Production of Sulfonic Acid Salts

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Production of Sulfonic Acid Salts
United Arab Emirates UniversityCollege of
EngineeringChemical Engineering Department
Graduation Project II
Group Members
Ahlam Mohammed 200211739 Kholoud
Sahool 200221677 Maitha
Muftah 200203114
Project Advisor Dr. Basim Abu-Jdayil
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Outline
Equipment Design
Introduction
HAZOP Study
Objective
Site Location
Cost Estimation
LABSA Production Process Modification
Conclusion and Recommendation
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Introduction

• The UAE is considered as one of the most
  important countries in the oil and gas industry.

• Huge amounts of sulfur are produced from the
  desulphurization process and sold to the chemical
  plants.

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Objective

• The aim of this project is to utilize the sulfur
  from the oil and gas industry to produce Linear
  Alkyl Benzene Sulphonic Acid Salt (LABSA).
• The aim of GP2 is to design the equipment in the
  LABSA plant.

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GP1 Accomplishments

• Selecting the LABSA as the product in the
  sulfonic acid salt plant.
• The Sulfur Trioxide Technique was chosen as the
  best method for producing LABSA.
• Applying the mass and energy balance on the
  process.
• Determining the capacity of the plant which was 1
  ton per year.

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LABSA Production Process Modification

• LABSA Plant Capacity
• In GP1 the amount of LABSA produced was 1 ton per
  year.
• In GP2 the capacity increased to 30,000 ton per
  year.
• Modified LABSA Process
• The modifications include the addition of
  different equipment in the plant and they are

• Air dryer Unit
• Compressor
• Pumps
• Storage Tanks

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Modified LABSA Process PFD
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Equipment Design
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Sulfur Melter
The melter aims to transform the solid sulfur to
liquid by using hot steam.
The calculated Parameters
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Heat Exchanger
Heat exchanger is a devise that is used to
transfer thermal energy from one fluid to
another without mixing the two fluids.
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Air Dryer Unit

• The air dryer is a column packed with desiccant
• material which selectivity holds the water.

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SO2 Reactor

• The SO2 Reactor is a Plug Flow Reactor (PFR)
  which is used for
• chemical reactions in continuous and flowing
  systems.

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SO2-SO3 Converter

• The SO2-SO3 converter is a typical PFR packed
  with some solid
• material (V2O5).

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Sulphonation Reactor

• Sulphonation reactions are preferred to be
  conducted in multitube falling film reactors.

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Gas-Liquid Separator

• The gas-liquid separators are vertical vessels
  used to
• separate the liquid from the gas stream by
  gravity.

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Cyclone

• Cyclones are widely used as gas-solids separators
  by
• employing centrifugal force also they are
  frequently used
• for gas-liquid separation.

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Absorber

• Absorbers are packed columns where the gas and
  liquid are contacted continuously.

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Pump
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Compressor

• A gas compressor is a mechanical device that
  reduces the
• gas volume by increasing the pressure. To design
  the compressor the type and the actual power are
  determined.

• Centrifugal Compressor
• Actual Power 118.1246 kW 120 kW

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Cost Estimation
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Cost Estimation

• Cost estimation is used to estimate the future
  cost of
• the chemical plant and provide the engineer with
  general
• expectation for the budget preparation.
• To calculate the capital cost the following steps
  where
• followed
• Calculate the purchased cost (Cpo)

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Capital Cost Estimation

1. Calculate the bare module (FBM)
2. Calculate the bare module cost (CBM)
3. Find the grass root cost (CGR)

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Capital Cost Estimation

• Capital Cost Estimation for the LABSA Process

CTM 2631712.71 CGR,2001 3252328.70 CGR,2008
4440207.145
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Operating Labor Cost Estimate

• Calculating the cost of operating labor (COL)
  helps in
• estimating the labor requirement for the LABSA
  process.

Equipment Summation
Solid Handling
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Operating Labor Cost Estimate
6.366
Operating Labor 4.5 x 6.366 28.645 29
operators
29 x 50,000 1432244.742/yr
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Cost of Operating Utility

• The cost of each utility required by the LABSA
  production
• process is calculated (CUT)

CUT 562601.55/yr
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Raw Material Cost

• The raw material cost (CRM) is calculated by
  knowing the
• price of the raw material and the chemical feed
  stocks
• required by the process

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Waste Treatment Cost

• It is important to calculate the waste treatment
  cost (CWT)
• because it helps protecting the environment from
  pollution

CWT 1056.525/yr
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Total Manufacturing Cost

• The cost of manufacturing (COM) is the total
  operating cost
• per year

COM 56829715.232/yr
Profit Income Total Costs
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HAZOP Study
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HAZard and Operability Studies

• The HAZOP study technique makes use of a series
  of
• parameters and guide words.
• The objectives of the HAZOP study are
• Identify all potential causes of the process
  disturbance which could lead to significant
  safety.
• Recommending suitable modifications which reduce
  the risks

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HAZard and Operability Studies
HAZOP Study for Gas-Liquid Separator (Flow
Deviation)
Consequences Action Causes Deviation Guide Word
Plant shut down No product Repair valve Repair pipe Valve failure Pipe failure Flow No
Less product Less performance of plant Clean pipe Repair leakage Fit low flow alarm (FAL) Valve blocked Pipe blocked Pipe leak Flow Less
More product Flooding and overflow Repair valve Repair LC Fit high flow alarm (FAH) Valve failure LC failure Flow More
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HAZard and Operability Studies
HAZOP Study for Gas-Liquid Separator (Temperature
Deviation)
Guide Word Deviation Causes Consequences Action
Less Temperature No separation Less efficiency Less product Less performance Clean pipe Repair leakage
More Temperature No separation Less efficiency More product Flooding and overflow Repair valve Repair LC
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HAZard and Operability Studies

• Chemical Waste

The absorber chemical waste consists mainly of
Sulfuric Acid (H2SO4) and Sodium Sulfite
(Na2SO3)

• The H2SO4 is formed by the reaction of water
  with sulfur trioxide

• The Na2SO3 is formed by the reaction of sulfur
  dioxide
• with caustic soda

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Site Location
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LABSA Plant Site Location

• Determining the location of the LABSA plant is
  considered an essential factor in designing any
  plant.
• Selecting the suitable location for the plant
  helps in lowering the cost of some important
  factors such as transportation and raw material
  supply.

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Other Site Location Factors
Site Location Case Study Evaluation Results
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Conclusion and Recommendation

• In the plant the sulfur is utilized to produce
  LABSA.
• The Sulfur Trioxide Technique is considered the
  best method because it utilizes the sulfur and
  reduces the amount of toxic gases.
• All the equipment in the plant are designed by
  calculating their dimensions.
• The project profit is 7,268,204.522/yr which
  makes the project profitable.
• Abu-Dhabi is selected as the best location for
  the LABSA plant.
• The sulfur enters another industries such as
  manufacturing fertilizers and producing sulfuric
  acid.

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• Thank you for your Attention

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