Technical and Economic Analysis of Acrylonitrile Production from Polypropylene

Journal Preproofs Technical and economic analysis of acrylonitrile production from polypropy lene Fatemeh Rezaie Vahid Pirouzfar Afshar Alihosseini PII S2451904919301921 DOI httpsdoiorg101016jtsep2019100463 Reference TSEP 100463 To appear in Thermal Science and Engineering Progress Received Date 22 June 2019 Revised Date 15 December 2019 Accepted Date 15 December 2019 Please cite this article as F Rezaie V Pirouzfar A Alihosseini Technical and economic analysis of acrylonitrile production from polypropylene Thermal Science and Engineering Progress 2019 doi httpsdoiorg101016 jtsep2019100463 This is a PDF file of an article that has undergone enhancements after acceptance such as the addition of a cover page and metadata and formatting for readability but it is not yet the definitive version of record This version will undergo additional copyediting typesetting and review before it is published in its final form but we are providing this version to give early visibility of the article Please note that during the production process errors may be discovered which could affect the content and all legal disclaimers that apply to the journal pertain 2019 Published by Elsevier Ltd 1 Technical and economic analysis of acrylonitrile production from polypropylene Fatemeh Rezaie a Vahid Pirouzfar a Afshar Alihosseini a a Department of Chemical Engineering Islamic Azad University Central Tehran Branch Tehran Iran Abstract In this research we investigate the propylene ammoxidation process which is under the license of Sohio Company as well as its supply and demand production method and economical analysis of acrylonitrile production process Acrylonitrile is a key material in textile plastic and packaging industries as well as automobile manufacturing This research studies the economic aspects of its production process Over time the need for this product has become more sensible due to the enhancement of production and autarky We do not have any acrylonitrile production unit in Iran at this time Some acrylonitrile process simulations and its economic analysis have been carried out with HYSYS and Icarus software respectively then we compared the results with those obtained from COMFAR software in the Persian Gulf Petrochemical Holding Results indicated that this process is economically feasible only in large scale production It is very important to take precautions since hazardous precursors are used in this process Hydrogen cyanate is an extremely hazardous material that is produced as a byproduct in this process There is not any solution for disposal or any usage for this byproduct in Iran Results obtained from Icarus software were more precious and promising compared to desk calculations Comparison of these two production units with different production capacities has indicated that reduction in production rate of return was lower in the large unit and it is better to establish a smaller unit for acrylonitrile production Keywords Economic considerations Simulation Acrylonitrile Production Polypropylene Corresponding author VPirouzfar Tel 98 912 2436110 Email address vpirouzfariauctbacir 2 1 Introduction Advancements in simulation and modeling and availability of optimized process plants have made science engineering and economic considerations feasible and enabled research engineers to make use of simulations for modeling material production and related phenomena and systems 14 Acrylonitrile is a source of actin monomer in various polymeric products it is the most applicable material in production of polymers used in textile fiber production ABS Acrylonitrile butadiene styrene is mostly used as an alternative material to metals in engineering applications Furthermore it has some unique usages as a acrylonitrile polymers due to its reactivity where it affects resistive properties of gas with resistant and highly resistant 510 One of the special applications of acrylonitrile is in the production of carbon fibers utilized in aviation defense and industry These applications include rocket engine nozzles rocket cones and some parts used in airplanes and other transportation vehicles that need to have a lightweight and high strength 9 Acrylonitrile is a precursor in acrylic fibers ABS resins and plastic production processes and plays an important role in production of synthetic and chemical fibers Acrylonitrile production is achieved via oxidation of air propylene and ammonia 1013 Despite the availability of raw materials and also a good consumption market acrylonitrile production units have not yet been established here Acrylonitrile production is not feasible in smallscale and considering the increasing demand we need to establish some largescale production units in the country Propylene and ammonia as the raw materials in acrylonitrile production are extremely hazardous materials and safe methods are required for their usage storage and transportation The