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    Production of LABSA

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    Naveen Kamat
    The document summarizes a graduation project to design a LABSA production plant. It includes: 1) Modifying an existing 1 ton/year LABSA process to produce 30,000 tons/year, adding equipment like an air dryer unit and compressor. 2) Designing the major equipment based on calculations, like a sulfur melter, heat exchanger, and compressor. 3) Estimating capital costs, operating costs, raw material costs, and total manufacturing costs. 4) Conducting a HAZOP study to identify potential safety issues for equipment like gas-liquid separators. 5) Selecting Abu Dhabi as the optimal site for its sulfur supplies, ports, and proximity to

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    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd

    Production of LABSA

    Uploaded by

    Naveen Kamat
    3K views39 pages
    The document summarizes a graduation project to design a LABSA production plant. It includes: 1) Modifying an existing 1 ton/year LABSA process to produce 30,000 tons/year, adding equipment like an air dryer unit and compressor. 2) Designing the major equipment based on calculations, like a sulfur melter, heat exchanger, and compressor. 3) Estimating capital costs, operating costs, raw material costs, and total manufacturing costs. 4) Conducting a HAZOP study to identify potential safety issues for equipment like gas-liquid separators. 5) Selecting Abu Dhabi as the optimal site for its sulfur supplies, ports, and proximity to

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    linear alkyl benzene sulphonates

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    The document summarizes a graduation project to design a LABSA production plant. It includes: 1) Modifying an existing 1 ton/year LABSA process to produce 30,000 tons/year, adding equipment like an air dryer unit and compressor. 2) Designing the major equipment based on calculations, like a sulfur melter, heat exchanger, and compressor. 3) Estimating capital costs, operating costs, raw material costs, and total manufacturing costs. 4) Conducting a HAZOP study to identify potential safety issues for equipment like gas-liquid separators. 5) Selecting Abu Dhabi as the optimal site for its sulfur supplies, ports, and proximity to

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    3K views39 pages

    Production of LABSA

    Uploaded by

    Naveen Kamat
    The document summarizes a graduation project to design a LABSA production plant. It includes: 1) Modifying an existing 1 ton/year LABSA process to produce 30,000 tons/year, adding equipment like an air dryer unit and compressor. 2) Designing the major equipment based on calculations, like a sulfur melter, heat exchanger, and compressor. 3) Estimating capital costs, operating costs, raw material costs, and total manufacturing costs. 4) Conducting a HAZOP study to identify potential safety issues for equipment like gas-liquid separators. 5) Selecting Abu Dhabi as the optimal site for its sulfur supplies, ports, and proximity to

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 39

    Company LOGO

    United Arab Emirates University College of Engineering Chemical Engineering Department Graduation Project II

    Production of Sulfonic Acid Salts


    Group Members: Ahlam Mohammed Kholoud Sahool Maitha Muftah 200211739 200221677 200203114

    Project Advisor: Dr. Basim Abu-Jdayil

    Outline

    Introduction

    Equipment Design

    HAZOP Study

    Objective

    Cost Estimation

    Site Location

    LABSA Production Process Modification


    2

    Conclusion and Recommendation

    GPII-Production of Sulfonic Acid Salt

    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.

    GPII-Production of Sulfonic Acid Salt

    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.

    GPII-Production of Sulfonic Acid Salt

    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.

    GPII-Production of Sulfonic Acid Salt

    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


    6
    GPII-Production of Sulfonic Acid Salt

    Modified LABSA Process PFD

    GPII-Production of Sulfonic Acid Salt

    Equipment Design

    GPII-Production of Sulfonic Acid Salt

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

    The calculated Parameters:

    V 3.802 m3
    Q 5680 kJ kg

    GPII-Production of Sulfonic Acid Salt

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

    10

    GPII-Production of Sulfonic Acid Salt

    Air Dryer Unit


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

    11

    GPII-Production of Sulfonic Acid Salt

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

    12

    GPII-Production of Sulfonic Acid Salt

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

    13

    GPII-Production of Sulfonic Acid Salt

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

    14

    GPII-Production of Sulfonic Acid Salt

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

    15

    GPII-Production of Sulfonic Acid Salt

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

    16

    GPII-Production of Sulfonic Acid Salt

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

    17

    GPII-Production of Sulfonic Acid Salt

    Pump

    18

    GPII-Production of Sulfonic Acid Salt

    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

    19

    GPII-Production of Sulfonic Acid Salt

    Cost Estimation

    20

    GPII-Production of Sulfonic Acid Salt

    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:

    1) Calculate the purchased cost (Cpo):

    log 10 C p K1 K 2 log 10 ( A) K 3 log 10 ( A)


    0

    21

    GPII-Production of Sulfonic Acid Salt

    Capital Cost Estimation


    2) Calculate the bare module (FBM):

    FBM B1 B 2 FM F p
    3) Calculate the bare module cost (CBM):

    C BM C P FBM
    o

    4) Find the grass root cost (CGR) :

    CTM 1.18 C BM ,i

    CGR CTM 0.5Co BM ,i


    22
    GPII-Production of Sulfonic Acid Salt

    Capital Cost Estimation


    Capital Cost Estimation for the LABSA Process:

    CGR, 2008

    cost index 2005 cost index 2001

    CGR, 2001 (1.053 )

    CTM= $2631712.71
    CGR,2001= $3252328.70 CGR,2008= $4440207.145

    23

    GPII-Production of Sulfonic Acid Salt

    Operating Labor Cost Estimate


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

    N OL (6.29 31.7P 2 0.23N np ) 0.5


    N np Equipment Summation

    Solid Handling

    24

    GPII-Production of Sulfonic Acid Salt

    Operating Labor Cost Estimate

    N OL 6.366
    Operating Labor= 4.5 x 6.366 = 28.645 29 operators

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


    25
    GPII-Production of Sulfonic Acid Salt

    Cost of Operating Utility


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

    CUT= $ 562601.55/yr

    26

    GPII-Production of Sulfonic Acid Salt

    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:
    Sulfur Cost 120 $ kg hr day 1 ton 338 24 365 0.95 $337540 .320 / yr ton hr day yr 1000 kg

    LAB Cost 10 .007

    kmol kg hr day $ 1 ton 240 24 365 2050 0.95 $40972900 .968 / yr hr kmol day yr ton 1000 kg
    ton $113 .295 hr day 24 365 0.95 $139257 .614 / yr hr ton day yr

    NaOH Cost 0.1477

    CRM $41449698 .902 / yr

    27

    GPII-Production of Sulfonic Acid Salt

    Waste Treatment Cost


    It is important to calculate the waste treatment cost (CWT) because it helps protecting the environment from pollution:
    kg m3 hr day 41 $ Air Dryer Waste Cost 2.922 1 24 365 0.95 $996.992 / yr hr kg day yr 1000 m3
    ton 56 $ 1 m3 kg hr day Absorber Waste Cost 0.1152 1000 24 365 0.95 $59.533 / yr hr 1000 m3 901.8 kg ton day yr

    CWT= $1056.525/yr

    28

    GPII-Production of Sulfonic Acid Salt

    Total Manufacturing Cost


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

    COM 0.280 FCI 2.73C OL 1.23(CUT CWT C RM )


    COM = $ 56829715.232/yr Profit = Income Total Costs

    Pr ofit $7268204.522 / yr

    29

    GPII-Production of Sulfonic Acid Salt

    HAZOP Study

    30

    GPII-Production of Sulfonic Acid Salt

    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

    31

    GPII-Production of Sulfonic Acid Salt

    HAZard and Operability Studies


    HAZOP Study for Gas-Liquid Separator (Flow Deviation)
    Guide Word No Deviation Flow Causes o Consequences Action o Plant shut down o No product Repair valve Repair pipe o Less product o Less performance of plant Clean pipe Repair leakage Fit low flow alarm (FAL) o More product o Flooding and overflow Repair valve Repair LC Fit high flow alarm (FAH)
    GPII-Production of Sulfonic Acid Salt

    Valve failure Pipe failure

    Less

    Flow

    Valve blocked Pipe blocked Pipe leak

    More

    Flow Valve failure LC failure

    32

    HAZard and Operability Studies


    HAZOP Study for Gas-Liquid Separator (Temperature Deviation)
    Guide Word Less Deviation Temperature Causes No separation Less efficiency o o o o o Consequences Action Less product Less performance Clean pipe Repair leakage More product Flooding and overflow Repair valve Repair LC

    More

    Temperature

    No separation Less efficiency

    33

    GPII-Production of Sulfonic Acid Salt

    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

    34

    GPII-Production of Sulfonic Acid Salt

    Site Location

    35

    GPII-Production of Sulfonic Acid Salt

    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.

    36

    GPII-Production of Sulfonic Acid Salt

    Other Site Location Factors


    Site Location Case Study Evaluation Results:

    37

    GPII-Production of Sulfonic Acid Salt

    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.

    38

    GPII-Production of Sulfonic Acid Salt

    Thank you for your Attention

    39

    GPII-Production of Sulfonic Acid Salt

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