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ACRYLONITRILEPHILIPPINES
CORPORATION PLAN
DESIGN
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VISION-MISSION STATEMEN
COMPANY MISSION
Acrylonitrile Philippines Corporation
aims to establish strong connection in
both local and international markets by
providing high quality acrylonitrileproduct.
COMPANY VISION
Acrylonitrile Philippines env
become the leading acrylon
manufacturer and supplier
Philippines; providing acrylointermediates in accordanc
standard conforming to the
product for chemical, latex,
textile fiber industries.
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Incorporators and Officers
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PRE-OPERATING PERIOD
Activities during the pre-operating period:
To conduct feasibility study or marketing plan,
Establishing the by-laws and required forms of incorporation,
Financing or seeking sources of capital
Hiring and training of personnel
Setting up and choosing potential plant location
Finalizing the plant layout design and its construction
The equipment design and specification, equipment installation
And the ordering and delivery of equipment and raw materials.
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PRE-OPERATING PERIOD ORGANIZATICHART
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OPERATING PERIOD
The plant will operate 360 days a year, 24 hours a day and seven days a weevery year during the month of December is allotted for the plant shutdown,
includes equipment maintenance and repair.
The employees are required to follow the work schedule. Work will start from
oclock in the morning (7:00 AM-3:00 PM). The second shift will start from 3:
11:00 PM. Evening shift will start from 11:00PM to 7:00 AM.
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OPERATING PERIOD ORGANIZATIOCHART
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CONSTRAINTS
ENVIRONMENTAL CONSTRAINTS
Potential environmental damage that would result from a plant a
spill have been considered. Potential emissions to the environm
the proposed acrylonitrile plant have been assessed in three ca
airborne emissions; waterborne emissions; and solid waste.
Nonetheless, emergency response plans should be developed
the environmental impact from a release of acrylonitrile. The co
regulates the production, handling, storage and release and dis
acrylonitrile and its byproducts through comprehensive environm
laws or standards.
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CONSTRAINTS
ECONOMIC CONSTRAINTS
Acrylonitrile is widely used in the production of acrylic fibers, SA
resin and SBR latex and other smaller-volume applications inclu
paints, caulking, automobile seals, carpets, sweaters, seat cush
head rests, seals and gaskets.
The major constraint in this regard is the dependence of polyme
companies and clothing and carpets industries to the competitor
imports of acrylonitrile. The company will create strategic busine
partnership with different companies to supply their needs.
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CONSTRAINTSHEALTH AND SAFETY CONSTRAINTS
Acrylonitrile is toxic if inhaled or swallowed or in contact with the
To avoid these incidents the APC will equip suitable first-aid uni
written procedure on how to handle exposures to acrylonitrile. H
identification, risk assessment and determining control (HIRADC
part of the safety practice of the company.
The company will have behavioral based safety (BBS)program.
trainings regarding occupational safety and health, internationa
organization for standardization (ISO), quality management pra
good manufacturing practices will be provided.
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CONSTRAINTS
MANUFACTURABILITY AND SUSTAINABILITY CONSTRAINTS
Due to its systems of production, transportation designs and wit
training of personnel that must be implemented and acceptable
data of raw materials supply, the manufacturability is not limited
Common problems associated with the delivery of raw materials
to weather issues like storms and floods. However, it is of distrib
responsibility to address this. And to make our product sustaina
production schedule was set.
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CONSTRAINTSETHICAL AND PROFESSIONAL CONSTRAINTS
The company follows the standards and rules set by the dep
of labor and employment.
The company practices the corporate social responsibility to
the active compliance with the law, ethical standards and int
norms. Yearly evaluation for the company will be done to asquality of management in people and processes and to quan
impact on the society on various areas.
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MARKET FEASIBILITYFour Mathematical Methods Computed Standard
deviationDescription
Arithmetic Straight Line
Method(ASLM)
19.69 Arithmetic Straight Line Method
assumes that the annual increasfuture will be the same although
increase in percent will keep on
Arithmetic Geometric Curve
Method(AGCM)
19.73 In this method, the rate of increa
projected values is constant; ho
amount of change keeps on incr
Statistical Straight Line Method
(SSLM)
2.83 For this method, the change in t
uniform, while the change as a %for the year is decreasing.
