DESIGN OF A PLANT TO PRODUCE SODIUM HYDROXIDE,

Transcription

1 DESIGN OF A PLANT TO PRODUCE SODIUM HYDROXIDE, HYDROGEN AND CHLORINE USING ONE TONNE PER DAY SODIUM CHLORIDE BY MERCURY CELL METHOD BY EZUTEH ALEX IFEANYI 2003/14990EH DEPARTMENT OF CHEMICAL ENGINEERING FEDERAL UNIVERSITY OF TECHNOLOGY MINNA, NIGER STATE A PROJECT SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE AWARD OF DEGREE OF BACHELOR OF ENGINNERING (B.ENG) OCTOBER 2008

2 ESIGN OF A PLANT TO PRODUCE SODIUM HYDROXIDE, OGEN AND CHLORINE USING ONE TONNE PER DAY SODIUM CHLORIDE BY MERCURY CELL METHOD BY EZUTEH ALEX IFEANYI 2003/14990EH DEPARTMENT OF CHEMICAL ENGINEERING FEDERAL UNIVERSITY OF TECHNOLOGY MINNA, NIGER STATE OCTOBER 2008.

3 DECLARATION I Ezuteh Alex Ifeanyi with registration No EH declarc that this project report is my original work and has not been presented elsewhere to the best of my knowledge. It was culti~d of under the supervision of Dr. Duncan Aluko. Signature Datc

4 CERTIFICATION This Design project was design, examined and certified under the supervision of Dr. D. F. Aloko to be adequate in scope and quality for the partial fulfillment of the requirement for the Award of Bachelor of Engineering (B. ENG) in Chemical Engineering ~(- DR. D. F. ALOKO DATE Project Supervisor DR. M. O. EDOGA DATE Head of Department EXTERNAL EXAMINER DATE

5 DEDICATION This Design project is dedicated to Almighty God, for its mercy over us and to our lovely parent..; for making this project a reality.

6 ACKNOWLEDGEMENT Our sincere thanks goes to the Almighty God who has kept us alive till this day to see this last memory. We wish to express our profound gratitude to our supervisor, Dr. D. F Aloko for his numerous advice and encouragement during the course of the design project. Also, in this respeet, my special thanks goes to my head of department, Dr. M. 0 Edoga and staffs of the chemical engineering department. Our unique gratitude goes to our beloved parents. They stood for and supported us with all their might financially, in prayers and love. To our dear parents once again we say 'Thank yuu very much'. We are also indebted to professor K. O. Onifade, Professor 1. O. Odigure, the Dean of Engineering, Dr. M.O. Edoga, the I-lead of Department, Chemical Engineering. And to all Lecturers in Chemical Engineering department. We thank you for impacting the basic engineering knowledge in us. We love you all. To our wonderful course mates, you have been a source of inspiration and challenge thanks for your companion.

7 ABSTRACT The aim of this project is to design a plant that will produce sodium hydroxide, hydrogen and chlorine using one tonne per day sodium chloride by MERCURY CELL METHOD. The detailed design work was done with the aid of computer aided design (CAD) software's like HYSYS and MATHCAD. The major units in the plant are: Reactor unit, Separation and Drying unit, and the Recovery unit. The design of equipment undertaken are Brine saturator, Brine precipitator, Clarifiers, Filters, Mercury Cells, Decomposers having a diameters of 0.024m, 0.019m, 0.02m, 0.031m, 0.020m, and a height of 0.017m. Safety-Control, environmental impact assessment, plant location and site layout were also carried out. Standard Cost estimation was carried out using detailed factorial method and this gives the total capital investment cost to be x 1011 naira needed to generate a net profit of x naira per year within a pay back period of approximately years for a plant life of 15years. The rate of return is %.

8 TABLE OF CONTENT CONTENTS PAGES TITLE PAGE DECLARATION CERTIFICATION DEDICATION ACKNOWLEDGEMENT ABSTRACT TABLE OF CONTENT LIST OF TABLES LIST OF FIGURES 11 III IV V Vi-IX X Xl CHAPTER ONE 1.0 INTRODUCTION 1.1 Uses of Hydrogen, Chlorine and Sodium Hydroxide 1.2 Aims and Objectives Problem Statement The Process 1.3 Scope of Work Process Design Chemical Engineering Design Cost Analysis CHAPTER TWO LITERATURE REVIEW Evaluation of Potential Process Root 5 5

9 2.1.1 The Membrane Cell process The Diaphragm Cell Process The Mercury Cell Process Process Description of Mercury Cell Process Equipment in Sodium Hydroxide Production Mercury Cell Decomposer CHAPTER THREE 3.0 MATERIAL BALANCE CHAPTER FOUR 4.0 ENERGY BALANCES CHAPTER FIVE 5.0 FLOW SHEET/ FLOW DIAGRAM Introduction Flow Sheet Presentation Block Diagram Pictorial Representation Engineering Flow Sheet Inf0rmation to be Included Essential Information Optional Information 102 CHAPTER SIX 6.0 EQUIPMENT DESIGN 103

10 6.1 Design of Brine Saturator Design of Precipitator Design of Filter Tank Design of Clarifier Design of Mercury Electrolytic Cell Design of Amalgam Decomposer CHAPTER SEVEN 7.0. EQUIPMENT OPTIMIZATION Optimization of Brine Saturator Optimization of Precipitator Optimization of Filter Tank Optimization of Clarifier Optimization of Mercury Electrolytic Cell Optimization of Amalgam Decomposer 137 '- 138 CHAPTER EIGHT 8.0 SAFETY AND QUALITY CONTROL Environmental Pollution First Aids Measures and Application Ingestion of Caustic Soda Fire Hazards and Fire Fighting Methods Spill Precautions and Clean lip Methods Handling of Chemicals Mercury Cell Environmen ai Pollulion Control

11 CHAPTER NINE 9.0 PROCESS CONTROL AND INSTRUMENTATION Type of Control Instruments Cor.trol Mechanism Control Sensor Transmitter, Controller and Control Valves 145 CHAPTER TEN 10.0 ENVIRONMENTAL ACCEPTABILITY 10.1 Methods of the Treatment of the Sludge Bioremediation CHAPTER ELEVEN 11.0 START UP AND SHUT DOWN PROCEDURE 11.1 Start up Procedure Shut down Procedure Emergency shut down of plant Start Up After Emergency Shut Down CHAPTER TWELVE 12.0 SITE FOR PLANT LOCATION,, ' 150 ISO Factors Considered for Site and Plant Location Location, with respect to the Marketing Area Raw Materials Transport Availability of Labour

12 Utilities (services) Environmental impact and Effluent Disposal Local Community Considerations Availability of Suitable Land Climate Political and Strategic Consideration Selection of site Justification of the Selected Site CHAPTER THIRTEEN 13.0 ECONOMIC ANALYSIS OF PLANT Total Investment Cost Total Fixed Investment cost Income and Cost Operation Operating Cost Fixed Operating Cost Direct Labour Cost Plant Maintenance and Repairs General Expenses Total Variable Cost Profit Analysis Pay Back Period Rate of Return 162

13 CHAPTER FOURTEEN 14.0 CONCLUSION AND RECOMMENDATION 14.1 Conclusion 14.2 Recommendation APPENDIX REFERENCE