PRODUCTION OF

ACETIC ACID
MUHAMMAD IKMAL BIN HAMID
MUHAMMAD MUSTAQIM SAFIY BIN MUSTAFA MAAROF
MUHAMAD AL-NAZREEN BIN AKHIRUDDIN
MUHAMMAD AIZAT EDZMIR BIN KHIDZIR
MUHAMMAD ALIFF BIN MUHAMMAD SOHAIMI

ORGANIZATION STRUCTURE

CHIEF EXECUTIVE OFFICER

MUHAMMAD IKMAL BIN HAMID
SALES AND MARKETING DIRECTOR
MUHAMMAD AIZAT EDZMIR BIN KHIDZIR
INTELECTUAL PROPERTY DIRECTOR
MUHAMAD AL-NAZREEN BIN AKHIRUDDIN
CHIEF TECHNOLOGIST
MUHAMMAD MUSTAQIM SAFIY BIN MUSTAFA MAAROF
FINANCE DIRECTOR
MUHAMMAD ALIFF BIN MUHAMMAD SOHAIMI

INTRODUCTION

The objective of the development of new acetic acid processes has been to reduce raw
material consumption, energy requirements, and investment costs.

Significant cost advantages resulted from the use of carbon dioxide and of low-priced
methane as feedstocks

Acetic acid is an important commodity used in chemical industries, with about 9 million tons
of world demands per year.

The demand is estimated to grow at a very high pace, next only to ester solvents, which is
the strongest growth segment of acetic acid.

METHANE

Methane is a chemical compound with the chemical formula CH4. It is a

group 14 hydride and the simplest alkane

The main component of natural gas. The relative abundance of

methane on Earth makes it an attractive fuel

Methane is used in industrial chemical processes and may be

transported as a refrigerated liquid

Methane is important forelectricity generation by burning it as a fuel in

agas turbineorsteam generator.

Compared to otherhydrocarbon fuels, methane produces lesscarbon

dioxidefor each unit of heat released.

ACETIC ACID

Acetic acidis anorganic compoundwith thechemical formulaCH3COOH (also written as

CH3CO2H or C2H4O2).

Acetic acid is the main component ofvinegarapart from water.

It is an importantchemical reagentand industrial chemical.

The global demand for acetic acid is about 6.5 millionmetric tons per year.

The largest single use of acetic acid is in the production of vinyl acetatemonomer, closely
followed by acetic anhydride and ester production.

The majorestersof acetic acid are commonly used as solvents forinks,paintsandcoatings.

CH4 + 2O2
CH4 + CO2
CH3COOH

CO2 + 2H2O

SCREENING AND SCORING

SITE LOCATION

Site selection for a plant, requires careful considerations of the numerous factors

Decisions are strategic, long-term and non-repetitive in nature.

A suitable site must be found for a new project, and the site and equipment layout planned

Provision must be made for the ancillary buildings and services needed for plant operation
and for the environmentally acceptable disposal of effluent.

GENERAL CONSIDERATION ON
THE SITE SELECTION

Location with respect to marketing area

Raw material supply

Transport facilities

Availability of labor

Availability of utilities: water, fuel, power

Availability of suitable land

Environmental impact including effluent disposal

Local community consideration

Climate

Political and strategic consideration

LIST OF SITE FOR

CONSIDERATION

From the factors that were listed, we have choose three suitable places to become the site
for our plant.

The listed sites are:

Sl.
No.

Factor

1. Kerteh, Terengganu
2. Gebeng, Pahang
3. Bintulu, Sarawak

Factor
Weigh
ts

Site Rating 0-5 Sliding scale

Kerteh

Gebeng

Bintulu

1.
2.

Location
Industrial
Infrastructure

5
4

4
5

3
4

4
4

3.

Community
Infrastructure

4.
5.
6.
7.
8.
9.

