The main aim of this project is to conserve energy and prevent heat loss in Ammonia Recovery Plant by application of Energy Conservation concept. The main purpose of establishing of Ammonia Recovery plant is to recover the maximum percentage of ammonia by using effluent stream containing ammonia waste water from TMP plant with reaction of Calcium Hydroxide with stream.
As, it is Recovery plant, it is necessary to converse energy in order to reduce operating cost. In Phase 1 , we have done process selection, literature survey, material balance and energy balance of the whole plant The project also includes the properties of products and raw materials.In phase-2, we have done designing of an equipment, Cost estimation of the plant, Plant location and layout , safety and Hazard, Energy conservation concept as well as result and conclusion. In our project , we have reduce the operating cost of the plant as well as conserve the energy by the elimination of cooling water in Heat exchanger and reducing in consumption of natural gas used in spray dryer with saving calculation and proposed design.
INDEX
CHP. NO. CHAPTER PAGE NO.
1. INTRODUCTION OF UNIT 1
2. INTRODUCTION OF AMMONIA RECOVERY PLANT 4
3. PHYSICAL AND CHEMICAL PROPERTIES 6
3.1 Properties of raw material 7
3.2 Properties of products 7
3.3 Application of ammonia 8
4. LITERATURE SURVEY 9
4.1 Current waste water treatment process ammonia removal 10
4.2 Successful Ammonia removal from waste water using liquid cell membrane 10
4.3 Carbtrol 10
5. PROCESS SELECTION FOR RECOVERY OF AMMONIA 11
5.1 Process details 12
5.2 Chemistry of process 12
5.3 Block diagram 13
5.4 Detail process flow sheet 14
5.4 Process description 15
6. MATERIAL BALANCE 16
6.1 Material balance over reactor 17
6.2 Material balance over stripper-1 18
6.3 Material balance over clarifier 19
6.4 Material balance over stripper-2 19
6.5 Material balance over evaporator -1 20
6.6 Material balance over evaporator-2 21
6.7 Material balance over flash vessel 21
6.8 Material balance over distillation column 22
7. ENERGY BALANCE 23
7.1 Energy balance over reactor 24
7.2 Energy balance over sripper-1 24
7.3 Energy balance over sripper-2 24
7.4 Energy balance over evaporators & flash vessel 25
7.5 Energy balance over distillation column 25
8. EQUIPMENT DESIGN 26
9. COST ESTIMATION 30
9.1 FACTORS AFFECTING INVESTMENT AND PRODUCTION COSTS 31
9.2 TOTAL CAPITAL INVESTMENT 31
9.3 TOTAL PRODUCTION COST 33
9.4 PAYOUT PERIOD 35
9.5 BREAK EVEN POINT 35
10 PLANT LOCATION & LAYOUT 36
10.1 PLANT LOCATION 37
10.2 PLANT LAYOUT 37
11 UTILITIES 39
12 HAZARD AND SAFETY 41
12.1 AMMONIA 42
12.2 CALCIUM CHLORIDE 43
13 ENERGY CONSERVATION CONCEPT 44
14 RESULT & CONCLUSION 47
15 REFERENCES 49
LIST OF TABLES
TABLE NO. NAME OF TABLE PAGE NO.
3.1 Physical and chemical properties of Ammonium chloride 7
3.2 Physical and chemical properties of Calcium hydroxide 7
3.3 Physical and chemical properties of Ammonia 7
3.4 Physical and chemical properties of Calcium chloride 8
8.1 Data for equipment design 27
9.1 Equipment cost 32
9.2 Direct Cost 32
9.3 Indirect cost 33
9.4 Fixed charges 33
9.5 Direct Production Cost 33
9.6 General expenses 34
12.1 Ammonia 42
12.2 Calcium chloride 43
LIST OF FIGURES
FIG.NO NAME PAGE NO.
5.1 Flow Diagram for manufacturing process 13
5.2 Process Detailed Sheet for manfg. process 14
8.1 Temperature profile 27
9.1 Cumulative cash flow diagram 31
10.1 Plant layout 38
13.1 Existing & proposed design 45
LIST OF ABBREVIATIONS
m Mass flow rate of fluid kg/s
Cp Specific heat of fluid KJ/kg 0C
‘Tlm Logarithmic Mean Temperature difference 0C
Ft Temperature correction factor
A Heat transfer area m2
U0 Overall heat transfer coefficient W/m2 0C
Nt Number of tubes
Np Number of passes
d0 Tube side outer diameter m
di Tube side inner diameter m
Db Tube bundle diameter m
Ds Shell diameter m
G Mass velocity kg/m2 s
?? Viscosity of fluid kg/ m s
?? Density of fluid kg/ m3
Re Reynolds number
Pr Prandlt number
k Thermal conductivity W/m 0C
L Tube length m
Nu Nusselt number
Hi Tube side heat ransfer coefficient W/m2 0C
H0 Shell side heat ransfer coefficient W/m2 0C
U Velocity of fluid m/s
Jf Friction factor
Pt Tube pitch m
Bs Baffle spacing m
Hid Fouling coefficient for tube side fluid W/m2 0C
Hod Fouling coefficient for shell side fluid W/m2 0C
‘p Pressure drop Pa
CHAPTER 1
INTRODUCTION OF UNIT
1.INTRODUCTION OF UNIT
1.1INRODUCTION TO U.P.L:
United Phosphorus Limited (UPL) incorporated in 1969 is a leading global producer of crop protection products, intermediates, specialty chemicals and other industrial chemicals. UPL has its presence across value added Agro inputs ranging from seeds to crop protection and post harvest activity. Being the largest manufacturer of agrochemicals in India, UPL offer a wide range of products that includes insecticides, Fungicides, Herbicides, Fumigants, PGR and Rodenticides. UPL operate in every continent and have customer base in 86 countries, making UPL global player of crop protection products in the world. The company ranks amongst the top 5 post- patent agrochemical manufacturers in the world.
