A

Project Report On
Wire Enamel (Phase I)

Submitted in partial fulfilment towards the Bachelor’s Degree in the

field of Chemical Engineering
Prepared By
LUHARIYA ANJALI J.
( I.D.No. )

Under the Guidance of

Assist. Prof. Mudita Garg

Department of Chemical Engineering

Faculty of Technology, Dharmsinh Desai University
College Road, Nadiad – 387 001
April -2020
Industry Certificate..
 CERTIFICATE

This is to certify that Luhariya Anjali J. (I.D. NO. ) has duly submitted his
Project Report on Wire Enamel

Wire Enamel & Varnish PLANT as a partial fulfilment towards bachelor’s

degree in Chemical Engineering at Dharmsinh Desai University, Nadiad in the

year 2023.

ASSIST. PROFESSOR Professor & Head,

Dept. of Chemical Engg., Dept. of Chemical
Engg. DDU, Nadiad. DDU, Nadiad
DATE: DATE:
 PREFACE

Technical studies can’t be prefaced without practical training. Hence plant training has
great value for an engineering student. Technical knowledge gives theoretical aspect of
technology, but practical training gives knowledge of industrial activities. My aim in plant
training is to carry our detailed study of industrial instrument and process control besides
education aspects. I also tried to observe important aspect of industrial management, discipline,
and safety precautions. I saw how engineers coordinated with running of plant.
In present work, I discussed what I studied in Wire Enamel & VArnish Plant of
Elantas Beck India ltd. The report contains some general information about detailed process
description, salient features of the plant, diagrams, material balance, equipment details, safety
rules along with utilities and ETP.
I must say that this type of training will fill the gap between theoretical and practical
knowledge. Once again, I want to say thanks to all those who helped me in this endeavour

directly or indirectly.

Luhariya Anjali J.
 DECLARATION

I Vansadia Yuvrajsinh Dhavalsinh declare that, the project report on

comprises my original work towards the degree of Bachelor of Technology in

Chemical Engineering at Dharmsinh Desai University and is not copied from any

published or proprietary source. I further declare that this work is not submitted

elsewhere towards degree or diploma in any university or college. The whole content

of this project work is genuine and distinctive.

Luhariya Anjali J.
Dhavalsinh

(ID ),

Semester VIII,

Department of Chemical

Engineering, Faculty of Technology,

Dharmasinh Desai Unviversity,Nadiad.

I
 PHASE – I
Wire Enamel Production
i
 ACKNOWLEDGEMENT
I feel obliged that a prestigious organization like Elantas Beck gave me a chance to get a valuable
technical exposure of the industry through the vocational training program. The eight weeks of
training period has given me a lot of knowledge regarding the practical application of the
theoretical knowledge that is taught in the engineering institutes. And this practical exposure is
must in the academics of every engineering student.
During the training period I have been guided by a number of Elantas personnel and without their
active and enthusiastic support this training would not have been possible. First of all, I would like
to thank Mr. Deepak Mungalpara (Plant Head) and Mr. Kiran (Production Officer) for
accepting me for availing the benefit of the training program.
It is prestigious for me to take training at Elantas Beck, Ankleshwar. The eight weeks of training
has given me an experience and exposure to the practical application of the theoretical know-how.
I’d like to thank Mr. D.B.PATEL (Senior Manager at WNA-II), Mr. JEEL JAVIA(Shift
Engineer at WNA-II) for their valuable time and support during my training and helped me
learning the process and field operations of the plant.
Last I would like to thank my college Dharmsinh Desai University, chemical Engineering
Department.
Yours sincerely,

Anjali.

I
 CONTENTS

PREFACE ....................................................................................................................................... V

NOMENCLATURE ..................................................................................................................... VI

ABBREVIATION ....................................................................................................................... VII

LIST OF FIGURES .................................................................................................................... VIII

LIST OF TABLES ........................................................................................................................ IX

ACKNOWLEDGEMENT .............................................................................................................. X

1. INTRODUCTION .................................................................................................................... 1

1.1 History ....................................................................................................................... 2

1.2 Details of weak nitric acid and capacity .................................................................... 3
1.3 Market value .............................................................................................................. 3
1.4 Competitors ............................................................................................................... 3
1.5 Technology provider ................................................................................................. 3
1.6 Applications .............................................................................................................. 4
1.7 Conclusion ................................................................................................................ 4
2. SELECTION OF PROCESS ................................................................................................... 5

2.1 Introduction ............................................................................................................... 6

2.2 Discussion on various methods for production of Weak Nitric Acid ....................... 6
2.3 Selection of technology ............................................................................................. 9
2.4 Raw material specification ....................................................................................... 10
2.5 Physiochemical Properties ....................................................................................... 10
2.6 Process Block Diagram ............................................................................................ 12
2.7 Process Description .................................................................................................. 12
2.8 Process Flow Diagram ............................................................................................. 16
2.9 Conclusion ............................................................................................................... 17
3. MATERIAL BALANCE ........................................................................................................ 18

3.1 Introduction ................................................................................................................. 19

3.2 Material balance around each Equipment ....................................................................19

3.3 Overall Material balance diagram ............................................................................... 25

3.4 Conclusion ................................................................................................................... 28

4. ENERGY BALANCE ............................................................................................................ 29

4.1 Introduction ................................................................................................................. 30

4.2 Energy balance around each equipment ...................................................................... 30
4.3 Conclusion ................................................................................................................... 37
5. PLANT UTILITIES ............................................................................................................... 38

5.1 Introduction ................................................................................................................. 39

5.2 Electricity .................................................................................................................... 39
5.3 Cooling Water ............................................................................................................. 41
5.4 Chilled water ............................................................................................................... 44
5.5 DM water .................................................................................................................... 46
5.6 Conclusion .................................................................................................................. 49
6. DETAILED DESCRIPTION OF THE EQUIPMENT ....................................................... 50

6.1 Introduction ................................................................................................................ 51

6.2 List of all major and minor equipment ....................................................................... 51
6.3 Conclusion .................................................................................................................. 54
7. DESIGNING OF EQUIPMENT ........................................................................................... 55

7.1 Introduction ................................................................................................................. 56

7.2 Design of Minor Equipment ........................................................................................ 56
7.2.1 Storage Tank ............................................................................................................. 56
7.2.2 NOx Compressor ...................................................................................................... 63
7.2.3 Centrifugal Pump ...................................................................................................... 64
7.3 Designing of Major equipment .................................................................................... 67
7.3.1 Process Design .......................................................................................................... 67
1. Actual Number of Trays ............................................................................................. 71
 2. Rate of reaction in Absorption column ...................................................................... 72
7.3.2 Mechanical Design ................................................................................................... 74
1. Height of the column ................................................................................................. 74
2. Torispherical head ..................................................................................................... 78
3. Elliptical Head ........................................................................................................... 78

4. Nozzle Design ........................................................................................................... 78

5. Flange Design ............................................................................................................ 80

6. Hub design ................................................................................................................. 81
7. Bolt Design ................................................................................................................ 81
8. Skirt support .............................................................................................................. 82
7.4 Conclusion .................................................................................................................. 84
8. PUMPS, PIPING AND CONTROL VALVES..................................................................... 86

8.1 Introduction ................................................................................................................ 87

8.2 Pumps ......................................................................................................................... 87
8.3 Piping .......................................................................................................................... 88
8.4 Control valves ............................................................................................................. 89
8.5 Control loops in the plant ............................................................................................ 90
8.6 Piping And Instrumentation Diagram ......................................................................... 92
8.7 Conclusion .................................................................................................................. 93
9. SAFETY, HEALTH AND ENVIRONMENT ...................................................................... 93

9.1 Introduction ................................................................................................................. 94

9.2 Safety measures taken in industry ............................................................................... 94
9.3 Safety equipments used in plant .................................................................................. 96
9.4 All the auxiliary equipment related to safety ............................................................... 99
9.5 Various pollution control measures taken by the industry .......................................... 100
9.5.1 Effluent Treatment Plant ........................................................................................... 100
9.6 Conclusion ................................................................................................................... 104
10. PLANT LOCATION AND LAYOUT ................................................................................ 106

10.1 Introduction .....................................................................................................................

107
 10.2 Plant Location ............................................................................................................ 107
10.3 plant Layout ............................................................................................................... 110
10.4 Conclusion ................................................................................................................. 114
11. COST ESTIMATION .......................................................................................................... 115

11.1 Introduction ............................................................................................................... 116

11.2 Cost of each equipment used in plant ........................................................................ 116
11.3 Direct Cost ................................................................................................................. 118
11.4 Indirect Cost ............................................................................................................... 119
11.5 Fixed Capital Investment ........................................................................................... 119
11.6 Total Capital Investment ............................................................................................ 120
11.7 Total Production Cost ................................................................................................. 120
11.8 Direct Production Cost ................................................................................................ 120
11.9 Profit Calculation ........................................................................................................ 122
11.10 Rate of Return ............................................................................................................. 123
11.11Payout Period ............................................................................................................... 123
11.12Turnover Ratio ............................................................................................................. 123
11.13 Break Even Point ........................................................................................................ 123
11.13 Conclusion .................................................................................................................. 124
12. CONCLUSIONS ................................................................................................................... 125

APPENDIX 1 MSDS .................................................................................................................. 128

APPENDIX 2 EXCEL SHEET ................................................................................................. 134

13. REFERENCES ..................................................................................................................... 139

 PREFACE

Practical knowledge means visualization of the knowledge, for which we read any books for
this, we perform experiments and get observations. Practical knowledge is very important in
every field.

Also only relying on the theoretical aspects of a subject is not a method for gaining knowledge
of industrial level. True test began at industrial field so to tackle this it is important to gain
practical knowledge.

During this period, a student works in industry and Gets All type of experience and
knowledge about working and maintenance of various machinery.

V
NOMENCLATURE

Symbol Description S.I.UNITS

A Area m2

D Diameter M

„ρ Density kg/m3

„μ Viscosity Pa.sec

Q Heat Flow Rate Watt

N Revolution per second –

N Revolution per minute -

Hr Heat Of Reaction

Joule

H Height M

 Latent Heat Of Vaporization kJ/kg

L Length M

F Permissible Stress Pa

P Pressure Pa

NRe Reynolds Number -

NPr Pradtl Number -

Cp Specific heat kJ/kg*K

T Temperature K

T Thickness M

M Mass Flow Rate kg/sec

V Volumetric Flow Rate m3/sec

W Weight N
VI
ABBREVIATION

EPC Engineering, procurement and construction

TPA Tones Per Annum

PPM Parts Per Million

ASTM American society for Testing and Materials

OHSAS Occupational Health & Safety Assessment Series

TWA Time Weighted Average

TLV Threshold Limit Value

BPO Business Process Outsourcing

ISO International Organization for Standardization

Psig Pounds per square inch, gauge

PBD Process Block Diagram

PFD Process Flow Diagram

P&ID Piping & Instrumentation Diagram

VII
LIST OF FIGURES

Figure 1.1 Structure of HNO3 ........................................................................................................

2
Figure 2.1 Production of HNO3 by chile saltpeter process ...........................................................
6
Figure 2.2 Production of Nitric acid by direct synthesis process ...................................................
8
Figure 2.3 Process block diagram ................................................................................................
12
Figure 2.4 Reactor for catalytic ammonia oxidation with steinmuller.........................................
15
Figure 2.5 Process Flow Diagrams ..............................................................................................
16
Figure 3.1 Overall material balance diagram ...............................................................................
28
Figure 4.1 Energy balance around reactor ...................................................................................
33
Figure 5.1 Steam generation plant ...............................................................................................
40
Figure 5.2 Cooling tower circuit ..................................................................................................
41
Figure 5.3 A fictitious PV diagram for a typical refrigeration cycle ...........................................
45
Figure 5.4 DM water plant ...........................................................................................................
49
Figure 7.1 Schematic view of absorption tower ..........................................................................
68
Figure 7.2 Equilibrium and operating line of absorption .............................................................
71
Figure 8.1 Cascade controller ......................................................................................................
90
Figure 8.2 Ratio controllers .........................................................................................................
91
Figure 8.3 P&ID of WNA Plant (Source: Plant Manual) ........................................................... 92
Figure 9.1 Personal Protective Equipment’s ............................................................................... 97
VIII
Figure 9.2 Process flow diagram of ETP ...................................................................................
103
Figure 10.1 Plant Layout of Weak Nitric Acid-1 plant ..............................................................
112

IX
LIST OF TABLES
Table 2.1 Availability and transportation of Raw materials ........................................................
10
Table 2.2 Chemical properties of NH3 and HNO3 .......................................................................
11
Table 3.1 Material balance of absorption tower ...........................................................................
21
Table 3.2 Material balance of heat recovery section ....................................................................
22
Table 3.3 Material balance around reactor ...................................................................................
25
Table 3.5 Material balance around NH3-Air mixture ...................................................................
26
Table 3.6 Material balance around Evaporator-1 .........................................................................
27
Table 3.7 Material balance around Evaporator-2 .........................................................................
27
Table 4.1 Summary table of Energy balance ................................................................................
36
Table 6.1 List of all major and minor equipment with their Capacity and MOC ........................
51
Table 6.2 Maximum and Minimum operating temperature and pressure of each equipments ....
52
Table 7.1 Storage Vessel Thickness .............................................................................................
59
Table 7.2 Summary table of Storage Vessel ................................................................................
63
Table 7.3 Summary table of NOx compressor ..............................................................................
64
Table 7.4 Data require in designing pump ...................................................................................
65
Table 7.5 Summary table of centrifugal pump .............................................................................
66
Table 7.6 Equilibrium data ...........................................................................................................
69

X
Table 7.7 Summary table for Absorption tower design ...............................................................
84
Table 8.1 Various types of pumps used in the plant – their characteristics, suppliers .................
87
Table 8.2 List of Control valves ...................................................................................................
89
Table 9.1 Location of Fire Fighting Equipments .........................................................................
98
Table 9.2 Location of safety valves..............................................................................................
99
Table 10.1 Summary Table of Plant Layout of WNA-1 ............................................................
113
Table 11.1 Cost of the equipments used in plant .......................................................................
117
Table 11.2 Direct Cost ...............................................................................................................
118
Table 11.3 Indirect Cost .............................................................................................................
119
Table 11.4 Raw materials cost for one hour ...............................................................................
120
Table 11.5 Direct Production Cost .............................................................................................
120
Table 11.6 Fixed Charges ...........................................................................................................
121
Table 11.7 General Expenses .....................................................................................................
121
ACKNOWLEDGEMENT
This training report is prepared not only by a solo effort. A great deal of effort and time has
been involved in preparing this report. Many people are involved in it directly or indirectly.
During the course of my project work, I have been guided by many without whom this project
may not have seen the light of the day. It is my sincere desire to express my gratitude for their
guidance and support.

I would like to take this opportunity to thank, Mr. H.K.Parekh (Senior training officer) and
Mr. S.T.SHARMA (Cheif. Manager) for their guidance.

XI
I am also thankful to

Mr. H.N.SARVAIYA (Chief Manager of WNA plant)

Mr. Vaibhav Gupta (Sr. Shift Engineer. of WNA plant)

Mr. Jeel Javiya (Shift Engineer of WNA plant)

Last but not the least I would like to thank my project guide Mudita Garg , Assist.
Professor and head of department of Chemical Engineering of Dharmsinh Desai
University, Dr. M.S.RAO for sending me to such a reputed company which has really helped
me in boarding the horizon of my knowledge.

XII
 CHAPTER 1

INTRODUCTION

1.1 History:
Nitric acid (HNO3), also known as AQUA FORTIS and spirit of niter, is highly corrosive mineral
acid.

The pure compound is colorless, but older samples tend to acquire a yellow cast due to
decomposition into oxidation of nitrogen and water. Most commercially available nitric acid has
a concentration of 68% in water. When the solution contains more than 86% HNO 3, it is referred
to as fuming nitric acid. Depending on the amount of nitrogen dioxide present, fuming nitric acid

Page 1
is further characterized as white fuming nitric acid or red fuming nitric acid, at concentrations
above 95%.

Nitric acid is the primary reagent used for nitration – the addition of a nitro group, typically to
an organic molecule. While some resulting nitro compounds are shock- and thermally-
sensitive explosives, a few are stable enough to be used in munitions and demolition, while
others are still more stable and used as pigments in inks and dyes. Nitric acid is also commonly
used as a strong oxidizing agent.

Names:

A. IUPAC name: Nitric acid

B. Other name: Aqua fortis, Acidium nitricum

Structure:

Figure 1.1 Structure of HNO3

1.2 Details of weak nitric acid and capacity:

Nitric acid (HNO3) is a transparent or yellowish liquid. Nitric acid is a strong mineral acid with
oxidizing properties, miscible with water. Density and oxidizing properties will vary with
concentration. The acid is produced from ammonia by oxidation over a platinum catalyst and
absorption of the resulting nitrogen oxide in water. Concentrations up to 68% can be produced
by conventional distillations. Capacity of the plant: 630 MTPD

World production: 50 Million tons per day

1.3 Market value:

Page 2
 Market value is the price at which the chemical or product would trade in a competitive Market.
Market value is often used interchangeably with open market value, although these terms have
distinct definitions in different standards and may differ in some circumstances. Price of Weak
Nitric Acid: 7 Rs/kg

1.4 Competitors:
1. Deepak Nitrate Ltd, Nandesari
2. Adarsh chemicals, Chennai
3. Suvidhi Industries:-Vapi
4. Pk chlorochem Participate:-Baroda
5. Radha Enterprise:- Pune
6. Organica Enterprises, Dahisar, Mumbai
7. Diamond organics, Sanwali, UP
8. Shivachem Enterprise, Delhi
9. Neel chemicals, Mumbai
10. Vijay Chemicals, Mumbai

1.5 Technology provider:

Technology Provider: M/s. UHDE, Germany

Detailed Engineering: M/s. UDHE, Bombay

DCS: Yokogawa, Japan.

1.6 Applications:
The largest use of nitric acid is in the fertilizer industry which is about 75%. The second largest
use is for manufacturing of chemicals. Some examples are cyclohexanone, Dinitrotoluene,
Nitrobenzene etc.It is also used in explosives, metal nitrates, Nitrocellulose, Nitrochlorobenzene, a
metal treatment solvent, rocket propellants and nuclear fuel processing, metal pickling, Mfg. of
pharmaceuticals, plant protective agents, Fine chemicals production, Polyurethanes production,

Nylone production, Nitrogen oxide as a rocket fuel etc.

