e

The Republic of Sudan

Al-Neelain University

Faculty of Engineering

Chemical Engineering Department

Design of Phenol Production Unit

DPPU

Aproject....

Supervisor:
[Link] Fadul Bashir
Prepared by:
1. Taha Ahmed Abbaker
2. Willma John Packwan
3. Rowida Adam Monzil
4. Muzdalifa Khalid Ali

October 2025

I
 ‫الية‬
‫قال تعالي ‪:‬‬
‫( وقل ربي زدني علما )‬
‫صدق ا العظيم‬

‫‪I‬‬
II
III
 Table of Contents
‫اﻻية‬...……………………………………………….............……………………… I
Dedication...………………………………………………..………...…...………...ii
Acknowledgement …………………………...……………..…………..………... iv
Table of contents…………………...…………………………..……………….......v
List of Table ...……………………………………….…………..……….………...xi
List of Figure ………………………………………………….……………….…..ix
Abstract ……………………………………………….…………….………….…xiii
‫………المستخلص‬...……………………………………………..……..................…xiv
Chapter one: Introduction and literature review
1.1 Introduction ………………………………………………..………………..1
1.2 Historical Background……………………………………………….……….1
1.3 Classification of Diesel fuels ……………………………….………………..2
1.4 Composition of diesel fuel ……………………………….…………………..3
1.5 Diesel Fuel Production Processes…………………………..………………...3
1.5.1 Petroleum diesel Process……………………………….…………………..3
1.5.2 Synthetic diesel process ………………………………………………..…..4
1.5.3 Biodiesel process …………………………………………………...……...5
1.5.4 Diesel Hydro treating Processes …………………………………….……..5
1.6 Introduction to Hydro treating Process……………………………...……….6
1.7 Hydro treating process configurations………………………………..……...6
1.8 HYDROTREATING CATALYSTS …………………………….…………...8
1.9 Chemistry of Hydro treating Process …………………………….………….9
1.10 Hydro-treating Reactions…………………………………………………...9
1.11 Process description ………………………………………………….…….12
Chapter two Material Balance
2.1 Introduction ………………………………………………………………...14
2.2 Overall material balance …………………………………………………...16
2.3 partial Material balance …………………………………………………….17
2.3.1Material balance around mixture ………………………………………...17

V
2.3.2 Material balance around Reactor …………………………………………….17
2.3.3Material balance around mixture valve ……………………………………….18
2.3.4 Martial balance around cold High pressure
Separator drum …………………………………………………………………….18
2.3.5 Martial balance around low pressure
Separator drum …………………………………………………………………….19
2.3.6 Martial balance around striping column ……………………………………19
Chapter three Energy Balance
3.1 Introduction to Energy Balance ………………………………………………..21
3.1.2 Assumption considered ………………………………………………………21
Conservation of energy……………………………………………………… 21
3.2 partial Energy Balance ………………………………………………………...22
3.2.1 Energy balance around reactor ………………………………………………22
3.2.2 Energy balance around reactor furnace ……………………………………... 23
3.2.3Energy balance around column furnace ……………………………………...23
3.2.4 Energy balance around first heat exchanger………………………………... 24
3.2.5 Energy balance around second heat exchanger ……………………………...25
3.2.6 Energy balance around 3th heat exchanger………………………………….. 26
3.2.7 Energy balance around air cooler …………………………………………….27
3.2.8 Energy balance around water cooler …………………………………………28
3.2.9 Energy balance around striping column ……………………………………...29
3.2.10 Energy balance around
Striper heat exchanger ……………………………………………………………...30
Chapter four Process Design
4.1 Introduction …………………………………………………………………….32
4.2 Design of Distillation column …………………………………………………32
4.2.1 Selection of column type …………………………………………………….33
4.2.2 Design procedure and calculations …………………………………………...33
4.2.3 Design calculation ……………………………………………………………34
4.3 Heat exchanger design ………………………………………...………………39
4.3.1 Introduction to heat exchanger design ………………………………………39

