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Mian Project
Thesis · September 2007
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Operating Conditions
T1=25oC, P1=9 bar
ρv=11.02 kg/m3
Q1=7.06x105kJ/hr
mol% kgmol/hr kg/hr
NO2 10.87 103.6 4765.6
NO 4.85 46.3 1389
O2 7.45 70.82 2266.24
N2 76.84 732.84 20499.92
952.86 28920.76
T2=25oC, P2=10 bar,
ρL=1209.8 kg/m3
Q2=1.8x106kJ/hr
wt% kg/hr
HNO3 40 9228.24
H2O 60 13842.9
23071.14
T4=50oC, P4=9.7 bar
ρL=1360 kg/m3
Q4=2.12x106kJ/hr
wt% kg/hr
HNO3 60 16634.5086
H2O 40 11128.5130
27763.0216
2
1
2
4
3
3. 3NO H O 2HNO NO ΔH 46000kJ/kgmol
The overall reaction,
2. 4NO 3O 2H O 4HNO ΔH 263000kJ/kgmol
1. 4NO O 2H O 4HNO ΔH 149000kJ/kgmol
2 2 3 r 25 C
2 2 3 r 25 C
2 2 2 3 r 25 C
T3=45oC, P3=8.62 bar
ρv=9.8 kg/m3
Q3=5.4x105kJ/hr
mol% kgmol/hr kg/hr
NO2 O.14 1.036 47.656
NO 0.186 1.389 41.67
O2 1.54 11.49 367.68
N2 98.13 20928.93732.14 20471.92
746.06
Chapter: 05 Equipment Design
82
Number of plates calculation:
The equilibrium data for the solution is determined by the following relation:
Ye = .6X (1)
X .02 .04 .06 .08 .10 .12 .14
Ye .012 .026 .04 .048 .06 .07 .081
This data is for equilibrium curve. Now applies the overall balance on the absorber:
Lm(X1-X2) = Gm (Y1-Y2)
As there is no concentration of NO2 in inlet liquid stream, so X2 = 0
Now the above equation becomes:
Lm(X1-0) = Gm (Y1-Y2)
LmX1 = Gm( Y1-Y2 )
Y1= LmX1/Gm +Y2
This is Eq. for operating line
Lm = Liquid flow rate/area
Lm = 136.54 Kg mol/hr m2
Gm = Gas flow rate/area
Gm = 148.85 Kg mol/hr m2
Now equation (2) becomes;
Y1 = .92X1 + .001 (3)
Data for the operating line can be obtained by letting the suppose value of X1 as given
below:
X1 .02 .04 .06 .08 .10 .12 .14
Y1 .019 .038 .056 .075 .093 .11 .129
Now draw the operating line and equilibrium curve on the graph in order to find the
number of stages as given in figure.
Number of theoretical trays find from the graph are 6
Chapter: 05 Equipment Design
83
Chapter: 05 Equipment Design
84
Now calculate actual No. of trays:
Nactual = NO. Of Theoretical trays/ E
Efficiency of column is finding by the following relation:
By drichmer and bradform relation:
E = 17 – 61.1Log (μFavg)
μFavg = Viscosity of feed at average temperature and pressure
E = 17– 61.1Log (0.23)
= 55%
E = 0.55
Now, actual number of trays (Nactual) is:
N actual = Theoretical trays/E
= 6/0.55
N actual = 10
CALCULATION OF COLUMN DIAMETER:
On the basis of flow rates by following the method given in Chemical
Engineering, Coulson & Richardson, Vol.6 (3rd edition)
At bottom:
Maximum liquid flow rate at bottom:
Liquid mass flow rate = Lw = 31212.81 kg/hr = 8.67 kg/s
ρL at 50˚C = 1.312 g/cm3 = 1312 kg/m3
Maximum vapor flow rate at bottom:
Vapor mass flow rate = Vw = 28920.76 kg/hr
Vapor molar flow rate = Vm = 952.86 kgmol/hr
Average molecular weight of inlet gaseous stream:
Mr(avg) = 28920.76Kg /952.86 =30.35
P = 9 bar = 900 kpa
T= 25˚C = 298 K
Pv = PMr/RT = 900 *30.35 /8.314 * 298 = 11.02
Now from Coulson & Richardson vol 6 the vap-liquid factor is calculated as:
Chapter: 05 Equipment Design
85
FLV = Lw/Vw (Pv/PL)1/2 = 31212.81/28920.76 (11.02/1312)1/2 = 9.7 * 10-2
By selecting plate spacing=0.6m
Now from figure 11.27 pg#567, Coulson & Richardson vol. 6 (3rd edition), value of
K1=0.11
Flooding velocity;
1.22m/s
11.08
0.11 1360 11.08
ρ
UKρρ
V
LV
f1
Superficial velocity:
Design for 85% flooding at maximum flow rate,
Maximum volumetric flow rate=Vv = Vw/(ρvx3600)=0.73m3/s
Net area required=(volumetric flow rate/superficial velocity) = Vv/Ǔv
An=0.70m2
By taking downcomer area as 12% of the total column cross sectional area.
Column cross sectional area:
Ac= 0.70/0.88 = 0.80m2
Column Diameter:
At top:
Maximum liquid flow rate at top:
Liquid mass flow rate = Lw = 23071.14 kg/hr = 5.359 kg/s
ρL at 25˚C = 1.2098 g/cm3 = 1209.8 kg/m3
Maximum vapor flow rate at bottom.
m/s 1.037 0.85 U U ˆ
v f
1m
Π
A4
Dc
c
Chapter: 05 Equipment Design
86
Vapor mass flow rate = Vw = 20928.93 kg/hr
Vapor molar flow rate = Vm = 746.06 kgmol/hr
Average molecular weight of inlet gaseous stream =
Mr(avg) = 20928.93/746.06 = 28.05 Kg/Kgmol
T= 40˚C = 313 K
Pv = PM/RT= 864.2 * 28.51 /8.314 *298 =9.8 Kg/m3
Vapor liquid flow factor,
FLv = Lw/Vw (Pv/PL) = 23071.14/20298.93 (9.3/1209.8)1/2 = 9.6 * 10-2
By selecting plate spacing = 0.6m
Now from figure 11.27 pg#567, Coulson & Richardson vol. 6 (third edition), value of
K1=0.1
Flooding velocity:
1.106m/s
9.8
0.1 1209.8 9.8
ρ
UKρρ
V
LV
f1
Superficial velocity:
Design for 85% flooding at maximum flow rate,
Uv Vv 0.85 1.106m/s 0.85 0.9401m/s ˆ
Maximum volumetric flow rate=Vv = Vw/(ρvx3600) = 0.59 m3/s
Net area required = (volumetric flow rate/superficial velocity) = Vv/Ǔv
An = 0.63m2
By taking downcomer area as 12% of the total column cross sectional area.
Column cross sectional area:
Ac= 0.67/0.88 = 0.72m2
Chapter: 05 Equipment Design
87
Column Diameter:
So it can be concluded from the calculation at the top that the diameter of the
column at bottom and at the top is same and is found out to be 1 m.
LIQUID FLOW ARRANGEMENT:
Maximum volumetric flow rate at bottom of the column = Lw/(ρLx3600)
= 6.38x10-3 m3/sec
Maximum volumetric flow rate at top of the column = Lw/(ρLx3600)
= 5.30x10-3 m3/sec
Now from the figure 11.28 pg#568, Coulson & Richardson vol. 6 (3rd edition), for
1m dia. column at the given flow rates, required pattern is “Cross Flow (single pass)”
PROVISIONAL PLATE DESIGN:
2
2
c0.785m
4
Column cross sectional area A ΠD
Diameter of column 1m
Downcomer Area:
Downcomer area is 12% of cross sectional area;
1m
Π
A4
Dc
c
Chapter: 05 Equipment Design
88
2
Downcomer area Ad 0.12Ac 0.120.785 0.0942m
Net Area:
2
Net area An Ac Ad 0.785 0.0942 0.6908m
Active Area:
2
Active or bubbling area Aa Ac 2Ad 0.785 2(0.0942) 0.5966m
Hole Area:
Let take hole area 10% of Aa as first trial ;
2
Hole area Ah 0.1Aa 0.10.5966 0.05966m
Weir height:
Weir Height hw Take weir height 50mm
Weir length:
100 12%
A
A
c
d
From Graph b/w (Ad/Ac)*100 vs. lw / Dc on page # 572 by “Coulson and
Richardson’s”, volume 6 (3rd edition)
l 0.77 D 0.77 1m 0.77m
0.77
D
l
wc
c
w
Hole size:
Take hole diameter = 5mm
Plate thickness:
Plate thickness = 3mm (for austentic stainless steel 304L)
Chapter: 05 Equipment Design
89
WEEP POINT:
Weir Liquid Crest:
Maximum liquid rate=Lw(max) = 7.712 kg/sec
Take minimum feed rate as 70% of maximum fee rate of turn down ratio 70%
Minimum liquid rate= Lw(min) = 7.712x0.70 = 5.3984 kg/s
28.4mm
1360 0.77
750 7.712
ρ
L
h 750
2/3 2/3
Lw
w
ow
max
max
22.4mm
1360 0.77
750 5.3984
ρ
L
h 750
2/3 2/3
Lw
w
ow
min
min
ENTRAINMENT:
ψ 5.1 10 0.051 (well below 0.1)
Now, from figure#11.29 at page#570 fromC & R vol 6, the value of fraxtional
entrainment is,
F 8.2 10
100 90%
1.22
Percentage flooding 1.11
U 1.22m/s
1.11m/s
0.6908m
0.7659m /s
A
UV
Volumetric flow rate V 0.7659m /s
100 (U based on net area)
U
Percentage flooding U
2
2
LV
f
2
3
n
v
v
3
v
v
f
v
As, entrainment is less than 0.1, process is satisfactory.
HEIGHT OF THE COLUMN:
No. of plates = 10
Tray spacing = 0.6 m
Distance between 15 plates = 0.6 m10 = 6 m
Top clearance = 1.2 m
Bottom clearance = 1.2 m
Tray thickness = 3 mm/plate
Total thickness of trays = 0.003 m 10= 0.03 m
Total height of column = (6 + 1.2 + 1.2+ 0.03) m = Ht = 8.43 m
Chapter: 05 Equipment Design
93
PLATE SPECIFICATION SHEET:
Plate No.
Plate I.D.
Hole Size
Hole Pitch lp
Active Holes
Turn Down
Plate Material
Downcomer Material
Plate spacing
Plate Thickness
Plate pressure Drop
1
1m
5mm
12.5mm Δ
3038
70% of max rate
Austentic stainless steel 304L
Austentic stainless steel 304L
0.6m
3mm
2.34 kpa
Chapter: 05 Equipment Design
94
STRIPPING COLUMN DESIGN
STRIPPING
A process in which mass transfer occur from liquid phase to gas phase is called stripping.
It is a unit operation in which solute is separated from solvent on the basis of difference
in volatility in the presence of suitable solvent or passing through a reboiler.The stripping
column contains normal fractionation trays and is designed to strip the gases from the
rich solvent. Feed is entered from the top to the stripping column. The stripping reboiler
heating medium is usually steam from the pressure steam system. The heat input is set to
ensure essentially complete stripping of gases from the rich solvent. The amount of lean
solvent diverted to the stripper feed is determined by stripper selectivity. High
hydrocarbon concentrations in the stripper feed stream make the selective stripping of
gases more difficult. Lean solvent for this purpose may be added from the lean solvent
line. The overhead vapors which contain hydrogen chloride, methyl chloride, and some higher
boiling chloromethane, are sent to scrubber and bottoms, containing methylene chloride,
chloroform, and carbon tetrachloride are to heat exchanger stream. Component to be
removed from an entering liquid is called solute.
Absorbers and strippers are often used in conjunction with each other. Absorbers are
often employed to remove trace components from gas streams. Strippers are often applied
to remove the trace components from the liquid in a more concentrated form. Absorption
and stripping operations are carried out in vertical, cylindrical columns or towers
containing plates or packing elements. The plates and packing provide a surface area for
the liquid and gas to come into contact facilitating mass transfer between the two streams.
The gas and liquid streams for both operations are commonly counter-current for a more
effective mass transfer. The columns are simpler than those for distillation are because
they commonly do not include a condenser.
The solute in the solvent is removed in the stripping column by a stripping gas that enters
at the bottom of the column. The solvent now exits from the bottom of the column and is
condensed before it is recycled back to the absorption column. The gas exiting the
stripping column can now be stored or processed easier. Absorption and stripping are
conducted in tray towers, packed columns, spray towers, bubble columns, and centrifugal
contactors. For the additional design considerations, one needs to specify an isothermal or
non isothermal absorber. Each case will be dealt with separately, starting with the
isothermal, and followed by the non-isothermal with an example problem. The nonisothermal
case is of more importance as it more closely models current topics in our
design of the anhydride plant and is presented in more detail than the isothermal case.
