The document provides an internship report submitted to ICI Soda Ash Business describing the 4-week internship. It includes an introduction to the company and soda ash manufacturing process. The process involves reacting salt and limestone in kilns to produce soda ash and involves several steps: preparing brine, absorbing ammonia, carbonating in towers to produce sodium bicarbonate, filtering, drying in calciners to produce soda ash, and distilling to recover ammonia for reuse. The report also describes the progress made each week covering topics like process equipment, boiler operations, valves, flow measurement, and control theory.
Manufacture of caustic soda and chlorine using electrolysis process ...Ankush Gupta
This document discusses the manufacture of chlorine and caustic soda using electrolysis processes. It provides background on the chlor-alkali industry and describes the three main electrolysis processes: diaphragm cell, mercury cell, and membrane cell. The membrane cell process is highlighted as the most energy efficient and environmentally friendly option. Properties and production details of chlorine, caustic soda, and hydrogen are also outlined. A literature review covers previous research on improving chlor-alkali cell efficiency and treating wastewater from the process.
Urea reactor liner leakage(a case study)Prem Baboo
The document discusses liner leakage issues in the urea reactor of a fertilizer plant in India. It describes two instances of leakage detected through the weep hole monitoring system, in 2006 and 2017. Both times, the plant underwent shutdowns to locate and repair the leak. Detection methods like soap solution, ammonia testing, and differential pressure checks were used. The 2017 leak took longer to locate and required welding repairs between trays. The shutdown lasted 72 hours before feed was restored. Proper monitoring and maintenance of weep holes and liners is important for preventing corrosion and leaks.
This document discusses piping, fittings, and valves used in fluid dynamics. It begins by defining common piping terminology and describing common piping materials like steel, copper, plastic, and ceramics. It then discusses factors for pipe selection like fluid type and operating conditions. Key aspects of piping design covered include material roughness, pipe sizing methods using schedules and BWG, and considerations for pipe expansion and supports. Common pipe fittings are also defined, including flanges, elbows, reducers, and flow measurement devices. Finally, the document outlines the purpose and types of valves used to control fluid flow, such as globe, ball, gate, and safety valves.
Design of Tall Vessels (Distillation columns)Mayank Mehta
The document discusses the design of tall vessels used in chemical process industries. It covers stresses in the vessel shell from various loads including pressure, dead weight, wind, seismic forces, and eccentric loads. Methods are presented to determine equivalent stresses and longitudinal/axial stresses. Factors that influence the natural vibration period of vessels are also examined to avoid resonance from wind loads. The document provides equations to calculate stresses from different loads and determine the resultant longitudinal stresses in tall vessels under combined loading conditions.
This document is a declaration form for a thesis submitted by five students - Abubakar Saleem, Muhammad Noman Saeed, Irfan Riaz, Umair Shoaib, and Muhammad Humza. The thesis is titled "A Plant Design Report on Production of 100,000 MTPY of Styrene from Dehydrogenation of Ethyl benzene". The declaration form certifies that the thesis is the original work of the students and complies with university policies regarding publishing and copyright. It has been reviewed and approved by the students' supervisor, Dr. Fahad Rehman.
Power plant chemistry internal water treatmentumar farooq
This document provides an overview of internal water treatment in power plants. It was authored by Umar Farooq, a senior chemist working for NOMAC in Saudi Arabia. The document covers basic chemistry concepts, properties of water, types of hardness, and various internal water treatment methods including phosphate and oxygen scavenger treatment. The goal of internal water treatment is to prevent scale and corrosion in boiler systems by maintaining proper water chemistry conditions. Phosphate treatment works by precipitating hardness minerals to form a protective sludge layer, while oxygen scavengers like sodium sulfite and hydrazine remove dissolved oxygen to inhibit corrosion.
Hydrogenation Reactors
Stirred Vessels
Loop Reactors
Other reactor types
Appendix
- List of contact details for suppliers
- Information from supplier’s websites
Manufacture of caustic soda and chlorine using electrolysis process ...Ankush Gupta
This document discusses the manufacture of chlorine and caustic soda using electrolysis processes. It provides background on the chlor-alkali industry and describes the three main electrolysis processes: diaphragm cell, mercury cell, and membrane cell. The membrane cell process is highlighted as the most energy efficient and environmentally friendly option. Properties and production details of chlorine, caustic soda, and hydrogen are also outlined. A literature review covers previous research on improving chlor-alkali cell efficiency and treating wastewater from the process.
Urea reactor liner leakage(a case study)Prem Baboo
The document discusses liner leakage issues in the urea reactor of a fertilizer plant in India. It describes two instances of leakage detected through the weep hole monitoring system, in 2006 and 2017. Both times, the plant underwent shutdowns to locate and repair the leak. Detection methods like soap solution, ammonia testing, and differential pressure checks were used. The 2017 leak took longer to locate and required welding repairs between trays. The shutdown lasted 72 hours before feed was restored. Proper monitoring and maintenance of weep holes and liners is important for preventing corrosion and leaks.
This document discusses piping, fittings, and valves used in fluid dynamics. It begins by defining common piping terminology and describing common piping materials like steel, copper, plastic, and ceramics. It then discusses factors for pipe selection like fluid type and operating conditions. Key aspects of piping design covered include material roughness, pipe sizing methods using schedules and BWG, and considerations for pipe expansion and supports. Common pipe fittings are also defined, including flanges, elbows, reducers, and flow measurement devices. Finally, the document outlines the purpose and types of valves used to control fluid flow, such as globe, ball, gate, and safety valves.
Design of Tall Vessels (Distillation columns)Mayank Mehta
The document discusses the design of tall vessels used in chemical process industries. It covers stresses in the vessel shell from various loads including pressure, dead weight, wind, seismic forces, and eccentric loads. Methods are presented to determine equivalent stresses and longitudinal/axial stresses. Factors that influence the natural vibration period of vessels are also examined to avoid resonance from wind loads. The document provides equations to calculate stresses from different loads and determine the resultant longitudinal stresses in tall vessels under combined loading conditions.
This document is a declaration form for a thesis submitted by five students - Abubakar Saleem, Muhammad Noman Saeed, Irfan Riaz, Umair Shoaib, and Muhammad Humza. The thesis is titled "A Plant Design Report on Production of 100,000 MTPY of Styrene from Dehydrogenation of Ethyl benzene". The declaration form certifies that the thesis is the original work of the students and complies with university policies regarding publishing and copyright. It has been reviewed and approved by the students' supervisor, Dr. Fahad Rehman.
Power plant chemistry internal water treatmentumar farooq
This document provides an overview of internal water treatment in power plants. It was authored by Umar Farooq, a senior chemist working for NOMAC in Saudi Arabia. The document covers basic chemistry concepts, properties of water, types of hardness, and various internal water treatment methods including phosphate and oxygen scavenger treatment. The goal of internal water treatment is to prevent scale and corrosion in boiler systems by maintaining proper water chemistry conditions. Phosphate treatment works by precipitating hardness minerals to form a protective sludge layer, while oxygen scavengers like sodium sulfite and hydrazine remove dissolved oxygen to inhibit corrosion.
Hydrogenation Reactors
Stirred Vessels
Loop Reactors
Other reactor types
Appendix
- List of contact details for suppliers
- Information from supplier’s websites
Practical Fundamentals of Chemical Engineering Living Online
Many technical professionals today find themselves working with large scale chemical processes even though they don't have formal training in Chemical Engineering. This workshop intends to fill this gap and provide you with knowledge of chemical engineering fundamentals along with the ability to apply this knowledge to specify, design, operate, maintain and troubleshoot chemical processes. If you are a non-chemical engineer this manual will enable you to confidently talk to and work effectively with chemical engineers and process equipment.
http://www.idc-online.com/content/practical-fundamentals-chemical-engineering-27?id=21
The chlor-alkali process is an industrial process that uses electrolysis to produce chlorine, sodium hydroxide, and hydrogen from salt water. It involves passing an electric current through a brine solution to drive the following reaction: 2NaCl + 2H2O → 2NaOH + Cl2 + H2. The process was first developed in the 1850s but improved in the 1890s with the mercury cell. Today, membrane and diaphragm cells are more commonly used, accounting for 60% and 14% of European production respectively. The main uses of the products are in polymers, pesticides, antiseptics, acid production, metallurgy, and the paper industry.