LOCATION:
Manufacturing site of united phosphorus limited unit 1 is located at Ankleshwar, plot no.117-118, G.I.D.C in district Bharuch, Gujarat
1.2 QUALITY AND OBJECTIVES:
1. To improve F.T.P.R (first time passing report) level from 88% to 98%.
2. To improve finished product on time delivery of factory level from 87% to 98%.
3. To established reduction in process testing from 100% to 70%.
4. To established reduction in RMC PM testing from 100% to 70%.
5. To improve yields of products,
(1)TMP: FROM 91% TO 91.5%.
(2)MCP: FROM 75% TO 76%.
(3)ANTRACOL: FROM 89 % TO 90%.
(4)MANCOZEB: FROM 92% TO 93%.
1.3 PLANTS IN U.P.L UNIT 1:
MANCOZEB (DRY & WET SECTION):
The MANCOZEB is mainly used as fungicides.
Production rate of MANCOZEB: 22400 kg/day.
MONOCROTOPHOS (MCP):
The MCP is used as insecticides.
Production rate of MCP: 600 MT/Month
TRI METHYLE PHOSPHITE (TMP):
Intermediate used in the manufacture of Monocrotophos and other important organo-phosphorus insecticides. Also used in phosphorus based flame retardants.
Production rate of TMP: 45 MT/day.
AMMONIA RECOVERY PLANT:
The plant is used for recovery of ammonia from aqueous Ammonium chloride (NH4CL).
Recovery of ammonia: 1.8 MT/day
ANTRACOL:
It is used as fungicides.
Production rate of Antracol: 95 MT/day.
EFFLUENT TREATMENT PLANT:
The ETP is used to purify water and remove any toxic and non-toxic materials and chemicals from it. The treatment of effluents in chemical industry is essential to prevent pollution of the receiving water. The effluent water treatment plants are installed to reduce the possibility of pollution; biodegradable organics If left unsolved, the levels of contamination in the process of purification could damage bacterial treatment beds and lead to pollution of controlled waters
‘
CHAPTER 2
INTRODUCTION OF AMMONIA RECOVERY PLANT
2. INTRODUCTION T OF AMMONIA RECOVERY PLANT
The plant was inaugurated by honorable HarisinhjiMahida, Minister of industries, energy, mines and panchayat on 22.10.1989.
AMMONIA expansion inaugurated on 29/07/1991 by ShriM.S.Gill.
The plant produces 54 MT of AMMONIA per Month. (1.8 MT/day)
It is also used in pharmaceutical industries.
2.1 FUNCTIONAL OBJECTIVES OF AMMONIA RECOVERY PLANT:
To achieve the targeted production with displaceable quality.
To attain 99 % FTRP (First time passing report) for AMMONIA production.
To attain 92.5 % yield.
Zero accident incident for the financial year.
‘
CHAPTER 3
PHYSICAL AND CHEMICAL PROPERTIES
3. PHYSICAL AND CHEMICAL PROPERTIES:
3.1 PROPERTIES OF RAW MATERIAL:
3.1.1 AMMONIUM CHLORIDE:
Table 3.1
Chemical formula NH4CL
Molecular weight 53.491 g/ mole
Appearance Clear, Colorless liquid
Odor Odorless
Solubility Easily soluble in water
Specific gravity 1.53
PH 9.245
Boiling point 520 0C
Melting point N.A
3.1.2. CALCIUM HYDROXIDE (Ca(OH)2):
Table 3.2
Chemical formula Ca(OH)2
Molecular weight 74.093gm/mole
Appearance Solid White powder
Odor Odorless
Solubility Soluble in water (0.185 gm/100ccwater),Glycerol & acid
Specific gravity 2.24
PH 12.4
Boiling point Decomposition
Freezing point 5800C
Vapour density (air): N.A
Density 2.211 gm/cm3
Std. enthalpy of formation -987 kJ/mole
3.2 PROPERTIES OF PRODUCT:
3.2.1AMMONIA:
Table 3.3
Chemical formula NH3
Molecular Weight 17 gm/ mole
Appearance Colorless liquid
Boiling point -330C
Melting point -770C
Specific gravity 0.86
3.2.2 CALCIUM CHLORIDE:
Table 3.4
Chemical formula CaCl2
Molecular weight 110.98gm / mole
Appearance Solid white powder
Odor Odorless
PH 8-9
Boiling point 19350C
Melting point 7750C
Specific gravity 2.15
3.3 APPLICATIONS OF AMMONIA:
Used in plastic industry as Secondary Antioxidants/Stabilizers.
Used in pharmaceutical industries.
Used as a raw material of MCP (mono crotophos).
Used as a ligand inorganometallic chemistry.
Used as a reagent in organic synthesis.
Used in fertilizer industries.
Used in organo phosphorus insecticides.
Used in phosphorus based flame retardants.
‘
CHAPTER 4
LITERATURE SURVEY
4. LITERATURE SURVEY
The new technologies which are introduced in recovery of ammonia or removal of ammonia from effluent stream or waste water are as follows:
Successful Ammonia Removal from Wastewater Using Liqui-Cel?? Membrane
Ammonium Removal from Concentrated Waste Streams with the Anaerobic Ammonium Oxidation (Anammox) Process in Different Reactor Configurations
How CASTion Helps Remove Ammonia
Ammonia removal in Wastewater Treatment Applications with BIOBUG?? NB from BIO-SYSTEMS International
Ring lace Fixed-Film Media
CARBTROL
4.1CURRENT WASTE WATER TREATMENT PROCESS-AMMONIA REMOVAL:
Ammonia is usually separated from wastewater by the ion exchange process. In conventional sewage plants ammonium is converted to nitrogen by executing two oxidation steps, in which nitrogen is first converted to nitrite and subsequently to nitrate (nitrification), whereupon the generated nitrates are reduced in a two-step reduction process first to nitrite and subsequently to molecular nitrogen (denitrification). Depending on the process method employed nitrification and denitrification may be performed in the same reactor one after the other, or they may be carried out in different reactors.
