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Fertilizer Grade Magnesium Sulphate Production from Dolomite
Technical Report · September 2016
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CH4013: Comprehensive Design Project I
Group Report
Fertilizer Grade Magnesium Sulphate Production from Dolomite
Group members: 120466C – Perera I.Y.C.

120491X – Premadasa H. M. I. S
120500D – Pushpakumara K. A. P. S.
120509M – Rammuni M. N.
Date of submission: 19.09.2016
Supervisors: Prof. Perera S.A.S.

Mrs. Jayangi Wagaarachchige
Department of Chemical and Process Engineering

University of Moratuwa
ABSTRACT
The escalating demand for the chemical fertilizers in Sri Lanka has to be overcome by
increasing the production of fertilizers using locally available raw materials and much
technically advanced processes. Hence, this design project is carried out in a chemical and
process engineering aspect, for the manufacturing of Fertilizer Grade Magnesium Sulphate
[MgSO4.7H2O: Epsom salt] using Sri Lankan dolomite.
The main chemical reaction of the process will be;
Ca.Mg(CO3)2(s) + 2H2SO4(aq) MgSO4(aq) + CaSO4.2H2O(S) + 2CO2(g) + 2H2O
The production plant is expected to have a total production of Epsom salt in a quantity of
100,000 MT per annum of which 30,000 MT is to be issued for the local market and the rest
of 70,000 MT is for the overseas. In addition, Plaster of Paris [CaSO4. 0.5H2O(s)] will be
manufactured as the main byproduct of the plant;
CaSO4. 2H2O(s) CaSO4. H2O(s) + H2O(g)
The annual Plaster of Paris production capacity of the plant is estimated as 190,759 MT of
which 57,238 MT are focusing on the local demand and 133,521 MT are to be shipped for
export markets.
Considering many parameters and constraints it is decided that Habarana is the ideal location
to setup the proposed fertilizer production plant. The Environment, Health and Safety impacts
of the plant has been assessed via a proper HSE assessment and the recommendations are
made for the identified aspects. Further this report describes, the material and energy flows
for the entire plant which has been determined using relevant chemical and process
engineering concepts.
Unit Production Cost of Epsom Salt 43401.24 LKR per MT
Unit Production Cost of Plaster of Paris 22751.87 LKR per MT
Initial Investment 921,191,180 LKR
Expected plant operating life time 15 years
Payback Period 7.6 years
IRR 22%
Comprehensive Design Project | CH4013 II | P a g e

ACKNOWLEDGEMENT
Foremostly, we would like to express our profound gratitude to the supervisors in charge
Prof. S.A.S. Perera and Ms. Jayangi Wagaarachchige for their tremendous contribution to
make our Design Project successful, by providing an invaluable guidance and generously
sharing their knowledge with us throughout the entire period. If not their support and
supervision given, it would have been difficult for us to find the path in presenting a proper
design for a production plant of Fertilizer Grade Magnesium Sulphate with a wide
perspective in Chemical and Process Engineering aspects.
We consider it as a great opportunity to follow this module “CH4013: Comprehensive Design

Project I” with the application of obtained theoretical knowledge into practice, on our way to
become professional engineers. In that part, we would like to grant our deepest appreciation
to Prof. Padma Amarasinghe; the module coordinator and Dr. Sanja Gunawardena, the Head
of Chemical and Process Engineering Department in University of Moratuwa for leading us
to acquire the experience of proper plant designing.
Further, we would like to convey our deepest thanks to Prof. P.G.R Dharmaratne and Eng.
P.V.A. Hemalal of Earth Resource Engineering Department in University of Moratuwa for
their support given in finding the required data and information for the Design Project.
Eventually, we make this moment to highly admire the assistance of all the academic staff
members and our badge mates of Chemical and Process Engineering Department in
University of Moratuwa.
The knowledge gathered herein and the practical experience learnt will be bench beneficial
and unforgettable in the long run of our careers as Chemical and Process Engineers.
Comprehensive Design Project | CH4013 III | P a g e

CONTENTS
Page No.
1 Chapter 1 | Introduction ...................................................................................................... 1
2 Chapter 2 | Literature Review and Process Selection ....................................................... 4
2.1 Industrial production of magnesium Sulphate................................................................ 4

2.1.1 Production of magnesium sulphate using brines .................................................. 4
2.1.2 Production of magnesium sulphate using dolomite .............................................. 5
2.1.2.1 Double decomposition of Gypsum and Magnesium oxide .......................... 6
2.1.2.2 Catalytic reaction with gaseous Sulfur dioxide ............................................ 6
2.1.2.3 Reaction with Ferrous sulfate ....................................................................... 7
2.1.2.4 Reaction with Sulfuric acid .......................................................................... 7
2.2 Process Selection .......................................................................................................... 8
2.2.1 Raw Materials......................................................................................................... 8
2.2.1.1 Dolomite ........................................................................................................ 8
2.2.1.2 Sulfuric Acid ............................................................................................... 10
2.2.2 Products ............................................................................................................... 12
2.2.2.1 Main product - Fertilizer Grade Magnesium Sulphate ............................... 12
2.2.2.2 By product - Plaster of Paris........................................................................ 14
2.3 Production process of the plant ................................................................................... 14
2.3.1 Particle size reduction ......................................................................................... 16
2.3.2 Leaching .............................................................................................................. 16
2.3.3 Solid liquid Separation ........................................................................................ 18
2.3.4 Evaporation ......................................................................................................... 18
2.3.5 Crystallization ...................................................................................................... 28
2.3.6 Drying ................................................................................................................. 18
2.4 Equipment for the production process ......................................................................... 19
3 Chapter 3 | Feasibility Study and Process Chemistry Establishment ........................... 21
3.1 Plant Location............................................................................................................... 21

3.2 HSE (Health, Safety and Environment) Assessment ................................................... 22
3.2.1 Impacts from Raw Materials ................................................................................ 23
Comprehensive Design Project | CH4013 IV | P a g e

Page No.
3.2.1.1 Dolomite ..................................................................................................... 23

3.2.1.2 Sulphuric acid .............................................................................................. 24
3.2.2 Impacts from Products.......................................................................................... 25
3.2.2.1 Magnesium Sulphate ................................................................................... 25
3.2.2.2 Plaster of Paris ............................................................................................. 25
3.2.3 General Concerns ................................................................................................. 26
3.3 Economic Evaluation ................................................................................................... 27
3.3.1 Production capacity calculations .......................................................................... 27
3.3.2 Capital expenditure............................................................................................... 28
3.3.3 Overheads ............................................................................................................. 29
3.3.4 Raw material costs................................................................................................ 30
3.3.5 Calculations of wages ........................................................................................... 31
3.3.6 Project appraisal ................................................................................................... 32
3.4 Chemical Engineering Aspect of the Process ............................................................... 34
3.4.1 Basic reaction steps and reaction kinetics ............................................................ 34
3.4.1.1 Reactor......................................................................................................... 34
3.4.1.2 Dryer 2 (POP Dryer) ................................................................................... 34
3.4.2 Unit processes and flow rates ............................................................................... 35
3.4.2.1 Particle size reduction ................................................................................. 35
3.4.2.2 Reactor......................................................................................................... 35
3.4.2.3 Solid liquid separation ................................................................................. 35
3.4.2.4 Evaporation ................................................................................................. 35
3.4.2.5 Crystallization ............................................................................................. 36
3.4.2.6 Centrifugation .............................................................................................. 36
3.4.2.7 Drying .......................................................................................................... 36
4 Chapter 4 | Mass and Heat Balance for the Proposed Plant ........................................... 37
4.1 Material Balance........................................................................................................... 37

4.1.1 Data ...................................................................................................................... 37
4.1.2 Calculations .......................................................................................................... 38
4.1.2.1 Dolomite [Mg.Ca(CO3)2] requirement ........................................................ 38
4.1.2.2 Sulphuric [H2SO4(aq)] requirement .............................................................. 38
Comprehensive Design Project | CH4013 V|Page

Page No.
4.1.2.3 Calculations for reactor ............................................................................... 41

4.1.2.4 Calculations for product flow rates ............................................................. 41
4.1.2.5 Calculations for solid-liquid separation ...................................................... 43
4.1.2.6 Calculations for evaporator ......................................................................... 44
4.1.2.7 Calculations for Epsom [MgSO4.7H2O(s)] production ................................ 45
4.1.2.8 Calculations for Plaster of Paris [CaSO4. 0.5H2O(s)] production ................ 46
4.1.2.9 Calculations for the wastewater stream ....................................................... 47
4.2 Energy Balance............................................................................................................. 48
4.2.1 Particle size reduction .......................................................................................... 49
4.2.2 Reactor ................................................................................................................. 50
4.2.3 Solid-Liquid Separation ....................................................................................... 51
4.2.3.1 Gravity Settling Tank .................................................................................. 51
4.2.3.2 Vacuum Filter .............................................................................................. 51
4.2.4 Evaporator ............................................................................................................ 52
4.2.5 Crystallizer ........................................................................................................... 53
4.2.6 Dryer 1 (Epsom Dryer) ........................................................................................ 54
4.2.7 Dryer 2 (POP Dryer) ............................................................................................ 55
4.2.8 Total energy requirements ................................................................................... 55
4.2.9 Energy Balance sheet for Reactor ........................................................................ 57
4.2.10 Energy Balance sheet for Solid-Liquid Separation ............................................ 58
4.2.11Energy Balance sheet for Evaporator ................................................................. 59
4.2.12 Energy Balance sheet for Crystallizer................................................................ 60
4.2.13 Energy Balance sheet for Dryer 1 (Epsom Dryer) ............................................. 61
4.2.14 Energy Balance sheet for Dryer 2 (POP Dryer)................................................. 62
Site Layout .............................................................................................................................. 63
5 Chapter 5 | Conclusions ...................................................................................................... 64
References .............................................................................................................................. 66
Comprehensive Design Project | CH4013 VI | P a g e

LIST OF FIGURES
Page No.
Chapter 1 | Introduction
Figure 1.1: Extents of paddy cultivation w.r.t. the usage of fertilizer type ......................... 2
Chapter 2 | Literature Review and Process Selection
Figure 2.1: Production of magnesium sulphate using brines ............................................... 5

Figure 2.2: Dolomite [Ca.Mg(CO3)2] .................................................................................. 9
Figure 2.3: Magnesium Sulphate [MgSO4] ....................................................................... 12
Figure 2.4: Magnesium deficiency symptoms ................................................................... 13
Figure 2.5: Plaster of Paris [CaSO4.½H2O] ..................................................................... 14
Figure 2.6: Production process of the proposed plant........................................................ 15
Figure 2.7: Effect of temperature on MgSO4 recovery ...................................................... 16
Figure 2.8: Equipment flow of the proposed plant ............................................................ 19
Chapter 3 | Feasibility Study and Process Chemistry Establishment
Figure 3.1: Dolomite ore locations in Sri Lanka................................................................ 21

Figure 3.2: Protection layers of the proposed plant ........................................................... 26
Figure 3.3: Graph | NPV Vs Time .................................................................................... 33
Chapter 4 | Mass and Heat Balance for the Proposed Plant
Figure 4.1: Graph | molar concentration vs density of H2SO4(aq)....................................... 39

Figure 4.2: Dilution of H2SO4(aq) ....................................................................................... 40
Figure 4.3: Mass balance of the reactor ............................................................................. 42
Figure 4.4: Solid-liquid separation .................................................................................... 43
Figure 4.5: Graph | (w/w)% vs density of MgSO4(aq) ........................................................ 44
Figure 4.6: Mass balance of the evaporator ....................................................................... 44
Figure 4.7: Mass balance of Epsom Production ................................................................ 45
Figure 4.8: Mass balance of the dryer 2 ............................................................................. 46
Figure 4.9: Energy balance for the reactor......................................................................... 50
Figure 4.10: Energy balance for the evaporator................................................................. 52
Figure 4.11: Energy balance for the crystallizer ................................................................ 53
Figure 4.12: Energy balance for dryer 1 ............................................................................ 54
Comprehensive Design Project | CH4013 VII | P a g e

LIST OF TABLES
Page No.
Chapter 1 | Introduction
Table 1.1: Fertilizer demand (MT) by main crop categories (excluding paddy) ....................... 1
Chapter 2 | Literature Review and Process Selection
Table 2.1: Chemical composition of Sri Lankan dolomite ...................................................... 10

Table 2.2: Market prices for magnesium sulphate fertilizers in Sri Lanka .............................. 13
Table 2.3: Effect of Solid Liquid ratio on MgSO4 recovery .................................................... 17
Chapter 3 | Feasibility Study and Process Chemistry Establishment
Table 3.1: Production capacity of Fertilizer Grade Magnesium Sulphate ............................... 27

Table 3.2: Production capacity of Plaster of Paris ................................................................... 27
Table 3.3: Machinery cost........................................................................................................ 28
Table 3.4: Total capital expenditure calculations .................................................................... 29
Table 3.5: Calculations for overheads ..................................................................................... 30
Table 3.6: Raw material costs .................................................................................................. 30
Table 3.7: Calculations for wages ............................................................................................ 31
Table 3.8: Project appraisal...................................................................................................... 32
Chapter 4 | Mass and Heat Balance for the Proposed Plant
Table 4.1: Molecular weights of chemicals ............................................................................. 37

Table 4.2: Sulphuric requirement of dolomite ......................................................................... 39
Table 4.3: Physical properties of species ................................................................................. 48
Table 4.4: Energy requirement for particle size reduction ...................................................... 49
Table 4.5: Energy requirement for solid-liquid separation ...................................................... 51
Table 4.6: Steam requirement of the process ........................................................................... 55
Table 4.7: Electricity requirement of the process .................................................................... 56
Table 4.8: Oil fired energy consumption ................................................................................. 56
Table 4.9: Total energy requirement of the process ................................................................ 56
Comprehensive Design Project | CH4013 VIII | P a g e