VI
4.3.2The principal types of heat exchanger ………………………………………39
4.3.3 Design procedure …………………………………………………………….39
3.3.4Design objective ……………………………………………………………..40
3.3.5 Design calculation …………………………………………………………...40
4.4 Reactor design ………………………………………………………………...48
4.4.1 Introduction to reactor design ……………………………………………….48
4.4.2 Requirements of industrial chemical reactor design ………………………..49
4.4.3 design calculation …………………………………………………………..50
Chapter five Process Control
5.1 Introduction …………………………………………………………………...54
5.1.2Process ……………………………………………………………………...54
5.1.3Process Control ……………………………………………………………...54
5.1.4Control Loop ………………………………………………………………..54
5.1.5Process Variable ……………………………………………………………..55
5.2 Applications of control in DHT unit …………………………………………55
5.2.1 Steam stripping column control …………………………………………….55
5.2.2 Reactor variables control …………………………………………………..56
5.2.3 Heat exchanger control …………………………………………………….57
Chapter six Safety and Environment
6.1 Introduction …………………………………………………………………..61
6.1.2 Safe work is a work without any damage / loss to …………………………61
6.1.3 To prevent loss ……………………………………………………………..61
6.1.4Common hazard in a plant ………………………………………………….61
6.1.5 Fire hazards of diesel ………………………………………………………..61
6.2 Diesel hydro treating unit safety ……………………………………………...62
6.2.1 Safety characteristics and safety measures of the device …………………...62
6.2.2 Safety measures of the device ……………………………………………….62

VII
6.3 Environmental considerations ……………………….……………………….63
6.3.1 Measures for discharge and control of three wastes
in hydrogenation device ………………………………………………………….63
[Link] Waste gas ………………………………………………………………….63
[Link] Waste liquid Sewage ……………………………………………………..63
[Link] Dirty oil …………………………………………………………………...64
[Link] Waste residue ……………………………………………………………..64
Chapter seven Plant location and Layout
7.1 Introduction …………………………………………………………………68
7.1.1 Plant Location and Site Selection …………………………………………..68
7.1.2 Location, with respect to the marketing area ……………………………….68
7.1.3 Raw material supply ………………………………………………………..68
7.1.4 Transport facilities …………………………………………………………68
7.1.5Availability of labor …………………………………………………………69
7.1.6 Availability of utilities ……………………………………………………...69
7.1.7 Availability of suitable land ………………………………………………..69
7.2 Environmental impact and effluent disposal …………………………………70
7.2.1 Local community considerations …………………………………………..70
7.2.2 Climate ……………………………………………………………………..70
7.2.3 Political and strategic considerations ………………………………………70
7.3 Site Layout: ………………………………………………………………….70
7.4 Plant Layout: ………………………………………………………………...72
7.4.1The process requirements …………………………………………………..72
7.4.2 Convenience of operation …………………………………………………..72
7.4.3 Convenience of maintenance ………………………………………………72
7.4.4 Safety ……………………………………………………………………….73
7.4.5 Future expansion ……………………………………………………………73
7.5 Modular construction ………………………………………………………….73

VIII
7.6 General considerations ………………………………………………………...73
7.6.1 Buildings ……………………………………………………………………..74
7.6.2 Plant expansion ………………………………………………………………74
7.6.3 Other services ………………………………………………………………..74
7.6.4 Wind direction ………………………………………………………………..74
7.6.5 Storage facilities ……………………………………………………………...75
7.7 DHT unit layout ………………………………………………………………..75
7.7.1 Scope ………………………………………………………………………...75
7.7.2 Site of feed storage …………………………………………………………...75
7.7.3 Site of process equipment ……………………………………………………75
7.7.4 Site of products ………………………………………………………………75
7.8Control room consideration …………………………………………………….75
Chapter eight Cost Estimation
8.1 Introduction …………………………………………………………………….78
8.1.1 The actual production capacity ………………………………………………78
8.1.2 Installed capacity …………………………………………………………….78
8.2 Factors Affecting Investment and Production Costs ………………………….78
8.3 Accuracy of Estimates: ………………………………………………………..79
8.4 Capital Investment Cost ………………………………………………………..79
8.5 Operation cost ………………………………………………………………….81
8.5.1Variable operation cost ………………………………………………………..81
8.5.2 Fixed operation cost ………………………………………………………….83
8.6 Total annual income ……………………………………………………………84
8.7 Net profit ……………………………………………………………………….84
8.8 Taxes of net profit ………………………………………………………………84
8.9 Annual net profit ……………………………………………………………….84
8.10 Payback period ………………………………………………………………..84
Chapter nine Recommendation and Conclusion
9.1 Conclusion………………………………………………………………………86
9.2 References ……………………………………………………………………...87
9.3 Appendices ……………………………………………………………………..89