4.2 SUCCESSFUL AMMONIA REMOVAL FROM WASTE WATER USING LIQUI CEL MEMBRANE:
There are many conventional ways to remove ammonia from water but most of them produce a secondary waste stream that can cause a whole list of other problems. Membrane Contactors offer a superior solution for stripping Ammonia because they provide a large surface area that facilitates fast separation of the ammonia from the wastewater. The extraction process uses Liqui-Cel?? Membrane Contactors
ADVANTAGES:
The process is durable and reliable.
They offer a great alternative by extracting ammonium salt during the treatment, which has some commercial value.
It is cost effective.
4.3 CARBTROL:
Carbtrol offers a line of ammonia removal systems for removal of ammonia from wastewater using selective ion exchange resin. The media removes only the ammonia, non-polluting constituents pass to the sewer.
CHAPTER 5
PROCESS SELECTION FOR RECOVERY OF AMMONIA
5. PROCESS SELECTION FOR RECOVERY OF AMMONIA
5.1: PROCESS DETAILS:
Types of process technology:
There is not specific technology; company use owned developed AMMONIA RECOVERY process is used.
Selection of process:
ARP process is used.
5.2 CHEMISTRY OF PROCESS:
Chemical reaction occurs in manufacturing process:
Main reaction:
2NH4CL + Ca (OH) 2 ‘ CaCl2 + 2NH3+ 2H2O
5.3 BLOCK DIAGRAM:
Figure 5.1: Block Diagram
5.4 DETAIL PROCESS FLOW SHEET:
Figure 5.2: Process flow diagram
5.5PROCESS DESCRIPTION:
Ammonia recovery process is combination of batch & continuous operation process with the help of PID (proportional integral derivative) control system.
BATCH PROCESS:
In reactor Section, the effluent stream coming from TMP plant contains 17% NH4Cl is charged into the reactor from the top.
The lime Ca(OH)2 is charged from the top using the air between & screw conveyor. Reaction occurs at normal atmospheric condition.
After reaction completed 4.5% NH3, 15.2% CaCl2& rest of produced from the bottom of the reactor all the slurry is sent to the hold tank.
In hold tank pressure is maintained .5 kg/cm2& temperature around 95-1000C.
CONTINUOUS PROCESS:
Material (slurry) from the hold tank is fed to the upper portion of the stripper -1 through the pump.
Feed temp is 95-98 0C. And in stripper -1 top temp 104-1070C & bottom temp 103-1090C is maintained.
Here for heating the material, process stream from stripper -2 vapors is used .The main purpose of stripper-2 Vapor as a heat source for stripper-1 is in to obtain Maximum recovery of energy (heat) mean minimization of heat utilization.
The top product from stripper -1 contains 18% NH3& rest of water is sent to the distillation column via mist eliminator, cyclones & condenser.
Distillation column is packed type stream distillation. It is operated at high pressure. The feed is fed at middle of the distillation column and steam from boiler section is fed at the bottom of column as a heat source.
In steam distillation column /tower, temperature at top 40 to 450C, bottom 190 to 1950C is maintained. Pressure 15 to 17 kg/cm2.
From the top of the tower /column 99.5% of NH3 is produced, condensed & sent to the reflux. Here reflux ratio is kept about 1:1.4
Distillation are collected & stored in storage tank.
From the stripper -1 bottom product containing 16% CaCl2 solution is goes to the clarifier .The clarifier bottom product contains impurities & excess limes goes to the RVDF , where the solid cake is separated & sent to ETP plant& clear liquid is sent back to the clarifier.
The overflow of the clarifier is fed to sripper-2. Stripper -2 temperatures maintained at top 111 to 1140C bottom 114 to 117 0C .Here for heating the process stream from evaporator 1 and 2 & also from flash vessel via reboiler is used.Top vapor from stripper -2 is sent to the stripper -1 as process stream as a heating source.
The bottom product containing 21% CaCl2 solution is sent to the evaporator 1 & 2.In evaporator temp around 150 to 155 0C & pressure 2.1 kg/cm2 is maintained.
From the bottom of the evaporator the 27% CaCl2 is obtained which is sent to the flash vessel. In flash vessel vacuum pressure is maintained 175 to 250mmHG & temperature around 65 to 75 0C.Here the water is flashed (vaporized) & goes to the TMP Plant through condenser as a process water.