Reboiled strippers typically have forced reboilers and employ a reboiling medium at a
temperature as low as possible to minimize solvent decomposition. The reboiler outlet
temperature arises as the bottom heavies concentration increases. Waste is withdrawn
when reboiler capacity is expended or when temperature target is reached .Because feed
vaporizations Occurs primarily in reboiler , the tray liquid flow rates across the column
are fairly constant , simplifying the tray design .Rebolied stripper operating pressure are
lower than any other part of extraction unit .
Chapter: 05 Equipment Design
95
CHOICE BETWEEN PLATE AND
PACKED COLUMN
If the diameter of column is greater than 0.762m then a plate column is
selected.
Plate columns are designed to handle wide range of liquid flow rates without
flooding
For large column heights, weight of the packed column is more than plate
column.
Periodic cleaning is easy in plate columns as compared to packed columns.
When temperature change is involved, packing may be damaged.
If a system contains solid contents, it will be handled in plate column, because
solid will accumulate in the voids, coating the packing materials and making it
ineffective.
Inter stage cooling can be provide to remove heat of reaction or solution in plate
column.
SELECTION OF TRAYS
The terms "trays" and "plates" are used interchangeably. There are many types of tray
designs, but the most common ones are:
SIEVE TRAYS
Sieve trays are simply metal plates with holes in them. Vapour passes straight upward
through the liquid on the plate. The arrangement, number and size of the holes are design
parameters
Chapter: 05 Equipment Design
96
VALVE TRAYS
In valve trays, perforations are covered by lift able caps. Vapour flows lifts the caps, thus
self creating a flow area for the passage of vapour. The lifting cap directs the vapour to
flow horizontally into the liquid, thus providing better mixing than is possible in sieve
trays.
Bubble cap trays
A bubble cap tray has riser or chimney fitted over each hole, and a cap that covers the
riser. The cap is mounted so that there is a space between riser and cap to allow the
passage of vapors. Vapors rises through the chimney and is directed downward by the
cap, finally discharging through slots in the cap, and finally bubbling through the liquid
on the tray.
Comparison of sieve tray and other trays
Sieve tray
1. Their maintenance cost is low.
2. Their fouling tendency is low.
3. They have large capacity.
4. They are highly efficient (60-85%).
5. Their design procedures are well known.
6. Their operating range is satisfactory (50-120% of design capacity).
7. Sieve trays give the lowest pressure drop.
8. Minimum entrainment as compared to bubble cap and valve tray.
9. Simple to construct.
Chapter: 05 Equipment Design
97
Bubble cap tray
1. They cause entrainment.
2. They are appreciably more expensive.
3. Their capacity rating is low.
4. They give highest pressure drop.
5. They are used when low vapors (gas) rates have to be handled and a positive
liquid seal is essential at all flow rates.
Valve tray
1. They are essentially sieve trays with large diameter holes covered with by
movable flaps
2. Their operating capacity is low as compared to sieve trays but higher than bubble
caps trays.
3. They give higher pressure drop than sieve trays.
CALCULATION OF EQUILIBRIUM STAGES
Si =KiV / L
Where
Si = Stripping factor for component i
Ki = vapour / liquid equilibrium ratio for component i
V= entering vapour flow rate into the column
L = entering liquid flow rate into the column
Feed is entering at 37.78oC into the stripper .
Top remperature = 13oC
Bottom temperature Ts =328 K.
Ki at 35oC = 1.45
So Si = 1.45 * 422.1768 /334
Si = 1.8328
Chapter: 05 Equipment Design
98
Calculation of theoretical number of stages
To find the theoretical number of stages use Kremser Edmister method
According to this method
Solute fraction stripped = Si N+1 - Si / Si N+1 -1
Where
Si = stripping factor fpr component i
N = number of equilibrium stages required for specified solute fraction stripped.
Now calculate the % age stripped of the key component in each stage .
KEY COMPONENT STAGES % STRIPPED
1 82.91
2 84.23
3 88.76
4 96.59
5 99.30
6 99.86
7 99.97
8 99.98
9 99.99
So N=9 theoretical stages should be sufficient to achive 99.99 % recovery .
DETERMINATION OF ACTUAL # OF STAGES
N act = N / E
= 9/0.5
= 18
V
L ( ρV / ρL ) 1/ 2 =
427.64
334
( 1.362/1425 ) 1/ 2
= 0.024
From fig
Csb =0.05 m/sec
Chapter: 05 Equipment Design
99
Then vapour velocity at flood conditions Vnf in the column is given by
Vnf = Csb (σ/20) 0.2 (ρL -ρV / ρV )0.5
Csb = souders and brown factor at flood conditions in m/sec
σ = Tension Surface (σ)
ρL = density of liquid in the column
ρV = density of vapour sreams in the column
Vnf = 0.05 (155 / 20) 0.2 (1425 – 1.362/1.362) 0.5
=1.3428 m/sec
The actual vapour velocity Vn is selected by assuming atat it is 50 to 90 percent of the
net vapour velovity at flood conditions
So assume V n is 80 % of Vnf .
Vn = 1.3428* 0.8
Vn = 1.07 m/sec
The net column area area used in the sepration process = An
An = m .
v/Vn
Where
m.
v = volumetric flow rate of vapour
An = 29.04*427.64 / 3600*1.07 * 1.362
An = 0.777 m2
Assume the downcomer occupies 15 % of the cross section area of the column,thus
Ac = An / 0.85
Ac = 0.777/ 0.85
Ac = 0.914
The column diameter is calculated as
D = (4 Ac / π )1/ 2
D = 1.078 m
HEIGHT EVALUATIN OF STRIPPER
Height of the stripper is given by the relation
Hc = ( Nact -1) * Hs + H
Where
Hc =Actual column height
Nact = Actual # of trays
Hs = plate spacing
H = Additional height required for column operation
Hc = (18-1)*0.46 + 0.92
Hc = 8.74 m
Chapter: 05 Equipment Design
100
Sieve Plate Design
Column dia =1.078m
AC (cross flow area ) =0.777m2
Down comer area Ad= 0.15*Ac = 0.914 m2
Net area An = Ac – Ad =1.55-0.233
= 1.105 m2
Active area Aa = Ac -2*Ad
Aa =0..91 m2
Hole area An, Take 10% of Aa as 1st =0.1*0.91
Hole area = .091 m2
Weir length
Ad / Ac = 0.195/ 1.3 = 0.15
(from figure 11.31 vol.6)
Lw / dc = 0.81
Lw 1 . 28 0 . 81
= 1.0368 m
Take weir height , hw = 50 mm
Hole diameter, dh = 5 mm
Plate thickness = 5 mm
Chapter: 05 Equipment Design
101
Check Weeping
Maximum liquid rate Lm’ = 329 × 63 / 3600 = 5.7575 kg/sec
Minimum liquid rate at 70% turn down 0.7 5.7575
= 4.03 kg/sec
how = weir crust
Maximum
2/3
1402 1.0368
5.7575
750
ow h
= 19.48 mm liquid
Minimum
2/3
1402 1.0368
4.03
750
ow h
= 15.4 mm liquid
at minimum hw + how = 50 + 15.4
=65.4mm liquid
from fig 11.30, Coulson and Richardson Vol.6
K2 = 30.6
The design vapour velocity
1/ 2
2
min
0.9 25.4
v
Kd
Uh
Chapter: 05 Equipment Design
102
min 1/ 2 1.362
= 10.488 m/s
Vapour velocity at Base of column =422.62*63/3600*1.284 = 0.98m/sec
Actual minimum vapour velocity
Ah
minimumvapour rate
0.091
0.980.7
= 7.54 m/s
So minimum vapor rate will be well above the weep point.
Plate Pressure Drop
Dry Plate Drop
Max. Vapour velocity through holes
h U ˆ = Volumetric Flow Rate / Hole Area
10.77
0.091
ˆ 0.98 h U m/s
from fig. 11.43 for plate thickness/hole dia = 5/5 = 1
and 0.1
0.91
0.091
a
h
p
h
A
A
A
A
Co =0.84
From Eq.11.88 Coulson vol.6
Chapter: 05 Equipment Design
103
L
V
o
h
dC
U
h
2ˆ
51
1425
1.284
0.84
10.77
51
2
d h =7.54mm liquid
Residual Head
8.77
1425
12.5 103
r h mm liquid
Total Pressure Drop
ht = hd + (hw + how) + hr
Total pressure drop = 7.54 + (50 +19.48) + 8.77
ht = 85.8 mm liquid
Down comer Liquid Backup
Take hap = hw – 10 = 40 mm
Area under apron “Aap”
1.036840103
= 0.04147 m2
As this is less than Ad use Aap in eq. 11.92 coulson vol.6 i.e,
Chapter: 05 Equipment Design
104
2
166
L ap
wd
dc A
l
h
2
1425 0.041472
5.757
166
dc h
= 1.57529 mm liq.
Backup in down comer
hb = (hw + how) + ht + hdc
hb =(50 + 19.48) + 85.804 + 1.5753
= 156.86 mm liq.
hb < ½ (Tray spacing + weir height)
0.157<1/2(0.46+0.81)
So tray spacing is acceptable
Check Residence Time
wd
d bc L
r L
Ah
t
___________5.757
0.1950.157 1425
r t
= 7.58 sec
≡ 8 sec
3 sec. so, result is satisfactory
Chapter: 05 Equipment Design
105
Check Entrainment
Uv = Maximum Volumetric Flow Rate of vapors/Net Area
UV = 0.98/1.105 = 0.89 m/s
Flv= Lw / Vm (ρv/ρL) 1/2
=0.1
= K1 = 0.075
Uf =k1{( ρL- ρv ) / ρv}1/2 =2.5 m/sec
Percent flooding = UV actual velocity (based on net area ) / Uf
Percent flooding = 0.89/2.5 = 35.6 %
FLV(base) = .1
from fig. 11.29 coulson vol.6
Fractional Entrainment = 0.003 well below 0.1 Satisfactory
Trial Lay Out
Use cartridge type construction. Allow 50 mm imperforated strip round plate edge;
50 mm wide calming zone.
From fig. 11.32
Lw/Dc = 0.825
Q = 107o
Chapter: 05 Equipment Design
106
Angle subtended at plate edge by imperforated strip = 180 – 107 = 73o
Max length, unpeeforoted edge strip:
180 1.73
1.4150103 73 r t
Area of imperforated edge strip Ap/ 50 10 3 1.73) 0.0865 m2
Mean length of calming zone 1.41 50 10 sin 1.03 2
3 99 m
Area of calming zone Acal 21.0350103 0.1m2
Total area of perforations, Ap = Aa – Ap/ - Acal = 0.89 – 0.0865 – 0.1 =0. 70m2
0.127
0.70
0.089
p
h
A
A
From fig. 11.33 Coulson vol.6
lp/dh = 2.8
Satisfactory within 2.5 - 4.0
No of Holes
Area of one hole 1.964105
Number of Holes = Hole Area / Area of one hole
No. of holes 1.964 10 5
0.91
Chapter: 05 Equipment Design
107
= 4531.57
≡ 4634
Chapter: 05 Equipment Design
108
Specification Sheet
Identification
Item Main Stripper
Item # D – 102
Tray type: Sieve tray
Function : To strip NO2
Operation: Continuous
Top Bottom
Temperature 286 K 328 K
Design Data :
Operating Pressure = 1 atm Weir Height = 50mm
No of actual Trays = 18 Weir length = 1.0368 m
Diameter of Column = 1.28 m Hole Area = .000964 m2
Tray spacing = 0.46 m Hole Diameter = 5 mm
Height of Column = 8.74 m No of Holes =4634
Fractional Entrainment = 0.003 Overall efficiency = 50 %
Plate pressure drop = 85.804 mm liquid
Chapter: 05 Equipment Design
109
DESIGN OF DISTILLATION COLUMN
In industry it is common practice to separate a liquid mixture by distilling the
components, which have lower boiling points when they are in pure condition
from those having higher boiling points. This process is accomplished by partial
vaporization and subsequent condensation.
Definition
“Process in which a liquid or vapor mixture of two or more substances is separated
into its component fractions of desired purity, by the application and removal of
heat”.
Chapter: 05 Equipment Design
110
TYPES OF DISTILLATION COLUMNS
There are many types of distillation columns, each designed to perform specific
types of separations, and each design differs in terms of complexity.
Batch columns
Continuous columns
Batch Columns
In batch operation, the feed to the column is introduced batch-wise. That is, the
column is charged with a 'batch' and then the distillation process is carried out.
When the desired task is achieved, a next batch of feed is introduced.
Continuous Columns
In contrast, continuous columns process a continuous feed stream. No
interruptions occur unless there is a problem with the column or surrounding
process units. They are capable of handling high throughputs and are the more
common of the two types. We shall concentrate only on this class of columns.
CHOICE BETWEEN PLATE AND PACKED COLUMN
Vapor liquid mass transfer operation may be carried either in plate or packed
column. These two types of operation are quite different. The relative merits of
plate over packed column are as follows:
1-Plate column are designed to handle wide range of liquid flow rates without
flooding.