This is course on Plant Simulation will show you how to setup hypothetical compounds, oil assays, blends, and petroleum characterization using the Oil Manager of Aspen HYSYS.
You will learn about:
Hypothetical Compounds (Hypos)
Estimation of hypo compound data
Models via Chemical Structure UNIFAC Component Builder
Basis conversion/cloning of existing components
Input of Petroleum Assay and Crude Oils
Typical Bulk Properties (Molar Weight, Density, Viscosity)
Distillation curves such as TBP (Total Boiling Point)
ASTM (D86, D1160, D86-D1160, D2887)
Chromatography
Light End
Oil Characterization
Using the Petroleum Assay Manager or the Oil Manager
Importing Assays: Existing Database
Creating Assays: Manually / Model
Cutting: Pseudocomponent generation
Blending of crude oils
Installing oils into Aspen HYSYS flowsheets
Getting Results (Plots, Graphs, Tables)
Property and Composition Tables
Distribution Plot (Off Gas, Light Short Run, Naphtha, Kerosene, Light Diesel, Heavy Diesel, Gasoil, Residue)
Oil Properties
Proper
Boiling Point Curves
Viscosity, Density, Molecular Weight Curves
This is helpful for students, teachers, engineers and researchers in the area of R&D, specially those in the Oil and Gas or Petroleum Refining industry.
This is a "workshop-based" course, there is about 25% theory and about 75% work!
At the end of the course you will be able to handle crude oils for your fractionation, refining, petrochemical process simulations!
Fired Equipment presentation on Types, Classification and governing Equations...Hassan ElBanhawi
Based on my 8 years of experience in Oil & Gas industry I can claim that you can find here All what you need to know about Fired Equipment. This is an introduction to understand more about their:-
-Types
-Basic Principles and equations
-Worked Example
You can find also more at:
http://hassanelbanhawi.com/staticequipment/firedequipment/
All the data and the illustrative figures presented here can be found through two reference books:-
ENGINEERING DATA BOOK by Gas Processors Suppliers Association
Process Technology - Equipment and Systems by Charles E. Thomas
Thank you.
This experiment involves conducting a saponification reaction between sodium hydroxide (NaOH) and ethyl acetate (Et(Ac)) in a continuous stirred tank reactor (CSTR) to determine the effect of residence time on conversion. A calibration curve will be prepared to relate conductivity measurements to conversion values for the 0.1M NaOH and 0.1M Et(Ac) reaction. The objectives are to determine conversion, the reaction rate constant, and the effect of residence time on conversion.
Power plant chemistry ( External Water Treatment )umar farooq
The document provides an overview of power plant chemistry and related topics. It discusses basic chemistry concepts, heat transfer, water chemistry, types of hardness in water, and marine ecology surveys. The document is presented in multiple parts that cover fundamental concepts, water treatment processes, steam water cycle systems, boiler operations, and course objectives for participants.
This document summarizes the MerOx sweetening process, which involves the oxidation of mercaptans in hydrocarbon streams. It discusses the types of sweetening processes, including removal and conversion. MerOx stands for mercaptan oxidation and involves oxidizing mercaptans to alkyl disulfides using oxygen in the presence of a metal chelate catalyst. The process occurs in three main vessels: a pre-wash vessel to dissolve mercaptans using caustic, a reactor vessel where the oxidation occurs over activated charcoal and catalyst, and a settler vessel where the products separate by gravity. The overall reactions convert mercaptans and hydrogen sulfide to alkyl disulfides, sodium thiosulfate, and regenerate ca
Chemical Process Industry (Production of Caustic Soda & Chlorine)Dharisinee Dharsh
This document summarizes the process of electrolysis of salt water to produce chlorine and caustic soda. It describes how salt water is purified and passed through an electrolytic cell where an electric current splits it into sodium, chlorine, and hydrogen gas/hydroxide. The specific reactions and production processes vary depending on whether mercury, diaphragm, or membrane cells are used, but all utilize electricity to drive the decomposition of brine into its constituent elements.
This document discusses various processes used to remove mercaptans from petroleum products. It begins by explaining that mercaptans cause foul odors and corrosion and need to be removed. Then it describes processes that include caustic scrubbing, solutizer extraction, doctor treating using lead compounds, copper chloride sweetening, merox extraction, and sulfuric acid treatment. The doctor treating process reacts mercaptans with lead compounds to form disulfides. Merox extraction oxidizes mercaptans to disulfides using a catalyst. Sulfuric acid treatment and clay treatment can also remove olefins, gums and improve product properties.
This document provides information on the Benfield process for removing carbon dioxide from gas streams. It discusses key aspects of the process including:
- Absorption of CO2 into a potassium carbonate solution and regeneration of the solution by heating.
- Use of an activator like DEA to improve CO2 absorption.
- Comparison with other CO2 removal processes like Rectisol and considerations for process selection.
- Parameters that affect the absorption and regeneration steps like pressure, temperature, and flow rates.
- Causes and prevention of corrosion in the system through vanadium addition and factors that can cause foaming of the solution.
Aspen Plus is a process simulation software that contains mathematical models of common chemical process equipment. It allows users to link models of individual units together to simulate entire chemical plants. The software solves the system of equations generated by the linked models to determine unknown process variables. It includes a large database of physical property data for chemicals that can be used as inputs for the unit models. Users set up simulations in Aspen Plus by defining chemicals, selecting property methods, building a flowsheet from unit operation blocks, specifying input parameters, and running simulations to obtain output results.
Qualification of separation performance in gas\liquid separationDodiya Nikunj
1) The document discusses methods for quantifying the performance of gas/liquid separators by measuring factors like entrainment levels, droplet size distributions, and velocity profiles.
2) Key aspects that can be quantified include the amount and size of entrained droplets or bubbles, continuous phase velocities, and droplet/bubble separation performance based on geometry.
3) Quantifying these factors leads to a more accurate representation of separator design and performance compared to traditional techniques.
1) The document discusses mechanical design of pressure vessels. It covers classification of pressure vessels and design considerations like stresses and stability.
2) Pressure vessels are classified based on thickness-to-diameter ratio into thin-walled and thick-walled vessels. Common shapes are cylindrical and spherical.
3) Design codes specify guidelines for design, materials, fabrication, inspection and testing of pressure vessels. Stresses like circumferential, longitudinal and shear stresses are derived. Failure theories like maximum principal and shear stresses are discussed.
4) Buckling stability is important for thin-walled vessels under compression. Membrane stress equations are provided for common vessel shapes like cylinders, spheres, cones and ellipsoids.
An Overview to the most common Industrial Mass Transfer Operations & Process Separation Technologies
Course Description
In this course we will cover the most basic processes involved in Mass Transfer Operations. This is an overview of what type of processes, methods and units are used in the industry. This is mostly an introductory course which will allow you to learn, understand and know the approach towards separation processes involving mass transfer phenomena.
It is an excellent course before any Mass Transfer Process or Unit Operation Course such as Distillations, Extractions, Leaching, Membranes, Absorption, etc...
This course is extremely recommended if you will continue with the following:
Flash Distillation, Simple Distillation, Batch Distillation
Gas Absorption, Desorption & Stripping
Binary Distillation, Fractional Distillation
Scrubbers, Gas Treating
Sprayers / Spray Towers
Bubble Columns / Sparged Vessels
Agitation Vessels
Packed Towers, Tray Towers
Membranes
Liquid Extraction
Dryers / Humidifiers
Adsorbers
Evaporators/Sublimators
Crystallizers
Centrifugations
And many other Separation Technology!
