PPC Production Plant

CHAPTER I
INTRODUCTION AND ITS BACKGROUND
Limestone, being a sediment deposit has many significant variety of uses
in the different types of industries. These are done by processing the limestones
to form a certain processed output that can either be used for cement industries,
or glass making; or serve as an effective additive in the process of making
different products, like papers, plastics, sealant, adhesives, rubbers, inks, or
pharmaceutical coating supplements. Moreover, limestones being 10% of the
overall sedimentary rocks in the world are being mined to be further processed
for it to become beneficial products.
Numerous variety of processes are used in processing limestones, one of
the well-known process is calcination. Calcination, or the heating of solids to a
high temperature for the purpose of removing volatile substances, oxidizing a
portion of mass, or rendering them friable. Calcination is also sometimes
considered a process of purification. Furthermore, Calcination reactions usually
take place at or above the thermal decomposition temperature or the transition
temperature.
One of the products of calcining limestones is the Precipitated Calcium
Carbonate (PCC). Precipitated calcium carbonate (PCC) is an innovative product
derived from lime, which has many industrial applications. PCC is made by
hydrating high-calcium quicklime and then reacting the resulting slurry, or “milk-
of-lime”, with carbon dioxide. The resulting product is extremely white and
typically has a uniform narrow particle size distribution. PCC is available in

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numerous crystal morphologies and sizes, which can be tailored to optimize
performance in a specific application. PCC is considered to be non-toxic. In the
U.S., the Food and Drug Administration has affirmed precipitated calcium
carbonate to be GRAS (Generally Recognized As Safe). As long as the PCC
meets certain purity requirements, it can be used as a direct food additive, as a
pharmaceutical or as an indirect additive in plastic, or paper products that come
in contact with food.
The production of PCC usually involves the process of precipitation and
slaking as its climatic stage. Calcination is also a main process in the production
of PCC for during this stage, limestones are decomposed to become quick limes.
These quick limes are then sent to a vessel to where it will be slaked to become
slaked limes. Finally, the finishing touch of the production of PCC is where the
slaked limes are precipitated to a controlled system to where it produces PCC.
These produce PCCs are usually dried using filter press for it to fully form as
powdered form, which are practically used in the different industries as additives.
In the Philippines, the supply of PCC is currently lesser of what is demand
of it by the different local industries. It is known that the supply of PCC in the
Philippines mostly comes from imports from India, Japan, and Malaysia.
Therefore, an additional producer and supplier of PCC in the Philippines would
be reasonably viable to resolve this unbalance supply – demand system for PCC
in the Philippines.
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LOCATION
The location to where the plant will be established will be at Mabini,
Batangas (13.763959, 120.960321), as seen in Figure 1. The location of the
plant was determined by considering different factors, these factors were the
availability of raw materials, road accessibility, the availability of water supply
(Batangas Bay), distance from residential houses, and climate.
Figure 1. Plant Location of PCC Production Plant
Since the raw materials of the PCC Production Plant is limestones, the
limestone deposits in Mabini, Batangas were considered. The limestones will be
mined by Talibayog Mining Corp. The limestone deposits in Mabini, Batangas is
estimated to be at 13.5 hectares in area. The mining area is then conservatively
estimated to contain at least 50 years of limestone deposits, considering the
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mining rate of 2 million tons per year. Moreover, the chosen location for the PCC
Production Plant is close to one of the limestone deposits in Mabini, Batangas to
where the transportation of the limestones to the plant would be at ease.
On regards to the road accessibility of the chosen location for the plant,
the path to the location were visibly accessible for it is adjacent to the main road
of Bauan – Mabini road. Furthermore, transportation by means of land vehicle
would be safe and straightforward.
The chosen location for the plant also considered its availability of water
supply. The location is deliberately chosen for it to be placed coastline to the
Batangas Bay. The Batangas Bay will serve as the plant’s primary source of
water, taking regards to the treatment of the water from Batangas Bay before
using it during operation.
Furthermore, the chosen location would mean that it would offer job
opportunities to those residents living in Mabini, Batangas. Since, the plant
location would be estimated 350 meters to the nearest residential houses, those
who live from that specific area would be the priority in these job opportunities,
taking consideration to the capability of those individuals.
RAW MATERIALS
Limestones will be the raw materials of the PCC Production Plant. These
limestones will be mined in Mabini, Batangas by Talibayog Mining Corp., to
which will supply the mined limestones as raw materials for the plant. The overall
area of limestone deposits in Mabini, Batangas is estimated to be at 13.5
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hectares, that can supply the plant for an estimated time of 50 years, considering
2 million tons per year as the mining rate.
PRODUCT
The product of the PCC Production Plant is Precipitated Calcium
Carbonate or PCC. PCC will be done by means of processing the limestones.
PCC has numerous applications to which are the following:
 Paper coating
 Rubber additive
 PVC/Plastic additive
 Flattering agent in paint industries
 Electrical insulators
 Toothpaste making
 Pharmaceuticals
 Food packaging
Moreover, the plant aims to produce a high-quality PCC product that will
meet the standard specification of PCC. The standard specification of
PCC is shown at Table 1.
Name Precipitated Calcium Carbonate

Chemical Formula CaCO3
Grade Name GSC/Glucal
Color Bright White
B.D. gm/ml 0.40 to 0.9 gm/ml
Phase Calcite/ Aragonite
Loss of Drying <1%
Residue on 325 Mesh <0.10%
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Soluble Alkali <0.15
Solution Test Clear
pH Level 9.5 – 10.2
Particle size (D50) Different Grades 2 – 8 microns
Purity as CaCO3 % 98%
Table 1. Standard Specifications of Precipitated Calcium Carbonate
(PCC)
In addition, the main target customer of the product of the plant will be
D&L Industries, Inc., which is a plastic manufacturing industry that specializes the
use of PCC as their components in manufacturing plastics. Furthermore,
produced PCC will also be sold in the local market.
PLANT CAPACITY
The PCC Production Plant capacity will be based on the demand for PCC
in the Philippines, specifically the demand in PCC of D&L Industries, Inc. It is
statistically stated that the global market for PCC is projected to reach 98.7
million tons by 2020, driven by robust demand from paper and plastics end – use
sectors. Moreover, 6.6% CAGR of that global market comes from the Asia, to
which 17% of it is at South East Asia (SEA), the Philippines shares 5% of that
statistic forecast. Furthermore, the calculated market of PCC in the Philippines
would be estimated at 110,741.4 tons annually.
The plant is considering supplying 15% of the PCC locally, therefore the
annual plant capacity will be estimated at 16,611.21 tons/year. Moreover, in
terms of daily production, the plant capacity will be estimated at 45 tons/day.
DEMAND
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The demand for PCC is booming, statistically it is stated that the global
precipitated calcium carbonate market is expected to reach an estimated $23.5
billion by 2022 with a CAGR of 4.6% from 2017 to 2022. This growth owing to
rising demand from end-use industries including rubber, plastic, and paper.
Application in plastics segment accounted for a share of over 20% in
2015. Rising product use in the plastics industry coupled with growing application
scope in modifying the functional properties of various grades of plastics is
expected to drive the demand over next eight years. Furthermore, rising use of
precipitated calcium carbonate in the plastic processing sector as a filler material
and reinforcing agent to manufacture high-grade plastic products is expected to
drive the growth. Figure 2 shows the global PCC market revenue, by application,
2013 – 2024.
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Figure 2. Global Precipitated Calcium Carbonate (PCC) Market
Revenue, by Application, 2013 – 2024 (USD Million)
In the Philippines, the demand for PCC is statistically estimated to be at
110,741.4 tons/year. To which the application of plastic production and
pharmaceutical industries greatly influence this number. Moreover, D&L
Industries, Inc.’s demand for PCC shares 8.3% of that demand for PCC locally,
thus, having a demand of PCC to be estimated at 9191.5362 tons/year.
MARKET SHARE
The market share of the PCC Production Plant of PCC in the Philippine
Market will be at 10% of the total annual market of the PCC in the local market.
The annual market for PCC locally is statistically estimated to be at 110,741.4
tons/year, thus PCC Production Plant will share 16,611.21 tons/year.
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CHAPTER II
DESIGN OBJECTIVES
The main focus of this project proposal is to design a Precipitated Calcium
Carbonate (PCC) Production Plant that will process the raw material, limestone
to produce precipitated calcium carbonate from a capacity of 45 tons/day based
on the provided information on the previous chapter.
Moreover, this study intends to target the following specific objectives in
order to come up with a feasible and economical project design.
1. To be able to contrive three (3) design options following some of the
engineering standards and realistic constraints.
2. To gather data and information needed in relation to technical and economic
aspects that will justify the viability of the proposed project designs.
3. To assign the proper technical design specifications for the equipment of the
three design options following standard requirements.
4. To determine the capacity and efficiency of each unit of the plant by the
computation of the following:
4.1 Material Balance
4.2 Energy Balance
5. To present acceptable designs having processes that are capable of operating
under conditions which will yield a profit providing an evaluation and
computations of the economical expenditures:
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5.1 Capital Expenditures
5.2 Operating Expenditures
5.2.1 Annual Net Income
5.2.2 Rate of Return
5.2.3 Payback Period
6. To provide safety and loss prevention considerations in the process designs
under the following:
6.1 Identification and assessment of the hazards;
6.2 Control of hazards;
6.3 Control of the processes; and
6.4 Limitations of the loss
7. To provide a construction management, project scheduling of assembling each
sections of the plant at the plant’s manufacturer’s site, and the sequence and
arrangement of the major items of equipments given on the process flow-sheet.
8. To provide a summary of findings, conclusion and recommendations for
Precipitated Calcium Carbonate Production Plant.
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CHAPTER III
TECHINCAL ASPECTS
This chapter includes the complete equipment layouts planned taking into
considerations the process diagrams, operations of the equipment, the process
units under standard specifications, mass balances and energy balances for
each unit, and the provisions for the ancillary buildings and services needed for
the plant operation.
DESIGN BASIS
The following estimation are assessed based on the statistical forecast
market demand of precipitated calcium carbonate (PCC) between the years of
2013 - 2024.
The required plant capacity of the PCC Production Plant would be 45
tons/day, to which will supply 15% of the PCC market demand locally. Moreover,
8.3% of the PCC produced by the plant will be sold to D&L Industries, Inc.,
specifically to be estimated at 9191.5362 tons/year. The 6.7% of the produced
PCC which is estimated to be at 7419.6738 tons/year will be sold to the local
market. Furthermore, the required plant capacity of the PCC Production Plant will
serve as a strong basis in designing the processes to be used in the production
of PCC.
The plant will focus on the process of Calcination, a well-known process in
processing limestones that is currently the industry standard for PCC production.
Moreover, calcination process would only process the limestones to a quick lime,
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before being sent to the slaking process and precipitation process to which will
be the final stage in the production of PCC.
GENERAL DESCRIPTION OF THE PROCESS
Figure 3. Simplified Block Flow Diagram of PCC Process
The basis for the process of the production of PCC is shown at figure 3.
Figure 3 shows the block flow diagram for processing PCC. The process shows
the general procedural processes to be used in the production of PCC, these
processes are crushing, screening, pre – heating, calcination, cooling and
slaking, precipitation, and compression and drying, to all which focuses on the
production of PCC.
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The chemical reaction involves in the production of PCC usually are in the
processes of calcination, cooling and slaking, and precipitation. These processes
that involve chemical reactions are shown below.
Calcine (heat) in a kiln to 1850° F, which takes the calcium carbonate
apart, forming quick lime (CaO) and carbon dioxide gas (CO2). The carbon
dioxide can be captured for reuse. These is shown in reaction 1.
CaCO3 + Heat → CaO + CO2 ↑ Reaction 1
Afterwards, the produced quick lime will be added with water in the cooling
and slaking process to form calcium hydroxide (Ca(OH)2) or slaked lime. These
is shown in reaction 2.
CaO + H2O → Ca(OH)2 Reaction 2
The final process the involves a chemical reaction would be the
precipitation process to which the captured carbon dioxide will be added with the
slaked lime. Calcium carbonate reforms, and since it is insoluble in water,
precipitates out. The reaction is shown in reaction 3.
Ca(OH)2 + CO2 → CaCO3 ↓ + H2O Reaction 3
Furthermore, after the produced PCC (CaCO3) is done with the
precipitation process it will be sent out to the compression and drying process to
which will be dried of moisture and will then be sent out for packaging.
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DESIGN OPTION 1
A. Process Flow Diagram
Fig
ure 4. Process Flow Diagram of PCC Production Plant (Design Option 1)
The process flow diagram option 1 is shown in figure 4 to which
describes the process flow in the production of PCC that on the
maximization of the output production yield, specifically at the calcination
process (CaO). The extension of the calcination process from the
installation of a pre – heater and the rotary kiln will maximize the formation
of quick lime from the crushed limestones feed.
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Primarily, this process flow diagram option 1 starts with the
crushing of limestones to which will be powdered to particle size of not
greater than 100 Mesh (149 micron) or 0.0058 inches. To assure the
precision of the particle size of the crushed limestones, a vibrating sieve is
installed, to which will screen the crushed limestones whether they met
the required particle size and if the particle size is larger than the 100
Mesh then it will be sent back to the crusher to be crushed again.
Then, the crushed limestones will be sent to a bin to which will be
prepared for the calcination process. The calcination process in this
design involves three (3) heating units; the pre – heater assembly, the
calciner, and the rotary kiln. The pre – heater will initially heat the crushed
limestones to a temperature ranging of 1850 °F to 2003 °F, this will cause
the release of 25 – 35% of the CO2 from the limestones. The heat that will
be applied to the pre – heater will come from the heat exiting the calciner.
After the pre – heater assembly, the limestones will be sent to the calciner
to which the limestones will be heated to a temperature ranging of 2732°F
to 3632°F. In the calciner, the release of CO2 from the limestone would
have a cumulative percent of 50 – 80%. And the end of the calciner, the
limestones will now be sent to the rotary kiln where the final heating
process will be done, this is done to ensure that the yield for CaO will be
at its maximum. Moreover, in the rotary kiln, the limestone will be heated
to a temperature similar to the calciner to exhaust its remaing CO2
content, to which the overall CO2 release would be at 90 – 95%. The final
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output in the rotary kiln would be the calcium oxide (CaO) or the quick lime
that will be sent to the cooling vessel to where it will be cool down and
slaked with water.
In the cooling vessel, the quick lime will be cooled down by means
of adding water from the cooling tower. The quick lime will be subjected
and slaked with cooled water for it form a calcium hydroxide (Ca(OH)2) or
slaked lime. The exhaust of the cooling vessel will be sent out to the rotary
kiln to where its exhaust would be sent to the calciner and which will be
sent to the pre – heater having a final exhaust temperature of 230°F to
260°F. The exhaust will be sent out to the gas filter and scrubber for
treatment to which the cleaned gas or CO2 will be sent to the precipitation
reactor.
Moreover, the slaked lime will be sent to a tank unit to where it
would be prepared for the precipitation process. The precipitation process
will occur in the precipitation reactor where the slaked lime is subjected to
the captured CO2 from the scrubber to form calcium carbonate (CaCO3).
And since it is insoluble with water, the precipitate will be extracted.
Furthermore, to maximize the precipitate, recirculation between two (2)
precipitation reactor would be necessary so that the yield for calcium
carbonate would be optimum.
The precipitated calcium carbonate will be sent to the screening
unit so that the water will be fully drained from the PCC. Furthermore, the
PCC will be fully dried and formed in the filter press to which then be
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filtered in the gas filter to remove the remaining CO2 content from the
PCC.
B. Process Units and Their Functions
Crusher
A crusher is a machine designed to reduce large rocks into smaller
rocks, gravel, or rock dust. Crushers may be used to reduce the size, or
change the form, of waste materials so they can be more easily disposed
of or recycled, or to reduce the size of a solid mix of raw materials (as in
rock ore), so that pieces of different composition can be differentiated.
Figure 5. Crusher Unit
Source: Terex Pegson
Vibrating Sieve
Vibratory sieves are used in the medium separation range. The
screen type is a vibratory sieve which employs direct excitation of screen
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mesh; thus the screen housing only takes a static function. It also
preserves the building and/or the steel structure.
Figure 6. Vibrating Sieve
Source: Sinfonia Technology
Rotary Kiln
A rotary kiln is a pyroprocessing device used to raise materials to a high
temperature (calcination) in a continuous process.
Figure 7. Rotary Kiln Unit
Source: Nmlindia
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Air Preheater
Air preheater are heat exchanger to preheat or air heating of the
combustion air by means of flue gas, steam, water or thermal oil. Air
preheaters are used when exhaust temperatures of combustion systems
are particularly high. This extracts the hot exhaust valuable energy, which
discharged otherwise unused into the atmosphere and warming means of
this exhaust heat the combustion air of the combustion process.
Figure 8. Pre -
Heater Assembly
Source: Ljustrom
Industrial Furnace
An industrial furnace is an equipment used to provide heat for a
process or can serve as reactor which provides heats of reaction. Furnace
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designs vary as to its function, heating duty, type of fuel and method of
introducing combustion air.
Figure 9. Industrial Furnace
Source: Apex Industrial