NOMENCLATURE
Symbol Units
Density d gcm-3 (gml-1)
Mass flow rate ̇ MT per day
Molecular mass M Kgkmol-1
Temperature T K
Specific molar enthalpy of formation ̃ kJmol-1
Specific molar heat capacity ̃ kJkmol-1K-1
Abbreviations:
CSTR Continues Stirred Tank Reactor
EHS Environmental, Health and Safety
IARC International Association for Research on Cancer
IRR Internal Rate of Return
LKR Sri Lankan Rupees
MT Metric Tons
NFPA National Fire Protection Department
NPV Net Profit Value
OHSAS Occupational Health and Safety Association
POP Plaster of Paris
PPE Personal Protective Equipment
PV Profit Value
SIS Safety Instrumented System
TPA Tons Per Annum
Comprehensive Design Project | CH4013 IX | P a g e

CHAPTER 1
INTRODUCTION
As one of the major aspects of agriculture, Soil Management plays a huge role when it comes
to maximizing the agro-production capacities. Soil Fertility Maintenance which is a part of
soil management needs a close attention at the proper time of any cultivation process in order
to enhance the soil quality and performance. If other requiring factors are there, fertilizers can
convert unusable lands eligible for agricultural purposes.
In that case, application of different fertilizer materials are supposed to provide the major
nutrients including Nitrogen (N), Phosphorus (P2O5), Potassium (K2O), Calcium (Ca),
Magnesium (Mg), Sulfur (S) and Micronutrients (Cu, B, Fe, Mn, Mo, Zn etc.) that
are essential to the growth of plants (Mitchell, 1999). Different agricultural fields require
different amounts of each nutrient depending on their environment and plant species. Hence,
fertilizers have to be manufactured in numerous types based on their demand.
In Sri Lanka, organic manure was widely used for agricultural purposes in the past eras; but
since 1950s, Sri Lankan farmers started to use imported fertilizers. Along with the
government subsidizing to fertilizers, farmers were able to achieve a high yield of products
with greater use of soil nutrients. According to the local fertilizer sales quantity data from
2008 to 2012, there is a significant and consistent growth in fertilizer demand for all major
crop categories as well as for the industry as a whole; with paddy and tea plantations being
the largest consumers of fertilizers.
Table 1.1: Fertilizer demand (MT) by main crop categories (excluding paddy)
(National Accounts of Sri Lanka, 2014)
Fertilizer demand (MT)

Year
Tea Rubber Coconut Vegetables Others
2008 113,418 7,552 16,872 14,476 17,702

2009 171,659 7,150 17,625 16,513 19,721
2010 193,474 10,825 26,502 24,544 26,334
2011 169,344 14,291 54,194 44,645 52,659
2012 195,593 15,559 45,710 59,433 64,507
Comprehensive Design Project | CH4013 1|Page

Figure 2.1 evince the extents of paddy cultivation in Sri Lanka, with respect to the usage of
fertilizer type for the agricultural year 2013/2014. It implies that there is a tremendous trend
to utilize chemical fertilizers such as Ammonium nitrate, Potassium carbonate and
Magnesium Sulphate among the local farmers.
2% 1%
Chemical fertilizers
Chemical and Organic

fertilizers
39%
Total extent of Organic fertilizers
964,268 hectares 58%
None
Figure 1.1: Extents of paddy cultivation w.r.t. the usage of fertilizer type
(National Accounts of Sri Lanka, 2014)
In addition, most recent available records from the Department of Census and Statistics of Sri
Lanka, year 2014 have recorded a 14.9 percent rise for overall imports of chemical fertilizers
(National Accounts of Sri Lanka, 2014).
These statics predict that the demand for the chemical fertilizers in Sri Lanka will be
escalated within the next few decades and it should be overcome by increasing the production
of fertilizers using locally available raw materials and much technically advanced processes.
Among the industrial minerals found in Sri Lanka, dolomite [Ca.Mg(CO3)2] can play a major
role in the production of magnesium containing fertilizers. Dolomite in its natural form can
be used as a fertilizer to add magnesium to soil; but its poor water solubility makes it useless
for short term crops. Hence it should be converted into a water soluble form such as hydrated
magnesium sulphate (in the form of MgSO4.7H2O and MgSO4.H2O) to achieve its maximum
advantage as a fertilizer. This design project is carried out in a chemical and process
engineering aspect, for the manufacturing of fertilizer grade magnesium sulphate
[MgSO4.7H2O] and Plaster of Paris (as the byproduct) using Sri Lankan dolomite.

Design Constraints:
In the aspect of design constraints, the government regulations over the possible
environmental, health and safety impacts related with the activities of a fertilizer production
plant are important to consider. The engineering design, facility development and
implementation of the process should be done according to the prevailing standards issued by
the Central Environmental Authority and Factory Ordinance Act of Sri Lanka.
The other main factor to be concerned here is the market constraints. Currently the fertilizer
market of Sri Lanka is dominion over by some of the multinational and foreign companies.
Hence, the expected fertilizer production plant has to compete with them to being the
foremost fertilizer supplier to the local market. This is expected to be overcome by issuing
fertilizer to the local market with concessionary and attractive selling prices.
Further the procurement of required raw materials will be a challenge if they have to be
imported; because of its higher transportation costs, demurrages and relevant tax
expenditures. In that case, proper compromises and corporations with the government will be
an advantage. The community constraints that can be arisen with the construction of the plant
and implementation of the production process have to be overcome by organizing community
awareness programmes and attracting people towards the project with CSR (Corporate Social
Responsibility) programmes.
Objectives:
- To design a plant with a production rate of 100,000 TPA Fertilizer Grade Magnesium
Sulphate (MgSO4·7H2O) as the main product and Plaster of Paris (CaSO4· H2O) as
the by product from dolomite.
- To employ the local natural resources industrially in an effective manner and

increasing the agricultural production yield with the utilizing of manufactured
fertilizers.
- To retain and earn foreign exchange to the country by substituting the current imports
and acquiring the fertilizer export market while creating new direct and indirect job
opportunities.

CHAPTER 2
LITERATURE REVIEW AND PROCESS SELECTION
This chapter describes the selection of suitable process for the proposed Fertilizer Grade
Magnesium Sulphate manufacturing plant led by a literature review on the prevailing
production methods of magnesium sulphate in industrial scale and applicable technologies.
The later part of the chapter narrates the basic process steps of the selected process along with
the chemical descriptions of raw materials, products and their applications.
2.1 Industrial production of magnesium Sulphate
Over the decades, magnesium salts are produced from magnesium bearing minerals such as
natural kieserite [MgSO4·H2O], langbeinite [K2Mg2(SO4)3], brucite [Mg(OH)2], dolomite
[CaMg(CO3)2] and seawater concentrates (brines that salt content ranging from 3.5% to
26%). In the case of hydrated magnesium sulphate, it has been produced primarily through
the processing of brines comprised of magnesium sulphate and natural poly-metallic ores;
mainly the dolomite.
2.1.1 Production of magnesium sulphate using brines
In spite of the earth‟s crust, some of the minerals including magnesium salts are highly
available in seawater. Typically saline water comprises 1,272 ppm of Mg2+(aq) and 2,648 ppm
of SO42-(aq) (Gordon, 2011), making it viable to assume that the magnesium is present in the
seawater as its sulphate form (MgSO4(aq)), which can be extracted through several mass
transfer processes.
During seawater desalination or flash evaporation of saline water for sodium chloride
recovery, magnesium sulphate remaining in the brine gets concentrated along with the other
salts (magnesium chloride, potassium chloride etc.). Here, the end liquor left out after the
crystallization of sodium chloride is considered as a potential source for the recovery of
magnesium sulphate.
This bittern which containing a number of salts is stirred in a steam jacketed dissolver at
110oC for a time period (depending on the production capacity, mineral concentration etc.)
and allowed to settle afterwards. Then the suspended slurry which consists of kieserite
(MgSO4.H2O) is filtered at 110oC through a sparkler pressure filter.

After the filtration, obtained cake (mainly consists of magnesium sulphate in 45 to 52%) is
dissolved with a requisite amount of water and the solution is heated to 60 oC. Subsequently
the Epsom salt (MgSO4.7H2O) is crystallized out by cooling the resulted solution to room
temperature and an additional crop of Epsom salt can be obtained by further chilling of the
mother liquor (resulted from the gravity settling tank) up to 10oC. (Nicolaas, 1900)
Brine left out Stirring at 110oC in steam

Gravity Settling
after the NaCl jacketed dissolver Suspended
crystallization slurry
Filtration through
sparkler pressure filter
Resulted Cake mainly

Chilling at 10oC
Liquor consist of
MgSO4
Water
Epsom Salt Epsom

Crystallization Heating at 60oC
MgSO4.7H2O Solution
Figure 2.1: Production of magnesium sulphate using brines
However this production process is not employed to produce magnesium sulphate in large
quantities as its net yield per unit amount of seawater is much lower than the other methods.
In addition, the lengthy process and the necessity to use of corrosion-resistant equipment for
practicing this prior art method is considered as apparent disadvantages
2.1.2 Production of magnesium sulphate using dolomite:
Dolomite [Ca.Mg(CO3)2] is a fairly soft mineral that is available in large sedimentary rock
beds. Hence, dolomite is used for the following processes after the pre-processing steps such
as crushing and screening in order to increase the reaction rates and to obtain a high yield.

2.1.2.1 Double decomposition of Gypsum and Magnesium oxide:
As a conventional method, magnesium sulphate is produced by the process of double

decomposition of gypsum [CaSO4.2H2O] and magnesium oxide; obtained by the combustion
of MgCO3 present in dolomite. When dolomite is partially combusted by the ordinary kiln
process under a controlled environment (at a temperature below than which the calcium
carbonate is decomposed), the magnesium carbonate in dolomite is converted into
magnesium oxide and carbon dioxide.
Ca.Mg(CO3)2(s) + O2(g) CaCO3.MgO(s) + CO2(g)
According to the literature (Grigor Yarn, 1969) a satisfactory crop of magnesium sulphate
can be obtained when this partially de-carbonated dolomite is engaged in the double
decomposition reaction, in which the two compounds exchange their ions.
CaCO3.MgO(s) + CaSO4(aq) + CO2(g) MgSO4(aq) + 2CaCO3(s)
Here, the maximum yield of magnesium sulfate is reported as 76.6% for the optimal exposure
of 6 hours. Further increase in exposure time may result in practically effect on the yield of
magnesium sulfate with increasing carbon dioxide pressure.
One of the major disadvantages of this process is that the reaction for producing magnesium
sulfate is reversible and thus it is difficult to carry out until the completion, unless magnesium
sulfate is constantly removed from the system.
2.1.2.2 Catalytic reaction with gaseous Sulfur dioxide:
In one of the conventional commercial processes of producing magnesium sulphate, dolomite

rocks are decomposed to magnesium oxide [MgO(s)] by heating at a temperature between
850°C - 900°C. Subsequently, gaseous sulphur dioxide (SO2(g)) is directed through a slurry of
obtained magnesium oxide to be absorbed and form magnesium bi-sulphate [Mg(HSO4)2(aq)]
solution. Then this solution is followed by aerial oxidation at 50°C - 60°C in the presence of
metallic catalysts and magnesium sulphate will be resulted. (Kirk and Othmer, 1969).
This process is not economical due to its extensive purification process to recover magnesium
sulphate in pure form. Furthermore, it is an energy intensive and heat sensitive process where
the energy has to be externally supplied for the decomposition of mineral product
(magnesium sulphate).

2.1.2.3 Reaction with Ferrous Sulfate:
This method of producing magnesium sulfate comprises the interaction of ferrous sulfate or
ferrous sulfate containing material with magnesium carbonate in dolomite by forming a
suspension in an aqueous medium of two compounds and passing the gaseous carbon dioxide
through the resultant suspension.
The introducing CO2(g) is to be dissolved in the suspension while maintaining the system at a
temperature of 0°C to 25°C for a period of 10 hours. The presence of carbon dioxide permits
completion of the reaction between ferrous sulfate and magnesium carbonate with a degree of
conversion being as high as 98%.
Additional heating of the suspension at a temperature of 80°C to 100°C after the CO2(g)
dissolving, generates a precipitate of water-insoluble ferrous compounds and a supernatant
liquid comprises of magnesium sulfate (Sokolov et al., 2016). Subsequently, evaporation of
water from the supernatant liquid results in the crystallization of magnesium sulfate.
Nevertheless this process is not economically viable due to the raw materials (ferrous
sulphate containing compounds) are being costly and energy intensive, especially in the
crystallization part. Moreover, the resulting magnesium sulphate from this method is difficult
to purify.
2.1.2.4 Reaction with Sulfuric acid:
The reaction of dolomite with sulphuric acid is considered as one of the most widely used
magnesium sulphate production procedures around the world. Here, as the first step dolomite
is undergone a particle reduction process using suitable equipment such as jaw crushers and
ball mills. After the dolomite particles are crushed into an optimum size, they are directed to
react with sulphuric acid in order to produce magnesium sulphate.
Ca.Mg(CO3)2(s) + 2H2SO4(aq) MgSO4(aq) + CaSO4.2H2O(S) + 2CO2 + 2H2O
From the reaction magnesium sulphate can be obtained in the aqueous phase and calcium
sulphate will precipitate. These two phases can be separated using filtration and by
crystallizing the filtrate under specific conditions, magnesium sulphate will turn into its
hydrate forms providing fertilizer grade Epsom salt [MgSO4·7H2O] and Kieserits
[MgSO4·H2O].

