Download - Production of LABSA
Company LOGO
Production of Sulfonic Acid Salts
United Arab Emirates UniversityCollege of Engineering
Chemical Engineering Department Graduation Project II
Group Members:Ahlam Mohammed 200211739Kholoud Sahool 200221677Maitha Muftah 200203114
Project Advisor: Dr. Basim Abu-Jdayil
GPII-Production of Sulfonic Acid Salt
Outline
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Introduction
Objective
LABSA Production Process Modification
Equipment Design
Cost Estimation
HAZOP Study
Site Location
Conclusion and Recommendation
GPII-Production of Sulfonic Acid Salt
Introduction
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•The UAE is considered as one of the most important countries in the oil and gas industry.
•Huge amounts of sulfur are produced from the desulphurization process and sold to the chemical plants.
GPII-Production of Sulfonic Acid Salt
Objective
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• The aim of this project is to utilize the sulfur from the oil and gas industry to produce Linear Alkyl Benzene Sulphonic Acid Salt (LABSA).
• The aim of GP2 is to design the equipment in the LABSA plant.
GPII-Production of Sulfonic Acid Salt
GP1 Accomplishments• Selecting the LABSA as the product in the sulfonic
acid salt plant.• The Sulfur Trioxide Technique was chosen as the best
method for producing LABSA. • Applying the mass and energy balance on the
process.• Determining the capacity of the plant which was 1 ton
per year.
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GPII-Production of Sulfonic Acid Salt
LABSA Production Process Modification
•LABSA Plant Capacity
In GP1 the amount of LABSA produced was 1 ton per year.In GP2 the capacity increased to 30,000 ton per year.
•Modified LABSA Process
The modifications include the addition of different equipment in the plant and they are:
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Air dryer Unit Compressor Pumps Storage Tanks
GPII-Production of Sulfonic Acid Salt
Modified LABSA Process PFD
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GPII-Production of Sulfonic Acid Salt8
Equipment Design
GPII-Production of Sulfonic Acid Salt
Sulfur Melter
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The melter aims to transform the solid sulfur to liquid by using hot steam.
3802.3 mV
kgkJQ 5680
The calculated Parameters:
GPII-Production of Sulfonic Acid Salt
Heat Exchanger
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Heat exchanger is a devise that is used to transfer thermal energy from one fluid to another without mixing the two fluids.
GPII-Production of Sulfonic Acid Salt
Air Dryer Unit
The air dryer is a column packed with desiccant material which selectivity holds the water.
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GPII-Production of Sulfonic Acid Salt
SO2 Reactor The SO2 Reactor is a Plug Flow Reactor (PFR) which is used for chemical reactions in continuous and flowing systems.
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GPII-Production of Sulfonic Acid Salt
SO2-SO3 ConverterThe SO2-SO3 converter is a typical PFR packed with some solid material (V2O5).
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GPII-Production of Sulfonic Acid Salt
Sulphonation ReactorSulphonation reactions are preferred to be conducted in multitube falling film reactors.
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GPII-Production of Sulfonic Acid Salt
Gas-Liquid Separator
The gas-liquid separators are vertical vessels used to separate the liquid from the gas stream by gravity.
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GPII-Production of Sulfonic Acid Salt
CycloneCyclones are widely used as gas-solids separators by employing centrifugal force also they are frequently used for gas-liquid separation.
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GPII-Production of Sulfonic Acid Salt
Absorber
Absorbers are packed columns where the gas and liquid are contacted continuously.
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GPII-Production of Sulfonic Acid Salt
Pump
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GPII-Production of Sulfonic Acid Salt
Compressor
A gas compressor is a mechanical device that reduces the gas volume by increasing the pressure. To design the compressor the type and the actual power are determined.
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•Centrifugal Compressor
•Actual Power= 118.1246 kW ≈ 120 kW
GPII-Production of Sulfonic Acid Salt20
Cost Estimation
GPII-Production of Sulfonic Acid Salt
Cost Estimation
Cost estimation is used to estimate the future cost of the chemical plant and provide the engineer with generalexpectation for the budget preparation.
