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Hexamine PDF
Hexamine PDF
Hexamine PDF
2013-2014
SHRI.K.J.POLYTECHNIC,BHARUCH
HEXAMINE
2013-2014
Project Report
2013-2014
A
PROJECT REPORT
ON
“HEXAMINE”
PREPARED BY :-
2. 116450305054 JAYVEERSINH
GUIDED BY:-
Mr.R.I.RATWANI
( H.O.D)
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2013-2014
Gujarat technological university is one of the biggest university which offers the
various types of courses likes masters,bachelors,diploma,post
graduate,medical,pharmacy,etc..
This project is given by GTU to the partial fullfillment of the diploma in chemical
engg.
To undeerstand and analysed the various project done in the industry through
project
surveys and visiting of the industry . GTU also describe the meaning of giving the
project
to the enigneer in the 6th semister for well learning of the manufacturing of the
chemicals
and their detail study including the project management, production, properties of
the
chemical,economic evalution as per company capacity and dail production rate, it
also
include the site selection parameters which gives engineers the study of the plant
site setup
and the layout of the plant .
The reason of giving project to the engineers is to develop the leadership ,project
management ,surveys and detail study.
Thanks to GTU,
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HEXAMINE 2013-
2014
BHARUCH-392001
Date: / /2014
----------------------------- ------------------------------
Mr.R.I.Ratwani Mr.R.I.Ratwani
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Preface…
Teaching is the important knowledge, but training develops habits. It assures
that
Technical skills cannot be perfect without practical training… Hence, the
practical
training is grate valuable for Engineering Student the Actual aim of in Plant
training is to get all Operation and Process which are Carried Out in the
Industries
and More about the Chemical Equipment..
Practice makes a man perfect in practical training a person Deals with Many
technical
Problems. In real Operation and Process another Aim of in Plant training is to
learn
Industrial Management and Discipline.
The report provides preliminary information and gives an idea and in sigh into
the
process design aspects.
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ACKNOWLEDGEMENT…
D.Chemical Engineering
(3rd year)
INDEX
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PAGE
SR.NO SUBJECT
NO.
1 INTRODUCTION AND HISTORY OF PRODUCT 8
9 UTILITIES REQUIRED 43
12 ECONOMIC EVALUTION 57
15 CONCLUSION 85
16 REFERENCE 86
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CHAPTER -1
INTRODUCTION AND
HISTORY OF PRODUCT
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A detail process study was done on the Hexamine production plant in Semester VII.
All
the available processes were studied and the best suitable and feasible process was
selected. In this semester, Energy Balance, cost estimation etc. of the selected
process was
done on the basis of the future trend of demand and purity required. All the
utilities and the
supporting infrastructure required were determined.
This project report also consists of the designing of the selected process. The
designing
consists of sizing of the all the major equipments present in the process. A
detailed
mechanical design of the main Reactor was also done.
Rough plant layout is also prepared to get an idea of required plot area. A
detailed financial
study comprising Project cost estimate, Cost of production and financial analysis
was also
carried out. The project was found to be financially sound with an attractive pay
out
period.
Altogether this report consists of all the engineering and financial aspects
required for
setting up a Hexamine manufacturing facility.
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HISTORY OF HEXAMINE
The chemical structure of Hexamine is known in great detail. The carbon and
nitrogen
atoms are all equivalent. In the three dimensional structure, the nitrogen atoms
occupy the
summits of an octahedron. It crystallizes as rhombic dodecahedron. On heating it
sublimes
with decomposition at temperature above 200 oC but does not melt. Products of
thermal
decomposition include ammonia, hydrogen cyanide, methane, hydrogen, nitrogen and
resinous oil. Charring becomes apparent at about 280 oC when it is heated in sealed
tube.
Its heat of combustion (adjusted to 25 oC) is approx 1003.0 k cal per g mole (10).
thermo
dynamic properties as reported by change western per g mole at 25 oC are heat of
formation 28.8 k cal , free energy 102.7 k cal heat capacity 36.4 cal/ oC and
entropy
36.048cal/ oC . It is soluble in water and can be crystallized as a hydrate
(CH2)6N4.6H2O
which is stable at temperature below 14 C. Hexamethylene tetra amine forms a
saturated
aqueous solution containing 46.5% by weight at 25 oC. Its solubility decreases with
increase in temperature; the solubility also reduced by dissolving ammonia.
Hexamethylene tetra amine is soluble in chloroform (13.4g /100 ml at RT) and ethyl
alcohol (2.9 g /100 ml at RT) and methanol (7.3 g /100 ml at RT). It is slightly
soluble
(less than approx 1%) in carbon tetra chloride, acetone, benzene and ether and it
is
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Hexamine is reduced with zinc and acetic acid or by electrolytic means to give
methyl
amines. It forms addition compounds with chlorine, bromine and iodine. Its tendency
to
form addition complexes is highly marked in case of in case of metallic salts which
may be
illustrated by silver nitrate and mercuric chloride derivatives.
