United Arab Emirates University

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United Arab Emirates University College of
Engineering Chemical and Petroleum Engineering
Department Graduation Project II
Design of an Integrated Process for the
Production of Acetylene with Minimum Waste
Generation
Students Names
ID Mohamed Faisal Al-Ali 200200988 Abdulla
Ahmed Al-Hosani 200235709 Yousef
Al-Hosani 200101288
Project Advisor Dr. Muftah El-Naas Presented to
Coordinator Dr. Mamdouh Ghannam
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Contents

• Introduction
• Problem Definition
• Objective
• Equipments Design
• Condenser
• Air Heater
• Compressor
• Pump
• Cyclone
• Dryer
• Cost Estimation
• Environmental Impact HAZOP
• Conclusion

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Introduction

• Production of acetylene involves the reaction of
  solid calcium carbide with water in semi-batch
  reactor

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Problem Definition

• This process generates huge amount of calcium
  hydroxide slurry that presents major economical
  and environmental challenges to acetylene
  industry

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Objective

• The objective of this project is to design a
  process for management calcium hydroxide, where
  it will convert the generated calcium hydroxide
  into a useful and valuable product

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Process Design

• The process consists of six units
• Gas compressor
• Air heater
• Jet spouted bed dryer
• Cyclone
• Condenser
• Pump

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Process Design
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• Equipments Design

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• Condenser

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The steps in a typical design procedure
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Condenser

• Q394 kW
• Th,in 120?C, Th,out 60?C
• Tc,in 30?C, Tc,out 45 ?C
• calculate the mean temperature difference

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Condenser Design

• Q 394 kW
• A9.2 m2
• Type of H.E
• Shell and tubes (Horizontal)
• Condensation in the shell side
• Length of tubes 1 m
• Number of tubes 155 tubes
• Bundle diameter 0.4 m

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• Air Heater

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Air Heater

• A fired heater is a direct-fired heat exchanger
  that uses the hot gases of combustion to raise
  the temperature of a feed flowing through coils
  of tubes aligned throughout the heater.
• Applications
• Hydrocarbon and chemical processing industries
  refineries
• Gas plants
• Petrochemicals
• Chemicals and Synthetics
• Ammonia and fertilizer plants

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Air Heater

• Inlet to furnace
• Fuel Methane (CH4)
• Air
• CH4 2 O2 2H2O CO2
• Heating Value for CH4 55,508.73 kJ/kg
• Rate duty 791,464 kJ/hr
• Amount of Methane needed 14.3 kg/hr
• Excess Air 20
• Amount of Air fed 295 kg/hr

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• Compressor

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Compressor

• A gas compressor is a mechanical device that used
  to increases the pressure of a Compressible fluid
  by reducing its volume.
• The most common type of compressor is
  reciprocating, rotary van compressors, rotary
  screw compressor and Centrifugal compressor.

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Compressor Design

• Requirements
• 1-Determine compressor type2- Compressor
  efficiency
• 3- Reversible adiabatic Power
• 4- Actual power

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Unit Value  
atm 1 Inlet pressure
atm 5 Outlet pressure
K 333 Inlet temperature
K 528 Outlet temperature
kg/h 4221 Feed mass flow rate
(ft3/min) 2525 Feed volumetric flow rate
  Reciprocating Type
________ 0.85 Efficiency
kW 229 Reversible adiabatic power
kW 269 Actual power
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• Pump

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• Feed flow rate 450 kg/hr
• Discharge pressure 10 atm
• Calculated
• Mixture density
• Volumetric flow rate
• 18058m
• Type selected Rotary pump

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• Fluid pumping power
• Using efficiency 0.8
• Shaft power 0.3 kW

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• Spouted Bed
• Dryer

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• Design Parameter

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• Physical properties of ceramic and air in the
  dryer

