Professional Documents
Culture Documents
This project is the result of the continuous guidance and encouragement of the
teachers of The Department of Chemical Engineering and Technology, IIT (BHU),
Varanasi.
I express my deep sense of gratitude and reverence to Prof. A.S.K. Sinha, Head of
Department, Department of Chemical Engineering and Technology, IIT (BHU),
Varanasi and Prof. A.K. Verma, Dr. Durga Prasasd and Mrs. Bhavana Verma, Project
Coordinators, for providing me opportunity to work on this project and for their
scrupulous supervision and being available for us to sort out any kind of trouble in the
way.
It is my privilege to express my indebtedness and deep sense of gratitude to all the
respected teachers of our department for their guidance throughout the duration of the
project. I also extend my gratitude to library staff for their cooperation.
Finally, I would like to thank my team mates, Ashwin Sancheti and Keshav Baranwal,
for their unalloyed helping hands in proving me with materials and moral support
which helped me to complete the project.
Date: _________
____________
Avinash Nayak
09102EN023
B. Tech Pat IV
Department of Chemical Engineering and Technology
IIT (BHU), Varanasi
1
INDEX
Topic
Page No.
Title
Acknowledgement
2. Introduction
2.1 Uses
2.2 Grades of Soda ash
2.3 Demand and Production Statistics
2.4 Projected Demand
3.
Process Description
3.1 Various Processes used for Soda ash Manufacture
3.2 Selection and description of Process
3.3 Flow Sheet of selected Process
10
11
Raw Materials
22
4.
5. Material Balance
5.1. Lime Kiln
5.2. Mixer
5.3. Slaker
5.4. Ammonia Absorption tower
5.5. Calciner
5.6. Carbonating Tower
19
24
33
6.1. Slaker
6.2. Ammonia Absorption Tower
6.3. Calciner
6.4. Ammonia Still
6.5. Carbonating Tower
6.6. Lime Kiln
7. Process Design
7.1. Process Design of Ammonia absorption Column
7.2. Process design of Brine Cooler
7.3. Process Design of Carbonating Column
41
8. Equipment Design
8.1. Designing of Ammonia Absorption Column
8.2. Design of Brine Cooler
68
86
89
93
98
102
14.Plant Safety
104
107
108
115
18. Bibilography
116
2) INTRODUCTION
Soda ash, the common name for sodium carbonate (Na2CO3), has significant
economic importance because of its applications in manufacturing glass, chemicals,
paper, detergents and many other products. It has been used since ancient times. The
Egyptians, for instance, umade glass containers from soda ash as early as 3500 BC.
And the early Romans expanded its use beyond glass as an ingredient in medicinals
and bread.
Sodium Carbonate
105.989
8510C
2.533
0.249 cal/gm/0C
0.249 Btu/lb/0F
0.256 cal/gm/0C
75.5 cal/gm
2550 cal/gm
30.0 cal/gm
156.4 cal/gm
208.8 cal/gm
7 gms Na2CO3 in 100 gms H2O
44.7 gms Na2CO3 in 100 gms H2O
49.5 gms Na2CO3 in 100 gms H2O
100% Na2CO3 = 58.48% Na2O
1lb. Na2CO3 = 0.6881 lb. HCI
Water Treatment
Soda Ash can be used to control pH (acidity) levels in water and also provides the
sodium ion needed for water softening.
Pulp & Paper
Soda Ash supplies the sodium ion required in the pulping of wood fiber.
Some more uses of soda ash
1. Mineral processing in mining
2. Soaps and detergents
3. Metal refining
2.2) Grades in Soda Ash
6
Product
Description
Documents
Absorptaplus
MSDS
Tech Data Sheets
MSDS
Grade 100
Grade 160
Grade 260
MSDS
size.
Grade 50
MSDS
Optipro
Table 2.2
2.3) Demand and Production statistics at national and international level
The manufacture of soda ash in India started in 1932 at Dharangadhra in Gujarat with
an installed capacity of 50 tonne per day under the name of 'Shri Shakti Alkali Woks'
which later became Dharangadhra Chemical Works Ltd. This was followed by the
entry of Tata Chemicals at Mithapur in Gujarat in 1994 with an installed capacity of
100 tonne per day. In a span of 50 years it has grown to be the biggest soda ash unit in
the country with daily capacity of 2000 tonne. In the same Saurashtra region
in Gujarat, two more soda ash plants came up after-wards. Saurashtra Chemicals at
Porbandar was commissioned in 1959 with a capacity of 200 tonne per day which has
been expanded to 800 tonne per day. Gujarat Heavy Chemicals Ltd at Sutrapada, near
Veraval was commissioned in 1988 with a capacity of 1200 tonne per day. All these
four units in Saurashtra are based on Solvay process.
The present installed capacity of Sixteen soda ash manufacturing units is 69.09 lakh
tonne. With the expansion of existing soda ash manufacturing units and after
commencement of production of the new units the total production of soda ash will be
97.4 lakh tonne.
Raw materials for Solvay process are salt, lime-stone and coke. Ammonia is also used
in the process as an intermediate carrier Catalyst. In soda ash industry solar salt is
used which contains 93-94% NaCl as against 98% available in the international
market. Similarly, the quality of lime stone does not meet international standard. As
regards coke the industry has no option but to import it from China, Japan etc.
Coal is not a raw material for soda ash manufacture but all soda ash units are having
coal based captive power plants for cogeneration of steam and power required in the
industry.
The present global capacity of soda ash is 67.0 million tonne per annum and the long
term growth rate is 1.5-2%. A list of Global major soda-ash units are given.
The major technology suppliers are :
Solvay and Cie SA, Belgium
AKZO-ZOUT Chemie BV, Netherlands
Asahi Chemical Industry, Japan
Polimex Cheepok, Poland
Technology Exports Divn, DSTA, China
expected to grow by 8.4% and 6.1%, respectively, during the year," CMIE ( Centre for
Monitoring Indian Economy) said in a recent report. After falling for three
consecutive months, the chemical production index rose by 5.3% in July 2012
compared to a year ago.
3) PROCESS DESCRIPTION
3.1) Brief Description of various process
(A)Le Blanc Process
This process was invented by Nicolas Le Blanc, a French man ,who in 1775, among
several others submitted an outline of a process for making soda ash from common
salt, in response to an offer of reward by the French academy in paris. Le Blanc
proposal was accepted and workable on a commercial scale.
Process Description
Reactions
2NaCl+H2SO4 Na2SO4+2HCL
4C+ Na2SO4 NaS+4CO
Na2S+ CaCO3 Na2CO3+CaS
10
ammonium chloride is centrifuged and dried. The product is 98% pure and is marked
as ammonium chloride fertilizer with nitrogen content of 25%. The mother liquor
obtained after the separation of ammonium chloride crystals is recycled to the
carbonation vessels placed in series. Carbon dioxide obtained from ammonia plant
and the calciner section of soda ash plant is injected in the carbonation vessels. There
is provision of cooling coils in the lower carbonation vessels. Sodium bicarbonate is
formed. The growth of crystals, of sodium bicarbonate is controlled by the supply of
cooling water to cooling water to cooling coils in carbonation vessels. Sodium
bicarbonate is thickened in a thickener and centrifuged. The sodium bicarbonate is
calcined to soda ash.
Raw material consumption per ton of co-product
The plant has several advantages over the conventional Solvay process in as
much as it uses less raw material, has no effluent disposal problem, and both sodium
and chloride radical of salt are fully utilized giving valuable ammonium as a
byproduct.
