A Final Year Plant Design Project on

Production of 75 Tons of Oxalic Acid

From Sugar cane Molasses Using
Nitric Acid

1
CONTENTS

• Introduction to the Process

• Demand of Process
• Manufacturing Processes
• Material Balance
• Energy Balance
• Equipment Design
• Cost
• Hazard Identification &
Control

2
INTRODUCTION

• Oxalic acid is an organic compound with the formula C₂H₂O₄.

Oxalic acid, also known as ethanedioic acid
• The anhydrous grade of oxalic acid is utilized in a wide array of
industrial applications ranging from pharmaceutical to textiles.
• Commercially different methods installed.
• The product purity is usually in the range of 99.4-99.9% and is
commercially available in crystallized and powdered
compositions

3
 MARKET SHARE OF OXALIC
ACID IN MAJOR SECTORS IN
2018.

1-Oxalic acid specific uses | LuBon Industry CO.,LTD. 4

 IMPORTS OF 2018 IN
MILLION US-DOLLARS

http://www.pbs.gov.pk/sites/default/files//MONTHLY%20BULLETIN%20OF%20STATISTICS%20%
20NOVEMBER%2C%202018.pdf 5
MANUFACTURING
PROCESSES

1. Oxidation of carbohydrates with nitric acid

2. Mixing of saw dust with caustic soda.
3. By olefins and glycol (oxidation reaction)
4. From Sodium Formate
5. From Propylene.
6. By Using Aspergillus Niger

http://ethesis.nitrkl.ac.in/5372/1/109CH0030.pdf

6
COMPARISON OF MANUFACTURING
PROCESSES
Designation Temperature Pressure(atm) Time (hrs.) Yield(%)
(C0 )
From 65 1 3 75
Oxidation of
Molasses
Mixing of saw 200-220 2 3 80
dust with
caustic soda
By olefins 60-100 1 2 85
and glycol
From Sodium 2000 150 2 88
Formate
From 250-300 2 2 85
Propylene
By Using 300 1 7days 61
Aspergillus
Niger
7
PROCESS DESCRIPTION
Process of making Oxalic acid:
• Treatment of the raw material(Molasses, Nitric acid, V2O5) in
Batch Reactor.
• Separation of Oxalic acid from unreacted material in 2-stage
Crystallization Process.
• Drying of Oxalic acid Crystals in Drier.
Treatment of Polluting Gas Nitric Oxide(NO):
• Conversion of NO to NO2 in Fluidized bed reactor in presence
of Al2O3 catalyst
• Absorption of NO2 in Water in Absorption Column in making
weak HNO3(by-product)
https://patents.google.com/patent/CN1030747A/en 8
 Air Polluting Gas Treatment Section

CYCLON
HNO3/ SEPARATOR
V2O5 P-21 Pure
water NO
Molasses P-11

(glucose)
NO
NO AL2O3 cat E-7

AL2O3

NO+NO2

P-8

Steam Heater NO Gas

Oxalic
Steam Heater
acid+Unreacted
Reactor material
Compressor Absorber
O2 Gas FBR
Weak
Activated Carbon Filter HNO3(liq)

P-36

Hot
P-31 water Hot air
out
P-35

Hot air
Feed Holding Tank Crystalizer-1 in
Centrifuge-1 P-34
Centrifuge-2
P-41

Oxalic acid Mother Mothe

crystals liqour Crystalizer-2 r liqour Turbo Dryer
99% Pure
Product Recovery Section Oxalic Acid
9
PLANNED CAPACITY

Total installed 22500 tons

capacity per year

Per day 75 tons per

production day

10
MATERIAL BALANCE
Raw Material
Sugar cane Molasses Composition:
Glucose : 80%
Sucrose : 2 %
Water 17.8
Others:
Nitric Acid: HNO3(liq.)
Catalyst : V2O5

11
MATERIAL BALANCE
Process Equipment's on which material balance is applied:
• Isothermal Batch Reactor
• Fluidized Bed Reactor
• Absorber
• Crystallizer
• Centrifuge
• Drier

12
OVERALL BALANCE
Production of oxalic acid= 75TPD
C6H12O6 + 6HNO3 V2O5 3[COOH]2*6H2O +6NO
• Glucose Required
66646.8 kg/Batch
• Nitric Acid Required
139954.5 kg/Batch
• Catalyst V2O5
936 kg/Batch

