Design A Plant To Manufacturing of Ferrous Sulfate Monohydrat

DESIGN THE MANUFACTURE OF (20 TONES/DAY) FERROUS SULFATE MONOHYDRATE
THE PROJECT REPORT ON THE DESIGN THE

MANUFACTURE OF (20 TONES/DAY) FERROUS SULFATE
MONOHYDRATE FROM WASTE PICKLE LIQUOR
SUBMITTED BY:
SURESH KUMAR
ROLL NO: 08/S8/33
REGISTRATION NO: S/III/13/40
INDIAN INSTITUTE OF CHEMICAL ENGINEERS

SEPTEMBER -2013
1
(A) STATEMENT OF THE PROBLE
2
Design the manufacture of (20 Tones/day) Ferrous Sulfate monohydrate
from waste pickle liquor.
Pickling is generally associated with the removal of scale with mineral
acid. Sulfuric acid is the most commonly used pickling acid. The spent
pickle liquor generally contains about 15 to 20% ferrous sulfate and
about 2 to 5% sulfuric acid. This spent liquor is first neutralized with
excess iron in a neutralization tank and then filter of excess iron. The
solubility of ferrous sulfate increases up to 65 0C and then decreases
where ferrous sulfate exists as monohydrate. At ordinary low
temperatures, it exists as ferrous sulfate heptahydrate. An evaporative
crystallizer is used to produce ferrous sulfate monohydrate which
operates at 650C. After separation of crystals, the mother liquor is
recycled back to neutralization tank.
Prepare a design report consisting of the following.
Full Marks
3
1. Literature Survey
15
2. Detailed flow sheet
15
3. Material and Energy balance
20
4. Design of neutralizer unit including mechanical design
30
5. Design of Evaporative crystallizer unit including mechanical design
40
6. Instrumentation and process control in the process
15
7. Plant layout
10
8. Safety and pollution abetment aspects
10
9. Cost Estimation
15
10. Detailed engineering drawing of the neutralizer and evaporative
30
crystallizer
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Total 200
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CONTENTS
TOPICS PAGES
A. Major performance & Equipment data 6
1. Literature survey 12
2. Detailed flow sheet 29

[Docket]
3. Material and Energy Balance of the plant 33
4. Design of neutralizer unit 46
5. Design of Evaporative crystallizer 69
6. Instrumentation and process control in the process

83
[Docket]
7. Plant Layout 88
[Docket]
8. Safety and pollution abatement aspects 99
9. Cost estimation 116
10. Detaited engineering drawing of the reactor and centrifuge 126

[ Docket]
11. Nomenclature 129
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12. Bibliography 137
CHAPTER-I
MAJOR PERFORMANCE & EQUIPMENT DATA
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I. MAJOR PERFORMANCE & EQUIPMENT DATA
OVERALL MATERIAL BALANCE AROUND THE PROCESS
COMPONENT BASIS 100KG PRODUCTION AS PER PRODUCTION RATE

INLET( KG) OUTLET( KG) INLET(KG) OUTLET(KG)
Ferrous sulfate
through Pickle 89.4 0 795.66 0
liquor
Sulfuric acid
Through pickle 22.35 0 198.92 0
liquor
Water through
pickle liquor 335.25 335.25 2983.73 2983.73

Lime solution 88.71 26.613 789.52 236.86
Water 10.6 25.31 94.34 225.26
Sulfuric acid
required 57.72 0 513.71 0

Ferrous sulfate
monohydrate 0 100 0 889
formed
Impurity 1.18 6.90 10.5 61.41

Calcium Sulfate 0 111.12 0 988.97
TOTAL 605.21 605.19 5386.38 5385.23
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PROCESS DESIGN OF THE NEUTRALIZER
Type of Neutralizer CONICAL

No of Neutralizer 1
Volume of Neutralizer 12.72 m3
Height of Neutralizer 3.038 m
Diameter of Neutralizer 4.000 m
Inlet nozzle diameter of the Neutralizer for 48 mm
Pickle liquor
Lime solution
Outlet nozzle diameter of the Neutralizer 60 mm
MECHANICAL DESIGN OF THE NEUTRALIZER
Shell material LOW CARBON STEEL

Shell thickness 20 mm
Effective gasket seating width 7.9 mm
Nozzle Thickness 20 mm
Agitator type Turbine
Power taken to agitator 450 Kw
Agitator diameter 1200 mm
Permissible stress of Shaft 25488 N/mm2
Max. Torque 32406 Nm
Actual Shaft Speed 200 rpm
Critical Shaft Speed 320 rpm
Flange Thickness 35 mm
Max. Stud diameter 20 mm
Force per bolt 9421 N
Bolt Size 24 M
Coupling diameter 130 mm
Height of bracket from foundation 2.25m
Maximum compressive load 15830 kg/cm2
Base plate thickness of Bracket 25mm
Web plate thickness of Bracket 20mm
Base plate thickness for column 20mm
PROCESS DESIGN OF THE CALENDRIA EVAPORATIVE CRYSTALLIZER
Type of Crystallizer CALENDRIA
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No of Crystallizer 01
Crystallizer Area 64.97 m2
Crystallizer feed nozzle diameter 60 mm
Crystallizer Product nozzle diameter. 60 mm
Steam Inlet nozzle diameter 40 mm
MECHANICAL DESIGN OF CALENDRIA EVAPORATIVE CRYSTALLIZER
Evaporator material LOW Carbon Steel

Number of tubes 605
Pitch of the tube (triangular) 125 mm
Evaporator Area 9860 mm
Tube Material Brass
Area of central down take 1880 mm
Diameter of tube sheet 3710 mm
Calendria Sheet Thickness 12 mm
Tube Sheet Thickness 36 mm
Thickness of Flange 40 mm
Number of bolts 112
Pitch circle diameter 3825 mm
Size of bolts 20 M
Outside diameter 3894 mm
Drum height 3000 mm

Drum Thickness 10 mm
Critical External Pressure 0.058 N/mm2
Permissible stress 15.9 N/mm2
Head thickness is based on an external pressure 0.1 N/mm2
Conical head angle 1200
COST ESTIMATION OF THE PLANT
SL.No ACCOUNT HEAD EXPENDITURE IN RUPEES
9
1 PURCHASE EQUIPMENT COST (E1) 148115711
2 PURCHASE EQUIPMENT INSTALLATION 57765127

( 39% of E1 )
3 INSTRUMENTATION (INSTALLATION) 41472399
( 28% of E1)
4 PIPING (INSTALLED ) 66652069

(45% of E1 )
5 ELECTRICAL (INSTALLED ) 14811571
(10% of E1 )
6 BUILIDING ( INCLUDING SERVICE) 32585456
(22% of E1)
7 SERVICE FACILITIES (55% of E1 ) 81463641
8 LAND ( 6% of E1 ) 8886942
TOTAL DIRECT COST (D) 451752916

INDIRECT COST ( I)
1 ENGINEERING AND SUPERVISION 22217356
(15% OF E1 )
2 CONSTRUCTION EXPENSES 17773885
(12% OF E1 )
3 LEGAL EXPENCES 2962314
(2% OF E1 )
4 CONTRACTORS FEE 5924628
(4% OF E1 )
5 CONTINGENCY 14811571
( 10% OF E1 )
TOTAL INDIRECT COST (I) 63689754
TOTAL DIRECT + INDIRECT COST 515442670

