Fixed capital cost
Fixed capital is the total cost of the plant at start-up and it is not recovered at the end of
the project life, other than the scrap value. Fixed capital includes following costs.
• Design, engineering and construction supervision.
• All items of equipment and their installation.
• All piping, instrumentation and control system.
• Buildings and structures.
• Auxiliary facilities such as utilities, land and civil engineering work.
Fixed capital cost is estimated using the factorial method which uses several factors of the
equipment cost. Figure 6.3.1 shows the typical factors for estimation of project fixed capital cost.
In here, process type is fluids-solids process type.

Figure 6.3.1: The typical factors for estimation of project fixed capital cost

Total physical plant cost (PPC) for fluids and solids process type can be calculated by
using figure 6.3.1.
PPC = PCE × (1 + 𝑓1 + 𝑓2 + 𝑓3 + 𝑓4 + 𝑓5 + 𝑓6 + 𝑓7 + 𝑓8 + 𝑓9 )

31
PPC = 10678.14 × (1 + 0.5 + 0.2 + 0.1 + 0.1 + 0.05 + 0.25 + 0.25 + 0.05 + 0.3)
PPC = 29898.79 USD
Then, fixed capital cost is calculated.
Fixed capital = PPC × (1 + 𝑓10 + 𝑓11 + 𝑓12 )
Fixed capital = 29898.79 × (1 + 0.2 + 0.05 + 0.1)USD
Fixed capital = 40363.37 USD

6.3.2 Working capital cost

Working capital which is recovered at the end of the project is the additional investment needed.
Working capital varies from 5% to 30% of the fixed capital for single product processes to
processes producing diverse range of products. Working capital includes the following costs.
• Start-up.
• Initial catalyst charges.
• Raw materials and intermediates in the process.
• Finished product inventories.
• Funds to cover outstanding accounts from customers.
Working capital is assumed varies from 10 % of the fixed capital.
Fixed capital×10
Working capital =
100
40363.37×10
= USD
100
= 4036.34 USD
Then, total capital investment is calculated.
Total Capital Investment = Fixed capital + Working capital
= (40363.37 + 4036.34) USD
= 44399.71 USD
Figure 6.3.2 illustrates the LKR to USD exchange rate. Cost can be converted in to LKR
using the figure 6.3.2

Value of USD in LKR

200
y = 5E-43e0.0508x
R² = 0.9532
150

100

50

0
2008 2010 2012 2014 2016 2018 2020 2022

Figure 6.3.2: LKR to USD exchange rate

32
Value of USD in LKR in 2025 = 237.05
Total capital investment = 44399.71 × 237.05 LKR
= 34043921.64 LKR
6.4 Operational cost
To judge the feasibility of a project and to choose between potential alternative
processing schemes, an estimation of the operating costs, or the cost of producing the product, is
required. The flow-sheet, which shows the raw material and service specifications, as well as the
capital cost estimate, can be used to estimate these costs. The item mentioned below will be
included in the cost of manufacturing a chemical product. They've been split into two parties.

6.4.1 Fixed operating costs

Costs that do not change with the pace of output These are the bills that must be charged
regardless of the quantity of goods made.
• Maintenance (Labor and materials)
• Operating labor
• Laboratory costs
• Supervision
• Plant overheads
• Capital charges
• Local taxes
• Insurance
• License fees and royalty payments
6.4.2 Variable operating costs
Costs that are proportional to the volume of product manufactured.
• Raw materials
• Miscellaneous operating materials
• Utilities (Services)
• Shipping and packaging
Operational costs can be calculated using the estimations given in below figure 6.4.1 Figure
6.4.1 shows the summary of production costs.

33
 Figure 6.4.1: Summary of production costs

Maintenance cost is assumed 8 % of fixed capital.

Fixed capital cost×8
Maintenance cost =
100
40363.37×8
= USD
100
= 3229.07 USD
Operating time = 212.5 day/year
Number of shifts =2
Number of labors =4
Figure 6.4.2 shows the operating daily payment for one labor.

