CHLOROBENZENE PRODUCTION

PLANT

By Group 1:

Varun, Bhatia (H00280477)

Mahnoor, Muhammad (H00263479)
Ojas, Mainkar (H00255996)
Zubayr, Abdullahi (H00231670)
Hamdaan, Phoolwala (H00228114)

1
TABLE OF CONTENTS
 TABLE OF CONTENTS .................................................................................................................................... 2
INTRODUCTION ..................................................................................................................................................... 3
WHY THIS PROJECT WAS CHOSEN? .............................................................................................................................. 3
PROCESS DESCRIPTION .......................................................................................................................................... 4
PROCESS FLOW DIAGRAM ..................................................................................................................................... 5
MARKET ANALYSIS................................................................................................................................................. 6
SWOT ANALYSIS .................................................................................................................................................... 8
LOCATION ANALYSIS .............................................................................................................................................. 9
PROCESS MATERIAL AND ENERGY BALANCE ........................................................................................................ 11
MATERIAL BALANCE .............................................................................................................................................. 11
ENERGY BALANCE ................................................................................................................................................. 11
HYSYS SIMULATION ............................................................................................................................................. 12
ECONOMICS ANALYSIS......................................................................................................................................... 13
HAZOP ANALYSIS ................................................................................................................................................. 18
(HAZARD AND OPERABILITY STUDY) .................................................................................................................... 18
SUSTAINABILITY................................................................................................................................................... 21
APPENDIX ............................................................................................................................................................ 22
HEALTH AND SAFETY: MSDS .................................................................................................................................. 22

2
Introduction
Chlorobenzene is manufactured commercially by the chlorination of benzene to produce
a mixture of mono-chlorobenzene, dichlorobenzene and other similar products. Benzene
and chlorine are the starting points of the process which are brought from neighboring
industries and is stored at the plant location. The aim of this production is to produce
around 90000 tons of chlorobenzene per year which include both mono and di-
chlorobenzene to provide domestic uses for households globally and the primary uses
are as a source of raw materials to synthesis compounds for pharmaceutical and
pesticide uses.
A plant is established at the city of Mumbai in India operating 365 days per year with an
efficient number of workers. Establishing a plant in India gives a good benefit to the
revenue gain due to the reason that there is a high demand of this product which is also
said to have a large revenue percentage in Asia than other regional areas. Besides, the
growth of the market size of chlorobenzene gives a good advantage to set up the project.
Additionally, having a large manufacturing base and an easier access of input feeds.
Infrastructure provision is said to be very poor in India and can be resolved by structuring
this project in a way that expands the demands of customer’s satisfaction and
commercially viability which tends to give better outcomes in which the government tends
to provide a better infrastructure. Additionally costly and low quality of power is known in
India which results in problems faced such as equipment failure, requiring medical
attention due to electrical accidents and the loss of opportunities and revenue. The
solution can be resolved by providing proper wiring within the facility. Furthermore,
placing energy storage systems for important equipment’s within the plant.
In the future the production of chlorobenzene is aimed to increase due to the high demand
from customers globally and the variety of many uses utilized as solvents used for paints,
room deodorants, chemical manufacturing and other uses giving a major impact on the
market.

Why this project was chosen?

The project relates itself with the production of chlorobenzene, a very common organic
compound widely used as an industrial solvent, and more often also used in the polymer-
resin industry. The method generally applied is the chlorination of benzene in presence
of catalyst to produce variable ratio of multiple chlorobenzene. The project thus chosen
is a widely industrial process with multiple application benefits whilst aiming to inculcate
employment generation, improve sustainability, validate process feasibility and increasing
market competition to regions of limited product availability. The product not only
increases the world-wide production of chlorobenzene but also tackles scientific analysis
of reaction mechanism and at the same time considers various possibilities of different
plant models and processes through which this process would be both economically
viable and environmentally sustainable.

3
Process Description
Chemical Reaction:
• C6 H6 + Cl2 => C6H5Cl + HCl
• C6H5Cl + Cl2 => C6H4Cl2 + HCl
The design project carried out effectively deals with commercial scale production of
Chlorobenzene by direct chlorination of benzene in presence of ferric chloride, catalyst.
The process follows Friedel-Crafts alkylation chemical mechanism. The targeted annual
produce is 70000 tons/year situated in India. The obtained products through this process
are, mono-chlorobenzene and by-product, di-chlorobenzene. The process achieves a
98% product purity.
Chlorination of benzene takes place continuously in a chlorinator by supplying pure
benzene feed mixed with ferric chloride catalyst (or iron turnings/scrap) and mixed with
chlorine gas to produce chlorinated benzene derivatives. Benzene is stored in a deep-
steel vessel. Chlorine gas is supplied as gas to the chlorinator. Both feedstocks are
maintained at room temperature and atmospheric pressure. The reaction undergoes in
the reactor at 2.4 bar to produce chlorobenzenes and also HCl as by-product. Multiple
reactors can be placed in series or parallel to increase feed conversion to desired
products.
After going through multiple reactor systems, the product stream is directly separated to
produce pure HCl and remaining products is recycled back to the reactor to improve the
efficiency of the process. The bottom product stream from the second reactor is
continuously distilled to give pure chlorobenzene derivatives. The final product is then
stored and ready to be sold.

