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Libya Ministry of Higher Education Bright Star University – Braga

Bright Star University – Braga

Faculty Of Technical Engineering Department of Chemical Engineering

AMMONIUM NITRATE

AN

By

Sharefa Hamad Mohammed 21152878

Hana Abduallah Idris 21152899

Hana Imhumd Rashed 21152876

Mabroka Abdalhamid Bushnaf 211521037

Laylaa Alsalihin Iihmudh 21161157

Supervised By

Abdalhamid Almisri

DEGREE OF BACHELOR IN CHEMICAL ENGINEERING

FACULTY OF TECHNICAL ENGINEERING

CODE OF PROJECT ( CHE 2017 049F108 )

i

AMMONIUM NITRATE

By:

Sharefa Hamad Mohammed 21152878

Hana Abduallah Idris 21152899

Hana Imhumd Rashed 21152876

Mabroka Abdalhamid Bushnaf 211521037

Laylaa Alsalihin Ihmudh 21161157

Supervised by:

Abdalhmid Almisri

Project Report Submitted as Partial Fulfillment of the Requirements for the Degree of Bachelor in Chemical Engineering

Month, 2018

ii

ABSTRACT

A Plant is to be designed for production of (22590 ton/year) of crystalline

Ammonium Nitrate coming With nitric acid liquid ammonia. The product is

required in dry crystalline condition containing (0.1) percent moisture, and should

be incorporated in the design.

Nitrate acid is available at concentration (47.5% W) storage for (48 hours) supply

is required. Liquid ammonia under pressure, (99% W NH3) containing (1%) water,

is available and storage is also required at least for this for (48 hours) supply. The

crystals are withdrawn as (30%) slurry.

Then, the centrifuged in batch centrifuged discharged with (2%W) adhering

moisture onto a conveyer which feeds them continuously into a counter current

rotary air dryer, fed with air at (250ºF). The effluent air passes through a dust

collection system. The dried product contains (0.1%) moisture is sieved and the

undersize product is recycled together with the dust from the drier to the

evaporator stage. It can be assumed that these recycle streams amount to (0.5 and

0.3 ton/day) , respectively. Losses on the process will be assessed at (0.3 ton/day)

and may be assumed to occur at the centrifugal stage.

iii

DEDICATION

بدأنا بأكثر من يد وكافحنا بعزم وجد وها نحن اليوم والحمد لله نطوي سهر الليالي وتعب السنين..

إلى منارة العلم والعالمين إلى سيد الخلق إمام المرسلين...إلى الأمي الذي علم المتعلمين...

"رسول الله صلى الله عليه وسلم"

نوراً لي في طريقي..... إلى من كان رضاها زاداً لي في حياتي... ودعواتها

"أمي الغالية"

إلى الذي علمني كيف أمسك قلمي لأكتب أول حرف الهجاء...إلى عاقد الحاجبين مبتسماً ليخفي تعبه...إلى من

كان المشي خلفه افتخاراً.....

"أبي العزيز"

إلى الشموع التي تنير دربي...إلى السعادة التي تملأ حياتي.....

"أخوتي وأخواتي"

لى من عرفت معهم معنى المحبة والأخوة...إلى من شاركوني أسعد اللحظات ونقشت معهم على مر السنين إ

أجمل الذكريات.....

"أصدقائي"

إلى كل من علمني حرفاً وأنار بالعلم طريقي.....

"أستاذي الفاضل"

إليكم جميعاً اهدي ثمرة جهدي

. . . . . .طالبات المشروع

iv

ACKNOWLEDGEMENTS

I would like to express my appreciation to my supervisor, ( Abdalhmid Almisri) who has

cheerfully answered my queries, provided me with materials, checked my examples, assisted me

in a myriad ways with the writing and helpfully commented on earlier drafts of this project. Also,

I am also very grateful to my friends, family for their good humor and support throughout the

production of this project

v

APPROVAL

This project report is submitted to the Faculty of Technical Engineering, Bright Star University –

Braga, and has been accepted as partial fulfillment of the requirement for the degree of bachelor

in Chemical Engineering. The members of the Examination Committee are as follows:

________________________________________

Supervisor

Abdalhmid Almisri

Department of Chemical Engineering

Faculty of Technical Engineering

Bright Star University – Braga

____________________________________________

Examiner 1

The examiner name

Department of Ashraf Adam Engineering

Faculty of Technical Engineering

Bright Star University – Braga

____________________________________________

Examiner 2

The examiner name

Department of Anas al-Abani Engineering

Faculty of Technical Engineering

Bright Star University – Braga

vi

DECLARATION

I hereby declare that the project report is my original work except for quotations and citations,

which have been duly acknowledged. I also declare that it has not been previously, and is not

concurrently, submitted for any other degree at Bright Star University – Braga or at any other

institution.

With best regarding of project prepared students:

Sharefa Hamad Mohammed 21152878

Hana Abduallah Idris 21152899

Hana Imhumd Rashed 21152876

Mabroka Abdalhamid Bushnaf 211521037

Laylaa Alsalihin Ihmudh 21161157

TABLE OF CONTENTS

vii

ABSTRACT ii

DEDICATION iv

ACKNOWLEDGEMENTS iv

APPROVAL v

DECLARATION vi

LIST OF TABLES x

LIST OF FIGURES xii

NOMENCLATURES xii

CHAPTER 1: INTRODUCTION

1.1 INTRODUCTION 1

1.2 Problem Statement 2

1.3 Description of Proess 3

1.4 Data to be used in design 3

1.5 Production 4

1.6 Ammonium Nitrate Process 4

1.6.1 Crystalline phases 6

1.6.2 Reaction 6

1.7 Fertilizer 7

CHAPTER 2:MATERIAL AND ENERGY BALANCE

2.1 The Material Balance 9

2.1.1 Material Balance of Reactor 9

2.1.2 Material Balance around the Dryer 11

2.1.3 Overall Material Balance 13

2.1.4 Material Balance around the Washing Tower 14

2.1.5 Ammonium Nitrate Material Balance 14

2.1.6 Material Balance around the Crystallizer 16

2.1.7 Material Balance around the Evaporator 17

2.1.8 Material Balance around Branches 18

viii

2.1.9 Overall Material Balance around the 18

2.2 The Energy Balance 20

2.2.1 Heat Balance around Ammonia Evaporator 20

2.2.2 Latent Heat for steam at 11bar 21

2.2.3 Heat Balance around Nitric Acid Heater 22

2.2.4 Heat Balance around the Reactor 22

2.2.5 Heat Balance around the Evaporator 25

2.2.6 Heat Balance around the Crystallizer to Find Crystallizer Temperature 27

2.2.7 Heat Balance around the Dryer 30

CHAPTER 3:PROCESS DESIGN OF EVAPORATOR

3.1 Calculation Heat Transfer Surface Area 32

3.2 Calculation The Overall Heat Transfer 32

3.3 Use One Shell and One Tube Pass 35

3.3.1 Using a Split ring floating head 35

3.3.2 Pressure Drop Inside the Tubes 36

3.4 Process Design of the Vapour- Liquid Separator 37

3.5 Process Design 37

3.6 Choosing Pitch of Heat Exchanger 43

3.7 Calculation Coefficient of Overall Heat Transfer 46

3.8 Calculation of Pressure Drop Inside Heat Exchanger 47

3.8.1 Pressure Drop Tube Side 47

3.8.2 Pressure Drop Shell Side 48

3.9 Mechanical Design for Separator 48

3.9.1 Thickness of the Shell 48

3.9.2 Design for the Atorispherical dished 50

3.9.3 Design of conical closure 50

3.10 Calculation the Nozzle Size on Wall of the Separator 51

ix

3.11 The Velocity through Outlet of the Separator 52

CHAPTER 4:INSTRUMENTATION AND CONTROL

4.1 Instruments 54

4.1.1 Instrumentation and control objectives 54

4.1.2 Guide Rules 55

4.2 Typical control systems 56

4.2.1 Level Control 56

4.2.2 Pressure Control 56

4.2.3 Ratio Control 57

4.2.4 Flow Control 57

4.2.5 Temperature Control 58

4.3 Incorporation of the Controllers 59

CHAPTER 5: SAFETY AND ENVIRONMENTAL

5.1 Introduction 61

5.2 Task Evaluation 61

5.3 Chemical Storage 61

5.4 Emergencies and Spills 62

5.5 Housekeeping 62

5.6 MSDS Information 63

5.7 Chemical Users Information 64

5.8 Chemical Reaction Information 64

5.9 Control Measures 64

5.10 Health Hazards 64

5.11 Safety and Environment Precautions 65

5.11.1 Acute Health Effects 65

5.11.2 Long-Term Health Effects 66

CHAPTER 6: MATERIAL OF COST

6.1 Introduction to Material of Construction 67

x

6.2 The Sizing of the Plant 67

CHAPTER 7: PLANT LAYOUT AND CONCLUSION

7.1 Plant layout 84

7.2 Conclusion 86

REFERENCES 87

APPENDICES

Appendix A

LIST OF TABLES

xi

Table.1.1: Data to be used in design .................................................................................................

Table.1.2: Crystalline Phases……………………………………………………………………….

Table.2.1.1: Reactor Inlet and Outlet Components………………….……………………………..

Table.2.1.2: Material Balance Around the Dryer…………………………………………………..

Table.2.1.3: Material Balance Around Washing Tower……………………………………………

Table.2.1.4: Material Balance Around Crystallizer………………………………………………

Table.2.1.5: Material Balance Around Evaporator…………………………………………………

Table.3.1: Data of Temperature / Growth Rate Relation…………………………………………...

Table.4.1: Some Symbols Used in the Control Systems…………………………………………...

Table.5.1: Exposure and Hazard Level……………………………………………………………..

Table.5.2: Type of Effect and Effect Level………………………………………………………...

Table.6.1: Sizing of Ammonia Vaporizer…………………………………………………………..

Table.6.2: Sizing of Nitric Acid Heat Exchanger…………………………………………………

Table.6.3: Sizing of Reactor……………………………………………………………………….

Table.6.4: Sizing of Evaporator……………………………………………………………………

Table.6.5: Sizing of Crystallizer……………………………………………………………………

Table.6.6: Sizing of Ammonium Nitrate Dryer……………………………………………………

LIST OF FIGURES

Figure 1.1: Ammonium Nitrate ; Chemical fromula and White Crystalline ....................................

Figure 1.2: Simplified Flowchart for the Stengel Process for Ammonium Nitrate……………….

xii

Figure 2.1.1: Material Balance Around the Reactor .........................................................................

Figure 2.1.2: Material Balance Around the Dryer ............................................................................

Figure 2.1.3: Material Balance Around the Washing Tower………………………………………

Figure 2.1.4: Material Balance Around the Crystallizer…………………………………………...

Figure 2.1.5: Material Balance Around the Evaporator…………………………………………….

Figure 2.1.6: Plant of Ammonium Nitrate…………………………………………………………

Figure 2.2.1: Energy Balance Around Ammonia Evaporator…………………………………….

Figure 2.2.2: Energy Balance Around Nitric Acid Heater…………………………………………

Figure 2.2.3: Heat Balance Around the Evaporator……………………………………………….

Figure 2.2.4: The relation between Solubility versus Temperature for Ammonium Nitrate……..

Figure 3.1: Growth Rate of Ammonium Nitrate Crystals With Temperature……………………

Figure 3.2: Forced Circulation Evaporator With One pass Vertical Separator……………………

Figure 4.1: A typical arrangement for the Level Control …………………………………………

Figure 4.2: A typical arrangement for the Pressure Control………………………………………

Figure 4.3: A typical Scheme for ratio Control…………………………………………………….

Figure 4.4: A typical arrangement for the Flow Control…………………………………………..

Figure 4.5: A typical arrangement for Temperature Control………………………………………

Figure 4.6: Flow Scheme of Typical process with Controllers…………………………………….

Figure 7.1: Plant Diagrams…………………………………………………………………………

NOMENCLATURES

Cp

Heat Capacity

KJ/Kg .Cº

xiii

T Temperature Cº

ΔH Enthalpy Change KJ/hr

M MASS Flow Rate Kg/hr

ρ density Kg/m3

U Overall Heat Transfer

Coefficient W/m2.Cº

A Total Heat transfer area m2

ΔTlm Mean Temperature Difference Cº

do Outside Tube Diameter mm

di inside Tube Diameter mm

V Velocity m/s

L Tube length m

xiv

hi Tube side film coefficient w/m3.ºc

h0 Shell side film coefficient w/m3.ºc

Gs Shell side mass velocity Ib/hr.ft2

μ Shell side fluid viscosity Ib/hr.ft

Kf Shell side fluid thermal But/Ib .ºF

Np Number of passes

Jf B asic friction factor

ΔPt tube –side pressure drop N/m or atm

Ds Shell diameter m

De Equivalent diameter m

1

CHAPTER 1

INTRODUCTION

1.1 . Introduction

The chemical compound Ammonium Nitrate, the nitrate salt of ammonium, has the

chemical formula NH4NO3, simplified to N2H4O3. It is a white crystalline (Fig. 1-1) solid

which is highly soluble in water. It is predominantly used in agriculture as a high-nitrogen

fertilizer. The compound is used as explosives in mining, and also sometimes in improvised

explosive devices. It is the main component of (ANFO), a popular explosive, which

accounts for (80%) explosives used in North America. It is used in instant cold packs, as

hydrating the salt is an endothermic process.

Ammonium Nitrate is found as a natural mineral (ammonia nitrate; the ammonium

analogue of saltpetre and other nitrate minerals such as sodium nitrate) in the driest regions

of the Atacama Desert in Chile, often as a crust on the ground and/or in conjunction with

other nitrate, chlorate, iodate, and halide minerals. Ammonium Nitrate was mined there in

the past, but virtually (100%) of the chemical now used is synthetic.

Fig. 1-1 :Ammonium Nitrate ; chemical formula and white crystalline

2

1.2. Statement of the problem

A plant is to be designed for production of (22590 tons /year) of crystalline Ammonium

Nitrate coming with nitric acid and liquid ammonia.

The product is required in dry crystalline condition containing (0.1) percent moisture, and

should have no allowance for maintenance shut-down and should be incorporated in the

design.

