The process used in the manufacture of aniline from nitrobenzene is described in Appendix F, design problem F.8. The process involves six significant stages:

Vaporization of the nitrobenzene

Hydrogenation of the nitrobenzene

Separation of the reactor products by condensation

Recovery of crude aniline by distillation

Purification of the crude nitrobenzene

Recovery of aniline from waste water streams

Estimate the capital cost of a plant to produce 20,000 metric tons per year.

Data from problem F.8
 1. Prepare a material balance on an hourly basis for the complete process in weight units.
2. Prepare a heat balance for the reactor system, comprising vaporizer, reactor and condenser/cooler.
3. Draw a process flow diagram for the plant. This should show all items of equipment approximately  to scale and at the correct elevation. The catalyst regeneration equipment should be shown.
4. Chemical engineering design:
(a) Vaporizer
Give the detailed chemical engineering design, and give reasons for using the type chosen.  Specify the method of control.
(b) Reactor
Give the detailed chemical engineering design for the fluidized-bed and heat-transfer surfaces. Select a suitable heat-transfer fluid and give reasons for your selection. Do not attempt to  specify the filters or to design the condenser/cooler in detail.
(c) Crude aniline separator
Specify the diameter, height and weir dimensions and sketch the method of interface level  control which is proposed.
(d) Amine water stripper
Give the detailed chemical engineering design of the column.

5. Prepare a full mechanical design for the reactor. Make a dimensioned sketch suitable for submission  to a drawing office, which should include details of the distributor, and show how the heat transfer  surfaces will be arranged. An indication of the method of supporting the candle filters should be  shown, but do not design this in detail.
6. Prepare an equipment schedule detailing all major items of equipment, including tanks and pumps.  A specimen pipeline sizing calculation for the reactor inlet pipe should be given. All materials of  construction should be specified.
7. Describe briefly how the plant would be started up and shut down, and discuss safety aspects of  operation.
8. Write a short discussion, dealing particularly with the less firmly based aspects of the design, and  indicating the semi-technical work which is desirable.