INTRODUCTION

1.1 Company profile

A part of the renowned HC Kothari Group, they are the largest producer of premium quality
Polyisobutylene in India. Since their founding in 1990, the company has enjoyed a strong market position in India
with a rapidly growing brand across the globe that represents quality, customer responsiveness, dependability and
a commitment to the environment. In the financial year 2007-2008, Kothari Petrochemicals commissioned a
second plant in Manali that in order to supply Polyisobutylene worldwide. They have offices in Chennai, Manali,
Mumbai and Belgium, and supply to customers in 20 countries around the world.

1.2 Global Outlook

In the year 2007-2008, the company undertook aggressive restructuring of its leadership team, business
processes and culture to strengthen its position as a trusted brand worldwide. The restructuring actions have
resulted in improved operating efficiency, superior global consistency, and strengthened financial performances.
They have metamorphosed from a regional company to a global business and continue to implement best practices
that are shared and implemented globally.

1.3 Quality through Innovation & Technology Improvements

Innovation and technology improvements remain the industry’s most critical competitive factor. Continued
investment and acceleration in them have resulted in high quality levels of their products that are unmatched in
India, and at parity with the leading global suppliers of Polyisobutylene. An ISO 9000 and ISO 14000 certification

only adds value to their statement.

1.4 Enviable Clientele

They are committed to providing high quality Polyisobutylene products to meet the needs of a variety of
customers. Their products have been tested and certified by major customers, such as Infineum, Lubrizol, Shell
and Exxon, and are used across a wide range of industries worldwide.

16
CHAPTER 2

17
 OUTLINE OF POLYISOBUTYLENE

2.1 INTRODUCTION:
❖ KVIS is the trade name of Polyisobutylene produced by Kothari Petrochemicals. KVIS is a linear polymer of
isobutylene of different molecular weights, and possesses excellent resistance to oxidative and thermal
degradation

❖ Polyisobutylene is chemically inert, hydrophobic and impermeable to water vapour or gas.

❖ KVIS is a synthetic liquid polymer, which is a straight chain hydrocarbon structure of Polyisobutylene that is
produced in a variety of grades through a rigid low temperature polymerization process. It is derived from raw
material consisting of mainly Isobutylene.

❖ The compact straight chain structure results in brilliant moisture and barrier properties and is soluble in a wide
range of organic solvents.

❖ All KVIS grades are colourless (water white), non-staining and have little or no odour and are mostly used in
applications where low temperature flexibility is a requirement.

2.2 SOURCE:

• Derived from catalytic cracking of crude oil.

• C3,C4% of isobutene in the feed - 25%

2.3 STRUCTURE:

Figure 1: Chemical Structure of Polyisobutylene

IUPAC NAME: Polyisobutylene

18
OTHER NAME: Polyisobutylene, butyl rubber

2.4 PHYSICAL PROPERTIES:

Table 1: Properties of Polyisobutylene

Figure 2: 3D Molecular Structure of Polyisobutylene

19
2.5 CHEMICAL PROPERTIES
❖ Chemical stability of Polyisobutylene’s is much superior to unsaturated mineral oil because of its high
saturation.
❖ Polyisobutylene’s have a very low acid value (is a measure that indicates the concentration of free fatty
acid in the oil) and the value stands good in circumstances where the product is stored for extensive
periods.
❖ The degree of modification from ultraviolet rays, heat or oxygen is demonstrated by the acid value. Only
severely high temperatures can cause decomposition.

20
CHAPTER 3

21
 PROCESS DESCRIPTION

MANUFACTURE OF POLYISOBUTYLENE:

Figure 3:– Manufacturing Process of Polyisobutylene

22
3.1 RAW MATERIALS
Raw Materials: High-purity isobutylene (99%+) or a refined C4 hydrocarbon stream (raffinate) containing
isobutylene is used.
Purification: The feedstock must be rigorously dried to remove moisture and oxygenates (using molecular sieves,
activated alumina) to prevent deactivation of the cationic catalyst.
Diluent/Solvent: An inert solvent, such as isobutane, hexane, or methyl chloride, is added to the mixture to
dissolve the monomer, dilute the reaction to manage heat, and facilitate uniform temperature control

Table 2: Feed composition

Figure 4: Feed Composition of Raw Materials

3.2 Polymerization (Catalysis and Reaction)

Catalyst System: The process typically uses Friedel-Crafts catalysts such as (aluminium chloride) or (boron
trifluoride).

23
The catalyst is often complexed with a co-initiator (water, alcohol, or ether) to form an active cationic species.

Reaction Conditions:

Temperature: Low temperatures, often around -10°C to -40°C for high reactive PIB (HRPIB), or lower, are
maintained using liquid propane or ethylene cooling systems.

Reactor Type: A continuous stirred tank reactor (CSTR) or a loop reactor is commonly used, which allows for
excellent mixing and efficient heat removal.

Mechanism: The active cation initiator attacks the double bond of the isobutylene monomer, forming a
carbocation. This propagates by adding further monomer units to form long-chain molecules (propagation step).

3.3 Deactivation and Quenching

Once the desired molecular weight is reached, the reaction mixture is quenched. The catalyst is neutralized
(deactivated) using aqueous alkali (e.g.,) or water, which also stops further polymer formation.

3.4 Separation and Purification

Flash Vaporization: The mixture, now containing polyisobutylene, unreacted monomers, solvent, and
deactivated catalyst, goes to a flash vessel where the unreacted isobutylene and diluent are vaporized and removed
from the top.

Recovery: The separated isobutylene and solvent are distilled, purified, and recycled back to the reactor.

Washing and Drying: The crude polyisobutylene is washed with water to remove residual ionic species and then
dried under vacuum to remove any remaining volatile organic compounds.

24
CHAPTER 4

25
 MATERIAL BALANCE
4.1 INTRODUCTION
A mass balance, also called a material balance, is an application of conservation of mass to the analysis of physical
systems. By accounting for material entering and leaving a system, mass flows can be identified which might
have been unknown, or difficult to measure without this technique. The exact conservation law used in the analysis
of the system depends on the context of the problem but all revolve around mass conservation, i.e. that matter
cannot disappear or be created spontaneously. Therefore, mass balances are used widely in engineering and
environmental analyses. For example, mass balance theory is used to design chemical reactors, analyse alternative
processes to produce chemicals as well as in pollution dispersion models and other models of physical systems.
Closely related and complementary analysis techniques include the population balance, energy balance and the
somewhat more complex entropy balance. These techniques are required for thorough design and analysis of
systems such as the refrigeration cycle. In environmental monitoring the term budget calculations is used to
describe mass balance equations where they are used to evaluate the monitoring data (comparing input and output,
etc.) In biology the dynamic energy budget theory for metabolic organization makes explicit use of mass and
energy balances. The mass that enters a system must, by conservation of mass, either leave the system or
accumulate within the system. Mathematically the mass balance for a system without a chemical reaction is as
follows. Input= Output +Accumulation The above equation also holds good for systems with chemical reactions
if the terms in the balance equation are taken to refer to total mass i.e. the sum of all the chemical species of the
system. In the absence of a chemical reaction the amount of any chemical species flowing in and out will be the
same.

26
Basis: 946.85 Kg/h of Polyisobutylene
Table 3: MOLECULAR WEIGHT OF COMPONENTS

Figure 5: Molecular Weight Distribution of Components

4.2 CALCULATION:
Production per year = 7200 MT
Production per hour = 946.85 kg/h [ 0.728kmol/h]
Light polymer produced = 11% of Polyisobutylene production
= 0.11x946.85
=104.14 kg/h
Polyisobutylene + light polymers = 946.85+104.14
= 1050 kg/h
Isobutylene (25%) polymers(21%)
Feed rate = 1050x100
21
= 5000 kg/h
Isobutylene concentration in feed = 25%
Isobutylene rate in feed = 5000x0.25
27
 = 1250 kg/hr

Butanes –butenes concentration in feed = 75%

Butanes –butenes rate in feed = 5000x 0.75
= 3750 kg/hr

Reacted isobutylene concentration = 21%

5000x0.21= 1050 kg/hr 18.75 kmol/hr
Un reacted isobutylene concentration = 4%
5000x0.04= 200kg/hr 3.57 kmol/hr
Due to heat producing in the reactor unreacted isobutylene and butane- butane streams are vapourised by
absorbing the heat.
Heat of reaction = 934826.75 kJ/hr
Flow rate of butane - butene vapourised m = Q/λ
λ = latent heat of vapourization for butanes =385.6kJ/kg

m=934826.75x1.15075
= 1,075,710 kj/hr

M=Q/ λ = 1,075,710/ 385.6 = 2790 kg/hr

Butane - butenes vapour = 2790-200

= 2590 kg/hr [44.66 kmol/hr]
Butane – butenes liquid = 3750-290=1160kg/hr [20.00kmol/hr]

28
4.3 REACTOR:

Butane – butene in vapour- 2250.54kg/hr Unreacted

isobutene- 173.8 kg/hr

R
Isobutene-1086.25kg/hr

Butane-butene-3258.75kg/hr

Catalyst- 2.5 kg/hr

Butane – butene in liquid – 1008.21kg/hr

Product- 822 kg/hr

FEED COMPOSITION:

Components Molecular weight Amount (kg/h)

