Assignment-1

SUBMITTED TO: SUBMITTED BY:

Dr. Rohidas Gangaram Bhoi Abhishek Kumawat

(Assistant Professor) (2017UCH1564)

PEPD
Submitted On: 07/04/2020

Department Of Chemical Engineering

Malaviya National Institute of Technology,
Jaipur - 302017
SESSION: 2019-2020
Question -1 The stream data for process involving an exothermic chemical reaction are
given in following table.

Stream Enthalpy 𝑻𝑺 (℃) 𝑻𝑻 (℃)

No. Type Change(kW)
1 Hot -7000 377 375
2 Hot -3600 376 180
3 Hot -2400 180 70
4 Cold 2400 60 160
5 Cold 200 20 130
6 Cold 200 160 260

A. Show that it is a threshold problem requiring only cold utility with ∆𝑻𝒎𝒊𝒏 is 117℃
with a cold utility duty of 10,100 kW.
B. It is proposed to use steam generation as cold utility for which ∆𝑻𝒎𝒊𝒏 is 10℃
a. Assume that saturated boiler feed water is available and that the steam
generated is saturated in order to calculated how much steam can be generated
by the process at a pressure of 41 bar. The temperature of saturated steam at
this pressure is 252 bar and the latent heat is 1706kJ/kg
b. If the steam is superheated to a temperature of 350℃, calculate how much stem
can be generated at 41 bar. Assume the heat capacity of team is 4.0kJ/kg.K.
c. What would happen if steam in part b is generated from boiler feed water at
100℃ with heat capacity of 4.2 kJ/kg.K. How would the steam generation be
calculated under these circumstances?

Solution - (A) ∆Tmin = 117℃

Stream Enthalpy 𝐓𝐒 𝐓𝐓 𝐓∗𝐒 𝐓∗𝐒 𝐂𝐏

No. Type Change(kW) (℃) (℃) (℃) (℃)
1 Hot -7000 377 375 260 258 3500
2 Hot -3600 376 180 259 63 18.86
3 Hot -2400 180 70 63 -47 21.818
4 Cold 2400 60 160 60 160 24
5 Cold 200 20 130 20 130 1.81
6 Cold 200 160 260 160 260 2

∆H = (∑ CH − ∑ CC ) ∆T
 T1 = 260℃
∆H = 3498
T2 = 259℃ H1
∆H = 3516.36
T3 = 258℃ C3
∆H = 1603.28
T4 = 160℃ H2
∆H = −169.2
T5 = 130℃ C1
∆H = −499.15
T6 = 63℃ C2
∆H = −11.97
T7 = 60℃
∆H = 800.32
T8 = 20℃ H3

T9 = −47℃ ∆H = 1461.8

T1 𝑄𝐻 𝑚𝑖𝑛 = 0
3498
T2 3500
3516.4
T3 7018.36
1603.3
T4 8946.16
-169.2
T5 10418.56
-499.15
T6 10616.74
-11.97
T7 10551.28
1603.3
T8 10271.28
-169.2
T9 10198.28

(B) ∆Tmin = 10℃

Stream Enthalpy 𝐓𝐒 𝐓𝐓 𝐓∗𝐒 𝐓∗𝐒 𝐂𝐏

No. Type Change(kW) (℃) (℃) (℃) (℃)
1 Hot -7000 377 375 367 365 3500
2 Hot -3600 376 180 366 170 18.86
3 Hot -2400 180 70 170 60 21.818
4 Cold 2400 60 160 60 160 24
5 Cold 200 20 130 20 130 1.81
 6 Cold 200 160 260 160 260 2
∆H = (∑ CH − ∑ CC ) ∆T

T1 = 367℃
∆H = 3500
T2 = 366℃ H1
∆H = 3518.36
T3 = 365℃
∆H = 1927.8
T4 = 260℃ H2
∆H = 1472.84
T5 = 170℃ C3
∆H = 198.18
T6 = 160℃
∆H = −65.46
T7 = 130℃ H3 C1
∆H = −280
T8 = 60℃ C2
∆H = −72.72
T9 = 20℃

T1 𝑄𝐻 𝑚𝑖𝑛 = 0 kW
3500
T2 3500 kW
3518.6
T3 7018.36 kW
1927.8
T4 8946.16 kW
1472.4
T5 10418.56 kW
198.18
T6 10616.74 kW
-65.46
T7 10551.28 kW
-280
T8 10271.28 kW
-72.72
T9 10198.56 kW

Cold Utility for ∆Tmin 10℃ = 10198.56kW

(a) Cold Utility for ∆Tmin 10℃ = 10193.56kW

For ∆Tmin 10℃

λ = 1706kJ/kg

QC min = 10198.56

QC min = mλ

m = 5.978kg/s

(b) For ∆Tmin 10℃

λ = 1706kJ/kg

QC min = 10198.56

QC min = mλ + mCPS ∆TS

m = 4.861 kg/s

(c) QC min = mλ + mCPW ∆TW + mCPS ∆TS

10198.56 = 𝑚[4.2 × (252 − 100) + 1706 + 4 × (350 − 252)]

m = 3.727kg/s
Question-2 Identify any two chemical components and prepare a short report covering
following points.

a. Three or more different routes to synthesize it with its merits and demerits.
b. Most preferred route to synthesize it with worldwide capacity.
c. The Indian scenario in terms of name of the companies producing it, their capacity
etc.

Answer-

1. PHOSPHORIC ACID –
Phosphoric acid is a weak acid with the chemical formula H₃PO₄. Orthophosphoric acid
refers to phosphoric acid, which is the IUPAC name for this compound.

(A) Phosphoric acid (H3PO4) can be produced by 3 main commercial methods:

(a) Wet Process
(b) Thermal Process
(c) Electric Furnace Process

 Wet Process - In a wet process facility (see figure), phosphoric acid is produced by
reacting concentrated acid(either sulphuric acid or hydrochloric acid)with naturally
occurring phosphate rock. A high grade of phosphate rock is necessary to avoid
solubilization of impurities such as aluminium, silicon, iron oxides and alkali metals.
The process can be carried out by either of the two methods:
1.) Wet process using conc. Sulphuric acid (93-98%)
2.) Wet process using conc. Hydrochloric acid

 Thermal Process –
 Thermal process is also known as electric arc furnace process.
 It was the primary mention of producing phosphoric acid before
being dominated by the wet process with sulphuric acid.

2Ca3(PO4)2 +6SiO2+10CP4+10CO+6CaSiO3
P4+10CO+10O2 P2O5+10CO2
P2O5 + xH2O H3PO4+(x-3)H2O
  Electric Furnace Process –
 It is similar to the Thermal Process, but the heat requirement to
evaporate P4 comes from the burning of petroleum coke instead from
electricity.
 Like the previous method, P4 reacts with oxygen to form P2O5
 This P2O5 is scrubbed with water to form H3PO4
 P2O5 recovery of furnace process is about 87%.
2Ca3(PO4)2 +6SiO2+10CP4+10CO+6CaSiO3
P4+10CO+10O2 P2O5+10CO2
P2O5 + xH2O H3PO4+(x-3)H2O

CURRENTLY WORLDWIDE PROCESS USED –

 Wet process is by far the most common route.
 Phosphoric acid is produced by reacting sulfuric acid (H2SO4) with naturally occurring
phosphate rock.
 The reaction also forms calcium sulfate (CaSO4), commonly referred to as gypsum.
 The insoluble gypsum is separated from the reaction solution by filtration.
 The operating conditions are generally selected so that the calcium sulfate will be
precipitated in either the dehydrate or the hemihydrates form, thus producing 26-32%
P2O5 at 70-80°C for dehydrate precipitation and 40-52% P2O5 at 90- 110°C for
hemihydrates precipitation.

Indian Scenario of Phosphoric Acid-

India is the largest country importing Phosphoric acid in the world accounting for over 45% of
world trade.

• The demand for phosphoric acid in India stood at 4,948 KTPA in 2018and is projected to grow
at a CAGR of 5.96% during 2019-2030 to reach 8,773 KTPA by 2030.

• Main consumption sectors of Phosphoric Acid in India:-

1. fertilizers 2. Sugar industry 3. refining sector

• Major consumers of Phosphoric Acid in India: - 1. Gujarat State Fertilizers and Chemical
Limited 2. IFFCO -Indian Farmers Fertilizer Cooperative 3. Paradip phosphates limited

• Major producer of phosphoric in India :- Aditya Birla Chemicals. a. Aditya Birla Grasun
Chemicals Limited (ABGCL), China b. Aditya Birla Chemicals India Limited (ABCIL),
Karnataka, India. S
2. NITRIC ACID –
 Industrially nitric acid can be prepared by the following methods
namely,
 CHILE SALTPETRE METHOD BY NANO3 (oldest)
 BRIKLAND EYDE’S METHOD BY USING AIR
 OSTWALD’S METHOD BY AMMONIA SOLVEY PROCESS (most widely
used)

 Chile Saltpetre Method (By NaNO3) -

 It is the first commercial process of manufacture of nitric acid from sodium
nitrate extracted from Chile saltpetre.(The process is now become obsolete since
second decade of nineteenth century.)
 Equal weight of sodium nitrate (or potassium nitrate) and sulphuric acid is
charged to cast iron retort having outlet provided at bottom to take out solution
of sodium bisulphate.
 The reactants are heated to about 2000C by the hot furnace gases.
 The furnace gases are produced by combustion of coal in the furnace.
 Then the vapour of nitric acid are cooled and condensed in water cooled silica
pipes.
 The cooled acid is collected in stoneware receiver.
 The un-condensed vapours are scrubbed with water in absorption tower which is
packed with stone ware balls and cooled by cold water.
 The dilute acid is re-circulated till it becomes concentrated.
 The residual sodium bisulphate is removed by outlet provided at the bottom of
retort.
NaNO3 + H2 SO4→NaHSO4 + HNO3

 Brikland Eyde’s Method (Arc Process) –

• CO2 and dust free air is heated in an arc furnace at 3000°C. Nitric oxide is
formed.
• Gases coming out from the furnace are cooled at 1000°C by passing through
cooler then gases are passed in a boiler and cooled at 150°C.
• Cold water is circulated around the boiler to cool the gases. Gaseous mixture is
now passed through aluminum tubes. The temperature of gaseous mixture
becomes 50 C.
• Gaseous mixture is passed in oxidizing tower where NO is oxidized into
NO2 . 2NO + O2 2NO2
• NO2 is absorbed in water in absorption tower then dilute HNO3 is obtained.
3NO3 + H2O 2 HNO3 + NO
 INDIAN SCENARIO 
S. NO. Major producers Concentrated Nitric Dilute Nitric
Acid (In TPD ) Acid (In TPD)

1 Deepak Fertilizers 100 ------

& Petrochemicals
carpo. Ltd.

2 Deepak Nitric Ltd. 100 660

3 GNFC (Gujarat 100 630

Narmada Valley
Fertilizers Corp.)

4 Hindustan Organic 100 ------

Chemicals Ltd.
5 VBC Industries 80 ------
Ltd.

6 Rourkela ---- 1000

Chemicals &
Fertilizers LT