20TH CHEMICAL
ENGINEERING PLANT
DESIGN CONTEST
PRESENTATION
VINYL CHLORIDE MONOMER (VCM) PLANT DESIGN
VinyQ Representitives
Mutaman Abdelrahim ABDULRAHMAN ELHASSAN
Environmental Engineer Financial Manager Chemical Engineer
Distillation Column Mechanical
04 VinyQ Identity 21 Design
05 Senior Design Project (SDP)
24 HAZOP Study
06 Market Analysis Heat Exchanger Mechanical
28 Design
07 Vinyl Chloride Monomer (VCM)
OUTLINE
34 Economic Analysis
08 Vinnolit Process Technology
39 Conclusion
10 Mass Integration
Environmental Impact Assessment
11 (EIA)
18 Site Location Selection
VinyQ Identity:
Mission:
VinyQ designs and engineers world-class Vinyl Chloride Core values:
Monomer (VCM) plants, committed to the safe,
sustainable, and efficient production of Vinyl Chloride.
We uphold our core values of safety, excellence, and
integrity, partnering with clients to achieve their
strategic goals while adhering to the highest
environmental standards and sustainability practices. Safety Integrity Excellence
Vision:
VinyQ aspires to be a globally recognized leader in
sustainable VCM process design by 2030. We will be
renowned for our innovative solutions that minimize
environmental impact and optimize resource utilization
throughout the VCM production lifecycle. We envision a
future where VCM production seamlessly aligns with a
circular economy, promoting responsible chemical
manufacturing for a thriving Qatar and a healthier planet.
04
Senior design project (SDP):
Project: Sustainable VCM Plant Design
Objectives & Goals:
360,000 MT/Year of VCM (99.99%)
27,000 MT/Year of EDC (99.8%)
Sodium hypochlorite!
Location: Mesaieed (Why?)
Area: 200-300 Acres
Technology licensor: Vinnolit GmbH & Co. KG
05
VCM
Market analysis: CAGR = 6.35 %
$ 25.00 bn $ 9.05 billion increase !!
Among the top 20 largest petrochemicals
$ 20.00 bn
99% of VCM is used to manufacture
polyvinyl chloride (PVC)
$ 15.00 bn
PVC consumption is second to low-density $ 23.27 bn
polyethylene. $ 10.00 bn
$ 14.22 bn
$ 5.00 bn
$ 0.00 bn
2022 2029
06
Vinyl Chloride (H2C=CHCl):
APPLICATIONS
Colorless gas at ambient temperature and
pressure
Slightly sweet odor
Flammable
Carcinogenic (potential to cause cancer)
Highly reactive - readily undergoes
polymerization
Threshold limit value (TLV-TWA): 1 ppm
Flammability limits: 3.6% - 33.0%
Odor threshold: 3,000 ppm
07
VINNOLIT PROCESS BFD:
08
PROCESS FLOW DIAGRAM (PFD):
System #3:
EDC distillation
System #5:
VCM purification
09
MASS INTEGRATION (DIRECT RECYCLING):
Source (1769 kg/h):
23.70 % of Ethylene
6.58 % of HCl
& 50.84 % of EDC
Sink
Savings in fresh ethylene
= 3,269.85 MT/year
($ 3,269,848.09 saved)
10
Environmental impact assessment (EIA):
Category Limits
NOx 55 mg/Nm3
CO2 - Limits according to:
Environmental protection law
SO2 35 mg/Nm3
Decree No.30 of 2002
Flue gas temperature < 200 °C
Sea water discharge temperature ∆T=3 °C
Wastewater discharge to sea TSS: 50 mg/L, pH: 6-9, COD: 100mg/L
Noise 85 dB
11
Others:
Noise, dust
Solid wastes: Liquid discharge:
Catalyst Hazards Chlorinated wastewater
Coke formation identification Cleaning agents
Scraps Heavy ends
Gaseous:
COx, NOx, SOx,
Light ends,
Fugitive-releases
12
1400 NOx emissions
1200
Component emission Carbon footprint
1000
NOx 1,266.91 mg/Nm3 800
600
CO2 896.66 kg/MT of VCM
400
SOx -
200
0
NOx CO2
13
Mitigative measures: For normal and
abnormal operations
Hazard Measures
NOx Reduction reactions, water injection, and low NOx burners
CO2 Carbon capture and storage
Flocculation/sedimentation >> gas stripping >> catalytic
Chlorinated wastewater
oxidation >> micro filtration
Catalyst and scraps Regeneration or disposal (Basel convention)
Dust particles & smoke PPE, dust suppression & smoke reduction methods
14
Hazard Measures
Coke formation Decoking and coking inhibitors
High efficiency thermal oxidation >> water to caustic scrubbing
Light & heavy ends or
Catalytic oxidation (heat recovery + recycle of HCl)
Cleaning agents Neutralize then disposal to landfill
Noise PPE and noise suppressors
Fugitive releases Equipment seals and proper ventilation
15
Proposed Treatment of
light and heavy ends:
16
Social impact:
The establishment and operation of industrial plants can significantly influence the
surrounding communities and the broader society.
