Production of LABSA

Company
LOGO
Production of Sulfonic
Acid Salts
United Arab Emirates University
College of Engineering
Chemical Engineering Department
Graduation Project II
Group Members:
Ahlam Mohammed 200211739
Kholoud Sahool 200221677
Maitha Muftah 200203114

Project Advisor:
Dr. Basim Abu-Jdayil
GPII-Production of Sulfonic Acid Salt
Outline
2
Introduction
Objective
LABSA Production
Process
Modification
Equipment Design
Cost Estimation
HAZOP Study
Site Location
Conclusion and
Recommendation
Introduction
3
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.

Objective
4
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.
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.

5
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:

6
Air dryer Unit
Compressor
Pumps
Storage Tanks

Modified LABSA Process PFD
7
8
Equipment Design
Sulfur Melter
9
The melter aims to transform the solid sulfur to liquid by using
hot steam.
3
802 . 3 m V
kg
kJ
Q 5680
The calculated Parameters:
Heat Exchanger
10
Heat exchanger is a devise that is used to transfer thermal energy
from one fluid to another without mixing the two fluids.
Air Dryer Unit
The air dryer is a column packed with desiccant
material which selectivity holds the water.
11
SO
2
Reactor
The SO
2
Reactor is a Plug Flow Reactor (PFR) which is used for
chemical reactions in continuous and flowing systems.
12
SO
2
-SO
3
Converter
The SO
2
-SO
3
converter is a typical PFR packed with some solid
material (V
2
O
5
).

13
Sulphonation Reactor
Sulphonation reactions are preferred to be conducted in
multitube falling film reactors.
14
Gas-Liquid Separator
The gas-liquid separators are vertical vessels used to
separate the liquid from the gas stream by gravity.
15
Cyclone
Cyclones are widely used as gas-solids separators by
employing centrifugal force also they are frequently used
for gas-liquid separation.
16
Absorber
Absorbers are packed columns where the gas and liquid
are contacted continuously.
17
Pump
18
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.
19
Centrifugal Compressor

Actual Power= 118.1246 kW 120 kW
20
Cost Estimation
Cost Estimation
Cost estimation is used to estimate the future cost of
the chemical plant and provide the engineer with general
expectation for the budget preparation.

To calculate the capital cost the following steps where
followed:

1) Calculate the purchased cost (C
p
o
):
21

2
10 3 10 2 1
0
10
) ( log ) ( log log A K A K K C
p

Capital Cost Estimation
2) Calculate the bare module (F
BM
):

3) Calculate the bare module cost (C
BM
):

4) Find the grass root cost (C
GR
) :
p M BM
F F B B F
2 1

BM
o
P BM
F C C
i
i BM
TM
C C
,
18 . 1

i BM
o
TM GR
C C C , 5 . 0
22
Capital Cost Estimation for the LABSA Process:
) 05 . 1 (
2001 cos
2005 cos
3
2001 , 2008 ,

GR GR
C
index t
index t
C
Capital Cost Estimation
23
C
TM
= $2631712.71
C
GR,2001
= $3252328.70
C
GR,2008
= $4440207.145

Operating Labor Cost Estimate
Calculating the cost of operating labor (C
OL
) helps in
estimating the labor requirement for the LABSA process.
5 . 0 2
) 23 . 0 7 . 31 29 . 6 (
np OL
N P N
np
N
Equipment Summation
P Solid Handling
24
Operating Labor Cost Estimate
OL
N
6.366
Operating Labor= 4.5 x 6.366 = 28.645 29 operators