Scrubber
The term wet scrubber describes a variety of devices that remove
pollutants from a furnace flue gas or from other gas streams. In a wet
scrubber, the polluted gas stream is brought into contact with the
scrubbing liquid, by spraying it with the liquid, by forcing it through a pool
of liquid, or by some other contact method, so as to remove the pollutants.
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Figure 10. Scrubber Unit
Source: Tri-Mer industrial

Cooling Tower
A cooling tower is a specialized heat exchanger in which air and
water are brought into direct contact with each other in order to reduce the
water's temperature. As this occurs, a small volume of water is
evaporated, reducing the temperature of the water being circulated
through the tower.
Figure 11. Cooling Tower
Source: Kolmetz
Calciner
Rotary calciners, also commonly called indirect kilns, are used in
thermal processing operations where exhaust gases must be minimized,
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when processing finely divided solids, or where temperature must be
tightly controlled along the length of the kiln.
Figure 12.
Calciner Unit
Source: Phoenix Equipment

Gas Filter
A filter is a filter in the fuel line that screens out dirt and dust
particles from the fuel, normally made into cartridges containing a filter
paper. They are found in most internal combustion engines.
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Figure 13. Gas Filter Unit
Source: Restek
Precipitation Reactor
A precipitation reactor is a reactor vessel to which the slaked lime
(Ca(OH)2) is subjected with Carbon Dioxide (CO2). The reaction between
the slaked lime and CO2 will yield CaCO3 or calcium carbonate. The
precipitation reactor then precipitates the formed CaCO3 which is then
extracted.
Figure 14. Precipitation