34
 Payment (LKR)
1400
y = 1E-71e0.0845x
1200
R² = 0.9832 1150
1050
1000
950
810 850
800 775
675
600

400

200

0
2011 2012 2013 2014 2015 2016 2017 2018 2019

Figure 6.4.2: Operating daily payment

Operating daily payment in 2025 = 594660 LKR

Operating labor cost = 2508.58 USD
Laboratory cost is assumed as 22 % of operating labor cost.
Operating labor cost×8
Laboratory cost =
100
2508.58×8
= USD
100
= 551.89 USD
Assumed, there is no supervision cost.
Plant overhead cost is 50 % of operating labor cost.
Operating labor cost×50
Plant overhead cost =
100
2508.58×50
= USD
100
= 1254.29 USD
Capital charges is 10 % of the fixed capital cost.
Fixed capital cost×10
Capital charges =
100
40363.37×10
= USD
100
= 4036.34 USD
Insurance is 1 % of the fixed capital cost.
Fixed capital cost×1
Insurance cost =
100
40363.37×1
= USD
100
= 403.63 USD
Local taxes are 2 % of fixed capital cost.

35
 Fixed capital cost×2
Local taxes cost =
100
40363.37×2
= USD
100
= 807.27 USD
Royalties is 1 % of fixed capital cost.
Fixed capital cost×1
Royalties =
100
40363.37×1
= USD
100
= 403.63 USD
Total fixed cost = 13194.7 USD
Raw materials do not need for the tray dryer. So, raw material cost can be neglected.
Miscellaneous materials are 10 % of maintenance cost.
Maintenance cost×10
Miscellaneous materials =
100
3229.07×10
= USD
100
= 322.91 USD
Shipping and packaging are usually negligible.
Total variable cost = 327.31 USD

6.5 Direct Production Cost

Total operating cost in 2025 = Total fixed cost + Total variable cost
= (13194.7 + 327.31) USD
= 13522.01 USD
Sales Expense = Direct Production Cost × 20 %
= 13522.01 × 0.2 USD
= 2704.40 USD
Assumed, general overhead, research and development cost are neglected.

6.6 Total Annual Cost

Annual operating cost in 2025 = Direct production cost + Sales expense
= (13522.01 + 2704.40) USD
= 16226.41 USD
= 16226.41 × 237.05 LKR
= 3846470.49 LKR

36
 CHAPTER 7
SAFETY ANALYSIS

7.1 Introduction
A Hazard and Operability study (HAZOP) is a systematic technique for identifying potential
hazards and operability problems. This was originally created for chemical industry and now it is
widely used for systems processing and handling hazardous material. A HAZOP review is an
important and essential in an industrial plant to identify hazard consequences and take prevention
actions beforehand. A HAZOP analysis for the tray dryer is given in this chapter.

7.2 HAZOP analysis of process

Table 7.2.1: HAZOP analysis of process

37
Project Name: Production of Aspirin and salicylic acid using Date:
Phenol and NaoH 01/04/2021
Process: Obtaining dried Salicylic acid.
Section: Dryer
Study Process Deviati Possible causes Possible Actions required
Parameter ons consequences
(Guide
words)

Feed input Flow No Closing shut off Damages Making sure shut
valve. happening to off valve is
sensors and other always open.
Malfunctioning of equipment.
control valve. Installing a
Not getting an locking system to
Failure of level output prevent someone
controller or
from closing the
sensor. Energy wastage
shut off valve.
Fully blocked
inlet pipe. Regular
maintenance of
valves and
pipes.

Installing
filters to
prevent any
blockages.

