2. Project Advisor: Miss Iqra Sohail
• Problem Definition
• Equipment(Mixer) Design
Shahbaz Ali
(CH-301)
• Process Selection
• Process Description
Hafiz Muhammad Ali Ejaz
(CH-051)
• Material/Energy Balance
• Equipment (Exchanger/Pump) Design
Hafiz M. Arsalan Aslam
(CH-064)
• Equipment (Rotary Filter) Design
• Economic Evaluation/Conclusion
Mustafa Hussain
(CH-305)

3. Gantt Chart

4. Shahbaz Ali
Problem Definition

5. Global Warming……?

6. • Global warming is the rise in the average temperature
of Earth's atmosphere and oceans since the late 19th
century and its projected continuation.
• Since the early 20th century, Earth's mean surface
temperature has increased by about 0.8 °C (1.4 °F),
with about two-thirds of the increase occurring since
1980.
• It will increase to about 2-5 °C by the end of this
century.
• CO2 level (October 2012) 391 ppm

7. Solution………?

9. • Cement industry is responsible for 5% of global CO2
emissions
• 932 MT CO2 (approx.)emission per year per cement plant
• Each ton of cement emits 0.7-1.1 tons of CO2.
• Calcination Process (50%)
• Combustion of fuels in kiln (40%)
• Transportation (5%)
• Electricity (5%)
• High CO2 concentration in their flue gases of about 14-33%
compared to 12-14% CO2 for coal -fired power plants and 4%
for gas fired plants.

10. Our Project

11. • We have taken a basis of 0.1 MT Cement
production per year and our cement industry
produces more than 0.3 MT of CO2 per year
• Our process is capable of removing 0.267 MT
CO2 per year
• This includes the CO2 from the kiln and fuel

12. So What’s New?

13. Hafiz Muhammad Ali
Ejaz
Process Selection
Process Description

14. Process
Selection
 Primary Processes
 Post-Combustion
 Pre-Combustion
 Oxy-Fuel-Combustion
Combustion
Chamber
Air + Fuel
Flue Gas Separation
N2
Captured CO2
Air Air
Separation
Unit
N2
O2
Gasification +
Water Gas Shift Reaction
Fuel
Syn
Gas Separation
Captured CO2
H2 as Fuel
Air Air
Separation
Unit
N2
O2
Fuel
Captured CO2
Combustion
Chamber
Fuel + O2

15. Process
Selection
 Primary Processes
 Post-Combustion
 Pre-Combustion
 Oxy-Fuel-Combustion
 Secondary Methods
 Absorption
 Adsorption
 Membrane Separation

16. Process
Selection
 Primary Processes
 Post-Combustion
 Pre-Combustion
 Oxy-Fuel-Combustion
 Secondary Methods
 Absorption
 Amine
 Ammonia
 Sodium Hydroxide
 Adsorption
 Membrane Separation

17. Our Selection
 Post-Combustion
 Sodium Hydroxide Absorption
(Mineralization Process )

18. Process Description
Inputs
Flue Gas
Sodium Hydroxide
Process
Gas Handling
Caustic Preparation
Absorption
Solid Separation
Output
Sodium Bicarbonate
Sodium Carbonate
Clean Flue Gas

19. CO2 (g) + 2 NaOH (l)  Na2CO3 + H2O
Na2CO3 + H2O (l) + CO2 (g)  2 NaHCO3
Simplified PFD

20. Process Flow Diagram

21. Hafiz Muhammad Arsalan
Aslam
Material/Energy Balance
Equipment(Pump/Exchanger) Design

22. Material Balance
 Basis
 0.1 Mton Cement Production

23. Applying Material Balance around ……..

24. Known Values
Flue Gas 10.04 kg/sec
CO2 41.82 %
H2O 3.12 %
SO2 0.15 %
O2 1.87 %
N2 53.05 %
Conversion (X) 45 %
Molarity (MAbsorbent) 1 kmol/m3
Conversion (X) 80%
Calculated Values
NaOH Required 4.38 kg/sec
Na2CO3 Produced 5.80 kg/sec
H2O Produced 0.99 kg/sec
NaOH Requirement 4.38 kg/sec
Total Solution 113.82 kg/sec
Water 109.45 kg/sec
Na2CO3 Requirement 5.67 kg/sec
NaHCO3 Production 8.99 kg/sec
H2O Produced 0.96 kg/sec
CO2 Left 2.94 kg/sec
CO2 Left 0.59 kg/sec
Effluent 118.81 kg/sec
Na2CO3 0.13 kg/sec
NaHCO3 8.99 kg/sec
Impurities 0.06 kg/sec
Water 109 kg/sec
Material Balance
CO2 (g) + 2 NaOH (l)  Na2CO3 + H2O
Na2CO3 + H2O (l) + CO2 (g)  2 NaHCO3

25. Energy Balance

26. Applying Energy Balance Around …….

27. Known Values
Calculatd Values
TFue,out,1 = 140 oCTFlue = 300 oC
TWater,in = 35 oCTWater,in = 35 oC
TFue,out,2 = 30 oC
Heat Produced = 5728 kW
Q = 5428 kW
mWater = 21.9 kg/secmWater = 34.25 kg/sec
Q = 3469 kW
Heat of Formations @ 25oC
Reactants kJ/mol
NaOH -470
CO2 -394
Products
Na2CO3 -1152
H2O -286
Heat of Formation @ 25oC
Reactants kJ/mol
Na2CO3 -1152
CO2 -394
H2O -286
Products
NaHCO3 -930
Heat Produced = 3001 kW
E-101
E-102
R-1
R-2
TWater,out = 70 oC TWater,out = 35 oC

28. Equipment Designing

29. Heat Exchanger Design
• InletTemperature = 300 oC
• OutletTemperature = 140 oC
Hot Fluid (Shell Side):
• InletTemperature = 35 oC
• OutletTemperature = 70 oC
Cold Fluid (Tube side):
• Shell andTube (2 - Shell 4 -Tube Pass)Heat ExchangerType:
• 143 m2
Provisional Area =
• Tube Side Pressure Drop = 65 kPa = 0.65 bar
• Shell Side Pressure Drop = 134.9 kPa = 1.349 bar
Pressure Drop:
• Carbon SteelMaterial:
• $ 122ThousandPurchase cost in 2012 =
E-101

30. Pump Design
• CentrifugalPumpType =
• Alloy 20Material =
• 0.2446 mOptimum Diameter =
• 2.15 m/sDesignVelocity =
• 0.2489 mDiameter of Pipe =
• 119 mTotal Length of Pipe =
• 16.2 kPaPressure Drop =
• 70 %Efficiency =
• 8 mNPSH Available =
• 48kWPower Requirement =
• $ 32ThousandPurchase Cost in 2012 =
P-101

31. Feed Mixer Design
• 113.82 kg/ secNaOH Feed =
• 19000 gallon = 72 m3
Volume =
• 4.5 mTank Diameter =
• Carbon SteelMaterial =
• 1.5 mAgitator Diameter =
• 90 rpmRotations =
• 75 %Liquid Fill =
• 3.37 %Fluid Height =
• 35 CTemperature =
• 26 secondsMixingTime =
• 153 kWPower Required =
• 7 m/sTip Speed =
• $ 110ThousandPurchase Cost in 2012 =
MX-101

32. Mustafa Hussain
Equipment(Filter) Designing
Economics/Conclusion

33. Rotary Vacuum Drum Filter
• 119 kg/secMass of Slurry =
• 8%Solid Fraction =
• 92%Liquid Fraction =
• 100 m2Filter Area =
• 397 m3/hr = 0.11 m3/secVolume of Filtrate =
• 12 revolutions per hourSpeed =
• 105 seconds = 1.75 minutesFilteringTime =
• 27 horsepowerPower required =
• Carbon SteelMaterial =
• $ 534ThousandPurchase Cost in 2012 =
RF-101

34. Economic Evaluation
 Cash Flow
• 10.50 % (From State Bank of Pakistan)
Current Interest
Rate
• $ 25.5 Million
Total Investment
Required
• $ 57.5 Million
Annual
Operating Cost
• $ 83 MillionAnnual Revenue
Economics

35. • Cash Flow Diagram
• $ 184 Million ProfitableNet PresentValue (NPV)
• $ 22.4 Million ProfitableAnnualWorth (AW)
• 2 yearsPay Back Period
• 1.37 (Conventional) ProfitableBenefit/Cost (PW)
Economics

36. Conclusion

37. Carbon Mineralization VS
Carbon Sequestration
 Technical feasibility
 Ability to retrofit existing plant
 Permanent Storage
 Lower projected cost of capture
 AvoidTransportCosts (Average of $25/ton)
 Avoid pipeline development costs ($1-2 M/mile for new
pipelines)
 Avoid Monitoring cost
 Stable and safe form
 Low Risk
 Potential for “carbon-negative” products
 SOX/NOX/Heavy Metal/Particulates removal

38. Carbon Credits
$ 30.00 for CO2 credits per ton.
$ 750 for SOx credits per ton.
$ 1,900 for NOx credits per ton.
So, the credits’ revenue stream from this process
would equal $ 5 million per year.

39. THANK YOU