Nitrate acid is available at a concentration (47.5%W) storage for (48 hours) supply is

required. Liquid ammonia under pressure , (99%W NH3) containing (1%) water, is

available and storage is also required for this for (48 hours) supply. Other services are:

Steam at (150 Ib/in2 (psi) gauge saturated.

Water at (15°C) , (80 Ib/in2 (psi)) gauge.

Electricity (440V) , 3- phase , A.C 50 Cycle / second (50HZ).

The crystals are withdrawn as (30%) slurry. Then is centrifuged in batch centrifuges.

Discharged with 2%W adhering moisture onto a conveyer which feeds them continuously

into a counter current rotary air dryer, fed with air at (250°F). The effluent air passes

through a dust collection system. The dried product contains (0.1%) moisture is sieved and

the undersize product is recycled together with the dust from the drier to the evaporator

stage. It can be assumed that these recycle streams amount to (0.5 and 0.3 ton/day) ,

respectively. Losses on the process will be assessed at (0.3 ton/day) and may be assumed to

occur at the centrifugal stage.

Ammonium Nitrate can also be made via metathesis reactions:

3

1.3. Description of process

Ammonia gas and Nitric acid are reacted to give a solution of Ammonium Nitrate which is

concentrated then cooled in an evaporative crystallizer. The centrifuged and the resulting

crystals dried and sieved, the liquid ammonia from the storage at (120 psig) pressure at

(60°F), is vaporized in a steam heated heat exchanger and passed into the reactor together

with the nitric acid. The exothermic reaction raises the temperature to boiling point and

evaporates part of the water forming a hot concentrated solution of Ammonium Nitrate .

The reactor is designed to prevent undue entrainment of liquid in the water- vapor off take

and has adequate volume to allow the reaction to proceed smoothly at a controlled (pH),

which must be on the alkaline side for safety reasons. The resultant Ammonium Nitrate

solution is concentrated to (77% w) in a single effect , forced circulation vacuum

evaporator and is fed to a classifying vacuum crystallizer . The crystallizer is designed to

allow the growth of crystals to the required size and a fines separator is provided to allow

for the removal and solution of excess nuclei.

1.4. Data to be used in design A) Solubility of Ammonium Nitrate in Water

Temperature(°C) gm NH4NO3 / 100gm saturated solution 00.0 54.2

12.2 60.0

20.0 65.6

25.0 68.1

30.0 70.3

35.0 72.5

40.0 74.3

4

1.5. Production The industrial production of Ammonium Nitrate entails the acid-base reaction of

ammonia with nitric acid:

Ammonia is used in its anhydrous form (i.e. gas form) and the nitric acid is concentrated.

This reaction is violent owing to its high exothermic nature.After the solution is formed,

typically at about (83%) concentration, the excess water is evaporated to an Ammonium

Nitrate (AN) content of (95% to 99.9%) concentration (AN melt), depending on grade. The

AN melt is then made into "prills" or small beads in a spray tower, or into granules by

spraying and tumbling in a rotating drum.

The prills or granules may be further dried, cooled, and then coated to prevent caking.

These prills or granules are the typical AN products in commerce.

The ammonia required for this process is obtained by the Haber process from nitrogen and

hydrogen. Ammonia produced by the Haber process is oxidized to nitric acid. Another

production method is used in the so-called Odd process.(Sodium sulfate is removed by

lowering the temperature of the mixture. Since sodium sulfate is much less water-soluble

than Ammonium Nitrate, it precipitates, and may be filtered off. For the reaction with

calcium nitrate, the calcium sulfate generated is quite insoluble, even at room temperature.

1.6. Ammonium Nitrate Process Ammonium Nitrate is a very important nitrogenous fertilizer because of its high nitrogen

content (33%), the simplicity and cheapness of its manufacture , and its valuable

combination of quick acting nitrate and slower acting ammoniacal nitrogen. Its tendency to

cake on storage reduced its acceptability at first but proper granulation, the addition of

antihygroscopic agent, better packaging have largely remedied this problem. Most

commercial and many military explosives contain cheap Ammonium Nitrate as the major

explosive ingredient.

5

Ammonium Nitrate is difficult to detonate, but, sensitized with oil or mixed with other

explosive material, it can be detonated with a large booster primer.

Ammonium Nitrate mixture are “permissibles” that is, permitted for use in coal mines

where combustible vapors may be encountered. The use of explosive in mines and quarries

provide a large and continuing market. Amotal is a mixture of (TNT) and granular

Ammonium Nitrate (AN). This is the major conventional military explosive. On explosive

decomposition, AN rapidly and violently decomposes to form elemental nitrogen.

Under different conditions, (i.e., ), it is safely decomposed to form an

aesthetic nitrous oxide. This is the commercial method of preparation.

Ammonium Nitrate is made by reacting nitric acid ( made by oxidizing ammonia)with

ammonia:

If properly proportioned and preheated, the reaction can be run continuously to produce

molten Ammonium Nitrate containing very little water (1 to 5%) which can be formed into

small spheres (preills) by dropping the reaction product through a shot tower or into flakes

by cooling it on belts or drums. By fluidized bed treatment , it is possible to obtain a dry

granular material as product. Batch processes have also been used, but the labor and

equipment costs are prohibitive. (Fig.1.2) shows a typical flowchart

6

1.6.1 Crystalline phases Transformations of the crystal states due to changing conditions (temperature, pressure)

affect the physical properties of Ammonium Nitrate. These crystalline states have been

identified:

The type V crystal in the table below is a quasi-cubic form which is related to caesium

chloride, the nitrogen atoms of the nitrate anions and the ammonium cations are at the sites

in a cubic array where Cs and Cl would be in the CsCl lattice

1.6.2 Reactions Ammonium Nitrate reacts with metal hydroxides, releasing ammonia and forming alkali

metal nitrate:

Ammonium Nitrate gives ammonium chloride and nitric acid upon reaction with

hydrochloric acid:

Ammonium Nitrate leaves no residue when heated:

System Temperature (°C) State Volume change (%)

> 169.6 Liquid

I 169.6 to 125.2 Cubic +2.1

II 125.2 to 84.2 Tetragonal −1.3

III 84.2 to 32.3 α-rhombic +3.6

IV 32.3 to −16.8 β-rhombic −2.9

V −16.8 Tetragonal

7

Ammonium Nitrate is also formed in the atmosphere from emissions of NO, SO2, and NH3,

and is a secondary component of PM10

1.7. Fertilizer Ammonium Nitrate is an important fertilizer with the NPK rating(34-0-0 ,34% nitrogen).It

is less concentrated than urea (46-0-0), giving Ammonium Nitrate a slight transportation

disadvantage. Ammonium Nitrate's advantage over urea is that it is more stable and does

not lose nitrogen to the atmosphere. During warm weather it is best to apply urea soon

before rain is expected to minimize nitrogen loss

8

Fig. 1-2 : Simplified Flowchart for the Stengel Process for Ammonium Nitrate Manu

facture

9

CHAPTER 2

MATERIAL AND ENERGY BALANCE

2.1 Material Balance:

2.1. 1. Material Balance of Reactor 1. The data taken to be considered in calculating the material balance with a

capacity ( ) .This quantity is including the product and

purged (

2.

3.

4.