Availability of water
Effluent disposal
Availability of Power
Availability of Gas
Site size and Nature
Ecology and Pollution

4
4
4
2
3
2

5
4
4
4
5
3

5
4
4
4
4
3

5
4
4
4
5
3

PROCESS FLOW DIAGRAM (PFD)

Figure 1 : Selected PFD for production of acetic acid

EQUIPMENTS DESIGN

REACTOR
Rule 8
High production rates at short residence times (sec or min).
DESIGN TEMPERATURE

709.878 K

LIQUID VOLUME

27.8 L

VESSEL DIAMETER

0.1524 m

VESSEL TANGENT TO

1.524 m

TANGENT HEIGHT
DESIGN GAUGE

577689 N/sqm-gauge

PRESSURE
VOLUME OF REACTOR

4995.7 L

EQUIPMENT

Jacketed nonagitated

DESCRIPTION
EQUIPMENT WEIGHT

453.592 kg

REACTOR 1

REACTOR 2

Conversion (methane)
X = 0.97

DESIGN TEMPERATURE

709.878 K

LIQUID VOLUME

27.8 L

VESSEL DIAMETER

0.1524 m

VESSEL TANGENT TO

1.524 m

TANGENT HEIGHT
DESIGN GAUGE PRESSURE

577689 N/sqm-gauge

VOLUME OF REACTOR

3551.52 L

EQUIPMENT DESCRIPTION

Jacketed nonagitated

EQUIPMENT WEIGHT

453.592 kg

EQUIPMENTS DESIGN

SEPARATOR

Rule 3

Vertical vessel

Rule 4

L/D between 2.5 and 5 with optimum at 3.0

Rule 5 Liquid holdup time is 5 min based on volume of vessel

Rule 9 Gas velocity u is given by
DESIGN TEMPERATURE

606.234 K

OPERATING TEMPERATURE

578.457 K

VESSEL DIAMETER

0.9144 m

VESSEL HEIGHT

3.6576 m

VOLUME OF SEPARATOR

2401.9 L

EQUIPMENT DESCRIPTION

VERTICAL

EQUIPMENT WEIGHT

1179.34 kg

EQUIPMENTS DESIGN
HEATER

COOLER

TUBE DESIGN

616.483 K

TEMPERATURE
TUBE OPERATING

TUBE DESIGN TEMPERATURE

TUBE OPERATING

709.878 K
308.15 K

588.706 K

TEMPERATURE
TUBE DESIGN GAUGE

415796 N/sqm-gauge

PRESSURE
TUBE OUTSIDE DIAMETER
TUBE LENGTH EXTENDED
HEAT TRANSER AREA
EQUIPMENT DESCRIPTION
EQUIPMENT WEIGHT

0.0254 m
6.096 m
0.3966 m2
Double Pipe
127 kg

TEMPERATURE
TUBE DESIGN GAUGE
PRESSURE
TUBE OUTSIDE DIAMETER
TUBE LENGTH EXTENDED
HEAT TRANSER AREA
EQUIPMENT DESCRIPTION
EQUIPMENT WEIGHT

243421 N/sqm-gauge
0.0254 m
6.096 m
0.498 m2
Double Pipe
122.47 kg

COSTING
AND
PROFITABILITY
ANALYSIS

ESTIMATING DESIRED PURCHASED COST

Equipment
number
1

3.29

$1 807.17

(2001)

C2 (2016)

$5 945.59

$8 402.3 x (2

Heater

units)
-

4.0

$7 186.21

$28 744.84

Reactor

$40 622.15 (2
units)

4.07

$4 825.03

$19 637.87

Separator

$27 752.2 x (2
units)