(D+I)
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CHAPTER-1
LITERATURE SURVEY
L ITERATURE SURVEY
INTRODUCTION
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One billion gallons of waste pickle liquor are discharged from American steel mills
every year. This waste, which results from cleaning steel in various stages of its
manufacture, contains enough iron to built more than 200000 automobiles and contains
about one million tons of sulfuric acid.
During the last seventy years, many processes have been proposed both for the recovery
of the iron or acid values of waste pickle liquor and for the elimination of the waste.
From 1888 when Kirk man received a British patent on waste -acid treatment to the
present day, increasingly intensive research effort has been devoted to finding a practical
answer to this problem. The desirable characteristics of a satisfactory solution to the
pickle liquor disposal problem may be summarized as follows:
1. Elimination of Pollution
2. Attractive economics
3. Simple and compact operation with demonstrated
reliability
4. Products that can be readily disposed of.
No one process, certainly, will meet these criteria for all pickling operations, and
therefore Koppers offers to built a variety of plants covering both the by -product
recovery and simple disposal techniques.
THE INDUSTRIAL REVOLUTION
The huge increase in demand for strip steel for automobiles and cans eventually led to the
development of continuous strip picklers, in which the uncoiled strip was drawn
continuously through tubs of hot sulfuric acid. Early lines processed several narrow strips
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at speeds of 30 to 100 fpm, with the successive coils being held together with mechanical
clips, but, in time, speeds of up to 400 fpm were obtained with welding of each coil to the
next - take-up systems or looping pits were added to keep the pickler on stream while the
welding was taking place.
A NEW ACID ON THE SCENE
Some specialty batch picklers had used hydrochloric acid previously, especially if a high
quality surface was needed, but the expense, corrosiveness and fuming problems made
this acid unattractive. However, from 1960 to 1965, three things took place to change
this:
- the development of light-weight, strong and cheap plastics materials,
such as FRP and polypropylene, which made corrosion and fume control
easier
- the development of processes to regenerate (or reclaim) the spent acid -
not just the free acid, but also the acid that had reacted with the scale
- the increasing public awareness of the damage to the environment that
results from dumping spent sulfuric pickle acid into streams and rivers
Strip picklers then realise that hydrochloric acid could be an attractive alternative to
sulphuric acid not only because it could be regenerated (so eliminating the pollution
problem) but also because pickling speeds were higher, scale breakers were not needed,
and product quality was better.
PHYSICAL AND CHEMICAL PROPERTIES:
Synonyms : Ferrous Sulfate Monohydrate, Mono
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Trade Name: Iron Sulphate Monohydrate
Molecular Weight: 169.91
Product Use: Fertiliser
Chemical formula : FeSO4. H2O
Form : Powder
Color : Greyish - yellow
Odor : Odourless
pH Value (20 oC) at 50 g/l H2O : 1.5-3.8
Melting point : ( approx ) ~ 300 oC ( release of crystal water ),
Boiling point : Not available
Ignition temperature : Not combustible
Flash point : Not flammable
Explosion limits
Lower : Not applicable
Upper : Not applicable
Vapour pressure : not applicable
Density (20oC) : ~ 2.97 g/cm3
Bulk density : ~ 850 kg/m3
Solubility in water (20oC) : 256 g/L
Thermal decomposition : > ~ 300 oC
CHEMICAL STABILITY & REACTIVITY INFORMATION
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CHEMICAL STABILITY
Under normal conditions of temperature and pressure, Ferrous Sulfate Monohydrate is
stable. Ferrous Sulfate Monohydrate reacts in moist air to form ferric sulfate. Ferrous
Sulfate Monohydrate looses water in dry air and may discolour upon exposure to moist
air, forming a brown coating of extremely corrosive, basic ferric sulfate.
CHEMICAL STABILITY: CONDITIONS TO AVOID
Water of crystallization will be released when exposed to temperatures over 300 deg. C.
INCOMPATIBILITY
Avoid strong alkalis, soluble carbonates, gold and silver salts, lead acetate, lime water,
potassium iodide, potassium, sodium tartrate, sodium borate, and tannin.
HAZARDOUS DECOMPOSITION
Sulfur oxides and dioxides are normal decomposition products. May liberate toxic metal
fumes and acrid smoke.
HAZARDOUS POLYMERIZATION
WILL NOT OCCUR.
THE THEORY
Quite often the pickling process is wrongly referred to as a "cleaning" process. As we
discuss the technology involved in pickling, we will discover just how wrong that
reference really is.
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The pickling process is in fact a chemical process and has very little to do with "cleaning"
the steel. In other words, pickling does not remove anything but mill scale; to remove
grease or soot or whatever from the steel, don't look to the pickle tank to do it.
In order to appreciate the following discussion on the theory of pickling, it is helpful to
be familiar with some basic chemistry. The action which creates the bubbles under the
scale is caused by the acid reacting with iron. This is called a "chemical reaction".
Chemical reactions are expressed in equations, showing all components needed to create
the reaction on the left side and all components being created on the right side of the
equation. Thus the chemical reactions at work in the pickling process are expressed as
follows:
Iron Oxide + Sulfuric Acid = Iron Sulfate + Water
(FeO) (H2SO4) (FeSO4) (H2O)
Iron + Sulfuric Acid = Iron Sulfate + Hydrogen
(Fe) (H2SO4) (FeSO4) (H2)
Sulphuric acid in its pure molecular state will not react with either iron or iron oxide, it
must be dissolved in water in order to become reactive. It follows therefore, that these
reactions only take place in aqueous solutions (in the presence of water).
Both reactions create iron sulfate as a by product and both reactions are exothermic,
meaning heat is created during the reaction. However, there is a distinct difference
between the two in that iron dissolves quite rapidly, even violently at higher
temperatures, while iron oxide dissolves very slowly or hardly at all under certain
conditions.
THE PICKLING EXPERIMENT
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If we now immerse a piece of steel covered with mill-scale in a sulphuric acid solution,
we will observe the following:
bubbles form at every crack in the mill-scale
little flakes of mill-scale float off the steel
bubbles form on the newly
exposed surfaces of the steel
the solution temperature rises slightly
the acid concentration is decreasing
the solution is turning slightly green
more and more mill-scale flakes are floating dispersed in the
solution and are slowly settling to the bottom
finally, the surface of the steel is free of mill-scale and instead is covered in
furiously dancing bubbles which are rising rapidly to the surface of the solution
an acrid odour rises from the surface of the solution
the colour of the steel changes from a bright silvery gray to a dull
blackish gray
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the steel is removed, the action in the solution stops,microscopically tiny
particles suspended in the solution slowly settle to the bottom.
A layer of precipitate is visible on the bottom of the vessel.
The above observations accurately describe all the events taking place when steel is being
pickled.
THROWING CURVES
Looking at the solubility curve, we can see, that three separate conditions determine the
state of solubility: solution temperature, acid concentration and ferrous sulfate
concentration (expressed as iron). Also we can see that the curves come to a definite
peak; the line connecting these peaks is the phase change line. At this point, let us
observe another experiment using the same pickling solution from the previous
experiment just prior to dumping it. Assuming that the solution is at 180F, 10.8% iron
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and 10% acid. To find out how this solution relates to the solubility curve, follow this
procedure:
- - draw a vertical line at 180F
- - note where this line intersects with the curve representing 10% acid
- - draw a horizontal line from this intersection to the left
- - note where this line intersects with the iron scale: 10.8%
To find out, what significance this has on our experiment, we must know more about how
to interpret the solubility curve:
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PICKLING LIQUOR REGENERATION
The pickling acid bath contains mainly ferrous chloride (FeCl2) produced on account of
the following reaction and the unused hydrochloric acid (HCl).
Fe0 + 2 HCl = FeCl2 + H20
The regeneration of spent pickling liquor is carried out by oxidizing its dissolved iron
chloride (FeCl2) in a fluidized bed reactor at about 800C. The valuable ferric
oxide (Fe203) is also produced as a by-product. For this, the reaction is reverse of
pickling reaction, producing gaseous hydrochloric acid.
4 FeCl2 + 02 + 4 H20 = 2 Fe203 + 8 HCl
The hot reactor gases are first passed through the cyclone separator to recover the Fe 203
granules and then passed through the pre-evaporator to concentrate the incoming spent
pickling liquor. The hydrochloric acid is recovered by the absorption of gaseous HCl in
water in the absorber.
OTHER PROCESSES:
A process for producing ferrous sulfate monohydrate directly from iron in the absence of
the production of the intermediate ferrous sulfate heptahydrate, the steps of said process
comprising:
Generally speaking, this invention relates to a process for the production of ferrous
sulfate from scrap iron. More particularly, this invention relates to the production of
ferrous sulfate monohydrate from scrap iron in the absence of the intermediate formation
of ferrous sulfate heptahydrate . As is well known, ferrous sulfate is particularly useful as
a starting material in the manufacture of pure iron oxide which, in turn, is useful in the
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manufacture of ferrites. When it is realized that only slightly more than 61 lbs. of ferrous
sulfate monohydrate yields the same quantity of ferrous sulfate as 100 lbs. of ferrous
sulfate heptahydrate, the economic advantages of using the monohydrate form for the
production of iron oxide become obvious, even if one is only considering the difference
in handling weight involved. The difference, of course, as well known, is in the water
content of the heptahydrate form of ferrous sulfate which must be driven off so as to
provide a satisfactory economical ingredient for the production of pure iron oxide.
Other advantages of the monohydrate form of ferrous sulfate over the heptahydrate form
include the fact that it is more readily calcined to form iron oxide and it does not fuse
nearly as readily when heated as does the heptahydrate. In addition, when stored, it is
much more stable and does not rapidly oxidize in air or absorb moisture as does the
heptahydrate form. In the past, attempts have been made to produce ferrous sulfate from
iron by dissolving the iron in sulfuric acid. However, such a reaction produces the more
undesirable heptahydrate form of ferrous sulfate, as well known. Attempts have been
made to overcome this problem, particularly in processes for recovering iron salts from
waste pickle liquors. However, such processes are directed to different problems than
those related to the production of the monohydrate from scrap iron in that such processes
involve solutions which must be handled in a manner so as to remove the iron salts
therefore and include the application of elevated temperatures or pressures or a
combination of the two for producing an intermediate monohydrate product from such
pickle liquor solutions. Thus, the problem arises where in order to produce ferrous
sulfate directly from iron, such as steel scrap, one obtains the undesirable ferrous sulfate
heptahydrate which from an economic standpoint creates certain problems in its use in
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the production of further products therefore, and conversely, if it is attempted to produce
the more desirable final product of the ferrous sulfate monohydrate, uneconomical
processes such as utilization of expensive evaporation and/or high pressure techniques
must be used in order to control the reaction for the recovery thereof from spent pickle
liquors. By contrast, and quite unexpectedly, it has now been found in accordance with
this invention that by combining iron, such as steel scrap, with a sulfuric acid solution at
a concentration of between about 10-90 percent for a period of time to reduce the acid
concentration to a particular level, separating any precipitate and/or impurities contained
therein from the acid solution of reduced concentration, and thereafter adding
concentrated sulfuric acid in an amount sufficient to increase the frre acid concentration
to within a particular range, a ferrous sulfate monohydrate precipitate is formed which is
readily separated from the reacting environment and under conditions requiring no
pressure and very little temperature. The reaction takes place with little or no control
necessary and the end product is separated after a period of time with the only
requirement being that the reaction be allowed to go to completion at a particular level of
free acid concentration. The resulting precipitate is readily separated from the reacting
solution by filtration and if a batch-type procedure is used, as described in more detail
below, any unreacted iron in the filter cake is easily separated therefore magnetically. As
is obvious with such an arrangement, little attention must be given to the reactants during
the reaction period thus reducing substantially the cost simply because no temperature
and/or pressure controls must be utilized to any appreciable extent for maintaining
control during the reaction period. It has been found, in accordance herewith, that a
substantially pure form of ferrous sulfate monohydrate is achieved. In addition, the
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process in accordance herewith, is readily applicable to a continuous procedure in which
sulfuric acid and iron are reacted, with the sulfuric acid being at a particular range of
concentration and with the sulfuric acid being continuously circulated through a container
of scrap iron. This continuous procedure continues until the free acid concentration is
reduced to a particular level at which time the acid solution is drawn off and filtered to
separate out any impurities and/or precipitate. To the filtrate is added concentrated
sulfuric acid to bring the free sulfuric acid concentration up to a particular range of
concentration at which point the pure ferrous sulfate monohydrate is precipitated. The
product is thereafter filtered off and the filtrate is recalculated back through the scrap iron
container where additional amounts of iron scrap are added continuously to maintain the
initial reacting conditions. Accordingly, it is one object of this invention to produce
ferrous sulfate monohydrate from iron, such as iron scrap, In addition, it is another object
of this invention to produce such ferrous sulfate monohydrate in substantially pure form
and in the absence of the production of the intermediate ferrous sulfate heptahydrate. It is
a further object of this invention to produce such ferrous sulfate monohydrate by the
reaction of the iron with sulfuric acid which reaction requires little or no control during
the reaction period. A further object of this invention is a process for the production of
ferrous sulfate monohydrate directly from scrap iron in the absence of any pressure
requirements and at only slightly elevated temperatures and requiring no expensive
evaporative and/or calcining procedures. In addition, it is an object of this invention to
produce substantially pure ferrous sulfate monohydrate which is readily separable from
the reaction environment, and which product in turn is readily separable from any
unreacted iron from the reaction of the process. Before describing this invention in more
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detail, it may be well to note that this invention has been found applicable to a wide
variety of iron sources, such as, for example, scrap iron left over from detaining
operations, which operations are usually applicable to discarded tin scrap in which the
relatively valuable tin plate has been separated from the steel thereof, as well known. For
example, satisfactory results have been achieved in accordance herewith, and under
satisfactorily and economically attractive conditions in commercial scale operations with
ferrous scrap resulting from detaining operations with the ferrous scrap being added to
the reaction zone along with a sulfuric acid solution in a concentration of between about
10-90 percent, and maintaining the admixture at a temperature between about ambient to
100C. for a period of time sufficient to reduce the free acid concentration down to
between about 2-35 percent, separating the resulting solution from the unreacted iron,
filtering the solution to remove any precipitation and impurities contained therein, adding
concentrated sulfuric acid to the solution to bring the free acid concentration up to
between about 35-45 percent for precipitating pure ferrous sulfate monohydrate, and
separating the pure ferrous sulfate monohydrate from the filtrate. The reaction
environment requires no application of pressure and/or vacuum procedures in order to
provide satisfactory results, in accordance herewith. The reaction produces a ferrous
sulfate monohydrate substantially with no control thereof and the precipitated ferrous
sulfate monohydrate is readily separated from the reaction zone, and in certain instances
the resulting separated precipitate may be separated from any unreacted ferrous scrap
merely by application of magnetic means. In considering generally the conditions for
achieving the enhanced results in connection herewith, which conditions are more
specifically set forth below, one may note that satisfactory ferrous sulfate monohydrate
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product may be produced in accordance herewith in cyclic operations in which after the
precipitate product has been separated from the acid solution, and any unreacted iron
separated from the precipitate product if a batch-type procedure is used, additional
quantities of iron and sulfuric acid may be introduced into the reaction zone for the
production of additional amounts of ferrous sulfate monohydrate, with care being taken
only to maintaining the free sulfuric acid concentrations in the reaction zones within the
ranges noted above. A preferred cycle of operation in accordance herewith for producing
the ferrous sulfate monohydrate product includes admixing iron, such as scrap produced
by detaining operations, and sulfuric acid in a reaction zone having between about 10-90
percent free sulfuric acid concentration, and preferably 40% H2 SO4. The temperature of
the admixture is maintained between ambient and 100C., and preferably 50C. The
reaction zone is maintained as above for the period of time necessary to reduce the free
acid concentration down to the range of between about 2-35 percent for the reaction to
come to completion, and preferably about 20-30 percent, and thereafter, any precipitates
and impurities are separated from the solution. Then concentrated sulfuric acid is added
to the solution to bring the free acid concentration up to between about 35-45 percent,
preferably 40 percent, to precipitate out the pure ferrous sulfate monohydrate product.
The precipitate is separated from the acid solution, preferably by centrifuge, to obtain a
substantially pure ferrous sulfate monohydrate product and the remaining filtrate is
recycled to the first reaction zone for further reaction with additional quantities of iron.
The process in accordance herewith achieves the desired pure ferrous sulfate
monohydrate directly from a reaction of iron and sulfuric acid in the absence of the
production of any of the undesirable intermediate ferrous sulfate heptahydrate, and with
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little or no control being necessary for the reaction environment, thus eliminating
expensive evaporative, pressure and/or vacuum application procedures. Further, the
ferrous sulfate monohydrate has a much larger quantity of the desired ferrous sulfate on a
weight for weight basis and is readily stored for long periods of time without requiring
provisions for preventing oxidation and water absorption. The results achieved by the
process, in accordance herewith, examples were prepared using the preferred ratio of
reactants, in accordance herewith, and under the preferred control conditions for the
reaction zone. It is to be understood, however, that these examples are being presented
with the understanding that they are to have no limiting character on the broad disclosure
of the invention as generally set forth herein and as directed to men skilled in the art.
STORAGE AND HANDLING:
STORAGE: Store in cool, dry, well ventilated area removed from combustible materials,
herbicides, fungicides and foodstuffs. Ensure containers are labeled, protected from
physical damage and sealed when not in use. Keep from extreme heat and open flames
and make sure that the product does not come into contact with substances listed under
"Materials to avoid" in Section 10. Bagged fertilizers should be stored under cover and
out of direct sunlight. If stacking is necessary, bulk bags should be stored in a stable
manner, preferably in a pyramidal style. Bulk bags should not be stacked more than two
high for bags containing 1000 kg or more, or more than four high for bags containing up
to 500kg. The pallet Capacity Rating (Design Weight) should not be exceeded on the
bottom tier for other packs
26
HANDLING: Before use carefully read the product label. Use of safe work practices are
recommended to avoid eye or skin contact and inhalation. Observe good personal
hygiene, including washing hands before eating. Prohibit eating, drinking and smoking in
contaminated areas.
DISPOSAL CONSIDERATIONS
DISPOSAL: There are many pieces of legislation covering waste disposal and they differ
in each state and territory, so each user must refer to laws operating in their area. In some
areas, certain wastes must be tracked. The Hierarchy of Controls seems to be common -
the user should investigate: Reduce, Reuse, and Recycle and only if all else fails should
disposal be considered. Special help is available for the disposal of Agricultural
Chemicals. The product label will give general advice regarding disposal of small
quantities, and how to cleanse containers.
ECOLOGICAL INFORMATION:
ENVIRONMENT: Avoid contamination of waterways.
ECOTOXICITY EFFECTS: Dissolves slowly in water. Harmful to aquatic life at low
concentrations.
ENVIRONMENTAL EFFECTS: Can be dangerous if allowed to enter drinking water
intakes. Do not contaminate domestic or irrigation water supplies, lakes, streams, ponds,
or rivers.
MOBILITY IN ENVIRONMENTAL MEDIA: Dissolves slowly in water
Persistence/degradation: Will persist for weeks in soil, but is a plant nutrient.
27
CHAPTER-2
DETAILED FLOW SHEET
28
2. DETAILED FLOW SHEET
BRIEF OUTLINE OF THE FERROUS SULFATE MONOHYDRATE FROM
PICKLE LIQUOR:
Spent pickle liquor is a waste material of the pickling operation of steel mills. Pickling is
a treatment of iron and steel plant with aqueous sulfuric acid solutions to remove the
scale from their surfaces. The sulfuric acid interacts with the iron oxide during the
pickling, and forms water soluble ferrous sulfate with it. The effectiveness of the sulfuric
acid solution gradually diminishes as its acid content decreases and its FeSO 4, content
increases. The disposal of large amounts of pickle liquor not only represents a serious
loss in unreacted sulfuric acid, but causes an objectionable pollution problem, even after
neutralization. The pickle liquor is received at the steel plant at a temperature of about
87.80C and normally with contain 5% H2SO4 and 20% FeSO4. This solution is
neutralized with excess iron in a neutralization tank. The pickle liquor can be neutralized
with lime [Ca(OH)2] to precipitate out the metals as hydroxides. Most of the sulphate will
also precipitate out as calcium sulphate (gypsum) so that a mixed filter cake is produced.
The neutralization of pickle liquor with calcium hydroxide or oxide, with the
precipitation of iron as ferrous` hydroxide and the formation of calcium sulfate, generally
requires a quantity of lime considerably in excess of the stoichiometric amount. When the
lime slurry is combined with the pickle liquor, the surfaces of the lime particles are
coated with-a nearly impervious layer of ferrous hydroxide and sometimes calcium
sulfate, thereby decreasing the availability of the lime, necessitating the use of. a
considerable excess for neutralization.
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After filtration the solubility of ferrous sulfate increases up to 650C and then decreases
where ferrous sulfate exists as monohydrate. At ordinary low temperatures, it exists as
ferrous sulfate heptahydrate. The calendria type evaporative crystallizer is used to
produce ferrous sulfate monohydrate. The crystallizer is operated at 650C and pressure at
0.1N/mm2 . d combine with it to form ferrous sulfate heptahydrate and simultaneously
with the concentrating of the sulfuric acid in the pickle liquor as a result of the extraction
of water therefore, solubility of ferrous sulfate in the pickle liquor decreases with the
result that the ferrous sulfate heptahydrate precipitate in the slurry is greater in quantity
based on the ferrous sulfate than the amount of ferrous sulfate monohydrate added to the
spent pickle liquor. The ferrous sulfate heptahydrate crystals are separated from the liquid
leaving a more concentrated pickle liquor,
The recovered heptahydrate may be reconverted to monohydrate by dehydration and
recycled to the water extraction step for the regeneration of a new amount of pickle
liquor. Thus, the process is self-sustaining, as after the initial start up, it furnishes its own
water extracting agent, and no ferrous sulfate monohydrate is required from external
sources to maintain the operation. Moreover, an excess of ferrous sulfate monohydrate is
produced, equivalent to the amount which precipitates out of the pickle liquor or
concentration. This material may be withdrawn from the process and utilized in the
sulfuric acid manufacture. The concentration of the sulfuric acid in the pickle liquor may
be increased to by water extraction with ferrous sulfate monohydrate.
REACTION:
REACTION: (NEUTRALIZATION UNIT)
30
FeSO4+ Ca(OH)2---- FeO + CaSO4+ H2O------------------(i)
H2SO4 + Ca(OH)2 -- CaSO4 +H2O---------------------------(ii)
FORTIFIER
FeO +2 H2SO4 ----FeSO4 + H2O---------------------------------------(iii)
CRYSTALLIZER
FeSO4 + H2O---- FeSO4.H2O---------------------------------------------(iv)
PROCESS FLOW SHEET:
DETAILED FLOW SHEET OF FERROUS SULFATE MONOHYDRATE FROM
PICKLE LIQUOR
31
CHAPTER-3
MATERIAL AND ENERGY BALANCE
32
MATERIAL BALANCE
INTRODUCTION:
Material and energy balances are very important in an industry. Material balances are
fundamental to the control of processing, particularly in the control of yields of the
products. The first material balances are determined in the exploratory stages of a new
process, improved during pilot plant experiments when the process is being planned and
tested, checked out when the plant is commissioned and then refined and maintained as a
control instrument as production continues. When any changes occur in the process, the
material balances need to be determined again.
MATERIAL BALANCE:
Desire rate of production of Ferrous Sulfate Monohydrate = 20 Tones/Day =7300
Tones/Year
Note;
[In a continuous plant the on steam time varies from 93% to 96%,here operating factor is
93% of steam time , In the present case 1 year will be 365*0.93 =339.5 working days i.e.
340workig days.]
So.
Desire rate of production
= (7300X1000 )/ (24X340) Kg/hr
= 894.60 Kg/hr
Material balance of the entire plant will be calculated on the basis of 100kg of Product.
33
REACTION:
(Neutralization Unit):
FeSO4+ Ca(OH)2---- FeO + CaSO4+ H2O..................(i)
H2SO4 + Ca(OH)2 -- CaSO4 +H2O..............................(ii)
Main reaction:
FeO +2 H2SO4 ----FeSO4 + H2O................................(iii)
Crystallizer:
FeSO4 + H2O---- FeSO4.H2O......................................(iv)
3.a.IV. MATERIAL BALANCE OVERALL PROCESS AT A GALANCE
DATA AND ASSUMPTION
i) Sulfuric acid inlet through Pickle liquor as 5%.
ii) Ferrous sulfate 20% based on feed.
iii) Rest material is water = 75% of feed.
iv) Lime [Ca(OH)2]as a neutralizing agent.
v) Ca(OH)2 solution is 70% pure. Rest is water.
vi) After neutralizer solution react with 98% pure sulfuric acid.
vii) Rest 2% of sulfuric acid is impurity.
CALCULATION
Basis : 100 kg of Ferrous sulfate monohydrate production
34
Time : 1hour operation
We get from reaction,
100 kg of Ferrous sulfate monohydrate Crystal production.
So, from equation (iv),we get
Ferrous sulfate required= (151.8/169.8)*100= 89.40 kg
Water required = (18/169.8) *100=10.6 kg
From equation (iii),
Ferrous oxide required =( 71.8/151.8)* 89.40 =42.29 Kg
Sulfuric acid required( (98% ) ={(98/151.8)* 89.40}/0.98 = 58.90 kg
Impurity = 58.9*0.02= 1.18 kg
Pure Sulfuric acid = 58.90-1.18 = 57.72 Kg
Water produced = (18/151.8)* 89.40 kg = 10.60 kg
From equation (i),
Ferrous sulfate required = (151.8/71.8)* 42.29 =89.41 kg
Lime solution required (70% )[ Equation. i] = { (76/151.8)*89.41}/0.70 kg = 63.95 kg
Calcium Sulfate formed = ( 136/151.8)*89.41 =80.10 Kg
Water formed = (18/151.8) * 89.41 = 10.60 Kg
Pickle liquor required = 89.41/0,2 =447.05 Kg
Sulfuric acid enter through feed = 447.05* 0.05 = 22.35 kg
From equation (ii),
Lime solution required(70%) [Equation ii] ={(76/98)* 22.35} /0.70 =24.76 Kg
Calcium Sulfate formed = (136/98)* 22.35 = 31.02 Kg
Water formed (equ.ii) = (18/98)* 22.35 = 4.11 Kg
35
Total Calcium Sulfate (equation i +equation ii) = 111.12 Kg
Total Lime solution = 63,95+24.76 =88.71 Kg
Total water formed (equation i + equation. ii+ equation. iii) = 4.11+10.60+10.60 =25.31
Kg
Desire rate of production = 889.71 Kg/hr
Conversion factor = (889.71/100) =8.897 8.90
SO. total pickle liquor= 447.00* 8.9=3978.30 Kg
Ferrous sulfate inlet through pickle liquor= 89.4*8.9= 795.66Kg
Sulfuric acid inlet through pickle liquor = 22.35* 8.9 = 198.92 kg
Water enter through pickle liquor = 335.25* 8.9 = 2983.73 Kg
Impurity at outlet = 1.18/0.171
=6.90 Kg
OVERALL Material BALANCE AROUND the process
COMPONENT BASIS 100KG PRODUCTION AS PER PRODUCTION RATE