Application as Raw material:

1. Concentrated nitric acid
2. Ammonium nitro phosphate

Page 3
3 .Calcium ammonium nitrate
4. Aniline
5. Toluene di-isocynate

1.7 Conclusion:
This chapter gives us glimpse of weak nitric acid product as well as production capacity and
competitors. Weak nitric acid is very useful product particularly in fertilizer industry as well as it
has wide application as a raw material in many industries. Plant is designed for 630 MTPD
production of weak nitric acid. But, production is not always exactly same as designed capacity.
It changes according to availability of Raw material, Season, efficiency of any equipment etc.
So, it is decided to make complete report on the same.

Page 4
 CHAPTER 2
SELECTION OF PROCESS
2.1 Introduction:

In this chapter, various methods for production of WNA are explained. This chapter also consist
raw material consumption pattern, description of process, process block diagram, process flow
diagram of WNA-1 plant.

2.2 Discussion on various methods for production of Weak Nitric Acid:

Weak Nitric Acid is produced by following 3 methods:

2.2.1 Acidulation of natural sodium nitrate with sulfuric acid Process:

Chile Saltpeter or Nitrate process is old process used in around 1920’s which may
now been replaced with new technologies but even though the chemical process and

Page 5
technology involved in this process will help us to understand the nitric acid creation.
Chile saltpeter is substance which contains NaNO 3 with %age around 35-60% and
remaining %age of KNO3 and NaCl. A raw Chile saltpeter is concentrated by
crystallization in pre-treatment of ore to attained 95% NaNO3 and remaining KNO3 as
feed raw material. Sulfuric acid with 93% concentration is mixed with the refined
Chile saltpeter material as per the ratio required by stoichiometry and sent into a
o
retort which is made of cast iron and the mixture is heated to 200 C with help of
furnace flue gases and coal fire. In this process, following reaction takes place to produce
nitric acid as vapors.

NaNO3 + H2SO4 → NaHSO4 + HNO3

Figure 2.1 Production of HNO3 by chile saltpeter process (Source: www.inclusive-science-

engineering.com )
All hot vapors of nitric acid are sent to cool down in water circulated cooled silica pipes. Then
Condensed HNO3 is collected in receiver tank which has material resistant to nitric acid.
Uncondensed gas which escapes from the collector is scrubbed with cooled water in packed bed
tower to collect nitric acid in dilute form. Liquid sodium bisulphate is collected from the bottom
outlet of the retort.

Drawbacks: Production of nitric acid by this process is very less compare to other methods. Cost

of process is also very high with respect to production of nitric acid. 2.2.2 Direct synthesis from

nitrogen and oxygen:

The Birkland-Eyde was one of the competing industrial processes in the beginning of production
of nitrogen based fertilizer. This method was developed by Norwegian industrialist and scientist
Kristian Birkland with his business partner Sam Eyde in 1903.

Page 6
This process was used to fix atmospheric nitrogen (N2) into nitric acid (HNO3), one of several

chemical processes generally referred to as nitrogen fixation. Reactions take place in this process

are as follow:

N2 + O2 → 2NO

2NO + O2 → 2NO2

4NO2 + 2H2O + O2 → 4HNO3

Air freed from CO2 and moisture is passed through electric arc chamber. It consists of two
copper electrodes which are continuously circulated by cold water and are connected with AC
dynamo. A powerful electromagnet placed at right angles to the electrodes spreads the arc in the
form of a disc.

The chamber is also provided with inside suction pumps for rapid circulation of air across the
flame through holes of refractiontory fire work. Nitrogen and oxygen of air combine at 2000 °C
temperature to form nitric oxide. The hot exit gases (1000 °C) leaving the chamber is passed
through tube fire boiler for steam generation.
The temperature of gases leaving the boiler is significantly reduced down to 1500 °C. The gases
are allowed to pass through oxidation chambers made of iron and lined inside with acid proof
stone. Here, nitric oxide is further oxidized to nitrogen peroxide in presence of air. The exit
gases from oxidation towers are passed through a series of absorption tower filled with broken
quartz through which cold water or dilute nitric acid is continuously sprayed from top.

st
The gas which enter from the base of 1 tower leave at the top. Continuous counter current flow

rd
of gases in each tower is maintained by a centrifugal fan. The 3 tower is fed with cold water

and the dilute nitric acid is collected at the base is re-circulated to the top of the preceding

tower.

Page 7
 Figure 2.2 Production of Nitric acid by direct synthesis process (Source: Wikipedia)

Drawbacks: The direct combustion of air in an electric arc developed by Birkeland and Eyde
was abandoned because of its poor energy efficiency and high consumption of electrical energy.
There were enormous amounts of gases in circulation compared to low concentration of NO
which was formed (about 2%) on account of the fact that high temperature also promotes the
reverse dissociation reaction.
2.2.3 Oxidation of Ammonia:

1. Production of WNA by mono pressure process:

The process operates at 6 bar pressure in the burner section & at the same pressure of 6 bar in
absorption section too. Ammonia and air are mixed in the reaction at 6 bar pressure and
890°C and formation of NOx gas will take place in reactor. This gas is send to absorption
column where absorption of NOx in water will take place. And we can get 61.5% nitric acid
by this process. Here the pressure is same throughout the process so it is called mono
pressure process. 2. Production of WNA by dual pressure process:

Page 8
The process operates at 3.9 bar pressure in the burner section & at a pressure of 10.8 bar in
absorption section. Ammonia and air are mixed in the reaction at 4.4 bar pressure and 890°C
and formation of NOx gas will take place in reactor. This gas is again compressed to 10 bar
pressure and send to absorption column where absorption of NOx in water will take place.
And we can get 61.5% nitric acid by this process. Here the reaction is at low pressure and
absorption is at high process so it is called dual pressure process

2.3 Selection of technology:

Here, Weak Nitric Acid-1 plant is run on dual pressure process. Dual pressure process has
very large production than mono pressure process. In mono pressure process whole process
takes place at only one pressure value. (Here, Reactor and Absorption column both are
operated on mono pressure- 3.9 bar). We know that, High pressure is favorable condition for
absorption. So, in dual pressure process, absorption takes place at 11 bar instead of 3.9 bar.
So, process parameters are favorable in dual pressure process. If we want to get large
production than dual pressure process is favorable. In mono pressure process, we don’t need
NOx compressor, secondary air compressor as well as there is only one column instead of
absorption column and bleaching column separately. So, capital as well as working
investment is smaller in mono pressure process than dual pressure process. WNA-1 plant is
run on dual pressure process and WNA-2 plant is run on mono pressure process.

Page 9
 2.4 Raw material specification:
2.4.1 Availability and transportation of Raw materials:

Table 2.1 Availability and transportation of Raw materials

Raw materials Availability and transportation

Ammonia Ammonia is produce in GNFC plant itself

and it is transported through pipeline to
WNA plant.

Air Air is available in atmosphere. It is sucked

from atmosphere and transported through
compressor to reach 3.9 bar and passes
through various filters to remove impurities
from atmospheric air.

2.4.2 Raw material consumption pattern (Per hour):

 Ammonia = 7795.39 kg 
Air = 90525.75 kg

2.4.3 Cost of Raw material (Per Kg):

 Ammonia = 6 Rs

2.5 Physiochemical Properties:

2.5.1 Physical Properties:

1. Ammonia:

• Ammonia is a colorless gas.

• It has a pungent odor and an alkaline or soapy taste. When inhaled suddenly, it brings tears
into the eyes.
• It is lighter than air and is therefore collected by the downward displacement of air.  It is
highly soluble in water.

Page
10
 • It can be easily liquefied at room temperature by applying a pressure of about 8-10
atmosphere.

2. Nitric acid:

• Nitric acid is a liquid with an acrid, pungent and suffocating odor.

• There are different concentrations of nitric acid available and they are

colorless, yellow or red accordingly.

2.5.2 Chemical Properties:

Table 2.2 Chemical properties of NH3 and HNO3 (Source: GNFC WNA manual)

Chemical Formula NH3 HNO3

Nitrogen Percentage 85 22.22

Molecular weight 17.031 gm/gmol 63.01 gm/gmol

Density 0.769 kg/m3 1512.9 kg/m3

Melting Point -77.73 °C -42°C

Solubility in water 47% w/w Completely miscible

Boiling Point -33 °C 83 °C

Solubility Soluble in chloroform,

Ether, alcohol

Viscosity 0.276 Cp 2.5 (at 20°C)

Vapor Pressure 857.3 KPa 48 mmHg (at 20°C)

Threshold limit value 225 PPM 138 PPM

Page
11
Auto ignition 651 °C

Temperature

Upper Explosive limit 25%

Lower Explosive limit 16%

2.6 Process Block Diagram:

Figure 2.3 Process block diagram

2.7 Process Description:

Liquid ammonia from ammonia storage tank is fed to the NH3 evaporation system with 5°C and
18 bar pressure. The evaporation system consists of three evaporators. Ammonia enters
evaporator-1, which is operated by chilled water from absorption tower. This evaporator
vaporizes about 78% of ammonia required in the process. System pressure is 6.67 bars and
temperature of ammonia vapors is 19°C. The left out ammonia is then fed to evaporator-2,
operated by warm return cooling water, and the ammonia vapor outlet is admixed with the
outlet of evaporator-1. Both the evaporators are equipped with drop separators at their tops
to prevent ammonia droplets being carried away with vapor and are fed back to evaporation
system. To avoid the accumulation of water in both evaporators, a part of NH 3water
mixture is fed to third evaporator, the NH 3 stripper, which is operated by LP steam, where
Page
12
almost all ammonia is vaporized and the bottoms are sent to ETP for treatment. The
ammonia vapor produced from NH3-evaporation system passes through ammonia gas filter
and is preheated in preheater-1 operated by LP steam which increases the temperature to
40°C. To increase the temperature further it is fed to preheater-2 operated by LP steam. It
can increase the ammonia vapor temperature to about 90°C.

The oxygen for oxidation of NH3 is made available from atmospheric air is sucked in the air
compressor driven by steam turbine. An air filter is installed at the suction of air compressor
to remove any solid impurities entering the compressor to 3.9 bar and temperature of 237°C
and is supplied as primary air for process and for beaching of raw acid is made available
from standard intercooler secondary air compressor driven by back pressure steam turbine.
The ammonia vapor and compressed air is mixed in NH3-air mixer to maintain the ratio of
ammonia to ammonia air mixture about 10.1%. This mixed gas is then fed to NH3-burner at a
temperature of 183°C. The NH3-burner is equipped by Pt/Rh catalyst gauzes maintained at
890°C. As the mixed gases passes through these gauzes, the ammonia in mixed gas is
oxidized at a temperature of 890°C. The NO-gases produced by the reaction them passes
through the heat recovery train. The heat recovery train consists of a series of heat
exchangers such as waste heat boiler, tail gas heater-IV, the economizer, tail gas heater-III
and cooler condenser. The first equipment is the waste heat boiler located in the same
assembly as the burner. It consists of a steam super heater and an evaporation coil. Water
from steam drum is circulated through these coils where it is vaporized using the heat from
the reaction gases. The steam passes through super heater and is used to drive the turbine of
air compressor, and thus cooling down the reaction gases to about 470°C. The NO gases then
enter tail gas heater-IV from tube side and are cooled to 316°C and the tail gas from shell
side is heated from 208°C to 430°C. The reaction gases are then fed to economizer, which is
operated by boiler feed water, where the gases are cooled to 224°C and BFW is heated from
125°C to 244°C . The NO-gases then passes through tail gas heater-III where it is cooled to
170°C and tail gas is heated from 110°C to 200°C.The next step is to compress the NO-gases
because the absorption operation of NO-gases is favored by high pressure and low
temperature. Beside the heat recovery the oxidation of nitrous gases also occur in the path.
Reaction gases are cooled to 50°C in cooler condenser-I operated by cooling water.

Page
13
 For further cooling NO-gases are fed to cooler condenser-II operated by chilled water and
the temperature is lowered to 48°C. The acid condensate formed in the cooler condenser-II is
mixed with that of cooler condenser-I and is fed to the absorption tower on the tray having the
same composition (approx. 37% w/w). The cold NO-gases has to be free from water droplets to
avoid any damage to blades of compressor, so it is passed through the drop separator located
near the suction of NOx compressor operated by tail gas turbine which in turn is driven by heated
tail gas discharged from tail gas discharged from tail gas heater-IV. The NO-gases are
discharged at 10.8 bar and temperature of 160°C. In order to bring down temperature of NO-
gases it is passed through the tail gas heater-II where it is cooled to 110°C. It is fed to the
absorption tower via cooler condenser-III. Absorption of NO-gases in the water takes place in
the absorption tower in a counter-current manner. The absorption tower contains 41 sieve trays
and the NO-gases are fed from the bottom and process water enters from the top. Cooling water
and chilled water is used to remove the heat of reaction and heat of absorption. The unbleached
acid is collected at absorption tower bottom and is transferred to the bleaching tower where
unbleached NO-gases are oxidized using secondary air. The secondary air passes through tail gas
heater-I before entering the bleaching tower. This step helps in maintaining the temperature of
bleaching tower at 60°C and also to heat up the tail gases discharged from the absorption tower.
The discharged of the bleaching tower is the product which is sent to HNO3 storage. Reactions
involved in production of HNO3:

1. Oxidation of ammonia:

1. 4 NH3 + 5 O2 4 NO + 6 H2O ……eq 2.1

2. 4 NH3 + 3 O2 2 N2 + 6 H2O ……eq 2.2

Reaction -1 proceeds at Pt/Rh gauze while the volume increases, is promoted by decreasing
pressure, increasing pressure on the other hand supports the undesired secondary reaction-2.
Moreover the gauze temperature at 890⁰C, a favorable gas velocity and the use of specified
gauze alloy of 95 % platinum and 5% rhodium are decisive for good conversion according to
equation 1 and also for reducing catalyst losses. Catalyst losses are further affected by start up
and shutdown with respect to high ammonia conversion efficiency and low catalyst Consumption
continuous operation is favorable. There is catchment system of Pd-Ni to recover Pt catalyst.
2. Oxidation of Nitrogen oxide:
Page
14
 1. 2 NO + O2 2 NO2 ……eq 2.3

In above reaction, NO2 is formed by means of oxidation of NO with supplied air.

Figure 2.4Reactor for catalytic ammonia oxidation with steinmuller (Source: WNA manual)

3. Absorption of Nitrous Oxide:

1. 3 NO2 + H20 2 HNO3 + NO ……eq 2.4

The overall reaction equation indicates the 2 mole of NO 2 is converted to nitric acid (HNO₃)
while simultaneously 1 mole is reduced to NO.
2.8 Process Flow Diagram:

Page
15
 Figure 2.5 Process Flow Diagrams (Source: WNA-1 plant manual)
2.9 Conclusion:
As discussed in this chapter, there are various methods available to produce nitric acid. But as
explained in this chapter, every method has its own merits and demerits. We use oxidation of

Page
16
ammonia method to produce weak nitric acid. It is most efficient method among all available
methods. Mono pressure method is viable economically as well as production wise. Reaction
parameters like pressure and temperature should be maintain at design value for maximum
production as well as safety aspect. Apart from process description and reaction, PBD and PFD
are also very useful to understand any process. PBD consist only major equipments whereas PFD
consist minor equipments like HE, compressor, turbine etc. Now, we are in the position to carry
out complete material and energy balance for identification of size of equipments and utilities
requirement.

Page
17
 CHAPTER 3
MATERIAL BALANCE

Page 18
3.1 Introduction:
A mass balance, also called a material balance, is an application of conservation of mass to the
analysis of physical systems. By accounting for material entering and leaving a system, mass
flows can be identified which might have been unknown, or difficult to measure without this
technique. The exact conservation law used in the analysis of the system depends on the
context of the problem, but all revolve around mass conservation, i.e. that matter cannot
disappear or be created spontaneously.

Therefore, mass balances are used widely in engineering and environmental analyses. For
example, mass balance theory is used to design chemical reactors, to analyses alternative
processes to produce chemicals, as well as to model pollution dispersion and other processes of
physical system.

3.1.1 Capacity of the plant:

Actual plant capacity = 630 MTPD
Assume plant capacity = 630 * 1.7
= 1071MTPD
= 44625 kg /hr
Basis: 1071 MTPD Production of 61.5 % Nitric Acid
Raw material: NH3 (In liquid form)

3.1.2 Chemical Reactions: Conversion:

I 4NH3 + 5O2  4NO + 6H2O 95%
II 4NH3 + 3O2  2N2 + 6H2O 5%
Conversion of above two reactions is 100% combined.
IV 3NO2 + H2O  NO + 2HNO3 100%
III 2NO + O2  2NO2 100%

3.2 Material balance around each Equipment:

3.2.1 Material balance around Absorption column:
According to IV reaction for 1071 MTPD 61.5 %Of Weak nitric acid is produced
So now to produced 44625 Kg of weak nitric acid of 61.5 %
Amount of HNO3 to be produced is = 41625 *0.615 = 27444.375 kg/hr

Page 19
Molecular weight of HNO3 is 63 kg/kmol
So Kmol of HNO3 Produced is = (27444.375/63) = 435.625 kmol/hr
Amount of water in 61.5% WNA is = 44625 – 27444.375 = 17180.625 kg/hr
 Now according to stochiometry of reaction IV
• 2 kmol of HNO3 produced = 3 kmol of NO2 is required So,
435.625 kmol HNO3 produced = 435.625 * (3/2)
= 653.4375kmol/hr
Amount of NO2 required = 653.4375 * 46
= 30058.125 kg/hr
• 2 kmol of HNO3 produced = 1 kmol of water required 435.625
kmol of HNO3 produced = 435.625 * (1/2)
= 217.8125 kmol/hr
Amount of H2O required = 217.8125 * 18 + water in WNA
= 3920.625 + 15967.875
= 19888.5 kmol/hr
• 2 kmol of HNO3 produced = 1 kmol of NO produced
435.625 kmol of HNO3 produced = 435.625 * (1/2)
= 217.8125 kmol/hr NO is produced
Amount of NO produced =217.8125 * 30
= 6534.375 kg/hr
Input = NO2 + H2O required + H2O required to dilute Nitric acid
= 30058.125 + 3920.625 + 17180.625
Input = 51159.375 kg/hr
Output = NO + HNO3 + H2O required to dilute Nitric Acid
= 6534.375 + 27444.375 + 17180.625
Output = 51159.375 Kg/hr
Input = Output

NOTE: N2 also enters with NO2 gas which is shown in material balance of reactor.
So, we have to mention N2 in the inlet stream of absorption tower.
Table 3.1 Material balance of absorption tower

Page 20
 Components Identification Input(kg/hr) Output(kg/hr)

NO2 Reactant 30058.125 0

HNO3 Product 0 27444.375

H2O Solvent 21101.125 17180.625

NO Product 0 6534.375

N2 Inert 93903.743 93903.743

Total Mass balance 145062.993 145062.993

3.2.2 Material balance of Heat recovery section:

According to reaction III
Conversion of reaction III is 100% Now
according to stoichiometry
• 2 kmol of NO2 produced = 2 kmol of NO required 653.4375
kmol of NO2 produced = 653.4375 *(2/2)
= 653.4375 kmol
Amount of NO required is = 653.4375 * 30
= 19603.125 kg/hr
NOTE: Here we produced 6534.375 kg/hr NO in absorption tower. Hence, we need 19603.125
– 6534.375 = 13068.75 kg/hr or 435.625 Kmol/hr NO to make up Required quantity.
• 2 kmol of NO2 produced = 1 kmol of O2 required 653.4375 kmol
of NO2 produced = 653.4375 * (1/2)
= 326.71875 kmol/hr
NOTE: Here 97.442 kmol/hr O2 comes from rector output.