IX
Appendixes of Tables
Table (A-1) Typical overall coefficient …………………………………………….89
Table (A-2) Fouling factors (coefficients) typical values: …………………………89
Table (A-3) stander dimensions of steel tube : ……………………………………90
Table (A-4) conductivity of metals ……………………………………………….90
Table (A-5) typical tube arrangement …………………………………………….90
Appendixes of Figures:
Figure (B-1) Erbar Maddox correlation . …………………………………………..91
Figure (B-2) flooding velocity sieve plate . ……………………………………….91
Figure (B-3) tube side heat transfer factor …………………………………………92
Figure (B-4) Temperature correction factor: one shell pass; two or
more even tube passes. ………………………………………………………..…..92
Figure (B-5) shell side heat transfer factor, segmental baffle ……………………93
Figure (B-6) shell side friction factor, segmental baffle ………………………….93
Figure (B-7) shell bundle clearance ……………………………………………….93

X
 LIST OF TABLE
Table (1.1) Properties of diesel fuel ……………………………………………….3
Table (1.2) Process parameters : …………………………………………...……..11
Table (1.3) Row feed from RFCC to DHT unit Properties : …………………......11
Table (2.1): Stream lines codes. ………...………………………………………….15
Table (2.2): summary of general material balance: ……………………………….16
Table (4.1) Feed specifications ……………………………………………………34
Table (4.2 ) Average relative volatility (αav) ……………………………………...34
Table (4.3) calculated using trial and error method …………………………….35
Table (4.4) Summery of Distillation column design calculation ………………….38
Table ( 4.5 ) Enthalpy and mass flow rate ………………………………………..40
Table ( 4.6) fluids properties ……………………………………………………...41
Table ( 4.7 ) illustrated exchanger layout …………………………………………43
Table ( 4.8 ) Heat exchanger design summary ……………………………………46
Table (4.9 ) Design summary in shell &tube sides: ………………………………47
Table (4.10) Design summary of reactor : ………………………………………..52
Table (5.1) Indices for DHT Process control ………………………………………59
Table ( 6.1 ) diesel hazards specification …………………………………………..61
Table (6.2) Environmental department measurement and control …………………65
Figure (7.1) plant layout …………………………………………………………...76
Table (8.1) equipment prices ……………………………………………………….80
Table (8.2) below represent utilities required for DHT unit ……………………….82

XI
LIST OF FIGURES
Figure ( 1.1 ) diesel fuel from simple distillation column ………………………….4
Figure ( 1.2 ) Synthetic diesel process ……………………………………………..4
Figure ( 1.3 ) Biodiesel process flow sheet ……………………………………….. .5
Figure ( 1.4 ) Diesel Hydro treating flow sheet …………………………………...5
Figure ( 1.5 ) DHT unit a cold separator layout …………………………………...7
Figure ( 1.6 ) DHT unit hot separator layout ………………………………………7
Figure (1.7 ) DHT flow scheme ……………………………………………………12
Figure (2.1) DHT flow scheme ……………………………………………………14
Figure (4.2 ) schematics drawing of hydro treating reactor ……………………….49
Figure ( 5.1 ) a level transmitter (LT) ……………………………………………...54
Figure (5.2 ) Model of stripper top control ………………………………………...55
Figure (5.3 ) Model of stripper bottom control …………………………………….56
Figure (5.3) stripper bottom temperature control …………………………………..56
Figure (5.5) DCS Screen of heater and Reactor control …………………………...57
Figure (5.6) model reactor bed temperature control ……………………………….57
Figure (5.7) Conventional Process Control ………………………………………..58
Figure (5.8) Digital Process Control ………………………………………………58

XII
 Chapter one
INTRDUCTION

XV
1.1 Introduction :

1.2 Historical Background:

1
1.3 Classifications of phenol :

2
1.6 Introduction to Hydro treating Process:

1.7 Hydro treating process configurations:

Di

6
1.8 HYDROTREATING CATALYSTS :

