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CONTENTS
Introduction Cradle to gate Mining products Agricultural products Evapotranspiration Gate to gate Differentiation on requirement basis Single product system Multi-product system
1 Cradle to gate:
These calculations refer to the water consumption and pollution pattern of a product during its growth period as a raw material and its transportation to the manufacturing unit. This WFP depends broadly on the location, environmental conditions, time period and method of cultivation in case of agricultural products. Before one can start the WFP calculations one must have a brief idea about the process of development of raw material and its developing conditioning. *This WFP of mining materials is negligible as compared to agricultural products. One may note that process using atmospheric air as their raw material has 0 WFP (from cradle to gate) of their raw material. (i) Components of WFP for mining products from cradle to gate:
All the water calculations are done on the weight basis of the mining material (vol water/kg product). Various types of water included are: 1. Water entrained in the raw material. (Wen) (We are not concerned with its development process or conditioning or sort of water trade during this period because it is a natural process) 2. Water consumption during extraction process. (Wex) (if the drilling is done wet basis etc.) 3. Water consumption during its storage and transportation for maintaining proper conditions. (Wst) 4. Water consumption of miscellaneous purposes. (Wms) 5. WFP (gate to grave) of other material utilized for extraction like explosives. (Wmat)
WFP of this period is the final sum of the above components. Calculation formula: WFP (cradle to grave) = Wen + Wex + Wst + Wmat + Wms
(ii)
It is same as WFP of the mining product but the method to find its entrained water and WFP of crop is rather complex. Now we have to consider the location, environmental conditions, type of crop (its requirement) and method of cultivation. At different locations the environmental conditions are different and thus methods are different (also could be for economical reason or technological gap) and for this reason a concept of EVAPOTRANSPIRATION is introduced to accommodate simplicity. EVAPOTRANSPIRATION:
It relates the amount of water given in the field to the amount of water utilized by the crop for growth, water evaporated during its growth, water absorbed by the earth to recharge and water drained from the crop field to the river basins or ponds.
A simple diagram relating the water distribution is shown above. As shown in the above diagram we are only interested in the amount of water given in and its distribution and not how or what happens to the rest of water for the evaluation that is why rest of distribution is not shown. This evapotranspiration is a part of finding the amount of water entrained in the crop. Calculation procedure: Water is given to the field on area basis (hectare), but all the calculations are done on the quantity of crop produced (volume of water/ kg of crop) Water given in the field (Wgiv) = Wcrop + Weva + Wear + Wdrain WFP of the crop is = Wcrop + Weva Water entrained by the crop = Wcrop But the calculations of water given to the field and water taken by the crops or water evaporated are not an easy task. Water is given in fields by ways: By pumps: by pumping the water from the nearest river or tube well or pond in the fields. One can easily determine the amount of water supplied by the knowing the flow rate and time for which it was used Water supplied = flow rate * time. By rain: now this is rather difficult to measure and is approximated. By knowing the amount of rain fall (in mm) in the local region (from the weather department) one can know the amount of rain fall on field as following Water supplied = Rain fall in mm * area of the field. Now the point comes in determining the distribution of this water. Knowing the chemistry of the crop one can find the amount of water in different parts of crop and then water/ unit kg of crop. Which will depend upon the quality of crop and is different in different locations. Now when we have determined the water entrained in the crop and its WFP, we can proceed with the calculation of WFP during cradle to gate period. Water is calculated at following steps: 1. Water WFP of the crop, (Wcrop + Weva).
2. 3. 4. 5.