14
countercurrent to the rising ammoniacal gases. The temperature of inlet brine is about
300C and that of exit is about 360 to 420C.
Precipitation of Bicarbonate: The ammoniated brine from the absorber coolers is
pumped to the top of one column in a block of columns used to precipitate
bicarbonate. This column which has been fouled or partially plugged with sodium
bicarbonate after several days of crystallization is referred to as a cleaning column.
Lime kiln gas, compressed to about 414 kPa (60psi), enters the bottom of the cleaning
column and bubbles up through the solution to absorb most of the carbon dioxide. The
concentration of carbon dioxide in the liquor is kept below the precipitation
concentration. Relatively little cooling is required. The scale is dissolved off the
cooling surfaces of the cleaning column by the fresh ammoniated brine, assisted by
gas agitation. The liquor leaving this column is fed in parallel to the top of the
remaining columns in to block. A stronger carbon dioxide gas made up of a mixture of
kiln gas an bicarbonate calciner gas is fed to these crystallizing or making columns
and bubbles up through the solution. This process precipitates sodium bicarbonate and
is accompanied by the evolution of considerable heat which must be removed to
improve yield. Crystals formed during the carbonation step gradually foul the heat
exchange surfaces and thus a crystallizing column must alternately be the cleaning
column. The gases, which are predominantly nitrogen, but also contain carbon dioxide
and ammonia, are vented from the cleaning and making columns and collected of
recycling to the absorber.
Filtration of Bicarbonate: The slurry, collected from the crystallizing towers, is fed
to continuous vacuum filters or centrifuges which separate the crystals from the filter
liquor. The filter cake is carefully washed with fresh water to control the residual
chloride to meet customer specifications. The dewatering characteristics of the
bicarbonate crystals are very dependent on operating conditions in the crystallizing
15
columns. Air drawn through the vacuum filter (or the vent gas from the centrifuge
operation) is returned to the absorption section. The filter cake, often called crude
bicarbonate or ammonia soda, liquor and is made up of sodium bicarbonate and
small amounts (5 mol% on a dry basis) of ammonia primarily in the form of
ammonium bicarbonate. The cake is then conveyed to the calcining operation.
Recovery of Ammonia: The filter liquor contains unreacted sodium chloride and
substantially all the ammonia with which the brine was originally saturated, present as
fixed and free ammonia. The fixed ammonia or ammonium chloride
corresponds stoichiometrically to the sodium bicarbonate that had been precipitated.
Free ammonia includes ammonium hydroxide, bicarbonate, carbamate, and the
several possible carbon compounds of ammonia that decompose at moderate
temperatures. Before preheating, sulfide solution may be added for corrosion
protection. The sulfide is distilled for eventual absorption by the brine in the absorber.
The filter liquor is preheated by indirect contact with the gases leaving the distiller.
The warmed feed liquor then enters the main coke-, or bubble cap filled sections of
the distiller where heat decomposes free ammonium compounds and steam strips
almost all of the free ammonia and carbon dioxide. The carbon dioxide free solution
is usually treated with milk of lime (or anhydrous lime) in an external well agitated
limiting tank called a prelimer. Here the ammonium chloride reacts with the milk of
lime and evolved ammonia gas is vented back to the distiller. The resulting hot
calcium chloride solution, containing residual ammonia in the form of ammonium
hydroxide, flows back to a lower section of the distiller. Low pressure steam sweeps
practically all of the ammonia out of the limed solution. The final solution, known as
distiller waste, contains calcium chloride, unreacted sodium chloride, and the
excess lime, and is diluted by the condensed steam and the water in which the lime
was conveyed to the reaction. Distiller waste also contains the inert of this solution.
16
However, the waste liquors are usually pumped to settling basins where the suspended
solids are deposited. The clear over flow contains dissolved salts, which are
objectionable contaminants are locations where the quality of the receiving waters is
materially affected. Close control of the distillation is required to thoroughly strip
carbon dioxide to avoid waste o flame and achieve nearly complete ammonia
recovery. The hot (560C) mixture of wet ammonia and carbon dioxide leaving the top
of the distiller is cooled to remove water vapor before being sent to the absorber.
Lime Preparation: The most suitable limestone, hard and strong with low
concentrations of impurities, is graded to reasonably uniform coarse size. Although
other fuels may be used, the limestone is usually mixed with about 7% metallurgical
grade coke or anthracite and then burned in vertical shaft kilns. Air is admitted
continuously into the bottom of the kiln an gas is sucked off the top. The fuel burns in
a zone a little below the middle of the kiln, and the stone burns to lime. Carbon
dioxide is generated by decomposition of limestone and combustion of carbon in the
fuel. The kiln gases are diluted with nitrogen from the air used to burn the fuel and
usually stone dust, ash particles, and gaseous impurities. The gas is partially cooled in
the kiln by the upper layers of stone, and further cooled and cleaned before entering
the compressors feeding the carbonating columns. The lime, cooled somewhat by the
entering air in the lower parts of the shaft kiln is discharged intermittently and usually
in rotary slackers that produce a thick suspension, commonly called milk of lime,
which is stored in agitated tanks. The heat of the reaction produces milk of lime at a
temperature of 90-1000C; water addition is controlled to give a free calcium oxide. In
some operations, dry lime is used in place of the milk of lime. It is pulverized and
added continuously to the prelimer in the distillation step, thus reducing the water
added and steam consumption and producing a concentrated distiller waste.
Calcining the Bicarbonate to Soda Ash: To prevent dilution of the decomposition
17
quantities of by-product ammonium chloride, more ammonia is first added to the filter
liquor, which is chilled to approximately 100C. Solid sodium chloride is added,
dissolved, and ammonium chloride precipitates, which is separated for sale, the
mother liquor being recycled to the carbonation operation. There are significant
differences in equipment of the conventional ammonia soda process and the
ammonium chloride producing soda ash process. For example, there is no ammonia
recovery and therefore no distillation tower, likewise, no milk of lime and
consequently no lime kilns which are also the source of carbon dioxide for
bicarbonation. However, the ammonium chloride producing process requires, unlike
the regular ammonia soda plant, equipment to process solid salt, and of the
ammonium chloride production, crystallizers, filters, dryers, and cooling equipment of
corrosion resistant materials. In addition, an ammonia source is required which
preferably also supplies carbon dioxide for the bicarbonation.
Figure 3.1
20
FIgure 3.2
4)
RAW MATERIALS
21
Input bulk requirements for the Solvay process are salt, coal, and limestone. Salt is
used as brine, pumped from deep wells or as crystalline salts via evaporation
procedures. Ammonia make up in the recirculation load amounts to about 1.5kg/ton of
soda ash.
(i)Specifications and Availability of raw materials
Generally quick lime is used in the manufacture of calcium carbide. The calcium
carbide manufactures generally prefer lime containing 95% CaO (min.), not more
than 3% SiO2, not exceed 2%. Though chemical composition is the guiding factor, the
physical characteristics of the limestone are also very important. For the manufacture
of bleaching powder also, fat lime-containing CaO 95% and above is required. Total
Fe2O3+ Al2O3 + MnO2 should be less than 2%; MgO should be below 2% and
SiO2 less than 1.5%. Bleaching powder is prepared by absorption of chlorine by dry
hydrated lime. The hydrated lime should not contain more than 2% of excess water.