8
Actually, nickel-tungsten is most effective for nitrogen removal and saturation of ar-
omatic rings to reduce aromatic content but is much more expensive than nickel-
molybdenum and is, therefore, seldom used in fuels refineries. The ability to adjust
pore size to concentrate pores around a particular diameter has a great impact on the
hydro treating activity both at start-of-run (SOR) and as the catalyst ages. Reactions
taking place in the hydro treating of gas oils [(200 to 566°C)] generally require a
minimum pore size to overcome most diffusion restrictions. Pores that are larger
than necessary lend little to improving diffusion characteristics, and as the pore di-
ameters of the catalyst increase, the surface area decreases (at constant pore vol-
ume).
Activity generally decreases with surface area, and loss in pore volume occurs in the
smallest diameter pores first. Highest activity retention is maintained if the pore vol-
ume is concentrated in a very narrow range of pore diameters. At the hydro treating
severity to reduce sulfur in LCO to 0.05 wt%, the performance of high activity Ni-
Mo and Co-Mo catalysts appears to be equivalent. Catalyst consumption varies from
(0.003 to 0.02 kg/m3) feed depending upon the severity of operation and the gravity
and metals content of the feed.
1.9 Chemistry of Hydro treating Process :
The chemistry of hydro treating and hydro cracking is commonly taken together and
termed hydro processing and is similar for both sections of the hydro processing
unit. The conversions in hydro processing can be classified into desirable and unde-
sirable reactions. The desirable reactions are desulfurization and denitrogenating ,
saturation (i.e., hydrogen addition to olefin and aromatic molecules). Undesirable
reactions are contaminant poisoning (metals deactivating the catalyst) as well as
coking of the catalyst.
1.10 Hydro-treating Reactions:
The hydro treating reactions that take place are the removal of sulfur, nitrogen, organ
metallic compounds, oxygen, and halide.

9
 Chapter two

Material Balance

13
 Chapter three
Energy Balance

20
3.1 Introduction to Energy Balance:
Energy can be separately conserved in all but nuclear processes. Energy can exist in
several forms: heat, mechanical energy, electrical energy, and it are the total energy
that is conserved. Energy balance around a unit or equipment equilibrates the exiting
and entering forms of energy. In process design, energy balances are made to deter-
mine the energy requirements of the process: the heating, cooling, and power re-
quired in plant operation.
3.1.2 Assumption considered:
1. Steady- state operation conditions.
2. Reference temperature Tref = 25° C.
3. = ( − )
4. SG of RFCC gas oil ≈0.856
Conservation of energy:
A general equation can be written for the conservation of energy
Energy out = Energy in + Generation – Consumption – Accumulation
At steady state conditions, there is no accumulation of heat, the above equation can
be written as:
Energy out = Energy in + generation – Consumption

21
 Chapter four
Process Design

31
4.1 Introduction:
Process design establishes the sequence of chemical and physical operations; operat-
ing conditions; the duties, major specifications, and materials of construction (where
critical) of all process equipment (as distinguished from utilities and building auxil-
iaries); the general arrangement f equipment needed to ensure proper functioning of
plant; line sizes; and principles instrumentation. The process design is summarized
by a process flow sheet, a material and energy balance, and set of individual equip-
ment specifications. Varying degree of thoroughness of a process design may be re-
quired for different purpose. Sometimes only a preliminary design and cost estimate
are needed t evaluate the advisability of further research on a new process or a pro-
posed plant expansion or detailed design work; or a preliminary design may be
needed to establish the approximate funding for a complete design and construc-
tions. A particularly valuable function of preliminary design is
that it may reveal lack of certain data needed for final design. Data of costs of indi-
vidual equipment are supplied in this book, but the complete economics of process
design is beyond its scope.
4.2 Design of Distillation column
The typical vapor-liquid contacting operations include distillation, absorption, strip-
ping, leaching and humidification. Distillation and absorption are two most widely
used mass transfer processes in chemical industries. Design of plate column for ab-
sorption and distillation involves many common steps of calculation such as deter-
mination of number of theoretical plates, column diameter, plate hydraulic design,
etc. In. The vapor and liquid streams leaving the tray are in equilibrium under the
ideal condition. The separation in distillation is based on the relative volatility of
the components.

