air sepration

CHAPTER 1

PROJECT DETAILS

1.1 Problem Statement

T.H. Chemicals Pvt. Ltd. Purify various components of air in Perticular oxygen,

nitrogen and argon. A feasibility study is to be performed to investigate the possibility of

producing 2182 ton per day of 99.275% nitrogen and 682 ton per day of 99.49% oxygen and

54.5 ton per day of 99% argon from air.

1.2 Background of the problem

The components presented in air (Nitrogen, Oxygen, Argon etc.) are very often

applied components in chemical technology. Large quantities of high‐purity air products are

used in several industries, including the steel, chemical, semiconductor, aeronautical,

refining, food processing, and medical industries.

Air at lower temperatures (‐196oC) becomes in liquid and so we can do the

distillation of the air to its components. Distillation of air is currently the most commonly

used technique for production of pure oxygen, nitrogen and Argon on an industrial

scale. An example of an industrial process that requires pure oxygen and nitrogen is an

IGCC (integrated gasification combined cycle), where the oxygen is fed to a gasified and the

nitrogen to a gas turbine. The History of air separation has long time, in 1895 World´s first

air liquefaction plant on a pilot plant scale, commercial scale, production scale, 1904

‐World's first air separation plant for the recovery of nitrogen, 1910 World's first air

separation plant using the double column rectification process, 1950 First Linde‐Frankl

oxygen plant without pressure recycle and stone filled reactors, 1954 World's first air

separation plant with air purification by means of absorbers, 1978 Internal compression of

oxygen is applied to tonnage air separation plants, 1984 World's largest VAROX air

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separation plant with variable oxygen demand adjustment, 1990 World's first

tale‐controlled air separation plant with unmanned operation. Pure argon production by

rectification. 1991 World's largest air separation plant with packed columns, 1992 Air

separation plants produce mega pure gases, and 1997 Lined sets a new milestone in air

separation history. Four nitrogen generation trains are being provided, each in itself

constituting the largest air separation plant ever built. Nitrogen capacity 1,200

MMSCFD (40,000 t/d). 2000 Development of the advanced multi‐stage bath type

condenser. In chemical technology we need to allot of oxygen, nitrogen and argon. Air

separation has become a process integral to many manufacturing processes. The largest

markets for oxygen are in primary metals production, chemicals and gasification, clay, glass

and concrete products, petroleum refineries, and welding. The use of medical oxygen is

an increasing market. Gaseous nitrogen is used in the chemical and petroleum industries

and it is also used extensively by the electronics and metals industries for its inert properties.

Liquid nitrogen is used in applications ranging from cryogenic grinding of plastics to food

freezing. Argon, the third major component of air, finds uses as an inert material

primarily in welding, steelmaking, heat treating, and in the manufacturing processes for

electronics. The separation of air into its components is an energy intensive process. The

companies designing air separation processes have aggressively reduced the required

energy to the point that it is possible to sell a truckload of liquid nitrogen for is less than

many common consumer products. This surprising result has been accomplished by

advances in process design, process operation, manufacturing approaches and techniques,

and improvements in supply chain management. Process designs have increasingly utilized

mass and energy integration. Substituted process operations have increased the ability to

operate efficiently at a wider range of product on requirements, significantly improved

productivity through pervasive Automation and advanced control developed the

capability to efficiently handle rapid production rate and product split changes, and

leveraged advances in remote communications. Supply chain improvements have

ranged from improved purchasing practices to optimized scheduling of product delivery

to coordinated operation of separate facilities. Much has been written concerning the design

of air separation processes and certainly the worldwide patent activity for flow sheet and

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equipment innovation continues. Advanced control has been practiced in the air separation

business for decades. The first application of computer control for an air separation plant

was completed in the early 1970s. Since that time, most advanced control technologies

have been applied in an attempt to improve the efficiency and productivity of air separation

facilities. The current work aims to describe the air separation process including heat

exchange and cryogenic distillation. An ASPEN Plus simulation of cryogenic air

separation into Nitrogen, Oxygen and Argon is created. The influence of different process

parameters on distillation efficiency is analyzed.

3

CHAPTER 2

PROJECT DESCRIPTION

2.1 Air separation technologies

Air separation plants are designed to generate oxygen, and argon from air

through the process of compression, cooling, liquefaction and distillation of air. Air is

separated for production of oxygen, nitrogen, argon and ‐ in some special cases ‐

other rare gases (krypton, xenon, helium, neon) through cryogenic rectification of air.

The products can be produced in gaseous form for pipeline supply or as cryogenic

liquid for storage and distribution by truck. One of the largest producers of air

separation plants is Lined Company. It has built approx. 2,800 cryogenic air separation

plants in more than 80 countries (Source: http://tn‐sanso‐plant.com/en/air.html [4]) and

has the leading market position for air separation plants.

Figure 2.1: air separation scheme

4

Air can be separated into its components by means of distillation in special

units. So‐called air fractionating plants employ a thermal process known as

cryogenic rectification to separate the individual components from one another in

order to produce high‐purity nitrogen, oxygen and argon in liquid and gaseous form

Different type of air separation technologies was developed

• Cryogenic Air separation

• Membrane Air separation

• Separation by adsorption

• Other

Different technologies are applicable for different requirement on amount and

purity of the products. Figure (4) shows the Oxygen production process selection grid.

A similar graph describing the ranges for which the different nitrogen processes are

applicable can be seen in Fig. (4)

Figure 2.2: Oxygen production process selection grid









• Other














• Other






5

Methods such as membrane separation are also available but they are currently

used far less pervasively than the other two approaches.

Figure 2.3: Nitrogen production process selection grid.

2.2 Cryogenic Air Separation Process

Large quantities of high-purity air products are used in several

industries, including the steel, chemical, semiconductor, aeronau-tical,

refining, food processing, and medical industries. Methods of air separation

include cryogenic and non-cryogenic approaches. Although non-cryogenic

processes such as pressure swing adsorption and membrane separation

have become more competitive, cryogenic distillation technology is still the

dominant choice for producing large quantities of very high-purity and

liquified air products Cryogenic air separation is an energy intensive process

that consumes a tremendous amount of electrical energy. The U.S.

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industrial gas industry consumed approximately 31,460 million kilowatt

hours in the USA in 1998, which accounts for 3.5% of the total electricity

purchased by the manufacturing industry.

Optimal operation and control of cryogenic air separation processes

has received significant attention, with the primary goal of reducing energy

consumption and improving economic performance during operation

2.3 Process Description

In the proposed design the environmental air contains mainly

oxygen, nitrogen and argon and some amount of CO2 and water vapour and

traces of some other gases is compressed in a centrifugal compressor from

atmospheric pressure 1atm to 7atm which raise the temperature of air

mixture from 250C to 43.50C.We raise the temperature of air mixture to

600C through steam to make the air mixture according to the operating

condition of membrane separation unit

After air compression, the air mixture is fed to the membrane

separation unit to remove W2 and water vapour . Most of the water vapour

and carbon di oxide and hydro carbons are removed by memberane

separation unit. When the ai stream eaves the memberane seperaton unit , it

is assumed to no contain of water vapour , carbon di oxide or

hydrocarbons.

The purified compressd air feed is cooled cascade of I stage heat

exchanger where it is reached oraganic temperature or liqifaction

temperature or liqification entered in the high pressure distillation column

to begain the sepration process. The top product of high pressure

distillation column is compared in throlled valve to of atm and then feed to

the to of the low pressre distillation clumn . The bottom stream from high

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pressure distillation column in also compressed to 1 atm and fed to low

pressure distillation colluumn .

Oxygen has the maximum boiling pont of the thre main component

and that’s why Oxygen of 99.49% purity is taken from the bottom of low

pressure column ( distillation column 2) nitrogen of 99.275% is taken from

the top of the low pressure distillation column 2 at -1850C and 1 atm , and

stored . An Argon rich stream can be with drawn from the 10th tary of low

Argon purification system.

The condenser of distillation Collumn 1 and the reboiler of

distillation column 2 are inter connected so that the condenser provides the

heat needed by the boiler and reboiler provides the cooling needed by the

condenser.

Now the Argon rich stream from low pressure distillation column at

-1870C and 1 atm is send to distillation column 3 where nitrogen is

saperated from oxygen and Argon . The nitrogen rich distillate stream in

Condensor in condensed in condenser and one part is sent to the column 3

a reflux and another part at -1850C and 1 atm recycle to combine with feed

stream of column 2 The bottom stream is then fed to Argon seperion

Column 4 where argon and oxygen is separated . The Oxygen rich bottom

stream at -1860C from colum 4 is recycled back to the bottom of low

pressure distillation column 2. The overhead product of Column 4 i.e argon

rich stream at -1860C is condensed and fed to the argon purification column

5 to separate out the remaining nitrogen and oxygen , and exit as distillate

and vented to the atmosphere 99% pure argon exit as the bottom stream.

8

CHAPTER 3

RAW MATERIAL AND PRODUCT SPECIFICATION

3.1 Air properties

Air is a mixture of gases, consisting primarily of nitrogen (78 %), oxygen (21 %)

and the inert gas argon (0.9 %). The remaining 0.1 % is made up mostly of carbon dioxide

and the inert gases neon, helium, krypton and xenon. Air can be separated into its

components by means of distillation in special units. Air is usually modeled as a uniform

(no variation or fluctuation) gas with properties averaged from the individual components.

Figure 3.1: Air composition

Dry Air: Dry Air is relatively uniform in composition, with primary constituents as

shown below. Ambient air, may have up to about 5% (by c volume) water content and

may contain a number of other gases (usually in trace amounts) that are removed at one

or more points in the air separation and product purification system.

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The two most dominant components in dry air are Oxygen and Nitrogen. Oxygen has a 16

atomic unit mass and Nitrogen has 14 atomic units mass. Since both of these elements

are diatomic in air ‐ O2 and N2, the molecular mass of Oxygen is 32 and the molecular

mass of Nitrogen is 28. Table 3.2 shows some properties of air components.

Table 3.1: Some properties of air components

Gas

Ratio compared to Dry

Air (%)

Molecular

Mass

‐ M ‐

(kg/kmol)

Chemica

l

Symbol

Boiling Point

By volume By weight (K) (oC)

Oxygen 20.95 23.20 32.00 O2 90.2 ‐182.95

Nitrogen 78.09 75.47 28.02 N2 77.4 ‐195.79

Carbon Dioxide 0.03 0.046 44.01 CO2 194.7 ‐78.5

Hydrogen 0.00005 ~ 0 2.02 H2 20.3 ‐252.87

Argon 0.933 1.28 39.94 Ar 84.2 ‐186

Neon 0.0018 0.0012 20.18 Ne 27.2 ‐246

Helium 0.0005 0.00007 4.00 He 4.2 ‐269

Krypton 0.0001 0.0003 83.8 Kr 119.8 ‐153.4

Xenon 9 10‐6 0.00004 131.29 Xe 165.1 ‐108.1

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Other components in air:

Sulfur dioxide ‐ SO2 ‐ 1.0 parts/million (ppm)

• Methane ‐ CH4 ‐ 2.0 parts/million (ppm)

• Nitrous oxide ‐ N2O ‐ 0.5 parts/million (ppm)

• Ozone ‐ O3 ‐ 0 to 0.07 parts/million (ppm)

• Nitrogen dioxide ‐ NO2 ‐ 0.02 parts/million (ppm)

• Iodine ‐ I2 ‐ 0.01 parts/million (ppm)

• Carbon monoxide ‐ CO ‐ 0 to trace (ppm)

• Ammonia ‐ NH3 ‐ 0 to trace (ppm)

Dry air properties at temperatures ranging 175 ‐ 500 K are indicated in the table 2.