Statistical Parabolic Curve
Method (SPPM)
2.65 In SPPM, the change in the pred
may be increasing or decreasing
percentage change of the value
year may also be increasing or d
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MARKET FEASIBILITYHISTORICAL DEMAND FOR
ACRYLONITRILEYear Net Weight (kg)
2004 12295122
2005 12993375
2006 10920990
2007 13337358
2008 17340349
2009 20762683
2010 23250395
2011 22615526
2012 24329797
2013 26468538
Year Net Weigh
2004 1,295,1
2005 2,993,3
2006 1,920,9
2007 3,337,3
2008 7,340,3
2009 9,762,6
2010 8,250,3
2011 10,180,8
2012 14,329,7
2013 16,468,5
HISTORICAL SUPPLY FOR
ACRYLONITRILE
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MARKET FEASIBILITY Graphical representation of the historical demand
of acrylonitrile[national statistics office (NSO)
public reference unit, 2014]
0
5000000
10000000
15000000
20000000
25000000
30000000
2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
N
etWeightin(kg)
Year
Graphical Representation o
Supply of Acrylonitrile [
Exchange Commission, Pu
Unit, 2014]
0
2,000,000
4,000,000
6,000,000
8,000,000
10,000,000
12,000,000
14,000,000
16,000,000
18,000,000
2004 2005 2006 2007 2008 2009
NetWeight(kg)
Year
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MARKET FEASIBILITY
HISTORICAL DEMAND FOR PROPYLENE
Year Weight (kg)
2004 70,335,973
2005 71,771,401
2006 73,236,123
2007 74,730,7382008 76,255,855
2009 77,812,097
2010 79,400,099
2011 81,020,510
2012 85,567,875
2013 87,693,596
HISTORICAL SUPPLY FOR
Year Weig
2004 80,4
2005 79,5
2006 78,2
2007 79,72008 85,2
2009 79,8
2010 85,4
2011 88,0
2012 93,4
2013 90,7
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MARKET FEASIBILITY
HISTORICAL DEMAND FOR AMMONIA
Year Weight (kg)
2004 93337297
2005 98249787
2006 103420828
2007 1088640302008 114593715
2009 120624964
2010 126973646
2011 133656470
2012 137667870
2013 141983340
HISTORICAL SUPPLY FOR A
Year We
2004 86
2005 96
2006 106
2007 1172008 119
2009 121
2010 133
2011 137
2012 145
2013 153
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MARKET FEASIBILITYGRAPHICAL REPRESENTATION OF THE DEMAND
OF PROPYLENE AND AMMONIA [NATIONAL
STATISTICS OFFICE (NSO) PUBLIC REFERENCE
UNIT, 2014]
0
20000000
40000000
60000000
80000000
100000000
120000000
140000000
160000000
2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
NetWeight(kg)
Year
Ammonia
Propylene
GRAPHICAL REPRESENT
SUPPLY OF PROPYLENE[NATIONAL STATISTICS O
PUBLIC REFERENCE UN
0
20000000
40000000
60000000
80000000
100000000
120000000
140000000
160000000
180000000
2004 2005 2006 2007 2008 2009
NetWeight(kg)
Year
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MARKET FEASIBILITY PROJECTED DEMAND AND SUPPLY OF ACRYLONITRILE FOR THE NEX
YEARS USING STATISTICAL PARABOLIC PROJECTION METHOD AND
STATISTICAL STRAIGHT LINE METHODYear Demand (kg) Supply(kg) Difference(kg
)
2014 29,342,774 16,733,828 12,608,946
2015 31,675,639
18,396,716
13,278,923
2016 34,095,750
20,059,604
14,036,146
2017 36,603,106 21,722,492 14,880,614
2018 39,197,708 23,385,379 15,812,329
2019 41,879,555 25,048,267 16,831,288
2020 44,648,648 26,711,155 17,937,493
2021 47,504,986 28,374,042 19,130,944
2022 50,448,570
30,036,930
20,411,640
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MARKET FEASIBILITYGRAPHICAL REPRESENTATION OF THE PROJECTED DEMAND AND SUP
ACRYLONITRILE
0.00
10,000,000.00
20,000,000.00
30,000,000.00
40,000,000.00
50,000,000.00
60,000,000.00
2014 2015 2016 2017 2018 2019 2020 2021 2022 2023
NetWeight(kg)
Year
Demand
Supply
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MARKET FEASIBILITYPROJECTED DEMAND AND SUPPLY OF
AMMONIA FOR THE NEXT TEN YEARS USINGSTATISTICAL PARABOLIC PROJECTIONMETHOD
Year Demand (kg) Supply(kg)
2014 158691802 160108316
2015 173324518
175992401
2016 188508974 192558827
2017
204245172
2098075942018
220533110
227738701
2019 237372788
246352149
2020 254764207
265647939
2021 272707367
285626069
2022 291202268
306286539
2023 310248909
327629351
PROJECTED DEMAND AND SUPPL
PROPYLENE FOR THE NEXT TEN STATISTICAL PARABOLIC PROJECMETHOD