32
4.2.1 Selection of column type:
1/ Plate or Packed
Packed towers (columns) are also used as the contacting devices for gas absorption,
liquid-liquid extraction and distillation. The gaseous mixture is allowed to contact
continuously with the u liquid counter-currently in a packed column. The liquid
flows downward over the packing surface, and the gaseous mixture flows upward
through the space in the packing. The performance of the column strongly depends
on the arrangement of the packing to provide good liquid and gas contact throughout
the packed bed. The solute gas is absorbed by the fresh solvent (liquid) entering at
the top of the tower where the lean gas leaves system. The liquid enriched with ab-
sorbed solute gas, leaves the column bottom through the exit port. In a plate tower,
the liquid and gas are contacted in stage-wise manner on the trays; while gas-liquid
contact is continuous in a packed column. There are always some uncertainly to
maintain good liquid distribution in a packed tower. For this reason, it is difficult to
accurately estimate the packed tower efficiency.
4.2.2 Design procedure and calculations:
1. Feed specifications.
2. Specify key and non-key components.
3. Calculate minimum theoretical stages using fenske equation
4. Calculate minimum reflux ratio using Underwood equations
5. Calculate actual theoretical stages for specified reflux ratio using.
Gilliland correlations.
6. Calculations of the column Efficiency and the number of real stages
7. Calculate the height of the column.
8. Calculate feed stage location using kirbride equation.
9. Calculate column diameter (top and bottom).
10. Selection of liquid – flow arrangement.
11. Provisional plate design.
[Link] calculations.
13. Plate pressure drop (column pressure drop).

33
4.3 Heat exchanger design
4.3.1 Introduction to heat exchanger design:
Heat exchangers are devices that facilitate the exchange of heat between two
fluids that are at different temperatures while keeping them from mixing with
each other. Heat exchangers are commonly used in practice in a wide range
of applications, from heating and air-conditioning systems in a household, to
chemical processing and power production in large plants. Heat exchangers
differ from mixing chambers in that they do not allow the two fluids involved
to mix.
4.3.2The principal types of heat exchanger are:
1- Double - pipe exchanger: the simplest type, used for cooling and heating.
2-Shell and tube exchangers: used for all applications.
3-Plate and frame exchangers (plate heat exchangers): used for heating and
cooling.
4-Plate-fin exchangers.
5- Spiral heat exchangers.
6-Air cooled: coolers and condensers.
7-Direct contact: cooling and quenching.
8-Agitated vessels.
9-Fired heater.
4.3.3 Design procedure:
1-Define the duty: heat-transfer rate, fluid flow-rates, and temperatures.
2- Collect the fluid physical properties required: density, viscosity, and
thermal conductivity.
3-Decide on the type of exchanger to be used.
4-Select a trial value for the overall coefficient, .
5- Calculate the mean temperature difference, .
6- Calculate the area required.

39
4.4 Reactor design:
4.4.1 Introduction to reactor design:
The

48
 Chapter five
Process Control

53
 Chapter six
Safety and Environment

60
[Link] :

the

62
8/

6.

63
3/ .
[Link] Waste residue:

64
 Chapter seven
Plant location and Layout

67
7.1 Introduction
7.1.1 Plant Location and Site Selection:
The geography location of the final plant must be taken into consideration when a
process design is developed.
The location of the plant can have a crucial effect on the profitability of a project,
and the scope for future expansion. Many factors must be considered when selecting
a suitable site. The principal factors to consider are:
7.1.2 Location, with respect to the marketing area:
For materials that are produced in bulk quantities where the cost of the product per
tone is relatively low and the cost of transport represent a significant fraction of the
sales price, the plant should be located close to the primary market. This considera-
tion will be less important for low volume production, high-priced products. In an
international market, there may be an advantage to be gained by locating the plant
within an area with preferential tariff agreements; such as the European Community
(EC).
7.1.3 Raw material supply:
The availability and price of suitable raw materials will often determine the site loca-
tion. Plants producing bulk chemicals are best located close to the source of the ma-
jor raw material.

7.1.4 Transport facilities:

The transport of materials and products to and from the plant will be an overriding
consideration in site selection. If practicable, a site should be selected that is close to
at least two major forms of transport: road, rail, waterway (canal or river), or a sea
port. Road transport is being increasingly used, and is suitable for local distribution
from a central warehouse. Rail transport will be cheaper for the long-distance
transport of bulk chemicals. Air transport is convenient and efficient for the move-
ment of personnel and essential equipment and supplies, and the proximity of the
site to a major airport should be considered.