Isobutene 25% 56 1250
Butane-butenes 58 3747.5
Catalyst 113 2.5
TOTAL 5000 kg/h

29
PRODUCT COMPOSITION:
Components Molecular weight Amount (kg/h)

Isobutene in vapour 56 200

Butane-butenes in vapour 58 2590

Polyisobutylene 1300 946

Light polymers 1000 90.50

Spent catalyst 133 2.5

Butane-butenes in liquid 58 1160

Total 5000 kg/h

Input = output
(5000kg/hr) = (5000kg/hr)

30
4.4 CAUSTIC WASH DRUM

Fresh caustic = 91.03 kg/hr

polymer=912.42kg/hr
Polymer =912.42kg/hr spent
Acid Catalyst=2.5 kg/hr
Catalyst= 13.53 kg/hr
CAUSTIC WASH DRUM
Butane-Butene =1008.75
kg/hr Butane- butenes=1008.75
Blow down = 80kg/hr
FEED COMPOSITION:

Components Molecular weight Amount (kg/hr)

Polymer 1300 912.44
Acid catalyst 133 2.5
Butane-butenes 58 1008.21
Fresh caustic 40 91.03
TOTAL 2014.7 kg/hr

PRODUCT COMPOSITION:

Components Molecular weight Amount (kg/hr)

Spent caustic 40 13.53
Polymer 1300 912.44
Butane-butenes 58 1008.21
Blow down - 80
TOTAL 2014.7 kg/hr

INPUT = OUTPUT
(2014.7 kg/hr) (2014.7 kg/hr)

31
 4.5 WATER WASH DRUM

Fresh water = 867 kg/hr

Polymer = 912.42 kg/hr spent Polymer = 912.42 kg/hr

Catalyst =13.53 kg/hr WATER WASH Spent water = 500.53 kg/hr
Butane- DRUM Butane- butene
butenes=1008.75kg/hr =1008.75kg/hr

Blow down = 380 kg/hr

FEED COMPOSITION:

Components Molecular weight Amount (kg/hr)

Polymer 1300 912.42
Spent caustic 40 13.53
Butane-butenes 58 1008.21
Fresh water 18 867
TOTAL 2801.7 kg/hr

PRODUCT COMPOSITION:

Components Molecular weight Amount (kg/hr)

Spent water 18 500.53
Polymer 1300 912.42
Butane-butenes 58 1008.21
Blow down - 380
TOTAL 2801.7 kg/hr

INPUT = OUTPUT

(2801.7 kg/hr) (2801.7 kg/hr)

32
4.6 COALESCER:

Polymer =912.42kg/hr
polymer = 912.42 kg/hr COALESCER
spent Catalyst= 13.53 kg/hr
Spent water = 500.53 kg/hr Butane- butenes=1008.75kg/hr

Butane- butenes= 1008.75 kg/hr

Blow down = 500.53 kg/hr

FEED COMPOSITION:

Components Molecular weight Amount (kg/hr)

Polymer 1300 912.42

Spent water 18 500.53
Butane-butenes 58 1008.21
TOTAL 2422.70 kg/hr

PRODUCT COMPOSITION:

Components Molecular weight Amount (kg/hr)

Polymer 1300 912.42
Butane-butenes 58 1008.21
Blow down - 500.53
TOTAL 2422.70 kg/hr

INPUT = OUTPUT

(2422.70 kg/hr) (2422.70 kg/hr)

33
4.7 DEBUTANIZER:
Butane – butenes= 1008.75 kg/hr

Polymer =912.42 kg/hr

DEBUTINIZER
Butanes- butene

=1008.75kg/hr

Polyisobutylene = 822 kg/hr

Light polymer = 90.42 kg/hr

FEED COMPOSITION:

Components Molecular weight Amount (kg/hr)

Polymer 1300 912.42

Butane-butenes 58 1008.21

TOTAL 1920.63 kg/hr

PRODUCT COMPOSITION:

Components Molecular weight Amount (kg/hr)

Polybutene 1300 822

Butane-butenes vapors 58 1008.21

Light polymer 1000 90.4

TOTAL 1920.63 kg/hr

INPUT = OUTPUT
(1920.63 kg/hr) (1920.63 kg/hr)
4.8 ATMOSPHERIC FLASH COLUMN:
Light polymer = 63.29 kg/hr

ATM FLASH COLUMN

Polymer = 822 kg/hr

Light polymer= 90.42 kg/hr

Polyisobutylene= 822 kg/hr

Light polymer= 21.126 kg/hr

FEED COMPOSITION:

Components Molecular weight Amount (kg/hr)

Polybutene 1300 822
Light polymer 1000 90.42
TOTAL 912.42 kg/hr

PRODUCT COMPOSITION:

Components Molecular weight Amount (kg/hr)

Polybutene 1300 822
Bottom light polymer 1000 27.126
Overhead Light polymer 1000 63.294
TOTAL 912.42 kg/hr

INPUT = OUTPUT
(912.42 kg/hr) (912.42 kg/hr)
4.9 VACUUM FLASH COLUMN:
Light polymer = 27.126 kg/hr

Polymer = 822 kg/hr VACCUM FLASH COLUMN

Light polymer= 27.126

kg/hr

Polyisobutylene = 822 kg/hr

FEED COMPOSITION:

Components Molecular weight Amount (kg/hr)

Polybutene 1300 822
Light polymer 1000 27.126
TOTAL 849.126 kg/h

PRODUCT COMPOSITION:

Components Molecular weight Amount (kg/hr)

Polybutene 1300 822

light polymer 1000 27.126

TOTAL 849.126 kg/hr

INPUT = OUTPUT
(849.126 kg/hr) (849.126 kg/hr)
OVERALL MATERIAL BALANCE

Figure 6: overall material balance PFD

CHAPTER 5
 ENERGY BALANCE

Energy takes many forms such as heat, kinetic energy, chemical energy, potential energy but because of

inter conversions it is not always easy to isolate separate constituents of energy balances. However, under some

circumstances certain aspects predominate. In many heat balances. The most common important energy form is

heat energy and the conservation of this can be illustrated by considering operations such as heating and drying.

In these, enthalpy (total heat)is conserved and as with the mass balances so enthalpy balances can be written

round the various items of equipment. or process stages, or round the whole plant, and it is assumed that no

appreciable heat is converted to other forms of energy such as work. Heat is absorbed or evolved by some

reactions in processing but usually the quantities are small when compared with the other forms of energy entering

into food processing such as sensible heat and latent heat. Latent heat is the heat required to change, at constant

temperature, the physical state of materials from solid to liquid, liquid to gas, or solid to gas. Sensible heat is that

heat which when added or subtracted from materials changes their temperature and thus can be sensed. The units

of specific heat are J/kg K and sensible heat change is calculated by multiplying the mass by the specific heat by

the change in temperature, (m x cp x ∆T). The units of latent heat are J/kg and total latent heat change is calculated

by multiplying the mass of the material, which changes its phase by the latent heat. Having determined those

factors that are significant in the overall energy balance, the simplified heat balance can then be used with

confidence in industrial energy studies. Such calculations can be quite simple and straight forward but they give

a quantitative feeling for the situation and can be of great use in design of equipment and process.
 Specific heat of components:

COMPONENTS SPECIFIC HEAT (kJ/kgoC)

Isobutylene 1.487 kJ/kg°C

Butane- butenes 1.675 kJ/kg°C

Polyisobutylene 2 kJ/kg°C

Light polymers 1.7 kJ/kg°C

5. CHILLER:

Figure 7: Energy Balance – Chiller

FEED COMPOSITION:
Inlet temperature = 30 OC
Reference temperature = 25 OC

TEMP
MASS FLOW Cp Q=mCpΔT
COMPONENTS DIFFERENCE
RATE (kg/h) (kJ/kg°C) (kJ/h)
(°C)

Isobutylene 1257.25 5 1.487 9347.65

Butane-butenes 3771.75 5 1.675 31588.41

 TEMP
MASS FLOW Cp Q=mCpΔT
COMPONENTS DIFFERENCE
RATE (kg/h) (kJ/kg°C) (kJ/h)
(°C)

TOTAL QIN 40936.06

Product Composition
Outlet Temperature = 18°C

Mass Flow Temperature 𝑄=

Components 𝐶𝑝 (kJ/kg·°C)
Rate (kg/h) Difference (°C) 𝑚𝐶𝑝 Δ𝑇(kJ/h)

Isobutylene 1257.25 -7 1.487 -13086.71

Butane–
3771.75 -7 1.675 -44223.77
butenes

TOTAL 𝑄𝑜𝑢𝑡 -57310.48

Calculation
𝑄𝑖𝑛 = 40936.06 kJ/h
𝑄𝑜𝑢𝑡 = −57310.48 kJ/h

Energy Balance Equation:

𝑄 = 𝑄𝑜𝑢𝑡 − 𝑄𝑖𝑛
𝑄 = −57310.48 − 40936.06
𝑄 = −98246.54 kJ/h

Latent Heat of Vaporization

𝜆 = 183 kJ/kg
𝑄 = 𝑚𝜆
 98246.54
𝑚=
183
𝑚 = 536.87 kg/h

5.2 REACTOR: Butane – butene in vapour- 2250.54kg/hr

Unreacted isobutene- 173.8 kg/hr

R
E
A
C
T
O
R

Isobutene-1086.25kg/hr
Butane-butene-3258.75kg/hr

Catalyst- 2.5 kg/hr

Butane – butene in liquid – 1008.21kg/hr
Product- 822 kg/hr

FEED COMPOSITION:
Inlet temperature = 18 oC
Reference temperature = 25 oC
 COMPONENTS MASS TEMPERATUE Cp(kJ/kg Q= mCpΔT
FLOW DIFFERENCE oC) (kJ/h)
RATE(kg/h) (oC)