Hexamine is analyzed by boiling a weighed sample (approx.) with 40ml 1N sulfuric
acid
until all formaldehyde is vaporized, and titrating the excess acid. Each ml of 1N
acid
consumed is equal to 0.03504g of hexamine.
Hexamine is not poisonous but some human beings are sensitive to it and are
subjected t
skin rash when they come in contact with it t its vapours. If toxic symptoms are
observed
then a physician may be consulted.
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CHAPTER-2
PRESENT STATUS
INCLUDING LIST OF
INDUSTRIES
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CHAPETER : 3
PROPERTIES AND
APPLICATION OF PRODUCT
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Hexamine does not melt and sublimates almost under composed in a vacuum at 230-
270°C.Decomposition begins at temperatures above 270°C. Hexamine is highly soluble
In water. Solubility decreases slightly as temperature rises.
The solutions are slightly alkaline, with pH values usually between 8 and 9. In
organic
Solvents, Hexamine is barely soluble.
The following table shows the solubility of the pure product in a number of
important
Solvents
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Apart from its tendency to stick, Hexamine is not subject to changes during storage
and can
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be used even after several months. To improve the flow properties, particularly for
the
grades marked free flowing, special highly dispersed silica are added.
These additives are chemically neutral for those areas in which these grades are
used. They
are essential to enable the product to be used effectively. When conducting a test
analysis of
these grades, it should be remembered that the ash content is higher and the
Hexamine
content lower.
When working with finely ground grades, precautionary measures must be taken
against
explosive dust/ air mixtures. Explosion pressure can reach 12.7 bars, with a
maximum
pressure build-up speed of 370 bar/sec.
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A hexamine fuel tablet is a very useful form of hexamine used as solid fuel in
tablet form.
The tablets burn smokelessly, have a high energy density, do not liquify while
burning and
leave no ashes. Invented in Murrhardt, Germany in 1932, the main component is
hexamine.
The tablets are used for cooking by campers, the military and relief organizations.
The
tablets are often used with disposable metal stoves that are included with Combat
ration
packs. Backpackers concerned with ultra light gear, tend to buy or make their own
much
lighter stove. An Esbit stove can be made by cutting off the bottom of an aluminum
pop can,
and turning it upside down to support the fuel tab; a pot can be supported above
this with a
circle of mesh chicken wire or tent pegs. Although not ideal, fuel tab can be
placed on a rock
or on the dirt, with a pot supported above by rocks. Another common use is to
provide a safe
heat source for model steam engines.
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Fuel tablets are ultra light weight compared to other stove options.Compact; entire
stove
system and fuel can be stored inside cooking pot; use plastic bags inside and out
due to
burned residue. They are simple.
Boils water, but not ideal for any cooking requiring simmering. Expensive fuel and
less
widely available, compared to alternatives such as alcohol or petrol stove fuels.
Hexamine tablets give off noxious fumes, requiring foods being cooked to be
contained in a
receptacle such as a pot or pan. Burned tabs will leave a sticky dark residue on
the bottom of
pots, although this can be easily removed by rubbing the pot on grass.
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CHAPTER-4
PROPERTIES OF
RAW MATERIALS
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FORMALDEHYDE
AMMONIA
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CHAPTER-5
VARIOUS PROCESSES OF
MANUFACTUING
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6CH 2 O 4 NH 3 C6 H 12 N 4 6H 2 O
The reaction is strongly exothermic. The normally expected temperature rise should
not,
take place, since at, too high a temperature there is the danger of producing by-
products.
The first plants for production of hexamine operated at, a reaction temperature of
about
20 oC, and used aqueous solutions of formaldehyde and ammonia as raw materials in
the batch process. In some cases a part of the ammonia was gaseous. The reaction
temperature and the relatively great, heat of reaction has always been difficult to
control.
To provide the cooling surfaces, large units of correspondingly large volumes were
necessary. The procedure was batch wise and required as much as 36 hours per
charge.
The hexamine obtained in solution (10 to 20% depending on the consent, ratio of the
raw
materials) was concentrated in vacuum (about 40 mm. Hg.) until hexamine was
crystallized during a continuous addition of ammonia. After this operation,
requiring 24
hours, the product obtained was re crystallized to hexamine.
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fitted still pot. In order to prevent losses of ammonia or formaldehyde gas, their
effective
concentrations in the reactor must be very low, or they would pass off with the
vapors and
be lost to the reaction. The optimum temperature of the reaction may be controlled
by
varying the total pressure at which the reaction mixture is allowed to boil or by
controlling
the partial pressure by the presence of noncondensable gases. The reaction under
these
desirable conditions is extremely fast. The solid hexamine is removed continuously
from
the reactor either as fine white crystals or as a solution of any desired
concentration. The
heat of the reaction and of the hydration of the starting gases performs the entire
water
removal and eliminates the need of additional evaporative equipment and heat.