13
 BATCH REACTOR
C6H12O6 + 6HNO3 V2O5 3[COOH]2*6H2O +6NO
Yield = 75%

14
 FLUIDIZED BED REACTOR

2NO + O2 2N02
Conversion of NO to NO2 is 90%

Balance sheet for FBR

Input Output

Feed in Feed in Feed in Feed in

Component Kmol/hr. Kg/hr. Component Kmol/hr. Kg/hr.
NO 69.425 2082.75NO2 62.4825 2874.195

NO
O2 31.25 1000 (unreacted) 6.9425 208.275
Al2O3 0.347 34.71Al2O3 0.347 34.71
Total 3117.47 3117.47
15
 ABSORBER
3NO2 + H2O 2HNO3 + NO
Conversion is 80%

Balance sheet for Absorber

Input Output

Feed in Feed in Feed in Feed in

Component Kmol/hr. Kg/hr. Component Kmol/hr. Kg/hr.
NO2 62.4825 2874.195Nitric Acid 33 2079

23.4583333
H2O 15 270NO 3 703.75

NO
(unreacted) 6.9425 208.275NO2 (unreacted) 12.5 575
Total 3357.75 3357.75
16
 CRYSTALLIZER-1
Balance sheet for crystallizer 1
Input Output
Component Feed in Kg Component Feed in Kg
103476
Oxalic acid 74999.99 Crystals
H2O 29991.65 Mother Liquor 53165
Glucose(unreacted) 16660
Nitric acid(unreacted) 34989

Total 156641.97 Total 156641.97

Solubility of Oxalic acid at 65.5C0 = 74.5g/100 g of Water

Solubility of Oxalic acid at 25C0 = 20.5g/100 g of Water
So, initial concentration of feed,
Cin=74.5/174.5= 0.42 g/g of solution
C0= 20.5/120.5= 0.152 g/g of solution
https://plot.ly/~maddyjones7/15/temperature-vs-solubility-for-oxalic-acid-
in-h2o-and-7030-h2o-dioxane-solvent.embed 17
 CRYSTALLIZER 2
Balance sheet for crystallizer 2
Input Output
Component Feed in Kg Component Feed in Kg

Feed 103476 Crystals 76234

Water 47758 Mother Liquor 75000

Total 151234 total 151234

Solubility of Oxalic acid at 85C0 = 90g/100 g of Water

Solubility of Oxalic acid at 37C0 = 36.6g/100 g of Water
So, initial concentration of feed,
Cin=90/190= 0.474 g/g of solution
C0= 36.6/136.6= 0.267 g/g of solution
http://ajrconline.org/HTMLPaper.aspx?Journal=Asian%20Journal
%20of%20Research%20in%20Chemistry;PID=2012-5-11-1

18
 TURBO DRIER
Air required
536590 kg/B

• For evaporation of 1 kg of water at Weight of moist

1 atm of pressure, hot air crystals Dry Crystals
requirement is 10-20 m3 76234 kg/B 75000 kg/day
Drier
• 15m3 of air required will be
=15*29= 435 kg
• for 1234 kg, amount of air needed
= 435*1234= 536590 kg
Moisture
1234 kg

19
C6H12O6 NO NO2 H2O
66646.8 kg/B V2O5 2082.75 2874.19 kg/hr 270
Al2O3
HNO3 936 kg/B kg/hr. Unreacted NO kg/hr.
34.71 kg/hr. 208 kg/hr
139954.5 O2
kg/B 1000 kg/hr

Reactor Fluidized
Absorber
Bed Reactor
Oxalic
acid + C=103476
unreacted kg/B
H2O=47758
material M=53165
C=103476 Kg
156641.97 kg/B
kg/B
kg/B
Crystallizer Centrifuge 1 Crystallizer
1 2
C=76234
kg/B
Air= 536590 kg
M=75000
kg/B
Dry Crystals Drier Centrifuge
75000 kg/day
C=76234 kg/B 2
Moisture =1234kg
ENERGY BALANCE
Specific heat capacity (kJ/kg K) of compounds

• NO :29.5 + (-9.37×10-4) T + (97.4×10-7) T2 + (-4.18×10-9) T3

• NO2 : 24.9 + (48.35×10-3) T + (-2.08×10-5) T2 + (29.31×10-11) T3

• O2 : 28.106 + (-3.680×10-6) T + (17.459×10-6) T2 + (-1.065×10-8)
T3
Reference: Ideal gas specific heat capacity equations at constant pressure from Coulson
&Richardson’s Chemical Engineering Design Book Fourth Edition.