.Source: Klean Esp
C. Technical Design Specifications
The selection of the equipments specifications follow different testing
standards that are recognized worldwide and that ensure the quality
performance of the process units. The following are the different units with
their corresponding specifications:
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SPECIFICATIONS OF JAW CRUSHER
CRUSHER TYPE 428 Fixed Hammer Impactor
FEED OPENING 1067mm x 711mm
ROTOR WIDTH 1066 mm
ROTOR DIAMETER 1066 mm (Over Hammers)
Source: Terex Pegson
SPECIFICATIONS OF VIBRATING SIEVE
AMPLITUDE (MM) 6P – 9; 8P – 10
VIBRATING FREQUENCY PER MIN. 50/60Hz – 6P - 980/－; 8P - －/880
SCREEN OPENING 5mm－50mm
Source: Sinfonia Technology
SPECIFICATIONS OF ROTARY KILN
TOTAL LENGTH OF REACTION CHAMBER 2m
HEATING ZONE LTH 1.2 m
DEAD LTH 0.8m
INSIDE DIAMETER OF CHAMBER 300 mm
TENTATIVE VOLUME OF CHAMBER 84823 CC = 84.823 Litre
Source: Nmlindia
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SPECIFICATIONS OF AIR PREHEATER
BOILER SIZE (ELECTRICAL OUTPUT) 500 MW
SIZE 2 x 30
DIAMETER (M) 11.4
AREA (M²) 97
HEIGHT (M) 1.8
ROTATION SPEED (RPM) 2
Source: Ljustrom
SPECIFICATIONS OF FURNACE
FURNACE MODEL CM – 1830 -12 HTF
HEATUP RATE MINUTES 180
FURNACE WEIGHT 48 kg
NUMBER OF ELEMENTS 8
CHAMBER DIMENSION 330 x 279 x 305 mm
DOOR OPENING 26 7 x 254 mm
Source: Apex Industrial
SPECIFICATIONS OF SCRUBBER
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Vertical packed-bed wet scrubber with liquid
TYPE
scrubbant tank
REMOVAL EFFICIENCY less than 99%
PACKING MATERIAL AND Lantec Q-PAC
HEIGHT
DIAMETER 200mm (8”)
Source: Tri-Mer industrial
SPECIFICATIONS OF COOLING TOWER
CIRCULATING WATER FLOW, 15.6
M3/HR
HOT(INLET) WATER TEMP. ℃ 37
COLD(OUTLET) WATER TEMP. 32
WET BULB TEMP. INLET ℃ 27
NOMINAL CAPACITY, KCAL/HR 78 000
DRIFT LOSS, % OF 0.01
CIRCURATING FLOW
EVAPORATION LOSS(AT 0.83
DESIGN), %
Source: Kolmetz
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SPECIFICATIONS OF CALCINER
OPERATING TEMP. ℃ 1205
MOTOR POWER 30 HP
MOTOR SPEED 2.32 RPM
GAS FIRED SYSTEM 60MM Btu/hr
CAPACITY 78 inches
Source: Phoenix Equipment
SPECIFICATIONS OF GAS FILTER
OUTLET GAS QUALITY (%) greater than 99.9999
MAXIMUM PRESSURE/ MAXIMUM FLOW 11 bar 159 psi/ 7 L/min
RATES
INDICATOR COLOR CHANGE Yellow/orange to clear Green
to
grey
ESTIMATED LIFETIME (YEARS) Greater than 1
Source: Restek
SPECIFICATIONS OF REACTOR
HEATING TIME >150°C
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MAXIMUM PRESSURE 14 barg 200 21 min 44 min
Source: Klean Esp
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PIPING AND INSTRUMENTATION DIAGRAM
Figure 15. P&ID of PCC Production Plant
The P & ID diagram of PCC Production Plant shows the complete cycle
process of all components, flow lines, valves, and indicators of all operating
conditions used.
The start of the P&ID is with the limestone as the feed that will be sent to
the crusher unit to which it will be crushed to a particle size of not greater than
100 Mesh (149 micron) or 0.0058 inches. The precision of the particle size of the
crushed limestones that will enter the calcination stage will be screened by a
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vibrating sieve. Moreover, when the crushed limestone is less than or equal the
specific particle size, it will be sent to the bin via conveyor belt for the preparation
in the calcination stage.
In the calcination stage, three heating process will be included to which
will aid maximizing the yield output of CaO from the crushed limestones. These
heating process includes the pre – heater assembly, calciner, and the rotary kiln.
The first heating process that the crushed limestones will be sent to is the pre –
heater assembly, in the pre – heater assembly the crushed limestones will be
heated to a temperature ranging of 1850°F to 2003°F, this will cause the release
of CO2 from the crushed limestones of 25 – 35% of its content. To have control
on the temperature going in the pre – heater assembly, CV1 manipulates the
entering hot gas from the calciner. CV1 receives data from TY1 to which has
been processed by TC1, the temperature data gathered by the TI1 and TT1 were
the data processed by TC1.
In the calciner, the heat temperature applied is ranging from 2732°F to
3632°F. Moreover, the heat that supplies the calciner comes from direct
combustion of coal and the heat coming from the rotary kiln. The cumulative
release of CO2 expected in the calciner is about 50 – 80%. In order to have a
controlled temperature condition, the heat coming from the rotary calciner is
controlled by a CV2, this is to ensure that there won’t be any overheating in the
calciner unit.
The rotary kiln ensures the optimum output of CaO in the calcination
stage, having a system temperature similar to the calciner. The expected
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cumulative release of CO2 from the limestone in the rotary kiln is about 90 –
95%. Moreover, the heat that supplies the rotary kiln comes from the exhaust of
hot gases in the cooling vessel, and the heat coming from the Furnace, both of
which are controlled by CV4 and CV3, respectively.
Calcium Oxide (CaO) or quick lime is the main product of the calcination
stage, to which will be sent to a cooling vessel that will be slaked and cooled with
water coming from the cooling tower. The temperature needed to be controlled in
the cooling vessel is approximately at 185°F and is controlled by the CV5. CV5
controls the flow of cooled water from the cooling tower to the cooling vessel.
Once the quick lime is cooled down and slaked, Ca(OH)2 or slaked lime will be
the output in this process. Furthermore, the water used will be sent back to the
cooling tower for recycle purposes.
Slaked lime will then be sent to a tank storage unit to where it will be
prepared for the precipitation stage. Precipitation stage requires the reaction of
Ca(OH)2 with CO2 to yield CaCO3 (Calcium Carbonate) and water. This reaction
will occur at two (2) precipitation reactors, this is to maximize the yield output
during this process. Since, CaCO3 is insoluble to water, the water will be drained
out in the precipitation reactor so that the precipitated CaCO3 will be sent down
to the next process.
The precipitated calcium carbonate will be sent to the screening unit to
where it will be filtered out with excess water. The screening unit will involve two
phases; the prescreen tank, and the screening tank, this is done to partial filter
out the PCC with its water content.
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The final touch for the PCC is done in the filter press. The filter press
compresses the PCC so that it will be dried of moisture. The dried PCC is finally
sent to a gas filter, to which it removes remaining CO2 from the PCC.
3D PLANT DESIGN
The PCC Production Plant were modelled and designed using Solidworks
and Blender.
Figure 16. 3D Plant Design of PCC Production Plant (Top View)
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Figure 17. 3D Plant Design of PCC Production Plant (Side View)
Figure 18. 3D Plant Design of PCC Production Plant (Front View)
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PLANT LAYOUT
The plant layout of the PCC Production Plant is shown in Figure 32. The
plant layout shows the physical arrangement of the equipment, facilities and
service departments involved in the design.
Figure 33. Plant Layout of PCC Production Plant.
Since the overall change between each design options only varies to the
process of producing PCC, the overall plant layout would not be affected. The
processes in the plant is only a part of the plant layout, moreover any
modifications of the plant layout would be unnecessary, for the auxiliary facilities,
stations, area, and departments is the same for all design options.
Components of Plant
The following are the components and parts of the production plant:
A. Water Tank
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A water tank is a container for storing water. Water tanks are
used to provide storage of water for use in many applications in the
plant like supplementation of water for the hydrant, water for the
cooling tower, for cleaning, and etc.
B. Pump House
The pump house is a facility wherein the pumps are placed,
specifically the pumps used to transfer water within the plant. The
pump house is usually known as the pump manifold for it contains
the pumps that controls the flow of fluid throughout the plant.
C. Silo
The silo is where the produced PCC are stored. The silo
dimension is 50 ft in diameter, and 150 ft in height.
D. Loading Station
The loading station is where the stored PCC is load to the
delivery trucks. The delivery trucks deliver the PCC to the
customers of the production plant. The loading station also contains
the packaging and transport of the produced PCC.
E. Calcination Process
The calcination process or the process facilities is where all
the processes in the plant occurs. The calcination process holds all
the equipment, transport system, and instruments used in the
production of PCC.
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F. Fire and Safety
The fire and safety is the main area of where all the fire
safety equipment and the main fire hydrant is located. Moreover,
this is where the division of pipes to the fire hydrant that are located
throughout the plant.
G. Laboratory
The laboratory is the facility to where different testing and
sampling of the raw materials, additives, and products are
performed. The laboratory holds different laboratory equipment that
are used to test the quality of the produced PCC. Furthermore, this
is also where the verification whether the produced PCC is in good
or bad quality.
H. Machine Shop
The machine shop is where the different faulty equipment is
fixed, this is also where different projects concerning with
metal/woodworks are done.
I. Hazardous Waste Management Area
The hazardous waste management area is where the
disposal and management of the hazardous waste material
produced by the plant are handled. This facility ensures that the
36
handle of the hazardous waste is in compliance with the legal
standard in terms of health, safety, and environment.
J. Court
The court or a basketball court is a leisure facility for
exercise of the employees, workers, or contractors.
K. Warehouse.
The warehouse is a handling storage facility, where different
non-active industrial equipment, instruments, protective clothing,
housekeeping equipment, and any other resources in the plant are
stored and properly handled.
L. Parking Area
The parking area is a space allotted for the parking of the
trucks, different handling vehicles, and as well as the vehicles of
the employees, workers, and contractors working in the plant.
M. Assembly Area
The assembly area is a space allotted in the plant to where
the employees, workers, and contractors gather to discuss daily
reports, problems, and planned activities in the plant. This is also
where flag ceremonies are done each morning, and when there is
an earthquake or fire, the assembly area serves also the
evacuation area for safety purposes.
N. Inspection Area
37
The inspection area is a security facility in the plant, to where
the vehicles entering and exiting the plant are inspected externally.
The inspection is done by the security guards having legal actions
and notice. This is also where the exiting trucks containing the
produced PCC are final checked and inspected.
O. Admin
The admin, or the office administration is a facility
concerning with the set of day-to-day activities that are related to
financial planning, record keeping & billing, personnel, physical
distribution and logistics, within the plant. Moreover, the admin
holds the receiving and waiting area, the canteen, infirmary, plant
executive boardroom, and the office working area.
The admin also serves as the quality control of the process
in the plant during operation.
P. Power Generator
The power generator is a facility that holds the emergency
generator in the plant. The emergency generator is usually
powered up when there is a blackout in the plant. The generator
can fully power up the entire plant during those emergency cases.
DESIGN CALCULATIONS
Material Balance
38
In order to have an analysis of the overall physical system in the
production plant, a material balance will be done. Material balance accounts and
calculates the mass entering and leaving the system.
Assumptions, data and process information are researched to come up
with a realistic material balance with a basis of 100 tons of limestones as feed
per day.
The following material balance of each design are shown below. For
design option 1
100tons 1 day 4.167 tons

Limestones feed = ( )=
day 24 hours hour
CRUSHER
Assumption: 85% efficiency

4.167 tons m1 m3
m1 = limestones feed =
hour
m1 + m3 = m2
m3 = 0.15m1
m1 + 0.15m1 = m2
4.167 tons
(1.15) = m2
hour m2
4.79205 tons
= m2
hour
VIBRATING SIEVE

m2 = m3 + m4 m2 m4
m2 = 0.15m1 + m4
4.79205 tons 4.167 tons
= (0.15) + m4
hour hour
m3
4.167 tons
m4 =
hour
39
LIMESTONE BIN
m4

m4 = m5
4.167 tons
= m5
hour
m5
PRE – HEATER ASSEMBLY
Assumptions: 48.5% efficiency

1 ton limestone = 2.5 tons of hot gases from calciner
m5 + m7 = m6 + m8 m5 m8
m7 = 0.4m5
m8 = 0.175m5 + 0.85m7
m5 + 0.4m5 = m6 + 0.175m5 + 0.34m5
4.167 tons 4.167 tons
+ ( 0.4 ) =m6+ ¿
hour hour m7
4.167 tons 4.167 tons
( 0.175 ) + (0.34)
hour hour
3.687795tons
m6 = m6
hour
1.6668tons
m7 =
hour
2.146 tons
m8 =
hour
CALCINER
Assumptions: 55% efficiency

1 ton limestone = 2 tons of coal
1 ton limestone = 2.5 tons of hot gases from kiln
m6 + m11 + m10 = m9 + m7
m10 = 0.5m6 m6 m7
m11 = 0.4m6
m11
m6 + 0.4m6 + 0.5m6 = m9 + m7
3.687795tons 3.687795 tons
+ ( 0.87 ) +¿
hour hour
3.687795tons 1.6668 tons
( 0.67 )=m9+ m10
hour hour
40
5.34 tons
m9 =
hour
1.84 tons m9
m10 =
hour
1.475tons
m11 =
hour
ROTARY KILN
Assumptions: 72.37% efficiency

1 ton limestones = 3.5 tons of hot gas from Furnace
1 ton limestone = 2.5 tons of hot gases from CV
m9 + m14 + m12 = m11 + m13
m12 = 0.29m9 m11 m14
m14 = 0.4m9 m9
m9 + 0.29m9 + 0.4m9 = m11 + m12 m13
5.34 tons 5.34 tons 5.34 tons
+ ( 0.29 ) + ( 0.4 ) +¿ m12
hour hour hour
1.475tons
+m12
hour
7.55tons
m13 =
hour
1.55tons
m12 =
hour
2.135tons
m14 =
hour
FURNACE

1 ton of coal = 2 tons of air
m15 + m16 = m12
m15 = 0.5m16 m12 m16
2m16 + m16 = m12
1.55 tons
2 m16+ m16=
hour
0.5167 tons
m16 =
hour m15
0.26 tons
m15 =
hour
GAS FILTER 1
41
m8 m18
m8 = m18 + m17
m17 = 0.15m8
m8 = m18 + 0.15m8
2.146 tons 2.146 tons
=m18+ (0.15)
hour hour
1.8241tons
m18 =
hour m17
0.3219 tons
m17 =
hour
SCUBBER

1 ton of filtered gas = 1.5 ton of water m18 m21
m18 + m19 = m20 + m21
m18 = 0.67m19
m20 = 0.4m18 m19
m18 + 1.49m18 = 0.4m18 + m21
1.8241tons 1.8241 tons
+ ( 1.49 )=¿
hour hour
1.8241tons
( 0.4 ) +m21 m20
hour
3.812369tons
m21 =
hour
2.72tons
m19 =
hour
0.7296 tons
m20 =
hour
COOLING VESSEL
Assumptions: 72% efficiency m14