Positive Potential negative
Job Opportunities Health Risks
Economic Growth Air Pollution
Infrastructure development Noise and Visual pollution
Social responsibility Water contamination
17
Site location:
10
18
Factor Weight Dukhan Mesaieed Ras laffan
Location to marketing area 0.10 4 9 5
Raw material supply 0.10 6 9 9
Transport facilities 0.10 7 9 8
Availability of labors 0.10 8 8 8
Availability of utilities 0.10 6 9 9
Availability of suitable land 0.10 8 8 9
Environmental impact & disposal 0.10 5 9 8
Local community 0.10 6 7 7
Climate 0.10 7 6 6
Political & strategic considerations 0.10 6 7 9
Total weighted score 1 6.2 8.35 8.10
Site location evaluation matrix: 19
20
Mechanical design of the distillation columns:
Design objectives:
To mechanically design the separation
equipment of the VCM production plant,
that is, two distillation columns used for
HCl recovery (C-501), and VCM separation
(C-502).
To evaluate the functionality and
performance of the designed distillation
columns.
21
Results and discussion:
Distillation Column (C-501)
Plate Spacing(m) 0.6
Diameter (m) 2.26
Liquid Arrangment double space
Weir height(mm) 50
hole diameter (mm) 5
Plate Thikness(mm) 5
Plate pressure drop(kpa) 1.4
Residence time (s) 4.82
Area of one hole (m^2) 0.000019625
Number of holes 15528
Actual Number of trays 35.7
Height (m) 21.34
Column Head Height (mm) 514.6
Column Wall thikness (mm) 16.42
22
23
06
HAZOP study:
Before P&ID
Action
Guide word Deviation Cause Consequence
required
Study note
24
Guide word Deviation Cause Consequence Action required
Temperature ·Low product purity
·Instrumentation failure
·Low separation efficiency
·High feed temperature
High ·Pressure build-up ·Install temperature indicator & controller
·High steam flow on C-502 reboiler
·Leak of hazardous chemicals ·Install high pressure alarm
Pressure Low cooling utility flow on C-502 condenser
Explosion and fire ·Install pressure relief valve
·Install pressure transmitter and controller
·Install low pressure alarm
·Low product purity ·Control utility amount on reboiler and
Temperature ·Flooding and weeping condenser
·Instrumentation failure
·Pressure change ·Regular checking and maintenance
Low ·High cooling utility flow on C-502 condenser
·Product loss Implement procedural strategies
Low steam flow on C-502 reboiler
·Phase change
Pressure Low separation efficiency
·Liquid overflow or spillage risk
·Pipe blockage/fouling
·Disruption of column operation ·Install high and low level alarms
High ·Instrumentation failure
·Pressure build-up ·Install control valve on the reflux and
High feed flow
Explosion and fire distillate pipes
Reflux drum
·Implement level control strategies
level
·Regular checking and maintenance
·Less reflux and distillate Design proper venting system for liquid
·Instrumentation failure
Low ·Low product purity carryover prevention
Pipe leakage/rupture
Low separation efficiency
·Install composition analyzer and controller
Low VCM
Low Low separation efficiency Low product purity ·Install low composition alarm
composition
Implement procedural strategies
Study note example on top section
25
P&ID on C-502 top section:
Fail open
4 control valves
3 control loops
5 alarms
1 pressure relief valve
26
Complete P&ID on C-502:
3 distinct sections
8 control valves
7 control loops
9 alarms
1 pressure relief valve
27
Mechanical design of the heat exchanger:
Design objectives:
To mechanically design, develop, and optimize a shell and tube heat exchanger that
meets the operational requirements using Kern's method, following TEMA standards
and complying with additional relevant standards such as ASME BPV and BS/GPSA if
needed.
To employ the HTRI software for rigorous thermal and hydraulic modeling of the heat
exchanger.
To evaluate the functionality and performance of the designed heat exchanger.