Chapter: 05 Equipment Design
111
2-If a system contains solid contents; it will be handled in plate column, because
solid will accumulate in the voids, coating the packing materials and making it
ineffective.
3-Dispersion difficulties are handled in plate column when flow rate of liquid are
low as compared to gases.
4-For large column heights, weight of the packed column is more than plate
column.
5-If periodic cleaning is required, man holes will be provided for cleaning. In
packed columns packing must be removed before cleaning.
6-For non-foaming systems the plate column is preferred.
7-Design information for plate column is more readily available and more reliable
than that for packed column.
8-Inter stage cooling can be provided to remove heat of reaction or solution in
plate column.
9-When temperature change is involved, packing may be damaged.
Our mixture which is to be processed is “Water, Isopropyl alcohol, Acetone”. I’ve
selected plate column because:
1-System is non-foaming.
2-Temperature is high i.e. 90C.
CHOCE OF PLATE TYPE
There are three main types, sieve tray, bubble cap, valve tray. I’ve selected sieve
tray because:
1-They are lighter in weight and less expensive. It is easier and cheaper to install.
2-Pressure drop is low as compared to bubble cap trays.
3-Peak efficiency is generally high.
4-Maintenance cost is reduced due to the ease of cleaning.
Chapter: 05 Equipment Design
112
Sieve trays
Sieve trays are simply metal plates with holes in them. Vapor passes straight
upward through the liquid on the plate. The arrangement, number and size of the
holes are design parameters.
Because of their efficiency, wide operating range, ease of maintenance and cost
factors, sieve and valve trays have replaced the once highly thought of bubble cap
trays in many applications.
Main Components of Distillation Columns
Column internals such as trays/plates and/or packing which are used to enhance
component separations.
A reboiler to provide the necessary vaporization for the distillation process.
The liquid removed from the reboiler is known as the bottoms product or
simply, bottoms.
A condenser to cool and condense the vapor leaving the top of the column.
The condensed liquid that is removed from the system is known as the
distillate or top product.
A reflux drums to hold the condensed vapor from the top of the column so
that liquid (reflux) can be recycled back to the column. The condensed
liquid is stored in a holding vessel known as the reflux drum. Some of this
liquid is recycled back to the top of the column and this is called the reflux.
Chapter: 05 Equipment Design
113
A schematic of a typical distillation unit with a single feed and two product
streams is shown above.
Chapter: 05 Equipment Design
114
FACTORS AFFECTING DISTILLATION COLUMN OPERATION
Vapor Flow Conditions
Adverse vapor flow conditions can cause:
Foaming
Entrainment
Weeping/dumping
Flooding
Foaming
Foaming refers to the expansion of liquid due to passage of vapor or gas. Although
it provides high interfacial liquid-vapor contact, excessive foaming often leads to
liquid buildup on trays. In some cases, foaming may be so bad that the foam mixes
with liquid on the tray above. Whether foaming will occur depends primarily on
physical properties of the liquid mixtures, but is sometimes due to tray designs and
condition. Whatever the cause, separation efficiency is always reduced.
Entrainment
Entrainment refers to the liquid carried by vapor up to the tray above and is again
caused by high vapor flow rates. It is detrimental because tray efficiency is
reduced: lower volatile material is carried to a plate holding liquid of higher
volatility. It could also contaminate high purity distillate. Excessive entrainment
can lead to flooding.
Chapter: 05 Equipment Design
115
Weeping/Dumping
This phenomenon is caused by low vapor flow. The pressure exerted by the vapor
is insufficient to hold up the liquid on the tray. Therefore, liquid starts to leak
through perforations. Excessive weeping will lead to dumping. That is the liquid
on all trays will crash (dump) through to the base of the column (via a domino
effect) and the column will have to be re-started. Weeping is indicated by a sharp
pressure drop in the column and reduced separation efficiency.
Flooding
Flooding is brought about by excessive vapor flow, causing liquid to be entrained
in the vapor up the column. The increased pressure from excessive vapor also
backs up the liquid in the down comer, causing an increase in liquid holdup on the
plate above. Depending on the degree of flooding, the maximum capacity of the
column may be severely reduced. Flooding is detected by sharp increases in
column differential pressure and significant decrease in separation efficiency.
Reflux Conditions
Minimum trays are required under total reflux conditions, i.e. there is no
withdrawal of distillate. On the other hand, as reflux is decreased, more and more
trays are required.
Chapter: 05 Equipment Design
116
Feed Conditions
The state of the feed mixture and feed composition affects the operating lines and
hence the number of stages required for separation. It also affects the location of
feed tray.
State of Trays and Packings
Remember that the actual number of trays required for a particular separation duty
is determined by the efficiency of the plate. Thus, any factors that cause a decrease
in tray efficiency will also change the performance of the column. Tray
efficiencies are affected by fouling, wear and tear and corrosion, and the rates at
which these occur depends on the properties of the liquids being processed. Thus
appropriate materials should be specified for tray construction.
Column Diameter
Vapor flow velocity is dependent on column diameter. Weeping determines the
minimum vapor flow required while flooding determines the maximum vapor flow
allowed, hence column capacity. Thus, if the column diameter is not sized
properly, the column will not perform well.
DESIGNING STEPS OF DISTILLATION COLUMN
a) Calculation of minimum reflux ratio.
b) Calculation of optimum reflux ratio.
c) Calculation of theoretical no. of stages.
d) Calculation of actual no. of stages.
e) Calculation of diameter.
f) Calculation of height.
Chapter: 05 Equipment Design
117
g) Calculation of pressure drop.
h) Calculation of no. of holes.
i) Calculation of weeping and flooding.
Design of Regenerator
Diameter of the Column:
Top
Product
Bottom
Product
Feed
At Top:
T = 185 0F = 185 + 460 = 6450R
P = 14.7 Psig =29.4 Psia
Avg. M.Wt. = 62.1Kg/Kgmol
ρL = 60.47 lbm/ft3 (From Plant Design book)
Chapter: 05 Equipment Design
118
R = 10.73 lbf.ft3/in2 lbmol 0R
ρg = PM/RT =29.4x62.1/10.73x645= 0.26 lbm/ft3
From Plant Design by Peters & Timmerhaus; (Page No.656,Edition 4rth)
Vm = Kv √ [(ρL - ρg) / ρg] (Souders $ Browns Eq)
Where,
Vm = max. allowable superficial vapour velocity (ft/sec)
Kv = an empirical constant (ft/sec)
For the tray spacing of “24 inch” (From Plant Design book ,Page No.684 ,4rth Edition)
Vm= 0.3 √ [(60.47-0.26) / 0.26] Here Kv=0.3(From Graph,Plant
Design Book,4rth Edition,Page No.657)
Vm = 4.56 ft/sec
For the diameter of the column;
Mass flow rate / Area = Vm x ρg
Area = Mass flow rate(G) / Vm x ρg
(Л / 4)D2 = G / Vm x ρg
D = √ [4 G / (Л x Vm x ρg x 3600)]
D = √ [(4 x 13095.06) / (Л x 4.56x0.26 x 3600)]
D = 2 ft
At Bottom:
T =248 0F=248+460=7080R
P = 14.7 Psig = 29.4Psia
Avg.M. Wt. = 48.6 Kg/Kgmol
ρL = 58 lbm/ft3 (From Plant Design book)
R = 10.73 lbf.ft3/in2 lbmol 0R
ρg = PM/RT = 29.4x48.6/10.78x70 =0.18 lbm/ft3
For the tray spacing of “24 inch” (From Plant Design book ,Page No.684 ,4rth Edition)
Vm = Kv √ [(ρL - ρg) / ρg] Here Kv=0.3(From Graph,Plant Design
Book,4rth Edition,Page No.657)
Vm = 0.3 √ [(58-0.18)/0.18]
Chapter: 05 Equipment Design
119
Vm =5.38 ft/sec
Now;
D = √ [4 G / Л x Vm x ρg x 3600]
D = √ [(4x19646) / Л x5.38x 0.18 x 3600]
D= 2.68 ft
No. of Plates Required:
At 216.50F,=1000C approx.(From Perry)
Vapour pressure of HNO3 = 545 psi
Vapour pressure of H2O = 185psi
Relative Volatility; α = 545/185=2.946
For the calculation of minimum reflux ratio;
Rmin. = (1/ α - 1) [Xd / Xf – α ( 1 – Xd / 1 – Xf )] (Underwood and Fenske equation)
Rmin. = (1/ 2.946 – 1) [0.933 / 0.533 –2.946 ( 1 – 0.933 / 1 –0.533 )]
Rmin. = 0.514x(1.75-0.421)
Rmin. = 0.683
As the optimum reflux ratio is (1.1 to 1.5) times the minimum reflux ratio;(In Richardson
$ Coulson,Vol-2)
F = 354.34 Kgmol/
hr
Xf = 0.533
D = 99.203 Kgmol/hr
Xd = 0.933
W = 255.143 Kgmol/hr
Xw = 0.378
Chapter: 05 Equipment Design
120
So,
R = 1.2 (0.683 )
R = 0.82
Equation of the Top operating line;
Yn = ( Ln / Vn )Xn+1 + ( D / Vn )Xd
Ln / D = R =0.82 => Ln =0.82 D
Ln = 0.82 (99.203) = 81.346 kgmol/hr
Vn = Ln + D = 81.346+99.203 = 180.549 kgmol/hr
Therefore,
Yn = ( 81.346/180.549 )Xn+1 + (99.203/180.549)x0.933
Yn = 0.45 Xn+1 + 0.512
Equation of the Bottom operating line;
Ym = ( Lm / Vm )Xm+1 - ( W / Vm )Xw
Vm = Vn =180.549 kgmol/hr
Lm = Ln + F = 81.346+354.34 =435.686kgmol/hr
Therefore;
Ym = (435.686/180.549 )Xm+1 - ( 255.143/180.549 )x0.378
Ym =2.413 Xm+1 – 0.534
Equilibrium Data; We have eq.
ya = α xa / [1 + (α – 1)xa]
xa 0 0.1 0.2 0.3 0.4 0.5 0.6
ya 0 0.25 0.42 0.56 0.66 0.75 0.82
By “McCabe-Thiele Method”:
Using “top and bottom operating lines” and the “equilibrium curve” from the
graph,
The theoretical no. of stages required = 08
Chapter: 05 Equipment Design
121
Efficiency: (Drickamer $ Bradford Eq.)
E = 17 – 61.1 log ( μFavg. ) (From Plant Design book ,Page No.665 ,4rth Edition)
Now, At 216.5 0F
μFavg. = [(0.45x0.533)+(0.028x0.467)]=0.253Cp , U,HNO3 is taken from
Perrys,Transport Properties. (2-322,2-323) that is 0.45Cp $ U,H2O is taken from Plant
Design Book,Page No.(872,873) that is 0.028Cp
E = 17 – 61.1 log ( 0.253 )
E = 17 – 61.1 x(-0.597)
E = 53.5 %
As,
Efficiency = Theoretical no. of stages / Actual no. of stages
Actual no. of stages = Theoretical no. of stages / Efficiency
Actual no. of stages = 8 / 0.535
= 14.95 ~ 15
Height of the Column:
Height of column occupied by trays = No. of trays x Tray spacing
No. of trays =15
Tray spacing = 24 in = 2 ft
Height of column occupied by trays = 15 x 2 =30 ft
Height occupied by one distributor = 0.5 m = 1.64 ft (By Rule of
Thumb, Height occupied by one distributor is ( 0.3 m to 0.5m)
No. of distributors used in column = 3
Height occupied by distributors = 3 x 1.64 = 4.92 ft
By Rule of Thumb,We have:
Height at the bottom of the column to maintain the liquid level = 4 ft
Height at the bottom for security purpose = 4 ft
Height at the top of the column above the top most tray = 4 ft
So,
Total Height of the column = 30 + 4.92 + 4 + 4 + 4
Chapter: 05 Equipment Design
122
=46.92 ft
Pressure Drop in the Sieve Tray column:
Diameter of the tray (Avg.) =2.34 ft As (Dia of tray = Dia of column)
Total column area = (Л / 4) D2
= (Л / 4) 2.342
= 4.3 ft2
Taking “15%” Down comer area,
Down comer area = 4.3 x 0.15
= 0.645 ft2
Taking “85%” active area of the column,
Active area of the column = 4.3 x 0.85
= 3.6 ft2
Taking hole area as “10%” of the active area,
Sieve hole area = 3.6 x 0.10
= 0.36 ft
Taking hole diameter = 3/16 in
Taking tray thickness = 3/16 in
As,
Pressure drop = ΔPT = (ρL x g x ht) / 144 gc
ht = hc + ho + hw + 0.5hg
Where,
hc = Head equivalent to gas pressure drop
through the holes in sieve tray
ho = Height of liquid crest
hw = Weir height
hg = Average liquid gradient
Now,
Chapter: 05 Equipment Design
123
hc = K.H [(Vc
2 x ρg) / 2gc x ρL)]
Where,
Vc = Linear velocity through the sieve hole
Vc = Superficial velocity (Total column area / Total sieve hole area)
= 4.97 (4.3 / 0.36 )
= 59.36 ft/sec
To calculate the Kinetic head,
Hole area / Active area = 0.36 / 3.6 = 0.1
Tray thickness / Hole diameter = (3/16) / (3/16) = 1
From the fig. 16.12 by Peters & Timmerhaus,Page No.670
K.H = 1.4
So,
hc = 1.4 [(1.4x59.36^2x0.22 / 2 x 32.2 x 59.24)]
hc = 0.28 ft
Now,
ho = [ 1.7 QL /lw g ]2/3
Where;
QL = Vol. flow rate of liquid (ft3/sec)
lw = Weir length (ft)
So,
QL = 19646 lbm ft^3 1 hr
hr 59.24lbm 3600 sec
= 0.092 ft3 / sec
lw = 75% of tray diameter(By Rule of Thumb)
= 0.75 x2.34
= 1.8ft
Therefore
ho = [ 1.7 QL / lwg ]2/3
= [(1.7 x 0.092) /1.8x32.2]2/3
= 0.092 ft
Chapter: 05 Equipment Design
124
How,
Weir height = hw = 2 in
= 0.167 ft (R & Coulson vol. 6 or Rule of
Thumb)
Let liquid gradient is negligible or usually ignored in case of sieve trays, (From Plant Design
book ,Page No.672 ,4rth Edition)
hg = 0
Therefore,
ht = 0.28+0.167+0.06
= 0.507 ft
ΔPT = (59.24.x 32.2 x 0.507) / (144 x 32.2)
ΔPT = 0.208 Psig
%Pressure Drop due to liquid head above the sieve holes:
% ΔP = [( ho + hw ) / ht] x 100
= [( 0.06 + 0.0.167 ) /0.507] x 100
% ΔP = 44.8 %
Chapter: 05 Equipment Design
125
DESIGN OF PARTIAL CONDENSER
Sometimes it is desirable to condense only a portion of the vapor in a condenser such as
may be needed only for reflux. Such a condenser is a partial condenser although the term
dephlagmator was formally used. The calculation of a partial condenser does not alter the
method of computing the condensing film co-efficient. The calculation of a pressure drop
for a partial condenser is obtained with sufficient accuracy from the average of the
pressure drops based on the inlet and the outlet conditions.