O2 fed = 326.71875 – 97.442 = 229.276 Kmol/hr

Amount of O2 required = 229.276 * 32 = 7336.832 Kg/hr
Since air is considered so N2 is also considered
Amount of N2 is = 229.276 * (0.79/0.21) *28

Page 21
 = 24150.4053 kg/hr
NOTE: N2 also enters with NO2 gas which is shown in material balance of reactor.
So, we have to mention that N2 in the inlet stream of heat recovery system. H2O
which is generated in reactor also enters in heat recovery system and removes as
steam in the outlet stream of heat recovery system.

Input = NO + O2 + N2 + H2O
= 19603.125 + 10455 + 93903.743 + 12380.904
Input = 136342.772 kg/hr
Output = NO2 + N2 + H2O
= 30058.125 + 93903.743 + 12380.904
Output = 136342.772 kg/hr
Input = Output
Table 3.2 Material balance of heat recovery section

Components Identification Inlet(kg/hr) Outlet(kg/hr)

NO Reactant 19603.125 0

O2 Reactant 10455 0

NO2 Product 0 30058.125

N2 Inert 93903.743 93903.743

H2O Steam 12380.904 12380.904

TOTAL Mass balance 136342.772 136342.772

3.2.3 Material balance of Reactor:

Conversion
I 4NH3 + 5O2  4NO + 6H2O 95%
II 4NH3 + 3O2  2N2 + 6H2O 5%

Page 22
Here conversion of reaction 1st is 95 %
 Now according to stoichiometry,
• 4 kmol of NO produced = 4 kmol of NH 3 is required 435.625 kmol of
NO produced = 435.625 * (4/4)
= 435.625 kmol/hr
Amount of NH3 required = 435.625 * 17
= 7405.625 kg/hr
Actual amount of charged NH3 = (7405.625/0.95)
= 7795.39 kg/hr
Actual amount of charged NH3 = 458.55 kg/hr
Amount of NH3 used in 1st reaction = 7405.625 kg/hr
Amount of NH3 used in 2nd reaction = 7795.39 – 7405.625
= 389.769 kg/hr
• 4 kmol of NO produced = 5 kmol of O2 required
435.625 kmol of NO produced = 435.625 *(5/4)
= 544.531 kmol/hr Amount
of O2 required = 544.531 * 16
= 17425 kg/hr O2 required In
reactor Air is fed in 15% excess
Theoretically O2 required,

 4 Kmol NH3 required = 5 Kmol of O2 required

458.55 NH3 charged = 573.19 Kmol of O2 theoretically required
0.15 = (O2 fed – O2 theoretically required) / (O2 theoretically required)
= (O2 fed – 573.190 / (573.190)
O2 fed = 659.158 Kmol/hr = 21093.394 Kg/hr

 4 kmol of NO produced = 6 kmol of H 2O produced 435.625

kmol of NO produced = 435.625 * (6/4)
= 653.4375 kmol/hr
Amount of H2O produced in 1st reaction = 11761.875 kg/hr

Page 23
  Ammonia reacted in 2nd reaction = 22.927 kmol/hr According to
stoichiometry,
 4 kmol of NH3 required = 3 kmol of O2
21.3 kmol of NH3 required = 22.927 * (3/4)
= 17.195 kmol/hr O2 required Amount
of O2 required = 550.262 kg/hr
Amount of O2 unreacted = 659.168 – (544.531 + 17.195)
Amount of O2 unreacted = 3118.144 kg/hr
For requirement of O2 we supplied air
Amount of N2 in air = 659.168 * (0.79/0.21) * 28
= 69432.36 kg/hr
 From Second reaction N2 is produced,
4 kmol of NH3 reacted = 2 kmol of N2 produced
22.927 kmol of NH3 reacted = 22.927 * (2/4)
= 11.4635 kmol / hr Amount
of N2 produced = 11.4635 * 14
= 320.978 kg/hr

 Amount of H2O produced in 2nd reaction

4 Kmol of NH3 reacted = 6 kmol of H2O produced
22.927 kmol of NH3 reacted = 22.927 * (6/4)
= 34.3905 kmol/hr Amount
of H2O produced = 34.3905 * 18
= 619.029 kg/hr water produced
Input = NH3 + O2 + N2
= 7795.39 + 21093.394 + 69432.36
Input = 98321.144 Kg/hr
Output = (O2 unreacted + N2 fed + N2 produced + NO + H2O)
= 3118.144 + 69432.36 + 320.978 + 13068.75 + 11761.875 + 619.029
Output = 98321.144 Kg/hr
Input = Output
Table 3.3 Material balance around reactor

Page 24
 Components Identification Input(kg/hr) Output(kg/hr)

NH3 Reactant 7795.39 0

O2 Reactant 21093.394 0

NO Product 0 13068.75

N2 Inert 69432.36 69432.36

H2O Product 0 12380.904

Total Mass balance 98321.144 98321.136

3.2.4 Material balance around Mixture Filter:

Mixture filter removes impurities from the mixture of NH 3-Air. Impurities mainly consist of oil
droplets which is associated with air. Oil droplets around 1000 PPM removes from the NH 3-Air
mixture filter.

Table 3.4 Material balance around Mixture filter

Components Identification Input(Kg/hr) Output(Kg/hr)

NH3 Reactant 7795.39 7795.39
O2 Reactant 21093.394 21093.394
N2 Inert 69432.36 69432.36
Oil droplets Impurities 1000 PPM 1000 PPM
Total Mass balance 98321.144 98321.144
3.2.5 Material balance around NH3-Air mixture:
Input = Ammonia + O2 + N2
Input = 7795.39 + 21093.394 + 69432.36
Input = 98321.144 kg/hr
Output = Ammonia + O2 + N2
Output = 7795.39 + 21093.394 + 69432.36
Output = 98321.144 kg/hr

Page 25
Input = Output
Table 3.5 Material balance around NH3-Air mixture
Components Identification Input(Kg/hr) Output(Kg/hr)
NH3 Reactant 7795.39 7795.39
O2 Reactant 21093.394 21093.394
N2 Inert 69432.36 69432.36
Total Mass balance 98321.144 98321.144

3.2.6 Material balance around Evaporator-1:

NH3 liquid enters in liquid form in Evaporator-1. Our process is a gas phase reaction. So we need
ammonia in gas phase. So, Ammonia is passes through 2 evaporators as described in section 2.7
[chapter 2]. In evaporator-1, we use 278587.7 kg/hr chilled water to vaporize liquid ammonia.
[Refer: 4.2.1]
Input = NH3 + Chilled water
= 7795.39 + 278587.7 Input
= 286383.09 Kg/hr
Input = NH3 + Chilled water
= 7795.39 + 278587.7
Input = 286383.09 Kg/hr
Input = Output
Table 3.6 Material balance around Evaporator-1

Components Identification Input(Kg/hr) Output(Kg/hr)

NH3 Reactant 7795.39 7795.39
Chilled water Vaporizing medium 278587.7 278587.7
Total Mass balance 286383.09 286383.09

3.2.7 Material balance around Evaporator-2:

From evaporator-1, 78% ammonia vaporizes and remaining 22% going to Evaporator-2. Here,
110075 kg/hr cold water is used to vaporize ammonia. [Refer: 4.2.2] Input
= NH3 + cold water
= 1714.977 + 110075 Input
= 111789.97 Kg/hr
Page 26
Input = NH3 + cold water
= 1714.977 + 110075
Input = 111789.97 Kg/hr
Input = Output
Table 3.7 Material balance around Evaporator-2

Components Identification Input(Kg/hr) Output(Kg/hr)

NH3 Reactant 1714.977 1714.977
Cold water Vaporizing medium 110075 110075
Total Mass balance 111789.97 111789.97
3.4 Overall Material balance diagram:

Figure 3.1 Overall material balance diagram

3.4 Conclusion:
Material balance is basic thing that one has to do in the plant. By fixing our daily production, we
can calculate how much quantity of raw material is required. Here, we have fix 630 MTPD
production of WNA in plant. According to stochiometry and conversion of specific reaction, we
have calculated amount of ammonia and air as a raw material. By put it in an overall material
balance diagram, we can understand flow of material with its amount. When recycle or recovery
Page 27
of any component is taking place in process, in that case overall material balance diagram is very
important to understand it easily and correctly. After completing material balance, we are in
position to find amount of heat required to be supplied or removed from the system. This
analysis will help us to determine the capacity of utilities to be installed in the plant.

CHAPTER 4
ENERGY BALANCE
4.1 Introduction:

Present chapter comprises energy balance around evaporator-1, evaporator-2, pre heater, reactor,
waste heat re boiler, economizer and tail gas heater.

4.2 Energy balance around each equipment:

Page 28
4.2.1 Energy balance around evaporator-1:

Evaporator-1 is used to vaporize liquid NH3. Here, 458.55 Kmol/hr NH3 is entered and chilled
water is used to vaporize liquid NH3.

• Chilled water inlet temp. = 24

• Chilled water outlet temp. = 16
• Ammonia inlet temp. = 5
Pressure in the upstream of control valve = 18 bar
Pressure in downstream of control valve = 6.16 bar
So, boiling point of ammonia at 6.16 bar is 10
 Total heat transferred = latent heat + sensible heat

Here, latent heat of vaporization of ammonia at 10 = 300 cal/gm

= 21343.5 KJ/ kmol

Specific heat of ammonia = 4.65 KJ/kg k

= 4.65 * 17

= 79.05 KJ/kmol k

Specific heat of water = 4.1570 KJ/kg k

= 4.157* 18

=74.826 KJ/kmol k

Flow rate of ammonia = 458.55 kmol/hr

Total heat transferred = m (λ + Cpammonia* ∆𝑡)

= 458.55 *(21343.5+79.05* 5)

= 9.96*106 KJ/hr

Total heat transferred = m *Cpwater *∆𝑡

9.96* 106 = m*4.1570*8

Page 29
 m = 278.5877 ton/hr chilled water is required

4.2.2 Energy balance around Evaporator-2:

Evaporator-1 vaporizes 78% NH3 and remaining 22% NH3 vaporizes in Evaporator-2. Here, cold

water is used to vaporize entered 100.881 Kmol/hr liquid NH3.  Here, cooled water is used as

heating medium.

• Cooled water inlet temp = 42℃

• Cooled water outlet temp = 37℃

• Specific heat of water = 4.18 KJ/kg k

Latent heat of vaporization of ammonia = 23012 KJ/kmol

Here, 78% of ammonia is vaporized in evaporator-1, Remaining

22% is vaporized in evaporator-2.

Flow rate of ammonia to Evaporator-2 = 0.22 * 458.55

= 100.881 kmol/hr

Total heat transferred = m*𝜆

= 2.32*106 KJ/hr

Amount of cooled water required,

m*Cpwater* = 2.32*106 m

= 2.32*106/(4.18*5)

m = 110.075 ton/hr cooled water required in evaporator-2.

4.2.3 Energy balance around pre heater: Pre heater increases temperature of

7795.35 kg/hr entered NH3 from 19° c to 90°c.

Page 30
  Here, temp. of ammonia is increase from 19 to 90

• Specific heat of ammonia at mean temp. =2.4309 KJ/kg k

• Feed temp of steam = 160

• Latent heat of steam = 2074.03 KJ/kg

Flow rate of ammonia = 458.55 kmol/hr

= 458.55*17

= 7795.35 kg/hr

Total heat transferred = m*Cpammonia*

Q = 7795.35*2.4309* 71

Q = 1.345*106 KJ/hr

Now, amount of steam required

Q = m*λ m =

1.345*106/2074.03

m = 648.49 kg/hr

Hence, 648.49 Kg/hr of steam is required to heat ammonia.

4.2.4 Energy balance around reactor:

NH3-Air mixture stream (7795.39 kg/hr NH3, 90525.754 kg/hr Air) entered at 3.9 bar, 183°C.
Optimum reaction temperature is 890°C.
7795.39 kg/hr of NH 3
3118.144 kg/hr of O 2

69753.338 kg/hr of N 2
21093.394 kg/hr of O 2
Reactor 13068.75 kg/hr of NO

69432.36 kg/hr of N 2 112380. 904 kg/hr of water

Page 31
 Figure 4.1 Energy balance around reactor

 Inlet stream to reactor is at 3.9 bar and 183℃

• Heat capacity of gases at 183 ℃

CpNH3=2.24 KJ/kg k

CpO2=0.961 KJ/kg k

CpN2=1.05 KJ/kg k

• Mass fraction of inlet gases

XNH3=8.107%

X O2=21.412%

XN2=70.481% Specific heat capacity of inlet mixtures = CpNH3 *

XNH3 + CpO2 * X O2 + CpN2 *XN2

= 2.24*0.079+ 0.961*0.2145 + 1.05*0.71

= 1.128 KJ/kg k

I/P heat to reactor = m*Cp *∆𝑡

= 98321.144*1.128*(456-303)

= 16968656.32 KJ/hr
 O/P heat from reactor = I/P heat to reactor + heat of reaction

Heat of reaction of exothermic reactions

For 1st reaction = -226 KJ/mol NH3

= -98451250 KJ/hr
Page 32
 For 2nd reaction = -317 KJ/mol NH3

= -7267859 KJ/hr

Total heat of reaction = (-98451250) + (-7267859)

= 105719109 KJ/hr

O/P heat from reactor = I/P heat to reactor + heat of reaction

= 122687765.3 KJ/hr

 Total heat from the output of the reactor is going to recover to the heat recovery

Section. 4.2.5 Energy balance around Waste heat boiler:

Waste heat re boiler decreases temperature of process gas from 890 °C to 475 °C by using water.
Process gas consist 3118.144 kg/hr O2, 69753.338 kg/hr N2, 13068.75 kg/hr NO and 12380.904
kg/hr water.

 Water inlet temp is 160 , and pressure 67.76 bar

At, this pressure boiling point of water = 287

Process gases at outlet of waste heat boiler is at 475

Heat at outlet of waste heat boiler = m*Cp *

= 13068.75*1.05*(798-303)

= 6106373.438 KJ/hr
Heat supply to water = heat entered – heat exited

= 122687765.3 – 6106373.438

= 116581391.9 KJ/hr

 This heat is supplied to water to generate super heated steam which is used in steam
turbine.
• Heat capacity of steam at 270 = 4.3022 KJ/kg k
Page 33
 • Latent heat of water at 287 = 1610 KJ/kg

m*Cpwater* + m* λ +m *Cpsteam = heat supply to water m*(4.316*(287-160) +

1610 + 4.3022 * (450-287)) = 116581391.9 KJ/hr m = 40771.41 kg/hr steam

generated or water needed in waste heat re boiler.

4.2.6 Energy balance around Tail-gas heater:

Tail gas heater reduces temperature of process stream (3118.144 kg/hr O 2, 69753.338 kg/hr N2,
13068.75 kg/hr NO) temperature from 475 °C to 300 °C.

 Here, cooling is done by tail gas.

• Inlet temp of tail gases = 20

• Outlet temp of tail gases = 400
• Inlet temp of process stream = 475
• Outlet temp of process stream = 300
Heat inlet to tail gas heater = 6106373.438 KJ/hr

Heat outlet at tail gas heater = m* Cp *

= 30058.125*2.1*(748 – 573)

= 11046360.94 KJ/hr

Heat remained in tail gas heater = (Heat inlet in the tail gas heater + heat of reaction –
Heat outlet from the tail gas heater)

= (6106373.438 + 11046360.94 – 11046360.94)

= 32305950 KJ/hr

This heat is removed by tail

gases, m*Cp *∆𝑡 = 32305950 m*

1.1155* (400-20) = 32305950

Page 34
m = 76213 tone/hr tail gas is needed.

4.2.7 Energy balance around Economizer:

 All the heat coming out from tail-gas heater is removed in economizer.

In economizer, cooling water is used.

Heat remove in the economizer = 11046360.94 KJ/hr

• Inlet water temp. = 30℃

• Outlet water temp. = 48℃

m*Cp * ∆𝑡 = heat removed in the

economizer m*4.31*(48-30) = 11046360.94

m = 142.386 tone/hr water is needed.

Table 4.1 Summary table of Energy balance

Equipment Utility Quantity (kg/hr)

Evaporator-1 Chilled water 278587.7
Evaporator-2 Cold water 110075
Pre heater Steam 648.49
Waste heat re boiler Water 40771.41
Economizer Cold water 142386
4.3 Conclusion:

Heat integration is most important in any industry. Because, utilities are very costly. So, it is very
important to do not waste heat. Here, In WNA plant, only at startup time, we need energy from
boiler plant. After steady state, WNA plant does not need any energy from boiler plant. Because
heat removed by reactor is utilize and energy required in plant is fulfilling by it. We have seen in
energy balance around waste heat re boiler, heat removed by re boiler is taken by cold water and
water converted to superheated steam which is going to use in steam turbine. This can also help
in final estimation cost to find working capital cost and fixed capital cost.

Page 35
 CHAPTER 5
PLANT UTILITIES

5.1 Introduction:

There are several types of utilities used in the plant, but main of them are described below:

1. Electricity
2. Cooling water
3. Chilled water
4. DM water

5.2 Electricity:

Page 36
There is a steam generation plant from where generated steam used in the plant. Company has
three boilers. Boilers were supplied and commissioned by M/S Foster Wheeler Power Products.
UK Ltd. and TGs were made of M/S. BHEL Ltd.

Each boiler is designed to generate steam at the rate of 275 T/hr. at a pressure of 105 Kg/cm 2 abs
and at a temperature of 510ºC at the outlet of the Boiler. All the three boilers are connected to a
single common-header to supply high-pressure steam of different consuming points. Normally,
two boilers are kept in service, which are sufficient enough to meet the steam requirement of the
complex and the third boiler is kept as stand by which will be either under wet preservation of
under maintenance, inspection etc. The normal steam generation of each boiler is about 220 T/hr.

