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United Arab Emirates UniversityCollege of EngineeringChemical and Petroleum Engineering DepartmentGraduation Project II

Design of an Integrated Process for theProduction of Acetylene

with Minimum Waste Generation

Students Names: ID:Mohamed Faisal Al-Ali 200200988Abdulla Ahmed Al-Hosani 200235709 Yousef Al-Hosani 200101288

Project Advisor: Dr. Muftah El-Naas

Presented to

Coordinator:

Dr. Mamdouh Ghannam 1



Contents

Introduction Problem Definition Objective Equipments Design

Condenser Air Heater Compressor Pump

Cyclone Dryer

Cost Estimation Environmental Impact & HAZOP

Conclusion 2



Introduction

Production of acetylene involves the reaction of solidcalcium carbide with water in semi-batch reactor

3



Problem Definition

This process generates huge amount of calciumhydroxide slurry that presents major economical andenvironmental challenges to acetylene industry



Objective

The objective of this project is to design aprocess for management calcium hydroxide,

where it will convert the generated calciumhydroxide into a useful and valuable product

5



Process Design

The process consists of six units:

Gas compressor

Air heater

Jet spouted bed dryer

Cyclone

Condenser Pump

6



Process Design

7

3

4

5

7

6

Water

Dry Air

2

Dry Air

1

1

3

5

7

6

2

8

4

Dry Air

2

Dry Air

1

1

3

5

7

6

2

8

4

Dry Air

2

Dry Air

1

1

3

5

7

6

2

8

4

Dry Air

2

Dry Air

2

1

3

5

7

6

2

8

4

1 1 1

8

Ca(OH)2

Powder



EquipmentsDesign



Condenser



2. Physical

properties

1. Define the

duty

7. Calculate

the

individual

and overall

coef .

6. Calculate

area

required

5. Calculate

the mean

temperature

difference

4. Trial

value for the

overall

coefficient

3. Type of

exchanger

The steps in a typical designprocedure



Condenser

Q=394 kW

Th,in =120C, Th,out =60C

Tc,in =30C, Tc,out =45

C

calculate the mean temperature difference

hr kg m

hr kg m

c

h

/20050

/4627

.

.

C Ln

T m

11.49)30/75(

3075



Condenser Design

Q= 394 kW

A=9.2 m2

Type of H.E

Shell and tubes (Horizontal)

Condensation in the shell side

Length of tubes = 1 m

Number of tubes = 155 tubes

Bundle diameter = 0.4 m



Air Heater



Air Heater A fired heater is a direct-fired heat exchanger that uses the hot gases of

combustion to raise the temperature of a feed flowing through coils of tubesaligned throughout the heater.

Applications:

Hydrocarbon and chemical processing industries refineries

Gas plants

Petrochemicals Chemicals and Synthetics

Ammonia and fertilizer plants



Air Heater Inlet to furnace

Fuel : Methane (CH4)

AirCH4 + 2 O2 2H2O + CO2

Heating Value for CH4 = 55,508.73 kJ/kg

Rate duty = 791,464 kJ/hr

Amount of Methane needed = 14.3 kg/hr

Excess Air = 20%

Amount of Air fed= 295 kg/hr



Compressor



A gas compressor is a mechanical device that used to increases the

pressure of a Compressible fluid by reducing its volume.

The most common type of compressor is reciprocating, rotary van

compressors, rotary screw compressor and Centrifugal compressor.

17



Compressor Design

Requirements 1-Determine compressor type2- Compressor efficiency

3- Reversible adiabatic Power 4- Actual power



19



UnitValue

atm1Inlet pressure

atm5Outlet pressure

K 333Inlet temperature

K 528Outlet temperature

kg/h4221Feed mass flow rate

(ft3/min)2525Feed volumetric flow

rate

ReciprocatingType

________ 0.85Efficiency

kW229Reversible adiabatic

power

kW269Actual power



Pump



Feed flow rate 450 kg/hr

Discharge pressure 10 atm

Calculated Mixture density:

Volumetric flow rate=

=18058m

Type selected: Rotary pump

3kg/m1045.8mix

min0072.0

m 31 m

mix

g mix

P

Head

kW0.22(0.0068)(1.67)(19)

