Escolar Documentos
Profissional Documentos
Cultura Documentos
Bachelor of Engineering
In
Chemical Engineering
Submitted by
AKSHIT PATIDAR
(0701CM151005)
CERTIFICATE
This is to certify that the project titled “Manufacturing of Titanium Oxide” is a bona fide record
of the work carried out by AKSHIT PATIDAR (Roll No. 0701CM151005) under my
supervision and guidance for the partial fulfilment of the requirements for the degree of
Bachelor of Engineering in Chemical Engineering. During the academic session 2018-2019 in
the Department of Chemical Engineering, in Ujjain Engineering college, Ujjain.
Date:
Place:
i
UNDERTAKING
The work presented in my thesis titled “Manufacturing of titanium oxide”, submitted to the
Department of Chemical Engineering, Ujjain Engineering college, Ujjain, Madhya Pradesh,
for the award of Bachelor of Engineering, is my original work. I haven’t either plagiarized nor
submitted the same work for award of any other degree. In case this undertaking is found
incorrect, I accept that my degree may be withdrawn.
Ujjain Sign
ii
ACKNOWLEDGEMENTS
First of all, I would like to express my sincere gratitude to Prof. Sanjay Verma for his
tremendous help, support and guidance throughout the work. The road to success was
accessible only with his encouragement, and his philosophy of aiming for higher achievements.
He has not only suggested the problem but also helped me in various other aspects of the
project. This work has been possible only because of his inspiration, motivation and full
freedom given to me to incorporate my ideas.
iii
ABSTRACT
Titanium is a very important element for several industrial applications, being one of the ninth
most abundant elements in the Earth's crust (0.63% wt.). In this work it will discuss the different
mining and industrial activities involved in the production of titanium dioxide. The first step
analysed will treat about the beneficiation mining process of titanium mineral, and secondly, it
will discuss the two main processes of the TiO2 manufacturing (sulphate and chloride routes).
In addition, we will show different uses of the titanium dioxide pigment as filler in paper,
plastics and rubber industries and as flux in glass manufacture, etc. Finally, we will show that
the old wastes are currently called co-products since they were vaporized, being
commercialized by the Spanish industry of TiO2 production in different fields such as
agriculture, civil engineering, or cement manufacturing. Titanium was discovered in 1791 by
the British clergyman and mineralogist William Gregor while analysing black magnetic sands
from Menachan in Cornwall (England). He produced a white metallic oxide from the mineral
menaccanite, a variety of ilmenite, and named the new element menachite. Titanium dioxide
(TiO2) has been widely used as pigment in paints, paper and cosmetic products, as well as
high-tech applications such as solar cells, semiconductors, biomedical devices and air
purification. TiO2 pigment is primarily produced by a high temperature chloride process,
which forms CO2 as a reaction by-product. A novel hydrometallurgical process for making
TiO2 pigment without direct CO2 emission is investigated. The novel process involves alkaline
roasting of Titania slag, with subsequent washing, leaching, solvent extraction, hydrolysis, and
calcination stages, resulting in high-purity anatase or rutile pigments. Experimental validation
for each of the processing steps is demonstrated. Pigment whiteness is critically sensitive to
trace amounts of discolouring impurities such as iron. The use of solvent extraction proved to
be highly effective in reducing the concentration of discolouring impurities in the final pigment
to commercially acceptable levels.
iv
CONTENTS
Certificate i
Undertaking ii
Acknowledgements iii
Abstract iv
Content v
List of Figures vi
List of tables vii
Chapter 1 Introduction 01
Chapter 2 Literature Review 02
Chapter 3 Objective of the Project 04
Chapter 4 Process Description 05
4.1 Properties of titanium oxide 05
4.1.1 Physical Properties 05
4.1.2 Chemical Properties 06
4.1.3 Mechanical Properties 06
4.2 Application 07
4.3 Various Manufacturing Process 09
4.4 comparison and process selection 10
4.5 Process Description 11
Chapter 5 Material Balance 13
Chapter 6 Energy Balance 21
Chapter 7 Design of Equipments 29
7.1 Design of Condenser 29
7.2 Design of Cyclone Separator 32
Chapter 8 Cost Estimation and Economic Analysis 35
Chapter 9 Safety and Environmental Aspects 39
Chapter 10 Plant selection and Layout 43
Chapter 11 Conclusion 48
Chapter 12 References 49
v
LIST OF FIGURES
vi
LIST OF TABLES
vii
CHAPTER 1
INTRODUCTION
Titanium dioxide is the whitest pigment widely used in the manufacture of paints and enamels.