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Temperature

(K)

Specific Heat Capacity Ratio of

Specific

Heats

‐ k ‐

(cp/cv)

Dynamic

Viscosity

‐ μ ‐

10‐5

(kg/m s)

Thermal

Conductivity

10‐5

(kW/m K)

Prandtl

Number

Kinematic

Viscosity1)

‐ ν ‐

10‐5

(m2/s)

Density1)

‐ ρ ‐

(kg/m3)‐ c ‐

(kJ/kgK)

‐ c ‐

(kJ/kgK)

175 1.0023 0.7152 1.401 1.182 1.593 0.744 0.586 2.017

200 1.0025 0.7154 1.401 1.329 1.809 0.736 0.753 1.765

225 1.0027 0.7156 1.401 1.467 2.020 0.728 0.935 1.569

250 1.0031 0.7160 1.401 1.599 2.227 0.720 1.132 1.412

275 1.0038 0.7167 1.401 1.725 2.428 0.713 1.343 1.284

300 1.0049 0.7178 1.400 1.846 2.624 0.707 1.568 1.177

325 1.0063 0.7192 1.400 1.962 2.816 0.701 1.807 1.086

350 1.0082 0.7211 1.398 2.075 3.003 0.697 2.056 1.009

375 1.0106 0.7235 1.397 2.181 3.186 0.692 2.317 0.9413

Table 3.2: Some properties of air at temperatures ranging 175 ‐ 500 K

400 1.0135 0.7264 1.395 2.286 3.365 0.688 2.591 0.8824

450 1.0206 0.7335 1.391 2.485 3.710 0.684 3.168 0.7844

500 1.0295 0.7424 1.387 2.670 4.041 0.680 3.782 0.7060

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Common Pressure Units frequently used as alternative to "one Atmosphere"

76 Centimeters (760 mm) of Mercury

• 29.921 Inches of Mercury

• 10.332 Meters of Water

• 406.78 Inches of Water

• 33.899 Feet of Water

• 14.696 Pound‐Force per Square Inch

• 2116.2 Pounds‐Force per Square Foot

• 1.033 Kilograms‐Force per Square Centimeter

• 101.33 Kilopascal

Table 3.3: Some other physical properties of air components:

Nitrogen Oxygen

Normal boiling point °K 126.1 154.4

critical pressure at 34.6 51.3

Critical temperature °K 77.35 90.19

Oxygen has the highest boiling point of the three main components and is taken from

the bottom of the LP column. Nitrogen is taken from the top of the LP or HP columns. An argon

rich stream can be product in other distillation columns withdrawn from the middle of the LP

column. Figure 2 (Source: reference [9] www.engineeringtoolbox.com/dry‐air‐properties‐

d_973.html) shows the air density versus temperature and pressure.

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Figure 3.2: Air density versus temperature and pressure

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3.2 Products of air separation and their applications

These are the Air products:

3.2.1 Oxygen:

Oxygen makes up 21 percent of the air we breathe. Our bodies need oxygen to

support life, so oxygen has many medical and healthcare uses.

Oxygen is also used in many industries, in clouding metal and glass manufacturing,

chemicals and petroleum processing, pharmaceuticals, pulp and paper, aerospace,

wastewater treatment and even fish farming.

Chemical formula: O2‐ other names: oxygen gas, gaseous Oxygen (GOX), liquid

oxygen (LOX)

3.2.1.1 Physical and Chemical Properties:

Oxygen has no color or smell. Oxygen is slightly heavier than air and slightly

water soluble. Oxygen combines readily with many elements to form compounds

called “oxides.” One example is iron oxide, or rust, that forms on iron in the presence of

oxygen and moisture. Although oxygen itself is nonflammable, combustible

materials burn more strongly in oxygen. Even though most applications use oxygen in

the gas form, it can be cooled to a pale Blue liquid at extremely low temperatures

(‐297°F/‐183°C). To put that temperature into perspective, water freezes at 32°F/0°C.

3.2.1.2 Uses and Benefits:

Our bloodstream absorbs oxygen from the air in our lungs to fuel the cells in our

bodies. Healthcare providers use medical oxygen for patients in surgery and for those who

have difficulty breathing. For home use, lightweight Portable oxygen cylinders give

patients freedom to gout in to the community.

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Oxygen promotes combustion, so it help manufacturers save upland energy and

reduce the emission of green house gases such as carbon dioxide, nitrogen oxide or sulfur

oxide. Using oxygen‐enriched air increases production efficiency in steel, rocket

fuel, glass, chemical and metallurgical processing applications.

Manufacturers of aluminum, copper, gold and lead use oxygen to remove

metals from ore more efficiently. As a result, they can often use lower‐grade ores and

raw materials, which helps conserve and extend our natural resources. For metal

fabrication, oxygen is often used with acetylene, propane, and other gases to cut and weld

metals.

The chemical and petroleum industries combine oxygen with hydrocarbon

building blocks to make products such as antifreeze, plastic and nylon. The pulp and

paper industry uses oxygen to increase paper whiteness while reducing the need for

other bleaching chemicals. They also use it to reduce odors and other emissions.

Municipal and industrial wastewater plants use oxygen to make the treatment process

more efficient and increase basin capacity during plant expansions or plant upsets.

Municipal Water plants use oxygen as feed gas to their ozone systems to remove taste,

odor and color from drinking water. Oxygenated water also improves the health and size of

the fish for fish farming operations so farmers around the world can supply high‐quality

food.

3.2.1.3 Industrial Use:

We ship oxygen as a high‐pressure gas or a cold liquid. We often ship and

store larger quantities of oxygen in liquid form, because it occupies much less space

that way. Depending on how much oxygen gas our customer uses, we store and ship it in

high‐ pressure cylinders and tubes. Industry guidelines cover the storage and

handling of compressed gas cylinders. Workers should use sturdy work gloves, safety

glasses with side shields and safety shoes when handling compressed gas cylinders. We

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store and ship liquid oxygen in three different types of containers‐dowers,

cryogenic liquid cylinder sand cryogenic liquid tanks. The second trainers are similar

to heavy‐duty vacuum bottles used to keep your coffee hot or your water cold.

Because of its low temperature, liquid oxygen should not come in contact with skin.

If workers handle containers of liquid oxygen, it is important to wear a full face‐shield

over safety glasses to protect the eyes and face. Workers should also wear clean, loose

fitting, thermal‐insulated gloves; a long‐sleeved shirt and pants without cuffs; and safety

shoes.

The risk of fire increases when oxygen levels in the air are higher than normal.

Clothing and hair readily trap oxygen and are highly combustible. It is important to have

good ventilation when working with oxygen and to periodically test the atmospheres

in confined areas to ensure that oxygen levels do not increase and create an increased

fire hazard. Personnel should know the risk, keep the area clear of combustible

materials and post “No Smoking” signs. Equipment used in oxygen service must be

cleaned according to strict industry guidelines to avoid contamination.

3.2.2 Nitrogen:

Nitrogen makes up 78 percent of the air we breathe. Nitrogen has many

commercial uses. In fact, more nitrogen is sold by volume than any other inorganic

chemical. Nitrogen is used in oil and gas industries, metalworking, electronics, food

processing and many manufacturing processes.

Chemical Formula: N2 other names: nitrogen gas, gaseous Nitrogen (GAN), liquid

nitrogen (LIN)

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Nitrogen has no color or smell. It does not burn. It’s slightly lighter than air

and slightly water soluble. Nitrogen is inert, which means that it does not react with many

materials. However, it can form compounds under certain conditions. For

example, at high temperatures, nitrogen reacts with oxygen to form various oxides

of nitrogen. It can also form other compounds in the presence of catalysts. When cooled

to extremely low temperatures (‐321°F/‐196°C), nitrogen exists in liquid form. To put

that temperature into perspective, water freezes at 32°F/0°C.


Industries use both liquid nitrogen and nitrogen gas. Nitrogen helps make many

industrial processes safer for workers and the public.

Refineries, petrochemical plants and marine tankers use gaseous nitrogen to

clean out vapors and gases from the equipment they use. Industries also use gaseous

nitrogen to “blanket,” or maintain an inert protective atmosphere over chemicals in

process and storage equipment. Metal fabricators use liquid nitrogen to help control

process temperatures in thermal spray coating, making the process more efficient.

Machine shops use liquid nitrogen instead of cutting fluids in machining operations,

which eliminates the need for oil‐based products. Manufacturers use liquid nitrogen to

cool soft or heat‐sensitive materials so they can grind them. They use cryogenic grinding

to produce medicines, spices, plastics and pigments. Recyclers use liquid nitrogen to cool

polymers including plastic and rubber so they can grind them and recover key raw

materials used to manufacture new products. For example, they use nitrogen to turn

rubber scrap tires into Useable products, such as synthetic running tracks, instead of

discarding the rubber in a landfill. Many of the foods we eat are frozen in

nitrogen‐cooled freezers. Because the nitrogen is so cold, it often improves the quality of

the frozen food products. The liquid nitrogen replaces traditional refrigerants, such as

fluorocarbons and ammonia, which may cause environmental or health concerns when

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they leak from processing equipment. After the nitrogen cools the food, the nitrogen

goes safely back into the air.

3.2.2.3 Industrial Use:

We ship nitrogen as a high‐pressure gas or a cold liquid. We often ship and

store gases in liquid form, because they occupy much less space that way. We store and

ship nitrogen gas in two different container sizes. Depending on how much our customer

uses, we provide the gas in high‐pressure cylinders and tubes. Industry guidelines cover

the storage and handling of compressed gas cylinders. Workers should use sturdy work

gloves, safety glasses with side shields and safety shoes when handling compressed gas

cylinders. We also store and ship liquid nitrogen in three different types of

containers—Dewar’s, cryogenic liquid cylinders and cryogenic liquid tanks. These

containers are similar to heavy duty vacuum bottles used to keep your coffee hot or your

water cold. Because of its low temperature, liquid nitrogen should not come in contact

with skin. For workers who handle containers of liquid nitrogen, it is important to wear

a full face‐shield to protect the eyes and face. Workers should also wear clean,

loose‐fitting, thermal‐insulated gloves; a long‐sleeved shirt and pants without cuffs; and

safety shoes. To prevent suffocation, it is important to have good ventilation when

working with nitrogen. Confined workspaces must be tested for oxygen levels prior to

entry. If the oxygen level is lower than 19.5 percent, personnel, including rescue

workers, should not enter the area without special breathing equipment that provides

an independent source of clean breathing air.

3.2.3 Argon:

Argon is a gas that occurs naturally. It makes up slightly less than 1 percent of the air we

breathe. Argon is used in metals production, processing and fabrication and electronics

manufacturing.

Chemical formula: Ar ‐ other names: argon gas, gaseous argon (GAR), liquid argon

(LAR)

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Argon has no color or smell. It does not burn. It’s heavier than air and will tend to settle

in low‐lying areas. Argon is slightly water soluble.

Argon is a member of a special group of gases known as the “noble” or “inert” gases.

Other

gases in this group are helium, neon and krypton. The term “inert” means that they will

not readily combine chemically with other material When cooled to extremely low

temperatures (‐303°F/‐186°C), argon exists in liquid form, known as a cryogenic liquid.

To put that temperature into perspective, water freezes at32°F/0°C.


The metals and semiconductor manufacturing industries use argon to purge or clean

out vapors and gases from the equipment they use.

Metal producers and semiconductor manufacturers also use argon to “blanket,” or

maintain an inert protective atmosphere over metals and silicon crystals to prevent

unwanted chemical reactions from occurring. In metal fabrication processes like welding,

argon shields the weld against the metal oxide impurities that would form if the molten

weld bead came in contact with oxygen. Argon gas is also used in heat treating furnaces

to cool parts when other cooling gases might negatively affect the parts.

The lighting industry uses argon for filling incandescent bulbs, because it will not react

with the filament. In combination with other rare gases, argon creates special color

effects, which are often called “neon lights.” Argon is also used to fill the space in

insulated glass windows to improve the thermal efficiency of our homes.

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3.2.3.3 Industrial Use

We ship argon as a gas or a cryogenic liquid. We often ship and store gases in liquid

form, because they occupy much less space that way.

Depending on how much argon gas our customer uses, we store and ship it in

high‐pressure cylinders and tubes. Industry guidelines cover the storage and handling of

compressed gas cylinders. Workers should use sturdy work gloves, safety glasses with side

shields and safety shoes when handling compressed gas cylinders. We also store and ship liquid

argon in three different types of containers—Dewar’s, cryogenic liquid cylinders and cryogenic

liquid tanks. These containers are similar to heavy‐duty vacuum bottles used to keep your

coffee hot or your water cold. Because of its low temperature liquid argon should not come

in contact with skin. If workers handle containers of liquid argon, it is important to wear a

full face‐shield over safety glasses to protect the eyes and face. Workers should also wear

clean, closefitting, thermal‐insulated gloves; a long‐sleeved shirt and pants without cuffs;

and safety shoes. To prevent suffocation, it is important to have good ventilation when

working with argon. Confined workspaces must be tested for oxygen levels prior to entry.

If the oxygen level is lower than 19.5 percent, personnel, including rescue workers, should

not enter the area without special breathing equipment.

