Production of LABSA

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Production of Sulfonic Acid Salts

United Arab Emirates UniversityCollege of Engineering

Chemical Engineering Department Graduation Project II

Group Members:

Ahlam Mohammed 200211739Kholoud Sahool 200221677Maitha Muftah 200203114

Project Advisor: Dr. Basim Abu-Jdayil

GPII-Production of Sulfonic Acid Salt

Outline

Introduction

Objective

LABSA Production Process Modification

Equipment Design

Cost Estimation

HAZOP Study

Site Location

Conclusion and Recommendation

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.

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.

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.

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

Modified LABSA Process PFD

GPII-Production of Sulfonic Acid Salt8

Equipment Design

Sulfur Melter

The melter aims to transform the solid sulfur to liquid by using hot steam.

3802.3 mV

kJQ 5680

The calculated Parameters:

Heat Exchanger

Heat exchanger is a devise that is used to transfer thermal energy from one fluid to another without mixing the two fluids.

Air Dryer Unit

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

SO2 Reactor The SO2 Reactor is a Plug Flow Reactor (PFR) which is used for

chemical reactions in continuous and flowing systems.

SO2-SO3 ConverterThe SO2-SO3 converter is a typical PFR packed with some solid

material (V2O5).

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

Gas-Liquid Separator

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

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

Absorber

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

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

GPII-Production of Sulfonic Acid Salt20

Cost Estimation

Cost estimation is used to estimate the future cost of the chemical plant and provide the engineer with generalexpectation for the budget preparation.

To calculate the capital cost the following steps where followed:

1) Calculate the purchased cost (Cpo):

210310210

10 )(log)(loglog AKAKKC p

Capital Cost Estimation

2) Calculate the bare module (FBM):

3) Calculate the bare module cost (CBM):

4) Find the grass root cost (CGR) :

pMBM FFBBF 21

PBM FCC

iiBMTM CC,

TMGR CCC ,5.0

• Capital Cost Estimation for the LABSA Process:

)05.1(2001cos

2005cos 32001,2008, GRGR C

indext

indextC

Capital Cost Estimation

CTM= $2631712.71

CGR,2001= $3252328.70

CGR,2008= $4440207.145

Operating Labor Cost Estimate

Calculating the cost of operating labor (COL) helps in

estimating the labor requirement for the LABSA process.

5.02 )23.07.3129.6( npOL NPN

npN Equipment Summation

P Solid Handling

Operating Labor Cost Estimate

OLN 6.366

Operating Labor= 4.5 x 6.366 = 28.645 ≈ 29 operators

)2001(OLC 29 x $50,000 = $1432244.742/yr

Cost of Operating Utility

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

CUT= $ 562601.55/yr

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:

tonCostSulfur /320.337540$95.0

136524338

kmolCostLAB /968.40972900$95.0

1$205036524240007.10

tonCostNaOH /614.139257$95.036524

295.113$1477.0

yrCRM /902.41449698$

Waste Treatment Cost It is important to calculate the waste treatment cost (CWT)

because it helps protecting the environment from pollution:

kgCostWasteDryerAir /992.996$95.0

41365241922.2

tonCostWasteAbsorber /533.59$95.0365241000

561152.0

CWT= $1056.525/yr

Total Manufacturing Cost The cost of manufacturing (COM) is the total operating cost per year:

)(23.173.2280.0 RMWTUTOL CCCCFCICOM

COM = $ 56829715.232/yr

yrofit /522.7268204$Pr

Profit = Income – Total Costs

HAZOP Study

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

HAZOP Study for Gas-Liquid Separator (Flow Deviation)

Guide Word Deviation Causes o Consequences Action

No Flow Valve failure Pipe failure

o Plant shut downo No product Repair valve Repair pipe

Less Flow Valve blocked Pipe blocked Pipe leak

o Less producto Less performance of plant Clean pipe Repair leakage Fit low flow alarm (FAL)

More Flow Valve failure LC failure

o More producto Flooding and overflow Repair valve Repair LC Fit high flow alarm (FAH)

HAZOP Study for Gas-Liquid Separator (Temperature Deviation)

Guide Word Deviation Causes o Consequences• Action

Less Temperature No separationLess efficiency o Less product

o Less performance Clean pipe Repair leakage

More Temperature No separationLess efficiency o More product

o Flooding and overflow Repair valve Repair LC

• 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 dioxidewith caustic soda

Site Location

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.

Other Site Location Factors

Site Location Case Study Evaluation Results:

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.

Thank you for your Attention

Production of LABSA

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