4
Process Flow Diagram

5
Market Analysis
A global overview of the production of chlorobenzene in terms of the market size &
forecast, market by application and the regional revenue. The marketing of these products
involve the following:
• Mono-chlorobenzene
• Ortho-dichlorobenzene
• Para-dichlorobenzene
• Others

From the year 2015-2025 the chlorobenzene market is increasing in tons and estimated
to reach 2201 kilo tons in 2024 from 1579 kilo tons in 2015. Chlorobenzene is frequently
used to manufacture other chemicals such as insecticides, deodorizers and etc. The
items manufactured supplies a high demand for the products which increases the global
marketing rate in various industries. A representation of global size and forecast during
the years 2015 to 2025 is shown below.

Global marketing of chlorobenzene is segmented into North America, Europe, Asia pacific
and the rest of the world which is further divided into different countries. The percentage
revenue is the largest in the Asia pacific which includes India of about 79.4% and is higher
than the other segmented geographical areas.

6
7
 SWOT analysis

Beneficial Harmful
Strengths Weaknesses

• Powerful existence in some • High cost and low quality of

export market segments power
• Availability of resources within • Infrastructure provision are not
the country globally first class
Internal

• India has a large manufacturing • Multiple levies (including service

base tax, sales tax and electricity
• Potential to manufacture world duty)
class end products
• Demand for chlorobenzene
which is used for domestic uses
which increases the rate of
production and income
Opportunities Threats

• India has the space for great • Cause of extinction if industry

value addition having an obtains competitiveness
inexpensive source for chemical
feedstock
• Great amount of markets
External

opening up from developed

countries are going off patent
giving a good advantage for the
products to sell

8
Location Analysis
Location Matrix India China Japan U.S.
Raw Material 8 9 8 9
Marketability 9 8 8 9
Infrastructure 8 10 9 9
Geographical Location 9 8 8 8
Import and Export 10 10 9 8
Labor 10 9 8 7
Rules and Regulations 9 7 8 7
Total 63 61 58 57

Raw Material

The raw materials required are Benzene and Chlorine. China, US and Japan produce
Benzene in abundance as compared to India, but chlorine production rate in India is more
or less equal to that of other countries.

Marketability, Import and Export

In Asia-Pacific region, India comes in the top 3 regions for manufacturing chlorobenzene.
China, Japan and USA produce Chlorobenzene in abundance. India’s import and export
value has increased multi-fold in the past decade. Recently, India’s economy surpassed
China’s to become the world’s fastest growing large economy.

Infrastructure

China, Japan and USA top the list from infrastructure perspective. Compared to the
countries chosen, India lacks in infrastructure, but recent reports suggest that India is
going to increase the construction activity by improving the ports thus smoothening the
ports.

Geographical Location

India is close to Middle Eastern and African countries as compared to Japan, China and
USA. It is equidistant to many other countries in the Far East.

Labor
Labor cost in India is the cheapest. The cost is higher in China. USA and Japan are
relatively higher than China.

9
 Matrix
Location
• Location relative to closest
seaport
• Coordinates
• Site size
• Soil conditions
Land Cost
• Purchase & Annual Lease
Weather
• Avg. Temp.(Avg. Max/Avg.
Min)
• Avg. Peak Temp. (Month)
• Avg. Annual Rainfall
• Avg. Relative Humidity
• Avg. Wind speed
• Earthquake
• Tropical Cyclones & Flooding
Access to Raw Materials and Utility
Supply
Transport Infrastructure
Indigenous Issues
Environmental Considerations
Navi Mumbai
30km from Jawaharlal Nehru Port
(JNP)
19.0679° N, 73.1080° E
Dry soil
• 26.8oC (30oC/23.3oC)
• 33.7oC (May)
• 3044mm
• 75%
• 10m/s
• For earthquakes, the zone is
classified as Moderate Damage
Risk Zone
• Exposed to high tide, heavy rains
and cyclonic storms which leads to
flooding.
Raw materials can be accessed from
nearby industries. Benzene and
chlorine industries are close to 1hr
away from the plant.
22km away from the Airport and
25kms from the nearest port.
Relocation of several villages due to
construction of an Airport.
Damage to neighboring flora and fauna
due to construction of an airport.
Tarapur
10km from the port
17.7°N 75.47°E
Dry soil
• 26.5oC (29.9oC/22.4oC)
• 33.1oC (May)
• 788mm
• 70%
• 13m/s
• Earthquakes had no impact
on plants but still it is
classified as Moderate
Damage Risk Zone
• Exposed to high tide, heavy
rains and cyclonic storms
which leads to flooding.
No nearby industries which can
provide gaseous chlorine.
The closest international airport
is 3hrs away by road. Ports
No indigenous issues in this area
are noted.
No flora and fauna are in danger.
Gujarat
10.4km from New Bedi Port in
Jamnagar, Gujrat
22°27'35.3"N 70°02'56.3"E
Dry Soil
• 26.1 oC (32.2 oC /19.8 oC)
• 47 oC (May)
• 487mm
• 77%
• 11m/s
• For earthquakes, the zone
is classified as Moderate
Damage Risk Zone
The nearest industries that provide
the raw materials are 5 hours away.
The closest international airport is 6
hours away by road.
No indigenous issues in this area
are noted.
No flora and fauna are in danger.
10
 Process Material and Energy balance
Material Balance

