Thesis & design presentation

CHE 400 Thesis I & II

Suman Sarkar0802019

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STUDY OF DIFFERENT TYPES OF ETP PROCESSES AND TO

DEVELOP A THEORETICAL COST EFFECTIVE MODEL OF

EFFLUENT TREATMENT PLANT (ETP) FOR TANNERIES OF

HAZARIBAGH

Supervisor

Dr. Easir Arafat Khan

Assistant Professor

Department of Chemical Engineering, BUET

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Outline

• Background

• Objective

• Methodology (Experimental/ Simulation Principle-

Procedure)

• Results and Discussion

• Conclusion & Recommendation

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Background:

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In developing countries like Bangladesh water pollution

due to industrial wastewater is a serious concern. Most

of the industries in Bangladesh do not treat their

wastewater properly and let it go to the river which

cause the pollution of river water. These untreated

wastewater has very bad effect on agriculture, aquatic

plant, fish and human health.

Tanneries in Hazaribagh cause massive pollution to

Buriganga and nearby areas of Hazaribagh.

Objectives

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To study the wastewater quality of several industries

and compare with national standards

To study installation & operating cost and efficiency of

different ETP

Compare the ETPs based on installation & operating

cost and efficiency and develop a theoretical cost

effective model of ETP for Tanneries of Hazaribag

Methodology

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Laboratory experiment (BOD, COD, DO, TDS, pH

measurement)

Industrial data analysis (cost analysis)

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Lab Experiment

BOD5 measurement:

Chemical procedure

BOD5 = DO5 – DO1

COD measurement:

Chemical procedure

Heating and instrumental measurement

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Lab Experiment cont’d

Direct instrumental measurement:

DO

TDS

pH

Lab Experiment cont’d

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Aeration(BOD5 )

HeatingCOD

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Lab Experiment cont’d

DO pH

TDS

Lab Experiment cont’d

Parameters

Chemicals

Industry Paint Industry DOE

Waste water

Treated water

Waste Water

Treated water

pH 3 7.3 6.93 7.03 6 - 9

BOD5 450 ppm 38 ppm 250 ppm 16 ppm 50 ppm

COD 1200 ppm 172 ppm 670 ppm 46 ppm 200 ppm

TDS 4288 ppm 1900 ppm 1130 ppm 870 ppm 2100 ppm

DO 0 5.35 ppm 0 6.1 4.5 - 8

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Parameter Tannery Effluent Department of Environment

(DOE)pH 3.88 6 - 9

BOD5(mg/l) 1454 50

COD(mg/l) 3386 200

TDS(mg/l) 14572 2100

DO(mg/l) 0.0 4.5 - 8

Cr(ppm) 987 0.5 (0.1 for Cr6+)

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Lab Experiment cont’d

Industry of Chemicals

Paint Industry

No. of Employee 4 6

Working Shifts 1 3

Working Hours 8 24

Liquid effluent discharge (m3/d)

8 120

Point of discharge Unused open land Pond

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Industrial data analysis

Fixed Cost Annual variable cost

Chemicals Tk. 1300000 Tk. 800000

Paint Tk. 3050000 Tk. 6200000

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Cost analysis

Chemicals

Industry Paint Industry

Chemical Process

Biological Process

Chemical Process

Biological Process

Operating Cost

Tk. 121000

Tk. 78000 Tk. 3550000

Tk. 1252000

Installation Cost

Tk. 410000

Tk. 740000

Tk. 1150000

Tk. 1650000

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Cost analysis cont’d

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Cost analysis cont’d

Cost analysis cont’d

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Cost analysis cont’d

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Installation cost of Biological treatment process

units were larger than Chemical treatment process

units

Operation cost of chemical treatment process was

larger than biological treatment process

Cost analysis cont’d

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Cost analysis cont’d

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Paint Industry produces 10 times more effluent

than Chemicals Production Industry

The ratio of cost of

Material supply = 1.78:1

Consultancy-commissioning-supervision = 1.67:1

Civil work = 4.8:1

Total fixed cost = 2.346:1

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ETP Model

Presence of Cr

Cr neutralization methods

Adsorption

Sawdust

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ETP Model cont’d

Conclusion & Recommendation

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BOD, COD, TDS, DO, pH of treated water will

reach DOE specification

Cr removal will not reach DOE specification

Conclusion

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Conclusion & Recommendation cont’d

Lab experiment

Low cost adsorbent having optimum pH 2.5 – 3.5

Presence of alkalinity, chloride, oil and grease,

phenol compounds, sulfide etc.