CHAPTER 6
MATERIAL BALANCE
6. MATERIAL BALANCE
CHEMICAL REACTION
2NH4CL + Ca (OH) 2 ‘ CaCl2 + 2NH3+ 2H2O
MOLECULAR WEIGHT OF COMPOUNDS IN THE REACTION
Ammonium chloride (NH4CL):2*53.5=107
Calcium hydroxide (Ca (OH) 2):74*1=74
Calcium chloride (CaCl2):111*1=111
Ammonia (NH3) : 17*2=34
6.1MATERIAL BALANCE OVER REACTOR:
BASIS: 18000 lit NH4CL Solution
Concentration of NH4CL =17%
Specific gravity of Solution =1.05
Lime (Ca (OH) 2 )=(90% purity + 10% excess)
TOTAL INPUT:
NH4CL=18000lit*1.05*0.17
=3213kg
WATER=18700-3213=15687kg
(Ca (OH) 2)=3213*74*1.1/(0.9*107)
=2715.869kg
TOTAL OUTPUT:
NH3=5928.869*34/181
=1113.71kg
(CaCl2)=5928.869*111/181
=3635.936kg
Water=16866.23kg
6.2 MATERIAL BALANCE OVER STRIPPER-1
TOTAL MATERIAL BALANCE:
INPUT
Material balance for (CaCl2)
0.152*18700=0.16*bottom flowrate
Bottom flow rate=17765kg/hr
Material balance for ammonia
0.045*18700=0.18*Top flow rate
Top flow rate=4675kg/hr
Stream from stripper-2=3740kg/hr
6.3MATERIAL BALANCE OVER CLARIFIER:
OVERALL MATERIAL BALANCE:
Input= Overflow+ Bottom flow (waste)
MATERIAL BALANCE FOR CALCIUM
CHLORIDE
Input = Overflow+Bottom flow
2842.4 kg/hr =2842.4 kg/hr + 0
2842.4 kg/hr =2842.4 kg/hr
MATERIAL BALANCE FOR IMPURITIES
Input= 617.1 kg/hr
Bottom Residue=617.1 kg
6.4 MATERIAL BALANCE OVER SRIPPER-2:
MATERIAL BALANCE FOR WATER
Input=13447.17 kg/hr
Bottom product(79%)=13535.238*0.79
= 10692.838 kg/hr
Top product=Input- Bottom product
=13447.17-10692.838
=2754.332 kg/hr
6.5 MATERIAL BALANCE OVER EVAPARATOR-1:
Water evaporated=1691.90 kg/hr
CaCl2 (21%)+ Water=
13535.24 kg/hr
Input: CaCl2 (21%)= 2842.4 kg/hr
Water = 10692.836 kg/hr
Total Flow rate= 13535.24 kg/hr
MATERIAL BALANCE FOR CALCIUM CHLORIDE
Input=output
2842.4 kg/hr=0.42*Bottom product flow rate
Bottom flow rate=11843.33 kg /hr
MATERIAL BALANCE FOR WATER:
Input= bottom flow rate *0.76
=11843.33*0.76
=9000.93kg/hr
Now, at top product flow rate,
Top flow rate =input-bottom (water)
=10692.836-9000.93
=1691.906kg/hr
Input=output
10692.936=109.906+9000.93
10692.936=10692.936
6.6 MATERIAL BALANCE OVER EVAPORATOR-2:
Input=output
Input=11843.33kg/hr (24% (CaCl2)an left (76% water )
Now balance for (CaCl2)
Input= output at top + output at bottom
11843.33*0.24=0+(0.27*x)
Now bottom flow rate (x) = 10527.407 kg/hr
BALANCE FOR WATER
INPUT= vaporized at top +output at bottom
0.76 * 11843.33 kg/hr = vaporized at top + 0.73 * 10127.407
So, water vaporized =1315.92 kg/ hr
6.7 MATERIAL BALANCE OVER FLASH VESSEL:
Now balance for water:-
Input = vaporized + bottom flow rate
7865.007= vaporized + (0.7 *9474.66)
So, vaporized water =1038.745 kg /hr
6.8 MATERIAL BALANCE OVER DISTILLATION COLUMN:
3420kg/hr of feed to distillation column
F=3420kg/hr+STEAMINLET(2100kg/hr)=5520kg/hr
Xd =wt fraction of ammonia in product= 0.995
Xw =wt fraction of ammonia in waste product = 0.5
OVERALL MATERIAL BALANCE
F= D+ W
5520=D+W
D= (5520-W)
COMPONENT BALANCE FOR AMMONIA
Fxf =Dxd + Wxw
(3.8*9*18)= (5520-W) 0.995 + W (0.0050)
615.6 = 549204 ‘ 0.995 W + 0.005W
-4876.8=-0.990W
W=4926.06kg/hr(water+ammonia)
Ammonia at bottom =4926.06*0.005
= 24.63kg/hr
Now ammonia top,
615.06=D+24.63
D=590.43kg/hr(anhydrous ammonia)
Reflux ratio (L/D)= 1:4
So, 590.43*1.4 =826.602kg/hr
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CHAPTER 7
ENERGY BALANCE
7. ENERGY BALANCE
7.1ENERGY BALANCE OVER REACTOR:
Standard heat of formation of NH4CL=-314.55 kcal/mol
Cacl2 =-877.3 kcal/mol
H2O=-285.5 kcal/mol
Ca (OH)2=-286.09 kcal/mol
HEAT of reaction ??HX=??H(PRODUCT)-??HR(REACTANT)
2NH4CL + Ca (OH) 2 ‘ CaCl2 + 2NH3+ 2H2O
??HR =-877.3 +2(-80.8)+2(-285.5)-(2(-314.55)+(-986.09))
-1609.9-(-1615.19)
=5.29Kcal/mol
So, reaction is endothermic reaction.
7.2ENERGY BALANCE OVER STRIPPER-1:
Inlet flow rate =18700kg/hr
Cp=0.6
Feed temperature =960c
Input ‘heat produced in feed
Q1 =mCP??T
Q1=18700*0.6(896-32)
Q1=718,080Kcal/hr
Q= M??
??=651kcal/mol
M=3740kg/hr
Q2= 3740*651
=2434740Kcal/hr
7.3ENERGY BALANCE OVER STRIPPER -2:
INPUT DATA
Feed in , m=17765kg/hr
Cp=0.6
Feed temp, T=880C ,ambient temp, T=450C
Q1= mCP??T
=17765*0.6*(88-45)
=458337Kcal/hr
OUTPUT BALANCE
Q=M??
=2754.33*652
=1795823.13Kcal/hr
Bottom product , m=13535.238kg/hr
Cp=0.6,T=1150C
Q3= mCP??T
=13535.238*0.6*(115-88)
=219270.8556Kcal/hr
Q total=1795823.16+219270.8556
=2015094.016Kcal/hr
Amount of steam required =m=Qtotal/??
= 2015094.016/590
=3415.413kg/hr
7.4ENERGY BALANCE OVER EVAPORATOR (1,2 ) AND FLASH VESSEL:
Heat input in evaporator= Heat output from stripper -2
Q=219270.853Kcal/hr
M=13535.24kg/hr
Steam inlet =3473kghr
Q=m??
=3473*473
=1642824Kcal/hr
Qoutlet from combined evaporator-1,2 and flash vessel (top)
Top heat produced =Q from above two evaporators*?? +Q from top of flash vessel *??
