Project Report

On
Plant design for production of
Sodium Hexametaphosphate
(Na6[(PO3)6])

By
Mr. Umesh R. Thorbole
(17CH051)
Mr. Krushna B. Shedge
(17CH046)
B.E. Chemical

In the guidance of
Dr. M. Y. Naniwadekar

DEPARTMENT OF CHEMICAL ENGINEERING

AISSMS COLLEGE OF ENGINEERING, PUNE - 411001

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 All India Shri Shivaji Memorial Society’s
College of Engineering, Pune-1

Certificate

This is to certify that the project entitled “Plant Design for

production of Sodium Hexametaphosphate”
Submitted by
Umesh R. Thorbole
(17CH051)
Krushna B. Shedge
(17CH046)
Is a bonafide work carried out by student under the supervision of
Dr. M. Y. Naniwadekar and it is submitted towards the partial
fulfillment of the requirement of Bachelor of
Engineering(Chemical Engineering).

Dr. M. Y. Naniwadekar Dr. P.N.Dange

Guide Head of Department

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 ACKNOWLEDGEMENT

I would like to express profound gratitude to our project Guide Dr. M. Y.

Naniwadekar , Head of Department Dr.P. N. Dange for their invaluable support, encouragement,
supervision and useful suggestion throughout this project work. The moral support and continuous
guidance enabled us to complete the work successfully. Last but not least, I am thankful and indebted
to all those helped directly and indirectly in completion of this project.

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 ABSTRACT
The main purpose of this project is to conduct a comprehensive study that
would lead ultimately to an integrated design, in a chemical engineering point of view, of a plant that
produces Sodium Hexametaphosphate(SHMP) with a production capacity specified in advance. This
study will take into consideration aspects including the plant's process unit design, process flow
diagrams, cost estimations, operation parameters, equipment sizing, construction materials and
environment/safety precautions. This project requires the theoretical and practical application of mass
transfer, heat transfer, fluid dynamics, unit operations, reaction kinetics and process control. There are
several tasks that are crucial to the completion of the project outlines including mass and energy
balances, Hysys simulation of the Process Flow Diagrams, design of the reactor, design of heat
exchangers, design of the crystallizer, energy optimization, economic analysis and hazard analysis.

Sodium Hexametaphosphate (Na6[(PO3)6]), the target product of the project's

plant, is an inorganic compound which is basically polymer of sodium orthophosphate. It acts as a
water softner in boiler water of power plant and other industrial water,and widely used as food quality
improver and preservative in food industry.. The most widely produced grade is in crystalline grain
size of crystallized glass sheets. In this project's study, SHMP is to be produced through neutralization
reaction followed by melt polymerization at higher temperatures by following reaction:

The desired reaction is endothermic with a overall yield of 90-92%. The project's
target is to design a plant with a capacity of 100 kg SHMP/hr. This plant is to include three major
units; a reactor, an crystallizer, an filter, mixing tanks. Also it includes pumps, rotary dryer, and
condenser. All are to be designed and operated according to this production capacity.

List of Figures

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Fig. 1.1 Molecular Structure of SHMP

Fig. 2.1 Process Flow Diagram of SHMP by Soda Ash Method

Fig. 3.1 PFD of SHMP from Sodium Choride Method (Mass Balance)

Fig. 3.2 Mass Balance for H3PO4 Dilution Tank

Fig. 3.3 Mass Balance for NaCl Saturator

Fig. 3.4 Mass Balance for Mixing Tank

Fig. 3.5 Mass Balance for Pump

Fig. 3.6 Mass Balance for Reactor

Fig. 3.7 Mass Balance for Crystallizer

Fig. 3.8 Mass Balance for Filter

Fig. 3.9 Mass Balance for Rotary Dryer

Fig. 3.10 Mass Balance for Pulverizer

Fig. 3.11 Mass Balance for Screening

Fig. 3.12 Mass Balance for Condenser

Fig. 4.1 Energy Balance of H3PO4 Dilution Tank

Fig. 4.2 Energy Balance of NaCl Saturator

Fig. 4.3 Energy Balance of Mixing Tank

Fig. 4.4 Energy Balance of Pump

Fig. 4.5 Energy Balance of Reactor

Fig. 4.6 Energy Balance of Crystallizer

Fig. 4.7 Energy Balance of Filter

Fig. 4.8 Energy Balance of Rotary Dryer

Fig. 4.9 Energy Balance of Pulverizer

Fig. 4.10 Energy Balance of Screening

Fig. 4.11 Energy Balance of Condenser

Fig. 5.1 A Typical CSTR Reactor

Fig. 5.2 CSTR Reactor with mass flow rates of Inlet and Outlet

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Fig. 5.3 Power Curve for Reactor Configuration

Fig. 5.4 Temp. profile of hot and cold fluid

Fig. 5.5 Utility Line Diagram of Manufacturing of SHMP

Fig. 5.6 P&ID Diagram of CSTR

Fig. 5.7 P&ID Diagram of Condenser (SATHE)

Fig. 5.8 Plant Layout of Manufacturing of SHMP

List of Tables
Table. 2.1 Parameters for Selection of Process

Table 3.1 Gibbs Energy of Formation of Reactants and Products

Table 3.2 Excel Sheet Mass Balance of SHMP

Table 3.3 Excel Sheet of Mass Balance of All Streams

Table 4.1 Excel Sheet of Energy Balance of All Streams

Table 6.1 Excel Sheet for TPC and Selling Price for Manufacturing of SHMP

Table 6.2 Excel Sheet of Fixed Capital Investment for Manufacturing of SHMP

Table 6.3 Excel Sheet of Break-even point for Manufacturing of SHMP

Contents
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1.Introduction.………………………………..…………...7

2.Literature Survey.…………………….………………..1

3.1 Introduction

3.2 Process No.1 - Soda Ash Method

3.3 Process No.2 - Sodium Chloride Method

3.4 Process No.3 - Caustic Soda Method

3.5 Selection of Process

3.6 Conclusion

3. Mass Balance ………………………...……...………..18

∆G of formation of components.

∆G of overall reaction.

Flowsheet mass balance.

Component mass balance.

Summary

4. Energy Balance……..………………………………...30

Specific heat capacities (Cp) of reactants and products.

Specific heat capacities of mixture.

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 Energy balance of reaction.

Component energy balance.

Summary

5. Equipment Design and Sizing…………………..…43

Reactor Design

Condenser Design

Utility Line Diagram

P&ID Diagram

Plant Layout

6. Costing……………………………….……………….62

Total Product Cost

Fixed Capital Investment

Break-even Point

7. Results………………………………………………….70

8. Final Conclusion…………………………………......72

9. References..…………………………………..………..74

10. Bibliography…………………………………………75

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1. Introduction
Sodium hexametaphosphate (SHMP) is a hexamer of sodium orthophosphate which contains six
repeating phosphate units. It is a kind of sodium metaphosphate polymers. It is also known as
"polyvinylidene sodium," "sodium multiple metaphosphate", "sodium metaphosphate vitreous body",
and "Graham salt". It was first prepared in 1963 by german chemist “Erich Thilo” and Ulrich Schulke.

It is a colorless transparent glass-like solid or white powder with greater solubility but low dissolving
rate in water. Its aqueous solution exhibits acidic property. Its complex of divalent metal ion is
relatively more stable than the complexes of mono-valent metal ion. It can easily be hydrolyzed to
orthophosphate in warm water, acid or alkali solution. Hexametaphosphate has a relative strong
hygroscopicity with being sticky after absorbing moisture. For certain metal ions (e.g., calcium,
magnesium, etc.), it has the ability to form soluble complexes, and thus being able to being used for
demineralizing water. It can also from precipitate with lead and silver ions with precipitate being re-
dissolved in excess amount of sodium hexametaphosphate solution to form a complex salt. Its barium
salt can also form complexes with the sodium hexametaphosphate.

Fig. 1.1 Molecular Structure of SHMP

Properties
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 ➢ Molecular Wt. 611 g/mol

➢ Appearance White crystals, Odorless

➢ Density 2.484 g/cc

➢ Melting Point 6280C

➢ Boiling Point 15000C

➢ Solubility Soluble in water

Insoluble in organic solvents

➢ Refractive Index 1.482

➢ CAS No. 10124-56-8

Toxicity

Adult 0~70 mg/kg (in terms of phosphorus); LD50:4g/kg (rat, oral). According to the provision of the
GB2760-86, it is allowed for being applied to canned food, fruit juice drinks, dairy products, soy milk
as quality improver; the maximum usage amount is 1.0 g/kg. When being used as composite phospha
te, calculated as the total phosphate, the canned meat products shall not exceed 1.0 g/kg; for condensa
tion of milk, it shall not exceed 0.50 g/kg.

Uses
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1. It is less frequently for being used alone and is generally used in mixture with pyrophosphate and
metaphosphate.

2. It can be used as a food quality improver in food industry, pH adjusting agent, metal ion chelating
agents, dispersants, extenders, etc. It can be used as a kind of common analytical reagents, water and
also used for photofinishing and printing.
3.It can be used as a detergent, preservative, cement hardening accelerator, fiber dyeing and cleaning
agents; it can also used for medicine, food, petroleum, printing and dyeing, tanning, and paper industry.
4. It can be used as texturizing agent; emulsifiers; stabilizer; chelating agent. The mixture is mainly
used for ham, sausage, surimi such as the tissue improver for water retention, tendering and meat
softening. It can also be used for prevention of crystallization of canned crab as well as dissolving
agent of pectin.

5. It can be used as the water softening agent of boiler water and industrial water (including water for
the production of dyes, water for the production of titanium dioxide, water for printing and dyeing,
and slurry mixing, water for cleaning color copy of the film, as well as chemical industrial water and
the water for the medicines, reagents production, etc.) as well as the water treatment agent for the
industrial cooling water; it can also be used as a corrosion inhibitor, flotation agent, dispersant agent,
high temperature binding agent, dyeing auxiliaries, metal surface treatment, rust inhibitors, detergent
additives and also cement hardening accelerator.

6. Coated paper production can use it as pulp dispersants in order to improve the penetration capability.
In addition, it can also be apply to the washing utensils and chemical fiber in order to remove iron ions
of the pulp.

7. In the oil industry, it can be used for the antirust of the drilling pipe and adjusting the slurry viscosity
upon the control of oil drilling.
8. It can be used as the quality improver with various effects of increasing the complex metal ions of
food, pH, ionic strength, thereby improving the adhesive capability as well as the water holding ability
of food.

9. China provides that it can be applied to the dairy products, poultry products, ice cream, instant
noodles and meat with the maximum permitted amount being 5.0 g/kg; the maximal permitted usage
amount in canned food, fruit juice (flavored) drinks and vegetable protein drink is 1.0g/kg.

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It can be used as a food quality improver in food industry and applied to canned food, fruit juice drinks,
dairy products, and soy milk.

10. It can be used as Ph adjusting agent, metal ion chelate agent, adhesive and bulking agents. When
being applied to beans and canned fruits and vegetables, it can be stabilize the natural pigment and
protect the food color and lustre; when being used in canned meat, it can be used for preventing the
emulsification of the fat and maintaining its uniform texture; when being applied to meat, it can be
used to increase the water holding capacity and prevent the deterioration of fat in the meat. It can also
help to clarify the wine when being supplied to beer and further prevent turbidity.

11. It also has applications in fabric dyeing, tanning, paper, color film, soil analysis, radiation
chemistry and analytical chemistry and other departments

Current Global Production

➢ The SHMP production mainly concentrates in China. Each year, China exports about 50000
MT SHMP to the world. USA is a net importer of SHMP.

➢ Other than China; USA, India, Germany, Czech Republic, Indonesia are major Producers.

➢ The largest consumption region is Asia-Pacific with annual consumption of 309749 MT

followed by Europe who held 12% share annually.

➢ The global SHMP market in 2020 values at 569.8 million USD and expected to reach 692.9
million USD in 2026 with growth rate of CAGR 2.8% during 2021-2026.

➢ The major manufacturers are Aditya Birla Chemicals, Prayon, ICL, Xingfa Group, Sundia,
Northwest Chemical, Mexichem, TKI, Recochem, Innophos, Chengxing Group, Chuandong
Chemical, Blue Sword Chemical, Mianyang Aostar, Sino-Phos Jinshi, Norwest Chemical,
WeifaHuabo, Nandian Chemical, Huaxing Chemical, Kindia May, Tianjia Chemical, Tianrun
Chemical, Zhenhua Industry.

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Why it is important ?
1. Since Indo-China Trade war in 2020 and US-China trade war in 2019, US already imposes
anti-dumping duty on SHMP from china to end its monopoly. US is also looking for new
manufacturers.

2. Now India has great opportunity for global exports of SHMP with less costly raw material,
cheap labour and government incentives.

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 2. Literature Survey

Process No.1 : Soda Ash Method

by Zhang Yaohua (P.No. CN105712331A)
Raw materials:- Soda Ash, Phosphoric Acid.

Catalyst :- KOH and NaClO3

Equipments :- Neutralization Kettle, Filter, Dryer, Quartz Crucible, Rotary Dryer , Pulverizer.

Reactions:-

Process Flow Diagram

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 Fig. 2.1 Process Flow Diagram of SHMP by Soda Ash Method

Process Description:-
It is the neutralization reaction followed by melt
polymerization at high temperature and rapid cooling. The soda solution was subjected to
neutralization reaction with phosphoric acid solution at 80-1000C for 2 hours which results in
monosodium orthophosphate solution;which then concentrated by evaporation, cooling, filtering and
dewatering into dryer at 110-130°C with moisture content of 0.1-0.2 %. Then it is fed to into silica
crucible and heated gradually towards 630-650°C to remove all water resulting in molten sodium
hexametaphosphate. Then the chilling shock is applied to sodium hexametaphosphate by Rotary Dryer
which brought down temp. from 650 to 80°C. Then it is crystallised and send to pulverizer for Sizing
and further for packaging.

Process No.2 - Sodium Chloride Method

By Chen Mei’e, Zhang Weigong, Yu Yuoping (P.No. CN101462711A)

Raw materials:- Sodium Chloride, Phosphoric Acid.

Catalyst :- Phosphatase 11, Phosphatase 79

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Equipments :- Mixing Tank, Pump, Filter, Dryer, Quartz Crucible, Condenser, Rotary Dryer ,

Pulverizer.

Reactions:-

Process Flow Diagram

Fig. 2.2 Process Flow Diagram of SHMP by Sodium Chloride Method

Process Description:-
This is the second method which is called sodium chloride method.
The raw materials are Sodium Chloride and phosphoric acid. Here Sodium Chloride and phosphoric
acid are evenly mixed at ratio of 1:1 in the mixing Tank. Then it is subjected to melt polymerization
in the furnace at temperature at 650-700 degree celcius for at least 30min to form melt sodium
hexametaphosphate and removal of all HCl produced. Then product is subjected to rapid cooling to
be glassy or further sent to pulverizer for crushing, sizing and packaging to make white crystal sodium
hexametaphosphate powder in which P2O5 content in SHMP reaches more than 67.5%.

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Process No.3 - Caustic Soda Method
By Qu Yun, Zohang Yajuan, Fan Jiali, Yang Jiaxin, Li Wei
(P.No. CN105329871A)

Raw materials:- Liquid Caustic Soda(48% by conc.), 80% Phosphoric Acid,

Catalyst :- Sodium Nitrate (0.05-0.2%),

Equipments :- Neutralization Kettle, Filter, Dryer, Quartz Crucible, Rotary Dryer , Pulverizer.

Reactions:-

Process Flow Diagram

Fig. 2.3 Process Flow Diagram of SHMP by Caustic Soda Method

Process Description:-

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 Then the last one is caustic soda method which usually used for
production of food grade SHMP. Here raw materials are liquid caustic soda (NaOH) 48% by
concentrated phosphoric acid (80% concentration) and 0.05 to 0.2 % sodium nitrate which act as
catalyst. First caustic soda liquid is added into neutralization kettle and then phosphoric acid is slowly
added into caustic soda under agitation . This reaction is exothermic. The reaction continue until sticky
shape solution is formed. Then sodium nitrate is added into centralised solution with the temperature
about 95-100 degree celcius. The monosodium orthophosphaste is formed. Then after cooling,
filtration and dewatering into dryer it is fed to furnace. The temperature is kept in furnace at about
650-180 degree celcius for about 45-90 min . Then the molten SHMP is rapidly cooled and make
powdered by quenching , pulverizing sents to packing.

Selection of Process:-
This is the table below for selection of process. The selection is based upon
the following parameters such as Temperature, Pressure, Mole Ratio, Catalyst, Polymerization Degree,
P2O5 content, By-product, Moisture content and Conversion.

Table. 2.1 Parameters for Selection of Process

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Conclusion
In conclusion of Literature Survey, we conclude that Process No.2 which is Sodium Chloride Method
is best for production of Sodium Hexametaphosphate.

Because,

It is simple process with less equipments and short production flow, convenient operation and easy
realization of industrialized production.

The starting material NaCl is cheap and easy to get as compared to starting material of other process
which more costly.

High P2O5 content in formed SHMP represents good quality.

Then the phosphoric acid which is expensive raw material is required less amount in this process than
other two processes.

With low polymerization degree and high conversion rate this is the best method for production of
Sodium Hexametaphosphate.

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 3. Thermodynamic Feasibility and
Mass Balance of Process

4.1 Thermodynamic Feasibility of Reaction

Thermodynamic feasibility of reaction is depends upon ∆G i.e. Gibbs free energy of reaction.
If ∆G is negative, more likely less than -50kJ/mol then the reaction is feasible.

∆G of formation of components.
In order to calculate the ∆G of reaction we will need the ∆G of formation of all
compounds i.e. all reactants and products. These are the the ∆G of formation of all compounds in the
reaction in the table below:

Table 3.1 Gibbs Energy of Formation of Reactants and Products

We calculated all these values from “Carl Yaws Chemical Engineering Handbook” and “CRC
Handbook of Chemistry and Physics”.

Also we calculated the ∆G of formation of SHMP from Gaussian Software; a computational

chemistry software which uses group contribution method for calculations.

∆G of overall reaction
∆Greaction = (∑n.∆fG0)product - (∑n.∆fG0)reactant

∆Greaction = [(6*∆fGH2O) + (6*∆fGHCl)+ (1*∆fGSHMP)] - [(6*∆fGNaCl) + (6*∆fGH3PO4)]

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 ∆Greaction = [(6*-288.60) + (6*-95.30)+ (1*-8262.86)] - [(6*-384.10) + (6*-1123.6)]

∆Greaction = -168 kJ/mol.

Here, we have calculated gibbs free energy of overall reaction which is -168 kJ/mol which is
less than -50kJ/mol. So, the reaction is feasible.

Flowsheet mass balance.

Fig. 3.1 PFD of SHMP from Sodium Choride Method (Mass Balance)

In the above Process Flow diagram we can see the all the equipments and all the streams with unique
stream numbers.

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 Table 3.2 Excel Sheet Mass Balance of SHMP

Now on the basis of 100 kg/hr of SHMP production we have calculated the theoretical amount of
raw materials required for given production and by-product values also. From the calculation we
need 57.37 kg/hr of NaCl and 110.5265 kg/hr of phosphoric acid.

But by yield calculation, the real amount of raw materials is 63.06 kg/hr og NaCl and 124.27 kg/hr of
phosphoric acid.

Component mass balance.

Here, we are going to see mass balance of each component.

1. H3PO4 dilution tank

ṁ1 = 124.27 kg/hr

ṁ2 =7.76 kg/hr

ṁ3 = 132.03 kg/hr

Phosphoric acid available in market is 85% by concentration and we need 80%

concentration for our process . So we add 4.8kg/hr of water into 110.53kg/hr of H3PO4 to reduce
concentration and mix thoroughly in this dilution tank. The resulting stream is 80% 115.32 kg/hr
H3PO4.

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 Fig. 3.2 Mass Balance for H3PO4 Dilution Tank

2. NaCl Saturator
ṁ4 = 63.06 kg/hr

ṁ5 = 175.155 kg/hr

ṁ6 = 238.211 kg/hr

ṁ22 = 3.5854 kg/hr

ṁ23 = 3.5854 kg/hr

As we know, NaCl in market is in the crystalline form but we need aqueous

solution of NaCl for our process. So we will add 159.36kg/hr of water into into 57.37kg/hr of NaCl
with constant heating from steam . We calculated the amount of water to be added from the solubility
of NaCl in water which is 360g/l . The resulting stream is 216.73 kg/hr aqueous solution.

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 Fig. 3.3 Mass Balance for NaCl Saturator

3. Mixing Tank
ṁ3 = 132.03 kg/hr

ṁ6 =238.21 kg/hr

ṁ7 = 370.291 kg/hr

Mixing tank is basically continues stirred tank which mix H3PO4 and NaCl at
right proportion in order to feed the reactor. Here resulting stream is 332.05 kg/hr of NaCl and H3PO4
solution at 1:1 mol ratio.

Fig. 3.4 Mass Balance for Mixing Tank

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4. Pump
ṁ7 = 370.29 kg/hr
ṁ8 = 370.29 kg/hr
We use centrifugal pump in order to fed the stream coming from mixing tank to the reactor.

Fig. 3.5 Mass Balance for Pump

5. Reactor
ṁ8 = 370.29 kg/hr
ṁ9 = 261.81 kg/hr
ṁ18 = 108.48 kg/hr
This is the main component of our process. The outlet stream from pump is fed to
reactor where it is heated at 650-700 degree celcius for about 30min of residence time which converts
feed into SHMP by melt polymerization and removal of HCL produced takes place. The HCL forms
azeotrope with water and leave the reactor from top. The remaining SHMP and water are further sent
to crystallizer at rate of 261.81 kg/hr and HCL , water , azeotrope is fed to condenser for further cooling
at the rate of 108.48 kg/hr.

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 Fig. 3.6 Mass Balance for Reactor

6. Crystallizer
ṁ9 = 261.811 kg/hr
ṁ10 = 223.57 kg/hr

ṁ25 = 15.202 kg/hr

ṁ26 = 1468.80 kg/hr
ṁ27 = 1468.80 kg/hr
The stream from reactor fed to crystallizer which contains SHMP and water
which crystallizes SHMP and further sent to filter and remaining mother liquor is removed. Here we
need rapid cooling for high purity. Cooling is done by cold water. M.L. is further sent to recycle.

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 Fig. 3.7 Mass Balance for Crystallizer

7. Filter
ṁ10 = 246.609 kg/hr
ṁ11 = 140.368 kg/hr

ṁ12 = 106.18 kg/hr

Filter removes 95% of water from feed . Here 140.368 kg/hr of water filtrate is removed
which is sent for further reuse. The remaining 106.18kg/hr stream from filter is sent to rotary dryer .

Fig. 3.8 Mass Balance for Filter

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8. Rotary Dryer
ṁ12 = 106.18 kg/hr
ṁ13 = 101.2372 kg/hr
ṁ14 = 14.8 kg/hr

ṁ15 = 19.7428 kg/hr

Rotary dryer removes the most of remaining water from feed. Which produces

99% pure SHMP . We 14.8 kg/hr of flue gases and air for drying in rotary dryer . The outlet stream

from rotary dryer is 99% 101.2372 kg/hr SHMP.

Fig. 3.9 Mass Balance for Rotary Dryer

9. Pulverizer
ṁ13 = 101.2372 kg/hr
ṁ14 = 101.2372 kg/hr

Pulverizer crushes the SHMP crystal chunks to required size for customers.

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 Fig. 3.10 Mass Balance for Pulverizer

10. Screening
ṁ16 = 101.2372 kg/hr
ṁ17 = 100 kg/hr

ṁ24 = 1.2372 kg/hr

Now screening is to be done to remove large size SHMP grains which gives us
the final product which is 99% 100kg/hr pure SHMP.

Fig. 3.11 Mass Balance for Screening

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11. Condenser
ṁ18 = 108.48 kg/hr
ṁ19 = 108.48 kg/hr
ṁ20 = 732.7 kg/hr

ṁ21 = 732.7 kg/hr

Now back to the reactor, the by-product HCL is cooled down in the condenser by
water which gives us 33% liquid HCL which further stored in storage tank.

Fig. 3.12 Mass Balance for Condenser

Summary
We have calculated all the mass flow rate using excel. This is the snapshot of our excel sheet.

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Table 3.3 Excel Sheet of Mass Balance of All Streams

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 4. Energy Balance of Process
Now we are going to see energy balance of our process. So what us
energy balance and why are we doing it? In Chemical engineering energy balance is the consideration
of energy input, output and consumption or generation in a process or storage. It is bases on first law
of thermodynamics. It has many benefits. It gives us heat required for a process, rate of heat removal
from process . It helps to design heat exchangers to determine energy requirement of a process also
pattern of energy usage , process control and process design and development.

Specific heat capacities (Cp) of reactants and products.

There are many methods and approaches to calculate energy balance of a
process out of which we are choosing the method of calculation based on specific heat capacities of
reactants and products. These are the Cp values of reactants and products , we got all these values from
Carl Yaws Chemical engineering handbook.

Specific heat capacities of mixture.

Now we know that most of streams are mixture of two or more product. So, this is the formula for
calculating specific heat capacities of mixture Cp(mix).

Cp(mix) = ∑xi.Cpi (i =1,2,3,4,5,……,n)

where,

xi = mass fraction of ‘i’ th component in the mixture.

Cpi = specific heat capacity of ‘i’ th component.

Energy balance of reaction.

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Now we calculated heat of reaction by the following formula -

∆Hreaction = (∑∆fH0)product - (∑∆fH0)reactant

∆Hreaction = [(6*∆fHH2O) + (6*∆fHHCl)+ (1*∆fHSHMP)]

- [(6*∆fHNaCl) + (6*∆fHH3PO4)]

∆Hreaction = [(6*-285.8) + (6*-92.30)+ (1*-7339.02)]

- [(6*-411.12) + (6*-1271.7)]

∆Hreaction = +489.3 kJ/mol.

By calculation heat of reaction is 489.3 kj/mole. So, obviously heat is required for the reaction i.e. the
reaction is endothermic.

Component Energy Balance.

1. H3PO4 dilution tank

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 Here we dilute 85% phosphoric acid to 80% phosphoric acid by adding water at
710C. The resulting stream is 80% phosphoric acid at 350C.

Fig. 4.1 Energy Balance of H3PO4 Dilution Tank

2. NaCl Saturator

NaCl is dissolved in water to form aqueous NaCl solution. We provided heat by

steam at 95-1000C to heat the solution and to increase solubility. The resulting stream is aqueous NaCl
at 350C.

35
 Fig. 4.2 Energy Balance of NaCl Saturator

3. Mixing Tank

Mixing tank is used to provide feed to the reactor at mole ratio of 1:1. Here both
H3PO4 and NaCl are mixed to feed the reactor via pump . The resulting stream is at 350C.

Fig. 4.3 Energy Balance of Mixing Tank

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4. Pump

Pump feeds NaCl-Phosphoric acid mixture to the reactor at 350C.

Fig. 4.4 Energy Balance of Pump

5. Reactor
This is core of our energy balance. Feed from pump is heated from 350C to 6750C for
about 30 min of residence time by natural gas supply. Here NaCl and H 3PO4 fuses together to form
Sodium Hexametaphosphate and HCL and water as byproduct. SHMP removes from bottom at 7000C
for further crystallization and HCL forms azeotrope with water and leaves the reactor from top at
7000C.

37
 Fig. 4.5 Energy Balance of Reactor

6. Crystallizer
In crystallizer, SHMP is crystallizes out with water and cools down at 80 0C. The
mother liquor is removed at 770C for further recycling. The SHMP and water stream is fed to
the filter at 800C.

38
 Fig. 4.6 Energy Balance of Crystallizer

7. Filter
In filter it removes 95% water from input stream and cools down at 250C for further
reuse. The remaining SHMP stream is then fed to the rotary dryer at 250C.

Fig. 4.7 Energy Balance of Filter

39
8. Rotary Dryer
Now rotary dryer is used to again remove the water from input stream. Here air and
flue gases stream which is at 1200C is passed through SHMP stream resulting removal of most of the
moisture and produce 99% SHMP . The output SHMP stream is at 400C and flue gases and air with
moisture cools down to 300C by heat transfer in rotary dryer.

Fig. 4.8 Energy Balance of Rotary Dryer

9. Pulverizer
Now pulverizer is used for crushing the SHMP crystal chunks to required size for
customers. Here output SHMP stream cools down at 300C by natural heat transfer.

40
 Fig. 4.9 Energy Balance of Pulverizer

10. Screening
After that screening is done to remove large SHMP crystal chunks which gives us final
product i.e.99% 100kg/hr of SHMP where it further packed and stored at 250C.

Fig. 4.10 Energy Balance of Screening

41
11. Condenser
Now back to the reactor, HCL- water vapour azeotrope stream which is at 7000C need
to be cool down which is done by condenser. The cold water at 18 0C fed to condenser cools down
HCL at 200C which will further stored in storage tank. The cold water is converted into steam by heat
transfer in condenser which we reuse further for our process.

Fig. 4.11 Energy Balance of Condenser

42
 12. Summary
In summary we have calculated all these values at Q and Cp(mix) in the Excel .
This is the snapshot of our energy balance Excel sheet. Here we can see all the values of Cp, Cp(mix),
mass fraction of all stream and Q values. So, it is easy to manipulate calculations if there are any
changes in process parameters.

Table 4.1 Excel Sheet of Energy Balance of All Streams

43
 5. Equipment Design and Sizing

Reactor Design

Fig. 5.1 A Typical CSTR Reactor

We choose Continuous Stirred Tank Reactor (CSTR) for our process.

This is the reaction of the process.

The Limiting Reactant (CA) is H3PO4 .

So, the inlet stream ṁ8 is volumetric flow rate vo .

ṁ8(vo) = 370.29 kg/hr = 0.28165 m3/hr ……………(dividing by density)

 From CSTR performance equation τ = V/vo = (CAo,XA)/(-rA)

44
 We calculated ,

FAo = G/(MMA) = 0.0002994 kmol/s

CAo = 3.4774 kmol/m3

Residence Time = 30 min.

rA = 0.001758 kmol/m3.s

Fig. 5.2 CSTR Reactor with mass flow rates of Inlet and Outlet

Reactor Sizing

1. Volume of the reactor -

τ = V/vo

Where, τ = Residence Time = 30 min. = 0.5 hr

vo = 0.28165 m3

So,

V = 0.140825 m3

Total Volume = V + (10% Head Volume)

 VR= Total Volume of the Reactor = 0.155 m3

45
Now we are going to calculate height and diameter of the reactor.

2. Height and Diameter of the reactor –

Consider – H/D ratio = 1.5

Volume of the cylinder (VR) is ,

VR = (π/4)D2H

VR = (π/4)D2(1.5D)…………………(Putting H= 1.5 D)

DR = 0.51m

HR = 1.5DR = 0.765m

Now we are going to calculate Reactor Pressure by ideal gas formula ,

PV = nRT

P = (n/V)RT

P = (CAo)RT

Reactor Pressure (P) = 0.0034774*0.082*948

= 0.27 atm

PR = 1 atm + 0.27 atm = 1.3 atm

Now next is reactor head dimension. We choose spherical head for our reactor.

3. Reactor Head Dimension –

Head Diameter is equal to reactor diameter. So ,

DH = DR = 0.51 m

Head Height – HH = DR/2 = 0.255 m.

Head Volume – VH = (π/12)DR3

46
 VH = 0.0140834 m3

Next is Stirrer design. We choose Radial Turbine Stirrer with 6 blades.

4. Stirrer Design –

Stirrer Clearance – C = DR/6 = 0.085m

Stirrer Length – LH = HR - C = 0.68m

Stirrer Diameter (Dst) = DR/3 = 0.17 m

Stirrer Blade width(WB) = Dst /5 = 0.034m

Wall baffle (W) = DR/10 = 0.051m

Now next is Stirrer Power Consumption.

 Stirrer Power Consumption –

The Power formula from M.V.Joshi -

Power – P = (Np*ρ*N3* D5st )/(g*75)

where

P power is in hp.

ρ is density of the fluid in kg/m3 .

N is Stirrer speed in rps.

Dst is stirrer diameter in meters.

g is the acceleration due to gravity in m/s2

Np is the power factor. It depends on Reynolds no.

So, first we calculate Reynolds No.

Reynolds no. = (N*Dst2*ρ)/ μ

where,

47
N =Stirrer speed = 480rpm = 8 rps

ρ = Density of fluid = 1345 kg/ m3

μ = Viscosity of fluid = 0.0017914 cP

Reynolds no. (Re) = 173587.13

Fig. 5.3 Power Curve for Reactor Configuration

From graph If Re> 104 then Np = 6.1

Putting all the values in Power formula ,

Power (P) = (Np*ρ*N3* D5st )/(g*75)

We get ,

P = 0.8107 hp

Pactual = P + Gland Loss + Transmission Loss

Where,

Gland Loss is generally 10% of the Power (P)

Transmission Loss is generally 20% of the Power (P).

So,

Pactual = 0.8107 + (10% of P) + (20% of P)

48
 Pactual = 1.07 hp

But it is advisable to use 1.5 hp motor electricity load fluctuation.

Now we are going to see reactor jacket design.

5. Reactor Jacket –

First we are going to calculate mass flow rate of heating fluid (ṁw) by the formula ,

ṁw) = Q/(Cp* ΔT)

Where ,

Heat required = Q = 671747.078 kJ/hr = 186596.4 kJ/s

Heat Capacity of Heating Fluid = Cp = 2.67 kJ/kg.k

Temp. difference of inlet and outlet of Heating Fluid ΔT = 455oC = 728K

So ,

Mass flow rate of heating fluid (ṁw) = Q/(Cp* ΔT)

ṁw = 0.096 kg/s

After that we calculated Jacket Dimension i.e. Height of jacket , Length of Jacket ,

Area of jacket , Hydraulic diameter , etc.

 Jacket Dimension –

1. Height of jacket (Hj) = HR/2 = 0.3825m

2. Let pitch between baffles (Pj) = 0.0765m

3. No. of Spiracles (Ns) = Hj / Pj

Ns = 5

4. Length of Jacket (Lj) = Ns*π*DR

Lj = 8.012m

5. Area of jacket (Aj) = Δb* Pj ………………( Δb = 0.02827)

49
 Aj = 0.002163 m2

6. Hydraulic diameter (de) = 4(Δb* Pj )/2(Δb+Pj )

de = 0.04128m

7. Velocity through channel (u) = ṁw/ρ*Aj

u = 0.48 m/s

Now we are going to calculate film heat transfer coefficient of jacket.

 Film heat transfer coefficient of jacket –

First we have to calculate Reynolds No. and Prandtl No. of heating fluid flow.

So,

Reynolds no. = (u*de*ρ)/ μ …………(μ = viscocity of jacket fluid )

Re = 283062.85

Prandtl no. (Pr) = (Cp*μ)/k ………………(k = thermal conductivity of fluid)

Pr = 0.0002588

Now, by using Dittus Boulter equation,

hj*de/k = 0.0023*Re0.8*Pr0.33

hj = 603.2 W/m2k

And, hd = 1/fd ……………………………..( fd =0.002 m2.oC/W )

hd = 1/0.002

hd = 500 W/m2.oC

Now calculate overall heat transfer coefficient (Uo) using hj and hd

Overall Heat Transfer coefficient (Uo) –

1/Uo = (1/hj) + (1/hd)

1/Uo = (1/603.2) + (1/500)

50
 Uo = 273.38 W/m2.oC

Finally we are going to calculate heat transfer area of the jacket.

Heat transfer area of the jacket (A) –

A = Q/(ΔTm*Uo)

where ΔTm is mean temp. difference = (675 + 145)/2

ΔTm = 410oC

A = 186596.4/(273.38*410)

A = 1.66 m2

At last we calculated standard plate thickness for reactor fabrication.

6. Standard Plate Thickness –

Material of construction MOC is Stainless steel 304.

Design pressure (PR) = P + (10% of P)

= 1.3atm + (0.1*1.3atm)

= 1.43atm

PR = 144859 Pa

Allowable stress for stainless steel 304 (f) = 32.9*105 Pa

Joint Efficiency (j) = 0.85,

Corrosion Allowance = C = 0.0032

Thickness formula ,

Thickness (t) = {PR*DR/(2*f*j – P)} – C

= 4.5243*10-3 m = 4.5243 mm

Thickess of Plates (t) = 5 mm

51
Condenser Design
We choose floating head type shell and tube heat exchanger with total condenser as our
condenser.

First we calculate the condenser duty (Q) i.e.,

Heat transferred from vapour = Q = 214596.76 kJ/hr

Q = 59.61 kW

Cooling water flow = 732.7122 kg/hr

Cooling water flow = 0.20353 kg/s

This is like trial and error method .So, first we assumed Overall heat transfer coefficient
from values given to different chemicals in R.C. Vol.6. So ,

Assume overall heat transfer (U) = 300 W/m2.oC

We chose horizontal exchanger , condensation in the shell and four tube passes.

Then we calculated logarithmic mean temp. difference with correction factor ΔTLMTD.

Fig. 5.4 Temp. profile of hot and cold fluid

ΔTlm = {(675- 100) – (30- 18)}/ln[(675- 100)/ (30- 18)]

ΔTlm = 145.5oC

ΔTlm correction factor = Ft = 0.92 from RC6

52
ΔTm = 0.92*145.5 = 134oC

Trial Area (T) = Q/(U* ΔTm )

= 59.61/(300*134)

Trial Area (T) = 1.48284 m2

Now for tubes,

We choose outer diameter of tube as 16mm , thickness is 2mm and length of the tube is

1.83m (6ft) as standard. So,

o.d. = 16mm = 16*10-3 m

i.d. = 14mm = 14*10-3 m

Length = L = 1.83 m

Thickness = 2 mm

So ,

Surface area of one tube (At) = 16*10-3*π *1.83

At = 0.092 m2

Number of tubes (Nt) = T/At

= 1.48284/0.092

Nt = 16

We are using square pitch for tube arrangement.

And we are going to calculate Pitch Length.

Pitch Length (Pt) = 1.25*o.d

= 1.25*16

Pt = 20mm

Then tube bundle diameter ,

53
 Tube bundle diameter (Db) = do(Nt /k1)(1/n1) ……….(We get values of k1 and n1 from RC6)

= 16(16/0.158)(1/2.263) ..... (k1 = 0.158 and n1 = 2.263)

Db = 123.12 mm

Number of tubes in centre row (Nr) = Db/Pt

= 123/20

Nr = 6

Now we are going to calculate Shell Side Coefficient .

1. Shell side coefficient –

Now to estimate tube wall temperature (Tw).

We are going to assume shell side condensing coefficient of 800 W/m2 0C,

Shell side = (675+30)/2 = 352.5oC

Tube side = (100+18)/2 = 59oC

(352.5-Tw) 800 = (352.5 - 59) 300

Tw= 242.42oC

Mean temperature of condensate = (352.5 + 242.42)/2

= 297.25oC

Physical properties of HCl at 297.25oC

Viscosity = μL = 1.87 mNs/m2 ,

Density = ρL = 1160 kg/m3

Thermal Conductivity = kL = 0.376 W/m0C,

Vapour Density = ρV =1.5925 kg/m3

54
ᴦT = Wc/LNT = (108.48/3600)/(1.83/16)

ᴦT = 1.029*10-3 kg/s.m

Nr=2/3*no. of tube in centre row=2/3*6 = 4

ho = 0.95*kL[ρL(ρ L- ρV)g/(µLᴦh)]1/3*(Nr)-1/6

ho = 864.23 W/m2 0C

Close enough to what we assumed i.e. 800 W/m2 0C . So, no need to re-calculate.

Now we are going to calculate Shell Side Coefficient .

2.Tube side coefficient →

Tube cross sectional area = [(16-2)*10-3]2*16/4

= 6.1575*10-4 m2

Density of water at 600C = 983 kg/m3

Tube velocity = (cooling water flow/density)*(1/Tube Cross Sectional Area)

= (0.20353/983)*(1/6.1575*10-4)

Tube velocity = 0.3363 m/s

Tube side coefficient = hi is,

hi = 4200(1.35+0.02*59)*(0.3363)0.8/(14)0.2

hi = 2621.35 w/m2 0C

We get fouling factor coefficients from RC6. So,

Fouling factor coefficients →

1.Water = hid = 6000 w/m0C

2.HCl = hod = 5000 w/m0C

55
Thermal conductivity of tube material = Kw = 57.5 w/m0C

Overall coefficients =1/U=1/ho + 1/ hod + do.ln[do/di]/2.Kw + do/di[1/hid + 1/hi]

= (1/854.25)+(1/5000)+16*ln(16/14)/2*57.5+(16/14)[1/6000+1/2621.55]

U = 48.60 w/m2 0C

The calculated value of U is significantly lower than the assumed i.e. 300 w/m2 0C

So, repeat the calculation using new U i.e. 50 w/m2 0C.

1. Total area = 59.61*103/50*134 = 8.8970 m2

2. No. of tubes = 8.8970/0.092 = 96

3. Tube bundle diameter =Db=do(Nt/Kt)1/n = 271.95 mm

No. of tubes in centre row = Nr = Db/Pt= 13.5875

4. ᴦh = Wc/L.Nt = 1.70247*10-4 kg/s.m

5. Nr = 2/3*13.5875 = 9

hc = 0.95*kL[ρL(ρ L- ρV)g/(µLᴦh)]1/3*(Nr)-1/6

hc = 854.24 w/m2 0C

Now tube velocity = 0.3363*16/96 = 0.05605 m2

hi = 4200(1.35+0.02*59)/140.2*0.056050.8

hi = 625.08 w/m2 0C

Overall coefficient =1/U=

= 1/854.24+1/5000 +16*ln(16/14)/ (2*57.5)+16/14*(1/6000+1/625.08)

U = 45.52 w/m2 0C

Now this value of U is close enough to what we have assumed.

So, no need to change.

56
Now next we are going to see pressure drop on both sides of the condenser.

Pressure drop should not be more than 1 atm. Or 100 kPa.

So, First is shell side pressure drop.

3. Shell Side Pressure Drop –

We are using pull through floating head heat exchanger.

Here Baffle Spacing is 1/5th of shell diameter with 15% cut.

Baffle spacing = (shell dia.)/5 with 15% cut.

From fig. 12.10 for 15% cut baffle clearance is 88mm

So, clearance = 88 mm

Shell i.d (Ds) = (tube bundle dia. + clearance )

= 272 + 8

Ds = 360 mm,

Baffle spacing (lb) = 360/5

lb = 72 mm

We are using Kerns method to make approx. estimate

Cross-flow area As = (Pt - o.d) *Ds*lb/Pt

= (20-16)*360*72*10-6/20

As = 5.184*10-3 m2

Mass flow rate (Gs) , based on inlet condition,

Gs = 108.48*1/(3600*5.184*10-3)

Gs = 5.183 kg/s.m2

Equivalent diameter (de) = 1.27/do .*(Pt2 - 0.785*do2)

57
 = 1.27/16*[202 - (0.785*162)]

de = 15.8 mm

Vapour viscosity = 0.00156 m.Ns/m2

Reynolds No. = Re = Gs*de/µ

= 5.183*15.8*10-3/(0.00156*10-3)

Re = 58,872

From fig.12.30 , For Re = 58,872 friction factor = jf =5*10-2

And ,

us = Gs/ ρV = 5.183/1.5923

us = 3.65 m/s

Take pressure drop as 50% of that calculated, using inlet flow; neglect the viscosity
correction.

So,

∆Ps=1/2[8*jf*(Ds/de)*(L/lo)* (ρ *Vs2/2)]

=1/2[8*5*102(360/15.8)*(1.83/0.072) (8.2747*3.652/2)]

∆Ps=6384.14 N/m2= 6.384 kPa

So, shell side pressure drop is acceptable.

Now , next is tube side pressure drop.

2. Tube side pressure drop -

Viscosity of water = 0.4658 mNs/m2

Reynolds No. = Re = Ut* ρ*di/µ

58
 = 0.3363*983*14*10-3/(0.4658*10-3)

Re = 9936

From fig.12.24 for Re = 9936 jf = 4.75*10-3

So ,

∆Pt = 4[8*jf*(L/di)+2.5]* ρ*ut2/2

= 4[8*4.75*10-3*(1.83/14*10)+2.5]*983*0.33632/2

∆Pt = 1243.4 N/m2

∆Pt = 1.243 kPa

Tube side pressure drop is acceptable.

At last we are going to see MOC and standard plate thickness.

6. Standard Plate Thickness –

MOC is Stainless steel-304 same as the reactor.

Design pressure (PR) =1.43 atm = 144859 Pa

Allowable stress (f) = 38.9*105 Pa

Joint Efficiency (j) = 0.85,

Corrosion Allowance = 0.0032

Thickness (t) = {PR*DR/(2*f*j – P)} – C

= 3.9685*10-3 m = 3.9685 mm

Thickess of Plates (t) = 3.9685 mm

59
Utility Line Diagram

Next is utility line diagram

In our process we need four utilities i.e. cold water, dry air, steam and electricity.

We need steam for NaCl saturator, dry air for Rotary Dryer, Cold water for condenser and electricity
to almost all equipments but primarily for mixing tanks, reactor, pump and pulverizer.

At the bottom you can see all utility outlets from plant.

Fig. 5.5 Utility Line Diagram of Manufacturing of SHMP

60
P&ID of Equipments

1. Reactor P&ID

We have developed P&ID for reactor and condenser ; two main equipments.

Here in reactor P&ID you can see on the left side, to maintain constant temperature in
reactor we control heating fluid flow rate using flow controller and temperature controller.

On the right side, we can see we control inlet of feed and outlet of by-product HCL using
flow controller.

Add the bottom we control flow rate of product for constant reactor volume using level
controller.

Fig. 5.6 P&ID Diagram of CSTR

2. P&ID of Condenser

61
In this P&ID of condenser, for steady temperature of HCl outlet we control cooling water
flow rate by flow indicator and flow controller along with temperature transmitter and
temperature controller for HCl outlet.

Fig. 5.7 P&ID Diagram of Condenser (SATHE)

Plant Layout
62
Next is plant layout.

Here you can see plant area with future expansion area, warehouse, STP, utilities, cooling water,
maintenance area, lab area, fire station, administrative building along with parking area, Canteen,
General Assembly area, emergency water supply, etc.

We put utilities near plant area to reduce piping cost and ease on operatability.

Fig. 5.8 Plant Layout of Manufacturing of SHMP

6. Costing
63
Next is costing.

Here we are going to calculate total product cost (TPC), Fixed capital investment and break
even point. We have done all the calculation from “Plant Design And Economics for
Chemical Engineer” by Peters M.S. and Timmerhaus K.D.

1. Total product cost (TPC)

Basis is 2.4 turn per day

Cost of NaCl (industrial grade) is - Rs. 3/ kg

Cost of 85% Phosphoric Acid (Industrial grade) is – Rs. 25/kg

Direct material cost = Cost of NaCl + Cost of H3PO4

DMC = (Rs. 4104) + (Rs. 66000) = Rs. 70,104

Direct labour cost is 14% of TPC.

Direct labour cost (DLC) = Rs. 35,538

Power and utilities cost is 12% of TPC.

Power and utilities (PU) = Rs. 31,156

Plant overhead cost is 19% of TPC.

Plant overhead cost (POC) = Rs. 48,461

Direct Production cost is addition of Plant overhead cost , Power and utilities cost and
Direct labour cost. So,

Direct Production cost (DPC) = DMC + DLC + PU

64
 DPC = Rs.1,36,798

Fixed charge (FC) is 10 % of Direct Production Cost

Fixed charge (FC) = Rs.13679.8

Manufacturing cost = DPC + FC + POC

= 136798 + 13679.8 + 48461

Manufacturing cost = Rs.1,98,938.8

Marketing cost is 30 % of manufacturing cost

Marketing cost = Rs. 59681.64

Total product cost(TPC) = Manufacturing cost + general expences

TPC = Rs. 258620.44

Now, we are going to calculate selling price of SHMP.

Let ‘X’ be the selling price of SHMP per kg.

Total selling price = 2400*X

We are taking profit of 10% of selling price. So,

Profit = 10 % of selling price = 0.10*2400*X = 240*X

By profit formula,

Profit = Total selling price - Total product cost

240*X = 2400*X - 258620.44

258620.44 = 2160*X

65
 X = Rs.119.7316852

Selling Price of SHMP per kg should be Rs.120.

This is the excel sheet of TPC calculation.

Table 6.1 Excel Sheet for TPC and Selling Price for Manufacturing of SHMP

Next is fixed capital investment.

2. Fixed Capital Investment –

First is purchased equipment cost.

Here we can see approx. cost of all equipments.

1) Cost of CSTR = Rs. 73000

2) Cost of Condenser = Rs. 68000

3) Cost of Mixing Tanks = Rs. 219000

4) Cost of Crystallizer, Pump, Filter,

66
 Rotary Dryer, Pulverizer = Rs.162000

Purchase Equipment Cost = Rs. 522000

After that we calculate all other cost like piping and instrumentation cost, electrical, building
cost, Services, Yard Improvement, Direct plant cost, engineering and Procurement, other expenses
contingency, etc. with appropriate formulae from Timmerhaus book.

You can see all the calculations with proper formulae done in below excel sheet.

Table 6.2 Excel Sheet of Fixed Capital Investment for Manufacturing of SHMP

Fixed Capital Investment is Rs. 21,67,083

Last is break-even point(in terms of quantity).

67
The point where total product cost equals total income is called break-even point.

3. Break-even Point –

Direct Production Cost/yr = Rs. (136798*8000/24)

Operating days/year = (8000hr/24) days……(8000 hr/yr is standard operating hrs for

continuous process)
Annual Sales = 800000 kg/yr……..(8000hrs*100kg)

Direct Production Cost/kg = (DPC/Annual Sales)

= (136798*8000/800000*24)

= Rs. 57/kg

Let the break-even be 'n' kg per year.

(FC + GE + POC) + (DPC/kg)*n = (Selling Price/kg)n

40607480 + 57n = 120n

n = 646718.9 kg/year

Break-even point = 80.84 kg/hr

So, our production capacity which is 100 kg/hr is already above break even point.

By calculation we get other values as follows,

Total Revenue/yr = Rs. 9,60,00,000

Total Costs/yr = Rs. 8,62,07,480

Net Profit/yr = Rs. 97,92,520

(before taxes)

Below is the excel sheet of calculation of Break-even point.

68
 Table 6.3 Excel Sheet of Break-even point for Manufacturing of SHMP

7. Results

69
Results for literature survey-

1. SHMP by NaCl method is better than other two because of high P2O5 content, low temp.,
easy operation and value added by product.

Results for mass balance-

1. ∆G of reaction = - 168 kJ/mol.

2. For 100 kg/hr of SHMP production we need 124 kg/hr of H3PO4 and 63 kg/hr of NaCl.

3. Yield is about 90% .

4. Conversion is about 91%.

Results for energy balance -

1. Heat of reaction is +489 kJ/mol and reaction is endothermic.

2. Reactor duty = 186.59 kW

3. Condenser duty = 59.61 kW

Results for design -

1. We design jacketed CSTR of Volume = 155 litre , height = 1.02m and Diameter = 0.51m.
with radial turbine stirrer with six blades and stirrer motor of 1.5hp. And jacket with area of
1.66 m2 .

2. We design pull through floating type condenser with 16mm outer diameter tubes with
standard length of 6ft (1.83m) and no. of tubes = 96 . Then shell with dia. of 360mm and
Overall Heat Transfer Coefficient (Uo ) of 45.5 W/m2.0C.

3. MOC for both CSTR and Condenser is Stainless Steel - 304 with plate thickness of 5mm.

Results for costing -

70
1. TPC/day = Rs. 2,58,620

2. Selling price of SHMP/kg = Rs.120 taking profit of 10%.

3. Fixed capital investment = Rs.21,61,083.

4. Break even point = 6,50,000 kg/yr.

5. Annual Revenue = Rs.9,60,00,000

6. Annual Profit = Rs.97,92,520

7. Total Costs/yr = Rs. 8,62,07,480

8. Final Conclusion
71
Conclusion for Literature Survey –

1.We conclude that NaCl method is best for production of SHMP.

Because, of cheap raw material, high P2O5 content, lower requirement of expensive raw material,
high conversion, low reaction temp.

Conclusion for Mass Balance -

1.We have successfully calculated mass balance of the process and flow rate of the each
stream.

2.∆G of reaction is -168 kJ/mol.

3.So, reaction is highly feasible.

4.The yield of the process is about 90-92%.

5.The chosen process is very feasible which gives high purity SHMP with low cost raw
material.

Conclusion of Energy Balance -

1.We have successfully calculated Energy Balance of our process.

2.Heat of reaction is +489 KJ/mol which is endothermic.

3.Chosen process is energy efficient and economically feasible.

4.We can determine energy input to the each stage easily.

Conclusion for Equipment design -

72
1. Equipment design and sizing of CSTR with spiral baffle jacket and Condenser which is
floating head type SATHE.

2. The MOC of both Reactor and Condenser is SS-304.

3. We follow all guidelines of IS 5553-2 for Reactor and IS 4503:1967 for Heat Exchanger.

4. We optimize our design for low production cost and high efficiency.

5 .We have developed PFD, ULD, P&ID and Plant Layout diagram in Autocad.

Conclusion of Costing –

1. TPC of plant is Rs. 2,58,620/day.

2. Break-even point is within our production capacity.

3. TCI of plant is Rs. 27,08,853 and ROI is 36%.

4. Selling price of SHMP is Rs.120/kg which is market competitive but scale-up is required

to beat the market.

5. All the calculations are done in excel. So, scale-up is easy.

6. This project is supported by Reva Process Technologies. Ltd.

9. References

73
1. Bhatt B. I., Vohra S. M., “Stoichiometry,” Fifth Edition, Tata McGraw Hill, New Delhi,
(2010).

2. Carl L. Yaws , “Chemical Properties Handbook,” Mc-Graw Hill , New York , NY ,

(1999).

3. Chen M., Zhang W., and Yu Y., 2008. Method of producing sodium hexametaphosphate
by sodium chloride method, CN101462711A.

4. Coulson J. M., Richardson J.F., Sinnott R.K., “Coulson & Richardson’s Chemical
Engineering,” Fourth Edition, Vol. 6, Elsevier Butterworth-Heinemann, Oxford, MA, (2005).

5. David R. L., “CRC Handbook of Chemistry and Physics,” 82 nd Edition , CRC Press,
Inc., Boca Raton, Florida, FL, (2001).

6. U.S. International Trade Commision , December 2018. Sodium Hexametaphosphate

from China, 731-TA-1110.

7. Edward J.P., Harrison N.Y., September 1980. Preparation of Sodium Orthophosphate

Mixtures, US4224294.

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Ring Hexametaphosphate Anion.

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 13. Peters M.S., Timmerhaus K.D., “Plant Design And Economics for Chemical

Engineer,” Fourth Edition , McGraw – Hill , New Delhi, (1991).

10. Bibliography

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1. SHMP - Sodium Hexametaphosphate

2. g/cc - grams per cu.m

3. CAGR - Compound Annual Growth Rate

4. kJ/mol - kilojoule per mole

5. kg/hr - kilogram per hour

6. Cp - Heat Capacity

7. Cp(mix) - Heat Capacity of mixture

8. xi - Mass fraction of component

9. ∆Hreaction - Heat of reaction

10. ∆fH0 - Heat of formation

11. ∆Greaction - Gibbs free energy of reaction

12. ∆f G0 - Gibbs free energy of formation

13. Re - Reynolds No.

14. Pr - Prandtl No.

15. hj - Film heat transfer coefficient of reactor jacket

16. ∆TLMTD - Logarithmic mean temp. difference

17. Uo - Overall heat transfer coefficient

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