This method is ideal to produce fertilizer grade magnesium sulphate as it does not need high
purified products and is much economical if we use waste suphuric acid from other
manufacturing processes (e.g.: TiO2 production) as the raw material.
2.2 Process Selection
Recent surveys reveal that the increasing demand of magnesium sulphate for large scale
agricultural applications leaves a gap between its supply and demand, as the production rate
from existing manufacturing processes are considerably lower. Thus, today there is a
substantial tendency to implement technically advanced and much economic processes to
produce magnesium sulphate using inland dolomite ores, rather than using conventional
methods as it is.
In that case, the proposed fertilizer grade magnesium sulphate production plant is supposed to
design under the process which based on the following reaction (with the theoretical
background from 2.1.2.4);
In follow, the overall process of the selected method along with the descriptions on its
required raw materials, main product and byproducts of the process, production process of
the plant and its main equipment requirements has been descriptively outlined in an
engineering perspective;
2.2.1 Raw Materials
2.2.1.1 Dolomite:
Chemical formula: Ca.Mg(CO3)2
Dolomite is a rock forming mineral with consisting of calcium and magnesium in combining
with carbonates with the chemical composition of above. In spite of being a fertilizer, there
are many uses of dolomite. This mineral can be applied in a form of neutralizer in chemical
industry and as a source of MgO, which is used in livestock nutrient supply and ingredient for
the production of ceramics and glass (used for high refractive optical glasses). Further,
dolomite is utilized to control the buffer changes in water and in the production of face
cream, toothpastes and baby products as a base. (Dolomite, 2005).

Globally, this mineral can be found in various places around the hydrothermal veins, lakes,
shallow oceans, evaporative basins and lagoons with different arrangements and colours.
Some the locations for fine examples are Italy (Brosso, Traversella), Spain, Austria,
Germany, Switzerland, Yugoslavia, England (Cumbria), Russia, Brazil, Mexico and USA
(North Carolina, Kansas, Oklahoma).
Considering Sri Lanka, major dolomite occurrences in the metamorphic basement are found
in Digana, Kekirawa, Polonnaruwa, Balangoda, Baddulla and Okkampitiya areas. The most
recent studies carried out by several researchers have showed that the dolomite occurrences
are further located in the areas of Illukpellessa, Rajawaka and Molamure.
In addition to be found in nature, this complex mineral can be precipitated from the solutions
which are rich in Magnesium (Mg), Calcium (Ca) and Carbonate ions (CO32-) and formed
into sediment. More often, most of the dolomite is formed through the chemical alteration
through prime limestone. In that case, carbonates in limestone are unstable and when exposed
to magnesium rich fluids, a part of the Calcium ions may be replaced by Magnesium ions to
form the more stable carbonate known as “Dolomite” (Clark, Herron, & Hurley, 2009).
Properties of dolomite can be varied due to the containing compositions of calcium and
magnesium while the ideal composition is considered to contain equal amounts of calcium
and magnesium. When the composition of calcium is higher in 10% or more than of the ideal
scenario, it is called as „High-calcium dolomite‟. In other words, as calcitic dolomite or lime
dolomite. When the calcium composition is increased from 50% to 90% and the magnesium
composition is reduced; the rock is named as „Dolomite limestone‟. Further reduction in
magnesium composition to 5%, the
rock is known as „Limestone‟ (Clark,
Herron, & Hurley, 2009).
Dolomite exhibits a crystal structure

usually in rhombohedra in shape. This
could be found in different colors such
as white, reddish white, brownish
white, gray, pink or colorless in
transmitted light.
Figure 2.2: Dolomite [Ca.Mg(CO3)2]

Chemical composition of the Sri Lankan dolomite can be found in literature as follow
(Liyanage and Alles, 1999).
Table 4.1: Chemical composition of Sri Lankan dolomite
Composition
Component
(mg g-1 of dolomite)
Calcium 269 ± 8
Magnesium 53 ± 0.8
Iron 0.067 ± 0.048
Aluminium 0.05 ± 0.001
Carbonate 477 ± 15
Sulphate 57.6 ± 1.5
Phosphate 0.21 ± 0.02
Chloride 56.1 ± 0.9
Nitrate 24.8 ± 0.5
Silicate 5.1 ± 1.1
Hygroscopic moisture 56.47 ± 1.2
2.2.1.2 Sulfuric Acid:
Chemical formula: H2SO4
Sulfuric acid is considered as the most produced chemical of the modern world;
approximately it is 150,000,000 tons per year (Sulfuric acid, 2009). This is a highly corrosive
acid with a molecular weight of 98.079gmol-1.
Physically sulfuric acid is an odorless and colorless solution (sometimes can be slightly
yellowish) and upon the concentration of the acid varied properties can be visible. Due to the
strong acidic nature this could be deleterious to metals, living organisms and even to the rock
based materials. In contact of the acid may result severe burns on the contacted skin and if
splashed onto eyes can result eye blindness permanently and irreversible damage if
swallowed. Therefore, in conducting activities of the proposed plant extra precautions should
have to be taken for safety.
Comprehensive Design Project | CH4013 10 | P a g e

When considering the chemical properties, H2SO4 has a high polarity and a high
conductivity. H2SO4 reacts with water through an exothermic reaction, producing high
thermal energy. Affinity of H2SO4 to water is strong, hence when diluting H2SO4 has to be
the limiting regent. Further, H2SO4 is a very reactive ingredient which reacts with most bases
producing corresponding sulfates. It also reacts with metals, non-metallic substances such as
carbon and sulfur producing gaseous substances (i.e. CO2 and SO2).
There are a vast number of applications of sulfuric acid. Basically, it is highly applied in the
production of fertilizers including calcium phosphate and magnesium sulfate, explosives,
petroleum products, detergents, dyes, insecticides, drugs, plastics, steel and storage batteries.
Due to the high affinity to water, pure sulfuric acid cannot be found on earth and has to be
produced in diluted forms. For the production of the magnesium sulfate, H2SO4(aq) can be
procured by importing it as concentrated sulfuric acid (98%) or as waste sulfuric acid from
manufacturing of TiO2 pigment. Otherwise it may be much economical to get supply the
sulfuric acid requirement by establishing a local manufacturing plant. When the waste
sulfuric is used as the raw material, the end product will also contain some other beneficial
nutrients (iron sulfate) making it much advantage to use as a fertilizer.
Sulfuric acid is commercially available in different concentrations. The most diluted one
holds 10% mass fraction of H2SO4 and is commonly known as diluted sulfuric acid. In mass
fraction of 29 to 32%, it is called as battery acid which used in lead-acid batteries. Solutions
contained, 62 to70% mass fractions are known as fertilizer acid or chamber acid which is
produced by the lead chamber process. With mass fraction around 80% H2SO4 called the
tower acid or Glover acid and finally with the mass fraction of 98% called the concentrated
sulfuric acid.
If the sulfuric acid is directly used for the reaction with dolomite without increasing the
concentration (i.e. 24% or less weight percentages), the yield of magnesium sulfate will be
low (Maria Demosthenous, 2013). If the higher concentration of the sulfuric acid (higher than
40%) is used for the reaction with dolomite, it would take an extra cost to increase the
concentration and on the other hand this can result in very high yield of magnesium sulfate
But it will make the separation of magnesium sulphate crystals from the liquor difficult
(Maria Demosthenous, 2013). Hence the acceptable range of the concentration of sulfuric
acid for it its reaction with dolomite lies in between 26 to 40%, which will require only a
temperature range of 35oC to 20oC in crystalline step.

2.2.2 Products
2.2.2.1 Main product - Fertilizer Grade Magnesium Sulphate
Chemical formula: MgSO4·7H2O - Magnesium Sulphate Heptahydrate; Epsom salt
Figure 2.3: Magnesium Sulphate [MgSO4]
Magnesium is an important nutritional component for chlorophyll being one of two such
nutrients that a plant can absorb from the soil. In other words, this nutrient plays a special
role in photosynthesis as a metallic element. It is the activating agent of many enzymes and
has a big effect for carbon metabolism, nitrogen metabolism and active oxide action of the
plant. Hence, magnesium can be considered as one of the major factors in the growth of a
plant, and will result in a lower yield if insufficient.
Many intensely, used lands are lack of magnesium especially the sandy-textured soils as well
as soils with a relatively low pH (most often highly weathered tropical soils are in such
nature). In this case, it is important to provide magnesium containing fertilizers especially to
the high yield expecting commercial crops.
Same as Magnesium, Sulfur deficiency also affects the growth of plants. Uniform pale color
leaves, severe stunting with reduced leaf size, and less branching caused by reduced activity
of axillary buds are some clear indications of sulfur deficiency in crops. Soils in heavy
rainfall areas as well as those with burned vegetation are often lack of Sulfur. Hence, by
externally providing magnesium to the soil in its sulphate form (i.e. MgSO4·7H2O,
MgSO4·H2O) both of this sulphur and magnesium deficiencies can be overcome
simultaneously.

Figure 2.4: Magnesium deficiency symptoms
Considering the chemical structure of the hydrate forms of magnesium sulfate; it exists in a
stable rhombic and in an unstable monoclinic form. The rhombic form is the stable phase in
aqueous solutions at normal temperatures.
In addition to the physical and chemical composition of a fertilizer, its physical state also
plays a major role in its effectiveness. Magnesium sulphate fertilizers are available in both
powder and granular form. It is perfect to be applied for the acid soils, highly leaching soils
and sandy soils.
Fertilizer grade magnesium sulphate is usually white in nature and used in many countries
and regions for the long term plantations including rubber, tobacco, and orange. In Sri Lanka,
Magnesium sulphate is used for agricultural purposes in both forms of Epsom salt
(MgSO4.7H2O) and Kieserite (MgSO4.H2O).
The basic process to manufacture the above two types of fertilizers are almost similar except
the additional steps to remove high amount of bounded water for kieserite (MgSO4.H2O). But
According to the recent (June, 2016) market prices for magnesium sulphate fertilizers in Sri
Lanka (refer Table 2.2), there is no much deviation between Epsom salt and Kieserite selling
prices. Hence, it will be much profitable to produce Epsom salt (MgSO4.7H2O) from the
proposed plant instead of Kieserite.
Table 2.2: Market prices for magnesium sulphate fertilizers in Sri Lanka
(Lakpohora.lk, 2016)
Selling Price per metric ton Selling price per bag 10 kg
Fertilizer
(LKR) (LKR)
Commercial Epsom salt 40,000.00 650.00
Kieserite 48,000.00 890.00

2.2.2.2. By product - Plaster of Paris
Chemical formula: CaSO4. H2O - Calcium Sulfate Hemihydrate
In the production process of the fertilizer grade magnesium sulphate from the reaction
between dolomite and sulphuric acid, solid gypsum (CaSO4. 2H2O) can be achieved as a side
product. When this gypsum is heated to a temperature around 150ºC, it turns in to Plaster of
Paris by losing water molecules. Likewise when water is added to Plaster of Paris, it turns
back in to gypsum.
𝛥 at 150ºC
Plaster of Paris has a wide range of applications from medical purposes to artistic purposes.
Commercially available Plaster of Paris is in the form of a dry white powder and in
architecture, it sets in to resilient lightweight structures after it‟s been shaped while wet. It
has medical applications such as orthopedic casts to support broken bones, dentistry
applications, for sculptures and murals as well as for fire protection material.
𝟏
Figure 2.5: Plaster of Paris [CaSO4. 𝟐 H2O]
2.3 Production process of the plant
The following part will describe the production process of fertilizer grade magnesium
sulphate of the proposed plant. The fundamental process steps along with some of the
important parameters which should be considered in designing the plant and their effect
towards the process will be as follow.