=(13535.238-10527.467)*509)+(1052.753*473)
=2102589.18 Kcal/hr
Q produced in combined evaporators and flash vessel
Q=9474*0.6(138-75)
=3581172Kcal/hr
7.5 ENERGY BALANCE OVER DISTILLATION COLUMN:-
Feed mass flow rate =3420kg/hr
Q in feed =3420*0.6*80
=178560kg/hr
Q in inlet steam (19kgf/cm2)= m??
=2100*668
=1402800Kcal/hr
Q produced in top product =(0.999*327+0.001*540+35)*591
=214067.883Kcal/hr
Reflux flow rate =830kg/hr
Heat out =heat produced in top ‘heat produced in reflux
=214067.883-(29050*35)
=185017.833Kcal/hr
Bottom flow rate=2804.4Kg/hr
Q=2804.4*1*(195-56)
=389756Kcal/hr
CHAPTER 8
EQUIPMENT DESIGN
8. EQUIPMENT DESIGN:
DATA:
Coolant 30% cacl2 soln. Unit
Flow rate 4926 9380 Kg/hr.
Viscosity .00016 .002 MN/Sm2
Specific heat 0.7 1 Kg/kg 0c
Thermal conductivity .477 .656 W/m 0c
Density 850 1710 Kg/m3
U(ASSUMED) 600 W/m2′
Table 8.1: Data
DIMENSIONS:
Tube inner diameter: 0.0148m Pitch size: 0.0238m Number of passes: 1-6 pass
Tube outer diameter: 0.0191m Tube length: 3.048m
Here, we have taken
Tube side: – waste water
Shell side:-30% cacl2soln
HEAT DUTY:
1-Tube side:
Qt= (mCp’T) t
=4926*1*(180-110)
=1649618.88 KJ/hr
Qt=458.28 KW
2-Shell side:
Qt= (mCp’T) s
394080=ms*0.7*60
Ms=9380 kg/hr
Ms=mass flow rate of hot water=25.25 kg/sec
Finding LMTD of temperature:
Figure 8.1
‘T1=90 ‘
‘T2=70’
‘Tln=’T2-‘T1/ln (‘T2/’T1)
=79.58′
Uses 1-6 pass,
R=(T1-T2)/(t2-t1)=1.333
s=(t2-t10)/(T1-T2)=0.4
FT=0.85
‘Tm=67.64’
Assume,U0=600W/m2′
Qt=U0*A*’Tm
A=Provisional heat transfer area=Qt/ (U0*’Tm)
= (458.227*103)/ (600*67.64)
A=11.290m2
A=Nt*??*d0*L
NT=Total no. of passes=A/ (??*d0*L)
=11.290/ (3.14*0.015875*3.048)
Nt=78
Total no. of passes is 78.
For, 1-6 pass & for Triangular pitch:-
k1=0.0743
n1=2.499
Tube Bundle Diameter:-
Db=d0*(Nt/k1) (1/n1)
=19.1*(25/0.319) (1/2.142)
Db=256.826mm
As= ((Pt-d0)/Pt)*Ds*Bs
Where, Bs=baffle spacing=Ds/5
=31.2 mm=0.0312 m
Shell side flow area=As
As= (((1.25d0)-d0)/ (1.25d0))*0.156*0.0312
As=5.832*10-3 m2
Shell side mass velocity=Gs
Gs=ms/As
=0.7014/ (9.734*10-4)
Gs=446.845 kg/m2s
Shell side Hot water velocity=us=Gs/??
us=720/1000=0.720m/s
Shell side equivalent diameter (de) for Triangular pitch:-
de= (1.1/do)*(Pt2-(0.907do2))
= (1.1/19.1)*(23.82-(0.907*19.12))
de=13.56 mm=0.0136 m
Reynolds no. for shell side hot water=Re
Re=de*Gs/??
= (0.0136*720)/ (0.981*10-3)
Re = 9952.294>4000
Pr= Cp*?? / K
= (4.18*103*0.981*10-
Pr = 8.597
Nu=ho*de/kf=0.36*Re0.55*Pr0.33(??/??w) 0.14
ho= (0.36*Re0.55*Pr0.33*kf)/de
= (0.36*(9952.294)0.55*(8.597)0.33*0.477)/0.01356
ho=4071.490 W/m2′
Overall heat transfer coefficient = Uo
(1/Uo)=(1/ho)+(1/hod)+((do*ln(do/di))/(2k??w))+((do/di)*(1/hid))+((do/di)*(1/hi))
= (1/4071.490) + (1/4000) + ((0.0191*ln (0.0191/0.0148))/ (2*50)) + ((0.0191/0
0148)*(1/3000)) + ((0.0191/0.0148)*(1/1648.438))
Uo=845.267W/m*’
Thermal conductivity of the tube material kW=50 W/ (m2′)
Heat transfer area required, required=Qt/ (Uo’Tm)
= (14.666*103)/ (569.026*10.863)
Arequired=8.014 m2
% Excess heat transfer area =(Apro/Ar ‘ 1)* 100
=[(11.290/8.014)]*100
% Excess heat transfer area=40.878%
Tube side pressure drop=’pt
‘pt=Np[(8*Jf*(L/di)*(??/??w)-m) +2.5]*((??ut2)/2)
= 1*[(8*3.6*10-3*(1.5/0.0148)*(1)-m) +2.5]*((979*7.62)/2)
‘pt=10686.234 Pa =20.310 kPa<‘pt max (68 kPa)
Hence, tube side pressure drop is less than maximum or optimum pressure drop.
Shell side pressure drop=’ps
‘ps=8*Jf*(Ds/de)*(L/Bs)*((??sus??2)/2)*(??/??w)-0.14
=8*(9.26*10-2)*(155.564/13.56)*(1500/31.113)*((1000*0.7202)/2)*(1)-0.14
‘ps=10620.250 Pa =26.364 kPa<‘psmax(13.73kPa)
Hence, shell side pressure drop is less than maximum or optimum pressure drop.