Specific Heat Capacity of component KJ/Kg: T=823 K

Nitric Oxide = 1.34 KJ/Kg K
Oxygen = 1.16 KJ/Kg K

21
ENERGY BALANCE
Specific Heat Capacity of component KJ/Kg: T=338 K
Glucose = 1.21 KJ/Kg K
Oxalic acid= 1.62 KJ/Kg K
Nitric acid= 0.92 KJ /Kg K
Nitric oxide= 0.97 KJ/Kg K
Specific Heat Capacity of component KJ/Kg: T=313 K
Nitric oxide= 0.95 KJ/Kg K
Specific Heat Capacity of component KJ/Kg: T=368 K
Nitrogen Dioxide = 0.86 KJ/Kg K
Nitric acid= 0.99 KJ/Kg K
https://webbook.nist.gov/cgi/cbook.cgi?ID=C7697372&Mask=1&Type=JANAF
G&Table=on
22
 BATCH REACTOR
Energy Balance For Reactor

Inlet T= 65⁰C Outlet T=65⁰C

Specific Enthalpy mass Specific Enthalpy
Component mass rate Heat ∆T in Component rate Heat ∆T out
Kg/day Kj/Kg C Kj/Kg Kg/day Kj/Kg C Kj/Kg
4859993.5
Glucose 66664.8 1.21 40 3226576.3Oxalic acid 74999.9 1.62 40 2
Nitric acid 139954.2 0.92 40 5150314.6Nitric Oxide 49986 0.97 40 1939456.8
Total 8376890.9Total 6799450.3

C6H12O6 + 6HNO3 V2O5 3[COOH]2*6H2O +6NO ∆H0= -719KJ/mol

∆Hreaction = moles produced * heat of reaction
= (8.33Kmol) *(-719MJ/Kmol) = -5985 MJ
https://atct.anl.gov/Thermochemical%20Data/version%201.118/species/?species_number=674

Energy Balance: Hr(T) = Hproducts – Hreactants + Hreaction

Hr(T) =6799.4-8376.8.4-5985= -7582 MJ/Batch
Heat should be removed at the rate of 7582 MJ/Batch. 23
 FLUIDIZED BED REACTOR
Energy Balance For Fluidized Bed Reactor
Inlet T= 360⁰C Outlet T=95⁰C
mass Specific Enthalpy mass Specific Enthalpy
Component rate Heat ∆T in Component rate Heat ∆T out
Kg/hr. Kj/Kg K KJ Kg/hr. Kj/Kg K KJ

Nitric oxide 2082.75 1.34 335 934946.8 Nitrogen- 2874 0.86 70 173024.8

Oxygen 1000 1.16 335 388600 dioxide

Total 1323546 173024.8

2NO + O2 2N02 ,∆H0= 33 KJ/mol

∆Hreaction = moles produced * heat of reaction
= (62.4kmol/hr.) *(33MJ/Kmol) = 1901 MJ/hr.
https://opentextbc.ca/chemistry/back-matter/standard-thermodynamic-properties-for-selected-substances/

Energy Balance: Hr(T) = Hproducts – Hreactants + Hreaction

Hr(T) =173-1324+1901 = 750 MJ/hr.
Heat should be provided at the rate of 750 MJ/hr.
24
 ABSORBER
Energy Balance For Absorber
Inlet Outlet
mass Specific mass Specific Enthalpy
Component rate Heat ∆T Enthalpy in Component rate Heat ∆T out
Kg/hr. Kj/Kg C Kj/Kg Kg/hr. Kj/Kg C Kj/Kg
Nitrogen
dioxide 2874.1 0.86 70 173024.83Nitric Acid 2079 0.99 70 154074.8
Water 270 4.18 20 22572Nitric oxide 703.75 0.95 18 12034

Total 195596.82Total 166108.9

3NO2 + H2O 2HNO3(aq) + NO ∆H0= -112 KJ/mol

∆T(gas)= 95-25C0 ∆TNO= 18 C0 ∆THNO3= 95-25C0 ∆TH2O= 20 C0
Heat Generated from Reaction:
∆Hreaction = moles produced * heat of reaction
= (32kmol/hr.) *(-112 MJ/Kmol) = -3461MJ/hr.
https://opentextbc.ca/chemistry/back-matter/standard-thermodynamic-properties-for-selected-substances/