Boilers are of monowall, radiant, single drum, front fired, water wall type and were initially
designed to fire natural Gas and Coal in 8 burners arranged in a 4 tiers. From the very beginning
itself coal firing was not used as decided by Government of India. A Natural Gas was
sufficiently available. Later on due to restriction of NG to 3.0 MSM3 by M/S. GAIL, the fuel
firing system of boilers has been modified so as to fire NG as well as Natural Gas Liquid (NGL)
with the help of M/S. Thermax Babcock and Wilcox Ltd. The earlier NG consumption of the
complex was up to the tune of 3.4 to 3.6 MSM3. Steam is the vaporized form of water. This
vapor is commonly visible as a cloud escaping from the spout of teakettle in which water in the
teakettle produces 1600 times more volume in steam form.
These properties of steam, its ability to carry a large amount of heat and the large quantity of
steam which can be made from a small amount of water, make steam an ideal substance for
transferring heat conveniently and economically to every corner of the plant. Another property of
steam is the way its volume varies with change in temperature and pressure of the same. We take
advantage of these properties by generating steam at high pressure to operate steam turbines,
drive generator, compressor and pumps. The low-pressure exhaust steam from the turbines is
then used for process requirements.
Steam itself will not burn nor will it support combustion and this property of steam is utilized to
purge or remove oil or gas or to extinguish a small fire.
The intent of the ensuing discussions is to present the fundamentals and precautions encountered
in steam generation. The fundamentals presented touch the basics of heat transfer and their
respective contribution to steam generation, furnace Details, material selection, fuels etc. the

Page 37
precautions mentioned pertain to feed water treatment in areas of oxygen removal, alkalinity and
scale formation.

Figure 5.1 Steam generation plant (Courtesy: MS Paint)

5.3 Cooling Water:

Cooling Tower is a familiar sight in all industries. A tower through which water is circulated to
remove the heat generated from various heats generating operations and the hot water comes
back to the CoolingTower. This water is cooled in the CoolingTower collected in the Sump and
recirculated, the cycle continues. This is basic definition of CoolingTower.
There are three types of Cooling Towers:
1. Natural Draft : Natural re-circulation of air-cools the hot water
2. Forced Draft : Using a fan, air is forced in the cooling tower
3. Induced Draft : Air is sucked through the water shower using a fan

Page 38
 Figure 5.2 Cooling tower circuit (Courtesy: MS Paint)

5.3.1 Functioning of Cooling Tower

Water is lost through the Cooling Tower by evaporation during the process of heat exchange.
Fresh water is added to the cooling tower to make up the losses. Evaporated water leaving along
with air is pure water. While incoming water contains Dissolved Solids and Suspended matters,
etc.Therefore there is always a concentration of Dissolved Solids in the recirculating Cooling
Water due to evaporation. This Solids build up in recirculating water should not exceed certain
limits else deposition in Heat Exchanger may take place. In order to remove such Dissolved
Solids, part of water removed periodically or continuously is known as Blow down (Bleed Off).
Make up water (M) = Water lost by evaporation (E) + Blow down (B) + Drift loss (D).

5.3.2 General Terms Used in Cooling Water Systems:

1. Acidity
Presence of acid in water, pH of water less than 7.

2. Alkalinity
Presence of alkali in water, pH of water is more than 7.

3. Hold up capacity of the system

Page 39
It is an amount of water contained in basin and sump of cooling tower + water contained in
piping and equipment.

4. Blow down
Since pure water is evaporated out of the system, the dissolved and the suspended solids are
concentrated in the circulating water. Beyond certain limit, these solids will cause massive scale
and corrosion. In order to balance this, a certain amount of water is removed from the system by
blow down.

5. Make up Water
This is the water, which is to be added to replace the water lost by evaporation, blow down, drift
and leakages.

6. Drift
Some water droplets escape alongwith the evaporation. A usual drift loss in conventional cooling
towers is in the range of about 0.05 – 1 % of the recirculation rate.

7. System Losses
Circulating water is lost in the plant through pumps, valves or leakages through flanges, etc
8. Evaporation Losses
The water lost to the atmosphere in the cooling process is evaporation. The rate of evaporation
depends upon the temperature differential and the circulation rate. It amounts to about 0.1% of
the circulation rate for each 10 of temperature drop.

9. Cycle of Concentration
Due to evaporation of water in Cooling tower the impurities get concentrated in recirculating
water. Number of times the impurities get concentrated in recirculating water is known as Cycle
of Concentration (C.O.C.).

Cycle of concentration

5.3.3 Typical Problems in Cooling Tower

Page 40
1. Scaling
The salt like calcium carbonate, calcium sulfate and calcium phosphate in the cooling water has
reverse solubility, i.e. at high temperature their solubility decreases. This causes precipitation and
scaling in heat exchange. Cooling water is heated in the heat exchangers where temporary
hardness salts decompose and form scales.
Cooling water is concentrated in the system due to evaporation in tower. Due to concentration,
sparingly soluble salts like calcium sulphate tend to precipitate out and form scales. Thus scale of
calcium carbonate, calcium sulphate and calcium phosphate are often found in the heat
exchanger.

2. Corrosion
Cooling water is corrosive to mild steel, copper, etc. due to higher TDS. More are the dissolved
salts in water more are the corrosiveness. Also various galvanic cells are formed in the heat
exchangers due to differential metal, combination, concentration, temperature, velocities and
stress strain on metal. Corrosion is generally observed all over the cooling system. But it is more
near welding, joints and under the deposition.

3. Microbiology
Cooling water is ideal medium for microbiological growth. It provides optimum temperature;
oxygen, nutrient and sufficient surface area for growth. Algae, bacteria and fungus are
commonly found in cooling system. If not controlled in time, microbiological growth can be
Plugged heat exchanger and causes corrosion and reduce cooling tower efficiency.

4. Bacteria
Bacteria are mainly of two types aerobic and anaerobic. Aerobatic secrets certain enzymes,
which form sticky masses, called as slime. Slime can form on heat transfer equipment as well as
on complete pipelines. Slime attracts other suspended particles in water to form deposits, which
is generally called biofouling.

 Disadvantages due to above problems in Cooling Water Systems

1) Problems of scale, deposition, fouling leads to maintenance cost for frequent cleaning of
heat exchanger etc.

Page 41
 2) Corrosion can damage heat transfer equipment and thereby leads to replacement cost.
3) Frequent unscheduled forced shutdown for cleaning heat exchangers, lines etc. causes’
production loss.
4) Scale, deposition, corrosion and fouling in cooling water system forced to run the system
at lower cycle of concentration. Hence water consumption is huge.
5) Energy consumption is more e.g. pumping cost

5.4 Chilled water:

Chilled water is used in Evaporator-1 and upper part of absorption column. Plant has its own
chilled water plant which is designed by Thermax private limited. This plant is basically works
on principle of vapor compression cycle. Here, Ammonia is used as a refrigerant. We get chilled
water of -5 °C which is used in Concentrated Nitric Acid (CNA) plant. After using in CNA plant,
temperature of chilled water will be increased and used in absorption column of WNA plant.
Outlet of chilled water from absorption column will be 24 °C. It is also used in Evaporator-2 as a
hot medium.
Vapor compression cycle:

The vapor-compression uses a circulating liquid refrigerant as the medium which absorbs and
removes heat from the space to be cooled and subsequently rejects that heat elsewhere. Figure 1
depicts a typical, single-stage vapor-compression system. All such systems have four
components: a compressor, a condenser, a thermal expansion valve (also called a throttle valve or
metering device), and an evaporator. Circulating refrigerant enters the compressor in the
thermodynamic state known as a saturated vapor and is compressed to a higher pressure,
resulting in a higher temperature as well. The hot, compressed vapor is then in the
thermodynamic state known as a superheated vapor and it is at a temperature and pressure at
tubes. This is where the circulating refrigerant rejects heat from the system and the rejected heat
is carried away by either the water or the air (whichever may be the case).

Page 42
 Figure 5.3 A fictitious PV diagram for a typical refrigeration cycle (Source: Wikipedia )

The condensed liquid refrigerant, in the thermodynamic state known as a saturated liquid, is next
routed through an expansion valve where it undergoes an abrupt reduction in pressure. That
pressure reduction results in the adiabatic flash evaporation of a part of the liquid refrigerant. The
auto-refrigeration effect of the adiabatic flash evaporation lowers the temperature of the liquid
and vapor refrigerant mixture to where it is colder than the temperature of the enclosed space to
be refrigerated.

The cold mixture is then routed through the coil or tubes in the evaporator. A fan circulates the
warm air in the enclosed space across the coil or tubes carrying the cold refrigerant liquid and
vapor mixture. That warm air evaporates the liquid part of the cold refrigerant mixture. At the
same time, the circulating air is cooled and thus lowers the temperature of the enclosed space to
the desired temperature. The evaporator is where the circulating refrigerant absorbs and removes
heat which is subsequently rejected in the condenser and transferred elsewhere by the water or
air used in the condenser.

To complete the refrigeration cycle, the refrigerant vapor from the evaporator is again a saturated
vapor and is routed back into the compressor.

5.5 DM water:

5.5.1 Equipment’s of DM plant:

(1) Dual media filter: Capacity- 18 m3/hr, working gauge pressure- 6.0 bar. There are two beds
of sand and gravels. Dual media filter is a one type of sand filter. Raw water from the process
Page 43
 water storage sump (800 m3 capacity) at 5800-kg/hr-flow transfer to DMF. Process water
passes to DMF to remove suspended solids and turbidity. Back washing of the filter beds has
to be carried out periodically more frequently if pressure drop across the bed exceeds 0.7 bars
and this indicates the accumulation of the dust in the bed. Backwash is taken once in a week.
There is a pressure control valve to maintain DMF inlet pressure at 6.0 bar g. The pressure
control valve is operated on pressure transmitter, which is located on DMF inlet line.
(2) Activated carbon filter: Capacity: 18 m3/hr, Filter- activated charcoal, the outlet water from
dual media filter comes in activated carbon filter. Activated carbon filters is used to remove
oil and free chlorine.
(3) Strong acid cation: Capacity- 12 m3/hr, M.O.C- MS rubber lined, Resin-Tulsan T-42 (760
liter), Working pressure-4.0 bar g. Quantity of resin-660 m3, HCL required- 39.6 kg on 100 %
base. Output between regeneration- 220 m3, in a cation exchange cation like ca+2, mg+2, Na+2
are replaced by hydrogen ion H+,

Cacl2 + R-H= R-Ca + HCL

NaCl+ R-H= R-Na +HCL
Mgso4 + R-H= R-Mg + H2SO4
CaSO4+ R-H= R-Ca + H2SO4
Periodically we check the quality of the SAC outlet water during their service cycle. The quality
of the SAC outlet water is as per bellow.
PH- 3.0
Sodium-< 300ppb
Free mineral acid-30 ppm
If any of the one parameter gets disturbed we have to do regeneration generally after 18 hrs.
(4) Degasser tower:
Top portion: filled with poly propylene rings.
Bottom portion- storage tank (1600 * 1800)
MOC-M.S
Size- 500 * 2500
Degasser air blowercapacity-212 m3/hr
Degasser pump- 12 m3/hr

Page 44
 Water coming from strong acid cation enters in the top portion of the degasser tower. Air is
blown from the bottom of the tower. Temporary hardness is removed by blowing air through packing.
Air will decompose bicarbonate and CO 2 will liberate which will be removed from the top portion of

the tower.

(5) Strong base anion: Capacity-12 m3/hr

5.5.2 Process of demineralization:
Demineralization or deionization is the process of removing mineral salt from water by using the
ion exchange process. Demineralization involves two ion-exchange reactions. Initially, the
Cation such as calcium, magnesium and sodium are removed in a hydrogen Cation exchanger,
the exchangeable ion in the resin bed being hydrogen. The salts are converted to their respective
acids. The acidic water is then passed through an anion exchange where the anions such as
sulphates, chlorides, etc. are removed by exchange of hydroxyl ions. Ion exchange is an
equilibrium & reversible reaction. In the hydrogen Cation exchange resins the Cation group
shows the greater affinity for other Cation in presence to hydrogen ions. This process is reversed
when the resin bed gets exhausted of hydrogen ions and it regenerated with a strong acid, the
reverse process-taking place because of hydrogen ions being presented in high concentration in
the regenerate acid (either HCl or H2SO4).The anion exchange resin contains activated amine
groups and the OH radical replace the anion like SO 4 and Cl2. There are two type of anion
exchange resins, strong basic and weekly basic. The strong basic anion exchange resin is
regenerated with Caustic soda and the weekly basic anion exchange resin is regenerated with
Sodium carbonate or Caustic soda.
Hydrogen Cation Exchange,

R.SO3H + NaCl RSO1Na + HCl

2RSO3H + CaSO4 (R.SO1) 1Ca + H2SO4

Weakly basic anion Exchange

RNH1 + HCl RNH1Cl + H2O

Strong basic anion exchange

R4N.OH + H2SIO2 R4N.HSIO2 + H2O
Page 45
When the supply of exchangeable ions within the resin is exhausted, the treated water quality
deteriorates and the resins require regeneration.
The cation exchange resins with mineral acid such as HCl or H2SO4. The strong basic anion
exchange resin is regenerated with Caustic soda and the weekly basic anion exchange resin is
regenerated with Sodium carbonate or Caustic soda.

Figure 5.4 DM water plant

5.6 Conclusion:
Page 46
Typical plant utilities are cooling water, chilled water, steam, process water, DM water,
Instrumental air etc required in chemical industry. In WNA plant, chilled water is used in
evaporator-1 and absorption column. Cold water is used in evaporator-2 and absorption column.
As mentioned in previous chapter, at the start time only, steam is taken from boiler plant. After
steady state, steam is not taken from boiler plant. It is fulfill by heat integration of WNA plant.
Instrumental air is used to operate control valves of WNA plant.

CHAPTER 6
DETAILED DESCRIPTION OF THE EQUIPMENT

Page 47
6.1 Introduction:

From chapter 3, material balance, we came to know the total number of unit operations and unit
processes required for the production of weak nitric acid of the said capacity. Based on the
capacity selected the following section will discuss on the capacity of all the equipments used
along with MOC used for the fabrication of same.

6.2 List of all major and minor equipment:

Table 6.1 List of all major and minor equipment with their Capacity and MOC

Serial Number Name of equipment Number of Capacity MOC

equipments (m3)

1 Cooling Water 1 10 SS 304

Evaporator

2 Chilled Water 1 10 SS 304

Evaporator

3 NH3 Pre heater 1 6 SS 304

4 NH3 air mixture 1 15 Carbon steel

5 Reactor vessel 1 22 SS 316

6 Economizer 1 12 SS 317

7 BFW Pre heater 1 12 SS 316

8 Tail gas heater 4 12 SS 316

9 De aerator drum 2 4 Carbon steel

10 Cooler condenser 1 8 Carbon steel

11 Absorption tower 1 25 SS 304

Page 48
12 Bleaching column 3 7 SS 304

13 Storage tanks 1 4 SS 304

14 Instrument air storage 2 3 Carbon steel

Tanks

15 BFW and process water 1 5 Carbon steel

storage tanks

16 Pumps 1 Carbon steel

17 Cooling water system 3 5 SS 304

18 Stack 2 Carbon steel

19 Blow down vessel with 2 5 SS 316L

dosing stations

20 Air compressor 1 8 SS 304

21 NOx compressor 1 7 SS 317

Table 6.2 Maximum and Minimum operating temperature and pressure of each equipments

Serial Name of Minimum Maximum Minimum Maximum

Number Temp. (°C) Temp. (°C) Pressure Pressure
Equipment
(Kgf/cm2) (Kgf/cm2)

1 Cooling Water 50 75 5 9
Evaporator

2 Chilled Water 50 75 5 9
Evaporator

Page 49
3 NH3 Pre heater 60 120 7 10

4 NH3 air mixture 180 210 7 10

5 Reactor vessel 850 950 3 5

6 Economizer 240 300 2 4

7 BFW Pre heater 210 280 2 4

8 Tail gas heater 300 400 2 4

9 De aerator drum 110 150 2 4

10 Cooler condenser 70 110 2 4

11 Absorption tower 35 70 7 10

12 Bleaching 35 70 8 10
column

13 Storage tanks 30 120 1 3

14 Instrument air 30 90 16 20

storage tanks

15 BFW and process 30 150 3 5

water storage

Tanks

16 Pumps 30 55 1 2.7

17 Cooling water 30 120 1 1.5

System

18 Stack 150 200 1 3.5

Page 50
19 Blow down Vessel 150 200 2 4
with dosing
stations

20 Air compressor 200 270 1 5

21 NOx compressor 100 180 8 13

NOTE: All above mentioned information about each equipment is taken from Equipment data

Sheet available in WNA plant.

6.3 Conclusion:

Numerous equipments are involved in construction of any chemical plant. After selection of any
process, it is inevitable to decide the equipment necessary to accomplish the process. Suitable
material of construction (MOC) is decided based on the fluid to be handled, considering their
behavior in nature, properties, corrosion, fouling and reactivity with the material of equipment.
The MOC should be selected on the basis of its ability to withstand such conditions and work
efficiently without obtaining damage. By concluding this chapter, we are in position to design
equipment.

Page 51
 CHAPTER 7
DESIGNING OF EQUIPMENT

7.1 Introduction:

In this chapter, Process design of storage tank, Centrifugal pump, NOx compressor is described
as minor equipment design and process as well as mechanical design of absorption column are
described as major equipment design.

7.2 Design of Minor Equipment:

7.2.1 Storage Tank:
There are 4 storage tanks of WNA is available in WNA-1 plant. Each of have capacity of 1700
MTPD. Due to safety purpose, storage tank is not fully filling with WNA. All the storage tanks
are interaction type tanks. So, we can equalize tanks. From 1 st storage tank, WNA is going to
CNA1 plant. Like that, CNA-2 plant takes WNA from 2 nd tank and CAN-3 plant takes WNA
from 3rd tank. From 4th storage tank, WNA is going in cargo for selling. Storage Tank for Weak
Nitric Acid:

• MOC : SS-304
• Maximum Allowable Stress : 10000 psi = 702.72 kg/cm2

• ƍMOC: 8000 kg/m3

Page 52
 • ƍWNA: 1360.75 kg/m3
• Superimposed Load : 125 kg/m2
• Capacity of storage tank = 1700 MTPD

= 1700*Roll Number

= 1700*1.7

= 2890 MTPD

= 2890*103 kg

= 361.25 m3
We have to take 20% extra volume.