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CHAPTER 4

MATERIAL BALANCE

Material balances are the basis of process design. A material balance taken over

complete process will determine the quantities of raw materials required and products

produced. Balances over Individual process until set the process stream flows and

compositions. The general conservation equation for any process can be written as

Material out = material in + accumulation

For a steady state process the accumulation term is zero. If a chemical reaction is taking

place a particular chemical species may be formed or consumed. But if there is no chemical

reaction, the steady state balance reduces to:

Material out = Material in

A balance equation can be written for each separately identifiable species present,

elements, compounds and for total material. [10]

4.1 BASIS:

Basis = 67167 TPA

The process is planned and developed as a continuous process. A plant is operated for

24 Hours per day and 335 per year.

4.2 Capacity in Kmol/hr:

Capacity of Nitrogen = 1527Ton/day

=1527*1000/24 kg/hr

= 63625 kg/hr

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=63641.67*kg/hr*1/28

Capacity of Nitrogen= 2272.91 kmol/ hr

Assume loss of production = 1 %

Now total cap of Nitrogen = 2272.91 + 227291.02*0.01

Final capacity of Nitrogen = 2295.64 kmol/ hr

Capacity Of Oxygen = 477 Ton/ day

=477*1000/24 Kg/ hr

= 18316.67 kg/hr * 1/32kg/mol

Capacity of Oxygen = 572.395 kmol /hr

Assume loss of production = 1 %

Now total of capacity of O2 =572.395+572.395*0.01

Final capacity of Oxygen = 578.119 kmol/ hr

Capacity Of Argon =38.15 Ton/ day

= 38.15*1000/24 kg/hr

= 1590.58 kg/hr *1/40 kg/kmol

Capacity of Argon = 4.03 kmol/hr

Assume loss of production = 1%

Now total Capacity of Ar = (39.73*0.01)+39.73

Final Capacity Of Argon = 40.359 kmol/hr

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4.3 Material Balance For Coloumn :- 5

(Light ends) Distillate

XD = 0.01

Feed Xf =0.989

W Bottom product Xw=0.99

Xd =0.01

Xw = 0.09

Xf = 0.989

W5 = 40.1359 kmol /hr

F5 = D5 + W5

F5 = D5 + 40.1359………………………….(1)

X5 F5 = XD . D5 + XwW5

0.989F5 = 0.01 D5 +0.99*57.337………………(2)

F5 = 40.1772 kmol / hr

D5 = 0.04099 kmol /hr

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Table 4.1 Material balance for column:-5

Component In,

Kmol/hr

Out, Kmol/hr

Feed Bottom Distillate

Nitrogen 0.00842 0.09226 0.028

Oxygen 0.3052 0.29302 0.01257

Argon 39.7355 39.7355 0.0004099



XD = 0.989

Feed Xf =0.1066


D4 = F5

D4 = 40.175 kmol / hr

XD = 0.098

Xw = 0.002

Xf = 0.1006

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F4 = D4 + W4

F4 = 40.1751 + W4………………..(1)

XfX4 = XDD4 + XwW4

0.1066 F4 = 0.989*40.1751 + XwW4

F4 = 379.106 kmol/hr

W4= 338.932 Kmol/hr


Component In,

Kmol/hr

Out, Kmol/hr


Nitrogen 0.123592 0.0 0.11984

Oxygen 338.98 337.90 0.3052

Argon 7.46 0.6769 39.032



XD = 0.0069

Feed Xf =0.08375


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W3 = F4

W3=379.1102 kmol / hr

Xw= 0.1066

XD= 0.0069

Xf = 0.0069

F3= D3+ W3

F4 = D3+ 379.51102 kmol/hr………………..(1)

XfX3= XDD3 + XwW3

0.08375 F3 = 0.989*57.396 + XwW4

F3= 491.183 kmol/ hr

D3= 112.721 Kmol/hr


Component In,

Kmol/hr

Out, Kmol/hr


Nitrogen 113.4 0.12356 111.58

Oxygen 336.7 331.33 0.12061

Argon 41.190 40.4131 0.777

27



D2=3279.49

F2=4807.992kmol/hr

F3=702.617 kmol/hr

W2=825.885Kmol/hr

Entering Stream In column:- 2

F2= D1+ W1 + D3+ W4

= D1 + W1+ 161.0311 + 484.189

F2 = 645.22 + D1 + W1……………………(1)

Material Balance Eqn

F2 = D2+ W2+ F3……………….(2)

F2 = 3279.49 + 825.885 + 702.617

F2 = 3365.5994 kmol/hr

From Eqn 1

D1 + W1= 4807.992 -992 -645.22

D1 + W1= 4162.772 …………(3)

28


Component In,

Kmol/hr

Out, Kmol/hr

Feed Bottom Distllate

Nitrogen 2395.75 0.0 2278.5952

Oxygen 941.44211 575.1711 12.725

Argon 27.965 2.898 3.696



XD = 0.00298

Feed Xf =0.0091

Xw=0.0173

XD = 0.00298

Xw = 0.0173

Xf = 0.0091

F4 = 4162.772………………..(1)

XfX1= XDD1 + XwW1

0.0091*4162 = 0.00298 D1 * 0.0173 W1………..(2)

D1= 1668.8kmol/ hr

29

W1= 1244.999 Kmol/hr


Component In,

Kmol/hr

Out, Kmol/hr


Nitrogen 2257.756 646.1 1635.676

Oxygen 611.5396 574.8155 28.602

Argon 26.516 21.5383 4.9735

4.8 Material balance On Memberane Unit

Composition of inlet Air

N2 = 0.78

O2 = 0.2096

Ar = 0.0091

Co2 = 0.0003

Water vapour = 0.00097

Let the flow of inlet Air = x moles / hr

Feed after passing memberane Unit F1 = 2913.9404 k mol /hr

Moles of inlet – moles of Co2 – Moles Of water Vapour = moles of air after passing

membrane unit

X – 0.0003X – 0.00097 X = 2913.9404

X = 2917.6 kmol/hr

So the flow rate of Unit air = 2917.6 kmol/hr

30

CHAPTER 5

ENERGY BALANCE

5.1 Compressor:-

QN2 = 25∫43.5 ncpdT

= n 25∫43.5(a+b+cT

2+dT

3)dt

= n[a +bt2/2 + C T3

/3 +dT4/4]

43.5

= 2275.756[29(43.5-25)] +0.2199 *10 [(43.5)2-(25)2] [(43.5)3(25)3] – 2.871*10-

9/4[(43.5)4-(25)4]

= 1224400.576 KJ/hr

QO2 = 25∫43.5nCpdT

= n 25∫43.5 (a+bT+CT2+dT3)dT

= n [a+bT2/2 CT3/3 +dT4/4 ]43.5

= 333627.4822 KJ/hr

QAr = 25∫43.5 nCpdT

= 2.794*37.9293*18

= 10213.68914 KJ/hr

QC02 = 25∫43.5nCpdT

= n 25∫43.5(a+b+cT

2+dT

3)dt

= n[a +bt2/2 + C T3

/3 +dT4/4]

43.5]

= 0.8752926[36.11(18.5)+4.233*10-2/2(1.26725)

-2.887*10-5/3[66687.875]+7.464*10-9/4 (3189985)

= 607.6461007KJ/hr

31

Qwv = 25∫43.5 ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

43.5

= 2.83011274[18.2964(18.5)+47.212*10-2/2(1267.25)

133.887*10- 5/3[66687.875]+7.464*10-91314.2*10-5/[3189985.063]

= 1723.306388 KJ/hr

5.2 Heat Exchanger :-1:

QN2 = 43.5∫60ncpdT

= n 43.5∫60(a+bT+cT

2+dT

3)dT

= n[a +bt2/2 + C T3

/3 +dT4/4]

60

= 2250.556[29(16.5)+0.2199*10-2/2][(60)2-(43.5)2]+0.5723*10-5/3[(60)3]

- 2.871*10-9/4[(60)4-(43.5)4]]

= 1081675.658 KJ/hr

QO2 = 43.5∫60ncpdT

= n 43.5∫60(a+bT+cT

2+dT

3)dT

= n[a +bt2/2 + C T3

/3 +dT4/4]

60

= 611.524 [29.10(16.5)+1.158*10-2/2][1707.75]

+0.6076*10-5/3[133687.125]+1.311 *10-9/4[9379389.937]

= 299511.1207 KJ/hr

QAr = 43.5∫60ncpdT

= 20.794*37.9293*16.5

= 9109.506 KJ/hr

QCO2 = 43.5∫60ncpdT

= n 43.5∫60(a+bT+cT

2+dT

3)dT

= n[a +bt2/2 + C T3

/3 +dT4/4]

60

= 0.8752592 [36.11(16.5)+1.158*10-2/2][1707.75]

32

-2.887*10-5/3[133687.125]+7.464*10-9/4[9379389.937

= 552.0382 KJ/hr

QWV = 43.5∫60ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

60

= 2.830112 [18.2964 (16.5)47.212*10-2/2][1707.75]

-133.88*10-5/3[133687.125]+1314.2 *10-9/4[9379389.937]

= 1835.18369 KJ/hr

Qtotal = 3121803.840 KJ/hr

MEDIA: Steam

T1= 1100C T2=81.50C

QN2 = 110∫81.5mcpdT

= m[a+bT2/2 +cT3/3+dT/4]81

m = [33.46(81.5-110)+0.6880*10-2/2[(81.522- (110)2]+0.7604*10-5/3[(81.5)3-

(110)3]-3.593*10-9/4[(81.5)4-(110)4]]

1989547.847 = m [-974.2942939]

m = 1431.52794 kmol/hr

5.3 Cascade :-

5.3.1 Heat Exchanger :-1

QN2 = 54.4∫26.4ncpdT= m[a+bT2/2 +cT3/3+dT/4]26.4

= 3251.08[29 (-28)+0.2199*10-2/2[(26.4)2- (54.4)2]

+0.572*10-5/3[(26.4)3-(54.4)3]-2.871 *10-9/4[(81.5)4-(26.4)4-(54.4)]]

= -1849602.3560 KJ/hr

33

QO2 = 54.4∫26.4ncpdT

= m[a+bT2/2 +cT3/3+dT/4]26.4

= 611.4696[29.10 (-28)+1.158*10-2/2[-2262.4]-0.6076*10-5/3[-142589.44]

+1.311*10-9/4[-8272053.36]

= -506118.255 KJ/hr

QAR = 54.4∫26.4ncpdT

= 20.794*37.88*(-28)

= -237537 .078KJ/hr

Qtotal = -2375737.078 KJ/hr

MEDIA: Oxygen

Q02 = -218∫-180mcpdT

T1= -2180c T2= -1800C

= m[a +bt2/2 + C T3

/3 +dT4/4]

-180

= m[29.10 (38)+1.158*10-2/2][-15124]-0.6076*10-5/3[4528232]

+1.311 *10-9/4](-1208770576)]

= m[1008.64686]

-3393910.111 = m[1008.664686]

m = 2355.328893 KJ/hr

5.3.2 Heat Exchanger:- 2

QN2 = 26.4∫-1.6ncpdT= n[a +bt2

/2 + C T3/3 +dT4

/4]-1.6

= 3257.08[29(-28)+0.2199 *10-2/2][(-16)2-(26.4)2]-0.5723*10-5/3

+1.311 *1][(-16)3-(26.4)3]2.87*10-9/4](-1208770576)][(-16)4-(26.4)4]-

=-184973.05 KJ/hr

34

QO2 = 26.4∫-1.6ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-1.6

=611.5396[29.10(-28)+1.158*10-2/2][-694.4]-0.6076 *10-5/3(-18403.84 )

+ 1.311*10-9/4](-485746)]

=-500718.5103 KJ/hr

QAr = 26.4∫-1.6ncpdT

= 20.794*37.88*(-28)

= -22054.94813 KJ/hr

Qtotal = -2365887.474 KJ/hr

MEDIA: Oxyge:

Q02 = -218∫-180mcpdT

T1= -2180c T2= -1800C

= m[a +bt2/2 + C T3

/3 +dT4/4]

-180

= m[29.10 (38)+1.158*10-2/2][-15124]-0.6076*10-5/3[4528232]

+1.311 *10-9/4](-1208770576)]

= m[1008.64686]

33798392.249 = m[1008.664686]

m = 2345.5639 kmol/hr


QN2 = -1.6∫-29.6ncpdT= n[a +bt2

/2 + C T3/3 +dT4

/4]29.6

= 2257.756[29(-28)+0.2199 *10-2/2][(29.6)2-(1.6)2]