68
7.1.0Availability of labor:
Labor will be needed for construction of the plant and its operation. Skilled construc-
tion workers will usually be brought in from outside the site area, but there should be
an adequate pool of unskilled labor available locally; and labor suitable for training
to operate the plant. Skilled tradesmen will be needed for plant maintenance. Local
trade union customs and restrictive practices will have to be considered when as-
sessing the availability and suitability of the local labor for recruitment and training.
7.1.6 Availability of utilities:
Chemical processes invariably require large quantities of water for cooling and gen-
eral process use, and the plant must be located near a source of water of suitable
quality. Process water may be drawn from a river, from wells, or purchased from a
local authority. At some sites, the cooling water required can be taken from a river or
lake, or from the sea; at other locations cooling towers will be needed. Electrical
power will be needed at all sites. A competitively priced fuel must be available on
site for steam and power generation. And utilities may include:
- Electricity.
- Steam, for process heating.
- Cooling water.
- Water for general use.
- Demineralized water.
- Compressed air.
- Inert-gas supplies.
- Refrigeration.
- Effluent disposal facilities.
7.1.7 Availability of suitable land:
Sufficient suitable land must be available for the proposed plant and for future ex-
pansion. The land should ideally be flat, well drained and have suitable load-bearing
characteristics. A full site evaluation should be made to determine the need for piling
or other special foundations.

69
7.2 Environmental impact and effluent disposal:
All industrial processes produce waste products, and full consideration must be giv-
en to the difficulties and cost of their disposal. The disposal of toxic and harmful ef-
fluents will be covered by local regulations, and the appropriate authorities must be
consulted during the initial site survey to determine the standards that must be met.
An environmental impact assessment should be made for each new project, or major
modification or addition to an existing process.
7.2.1 Local community considerations:
The proposed plant must fit in with and be acceptable to the local community. Full
consideration must be given to the safe location of the plant so that it does not im-
pose a significant additional risk to the community. On a new site, the local commu-
nity must be able to provide adequate facilities for the plant personnel: schools,
banks, housing, and recreational and cultural facilities.
7.2.2 Climate:
Adverse climatic conditions at a site will increase costs. Abnormally low tempera-
tures will require the provision of additional insulation and special heating for equip-
ment and pipe runs. Stronger structures will be needed at locations subject to high
winds (cyclone/hurricane areas) or earthquakes.
7.2.3 Political and strategic considerations:
Capital grants, tax concessions, and other inducements are often given by govern-
ments to direct new investment to preferred locations; such as areas of high unem-
ployment. The availability of such grants can be the overriding consideration in site
selection .
All the above factors should be considered simultaneously in selecting the optimal
plant location.
7.3 Site Layout:
The physical layout of plant should be design to print co-ordination between the op-
eration of the process equipment and the use of storage and material handling equip-
ment (buildings should be laid out to give the most economical flow of materials and
personnel around the site). Hazardous processes must be located at a safe distance
from other buildings.

70
Consideration must also be given to the future expansion of the site. The ancillary
buildings and services required on a site, in addition to the main processing units
(buildings), will include: :
1/ Storages for raw materials and products: tank farms and warehouses. Maintenance
workshops.-
2/ Stores, for maintenance and operating supplies.
3/ Laboratories for process control.
4/ Fire stations and other emergency services.
5/ Utilities: steam boilers, compressed air, power generation, refrigeration, trans-
former stations.
6/ Effluent disposal plant.
7/ Offices for general administration.
8/ Canteens and other amenity buildings, such as medical centers.
9/ Car parks .
When roughing out the preliminary site layout, the process units will normally be
sited first and arranged to give a smooth flow of materials through the various pro-
cessing steps, from raw material to final product storage. Process units are normally
spaced at least 30 m apart; greater spacing may be needed for hazardous processes.
The location of the principal ancillary buildings should then be decided. They should
be arranged so as to minimize the time spent by personnel in traveling between
buildings .
Administration offices and laboratories, in which a relatively large number of people
will be working, should be located well away from potentially hazardous processes.
Control rooms will normally be located adjacent to the processing units, but with po-
tentially hazardous processes may have to be sited at a safer distance. The sitting of
the main process units will determine the layout of the plant roads, pipe alleys and
drains. Access roads will be needed to each building for construction, and for opera-
tion and maintenance .

