Process design of absorption system for nitric acid

plant with 145 tons per day capacity

Name

Ali Abdullah

Nawaf Ahmed

1
 Table of content

• Introduction.
• History of nitric acid.
• Uses .
• Nitric acid in Saudi Arabia.
• Flow sheet.
• Cost Estimation.
• Conclusion.

2 Production of Nitric Acid

 Introduction
• Chemical reactions.
• Toxic and corrosive.
• Color.
• Scientific name is HNO3.
• Molecular weight 63 .
• Boiling at 84 oC and solidified at -43 oC .
• Other names(Aqua forties).

3 Production of Nitric Acid

 History of nitric acid

• 8th century(Jabir ibn Hayyan).

• In 1648(Johann Rudolf Glauber) .
• In 1825 .
• In 1900(Birkeland–Eyde).
• In 1906(Wilhelm Ostwald).

4 Production of Nitric Acid

 Uses
• Production of fertilizers.
• Production of explosives.
• Manufacture of nylon, adipic acid.
• oxidizing agent in the production of some solid fuels for rocket
propulsion.
•  identify low-grade alloys and assess purity of gold content.
• Polymer industry (polyamides and polyurethanes).

5 Production of Nitric Acid

 Nitric acid in saudi arabia

• Shuaa Al Kaune Oilfield Supplies & Services.

• World Rep Chemicals Division.
• Esad International.
• Sedres Maritime Co. Ltd.
• GULF DESERT CHEMICALS CO.

6 Production of Nitric Acid

 Flow sheet of nitric acid plant

Air
Compressor Secondary
Air

water
Output:
Gases:
Air steam 1- No2
Water
recycle steam Water 2- air
3- No
 
Input:
H20
Liquid  
NH3 Vaporizer Catalytic Absorption
Reactor Air Waste heat Cooler column.( 30
preheater boiler condenser plate )
Weak Hno3

Gas product : Output:

1. No 1-HNO3
2. No2 2- water
Water
3. O2
7 Production of Nitric Acid 4. N2
 Vaporizer
• Process.

8 Production of Nitric Acid

 Name water 1 water 2 liquid ammonia ammonia
Vapour 0 0 1 1
Temperature ( C ) 40 11.52113668 10 15
pressure ( kPa) 101.3249966 101.3249966 500 500
molar flow (kgmole/ hr) 11.10179764 11.10179764 129.1837881 129.1838
mass flow (kg/h) 200 200 2200 2200
std ideal liqvol flow (m3/hr) 0.200403608 0.200403608 3.571022731 3.571023
molar enthalpy (kj/kgmole) 283760.1503- 285921.4292- 46560.6966- 46375-
molar entropy (kj/kgmole-c) 37.28708026 16.06189522 154.7731775 155.4234
heat flow (kj/hr) 3150247.767- 3174241.849- 6014887.164- 5990893-
: composition by mass flow rate        
Air 0 0 0 0
NO 0 0 0 0
H2O 1 1 0 0
HNO3 0 0 0 0
NO2 0 0 0 0
Ammonia 0 0 1 1
Nitrogen 0 0 0 0
Oxygen 0 0 0 0
water

 
Input:
Vaporizer
Liquid
NH3

9 Production of Nitric Acid

 Air pre-heater
• Process

10 Production of Nitric Acid

 Name product 1 product 1.1 air 2 air3
Vapour 1 1 1 1
Temperature ( C ) 1000.179 862.6744 25 230
pressure ( kPa) 500 500 105.9433 500
molar flow (kgmole/ hr) 850.7076 850.7076 695.2738 695.2738
mass flow (kg/h) 22199.86 22199.86 20000 20000
std ideal liqvol flow (m3/hr) 67.2798 67.2798 23.28561 23.28561
molar enthalpy (kj/kgmole) 2063.66- 7049.17- 8.47127- 6091.59
molar entropy (kj/kgmole-c) 196.924 192.7816 154.7472 157.3859
heat flow (kj/hr) 1755570- 5996783- 5889.85- 4235323
: composition by mass flow rate        
Air 0 0 0 0
NO 0.1419 0.1419 0 0
H2O 0.1278 0.1278 0 0
HNO3 0 0 0 0
NO2 0 0 0 0
Ammonia 0.0186 0.0186 0 0
Nitrogen 0.7117 0.7117 0.79 0.79
Oxygen 0 0 0.21 0.21
Air
recycle
 
