Process Selection 0

Technological Institute of the Philippines
PROCESS
SELECTION
PROCESS SELECTION
Process Selection plays an important part in overall design of production
and operations management systems. Process Selection allows an organization
to offer a safe and reliable product and service through pragmatic design and
effective capacity planning. With the help of process selection, we can
understand the different types of processing including manual, rigid, and flexible
as well as various automated approaches to processing. Process selection allows
an operations manager to better understand the need for management of
technology. Together with capacity planning it helps an organization to develop
different approaches to meet the irregular demand pattern of the customers.
(PROCESS SELECTION: Types of Operation, Intermittent Processing)
In this section of the paper, we will look into three processes where we
can produce magnesium sulfate heptahydrate. There are five factors which we
will consider; Sustainability, Economics, Manufacturability, Safety and
Environmental Impact.
2
EVALUATION OF THE THREE PROCESSES FOR THE
PRODUCTION OF MAGNESIUM SULFATE HEPTAHYDRATE
PROCESS 1
Production of Magnesium Sulfate Heptahydrate from Dolomite with
Stirring Crystallization
Dolomite is a mineral usually composed of calcium magnesium carbonate
(CaMg(CO3)2). It is a type of limestone which has a saddle-shape crystal and is
most likely to exists in sedimentary and metamorphic rocks. The harvested
dolomite mineral is processed in a jaw crusher to reduce the mineral’s size and
then to a roll crusher to refine its size to approximately 1 mm.
The fine material is then passed through a stream of water where the
heavier particle (calcium oxide and magnesium oxide containing particles)
remains at the platform and the lighter particles (gangue) are washed away. The
heavier particles are then dried at 200ºC and is then fed to a tank with water-
diluted sulfuric acid.
CaMg(CO3)4 + 2 H2SO4 → CaSO4 + MgSO4 + 2 CO2 + 2 H2O
Leaching base on dolomite reaction with sulfuric acid
MgO + H2SO4 → MgSO4 + H2O
CaO + H2SO4 → CaSO4 + H2O
Calcium Oxide and Magnesium Oxide reaction
3
The solution is then separated from the solid particles through a solid-liquid
separator. The separated liquid is further filtrated to ensure that no solid particle
remains at the solution. The solution is then evaporated at 100ºC to 110ºC to
diminish the amount of water within the solution, giving a concentrated solution.
The concentrated solution is then fed to an agitating tank to reduce the
temperature before undergoing a crystallization process. The crystallization
process is down with stirring at 124 rpm and temperature at 15ºC to 48ºC. The
stirring method yields a more stable product content at 98%. The slurry is then
filtered to separate the crystals from the mother liquor. Finally, the crystals are
dried to remove the excess moisture.
4
Figure 6.1 Production of Magnesium Sulfate Heptahydrate from Dolomite via Stirring Crystallization
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I. SUSTAINABILITY
Raw Materials
A. Dolomite Mineral
A common rock forming mineral made of calcium
magnesium carbonate (CaMg(CO3)2). It is a primary component
of the sedimentary rock, dolostone, and the metamorphic rock,
dolomitic marble. It has a pearly luster and a transparent to
translucent diaphaneity. Dolomite is very similar to the mineral
calcite although dolomite is slightly harder.
SUPPLIER:
Philippine Mining Service Corporation (PMSC)
Address: 5th Floor, Mercedes-Benz Tower, Mindanao Avenue,
Cebu Business Park, Cebu City 6000, Philippines
Contact Number: +63 32 415 8740
Website:https://www.jfemineral.co.jp/e_mineral/business/mineral/
dolomite.html
B. Sulfuric Acid
A colorless, slightly viscous liquid that is usually diluted
with water. Sulfuric acid is a strong acid which is characterized
by its hygroscopic and oxidizing properties, it is chemically and
thermally stable. Dilute sulfuric acid is a strong dibasic acid which
dissolves all base metals.
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SUPPLIER:
TNC Chemicals Philippines, Inc.
Address: Km. 56 Bo. Turbina, Calamba, Laguna, Philippines
Website: https://www.tncchem.com
II. ECONOMICS
Cost of Raw Materials
Table 6.1 Price of Raw Materials in Stirring Crystallization
Technique
Raw Materials Price (₱ per ton)

Dolomite 2,920.43
Sulfuric Acid 20,341.71
Source of price: (www.alibaba.com)
Cost of Equipment
The estimated fixed capital cost required for the production of
Magnesium Sulfate Heptahydrate via Stirring Crystallization
Technique is computed using Lang method, factor for fluids
processing taken from Perry’s Chemical Engineering Handbook 8th
Ed.
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Table 6.2 Lang Factors
Lang Factors
Type of Plant Fixed Capital Total Capital
Investment Investment
Solid Processing 4.0 4.7
Solid Fluid Processing 4.3 5.0
Fluid Processing 5.0 6.0
Adopted from D.W. Green, R.H. Perry, Perry’s Chemical Engineers
Handbook, 8th Ed.
Table 6.3 Factors for Estimation of Project Fixed Capital Cost
Process Type
Item Fluid Solid – Fluid Solid
1. Major Equipment (PCE)
f1 Equipment Erection 0.4 0.45 0.50
f2 Piping 0.70 0.45 0.20
f3 Instrumentation 0.20 0.15 0.10
f4 Electrical 0.10 0.10 0.10
f5 Buildings, process 0.15 0.10 0.05
* f6 Utilities 0.50 0.45 0.25
* f7 Storages 0.15 0.20 0.25
* f8 Site Development 0.05 0.05 0.05
* f9 Ancillary Building 0.15 0.20 0.30
2. Total Physical Plant Cost (PPC)
PPC = PCE (1 + f1 + … + f9) = PCE x 3.40 3.15 2.80
f10 Design and Engineering 0.30 0.25 0.20

f11 Contractor’s Fee 0.05 0.05 0.05
f12 Contingency 0.10 0.10 0.10
Fixed Capital = PPC (1 + f10 + f11 + f12) 1.45 1.40 1.35
Adapted from Coulson and Richardson, Chemical Engineering Design, Volume 6
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Formula for the computation of Fixed Capital Cost was taken from
Chemical Engineering Design Vol. 6 by Coulson and Richardson
𝐶𝑓 = 𝑓𝐿 𝐶𝑒
Where: Cf = fixed capital cost

Ce= total delivered cost of all major equipment items
fL= the “Lang factor”, which depends on the type of process
Table 6.4 Detailed Estimation of Fixed Capital Cost of Equipment for

Process 1
Purchasing Total
Delivery
Equipment Quantity Equipment Equipment
Cost (₱)
Cost (₱) Cost (₱)
Jaw Crusher 1 965,010.00 48,250.50 1,013,260.50
Filter Unit 4 1,269,750.00 63,487.50 5,332,950.00
Roll Crusher 1 812,640.00 40,632.00 853,272.00
Hydraulic Washing 2 203,160.00 10,158.00 426,636.00
Reactor 3 7,497,857.59 374,892.88 23,618,251.41
Agitating Tank 2 1,117,380.00 55,869.00 3,519,747.00
Settling Tank 1 1,523,760.90 76,188.05 1,599,948.95
Storage Tank 4 1,015,800.00 50,790.00 1,066,590.00
Heat Exchanger 6 1,168,170.00 58,408.50 6,132,892.50
Separator 1 1,523,700.00 76,185.00 1,599,885.00
Evaporator 1 6,796,236.27 339,811.81 7,136,048.08
Crystallizer 2 3,555,300 177,765.00 3,733,065.00
Dryer 2 5,195,817.00 259,790.00 5,455,607.00
Water Curtain 1 162,528.00 8,126.40 170,654.40
*Delivery Costs at 5% of Purchasing Equipment Cost
Total Equipment Cost (PCE) = ₱ 74,100,579.34
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Total Physical Plant Cost (PPC):
𝑇𝑜𝑡𝑎𝑙 𝑃ℎ𝑦𝑠𝑖𝑐𝑎𝑙 𝑃𝑙𝑎𝑛𝑡 𝐶𝑜𝑠𝑡 = 𝑃𝐶𝐸 ( 1 + 𝑓1 + 𝑓2 + 𝑓3 + 𝑓4 + 𝑓5 )
𝑃𝐶𝐶 = ₱ 74,100,579.34( 1 + 0.45 + 0.45 + 0.15 + 0.10 + 0.10 )
𝑷𝑷𝑪 = ₱ 𝟏𝟔𝟔, 𝟕𝟐𝟔, 𝟑𝟎𝟑. 𝟓𝟐
Fixed Capital Cost (FCC):
𝐹𝑖𝑥𝑒𝑑 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐶𝑜𝑠𝑡 = 𝑃𝑃𝐶 ( 1 + 𝑓10 + 𝑓11 + 𝑓12 )
𝐹𝐶𝐶 = ₱ 166,726,303.52 ( 1 + 0.25 + 0.05 + 0.10 )
𝑭𝑪𝑪 = ₱ 𝟐𝟒𝟏, 𝟕𝟓𝟑, 𝟏𝟒𝟎. 𝟏𝟎
Working Capital Cost (WCC):
𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐶𝑜𝑠𝑡 = 𝐹𝐶𝐶 (0.05)
𝑊𝐶𝐶 = ₱ 241,753,140.10 (0.05)
𝑾𝑪𝑪 = ₱ 𝟏𝟐, 𝟎𝟖𝟕, 𝟔𝟓𝟕. 𝟎𝟎
Total Capital Investment (TCI):
𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 = 𝐹𝐶𝐶 + 𝑊𝐶𝐶
𝑇𝐶𝐼 = ₱ 241,753,140.10 + ₱ 12,087,657.00
𝑻𝑪𝑰 = ₱ 𝟐𝟓𝟑, 𝟖𝟒𝟎, 𝟕𝟗𝟕. 𝟏𝟎
Fixed Costs:
Maintenance Cost
𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝐶𝑜𝑠𝑡 = (0.10)(FCC)
𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝐶𝑜𝑠𝑡 = (0.10)( ₱ 241,753,140.10)
𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝐶𝑜𝑠𝑡 = ₱ 𝟐𝟒, 𝟏𝟕𝟓, 𝟑𝟏𝟒. 𝟎𝟏
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Operating Labor Cost (OLC):
For a plant capacity of 15,000 tons of product per year (15,000,000
kg per year), and having average conditions, the estimated operating
labor requirement is 38 employee-hours/day/processing steps.
Considering a 360 days’ annual operation and 3 processing steps:
Figure 6.2 Operating labor requirements for chemical process industries