1 ton of quicklime = 4 tons of water
m13 + m22 = m14 + m24 + m23 m13
m23 = 0.65m13
m22 = 0.25m13
m13 + 0.25m13 = m14 + m24 + 0.65m13
7.55tons 7.55 tons 2.135tons
+ ( 0.25 )= m22
hour hour hour
7.55tons
m 24+ (0.65)
hour
42
2.395tons
m24 =
hour m23 m24
4.9075 tons
m23 =
hour
1.8875tons
m22 =
hour
PUMP
Assumption: 100% efficiency m23

m23 = m25
4.9075 tons
m25 =
hour m25
COOLING TOWER
Assumptions: 18% efficiency m22

additional of 1 ton/hour of water
m25 + m26 = m22 + m27
m27 = 0.82m25
1 ton m26
m26 =
hou r
4.02415 tons
m27 = m27 m25
hour
SLAKED LIME TANK
m24

m24 = m28
2.395tons
m28 =
hour
m28
PRECIPITATION REACTOR 1
43
Assumptions: 60%
1.5 tons/hour of recycle from PR 2 m28
0.5m28 + 0.5m21 + m29 = m31 + m30
1.5tons m29
m29 =
hour
m31 = 0.4m28
0.5m28 + 0.5m21 + m29 = 0.2m28 + m30
1.1975tons 1.906 tons 1.5tons
+ + = m21
hour hour hour
1.1975tons
( 0.4 ) +m 30
hour m31
4.1245 tons
m30 =
hour
0.479 tons m30
m31 =
hour
PRECIPITATION REACTOR 2
m33 m28

Effluent of 3 tons/hour m29
0.5 ton/hour of recycle from PST
0.5m28 + m33 + m29 + 0.5m21 = 2m29 + m32
0.5 tons
m33 = m21
hour
m32 = 0.45m28
2.208tons m32
m32 =
hour
m29
PRESCREEN TANK
44
m35 m30
1 ton/hour of recycle from ST
m30 + m35 = m34 + m33
m33
1tons
m35 =
hour
4.1245 tons 1 tons 0.5 tons
+ =m34+
hour hour hour
4.6245 tons
m34 =
hour m34
SCREENING TANK
m34

m34 = m35 + m36
4.6245 tons 1 tons m35
= + m36
hour hour
3.6245tons
m36 =
hour
m36
FILTER PRESS
Assumption: 80%
m36 = m37 + m38 m36 m37
m38 = 0.2m36m36 = m37 + 0.2m36
3.6245 tons
3.6245 ¿ ns ¿ =m37+ ( 0.2)
hour hour m38
2.8996 tons
m37 =
hour
0.7249 tons
m38 =
hour
GAS FILTER 2
45
Assumption: 65%
m37 = m39 + m40 m37 m39
m39 = 0.35m36
m37 = 0.35m36 + m40
2.8996 tons 2.8996 tons
= ( 0.35 )+ m40
hour hour
1.88474 tons
m40 =
hour
1.01486tons
m36 =
hour m40
46
Energy Balance
For design option 1
Pre – heater assembly
4.167 tons 1000 kg kg

mlimestones =
hour (
1 ton
=4167
hr)
kJ
Cplimestones = 0.91
kgK
kJ
Cpquicklime = 0.44194
kgK
kJ
CpCO2@1600K = 1.338
kgK
T1 = 273.15; T2 = 1600K
Q T =mCp ∆T limestones + mCp ∆ T CO2 +mCp ∆ T quicklime
kg kJ kg kJ
(
Q T = 4167
hr )
(0.91
kgK
)( 1600 K −273.15 K)+ 4167
hr ( )
(1.338
kgK (
)(1600 K−273.15 K )+ 416
kJ 1 hr 1 min
Q T =14872635.0865 ( )
(
hr 60 mins 60 seconds
)
Q T =4131.28752402 kWh
Calciner
3.687795tons 1000 kg kg
mlimestones =
hour 1 ton (=3687.795 )
hr
kJ
Cplimestones = 0.91
kgK
kJ
kgK
kJ
CpCO2@2200K = 1.383
kgK
47
T1 = 273.15K ; T2 = 2200K
Q T =mCp ∆T limestones + mCp ∆ T CO2 +mCp ∆ T quicklime
kg kJ kg kJ
(
Q T = 3687.795
hr )
(0.91
kgK (
)(2200 K−273.15 K )+ 3687.795
hr )
(1.383
kgK (
)(2200 K −273.15 K)+ 36
kJ 1 hr 1min
Q T =19434012.6717 ( ( )
)
Q T =5398.33685325 kWh
Rotary Kiln
5.34 tons 1000 kg kg

mlimestones =
hour 1ton( =5340
hr )
kJ
kgK
kJ
CpCO2@2200K = 1.383
kgK
T1 = 273.15K ; T2 = 2200K
Q T =mCp ∆T CO 2+ mCp ∆ T quicklime
kg kJ kg kJ
(
Q T = 5340
hr)(1.383
kgK
)(2200 K−273.15 K )+ 5340
hr( )
( 0.44194
kgK
)(2200 K−273.15 K )
kJ 1 hr 1 min
Q T =18777499.3123 ( ( )
)
Q T =5215.97203118 kWh
Furnace
0.26 tons 1000 kg kg

mcoal =
hour (
1ton
=260
hr )
kJ
Cpcoal = 1.38
kgK
kJ
CpCO2@2200K = 1.383
kgK
48
T1 = 273.15K ; T2 = 2200K
Q T =mCp ∆T CO 2+ mCp ∆ T coal
kg kJ kg kJ
(
Q T = 260
hr )(
1.383
kgK )
( 2200 K −273.15 K ) + 260
hr
1.38 (
kgK )(
(2200 K−273.15 K ) )
kJ 1 hr 1 min
Q T =1384210.503 ( ( )
)
Q T =384.5029175 kWh
The plant’s total power requirement will be the summation of the Q T of all
the equipment in the plant that requires energy to operate.
Plant total power requirement
Plant total power requirement=Q T ( preheater )+Q T (calciner) +Q T (kil n) +Q T (burner )
Plant total power requirement=4131.28752402kWh+5398.33685325 kWh+5215.97203118 kWh +384.50
Plant total power requirement=15130.099326 kWh
In calculating the produced work in design option 1, the efficiency of the
equipment will be considered.
Equipment Efficiency
Pre – Heater Assembly 48.5%
Calciner 55%
Rotary Kiln 72.37%
℘
Furnace 60% Q= −(℘+Wpη)
η
Pre – Heater Assembly
℘
4131.28752402 kWh= −(℘+ 0.485℘)
0.485
49
℘=7161.74 kWh
Calciner
℘
5398.33685325 kWh= −(℘+ 0.55℘)
0.55
℘=20129.4 kWh
Rotary Kiln
℘
5215.97203118 kWh= −(℘+0.7237 ℘)
0.7237
℘=−15255.3 kWh
Furnace
℘
384.5029175 kWh= −(℘+ 0.6 ℘)
0.6
℘=5767.54 kWh
The plant’s total work produced will be the summation of the Wp of all the
equipment in the plant that requires energy to operate.
Plant Total Produced Work
Plant total produced work=℘( preheater )+℘(calciner) +℘(kiln) +℘(burner )
Plant total produced work=7161.74 kWh+20129.4 kWh−15255.3 kWh +5767.54 kWh
Plant total produced work=17803.38 kWh
The thermal efficiency of the plant will be calculated by the ratio of the
total produced work by the plant to the total power required by the plant
multiplied by 100%.
Thermal efficiency =( Plant total produced wor k /Plant total power requirement ) 100 %
Thermal efficiency =( 17803.38 kWh/15130.099326 kWh ) 100 %
Thermal efficiency =117.66862607 %
50
CHAPTER IV
ECONOMIC ANALYSIS
This chapter presents the data and detailed calculations of the cost
estimations that the proposed PCC plant would incur in order to justify if the plant
is economically viable.
Capital Costs
According to KLM Technology Group (2014), cost estimation may be
defined as the process of forecasting the expenses that must be incurred to
manufacture a product. These expenses take into consideration all expenditures
involved in design and manufacturing with all the related service facilities.
Lang (l947b) introduced the first factorial method for capital cost
estimating, and proposed a relationship between the cost of plant equipment and
the fixed capital cost (Lang, 1948).
C = f (E)
51
Where: C = Fixed capital cost
f = Factor
E = Delivered equipment costs
According to KLM Technology Group (2014), the multipliers depend on the
type of the plant to be constructed.
Source: Practical Engineering Guidelines for Processing Plant Solutions, 2014
Since the proposed plant is a majority of a solid processing plant, the
fixed capital investment is determined using the factor, 3.10. According to Lang,
the computed capital cost is considered apparent and used as basis for the
calculation of the true capital investment.
DESIGN OPTION 1
To be able to compute for the capital cost, the total purchased cost of the
equipments used in design option 1 are determined first:
Table 2. Equipment Installed Costs

