P ROD U CTION OF

A NHYD ROU S
HYD ROG EN FLU ORID E
FROM FLU ORSP A R
A CL A N | C A TA L A N | GO JO C R UZ | T AM B UL I | VI LL A R A N | Y USI
EXECU TIVE SU M MA RY
P R ODU CTI ON OF A NH Y DR OUS H YD R OGEN FL UOR ID E
FR O M FL UOR SP A R
Constraint
Availability of Raw Materials
Market Proximity
Waste Generation
High Temperature
Equipment / Noise
Nature Solution
Manufacturability Approaching alternative
suppliers
Economic Establishment of
Warehouses
Collection of email
addresses
Loyalty Programs
Environmental (Solid) Availing of a DENR-
accredited agency to treat
and dispose solid waste.
(Liquid) Treatment of waste
as per DAO 35.
(Gaseous) Continues
treatment by series of
scrubbers.
Health and Safety Insulation, regular
maintenance and personnel
training.
Exposure limits as per
OSHA
TRA D E-OFF A NA LYSIS
P R ODU CTI ON OF A NH Y DR OUS H YD R OGEN FL UOR ID E
FR O M FL UOR SP A R
 To Recover or to Dispose CaSO4 By-
product?
Two scenarios are analyzed; first is the recovery and market of calcium
sulfate and the other is the disposal of the said by-product.
The study aims to compare the total amount of cost for each scenario with
considerations such as environmental and economic in terms of production
cost factors and ultimately arrive with the best choice for the company.
COMPARISON
RECOVERY
Total Cost when Recovered CONCLUSION:
Based from the total cost of each
of the option, disposal of calcium
Total Sales per Year sulfate has lower cost compared
with the recovery of calcium
sulfate. Therefore, disposal of
calcium sulfate is proven to be
more practical than the recovery
Profit of calcium sulfate.

DISPOSAL
Total Cost of Disposal
INSTRU M ENTATION &
P ROCESS CONTROL
P R ODU CTI ON OF A NH Y DR OUS H YD R OGEN FL UOR ID E
FR O M FL UOR SP A R
# Meaning
L Level
W Weight
F Flow
P Pressure
T Temperature
PROCESS
EQUIPMENT
CONTROL SCHEMES
FLUORSPAR GRINDING MILL
CLASSIFIER
FLOTATION CELLS
THICKENER
ROTARY DRUM FILTER
ROTARY DRYER
ROTARY KILN
ACID SCRUBBER
WATER SCRUBBER
VAPORIZER
FLASH TANK
COOLER
STORAGE
EQUIPMENT
CONTROL SCHEMES
WATER STORAGE TANK
SULFURIC ACID STORAGE TANK
OLEIC ACID STORAGE TANK
SODA ASH SILO
SODIUM BISULFITE STORAGE TANK
FLUORSPAR SILO
OLEUM STORAGE TANK
 P U MP S,
COM P RESSORS, A ND
P IP E SIZING WITH
CONVEYORS
P R ODU CTI ON OF A NH Y DR OUS H YD R OGEN FL UOR ID E
FR O M FL UOR SP A R
FLUORSPAR SILO TO
BALL MILL
Type: Screw Conveyor
Design Requirement:
Conveyor
Speed
Data:
 Volumetric fl ow From CEMC, the material code
rate of fluorspar is 100D36
*100 = Density
*D = Lumpy
*3 = Average flowability
*6 = Moderate abrasive
capacity, conveyor size and speed
Note: A standard pitch
screw conveyor will
be used
 Where;
L=total length
of conveyor,ft
N=operating
speed,rpm
Fd=conveyor
diameter HP
Horsepower
factor
Requirement Friction Fb=hanger
HP bearing HP
factor
Material HP

Where;
C=capacity require,(ft^3)/hr-10.428
D=density of material as conveyed,lb/(ft^3 ) -1794
L=total length of conveyor,ft -55.77
Fm=material factor -2.0
Ff=flighting modification HP factor -1.0
Fp=Paddle HP factor -1.29
Total HP
 BALL MILL TO CLASSIFIER
Type: Screw Conveyor
Design Requirements:
Conveyor Speed
Motor horsepower
Material Specification

Type of Material : Fluorspar

Mass Flowrate ( 768.21 (1690.06 lb/hr)

Particle Size 0.044mm

Density ( 198.52

From plant layout, conveyor length should be 7.3 m (23.95 ft.)


VO LU M ETR I C FL OW R A TE OF FL UO R SP A R :

MATERIAL CODE :

from screw conveyor capacities table the degree of through loading for fluorspar is
30%. for conveying products horizontally or up slight inclines, use a standard pitch.