(Peters & Timmerhaus, 1991)
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Table 6.5 Current Daily Minimum Wage Rates (Wage Order No.
RBIII-21, National Wages and Productivity Commission,
SECTOR
Agriculture Retail & Service
Establishments
INDICATOR Non-
Non- Employing Not
Agriculture Plantation
Plantation More Than 10
Workers
Region III ₱ 380.00 ₱ 350.00 ₱ 334.00 ₱ 355.00
Department of Labor and Employment, August 2018)
Calculating for the operating labor costs using the data for manpower:
Operating labor cost
38 𝑒𝑚𝑝𝑙𝑜𝑦𝑒𝑒 − ℎ𝑜𝑢𝑟𝑠 360 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑑𝑎𝑦𝑠 𝑃ℎ𝑝 380

=( )( )( )
𝑑𝑎𝑦 − 𝑝𝑟𝑜𝑐𝑒𝑠𝑠𝑖𝑛𝑔 𝑠𝑡𝑒𝑝 𝑦𝑒𝑎𝑟 𝑒𝑚𝑝𝑙𝑜𝑦𝑒𝑒 − 8 ℎ𝑜𝑢𝑟𝑠
(3 𝑝𝑟𝑜𝑐𝑒𝑠𝑠𝑖𝑛𝑔 𝑠𝑡𝑒𝑝𝑠)(1 𝑦𝑒𝑎𝑟 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛)
𝐎𝐩𝐞𝐫𝐚𝐭𝐢𝐧𝐠 𝐥𝐚𝐛𝐨𝐫 𝐜𝐨𝐬𝐭 = ₱ 𝟏𝟓, 𝟓𝟗𝟓, 𝟐𝟎𝟎. 𝟎𝟎
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Figure 6.3 Various components of the production cost
Laboratory Cost:
𝐿𝑎𝑏𝑜𝑟𝑎𝑡𝑜𝑟𝑦 𝐶𝑜𝑠𝑡 = (0.23)(OLC)
𝐿𝑎𝑏𝑜𝑟𝑎𝑡𝑜𝑟𝑦 𝐶𝑜𝑠𝑡 = (0.23)(₱ 15,595,200.00 )
𝑳𝒂𝒃𝒐𝒓𝒂𝒕𝒐𝒓𝒚 𝑪𝒐𝒔𝒕 = ₱𝟑, 𝟓𝟖𝟔, 𝟖𝟗𝟔. 𝟎𝟎
Supervision Cost:
𝑆𝑢𝑝𝑒𝑟𝑣𝑖𝑠𝑖𝑜𝑛 𝐶𝑜𝑠𝑡 = (0.20)(OLC)
𝑆𝑢𝑝𝑒𝑟𝑣𝑖𝑠𝑖𝑜𝑛 𝐶𝑜𝑠𝑡 = (0.20)(₱ 15,595,200.00 )
𝑺𝒖𝒑𝒆𝒓𝒗𝒊𝒔𝒊𝒐𝒏 𝑪𝒐𝒔𝒕 = ₱ 𝟑, 𝟏𝟏𝟗, 𝟎𝟒𝟎. 𝟎𝟎
Plant Overheads:
𝑃𝑙𝑎𝑛𝑡 𝑂𝑣𝑒𝑟ℎ𝑒𝑎𝑑𝑠 = (0.50)(OLC)
𝑃𝑙𝑎𝑛𝑡 𝑂𝑣𝑒𝑟ℎ𝑒𝑎𝑑𝑠 = (0.50)(₱ 15,595,200.00 )
𝑷𝒍𝒂𝒏𝒕 𝑶𝒗𝒆𝒓𝒉𝒆𝒂𝒅𝒔 = ₱ 𝟕, 𝟕𝟗𝟕, 𝟔𝟎𝟎. 𝟎𝟎
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Capital Charges:
𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐶ℎ𝑎𝑟𝑔𝑒𝑠 = (0.10)(FCC)
𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐶ℎ𝑎𝑟𝑔𝑒𝑠 = (0.10)( ₱ 241,753,140.10)
𝑪𝒂𝒑𝒊𝒕𝒂𝒍 𝑪𝒉𝒂𝒓𝒈𝒆𝒔 = ₱ 𝟐𝟒, 𝟏𝟕𝟓, 𝟑𝟏𝟒. 𝟎𝟏
Local Taxes:
𝐿𝑜𝑐𝑎𝑙 𝑇𝑎𝑥𝑒𝑠 = (0.20)(𝐹𝐶𝐶)
𝐿𝑜𝑐𝑎𝑙 𝑇𝑎𝑥𝑒𝑠 = (0.20)(₱ 241,753,140.10)
𝑳𝒐𝒄𝒂𝒍 𝑻𝒂𝒙𝒆𝒔 = ₱ 𝟒𝟖, 𝟑𝟓𝟎, 𝟔𝟐𝟖. 𝟎𝟐
Insurance:
𝐼𝑛𝑠𝑢𝑟𝑎𝑛𝑐𝑒 = (0.01)(FCC)
𝐼𝑛𝑠𝑢𝑟𝑎𝑛𝑐𝑒 = (0.01)(₱ 241,753,140.10)
𝑰𝒏𝒔𝒖𝒓𝒂𝒏𝒄𝒆 = ₱ 𝟐, 𝟒𝟏𝟕, 𝟓𝟑𝟏. 𝟒𝟎
License Fee/Royalty Fees:
𝐿𝑖𝑐𝑒𝑛𝑐𝑒 𝐹𝑒𝑒/𝑅𝑜𝑦𝑎𝑙𝑡𝑦 𝐹𝑒𝑒𝑠 = (0.01)(FCC)
𝐿𝑖𝑐𝑒𝑛𝑐𝑒 𝐹𝑒𝑒/𝑅𝑜𝑦𝑎𝑙𝑡𝑦 𝐹𝑒𝑒𝑠 = (0.01)(₱ 241,753,140.10)
𝑳𝒊𝒄𝒆𝒏𝒄𝒆 𝑭𝒆𝒆/𝑹𝒐𝒚𝒂𝒍𝒕𝒚 𝑭𝒆𝒆𝒔 = ₱ 𝟐, 𝟒𝟏𝟕, 𝟓𝟑𝟏. 𝟒𝟎
𝑭𝒊𝒙𝒆𝒅 𝑪𝒐𝒔𝒕𝒔 = 𝑴𝑪 + 𝑶𝑳𝑪 + 𝑳𝑪 + 𝑺 + 𝑷𝑶 + 𝑪𝑪 + 𝑳𝑻 + 𝑰 + 𝑳𝑭
𝑭𝒊𝒙𝒆𝒅 𝑪𝒐𝒔𝒕𝒔
= ₱ 24,175,314.01 + ₱ 15,595,200.00 + ₱ 3,586,896.00
+ ₱ 3,119,040.00 + ₱ 7,797,600.00 + ₱ 24,175,314.01
+ ₱ 48,350,628.02 + ₱ 2,417,531.40 + ₱ 2,417,531.40
𝑭𝒊𝒙𝒆𝒅 𝑪𝒐𝒔𝒕𝒔 = ₱ 𝟏𝟑𝟏, 𝟔𝟑𝟓, 𝟎𝟓𝟒. 𝟖𝟒
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Variable Costs:
Miscellaneous Operating Materials (MOM):
𝑀𝑂𝑀 = 0.10(Maintenance Cost)
𝑀𝑂𝑀 = 0.10(₱ 24,175,314.01)
𝑴𝑶𝑴 = ₱ 𝟐, 𝟒𝟏𝟕, 𝟓𝟑𝟏. 𝟒𝟎
Variable Cost = MOM
𝑽𝒂𝒓𝒊𝒂𝒃𝒍𝒆 𝑪𝒐𝒔𝒕 = ₱ 𝟐, 𝟒𝟏𝟕, 𝟓𝟑𝟏. 𝟒𝟎
Direct Production Cost (DPC):
𝐷𝑃𝐶 = Variable Cost + Fixed Cost
𝐷𝑃𝐶 = ₱ 2,417,531.40 + ₱ 131,635,054.84
𝑫𝑷𝑪 = ₱ 𝟏𝟑𝟒, 𝟎𝟓𝟐, 𝟓𝟖𝟔. 𝟐𝟒
Indirect Production Cost (IPC):
Sales Expense:
𝑆𝑎𝑙𝑒𝑠 𝐸𝑥𝑝𝑒𝑛𝑠𝑒 = 0.20(Variable Cost + Fixed Cost)
𝑆𝑎𝑙𝑒𝑠 𝐸𝑥𝑝𝑒𝑛𝑠𝑒 = 0.20(₱ 134,052,586.24)
𝑺𝒂𝒍𝒆𝒔 𝑬𝒙𝒑𝒆𝒏𝒔𝒆 = ₱ 𝟐𝟔, 𝟖𝟏𝟎, 𝟓𝟏𝟕. 𝟐𝟓
General Overheads:
𝐺𝑒𝑛𝑒𝑟𝑎𝑙 𝑂𝑣𝑒𝑟ℎ𝑒𝑎𝑑𝑠 = 0.30(Variable Cost + Fixed Cost)
𝐺𝑒𝑛𝑒𝑟𝑎𝑙 𝑂𝑣𝑒𝑟ℎ𝑒𝑎𝑑𝑠 = 0.30(₱ 134,052,586.24)
𝑮𝒆𝒏𝒆𝒓𝒂𝒍 𝑶𝒗𝒆𝒓𝒉𝒆𝒂𝒅𝒔 = ₱ 𝟒𝟎, 𝟐𝟏𝟓, 𝟕𝟕𝟓. 𝟖𝟕
𝐼𝑃𝐶 = Sales Expense + General Overheads
𝐼𝑃𝐶 = ₱ 26,810,517.25 + ₱ 40,215,775.87
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𝑰𝑷𝑪 = ₱ 𝟔𝟕, 𝟎𝟐𝟔, 𝟐𝟗𝟑. 𝟏𝟐
Annual Production Cost (APC):
𝐴𝑃𝐶 = IPC + DPC
𝐴𝑃𝐶 = ₱ 67,026,293.12 + ₱ 134,052,586.24
𝑨𝑷𝑪 = ₱ 𝟐𝟎𝟏, 𝟎𝟕𝟖, 𝟖𝟕𝟗. 𝟑𝟔
Production Cost:
₱ 201,078,879.36
𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝐶𝑜𝑠𝑡 =
15,000 MT
( year )
₱ 𝟏𝟑, 𝟒𝟎𝟓. 𝟐𝟔
𝐌𝐓
The annual production cost required for the plant to produce
15,000 tons/year of Magnesium Sulfate Heptahydrate via Stirring
Crystallization Technique is estimated to be ₱ 201,078,879.36. Most
of the amounts were allotted for direct production cost. The estimates
were made without the utilities costs that account for the ₱ 13,405.26
/ton annual production rate.
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III. MANUFACTURABILITY
Number of Equipment in the Stirring Crystallization Technique
Table 6.6 shows the list of equipment needed for the Stirring
Crystallization Technique Process, with their corresponding
operating parameters.
Table 6.6 Equipment with their corresponding parameters in
Stirring Crystallization Technique
Operating Operating Pressure,

