Bostik India

DESIGN STEPS

TOTAL TYPES OF WASTES :

1) Solid Waste : 20 Kg/Hr, 100% organic ,CV =4000 Kcal/hr

2) Aqueous Waste: 150 Kg/Hr, 3% organic, Water 96%, inorganic 1%, CV =Nil

3) Cooling Water Blowdown: 400 Kg/Hr, Water with TDS, Water 99%, Inorganic 1%, CV = Nil

PRIMARY COMBUSTION CHAMBER :

SOLID WASTE :

Mass to be fed in to the PCC = 20 Kg/hr

Calorific value :

HCV= [35000*C+143000*(H-O/8)+9160*S]/100
LCV= HCV-9*H/100*2460

Waste composition : % Kg/hr

Organic 100 20
Moisture 0 0
Inorganics 0 0
20

Calorific Value 4000 kcal/kg

temperature T2 850 C

T1 30 C

A/W Ratio 5.41 1.48

Consider (36 % excess air) 8.00

Combustion air reqiured 160 kg/hr

D.G 157 kg/hr
Moist (Say 2 %) 3 kg/hr

Heat required for waste =

1 by organics m*0.6*(T2-T1)
10004.00 kcal/hr

2 by inorganics m*0.3*(T2-T1)
0.00 kcal/hr

3 by moisture m*{70+540+0.5(T2-100)}
0.00 kcal/hr

4 heat by Combustible air = Air * 0.28 *(T2-T1)

39360.00 kcal/hr

Total Heat Required = 49364 kcal/hr

0.049364 MKcal/hr

Heat Released by Organics = 80000 kcal/hr

 AQUEOUS WASTE :

Total Mass flowrate = 150 Kg/hr

Mass flowrate to PCC = 150 Kg/hr

Waste composition : % Kg/hr

Organic 3 5
Moisture 96 144
Inorganics 1 2
150

Calorific Value = 0 kcal/kg 36

A/W (50% extra) 0.00 0.00 #DIV/0!

ASSUMED Air Required = 90 kg/hr

D.G.= 88 kg/hr
Moist.= 2 kg/hr

Temperature T1 30 °C

T2 850 °C
Heat and Mass Balance :
1) Heat absorbed by Liquid waste =
1 by organics m*[0.6*(150-T1)+150+0.3(T2-150)]
1944.00 kcal/hr

2 by inorganics m*0.3*(T2-T1)
369 kcal/hr

3 by moisture m*{70+540+0.5(T2-100)}
141840 kcal/hr

4 heat by Combustible Air * 0.28 *(T2-T1)

air 22140 kcal/hr

Heat absorded by Liquid waste = 166293 kcal/hr

Heat released by Liquid waste = 0 kcal/hr

Assume 0 kcal/hr

Total Heat absorbed in PCC = 215657.00 Kcal/Hr

Total Heat absorbed( 10% Excess)= 237222.70 Kcal/hr

Total Heat released in PCC = 80000.00 Kcal/hr

Total Heat released ( 10 % loss) = 72000.00 Kcal/hr

Net heat Available (Released - Absorbed) = -165222.70 kcal/hr

Fuel Required (F.O.) = CV = 9650 29.95 Kg /hr , A/F = 13.04 18.00

30 kg/hr 1.38

Combustion Air Required = 540 kg/hr

D.G. 529 kg/hr
Moist 11 kg/hr

Mass out = 989 D.G = 829

Moist = 160

Thermal capacity of Chamber = 0.2432 Mkcal/hr 0.2521 Mkcal/hr

 CALCULATIONS FOR S.C.C:

AQUEOUS WASTE :

Mass flowrate =
0 Kg/hr

Waste composition : % Kg/hr

Organic 3 0
Moisture 96 0
Inorganics 1 0
0

calorific Value = 0 kcal/kg

A/F (38% extra) 0.00 0.00 #DIV/0!