Iron and oxides tend to discolour the bleached material. Magnesia renders the
bleaching powder hydroscopic. Silica and clay impede solution and setting of
bleaching powder. Limestone suitable for bleaching powder can be advantage utilized
by alkali industry for the manufacture of soda ash and caustic soda.
Sr.
Parameters
Guaranteed
Specification
Chemical Analysis
01 Ash (dry basis)
02 Fixed carbon
03 Moisture
04 V M (dry basis)
05 Sulphur (dry basis)
06 Phos (dry basis)
07 CSR
08 CRI
09 M 40
10 M 10
Table 4.1
12.5 % max
By Difference
5.0 % max,
1.5 % max
0.6 % max
0.055 % max
62% min
28% max
82% min
7.5% Max
Salt (Coarse)
High purity certified vacuum salt especially prepared to be of relatively coarse
crystals with a narrow grain size range. Strictly prepared in batch lots to optimise
grain size uniformity. Suitable for salting in some mechanical cheese manufacturing
plants using accurate pneumatic salt conveying equipment, which are sensitive to a
wide or variable range of grain sizes.
23
Figure 4.1
24
5) MATERIAL BALANCE
5.1) Material Balance for lime kiln
Thus,
Amount of CO2 required = 20833/106 x 44 = 8647.8 Kg/hr
CaCO3 CaO + CO2
C+ O2 CO2
Assuming 90% and equal conversion in both reactions and ideal conditions that
energy for the 1st reaction is provided by the 2nd reaction.
Moles of CaCO3/ Moles of C = 96.4/43.4 =2.226
Amount of Calcium Carbonate required = 8647/44 x 100/90 x1/1.449 x 100.8=
14654.9 Kg/hr
Amount of carbon required = 8647.8/44 x 100/90 x 1/3.226 x 12 =812.2 Kg/hr
However, calcium carbonate is also a source of slaked lime ( i.e.Ca(OH)2) which is
uses for separation of Ammonia still. Hence we need to make sure enough calcium
oxide is produced.
20833.3 Kg/hr of Na2CO3 = 20833.3/100 x 2 Kmoles of NH4Cl is Produced
Ca (OH)2+ 2 NH4Cl CaCl2 + 2 NH3 + H2O
Thus, Ca (OH)2 required = 20833.3/106 x 2/2 Kmoles/hr = 14544 Kg/hr
Hence, CaCO3 required = 20833.3/106x 2/2 x 100.8 x 100/90 =22012.2 Kg/Hr
Carbon required = 22012/(100.00x2.226) x 12 x 100/90 =1318.4 Kg/hr
Amount of oxygen required =1318.4 /12 x 32=3515.7 Kg/hr
Amount of air required = 100/23 x3515 Kg/hr
25
= 15285.7 Kg/hr
Output (Kg/hr)
22012.2
Lime stone
2201.2
(unreacted)
Carbon
1318.4
Carbon (unreacted)
131.8
Air
15285.7
Calcium Oxide
11094
Impurities
NA
376.718
of impurities)
Nitrogen
11769
Carbon dioxide
13549.4
Table 5.1
Thus,
Amount of NaCl salt required = 20833.3/106 x 2 x (23+35.5) = 22995.2 kg/hr
Amount of Water required = (13/0.3) x 22995.2 = 996450 kg/ hr
Input (Kg/hr)
Output (Kg/hr)
NaCl
22995.2
Brine solution
1019445
Water
996450
Concentration
0.3 NaCl/Lt
Table 5.2
5.3) Material Balance for Slaker
Calcium oxide from lime kiln = 11094.4 Kg/hr
Water is in 200% excess
Thus,
Amount of water required = 11094.4/56 x 300/100 x 18 = 10697.7 Kg/hr
Amount of Ca(OH)2 produced = 11094/56 x 74 = 14659.9 Kg/hr
Amount of slaked lime produced = 10697.7 + 11094.4 = 21792.1 Kg/hr
Input (kg/hr)
Output (Kg/hr)
Calcium oxide
11094.4
Calcium Hydroxide
14659.9
water
10697.7
Water
7131.3
Table 5.3
5.4) Material Balance for Ammonia Absorption Tower
Brine solution = water + NaCl salt
Amount of NaCl salt = 22995.2 Kg/hr
Amount of water = 996450 Kg/hr
Assuming 99% absorption of ammonia
Amount of ammonia absorbed = 22995.2 /58.5 x 17 = 6682.4 Kg/hr
27
Output (kg/hr)
6749.9
Ammonia
67.5
(unreacted)
NaCl
22995.2
Water
986485.5
Water
996450
Ammonium
13756.0
Hydroxide
NaCl
22995.2
Table 5.4
H298 = +Kcal/mol
Output (Kg/hr)
34999.9
Soda ash
28
20833.3
Water
3537.7
Carbon dioxide
8647.7
Table 5.5
H298 = +Kcal/mol
29
Input (Kg/hr)
Output (Kg/hr)
Water
986485.5
Sodium bicarbonate
33018.5
NaCl
22995.2
Water
986485.5
Ammonium
13756.0
Ammonium
21029.8
hydroxide
Carbon dioxide
chloride
22197.1
Carbon dioxide
4901.7
Table 5.6
H298 = +Kcal/mol
Output (Kg/hr)
20129.8
Calcium Chloride
21815.9
Ammonia (recycled) 67
Ammonia
6682.1
Calcium Hydroxide
Water
7075.2
chloride
14543.4
30
Table 5.7
Output (Kg/hr)
Sodium chloride
22995.2
Sodium carbonate
20833.3
Carbon
1318
Calcium chloride
21815.9
Lime stone
22012.2
Carbon dioxide
4901.7
Water
1007147
Water
1007147
Air
15285.7
Carbon (unreacted)
131.8
Nitrogen
11769
Lime stone
2201.2
(unreacted)
Oxygen (in Oxides
376
of impurities)
Table 5.8
Outputs:
Output temperature of products = T Kelvin
Heat Output
= (mCpt)CaO + (mCpt)CO2 + (mCpt)C(unreacted) + (mCpt)CaCO3 (unreacted) +(mCpt)C
31
or
T=2130C
6) ENERGY BALANCE
6.1) ENERGY BALANCE AROUND SLAKER
CaO + H2O Ca (OH)2
Input (Kg/hr)
Output(Kg/hr)
Calcium oxide
11094.4
Calcium hydroxide
14659.9
water
10697.7
water
7131.3
=250C
=2130C
= 0.775x109 calories
= -3.85x109 calories
Outputs:
Temperature of output stream
Heat output
= T Kelvin
T= 645 K
T= 3720C
Or
=250C
=600C
Input (Kg/hr)
Output(Kg/hr)
Ammonia
6749.9
Ammonia
67.5
(unreacted)
NaCl
22995.2
Water
986485.5
Water
996450
Ammonium
13756.0
Hydroxide
NaCl
Table 6.1
Heat input
= (mCpt)gases
= (1569 x 7440 x 25)
=0.29 x 109
Output:
Temperature of output liquid stream = 4000C
Temperature of output gas stream = 3000C
Heat output
33
22995.2
34
Kg/hr
Kmol/hr
Output
(Kg/hr)
Kmol/hr
Sodium
34999.9
473
Soda Ash
20833.3
196.5
Water
3537.7
196.5
Carbondioxide
8647.7
196.5
bicarbonate
Table 6.2
Inputs:
Reactant temperatures
=250C
Heat input
=0
Heat of reaction
Outputs:
Output stream temperature = 1800C
Heat output = (mcpt) Na2CO3 + (mcpt) H2O + (mcpt) CO2
=196.5 x 28900 x 150 + 196.5 x 8311 x 150 + 196.5 x 10610 x 150
=1.4141 x 109 calories
35
= 1.414 x 109
Heat supplied
Output
Ammonium
Kg/hr
Kmol/hr
20129.9
379.8
Calcium
Chloride
Ammonia
Kg/hr
Kmol/hr
21815.9
198.31
chloride
67
3.9
Ammonia
6682.2
393.1
14543.4
196.5
water
7075.2
393.1
(recycled)
Calcium
hydroxide
Table 6.3
Inputs:
Heat input
36
Outputs:
Temperature of output stream = 600C
Heat output
= (mcpt) NH3 +
Heat removed
=600C
Temperature of reactants
=250C
Heat input
=0
Heat Output
= -4.7 x 109calories
Heat removed =
Cooling water required
H= 43.4 Kcal/mol
C+ O2 CO2
Output (Kg/hr)
Lime stone
22012.2
Lime stone
2201.2
Carbon
1318
Carbon
131
Air
15285.7
Calcium Oxide
11094.4
Impurities
N.A.