3. Hexamine manufacture:
As we know the lower aldehydes react very rapidly with ammonia without any need of
catalysts and also at low temperature. This phenomenon is used for the production
of
Hexamine. Aqueous phase reaction of ammonia and formaldehyde is carried out in a
semibatch manner. In such plant reactors it is from 1 to 2 metric tons per day for
a reactor
of relatively small size with a yield on a one-pass basis of above 99% for both
ammonia
and formaldehyde.
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CHAPTER-6
MOST SUITABLE PROCESS
IN DETAIL(DESCRIPTION)
WITH FLOW SHEET
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From the above described processes we select the third process of Hexamine
manufacture.
The description the first process itself tells that how disadvantageous the process
is. The
reaction is strongly exothermic and hence it is difficult to control the heat
evolved and this
high temperature may lead to formation of byproducts that may be harmful. Due to
high
temperature evolution large cooling surfaces are needed to be provided leading to
increase
in the cost of manufacture. The earlier method of Hexamine production used batch
process
hence the process is very much time consuming as compared to our selected process.
The
labor cost is also added as the process is a batch one.
In the second given process both the reactants react in gaseous form and hence it
is very
difficult reaction. This is because ammonia in the gaseous form may prove very
dangerous.
Moreover the concentrations of ammonia and formaldehyde must be kept low. Otherwise
there will be loss of the gases (due to passing off with vapours) and ultimately
cause loss to
the reaction.
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HEXAMINE 2013-2014
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PROCESS DESCRIPTION
The feed of aqueous formaldehyde from the storage tank is charged in an agitated
and
refrigerated steel reactor. Ammonia and formaldehyde both are stored in storage
tanks.
Ammonia is then introduced in the formaldehyde solution. Ammonia added is kept
slightly
in excess to prevent side reactions to occur. The reaction is continued and the pH
is
maintained to about 8. The formaldehyde for the reaction may be produced from
methanol.
The reaction mixture is kept for 9 hours. At this time the product should be
alkaline to
phenolphthalein. As the stoichiometry shows water formation takes place due to the
reaction. The mixture of Hexamine and water is then removed from the agitated steel
reactor.
The liquid product in the outlet is then sent for several unit operations for
achieving pure
Hexamine. Activated charcoal is added for filtration of the liquid product
(Hexamine) and
then the liquid is filtered through canvas in the filter press. The liquid is
evaporated at a
maximum temperature of 30 oC and the pressure is kept about 20-30 mmHg. Aqueous
ammonia is again added at a rate of 7 ml/min for stability. The remaining mass
comprising
of solids is washed and centrifuged with 1 Kg 25% of ammonia. The product is dried
in the
drier at 30 oC. By processing the mother liquor the yield may be increased to 96-
100%.
The hexamine waste water is sent for purification to waste water treatment or the
effluent
treatment plant and cation exchange processes.
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The effective treatment of hexamine waste water is one of the major problems or the
producers of Hexamine. The waste water generally contains residual amounts of
reactants
i.e. formaldehyde and ammonia. As well as residual amounts of Hexamine. It is very
essential for removal of these impurities from water. There is no general process
or
hexamine water treatment.
Firstly the waste water is sent for distillation to remove all the volatile
impurities. The
waste water is sent through cation resins to remove cations. The cation resin is
used such
that it can be regenerated. Then they are passed through exposure to ultra violet
rays or
bacteria culture (bacteriological treatment) or removal of formaldehyde.
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Chapter-7
MAJOR EQUIPMENT
REQUIRED
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Agitator reactor.
Capacity = 19500 kg
Volume of NaOH = 18.829 m3
Gross volume = 19.24 m3
Diameter = 2.3 m
Height = 4.6 m
T = 25o C
P = 1 atm
Thickness = 6 mm
Material = mild steel
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Filter press :
Substance volume
Fomaldhyde (2275 kg) 2.1292
50% NaOH (1950kg) 1.283
3.41 m3
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Centrifuge washer:
Substance volume
ammonia (3933.3 kg) 2.55 m 3
Water (3700 kg) 3.7 m 3
Gross volume = 1.5 x 6.25 = 9.375m 3
Diameter = 1.82 m
Length = 3.64 m
Thickness = 6 mm
Material = s.s
Ambient pressure and temperature.
Evaporator :
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Chapter-8
MAJOR
INSTRUMENTATION
REQUIRED
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Pressure Measurement:
Pressure Gauge:
The bourdon tube is most frequently used in the pressure gauge. A bourdon tube
consist of
a long think walled cylinder of non circular cross section sealed at the end, made
from
materials such as phosphor bronze, steel & beryllium copper, and attached by a
light line
work to the mechanism which operates the pointer. The other and of tube is fixed
and is
open for the application of the pressure which is to be measured.