Water consumed during its extraction (cleaning). (Wex) Water consumed during its storage. (Wst) Water consumed for miscellaneous purposes. (Wms) WFP of other materials used. (Wmat)
2 GATE TO GATE:
These calculations refer to the consumption pattern of water during the manufacture process. It is calculated by determining the water consumption in the plant. In order to determine the WFP from gate to gate one 1st must be able to identify/ divide the consumption in different categories depending upon their type. A generalized table identifying the type of consumption is given below. But before one starts the WFP assessment one should have idea about basic functioning of the plant. Generally in a plant set up there are many further units of manufacturing, utilizing different raw materials and producing different products. But there is a one main product manufacturing and other supplementary product
manufacturing units. And one can never find the exact consumption in all the categories. And more over most of the consumption pattern keeps on changing with time as it depends upon the workers and working conditions and requirement of product. So one has to assume the missing data on the proper basis. * One should remember that during chemical reactions water may be produced or consumed dependently it should be accommodate in the calculations. * In a plant main consumption of water is for 2 things, cooling and steam generation and also for dilution in food industry. And this cooling water and most of the steam is returned to the environment at the plant site but in some other energy state, which can be practically neglected as the energy level difference between this returned streams and surrounding environment is very large so it does not make any difference. Gate to gate calculations can be broadly divided in 2 categories: 1 Plant producing only single product 2 Plant producing multi-products Plant producing single product: Its components are easily identified and are identical to the generalized divisions made, which is shown below. 1st we must chose the basis of calculation i.e. either product basis (volume of water/ unit of product) or time basis (volume of water/ unit time). Then one has to get the basic idea about the process of manufacturing in order to understand the consumption pattern and its requirement. Once we have chosen the basis and got the basic idea about what is going on, one can divided the consumption pattern into categories as shown above, this division can be modified as per the requirement, and start collecting the data. Let us take the example of the NFL (Nangal unit) and here some data is assumed on arbitrary basis. This unit has following plant 1 Urea plant (main product) 2 Ammonia plant (ammonia produced is totally consumed in urea plant, also gives many other products) 3 SGP (for urea and ammonia plant) 4 Nitric acid plant with NOx plant 5 Methanol plant (partially provides for ammonia plant) 6 De-aeration plant (supply DM water to all the plants) 7 Administrative departments (HRD, technical)
(During this time of evaluation, a new plant is being constructed at NFL for which a new whole set of buildings is made due to which it was difficult data collection as their network was changing daily. And can put it aside as it has nothing to with our ongoing calculations, but it has tremendously increased the WFP of NFL during this particular period if one is making an assessment on the plant rather product.) *Here it is not possible to choose product as basis for some particular products as they are interconnected up to some degree. Calculations procedure: Now as per the division we start our calculation from individual plants, let us take urea plant 1st. We have taken time basis as this plant is connected with ammonia plant hour 1 Here process water consumption is in the form of steam (Wproc) = 37542kg 2 Grey WFP (Wgrey) = 15308 kg 3 Water accommodated in the product (Waccu) = 205 kg (.49 wt% of product) = Wpro - Wdr 4 Steam generated in plant (Wpg) = nil 5 WFP of raw material (ammonia) (Wraw) = X (say) WFP of (CO2) = y (say) 6 water produced (Wpro) = nil 7 losses (Wloss) = L (say) (Cooling water intake (Wcooin) = 55442 m3 Cooling water output (Wcooot) = 55442 m3 No water losses during cooling) 8 maintenance water consumption (Wmtn) = M (say) 9 drained water (Wdr)= D (say) WFP of urea= Wproc + Wgrey + Wpg + Wraw Wpro + Wloss + Wmtn - Wdr = 37542 + 15308 + 205 + 0 + X + Y - 0 + L + M - D Since the water to whole NFL unit is delivered from Sutlej river therefore all the WFP are blue WFP. This was for a plant producing only one product, now for the plants which are interconnected or produce more than one product Plants producing multi-products: Here we can not take products as basis as different products are taken out of the process stream at different stages of production. So we take time as basis and we have to define the production of all the products on the basis of one product only, more over this product must be the last product of the production line. In order to do so one must know the actual set up installed.
Let us say that there are No. of products = p No. of stages in production line = s Say 1 product is taken out at every = nth stage And different stages of process few raw materials are introduced Say 2 (or i) raw materials are introduced at equal stages interval during 1st 4 stages (any no.) Now will take that product as basis, which is taken out in the last step = pth (say) Now say during production I kg of pth product
Calculation procedure: Process water calculations: One must know the process setup i.e. raw materials, all flow rates, conditions etc. 1 We choose time basis. 2 Amount of 1st product produced = p1 kg Amount of 2nd product produced = p2 kg Amount of pith product produced = pp kg And so on 3 time spent by each batch in each step is known. (start up time gap from operation conditions does not matter) 4 Let the amount of water taken in at 1st stage= W1 Let the amount of water taken out at 1st stage = W1o Let the amount of water left at the end of 1st stage = W1 W1o Let the amount of water taken in at 1st stage = W2 Net water in the stage 2 = W2 + (W1 W1o) And so on Therefore process water consumption of 1st product will be = W1o Similarly process water consumption of 2nd product will be = W2 + (W1 W1o) W2o
And so on, but at the same time some amount of later product is formed (or a step is taken towards its formation) but since this consumed water is still in the production line, hence we can say that the taken out water totally belongs to that current product. COMPARISON OF WFP DIFFERENT PRODUCT IN THE PRODUCTION INE
Let us take the example of NFL, Nangal units ammonia-II and methanol plant: Products are: 1 NH3 2 CO2 3 Tail gas for steam generation in SGP 4 Sulphur 5 O2 6 CH3O