INLET( KG) OUTLET( KG) INLET(KG) OUTLET(KG)
Ferrous sulfate
through Pickle 89.4 0 795.66 0
liquor
Lime solution 88.71 26.613 789.52 236.86
Water 10.6 25.31 94.34 225.26
Ferrous sulfate
monohydrate 0 100 0 889
Sulfuric acid
Through pickle 22.35 0 198.92 0
36
liquor
Water through
pickle liquor 335.25 335.25 2983.73 2983.73

Sulfuric acid
required 57.72 0 513.71 0

Impurity 1.18 6.90 10.5 61.41
Calcium Sulfate 0 111.12 0 988.97
Total 605.21 605.19 5386.38 5385.23
3.a.V. MATERIAL BALANCE AROUND NEUTRALIZER AT A GLANCE
DATA AND ASSUMPTION
i) Sulfuric acid inlet through Pickle liquor as 5%.
ii) Ferrous sulfate 20% based on feed.
iii) Lime [Ca(OH)2]as a neutralizing agent.
iv) Rest material is water = 75% of feed.
MATERIAL BALANCE AROUND NEUTRALIZER AT A GLANCE
Component Input Out put

Kg Kg
Ferrous sulfate through
Pickle liquor 795.66 0

Lime solution 789.52 236.86
Sulfuric acid Through
pickle liquor 198.92 0

Water through pickle
liquor 2983.73 2983.73

Calcium Sulfate 0 988.97
Water produce 0 130.92
37
Ferrous oxide 0 376.38

Impurity 0 49.80
Total 4767.83 4766.66
3.a.VI. MATERIAL BALANCE AROUND FORTIFIER AT A GLANCE
DATA AND ASSUMPTION
i) 98% pure Sulfuric acid is feed
MATERIAL BALANCE AROUND FORTIFIER AT A GLANCE

Kg Kg
Ferrous sulfate 0 795.75
Sulfuric acid 513.71 0

Water produce 0 94.34
Ferrous oxide 376.381 0
Impurity 40.30 40.30
Total 930.39 930.39
3.a. VII. MATERIAL BALANCE AROUND EVAPORATIVE CRYSTALIZER AT A
GLANCE
DATA AND ASSUMPTION
i) Temperature maintained at 650C
ii) Pressure at 0.1 N/ mm2
III) MATERIAL BALANCE AROUND EVAPORATIVE CRYSTALIZER
AT A GLANCE

Kg Kg
38
Ferrous sulfate 795.66 0
Water 3078.065 2983.72

Ferrous monohydrate 890
Impurity 20.10 20.10
Total 3893.83 3893.82
3 b. ENERGY BALANCE:
3.b.i .ENERGY BALANCE OF THE PLANT.
Process stream at high pressure or temperature, and those containing combustible
material, contain energy that can be usefully recovered. Whether it is economic to recover
the energy content of a particular stream will depend on the value of the energy that can
be usefully extracted and the cost of recovery. The value of the energy will depend on the
primary cost of energy at the site. It may be worth while recovering energy from a
process stream at a site where energy costs are high but where the primary energy cost
are low. The cost of recovery will be the capital and operating cost of any additional
equipment required. If the savings exceed the operating cost, including capital charges,
then the energy recovery will usually be worthwhile. Maintenance cost should be
included in the operating cost.
3.b.ii. ENERGY BALANCE
Energy balances can be calculated on the basis of external energy used per kilogram of
product, or raw material processed, or on dry solids or some key component. The energy
consumed in food production includes direct energy which is fuel and electricity used on
the farm, and in transport and in factories, and in storage, selling, etc.; and indirect energy
which is used to actually build the machines, to make the packaging, to produce the
39
electricity and the oil and so on. Food itself is a major energy source, and energy balances
can be determined for animal or human feeding; food energy input can be balanced
against outputs in heat and mechanical energy and chemical synthesis.
III.(b) iii. ENERGY BALANCE AROUND THE EVAPORATIVE CRYSTALIZER
Here we used a Calendria low carbon steel.
REACTIONS ARE AS BELLOW
FeSO4 + H20-------------- FeSO4H2O
Ferrous Sulfate Water Ferrous sulfate monohydrate
DATA & ASSUMPTIONS:
i) Temperature 65 C
CALCULATION:
The basic equation for solving for the capacity of the evaporator, which is written as,
q= UA T..................................(ii)
where T K is the difference in temperature between the condensing steam and the boiling
liquid in the evaporator. The feed to the evaporator is F kg/hr having the solid content of x F
mass fraction, temperature TF, and enthalpy hF J/kg. Coming out as a liquid is the
concentrated liquid L kg/h having solid content of x L, temperature T1, and enthalpy hL. the
vapour V kg/h is given off as pure solvent having a solid content of y V = 0, temperature T1,
and enthalpy of HV. Saturated steam entering is S kg/ hr and has a temperature of T S and
enthalpy of HS. The condensed steam leaving of S kg/hr is assumed usually to be at T S, the
40
saturation temperature, with an enthalpy of h S. This means that the steam gives off only is
latent heat, which is
= HS - hS------------------------------(ii)
The vapour V is in equilibrium with the liquid L, the temperature of vapour and liquid are
the same. Also the pressure P1 is the saturation vapour pressure of the liquid of composition
xL at its boiling point T1.
For the material balance since we are at steady state, the rate of mass in = rate of mass out.
Then for a total balance,
F= V +L
For a balance on the solute alone,
F xF = LxL
For the heat balance, since the total heat entering = total heat leaving
So, Heat in feed + Heat in steam = Heat of concentrated liquid + Heat in vapour + Heat in
condensed steam
The assumes no heat lost by radiation or convection, Substituting and we get,
F hF+ SHS = L hL + VHV + ShS------------------------(I)
Substituting into,
FhF + S = L hL + VHV -------------------------------(ii)
The heat q transferred in the evaporator is then,
q = S( HS - hS) = S x
The latent heat of steam at the saturation temperature T S can be obtained from the steam
tubes. However, the enthalpies of the feed and products are often not available. These
41
enthalpy- concentration data are available for only a few substances in solution. Hence,
some approximation are made in order to make a heat balance.
Here, we get,
xF = 0.2, F = 3893.83 Kg, L = 1393.72 Kg & V = 2500 Kg as per material balance.
Specific Heat of Ferrous sulfate = 0.167 cal/ gm 0C = 0.699 kJ/ Kg K
hF = 1* 0.699 * (65-25) = 27.97 kJ
We assume the steam supplied at saturated at 143.3 kPa, from steam table we get the steam
temperature is 383.2 K, at this temperature the latent heat 2230 kJ/kg
From equation, we get,
3893.83 x 27.97 + S x 2230 = 2500 x 0 + 1393.72 x 2618
or, 108.91 + 2230S = 3648.75
or, S = 1636.17 Kg
Steam required 1637 kg /h
3.b.iv. ENERGY BALANCE AROUND THE COOLER
DATA & ASSUMPTIONS:
(a) Pickle liquor enter the cooler at 87.8 0C & out let temperature at 25 0 C
(b) Cooling water enters at 250C and leaves at 400C i.e. rise in temperature is 150C
(c) Saturated steam of pressure 3 kg/cm2 absolute is supplied as heating media.
CALCULATIONS:
COOLING WATER REQUIREMENT FOR CONDENSER
Cooling water requirement for condenser is given by the equation;
WC x CP water x (T2 T1) = Wm x CP pickle liquor x (T3 T4) -------(iv)
Where,
42
WC = Weight of the cooling water ,kg
CP water = Specific heat of the water, Kcal/kg 0C
T2 T1 = Rise of Cooling water temperature, 0C
V = Vapor from the column top to overhead
condenser, kg mole /hr
Wm = Weight of the pickle liquor ,kg
CP pickle liquor = Specific heat of the water, Kcal/kg 0C
T3 T4 = difference of pickle liquor temperature , 0C
we get
WC x4.18 x 15 = 3978.745 x 4.18 x 62.8--------------(v)
or, WC = 16657.69 kg
Therefore, we use specific heat of pickle liquor is based on water specific heat because
pickle liquor consist of 75 % water.
So, Cooling water required = 16658 kg/ h
OTHER FORMS OF ENERGY
Motor power is usually derived, in factories, from electrical energy but it can be produced
from steam engines or waterpower. The electrical energy input can be measured by a
suitable wattmeter, and the power used in the drive estimated. There are always losses
from the motors due to heating, friction and windage; the motor efficiency, which can
normally be obtained from the motor manufacturer, expresses the proportion (usually as a
percentage) of the electrical input energy, which emerges usefully at the motor shaft and
so is available.
43
When considering movement, whether of fluids in pumping, of solids in solids handling,
or of foodstuffs in mixers. the energy input is largely mechanical. The flow situations can
be analysed by recognising the conservation of total energy whether as energy of motion,
or potential energy such as pressure energy, or energy lost in friction. Similarly, chemical
energy released in combustion can be calculated from the heats of combustion of the
fuels and their rates of consumption. Eventually energy emerges in the form of heat and
its quantity can be estimated by summing the various sources.
44
CHAPTER-4
DESIGN OF NEUTRALIZER UNIT
. Neutralization is the process of adjusting the pH of solution through the addition of an acid
or a base, depending on the target pH and process requirements. Spent pickle liquors are
45
neutralized with an alkali such as sodium hydroxide (caustic soda) or calcium hydroxide
(lime). In the case of stainless steel pickle liquors containing fluoride, lime is usually
utilized. Calcium fluoride is only slightly soluble, so that fluoride ions are precipitated
simultaneously with the metal ions. Unfortunately, neither lime nor caustic are effective
in removing nitrate ions which are tightly regulated in many jurisdictions. The cost of
these neutralizing chemicals and disposal of the resulting sludge is considerable and can
contribute appreciably to the overall cost of pickling the metal. The engineering design of
a successful neutralization system involves several steps. Engineering design should be
based on several factors such as optimum process parameter, laboratory-scale tests and
their results, and finally, cost analysis. Practical aspects such as availability of
neutralizing agent in the near vicinity and thus reduced transportation costs play an
important role in process design. The important steps involved in neutralization process
design are outlined below. All neutralization process, irrespective of type of waste, share
several basic features and operate on the principle of acid- base reaction. Successful
design of a neutralization process should consider the following:
Influent wastewater parameters
Type of neutralizing agent used
Availability of land
Laboratory scale experimental results
The overall design of neutralization process involves the design of the following
features:
i. Neutralization basin
ii. Neutralization agent requirements based on theoretical and treat ability studies
46
iii. Neutralization agent storage (e.g., silo, silo side valve, dust collector, and foundation
design)
iv. Neutralization agent feeding system
v. Flash mixer design.
CALCULATION OF NEUTRALIZATION SIZE
Assume solution depth = 1.5 m and detention time period= 40 min.
Total Flow rate per hour = Pickle Liquor + Lime solution
= 3978.745 + 789.52= 4768.265 Kg
Flow rate per hour = {4768.265 Kg /(1000 Kg/m3)}
= 4.768 m3/h
Required Volume = 4.768( m3/h) x (1/60 ) (h/min) x 40 min
=3. 18 m3
Total volume = 3.18/ 0.25 = 12.72 m3
So, Required Volume = (1/3 ) * A* h
here, A= area of the top of the tank
h= height of the tank
(1/3)* (/4)d2 * h = 12.72
Assume diameter = d= 4 m
or, (1/3)* (3.14/4) (4)2* h =12.72
or, h = 3.038 m
INLET AND OUTLET NOZZLE DIAMETER
CALCULATION :
Nozzle Diameter is given by D = (8.4 W0.45)/ 0.35
47
Where,
D = Diameter, mm
W = Mass flow of fluid, Kg/ hr.
= Density of fluid, kg/m3
CALCULATION OF INLET NOZZLE
Mass flow rate of Pickle liquor inlet = W = 3978.745 kg
Average Density of Inlet liquid= 960 Kg/m3
So, inside diameter of inlet nozzle
D inlet = 0.84 x (3978.745)0.45 / ( 960) 0.31
= 4.165 Cm
= 41.65 mm
Use 48 mm diameter including corrosion allowance.
Mass flow rate of Lime solution inlet = W = 789.52 kg
Average Density of Inlet liquid= 960 Kg/m3 Lime
inlet nozzle diameter
D inlet = 0.84 x (789.265)0.45 / ( 960) 0.31
= 2.012 Cm
= 20.12 mm
CALCULATION OF OUTLET NOZZLE
Mass flow rate of outlet nozzle
D outlet = ( 8.4 x W0.45)/ 0.35
48
Where,
W = Mass flow rate of outlet = 4766.66 kg
=Average density kg/m3 = 1000
We get,
D outlet = 0.84 x (4766.66)0.45 / (1000) 0.31
= 4.46 Cm
= 44.6mm
So use 60 mm diameter including corrosion allowance.
Type of Neutralizer Conical