It may be manufactured by two major processes: the chloride and the sulphate process. These
processes were compared and the chloride process was selected and analysed. Titanium dioxide
containing feed stock is subjected to high temperature carbo chlorination to produce titanium
tetra chloride, which is thereafter converted to titanium dioxide by oxidation. This project
involves the studying and collecting all preliminary information required for Titanium dioxide
manufacture, generating mass and energy balances for the plant, designing the various
equipment used in the plant and estimating the cost involved in setting up the plant.
Titanium dioxide is produced either in the anatase or rutile crystal form. Most titanium dioxide
in the anatase form is produced as a white powder, whereas various rutile grades are often off-
white and can even exhibit a slight colour, depending on the physical form, which affects light
reflectance. Titanium dioxide may be coated with small amounts of alumina and silica to
improve technological properties. Commercial titanium dioxide pigment is produced by either
the sulphate process or the chloride process. The principal raw materials for manufacturing
titanium dioxide include ilmenite. (FeO/TiO2), naturally occurring rutile, or titanium
slag. Both anatase and rutile forms of titanium dioxide can be produced by the sulphate
process, whereas the chloride process yields the rutile form.
Titanium dioxide can be prepared at a high level of purity. Specifications for food use currently
contain a minimum purity assay of 99.0%. Titanium dioxide is the most widely used white
pigment in products such as paints, coatings, plastics, paper, inks, fibres, and food and
cosmetics because of its brightness and high refractive index (> 2.4), which determines the
degree of opacity that a material confers to the host matrix. When combined with other colours,
soft pastel shades can be achieved. The high refractive index, surpassed by few other materials,
allows titanium dioxide to be used at relatively low levels to achieve its technical effect.
The food applications of titanium dioxide are broad. US regulations authorize its use as a colour
additive in foods in general at levels not to exceed 1%. The European Union also permits its
use in foods, in general, with some specified exceptions, at quantum sati’s levels. India restricts
its uses to chewing gum and bubble gum at not more than 1% and to powdered concentrate
mixes for fruit beverage drinks not to exceed 100 mg/kg. Japan lists its use as a food colour
without limitation, other than specifying certain foods in which it is not permitted. Finally,
titanium dioxide is listed in Table 3 of the Codex General Standard for Food Additives, which
lists additives that may be used in food, in general, unless otherwise specified, in accordance
with GMP.
1
CHAPTER 2
LITERATURE REVIEW
Gambhire et al., (2014) reported the synthesis of anatase TiO2 nanoparticles by sol-gel method
which were doped with various metals and non-metals and studied their photocatalytic
behaviour by degrading MB. The prepared photocatalyst exhibited smaller shape particles and
higher specific surface area. The high photocatalytic activity of the C-TiO2 under visible light
irradiation can be attributed to smaller particle size, high specific surface area, optical
absorption and displayed photocatalytic activity in the visible region.
Kapusuz et al., (2013) successfully synthesized composites by doping and co-doping B and Zr
ions in anatase TiO2 lattice by using sol-gel method to show increased photocatalytic
performance to higher levels. It was concluded that photocatalytic activity of TiO2 increased
by doping with B and Zr which result in formation of oxygen vacancies in crystal and also
forming Ti4+ defects which result in formation of more energy levels and thus increase the
photocatalytic activity.
Matejova et al., (2013) studied the photocatalytic reduction of carbon dioxide with the newly
synthesized gold enriched TiO2 and TiO2-ZrO2 catalysts which are prepared by sol-gel
process. It was shown that photocatalytic activity decreases over Au/TiO2-ZrO2 and Au/TiO2
compared to parent counterparts. It can be explained by presence of too large Au particles
which block oxide surface and either reduce the light absorption capability of catalysts or serve
as recombination centre.