-0.5723 *10-5/3(29.6)3-(1.6)3 -2.87*10-9/4][(-16)4-(26.4)4]-

= -1845841.732 KJ/hr

35

QO2 = 26.4∫-1.6ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-1.6

=611.539 [29.10(-28)+1.158*10-2/2](873.6)-0.6076 *10-5/3(-25930.24 )

+ 1.311*10-9/4](767649.792)

= -495156.9405 KJ/hr

QAr = 26.4∫--1.6ncpdT

= 20.794*37.88*(-28)

=-15438.46371 KJ/hr

Qtotal = -2356437.187 KJ/hr

MEDIA: - Oxygen

QO2 = -218∫-180mcpdT

T1= -2180c T2= -1800C

= m[a +bt2/2 + C T3

/3 +dT4/4]

-180

=m[29.10 (38)+1.158*10-2/2][-15124]-0.6076*10-5/3[4528232]

+1.311 *10-9/4](-1208770576)]]

3366338.838=m(1008.664686)

m = 2336.194792 kmol/hr

5.3.4 Heat Exchanger :- 4

QN2 = -29.6∫-57.6ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

57.6

= 3251.08[29(-28)+0.2199 *10-2/2][(57.6)2-(29.6)2]

-0.5723 *10-5/3(57.6)3-(29.6)32.87*10-9/4][(-57.6)4-(29.6)4]-

= -1842538.303 KJ/hr

36

QO2 = -29.6∫-57..6ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-57.6

= 611.244 [29.10(-28)+1.158*10-2/2](2441.6)

-0.6076 *10-5/3(-165168.64 )+ 1.311*10-9/4](10239875.07)

= -489430.5883 KJ/hr

QAr = 29.6∫-57.6ncpdT

= 20.794*37.88*(-28)

= -15438.46371 KJ/hr

Qtotal = -2347407.355 KJ/hr

MEDIA: Oxygen

QO2 = -218∫-180mcpdT

T1= -2180c T2= -1800C

= m[a +bt2/2 + C T3

/3 +dT4/4]

-180

= m[29.10 (38)+1.158*10-2/2][-15124]

-0.6076*10-5/3[4528232]+1.311 *10-9/4](-1208770576)]]

3353439.078 = m(1008.664686)

m = 2327.24247 kmol/hr


QN2 = -57.6∫-85.6ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-85.6

= 2275.756[29(-28)+0.2199 *10-2/2][(85.6)2-(57.6)2]

-0.5723 *10-5/3(85.6)3-(57.6)32.87*10-9/4][(-85.6)4-(57.6)4]-

= -1839844.155 KJ/hr

37

QO2 = -57.6∫-85.6ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-57.6

= 611.539[29.10(-28)+1.158*10-2/2](4009.6)

-0.6076 *10-5/3(-436119.04)+ 1.311*10-9/4](42682673.1)

= -483536.4957 KJ/hr

QAr = -57.6∫-85.6ncpdT

= 20.794*37.88*(-28)

= -15438.4637 KJ/hr

Qtotal = -2338819.116 KJ/hr

MEDIA: oxygen

QO2 = -218∫-180ncpdT

T1= -2180c T2= -1800C

= m[a +bt2/2 + C T3

/3 +dT4/4]

-180

= m[29.10 (38)+1.158*10-2/2][-15124]-0.6076*10-5/3[4528232]

+1.311 *10-9/4](-1208770576)]]

3341170.166 = m(1008.664686)

m = 2318.728055 kmol/hr


QN2 = -85.6∫-113.6ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-113.6

=2279.957[29(-28)+0.2199 *10-2/2][(113.6)2-(85.6)2]

-0.5723 *10-5/3(113.6)3-(85.6)32.87*10-9/4][(-113.6)4-(-85.61)4]

= -1837782.8 KJ/hr

38

Q02 = -57.6∫-85.6ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-57.6

= 698.9024 [29.10(-28)+1.158*10-2/2](5577.6)

-0.6076 *10-5/3(-838781.44)+ 1.311*10-9/4](112847788)

= -477471.711 KJ/hr

QAR = 85.6∫-113.6ncpdT

=20.794*37.88*(-28)

= 15438.46371 KJ/hr

Qtotal = -2330693.612 KJ/hr

MEDIA: Oxygen

Q02 = -218∫-180ncpdT

T1= -2180c T2= -1800C

= m[a +bt2/2 + C T3

/3 +dT4/4]

-180

= m[29.10 (38)+1.158*10-2/2][-15124]-0.6076*10-5/3[4528232]

+1.311 *10-9/4](-1208770576)]]

3329562.303 = m(1008.664686)

m = 2310.67236 kmol/hr

5.3.7 Heat Exchanger :-7

QN2 = -113.6∫-141.6nCpdT

=2275.756[29(-28)+0.2199 *10-2/2][(7145.6)- (-1373155.84)]

-0.5723 *10-5/3(-1373155.84)3-2.871*10-9/4](235486963.71)]

= -1836380.243 KJ/hr

39

Q02 = -113.6∫-141.6nCpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-141.6

=611.3576 [29.10(-28)+1.158*10-2/2](7145.6)

-0.6076 *10-5/3(-1373155.84)+ 1.311*10-9/4](235486963.7)]

= -471233.2727 KJ/hr

QAr = 113.6∫-141.6nCpdT

= 20.794*37.88*(-28)

= -15438.46371 KJ/hr

Qtotal = -23203051.5 KJ/hr

MEDIA: Oxygen

Q02 = -218∫-180mCpdT

T1= -2180c T2= -1800C

= m[a +bt2/2 + C T3

/3 +dT4/4]

-180

= m[29.10 (38)+1.158*10-2/2][-15124]

-0.6076*10-5/3[4528232]+1.311 *10-9/4](-1208770576)]]

3318645.685 = m(1008.664686)

m = 2303.096373 kmol/hr


QN2 = -141.6∫-169.6nCpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-141.6

= 2275.756[29(-28) +0.2199 *10-2/2][(8+13.6)

-(0.5723 *10-5/3(-209242.24)-2.871*10-9/4](4253519.2)]

= -1835658.67 KJ/hr

40

Q02 = -141.6∫-169.6ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-169.6

= 611.5396 [29.10(-28)+1.158*10-2/2](8713.6)

-0.6076 *10-5/3(-2039242)+ 1.311*10-9/4](425351944.2)]

= -46481.2251 KJ/hr

QAr = -141.s6∫-169.6ncpdT

= 20.794*37.88*(-28)

= -15438.46371 KJ

Qtotal = -2315915.86 KJ/hr

MEDIA: - Oxygen

Q02 = -218∫-180mcpdT

T1= -2180c T2= -1800C

= m[a +bt2/2 + C T3

/3 +dT4/4]

-180

=m[29.10 (38)+1.158*10-2/2][-15124]

-0.6076*10-5/3[4528232]+1.311 *10-9/4](-1208770576)]]

33084505.573 = m(1008.664686)

m = 2296.021057 kmol/hr


QN2 = -169.6∫-175ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-175

=2257.756[29(-5.4)+0.2199 *10-2/2][(-175)2 (-169)2

- (0.5723 *10-5/3(-175)2 (-169)3 2.871*10-9/4]((-175)4 (-169)4]

= -353995.8136 KJ/hr

41

Q02 = -169∫-175.6ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-169.6

= 611.5396[29.10(-5.4)+1.158*10-2/2](1860.84)

-0.6076 *10-5/3(-430973.46)+ 1.311*10-9/4](110513724.5)

= -88890.57338 KJ/hr

QAr = -169.6∫-175.6ncpdT

= 20.794*37.88*(-5.4)

= -2977.418002 KJ/hr

Qtotal = -445863.805 KJ/hr

media: - oxygen

Q02 = -218∫-180mCpdT

T1= -2180c T2= -2020C

= m[a +bt2/2 + C T3

/3 +dT4/4]

-180

= m[29.10 (16)+1.158*10-2/2][-6720]

-0.6076*10-5/3[2117824]+1.311 *10-9/4](-593564160)]]

636948.2928 = m(1008.664686)

m = 1056.03039.685 kmol/hr

42

5.4 Distillation Column:- 1 (Reboiler)

QN2 = -174∫-198ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-175

= 646.485[29(-24)+0.2199 *10-2/2][(-198)2- (174)2]

-0.5723 *10-5/3 ](198)3- (174)3 -2.871*10-9/4]](198)4- (-174)4

= -446971.5312 KJ/hr

Q02 = -174∫-198ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-141.6

= 821.165 [29.10(-24)+1.158*10-2/2](198)2- (174)2)

-0.6076 *10-5/3(-198)4- (174)3) + 1.311*10-9/4](198)4- (174)4)

= -368716.5577 KJ/hr

QAr = -174∫-198ncpdT

= 30.769*20.794*(-24)

= -10748.81784 KJ/hr

Qtotal = -826436.6971 KJ/hr

MEDIA: Oxygen

QAr = -174∫-218ncpdT

T1= -2180c T= -1850C

= m[a +bt2/2 + C T3

/3 +dT4/4]

-180

= m[29.10 (33)+1.158*10-2/2][-(185)2 *(218)2]

-0.6076*10-5/3][(185)3 (218)]+1.311 *10-9/4](][-(185)4 (218)4]

= m[874.7831947]

1180623.853 = m[874.7831947]

m = 944.7331655 kmol/hr

43

5.5 Interstage Cooler:

QN2 = -188∫-178ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-175

= 1635.676[29(10)+0.2199 *10-2/2][(-178)2- (188)2]

-0.5723 *10-5/3 ](178)3- (188)3 - 2.871*10-9/4] ](178)4- (188)4

= 471187.4885 KJ/hr

Q02 = -188∫-178ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-141.6

=74.1508572 [29.10(-10)+1.158*10-2/2](-3660)

-0.6076 *10-5/3(1004920) + 1.311*10-9/4] (-245322480 )

= 7565.552211 KJ/hr

QAR = -188∫-178ncpdT

= 70105*20.794*(-24)

= -1013.1318959 KJ/hr

Qtotal = 685540.329 KJ/hr

MEDIA: Oxygen

QO2 = -190∫-180m cpdT

T1= -1900c T2= -1800C

= m[a +bt2/2 + C T3

/3 +dT4/4]

-180

= m[29.10 (10)+1.158*10-2/2][-(180)2 *(-190)2]

-0.6076*10-5/3][(-180)3 (*190)3]+1.311 *10- 9/4](-180)4 (-190)4]

m = 1794.514812 kmol/hr

44

5.6 Distillation Column:- 2(Condenser)

QN2 = -19.5∫-185ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-185

= 2278.5952[29(-10)+0.2199 *10-2/2][(-185)2- (-195)2]

-0.5723 *10-5/3 ](-185)3- (-195)3 -2.871*10-9/4] ](-185)4- (-195)4

= 656430.0966 KJ/hr

Q02 = -195∫-185ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-141.6

= 12.6259[29.10(-24)+1.158*10-2/2](-3800)

-0.6076 *10-5/3(1083250)+ 1.311*10-9/4](-274550000)

= 3367.504 KJ/hr


= n[a +bt2/2 + C T3

/3 +dT4/4]

-185

= 5.28*20.794*10

= -7684.54624 KJ/hr

Qtotal = -660566.1468 KJ/hr

MEDIA: Steam


T1= -1100c T= -900C

= m[a +bt2/2 + C T3

/3 +dT4/4]

-90

= m[33.46(10)+0.6880*10-2/2][-(400)]

-0.7604*10-5/3][(-602000)] +3.593*10-9/4][-(-34390000)4]

m = 1887.7803 KJ/hr

45

5.7 distillation Column:- 3(Condenser)

QN2 = -19.5∫-185ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-195

= 111.594[29(-10)+0.2199 *10-2/2][(-195)2- (-185)2]

-0.5723 *10-5/3 ] [(-195)3- (-185)3 - 2.871*10-9/4] [(-195)4-

(-185)4]

= 35306.90128 KJ/hr

Q02 = -185∫-195ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-195.6

= 0.1723 [29.10(-10)+1.158*10-2/2](-3800)

-0.6076 *10-5/3(1083250)+ 1.311*10-9/4](-274550000)

= -32.1683838 KJ/hr


= 1.11*20.794*10

= -161.56938 KJ/hr

Qtotal = -32342.34415 KJ/hr

MEDIA: Steam

Q02 = -185∫-190ncpdT

m = 97.22109586

46

5.8 Distillation Collumn:-3(Reboiler)

QN2 = -184∫-196ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-196

= 0.1229592[29(-12)+0.2199 *10-2/2][(-196)2- (-184)2]