The tube is soldered or wended to a socket at the based, through which pressure
connection
is made. Bourdon tube is available in many shapes like, c type, spiral, & helical.
Advantages:-
1. Cost is low
2. Construction is simple
3. Life is long
4. Efficiency is high
5. Tubes are in different range
Disadvantages:-
1. Spring gradient is low (50psig)
2. Shock and vibration effect
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Temperature Measurement:
Temperature has been defined in a variety of ways. One example defines temperature
as
the measure of heat associated with the movement of the molecules of a substance.
This
definition is based on the fact that the molecules of all matter are in continuous
motion that
is sensed as heat.
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While there are many types of temperature sensing devices, they can be classified
into two
major groups – temperature sensors and absolute thermometer. Three of the most
common
types of the temperature sensors are thermocouples, resistance temperature devices,
and
filled systems.
Flow Measurement:
Flow is one of the most difficult process variables to measure accurately. One of
the
simplest methods for determining the flow rate is the fluid per unit time method,
which
assumes a basic premise of the fluid mechanics that mass is a conserved quantity.
The
mass entering a system is equal to the mass leaving the system and both are
measured over
the same time interval.
This method for accurate flow measurement takes into consideration two basic
properties
of fluid, which are density and viscosity and their effect on the accuracy of flow
measurement. The instruments used are Differential pressure meter and orifice
plates
Level Measurement:
Level is measured at the position of the interface between phases, where the phases
are
liquid/gas, solid/gas, or immiscible liquid/liquid. Level is simply a measure of
height
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defining the position of the interface that is the surface where the two phases
meet with
respect to a reference point. This measurement is often converted to a volumetric
or
gravimetric quantity. So level may be measured directly by defining the position of
the
interface or indirectly by measuring another quantity, such as volume and
interfacing the
level measurement by converting the quantity to a level measurement.
Ph Meter:
In our required process we need to maintain pH of 8.0. Because of this we use the
following specifications.
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Method have been developed which minimizes the problems encountered when measuring
Ph in pure waters. The method uses a quality glass pH electrode and special set of
a “pure
water pH additive” & a special se of diluted buffers containing the same background
of
“pure water pH additive”.
Adding the pure water pH additive to the samples increases the ionic strength thus
reducing the noise and improving time. The shift in pH caused by the addition of
the “pure
water pH additive” is minimal, between 0.005 & 0.01 pH units, since the same amount
of
pure water pH additive is added to the buffers and samples the net effect on the pH
is
negligible.
Control Valves:
Valve Sizing:-
Correct valve sizing is absolutely necessary for efficient and economical process
control
installation. Selection of suitable flow data for sizing calculation should proceed
with great
care. Realistic valves for minimum flow conditions are the most frequent reasons
for
incorrect sizing.
Since the control valve is an adjustable orifice its area is automatically changed
by the
controlling instrument to produce rate of flow under varying pressure drop
condition.
Therefore available operating range is sacrifice when pressure drops are specified
too low,
and when safety factors are unnecessarily high.
The amount of the operational pressure drop require for good control is a function
of the
pressure differential across the valve with respect to the drop through the entire
system.
The operational pressure drop should be at least 1/3 or ½ of the total system
pressure drop.
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In the process industries there are various types of the control elements in which
control
valve is one and is the final control element in any of the process loop. Control
valve has a
vast classification according to its various parameters, mechanisms and many other
factors.
Depending upon that all here following valves are described in brief with their
features and
applications:
1) Globe valves
2) Bellow sealed valves
3) Butterfly valves
4) Ball valves
5) Diaphragm valves
6) Pressure Reducing valves
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Chapter-9
Utilities required
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Utilities required
Steam
Cooling water
Raw water
DM water
Instrument air
Air
STEAM:
COOLING WATER:
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RAW WATER:
DM WATER:
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Chapter-10
Layout and location of plant
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The geographical location of the final plant can have strong influence on the
success of the
industrial venture. Considerable care must be exercised in selecting the plant
site, and
many different factors must be considered. Primarily the plant must be located
where the
minimum cost of production and distribution can be obtained but, other factors such
as
room for expansion and safe giving conditions for plant operation as well as the
surrounding community are also important. The location of the plant can also have a
crucial effect on the profitability of a project.
The choice of the rural site should first of all based on a complete survey of the
advantages
and disadvantages of various geographical areas and ultimately, oil the advantages
and
disadvantages of the available real estate. The various principal factors that must
be
considered while selecting a suitable plant site are briefly discussed in this
section. Tile
factors to be considered are:
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The source of raw materials is one of the most important factors influence site
selection of
a plant site. This is particularly true for the sulfuric acid plant because large
volumes of
sulfur are consumed in the process which will result the reduction of the
transportation and
the storage charges. Attention should be given to the purchased price of the raw
materials,
distance from the source of supply, freight and transportation expenses,
availability and
reliability of supply, purity of raw materials and storage requirements.