Shashikala et al., (2013) reported that hybrid photocatalyst of ZrO2-TiO2-CdS Nano size
showed enhanced photocatalytic activity for hydrogen generation from water as compared to
its constituent single phase oxides. The increased activity of multi component catalyst is
attributed to decreased particle size of CdS and increased lifetime of the charge carriers
resulting from the efficient interfacial transfer of photo generated electrons at the CdS/TiO2
and CdS/ZrO2 interface.
Du et al., (2013) synthesized a series of Ho-Zr-O nanocomposites with the help of sol-gel
method. Photosynthetic experiments demonstrated that Zr-Ho-O nanocrystals have excellent
visible-light responsive photocatalytic activities on dyes which result from the special defect
structures, better absorption of visible light and large specific surface area.
Wang et al., (2013) examined the photo-stability of titanium dioxide by coating it with
zirconium, cerium as well as some other transition metal oxides. It was shown that these coating
materials significantly improve the photo-stability of TiO2 particles, even with a small coated
amount.
Liu et al., (2012) reported that cerium-doped SiO2/TiO2 Nano structured fibres were prepared
by a facile sol-gel method and checked its effect on the degradation of methylene blue (MB)
under simulated sunlight irradiation. The 0.2% Ce-doped SiO2/TiO2fibers exhibited higher
photocatalytic activity towards decomposition of MB. Liu et al., (2012) reported that cerium-
doped SiO2/TiO2 Nano structured fibres were prepared by a facile sol-gel method and checked
its effect on the degradation of methylene blue (MB) under simulated sunlight irradiation. The
0.2% Ce-doped SiO2/TiO2fibers exhibited higher photocatalytic activity towards
decomposition of MB.
2
Murugesan et al., (2011) successfully synthesized Zr4+, La3+ and Ce3+ doped mesoporous
TiO2 materials by sol-gel method and evaluated their photocatalytic activity.
Gao et al., (2010) successfully reported the incorporation of Zr ion into the bulk lattice of TiO2
by a multi-step sol-gel process. The Zr-doped TiO2 photocatalysts exhibited much higher
photocatalytic efficiency than pure TiO2 in the degradation of bisphenol A under UV
irradiation and complete mineralization of BPA was achieved. The higher photocatalytic
activity of Zr doped TiO2 was attributed to gradually upward shift of the conduction bands
with increasing Zr content, thus resulting in a stronger reduction power of photogenerated
electrons and contributing to the improved photoactivity.
Rehman et al., (2009) explained about the strategies of making TiO2 and ZnO visible light
active. Among the various techniques employed to make TiO2 sensitive to visible light, co-
doping of nanometals has produced the most significant results.
Danciu et al., (2008) explored the preparation of TiO2-ZrO2 aerogels and worked on their
photocatalytic activity. The best catalytic activity was obtained for 9.39% Zr in mixed oxide.
3
CHAPTER 3
OBJECTIVE OF THE PROJECT
In this current project work we are aiming to produce 20000 tons Titanium dioxide by more
efficient, economic and eco-friendly method. There are basically two main processes for the
manufacture of Titanium dioxide. They are the Chloride and the Sulphate process.
4
CHAPTER 4
PROCESS DESCRIPTION
APPEARANCE: Titanium dioxide appears as a white crystalline solid with high opacity.
Odour: Odourless
.
Solubility: Insoluble in water.
pH: ca. 6 – 7
5
% Volatiles by volume @ 21C (70F): 0
Incompatibilities: For Titanium Dioxide: A violent reaction with lithium occurs around
200C (392F) with a flash of light; the temperature can reach 900C. Violent or incandescent
reaction may also occur with other metals such as aluminium, calcium, magnesium,
potassium, sodium, and zinc.