Energy Balance: Hr(T) = Hproducts – Hreactants + Hreaction

Hr(T) =166.1-195.6-3461 =-3477 MJ/hr.
25
Heat should be removed at the rate of 3477 MJ/hr.
CRYSTALLIZER-1
Feed rate in =Fin= 156641kg/B =1.8 kg/s
Rate of outflow of mother liquor =F0 = 53165 kg/B
Solubility of Oxalic acid at 65C0 = 74.5g/100 g of Water
So, initial concentration of feed,
Cin =74.5/174.5= 0.42 g/g of solution
Solubility of Oxalic acid at 25C0 = 20.5g/100 g of Water
Solubility of solid at exit-T,
C0=20.5/120.5= 0.152
𝐹𝑖𝑛∗𝐶𝑖𝑛−𝐹0∗𝐶0
%age yield of crystals = ∗ 100
𝐹𝑖𝑛∗𝐶𝑖𝑛
= 0.87
26
CRYSTALLIZER-1
Mean heat capacity of solution=Cpm= 1.62+4/2 = 2.8 kj/kg
Since, crystals produce = 103476kg/B = 1.1 kg/s
Heat of crystallization of oxalic acid dihydrate Crystals at 25C0
= -312 KJ/kg
Heat of crystallization = 1.1*322 = 330 KW
Since, solution is cooled from 65C0 to 37C0 ,
So, heat required to cool the solution = m*cp*∆T
= 1.8*2.8*(338-310)
= 141 KW
Total cooling duty = 470 KW
27
CRYSTALLIZER-2
Feed rate in =Fin= 151234kg/B =1.61 kg/s
Rate of outflow of mother liquor =F0 =75000 kg/B
Solubility of Oxalic acid at 85C0 = 90g/100 g of Water
So, initial concentration of feed,
Cin =90/190= 0.474 g/g of solution
Solubility of Oxalic acid at 37C0 = 36.6g/100 g of Water
Solubility of solid at exit-T,
C0=36.6/136.6= 0.267
𝐹𝑖𝑛∗𝐶𝑖𝑛−𝐹0∗𝐶0
%age yield of crystals = ∗ 100
𝐹𝑖𝑛∗𝐶𝑖𝑛
= 0.9
28
CRYSTALLIZER-2
Mean heat capacity of solution= Cpm = 1.62+4/2 = 2.8 kj/kg
Since, Crystals produced= 76234 kg/day = 0.88 kg/s
Heat of crystallization of oxalic acid dihydrate Crystals at 25C0
= -312 KJ/kg
Heat of crystallization = 0.88*322 = 283 KW
Since, solution is cooled from 85C0 to 37C0 ,
So, heat required to cool the solution = m*cp*∆T
= 1.61*2.8*(358-310)
= 210 KW
Total heat = 493 KW

29
DRIER
Amount of Oxalic acid crystal required=75000 kg
Amount of Oxalic acid fed into the drier=76234 kg
Therefore, amount of water evaporated = 76234-75000 =1234 kg
Inlet temperature of feed= 25C0
required temperature of hot air = tC0
∆t= tC0-25C0
Latent heat of vaporization= 2270 kJ/kg
Therefore, heat required to evaporate 1234 kg of
water=q=2270*1234=2801180 kJ
Specific heat of water= 4.187 kJ/kg C
Mass of water =1234 kg
Given temperature ∆t= tC0-25C0
30
 DRIER

But according to energy balance,

m*cp*∆t=m*λ
2227*4.187*(tC0-25C0) = 2801180
tC0 =501+25=526C0
No energy balance is required for centrifuge as inlet & outlet
temperature is same.

31
 NO

CYCLON
139954kg/Batch HNO3/ SEPARATOR
936kg/Batch V2O5 P-21
T=20C Pure
66646kg/Batch Molasses P-11 water NO
(glucose) 49986.2
NO T=18C
kg/Batch NO AL2O3 cat E-7

AL2O3
P=6 bar
T=65C T= 360C
NO+NO2
3082Kg/hr.
P-8
T=95C
P = 1bar
T= 65C Steam Heater NO Gas
Oxalic ∆ T=360-550C 2082kg/hr.
Steam Heater
acid+Unreacted
∆ T=25-65C Reactor material
Compressor Absorber
O2 GAS
T=65C 1000Kg/hr. FBR
156641.9kg Weak
Activated Carbon Filter HNO3 T=95C