Oxygen
376
Nitrogen
11769
Carbon Oxide
13549.4
Table 6.4
Temperature of reaction is 11000C
Inputs:
Temperature of input reaction = 250C
Therefore heat of reactants = 0
Heat of reaction at 1100 0C (H298) = -3.04 x 109 calories
7) PROCESS DESIGN
7.1) PROCESS DESIGN OF AMMONIA ABSORTION COLUMN
Ammonia Absorption column (Packed column)
39
1) Column Design
Material Balance across stage M for Ammonia
40
NH3 entering the stage as vapour + in water = NH3 going out in vapour phase + in
water
VYM-1 +LXM+1 = VYM+LXM
Thus,
Xm+1= (VYm + LXm Vym-1)/L---(2)
Also
VYm LXm+1 = VYm-1 LXm = VYo +LX1 = 256.58 * 1.8569 7114.77 *0.0663
This implies:
VYm LXm+1 = 4.731
From2:
Yo= 1.8589
Y1= 0.1375
Y2= 0.0086
-
X1=0.0663
X2=0.0043
X3=0
Column top
261.34 Kmol/hr
41
Column bottom
733.03 Kmol/hr
=0.0726 Kmol/sec
Liquid flow rate
7114.78 Kmol/hr
=1.9763 Kmol/sec
Gas density ( assuming 101325/(8.314x313)
=0.03893 Kmol/m3
ideas gas law rho=
=1.323 Kg/m3
=0.02036 kmol/sec
7586.48 Kmol/hr
=2.1074 Kmol/sec
rho= 0.905 Kg/ m3
P/RT
Average molecular
34 Kg/ Kmol
23.25 Kg/kmol
weight (gas)
Liquid density
Average molecular
1000 Kg/ m3
20.68 Kg/Kmol
1000 Kg/ m3
20.68 Kg/ Kmol
weight (liquid)
Flv = lw/vw
(rhog/rhol)^(1/2)
Vw= 203.34 x 34 Kg/hr
= 2.468 Kg/sec
Flv= 0.6024
Table 7.2
Ideal pressure drop in a packed tower absorber is 15- 50 mm H2O/ m packing.
Thus,
Assuming pressure drop of 20 mm H2O /m packing
We refer to Fig 11.44 Pg.6-3 Coulson Richardson vol. 6 3rd edition
At flooding
% flooding
K1= 0.36
K2 =0.95
(0.36/0.95 x100)(1/2)
=61.6 %
K1= 0.55
K2= 1.9
(0.55/1.9 x 100(1/2)
=53.8 %
Table 7.3
Selecting pall rings of 31/2 inch size for packing
Size = 89 mm
Bulk density = 64 Kg/ m3
Surface area , a= 85 m2/ m3
Packing factor, fp = 52/m
Mass flow rate of vapor / unit area of cross section
)1/2
Vw= (
Vw
1.007 Kg/m2 s
42
1.379 Kg/m2 s
Packing to diameter
4.704/1.379 =3.433 m2
= 1.376 m =1.5 m
16.85
=2.09 m =2.1 m
23.6
ratio
Table 7.4
Estimation of Column Height
We need to find height of each stage individually since the flow rate is
changing and cannot be assumed to be constant in the entire column.
Height of gas and liquid transfer unit
Hg =Gm/( Kg a P)
Hl = Lm/ (Kl a Cl)
Total height , Ht = Hg + ( m Gm* Hl/ Lm)
Where,
P = column operating pressure, atm
Cl= total concentration, Kmol/m3
Gm = molar gas flowrate/ unit corss section area, Kmol/ m2 sec
Lm = molar liquid flowrate / unit cross section area, Kmol/ m2 sec
Using Ondas method
KL(
KG(
Where:
K5= 5.23 for packing size above 15 mm and 2 for size below 15 mm
Lw = liquid mass flowrate / unit cross section area, Kg/ m2
Vw= gas mass flowrate / unit cross section area, Kg/ m2
A= area of packing/ unit volume, m2/m3
Dp= packing size, m
KG = gas film mass transfer coefficient, Kmol/m2atm
Kl= liquid film mass transfer coefficient, Kmol/m2sec
Dv =2.28 * 10-5 m2/sec
Dl =5* 10-9m2/sec
v =1.78 * 10-5 Kg/msec
3
Cl = 1000/20 = 50 mol/ m
=0.05 Kmol/m3
Thus we calculate height of each stage by using the above formulae
43
Property
Stage 1 (bottom)
Stage 2 (top)
2
Lw
12.557 Kg/m sec
27.473 Kg/m2sec
2
Lm
1.328 Kmol/m sec
0.612 Kmol/m2sec
Kl
0.147258 m/s
0.030762 m/s
Hl
3.469 m
7.675 m
Vw
1.659 Kg/m2sec
1.379 Kg/m2sec
Gm
0.0488 Kmol/m2sec
0.0593 Kmol/m2sec
2
Kg
0.00241 Kmol/m atm
0.000186 Kmol/m2atm
Fg
3.898 m
6.12m
Height of stage, ht
4.16 m
7.66 m
Table 7.5
Thus total height of absorption column is Ht1 +Ht2
= 11.82 m
= 12 m
Adding top and bottom clearances for heads height = 12+2= 14 m
liquid.
Have an open structure: low resistance to gas flow.
Promote uniform liquid distribution on the packing surface.
Promote uniform vapour gas flow across the column cross section.
44
Table 7.6
inch size plastic pall rings og poly propylene have been selected for
45
Size : 89 mm
Bulk density: 64 Kg/m3
Surface area, a: 85 m2 /m3
Packing factor, fp: 52 /m
Thus mass of packing required
of packing )
=(4.16x2.1 + 7.66x1.5)(64)
=1294.46 kg packing
=1300 kg packing
Packing support
The function of the support plate is to carry the weight ig the wet packing , whilst
allowing free passage of the gas and the liquid. These requirements conflicts; a poorly
designed support will give a high pressure drop and can cause local flooding.
Simple grid and perforated plates can be used, however in these designs the liquid and
gas have to vie for the same openings. Thus pressure drop across the support would
increase. So the best design for packing support is one in which liquid flows from the
bed; such gas injectors are shown in the diagram. These designs have a free area of
flow of the order of 85%, thus low pressure drop and no tendency to flooding. Also
they are available in wide range of sizes and materials.