So we say that partial condenser condenses the vapors at a point high enough to provide a
temperature difference sufficient to preheat a cold stream of process fluid . this save heat
and eliminates the need for providing a separate preheater .
DESIGN CALCULATIONS:
Heat duty:
NO=0.13464.7142.20463600=5035.78 lbm/hr
NO2=67.343 lbm/hr
N2=24490.513lbm/hr
H2O=7815.56 lbm/hr
Reference temperature=77oF
Enthalpies or heat rates carried
Q1 for NO=380705.1373 Btu/hr
Q2 for NO2 =6151.8095 Btu/hr
Q3 for N2=2005773.01 Btu/hr
Q4 for H2O =6510364.77 Btu/hr
Total heat load without condensation load
ΣQ=Q1+Q2+Q3=2392629.962 Btu/hr
If the mixture is cooled up to 50oF below the saturation temperature of steam then
Chapter: 05 Equipment Design
126
Q5=ΣmCpΔT=6008.15950 oF
=300407.9847Btu/hr
condenser duty total
Qc=Q4+Q5
=6810772.75 Btu/hr
Amount of coolent Water (treated)
Temperature limit
77 oF to 203 oF
Qc = ΣmCpΔT
m=54053.75 lbm/hr
Design of partial condenser
Film co-efficient of steam can be taken as
T1=392 oF , T2=342 oF
t1=77 oF , t2 =203 oF
R= T1 - T2/ t2- t1
=0.4
S= t2- t1 / T1 - t2 =0.4
FT=0.98
1 shell pass
2 tube passes
LMTD= 224.864 oF
Corrected T = FT LMTD=0.98224.864=220.366oF
Suppose overall heat transfer coefficient= UD = 200 Btu/lb.ft2. oF
Heat transfer area ,
Chapter: 05 Equipment Design
127
Q = UDA(t)w
A = 154.53 ft2
Exchange Layout
1-2, shell & tube heat exchanger
1OD, 5/4sq. pitch,
A = at Nt Lt
Lt = 18 ft.
a't = 0.2618 ft2/ft
A = 0.2618 18 Nt
Nt = 32.792
Nt = 32 (Nearest count)
So
A = 150.7968ft2
UD = 204.955 Btu/hr. ft2. oF
Shell side Tav=392+342/2=367 oF
Tube side Tav =203+77/2=140 oF
Assume ho=150 Btu/hr ft2 oF
Then
(T-tw)ho=(T-t)UD
(367-tw)150=(367-140)205
tw=57 oF
average condensate temperature =(57+367)/2
=211.88 oF
Tube bundle dia
Chapter: 05 Equipment Design
128
Db=2504(32/0.244)1/2.207
=0.752 ft
Hc=0.95KL[ L ( L - V )g/μTl]Nr
-1/6
Nr = Db /Pt
=35.305
=2/335.305=23.536
For,
ρv weighted must be used
ρv = ρVNO2yNO2+ ρVNOyNO+ ρVN2yN2+ ρVH2OyH2O
=1.7450.0018+0.765990.1346+0.71490.6546+0.50780.2089
=0.6923 lbm/ft3
So,
Tl =ml/Lnt
=93.84
By putting the values
hc=1777.88 Btu/hr. ft2. oF
Assume, ho =1500 Btu/hr. ft2. oF
tw=366 oF
average temperature of condensate =366.89 oF
KL =0.436
μL =0.0217 lbm/hr ft
L =50.05 lbm/hr ft
V =0.55 lbm/ft3
Now
Chapter: 05 Equipment Design
129
hc =0.950.43[50.05(50.05-0.55) 4.16108/0.021793.84]1/3 23.536 -1/6
=19050 Btu/hr. ft2. oF
TUBE SIDE CO-EFFICIENT (WATER)
at = 0.016136 m2
Velocity = 0.17359 m/ sec
hi = 4200(1.35+0.0265)0.173590.8 /22.0980.2
=266 Btu/hr. ft2. oF
hio = 231 Btu/hr. ft2. oF
UC =207 Btu/hr. ft2. oF
RD =0.0001 hr. ft2. oF/ Btu
Pressure drop for shell side is negligible
at =0.00412 ft2
flow area for 32 tubes
at’=at32/2=0.06605 ft2
Gs = m/at = 818351.629 lb/hr ft2
Res = De Gs/
=2045879.07
ρ = 58 lbm/ft3
s.gr=0.929
f=0.00001
5.22 10 D s
fGLn
P 10
2
t
t
=0.6857 psia
2 P
Chapter: 05 Equipment Design
130
V2/2g’= from fig. 27=0.098
PL =4n N2/2g’ ρ
=4*2*0.098/1=0.784
t P =0.784+0.6857
=1.4697 psi
Which is satisfactory
Chapter: 05 Equipment Design
131
Specification Sheet
Identification: Partial condenser
No. Required = 1
Function: Condense steam by removing the latent heat of vaporization
Operation: Continuous
Type: 1-2 Horizontal Condenser
Shell side condensation
Heat Duty = 6810772.75 Btu/hr = 7.18 * 10 6KJ/hr
Tube Side:
Fluid handled cold water
Flow rate = 54053.75 lbm/hr = 24569.5
Kg/hr
Pressure = 1 atm= 101.325 Kpa
Temperature =77 o F to 203 o F
25 0C to 95 0C
Tubes: 1 in. dia. 18 BWG
33 tubes
L = 18 ft = 5.48 m
2 passes
5/4 in triangular pitch
Shell side:
Flow rate= 37409 lbm/hr =
17004 kg/hr
Pressure 1 atm = 101.325 Kpa
Temperature 392oF to 342 oF`
200 0C to 172.22 0C
Utilities: Cold water
Chapter: 05 Equipment Design
132
Ud assumed = 200 Btu/hr.ft2. oF =
4088.133 KJ/hr m2 0C
UDcalculated=UD= 204.955Btu/hr.ft2. oF=
4169.8 KJ/hr m2 0C
UC =207 Btu/hr. ft2. oF = 4231 KJ/hr
m2 0 C
RD =0.0001 hr. ft2. oF/ Btu = 4.89*10-6 hr
m2 0C/KJ
NOMENCLATURE
as = Area of shell
a//
t = Flow area
at = Flow area per tube
B = Baffle Spacing
C = Clearance b/w tubes
Cp = Specific Heat Capacity
D = Inside diameter of tubes
De = Equivalent diameter of shell
Ds = Inside diameter of shell
f= Friction Factor
Gt = Tube side mass velocity
Gs = Shell side mass velocity
hi , ho = Inside and Outside film coefficient
hio = Value of hi when referred to the tube ,OD,Btu/hr.ft2.oF
Hv = Heat of vaporization
Chapter: 05 Equipment Design
133
ID = Internal Diameter
L = Tube Length,ft
LMTD = Log Mean Temperature Difference
m= Mass flow rate of vapors
mm,mw,mDME = Mass Flow rate of vapors of methanol,water,DME
n = Number of passes
OD = Outer Diameter
PT = Tube Pitch
ΔP, ΔPt, ΔPr = Total, tube, return pressure drop
ΔPs = Pressure drop of shell
Q = Heat Flow
Rd = Combined dirt factor
Re = Reynolds number, dimensionless
s= Specific Gravity
UC, UD = Clean overall coefficient for condensation, desuperheating
w = Mass Flow Rate of water
= Viscosity ; = Viscosity ratio, (/w) 0.14
Chapter: 06 Mechanical Design
134
Chapter: 6
Mechanical Design
Absorber
Mechanical design:
For stainless steel vessel:
So, max allowable stress f is;
f = 165 N/mm²
Operating pressure = 130.9psi
Design pressure is 10% of operating pressure
So, design pressure,
Pi = ((130.9×10/100)) + 130.9
Pi = (13.09+130.9)
Pi = 143.99psi
Thickness of shell:
Taking joint efficiency 80%
J = 0.80
t = Pi Di/2fJ−Pi
= ((143.99×3.2808)/ (2× 479042.95 ×.8) − (143.99)
t = 0.0006ft
= .0073 in
As less corrosive service,
So, taking corrosion allowance is taken as 0.118 inch /year
As plant life is 10 years, so for 10 years corrosion allowance is 1.18 inch
So, total thickness is;
T = 0.0073 + 1.18
T = 1.187 inch
Chapter: 06 Mechanical Design
135
Thickness of head:
We choose torispherical head. So, the equation for thickness of tori spherical head is;
Cs = 1/4[3+(Rc/Rk)1/2]
= ¼[3+1.29] = 1.07
t = PiRcC s / 2fj + Pi(Cs-.2)
= .00065ft
= .008in
. So, taking corrosion allowance is taken as 0.118 inch /year
As plant life is 10 years, so for 10 years corrosion allowance is 1.18 inch
So, total thickness is;
T / = .008 + 1.18
= 1.188 inch
Chapter: 06 Mechanical Design
136
Oxidation Tower
Mechanical design:
For stainless steel vessel:
So, max allowable stress f is;
f = 165 N/mm²
Operating pressure = 14.7 psi
Design pressure is 10% of operating pressure
So, design pressure,
Pi = ((14.7×10/100)) + 14.7
Pi = (14.7 + 1.47)
Pi = 16.17 psi
Thickness of shell:
Taking joint efficiency 85%
J = 0.85
t = Pi Di/2fJ−Pi
= ((16.17 × 3.64)/ (2× 479042.95 ×.85) − (16.17)
t = 0.00007ft
= .0009 in
As less corrosive service,
So, taking corrosion allowance is taken as 0.11 inch /year
As plant life is 10 years, so for 10 years corrosion allowance is 1.18 inch
So, total thickness is;
T = 0.0009 + 1.18
T = 1.1809 inch
Chapter: 06 Mechanical Design
137
Thickness of head:
We choose torispherical head. So, the equation for thickness of tori spherical head is;
Cs = 1/4 [3+ (Rc/Rk)1/2]
= ¼[3+1.29] = 1.02
t = PiRcCs / [2fj + Pi (Cs-.2)]
= .00007ft
= .00084in
So, taking corrosion allowance is taken as 0.11 inch /year
As plant life is 10 years, so for 10 years corrosion allowance is 1.18 inch
Total thickness of head
T / = .00084 + 1.18
= 1.1808 inch
Chapter: 06 Mechanical Design
138
Distillation Column
Mechanical Design:
Carbon steel is used as the material of construction.
Diameter of the column = 2.34 ft =28.08 in
Pressure of the column = 14.7 psig
Max. allowable pressure or Design pressure = 14.7 (1.1 )= 16.7 Psig As (Design
Pressure = 10 to 15% of Working Pressure)
psigMax. allowable design stress = 13700 psig
Joint efficiency(For fully Radiographed) = 1.0 , (From Plant Design book ,Page No.(537,538) ,4rth
Edition)
Now wall thickness;
t = PiDi / (2Jf – Pi)
= (16.17 x 28.08) / (2 x 1 x 13700 – 16.7)
= 0.016 in
During the normal operation;
Corrosion allowance for carbon steel = 1.0 mm = 0.04 in (From R $ C, Vol- )
Therefore,
Total thickness = 0.016 + 0.04
= 0.056in
As
The design pressure = 14.7 psig = 1.114 bar < 15 bar
So the head is “Torispherical head”.