Stream 1 2 3 4 5 6 7 8 9
Vapor Fraction 0.00 1.00 1.00 1.00 0.00 0.45 1.00 0.00 1.00
Temperature [C] 25.00 25.00 144.52 25.00 25.28 40.42 345.66 345.66 375.69
Pressure [kPa] 100.00 100.00 300.00 230.00 400.00 150.00 150.00 150.00 240.00
Molar Flow [kgmole/h] 94.49 110.15 110.15 110.15 94.49 237.65 237.65 0.00 237.65
Mass Flow [kg/h] 7378.00 7810.00 7810.00 7810.00 7378.00 18869.68 18869.72 0.00 18869.72
Liquid Volume Flow [m3/h] 8.36 5.00 5.00 5.00 8.36 16.71 17.59 0.00 17.59
Heat Flow [kJ/h] 4686251.22 -2654.61 455404.64 -2654.52 4689634.95 5475507.25 5475556.27 0.00 6255526.46

Stream 10 11 12 13 14 15 16 17 18
Vapor Fraction 0.45 1.00 0.00 0.00 0.00 0.79 1.00 0.00 0.00
Temperature [C] 40.00 108.62 108.62 79.04 189.54 45.00 -30.25 112.20 112.13
Pressure [kPa] 205.53 205.53 205.53 140.00 150.00 150.00 150.00 150.00 150.00
Molar Flow [kgmole/h] 237.65 142.59 95.05 77.75 17.30 142.59 109.51 33.08 33.00
Mass Flow [kg/h] 18869.72 7685.19 11184.54 8649.43 2535.11 7685.19 3993.98 3691.22 3681.68
Liquid Volume Flow [m3/h] 17.59 7.94 9.88 7.85 2.03 7.94 4.59 3.35 3.34
Heat Flow [kJ/h] -6227113.83 -7832648.74 1605533.14 1384974.44 115907.41 -9464536.23 -10288986.00 790739.33 788526.82

Energy Balance

Name Q100 Q101 Q102 Q103 Q104 Q105 Q106 Q107 Q108
Heat Flow [kJ/h] 458059.25 458059.16 3383.73 779970.18 12482640.28 1631887.49 -33710.44 9080303.02 8977639.66

11
HYSYS Simulation

12
Economics Analysis
Capital cost INR USD
Land Price 35000000 491021.3244
Plant Construction 179891724.5 2523733.509
Utility 583241570 8182401.375
Safety Equipment 8468195 118801.8378
Miscellaneous 10000000 140291.807
Total Capital Cost 816,601,490 11456249.85

Capital Cost Distribution

1% 4%

1% Land Price
22%
Plant Construction
Utility
72%
Safety Equipment
Miscellaneous

13
 Operation Cost INR/annum USD/annum
Raw Material 2795340240 39370989.3
Energy 221497733.4 3119686.386
Labor 78750000 1109154.93
Transport 1301666.667 18333.33333
Utility Operation 250669760 3530560
Total Operational Cost 3347559400 47148723.95

Operational Cost Distribution

84%
Raw Material
Energy
Labor
0%
Transport
7%
2%
Utility Operation
7%

14
Following is the net cash flow summary for 20 years of industrial operations of this plant.
Economic Analysis
Capital cost OP Cost Revenue Profit
(USD)
Year 0 - - - -
Year 1 (11,456,249.85) - - -
Year 2 - (47,148,723.95) 50,247,316.39 3,098,592.45
Year 3 - (47,148,723.95) 50,247,316.39 3,098,592.45
Year 4 - (47,148,723.95) 50,247,316.39 3,098,592.45
Year 5 - (47,148,723.95) 50,247,316.39 3,098,592.45
Year 6 - (47,148,723.95) 50,247,316.39 3,098,592.45
Year 7 - (47,148,723.95) 50,247,316.39 3,098,592.45
Year 8 - (47,148,723.95) 50,247,316.39 3,098,592.45
Year 9 - (47,148,723.95) 50,247,316.39 3,098,592.45
Year 10 - (47,148,723.95) 50,247,316.39 3,098,592.45
Year 11 - (47,148,723.95) 50,247,316.39 3,098,592.45
Year 12 - (47,148,723.95) 50,247,316.39 3,098,592.45
Year 13 - (47,148,723.95) 50,247,316.39 3,098,592.45
Year 14 - (47,148,723.95) 50,247,316.39 3,098,592.45
Year 15 - (47,148,723.95) 50,247,316.39 3,098,592.45
Year 16 - (47,148,723.95) 50,247,316.39 3,098,592.45
Year 17 - (47,148,723.95) 50,247,316.39 3,098,592.45
Year 18 - (47,148,723.95) 50,247,316.39 3,098,592.45
Year 19 - (47,148,723.95) 50,247,316.39 3,098,592.45
Year 20 - (47,148,723.95) 50,247,316.39 3,098,592.45