) 2001 (
OL
C
29 x $50,000 = $1432244.742/yr
25
Cost of Operating Utility
The cost of each utility required by the LABSA production
process is calculated (C
UT
):
26
C
UT
= $ 562601.55/yr
Raw Material Cost
The raw material cost (C
RM
) is calculated by knowing the
price of the raw material and the chemical feed stocks
required by the process:
yr
kg
ton
yr
day
day
hr
hr
kg
ton
Cost Sulfur / 320 . 337540 $ 95 . 0
1000
1
365 24 338
$
120
yr
kg
ton
ton yr
day
day
hr
kmol
kg
hr
kmol
Cost LAB / 968 . 40972900 $ 95 . 0
1000
1 $
2050 365 24 240 007 . 10
yr
yr
day
day
hr
ton hr
ton
Cost NaOH / 614 . 139257 $ 95 . 0 365 24
295 . 113 $
1477 . 0
yr C
RM
/ 902 . 41449698 $
27
Waste Treatment Cost
It is important to calculate the waste treatment cost (C
WT
)
because it helps protecting the environment from pollution:
yr
m yr
day
day
hr
kg
m
hr
kg
Cost Waste Dryer Air / 992 . 996 $ 95 . 0
$
1000
41
365 24 1 922 . 2
3
3

yr
yr
day
day
hr
ton
kg
kg
m
m hr
ton
Cost Waste Absorber / 533 . 59 $ 95 . 0 365 24 1000
8 . 901
1 $
1000
56
1152 . 0
3
3

28
C
WT
= $1056.525/yr
Total Manufacturing Cost
The cost of manufacturing (COM) is the total operating cost
per year:
) ( 23 . 1 73 . 2 280 . 0
RM WT UT OL
C C C C FCI COM
COM = $ 56829715.232/yr
yr ofit / 522 . 7268204 $ Pr
29
Profit = Income Total Costs
HAZOP Study
30
HAZard and Operability Studies
The HAZOP study technique makes use of a series of
parameters and guide words.

The objectives of the HAZOP study are:
Identify all potential causes of the process disturbance
which could lead to significant safety.
Recommending suitable modifications which reduce the
risks
31
HAZOP Study for Gas-Liquid Separator (Flow Deviation)
32
o Consequences
Action
Causes Deviation Guide Word

o Plant shut down
o No product
Repair valve
Repair pipe

Valve failure
Pipe failure
Flow No

o Less product
o Less performance of plant
Clean pipe
Repair leakage
Fit low flow alarm (FAL)

Valve blocked
Pipe blocked
Pipe leak
Flow Less

o More product
o Flooding and overflow
Repair valve
Repair LC
Fit high flow alarm (FAH)

Valve failure
LC failure
Flow More
HAZOP Study for Gas-Liquid Separator (Temperature Deviation)
33
Guide Word Deviation Causes o Consequences
Action
Less Temperature No separation
Less efficiency

o Less product
o Less performance
Clean pipe
Repair leakage
More Temperature No separation
Less efficiency

o More product
o Flooding and overflow
Repair valve
Repair LC
Chemical Waste
The absorber chemical waste consists mainly of Sulfuric
Acid (H
2
SO
4
) and Sodium Sulfite (Na
2
SO
3
):
The H
2
SO
4
is formed by the reaction of water with
sulfur trioxide
The Na
2
SO
3
is formed by the reaction of sulfur dioxide
with caustic soda
34
Site Location
35
LABSA Plant Site Location
Determining the location of the LABSA plant is considered
an essential factor in designing any plant.

Selecting the suitable location for the plant helps in
lowering the cost of some important factors such as
transportation and raw material supply.
36
Other Site Location Factors
Site Location Case Study Evaluation Results:
37
Conclusion and Recommendation
In the plant the sulfur is utilized to produce LABSA.
The Sulfur Trioxide Technique is considered the best method
because it utilizes the sulfur and reduces the amount of toxic
gases.
All the equipment in the plant are designed by calculating their
dimensions.
The project profit is $7,268,204.522/yr which makes the project
profitable.
Abu-Dhabi is selected as the best location for the LABSA plant.
The sulfur enters another industries such as manufacturing
fertilizers and producing sulfuric acid.
38
Thank you for your
Attention
39

Production of LABSA

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