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Calculated Parameters
m 1.33 H1
m 1.53 H2
m 0.63 Dp
m3 0.07 Vp
kg of inert particles 134.82 Mass
  478.02 Rms
  1059598 Ar
m/s 3.79 Ums
m/s 18.53 U
m 0.362 h
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• Cyclone

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• The humid air leaving the dryer is sent to a
  cyclone to separate the solid particles.
• Cyclone are the most widely used type of dust
  collector at range 10 to 100µm of solid diameter

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Dimensions of Cyclone
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• Cost
• Estimation

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Cost Estimation

• Capital cost is the cost of the plant ready for
  start-up
• Operating cost is the cost to run the plant

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Capital Cost

• Factor Affecting the Costs Associated with
  Evaluation of Capital Cost of Chemical Plants
• Direct project expenses
• Equipment free on board
• Purchased cost of equipment at manufactures site
• Material required for installation
• Piping, foundation structure support,
  instrumentation electrical and painting the
  equipment
• Labor to install the equipment and material

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Capital Cost

• Factor Affecting the Costs Associated with
  Evaluation of Capital Cost of Chemical Plants
• Indirect project expenses
• Freight, insurance and tax
• Transportation cost for shipping equipment to the
  site
• Construction overhead
• Vacation, sick leave retirement benefit and
  overhead supervisor personnel
• Contractor engineering expenses
• Salaries for the engineering and project
  management personnel on the project

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Capital Cost

• Factor Affecting the Costs Associated with
  Evaluation of Capital Cost of Chemical Plants
• Contingency and fee
• Contingency
• Loss of time due to storms and strikes, small
  change in the design and unpredicted price
  increases
• Fee
• Depending on the type of the plant

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Capital Cost

• Factor Affecting the Costs Associated with
  Evaluation of Capital Cost of Chemical Plants
• Auxiliary facilities
• Site development
• Land, grading and excavation of the site,
• Auxiliary building
• Administration offices, maintenance shop and
  control room, ware-houses and services building
• Off-sites and utilities

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Capital Cost

• Bare Module Cost for Equipment
• Represent the sum of direct and indirect costs
• CBMCop B1B2 Fp FM
• Where
• CBM bare module cost
• Cop purchased cost for base condition (carbon
  steel, 1 atm)
• Fp pressure factor
• FM material factor

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Capital Cost

• Total Module cost and Grass Roots
• The term total module cost refers to the cost of
  making small-to-moderate expansions or
  alterations to an existing facility
• Contingency and fee
• The term grass-roots refers to a completely new
  facility in which we start the construction on
  essentially undeveloped land, a grass field
• Auxiliary facilities

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Capital Cost

• Total Module Cost and Grass Roots

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Total cost manufacturing
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Profit

• Amount of Ca(OH)2299,592 kg/year
• Ratio of operating 0.95 day per year
• Cost of product 15/kg
• Revenue 4,868,370/year
• Profit Revenue Cost of manufacturing
• 
  2,904,035/year

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Environmental Impact HAZOP

• This project is environmental friendly
• Reducing the waste that come from reaction
  between calcium carbide and water to produce
  acetylene.
• By this project, recycle the calcium hydroxide
  slurry to find powder of calcium hydroxide that
  can market again

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Health risks from calcium hydroxide

• Difficulty in breathing
• Internal bleeding
• Hypotension
• Skeletal muscle paralysis, interference with
  action-myosin system
• An increase in blood pH, which is damaging to
  internal organs

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HAZOP

• HAZard
• OPerability
• Methodology
• Guide word (more, less,Non)
• Parameters (Temperature, pressure, flow)

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Example
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Conclusion

• Huge amounts of calcium hydroxide slurry are
  produced in acetylene industry.
• In this project, different options of drying
  slurry were investigated in terms of advantages,
  disadvantages, amounts applied and efficiency in
  drying.
• One of these options (Jet Spouted Bed Dryer) was
  selected.
• Material and energy balance were carried out
• Design and Cost Estimation

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Thank you
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