Year Demand (kg)
2014 110795095
2015 119243683
2016 127879141
2017
1367014672018 145710662
2019 154906727
2020 164289660
2021 173859462
2022 183616134
2023 193559674
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MARKET FEASIBILITYGRAPHICAL REPRESENTATION OF THE
PROJECTED DEMAND AND SUPPLY OFAMMONIA
GRAPHICAL REPRESENTATIO
PROJECTED DEMAND AND SUPROPYLENE
0
50000000
100000000
150000000
200000000
250000000
300000000
350000000
2014 2015 2016 2017 2018 2019 2020 2021 2022 2023
NetWeigh
t(kg)
Year
Demand
Supply
0
50000000
100000000
150000000
200000000
250000000
2014 2015 2016 2017 2018 2019 2020 2
NetWeig
ht(kg)
Year
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PROJECTED TIMETABLE1 3- Nov -1 3 1 7- Fe b- 14 2 4- Ma y- 14 2 8- Au g- 14 2 -D ec- 14 8 -Ma r- 15 1 2- Ju n- 15 1 6- Se p- 15 2 1- De c- 15 2 6- Ma r- 16 3 0-J
Feasibility Study and Project Planning
Incorporation
Financial Acquisition
Plant Site Negotiation
Plant Size Acquisition
Preparation of Engineering Design and Specification
Plant Construction Bidding
Plant Construction
Order and Fabrication of Equipment
Equipment Arrival
Hiring of Personnel
Installation of EquipmentOrder and Delivery of Raw Materials
Training of Personnel
Trial Run
Advertising and Promotion
Start of Normal Operation
Plant SiteNegotiation
Plant SizeAcquisition
Preparation ofEngineeringDesign and
Specification
PlantConstruction
Bidding
PlantConstruction
Order andFabrication of
Equipment
EquipmentArrival
Hiring ofPersonnel
Installation ofEquipment
Order andDelivery of Raw
Materials
Training ofPersonnel
Trial RunAdvertising and
PromotionStart of Normal
Operation
Start Date 7-Apr-149-Jun-145-May-145-May-1415-Aug-145-May-145-Jan-155-Oct-145-Jan-154-Jun-158-Jun-157-Sep-157-Sep-156-Mar-16
Duration 635691311153081202431509591181181365
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PROCESS SELECTION
PROCESS 1
Manufacturing acrylonitrile by combining propylene, am
and air in a process called ammoxidation. During ammo
propylene, ammonia and air are fed through a catalyst a
temperature. The vessel containing the chemical reactiocalled a fluid bed reactor, where the powdered catalyst m
fluid-like throughout the reactor.
PROCESS 1 SOHIO PROCESS
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PROCESS 1: SOHIO PROCESS
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PROCESS SELECTION
PROCESS 2MANUFACTURE OF ACRYLONITRILE FROM ETHYLENE CYANOHYDRIN
Germany and the United States first produced acrylonitrile on a
industrial scale in the early 1940s. These processes were base
catalytic dehydration of ethylene cyanohydrin. Ethylene cyanohproduced from ethylene oxide and aqueous hydrocyanic acid a
the presence of a basic catalyst. The intermediate was then deh
in the liquid phase at 200 C in the presence of magnesium car
and alkaline or alkaline earth salts of formic acid.
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PROCESS SELECTIONPROCESS 2
MANUFACTURE OF ACRYLONITRILE FROM ETHYLENE CYANOHYDRIN
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PROCESS SELECTION
PROCESS 3MANUFACTURING OF ACRYLONITRILE FROM ACETYLENE AND HYDRO
ACID
Catalyst consisting of cuprous chloride and ammonium chloride
solution in hydrochloric acid. A large excess of acetylene is use
mol/mol HCN) at a pressure slightly above 0.1106 pa absolute
temperature of 80 to 90C.
The molar yield is up to 90 per cent in relation to hydrogen cya
75 to 80 per cent in relation to acetylene. The main by-products
acetaldehyde, vinyl acetylene, divinyl acetylene, vinyl chloride,
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PROCESS SELECTIONMANUFACTURING OF ACRYLONITRILE FROM ACETYLENE AND HYDR
ACID
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PROCESS SELECTION TABCOMPARISON
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CRITERIA FOR PLANT LOCATTRANSPORTATION FACILITIES AVAILABLE- Transportation access to
markets adds to economic scale in production, distribution, and consumtherefore transportation increasing economic growth.