No of Neutralizer 01
Volume of Neutralizer 12.72 m3
Height of Neutralizer 3.038 m
Diameter of Neutralizer 4.000 m
Pickle liquor
Lime solution
Outlet nozzle diameter of the Neutralizer 60 mm
MECHANICAL DESIGN OF THE NEUTRALIZER
DATA AND ASSUMPTION:
SHELL SIDE
i) Internal diameter = 4000 mm
ii)Material = LOW CARBON STEEL
iii) Permissible Stress = 13.00 Kg / mm2
49
iv) Working pressure = 1.033 Kg / Cm2
FLANGED AND SHALLOW DISHED
i) Internal diameter = 4000 mm
ii) Crown radius = 4000 mm
iii) Knuckle radius = 6% of shell I.D. = 240 mm
iv) Material = Same as Shell
BOLTS
i) Material = Hot soled carbon steel
ii) Permissible Stress = 5.87 Kg / mm2
iii) Permissible Stress (Operating condition) = 5.45 Kg / mm2
FLANGES
i) Material = Carbon steel
iii) Gasket = Asbestos
CALCULATION;
DESIGN OF SHELL
We know the equation of thickness of shell,
t = (PD1)/ (2fj-P)----------------------------------(vi)
Where, P = Design pressure
J = joint efficiency
f = design on permissible stress at design temperature
= 13.00kg/mm2
D1 = Internal diameter = 4000 mm
50
Hence design pressure = 10% excess of internal pressure
We know internal pressure =1atm=1.033 kg/cm2
So design pressure = P=(1.1*1.033) =1.136 kg/cm2
t = (1.136x 4000)/{2x13.00x100x(0.85-1.136)}
= 5.84mm
Use minimum thickness 20 mm.
4. b.iii. DESIGN OF GASKET
The flange is made of cast iron with a glass lining (raised face) in the form of a ring. A
flat Teflon gasket of 4000 mm internal diameter and 4040 mm external diameter and
3mm thickness is used to cover the raised face.
Gasket factor = (m) = 2.00
Minimum design seating stress = 112 kg / mm2
Basic gasket seating width (b0) = 0.5 X ( 4000 -4040)/2
=10mm
Effective gasket seating width (b) = 2.5x b0
= 7.9mm
NOZZLE THICKNESS
We get,
tn = [(PD) / ( 2fj P )]---------------------------------------(vii)
Where,
tn = Nozzle thickness, P = Design pressure
f = Permissible stress, D = Inside diameter
51
J = Joint efficiency =1 (For Seamless pipe)
We get,
tn = (1.136x 4000)/(2 x1300 x1 x 1.136)-----------------------(viii)
= 1.54 mm
use 20 mm thickness
DESIGN OF AGITATOR
DATA & ASSUMPTION:
Diameter of the vessel = 4000 mm
Internal pressure of the vessel = 0.5 N/ mm2
Diameter of the agitator = 1200 mm
Maximum Speed = 200 rpm
Liquid in vessel sp gravity = 1.2
viscosity = 600 cp
Overhang of agitator shaft between bearing and agitator = 2200 mm
Agitator blades (flat) nos. =6
With of the blade = 75 mm
Thickness of blade = 10 mm
Baffles at tank wall nos. =4
Shaft material - commercial cold rolled steel
Permissible stress for key (carbon steel)
shear = 65 N/ mm2
crushing = 130 N/mm2
52
Carbon steel stuffing box
permissible stress = 95 N/mm 2
Studs and bolts (hot rolled carbon steel)
permissible stress = 58.7 N/mm2
Assumed that the vessel geometry conforms to the standard tank configuration.
From the equation,
NRC=(Nda2)/ ------------------------------(ix)
where,
NRC = Reynolds Number
= density of the liquid in Kg/ m3
da = agitator diameter in m.
= viscosity in kg/m sec
N = speed of agitator in revolution per second
We get,
NRC= [1.2 x 1000 x (200/60) x ( 1200/1000)2]/ 600 x 10-3
= 9600
From the power curve,
NP = 2.8
From the equation,
P= [(NP x x N3 x Da5)/gc x 75 ]------------------(x)
where,
N = Power in Kg m.
gc = gravitational acceleration in m/sec.
53
P = {2.8 x 1.2 x 103 x (200/60)3 x (1200/1000)5 }/9.81 x 75
= 420.90 hp
Gland losses =10% = 42.09 hp
Power input = 420.90 + 42.09 = 462.99 hp
= 462 .99 x 0.7457 =345 Kw
Transmission system losses = 20%
= 462.99 x 0.2 =92.60 hp
Total hp = 462.99 + 92.60 = 555.59 hp
= 555.59 x 0.7457 = 414 .30 Kw
This will be taken as 425 kw to allow for fitting losses.
Use 450 Kw ( 603 hp) motor
SHAFT DESIGN
For shaft design assume power required as 603 hp. Use solid shaft of diameter d.
From the equation, we get,
Average Torque = TC = (hp x 750x 60)/ (2 x N)-----------------------(xi)
= (603 x 750 x 60)/ 2 x 200
= 21604 Nm
Max. Torque = Tm = 1.5 x 21604 = 32406 Nm
ZP = (1.5 x TC ) / fS --------------------------------(xii)
=32406 /55 = 589.2 cm3
or, ( d3)/16 = 589.2
54
or, d3 = 3002 = 14.4cm 15 cm
From the equation,
Fm = Tm/ (0.75 x Rb)---------------------------(xiii)
Where,
Rb = radius of the blade
The torque Tm is resisted by a force Fm acting at a radius of 0.75Rb from the axis of the
agitator shaft.
Fm = (32406 x 1000)/ (0.75 x 600)
= 72013 N
The maximum bending moment M occurs at a point near the bearing, from which the shaft
overhangs
M = Fm x l = 72013 x 2.2
[ where, l = shaft length between agitator and bearing]
= 158428.6Nm
From the equation,
Me = (1/2) [ M + M2+ (Tm)2] --------------------------------(xiv)
where, M = bending moment.
Me = (1/2) [ 158428.6 + (158428.42 + 324062)]
= 160068 Nm
f = Me/ Z ------------------------------------(xv)
where,
Z= modulus of section of the shaft cross section.
55
f = 160068 x 1000 / {( x 43 x 1000)/32}
= 25488 N/mm2
Stress f is higher than the permissible elastic limit ( 246 N/mm2). Therefore, use a 6 cm
diameter shaft for which the stress will be
f =221 N/mm2
DEFLECTION OF SHAFT
From the equation,
= Wl3/ 3 EI------------------------------------------(xvi)
Where,
l = appropriate length
W = Concentrated load
E = modulus of elasticity
I = moment of inertia of the cross section of shaft
We get,
= Fm x (220)3 /3 x 19.5 x{ ( x 64)/4} x 104 x 1000
= {72013 x (220)3 x 4 }/ {3 x 19.5 x x 64 x 104 x 1000}
= 1.29cm
From the equation,
NC= (60 x 4.987 )/ [1+2+3+( S/1.27)]2 -----------------------(xvii)
Where 1,2,3 & S are the deflections in cm due to each load.
Nc = (60 x 4.987)/ 1.29 = 263.45 rpm
56
Since the actual shaft speeds is 200 rpm which is 76% of the critical speed, it is necessary to
increase the value of critical speed, by decreasing the deflection. So, we chose 6.5 cm
diameter shaft.
therefore, = 0.94 cm
Nc = (60X 4.987) / 0.94 = 320 rpm
Actual speed of 200 rpm is satisfactory, which is 62.5 % of the critical speed.
BLADE DESIGN
From the equation,
f = Max. BM/Z = F {0.75 x (Rb - Rh)}/ (b1 x bw2/6)--------------(xviii)
Where, F = force on each blade
Rb = radius of blade
Rh = radius of hub
We get,
f = ( 673 x 1000) / {10 x (75)2/6}
= 71.78 N/ mm2
The value of the stress is well within the endurance limit for carbon steel.
HUB AND KEY DESIGN
Hub diameter of agitator = 2 x Shaft diameter
= 2 x 6.5 = 13 cm
Length of hub = 2.5 x 6.5 = 16.25 cm
Length of key (ll ) = 1.5 x Shaft diameter
= 1.5 x 6.5 = 9.75 cm
From the equation,
57
Tmax/(d/2)= ll b fs = (it/2) fc ---------------------------(xix)
= (673x 100)/ {(6.5 x 10) /2}
= 9.75 X b x 65 = 9.75 x (t/ 2) x 1300 x 10
b = 3.27 mm
t = 3.27 mm
Use 4 mm x 4 mm x 10 cm key.
STUFFING BOX AND GLAND
Internal design pressure = 0.55 N/mm2
From the equation,
b= d + d = 6.5 + 6.5 = 9.05 cm----------------------(xx)
Load on gland
t =( Pb/2f )+ c--------------------------------(xxi)
= (0.55 x 9.05 x 10)/ (2x 95) = 0.262 + c = 4 mm
And we get,
a = b+ 2t = 9.05 + 0.8
= 9.85 cm
10.00 cm
Load on the gland
F = [( / 4) x 0.55 ( 9.052 - 6.52) x 100]------------------(XXII)
=1712 N
Size of stud
1712 = ( x do2/4)x n x f1
= ( x do2/4) x 4 x 58.7
58
do2 = 9.29 cm = 92.9 mm
do = 9,63 mm
Minimum stud diameter = 20 mm
Flange thickness = 1.75 x 20 = 35 mm
COUPLING
A clamp coupling is taken. It is made of cast iron .
We get from the equation,
Force per bolt
= (2x Tmax)/[ d x (n/2)] --------------------------------------(xxiii)
= (2x 673 x 1000) / { x 0.35 x 65 x (4/2)}
= 9421 N
Area of the bolt = 9421/ 5870 = 1.605 cm2
Diameter of the bolt = (1.605 x 4) / = 2.044 cm
= 20.44 mm
Use 24 M size bolts
Overall diameter of coupling = 6.5 x 2 = 13 cm
BRACKET OR LUG SUPPORT FOR A VERTICAL CONICAL VESSEL
These can be easily fabricated from plates and attached to the vessel wall with minimum
welding length. They are made to rest on short columns or on beams of a structure
depending on the elevation required. They can be easily leveled. Due to the eccentricity of
these support and the resulting bending moment, compressive, tensile and shear stresses are
induced in the vessel wall. These stresses must be combined with circumferential and
59
longitudinal stresses produced in the vessel wall due to operating pressure. The shear
stresses being of a smaller magnitude can be ignored.
DATA AND ASSUMPTION
Diameter of the vessel = 4000 mm
Height of the vessel = 3.038 mm
Clearance of the vessel with contents = 1 meter
Weight of the vessel bottom to foundation = 60000 kg
No. of brackets = 4
Diameter of anchor bolt circle = 2755 mm
Wind pressure (P) = 128.5 kg/ cm2
Height of the bracket from foundation = 2.25 meter
Permissible stresses for structural steel:-
Tension = 14000kg/ cm2
Compression = 1233kg/ cm2
Bending = 1573 kg/ cm2
Permissible bearing pressure for concrete = 35 kg/ cm2
MAXMUM COMPRESSIVE LOAD
Wind pressure from the equation,
Pw = K p h D0-------------------------(xxiv)
Where,
K = Coefficient depending on the slop factor [0.7 for cylindrical surface]
H= Height of the vessel
D0 = Outside diameter of the vessel
60
= (4000+2 X10)
= 4020 mm
= 4.020meter
We get,
Pw = (0.7 x 128.5 x 3.038 x4.020)
= 1098 Kg
Then we get from the equation,
P = [{4 x Pw x ( H F )}/ n Db + ( w / n)]------------------------(xxv)
Where,
P= Total force due to wind load action acting on the vessel.
E = Vessel clearance from foundation to vessel bottom
H= Height of the vessel above the equation
Db = Diameter of the bolt circle
w = Maximum Weight of the vessel with attachments and contents
n = No. of brackets
We get,
P = {(4 x 1098 x 3.038)/ (4 x 4.020)}+ (60000 /4 )
= 15830 Kg [ Where, h = H - F ]
BRACKET
BASE PLATE
Suitable base plate size:-
a = 140 mm =14 cm;
b = 150 mm=15 cm
61
Paw= ( P/ab) -------------------------(xxvi)
= ( 15830)/(14 x15)
=75.39 kg/ cm2
We get,
f = [0.7 Paw x ( b2 / T12) { a4/ ( b4+a4)}]--------------(xxvii)
The thickness t1 should be so chosen that the stress (f) should be within permissible limits.
i.e. f =[ 0.7 x 75.39x (152/T2) { 144/ (154+144)}]
=( 5122/ T2)
Now we know that,
f = 1575 kg / cm2
Then we get,
T2 = [(5122/1575)X 100]
= 18.03 mm
We use 25 mm thickness.
WEB PLATE
Stress at the edge,
f = (3PC/ T2 h2)---------------------------(xxviii)
The edge is at an angle from the horizontal.
The maximum compressive stress parallel to the edge of the web plate
= (3PC/ T2 h2) x (1/cos)-----------------------------(xxix)
Where,
62
C =[ (A D)/2]----------------------------------------------(xxx)
And C, T2, h, are the stress shall not exceed the permissible value.
Bending moment of each plate = (15830/2) x {(4.020 4.000)/2} x 100
=7915 Kg cm
Stress at the edge of
f = [{7915/( T2 x 14x14)} x (1/0.707) x (1/100)]
= (0.57/ T2)
We know that,
f = 1575 kg/cm2
We get,
T2 = 0. 00036 cm
=0.004 mm
Use 20 mm thickness.
COLUMB SUPPORT FOR BRACKET
It is proposed to use a channel section as column.[6].
Size = 150 x75
Area of cross section (A) = 20.88 cm2
Modulus of section (ZYY) = 19.4 cm2
Radius of section (YY) = 2.21 cm
Weight = 16.4kg/m
Height of the foundation = 2.25 m
Equivalent length for fixed ends (le) = (L/2)
= (2.25/2)
63
=1.125m
Slenderness ratio = ( le/)
= [(1.125 x100)/ 2.21]
= 51.0
Then we get from the equation,
f= [(w/A x n) +{ ( w x e )/ n x z}]-----------------(xxxi)
Where,
w = Load an column, A= Area of cross section,
z = Modulus of section of the cross section,
n = Number of column, e = Eccentricity,
We get,
f = (15830/20.88) + {(15830 x 0.75)/27.2}
= 1194.6 kg/cm2
We get,
fc = [(w/A x n) [ 1+ a (le/)2] + {( w x e ) / n x z }]
Where,
le = Effective length of the column
a = Constant
r = Radius
We know, le = 0.5 ( for fixed ends of the column)
We get,
fc = [(15830/2x20.88){ 1+ (1/7500) (51.0)2}]+{(15830x 0.75)/27.2}
= 947 kg/cm2
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The calculated values are less than the permissible compressive stress and hence the
channel selected is satisfactory.
BASE PLATE FOR THE NEUTRALIZER
The size of the column is = 150 x 75
The base plate extends 20 mm on either side of the channel
Side B = 0.8 x 75 + 2 x 20 = 100 mm
Side C = 0.95 x 150 + 2 x 20 = 182.5 mm
Now we get from the equation, Pb = P x (1/ B x C)
Here B and C are the two sides
Bearing pressure,
Pb = (15830/4 ) x { 1/ (10 x 18.25)}
=21.68 kg/cm2
Than the permissible bearing pressure for concrete stress in the plate
f = [{(21.68/2) x (20)2}/100] / (t2/6)
= 260.22/ t2
Where,
f = 1575kg/cm2
Therefore, t2 = 260.22/1575
Or, t = 0.41 Cm
= 4.1mm
Use 20 mm thickness
MECHANICAL DESIGN OF THE NEUTRALIZER A GLANCE
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Shell material Low carbon steel