Material balance around the reactor is shown in Fig. (2-1)

10

Ammonia Gas

AKg/hr NH4NO3

C Kg/hr

HNO3 Acid

B Kg/hr

Fig. (2-1) Material balance around the reactor

Reactor

11

The following table (2-1) is the amount in and out of the reactor:

`Table (2-1)Reactor Inlet and Outlet Components

2.1.2 Material Balance around the Dryer

Since as stated in the project statement there are

:

INLET OUTLET

Components

Components

Ammonia Gas 100% 00666.7 00 3137.5

Water in gas 00006.734 Water in solution 2732.43

Nitric Acid 100% 02470.800 Inerts 0005.201

Inerts 00005.201

Water in acid 02725.700

TOTAL 5,875.13 TOTAL 5875.13

12

Since the moisture in each of is (o.1 moisture) (See Fig. (2-2)).

Water Vapour (H2O)

[ W6

W5

2% Moisture

W7

R1

W8

Fig. 2.2: Material balance around the dryer

Water Material Balance is:

2.1.3 Overall Material Balance

DRYER

13

Solving above equation:

The composition of Ammonia Nitrate Entering the dryer is (98%).

Table(2-2): Material Balance around the Dryer

INLET kg/hr OUTLET kg/hr

Ammonia Nitrate 100% 3167.629 Water Vapour 0061.470

Water Entering with

Ammonia Nitrate 0064.645 Ammonia Nitrate 100% 3167. 629

Moisture with Ammonia

Nitrate 0003.171

TOTAL 3232.27 TOTAL 3232.27

14

2.1.4 Material Balance Around the Washing Tower

W4 W5=3232.27 Kg/hr

2% Moisture

Fig. 2-3: Material balance around the Washing Tower

Overall material balance aroundthe washing tower:

2.1.5. Ammonium Nitrate Material Balance

The table(2-3) shows the Material Balance in and out of the Washing Tower: Table

2-3:Material Balance around Washing Tower

WASHING TOWER

15

INLET kg/hr OUTLET kg/hr

Ammonia Nitrate 100% 3179.87 Ammonia Nitrate 100% 3167.62

Water Entering with

Ammonia

Nitrate solution

0064.89 Water entering

withNH4NO3solution 0064.645

Amount of NH4NO3Washed

solution 0012.25

Amount of Water in washed

solution 0000.25

TOTAL 3244.76 TOTAL 3244.76

2.1.6 Material Balance around the Crystallizer

Since the outlet of the slurry is taken to washing tower and the rest

is solution is recycled to the evaporator, then:

The composition of the Recycled as shown in Fig.(2-4) can be calculated as

follows:

16

W3 W4=3244.77 Kg/hr

77% NH4NH3 2% Moisture

R1

Fig. 2-4: Material balance around the Crystallizer

So, Material Balance is:

Where is the composition of Recycled .

The table(2-4) shows the Material Balance around the Crystallizer

Table (2-4) Material Balance around Crystallizer

OUTLET kg/hr INLET kg/hr

CRYSTALEIZER

17

Ammonia Nitrate 100% 8328.219 Ammonia Nitrate 100% 3179.87

Water in NH4NO3solution 2487.65 Water inNH4NO3 solution 0064.89

Recycled NH4NO3 5148.35

Water in NH4NO3Recycled 2422.75

TOTAL 10815.86 TOTAL 10815.86

2.1.7 Material Balance Around the Evaporator Water vapour + (NO2)

W0=5879.765Kg/hr W1 W3=10815.87Kg/hr

R=33.3Kg/h R1=7571.109Kg/hr

98% NH4NO3 68% NH4NO3

Fig. 2-5: Material Balance around the Evaporator

2.1.6 Material Balance around the Branches

To find the solution Entering the evaporator, Material

Balance around the Branches:

EVAPORATOR

18

Assume the Inerts Entering with Nitric acid is and is removed in the Evaporator,

so the gases out of the Evaporator are

2.1.8 Overall Material Balance around the Evaporator

The table(2-4) shows the Material Balance around the Crystallizer

Table (2-5) Material Balance around Evaporator

INLET kg/hr OUTLET kg/hr

NH4NO3 solution

(61.5% NH4NO3 ) 13484.174

NH4NO3 solution

( 0.77 NH4NO3) 10815.87

Water Vapour 2668.304

TOTAL 13484.174 TOTAL 13484.174

2.2 Energy Balance :

19

2.2.1 Heat Balance around Ammonia Evaporator:

Fig. 2.7:EnergyBalance Around Ammonia Evaporator

20

2.2.2 Latent Heat for Steam at 11 bar

.

Where:

The amount of steam required to evaporate the NH3 :

So, the amount of steam required to increase the temperature of liquid ammonia from

(15°C) to saturation temperature of ammonia is:

2.2.3 Heat Balance around Nitric Acid Heater

Assume that Nitric acid entering the heater at ( ) and out at ( )

21

Fig. 2.8:Heat Balance around Nitric Acid Heater

Since the acid entering at ( ), then the Enthalpy:

Heat capacity of the acid at 47.5% (Ref. 3, Fig. 3.39):

2.2.4 Heat Balance around the Reactor

22

To calculate the heat of reaction at the temperature of the reaction:

Where:-

Data of heat of formation for the reactant and product is taken from (Ref. 3).

Temperature of entering ( to the reactor

Temperature of entering of Ammonia gas to the reactor

23

Where:

The amount of water required for cooling the reactor data:

=

24

2.2.5 Heat Balance around the Evaporator

25

To find out the amount of steam required to increase the composition of Ammonium

Nitrate solution from 61.5% to 77%, the heat balance around the Evaporator:

Heat balance around the Branch to find the temperature of inlet Ammonium Nitrate to the

Evaporator:

26

5875.13Kg/hr

(198.5

R=33.3 Kg/hr R1=7541.4 Kg/hr (23

From the Dryer From the Crystallizer

Fig2.2.3:Heat Balance around the Evaporator

2.2.6 Heat Balance around the Crystallizer to Find the Crystallization

Temperature

27

5148.2

100

TEMPERATURE SOLUBILITY

0 54 12 60 20 66 25 68 30 70 35 72 40 74 50 78 60 81 70 84 80 87 90 89 100 91 110 93 120 95 130 96 140 98 150 99

28

Fig. 2-4: The relation between Solubility versus Temperature for Ammonium Nitrate

29

Heat Balance around the Dryer

30

Solving to find out

31

CHAPTER 3

PROCESS DESIGN OF EVAPORATOR

3.1 Calculation Heat Transfer Surface Area

Where;

3.2 Calculation the Overall Heat Transfer in the Evaporator (Ref.3,

P.485)

Taking heat transfer coefficient of the steam flowing in the shell side:

Heat transfer coefficient of inside pipe of the evaporator (Forced circulation), can be

calculated from the equation:

32

To avoid scale formation on the inside of the pipe of this type of evaporator, solution

circulation flow rate should be high relative to the feed flow rate , for this reason we cannot

calculate the velocity based on feed flow rate. For design purpose, assume the velocity (2 to

5 m/s) inside the pipes.(Ref. 3, P. 485).

At this temperature, the physical properties of the solution inside the

evaporator:

33

To calculate the overall heat transfer coefficient, we use the following equation:

.

34

3.3 Use One Shell Pass and One Tube Pass

The steam flowing on shell side (clean fluid), so we use (1.25) triangular pitch.

