MATERIAL BALANCE CALCULATIONS

FOR AMMOINUM SULPHATE MANUFACTURE

Chemical reactions involved for the Ammonium sulphate:-
NH3+H2ONH4OH +8.3 Cal/g mol------(1)
2NH4OH+CO2 (NH4)2CO3 +22 cal/g mol ----(2)
(NH4)2CO3+CaSO4 (NH4)2SO4+CaCO3 + 3.9 cal/g mol-----(3)

Molecular weights(in g/mol):-

NH3=17
H2O=18
NH4OH=35
CO2=44
(NH4)2CO3=96
CaSO4=136
CaCO3=100
(NH4)2SO4=132
If we require to produce 300 tonnes of Ammonium Sulphate.And
considering 24 hr operation of the Ammonium sulphate plant.
Then production rate per hour is :-
300 tonnes=300,000kg
Therefore,Ammonium Sulphate produced per hour is =300,000/24
=12,500Kg/hr
And it has been found that the approx. 100 kgs of the Ammonium
Sulphate produced is lost in filtration process.
Required production rate=12,400 Kg/hr
Assumptions:-
Considering complete conversion in the (1) and (2) reactions and for
reaction (3) conversion is 96%.
Now the Gypsum obtained has the following composition:-
Gypsum composition
Gypsum= 85%
Calcium Carbonate= 10.4%
Insolubles=3.6%
Free moisture= 1%
BASIS:-1-HOUR OPERATION
Gypsum required :
Now if we consider all the reactions to take place stoichiometrically.
Then from reaction (3) we have:-
(NH4)2CO3+CaSO4 (NH4)2SO4+CaCO3 + 3.9 cal/g mol-----(3)
136 kg 132 kg
132 kg of ammonium sulphate requires 136 kg of gypsum,
So,1kg of ammonium sulphate requires 136/132= 1.03kg
So, 12500 would require=12500*1.03=12875kg.
As the reaction has 96% conversion and the gypsum is only 85% of
the gypsum supplied so Net gypsum required=
12875*1/0.85*1/0.96
 =15,778.18 kg
Ammonium carbonate required :
(NH4)2CO3+CaSO4 (NH4)2SO4+CaCO3 + 3.9 cal/g mol-----(3)
96 kg 136kg
96 kg of Ammonium carbonate requires 136 kg of gypsum
So, 1 kg will require = 96/136=0.70
So, 15778.18 will require= 0.70*15778.18=11044.72kg
Aqueous ammonia required:
2NH4OH+CO2 (NH4)2CO3 +22 cal/g mol ----(2)
70kg 96kg
From the reaction (2) we see that the 96 kg of ammonium carbonate
requires 70 kg of ammonium hydroxide .
So,11044.72 kg of ammonium carbonate would require:
70/96*11044.72=8053.44kg
Ammonia required :-
NH3+H2ONH4OH +8.3 Cal/g mol------(1)
From this reaction we see that 1mole of ammonia produces ,1 mole of
ammonium hydroxide but this is only the half of the actual
requirement by reaction (2)
Ammonia of Aq. Ammonia produced =8053.44/2=4026.72kg
Hence ,35 kg of Aq.ammonia requires 17 kg of ammonia
4026.72kg of Aq.ammonia would require:
17/35*4026.72=1955.83 kg
Carbon dioxide required:
From reaction(3)
100 kg of ammonium carbonate requires 44kg of carbon dioxide.
11,044.72 kg of ammonium carbonate would require:
44/100*11,044.72=4859.67 kg
Water required :
35 kg of aq.ammonia requires 18 of water
4026.72kg of aqueous ammonia would require:-
18/35*4026.72=2070.88 kg

Summarising the results obtained above we have:-

RAW MATERIALS AMOUNT(kg/hr)

Gypsum 15,778.18
Ammonium Carbonate 11044.72

Aqueous Ammonia 8053.44

Ammonia 1955.83
Carbon dioxide required 4859.67

Water required 2070.88