To calculate the capital cost the following steps where followed:
1) Calculate the purchased cost (Cpo):
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210310210
10 )(log)(loglog AKAKKC p
GPII-Production of Sulfonic Acid Salt
Capital Cost Estimation2) Calculate the bare module (FBM):
3) Calculate the bare module cost (CBM):
4) Find the grass root cost (CGR) :
pMBM FFBBF 21
BMo
PBM FCC
iiBMTM CC,
18.1
iBMo
TMGR CCC ,5.0
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GPII-Production of Sulfonic Acid Salt
• Capital Cost Estimation for the LABSA Process:
)05.1(2001cos2005cos 3
2001,2008, GRGR Cindextindext
C
Capital Cost Estimation
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CTM= $2631712.71
CGR,2001= $3252328.70
CGR,2008= $4440207.145
GPII-Production of Sulfonic Acid Salt
Operating Labor Cost Estimate
Calculating the cost of operating labor (COL) helps in
estimating the labor requirement for the LABSA process. 5.02 )23.07.3129.6( npOL NPN
npN Equipment Summation
P Solid Handling
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GPII-Production of Sulfonic Acid Salt
Operating Labor Cost Estimate
OLN 6.366Operating Labor= 4.5 x 6.366 = 28.645 ≈ 29 operators
)2001(OLC 29 x $50,000 = $1432244.742/yr
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GPII-Production of Sulfonic Acid Salt
Cost of Operating Utility The cost of each utility required by the LABSA production process is calculated (CUT):
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CUT= $ 562601.55/yr
GPII-Production of Sulfonic Acid Salt
Raw Material Cost The raw material cost (CRM) is calculated by knowing the price of the raw material and the chemical feed stocks required by the process:
yrkgton
yrday
dayhr
hrkg
tonCostSulfur /320.337540$95.0
1000136524338$120
yrkgton
tonyrday
dayhr
kmolkg
hrkmol
CostLAB /968.40972900$95.010001$
205036524240007.10
yryrday
dayhr
tonhrtonCostNaOH /614.139257$95.036524295.113$1477.0
yrCRM /902.41449698$
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GPII-Production of Sulfonic Acid Salt
Waste Treatment Cost It is important to calculate the waste treatment cost (CWT) because it helps protecting the environment from pollution:
yrmyr
daydayhr
kgm
hrkgCostWasteDryerAir /992.996$95.0$
100041365241922.2 3
3
yryrday
dayhr
tonkg
kgm
mhrton
CostWasteAbsorber /533.59$95.03652410008.901
1$100056
1152.03
3
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CWT= $1056.525/yr
GPII-Production of Sulfonic Acid Salt
Total Manufacturing Cost The cost of manufacturing (COM) is the total operating cost per year:
)(23.173.2280.0 RMWTUTOL CCCCFCICOM
COM = $ 56829715.232/yr
yrofit /522.7268204$Pr
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Profit = Income – Total Costs
GPII-Production of Sulfonic Acid Salt
HAZOP Study
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GPII-Production of Sulfonic Acid Salt
HAZard and Operability StudiesThe HAZOP study technique makes use of a series of parameters and guide words.
The objectives of the HAZOP study are:• Identify all potential causes of the process disturbance
which could lead to significant safety.• Recommending suitable modifications which reduce the
risks
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GPII-Production of Sulfonic Acid Salt
HAZard and Operability StudiesHAZOP Study for Gas-Liquid Separator (Flow Deviation)
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Guide Word Deviation Causes o Consequences Action
No Flow Valve failure Pipe failure
o Plant shut downo No product Repair valve Repair pipe
Less Flow Valve blocked Pipe blocked Pipe leak
o Less producto Less performance of plant Clean pipe Repair leakage Fit low flow alarm (FAL)
More Flow Valve failure LC failure
o More producto Flooding and overflow Repair valve Repair LC Fit high flow alarm (FAH)
GPII-Production of Sulfonic Acid Salt
HAZard and Operability StudiesHAZOP Study for Gas-Liquid Separator (Temperature Deviation)
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Guide Word Deviation Causes o Consequences• Action
Less Temperature No separationLess efficiency o Less product
o Less performance Clean pipe Repair leakage
More Temperature No separationLess efficiency o More product
o Flooding and overflow Repair valve Repair LC
GPII-Production of Sulfonic Acid Salt
HAZard and Operability Studies• Chemical Waste
The absorber chemical waste consists mainly of Sulfuric Acid (H2SO4) and Sodium Sulfite (Na2SO3):
The H2SO4 is formed by the reaction of water with sulfur trioxide
The Na2SO3 is formed by the reaction of sulfur dioxidewith caustic soda
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GPII-Production of Sulfonic Acid Salt
Site Location
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GPII-Production of Sulfonic Acid Salt
LABSA Plant Site Location• Determining the location of the LABSA plant is
considered an essential factor in designing any plant.
• Selecting the suitable location for the plant helps in lowering the cost of some important factors such as transportation and raw material supply.
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GPII-Production of Sulfonic Acid Salt
Other Site Location Factors Site Location Case Study Evaluation Results:
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GPII-Production of Sulfonic Acid Salt
Conclusion and Recommendation
• In the plant the sulfur is utilized to produce LABSA.• The Sulfur Trioxide Technique is considered the best method
because it utilizes the sulfur and reduces the amount of toxic gases.
• All the equipment in the plant are designed by calculating their dimensions.
• The project profit is $7,268,204.522/yr which makes the project profitable.
• Abu-Dhabi is selected as the best location for the LABSA plant.• The sulfur enters another industries such as manufacturing
fertilizers and producing sulfuric acid.
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GPII-Production of Sulfonic Acid Salt
Thank you for your Attention
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