Isobutylene 1806.25 -7 1.487 -18801.256

Butane-butenes 3258.75 -7 1.675 -38208.843

TOTAL −57310.48 kJ/h

(Qin)

PRODUCT COMPOSITION:
Outlet temperature = 45 oC

Mass Flow Temperature

Components 𝐶𝑝 (kJ/kg·°C) 𝑄 = 𝑚𝐶𝑝 Δ𝑇(kJ/h)
Rate (kg/h) Difference (°C)

Polyisobutylene 951.43 20 2.000 38057.20

Light polymers 104.66 20 1.700 3558.44

Unreacted
201.16 20 1.487 5980.49
Isobutylene

Butane–butenes 3771.75 20 1.675 126353.63

TOTAL 𝑄𝑜𝑢𝑡 173949.76

Calculation
𝑄𝑖𝑛 = −57310.48 kJ/h
 𝑄𝑜𝑢𝑡 = 173949.76 kJ/h

Energy Balance Equation

𝑄𝑖𝑛 + Heat of Reaction + 𝑄 = 𝑄𝑜𝑢𝑡
−57310.48 + 1082021.20 + 𝑄 = 173949.76
𝑄 = −850760.96 kJ/h

Latent Heat of Vaporization of Butanes

𝜆 = 385.6 kJ/kg

Amount Vaporized
850760.96
𝑚=
385.6
𝑚 = 2206.33 kg/h

Remaining Liquid Butane–butenes

3771.75 − 2206.33 = 1565.42 kg/h
5.3 CONDENSER

Figure 8: Energy Balance – Condenser

Feed Composition
Inlet Temperature = 45°C

Mass Flow Temperature 𝑄=

Components 𝐶𝑝 (kJ/kg·°C)
Rate (kg/h) Difference (°C) 𝑚𝐶𝑝 Δ𝑇(kJ/h)

Unreacted
201.16 20 1.487 5980.49
Isobutylene

Butane–butenes
2206.33 20 1.675 73912.05
vapor

TOTAL 𝑄𝑖𝑛 79892.54

Product Composition
Outlet Temperature = 18°C

Mass Flow Rate Temperature 𝑄=

Components 𝐶𝑝 (kJ/kg·°C)
(kg/h) Difference (°C) 𝑚𝐶𝑝 Δ𝑇(kJ/h)

Unreacted
201.16 -7 1.487 -2093.17
Isobutylene

Butane–butenes
2206.33 -7 1.675 -25869.22
vapor

TOTAL 𝑄𝑜𝑢𝑡 -27962.39

Calculation
𝑄 = 𝑄𝑜𝑢𝑡 − 𝑄𝑖𝑛
𝑄 = −27962.39 − 79892.54
𝑄 = −107854.93 kJ/h
Latent Heat of Condensation:
𝜆 = 430 kJ/kg
107854.93
𝑚=
430
𝑚 = 250.83 kg/h

5.4 CAUSTIC PRE-HEATER

Feed Composition
Inlet Temperature = 45°C

Mass Flow Rate Temperature 𝑄=

Components 𝐶𝑝 (kJ/kg·°C)
(kg/h) Difference (°C) 𝑚𝐶𝑝 Δ𝑇(kJ/h)

Polyisobutylene 951.43 20 2.000 38057.20

Light polymers 104.66 20 1.700 3558.44

Butane–butenes
1565.42 20 1.675 52441.57
liquid

TOTAL 𝑄𝑖𝑛 94057.21

Product Composition
Outlet Temperature = 83°C

Mass Flow Rate Temperature 𝑄=

Components 𝐶𝑝 (kJ/kg·°C)
(kg/h) Difference (°C) 𝑚𝐶𝑝 Δ𝑇(kJ/h)

Polyisobutylene 951.43 58 2.000 110365.88

 Mass Flow Rate Temperature 𝑄=
Components 𝐶𝑝 (kJ/kg·°C)
(kg/h) Difference (°C) 𝑚𝐶𝑝 Δ𝑇(kJ/h)

Light polymers 104.66 58 1.700 10319.48

Butane–butenes
1565.42 58 1.675 152080.55
liquid

TOTAL 𝑄𝑖𝑛 272765.91

Calculation
𝑄 = 𝑄𝑜𝑢𝑡 − 𝑄𝑖𝑛
𝑄 = 272765.91 − 94057.21
𝑄 = 178708.70 kJ/h

Latent Heat of Vaporization of Steam:

𝜆 = 2264.7 kJ/kg
178708.70
𝑚=
2264.7
𝑚 = 78.91 kg/h
5.5 PRE-HEATER

Figure 9: Energy Balance – Pre-Heater

Feed Composition
Inlet Temperature = 83°C
Reference Temperature = 25°C

Mass Flow Rate Temp Difference Q = mCpΔT

Components Cp (kJ/kg°C)
(kg/h) (°C) (kJ/h)

Polyisobutylene 822 58 2 95352

Light polymers 90.42 58 1.7 8915.412

Butane-butenes
1008.75 58 1.675 98000.0625
liquid

TOTAL(Qin) 202267.474

Product Composition

Outlet Temperature = 121°C

Mass Flow Rate Temp Difference Q = mCpΔT

Components Cp (kJ/kg°C)
(kg/h) (°C) (kJ/h)

Polyisobutylene 822 96 2 157824

Light polymers 90.42 96 1.7 14756.544

Butane-butenes
1008.75 96 1.675 162207
liquid

TOTAL(Qout) 334787.544
Calculation
𝑄 = 𝑄𝑜𝑢𝑡 − 𝑄𝑖𝑛
𝑄 = 334787.544 − 202267.474
𝑄 = 132520.07 𝑘𝐽/ℎ

Latent heat of vaporization of steam

𝜆 = 2264.7 𝑘𝐽/𝑘𝑔

Steam required
132520.07
𝑚=
2264.7
𝑚 = 58.515 𝑘𝑔/ℎ
 5.6 DEBUTANIZER

Butane – butenes = 1008.75

kg/hr

Polymer =912.42 kg/hr

Butanes- butene
=1008.75kg/hr

Polyisobutylene= 822
kg/hr Light polymer =
90.42 kg/hr

Figure 10: Energy Balance – Debutanizer

Feed Composition
Inlet Temperature = 121°C
Reference Temperature = 25°C

Mass Flow Rate Temp Difference Q = mCpΔT

Components Cp (kJ/kg°C)
(kg/h) (°C) (kJ/h)

Polyisobutylene 822 96 2 157824

Light polymers 90.42 96 1.7 14756.544

Butane-butenes 1008.21 96 1.675 162207

TOTAL(Qin) 334787.544
Product Composition (Top Vapour at 49°C)

Mass Flow Rate Temp Difference Cp Q = mCpΔT

Components
(kg/h) (°C) (kJ/kg°C) (kJ/h)

Butane-
1008.21 24 1.675 40530.042
butenes

Product Composition (Bottom Liquid at 212°C)

Mass Flow Rate Temp Difference Q = mCpΔT

Components Cp (kJ/kg°C)
(kg/h) (°C) (kJ/h)

Polyisobutylene 822 187 2 307428

Light polymers 90.42 187 1.7 28744.518

TOTAL Bottom
336172.518
Q

Calculation
Condenser Heat Load
Reflux Ratio
𝑅 = 3.5

Vapor Flow
𝑉 = 𝐷(𝑅 + 1)
𝑉 = 1008.21 × 4.5
𝑉 = 4536.94 𝑘𝑔/ℎ
Latent Heat
𝜆 = 385.6 𝑘𝐽/𝑘𝑔
𝑄𝑐 = 4536.945 × 385.6
𝑄𝑐 = 1749445.992 𝑘𝐽/ℎ

Cooling Water Required

1749445.992
𝑚=
4.18 × 24
𝑚 = 17438.656 𝑘𝑔/ℎ

Reboiler Heat Load

𝑄𝑟 = 376702.56 + 1749445.992 − 334787.544

𝑄𝑟 = 1791361.008 𝑘𝐽/ℎ

Steam Required
1791361.008
𝑚=
2206.66
𝑚 = 811.797 𝑘𝑔/ℎ
5.7 ATMOSPHERIC FLASH COLUMN

Light polymer = 63.29

kg/hr
Polymer = 822
kg/hr Light
polymer=90.42
kg/hr

Polybutene = 822
kg/hr Light polymer=
21.126 kg/hr

Figure 11: Energy Balance – Atmospheric Flash Column

Feed Composition

Mass Flow Rate Temp Difference Q = mCpΔT

Components Cp (kJ/kg°C)
(kg/h) (°C) (kJ/h)

Polyisobutylene 822 187 2 307428

Light polymers 90.42 187 1.7 28744.518

TOTAL(Qin) 336172.518
Product Composition (Top Vapour at 56°C)

Mass Flow Rate Temp Difference Cp Q = mCpΔT

Components
(kg/h) (°C) (kJ/kg°C) (kJ/h)

Light
63.294 31 1.7 3335.5938
polymers

Product Composition (Bottom Liquid at 207°C)