For Torispherical head,
t = PiRcCs / [2Jf + Pi(Cs – 0.2)]
Where,
Cs = 1/4 [3 + √(Rc/Rk)]
Where
Cs =Stress Conc. factor
Rc = Crown Radius = Di = 28.08 in
Rk = Knuckle Radius = 6 % of Di
= 0.06 x 28.08 = 1.68
Cs = 1/4 [3 + √(28.08/1.68)]
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= 1.77
Now,
t = (16.17 x 28.08x 1.77) / [(2 x 1 x 13700) + 16.17x(1.77 – 0.2)]
= 0.029 in
For Carbon steel,
Corrosion allowance = 1.0 mm = 0.04 in
Total Head thickness = 0.029 + 0.04
= 0.069 in
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140
Stripper
Mechanical design:
For stainless steel vessel:
Design stress = 145 N/mm2
Operating pressure = 14.7psi
Design pressure is 10% of operating pressure
So, design pressure,
Pi = ((14.7×10/100)) + 14.7
Pi = (1.47 + 14.7)
Pi = 16.17 psi
Thickness of shell:
Taking joint efficiency 85%
J = 0.85
t = Pi Di/2fJ−Pi
= (16.17× 4.199)/ (2× 420977.13×.85) − (16.17)
t = 0.00009ft
= .0011 in
As less corrosive service,
. So, taking corrosion allowance is taken as 0.118 inch /year
As plant life is 10 years, so for 10 years corrosion allowance is 1.18 inch
So, total thickness is;
T = 0.0011 + 1.18
T = 1.181 inch
Thickness of head:
We choose torispherical head. So, the equation for thickness of tori spherical head is;
Cs = 1/4[3 + (Rc/Rk)1/2]
= .1/4[3 + 4.09] = 1.77
t = PiRcC s / 2fj + Pi(Cs-.2)
= .00007ft
Chapter: 06 Mechanical Design
141
= .0008in
So, taking corrosion allowance is taken as 0.118 inch /year
As plant life is 10 years, so for 10 years corrosion allowance is 1.18 inch
So, total thickness is;
Total thickness of head
T / = .0008 + 1.18
= 1.18 inch
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Chapter: 07
INSTRUMENTATION & CONTROL
INRODUCTION:
Measurement is a fundamental requisite to process control. Either the control can be
affected automatically, semi-automatically or manually. The quality of control obtainable
also bears a relationship to the accuracy, re-product ability and reliability of the measurement
methods, which are employed. Therefore, selection of the most effective means of
measurements is an important first step in the design and formulation of any process control
system.
Objectives of Process Control
Safety.
Production Specifications.
Operating Constraints.
Economics.
Environmental regulations
PROCESS MESUREMENT INSTRUMENTATION:
The importance of process measurement in a process plant cannot be neglected. Current
process control technology relies on accurate and repeatable measurements in order to
produce a return on investment consistent with the design of the process plant.
The measurement instruments cannot measure the process parameter directly. Rather
measures some other parameter, and infers that in the desired parameters. Consider the
following examples.
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I. Suppose it is required to read the temperature of a room using alcohol in a glass
thermometer. It is clear that, in reality the expansion and contraction of alcohol is
what is being measured relative to the room temperature. The height of the alcohol
column is, intern, compared to a calibrated scale and a temperature measurement is
inferred.
II. If a steam pressure in a boiler drum is required by using a common pressure gauge, in
reality the mechanical deflection of the measuring element inside the gauge is what is
being measured relative to the steam pressure. This deflection of the measuring
clement is converted to angular motion; a pointer is linked to the measuring element
and compared to a calibrated scale as an inferred pressure measurement.
The phenomenon of inferred measurement causes the instrument to carry out a.c. conversion
from one energy to another, i.e. in case of room thermometer, from heat energy to
mechanical energy. However, this conversion process increases the complexity of the
instrument and consequently increases the potential sources of error.
The most common parameters measured on a process plant are Sometimes referred to as Big
Four” i.e. pressure, temperature, level and flow. These accounts for about 80% of all
measurements on a typical process plant.
The remaining 20% include analytical measurements cf density, humidity and speed etc.
Chapter:07 Instrumentation & Plant Control
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TYPES OF INSTRUMENTATION
Following are some of the main types of instrumentation
RECORDING INSTRUMENTATION
In Practical work process parameters such as temperature, pressure, and flow require
continuous measurements. If a review of the measurements is required provision must be
made to note the parameters with respect to time. The recorder is a device to accomplish this
task and may take many forms depending upon the application. The usual method is to
inscribe the measurement of the parameter on a chat with respect to time. These charts can be
circular or linear, and may be driven by a clock mechanism. The process parameter is record
by a pen which leaves a trace on the chart. The duration of the record is a Function of chart
speed (time base) and length of chart paper.
INDICATION INSTRUMENTATION
To provide visual indication of process parameters to the plant operators, instrument
indicators are used extensively in process. The indicators may be traditional circular dial type
digital display. Indicator may be field mounted, or panel mounted in a control room.
The indicator mechanism is selected to match the parameter signal and desired range of
measurement, i.e. it may use a pointer on a calibrated scale to, indicate. In recent years
circular gauges have been superseded by linear indicator displaying the process parameter in
the form of a pointer against a calibrated scale. I)igital display unit, which give a numerical
indication of the process parameter are becoming increasingly common.
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ALARM INSTRUMENTATION
The purpose of alarm instrumentation is to detect process parameters that deviate outside the
predetermined limits. An alarm instrument loop usually consists of a switch or contact
closure device as a field device, and on end device such as horn, light or bell. The alarm loop
is normally digital having two conditions corresponding to an alarm state and a non alarm
state.
PROCESS CONTROL SYSTEM
The three main objects of control systems are.
I. To suppress the influence of external disturbances on a process.
II. To ensure the stability and safety of a process plant.
III. To optimize the productivity of a process plant.
CANCELING THE EFFECT OF DISTURBANCES
To suppress the influence of disturbances is the most common objective of’ a control system.
This control objective attempts to return the process parameter back to the set point as
effectively as possible. The control systems made changes to the process to cancel the effects
of any external disturbances.
PROCESS STABILITY
Ensuring the stability of a process is an important aspect of control. With out stable control
the behavior of control process can range form virtually inactive, to very little control action
taking place. This may lead to unstable process.
An unstable condition affects the safety of plant and personnel, in addition causing poor
productivity.
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146
OPTIMIZING THE PRODUCTIVITY OF THE PROCESS
With proper control of process variables and stability of the process it is possible to run the
plant at the optimum production rate.
THE FEED BACK CONTROL LOOP
A fundamental part of any industrial control system is the feed back control loop. It consists
of following parts.
I. Controller
II. Measurement Element
III. Final Control Element
IV. Process
The process variable may be energy or material which is to be adjusted to a definite value
Examples of process variables are pressure, level, flow, temperature and composition.
SET POINT
The set point is the desired value of the process variable.
ERROR
It is the difference between the actual value of the controlled variable and the set point.
OR
It is the margin by which an automatic controller misses the desired value.
FEED BACK
Feed back is the form of information gained by monitoring the controlled variable, and
comparing the controlled variable signal to the set point. If the feed back causes the
difference between the set point and the controlled variable to increase, then the feed back is
positive. This situation is dangerous and undesirable.
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However under negative fed back control, the set point (usually a fixed value) and the
controlled variable are continually compared and the error between the two diminishes.
CLOSE FEED BACK CONTROL LOOP
If all the components of the loop are interconnected so that information can be passed
continuously around the loop, the loop is called closed fed back control loop.
OPEN FEED BACK CONTROL LOOP
If the flow of information around the loop is interrupted in any way (as, for example when
the controller is placed on manual control) then the loop is said to be open and automatic
feed back cases.
Following are the main parts of control loop.
I. CONTROLLER
The principle function of’ a controller is to generate an output signal that will control the
final control clement in order to remove error. The controller is normally the only component
in the loop that is capable of counteracting the effect of disturbances on the process.
II. SENSING OR MEASUREMENT ELEMENT
This measures the value of a controlled variable. Sensing elements are used to convert a
measurement. such as pressure, temperature, or flow, into a movement or signal that can be
used for transmission to a controller, recorder or an indicator. They are also called detectors
or sensors.
III. FINAL CONTROL ELEMENT
This is the component of a control system that adjust the value of the controlled variable e.g.
valve, variable transformation.
IV. PROCESS
Process may be defined as manufacturing operation which uses energy to produce a change
in a material, or to produce another energy conversion. The process may take many forms. It
may be the maintenance of water level in a boiler tank, the control of flow rate of various
liquids and gases, or the maintenance of pressure in a vessel.
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TEMPERATURE MEASUREMENT AND CONTROL
Temperature measurement is used to control the temperature of outlet and inlet
streams in heat exchangers, reactors, etc.
Most temperature measurements in the industry are made by means of thermocouples
to facilitate bringing the measurements to centralized location. For local
measurements at the equipment bi-metallic or filled system thermometers are used to a lesser
extent. Usually, for high measurement accuracy, resistance thermometers are used.
All these meters are installed with thermo-wells when used locally. This provides
protection against atmosphere and other physical elements.
PRESSURE MEASUREMENT & CONTROL
Like temperature pressure is a valuable indication of material state and composition.
In fact, these two measurement considered together is the primary evaluating devices of
industrial materials.
Pumps, compressor and other process equipment associated with pressure changes in
the process material are furnished with pressure measuring devices. Thus pressure
measurement becomes an indication of energy increase or decrease.
Most pressure measurement in industry are elastic element devices, either directly
connected for local use or transmission type to centralized location. Most extensively used
industrial pressure element is the Bourdon Tube or a Diaphragm or Bellows gauges.
FLOW MEASUREMENT AND CONTROL
Flow-indicator-controllers are used to control the amount of liquid. Also all manually
set streams require some flow indication or some easy means for occasional sample
measurement. For accounting purposes, feed and product stream are metered. In addition
utilities to individual and grouped equipment are also metered.
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Most flow measures in the industry are/ by Variable Head devices. To a lesser extent
Variable Area is used, as are the many available types as special metering situations arise.
.
CONTROL SCHEMES OF DISTILLATION
COLUMN
GENERAL CONSIDERATION
OBJECTIVES
In distillation column control any of following may be the goals to achieve
1. Over head composition.
2. Bottom composition
3. Constant over head product rate. .
4. Constant bottom product rate.
MANIPULATED VARIABLES
Any one or any combination of following may be the manipulated variables
1. Steam flow rate to reboiler.
2. Reflux rate.
3. Overhead product withdrawn rate.
4. Bottom product withdrawn rate
5. Water flow rate to condenser.
LOADS OR DISTURBANCES
Following are typical disturbances
1. Flow rate of feed
2. Composition of feed.
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3. Temperature of feed.
4. Pressure drop of steam across reboiler
5. Inlet temperature of water for condenser.
CONTROL SCHEME
Overhead product rate is fixed and any change in feed rate must be absorbed by
changing bottom product rate. The change in product rate is accomplished by direct level
control of the reboiler if the stream rate is fixed feed rate increases then vapor rate is
approximately constant & the internal reflux flows must increase.
ADVANTAGE
Since an increase in feed rate increase reflux rate with vapor rate being approximately
constant, then purity of top product increases.
DISADVANTAGE
The overhead reflux change depends on the dynamics of level control system that adjusts it.
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Control scheme of distillation column
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152
Chapter: 08
Safety
INTRODUCTION (ABSTRACT):
Every organization has a legal and moral obligation to safe-guard the health and welfare of
its employees and general public. Safety also leads to good business. So by good
management practice and ensuring safe operations personal safety, plant safety and efficient
operations can he achieved.
GENERAL GOALS OF SAFETY
The ultimate goal of safety is the complete protection of
i. Personnel injury and loss of life.
ii. Destruction of plant and property as a result of:
a. Accidents
b. Fires
c. Explosions or
d. Other hazards situation
MAJOR CAUSES OF HAZARDS:
Process industries have a wide range of hazards. These hazards are the result of the presence
of:
i. Sizable quantities of flammable and unstable materials.
ii. I ugh temperatures which promote ignition and decomposition.
iii. High pressure which may release in the case of structural failure or explosion.
iv. Improper handling of material by employees.
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153
PROTECTION AGAINST HAZARDS:
The Hazards and their prevention may be divided into two major groups.
1. Mechanical Hazards and protection.
2. Personal health Hazards and protection
PROTECTION AGAINST MECHANICAL HAZARDS
MAJOR MECHANICAL HAZARDS
Major Hazards are accidents which may happen due to mechanical failure of equipment
under sever operating conditions of temperature and pressure.