3.3.1 Using a Split Ring Floating Head

Shell side:

35

3.3.2 Pressure Drop Inside the Tubes

36

3.4 Process Design of the Vapor –Liquid Separator

3.5 Process Design of classifying vacuum crystallizer.

37

Table (3-1) Data of Temperature / Growth Rate Relation

Temperature Growth Rate

0 4.5

23 3.7

40 3.3

38

Fig. 3-1: Growth Rate of Ammonium Nitrate Crystals with Temperature

39

Where:

40

Where:

Where:

41

.

42

.(This is standard length) .

Note:

3.6 Choosing Pitch of Heat Exchanger

43

44

45

:

3.7 Calculation of Overall Heat Transfer Coefficient

46

3.8 .Calculation of Pressure Drop Inside Heat Exchanger

3.8.1 Pressure Drop Tube Side

47

3.8.2Pressure Drop Shell Side

3.9. Mechanical Design for Separator.

The following steps were used in mechanical design of the separator:

3.9.1Thickness of the Shell

Assume different value for the thickness. The following ratio was estimated:

To estimate the pressure, which the thickness assumed can be taken:

: is a constant that can be found from the graph ), according to

the material of construction with the ratio which were tested at temperature of

48

in the evaporator. The value of pressure allowed is close to atmospheric

pressure, then the assumed value of the thickness.

In the graph to find the thickness of the shell required from the different

thicknesses where we find shell thickness is the lowest value for allowed

pressure (Atmospheric pressure) to assure this value the following steps were

followed:

So;

From , choose the next higher available plate thickness for actual fabrication:

Choosing for actual thickness.

49

3.9.2Design for the Atmospherically dished closure (cover)

Assuming different values for the thickness of dish and was found thickness of

is the minimum which can take the allowable pressure (atmospheric Pressure).

Following the procedure used in (

3.9.3 Design of conical closure

Choosing different values for the thickness and was found that thickness of is

the proper one for pressure of one atmosphere we follow the procedure in

50

3.10. Calculation the Nozzle Size on Wall of the Separator

To calculate the diameter of the nozzle, the following procedure is to be followed:

Consider that diameter of nozzle is equal to the outlet diameter nozzle flow of vapour.

So, the inlet nozzle to separator :

51

Note:

The actual velocity through feed nozzle to the separator is lower than above value. This is

due that it is calculated for complete evaporation in the heat exchanger before entering

the separator, but actually most evaporation is happen in flash chamber.

3.11.The Velocity through Outlet of the Separator

Consider that diameter of the nozzle is equal to half diameter of inlet diameter to the

separator. i.e.

52

Fig. 3-2:Forced Circulation Evaporator with One Pass Vertical separator

53

CHAPTER 4

INSTRUMENTATION AND CONTROL

4.1.Instruments

Instruments are provided to monitor the key process variables during plant operation. They

may be incorporated in automatic control loops, or used for the manual monitoring of the

process operation. Instruments monitoring critical process variables will be fitted with

automatic alarms to alert the operators to critical and hazardous situations.

It is desirable that the process variable to be monitored be measured directly; often,

however, this is impractical and some dependent variable, that is easier to measure, is

monitored in its place. For example, in the control of distillation columns the continuous,

on-line, analysis of the overhead product is desirable but difficult and expensive to achieve

reliably, so temperature is often monitored as an indication of composition. The

temperature instrument may form part of a control loop controlling, say, reflex flow; with

the composition of the overheads checked frequently by sampling and laboratory analysis.

4.1.1Instrumentation and control objectives

The primary objectives of the designer when specifying instrumentation and control

schemes are:

I. Safe plant operation

a) To keep the process variables within known safe operating limits.

b) To detect dangerous situations as they develop and to provide alarms and

automatic shut-down systems.

c) To provide interlocks and alarms to prevent dangerous operating procedures.

II. Production rate:

To achieve the design product output.

III. Product quality:

54

To maintain the product composition within the specified quality standards.

IV. Cost:

To operate at the lowest production cost, commensurate with the other objectives. These

are not separate objectives and must be considered together. The order in which they are

listed is not meant to imply the precedence of any objective over another, other than that of

putting safety first. Product quality, production rate and the cost of production will be

dependent on sales requirements. For example, it may be a better strategy to produce a

better-quality product at a higher cost.

In a typical chemical processing plant, these objectives are achieved by a combination of

automatic control, manual monitoring and laboratory analysis

4.1.2Guide Rules:

The following procedure can be applied when drawing up preliminary (P &I) diagrams:

I. Identify and draw in those control loops that are obviously needed for steady plant

operation, such as:

a) Level controls,

b) Flow controls,

C) Pressure controls

d) Temperature controls.

II. Identify the key process variables that need to be controlled to achieve the specified

product quality.

III. Identify and include those additional control loops required for safe operation.

IV. Decide and show those ancillary instruments needed for the monitoring of the plant

operation by the operators.

V. Decide on the location of sample points.

VI. Decide on the need for recorders and the location of the readout points.

4.2.Typical control systems

55

4.2.1Level Control

In any equipment where an interface exists between two phases (e.g. liquid-vapour),

some means of maintaining the interface at the required level must be provided. This may

be incorporated in the design of the equipment, as is usually done for decanters or by

automatic control of the flow from the equipment.

Figure (5-1) shows a typical arrangement for the level control at the base of a

column. The control valve should be placed on the discharge line from the pump.

Fig. 4-1:A typical arrangement for the level control

4.2.2Pressure Control

Pressure control will be necessary for most systems handling vapor or gas. The method of

control will depend on the nature of the process. Typical schemes are shown in Figure (8-2)

The scheme would not be used where the vented gas was toxic, or valuable. In these

circumstances the vent should be taken to a vent recovery system, such as a scrubber.

Fig. 4-2:Atypical arrangement for the pressure control

4.2.3Ratio Control

56

Ratio control can be used where it is desired to maintain two flows at a constant ratio; for

example, reactor feeds and distillation column reflux. A typical scheme for ratio control is

shown in the following figure.

Fig. 4-3:A typical scheme for ratio control

4.2.4Flow Control

Flow control is usually associated with inventory control in a storage tank or other

equipment. There must be a reservoir to take up the changes in flow-rate .To provide flow

control on a compressor or pump running at a fixed speed and supplying a near constant

volume output, a by-pass control would be used, as shown in figure(8-3).

Fig. 4-4:Atypical arrangement for the flow control

4.2.5Temperature Control

57

The temperature being controlled by varying the flow of the cooling or heating medium . A

typical scheme for temperature control is shown in the Figure .

Fig. 4-5:A typical scheme for temperature control

Table (4-1) Some Symbols used in the Control Systems

4.3

Incorporation of the Controllers

symbol Nomenclature

TI Temperature indicator

TIRC Temperature indicator

FC Flow controller

FRC Flow recorder

Controller FI Flow indicator

PI Pressure indicator

PC Pressure controller

XC Ratio controller

FR Flow recorder

LIR Level indicator

recorder PRC Pressure recorder

controller CI Composition indicator

LA Level alarm

PA Pressure alarm

58

The following scheme in Figure (4-6) shows incorporation of controllers in the automatic

control system of the plant.

