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| Author | : Mohammed ElFaki |
| Publisher | : |
| Total Pages | : 246 |
| Release | : 2018 |
| Genre | : |
| ISBN | : |
| Author | : Amal Radwan Jamal Eddin |
| Publisher | : |
| Total Pages | : 424 |
| Release | : 2018 |
| Genre | : |
| ISBN | : |
Most of the industrial processes nowadays are accompanied by the usage of intermediate products in order to obtain the final desired product. Intermediate products are products that need to be further refined by the producer before they are sold to the target consumer. The idea of having an intermediate product is very useful for the industries, as these compounds are further processed rather than being directed into an incinerator or to waste treatment. Acrolein is one of the chemicals that are considered to be intermediate materials for the production of other materials used in day-to-day life.The aim of this project is to design a chemical plant that produces 60,000 tons/year capacity of acrolein with a high purity of approximately 98% from a raw material which was selected to be propylene. This final decision of the best raw material to select was taken after going through the general steps for selecting a raw material. Starting with the elimination based on yield, selectivity, and lack of practical foundation, followed by the elimination based on gross profit analysis, as well as the availability of the raw material in United Arab Emirates. Material balance calculations were done on a selected process flow diagram in order to know how much material should be fed to the process and at what flow rate does the product, by-product, and the unreacted materials leave and exit each single unit achieving the desired capacity material. In addition, energy balance calculations were done around around each piece of equipment installed in the process plant. Operating conditions were assumed based on different studies and sources and material and energy balance equations were applied properly. The process flow diagram was modified to overcome the challenges of the process where heat integration was applied on the reactor process since the reaction is extremely exothermic. In addition, a recycle stream was added in order to recycle all the raw material and reach 100% conversion of propylene, Moreover, since a huge amount of water was found leaving a process stream, it was suggested to treat the water and deionize it for the aim of it being used. From various equipment installed in the process plant, one from each of the main equipment were designed including, heat exchangers, reactors, fractionators, flash distillation columns, liquid-liquid extraction columns, pumps, and compressors. When designing each single equipment appropriate detailed design calculations were followed. The area of the shell and tube heat exchanger (E101) was found to be of 13430.5 ft2. The reactor (R101) diameter was found to be 0.385m with a length of 1.1553 m. The detailed design calculation of the extraction column (T101) shows that the height of the column is to be 45.88m. For, the fractionator (T103), the number of trays were found to be 11 stages. The diameter and length were 0.6 m and 9.4 respectively. The diameter and the length of the flash distillation column (T106) were found to be 15.1 m and 46 m respectively. Based on the head and flow rates, Pump (P101) type was selected to be centrifugal. The power out of the pump was found to be 36.98 hp while the power in to the pump was found to be 57.78 hp. A compressor (C104) was found to be of a type rotary compressor with a work of 290 kw. The number of compressor stages were found to be 2 stages. A process economic analysis was done on the constructed plant to determine whether the plant at hand is a good investment or not. The plant capital cost was found to be 40, 959, 756.7 US dollars, the manufacturing cost was found to be 207, 206, 460.6 US dollars a year. The revenue was found to be 219, 834, 000 US dollars. Based on the undiscounted analysis, the rate of return was found to be 14.7% and the payback period is approximately 4 years. Based on the discounted profitability analysis, the discounted rate was found to be 14.7%. The ethical, safety, and environmental issues related to the designed chemical plant of acrolein production were discussed in detail in this project.
| Author | : Areej Elsharabaty |
| Publisher | : |
| Total Pages | : 572 |
| Release | : 2018 |
| Genre | : |
| ISBN | : |
Through the 20th century, and since the inventory of the first ammonia synthesis device by Haber, the catalytic ammonia synthesis process took the attention of many scientists and researchers. It is one of the mankind largest synthetic chemical reactions that has a strategic importance in the chemical industry. The aim of this project is to design a chemical plant that produces 300, 000 tons/year of ammonia from pure nitrogen and hydrogen. The project utilizes post CO2 capture process, and Haber process [sic] for the production of ammonia, where post CO2 capture is used to get nitrogen from exhaust gas of power plants , and Haber process[sic[ to synthesize ammonia over an iron oxide catalyst. A detailed process flow diagram was made for the process, and, material and energy balances were performed on the whole process. The required amount of nitrogen and hydrogen needed for the process were found to be 30280.8 kg N2 /hr and 6550.48 kg H2 /hr respectively. Detailed design calculations were constructed for one unit from each equipment in the plant, including an absorber, a heat exchanger, a compressor, a pump, a mixer, ammonia reactor, and ammonia storage tank. The design included calculations such as height, diameter, volume and are, in addition to the catalyst for the ammonia reactor. Economic analysis was constructed , and the plant was found to be profitable with a payback period of 7 years. HAZOP was constructed for all the designed units as environmental impacts and ethical issues of the process were discussed.