15
Following is the cumulative cash flow for every subsequent year.

Cumulative Cash Flow(USD) Years

- 0
(11,456,249.85) 1
(8,357,657.40) 2
(5,259,064.95) 3
(2,160,472.50) 4
938,119.94 5
4,036,712.39 6
7,135,304.84 7
10,233,897.29 8
13,332,489.74 9
16,431,082.19 10
19,529,674.64 11
22,628,267.09 12
25,726,859.54 13
28,825,451.99 14
31,924,044.44 15
35,022,636.89 16
38,121,229.34 17
41,219,821.79 18
44,318,414.24 19
47,417,006.68 20

16
 Pay-back Time Profile
50,000,000.00 Profit Period
Cummulative Cash Flow Profile (USD)

40,000,000.00

30,000,000.00

20,000,000.00 Payback Time = 4.7 years

10,000,000.00

-
0 2 4 6 8 10 12 14 16 18 20
(10,000,000.00)
Capital Investment
(20,000,000.00)
Years

NPV $47,417,006.68
IRR 26.75%
ROI 27.05%
Payback time(years) 4.7

17
HAZOP Analysis
(Hazard and Operability Study)
Name Compressor
Unit (C-100) Stream 3
Process Variables
Deviation Cause Consequence Action
No No flow rate Blockage on Operation fail Using stand by
of chlorine compressor compressor
Flow

Low Low flow Low efficiency on Reacting mixtures change Using stand by
rate of compressor and encounters an compressor
chlorine unsuccessful product
High High flow Difficulty with flow Reacting mixtures change bypass extra
rate of indicator and encounters low purity flow of chlorine
chlorine product back to storage
Process Variables
Deviation Cause Consequence Action
No - - - -
Temperature

Low - - - -

High Temperature High compression Excessive duty on heat A better

more than of the gas exchanger that causes control of the
required corrosion compressor
Process Variables
Deviation Cause Consequence Action
No - - - -
Pressure

Low Pressure less Low efficiency on Reaction conditions changes Using stand by
than compressor which compressor
required causes blockage on
pipe
High Pressure Failure in Mechanical failures Using a
more than compressor which pressure valve
required changes reaction
conditions

18
 Name Heat Exchanger
Unit (E-101) Stream 5
Process Variables
Deviation Cause Consequence Action
No No flow rate of Blockage on whole pipe Operation fail Use of
Benzene Maintenance

Low Low flow rate of Problem with Pump (P- Reacting Using stand
Flow

Benzene 100) mixtures change by pump

and encounters
an unsuccessful
product
High High flow rate of Blockage of pipe slightly Reacting bypass extra
Benzene mixtures change flow of
and encounters chlorine back
low purity to storage
product
Process Variables
Deviation Cause Consequence Action
No - - - -
Temperature

Low Temperature lower Causes fouling due to Change of A better

than required low flow rate reaction control of the
fluid flow
High Temperature more High flow of heating Change of A better
than required fluid, due to hot reaction control of the
surroundings fluid flow

Process Variables
Deviation Cause Consequence Action
No - - - -
Pressure

Low Pressure less than Blockage of pipe slightly Reaction Use of

required conditions Maintenance
changes
High Pressure more than Problem with Pump (P- Mechanical Using a
required 100) failures pressure
valve

19
 Name Distillation column
Unit (T-100) Stream 3
Process Variables
Deviation Cause Consequence Action
No No flow of chlorobenzene Blockage of Favorable Maintenance
pipe product not required
obtained
Flow

Low Flow of chlorobenzene less Slightly Back flow of Position a

than required blockage of substances check valve
pipe

High Flow of chlorobenzene more High flow of Causes flooding Position a

than required pressure in column manual valve

Name Reactor
Unit (R-100) Stream 3
Process Variables
Deviation Cause Consequence Action
No - - - -
Temperature

Low Temperature Breakdown of Low conversion Checking of

less than heater rate on reactor temperature
required controller routinely

High Temperature Breakdown of Causes Checking of

more than heater explosion temperature
required controller routinely

Process Variables
Deviation Cause Consequence Action
No - - - -
Pressure

Low Pressure less Breakdown of Low conversion Checking of

than required pressure rate on reactor pressure
controller routinely
High Pressure more Breakdown of Causes Checking of
than required pressure explosion pressure
controller routinely