RESULT:
‘pt=Tube side pressure drop=20310 Pa =20.310kPa<‘pt max (30kPa)
‘ps= Shell side pressure drop =26364Pa =26.364 kPa<‘psmax(50-70kPa)
CHAPTER 9
COST ESTIMATION
‘
9. COST ESTIMATION
An acceptable plant design must present a process that is capable of operating under conditions which will yield a profit. Since net profit equals total income minus all expenses, it is essential that the chemical engineer be aware of the many different types of costs involved in manufacturing process.
In the analysis of costs in industrial processes, capital-investment costs, manufacturing costs and general expenses including income taxes must be taken into consideration.
Figure 9.1: Cumulative Cash Flow Diagram
9.1 FACTORS AFFECTING INVESTMENT AND PRODUCTION COSTS:
The Engineer must keep up-to-date information on the following factors:
Sources of Equipment
Price fluctuations
Company policies
Governmental regulations
9.2 TOTAL CAPITAL INVESTMENT:
The capital needed to supply the necessary manufacturing and plant facilities is called fixed capital investment, while that necessary for the operation of the plant is termed the working capital. The sum of the fixed capital investment and the working capital is known as the total capital investment. The fixed capital portion may be further subdivided into manufacturing fixed capital investment and non-manufacturing fixed capital investment.
9.2.1 EQUIPMENT COST (PEC):
Table 9.1
Equipment’s Costs (rs.)
Distillation column 600000
Stripper column ?? 2 1000000
Reactor ?? 4 3741000
Evaporator 1247000
Scrubber 50000
Clarifier 498800
Heat exchanger ?? 6 2244600
Holding tank ?? 2 997600
Rotary dryer 935250
Flash vessel 124700
Total 11438950
In the estimation the following items are founds:
Total Capital Investment (TCI)
Total Product Cost (TPC)
Gross Profit (GP)
Net Profit (NP)
9.2.2 TOTAL CAPITAL INVESTMENT (TCI):
The sum of the Fixed-capital investment and the Working capital is known as the total capital investment.
9.2.3 FIXED CAPITAL INVESTMENT (FCI):
The capital needed to supply the necessary manufacturing and plant facilities is called the fixed capital Investment. Fixed cost is the sum of the direct cost (DC) and Indirect cost (IC).
9.2.4 DIRECT COST (DC):
Table 9.2
Type % of PEC Cost (Rs.)
Installation 8 915116
Instrumentation 5 571947
Piping 12 1372674
Electricity 6 686337
Building 10 4143895
Yard 3.5 400373
Services 17 1715842
Land 1 114389
Total DC 6119837
INDIRECT COST (IC):
Table 9.3
Type % of PEC Cost (Rs.)
Supervision 5 571947
Construction 12 1372674
Legal 2 228779
Contractor’s 3 343168
Contingency 6 686337
Total IC 3202905
Fixed Capital Investment (FCI) = DC+IC
= 6119837 + 3202905
= 9322742 Rs.
Working Capital Investment (WCI) = 15% of FCI
= 0.15 * 9322742
= 1398411.3 Rs.
Total Capital Investment = FCI+WCI
= 9322742 + 1398411.3
= 10721153.38 Rs.
9.3 TOTAL PRODUCTION COST (TPC)
Total production cost is the sum of raw material, manufacturing cost and general expenses.
9.3.1 MANUFACTURING COST (MC):
FIXED CHARGES (FC):
Table 9.4
Type % of FCI Cost (rs.)
Depreciation 15 1398411.3
Taxes 2 186454.84
Insurance 0.5 46613.71
Total FC 1631479.85
DIRECT PRODUCTION COST (DPC):
Total Fixed Charges = 20% of Total Production Charges
Total Production Charges (TPC) = TFC/0.2
= 8157399.25 Rs.
Table 9.5
Type Characteristic Cost(rs.)
Maintenance 3% of FCI 279682.26
Operating Supplies (OS) 10% of Maintenance 27868.226
Lab Charges 10% of OS 2796.8220
Utilities 100% of TPC 8157399.25
Operating Labor (OL) 10% of TPC 815739.925
Direct Supervisory (DS) 10% of OL 815739.925
Total DPC 9365160.412
Plant overhead charges = 60% (OL+DS)
= 0.60* (8597313.917)
=5158388.3 Rs.
Total Manufacturing Cost=FC + DPC + POC
= 5158388.3+ 9365160.41+ 1631479.85
= 16155028.56 Rs.
GENERAL EXPENSES (GE):
Table 9.6
Type Characteristic Cost Rs.)
Administrative Cost 50% of OL 407869.96
Distributive Cost 3% of FC 48944.3955
R&D 4% of FC 65259.174
Finance Interest 10% of TCI 1072115.338
Total GE 1594188.827
RAW MATERIAL COST:
CaOH2 = 8 Rs/ Kg
NH4Cl = recycled
Annual cost for CaOH2 = 2.8 *8000 * 3000=68616000 Rs/ year
TOTAL PRODUCTION COST (TPC) = RMC + GE + MC
= 68616000 + 1594188.8 + 16155028.
= 68365216.8 Rs / year
9.3.2 GROSS PROFIT (GP)
Market sale price of products: Anhydrous Ammonia= 16 Rs/Kg
Calcium Chloride = 20 Rs/Kg
Gross Profit = Total Revenue ‘ Total Product Cost
Total Revenue = NH3+Cacl2/year * selling price
= 3000* (16000 + 20000)
= 108000000 Rs / year
Gross Profit = TR ‘ TPC
= 108000000 ‘ 86365216.8
= 21634783.2 Rs/ year
9.3.3 NET PROFIT (NP)
Net profit is the profit gained after income tax.
Net profit = GP ‘ income tax (0.34 of GP)
=21634783.2-7355826.2
= 14278957 Rs/ year
9.3.4 RATE OF RETURN (ROR)
Rate of Return before tax = GP/TCI * 100
= (21634783.2/ 10721153.3) * 100
= 201.7%
Rate of Return after tax = NP/TCI * 100
= (14278957/ 10721153.3) * 100
= 133.7%
9.4 PAY OUT PERIOD (POP)
Pay out Period = (depreciable FCI) / (Avg. Profit per yr. + Avg. Depreciation per yr.)