ACCESSIBILITY TO THE TARGET MARKET- Accessibility to the target
affects the cost of the product and it requires a lot of time for distribution
WATER SOURCE QUALITY AND QUANTITY- Numerous plant uses lar
of water in operating plant and some operations that needed the supply
SPECIAL BUSINESS INCENTIVES-Incentives create a good relation to
manufacturer and the consumers
CLIMATIC CONDITIONS-Climate affects the operation of the plant, the
the transportation of the raw material and the products.
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CRITERIA FOR PLANT LOCATUTILITIES COSTS AND AVAILABILITY-Plant operations are dependent
and electricity; therefore utilities should take into consideration
TREATMENT FACILITY- The location of the plant should have a correct
disposal and treatment facility because it is one of the requirements by t
CONSTRUCTION COST- Cost of the construction includes the equipme
construction of the plant, and the land.
OPERATING LABOUR- It will determine the number of manpower that ineeded in the operation of the plant.
TAXES- Taxes will affect the business in one way or other
LIVING CONDITIONS AND EXPANSION POSSIBILITIES- The chosen
must be economic zone and have large area for future expansion and d
considering the projected business growth
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PLANT LOCATION 1
TIPCO Estates corporation (TECO) Special EconoZone, Mabalacat, Pampanga, Philippines
Is a 68-hectare privately industrial complex and w
proclaimed as TECO special economic zone.
Industrial firms have chosen to locate here includ
sorting facilities, chemical processing, warehous
storage and manufacturing services.
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PLANT LOCATION 2Light Industry & Science Park III (LISP III)
LISP III is a 109hectare industrial park in Sto. T
Batangas.
LISP III is an Ecozone. Companies operating in t
ecozones are entitled to a tax incentive package
other benefits accorded by the Philippine econom
authority (PEZA) to qualified export-oriented com
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PLANT LOCATION 3The first cavite industrial estate (FCIE) situated in
Lankaan, Dasmarinas In Cavite.
It has a 154.5 hectare industrial subdivision esta
in 1991.
It was built to serve all the basic needs of manufconcerns from light-to-medium scale industry. It
classified as a special economic zone area by
Philippines Economic Zone Areas (PEZA).
SUMMARY OF CRITERIA FOR PLANLOCATION
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LOCATIONCriteria %
(TECO)Pampanga
(LISP)Batangas
(FCIE)Cavite
Transportation Facilities 10 8 7 6
Accessibility to Target Markets10 8 7 6
Water source quality and quantity
10
8
8
7
Special Business Incentives
10 9 9 9
Climatic Conditions
10 8 6 7
Utilities Costs And Availability
10 7 7 8
Treatment Facility
5 4 4 4
Construction Cost 10 7 7 7
Operating Labour
10 7 8 9
Taxes
5 4 4 4
Living conditions/expansion
possibilities10 9 8 6
Total
100
79
75
73
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PRODUCT DESCRIPTIONProperties Other Charateris
Melting point (C) -83.55 Colourless liquid with a swe
odour; vapours may be ign
distance; the compound ca
electrostatic charges throug
agitation; acrylonitrile polym
when hot, which may cause
to explode;uninhibited acry
explosive at room temperat
compound reacts violently
oxidizers, strong acids and
silver nitrate; the compounddecomposes in a fire, relea
gases; vapour is heavier th
may travel along the groun
assemble at lowest place; c
adverse effects well below
threshold.
Boiling point (C) 77.3
Solubility in water (g/litre) (20C) 73.5
Specific density (20C) 0.8060
Relative vapour density 1.8
Vapour pressure (kPa) (23.6C) 13.3
Flash point (open cup) 0C
Flash point (closed cup) -4.4C
Octanol/water partition coefficient 0.12
Flammability (explosive) limits 3 - 17 %
Relative molecular mass 53.06
Assay 99%
Autoignition temp. 897 F
Refractive index n20/D 1.391(lit.)