Total volume = 1.2*361.25 = 433.5 m3

Surface area is to be minimized, f(r,h) =

2 rh + 2
[Close Tank]

(We have to do conical head design or self supported roof)

Constraint : g(r,h) = 0 g(r,h)

= V- 2
h

P(r,h, ) = 2 rh + 2
+ (V- 2
h)

2 h+4 + (- h) = 0 ....................... 1

Page 53
 h)*(1) = 0

V= 2
h

From equation 1

h + 2r =

……….A
From equation 2

2 2

……….B

From equation A and B,

r=

V= 2
h

V= 3

433.5 = V = 3

Page 54
 r = 4.102 m & d =

8.204 m h = 8.204 m

Diameter of the tank = 8.204 m

Height of tank = 8.204 m

Young modulus for SS-304 = 1.9 1011Pa

J = 0.85

Corrosion Allowance = 2 mm

Plate Size = 1m * 2 m

P = (H – 0.3)*100 + P’
P = 1360.75*10-6*(8.204 – 0.3)*100 + 0.0125

P = 1.088 kg/cm2

t c

= 9.47 mm

t = 10 mm

For course of 1 m, 10 mm thickness

H = 8.204 – 1 = 7.204 m

Table 7.1 Storage Vessel Thickness

H (m) P (kg/cm2) t (mm) H’ (m)

8.204 1.088 10 8.204 – 1 = 7.204

Page 55
 7.204 0.951 10 7.204 – 1 = 6.204

6.204 0.815 8 6.204 – 1 = 5.204

5.204 0.679 8 5.204 – 1 = 4.204

4.204 0.543 6 4.204 – 1 = 3.204

3.204 0.407 5 3.204 – 1 = 2.204

2.204 0.271 5 2.204 – 1 = 1.204

1.204 0.135 5 1.204 – 1 = 0.204

Bottom Design,

Diameter of bottom,

Db

= [8.204 + 2*(10*10-3) +

Db = 8.354 m

di = 8.204 m , di< 12 m

tb= 6 mm

Roof Design,

= 1/5

= tan-1(1/5)

= 11.31°

P = Pressure based on class of vessel + Superimposed Load

Page 56
 P = 625 + 125 P

= 750 kg/m2

Thickness of Roof,

tr

tr

tr = 18.22 mm
tr = 20 mm Load,

w= DP

w=

w = 388685.8167 N

Compressive Stress,

T=

T1 = 76935.628 N/m

Tensile Stress,

T3 = T1cos

T3 = 76935.628*

T3 = 75441.57 N/m
Page 57
2fA = T3D

A=

A =

A=

A=

A = 8.98*10-4 m2
A = 898.036 mm2

A' = Ac + As + Ar

Ac = Area of curb member

If D ,

Then Ac = 65*6

Ac = 390 mm2

As = Area of shell effective

As = 1.5 ts s

As = 1.5*5*

As = 1603.5 mm2

Ar = Area of roof effective

Ar 0.75 t r

Page 58
Where, R

9142∗12
√
A = 0.75*8*r sin(11.31)

Ar = 1041.82 mm2

A' = 390 + 1603.5 + 1041.82

A' = 3035.32 mm2

A'> A So, Self supported roof is there. Conical roof is not required.
Table 7.2 Summary table of Storage Vessel

Capacity (m3) 433.5

Height (m) 8.204
Diameter (m) 8.204
Bottom plate diameter (m) 8.354
Bottom plate thickness (mm) 6
Thickness of roof (mm) 20
Type of roof Self supported roof

7.2.2 NOx Compressor:

NOx gas compressor used to compress NO2 gas from 3.9 bar to 10.9 bar. This compressor used to
reach favorable conditions for absorption tower. Because, High pressure and low temperature
conditions are favorable for absorption tower.

Suction pressure = P1 =3.913 bar Discharge

pressure P2 = 10.8 bar

Suction temperature T1= 46 °c

Page 59
Mass flow rate of gas = 30058.125 kg / hr

= 8.349 kg /s

= 0.1815 Kmol/s

n = 1.4

Adiabatic Work done = (n/n-1)*RT1[(P2/P1)^ (n/n-1) - 1]

= (1.4/1.4-1)*8.314*319*[(10.8/3.913)^(1.4/1.4-1) – 1]

= 314958.0412 J/mol

Power = Adiabatic Work done * molar flow rate of NO2 gas

= 314958.0412 *103 * 0.1815

Power = 9.449 MW

Total Power output from compressor = 9.449 MW

Power input from steam turbine = 3.115 MW

Power input from tail gas turbine = 8.225 MW

Therefore, Total power input to compressor = 11.340 MW

Power output
So, Compressor train efficiency = *100 Power input

= 84.37%
Hence, Compressor Train efficiency is 84.37%.

Table 7.3 Summary table of NOx compressor

Power output from compressor (MW) 9.449
Power input from compressor (MW) 11.340

Page 60
Efficiency (%) 84.37

7.2.3 Centrifugal Pump:

Actually, there are many pumps used in the plant (mentioned in table 8.1).Here, centrifugal
pump of capacity 350 m3/hr is used to flow cold water from cooling tower to evaporator-2.
Following data are taken from equipment data sheet of WNA-1 plant.

• MOC used =SS304

• RPM =1487
• Efficiency = 86 %
• Flow rate = 350 m3/hr
• Fluid: water

Table 7.4 Data require in designing pump

Suction Discharge

Fluid temp. (°C) 50 42

Pressure (Pa) 101325 455962.5

Density (Kg/m3) 999.75 999.99

Viscosity (Pa s) 0.547*10-3 0.653*10-3

Length of pipe (m) 15.9 229.2

Diameter of pipe D(mm) 450 350

0.159 0.0961
Area
Velocity [Capacity/Area] (m/s) 1.01 2.48

Reynolds No. 646090.7221

[
e (mm) 0.03
0.03

Page 61
 Roughness Factor [e/D] 8.57*10-5 6.67*10-5

Friction factor** 0.0125 0.01125

Friction losses [0.085*(Re)-0.25] 2.11*10-3 2.35*10-3

** Friction factor can be finding by graph of roughness factor Vs Friction factor.

Head losses at the discharge =

Head losses at the discharge (hf) = 35.835 m2/s2

According to Bernoulli’s equation,

P1/ρ + g*Z1 + V 12 /2 + n*Wp = P2/ρ + g*Z2 + V22/2 + hf

(101325/999.75) + (9.81*0) + (4.1062/2) + 0.86*Wp = (455962.5/999.99) + (9.81*19) + (2.482/2)

+ 35.835

W=p
0.86

Wp = 663.401 m2/s2

Wp = 663.401 * (350/3600) * 1000

Wp = 262.043 KW

NPSH = (Pi/ρ*g) + (V 12 /2*g) – (Pv/ρ*g) – (hf/g)

(Vapor pressure of water at 50 °c = Pv = 1232.285 Pa)

= (101325/999.75*9.81) + (4.1062/2*999.85) – (1232.285/999.75*9.81) – (35.835/9.81)

= 10.331 + 8.43*10-3 – 1.257 – 3.65

Page 62
NPSHAvailable = 5.43 m

NPSHRequired = 4.75 m (Taken from WNA-1 plant equipment data sheet)

Table 7.5 Summary table of centrifugal pump

Power (KW) 262.043

NPSHAvailable (m) 5.43
NPSHRequired (m) 4.75
7.3 Designing of Major equipment: [Absorption Tower]
In WNA plant the absorption tower present is made of SS-304 and containing sieve type
trays. In this column, physical as well as chemical absorption is taking place. First of all,
NO2 gas is enters from the bottom of the column. It passes through perforations of sieve
trays. In fact, from the bottom, gas mixture is enters. In gas mixture, NO 2 gas is absorbs in
solvent. N2 gas is act as an inert in gas mixture. In the operation, water is used as a solvent.
Actually, 42 sieve trays are in absorption column. From tray number 1 to 27, cooling water is
used as a solvent and from tray number 28 to 42, chilled water is used as a solvent. Because
as gas goes upper side in column, it weakens. So, chilled water is used in the upper side of
column. 7.3.1 Process Design:

Here in absorption tower following reaction is taking place.

3NO2 + H2O 2HNO3 + NO

From material balance, we know the quantity of gas mixture (NO2 + N2) entering in the
absorption tower.

Moles of NO2 enter in the absorption tower = 653.4375 Kmol/hr

Moles of N2 enter in the absorption tower = 3353.705 Kmol/hr

G1 = 4007.1425 Kmol/hr = 1.113 kmol/s

Mole Ratio of NO2 at the inlet of absorption tower,

Page 63
Y =

Y1 = 0.194

Now, it is desire to scrub 99.9% NO2.

Y2 = 1*10-3*0.194 = 1.94*10-4

Page 64
 Figure 7.1 Schematic view of absorption tower (Source: WNA-1 plant manual)

Pure water is used as a solvent.

X2 = 0
It is desire to produce 61.5% Nitric acid.

Page 65
Hence, X1 = 0.615 Gs

= G1*(1-Y1)

= 1.113*(1-0.194)

Gs = 0.931Kmol/s

Equilibrium equation :

Vapor pressure of 61.5% HNO3 at 50 °C (Pv) = 37.7 KPa

Total Prsessure Pt = 1 atm

According to Rault’s law, yPt

= xPv

y*(1) = x*(37.7/101.325)

Table 7.6 Equilibrium data

X Y

0.1 0.035

0.2 0.066

0.3 0.092

0.4 0.118

0.5 0.141

0.6 0.162

Page 66
 0.7 0.1862

0.8 0.1976

0.9 0.2077

1.0 0.2285

So, we have to find Lmin (Minimum solvent flowrate),

By putting Y1 (0.193) in equilibrium data, we get Xmax (0.79)

Lmin/Gs = (Y1 – Y2 ) / (Xmax – X2)

Lmin = 0.228 Kmol/s

Let’s take, L = 1.7* Lmin L

= 1.7*0.228

Ls = L = 0.3876 Kmol/s

(Ls/Gs) = (Y1 – Y2) / (X1 – X2)

(0.3876/0.931) = (0.194 – 1.94*10-4) / (X1 – 0)

X1 = 0.465

Page 67
 Y 0.25

0.2

1
0.15

2 Equilibruim line

0.1 Operating line

0.05

0
0 0.2 0.4 0.6 0.8 1 1.2
X

Figure 7.2 Equilibrium and operating line of absorption (Source: MS Excel)

1. Actual Number of Trays:

m = 0.373

A = (Ls)/(m*Gs) = (0.3876/(0.373*0.931))

= 1.1661

According to kremser equation,

/
N = Log() Log(A)

By putting all the values in the above equation, we get number of trays,

Page 68
 N=

2.229
N=
0.0667

N = 33.4

Here, tray efficiency is 80%

Actual number of Trays = 33.4/0.8

Actual number of sieve trays = 42

2. Rate of reaction in Absorption column:

(-r A
’’
) = [(D Bl C B/D ) + (P /H )] / A
AL A [ (1/H A K ) + (1/K AL ) ] ............. A
AG

Where,

DBL = Diffusivity of water

DAL = Diffusivity of NO2 CB

= Concentration of water

P = Partial Pressure of the NO2

HA = Henry’s constant

KAG = M.T.C. in the gas phase

KAL = M.T.C. in the liquid phase

DBL = [(117.3*10-18*(ωMB)0.5T)]/ (µVA)0.6

= [(117.3*10-18*(2.26*18)0.5*323)] / (0.5465*10-3*0.0756)
Page 69
DBL = 5.84*10-9 m2/s
DAL = [(10-4*(1.084 – 0.249*(1/MA+1/MB)0.5)*T1.5*(1/MA+1/MB)0.5)] / [Pt*RAB2*KT/EA]

= [(10-4*(1.084 – 0.249*(1/46+1/18)0.5)*3231.5*(1/46+1/18)0.5)] / [1013*0.07562*0.8]

DAL = 3.61*10-5 m2/s

PA = y1*Pt

= 0.163 * 101325

PA = 16515.975 Pa

CB = 1 Kmol/m3

HA = C/PA

= 220/16515.975 [Solubility of NO2 in water at 50 °c is 220 M]

HA = 1.33*10-2 M/Pa

N=A

NA = 0.195 Kmol/m2 s

NA = KAG*(Y1 – Y2)

KAG

KAG = 1.006 Kmol/m2s

NA = KAL*(X1 – X2)

KAL
Page 70
 KAL = 0.317 Kmol/m2s
Now, put all the values in the equation A to find rate of reaction of this reaction.

(-r A’’ ) = [(D Bl C B/D AL) + (P /H )] / A A [ (1/H A K AG ) + (1/K AL )]

= [(5.84*10-9*1/3.61*10-5)+(16515.975/1.33*10-2)]/[(1/1.33*10-2*1.006)+ (1/0.31)]

(-r A’’ ) = 15.934 Kmol/m3s

7.3.2 Mechanical Design:

1. Height of the column:

Internal Pressure = 10.8 bar

Design Pressure = 1.1 * 10.8 bar = 11.88 bar

Temperature = 50 °C

Thickness of insulation =80 mm

MOC = SS-304

F.O.S. = 2.5

Maximum allowable stress = 40000 psi

Tensile strength of this MOC = 100000 psi

E = 190 GPa

Corrosion Allowance = 2 mm Joint

efficiency Factor = 0.85

Top disengaging space =1 m

Weight of attachments (pipes, ladders platform) = 750 N/m

Page 71
 Wind velocity Vw= 2.5 m/s
Density of liquid = 999.75 Kg/m3.

Density of MOC = 8000 Kg/m3

Density Of insulation = 5640 Kg/m3

Inside Diameter = 2.46 m Column

Shell Thickness:

ts = P*D / (2fJ – P)

ts = 1203741*2.46 / ((2*220608000*0.85) – 1203741)

ts = 4 mm + C.A.

ts = 4 + 2

ts = 6 mm

Axial Stress due to pressure:

fap= PD/4(t - c)

= 1203741*2.46 / 4*(6 - 2)*10-3

fap = 88991847.5 N/m2 ............. 1

Now, Do = Di + 2t

Do = 2.476 m Stresses

due to load:

Due to weight of shell:

Fdx =Weight of Shell/ cross section of shell

= (∏/4)*(D02-D i 2)*ƿ*H/ ((∏/4)*(D02-D i 2))

Page 72
Fdx = 77008.5H N/m2 ............. 2
Due to Weight of Insulation:

Fdins= (∏*Dins*ƿins*tins*H)/ (∏*Dm*(t-C))

Dm = (Do+ Di)/2 = 2468 mm

Dins = Do + 2*tins

= 2476 + 2(80)

= 2636 mm

Fdx = (2636 * 80 * 5640 * H) / (2468 * 20)

Fdx = 122952H N/m2 ............. 3 Due

to weight of liquid & tray: Bulk

weight of packing = 237 Kg/m3. ρliq =

1035.74 kg/m3

Fdwpacking = (H)* (Π/4*234)* Di2

Fdwpacking = 36490.4773H Pa ............ 4

Fliq = (∏*Di*Di*H*9.81 /4) / (∏* Dm*(ts -C))

Fliq = 298288.633H N/m2 ............. 5

Due to attachments:

Attachment Weight = 800 N/m

Fdatt = Wt. of attachments * H / (∏*Dm*(ts-C))

= 800*H / (3.14*2483*20*0.0001)

Fdatt = 15298.975H N/m2 ............ 6

Page 73
Now,
Total Stress = (77008.5 + 122952 + 15298.975 + 36490.4773 + 298288.633)*H

Fdh= 1455490.452H N/m2

Also, dead weight of top tower should be added for bottom column.

Its value is 641094.137H N/m2

Total Fdh= 1191600.85H N/m2

Stresses due to wind load: Wind

velocity = 2.5 m/s.

Fwind= 1.4* Pw* H2 / П*Do*(t-c)

Pw = 0.05(3.6*2.52) =

1.125 N/m2

Fwind = 1.4*1.125*H2 / Π*2504*20*0.0001

Fwind = 10.0873H2 N/m2 ............ 7

FAllowable = 187516800 Pa ............ 8

Now, we have

AH2+ BH + C = D

A = 10.0872 B

= 1191600.85

C = 88991847.5

D = 187516800

On solving the equation,

Page 74
10.0872H2 + 1969039.055H + 88991847.5 = 187516800
H = 52.234 m

Hence, Height of the column is 52.234 m.

2. Torispherical head: (bottom head)

Rc = ID – 6 inch

= 2.46 -0.1524

= 2.3076 m

Rk = 10% of ID =0.246 m

Cs=0.25*(3+(Rc/Rk)0.5) =0.25*(3+(2.3076/0.246)0.5)

=0.87

Thickness (t) = (PRcCs/2fJ) + CA

= 4.65 + 2

= 6.65 mm

Available market thickness is 8 mm.

3. Elliptical Head: (Top head)

t = (PDV)/(2fJ-0.6P) Where , V = 0.5(2 + k^2)

= (10.74*105*2.46)/((2*275*10^6*0.85)-0.6(10.74*105))

= 5.65 mm + 2 mm

= 7.75 mm

Available market thickness is 8 mm.

4. Nozzle Design:

Page 75
 • Manhole = 1000 mm
• P = 10.74 x 105 Pa
• di= 1000 mm  f = 275 MPa
tr = pdi/(2fj-p) + CA

= 2.29 + 2

= 4.29 mm

But, Minimum available thickness in market is 5mm.

So, Thickness of nozzle = 5 mm

A = (dn + 2C)*tr

= 0.007311 m2

As = (d +2C)(ts – tr-C)

= 0.00072 m2

An = Ao + Ai

Ao = 2Ho (tn – trn-C) = 2*54.888*(5-2.235) = 7.70*10-5 m2

Ai = 0

An = 7.70*10-5 m2

Ar = A – (As + An) =

0.0065 m2

Hence, Compensation Required.

Ar = (Drpo - Drpi) tp

= [2(dn +2C)-( dn +2 tn) ] tp

tp= 2 mm

5. Flange Design:

Page 76
Data:

• Design Pressure : 10.74 x 105 Pa

• Maximum allowable Stress at design temp: 275 MPa
• (fb)b = 79.05 x 106 Pa
• (fb)a = 89.45 x 106 Pa
• Nmin =0.1
• Gasket Factor m =2.75
• Y = 2551000 N/m2

(G / G )
o i

G0 – Gi = 2*Nmin

1.024*Gi – Gi = 2*0.1

Gi = 0.809 m

Go = 0.829 m

N = (Go - Gi)/2 Here,

raised type gasket bo =

N/2 = 5 mm , bo<

6.3mm, b=bo G = (Go +

Gi)/2

= 1.02158 m

6. Hub design:

Page 77
go = (Do- Di )/2 = 0.005 m g1 =

0.007075 m h = 0.0075

7. Bolt Design:

Db = 0.01905 m

Arb = 0.0002850 m2

Fa = 89456340.76 N/m2

Fb = 79059002.9 N/m2

G = 1.02158 m Y =

25510000 N/m2 b =

0.005 m

• Wm2=3.14*G*b*Y
= 413774.57 N
• Wm1 = (3.14/4)*G2*p + 2*3.14*G*m*p
= 995737.8753 N

• Am1 = Wm1 /fb

= 0.01259 m2

• Am2 = Wm2 /fa

= 0.00462 m2

• Amax = (3.14/4)*d b2 *n

N = 16.228 bolts

N = 20 bolts
• Bolt Circle Diameter
C1 = Dfi + 2(g1 + R) = 1.0858 m
R= (G- Do)/2 + 10 + db/2

Page 78
 = 0.0308 m
• Bolt spacing : 3.14*C/n
= 170.55 mm

There are 5 more nozzles on the absorption column.