Average depreciation per year = dep. of equipment + dep. of building
= 3% OF FCI + 2% OF FCI
= 279682.2 + 186454.8
= 466137.1 Rs / year
Assuming salvage value at the end of service life = 5% of FCI
= 466137.1 Rs / year
POP = 9322742 / (14278957 + 466137.1)
= 0.63*12
=7.5 months
9.5 BREAK EVEN POINT (BEP):
Fixed Cost = RMC+GE+TMC
= 863652216.8 Rs/yr.
Total production Cost =108000000 Rs/Kg
For Breakeven point,
X*Total production Cost= Fixed Cost
Therefore, X= 86365216.8/108000000
=0.799
X = 9.58 months.
Hence, Plant can earn profit after 9.5 months of its installation and its payout period is 7.5 months. Therefore, the company recovers its initial investment amount within 7.5 months.
CHAPTER 10
PLANT LOCATION AND LAYOUT
10. PLANT LOCATION AND PLANT LAYOUT:
OBJECTIVES:
‘ Describe the concepts of plant location and plant layout
‘ Identify the various factors to be considered for selection of plant location from
State/area to the specific site
‘ Distinguish among the alternative patterns of plant layout
10.1 PLANT LOCATION:
Plant location refers to the choice of region and the selection of a particular sitefor setting up a business or factory.But the choice is made only after considering cost and benefits of differentalternative sites. Each individual plant is a case in itself.Businessman should try to make an attempt for optimum or ideal location.
An ideal location is one where the cost of the product is kept to minimum, with alarge market share, the least risk and the maximum social gain For achieving this objective, small-scale entrepreneur can make useof location analysis for this purpose.
10.2 PLANT LAYOUT:
The efficiency of production depends on how well the various machines;production facilities and employee’s amenities are located in a plant. Plant layout encompassesnew layout as well as improvement in the existing layout. It involves a judicious arrangementof production facilities so that workflow is direct.
10.2.1 DEFINITION:
Plant layout refers to the arrangement of physical facilities such as machinery,equipment, furniture etc. within the factory building in such a manner so as tohave quickest flow of material at the lowest cost and with the least amount ofhandling in processing the product from the receipt of material to the shipment of the finished product.
10.2.2 IMPORTANCE:
Plant layout is an important decision as it represents long-term commitment It facilitates the production process, minimizesmaterial handling, time and cost, and allows flexibility of operations, easyproduction flow, makes economic use of the building, promotes effectiveutilization of manpower, and provides for employee’s convenience, safety,comfort at work, maximum exposure to natural light and ventilation
An efficient plant layout is one that can be instrumental in achieving thefollowing objectives:
a) Proper and efficient utilization of available floor space
b) To ensure that work proceeds from one point to another point without anydelay
c) Provide enough production capacity.
d) Reduce material handling costs
e) Reduce hazards to personnel
i) Provide for volume and product flexibility
PLANT LAYOUT:
Figure 10.1 Plant Layout
CHAPTER 11
UTILITIES
11. UTILITIES
The word utilities are generally used for the ancillary service needed in the operation of the any procedure process. These services will normally be supplied from a central site facility and will include:
Electricity
Steam for process heating
Cooling water
Water for general use
Refrigeration
Effluent disposal facilities
ELECTRICITY
The power required for running motors drives lighting and general use may be generated onsite, but will more usually by purchased from the local supplied company. The voltage which the supply is taken or generated will depend on the demand. For a large site the supply will be taken at a very high voltage.
STEAM FOR PROCESS HEATING
The steam for heating is usually generated in water boiling using the most economical fuel level available. The process temperature required can usually be obtained with low temperature steam and steam distributed at relatively low pressure. High pressure or proprietary heat transfer fluids, such as down them will be needed for high process temperature.
COOLING WATER
Natural and forced draft cooling tower are generally used to provide the cooling water required in the site, unless water can be drawn from a convenient river or lake in sufficient quantity.
WATER FOR GENERAL USE
The water required for the general purposes on a site will usually be taken from the local main supply, unless a cheaper source of suitable quantity water is available from a river, lake or well.
REFRIGERATION
It will be needed for processes that require temperature below those that can be economically obtained with cooling water. For temperatures down to around 10 0C chilled water can be used.
EFFLUENT DISPOSAL
Facilities will be required at all sites for the disposal of waste materials without creating a public nuisance.
CHAPTER 12
HAZARD & SAFETY’
12.1 AMMONIA:
Table 12.1
Material Identification & Use
Name/Identifier Ammonia
User United Phosphorus Limited (Unit.1)
Chemical Name Anhydrous Ammonia ,Spirit of Hartshorn
Formula NH3
Physical Data for Material
Physical State Liquid
Odor & appearance Colour Liquid, Pungent, Suffocating Odour
Specific Gravity 0.86
Vapour Pressure 8573 h pa
Vapour Density 0.59
Boiling Point -33 ?? c
Freezing Point -77??c
Solubility in Water Soluble
pH N.A.
Density 0.85kg/m3
Reactivity Data
Chemical stability Stable under Normal Temperature and Pressure
Incompatibility Water, Sodium or Potassium metal, strong oxidants, nitric acid
Hazardous Products Thermal Composition may be produced Phosphine and Diphosphine
Preventive Measures
Respiratory A full face piece respirator with an ammonia/methylamine cartridge should be wear.
Eyes Use safety goggles
Clothing Wear long-sleeved shirt and long pants.
Gloves PVC, Neoprene
Footwear Safety Shoes
First Aid Measures
General When possible , have a product container with you when calling to doctor
Eyes Immediately flush eyes with plenty of water. Get medical help.
Skin Rinse Plenty of water on affected area and get medical help.
Ingestion If swallowed, DO NOT INDUCE VOMITING. Give large quantity of water
Inhalation Remove to fresh air. Get medical attention immediately.