Mass Flow Rate Temp Difference Cp Q = mCpΔT

Components
(kg/h) (°C) (kJ/kg°C) (kJ/h)

Light polymers 27.126 182 1.7 8392.78

Polyisobutylene 822 182 2 299208

TOTAL Bottom
307600.78
Q

Calculation
QOUT=3335.5938+307600.78
𝑄𝑜𝑢𝑡 = 310936.37 𝑘𝐽/ℎ

balance:
𝑄 = 𝑄𝑜𝑢𝑡 − 𝑄𝑖𝑛
𝑄 = 310936.37 − 336172.518
𝑄 = −25236.148 𝑘𝐽/ℎ
Polymer Vaporization
Energy available for vaporization:
𝑄 = 25236.148 𝑘𝐽/ℎ

Latent heat of light polymers:

𝜆 = 1100 𝑘𝐽/𝑘𝑔

Amount of polymer vaporized:

𝑄
𝑚=
𝜆
25236.148
𝑚=
1100
𝑚 = 22.94 𝑘𝑔/ℎ
5.8 VACUUM FLASH COLUMN

Light polymer = 27.126

kg/hr
Polymer = 822 kg/hr
Light polymer= 27.126
kg/hr

Polyisobutylene = 822 kg/hr

Figure 12: Energy Balance – Vacuum Flash Column (Detailed)

Feed Composition

Mass Flow Rate Temp Difference Cp Q = mCpΔT

Components
(kg/h) (°C) (kJ/kg°C) (kJ/h)

Polyisobutylene 822 182 2 299208

Light polymers 27.126 182 1.7 8392.78

TOTAL (Qin) 307600.78

Product Composition (Top Vapour at 32°C)

Mass Flow Rate Temp Difference Cp Q = mCpΔT

Components
(kg/h) (°C) (kJ/kg°C) (kJ/h)

Light
27.126 7 1.7 322.799
polymers

Product Composition (Bottom Liquid at 185°C)

Mass Flow Rate Temp Difference Cp Q = mCpΔT

Components
(kg/h) (°C) (kJ/kg°C) (kJ/h)

Polyisobutylene 822 160 2 263040

Calculation

Total heat output:

𝑄𝑜𝑢𝑡 = 263040 + 322.799
𝑄𝑜𝑢𝑡 = 263362.799 𝑘𝐽/ℎ

Heat balance:
𝑄 = 𝑄𝑜𝑢𝑡 − 𝑄𝑖𝑛
𝑄 = 263362.799 − 307600.78
𝑄 = −44237.981 𝑘𝐽/ℎ

Polymer Vaporization
Energy available for vaporization:
𝑄 = 44237.981 𝑘𝐽/ℎ

Latent heat of light polymers:

 𝜆 = 1100 𝑘𝐽/𝑘𝑔

Polymer vaporized:
𝑄
𝑚=
𝜆
44237.981
𝑚=
1100

𝑚 = 40 .22 𝑘𝑔/ℎ
Figure 13: overall energy balance PFD
CHAPTER 6
 DESIGN OF EQUIPMENTS

6.1DESIGN OF DEBUTANIZER COLUMN

Figure 14: Design of Debutanizer Column

BASIS: 946.85 Kg/h

A- PIB (polyisobutylene)
B -LP (light polymer)
Density of A(ρA)
= 450
Density of B(ρB)
= 144
Design Pressure = 7-8 kg/cm
Design procedure for column :
1. Number of stages : Theoretical stages
2. By Ratchford Rice correlation :
Maximum velocity (or) Vpermitted Vper=K√ (ρL – ρV) / √ρV Yi = K Xi, i= A(or)B
3. Height of the column (h) =?
4. Diameter of column (d) = ?
5. Volume of the column (v) =?

Overall Mass Balance

The standard mass balance equations are:
𝐹 =𝑉+𝐿
𝐹𝑧𝐴 = 𝑉𝑦𝐴 + 𝐿𝑥𝐴

Where:
• 𝐹= Feed flow rate
• 𝑉= Vapour flow rate

• 𝐿= Liquid flow rate

• 𝑧𝐴 = Feed mole fraction of component A
• 𝑦𝐴 = Vapour mole fraction of component A
• 𝑥𝐴 = Liquid mole fraction of component A

Given Values
Feed flow rate
𝐹 = 5029 kg/hr

Feed composition
𝑧𝐴 = 0.961

Vapour composition
𝑦𝐴 = 0.02

Liquid composition
𝑥𝐴 = 0.97
Step-by-Step Calculation
Substitute Equation (1) into Equation (2)
𝐹𝑧𝐴 = (𝐹 − 𝐿)𝑦𝐴 + 𝐿𝑥𝐴

Substitute the numerical values

(5029 × 0.961) = (5029 − 𝐿) × 0.02 + (𝐿 × 0.97)
4832.869 = (100.58 − 0.02𝐿) + 0.97𝐿

Solving for Liquid Flow Rate

4832.869 − 100.58 = 0.95𝐿
4732.289 = 0.95𝐿
𝐿 = 4981.357 kg/hr

Vapour Flow Rate

𝑉 =𝐹−𝐿
𝑉 = 5029 − 4981.357
𝑉 = 47.643 kg/hr

Relative Volatility (𝜶𝑨𝑩 )

Relative volatility represents the ease of separation between two components.
Given:
𝑦𝐴 = 0.02
𝑦𝐵 = 1 − 𝑦𝐴 = 0.98
𝑥𝐴 = 0.97
𝑥𝐵 = 1 − 𝑥𝐴 = 0.03

Relative volatility equation:

𝑦𝐴 /𝑦𝐵
𝛼𝐴𝐵 =
𝑥𝐴 /𝑥𝐵

Substitute the values:

 0.02/0.98
𝛼𝐴𝐵 =
0.97/0.03
0.02041
𝛼𝐴𝐵 =
32.3333

𝛼𝐴𝐵 ≈ 0.00063

Fenske Equation
𝑥 (1 − 𝑥𝑊 )
log ( 𝐷 )
𝑥𝑊 (1 − 𝑥𝐷 )
𝑁𝑚𝑖𝑛 =
log 𝛼𝑎𝑣𝑔

Where:
• 𝑁𝑚𝑖𝑛 = Minimum number of theoretical stages
• 𝑥𝐷 = Mole (or mass) fraction of component A in the distillate

• 𝑥𝑊 = Mole (or mass) fraction of component A in the bottom product

• 𝛼𝑎𝑣𝑔 = Average relative volatility

Given Values
𝑥𝐷 = 0.995
𝑥𝑊 = 0.005
𝛼𝑎𝑣𝑔 = 1.41

Step-by-Step Calculation
Substitute the values into the Fenske equation:
0.995(1 − 0.005)
log [ ]
0.005(1 − 0.995)
𝑁𝑚𝑖𝑛 =
log (1.41)

Simplifying the numerator

1 − 0.005 = 0.995
1 − 0.995 = 0.005
0.995 × 0.995
log [
𝑁𝑚𝑖𝑛 = 0.005 × 0.005]
log (1.41)
 log (39601)
𝑁𝑚𝑖𝑛 =
log (1.41)

Final Result
log (39601) = 4.597

log (1.41) = 0.149

4.597
𝑁𝑚𝑖𝑛 =
0.149

𝑁𝑚𝑖𝑛 = 30.8

𝑁𝑚𝑖𝑛 ≈ 31

Column Design Calculations

1. Maximum Vapour Velocity (𝑽𝒑𝒆𝒓 )

Using the capacity factor 𝐾 = 0.021

√𝜌𝐿 − 𝜌𝑉
𝑉𝑝𝑒𝑟 = 𝐾
√𝜌𝑉

Substituting the values:

√830 − 750
𝑉𝑝𝑒𝑟 = 0.021 ×
√750
𝑉𝑝𝑒𝑟 = 0.021 × √0.1066
𝑉𝑝𝑒𝑟 = 0.021 × 0.3265
𝑉𝑝𝑒𝑟 = 𝟎. 𝟎𝟎𝟔𝟖𝟓𝟖 𝐦/𝐬

Where:
• 𝐾= Capacity factor
• 𝜌𝐿 = Liquid density
• 𝜌𝑉 = Vapour density
2. Area of the Column (𝑨)
The cross-sectional area of the column is calculated from the volumetric vapour flow.
𝑉𝑚𝑎𝑠𝑠
𝐴=
𝑉𝑝𝑒𝑟 × 3600 × 𝜌𝑉

Substituting the values:

11880.9
𝐴=
0.006858 × 3600 × 750
11880.9
𝐴=
18516.6
𝐴 = 𝟎. 𝟔𝟒𝟏𝟔 𝐦𝟐

3. Diameter of the Column (𝑫)

The column diameter is obtained from the circular area relationship.

4𝐴
𝐷=√
𝜋

Substituting the values:

4 × 0.6416
𝐷=√
3.14159
𝐷 = √0.8169
𝐷 = 𝟎. 𝟗𝟎𝟑𝟖 𝐦

4. Height of the Column (𝑳)

Using the aspect ratio:
𝐿
= 2.5
𝐷
𝐿 = 2.5𝐷

Substituting the value of 𝐷:

𝐿 = 2.5 × 0.9038
𝐿 = 𝟐. 𝟐𝟓𝟗𝟓 𝐦
5. Volume of the Column (𝑽𝒄𝒐𝒍 )
The internal volume of the column is calculated using the cylindrical volume equation.