156641.9Kg P-36

Hot T=85C
P-31 water Hot air
T=25C 47758kg out
Q=470 P-35
T=37C
KW T=25C
Q=493
KW Hot air
103476kg 76234kg in
Feed Holding Tank T=65C Crystalizer-1 Centrifuge-1 P-34
Centrifuge-2
P-41

Oxalic acid Mother Mothe T=526C

536590kg
crystals liqour Crystalizer-2 r liqour Turbo Dryer
156641.9kg 53165kg 103476kg
75000kg 99% Pure
Oxalic Acid

32
 MATERIAL OF CONSTRUCTION

When selecting a material of construction, the most important

characteristics to be considered are:
• Mechanical properties
• Effect of elevated temperature and pressure
• Corrosion resistance
• Ease of fabrication
• Material cost

33
 EQUIPMENT DESIGN
• Crystallizer
• Batch Reactor
• Heat Exchanger
• Absorber

34
 CRYSTALLIZER
Equipment Crystallizer
Crystallizer Type Agitated Cooler Crystallizer
MOC Mild Steel
Feed rate 1.7 kg/s
Total Cooling Duty 470 kW

Overall Heat Transfer Coefficient 475 W/m2K

Heat transfer area 32 m2

Height 4.6 m
Diameter 1.8 m
Thickness of shell 169 mm
Thickness of hemispherical Head 51 mm
Weight 372826 N

35
 FORMULAE USED

𝐹𝑖𝑛∗𝐶𝑖𝑛−𝐹0∗𝐶0
• %age yeild of crystals = ∗ 100
𝐹𝑖𝑛∗𝐶𝑖𝑛
• Heat Transfer Area Required = Q/U*∆Tlm
• Height of Crystallizer = ,A= π*D*H , H=2.5D
• H = 1.15*Hreq
• Wall thickness of cylindrical section of vessel = t =(Pi*di) /(f-Pi)
• Thickness of hemispherical head of vessel = t = (Pi * Di) / (4Jf – 1.2Pi)
• Wv = 240Cv*Dm*(Hv+0.8Dm) *t
Cv= a factor account for the weight of nozzels, internal supports,
So, Cv=1.15 for vessels with plate support rings

36
BATCH REACTOR
Equipment Reactor
Reactor Type Batch Reactor
MOC Stainless steel
Weight of Catalyst 936 kg
Volume of Catalyst 0.64 m3
Volume of Reactor 52 m3
Diameter of Vessel 2.1 m
Height of Vessel 6.4 m
Weight of Vessel 209801 N
Pressure 1 bar
Temperature 65 C0
Thickness of Hemispherical Head 37 mm
Thickness of Cylindrical shell 127 mm

37
Thickness of Cooling Jacket 0.35 m
 FORMULAE USED
𝑋𝑎 𝑑𝑋𝑎
• Wcat= 𝐹𝐴0 ∗ ‫׬‬0
−𝑟𝑎
𝐹𝐴0 𝑋𝑎 𝑑𝑋𝑎
• Vreaction = ∗ ‫׬‬0 𝑑𝑡
−𝑟𝑎
• Vreactor = 1.15* Vreaction
• V=πd2L/4
• For Reactor, Estimated Ratio , L=3d
• Weight of vessel=Area *Density*thickness
• Wall thickness of cylindrical section of vessel = t =(Pi*di) /(f-Pi)
• Thickness of hemispherical head of vessel = t = (Pi * Di) / (4Jf – 1.2Pi)

38
HEAT EXCHANGER
Fluid Units Shell Side(NO gas) Tube Side(Steam)
Cold Fluid Hot Fluid
Total Flow Kg/hr. 2082 4860
Density Kg/m3 0.97 0.507
Viscosity mNm-2s 4e-4 3.2e-4
Specific Heat KJ/kgC0 1.052 2.2
Capacity
Thermal Conductivity KW/mC0 0.05 0.08
Temperature C0 Inlet =360 C0 Inlet=600 C0
outlet=550 C0 outlet=560 C0
Operating Pressure bar 2 2
Fouling Coefficient W/m2C0 2000 7000