Air Required = 0 kg/hr

D.G.= 0 kg/hr
Moist.= 0 kg/hr

Temperature T1 30 °C

T2 1000 °C

Heat absorbed by Aqueous waste =

1 by organics m*[0.6*(150-T1)+150+0.3(T2-150)]
0.00 kcal/hr

2 by inorganics m*0.3*(T2-T1)
0 kcal/hr

3 by moisture m*{70+540+0.5(T2-100)}
0 kcal/hr

4 heat by Combustible Air * 0.28 *(T2-T1)

air 0 kcal/hr

heat absorded by Aqueous waste = 0 kcal/hr

heat released by Aqueous waste = 0 kcal/hr

MASS FROM PCC : Total Flue Gas = 989 kg/hr

D.G. = 829 kg/hr
moist. = 160 kg/hr

Temperature T1 850 °C

T2 1000 °C

Heat absorbed by Flue gas from PCC = 46790 kcal/hr. 44482.5

Total Heat absorbed in SCC 46790 Kcal/hr

Heat absorbed in SCC (10% excess) 51469 Kcal/hr

Total Heat released in SCC 0 kcal/hr

Total Heat released in SCC (10% lost) 0 Kcal/hr

Net heat available = R- A = -51469 kcal/hr.

Fuel Required (F.O.) = 9650 10.8 kg/hr 10

kg/hr
Combustion Air Required = 180 Kg/Hr
D.G. = 176 kg/hr 40
Moist.= 4 kg/hr
MASS OUT FROM S.C.C @ 1000 deg C

Dry gas = 1015 Kg/hr

Out = 1179 kg/hr
Moist = 163 Kg/hr

Thermal Capacity of SCC = 354950.16 Kcal/hr. 353550.000 Kcal/hr.

0.3550 Mkcal/hr. 0.3536 Mkcal/hr.

Design Consideration :

Lets SCC = 0.3536 Mkcal/hr at 1000 Deg C

Flue gas = 1179 Kg/hr

D.G. = 1015 Kg/hr
Moist.= 163 Kg/hr

Total Air Required for Combustion of feed = 250 Kg/hr

Total air reqired for Combustion Fuel = 720 Kg/hr
Air for cooling of Chamber = 0 Kg/hr
Infiltration Air = 0 Kg/hr

Total amount of air = 970 Kg/hr

833 m3/hr
999 m3/hr

Total air required for Combustion in PCC = 250 kg/hr

Infitration Air = 0 kg/hr

Air required for Combustion of Fuel in PCC = 540 kg/hr

Total air reqired for Combustion in PCC = 790 kg/hr

Air required for Combustion of waste in SCC = 0 kg/hr

Air reqired for Combustion of Fuel in SCC = 180 kg/hr

Total air reqired for Combustion in SCC = 180 kg/hr

Fuel required in PCC 30 kg/hr

Fuel required in SCC 10 kg/Hr

Total Fuel Requirement 40 kg/Hr

COOLING AIR REQUIREMENT:

Cooling Air Requirement to cool to 600 deg C

Before sending it to spray dryer
827 Kg/hr
827 Kg/hr

Mass out from After cooling to @ 800C = 2006 Kg/hr

Dry gas = 1826 Kg/hr

Moist = 180 Kg/hr

 SPRAY DRYER 637.5 161.6341 932.837
625 158.2396 927.4038
Total Gas = 2006 kg/hr 650 165.0285 938.2702
Dry gas 1826 kg/hr 850 220 1030.57
moisture 180 kg/hr ENTHALPY in kcal/kg
TEMP air MOIST
inlet temp 600 C 19152 75 17.73 626.8
outlet temp 200 C 100 23.765 640.228
200 48.14 692.9
Enthalpy @ t1 600 C 250 60.525 719.34
D.G 151.5 Kcal/hr 300 73.048 746.11
MOIST 916.5 Kcal/hr 400 98.4268 800.9361
600 151.4507 916.5375
Enthalpy @ t2 200 C 700 178.6064 960.0029
D.G 48.1 Kcal/hr 800 206.0226 991.2487
MOIST 692.9 Kcal/hr 900 233.7183 1022.492
1000 261.7603 1086.95
Amount of Water Evaporated 345 Kg/hr 1100 290.0246 1153.168
10% Total Dissloved Salts 35 Kg/hr 1150 304.5091 1187.163
1200 318.9124 1221.185
346
VENTURI SCRUBBER 384.6 38.5 HUMIDITY