Catalytic
Reactor Air
preheater

11 Production of Nitric Acid

 Reactor
• Catalytic convertor reactor.
• 4NH3 + 5O2 4NO + 6H2O

12 Production of Nitric Acid

 Name mix out liq 1 product 1
Vapour 1 0 1
Temperature ( C ) 188.5827 1000.179 1000.179
pressure ( kPa) 500 500 500
molar flow (kgmole/ hr) 824.4576 0 850.7076
mass flow (kg/h) 22200 0 22199.86
std ideal liqvol flow (m3/hr) 26.85663 0 67.2798
molar enthalpy (kj/kgmole) 2129.36- 31400 2063.66-
molar entropy (kj/kgmole-c) 161.3477 180.2435 196.924
heat flow (kj/hr) 1755570- 0 1755570-
: composition by mass flow rate      

Air 0 0 0
NO 0 0.0075 0.1419
H2O 0 0 0.1278
HNO3 0 0 0
NO2 0 0 0
Ammonia 0.0991 0 0.0186
nitrogen 0.7117 0.9925 0.7117
Oxygen 0.1892 0 0

Air
recycle
 
Catalytic
Reactor Air
preheater
13 Production of Nitric Acid
 Waste heat boiler
• Process

14 Production of Nitric Acid

 Name product 1.1 product 1.2 water 3 steam 1
Vapour 1 0.963326 0 1
Temperature ( C ) 862.6744 91.95073 25 99.99839
pressure ( kPa) 500 500 101.325 101.325
molar flow (kgmole/ hr) 850.7076 850.7076 499.5809 499.5809
mass flow (kg/h) 22199.86 22199.86 9000 9000
std ideal liqvol flow (m3/hr) 67.2798 67.2798 9.018162 9.018162
molar enthalpy (kj/kgmole) 7049.17- 34279.5- 284903- 238534-
molar entropy (kj/kgmole-c) 192.7816 150.7775 26.5595 181.1521
heat flow (kj/hr) 5996783- 2.9E+07- 1.4E+08- 1.2E+08-
: composition by mass flow rate        
Air 0 0 0 0
NO 0.1419 0.1419 0 0
H2O 0.1278 0.1278 1 1
HNO3 0 0 0 0
NO2 0 0 0 0
Ammonia 0.0186 0.0186 0 0
Nitrogen 0.7117 0.7117 0 0
Oxygen 0 0 0 0
steam Water

Waste heat
boiler
15 Production of Nitric Acid
 Shell & tube cooler condenser
• Process.
• 2NO + O2 2NO2

16 Production of Nitric Acid

 Name mix out 2 liq 2 product 2
Vapour 1 0 1
Temperature ( C ) 126.1593 253.1105 253.1105
pressure ( kPa) 500 500 500
molar flow (kgmole/ hr) 1545.981 0 1493.481
mass flow (kg/h) 42199.86 0 42199.86
std ideal liqvol flow (m3/hr) 90.56541 0 48.2011
molar enthalpy (kj/kgmole) 16123.4- 214508- 16690.2-
molar entropy (kj/kgmole-c) 156.2158 127.5343 164.2462
heat flow (kj/hr) 2.5E+07- 0 2.5E+07-
: composition by mass flow rate      
Air 0 0 0
NO 0.0747 0 0
H2O 0.0672 0.6864 0.0672
HNO3 0 0 0
NO2 0 0.1935 0.1145
Ammonia 0.0098 0.0189 0.0098
Nitrogen 0.7488 0.0927 0.7488
Oxygen 0.0995 0.0086 0.0597