Regular
maintenance and
monitoring of the
controllers,
sensors and
controller valves
High Failure of level Fall in Regular
controller or temperature and maintenance and
sensor. reduction of monitoring of the
drying rate which controllers,
will eventually

38
 Failure of increase water sensors and
controller valve. content in the final controller valves
product.

High flow of
output
Low Failure of level Increase the Regular
controller or drying rate and maintenance and
sensor. reduces the water monitoring of the
Failure of content in the final controllers,
controller valve. product sensors and
controller valves.
Partially blocked Damage to sensors
line. and other
equipment inside.

Temperature High High temperature Dryer internal Regular

in the centrifugal parts can be maintenance and
separator. damaged monitoring of the
valves, insulation
Product quality and pressure
may be reduced gauges.

Low Water will be Regular

Low temperature remained in the maintenance and
at the centrifugal product, causing a monitoring of the
separator. reduction of valves.
quality.

Hot air input Flow No Closing shut off Drying rate will Regular
valve. reduce and finally maintenance of
stop after some valves, sensors
Malfunctioning time. and controllers.
temperature
controller or Regular
sensor. maintenance of
hot air pipe lines
Malfunctioning
controller valve or Making sure shut
inlet nozzle off valve is

39
 always open
Blockage in hot during operation
air line. and install locking
system or
automatic system
to prevent
someone from
accidently closing
it.
High Increased hot air drying rate will Regular
pressure. increase and maintenance of
Malfunctioning desired control valves,
temperature composition might sensors and
controller or change. controllers.
sensor.
Monitoring the
Malfunctioning
Hot air pressure
control valve or
and installing an
inlet nozzle
alarming system
for unacceptable
levels.
Low Decreased hot air Drying rate will Regular
pressure. decrease and maintenance of
Malfunctioning desired controllers,
temperature composition might sensors and
controller or change. control valves.
sensor.
Regular
Malfunctioning
maintenance of
control valve.
hot air lines and
Partially blocking steam traps for
the hot air line. blockages.
Malfunctioning
steam inlet valve
or nozzle
Temperature High High hot air Drying rate will Regular
output from increase and maintenance of
heater. desired pressure gauges,
composition might sensors and
Failure of change. controllers.
temperature

40
 sensors,
controllers and Damaging the Monitoring the hot
pressure gauges internal salicylic air pressure and
acid compositions. installing an
alarming system
in case of
unacceptable
levels.
Low Low steam output Drying rate will Regular
from heater decrease and maintenance of
desired pressure gauges,
Failure of composition might sensors and
temperature change. controllers.
sensors,
controllers and Monitoring the hot
pressure gauges air pressure and
installing an
alarming system
in case of
unacceptable
levels.
Pressure High Pressure Increased pressure Installing an alarm
controller can increase the system for unusual
and sensor temperature and changes of
malfunction hence increase the pressure.
drying rate and
Pressure gauge affect product Regular
malfunctioning composition and maintenance of
quality. controllers,
control valves,
Further increment pressure gauges
in pressure may and sensors.
affect the
mechanical
integrity of the
tubes and shell

Low Pressure Decreased Installing an alarm

controller pressure can system for unusual
and sensor reduce the hot air changes of
malfunction temperature and pressure.

41
 hence the driving
Pressure gauge force and lowers Regular
malfunctioning the drying rate maintenance of
affecting the controllers,
product control valves,
composition. gauges and
sensors.
Product Flow No Closing shut off Feed stuck in the Making sure shut
output from valve. dryer without flow off valve is in to
dryer. out through output open. install
Malfunctioning line. locking system.
level controller,
control valves and Regular
sensors. maintenance and
inspection of
Blockage in controllers,
product line. sensors, control
valves and sensors
No feed flow
and pipes.
High Malfunctioning Higher production Regular
level controller, rate might cause maintenance of
control valve or to degrade product controllers,
sensor. quality. control valves and
sensors.
Control valve
failure in feed
flow

Low Malfunctioning Increasing the Regular

control valve or retention time and maintenance of
sensor. degrading the controllers,
product quality. control valves and
Partially blocked sensors and pipes
product pipe. for blockages.
Temperature High Product quality Regular
Blockage of valve can be reduced maintenance of
controllers,
Temperature control valves,
controller system pressure gauges
or level controller and sensors
system failure.