Location:
The characteristics of the land at the proposed plant site should be examined
carefully. The
topography of the tract of land structure must be considered; since either of both
may have
a pronounced effect on the construction costs. The cost of the land is important,
as well as
local building cost sand living conditions. Future changes may make it desirable or
necessary to expand the plant facilities. The land should be ideally flat, well
drained and
have load-bearing characteristics. A full site evaluation should be made to
determine the
need for piling or other special foundations.
Transport:
The transport of materials and products to and from plant will be an overriding
consideration in site selection. If practicable, a site should be selected so that
it is close to
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at least two major forms of transport: road, rail, waterway or a seaport. Road
transport is
being increasingly used, and is suitable for local distribution from a central
warehouse.
Rail transport will be cheaper for the long distance transport. If possible the
plant site
should have access to all three types of transportations. There is usually need for
convenient rail and air transportation facilities between the plant and the main
company
head quarters, and the effective transportation facilities for the plant personnel
are
necessary.
Availability of labors:
Labors will be needed for construction of the plant and its operation. Skilled
construction
workers will usually be brought him from outside the site, but there should be ail
adequate
pool of unskilled labors available locality, and labors suitable for training to
operate the
plant. Skilled tradesmen will be needed for plant maintenance. Local trade union
customs
and restrictive practices will have to be considered when assessing tile
availability and
suitability of the labors for recruitment and training.
Availability of utilities:
The “utilities” is generally used for the ancillary services needed in the
operation of any
production process. These services will normally be supplied from a central
facility and
includes water, fuel and electricity which are briefly described as follows:
Water:-
Tile water is required for large industrial as well as general purposes, starting
with water
for cooling washing, steam generation and as a raw material ]it the production of
sulfuric
acid. The plant therefore must be located where a dependable water supply is
available
namely lakes, rivers, wells, seas. It the water supply shows seasonal fluctuations,
it’s
desirable to construct a reservoir or to drill several standby wells. Tile
temperature, mineral
content, slit and sand content, bacteriological content, and cost for supply and
purifications
treatment must also be considered when choosing a water supply. Demineralized
water,
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from which all the minerals have been removed is used where pure water is needed
for the
process use, in boiler feed. Natural and forced draft cooling towers are generally
used to
provide the cooling water required on site.
Electricity:
Power and steam requirements are high in most industrial plants and fuel is
ordinarily
required to supply these utilities. Power, fuel and stem are required for running,
the various
equipments like generators, motors, turbines, plant lighting and general use and
thus be
considered as one major factor is choice of plant site.
Facilities must be provided for the effective disposal of the effluent without any
public
nuisance. In choosing a plant site, the permissible tolerance levels for various
effluents
should be considered and attention should be given to potential requirements for
additional
waste treatment facilities. As all industrial processes produce waste products,
full
consideration must be given to the difficulties and coat of their disposal. The
disposal of
toxic and harmful effluents will be covered by local regulations, and the
appropriate
authorities must be consulted during the initial site survey to determine the
standards that
must be met.
The proposed plant must fit with and be acceptable to the local community. Full
consideration must be given to the safe location of the plant so that it does not
impose a
significant additional risk to the community
Climate:
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considered for selection a site for the plant. Stronger structures will be needed
at locations
subject to high wind loads or earthquakes.
Capital grants tax concessions, and other inducements are often given by
governments to
direct new investments to preferred locations, such as areas of high unemployment.
The
availability of such grants can be the overriding considerations in site selection.
State and local tax rates on property income, unemployment insurance, and similarly
items
vary from one location to another. Similarly, local regulations on zoning, building
codes,
nuisance aspects and other facilities can have influence in the final choice of the
plant site.
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Chapter-11
Site selection parameter
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Plant layout:
After the flow process diagrams are completed and before detailed piping,
structural and
electrical design can been, the layout of process units in a plant and the
equipment within
these process unit must be planned. This layout can play an important part in
determining
construction and manufacturing costs, and thus must be planned carefully with
attention
been given to future problems that may arise.
Thus the economic construction and efficient operation of a process unit will
depend on
how well the plant and equipment specified on the process flow sheet is laid out.
Tile
principal factors that are considered are listed below:
1. Economic consideration: construction and operating costs.
2. Process requirements.
3. Convenience of operation.
4. Convenience of maintenance.
5. Health and safety considerations.
6. Future plant expansion.
7. Modular construction.
8. Waste disposal requirements.
Costs:
The cost of construction can be minimized by adopting a layout that gives the
shortest run
of connecting pipe between equipment, and least amount of structural steel work.
However, this will not necessarily be the best arrangement for operation and
maintenance.
Process requirements:
An example of the need to take into account process consideration is the need to
elevate
the base columns to provide the necessary net positive suction head to pump.