| Author | : Mohamed Adil |
| Publisher | : |
| Total Pages | : 286 |
| Release | : 2017 |
| Genre | : |
| ISBN | : |
Hydrogen is the first element in the periodic table and the most abundant element on earth. Also, around 75% of the universe's mass consists of it, moreover; it's one of the main factors in chemical industry as it's considered the starting brick in the manufacturing of ammonia, methanol and polymers. Around 50 million tons of hydrogen is produced every year in the world. it comes from different sources, some are really expensive like the Electrolysis of water and other unsafe methods that may raise some issues with the environmental laws. The biodiesel production process offers a huge amount of crude glycerol that can be used after purification to produces tons of hydrogen and at the same time it's considerably safe. Our goal is to design a chemical plant that produces hydrogen from crude glycerol at a rate of 35, 000 ton/yr with a purity of 99%. The method used in this project was steam reforming because of the many advantages of it among other methods like supercritical and auto-thermal , giving higher conversion and purity. Process Flow Diagram was created to be the first and the main fundamental block for this project, moreover; mass and energy balance calculations were done by starting with a 10,000 ton/yr of crude glycerol then performing a scale up to identify the real amount needed to produce the required hydrogen. Following this a design of three units: absorber, heat exchanger and the steam reformer reactor, then a cost estimation was done for the whole design and the design was done to meet the regulation of the environment by performing a safety and hazardous investigation.
| Author | : Mirza Mustafa Baig |
| Publisher | : |
| Total Pages | : 316 |
| Release | : 2017 |
| Genre | : |
| ISBN | : |
The aim of this report was to design a chemical plant producing 55, 000 tons/year Hydrogen with 99% purity. The complete plant was designed from cradle to grave and detail explanation of every unit has been provided. The plant is mainly divided into two essential parts namely purification and reformer. At first crude glycerol goes under several process and attains purity of 99% and then pure glycerol undergoes numerous process under high pressure and temperature to produce Hydrogen and side product carbon dioxide. Designing was accomplished by using different software. Three equipment 's were designed namely Shell and tube heat exchanger, reformer and Absorber. The design of shell and tube heat exchanger added more information to our knowledge, the height, area, number of baffles, baffle spacing, number of tube, shell and tube diameter all these information were calculated using conventional calculation and using excel sheet. Secondly, reformer was designed using another software name polymath, this software helped us to solve multiple differential equations by which we were able to find the weight of the required catalyst Ni/Al2O3, to reach conversion of 95% with specified diameter and the length of the catalyst. Finally, the third equipment was designed by using conventional calculations and excels sheet formulas to ease calculation. The design gave us the results by providing us with the cross sectional area, overall height of transfer unit, and height of packed bed without allowance for end.
| Author | : Sarah Muhammad Tasleem |
| Publisher | : |
| Total Pages | : 312 |
| Release | : 2018 |
| Genre | : |
| ISBN | : |
This report was done with the core purpose of designing a plant which produces an annual amount of 60, 000 tons of acrylic acid. It follows a series of detailed description of the mentioned chemical compound and the pathways through which it can be synthesized.Based on several factors, one pathway along with the detailed analysis of the required industrial raw materials and equipments is introduced and demonstrated through a process flow diagram, and the mass and energy balance along each unit is then analysed. The selected pathway is through the two -step oxidation of propylene, and the process uses two catalysed reactors (the first for acrolein yield and the second for acrylic acid yield), a gas absorption column for removing the reactors' undesired by products using water as solvent, a liquid-liquid extraction unit to separate the desired acid from water using iso-propyl ether as the solvent, a solvent recovery unit and 2 more distillation units for further purification. Using the end product flow rate of 60, 000 tons/year and calculations based on conversions and stoichiometry, the inlet flow rates of the three streams are dtermined to be 110.64 kmol/hr of propylene, 790.286 kmol/hr of air, and 125.4 kmol/hr of steam . Energy balances around the elements of the entire process flow diagram was performed and the detailed design of each type of equipment was determined. Based on the parameters of the design , the costs and profitability of the proposed plant was analysed, and from the results obtained, the payback period is determined to be 6 years , and the rate of return on investment is 11.37%. Following the chapter of profitability analysis, ethical and safety issues of the project (such as HAZOP), and factors of project management are to be discussed in detail as well.