Density = 4 g/cm3
Porosity = 0%
6
Resistivity (700°C) = 2.5x104 ohm.cm
4.2 APPLICATIONS
Applications for sintered Titania are limited by its relatively poor mechanical properties. It
does however find a number of electrical uses in sensors and electro catalysis. By far its most
widely used application is as a pigment, where it is used in powder form, exploiting its optical
properties.
Pigments
The most important function of titanium dioxide however is in powder form as a pigment for
providing whiteness and opacity to such products such as paints and coatings (including glazes
and enamels), plastics, paper, inks, fibres and food and cosmetics.
Titanium dioxide is by far the most widely used white pigment. Titania is very white and has
a very high refractive index – surpassed only by diamond. The refractive index determines the
opacity that the material confers to the matrix in which the pigment is housed. Hence, with its
high refractive index, relatively low levels of Titania pigment are required to achieve a white
opaque coating.
The high refractive index and bright white colour of titanium dioxide make it an effective
opacifier for pigments. The material is used as an opacifier in glass and porcelain enamels,
cosmetics, sunscreens, paper, and paints. One of the major advantages of the material for
exposed applications is its resistance to discoloration under UV light.
Photo Catalysis
Titania acts as a photo sensitizer for photo voltaic cells, and when used as an electrode coating
in photo electrolysis cells can enhance the efficiency of electrolytic splitting of water into
hydrogen and oxygen.
Oxygen Sensors
Even in mildly reducing atmospheres Titania tends to lose oxygen and become sub
stoichiometric. In this form the material becomes a semiconductor and the electrical resistivity
of the material can be correlated to the oxygen content of the atmosphere to which it is exposed.
Hence Titania can be used to sense the amount of oxygen (or reducing species) present in an
atmosphere.
7
Antimicrobial Coatings
The photo catalytic activity of Titania results in thin coatings of the material exhibiting self-
cleaning and disinfecting properties under exposure to UV radiation. These properties make
the material a candidate for applications such as medical devices, food preparation surfaces, air
conditioning filters, and sanitary ware surfaces.
8
4.3 VARIOUS MANUFACTURING PROCESSES
There are basically two main processes for the manufacture of Titanium dioxide. They are the
Chloride and the Sulphate process.
CHLORIDE PROCESS
The chloride process yields the rutile form of titanium dioxide. At temperatures between 800
and 1200 oC, chlorine is reacted in a fluidized bed reactor with a titanium-containing mineral,
e.g., mineral rutile (which is not readily attacked by sulfuric acid), under reducing conditions
(presence of coke) to form anhydrous titanium (IV) chloride. Purification of the anhydrous
tetrachloride requires separation by fractional condensation. Conversion of the tetrachloride to
titanium dioxide may be accomplished by either direct thermal oxidation or reaction with steam
in the vapour phase at temperatures in the range of 900-1400 oC. A minor amount of aluminium
chloride is generally added to promote formation of the rutile form. The titanium dioxide is
washed, calcined, and packaged.
SULPHATE PROCESS
Ilmenite and titanium slag is digested with sulfuric acid and the product is diluted with water
or dilute acid. Most of the titanium dioxide from the ore is solubilized as a titanium oxo-
sulphate and iron is present in its +II oxidation state. The resulting liquor is clarified by
sedimentation to remove insoluble residues such as silica. Iron is removed by crystallization as
its sulphate salt (FeSO4•7H2O), followed by filtration.
To produce the anatase form of the titanium dioxide, a small portion of the clarified liquor is
neutralized with alkali to produce anatase micro crystals. These micro crystals are then
introduced into the mother liquor, which is then hydrolysed under carefully controlled
conditions to produce crystals of anatase. These are subsequently filtered, washed, calcined,
and micronized. During calcination, the final temperature reaches about 800 -850 oC.
9
4.4 COMPARISON AND PROCESS SELECTION
The Chloride and the Sulphate processes are compared on the basis of the following aspects
and the suitable process is selected.
From the above comparison, the Chloride process has been selected for the project.
BACKGROUND
PRODUCTION REACTIONS
10
The reactions involved in the manufacture of titanium dioxide are,
Feedstock containing, titanium dioxide (85% pure) and finely divided coke are added to
chlorine gas in a reactor, where the titanium dioxide undergoes chlorination reaction at 800 oC.