46
Liquid Distributors
The satisfactory performance of a plate column is independent on maintaining a
uniform flow of liquid throughout the column, and good initial liquid distribution is
essential. It is generally considered necessary to provide at least five points of
introduction of liquid for each 0.1 m2 of tower cross section for large towers (d> 1.2
m). Various designs of distributors are used. The two most commonly used designs
are orifice type and weir type.
47
Figure 7.3
Weir type is selected because it does not create significant pressure drop unlike orifice
type. IN weir type liquid flows over notched weirs in the gas stand pipe. This type can
be designed to cope with a wider range of liquid flow rates than simple orifice type.
Figure 7.4 Weir- trough liquid distributor. ( Chemical Process Product Division,
Norton Co.)
Liquid redistributor
48
However, we need to provide for redistribution of liquid at intervals from 3-10 times
the tower diameter, but at least every 6 to 7 m.
Redistributors are used to collect liquid that has migrated to the column walls and
redistribute it evenly over the packing. They will also even out any mal- distribution
that has occurred within the packing. A full re- distributor combines the function of a
packing support and a liquid distributor; a typical design is shown in figure.
Figu
re 7.5
49
= 40.88kg/s
Cp =3.555 KJ/Kg. k
K=0.49w/m.k
b) Shell Side (water) at 250C
Cp =4.18 KJ/Kg. k
K=0.608w/m.k
1) Heat Balance
Qh=mhCp(T1-T2)
=40.88*3.555*(40-30)
=1453.28 kW
50
2)
3)
4)
5)
6)
At steady state,
Qh= Qc=mcCp(t1-t2)
1453284=mc*4.18*(29-20)
Mc = 38.63 kg/s
LMTD
LMTD = 10.50C
FT = LMTD Correction factor
R = 0.90 & S= 0.5
From graph of FT vs S
FT =0.85
LMTD (corrected )= 0.85*10.5=8.90C
Heat Transfer area:
Choose overall heat transfer coefficient = 1000 W/(m2K)
Q = UA(LMTD)
A = 1453284/1000*8.90
=162.956 m2
Tube selection
in. OD , 16 BWG tubes
OD = in. = 19.05 mm
ID = 0.62 in. =15.75 mm
Length of tube L =20 ft= 6m
in tubes arranged in triangular pitch
TEMA P or S , Floating Head type:
Heat transfer area per tube = 0.3589 m2
Number of tubes
= 162.956/0.3589
= 454
Nearest tube from table
NT=456
Assuming 4 tube pass and 1 shell pass,
Thus, 114 tubes per pass
Shell ID (DF) calculation
We find k1 and n1 factors (0.175 & 2.285 respectively ) for triangular pitch
Bundle Diameter Db =595.4 mm
Clearance depends on type of head selected
Thus, clearance for floating head type for given Db =60 mm
DF=655 mm
Corrected heat transfer area =0.3589*456=163.659m2
Corrected overall heat transfer coefficient
U=995.7 W/(m2K)
Tube side velocity
No. of passes NP = 4
Flow area
=(3.14*Dt2/4)*NT/NP
= (3.14*0.0165/4)*114
AP =0.0222 m2
Vt
= mc/(Aa
=40.88/(0.0222*999)
=1.866 m/s
Velocity is within the range 1 to 2 m/s
7) Shell side velocity
51
Sm =((P1-D0)Ls)Ds/P1
=((0.0238-0.01905)*0.524)*0.655/0.0238
= 0.0687
Vs = mc/(
=38.63/(999*0.0687)
=0.563 m/s
Nb+1=L/Ls=6/0.524=11.45
Thus, Nb=11 baffles
8)Shell side heat transfer coefficient
Nnu=jhNre(Npr)1/3
Nre= VsD0
=0.563*0.01905*999/0.000897
=8479
Jh= 0.006
Npr=0.000897*4180/0.608
=6.164
Nnu= 92.176
h0= 92.716*0.608/0.01905 = 4167.48 W/m2K
52
U= 951 w/m2K
Assumed value and designed value are almost same.
53
/(2Di)
/2
<1 mNsec/m2
7.3) PROCESS DESIGN OF CARBONATING COLUMN
Feed to the absorption tower is sodium chloride solution (brine).
Containing 248 gms NaCl per liter of solution.
Water
Input
Moles
Output
(mol/hr)
(Kg/hr)
111084
(mol/hr)
6171
(Kg/hr)
39622
373
Sodium
bicarbonate
54
NaCl
Ammonium
27594
16509
471
532
Water
Ammonium
11084
2523
6171
47
hydroxide
Carbondioxide 25416
577
chloride
Carbon
4661
105
dioxide
Total
7753
6698
Table 7.6
Given
Brine solution flow rate
Water flow rate
L1
=25416 Kg/hr
= 4661 Kg/hr
Density of gas s
Density of liquid
=1125 Kg/ m3
C SB,F
= 0.24 ft/sec
= 0.9 x 7.45
Unf
=2.011 m/sec
=6.70 ft/sec
=3.56/2.011
An
=1.77 m2
Ad
56
Ac= 7.065 m2
Ad=.612 m2
Lw= 2.1 mm
Active area
Aa
=Ac - 2Ad
Aa
= 5.841 m2
Acz
=10 % Ac
Acz
=0.7065 m2
=35325 m2
Ap= Ac-2Ad-Acz-Awz
Ap= 7.065 2 x .612 -7.065 -0.035 = 4.8 m2
(4) Selection of bubble cap
For tower of diameter 2.5 m
Cap diameter = 100mm = 4 in
4 inch size bubble cap, carbon steel US stnadard 12 OD = 4.093 in
ID = 3.875
Height overall 3 in
No. of slots
= 26
57
Slot width
Bottom
= 0.333 in
Top
=0.107 in
Slot height
=1.25 in
58
Standard height
0.5 in skirt height = 0.5 in
1.0 in skirt height =3 in
1.5 in skirt height=3.5 in
Cap areas =4.8 in2
Risers =7.3 in2
Reversal =5.9 in2
Annular = 8.12 in2
Slot = 13.15 in2
= 1.93 m2
59
) Uh2
)/
)1/5(hsh)4/5(Us)2/5
K2 calculation
(Annular area/riser area )=1.4
From plot of this area ratio vs K2, K2= 13
hl = 47.39 + 13*(0.8065/1125)*14.642
hl = 51.8 mm
Height of crest over weir (how)
how= fw*664(q/lw)2/3
60
61
=123.2 mm
Head loss over down comer apron
hd= 165.2 {q/Ada}2
10) Column efficiency
Point Efficiency ( EOG)
Number of gas phase transfer units :
Ng=(0.776+ 0.00457hw Uapg0.5 + 105W) Nsc0.5
hw =weir height in mm = 62.5 mm
Ua= gas velocity through active area = 1.476 m/s
W= liquid flow rate in m3/(s.m) of width of flow path on plate= 0.007289 m3/(m.s)
Nsc g = Gas schimdt no.