𝜋𝐷2 𝐿
𝑉𝑐𝑜𝑙 =
4

Substituting the values:

3.14159 × (0.9038)2 × 2.2595

𝑉𝑐𝑜𝑙 =
4
5.80
𝑉𝑐𝑜𝑙 =
4
𝑉𝑐𝑜𝑙 = 𝟏. 𝟒𝟓 𝐦𝟑

6. Conversion to Liters

1 𝑚3 = 1000 𝐿
1.45 × 1000
= 𝟏𝟒𝟓𝟎 𝐋
DESIGN SUMMARY:
By Fensky Equation ,
1) Number of the theoretical stages used =31
By Ratchford Rice Equation,
2) Maximum velocity of the feed permitted = 0.006858 m/s
3) Diameter of the column = 0.9038 m
4) Length of the column = 2.2595 m
5) Total volume capacity =1.45M3
CONDENSER: =1450 liters

The distillation column is designed to separate the butane–butene mixture from heavier polybutene components
in the polybutene manufacturing process. The separation is carried out based on the difference in volatility of the
components.
The design calculations were performed using equilibrium stage methods, including the Fenske equation for
minimum number of stages, Underwood equation for minimum reflux ratio, and Gilliland correlation for actual
number of stages.
The column operates at near atmospheric pressure with the top product containing mainly light hydrocarbons
(butane and butene) and the bottom product containing polybutene.
6.2 DESIGN OF CONDENSER:

PROPERTIES UNIT SHELL SIDE TUBE SIDE

Fluid circulated – Butane–butene Water

Fluid flow rate kg/h Inlet: vapour (2423.8) ?

Fluid temperature (Inlet/Outlet) °C 50 / 38 27 / 33

Specific heat capacity (Cp) kJ/kg°C 1.675 4.18

Density kg/m³ 604 1000

Combined dirt factor m²°C/W 1.8 × 10⁻⁴ 0.42 × 10⁻⁴

Figure 15: Design of condenser

CONDENSER HEAT LOAD CALCULATION
Given Data
Mass flow rate of vapour
𝑚ℎ = 2423.564 𝑘𝑔/ℎ

Latent heat of condensation

𝜆 = 387.78 𝑘𝐽/𝑘𝑔

Heat Load of Condenser

Heat removed during condensation:
𝑄 = 𝑚ℎ 𝜆
𝑄 = 2423.564 × 387.78
𝑄 = 939,918.9 𝑘𝐽/ℎ
𝑄 = 9.399 × 105 𝑘𝐽/ℎ

Convert to kW

9.399 × 105
𝑄=
3600
𝑄 = 261.08 𝑘𝑊

COOLING WATER FLOW RATE

Heat removed by cooling water:
𝑄 = 𝑚𝑐 𝐶𝑝 Δ𝑇

Where
𝑚𝑐 = cooling water flow rate (kg/s)
𝐶𝑝 = specific heat of water = 4.185 kJ/kg°C
Δ𝑇= temperature rise of cooling water
Δ𝑇 = 33 − 27
Δ𝑇 = 6∘ 𝐶

Cooling Water Flow Rate

 𝑄
𝑚𝑐 =
𝐶𝑝 Δ𝑇
261.08
𝑚𝑐 =
4.185 × 6
261.08
𝑚𝑐 =
25.11
𝑚𝑐 = 10.39 𝑘𝑔/𝑠

≈ 10.41 kg/s

FLUID ALLOCATION
Tube side : Cooling water
Shell side : Butane–butene vapour
Cooling water is placed in tube side because:
• Easier cleaning
• Lower fouling
• Higher pressure tolerance

DRIVING FORCE FOR HEAT TRANSFER

Hot fluid temperature:
𝑇ℎ1 = 50∘ 𝐶
𝑇ℎ2 = 38∘ 𝐶

Cold fluid temperature:

𝑇𝑐1 = 27∘ 𝐶
𝑇𝑐2 = 33∘ 𝐶

Temperature Difference
At inlet
Δ𝑇1 = 𝑇ℎ1 − 𝑇𝑐2
Δ𝑇1 = 50 − 33
Δ𝑇1 = 17∘ 𝐶
At outlet
Δ𝑇2 = 𝑇ℎ2 − 𝑇𝑐1
Δ𝑇2 = 38 − 27
Δ𝑇2 = 11∘ 𝐶

Log Mean Temperature Difference (LMTD)

Δ𝑇1 − Δ𝑇2
𝐿𝑀𝑇𝐷 =
ln (Δ𝑇1 /Δ𝑇2 )
∘
Δ𝑇1 = 17 𝐶
Δ𝑇2 = 11∘ 𝐶
17 − 11
𝐿𝑀𝑇𝐷 =
ln (17/11)
6
𝐿𝑀𝑇𝐷 =
0.435
𝐿𝑀𝑇𝐷 = 13.79∘ 𝐶

Correction Factor
Δ𝑇𝑚 = 𝐹𝑇 × 𝐿𝑀𝑇𝐷
Δ𝑇ℎ
𝑅=
Δ𝑇𝑐
50 − 38
𝑅=
33 − 27
12
𝑅= =2
6
Δ𝑇𝑐
𝑃=
𝑇ℎ1 − 𝑇𝑐1
6
𝑃=
50 − 27
6
𝑃=
23
𝑃 = 0.26

From LMTD correction factor charts

𝐹𝑇 = 0.93
Δ𝑇𝑚 = 0.93 × 13.79
Δ𝑇𝑚 = 12.8∘ 𝐶
Estimated Unit
Trial Overall Heat Transfer Coefficient
Assume

𝑈𝑜 = 500 𝑊/𝑚2 𝐾

Trial Heat Transfer Area

𝑄
𝐴0 =
𝑈𝑜 Δ𝑇𝑚
261.08 × 103
𝐴0 =
500 × 12.8
𝐴0 = 40.8 𝑚2

(Your value 41.21 m² is acceptable)

Tube Dimensions
Outside diameter
𝐷𝑜 = 20 𝑚𝑚

Inside diameter
𝐷𝑖 = 16.8 𝑚𝑚

Tube length
𝐿 = 4.88 𝑚

Pitch
𝑃𝑡 = 25 𝑚𝑚

Triangular pitch

Effective Tube Length

𝐿𝑒 = 𝐿 − 2𝑡𝑠
Tube sheet thickness
𝑡𝑠 = 0.025𝑚
𝐿𝑒 = 4.88 − (2 × 0.025)
𝐿𝑒 = 4.83𝑚
Number of Tubes
Surface area of one tube
𝐴𝑡 = 𝜋𝐷𝑜 𝐿𝑒
𝐴𝑡 = 3.14 × 0.02 × 4.83
𝐴𝑡 = 0.303 𝑚2

Total tubes
𝐴0
𝑁𝑇 =
𝐴𝑡
41.21
𝑁𝑇 =
0.303
𝑁𝑇 = 136

Selected from tube count table

𝑁𝑇 = 138

Tube Side Heat Transfer Coefficient

Dittus–Boelter equation
ℎ𝑖 𝐷𝑖
= 0.023𝑅𝑒 0.8 𝑃𝑟 0.33
𝑘

Tube Side Flow Area

𝜋 2 𝑁𝑇
𝐴𝑟 = 𝐷 ( )
4 𝑖 𝑁𝑃
3.14
𝐴𝑟 = (0.0168)2 (138/2)
4
𝐴𝑟 = 0.0153𝑚2

Mass Velocity
𝑚𝑐
𝐺𝑡 =
𝐴𝑟
 10.41
𝐺𝑡 =
0.0153
𝐺𝑡 = 680.4 𝑘𝑔/𝑚2 𝑠

Reynolds Number
𝐺𝑡 𝐷𝑖
𝑅𝑒 =
𝜇

Water viscosity

𝜇 = 0.8 × 10−3 𝑘𝑔/𝑚𝑠

680.39 × 0.0168
𝑅𝑒 =
0.0008
𝑅𝑒 = 14288

Prandtl Number
𝐶𝑝 𝜇
𝑃𝑟 =
𝑘
4.18 × 103 × 0.8 × 10−3
𝑃𝑟 =
0.559
𝑃𝑟 = 5.98

Tube Side Heat Transfer Coefficient

ℎ𝑖 (0.0168)
= 0.023(14288)0.8 (5.98)0.33
0.559
ℎ𝑖 = 2911.9 𝑊/𝑚2 𝐾

Outside Heat Transfer Coefficient

𝐷𝑖
ℎ𝑖𝑜 = ℎ𝑖 ( )
𝐷𝑜
0.0168
ℎ𝑖𝑜 = 2911.9 ×
0.020
ℎ𝑖𝑜 = 2446 𝑊/𝑚2 𝐾
Overall Heat Transfer Coefficient

