GHJK

Technological Institute of the Philippines
PROCESS
SELECTION
219
PROCESS 1
A. PRODUCTION OF ACRYLONITRILE PROPYLENE

AMMOXIDATION PROCESS
I. INTRODUCTION
Sohio process gives highest conversion of propylene (about 98%) with high
selectivity for ACN. The reaction flow diagram is quite simple. It consist of
catalytic, vapor phase, one step conversion operating at a moderate
temperature, ordinary pressures and residence time of a few seconds.
II. REACTION MECHANISM:
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III. PROCESS DESCRIPTION
Ammonia, propylene and air are feed material. Liquid ammonia is

fed to ammonia vaporizer (V-001) in shell side stream via fitter. Vaporized
ammonia is then passed through an entrainment separator (ES-001) to
remove and return any liquid ammonia entertainment.
Vapor ammonia is now passed through super heater (HX-001)

where vapor ammonia is heated to 65°C using low pressure stream.
Superheated ammonia at 65°C is fed to the reactor at pressure 2.3 Kg/cm2
g. Propylene is supplied to plant in liquefied form. This propylene is
vaporized in vaporizer (V-002) as in case of ammonia. Then, vaporized
propylene is now passed through entrainment separator (ES-002) and now
passed through super heater (HX-002) where vapor propylene is heated to
65°C using low pressure stream. It is fed at 2.5 Kg/cm2G pressure to
reactor. Air is sucked from open atmosphere by using an air compressor
(CP-001). The air compressor is run by a steam turbine which is fed with
high pressure steam obtained by using heat of reaction in reactor. The air
compressor provides air at 2.5 Kg/cm2 g pressure.
The reactor (R-001) is a large - diameter cylindrical vessel provided

with a gas - distribution grid for supporting the fluid bed, as well as with
injection devices for feeding the gaseous reactants. The optimal catalyst
particles size is in the range 40 to 100 μ m, in which the presence of a certain
amount of fines is necessary for ensuring homogeneous fluidization. The
gas velocity is slightly above the minimum, in general between 0.4 to 0.5
m/s. Trays or screens, usually between 5 and 15, can be placed transversally
in order to reduce the negative effect of back mixing. This modification
gives much better performance in term of acrylonitrile yield. Because of the
highly exothermal reaction cooling coils are immersed in the fluid bed.
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Since the temperature of reaction is around 420 – 450 ° C high –

pressure steam of 30 to 40 bar can be raised. Overpressures of 0.5 to 2 bar
are preferable. Almost complete conversion of propylene may be seen and
selectivity around 80% in acrylonitrile can be obtained 15% for HCN, 4%
for acetonitrile and 1% for acrolein. The residence time in the reactor is
between 2 and 20 s, with an optimal range from 5 to 10 s longer residence
time gives more byproducts.
The major feed stream to recovery section is the reactor effluent

gases which is partially cooled at 232 °C (HX-003) is introduced to the
bottom of the quench (Q-001) column through a sparger and is adiabatically
cooled down to 85 °C in the lower stage of quench column. The quench
column is made of two sections. At bottom section, water circulation
through proper distributions helps to settle fine catalyst. Whereas at top
section un reacted ammonia is neutralized by reacting with 30 – 40 %
H2SO4 solution distributed by spray spargers and forms 20-25 weight %
Ammonium Sulfate [(NH4)2SO4] solution. The amount of acid is
determined by maintaining pH in the range of 3-4.5. liquid droplets carried
upward by effluent gas will knocked down by demister tray above each
section and returned to the bottom through demister tray liquid down comer.
Solvent water or DM water is sparged at the column top to flush demister
tray and water recycled from the heads column and stripper bottom are fed
to bottom section for flushing tray. Antifoam is added in circulating water
to prevent foaming in the column.
Then, the cleaned gas is cooled to 30 ° C (HX-004) before

absorption. The off - gas is submitted to a first separation of acrylonitrile.
In the decanter the liquid splits into two phases. The aqueous phase is sent
to the acrylonitrile recovery (RC -001). The off - gas from flash is
compressed at 4.5 bar and submitted to absorption (AB-001). To ensure
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high acrylonitrile recovery of 99.5%, cold water at 5 ° C is used. The column

has 10 theoretical stages. A three - phase option is used to account for the
possible occurrence of two - liquid phases with a convergence algorithm for
“strong non ideal liquid”. A design specification is employed to adjust the
water flow rate to achieve 99.5% AN recovery. Flow hrough this circulating
system is regulated toaintain a constant temperature 21 °C in the absorber
bottom.
The residual gas leaving, containing unconverted propene, CO2 and

other VOC, is usually sent directly to flare after catalytic combustion. Next,
the recovery of useful components from the aqueous solution is targeted.
The working assumption is high recovery, over 99.9% for acrylonitrile, and
over 95% for both HCN and acetonitrile as valuable byproducts. An
appropriate separation technique is re-boiled stripping. After top vapor
condensation, phase separation takes place by a L – L split, the water phase
being refluxed in the stripping column, while the organic phase recovers the
acrylonitrile. Simulation shows that 10 theoretical stages are sufficient. The
separation performance can be followed in terms of component split at
variable distillate rate or re boiler duty. One observes that high acrylonitrile
recovery can be obtained rather easily in the top product, while HCN and
acetonitrile have the tendency to pass in the bottom. If the last two species
are waste, the stripping should be conducted at low boil up and lower feed
temperature. If these are to be recovered in top then the re-boiler duty and
feed temperature should increase. The option considered at this stage is full
recovery of AN, HCN and ACN in a single stream for downstream
processing. The raw acrylonitrile stream contains approximately 85%
acrylonitrile and 5% water, the rest being organic impurities, namely HCN,
acroleine and acetonitrile. The bottom stream consists of water with nitrile
impurities and heavies. This stream is further split to 91% for recycling to
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absorption, 2% for recycling to quench and the rest as wastewater. The

highly toxic material can be removed by using multi effect evaporation. The
vapor stream containing light nitriles is condensed and sent to a biological
treatment station.
HC-001 has the target of removing the “heads” including light

impurities as HCN and acroleine. HCN separates easily in top, although
over 99% recovery demands tall columns and a high reflux ratio. The
removal of acroleine is much more difficult. A solution of this problem is
chemical conversion to a heavier species by reaction with HCN. The
reaction may take place in a pretreatment vessel, or directly on the stages of
the distillation column. The water - free acrylonitrile is obtained as bottoms
in the dewatering column (DW-001). Water leaves in top a binary
azeotrope, followed by reflux of organic phase. Since heavy impurities
inevitably appear, a final vacuum distillation (PC-001) of acrylonitrile is
performed in practice before shipping.
The next column (DC-001) handles the separation of

acrylonitrile/acetonitrile binary by extractive distillation. A large amount of
water is necessary to modify the volatility of components. The simulation
indicates a ratio solvent/mixture of 10: 1, which corresponds roughly to the
complete dissolution of acrylonitrile in water. The column has 40
theoretical stages, being simulated as re-boiled stripping.
Raw acetonitrile, namely a binary azeotrope with 20% water,

separates in top. The bottom stream contains water with heavy impurities.
Vacuum distillation (RC-002) at 0.5 bar is adequate to limit the bottom
temperature.
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IV. EQUIPMENT UTILIZED
Table 5.1: Equipment’s for Ammoxidation of Propylene Process
TAG NUMBER EQUIPMENT
1 H-001 Heat Exchanger
4 R-001 Reactor
5 HX-001 Heat Exchanger
6 Q-001 Quencher
7 F-001 Filter
9 AB-001 Gas Absorber 1
10 AB-002 Gas Absorber 2
12 RC-001 Recovery Column
13 D-001 Decanter
14 HC-001 HCN Column
15 PC-001 Product Column
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V. RAW MATERIALS
PROPYLENE
Propylene is a colorless gas with a faint petroleum like odor. It is

shipped as a liquefied gas under its own vapor pressure. For transportation
it may be stench. Contact with the liquid can cause frostbite. It is easily
ignited. The vapors are heavier than air. Any leak can either be liquid or
vapor. It can asphyxiate by the displacement of air. Under prolonged
exposure to fire or intense heat the containers may rupture violently and
rocket. It is used to make other chemicals.
Figure 5.1: Propylene Storage
Acrylonitrile (AN) is commercially produced by a reaction of

propylene and ammonia in the presence of a catalyst. Having both olefinic
(C=C) and nitrile (C-N) groups permits a large variety of reactions and
makes AN a versatile chemical intermediate. The nitrile group can undergo
hydrolysis, hydrogenation, esterification and reduction. Reactions of the
carbon double bond include polymerization, copolymerization,
cyanoethylation, cyclization and halogenation. One of the reasons for the
226
versatility of acrylonitrile is that it can form copolymers with other

unsaturated compounds, such as styrene and butadiene, for example a raw
material for acrylic acid, acrylic esters, acrylic amide in the synthesis of
compounds used for the production of adhesives, anti-oxidants, binders and
emulsifiers.
AMMONIA
Ammonia is a colourless gas with a sharp, penetrating odour. Its