Dolomite
Ca.Mg(CO3)2(s)
Particle size reduction

for an optimum of 150µm
Sulphuric Acid
H2SO4(aq)
Leaching
(Reaction of dolomite with
sulphuric acid)
Solid – Liquid separation

using gravity settling followed
by vacuum filtration
Filtrate Residue
[MgSO4(aq)] CaSO4. 2H2O
Evaporation Drying
(Removal of free water) (Removal of bonded water)
Concentrated
MgSO4 solution
Crystallization (at below 10oC)

150ºC
followed by Centrifugation 𝛥
and Drying (100oC)
Fertilizer Grade Magnesium Sulphate Plaster of Paris

MgSO4.7H2O, MgSO4.H2O CaSO4. H2O
Figure 2.6: Production process of the proposed plant

2.3.1 Particle size reduction
It is essential to consider the optimum size of the dolomite particles as the reduction of size
will increase the surface area resulting high leaching efficiencies; but employing a high cost.
In previous researches the relationship between particle size and magnesium recovery by
leaching process has been studied (i.e. Rashad and Baioumy, 2005). Such studyings have
been identified that the optimum size of the dolomite particles to be 150µm for a maximum
yield of magnesium sulphate. But as the dolomite ore is available in 1m range, a hammer
crusher and a ball mill will use in series to achieve the required particle size.
2.3.2 Leaching
Here, the reaction of dolomite with sulphuric acid is to be carried out.
There are several important parameters to be manipulated in the leaching process; namely
temperature, reaction time and liquid to solid ratio. Previous researches had been carried out
to study the effect of these parameters on leaching process.
Effect of Temperature:
According to the research study of Rashad and Baioumy, 2005; as the temperature of
leaching process increases the magnesium recovery also increases.
100
90
MgSO4 Recovery %
80
70
60
50
40
20 30 40 50 60 70 80 90
Temperature (oC)
Figure 2.7: Effect of temperature on MgSO4 recovery

(Rashad and Baioumy, 2005)

If a low temperature is used, the magnesium recovery at equilibrium is reduced due to low
kinetic energy of the reactants. However if a higher temperature is used, it results in high
corrosive properties of sulfuric acid and increasing in the energy requirement making a
higher operational cost. Hence an optimum temperature has been found as 60oC which yields
the maximum production at a reasonable cost.
Effect of reaction time:
As in many reactions; the magnesium recovery also required a considerable amount of time
to reach the equilibrium stage. But as the reaction time increases, the required vessel volumes
also increase and result in escalating the manufacturing cost. Therefore to avoid those
difficulties, 50 minutes is considered as the optimum reaction time for the leaching process.
Effect of solid - liquid ratio:
Table 4.2 shows that the concentration of the leached magnesium is reducing with the
increment of solid to liquid ratio. At low ratios the solution is nearly saturated with the
magnesium and hence susceptible to loss of magnesium ions during the filtration. Also the
viscosity of the slurry is higher at lower solid to liquid ratios which will result difficulties in
filtration. At the higher solid to liquid ratios the viscosities as well as the concentrations are
reduced. As a result the filtration becomes easier, but the evaporation process will require a
large amount of energy and results in higher operational costs. Hence 1/4 gml-1 is selected as
the optimum solid-liquid ratio.
Table 2.3: Effect of Solid Liquid ratio on MgSO4 recovery

(Rashad and Baioumy, 2005)
Solid – Liquid ratio (gml-1) MgSO4 concentration (w/w %)
1:3 18.58
1:4 15.99
1:5 12.67
1:6 10.70
1:8 8.78
1:10 6.27

2.3.3 Solid liquid separation
Several options such as gravity settling, filtration and centrifuging are available for solid
liquid separation. The slurry obtained after the leaching is having a large amount of solids
and hence it is possible to settle them under gravity and the further separation is possible
using filtration. Even though centrifuging provides better filtration; due to the higher
operational cost it is not viable. In the case of filtration, vacuum filtration is selected over
pressure filtration considering its lower operational and maintenance cost along with its easy
removal of produced cake. Further, Anionic Polyacrylamide can be used to increase the
filtration rate in vacuum filtration.
2.3.4 Evaporation
The obtained filtrate by the solid liquid separation is not sufficiently concentrated for the
crystallization by cooling. Hence the evaporation is carried out to increase the concentration
of the filtrate by removing water. Instead of increasing the temperature above 100 oC the
required evaporation is possible to achieve using a multi effect evaporator system which will
operate under vacuum with a considerable operational cost reduction.
2.3.5 Crystallization
After increasing the magnesium sulphate concentration in the evaporation stage the
temperature of the liquid is dropped to allow the formation of the crystals. Depending on the
concentration achieved in the evaporating stage the structure of the formed crystals will vary.
According to the literature, concentrated filtrate with the densities of 1.35 to 1.45gml-1 gives
MgSO4.7H2O crystals and further increase in the density up to 1.5 give a mixture of
MgSO4.7H2O and MgSO4.6H2O. To achieve an acceptable yield of the product,
crystallization step will require a very low temperature (below 10 oC) (Rashad and Baioumy,
2005). After the crystallization of MgSO4.7H2O, the resulted stream is directed for
centrifugation in order to separate the crystals from its mother liquor.
2.3.6 Drying
The drying is to be taken place as the finishing step of Epsom production to remove free
moisture from centrifuged MgSO4.7H2O. Further, the residue which obtained from the
bottom of the settling tank and the vacuum filter is dried above 150oC to obtain plaster of
Paris by removing free water and bonded water of calcium sulphate using an industrial dryer.

2.4 Equipment for the production process
Dolomite
Ca.Mg(CO3)2(s)
Hammer Crusher followed

by a Ball Mill (+ Cyclone
Separator and a Bag Filter)
Sulphuric Acid
H2SO4(aq)
Reactor Vessel
(Continuous reactor)
Residue
Gravity Settler followed by a
CaSO4. 2H2O
Vacuum Filter
Filtrate
[MgSO4(aq)]
Evaporator Dryer 2
Concentrated
MgSO4 solution
Crystallizer followed by a 150ºC

Centrifuger and Dryer 1 𝛥
Fertilizer Grade Magnesium Sulphate Plaster of Paris

MgSO4.7H2O, MgSO4.H2O CaSO4. H2O
Figure 2.8: Equipment flow of the proposed plant

For the size reduction several type of equipment are available such as jaw crushers, hammer
crushers, roller mills, ball mills etc. Since the dolomite ores comprise of 1m size ranged rocks
and only hammer crushers are capable of handling such large ores, it is selected as the first
stage of size reduction. It will reduce the size up to the 25mm range and the size of the
obtained particles will be further reduced up to the required 150 μm range using a ball mill
(Clark, 2005). Afterwards the dolomite stream is directed to a cyclone separator and a bag
filter for a proper separation of the required particles. In addition, a pH adjusting vessel is to
be used in order to achieve the required sulphuric acid concentration (i.e. to dilute the 98%
sulphuric acid to the required concentration).
Since the products from the reactor are in the form of slurry, plug flow reactors are prone to
block easily; hence it is not selected for carrying out the process reaction. Although it is
possible to use both batch and continuous reactors for the leaching purposes, if a batch
reactor is used at least two reactors will be required for continuous operation and cleaning
after every batch will be labor intensive and costly. Hence a continuous reactor is more
suitable for the leaching. The other advantage of using CSTR is; if the required volume of the
reactor is undesirably large, it is possible to use two CSTRs which will give the same
expected results in combine.
For the solid liquid separation, both of a gravity settler and a vacuum filter are to be used.
Gravity settling is the economical method of separation due to its low energy cost and low
maintenance. Here, it is more suitable to build at least two parallel settlers and dimensions of
the settler will depend on the required separation. A vacuum filter is used for further
separation of the resulted liquor from the gravity settling tank where the vacuum will be
provided using steam jet ejectors.
The obtained liquid phase from the vacuum filtration is directed for multi effect evaporation
in order to reduce its density up to the required level and the resulted liquor will be moved to
the crystallizer. Crystallizer will reduce the temperature of the concentrated filtrate and allow
crystals to be formed (a refrigeration cycle or an adsorption chiller will be used for the
cooling purposes). After that, a centrifuger is used to separate the crystals from its mother
liquor and the finishing of the product will be obtained by removing additional moisture
using a dryer. For the production of Plaster of Paris and additional moisture removal of
Epsom salt; hot air dyers (such as fluidized bed dryers, kiln dryers, belt dryers) or the heated-
surface dryers (such as drum dryers) will be considered based on their suitability.

CHAPTER 3
FEASIBILITY STUDY AND PROCESS CHEMISTRY ESTABLISHMENT
Basically this chapter contains the feasibility analysis for the proposed project with intention
to determine whether it is viable with concerns on the aspects of plant location, economic
implications and HSE (Health, Safety and Environmental) impacts. It comprises of
preliminary technical and economic evaluations of the project that should be considered
before the extensive investments of time, effort and capital. Moreover, the latter part of the
chapter will outline the chemical engineering aspects of the selected process with conclusive
technical decisions.
3.1 Plant Location
Sri Lanka inherits very large reserves of dolomites that widely dispersed in the areas of
Kandy, Habarana, Ratnapura, Matale North and Badullla with negligible compostion
variations (Fernando, 1986).
Among them, Habarana stands

Dolomite Ore
out as the most accessible area
Locations
for an industrial setup of
Fertilizer Grade MgSO4
manufacturing plant with its
Trincomalee
geographical nature of
widespread plains as well as vast
Habarana
unpopulated areas.
Matale
In the case of infrastructure, with
Kandy
direct A-Level roadway access to
main agricultural cities such as
Colombo
Dambulla, Anuradhapura,
Balangoda
Polonnaruwa and Kurunagala;
Habarana is indeed a perfect
choice for the intended purpose.
Figure 3.1: Dolomite ore locations in Sri Lanka
(Abeysinghe, 1996)

On the other hand, with its close proximity to Trincomalee Sea Port, locally unavailable raw
materials such as sulpuric acid can be provided through the port. In there, it further has the
advantage of having a direct route through A6 to Trincomalee port which can facilitate the
transportation of raw materials (i.e. imported sulphuric acid) and products (especially for
exporting and distributing purposes).
In the utilities front, with the perk of being in the midst of agricultural lands; Habarana is
located in an area where a widely spread and water rich irrigation system exists throughout
the year. Electrical power is available from the National Power Grid and any additional fuel
can be easily supplied from the Trincomalee port.
As there is no any frequent extreme weather conditions as well as no recorded catastrophic

natural events, Habarana can be estimated as a naturally sheltered location to establish an
industrial production plant.
Habarana is centered by the areas with an agricultural base such as North central, Eastern and
Central provinces which are having of fertilizer interest as far as the Sri Lankan agro-market
is concerned. So by establishing the proposed plant in such area, the demand of the Fertilizer
Grade MgSO4 can be satisfied with no bother. Labour availability is also a very healthy factor
for this area with it being relatively close to well-populated areas with a traditional and
capable work force.
3.2 HSE (Health, Safety and Environment) Assessment
With the intention of achieving a high efficient production plant, investors are eager to use
advanced technological techniques. But in the case of legal and ethical aspects, it is also
important to concern about the safety, health as well as environmental impact caused by the
proposed production plant.
By proceeding a HSE assessment it is expected to minimize the major accident hazards

within and out of the proposed facility that can lead to both acute and chronic effects on
health and safety of the community and environment.
Following is a brief overview of an estimation of health, safety and environmental impact

caused by various elements in their production, storage and distribution associated with the
proposed industrial process.

3.2.1 Impacts from Raw Materials
3.2.1.1 Dolomite [Ca.Mg(CO3)2(s)]:
Hazardous level:
Dolomite is an odorless, non-hazardous, chemically stable as well as non-flammable

substance. According to the NFPA 704 hazard classification system; issued by the National
Fire Protection Association (NFPA) of United States, Dolomite has been identified as a
material that won‟t undergo combustion on typical fire conditions (will not burn in air when
exposed to a temperature of 820 °C for a period of 5 minutes) but it‟s exposure may cause
irritation to eyes, skin, respiratory system and gastrointestinal tract with only minor residual
(Lhoist Group, 2012). On the other hand, as the dolomite is naturally occurring mineral, any
adverse environmental impact cannot be expected that may result in severe damages.
Dolomite is not listed by OHSAS (Occupation Health and Safety Assessment Series) or
IARC (International Agency for Research on Cancer) as a carcinogenic material, but may
contain trace amounts of crystalline silica which has been classified by IARC as a carcinogen
to humans when inhaled in the form of quartz or crystallite.
Mitigation of hazards:
In the mining of dolomite ores, it is expected to implement safety and risk management
systems for reducing inaccurate ergonomics of workers, noise induced hearing losses and
respiratory diseases of workers and surround community.
The size reduction step (crushing from hammer crusher and ball mill) of the proposed MgSO4
production plant, may result in dolomite dust formation. Reductions of this respirable dust is
to be accomplished through engineering controls including dust collection; local exhaust
ventilation and water spray (application of water, surfactants or foam at the crusher, conveyor
feed and at other discharge points) systems.
In order to avoid the adverse health effects from the mineral dust N95/ Oxypura mask is to be
used as one of the Personal Protective Equipment (PPE) for the in-plant workers. Use of spill
resistant goggles and gloves are further recommended in case of excessive dust formations
and cleaning or maintenance procedures.

3.2.1.2 Sulphuric acid [H2SO4(aq)]
Hazardous level:
Sulphuric acid is a heavy, oily liquid which a pungent odor may exist based on the impurities
present in the acid. This is usually categorized as a hazardous and highly reactive non-
flammable substance.
According to the NFPA 704 hazard classification system, a short exposure of H2SO4(aq) could
cause serious or moderate temporary residual injuries that may result severe burns if
contacted on skin or eyes while mist may cause respiratory irritations. Inhalation and
swallowing of sulphuric acid is much harmful and even able to cause death. Further it may
undergo violent chemical changes at elevated temperatures and pressures and reacts violently
with water or may form explosive mixtures with water (NFPA, 2009).
Sulphuric acid may form flammable hydrogen gas upon the contact with most metals and
may create a corrosive environment by changing the acidic level of the surrounding. Further,
soil and water contamination can be happened if the storages are leaked or got spill.
As there is a possibility to generate heat by the process reaction, it is highly intended to use
corrosive resistant materials and heat resistant shields to fabricate the reactor vessel; as well
as it is important to store the acid with proper secondary containment (e.g. high-density cross-
linked polyethylene).
When dealing with sulphuric acid, chemical resistant goggles along with full face masks or
face shields, chemical resistant aprons, gloves and gum boots are to be used as PPEs. Use of
respirators is recommended based on the anticipated level of exposure and safe working
limits. Emergency showers and eye washers are to be installed in close proximity to storing
and handling areas of sulphuric acid.
In the case of accidental release, spillage will be covered with dry sand as a primary action it
is recommended to use spill control kits appropriately. Spilled substances will be prevented
from entering into sewers or waterways using drain lines. For the disposing process; sodium
carbonate, lime or any other suitable neutralizing agent has to be used to neutralize the
residue and loosely covered plastic containers are to be used for the discharge.