1 1 −1
𝑈𝑜 = ( +𝑅𝑑𝑖 +𝑅𝑑𝑜 +𝑅𝑤 + )
ℎ𝑜 ℎ𝑖𝑜
𝑈𝑜 = 556.29 𝑊/𝑚2 𝐾

Heat Transfer Area Required

𝑄
𝐴𝑟 =
𝑈𝑜 Δ𝑇𝑚
261.08 × 103
𝐴𝑟 =
556.29 × 12.8
𝐴𝑟 = 36.67 𝑚2

Area Available
𝐴𝑎 = 𝜋𝐷𝑜 𝐿𝑒 𝑁𝑇
𝐴𝑎 = 3.14 × 0.02 × 4.83 × 138
𝐴𝑎 = 41.86 𝑚2

Percentage Excess Area

𝐴𝑎 − 𝐴𝑟
%𝐸𝑥𝑐𝑒𝑠𝑠 = × 100
𝐴𝑟
41.86 − 36.67
%𝐸𝑥𝑐𝑒𝑠𝑠 = × 100
36.67
%𝐸𝑥𝑐𝑒𝑠𝑠 = 14%
DESIGN SUMMARY:

Design Summary

Heat duty of the heat exchanger = 261.08 kW

Area required for heat transfer = 36.67 m2
Area available for heat transfer = 41.86m2
% Excess area = 14%
Number of tubes = 138
Number of passes on tube side =2
Number of passes on shell side =1
Shell ID = 387.35 mm
Film heat transfer coefficient tube side = hio = 2445.968 W/m2 ºC
Film heat transfer coefficient shell side = ho =658.83 W/m2 ºC
 Pressure drop tube side ΔPT = 6.43 kPa
Pressure drop shell side ΔPS = 4.76kPa

The condenser is designed to condense the overhead vapour mixture of butane–butene coming from the
distillation column. Cooling water is used as the cooling medium to remove heat from the vapour and convert it
into liquid form. A shell and tube heat exchanger type condenser is selected because of its high heat transfer
efficiency, easy maintenance, and suitability for industrial applications.
In this design, butane–butene vapour flows through the shell side, while cooling water flows through the tube
side. Cooling water is placed in the tube side to facilitate easy cleaning and to handle higher pressure.
The heat duty of the condenser is calculated based on the latent heat released during condensation of the vapour
stream. Using the calculated heat load and the log mean temperature difference (LMTD) method, the required
heat transfer area is determined. The overall heat transfer coefficient is calculated by considering tube-side and
shell-side heat transfer coefficients, fouling resistance, and tube wall resistance.
 DESIGN OF EQUIPMENTS USING ASPEN PLUS
Debutanizer (distillation column)
Procedure:
Step 1: Open Aspen Plus Version 14 Software.

Step 2: Open New → blank document → click create.

Step 3: Go To Properties → Title → Enter the Title Name.

Step 4: Go To Components → Find → Search the Components → Click Add.

Figure 16: Aspen Plus – Component Selection

Step 5: Go The Method and Give the Base Method as ‘SRK’ and Click Simulation.

Figure 17: Aspen Plus – Base Method (SRK) Configuration

Step 6: in simulation go the columns block and add RADFRAC and click on the material
steam and draw the input along with output steam.

Figure 18: Aspen Plus – RADFRAC Block Setup

Step 7: Click On the Input Stream and Give the Input Data.

Figure 19: Aspen Plus – Input Stream Data

Figure 20: Aspen Plus – Feed Stream Configuration

Figure 21: Aspen Plus – Column Specifications
Figure 22: Aspen Plus – Simulation Run
Step 8: run the analysis and the result will be available in the block → result

Figure 23: Aspen Plus – Analysis Results

Figure 24: Aspen Plus – Temperature Profile

 Figure 25: Aspen Plus – Block Results

Step 9: To Add Column Internal Design

To add column internal design, first open the simulation and select the distillation column (RADFRAC or
column block) from the flowsheet. Then go to the column configuration section or the rating/design environment
and click on “Generate New Design” to create a column internal design setup. After that, enter the column
dimensions such as column height and column diameter, and specify the number of stages along with the feed
stage location.

Next, select the type of internals, either a tray column or a packed column. If a tray column is selected, choose
the tray type such as sieve tray, valve tray, or bubble cap tray, and enter parameters like tray spacing (typically
0.45–0.6 m), weir height, downcomer area, and tray efficiency. If a packed column is selected, add a packing
section, select the packing type (random or structured), specify the packing material such as stainless steel,
ceramic, or plastic, and enter the packing height.

Then define the pressure drop across the trays or packing section and input the operating parameters including
reflux ratio, condenser type (total or partial), and reboiler type. After that, check the hydraulic parameters such as
flooding percentage, as well as weeping and entrainment limits.

Finally, run the simulation and verify convergence, and analyse the results in terms of product purity, temperature
profile, and composition profile. If necessary, optimize the design by adjusting the reflux ratio, number of stages,
and column diameter or internals to achieve better performance.

RESULT:

Figure 26: Aspen Plus – Optimization Results

DESIGN SUMMARY:
Feed & Operating
Conditions:

Parameter Value Unit

Feed Temperature 110 °C

Feed Pressure 7 bar

Total Feed Flow Rate 5029 kg/hr

Column Configuration:

Parameter Value

Calculation Type Equilibrium

Number of Stages 30

Condenser Type Partial Vapor

Reboiler Type Kettle

Vapor–
Valid Phases
Liquid

Convergence
Standard
Method

Operating Specifications:

Parameter Value Unit

Distillate Rate 1000 kg/hr

 Parameter Value Unit

Bottoms Rate 4029 kg/hr

Reflux Ratio 2.5 —

Optimization:

Parameter Existing Column Your Designed Column

Column Height 15 m 23 m

Number of Sections 2 sections 2 Sections

Random Packing + Valve Pall Rings (Packing) + Bubble Cap

Type of Internals
Trays Trays

Top Section Random Packing Pall Ring Packing

Bottom Section Valve Trays Bubble Cap Trays

Separation Efficiency Moderate High

Very good (especially in bubble cap

Vapor–Liquid Contact Limited
trays)

Low at top (packing), controlled at

Pressure Drop Moderate
bottom

Handling of Heavy/Viscous Fluid

Less effective Very effective (bubble cap trays)
(PIB)

Mass Transfer Efficiency Moderate Improved

Operational Stability Moderate High

Energy Efficiency Lower Better due to improved separation

Parameter Existing Column Your Designed Column

Product Purity Moderate Higher purity

Design Simplicity Simple Moderately complex

Flexibility Moderate High

The distillation column was optimized by evaluating multiple types of trays and packings. Among the packing
options, Pall Rings and Super Pak were identified as the most effective. In the second section of the column,
bubble cap trays and sieve trays were selected due to their superior performance.

Packing is used in the top section of the column to enhance vapor–liquid equilibrium, thereby improving
separation efficiency. Sieve trays can also be applied in the upper section to balance pressure drop. In the bottom
section, bubble cap trays are preferred because they provide improved vapor–liquid contact, making them suitable
for handling high-viscosity fluids and achieving higher purity.

Thus, by appropriately combining packing at the top and different tray types in various sections, the overall
performance, efficiency, and product purity of the distillation column are significantly enhanced.
DESIGN OF REBOILER:

Figure 27: Design of Reboiler – Schematic Diagram

Figure 28: Reboiler Design – Heat Transfer Area
Figure 29: Reboiler Design – Shell Configuration
Figure 30: Reboiler Design – Tube Layout
Figure 31: Reboiler Design – Equipment Summary
CHAPTER 7
 PROCESS ECONOMICS

7.1 CALCULATION OF TOTAL INVESTMNT

Acceptable plant design must present a process that is capable of operating under conditions, which will yield
profit. Since net profit equals total volume minus all expenses, it is essential that the chemical engineer be aware
of the many different types of cost involved in the manufacturing process. Capital must allocate for the direct
plant expenses, such as those for raw material, labour and equipment.

Besides direct expenses many others indirect expenses are incurred, and these must be included If a complete
analysis of the total cost is to be obtained. Some examples of these indirect expenses are administrative salary,
product distribution cost and cost for inter plant communication. A capital investment is required for every
industrial process and determination of necessary investment is an important part of the plant design process. The
total investment for any process consists fixed capital investment for practical equipment and facilities in the plant
plus working capital, which must be available to pay salaries, keep raw material and products on hand, and handle
other special items requiring the direct cost outline.

When the cost for any type of commercial process is to be determined, sufficient

accuracy has to be provided for reliable decision. There are many factors affecting investment and production
cost. These are;

• Source of equipment
• Price fluctuation
• Company policies
• Operating and rate of production
• Governmental policies
Before an industrial plant can be put into operation, a large sum of money must be supplied to purchase and install
the necessary machinery and equipment. Land and service facilities must be obtained, and the plant must be
erected completely with all piping, controls and services. The capital needed to supply the necessary
manufacturing and plant facilities is called the fixed-capital investment, while that necessary for the operation of
plant is termed the working capital. The sum of the fixed capital investment and the working is known as the total
capital investment. Generally, the working capital amounts 10-20% of the total capital investment. Following is
the breakdown of the fixed capital investment for a chemical process.

