Process design of absorption system

for nitric acid plant with 145 tons

per dayName
capacity
Ali Abdullah
Nawaf Ahmed

Table of content

Introduction.
History of nitric acid.
Uses .
Nitric acid in Saudi Arabia.
Flow sheet.
Cost Estimation.
Conclusion.
Production of Nitric Acid

Introduction

Chemical reactions.
Toxic and corrosive.
Color.
Scientific name is HNO3.
Molecular weight 63 .
Boiling at 84 oC and solidified at -43
oC .
Other names(Aqua forties).
3

Production of Nitric Acid

History of nitric acid

8th century(Jabir ibn Hayyan).

In 1648(Johann Rudolf Glauber) .
In 1825 .
In 1900(BirkelandEyde).
In 1906(WilhelmOstwald).

Production of Nitric Acid

Uses

Production of fertilizers.
Production of explosives.
Manufacture of nylon, adipic acid.
oxidizing agent in the production of some solid
fuels for rocket propulsion.
identify low-grade alloys and assess purityof
goldcontent.
Polymer industry
(polyamidesandpolyurethanes).

Production of Nitric Acid

Nitric acid in saudi arabia

Shuaa Al Kaune Oilfield Supplies &

Services.
World Rep Chemicals Division.
Esad International.
Sedres Maritime Co. Ltd.
GULF DESERT CHEMICALS CO.

Production of Nitric Acid

Flow sheet of nitric acid

plant
Air
Compressor

Secondary
Air

water
steam

Air
recycle

Input:

Liquid
NH3

steam

Water
H20

Vaporizer

Catalytic
Reactor

Air
preheater

Wasteheat
boiler

Water
7

Water

Output:
Gases:
1-No2
2-air
3-No

Production of Nitric Acid

Cooler
condenser

WeakHno3

Absorption
column.(30
plate)

Gasproduct:
1. No
2. No2
3. O2
4. N2

Output:
1-HNO3
2-water

Vaporizer
Process.

Production of Nitric Acid

Name

water 1

water 2

Vapour
Temperature ( C )
pressure ( kPa)
molar flow (kgmole/ hr)
mass flow (kg/h)
std ideal liqvol flow (m3/hr)
molar enthalpy (kj/kgmole)
molar entropy (kj/kgmole-c)
heat flow (kj/hr)
:composition by mass flow rate
Air
NO
H2O
HNO3
NO2
Ammonia
Nitrogen
Oxygen

0
40
101.3249966
11.10179764
200
0.200403608
283760.150337.28708026
3150247.767
0
0
1
0
0
0
0
0

0
11.52113668
101.3249966
11.10179764
200
0.200403608
285921.429216.06189522
3174241.849
0
0
1
0
0
0
0
0

water

Input:

Liquid
NH3

Vaporizer

Production of Nitric Acid

liquid
ammonia
1
10
500
129.1837881
2200
3.571022731
46560.6966154.7731775
6014887.164
0
0
0
0
0
1
0
0

ammonia
1
15
500
129.1838
2200
3.571023
46375155.4234
5990893
0
0
0
0
0
1
0
0

Air pre-heater
Process

10

Production of Nitric Acid

Name

product 1

product 1.1

air 2

air3

Vapour

Temperature ( C )

1000.179

862.6744

25

230

pressure ( kPa)

500

500

105.9433

500

molar flow (kgmole/ hr)

850.7076

850.7076

695.2738

695.2738

mass flow (kg/h)

22199.86

22199.86

20000

20000

std ideal liqvol flow (m3/hr)

67.2798

67.2798

23.28561

23.28561

molar enthalpy (kj/kgmole)

2063.66-

7049.17-

8.47127-

6091.59

molar entropy (kj/kgmole-c)

196.924

192.7816

154.7472

157.3859

heat flow (kj/hr)

1755570-

5996783-

5889.85-

4235323

:composition by mass flow rate

Air

NO

0.1419

0.1419

H2O

0.1278

0.1278

HNO3

NO2

Ammonia

0.0186

0.0186

Nitrogen

0.7117

0.7117

0.79

0.79

Oxygen

0.21

0.21

Air
recycle

Catalytic
Reactor
11

Air
preheater

Production of Nitric Acid

Reactor
Catalytic convertor reactor.
4NO + 6H2O
4NH3 + 5O2

12

Production of Nitric Acid

Name
Vapour
Temperature ( C )
pressure ( kPa)
molar flow (kgmole/ hr)
mass flow (kg/h)
std ideal liqvol flow (m3/hr)
molar enthalpy (kj/kgmole)
molar entropy (kj/kgmole-c)
heat flow (kj/hr)
:composition by mass flow rate

mix out
1
188.5827
500
824.4576
22200
26.85663
2129.36161.3477
1755570

liq 1
0
1000.179
500
0
0
0
31400
180.2435
0

product 1
1
1000.179
500
850.7076
22199.86
67.2798
2063.66196.924
1755570

Air
NO
H2O
HNO3
NO2
Ammonia
nitrogen
Oxygen

0
0
0
0
0
0.0991
0.7117
0.1892

0
0.0075
0
0
0
0
0.9925
0

0
0.1419
0.1278
0
0
0.0186
0.7117
0

Air
recycle

Catalytic
Reactor
13

Air
preheater

Production of Nitric Acid

Waste heat boiler

Process

14

Production of Nitric Acid

Name

product 1.1

product 1.2

water 3

steam 1

Vapour

0.963326

Temperature ( C )