42
 Low Low hot air Drying rate may Regular
supply be reduced maintenance of
controllers,
Temperature control valves,
controller system pressure gauges
or level controller and sensors
system failure.

Hot air Flow No No hot air Pressure will be Regular

output from suppling rise-up in the maintenance of
dryer. Dryer controllers,
No feed flow control valves,
suppling Dryer is not pressure gauges
happening and sensors
Temperature
controller system
or level controller
system failure.

Manual valve
closed
High Temperature Product quality Regular
controller system can be reduced by maintenance of
or level controller too much drying controllers,
system failure. the product control valves,
pressure gauges
High hot air input and sensors

Low Temperature Drying rate will Regular

controller system be reduced maintenance of
or level controller controllers,
system failure. control valves,
pressure gauges
Low steam input and sensors

43
Temperature High Pressure is build- Product quality Regular
up in the dryer can be reduced by maintenance of
drying controllers,
Pressure gauge control valves,
pressure gauges
and sensors

failure

Temperature
controller system
or level controller
system failure.

Low Pressure is Drying rate will Regular

reduced in the be reduced maintenance of
dryer controllers,
control valves,
Pressure gauge pressure gauges
failure and sensors

Temperature
controller system
or level controller
system failure.

44
 Pressure High Pressure is build- Drying rate will Regular
up in the dryer be decreased maintenance of
controllers,
Pressure gauge control valves,
failure pressure gauges
and sensors
Temperature
controller system
or level controller
system failure.

Low Pressure is Drying rate will Regular

reduced in the be increased maintenance of
dryer controllers,
control valves,
Pressure gauge pressure gauges
failure and sensors

Temperature
controller system
or level controller
system failure.

Dryer inside Pressure High Failures in valves Damage to the Use trained
equipment operators.

Good
maintenance in
the valve and
flow meter.

Regular
monitoring
Low Failures in valves Difficult to Use trained
remove air operators.

Drying process Good

failure maintenance in
the valve and
flow meter.

Regular
monitoring.

45
Temperature High Failures in Product line Use trained
insulation outputs quality operators.
decrease.
Failure in control Good
panels maintenance in
the valve and
flow meter.

Regular
monitoring
Low Failures in Product line Use trained
insulation outputs quality operators.
decrease.
Failure in control Good
panels maintenance in
the valve and
flow meter.

Regular
monitoring

46
 CHAPTER 8
AUXILIARY EQUIPMENT DESIGN

8.1 Introduction
Auxiliary equipment is also important when designing a process plant. Auxiliary equipment
considered here is the main blower which carries gas mixture to the outlet of the tray dryer.
The moistured hot air coming out from the outlet of the dryer. The connected line is sent through
the blower into the outlet.

Figure 8.1.1: Equipment layout

8.2 Blower selection

The type of equipment suited for pumping depends on the gas flow rate, differential pressure
required and operating pressure.
There are 5 types of air blower,

47
 Air blowers

Positive Centrifugal High Speed Regenerative

Displacement Helical Screw Blowers Blowers Blowers
/ Rotary Lobe Blowers
Blowers

Figure 8.2.1: Different type of air blowers

Positive displacement blower

• To move both air and neutral gases.
• Best choice for applications that require low pressure.
• Little maintenance
Helical Screw Blowers
• Applying in higher pressures
• Leads to a smooth air flow and limited air leakage
Centrifugal Blowers
• It can handle high pressure and high flow rates
• Change the airflow’s direction
High Speed Blowers
• High speed blowers can reach a pressure up to 25 psi and a flow up to 15,000 m3 per hour
Regenerative Blowers
• To move large air volumes.
• Easy to maintain
Considering the low pressure applications and easy maintain Positive Displacement is selected to
use.