3.2.2 Impacts from Products
3.2.2.1 Magnesium Sulphate [MgSO4]
Hazardous level:
Magnesium sulphate is an odorless, non-flammable and non-hazardous solid substance with

negligible adverse environmental impacts. By the NFPA hazard classification system, it has
been ranked as a stable substance, even under fire exposure conditions. But it may be
hazardous in case of ingestion and slightly hazardous in direct skin contact.
It is recommended the use of rubber gloves, goggles and masks as PPEs when handling
MgSO4 to avoid skin and eye contacts. In case of a spillage, standard dry collecting methods
are to be used to gather spilled materials. In other words, the spilled residue should be
removed from surfaces using adequate amount of water and coir dust, shovels and brooms.
Moreover, spilled substance can be swept into containers after moistening to prevent dusting.
3.2.2.2 Plaster of Paris [CaSO4. H2O(s)]
Hazardous level:
Plaster of Paris is a non-flammable and non-hazardous substance in the form of a white

powder with no odor. According to the NFPA hazard classification system it has reported that
the exposure of Plaster of Paris would cause irritation with minor residual injuries. Further it
may harmful if swallowed and breathing the dusts may cause respiratory difficulties.
Addition of large amounts of Plaster of Paris into water resources can cause negative impacts
on the environment by increasing the hardness of water.
Processes that are related with Plaster of Paris are to be implemented with adequate
ventilation in order to avoid contact with eyes, skin and respiratory system. It is
recommended to thoroughly wash the contacted areas with water after handling Plaster of
Paris. As PPEs, rubber gloves, goggles and masks are to be used. In case of a spillage, dry
methods are recommended to collect spilled materials.

3.2.3 General Concerns
By the design, various protection layers are to be in place within and around the plant to
lower the frequency of undesired consequences related with the operation of the proposed
plant. For example, the proposed plant is to be established away from the suburbs and
populated areas in order to avoid any undesirable impacts on health and safety of the
community or environment.
Standard operating procedures of the equipment and basic process control systems must be
implemented to prevent the occurrence of hazardous incidents and to ensure the process risk
is successfully mitigated to an acceptable level; alarms with defined operator response, Safety
Instrumented Systems (SIS), pressure relief devices (active devices) are to be employed
during the operation of the plant. Blast walls and dikes (passive devices), gas and fire
protection systems and deluge systems are to be used as the plant emergency response
techniques.
Community emergency response

Emergency Broadcasting
Plant emergency response

Evacuation procedures
Mitigation
Mechanical mitigation system, safety instrumented mitigation system,
operator supervision
Prevention
Mechanical protection systems, Process alarms with operator
corrective action, safety instrumented control system, safety
instrumented prevention system
Control and monitoring

Basic process control systems, monitoring systems (process
alarms), operator supervision
Process
Figure 3.2: Protection layers of the proposed plant

3.3 Economic Evaluation
The following economic evaluation is to identify the best course of actions for the proposed
plant in the aspects of production capacities, capital expenditures, wages for employees and
other project appraisals based on the evidence available.
3.3.1 Production capacity calculations
Table 3.1: Production capacity of Fertilizer Grade Magnesium Sulphate [MgSO4.7H2O (Epsom)]
Quantity
(Metric tons per annum)
Total Production of Epsom estimated for the plant 100,000
Amount of Epsom production for local consumption

30,000
(based on the current local demand)
Amount of Epsom production for export purposes
70,000
(= total production – local demand)
Table 3.2: Production capacity of Plaster of Paris [CaSO4.1/2H2O]
Quantity
(Metric tons per annum)
Total production of Plaster of Paris 190,759
Amount of Plaster of Paris production for local

57,238
consumption (based on the current local demand)
Amount of Plaster of Paris production for export
133,521
purposes (= total production – local demand)
The additional production quantities (which exceeds the local demand) of Epsom salt and
Plaster of Paris is to be exported with more focusing on their demand on regional basis; i.e. It
is much viable to concern the East Asian market for exporting the Epsom salt, as they‟re
having a forecasted annual growth rate of 3.2% in Epsom demand for next 10 years (Global
Heptahydrate (Epsom Salt), 2016) and for exporting the Plaster of Paris, African market is
preferable due to the 10% annual growth of their regional Plaster of Paris demand.

3.3.2 Capital expenditure
Capital expenditure is calculated based on the costs of required equipment and the costs
related with the proposed land, transportation, piping and installation, management software,
civil works and other applicable rates. In some cases, calculations have been proceeded using
linear interpolation of expenditures for the prevailing plants with respect to the capacities.
All the calculations and the estimations are done based on 1USD = 145LKR
Table 3.3: Machinery cost (Liquidity Services, 2013)
Unit price
Equipment Quantity Cost (LKR)
(LKR)
Hammer crusher 1 3,625,000 3,625,000
Ball mill 1 14,500,000 14,500,000
Cyclone separator and Bag filters 1 2,900,000 2,900,000
pH adjusting vessel 1 4,350,000 4,350,000
Reactor 1 29,141,000 29,141,000
Gravity settling tanks 2 11,656,400 23,312,800
Vacuum filters 2 4,371,150 8,742,300
Evaporator and Crystallizer 2 7,285,250 14,570,500
Dryer 2 22,086,750 44,173,500
Centrifuger 1 5,800,000 5,800,000
Boiler 1 14,500,000 14,500,000
Pumps 5 2,900,000 14,500,000
Cooling tower 1 7,250,000 7,250,000
Heat exchangers 6 7,250,000 43,500,000
Sulphuric tanks 4 22,000,000 88,000,000
Earth moving vehicle (Backhoe) 1 15,000,000 15,000,000
Waste water treatment plant 1 17,000,000 17,000,000
Quality control equipment (Digital
1 by each 5,000,000
balance + oven + pH meter)
Workshop items 3,130,000
Total 358,995,100

In order to calculate the total capital expenditure, it is assumed that the required area for the
proposed plant site is 25 hectares (1 hectare of land costs 10 million LKR) while the total
piping and installation cost is holding 30% and the transporting with other applicable rates
are holding 40% from the total machinery cost. The contingency for the total capital
expenditure is taken as 10% from the total machinery cost.
Table 3.4: Total capital expenditure calculations
Unit cost
Type Total Cost (LKR)
(LKR)
Total machinery cost 358,995,100
Land cost 10,000,000 250,000,000
Piping and installation 30% 107,698,530
Transporting and other applicable rates 40% 143,598,040
Facilities development 3,000,000
Plant management software (Stellmack, 2016) 10,000,000 10,000,000
Civil works 12,000,000 12,000,000
Contingency 10% 35,899,510
Total capital cost 921,191,180
3.3.3 Overheads
This term includes the ongoing expenses of operating the plant along with power
requirements, process water and chemical requirements, expenses related with water disposal,
insurance and the other utilities (compressed air, cooling). All the costs are calculated based
on the details in 3.3.2 and the results from chapter 4.
Here, it is assumed that the total electricity requirement is gained from the National Grid at a
charge of 12.20 LKR per kWh with fixed costs (Ceylon Electricity Board, 2015) and the
furnace oil for the operation of boiler and dryers are gained from Ceylon Petroleum
Corporation at a charge of 80.00 LKR per litre (Ceypetco, 2015). Cost for the safety
equipment is presumed with the concern of HSE Assessment in 3.2

Table 3.5: Calculations for overheads (Stellmack, 2016)
Cost per year

(LKR)
Insurance 7,200,000
Furnace oil 10,000,000
Electricity 4,200,000
Water 4,000,000
Water disposal 7,000,000
Chemicals 5,000,000
Safety equipment 10,000,000
Other costs 2,500,000
Total cost 49,900,000
3.3.4 Raw material costs
For the proposed plant, dolomite and sulphuric acid are to be used as main raw materials
while the water is utilized as a sub raw material. Following calculations are carried out to
determine the costs for those raw materials.
Table 3.6: Raw material costs (RELX Group, 2016)
Unit cost Units Cost per year

Material Type of cost
(LKR per MT) (MT) (LKR)
Procurement + Loading +
Dolomite 45 195,814 8,811,630
Transport
Purchasing 22,086 174,557 3,855,265,902

Sulphuric
acid (98%)
Transport 2,000 174,557 349,114,000
Water Procurement 4 713,026 2,852,104
Total cost 4,216,043,636

3.3.5 Calculations of wages
Accordance with the proposed machinery and the other requirements, the number of
employees for the plant site are estimated to be 110 and all the costs are determined based on
the prevailing local salary status relating to the machinery and expenditure details in 3.3.2.
Table 3.7: Calculations for wages
Salary per Number of Wages per

Occupation
month (LKR) employers month (LKR)
Factory Manager 200,000 1 200,000
Project Engineer (Mech. & Electrical) 150,000 2 300,000
Assistant Engineer 80,000 3 240,000
Technician 50,000 20 1000,000
Operators 35,000 36 1,260,000
Lab operators 50,000 2 100,000
Security Guards 35,000 7 245,000
HR person 50,000 2 100,000
Store Keeper 40,000 3 120,000
Finance Manager 70,000 2 140,000
Account assistant 30,000 2 60,000
Supportive staff 25,000 30 750,000
Total number of employees 110
Total wages per month 4,515,000
Total cost for one year 54,180,000
Now, the following financial analysis is carried out in order to assess the economic viability
of the project by determining its Internal Rate of Return (IRR) and the payback period. The
operating life time of the plant is considered as 15 years.

3.3.6 Project appraisal
Table 3.8: Project appraisal
Unit cash flow Quantity Total cash flow

(LKR per MT) (MT per year) (LKR per year)
Epsom production capacity 100,000
Epsom selling price (Local) 40,000 30,000 +1,200,000,000
Epsom selling price (Foreign) 21,000 70,000 +1,470,000,000
Plaster of Paris production capacity 190,759
Plaster of Paris selling price (Local) 14,000 57,238 +801,332,000
Plaster of Paris selling price (Foreign) 17,500 133,521 +2,336,617,500
Revenue +5,807,949,500
Total Material cost -4,216,043,636

Transportation, taxes & demurrages
2,600 70,000 -182,000,000
(to East Asian market) for Epsom
Transportation, taxes & demurrages
7,500 133,521 -1,001,407,500
(to African market) for P.O.P.
Gross Profit +408,498,364
Administration costs (wages) -54,180,000
Overhead Costs -49,900,000
Depreciation cost - 61,186,000
Other costs - 20,000,000
Profit before tax +223,232,364
Taxes 15% - 33,484,855
Profit after tax +189,747,509
Total capital cost -921,191,180
Scrap value +3,401,180
Discount rate 14%
IRR 22%
Payback period 7.6 years

Now, the NPV values are calculated for 15 years (refer annex1) and using the obtained values
the payback period for the proposed plant can be determined as shown in the figure 3.3.
600
400
200
0
NPV (LKR x 106)
0 2 4 6 8 10 12 14 16
-200
-400
-600
-800
-1,000
Time (Year)
Figure 3.3: Graph | NPV Vs Time
Hence, the payback period for the proposed project is 7.6 years.
Initial Investment 921,191,180 LKR
Operating Plant Life Time 15 years
Net Present Value after 15 years 408,566,330 LKR
Payback Period 7.6 years
IRR 22%
As a summary, the proposed project has a payback period of nearly a half of its operating life
time and the Internal Rate of Return (IRR) of the project is 22% when the discount rate is
14%. Hence, it can be deduced that this proposed Fertilizer Grade Magnesium Sulphate
Manufacturing Plant is much economically viable to implement.

3.4 Chemical Engineering Aspect of the Process
This section includes the process chemistry establishment of the proposed plant with basic
reaction steps and their kinetics, unit processes and expected flow rates etc.
3.4.1 Basic reaction steps and reaction kinetics
3.4.1.1 Reactor
Two desired reactions in the reactor vessel will be as follow.
MgCO3(s) + H2SO4(aq) MgSO4(aq) + CO2(g) + H2O(l)
CaCO3(s) + H2SO4(aq) CaSO4.2H2O(aq) + CO2(g) + H2O(l)
The optimum conditions for the above reactions;
Temperature 60 0C
Liquid to solid ratio 1:4 gml-1
Particle size 150 µm
Reaction time 50 min
In addition, the following reactions may also occur within the reactor due to the impurities in
dolomite. Since the percentages of these impurities are very low it can be appropriately
neglected for further calculations.
Fe2+(s) + SO42-(aq) FeSO4(aq)
2Al3+ (s) + 3SO42-(aq) Al2(SO4)3(aq)
3.4.1.2 Dryer 2 (POP Dryer)
In the dryer, which is used for the production of Plaster of Paris as the by product, first the
free water will be removed and then the following reaction will be occurred in order remove
bonded water of solid CaSO4. 2H2O.
𝛥 at 150ºC

3.4.2 Unit processes and flow rates
3.4.2.1 Particle size reduction
As a raw material preparation step, particle size reduction of dolomite is to be done using a
hammer crusher and a ball mill followed by a cyclone separator and a bag filter. Here, an
exhaust fan will be used for the removal of dust.
Flow rate for the particle size reduction is estimated as 652.7118 MT per day.
3.4.2.2 Reactor
The sulphuric acid feed stream to be directed to the reactor through a pH adjusting vessel. In
there the preheating of sulphuric acid stream can be done using the recycling the steam
generated from the dryers.
Flow rate of solids (dolomite) is estimated as 652.7118 MT per day while the flow rate of
liquid (sulphuric acid) is 2,958.6121MT per day.
3.4.2.3 Solid liquid separation
For the solid liquid separation process the slurry which consists of gypsum, magnesium
sulphate and free water is to be directed at a rate of 3,382.9915 MT per day. The flow rate of
resulted solid stream is estimated as 806.6625 MT per day and the flow rate of liquid will be
2,576.3289 MT per day.
Further, liquid stream which is out of the vacuum filter is to be preheated using the steam
generated from the evaporator while the solid stream is directed to the POP dryer.
3.4.2.4 Evaporation
The filtrate from the separation unit is the magnesium sulphate pregnant liquor with density
of 1.0639gml-1 and it is required to be concentrated up to 1.45gml-1 in order to obtain
MgSO4.7H2O (Epsom salt).
Nearly 2117.3371 MT of water will be removed from the magnesium sulphate liquor daily
and flow rate of liquid will be 458.9917MT per day.