At the end of the Course:
You will be able to understand the mass transfer operations concepts. You will be able to identify Mass Transfer Unit Operations. You will be also able to ensure the type of method of separation technology used.
You will be able to apply this theory in further Unit Operations.
Theory-Based Course
This is a very theoretical course, some calculations and exercises are present, but overall, expect mostly theoretical concepts.
Difference Between Upstream & Midstream & Downstream Activities in Oil and Ga...Student
The Upstream activities sector include the searching and extraction of underground crude oil and natural gas , drilling exploratory wells, and subsequently drilling and operating the wells that recover and bring the crude oil and/or raw natural gas to the surface.
In the petroleum industry, locating underground or underwater oil reserves characterizes the upstream process. Additionally, the upstream process in this industry involves bringing oil and gas to the surface. Extraction wells represent an example of a structure operating in this stage in the process. The upstream stage in the production process may also manifest itself as a supplier providing raw materials to manufacturers or other businesses that ultimately process the materials.
What i learnt as an intern by Ihsan Wassan Ihsan Wassan
The document summarizes the key learnings from an internship at Pakistan Steel. It provides an overview of the company and its various production units, including the coke oven by-product plant, sintering plant, iron making department, and steel making plant. It describes the processes within the coke oven batteries, coke quenching plant, and by-product section. It also discusses the roles and responsibilities of the Directorate of Industrial Liaison in facilitating internship opportunities between universities and industries.
NALCO is Asia's largest integrated aluminium producer, operating bauxite mines, alumina refineries, aluminium smelters, and casting facilities in Odisha, India. It produces aluminium metal, ingots, billets, wire rods, and alloy products. The company's operations are divided into three major areas: carbon area for anode production, potline area for electrolysis, and casting area for final product shaping. NALCO sources bauxite from open-cast mines and produces alumina at a refinery before smelting aluminium in large pots at its smelter facility.
Practical Fundamentals of Chemical Engineering Living Online
Many technical professionals today find themselves working with large scale chemical processes even though they don't have formal training in Chemical Engineering. This workshop intends to fill this gap and provide you with knowledge of chemical engineering fundamentals along with the ability to apply this knowledge to specify, design, operate, maintain and troubleshoot chemical processes. If you are a non-chemical engineer this manual will enable you to confidently talk to and work effectively with chemical engineers and process equipment.
http://www.idc-online.com/content/practical-fundamentals-chemical-engineering-27?id=21
The chlor-alkali process is an industrial process that uses electrolysis to produce chlorine, sodium hydroxide, and hydrogen from salt water. It involves passing an electric current through a brine solution to drive the following reaction: 2NaCl + 2H2O → 2NaOH + Cl2 + H2. The process was first developed in the 1850s but improved in the 1890s with the mercury cell. Today, membrane and diaphragm cells are more commonly used, accounting for 60% and 14% of European production respectively. The main uses of the products are in polymers, pesticides, antiseptics, acid production, metallurgy, and the paper industry.
This is course on Plant Simulation will show you how to setup hypothetical compounds, oil assays, blends, and petroleum characterization using the Oil Manager of Aspen HYSYS.
You will learn about:
Hypothetical Compounds (Hypos)
Estimation of hypo compound data
Models via Chemical Structure UNIFAC Component Builder
Basis conversion/cloning of existing components
Input of Petroleum Assay and Crude Oils
Typical Bulk Properties (Molar Weight, Density, Viscosity)
Distillation curves such as TBP (Total Boiling Point)
ASTM (D86, D1160, D86-D1160, D2887)
Chromatography
Light End
Oil Characterization
Using the Petroleum Assay Manager or the Oil Manager
Importing Assays: Existing Database
Creating Assays: Manually / Model
Cutting: Pseudocomponent generation
Blending of crude oils
Installing oils into Aspen HYSYS flowsheets
Getting Results (Plots, Graphs, Tables)
Property and Composition Tables
Distribution Plot (Off Gas, Light Short Run, Naphtha, Kerosene, Light Diesel, Heavy Diesel, Gasoil, Residue)
Oil Properties
Proper
Boiling Point Curves
Viscosity, Density, Molecular Weight Curves
This is helpful for students, teachers, engineers and researchers in the area of R&D, specially those in the Oil and Gas or Petroleum Refining industry.
This is a "workshop-based" course, there is about 25% theory and about 75% work!
At the end of the course you will be able to handle crude oils for your fractionation, refining, petrochemical process simulations!
Fired Equipment presentation on Types, Classification and governing Equations...Hassan ElBanhawi
Based on my 8 years of experience in Oil & Gas industry I can claim that you can find here All what you need to know about Fired Equipment. This is an introduction to understand more about their:-
-Types
-Basic Principles and equations
-Worked Example
You can find also more at:
http://hassanelbanhawi.com/staticequipment/firedequipment/
All the data and the illustrative figures presented here can be found through two reference books:-
ENGINEERING DATA BOOK by Gas Processors Suppliers Association
Process Technology - Equipment and Systems by Charles E. Thomas
Thank you.
This experiment involves conducting a saponification reaction between sodium hydroxide (NaOH) and ethyl acetate (Et(Ac)) in a continuous stirred tank reactor (CSTR) to determine the effect of residence time on conversion. A calibration curve will be prepared to relate conductivity measurements to conversion values for the 0.1M NaOH and 0.1M Et(Ac) reaction. The objectives are to determine conversion, the reaction rate constant, and the effect of residence time on conversion.
Power plant chemistry ( External Water Treatment )umar farooq
The document provides an overview of power plant chemistry and related topics. It discusses basic chemistry concepts, heat transfer, water chemistry, types of hardness in water, and marine ecology surveys. The document is presented in multiple parts that cover fundamental concepts, water treatment processes, steam water cycle systems, boiler operations, and course objectives for participants.
This document summarizes the MerOx sweetening process, which involves the oxidation of mercaptans in hydrocarbon streams. It discusses the types of sweetening processes, including removal and conversion. MerOx stands for mercaptan oxidation and involves oxidizing mercaptans to alkyl disulfides using oxygen in the presence of a metal chelate catalyst. The process occurs in three main vessels: a pre-wash vessel to dissolve mercaptans using caustic, a reactor vessel where the oxidation occurs over activated charcoal and catalyst, and a settler vessel where the products separate by gravity. The overall reactions convert mercaptans and hydrogen sulfide to alkyl disulfides, sodium thiosulfate, and regenerate ca
Chemical Process Industry (Production of Caustic Soda & Chlorine)Dharisinee Dharsh
This document summarizes the process of electrolysis of salt water to produce chlorine and caustic soda. It describes how salt water is purified and passed through an electrolytic cell where an electric current splits it into sodium, chlorine, and hydrogen gas/hydroxide. The specific reactions and production processes vary depending on whether mercury, diaphragm, or membrane cells are used, but all utilize electricity to drive the decomposition of brine into its constituent elements.
This document discusses various processes used to remove mercaptans from petroleum products. It begins by explaining that mercaptans cause foul odors and corrosion and need to be removed. Then it describes processes that include caustic scrubbing, solutizer extraction, doctor treating using lead compounds, copper chloride sweetening, merox extraction, and sulfuric acid treatment. The doctor treating process reacts mercaptans with lead compounds to form disulfides. Merox extraction oxidizes mercaptans to disulfides using a catalyst. Sulfuric acid treatment and clay treatment can also remove olefins, gums and improve product properties.
This document provides information on the Benfield process for removing carbon dioxide from gas streams. It discusses key aspects of the process including:
- Absorption of CO2 into a potassium carbonate solution and regeneration of the solution by heating.
- Use of an activator like DEA to improve CO2 absorption.
- Comparison with other CO2 removal processes like Rectisol and considerations for process selection.
- Parameters that affect the absorption and regeneration steps like pressure, temperature, and flow rates.
