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
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.
DECLARATION I Ezuteh Alex Ifeanyi with registration No. 2003114990EH 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
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
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.
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.
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 6.824 x 1011 naira needed to generate a net profit of 9.954 x 10 10 naira per year within a pay back period of approximately 6.856 years for a plant life of 15years. The rate of return is 15.914%.
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 1.2.1 Problem Statement 1.2.2 The Process 1.3 Scope of Work 1.3.1 Process Design 1.3.2 Chemical Engineering Design 1.3.3 Cost Analysis 1-3 3 3 3 3-4 4 4 4 4 CHAPTER TWO 2.0 2.1 LITERATURE REVIEW Evaluation of Potential Process Root 5 5
2.1.1 The Membrane Cell process 5-7 2.1.2 The Diaphragm Cell Process 7-9 2.1.3 The Mercury Cell Process 9-12 2.2 Process Description of Mercury Cell Process 12-14 2.3 Equipment in Sodium Hydroxide Production 15 2.4 Mercury Cell 15-16 2.5 Decomposer 16-17 CHAPTER THREE 3.0 MATERIAL BALANCE 18-71 CHAPTER FOUR 4.0 ENERGY BALANCES 72-98 CHAPTER FIVE 5.0 FLOW SHEET/ FLOW DIAGRAM 99 5.1 Introduction 99 5.2 Flow Sheet Presentation 99-100 5.2.1 Block Diagram 100 5.2.2 Pictorial Representation 100 5.2.3 Engineering Flow Sheet 101 5.3 Inf0rmation to be Included 101 5.4 Essential Information 101 5.5 Optional Information 102 CHAPTER SIX 6.0 EQUIPMENT DESIGN 103
6.1 Design of Brine Saturator 103-106 6.2 Design of Precipitator 107-113 6.3 Design of Filter Tank 113-118 6.4 Design of Clarifier 118-122 6.5 Design of Mercury Electrolytic Cell 122-127 6.6 Design of Amalgam Decomposer 127-131 CHAPTER SEVEN 7.0. EQUIPMENT OPTIMIZATION 132 7.1 Optimization of Brine Saturator 132-133 7.2 Optimization of Precipitator 133-134 7.3 Optimization of Filter Tank 134 7.4 Optimization of Clarifier 135-136 7.5 Optimization of Mercury Electrolytic Cell 136-137 7.6 Optimization of Amalgam Decomposer 137 '- 138 CHAPTER EIGHT 8.0 SAFETY AND QUALITY CONTROL 139 8.1 Environmental Pollution 139 8.2 First Aids Measures and Application 139-140 8.3 Ingestion of Caustic Soda 140 8.4 Fire Hazards and Fire Fighting Methods 140-141 8.5 Spill Precautions and Clean lip Methods 141 8.6 Handling of Chemicals 141 8.7 Mercury Cell Environmen ai Pollulion Control 142-143
CHAPTER NINE 9.0 PROCESS CONTROL AND INSTRUMENTATION 144 9.1 9.2 9.3 Type of Control Instruments Cor.trol Mechanism Control Sensor 144 144 144-145 9.4 Transmitter, Controller and Control Valves 145 CHAPTER TEN 10.0 ENVIRONMENTAL ACCEPTABILITY 10.1 Methods of the Treatment of the Sludge 10.1.1 Bioremediation 146 146 146-148 CHAPTER ELEVEN 11.0 START UP AND SHUT DOWN PROCEDURE 11.1 Start up Procedure 149 149-150 11.2 Shut down Procedure 11.2.1 Emergency shut down of plant 11.2.2 Start Up After Emergency Shut Down CHAPTER TWELVE 12.0 SITE FOR PLANT LOCATION,, ' 150 ISO 150-151 152 12.1 Factors Considered for Site and Plant Location 12.1.1 Location, with respect to the Marketing Area 12.1.2 Raw Materials 12.1.3 Transport 12.1.4 Availability of Labour 152 152 152 153 153
12.1.5 Utilities (services) 153 12.1.6 Environmental impact and Effluent Disposal 154 12.1. 7 Local Community Considerations 154 12.1.8 Availability of Suitable Land 154 12.1.9 Climate 154 12.1.10 Political and Strategic Consideration 154 12.2 Selection of site 154 12.3 Justification of the Selected Site 154-155 CHAPTER THIRTEEN 13.0 ECONOMIC ANALYSIS OF PLANT 156-157 13.1 Total Investment Cost 157 13.1.1 Total Fixed Investment cost 157 13.2 Income and Cost Operation 157 13.2.1 Operating Cost 157 13.2.2 Fixed Operating Cost 158 13.2.3 Direct Labour Cost 158 13.2.4 Plant Maintenance and Repairs 158 13.3 General Expenses 159 13.4 Total Variable Cost 159-160 13.5 Profit Analysis 160-162 13.6 Pay Back Period 162 13.7 Rate of Return 162
CHAPTER FOURTEEN 14.0 CONCLUSION AND RECOMMENDATION 14.1 Conclusion 14.2 Recommendation 163 163 163 APPENDIX REFERENCE 165-166