862.6744

91.95073

25

99.99839

pressure ( kPa)

500

500

101.325

101.325

molar flow (kgmole/ hr)

850.7076

850.7076

499.5809

499.5809

mass flow (kg/h)

22199.86

22199.86

9000

9000

std ideal liqvol flow (m3/hr)

67.2798

67.2798

9.018162

9.018162

molar enthalpy (kj/kgmole)

7049.17-

34279.5-

284903-

238534-

molar entropy (kj/kgmole-c)

192.7816

150.7775

26.5595

181.1521

heat flow (kj/hr)

5996783-

2.9E+07-

1.4E+08-

1.2E+08-

:composition by mass flow rate

Air

NO

0.1419

0.1419

H2O

0.1278

0.1278

HNO3

NO2

Ammonia

0.0186

0.0186

Nitrogen

0.7117

0.7117

Oxygen

steam

15

Water

Wasteheat
boiler

Production of Nitric Acid

Shell & tube cooler

condenser
Process.
2NO + O2

16

2NO2

Production of Nitric Acid

Name
Vapour
Temperature ( C )
pressure ( kPa)
molar flow (kgmole/ hr)
mass flow (kg/h)
std ideal liqvol flow (m3/hr)
molar enthalpy (kj/kgmole)
molar entropy (kj/kgmole-c)
heat flow (kj/hr)
:composition by mass flow rate
Air
NO
H2O
HNO3
NO2
Ammonia
Nitrogen
Oxygen

17

mix out 2
1
126.1593
500
1545.981
42199.86
90.56541
16123.4156.2158
2.5E+07
0
0.0747
0.0672
0
0
0.0098
0.7488
0.0995

Production of Nitric Acid

liq 2
0
253.1105
500
0
0
0
214508127.5343
0

0
0
0.6864
0
0.1935
0.0189
0.0927
0.0086

product 2
1
253.1105
500
1493.481
42199.86
48.2011
16690.2164.2462
2.5E+07
0
0
0.0672
0
0.1145
0.0098
0.7488
0.0597

Name

product 2

product 2.1

water 4

steam 2

Vapour
Temperature ( C )
pressure ( kPa)
molar flow (kgmole/ hr)
mass flow (kg/h)
std ideal liqvol flow (m3/hr)
molar enthalpy (kj/kgmole)
molar entropy (kj/kgmole-c)
heat flow (kj/hr)
:composition by mass flow rate
Air
NO
H2O
HNO3
NO2
Ammonia
Nitrogen
Oxygen

1
253.1105
500
1493.481
42199.86
48.2011
16690.2164.2462

0.900849
40
500
1493.481
42199.86
48.2011
27492.6132.6717

0
20
101.325
499.5809
9000
9.018162
28528222.76673

0.644702
99.9987
101.325
499.5809
9000
9.018162
252988142.4168

2.5E+07
0
0
0.0672
0
0.1145
0.0098
0.7488
0.0597

4.1E+07
0
0
0.0672
0
0.1145
0.0098
0.7488
0.0597

1.4E+08
0
0
1
0
0
0
0
0

1.3E+08
0
0
1
0
0
0
0
0

steam

18

Water

Cooler
condenser

Production of Nitric Acid

Absorption column

3NO2 + H2O
Name

2HNO3 + NO

Vapour
Temperature ( C )

product
2.2
0.893868
40.1145

liquid
product
0
54.70821

pressure ( kPa)
molar flow (kgmole/ hr)

500
1504.583

500
137.8858

mass flow (kg/h)

42399.86

4229.698

std ideal liqvol flow

(m3/hr)
molar enthalpy
(kj/kgmole)
molar entropy
(kj/kgmole-c)
heat flow (kj/hr)

48.4015

3.400993

29383.5-

252010-

131.8825

30.81594

4.4E+07-

3.5E+07-

composition by mass
:flow rate
Air
NO
H2O
HNO3
NO2
19
Ammonia

vapor
out
1
54.7082
1
500
1331.69
7
38170.1
2
58.7017
8
7104.47145.377
1
9460999

0
0
0
0
0
0.0275
0.0716
0.419
0.0166
0
0.5781
0.0515
0.1139 Production
0 of Nitric Acid
0
0.0097
0.0028
0.0105

Name

water 5

Vapour
Temperature ( C )
pressure ( kPa)
molar flow (kgmole/ hr)
mass flow (kg/h)
std ideal liqvol flow (m3/hr)
molar enthalpy (kj/kgmole)
molar entropy (kj/kgmole-c)
heat flow (kj/hr)
:composition by mass flow rate
Air
NO
H2O
HNO3
NO2
Ammonia
Nitrogen
Oxygen