59

Fig. 4-6: FLOW SCHEME OF TYPICAL PROCESS WITH CONTROLLERS

CHAPTER 5

SAFFTY AND ENVIRONMENTAL

5.1 Introduction

The following general safety rules shall be observed when working with chemicals;

Read and understand the Material Safety Data sheets (MSDS).

Keep the work area clean and orderly.

Use the necessary safety equipment.

Carefully label every container with the identity of its contents and appropriate hazard

warnings.

Store in compatible chemicals in separate areas.

Substitute less toxic materials whenever possible.

Limit the volume of volatile or flammable material to the minimum needed for short

operation periods.

Provide means of containing the Material if equipment or containers should break or spill

their contents.

5.2 Task Evaluation

Each task that requires the use of chemicals be evaluated to determine the potential hazards

associated with the work. This hazard evaluation must include the chemical or combination

of chemicals that will be used in the work, as well as other materials that will be used near

the work

5.3 Chemical Storage

The separation of chemicals (solids or liquids) during storage is necessary to reduce the

possibility of unwanted chemical reactions caused by accidental mixing. Explosives should

60

be stored separately outdoors. Use either distance or barriers (e.g., trays) to isolate

chemicals into the following groups :

Flammable Liquids: store in approved flammable storage lockers.

Acids: treat as flammable liquids.

Bases: do not store bases with acids or any other material.

Other liquids: ensure other liquids are not incompatible with any other

chemical in the same storage location.

Lips, strips, or bars are to be installed across the width of storage shelves to

restrain the chemicals in case of earthquake.

Chemicals will not be stored in the same refrigerator used for food storage.

Refrigerators used for storing chemicals must be appropriately identified by

a label on the door.

5.4.Emergencies and Spills

In case of an emergency, implement the following proper Emergency Action Plan;

1. Evacuate people from the area.

2. Isolate the area.

3. If the material is flammable, turn off ignition and heat sources.

4. Only personnel specifically trained in emergency response are permitted to

participate in chemical emergency procedures beyond those required to evacuate

the area.

5. Call for Emergency Response Team assistance if required.

5.5.Housekeeping

61

Maintain the smallest possible inventory of chemical to meet immediate

needs.

Periodically review stock of chemicals on hand.

Ensure that storage areas, or equipment containing large quantities of

chemicals, are secure from accidental spills.

Rinse emptied bottles that contain acids or inflammable solvents before

disposal.

Recycle unused laboratory chemicals wherever possible.

Do not place hazardous chemicals in salvage or garbage receptacles.

Do not pour chemicals onto the ground.

Do not dispose of chemicals through the storm drain system.

Do not dispose of highly toxic, malodorous chemicals down sinks or sewer

drains.

5.6.MSDS Information

Material Safety Data Sheets are provided by the chemical manufacturer to provide

additional information concerning safe use of the product. Each MSDS provides:

1.Common Name and Chemical Name of the material.

2. Name, address and phone number of the manufacturer.

3. Emergency phone numbers for immediate hazard information.

4. Data the MSDS was last updated.

5. Listing of hazardous ingredients.

6. Chemical hazards of the material.

7. Information for identification of chemical and physical properties.

62

5.7.Chemical Users Information

Chemical Users must have a good knowledge about “Fire and/or Explosion Information”

(i.e):-

1. Material Flash Point, auto-ignition temperature and upper/lower flammability

limits.

2. Proper fire extinguishing agents to be used.

3. Fire fighting techniques.

4. Any unusual fire or explosive hazards.

5.8.Chemical Reaction Information

1. Stability of Chemical.

2. Conditions and other materials which can cause reactions with the chemical.

3. Dangerous substance that can be produced when the chemical reacts.

5.9.Control Measures

1. Engineering Controls required for safe product use.

2. Personal protective equipment required for use of product.

3. Safe storage requirements and guidelines.

4. Safe handling procedures.

5.10.Health Hazards

Health and safety data are shown on the material safety data sheets which are available

from suppliers and can be found on the internet.

63

Ammonium Nitrate is not very hazardous to health and is usually used in fertilizer

products.

The chances of direct personal exposure to the chemical are very low, because the

fertilization of the soil by use of Ammonium Nitrate is done at early stages of plant growth

and usually does not remain detectable on the harvested plants or when the plants reach the

consumer.

Ammonium Nitrate has an LD50 of 2217mg/kg,. which for comparison is about two-thirds

that of table salt.

5.11 Safety and Environment Precautions

The main concern is mainly with precautions and protocols that are to be followed

while handling materials in the plant. Safety equipment includes: “splash goggles,

protective coats, gloves and safety shoes” are all required in dealing with these materials

regardless of their reactivity and stability. These documentations will include the two target

materials and compounds encountered and utilized in the plant as follows:

5.11.1Acute Health Effects

Short-term exposure to Ammonium Nitrate can cause symptoms ranging from minor

irritation to nausea, vomiting, gastric irritation, headaches, dizziness, and hypertension.

Table (5-1) Exposure and Hazard Level

Area of expo Area of exposure sure Hazard level Hazard level

Ingestion Moderately hazardous

Skin contact Moderately hazardous (irritant)

Eye contact Moderately hazardous

Inhalation Moderately hazardous

64

5.11.2 Long-Term Health Effects

The toxicity of Nitrates when ingested is due to in vivo conversion to Nitrites. The

material safety data sheet considers chronic ingestion of more than 5mg/kg/day

unacceptable. The primary overdose effects of chronic exposure are orthostatic

hypotension and methemoglobinemia. Other common effects include: faintness, fatigue,

weakness, depression, mental impairment, dizziness, shortness of breath, and reflex

tachycardia; headache, nausea, vomiting, and nephritis may also occur.

Table (5-2) Type of Effect and Effect Level

Types of effect Effect level

Carcinogenic effects

Though no Ammonium Nitrate-specific studies are available, nitrates

can be reduced to nitrites in the body, and the formed nitrites can

subsequently react with amines to form suspect carcinogens N-

nitrosamine.

Mutagenic effects In general, nitrates and nitrites are genotoxic.

Teratogenic effects None

Developmental

toxicity

Though not specific to Ammonium Nitrate, some studies have shown

a link between birth defects (particularly neural tube defects) and

nitrate-contaminated well water.

Prolonged exposure

Causes damage to lungs and mucous membranes and may also cause

damage to blood and gastrointestinal tract. Chronic ingestion may also

cause nephritis.[19]

65

CHAPTER 6

MATERIAL OF COST

6.1 Introduction to Material of Construction

Ammonium Nitrate solution is one of solutions which causes corrosion to the most

of metals especially copper and its alloys.

Stainless steel resisting corrosion of the type 304 and 316 are used to handle hot

Ammonium Nitrate solutions. Pumps and valves constructed from FA-20 alloy which

contains 20%Cr, 29%Ni and small amount of molybdenum, copper and silicon.

Stainless steel resisting corrosion has a wide use in chemical process plants.

The resisting properties of the stainless steel can be improved by increasing the

amount of Cr, which can give better corrosion resistance at oxidation environment.

Increasing Ni content improves corrosion resistance in non-oxidation environment.

Stainless steel 304 and some time called (18/8) stainless steel , is the usual type of

stainless steel resistance to corrosion and which contains the minimum amount of Cr and

Ni which give Austinic composition and contains less amount of carbon to give a good heat

treatment to prevent removal of welding.