- Causes and prevention of corrosion in the system through vanadium addition and factors that can cause foaming of the solution.
Aspen Plus is a process simulation software that contains mathematical models of common chemical process equipment. It allows users to link models of individual units together to simulate entire chemical plants. The software solves the system of equations generated by the linked models to determine unknown process variables. It includes a large database of physical property data for chemicals that can be used as inputs for the unit models. Users set up simulations in Aspen Plus by defining chemicals, selecting property methods, building a flowsheet from unit operation blocks, specifying input parameters, and running simulations to obtain output results.
Qualification of separation performance in gas\liquid separationDodiya Nikunj
1) The document discusses methods for quantifying the performance of gas/liquid separators by measuring factors like entrainment levels, droplet size distributions, and velocity profiles.
2) Key aspects that can be quantified include the amount and size of entrained droplets or bubbles, continuous phase velocities, and droplet/bubble separation performance based on geometry.
3) Quantifying these factors leads to a more accurate representation of separator design and performance compared to traditional techniques.
1) The document discusses mechanical design of pressure vessels. It covers classification of pressure vessels and design considerations like stresses and stability.
2) Pressure vessels are classified based on thickness-to-diameter ratio into thin-walled and thick-walled vessels. Common shapes are cylindrical and spherical.
3) Design codes specify guidelines for design, materials, fabrication, inspection and testing of pressure vessels. Stresses like circumferential, longitudinal and shear stresses are derived. Failure theories like maximum principal and shear stresses are discussed.
4) Buckling stability is important for thin-walled vessels under compression. Membrane stress equations are provided for common vessel shapes like cylinders, spheres, cones and ellipsoids.
An Overview to the most common Industrial Mass Transfer Operations & Process Separation Technologies
Course Description
In this course we will cover the most basic processes involved in Mass Transfer Operations. This is an overview of what type of processes, methods and units are used in the industry. This is mostly an introductory course which will allow you to learn, understand and know the approach towards separation processes involving mass transfer phenomena.
It is an excellent course before any Mass Transfer Process or Unit Operation Course such as Distillations, Extractions, Leaching, Membranes, Absorption, etc...
This course is extremely recommended if you will continue with the following:
Flash Distillation, Simple Distillation, Batch Distillation
Gas Absorption, Desorption & Stripping
Binary Distillation, Fractional Distillation
Scrubbers, Gas Treating
Sprayers / Spray Towers
Bubble Columns / Sparged Vessels
Agitation Vessels
Packed Towers, Tray Towers
Membranes
Liquid Extraction
Dryers / Humidifiers
Adsorbers
Evaporators/Sublimators
Crystallizers
Centrifugations
And many other Separation Technology!
At the end of the Course:
You will be able to understand the mass transfer operations concepts. You will be able to identify Mass Transfer Unit Operations. You will be also able to ensure the type of method of separation technology used.
You will be able to apply this theory in further Unit Operations.
Theory-Based Course
This is a very theoretical course, some calculations and exercises are present, but overall, expect mostly theoretical concepts.
Difference Between Upstream & Midstream & Downstream Activities in Oil and Ga...Student
The Upstream activities sector include the searching and extraction of underground crude oil and natural gas , drilling exploratory wells, and subsequently drilling and operating the wells that recover and bring the crude oil and/or raw natural gas to the surface.
In the petroleum industry, locating underground or underwater oil reserves characterizes the upstream process. Additionally, the upstream process in this industry involves bringing oil and gas to the surface. Extraction wells represent an example of a structure operating in this stage in the process. The upstream stage in the production process may also manifest itself as a supplier providing raw materials to manufacturers or other businesses that ultimately process the materials.
What i learnt as an intern by Ihsan Wassan Ihsan Wassan
The document summarizes the key learnings from an internship at Pakistan Steel. It provides an overview of the company and its various production units, including the coke oven by-product plant, sintering plant, iron making department, and steel making plant. It describes the processes within the coke oven batteries, coke quenching plant, and by-product section. It also discusses the roles and responsibilities of the Directorate of Industrial Liaison in facilitating internship opportunities between universities and industries.
NALCO is Asia's largest integrated aluminium producer, operating bauxite mines, alumina refineries, aluminium smelters, and casting facilities in Odisha, India. It produces aluminium metal, ingots, billets, wire rods, and alloy products. The company's operations are divided into three major areas: carbon area for anode production, potline area for electrolysis, and casting area for final product shaping. NALCO sources bauxite from open-cast mines and produces alumina at a refinery before smelting aluminium in large pots at its smelter facility.
Urea Dust & Ammonia Emission Control Prill Tower Project at Al BayroniAli Akbar
This document summarizes a presentation given about a project to control urea dust and ammonia emissions from a prilling tower at an urea plant in Saudi Arabia. The project involved installing an air cleaning unit with acid wash scrubbers to absorb urea dust and ammonia from the exit air stream. The absorbed materials were then sent to a crystallization unit to produce ammonium sulfate as the final product. The project successfully reduced urea dust and ammonia emissions below international standards and produced a new fertilizer product. It provided lessons learned for other plants seeking to control emissions from prilling towers.
Venkateshwara Power Projects Pvt Ltd (a part of Mahadik Group) is established
in 2019 to set up a greenfield distillery in Bedikhal in Chikodi Taluk in Belgaum
district of Karnataka. The project involves setting up of a 90 klpd molasses-based
distillery. The project cost is estimated at Rs. 1073.0 million. The main objective
of this plant is to produce Ethanol and generation of electricity.
1. Caustic soda is produced through the electrolysis of brine solution, producing chlorine gas and hydrogen gas as byproducts.
2. Chlorine gas is dealt with by being converted to hydrochloric acid, liquefied chlorine, or absorbed in lime solution to produce sodium hypochlorite. Remaining chlorine is not released into the atmosphere.
3. Hydrogen gas is flammable and hazardous, so plants are equipped with hydrochloric acid plants and flares to convert hydrogen to hydrochloric acid or ensure it is completely burned, preventing release into the atmosphere. Water seals also maximize safety.
A Rotary kiln is a pyroprocessing device used to raise materials to a high temperature (calcination) in a continuous process. Materials produced using rotary kilns include: Cement. Lime.
1) Tata Steel is India's largest private sector steel company with an annual production capacity of 30 million tonnes across 26 countries. 2) The document describes the sulfur recovery system at Tata Steel's Jamshedpur plant which removes sulfur from coke oven gas through a Claus process involving reactors and condensers. 3) It focuses on improving the availability of sulfur transfer pumps which transport recovered liquid sulfur to storage vessels.
The document discusses a study on the design of a hammer mill conducted by four students for their Bachelor of Technology degree. It includes an abstract, acknowledgements, bonafide certificate, declaration, contents, and introduction sections. The study aims to improve the crushing efficiency and lifetime of hammer mill hammers through redesigning the hammer head. Test results show the new design increased crushing efficiency from 81-84% to 88-91% and extended hammer lifetime from 10 to 12 months.
This business plan proposes establishing a fly ash brick manufacturing plant. Fly ash is a byproduct of coal combustion in thermal power plants and currently causes environmental issues. The plan's promoters have MBA and engineering backgrounds. The plant will be located in Raichur district, Karnataka near a thermal power plant and water source. It will employ local villagers and have an annual production capacity of 24 million bricks. The total project cost is approximately 30 lakh rupees to be financed through a bank loan. The plant is expected to be profitable with annual revenues of over 81 lakh rupees and profits of over 10 lakh rupees after covering costs of raw materials, wages, utilities, and depreciation.
This document provides a summary of the cement manufacturing process at Rawan Cement Works in Chhattisgarh, India. It discusses the key steps: mining limestone, preparing and storing raw materials, fuel preparation, clinkerization through pyroprocessing, cement grinding, and packing and dispatching. The plant has a production capacity of 5.17 million tonnes of clinker per year. It mines limestone from its captive quarry covering 722.834 hectares and uses various machines for crushing, transporting, and grinding the raw materials in its manufacturing process to produce different varieties and grades of cement.
ILSHIN AUTOCLAVE CO., LTD is a Korean company established in 1993 that specializes in manufacturing high pressure equipment. Their business areas include autoclaves, reactors, supercritical fluid systems, nano dispersers, presses, pressure vessels, and various testing equipment. ILSHIN aims to become a world-class company through technical development, manufacturing plant-scale equipment, gaining the number one market share, and globalizing their operations and partnerships.
The document provides details on analyzing and selecting a solution to reduce excessive quinoline insoluble (Q.I.) content in clarified coal tar from a steel plant in Eastern India. It includes:
1. A global survey of 9 Q.I. reduction techniques used worldwide, including solvent extraction, centrifugation, and filtration methods.
2. Calculations to determine the coal tar throughput of 58.5 tonnes/day based on the plant's coking capacity.
3. A scoring system to evaluate the techniques based on criteria like cost, efficiency, and product quality. High pressure CO2 separation and benzene solvent extraction scored highest.
4. The proposed solution focuses on these two techniques
This document provides details about a student's vocational training project studying the properties and performance of catalysts. It includes an acknowledgment section thanking the organizations that supported the project. It also includes a certificate signed by the project guide validating the student completed the project work. The document contains an index and introduces the project focus on studying the coke by-product plant and processes for purifying coke oven gas, specifically the removal of ammonia.
This document describes the design and testing of an aqua silencer. An aqua silencer is an exhaust silencer that uses activated charcoal and lime water to reduce emissions and noise from automobile exhaust. It works by splitting exhaust gases into small bubbles using a perforated tube, then passing the gases through an activated charcoal layer to filter pollutants before dissolving them into the surrounding lime water. Testing on a single cylinder engine showed the aqua silencer reduced carbon monoxide by 85%, hydrocarbons by 67%, and carbon dioxide by 75% compared to a conventional silencer, while also lowering noise levels. The aqua silencer provides effective emission control through the combined effects of activated charcoal filtration and lime water absorption
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The document provides details about the internship of Ashutosh Khushu at NIRMA LTD plant located in Bhavnagar, India. It discusses the various sections of the soda ash plant including brine preparation and purification, production of lime and gas cleaning, lime grinding and ammonia recovery, carbonation, and filtration and calcination. The internship helped Ashutosh gain practical experience and apply his theoretical knowledge to better understand how a real soda ash production system works.
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Attock Cement Pvt. Ltd Internship report.
VISION:
To be the leading organization continuously providing high quality cement, excelling in every aspect of its business and to remain market leader in cement industry.
1. | COMSATS INSTITUTE OF INFORMATION TECHNOLOGY LAHORE | July 29, 2015
INTERNSHIP REPORT
SUBMITTED TO:
Mr. TAUFIQ CHEEMA Technical Manager
Mr. ASIM QAISER Development Manager
SUBMITTED BY: Ansa Aman Ullah
DURATION: 4 Weeks
DEPARTMENT: Technical
COMPANY NAME: ICI SODA ASH BUSINESS KHEWRA
2. PAGE 1
Contents
1. INTRODUCTION ............................................................................................................................2
2. PROCESS CHEMISTRY....................................................................................................................3
3. PROCESS DESCRIPTION ................................................................................................................3
PFD: Soda Ash..................................................................................................................................................4
4. WEEKLY PROGRESS .......................................................................................................................5
4.1 1st WEEK-PROGRESS ........................................................................................................................ 6
Process flow of Soda Ash manufacture from the white book. ..................................................................... 6
Failure scenarios for Solid-Fluid Separators & Process Handling Equipment ............................................ 6
Steam Turbine Technology.......................................................................................................................... 6
Centrifugal Pumps........................................................................................................................................7
4.2 2nd WEEK-PROGRESS .......................................................................................................................7
Cooling Tower Basics and Common Misconceptions. .................................................................................7
Pressure Design of Straight Pipes................................................................................................................ 8
Project Phases & Management.................................................................................................................... 9
4.3 3rd WEEK-PROGRESS ....................................................................................................................... 9
Boiler Basics................................................................................................................................................. 9
Water-Tube boilers..................................................................................................................................... 10
Boiler Rating and Efficiency........................................................................................................................ 10
Pressurized Deaerators ............................................................................................................................... 11
4.4 4th WEEK-PROGRESS....................................................................................................................... 11
Manual Valves and Valve selection. ............................................................................................................ 11
Types of Steam Flowmeters. ........................................................................................................................12
Basic Control Theory and Modes of Control. ..............................................................................................13
Understanding Pump Performance Curves. ................................................................................................13
5. CONCLUSION & RECOMMENDATIONS...................................................................................... 14
6. REFERENCES................................................................................................................................. 15
3. PAGE 2
1. INTRODUCTION
ICI Pakistan Ltd. Soda ash business manufactures soda ash (sodium carbonate) by a commercially
known Solvay process. It is located in Khewra in the north part of the Punjab. The plant is situated in
an area where the two main raw materials namely limestone and salt are abundant. It is easily
accessible via road. Railway track also passes through Khewra. There is an airstrip at the worksite for
chartered flights to Lahore.
Two grades of chemically identical soda ash are produced one is the light ash (LA) and the other one
is dense ash (DA), with the only difference in their densities, 500g/l and 950g/l respectively.
The plant has a total production of 350KTPA LA and 84KTPA DA. 80% of ICI’s DA product falls in
the range of 16 Mesh to 120 Mesh. DA is mainly used in glass industry. ICI Soda Works also
manufactures 26KTPA Refined Sodium Bicarbonate (RSB). ICI Soda Works divided its whole
production in two main plant namely Plant A and Plant B with a total production of ? each respectively.
The total electrical requirement of the plant is 230KWatts/ton of Ash, out of which 180KW is self-
generated and while 50KW is supplied by WAPDA. Four steam turbines are utilized for self-generated
electricity and in case of a power cut from WAPDA two backup diesel engines are also available.
Sodium silicate, caustic, bicarbonate, steel, soap, pulp & paper, textile, water softeners, laundry &
many others consumes soda ash in one form or the other.
The company provides employment to the people of Khewra and its surrounding community. Workers
are provided with accommodation, health and education facilities since company has residential
colony, hospital and a secondary school within work premises. Hospital and school is rendering its
facilities to the surrounding community as well.
ICI Soda Ash Business has a department for its safety and security policy named as “Health, Safety,
Environment and Security” (HSE & S) as the company is well aware of its importance to hold a license
to operate. Their safety policies is based on believe and commitment. Almost 95 procedures are
mentioned in the Blue Book regarding safety. HSE &S includes Safety improvement Team (SIT),
Work To Permit (WTP), Environmental impact Assessment (EIA), Training Need Analysis (TNA),
Emergency Response Squad (22 membered,510 fire extinguishers), proper Auditing system and a
Learning-Event Database in its procedural working and setup. All these collectively rendered more
safe and secure environment for the company occupational as well as managerial works. Learning-
Event Database is provided with 24 categories of safety. M-form services are also incorporated for
any modification on plant site.
4. PAGE 3
2. PROCESS CHEMISTRY
The basic chemistry of the process is quite simple and is described by following reaction:
2NaCl + CaCO3 → Na2CO3 + CaCl2
However industrially it is complex enough to get the two ions of salt and two of limestone to change
places producing sodium carbonate and cannot be done directly, therefore ammonia is introduced as a
carrier for carbon dioxide. Therefore it is also known as Ammonia Soda Process.
3. PROCESS DESCRIPTION
To carry out the process ICI makes use of following raw materials:
Raw materials for Soda Ash manufacturing, 2015
Raw Materials PTA Source
Salt 1.66 tes PMDC, ICI Old Mines
Limestone 1.28 tes Tobar
Ammonia 4-4.5 kg Daood Hercules, Pak
American Fertilizers
Fuel 13.5 MMBTU SNGPL(natural gas),
PARCO(furnace oil),
Local & Imported coal
Water 8.5 m3
Waatli
Source: ICI Soda Ash Works
Following are the main section incorporated in the process:
1. Brine Basins
2. Kiln
3. Absorbers
4. Mono Carbonating Towers (MCT)
5. Solvay Carbonating Towers (CT)
6. Rotary filters
7. Distillation columns
8. Calciner
5. PAGE 4
In addition the process flow of the plant is briefly illustrated through PFD given below:
PFD: Soda Ash
The brine is prepared in the brine basins from water and salt and is sent to the absorbers where
ammonia is also introduced and absorption takes place here under. In the meanwhile coke along with
the lime in a preset ratio of 76kg/ton of limestone is introduced in the kilns where coke is burnt giving
off carbondioxide (CO2), which is sent to absorption section, liberating heat utilized in decomposition
of limestone to lime (CaO).This lime is then sent to the dissolver along with the water for milk of lime
(MOL).The sieved MOL is stored in the prelimers prior to pumping across distillation columns.
6. PAGE 5
Meanwhile, the ammoniated brine obtained from the absorption tower known as vat or green liquor
after cooling is pumped into the top of a series of towers called Mono-Carbonating Towers and Solvay
Towers. The purpose of Mono-Carbonating Tower is to partially carbonate ammoniated brine so that
NH3 absorbed in the brine is converted to ammonium carbonate (NH4)2CO3 while the main
carbonation occurs in Solvay Towers whereby carbondioxide gas is introduced for this purpose at
operating conditions of ?. A magma is produced, which comprises sodium bicarbonate (NaHCO3) in
crystal form which is washed through water in rotary filters, and ammonium chloride (NH4Cl) in
solution. There is liberation of a considerable amount of heat during carbonation which is removed by
water-cooled tubes at the bottom of the towers. The damp sodium bicarbonate is then fed into the large
rotary driers or calciners where heat through steam decomposes the sodium bicarbonate to give the
product with the evolution of strong CO2 and water. The carbondioxide gas is cooled, washed and
added to the gas from the kilns for reabsorption in the Solvay Towers. In addition, the NH4Cl solution
(spent process liquor) from Solvay Towers is sent to the distillation columns where ammonia is
recovered for reabsorption into brine. In the upper half of column the free ammonia is liberated by
heat through steam provided at the bottom of distillation columns and in the lower half the fixed
ammonia is liberated from Milk of Lime (MOL). Moreover, in order to economize on the use of steam
the feeder liquor is preheated in a column called the Caisse Cooler where heat exchange takes place
with outgoing gases.
There is a Dense Ash plant too for converting a part of the light ash produced to a product which is
twice as dense compared to light ash. Light soda ash is mixed with Soda Liquor in closely controlled
conditions to form monohydrate crystals, which are then dehydrated in a fluidized bed to give the
desired product:
Na2CO3 + H2O → NA2CO3.H2O + Heat (Sod. Carbonate Monohydrate)
Na2CO3.H2O + Heat → Na2CO3 + Heat (Dense Ash)
4. WEEKLY PROGRESS
During the internship learning based tasks were assigned as a scheduled activity along with few visits
to field area.
First two days specifically devoted to safety classes in which the basic and very essential learnings
were delivered of their safety, health, environment and security policy. A brief introduction was given
about the ICI’s well equipped and trained SHE department, which includes the working of their
Learning-Event Database, Blue Book procedures.
From the 3rd
day to onward, internship continued under the supervision of technical department. The
whole process was studied.
7. PAGE 6
4.1 1st WEEK-PROGRESS
In the 1st
week following sections were covered:
Process flow of Soda Ash manufacture from the white book.
Failure scenarios for Solid-Fluid Separators & Process Handling
Equipment
In this section, potential failure mechanisms and their design alternatives for reducing the risks
associated with such failures for solid fluid separators and solid handling and processing equipment
and were discussed. Most frequently used solid-fluid separators are the centrifuges, filters, dust-
collectors, cyclones & electrostatic precipitators. Ignition of flammable vapors in centrifuges by static
electricity, mechanical damages caused by friction, relief valve plugging in filters, dust deflagration
due to electrostatic spark discharge or glowing particles from the upstream equipment, fluid leakages
resulting from catastrophic bearing failure, mechanical failures and spills and leakages of flammable
or toxic liquids due to gasket failure are some of the common scenarios, all dictated by over-pressures,
high temperatures and loss of containments in one way or the other.
Their potential design solutions can be implemented inherently by modification or alteration in their
design scenarios on passive efforts also on active and procedural basis, when once encountered on
operation, through control actions on spot. Some of them includes permanent bounding and grounding,
using inert atmospheres, automatic deflagration and fire suppression system, emergency relief devices,
water deluge system, conveying solids as pellets instead of granules or powder and use of
nonflammable solvents.
Steam Turbine Technology
Steam turbines are one of the most versatile and oldest prime mover technologies still in general
production used to drive a generator or mechanical machinery. Unlike gas turbine and reciprocating
engine CHP systems where heat is a byproduct of power generation, steam turbines normally generate
electricity as a byproduct of heat (steam) generation. A steam turbine is captive to a separate heat
source and does not directly convert fuel to electrical energy. The energy is transferred from the boiler
to the turbine through high pressure steam that in turn power the turbine and generator. This enables
steam turbine to operate with an enormous variety of fuels. These are commonly industrially found in
paper mills, chemical plants, food industry (sugar mills) and commercially in district heating systems.
The process thermodynamics is based on Rankine cycle and can have variations according to the
particular need and application including condensing, non-condensing (back-pressure), extraction and
admission turbines. They are more rugged and with operational life often exceeding 50 years. Their
performance and efficiency enhancement can be incorporated through high pressures, steam reheat
8. PAGE 7
and combustion air preheating (from the boiler exhaust gas stream heat recovery) in large industrial
systems.
Centrifugal Pumps.
Centrifugal pumps have great application in the industry, with purpose of pumping fluid and imparting
energy for various needs. In addition to its basics various calculations and technical understanding
were performed including the head-versus pressure calculations, effect of specific gravity of fluid on
pumping, net positive suction head requirements, concepts related to gauge and absolute pressures,
suction lift and head, discharge head and total head and how all these parameters play a part in proper
operation of a pump were studied and discussed. Moreover, API for centrifugal pumps were also apart
of technical understandings.
To be well known to this equipment, a field trip was also organized under the supervision of Mr. Yasir
Akram where centrifugal pumps installed at various locations on the site were examined and their
operational technicalities discussed.
4.2 2nd WEEK-PROGRESS
Sections covered during 2nd
week:
Cooling Tower Basics and Common Misconceptions.
Cooling Tower is a simple equipment in comparison to most of the industrial equipments. The basic
principle of this device is that of evaporation condensation and exchange of sensible heat, itself it is
neither a heat source nor a heat sink. The capability of a cooling tower is a measure of how close the
tower can bring the water temperature to the wet-bulb temperature (WBT) of the entering air which is
basically the Approach of a cooling tower. The lower the WBT, which indicates either cool air, low
humidity or a combination of two, the lower the cooling tower can cool the water. Any approach less
than 5 °F is not customary in the industry. Moreover performance of a cooling tower is defined by
following five parameters:
1- Hot-water temperature (HWT), 2-Cold-Water temperature (CWT), 3-Wet-Bulb temperature
(WBT), 4-Water Flowrate (L), 5-Air Flowrate (G).
One misconception prevails regarding range of a cooling tower but it is to be known that the range
is completely independent of a cooling tower characteristics so it would be inappropriate to mention
that the tower is cooling the water let say 20°.Infact the measure of actual thermal capability of a
cooling tower is not the total amount of heat rejected rather it is the level at which this heat is rejected.
Moreover as the concept of Approach is concerned, with the fall in the WBT, CWT also goes down
but not in a one-to-one relationship i-e: for each 2°F drop in WBT the CWT will drop approximately
9. PAGE 8
1°F.Therefore, it might be possible that the approach of a cooling tower may differ from the designed
with changing weather conditions or more specifically the WBT.
In addition to these technical concepts, a problematic scenario was also assigned where on given
operating conditions heat load and makeup water were to be evaluated. It was done making use of the
following parameters and equations:
Approach (Two - Ta, wi) Temperature difference between the temperature of the condenser water
leaving the tower and the wet bulb temperature of air entering the tower.
Range (Twi - Two) Temperature difference between the temperature of condenser water entering the
tower and the temperature leaving the cooling tower.
Effectiveness of Cooling Tower =
Range
Approach + Range
x10
Blowdown: Water discharged to the drain periodically to avoid buildup of dissolved solids. The
Blowdown is 0.9 % of total circulating water flow.
Drift loss: Water droplets that are carried out of the cooling tower with the exhaust air. Drift droplets
have the same concentration of impurities as the water entering the tower. It is about 0.1 % of
circulating water.
Makeup (0.9%BD+0.1%DL+1.2%EL): Water added to the circulating water to compensate for the
loss of water to evaporation, drift, and blowdown. Evaporation losses are 1-1.2% of circulating water.
Heat-Load [Btu/hr.]=500 x water flowrate [GPM] x Range [°F]
The cooling tower on the work site were also visited to have a sound grip on the design of a tower
where there was a counter-current flow of induced cooling tower design.
Pressure Design of Straight Pipes.
Pipe thicknesses varies with the varying duty of design pressures therefore it is necessary to size a pipe
with a thickness to bear the pressure conditions with mechanical, erosion and corrosion allowances
known as minimum thickness required for a selected pipe (tm). It is given by:
tm=t + c
Where c is the sum of mechanical allowances (thread or groove depth) plus corrosion and erosion
allowances, and ‘t’ is the design pressure thickness, as calculated (for internal pressures):
t=PD/2(SE+PY)
All values for these parameter can be extracted from the relevant literature. Here the main objective
was to get use to the step by step calculations and how to proceed and go through various phases for
10. PAGE 9
one required parameter. This adds a basis to design scenarios that will surely be encountered in the
near future.
Project Phases & Management
Project scheduling and understanding/handling risk is crucial to success in science and engineering.
Project management is the art of matching a project goals, tasks. And resources to accomplish a goal
as needed that is within limited time, money and resources. It is more like to do the right thing with
the right tools in a right way.
While project is more like a process, it has a beginning and an end with various sequential phases. A
phase represents a grouping of similar activities that has a very loosely defined beginning and end.
Project lifecycle has four major phases namely initiation, planning, execution and project close-out.
The initiation involves:
1. Defining the goals of the project (document that list goals with short success defining
statement).
2. Defining project tasks/activities for set goals.
3. Determining and verifying resource requirements (time, money, people, space, equipment etc.)
4. Identifying risks and develop mitigation (backup) plans.
Planning holds:
Development of a complete schedule involving a giant chart which plots the tasks, people responsible
for these tasks, and a timeline. It also includes detailed staffing, procurement and project controls plans.
Whereas the execution phase is all about carrying out all these tasks and activities which are being
scheduled and plan for the accomplishment of the desired goals. During this phase a good
co0ordination among the members and a sound grip on documentation, modifications and reviews of
schedule and status are on keynote for the completion of a project.
And at last the close-out phase being after the goals have achieved, for revisions and improvements in
the future projects. Basically the performance of the project team is evaluated in this phase.
4.3 3rd WEEK-PROGRESS
3rd
week was engaged in tasks related to boilers:
Boiler Basics
A phase change occur in a boiler from liquid to steam by heating process. Mainly there are two types
of boilers, water tube boilers and fire tube boilers. Blowdown is carried to control the TDS of the
boiler water within the recommended limits. Make-up water is feed to compensate for losses due to
11. PAGE 10
steam generation and blowdown. Fire tube boilers generate saturated steam as heat is within tubes
surrounded by water to boil while the water tube boilers generate superheated steam where the water
is within tubes surrounded by heat for boiling/steam generation. Soft & BFW total hardness, dissolved
oxygen in BFW, return condensate pH, boiler water pH and TDS, Boiler water caustic alkalinity,
oxygen scavenger reserves and scale inhibitor reserves are some of the important operating parameter
for boiler systems.
Boiler water treatment is therefore necessary for proper operation where scale inhibitors, neutralizing
amines and oxygen scavengers are typically used to control parameters affecting the efficiency and
working of boiler systems.
Water-Tube boilers
Many of these operate on principle of natural water circulation (thermosiphoning). Cooler water is fed
into the steam drum behind a baffle where, because the density of the cold water is greater, it descends
in the downcomer towards the lower or mud drum, displacing the warmer water up into the front tubes
and the cycle continues. Heat is absorbed by radiant mode through furnace section lining (finned tubes),
and from hot flue gases by conduction and convection.
Economizer and super heater are the two main parts of a water tube boiler. Economizer is a heat
exchanger through which the feed water is pumped and this heat is taken off from the flue gases which
after passing through the boiler still hot enough to be used for improving the efficiency of a boiler. In
broad terms a 10°C increase in the feed water will give an efficiency improvement of 2%.
Super heater is also a heat exchanger where additional heat is added to the saturated steam to get
converted to the superheated steam. In water tube boilers it may be the additional pendant suspended
in the furnace area where the hot gases will provide the degree of superheat required.
Boiler Rating and Efficiency
There are three types of boiler rating commonly used:
‘From and at’ rating: the amount of steam in kg/h which the boiler can create ‘from and at
100°C’, at atmospheric pressure.
kW rating: Steam output (kg/h)=Boiler rating (kW) x [(36oos/h)/energy to be added (kJ/kg)].
It is not an evaporation rate but subject to the same ‘From and at’ factor.
Boiler horsepower (BoHP): Amount of energy required to evaporate 34lb of water at 212°F
atmospheric conditions. This unit tends to be used only in USA and Australia.
Boiler efficiency is simply relating the energy output to the energy input:
Boiler Efficiency (%) =Heat exported in steam/Heat provided by fuel x 100
12. PAGE 11
Where heat exported in steam is calculated through knowledge of feed water temperature, pressure at
which the steam is exported and the steam flowrate from steam tables.
To get in detail, few technical problems related to the boilers rating, efficiency and steam requirement
were done. All these helped to grasp more conveniently the boiler needs, how to keep it on safe side
of operation and get the maximum of it in an efficient way.
Pressurized Deaerators
Deaeration is an important pretreatment phase for the boiler feed water where the gases need to be
removed since oxygen is the main cause of corrosion in the boilers and CO2 presence also lower the
pH thus the water tend to be more acidic and the rate of corrosion increases. Moreover the essential
requirements to reduce the corrosion is to maintain the pH around 8.5-9, the lowest level at which the
CO2 is absent.
Operating principle: if a liquid is at saturation temperature, the solubility of a gas in it is zero.
The first step for treatment is to heat the water since the higher the temperature, the lower will be the
oxygen content. However, high temperature operation at atmospheric pressure can be difficult due to
the close proximity of the saturation temperature and the probability of cavitation in the feed pump.
Therefore oxygen scavengers (sodium sulphite, hydrazine or tannin) are used for further removal.
But the cases exist where plant due to their size, special application or local standards will need to
either reduce or increase the amount of chemicals used. For such plants it is common practice to use a
pressurized Deaerators.
These are mainly used for high pressure water tube boilers and steam plant handling superheated steam
where it is vital to keep the oxygen level less than 7bbp through pressurized Deaerators since the rate
of attack rapidly at higher temperatures due to dissolved gases.
Calculations were also made for the energy input (steam) requirements for Deaeration of a typical
boiler feed water.
4.4 4th WEEK-PROGRESS
In the last week, Process control and instrumentation relevant tasks were assigned:
Manual Valves and Valve selection.
Major function of a valve in fluid handling systems includes stopping and starting the flow, controlling
flowrate and diverting flow. There is also a grouping of valves by the method of flow regulation:
Closing-down valves (globe and piston), sliding valves (gate valves), rotary valves (plug, ball,
butterfly) and flex body valves (pinch, diaphragm).
13. PAGE 12
Valves for stopping and starting flow are normally selected for low resistance and straight-through
flow passages, these are usually sliding, rotary and flex body valves. Valves for controlling the
flowrate are typically closing down valves because of the directly proportional relationship b/w the
size of the seat opening and the travel of the closure member. Rotary and flex body may also be used
but only over a restricted valve-opening range. Valves for diverting flow have three or more ports
depending on the duty and are plug valves and ball valves.
Valves for fluids carrying solids in suspension must have a closure member that slides across the seat
with a wiping motion. Valves are provided with many types of end-connections, most important are
threaded, flanged and welding end-connections.
All these various valves types and their end-connection were observed at various locations at visit to
plant site under the supervision of Mr.Tanveer. During this visit, an introductory round to ICI
laboratory machinery and usage was also made. It was a good piece of knowledge earned that how the
analysis of all the raw materials and products were made prior to any big decision for their
specification and quality checks.
Types of Steam Flowmeters.
Among various types of flowmeters following are those suitable for steam and condensate
applications:
1. Orifice plate
2. Turbine (shunt and bypass type too)
3. Variable area
4. Spring loaded variable area (SLVA)
5. Direct in-line/targeted variable area
6. Ultrasonic
7. Vortex shedding
Their installation involves the pressure tapping positioning as well as factors related to the pipe-work
must be keen to known includes the minimum of downstream straight pipe dia and upstream straight
pipe dia where the latter is affected by the discharge co-efficient of the flowmeter [β=d(flowmeter
dia)/D (pipe dia)], nature and geometry of the preceding obstruction.
Orifices are used anywhere the flowrate remains within the limited turndown ratio of 4:1 to 5:1, this
may include the boiler house. Turbine flowmeters, with turndown ratio of 25:1, are for liquids,
condensates and insertion type of these may include the applications for steam (saturated
&superheated) and gas/air as well. Rota-meters with turndown ratio 10:1 are for metering of gases,
small air-flow metering, and lab applications. These are sometime used as flow indicating devices
rather than flow-metering. Whereas SLVA with high turndown ratio 100:1 are for boiler house and
14. PAGE 13
large plant applications. Ultrasonic are best suited for corrosive liquids as well as has typical
application in monitoring the fluids such as measuring condensate return. They can also be used for
energy monitoring. While the vortex shedding finds its application in direct steam measurements at
both boiler and point of use locations, also in natural gas measurements for boiler fuel flow.
Basic Control Theory and Modes of Control.
Control of a process is the most crucial factor in performance and success of a safe and efficient plant
operation, therefore it is always necessary to have complete control over the plant in order to get the
required output. A typical control system may consist of a sensing element, measuring device,
transmitter, controller and the final control element which of most cases are valves.
There are two basic modes of control:
Two step/Two position (On/off)-the valve is either fully open or fully closed, with no
intermediate state. These are simple and very low cost.
Continuous (modulating)-the valve can move between fully open or fully closed, or may held
at any intermediate position.
There are three basic control actions that are often applied to continuous control:
5. Proportional (P) action with adjustable gain to obtain stability.
6. Integral (I) action to compensate for offset due to load changes.
7. Derivative (D) action to speed up valve movement when rapid load changes take place.
Depending on the control requirement, following characteristic features help in selection of a more
appropriate duty:
Controller Response time Overshoot Error
Proportional Small Large Small
Integral Decreases Increases Zero
Derivative Increases Decreases Small change
Understanding Pump Performance Curves.
Pump performance curves are just like the control panel of the pumps. All operators, engineers,
mechanics, and anyone involved with the pumps should understand the curve and its elements, and
how the relate. The performance curve indicates that the pump will discharge a certain volume or flow
15. PAGE 14
(gpm) of a liquid, at a certain pressure or head (H), at an indicated velocity or speed, while consuming
a specific quantity of horsepower (HP).
Performance curve of a pump includes the following four curves on a common graph:
The Head-Flow Curve (H-Q Curve)
The Efficiency Curve
The Energy Curve (records Brake Horsepower-BHP)
The Pump’s minimum Requirement Curve (NPSHr curve)
With the curve, we can take the differential pressure gauge readings on the pump and understand them.
We can use these readings to determine if the pump is operating at, away (to the left or right) from its
best efficiency zone and determine if the pump is functioning adequately. We can even visualize the
maintenance required for the pump based on its curve location, and visualize the corrective procedures
to resolve the maintenance.
With all these technical facilities provided by these curves, it was quite good to learn about a pump
performance by knowing how to make best use of these curve and in practice how to evaluate these
parameters from the curves. That will be pretty good in the future works.
5. CONCLUSION & RECOMMENDATIONS
ICI Soda Ash Business is no doubt an emerging industry for young engineers to avail the opportunities
for their professional skills and experiences from interns to trainees and joining as an engineer to
impart their roles in the industrial sector. The environment here is friendly and co-operative. On
completion of my internship I have grasped valuable information relating working environment, time
and work management in addition to my engineering or more specifically technical knowledge. As a
fresh engineer one must know the various equipment used in industries with the best knowledge of
16. PAGE 15
how to operate them efficiently, therefore I have learned it during my internship which will definitely
add value to my career projects in future.
For conducting internships over here, Company and the concerned departments besides being enough
co-operative and responsible for their interns intellectual empowerment though if indulge their little
consideration towards more strategic, well organized and planned setup to share their experiences
among them will hopefully help in a good repute of company in the social as well as industrial sector.
So there might be a common room where combined meetings and sessions of these interns held where
they can share their routine activities and knowledge and where the supervisors and other experienced
personnel from the company rendered their precious time to impart fruitful information to the interns.
6. REFERENCES
1. Shahab Mufti, Technical Department. SODA ASH MANUFACTURING PROCESS AT
KHEWRA.2nd
edition. ICI Pakistan Ltd Khewra.
2. Cooling Tower Basic and Common Misconceptions. Jalal Engineering, oshuja@cyber.net.pk.
Page No. 1-6. [Accessed July 10, 2015]
3. http:/www.spiraxsarco.com/Resources/Pages/Steam.Engineering-Tutorials/the boiler
house/water-tube boilers.aspx. Page No. 1-6 [Accessed July 15, 2015]
4. Muhammad Hyder Raza, Sales Engineer. Presentation: Boiler Inspection & Boiler
Efficiency. ONDEO Nalco Gulf Ltd. [Accessed July 15, 2015]
5. http:/www.spiraxsarco.com/Resources/Pages/Steam.Engineering-Tutorials/the boiler
house/Boiler Ratings.aspx. Page No. 1-3 [Accessed July 16, 2015]
6. http:/www.spiraxsarco.com/Resources/Pages/Steam.Engineering-Tutorials/the boiler
house/Boiler Efficiency and Combustion.aspx. [Accessed July 16, 2015]
7. http:/www.spiraxsarco.com/Resources/Pages/Steam.Engineering-Tutorials/the boiler
house/Pressurized Deaerators.aspx. Page No. 1-9 [Accessed July 16, 2015]
8. http:/www.spiraxsarco.com/Resources/Pages/Steam.Engineering-
Tutorials/flowmetering/types-of-steam-flowmeter.aspx. Page No. 1-18 [Accessed July 24,
2015]
9. http:/www.spiraxsarco.com/Resources/Pages/Steam.Engineering-Tutorials/basic-control-
theory/basic-control-theory.aspx. Page No. 1-15 [Accessed July 24, 2015]
10. Steam Tables. ASME Steam Tables 1967 by The American Society of Mechanical Engineers.
11. Pilot API: Centrifugal Pumps.