28
HE-301 Cooler Data:
Physical Properties
- EDC process stream Cooling water utility stream
Temperatures
T (°C) 86.49 35
t (°C) 40 30
Pressures
Pi (KPa) 100 100
Po (KPa) 70 100
Mass heat capacity (KJ/kg⋅°C) 1.32200 4.435
Viscosity (N⋅s/m^2) 0.0004814 0.000756
Thermal conductivity (W/m⋅°C) 0.1165 0.6217
Density (Kg/m^3) 1253 1002
29
Results and discussion:
Tube side Shell side Calculated Overall heat transfer coefficient (Uo)
pressure drop pressure drop
Shell ho (W/m^2⋅°C) 990.64
Re 31559.46 14586.50
hod (W/m^2⋅°C) 5000.00
Jf 0.0037 0.05 Kw (W/m⋅°C) 50.00
hi (W/m^2⋅°C) 5584.09
ΔP (N/m^2)=(KPa) 13.74 13.49
hid (W/m^2⋅°C) 6000.00
ΔP (psi) 1.99 1.96
1/Uo [(W/m^2⋅°C)^-1] 0.00
Uo (W/m^2⋅°C) 609.00
Relative (approximation) Error (%) 1.48
Acceptable values within range
30
Results and discussion:
31
Cost Estimation:
Fixed Capital Investment
Methods Cost $
Historical Data $19,261,898.11
Step Counting $475,323,545.50
Lang Factor $90,379,600.34
32
Lang factor example:
Heat Exchangers
Equipment S (size parameter) (m^2) a b n Cost
HE-101 505 10000 88 1 $190,540.00
HE-201 505 10000 88 1 $190,540.00
HE-203 505 10000 88 1 $190,540.00
HE-205 505 10000 88 1 $190,540.00
HE-208 505 10000 88 1 $190,540.00
HE-209 505 10000 88 1 $190,540.00
HE-301 505 10000 88 1 $190,540.00
HE-501 505 10000 88 1 $190,540.00
HE-502 505 10000 88 1 $190,540.00
Total Cost $1,714,860.00
Updated Total Cost $2,897,991.58
33
34
Operating Cost:
Price Rate (unit) from
Total Cost
Raw Material Unit (USD/Unit) (Middle material balance
(USD/year)
East Estimates) chapter
Ethylene ton/year $1,000.00 173225.51 $173,225,506.50
Chlorine ton/year $500.00 223353.59 $111,676,793.35
Oxygen Nm³ $0.75 15881236.8 $11,910,927.60
Catalyst kg/year $15.00 167671 $2,515,065.00
Inhibitor kg/year $10.00 7391.6 $73,916.00
Total $299,402,208.45
35
Employee Position # of Employees Annual Salary (USD)** Total Paid Salary (USD)**
Plant Chairman 1 $120,000.00 $120,000.00
Plant Manager 1 $95,000.00 $95,000.00
Unit Managers 5 $80,000.00 $400,000.00
Computer Programmer 1 $70,000.00 $70,000.00
Computer Engineer 2 $82,000.00 $164,000.00
Chemical Engineers 5 $80,000.00 $400,000.00
Process Engineers 5 $80,000.00 $400,000.00
+ Insurance cost
Electrical Engineers 3 $75,000.00 $225,000.00
+ License and royality
Environment Engineers 3 $68,000.00 $204,000.00
Industrial Engineers 3 $68,000.00 $204,000.00
payment
Mechanical Engineers 2 $72,000.00 $144,000.00
+ Maintenance cost
Maintenance Engineers 2 $35,000.00 $70,000.00 + Depreciation
Operator 30 $72,000.00 $2,160,000.00 + Contractors cost
Supervisor 5 $75,000.00 $375,000.00 + Utilities
Financial Manager 1 $70,000.00 $70,000.00 + Consultation cost
Production Manager 1 $72,000.00 $72,000.00
+ Social
Sales Manager 1 $70,000.00 $70,000.00
etc.
Budget Analysts 2 $58,000.00 $116,000.00
Financial Analysts 1 $68,000.00 $68,000.00
Tax Prepares 2 $40,000.00 $80,000.00
Auditor 2 $42,000.00 $84,000.00
Total 78 - $5,591,000.00
36
Cash Flow:
37
Profitability:
Cumulative investment $1,155,499,511.28
Investment ($US) $142,347,870.53
Life of project (yr) 30
Payback period: 6
years
ROR 0.2706
ROR % 27.06
DCFRR % 10
38
CONCLUSION:
VinyQ identity
Compliance with Qatar’s regulations and
international codes/standard
Hazards emission control
Site location: Mesieed industrial city
Distillation column design and control
Design of 3 heat exchangers
Economic analysis (PBP: 6 years, ROR%:
27.06 %)
39
THANKS FOR
LISTENING
We look forward to working
with you.