Sludge management

Recommendation

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END of

Thesis I & II

CHE 408 Process Design Sessional I & II

Suman Sarkar0802019

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Design of Natural Gas Processing with Hysis

simulation

Supervisor

Dr. Dil Afroza Begum

Professor

Department of Chemical Engineering, BUET

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Outline

• Objectives

• Project definition

• Available Process

• Design Basis

• Process Block Diagram

• Process Flow Diagram (PFD)

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Outline cont’d

• Comparison between raw & products gas

• List of Major Equipments

• Individual Major Equipment Design

• Mechanical Design

• P&I Diagram

• Overall Economic Analysis

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Objectives

Ensuring more efficient and profitability Design

Improving plant control, operability

Reducing human error and time requirement

Eliminating process bottle necks and minimizing

process network

By hysis simulation:

Project definition:

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Project definition cont’d

• Location- Golapgonj, Sylhet

• Capacity-550 MMSCFD

• Raw materials-Raw Natural Gas From 3

Producing Gas Wells, DEAmine Solution, TEG.

• Utility- Cooling water, Electricity (2 MW Capacity),

Natural Gas.

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Available Process

• Gas Sweetening

Solid Bed Sweetening Process: Molucular Sieves

Aquasorption Process (Wash Water Process)

Selexol Process

Chemical Absorption Process(MEA,DEA,TEA

Processes)

The Holmes-Stretford Process

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Available Process cont’d

• Gas Dehydration

Absorption Process(Methanol, Glycol Process)

Adsorption Process (Solid Dessicants, Alumina,

Silica Gel, Molecular Sieves)

Design Basis

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Climate Condition:

Ambient Temperature-

Max- 35oC Min-12oC

Design max temp- 40oC Min temp-5oC

Annual Avg. Atmospheric pressure-0.11 MPa

Annual Avg. relative Humidity- 80%

Wind Velocity-52 miles/hr

Rain- Annual avg Rainfall- 2850 mm

Process Block Diagram

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PFD (Hysis Simulation):

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Comparison Between Raw Natural gas & Product gas

Raw Natural GasComponents CompositionMethane 0.8634

Ethane 0.0574

Propane 0.0088

i-Butane 0.0007

i-Butane 0.0005

n-Pentane 0.0005

n-Hexane 0.0003

H2O 0.0467

Nitrogen 0.0018

CO2 0.0204

Components Composition

Methane 0.930973

Ethane 0.053632

Propane 0.000658

i-Butane 0.000022

i-Butane 0.000014

n-Pentane 0.000007

n-Hexane 0.000002

H2O 0.000101

Nitrogen 0.002029

CO2 0.012562

Product Gas

List of Major Equipments

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Equipment Name QuantityDesignation in the

HYSYS Simulation

Compressor 1 K-100

Heat Exchanger 2 E-100, E-102

Absorber 2 T-100, T-102

Separator 3 V-100, V-101, V-104

Pump 2 P-100, P-101

Storage Tank 1 V-106

Stripper Column 2 V-102, V-103

Stabilizer Column 1 V-105

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Design Parameter

Separator Diameter: 8.12 ft

Minimum Separator height: 40.6

Thickness of the Separator: 3.3 ft

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Gas-Liquid Separator

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Design Parameter cont’d Microsoft Office Word Document

Pump (P-100) of Dehydration plant

Total frictional loss:

2.44 ft

Total head: 43.11 ft

Power requirement:

17.1hp

Material: cast iron

RPM: 1750

Flow capacity: 770GPM

(max)

Impeller size: 11-3/4”

Weight: 255 lbs

Price: $ 4662.00

Specification of pump:

Mechanical Design of Separator

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P & ID Diagram

Figure: P & I diagram for gas liquid separator

P & ID Diagram cont’d

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Overall Economic Analysis

Equipment Cost at Present(2014)- $1.088 million

Total Capital Investment - $ 6.12 million

Total Annual Expenses- $ 13.24 million

Net Profit After Tax(15%)- $ 15.4 million

Pay back period – 3 year 11 month

Salvage value- $ 0.532 million

Depreciation- $0.765 million/year

IRR i% = 24.58 %

ERR i% = 19.67%

Project life – 20 years

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THANK YOU