FOR A CUT FLIGHT STANDARD PITCH WITH CONVEYOR LOADING
OF 30%

FOR A CAPACITY OF 6.56 AND 30%B THROUGH LOADING, A

SCREW DIAMETER OF 6 . 0 I N C H E S SHOULD BE USED.

MAXIMUM RECOMMENDED SPEED = 6 0 . 0 R P M

THE COMPUTED SPEED OF CONVEYOR SHOULD NOT EXCEED THE MAXIMUM RECOMMENDED SPEED.

THUS, 51.39 RPM MAY BE ACCEPTED SINCE IT IS BELOW THE MAXIMUM RECOMMENDED SPEED.


CALCULATION OF MOTOR HORSE POWER
FRICTION HP:

WHERE;

FOR A SCREW DIAMETER OF 6.0 INCHES:

CONVEYOR DIAMETER HP FACTOR

TAKE STELLITE AS THE BEARING TYPE.

HANGER BEARING HP FACTOR:

MATERIAL HP:

FR OM M A TER I A L C HA R A CT ER I STI CS TA B L E TH E HO R SEP O WER M A T ER IA L

FA C TOR

DENS IT Y OF F L UOR SP A R A S C ONVEY ED = 19 8.5 2 L B/ FT ^ 3

TOTAL HP:

WHERE;

IN THIS CASE,
IF IS THEN
IF IS THEN

USING SCREW CONVEYOR DRIVE WHICH IS SPECIALLY DESIGNED FOR SCREW CONVEYOR, E = 0 . 8 8
CLASSIFIER TO FLOTATION CELL
Data:

Volumetric fl ow
rate
 Setting the fl uid
velocity to 1 m/s

Din = 0.035052 m
Fluid friction factor
Velocity

nRe = 22,140.148 turbulent

flow
 Friction Loss Due To
Friction Losses Due
Pipe Line
To Valves And Fittings
L = 10.8 m
 Friction Loss Due To
Friction Loss Due To
Sudden Enlargement
Sudden Contraction
TOTAL FRICTIONAL CALCULATION OF
LOSSES KINETIC ENERGY

CALCULATION OF POTENTIAL
ENERGY
OVERALL MECHANICAL ENERGY
BALANCES

Since work is in negligible

value, pump is not needed
OLEIC ACID TO FLOTATION CELL
Data:

Volumetric fl ow
rate
 Setting the fl uid
velocity to 0.5 m/s

Din 0.0068326 m
Fluid
Velocity
friction factor

nRe = 0.1749744 laminar

flow
 Friction Loss Due To
Friction Losses Due
Pipe Line
To Valves And Fittings
L=
47.22m
 Friction Loss Due To
Friction Loss Due To
Sudden Enlargement
Sudden Contraction
TOTAL FRICTIONAL CALCULATION OF
LOSSES KINETIC ENERGY

CALCULATION OF POTENTIAL
ENERGY
OVERALL MECHANICAL ENERGY
BALANCES

Since the value is positive, a pump is required (Sinnot, 2005).

However, the calculated value for power requirement is in negligible
amount, therefore pump is not needed.
 SODA ASH TANK TO FLOTATION
CELL
Type: Screw Conveyor
Design Requirements:
Conveyor Speed Material
Material Specification
Specification
Type of
Motor horsepower Type of Soda Ash
Material : Soda Ash
Mass :
Material
2.58 (5.68 lb/hr)
Flowrate (
Particle Size 0.075mm
2.58 (5.68 lb/hr)
Density ( 157.29

Particle Size 0.075mm

157.29

From plant layout, conveyor length should be 57.76 m (189.50 ft.)


VO LU M ETR I C FL OW R A TE OF SOD A A SH :

MATERIAL CODE:
FROM SCREW CONVEYOR CAPACITIES TABLE THE DEGREE OF THROUGH LOADING FOR SODA ASH IS 30%. FOR CONVEYING
PRODUCTS HORIZONTALLY OR UP SLIGHT INCLINES, USE A STANDARD PITCH.

a Cut flight standard pitch with conveyor loading of 30%

For

For a capacity of 0.07 and 30%B through loading, a screw diameter of 6 inches should be used.

MAXIMUM RECOMMENDED SPEED = 6 0 R P M

THE COMPUTED SPEED OF CONVEYOR SHOULD NOT EXCEED THE MAXIMUM RECOMMENDED
SPEED.