Exposure limit 17%
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OVERALL MATERIAL AND ENER
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OVERALL MATERIAL AND ENERBALANCE
Mass Output
Componen
t
Weight
(kg)
N2 18010.72
O2 459.07
HCN 187.50
C3H6 0.0079
NH3 417.98
CO2 1209.95
Acrylonitri
le3640.36
Acrolein 197.50
Acetonitril
e110.76
H2O 4599.73
Reactor feed
Componen
t
Weight
(kg)
C3H6 85.6470
NH3 102.776
4
Compressed Air
Compone
nt
Weight
(kg)
N2 18010.722
63
O2 5467.7064
34
Equipment 1: Fluidised Bed Reactor
OVERALL MATERIAL AND ENER
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QUENCHER
OVERALL MATERIAL AND ENERBALANCE
OVERALL MATERIAL AND ENER
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0.00786
kg/hr C3H6
459.0222 kg/hr O2
18008.92
kg/hr N2
1209.833
kg/hr CO2
187.4856 kg/hr HCN
3603.851 kg/hr AN
109.7509
kg/hr ACR
195.583
kg/hr ACN
Top Products
Component Weight (kg)
C3H6 0.007859942
O2 459.0221773
N2 18008.92156
CO2 1209.832592
HCN 187.485553
Acrylonitrile 3603.851149
Acetonitrile 109.7509203
Acrolein 195.5829506
H2O 4571.733389
4571.733 kg/hr H2O
Vaporizer
OVERALL MATERIAL AND ENERBALANCE
OVERALL MATERIAL AND ENER
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0.007859942 kg/hr C3H6
459.0221773 kg/hr O2
18008.92156 kg/hr N2
1209.832592 kg/hr CO2
0.360385115 kg/hr AN
67873.13 kg/hr H2O
187.485553 kg/hr HCN
3603.490764 kg/hr AN
109.7509203 kg/hr ACR
195.5829506 kg/hr ACN
72444.863 kg/hr H2O
After Reaction:
134.5736363 kg/hr HCN
72444.863 kg/hr H2O
3603.490764 kg/hr AN
195.5829506 kg/hr ACN
109.7509203 kg/hr ACR
0.00786 kg/hr C3H6
459.0222 kg/hr O2
18008.92 kg/hr N2
1209.833 kg/hr CO2
187.4856 kg/hr HCN
3603.851 kg/hr AN
109.7509 kg/hr ACR
195.583 kg/hr ACN
4571.733 kg/hr H2O
Absorber
OVERALL MATERIAL AND ENERBALANCE
OVERALL MATERIAL AND ENER
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Component Top
Kg/hr
C3H3N 3571.05934
7
HCN 131.209295
4
H2O 3571.05934
7
Total 7273.32799
134.57363
63
kg/hr
HCN
67873.130
22
kg/hr
H2O
3603.4907
64
kg/hr AN
195.58295
06
kg/hr
CAN
109.75092
03
kg/hr
ACR
Compone
nt Bottom
C3H3N 32.431417
CH3CN195.582
95
HCN3.36434
09
H2O124907.
17
Total125138.
55
Recovery Column
OVERALL MATERIAL AND ENERBALANCE
OVERALL MATERIAL AND ENER
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Component
Organic
phase
Kg/hr
C3H3N 3571.05935
HCN 131.209295
H2O 178.552967
Total 3880.82161
Component
C3H3N
HCN
H2O
Total
Decanter
OVERALL MATERIAL AND ENERBALANCE
OVERALL MATERIAL AND ENER
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HCN 131.2
5
Total 131.25
Component Input
Kg/hr
C3H3N 3571.059347
HCN 131.2092954
H2O 178.5529674
Total 3880.82161
C3H3N 3571.0
47
H2O 178.55
74
Total 3749.6
14
Head Column
OVERALL MATERIAL AND ENERBALANCE
OVERALL MATERIAL AND ENER
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C3H3N 3571.0
7
H2O 36.071
4
Total 3607.1
4
Component Inlet
Kg/hr
C3H3N 3571.059347
H2O 178.5529674
Total 3749.612314
H2O 1
Total
Product Column:
OVERALL MATERIAL AND ENERBALANCE
TABLE OF STANDARDS
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Code Description
Batas Pambansa Bilang 68 Corporation Code of the Philippines Articles o
Republic Act No. 8749 Philippine Clean Air Act of 1999 Wast
Republic Act No. 9275 Philippine Clean Water Act of 2004
Wast
Presidential Decree No. 984 Pollution Control Law of 1976 Wast
DENR Administrative Order No. 90-35 Revised Effluent Regulations of 1990 Wast
Presidential Decree No. 856 Sanitation Code of the Philippines Wast
Presidential Decree No. 442 The Labor Code of the Philippines
Manag
OSHA Occupational Safety and Health Administration Health
NIOSH National Institute of Occupational Safety and
Health
Health
Presidential No. 442 Labor Code of the Philippines Management Stu