Titanium tetrachloride and chlorides of iron and silicon are formed by the following reactions.
Pressure is maintained at about 1.5 atm and the residence time in the reactor is about 1 hour.
The outlet stream from the chlorinator at 800°C is fed to a cooler and cooled to 320°C using
water as coolant. Iron chloride condenses and settles down as liquid. Unreacted solids also
settle down and are separated. The vapor stream from the top is fed to the condenser.
The gas stream from the cooler is cooled to 137oC where TiCl4 is condensed. The effluent gas
is then sent to a converter, where Carbon monoxide is converted into Carbon dioxide. The
condensed pure TiCl4 liquid at its bubble point is fed to the oxide burner.
Pure TiCl4 liquid is vaporized and burnt with oxygen to form titanium dioxide solid (0.3μm
particle size) and chlorine gas. The reaction takes place at a temperature of 1000oC.
The stream containing chlorine gas and titanium dioxide solids are separated using a high
efficiency Cyclone Separator. The Chlorine gas is recycled to the Chlorinator. The product is
removed, cooled and surface treated.
11
SURFACE TREATMENT OF PRODUCT
‘Pure’ TiO2 base pigments, whether anatase or rutile, provide high opacity and excellent colour
but have a relatively reactive surface. The majority of commercial pigments are therefore
coated with an inorganic treatment or coating, and often an organic treatment.
Reasons for surface treating titanium dioxide pigment
Nearly all commercial TiO2 pigments have a surface treatment or coating to:
· Improve durability
Depending on the end application, the surface treatment is usually a combination of alumina,
silica and/or zirconia, deposited onto the core TiO2 particles from either the chloride or sulphate
base pigment process, by a wet precipitation process. A final coating of polyol or other organic
chosen to enhance the dispersion of the pigment in a resin system and/or dry bulk handling
characteristics is then added.
Following surface treatment, the pigment is dried, intensively milled and packed into bags. It
may also be supplied in semi and full bulk deliveries or, especially in North America, converted
to high concentration slurry for direct use in water-based paint systems.
The coatings on TiO2 pigments are deposited under very closely controlled conditions of time,
temperature and pH to develop the required characteristics. The final analysis of a surface
coating shows only part of the expertise in making high performance TiO2 pigments. Order of
addition and precipitation as well as the processes parameters are critical to making the
optimum product.
12
CHAPTER 5
MATERIAL BALANCE
13
BASIS: 20000 TPA of 98% TiO2 (Capacity of Plant)
Material entering:
O2 = 996.03 kg/hr
Material leaving:
14
Cl2 required = 2924.75 * 284.48 / 159.74
= 5208.67 kg/hr
Composition of Ore:
15
Cl2 required = 344.088 * 213.36 / 143.7
= 510.89 kg/hr
O2 required = 871.53 * 8 / 28
= 249 kg/hr
16
MATERIAL BALANCE:
CHLORINATOR:
= 10290.13 kg/hr
Material Leaving = 5917.38 + 486.66 + 776.87 + 916.17 + 871.53 + 781.3 + 98.87 + 441.22
= 10290.13 kg/hr
17
Table 5. Various materials leaving the chlorinator
COOLER:
= 10290.13 kg/hr
18
CONDENSER:
OXIDE BURNER:
19
CYCLONE SEPARATOR:
= 6222.08 kg/hr
= 6222.08 kg/hr
CONVERTER:
= 3553.66 kg/hr
= 3553.66 kg/hr
20
CHAPTER 6
ENERGY BALANCE
REACTOR:
21
Table 6. Molecular Heat Capacity Data of Various Materials
Q = mCpΔt
= 61392.055 KJ/hr
= 13452.465 KJ/hr
= 2135595.28 KJ/hr
Heat generated within the system = 31.1 * 249.83 + 2.86 * 173.4 + 4.79 * 1971.6
= 17709.601 KJ/hr
Heat associated with output stream = (31.13 * 107.57 * 800) + (20.82 * 54.88 * 800) + (31.13
= 5868712.56 KJ/hr
= 3640563.155 KJ/hr
22
COOLER:
23
Heat in to the cooler = heat of from the chlorinator
= 586812.56 KJ/hr
Heat out = (4.79*77.78*320) +(5.52*67.65*320) +(8.24*16.29*320) + (31.13*149.44*320)
+(4.79*3093.63)
= 2636608.22 KJ/hr
= 19250 KJ/hr
CONDENSER:
24
Heat in = heat out from cooler with crude TiCl4
= 31.13*149.10*320 + 20.82*47.76*320 + 31.13*30.61*320 +
10.98*36.05*320 + 2.86*136.88*320
= 2360333.216 KJ/hr
10.98*35.62*137 + 2.86*137.88*137
= 356786.52 KJ/hr
= 1724901.969 KJ/hr
= 278644.72 KJ/hr
= 2218.86 kg/hr
COMBUSTION CHAMBER
25
Table 9. Heat capacity data of materials entering combustion chamber
Heat in = 31.13*149.44*137+31.13*26.09*25
= 657637.75 KJ/hr
= 16796.5 KJ/hr
+3.11*1000*149.44+3.11*35.51*1000
= 5071994.15 KJ/hr
= 4397560.75 KJ/hr
26
CONVETER
+ 76.565*26.09*25
= 356786.52+10804.52
= 367591.04 KJ/hr
= 371030.905 KJ/hr
COOLER 2:
27
Heat removed = mCp ΔT
= 28.01*83.15*960
=2235870.24 KJ/hr
Amount of cooling water = 2235870.24 / 4.186*60
= 8902 kg/hr
COOLER 3:
= 371030.905 KJ/hr
= 121793.92 KJ/hr
= 82127.64 KJ/h
= 1985 kg/hr
28
CHAPTER 7
DESIGN OF EQUIPMENTS
ASSUMPTIONS:
Tube side -2
4) No sub-cooling.
SPECIFICATIONS
Shell ID = 0.3365m
Tube OD = 0.019m
Tube ID = 0.0157m
HEAT BALANCE
To Find LMTD
29
= 177.65°C
= 173.21°C
= 50 x 20.44
=1022 KJ/hr.m2 K
= 1.574 m2
A = nπDL
n = 19 tubes.
DESIGN SPECIFICATIONS:
SHELL: ID = 0.3365m
No. of pass = 1
TUBE: OD = .019m
ID = .0157m
No. of pass = 2
No. of tubes = 19
30
DESIGN OF FLUIDIZED BED
Design Equation:
Since the rate of reaction is constant throughout reaction period. So, this reaction can be Zero order then
reaction kinetics is
-rA = k
V/FA0 = XA/ k
= 182.96 kmol/ hr
= 29.735 m3
L/D ratio = 8
= 13.87 min
Porosity Є = 0.75
31
Viscosity of the Chlorine gas μ = 3.75*10-5 Kg/ms
= 0.040m/s
Pressure Drop
= 1739.5 N/m2
Design specifications:
L/D ratio = 8
= 1.204 m3/s
32
= 1.204 / 27
= 0.0446 m3
= 0.0876 m2
R1 = 0.334 m
Re = 0.167 m
As = 2Πrl
r = 0.334 m
L = 2.672 m
As = 2Π*0.334*2.672
= 5.607 m2
A1 = 0.0446 m2
Ψ = fc*(As/ A1)
= 0.005*(5.607/0.0446)
= 0.63
33
From graph Φ vs r1/re
R1/re=2
Φ = 0.95
1.021{272[1+2∗0.952(2∗0.334/0.167 – 1)]+2∗5.8442}
ΔP =
203
= 23.86 millibar
= 24.33 cm of H2O
The pressure drop obtained is <25 cm of H2O, so the existing cyclone is satisfactory.