17 Production of Nitric Acid

 Name product 2 product 2.1 water 4 steam 2
Vapour 1 0.900849 0 0.644702
Temperature ( C ) 253.1105 40 20 99.9987
pressure ( kPa) 500 500 101.325 101.325
molar flow (kgmole/ hr) 1493.481 1493.481 499.5809 499.5809
mass flow (kg/h) 42199.86 42199.86 9000 9000
std ideal liqvol flow (m3/hr) 48.2011 48.2011 9.018162 9.018162
molar enthalpy (kj/kgmole) 16690.2- 27492.6- 285282- 252988-
molar entropy (kj/kgmole-c) 164.2462 132.6717 22.76673 142.4168
heat flow (kj/hr) 2.5E+07- 4.1E+07- 1.4E+08- 1.3E+08-
: composition by mass flow rate        
Air 0 0 0 0
NO 0 0 0 0
H2O 0.0672 0.0672 1 1
HNO3 0 0 0 0
NO2 0.1145 0.1145 0 0
Ammonia 0.0098 0.0098 0 0
Nitrogen 0.7488 0.7488 0 0
Oxygen 0.0597 0.0597 0 0
steam Water

Cooler
condenser
18 Production of Nitric Acid
 Absorption column
• 3NO2 + H2O 2HNO3 + NO
Name product 2.2 liquid product vapor out
Vapour 0.893868 0 1
Temperature ( C ) 40.1145 54.70821 54.70821
pressure ( kPa) 500 500 500
molar flow (kgmole/ hr) 1504.583 137.8858 1331.697
mass flow (kg/h) 42399.86 4229.698 38170.12
std ideal liqvol flow (m3/hr) 48.4015 3.400993 58.70178
molar enthalpy (kj/kgmole) 29383.5- 252010- 7104.47-
molar entropy (kj/kgmole-c) 131.8825 30.81594 145.3771
heat flow (kj/hr) 4.4E+07- 3.5E+07- 9460999-
: composition by mass flow rate      
Air 0 0 0
NO 0 0 0.0275
H2O 0.0716 0.419 0.0166
HNO3 0 0.5781 0.0515
NO2 0.1139 0 0
Ammonia 0.0097 0.0028 0.0105
Nitrogen 0.7453 0.0001 0.8279
Oxygen 0.0594 0 0.066

19 Production of Nitric Acid

 Name water 5 liquid product air 6 air 5 vapor out
Vapour 0 0 1 1 1
Temperature ( C ) 37.77778 54.70821 20 20 54.70821
pressure ( kPa) 101.3 500 101.3 101.3 500
molar flow (kgmole/ hr) 22.2036 137.8858 312.8732 104.2911 1331.697
mass flow (kg/h) 400 4229.698 9000 3000 38170.12
std ideal liqvol flow (m3/hr) 0.400807 3.400993 10.47852 3.492841 58.70178
molar enthalpy (kj/kgmole) 283929- 252010- 154.153- 154.153- 7104.47-
molar entropy (kj/kgmole-c) 35.76032 30.81594 154.6268 154.6268 145.3771
heat flow (kj/hr) 6304253- 3.5E+07- 48230.4- 16076.8- 9460999-
: composition by mass flow rate          
Air 0 0 0 0 0
NO 0 0 0 0 0.0275
H2O 1 0.419 0 0 0.0166
HNO3 0 0.5781 0 0 0.0515
NO2 0 0 0 0 0
Ammonia 0 0.0028 0 0 0.0105
Nitrogen 0 0.0001 0.79 0.79 0.8279
Oxygen 0 0 0.21 0.21 0.066
Output:
Gases:
1- No2
2- air
3- No
Absorption
column.( 30
plate )