20
Sustainability
For a long period of time, humans have been consumers rather than conservationists.
Since, without Earth, sustaining won’t be possible for us humans, this project has carefully
considered the sustainability issue and has planned the idea from that viewpoint.
Sustainability stands on three pillars – economy, society and environment. A process is
truly sustainable only when it is socially, economically and ecologically feasible.
Economic
There are many pharmaceuticals, paints, adhesive, polymers, dyes etc. plants which use
m-chlorobenzene and o-chlorobenzene as the major raw material or solvent. The
production of such a large amount of solvent gives 3M$ for 70,000 t/yr. production. From
a business perspective the amount earned isn’t too less nor too much. The greed to
satisfy our senses by going against ethics isn’t there in our policy.
The word ‘business’ may give a connotation that in the future we will increase the prices
for a higher rate just to satisfy our greed, but we’ve gone beyond the narrow sight of
economy as organized by the world and therefore no matter what hurdles may come
forward, we won’t break the three pillars of sustainability.1 (Scott Cato, M.,2009)
Social
No harm is caused to the public as the land is industrial.
Ecology
Since the land chosen is an industrial land and far away from the residential complex or
any ecological site, there is no harm to the environment. Although, 32,000 t/yr. of a toxic
gas like HCl is produced, safety considerations are been taken so that no gas leaves into
the atmosphere. The aim is to protect the environment by all means. As mentioned earlier,
Benzene and chlorine gas are the major raw materials used in our industry. Benzene is
virtually harmless as it gets diffused faster into the atmosphere when exposed (due to car
exhaust, paints etc.). Normal usage of it doesn’t cause harm to flora and fauna. But if a
significant spill of benzene takes place (which is rare) the harmful effect of that on the
environment is not worrisome. 2 As for chlorine, it very harmful to the environment. If
released accidently into air and water, it will be damaging to the environment as chlorine
reacts with the organic and inorganic materials in water to form chlorinated organic
materials and chlorine salts respectively. If reacted in air it will affect the animal’s immune
system.3

1
Scott Cato, M. (2009). Green Economics. London: Earthscan, pp. 36–37. ISBN 978-1-84407-571-3.
2
https://www.petro-online.com/news/safety/15/breaking-news/what-are-the-effects-of-benzene-on-the-
environment/33958
3
https://www.lenntech.com/periodic/elements/cl.htm

21
Appendix
Health and Safety: MSDS
MATERIAL SAFETY DATA SHEET
SECTION 1: CHEMICAL IDENTIFICATION
Trade name: Benzene
Chemical name: Benzene
C.A.S. no.: 71-43-2
Molecular formula: C6H6
Molecular weight: 78.11 g/mole
SECTION 2: COMPOSITION AND INFORMATION ON INGREDIENTS
Name: Benzene C.A.S. no.: 71-43-2 % by weight: 100.00
SECTION 3: HAZARDS IDENTIFICATION
Potential acute health effects:
It causes skin and eye irritation. It causes aspiration hazard. It is a flammable liquid

Potential chronic health effects:

Chronic Aquatic toxicity.
SECTION 4: FIRST AID MEASURES
Eye contact:
Rinse thoroughly with plenty of water for at least 15 minutes and consult a physician.

Skin contact:
Wash off with soap and plenty of water. Take victim immediately to hospital. Consult a physician.

Serious skin contact:

Take victim immediately to hospital. Consult a physician.

Inhalation:
If breathed in, move person into fresh air. If not breathing, give artificial respiration. Consult a physician.

Ingestion:
Do NOT induce vomiting. Never give anything by mouth to an unconscious person. Rinse mouth with water.
Consult a physician

SECTION 5: FIRE AND EXPLOSION DATA

22
Flammability of the product: Flammable liquid and vapor
Auto-ignition temperature: 562 ºC
Flash points: -11 ºC -
Flammable limits: 1.3 % 7.1 %
Fire hazards in presence of Sensitive to static discharge
various substances:

Firefighting media and instructions:

Carbon oxides Flash back possible over considerable distance, Container explosion may occur under fire
conditions.

SECTION 6: ACCIDENTAL RELEASE MEASURES

Small spill:
Use personal protective equipment. Avoid breathing vapors, mist or gas. Ensure adequate ventilation. Remove
all sources of ignition. Evacuate personnel to safe areas. Beware of vapors accumulating to form explosive
concentrations

Large spill:
Contain spillage, and then collect with an electrically protected vacuum cleaner or by wet-brushing and place in
container for disposal according to local regulations.

SECTION 7: HANDLING AND STORAGE

Precautions:
Avoid contact with skin and eyes. Avoid inhalation of vapor or mist. Avoid exposure - obtain special instructions
before use. Keep away from sources of ignition. Take measures to prevent the buildup of electrostatic charge.

Storage:
Store in cool place. Keep container tightly closed in a dry and well-ventilated place. Containers which are
opened must be carefully resealed and kept upright to prevent leakage.