7.2 TYPES OF CAPITAL COST ESTIMATE

Preliminary estimate (budget authorization estimate scope method): based on sufficient data to permit
the estimate to the budget, probable accuracy of this estimate is within ± 20%

Order of magnitude estimate (ratio estimate) based on similar cost data; probable accuracy of this
estimate over ± 30%

Study estimate based on knowledge of major items of equipment, probable accuracy of this estimate
up to ± 30%

Detailed estimate based on complete engineering drawing, specification and site survey, probable
accuracy of this estimate within ± 10%

• Direct cost

• Purchased equipment cost

• Purchased equipment installation

• Instrumentation and control

• Piping

• Electrical equipment and material

• Building (including services)

• Yard improvement

• Land

• Indirect cost

• Engineering supervision
 • Construction expenses

• Contractor’s fee

• Contingency

7.3 COST OF PURCHASED EQUIPMENT

PIB plant capacity = 7200 MT

[Link] NAME OF THE COST OF THE NO. OF RUPEES

EQUIPMENT EQUIPMENT EQUIPMENT

1. Distillation column 2000000 3 6,000,000.00

2. Reboiler 400000 3 1,200,000.00

3. Flash column 2000000 2 4,000,000.00

4. Condenser 400000 6 2,400,000.00

5. Heat exchanger 250000 3 750,000.00

6. Storage tank 250000 2 50,000.00

7. Cooler 175000 1 1,75,000.00

8. Cooling tower 1500000 1 1500,000.00

9. Pump 75000 13 975,000.00

10. Vessel 50000 13 650,000.00

TOTAL 17,700,000.00

Purchased equipment cost = Rs.17,700,000.00

7.4 DIRECT COST ESTIMATION (DC):
TYPE OF COST RANGE(%) ASSUMED(%) COST IN RUREES

Purchased equipment
cost
- - 17,700,000.00
Installation cost 35-45% of PEC 40% 7,080,000.00

Instrument & control 06-30% of PEC 20% 3,540,000.00

installed
Piping installation 10-80% of PEC 60% 10,620,000.00
cost
Electrical installation 10-40% of PEC 25% 4,425,000.00
cost
Building process 10-70% of PEC 50% 8,850,000.00
&auxiliary
Service facilities cost 30-80% of PEC 70% 12,390,000.00

Yard improvement 10-15% of PEC 15% 2,655,000.00

cost
Land cost 04-08% of PEC 08% 1,416,000.00

TOTAL Rs.68,676,000.00
7.5 INDIRECT COST ESTIMATION (IC):

Expenses which are not directly involved with material and labour of actual installation or complete
facility

TYPE OF COST RANGE (%) ASSUMED (%) COST IN RUREES

Engineering and 5-30% of DC 20% 16,012,600.00

supervision

Construction expenses 10% of DC 10% 8,006,300.00

Contractors fees 2-7% of DC 5% 4,003,150.00

contingency 8-20% of DC 15% 12,009,450.00

TOYAL 40,031,500.00

FIXED CAPITAL INVESTMENT (FCI):

Fixed capital investment = DC+ IC = 68,676,000+ 40,031,500 = Rs.108,707,500.00

WORKING CAPITAL INVESTMENT (WCD):

Working capital investment = 10-20% of FCI Assume

that, 15%

Therefore, Working capital investment = Rs. 16,306,125.00

7.6 TOTAL CAPITAL INVESTMENT (TCI):

Total capital investment FCI + WCI = 108,707,500.00+16,306,125.00 = Rs.125,013,625.00

ESTIMATION OF FIXED CHARGES (FC):

TYPES OF COST RANGE% ASSUMED% COST IN Rs

Depreciation (for 10% of FCI 10% 12,094,450.00

machinery)

Local taxes 3-4% of FCI 04% 4,803,780.00

Insurances 0.4-1% of FCI 0.8% 960,756.00

Rent 8-12% of FCI 12% 14,411,340.00

TOTAL Rs. 32,270,326.00

But fixed charges (FC) = 10-30% of TOTAL PRODUCT COST (TPC)

Assume 30%

Therefore, the total product cost (TPC) = 32,270,326.00/ 0.3

= Rs. 107,567,753.33
7.7 DIRECT PRODUCTION COST :

TYPE OF COST RANGE% ASSUMED% COST IN Rs

Raw material 10-50% of TPC 19% 20,437,873.13

Operating labor 10-20% of TPC 15% 16,135,163.00

Direct supervisory & 10-20% of TPC 20% 3,227,032.60

electric labor

Utilities 10-20% of TPC 20% 21,513,550.66

Maintenance (M) 2-10% of TPC 04% 4,803,780.00

Operating supplies(OS) 10-20% of TPC 15% 193,621.96

Laboratory charges 10-20% of TPC 18% 2,094,329.34

Patent and royalties 2-6% of TPC 06% 6,454,065.20

PLANT OVERHEAD COST:

Plant overhead cost = 50-70% of (OL+OS+M)

OL+OS+M = 16,135,163.00+ 193,621.96+4,803,780.00 = 21,132,564.96

Assume that, 55%

Therefore, the plant overhead cost = Rs.11,622,910.73

7.8 GENERAL EXPENSES:

TYPE OF COST RANGE% ASSUMED% COST IN Rs

Administration cost 40-60% of 0L 45% 7,260,823.35

Distribution & selling 2-30% of TPC 12% 12,908,130.40

price

Research and 03% of TPC 03% 3,227,032.60

development cost

TOTAL Rs. 23,395,986.35

Therefore, manufacturing cost (MC) = product cost + fixed charges + plant overhead expenses

= 107,567,753.33+32,270,326.00+23,395,986.35

= 163,234,065.5

TOTAL PRODUCTION COST:

Total production cost = MC + GE = 163,234,065.57 + 23,395,986.35 = Rs.186,630,052.20

Gross earnings and rate of return:

The plant is working for say 355 days a year Selling

price = Rs.45/kg for PIB

Total income = 7842 x 355 x 45 = Rs.125275950.00

Gross income = total income – total product cost

= 125275950.00 – 107,567,753.33
= Rs.17708196 Tax = 50%
Net profit = Rs.8854098
Rate of return:

= (net profit x 100)/ total capital investment

= (8854098 x 100) / 138,108,675.00

= 6.41 %
7.9 CALCULATION OF PAY OUTTIME:

PAY OUT TIME (n) = - log (1-(1 x TCI)) / log(1+I)

Where, R= net profit + depreciation; I = interest rate

R = 88854098 + 12,094,450.00

= Rs.20948548

Interest rate, at 1%

PAY OUT TIME (n) = - log (1-(0.01 x 138,108,675/ 20948548)/log (1+0.01)

= 6.85

BREAK DOWN ANALYSIS:

Annual fixed charges = Rs.32,270,326.00

Total annual sales = Rs. 125275950.00

Wholesale selling price of PIB per kg = Rs.45

Direct production cost of PIB per kg = (32,270,326.00 x 45)/(125275950.00)

= 10.30
Rs/kg

Let n kg per annum be the break-even production rate, then no of kg needed for a break- even point is
given by = (32,270,326.00 + (10.30 x n) = 45 x n

32,270,326.00 = (45-10 .30) x n

n = 32,270,326.00/ (45-10.30) = 929980 kg/year n

= 929980 kg/355 =2619.66 kg/day

therefore break down production rate for 7842 kg of PIB is 2619.6 kg/day or 33.33% of the plant capacity.
CHAPTER 8
 PLANT LAYOUT

Figure 32 : Plant Layout – Polyisobutylene Manufacturing Unit

CHAPTER 9
PROCESS SAFETY
Safety department is a very important and necessary department in every industry especially in
chemical process industries without safety the industry cannot function properly. Safety means to
give safety to men and machines by preventing accidents in an industry. Accidents may be defined
as unexpected harmful events which may causes injury to persons of damages property. If the
accidents are not prevented, it will result in the following,

❖ Reduced Production
❖ Increased cost
❖ Wastage in Resource
❖ Human Sufferings
Therefore, accidents must be prevented in every industry.
CAUSES OF ACCIDENTS:
Analysis of accidents in different industries shows 88% of accidents are caused by human causes
10% of the accidents are caused by mechanical failures and 2% accidents are caused by nature.
The main causes of accidents are,

❖ Unsafe conditions
❖ Unsafe activities
❖ Environmental factors
❖ Human factors
DANGEROUS SOURCES IN KPL PLANT:
Hydrocarbon gases and other petroleum products have dangerous and harmful properties.
Breakdown and accidents are due to the following reasons,
❖ Hydrocarbon and its products are combustible and more over can self ignite at a definite
temperature
❖ A large number of gas and their vapors can produce explosive mixtures with air.
❖ The technological processing of gas is often conducted at an increased pressure and
apparatus and pipelines may rupture owing to a sudden increase of the pressure above the
rated one.
9.2 SAFETY ASPECTS NEEDED ON THE SPOT:
In the onsite or offsite the accidents will be prevented. The following are the some of the important
personal safety devices which may be used in the industry. They are,

❖ Helmet
❖ Safety shoes
❖ Goggles
❖ Safety belts
❖ Gloves
❖ Respirators
❖ Safety Cloths
❖ Nose Monk
❖ Hand shield
❖
9.3 TYPES OF NOZZLES:
Different types of nozzles are used for different purposes in industry. They are of follows,
❖ JET NOZZLE:
Jet Nozzle is mainly used to prevent or put off the fire at very heights. This nozzle is mainly used
to prevent the fire from a definite distance.

❖ FLORA NOZZLE:
Flora nozzle is mainly used to prevent the fire from the outside of the system. This is mainly used
to prevent the explosive system when there is unsafe condition is provided at the surroundings.

❖ MAYURA NOZZLE:
Mayura nozzle is used to prevent the transformation of fire from one side to another.