71
Utility buildings should be sited to give the most economical run of pipes to and
from the process units. Cooling towers should be sited so that under the prevailing
wind the plume of condensate spray drifts away from the plant area and adjacent
properties. The main storage areas should be placed between the loading and un-
loading facilities and the process units they serve. Storage tanks containing hazard-
ous materials should be sited at least 70 m (200 ft.) from the site boundary.
7.4 Plant Layout:
The economic construction and efficient operation of a process unit will depend on
how well the plant and equipment specified on the process flow-sheet is laid out.
The principal factors to be considered are :
Economic considerations: construction and operating costs
The cost of construction can be minimized by adopting a layout that gives the short-
est ran of connecting pipe between equipment, and the least amount of structural
steel work. However, this will not necessarily be the best arrangement for operation
and maintenance.
7.4.1The process requirements:
An example of the need to take into account process considerations is the need to
elevate the base of columns to provide the necessary net positive suction head to a
pump or the operating head for a thermo siphon Reboiler.
7.4.2 Convenience of operation:
Equipment that needs to have frequent operator attention should be located conven-
ient to the control room. Valves, sample points, and instruments should be located at
convenient positions and heights. Sufficient working space and headroom must be
provided to allow easy access to equipment.
7.4.3 Convenience of maintenance:
Heat exchangers need to be sited so that the tube bundles can be easily withdrawn
for cleaning and tube replacement. Vessels that require frequent replacement of cata-
lyst, packing or cleaning should be located on the outside of buildings. Equipment
that requires dismantling for maintenance, such as compressors and large pumps,
should be placed under cover.

72
7.4.4 Safety:
Blast walls may be needed to isolate potentially hazardous equipment, and confine
the effects of an explosion. At least two escape routes for operators must be provided
from each level in process buildings .
7.4.0 Future expansion:
Equipment should be located so that it can be conveniently tied in with any future
expansion of the process. Space should be left on pipe alleys for future needs, and
service pipes over-sized to allow for future requirements.
7.0 Modular construction:
In recent years there has been a move to assemble sections of plant at the plant man-
ufacturer's site. These modules will include the equipment, structural steel, piping
and instrumentation. The modules are then transported to the plant site, by road or
sea .
The advantages of modular construction are:
1/ Improved quality control.
2/ Reduced construction cost.
3/ Less need for skilled labor on site.
4/ Less need for skilled personnel on overseas sites
Some of the disadvantages are:
5/ Higher design costs.
6/ More structural steel work.
7/ More flanged connections.
8/ Possible problems with assembly, on site.
7.6 General considerations:
Open, structural steelwork, buildings are normally used for process equipment;
closed buildings are only used for process operations that require protection from the
weather .

73
The arrangement of the major items of equipment will usually follow the sequence
given on the process flow-sheet: with the columns and vessels arranged in rows and
the ancillary equipment, such as heat exchangers and pumps, positioned along the
outside.
Other allowance are made for certain types of hazards, certain steps have to be fol-
lowed:
Locating ignition sources up wind (based on prevailing wind description) from
points of possible release of flammable. Materials providing adequate access ways
for the movement of equipment and people inside the processing plant area.
Great precaution should be taken to ensure, the safety of equipment building areas
and people working.
7.6.1 Buildings:
It always as fundamental in the chemical engineering industries that buildings
should be built around the process area, instead of the process being made to fit
building of conventional design.
7.6.2 Plant expansion:
Future expansion of plant should always be kept in mind and allowance is made for
any thought of multiplying the number of units or increasing the size of the prevail-
ing units.
7.6.3 Other services:
A plant must be prepared for the convenience of its employees and general adminis-
trative staff. Room is made for recreational activities such as rest room, cafeteria,
and change room for workers. Providing a medical facility is importance for safety
of employees and to take care of any sudden emergencies that might be happened.
Other important parts needed for plant efficient operation are administrative offices,
laboratories, workshops and stores.
7.6.4 Wind direction:
Wind direction will determine the general of many things. All equipment that spill
flammable should be located down wind. Plant offices, central lab, fire station, pow-
er house, cafeteria, store house, parking, main water pump should be located upwind
side.

74
 7.6.0 Storage facilities:
Tank farms and warehouses that contain non-hazardous, nonflammable and non-
explosive material should be located up wind of the plant. Facilities do not fit with
above category should be located down wind and should be located at least 75m far
from any processing area.
7.7 DHT unit layout:
7.7.1 Scope:

7.7.2 Site of feed storage:

7.7.3 Site of process equipment:

7.7.4 Site of products:

7.8Control room consideration:

Located between tanks and the process with the following considerations:
1. Concrete construction.
2. Wind direction (leakage of gas).
3. Good air conditioning, for computers and other controlling devices.
4. Good lighting.