Equipment Quantity
Temperature, oC bar
Storage Tank 4 50 0.5
Jaw Crusher 1 30 1
Roll Crusher 1 30 1
Screener 2 30 1
Washer 2 40 1
Dryer 2 200, 80 1
Pre-heater 4 60, 80 1
CSTR Reactor 1 60 1
Neutralizer 2 40 1
Evaporator 1 110 1
Settling Tank 1 75 1
Solid-Liquid
1 45 1
Separator
Filter 2 30 1
Agitating Tank 2 80, 50 1
Crystallizer 2 45, 20 1
Cooler 2 45 1
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Number of Energy Intensive Equipment
Table 6.7 shows the list of equipment to be used in production

of Magnesium Sulfate Heptahydraten via Stirring Crystallization
Technique, with their corresponding operating parameters
Table 6.7 Intensive equipment in Stirring Crystallization Technique
Equipment Quantity Complexity

- High Energy Requirement
- Complex Design of
Reactor 1
Equipment
- High operating Temperature

Crystallizer 2 - Complex Design of
Equipment

- Complex Design of
Evaporator 1
Equipment
Purity
The purity of the product is 98%.
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IV. SAFETY
Health Hazard
In Production of Magnesium Sulfate Heptahydrate from Dolomite
via Stirring Crystallization Technique, there are equipment that
exceeded 150 oC, and those are (equipment with high temp).
Precautions and warning must be putted near the area where the
equipment are located. Also, Personal protective equipment is
required in the manufacturing area.
Toxicological Rating
Toxicity level of raw material is analyzed, which may be seen in
table 1.4, based on the corresponding health hazards that it may cause
to humans. Basis for attaining the level of toxicity was in table 1.5,
which explains in detail the health hazards of the raw materials and
from the information in table 1.5, health hazard rating was made
taking 0 - for minimal hazard and no significant risk to health,1- slight
hazard or minor reversible injury possible, 2 - moderate hazard
temporary or minor injury may occur, 3 - serious hazard major injury
likely unless prompt action is taken and medical treatment given, 4 -
severe hazard, life-threatening, major of permanent damage may
result from single or repeated exposures.
19
Table 6.8 Toxicity level of scores of raw materials in Production of Magnesium
Sulfate Heptahydrate from Dolomite via Stirring Crystallization Technique
Raw Materials
Level of
Measure Sulfuric
Importance Dolomite
Acid
Severity of Immediate
0.30 1 3
Effects
Sensitization Level 0.10 1 3
Carcinogenicity Level 0.25 1 0
Reproductive Toxicity
0.20 0 0
Level
Severity of Chronic
0.15 3 3
Effects
Weighted Score 1.1 1.65
Total 2.75
20
Table 6.9 Basis of Toxicity Level Scores (from MSDS of Magnesium
Hydroxide)
Raw Materials
Criteria
Dolomite Sulfuric Acid
Severity of May cause skin and eye Causes severe skin and
Immediate Effects irritation eye damage
A severe skin and eye
Sensitization Level Skin and eye irritant
irritant
Respirable crystalline
silica has been classified
by IARC and NTP as a
There is no evidence
Carcinogenicity known human
that Sulfuric Acid
Level carcinogen, and
causes cancer.
classified by ACGIH as a
suspected human
carcinogen.
There are no studies in
humans that evaluated
reproductive or
Reproductive reproductive or
developmental effects
Toxicity Level developmental effects
associated with the
associated with the
ingestion of Sulfuric
ingestion of Dolomite
Acid
Repeated inhalation of Red skin. Dry skin.
respirable crystalline Itching. Skin
silica (quartz) may cause rash/inflammation.
Severity of Chronic
silicosis, a fibrosis Affection/discoloration
Effects
(scarring) of the lungs. of the teeth.
Silicosis is irreversible Inflammation/damage
and may be fatal. of the eye tissue.
(from MSDS of LabChem, Lafarge, CSBP)
21
V. ENVIRONMENTAL ASPECTS
Environmental hazard level of raw materials is analyzed, which may
be seen in Table 1.6, based on the corresponding hazards that it may cause to
environment. Basis for attaining the level of hazard to the environment was
in Table 1.7, which explains in detail the possible environmental hazards of
the raw materials and from the information in Table 1.7 environmental hazard
rating was made taking 0 – for minimal hazard and no significant risk to
environment, 1 - slight hazard or minor reversible damage possible, 2 -
moderate hazard temporary or minor damage may occur, 3 - serious hazard
major damage to environment unless prompt action is taken, 4 - severe
hazard, permanent damage may result.
Table 6.10 Environmental Hazard Level of Raw Materials in

Stirring Crystallization Process
Raw Materials
Level of Dolomite Sulfuric
Measure
Importance Rock Acid
Air Toxicity 0.15 0 0
Aquatic Toxicity 0.15 0 3
Toxicity on Plants and
0.20 0 2
Animals
Toxicity of Immediate
0.20 1 1
Degradation
Long-term Degradation
0.30 1 0
Effects
Total 1.55
22
Table 6.11 Basis of Environmental Hazard Level Score

Raw Materials
Criteria Dolomite Rock Sulfuric Acid
Air contaminant = 5 Not classified as
Air Toxicity mg/M3 dangerous for the ozone
Not listed as hazardous. layer.
Not classified as
Harmful to aquatic life
hazardous. Shows no
in very low
Aquatic Toxicity bioaccumulation effect
concentrations. Mild
or food chain
water pollutant.
concentration toxicity.
Shows no Harmful to fishes.
Toxicity on Plants and bioaccumulation effect Exposure to animals
Animals or food chain may cause acute
concentration toxicity. toxicity.
Not classified as May evolve toxic gases
hazardous to when heated to
Degradation
environment. decomposition.
No effect on ozone
Long-Term Avoid releasing to the
layer, and global
Degradation Effects environment
warming.
(from MSDS of LabChem, Lafarge, CSBP)
23
PROCESS II
Production of Magnesium Sulfate Heptahydrate from Magnesium Oxide
via Ignition of Magnesium Hydroxide
Magnesium Hydroxide is an inorganic compound with the formula
Mg(OH)2. The solid mineral form of Magnesium Hydroxide is brucite. Brucite
is used as a flame retardant because it thermally decomposes in a similar way as
aluminium hydroxide and mixtures of huntite and hydromagnesite, to release
water. The superior properties of the synthetic form of Mg(OH)2, in terms of
purity and particle size distribution, has opened up far more applications. The
largest industrial application of Mg(OH)2 is flame retardants for articles such as
roofing, isolation materials, plastic articles and coatings. The mechanism of
flame retardancy is based on the endothermic decomposition of the material into
MgO and H2O. This reaction adsorbs heat, which delays ignition of the associated
substance. The water that is released dilutes combustible gases and inhibits
oxygen from aiding the combustion. Magnesium oxide is prepared by igniting
magnesium hydroxide at 332 °C (630 °F) with combustion reaction of:
The magnesium oxide formed is then reacted with sulfuric acid to
produce magnesium sulfate.
The magnesium Sulfate produce from the reaction is then introduced to
an evaporator to separate the water from the product and is then crystallized to
obtain higher purity.
24
Crystallization at temperatures between 1.8 and 48 °C yields the
heptahydrate, MgSO4•7H2O. Below 1.8 °C, a dodecahydrate, MgSO4•12H2O
crystallizes out. Above 48 °C, a lower hydrate crystal forms. The crystals is
separated from the mother liquor by centrifugation, and is further dried to get the
optimum yield of Epsom salt. The drying medium used in the dryer is air pre-
heated to 70 °C.
25
Figure 6.4 Production of Magnesium Sulfate Heptahydrate from Magnesium Hydroxide via Calcination
26
I. SUSTAINABILITY
Availability of Raw Materials
Magnesium Hydroxide and Sulfuric acid are the raw materials of
the reaction.
MAGNESIUM HYDROXIDE
Magnesium hydroxide is an inorganic compound. It is naturally
found as the mineral brucite. Magnesium hydroxide can be used as an
antacid or a laxative in either an oral liquid suspension or chewable tablet
form. Additionally, magnesium hydroxide has smoke suppressing and
flame retardant properties and is thus used commercially as a fire
retardant. It can also be used topically as a deodorant or for the relief of
canker sores.(https://pubchem.ncbi.nlm.nih.gov/compound/Milk-of-magnesia)
Magnesium hydroxide is not available locally; the largest sellers
and suppliers of magnesium hydroxide are found in China. Some of the
companies that produce and supply this material are:
SUPPLIERS:
 Weifang Kaibo Magnesium Salt Co., Ltd.
 Dandong Tianci Fire – Retardant Material
 Chemfine International Co., Ltd.
 Hebei Suoyi New Material Technology Co., Ltd.
The major manufacturers mainly concentrate in Europe, North America,
Japan and China. In 2016, North American magnesium hydroxide production
27
share was about 22%. Europe production share took 17% and Japan
production share took 17%. China took about 32%. In 2012, the reported
supply for magnesium hydroxide was 613,000 MT, in 2017, was 788,000,
and it was expected to grow up to 3.41% in 2022, 814.870.8 MT. Below is
the projected supply and demand curve for magnesium hydroxide from 2012
– 2022.
850000
800000
Demand / Supply
750000
700000
650000
600000
2012 2014 2016 2018 2020 2022
Date
SUPPLY DEMAND
Figure 6.5 Supply and Demand for Magnesium Hydroxide
SULFURIC ACID
Sulfuric acid (H2SO4), also called oil of vitriol, or hydrogen
sulfate, dense, colorless, oily, corrosive liquid; one of the most important
of all chemicals, prepared industrially by the reaction of water with sulfur
trioxide, which in turn is made by chemical combination of sulfur dioxide
and oxygen either by the contact process or the chamber process. It is
used in the manufacture of fertilizers, pigments, dyes, drugs, explosives,
28
detergents, and inorganic salts and acids, as well as in petroleum refining
and metallurgical processes. (www.britannica.com)
SUPPLIER:
The global sulfuric acid market size was valued at USD 10.10 billion
in 2016 and is expected to witness progress due to increase and planned
growth in fertilizers using phosphates. The rise can be attributed to the
presence of stringent environmental regulations to control emissions,
which is expected to lead to increased use of smelters to capture sulfur
dioxide products.
II. ECONOMICS
Table 6.12 Price of Raw Materials for Calcination Process
Raw Materials Price (₱ per ton)