39
Equipment Shell & Tube Heat Exchanger
MOC 304 Stainless steel
Heat load 118 kW
∆Tlm 93.29 C0
Heat transfer area 23 m2
Inner Dia. Of Tube 19 mm
Outer Dia. Of Tube 14.83 mm
Length of tube 1.4 m
No. of tubes 364
ht 238 W/m2C0
1.25 Square Pitch
Bundle Dia. 561 mm
Clearance(split ring floating head) 50 mm
Shell Dia. 611 mm
Baffle Spacing 122 mm
Equivalent Dia. 11.46 mm
hs 278 W/m2C0
Over all heat transfer co-efficient 100 W/m2 C0
40
FORMULAE USED
• Heat load = m*Cp*∆T
• Heat transfer area A = Q/U*∆Tlm
• For 1.25P0 Square Pitch, Db = d0(Nt/k1) ^1/n1
𝜋
• Cross sectional area of tube = ∗ 𝑑𝑖2
4
4200∗ 1.35+.02∗𝑡𝑚 𝑢𝑡 .8
• Tube-Side Heat Transfer Co-efficient =hi=
𝑑𝑖
𝑝𝑡−𝑑0
• Cross flow area of shell side =As = ∗ 𝑙𝑏 ∗ 𝑑𝑠
𝑝𝑡
𝐾 .33
• Shell Side Heat Transfer Co-efficient =hs = ∗ 𝑅𝑒 ∗ 𝑗ℎ Pr
𝐷0
1 1 𝑑0∗𝑙𝑛𝑑0/𝑑𝑖 𝑑0 1 𝑑0 1
• 1/Uo = + + + * + *
ℎ𝑠 5000 2∗50 𝑑𝑖 2000 𝑑𝑖 ℎ𝑡
41
ABSORBER
Equipment Absorber
MOC Stainless steel
Column Packed Column
Temperature 95 C0
Pressure 1 bar
Feed Gas Rate 3082 kg/hr.
NO2 93 %wt.
NO 7 %wt.
Mole Fraction of NO2 in feed 0.89
Partial Pressure of NO2 in feed 0.89 bar
Solubility data of NO2 in water:
Mass fraction NO2 Partial
of NO2 in Pressure in Source: Data from Perry, J.H.1973.Chemical
water gas(bar) Engineers’ Handbook .5th.edn,.McGraw-
0.12 0.1 Hill,.New.York.
0.18 0.2 https://coifpm.com/wp-content/uploads/2018/07/26.-
0.35 0.5 Tan_2013_2.pdf
0.79 0.89
42
0.83 1
Mole.Fraction.of.NO2.in.Liquid.Phase.and.Gas.Phase.at.Equilibrium
Mole fraction of NO2 in Mole Fraction of NO2 in
water(x) Gas Phase(Y)
0 0
0.115 0.2
0.3 0.5
0.46 0.75
0.65 1

Mole fraction of gas entering the column= y1=0.89

For 90% recovery of gas = y2 = 0.1 * 0.9 = 0.09
Since x1 = 0.52, x2=0
So, slope of the operating line or minimum liquid to gas ratio
𝐿𝑚 𝑌1−𝑌2
= = 1.57
𝐺𝑚 𝑋1−𝑋2
Gm = 1.13 kmol/min = 0.874 kg/s
Lm = 1.13*1.53 =1.77 kmol/min
L = 1.15* Lm = 2.04 kmol/min
𝐿
= 1.80 , x1 = 0.42 43
𝐺
 Plot of mole fraction in gas phase verses liquid
phase in equilibrium
1.2
Mole fraction of NO2 in gas phase(y)

𝐿 𝐿𝑚
=1.57
1 = 1.80 𝐺𝑚
𝐺
0.8

0.6

0.4

0.2

0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
Mole fraction of NO2 in liq phase(x)
P = 1 bar
Series1 operaing line(min) Operating line(max) T = 95 C0

Slope of the equilibrium line = 1.53

𝐺
Absorption factor = m = 0.85
𝐿
𝐺 𝑦1 𝐺 1
NOG = ln 1−m ∗ +m ∗ 𝐺
𝐿 𝑦2 𝐿 1−m
𝐿

NOG = 6
44
So, number of theoretical stages are 6.
ABSORBER
Equipment Absorber
Gas Flow rate 0.874 kg/s
Liquid Flow rate 1.62 kg/s
Type of Packing Intelex saddles
Material of Packing Ceramic
Size of Packing 38mm
HOG 0.75 m
NOG 6
Height of Packing 4.5 m
Height of Column 5.1
Diameter of Column 1.1 m

Column dia. to packing ratio 31.5

Percentage Flooding at selected 39%
Dia.