Dg = Gas diffusion coefficient
Nsc g = 1.0644
Ng = 1.465
Number of liquid phase transfer units NL=KL.a.L
KL= liquid phase transfer coefficient
L=residence time of the liquid in the froth, sec
a = effective interfacial area for mass transfer, m2/m3
hL = effective clear liquid height, mm
62
0.15
+0.15)
=0.1484
NL= 0.221
= mt( G1/L1)((1+Yt)/(1+Xt))
=15*(1/8.758)(1+0.01843)
= mb( G1/L1)((1+Yb)/(1+Xb))
=5.428*(1/8.758)(1+1.843)/(1+0.218)
=1.446
=(
+ t)/2 =1.595
NoG=1/(1/NG+ /NL)=0.495
EOG=1-e-NOG=0.3684= 36.84 %
63
8) EQUIPMENT DESIGN
8.1) Mechanical Design of Ammonia Absorption Column
Diameter of the tower Di = 2.0m
Working pressure = 1 atm=1.0329 kg/m2
Design pressure Pd = 1.1362 kg/ m2
Shell material Plain Carbon steel
Permissible tensile stress (ft) = 950kg/cm2
Insulation thickness = 100mm
Density of insulation = 770 kg/m3
Tray spacing = 610mm
Top disengaging space = 1m
Bottom separator space = 2m
Skirt height = 2m
64
1) Shell thickness
ts = PDi /(2fJ-P) + C
P= design pressure in kg/cm3
f=allowable tensile stress kg/cm3
C= corrosion allowance
J=joint factor
ts = (1.1362*2000)/(2*950*0.85-1.1362)
ts = 4 mm
Minimum thickness allowable is 6mm Hence ts = 6mm
2) Head Design
Shallow dished and torispherical head
Thickness of head is given by
65
th = PRCW/2fJ
Rc =crown radius
W=stress intensification factor
W= 0.25(3 + (Rc/Rk)
Rk = knuckle radius ,6% of crown radius.
W= 1.7706
th = 1.1362*2000*1.7706/2*950*0.85
ts = 2.491 mm
minimum thickness is ts = 6mm
2006*(6-2)
fd(ins) = 2.122X
6) Compressive Stress due to the weight of the liquid and tray
fd = Wliq / Dm(ts-C)
Wliq = ((X-top space)/TS+1) (d2/4)L
Wliq = ((X-1)/0.61)+1) (*22/4)*1193
= [61.44X-27.03] kg/cm
fd =[61.44X-27.03]/( *2.006*(6-2))
fd = [24.37X-10.722] kg/cm2
7) Stress due to the weight of the attachments
The total weight of the attachments
Wa = (2670 + 140X)
Fd(att) = (2670 + 140X)/(*2006*4) = 10.59 + 0.55X
8) Total compressive dead weight stress at height X
fds=27.812 X 19.755
9) Stress due to wind load at distance X
fws = 1.4*PwX2/*Do(ts-c)
= (1.4*130*X2)/(*201.2*.4)
= 0.7198X2
10) Stress in upwind side
fmax= fws+fap-fdx
0.8*950= 0.7198X2+142.025-27.812X+19.755
0.7198X2-27.812X-597.917=0
X=53.32 m
11) Stress in down side
fmax= fws+fap+fdx
67
0.7198X2-27.812X-882.28=0
X=49.30 m
From this ,for whole tower 6mm thickness is enough.
12) Skirt design
The material of construction for skirt is carbon steel IS: 2062-1962
Minimum weight of vessel
Wmin= (Di+ts) ts(H-2)s + 2WH
H=10.5 (Total height of tower including skirt height)
s= 7700kg/m3 (specific weight of shell material)
WH= 2670kg (weight of head)
Wmin= (2+0.006) (0.006)(10.5-2)7700 + 2*2670
Wmin= 8688.27 kg
MW(min) = PW(min)*H/2
= 2457*10.5/2
= 16584.75 kg m
Maximum wind moment
MW(min) = PW(min)*H/2
= 2702.7*10.5/2
= 18243.22 kg m
Bending stresses
fb(min)= 4Mw(min)/ *D2*t
= 4*16584.75/ *22*t
= 0.5279/t kg/cm2
fb(max)= 4Mw(max)/*D2*t
= 4*18243.22/*4*t=0.5806/t kg/cm2
Minimum dead load stress
Fds(min)= Wmin/dt
= 8688.27/*2*t
= 0.1382/t kg/cm2
Maximum dead load
Fds(max)= Wmax/dt
= 0.8837 kg/cm3
Maximum tensile stress without any eccentric load
fz= fbs(max)-ffs(min)
980*0.8= 0.0529/t
t= 0.0771mm
Maximum compressive stress without any eccentric load
fz=fbs(max)-fbs(min)
69
l=0.1 m
therefore fc= 0.122*106
thickness of bearing plate
tbp=l(3fc/f)
= 100(3*0.122*106/96*106) = 61.2 mm
Bearing plate thickness of 61.2 mm is required
As the plate thickness required is larger than 20mm gussets may be used to reinforce
the plate.
For l/b=1
M(max) = MY= 0.199fcl2
= 0.119*0.122*106*0.12
= 145.18 kg
tbp=(6Mmax/f) = 9.52 mm
if gussets are used at 100mm spacing ,bearing plate thickness of 10mm will be
sufficient
fmin= Wmin/A Mw/Z
= 8688/(2-l)l + 18234.22/(2-l)2l
= 30641 kg/m3
j=WminR/Mw
R=moment arm for that weight of vessel.
R=0.42 Dol
R= 8688*0.42*2.2/18243.22
R= 0.44
As the value is less than 1.5, the vessel will not be steady by its own weight.
Therefore anchor bolts are to be used
Pbolt*n=fmin*A
71
= 30641*3.14*(2-0.1)*0.1
=1828
For hot rolled carbon steel f=5.73*106 kg/m2
(arn)f=nPbolt
arn=319 m2
For 12X1.5 ,ar=63mm2
Number of bolts=319/63=5 bolts
(13) Nozzles
Diameter of liquid inlet and outlet nozzles = 180mm
Diameter of gas inlet and outlet nozzles =75 mm
Thickness of nozzles t=10mm
73
Shell side
(1) Shell thickness
ts= PD/(2fJ+P)
= 0.11*838/(2*95*0.85+0.11)
= 0.57
Minimum thickness of shell must be=6.3 mm
Including corrosion allowance shell thickness is 8mm
(2) Head thickness.
Shallow dished and torispherical
ts=PRcW/2fJ
= 0.11*838*1.77/(2*95*1)
= 0.858
Minimum shell thickness should be 10mm including corrosion allowance.
74
(5) Flanges
Design pressure=0.11 N/mm2
Flange material IS: 2004-1962,class 2
Bolting steel: 5% Cr-Mo steel
Gasket material: asbestos composition
Shell thickness: 8mm=go
Outside diameter of shell: 854 mm
Allowable stress of flange material: 100MN/m2
Allowable stress of bolting material: 138MN/m2
Determination of gasket width
dO/di = [(y-Pm)/(y-P(m+1))]0.5
Assume a gasket thickness of 1.6mm
y = minimum design yield seating stress = 25.5 MN/m2
75
Radial clearance from bolt circle to point of connection of hub or nozzle and back of
flange = R = 0.027 m
C = nBs/ = 0.9243
C =ID + 2(1.415g + R)
= 0.854 +2[(1.415)(0.008)+0.027]
= 0.9301m
Choose C = 0.93m
Bolt circle diameter = 0.93m
Calculation of flange outside diameter
A=C+ bolt diameter +0.02
=0.93+0.018+0.02
= 0.968
Let A=0.97 m
77
W3=Wo-H=Hp
= 0.01 MN
Mo=Total flange moment
Mo=W1a1 + W2a2 + W3a3
a1=(C-B)/2=(0.93-0.854)/2
a1=0.038 m
a3=(C-G)/2=(0.93-0.865)/2
a3=0.0325 m
a2= (a1 + a3)/2= (0.038+0.0325)/2=0.03525 m
Mo=0.038*0.063+0.03525*0.0016+0.0325*0.01
Mo= 2.775*10-3 MN-m
(b) For bolting condition
Mg=Wa3
78
W= (Am+Ab)*Sg/2
Ab=44*1.54*10-4 =6.76*10-3 m2
Am= 2.836*10-03 m2
W= (2.836*10-3+6.76*10-3)*138/2
W= 0.6621 MN
Mg= 0.6621*0.0325
= 0.02333 MN-m
Mg>Mo, Hence moment under operating condition Mg is controlling, Mg=M
=1004.63/(3.14*0.4272*0.01)
= 17.35 kg/cm2
the stresses are well within the permissible values.