-0.5723 *10-5/3 ](-196)3- (-184)3 -2.871*10-9/4] ](-196)4-

(-184)4

= -42.726456 KJ/hr

Q02 = -184∫-196ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-195.6

= 338.786 [29.10(-12)+1.158*10-2/2](-4560)

-0.6076 *10-5/3(-1300032)+ 1.311*10-9/4] (-329560320)]

= -108430.5287 KJ/hr


= 57.733*20.794*10

= -10084.20042 KJ/hr

Qtotal = -11855.4556 KJ/hr

MEDIA: Oxygen

Q02 = 218∫-198ncpdT

T1= -2180c T= -1980C

= m[a +bt2/2 + C T3

/3 +dT4/4]

-90

= m[29.10(20)+1.15*10-2/2][-8320]

-0.6076*10-5/3][2597840]+1.311*10-9/4] (- 721576960)]

m = 224.402196 kmol/hr

47


QN2 = -186∫-173ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-173

= 0.12047[29(13)+0.2199 *10-2/2][(-173)2- (-186)2]

-0.5723 *10-5/3 ] (-173)3- (-186)3 -2.871*10-9/4] ](-173)4-

(-186)4

= 45.11396431 KJ/hr


= 56.76*20.794*10

= -10740.4337 KJ/hr

Qtotal = -10891.95054 KJ/hr

MEDIA: Steam

Q02 = -110∫-87ncpdT

= m[a +bt2/2 + C T3

/3 +dT4/4]

-141.6

= [33.46(-23)+0.6880*10-2/2](-4531)

-0.76074 *10-5/3(1083250)+ [3.593*10-9/4](-89120239)

15559.92934 = m[-786.7911435]

m = 13.84350933 kmol/hr


QN2 = -170∫-175ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-175

= 0.028[29(-5)+0.2199 *10-2/2][(-175)2- (-170)2]

48

-0.5723 *10-5/3 ](-175)3- (-170)3 -2.871*10-9/4] ](-195)4-

(-185)4

= -4.32800694 KJ/hr

Q02 = -170∫-175ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-175

= 0.01958612 [29.10(-5)+1.158*10-2/2](-1725)

-0.6076 *10-5/3(-446375) + 1.311*10-9/4](-102680625)

= -1.692718915 KJ/hr


= (0.0005857)*(20.794)*(10)

= -0.042262666 KJ/hr

Qtotal = -5.7681462 KJ/hr

MEDIA: Oxygen

QAR = -218∫-203 ncpdT

T1= -2180c T= -2030C

= m[a +bt2/2 + C T3

/3 +dT4/4]

-203

= m[29.10 (15)+1.158*10-2/2][-6315]

-0.6076*10-5/3[1994805] +1.311 *10-9/4]

(-560348895)]

[-8.240208956] = m[-395.7123506]

m = 0.014576613 kmol/hr

49

5.11 Distillation Collumn:-5(Reboiler):-

QN2 = -167.5∫-170 ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-170

= 0.09226[29(-2.5)+0.2199 *10-2/2][(-170)2- (-197)2]

-0.5723 *10-5/3 ](-170)3- (-167.5)3 -2.871*10-9/4] ](-170)4-

(- 167.5)4

= -6.644032448 KJ/hr

Q02 = -167.5∫-170ncpdT

= n[a +bt2/2 + C T3

/3 +dT4/4]

-170

= 0.29302 [29(-25)+0.2199*10-2/2](-170)2-(167.5)2

-0.6076 *10-5/3+](-170)3-(167.5)3 1.311*10-9/4](-170)4-

(167.5)4]

= -1975434474 KJ/hr

QAR = -167.5∫-170ncpdT

= 56.76*20.794*(-2.5)

=-2065.46802 KJ/hr

Qtotal = -2091.866397 KJ/hr

MEDIA: Oxygen

Q02 = -218∫-205 ncpdT

T1= -2180c T= -1980C

= m[a +bt2/2 + C T3

/3 +dT4/4]

-205

= m[29.10(13)+1.15*10-2/2][-5499]

-0.6076*10-5/3][1745107] +1.311*10-9/4] (-49242995)]

m = 6.102917637 kmol/hr

50

CHAPTER 6

DESIGNING OF EQUIPMENTS

6.1 Designing of Shell and Tube Heat Exchanger :-

Fig 6.1 Heat Exchanger (shell and tube)

t1 = cold fluid inlet temperature, K =298.15 K

t2 = cold fluid outlet temperature,K = 418.15 K

T1 = hot fluid inlet temperature,K = 458.15 K

T2 = hot fluid outlet temperature,K = 423.15 K

Purpose to vaporise the O-xylene by hot fluid i.e medium pressure steam (mps)

Heat gain by the O-xylene , Q = mCPΔT * mL

= (2734*1.764*120)+(2734*0.3418)

= 579836 KJ/h

t1

t2

T2

T1

51

Heat removed by steam, Q = (mCPΔT )

579836 = m*4.187*(185.15-150.15)

= 3956.7 kg/h

Flow rate of steam = 3956.7 kg/h

ΔTLM = log mean temperature difference, K

ΔTLM = (125-40)/ln(125/40)

= 74.56 K

Heat exchanger tube specification :-

O.D = 0.025m

I.D = 0.015m

L= 4.5m

R = (T1-T2)/(t2-t1)

S = (t2-t1)/(T1-t1)

R = 35/120 = 0.2916

S= 120/160 = 0.75

Ft = temperature correction factor

Shell passes = 1

tube passes = 2

By graph , Ft = 0.86

ΔtM= Ft ΔTLM

= 64.12 K

Q = UA FT ΔTLM

From Richardson – coulson -6 , table no- 12.1

Hot fluid = steam ; cold fluid = organic solvent

U= 500-1000 (W/m2̊C)

Assume , U= 500 (W/m2̊C)

So, A = 5m2

52

Fig 6.2 Graphical diagram between ft and S

Surface area of one tube = = DL= 0.391 m2

No. Of tubes requires,NT = 5/0.391 = 13 tubes

Cross sectional area of one tube = ∗= 2.27* 10-4m2

Total tube area = (13 *2.27* 10-4) = 2.95*10-3m2

Triangular pitch , PT = 1.25*DO

= 31.75 mm

Tube passes =2 ; K1= 0.249 ; n1= 2.207

Db= DO*(NT/K1)1/2.207

= 152.58 mm

Tube per pass = NT / 2

= 6.5 = 7

Tube side coefficient :-

Steam mean temp. = (458+423)/2

= 440.5K





Total tube area = (13 *2.27* 10-4) = 2.95*10-3m2


= 31.75 mm

Tube passes =2 ; K1= 0.249 ; n1= 2.207

Db= DO*(NT/K1)1/2.207

= 152.58 mm


= 6.5 = 7



= 440.5K





Total tube area = (13 *2.27* 10-4) = 2.95*10-3m2


= 31.75 mm

Tube passes =2 ; K1= 0.249 ; n1= 2.207

Db= DO*(NT/K1)1/2.207

= 152.58 mm


= 6.5 = 7



= 440.5K

53

Total flow area = (tube per pass)*(one tube c.s.a)

= 1.59* 10-3 m2

Density Steam = 3.915 kg/m3

Assume , bundle clearance = 500 mm

Ds= 202.458 mm

Baffle spacing = Ds* (0.3)

= 60.73 mm

Fig 6.3 Graphical diagram between bundle diameter and shell inside diameter


= 1.59* 10-3 m2



Ds= 202.458 mm


= 60.73 mm



= 1.59* 10-3 m2



Ds= 202.458 mm


= 60.73 mm


54

6.2 Designing Of Compresser (Air Passing)

m = 4168.06 kmol/hr m = 4168.06 kmol/hr

P1= 1atm P2 = 7 atm

T1= 25̊C T2 = 43.5 ̊C

Fig:- 6.4 compressor

ρair = 1 kg/m3

= (1/28.96) kmol/m3

mair = 4168.06 kmol/hr

qo = volume of gas compressed, std m3/s.

qo = Vair = mair/ ρair

= 33.529 m3/s

Pressure ratio = 7/1 = 7

Ta= inlet temperature, K

PB= power , KW

γ = ratio of specific heat ,cp/cv

Here, assume γ = 1.4

Here, Centrifugal compressor so the ή = 0.82Fluid power , PB = (0.371*Taγqo)/{(γ-1)ή}*[(Pb/Pa)

(γ-1)/γ - 1]

= 11766.20452 KW

Shaft power = fluid power/ή

= 14349.0299 KW

55

CHAPTER-7

FIRE AND SAFETY

7.1 Fire Chemistry:-

The well known “Fire triangle” requires the three ingredients of fire namely fuel,

oxygen and source of ignition. “A fire is a combination of fuel, oxygen and source of ignition”.

7.2 Fire Prevention:-

Fire prevention can be done in three ways:

7.2.1 Eliminate sources of ignition.

7.2.1 Eliminate combustible substances.

7.2.3 Eliminate air excess to combustible substances.

7.2.1 Fire Prevention through Elimination of Ignition Sources:-

To prevent fire the first is to remove the cause of fire. Studies made by fire insurance

company shows that majority of fires are caused by following general sources of ignition:

Electrically limited fire: Improper earthing, short circuiting, loose electrical contacts,

temporary direct connections without proper fittings, high current, over heating of electrical

equipment are among the common cause of electrically initiative fires.

Smoking ignited fire: Smoking or even carrying cigarettes/biddies/matches/lighter etc. in

the following areas is a serious offence. All non-smoking areas should carry “NO SMOKING”

signboards.

Friction and overheated material: In flame proof areas, frictional fires can also be started

by the friction of moving parts of machinery which are overheated due to excess friction. This

is likely in non-lubricated and not well maintained machinery.

56

7.2.2 Fire Prevention Through Elimination Of Combustible Materials:-

Waste and combustible materials: All combustible wastes and materials like waste paper,

cotton waste etc. accumulated after a job should be transported to waste bins and is the

responsibilities of the person doing the job that creates the wastes. Tins and cans of flammable

materials like paints, oils, spirit etc.: These should b handled carefully ensuring that no undue

spillages takes place during their uses and any spillages takes place during their use and any

spillage should be cleaned immediately.

Fueling of vehicle tanks: Engine should be always switched off while fueling a vehicle. If

diesel or petrol spills over during fueling, dry sand should covered over the spill immediately

till only dry sand is visible on the spilled area.

Waste disposal: All combustible waste must be regarded in such a way that can be

disposed off as such and not burnt.

7.2.3 Prevention Through Elimination Oxygen Supply:-

Smoothening: It is a process of covering the burning area with a non-combustible

substance like asbestos or fire proof blanket, wet thick cotton blanket or sand.

7.3 Classification Of Fires:-

Fires are classified according to the nature of fuel burning and fire extinguishing

methods that can be applied and the following is the fire classification under the Indian fire

code.

CLASS “A” FIRE

CLASS “B” FIRE

CLASS “C” FIRE

CLASS “D” FIRE

CLASS “E” FIRE

57

CLASS “A” FIRE: Fires where the burning fuel is a cellulosic material such as wood,

clothing, paper etc. is called class “A” fire.It can be extinguished by the water and sand. Class

“A” fires can also be extinguished by all the available means of extinguishing fires like foam,

soda acid, dry chemical powder, carbon dioxide etc.

CLASS “B” FIRE: Fires where the burning fuel is a flammable liquid Naphtha, petrol etc. are

categorized as class “B” fire. Blanketing is a useful first aid fire control for “B” class fire.

Water is forbidden as a fire fighting means on class “B” fires. Foam, carbon dioxide, dry

chemical powder extinguishers are the desired means of controlling “B” class fires.

CLASS “C” FIRE: Fire involving flammable like natural gases hydrogen are classified as

class “C” fire. The best means of extinguishing “C” type fire is by stopping the gas supply to

the leaking vessels or pipe lines if possible. This must be the intermediate and very first step.

Dry chemical powder and carbon dioxide are useful in controlling “C” class fire.

CLASS “D” FIRE: Fire involving material like magnesium, aluminum, zinc, potassium etc.

are classified as class “D” fire. Sand buckets are useful in most cases of metallic fires. Special

dry chemical powder also works on class “D” fires.

CLASS “E” FIRE: Fires involving electrical equipments are classified as “E” class fires.

Only carbon dioxide and D.C.P extinguishers are used on class “E” fires.

7.4 Fire Fighting Gadgets And Appliances:-

CO2:- It contain under pressurized liquid carbon dioxide.