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Convenience of operation:
Equipment that needs to have frequent attention should be located convenient to the
control room. Valves, sample points, and 4isti-umeiits should be located at
convenient
positions and height. Sufficient working space and headroom must be provided to
allow
easy access to equipment.
Convenience of maintenance:
Heat exchanges need to be sited so that the tube bundles can be easily withdrawal
for
cleaning and tube replacement. Vessels that require frequent replacement of
catalyst or
packing should be located on the outside of building. Equipment that requires
dismantling
for maintenance, such as compressors and large pumps, should be places under cover.
Blast walls may be needed to isolate potentially hazardous equipment, and confine
tile
effects of an explosion. At least two escape routes for operators must be provided
from
each level in process buildings
Equipment should be located so that it can be conveniently tied in with any future
expansion of the process. Space should be left on pipe alleys for future needs, and
service
pipes over-sized to allow for future requirements.
Modular construction:
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In recent years there has been a move to assemble sections of plant at tile plant
manufacturer’s site. These modules will include the equipment, structural steel,
piping and
its instrumentation. The modules are then transported to the plant site, by road or
sea.
The advantages of modular construction are:
1. Improved quality control.
2. Reduces construction cost.
3. Less need for skilled labors on site.
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PLANT LAYOUT
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Chapter-12
Economic evalution
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HEXAMINE 2013-2014
Economic evaluation
Basis Ton/day Working day
Ton/year
Plant Capacity 30 350
10500
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HEXAMINE 2013-2014
Total
Equipments No Capacity Price/unit
price
Reactor 1 10 M 1,700,000 1,700,000
Centrifuge 1 10hp 533617 533,617
Dryer 1 9M 1533617 1533617
NH3 liquefaction Plant 1 1000000 1000000
Pumps 8 5hp 41500 332,000
Storage tank 1 50M 932567 1865134
NH3 Storage tank 1 20M 465000 465,000
Water Storage tank 1 50M 932567 932567
Boiler 1 7M 1265655 1,265,655
Cooling Tower 1 355690 355,690
Holding Tank 2 20M 565000 1130000
Total 9,579,663
Direct cost
37456482.3
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3745648.23
A Engineering and supervision 10 % D.C.
3
Construction expenses and contractor
7491296.46
B fee 20 % D.C.
6
3745648.23
C Contingency 10 % D.C.
3
Indirect Cost
14982592.9
Working Capital:
13109768.8
(iv) Working capital 15 % T.C.
2
Manufacturing Cost:
3146344.51
5 Maintenance and repair 6 % F.C.I.
6
471951.677
6 Operating supplies 15 % M & R
4
7 Lab charges 10 % O.L.C.
489600
8 Patent and Royalty 2 % T.P.C.
17716020
603224966.
Direct product cost
Fixed Charges:
Plant Overhead:
1 Plant Overhead 50 % (O.L.C + sup. + Main)
4388372.258
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HEXAMINE 2013-
2014
Manufacturing Cost:
General Expenses:
Selling Price:
Total Income:
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Gross Earning:
Net Profit:
( F.C.I+Dep/year) /(Net
Pay out peroid :- profit+Dep/year) 1.994557744
Rate of Return:
Rate of Return :- net profit/(F.C.I.+W.C.)×100 36.01803367
F.C. 144926026 Rs
D.P.C /Kg 57.449997 Rs/kg
Sell Price 75 Rs/kg
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HEXAMINE 2013-2014
Chapter-13
Important aspects of safety
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Hazards Identification:
Emergency Overview CAUTION! May form combustion dust concentrations in air.
nuisanance dust Irritating to eyes and respiratory system..
First-Aid Measures:
Ingestion: Wash out mouth thoroughly with water and give plenty of water to drink.
Obtain Medical Attention.
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Skin Contact
1) Wash off thoroughly with water.
2) Remove contaminated clothing and wash before re-used.
3) In severe cases, Obtain Medical Attention.
Eye Contact Irrigate thoroughly with water for at least 10 minutes.
If discomfort persists, Obtain Medical Attention.
Fire-Fighting Measures:
Extinguishing Media Foam, water fog, dry chemical. Fire and Explosion Hazards Fine
dust
dispersed in air in sufficient concentrations, and in the presence of an ignition
source is a
potential dust explosion hazard.May evolve toxic fumes in fire. Special
Firefighting
Procedures. Special Equipment for the Protection of Firefighters In the event of a
fire, wear
full protective clothing and NIOSH-approved self-contained breathing apparatus with
full
facepiece operated in the pressure demand or other positive pressure mode and full
protective clothing for Chemicals.
Environmental Precautions:
1) Remove all sources of ignition.
2)This material should be kept out of sewage and drainage systems and all bodies of
water.
3) Clean up releases as soon as possible
4) Ventilate the area of leak .
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Storage:
1) Keep the Storage area dry , drafty and cool.
2) Keep away from all sources of ignition.