SECTION 8: PHYSICAL AND CHEMICAL PROPERTIES

Physical state and appearance: Clear colorless liquid
Odor: No data available
Molecular weight: 78.11 g/mole
Color: Colorless
pH: -
Boiling point: 80 ºC Melting point: 5.5 ºC
Critical temperature: -
Vapor pressure: 99.5 HPa @20 ºC Vapor density: -
Solubility:

23
ca.1,88 g/l at 23,5 °C - soluble
SECTION 9: STABILITY AND REACTIVITY DATA
Stability: Stable under recommended storage conditions
Corrosively: -
Polymerization: -
SECTION 10: DISPOSAL CONSIDERATIONS
Waste disposal:
Burn in a chemical incinerator equipped with an afterburner and scrubber but exert extra care in igniting as this
material is highly flammable. Offer surplus and non-recyclable solutions to a licensed disposal company

MATERIAL SAFETY DATA SHEET

SECTION 1: CHEMICAL IDENTIFICATION
Trade name: Benzene Chloride
Chemical name: Mono-chlorobenzene
C.A.S. no.: 108-90-7
Chemical family: Aromatic organic compounds
Common synonyms: Chlorobenzene
Molecular formula: C6H5Cl
Molecular weight: 112.56 g/mole
SECTION 2: COMPOSITION AND INFORMATION ON INGREDIENTS
Name: Mono-chlorobenzene C.A.S. no.: 108-90-7 % by weight: 100.00
SECTION 3: HAZARDS IDENTIFICATION
Potential acute health effects:
Causes respiratory tract irritation resulting in breathing difficulty. Causes gastrointestinal irritation, vomiting and
nausea. Causes skin irritation including swelling, redness and cracking of skin. Causes eye irritation including
stinging and tearing

Potential chronic health effects:

Exposure of substance causes damage to the blood system, liver and kidneys
SECTION 4: FIRST AID MEASURES
Eye contact:
Rinse with water for 15 minutes

Skin contact:
Rinse with plenty of water while removing clothing

24
Serious skin contact:
Call and seek for medical attention. Wash contaminated clothing before reuse

Inhalation:
Evacuating for fresh air and keeping comfortable for breathing. If breathing has stopped, give artificial
respiration

Serious inhalation:
Call poison center and seek for medical attention. If breathing is difficult, give oxygen by qualified medical
personal only

Ingestion:
Rinse mouth with water and do not induce in vomiting. If vomiting occurs, keep victims head forward to reduce
the potential risk of aspiration

SECTION 5: FIRE AND EXPLOSION DATA

Flammability of the product: Flammable liquid and vapor
Auto-ignition temperature: 600 ºC
Flash points: 28 ºC -
Flammable limits: 1.3 % 7%
Products of combustion: Carbon oxides, Hydrogen chloride, Phosgene
Fire hazards in presence of Sensitive to static discharge
various substances:

Firefighting media and instructions:

Extinguishing medias: Carbon dioxide, dry chemicals and alcohol resistant foam
Prevent using solid water stream as it can spread and produce fire

SECTION 6: ACCIDENTAL RELEASE MEASURES

Small spill:
Ventilate the area. Use only non-sparking tools to clean up

Large spill:
Ventilate the area. Absorb spill with non-combustible, inert absorbent material for example; sand

SECTION 7: HANDLING AND STORAGE

25
Precautions:
Keep away from heat, keep container sealed tightly, do no breathe in vapor, wash hands, wear safety
equipment’s, use only non-sparking tools, use in well ventilated area

Storage:
Keep container sealed tightly. Store container locked up in a well-ventilated area. Only accessible to trained and
authorized personal.

SECTION 8: EXPOSURE CONTROL AND PERSONAL PROTECTION

Engineering controls:
Using engineering controls
Personal protection:
Wearing protective equipment’s for face, eye and skin

SECTION 9: PHYSICAL AND CHEMICAL PROPERTIES

Physical state and appearance: Clear colorless liquid
Odor: Hydrocarbon odor
Molecular weight: 112.56 g/mole
Color: Colorless
pH: -
Boiling point: 132 ºC Melting point: -45 ºC
Critical temperature: -
Vapor pressure: 9 mm Hg @25 ºC Vapor density: 3.9
Solubility:
Slightly soluble in water and soluble in most organic solvents
SECTION 10: STABILITY AND REACTIVITY DATA
Stability: Stable under normal conditions
Corrosively: -
Polymerization: Not occurring
SECTION 13: DISPOSAL CONSIDERATIONS
Waste disposal:
Disposal must take place in accordance with standard safety and control regulations as prescribed by the
federal, state and environmental authorities.

26
 MATERIAL SAFETY DATA SHEET
SECTION 1: CHEMICAL IDENTIFICATION
Trade name: Benzene Chloride
Chemical name: p-Dichlorobenzene
C.A.S. no.: 106-46-7
Chemical family: Aromatic organic compounds
Common synonyms: 1,4-Dichlorobenzene
Molecular formula: C6H4Cl2
Molecular weight: 147.01 g/mole
SECTION 2: COMPOSITION AND INFORMATION ON INGREDIENTS
Name: Dichlorobenzene C.A.S. no.: 106-46-7 % by weight: 100.00
SECTION 3: HAZARDS IDENTIFICATION
Potential acute health effects:
Causes eye irritation. Solid produces burning sensation when held in contact with the skin, but irritation is slight.
May cause gastrointestinal irritation with nausea, vomiting and diarrhea, liver and kidney damage. Inhalation of
vapors causes irritation of eyes, throat, and skin. Exposure may cause nausea, vomiting, weight loss, anorexia
and hepatic necrosis with jaundice.
Potential chronic health effects:
Possible cancer hazard based on tests with laboratory animals. May cause anemia and other blood cell
abnormalities. Chronic inhalation may lead to decreased pulmonary function.
SECTION 4: FIRST AID MEASURES
Eye contact:
Rinse with water for 15 minutes