Output:
1-HNO3
20 Production of Nitric Acid
2- water
 Name tail gas nitric acid
Vapour 1 0
Temperature ( C ) 58.36732 66.38617
pressure ( kPa) 1000 1000
molar flow (kgmole/ hr) 1730.931 178.0201
mass flow (kg/h) 49293 5506.821
std ideal liqvol flow (m3/hr) 72.05402 4.420918
molar enthalpy (kj/kgmole) 3550.2- 249596-
molar entropy (kj/kgmole-c) 139.5511 33.24424
heat flow (kj/hr) 6145160- 4.4E+07-
: composition by mass flow rate    
Air 0 0
NO 0.0213 0
H2O 0.0111 0.4105
HNO3 0.0241 0.5851
NO2 0 0
Ammonia 0.0079 0.0043
Nitrogen 0.8334 0.0001
Oxygen 0.1022 0
Output:
Gases:
1- No2
2- air
3- No
Absorption
column.( 30
plate )

Output:
1-HNO3
21 Production of Nitric Acid
2- water
 2NO + O2 2NO2
3NO2 + H2O 2HNO3 + NO

22 Production of Nitric Acid

 Total Capital investment
Direct Cost  Factors Cost
Purchased Equipment  0.25
$1,545,730.9
Delivery, percent of purchased equipment 0.2 * purchased equipment
$309,146.2
:Subtotal: delivered equipment  
$1,854,877.0
Direct cost  
 
Purchased Equipment Installation delivered equipment * 0.07
$519,365.6
Instrumentation & Controls (Installed) delivered equipment *0.04
$296,780.3
Piping (Installed) delivered equipment *0.10
$741,950.8
Electrical system (Installed) delivered equipment *0.08
$593,560.7
Building (including services) delivered equipment *0.10
$741,950.8
Yard improvements delivered equipment *0.02
$148,390.2
Land delivered equipment *0.02
$148,390.2
Service facilities (Installed) delivered equipment *0.10
$741,950.8
:Total Direct Cost  
$5,787,216.4
Indirect Cost  
 
Engineering & Supervision delivered equipment *0.08
$593,560.7
Construction expenses delivered equipment *0.08
$593,560.7
Contractor's fee delivered equipment *0.02
$148,390.2
Contingency delivered equipment *0.04
$296,780.3
:Total Indirect Cost  
$1,632,291.8
:Fixed Capital Investment Total indirect + Total direct 
$7,419,508.2
Working Capital TCI*0.2
$1,854,877.0
Total capital investment  
$9,274,385.2
23 Production of Nitric Acid
 Total Production Cost
Factor Cost ($/yr) Estimating way
liquid ammonia
Raw Materials $ 8008000 -catalyst
Operating Labor $ 900000 1500*50*12
Operating Supervision $ 180000 20%*OL
Utilities $ 1574236.317 10% TPC
Maintenance & Repair $ 370975.4088 5% FCI
Operating Supplies $ 55646.31132 15% M&R
Laboratory Charges $ 180000 20% of OL
Financing $ 463719.26 5%*TCI
Insurance $ 74195.08176 1%* FCI
Plant Overhead $ 1574236.317 10% TPC
General Expenses $ 2361354.476 15%TPC
Total production cost /yr $ 15742363.17 Subtotal
24 Production of Nitric Acid
 Net profit
• Selling Price of nitric acid per ton = 375 $ , nitric acid factory
operates only 315 days in a year and the production of nitric
acid per day is 145 Ton per day (from material balance):
• Total income = 375*315*145= $ 17,128,125.00
• Gross income = Total income - Total product cost= 17128125-
15742363 = 1385761.83$
• Net profit= gross income + taxes , but we don’t have taxes in
Saudi Arabia so Net profit= gross income .
• Payout period = (FCI/Net profit ) = (7,419,508.18 $ / 1728125
$) = 5 year
• The maximum payout period is 5 years .

25 Production of Nitric Acid

 Conclusion
• Use a program like hysys defiantly simplify the
idea of making a plant .
• After calculating cost estimation, the profit
income start after maximum 5 years.

26 Production of Nitric Acid

 Thank you for listening

27 Production of Nitric Acid