SODA ACID: - Contain a double container with sodium bicarbonate solution in outer container

and dilute sulphuric acid in the inner container. After the inner container both react and produce

a liquid of entrapped CO2.

FOAM: - Contain aluminous sulphate in inner container and sodium bicarbonate in outer one.

After cracking the container both reacts to produce carbon dioxide and the foam stabilizer

makes stable form of carbon dioxide.

58

DRY CHEMICAL POWDER: - It contains an inert dry chemical powder of sodium

bicarbonate or potassium bicarbonate or potassium chloride and diammonium phosphate along

with liquid carbon dioxide under pressure.

HALON/ BROMOCHLOROFLUORO METHANE: -Halon is in the form of a liquid gas

under pressure that is released on pressing the knob.

7.5 Safety Programme :-

The company conducts regular programmes for safety measures, which not only creates

awareness about safety but also maintains it; the fire and safety department of organizes many

programmes to motivate in this direction and to make the employees aware. National safety day

4th march is being celebrated each year with earnestness and includes various awareness

programmes, competitions and includes various awareness programmes, competitions etc. some

of these are listed below:

1. Training programmes on safety.

2. Home safety.

3. Use of safety equipments.

4. Safety quiz.

5. Safety slogan competition.

7.6 Safety Provisions:-

1. Personal protective equipment (PPEs ): The various types of PPEs are:-

Helmet for head protection.

Goggles for eye protection.

Ear plugs and muff for ear protection.

Safety shoes for foot protection.

Gloves for hand protection.

Face shields foot protection.

59

Full body protection suits.

Hoods for head, neck, face, and, eye protection.

Safety belts or life belts or harness.

Breathing apparatus or respiratory protection equipment.

Fencing of machinery.

Devices for cutting of power.

Hoists and lifts.

60

CHAPTER 8

PLANT UTILITIES

The utilities such as water, air, steam, electricity etc. are required for most of the

chemical process industries. These utilities are located at a certain distance from processing

area, from processing area hazardous and storage area etc, where a separate utility department

works to fulfill the utilities requirements.

Steam Generation

Cooling water

Water

Electricity

Compressed air

The utilities required for the plant are summarized as below.

8.1 Steam Generation:

Steam is used in plants for heating purpose, where direct contact with substance is not

objectionable. The steam, for process heating, is usually generated in water tube boiler using

most economical fuel available i.e. coal, fuel oil on the site.

In reboiler of distillation column,drying column and evaporator steam is used at

different temperature depending on requirement.

61

8.2 Cooling Water:

Cooling water is generally produced in plant by cooling towers. Cooling tower is used

to cool the water of high temperature coming from process. Cooling tower mainly decreases

temperature of water from process. There are two types of cooling tower.

8.2.1 Natural Type:

In this cooling tower the water from the process is allowed to fall in a tank. From some

height when falling it comes in contact with an air & gets cool.

8.2.2 Mechanical Type:

They are classified in three types:

Induced draft

Forced draft

Balanced draft

In induced draft a fan is rotating at the bottom while in balanced draft fan is rotating at the

centre. In forced draft a fan rotating at top.

Cooling by sensible heat transfer

Cooling by evaporation

8.3 Water:

The water is required for large industrial as well as general purposes, starting with

water for cooling, washing and steam generation. The plant therefore must be located where a

dependable water supply is available namely lakes, rivers, wells, seas. If the water supply

shows seasonal fluctuations, the temperature, mineral content, slit and sand content,

bacteriological content, and cost for supply and purification treatment must also be considered

when choosing a water supply.

62

8.4 Electricity:

Power and steam requirements are high in most industrial plants and fuel is ordinarily

required to supply these utilities. Power, fuel and steam are required for running the various

equipment like generators, motors, turbines, plant lightings and general use and thus be

considered, as one major factor is choice of plant site.

63

CHAPTER 9

ENVIRONMENTAL PROTECTION

9.1 Environmental Legislation:

Environmental legislation provides a legal tool with which activities affecting the

environment are regulated .these approaches are generally followed:-

Legislation that are limited in scope and deal with only one aspect of environmental

protection such as water pollution control ,air pollution control etc.the law for prevention and

control of the water pollution was enacted in 1974 and one for the prevention and control of air

pollutiomn was enacted in 1981 by the Indian parliament thogh this is piecemeal approach

towards environmental protection ,yet in developing countries like INDIA it is reasonable

policy.it is expected that the stage by stage control of the pollution in different spheres would

ultimately form part of the compressive policy.a proper co ordination of different activities and

the laws governing them is ,however important

Second approach to the environmental protection is comprehensive and deals with all

types of the pollution ,viz water air ,land ,noise ,etc. the laws based on this have to be massive

and the organizations implementing them have necessarily to be big ones

Third approach envisages of environmental protection with national development

planning .this, undoubtly, is the best approach as the environment as a whole is subjected to

national planning .prohibitive and the restricted manner ,in general ,become passive in

character with the passage of time .legislative measures should ,therefore, have a built in

dynamic character and be in the position to direct the activities of the country so as to prevent

them from becoming detrimental to the environment. The environmental ,therefore ,is sought to

be protected in a large measure by national plans of economic development.

64

9.2 Water (Prevention and Control of Pollution )Act,1974:

An Act to provide for the prevention and control of water pollution and the maintaining

or restoring of wholesomeness of water, for the establishment, with a view to carrying out the

purposes aforesaid, of Boards for the prevention and control of water pollution, for conferring

on and assigning to such Boards powers and functions relating thereto and for matters

connected therewith.

The central and state water pollution control boards adopted the following use based

classification of waters:-

Table 9.1 Fresh water:

Classification Best use to which it can be put

A DRINKING WATER SOURCES

WITHOUT TREATMENT BUT AFTER

DISINFECTION

B OUTDOOR BATHING

C DRINKING WATER SOURCE WITH

CONVENTIONAL TREATMENT

FOLLOWED BY THE DISINFECTION

D PROPOGATION OF THE WILD LIFE

E IRRIGATION,INDUSTRIAL

COOLING&CONTROLLED WASTE

DISPOSAL

65

Table 9.2 Sea water(including estuaries &tidal waters):

Classification Best use to which it can be put

A Water sport ,shell fishing ,salt pans

B Commercial fishing ,noncontact recreation

C Industrial cooling

D Harbor

E Navigation, controlled waste disposal

9.3 Air (Prevention and Control of Pollution )Act,1981:

The Act is designed to prevent, control and abatement of air-pollution; the provisions

relate to preservation of quality of air and control of pollution. Keeping in view these objects

the Act has provided for measures, which are preventive in nature, in the cases of indusries to

be established; and in the case of indusries already established, they are remedial. In the case of

estblished industries, it insists on obtaining consent of Board, making the industy amenable to

the administrative control of the Board. Once a consent is given, the Board can issue orders,

directions etc; which are to be complied with by the industry.

9.3.1 Bodies Constituted To Enforce The Act:

Central Pollution Control Board constituted under section 3 of the Water (Prevention

and control of Pollution) Act, 1974 was authorized to exercise the powers and performs the

functions for the prevention and control of air pollution.

66

State Pollution Control Boards constituted under section 4 of the Water (Prevention and

control of Pollution) Act, 1974 was authorized to exercise the powers and performs the

functions for the prevention and control of air pollution.

9.3.2 Fuctions Of The Central Control Board Are:

To advise the central government on any matter concerning the improvement of the quality

of air

To plan and cause to be executed a nation wide program foer the prevention and control of

air pollution

To coordinate the activities of the stae board &resolve disputes between them

To lay down standards for the quality of air

To collectand disseminates information concerning matters relating to air pollution

To perform other prescribed function

9.4 Noise Pollution:

Noise pollution has recently been recognized as pollution. There is ample medical

evidence that it affects speech, hearing and the general health and behavior of people exposed

to it over extended periods of time noise due to traffic is the pervasive and is, in the fact, a

controlling factor in combination with an octave band analyzer can be used to determine the

noise level. The community noise level is expressed as a weighed sound pressure level in

decibels dBa the sources of noises in environs of industries include metal fabrication process

,high pressure burners 9in furnaces ,rotary equipments, mobile units like welding machine,

cranes, vehicles, etc. pipeline carrying high velocity fluids and solids and vibrating and

grinding equipments among many other

67

CHAPTER 10

ORGANIZATIONAL STRUCTURE AND MANPOWERREQUIREMENT

10.1 Organizational Structure :-

CEO

General Manager ProductionManagerManager

Finance Manager Manager HumanResoucers

ChiefAccountant

BudgetAnalyst

TrainingSpecialist

BenefitsAdministrator

PlantSupritendent

MaintenanceSupritendent

Cooling

unit

Mechanical unit

Electricalandinstrumentationunit

Fire andsafetyhazard

Skilledlabour

Semiskilledlabour

Unskilledlabour

Skilledlabour

Semiskilledlabour

UnskilledlabourFigure.11.1 : organisation chart

68

10.2 Employees Required:

The following employees are required for the organization

S. No. Post quantity Salary

1) General Manager 1 2,45,000 pm

2) Production Manager 1 2,20,000 pm

3) Finance Manager 1 2,00,000 pm

4) Human Resources Manager 1 2,00,000 pm

5) Sales Manager 1 2,00,000 pm

6) Plant Superintendent 1 1,60,000 pm

7) Maintenance Superintendent 1 1,60,000 pm

8) Chief Accountant 1 1,20,000 pm

9) Accountant 2 1,00,000 pm

10) Chief Budget Analyst 1 1,00,000 pm

11) Budget Analyst 2 80,000 pm

12) Training Specialist 1 1,00,000 pm

13) Benefit Administrator 1 1,00,000 pm

14) HOD Chemical Section 1 2,00,000 pm

15) HOD Mechanical Section 1 2,00,000 pm

16) HOD Electrical Section 1 2,00,000 pm

17) HOD Fire & Safety 1 2,00,000 pm

18) Transportation 2 40,000 pm

19) Chemist 2 x 3shift 30,000 pm

20) Mechanic 2 x 3shift 20,000 pm

21) Electrician 2 x 3shift 20,000 pm

22) Fitter 2 x 3shift 16,000 pm

23) Labours (cleaning, peons etc.,) 15 x 3shift 10,000 pm

24) Security Head 1 x 3 shift 60,000 pm

25) Security Guards 12 x 3shift 16,000 pm

Total employees 129 41,32,000 pm

69

CHAPTER 11

MARKET PROSPECT

11.1 Nitrogen Use Scenario In India:

Nitrogen is one of the major plant nutrients without which the agricultural production is

not possible. Nitrogen use in Indian agriculture was nearly 55000 tons in 1950-1951 that

increased to 11.31 million tons in 2001-2002. The total food production of the country has also

experienced the similar increase from 50.83 to 222 million tons in the respective years.

Interestingly the N fertilizer consumption of India remained almost constant during the last six

years indicating the possibility of reducing N consumption. The highest N consumption is in

North zone owing to the introduction of rice-wheat cropping system followed by West, South

and East. The N use efficiency has been reported to be varying between 30% to 50% depending

on the crops and the management. But in most of the cases, N use efficiency has been

calculated based on the total N removed by the crops (above ground part only) ignoring the N

content left in the roots. It has been observed in controlled experiments that the total N uptake

by roots varied from 18% to 44% of the total N removed by the above ground parts, i.e. grain

and straw. If the root N is also accounted, the N use efficiency will be higher than reported. The

management of other organic sources has to be improved so as to increase the fertilizer use

efficiency as well as to check the direct release of N in the atmosphere. In this review all these

issues will be dealt.

11.2 Oxygen Use Scenario In India:

11.2.1 Introduction:

Oxygen is the second most widely used industrial gas, after nitrogen. It is commonly

accepted to have been discovered by Joseph Priestley in 1774. It constitutes 21 percent of the

Earth's atmosphere and over the past 100 years has grown to be consumed by a wide range of

70

industries, including steel and non-ferrous metals, chemicals, petrochemicals, glass, ceramics,

paper and healthcare.

11.2.2 Market Growth:

The global oxygen market has maintained a steady 5-6 percent growth over the last ten

years. Worldwide oxygen capacity rose from 0.75 to 1.2 million tpd from 1996 to 2006. The

focus of this growth has, however, shifted, with marginal growth in some developed countries

balanced by massive growth in developing economies. The oxygen supply in Western Europe,

for example, has grown by 46 percent over the last ten years, but grew by less than 1 percent

from 2005 to 2006.