Equipment Quantity Cost (Php)
Jaw Crusher 1 416,689.75
Vibrating Sieve 1 1,823,017.67
Limestone Bin 1 1,562,586.57
Pre - Heater Assembly 1 520,689.80
Calciner 1 78,103,469.27
Rotary Kiln 1 41,659,393.47
Industrial Furnace 1 5,207,424.18
Gas Filter 1 521,090.65
Scrubber 1 781,050.00
Cooling Vessel 1 521,090.65
Slaked Lime Tank 1 521,090.65
Cooling Tower 1 156,303.14
52
Precipitation Reactor 2 5,210,104.8
Screening tank units 1 2,605,052.40
Filter Press 1 5,207,424.18
Total Cost 144,816,477.2
The fixed capital cost computation is determined by this equation:
C = f (E)
C = 3.10 (Php 144,816,477.2)
C = Php 448,931,079.3 (this is considered apparent)
CAPITAL EXPENDITURES (CAPEX)
I. Direct Costs
a. Purchased Equipment
The most accurate estimate of the purchased cost of equipments
for the proposed plant is provided by a current price quote from a suitable
vendor.
Purchased Equipment Cost (PEC) = Php 144,816,477.2
b. Purchased Equipment Installation
The installation cost of the process equipments is estimated as
being an amount equivalent to 43 percent of the purchased equipment
cost. (KLM, 2014).
53
Table 3. Installation Cost
Source: KML Technology Group, 2014
 Foundations Cost (7% of the PEC)
i. Material Cost (4% of the PEC)
Material Cost = 0.04 x Php 144,816,477.2
Material Cost = Php 5,792,659.09
ii. Labor Cost (3% of the PEC)
Labor Cost = 0.03 x Php 144,816,477.2
Labor Cost = Php 4,344,494.32
 Platforms and Support Cost (11% of the PEC)
i. Material Cost (7% of the PEC)
ii. Labor Cost (4% of the PEC)
Labor Cost = 0.04 x Php 144,816,477.2
 Erection of Equipment (25% of PEC)
54
i. Labor Cost (25% of PEC)
Labor Cost = 0.25 x Php 144,816,477.2
Labor Cost = Php 36,204119.3
Total Purchased Equipment Installation Cost = Php 62,271,085.2
c. Piping Installation
This covers labors, valves, fittings, pipe, supports, and all other
terms involved in the complete erection of all piping used directly in the
process.
The cost of piping depends upon the type of process involved.
(KLM Group, 2014) Since the proposed plant is a fluid processing plant,
the cost is estimated at 66 percent of the purchased equipment value.
Table 4. Piping Cost
 Material Cost (9% of the PEC)
 Labor Cost (7% of the PEC)
Labor Cost = 0.07 x Php 144,816,477.2
55
Total Piping Installation Cost = Php 23,170,636.35
d. Instrumentation and Controls Installation
This includes not only the instruments but also all auxiliaries for the
entire plant.
Instrumentation cost is calculated depending upon the type of
controls is to be operated, either few or no controls, specific controls, or
the use of extensive controls with their equivalent percentages. (KLM
Group, 2014).
Table 6. Instumentation Cost
Since the proposed plant will use only few controls, it is estimated
to be at 5 percent of the purchased equipment value.
 Material Cost (4% of the PEC)
 Labor Cost (1% of the PEC)
Labor Cost = 0.01 x Php 144,816,477.2
Total Instrumentation and Controls Installation Cost = Php 7,240,823.86
56
e. Electrical Installation
This includes power wiring, lighting, transformation and service,
and instrumentation and control wiring.
The complete installed cost of electrical may be estimated as being
equivalent to 10 to 15 percent of the purchased equipment cost. (KLM
Group, 2014)
Electrical Cost = 0.15 x Php 144,816,477.2
Electrical Cost = Php 21,722,471.58
f. Buildings
This covers the costs of buildings to be erected and the building
components including the cost for plumbing, heating, lighting, and
ventilation of the plant.
The costs of the buildings including services depend upon the
different type of the process plant.
Table 6. Cost buildings include services
Since PCC plant is a new plant at a new site, the cost is estimated
to be at 68 percent of the purchased equipment price. (KLM Group, 2014)
Building Cost = 0.68 x Php 144,816,477.2
Building Cost = Php 98,475,204.5
57
g. Yard Improvements
This consists of construction for fencing, grading, roads, sidewalks,
railroad sidings, and landscaping.
The cost of yard improvements for chemical plants is estimated as
an amount equivalent to 10 to 20 percent of the purchased equipment
cost. (KLM Group, 2014)
Yard Improvements Cost = 0.20 x Php 144,816,477.2
Yard Improvements = Php 28,963,295.44
h. Service Facilities Installation
This includes the utilities of the plant for supplying steam, water,
power, compressed air, and fuel. Waste disposal, fire protection, and
miscellaneous service systems are also included.
The costing for service facilities depend upon the type of services
that is used in the plant, either the use of minimum additional services, or
average services or the use of the complete new services, with their
respective percentages. For the proposed plant, complete new services
are to be installed and this covers a 75 percent of the purchased
equipment value. (KLM Group, 2014)
Service Facilities Installation Cost = 0.75 x Php 144,816,477.2
Service Facilities Installation Cost = Php 108,612,357.9
58
i. Land
Land cost for the plant amount to be 4 to 8 percent of the
purchased equipment cost.
According to KLM Group (2014), the value of land does not usually
decrease with time that is why this cost should not be included in the fixed
capital investment when estimating certain cash flow, such as
depreciation.
Land Cost = 0.08 x Php 144,816,477.2
Land Cost = Php 11,585,318.18
Table 7. Summary of the Total Direct Cost Estimates
Direct Costs
Component Cost (Php)
Purchased Equipment 144,816,477.2
Purchased Equipment Installation 62,271,085.2
Piping Installation 23,170,636.35
Instrumentation and Control Installation 7,240,823.86
Electrical Installation 21,722,471.58
Buildings 98,475,204.5
Yard Improvements 28,963,295.44
Service Facilities 108,612,357.9
Land 11,585,318.18
Total 506,857,670.2
II. Indirect Costs
a. Engineering and Supervision
This covers engineering services such as drafting, purchasing,
accounting, construction design and engineering, travel, and
communications cost.
59
This cost is normally considered an indirect cost in fixed capital
investment and is approximately 30 percent of the purchased equipment
cost or 8 percent of the total direct costs of the process plant. (KPL Group,
2014)
Engineering and Supervision Cost = 0.08 x Php 506,857,670.2
Engineering and Supervision Cost = Php 40,548,613.62
b. Construction Cost
This consists of temporary construction and operation, construction
tools and rentals, home office personnel located at the construction site,
construction payroll, travel and living, and taxes and insurance of the
plant.
Roughly average amount of the construction expenses is 10
percent of the total direct costs for ordinary chemical process plants. (KLM
Group, 2014)
Construction Cost = 0.10 x Php 506,857,670.2
Construction Cost (CC) = Php 50,685,767.02
c. Contractor’s Fee
It is estimated as being equivalent to 2 to 8 percent of the direct
plant cost which is the sum of the fixed capital investment and
construction expense.
Contractor’s Fee = 0.08 x Php 506,857,670.2
60
Contractor’s Fee = Php 40,548,613.62
d. Contingency
This includes extra costs added into the project budget for
unpredictable expense, minor process changes, and estimating errors of
the plant.
It may be estimated depending upon the contingency level of the
installation used.
Table 8. Cost of Contingency
For the proposed plant which will be using few installation of
controls, there is a low level of contingency and is approximately 10
percent of the direct plant cost.
Contingency Cost = 0.10 x Php 506,857,670.2
Contingency Cost = Php 50,685,767.02
Table 9. Summary of Indirect Cost Estimates
Indirect Costs
Component Cost (Php)
Engineering and Supervision 40,548,613.62
Construction Cost 50,685,767.02
Contractor’s fee 40,548,613.62
Contingency 50,685,767.02
Total 182,468,761.3
61
True Fixed Capital Investment = Direct Costs + Indirect Costs
= Php 506,857,670.2 + Php 182,468,761.3
True Fixed Capital Investment = Php 689,326,431.5
III. Working Capital
Working capital is the additional investment needed, over and above the
fixed capital, to start the plant up and operate it to the point when income is
earned. It includes the cost of:
1. Start-up.
2. Initial catalyst charges.
3. Raw materials and intermediates in the process.
4. Finished product inventories.
5. Funds to cover outstanding accounts from customers.
Most of the working capital is recovered at the end of the project. The total
investment needed for a project is the sum of the fixed and working capital.
Working capital can vary from as low as 5 per cent of the fixed capital for a
simple, single-product, process, with little or no finished product storage; to as
high as 30 per cent for a process producing a diverse range of product grades for
a sophisticated market, such as synthetic fibres. A typical figure for
petrochemical plants is 15 percent of the fixed capital. (Chemical Engineering
Project, 2018)
Working Capital = 0.15 x Capital cost
= 0.15 x Php 448,931,079.3
62
Working Capital = Php 67,339,661.9
∴ CAPEX=True ¿ Capital Investment +WorkingCapital
¿ Php 689,326,431.5+ Php 67,339,661.9
CAPEX=Php 756,666,093.4 (estimated)
OPERATING EXPENDITURES (OPEX)
The operating expense will be interpreted to mean all expenses required
to make a product and to ready it for shipment. These expenses are divided into
three classifications as follows: direct production costs, fixed charges, and plant
overhead costs.
I. Direct Production Costs
a. Raw Material Costs
According to the KLM Group (2014), it should be based on the
mass balance done for the process.
- Limestones
kg 1 ton tons 24 h
4166.67 × =4.167 × =100 TPD
h 1000 kg h d
tons 330 d 1565.64

100 × × =Php51666120 / yr
d yr ton
- Coal
63
kg 1ton tons 24 h
125 × =0.125 × =3 TPD
h 1000 kg h d
tons 330 d 2191.90

3 × × =Php2169981/ yr
d yr ton
- Water
cu . m 330 d Php 24.81

64.8 × × =Php530537.04 / yr
d yr cu .m
Raw Materials
Material Requirement Base Cost Total Cost (330
days)
Limestone 100TPD Php 1565.64/ton Php 51666120
Coal 3TPD Php 2191.90/ton Php 2169981
Water 64.8 m3 Php 24.81/m3 Php 530537.04
Total Php 54366638.04
b. Operating Labor
Based on KLM Group (2014), the cost of personnel required for
plant operations should be itemized. It should be the second largest cost
of the plant.
64
Table 10. Detailed Manning Estimates
Personnel No. of Annual Total Annual Annual Total Annual

Wage Wage
Employee Deduction Deduction
(Php)
General Manager 1 603,700 603,700 125,000.07 125,000.07
Operations 3 316,582 949,746 50,000.08 150000.24
Supervisor
Marketing/ 1 584,530 584,530 125,000.05 125,000.05
Advertising
Manager
Sales Manager 1 491,907 491,907 50,000.29 50,000.29
Financial Analyst 1 304,996 304,996 50,000.07 50,000.07
Inspectors 2 185,977 371,954 22,500.08 45000.16
Process Operators 7 294,991 2,064,937 50,000.05 350000.35
Chemical 5 263,125 1,315,625 50,000.02 250000.1
Engineer
Laboratory Analyst 2 191,096 382,192 22,500.09 45000.18
Safety Engineer 3 230,060 690,180 22,500.16 67500.18
Chemist 2 244,313 488,626 22,500.17 45000.34
65
Mechanical 5 245,259 1,226,295 22,500.19 112500.95
/Electrical/ICE
Technician
Helpers, 6 181,757 1,090,542 22500.07 135000.42
Maintenance and
Repair Workers
Security 8 145,733 1,165,864 22500.01 180000.08
Janitor 4 96,000 384,000 8500.07 34000.28
Driver 5 149,222 746,110 22500.02 112500.1
Total 56 12861204 1876503.86
Total Operating Labor Cost = Php12,861,204 – Php1,876,503.86
Total Operating Labor = Php 10984700.14
66
c. Direct Supervisory and Clerical Labor
It includes the cost of administrative, engineering and
supportive personnel of the plant. It is estimated to be 15
percent of the operating labor value. (KLM Group, 2014)
Direct Supervisory and Clerical Labor Cost = 0.15 x Php 10984700.14
Direct Supervisory and Clerical Labor Cost =Php 1647705.021
d. Utilities
It is based on the process requirement per year of production.
Table 11. Summary of Yearly Utility Costs
Utilities
Utilities Requirement Based Cost Total Cost ( Per 330

Days)
Cooling Water 64.8m3/d Php 24.81m3 Php 530537.04
Coal 3TPD Php 2191.90/tons Php 2169981
CO2 14TPD Php1304.70/tons Php 6027714
Total Php 8728232.04
e. Maintenance and Repairs
This covers the amount of labor and materials associated with the
maintenance of the plant. For the plant operating and using complicated
process, it is estimated to be 7 to 11 percent of the true fixed capital
investment.
Maintenance and Repair Cost = 0.11 x TFCI
Maintenance and Repairs Cost (M&RC) = Php 75825907.465
f. Operating Supplies
68
This includes miscellaneous supplies that support daily
operation but not considered as raw materials. These are chart papers
miscellaneous chemicals, filters, respirators and protective clothing
for operators.
According to KLM Group (2014), it is based upon the
maintenance and repairs value that is estimated to be 15 percent.
Operating Supplies Cost = 0.15 x (M& RC)
Operating Supplies Cost = Php 11373886.1198
g. Laboratory Charges
This includes the cost of routine and special laboratory tests
required for product quality control and troubleshooting of
the plant.
It is estimated to be 10 to 20 percent of the operating labor. (KLM
Group, 2014)
Laboratory Charges = 0.20 x Php 10984700.14
Laboratory Charges = Php 2196940.028
69
Table 12. Summary of Direct Operating Cost Estimated and Itemized
Direct Operating Costs