Magnesium Hydroxide 25,000.00
Sulfuric Acid, 98% 20,341.71
Cost of Equipment
Estimated capital investment is computed using the Lang
Method, factor for solid-fluid processing in table 6.2 and 6.3.
29
Table 6.13 Detailed Estimation of Fixed Capital Cost of Equipment in Process 2
Purchasing Delivered Total

Equipment Quantity Equipment Equipment Equipment
Cost (₱) Cost (₱) Cost (₱)
Storage Tank 3 1,015,800.00 50,790.00 3,199,770.00
Calciner 1 25,648,899.21 1,282,444.96 26,931,344.17
Scrubber 1 11,006,524.11 550,326.21 11,556,850.32
Washer 2 203,160.00 10,158.00 426,636.00
Filter 1 1,269,750.00 63,487.50 1,333,237.50
Pre-heater 1 1,168,170.00 58,408.50 4,906,314.00
CSTR Reactor 1 7,497,857.59 374,892.88 7,872,750.47
Heater 2 6,796,236.27 339,811.81 7,136,048.08
Evaporator 1 3,555,300.00 177,765.00 3,733,065.00
Crystallizer 1 2,031,600.00 101,580.00 2,133,180.00
Centrifuge 1 5,195,817.00 259,790.85 5,455,607.85
Dryer 1 1,015,800.00 50,790.00 3,199,770.00
TOTAL 16 71,128,384.18 3,269,455.71 74,684,803.39
*Delivered Equipment Costs at 5% of Purchasing Equipment Cost

𝑃𝑃𝐶 = 𝑃𝐶𝐸 ( 1 + 𝑓1 + 𝑓2 + 𝑓3 + 𝑓4 + 𝑓5 )
𝑃𝑃𝐶 = 74,684,803.39(1 + 0.45 + 0.45 + 0.15 + 0.10 + 0.10)
𝑷𝑷𝑪 = ₱ 𝟏𝟔𝟖, 𝟎𝟒𝟎, 𝟖𝟎𝟕. 𝟔𝟑
𝐹𝑖𝑥𝑒𝑑 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐶𝑜𝑠𝑡 = 𝑃𝑃𝐶(1 + 𝑓10 + 𝑓11 + 𝑓12 )
𝐹𝐶𝐶 = 168,040,807.63 (1 + 0.25 + 0.05 + 0.10)
𝑭𝑪𝑪 = ₱ 𝟐𝟒𝟑, 𝟔𝟓𝟗, 𝟏𝟕𝟏. 𝟎𝟔
30
𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐶𝑜𝑠𝑡 = 𝐹𝐶𝐶(0.05)
𝑊𝐶𝐶 = 243,659,171.06 (0.05)
𝑾𝑪𝑪 = ₱ 𝟏𝟐, 𝟏𝟖𝟐, 𝟗𝟓𝟖. 𝟓𝟓
𝑇𝐶𝐼 = 243,659,171.06 + 12,182,958.55
𝑻𝑪𝑰 = ₱ 𝟐𝟓𝟓, 𝟖𝟒𝟐, 𝟏𝟐𝟗. 𝟔𝟏
Fixed Costs:
Maintenance Cost:
𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝐶𝑜𝑠𝑡 = 0.10(𝐹𝐶𝐶)
𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝐶𝑜𝑠𝑡 = 0.10 (243,659,171.06 )
𝑴𝒂𝒊𝒏𝒕𝒆𝒏𝒂𝒏𝒄𝒆 𝑪𝒐𝒔𝒕 = ₱ 𝟐𝟒, 𝟑𝟔𝟓, 𝟗𝟏𝟕. 𝟏𝟏
For a plant capacity of 15,000 tons of product per year
(15,000,000 kg per year), and having average conditions, the
estimated operating labor requirement is 38 employee-
hours/day/processing steps. Considering a 360 days’ annual
operation and 3 processing steps:
Calculating for the operating labor costs using the data for
manpower and using figure 6.2 and figure 6.3.
31

38 𝑒𝑚𝑝𝑙𝑜𝑦𝑒𝑒 − ℎ𝑜𝑢𝑟𝑠 360 𝑑𝑎𝑦𝑠 𝑃ℎ𝑝 380
=( )( )( )
𝑑𝑎𝑦𝑠 − 𝑝𝑟𝑜𝑐𝑒𝑠𝑠𝑖𝑛𝑔 𝑠𝑡𝑒𝑝 𝑦𝑒𝑎𝑟 𝑒𝑚𝑝𝑙𝑜𝑦𝑒𝑒 − 8 ℎ𝑜𝑢𝑟
(3 𝑝𝑟𝑜𝑐𝑒𝑠𝑠𝑖𝑛𝑔 𝑠𝑡𝑒𝑝 )(1 𝑦𝑒𝑎𝑟 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛)
𝑶𝑳𝑪 = ₱ 𝟏𝟓, 𝟓𝟗𝟓, 𝟐𝟎𝟎. 𝟎𝟎
Laboratory Cost:
𝐿𝑎𝑏𝑜𝑟𝑎𝑡𝑜𝑟𝑦 𝐶𝑜𝑠𝑡 = (0.23)(₱ 15,595,200.00 )
Supervision Cost:
Plant Overheads:
𝑃𝑙𝑎𝑛𝑡 𝑂𝑣𝑒𝑟ℎ𝑒𝑎𝑑𝑠 = (0.50)(₱ 15,595,200.00 )
Capital Charges:
𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐶ℎ𝑎𝑟𝑔𝑒𝑠 = (0.10)(₱ 243,659,171.06)
𝑪𝒂𝒑𝒊𝒕𝒂𝒍 𝑪𝒉𝒂𝒓𝒈𝒆𝒔 = ₱ 𝟐𝟒, 𝟑𝟔𝟓, 𝟗𝟏𝟕. 𝟏𝟏
32
Local Taxes:
𝐿𝑜𝑐𝑎𝑙 𝑇𝑎𝑥𝑒𝑠 = (0.20)(₱ 243,659,171.06)
𝑳𝒐𝒄𝒂𝒍 𝑻𝒂𝒙𝒆𝒔 = ₱ 𝟒𝟖, 𝟕𝟑𝟏, 𝟖𝟑𝟒. 𝟐𝟏
Insurance:
𝐼𝑛𝑠𝑢𝑟𝑎𝑛𝑐𝑒 = (0.01)(₱ 243,659,171.06)
𝑰𝒏𝒔𝒖𝒓𝒂𝒏𝒄𝒆 = ₱ 𝟐, 𝟒𝟑𝟔, 𝟓𝟗𝟏. 𝟕𝟏
𝑳𝒊𝒄𝒆𝒏𝒄𝒆 𝑭𝒆𝒆/𝑹𝒐𝒚𝒂𝒍𝒕𝒚 𝑭𝒆𝒆𝒔 = ₱ 𝟐, 𝟒𝟑𝟔, 𝟓𝟗𝟏. 𝟕𝟏
= ₱ 24,365,917.11 + ₱ 15,595,200.00 + ₱ 3,586,896.00
+ ₱ 3,119,040.00 + ₱ 7,797,600.00 + ₱ 24,365,917.11
+ ₱ 48,731,834.21 + ₱ 2,436,591.71 + ₱ 2,436,591.71
𝑭𝒊𝒙𝒆𝒅 𝑪𝒐𝒔𝒕𝒔 = ₱ 𝟏𝟑𝟐, 𝟒𝟑𝟓, 𝟓𝟖𝟕. 𝟖𝟒
Variable Costs:
𝑀𝑂𝑀 = 0.10(₱ 24,365,917.11)
𝑴𝑶𝑴 = ₱ 𝟐, 𝟒𝟑𝟔, 𝟓𝟗𝟏. 𝟕𝟏
33
Variable Cost = MOM
𝑽𝒂𝒓𝒊𝒂𝒃𝒍𝒆 𝑪𝒐𝒔𝒕 = ₱ 𝟐, 𝟒𝟑𝟔, 𝟓𝟗𝟏. 𝟕𝟏
𝐷𝑃𝐶 = ₱ 2,436,591.71 + ₱ 132,435,587.84
𝑫𝑷𝑪 = ₱ 𝟏𝟑𝟒, 𝟖𝟕𝟐, 𝟏𝟕𝟗. 𝟓𝟓
Sales Expense:
𝑆𝑎𝑙𝑒𝑠 𝐸𝑥𝑝𝑒𝑛𝑠𝑒 = 0.20(₱ 134,872,179.55)
𝑺𝒂𝒍𝒆𝒔 𝑬𝒙𝒑𝒆𝒏𝒔𝒆 = ₱ 𝟐𝟔, 𝟗𝟕𝟒, 𝟒𝟑𝟓. 𝟗𝟏
General Overheads:
𝐺𝑒𝑛𝑒𝑟𝑎𝑙 𝑂𝑣𝑒𝑟ℎ𝑒𝑎𝑑𝑠 = 0.30(₱ 134,872,179.55)
𝑮𝒆𝒏𝒆𝒓𝒂𝒍 𝑶𝒗𝒆𝒓𝒉𝒆𝒂𝒅𝒔 = ₱ 𝟒𝟎, 𝟒𝟔𝟏, 𝟔𝟓𝟑. 𝟖𝟕
𝐼𝑃𝐶 = ₱ 26,974,435.91 + ₱ 40,461,653.87
𝑰𝑷𝑪 = ₱ 𝟔𝟕, 𝟒𝟑𝟔, 𝟎𝟖𝟗. 𝟕𝟖
𝐴𝑃𝐶 = ₱ 67,436,089.78 + ₱ 134,872,179.55
𝑨𝑷𝑪 = ₱ 𝟐𝟎𝟐, 𝟑𝟎𝟖, 𝟐𝟔𝟗. 𝟑𝟑
34
Production Cost:
₱ 202,308,269.33
15,000 MT
( year )
₱𝟏𝟑, 𝟒𝟖𝟕. 𝟐𝟐
𝐌𝐓
The annual production cost required for the plant to produce 15,000
tons/year of Magnesium Sulfate Heptahydrate via Stirring Crystallization
Technique is estimated to be ₱ 202,308,269.33. Most of the amounts were
allotted for direct production cost. The estimates were made without the utilities
costs that account for the ₱ 13,487.22/ton annual production rate.
35
Number of Equipment in Ignition of Magnesium Hydroxide