boiling point is −33.35 °C (−28.03 °F), and its freezing point is −77.7 °C
(−107.8 °F). It has a high heat of vaporization (23.3 kilojoules per mole at
its boiling point) and can be handled as a liquid in thermally insulated
containers in the laboratory. (The heat of vaporization of a substance is the
number of kilojoules needed to vaporize one mole of the substance with no
change in temperature.) The ammonia molecule has a trigonal pyramidal
shape with the three hydrogen atoms and an unshared pair of electrons
attached to the nitrogen atom. It is a polar molecule and is highly associated
because of strong intermolecular hydrogen bonding.
Figure 5.2: Ammonia Storage Tank
227
VI. PLANT ECONOMY
The total capital investment and the annual production rate calculations for
the Ammoxidation process are shown in this section.
TOTAL CAPITAL INVESTMENT
Estimated fixed capital cost is calculated using the Lang Method, factor
from Perry’s Chemical Engineers’ Handbook 8th Ed.
Table 5.2: Lang Factors (Green & Perry, 2008)
Type of plant Fixed capital Total capital

investment investment
Solid processing 4.0 4.7
Solid-fluid 4.3 5.0
processing
Fluid processing 5.0 6.0
Source: M. S. Peters, K. D. Timmerhaus, and R. West, Plant Design and
Economics for Chemical Engineers, 5th ed., McGraw-Hill, New York, 2004.
228
Table 5.3: Cost of Equipment for Ammoxidation of Propylene Process
Delivered PCE
Equipment
= DEC x
Equipment Quantity
Cost (Php) factor
(DEC)
Storage Tank 6 ₱ 6,682,500 ₱ 33,412,500
Heat Exchanger 6 ₱ 8,910,000 ₱ 44,550,000
Fluidized Bed Reactor 1 ₱ 10,154,000 ₱ 50,770,000
Quencher 1 ₱ 4,950,000 ₱ 24,750,000
Absorber 2 ₱ 148,500 ₱ 742,500
Recovery Column 1 ₱ 79,200,000 ₱ 396,000,000
Distillation Column 2 ₱ 9,900,000 ₱ 49,500,000
Total Purchased Cost of Equipment

₱ 126,954,200 ₱ 634,771,000
(PCE)
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Table 5.4: Estimation of Fixed Capital Cost (Sinnot R. K., 2005)
Item Process type

Fluids Fluids- Solid
solids s
1. Major equipment, total purchase PCE PCE PCE
cost
ƒ1 Equipment erection 0.4 0.45 0.50
ƒ2 Piping 0.70 0.45 0.20
ƒ3 Instrumentation 0.20 0.15 0.10
ƒ4 Electrical 0.10 0.10 0.10
ƒ5 Building, process 0.15 0.10 0.05
*ƒ6 Utilities 0.50 0.45 0.25
*ƒ7 Storages 0.15 0.20 0.25
*ƒ8 Site development 0.05 0.05 0.05
*ƒ9 Ancillary building 0.15 0.20 0.30
2. Total physical plant cost (PPC)
𝑷𝑷𝑪 = 𝑷𝑪𝑬(𝟏 + ƒ𝟏 + ⋯ + ƒ𝟗 )
= 𝑷𝑪𝑬 𝒙 3.40 3.15 2.80
ƒ10 Design and Engineering 0.30 0.25 0.20
ƒ11 Contractor’s fee 0.05 0.05 0.05
ƒ12 Contingency 0.10 0.10 0.10
𝑭𝒊𝒙𝒆𝒅 𝒄𝒂𝒑𝒊𝒕𝒂𝒍
= 𝑷𝑷𝑪 (𝟏(𝟏 + ƒ𝟏𝟎
+ ƒ𝟏𝟏 + ƒ𝟏𝟐 )
= 𝑷𝑪𝑬 𝒙 1.45 1.40 1.35
*Omitted for minor extensions or additions to existing sites
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PPC = PCE(1 + f1 + f2 + f3 + f4 + f5 + f6 + f7 + f8 + f9 )
𝑃𝑃𝐶 = ₱634,771,000(1 + 0.4 + 0.7 + 0.2 + 0.10 + 0.15 + 0.5 + 0.15
+ 0.05 + 0.15)
𝑃𝑃𝐶 = ₱ 2,158,221,400
FIXED CAPITAL COST (FCC)

𝐹𝐶𝐶 = 𝑃𝑃𝐶 (1 + 0.3 + 0.05 + 0.10)
𝐹𝐶𝐶 = ₱2,158,221,400(1 + 0.3 + 0.05 + 0.10)
𝑭𝑪𝑪 = ₱ 3,129,421,030
WORKING CAPITAL COST (WCC):

𝑊𝐶𝐶 = 𝐹𝐶𝐶(0.05)
𝑊𝐶𝐶 = ₱ 3,129,421,030 (0.05)
𝑊𝐶𝐶 = ₱ 156,471,051.5
TOTAL CAPITAL INVESTMENT (TCI):

𝑇𝐶𝐼 = 𝐹𝐶𝐶 + 𝑊𝐶𝐶
𝑇𝐶𝐼 = ₱3,129,421,030 + ₱156,471,051.5
𝑻𝑪𝑰 = ₱ 𝟑, 𝟐𝟖𝟓, 𝟖𝟑𝟐, 𝟎𝟖𝟐
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FIXED COSTS CALCULATION:
MAINTENANCE COST:
Maintenance Cost = (0.10)(FCC)
Maintenance Cost = (0.10)( ₱3,285,832,082)
𝐌𝐚𝐢𝐧𝐭𝐞𝐧𝐚𝐧𝐜𝐞 𝐂𝐨𝐬𝐭 = ₱ 328,583,208.2
OPERATING LABOR COST (OLC):
For a plant capacity of 58 tons of product per day, and having average
conditions, the estimated operating labor requirement is 60 employee-
hours/day/processing step. Considering a 300 days’ annual operation and
3 processing steps:
Figure 5.3: Operating labor requirements for chemical process industries

(Peters & Timmerhaus, 1991)
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Table 5.5: Latest Wage Orders and Implementing Rules Issued by the
Regional Boards as of March 2017 (Department of Labor and
Employment, 2017)
INDICATOR SECTOR
Non- Agriculture Retail &

Agriculture Service
Plantation Non-
Establishments
Plantation
Employing
Not More
Than 10
Workers
CAR PHP 300 PHP PHP PHP 270.00

290.00 285.00
Calculating for the operating labor costs using the data for manpower:
Operating labor cost