Components Cost (PHP)
Raw Material Php 54366638.04
Operating Labor Php 10984700.14
Direct Supervisory and Clerical Labor Php 1647705.021
Utilities Php 8728232.04
Maintenance and Repairs Php 75825907.465
Operating Supplies Php 11373886.1198
Laboratory Charges Php 2196940.028
Total Php 165124008.854
II. Fixed Charges
These are expenses that remain practically constant from year to
year and independent of changes in the production rate.
a. Depreciation
It considers the costs associated with the physical plant
which are the buildings and the equipments. It is estimated to be
10% of the fixed capital investment. (KLM Group, 2014)
Depreciation = 0.10 x Php 689,326,431.5
Depreciation = Php 68932643.15
b.Local Taxes
It is considered to be 1 to 2 percent of fixed capital
investment. (KLM Group, 2014)
70
Local Taxes = 0.02 x Php 689,326,431.5
Local Taxes = Php 13786528.63
c. Insurances
It is considered to be 1 percent of fixed capital investment.
(KLM Group, 2014)
Insurances = 0.01 X Php 689,326,431.5
Insurances = Php 6893264.315
Table 13. Summary of Fixed Charges Estimates
Fixed Charges
Components Cost (Php)
Depreciation Php 68932643.15
Local Taxes Php 13786528.63
Insurance Php 6893264.315
Total Php 89612436.095
III. Plant Overhead Costs
e. Payroll Overhead Costs
71
It considers all the costs associated with the operations of
the auxiliary facilities supporting the manufacturing process of the
plant.
It is considered to be 10 percent of the operating labor plus
the supervision. (KLM Group, 2014)
Payroll Overhead Costs = 0.10 (10984700.14 +
1647705.021)
Payroll Overhead Costs = Php1263240.5161
f. Plant Overhead Costs (8 percent of the fixed capital investment)
Plant Overhead Costs = 0.08 x Php 689,326,431.5
Plant Overhead Costs = Php 55146114.52
Total Plant Overhead Costs = Php 56409355.0361
∴ OPEX=Direct Operat ing Costs +¿ Charges+ Plant Overhead
OPEX=Php 311145799.985
IV. General Expenses
a. Administration Costs
72
It is consist of other salaries, other administration, buildings,
and other related activities. It is based upon operating labor that
covers 20 to 30 percent. (KLM Group, 2014)
Administration Costs = 0.30 x Php 10,984,700.14
Administration Costs = Php 3,295,410.042
b. Distribution and Selling Costs
It covers the costs for sales and marketing required to sell
chemical products, sales offices, shipping, and advertising of
the plant. It is estimated 0 to 7 percent of fixed capital
investment.
Distribution and Selling Costs = 0.07 x Php 689,326,431.5
Distribution and Selling Costs = Php 48252850.205
c. Research and Development
It includes research activities for the development of
processes and product of the plant. It is estimated to have an
equivalent percentage of 2 to 5 percent of fixed capital
investment.
Research and Development Costs = 0.05 x Php
689,326,431.5
Research and Development Costs = Php 34466321.575
Total General Expenses = Php 86014581.822
73
Table 14. Summary of Cost Estimates for the Computations of
Total Capital Investment

Components Cost (PHP)
CAPEX Php 756,666,093.4
OPEX Php 311,145,799.985
General Expenses Php 86,014,581.822
Total Php 1153826475.21
Total Annual Income
= 14850000 kg/year x Php 70/kg = Php 1039500000
Economic Indicators
a. Payback Period
Total Capita l Investment

Payback Period =
Annual Income
Php 1153826475.21
Php 742500000/ year
Payback Period =1.55 years
b. Net Present Value (NPV)
NPV =Total Capital Investment−Total Annual Income
¿ Php1153826475.21−Php742500000
NPV =411326475.21
c. Rate of Return
74
Total Capital Investment−Total Income
Php 1153826475.21−Php 742500000

¿
Php 1153826475.21
RO R=35.65 %
75
CHAPTER V
ENVIRONMENTAL MANAGEMENT
This chapter provides information about the different effects or impacts of
the production of PCC to mankind and welfare, and the possible solutions,
following the environmental impact assessment (EIA) procedure.
Environmental Impact Assessment (EIA)
The effect of the operation of the process plant upon the environment and
population must be considered during design stages. The formal environmental
impact analysis consists of two sections:
A. The treatment of concentration of wastewater effluent and gaseous
emissions during normal operation.
Law
Greenhouse Gases, mandated under Section 31 of the Philippine Clean
Air Act of 1999, R.A. No. 8749, are directly enforceable federal regulations
issued for the categories of sources of air pollution that may reasonably be
anticipated to endanger environment. These type of greenhouse gases are those
gases that can potentially or can reasonably be expected to induce global
warming, which include carbon dioxide, methane, oxides of nitrogen,
chorofluorocarbons, and the like. Section 31 of the Philippine Clean Air Act of
1999, R.A. No. 8749 requires the control of the exhaust of those greenhouse
gases in the atmosphere, that these met meteorological factors affecting
76
environmental conditions including ozone depletion and greenhouse gases are
monitored and implement a national plan consistent if not contained in a certain
area.
I. Waste Generation
The wastes that can be generated from the production of PCC will be
treated to ensure the safety of the environment, moreover the treated waste by –
products are tested to see if they meet the standard requirement to be discharge
in the environment, or it will then be recycled and be used again in the process.
II. Waste Management
The waste produced in the PCC Process Plant would be disposed once
they met the standard required properties. The produced Carbon Dioxide from
the heating units are treated using the gas filter and scrubber and will be sent to
the precipitation unit as its reactant to the slaked lime, moreover, the waste
produced during the treatment process of the carbon dioxide are disposed to the
environment once tested and had passed the required properties.
The filter cartridges that are used in the gas filters are checked monthly
and are replaced when worn out.
For the wastewater that were discharge from the cooling and slaker unit, it
will be disposed on a land fill provided by the plant. This wastewater will be first
cooled down and are considered mud that can be disposed on landfills.
77
Social and Environmental Impacts
One of the effects of the waste produced by the PPC Process Plant is that
the miniscule particulates that could harm the health of the residents living near
the plant if not wearing dust mask. In order to control these particulates, the
exhaust of the gases from the heating units are sent to the gas filters so that
these particulates are filtered out before sending the treated gas to the
atmosphere.
Other environmental impact considerations are the thermal pollution. The
used cooling water or coolant in the plant serves as the main contributor to this
type of pollution. Thermal pollution happens when water used as a coolant is
returned to the natural environment at a higher temperature, the sudden change
in temperature decreases oxygen supply and affects ecosystem composition.
Moreover, in order to control and prevent this type of pollution, the waste water in
the coolant are first cooled down before disposing it the ocean or in landfills when
containing mud or dirt.
In the event of major plant accident, enormous pile of limestones, and
processed limestones are released, this causes massive release of particulates
into the atmosphere. Particulates can cause lung irritation, which can lead to
increased permeability in lung tissue, moreover particulates aggravate the
severity of chronic lung diseases, and can increase susceptibility to viral and
bacterial pathogens leading to pneumonia in vulnerable persons who are unable
78
to clear these infections. Residents near the plant should wear dust mask, so that
they would not intake any of the particulates release from the plant.
B. The handling of a major plant accident, including all substances
within the plant and any subsequent reaction products that could
cause health and environmental issues, and the containment and
clean up.
Material Safety Data Sheet
Precipitated Calcium Carbonate, MSDS
Section 1: Chemical Product and Company Information
Product Name: Precipitated Calcium Carbonate
Chemical Name: Calcium Carbonate
Chemical Family: Alkaline Earth
Chemical Formula: CaCo₃
Molecular Weight: 100.09
Trade name and synonyms: Calcium carbonate, Precipitated Calcium Carbonate
slurry, PCC, PCC slurry, Calcite PCC, Aragonite
PCC
Material Use: Mineral Filler
79
Section 2: Composition and Information on Ingredients
Hazardous Approximated C.A.S Exposure Limits