1. Water inlet (Dia.- 0.1 m)

2. Water outlet (Dia. - 0.1 m)
3. NO2 inlet (Dia. - 0.2 m)
4. NO2 outlet (Dia. - 0.2 m)
5. Condensate discharge (Dia. - 0.2 m)
Calculation for these nozzles are attached as an excel sheet in Appendix 2.

8. Skirt support:

Diameter Of vessel: 2.46 m

Height of vessel: 52 m

Weight of vessel + attachments: 200000 N

Diameter of skirt: 3000 mm

Height of skirt: 4.8 m

Wind pressure: 1285 N/m2

Allowable strength of concrete: 35 kgf/cm2

(a) Dead weight due to vessel + attachments:

Fd = 200000/(Π*2460*tsk) Fd

= 212.5/tsk N/mm2

(b) Wind load stress:

Mw = Plw*(h1/2) + K*P*h2*d0*(h1 + h2/2)

= K*P*h1*dr*(h1/2) + K*P*h2*d0*(h1 + h2/2)

Page 79
 = 0.7*10.74*105*20*3*(20/2) + 0.7*10.74*105*(52 + 4.8 – 200)*3*(20 + 14.9)

Mw = 3646.194 N m

Fw = (4*Mw)/(Π*d02*Lsk)

= 473.36/tsk N/mm2

(c) Stress due to seismic load:

Fsb = (4*C*W*H)/(3*Π*do2*Lsk)

= (4*0.08*200000*36.8*1000)/(3*Π*30002*Lsk)

= 399.3/tsk N/mm2

Since, Fw > Fs , so go ahead with Fw.

Now, two total stresses. (I)

Maximum tensile stress:
Ft(max) = 473.36/tsk – 212.5/tsk

= 261.3/tsk Ft(max) = 140 N/mm2 tsk

= 3 mm (II) Maximum

Compressive stress:

fc(max) = 473.36/tsk + 212.5/tsk

= 686.3/tsk

fc(max) = (Y*P)/3 = 66.6 N/mm2

tsk = 10.3 mm

So, go ahead with 12 mm support thickness.

Table 7.7 Summary table for Absorption tower design

Page 80
Minimum water flow rate (Kmol/s) 0.228
Actual water flow rate (Kmol/s) 0.3876
Theoretical number of sieve trays 33
Actual number of sieve trays 42
Rate of reaction in absorption tower 15.934
(kmol/m3s)
Shell thickness (mm) 6
Height of column (m) 52.234
Bottom head thickness (mm) 8
Top head thickness (mm) 8
Thickness of nozzle (mm) 5
Ring pad thickness (mm) 2
Thickness of flange (mm) 30
Outside diameter of flange (m) 1.124
Skirt support thickness (mm) 10.3

7.4 Conclusion:
1. After production, we need to store produce chemical. Hence, mostly every plant has its
storage tank. In WNA plant, there are 4 storage tanks which are of interaction type.
2. NOx compressor is used to compress NO2 gas from 3.9 bar pressure to 10.9 bar pressure.
Temperature of NO2 is also increases from 48 °C to 160 °C. There is a drop separator too
before NOx compressor, because if any drop enters in compressor then it may be lead to
undesirable behavior of compressor.
3. Pumps are very essential equipment in any plant. In WNA plant, various types of pumps
are used for different purposes. In that, centrifugal pump is used to circulate cooling
water from cooling towers to evaporator-2. Centrifugal pump discharges fluid with high
velocity. Here, efficiency of pump is 86%.
4. In WNA plant, Absorption is taking place with chemical reaction in column. This tower
has 41 sieve trays. From plate 1 to 26, cooling water is used as a solvent medium and

Page 81
from 26 to 41 trays; chilled water is used as a solvent. Because, Gas weakens as it goes
upper side of column, so we need more driving force for desire result.

Page 82
 CHAPTER 8
PUMPS, PIPING, FITTINGS AND CONTROL VALVE
8.1 Introduction:

In this chapter, there is a list of different pumps and control valves used in the WNA-1 plant. It
also consist piping color code system and control loops of WNA-1 plant.

8.2 Pumps:

A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by mechanical
action. Pumps can be classified into three major groups according to the method they use to
move the fluid: direct lift, displacement, and gravity pumps. Pumps operate by some mechanism
and consume energy to perform mechanical work by moving the fluid. Pumps operate via many
Page 83
 energy sources, including manual operation, electricity, engines, or wind power, come in many
sizes, from microscopic for use in medical applications to large industrial pumps.

Table 8.1 Various types of pumps used in the plant – their characteristics, suppliers

Sr no. Description Fluid Suction Discharge NPSH Flow

Density Pressure Pressure (m) rate
(kg/m^3) (bar) (bar) (m^3/h
r)

1. Process water pump 991 1.2 5 510 400

2. Cond feed pump 1220 1.5 7.8 630 150

3. BFW pump 1008 1.1 9 320 350

4. Hydrazine pump 1435 2 66 220 240

5. Acid con pump 1145 4 12 160 145

6. Cooling water pump 997 1 8 480 560

7. DM water pump 995 1.4 6 400 470

8. Absorption cooling 997 1.1 15 270 260

Pump

9. Ammonia pump 890 4 9 470 350

10. Lube oil pump 788 1.05 3 180 80

11. Tsp dosing pump 800 1.7 6.3 195 50

12. BFW circulation pump 999 1.5 8.5 230 250

13. Waste water pump 1226 1.5 3 477 320

Page 84
 8.3 Piping:
In Plant piping material is selected on the base of bellow criteria:

• Material specification
• Chemical composition
• Mechanical properties
• Brittle facture toughness
• Carbon equivalent
• Inspection time
• Easy to repairing  Welding procedure
Mainly SS 316 pipes are used to avoid corrosion and for a longer life.

Line color codes:

Cooling water inlet

line

Cooling water outlet

line

Vent line

Steam line

Vacuum line
Raw water line

8.4 Control valves:

Table 8.2 List of Control valves (Source: WNA-1 plant manual)

Sr no Tag no Service Fail position

1. FC Liq NH3 to evaporator CLOSE

2. FC Ammonia evaporator -1 OPEN

Page 85
 3. RATIO ammonia air ratio controller CLOSE

4. FC Ammonia to pre heater CLOSE

5. PC Mp steam header OPEN

6. FC Hydrogen to pilot burner CLOSE

7. PC Hydrogen to main burner CLOSE

8. FC Hp steam import OPEN

9. LC Level in evaporator OPEN

10. FC Tail gas heater to economizer CLOSE

11. LC Absorption tower level controller OPEN

12. FC Air to absorption tower CLOSE

13. FC Cooling water to plant OPEN

14. TC Tail gas turbine inlet CLOSE

15. FC Air compressor blow off OPEN

16. LC Tank level controller OPEN

8.5 Control loops in the plant:

Cascade controller

Here cascade controller is used to maintain minimum flow in air compressor for the safety of
compressor.

1. Primary controller – to maintain pressure by using turbine rpm

2. Secondary controller- to maintain minimum flow by valve

Page 86
 Figure 8.1 Cascade controller (Courtesy: MS Paint)

Ammonia-Air Ratio Controller

For good ammonia oxidation efficiency a constant reaction temperature of 900°C is required on
the catalyst bed. Since increase of the ammonia in the ammonia-air mixture by 1% by vol. raises
the reaction temperature by approx.67.5 K, this temperature can be controlled by the ammonia /
(air + ammonia) ratio. However, the maximum ratio is limited by the explosion limit of the
ammonia-air mixture, which is approx. 14% by vol. The figure depends mainly on the pressure
of the mixture.
Therefore, the ammonia ratio control is provided with several alarms and interlocks as described
in the alarm and interlock system. The primary air flow is used as master flow, while the
ammonia flow will be controlled. The output signal from the air flow transmitter is fed into the
FFC120202 controller, which also receives the output signal from the ammonia flow transmitter.
Both signals will be used for computing the ratio. The ratio controller output is transmitted to the
ammonia.

Page 87
Figure 8.2 Ratio controllers (Courtesy: MS Paint)

Page 88
8.6 Piping And Instrumentation Diagram :-

Figure 8.3 P&ID Of WNA Plant (Source : Plant Manual)

8.7 Conclusion:

Every chemical industry needs pumps, valves and its instrumentations. Pumps are used to
transfer a liquid from one point to another point by changing its flow rates. If needed flow rate is
lesser than pump capacity then also we have to run pump on its capacity. But in that case, there
is a provision of back flow stream.

Page 89
 CHAPTER 9
SAFETY, HEALTH AND ENVIRONMENT

Page 90
9.1 Introduction:
In this chapter, there is a discussion about different safety measures taken in WNA-1 plant.
There is also discussion about environment and health related policy of the GNFC as an aspect of
WNA1 plant.

9.2 Safety measures taken in industry:

Accidents can be avoided if:
The production plant is always kept clean and in technically proper condition. Any cotton rags,
paper, other waster, tools, instruments no longer used, and similar must be kept in special
containers or at special places. Escape ways and fire escapes must be kept free. Absorption
covers on mobile parts of the equipment must be or dearly fixed. Cleaning works on running
machines should be avoided. Stays under pending loads should be avoided. For works which
cannot be carried out from firm platforms skeletons must be expertly erected, or if possible, steps
as prescribed by directions can be used. For works in some height safety belts must be worn. All
persons not concerned with the operation of the plant, must leave the plant. To avoid
misunderstanding the order is best given in writing and completion of the work is also
confirmed. The personnel must be informed of the safety regulations and accident instructions at
regular intervals. When using solvents, the appropriate instructions to avoid explosive ratios or
health injuries must be followed. The personnel must be informed of the safety regulations and
accident instructions at regular intervals.

Special measures to prevent explosions of ammonium nitrate and ammonium nitrite: The
mixture of nitrous gases and unburned ammonia can lead to formation of Ammonium nitrate and
ammonium nitrite. During start-up for a short period, this gas mixture cannot be avoided. To
avoid the formation of ammonia water in the gas cooler which might possibly result into an
explosion in case of subsequent ammonium nitrate &ammonium nitrite formation, nitric acid is
injected during the ignition phase. In any plant safety measures are the most important. Safety is
maintained in the plant by two ways; one way by keeping trip parameter for the most hazardous
situation in the continuous process and second by aligning interlock systems to prevent
Unsequential operation during the start-up and shutdown step of the plant.
There is mainly two trip parameter for this plant:
1. Ammonia trip
2. Compressor trip

Page 91
 1. Ammonia trip
Ammonia to air ratio high: 10.5%, the reason for which above this limit the reaction goes

explosive range.
Ammonia to air ratio low: 7.2 %, the reason for which is that due to less Ammonia the gauze
temperature goes down below 890 °C which is the optimum temperature for reaction.

Gauze temperature high: 940 °C, the reason for which is that the reaction becomes explosive
above this limit and the catalyst starts eroding.

Gauze temperature low: 540 °C, the reason for which is that below this reaction occurs away
from the optimum condition hence providing less conversion.

Ammonia evaporator I and II: level high 85%, the reason for which above this the liquid
Ammonia gets carried away in the gaseous state and can create problem if it enters in the reactor.

Steam drum level low : 25%, the reason for which if the level is continuously go down, at one
point the pump start cavitations and coil is not completely filled with water and hence it will get
damaged.

Boiler water circulation low: 250 m3/hr, the reason for which is that below which the pipe will
get only partially filled and some regions say remain without wetting and hence the coil may get
damaged.

2. The Compressor trip:

In case of Ammonia gets trip the compressor trip will be actuated with the delay adjustable 30
seconds.
Pressure delivery side air compressor high, Pmax = 4.3 bar g
Pressure delivery side NO compressor high, Pmax= 11.5 bar g
Pressure suction side NO compressor low, Pmin = 0.04 bar g
Instrument air pressure low, Pmin = 3.5 bar g

Page 92
 Electric power supply failure
Over speed tail gas turbine = 8582 rpm

9.3 Safety equipments used in plant:

1. Helmets: For protection of head, helmets made of PVC, Fiberglass, Laminated plastics
&Vulcanized rubber are used. They provide protection against heat, spark & other dangerous

conditions.
2. Gloves: Protection of hands and arms are required when material handled has sharp
ends & edges, material is hot & molten or material is corrosive. The safety equipments used are
gauntlet gloves, wrist gloves and thumb & finger guard. The gloves are made up of PVC, rubber,

cotton & asbestos.

3. Suits: For protection of body against potential harm body protectors like aprons,
jackets spark arrestors, asbestos suits & asbestos blanket are used.

4. Ear Plugs: Noise level above 90 Decibel is hazardous for an exposure of more than 8
hrs/day or 48 hrs/week. It may cause permanent deafness, irritation, temporary deafness & hearing

losses. Ear plugs or earmuffs made up of plastics & rubbers are used for ear protection.
5. Safety boots: Foot & leg protection is required when heavy material caustics &
corrosive liquid, wet & molten conditions are presents. Safety equipments used are safety shoes &

boots.
6. Goggles & Helmets: Eye & face injury can be caused by dust, air bone particles &
radiation. For protection of eyes & face, safety spectacles, mono goggles, impact goggles, welding
goggles, face shield, etc

Page 93
 Figure 9.1 Personal Protective Equipments (Source: www.shutterstock.com)

The safety measures taken in the tanks are:

N2 blanketing is provided in all the tanks to avoid the formation of explosive vapor air mixture &
to keep the float floating on the liquid. N2 blanketing is avoided in naphtha tanks. Each tank is
separated by DYKE area in case of overfilling, leakage & collapsing of tank. Each tank is
provided with a Pressure Vacuum Release Valve. This valve helps in maintaining pressure in the
tank during tank filling. It has 15-25 KSC N2 pressure cut off. Pressure Release Valve is
provided on all tanks in order to relative pressure when pressure in the tank builds up. In furnace
oil tank, steam jacket is provided around the tank to decrease viscosity of oil. This helps in easy
transportation of oil & reduces pipe chocking. The tanks containing material having very low
flash point have been provided with Medium Velocity Water Spray (MVWS) system. As the
temp around the tank rises, the QBD bulb melts & water sprinkler starts.
The safety measures taken in case of fire are:
Sprinkler system – it sprinkles water on the tank when it catches fire.

Page 94
Aqueous Film Floating Foam System – when tank catches fire, AFFF system starts & foam starts
falling on float.
Manual Call Point – it is operated manually. It helps in sending signals to the control room &
safety dept in case of fire.
Fundamentals of fire:
Fire is rapid combustion resulting in release of heat and light of flame. Flame is luminous hot
zone of the fire.
Fire requires three things
1) Combustible material
2) Air (Oxygen)
3) Heat and local temp
Remove any one/two and fire will be extinguished.
Cooling - Removal of heat.
Smothering - Removal of Oxygen supply
Starving -Removal of Combustible material supply.

Table 9.1 Location of Fire Fighting Equipments (Source: WNA-1 plant manual)

Sr No. Location/Area

1. 10K05 filter house East side

2. 10P004 East side

3. Near West side staircase

4. Near 10P011

5. Near 81D001

6. Behind M/M workshop

7. Near pickling room entrance

9.4 All the auxiliary equipment related to safety:

• Safety Valves

Page 95
 • Rupture Disk
• Pressure Relief valves
 For fire fighting
• Fire and Safety department
• Water hydrant system
• CO2 extinguishers
• Fire tender
• Fire detectors
• Fire alarm
 For tank safety
• Sprinkler system
• Dyke wall around tank
• Breather valve & safety valves
• Foam system

Table 9.2 Location of safety valves (Source: WNA-1 plant manual)

Sr no Tag no Location Set pressure

Bar (g)

1. PSV Ammonia evaporator 12

2. TSV Hydrogen burner 8

3. PSV Mp steam header 50

4. PSV Steam drum 45

5. PSV Reactor-1 11

6. PSV Absorption column 3.2

Page 96
 7. PSV Instrument air storage vessel 15

8. PSV Plant air storage vessel 15

9. PSV De aerator 6

10. PSV Tail gas reactor 4

11. PSV Storage tanks 2.5

12. PSV Tail gas heater 2.2

13. PSV HP steam drum 95

14. PSV Economizer 2.2

9.5 Various pollution control measures taken by the industry:

9.5.1 Effluent Treatment Plant:

• Water can be considered as the most important raw material of civilization, since
without it people cannot live and agriculture and industries cannot operate.
• Water quality control becomes more important in today’s life for controlling pollution.
In Gujarat it's controlled and regulated by a board known as GPCB (Gujarat Pollution
Control
Board)
There are three basic types of treatment process:
1) Bio-logical process, which utilize biochemical reactions to remove soluble or colloidal
organic impurities.
2) Physical process, that depends simply on the physical properties of impurities.
3) Chemical process, which utilizes chemical reaction to remove impurities.
By using above methods alone, or in combination, which is more common, an almost complete
purification is possible.
Effluent Treatment Unit:

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97
Effluent Treatment unit consists of primary, secondary & tertiary treatment. These units are
described in detailed as below:
 Primary Treatment Unit:
Primary treatment unit comprising of following:
a) Oil & grease removal system with electric skimmer
b) Equalization cum neutralization tanks
c) Flash mixers
d) Primary clarifiers
a) Oil & Grease Removal System:
Effluent from absorption bottom after cooling, it is fed in to oil and grease removal tank. Oil &
grease removal system is equipped with electrically operated oil skimmer to remove the lighter
oily fraction from the top of the tank and facility for removal of heavier fraction from bottom of
the tank.
The lighter oily fraction from the top of the tank and heavier fraction from the bottom of the tank
is collected in a collection tank and from collection tank it is pumped to tarry waste collection
tank for incineration.
b) Equalization cum Neutralization Tank:
Effluent from oil and grease removal tank is transferred by gravity to equalization cum
neutralization tanks (2 no’s). The effluents from utilities and domestic/sanitary waste water
stream are mixed with effluents (from oil & grease removal tank outlet) in the equalization cum
neutralization tanks.
In equalization cum neutralization tanks, caustic, lime and acid dosing system is provided to
neutralize the wastewater based on the pH. c) Flash mixer:
Equalized & neutralized effluents from equalization cum neutralization tanks is transferred by
gravity to flash mixers having alum-dosing facility.
Flash mixers are provided for proper mixing of effluents with coagulation chemicals (alum) to
enhance the better flocks formation and to increase the removal efficiency of suspended solids
and COD, BOD and color to some extent.
d) Primary Clarifiers:
Effluent from flash mixers is transferred by gravity to primary clarifier I and II. Where adequate
detention time is provided to settle the suspended solids present in the effluent.