34
CHAPTER 8
COST ESTIMATION AND ECONOMIC ANALYSIS
Reactor = 55
Condenser = 0.699
Cooler = 5.98
Combustion chamber = 85
Converter = 45
CO2 storage = 30
Cyclone separator = 20
(30% of PEC)
(20% of PEC)
Land cost = 20
Building cost = 10
35
Construction expenses = 21.88
= 29.66 LAKHS
= 614.586 LAKHS
VARIABLE COST:
UTILITIES:
36
OPERATING COST:
DEPRECIATION
= 25.168 lakhs
= 22.651lakhs
= 0.3 Lakhs
37
TOTAL DEPRECIATION = 22.951 LAKHS
= 18.44 Lakhs
= 37.775 Lakhs
= 2337.86 Lakhs
= 1309.2 Lakhs
TAX RATE = 40%
38
CHAPTER 9
SAFETY AND ENVIRONMENTAL ASPECTS
1. Substance name
TITANIUM DIOXIDE
2. Composition/information on ingredients
Chemical nature
· RUTILE
· ANATASE
3. Possible hazards
· If inhaled: keep patient calm, remove to fresh air, summon medical help
· On contact with eyes: Wash affected eyes for at least 15 minutes under running water with
eyelids held open.
5. Firefighting measures
· Suitable extinguishing media: water, carbon dioxide (CO2), dry extinguishing media, foam
39
6. Accidental release measures
· Environmental precautions: Do not let product enter drains. Methods for cleaning up:
Sweep/shovel up.
Handling
· Breathing must be protected when large quantities are decanted without local exhaust
Ventilation
Storage
· Observe MAK value for inert dust: 6 mg/m3 Personal protective equipment
Odour: odourless
40
Density: (20 ’C) 3.9 g/cm3 (approx.)
Elimination information
· The product is virtually insoluble in water and can thus be separated from water
mechanically in suitable effluent treatment plants.
Ecotoxic effects
· No data available
· Do not discharge product into natural waters without pre-treatment (biological treatment
plant).
· Product must be disposed of by special means, e.g. suitable dumping in accordance with
local regulations.
41
14. Transport information
· National legislation/regulations
· The information contained herein is based on the present state of our knowledge and does
not therefore guarantee certain properties.
· Recipients of our product must take responsibility for observing existing laws and
regulations.
42
CHAPTER 10
PLANT SITE SELECTION AND LAYOUT
PLANT LOCATION
The important part in the setting of a factory is to select a suitable site or location to house the
factory because an inappropriate selection of location would end the activity of the plant no
matter how efficient the equipments, management etc are. The problem can be divided in to
two main parts:
(a)For the general location of the factory following factors must be considered:
1) The Raw materials should be easily available at comparatively low cost and at low freight
charges.
2) The market should be near the factory for the quick service to the customers and easy
transportation.
3) There should be good transport facilities for bringing raw material and sending finished
product.
4) Skilled and cheap laborers should be available near the plant site.
5) Availability of power and fuel were very influencing in olden days to day it has not much
effect on plant site.
6) Climatic and atmospheric conditions are governing factor to several chemical industries.
However, air conditioning systems have changed the situation.
7) All factories need soft and pure water especially in large quantities.
8) Availability of Capital.
9) Social and recreational facilities can be created near the factory site.
10) Banking facilities are necessary for the factories, which require constant feeding of the
working capital.
11) Existence of related factories sometimes play very important role in selection of site.
12) The factors like local bye laws, taxes, fire protection facilities, post and telegraph
facilities should also be considered.
43
SELECTION OF ACTUAL SITE:
· The cost of levelling the land are providing foundations, subsoil conditions for foundations
and drainage
· The cost of bricks, sand, cement, limes, steel and other materials required for construction
· Facilities for housing the workers and if necessary, their transport from their place of
residence to work sites.
· Cost of laying the water supply, provide sewage and disposal work.
· Any restrictions placed by the planning department are local by-laws be well studied.
RAW MATERIALS
The availability and the price of suitable raw materials will often determine the site location.
Plants producing bulk chemicals are best located close to the source of the major raw material,
where this is also close to the marketing area.
TRANSPORT
The transport of materials and products to and from plant will be an over ridding consideration
in site selection. If practicable, a site should be selected that is close to at least two major forms
of transport road, rail, water way or a sea port. Road transport is being increasingly used and
is suitable for local distribution from a central ware house. Rail transport will be cheaper for
the long-distance transport of bulk chemicals. Air transport is convenient and efficient for the
movement of personal and essential equipment and supplies and the proximity of the site to a
major airport should be considered.