Ingredients Concentration Number (mg/m³)
OSHA ACGIH RSST MSHA NIOS NIOSH
PEL TLV VEMP PEL H REL IDLH
(% by weight) (Twa) (Twa) (Twa) (Twa) (Twa)
8/40h 8/40h 8/40h 8/40h 8/40h
Calcium 90 to 100 471-34-1 15 (T) TLV 10 (T) 10 (T) 10 (T) N/A
carbonate (Dry Basis) 5 (R) withdrawn 5 (T)
Section 3: Physical and Chemical Properties
Physical State: Solid
Odor and Appearance: Odorless – White Slurry, Consistency of cream. Dries to a
fine white crystalline powder
Specific Gravity: 2.68 – 2.76
Solubility in water (20°C): 0.00066g/100g
pH (25°C): 8.0 – 9.2
Density (kg/m³): 900 1900
Section 4: Fire and Explosion Hazard
Flammability of the Product: Non-flammable.
Extinguishing media: Calcium carbonated does not burn. Use extinguishing
media appropriate to surrounding fire conditions.
Special Fire Fighting Procedures: Calcium carbonate is generally non-flammable,
but ignites in contact with chlorine. Wear adequate personal
protection to prevent contact with material or its combustion
products. Firefighters should use self-contained NIOSH
80
approved breathing apparatus with full face piece to protect
against the product of combustion.
Section 5: Reactivity Data
Chemical Stability: Calcium carbonate is a very stable chemical substance.
Decomposes at 870°C to form carbon dioxide and calcium
oxide.
Incompatibility to other substances: Fluorine, Magnesium, Aluminum, Silicon,
Hydrogen, Mercury, Aluminum sulfate, Ammonium salts,
Acids
Reactivity: Calcium carbonate is a very stable chemical substance.
Decomposition does not occur at normal temperatures
(inferior to 600°C). Reacts chemically with strong acids to
form calcium based compounds and to liberate carbon
dioxide.
Hazardous Decomposition Products: Decomposition at 870°C will produce
carbon dioxide and calcium oxide.
Hazardous Polymerization Products: Will not occur.
Section 6: Toxicological Information
Route of Entry: Skin contact, Eye contact, Acute Inhalation, Ingestion
Effects of acute Exposure to products:
Skin: May cause skin irritation. Skin-Rabbit-500mg/24h- Moderate.
81
Eyes: May cause eye irritation with discomfort or pain, local redness and
swelling of the conjunctiva. Eye-Rabbit-750μg/24h- severe.
Inhalation: Inhaled in form of dust, may cause respiratory trac,
irritation/inflammation. Exposure may cause coughing and sneezing. Large
amount may cause chemical pneumonitis.
Ingestion: Cause Gastro-Intestinal Irritation. If ingested in large quantities
may cause nausea, constipation and hypercalcaemia, hrmohrrage.
Section 7: Preventive Measures
Personal Protective Equipment
Wear clean, dry gloves, full length pants over booth, long sleeved shirt
buttoned at the neck, head protection and approved eye protection selected for
the working conditions.
Gloves (Specify)
Gauntlets Cuff Style
Respiratory (Specify)
Use a NIOSH Approved anti-dust mask for particulate concentration
exceeding the occupational exposure limit.
NIOSH Approved Respirator.
Up to 50 mg/m3 : (APF=5) Any particulate respirator equipped with an N/R/95,
N/R/99 or 100 filter and quarter mask respirator
82
Up to 100 mg/m3 : (APF=10) Any particulate respirator equipped with an N/R/95,
N/R/99 or 100 filter and half-mask respirator.
Up to 250 mg/m3 : Any powered, air purifying respirator equipped with N/R/95,
N/R/99 or 100 filter or supplied – air respirator with elastomeric half – mask /
facepiece.
Eyes
ANSI, CSA or ASTM approved safety glasses with side shields. Tight
fitting dust goggles should be worn when excessive (visible) dust conditions are
present. Do not wear contact lenses without fitting goggles when handling this
chemical.
Footwear
Usual protection.
Clothing
Fully covering skin.
Other
Evaluate degree of exposure and use PPE if necessary.
Engineering Controls
Enclose dust sources; use exhaust ventilation or other engineering
controls and handling points to keep airborne levels below recommended
exposure limits.
83
Waste Disposal
Transport to disposal area or bury.
Handling Procedures and Equipment
Avoid skin and eye contact. Minimize dust generation. Wear protective
goggles and in cases of insufficient ventilation, use NIOSH approved anti-duck
mask. An eye wash station should be readily available where this product is
used.
Storage requirements
Keep tightly closed containers in a cool, dry and well-ventilated area, away
from acids.
Section 8: First Aid Measures
Skin
Carefully and gently brush the contaminated body surfaces in order to
remove all traces of Calcium Carbonate. Use a brush, cloth or gloves. Remove
all Calcium Carbonate – contaminated clothing. Rinse contaminated area with
lukewarm water. If irritation occurs or persists seek medical attention.
Eyes
Immediately rinse contaminated eye(s) with gently running lukewarm
water (saline solution is preferred) for 15-20 minutes. In case of an embedded
particle in eye, or if irritation occurs or persists, consult a physician.
84
Inhalation
Move source of dust or move victim to fresh air. Obtain medical attention
immediately. If victim does not breathe, give artificial respiration. Contact a
physician immediately.
Ingestion
If victim is conscious, wash out mouth with water. Have conscious person
drink several glasses of water to dilute. Induce vomiting. Contact a physician
immediately. Never give anything by mouth to an unconscious or convulsing
person.
General Advise
Consult a physician for all exposures except minor instances of inhalation.
Section 9: Regulatory Information
Component Calcium Carbonate has been reviewed against the following
regulatory listings:
 SARA Section 302 & 304 – Emergency Planning Notification. Extremely
Hazardous Substances List and Threshold Planning Quantity : Not Listed
 SARA Section 311/312 – Hazardous Categories : Not Listed
 SARA Section 313 – Toxic Release Inventory. Toxic Chemical List : Not
Listed
 CERCLA – Hazardous Substance : Not Listed
 RCRA – Hazardous Waste Number and Classification : Not Listed
85
CWA 311 – Clean Water Act List Hazardous Substances : Not Listed
Toxic Substances Control Act (TSCA): All naturally occurring components of this
product are automatically included in the USEPA TSCA Inventory .
Canadian Environmental Protection Act (CEPA) – Substances Lists (DSL/NDSL):
Calcium carbonate is specified on the public portion of the Domestic Substance
List
Section 10: Other Information
Hazardous Materials Identification System
National Fire Protection Association
Fire Hazard
Health Hazard Thermal Hazard
Specific Hazard
CHAPTER VI
PROJECT EXECUTION MANAGEMENT
86
This chapter contains the project construction management and strategy
including the quality control and assurance, working scheduling and overall
management and commissioning of the project. This also presents a detailed
Gantt Chart which takes into consideration the major activities and time allotted
to each activity. This also includes the preparation of simulation video of the
whole processing plant system highlighting the plant lay-out and processes
I. Preliminaries
This stage includes the will set the start-up processes for the project such
as the scope and nature of the project which includes the planning, feasibility
study, basis of design stage, and design layout stage.
A. Planning Stage
Identification of the phases, activities, and tasks needed for the execution
of the plant are include the planning stage. Different key project controls will be
analyzed including the business requirements, operations, budget allocated for
the construction and operation and the project commission.
B. Feasibility Study Stage
Feasibility study stage tests the viability of the project. The goal of this
stage is to place emphasis on potential problems that could occur during
construction and operation if the project is pursued and determine if, after all
significant factors are considered, the project should be pursued.
87
C. Basis of Design Stage
Basis of design is developed by the project requirements. Basis of design
describes the technical approach planned for the project as well as the design
parameters to be used.
D. Design Layout Stage
Design layout stage includes the detailed construction plan which is the
main need, manufacturing process and allocations of the different equipment.
Capital cost estimation for the proposed plant will be made and feasible returns
on the required investment will be determined. Specification of the product,
operating factors, material and energy balance will be considered in this stage.
II. CONSTRUCTION
The construction of the plant is considered consisting complete design,
having civil works, mechanical works, electrical works, automotive control the
procurement of buildings and making a site development.
A. Complete Design Stage
Complete plant layout and blueprints will be the main consideration in this
stage as well as instructions for construction. For the fabrication of special
equipment, detailed drawings will be made. Specifications will be prepared for
purchasing standard type of materials and equipment.
88
B. Procurement and Construction Stage
In this stage managing activities and tasks are made. Availability, quality,
quantity and cost are the main factors to be considered. Equipment should will
operate efficiently during the production. Raw materials will be gathered and
properly stored while the machineries and equipment are being installed. Two
years will be allocated to completely construct the plant.
C. Commissioning and Dry-run Stage
This stage will verify the process by ensuring that the subsystems including
pipes, electrical, fire/life safety, building, ventilation, interior systems, utilities,
lights, wastewater, controls, and building security achieve the project
requirements.
In this stage, the safety of running the plant processes and operations
must be practiced since safety is the most important thing to consider. The plant
will be tested to its efficiency and capacity to produce the products by a dry run.
Changes and adjustments regarding the processes or the product quality will be
done to avoid any unexpected accidents before and during the official start of the
plant operation. Furthermore, personnel hiring and training will be conducted in
this phase.
D. Operation Stage
89
The plant will start its normal operation after the, planning, compliance to
all the government and company requirements and specification, and ensuring
the safety of its processes and quality of its product. This stage contains the
production life of the plant which is estimated to be in 2043.
III. QUALITY ASSURANCE AND CONTROL
In order to operate the plant safely and maintain specific conditions such
as temperature and pressure, the plant must be properly controlled. The control
of the process was broken down into three stages; crushing unit, heating unit,
and slaker and precipitation unit. The primary concern of the crushing unit of the
plant is maintaining a constant feed rate of limestone of 6.25 tons/hr. This feed
rate provides the jaw crusher to be less stress on its gears and crushing
materials. Maintaining the feed rate is important for also the intake rate the
heating unit takes from the crushing unit depends on the feed rate the crushing
unit crushes. Moreover, the feed rate is controlled by the operator who controls
the speed of the conveyor.
In the heating unit, three main equipment are used which are the pre –
heater assembly, calciner, and the rotary kiln. The corresponding temperature of
each equipment should be maintained. The temperature for the pre – heater
assembly should be maintained at around 1850 °F to 2003 °F this is to ensure
the carbon dioxide release from the limestone at an efficiency of 25 – 35%.
Moreover, excessive temperature could cause the pre – heater assembly to
overheat which may cause for it to malfunction, especially on the temperature
90
controller and material used for construction. In the calciner, the temperature
should be maintained at around 2732°F to 3632°F to have a release of carbon
dioxide from the pre – heated limestones to 50 – 80% of the cumulative carbon
dioxide wt%. The calciner’s temperature should be controlled so that the
limestones are properly cooked and not cause an undesired overcooked quick
lime. Moreover, the temperature in the rotary kiln should be kept similar to the
calciner’s temperature. The main role of the rotary kiln is to maximize the carbon
dioxide release from the limestones, which is estimated to have a cumulative
release of 90 – 95%.
In the slaker and precipitation unit, the process variables that are needed
to control is the temperature, pressure, and flow of cooling water. The slaker is
composed of the cooling and slaker vessel to which cools the quick lime from the
rotary kiln. The cooling process is done by adding cooling water to the quick lime
and slaking it. The control for the flow of cooling water is done by a control valve.
Controlling the water intake is necessary for the temperature inside the cooling
and slaker vessel depends on the amount of cooling water going in the vessel.
Moreover, the cooling water flow rate should be maintained at around 1.8875
tons/hour. In addition, the precipitation unit is composed of the precipitation
reactor to which the precipitation reaction occurs between the slaked lime and
the carbon dioxide from the gas treatment unit. The process variables needed to
be controlled on that unit is the flow rate of carbon dioxide and the pressure
inside the reactor. The pressure depends on the carbon dioxide the reactor
intakes, to which the flow rate of carbon dioxide should be maintained at around
91
1.5 tons/hour. It is necessary to control the carbon dioxide flow rate, for
excessive intake could result to a poor-quality PCC product and may even cause
wear out of material of construction of the reactor. The flow rate is controlled by a
control valve operated in the quality control.
Organizational Chart
In order to accomplish all the project plan, there should always have
people responsible in controlling, maintaining and marketing the company. A
group of people called organization which has the intention of organizing an
accomplished and overall common goal is an organization. There are several
important aspects to consider about the goal of the business organization. These
features are explicit (deliberate and recognized) or implicit (operating
unrecognized or behind the scene event). Ideally, these features are carefully
considered and established usually during the strategic planning process.
Overall Management and Commissioning
The organizational set-up for the proposed plant is composed of three
functional department.
Administrative Personnel Department
The department serves as the industrial relations division of the company.
It is in-charge in keeping the personnel information files and makes report on the
92
activities of the employees. It proceeds training for new applicants. Employee’s
services such as material and legal counsel also provided by the department.
Marketing – Finance Department
The department will be in-charge in the marketing research and planning,
production planning and also pricing. This will handle the advertising and
promotion program, and actual distribution of the product and public relation
aspects. Consists of the group of people who responsible for discovering or
developing a need for demand for the company’s goods and services. They also
seek to maintain a responsive working relationship with consumers or potential
consumers.
Production/Process Department
The department is responsible for the planning, control and decision
making necessary for carrying out the process. It establishes operations, its parts
and sequences and proper class of machines required for the operations.
Labour Requirements
The compensations of each employee are based on various factors.
These factors include the duty, nature of their work and according to their
capabilities.
93
General Manager
Executive Summary
Marketing/Sales General Account Process/Production Quality Control HRD Manager

Manager Manager Manager Manager
Secretary Secretary Secretary Secretary Secretary
Marketing Accountant Process/Environme Quality Control Training &

Assistant ntal/Safety Head Employment Assistant
Engineer
Auditor
Advertising Officer R&D Specialist Medical Officer
Section Supervisor
Payroll Officer
Sales Laboratory General Services
Representatives Operator Supervisor Officer
Purchasing
Organizational Set-Up, Job Descriptions
Manager and Qualifications
94
Instrumentation &
Figure 23 Laboratory Analyst Driver
Table 15. Top Management Assistant Control/Electrical
Purchasing Officer Organizational Chart
Technician
Job Description Qualification
Security Guard Janitor
Position
Mechanical
Technician
Utility Man 94
General Manager He is the stockholder and head of the firm.  Male or Female
He is the responsible for the overall  Licensed Chemical or Mechanical
management of the plant. Engineer
 With minimum of 5 years experience in
the related works and duties.
Executive Secretary Responsible for communication,  Graduate of BS Information and
documentation and safekeeping of records Management System or any business
of the plant’s day to day activities. or management related degree
 With at least 3 years of working
experience
 Must have an excellent communication
skills
 Must be self-motivated
Table 16. Administrative Personnel Department
Position Job Description Qualification

HRD Manager Responsible for defining and conducting  Male or Female
administrative activities establishing the  BS Commerce Major in Management or BS
95
responsibilities for the people who will Psychology
carry them out  With at least 3 years of experience
General Account Responsible in handling financial matters,  Male or Female
Manager performing accounting control and  With at least 5 years of working experience
processes
77Secretaries Responsible for the safekeeping of the  Female
management of all the transactions of the  Graduate of Secretarial Course
department  Computer Literate
Purchasing Officer Works closely with marketing and finance  Male or Female
department, responsible for the  BS Industrial Engineering
procurement function and considerable  Economics Graduate
influence upon the purchase of the  With at least 3 years of working experience
material, supplies, and facilitate as they related to said duty
facilitate or impede the production
process
Assistant Purchasing Generally concern with scheduling of raw  Male or Female
Officer materials in the plant and delivery of  BS IE or Commerce Graduate
finished product on the plant, warehouse
to either regional or the customer’s facility
Training and Responsible for securing the services of  Male or Female
Employment the people with the knowledge and skill to  BS Behavioural Science / Psychology
Assistance carry out necessary activities graduate
96
Assist HR Manager
Janitors Responsible for the cleanliness and  Male
orderliness of the plant  Agency member
Driver In-charge of the transportation of raw  At least high school graduate
materials and delivery of products
Utility Men Acts as errand and responsible in  Male
accomplishing assigned task  At least high school graduate
Security Officer Responsible for the proper  Male
implementation of security rules and  Security agency member
regulation
Responsible in the routine check-up in  Male or Female
the medical services of the company’s  General Medicine Graduate ( preferably,
employees Licensed) 97
Table 17. Marketing – Finance Department