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98
Primary clarified effluent is then transferred to Aeration tanks from the top of the primary
clarifiers and primary sludge form the bottom the primary clarifiers is transferred either to
primary sludge drying beds or filter press for drying (through primary sludge sump)
 Secondary Treatment Unit:
Activated sludge process is used for biological treatment of primary treated effluent. It consists
of Aeration tank I & II, secondary clarifier, secondary sludge sump, secondary sludge drying
beds & treated effluent sump I. a) Aeration Tanks:
Two nos. of aeration tanks of required capacity are provided. Required nos. of aerators is
provided to ensure required oxygen supply to biomass for degradation of organic present in the
effluent. As a nutrient for bacterial culture, solution of urea and DAP is dosed on day-to-day
basis. Required detention time in aeration tanks is provided. b) Secondary Clarifier:
Secondary clarifier of required capacity is provided. The overflow from aeration tanks is fed to a
secondary clarifier wherein the bio sludge is settling at the bottom and clarified effluent is
overflow to a treated effluent sump.
c) Secondary Sludge Drying Beds:
Total six nos. of secondary sludge drying beds is provided for the drying of excess bio-sludge
generated from the secondary clarifier. Dried sludge is incinerated and the ash generated after
incineration is sent for secured land filling to Bharuch Enviro Infrastructure Limited,
Ankleshwar. Filtrate of biological sludge drying beds is pumped transferred to equalization cum
neutralization tank.

 Tertiary Treatment Unit:

This includes pressure sand filtration and sodium hypochlorite treatment: a)
Sodium Hypo chlorite Treatment:
The clarified effluent of secondary clarifier is treated with the sodium Hypochlorite solution in
treated effluent collection sump-I to reduce the color of effluent. This is also help full for
disinfection of effluent.
b) Pressure Sand filters:
Two nos. of pressure sand filters of higher capacity is provided. The suspended solid present in
the secondary clarified effluent is removed in these filters. Filtered effluent is then collected into
treated sump-II for final disposal.

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99
 Figure 9.2 Process flow diagram of ETP (Courtesy: Draw.io)

Process flow description

Process effluents consist of water with aromatics/ hydrocarbon pumped to ETP. All non-benzene
hydrocarbons are collected in underground drainage and pumped to slops tank via underground
tank. All floor wash water is routed to ETP via channels to pit. Effluents from tank farm are
collected in a pit and periodically pumped to ETP Various steps in effluent treatment unit are
given below:
(i) Free oil separation:
Effluent from plant contains free as well as emulsified oil. For removal of free oil, effluent is
passed through a tank in which corrugated plate interceptors are provided wherein free oil settled
as thin layer at the top is removed by an oil skimmer and transferred to oil tank. Oil from tank is
pumped to slop tank. Effluent free from free oil overflows in to dissolve air floatation (DAF)
unit. (ii) Emulsified oil removal:
Effluent contains emulsified oil to very small extent and for removal of this oil, dissolve air
floatation unit is provided which also reduces organic content of effluent. In this unit, re-
circulated effluent saturated with air is diffused at high pressure. When it is released to

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100
atmosphere, due to buoyancy effect minute oil droplets and other suspended particles rise to the
top.
Sediment particle settled at the bottom of the unit are swept in to sludge tray by a scrapper
attached to rotating middle shell. The sludge generated is taken in to sludge drying beds for
drying. Polyelectrolyte is added in to DAF unit so that it breaks emulsified oil and makes it
possible to remove the oil.
(iii) Biological treatment:
This treatment is given to effluent in order to reduce biological oxygen demand, chemical
oxygen demand and suspended solids. Effluent is taken into aeration tank and then secondary
classifier.
In aeration tank, micro-organisms will be developed. Some nutrients like urea solution, cow dung
are also added. Microorganisms will act on organic effluents. Process is based on activated
sludge process with extended aeration principle. Air is supplied for aeration purpose.
In case of effluent containing benzene in it, activated carbon powder is used. This will adsorb
non degradable organic material. Effluent from aeration tank is taken to secondary settling tank.
Suspended solids are removed here. The effluent enters centrally near bottom of tank and an
agitator is rotating at 0.5 RPM which helps in setting of suspended solids. Settled solids are
taken to sludge beds.

9.6 Conclusion:

“Safety first” is a slogan which we seen in every industry. Even, there is a celebration of “Safety
week” in most of the industries. Safety of equipment that salvage from corrosion, damage,
failureness. Safety of any piping from leakage, bounding and breakage. Safety from any
hazardous chemical to prevent fire and explosions. Safety equipments are provided for
controlling or preventions of high pressure & temperature of fluid. And mainly safety of all
human which are working in industry and plant from slippery area, fire explosions, falling from
heights, from contacting of any body part with hazardous chemicals like eye, skin, inhalation
and ingestions etc. But safety measures are provided in MSDS of all chemical substance which
contains information about the hazardous behavior of them (health, fire, reactivity and
environmental) and how to work safely with those chemical products.

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101
We live in an environment. So, environment should be well protected by all the industries. There
are certain environmental norms fixed by GPCB which should be maintaining by every industry.
In WNA plant, there is a analyzer for the absorption tower discharge and stack discharge. These
analyzers measures quantity of NOX discharges from these equipments. Because NOX are very
hazardous for human health. Hence, It should be maintain under the range given by GPCB. Data
from these analyzers are directly going to GPCB headquarter, Gandhinagar. GPCB monitored
this data constantly and if there is any clause violation by company, then they can take strict
actions against respective industry.

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102
 CHAPTER 10
PLANT LOCATION AND PLANT LAYOUT
10.1 Introduction:
Present chapter comprises of various factors affecting the plant location and plant layout. The
Layout of Weak Nitric Acid-1 is also shown.

10.2 Plant Location:

Plant location is however one of the most important part of final planning. Selection of suitable
location of the plant is very important because success of the plant is based on this point. The
geographic allocation 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, but other factors, such as room for expansion and general living
conditions, are also important.

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An approximate idea as to the plant location should be obtained before a design project reach
detailed-estimate stage, and firm location should be established upon completion of the detailed-
estimate design. The choice of the final site should first be based on a complete survey of the
advantage sand disadvantages of various geographical area and, ultimately ,on the advantage
sand disadvantages of available real estate.
The following factors should be considered in choosing a plant site:
• Raw materials
• Markets
• Power and fuel
• Climate
• Transportation facilities
• Water supply
• Waste disposal
• Labor supply
• Taxation and legal restrictions
• Site characteristics
• Flood and fire protection
• Community factors
The factors that must be evaluated in a plant-location study indicate the need for a vast amount of
information, both quantitative (statistical) and qualitative.

Raw materials:
The source of raw materials is one of the most important factors influencing the selection of a
plant site. This is particularly true if large volumes of raw materials are consumed, because
location near the raw-materials source permits considerable reduction in transportation and
storage charges. Attention should be given to the purchased price of the raw materials, distance
from the source of supply, freight or transportation expenses, reliability of supply, purity of the
available raw materials, and storage requirements.
Market:
The location of market so intermediate distribution centers affects the cost of product distribution
and the time required for shipping. Proximity to the major markets is an important consideration
in the selection of a plant site, because the buyer usually finds it advantageous to purchase from

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nearby sources. It should be noted that markets are needed for byproducts as well as for the
major final products.
Power and fuel:
Power and steam requirements are high in most industrial plants, and fuel is ordinarily required
to supply the utilities .Consequently ,power and fuel can be combined as one major factor in the
choice of a plant using electrolytic processes are often located near large hydroelectric
installations. If the plant requires large quantities of coal or oil, location near a source of fuel
supply may be essential for economic operation. The local cost of power can help determine
whether power should be purchased or self-generated.

Climate:
If the plant is located in a cold climate, costs may be increase by the necessity for construction of
protective shelters around the process equipment, and special cooling towers or air-conditioning
equipment may be required if the prevailing temperature are high. Excessive humidity or
extremes of hot or cold weather can have a serious effect on the economic operation of a plant
and these factor should be examined when picking a plant site.
Transportation facilities:
Water, rail roads and highways are the common means of transportation used by industrial
concerns. The kind and amount of products and raw materials determine the most suitable type
of transportation facilities. In any case, careful attention should be given to local freight rates and
existing railroad lines. The proximity to rail road center sand possibility of canal, river, lake, or
ocean transport must be considered. If possible, the plant site should have access to all three
types of transportation and certainly, at least two types should be available. Effective
transportation facilities for the plant workers are necessary.
Water supply:
The process industries use large quantities of water for cooling, washing, steam generation and
raw material. The plant therefore must be located where a dependable supply of water is
available .The temperature, mineral content, silt or sand content, bacteriological content and cost
for supply and purification treatment must so be considered when choosing a water supply.
Waste disposal:
In recent years, many legal restrictions have been placed on the methods for disposing of waste
materials from the process industries. The site selected for a plant should have adequate capacity

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 and facilities for correct waste disposal. Even though a given has no restrictions on pollution, it
should not be assumed that this condition will continue to exist. Waste disposal can be
accomplished by water, land, or air dispersal. In choosing a plant site, the permissible tolerance
levels for the various methods of waste disposal should be considered and attention should be
given to potential requirements for additional waste- treatment facilities.
Labor supply:
The type and supply of labor available in the vicinity of a proposed plant site must be examined.
Consideration should be given to prevailing pay rates, restrictions to number of hours worked
per week, competing industries that can cause dissatisfaction or high turnover rates among the
workers, racial problems and variations in the skill and intelligence of the workers.
Taxation and legal restrictions:
State and local tax rate so property, income, unemployment insurance and similar items vary
from one location to another. Similarly, local regulations on zoning, building codes, nuisance
aspects and transportation facilities can have a major influence on the final choice of a plant site.
10.3 plant Layout:
10.2.1 General:

 Layout of WNA plant will be determined on the basis of several factors such a safety,
increased production, better utilization of labor, and shorter manufacturing time.all
contributing to lower the cost of production of Weak Nitric Acid. For optimization among
all these factors, following principles have been adopted.

10.2.2 Detailed about factor affecting plant layout

Equipment layout

 WNA plant is divided in different sections. The equipment in WNA plant is at different
floor, this will enable not only in saving in floor space area, but also each and every
equipment will have easier accessibility for replacement or maintenance.  There is
ample space around plant for initial construction and maintenance.

Plant layout

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  Enough attention has been given in allotting space on each section to take care to future
expansion or modification of plant capacity. Plant in its present condition is capable of
providing space for replacement of equipment with higher capacity.

Utilities servicing
 The distribution of air, cooling water, steam and power is quite flexible in the plant.
There is one distribution cooling water headed and one common receive cooling water
from all of the heat exchangers of the plant
Building

 The building will have approximate 25ft wide road on every sides of plant, thus allowing
any truck to reach plant location for replacement or dismantling of any equipment.
 The control room is near to the WNA plant.
Roads

 The building will have approximate 25ft wide road on every sides of plant, thus allowing
any truck to reach plant location for replacement or dismantling of any equipment .
Safety

 Safety related all the equipment and safety alarms are provided at all the critical pointsin
the plant.

Page 107
Figure 10.1 Plant Layout of Weak Nitric Acid-1 plant (Courtesy: Draw.io)

Page 108
 Table 10.1 Summary Table of Plant Layout of WNA-1

Symbol Description

P.F. Panel Filter

R.F. Rollamatric Filter

B.F. Back Filter

E1 Evaporator-1

E2 Evaporator-2

D.S.1 Drop Separator-1

D.S.2 Drop Separator-2

P NH3 Pre heater

R Reactor with Waste Heat Re boiler

M NH3-Air Mixture

C.C. Catalytic Column (BASF column)

A.C. Absorption Column

B.T. Bleaching Tower

T1 Tail Gas Heater-1

T2 Tail Gas Heater-2

T3 Tail Gas Heater-3

T4 Tail Gas Heater-4

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10.4 Conclusion:

The choice of final site should be 1 st based on complete survey of advantages and disadvantages
of various geographical areas as well as all the points mentioned in this chapter. This chapter has
complete view of plant location. The factors should keep in mind is : raw material availability,
location and market areas, energy availability, climate, transport, water and labor supply, waste
disposal, legal restrictions and finally site characteristics.

GNFC is at very decent place where it has good transportation facility as well as it has huge land
for township too. So that employees can live there with their families and can go to their
workplace easily. So, employees can satisfy with the facilities provided by company and they
can manage both family and work very easily. So, by this all aspects, Plant location is very
important.

Page 110
 CHAPTER 11
COST
ESTIMATION

11.1 Introduction:
Present chapter comprises cost of each equipment used in the plant, direct and indirect cost, total
production cost, total capital investment of the WNA-1 plant. It also gives information about rate
of return, payback period and breakeven point.

11.2 Cost of each equipment used in plant: Cost

of Absorption tower:

• Inside diameter of column = 2.46 m

• Thickness of column = 6 mm
• Density of fluid = 990.75 kg/m3
• MOC = SS-304

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 • Cost of MOC = 250 Rs./kg
• Cost of fabrication = 30 Rs./kg
• Cost index = 1.6

Weight of absorption column = Volume * Density

= (Π/4*(d2*t)) * 999.75

= (0.785*2.462*6*10-3*999.75)

= 2849.59 kg

Weight of absorption column = 2849.59 kg

Cost of absorption column = Cost of MOC + Cost of fabrication

= 24993.75*250 + 24993.75*30

Cost of absorption column = 62,50,000 Rs.

WNA-1 plant is commissioned in year of 1990. So, this cost is the cost of absorption column
in 1990 year. Here, a Cost index is 1.6. Hence, cost of absorption column in year 2018,

= 1.6*62,50,000
Cost of absorption column in year 2018 = 1,00,00,000 Rs.

By this way, cost of each equipment used in plant is mentioned in Table 11.1.

Table 11.1 Cost of the equipments used in plant

Name of equipment Capacity(m3) Cost per unit No. of Units Total Cost

(In rupees)

Cooling 10 24,22,785 1 24,22,785

Water Evaporator

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Chilled 10 32,00,000 1 32,00,000

Water Evaporator

NH3 pre heater 6 10,80,000 1 10,80,000

NH3 air mixture 15 9,93,000 1 9,93,000

Reactor vessel 22 5,00,00,000 1 5,00,00,000

Waste Heat Re boiler, 12 400,00,000 1 4,00,00,000

Steam Drum and

Economizer

BFW Pre heater 12 14,75,000 2 29,50,000

Tail gas heater 12 64,98,000 4 2,59,92,000

De aerator drum 4 14,40,000 1 14,40,000

Cooler condenser 8 84,72,266.667 3 2,54,16,800

Absorption tower 25 1,00,00,000 1 1,00,00,000

Bleaching column 7 28,00,000 1 28,00,000

Instrument air storage 3 9,00,000 2 18,00,000

Tanks

BFW and process water 4 9,00,000 2 18,00,000

storage tanks

Cooling water system 5 50,00,000 1 50,00,000

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 Blow down vessel with 6 10,00,000 5 50,00,000

dosing stations

Drop Separator 4 5,00,000 2 10,00,000

Air compressor and 12 60,00,000 1 60,00,000

NOx compressor

Pumps 4,00,000 15 60,00,000

Stack 20,00,000 1 20,00,000

Total Purchased Equipment Cost (PEC) = Rs. 23,64,37,200

11.3 Direct Cost:

Table 11.2 Direct Cost

Sr. Components Assumed % of Total PEC Cost( In Rupees)

No. (Purchase Equipment Cost)

1 Purchased equipments 100 % 23,64,37,200

2 Purchase equipment 20 % 4,72,87,440

installation

3 Instrumentation 5% 1,18,21,860

4 Piping 20 % 4,72,87,440

5 Electrical cost 15 % 3,54,65,580

6 Building 15 % 3,54,65,580

7 Yard improvement 2% 47,28,744

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 8 Service facilities 5% 1,18,21,860

9 Land 5% 1,18,21,860

Total Direct Cost = Rs. 44,21,37,564

11.4 Indirect Cost:

Table 11.3 Indirect Cost

Sr. Components Assumed % of Total PEC Cost

No. (Purchase Equipment Cost) ( In Lakh)

1 Engineering & Supervision 15 % 3,54,65,580

2 Construction expenses 12 % 2,83,72,484

3 Contractor’s Fees 5% 1,18,21,860

4 Contingency 10 % 2,36,43,720

Total Indirect Cost: Rs 9,93,03,644

11.5 Fixed Capital Investment:

Fixed capital investment = Direct cost + Indirect cost

= 44,21,37,564 + 9,93,03,644
= 54,14,41,208

11.6 Total Capital Investment:

Working capital Investment = 20% of Total capital investment

So, Total Capital Investment = 54,14,41,208 / 0.80

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 = 87,68,01,510

& Working Capital Investment = 13,53,60,302

11.7 Total Production Cost:

Table 11.4 Raw materials cost for one hour

Raw Material Quantities per Cost Per kg (In Total Cost (In Rs.)
hour (In kg) Rs.)