Table 6.14 shows the list of equipment to be used in production
of Magnesium Sulfate Heptahydrate from Magnesium Oxide via
Ignition of Magnesium Hydroxide, with their corresponding
operating parameters.
Table 6.14 Equipment and their corresponding operating parameters in

Ignition of Magnesium Hydroxide
Operating Operating
Equipment Quantity
Temperature, oC Pressure, bar
Magnesium Hydroxide
1 30 0.5
Storage Tank
Calciner 1 500 1
Scrubber 1 30 1
Washer 2 250 1
Filter 1 200 0.6
Sulfuric Acid Tank 1 30 0.5
Reactor 1 200 1
Evaporator 1 210 1
Crystallizer 1 45 1
Centrifuge 1 50 1
Dryer 1 70 2
Magnesium Sulfate
1 30 0.5
Storage Tank
36
Table 6.15 shows the list of energy intensive equipment

to be used in production of Magnesium Sulfate Heptahydrate
from Magnesium Oxide via Ignition of Magnesium Hydroxide.

Ignition of Magnesium Hydroxide

Calciner 1
- Complex Design of Equipment
Washer 1 - High Energy Requirement
Filter 1 - High Energy Requirement

Reactor 1
Evaporator 1
Purity
The purity of the product is 99.50%.
37
IV. SAFETY
Health Hazard
In Production of Magnesium Sulfate from Magnesium Hydroxide
via Calcination, there are equipment that exceeded 150 oC, and those
are (equipment with high temp). Precautions and warning must be
putted near the area where the equipment are located. Also, Personal
protective equipment is required in the manufacturing area.
Toxicity level of raw material is analyzed, which may be seen
in table (number), based on the corresponding health hazards that it
may cause to humans. Basis for attaining the level of toxicity was in
table (number), which explains in detail the health hazards of the raw
materials and from the information in table (number), health hazard
rating was made taking 0 - for minimal hazard and no significant risk
to health,1- slight hazard or minor reversible injury possible, 2 -
moderate hazard temporary or minor injury may occur, 3 - serious
hazard major injury likely unless prompt action is taken and medical
treatment given, 4 - severe hazard, life-threatening, major of
permanent damage may result from single or repeated exposures.
38
Table 6.16 Toxicity level scores of raw materials in Calcination Process

Raw Materials
Level of
Measure Magnesium Sulfuric
Importance
Hydroxide Acid
Severity of Immediate Effects 0.30 1 3
Reproductive Toxicity Level 0.20 0 0
Severity of Chronic Effects 0.15 0 3
Total 2.20
Table 6.17 Basis of Toxicity Level Scores for Calcination Process
Raw Materials
Criteria
Magnesium Hydroxide Sulfuric Acid
Severity of May cause skin and eye Causes severe skin and
Immediate Effects irritation eye damage
Repeated and prolonged
A severe skin and eye
Sensitization Level exposure may lead to
irritant
irritation.
Not listed as
carcinogenic according There is no evidence
Carcinogenicity
to the International that Sulfuric Acid
Level
Agency for Research on causes cancer.
Cancer.
There are no studies in There are no studies in
humans that evaluated humans that evaluated
reproductive or reproductive or
Reproductive
developmental effects developmental effects
Toxicity Level
associated with ingestion associated with the
of Magnesium ingestion of Sulfuric
Hydroxide. Acid
Severity of Chronic No evidence of Red skin. Dry skin.
Effects carcinogenicity. Itching. Skin
39
rash/inflammation.
Affection/discoloration
of the teeth.
Inflammation/damage
of the eye tissue.
(from MSDS of ScienceLab, Toxicological Review of Ammonia, Toxicological
Review of Nitric Acid)
V. ENVIRONMENTAL ASPECT
Environmental hazard level of raw materials is analyzed, which
may be seen in table 6.18, based on the corresponding hazards that it
may cause to environment. Basis for attaining the level of hazard to
the environment was in table 6.19, which explains in detail the
possible environmental hazards of the raw materials and from the
information in table 6.18, environmental hazard rating was made
taking 0 – for minimal hazard and no significant risk to environment,
1 - slight hazard or minor reversible damage possible, 2 - moderate
hazard temporary or minor damage may occur, 3 - serious hazard
major damage to environment unless prompt action is taken, 4 -
severe hazard, permanent damage may result.
40
Table 6.18 Environmental hazard level scores of raw

materials in Calcination Process
Raw Materials
Level of Magnesium Sulfuric
Measure
Importance Hydroxide Acid
Toxicity on Plants and Animals 0.20 1 2
Toxicity of Immediate Degradation 0.20 0 1
Long-term Degradation Effects 0.30 0 0
Total 1.70
Table 6.19 Basis of Environmental hazard level Scores (from MSDS of

ScienceLab, PraxAir, OCI Nitogen)
Raw Materials
Magnesium
Criteria Sulfuric Acid
Hydroxide
Not classified as
Not classified as
Air Toxicity dangerous for the ozone
hazardous
layer.
Harmful to aquatic life
Avoid contaminating in very low
Aquatic Toxicity
waterways concentrations. Mild
water pollutant.
Shows no
bioaccumulation effect Harmful to fishes.
Toxicity on Plants and or food chain Exposure to animals
Animals concentration toxicity. may cause acute
But may affect aquatic toxicity.
life.
Not classified as May evolve toxic gases
hazardous to when heated to
Degradation
environment. decomposition.
No effect on ozone
Long-Term Avoid releasing to the
layer, and global
Degradation Effects environment
warming.
41
PROCESS III
Production of Magnesium Sulfate Heptahydrate from Magnesite via