Marketing Sales Responsible for the general marketing  Male or Female
Manager activities, facilitate the expedite product  BS IE/Commerce Graduate
and service exchange effectively and  With at least 3 years of work-related
97
efficiently experience
Accountant Responsible for the custody and control of  Certified Public Accountant
all the accounts and financial records of  With at least 3 years of work-related
the company experience
Auditor Responsible for auditing all financial  Certified Public Accountant
accounts and records of the company  With at least 3 years of work-related
experience
Payroll Officer Responsible for the computation of  BS Accountancy / Commerce Graduate
salaries and other financial aspects
concerning the employees
Advertising Officer Responsible for the formulation of  Graduate of BS Business Management
advertising strategies to help make the major in Advertising
products more competitive  With at least 2 years of work-related
experience
Advertising Assistant Assist the Advertising Officer  Graduate of BS Business Management
major in Advertising
Sales Representative In charge of the implementation of  Graduate of BS Business Administration
marketing strategies  With good interpersonal skills.
Table 18. Manufacturing Department
98
Process Engineer Responsible in controlling and implementing  Male or Female
of policies and procedures in accordance with  Licensed Chemical / Mechanical
the set standards Engineer
 With at least 5 years of work-related
experience
Quality Control Responsible for insuring high quality products  Licensed Chemical Engineer/
Manager and for setting up standards and procedures Registered Chemist
of the process  With at least 3 years of work-related
experience
Production Engineer Responsible with the up keep and repair of  Male or Female
production equipment, buildings, and plant  Licensed Mechanical/Chemical
services and the design modification of the Engineer
plant and processes  With at least 3 years of work-related
experience
Process Supervisor Furnishes production schedule and machine  Male or Female
loading programs and has direct supervision  Licensed Chemical / Mechanical
of the production operators Engineer
experience
Laboratory Analyst Responsible in conducting laboratory tests  Male or Female
and chemical analysis  icensed Chemical / Mechanical
99
Engineer
experience
Production Operator Responsibility includes inspection and  Male
monitoring of assigned equipment processes  Technical / Vocational Graduate
and finished products
Ensures proper operation
Field Operator In-charge of supervision of external operation  BS Mechanical/Chemical Engineering
of the production and perform minor repairs graduate
Lead Operator In-charge of the control system and  BS Mechanical/Chemical Engineering
procedures and perform minor repairs graduate
Mechanical Technician Responsible for overall maintenance and  Male
repairs of the different equipment and  Licensed Mechanical Engineer /
facilities, instrumentation and piping Certified Instrumentation Engineer
experience
Electrical Technician Responsible for overall repairs and  Registered Electrical Engineer / Master
maintenance of the electrical facilities and Technician
wirings  With at least 3 years of work-related
experience
Safety Engineer Responsible for checking the overall status of  Registered Chemical / Mechanical
plant and its equipment for safety purposes Engineer
100
experience
Environmental Responsible for making necessary  Graduate of BS Chemical Engineering
Engineer adjustments to meet the standards given by with Masters in Environmental
the government agencies regarding Management
environmental considerations
Research and Responsible for checking the new trends and  Registered Chemical / Mechanical
Development needed adjustments of the plant for Engineer preferably with Master’s
Supervisor and optimization purposes Degree
Specialist  With at least 3 years of work-related
experience
Quality Responsible for ensuring high quality  BS Chemistry/Chemical Engineering
Control/Assurance products and for setting up standards and Graduate
Head procedures of the process  With at least 3 years of work-related
experience
101
PROJECT SCHEDULING
GANTT CHART
Project Schedule
YEAR
Activities 2018 2019 2020

J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D
A E A P A U U U E C O E A E A P A U U U E C O E A E A P A U U U E C O E
N B R R Y N L G P T V C N B R R Y N L G P T V C N B R R Y N L G P T V C
Planning
Feasibility Study
Stage
Basis of Design
Phase
Design Layout
Stage
Complete Design
Stage
102
Project Schedule
YEAR
Working 2021 2022 2023 2043
J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D
Activities A E A P A U U U E C O E A E A P A U U U E C O E A E A P A U U U E C O E
N B R R Y N L G P T V C N B R R Y N L G P T V C N B R R Y N L G P T V C
Procurement
and
Construction
Stage
Commissionin
g and Dry-run
Stage
Operation
Stage
103
Preparation of Simulation Video
The simulation video of the PCC Production Plant showcases the different
processes necessary in producing precipitated Calcium Carbonate. These
processes include the crushing stage which primarily is composed of the jaw
breaker; the heating stage which is composed of the pre – heating assembly,
calciner, and rotary kiln; the cooling and slaker stage which is composed of the
cooling and slaker unit; the precipitation stage which is composed of the
precipitation reactors; the drying and compression stage which is composed of
the filter press; and the storage and distribution stage which is composed of the
silos and loading area.
The simulation video also presents the raw materials and the source of
those raw materials needed for the production of PCC. Moreover, the global and
local demand for PCC are also presented to which the PCC Production Supply
are planning to supply a portion of market percentage of those demand,
especially on the local market.
104
CHAPTER VII
SUMMARY OF FINDINGS, CONCLUSIONS AND RECOMMNEDATIONS
This chapter presents the summary of findings, conclusions and
recommendation for the development of a solid waste-to-energy incineration
plant using municipal and industrial solid waste.
Summary of Findings
The following results relative to the Precipitated Calcium Carbonate Plant
were summarized as follows:
1. The proposed Precipitated Calcium Carbonate Plant will be located at
at Mabini, Batangas. The plant is considering supplying 15% of the PCC locally,
therefore the annual plant capacity will be estimated at 16,611.21 tons/year.
Moreover, in terms of daily production, the plant capacity will be estimated at 45
tons/day.
2. Through Precipitated Calcium Carbonate Plant an additional producer
and supplier of PCC in the Philippines would be added since the supply of PCC
is currently lesser of what is demand of it by the different local industries. The
PCC plant reasonably viable to resolve this unbalance supply – demand system
for PCC in the Philippines.
105
Conclusions
The following conclusions are based from the summary of findings
mentioned above.
1. The proposed plant varies in some considerations such as electricity
supply and demand; target customers, target location and market are
important which will serve as the foundation for the development of the
proposed plant.
2. To evaluate the plant overall efficiency of the proposed plant, technical
aspects including equipment cost, equipment specifications, mass
balance and energy balance is needed
3. Alternatives designs are necessary to fully evaluate the proposed
plants and choose the best option.
4. In determining if the proposed plant is economically viable, Technical
aspects including equipment cost, equipment specifications, mass
balance and energy balance are needed to be computed and evaluate.
5. The assessment of the proposed plant will be determined during
construction and operation of the plant.
6. This proposed design, which uses calcination process, which will emit
exhaust CO2 and dust will be subjected to gas treatment through the
use of filters to be used again in the process.
106
Recommendations
Based on the foregoing findings and conclusions presented, the following
recommendations are suggested:
1. The Precipitated Calcium Carbonate Plant requires a location with large
deposit of limestone to account for the raw material requirement for the
production of PCC.
2. The use of renewable energy as the source of the plant’s energy since it
needed large amount of energy needed for each of the operations to run.
3. The use of more advanced gas filters for exhaust CO2 and dust is
advisable.
4. Equipment should handle optimum electricity recovery. Maintenance of
the equipment is highly recommended to avoid malfunctions of the
equipment.
5. Health, safety and environment must take into consideration during project
execution and operation of the energy plant.
107

PPC Production Plant

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PPC Production Plant

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CHAPTER I

INTRODUCTION AND ITS BACKGROUND

Limestone, being a sediment deposit has many significant variety of uses

or glass making; or serve as an effective additive in the process of making

different products, like papers, plastics, sealant, adhesives, rubbers, inks, or

pharmaceutical coating supplements. Moreover, limestones being 10% of the

for it to become beneficial products.

Numerous variety of processes are used in processing limestones, one of

the well-known process is calcination. Calcination, or the heating of solids to a

high temperature for the purpose of removing volatile substances, oxidizing a

portion of mass, or rendering them friable. Calcination is also sometimes

considered a process of purification. Furthermore, Calcination reactions usually

take place at or above the thermal decomposition temperature or the transition

One of the products of calcining limestones is the Precipitated Calcium

Carbonate (PCC). Precipitated calcium carbonate (PCC) is an innovative product

typically has a uniform narrow particle size distribution. PCC is available in

performance in a specific application. PCC is considered to be non-toxic. In the

carbonate to be GRAS (Generally Recognized As Safe). As long as the PCC

meets certain purity requirements, it can be used as a direct food additive, as a

pharmaceutical or as an indirect additive in plastic, or paper products that come

in contact with food.

The production of PCC usually involves the process of precipitation and

slaked limes are precipitated to a controlled system to where it produces PCC.

In the Philippines, the supply of PCC is currently lesser of what is demand

Therefore, an additional producer and supplier of PCC in the Philippines would

The location to where the plant will be established will be at Mabini,

Batangas (13.763959, 120.960321), as seen in Figure 1. The location of the

availability of raw materials, road accessibility, the availability of water supply

(Batangas Bay), distance from residential houses, and climate.

Figure 1. Plant Location of PCC Production Plant

limestone deposits in Mabini, Batangas were considered. The limestones will be

mined by Talibayog Mining Corp. The limestone deposits in Mabini, Batangas is

estimated to be at 13.5 hectares in area. The mining area is then conservatively

estimated to contain at least 50 years of limestone deposits, considering the

Production Plant is close to one of the limestone deposits in Mabini, Batangas to

where the transportation of the limestones to the plant would be at ease.

of Bauan – Mabini road. Furthermore, transportation by means of land vehicle

would be safe and straightforward.

supply. The location is deliberately chosen for it to be placed coastline to the

using it during operation.

opportunities to those residents living in Mabini, Batangas. Since, the plant

taking consideration to the capability of those individuals.

limestones will be mined in Mabini, Batangas by Talibayog Mining Corp., to

area of limestone deposits in Mabini, Batangas is estimated to be at 13.5

2 million tons per year as the mining rate.

The product of the PCC Production Plant is Precipitated Calcium

Carbonate or PCC. PCC will be done by means of processing the limestones.

PCC has numerous applications to which are the following:

 Flattering agent in paint industries

meet the standard specification of PCC. The standard specification of

PCC is shown at Table 1.

Name Precipitated Calcium Carbonate

use of PCC as their components in manufacturing plastics. Furthermore,

produced PCC will also be sold in the local market.

in the Philippines, specifically the demand in PCC of D&L Industries, Inc. It is

statistic forecast. Furthermore, the calculated market of PCC in the Philippines

would be estimated at 110,741.4 tons annually.

annual plant capacity will be estimated at 16,611.21 tons/year. Moreover, in

terms of daily production, the plant capacity will be estimated at 45 tons/day.

precipitated calcium carbonate market is expected to reach an estimated $23.5

Application in plastics segment accounted for a share of over 20% in

scope in modifying the functional properties of various grades of plastics is

precipitated calcium carbonate in the plastic processing sector as a filler material