Stress in the shell at mid point
f2 =M2/(k2 R2 t)
= 604.45 kg/cm2
Axial stress in the shell due to internal pressure
fp= PD/4t
= 0.11*836/4*10
= 225.53 kg/cm2
f2 + fp = 829.98 kg/cm2
the sum f2 and fp is well within the permissible values.
82
The most commonly encountered problem in chemical industry is the regular type
problem, in which the set point is constant and we compensate the offset as rapidly as
possible without instability.
The function fulfilled by an instrument may be:
Indicating
Recording
Controlling
83
These controllers may not take into account variation in temperature pressure
composition molecular weight or other factors that affect mass flow rates. This is
especially true of gas flows, variation being caused by changes in temperature
compensators on the airflow controllers to help reduce quality variation.
Applied automation Inc. Oklahoma 1968 pioneered in a program to determine the
affect of all known variables on quality and economics. They conducted computer
aided implant process investigation of reactor pelleting and drying areas of carbon
black plant. Special equipment include a process computer several automatic
sampling and chromatographic analysis and peripheral equipment necessary to
continuously sense process variable condition calculate mass rate calculate complete
material and energy balances and to control online or loops necessary to assure
consistent quality.
Flow control:
Flow control is usually associated with inventory controlling storage or other
equipment to provide flow control on a compressor or pump running at a fixed speed
and applying a rear constant volume output, a by pass control would be used.
The following protocol has been followed while designing the controller systems:
For controlling each process parameter, the PID controllers have been used.
84
In general wherever the ratio control can be used, has been used, Since
addition of one of the component also decides the amount of the other
components to be added, the ratio control can be easily used.
The flow of steam and cooling water through heat exchangers, have been fixed
based on the tower top and tower bottom temperatures.
treatment. Their effect on the cost of production will naturally depend on the process
85
soda ash
Decomposition of bicarbonate: 1100 to 1300 kg/t soda ash
Drying of monohydrate ( dense soda ash): 350 to 450 kg/t soda ash
86
2. Process Water
Water requirements fall under three categories, cooling, process and miscellaneous
sucj as washing or drinking. For cooling purpose it is usalluy uneconomical and
occasionally violation of conservation lawa to use treated water on once through
basis, although untreated river or sea water may be used in this manner.
Basically the main consumer of water apart from brine is the slaker where the lime
coming from the lime kilns reacts with water to produce milk of lime. The quantity is
in the range of 1.9 to 2.4 m3/t soda ash.
The quantity requirement for the water is not high. It is normally taken at the outlet of
the cooling water system ( warm water). Other water needs, in the range of 0.6 to 1.2
m3/t soda ash require higher purity (absence of Ca and Mg salts) for different uses as
additional wash water to wash the sodium bicarbonate cake at the filter outlet.
The above quoted process water needs exclude the water entering the process in the
form of brine which typically represents 4500-5200 Kg/t soda ash and steam
condensate mainly partially condensing in the distillation tower (roughly 650 kg/t
soda ash).
3. Cooling waters
Many unit operation of the soda ash process are exothermic. The cooling agent is
normally cooling water in open or closed loop. The closed loop requires a cooling
tower with special water treatment. The open loop is the once through system using
for example river water. In the latter case the total flow of cooling water required for :
CO2 compression
Distillation
Absorption
Calcinations
-Amounts to 50 to 100 m3/t soda ash depending upon the cooling water temperature.
Cooling water consumption is minimized by managing different cross flow heat
exchangers.
4. Electricity
Electric power is required to run motors, pumps, compressors, blowers, impellers, etc.
The gas compressors can be driven by either electric motors or steam turbines, leading
to a range of electrical consumption between 50 and 130 KWh/t soda ash. The
necessary consumption for compression is also linked to CO 2 concentration. Thus it
becomes necessary to have a reliable power source.
Normally big plants have their own thermal power station, in which there are huge
boilers, in which steam is generated, which is used to run turbines. This generated
steam can be used in reboilers and heat exchangers.
In most cases it represents a modest part of total operating cost. Electrical power in
India is mostly purchased from a public utility. All major contracts contain demand
component as energy component and variable fuel-cost component.
The demand charge is based on the maximum power requirement drawn by the plant
during a measurable period. The demand charges represent fixed charge which must
be paid by the utility for generation, transmission and distribution facilities.
The energy charge is based on kilowatt used. It can be used as a flat unit cost per
kilowatt-hour. Because of the demand charge a maximum utilization of demand
capacity will result in the lower units of electricity.
88
The fuel adjustment charge reflects the increased or decreased cost of fuel to the
power company.
In addition to the cost of power from the utilities company, the power must be
transformed and distributed through the plant properly. For a chemical plant these
distribution charges may be 50% of the purchased power of the power from utility.
5. Waste disposal
It may be a major or minor cost. In a large palnt, effluent from spills discarded
fractions etc are run together into a tank or pond, neutralized and perhaps diluted until
they are very innocuous to the water body into which they are eventually drained.
Marketing Area
For materials that are produced in bulk quantities: Such as cement, mineral acids and
fertilizers, where the cost of the product per ton is relatively low and the cost of
transport is a significant fraction of the sales price, the plant should be located close to
the primary market. This consideration will be less important for low volume
production, high-priced products; such as pharmaceuticals. In an International market,
there may be an advantage to be gained by locating the plant within an area with
preferential tariff.
Raw Materials
The Availability and Price of Suitable Raw Materials Will Often Determine the Site
Location. Plants Producing Bulk Chemicals Are Best Located Close To the Source Of
The Major Raw Material; Where This Is Also Close To The Marketing Area. Soda
Ash Plant Should Be Located Near the Salt Lakes or Near Sea, Where Sodium
Chloride Is Available Abundantly.
Transport
The Transport of Materials and Products To and From Plant Will Be an Overriding
Consideration in Site Selection. If Practicable, a Site Should Be Selected That Is
Close At Least Two Major Forms Of Transport: Road, Rail, Waterway or a Seaport.
Road Transport Is Being Increasingly Used, and Is Suitable For Local Distribution
from a Central Warehouse. Rail Transport Will Be Cheaper For The Long-Distance
Transport Of Bulk Chemicals. Air Transport Is Convenient and Efficient For the
Movement of Personnel And Essential Equipment and Supplies, and the Proximity of
the Site to a Major Airport Should Be Considered.
90
Availability of Labour
Labour Will Be Needed For Construction Of The Plant And Its Operation. Skilled
Construction Workers Will Usually Be Brought In From Outside the Site, But There
Should Be an Adequate Pool of Unskilled Labor Available Locally; and Labor
Suitable For Training To Operate The Plant. Skilled Tradesmen Will Be Needed For
Plant Maintenance. Local Trade Union Customs and Restrictive Practices Will Have
To Be Considered When Assessing the Availability and Suitability of the Labour For
Recruitment and Training.