Handling and Storage
Handling Procedure Handle and open container as to prevent spillage
Storage Procedure Store below 25??c.Keep in a tightly container.
12.2 CALCIUM CHLORIDE:
Table 12.2
Material Identification & Use
Name/Identifier Calcium Chloride
User United Phosphorus Limited (Unit.1)
Chemical Name Calcium Chloride
Chemical Formula Ca(OH)2
Physical Data for Material
Physical State Solid powder form
Odor & appearance Odourless
Specific Gravity 1.7
Vapour Pressure NA
Vapour Density NA
Boiling Point 1600??c
Freezing Point 260??c
Solubility in Water Soluble
Ph Approx. 5-8
Density 1710 Kg/m3
Reactivity Data
Chemical stability Stable under normal conditions. If exposed in open,it absorbs moisture and converts into solution
Condition of Instability NA
Hazardous Products NA
Preventive Measures
Respiratory Not required
Eyes Safety Goggles
Clothing Wear long sleeved shirts and long pants
Gloves Butyl rubber hand gloves
Footwear Safety shoes
First Aid Measures
General When possible, have the product container with you when calling on emergency number.
Eyes Hold eye open and rinde with water for 20 minutes.
.Skin Wash off immediately with plenty of water. Call a doctor immediately.
Ingestion Call a doctor immediately. Rinse out mouth and give water in gulps to drink.
Inhalation Move to fresh air and provide enough air
Handling and Storage
Handling Procedure No special precautions.
Storage Procedure No special precautions.
CHAPTER 13
ENERGY CONSERVATION CONCEPT
13. ENERGY CONSERVATION CONCEPT:
As, our aim of the project in Ammonia recovery plant is to conserve the energy and to minimize its operating cost ; we have find an optimum solution which minimize the operating cost as well as conserve the energy .
EXISTING DESIGN: PROPOSED DESIGN:
Figure 13.1 Existing&Proposed Case
The bottom product of column at 180 c passes through the series of two condenser in order to reduce bottom product (waste water) temperature up to 100 c by using cooling water as utilities and passes to antracol column.
Now, 30% CaCl2 from storage tank at 30??c goes to spray dryer to increase the concentration by removing excess water from it. In spray dryer, natural gas is used to give heat to CaCl2 from 30??c to 450 c to increase the concentration.
According to above diagram we have replace two heat exchanger by one new H.E .
The 30% CaCl2 at 30 c passes to the H.E in tube side and its outlet tem is 90 c ,then it passes to spray dryer. Hence the quantity of natural gas require to achieve 450 c becomes reduce.Simultaneously the use of cooling water in two H.E are eliminated.
Saving Calculations:
Q= 394080 KCal/Hr
Calorific value of natural gas = 8300 Kcal/Kg
Natural gas saving = 394080/8300 =48 Kg/Hr
Cost of natural gas = 25 Rs/ Kg
Saving due to natural gas =1186 Rs/Hr
For 10 month of working per year:
Saving of natural gas per year =7969920 Rs/Annum
Saving due to cooling water:
Q=394080 Kcal/Hr
TR saving of cooling water =394080/302=1304TR/Hr
1TR cooling water =-1 Rs/Kg
Saving due to cooling water = 1304 Rs/Hr
Saving of cooling water per year =8768900 Rs /Year
Total saving /year =16738820 Rs/Annum
Therefore by eliminating the use of cooling water and using less amount of natural gas in spray dryer to heat the CaCl2 solution, we have done energy conservation as well as minimize the operating cost by saving of 1.67 Cr/annum in ammonia recovery plant .
CHAPTER 14
RESULT& CONCLUSION
RESULT:
With the replacement of existing design by new proposed design ,we have reduce the operating cost of plant by saving up to 1.67 crore per annum with the elimination of cooling water used in two Heat Exchanger and deduction in using natural gas in Spray chamber. With
This concept we can reduce the cooling water cost around 87,68,900 Rs/annum and Natural gas around 79,69,920 Rs/Annum.
CONCLUSION:
From this project, we conclude that; if we implement the new proposed design shown in above chapter instead of existing one, then we can minimize the operating cost of the plant as well as conserve the energy. As mentioned in our result we can save up to 1.67 corer/annum in ammonia recovery plant by eliminating the use of cooling water which are used in Heat Exchanger and reduction in consumption of natural gas in spray dryer.
CHAPTER 15
REFERENCES
15. REFERENCES:
LITERATURES:
TEMA,8thEd;Standardofn tubular Heat exchanger Manufacturers Association , New York ,USA,1988
Perry, RH and Green D.,Perry`s chemical Engineers` Handbook;6th Ed., McGraw Hill, USA,1984
Hughmark , GA ., Chem Engineeer.Progr.60(7),1964,p.59
Saunders;EAD., Heat Exchangers, 1st Ed.., Longmans , UK,1988
Thakore S.B. and B.I Bhatt ‘Introduction to Process Engineering and Design’ Tata McGraw hill Publications Co. Ltd., New York.2005,pg 193
Bagajewicz, M. and J. Shuncheng, Ind. Eng. Chem. Res.,40(2),2001,617-626
Adham, K.,Chem.Engg.Progr.,96(8),2000,p.37
MCadams, W.H, Heat transmission ,2ndedition,McGraw Hill,Inc.,USA 1942
Plant economics by peter &teamwerhauss,3rd Ed.,pg. 145
Minton ,P.E. ChemEngg., 77(10),.May 4,1970.,pg. 103
WEBSITES:
http://pubchem.ncbi.nlm.nih.gov
http://pubchem.ncbi.nlm.nih.gov
www.google.com/patents
www.freepatentsonline.com/
5. en.m/wiki/ammonium chlorideen.mwikipedia.org/wiki/calcium chloride
6. http://en.m.wikipedia.org/wiki/Water data page
7. www.upl.co.in
8. www.che.iitb.ac.in
9. www.iiche.org.in
10. chemical.iitd.ac.in/
11.www.engineeringtoolbox.com
12.www.alibaba.com
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