DESIGN OF A PLANT TO PRODUCE 1000,000 POUND POLYSTYRENE PER ANNUM. AGOCJ IA PAUL LUCKY C ()EH) SEET

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1 DESIGN OF A PLANT TO PRODUCE 1000,000 POUND OF POLYSTYRENE PER ANNUM. BY AGOCJ IA PAUL LUCKY C ()EH) SEET CHEMICAL F~NGINEERING DEPl RTl\1ENT FEDERAL u NIVERSITY OF TECHNOLOGY MJ NNA, NIGER SUB v1itted TO THE DEPARTMENT CHEMICAL ENGTNEERING FEDERAL UN ~VERSITY OF TECHNOLOGY 1.1INNA, NIGERIA )EPTEMBER, 2008

2 DECLARATION I here by declare that this project presented in pclltiai fulfillment of the requirement for the award of Bachelor of Engineering (B.Eng) degree has not been presented before either wholly or partially for any degree elsewhere. Information hereby obtained from publication and unpublished work of other is acknowledged accordingly. l~ It {~IfO~

3 CERTIFICATION This is to certified that I have supervised, read an J approved this design project report, which I have found adequate both scope and quality for the award of the Bachelor of of Engineering of Federal University of Technology, Minna and is approved for its contrihut-ion to scientific knowledge and literary presentation ~.. f",-~v. ~~ ~. r: Supervisor Engr. A M uktar Date Dr. Edoga H.O.D (Chemical engineering) Date External Examiner Date 11

4 DEDICATION I dedicate this report to God almighty in appreciation to all he has done in my life. Also to my dear mother, Mrs. Veronica Agocha, for her love, caring and support in my study period. I also dedicate this report to my brother, Mr. Agocha Michael Peter for his fatherly suppoli and caring. ". III

5 ACKNOWLEDGEMENT First of all, I would like to express my deep gratitude to my able Supervisor, Engr A Muktar, for his guidance, valuable id eals, optimism as well as sense of honor. In pmiicular, I do appreciate his encouragement and support in my time of "losing factor". It will be an enjoyable memory for me to work in his group in future. I also particularly thank him for his advice and linguistic correction during my entire work. It is him who made me learn how to prepare a proper scientific paper. I am very grateful to Professor R.S Onifade, Who thro 19h his fatherly advice and love motivated me and stood for me throughout my trying time. More so, I want to thank the rest of my colleagues in the Department of Chemical Engineering, Federal University of Technology, Minna, for their various supports during this programme. I am deeply indebted to my mum Mrs. Agocha Veronica for her unconditional love, encouragement and support all my life. Also, worth mentioning is Ester I, who assisted me financially. Above all, I own everything to the Almighty God for his guidance and mercy. IV

6 ABSTRACT Presented in this report is the design of a polystyrene plant that supposes to carryout polymerization of styrene to pro duce polystyrene. The plant has a capacity of 100,000 pound per aru1um of polystyrene. Assumptions where necessary were made and detailed material and energy balances were effectively carried out. Also in this design 317 production days per annum were assumed and tj e remammg 48 days should be used for start up, maintenance, shutdown and holidays. In the design, the method employ is the suspension polymerization from the different types of polymerizations. However, the reaction is a batch type of reaction in which the monomer styrene is converted over a time period of 5.5 hours. Catalyst, suspending, stabilizing agent and initiator is used during the production as been blended with styrene monomer and recovered at the end of the reaction after been washed. Hence the percentage of conversion is 99.9% conversion. Therefore the production is pound per year of polystyrene. The production required a heater of 0.85 diameter heights v

7 RATION i TIFICATION ' "..... ' "... "..... i i ICATION iii OWLEDGEMENT iv ONE: INTRODUCTION APTER TWO: LITERATURE REVIEW :0 GENERAL HISTORY : 1 STRUCTURE OF POLYSTYRENE :2 PREPARATION METHOD OF POLYSTYRENE :3 PROPERTIES OF POLSTYRENE :4 GRADES OF POLySTyRENE :5 STABILITY OF POLySTyRENE :6 PREPARATION OF LIGHT STABILIY POLySTyRENE :6: 1 ANTIOXIDANTS :6:2 ULTRA- VIOLET ABSORBERS :6:3 ANTISTATS :6:4 FLAMES RETARDANTS :7 DESIGN ROUTE :7:1 AKYLATION DEHYDROGENATION POLYMERIZATION :7:2 DEHYROGENATION POLYMERIZATIONS (DP) :7:3 D.P. PROCESS FLOW DIAGRAM... 21

8 2:7:4 PROBLEMS OF CONVENTION EBD PROCESS :7:5 ADVANTAGE OF CARBON-DIOXIDE IN DEHyDROGENATION :7:6 CHARACTERISTICS SODEC02 PROCESS :8 ADVANTAGES & DISADVANTAGES OF POLySTyRENE :9 PROCESS DESCRIPTIONS :9:1 SOLUTION POLyMERIZATION EMULSION POLyMERIZATIONS SUSPENSION POLyMERIZATION : 10 SELECTED DESCRIPTION OF SELECTED TECHNOLOGy MODIFIED SUSPENSION POLyMERIZATION JUSTIFICATION OF SELECTED PROCESS ROUTE CHAPTER THREE: MATERIAL BALANCE Al CHAPTER FOUR: ENERGY BALANCE CHAPTER FIVE: FLOW SHEET CHAPTER SIX: EQUIPMENT DESIGN CHAPTER SEVEN: OPTIMIZATION OF EQUIPMENT CHAPTER EIGHT: SAFETY AND QUALITY CONTROL :1:1 H.AZARDS :1:2 INVENTORIES : 1:3 MATERIAL INVENTORIES : 1:4 EQUIPMENT INVENTORy : 1:5 HAZARD IDENTIFICATION : 1:6 EXPLOSIONS

9 8: 1 : 7 FIRES : 1:8 POISONING :1:9 SAFETY MEASURES :1:10 STRATEGIES :1:11 RISK MANAGEMENT IAPTER NINE: PROCESS CONTROL AND INTRUMENTA TlON : 1 GENERAL INSTRUMENTATION CONTROL :2 CONTROL OBJECTIVES :3INSTRUMENTS :4 CONTROL SySTEMS HAPTER TEN : ENVIRONMENTAL ACCEPTABILITY HAPTER ELEVEN: START UP AND SHUT DOWN HAPTER TWELVE: SITE & PLANT LOCATION HAPTER THIRTEEN: ECONOMIC & COSTING HAPTER FOURTEEN : RECOMMENDATION FEREN CE