petrochemical industry itself is a consumer of acrylonitrile other than downstream consumers and lack of acrylonitrile production units has caused outflow of about 100 million dollars for importing per year 1416 These applications include rocket motor nozzles missile cones and acrylic fiber Acrylonitrile is a key monomer for economic production of different polymers The 5 most important consumption fields are fibers resins polymers intermediates rubber and some other unique applications Also some acrylonitrile copolymers have special applications where gas disinfection is needed with high resistance These resins have direct applications in alcoholic drink bottles and other glass and metallic bottles for drinks Other applications include food industry chemicals agriculture and medical packaging 3 Since acrylonitrile is a highly volatile polar solvent it has extensive applications in liquid extraction from fatty acids and animal and vegetable oils Acrylonitrile as a distilled solvent is applied in the petrochemical industry for olefindiolefin and C4 hydrocarbon extraction 1725 Acrylonitrile was first synthesized by Charles Mohr in 1983 its multistage production equipment was expensive 26 The largest and richest Cyanamid producers in America are Union Carbide Du Point and Monsanto Despite the high production costs acrylonitrile has still remained more interesting than many other chemicals with lower volume and limited applications Sohio carried on some researches on catalytic oxidation which led to some enhancements in acrylonitrile production and resulted in a considerable reduction in production costs in a way that all other acrylonitrile synthesis methods except from acetylene were obsolete 2728 researchers have developed Sohio process with a novel onestage synthesis method that used acrylonitrile as a key precursor for chemicals all over the world Sohio has introduced a rich cheap and high quality acrylonitrile to the market as a result of his innovative experiences and bold engineering which is the main factor in the growth of plastics and acrylic fiber Today almost all acrylonitrile production is achieved via Sohio method 28 Developed Warrenville is used globally in acrylonitrile production units Sohio was a part of British Oil Company PLC in 1987 Everyone deals with acrylonitrile every day It is a key element in acrylic fibers used in fabrics and carpets ABS is a stable material used in the production of automobile elements phones computer covers and sports equipment Nitrile rubber is utilized in hose production for fuel pumping Acrylonitrile is used in production of gas permeable plastics ductile bottles for chemical storage cosmetics and cleaning liquids storage packages for fresh meat and sterile medical equipment and many other products Plastic resins paints adhesives and coatings are also some of its other products Acrylonitrile was discovered during a process and was developed it was introduced by researchers and engineers of Standard Petroleum Company or Sohio which was a part of British Petroleum Company in 1987 29 This is a direct onestep method for synthesis of acrylonitrile from propylene ammonia and water on a catalytic bed Discovery and commercialization of this process were results of talent innovation systematic work and risktaking of Sohio employees Sohio discovery has presented lowcost mass production of 4 acrylonitrile with high purity and considerable enhancement in the production of elastic plastics synthetic fibers and advancements in food packaging industry Today more than 95 of global acrylonitrile is produced by or is under the license of BP 3031 The most powerful factors in future acrylonitrile pricing will be technology advancement and cost of propylene as the raw material Various information might be obtained for acrylonitrile pricing from investment and calculations 17 1 Propylene accounts for 3545 of the acrylonitrile sales price Therefore the extent of reaction reaction progress and propylene cost are key parameters 2 Normally a list of essential commodities utilized in petrochemical plants is an effective parameter in the sales price Some other important parameters are the environment prediction of rising in energy and hydrocarbon raw material cost An increase in Persian Gulf natural gas price will directly increase the acrylonitrile price The increase in ammonia price will indirectly increase the acrylonitrile price but it is more complicated about propylene 32 Some research works on propylene are available in the literature and it seems that polypropylene price of propylene is decreasing as the main product of petrochemicals While large quantities of propylene are used in the production of alkaline revealed gasoline propylene alkalinity has been in a nongasoline cylinder compared to alkylated acetylene 33 In the case of price predictions Professor Robert Stabo has cited 4 effective parameters on the reduction of petrochemical products prices in his statistical study two main effective