/min)V(mP(atm)1.67(kW) power pumpingFluid 3



Fluid pumping power

Using efficiency =0.8

Shaft power =0.3 kW

kW0.22(0.0068)(1.67)(19)

/min)V(mP(atm)1.67 3



Spouted Bed

Dryer



Design Parameter

Dp

Hp

H1

H2

Dc

Di

θ

h



Physical properties of ceramic and air in the dryer



Calculated Parameters

m1.33H1

m1.53H2

m0.63Dp

m30.07Vp

kg of inertparticles134.82Mass

478.02Rms

1059598Ar

m/s3.79Ums

m/s18.53U

m0.362h



Cyclone



The humid air leaving the dryeris sent to a cyclone to separatethe solid particles.

Cyclone are the most widely usedtype of dust collector at range 10

to 100µm of solid diameter



Dimensions of Cyclone



Cost

Estimation



Cost Estimation

Capital cost is the cost of the plant ready for start-up

Operating cost is the cost to run the plant



Capital Cost

Factor Affecting the Costs Associated withEvaluation of Capital Cost of Chemical Plants

Direct project expenses

Equipment free on board

Purchased cost of equipment at manufacture’s site

Material required for installation Piping, foundation & structure support, instrumentation &

electrical and painting the equipment

Labor to install the equipment and material



Capital Cost

Factor Affecting the Costs Associated withEvaluation of Capital Cost of Chemical Plants

Indirect project expenses

Freight, insurance and tax

Transportation cost for shipping equipment to the site

Construction overhead Vacation, sick leave retirement benefit and overhead

supervisor personnel

Contractor engineering expenses Salaries for the engineering and project management

personnel on the project



Capital Cost Factor Affecting the Costs Associated withEvaluation of Capital Cost of Chemical Plants

Contingency and fee

Contingency Loss of time due to storms and strikes, small change in the

design and unpredicted price increases

Fee Depending on the type of the plant



Capital Cost Factor Affecting the Costs Associated withEvaluation of Capital Cost of Chemical Plants

Auxiliary facilities

Site development Land, grading and excavation of the site,

Auxiliary building Administration offices, maintenance shop and control room,

ware-houses and services building

Off-sites and utilities



Capital Cost Bare Module Cost for Equipment

Represent the sum of direct and indirect costs

CBM=Cop [B1+B2 Fp FM]

Where;

CBM = bare module cost

Co

p= purchased cost for base condition (carbon steel, 1 atm)

Fp= pressure factor

FM= material factor



Capital Cost Total Module cost and Grass Roots

The term total module cost refers to the cost of making small-to-moderate expansions or alterationsto an existing facility Contingency and fee

The term grass-roots refers to a completely new

facility in which we start the construction onessentially undeveloped land, a grass field Auxiliary facilities



Capital Cost Total Module Cost and Grass Roots



Total cost manufacturing



Profit Amount of Ca(OH)2=299,592 kg/year

Ratio of operating: 0.95 day per year

Cost of product: $15/kg

Revenue = $ 4,868,370/year

Profit= Revenue – Cost of manufacturing=

$2,904,035/year



Environmental Impact & HAZOP

This project is environmental friendly

Reducing the waste that come from reaction betweencalcium carbide and water to produce acetylene.

By this project, recycle the calcium hydroxide slurry tofind powder of calcium hydroxide that can market

again



Health risks from calcium hydroxide Difficulty in breathing

Internal bleeding

Hypotension Skeletal muscle paralysis, interference with action-

myosin system

An increase in blood pH, which is damaging to

internal organs



HAZOP HAZard

OPerability

Methodology

Guide word: (more, less,Non)

Parameters: (Temperature, pressure, flow)



Example:



Conclusion Huge amounts of calcium hydroxide slurry are

produced in acetylene industry.

In this project, different options of drying slurry wereinvestigated in terms of advantages, disadvantages,amounts applied and efficiency in drying.

One of these options (Jet Spouted Bed Dryer) was

selected. Material and energy balance were carried out

Design and Cost Estimation



Thank you

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