THUS, 60 RPM MAY BE ACCEPTED


CALCULATION OF MOTOR HORSE POWER
FRICTION HP:

MATERIAL HP:

From material characteristics table the horsepower material factor

Density of Soda Ash as conveyed = 157.29 lb/ft^3

Total HP:

Where;

IN THIS CASE,
IF IS THEN
IF IS THEN

USING SCREW CONVEYOR DRIVE WHICH IS SPECIALLY DESIGNED FOR SCREW CONVEYOR, E =
0.88

THICKENER TO ROTARY
FILTER
Data:

Volumetric fl ow
rate
 Setting the fl uid
velocity to 1 m/s

Din = 0.02664 m
Fluid
Velocity

friction factor

nRe = 15,588.23 Turbulent

flow
 Friction Loss Due To
Friction Losses Due
Pipe Line
To Valves And Fittings
L=
15.01m
 Friction Loss Due To
Friction Loss Due To
Sudden Enlargement
Sudden Contraction
TOTAL FRICTIONAL CALCULATION OF
LOSSES KINETIC ENERGY

CALCULATION OF POTENTIAL
ENERGY
OVERALL MECHANICAL ENERGY
BALANCES

Since the value is positive, a pump is required (Sinnot, 2005).

However, the calculated value for power requirement is in negligible
amount, therefore pump is not needed.
 ROTARY FILTER TO ROTARY DRYER
Type: Screw Conveyor
Design Requirements:
Conveyor Speed
Motor horsepower
Material
Material Specification
Specification
Type of Calcium Fluoride, Silicon dioxide and
Type of Calcium Fluoride, Silicon dioxide and
Material : Water
Mass :
Material Water
482.66 (1061.85 lb/hr)
Flowrate (
Particle Size 482.660.075 mm lb/hr)
(1061.85
Density ( 175.27

Particle Size 0.075 mm

175.27

From plant layout, conveyor length should be 32.89 m (107.91 ft.)


VOLUMETRIC FLOWRATE:

MATERIAL CODE:

FROM CEMC, THE MATERIAL CODE OF FLUORSPAR IS AND FOR SILICON DIOXIDE IS 7 5 A 2 7

FROM SCREW CONVEYOR CAPACITIES TABLE THE DEGREE OF THROUGH LOADING IS 45%. FOR
CONVEYING PRODUCTS HORIZONTALLY OR UP SLIGHT INCLINES, USE A STANDARD PITCH.

FOR A CUT FLIGHT STANDARD PITCH WITH CONVEYOR LOADING OF 30%

FOR A CAPACITY OF 9.36 AND 45% THROUGH LOADING, A SCREW DIAMETER OF 6 . 0 I N C H E S SHOULD
BE USED.


MAXIMUM RECOMMENDED SPEED = 1 6 5 R P M

THE COMPUTED SPEED OF CONVEYOR SHOULD NOT EXCEED THE MAXIMUM RECOMMENDED SPEED.

THUS, 4.25 RPM MAY BE ACCEPTED SINCE IT IS BELOW THE MAXIMUM RECOMMENDED SPEED.

CALCULATION OF MOTOR HORSE POWER

FRICTION HP:

FOR A SCREW DIAMETER OF 6.0 INCHES:

CONVEYOR DIAMETER HP FACTOR

HANGER BEARING HP FACTOR:

MATERIAL HP:

FROM MATERIAL CHARACTERISTICS TABLE THE HORSEPOWER MATERIAL FACTOR

DENSITY OF COMPONENT AS CONVEYED = 175.27 LB/FT^3

TOTAL HP:

WHERE;


IF IS THEN
IF IS THEN

USING SCREW CONVEYOR DRIVE WHICH IS SPECIALLY DESIGNED FOR SCREW CONVEYOR, E =
0.88
ROTARY KILN TO ACID
SCRUBBER
Data:

Volumetric fl ow
rate
 Setting the velocity
to 15 m/s

The nominal pipe size to be used is 4 inch

(Perry & Green, 2008)
Din = 0.10226 m
Velocity
friction factor

nRe = 109,381.99
SUCTION LINE
Line Loss
Static Pressure

SUCTION PRESSURE
DISCHARGE LINE
Line Loss
Static Pressure Dynamic Loss

DISCHARGE PRESSURE
ACID SCRUBBER TO
VAPORIZER
Data:

Volumetric fl ow
rate
 Setting the fl uid
velocity to 1m/s

Din = 0.0157988 m
Fluid
Velocity
friction factor

nRe = 3,308.5115
Turbulent flow
 Friction Loss Due To
Friction Losses Due
Pipe Line
To Valves And Fittings
L = 57.93
m
 Setting the throat
FRICTION LOSSES DUE TO METERING DEVICE
diameter to 20% of
pipe diameter
FRICTION LOSSES DUE TO METERING DEVICE
VENTURI METER IS TO BE USED
Y = 0.10
 Friction Loss Due To
Friction Loss Due To
Sudden Enlargement
Sudden Contraction
TOTAL FRICTIONAL CALCULATION OF
LOSSES KINETIC ENERGY

CALCULATION OF POTENTIAL
ENERGY
OVERALL MECHANICAL ENERGY
BALANCES

Since the value is positive, a pump is required (Sinnot, 2005).

However, the calculated value for power requirement is in negligible
amount, therefore pump is not needed.
VAPORIZER TO DISTILLATION
COLUMN
Data:

Volumetric fl ow
rate
 Setting the velocity
to 15 m/s

The nominal pipe size to be used is 5 inch (Perry &

Green, 2008)
Din = 0.12819 m
Velocity
friction factor

nRe = 114,125.62
SUCTION LINE
Line Loss
Static Pressure

SUCTION PRESSURE
DISCHARGE LINE
Line Loss
Static Pressure Dynamic Loss

DISCHARGE PRESSURE
COMPRESSOR Power
Requirement

Assume 80%
effi ciency
compressor (from
Plant Design and
Economics for ChE)
INSULATION
*Q=75,221.1167 W
*Fiber glass is the
recommended insulating
material
*k = 0.036 W/mK
*ri = 0.0641m
SULFURIC ACID TANK TO ROTARY KILN
Mass flow 583.56
rate 0.1621
0.1621
Density 1840
Viscosity
Density 0.019
1840

Viscosity 0.019

Solving for the volumetric flow rate:

Calculating the inside diameter of pipe with the assumed velocity of 1 m/s from the table:
Table 5.4 (Towler & Sinnott, 2007)

TABLE 10-22: PROPERTIES OF STEEL PIPE (PERRY & GREEN, 2008)

Nominal Pipe
Size
Schedule 40S
number
Inside 0.824 0.0209 m
Diameter in
Outside 1.050 0.0267m
Diameter in

Solving for the fluid velocity:

To
solve for Reynolds number:

Since Reynolds number obtained is lower than 2,100 therefore the fluid flow is laminar (Geankoplis, 1995)

For friction in Laminar Flow:

To calculate frictional loss per meter`:

TO CALCULATE FRICTION LOSS DUE TO VALVES AND FITTINGS:
K fittings kf

90o elbows 0.75 1 0.75

Total 0.75

TO CALCULATE FRICTION LOSS DUE TO PIPE LINE:

TO CALCULATE FRICTION LOSS DUE TO SUDDEN CONTRACTION

(ENTRANCE LOSS):

CALCULATING THE TOTAL FRICTIONAL LOSSES:

FRICTION LOSS DUE TO SUDDEN ENLARGEMENT (EXIT LOSS):

TO CALCULATE KINETIC ENERGY: TO CALCULATE PRESSURE HEAD:

Substituting the values at the overall mechanical energy balance
on pumping system with
TO CALCULATE POTENTIAL ENERGY:

Since power requirement is negative, pump is not required (Sinnot,

2005)
 OLEUM TANK TO ACID SCRUBBER
Mass flow 216.0
rate 0.06
0.06
Density 1920
Viscosity
Density 0.048
1920

Viscosity 0.048

Solving for the volumetric flow rate:

Table 5.4 (Towler & Sinnott, 2007)



Table 10-22: Properties of Steel Pipe (Perry & Green, 2008)

Nominal Pipe Size

Schedule number 40S

Inside Diameter 0.824 in 0.0209 m
Outside Diameter 1.050 in 0.0267 m
CONDENSER TO AHF VESSEL
Mass flow 171.35
rate 171.35
0.048
Density 34.26
Viscosity 0.048
0.000637
Density
34.26

Viscosity
0.000637

Table 5.4 (Towler & Sinnott, 2007)