Meanwhile, the North Pacific Rim is experiencing significant growth, with a capacity

increase of 16 percent over the last year. This demand for oxygen in such places as China is

confirmed by the recent trend towards gas companies establishing ASU production facilities in

the country together with the high output of plants and equipment by local manufacturers.

We believe it is important to cover two of the major consuming sectors and look at what

trends are taking place that will impact on oxygen demand in the near future. We also address

the swing towards huge oxygen demand from the gas-to-liquids sector.

11.2.3 The Steel Industry:

The largest end-user industry using oxygen is the $1 trillion global steel industry, which

consumes 48 percent of global oxygen output - approximately 580,000 tpd. Of this usage, 60

percent is captive, that is produced and consumed solely by the end-user. The majority is

provided by the industrial gas companies themselves under long-term (usually 15 year) supply

contracts. With such high usage, steel demand is clearly the primary driver for oxygen market

growth.

In steel production, oxygen is used to enrich air, increasing combustion temperatures in

blast and open-hearth furnaces, and to replace coke with other combustible materials. However,

71

technologies have changed over the years and the Electric Arc Furnace and mini-mills are

gaining increasing popularity as a production method. At the real tonnage end of production,

direct coal injection, direct reduction furnaces and other technologies are being used to improve

efficiency and scale.

Common to all technologies is the fact that the consumption of oxygen per ton of crude

steel produced has continued to rise. In the 1970s it was common to see oxygen demand

running at 15 cubic metres per ton of steel produced. This rose on average to 25 m3/ton in the

1980s, and then further to 35m3/ton in the 1990s. Some technologies now being introduced

across the world require in excess of 100 m3/ton produced.

In China, the industry is trying to modernise its steel production facilities in order to

improve both efficiency and quality. Eastern Europe or, more appropriately, the former Soviet

Union, is also an interesting market as there is a large amount of oxygen capacity linked to steel

production but this has been under utilised since the break-up until recently. 98 percent of the

installed capacity is captive but it appears that the trend is moving towards outsourcing to the

gas companies - see recent Linde, Air Liquide and Cryogenmash announcements.

With the current rise in steel demand driven by construction and infrastructure projects

around there will be a continuing trend towards higher oxygen demand from the steel sector for

the next 5 years at least.

11.2.4 Chemicals:

The second largest end-user industry for oxygen is the chemicals industry, which

includes refined products, petrochemicals, agrochemicals, pharmaceuticals, polymers, pigments

and oleochemicals. The industry 19 per cent of the worldwide oxygen demand. 40 percent of

this is through on-site supply schemes. It manufactures a diverse range of materials and

products. The largest sector by turnover is the pharmaceuticals industry, followed by three main

groups: chemicals, specialist and products.

72

But how is the chemical industry performing? On a global level the industry is about a

US$2 trillion-dollar business that has been enjoying an upward growth trend at about 3-4

percent annually, since 1994. Mature markets such as Europe, US and Japan remain the largest

markets with Europe boasting $628 billion annual sales followed closely by the US with annual

sales of $506 billion, Japan $225 billion and China $184 billion.

However, it is clear that the strongest growth in production capacity (which will impact

on oxygen demand) derives once again from emerging regions such as Asia Pacific and Latin

America where multinational companies are building production facilities in order to meet

increased demand. China in particular is a good example of above average annual growth rates

of up to 14 per cent due to economic growth and GDP, compared to Europe which is ticking

along at three per cent per year growth.

Despite the overall positive upward trend, the European Chemical Industry Council is

worried over the future of European global competitiveness. This concern is caused by high

growth demand in Asia, increasing imports into Europe from Asia and Middle East,

delocalisation of customer industries, high production cost and an increasingly regulated

environment.

According to the Council, China is taking an increasing share of global chemicals

production. A spokesman stated: $quot;The region's rate of industrial production exceeds that

of the rest of the world. In addition, given its focus on agriculture, manufacturing and durable

goods, there is a higher demand for chemicals than in developed economies. A third factor is

the dynamism in the emerging countries of industries such as electronics/electrical, textiles,

construction, leather, and plastics processing. These sectors are very important end-users of

chemicals.

According to the spokesman, the mature markets are concerned that manufacturers are

moving to other regions of the world, such as the Middle East, which offers producers both

large-scale and low-cost production due to easy access to raw materials and cheaper labour.

73

Producers also want to get closer to their customer base and the Middle East offers all the

advantages to fulfil these requirements.

As a consequence, Europe's exports have dried up and it has become a major importer

of chemicals over the past two decades. This has lead to major mergers among the European

players to maintain competitiveness and a global presence. The situation hasn't been helped

either by the high energy prices in Europe or sudden high gas prices in the States.

Just five years ago, the chemical industry in Europe thought they would stay in business

by becoming a specialised chemical producer rather than remain a commodity supplier. The

Council, however, think the chemicals industry has turned a full circle. Special chemicals can

be produced and supplied cheaply from India and China, and fine chemical manufacturers have

realised that price is not everything. They have started to value other things like quality and

environmental issues. Their challenge is now to create tighter relationships with their

customers, generating loyalty and uneasiness to change suppliers.

11.2.5 What Future Does This Have For Oxygen Demand For Chemicals:

Commodity chemicals needed for consumer materials will be produced where the cost

base is low - hence the huge project activity in the Middle East. Ethylene crackers in excess of

1 million tons are being built, together with the associated downstream derivatives, some of

which will need oxygen in their processes, for example EDC/VCM and ethylene glycol. Just

look at the increase in oxygen capacity that has occurred over the past decade in Saudi Arabia

alone - over 8,000 tpd of oxygen is consumed in the petrochemicals sector.

Oxygen demand is growing even faster than that as the abundance of low cost natural

gas and ethane is leading to other major petrochemical production investments - such as

methanol. Mega-methanol technology can follow one of two routes - one is oxygen intensive

and we have seen some major plants installed in Iran in the past 5-6 years with associated large

oxygen capacity.

74

It will be interesting to see the development of chemicals production elsewhere around

the world. For example Russia has huge natural gas reserves but much of the gas fields are

land-locked and far from the demand centres such as China, Europe and the US. Development

of these reserves to chemicals output will occur but at a slower rate than the Middle East - with

one possible exception in Sakhalin Island.

75

CHAPTER 12

SITE SELECTION AND PROJECT LAYOUT

12.1 Site Selection:

The geographical location of the final plant can have a strong influence on the success

of an industrial venture. Much care must be exercised in choosing the plant site and many

different factors must be considered. Primarily the plant should be located where the minimum

cost of production and distribution can be obtained. The Location of the plant can have a

crucial effect on the profitability of a project, and the scope for future expansion. Many factors

must be considered.

An appropriate idea as to the plant location has to be obtained before a design project

reaches the detailed estimate stage. A firm location established upon the completion of detailed

estimate design. The factors which are considered for choosing a plant size are:

1)-Raw Material:

One of the main factors is the availability and price of suitable raw materials which

often determines 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.

2)-Market:

It affects the cost of product and market distribution and time for shipping nearby

market for by-product as well as the final products.

76

3)-Energy Availability:

Power requirements and steam requirement are high in most industries and fuel or

electricity are required to supply the utilities.

4)-Climate:

Extreme hot and cold weather and excessive humidity can have a serious effect on the

economic operation of the plant.

5)-Transportation Facilities:

Water, Rail Roads and highways are the common means of transportation used by

means of transportation used by many industrial concerns. The kind of raw material and

production determine the most kind of transportation. A site should have access to at least two

modes of transport between the plant and main office and transportation facilities for employees

are also desirable.

6)-Water Supply:

The process industries use large quantities of water for cooling, washing, steam

generation and as well as raw material. The plant therefore requires a dependable supply of

water. The temperature, mineral content, silt or sand content, bacteriological content and cost

for the purification treatment must also be considered when choosing a water supply.

7)-Water Disposal:

The site selected for a plant should have adequate capacity and facilities for effective

waste removal.

77

8)-Labour Supply:

The type and supply of labour availability in the vicinity of a proposed plant site is to

be examined.

9)-Taxation and Legal Restrictions:

State and local tax rate on property, income, unemployment, insurance and similar

items various from location to another.Similarily local regulations on zone building codes and

effects. Transportation facilities also affect the final choice of plant site.

10)-Site Characteristics:

The site characteristics of topography and structure must be considered also land,

building cost, expansion area should also be considered.

11)-Flood and Fire Protection:

The risk to floods, hurricane, and earthquakes should be accessed. Fire department

should be nearby and loss fire hazards should be there.

12)-Community Factors:

The character and facilities of a community also affects the location of the plant.We

have selected the upper western coastal Region and Northern Plains because of the above

reasons.

78

12.2 Plant layout for Cryogenic Air Separation:

There are some consideration from the above points regarding the site establishment of

our plant so the most favorable site is the coastal site that is near the sea as from there the raw

materials are easily available, so regarding this the most suitable site for the establishment of

this plant is the Gujarat ‘s Ahmadabad as there the raw material that is Air is easily available.

Layout of the plant must arrangement for processing areas, and leading areas, in

efficient coordination and with regard to such factor as

1. New site development

2. Future expansion plans

3. Economic distribution of services water, process steam, power and gas/

4. Weather condition- if amendable to outdoor condition

5. Safety consideration- possible hazards of fire, explosion and fumes.

6. Waste disposal.

The layout should be such that the very aim of effective construction planning and

solving in engineering design construction, operating and maintenance cost is achieved.

12.2.1 Roadways:

For multipurpose service following factors must be taken into account

a. A means for intersection movement for road traffic both prod strain and vehicular.

b. Routing of heavy traffic outside the operation area.

c. Roadways for access to initial construction, maintenance and repair points.

d. Roadways to isolated point, storage tanks and safety equipment.

12.2.2 Utilities Services:

The distribution of water, steam, power and electricity is not always a major item, in as

much as the flexibility of distribution of these services permit design to meet almost any

79

condition. But a title regard for the proper placement each of these services, aids in case of

operation, order lines and reduction in cost of maintenance.

12.2.3 Storage:

Hazardous material become a decided menace to life and property when stored in large

quantities and should consequently isolated arranging storage of material so as to facilitate or

simply handling is also a point to be considered in design. Be bides, a great deal of plant layout

is governed by local and national safety fire code requirements. Expansion must always be kept

in mind. Selection of building and floor space are also points to be considered in designing

layout.

12.2.4 Equipment Layout:

In making layout, sample space should be assigned to each piece of equipment,

accessibility is an important factor for maintenance unless a process is well seasoned, it is not

always possible to predict just how its various units may have to be changed in order to be in

harmony with each other it is well known that in chemical manufacturing processes may be

adopted which may be appear to be sound after reasonable amount of investigation in the plant

stage yet frequently require minor or even major changes before all parts are property operating

together. It is extremely poor economy to fit the equipment layout too closely into a building. A

slightly larger building than appears necessary will cost little more than one is crowded. The

relative levels of the several pieces of equipment and there accessories determined there

placement. For example, overhead equipment must have space for lowering into place, and heat

exchanger equipment should be located near access area where truck or hoists can be placed for

pulling and replacing tune bundles. Thus space should be provided for repair and replacement

equipment, such gases and forked trucks, and snow removal, as well as acess way around doors

and underground notches.

80

12.2.5 Plant Expansion:

Expansion must always be kept in mind. The question of multiplying the number of

units or increasing the size of the prevailing units or units merits more study than it can be

given here. Suffice it to say that one must exercise engineering judgment; that has a penalty for

bad judgment scrapping of present serviceable equipment constitutes but one phase for shut

down due to remodeling may involve a greater loss of money than that due to rejected

equipment nevertheless, the cost of change must sometimes be borne for the economics of

larger units may in end make replacement imperative.

12.3 Organizational Structure:

Major submission of activities in an industrial enterprise may be characterized as

follows-

1) Managerial- planning, or gazing integrating, controlling and measuring.

2) Technical- research, development, engineering construction maintenance and

production.

3) Commercial- purchasing and marketing.

4) Financial- securing finds investigating and accounting.

Managing is a scientific kind of work which requires knowledge and understand of a set of

basic principle. Management visualized as compressing four principle sub function.

1) Planning- determines the objective of enterprise and basic policies and procedures.

2) Organizing- designing and manning the organization structure in keeping the objectives

and work to be done.

3) Integrating- achieving effective and efficient utilization of the resources of a business

through leadership, coordination, control and training of people at all levels.

4) Measuring- recording and interpreting critical performance data in order to better

accomplish function 1,2 and 3 above.