3.29

$1 684.61

$5 542.37

$7 832.47

Cooler
Total

Results of Capital Cost Estimation

$161 385.77

TOTAL CAPITAL COST

FIXED CAPITAL ESTIMATIONS

$292 108.24

WORKING CAPITAL
COST OF LAND ,

$43 816.24
$750 000

TOTAL CAPITAL COST

$1 085 924.48

RAW MATERIAL COST

needed
Air

= 85724.7 L/hr

Cost per unit

= $0.35/m3

$254 047/yr
Methane needed

= 24822.5 L/hr

Cost per unit

= $0.42/m3

Total cost of raw material

= $339 397/yr

ELECTRICITY COST
From data given in Aspen , the energy consumed for total plant operation are calculated in
electricity.
Voltage used

= 2.3 kV 30 kV

Rate

= $0.06/ kWh

Quantity used

= 3550 kW

Total of electric used

= $213/hr
= $1 840 320/yr

WASTEWATER TREAMENT COST

From

stream 12 . Volume per hour of wastewater is 582.623 L/hr equivalent to 0.5826 m 3/hr

For primary filtration, cost is $41/1000m3

Cost hourly = 0.5826 m3/hr
= $0.0238/hr
= $205.623/yr

ESTIMATION OF MANUFACTURING
COST
OPERATING LABOR COST

$811200/yr

RAW MATERIALS

$349,307.39/yr

ELECTRICITY

$2,751,148.8/yr

WASTE WATER TREATMENT

$205.623/yr

REVENUE FROM SALE

R =

= $ 5 905 872/yr

COM d 0.180 FCI 2.73COL 1.23(CUT CWT C RM )

= 0.18(292,108.24) + 2.73(811 200) + 1.23 (2 385 340)
= $5 201 124/yr

= 0.280(292,108.24) + 2.73(811200) +1.23(2 385 340)

= $5 230 334/yr

= 0.177(811200) + 0.009(292,108.24) + 0.16(5 230 334)

= $983 065/yr

= 0.708(811200) +0.068(292,108.24) +0.1(292,108.24)

= $623 404/yr

= 2 385 340 +1.33(811200) +0.069(292,108.24) + 0.03(5 230 334)

= $3 641 301/yr

NONDISCOUNTED CASH FLOW

d]

COM d

17.52

( 11.68 + 4.4)=
16.08

5.84

End of
Year (k)

Investment

Cash
Flow

Cumulative
Cash Flow

(75)*

(75)

(75)

(17.52)

(92.52)

(16.08)

(108.6)

23.36

591

520

48.19

48.19

(60.41)

5.84

17.52

591

520

48.19

48.19

(12.22)

5.84

11.68

591

520

48.19

48.19

35.97

5.84

5.84

591

520

48.19

48.19

84.16

5.84

591

520

48.19

48.19

132.35

591

520

46.15

46.15

178.5

591

520

46.15

46.15

224.65

10

591

520

46.15

46.15

270.8

11

591

520

46.15

46.15

316.95

12

591

520

46.15

46.15

363.1

dk

(R COM dk
+

) x (1-t)

dk

PBP

0.61 years

CCP

$363.1 x 104

CCR

3.01

ROROI

102% p.a

DISCOUNTED CASH FLOW

End of Year

Non-discounted cash flow

discounted cash flow

Cumulative discounted cash

(k)
0

(75)

(75)

flow
(75)

(17.52)

(17.52)/1.15 = (15.23)

(90.23)

(16.08)

(16.08)/1.152 = (12.16)

(102.39)

48.19

48.19/1.153 = 31.69

(70.7)

48.19

48.19/1.154 = 27.55

(43.15)

48.19

48.19/1.155 = 23.96

(19.19)

48.19

48.19/1.156 = 20.83

1.64

48.19

48.19/1.157 = 18.12

19.76

46.15

46.15/1.158 = 15.09

34.85

46.15

46.15/1.159 = 13.12

47.97

10

46.15

46.15/1.1510 = 11.41

59.38

11

46.15

46.15/1.1511 = 9.92

69.3

12

46.15

46.15/1.1512 = 8.63

77.93

Discount rate

15%

DPBP

0.74 years

NPV

$77.93 x 104

PVR

1.76