75
 Chapter eight

Cost Estimation

77
8.1 Introduction :
An acceptable plant design must present a process that is capable of operating under
conditions which will yield a profit. Since net profit equals total income minus all
expenses, it is essential that the chemical engineer be aware of the many different
types of costs involved in manufacturing processes. Economic analysis and cost esti-
mation are done to determine profitability of plant depending on production capacity
of the plant which determined by demand and market survey. Two types of produc-
tion capacities are known.
8.1.1 The actual production capacity:
Which is the capacity achieved at the existing situation.
8.1.2 Installed capacity:
Which can be achieved from a technical point according to equipment specifica-
tions.
A capital investment is required for any industrial process, and determination of the
necessary investment is an important part of a plant design project.
8.2 Factors Affecting Investment and Production Costs :
When a chemical engineer determines costs for any type of commercial process, the-
se costs should be of sufficient accuracy to provide reliable decisions. To accomplish
this, the engineer must have a complete understanding of the many factors that can
affect costs. For example:
Sources of Equipment.
Price fluctuations.
Operating Time and Rate of Production.
Company policies.
Governmental regulations.
And other factors affecting costs and the engineer must keep up-to date of this fac-
tor.

78
8.3 Accuracy of Estimates:
The accuracy of any estimate will depend on the competence of the people involved,
the completeness of the design information, the proper feedback of actual costs, and
the subsequent updating of all cost data. It has been noted before that it takes a while
for an engineer to get a qualitative and quantitative understanding of any process.
This is also true for a cost estimator. For this reason, many companies have the pro-
cess engineers do the capital cost estimating at the preliminary design stages. This
saves time, since a cost estimator does not need to go through this gestation period.
However, the process engineer must then spend some time keeping up with the ad-
vances in cost engineering. He must also receive feedback about the accuracy of his
estimates.
In any profession it is important that the people involved see the results of their
handiwork. If a mistake is made and the person making it never hears about it, he
will probably make it again. Presumably he did what he felt was right the first time,
Why should he change his ways unless he is corrected? For this reason it is im-
portant that each company have a procedure for gathering cost data while the plant is
being built. At its completion an analysis of the costs should be compared with all
the cost estimates made. The estimator should then be apprised of the results, and
some method should be used to update the factors involved in the cost estimates. On-
ly in this way can accurate cost estimating occur. Good cost estimations don’t just
happen. They require careful work and skilled judgment, and they cost money1.

8.4 Capital Investment Cost:

Is calculated according to cost indices as:

79
 Chapter nine
Recommendation and Conclusion

85
9.1 Conclusion
In this research we ....

9.2 Recommendation:
We use in this project real data from practical operation so we recommend to build
new DHT with counties regeneration reactor to reduce cost of regeneration.
According to our study of diesel hydro-treating unit we found the hydrogenation
process suitable to treat most petroleum cuts with respect to cost. So we recommend
in future treating virgin naphtha from CDU.

86
9.2 References

1. J.M. Coulson and J.F. Richardsons, ”Chemical Engineering Vol.1”, Fourth Edi-

tion, Oxford, Boston, Johannesburg, Melboume, New Delhi, and Singapore, 1996

2. J.M. Coulson and J.F. Richard sons, “Chemical Engineering Vol.2” Second Edi-

tion, New York, Toronto, and Germany, 1993.

3. J.M. Coulson and J.F. Richard Songs “Chemical Engineering vol.6”, Second Edi-

tion, New York, 1993.

4. J .[Link] Hust, J.H. Harker, “Process Design Plant”, Mc-Graw-Hill Company,

1979.

5. Khartoum Refinery Company, Operating Rules for Diesel Hydrogenation

Plant,l999

6. L. Bryce Andersen, Leonard [Link], “Introduction to Chemical Engineering”,

Mc-Graw-Hill Company, New York, Toronto, London, 1976.

7. Engineering encyclopedia – Aramco company, 1999.

8. Robert [Link] , hand book of petroleum refining processes , Mc Graw – Hill,

3rd edition ,.

9. W . L Nilsson, Petroleum refinery engineering– 4th edition.

10. Ronald William Missen , Charles , A Mims , Bradley, A Saville. John Willy,

Introduction to chemical reaction engineering and kinetics, & Sons Inc – New York.

87
11. P . Trambouze, Petroleum refining four material and equipments –,

institute France petroleum publications ( I F P ).

[Link] Arnold and Maurice Stewart et al: ''Surface Production Opera-

tions '',Volume 1, Design of Oil-Handing System and Facilities, Gulf P

Web site:

[Link]

13. petroleum refining technology and economics fifth edition

14. M .R. Riazi characterization and properties of petroleum fractions

88