parameters on reduction of petrochemical products prices in a 17 years period are 1 economic growth and largescale production facilities 2 benefit from production accumulation e g recently introduced catalyst 3 more producers 4 More products are standardized Today there are 60 producers in the United States of America 3437 The importance of high volumes and the propylene pricing shows that other petroleum companies may join Sohio in the production of acrylonitrile and as a result its price will decreases Many other petrochemical 5 companies have attracted petroleum companies and reduced production costs Other petrochemicals are also following this trend Petrochemicals continue to maintain their right position in real price cuts 23 Improvement of production low price of propylene larger factory and threats by new producers will increase other production costs and decrease the real price of acrylonitrile and cause relatively little increase in the product price This price advantage over competing monomers have helped them continue to expand the acrylonitrile derivatives in 1983 2627 Polyacryl Company is the main consumer of acrylonitrile in Iran that uses this material in the production of acrylic fibers The companys annual demand for acrylonitrile is about 60000 tons Acrylonitrile constitutes about minimum 85 of acrylic fibers Acrylic fibers are used in carpets furniture covers and winter tricot dresses and etc Other acrylonitrile consumers are Tabriz Petrochemical Company and 15 Khordad institution with total annual demand of 10000 tons for ABS resin production units Acrylonitrile constitutes about 2426 of these resins Asia is the largest importer and North America is the largest manufacturer of this product 33 The acrylonitrile price has risen dramatically over the past years and was 1921 ton this year Currently all acrylonitrile demand in Iran is supplied through imports It seems that countries that are consuming acrylonitrile about 60000 tonsyear will be able to establish a production unit if they have raw materials Iran is the only country that does not have an acrylonitrile production unit despite the annual requirement of 70000 tons and the availability of raw materials This has led to the outflow of more than 100 million per year Furthermore according to the estimations since raw material price is increasing the lack of acceleration in the implementation of acrylonitrile production units in the country will lead to more currency outflow in the coming years Since two software products with two different outputs have been compared this study has also provided more information about a production unit Such researches and feasibility studies have not been carried out yet in Iran Since two different sofware with different outputs are compared useful information is provided for establishing a production unit COMFAR software was used which is an old method and has been used by some 6 companies so far The other software is called Icarus which is a modern software in this field This study also provides information for a unit to be launched 38 2 Methods simulation and procedures 21 Modeling and evaluating economic processes In this paper Aspen HYSYS v10 software is used for process simulation HYSYS has a userfriendly interface and provides some features for optimization of theoretical operations and design One of the main features of this software is that it is able to handle any engineering issues in different industries HYSYS is so powerful in modeling steadystate conditions In this study NRTL equation of state is used for simulation Fig1 shows a general process simulation and process flow diagram of Acrylonitrile production After modeling the process with HYSYS results are sent to Aspen Capital Cost Estimator software Icarus for economic analysis Aspen Capital Cost Estimator is used to estimate the investment requirements of capital project The pricing basis for this release has been updated to the first quarter 2016 These results were obtained by running a general benchmark project containing a representative mix of equipment found in a facilities Our results are based on the overall mix of equipment bulk items and specified materials of construction contained in our project This software enables the process and mechanical design of heat exchangers and preparation of construction plans evaluation and troubleshooting of available heat exchangers simulation of available heat exchangers and technical and economic estimation for construction of a particular heat exchanger 39 22 Method and equations for economic calculations Equations 17 are used for calculating the rate of return on investment 4041 Total fixedcapital investment fixedcapital investment working capital Startup expense Startup expense is considered as a part of capital investment Startup expenses 01 Capital investment 7 Working capital 015409 Total investment Capital investment Direct costs Indirect costs Total cost of the product 103 Raw material cost facility costs 