Shell thickness 20 mm
Effective gasket seating width 7.9 mm
Nozzle Thickness 20 mm
Agitator type Turbine
Power taken to agitator 450 Kw
Agitator diameter 1200 mm
Permissible stress of Shaft 25488 N/mm2
Max. Torque 32406 Nm
Actual Shaft Speed 200 rpm
Critical Shaft Speed 320 rpm
Flange Thickness 35 mm
Max. Stud diameter 20 mm
Force per bolt 9421 N
Bolt Size 24 M
Coupling diameter 130 mm
Height of bracket from foundation 2.25m
Maximum compressive load 15830 kg/cm2
Base plate thickness of Bracket 25mm
Web plate thickness of Bracket 20mm
Base plate thickness for column 20mm
66
CHAPTER- 5
DESIGN OF EVAPORATIVE CRYSTALLIZER
67
PROCESS DESIGN OF EVAPORATIVE CRYSTALLIZER
Crystallization is a process in which solid crystalline phases separate from liquids. The
object of the process is usually the recovery of the solute from the solvent. The performance
of the process is evaluated by the size, shape, structure and purity of the solute. Crystalline
products have an attractive appearance, are free flowing, and easily handled and packaged.
EVAPORATIVE CRYSTALLIZATION
The calendria type evaporator preferably with short wide tubes and large central down
take, with the bottom in the form of a conical head can be used as a crystalliser.
AREA CALCULATION
CALCULATION:
The basic equation for solving for the capacity of the evaporator, which is written as,
q = UA T------------------------------(i)
where T K is the difference in temperature between the condensing steam and the boiling
liquid in the evaporator. The feed to the evaporator is F kg/hr having the solid content of x F
mass fraction, temperature TF, and enthalpy hF J/kg. Coming out as a liquid is the
concentrated liquid L kg/h having solid content of x L, temperature T1, and enthalpy hL. the
vapour V kg/h is given off as pure solvent having a solid content of y V = 0, temperature T1,
and enthalpy of HV. Saturated steam entering is S kg/ hr and has a temperature of T S and
enthalpy of HS. The condensed steam leaving of S kg/hr is assumed usually to be at T S, the
68
saturation temperature, with an enthalpy of h S. This means that the steam gives off only is
latent heat, which is
= HS - hS----------------------------------(ii)
The vapour V is in equilibrium with the liquid L, the temperature of vapour and liquid are
the same. Also the pressure P1 is the saturation vapour pressure of the liquid of composition
xL at its boiling point T1.
For the material balance since we are at steady state, the rate of mass in = rate of mass out.
Then for a total balance,
F= V +L-------------------------------------(iii)
For a balance on the solute alone,
F xF = LxL ----------------------------------(iv)
For the heat balance, since the total heat entering = total heat leaving
So,
Heat in feed + Heat in steam = Heat of concentrated liquid + Heat in vapour + Heat in
condensed steam
The assumes no heat lost by radiation or convection, Substituting and we get,
F hF + SHS = L hL + VHV + ShS------------------(v)
Substituting into,
FhF + s = L hL + VHV -------------------------------(vi)
The heat q transferred in the evaporator is then,
q = S( HS - hS) = S--------------------------------(vii)
The latent heat of steam at the saturation temperature T S can be obtained from the steam
tubes. However, the enthalpies of the feed and products are often not available. These
69
enthalpy- concentration data are available for only a few substances in solution. Hence,
some approximation are made in order to make a heat balance.
Here, we get,
xF = 0.2, F = 3893.83 Kg, L = 1393.72 Kg & V = 2500 Kg as per
From material balance.
Specific Heat of Ferrous sulfate = 0.167 cal/ gm 0C = 0.699 kJ/ Kg K
hF = 1* 0.699 * (65-25) = 27.97 kJ
We assume the steam supplied at saturated at 143.3 kPa, from steam table we get the steam
temperature is 383.2 K, at this temperature the latent heat 2230 kJ/kg
From equation no (i), we get
3893.83 x 27.97 + S x 2230 = 2500 x 0 + 1393.72 x 2618
or, 108.91 + 2230S = 3648.75
or, S = 1636.17 Kg
Steam required 1637 kg /h
The heat required q transferred through the heating surface area A
q= S x
or, q = 1636.17 x 2230 x (1000/3600) = 1013516 W
And we get , T= Ts-T1 = (383.2- 373.2) =10
then, q = 1013516 = U x A x T = 1560 x (A) x 10
[ U = overall heat transfer coefficient)
A = 64.97 m2
FEED, PRODUCT AND STEAM INLET NOZZLE DIAMETER
CALCULATION:
70
Nozzle Diameter is given by D = (8.4 W0.45)/ 0.35-----------------------------(viii)
Where,
D = Diameter, mm
W = Mass flow of fluid, Kg/ hr.
= Density of fluid, kg/m3
CALCULATION OF FEED NOZZLE
Mass flow rate of Feed = W = 3893.83 kg
Density of the fed liquid = 990 kg/m3
So, inside diameter of inlet nozzle
D inlet = 0.84 x (3893.83)0.45 / ( 990) 0.31
= 4.08 Cm
= 40.80 mm
CALCULATION OF PRODUCT NOZZLE
Mass flow rate of overflow nozzle
D overflow = (8.4 x W0.45)/ 0.35-----------------------------------(ix)
Where,
W = Mass flow rate of outlet = 3892.82 kg
= Average density kg/m3 = 1270 Kg/m3
We get
D Product = 0.84 x (3892.82)0.45 / (1270) 0.31
= 3.78 Cm
= 37.8mm
71
CALCULATION OF STEAM INLET NOZZLE
D mother liquor = (8.4 x W0.45)/ 0.35-------------------------------------(x)
Where,
W = Mass flow rate of Steam = 1636.17kg
= Average density kg/m3 = 1000 Kg/m3
We get,
D outlet = 0.84 x (1636.7)0.45 / (1000) 0.31
= 2.76Cm
= 27.6 mm
Use 40 mm diameter including corrosion allowance
PROCESS DESIGN OF THE EVAPORATIVE CRYSTALLIZER
Type of Crystallizer CALEMDRIA

No of Crystallizer 01
Crystallizer Area 64.97 m2
Crystallizer feed nozzle diameter 60 mm
Crystallizer Product nozzle diameter. 60 mm
Steam Inlet nozzle diameter 40 mm
MECHANICAL DESIGN OF THE EVAPORATIVE CRYSTALLIZER
DATA AND ASSUMPTION:
DATA:
i) Evaporator drum under vacuum =external pressure 0.1 N/mm2
ii)Amount of water to be evaporated = 25000 N/hr
iii) Heating Surface required = 220mm2
72
iv) Steam pressure = 0.13 N/mm2
v) Density of liquid = 9900N/m3
vi) Density of Vapour= 0.83 N/m3
M ATERIAL
i) Evaporator = Low carbon steel
ii) Tube = brass
iii) Permissible Stress for low carbon steel = 98 N/ mm2
iv) Modulus of elasticity for low carbon steel = 19.0 X 104 N/mm2
v) Modulus of elasticity for brass = 9.4 X 104 N/mm2
. FLANGES
i) Material = Carbon steel
iii) Gasket = Asbestos
4. HEAD
i) Conical head at bottom = Cone angle - 1200
ii) Conical head at top = Cone angle - 1200
CALCULATION
CALENDRIA WITH VERTICAL TUBES:
Use 100 mm outside diameter 1.5mm thick tubes. The length of the each tube is taken as
1220 mm, the effective length being 1165 mm.
Number of tube = {(Heat transfer area)/(x0.1x1.165)}
= 220/(x0.1x1.165)
73
= 605
Pitch of tube (triangular) = 125mm
Area occupied by tubes from the equation
an = n x 0.866 ST2 ..................................(i)
Where,
ST = pitch of tube.
n = number of tubes
an = Total area
From equation (i),
an = 605x0.806x(0.125)2
= 8.16 m2
Let the proportionality factor be 0.9.
Then we get from the equation
AS = x (D2/4)
= (n x0.866ST2)/
Where,
AS = area of the shell
D= inside diameter of the shell
Area required = 8.16/0.9 = 9.86 m2
Required area for central down take = 40% x cross-section area of tubes
= [0.4x 605x{(x0.01)/4}]
= 1.88 m2
Use a 1500 mm inside diameter and 1520 mm outside diameter pipe as a central down take.
74
Actual area of down take = ( x 1.522)/4 = 1.81 m2
Total area of the tube= 9.06 +1.81 = 10.87 m2
Diameter of tube sheet= (10.87 x 4)/ = 3.71 m2= 3700 mm
CALENDRIA SHEET THICKNESS
From the equation,
ts = PDi /(2fJ-P)-------------------------------(ii)
Where, Design Pressure = P
Diameter of tube sheet = Di
Permissible stress = f
Joint Efficiency = J
So, we get.
ts = (0.165 x 3710)/( 2 x 98 x 0.85 - 0.165)
= 3.67 mm
use 12 mm thickness sheet .
CALENDRIA TUBE SHEET THICKNESS:
From the equation,
k= {EStS (Do- tS)}/{EtNTi (do-tt)}....................................(iii)
Where,
ES =elastic modulus of shell
Et = elastic modulus of tube
Do= outside diameter of shell
do=outside diameter of tube
75
tS = shell thickness
tt = tube wall thickness
N = number of tubes in shell
Then we get from equation (ii),
k= {19.0x 104x 10( 3710 -10)}/ {9.5 x 104 x 605 x 1.5 x (100 -1.5)}
=0.832
From the equation
Shell side pressure = F ={k/ (2+3k)} = {0.832/ (2x3x0.832)}0.5
= 0.43
And from the equation, we calculate tube sheet thickness
t= FG (0.25p/f)---------------------------------------(iv)
Where,
t= effective thickness of the tube
p= design pressure
f= allowable stress at appropriate temperature
G= mean diameter of gasket
So, we get,
t= (0.43 x 3710) {(0.25x 0.165x 100)/98}
=32.8 mm
With corrosion allowance the thickness may be taken as 36 mm.
BOTTOM FLANGE OF CALENDRIA
A flange is provided at the bottom of calendria for fixing the conical head.
The size of flange selected is as follows:
76
Thickness of the flange = 40 mm
Number of bolts = 112
Pitch circle diameter = 3825 mm
Size of bolts = 20 M
Outside diameter = 3894 mm
EVAPORATOR DUM
The entrainment separator is to be used in the form of baffles, placed at the top of the drum.
The diameter of the drum may be same as that for the calendria. However, it is necessary to
check the size from the point of satisfactory entrainment separation.
From the equation, we get
Rd = (V/A) / 0.0172X { (L - V)/V}0.5--------------------------(v)
Assuming Rd = 0.8 for the baffle system
A = {(25000/3600) x (1/0.83)}/(0.8 x 0.0172) {( 9900- 0.83)/0.83}0.5
= 5.7 m2
Drum Diameter = (D= 5.7x 4)/
= 2.69m
Use drum length = 3 m
DRUM THICKNESS:
Drum is under vacuum. Design is, therefore, based on an external pressure of
0.1 N/mm2. Assume a thickness of 10 mm.
The critical external pressure is calculated by the equitation as follows:
pc= { 2.42E(1/Do)5/2}/ (1- 2)3/4[(L/Do)- 0.45(1/Do)1/2]-------------------(vi)
={ (2.42x 19x104)/(1- 0.32)3/4}x [ (10/3730)5/2/{(30/3730)- 0.45(10/3730)1/2}]
77
= 0.235 N/mm2
Pall =Pc/ 4 =0.058 N/mm2----------------------------------------(vii)
According to IS-2825
Unfired fusion welded pressure vessels, excluding:
a = Pressure exceeding 20 N/mm2,
b= Ratio of outside to inside diameter grater than 1.5,
c = Internal operating pressure less than 0.1 N/mm2,
d = Intern diameter less than 150 mm,
e = Nominal water capacity of 500 litres or less.
we get,
L/Do = 3000/(3710+20) = 0.806
Do/t = (3710+20)/ 10 = 373
Factor, B=350
Pall = B/(14.22x 373) = 350/ (14.22 x 373)
= 0.0662 N/mm2
The thickness of 10 mm is not satisfactory. Assume a thickness of 12 mm.
ps= {(2.42 x 19.104)/ (1-0.32)3/4} x (12/3734)5/2/[ (3000/3743) - 0.45 (12/3734)1/2]
= 0.371 N/mm2
Pall = 3.71/4 = 0.093 N/mm2
According to IS-2825,
we get,
L/Do = 3000/ (3710 +24) = 0.806
Do/t = (3710+24)/12 = 310
78
Factor, B=350
Pall = 450/(14.22x 310) = 0.102 N/mm2
The thickness may be taken as 13 mm inclusive of corrosion allowance.
The compressive stress from the equitation,
fc = pD/2t = (0.102x 3734)/(2 x12 ) = 15.9 N/mm2
which is well within the permissible stress value.
CONICAL HEADS AT TOP AND BOTTOM:
The head thickness is based on an external pressure of 0.1 N/mm 2 Assume a thickness of 14
mm. The conical head with an angle of 1200 is taken as equivalent to the shell, with the
length of shell as equal to the diameter of shell.
According to IS-2825,
L/Do = 3710/(3710+28) = 0.996 1
Do/t = (3710+28) / 14 = 267
Factor, B = 450.6
Pall = 450/(14.22 x 267) = 0.118 N/ mm2
The thickness may be taken same as the drum thickness.
MECHANICAL DESIGN OF EVAPORATIVE CRYSTALLIZER
Evaporator material LOW Carbon Steel

Number of tubes 605
Pitch of the tube (triangular) 125 mm
Evaporator Area 9860 mm
Tube Material Brass
Area of central down take 1880 mm
Diameter of tube sheet 3710 mm
Calendria Sheet Thickness 12 mm
Tube Sheet Thickness 36 mm
79
Thickness of Flange 40 mm
Number of bolts 112
Pitch circle diameter 3825 mm
Size of bolts 20 M
Outside diameter 3894 mm
Drum height 3000 mm
Drum Thickness 10 mm
Critical External Pressure 0.058 N/mm2
Permissible stress 15.9 N/mm2
Head thickness is based on an external 0.1 N/mm2
pressure
Conical head angle 1200
80
CHAPTER- 6
INSTRUMENTATION AND PROCESS CONTROL