Skin contact:
Rinse with plenty of water while removing clothing and shoes

Serious skin contact:

Call and seek for medical attention. Wash contaminated clothing before reuse

Inhalation:
Evacuating for fresh air and keeping comfortable for breathing. If breathing has stopped, give artificial
respiration

Ingestion:

27
If swallowed, do not induce vomiting unless directed to do so by medical personnel. Never give anything by
mouth to an unconscious person.
SECTION 5: FIRE AND EXPLOSION DATA
Flammability of the product: Flammable liquid and vapor
Auto-ignition temperature: 640 ºC
Flash points: 65 ºC -
Flammable limits: 1.3 % 7%
Products of combustion: Carbon oxides, Hydrogen chloride, Phosgene
Fire hazards in presence of Sensitive to static discharge
various substances:

Firefighting media and instructions:

Extinguishing medias: Carbon dioxide, dry chemicals and alcohol resistant foam
Prevent using solid water stream as it can spread and produce fire

SECTION 6: ACCIDENTAL RELEASE MEASURES

Small spill:
Ventilate the area. Use only non-sparking tools to clean up

Large spill:
Ventilate the area. Absorb spill with non-combustible, inert absorbent material for example; sand

SECTION 7: HANDLING AND STORAGE

Precautions:
Keep away from heat, keep container sealed tightly, do no breathe in vapor, wash hands, wear safety
equipment’s, use only non-sparking tools, use in well ventilated area

Storage:
Keep container sealed tightly. Store container locked up in a well-ventilated area. Only accessible to trained and
authorized personal. Store in a cool, dry, well-ventilated area away from incompatible substances.

SECTION 8: EXPOSURE CONTROL AND PERSONAL PROTECTION

Engineering controls:
Using engineering controls
Personal protection:
Wearing protective equipment’s for face, eye and skin

SECTION 9: PHYSICAL AND CHEMICAL PROPERTIES

28
Physical state and appearance: Solid
Odor: Hydrocarbon odor
Molecular weight: 147.01 g/mole
Color: White
pH: -
Boiling point: 174 ºC Melting point: 53 ºC
Critical temperature: -
Vapor pressure: 9 mm Hg @25 ºC Vapor density: 1.458
Solubility:
Insoluble
SECTION 10: STABILITY AND REACTIVITY DATA
Stability: Stable under normal conditions
Corrosively: -
Polymerization: Not occurring
SECTION 13: DISPOSAL CONSIDERATIONS
Waste disposal:
Disposal must take place in accordance with standard safety and control regulations as prescribed by the
federal, state and environmental authorities.

MATERIAL SAFETY DATA SHEET

SECTION 1: CHEMICAL IDENTIFICATION
Trade name: Sodium Hydroxide
Chemical name: Sodium Hydroxide
C.A.S. no.: 1310-73-2
Chemical family: Sodium Hydrate
Common synonyms: Sodium Hydrate, Caustic soda, lye
Molecular formula: NaOH
Molecular weight: 40.00 g/mole
SECTION 2: COMPOSITION AND INFORMATION ON INGREDIENTS
Name: Sodium Hydroxide C.A.S. no.: 1310-73-2 % by weight: 100.00
SECTION 3: HAZARDS IDENTIFICATION
Potential acute health effects:
Causes respiratory tract irritation resulting in breathing difficulty. Causes gastrointestinal irritation, vomiting and
nausea. Causes skin irritation including swelling, redness and cracking of skin. Causes eye irritation including
stinging and tearing

Potential chronic health effects:

29
Exposure of substance causes damage to the blood system, liver and kidneys
SECTION 4: FIRST AID MEASURES
Eye contact:
Rinse with water for 20 minutes

Skin contact:
Wash affected areas

Serious skin contact:

Call and seek for medical attention. Wash contaminated clothing before reuse

Inhalation:
Evacuating for fresh air and keeping comfortable for breathing. If breathing has stopped, give artificial
respiration

Serious inhalation:
Call poison center and seek for medical attention. If breathing is difficult, give oxygen by qualified medical
personal only

Ingestion:
Rinse mouth with water and do not induce in vomiting. If vomiting occurs, keep victims head forward to reduce
the potential risk of aspiration

SECTION 5: FIRE AND EXPLOSION DATA

Flammability of the product:
Auto-ignition temperature:
Flash points:
Flammable limits:
Products of combustion:
Fire hazards in presence of
various substances:
Non-Flammable
-
- -
- -
Thermal decompositions at high temperatures
Reactions with metals can cause explosive hydrogen gas

Firefighting media and instructions:

Extinguishing medias: Carbon dioxide, dry chemicals and alcohol resistant foam
Prevent using solid water stream as it can spread and produce fire

SECTION 6: ACCIDENTAL RELEASE MEASURES

Small spill:

30
Ventilate the area. Can be diluted and cautiously neutralized with preferably acetic acid

Large spill:
Ventilate the area. Absorb spill with diluted hydrochloric acid

SECTION 7: HANDLING AND STORAGE

Precautions:
Keep container sealed tightly, keep away from strong acids and metals which include(aluminum, zinc and tin),
wash hands, wear safety equipment’s, use in well ventilated area

Storage:
Keep container sealed tightly. Store container locked up in a well-ventilated cool area. Accessible only for well-
trained personnel

SECTION 8: EXPOSURE CONTROL AND PERSONAL PROTECTION

Engineering controls:
Using engineering controls (Mechanical ventilation)
Personal protection:
Wearing protective approved equipment’s for face, eye and skin

SECTION 9: PHYSICAL AND CHEMICAL PROPERTIES

Physical state and appearance: Liquid
Odor: Odorless
Molecular weight: 40.00 g/mole
Color: Colorless
pH: 14
Boiling point: 140 ºC Melting point: 12 ºC
Critical temperature: -
Vapor pressure: 1.5 mm Hg @25 ºC Vapor density: -
Solubility:
Completely miscible in water
SECTION 10: STABILITY AND REACTIVITY DATA
Stability: Stable under normal conditions
Corrosively: Corrosive, severe irritant
Polymerization: Not occurring
SECTION 13: DISPOSAL CONSIDERATIONS
Waste disposal:

31
Disposal must take place in accordance with standard safety and control regulations as prescribed by the
federal, state and environmental authorities.

MATERIAL SAFETY DATA SHEET

SECTION 1: CHEMICAL IDENTIFICATION
Trade name: Water
C.A.S. no.: 7732-18-5
Common synonyms: Dihydrogen oxide
Molecular formula: H20
Molecular weight: 18.02 g/mole
SECTION 2: COMPOSITION AND INFORMATION ON INGREDIENTS
Name: Water C.A.S. no.: 7732-18-5 % by weight: 100.00
SECTION 3: HAZARDS IDENTIFICATION
Potential acute health effects:
Not a hazardous substance or mixture according to Regulation (EC) No. 1272/2008.

SECTION 4: FIRST AID MEASURES

Eye contact:
Flush eyes with water as a precaution

Skin contact:
Wash off with soap and plenty of water

Inhalation:
Evacuating for fresh air and keeping comfortable for breathing. If breathing has stopped, give artificial
respiration

Ingestion:
Never give anything by mouth to an unconscious person. Rinse mouth with water.

SECTION 5: ACCIDENTAL RELEASE MEASURES

Personal precautions and Environmental precautions

32
Avoid breathing vapor, mist or gas. No special environmental precautions required

SECTION 6: HANDLING AND STORAGE

Precautions:
Non hazardous

Conditions for safe storage:

Store in cool place. Keep container tightly closed in a dry and well-ventilated place. Storage class (TRGS 510):
Non Combustible Liquids

SECTION 7: EXPOSURE CONTROL AND PERSONAL PROTECTION

Skin Protection:
Handle with gloves. Gloves must be inspected prior to use. Use proper glove removal technique (without
touching glove's outer surface) to avoid skin contact with this product
Body Protection
Impervious clothing, The type of protective equipment must be selected according to the concentration and
amount of the dangerous substance at the specific workplace.

SECTION 8: PHYSICAL AND CHEMICAL PROPERTIES

Physical state and appearance: Clear colorless liquid
Odor: No data available
Molecular weight: 18.02 g/mole
Color: Colorless
pH: 6-8 at 25 degrees Celsius
Boiling point: 100 ºC Melting point: 0 ºC
Vapor pressure: - @25 ºC Vapor density: -
SECTION 9: STABILITY AND REACTIVITY DATA
Stability: Stable under normal conditions
Corrosively: -
Polymerization: Not occurring
SECTION 10: DISPOSAL CONSIDERATIONS
Waste disposal:
Offer surplus and non-recyclable solutions to a licensed disposal company. Dispose of as unused product.

33
References
• https://www.variantmarketresearch.com/report-categories/chemicals-
materials/chlorobenzene-market
• http://www.centralbuild.com.au/blog/how-much-to-build-a-factory-or-warehouse/
• https://paycheck.in/salary/minimumwages/maharashtra

• http://economists-pick-research.hktdc.com/business-news/article/Research-
Articles/Make-in-India-Comparative-Production-Costs-of-Selected-Indian-
States/rp/en/1/1X000000/1X0A6T6F.htm#

• https://www.99acres.com/industrial-land-plot-for-sale-in-taloja-mumbai-others-
9680-sq-yard-spid-
P41180075?pos=SEARCH&from_src=[object%20HTMLInputElement]

• https://www.trukky.com/mumbai-to-pune

Section Handled
Economics, HYSYS, Material Balance,
Varun Process Description, Energy Balance
Economics, HYSYS, Sustainability, Location
Ojas Analysis
Economics, Report Layout , Process Flow
Mahnoor Diagram
HAZOP, SWOT, Introduction, Market Analysis
Zubayr
MSDS, Location Analysis, Material Balance,
Hamdaan Energy Balance

34