81

The organization function may be elaborated further as follows-

1) Classifying the total work into primary types such as research, engineering.

2) Dividing the work load so classified into amenable components and jobs.

3) Grouping like work into components comprising an orderly organization structure.

4) Define responsibility for performance of each component and job compensate and

assigned and delegated authority.

5) Fitting individual to jobs according to there capability.

The organization structure depends very much on objective size complexity and degree of

dispersion of enterprise. With change in circumstances change in organization structure may be

indicated.

Organization structure may be classes as-

(1) Centralized

(2) Decentralized

The centralized form is suitable for small, medium, sometime large, in which each

major function is manageable by one research director, all manufacture by one director of

manufacture, all sales by one director of sales, and so on responsibility of coordinating various

function being in the office of general manager.

Under decentralization, a company’s operations are subdivided according to product,

technology, geography, or fields of sale. The number of subdivisions may vary from up to score

or more. In any organization even the extreme degree of decentralization, a certain minimum of

central organization is needed. In addition the executive office there is for central staff officer,

groups and departments in various fields, such as treasury, law employee and public relations,

planning and soon.

An important point to be kept in mind in connection with small size requires capable

talents if success is to be achieved and sustained quite as much as in large enterprise. It is also a

82

principle that in all except the most extra ordinary circumstances the diverse talents necessary

for successful industrial management are not possessed by one person . Not only is the team

management usually better the one man ruling, but it’s provides for the succession in event of

death, in capacity or retirement

83

CHAPTER 13

COST ESTIMATION

13.1 Total Equipment Cost:

13.1.1 Cost Estimation Of Distillation Column :

Cost in year 2002=Rs 1240910

Cost index in year 2002=1116.90


Cost of Distillation unit in 2014=(cost in year 2002)*(cost index ratio in 2012to2002)

=1240910*1322.56/1116.9

=Rs 1469404

Cost of five distillation column in 2014=7347018

13.1.2 Cost Estimation Of Reboiler:




Cost of Reboiler in 2014=(cost in year 2002)*(cost index ratio in 2012to2002)

=1045910*1322.56/1116.9

=Rs 1238498

Cost of five reboilers in 2014=Rs 6192490

13.1.3 Cost Estimation Of Condenser :




Cost of Condenser in 2014=(cost in year 2001)*(cost index ratio in 2012to2001)

84

=354546*1322.56/1116.9

=Rs 419830

Cost of six condenser in 2014=Rs 2518978

13.1.4 Cost Estimation Of Pump :




Cost of Pump in 2014=(cost in year 2002)*(cost index ratio in 2012to2002)

=957273*1322.56/1116.9

=Rs 5667699

13.1.5 Cost Estimation Of Compressors :

Cost in year 2002= Rs 1090910

Cost index in year 2002= 1116.9

Cost index in year 2014= 1322.56

Cost of Compressor in 2014=(cost in year 2002)*(cost index ratio 2012 to 2002)

= 1090910*1322.56/1116.9

= Rs 1291784

13.1.5 Cost Estimation Of Storage Tank:




Cost of Storage tank in 2014=(cost in year 2002)*(cost index ratio in 2012to2002)

=42546*1322.56/1116.9

=Rs 50380

85

Cost of three storage tanks in 2014=151140

Therefore total purchase equipment cost=Rs 23169109+8883378

=Rs 32052487

13.2 Estimation Of Total Investment Cost:

13.2.1 Direct Cost (DC):

1. Purchased Equipment Cost (PEC)= Rs 32052487

2. Installation Cost Taking a 25% of PEC

Installation Cost = Rs 8013122

3. Insulation cost taking 8% of PEC

Insulation cost= Rs 2564199

4. Instrumentation Cost & Control Cost taking 10% of PEC

Instrumentation Cost& Control Cost = Rs 3205249

5. Piping Installed Cost taking a 20% of PEC

Piping Installed Cost = Rs 6410497

6. Electrical & Installed Cost Taking a 10% of PEC

Electrical & Installed Cost = Rs 3205249

7. Building Process, Auxiliary Cost taking a 10% of PEC

Building Process & Auxiliary Cost = Rs 3205249

8. Yard Improvement taking 20% of PEC

Service Facilities = Rs 6410497

9. Land Taking a 10% of PEC

Land Cost = Rs 3205249

Total direct cost = Rs 68271798

86

13.2.2 Indirect Cost:

1. Engineering & Supervision Cost taking 10% of DC

Engg.& Supervision Cost = Rs 6827180

2. Construction Expenses & Contractor’s Fee taking a 10% of DC

Expenses & Contractor’s Fee = Rs 6827180

Total Indirect Cost = Rs 13654360

13.3 Working Capital:

Working Capital (WC) taking 35%of TCI,

So, Working Capital , WC= 0.35TCI

But, Total capital investment, TCI= FCI+ WC

So, FCI = 0.65 TCI

FCI = DC+IDC

FCI =Rs 81926158

Now, We can calculate the value of TCI

TCI = Rs 126040243

WC= Rs 44114085

13.4 Estimation Of Total Product Cost:

Manufacturing Cost = Direct Product Cost + Fixed Charges + Plant Overhead

13.4.1 Fixed Charges:

1.Depreciation:- There are four types of depreciation is used in the industries. But we are using

straight line depreciation method for determining the depreciation on the Equipment,

Instrumentation & Piping.

87

Here we are taking salvage value 8% of the cost of Equipment, Instrumentation, & Piping.

NOW,

1.Depreciation on equipments

= (equipment cost – salvage value)/working years

= (32052487 – 0.08*32052487)/20

= Rs 1474415

2.Depreciation on Piping

= (Piping cost – salvage value)/year

= (6410497– 0.08*6410497)/20

= Rs 294883

3. Local Taxes

Local Taxes taking 1% of FCI

= Rs 819262

3) Insurance

Insurance taking 0.5% of FCI

= Rs 409631

Total fixed cost = Rs 2998191

Total Production cost (TPC):-

TPC=Manufacturing cost + General Expencess

TPC=(Direct production cost + Fixed charges + Plant overhead cost) + (0.1 TPC + 0.1 TCI)

TPC=(0.66TPC + 2998191 + 0.15 TPC) + (0.1 TPC + 0.1 TCI)

0.09 TPC=2998191 + 0.1*126040243

TPC = Rs 173357948

88

13.4.1.1 Direct Production Cost:

1).Raw Material Cost =30% of TPC

Total cost of raw material = Rs 37812073

2).Utilities Cost =10% of TPC

Total utilities cost =Rs 12604024

3).Operating Labour cost = 15% of TPC

TotalOperating Labour cost =Rs 18906037

4).Plant &Royalties = 5% of TPC

TotalPlant &Royalties cost =Rs 6302012

5). Direct Supervisory & Electrical labour cost= 15% operating labour

TotalDirect Supervisory & Electrical labour cost=Rs 2835906

6).Operating Supply Cost

Operating Supply Cost = 1%of FCI

= Rs 819262

7).Laboratory charges= 15% of operating labour cost

=Rs 2835906

8).Maintenance & Repair Cost

Maintenance & Repair Cost = 2.2% of FCI

= Rs 1802376

9).Plant overhead cost

Taking 15% of maintenance cost

= Rs 26003692

Total manufacturing cost = Rs112919479

89

13.5 Profit Analysis for the Project:

13.5.1 Earning:

Total Gross Earning = Total Income- Total Product Cost

For determining the total gross earning, we know

Annual methanol production = 18000 TPA

Selling Price = 14.5 Rs/kg

Annual Income =18000*1000*14.5

= Rs 261000000

Taking 90%annual sale

Total annual income =Rs 234900000

Gross Earning = Annual Total Income – Total Production Cost

= (234900000- 173357948)

= Rs61542052

Net Profit = Gross earning – Taxes

Taking tax 40% of gross earning

=61542052-0.40*61542052

Taxes = Rs 24616821

Profit:-

Net profit = Rs 36925231

Annual rate of return (ROR) = (Net profit /T.C.I.)*100

= (36925231/126040243)*100

= 29.29%=30%

13.5.2 Pay Back Period:

Pay back period = Total capital investment / Net profit

=126040243 / 36925231

= 3.414 year

≈ 4 year

90

13.5.3 Breakeven Calculation:

Breakeven cost per kg = F.C.I./Production capacity in kg

= 8192658/18000*1000

= 4.55 Rs/kg

General expenses = 10% of T.C.I. + 10% of TPC

=0.10*126040243 + 0.10*173357948

= Rs 29939819

Production per year (n)

=(Sum of plant overhead cost+Depreciation+General expenses)/(14.5-4.55)

=(26003692+ (1474415+294883)+29939819)/(14.5-4.55)

=57712809/(14.5-4.55)

(n) = 5800283kg

Breakeven point = (n/Total production)*100

= (5800283/18000*1000)*100

= 32.22% of capacity

91

13.5 Breakeven Chart:

Fig. 13.1 Break even chart





92

13.6 Cash flow chart:-

Net cash flow to the project

Income tax=Rs 2.462*107 Net profit after taxes= Rs 3.693*107

Net profit before taxes= Rs 3.693*107

Total sales=Rs 2.349*108Cost of operation =Rs 1.734*108

T.C.I= Rs 1.261*108

loans

Loan

Other capital input bonds common stock preferred stock

Operation for

Complete project

W.C.I=Rs 4.4114*107

Stockholdersdividend

F.C.I=Rs 8.193*107

Otherinvestment

Capital

Source

and

Sink

Repaymentof loans

93

CHAPTER 14

SUMMARY

This project describes the cryogenic air separation to its components (Nitrogen,

Oxygen and Argon). A special attention was devoted to the separation of argon. In theoretical

part we included information about air properties, separation process, air cooling, air

clearing, distillation of air, products of air and their application and other aspects of air

separation.

In practical parts we have described: Thermodynamic of air separation, in this section

the Peng‐Robinson state equation for calculation of equilibrium coefficient of nitrogen and

oxygen system was used. And also the isobaric t, xy and x,y diagrams of N2‐O2 and Ar‐O2

binary systems at different pressures were analyzed. After that we Calculated air distillation by

McCabe‐Thiele method, and Enthalpy balance of reboiler and total condenser was done.

Aspen simulation of air separation process forms the core of this work. The process

flowsheet including heat exchange and cryogenic separation was designed. Material and

enthalpy balance calculations in steady state were made for all basic process equipment. The

work contents the results of process simulation including results of material and enthalpy

balances, temperature and composition profiles in all columns. The optimal parameter of

distillation column such as reflux ratio, number of theoretical stages and feed stages were set.

Mechanical calculation of air distillation tower, safety aspects of air distillation process,

Principles of control of air distillation columns are another chapters of this work. And finaly the

economy of air distillation process is evaluated. Using Aspen Economic evaluation the

investment costs of air distillation process was estimated. The operational costs of the proces

were obtained based on the literature information and Afghanistan conditions.

94

CHAPTER 15

CONCLUSION

An air separation plant processing 4168.06 kmol/hr of air to the basic air

components Nitrogen (3247.02 kmol/hr), Oxygen (817.708 kmol/hr) and Argon (56.77 kmol/

hr) was designed. Purity of produced Nitrogen is 99.275% and Oxygen is 99.49 % and

purity of Argon 99 %. A system of 5 distillation towers was designed for separation of

air into Nitrogen, Oxygen and Argon.

From the thermodynamic analysis of binary isobaric diagrams of the systems

N2‐O2 and Ar‐O2 results that cryogenic separation of Nitrogen and Oxygen and also

separation of Nitrogen from Argon is not very difficult, but separation of Argon from

Oxygen can require large number of theoretical stages and large value of reflux ratio.

Argon is separated in the last two columns. A side stream reached with Argon is

drawn out from the top part of the column C2. In column C3 a mixture of Argon and

Nitrogen is distillated from Oxygen, which is removed from the bottom of this column.

The mixture of Nitrogen and Oxygen is separated in the column C4. The purity and

recovery of Argon beside conditions in columns C3 and C4 can be influenced also by

different factors in columns C1 and C2, such as distillate rate of column C1, side stream

stage, and reflux ratio in the column C2. The influence of these parameters was investigated.

From the economic evaluation of the process results that the cost of basic

equipments for air distillation process is around 30 millions USD, However the energy

consumption of the process is very high.

95

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97

air sepration

Engineering

separation of air

air nitrogen

history of air separation

distillation of air

air separation plantwas

air purification

air separationbusiness

tonnage air separation