GP2 Presentation LAst
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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
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Contents
Introduction Problem Definition Objective Equipments Design
Condenser Air Heater Compressor Pump
Cyclone Dryer
Cost Estimation Environmental Impact & HAZOP
Conclusion 2
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Introduction
Production of acetylene involves the reaction of solidcalcium carbide with water in semi-batch reactor
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Problem Definition
This process generates huge amount of calciumhydroxide slurry that presents major economical andenvironmental challenges to acetylene industry
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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
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Process Design
The process consists of six units:
Gas compressor
Air heater
Jet spouted bed dryer
Cyclone
Condenser Pump
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Process Design
7
3
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5
7
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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
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2
8
4
1 1 1
8
Ca(OH)2
Powder
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EquipmentsDesign
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Condenser
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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
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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
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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
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Air Heater
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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
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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
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Compressor
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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.
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Compressor Design
Requirements 1-Determine compressor type2- Compressor efficiency
3- Reversible adiabatic Power 4- Actual power
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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
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Pump
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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
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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
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Spouted Bed
Dryer
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Design Parameter
Dp
Hp
H1
H2
Dc
Di
θ
h
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Physical properties of ceramic and air in the dryer
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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
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Cyclone
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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
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Dimensions of Cyclone
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Cost
Estimation
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Cost Estimation
Capital cost is the cost of the plant ready for start-up
Operating cost is the cost to run the plant
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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
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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
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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
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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
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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
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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
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Capital Cost Total Module Cost and Grass Roots
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Total cost manufacturing
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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
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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
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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
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HAZOP HAZard
OPerability
Methodology
Guide word: (more, less,Non)
Parameters: (Temperature, pressure, flow)
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Example:
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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
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Thank you