60 𝑒𝑚𝑝𝑙𝑜𝑦𝑒𝑒 − ℎ𝑜𝑢𝑟𝑠 300 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑑𝑎𝑦𝑠 𝑃ℎ𝑝 300
=( )( )( )
𝑑𝑎𝑦 − 𝑝𝑟𝑜𝑐𝑒𝑠𝑠𝑖𝑛𝑔 𝑠𝑡𝑒𝑝 𝑦𝑒𝑎𝑟 𝑒𝑚𝑝𝑙𝑜𝑦𝑒𝑒 − 8 ℎ𝑜𝑢𝑟𝑠
(3𝑝𝑟𝑜𝑐𝑒𝑠𝑠𝑖𝑛𝑔 𝑠𝑡𝑒𝑝𝑠)(1 𝑦𝑟 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛)
𝐎𝐩𝐞𝐫𝐚𝐭𝐢𝐧𝐠 𝐥𝐚𝐛𝐨𝐫 𝐜𝐨𝐬𝐭 = 𝐏𝐡𝐩 𝟏𝟔, 𝟐𝟎𝟎, 𝟎𝟎𝟎. 𝟎𝟎
233
Figure 5.4: Costing and Project Evaluation
LABORATORY COST:
Laboratory Cost = (0.23)(OLC)
Laboratory Cost = (0.23)(₱ 16,200,000.00 )
𝐋𝐚𝐛𝐨𝐫𝐚𝐭𝐨𝐫𝐲 𝐂𝐨𝐬𝐭 = ₱ 𝟑, 𝟕𝟐𝟔, 𝟎𝟎𝟎
234
SUPERVISION COST:
Supervision Cost = (0.20)(OLC)
Supervision Cost = (0.20)(₱ 16,200,000.00)
𝐒𝐮𝐩𝐞𝐫𝐯𝐢𝐬𝐢𝐨𝐧 𝐂𝐨𝐬𝐭 = ₱𝟑, 𝟐𝟒𝟎, 𝟎𝟎𝟎
PLANT OVERHEADS:
Plant Overheads = (0.50)(OLC)
Plant Overheads = (0.50)(₱ 16,200,000.00)
𝐏𝐥𝐚𝐧𝐭 𝐎𝐯𝐞𝐫𝐡𝐞𝐚𝐝𝐬 = ₱𝟖, 𝟏𝟎𝟎, 𝟎𝟎𝟎
CAPITAL CHARGES:
Capital Charges = (0.10)(FCC)
Capital Charges = (0.10)(₱3,129,421,030)
𝐂𝐚𝐩𝐢𝐭𝐚𝐥 𝐂𝐡𝐚𝐫𝐠𝐞𝐬 = ₱312,942,103.00
LOCAL TAXES:
Local Taxes = (0.20)(𝐹𝐶𝐶)
Local Taxes = (0.20)(₱3,129,421,030)
𝐋𝐨𝐜𝐚𝐥 𝐓𝐚𝐱𝐞𝐬 = ₱ 𝟔𝟐𝟓, 𝟖𝟖𝟒, 𝟐𝟎𝟔. 𝟎𝟎
235
INSURANCE:
Insurance = (0.01)(FCC)
Insurance = (0.01)(₱3,129,421,030)
𝐈𝐧𝐬𝐮𝐫𝐚𝐧𝐜𝐞 = ₱ 31,294,210.30
LICENSE FEE/ROYALTY FEES:
Licence Fee/Royalty Fees = (0.01)(FCC)
Licence Fee/Royalty Fees = (0.01)(₱3,129,421,030)
𝐋𝐢𝐜𝐞𝐧𝐜𝐞 𝐅𝐞𝐞/𝐑𝐨𝐲𝐚𝐥𝐭𝐲 𝐅𝐞𝐞𝐬 = ₱31,294,210.30
𝐅𝐈𝐗𝐄𝐃 𝐂𝐎𝐒𝐓𝐒 = 𝐌𝐂 + 𝐎𝐋𝐂 + 𝐋𝐂 + 𝐒 + 𝐏𝐎 + 𝐂𝐂 + 𝐋𝐓 + 𝐈 + 𝐋𝐅
FIXED COSTS
= ₱ 328,583,208.2 + ₱16,200,000.00 + ₱3,726,000
+ ₱3,240,000 + ₱8,100,000 + ₱312,942,103.00
+ ₱625,884,206.00 + ₱31,294,210.30
+ ₱31,294,210.30
𝐅𝐈𝐗𝐄𝐃 𝐂𝐎𝐒𝐓𝐒 = ₱𝟏, 𝟑𝟔𝟏, 𝟐𝟔𝟑, 𝟗𝟑𝟕. 𝟖𝟎
236
VARIABLE COSTS:
MISCELLANEOUS OPERATING MATERIALS (MOM):
MOM = 0.10(Maintenance Cost)
MOM = 0.10( ₱328,583,208.2)
𝐌𝐎𝐌 = ₱3,2858,320.82
Variable Cost = MOM
𝐕𝐀𝐑𝐈𝐀𝐁𝐋𝐄 𝐂𝐎𝐒𝐓 = ₱32,858,320.82
DIRECT PRODUCTION COST (DPC):
DPC = Variable Cost + Fixed Cost
DPC = ₱32,858,320.82 + ₱1,361,263,937.80
𝐃𝐏𝐂 = ₱𝟏, 𝟑𝟗𝟒, 𝟏𝟐𝟐, 𝟐𝟓𝟗
INDIRECT PRODUCTION COST (IPC):
SALES EXPENSE:
Sales Expense = 0.20(Variable Cost + Fixed Cost)
Sales Expense = 0.20(₱1,394,122,259)
𝐒𝐚𝐥𝐞𝐬 𝐄𝐱𝐩𝐞𝐧𝐬𝐞 = ₱𝟐𝟕𝟖, 𝟖𝟐𝟒, 𝟒𝟓𝟏. 𝟕
237
GENERAL OVERHEADS:
General Overheads = 0.30(Variable Cost + Fixed Cost)
General Overheads = 0.30(₱1,394,122,259)
𝐆𝐞𝐧𝐞𝐫𝐚𝐥 𝐎𝐯𝐞𝐫𝐡𝐞𝐚𝐝𝐬 = ₱𝟒𝟏𝟖, 𝟐𝟑𝟔, 𝟔𝟕𝟕. 𝟔
IPC = Sales Expense + General Overheads
IPC = ₱278,824,451.7 + ₱418,236,677.6
𝐈𝐏𝐂 = ₱𝟔𝟗𝟕, 𝟎𝟔𝟏, 𝟏𝟐𝟗. 𝟑
ANNUAL PRODUCTION COST (APC):
APC = IPC + DPC
APC = ₱697,061,129.3 + ₱1,394,122,259
𝐀𝐏𝐂 = ₱𝟐, 𝟎𝟗𝟏, 𝟏𝟖𝟑, 𝟑𝟖𝟖
238
ANNUAL PRODUCTION RATE (APR):
₱𝟐, 𝟎𝟗𝟏, 𝟏𝟖𝟑, 𝟑𝟖𝟖

APR =
58 MT 300 working days
( )( )
day year
₱𝟏𝟐𝟎, 𝟏𝟖𝟐. 𝟗𝟓
APR =
𝐌𝐓
The annual production cost required for the plant to produce 58

MT/day of Acrylonitrile through ammoxidation process is estimated to be
₱2,091,183,388. Most of the amounts were allotted for direct production
cost. The estimates were made without the utilities costs that account for the
₱120,182.95/MT annual production rate.
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VII. MANUFACTURABILITY
PURITY
The acrylonitrile obtained from the ammoxidation process has a purity of

99.5%.
YIELD
The acrylonitrile obtained from the ammoxidation process has a product

yield of 80%.
BY-PRODUCTS
The by-product of the ammoxidation process are Hydrogen Cyanide

(HCN) and Acetonitrile (AN).
PROCESS USAGE
The production of acrylonitrile through ammoxidation process is

being used by different plants around the world such as Bayer AG in
Germnay, Shantou Xilong chemical co., ltd. In China.
240
VIII. SUSTAINABILITY
Propylene and Ammonia play the key raw materials in the

production of acrylonitrile by ammoxidation process. It is deemed vital that
these raw materials have an adequate supply in the Philippines since it will
be a major concern for selecting the best process to use. The possible
companies where the raw materials could be purchased here in the
Philippines is presented below:
A. Propylene
Some of the manufacturing plants of propylene in the Philippines are the

following:
 Pilipinas Shell Petroleum Corporation

Address: 156 Valero Street, Salcedo Village, Makati City, 1227,
Metro Manila
Website: http://pilipinas.shell.com.ph/
Landline: (063) 257 4961
 Philippine Polypropylene Incorporated

Address: 40, San Miguel Avenue, Mandaluyong, 1550 Metro
Manila
Website:https://www.bloomberg.com/research/stocks/private/snaps
hot.asp?privcapId=222843901
Landline: (02) 884 9200
241
 JG Summit Petrochemicals Group

Address: Barangay Simlong, Batangas City
Website: http://jgspetrochem.com/
Landline: +632 397 2674
B. Ammonia
Some of the manufacturing plants of ammonia in the Philippines are the

following:
 Linde Philippine Inc.

Address: 24 Emerald Ave, San Antonio, Pasig, 1605 Metro Manila
Website: http://www.linde.com/en/index.html
Landline: (02) 702 7500
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IX. SAFETY
Table 5.6: Equipment Parameters for Ammoxidation of Propylene Process
EQUIPMENT TEMPERATURE PRESSURE

(oC) (atm)
H-001 65 1
H-002 65 1
R-001 420 2.0265
H-001 220 1
Q-001 450 1
HX-001 30 1
HX-002 85 1
HX-003 5 1
AB-001 20 1
RC-001 82.7 1.1
HC-001 75.2 1.013
PC-001 128.2 0.5
243
Two of the equipment requires high operating temperature. The

reactor which is operating at 420 oC and 2 atm, and the Quencher that is
operating at 450 oC and 1 atm. Personal protective equipment for heat is
required when going to the area near the equipment.
Toxicity level
Table 5.7: Toxicity Level for Ammoxidation of Propylene Process
Measure Raw Materials
Propylene Ammonia
Severity of Immediate 1 1
Effects
Sensitization Level 0 0
Carcinogenicity Level 0 0
Reproduce Toxicity 0 0
Level
Severity of Chronic 0 2
Effects
Subtotal 1 3
Total 4
244
X. Environmental Impact
In Ammoxidation process the by products are Hydrogen Cyanide

which will be in a small amount that will be further treated and contained,
the other by product is Acetonitrile that will also be stored and if possible
be marketed from other manufacturers. The heavy impurities that is in the
wastewater system will be also further treated.
245
PROCESS 2
PRODUCTION OF ACRYLONITRILE BY ACETYLENE – HCN