Liquid Ammonia 7795.39 6 46,772

TOTAL 46,772

Raw Material cost = Rs. 46,772 per hr

So, Total raw material cost per year,

Total Raw Material Cost = 46,772*24*365 = 40,97,25,700 per year

11.8 Direct Production Cost:

Table 11.5 Direct Production Cost

Particulars Basis Chosen Cost (In Rupees)

Maintenance & Repairs 15 % of FCI 8,12,16,181

Operating Supplies 15% of WCI 2,03,04,045

Operating Labor (OL) 10 % of TPC 0.1X

Laboratory Charges 15 % of TPC 0.015X

Patents and Royalties 3 % of TPC 0.03X

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 Total 10,15,20,226 + 0.145X

Table 11.6 Fixed Charges

Particulars Basis Chosen Cost (In Rupees)

Depreciation 10 % of FCI 5,41,44,120

Interest 10 % of TCI 6,76,80,151

Local Taxes 4 % of FCI 2,16,57,648

Insurance 1 % of FCI 54,14,412

Total 14,88,96,331

Plant Overhead Cost = 60% of (Operating Labor + Maintenance & Repairs)

= 0.60 x (0.1X+ 8,12,16,181)

= 0.06X + 4,87,29,708

Table 11.7 General Expenses

General Expenses

Particulars Basis Chosen Cost (Lakh)

Administrative Costs 25 % of OL 0.25X

Distribution & Marketing Costs 20 % of TPC 0.2X

R&D 5 % of TPC 0.05X

Total 0.5X

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Total expenditure for production per year = Direct Production Cost

+ Fixed charges + Plant Overhead Cost + General Expenses

= 10,15,20,226 + 0.145X + 14,88,96,331+ 0.06X + 4,87,29,708

+ 0.5X

= 29,91,46,265 + 0.705X

Total production cost = Total Expenditure + Raw material cost

X = 29,91,46,265 + 0.705X + 40,97,25,700

∴X = Rs. 240,29,55,814

11.9 Profit Calculation:

Selling price of product = 7 Rs per kg

Selling price for 1071 MTPD production of 61.5% Weak Nitric Acid per year,

= 1071000*365*7

Selling price per year = Rs. 273,64,05,000

Gross profit = Selling price – Total production cost

= 273,64,05,000 – 240,29,55,814

= Rs. 33,34,49,186

If 30% Income tax then,

∴Amount of Income taxes = Rs. 10,00,34,755

Surcharge = 4 % on Income taxes = 0.04 x 10,00,34,755 = Rs. 40,01,390

Net profit = Gross profit – Income Taxes – Surcharge

= 33,34,49,186 – 10,00,34,755 – 40,01,390

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 = Rs. 22,94,13,040

11.10 Rate of Return:

R.O.R before Income taxes = (Gross profit /(Total Capital Investment) x 100

= (33,34,49,186/ (87,68,01,510) x 100

= 38.03 %

R.O.R after Income taxes = (Net profit/(Total Capital investment)x100

= (22,94,13,040/87,68,01,510)x100

= 26.16
% 11.11 Payout Period:

Pay out period = F.C.I / NET PROFIT

= 54,14,41,208/22,94,13,040

= 2.36 years

11.12 Turnover Ratio:

Turnover Ratio = Gross Annual Sales / Fixed Capital Investment

= 33,34,49,186 / 54,14,41,208

= 0.71

11.13 Break Even Point:

Total production cost = Total income

240,29,55,814 = X*1071000*7

X = 302.52

Hence, after 303 days, Profit will start in a continuous production for 1 year.

Page 119
11.13 Conclusion:

Cost estimation is most important chapter in this report. Because without this chapter, we cannot
start industry without knowing rate of return, breakeven point, pay out period etc. All calculation
is based on the market values of equipment. After calculation of all costs, we have an idea about
purchased equipment cost. We calculate direct-indirect investments, depreciation, plant overhead
cost, local taxes, insurance policy, general expenses etc.

Page 120
 CHAPTER 12
CONCLUSION
From this training period of 2 years, first of all, we have seen a giant industry by our neck eyes.
Earlier we have seen this type of industry in photos and books. We have seen many new
equipments like glass lined in exchanger in CAN plant, glass lined stripper in TDI plant, prilling
tower in urea plant, granular in ANP plant etc. Overall, it was very good exposure of 2 months.

In this training period, we spent two months in Weak Nitric Acid (WNA) plant. We come to
know history of nitric acid, applications of nitric acid, different methods of production of nitric
acid etc. Material and energy balances are an important part of any chemical industry and
through which a process is selected and the plant is operated. In material balance chapter, by

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fixing production of 61.5% WNA 630 MTPD, we require 7795.39 kg/hr NH 3 and 90525.75 kg/hr
air as a raw material.
In energy balance chapter, we tried to do energy balance on evaporator-1, evaporator-2, Pre
heater, Reactor, waste heat boiler, tail gas heater and economizer. Somehow I get some
knowledge about heat integration by energy balance chapter.

Utilities are also very important in a chemical industry. An engineer must have its knowledge. In
Plant utilities chapter, there is information about DM water, steam generation plant, cooling
towers etc. In chapter 6, details of equipment are provided for ease of understanding. equipment
details are shown containing MOC, Max and Min temperature and pressure value for each
equipment. Designing of equipment is an important role of a chemical engineer to know about
capacity, MOC, volume etc. In chapter 7, In design chapter, We found thickness of different
course for WNA storage tank, efficiency of NOx compressor, Power require for centrifugal pump
as well as NPSH for centrifugal pump in minor equipment design section. For major equipment,
we found number of sieve trays of absorption tower, height of absorption column, nozzle, flange,
bolt calculation as a part of mechanical design.

In chapter 8, various pumps used in the plant are listed in table. In every industry, the equipment
is labeled with specific codes and colors. These codes must be known before actually going in
the plant. In chapter 9, there is a discussion like every industry has some safety protocol which
has to be followed by all whoever present in the company. They lead “safety first”, no matter
how much expense. We also need to take care about environment.

Plant location should be appropriate before setting up the plant. By this statement, we meant
plant should be located where there is continuous supply of water, electricity and where transport
and raw material is easily available. With the assumed costs of each equipment, we can estimate
the cost of plant along with depreciation. From it, we got the sight of breakeven point, rate of
return and payout period.

Page 122
 APPENDIX 1
MSDS
1. Nitric Acid (50-70%)

SECTION 1: Identification of the substance:

1.1 Product Identifier:

Product name: Nitric Acid

Synonyms: Aqua Fortis; Azoic Acid

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Molecular Weight: 63.01 kg/kmol

Chemical Formula: HNO3 SECTION

2: Hazard Identification:

Classification of the substance or mixture:

Acute Inhalation Toxicity Category 3 - H331

Skin Corrosion/Irritation Category 1A - H314
Corrosive to Metals Category 1 - H290

SECTION 3: Composition/Information on Ingredients:

3.1 Substances:

Chemical EC-No CAS-No Weight % Classification Reach

Name Registration
Number
Nitric acid 231-714-2 7697-37-2 20-65 Ox. Liq. 2 H272 01-
2119487297-
23-0
027

SECTION 4: First aid measures:

4.1 Description of first aid measures

General Advice Immediate medical attention is required. Remove from exposure Lie down.
Do not breathe vapors, mist or gas. Do not get in eyes, on skin, or
on clothing. Use first aid treatment according to the nature of the
injury: Flush with plenty of water or Diphotherine.

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 4.2 Most important symptoms and effects, both acute and delayed
Main symptoms Causes severe skin burns and eye damage. Can burn mouth,
throat, and stomach. Pain, blistering, Burning feeling

and temporary redness. SECTION 5 Fire fighting measures:

5.1 Extinguishing media

Suitable Extinguishing Media:

The product itself does not burn. Use extinguishing measures that are appropriate to local

circumstances and the surrounding environment. Unsuitable Extinguishing Media: None

known.

SECTION 6: Accidental release measures:

6.1 Personal precautions, protective equipment and emergency

procedures
Ensure adequate ventilation. Evacuate non-essential personnel. Avoid contact with skin, eyes
and clothing. Avoid breathing vapors or mists. Do not touch or walk through spilled material. In
case of insufficient ventilation, wear suitable respiratory equipment.
SECTION 7 Handling and storage:

7.1 Precautions for safe handling

Handle in accordance with good industrial hygiene and safety practice. Avoid contact with
skin, eyes and clothing. Avoid breathing vapors or mists. Contact lenses should not be worn
when working with this product. Wash hands thoroughly after handling. Do not eat, drink and
smoke in work areas; wash hands after use; remove contaminated clothing and protective
equipment before entering eating areas. See annex for more detailed information.

SECTION 8 Exposure control/Personal protection:

8.1 Control parameters

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 Chemical European The United France Spain Germany
name Union Kingdom
Nitric acid STEL: 1 ppm STEL: 1 ppm STEL: 1 ppm VLA-EC:1 STEL: 1 ppm
STEL:2.6 STEL:2.6 STEL:2.6 ppm STEL:2.6
mg/m3 mg/m3 mg/m3 mg/m3
VLA-EC: 2.6
mg/m3

SECTION 9: Physical and chemical properties:

Information on basic physical and chemical properties:

Physical state @20°C

Appearance fluid

Color Colorless / Brown

Odor Pungent

Odor threshold 0.75 - 2.5 ppm

pH <1

SECTION 10: Stability and Reactivity:

Reactivity: Corrosive to Metals.

Chemical stability: Stable under normal conditions. SECTION

11: Toxicological Information:

11.1 Information on toxicological effects

Acute Toxicity

Ingestion Causes burns of the upper digestive

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 Skin Contact Corrosive to skin. Corrosive to eyes.

Inhalation Toxic if inhaled.

SECTION 12: Ecological Information:

Toxicity: Based on available data, the classification criteria are not

met.
May cause adverse effects in the aquatic environment due to changes in pH.

Chemical Toxicity to Algae Toxicity to Fish Toxicity to Toxicity to

name Micro- Daphnia and
Organisms Other
aquatic
invertebrates
Nitric acid Median lethal Median lethal
pH (96h) 3-3.5 pH (48h) 4.4-
(Lepomis 4.7
macrochirus) (Ceriodaphnia
Median lethal pH dubia)
(96h) ca.
3.7 (Oncorhynchus
mykiss)

SECTION 13: Disposal consideration:

13.1 Waste treatment methods:

Waste from residues/unused products: Dispose of in accordance with local regulations.

Contaminated packaging: Empty containers should be taken to an approved waste handling

Site for recycling or disposal.

SECTION 15: Regularity Information:

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Safety, health and environmental regulations/legislation specific for
the substance or mixture:
Restrictions on use: Dangerous substance category per Seveso Directive (2012/18/EU): H2

SECTION 16: Other Information:

Full text of H-Statements referred to under sections 2 and 3:

H272: May intensify fire, oxidiser.

H290: May be corrosive to metals.

H314: Causes severe skin burns and eye damage.

H331: Toxic if inhaled.

EUH071: Corrosive to the respiratory tract.

Page 128
 APPENDIX 2

EXCEL SHEET OF NOZZLE AND FLANGE

Page 129
 1. Nozzle Calculation:

Water Water NO2 Condensate Colum

Nozzle Manhole Inlet Outlet NO2 inlet outlet Outlet n1
Diameter 1 0.1 0.1 0.2 0.2 0.1 m
Thickness
trn 0.002297 0.000229 0.000229 0.000459 0.000459
819 782 782 564 564 0.000229782 m
tdn 0.004297 0.002229 0.002229 0.002459 0.002459
819 782 782 564 564 0.002229782 m
tn 0.005 0.005 0.005 0.005 0.005 0.005 m
Outside
Diameter 1.01 0.11 0.11 0.21 0.21 0.11 m
Opening
Diameter 1.004 0.104 0.104 0.204 0.204 0.104 m

0.007311 0.000757 0.000757 0.001485 0.001485

A 378 354 354 579 579 0.000757354 m^2
0.000720 7.46461E - 7.46461E- 0.000146 0.000146
As 622 05 05 421 421 7.46461E-05 m^2
Ho(Given) 0.1 0.1 0.1 0.1 0.1 0.1 m
0.003012 0.000312 0.000312 0.000612 0.000612 0.000312
0.054881 0.017663 0.017663 0.024738 0.024738
Ho 691 522 522 634 634 0.017663522
Hi 0 0 0 0 0 0 m
7.70737E - 9.78636E - 9.78636E- 0.000125 0.000125
Ao 05 05 05 694 694 9.78636E-05 m^2
Ai 0 0 0 0 0 0 m^2
7.70737E - 9.78636E - 9.78636E- 0.000125 0.000125
An=Ao+Ai 05 05 05 694 694 9.78636E-05 m^2

0.000797 0.000172 0.000172 0.000272 0.000272

As+An 696 51 51 115 115 0.00017251 m^2

0.006513 0.000584 0.000584 0.001213 0.001213

A'=A-(As+An) 682 844 844 464 464
0.000584844 m^2
Reinforcemen
t Yes Yes Yes Yes Yes Yes
Ring Pad
Drpo 2.008 0.208 0.208 0.408 0.408 0.208 m
Drpi 1.01 0.11 0.11 0.21 0.21 0.11 m

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 Drpo-Drpi 0.998 0.098 0.098 0.198 0.198 0.098 m
tp' 0.006526 0.005967 0.005967 0.006128 0.006128
736 798 798 605 605 0.005967798 m
tp 0.002 0.001 0.001 0.002 0.002 0.001 m

2. Flange, Gasket, Hub and Bolt Calculation:

Flange
m 2.75 2.75 2.75 2.75 2.75 2.75
Y 25510000 25510000 25510000 25510000 25510000 25510000 N/m^2
Nmin 0.01 0.01 0.01 0.01 0.01 0.01 m

Gasket
1.0500246 1.0500246 1.0500246 1.0500246 1.0500246 1.0500246
76 76 76 76 76 76
1.0247071 1.0247071 1.0247071 1.0247071 1.0247071 1.0247071
Go/Gi 17 17 17 17 17 17
Go-
Gi(=2*Nmin) 0.02 0.02 0.02 0.02 0.02 0.02 M
0.8094833 0.8094833 0.8094833 0.8094833 0.8094833 0.8094833
Gi 48 48 48 48 48 48 M
0.8294833 0.8294833 0.8294833 0.8294833 0.8294833 0.8294833
Go 48 48 48 48 48 48 M

b0 0.005 0.005 0.005 0.005 0.005 0.005 M

b=b0 0.005 0.005 0.005 0.005 0.005 0.005 M

Dfi 1.01 0.11 0.11 0.21 0.21 0.11 M

Gi 1.02 0.12 0.12 0.22 0.22 0.12 M
1.0452012 0.1229648 0.1229648 0.2254355 0.2254355 0.1229648
Go 6 54 54 66 66 54 M
0.0126006 0.0014824 0.0014824 0.0027177 0.0027177 0.0014824
N(old) 3 27 27 83 83 27 M
N 0.01 0.01 0.01 0.01 0.01 0.01 M

b0 0.005 0.005 0.005 0.005 0.005 0.005 M

b 0.005 0.005 0.005 0.005 0.005 0.005 M

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 1.0326006 0.1214824 0.1214824 0.2227177 0.2227177 0.1214824
G 3 27 27 83 83 27 M

Hub
g0 0.005 0.005 0.005 0.005 0.005 0.005 m
g1 0.007075 0.007075 0.007075 0.007075 0.007075 0.007075 m
H 0.0075 0.0075 0.0075 0.0075 0.0075 0.0075 m
Conditi 0.2766666 0.2766666 0.2766666 0.2766666 0.2766666 0.2766666 0.333333
on 67 67 67 67 67 67 < 33

Bolt
db 0.01905 0.01905 0.01905 0.01905 0.01905 0.01905 M
Arb 0.0002850 0.0002850 0.0002850 0.0002850 0.0002850 0.0002850 m^2
fa N/m^
89456340 89456340 89456340 89456340 89456340 89456340 2
fb N/m^
79059002 79059002 79059002 79059002 79059002 79059002 2

413774.51 48679.354 48679.354 89245.483 89245.483 48679.354

Wm2 36 54 54 32 32 54 N
995737.87 23732.837 23732.837 62538.734 62538.734 23732.837
Wm1 53 7 7 7 7 7 N

0.0046254 0.0005441 0.0005441 0.0009976 0.0009976 0.0005441

Am2 35 69 69 43 43 69 m^2
0.0125948 0.0003001 0.0003001 0.0007910 0.0007910 0.0003001
Am1 7 91 91 39 39 91 m^2

Am(=Am1 or 0.0046254 0.0005441 0.0005441 0.0009976 0.0009976 0.0005441

Am2) 35 69 69 43 43 69 m^2
n' 16.228252 1.9092061 1.9092061 3.5002112 3.5002112 1.9092061
28 51 51 77 77 51
n 20 4 4 4 4 4
0.0308253 0.0252662 0.0252662 0.0258838 0.0258838 0.0252662
R 15 14 14 91 91 14 M
1.0858006 0.1746824 0.1746824 0.2759177 0.2759177 0.1746824
C1 3 27 27 83 83 27 M
1.0858006 0.1746824 0.1746824 0.2759177 0.2759177 0.1746824
C2=C1 3 27 27 83 83 27 M
0.1705575 0.1371955 0.1371955 0.2167058 0.2167058 0.1371955

Page 132
 Bs 63 78 78 27 27 78 M
1.0858006 0.1746824 0.1746824 0.2759177 0.2759177 0.1746824
C=C1=C2 3 27 27 83 83 27 M
Flange
fa 10004985 10004985 10004985 10004985 10004985 10004985 N/m^
4.8 4.8 4.8 4.8 4.8 4.8 2

fb 89456340. 89456340. 89456340. 89456340. 89456340. 89456340. N/m^

76 76 76 76 76 76 2
1.1248506 0.2137324 0.2137324 0.3149677 0.3149677 0.2137324
Dfo 3 27 27 83 83 27 M
413774.51 48679.354 48679.354 89245.483 89245.483 48679.354
wm 36 54 54 32 32 54 N
hG 0.0266 0.0266 0.0266 0.0266 0.0266 0.0266 M
899876.58 12455.039 12455.039 41862.770 41862.770 12455.039
H 89 29 29 96 96 29 N
3.1469569 0.6314379 0.6314379 1.4664403 1.4664403 0.6314379
K 66 02 02 51 51 02
0.0617821 0.1379249 0.1379249 0.0905056 0.0905056 0.1379249
01 24 24 89 89 24
tf' 0.0657962 0.0187554 0.0187554 0.0221572 0.0221572 0.0187554
37 55 55 26 26 55 M
tf 0.03 0.02 0.02 0.02 0.02 0.02 M

Page 133
REFERENCES
• Perry’s chemical handbook by DON W. BROWN and ROBERT H. PERRY,8TH edition,
Mc-Graw hill publication
• Introduction to process engg and design by S.B,Thakore and B. I. Bhatt
• Mass Transfer Operation by Robert e. Treybal, Mc-Graw hill publication
• Unit Operation of Chemical Engineering by Maccabe and smith, Fourth Edition,
McGraw Hill
• STOICHIOMETRY by I B Bhatt AND S M Vora 3rd edition, Tata mc-Graw hill
company  Wikipedia for different component properties

• WNA-1 plant manual

• WNA-1 plant equipment data sheet
• Elements of Chemical Reaction Engineering by H. Scott Fogler 2nd Edition
• Joshi M.V.; Mahajani V.V. Process Equipment Design, 3rd ed.; Macmillan India Ltd:
New Delhi
• Peters Max S.; Timmer and haus Klaus D. Plant Design and Economics for Chemical
Engineers, 4th ed.; McGraw-Hill, Inc.: New York, 1991; p.300
• Coulson and Richardson Chemical Engineering volume 6: Woburn 1999