3) Keep away from the oxidisers
4) Make sure the extinguisher and Fire-detecting system was setting in appropriate
place.
5) Store in a tightly closed container.
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This material forms a strongly basic aqueous solution, and this property may cause
adverse environmental effects.
It has the following properties: A high biochemical oxygen demand and a potential
to
cause oxygen depletion in aqueous systems, a high potential to affect aquatic
organisms,
a high potential to affect secondary waste treatment microbial metabolism, a high
potential
to affect the germination and/or early growth of some plants, a low potential to
affect the growth of some plant seedlings, a low potential to biodegrade (Low
persistence)
with unacclimated microorganisms from activated sludge, a low potential to
bioconcentrate. After dilution with a large amount of water, followed by secondary
waste
treatment, this material is not expected to cause adverse environmental effects.
Disposal Considerations:
Recommended Methods for Safe and Environmentally Preferred Disposal
Dispose of in a manner consistent with federal, state, and local regulations.
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Description:
Health Hazard:
HAZARD DESCRIPTION: Irritant and corrosive to skin, eye, respiratory tract and
mucous membranes. May cause severe burns, eye and lung injuries. Skin and
respiratory
related diseases aggravated by exposure. Not recognized by OSHA as a carcinogen.
Not
listed in the National Toxicology Program annual report. Not listed as a carcinogen
by the
International Agency for Research on Cancer.
Effects Of Overexposure:
Skin: Irritation, corrosive burns, blisters formation. Contact with liquid will
freeze the
tissue, then produces a caustic burn. Inhalation: heavy, acute exposure may result
in severe
irritation of the respiratory tract, glottal edema, bronchialspasm, pulmonary edema
and
respiratory arrest.
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Chronic effects: Bronchitis. Extreme exposure (5000 ppm) can cause immediate death
from spasm, inflammation or edema of larynx.
Emergency Aid:
Skin: flush with copious amounts of water while removing contaminated clothing and
shoes. Do not rub, or apply ointment on affected area Ingestion: if conscious, give
large
amount of water to drink. Refer immediately to physician.
Eye: flush with copious amounts of water for 15 min. Eyelids should be held apart
and
away from eyeball for thorough rinsing. Speed and thoroughness in rinsing the eye
is most
important in preventing latent permanent injuries. Inhalation: remove to fresh air.
Administer oxygen or artificial respiration if necessary.
Note to Physician: Lung injury may appear as delayed phenomenon, pulmonary edema
may follow chemical bronchitis. Supportive treatment with necessary ventilation
actions,
including oxygen, may warrant consideration.
Physical Data:
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Not generally a fire hazard. If relief valves are inoperative, heat-exposed storage
containers
may become explosion hazards. Ammonia contact with chemicals such as mercury,
chlorine, iodine, bromine, silver oxide, or hypochlorites can form explosive
compounds.
Special hazards with chlorine to form chloramine gas, also a primary skin irritant
and
sensitizer. Combustion may form toxic nitrogen oxides.
Chemical Reactivity
Stability:
Stable at room temperature. Ammonia will react exothermically with acids and water.
Conditions To Avoid:
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Avoid mixing with sulfuric acid or other strong mineral acids. Avoid mixing with
hypochlorites (chlorine bleach) or other halogens and sodium hydroxide. Avoid
contact
with galvanized surfaces, copper, brass, bronze, aluminum alloys, mercury, gold,
silver,
and strong oxidizers. Avoid heating.
Stop source if possible. If Exposure concerns are present, stay upwind and use
water spray
downwind of leak source to absorb ammonia gas and dilute.
CAUTION: Adding water directly to liquid spills will increase volatilization of
ammonia,
thus increasing possibility of exposure.
Waste Disposal:
Listed as hazardous substance under CWA (40 CFR 1164.40 CFR 117.3 Reportable
Quantity 100 lbs. OR 45.4kg) Classed as a hazardous waste under RCRA (40 CFR 261.32
Corrosive # D002). Comply with all regulations. Suitably diluted product may be
disposed
of on agricultural land as fertilizer. Keep spill from entering streams or lakes.
Respiratory Protection:
MSHA/NIOSH approved respiratory protection with full face piece for gas and vapor
contaminants effective for anhydrous ammonia and able to be used for entry and
escape in
emergencies. Refer to 29 CFR 1910.134 and ANSI: Z88.2 for requirements and
selection.
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Ventilation:
Local exhaust sufficient to keep ammonia gas below Permissible Exposure Limits.
Refer to
29 CFR 1910.134 and ANSI: Z9.2 for requirements and selection.
Protective Equipment:
Splash-proof, chemical safety goggles, rubber gloves and boots to prevent contact.
Respiratory protection. Cotton work clothes recommended. Refer to 29 CFR 1910.132
to
1910.136 for requirements.