3.4.2.5 Crystallization
In order to cool the concentrated magnesium sulphate liquor (which resulted from the
evaporator) is to be used in a combine heat exchanger and heat up the feed sulphuric acid
stream. Then further reduction of temperature will be done using cooling water before it enter
the crystallizer. Then the crystallizer will reduce the temperature of the liquor below 10 oC to
form Epsom salt crystals. An adsorption refrigeration cycle will be used instead of vapor
compression refrigeration cycle due its lower energy requirement. Here, Epsom salt with
purity over 99% is to be produced.
The inlet flow rate of liquid stream to the crystallizer will be 458.9917MT per day.
3.4.2.6 Centrifugation
In the centrifugation process, resulted mother liquor will be removed from the product stream
with a continuing removal of free water. Here, it is estimated that the weight concentration of
MgSO4 in the super saturation liquid is 5.6% and the wastewater flow rate from the
centrifuger will be 92.1133 MT per day.
3.4.2.7 Drying
In the proposed process line, two drying units are to be implemented. The first one is in the
main product line and it will be used to remove additional moisture from Epsom salt at a rate
of 33.5466 MT per day.
The second dryer will be used for the production of Plaster of Paris. There, the free water
from CaSO4.2H2O will be removed at first. Then the solids will be further heated to obtain
the CaSO4.1/2H2O (Plaster of Paris) by removing the bonded water. Waste heat from the
boiler flue gas and the furnace oil combustion are the possible energy sources for this
process.
Even though the plaster of Paris will be slightly contaminated with MgSO4, SiO2 and FeSO4 it
will not affect the overall product quality. Production flow rate of Plaster of Paris for this unit
is estimated as 166.6592 MT per day.

CHAPTER 4
MASS AND HEAT BALANCE FOR THE PROPOSED PLANT
Under this chapter, material and energy balance calculations for the proposed fertilizer
manufacturing plant is carried out based on the mass and energy conservation theories and
other basic concepts of chemical engineering in order to estimate its utility requirements.
4.1 Material Balance
The widely applied formulas for the material balance calculations are as follow;
Rate of Rate of mass Rate of Rate of mass Rate of mass

+ = + +
mass in generated mass out accumulated reacted
Mass flow rate of a Volumetric flow rate Density of the

= x
component of the component component
Further in calculations, it is assumed that the number of operating days per annum for the
proposed plant is 300.
4.1.1 Data
Table 4.1: Molecular weights of chemicals (Perry, 2008)
Molecular mass (gmol-1)

Mg 24.30
Ca 40.08
CO32- 60.01
H2SO4 98.08
CO2 44.01
H2O 18.02
MgSO4.7H2O 246.47
CaSO4.2H2O 172.17

4.1.2 Calculations
The following mass balance calculations are carried out for the proposed plant operated under
a production capacity of 100,000 MT of MgSO4.7H2O per year.
4.1.2.1 Dolomite [Mg.Ca(CO3)2] requirement
Production capacity of the proposed plant = 100,000 MT of MgSO4.7H2O per year
Annual Mg requirement of the production plant = 100,000 MT per year x
= 5,859.2120 MT per year
Theoretical dolomite [Mg.Ca(CO3)2] requirement = 5,859.2120 MT per year x
= 186,022.8693 MT per year
Assuming overall magnesium recovery of the plant is 95%;
Actual dolomite [Mg.Ca(CO3)2] requirement = 186,022.8693 MT per year x
= 195,813.5466 MT per year

= 652.7118 MT per day; assuming 300
operating days
4.1.2.2 Sulphuric [H2SO4(aq)] requirement
In the reactor, it is expected the following chemical reactions of sulphuric acid with Calcium
(Ca2+), Magnesium (Mg2+), Iron (Fe2+) and Aluminium (Al3+) consists in dolomite.
Ca2+ (s) + H2SO4(aq) CaSO4(S) + 2H+(aq)
Mg2+ (s) + H2SO4(aq) MgSO4(aq) + 2H+(aq)
Fe2+ (s) + H2SO4(aq) FeSO4(aq) + 2H+(aq)
Al3+ (s) + 1.5 H2SO4(aq 0.5 Al2(SO4)3(aq) + 3H+(aq)
Using the stoichiometry of the above reactions, sulphuric acid consumption within the reactor
and the relevant mass flow rates can be calculated as follow.

Table 4.2: Sulphuric requirement of dolomite (Liyanage and Alles, 1999)
Sulphuric
Molecular
Kg per MT kmol per MT Stoichiometry requirement
mass
of dolomite of dolomite with H2SO4(aq) (kmol per MT
(gmol-1)
of dolomite)
Ca2+ 269 40.08 6.7115 1:1 6.7115
Mg2+ 53 24.30 2.1810 1:1 2.1810
Fe2+ 0.67 55.85 0.0119 1:1 0.0119
Al3+ 0.05 26.98 0.0018 1:1.5 0.0028
8.9072
Hence, required molar flow rate of H2SO4(aq) = 195,813.5466 x 8.9072 kmol per year
=1,744,150.4220 kmol per year
Since optimum solid : liquid ration is 1 : 4;

Required volumetric flow rate of H2SO4(aq) = 195,813.5466 MT per year x 4 m3MT-1
= 783,254.1865 m3 per year
Concentration of required H2SO4(aq) = = 2.2268 kmolm-3
Figure 2.1 narrates the density variation of H2SO4 solutions with its molar concentration
(moldm-3) values.
1.9
1.8
y = -0.0009x2 + 0.0629x + 0.9976
1.7
Density (gcm-3)
1.6
1.5
1.4
1.3
1.2
1.1
1
0 4 8 12 16
Molar concentration (kmlom-3)
Figure 4.1: Graph | molar concentration vs density of H2SO4(aq) (Haynes, 2014)

Hence, density of required H2SO4(aq) = 1.1332 MTm-3 (Figure 4.1)
Mass flow rate of H2SO4(aq) = 783,254.1865m3 per year x 1.1332MTm-3

= 887,583.6441 MT per year
= 2,958.6121 MT per day; assuming 300
operating days
The requirement of 98% (1.8361gcm-3) H2SO4(aq) can be calculated as follow;
Molar concentration of 98% H2SO4(aq) = 18.3460 kmolm-3 (Figure 2.1)
98% H2SO4(aq) requirement = 195,813.5466 x m3 per year
= 95,069.7930 m3 per year

= 316.8993 m3 per day ; assuming 300
operating days
Required mass of 98% H2SO4(aq) = 95,069.7930 m3 per year x 1.8361MTm-3

= 174,557.6469 MT per year
operating days
Hence, water requirement to dilute = 887,583.6441 - 174,557.6469

98% H2SO4(aq) = 713025.9972 MT per year
operating days
Hence, weight percentage of diluted sulphuric = = 19.2732%
H2O
713025.9972 MT per year
98% (1.8361gcm-3) H2SO4(aq) Diluting Vessel 19.2732% (1.1332gcm-3) H2SO4(aq)
174,557.6469 MT per year (pH adjustor) 887,583.6441 MT per year
Figure 4.2: Dilution of H2SO4(aq)

4.1.2.3 Calculations for reactor
CO32- (s) +2 H+(aq) H2O(l) + CO2(g)
Since CO32- is available in 477 Kg per MT of dolomite (Liyanage and Alles, 1999);
Reacting CO32- (s) moles per year = 195,813.5466 MT per year x
= 1,556,458.286 kmol per year
By the stoichiometry of the reaction CO32- : H2O : CO2 = 1 : 1 : 1
CO2 production from the reaction = 1,556,458.286 kmol per year x MTkmol-1
= 68,499.7292 MT per year

operating days
H2O production from the reaction = 1,556,458.286 kmol per year x MTkmol-1
= 28,047.3783 MT per year

operating days
Since microscopic moisture is available in 56.47 Kg per MT of dolomite;

(Liyanage and Alles, 1999)
Total H2O production in reactor = 28,047.3783 + (195,813.5466 x )

= 39,104.9250 MT per year
operating days
4.1.2.4 Calculations for product flow rates
The products will be generated according to the following reaction;
Since Ca is available in 269 Kg per MT of dolomite (Liyanage and Alles, 1999);

CaSO4.2H2O production = 195,813.5466 MT per year x
= 226,268.8555 MT per year

= 754.2295 MT per day ; assuming 300
operating days

Since Mg is available in 53 Kg per MT of dolomite (Liyanage and Alles, 1999);
MgSO4 production = 195,813.5466 MT per year x
= 51,407.9860 MT per year

= 171.3600 MT per day ; assuming 300
operating days
From the obtained calculations up to now;
Dolomite [Ca.Mg(CO3)2(s)] CO2(g)

195,813.5466 MT per year 68,499.7292 MT per year
Reactor
H2SO4(aq)
887,583.6441 MT per year
Slurry [CaSO4.2H2O(s) + MgSO4(aq) + H2O]
Figure 4.3: Mass balance of the reactor
Total mass input to the reactor = 195,813.5466 + 887,583.6441 MT per year

= 1,083,397.1910 MT per year
Hence, slurry output from the reactor = 1,083,397.1910 - 68,499.7292 MT per year
= 1,014,897.4620 MT per year
operating days
Since the slurry basically consists of CaSO4.2H2O(s), MgSO4(aq) (and impurity of FeSO4(aq),
Al2(SO4)3(aq), HCl(aq)) with free water (H2O) as the solvent;
Solvent content of the slurry = 1,014,897.4620 – (26,268.8555 + 356.85 + 62.07

+ 13477.68 + 2775.57 + 51,407.9860)
= 720,550.613 MT per year
operating days
The obtained slurry will be directed to the solid-liquid separation process in order to yield
CaSO4.2H2O and MgSO4(aq) in separate streams.

4.1.2.5 Calculations for solid-liquid separation
Assumptions : In the separation process, all the CaSO4.2H2O is separated (hence its content in
the filtrate is negligible) and the moisture equivalence of the solid stream is 6.5% of
its total mass after the separation process.
Hence, Solid flow rate after separation = (226,268.8555 x ) MT per year

(CaSO4.2H2O(s) + aqueous solution)
= 241,998.776 MT per year
operating days
Liquid flow rate after the separation = 1,014,897.4620 - 241,998.776 MT per year
(MgSO4(aq)) = 772,898.686 MT per year
operating days
Liquid stream [MgSO4(aq)]

Slurry [CaSO4(s) + MgSO4(aq) + H2O]
772,898.686 MT per year
Separator
1,014,897.4620 MT per year
Solid stream [CaSO4.2H2O(s) + MgSO4]
241,998.776 MT per year
Figure 4.4: Solid-liquid separation
Aqueous content in the solid stream = (241,998.776 x ) MT per year

= 15,729.9205 MT per year
Hence, mass concentration of MgSO4 = x 100%

in the liquid stream
= x 100% = 6.5187%
Figure 4.5 narrates the density variation of MgSO4 solutions with its mass concentration
(w/w%) values. Hence;
Density of the liquid stream = 1. 0639 gml-1 (Figure 4.5)

According to the literature; the required density for the crystallization of MgSO4.7H2O is
1.45 gml-1 (Rashad and Baioumy, 2005). Hence after the evaporation, the mass concentration
of the MgSO4 in liquid stream stream should be 36.5894% (Figure 4.5).
1.35
1.3
y = 0.0126x + 0.9818
1.25
1.2
Density (gcm-3)
1.15
1.1
1.05
1
0.95
0.9
0 5 10 15 20 25 30
Mass concentration (w/w%)
Figure 4.5: Graph | (w/w)% vs density of MgSO4(aq) (Haynes, 2014)
4.1.2.6 Calculations for evaporator
Free water removal

MgSO4(aq)
Evaporator
772,898.686 MT per year MgSO4(aq)
Density = 1.0639 gml-1 (w/w)MgSO4 = 36.5894%
Density = 1.45 gml-1
Figure 4.6: Mass balance of the evaporator
Total liquid flow rate out of the evaporator = = 137,697.3686 MT per year

operating days
Free water removal from the evaporator = (772,898.686 - 137, 697.3686) MT per year
= 635201.153MT per year
operating days

4.1.2.7 Calculations for Epsom [MgSO4.7H2O(s)] production
Once the MgSO4 pregnant liquor of 1.0639gml-1 was concentrated to 1.45gml-1 using the
evaporator, it is directed to the crystallizer through a trim cooler to form MgSO4.7H2O
crystals by cooling to 0oC.
Since Al2(SO4)3 and FeSO4 are highly soluble in water and its present amount in the product
stream is small (respectively 0.044% and 0.253% in w/w); the crystallization of above two
salts are assumed to be negligible.
The crystallizer operates at 0oC to produce Epsom salt and the saturation concentration of
MgSO4(aq) at 0oC is 5.6% (Haynes, 2014).
MgSO4(aq), 36.5894% (w/w)

137,697.3686 MT per year W
-1
Density = 1.0639 gml L
S MgSO4.7H2O(s)
Crystallizer Centrifuger Dryer 1
L 100,000 TPA
Super saturated MgSO4(aq)

L
5.6% (w/w)
Figure 4.7: Mass balance of Epsom production
Applying material balance to the crystallizer and centrifuge in combine;
137,697.3686 = S + L (1)
Applying material balance to the dryer1;
S = W + 100,000 (2)
Applying overall species balance for MgSO4;
(137,697.3686 x 0.3659) = (L x 0.056) + (100,000 x ) (3)

By solving the above equations;
Waste water flow from the centrifuge (L) = 27,633.9886 MT per year
operating days
Inlet flow rate to the dryer 1 (S) = 110,063.380 MT per year
operating days
Moisture removal from dryer 1 (W) = 10,063.380 MT per year

operating days
3.4.2.8 Calculations for Plaster of Paris [CaSO4. H2O(s)] production
Water removal
CaSO4.2H2O(aq) + aqueous solution Dryer 2
241,998.776 MT per year (POP Dryer) CaSO4. H2O(s) + MgSO4.H2O
Figure 4.8: Mass balance of the dryer 2
Since Ca is available in 269 Kg per MT of dolomite (Liyanage and Alles, 1999);
CaSO4. H2O production = 195,813.5466 x MT per year
= 190,758.6942 MT per year

operating days
Since the aqueous solution of 15,729.9205 MT per year is carried away by the solid stream
after the separation process, the Plaster of Paris cannot be achieved in its pure form. In fact,
the impurities from the ferrous, aluminum, magnesium and sulphate contents will be present
in the product stream and it can be estimated as 1242.309 MT per year.