Neutralization of Sulphuric Acid
Magnesium sulfate is an inorganic salt with the formula MgSO₄ₓ where
0≤x≤7. It is often encountered as the heptahydrate sulfate mineral epsomite,
commonly called Epsom salt. Magnesium sulfate heptahydrate or known as
Epsom salt has a wide application in medical, textile, tanning, and agricultural
industry (fertilizers).
Calcined magnesite powder is purified mainly from iron impurities by
passing it through magnetic separator. Water is heated first at 50℃ to warm and
then introduced in a jacketed reactor vessel. Powder magnesium carbonate or
known as magnesite is added progressively and mixed thoroughly with the water
by continuous stirring in the reactor vessel which operates at 105℃ to carried out
an exothermic reaction.
After the magnesite slurry has been homogenized the concentrated
sulphuric acid that is first preheated is added to the reactor over a period of 20
minutes. The reaction inloved is
𝑴𝒈𝑪𝑶𝟑(𝒔) + 𝑯𝟐 𝑺𝑶𝟒(𝒂𝒒) → 𝑴𝒈𝑺𝑶𝟒(𝒂𝒒) + 𝑪𝑶𝟐(𝒈) + 𝑯𝟐 𝑶(𝒍)
After completion of the reaction the solution is transferred to evaporator,
where it is concentrated. Then the reaction product is transferred to a series of
crystallizer with agitator where the temperature is reduced gradually; firstly to
42
105℃ -75℃, then to 75℃ - 45℃ and finally to 45℃ - 25℃. The amount of
magnesium sulfate heptahydrate crsytals increases as the temperature is reduced.
After a series of cooling crystallissed magnesium sulphate product is
washed and then passed into a centrifuge and the remaining liquor is recycled
back to the reactor vessel. The used of centrifuge can be technically beneficial in
that it helps to minimize adsorbed water on the surface of the magnesium sulfate
heptahdyrate (MgSO4.7H2O).
The magnesium sulfate heptahydrate crystalline product that has been
separated out is dried at a temperature of about 200℃. The final crystalline
product obtained after drying compromises a magnesium sulphate crystals
known as Epsom salt with a degree of hydration that is less than seven.
43
Figure 6.6 Production of Magnesium Sulfate Heptahydrate from Magnesite via Neutralization of Sulfuric Acid
44
I. SUSTAINABILITY
Availability of Raw Materials
Magnesite and sulfuric acid are the raw materials of the neutralization
process.
MAGNESITE
Magnesite is a magnesium carbonate mineral with a chemical
composition of MgCO3. It is named after the presence of magnesium in its
composition. Magnesite usually forms during the alteration of magnesium-
rich rocks or carbonate rocks by metamorphism or chemical weathering.
(https://geology.com)
As can be seen in Figure 6.1 China is the world’s largest producer of
magnesite, accounting for 69% of the total world output in 2010. The next
largest producers are Slovakia, Russia, Turkey, Austria, Brazil, Spain and
Australia, with 25% of production between them.
Figure 6.7 Worldwide Production of Magnesite in 2010 (World Mining

Data 2012)
45
SULFURIC ACID
Sulfuric acid (H2SO4), also called oil of vitriol, or hydrogen sulfate,
dense, colourless, oily, corrosive liquid; one of the most important of all
chemicals, prepared industrially by the reaction of water with sulfur trioxide,
which in turn is made by chemical combination of sulfur dioxide and oxygen
either by the contact process or the chamber process. It is used in the
manufacture of fertilizers, pigments, dyes, drugs, explosives, detergents, and
inorganic salts and acids, as well as in petroleum refining and metallurgical
processes. https://www.britannica.com)
SUPPLIER:
II. ECONOMICS
Table 6.20 Price of Raw Materials for Neutralization Process
Raw Materials Price ( ₱ per ton)
Magnesite 34,835.17
Sulfuric Acid, 98% 20,341.71
46
Cost of Equipment
Estimated capital investment is computed using the Lang
Method, factor for fluid processing are taken from Perry’s Chemical
Engineering Handbook 8th ed.
(In reference to Tables 6.2 and 6.3)
Table 6.21 Detailed Estimation of Fixed Capital Cost of Equipment for Process 3
Purchasing Delivered Total

Equipment Quantity Equipment Equipment Equipment
Cost (₱) Cost (₱) Cost (₱)
Reactor 1 7,497,857.59 374,892.88 7,872,750.47
Magnetic
1 25,648,899.21 1,282,444.96 26,931,344.17
Separator
Crystallizer 3 3,555,300.00 177,765.00 11,199,195.00
Washer 1 203,160.00 10,158.00 213,318.00
Evaporator 1 6,796,236.27 339,811.81 7,136,048.08
Heat
4 1,168,170.00 58,408.50 4,906,314.00
Exchanger
Centrifuge 1 2,031,600.00 101,580.00 2,133,180.00
Dryer 1 5,195,817.00 259,790.85 5,455,607.85
Storage
4 1,015,800.00 50,790.00 4,266,360.00
Tank
TOTAL 17 66,775,350.07 2,655,642.00 70,114,117.57
*Delivered Equipment Costs at 5% of Purchasing Equipment Cost
𝑇𝑜𝑡𝑎𝑙 𝑃ℎ𝑦𝑠𝑖𝑐𝑎𝑙 𝑃𝑙𝑎𝑛𝑡 𝐶𝑜𝑠𝑡 = 𝑃𝐶𝐸 ( 1 + 𝑓1 + 𝑓2 + 𝑓3 + 𝑓4 + 𝑓5 )
𝑃𝐶𝐶 = ₱ 70,114,117.57 ( 1 + 0.45 + 0.45 + 0.15 + 0.10

+ 0.10 )
47
𝑷𝑷𝑪 = ₱ 𝟏𝟓𝟕, 𝟕𝟓𝟔, 𝟕𝟔𝟒. 𝟓𝟒
𝐹𝑖𝑥𝑒𝑑 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐶𝑜𝑠𝑡 = 𝑃𝑃𝐶 ( 1 + 𝑓10 + 𝑓11 + 𝑓12 )
𝐹𝐶𝐶 = ₱ 157,756,764.54( 1 + 0.30 + 0.10 )
𝑭𝑪𝑪 = ₱ 𝟐𝟐𝟖, 𝟕𝟒𝟕, 𝟑𝟎𝟖. 𝟓𝟖
𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐶𝑜𝑠𝑡 = 𝐹𝐶𝐶 (0.05)
𝑊𝐶𝐶 = ₱ 228,747,308.58 (0.05)
𝑾𝑪𝑪 = ₱ 𝟏𝟏, 𝟒𝟑𝟕, 𝟑𝟔𝟓. 𝟒𝟑
𝑇𝐶𝐼 = 228,747,308.58 + ₱ 11,437,365.43
𝑻𝑪𝑰 = ₱ 𝟐𝟒𝟎, 𝟏𝟖𝟒, 𝟔𝟕𝟒. 𝟎𝟏
Fixed Costs:
Maintenance Cost
𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝐶𝑜𝑠𝑡 = (0.10)(FCC)
𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝐶𝑜𝑠𝑡 = (0.10)( ₱ 228,747,308.58)
𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝐶𝑜𝑠𝑡 = ₱ 𝟐𝟐, 𝟖𝟕𝟒, 𝟕𝟑𝟎. 𝟖𝟔
For a plant capacity of 15,000 tons of product per year
(15,000,000 kg per year), and having average conditions, the
48
estimated operating labor requirement is 38 employee-
hours/day/processing steps. Considering a 360 days’ annual
operation and 3 processing steps:
Calculating for the operating labor costs using the data for
manpower and using figure 6.2 and figure 6.3.
:
38 𝑒𝑚𝑝𝑙𝑜𝑦𝑒𝑒 − ℎ𝑜𝑢𝑟𝑠 360 𝑑𝑎𝑦𝑠 𝑃ℎ𝑝 380
=( )( )( )
𝑑𝑎𝑦𝑠 − 𝑝𝑟𝑜𝑐𝑒𝑠𝑠𝑖𝑛𝑔 𝑠𝑡𝑒𝑝 𝑦𝑒𝑎𝑟 𝑒𝑚𝑝𝑙𝑜𝑦𝑒𝑒 − 8 ℎ𝑜𝑢𝑟
(3 𝑝𝑟𝑜𝑐𝑒𝑠𝑠𝑖𝑛𝑔 𝑠𝑡𝑒𝑝 )(1 𝑦𝑒𝑎𝑟 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛)
𝑶𝑳𝑪 = ₱ 𝟏𝟓, 𝟓𝟗𝟓, 𝟐𝟎𝟎. 𝟎𝟎
Laboratory Cost:
𝐿𝑎𝑏𝑜𝑟𝑎𝑡𝑜𝑟𝑦 𝐶𝑜𝑠𝑡 = (0.23)(₱ 15,595,200.00 )
Supervision Cost:
Plant Overheads:
𝑃𝑙𝑎𝑛𝑡 𝑂𝑣𝑒𝑟ℎ𝑒𝑎𝑑𝑠 = (0.50)(₱ 15,595,200.00 )
49
Capital Charges:
𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐶ℎ𝑎𝑟𝑔𝑒𝑠 = (0.10)(₱ 228,747,308.58)
𝑪𝒂𝒑𝒊𝒕𝒂𝒍 𝑪𝒉𝒂𝒓𝒈𝒆𝒔 = ₱ 𝟐𝟐, 𝟖𝟕𝟒, 𝟕𝟑𝟎. 𝟖𝟔
Local Taxes:
𝐿𝑜𝑐𝑎𝑙 𝑇𝑎𝑥𝑒𝑠 = (0.20)(₱ 228,747,308.58)
𝑳𝒐𝒄𝒂𝒍 𝑻𝒂𝒙𝒆𝒔 = ₱ 𝟒𝟓, 𝟕𝟒𝟗, 𝟒𝟔𝟏. 𝟕𝟐
Insurance:
𝐼𝑛𝑠𝑢𝑟𝑎𝑛𝑐𝑒 = (0.01)(₱ 228,747,308.58)
𝑰𝒏𝒔𝒖𝒓𝒂𝒏𝒄𝒆 = ₱ 𝟐, 𝟐𝟖𝟕, 𝟒𝟕𝟑. 𝟎𝟗
𝑳𝒊𝒄𝒆𝒏𝒄𝒆 𝑭𝒆𝒆/𝑹𝒐𝒚𝒂𝒍𝒕𝒚 𝑭𝒆𝒆𝒔 = ₱𝟐, 𝟐𝟖𝟕, 𝟒𝟕𝟑. 𝟎𝟗
= ₱ 22,874,730.86 + ₱ 15,595,200.00 + ₱ 3,586,896.00
+ ₱ 3,119,040.00 + ₱ 7,797,600.00 + ₱ 22,874,730.86
+ ₱ 45,749,461.72 + ₱ 2,287,473.09 + ₱ 2,287,473.09
𝑭𝒊𝒙𝒆𝒅 𝑪𝒐𝒔𝒕𝒔 = ₱ 𝟏𝟐𝟔, 𝟏𝟕𝟐, 𝟔𝟎𝟓. 𝟔𝟏
50
Variable Costs:
𝑀𝑂𝑀 = 0.10(₱ 22,874,730.86)
𝑴𝑶𝑴 = ₱ 𝟐, 𝟐𝟖𝟕, 𝟒𝟕𝟑. 𝟎𝟗
Variable Cost = MOM
𝑽𝒂𝒓𝒊𝒂𝒃𝒍𝒆 𝑪𝒐𝒔𝒕 = ₱ 𝟐, 𝟐𝟖𝟕, 𝟒𝟕𝟑. 𝟎𝟗
𝐷𝑃𝐶 = ₱ 2,287,473.09 + ₱ 126,172,605.61
𝑫𝑷𝑪 = ₱ 𝟏𝟐𝟖, 𝟒𝟔𝟎, 𝟎𝟕𝟖. 𝟔𝟗
Sales Expense:
𝑆𝑎𝑙𝑒𝑠 𝐸𝑥𝑝𝑒𝑛𝑠𝑒 = 0.20(₱ 128,460,078.69)
𝑺𝒂𝒍𝒆𝒔 𝑬𝒙𝒑𝒆𝒏𝒔𝒆 = ₱ 𝟐𝟓, 𝟔𝟗𝟐, 𝟎𝟏𝟓. 𝟕𝟒
General Overheads:
𝐺𝑒𝑛𝑒𝑟𝑎𝑙 𝑂𝑣𝑒𝑟ℎ𝑒𝑎𝑑𝑠 = 0.30(₱128,460,078.69)
𝑮𝒆𝒏𝒆𝒓𝒂𝒍 𝑶𝒗𝒆𝒓𝒉𝒆𝒂𝒅𝒔 = ₱ 𝟑𝟖, 𝟓𝟑𝟖, 𝟎𝟐𝟑. 𝟔𝟏
𝐼𝑃𝐶 = ₱ 25,692,015.74 + ₱ 38,538,023.61
51
𝑰𝑷𝑪 = ₱ 𝟔𝟒, 𝟐𝟑𝟎, 𝟎𝟑𝟗. 𝟑𝟓
𝐴𝑃𝐶 = ₱ 64,230,039.35 + ₱ 128,460,078.69
𝑨𝑷𝑪 = ₱ 𝟏𝟗𝟐, 𝟔𝟗𝟎, 𝟏𝟏𝟖. 𝟎𝟒
Production Cost:
₱ 192,690,118.04
15,000 MT
( year )
₱𝟏𝟐, 𝟖𝟒𝟔. 𝟎𝟏
𝐌𝐓
The annual production cost required for the plant to produce
15,000 tons/year of Magnesium Sulfate Heptahydrate via Stirring
Crystallization Technique is estimated to be ₱ 192,690,118.04. Most
of the amounts were allotted for direct production cost. The estimates
were made without the utilities costs that account for the ₱
12,846.01/ton annual production rate.
52
Number of Equipment in the the Magnesite via Neutralization
of Sulfuric Acid Process
Table 6.22 shows the list of equipment needed for the
Magnesite via Neutralization of Sulfuric Acid Process, with their
corresponding operating parameters.
Magnesite via Neutralization Process
Operating Operating Pressure,