| Author | : |
| Publisher | : |
| Total Pages | : 484 |
| Release | : 1970 |
| Genre | : Fertilizers |
| ISBN | : |
| Author | : Eqbal Ahmed Amer |
| Publisher | : |
| Total Pages | : 480 |
| Release | : 2017 |
| Genre | : |
| ISBN | : |
This project aims to utilize the by-product crude glycerol coming from the production of biodiesel and transform it into a form that is more environmental friendly and useful like hydrogen. The purpose of this project was to produce a 99% pure hydrogen from crude glycerol and with a capacity of 70, 000 tons/year. The process design was divided into two main processes, which are the purification of crude glycerol process and the hydrogen production process. A detailed process flow diagram was made for both processes. Mass and energy balance calculations were performed on both processes. The mass balance calculations showed that the final product stream contained 7910 kg/hr of hydrogen along with 79.9 kg/hr of impurity containing carbon dioxide. In addition, detailed design calculations were performed on three major pieces of equipment, which include the steam reforming reactor, the CO2 absorber, and a heat exchanger. The detailed design included calculations such as the height, diameter, volume and area, in addition to the catalyst weight for the steam reforming reactor. The total capital cost for this plant design was calculated and found to be approximately 43.4948 million dollars. Throughout this project, several programs were used that included mainly Microsoft Excel program, Aspen Hysys, and Polymath. In addition, there were several challenges faced in each step of the project that included difficulty in finding the desired information, and time limitation as this project was performed over the course of only one semester.
| Author | : Sana Eid |
| Publisher | : |
| Total Pages | : 466 |
| Release | : 2017 |
| Genre | : |
| ISBN | : |
There are increasing concerns regarding the carbon emissions resulting from the use of fossil fuel. Hence, alternative sources of energy are currently being examined; one of these sources being hydrogen. Hydrogen is considered very promising since 1 kg of hydrogen has the same energy as 3 kg of gasoline and is an infinite, safe, and clean source of energy.The best raw material for this process is glycerol since 1 kg of glycerol is generated per 10 kg of biodiesel, and 1 mole of glycerol produces 7 moles of of hydrogen. The aim of this project is to produce 30, 000 ton/year of high purity hydrogen from glycerol. It is noteworthy that a chemical plant for converting glycerol to hydrogen has not yet been done; however, a lot of research about the topic has been conducted resulting in having several methods to select from. The production of hydrogen from glycerol can be done using several methods such as steam reforming, and partial oxidation. Hence, after researching and comparing the different methods the process of steam reforming with Ni/Al2O3 catalyst at 700°C was selected as it produces 99% pure hydrogen. The Ni/AL2O3 catalyst was found by a study to give the highest hydrogen selectivity (80%) and glycerol conversion (71%). There are some challenges to this process such as by-products formation hindering the hydrogen production and its purity; however, there are viable options to overcome them such as using the in-situ adsorption process. After creating the PFD based on available literature and designing a heat exchanger, absorber and steam reformer we found that 507 kg of Ni/Al2O3 are needed to produce 30,000 tons per year of hydrogen. 350,000 tons per year of glycerol are required for producing 30,00 tons per year of hydrogen. Furthermore, the design process resulted in knowing the equipment's specifications. The designed shell and tube heat exchanger with 3/4" OD tubes (14 BWG) on a 1"square pitch, 25% segmental cut baffles and 90 tubes, with a shell diameter of 13.24", and a tube internal diameter of 0.584" has been made to cool down the outlet gas mixture. On the other hand, the absorber required to get rid of the CO2 present in the final gas mixture in order to achieve 99% pure hydrogen has been made with a cross sectional area of 1.54 m2 , a diameter of 1.4 m, a pressure drop of 418 Pa/m, and an overall packed bed height of 4.9 m. Cost is another important factor to be taken into consideration while designing a chemical plant. The total cost for the desired chemical plant was found to be approximately 94 million dollars. The cost of the individual three designed process units: heat exchanger, absorber, and steam reformer were found to be 27, 088 dollars, 272,541 dollars and 35, 458 dollars respectively.
| Author | : |
| Publisher | : |
| Total Pages | : 1210 |
| Release | : 1966 |
| Genre | : Consular reports |
| ISBN | : |