45
 FORMULAE USED

• Material balance = Lm (x₁-x2) = Gm (y₁-y2)

• Lw*/Vw*√ (Ƥg/ƤL) for finding K factor.
• Vw*= √ [k₄Ƥv (ƤL-Ƥv)]/ [1.31Fp (UL/ƤL) ׄ ׄ ^.1
• Diameter = √4/π*Ac = 1.2m
• Column area = π/4*D²
• Z=HOG*NOG
• Density of gaseous mixture at 85 C0 = 1.526kg/m3
• Density of liquid = 1004 kg/m³
• Viscosity of liquid = 0.79*10−2

46
COST ESTIMATION

Fixed Capital Working Capital

It includes: It includes:
 Design  Start up
 Equipment and interaction  Catalyst cost
 Piping instrumentation and  Raw material
control system  Finished
 Building and structure  product inventories
 Auxiliary facilities such as
utilities

47
OXALIC ACID PLANT COST
INDEX

Cost index in 1979 = 250

Cost index in 2018 = 502
Present cost of Plant (2019) = (original cost) * (cost index in
2018)/ (cost index in 2009)
= (7*108) * (502/250) = Rs. 14.12*108
i.e., Fixed Capital Cost (FCC) = Rs. 14.12*108

48
 DIRECT COST

https://www.alibaba.com/trade/search?f0=y&IndexArea=product_en&CatId=&SearchText=batc
h+reactor&isPremium=y&refine_attr_value=1477-8225 49
INDIRECT COST

50
COST ESTIMATION OF OXALIC
ACID PLANT
Fixed Capital Investment Rs. 19.48*108
Working Capital Rs. 2.119*108
Total Capital Investment Rs. 21.598*108
Annual Production Cost Rs. 30.96 * 108

Production Rate 22500000 kg/yr.

Cost per unit mass(kg) of Rs. 137
Oxalic Acid
Market Price Rs. 179
Annual Profit Rs. 9.4*108
Pay Back Period 2.6 yrs.
Rate of Return 38% per year

51
 RISK ASSESSMENT

• Purpose of risk assessment is to evaluate the hazard, and then

minimize the level of its risk by adding control measures as
necessary.
• The OSHA permissible exposure limits (PELs) for oxalic acid
: TWA 1 mg/m3
,ST 2 mg/m3

52
HAZARDS OF OXALIC ACID

Potential Health • Oxalic acid is corrosive to tissue

• If ingested, it removes calcium from blood
Effects

• can cause severe irritation

Inhalation or • Renal damage
Ingestion • Estimated fatal dose is 5 to 15 grams

Skin Contact or • Can cause severe skin burns

• Oxalic acid is an eye irritant
Eye Contact
53
SAFETY MEASURES

• If inhaled then remove to fresh air or give

Inhalation or artificial respiration
• If ingested then give large quantities of lime
Ingestion water or milk

• for skin, Wipe off excess from skin and wash

Skin contact or skin with plenty of water
• For eyes, wash eyes with large stream of
eye contact water

Handling and • Keep in tightly closed container

• Keep in cool dry and ventilated area away fro
storage heat source

54
 HAZOP STUDY FOR REACTOR
Guide word Parameter Deviation Causes Consequences Action

No temperature No cooling Cooling Temperature Install high

water increase in temperature
malfunction reactor alarm
More temperature More Control Too much Instruct
cooling valve cooling water operators
flow failure, reactor cools on
Operator procedures
fails to take
action on
alarm
Other than composition possible Wrong Tank rupture Considering
reaction reagent sample
before
unload
As well as composition problem in Impurities Impure Check that
reactor in reagent Product no other
material is
delivered in
55
tank
 HAZOP STUDY FOR HEAT EXCHANGER

Guide word Deviation Causes Consequences Action

Less Less flow of pipe blockage Temperature of Low temperature

steam fluid remains alarm
constant
More More hot Failure of hot Temperature of high temperature
fluid flow water valve process fluid alarm
decrease
More of More Failure of Bursting of tube Install high
pressure on process fluid pressure alarm
tube sides valve
Contamination Contaminatio Leakage of tube Contamination Proper
n of process and cooling of process fluid maintenance and
fluid line water goes in operator alert
Corrosion Corrosion of Hardness of hot more heating proper
tube water and crack of maintenance
tube
56
THANK YOU

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