Equipment Quantity
Temperature, oC bar
Storage tank 4 50 0.5
Pre heater 1 50 1.5
Reactor 1 105 1
Cooling Vessel 3 75-25 1
Crystallizer 1 45 1
Centrifuge 1 50 1
Dryer 1 200 2
Separator 1 45 1
Washer 1 40 0.9
Evaporator 1 110 1
Storage tank 4 50 0.5
Heat Exchanger 2 - -
53

Table 6.23 shows the list of energy intensive equipment
to be used in production of Magnesium Sulfate Heptahydrate
from Magnesium Oxide via Ignition of Magnesium Hydroxide.

Neutralization Process

Reactor 1

Crystallizer 1 - Complex Design of Equipment
Purity
The purity of the product is 99%.
IV. SAFETY
Health Hazard
In the Magnesite via Neutralization of Sulphuric Acid Process,
there are 2 equipment operating in high temperature which are the
CSTR reactor (105 °C and evaporator (110 °C). Precautions and
warnings must be put near the area where this equipment are located.
Personal protective equipment is required in the manufacturing area.
54
Toxicity level of raw material is analyzed, which may be seen in
table 6.24, based on the corresponding health hazards that it may cause to
humans. Basis for attaining the level of toxicity was in table 6.25, which
explains in detail the health hazard of the raw materials and from the
information in table 6.24, health hazard rating was made taking 0 – for
minimal hazard and no significant risk to health, 1 – slight hazard or
minor reversible injury possible, 2 – moderate hazard temporary or minor
injury may occur. 3 – serious hazard major injury likely unless prompt
action is taken and medical treatment given, 4 – severe hazard, life-
threatening, major or permanent damage may result from single or
repeated exposures.
Table 6.24 Toxicity level scores of raw materials in Neutralization
Process
Raw Materials
Level of
Measure Sulfuric
Importance Magnesite
Acid
Severity of Immediate
0.30 3 3
Effects
Reproductive Toxicity
0.20 0 0
Level
Severity of Chronic
0.15 3 3
Effects
Total 3.20
55
Table 6.25 Basis of Toxicity Level Scores for Process 3
Raw Materials
Criteria
Magnesite Sulfuric Acid
Can damage the skin and
Severity of Immediate eyes, nausea and Causes severe skin and
Effects drowsiness upon eye damage
inhalation
Eyes, skin and nose A severe skin and eye
Sensitization Level
irritant irritant
There is no evidence that

magnesite causes cancer.
Magnesite has not been
classified for
carcinogenic effect by There is no evidence that
Carcinogenicity Level EPA, the Department of Sulfuric Acid causes
Health and Human cancer.
Services and American
Conference of
Governmental Industrial
Hygienists

No information was
reproductive or
Reproductive located regarding
developmental effects
Toxicity Level reproductive effect of
associated with the
magnesite in humans
ingestion of Sulfuric
Acid
Red skin. Dry skin.

Long term exposure to Itching. Skin
high dust concentrations rash/inflammation.
Severity of Chronic
may cause changes in Affection/discoloration
Effects
lung function of the teeth.
(pneumonia) Inflammation/damage of
the eye tissue.
(from MSDS of ScienceLab, Toxicological Review of Ammonia, Toxicological
Review of Nitric Acid)
56
V. ENVIRONMENTAL ASPECT
Environmental hazard level of raw materials is analyzed, which
may be seen in table 6.26, based on the corresponding hazards that it
may cause to environment. Basis for attaining the level of hazard to
the environment was in table 6.27, which explains in detail the
possible environmental hazards of the raw materials and from the
information in table 6.26 environmental hazard rating was made
taking 0 – for minimal hazard and no significant risk to environment,
1 - slight hazard or minor reversible damage possible, 2 - moderate
hazard temporary or minor damage may occur, 3 - serious hazard
major damage to environment unless prompt action is taken, 4 -
severe hazard, permanent damage may result.
57
Table 6.26 Environmental hazard level scores of raw materials in

Neutralization Process
Raw Materials
Level of
Measure Magnesite Sulfuric Acid
Importance
Toxicity on Plants and
0.20 0 2
Animals
0.20 1 1
Degradation
Long-term Degradation
0.30 2 0
Effects
Total 1.85
Table 6.27 Basis of Environmental hazard level Scores for Process 3

Raw Materials
Criteria Magnesite Sulfuric Acid
Not classified as
Not classified as
Air Toxicity dangerous for the ozone
hazardous
layer.
Harmful to aquatic life in
Avoid contaminating
Aquatic Toxicity very low concentrations.
waterways
Mild water pollutant.
Shows no
bioaccumulation effect
Harmful to fishes.
Toxicity on Plants and or food chain
Exposure to animals may
Animals concentration toxicity.
cause acute toxicity.
But may affect aquatic
life.
Compound is May evolve toxic gases
biodegradable, unlikely when heated to
Degradation
to persist decomposition.
No effect on ozone layer,
but magnesites are
Long-Term Degradation generally came from Avoid releasing to the
Effects mining which has a long environment
term effect in the
environment
(from MSDS of ScienceLab, PraxAir, OCI Nitogen)
58
SUMMARY OF EVALUATION OF THE THREE PROCESSES FOR

THE PRODUCTION OF MAGNESIUM SULFATE HEPTAHYDRATE
Table 6.28 Summary of Evaluation of the Three Processes
Stirring Neutralization of
Calcination
CRITERIA Crystallization Sulphuric Acid
Process
Technique Process
Magnesium
Dolomite Stone Hydroxide is not Magnesite
and Sulfuric Acid readily available dominantly
are readily in the Phiippines available in the
available in the while the Sulfuric China and
Philippines. For Acid is. For Sulfuric Acid is
the dolomite Magnesiun readily available
stone, there is a Hydroxide, it will in the Philippines.
local mining be supplied from For magnesite, a
company a company from mining company
Availability of specifically JFE China called specifically
Raw Materials Mineral Weifang Kaibo Yingkou Huafei
Company, Ltd. Magnesium Salt Trade Co. Ltd.
For sulfuric acid, Co., Ltd. For For sulfuric acid,
the local sulfuric acid, the the local
manufacturer is local manufacturer is
TNC Chemicals manufacturer is TNC Chemicals
Philippines Inc. TNC Chemicals Philippines Inc.
which can sustain Philippines Inc. which can sustain
the supply for the which can sustain the supply for the
production. the supply for the production.
production.
59
For Stirring For the For Neutralization