PROTECTION FROM MECHANICAL HAZARDS
The mechanical failure of equipment can be prevented by taking following steps into
account.
i. To prevent mechanical failure, the equipment should he designed according to
standards recommended by authorities. For example, pressure vessels and storage
tanks should be designed according to American Petroleum Institute (A.P.I.) code,
and they should be tested for 2 or more times at the designed pressure.
ii. While designing the equipment, it is necessary to select proper instruments and to
control the process at the safe operating conditions. Safety acts a guide line in the
design of control systems along with other factors.
iii. Clear and effective procedures play an important role in the safe operations of a
chemical plant. The equipment manufactures provide operating instructions. But in
the plant where hundreds of small units are looked, it is necessary to lay down
standard operating procedures (S.O.P’s) to ensure safe start up, shut down and normal
operations.
PERSONAL HEALTH HAZARDS AND PROTECTION
Accidents may also result during handling and storage of 1-lazardous material, Injury to plant
personal may also result due to toxicity of chemicals being handled during operations. It is
Chapter: 08 Safety
154
therefore, necessary to have a MI understanding of chemical and physical properties of
material being handled,
MAJOR HEALTH HAZARDS AT NITRIC ACID PLANT
At a typical nitric acid plant, large amount of nitric acid and nitrogen oxides are handled. So
major HAZARDS of nitric acid and nitrogen oxides are given below.
Nitric acid, its vapors and nitrogen oxides are
i. Highly toxic
ii. Fast in action
iii. Capable of producing sever injuries or death if improperly handled.
TYPICAL HAZARDS OF NITRIC ACID AND NITROGEN OXIDES
Typical Hazards of these chemicals can be divided into two groups.
i. Contact Hazards
ii. Respiratory Hazards
i. CONTACT HAZARDS
I. An injury may result by contact of skin with acid.
II. The symptoms resulting from skin contact vary from moderate irritation to sever
burns, depending on
a. Contact time and
b. Strength of acid
III. Signs of contact may include a yellow discoloration of skin.
IV. Sever burns may penetrate deeply causing ulceration.
ii. RESPIRATION HAZARDS
1. Due to highly toxic action of nitrogen oxides these gases are taken as the most toxic
gases.
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155
2. The major Hazards of these gases is the sever pulmonary problems.
3. The detail of problem is as follows
i. Sever pulmonary symptoms may set with in 5-8 hours after breathing as little
as 25 PPM through out an 8-hour period.
ii. Breathing 100-150 PPM for 0.5-1 hour may produce pulmonary edema.
iii. A few breaths of 200-700 PPM may produce sever pulmonary edema with in
5-8 hours.
4. Most cases of nitrous fume poisoning can be classified into the following categories.
i. Slight symptoms
ii. Mild immediate effects
iii. Sever effects
i. Slight symptoms
a. Slight symptoms may occur with in 48 hours breathing light nitrous oxide
fumes.
b. This form of poisoning occurs in industry.
ii. Mild Immediate Effects
From mild effects the recovery is apparently complete but after words the sever attacks
eventually continue. In typical case of NO poisoning the sequence of attacks may be
a. A few breaths of apparently harmless gas.
b. Only slight discomfort may be felt with worker continuing his job.
c. 5-8 hours after exposure, the victim may face very sever attack?
iii. Sever Effects
In case of sever attacks, attacks ma be followed by
a. Shocking
b. Dizziness and
c. Irregular respiration
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PROTECTION AGAINST HEALTH HAZARDS
Protection against health Hazards may he classified as:
I. Protection against contact Hazards.
II. Protection against respiratory Hazards.
I. PROTECTION AGAINST CONTACT HAZARDS
To protect contact Hazards following safety equipment should be provided to the workers.
a. Acid proof safety shoes
b. Acid proof over-all clothes
c. Rubber gloves
d. Safety goggles
e. Gas masks
f. Fire extinguisher
g. Some of employees should be given proper first aid training.
TREATMENT OF ACID CONTACT INJURY
Generally contact injury occur on
i. Skin
ii. Eye
i. SKIN INJURY TREATMENT:
a. II skin is a Heeled by the acid the affected part should he washed with
Na2CO3 solution or weak alkali solution.
b. Then the wound should he washed with water and dried.
c. Moist picric acid gauze is applied and bandaged.
d. If acid is swallowed, the victim should drink warm water soap-water or milk
in large quantities.
e. Vomiting should be introduced if it does not occur.
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157
ii. EYE INJURY TREATM ENT
a. If eye is affected immediately wash the eye with saturated solution of
Na2CO3.
b. Cover the eye and bandage.
c. Report the case at once so that a doctor may see it as soon as possible.
II. PROTECTION AGAINST RESPIRATORY HAZARDS
To protect respiratory Hazards the workers should he provided the safety equipment
including
a. Safety
b. Acid proof safety shoes
c. Acid prod over all clothes
d. Rubber gloves
e. Safety goggles
f. Gas masks
g. Fire extinguisher
TREATMENT OF RESPIRATORY HAZARDS
i. In the case of nitrogen oxides poisoning first acid should be given immediately.
ii. In such situation patient should he moved to open and un-contaminated atmosphere.
iii. No exertion should he allowed to the patient. Patient should breath pure
iv. Oxygen for 30 minutes to 1 hr for 6 hours.
v. If breathing is normal O2 inhaling should be discontinued.
Chapter: 09 Material of Construction
157
Chapter: 09
Material of Construction
INTRODUCTION
The corrosion problem affects many industries. In chemical industries it is one of the most
serious, and perhaps the most costly, of the problems confronting the chemical engineer, not
only because of the added cost to production due to replacement of apparatus, shutdowns for
repair, etc., but also because of possibility of contamination of the product through catalytic
action or other wise. Therefore losses due to Corrosion Can run into hundreds of millions of
rupees. Any development, therefore, that will have for its object the control or reduction of
this heavy loll must be welcomed by the chemist and the engineer.
The ammonia may be converted into nitric acid by an oxidation process was known as a
theoretical possibility for many years. The success of this process should not be considered
as due solely to the skill and ingenuity of the chemist. It is due as well to the availability of
suitable materials which satisfactorily resisting the corrosive action of the acid and capable of
fabrication into required forms, have made possible the construction of the necessary plants
and equipment. These materials are the iron chromium alloys. Therefore early nitric acid
plants were severely restricted in design by the available materials of construction until high
chromium content iron was developed in the 1920, commonly used construction materials
were acid brick, earthen ware and glass. As better materials of construction came along,
nitric acid process design could he improved. Higher operating pressures resulted in lower
plant capital cost.
CORROSION PRINCIPLES
In case of pure metals, what may be called the affinity of its atoms for the stranger atoms of
some other substance determines the readiness with which it will combine with this
substance, generally displacing some other element with which the stranger atoms have
previously been in combination. This is the basis of the process called “corrosion”. IF this
Chapter: 09 Material of Construction
158
affinity can be reduced by the atoms of some other metal, as is the case in solid solutions (a
solid solution is formed when two or more elements or compounds share a common lattice.
The composition may vary with in very wide limits), susceptibility to attack will be
considerably reduced. If this energy of affinity is still further reduced by the addition of a
third metal in the solid solution, there will result still greater resistance to attack. This is well
illustrated by numerous alloys. Iron is readily attacked by oxygen even at normal
temperatures. The addition of chromium in suitable proportions, which forms a solid
solution, produces practically complete resistance at ordinary temperatures and even at
moderately elevated temperatures. If a third metal, as nickel or silicon in proper is added,
which also enters solution with the iron and chromium resistance to oxidation is extended to
still higher temperatures, and the alloy becomes resistant to a number of materials which
neither the plain iron, nor even the iron chromium solid solution, will resist. The solid
solution class of alloys is inherently better, not only From the chemical resistance, but also
From a mechanical stand point, for such alloys almost always possess the best physical
properties as regards both strength and toughness of any alloy of the series.
Equipment for an ammonia oxidation plants includes.
I. Converters.
II. Absorption towers.
III. Heat exchangers.
IV. Valves.
V. Pipe lines, etc.
HIGH TEMPERATURE NH3 OXIDATION:
Alloys that will with stand high temperature and have good strengths at 1000- 1900oF are
available hut are usually very expensive. These alloys, for use in the ammonia burner, should
resist oxidation and nitriding and have good sealing resistance. Also, good thermal shock
properties are desirable, particularly for internals and un-cooled items that undergo high
stresses.
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159
The Fe-Ni-Cr alloys such as Inconel 601, Hastelloy X, Nichrorme, RA-333 etc, are suitable
alloys to consider for use in these high heat environment.
The major concern with equipment in the hot areas of the nitric acid is not strength, although
the alloys used must have some hot strength, but is whether the material can take the
environment without breaking down. In general ideally, the alloy should contain high nickel,
chrome and silicon. High nickel means over 35% Ni, high Cr means over 20% Cr, and high
Si means over 0.5% Si. Many wrought and even a few cast alloys ft into this analysis, and
any one of them can do the
NO & NO2 AT INTERMEDIATE TEMPERATURE:
As temperatures fall to 1000°F and below, and if the gases are dry, the standard austenitic
stainless steel arc used, providing they are not subjected to attack from cooling media that
contain high chloride levels. Alloys such as 304L, 321, 430, 329, 310 and Incoloy 800, may
be used in this area. Most of this equipment involves tubular components, although the dry
gases being cooled are not trouble some, the cooling media on the water side are often the
cause of failures. A careful look at the water side may be deciding factor in the choice of
materials.
Examples of trouble areas are in items of equipment. Such as tail-gas heaters, cooler
condensers and tail-gas pre-heaters. Type 304L and type 430 are the usual materials of
construction, but in some cases are being replaced by type 329, which has better corrosion
resistance. Some plants attributed their problems to acid condensate in the tail gas impinging
on the O.D. others felt the attack was on the tube I.D. as a result of the relatively cool tail gas
(from tail-gas heater) impinging on the tubes containing hot process gas and causing
localized cooling and re-boiling of weak acid.
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160
AQUEOUS NITRIC ACID CORROSION
The aqueous acid is strongly oxidizing and extremely corrosive to most materials such as
steel, copper alloys, rubber products, aluminum (low concentrations) and many more.
Materials for weak-acid condensers and absorption towers must be carefully selected since
these are the areas of most sever aqueous corrosion.
Choice of materials for wet acid service is the normal stainless alloys, special purpose
stainless alloys or high silicon irons (seldom used in modern construction except for pumps
and valves).
Type 304L cooling coils are used in absorption towers but the alloy is just barely adequate,
and alloys with better corrosion resistance are being looked at, particularly as higher
absorption pressures are being use. Most of’ the other standard grades of’ austenitic stainless
steels would have similar corrosion rates. Type 316 is not selected specifically for nitric acid
service because it has slightly less resistance than 304L and is more costly. Type 304L shows
poor corrosion resistance to hot, very strong acid, including fuming nitric acid (but has good
resistance to red and white fuming at room temperatures).
Chapter: 09 Material of Construction
161
Aluminum alloys are only good for very for very high acid concentrations (80-100%) at
ambient temperatures. Any dilution of the acid will cause accelerated attack.
High nickel alloys such as Inconel 600, Hstelloy B and C, Chlorimet 3 etc. do not perform as
well as regular type 304L, and so are not considered for use in aqueous acid conditions.
Gold, tantalum and platinum exhibit excellent resistance but are expensive.
Non metallic, and especially teflon and kynar, are used for nitric acid service when the acid is
weak and cold. Both teflon and kynar are good in the weak acids (to 20%) at high
temperatures, but at higher concentrations these plastics are only good at ambient
temperatures. Glass has excellent resistances to 400°F at all concentrations Viton linings are
the one rubber product that is popular. It is good to 100°F at all concentrations.
Chapter: 09 Material of Construction
162
Table 1 lists the concentrations and limiting temperatures for many materials that should or
should not be used in nitric acid service.
Chapter:10 Hazop Study & Envoirmental Impact Assessment Report
162
Chapter: 10
Hazop Study & Envoirmental Impact Assessment
Report
INTRODUCTION
A HAZOP survey is one of the most common and widely accepted methods of
systematic qualitative hazard analysis. It is used for both new or existing facilities and
can be applied to a whole plant, a production unit, or a piece of equipment It uses as its
database the usual sort of plant and process information and relies on the judgment of
engineering and safety experts in the areas with which they are most familiar. The end
result is, therefore reliable in terms of engineering and operational expectations, but it is
not quantitative and may not consider the consequences of complex sequences of human
errors. The objectives of a HAZOP study can be summarized as follows:
1) To identify (areas of the design that may possess a significant hazard
potential.
2) To identify and study features of the design that influence the probability of a
hazardous incident occurring.
3) To familiarize the study team with the design information available.
4) To ensure that a systematic study is made of the areas of significant hazard
potential.
5) To identify pertinent design information not currently available to the team.
6) To provide a mechanism for feedback to the client of the study team's detailed
comments.
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163
STEPS CONDUCTED IN HAZOP STUDY
1) Specify the purpose, objective, and scope of the study. The purpose may be
the analysis of a yet to be built plant or a review of the risk of unexisting unit.