IN THE PROCESS
81
INSTRUMENTATION AND PROCESS CONTROL IN THE PROCESS
PROCESS
A process is broadly defined as an operation that uses resources to transform inputs into
outputs. It is the resource that provides the energy into the process for the transformation
to occur.
PROCESS CONTROL
Process control is the act of controlling a final control element to change the manipulated
variable to maintain the process variable at a desired Set Point.
82
A corollary to the definition of process control is a controllable process must behave in a
predictable manner. For a given change in the manipulated variable the process variable
must respond in a predictable and consistent manner. Following are definitions of some
terms we will Nbe using in out discussion of process control:
The manipulated variable (MV) is a measure of resource being fed into the process, for
instance how much thermal energy.
A final control element (FCE) is the device that changes the value of the manipulated
variable.
The controller output (CO) is the signal from the controller to the final control element.
The process variable (PV) is a measure of the process output that changes in response
to changes in the manipulated variable.
The Set Point (SP) is the value at which we whish to maintain the process variable.
Figure shows a block diagram of a process with a final control element and sensors to
measure the manipulated variable and process variable. In single loop control systems the
actual value of the manipulated variable is often not measured, the value of the process
variable is the only concern.
83
BASICS OF PROCESS CONTROL
OPEN LOOP & CLOSE LOOP CONTROL
In open loop control the controller output is not a function of the process variable.
In open loop control we are not concerned that a particular Set Point be
maintained, the controller output is fixed at a value until it is changed by an operator.
Many processes are stable in an open loop control mode and will maintain the process
variable at a value in the absence of a disturbance
Disturbances are uncontrolled changes in the process inputs or resources. However, all
processes experience disturbances and with open loop control this will always result in
deviations in the process variable; and there are certain processes that are only stable at
a given set of conditions and disturbances will cause these processes to become
unstable. But for some processes open loop control is sufficient. Cooking on a stove top
84
is an obvious example. The cooking element is fixed at high, medium or low without
regard to the actual temperature of what we are cooking. In these processes, an example
of open loop control would be the slide gate position on the discharge of a continuous
mixer or ingredient bin.
In closed loop control the controller output is determined by difference between the
process variable and the Set Point. Closed loop control is also called feedback or
regulatory control. The output of a closed loop controller is a function of the error.
Error is the deviation of the process variable from the Set Point and is defined as E = SP -
PV.
A block diagram of a process under closed loop control is shown in figure
PROCESS CONTROL
Operations are automated to reduce variability, to minimize the time required, to increase
productivity, and so on. Remaining competitive in the world market demands that the
plant be operated in the best manner possible, and microprocessor-based process controls
provide numerous functions that make this possible. Safety is never compromised in the
effort to increase competitiveness, but enhanced safety is a by-product of the process-
control function and is not a primary objective. By attempting to maintain process
85
conditions at or near their design values, the process controls also attempt to prevent
abnormal conditions from developing within the process. Although process controls can
be viewed as a protective layer, this is really a by-product and not the primary function.
Where the objective of a function is specifically to reduce risk, the implementation is
normally not within the process controls. Instead, the implementation is within a separate
system specifically provided to reduce risk. This system is generally referred to as the
safety interlock system. As safety begins with the process design, an inherently safe
process is the objective of modern plant designs. When this cannot be achieved, process
hazards of varying severity will exist. Where these hazards put plant workers and/or the
general public at risk, some form of protective system is required. Process safety
management addresses the various issues, ranging from assessment of the process hazard
to assuring the integrity of the protective equipment installed to cope with the hazard.
When the protective system is an automatic action, it is incorporated into the safety
interlock system, not within the process controls.
86
CHAPTER- 7
PLANT LAYOUT
87
PLANT LAYOUT
INTRODUCTION
The efficiency of production depends on how well the various machines; production
facilities and employees amenities are located in a plant. Only the properly laid out plant
can ensure the smooth and rapid movement of material, from the raw material stage to the
end product stage. Plant layout encompasses
new layout as well as improvement in the existing layout.
It may be defined as a technique of locating machines, processes and plant services
within the factory so as to achieve the right quantity and quality of output
at the lowest possible cost of manufacturing. It involves a judicious arrangement
of production facilities so that workflow is direct.
DEFINITION
A plant layout can be defined as follows:
Plant layout refers to the arrangement of physical facilities such as machinery, equipment,
furniture etc. with in the factory building in such a manner so as to have quickest flow of
88
material at the lowest cost and with the least amount of handling in processing the
product from the receipt of material to the shipment of
the finished product.
According to Riggs, the overall objective of plant layout is to design a physical
arrangement that most economically meets the required output quantity and
quality.According to J. L. Zundi, Plant layout ideally involves allocation of space and
arrangement of equipment in such a manner that overall operating costs are
minimized.
IMPORTANCE
Plant layout is an important decision as it represents long-term commitment. An ideal
plant layout should provide the optimum relationship among output, floor area and
manufacturing process. It facilitates the production process, minimizes material handling,
time and cost, and allows flexibility of operations, easy production flow, makes economic
use of the building, promotes effective utilization of manpower, and provides for
employees convenience, safety, comfort at work, maximum exposure to natural light and
ventilation. It is also important because it affects the flow of material and processes,
labour efficiency, supervision and control, use of space and expansion possibilities etc.
ESSENTIALS
An efficient plant layout is one that can be instrumental in achieving the following
objectives:
Proper and efficient utilization of available floor space
To ensure that work proceeds from one point to another point without any delay
Provide enough production capacity.
89
Reduce material handling costs
Reduce hazards to personnel
Utilise labour efficiently
Increase employee morale
Reduce accidents
Provide for volume and product flexibility
Provide ease of supervision and control
Provide for employee safety and health
Allow ease of maintenance
Allow high machine or equipment utilization
Improve productivity
TYPES OF LAYOUT
As discussed so far the plant layout facilitates the arrangement of machines, equipment
and other physical facilities in a planned manner within the factory premises. An
entrepreneur must possess an expertise to lay down a proper layout for new or existing
plants. It differs from plant to plant, from location to location and from industry to
industry. But the basic principles governing plant layout are more or less same.
As far as small business is concerned, it requires a smaller area or space and can be
located in any kind of building as long as the space is available and it is convenient. Plant
layout for Small Scale business is closely linked with the factory building and built up
area. From the point of view of plant layout, we can classify small business or unit into
three categories:
1. Manufacturing units
90
2. Traders
3. Service Establishments
Manufacturing units
In case of manufacturing unit, plant layout may be of four types:
(a) Product or line layout
(b) Process or functional layout
(c) Fixed position or location layout
(d) Combined or group layout
(a) Product or line layout:
Under this, machines and equipments are arranged in one line depending upon the
sequence of operations required for the product. The materials move form one
workstation to another sequentially without any backtracking or deviation. Under this,
machines are grouped in one sequence. Therefore materials are fed into the first machine
and finished goods travel automatically from machine to machine, the output of one
machine becoming input of the next, e.g. in a paper mill, bamboos are fed into the
machine at one end and paper comes out at the other end. The raw material moves very
fast from one workstation to other stations with a minimum work in progress storage and
material handling. The grouping of machines should be done keeping in mind the
following general principles.
a) All the machine tools or other items of equipments must be placed at the point
demanded by the sequence of operations
b) There should no points where one line crossed another line.
c) Materials may be fed where they are required for assembly but not necessarily
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at one point.
d) All the operations including assembly, testing packing must be included in the
line
Advantages: Product layout provides the following benefits:
a) Low cost of material handling, due to straight and short route and absence of
backtracking
b) Smooth and uninterrupted operations
c) Continuous flow of work
d) Lesser investment in inventory and work in progress
e) Optimum use of floor space
f) Shorter processing time or quicker output
g) Less congestion of work in the process
h) Simple and effective inspection of work and simplified production control
i) Lower cost of manufacturing per unit
Disadvantages: Product layout suffers from following drawbacks:
a. High initial capital investment in special purpose machine
b. Heavy overhead charges
c. Breakdown of one machine will hamper the whole production process
d. Lesser flexibility as specially laid out for particular product.
Suitability: Product layout is useful under following conditions:
1) Mass production of standardized products
2) Simple and repetitive manufacturing process
3) Operation time for different process is more or less equal
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4) Reasonably stable demand for the product
5) Continuous supply of materials
Therefore, the manufacturing units involving continuous manufacturing process,
producing few standardized products continuously on the firms own specifications and
in anticipation of sales would prefer product layout e.g. chemicals, sugar, paper, rubber,
refineries, cement, automobiles, food processing and electronics etc.
Traders
When two outlets carry almost same merchandise, customers usually buy in the
one that is more appealing to them. Thus, customers are attracted and kept by good layout
i.e. good lighting, attractive colours, good ventilation, air conditioning, modern design
and arrangement and even music. All of these things mean customer convenience,
customer appeal and greater business volume.
The customer is always impressed by service, efficiency and quality. Hence, the
layout is essential for handling merchandise, which is arranged as per the space available
and the type and magnitude of goods to be sold keeping in mind the convenience of
customers.
There are three kinds of layouts in retail operations today.
1. Self service or modified self service layout
2. Full service layout
3. Special layouts
The self-service layouts, cuts down on sales clerks time and allow customers to
select merchandise for themselves. Customers should be led through the store in a way
that will expose them to as much display area as possible, e.g. Grocery Stores or
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department stores. In those stores, necessities or convenience goods should be placed at
the rear of the store. The use of colour and lighting is very important to direct attention to
interior displays and to make the most of the stores layout.
Services centres and establishment
Services establishments such as motels, hotels, restaurants, must give due attention to
client convenience, quality of service, efficiency in delivering services
and pleasing office ambience. In todays environment, the clients look for ease in
approaching different departments of a service organization and hence the layout
should be designed in a fashion, which allows clients quick and convenient access to the
facilities offered by a service establishment.
FACTORS INFLUENCING LAYOUT
While deciding his factory or unit or establishment or store, a small-scale businessman
should keep the following factors in mind:
a) Factory building: The nature and size of the building determines the floor space
available for layout. While designing the special requirements, e.g. air conditioning, dust
control, humidity control etc. must be kept in mind.
b) Nature of product: product layout is suitable for uniform products whereas process
layout is more appropriate for custom-made products.
c) Production process: In assembly line industries, product layout is better. In job order or
intermittent manufacturing on the other hand, process layout is
desirable.
d) Type of machinery: General purpose machines are often arranged as per process layout
while special purpose machines are arranged according to product layout
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e) Repairs and maintenance: machines should be so arranged that adequate space is
available between them for movement of equipment and people required for repairing the
machines.
f) Human needs: Adequate arrangement should be made for cloakroom, washroom,
lockers, drinking water, toilets and other employee facilities, proper provision should be
made for disposal of effluents, if any.
g) Plant environment: Heat, light, noise, ventilation and other aspects should be duly
considered, e.g. paint shops and plating section should be located in another hall so that
dangerous fumes can be removed through proper ventilation etc. Adequate safety
arrangement should also be made.
Thus, the layout should be conducive to health and safety of employees. It should ensure
free and efficient flow of men and materials. Future expansion and diversification may
also be considered while planning factory layout.
DYNAMICS OF PLANT LAYOUT
Plant layout is a dynamic rather than a static concept meaning thereby if once done it is
not permanent in nature rather improvement or revision in the existing plant layout must
be made by keeping a track with development of new machines or equipment,
improvements in manufacturing process, changes in materials handling devices etc. But,
any revision in layout must be made only when the savings resulting from revision
exceed the costs involved in such revision.
Revision in plant layout may become necessary on account of the following
reasons:
a) Increase in the output of the existing product
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b) Introduction of a new product and diversification
c) Technological advancements in machinery, material, processes, product design, fuel
etc.
d) Deficiencies in the layout unnoticed by the layout engineer in the beginning.
APPLICABILITY OF PLANT LAYOUT
Plant layout is applicable to all types of industries or plants. Certain plants require special
arrangements which, when incorporated make the layout look distinct form the types
already discussed above. Applicability of plant layout in manufacturing and service
industries is discussed below.
In case of the manufacturing of detergent powder, a multi-storey building is specially
constructed to house the boiler. Materials are stored and poured into the boiler at different
stages on different floors. Other facilities are also provided
around the boiler at different stations.
Another applicability of this layout is the manufacture of talcum powder. Here machinery
is arranged vertically i.e. from top to bottom. Thus, material is poured
into the first machine at the top and powder comes out at the bottom of the machinery
located on the ground floor.
Yet another applicability of this layout is the newspaper plant, where the time element is
of supreme importance, the accomplishment being gapped in seconds. Here plant layout
must be simple and direct so as to eliminate distance, delay and confusion. There must be
a perfect coordination of all departments and
machinery or equipments, as materials must never fail.Plant layout is also applicable to
five star hotels as well. Here lodging, bar, restaurant, kitchen, stores, swimming pool,
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laundry, shaving saloons, shopping arcades, conference hall, parking areas etc. should all
find an appropriate place in the layout. Here importance must be given to cleanliness,
elegant appearance, convenience and compact looks, which attract customers.
Similarly plant layout is applicable to a cinema hall, where emphasis is on comfort, and
convenience of the cinemagoers. The projector, screen, sound box, fire fighting
equipment, ambience etc. should be of utmost importance.
A plant layout applies besides the grouping of machinery, to an arrangement for
other facilities as well. Such facilities include receiving and dispatching points,
inspection facilities, employee facilities, storage etc.
Generally, the receiving and the dispatching departments should be at either end of
the plant. The storeroom should be located close to the production, receiving and
dispatching centres in order to minimize handling costs. The inspection should be right
next to other dispatch department as inspections are done finally, before dispatch. The
maintenance department consisting of lighting, safety devices, fire protection, collection
and disposal of garbage, scrap etc. should be located in a place which is easily accessible
to all the other departments in the plant. The other employee facilities like toilet facilities,
drinking water facilities, first aid room, cafeteria etc. can be a little away from other
departments but should be within easy reach of the employees. Hence, there are the other
industries or plants to which plant layout is applicable.
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CHAPTER- 8
SAFETY POLLUTION AND ABATEMENT ASPECT
SAFETY POLLUTION AND ABAT EMENT ASPECTS
INTRODUCTION
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Safety is a very important aspect to be kept in mind during our day to day life.
Especially safety plays a very significant role during the operation of a plant like ours and
its importance has to be understood by one and all. Prevention of any accidents is the
duty of the plant personnel especially the operators, who undoubtedly can play a major
role. They can meet this challenge only when they are well versed with all aspects of
operations, physical & chemical properties of chemicals being handled, hazards in
handling the chemicals and the first and the foremost thing is to know how to do a job
safety. The most important thing in safety is the attitude of the personnel towards safety
which would be a decisive factor in the safe operation of the plant. So all the personnel
should have a positive attitude towards safety.
Safety and loss prevention in process design can be consider under the following board
headings:
a. Identification and assessment of the hazards.
b. Control of the hazards: for example, by containment of flammable and
toxic materials
c. Control the process, Prevention of hazardous deviations in process variables
(pressure, temperature, flow) by containment of flammable and toxic materials.
d. Limitation of the loss. The damage and injury caused if an incident occurs:
pressure relief, plant layout, provision of fire-fighting equipment.
SAFETY INDEX
The safety and loss prevention guide development by Dow Chemical Company provides
a method for evaluating the potential hazards of a process and assessing the safety and
99
loss prevention measures needed. In this procedure, a numerical fire and explosion index
is calculated, based on the nature of the process and the properties of the materials. The
index can be used in two different ways. In the preliminary design, the Dow index will
indicate whether alternative, less hazardous processes should be considered in the
manufacture of the specific chemical product. In the final design, after the piping and
instrumentation diagrams and equipment layout have been prepared, the calculated index
is used as a guide to the selection and design of the preventive and protective equipment
needed for the safe plant operation. Safety is a very important aspect to be kept in mind
during our day to day life. Especially safety plays a very significant role during the
operation of a plant like ours and its importance has to be understood by one and all.
Prevention of any accidents is the duty of the plant personnel especially the operators,
who undoubtedly can play a major role. The most important thing in safety is the attitude
of the personnel towards safety which would be a decisive factor in the safe operation of
the plant.
HAZARDS IDENTIFICATION
EMERGENCY OVERVIEW:
Product exists as a greyish/brown granular powder. Loses water at about 300 deg.
Decomposes at higher temperatures. Soluble in water. The primary health hazard
associated with exposure to this compound is the potential for irritation of the eyes, skin,
nose and other tissues which come in contact with dusts or particulates of Ferrous Sulfate
monohydrate. Ferrous Sulfate Monohydrate is not flammable or reactive. Thermal
decomposition of Ferrous Sulfate Monohydrate produces irritating vapors and toxic
100
gases. Emergency responders should wear proper personal protective equipment for the
releases to which they are responding.
HAZARD STATEMENTS
CAUTION:
May cause irritation to eyes, skin, respiratory tract and gastrointestinal system. Harmful if
swallowed. Chronic Exposure may cause adverse liver effects. Target organs affected
from poisoning may include the liver, kidneys, digestive, circulatory, cardiovascular, and
central nervous systems. Avoid contact with eyes and skin. Avoid breathing dusts. Wash
thoroughly after handling. Keep container closed. Use with adequate ventilation.
POTENTIAL HEALTH EFFECTS: EYES
Exposure to particulates or solution of Ferrous Sulfate Monohydrate may cause moderate
to severe irritation of the eyes with symptoms such as stinging, tearing and redness.
Prolonged exposure of the eyes may cause discoloration to the sclera. Prolonged, low
level contact with corrosives may result in conjunctivitis.
POTENTIAL HEALTH EFFECTS: SKIN
Ferrous Sulfate Monohydrate can cause irritation of the skin, especially after prolonged
exposures. Repeated skin contact may lead to dermatitis (red, cracked skin).
POTENTIAL HEALTH EFFECTS: INGESTION
This product is harmful if swallowed. Ingestion of concentrated solutions or powder may
cause nausea, vomiting, diarrhea, and black stools. Pink to red-brown discoloration of the
urine is an indication of iron poisoning. Severe hemorrhagic gastritis with abdominal
pain, retching, and violent diarrhea may occur. Circulatory system may be affected with
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symptoms of shock, rapid, weak or no pulse, and severe hypotension may occur. Chronic
Exposure may cause adverse liver effects. Severe or chronic
Ferrous Sulfate poisonings may damage blood vessels. Large chronic doses cause rickets
in infants.
POTENTIAL HEALTH EFFECTS: INHALATION
Dusts and mists from solutions may cause mild to moderate irritation of the nose and
throat. May cause irritation of the respiratory tract.
8.IV. FIRST AID MEASURES
FIRST AID: EYES
Immediately flush the contaminated eye with plenty of water for 15 minutes. Seek
medical attention immediately.
FIRST AID: SKIN
If irritation occurs, wash gently and thoroughly with water and non-abrasive soap. If
irritation persists, seek medical advice. Completely decontaminate clothing, shoes, and
leather goods before reuse.
FIRST AID: INGESTION
Immediately give 8 ounces of water. If vomiting occurs naturally, rinse mouth and repeat
administration of water. Never give anything by mouth to an unconscious or convulsing
person. Obtain medical advice immediately.
FIRST AID: INHALATION
Remove source of contamination or move victim to fresh air. Apply artificial respiration
if victim is not breathing. Do not use mouth-to-mouth method if victim ingested or
inhaled the substance; induce artificial respiration with the aid of a pocket mask equipped
102
with a one-way valve or other proper respiratory medical device. Administer oxygen if
breathing is difficult. Get immediate medical attention.
FIRST AID: NOTES TO PHYSICIAN
Provide general supportive measures. Consult nearest Poison Control Centre for all
exposures except minor instances of inhalation or skin contact.
8.V. FIRE FIGHTING MEASURES
Fire and Explosion Hazards: Irritating and highly toxic gases may be produced by
thermal decomposition
Extinguishing Media: Copious quantities of water
Fire Fighting: If a significant quantity of this product is involved in a fire, call the fire
brigade. Firemen should wear self contained breathing apparatus and full protective
clothing.
HANDLING AND STORAGE
HANDLING PROCEDURES
All employees who handle this material should be trained to handle it safely. Do not
breathe dust. Avoid all contact with skin and eyes. Use Ferrous Sulfate Monohydrate only
with adequate ventilation. Wash thoroughly after handling.
STORAGE PROCEDURES
Keep container tightly closed when not in use. Store containers in a cool, dry location,
away from direct sunlight, sources of intense heat, or where freezing is possible. Material
should be stored in secondary containers or in a dyked area, as appropriate. Store
containers away from incompatible chemicals. Storage areas should be made of fire-
103
resistant materials. Post warning and NO SMOKING signs in storage and use areas, as
appropriate. Use corrosion-resistant structural
materials, lighting, and ventilation systems in the storage area. Floors should be sealed to
prevent absorption of this material. Inspect all incoming containers before storage, to
ensure containers are properly labelled and not damaged. Have appropriate extinguishing
equipment in the storage area (i.e., sprinkler system, portable fire extinguishers). Empty
containers may contain residual particulates; therefore, empty containers should be
handled with care. Do not cut, grind, weld, or drill near this container. Never store food,
feed, or drinking water in containers that held Ferrous Sulfate Heptahydrate. Keep this
material away from food, drink and animal feed. Do not store this material in open or
unlabeled containers. Limit quantity of material stored.
ACCIDENTAL RELEASE MEASURES
Spillage: Minor spills do not normally need any special cleanup measures. In the event of
a major spill, prevent spillage from entering drains or water courses. As a minimum, wear
overalls, goggles and gloves. Stop leak if safe to do so, and contain spill. Sweep up and
shovel or collect recovered product into labelled containers for recycling or salvage, and
dispose of promptly. After spills, wash area preventing runoff from entering drains. If a
significant quantity of material enters drains, advise emergency services. This material
may be suitable for approved landfill. Ensure legality of disposal by consulting
regulations prior to disposal. Thoroughly launder protective clothing before storage or re-
use. Advise laundry of nature of contamination when sending contaminated clothing to
laundry.
PERSONAL PROTECTION:
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The following information on appropriate Personal Protective Equipment is provided to
assist employers.
Personal Protective Equipment: Eyes/Face
Wear chemical goggles
Personal Protective Equipment: Skin
Where contact is likely, wear chemical resistant gloves, rubber boots, and coveralls.
Nitrile gloves are recommended. Gloves should be tested to determine their suitability for
prolonged contact with this material.
Personal Protective Equipment: Respiratory
None required where adequate ventilation conditions exist. If airborne concentrations are
above the applicable exposure limits, use NIOSH-approved respiratory protection.
Oxygen levels below 19.5% use of a full-face piece pressure/demand SCBA or a full face
piece, supplied air respirator with auxiliary self contained air supply.
Personal Protective Equipment: General
Have an eyewash fountain and safety shower available in the work area. Use good
hygiene practices when handling this material including changing and laundering work
clothing after use. Wash hands thoroughly after handling material. Do not eat, drink, or
smoke in work areas.
CHEMICAL STABILITY & REACTIVITY INFORMATION
Chemical Stability
Under normal conditions of temperature and pressure, Ferrous Sulfate Monohydrate is
stable. Ferrous Sulfate Monohydrate reacts in moist air to form ferric sulfate. Ferrous
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Sulfate Monohydrate looses water in dry air and may discolor upon exposure to moist air,
forming a brown coating of extremely corrosive, basic ferric sulfate.
Chemical Stability: Conditions to Avoid
Water of crystallization will be released when exposed to temperatures over 300 deg. C.
Incompatibility
Avoid strong alkalis, soluble carbonates, gold and silver salts, lead acetate, lime water,
potassium iodide, potassium, sodium tartrate, sodium borate, and tannin.
Hazardous Decomposition
Sulfur oxides and dioxides are normal decomposition products. May liberate toxic metal
fumes and acrid smoke.
Hazardous Polymerization
Will not occur.
TOXICOLOGICAL INFORMATION
Acute Toxicity
A: General Product Information
Pink urine discoloration is a strong indication of iron poisoning. Symptoms of severe
poisoning may occur within 30 minutes or may be delayed for several hours. Poisoning
may affect the liver, kidneys, digestive, circulatory, cardiovascular and central nervous
system. Systemic effects may include shock, rapid or weak pulse, severe hypotension,
dyspnea, and emphysema.
Additional Data: Interactions with medicines may cause adverse effects.
B: Component LD50/LC50
Ferrous Sulfate Heptahydrate
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Oral LD50 Mouse: 1520 mg/kg
Carcinogenicity
A: General Product Information
No information available.
B: Component Carcinogenicity
None of this product's components are listed by ACGIH, IARC, NIOSH, NTP, or OSHA.
Epidemiology
There is a large body of data on the clinical toxicology of ingested iron salts. There are
little data on the health effects from occupational (inhalation or dermal contact)
exposures. The recommended exposure limit reduces risk of skin and mucous membrane
irritation.
Neurotoxicity
Has not been identified.
Mutagenicity
Has not been identified.
Teratogenicity
No information available.
Other Toxicological Information
None.
STABILITY AND REACTIVITY
Reactivity: This product is unlikely to react or decompose under normal storage
conditions.
Conditions to Avoid: Moisture
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Incompatibilities: Alkalis, soluble carbonates and oxidising materials
Fire Decomposition Products: Sulphur oxides
Polymerisation: This product is unlikely to undergo polymerisation processes.
EXPLOSIONS:
As explosion is the sudden, catastrophic, release of energy, causing a pressure wave (blast
wave). An explosion can occur without fire, such as the failure through over-pressure of a
steam boiler of an air receiver.
When discussing the explosion of a flammable mixture it is necessary to distinguish
between detonation and deflagration. If a mixture detonates the reaction zone propagates
at supersonic velocity (approximately 300 m/s) and the principal heating mechanism in
the mixture is shock compression. Closed system, ventilation, explosion proof electrical
equipment and lighting are the prevention. In case of fire, keep drums, etc., cool by
spraying with water is fire fighting.
STATIC ELECTRICITY:
The movement of any non-conducting material, powder, liquid or gas, can generate static
electricity, producing sparks. Precautions must be taken to ensure that all piping is
properly earthed (grounded) and that electrical continuity is maintained around flanges.
Escaping steam, or other vapors and gases, can generate a static charge.
RISKS FACTOR:
The main hazards encountered in the plant process are:
a) Mechanical break-down risks
b) Electricity risks
c) Chemical exposure risks
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d) Fire and explosion risks
e) Corrosive material contact risks
f) Safety interlocks by-passing
Likely to be handled are given in the hazard chart. Action to be taken to skin contact.
Suffocation, asphyxiation and poisoning risks are occurs.
SPILLAGE DISPOSAL:
Personal protection: filter respirator for organic gases and vapors. Collect leaking and
spilled liquid in sealable containers as far as possible. Absorb remaining liquid in sand or
inert absorbent and remove to safe place.
GENERAL PROCESS HAZARDS
The general process hazards are factors that play a primary role in determining the
magnitude of the loss following an incident.
A. Exothermic chemical reactions: the penalty varies from 0.3 for a mild
exothermic, such as hydrogenation, to 1.25 for a particularly sensitive exothermic,
such as nitration.
B. Endothermic process: a penalty of 0.2 is applied to reactors, only. It is
increased to 0.4 if the reactor is heated by combustion of a fuel.