Total = 2351 kg/hr TEMP HUMIDITY kgmoist/kg gas

Dry gas 1826 kg/hr 15 0.0106
moisture 525 kg/hr 70 0.2782
75 0.3851
inlet temp T1 200 C 80 0.5511
outlet temp T2 75 C 85 0.8352
90 1.414
enthalpy @ t1 200 C 95 3.173
D.G 48.14 Kcal/hr 99 18.73
MOIST 692.9 Kcal/hr 30 0.0273
60 0.153
enthalpy @ t2 75 C 65 0.2051
D.G 17.73 Kcal/hr
MOIST 626.8 Kcal/hr

act 1420 Water Evaporated 151 kg/hr

167
@ venturi outlet

average mol. Wt. 24.89 kg

density of gas@ 0.872 kg/m³

outlet temp 0.0544 lb/ft³

Vol flow rate 2870.695 m³/hr 0.79742 m³/sec

101366.361 ft³/hr

Velocity of gas @ throat 70 m/s assumed

229.66 ft/s

c/s area of throat 0.0114 m² For v = 65 Dia = 115

0.1226 ft² for v = 75 Dia = 105

diameter 0.1204 m
lenth 0.3612 m

Pr. Drop 250 mm WC assume 585

9.843 inch WC

L 9.4330 gal/1000ft³gas

water circulated 956.19 gal/hr

3.619 M³/hr Extra 20 % = 4.3 M³/hr
4.5 m3/hr
@ venturi Outlet 2502 kg/hr
Dry gas 1826 kg/hr 24.8884
moisture 676 kg/hr 0.87154 2870.70

Moisture Holding Capacity @ 75 C 703 kg/Kg of moist ,as the Humidity @ 75 C 0.3851
For the Dry Air kg/Kg of moist

Amount of water being condensed = -27 kg/hr

CONDENSATION OCCURS

Mass out 2502 kg/hr

Dry gas out 1826 kg/hr
moisture out 676 kg/hr

I D FAN

INLET TEMP 75 C
D.G. 1826 kg/hr
MOIST 676 kg/hr
TOTAL 2502 kg/hr

MOL WT 24.89 kg

DENSITY 0.872 kg/m³

VOL FLOW 2871 m³/hr

30% Extra 3732 m³/hr

3750 m³/hr
Power Required for this System

Assume Pr.drop = 850 mm of water column; Efficiency 0.65

Power = 18.07 HP OR 13 KW

Taking 20% loss = 22 HP 16 KW

kgmoist/kg gas

mm
mm
kg/Kg of moist
 PCC SIZING :

Total mass 989 Kg/hr @ 850 deg C

Dry gas 829 Kg/hr
Moist 160 Kg/hr

Avg Mole wt.= 26.39 kg

Gas Density.= 0.2864 kg/m3

Vol.flow rate.= 3451 m3/hr

Thermal capacity of PCC = 0.2432 Mkcal/hr.

243171.00 kcal/hr

Assume: Thermal intensity of Combustion chamber = 100000 kcal/hrm3

Volume of chamber = Thermal capacity/Thermal intensity

= 2.43 m3

Dimensions: Height = 0.99 m 1 2.48

Breath = 0.99 m 1 2.5000

Length (L/H) = 2.5 2.48 m Actual volume = 2.4317

2.59

And the above dimensiones are can be corss checked for the sufficient
residence time (Minimum 2 sec) in the chamber

Residence time Rt = 2.54 ( ok,as the Rt more than 2 sec.)