Special Precautions
Storage And Handling:
Store in cool, well-ventilated area with containers tightly closed. OSHA 29 CFR
1910.111
prescribes handling and storage requirements for anhydrous ammonia as a hazardous
material.
Work-Place Protective Equipment:
As discussed above should be near, but outside of ammonia area. Eyewash and safety
shower in immediate vicinity. See 29 CFR 1910.141 for workplace requirements.
Disposal:
Ammonia is listed as a hazardous substance under FWPCA. See WASTE
Personal:
Avoid unnecessary exposure. Use protective equipment as needed. Do not wear contact
lenses.
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Hazards Identification:
Potential Acute Health Effects:
Very hazardous in case of eye contact (irritant), of ingestion, . Hazardous in case
of skin
contact (irritant, sensitizer, permeator), of eye contact (corrosive). Slightly
hazardous in
case of skin contact (corrosive). Severe over-exposure can result in death.
Inflammation of
the eye is characterized by redness, watering, and itching.
Eye Contact:
Check for and remove any contact lenses. Immediately flush eyes with running water
for at
least 15 minutes, keeping eyelids open. Cold water may be used. Get medical
attention
immediately.
Skin Contact:
In case of contact, immediately flush skin with plenty of water. Cover the
irritated skin
with an emollient. Remove contaminated clothing and shoes. Cold water may be
used.Wash clothing before reuse. Thoroughly clean shoes before reuse. Get medical
attention.
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LARGE FIRE: Use alcohol foam, water spray or fog. Cool containing vessels with
water
jet in order to prevent pressure build-up, autoignition or explosion.
Small Spill:
Dilute with water and mop up, or absorb with an inert dry material and place in an
appropriate waste disposal container. If necessary: Neutralize the residue with a
dilute
solution of sodium carbonate.
Large Spill:
Flammable liquid. Poisonous liquid.
Keep away from heat. Keep away from sources of ignition. Stop leak if without risk.
Absorb with DRY earth, sand or other non-combustible material. Do not get water
inside
container. Do not touch spilled material. Use water spray to reduce vapors. Prevent
entry
into sewers, basements or confined areas; dike if needed. Call for assistance on
disposal.
Neutralize the residue with a dilute solution of sodium carbonate. Be careful that
the
product is not present at a concentration level above TLV. Check TLV on the MSDS
and
with local authorities.
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Personal Protection:
Safety glasses. Lab coat. Vapor respirator. Be sure to use an approved/certified
respirator
or equivalent. Gloves (impervious).
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Toxicological Information
Routes of Entry: Absorbed through skin. Dermal contact. Eye contact. Inhalation.
Toxicity to Animals:
Acute oral toxicity (LD50): 42 mg/kg [Mouse]. (Formaldehyde)
Acute dermal toxicity (LD50): 15800 mg/kg [Rabbit]. (Methyl alcohol).
Acute toxicity of the mist(LC50): 454000 mg/m
4 hours [Mouse]. (Formaldehyde)
Toxic Effects on Humans:
Very hazardous in case of ingestion, .Hazardous in case of skin contact (irritant,
sensitizer,
permeator), of eye contact (corrosive), of inhalation (lung corrosive). Slightly
hazardous in
case of skin contact (corrosive). Ingestion: Prolonged or repeated ingestion may
cause
gastrointestinal tract irritation and ulceration or bleeding from the stomach.
Other effects
may be similar to that of acute ingestion.
Disposal Considerations
Waste Disposal:
Waste must be disposed of in accordance with federal, state and local environmental
control regulations.
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HEXAMINE 2013-2014
Chapter-14
Effluent treatment related to
product
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4. Auxiliary treatment- This mainly includes large number of physical and chemical
treatment processes that can be used before or after the biological treatment to
meet the
treatment objectives.
• Grit chambers use gravity to remove grit and dirt which mainly consists of
mineral
particles and coarse screens strain out large solids and when organic material
enters as
large particles comminutors can be used to reduce particle size to enhance
treatment in
later stages.
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PRIMARY TREATMENT - These are also mainly physical processes. These include-
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from the top of the clarifier over the weir. Solids get collected at the bottom
and sludge
must be periodically removed, dewatered and disposed.
SECONDARY TREATMENT
Biological treatment processes are used primarily for secondary treatment and use
microbial action to decompose suspended and dissolved organic wastewater. Microbes
use
the organic compounds as both a source of carbon and as a source of energy. Success
of
biological treatment depends on many factors such as the pH, temperature, nature of
pollutants, nutrient requirement of microbes, presence of inhibiting pollutants and
the
variations in the feed stream loading.
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CONCLUSION
From the financial analysis it is clear that the capital investment required for
installing is not very high. The payback period is also not very high and the plant
gives very attractive returns.
For the adequate supply of the raw material formaldehyde, in the future we can set
up a plant of formaldehyde from methanol. And if the setup is efficiently managed
we can hopefully affect the profitability to the great extent.
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REFERENCES
86