Stainless steel 316 corrosion resistance, molybdenum is to improve the properties

for corrosion resisting in the reduction environment.

The following tables are the constructional information and sizing for each

equipment

6.2The Sizing of the Plant

The following tables are the sizing for each equipment in the plant:

66

Table (6-1) Sizing of Ammonia Vaporizer

CLASSIFICATION VAPORIZER

Number Required 1

Job/Duty Evaporation of Liquid NH3

Type Heat Exchanger Steam Heated

Operation Continuous

Flow Rate Capacity 673.4 kg/hr

Material Handled Ammonia

Outlet Temperature

Shell Type Horizontal Cylindrical Shell

Ammonia Composition

Material of Construction Carbon Steel

Table (6-2) Sizing of Nitric Acid Heat Exchanger

CLASSIFICATION HEAT EXCHANGER

Number Required 1

Job/Duty Increasing Temperature of HNO3

Operation Continuous

Temperature

Nitric Acid Composition

Material of Construction Carbon Steel

Flow Rate Capacity

67

Table (6-3) Sizing of Reactor

CLASSIFICATION REACTOR

Number Required 1

Job/Duty Reaction of Ammonia with Nitric Acid to Produce

NH NO Type Fluidized Bed Reactor

Operation Continuous

Material of Construction Stainless Steel 316

Type of Reaction Exothermic Reaction

Flow Rate Capacity

Material Handled Ammonium Nitrate

Temperature

Table (6-4) Sizing of Evaporator

CLASSIFICATION EVAPORATOR

Number Required 1

Job/Duty Concentration of NH4NO3Solution

Type Single Vacuum Evaporator with Forced Circulation

Temperature

Flow Rate Capacity

Material Handled Ammonium Nitrate

Diameter

Material of Construction Stainless Steel 304L

Length

68

Table (6-5) Sizing of Crystallizer

CLASSIFICATION CRYSTALLIZER

Number Required 1

Job/Duty To Get the Required Crystals

Type Classifying Vacuum Crystallizer

Temperature

Flow Rate Capacity

Material Handled Ammonium Nitrate Solution

Material of Construction Stainless Steel 304

Diameter

Length

Density of NH4NO3 Crystals

Table (6-6) Sizing of Ammonium Nitrate Dryer

CLASSIFICATION DRYER

Number Required 2

Job/Duty Moisture Removal

Type Rotary Counter Current Dryer

Material Handled Ammonium Nitrate

Flow Rate Capacity

Inlet Air Temperature

Material of Construction Carbon Steel

69

EQUIPMENT COST ESTIMATING:

Reactor

Number: 1

Description:

Type: Mixer/settler

Material: Carbon steel

Pressure (psi): 300 psi (20.4 atm)

Costs

Year 2018 Cost : (€) € 249,981.00

Year 2018 Cost : ($) $217,484.00

Heat exchanger

Number: 1

Description:

Type: Shell/tube, fixed/U, large

Material: Carbon steel

Pressure (psi): 300 psi rating (20.4 atm)

Costs

Year 2018 Cost : (€) € 102,673.00

70

Year 2018 Cost : ($) $89,326.00

Heat exchanger

Number: 2

Description:

Type: Shell/tube, fixed/U, large

Material: Carbon steel

Pressure (psi): 300 psi rating (20.4 atm)

Costs

Year 2018 Cost : (€) € 102,673.00

Year 2018 Cost : ($) $89,326.00

Ejector

Number: 1

Description:

Type: Ejector, large

Material: Carbon steel

Pressure (psi): 125 psi rating (8.5 atm)

Costs

Year 2018 Cost : (€) € 4,181.00

Year 2018 Cost : ($) $3,637.00

Crystallizer

Number: 1

Description:

71

Type: Batch vacuum

Material: Carbon Steel

Volume (l): 14006

Costs

Year 2018 Cost : (€) € 140,176.00

Year 2018 Cost : ($) $121,953.00

Compressor

Number: 1

Description:

Type: Centrifugal, 1000 psi (68.0 atm)

Material: Carbon steel

Compressor

Power(kW): 1334

Costs

Year 2018 Cost : (€) € 679,487.00

Year 2018 Cost : ($) $591,153.00

Boiler

Number: 1

Description:

Type:

Oil/gas Fired field fab 150 psi sat (10.2

atm)

Material: Carbon steel

Boiler capacity

(kg/hr): 249475

72

Costs

Year 2018 Cost : (€) € 8,758,321.00

Year 2018 Cost : ($) $7,619,740.00

Boiler

Number: 2

Description:

Type:

Oil/gas Fired field fab 150 psi sat (10.2

atm)

Material: Carbon steel

Boiler capacity

(kg/hr): 249475

Costs

Year 2018 Cost : (€) € 8,758,321.00

Year 2018 Cost : ($) $7,619,740.00

Filter

Number: 1

Description:

Type: Cartrige

Material: Alluminium

73

Filter area (m2): 56.205

Costs

Year 2018Cost : (€) € 73,900.00

Year 2018 Cost : ($) $64,293.00

Filter

Number: 2

Description:

Type: Cartrige

Material: Alluminium

Filter area (m2): 56.205

Costs

Year 2018 Cost : (€) € 73,900.00

Year 2018 Cost : ($) $64,293.00

Cooling and Refrigeration

Number: 1

Description:

Type: Cooling pond

Material: Carbon steel

Cooling load

(kW/hr): 4930

Costs

Year 2018 Cost : (€) € 56,808.00

74

Year 2018 Cost : ($) $49,423.00

Cooling and Refrigeration

Number: 2

Description:

Type: Cooling pond

Material: Carbon steel

Cooling load

(kW/hr): 4930

Costs

Year 2018 Cost : (€) € 56,808.00

Year 2018 Cost : ($) $49,423.00

Centrifugal pump

Number: 1

Description:

Type: Horizontal 1 stage hor. Split

Material: Cast iron;API 610

Seal type: Packing

Costs

Year 2018Cost : (€) € 5,779.00

Year 2018Cost : ($) $5,028.00

75

Centrifugal pump

Number: 2

Description:

Type: Horizontal 1 stage hor. Split

Material: Cast iron;API 610

Seal type: Packing

Costs

Year 2018 Cost : (€) € 5,779.00

Year 2018 Cost : ($) $5,028.00

Centrifugal pump

Number: 1

Description:

Type: Horizontal API-610-1 stage

Material: Cast iron;API 610

Seal type: Packing

Costs

Year 2018 Cost : (€) € 14,632.00

Year 2018 Cost : ($) $12,730.00

Centrifugal pump

76

Number: 2

Description:

Type: Horizontal API-610-1 stage

Material: Cast iron;API 610

Seal type: Packing

Costs

Year 2018 Cost : (€) € 14,632.00

Year 2018 Cost : ($) $12,730.00

Centrifugal pump

Number: 1

Description:

Type: Vertical Sump 1stage

Material: Cast iron;API 610

Seal type: Packing

Costs

77

Year 2018 Cost : (€) € 8,484.00

Year 2018 Cost : ($) $7,381.00

Centrifugal pump

Number: 1

Description:

Type: Vertical turbine 4 stage

Material: Cast iron;API 610

Seal type: Packing

Costs

Year 2018 Cost : (€) € 6,025.00

Year 2018 Cost : ($) $5,242.00

Vacuum pump

Number: 1

Description:

Type: Blower, 1-stage dry seal, medium

Material: Alloy 20

Flowrate(l/min): 14032

Costs

Year 2018 Cost : (€) € 29,142.00

Year 2018 Cost : ($) $25,353.00

78

Vacuum pump

Number: 1

Description:

Type: Blower, 1-stage liquid seal, large

Material: Alloy 20

Flowrate(l/min): 54032

Costs

Year 2018 Cost : (€) € 36,889.00

Year 2018 Cost : ($) $32,093.00

Separator

Number: 1

Description:

Type: Cyclone, wet, NiHard lined, medium

Material: Carbon steel

Diameter (m): 0.3

Costs

Year 2018 Cost : (€) € 3,935.00

79

Year 2018 Cost : ($) $3,423.00

Separator

Number: 1

Description:

Type: Screw classifier, 2-screw

Material: Carbon steel

Diameter (m): 0.98

Costs

Year 2018 Cost : (€) € 61,604.00

Year 2018 Cost : ($) $53,595.00

Tank

Number: 1

Description:

Type: Vertical, cone top &bottom,small

Material: Aluminium

80

Volume (l): 19457

Costs

Year 2018 Cost : (€) € 35,044.00

Year 2018 Cost : ($) $30,488.00

Tank

Number: 2

Description:

Type: Vertical, cone top &bottom,small

Material: Aluminium

Volume (l): 19457

Costs

Year 2018 Cost : (€) € 35,044.00

Year 2018 Cost : ($) $30,488.00

Heat exchanger

Number: 1

Description:

Type: Air cooled, bare tube area

Material: Carbon steel

Pressure (psi): 150 psi rating (10.2 atm)

Costs

Year 2018 Cost : (€) € 214,322.00

Year 2018 Cost : ($) $186,460.00

81

Heat exchanger

Number: 1

Description:

Type: Evaporator, vertical tube

Material: Carbon steel

Pressure (psi): 150 psi rating (10.2 atm)

Costs

Year 2018 Cost : (€) € 750,805.00

Year 2018 Cost : ($) $653,200.00

Total Equipment

Cost = $17,635,649.00

82

CHAPTER 7

PLANT LAYOUT AND CONCLUSION

83

84

85

CONCLUSSION

A plant is to be designed for production of (22590 tons /year) of crystalline

Ammonium Nitrate coming with the reactions of nitric acid and liquid ammonia.

Feed component concentration;

i. Nitrate acid is 47.5 %W containing 52.5 %w water.

ii. Liquid ammonia under pressure, (99%W NH3) containing (1%) water, is

available and storage is also required at least for this for (48 hours) supply.

iii. The crystals are withdrawn as (30%) slurry.

The dried product contains (0.1%) moisture is sieved and the undersize product is recycled

together with the dust from the drier to the evaporator stage.

REFERENCES

System Temperature (°C) State Volume change (%)

> 169.6 Liquid

I 169.6 to 125.2 Cubic +2.1

II 125.2 to 84.2 Tetragonal −1.3

III 84.2 to 32.3 α-rhombic +3.6

IV 32.3 to −16.8 β-rhombic −2.9

V −16.8 Tetragonal

86

1. “ Encyclopedia of chemical Technology”, Vol. 2 ,

by: Kirk-Othmer , Third Edition.

2. “ Unit Operation of Chemical Engineering”

by: Jolian C. Smith and Warren L. McCabe, 1984.

3. “Transport Process and Unit Operation”

by: Christie J. Geankoplies, (Allyn and Bacon, INC, 1983).

4. “ Basic Principles and Calculation in Chemical Engineering”

by: David M. Himmelbau (Printice-Hall, INC, 1982).

5. “Shreve’s Chemical Process Industries”

by: George T. Austin (McGraw Hill, 1984).

6. “Chemical Engineering Handbook”

by: R.H. Perry and C.H. Chilton 5th edition,(McGraw Hill, 1973).

7. “Applied Process Design for Chemical and Petrochemical Plants”, Vol. 3 by: Ernest E.

Ludwig, 1983.

8. “Chemical Engineering” Vol. 6

by: J. M. Coulson, J. F. Richardson, 1982.

9. “Petroleum Refinery Engineering”

by: W. L. Nelson, 1969.

10. “Encyclopedia of Chemical Processing and Design “ Vol. 13 ,

by: John J. Mcketta, 1981..

11. “Process Control”

by: A. pollard, 1971.

12. “Process Design for Reliable Operation”

by: Norman P. Leberman.

87

88

APPENDICES

Appendix A

*

*

*

*

89

Appendix B

*

*

*

*

Appendix C

*

*

*

*

Appendix D

*

*

*

*

ضوابط كتابة الرسالة العلمية

.تكتب الرسالة باللغة الانجليزية فقط بما في ذلك صفحة "التهنئة" لغة الرسالة : ∙1

عبارة عن ملخص باللغة الانجليزية لمادة الرسالة )على سبيل المثال الملخص : ∙2والغرض من إجرائها وأهم النتائج التي تم الوصول اليها دون الدخول في التجارب العملية(

تفاصيل التجربة او الاستنتاجات الرياضية. ويتحتم على معد التقرير الاهتمام قدر الامكان بكتابة المخلص لأنه في كثير من الحالات يحدد الملخص رغبة القارئ في مطالعة بقية

كلمة. 200تجاوز عدد كلماته التقرير من عدمها على أن لا ي

تطبع الرسالة على ورق ابيض مقاس : الورق : ∙3

A4 (210×297mm)

.وتكون الطباعة على وجه واحد من الورق وباللون الاسود

نوع الخط : ∙4

90

اولاً العناوين الرئيسية .. Times New Roman, 16-Bold, UPPERCASE

ثانياً العناوين الفرعية الاولى ..Times New Roman, 14-Bold, Capitalize Each Word

ثالثاً العناوين الفرعية الثانية والثالثة .. الخTimes New Roman, 14-Bold, Sentence case

رابعاً مادة الرسالة ..

Times New Roman, 12, Sentence case

الهوامش : ∙5

سم من باقي الجوانب. 2.5سم من الجانب الايسر و 3.5يترك هامش عرضه

الفراغ بين السطور : ∙6

1.5 Space

الترقيم : ∙7

يتم ترقيم الصفحات الاعدادية )الملخص و جدول المحتويات ...الخ( في وسط اسفل الصفحة بالأحرف اللاتينية :

i,ii,iii,iv,v,vi ية في وسط اسفل الصفحة بالارقام :ويتم ترقيم الصفحات الاساس

1,2,3,4,…... عدد النسخ المطلوب : ∙8

.ثلاث نسخ ورقية وقرص مدمج

عدد الصفحات : ∙9

.صفحة 100وان لايتجاوز 60يجب ان لايقل عدد صفحات التقرير عن

نسبة النسخ المسموحة : ∙10

. % كحد اقصى30يجب ان لا تتجاوز نسبة النسخ في كامل الرسالة

تنسيق المكونات : ∙11

يتم اتباع التعليمات المتوفرة في النموذج المرفق أعلاه.