Given the purpose and the circumstances of the study, the objectives listed
above can he made more specific. The scope of the study is the boundaries of
the physical unit, and also the range of events and variables considered. For
example, at one time HAZOP's were mainly focused on fire and explosion
endpoints, while now the scope usually includes toxic release, offensive odor,
and environmental end-points. The initial establishment of purpose,
objectives, and scope is very important and should be precisely set down so
that it will be clear, now and in the future, what was and was not included in
the study. These decisions need to be made by an appropriate level of
responsible management.
2) Select the HAZOP study team. The team leader should be skilled in HAZOP
and in interpersonal techniques to facilitate successful group interaction. As
many other experts should be included in the team to cover all aspects of
design, operation, process chemistry, and safety. The team leader should
instruct the team in the HAZOP procedure and should emphasize that the end
objective of a HAZOP survey is hazard identification; solutions to problems
are a separate effort.
3) Collect data. Theodore16 has listed the following materials that are usually
needed.
Process description.
Process flow sheets.
Data on the chemical, physical and toxicological properties of all raw
materials,, intermediates, and products.
Piping and instrument diagrams (P&IDs).
Equipment, piping, and instrument specifications.
Process control logic diagrams.
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164
Layout drawings.
Operating procedures.
Maintenance procedures.
Emergency response procedures.
Safety and training manuals.
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165
HAZOP Guide Words and Meanings
Guide Words Meaning
No
Less
More
Part of
As well as
Reverse
Other than
Negation of design intent
Quantitative decrease
Quantitative increase
Qualitative decrease
Qualitative Increase
Logical opposite of the intent
Complete substitution
4) Conduct the study. Using the information collected, the unit is divided into
study "nodes" and the sequence diagrammed in Figure , is followed for each
node. Nodes are points in the process where process parameters (pressure,
temperature change between nodes as a result of the operation of various
pieces of equipment' such as distillation columns, heat exchanges, or pumps.
Various forms and work sheets have been developed to help organize the node
process parameters and control logic information.
When the nodes are identified and the parameters are identified, each node is
studied by applying the specialized guide words to each parameter. These guide words
and their meanings are key elements of the HAZOP procedure. They are listed in Table.
Repeated cycling through this process, which considers how and why each
parameter might vary from the intended and the consequence, is the substance of the
HAZOP study.
5) Write the report. As much detail about events and their consequence as is
uncovered by the study should be recorded. Obviously, if the HAZOP
identifies a not improbable sequence of events that would result in a disaster,
appropriate follow-up action is needed. Thus, although risk reduction action is
not a part of the HAZOP, the HAZOP may trigger the need for such action.
Chapter:10 Hazop Study & Envoirmental Impact Assessment Report
166
The HAZOP studies are time consuming and expensive. Just getting the P & ID's
up to date on an older plant may be a major engineering effort. Still, for processes with
significant risk, they are cost effective when balanced against the potential loss of life,
property, business, and even the future of the enterprise that may result from a major
release.
HAZOP Study of Ammonia Air mixing tee:
Intention: Transfer vapor to mixing tee.
Guide Word Deviation Cause Consequences and Action
LESS Flow CV plug gage
FRC failure
As no flow
MORE Flow FR/ ratio control
Miss-operation
Danger of high ammonia
concentration: fit alarm, fit
analyzers (duplicate) with
high alarm 14 percent NH3
Chapter:10 Hazop Study & Envoirmental Impact Assessment Report
167
Environmental Impact Assessmeent (EIA) Report
NOx: What is it? Where does it come from?
Nitrogen oxides, or NOx, is the generic term for a group of highly reactive gases, all of
which contain nitrogen and oxygen in varying amounts. Many of the nitrogen oxides are
colorless and odorless. However, one common pollutant, nitrogen dioxide (NO2) along
with particles in the air can often be seen as a reddish-brown layer over many urban
areas.
Nitrogen oxides form when fuel is burned at high temperatures, as in a combustion
process. The primary manmade sources of NOx are motor vehicles, electric utilities, and
other industrial, commercial, and residential sources that burn fuels. NOx can also be
formed naturally.
Chapter:10 Hazop Study & Envoirmental Impact Assessment Report
168
Health and Environmental Impacts of NOx
NOx causes a wide variety of health and environmental impacts because of various
compounds and derivatives in the family of nitrogen oxides, including nitrogen dioxide,
nitric acid, nitrous oxide, nitrates, and nitric oxide.
Ground-level Ozone (Smog) –
is formed when NOx and volatile organic compounds (VOCs) react in the presence of
sunlight. Children, people with lung diseases such as asthma, and people who work or
exercise outside are susceptible to adverse effects such as damage to lung tissue and
reduction in lung function. Ozone can be transported by wind currents and cause health
impacts far from original sources. Millions of Americans live in areas that do not meet
the health standards for ozone. Other impacts from ozone include damaged vegetation
and reduced crop yields
Acid Rain
- NOx and sulfur dioxide react with other substances in the air to form acids which fall to
earth as rain, fog, snow or dry particles. Some may be carried by wind for hundreds of
miles. Acid rain damages; causes deterioration of cars, buildings and historical
monuments; and causes lakes and streams to become acidic and unsuitable for many fish.
Particles
- NOx reacts with ammonia, moisture, and other compounds to form nitric acid and
related particles. Human health concerns include effects on breathing and the respiratory
system, damage to lung tissue, and premature death. Small particles penetrate deeply into
sensitive parts of the lungs and can cause or worsen respiratory disease such as
emphysema and bronchitis, and aggravate existing heart disease.
Water Quality Deterioration
- Increased nitrogen loading in water bodies, particularly coastal estuaries, upsets the
chemical balance of nutrients used by aquatic plants and animals. Additional nitrogen
accelerates "eutrophication," which leads to oxygen depletion and reduces fish and
shellfish populations. NOx emissions in the air are one of the largest sources of nitrogen
pollution in the Chesapeake Bay.
Climate Change
- One member of the NOx, nitrous oxide or N2O, is a greenhouse gas. It accumulates in
the atmosphere with other greenhouse gasses causing a gradual rise in the earth's
Chapter:10 Hazop Study & Envoirmental Impact Assessment Report
169
temperature. This will lead to increased risks to human health, a rise in the sea level, and
other adverse changes to plant and animal habitat.
Toxic Chemicals
- In the air, NOx reacts readily with common organic chemicals and even ozone, to form
a wide variety of toxic products, some of which may cause biological mutations.
Examples of these chemicals include the nitrate radical, nitroarenes, and nitrosamines.
Visibility Impairment
- Nitrate particles and nitrogen dioxide can block the transmission of light, reducing
visibility in urban areas and on a regional scale in our national parks.
National Environmental Quality Standards For
Industrial Gaseous Emissions(mg/Nm3,Unless
Otherwise Defined)
Parameter Source of emission Standards Revised
Standards
Oxides of Nitrogen 1) Nitric Acid manufacturing unit 400 3000
(NOx) 2) Gas fired 400 400
3) Oil fired _ 600
4) Coal fired _ 1200
Chapter: 11 Cost Estimation
170
CHAPTER: 11
COST ESTIMATION AND ECONOMICS OF PLANT
LOCATION
PLANT COST ESTIMATION
As the final process-design stage is Complete, it becomes possible to make accurate cost
estimation because detailed equipment specification and definite plant facility
information are available. Direct price quotation based on detailed specification can then
be obtained from various manufacturers. However o design project should proceed to the
final stages before costs are considered and cost estimate should be made through out all
the early stages of the design when complete specifications are not available. Evaluation
of costs in the preliminary design is said predesign cost estimation. Such estimation
should be capable of providing a basis for company management to decide if further
capital should be invested in the project.
Evaluation of costs in the preliminary design phase is some time called guess estimations.
A plant design obviously must present a process that is capable of operating under
condition which will yield a profit.
A capital investments is required to any industrial process, and determination of the
necessary investment is an important part of a plant design project. The total investment
for any process consists of the physical . equipment and facilities in the plant plus the
working capital for money which must be available to pay salaries keep raw materials
and products on hand and handle other special items requiring a direct cast out lay.
CAPITAL INVESTMENTS
Before an industrial plant can be put into operation, large amount of -money must be
supplied to purchase and install the necessary machinery and equipment, land and service
Chapter: 11 Cost Estimation
171
facilities must be obtained and the plant-must be erected. Complete with all pipe controls
inn services. In addition it is necessary to have money available for payment of expenses
involved in the plant operation.
The capital needed to supply the necessary manufacturing and plant facilities is called the
fixed capital investment while the necessary for the operation of the plant is termed as the
working capital investment.
1. Working Capital Investment
The capital which is necessary lor the operation of the plant is called working capital
investment.
2. Fixed Capital Investment
The capital needed to supply flu- necessary maMiif'acttirini1 and plant facilities is called
fixed capital investment.
The fixed capital investment classified in to two sub divisions,
i. Direct Cost
ii. Indirect Cost
DIRECT COST
The direct cost items arc incurred in the construction of the plant in addition to the cost of
equipment.
1. Purchased Equipment
2. Purchased Equipment Installation
3. Instrumentation and Control
4. Piping
5. Electrical Equipment and Materials
6. Building (Including Services)
7. Yard Improvement
8. Services Facilities
Chapter: 11 Cost Estimation
172
9. Land
INDIRECT COST
1. Design and Engineering
2. Contractor's Expenses
3. Contractor's Fee
4. Contingency
METHODS OF CAPITAL INVESTMENT
Various methods are employed for estimating capital investment. The choice of any
method depends on the foil owing-factors,
a. Amount of detailed information available
b. Accuracy Desired
Seven methods of estimating capital investments are outlined, estimate
1. Detailed item estimate
2. Unit estimate
3. Percentage of delivered equipment cost
4. “Lang” factor approximation of capacity ratio
5. Investment cost per capacity
The accuracy of an estimate depends on the amount of design detail available; and the
accuracy of the cost data available; and the time spent on preparing the estimate. In the
early stages of a project only an approximate estimate will be required an justified by the
amount of information by then developed.
Chapter: 11 Cost Estimation
173
PERCENTAGE DELIVERED EQUIPMENT
This method for estimating total investment requires the determination
of the delivered equipment cost. The cost of purchased equipment is the basis of several
pre design methods for estimating capital investment.The most accurate methods for
determining process equipment costs is to obtain firm bids from fabricators or suppliers.
Percentage of delivered equipment cost is the method used for estimating the fixed or
total capital investment requires determination of the delivered equipment cost. The other
items included in the total direct plant cost are then estimated as percentage of the
delivered equipment The addition components of the capital investment are based on
average percentage of total direct plant cost total direct and indirect plant costs or total
capital investment.
Estimating by percentage of delivered equipment cost is commonly used for preliminary
and study estimates. It yield most accurate results when applied to a project similar in
configuration to recently constructed plants.