 FINA NCIA L STU D Y
P R ODU CTI ON OF A NH Y DR OUS H YD R OGEN FL UOR ID E
FR O M FL UOR SP A R
ESTIMATION OF CAPITAL INVESTMENT
AND TOTAL PRODUCT COST Fixed-Capital Investment Total Product Cost
Item %PE Cost (Php) Cost (Php)
Direct Cost I. Manufacturing Cost
100 126,663,394.
1. Purchased Equipment A. Direct Costs
41
1. Raw Materials - 166,888,873.20
2. Equipment Installation 30 37,999,018.3
2. Utilities - 27,885,990.35
2
10 12,666,339.4 3. Operating Labor - 21,576,000.00
3. Piping and Insulation
4 4. Maintenance and repairs 0.02FCI 10,065,116.71
13 16,466,241.2 5. Operating Supplies 0.10MR 1,006,511.67
4. Instrumentation and Control
7
6. Laboratory Charges 0.10 OL 2,157,600.00
10 12,666,339.4
5. Electrical Installation Total Direct Production Cost 229,580,091.93
4
50 63,331,697.2 B. Fixed Costs
6. Service Facilities
1 1. Depreciation - 20,018,573.74
30 37,999,018.3 2. Local taxes 0.01 LC 840,000.00
7. Buildings and Structures
2 3. Insurance 0.04FCI 50,325,583.55
- 84,000,000.0
8. Land Cost Total Fixed Charges 71,184,157.29
0
Indirect Cost C. Plant Overhead Cost 0.5(OL,MR) 15,820,558.36
1.Engineering and Supervision 32 40,532,286.2 Total Manufacturing Cost 316,584,807.58
1 II. General Expense
19 24,066,044.9 A. Administrative Cost 0.02 OL 4,315,200.00
2. Contractors Fee
4 B. Distribution and Marketing Cost 0.02 DC 4,591,601.84
37 46,865,455.9
3. Contingencies C. Research and Development Cost 0.05 MC 15,829,240.38
3
- 503,255,835. Total General Expense 24,736,042.22
Total Fixed-Capital Investment (FCI) Total Product Cost
51 341,320,849.
79 100,651,167.
Working Capital 80
10
603,907,002
 RETURN OF INVESTMENT
A performance measure used to evaluate the
efficiency of an investment or to compare the
efficiency of a number of different investments.
Year Net Income after Investment % ROI
Tax (Hilton et. al, 2008)
2018 14,686,601.96 865,186,542.3 1.70
8
2019 30.00
95,359,492.37 879,163,568.9 10.85
7 25.00
2020 128,709,062.9 967,079,925.8 13.31 20.00
7 7

% ROI
15.00
2021 199,150,698.4 1,063,787,918. 18.72
10.00
3 46
2022 282,339,379.5 1,170,166,710. 24.13 5.00
5 30 0.00
2023 306,919,582.9 1,521,216,723. 20.18 2016 2018 2020 2022 2024 2026 2028
8 39 Year
2024 361,535,131.9 1,673,338,395. 21.61 Return of Investment on Asset
5 73
2025 420,539,700.7 1,840,672,235. 22.85
0 30
2026 518,923,729.1 2,208,806,682. 23.49
8 36
2027 591,614,240.0 2,871,448,687. 20.60
 BREAK EVEN ANALYSIS
Calculates the break-even point based on fixed costs, variable costs per unit of sales and revenue per unit of sales

Product Break-Even Break-Even Total Cost

Units (Php)
Hydroge 1,233,988. Php 340, 580,
n 20 kg 743.00
Fluoride
PAYBACK PERIOD
The payback period is the length of time until the sum of an investments cash flows
equals its cost.
Total Capital Investment = 603,907,002.61
Year Cost

2018 180,021,680.52

2019 254,937,321.98

2020 537,656,482.03

2021 1,280,710,593.55

2022 2,830,680,175.65

The payback period for the business was

2023 computed to be on a span of 4 years.
5,435,330,277.86
 TA BLE OF
STA ND A RD S
P R ODU CTI ON OF A NH Y DR OUS H YD R OGEN FL UOR ID E
FR O M FL UOR SP A R
 CONTRIBU TION TO
P HILIP P INE ECONOM Y
P R ODU CTI ON OF A NH Y DR OUS H YD R OGEN FL UOR ID E
FR O M FL UOR SP A R
 As an emerging
member of the
Chemical Industry
Sector
HOW
HYDROFLUOR
PHILIPPINES CAN
CONTRIBUTE TO
THE PHILIPPINE
ECONOMY.

As raw material
supplier for the
main industrial
As an
sectors employer
 As an emerging member of the Chemical
Industry Sector

By the year 2050, the Philippine economy is

projected to be the 16 t h biggest in the world,
 As raw material supplier for the main
industrial sectors

The main industries in the country include:

electronics assembly, business process
 As an employer

With the increasing trend of the demand and

stagnant supply for the product, HydroFluor
CONCLUSION

Higher level of income and employment are the

main indicators of GDP growth.