Utilities (Services)
The Word Utilities Is Now Generally Used For the Ancillary Services Needed In
The Operation of Any Production Process. These Services Will Normally Be Supplied
From A Central Facility; and Will Include:
General Use
Steam For Process Heating: - The Steams required For the Process Are Generated In
91
92
93
Operations
Equipment that needs to have frequent attention should be located convenient to the
control room. Valves, sample points, and instruments should be located at convenient
positions and heights. Sufficient working space and headroom must be provided to
allow easy access to equipment.
Maintenance
Heat exchangers need to be sited so that the tube bundles can be easily withdrawn for
cleaning and tube replacement. Vessels that require frequent replacement of catalyst
or packing should be located on the out side of buildings. Equipment that requires
dismantling for maintenance, such as compressors and large pumps, should be places
under cover.
Safety
Blast walls may be needed to isolate potentially hazardous equipment, and confine the
effects of an explosion. At least two escape routes for operators must be provided
from each level in process buildings.
Plant expansion
Equipment should be located so that it can be conveniently tied in with any future
expansion of the process. Space should be left on pipe alleys for future needs, and
service pipes over-sized to allow for future requirements.
Modular construction
In recent years there has been a move to assemble sections of plant at the plant
manufacturers site. These modules will include the equipment, structural steel, piping
and instrumentation. The modules are then transported to the plant site, by road or
sea. The advantages of modular construction are:
95
96
A detailed plant layout is drawn and submitted with this thesis report.
This plant layout is just a reference plant layout. There may be a lot of
changes in actual plant layout.
13) POLLUTION CONTROL & WASTE MANAGEMENT
The bulk of the solids in distiller waste in the soda ash plant is made up of chloride.
This arises from the fact that the waste contains all the chloride from the salt used,
chlorine is not utilized in the process.
Calcium chloride in solution permeates the soil bed and contaminates sources of water
supply. Only to a very limited extent is any portion of the waste allowed by municipal
authorities to be sent to rivers or any public waterways and that only after complete
settling. Also fish in the river were killed by the calcium chloride and the free lime
carried in the liquor.
The preparation of chlorine gas or hydrochloric acid from calcium chloride in the
waste went no longer be considered workable in view of the present more economical
methods for preparing such materials.
97
Waste Disposal: Large volumes of liquid wastes containing suspended and dissolved
solids are produced in an ammonia soda plant. The largest volume occurs from the
distiller operation where for every ton of product soda ash, nearly 10 m3 of liquid
wastes are produced, containing about one ton of calcium chloride, one-half ton of
sodium chloride, and other soluble and insoluble impurities. Traditionally this liquid
waste, after settling of suspended solids in large basins, was discharged into local
waterways. In the United States, federal guidelines , suggesting limits on suspended
solids and pH of liquid wastes discharged to local waterways, are used in the
development of local discharge permits. The guidelines also specified no discharges
from new ammonia soda ash plants. Although processes have been proposed to
reduce or eliminate waste streams, it is felt that in the United States, with its abundant
reserves of natural ash, the guidelines will prohibit installation of new ammonia
soda plants. In addition to regulations governing liquid wastes, local restrictions have
been placed on gaseous emissions from soda ash plants to protect air quality. The cost
to comply with the environmental regulations and the increasing operating costs
relative to natural ash have contributed heavily to the shutdown of synthetic soda ash
plants in the United States.
98
99
100
101
102
= 40% of
= 40% of
II. Indirect costs: expenses which are not directly involved with material and labour
of actual installation of complete facility (15-30% of Fixed-capital investment)
A. Engineering and Supervision: (5-30% of direct costs)
Consider the cost of engineering and supervision = 10% of Direct costs
i.e., cost of engineering and supervision
= 10% of 4.41 108 = 0.14.41 108 = Rs. 0.441108
104
i.e.
105
i.e.
iii.Direct Supervisory and Clerical Labour (DS & CL): (10-25% of OL)
Consider the cost for Direct supervisory and clerical labour = 12% of OL
Direct supervisory and clerical labour cost = 12% of 0.8415108
= 0.120.8415108
Direct supervisory and clerical labour cost = Rs. 0.1108
vii.
viii.
II. General Expenses = Administrative costs + distribution and selling costs + research
and development costs
Administrative costs:(2-6% of total product cost)
Consider the Administrative costs = 5% of total product cost
Administrative costs = Rs. 0.35063108
A. Distribution and Selling costs: (2-20% of total product cost); includes costs for
sales offices, salesmen, shipping, and advertising.
Consider the Distribution and selling costs = 15% of total product cost
Distribution and selling costs = 15% of 7.0126108
0.15 7.0126108 = Rs. 1.0519108
= (10.518108)
16.4 Profit
Net Profit = Gross income - Taxes = Gross income (1- Tax rate) Net profit =
(2.391108) (1.076108) = Rs. 1.315108
109
17) CONCLUSION
This is a Techno-Economic Feasibility Report for the production of soda ash. This
report aims to find out an appropriate process with consideration of the product
demand and raw material availability in long as well as short term. Besides, the report
seeks to find out an appropriate process as according to technical and economic
feasibility along with being technically feasible simultaneously. Detailed technical
analysis involves selection of the raw materials with maximum profitability to achieve
the best quality. Material balance and energy balance, overall and over individual
equipments is established to estimate the quantities of input and outputs, both in terms
of products/raw materials and energy. These are supplemented with process as well as
equipment design of all the equipments used in the chosen process, which are then to
be utilized in the plant. The next half of the process concerns with economic and
environmental feasibility of the process. Pollution control and safety control measures
are mentioned, before the selection of the plant location for convenience both to the
customers as well as raw material sources. Plant layout along with the organizational
chart is provided. The report then summarizes with the economic aspects of the report,
with calculation of Capital Investment, Product Cost, Selling Price, Profit, Return on
Investment, Payback Period, Cash Flow Diagram and Break Even Analysis.
110
18) BIBLIOGRAPHY
(1) M. Gopala Rao And Marshall Sittig, Drydens Outlines Of Chemical
Technology,
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(2) Kirk-Othmer, Encyclopedia Of Chemical Technology, 5th Ed, Volume-1, John
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(6) M.L Faith And Donald B.Keyes Industrial Chemicals John Wiley & Son (1965)
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Mc-Graw Hill International Edition,
(10) H.Sawistowski &W.Smith, Mass Transfer Process Calculations, Interscience
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(11) T.Hobler, Mass Transfer And Absorbers,Pergamon Press, Page No:462-4692
(12) R. K. Sinnott, Coulson And Richardsons Chemical Engineering Series,
Volume-6,
Chemical Equipment Design 3rd Ed., Butter Worth-Heinemann, Page No: 828-855,
891-895
(13) Joshi M. V., Process Equipment Design, 2nd Ed., Mc-Millan India Ltd,
(14) Max S. Peters And Klaus Timmerhaus, Process Plant Design And Economics
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Chemical Engineers, 3rd Ed., Mc-Graw Hill Book Company, Page No: 207-208,
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(15) Indian Standard Specification For Shell And Tube Heat Exchangers,
Is 4503-1967, Page No: 5-66
111
112
Index of Figures
Page no
20
21
21
48
49
50
51
52
113
Index of Tables
Page no
23
26
27
27
28
29
30
31
32
33
34
36
37
40
42
43
44
44
114
46
47
115