Fuel: ( F.O.) 3.5 % sulphur

Fuel Reqirement for startup ( to rise to 850 deg C) the MCC

Fuel is needed per m2 of chamber to raise to 850 deg C = 1.5 lpm2

MCC inside surface area 8.84 m2

Therefore fuel needed = 13.25 Litre

m³
 SCC SIZING

Total mass = 1179 Kg/hr @ 1000 deg C

Dry gas = 1015 Kg/hr
Moist = 163 Kg/hr

Avg Mole wt.= 26.73 kg

Gas Density.= 0.2559 kg/m3

Vol.flow rate.= 4605 m3/hr

1.2791 m3/s

Thermal capacity of SCC = 0.35 Mkcal/hr.

Assume: Thermal intensity of Combustion chamber = 110000 kcal/hrm3

Volume of chamber = Thermal capacity/Thermal intensity

= 3.21 m3

Dimension: Radius = 0.555 m 0.2575

Diameter = 1.110 m 0.515

Length (L/ D) = 3 3.329 m 1.545

Actual Volume = 3.218 m³

And the above dimensiones are can be corss checked for the sufficient
residence time (Minimum 2 sec) in the chamber

Residence time Rt = 2.52 ( ok,as the Rt more than 2 sec.)

Fuel:( F.O. ) 3.5 % sulphur

Fuel Reqirement to rise up the SCC Chamber to 1000 deg C

Fuel is needed per m2 of chamber to raise to 1000 deg C = 1.75 litre

SCC area = 13.54 m2

Therefore fuel needed = 23.70 Litre

SCRUBBER COLUMN DIA. DESIGN

MASS IN 2502 Kg/hr

Dry Gas = 1826 Kg/hr

Moisture = 676 Kg/hr

GAS FLOW RATE = Vw = 2502 Kg/hr

0.69 kg/s

DENSITY OF GAS = DL = 0.8715 Kg/m³

VOLUMETRIC FLOW OF GAS 2870.70 M³/hr

101366.36073 Ft³/hr

LID FLOW RATE 10 gal/1000ft³ of gas

(8 - 15 gal/1000ft3) 1013.66 gal/hr
3.8 M³/hr

LID DENSITY = DL = 1050 Kg/m³

LIQUID FLOW RATE IN KG/HR 4028.55 Kg/hr

= Lw 1.12 kg/s

PACKING TYPE SELECTION Ref. : : Chemical Engineering, Volume-6 ,

COULSON & RICHARDSON'S
NAME pall ring ceramics
SIZE 50 MM
PACKING FACTOR 105 1/M

LET,
WE FIND
Lw Dv
flow factor Vw DL = 0.046
ASSUME DESIGN PRESSURE DROP

DELTA P = 42 mmWC/M Packing ht

FROM THE ABOVE GRAPH WE FIND

K 4@ assumed Pressure

K4= 1.6 K4 is flood correction factor

Find K4 @ Flooding line

K 4 @Flood = 4.8

LET Percentage Flooding = ( K4/K4@ flood)0.5 X 100

57.74 %
 We Want Percentage between 50 - 75 %.

NOW WE FIND THE DIA OF SCR.