ROUTE
I. INTRODUCTION
It is the another industrial pathway developed by Bayer and

commercially operated by American DuPont, Goodrich, Knapsack, and
Monsanto involved the CuCl-NH4Cl catalyzed addition of HCN to
acetylene at 70-80°C: At the end of the sixties, the Monsanto and Cyanamid
plants were shut down. Consequently at the beginning of the seventies less
than 1% of the total acrylonitrile production was manufactured according
to this route.
II. REACTION MECHANISM
Single-step, homogeneously Catalyzed hydrocyanation in the liquid phase.
Reaction
246
Acrylonitrile is produced by the reaction of acetylene and hydrogen

cyanide in the presence of a catalyst under either liquid or vapor-phase
conditions.
Acetylene and hydrogen cyanide in a molar ration of 10 to 1 are feed

into a rubber lined cylindrical reactor (R-101) that is kept about two thirds
full of catalyst solution. The aqueous solution contains 26 per cent cuprous
chloride (based on the weight of dissolved copper). The catalyst may be
used to produce approximately 20 kg of acrylonitrile per kg of dissolved
copper before regeneration. This may be conveniently accomplished by
precipitating the copper with zinc and reconverting to cuprous chloride. The
aqueous catalyst solution is maintained at a temperature of 70°C, and the
reactor (R-101) is operated at essentially atmospheric pressure.
The reaction gases from the top of the reactor contain acrylonitrile,
unreacted acetylene, 1 to 3 per cent hydrogen cyanide, and small amounts
of numerous byproducts such as acetaldehyde, vinyl acetylene, divinyl
acetylene, vinyl chloride, cyanbutadiene, lactonitrile, and chloroprene. The
gases are washed counter currently with water in a scrubber (S-101), which
removes the acrylonitrile, hydrocyanic acid, and some of the by-products.
The washed gases are recycled to the reactor.
The water solution, containing about 1.5 per cent acrylonitrile, is

steam-distilled in a column (C-101) to give 80 per cent acrylonitrile. The
crude product is fractionated in a series of columns to yield 99 percent pure
acrylonitrile. The yield based on acetylene is about 80 percent and is
somewhat higher (90 to 95 per cent) based on hydrocyanic acid. The
greatest losses in yield arise from formation of vinyl acetylenes and their
derivatives. Various patents cover removal of vinyl acetylenes from the
247
liquid phase before distilling acrylonitrile (C-102) and from the gaseous
phase prior to recycling acetylene.
The vapor-phase process involves passing a mixture of equal

volumes of acetylene and hydrogen cyanide over a fixed metallic cyanide
catalyst (suspended on an inert carrier) at temperatures of 400 to 500°C.
The gaseous reactants may be diluted with steam or inert gases to improve
the yield, but it is still reported to be rather low. The addition of an acidic
substance, such as phosphoric acid, to the crude reaction product entering
the column is said to reduce secondary reactions and increase the yield of
acrylonitrile.
Table 5.8: Equipment’s for Acetylene and HCN Route Process
TAG NUMBER EQUIPMENT
1 R-101 Reactor
2 S-101 Scrubber
3 C-101 Recovery Column
4 C-102 Distillation
Column
5 A-101 Decanter
TOTAL NUMBER OF EQUIPMENT: 5
248
V. RAW MATERIALS
HYDROGEN CYANIDE
Hydrogen cyanide (HCN), sometimes called prussic acid, is a

chemical compound with the chemical formula HCN. It is a colorless,
extremely poisonous and inflammable liquid that boils slightly above room
temperature, at 25.6 °C (78.1 °F).HCN is produced on an industrial scale
and is a highly valuable precursor to many chemical compounds ranging
from polymers to pharmaceuticals.
Hydrogen cyanide is an excellent solvent for many salts, but it is not

widely used as a solvent because of its toxicity. In pure form, hydrogen
cyanide is a stable compound, but it polymerizes readily in the presence of
basic substances, such as ammonia or sodium cyanide. The salts are used in
the extraction of ores, in electrolytic processes, and in the treatment of steel.
Figure 5.5: HCN Storage Tank
249
ACETYLENE
Acetylene, also called Ethyne, the simplest and best-known member

of the hydrocarbon series containing one or more pairs of carbon atoms
linked by triple bonds, called the acetylenic series, or alkynes. It is a
colourless, inflammable gas widely used as a fuel in oxyacetylene welding
and cutting of metals and as raw material in the synthesis of many organic
chemicals and plastics; its chemical formula is C2H2.
Pure acetylene is a colourless gas with a pleasant odour; as prepared

from calcium carbide it usually contains traces of phosphine that cause an
unpleasant garliclike odour. Acetylene can be decomposed to its elements
with the liberation of heat. The decomposition may or may not give rise to
explosion, depending on conditions. Pure acetylene under pressure in
excess of about 15 pounds per square inch or in liquid or solid form
explodes with extreme violence.
Figure 5.6: Acetylene Tank
250
CUPROUS CHLORIDE
Cuprous chloride is a whitish to grayish solid that occurs as the

mineral nantokite. It is usually prepared by reduction of copper (II) chloride
with metallic copper. The pure compound is stable in dry air. Moist air
converts it to a greenish oxygenated compound, and upon exposure to light
it is transformed into copper (II) chloride. It is insoluble in water but
dissolves in concentrated hydrochloric acid or in ammonia because of the
formation of complex ions. Cuprous chloride is used as a catalyst in a
number of organic reactions, notably the synthesis of acrylonitrile from
acetylene and hydrogen cyanide; as a decolourizing and desulfurizing agent
for petroleum products; as a denitrating agent for cellulose; and as a
condensing agent for soaps, fats, and oils.
Figure 5.7: Copper(II) Chloride
251
VI. PLANT ECONOMY
the HCN route process are shown in this section.

from Perry’s Chemical Engineers’ Handbook 8th Ed. From Table 6.2 the
Lang factor for fluid processing is 5.
Table 5.9: Cost of Equipment for Acetylene and HCN Route Process
Equipment Quantity Delivered PCE
Equipment
= DEC x
Cost (Php) factor
(DEC)
Storage Tank 3 ₱ 6,682,500 ₱ 33,412,500
Scrubber 1 ₱ 4,925,250 ₱ 24,626,250
Recovery Column 1 ₱ 2,475,000 ₱ 12,375,000
Decanter 1 ₱ 2,970,000 ₱ 14,850,000
Total Purchased Cost of Equipment ₱ 20,517,750 ₱

(PCE) 102,588,750
252
From Table 5.4 the values for estimation of fixed capital cost for fluid
process are shown.
𝑃𝑃𝐶 = ₱102,588,750(1 + 0.4 + 0.7 + 0.2 + 0.10 + 0.15 + 0.5 + 0.15
+ 0.05 + 0.15)
𝑷𝑷𝑪 = ₱ 𝟑𝟒𝟖, 𝟖𝟎𝟏, 𝟕𝟓𝟎

𝐹𝐶𝐶 = 𝑃𝑃𝐶 (1 + 0.3 + 0.05 + 0.10)
𝐹𝐶𝐶 = ₱348,801,750(1 + 0.3 + 0.05 + 0.10)
𝑭𝑪𝑪 = ₱ 𝟓𝟎𝟓, 𝟕𝟔𝟐, 𝟓𝟑𝟕. 𝟓

𝑊𝐶𝐶 = ₱ 505,762,537.5(0.05)
𝑾𝑪𝑪 = ₱ 𝟐𝟓, 𝟐𝟖𝟖, 𝟏𝟐𝟔. 𝟖𝟖

𝑇𝐶𝐼 = ₱505,762,537.5 + ₱25,288,126.88
𝑻𝑪𝑰 = ₱ 𝟓𝟑𝟏, 𝟎𝟓𝟎, 𝟔𝟔𝟒. 𝟒
253
MAINTENANCE COST:
Maintenance Cost = (0.10)( ₱505,762,537.5)
For a plant capacity of 58 tons of product per day and having average
conditions, from Figure 5.3 the estimated operating labor requirement is 60
employee-hours/day/processing step. Considering a 300 days’ annual
operation and 3 processing steps:
From Table 5.5 the wage for non – agriculture sector is PHP 300