C. Materials handling and transfer: this penalty takes account of the hazard
involved in the handling, transfer and warehousing of the material.

D. Enclosed of indoor process unit: accounts for the additional hazard where
ventilation is restricted.
E. Access of emergency equipment: areas not having adequate access are
penalized. Minimum requirement is access from two sides.

F. Drainage and spill control: penalizes design conditions that would cause
large spills of flammable material adjacent to process equipment; such as
inadequate design of drainage.
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SAFETY CHECK LISTS
Check lists are useful aids to memory. A check list that has been drawn up by experienced
engineers can be a useful guide for the less experienced. However, too great a reliance
should never be put on the use of check lists, to the exclusion of all the factors to be
considered for any particular process or operation.
A short safety check lists are given by Carson and Mumford (1988) and Wells (1980).
Balemans (1974) gives a comprehensive list of guidelines for the safe design of chemical
plant, drawn up in the form of a check list. A loss of prevention check list is included in
the Dow Fire and Explosion Index Hazard Classification Guide, Dow (1987).
MATERIALS
(i) Flash point

(ii) Flammability range
(iii) Auto ignition temperature
(iv) Composition
(v) Stability
(vi) Toxicity
(vii) Corrosion
(viii) Physical properties
(ix) Heat of combustion/reaction
PROCESS
1. REACTORS
(a) Exothermic-heat of reaction
(b) Temperature control emergency systems
(c) Side reactions-dangerous?
(d) Effect of contamination
(e) Effect of unusual concentrations(including catalyst)
(f) Corrosion
2. PRESSURE SYSTEMS
(a) Need
(b) Design of current codes
(c) Materials of construction-adequate?
(d) Pressure relief-adequate?
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(e) Safe venting systems

(f) Flame arresters
CONTROL SYSTEMS
(a) Fail safe

(b) Back-up power supplies
(c) High / low alarms and trips on electrical variables
(1) Temperature
(2) Pressure
(3) Flow
(4) Level
(5) Composition
(d) Back up/duplicate systems on critical variables
(e) Remote operation of valves
(f) Block valves on critical lines
(g) Excess-flow valves
(h) Interlock systems to prevent mis operation
(i) Automatic shut-down systems
STORAGES
(a) Limit quantity

(b) Inert purging/blanketing
(c) Floating roof tanks
(d) Dykeing
(e) Loading /unloading facility-safety
(f) Earthling
(g) Ignition sources-vehicles
GENERAL
(a) Inert purging system needed

(b) Compliance with electrical code
(c) Adequate lighting
(d) Lighting protection
(e) Sewers and drains adequate, flame traps
(f) Dust-explosion hazards
(g) Build-up of dangerous impurities-purges
(h) Plant layout
(1) Separation of units
(2) Access
(3) Sitting of control rooms and offices
(4) Services
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(i) Safety showers, eye baths
FIRE PROTECTION
(a) Emergency water supplies

(b) Fire mains and hydrants
(c) Foam systems
(d) Sprinklers and deluge systems
(e) Insulation and protection of structures
(f) Access to buildings
(g) Fire-fighting equipment
EFFLUENT TREATMENT PLANT (ETP):
The water is polluted by the plant effluent. Here in the Ferrous sulfate plant, the bottom
draw is chiefly water with traces of heavier products and. A part of this water is removed
from the system along with the chlorine compound. Rest of the water is re-used in the
scrubber. A critical factor in this effluent water is the Biological Oxygen Demand (BOD).
It refers to the oxygen requirement by the metabolizing organisms. As the number of
organisms increases, the demand for O2 increases proportionally. Depletion of O2 in
water may lead to death of fish and other aquatic animals, a flat taste of water, and
eventual death of aerobes. The BOD is therefore an important indication of the levels of
pollution in the water.
112
113
CHAPTER-9
COST ESTIMATION
COST ESTIMATION OF THE PLANT
INTRODUCTION
The cost estimation is a specialised subject and a profession in its own right. the design
engineer, however, needs to be able to make quick, rough, cost estimates to decide
between alternative designs and for project evaluation. Chemical plants are built to make
114
a profit, and an estimate of the investment required and the cost of production needed
before the profitability of the project can be assessed.
COST INDICES
Most cost data that are available for making a preliminary or predesign estimate are only
valid at the time they were developed. Because prices may have changed considerably
with time due to changes in economic conditions, some method must be used for
updating cost data applicable at a past date to costs that are representative of conditions at
a later time. Cost Indices the value of money will change because of inflation and
deflation. Hence cost data can be accurate only at the time when they are obtained and
soon go out of date. Data from cost records of equipment and projects purchased in the
past may be converted to present-day values by means of a cost index. The present cost of
the item is found by multiplying the historical cost by the ratio of the present cost index
divided by the index applicable at the previous date. Ideally each cost item affected by
inflation should be forecast separately. Labor costs, construction costs, raw-materials and
energy prices, and product prices all change at different rates. Composite indices are
derived by adding weighted fractions of the component indices. Most cost indices
represent national averages, and local values may differ considerably.
TOTAL CAPITAL COST
Total Capital Cost The installed cost of the fixed-capital investment CFC is obviously an
essential item which must be forecast before an investment decision can be made. It
forms part of the total capital investment CTC. The fixed-capital investment is usually
regarded as the capital needed to provide all the depreciable facilities. It is sometimes
divided into two classes by defining battery limits and auxiliary facilities for the project.
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The boundary for battery limits includes all manufacturing equipment but excludes
administrative offices, storage areas, utilities, and other essential and nonessential
auxiliary facilities.
METHODS FOR ESTIMATING CAPITAL INVESTMENT
Various methods can be employed for estimating capital investment. The choice of any
one method depends upon the amount of detailed information available and the accuracy
desired. Seven methods are requiring progressive less detailed information and less
preparation time. Consequently, the degree of accuracy decrease with each succeeding
method.
I) Method A: Detailed item estimate
II) Method B: Unit cost estimate
III) Method C: Percentage of delivered-equipment cost
IV) Method D: Long factors for approximation of capital investment
V) Method E:Power factor applied to plant/capacity ratio
VI) Method F: Investment cost per unit capacity
VII) Method G: Turnover ratio..
COST ESTIMATION OF THE NEUTRALIZER
COST OF VESSEL BODY
Cost of Low carbon steel is Rs. 1260 per kg,
Weight of shell
Material content of the Vessel body
Ws = (/4) ( D02- Di2) x H x---------------------------------------(i)
Where,
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Di = Inside diameter of the Vessel
= 4.00 meter
D0 = outside diameter of the shell side
= Di + 2 x Shell thickness
= (4 + 2 x 0.020)
= 4.04 meter
H = Height of reactor
= 3.038 meter
= Density of material of shell body
= 9000 kg/m3
There fore,
Weight of Vessel body = (/4)[ (4.04)2 (4)2] x 3.038x 9000
= 6902 kg
Cost of Vessel body = 6902 x 1260
= Rs. 8697341 /-
OTHERS ACCESSORIES OF NEUTRALIZER
Others Accessories Costing= 120 % of Vessel body cost
= 8697341 x 1.2
= Rs. 10436809
FARRICATION COST
Fabrication cost = 40% of the Vessel material cost
= 8697341 x 0.4
= Rs. 3478936 /-
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Hence the total cost of the Neutralizer (T)
= Cost of Vessel material + Others Accessories Cost +Fabrication cost
= Rs. (8697341 +10436809+3478936)
= Rs. 22613086 /-
COST OF HEPTAHYDRATE FILTER
Heptahydrate Filter Cost = 60% of cost of Neutralizer (T)
= Rs. 13567851 /-
COST OF FORTIFER
Fortifer cost = 70% cost of Neutralizer (T)
= 0.7 x 22613086
= Rs. 15829160 /-
COST OF MONOHYDRATE FILTER ( 1st)
Cost of filter = 40 % cost of the Neutralizer (T)
= 0.4 x 22613086
= Rs. 9045234 /-
COST OF EVAPORATIVE CRYSTALLIZER
Cost of Crystallizer = 150% cost of Neutralizer (T)
= 1.5 x 22613086
= Rs. 33919629 /-
COST OF MONOHYDRATE FILTER ( 2st)
Cost of filter = 40 % cost of the Neutralizer (T)
= 0.4 x 22613086
= Rs. 9045234 /-
118
COST OF EFFLUENT TREATMENT PLANT
WASTE TREATMENT COSTS
Methods and costs of treating waste water and gas.
Waste gas: Take a credit for a combustible (fuel) waste gas that is at a
concentration above the upper flammability limit as the cost of an equivalent
amount of natural gas based on its lower heating value (LHV). (Tabulations of
data.) The same can be done if the combustible components are present below the
lower flammability limit, but sufficient oxygen is present for catalytic combustion
to recover the LHV. HYSYS gives the LHV for a stream under the Properties tab.
If the gas is below the lower flammability limit and consists of components that
can be burned to CO2 and H2O, assume that these components are eliminated in a
flame at a cost of 2.50/kg. Any products not permitted to be exhausted (such as
SO2 in many places) must be removed before the gas is released. Charge 10.00 per
kg of materials that must be removed. Assume these are 2001 prices; update the
burning cost using the price of natural gas and the waste treatment cost by the
price of electricity.
Waste water: Charge Rs. 12.50 per kg of components that must be removed before
discharge of the water. This cost is for 2001, so update using the cost of
electricity.
Cost of ETP = 150% cost of Neutralizer (T)
= 1.5 x 22613086
= Rs. 33919629 /-
COST OF OTHER ACCESSORIES
119
Cost of other accessories = 45% Cost of the Neutralizer(T)
=0.45 x 22613086
= Rs. 10175888 /-
TOTAL COST OF EQUIPMENT (E1)
= 22613086+ 13567851+ 15829160+ 9045234+ 33919629+ 9045234+ 33919629 +
10175888 = Rs. 148115711 /-
Sl. ACCOUNT HEAD EXPENDITURE