K4 Dv(DL --Dv)
Vw² =
13.1Fp(ML/DL)^0.1

μL = VISCOSITY OF LIQ
μL = 0.000404 Ns/m² 0.0045

Packing factor , Fp = 105

mass veocity of Gas, Vw = 2.16 kg/m²S 2.48 m/s gas velocity

COLUMN AREA REQUIRED

= 0.322 m²

with velocity = 2 m/s

D= 0.7124 DIA = 0.640 m

PACKING SIZE TO COLUMN DIAMETER RATIO

13 GREATER THAN 15

TOWER HEIGHT CALCULATION:

SO2 @ I/L = 488 mg/Nm3 Conc.= 0.1119 %

outlet kg/hr
0.288 SO2 @ O/L = 100 mg/Nm3 Conc.= 0.0836 %

Mass in (DG) = 1826 Kg/hr Inlet Temp = 75 ⁰C

Moist = 676 Kg/hr

Total = 2502 Kg/hr

0.69 kg/s

Avg Mole Wt = 24.89 Kg

Density of gas = DL = 0.8715 Kg/M³

Volumetric flow rate = 2870.70 M³/hr

Molar flow rate = Mass flow / Avg Mole wt.

= 100.53 kg/mole.hr
Wt %
SO2 @ I/L = 0.1119 %

SO2 @ O/L = 0.0115 %--------- To maintain the 100 mg/Nm3 at exit 0.29 Kg SO2

At 1 atm
SO2 @ I/L = 0.1125 kg/mole.hr Y1 = 0.0011 P1 = 0.0011 atm

SO2 @ O/L = 0.0116 kg/mole.hr Y2 = 0.0001 P2 = 0.0001 atm

∆Pln = (P1 - P2) / LN ( P1 / P2 )

= 0.0004 atm

Tower Dia = 0.640 m

Packed Volume ( V ) = = Nso2 / ( Kg * at * ∆Pln ) in m^3

Where , Nso2 = Kgmole/hr of SO2 at the Scrubber inlet

Kg = 0.003 G ^0.8 kg/hr.m2.atm

G = Mass flux in kg/hrm2 = 7770.16 kg/hrm2

Kg = 3.8857 kg/hr.m2.atm

at = Packing area m2/m3 from Table.6.3 105

1.5 " Pall ring
Packed Volume ( V ) = 0.6241 m3 ceramics

So Packing Height = Packed Volume ( V ) / Tower area

= 1.94 m
SULPHUR SCRUBBING :

Fuel consumed for start up 36.95 kg/hr

Fuel consumed 40.00 kg/hr (max of F.O.for start up/ continuous process )

Sulphur (assumed) = 3.5 %

Therefore total Sulphur content = 1.40 kg/hr

S + O2 ------------> SO2
32 32 64 kg/hr

SO2 generated == 2.80 kg/hr

O2 required == 1.40 kg/hr

Air required == 6.67 kg/hr

CAUSTIC SCRUBBING FOR SO2

SO2 + 0.5 O2 + 2NaOH ----------> Na2SO4 +

64 80 142

NaOH required 3.50 kg/hr

Salt formation 6.21 kg/hr

CAUSTIC SCRUBBING FOR HCl : No Cl in waste

CH3Cl + 1.5 O2 CO2 + H2O + Cl

50.5 48 44 18 35.5

1 0.950 0.871 0.356 0.703

H + Cl HCl
1 35.5 36.5

HCl + NaOH NaCl + H2O

36.5 40 58.5 18

1 1.096 1.603 0.493

Feed Rate = 0 Kg/Hr

Cl generated after decomposition = 0.00 Kg/Hr

Therefore, HCl generated = 0.00 kg/hr

NaOH required 0.00 kg/hr

Salt formation 0.00 kg/hr

Total NaOH req 3.50 kg/hr Caustic lye

Total Salt formation 6.21 kg/hr

To maintain a TDS level ( 20 % )

0.2 = 31.06 kg/hr

Water is to be recirculated = 4560 kg/hr 4

(for Packed Bed) wq

Total mass to be circulated = 4569 kg/hr

(Caustic + Water)

So the Conc of caustic in RC Tank = 0.1360 % per hr

Conc of caustic in RC Tank = 10.878 % 20 hrs per day

Bleed off of RC Tank = 1.839 Days

H2O
18
 8.75 100%
kg/hr

m3/hr

4 Days

hrs per day