=( )( )( )
254
From Figure 5.4 for the costing and project evaluation
LABORATORY COST:
Laboratory Cost = (0.23)(₱ 16,200,000.00 )
SUPERVISION COST:
PLANT OVERHEADS:
Plant Overheads = (0.50)(₱ 16,200,000.00)
255
CAPITAL CHARGES:
Capital Charges = (0.10)(₱505,762,537.5)
𝐂𝐚𝐩𝐢𝐭𝐚𝐥 𝐂𝐡𝐚𝐫𝐠𝐞𝐬 = ₱ 𝟓𝟎, 𝟓𝟕𝟔, 𝟐𝟓𝟑. 𝟕𝟓
LOCAL TAXES:
Local Taxes = (0.20)(₱505,762,537.5)
𝐋𝐨𝐜𝐚𝐥 𝐓𝐚𝐱𝐞𝐬 = ₱ 𝟏𝟎𝟏, 𝟏𝟓𝟐, 𝟓𝟎𝟕. 𝟓
INSURANCE:
Insurance = (0.01)(₱505,762,537.5)
𝐈𝐧𝐬𝐮𝐫𝐚𝐧𝐜𝐞 = ₱ 𝟓𝟎𝟓𝟕𝟔𝟐𝟓. 𝟑𝟕𝟓
Licence Fee/Royalty Fees = (0.01)(₱505,762,537.5)
𝐋𝐢𝐜𝐞𝐧𝐜𝐞 𝐅𝐞𝐞/𝐑𝐨𝐲𝐚𝐥𝐭𝐲 𝐅𝐞𝐞𝐬 = ₱ 𝟓𝟎𝟓𝟕𝟔𝟐𝟓. 𝟑𝟕𝟓
256
FIXED COSTS
= ₱ 50,576,253.75 + ₱16,200,000.00
+ ₱3,726,000 + ₱3,240,000 + ₱8,100,000
+ ₱50,576,253.75 + ₱101,152,507.5
+ ₱5,057,625.375 + ₱5,057,625.375
𝐅𝐈𝐗𝐄𝐃 𝐂𝐎𝐒𝐓𝐒 = ₱ 𝟐𝟒𝟑, 𝟔𝟖𝟔, 𝟐𝟔𝟓. 𝟖
VARIABLE COSTS:
MOM = 0.10( ₱50,576,253.75)
𝐌𝐎𝐌 = ₱ 𝟓, 𝟎𝟓𝟕, 𝟔𝟐𝟓. 𝟑𝟕𝟓
Variable Cost = MOM
𝐕𝐀𝐑𝐈𝐀𝐁𝐋𝐄 𝐂𝐎𝐒𝐓 = ₱ 𝟓, 𝟎𝟓𝟕, 𝟔𝟐𝟓. 𝟑𝟕𝟓
DPC = ₱ 5,057,625.375 + ₱ 243,686,265.8
𝐃𝐏𝐂 = ₱ 𝟐𝟒𝟖, 𝟕𝟒𝟑, 𝟖𝟗𝟏. 𝟐
257
SALES EXPENSE:
Sales Expense = 0.20(₱ 248,743,891.2)
𝐒𝐚𝐥𝐞𝐬 𝐄𝐱𝐩𝐞𝐧𝐬𝐞 = ₱ 𝟒𝟗, 𝟕𝟒𝟖, 𝟕𝟕𝟖. 𝟐𝟒
GENERAL OVERHEADS:
General Overheads = 0.30(₱248,743,891.2)
𝐆𝐞𝐧𝐞𝐫𝐚𝐥 𝐎𝐯𝐞𝐫𝐡𝐞𝐚𝐝𝐬 = ₱ 𝟕𝟒, 𝟔𝟐𝟑, 𝟏𝟔𝟕. 𝟑𝟔
IPC = ₱278,824,451.7 + ₱74,623,167.36
𝐈𝐏𝐂 = ₱ 𝟑𝟓𝟑, 𝟒𝟒𝟕, 𝟔𝟏𝟗. 𝟏
APC = IPC + DPC
APC = ₱ 353,447,619.1 + ₱248,743,891.2
𝐀𝐏𝐂 = ₱ 𝟔𝟎𝟐, 𝟏𝟗𝟏, 𝟓𝟏𝟎. 𝟑
258
₱𝟔𝟎𝟐, 𝟏𝟗𝟏, 𝟓𝟏𝟎. 𝟑

APR =
( )( )
day year
₱𝟑𝟒, 𝟔𝟎𝟖. 𝟕𝟏
APR =
𝐌𝐓

MT/day of Acrylonitrile through Acetylene and HCN route process is
estimated to be ₱ 602,191,510.3. Most of the amounts were allotted for
direct production cost. The estimates were made without the utilities costs
that account for the ₱ 34,608.71.017 /MT annual production rate.
259
VII. MANUFACTURABILITY
PURITY
The acrylonitrile obtained from the HCN route process has a purity of 95%.
YIELD
The acrylonitrile obtained from the HCN route process has a product yield
of 80%.
BY-PRODUCTS
The by-product of the HCN route process are the light and heavy impurities
that is within the waste water, which can be treated.
PROCESS USAGE
The production of acrylonitrile using HCN route process is often used in the
industry because of the low yield capacity of the process to produce
acrylonitrile.
260
Acetylene, Hydrogen Cyanide and Cuprous chloride play the

key raw materials in the production of acrylonitrile by ammoxidation
process. It is deemed vital that these raw materials have an adequate supply
in the Philippines since it will be a major concern for selecting the best
process to use. The possible companies where the raw materials could be
purchased here in the Philippines is presented below:
A. Acetylene
Some of the manufacturer of acetylene in the Philippines are the

following:
 Air Liquide Philippines Inc.

Address: 12F Ecotower, 32nd St. cor. 9th Ave. Bonifacio Global
City, Taguig City
Website: https://industry.airliquide.ph/
Landline: +63 2 838 1780 to 83
B. Hyrdogen Cyanide
As of to date there are no manufacturers of Hydrogen Cyanide in the

Philippines.
C. Cuprous Chloride
As of to date there are no manufacturers of Cuprous Chloride in the

Philippines
261
IX. SAFETY
Table 5.10: Equipment Parameters for Acetylene and HCN Route Process
Equipment Equipment Temperature Pressure
R-101 Reactor 70-80°C 1 atm
S-101 Recovery 40°C 0.752atm

Column
C-101 Distillation 77.3°C 1 atm

Column
C-102 Decanter 77.3°C 1 atm
No. of intensive 0
equipment
262
Toxicity level
Table 5.11: Toxicity Level for Acetylene and HCN Route Process
Acetylene Hydrogen Cuprous

Cyanide Chloride
Severity of 1 4 3
Immediate
Effects
Sensitization 0 3 2
Level
Carcinogenicity 0 5 2
Level
Reproduce 0 4 0
Toxicity Level
Severity of 0 4 2
Chronic Effects
Subtotal 1 20 9
Total 30
263
In HCN route process the raw materials that will be used specially
the hydrogen cyanide is a very toxic chemical that should be contained and
handled properly it can lead to toxic spills that can harm the community that
surrounds the plant, Furthermore, it can be a cause of poisoning of wildlife
in the vicinity that can harm the ecosystem.
264
PROCESS 3
PROCESS TO C-MANUFACTURE ACRYLONITRILE AND

HYDROGEN CYANIDE
I. Introduction
A process for co-manufacture of acrylonitrile and hydrogen cyanide

comprises combining a stream compr1s1ng hydrogen cyanide and an
acrylonitrile reactor product stream, to produce a combined product stream,
having a ratio of acrylonitrile to hydrogen cyanide of about 9 to 1 or less,
Which can be varied; and treating the combined product stream in a
recovery/purification system of acrylonitrile process Wherein pH is
controlled by addition of an acid to prevent HCN polymerization. The ratio
of acrylonitrile to hydrogen cyanide is generally between 2 to 1 and 9 to 1.
The stream comprising hydrogen cyanide is advantageously a hydrogen
cyanide product stream from a hydrogen cyanide synthesis reactor.
II. REACTION:
2NH3 + 3O2 + 2CH4 2HCN + 6H20
265
An ACRN product stream is obtained by the ammoxidation of

propylene, ammonia, and air in ACRN reactor 2(R-002) 310°C to 510°C
and 5 to 30 psig. A HCN product stream is obtained by reaction of methane,
ammonia, and air in a HCN reactor (R-001) at 1300°C, such as an
Andrussow reactor. The ACRN product stream is transferred to a quench
column (Q-001) where the hot ACRN product stream is cooled with water
spray containing sulfuric acid to neutralize the unreacted ammonia in the
ACRN product stream to produce ammonium sulfate which is removed
from quench column (Q-001) and treated to waste water column (WC-001).
Recovered HCN/ACRN is cycled back to Q-001. A waste water purge

stream is taken from waste water column (WC-001). The cooled ACRN
product stream is then combined with the HCN product stream in the
absorber column (AB-001), where the HCN and ACRN form a combined
product stream as they are absorbed into an aqueous solution. Water is
provided to the absorber column (AB-001). Non-absorbed compounds are
separated and removed as off-gas. The aqueous solution containing the
combined product stream from AB-001 is then transferred to a recovery
column (RC-001) for product purification. The combined product stream
from RC-001 is fed to decanter (D-001). Water from stripper column is fed
to absorber column (AB-001). A separate stream is taken from the recovery
column (RC-001) and fed to stripper column (SC-001) from which crude
acetonitrile is recovered and remaining aqueous stream is fed back into
recovery column (RC-001). Crude acetonitrile can be recovered or sent to
incineration.
266
The product stream from recovery column (RC-001) is transferred to

decanter (D-001) where the stream separates, forming an organic layer and
an aqueous layer. The aqueous layer is separated and returned as reflux to
recovery column (RC-001). The organic layer is transferred through line to
heads column (HC-001) where it is separated into crude ACRN and crude
HCN.
The crude HCN is sent to a HCN column (PC-001), where the HCN is
further purified and sent for storage. Recovered ACRN from HCN column
(PC-001) is returned to quench column (Q-001). Crude ACRN 31 is sent to
a drying column (DC-001), from which water is removed through line 37.
Dried ACRN is transferred to ACRN product column (PC-002) for