132 operating labor cost 0103fixedcapital 0025Income5 Gross earnings before tax Income Total cost of the product Rate of return 𝐴𝑛𝑛𝑢𝑎𝑙 𝑟𝑒𝑡𝑢𝑟𝑛 𝑇𝑜𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 100 23 Process Description Ammonia propylene and air are the main feeds of the reaction Liquid ammonia absorbs heat from the hot water side stream and vaporizes Then evaporated ammonia is absorbed by the separator to remove any excess liquid ammonia and recycle it Then ammonia vapor passes through superheated vapor and its temperature increases to 65 C using a low pressure stream Superheated ammonia vapor is fed to the reactor in 65 C with 23 kgcm2 pressure Propylene is supplied in the liquid phase through petrochemical plant pipeline Liquid propylene is directly sent to spray nozzles Propylene turns in to vapor like ammonia and evaporated propylene is removed by separation Preheated propylene vapor is fed into the reactor in 65 C with 25 kgcm2 pressure Air is supplied by an openair compressor driven by a turbine Feed reacts with high pressure vapor in high temperature Saving the electricity is important from economical aspects The compressor supplies air in 52 kgcm2 and under gravity Fluidized bed reactor is used for propylene ammoxidation and production of acrylonitrile via Sohio process The conditions and compositions of feedstock and products are summarized in Tables 1 and 2 3 Results and discussion 31 Technical Evaluation 8 The aim of acrylonitrile production simulation was calculating the rate of return ROR we simulated this process with HYSYS simulation software Diagrams were drawn by Icarus software and are presented in following figures along with dimensions and volume calculations In this software all equipment including tanks pumps are designed and provided in a PID and sizing of all equipment This way we will be able to obtain the price of each equipment considering its current market and then obtain the total cost of the project This process is based on the reaction between propylene ammonia and air as the feed They are fed to the reactor as propylene 98 ammonia and air with 1 126 and 103 ratios Reaction feed consists of liquid propylene ammonia and air after compression in a compressor The effluent of the reactor enters ammonia absorption column The bottom flow of the column ammonia absorption column mainly consists of water and ammonium sulfate including volatile telluric and molybdic acid A part of bottom flow stream enters cooling tower Sulfuric acid is added to the stream to maintain its acidic pH and increase the absorption of gaseous ammonia in reactor effluent The remaining bottom flow of absorption column is sent to ammonia stripping column for separation of organic products and viscous ammonium sulfate solution Inorganic material separation section vapors from the top of the ammonium sulfate stripping column are mixed with vapor from the ammonia absorption column and the resultant stream is returned to the acetonitrile stripping column and is cooled down to 100 C Vapors enter the organic absorption column and are washed with cold water through a countercurrent flow to separate COx N2 and O2 in the form of top vapor The high amount of gas stream produced 300000 lbh cannot be simply vented since it contains negligible amounts of organic materials and HCN It must be incinerated before venting Separation of CAN and water is achieved via azeotropic distillation CAN and water have an azeotrope with a low boiling point which forms two phases organic phase and aqueous phase in 44 C CAN rich phase is sent to an azeotropic distillation column bottom flow consists of CAN with inhibitors and heavy impurities In the final step of purification ACN is separated as the product distillate product The bottom phase which is waterrich enters the stripping column and the remaining CAN leaves aqueous 9 phase as a vapor low boiling azeotropic distillate then water is separated from the bottom The distillate phase is condensed and separated CAN rich upper phase is recycled for CAN recovery Finally HCN is separated and purified 32 Economic Analysis In this case the decision for investment is based on acrylonitrile production by Propylene ammoxidation under the license of Sohio Company Economic analysis is done by the software after the simulation of the process is completed The profitability of the process is analyzed using the rate of return ROR for capacity enhancement In order to calculate this criterion we need to calculate the initial cost of the project as well as the cost of production Main effective parameters on project economics are as follows Capital investment operating costs feed gas costs financing of the project taxes crude oil price prices of acrylonitrile products quality of acrylonitrile products compared to normal products security of gas supplies for the project operation duration product quality inflation rate duration of construction depreciation working life of the unit The equipment installation fees material charge and disciplinewise cost of acrylonitrile production plant are presented in Figs 2 to 5 respectively Also the investments obtained from the software for a unit with a capacity of 70000 tonsyear are summarized in Tables 3 to 8 In these tables the installation or construction cost is the cost of construction on site which includes materials manhour work manpower and miscellaneous expenses In the industry these three operations are referred to as EPC Table 5 and Fig 2 present a detailed list of equipment piping civil reinforcement insolation electrical works tools and painting costs Eventually total cost of the project is obtained from summation of total capital investment fixed indirect costs and fixed direct costs It needs to be mentioned that engineering costs limitations and other miscellaneous costs should be included but they have negligible values Rents and insurance are considered to be zero in these calculations 10 Considering the above calculations as shown in Fig 6 direct investment costs indirect investment costs and the total for acrylonitrile production unit are 19651741 19397615 and 39049356 respectively Obtained values show that acrylonitrile production is economically feasible As shown in diagrams raw material and equipment costs are greater than costs of piping civil and instrument while the cost of man hour needed for piping will be greater considering the time needed for piping Cost of raw materials like oils methanol catalyst and also selling price of biodiesel and glycerin which are byproducts of the biodiesel production process and are used in cosmetics industry are extracted from references and are presented in Table 4 and 5 These values are multiplied by the flow rate to obtain costs of raw materials and income from product sales in yr In order to make all the units identical yr all the costs should be multiplied by the CCF factor The aim of following all these steps is to calculate the rate of return on investment ROR Acrylonitrile production by simulation 9836 Acrylonitrile production in calculations of petrochemical Company 28 Tables 9 and 10 33 Economical investigation of propylenebased acrylonitrile production in PersianGulf Petrochemical Complex Feasibility study of the acrylonitrile production plant is done for implementation of a unit with a capacity of 200000 tonsyear in 1393 In this report desk calculations are done based on SRI documents and methods and principles of technicaleconomic investigations of petrochemical plants by development and chain value management department of Persian Gulf Holding then results are input to Comfar III software final results are presented based on input data and results of this software The simulated unit has 70000 tonyear capacity and will be compared with this 200000 tonyear production unit From the comparison of these two units according to our calculations the capital investments for the 200000 and 70000 tonsyear production units are 424610000 406840000 and 39049356 respectively The total investment cost for 200000 and 70000 tonyear production units will be 435640000 and 51010879 total feed costs will be 280620000 and 97597425 total product values will be 406840000 and 11 120210511 and rates of return on investment ROR will be 208 and 6233 respectively It can be concluded that as the capacity increases rate of return on investment decreases so a small unit would be a better choice As capacity increases costs will increase as well but at the same time profit increases too But it is better to implement smaller units due to the high cost of equipment purchase 5 Conclusion Ammoxidation of propylene and ammonia with air seems to be the best procedure for acrylonitrile production The design of the process based on the standard procedures is available Acrylonitrile is the most important industrial product whose increasing demand according to daily statistics shows that there is between supply and demand in the country for the future there is no chance of increasing the gap if there are several production units Propylene and ammonia as raw materials for acrylonitrile production are extremely hazardous and need to be handled safely during handling transportation and storage Hydrogen cyanide is also a hazardous material and is a side product of this reaction Therefore lots of attention needs to be paid to its handling storage and transportation Here we need a computer analysis to maintain yield and make sure that the product has high quality Acetonitrile byproduct is a good solvent for acetone especially in the extraction of butadiene and other solvents As was mentioned before we carried on a comparative study on economic evaluation of an acrylonitrile project After doing simulation and economic analysis by the software and performing calculations using economic formulas we presented the results and compared them with those obtained from petrochemicals Comparison between these two units shows that capital investment needed for units with 200000 and 70000 tonyr capacities will be 424610000 and 39049356 total capital investment will be 2806 million and 976 million total cost of feed will be 2806 million and 976 million total income from selling the product will be 40684 million and 1202 million and rates of return on investment will be 208 and 6233 respectively Considering this comparisons we conclude that as the capacity increases the rate of return decreases therefore a smaller unit would be a better choice As the capacity increases costs will increase as well and the profit increases too but it is better to choose a smaller unit due to the high costs of equipment This 12 process is suitable to be implemented in Iran but since there are no provisions for handling and disposal of hydrogen cyanide in Iran no action has been taken yet This project might return all the investment in about 5 years Effectively for 330 working days During the implementation of this project safety issues must be considered since materials that you are dealing with them are extremely hazardous and flammable Comparing two methods and calculations of economic analysis by the software with the results obtained from Persian Gulf Petrochemical Holding it can be concluded that software analysis is more accurate and promising compared to the desk calculations Comparing the rate of return in these two units and because of the difference in their volume of production the rate of return per unit is lower in larger units and it is better to choose a smaller unit of acrylonitrile production References 1 Wang M Liu Q Liang Y et al Process Integr Optim Sustain 2019 3 143 httpsdoiorg101007s4166001800603 2 Aviso KB Process Integr Optim Sustain 2018 2 301 httpsdoiorg101007s416600180056 z 3 Atikah MSN Harun R Process Integr Optim Sustain 2019 httpsdoiorg101007s41660 01900807 4 Ng DKS Lakerveld R Process Integr Optim Sustain 2019 3 1 httpsdoiorg101007s4166001900083w 5 Zolfaghari M Pirouzfar V Sakhaeinia H 2017 Technical characterization and economic 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dominance in acrylonitrile downstream Slow growth in most sectors except polyacrylamide Strongest growth in lowvolume consuming industries APIC 2015 DOWNSTREAM SECTOR ANALYSIS Source Tecnon OrbiChem 13 Steady growth in line with economic growth in most regions Chronic overcapacity diminishes profitability Styrene prices guide ABS competitiveness Exchange rate fluctuations disrupt trade flows APIC 2015 ABS MARKET TRENDS Source Tecnon OrbiChem 14 Langvardt P Acrylonitrile Ullmann s Encylopedia of Industrial Chemistry Wiley VCH Weinheim Germany 2002 15 Weissermel K Arpe H J Industrial Organic Chemistry Wiley VCH Weinheim Germany 2003 16 Chen B H Dai Q L Wu D W Modelling a loop fluidized bed reactor for propylene ammoxidation Chem Eng Sci 51 11 298 88 1996 17 Stergiou L Laguerie CF Gilot B Some reactor models for ammoxidation of propylene Chem Eng Sci 39 4 713 1984 18 Godbole S P Acrylonitrile recovery process USP 6054603 2000 14 19 Godbole S P Process for recovering acrylonitrile USP 0181086A1 2004 20 Wu H C Recovery of acrylonitrile by condensation USP 4232519 1980 21 Kirk othmer encyclopedia of chemical technology vol 1P 352369 4th Edition John Wily sons New York1987 22 Ulmanns encyclopedia of industrial chemistryVCH publicationsGermany vol A1P 177 1831985 23 El Halwagi M Pollution Prevention through Process Integration Systematic Design Tools A cademic Press S an Diego CA 1997 24 Midorikawa H Sugiyama N Hinago H Asahi Japan Process for producing acrylonitrile from propane by ammoxidation USP 5973186 1999 25 North American shale gas boom fuels consumption growth Water treatment remains biggest end use but growth is slow APIC 2015 ACRYLAMIDE MARKET TRENDS Source Tecnon OrbiChem 26 Working PK Bentley KS Hurtt ME Mohr KL 1987 Comparison of the dominant lethal effects of acrylonitrile and acrylamide in male Fischer 344 rats Mutagenesis 23215220 27 Smith R Chemical Process Design and Integration John Wiley Chichester 2005 28 Mcketta john J encyclopedia of industrial chemical processing design marcel dekker inc publication 29 D M Considine Chemical and Process Technology Encyclopedia McGraw Hill Book Company P 30 35 1974 30 Perry Robert don green perrys chemical engineers handbook seventh and sixth editionmegrawhill internayinal editions chemical engineering seriesnew York1998 31 Callahan J L Milberg E C Process for preparing olefi nically unsaturated nitriles USP 3230246 1966 32 Coulson J M and Richardson J Fchemical engineeringfirst editionvol 6pergamon pressoxford1983 15 33 Allen D T Shonnard D R Green Engineering Prentice Hall Upper Saddle River NJ USA 2002 34 R B Stobaugh S G Mcti Clark and G D Camirand Hydrocarbon Processing Vol 50 P 109 120 January 1971 35 Roland Nilsson and Arne Andersson Industrial and Engineering Chemistry Research and Development Vol 36 P 52075219 1997 36 J M Berty Chemical Engineering Progress Vol 70 No 5 P 7884 May 1974 37 Guan et al Catalyst for producing acrylonitrileUSP 6596987 2003 38 J L Callahan E C Milaberger R K Grasselli and H A Strecker Industrial and Engineering Chemistry Product Research and Development Vol 9 No 2 P 134142 1970 39 sources SRI in national petrochemical Company Central Library NPC 40 Kerk Othmer encyclopedia of chemical engineering 41 PEP Process economy program YEARBOOK 16 Fig 1 The process simulation with related process flow diagram PFD of Acrylonitrile Production 17 171001 1430367 207256 43457 494727 81906 372193 28447 equipment piping civil steel instrument Electrical Insulation paint Fig 2 the detail of equipment installation costs 18 8941600 2556955 146026 203365 1110455 74658 311697 11331 equipment piping civil steel instrument Electrical Insulation paint Fig 3 The direct costs of various disciplines for process capital cost and material charges 19 9112601 3987322 353286 246823 1605182 156565 683890 39779 equipment piping civil steel instrument Electrical Insulation paint Fig 4 The direct costs of various disciplines for process capital cost and amount of material and installing acrylonitrile process 20 Fig 5 The equipment class charting and the price of each equipment separately 21 3904935600 5101087900 9759742500 12021051100 3362 42461000000 43564000000 28062000000 40684000000 820 Fixed investment cost Investment sum Food collection Product total rate of return Fig 6 The comparison of two production units with capacity of 200 and 70 kilotons 22 Table 1 The conditions of feeds Feed Stream Name Air Propyl ene Boil er feed wate r Ammo nia Sulfu ric Acid WP Pressure barg 0 01 0 5 2 0 5 1 2 Temperat ure C 20 40 20 30 20 20 Mass Flow kgs 5 46 1 1 6 0 445 0 5 24 Std Ideal Liq Vol Flow m3h 36 30 7 60 21 64 5 03 1 57 86 56 Vapor Phase Fraction 1 0 0 0 0 0 Molar Enthalpy kcalkgm ole 104 5 41 480 06 6835 9 96 16962 78 76450 76 6835 9 96 24 Table 2 The condition of products Product Stream Name Heav y liqui d to dispo sal Acid acetoni trile Aqeos residu es to treat ment Acrylo nitril product OF F GA S HP STE AM Pressure barg 1 0 1 1 0 1 0 5 40 Tempera ture C 50 00 10 00 50 00 10 00 59 55 36 23 Mass Flow kgs 0 004 0 056 25 26 0 963 7 85 6 Std Ideal Liq Vol Flow m3h 0 01 0 21 90 90 3 60 53 3 21 64 Vapor Phase Fraction 0 0 0 0 0 99 0 Molar Enthalp y 6785 6 04 62386 89 67973 00 67679 26 819 6809 0 73 26 Table 3 Amount of input material cost Raw material Ammonia Propylene H2SO4 Mass Flow kghr 37148 8844 30502 Cost tone 450 1165 073 Annual Consumption kgyr 30275620 72078600 2485913 Annual Consumption toneyr 3027562 720786 248591 Annual Cost yr 13624029 83971569 1827 27 Table 4 The quantity of products and related plant revenue Product HCN Acetonitrile Acrylonitrile product Mass Flow kghr 1001 596 8863 Price tone 1600 3800 1921 Annual Productio n kgyr 81581 5 48574 72233450 Annual Productio n toneyr 8158 4857 7223345 Annual Revenue yr 130530 184581 138760457 Total Revenue 139075569 28 Table 5 Acrylonitrile Direct Capital Costs Account MH Labor Cost Matl Cost Total Cost 2 Equipment 4026 171001 1031700 0 1048800 1 3piping 3606 6 151638 5 2556955 4073340 4 sivil 7929 266694 169391 436085 5 Steel 1100 43457 203366 246823 6 Instrument s 1324 7 566502 1632090 2198592 7 Electrical 8207 336338 1148893 1485231 8 Insulation 1168 5 372193 311697 683890 9 Paint 908 28447 11331 39779 Direct total 8316 8 330101 7 1635072 3 1965174 1 29 Table 6 Acrylonitrile indirect capital costs Account MH Labor Cost Matl Cost Total Cost Const Equipment indirect 2591800 Const Mgt StaffSupv 11469 1343900 Engineering 44771 5532301 Orher Project costs 1742 2119743 contingency 7809871 Total indirect 57982 19397615 30 Table 7 Acrylonitrile indirect capital costs Account Total Cost Direct totals 19651741 Indirect totals 19397615 project totals 39049355 31 Table 8economic calculations related to the production of acrylonitrile from propylene and the rate of return Accoun t Accou nt Direct 196517 41 216169 15 yr work cap 766609 4 indirect 193976 15 213373 77 yr start up cap 429542 9 fix cap 390493 56 429542 92 yr raw materi al 975974 25 total invesm ent 510108 79 549158 15 yr utility 715904 9 total product 120210 511 120612 719 yr labor cost 225932 9 profit 188650 58 184628 50 yr revenu e 139075 569 ROR 33 62 32 Table 9 summary of financial results for the Persian gulf petrochemicals Synopsis of financial plan review results Fixed investment millions of dollars 42461 Working Capital Operating Million Dollars 1104 Total Investment Million Dollars 43564 Internal Rate of Return 82 33 Table 10 comparison of two production units of 200 k and 70 k tones 200 KT 70 KT Fixed investment cost 424610000 39049356 Investment sum 435640000 51010879 Food collection 280620000 97597425 Product total 406840000 120210511 Rate of return 8 20 33 62 34 The Acrylonitrile production process has been simulated using Aspen HYSYS Prediction of the capital and operating costs were made by Aspen Capital Cost Estimator Comparison of cases conclude that as the capacity increases rate of return decreases The capital investment for unit of 70000 kTy will be 3905 m