No. IN RUPEES
1 PURCHASE EQUIPMENT COST (E1) 148115711
2 PURCHASE EQUIPMENT INSTALLATION 57765127

( 39% of E1 )
3 INSTRUMENTATION (INSTALLATION) 41472399
( 28% of E1)
4 PIPING (INSTALLED ) 66652069

(45% of E1 )
5 ELECTRICAL (INSTALLED ) 14811571
(10% of E1 )
6 BUILIDING ( INCLUDING SERVICE) 32585456
(22% of E1)
7 SERVICE FACILITIES (55% of E1 ) 81463641
8 LAND ( 6% of E1 ) 8886942
TOTAL DIRECT COST (D) 451752916

INDIRECT COST ( I)
1 ENGINEERING AND SUPERVISION 22217356
(15% OF E1 )
2 CONSTRUCTION EXPENSES 17773885
(12% OF E1 )
3 LEGAL EXPENCES 2962314
(2% OF E1 )
120
4 CONTRACTORS FEE 5924628

(4% OF E1 )
5 CONTINGENCY 14811571
( 10% OF E1 )
TOTAL INDIRECT COST (I) 63689754
TOTAL DIRECT + INDIRECT COST 515442670

(D+I)
ESTIMATE COMPONENTS ARE IN TABLE
121
CHAPTER-10
DETAILED ENGINEERING DRAWING OF THE

NEUTRALIZER AND EVAPORATIVE
CRYSTALIZER
DETAILED ENGINEERING DRAWING OF NEUTRALIZER AN

EVAPORATIVE CRYSTALLIZER
122
NEUTRALIZER
The engineering design of a successful neutralization system involves several steps.
Engineering design should be based on several factors such as optimum process
parameters, laboratory- scale tests and their results, and finally, cost analysis. Practical
aspects such as availability of neutralizing agent in the near vicinity and thus reduced
transportation cost play an important role in process design.
NEUTRALIZER
[Original drawing are kept inside the Docket. ]
EVAPORATIVE CRYSTALLIZER:
123
This is the simplest type of industrial crystallizing equipment. Crystallization is induced
by cooling the mother liquor in tanks; which may be agitated and equipped with cooling
coils or jackets.
CALENDRIA EVAPORATIVE CRYSTALLIZER
[Original drawing are kept inside the Docket]
124
CHAPTER-11
NOMENCLATURE ARE USED
125
NOMENCLATURE
Nomenclature is a term that applies to either a list of names or terms, or to refer to
something that is a term or to the system of principles, procedures and terms related to
namingwhich is the assigning of a word or phrase to a particular object, event, or
property. The principles of naming vary from the relatively informal conventions of
everyday speech to the internationally-agreed principles, rules and recommendations that
govern the formation and use of the specialist terms used in scientific and other
disciplines.
Naming "things" is a part of our general communication using words and language: it is
an aspect of everyday taxonomy as we distinguish the objects of our experience, together
with their similarities and differences, which we identify, name and classify. The use of
names, as the many different kinds of nouns embedded in different languages, connects
nomenclature to theoretical linguistics, while the way we mentally structure the world in
relation to word meanings and experience relates to the philosophy of language
MATERIAL AND ENERGY BALANCE OF FERROUS SULFATE MONOHYDRATE
PLANT
R = Reflux Ratio
m = Mass flow rate
L = Amount of reflux, Kg mole/ hr
= Molar Latent heat, Kcal/ Kg mole
D = Total Kg moles of overhead product drawn
126
Wc = weight of cooling water required, Kg/hr
HP = Enthalpy of the product
HR = Enthalpy of the reactants.
HT = Enthalpy at the temperature
H25 = Standard heat of the reaction
VR = Vapor leaving the reboiler, Kg mole/hr
T2 T1 = Rise of cooling water temperature, C
V = Vapors entering the condenser from top of the column, Kgmole/hr
Cp = Specific heat
Ws = Steam requirement of reboiler. Kg/hr
11.a.ii. PROCESS DESIGN OF NEUTRALIZER AND EVAPORATIVE
CRYSTALLIZER
M = Average molecular weight of gas.
L = Length of Reactor, Meter
D = Diameter, mm
W = Mass flow rate of fluid, Kg/hr
= Density of the fluid, Kg/M3
R = Gas constant
T = Temperature in,
U0 = Linear gas velocity, m/ sec.
NRe = Reynoldss Number
L = Length of Reactor, Meter
127
P = Pressure in atm.
11.a.iii. MECHANICAL DESIGN OF NEUTRALIZER AND EVAPORATIVE
CRYSTALLIZER
P = Design Pressure Kg/ cm2
f = Design on permissible stress at
t = Design temperature, Kg/mm2
D1 = Internal Diameter of shell, mm
J = Joint Efficiency
T = Shell thickness
W = Stress intensification factor, mm.
R1 = Knuckle radius, mm.
Rc = Crown Radius, mm
th = Head thickness, mm.
b = Effective gasket or joint contact surface width under pressure.
b0 = Basic gasket seating width
G = Diameter of gasket load reaction
Ya = Minimum design seating stress, Kg / cm2
fb = Permissible stress in bolts under operating condition.
Wm1 = Bolt load at atmospheric condition, Kg.
Wm2 = Bolt load under operating condition, Kg.
Am2 = Total bolting area, cm2
m = Gasket factor.
B = Bolt circle diameter, mm.
128
C = corrosion allowance.
Wm = Total bolt load, Kg.
hG = Radial distance from gasket load reaction to bolt circle, mm.
H = Total hydrostatic end force.
t1 = Flange thickness
F = Vessel clearance from foundation to vessel bottom, meter.
H = Height of the vessel above the foundation, meter.
h = Height of the vessel, meter.
K = Constant.
n = Number of brackets
P = Total force due to wind load acting on the vessel, Kg/mm2.
w = Maximum weight of the vessel with load attachment and contents. Kg.
a = Constant, cm.
b = Constant, cm.
f = Bending stress for the structural steel, Kg/cm2
Pav = Average Pressure of the plate, mm.
T1 =Thickness of the web plate, mm.
A = Area of cross section.
Zyy = Modules of section
YY = Radius of Gyration.
le = Equivalent length, meter.
fc = Compressive stress, Kg.cm2
Pb = Bearing Pressure, Kg/ cm2
129
IN GENERAL USES
T = Shell thickness
Rc = Crown Radius, mm
W = Stress intensification factor, mm.
R1 = Knuckle radius, mm.
th = Head thickness, mm.
b = Effective gasket or joint contact surface width under pressure.
L = Length of the column, meter.
D = Diameter, mm.
W = Mass flow rate of fluid, Kg/ hr.
= Density of fluid, Kg/m3
P = Pressure in atm.
M = Average molecular weight of gas
R = Gas constant.
T = Temperature in 0C or 0K
P = Design Pressure Kg/ cm2
J = Joint Efficiency
f = Design on permissible stress at design temperature, Kg/mm2
D1 = Internal Diameter of shell, mm
F = Vessel clearance from foundation to vessel bottom, meter.
H = Height of the vessel above the foundation, meter.
h = Height of the vessel, meter.
130
K = Constant.
n = Number of brackets
P = Total force due to wind load acting on the vessel, Kg/mm2
b0 = Basic gasket seating width
G = Diameter of gasket load reaction
Ya = Minimum design seating stress, Kg / cm2
fb = Permissible stress in bolts under operating condition.
Wm1 = Bolt load at atmospheric condition, Kg.
Wm2 = Bolt load under operating condition, Kg.
Am2 = Total bolting area, cm2
m = Gasket factor.
B = Bolt circle diameter, mm.
C = Corrosion allowance.
Wm = Total bolt load, Kg.
hG = Radial distance from gasket load reaction to bolt circle, mm.
H = Total hydrostatic end force.
t1 = Flange thickness
P = Total force due to wind load acting on the vessel, Kg/mm2 .
w = Maximum weight of the vessel with load attachment and contents. Kg.
a = Constant, cm.
b = Constant, cm.
f = Bending stress for the structural steel, Kg/cm2
131
Pav = Average Pressure of the plate, mm.
T1 = Thickness of the web plate, mm.
A = Area of cross section.
Zyy =Modules of section
YY =Radius of Gyration.
le = Equivalent length, meter.
fc = Compressive stress, Kg.cm2
Pb = Bearing Pressure, Kg/ cm2
************************************
132
CHAPTER-12
BIBLIOGRAPHY
133
BIBLIOGRAPHY
HISTORY:
Bibliography (from Greek bibliographia, literally "book writing"), as a discipline, is
traditionally the academic study of books as physical, cultural objects; in this sense, it is
also known as bibliology. Carter and Barker (2010) describe bibliography as a twofold
scholarly discipline -- the organized listing of books (enumerative bibliography) and the
systematic, description of books as physical objects (descriptive bibliography). These two
distinct concepts and practices have separate rationales and serve differing purposes.
Innovators and originators in the field include W. W. Greg, Fredson Bowers, Philip
Gaskell, and G. Thomas Tanselle.
Bowers (1949) refers to enumerative bibliography as a procedure that identifies books in
specific collections or libraries, in a specific discipline, by an author, printer, or period
of production (3). He refers to descriptive bibliography as the systematic description of a
book as a material or physical artifact. Analytical bibliography, the cornerstone of
descriptive bibliography, investigates the printing and all physical features of a book that
yield evidence establishing a book's history and transmission (Feather 10). It is the
preliminary phase of bibliographic description and provides the vocabulary, principles
and techniques of analysis that descriptive bibliographers apply and on which they base
their descriptive practice.
BIBLIOGRAPHY FOR THIS PROJECT
134
1. Encyclopedia of Chemical Technology, by Kirk- Othmer, 5th ed. John Wiley, New
Yark.
2. Reklaitis, G.V. & Schneider, D.R. , Introduction to Material and Energy Balances,
John Wiley & Sons, New York.
3. Elements of Chemical Reaction Engineering, by H.Scott Fogler and M. Nihat
Gurmen. 4th ed., Prentice-Hall of India Pvt Ltd, 2008.
4. Joshi, M. V., Process Equipment Design, Macmillan India Ltd., 1981.
5. Kern, D. Q., Process Heat Transfer, McGraw Hill, 1965.
6. Austin G T, Shreves chemical Process Industries,Mc Graw Hill Book Company,
New Delhi 5th Edn. (1986).
7. Dryden. C.F ,Outlines of Chemical Technology, East West Press Pvt. Ltd., New
Delhi, 2nd Edition (1973).
8. Shukla S D and Pandey G.N., A test book of Chemical Technology Vol I, Vikas
Publishing House Pvt. Ltd., New Delhi.
9. Shukla S D and Pandey G.N., A test book of Chemical Technology Vol II, Vikas
Publishing House Pvt. Ltd., New Delhi
10. McCabe, W.L., Unit Operations of Chemical Engineering, McGraw Hill, 1988.
Koppel, L.B., & Coughanower, B. R., Process System and Analysis and Control,
McGraw Hill, 1965.
11. Sundaravadivel, S., & Chaudhary, D. S., Environmental Management, SciTech
Publications Pvt. Ltd.
12. Hougen, O.A., Chemical Process Principles, Vol.-1, Indian Edition, Asia Publishing
House.
135
13. Geankoplis, C. J., Transport Process and Unit Operation, 3rd edition, PHI, 2000.
14. Peter, M., and Timmerhaus, K. D., Plant Design and Economics for Chemical
Engineers, 4th edition, McGraw Hill.
15. Koppel, L.B., & Coughanower, B. R., Process System and Analysis and Control,
McGraw Hill, 1965.
16. J.M. Coulson and J.F.Richardson-Vol. V- Chemical Engineering.
17. Trybal, R. E. Mass Transfer Operation, McGraw Hill, Kogakusha Ltd., 1981
18. Perry,R.H.,Chemical Engineers Handbook, McGraw Hill, 1984.
19. Holman, J. P., Heat Transfer, McGraw Hill, 1989.
20. Stephanopoulas, G.,Chemical Process Control, Prentice-Hall of India Pvt Ltd,
1990.
21. Odum, E.P., Fundamental of Ecology, W.B. Sounders Company Ltd., 1971.
22. Badger, W. L., and Banchero, J. T., Introduction to Chemical Engineering, McGraw
Hill, Kogakusha Ltd.
136

Design A Plant To Manufacturing of Ferrous Sulfate Monohydrat

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Design A Plant To Manufacturing of Ferrous Sulfate Monohydrat

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DESIGN THE MANUFACTURE OF (20 TONES/DAY) FERROUS SULFATE MONOHYDRATE

THE PROJECT REPORT ON THE DESIGN THE

INDIAN INSTITUTE OF CHEMICAL ENGINEERS

(A) STATEMENT OF THE PROBLE

Design the manufacture of (20 Tones/day) Ferrous Sulfate monohydrate

from waste pickle liquor.

Pickling is generally associated with the removal of scale with mineral

pickle liquor generally contains about 15 to 20% ferrous sulfate and

about 2 to 5% sulfuric acid. This spent liquor is first neutralized with

solubility of ferrous sulfate increases up to 65 0C and then decreases

where ferrous sulfate exists as monohydrate. At ordinary low

temperatures, it exists as ferrous sulfate heptahydrate. An evaporative

crystallizer is used to produce ferrous sulfate monohydrate which

operates at 650C. After separation of crystals, the mother liquor is

recycled back to neutralization tank.

Prepare a design report consisting of the following.

A. Major performance & Equipment data 6

2. Detailed flow sheet 29

3. Material and Energy Balance of the plant 33

4. Design of neutralizer unit 46

5. Design of Evaporative crystallizer 69

6. Instrumentation and process control in the process

8. Safety and pollution abatement aspects 99

9. Cost estimation 116

10. Detaited engineering drawing of the reactor and centrifuge 126

11. Nomenclature 129

12. Bibliography 137

I. MAJOR PERFORMANCE & EQUIPMENT DATA

OVERALL MATERIAL BALANCE AROUND THE PROCESS

COMPONENT BASIS 100KG PRODUCTION AS PER PRODUCTION RATE

through Pickle 89.4 0 795.66 0

Through pickle 22.35 0 198.92 0

pickle liquor 335.25 335.25 2983.73 2983.73

Water 10.6 25.31 94.34 225.26

required 57.72 0 513.71 0

monohydrate 0 100 0 889

Impurity 1.18 6.90 10.5 61.41

TOTAL 605.21 605.19 5386.38 5385.23

PROCESS DESIGN OF THE NEUTRALIZER

Type of Neutralizer CONICAL

MECHANICAL DESIGN OF THE NEUTRALIZER

Shell material LOW CARBON STEEL

PROCESS DESIGN OF THE CALENDRIA EVAPORATIVE CRYSTALLIZER

Type of Crystallizer CALENDRIA

MECHANICAL DESIGN OF CALENDRIA EVAPORATIVE CRYSTALLIZER

Evaporator material LOW Carbon Steel

Outside diameter 3894 mm

Drum height 3000 mm

Critical External Pressure 0.058 N/mm2

Permissible stress 15.9 N/mm2

Head thickness is based on an external pressure 0.1 N/mm2

Conical head angle 1200

COST ESTIMATION OF THE PLANT

SL.No ACCOUNT HEAD EXPENDITURE IN RUPEES

1 PURCHASE EQUIPMENT COST (E1) 148115711

2 PURCHASE EQUIPMENT INSTALLATION 57765127

4 PIPING (INSTALLED ) 66652069

TOTAL DIRECT COST (D) 451752916

TOTAL DIRECT + INDIRECT COST 515442670

about one million tons of sulfuric acid.

answer to this problem. The desirable characteristics of a satisfactory solution to the

pickle liquor disposal problem may be summarized as follows: