CHAPTER 1

INTRODUCTION

1
 CHAPTER 1

INTRODUCTION

Ammonium nitrate (NH4NO3) formula wt 80 is the most commercially important

ammonium compound both in term of production volume and usage. As a straight
fertilizer, it account for 24% of world consumption of nitrogen fertilizer and, in addition,
is present in many blended and complex fertilizer, thus making an important contribution
to feeding the world population.

Ammonium nitrate does not occur in nature because it is very soluble. It was first
described in 1659 by the German scientist Glauber, Who prepared it by reaction of
ammonium carbonate and nitric acid. He called it nitrous flammans because its yellows
flame (from traces of sodium) was different from that of potassium nitrate. Thus
ammonium nitrate is a preferred source of fertilizer nitrogen in some countries.
Ammonium nitrate is a white crystalline salt which is colourless and odourless crystalline
solid substance or a white granular powder.

Ammonium nitrate is not obtained, but manufactured. The chemical equation that
describes this process is as follows;

HNO3 + NH3 → NH4NO3

(Nitric acid) (Ammonia) (Ammonium nitrate)

Ammonium nitrate is mainly used to make matches, fertilizers and antibiotics, but also
in the manufacturing of explosives. Ammonium nitrate is an oxidizing agent and can it
self ignite when it comes into contact with powdered metals and some organic materials.

2
During combustion toxic oxides of nitrogen are produced, as well as ammonia gas, which
are very irritable to the eyes, nose and the throat.

CHAPTER 2

PROPERTIES

3
 CHAPTER 2

PROPERTIES

2.1 Properties of Product (Ammonium nitrate):-

2.1.1 Physical properties:-

Chemical Name: Ammonium nitrate

Molecular weight: 80

Melting point: 169.6ºC

Boiling point: 210 ºC

Appearance: White crystalline substance

Odour: Odourless substance

Density: 1.403 gm/ml

Solubility: 118gm/100gm water at 0 ºC

PH: 5.4

Percentage by mass:
Nitrogen: 35%
Hydrogen: 5%
Oxygen: 60%

2.1.2 Chemical properties:-

1) Ammonium nitrate has a negative heat of solution in water, can therefore be used
to prepare freezing mixtures.

2) Ammonium nitrate is considered a very stable salt, even through ammonium salts

4
 of strong acids generally lose ammonia and become slightly acidic on storage. For
ammonium nitrate, endothermic dissociation from lowering ph occurs above 169ºC

NH4NO3 → NH3 + HNO3

3) When the salt is heated to temperatures from 200 to 230 ºC, exothermic
decomposition occurs. The reaction is rapid, but it can be controlled, and it is the
basis for the commercial preparation of nitrous oxide.

NH4NO3 → N2O + 2 H2O

Above 230 ºC, exothermic elimination of N2 and NO2 begin.

4 NH4NO3 → 3N2 + 2NO2 + 8H2O

The final violent exothermic reaction occurs with great rapidity when ammonium
nitrate dentonates.

2NH4NO3 → 2N2 + 4H2O + O2

2.2 Properties of Raw material:-

The raw material used in manufacturing of ammonium nitrate are ammonia and
nitric acid.

2.2.1 Ammonia

Physical properties:

Chemical formula: NH3

Molecular weight: 17

Boiling point: -33.5 ºC

5
 Melting point: -77.7 ºC

Liquid density: 0.682 gm/cc

Chemical Properties:
1) Anhydrous NH3 is present both in the gaseous and liquid under atm pressure and
temperature conditions it is present in gaseous form.
2) Ammonia readily dissolve in water forming aq. NH3 with liberation of heat
3) Ammonia vapor is colorless and has pungent odor.
4) Ammonia is lighter then air & therefore, in open atm it will be dispersed by virtue
of its own burgundy. However, air ammonia vapor form liquid may form
ammonia air mixture heavier then air, which may stay lose to the ground for
sometimes.
5) The TLV of NH3 is 50 ppm by volume. However its presence is Detroit able due
to its own even at 25 ppm.

2.2.2Nitric acid

Physical properties:

Chemical Formula: HNO3

Molecular weight: 63

Boiling point: 80 ºC

Melting point: -42ºC

Chemical properties:

1) Nitric acid is a strong acid because it gives off the hydronium ion as its only
positive ion.
2) When nitric acid is mixed with sulfuric acid it gives off the nitrate ion which can
be used to create explosive.
3) Nitric acid is dangerous especially when found in concentration above 50%
because it gives off fumes.

6
4) When nitric acid mix with any organic substance because it can cause an
explosion which is very bed thing.
5) Toxic limit: TLV 2 ppm

CHAPTER 3

LITERATURE SURVEY

7
 CHAPTER 3

LITERATURE SURVEY

1) Crystallization
2) Melt process
3) Stengel process
4) Short Prilling tower process
5) BAMAG -MAGUIN -A.G. Process
6) S.B.A process
7) Single step evaporation process
8) Kaltenback process
9) Montecatins process
10) GIAP process
11) ICI process
12) Fauser process
13) Vacuum flash process

1) Crytallization process

In this process, NH 4NO3 crystals are manufactured from direct reaction

between nitric acid & anhydrous ammonia.
After neutralization, the weak solution is concentrated to 83%. The
temperature in crystallization-evaporator is maintained between 35-37ºC.
Slurry liquor is centrifuged, crystals dried & sent for bagging and storage.

2) Melt process

8
 Anhydrous ammonia and concentrated nitric acid are pumped into melt of
Nh4NO3 maintained at 150 ºC. The product is cooled. Molten NH 4NO3 leave the
reactor at 200 to 250 ºC. The crystals are separated in a cyclone separator the
moisture content from the molten salts is driven off by blowing dry air.
The melt is then cooled on a hot steel belt, chilled and sent for further coating and
Packaging.

3) Stengel process

This process consists of neutralization NH 3 with preheated HNO3 an a reactor

at 3.5atm pressure and 204-238 ºC temperature.

4) Short tower prilling process

This process is free from trouble or expanse of drying as in the case of usual
prilling process. The ammonium nitrate is concentrated to about 99.5%. Practically all
water is evaporated in an evaporator. The special feature of this process is that it is
less expansive.

5) Bamang-Maguin-AG process

In this process, HNO3 & gaseous NH3 are introduced into the tower in which
fused ammonium nitrate at its boiling point & atm pressure is kept. The heat of
reaction is utilized to concentrate the salt solution. Evolved steam is served to preheat
the reaction.

6) S.B.A. process

In this process, neutralization is carried out either at atm pressure or high

pressure. Neutralization at higher pressure has the advantage of saving fresh steam
raising the pressure of secondary steam generated in the neutralization process.

Neutralization at atm pressure required a smaller initial investment & is

advisable when high pressure NH3 & high concentration HNO3 are not available.

9
7) Single step evaporation process

In this process, neutralization of 56-60% HNO 3 with gaseous NH3 is carried

out in a reactor at pressure of 3.5 atm. Where by a highly concentrated solution is
obtained as well as secondary steam with a high calorific value. The molten NH 4NO3
is prilled in a tower.

8) Kaltenbach process

In this process, the neutralization takes place at 4.5 atm pressure. The resulting
solution is concentrated from 80 up to 95% in first stage evaporator. Using the
secondary steam obtained from the neutralizer.

The solution is than mixed with a solution containing NH 4NO3 fines in a

homogenizer and is feed to the final kaltenbach type evaporator placed above the
prilling tower. The ammonium nitrate is concentration from 95 to98% to between
99.5 to 99.8% using the fresh steam at about 10 atm in the final evaporator.
The resulting ammonium nitrate is prilled and than cooled into a fluidized bed
cooler. After being cooled from 80-100 ºC to 28 ºC, the prills are passed over a
classifying screen and then into a cooling drum where they are dusted with limestone
before being packed & stored.
The finished product contains 34.5% nitrogen and 0.2-0.3% moisture and
consists of hard spherical granules between 1-3mm in diameter and a low caking
tendency.

9) Montecatins process

In this process neutralization takes place at atm pressure and at a temperature of

not more than 145 ºC. The heat of reaction is recovered in the from of secondary

10
steam, which is used to concentrate the ammonium nitrate solution in the evaporator
up to between 93-98%.

10) GIAP process

In this process, the prilled ammonium nitrate is obtained with a

concentration of 98.7% and not more than 1.2% moisture.

The raw material include gaseous NH 3 flash gases having 55-60% NH3
gases from urea distillation containing 80% N2, 47-49%HNO3, dolomite
containing.

The manufacture of prilled ammonium nitrate by GIAP process includes the

following stages.

1) Preparation of ammonium nitrate solution by neutralization of nitric acid

with NH3, followed by preliminary concentration.
2) Further concentration and crystallization of molten ammonium nitrate in a
prilling tower.
3) Cooling, packing & storage of finished product.

11) ICI process

In this process nitric acid feed is preheated by part of the vapors produced in
the neutralizer and is then split into two streams. Recycled, undersized product is
dissolved in one stream, conditioning material in the other. The recombined streams
are added to a two stage neutralizer along with ammonia and recirculated solution to
give 87 to 89% ammonium nitrate feed for evaporation. The C&I-Girdler-Cominco
process is similar in principal; the Pintsch-Bamag process uses a two-stage neutralizer
without recirculation.

11
12) Fauser process

Which operates above atm pressure, was an early attempt to fully utilize the
heat of neutralization. The neutralizing zone of the enclosed reactor operates at 500-
600kpa. Reactants enter at the bottom of this chamber and hot ammonium nitrate
stream upward, where it is discharged continuously into an outer vessel operated at
atm pressure. The arriving solution loses part of its water; subsequently most is
recirculated through the outer vessel to the lower neutralizing space, while part is
removed for further processing. Ammonia and nitric acid feed streams are preheated
by partial utilization of the steam from the outer vessel. Variations of the fauser
process are used extensively in the USSR; among these are the ITR, GIAP-
Kemerova, and TGL processes.

13) Vacuum flash process

Which operate under the atm boiling point of the solution include the Uhde-
I.G. Farbenidustrie process and the closely related Kestner process. In these,
ammonia, nitric acid and recirculated ammonium nitrate solution are fed into the
neutralizer. Hot solution overflows to an intermediate tank and then to a flash
evaporator kept at 18-20 kpa absolute pressure. Partial evaporation of water at this
point cools and concentrates the solution, part of which is routed to evaporation. The
rest is circulated to the neutralizer.

12
 CHAPTER 4

PROCESS SELECTION

AND

DESCRIPTION

13
 CHAPTER 4

PROCESS SELECTION AND DESCRIPTION

Advantages of Stengel Process
There are various processes to manufacture the ammonium nitrate. Stengel
process is one of them. The main features of the Stengel process is one stage
production of molten ammonium nitrate with a concentration up to 99% without
the use of evaporation. With the help of Stengel process by using with prilling
tower, we get high conversion up to 99.5%. Every equipment used in the process
is easily available,

A small investment cost is the main advantage offered by the Stengel process.

Disadvantages of other process compared to Stengel Process.

In other process the temperature in evaporator is maintained very low. And either
the conversion or the purity of product is very low compare to the Stengel
process. The cost is high for the other process compare to the Stengel process.

Mechanism for the manufacturing of ammonium nitrate

Ammonium nitrate is manufactured by the neutralization of nitric acid with

ammonia. The main stages in the manufacture of ammonium nitrate include:
Neutralization of nitric acid with gaseous ammonia, evaporation, prilling, drying
and cooling the prilled ammonium nitrate, dressing and packing the finished
product,

(a) Neutralization of nitric acid with gaseous ammonia

14
Ammonium nitrate is formed by neutralizing 100% nitric acid with gaseous
ammonia according to the following equation:

HNO3 + NH3 =NH4NO3 + 3 4.64 kcal/mole

The heat evolved in the reaction depends on the concentration of nitric acid and
with the temperature of both nitric acid & gaseous ammonia.

Neutralizing unit utilizing the heat of reaction at atmospheric pressure from the
many atmospheric neutralizing units available, the ITN type neutralizes are used
on large scale.

ITN neutralizes consist of a cylindrical vessel containing other cylinder of smaller

internal diameter. The inner cylinder serves as a neutralizing chamber and the
annular space between the inner-outer cylinders, serves as an evaporation
chamber.

NH3 & HNO3 are introduced at the upper end of neutralising chamber through
which reach to the bottom of the chamber, and the ammonium nitrate solution
formed passes from the upper of the inner cylinder into the annular evaporation
space.

Part of the water introduced with diluted HNO 3 is evaporated by the heat of
neutralization and flows out as secondary steam at the upper end of evaporation
chamber. The ammonium nitrate solution in evaporation chamber flows
continuously through a hydraulic valve into final neutralize!.

ITN Unit
NH3 & HNO3 are introduced at upper end of the neutralizing chamber, which is
packed with Rasching rings - for better mixing of the reactants. The ammonium
nitrate solution formed passes into the evaporation chamber through the orifices
in the wall of neutralizing chamber.

ITN-l Unit

15
 This is a version of ITN unit with no orifices from the neutralizing chamber to
evaporation chamber, NH3 & HNQ3 are introduced at the lower end of the
neutralizing chamber and the solution obtained overflows at the upper end in to
the evaporation chamber.

ITN-2 Unit
In this unit, the solution circulation is modified. The neutralizing chamber is open
at the upper end and provided with the orifice in the lower section.

The pressure of liquid column in neutralizing chamber is smaller than the pressure
of the liquid column in evaporation chamber. Because of the pressure difference,
the ammonium nitrate solution from evaporation chamber passes through the
orifice, ensuring a continuous and intense circulation between both the chambers,
resulting in intimate mixing of reagents.

The processing of neutralized ammonium nitrate solutions to produce the end

product has undergone a marked improvement.

(b) Evaporation of ammonium nitrate solution

The concentration of the ammonium nitrate solutions obtained in the

neutralizing equipments is generally 60% to 80%.

For prilling, these solutions must be concentrated first to between 96 &,

98%, the final concentration of the melt depending on the subsequent processing
method, namely whether the product is prilled in a water or crystallized on cooled
cylinders.

When the plant is not provided with drying equipment after the prilling
tower, the ammonium nitrate solution is concentrated in final evaporator upto
99.5-99.8% to obtain a product with less than 0.3% moisture content.

16
 When the solutions are evaporated, the boiling point increase with
increasing concentration of ammonium nitrate. At temperatures above 1850C, the
molten ammonium nitrate begins to decompose with evolution of heat.

To avoid the thermal decomposition of ammonium nitrate, the solutions

are concentrated in vacuum evaporators.

(c) Crystallization of ammonium nitrate

The crystallization of ammonium nitrate is an exothermic process. The

isiomorphous changes taking place during crystallization are accompanied by the
evolution of heat. The amount of heat evolved depends on the temperature of the molten
ammonium nitrate and on the temperature of the salt after crystallization. By this crystal
Jibing process, microcrystal line ammonium nitrate is obtained, which is normally used to
manufacture mining explosive-Ammonium nitrate in the form of flakes does not give
uniform distribution when worked onto the soil and cakes more readily than prilled
ammonium nitrate. For this reason, crystallization on rotary cylinders which was used
commercially until quite recently, has been replaced by the prilling process.

(d) Tower Prilling of Ammonium Nitrate

Recently the prilling of ammonium nitrate has been used more & more and most
ammonium nitrate is now treated in this way.

Prilling towers are commonly cylindrical with a conical bottom, but occasionally
they are square or rectangular in section. They are usually 12 to 16m in diameter, and the
cylinder part is 25-30m in height. The output capacity of tower of this type is up to 700
tonne per day of ammonium nitrate.

The walls of the tower are made from concrete or bricks with an inner lining of
acid proof bricks or aluminum sheet. The conical bottom is made from concrete or steel
with an aluminum or stainless steel lining. Reinforced concrete structures are preferred
because of the better thermal insulation they provide.

17
 Prilling lowers used for melts containing about 99,5% ammonium nitrate are
much smaller than older towers which process 95 to 98,5% ammonium nitrate. The
height of fall in the prilling tower is determined by the time required for the drops to set
and harden sufficiently.

(e) Drying of ammonium nitrate

It has been found from commercial practice that ammonium nitrate with moisture
content below 0.5% (preferably below 0,2%) can be stored for a long lime without caking
taking place,

A drying process must be incorporated into plant producing crystallized

ammonium nitrate with moisture content above L5% drying the finished product entails
evaporation of the surface moisture on the prills or crystals.

In the first stage of drying, the rate of evaporation of the water increases in the
second stage it remains constant, and in the third stage it falls suddenly.

The complete removal of the moisture from ammonium nitrate by drying is a

difficult and lengthy process. Because fines have a larger surface area. In commercial
drying plants for flaked or prilled ammonium nitrate, the time of passage through the
drier is between 40 & 60 minutes, and the moisture removed in this period is mostly from
the surface of the salt.

Drying process used in manufacturing ammonium nitrate include drying with cold
air, or drying with hot air followed by cowling with cold air. Drying with hot air is only
used when the crystallized ammonium nitrate contains between 2 & 3% water.

Description of the Stengel Process

18
 The Stengel process consists of neutralising ammonia with preheated nitric acid in
a reactor at a pressure of 33 atm and at a temperature between 204 to 238 0C. The main
feature of this process lies in the one-stage production of molten ammonium nitrate with
a concentration upto 99% without the use of an evaporator. To avoid the explosion risks,
the amount of ammonium nitrate in the reactor is very small.

Figure illustrates the flow diagram of the Stengel process for the manufacture of
ammonium nitrate. 57% to 60% nitric acid is through the preheater 2, where it is heated
with steam to a temperature between 143 & 165°C,

To avoid the corrosion of stainless steel that would occur at this temperature, the air
preheater is made of tantalum.

- Liquid ammonia is vaporized and heated with steam to between 145-150 0C in the
preheater 3 and is mixed with the preheater steam in the upper part of the rcactor-
4.

- Ammonia reacts with nitric acid at the surface of packing, and the heat of reaction
evaporates the water introduced with nitric acid.

The operating conditions in the reactor are as follows :

Temperature between 204-238°C, pressure 3.5atm, concentration of resulting melt

98% pH of the solution slightly alkaline because of trace of ammonia.

- The mixture of concentrated ammonium nitrate and secondary steam enters the
centrifugal separator 5. in which steam is separated by a counter current stream of
hot air at about 2000C that is introduced at the lower end of the separator. The hot
air reduces the moisture content of the melt from 2.0% to 0.2%.

After bubbling through the molten ammonium nitrate, the air must be filtered and
freed from traces of oil and other organic matter than could cause an explosion.
The filtered air is heated by secondary steam from the separator in the air
preheater-6.

19
- The molten ammonium nitrate at 194-2040C flows out at the lower end of the
separator and enters the discharge box 9, which feeds the cooled bell crystallizer
or the prilling tower.

- The temperature of steam on leaving the separator is 194-2040C. After passing

through the preheater 6, the steam and air are fed into the partial condenser 7,
which is a spraying scrubber with a conical bottom packed with Rasching rings.
The ammonium nitrate solution resulting from the condensation of the secondary
steam and the traces of entrained ammonium nitrate and ammonia from the
separator are recycled by pump through the condenser-scrubber. The ammonium
nitrate and ammonia present in the secondary steam arc recovered in the partial
condenser and reintroduced into the loop with recycled solution containing the
lines from the screen. When the solution reaches a given concentration, it is fed lo
nitric acid tank for neutralization.

- After the traces of ammonium nitrate and ammonia are separated and the air and
steam flow into the final condenser and where they arc scrubbed with water,
which is then discharged to waste, while the remaining steam and air are vented

- The molten ammonium nitrate is distributed from the discharge box 9 on to the
four water cooled steel belt conveyors 10 and solidifies in the form of a sheet
2.5mm thick that readily breaks up at the end of the belt.

- At the end of the belt conveyor, ammonium nitrate in the form of sheet is
transferred to a crusher 11.

- The crushed product is then transferred on a belt conveyor to the hammer mill 12
or to a jaw crusher, in which the material is broken up even further.

- The material then passes to the sizing screen 13, where the fineless then 0.85mm
in diameter-arc separated and sent to the dissolving tank 14, while the oversize,
over 4.0mm in diameter, is passed to the batch metering device.

- Dry air is blown through the sizing screen to prevent clogging.

20
- The batch metering device 15 automatically discharges 44 kg portions of
ammonium nitrate into the belt conveyor on to which portions 14 kg of the
Kieselguhr dressing agent are discharged I mm the second batch-metering device-
15.

- The finished product contains 3 kg Keiselguhr lo 97 kg ammonium nitrate.

- The dressing agent is introduced into the metering device from a bin provided
with a blade .stirrer and an air-agitating system to improve the flow of the
Kieselguhr dust. The conveyor bell continuously discharges the finished product
and the Kieselguhr, into the coating drum 16 for mixing.

- The ammonium nitrate prills are covered with a protective layer of Kieselguhr to
prevent their caking. From the coating drum, the finished product passes into the
bagging bin 17, from which it is weighed and loaded into 50 kg paper bags. The
bags are closed by machine with a latex glue.

- A more recently prilled ammonium nitrate has been produced using the Stengel
process. In this case, the molten ammonium nitrate introduced into the tower
almost anhydrous, having a concentration of about 99.5%,

- In the Stengel process, start up of the plant which consists of preheating the
reactor and separator with steam to a temperature of 100°C takes about half an
hour

The solution from the separator is recycled from the discharge box to the acid tank as
long as is necessary to achieve standard concentration of the resulting molten ammonium
nitrate. In case of failure, the process can be stopped in a short interval time.

Material of Construction

The equipment and pipes are generally made of nickel-chromium stainless steel, and the
nitric acid preheater is made of tantalum. It is advisable for the foundation of various
pipes of equipment to be covered with aluminum plate

21
1 he effluent drains from the plate are lined with aluminum plate, and the concrete floor
is covered with a nitric acid-resistance layer.

CHAPTER 5

MATERIAL BALANCE

22
 CHAPTER 5

MATERIAL BALANCE
Simple calculation for production of ammonium nitrate by Stengel Process.

Reaction: NH3 + HNO3  NH4NO3

Molecular Weight:
NH3 (Ammonia) = 17
HNO3 (Nitric Acid) = 63
NH4NO3 (Ammonium Nitrate) = 80

Basis: 1000 kg/hr of 60% nitric acid (HNO3)

5.1 Reactor

60% HNO3
(1000 Kg/hr)

NH3

23
 NH4NO3 (761.90 Kg/hr)

Figure 5.1

HNO3 in feed = 0.60 * 1000

= 600 kg/hr

Water in feed = 0.40 * 1000

= 400 kg/hr

63 kg/hr HNO3 = 80 kg/hr NH4NO3

600 kg/hr HNO3 =?

= 761.90 kg/hr NH4NO3 (100%)

63 kg/hr HNO3 = 17 kg/hr NH3

600 kg/hr HNO3 =?

= 161.90 kg/hr NH3

5.2 Separator

761.90 Kg/hr of 98%

NH4NO3 401.52 Kg/hr water
vapor

400 Kg/hr of water

760.38 Kg/hr NH4NO3

Figure 5.2
Assuming 99.8% of NH4NO3 obtained from separator.

99.8% NH4NO3 solution = 0.998*761.9

760.38 kg/hr (bottom)

Water & NH4NO3 from separation = 401.52 kg/hr

5.3 Final Condenser

24
 Input = 401.52 kg/hr of H2O & NH4NO3 solution

Here, 100% condensation of water takes place.

Water remove = 0.1 * 401.52
= 400 kg/hr

NH4NO3 removed = 401.52 – 400

= 1.52 Kg/hr

Result:

Total product rate = 760.38 kg/hr (99.8% NH4NO3)

= 18.25 T/day.

25
 CHAPTER 6

ENERGY BALANCE

26
 CHAPTER 6

ENERGY BALANCE

REACTION:-

NH3 + HNO3 NH4NO3

1) NH3 preheated
2) HNO3 preheated
3) Reactor
4) Air preheated
5) Partial Condenser
6) Final Condenser
7) Cooling belt conveyor

27
6.1 NH3 preheated
Table 6.1
TEMPRETURE COLD HOT
FLUID(NH3) FLUID(steam)
INLET 30°c 250°c
OUT LET 150°c 170°c

Mc NH3 = 161.90 Kg/hr

Cp steam = 1.9592 KJ/Kg K

Cp NH3 = a + bT + cT² + dT³

Where a=6.07
b=0.00823
c=-0.16*10^-6
d=-0.66*10^-9

Cp NH3 = 2.217 KJ/Kg K

Mc NH3 *Cp*∆T = Mc steam*Cp* ∆T

Mc steam = Mc NH3 *Cp*∆T/ Cp* ∆T

= 161.90*2.217*(150-30)/1.9592*(250-170)

Mc steam = 274.80 Kg/hr

6.2 HNO3 preheated

Table 6.2

TEMPRETURE COLD HOT

FLUID(HNO3) FLUID(steam)
INLET 30°c 250°c
OUT LET 165°c 175°c

Mc HNO3 = 1000 Kg/hr

28
Cp steam = 1.9592 KJ/Kg hr

Cp HNO3 = 2.59 KJ/Kg K

Mc HNO3*Cp*∆T = Mc steam*Cp* ∆T

Mc steam = Mc HNO3*Cp*∆T/ Cp* ∆T

= 1000*2.59*(165-30)/1.9592*(250-175)

Mc steam = 2379.54 Kg/hr

6.3 Reactor

NH3 + HNO3 NH4NO3

∆H°f NH3 = 289.28 KJ/Kg

∆H°f HNO3 = 406.88 KJ/Kg
∆H°f NH4NO3 = 702.92 KJ/Kg

For NH3:-

E = Mc*Cp*∆T
= 161.9*2.217*(210-150)
E = 21.53*10^3 KJ/hr

For HNO3:-

E = Mc*Cp*∆T
= 1000*2.59*(210-165)
E = 116.55*10^3 KJ/hr

29
 E total = (21.53*10^3) + (116.55*10^3)
E Reactant= 138.08*10^3 KJ/hr

For NH4NO3:-

E = Mc*Cp*∆T
= 761.90*0.088*210
E Product = 14.07*1063 KJ/hr

∆H°reaction = 760.38*702.92
= 534.48*10^3 KJ/hr

Q = EProduct- EReactant + ∆H°reaction

= (14.07*1063) - (138.08*10^3) + (534.48*10^3)
Q = 410.47*10^3 KJ/hr

After producing NH4NO3 (410.47*10^3 KJ/hr) energy produced. So that using brine
(Nacl) for controlling that much energy.

Q = Mc brine*Cp*∆T
Mc brine = 410.47*10^3/0.80 *(201-2)

Mc brine = 2578.36 Kg/hr

6.4 Air preheated

Table 6.3

TEMPRETURE COLD HOT

FLUID(Air) FLUID(steam)
INLET 30°c 194°c
OUT LET 100°c 150°c

30
Mc Steam = 401.52 Kg/hr
Cp steam = 1.9592 KJ/Kg K
Cp Air = 0.99 KJ/Kg hr
Mc Air*Cp*∆T = Mc steam*Cp* ∆T
Mc Air = Mc steam*Cp* ∆T/ Cp*∆T
= 401.52*1.9592*(194-150)/0.99*(100-30)
Mc Air = 397.30 Kg/hr

6.5 Partial condenser

Table 6.4
TEMPRETURE COLD HOT
FLUID(Air) FLUID(steam)
INLET 30°c 150°c
OUT LET 90°c 120°c

Mc steam = 401.52 Kg/hr

Cp steam = 1.9592 KJ/Kg K

Cp Air = 0.99 KJ/Kg K

Mc Air*Cp*∆T = Mc steam*Cp* ∆T

Mc Air = Mc steam*Cp* ∆T/ Cp*∆T

= 401.52*1.9592*(150-120)/0.99*(90-30)

Mc Air = 397.30 Kg/hr

6.6 Final condenser

31
 Table 6.5
TEMPRETURE COLD HOT
FLUID(Air) FLUID(water)
INLET 20°c 120°c
OUT LET 60°c 70°c

Mc water = 400 Kg/hr

Cp water = 4.186 KJ/Kg K

Cp Air = 0.99 KJ/Kg K

Mc Air*Cp*∆T = Mc water*Cp* ∆T

Mc Air = Mc water*Cp* ∆T/ Cp*∆T

= 400*4.186*(120-70)/0.99*(60-20)

Mc Air = 2114.14 Kg/hr

6.7 Cooling belt conveyor

Table 6.6

TEMPRETURE COLD HOT

FLUID(water) FLUID(NH4NO3)
INLET 20°c 194°c
OUT LET 80°c 110°c

Mc NH4NO3 = 760.38 Kg/hr

Cp water = 4.186 KJ/Kg K

Cp NH4NO3 = 0.088 KJ/Kg K

Mc NH4NO3*Cp*∆T = Mc water*Cp* ∆T

Mc water = Mc NH4NO3*Cp*∆T/Cp*∆T

= 760.38*0.088*(194-110)/4.186*(80-20)

32
Mc water = 22.3 Kg/hr

33
 CHAPTER 7

DESIGN OF EQUIPMENT

CHAPTER 7

34
 DESIGN OF EQUIPMENT
7.1 Design of Reactor
7.1.1 Process Design
NH3 + HNO3  NH4NO3

Assume:
Concentration of NH3 (CA0) = 1 kmol/lit
Concentration of HNO3 (CB0) = 0.6 kmol/lit

Suppose conversion of reactant is 98%.

A = 0.98, B = 0.98

CA & CB the concentration of A & B at any time:

CA = CA0 (1 – XA)
= 1 (1 – 0.98)

CA = 0.02 kmol/lit

CB = 0.6 (1 – 0.98)
= 0.012 kmol/lit

This reaction is second order and irreversible.

-rA = KCACB

ln = = CA0 (M-1) Kt

Where, M = = 0.6

ln = = 1 (0.6 - 1) Kt

-ln = (31.66) = -0.4 x K

K = 8.63 lit/Kmol.hr

Rate of reaction -rA = KCACB

= 8.63 x 0.2 x 0.012
= 0.002 Kmol/Lit.hr
Design Equation for CSTR

35
 Where, FAO = 161.90 kg/hr (NH3)
=
= 9.52 kmol/hr
=

V = 4666.52 Lit
= 4.66 m3

7.1.2 Mechanical Design

Volume of reactor = 4.55m3
V =
4.66 =
R = 1.03 m
Diameter = 2xR
= 2.07 m
Taking D = 2m, (l = 2D0 = 4.02m)
Internal pressure = 3.5 atm
= 0.35 N/mm2
Design pressure = 0.35 + 10% of 0.35
=
= 0.385 N/mm2
Material = Stainless steel (Cr-Ni)
Permissible stress at 210ºC fs = 130 N/mm2
J = Joint efficiency = 0.85
Thickness of shell, ts =
=
ts = 3.49 mm

Taking thickness of shell = 5mm

1) Testing of shell under different loading condition:

a) Stress in circumferential direction:

Ft =
=
Ft = 77.18 N/mm2

2) Stress in longitudinal on axial direction:

A) Due to internal pressure.

F1 =
F1 = 38.5 N/mm2 (tension)

36
 Due to weight of vessel and contents:
F2 =

Where,W = weight of vessel with its contents

= WV + Wc

Wv = Fss + Vs

Fss = 7752 kg/m3

Vs = Volume of SS access in reactor

=  x (D02 – Di2) x L
(L = 2D0 )
=  ((2.0) – (2) ) x 4.02
2 2

Vs = 0.5064 m3

Wv = 7752 x 0.5064
= 3925.85 kg
= 39258.53 N

Wc = Fsolution (NH4NO3) x Vc
= 1403.3 x 4.66
Wv = 6539.3 kg = 65393.7 N

W = 39258.53 + 65393.7
= 104.65 x 103N

F2 =
= 2.32 N/mm2 (compression)

Total longitudinal stress Fa = F1 + F2

= 38.5 – 3.32
= 35.18 N/mm2

We are neglecting wind load

According to shear strain theory

FR =
=
= 66.93 N/mm2
= 130 N/mm2
Here, FR < ts for stainless steel so, design is safe.

2) Head Design:

37
 Material : SS
Type : Conical
Thickness of head th =
=
= 5.93 mm
Taking thickness of head = 6mm

3) Design of Flange:

Flange of material = CS
Bolt material = CS
Gasket material = Solid flat metal sheet of SS
Gasket factor m = 4.25 (Table 12.11 B & Y)
Min. design seating stress y = 71 N/mm2

a) Gasket Design
=
=
= 1.002

Gi = Do + (30 + 0.50) mm
= (Di + 2t) + 40
Gi = (2000 + 2 x 5) + 40
= 2050 mm
G0 = 2054.1 mm

Min. gasket width N =

=
= 2.05 mm

Mean gasket diameter G = = 2052.05 mm

b) Calculation of bolt loads :

Wm1 =  bGy
b0 = N/2 = 1.025, b = b0
=  x 1.025 x 2052.05 x 71.
= 469158.97 N

Wm2 = 2bGmp + G2P

= x 1.025 x 2052.05 x 4.25 x 0.385 + (2052.05)2 x 0.385
= 1294911.8 N

c) Min. bolting area:

Am1 = =

38
 = 7992.48 mm2

Am2 = =
= 13213.38 mm2

Take higher Area.

F1 = allowable stress at atm temperature = 58.7 N/mm2

F2 = stress in bolt material at design temperature = 98 N/mm2

Optimum bolt size:

Table 7.1

D(mm) Ar Nm = n = nm R Bs E Dbc=Shell
in ID +
multiply 2*(1.45*G0
4 +R)
12.7 81.3 163 164 20.6 76.2 15.9 3977.85 2055
15.9 130.3 102 104 24 76.2 19 2522.54 2062
19 195 68 68 28.5 11 20.6 1649.35 2071

Optimum bolt size = 19mm = ¾”

Dbc = 2071.5 mm

Dof = Dbc + 2E
= 2071.5 + 2 (20.6)
= 2112.7 mm

Check of gasket width

For safe design
Abactual > Abrequired (higher Am1 & Am2)

Abactual =
=
= 19149.34 mm2
Abrequired = 13213.38 mm2

Abactual > Abrequired

So that design will be safe.

Thickness of flange:

39
 tf =
K =
HG = = = 1273287.53N
hg = = 9.72
K =
= 0.066

tf =

= 500.64 mm

4) Design of Nozzle

Assume inside diameter of nozzle : 350 mm

Thickness of shell : 5mm
th = =
= 0.62 mm

Nozzle compensation
Area of compensation required Ac = Dn x ts
= 350 x 5
= 1750 mm2
Area of compensation provided by :

1) Head
Ah = Dn x (tn – tn’)
tn = Actual thickness of head = 5mm
tn’ = Theoritical thickness of head = 5.93mm

= 350 x (6 – 5.93)
= 24.5 mm2

2) Nozzle
An = 2 x H1 x (tn – tn’)
H1 = height of effective compensation in branch wall external to
vessel
= 2.5 x ts
= 2.5 x 5
= 12.5 mm
An = 2 x 12.5 x (5 – 0.62)
= 109.5 mm2

Total area of compensation provided

AT = Ah + An
= 24.5 + 109.5
= 134 mm2

40
 AT < AC, so the area of compensatin required
Area of compensation required (Ar) = Ac + AT
= 1750 – 134
= 1616 mm2

dis = d + 2tn
= 350 + 2 x 5
= 360 mm
dor = 2d = 700mm
Compensation area required = (dor – dir) x tr’
1616 = (700-360) x tr’
tr' = 4.75mm

5) Design of Bracket Support

Diameter of vessel D = 2m
Height of vessel H = 4.02m
Liquid phase volume = 4.66 m3
Density of NH4Na3 = 1403 kg/m3
Mass of liquid = J x V = 1403.3 x 4.66
= 6539.37 kg
Quickness of shell = 5 mm
Material = SS
Fb = 157.7 N/mm2

a) Maximum compensive load

W = Wv + Wc
= Fss x Vs
= 7752 x 0.5064
Wv = 3925.85 Kg
= 39258.5 N

Wc = Jsolution x Vc = 1403.3 x 4.66

= 6539.37 kg = 65393.7 N
W = 39258.53 + 65393.7
= 104.65 x 103N

b) Base plate thickness:

Here, diameter of vessel is 2m
So, the number of bracket is 4
P =
= 26162.5 N

a = distance between two gasket plate = 140 mm

h = height of gasket plate = 145 mm
A x C = Size of base plate = 150 x 150 mm

41
 Pavg = =
= 1.24 N/mm2

Fb =
157.7 =
tb2 = 53.43
tb = 7.30 mm  8 mm

c) Design of gasket plate (Web plat)

Fb =
tan  =
 = 44

2b = Dbc – 2R
= R =
b = 33.25 R = 1002.5 mm

157.5 =

tw2 = 1.095
tw = 1.04 mm

6) Design of Agitator:

1) Diameter of agitation = (2/3 of Shell JD) = 1.3 m

2) Density of liquid = 1403.3 kg/m3
3) Max speed = 400 rpm
4) Overhang agitator shaft= 2.8m
5) Fs = 55 x 106 N/mm2
6) E = 19.5 x 1010 N/mm2
7) Ys = 360 x 106 N/m2

Power requirement for agitation & used 12.5 Hg for allowance of fitting and heavy load.

1) Torque
Tc =
= 22.38 m. Kg

Tm = 1.5 x Tg = 33.57 x 9.81

= 329.32 N.m

ts = (16*Tm) / 3.14* ds3

ds3 =

ds = 0.031m

42
2) BM
F = Fm =
F = Fm = 675. 54M
F = 651.6 x 10 N/m2
6
M = Fm x L
= 675.54 x 2.8
F< not Ys = 1891.54 N.m

Assume, ds = 0.038m Mc =
F = 353.3 x 106 N/m2 =
F < Ys Mc = 1905.76 N.m

3) Critical speed:

Ncr =  =
do = 0.038m I =
NG = W = Fm = 675.54
I = 1.02 x 10-7 m4
 = 0.24
Mcr = 601.25 rpm
Ncs < not N (60%)

do = 0.04 m
I = 1.25 x 10-7 m4
 = 0.20
Ncr =
Ncr = 666.00 rpm

7) Design of half coil jacket:

t =
=
= 3.49 mm

7.2 DESIGN OF STORAGE VESSEL

7.2.1 Mechanical design

Capacity = 500 m3
Material of construction = Stainless Steel
Design Temperature = 15-30 C
Design Pressure = 1atm
Fluid to be handled = Nitric acid
Density of fluid (NaOH) = 1518.1 Kg/m3

43
Boiling point of fluid (NaOH) = 1390 oC
Corrosion allowance =0
Allowable stress = 128 N/mm2
Density of M.O.C = 7750 kg/m3
Modulus of elasticity = 1.90*10-5 N/mm2
Joint efficiency = 0.85
Plate Dimension = 6m*1.5m*various thickness
For large volume tank
D/H=8/3
D=(8/3)H
V= π/4 * D2 * H
500 = π/4*(64/9)*H3
H= 4.46 m
H= 5 m
D= 2.67 H
D= 2.67 * 4.46
D= 13.35 m
D= 14 m

 Shell Design
Shell thicness of lowest course
t = (pD/2fJ)+C.A
p=(5-0.3)* 1.518 * 10-6 * 10
p=0.071346 N/mm2
t=0.071346 * 14 * 1000/(2 * 0.7 * 0.85) + 0.0
t = 4.59 mm
t ≈ 5 mm

 NO. Plates
Ns= nH * nV
nH = π * D –(nH*2*10-3)/L
nH = π * 14 –(nH*2*10-3)/5
nH = 8.79 plates
nV = H –[(nV*2*10-3)/w
nV = 4.46 –[(nV*2*10-3)/1.5
nV = 3.31
Ns= nH * nV
= 8.79 * 3.31
Ns = 29.09 ≈ 30 plates
 Bottom Design
Db = Ds+2ts+(2*welding thicness)+(0.0254*2)
= 14 + (2* 5 * 10-3) + (4*10-3) + 0.0508
Db = 14.0648m

44
No. of plate at bottom
Nb = (π/4)*Db2/L*w
= (π/4)*14.06482/5*1.5
= 20.69
Nb ≈ 21 plates
 Roof plate Thickness

D p
sinθ =
tr 0.204 xE
Assume tr = 20 mm
p= (tr * ρ * 10) +1250 N/m2
p=(0.020 * 7750 * 10) + 1250
p= 2800 N/m2

14000 2800 x106

sinθ =
20 1.95 x105 x0.204
sinθ = 0.1857
θ = 10.700
θ should be less than 11.30
 Reinforcement of top shell
a.
A1 = pD2cotθ/8f
P = liveload + dead load
= 77.50 N/m2
Cot θ = 84.66
A1 = 77.50 * 10-6 *140002 *84.66 /8 * 128
A1 = 1255.85mm2
b.
Require area for RCA
A2 = Ac + As + Ar
As = 1.5xtx Rt
= 1.5 x5 x 7000 x5
= 1403.12 mm2
Ar = 0.75 * tr *
r = (D/2)/ sinθ
= 7000/0.185
r = 37701 mm
Ar = 0.75 x 20 x 37701x 20
Ar = 13025.3 mm2
Ac = 65 * 65
= 4225 mm2
A2= 1403.12 + 13025.3 +4225 =18653.3mm2
A2 > A1

45
Therefore design is safe

46
 CHAPTER 8

INSTRUMENTATION & P.T. DIAGRAM

CHAPTER 8

INSTRUMENTATION & P.I. DIAGRAM

The concentration of ammonium nitrate and nitric acid solutions can be estimated
quickly from specific gravity measurement using a hydrometer. The approximate
concentration of the ammonium nitrate melt can be estimated by determining the boiling
point.

Automatic controls of the ratio of the ammonia to nitric acid flows in the
neutralizing stage ensure the smooth running of the process and minimize ammonia
losses. Any deviation from the optimum ratio of ammonia to nitric acid can result in
appreciable losses of raw materials.

The amount of nitric acid that is allowed to flow in is adjusted according to the free
acid in the solution leaving the ITN neutralizer.

47
 For a given constant ratio of ammonia for nitric acid flows, variations in the
concentration of nitric acid affect the amount of ammonia which is neutralized and so the
control scheme includes automatic flow correction for variation in the concentration of
nitric acid.

Control of the temperature in the reactor is achieved by automatically adjusting the

flow of gaseous ammonia and the pressure is adjusted automatically by a pressure
controller mounted in the secondary steam collector.

Ammonia pressure is adjusted by means of a pressure controller mounted in the

gaseous ammonia collecting pipe.

The concentration of the solution at the outlet of the first stage evaporator is
maintained by means of temperature controllers which adjust the outlet temperature of
the solution altering the flow of the solution of the evaporator. If the temperature of the
solution rises, the quantity of solution fed to the evaporator is increased.

A single operated automatic shut-off valve controls the steam feed to the evaporator
to avoid overheating and the consequent decomposition and explosion of the ammonium
nitrate that could occur.

The moisture content of the finished product can be determined rapidly by

electronic measurement of the conductivity.

48
 CHAPTER 9

SAFETY AND ENVIRONMENTAL ASPECT

49
 CHAPTER 9
SAFETY AND ENVIRONMENTAL ASPECT
Label Hazard Warning:

Danger:

Strong oxidizer contact with other material may cause fire or explosion. May be
harmful of swallowed or inhaled. Cause irritation to skin, eyes and respiratory tract.

Label Precautions:
- Do not store near combustible materials
- Store in a tightly closed container.
- Avoid breathing dust.
- Avoid contact with eyes, skin & clothing.
- Use only with adequate ventilation.
- Wash thoroughly after handling
- Store preferably below 300C

50
Label First Aid:

If inhaled remove to fresh air. Get medical attention for any breathing difficulty.
In case of contact, immediately flush eyes or skin with plenty of water for at least
15 minutes. If swallowed, do not induce vomiting. Give large quantity of water.
Never give any thing by mouth to an unconscious person. In all cases get medical
attention.

Environmental Fate:

When released in the soil, this material is expected to leach into ground water.
When released into the soil, this material is not excepted to evaporate
significantly. When released into water, this material is expected to readily
biodegrade.

HAZARDS IDENTIFICATION

Potential Health Effects:

Inhalation

May cause irritation to the respiratory tract, symptoms may include coughing, sore
throat and shortness of breath. At high temperature, exposure to toxic nitrogen
oxides decomposition product can quickly cause acute respiratory problems.
Inhalation of large amounts causes systemic acidosis and abnormal hemoglobin.

Ingestion

Large oral doses of nitrates may cause dizziness, abdominal pain, vomiting, bloody
diarrhea, weakness, convulsions, and collapse. Harmful if swallowed.

Skin Contact

Causes irritation to skin. Symptoms include redness, itching and pain.

51
Eye contact

Causes irritation, redness and pain

Chronic Exposure

Small repeated doses of nitrates may cause weakness, depression, headache, and
mental impairment.

First Aid Measures

Inhalation

Remove to fresh air. Get medical attention for any breathing difficulty.

Ingestion

If swallowed, do not induce vomiting. Give large quantity of water. Never give
anything by mouth to an unconscious person. Get medical attention immediately.

Skin contact

Remove any contaminated clothing. Wash skin with soap and water for at least
15 minutes. Get medical attention if irritation develops of persists.

Eye contact

Wash thoroughly with running water. Get medical advice if irritation develops.

Fire Fighting Measures

Fire

52
 Not combustible, but substance is a strong oxidizer and its heat of reaction with
reaction with reducing agents or combustibles may cause ignition. May support
combustion in an existing fire.

Explosion

Contact with oxidizable substances may cause extremely violent combustion.

Sealed containers may rupture when heated. Sensitive to mechanical impact.

Fire Extinguishing Media

Use flooding amount of water in early stages of fire involving ammonium nitrate.
Use any means suitable for extinguishing surrounding fire.

Special Information

In the event of a fire, wear full protective clothing and self contained breathing
apparatus.

Handling and Storage

- Keep in a tightly closed container, stored in a cool, dry, ventilated area. Protect
against physical damage
- Store in a dry location separate from combustible, organic or other readily
oxidizable materials. Avoid storage on wood floors
- Do not store above 540C preferably below 300C. Containers of this material may
be hazardous when empty since they retained product residue.

Exposure Controls/ Personal Protection

Ventilation System
A system of local and general exhaust is recommended to keep employee
exposures as low as possible.

53
 Local exhaust ventilation is generally preferred because it can control the
emission of the contaminant at its source, preventing dispersion of it into the
general work area.

Personal Respirators
For conditions of use, where exposure to dust or mist is apparent and engineering
controls are not feasible, a particular respiration may be worn.

For engineering or instances where the exposure levels are not known, use a full-
face positive pressure, air supplied respiration.

Skin Protection
Wear protective gloves and clean body-covering clothing

Eye Protection
Use chemical safety goggles
Maintain eye wash fountain and quick-drench facilities in work area.

54
 CHAPTER 10

PLANT LOCATION AND LAYOUT

55
 CHAPTER 10
PLANT LOCATION AND LAYOUT

The geographical location of the plant can have strong influence on the success of an
industrial venture and a care is taken while choosing a plant site. The plant must be
located where minimum cost of production is obtained but other factors as room for
future expansion and general living conditions should also be considered.

PLANT LOCATION

Factors, which generally apply to be economic and operability aspects of plant site
location, are classified into two major groups.
1. Primary Factors
2. Secondary Factors

PRIMARY FACTORS

Raw Material Supply:

It is one of the important factors toward choice of a plant. We should build the plant at
such a location where raw materials are available in ample quantity. Availability of raw
materials in the near by areas not only reduce availability problems but also reduces the
cost of transportation etc. In our case there are main raw materials are Ammonia and
Nitric acid which are easily available from the areas of chemical industries in Gujarat.

Market:
we are getting Ammonium nitrate is good nitrogen based fertilizer. In country like India
it is consumed in a great amount. And now the western region governs an established fact
that majority of Indian markets in all region. Transportation facilities are available to
link the Indian Territory with the western region via rail, road and water transportation.
Power and Fuel Supply:

56
Power & steam requirement of chemical industries are perhaps the largest among
industries, hence this is also a further factor of significance. In the western region
particularly in Gujarat and Maharashtra electricity supply position is satisfactory. Main
source of energy for small scale sector is Gujarat Electricity Board.

Water Supply:
Water is required in the plant for steam generation and cooling. The water supply
situation in western region especially in Gujarat region is satisfactory. Plant’s own
drilling wells may also provide water supply source.

Climate:
Excessive cold, deep snow, heat and excessive humidity reduce the productivity on the
part of workman. Moreover if the site location is in hot damp climate adjacent to salt
water, there is higher maintenances cost as because of corrosion problem.

SECONDARY FACTORS

Transportation:
In the secondary factors transportation is the main factor. There should be ease in
transportation of raw materials, products. So there should be rail line, road line. And for
foreign transportation airline should be nearer from the location.

Labor:
Skilled and unskilled labor availability with suitable labour rates is an important factor.
Point to be considered in labour studies is supply, kind, diversity, intelligence, wage
scale, regulations, efficiency, costs, stability in work and rate. In the region under
consideration there should be no problem so far as availability of labour in the selected
area is concerned.

Taxation and Legal Restriction:

57
State and local tax rates on property, income, unemployment, insurance and similar items
vary from one location to another. Similarly local regulations on zoning, building code,
nuisance aspects and transportation facilities can have major influence on the final choice
of a plant site. In fact zoning difficulties and obtaining the many required permits can
often be much more important in items of cost and time delays.

Waste Disposal:
With increasing industrialization more and more industrial waste is being released to
atmosphere. Increasing pollution has led to the legal restriction for waste disposal.
Generally Ammonium nitrate plant produced waste that creates disposal problems. So
waste disposal problem is one of the major considerations in the plant.

Site Characteristics:
The characteristics of the land at proposed plant site should be examined carefully. The
topography of the land and soil structure must be considered. Since either or both may
have pronounced effect on construction costs. It takes real vision when locating a new
plant to provide adequately for future expansion. Land is relatively cheap compared to
over all plant costs and if provisions are made for too much land, it can be sold usually at
a profit later on if there are other plants in the immediate neighborhood of a site under
consideration.

Flood and Fire Control:

Industrial plants located along rivers or near large bodies of water carry risks of flood
and hurricane damage. Protection from losses by fire is another important factor in
selecting a plant location. In case of major fire, assistance from outside fire department
should be available with in short time to prevent the fire from spreading.

Community Factors:
If a certain minimum number of facilities for satisfactory living of plant personnel do not
exist, if often becomes a burden for the plant personnel and their family. Cultural

58
 facilities of the community are important for sound growth. The problem of recreation
deserves special consideration.

Economic Relation with Other Industries:

As a rule, a chemical plant will have a better chance of success if located near other
plants of like nature. A group of plants can obtain favorable rail rates. Better technical
services are also available. Utilization of waste from related plants or similarity of
disposal offers unusual opportunities for economics.

PLANT LAYOUT

Layout may have several objectives such as increased output, reduced risk to health of
employees improved worker hour fewer product delays, saving in floor space, reduced
material handling, greater utilization of main power services and machinery reduce
inventory in process, shorter manufacturing time, easier adjustment to changing
condition etc. The major objective is to arrange that physical facilities (land, building,
machinery, materials, men, service etc.) in such a way also have:
 Overall integration of all factors affecting plant layout.
 All space effectively utilized.
 Flexible arrangement.
 Material moving a minimum distance.
 Satisfactory and safety for workers.
 There must be protection against fire, a fume and comfortable, pleasant working
environment and other feature that facilitate operation.

The plant layout is affected by:

 Manufacturing process.
 Lighting and ventilation.
 Building and construction material.
 Plant machinery.

59
 Material specification.
 Location and site of plants.
 Material handling.
 Storage of materials.
 Future expansion.
 Auxiliary equipment.
 Movement of special assembly equipment and easier supervision of the layout has been
planned and controlled.

Storage Layout:
Storage facilities for raw materials and intermediate and finished products may be
located in isolated areas or in adjoining areas. Hazardous material must be isolated.
Storage in adjoining area reduces material handling cost but care should be taken that it
should not be an obstacle towards the future expansion of the plant. Arranging storage of
raw material is also considered because it reduces material handling cost.

Equipment Layout:
In making layout, ample space should be assigned to each piece of equipment;
accessibility is an important factor for maintenance. It is poor economy to fit the
equipment layout too closely into a building. A slightly larger building should be
preferred. The operations that constitute a process are essentially series of unit
operations that may be carried out on simultaneously. This sort of layout will make
possible decision of operating labor so that one or two operators can be detailed to tend
all equipment of like nature. Access for initial construction and maintenance is necessary
part of planning.

Safety:
A great deal of planning is governed by local and national safety and fire code
requirements. The reactor being high-pressure unit should be located slightly away from
all other equipment and property.

60
Plant Expansion:
Plant expansion must always be kept in mind. So if in future one wants to develop the
plant or wants to increase the capacity or to implant some new equipments then he can
have a space for it. The question of multiply in number of units of increasing the size of
the prevailing unit or units is most important. So one must consider this point.

Floor Space:
Floor space may or may not be a major factor in design of a particular plant. The value
of land may be considerable item. The engineer should follow the rule of practicing
economy of the floor space in storage layout and equipment layout.

Utilities:
Proper placement of gas, steam, water, power and electricity services need practicing of
good design, aids in the case of operation ore lines, and reductions in cost of
maintenance.

Building:
It is fundamental in chemical engineering industries that the buildings should be built
around the process, instead of the process made to fit buildings of conventional design.
Through out chemical industry much through must be given to the disposal of waste
liquors, fumes, dust and gases, ventilation, fume elimination and drainage may require
the installation of extra equipment. This pays in better service from operators, less
discomfort, greater production and a better moral than when such conditions are left to
nature.

Material Handling Equipment:

Consideration of equipment of material handling is only a minor factor in most cases of
arrangements owing to the multiplicity of available material handling devices
engineering judgments must be exercised.

61
A good deal of automatic process is required for
 To run a full production scale plant continuously without attention from operators or
chemical technician.
 To reduce manpower requirement and therefore lowers labor costs.
 To reduce or eliminate human errors.
 Chosen adherence to optimum condition results in an improvements in overall process
quality.
 To reduce space requirements for the process unit.
 To increase safety in operation.
 To keep the personnel away from hazardous operations.

62
 CHAPTER 11

COST ESTIMATION

63
 CHAPTER 11

COST ESTIMATION

A) Total capital investment:-

1) Purchase equipment cost: (P.E.C)

Sr. Equipment MOC NO. of Total cost

No equipment (Rs.)
1 Nitric acid storage SS 1 3,50,000
tank
2 Preheater SS 3 60,000
3 Reactor SS 1 65,10,000
4 Separator - 1 75,000
5 Condenser - 2 1,56,000
6 Discharge box - 1 5,000
7 Cooling belt conveyor - 1 45,000
8 Breaker - 1 5,000
9 Crushing mill - 1 20,000
10 Nitrating screen - 1 10,000
11 Tank for dilution of SS 1 1,50,000
fines
12 Weighting scale - 1 5,000
13 Coating drum - 1 10,000
14 Bin for packing - 1 10,000

Total P.E.C 74,11,000

Table 11.1

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B) Fixed capital investment:-

1) Indirect cost:

Table 11.2

Sr. Item % taken Total cost (Rs)

No
1 Design and engineering 18 13,33,980
2 Construction Expanses 11 8,15,210
Total indirect cost 21,49,190

2) Direct cost:
Table 11.3

Sr. Item % Range of % taken Total cost

No P.E.C (Rs)
1 P.E.C 100 100 74,11,000
2 Installation 6-14 11 12,45,700
3 Instrumentation 2-8 7 6,56,400
4 Piping 3-20 13 11,70,500
5 Electrical 2-10 7 7,55,700
6 Building, process, 3-18 10 13,35,700
Auxiliaries
7 Land 1-2 1.5 2,48,950
Total Direct cost 1,28,23,950

Total Direct and indirect cost = 1,28,23,950 + 21,49,190

(TDIC) = 1,49,73,140 Rs

Contingency = 10% TDIC

= 14,97,314 Rs

Fixed capital investment (FCI) = TDIC + Contingency

= 1,64,70,454 Rs

65
 Working capital investment (WCI) = 15% FCI

= 24,70,568 Rs

Total capital investment (TCI) = FCI + WCI

= 1,89,41,022 Rs

C) Total Product cost:-

1) Direct production cost:

a) Raw material cost:

Basis: 66,74,244 Kg/Year of NH4NO3

HNO3 required = 87,60,000 Kg/year

Cost pre Kg of HNO3 = 8.75 Rs/Kg

HNO3 cost = 7,66,50,000 Rs/year

NH3 required = 14,18,244 Kg/year

Cost per Kg of NH3 = 10 Rs/Kg

NH3 cost = 1,41,82,440 Rs/year

Total Raw material cost a = 9,08,32,440 Rs/year

b) Operating labor cost:

Table 11.4

Sr. Category Pay/Month Salary/year No Total

No (Rs) salary(Rs)
1 Manager 25,000 3,00,000 1 3,00,000
2 Engineer 15,000 1,80,000 6 10,80,000
3 Operator 6,000 72,000 18 12,96,000
4 Worker 3,000 36,000 24 8,64,000

66
 5 Watchman 2,000 24,000 3 72,000
6 Office staff 4,000 48,000 5 2,40,000
7 Peon 1,500 18,000 2 36,000
8 Lab. Staff 3,500 42,000 4 1,68,000
Total 40,56,000

c) Laboratory charges = (10-20% of operating labor)

= 0.15* 40,56,000

= 6,08,400 Rs/year

d) Royalties = (0-6% of TPC)

= 0.03*Z

Where Z = Total production cost

e) Maintenance & Repair = 5% of FCI

= 0.05* 1,64,70,454

= 8,23,523 Rs/year

Direct production cost(A): = a+b+c+d+e

= 9,08,32,440+ 40,56,000+ 6,08,400+ 0.03*Z+

8,23,523
(A) = 9,63,20,363+ 0.03*Z

2) Fixed charges:-

a) Depreciation: = (10% FCI for Equipment)

=0.1* 1,64,70,454

=1647045.4 Rs

b) Local Taxes = (1-4% FCI)

= 0.025* 1,64,70,454

67
 = 411761.35 Rs

c) Insurance = (0.4-1% FCI)

= 0.005* 1,64,70,454

= 82,353 Rs

Fixed charges (B) = a+b+c

= 1647045.4+ 411761.35+ 82353

= 21,41,160 Rs

Total production cost (Z) = A+B

= 9,63,20,363+ 0.03*Z+ 21,41,160

Z (1-0.03) = 9,84,61,523

Total production cost (Z) = 101506724.7 Rs/year

D) Profibility

Market price of NH4NO3 = 17 Rs/Kg

Gross seen of NH4NO3 = 17* 66,74,244

= 11,34,62,148 Rs/year

Total income = 11,34,62,148 Rs/year

Total annual expanses = 101506724.7 Rs/year

1) Gross profit (Profit before taxes) = Total income – annual expanses

= 11,34,62,148 – 101506724.7

= 11955423.3 Rs/year

2) Income tax = 40% on gross profit

= 0.40* 11955423.3

68
 = 4782169.32 Rs/year

3) Net profit (after tax) = Gross profit – Income tax

= 11955423.3 – 4782169.32

= 7173253.98 Rs/year

E) Payout period:-

Payout period = FCI (Net profit + Depreciation)

= 16470454/ (7173253.98 + 1647045.4)

= 1.86 year

F) Rate of Return:-

1) Rate of return on total capital investment before income tax:

= Gross profit / TCI

= 11955423.3 / 1,89,41,022

=0.63

=63%

2) Rate of return on total capital investment after income tax:

= Net profit / TCI

= 7173253.98 / 1,89,41,022

= 0.37

=37%

69
CHAPTER 12

CONCLUSION

70
 CHAPTER 12

CONCLUSION

Ammonium nitrate can be manufactured by various processes. Raw material

for manufacture of the ammonium nitrate is ammonia and nitric acid.

Ammonium nitrate is one of the most popular forms of nitrogen fertilizer. It can
be used as direct or indirect fertilizer. Ammonium nitrate is also used for oxidizing agent
and explosive.

Stengel process is one of the low cost manufacturing processes. We can get about
99.5% concentrations at the end product.

71
CHAPTER 13

REFERENCES

72
 CHAPTER 13

REFERENCES

1) Kirk othemer,“Encyclopedia of chemical technology”, volume: 2

2) Ullman, “Encyclopedia of chemical engg.”, Volume: 3

3) Perry J.H, “Chemical engineering hand book”.

4) Charles Dryden “Outlines of chemical technology”.

5) Bhatt and vora, “Stoichiometry”.

6) M.S.peters & k.Timmrrhous. “Plant design & economics for chemical engg.”

7) M.V.Joshi, “Process equipment designing”.

8) Octave livenspiel, “Chemical reaction engg.”

9) Magazine : Chemical Weekly

Chemical eng.world

73