AVAILABILITY OF LABOUR
Labour will be needed for construction of the plant and its operation. Skilled construction
workers will usually be brought in from outside the site, but there should be an adequate pool
of unskilled labour available locally, and labour suitable for training to operate the plant.
Skilled tradesman will be needed for the maintenance. Local trade union customs and
restrictive practices will have to be considered when assessing the availability and suitability
of the labour for recruitment and training.
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UTILITIES (SERVICES)
The word ‘utilities’ is now generally used for ancillary services needed in the operation process.
The services will normally be supplied from a central facility and this will include
ELECTICITY
Power is required for operating the equipments, lightings, general use etc.
STEAM
Steam is required for the process are generated in the tube boilers using most economical fuels.
WATER
Natural and forced draft cooling towers are generally used to provide the cooling water required
on site. Water required for the general purpose will be taken from the local water supplies like
rivers, lakes and sea. Because of this reason all the plants located on the banks of river.
Dematerialized water, from which all the minerals have been removed by ion exchange is used
where the pure water is used for the process use, in boiler feed water.
PLANT LAYOUT
The economic construction and efficient operation of a process unit will depend on how well
the plant and equipment specified on the process flow sheet is laid out the principal factors
considered are Economic considerations:
· Convenience of operation
· Convenience of maintenance
· Safety
· Future expansion
· Modular construction
COSTS
The cost of construction can be minimized by adopting a layout that gives the shortest run of
connecting pipe between equipments, and at least amount of structural steel work. However,
this will not necessarily be the best arrangement of operation and maintenance.
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PROCESS REQUREMENT
An example of the need to take into account process consideration is the need to elevate the
base of column to provide the necessary net positive suction head to a pump or the operating
head for thermo-siphon re-boiler.
OPERATIONS
Equipment that needs to have frequent attention should be located convenient to the control
room. Valves, sample points, and instruments should be located at convenient positions and
heights. Sufficient working space and headroom must be provided to allow easy access to
equipment.
MAINTENANCE
Heat exchanger need to be sited so that the tube bundles can be easily withdrawn for cleaning
and tube replacement. Vessels that require frequent replacement of catalyst or packing should
be located on the outside of buildings. Equipment that requires dismantling for maintenance,
such as compressors and large pumps, should be places under cover.
SAFETY
Blast walls may be needed to isolate potentially hazardous equipment and confine the effects
of an explosion. At least two escape routes for operators must be provided from each level in
process buildings.
PLANT EXPANSION
Equipment should be located so that it can be conveniently tied in with any future expansion
of eh process. Space should be left on pipe alleys for future needs, and service pipes over-sized
to allow for future requirements.
MODULAR CONSTRUCTION
In recent years there has been a move to assemble sections of plant at the plant manufacturer’s
site. These modules will include the equipment, structural steel, piping and instrumentation.
The modules are then transported to the plant site, by road or sea The advantages of modular
construction are:
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Some of the disadvantage are:
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CHAPTER 11
CONCLUSION
A detailed plant study of Titanium Oxide production plant was done. At first, we learnt
thoroughly about the various processes for the manufacture of Titanium Oxide. Then,
we were keen enough to study on how the process goes on. After working on the
material balance and energy balance calculations, as a model to the design procedures,
we did the design of the various equipments included in process which included both
process and mechanical design.
Then by using principles of Economics, the total production cost was found out. By
knowing the sales revenue and taking into consideration the depreciation charges and
tax rates, the net annual profit, breakeven point, rate of return and payback period, net
present value and DCFRR was found out. Then we moved on to the Environment
Impact and the safety features of the plant. After we got an idea about that we proposed
the site and a layout for the plant taking all the processing factors into consideration.
Thus, the design of Nitric acid plant was completed.
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CHAPTER 12
REFERENCES
· “Plant Economics and Design for Chemical Engineers”, by Peters and Timmer Haus
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