Crystallization Calcination of Sulfuric Acid,
Technique, the Process, the total the total capital
total capital capital investment investment to
Total Capital
investment to to start a plant is start a plant is
Investment
start a plant is ₱ 255,842,129.61 ₱ 240,184,674.01
₱ 253,840,797.10 which the most which is the
which is cheaper expensive among cheapest among
than Process 2. the process. the process.
The annual The annual

The annual
production costs production costs
production costs
for Process 2 is for Process 3 is
for Process 1 is
₱ 202,308,269.33 ₱ 192,690,118.04
Annual ₱ 201,078,879.36
based on the cost based on the cost
Production Cost based on the cost
estimation done. estimation done.
estimation done
The cost is the The cost is the
which is cheaper
most expensive least expensive
than Process 2.
among the three. among the three.
For this process,

For this process, For this process,
the raw materials
the raw materials the raw materials
needed are
needed are needed are
magnesium
dolomite and magnesite and
hydroxide and
Price of Raw sulfuric acid, sulfuric acid,
sulfuric acid,
Materials which are priced which are priced
which are priced
at ₱ 2,920.43/ton at ₱ 34,835.17/ton
at ₱ 25,000.00/ton
and ₱ and
and
20,341.71/ton ₱ 20,341.71/ton
₱ 20,341.71/ton
respectively. respectively.
respectively.
60
For the Stirring

For the
Crystallization
Calcination For the
Technique, the
Process, the Neutralization
number of energy
number of energy Process, the
Energy Intensive intensive
intensive number of energy
Equipment in equipment is 4.
equipment is 5. intensive
the Process The Continuous-
Calciner, Washer, equipment is 2.
Stirred Tank
Filter Unit, Reactor, and
Reactor, two
Reactor, and Crystallizer.
Crystallizers, and
Evaporator.
Evaporator.
Purity of Final
98% 99.5% 99%
Product
For Process 1, the For Process 2, the For Process 3,

operating operating operating
temperature temperature temperature
Operating
ranges from 20 to ranges from 30 to ranges from 40-
Parameters
200 oC. Operating 500 oC. Operating 200oC. Operating
pressure ranges pressure ranges pressure ranges
from 0.5 to 1 bar. from 0.5 to 2 bas. from 0.5 to 2 bas.
Material handling For Process 2, the

is one of the main total weighted For the Process 3,
concern in putting score is 2.20 the total weighted
up a plant, which has the score is 3.20
Toxicological
toxicological lowest risk among which has the
Rating
rating is one of the three highest risk
the basis to processes. Note among the three
overview the that the lower processes.
material handling. total weighted
61
For Process 1, the score, the safer

total weighted the material
score is 2.75. handling.
In Process 1,
there is no In Process 3,
In Process 2, the
accounted long-term
magnesite may
emissions from degradation effect
affect the aquatic
Environmental all the equipment. is a risk. the
life when action is
Hazards of Raw The total environmental
not taken. The
Materials weighted score hazard score is
total weighted
for this process is 1.85 which has
score for this
1.55 which is the the highest score
process is 1.70.
lowest among the among the three.
process.
62
Table 6.29 Quantitative summary for the three processes’ evaluation
ATTRIBUTES P1 P2 P3
Economics (Php, ₱)
Price of Raw Materials 23,262.14 45,341.71 55,176.88
Total Capital Investment 253,840,797.10 255,842,129.61 240,184,674.01
Total Annual Production Cost 201,078,879.36 202,308,269.33 192,690,118.04
Manufacturability
Purity 98.00% 99.50% 99.00%
Number of intensive equipment 4.00 5.00 2.00
Safety
Operating parameters 3.00 1.00 2.00
Health Hazard 2.00 3.00 1.00
Toxicological Rating 2.75 2.20 3.20
Sustainability
Availability of Raw Materials 3.00 2.00 2.00
Environmental Impact
Environmental Hazards 1.55 1.70 1.85
63
Table 6.30 Normalized scores of the three processes
ATTRIBUTES P1 P2 P3
Economics
Price of Raw Materials 3.00 1.80 1.26
Total Capital Investment 2.84 2.82 3.00
Total Annual Production Cost 2.88 2.86 3.00
Manufacturability
Purity 2.95 3.00 2.98
Number of intensive equipment 1.80 1.20 3.00
Safety
Operating parameters 3.00 1.00 2.00
Health Hazard 2.00 3.00 1.00
Toxicological Rating 2.40 3.00 2.06
Sustainability
Availability of Raw Materials 3.00 2.00 2.00
Environmental Impact
Environmental Hazards 3.00 2.76 2.51
Table 6.31 Weighted and Transmuted Score
TOTAL SCORE
ATTRIBUTES WEIGHT
P1 P2 P3
Price of Raw Materials 0.05 0.15 0.09 0.06
Total Capital Investment 0.10 0.28 0.28 0.30
Total Annual Production Cost 0.20 0.58 0.57 0.60
Purity 0.10 0.30 0.30 0.30
Number of energy intensive equipment 0.15 0.27 0.18 0.45
Operating parameters 0.05 0.15 0.05 0.10
Health Hazard 0.05 0.10 0.15 0.05
Toxicological Rating 0.10 0.24 0.30 0.21
Availability of Raw Materials 0.10 0.30 0.20 0.20
Environmental Hazards 0.10 0.30 0.28 0.25
TOTAL 2.66 2.40 2.52
64
CONCLUSION
From Table 6.31, it can be seen that the Process 1, the Production of
Magnesium Heptahydrate via Stirring Crystallization Technique, met
most of the criteria that was set above. All of its raw materials are locally
available and has the lowest raw material cost. Raw materials of Process
1 are safe to use because there is no known reproductive toxicity effect
on humans. Environmentally, it can be seen that the Process 1 is the best
process since the raw materials has no known effect on the ozone layer.
Based on the evaluation, Process 1 is the most feasible process that can
be used in this design project.
65

Process Selection 0

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Technological Institute of the Philippines

Process Selection plays an important part in overall design of production

and operations management systems. Process Selection allows an organization

effective capacity planning. With the help of process selection, we can

as well as various automated approaches to processing. Process selection allows

an operations manager to better understand the need for management of

technology. Together with capacity planning it helps an organization to develop

different approaches to meet the irregular demand pattern of the customers.

(PROCESS SELECTION: Types of Operation, Intermittent Processing)

will consider; Sustainability, Economics, Manufacturability, Safety and

EVALUATION OF THE THREE PROCESSES FOR THE

PRODUCTION OF MAGNESIUM SULFATE HEPTAHYDRATE

Production of Magnesium Sulfate Heptahydrate from Dolomite with

Dolomite is a mineral usually composed of calcium magnesium carbonate

(CaMg(CO3)2). It is a type of limestone which has a saddle-shape crystal and is

most likely to exists in sedimentary and metamorphic rocks. The harvested

then to a roll crusher to refine its size to approximately 1 mm.

heavier particle (calcium oxide and magnesium oxide containing particles)

diluted sulfuric acid.

CaMg(CO3)4 + 2 H2SO4 → CaSO4 + MgSO4 + 2 CO2 + 2 H2O

Leaching base on dolomite reaction with sulfuric acid

MgO + H2SO4 → MgSO4 + H2O

CaO + H2SO4 → CaSO4 + H2O

Calcium Oxide and Magnesium Oxide reaction

remains at the solution. The solution is then evaporated at 100ºC to 110ºC to

The concentrated solution is then fed to an agitating tank to reduce the

temperature before undergoing a crystallization process. The crystallization

dried to remove the excess moisture.

A common rock forming mineral made of calcium

magnesium carbonate (CaMg(CO3)2). It is a primary component

of the sedimentary rock, dolostone, and the metamorphic rock,

dolomitic marble. It has a pearly luster and a transparent to

translucent diaphaneity. Dolomite is very similar to the mineral

calcite although dolomite is slightly harder.

Philippine Mining Service Corporation (PMSC)

Address: 5th Floor, Mercedes-Benz Tower, Mindanao Avenue,

Cebu Business Park, Cebu City 6000, Philippines

Contact Number: +63 32 415 8740

A colorless, slightly viscous liquid that is usually diluted

with water. Sulfuric acid is a strong acid which is characterized

by its hygroscopic and oxidizing properties, it is chemically and

thermally stable. Dilute sulfuric acid is a strong dibasic acid which

dissolves all base metals.

TNC Chemicals Philippines, Inc.

Address: Km. 56 Bo. Turbina, Calamba, Laguna, Philippines

Contact Number: +63 28 403 7725

Cost of Raw Materials

Table 6.1 Price of Raw Materials in Stirring Crystallization

Raw Materials Price (₱ per ton)

The estimated fixed capital cost required for the production of

Magnesium Sulfate Heptahydrate via Stirring Crystallization

Technique is computed using Lang method, factor for fluids

processing taken from Perry’s Chemical Engineering Handbook 8th

Table 6.2 Lang Factors

PPC = PCE (1 + f1 + … + f9) = PCE x 3.40 3.15 2.80

f10 Design and Engineering 0.30 0.25 0.20

Where: Cf = fixed capital cost

Table 6.4 Detailed Estimation of Fixed Capital Cost of Equipment for

Total Equipment Cost (PCE) = ₱ 74,100,579.34

Total Physical Plant Cost (PPC):

𝑇𝑜𝑡𝑎𝑙 𝑃ℎ𝑦𝑠𝑖𝑐𝑎𝑙 𝑃𝑙𝑎𝑛𝑡 𝐶𝑜𝑠𝑡 = 𝑃𝐶𝐸 ( 1 + 𝑓1 + 𝑓2 + 𝑓3 + 𝑓4 + 𝑓5 )

𝑃𝐶𝐶 = ₱ 74,100,579.34( 1 + 0.45 + 0.45 + 0.15 + 0.10 + 0.10 )

𝑷𝑷𝑪 = ₱ 𝟏𝟔𝟔, 𝟕𝟐𝟔, 𝟑𝟎𝟑. 𝟓𝟐