further purification before being sent through line 39 to storage from which
waste material is removed from ACRN product column (PC-002) through
line 38. Acetonitrile Waste Water stream from SC-001 is combined with
other waste water streams as combined waste water stream with wastewater
purge stream, which is collected and treated as needed. Acid to control pH
between pH 3.8 and 4.4 is added to absorber column 12(AB-001), recovery
column (RC-001), decanter (D-001), heads column (HC-001), and HCN
column (PC-001). An appropriate control system is used to monitor pH and
temperature at each location Where HCN concentration is sufficiently high,
that is, greater than 1% by Weight, that there is increased risk of HCN
polymerization.
267
Table 5.12: Equipment’s for C-Manufacture Process
Equipment Quantity
Storage Tank 3
Vaporizer 2
Entrainment Separator 2
Heat Exchanger 6
Fluidized Bed Reactor 1
Quencher 1
Absorber 1
Recovery Column 2
Distillation Column 4
268
V. RAW MATERIALS
PROPYLENE
Propylene is a colorless gas with a faint petroleum like odor. It is

shipped as a liquefied gas under its own vapor pressure. For transportation
it may be stench. Contact with the liquid can cause frostbite. It is easily
ignited. The vapors are heavier than air. Any leak can either be liquid or
vapor. It can asphyxiate by the displacement of air. Under prolonged
exposure to fire or intense heat the containers may rupture violently and
rocket. It is used to make other chemicals.
Acrylonitrile (AN) is commercially produced by a reaction of propylene and

ammonia in the presence of a catalyst. Having both olefinic (C=C) and
nitrile (C-N) groups permits a large variety of reactions and makes AN
versatile chemical intermediate. The nitrile group can undergo hydrolysis,
hydrogenation, esterification and reduction. Reactions of the carbon double
bond include polymerization, copolymerization, cyanoethylation,
cyclization and halogenation. One of the reasons for the versatility of
acrylonitrile is that it can form copolymers with other unsaturated
compounds, such as styrene and butadiene, for example a raw material for
acrylic acid, acrylic esters, acrylic amide in the synthesis of compounds
used for the production of adhesives, anti-oxidants, binders and emulsifiers.
269
AMMONIA
Ammonia is a colourless gas with a sharp, penetrating odour. Its

boiling point is −33.35 °C (−28.03 °F), and its freezing point is −77.7 °C
(−107.8 °F). It has a high heat of vaporization (23.3 kilojoules per mole at
its boiling point) and can be handled as a liquid in thermally insulated
containers in the laboratory. (The heat of vaporization of a substance is the
number of kilojoules needed to vaporize one mole of the substance with no
change in temperature.) The ammonia molecule has a trigonal pyramidal
shape with the three hydrogen atoms and an unshared pair of electrons
attached to the nitrogen atom. It is a polar molecule and is highly associated
because of strong intermolecular hydrogen bonding. The dielectric constant
of ammonia (22 at −34 °C [−29 °F]) is lower than that of water (81 at 25 °C
[77 °F]), so it is a better solvent for organic materials. However, it is still
high enough to allow ammonia to act as a moderately good ionizing solvent.
Ammonia also self-ionizes, although less so than does water.
Acrylonitrile was produced in pilot plant from propylene, ammonia, and

atmospheric oxygen in a fixed-bed reactor in the presence of Bi/Mo/Si oxide
shell catalyst. The propylene conversion, which can amount to about 70%
under optimal conditions, was studied as a function of structural properties
and the chemical composition of the catalyst, and of the composition of the
starting mixture. Acrylonitrile of adequate purity for use in polymerizations
could be obtained by multi-stage processing of the crude product.
270
V. Plant Economy
the C-manufacture process are shown in this section.

from Perry’s Chemical Engineers’ Handbook 8th Ed. From table 6.2 the
Lang factor for fluid processing is 5.
Table 5.13: Cost of Equipment for C-Manufacture Process
Equipment Quantity Delivered PCE

Equipment
= DEC x factor
Cost (Php)
(DEC)
Storage Tank 3 ₱ 6,682,500 ₱ 33,412,500
Fluidized Bed 2 ₱ 20,308,000 ₱ 101,540,000

Reactor
Quencher 1 ₱ 4,950,000 ₱ 24,750,000
Absorber 2 ₱ 297,000 ₱ 1,485,000
Recovery Column 2 ₱ 79,200,000 ₱ 396,000,000
Total Purchased Cost of ₱ 123,812,500 ₱ 619,062,500

Equipment (PCE)
271
From Table 5.4 the values for estimation of fixed capital cost for fluid
process are shown.
𝑃𝑃𝐶 = ₱619,062,500(1 + 0.4 + 0.7 + 0.2 + 0.10 + 0.15 + 0.5 + 0.15
+ 0.05 + 0.15)
𝑃𝑃𝐶 = ₱ 2,105,152,500

𝐹𝐶𝐶 = 𝑃𝑃𝐶 (1 + 0.3 + 0.05 + 0.10)
𝐹𝐶𝐶 = ₱2,105,152,500(1 + 0.3 + 0.05 + 0.10)
𝑭𝑪𝑪 = ₱ 3,052,471,125

𝑊𝐶𝐶 = ₱3,052,471,125(0.05)
𝑊𝐶𝐶 = ₱ 152,623,556.3

𝑇𝐶𝐼 = ₱3,052,471,125 + ₱152,623,556.3
𝑻𝑪𝑰 = ₱ 𝟑, 𝟐𝟎𝟓, 𝟎𝟗𝟒, 𝟔𝟖𝟏
272
MAINTENANCE COST:
Maintenance Cost = (0.10)( ₱3,052,471,125)
For a plant capacity of 58 tons of product per day, and having average
conditions, from Figure 5.3 the estimated operating labor requirement is 60
employee-hours/day/processing step. Considering a 300 days’ annual
operation and 3 processing steps:
From Table 5.5 the wage for non – agriculture sector is PHP 300

=( )( )( )
273
From Figure 5.4 for the costing and project evaluation
LABORATORY COST:
Laboratory Cost = (0.23)(₱ 16,200,000.00 )
SUPERVISION COST:
PLANT OVERHEADS:
Plant Overheads = (0.50)(₱ 16,200,000.00)
274
CAPITAL CHARGES:
Capital Charges = (0.10)(₱3,052,471,125)
𝐂𝐚𝐩𝐢𝐭𝐚𝐥 𝐂𝐡𝐚𝐫𝐠𝐞𝐬 = ₱305,247,112.5
LOCAL TAXES:
Local Taxes = (0.20)(₱3,052,471,125)
𝐋𝐨𝐜𝐚𝐥 𝐓𝐚𝐱𝐞𝐬 = ₱ 𝟔𝟏𝟎, 𝟒𝟗𝟒, 𝟐𝟐𝟓
INSURANCE:
Insurance = (0.01)(₱2,614,995,250)
𝐈𝐧𝐬𝐮𝐫𝐚𝐧𝐜𝐞 = ₱ 30,524,711.25
Licence Fee/Royalty Fees = (0.01)(₱3,052,471,125)
𝐋𝐢𝐜𝐞𝐧𝐜𝐞 𝐅𝐞𝐞/𝐑𝐨𝐲𝐚𝐥𝐭𝐲 𝐅𝐞𝐞𝐬 = ₱ 30,524,711.25
275
FIXED COSTS
= ₱ 305,247,112.5 + ₱16,200,000.00
+ ₱3,726,000 + ₱3,240,000 + ₱8,100,000
+ ₱305,247,112.5 + ₱610,494,225
+ ₱30,524,711.25 + ₱30,524,711.25
𝐅𝐈𝐗𝐄𝐃 𝐂𝐎𝐒𝐓𝐒 = ₱𝟏, 𝟑𝟏𝟑, 𝟑𝟎𝟑, 𝟖𝟕𝟑
VARIABLE COSTS:
MOM = 0.10( ₱305,247,112.5)
𝐌𝐎𝐌 = ₱30,524,711.25
Variable Cost = MOM
𝐕𝐀𝐑𝐈𝐀𝐁𝐋𝐄 𝐂𝐎𝐒𝐓 = ₱30,524,711.25
DPC = ₱30,524,711.25 + ₱1,313,303,873
𝐃𝐏𝐂 = ₱𝟏, 𝟑𝟒𝟑, 𝟖𝟐𝟖, 𝟓𝟖𝟒
276
SALES EXPENSE:
Sales Expense = 0.20(₱1,343,828,584)
𝐒𝐚𝐥𝐞𝐬 𝐄𝐱𝐩𝐞𝐧𝐬𝐞 = ₱𝟐𝟔𝟖, 𝟕𝟔𝟓, 𝟕𝟏𝟔. 𝟔
GENERAL OVERHEADS:
General Overheads = 0.30(₱1,343,828,584)
𝐆𝐞𝐧𝐞𝐫𝐚𝐥 𝐎𝐯𝐞𝐫𝐡𝐞𝐚𝐝𝐬 = ₱𝟒𝟎𝟑, 𝟏𝟒𝟖, 𝟓𝟕𝟓. 𝟒
IPC = ₱268,765,716.6 + ₱403,148,575.4
𝐈𝐏𝐂 = ₱𝟔𝟕𝟏, 𝟗𝟏𝟒, 𝟐𝟗𝟐
APC = IPC + DPC
APC = ₱671,914,292 + ₱1,343,828,584
𝐀𝐏𝐂 = ₱𝟐, 𝟎𝟏𝟓, 𝟕𝟒𝟐, 𝟖𝟕𝟔
277
₱𝟐, 𝟎𝟏𝟓, 𝟕𝟒𝟐, 𝟗𝟕𝟔