Hence, purity of the produced Plaster of Paris = x100% = 99.35%
Water removed from dryer 2 = 241,998.776 – (190,758.6942 + 1242.309)

= 49997.7728 MT per year
operating days
3.4.2.9 Calculations for the wastewater stream
Assuming all ferrous and aluminum contents in the liquid stream are removed with waste
water stream (FeSO4 and Al2(SO4)3 contents in the solid streams can be estimated as 7.11 and
1.23 MT per year respectively);
Since Fe is available in 0.67 Kg per MT of dolomite (Liyanage and Alles, 1999);
FeSO4 content in wastewater = (195,813.5466 x ) – 7.11

= 349.71 MT per year
operating days
Since Al is available in 0.05 Kg per MT of dolomite (Liyanage and Alles, 1999);
Al2(SO4)3 content in wastewater = (195,813.5466 x ) – 1.23

= 60.84 MT per year
operating days
MgSO4 content in wastewater = 27,633.9886 x 0.056 MT per year

= 1547.5034 MT per year
operating days

4.2 Energy Balance
The widely applied formulas for the energy balance calculations are as follow.
From the energy conservation theorem;
Rate of Rate of energy Rate of Rate of energy Rate of energy

+ = + +
energy in generated energy out accumulated reacted
For a stream that comprises of n components;
̇
∑ ̃ ∫ ̃
where ̇ = Mass flow rate of the i component (kgs-1)

Mi = Molecular mass of i component (kgkmol-1)
T = Temperature of the stream (K)
̃ = Specific molar enthalpy of formation of i at To (kJkmol-1)
̃ = Specific molar heat capacity of i (kJkmol-1K-1)
The energy balance calculations are carried out based on the obtained mass flow rates from
the above section of material balance. The data including specific mass enthalpy and specific
mass heat capacity values of each species are referred from (Perry, 2008) “Perry’s Chemical
Engineers’ Hand Book, 8th edition” and interpolations of data are applied where necessary.
i.e.
Table 4.3: Physical properties of species (Perry, 2008)
(x 103 kJkmol-1) ̃ (x 103 kJkmol-1K-1)
Ca.Mg(CO3)2(s) -2338.0192 167.7784 (for 299-372K)
CaSO4. 2H2O(s) -2005.5167 195.8112 (for 282-373K)
MgSO4(aq) - 1361.4736 111.7128(for 296-372K)

etc.
For some of the process units energy balance calculations are carried out using computer
based simulation methods (ASPEN PLUS V.8) and their energy balance is presented in the
form of energy flow in each stream of the system.

4.2.1 Particle size reduction
Here, we consider the energy requirement of the each equipment that are to be used for the
preparation of raw materials (i.e. hammer crusher, ball mill, cyclone separator and bag filter
for the particle size reduction process of dolomite and pH adjuster to achieve the required
sulphuric acid concentration).
The required capacities of the equipment are calculated based on the material balance in the
previous section and as the particle size reduction is a physical process; the temperatures of
the streams are assumed to be steady at the ambient temperature (30oC)
Based on the data acquired by the literature, net energy requirements for each of the
industrially available equipment can be tabulated as follow. (It has been assumed that the
energy efficiencies of cyclone separator, bag filter and pH adjuster are 95%, 99% and 98%
respectively);
Table 4.4: Energy requirement for particle size reduction (Focus Technology Co., Ltd, 2016)
Energy requirement
-1
Equipment Capacity (MThr )
(kW) (KJ per day)
Hammer Crusher 81.5889 of dolomite 100.52 8,684,928.00
Ball Mill 81.5889 of dolomite 567.37 49,020,768.00
299,808 .00
Cyclone Separator 81.5889 of dolomite 3.47
(95% efficiency)
64,800.00
Bag Filter 81.5889 of dolomite 0.75
(99% efficiency)
13,390,272.00
pH Adjuster 72.7324 of 98% H2SO4 154.98
(98% efficiency)
Total Energy requirment 827.09 71,460,576.00

4.2.2 Reactor
Dolomite [Ca.Mg(CO3)2(s)], 30oC CO2(g), 60oC

-20.8933 x 103 kW -23.5338 x 103 kW
Reactor
o
H2SO4(aq) , 30 C
-490.8715 x 103 kW
Slurry [CaSO4(s) + MgSO4(aq) + H2O]
-466.8925 x 103 kW
Figure 4.9: Energy balance for the reactor
𝛥H reactor = (-466.8925 x 103) + (-23.5338 x 103) – [(-20.8933 x 103) + (-490.8715 x 103)] kW

= 21.3385 x 103 kW = 76,818.60 x 103 kJ per hour = 1843.6464 x106 kJ per day
Assuming the reactor is well insulated and hence only 1% of the supply energy is wasted;
Required energy = 21.3385 x 103 kW x = 21.5540 x 103 kW = 1862.2656 x106 kJ per day
This energy requirement is to be supplied by recycling the steam generated from the dryers
and evaporator (operated at 108oC). For the calculations, amount of heat that will be released
by the generated steam while it is cooling down to 30oC can be taken as the excess energy of
the steam. Hence;
Total recycle steam supply = Steam generated from evaporator + dryer 1 + dryer2
= (2117.3371 + 33.5446 + 166.6592) MT per day
= 2317.5409 MT per day
Excess energy in the steam = Energy content of the steam from evaporator + dryer 1 + dryer2
= [2117.3371 x(2692.14-125.81)] + [33.5446 x (2676.01-125.81)]
+ [166.6592x (2776.81–125.81)]
= 5563.4947 x 106 kJ per day
Hence, Extractable excess = (5563.4947 - 1862.2656) x 106 kJ per day

energy from the steam = 3701.2291 x 106 kJ per day

4.2.3 Solid-Liquid Separation
4.2.3.1 Gravity Settling Tank
Capacity of the Gravity Settling Tank = 3,382.99 MT per day
According to the literature, the energy requirement for the industrially available gravity
settling tank of the above capacity is 12 kW (Focus Technology Co., Ltd, 2016).
Assuming that the gravity settling process is operated at the ambient temperature (30oC) and
the total energy efficiency of the gravity settling tank is 85%;
Actual energy consumption = 12 x kW = 14.1176 kW
= 1,219,760.64 kJ per day
4.2.3.2 Vacuum Filter
Capacity of the Vacuum Filter = 2900.00 MT per day
According to the literature, the energy requirement for the industrially available vacuum filter
of the above capacity is 18.5 kW (Focus Technology Co., Ltd, 2016).
Assuming that the energy efficiency of the vacuum filter is 80%;
Actual energy consumption = 12 x kW = 23.1250 kW
= 1,998,000.00 kJ per day
Table 4.5: Energy requirement for solid-liquid separation (Focus Technology Co., Ltd, 2016)
Energy requirement
Equipment Capacity (MThr-1)
(kW) (KJ per day)
1,219,760.64
Gravity Settling Tank 3,382.99 14.1176
(85% efficiency)
1,998,000 .00
Vacuum Filter 2900.00 23.1250
(80% efficiency)
In order to enhance the efficiency of the vacuum filter, a steam ejector is to be used.
According to the literature, the steam ejector will consume energy at a rate of 2 x103 kW.

4.2.4 Evaporator
After the separation process the liquid stream is at 55oC and using the recycling steam it can
be heated up to 100oC. Applying energy balance for the liquor (MgSO4(aq));
Absorbed energy by the liquor = Enthalpy of liquor at 100oC - Enthalpy of liquor at 55oC
= -469.6322 x103 kW – (-475.4305 x103 kW)
= 5.7983 x103 kW
Assuming the thermal efficiency of the heat exchanger is 0.95;

Removed heat from Steam = 6.1035 x103 kW
= 527.3424 x106 kJ per day
Hence remaining excess energy in the steam will be [= (3701.2291 x 106) – (527.3424 x106)];
3173.8867 x106 kJ per day and it is to be used for the preheating of boiler feed water and the
operation of dryer 1.
Now, considering the evaporator;
Steam, 108oC
-324.9044 x103 kW
Liquor [MgSO4(aq)], 100oC
Evaporator
3
-411.3678 x10 kW
Conc. MgSO4(aq)
-53.5226 x103 kW
Figure 4.10: Energy balance for the evaporator
𝛥H evaporator = [(-324.9044 x103) + (-53.5226 x103)] – [(-411.3678 x103)] kW

= 32.9408 x 103 kW = 118,586.88 x 103 kJ per hour = 2846.0851 x106 kJ per day

4.2.5 Crystallizer
Assumptions: 40% equipment efficiency and the feed temperature is at the ambient
temperature (30oC) and the outlet to be 0oC.
MgSO4 (aq) + H2O at 300C MgSO4.7H2O at 00C

Crystallizer
-61.9292 x 103 kW + -78.6874103 kW -159.3164 x 103 kW
Figure 4.11: Energy balance for the crystallizer
MgSO4.7H2O(aq) + 7 H2O(l) MgSO4.7H2O(s)
𝛥H Crystallizer = [(-159.3164 x 103)] kW – [(-61.9292 x103) + (-78.6874103) kW

= 20.4359 x 103 kW = 73,569.24 x 103 kJ per hour = 1,765.6618 x106 kJ per day
Hence, Actual energy requirement = 1,765.6618 x 106 x kJ per day
= 4414.1544 kJ per day

= 51.0900 x 103 kW
After the crystallizer the resulted stream is directed to the centrifuger in order to separate
crystals from the mother liquor. Hence;
Capacity of the centrifuger = 458.96 MT per day
According to the literature, the energy requirement for the industrially available centrifuger
of the above capacity is 58.05 kW (Focus Technology Co., Ltd, 2016).
Assuming that the energy efficiency of the centrifuger is 40%;
Actual energy consumption = 58.05 x kW = 145.1250 kW

4.2.6 Dryer 1 (Epsom Dryer)
Assumptions: Equipment efficiency is 95% and the feed for the dryer is at 0oC and the
outlets are at 100oC.
Water (Steam)
33.5446 MT per day, 1000C
Hydrated MgSO4.7H2O(aq) MgSO4.7H2O(s)

Dryer 1
366.8779 MT per day, 00C 333.3333 MT per day, 1000C
Figure 4.12: Energy balance for dryer 1
MgSO4.7H2O(aq) + H2O(l) MgSO4.7H2O(s) + H2O(g)
Since there are no chemical reactions in the unit, the energy required to heat the system from
0oC to 100oC per day can be obtained by;
Q = (mcƟ)MgSO4.7H2O + (mcƟ) H2O + (mL)H2O
= [366.88x103 kgx3.84kJkg-1K-1x(100 – 0)K]+[ 33.54×103kg×4.2kJkg-1K-1x(100 – 0)K]

+ [33.54 × 103 kg x 2257kJ/kg]
= 140,881,920kJ + 14,086,800kJ + 75,699,780kJ = 230,668.5 x 103 kJ per day
Hence, actual energy requirement = 230,668.5 x103 x = 242,808.9474 x 103 kJ per day
=2,810.2887 kW
Dryer 1 is to be operated using recycle steam which has an energy content of 3173.8867 x106
kJ per day. Hence, energy remaining in recycled steam after the drying will be 2931.0778
x106 kJ per day [= (3173.8867 x106) – (242.8089 x 106)]
This remaining energy content will be used to preheat the boiler feed water supply.