Chapter: 11 Cost Estimation
174
DIRECT COST
PURCHASED Equipment Cost =E
COMPONENTS % AGES OF E COST ($)
Purchased equipment installation 47% E a
Instrumentation (installed) 12%E b
Piping (installed) 66% E c
Electrical (installed) 11 % E d
Building (including Service) 18% E e
Yard improvement 10% E f
Service facilities 70%. E g
Land 6% E h
Total direct cost D
Total direct cost = D
INDIRECT COST
Engineering and supervision 33%E
Construction Expenses 41%E
Total indirect Cost I
Total direct and indirect cost D+I
Contractor's fee 5%(D+I)=y
Contigency 10%(D+I)= x
Chapter: 11 Cost Estimation
175
E/fixed Capital investment D+I+x+y
Working Capital investment W.C.I
W.C.I 15% total capital
COST ESTIMATION OF OUR PLANT
EQUIPMENT PURCHASE COST:
1. ABSORPTION COLUMN
Cost of trays:
*Cost of 1 tray = 360 $
Material factor = 1.1 (for cast iron)
Corrected cost/tray = 360 X 1.1 = 399.6$
Cost of 10 trays = 10 X 399.6 = 3996$
Cost of column:
For D = 1m
*Cost = 18000$
Material factor = 1.5 (for SS)
Pressure = 1.1
Purchased cost for column = 1.1 x 1.5 x 18000= 29700$
Total column cost = 29700 + 3996 = 33696$
2. SUPERAZEOTROPIC COLUMN:
Cost of trays:
Cost of one tray = 360$
Chapter: 11 Cost Estimation
176
Material factor = 1.11 (For SS)
Corrected cost per tray = 360x1.11 = 399.6
Cost of 10 trays = 10x399.6= 3996$
Cost of column:
For D = 1m
Cost = 18000$
Material correction factor = 1.5 (for SS)
Pressure factor = 1.1
Purchased cost for column = 1.1x1.5x18000= 29700$
Total column cost = 29700+3996 = 33696$
3. DISTILLATION COLUMN:
Cost of trays:
Cost of one tray = 400$
Material factor = 1.065 (for Carbon Steel)
Corrected cost per tray = 400x1.065x426 =
Cost of 15 trays = 15x426x426 = 6390$
Cost of column:
For D = 1m
Cost = 18000$
Material correction factor = 1.5 (for SS)
Chapter: 11 Cost Estimation
177
Pressure factor = 1.1
Purchased cost for column = 1.1x1.5x18000= 29700$
Total column cost = 29700+3690 = 36090$
4. STRIPPER
Cost of trays:
Cost of one tray = 360$
Material factor = 1.0
Corrected cost per tray = 360x1.0 = 360$
Cost of 18trays = 18x360 = 6480$
Cost of column:
For D = 1.25m
Cost = 20000$
Material correction factor = 1.5
Pressure factor = 1.1
Purchased cost for column = 1.1x1.5x20000= 33000$
Total column cost = 6480+33000 = 39480$
5. Reactor
Cost of catalyst:
Cost of 90% Pt, 10% Rh = 11257 x 0.9 + 29907 x 0.1 = 13122 $ / kg
Chapter: 11 Cost Estimation
178
Weight of catalyst = 11.8 kg
Cost = 13122 x 11.8 = 154839.6$
Reactor Head Cost:
Cost in 1977 = 7777.77$
Cost in 2005 = 89720.96$
Total Cost = 154839.6+89720.96 = 244560.56$
6. BOILER COST
Cost in 1977 = 34839.68$
Cost in 2006 = 374958.54$
7. NH3 EVAPORATOR COST:
Cost in 1977 = 22222.22 $
Cost in 2006 = 238805.96$
8. TAIL GAS TURBINE
Cost in 1977 = 236185.73$
Cost in 2006 = 2542951.9$
9. COMPRESSOR
Cost in 1977 = 409618.57$
Cost in 2006 = 4409618.56$
Chapter: 11 Cost Estimation
179
10. COOLER CONDENSOR
Heat transfer area = 30.23 m2
Pressure factor = 1.0
Type factor = 0.8
Material of construction:
Shell and tubes = stainless steel
Base cost = 30000$
Actual cost = 30000x 0.8 x 1.0 = 24000$
Its the cost in 1992
Cost is 2006 = 27443.28$
Total Equipment Cost =7981300.8$
DIRECT COST
Purchased equipment cost = 7981300.8$
Purchased equipment installation = 0.47 7981300.8 = 3751211.3$
Instrumentation & Process Control = 0.12 7981300.8 = 957756.0$
Piping (installed) = 0.66 7981300.8 =5267658.5$
Building (Including Services) = 0.18 7981300.8 = 1436634.1$
Yard improvements = 0.1 7981300.8 = 798130.0$
Service facilities (installed) = 0.7 7981300.8 = 5586910.5$
Land = 0.06 x 7981300.8 = 478878.0$
Total direct plant cost =26258479.24$
Chapter: 11 Cost Estimation
180
INDIRECT COST
Engg & Supervision = 0.33 7981300.8 = 2633829.2$
Construction expenses = 0.41 7981300.8 = 3272333.3$
Total Indirect Cost = 5906162.5$
Total Direct & Indirect Cost = 32164641.77$
Contractor’s fee = 0.05 32164641.77 = 1608232.08$
Contingency = 0.1 32164641.77 = 3216464.17$
FIXED CAPITAL INVESTMENT
Fixed Capital Investment = Total direct + indirect cost + contingency + Contractor’s fee
= 36989338.02$
Total capital investment = F.C.I + W.C
Now
W.C = 0.15 (T.C.I)
= 0.15(36989338.02 + W.C)
=(5548400.703/0.85)
= 65275530.239 $
Total capital investment = 43516868.26$
Chapter: 11 Cost Estimation
181
PRODUCT COST.
Depreciation Value.
d=(V – Vs)/n
Where
V=36989338.02$
Vs=5%V
n=10 years
d= 3513987.112$
Raw Material Cost.
For 1 M.T NH3 price=2366.7 Rs (Pak Saudi Fertilizer limited)
For 1 hr operation NH3 required = 92.59 Kgmole
For one day operation NH3 required
(92.59Kgmol NH3/hr)*(17 Kg NH3/1 Kgmole NH3)*(1 M.T/1000Kg)*(24hr/1 day)
=37.77 M.T/day
For one year NH3 required
=(37.77 M.T NH3/day)*(330 day/1 year)
=12466.317 M.T NH3/year
Price of NH3 for one year=12466.317*2366.7
=29504033.86 Rs
=491733.89$
W.C.I.
W.C=65275530.239 $
Total Amount=W.C+Raw material cost+Depreciation Value
Total Amount=69281251.23$
Chapter: 11 Cost Estimation
182
Cost of product= Total Amount/M.T of HNO3 produced in one year
=69281251.23$/140*330
= 500.6$/M,T
=0.523$/Kg
=31.38 Rs/Kg
Appendices
183
APPENDECES
Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
competitors.
Develop and implement private property rights, including allowances for land ownership
and expanded foreign ownership. Hasten to enable owners of farms to prevent damage
from livestock grazing or from other types of unlimited access to the farm land.
Establish copyright protection laws sufficient to ensure that designs and product
constructions cannot be copied by other businesses unless adequate royalties are paid to
owners.
Undertake campaigns to educate key institutions-such as courts, banks, customs
service, etc.-about the current status and modus operandi of public sector enterprises.
Establish the basic market data and information needed by businesses in Ethiopia, then
develop an appropriate information gathering and disseminating system.
Persuasive movement by the government on these strategic recommendations would provide
the foundation for more directed actions fostering improved conduct and performance of the
cotton textile sector. Ten tactical recommendations are emphasized in this regard:
Concentrate on learning to respond to and exploit the domestic market before assuming
an export emphasis.
Make financial documentation more accurate and transparent so managers can make
decisions to enhance profitability; restore integrity to the accounting and financial
conventions that have been adopted as a matter of government policy. Hasten to alter the
accounting for spare parts to reveal the true cost of spare parts inventories.
Call in or write off accounts receivable and explore the feasibility of writing off some
accounts payable. A sector-wide clearing-house empowered by the government could
assist in these actions.
In preparation for making each enterprise responsible for its survival, undertake a
systematic examination of each enterprise's debt situation, determine how much of its
debt will be forgiven and taken over by the government, and remove the liability from
the financial statements.
For each public enterprise determined to be viable, assist in the identification and
funding of education and training programs in technical, marketing, and management
areas. As early as possible, extend the availability of these programs to private sector
personnel; the treatment of public versus private enterprises in cotton, textile, and
apparel should disappear over the next few years.
Make it clear to both management and labor that their success depends on their
contribution toward the economic success of the enterprises, rather than on the exercise
of bureaucratic power. Take steps to de-emphasize the management-by-committee
approach and to emphasize individual initiative. Base promotions from within the
enterprises on performance and demonstrated potential; prohibit bureaucratic
interference with the promotion process and with the setting of salary levels.
Strive to maximize cooperation with existing or potential private sector enterprises. To
the extent that small private enterprises result from the down-sizing or dissolution of
some public sector enterprises, they should be encouraged to do business with each
other and with larger enterprises in the public and private sectors.
For each public enterprise determined to be viable, implement recommendations for
improving the technical conditions identified in this report. In every case, establish a
cleaning and maintenance program that is routinely monitored by management.
For each public enterprise determined to be viable, obtain assistance to help it undertake
a Strengths-Weaknesses-OpporNnities-Threat (SWOT) analysis of the
enterprise. This
will take weeks to accomplish under expert guidance. It should yield a conclusion on
which market segment(s) should be targeted and a mission statement on how each
segment will be served.
Following the execution of the SWOT analysis, each enterprise should establish a
marketing strategy and make a plan of action for executing it that includes a detailed
budget.
SECTION I
IWKWIIONAL FIUMEWORK AND STRUCTURE
SECTION I
INSTITUTIONAL FRAMEWORK AND STRUCTURE
This section describes key features of Ethiopia's cotton textile sector. The industry as
defined includes the following activities: cotton production, spinning, fabric formation (weaving
and knitting), dyeing and finishing, and cutting and sewing (ready-made garments and other
textile products).
In the past, Ethiopia has had an unregulated peasant sector that produced relatively small
amounts of cotton that were used in hand-looms to weave traditional, low quality textiles. This
tradition persists today, with unofficial estimates of hand-loom production as high as 20 percent
of Ethiopia's total fabric production. However, data on this segment of the cotton textile sector is
practically non-existent. The importance of hand weaving has almost certainly declined in recent
years, due to the vastly increased availability of donated, second-hand clothing and the increased
availability of imported textile products. Anecdotal evidence indicates that increasing amounts of
peasant-grown cotton are entering commercial textile channels. A number of privately held
commercial cotton farms supply commercial textile channels. However, public sector enterprises
that produce cotton provide approximately half of the domestically produced cotton to
commercial
textile channels in Ethiopia.
A chronological summary of the establishment of enterprises in Ethiopia's public cotton
textile sector is given in Exhibit 1-1. The oldest commercial textile manufacturing enterprise is
the Dire Dawa Textile Factory, established in 1939. All other textile manufacturing enterprises
were established during the 1950s, 1960s, 1980s and 1990s. Three of the agriculture enterprises
were established in the 1960s and one (Tendaho) was established in 1985. None of the
enterprises
were established during the 1940s or 1970s.
Before 1974, foreign interests were involved in the largely privately owned commercial
textile sector. After nationalization in 1974, the sector was transformed into a centralized
political
bureaucracy with no semblance of autonomy. In 1992, the Transitional Government of Ethiopia
(TGE) changed its legal status with Public Enterprise Proclamation No. 2511992, which charged
the government with the responsibility to operate in a manner consistent with open-market
competition, until the enterprises were privatized. The commercial textile sector today remains
almost entirely in the public sector; none of the pre-existing public sector enterprises have been
privatized. Although some small, privately held garment manufacturing enterprises are in
operation, there are no privately held spinning and weaving enterprises of any consequence.
The following discussion analyzes the public cotton textile sector, its role in the domestic
economy, and its structural organization. The section concludes by focusing on the importance of
structural change to achieve the performance desired from the public cotton-textile sector.
Ethio~ia Textile Sector Re~ort Chemonics International lnc.
Exhibit 1-1. Chronology of Establishment of Existing Public Sector Textile
Manufacturing
Enterprises in Ethiopia
1939: Dire Dawa Textile Factory
1953: Edget Yarn Factory
1956: Akaki Textile Factory
1958: Addis Garment Factory
1961 : Adei Abeba Textile Factory
1961: Bahir Dar Textile Factory
196 1 : Abobo Agriculture Dev. Enterprise
1961 : North Orno Agriculture Dev.
Enterprise
1963: Debre Birhan Blanket Factory
1963: Akaki Garment Factory
1966: Nefas Silk Sewing Thread Factory
1967: Middle Awash Agric. Dev.
Enterprise
1983: Gulelie Garment Factory
1985: Tendaho Agriculture Dev. Enterprise
1986: Kombolcha Textile Factory
1989: Awasa Textile Factory
1991: Arba Minch Textile Factory
1992: Nazareth Garment Factory
I
- largest employer of all the industrial groupings reported (Exhibit 1-4). Taken with apparel
manufacturing, the sectors' employment accounted for about 40 percent of total
manufacturing
employment in Ethiopia. Food and beverage manufacturing accounted for another 28
percent,
-, leaving 32 percent for all other manufacturing categories combined. Total manufacturing
employment was 82,379 people, with 94.4 percent in the public sector. In textile
manufacturing,
Exhibit 1-2: Measures of Sectoral Contributions to Manufacturing in Ethiopia,
by Ownership, 1990 (in 1,000 Birr)
Tobacco
Chemical
Metal and electrical
Non-metallic mineral products
Printing
Wood and furniture
Pa~er
Gross Value of Production
TOTAL 272.175 257.223 94.5% 14.952 5.5%
Sector Total Public I Private
Amount I Share I Amount 1 Share
Food 14 1,980 138,5 1 1 97.6% 3,469 2.4%
Beverage 69,587 69.261 99.5% 326 0.5%
Leather and footwear 31,011 27,811 89.7% 3,200 10.3%
Tobacco 3,896 3,896 100.0% -- 0.0%
Chemical 24,733 23,130 93.5% 1,603 6.5%
Metal and electrical 174,3 12 172,41 1 98.9% 1,901 1.1%
Non-metallic mineral products 1 19,2 16 1 18,369 99.3% 847 0.7%
Printing 9,118 7.241 79.4% 1,877 20.6%
Wood and hrniture 8,856 6,461 73.0% 2,395 27.0%
Paper 5.364 5.037 93.9% 327 6.1%
TOTAL 839,122 822,558 98.0% 16,564 2.0%
Fixed Capital Assets
Source: Ethiopia Statistical Abstract. 1992
TText1 e
Food 657,836 630,195 95.8% 27.641 4.2%
Beverage 434,279 425,549 98.0% 8,730 2.0%
Leather and footwear 242,370 226,82 1 93.6% 15,549 6.4%
Tobacco 182,037 182,037 100.0% -- 0.0%
Chemical 149,108 143.148 96.0% 5,960 4.0% ,