0
37.77778
101.3
22.2036
400
0.400807
28392935.76032
6304253
0
0
1
0
0
0
0
0

liquid
product
0
54.70821
500
137.8858
4229.698
3.400993
25201030.81594
3.5E+07
0
0
0.419
0.5781
0
0.0028
0.0001
0

Output:
Gases:
1-No2
2-air
3-No
Absorption
column.(30
plate)

20

Output:
1-HNO3
2-water

Production of Nitric Acid

air 6

air 5

1
20
101.3
312.8732
9000
10.47852
154.153154.6268
48230.4
0
0
0
0
0
0
0.79
0.21

1
20
101.3
104.2911
3000
3.492841
154.153154.6268
16076.8
0
0
0
0
0
0
0.79
0.21

vapor
out
1
54.70821
500
1331.697
38170.12
58.70178
7104.47145.3771
9460999
0
0.0275
0.0166
0.0515
0
0.0105
0.8279
0.066

Name
Vapour
Temperature ( C )
pressure ( kPa)
molar flow (kgmole/ hr)
mass flow (kg/h)
std ideal liqvol flow (m3/hr)
molar enthalpy (kj/kgmole)
molar entropy (kj/kgmole-c)
heat flow (kj/hr)
:composition by mass flow rate
Air
NO
H2O
HNO3
NO2
Ammonia
Nitrogen
Oxygen
Output:
Gases:
1-No2
2-air
3-No
Absorption
column.(30
plate)

21

Output:
1-HNO3
2-water

Production of Nitric Acid

tail gas
1
58.36732
1000
1730.931
49293
72.05402
3550.2139.5511
6145160
0
0.0213
0.0111
0.0241
0
0.0079
0.8334
0.1022

nitric acid
0
66.38617
1000
178.0201
5506.821
4.420918
24959633.24424
4.4E+07
0
0
0.4105
0.5851
0
0.0043
0.0001
0

2NO + O2
3NO2 + H2O
22

2NO2
2HNO3 + NO

Production of Nitric Acid

Total Capital investment

Direct Cost
Purchased Equipment

Factors

Delivery, percent of purchased

equipment
:Subtotal: delivered equipment
Direct cost
Purchased Equipment Installation
Instrumentation & Controls (Installed)
Piping (Installed)
Electrical system (Installed)
Building (including services)
Yard improvements
Land
Service facilities (Installed)
:Total Direct Cost
Indirect Cost
Engineering & Supervision
Construction expenses
Contractor's fee
Contingency
:Total Indirect Cost
:Fixed Capital Investment
Working Capital
Total capital investment

0.2 * purchased equipment

23

0.25

delivered equipment * 0.07

delivered equipment* 0.04
delivered equipment* 0.10
delivered equipment* 0.08
delivered equipment* 0.10
delivered equipment* 0.02
delivered equipment* 0.02
delivered equipment* 0.10

delivered equipment* 0.08

delivered equipment* 0.08
delivered equipment* 0.02
delivered equipment* 0.04

Total indirect + Total direct

Production of Nitric Acid

TCI*0.2

Cost

$1,545,730.9
$309,146.2
$1,854,877.0

$519,365.6
$296,780.3
$741,950.8
$593,560.7
$741,950.8
$148,390.2
$148,390.2
$741,950.8
$5,787,216.4

$593,560.7
$593,560.7
$148,390.2
$296,780.3
$1,632,291.8
$7,419,508.2
$1,854,877.0
$9,274,385.2

Total Production Cost

Factor

Cost ($/yr)

Raw Materials

$ 8008000

Estimating way
liquid ammonia
-catalyst

Operating Labor

$ 900000

1500*50*12

Operating Supervision

$ 180000

20%*OL

Utilities

$ 1574236.317

10% TPC

Maintenance & Repair

$ 370975.4088

5% FCI

Operating Supplies

$ 55646.31132

15% M&R

Laboratory Charges

$ 180000

20% of OL

Financing

$ 463719.26

5%*TCI

Insurance

$ 74195.08176

1%* FCI

Plant Overhead

$ 1574236.317

10% TPC

General Expenses

$ 2361354.476

15%TPC

Total production cost /yr

$ 15742363.17

Subtotal

24

Production of Nitric Acid

Net profit
Selling Price of nitric acid per ton = 375 $ , nitric acid
factory operates only 315 days in a year and the
production of nitric acid per day is 145 Ton per day
(from material balance):
Total income = 375*315*145= $ 17,128,125.00
Gross income = Total income - Total product cost=
17128125- 15742363 = 1385761.83$
Net profit= gross income + taxes , but we dont have
taxes in Saudi Arabia so Net profit= gross income .
Payout period = (FCI/Net profit ) = (7,419,508.18 $ /
1728125 $) = 5 year
The maximum payout period is 5 years .
25

Production of Nitric Acid

Conclusion
Use a program like hysys defiantly
simplify the idea of making a plant .
After calculating cost estimation, the
profit income start after maximum 5
years.

26

Production of Nitric Acid

Thank you for listening

27

Production of Nitric Acid