APR =
( )( )
day year
₱𝟏𝟏𝟓, 𝟖𝟒𝟕. 𝟑𝟎
APR =
𝐌𝐓

MT/day of Acrylonitrile through C-Manufacture process is estimated to be
₱2,015,742,976. Most of the amounts were allotted for direct production
cost. The estimates were made without the utilities costs that account for the
₱115,847.30/MT annual production rate.
278
VI. MANUFACTURABILITY
PURITY
The acrylonitrile obtained from the c-manufacture process has a purity of

99%.
YIELD
The acrylonitrile obtained from the c-manufacture process has a product

yield of 75%.
BY-PRODUCTS
The by-product of the C-Manufacture process are Hydrogen Cyanide

(HCN) and Acetonitrile (AN).
PROCESS USAGE
The production of acrylonitrile through C-Manufacture process is being

used by different plants around the world such as Bayer AG in Germnay,
Shantou Xilong chemical co., ltd. In China
279
Propylene and Ammonia play the key raw materials in the

production of acrylonitrile by C-Manufacture process. It is deemed vital that
these raw materials have an adequate supply in the Philippines since it will
be a major concern for selecting the best process to use. The possible
companies where the raw materials could be purchased here in the
Philippines is presented below:
A. Propylene
Some of the manufacturing plants of propylene in the Philippines are the

following:
 Pilipinas Shell Petroleum Corporation

Address: 156 Valero Street, Salcedo Village, Makati City, 1227,
Metro Manila
Website: http://pilipinas.shell.com.ph/
Landline: (063) 257 4961
 Philippine Polypropylene Incorporated

Address: 40, San Miguel Avenue, Mandaluyong, 1550 Metro
Manila
Website:https://www.bloomberg.com/research/stocks/private/snaps
hot.asp?privcapId=222843901
Landline: (02) 884 9200
280
 JG Summit Petrochemicals Group

Address: Barangay Simlong, Batangas City
Website: http://jgspetrochem.com/
Landline: +632 397 2674
B. Ammonia
Some of the manufacturing plants of ammonia in the Philippines are the

following:
 Linde Philippine Inc.

Address: 24 Emerald Ave, San Antonio, Pasig, 1605 Metro Manila
Website: http://www.linde.com/en/index.html
Landline: (02) 702 7500
IX. SAFETY
Two of the equipment requires high operating temperature. The

reactor 1 which is operating at 510 oC and 30 psi and the reactor 2 that is
operating at 1300 oC and 50 psi. Personal protective equipment for heat is
required when going to the area near the equipment.
281
Toxicity level
Table 5.14: Toxicity Level for C-Manufacture Process
Propylene Ammonia
Severity of 1 1
Immediate
Effects
Sensitization 0 0
Level
Carcinogenicity 0 0
Level
Reproduce 0 0
Toxicity Level
Severity of 0 2
Chronic Effects
Subtotal 1 3
Total 4
282
In C-Manufacture process the by products are Hydrogen Cyanide

which will be in a small amount that will be further treated and contained,
the other by product is Acetonitrile that will also be stored and if possible
be marketed from other manufacturers. The heavy impurities that is in the
wastewater system will be also further treated.
283
Table 5.15: PROCESS SELECTION SUMMARY
Propylene Acetylene - C-
CRITERIA Ammoxidation HCN Route Manufacture
Process Process Process
Total Capital
Total Capital Total Capital
Investment is
Investment is Investment is dependent on
dependent on dependent on equipment cost.
equipment cost.
equipment cost. Process 3 has
Process 1 has
Process 2 has 4 12 equipment.
19 equipment.
equipment. The The most
The most
ECONOMICS
TOTAL most expensive expensive

expensive
CAPITAL equipment are: equipment are:
equipment are:
INVESTMENT Reactor and Reactor 1 and
Reactor and
Product Reactor 2 and
Recovery
Column. The Recovery
Column. The
total capital Column. The
total capital
investment of total capital
investment of
this process is investment of
this process is
this process is
₱3.285,832,082 ₱531,050,664
₱3,205,094,681
284
Annual
Annual
Production Cost
Production Cost Annual
is dependent on
is dependent on Production Cost
Fixed Cost,
Fixed Cost, is dependent on
Variable Cost
Variable Cost Fixed Cost,
and Direct
and Direct Variable Cost
Production
Production and Direct
Cost. Variable
Cost. Variable Production Cost.
cost is
cost is Variable cost is
dependent on
dependent on dependent on the
the cost of raw
the cost of raw cost of raw
materials. Fixed
materials. Fixed materials. Fixed
Cost was
ANNUAL Cost was Cost was derived
derived on the
PRODUCTION derived on the on the bills paid
bills paid
COST bills paid regardless of the
regardless of
regardless of quantity
the quantity
the quantity produced. The
produced. The
produced. The raw materials in
raw materials in
raw materials in Process 2 are
Process 3 are
Process 1 are Acetylene and
propylene,
propylene, Hydrogen
ammonia and
Ammonia, and Cyanide. The
hydrogen
Air. The annual annual
cyanide. The
production cost production cost
annual
of Process 1 is of Process 2 is
production cost
₱2,091,183,388 ₱602,191,510.3
of Process 3 is
₱2,015,742,976
285
₱ 35,000/kg ₱ 35,000/kg
₱ 1528.78/kg
*Prices are *Prices are *Prices are

updated as of updated as of updated as of
January 2018 January 2018 via January 2018
CATALYST
via www.indiamart.c via
www.molbase.c om www.molbase.c
om om
%PURITY 99.5% 95% 99%
Acetonitrile Unreacted raw Acetonitrile

BY- materials
PRODUCTS Hydrogen Hydrogen
Cyanide Heavies Cyanide
MANUFACTURABILITY
There is no There is no
company using company using
this process in There is no this process in
the Philippines, company using the Philippines,
but companies this process in but companies
from different the Philippines , from different
PROCESS
countries such but one company countries such
USAGE
as Bayer A Gin produce Imperial as Bayer A Gin
Germany, Chemical Germany,
Shantou Xilong Industries from Shantou Xilong
in China are Great Britain in China are
using this using this
process. process.
286
YIELD 80% 80% 75%
The raw The raw

materials are materials are
SUSTAINABILITY
Import acetylene
locally locally
AVAILABILITY from other
available and available and
OF RAW country because
adequate adequate
MATERIALS it is not locally
amount is amount is
available.
available for the available for the
process. process.
The reactor is The reactor The reactor
TEMPERATURE operating at: operates at operates at:

SAFETY
420oC 70 oC, 1300 oC,
PRESSURE 202.65 kPa 101.325 kPa 344.642 kPa
287
Hydrogen
Ammonia is Ammonia is
Cyanide and
harmful in case harmful in case
Acetylene is
of inhalation of inhalation
harmful in case
and skin and and skin and
HAZARDOUS of inhalation and
eye contact. eye contact.
MATERIALS skin and eye
Personal Personal
contact. Personal
protective protective
protective
equipment is equipment is
equipment is
required. required.
required.
The main wastes The main wastes

are small are small
amounts of amounts of
propylene, CO2, propylene, CO2,
The main wastes
CO, and heavies. CO, and heavies.
are small amounts
The exhaust The exhaust
ENVIRONMENTAL IMPACT
of acetylene and
gases has gases has
HCN. A lot of
harmful effect to harmful effect to
waste in the
the environment the environment
ENVIRONMETAL bottoms of the
CO2 discharge to CO2 discharge to
IMPACT column 2. This
atmosphere in atmosphere in
waste must be
large quantities large quantities
treated first
should be should be
before releasing it
avoided. The avoided. The
to the
safe safe
environment.
concentration concentration
levels of carbon levels of carbon
dioxide must be dioxide must be
below 1 percent. below 1 percent.
288
Evaluation of Process:
Using Otto and Antonsson model on process selection in

engineering design, each criterion was given a value 1-5, depending on its
importance. The designers calculated the ability to satisfy each criterion
based on certain amount for every decisive factor of each method. The
computation of ranking for the ability to satisfy the criteria are as follows:
𝐻𝑖𝑔ℎ𝑒𝑟 𝑉𝑎𝑙𝑢𝑒 − 𝐿𝑜𝑤𝑒𝑟 𝑉𝑎𝑙𝑢𝑒

𝐷𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒 =
𝐻𝑖𝑔ℎ𝑒𝑟 𝑉𝑎𝑙𝑢𝑒
𝑆𝑢𝑏𝑜𝑟𝑑𝑖𝑛𝑎𝑡𝑒 𝑅𝑎𝑛𝑘 = 𝐺𝑜𝑣𝑒𝑟𝑛𝑖𝑛𝑔 𝑅𝑎𝑛𝑘 − (𝐷𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑥 10)
By evaluating the 12 attributes the selected process is the Ammoxidation

of Propylene process as shown in Table: 5.16.
Table 5.16: Evaluation of Process
289
Conclusion:
Acylonitrile production has three different methods in

producing the product. The processes have different raw materials and
equipment. One process is chosen from these three process. The process
must be economical, effective and efficient as the other two processes. The
chosen process for this design project is the ammoxidation of propene.
To put up an acrylonitrile production plant that utilizes propene

and ammonia as the main raw material, the capital investment needed is
higher than process 2 and 3 because process 1 is the most sustainable
because of the availability of the main raw materials and the availability of
the catalyst in the Philippines. The plant will also be safer for workers in
process 1 because there is only few intensive equipment. And also, the
purge that will be released in the atmosphere has no harmful effects in the
environment. The simplicity and reliability of the process makes the
company chose this process as a route of production of acrylonitrile. The
weighted score based on the attributes in Table 5.15, shows that it is the best
process route for acrylonitrile production.
290
Table 5.17: Quantitative Summary
Propylene Acetylene - C-
CRITERIA Ammoxidation HCN Route Manufacture
Process Process Process
TOTAL
CAPITAL ₱3.285,832,082 ₱531,050,664 ₱3,205,094,681
INVESTMENT
ECONOMICS
ANNUAL
PRODUCTION ₱2,091,183,388 ₱602,191,510.3 ₱2,015,742,976
COST
291
CATALYST ₱ 35,000/kg ₱ 1528.78/kg ₱ 35,000/kg
%PURITY 99.5% 95% 99%
Acetonitrile Unreacted raw Acetonitrile

BY- materials
PRODUCTS Hydrogen Hydrogen
Cyanide Heavies Cyanide
There is no There is no
MANUFACTURABILITY
company using company using

this process in There is no this process in
the Philippines, company using the Philippines,
but companies this process in but companies
from different the Philippines , from different
PROCESS
countries such but one company countries such
USAGE
as Bayer A Gin produce Imperial as Bayer A Gin
Germany, Chemical Germany,
Shantou Xilong Industries from Shantou Xilong
in China are Great Britain in China are
using this using this
process. process.
YIELD 80% 80% 75%
292
The raw The raw

materials are materials are
SUSTAINABILITY
Import acetylene
locally locally
AVAILABILITY from other
available and available and
OF RAW country because
adequate adequate
MATERIALS it is not locally
amount is amount is
available.
available for the available for the
process. process.
TEMPERATURE 420oC 70 oC, 1300 oC,

SAFETY
PRESSURE 202.65 kPa 101.325 kPa 344.642 kPa
293
Hydrogen
Ammonia is Ammonia is
Cyanide and
harmful in case harmful in case
Acetylene is
of inhalation of inhalation
harmful in case
and skin and and skin and
HAZARDOUS of inhalation and
eye contact. eye contact.
MATERIALS skin and eye
Personal Personal
contact. Personal
protective protective
protective
equipment is equipment is
equipment is
required. required.
required.
The main wastes The main wastes

are small are small
amounts of amounts of
propylene, CO2, propylene, CO2,
The main wastes
CO, and heavies. CO, and heavies.
are small amounts
The exhaust The exhaust
ENVIRONMENTAL IMPACT
of acetylene and
gases has gases has
HCN. A lot of
harmful effect to harmful effect to
waste in the
the environment the environment
ENVIRONMETAL bottoms of the
CO2 discharge to CO2 discharge to
IMPACT column 2. This
atmosphere in atmosphere in
waste must be
large quantities large quantities
treated first
should be should be
before releasing it
avoided. The avoided. The
to the
safe safe
environment.
concentration concentration
levels of carbon levels of carbon
dioxide must be dioxide must be
below 1 percent. below 1 percent.
294
PROCESS PRIMES
For the P1
The ACN Corporation add 1 equipment for Process 1 because it’s

environmental is low. By adding a scrubber it will lower the carbon
monoxide emission but it will also affect the economics.
Process 1
NEW TCC = ₱ 3,298,833,332
NEW FCC = ₱ 3,141,746,030
For the P2
ACN Corporation selected an alternative catalyst because the

price of the catalyst of process 1 is expensive. ACN Corporation consider
using Iron Antimony Oxide it will lessen the cost but it will lower the
product yield.
Catalyst:
Iron Antimony Oxide: Php 24,879/ kg
*Prices are updated as of January 2018 via www.molbase.com
Yield:
Process 1: 75%
295
For the P3
ACN Corporation reduce two equipment’s the ammonia and

propylene vaporizer. ACN Corporation consider buying the raw materials
in gaseous state.
Process 1
NEW TCC = ₱ 3,262,460,732
NEW FCC = ₱ 3,105,373,430
Table 5.18: Evaluation of P1
296
297

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Technological Institute of the Philippines

A. PRODUCTION OF ACRYLONITRILE PROPYLENE

II. REACTION MECHANISM:

III. PROCESS DESCRIPTION

Ammonia, propylene and air are feed material. Liquid ammonia is

Vapor ammonia is now passed through super heater (HX-001)

The reactor (R-001) is a large - diameter cylindrical vessel provided

Since the temperature of reaction is around 420 – 450 ° C high –

The major feed stream to recovery section is the reactor effluent

Then, the cleaned gas is cooled to 30 ° C (HX-004) before

high acrylonitrile recovery of 99.5%, cold water at 5 ° C is used. The column

The residual gas leaving, containing unconverted propene, CO2 and

absorption, 2% for recycling to quench and the rest as wastewater. The

HC-001 has the target of removing the “heads” including light

The next column (DC-001) handles the separation of

Raw acetonitrile, namely a binary azeotrope with 20% water,

IV. EQUIPMENT UTILIZED

Table 5.1: Equipment’s for Ammoxidation of Propylene Process

TAG NUMBER EQUIPMENT

1 H-001 Heat Exchanger

2 H-002 Heat Exchanger

3 H-003 Heat Exchanger

5 HX-001 Heat Exchanger

8 HX-002 Heat Exchanger

9 AB-001 Gas Absorber 1

10 AB-002 Gas Absorber 2

11 HX-003 Heat Exchanger

12 RC-001 Recovery Column

14 HC-001 HCN Column

15 PC-001 Product Column

Propylene is a colorless gas with a faint petroleum like odor. It is

Figure 5.1: Propylene Storage

Acrylonitrile (AN) is commercially produced by a reaction of

versatility of acrylonitrile is that it can form copolymers with other

Ammonia is a colourless gas with a sharp, penetrating odour. Its

Figure 5.2: Ammonia Storage Tank

VI. PLANT ECONOMY

TOTAL CAPITAL INVESTMENT

Table 5.2: Lang Factors (Green & Perry, 2008)

Type of plant Fixed capital Total capital

Table 5.3: Cost of Equipment for Ammoxidation of Propylene Process

Storage Tank 6 ₱ 6,682,500 ₱ 33,412,500

Heat Exchanger 6 ₱ 8,910,000 ₱ 44,550,000

Fluidized Bed Reactor 1 ₱ 10,154,000 ₱ 50,770,000

Quencher 1 ₱ 4,950,000 ₱ 24,750,000

Absorber 2 ₱ 148,500 ₱ 742,500

Recovery Column 1 ₱ 79,200,000 ₱ 396,000,000

Distillation Column 2 ₱ 9,900,000 ₱ 49,500,000

Total Purchased Cost of Equipment

Table 5.4: Estimation of Fixed Capital Cost (Sinnot R. K., 2005)

Item Process type

FIXED CAPITAL COST (FCC)

WORKING CAPITAL COST (WCC):

TOTAL CAPITAL INVESTMENT (TCI):

𝑻𝑪𝑰 = ₱ 𝟑, 𝟐𝟖𝟓, 𝟖𝟑𝟐, 𝟎𝟖𝟐

FIXED COSTS CALCULATION:

Maintenance Cost = (0.10)(FCC)

Maintenance Cost = (0.10)( ₱3,285,832,082)

𝐌𝐚𝐢𝐧𝐭𝐞𝐧𝐚𝐧𝐜𝐞 𝐂𝐨𝐬𝐭 = ₱ 328,583,208.2

OPERATING LABOR COST (OLC):

Figure 5.3: Operating labor requirements for chemical process industries

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