❖ DOUBLE PURPOSE NOZZLE:This is used for both jet and flora nozzle as a
combination. In KPL there may be a fire hydrant of every 50 meter and fire call point at
every time.
9.4 SAFETY PRECAUTIONS:
To prevent breakdown and accidents the safety rules must be strictly adhered to everyone begins
to work at a plant must be instructed in safety engineering fire prevention and the handling of
gases. The following basis safety measures are provided at the plants,

❖ Suction and exhaust ventilation is provided in all closed premises if an explosion or

toxically dangerous concentrations of products can appears in premises, special instruments
are installed in them that gives a signal when the concentration of the explosive of toxic
substances approaches the maximum tolerated value.
❖ Explosion – proof electric motors are installed in premises with an explosion hazard or
ventilated frame machines using air at an excess pressure
❖ Stationery and mobile mechanisms are provided to prevent accidents during repairs; they
include overhead cranes for Pump repair job cranes on the columns of the apparatus and
extractors for removing tube bundles from heat exchangers.
❖ The technological equipment and general refinery facilities are equipped with stationery
and mobile fire extinguishers.

➢ SEQUENCE CONTROLLER AND PHOTOCELL:

These are ensuring the following,
❖ No delay in firing of fuel and hence no accumulation of fuel in the combustion chamber
which eliminates the danger of back firing.
❖ If the flame is not established in the specified time by the action of photocell, the unit goes
to electrical look out stopping the firing sequence instantly, followed by an alarm;
Restarting of the burner requires manual reseating of the reset push button. On a working
boiler 17 flame fails due to some reason, the unit is brought to electrical lockout position
sounding the alarm. Thus accumulation of fuel and back firing are avoided during
subsequent firing operation. Once the unit goes into electrical lockout sufficient time should
be allowed for the modulating motor to come to low flame position before resetting the
sequence controller to avoid back firing. This time is roughly about 30 seconds.
➢ FLOAT ACTIVITY COUNTER CHECK SYSTEM:
Two morays are provided in the boiler each having. Three magnetic switches. The switch contacts
of the tow morays are inter connected by and electronic circuit. The circuit counter checks the
activities of the two morays. If the activities are ok ten float activity normal lamps come in the
control panel. If due to some reasons the float activity does not tally each other than FACC sounds
an alarm and trips the boiler. In which case the float activity normal lamp goes off. Now check the
morays operations before restarting. The top two switches of the both the morays are used for
starting and stopping the feed pump automatically depending upon the water level in the boiler.

The child switch of mobreys 1 is designated as low level switch and the third switch mobreys 2 is
designated as extra low-level switch. The function of this tow is as follows. When the float activities
are normal and due to some reason could be because of the pump not working or low-level water
in the boiler. Water level goes below pump on position, upon reaching its position, low level switch
trips the burner sounding an alarm. In case the low-level switch is defective and malfunctioning
then the extra low-level switch which is mounted slightly below the low-level switch trips the
burner raising an alarm.

➢ MODULATING PRESSURE SWITCH:

The modulation pressure switch is used for operation the burner in step less modulation mode.
When the pressure exceeds the set limit the potentiometer in the pressure switch comes into
operation. Due to the movement of the arm in the potentiometer, the unbalanced current flow in
the circuit. The modulating motor rotates so as to balance the current. Due to the movement of the
motor, fuel valve closes open depending upon the direction of rotation of motor and the steam
pressure is controlled within the set limit.
CHAPTER 10
 EQUIPMENT AUXILIARIES

CONDENSATION SYSTEM
High purity process water is required for caustic dilution, injection with ammonia into the
top at the fractionators, the debutanizer and secondary flash and is used as an alternate supply for
the feed water wash and the polymer water wash. Condensate is used as a source for the high purity
process water; however, it must first be cooled. At this time. Details of the Kothari Petrochemicals
Private Ltd. condensate system are not available.

BLOW DOWN DRUM:

Various acid and alkaline waste stream originate in the Polybutene process, Aqueous
streams from the feed water wash, caustic wash, polymer water wash, debutanizer overhead,
fractionators overhead, vacuum flash, column overhead and hydrogen water are produced
continuously and must be disposed, in addition there are intermittent streams from the dryer
depropaniser column overhead, feed caustic wash, coalesce, debutanizer preheater flash and the
polymerization reactor blow down. These streams are collected in the blow down drum where
the hydrocarbons can be vented to the flare. In addition, large quantities of solids are precipitates.

A stream soil is provided in the bottom to keep the system from freezing in cold weather and
the temperature is controlled manually. High pressure steam and water are pumped to the bottom
of this drum to aid in cleaning when plugging occurs.
CHAPTER 11
 APPLICATIONS

❖ CHEWING GUMS: Polybutene can improve the gum quality when mixed with
paraffin wax and resin; it can also make the gum more flexible and stable, maintaining
good hydrophobic property and excellent film-forming property.

❖ FOOD GLUTIN: Mixed with various adhesives (including pressure-sensitive

adhesive), polybutene has the functions of adhesive bonding and modification.

❖ FOOD PACKING: Polybutene can be mixed with various paraffin waxes and high
molecular polymers to serve as the releasing agent of packaging films; for example,
polymer of polybutene and paraffin wax can be used as the packaging films for cheese.
It can improve the low-temperature stability and water resistance of product.

❖ FOOD-GRADE HOT MELT ADHESIVE: Polybutene has a function of

plasticization, and can be used for thermal-plastic rubber, etc.

❖ BASKETBALLS: Polyisobutylene is impermeable to air and it is normally used on the

inside of basketballs to stop them from deflating

❖ MEDICINE PLASTER: Food-grade polyisobutylene is now widely used in the field

of medicine plaster. It has nice compatibility with both western medicines and
traditional Chinese medicines because of its unique net structure long chain and
macromolecule

❖ LUBRICATING OIL: Polyisobutylene added in small amounts to the lubricating oils used in
machining results in a significant reduction in the generation of oil mist and thus reduces the
operator's inhalation of oil mist.
CHAPTER 12
 CONCLUSION

The project aimed at optimizing the distillation column (debutanizer) design for light hydrocarbon separation
using polyisobutylene production. The project included the complete distillation process including raw
material handling, reactor system, separation unit and product recovery.

The distillation column was effectively optimized by selecting suitable internal configurations, where Pall
Rings and Super Pak packings improved separation efficiency in the top section. Sieve Trays and Bubble Cap
Trays were used in different sections to balance pressure drop and enhance vapor–liquid contact, especially in
the bottom section for handling high-viscosity fluids. Overall, this combination significantly enhanced the
column’s efficiency, performance, and product purity.

The existing column with a height of 15 m and combination of random packing and valve trays provides
moderate separation performance. However, it is less efficient in handling high-viscosity fluids like
polyisobutylene and offers limited vapor–liquid interaction.

The proposed column, with a height of 23 m and two-section design using Pall ring packing in the top and
bubble cap trays in the bottom, shows significant improvement. The packing enhances mass transfer and
reduces pressure drop, while the bubble cap trays provide excellent vapor–liquid contact and are highly
suitable for viscous systems.

Overall, the new design achieves better separation efficiency, higher product purity, improved operational
stability, and enhanced performance, making it more suitable for industrial application despite a slight increase
in column height and complexity.

Aspen Plus was used to perform simulations and optimizations of this process to gain further knowledge about
performance, convergence, and operating conditions; improvements were made to design efficiency, reduce
energy consumption, and have a more stable operation no matter the operating conditions.

The thermal efficiencies of the system were enhanced by ensuring that auxiliary equipment, such as the
condenser and reboiler, were properly designed and selected based on equipment type and operation. This
allows for maximum heat transfer, while at the same time reduces the potential for operation problems.

A comprehensive economic analysis of the plant indicated that this process is economically viable and has a
reasonable level of initial investment, an acceptable overall rate of return and a fully manageable payback
period. The design also meets safety requirements by applying safety measures and operating controls.

This project demonstrates the successful integration of theoretical concepts with simulation techniques and
practical design considerations for industry applications. This study also provides a solid basis for future
improvements associated with process optimization, energy integration, and commercial production scale-up.
 REFERENCES
1. American Institute of Chemical Engineers
Technical resources and design standards for chemical process industries.

2. Aspen Technology Inc.

Aspen Plus User Guide and Documentation, Version 10 or later.

3. Coulson and Richardson’s Chemical Engineering Volume 6

R.K. Sinnott and G. Towler, Chemical Engineering Design, 5th Edition, Elsevier, 2009.

4. Geankoplis, C.J.
Transport Processes and Separation Process Principles, 4th Edition, Prentice Hall, 2003.

5. Kothari Petrochemicals Limited

Plant data, process flow diagrams, and operational details obtained during industrial reference and
project work.

6. McCabe, W.L., Smith, J.C., and Harriott, P.

Unit Operations of Chemical Engineering, 7th Edition, McGraw-Hill, 2005.

7. National Institute of Standards and Technology

Thermodynamic and physical property data (NIST Chemistry WebBook).

8. Peters, M.S., Timmerhaus, K.D., and West, R.E.

Plant Design and Economics for Chemical Engineers, 5th Edition, McGraw-Hill, 2003.

9. Perry, D.W. Green and R.H.

Perry’s Chemical Engineers’ Handbook, 8th Edition, McGraw-Hill, 2008.

10. Smith, J.M., Van Ness, H.C., and Abbott, M.M.

Introduction to Chemical Engineering Thermodynamics, 7th Edition, McGraw-Hill, 2005.