There are 3 types of impellers using in air blowers,

48
 Impeller

Forward-Curved Backword- Radial

Curved/Inclined

Figure 8.2.2: Different type of impellers

Forward-curved impeller
• Produced high volume of air
• Create high static pressure
Backward curved impeller
• High efficency
• High static pressure
Radial impeller
• Low efficency
Considering the high efficiency backward curved impeller is selected to use.

8.3 Blower properties

Blowers are defined by ASME(American society of mechanical engineering) as the ratio of
discharge pressure over the suction pressure. Blowers have the specific ratio up to 1.11 to 1.20.
Below table is shown the blower air inlet properties,
Table 8.3.1: Inlet air properties

Input air
-1
Flow rate (kg s ) 5.000014
Temp (C0) 60
Density (kg m-3) 1.05
Volume rate (m3 s-1) 4.75
Humidity (g Kg(d.a)-1) 13.99
RH (%) 11.13
Wet bulb temp (C0) 21.71
Pressure (Pa) 100000

49
 Table 8.3.2: Blower equations

Solving blower equations and according to the ASME pressure ratio outlet flow rate, Pressure
and hot air density can be calculated.
Table 8.3.3: Outlet air properties
Outlet
Flow rate (kg s-1) 5.85
Density (kg m-3) 1.17
Volume rate (m3 s-1) 5.008884
Humidity (g kg(d.a)-1) 13.99
Pressure (Pa) 111000

50
 CHAPTER 9
ENVIRONMENTAL, SOCIAL AND ECONOMIC IMPACT OF THE
PROJECT

9.1 Introduction
This design project, some other important aspects that needed to be considered were that of the
social, economic and environmental impact of the said process plant. These aspects needed to be
considered as they are some of the pillars of sustainable practice. Therefore, in order to produce
quality products is not enough ut it has to e done in a sustaina le way to ensure that the
environment isn’t negatively affected and that the society and the economy are positively
affected. For this, the relevant rules and regulations have to be followed by the plant as well.
This chapter contains a study done by the group to assess the impacts of the project on the above
mentioned aspect. Thus, the following sections will elaborate on the social, economic and
environmental impacts of the proposed chemical processing plant.

9.2 Social and Economic Impact

The following are a few statistics about the conditions at Biyagama EPZ and Sri Lanka in terms
of employment based on figure 9.2.1 and figure 9.2.2;
No. of people employed in the Biyagama EPZ = 25564
The working age population in Biyagama (20-60 yrs) = 108188
The unemployment rate in Sri Lanka = 5.7%
No. of unemployed people in Biyagama = 6167

Figure 9.2.1 Working Population in Biyagama based on the Age

51
By establishing the Aspirin production facility in the Biyagama EPZ, more employment
opportunities will be available for people residing in Biyagama (and other areas). This will aid to
alleviate poverty levels in the community. Additionally, there will be a contribution to
infrastructure development in the area. However, the occupation of land will have a negative
impact, since Biyagama is located in Gampaha district, which is densely populated

Figure 9.2.2: Employment Statistics of EPZ Enterprises

9.3 Environmental Impact

There will be waste heat emissions, particulate and gaseous pollutants emissions from boilers,
Heaters, etc. Biyagama EPZ consists of many industrial facilities, including the Petroleum
Refinery at Sapugaskanda. The air emissions from the Aspirin production facility will add to the
poor air quality in Biyagama. Therefore, air pollution control measures such as the use of
scrubbers, absorption columns, etc. should be used to minimize the pollution.
The production process involves toxic chemicals that can be harmful to aquatic life, pollute the
groundwater, harm human health, etc. Biyagama and the surrounding areas have a history of
complaints from residents about water pollution due to the various industrial activities.
Therefore, any chemical spills must be contained so as not to contaminate the environment. And
the wastewater from the plant must be treated to meet the standards set by the CEA for water
emissions.

52
References
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53
APPENDIX A : P&ID FOR THE TRAY DRYER

54