4.2.7 Dryer 2 (POP Dryer)
Assumptions: 95% Equipment efficiency and the inlet temperature is at 50oC and the
outlet stream is at 150oC.
Steam, 150oC, -25.2830 x103 kW

CaSO4.2H2O(aq) + MgSO4(aq) Dryer 2
-87.9103 x103 kW (POP Dryer) CaSO4. H2O(s) + MgSO4.H2O
150oC, -1.1669 x103 kW
Figure 4.13: Energy balance of the dryer 2
Hence, considering the steady state of the system;

𝛥H Dryer 2 = Energy out – Energy in
= [(-25.2830) + (-1.1669)] x103 kW – [-87.9103 x103 kW]
= 61.4604 x103 kW
Since the dryer is operated using the furnace oil (Assuming the efficiency of the energy
production from the furnace oil is 80%);
Required energy from the furnace oil = 64.6951 x103 x = 80.8689 x103 kW
The calorific value of the furnace oil = 42,258.4 kJkg-1
Hence, furnace oil requirement = kgs-1 = 1.9137 kgs-1
4.2.8 Total energy requirements
The required energy for the proposed plant is supplied in the means of electricity, furnace oil
and steam. Their requirements will be as follow;
Steam requirement: Table 4.6: Steam requirement of the process
Equipment Energy consumption(MW)
Evaporator 32.9408
Steam jet ejector 2
Total consumption 34.9408

Electricity requirement: Table 4.7: Electricity requirement of the process
Hammer crusher 0.1005
Ball mill 0.5676
Cyclone separator 0.0035
Bag filter 0.00075
pH adjuster 0.1549
Gravity settling tank 0.01411
Vacuum filter 0.0231
Crystallizer 51.0900
Centrifuger 0.1451
Oil fired energy consumption: Table 4.8: Oil fired energy consumption
Dryer 2 (for Plaster-of-Paris) 80.8689
Hence, the total energy requirement;
Table 4.9: Total energy requirement of the process
Type Energy consumption (MW)
Electricity 52.0996
Fuel oil 80.8689
Steam 34.9408
Total energy requirement 167.9093

4.2.9 Energy Balance sheet for Reactor
Dolomite [Ca.Mg(CO3)2(s)], 30oC
-20.8933 x 103 kW
CO2(g), 60oC
Reactor
-23.5338 x 103 kW
H2SO4(aq) , 30oC
-490.8715 x 103 kW
Slurry [CaSO4(s) + MgSO4(aq) + H2O], 60oC
-466.8925 x 103 kW
Main Reaction:
𝛥H reactor 21.3385 x 103 kW
Energy Efficiency 99%
Steam Requirement 21.5540 x 103 kW, (108oC)
Wastewater Generation Nil

4.2.10 Energy Balance sheet for Solid-Liquid Separation
Slurry [CaSO4(s) + MgSO4(aq) + H2O] Solid-Liquid Liquid stream [MgSO4(aq)], 55oC

60oC, - 466.8925 x 103 kW Separation
- 235.6839 x103 kW
Solid stream [CaSO4.2H2O(s) + MgSO4]
55oC, -98.9103 x 103 kW
𝛥Hsolid-liquid separation 132.2983 x 103 kW
Gravity Settler Energy Consumption 14.1176 kW
Wastewater Generation Assumed as nil
Vacuum Filter Energy Consumption 23.1250 kW
Wastewater Generation Assumed as nil

4.2.11 Energy Balance sheet for Evaporator
Steam, 108oC
-324.9044 x103 kW
Liquor [MgSO4(aq)], 100oC
Evaporator
3
-411.3678 x 10 kW
Conc. MgSO4(aq), 108oC
-53.5226 x103 kW
Main Reaction:
MgSO4(aq) Conc.MgSO4(aq) + H2O(g)

(w/w)MgSO4 = 6.5187% (w/w)MgSO4 = 36.5894%
Density = 1.0639 gml- Density = 1.45 gml-1
1
𝛥H evaporator 32.9408 x 103 kW
Net Steam Generation 2117.3371 MT per day
Wastewater generation Nil
Steam requirement (175-180oC) for the evaporator is to be supplied from a boiler, operated at
10bar depends on the number of effects (which is to be estimated in further design) and the
steam economy of the total evaporating unit.

4.2.12 Energy Balance sheet for Crystallizer
MgSO4 (aq) + H2O at 300C MgSO4.7H2O at 00C

Crystallizer
3 3
-61.9292 x 10 kW + -78.687410 kW -159.3164 x 103 kW
Main Reaction:
MgSO4.7H2O(aq) + 7 H2O(l) MgSO4.7H2O(s)
𝛥H crystallizer 20.4359 x 103 kW
Power Requirement 51.0900 x 103 kW
For the Centrifuger;
Power Requirement 145.1250 kW
Wastewater Generation 92.1133 MT per day

4.2.13 Energy Balance sheet for Dryer 1 (Epsom Dryer)
Water (Steam), 1000C

-1032.0843 kW
Hydrated MgSO4.7H2O(aq), 00C MgSO4.7H2O(s), 1000C

Dryer 1
3
-159.3164 x 10 kW -160.9523 x 103 kW
Main Reaction:
MgSO4.7H2O(aq) + H2O(l) MgSO4.7H2O(s) + H2O(g)
𝛥H dryer 1 2,669.7743 kW
Energy Requirement 2,810.2887 kW
Steam Generation 33.5446 MT per day

4.2.14 Energy Balance sheet for Dryer 2 (POP Dryer)
Steam, 150oC
-25.2830 x 103 kW
CaSO4.2H2O(aq) + MgSO4(aq)
Dryer 2
50oC, -87.9103 x 103 kW (POP Dryer)
CaSO4. H2O(s) + MgSO4.H2O, 150oC
-1.1669 x 103 kW
Main Reaction:
𝛥 at 150ºC
𝛥H dryer 2 61.4604 x103 kW
Furnace Oil Requirement 1.9137 kgs-1
Steam Generation 166.6592MT per day

SITE LAYOUT
01. Security and Main Entrance 12. Dolomite Storage Area

02. Car Parks 13. Utilities Area
03. Administrations and Laboratory 14. Plant
04. Canteens 15. CO2 Cylindering Area
05. Common Area 16. Epsom Packing Area
06. Fire Trucks and Ambulance Park 17. Plaster of Paris Packing Area
07. Fire Departement and Medical Office 18. Product Loading Area
08. Instrumentation Storage 19 Issuing Office
09. Workshop 20 Security Posts and other Entrances
10. Wastewater Treatment Area 21 Separation Distance
11. Sulphuric Tanks
20
N
21 19
17
13
16
18
12 14
15 20
2
2
1
6 7
3
9 4
10 5
8
11
21

CHAPTER 5
CONCLUSIONS
With the growing demand for fertilizer and a readily available dolomite supply; a production
plant to produce Fertilizer Grade Magnesium Sulphate is an appropriate and timely
investment for Sri Lanka.
With the intention of having a much more technically advanced and economically efficient
production capacity, the proposed plant is to be implemented with the process related to the
reaction of dolomite and sulphuric acid;
Ca.Mg(CO3)2(s) + 2H2SO4(aq) MgSO4(aq) + CaSO4.2H2O(S) + 2CO2(g) + 2H2O
The magnesium sulphate will be produced in its hepta hydrate form (MgSO4.7H2O) and
Plaster of Paris is to be manufactured as the byproduct using resulted CaSO4.2H2O from the
above leaching process.
Since the main objective of the proposed plant is to produce fertilizer grade magnesium
sulphate, the purity of the end product will not be a huge factor. In that case, the procurement
of sulphuric acid can be done more economically using the waste streams of other
manufacturing processes (e.g.: TiO2 production). On the other hand, the required dolomite is
to be supplied from the local dolomite ores.
Optimum dolomite particle size of 150µm is is to be used for the process in order to achieve a
high leaching efficiency and a maximum yield of magnesium sulphate. As the available
dolomite ores are in the range of 1m, a hammer crusher followed by a ball mill will be used
in series to obtain the expected particle size.
After the preparation of raw materials, they are directed to the reactor for leaching. The
optimum temperature for the leaching process is 60oC and the optimum reaction time is 50
minutes. The resulted product streams from the reactor are in form of a slurry and has to be
separated using a gravity settler followed by a vacuum filter. Anionic Polyacrylamide is to
be used to increase the filtration rate in vacuum filtration.
The evaporation will increase the concentration of magnesium sulphate in the liquid stream
before its crystallization at 0oC to form MgSO4.7H2O.

Then the centrifuged product will be directed to a dryer to remove its moisture and obtain the
Epsom salt as a finished product. The bottom residue from the settling tank and the vacuum
filter is dried at a temperature of 150oC to obtain the byproduct; Plaster of Paris.
Considering the plant location; Central, North Central and Eastern provinces are more
susceptible due to raw material availability and ease of transportation of the raw materials
and the products. In spite of inheriting large dolomite reserves, with concerns of having high
grade infrastructure with access to main agricultural cities, close proximity to Trincomalee
Sea Port (making it easier to obtain the raw materials and export the products), availability of
suitable lands and utilities; Habarana is selected as the most preferable area to establish the
proposed manufacturing plant.
Concerning the Health, safety and Environmental aspects related to the plant; dolomite
mining can be identified as one of the main operations that should be implemented with a
proper safety and risk management system. Handling of sulphuric acid, particle size reduction
steps (crushing) can be sonsidered as the other processes that may tend to create hazardous
situations. Hence, in order to prevent the occurring of hazardous incidents and to mitigate
their effects on the employees and surrounding community several protection layers are to be
implemented with the establishment of the plant.
The expected initial investment for the proposed plant is 921,191,180 LKR with a payback
period of 7.6 years. From the production capacity of 100, 000 tons of Epsom salt per annum;
around 30 percent will be focused on overseas markets (especially the South Asian region)
and as the byproduct, Plaster of Paris is to be produced in a capacity of 190,759 tons per
annum with a specific aiming on the African region.
As a conclusion, it can be stated the the proposed Fertilizer Grade Magnesium Sulphate
production plant is a perfect investment for Sri Lanka and much viable to implement with
concerns on the aspects of economics, HSE (Health, Safety and Environmental) impacts and
Chemical Engineering perspectives.

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ANNEXES
1. NPV calculations for the proposed plant:
Assuming a 3% profit increase in each year with respect to the year 1;
Discount Discount Cash Flow

Year PV NPV (LKR)
Rate Factor (LKR)
0 14% 1 -921,191,180 -921,191,180 -921,191,180
1 14% 0.877192982 189,747,509 166,445,183 -754,745,997
2 14% 0.769467528 195,439,934 150,384,683 -604,361,313
3 14% 0.674971516 201,132,360 135,758,614 -468,602,700
4 14% 0.592080277 206,824,785 122,456,876 -346,145,824
5 14% 0.519368664 212,517,210 110,374,780 -235,771,044
6 14% 0.455586548 218,209,635 99,413,374 -136,357,670
7 14% 0.399637323 223,902,061 89,479,620 -46,878,050
8 14% 0.350559055 229,594,486 80,486,426 33,608,376
9 14% 0.307507943 235,286,911 72,352,594 105,960,970
10 14% 0.26974381 240,979,336 65,002,684 170,963,654
11 14% 0.236617377 246,671,762 58,366,825 229,330,480
12 14% 0.207559102 252,364,187 52,380,484 281,710,964
13 14% 0.182069388 258,056,612 46,984,209 328,695,173
14 14% 0.15970999 263,749,038 42,123,356 370,818,529
15 14% 0.140096482 269,441,463 37,747,801 408,566,330
Comprehensive Design Project | CH4013 X|Page
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Fertilizer Grade Magnesium Sulphate Production from Dolomite

Technical Report · September 2016

The user has requested enhancement of the downloaded file.

Fertilizer Grade Magnesium Sulphate Production from Dolomite

Group members: 120466C – Perera I.Y.C.

Date of submission: 19.09.2016

Supervisors: Prof. Perera S.A.S.

Department of Chemical and Process Engineering

The main chemical reaction of the process will be;

Ca.Mg(CO3)2(s) + 2H2SO4(aq) MgSO4(aq) + CaSO4.2H2O(S) + 2CO2(g) + 2H2O

CaSO4. 2H2O(s) CaSO4. H2O(s) + H2O(g)

Unit Production Cost of Epsom Salt 43401.24 LKR per MT

Unit Production Cost of Plaster of Paris 22751.87 LKR per MT

Initial Investment 921,191,180 LKR

Expected plant operating life time 15 years

Payback Period 7.6 years

Comprehensive Design Project | CH4013 II | P a g e

We consider it as a great opportunity to follow this module “CH4013: Comprehensive Design

Comprehensive Design Project | CH4013 III | P a g e

1 Chapter 1 | Introduction ...................................................................................................... 1

2 Chapter 2 | Literature Review and Process Selection ....................................................... 4

2.1 Industrial production of magnesium Sulphate................................................................ 4

3 Chapter 3 | Feasibility Study and Process Chemistry Establishment ........................... 21

3.1 Plant Location............................................................................................................... 21

Comprehensive Design Project | CH4013 IV | P a g e

3.2.1.1 Dolomite ..................................................................................................... 23

4.1 Material Balance........................................................................................................... 37

Comprehensive Design Project | CH4013 V|Page

4.1.2.3 Calculations for reactor ............................................................................... 41

Site Layout .............................................................................................................................. 63

5 Chapter 5 | Conclusions ...................................................................................................... 64

Comprehensive Design Project | CH4013 VI | P a g e

Chapter 2 | Literature Review and Process Selection

Figure 2.1: Production of magnesium sulphate using brines ............................................... 5

Chapter 3 | Feasibility Study and Process Chemistry Establishment

Figure 3.1: Dolomite ore locations in Sri Lanka................................................................ 21

Chapter 4 | Mass and Heat Balance for the Proposed Plant

Figure 4.1: Graph | molar concentration vs density of H2SO4(aq)....................................... 39

Comprehensive Design Project | CH4013 VII | P a g e

Chapter 2 | Literature Review and Process Selection

Table 2.1: Chemical composition of Sri Lankan dolomite ...................................................... 10

Chapter 3 | Feasibility Study and Process Chemistry Establishment

Table 3.1: Production capacity of Fertilizer Grade Magnesium Sulphate ............................... 27

Chapter 4 | Mass and Heat Balance for the Proposed Plant

Table 4.1: Molecular weights of chemicals ............................................................................. 37

Comprehensive Design Project | CH4013 VIII | P a g e

Density d gcm-3 (gml-1)

Mass flow rate ̇ MT per day

Molecular mass M Kgkmol-1

Specific molar enthalpy of formation ̃ kJmol-1

Specific molar heat capacity ̃ kJkmol-1K-1

CSTR Continues Stirred Tank Reactor

EHS Environmental, Health and Safety

IARC International Association for Research on Cancer

IRR Internal Rate of Return

LKR Sri Lankan Rupees

NFPA National Fire Protection Department