A

Project Report On
FORMIC ACID (Phase I)

Submitted in partial fulfillment towards the Bachelor’s

Degree in the field of Chemical Engineering

Prepared By: - MEHTA DHRUV KALPESHBHAI

CH056(ID NO. 20CHUOD005)
Under the Guidance of
SIDDHARTH MODI

Department of Chemical Engineering

Faculty of Technology, Dharmsinh Desai University
College Road, Nadiad – 387001
April -2023

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 CERTIFICATE

This is to certify that MEHTA DHRUV KALPESHBHAI (CH056,

I.D. NO. 20CHUOD005) has duly submitted his Project Report on
FORMIC ACID PLANT as a partial fulfillment towards bachelor’s
degree in Chemical Engineering at Dharmsinh Desai University,
Nadiad in the year 2023.

SIDDHARTH MODI, Dr. M.S. Rao

ASST. PROFFESOR, Professor & Head,
Dept. of Chemical Engg., Dept. of Chemical Engg.,
DDU, Nadiad. DDU, Nadiad
DATE: DATE:

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 PREFACE
Technical studies can’t be prefaced without practical training. Hence
plant training has great value for an engineering student. Technical
knowledge gives theoretical aspect of technology, but practical
training gives knowledge of industrial activities. My aim in plant
training is to carry our detailed study of industrial instrument and
process control besides education aspects. I also tried to observe
important aspect of industrial management, discipline, and safety
precautions. I saw how engineers coordinated with running of plant.

In present work, I discussed what I studied in FORMIC ACID Plant

of GNFC. The report contains some general information about
detailed process description, salient features of the plant, diagrams,
material balance, energy balance, equipment design, safety rules
along with utilities and ETP. I must say that this type of training will
fill the gap between theoretical and practical knowledge. Once again,
I want to say thanks to all those who helped me in this endeavor
directly or indirectly.

MEHTA DHRUV KALPESHBHAI

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 DECLARATION

I MEHTA DHRUV KALPESHBHAI declare that, the project report

on comprises my original work towards the degree of Bachelor of
Technology in Chemical Engineering at Dharmsinh Desai University
and is not copied from any published or proprietary source. I further
declare that this work is not submitted elsewhere towards degree or
diploma in any university or college. The whole content of this project
work is genuine and distinctive.

MEHTA DHRUV KALPESHBHAI,

CH056(ID. NO. 20CHUOD005),
Semester VIII,
Department of Chemical Engineering,
Faculty of Technology,
Dharmasinh Desai University, Nadiad.

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 PHASE – I
FORMIC ACID

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ACKNOWLEDGEMENT
I feel obliged that a prestigious organization like GNFC gave me a chance to
get a valuable technical exposure of the industry through the vocational training
program. The eight weeks of training period has given me a lot of knowledge
regarding the practical application of the theoretical knowledge that is taught in
the engineering institutes. And this practical exposure is must in the academics
of every engineering student.
During the training period I have been guided by a number of GNFC personnel
and without their active and enthusiastic support this training would not have
been possible. First of all, I would like to thank Mr. H. K. Parekh (Senior
Training Officer) for accepting me for availing the benefit of the training
program. It is prestigious for me to take training at GNFC, Bharuch. The eight
weeks of training has given me an experience and exposure to the practical
application of the theoretical know-how. I’d like to thank Mr. S.H. VOHRA
(Senior Manager at FORMIC ACID), Mr. B.B. GUJARATI (Shift
Engineer at FORMIC ACID) for their valuable time and support during my
training and helped me learning the process and field operations of the plant.
Last, I would like to thank my college Dharmsinh Desai University, chemical
Engineering Department.

Yours sincerely,
DHRUV K. MEHTA

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 CONTENTS

FORMIC ACID PLANT (PHASE-I) ..................................................

ACKNOWLEDGEMENT ....................................................................

PREFACE ..............................................................................................

LIST OF FIGURES......................................................................XVII

LIST OF TABLES...................................................................... XVIII

ABBREVIATIONS ....................................................................... XIX

NOMENCLATURE ........................................................................ XX

CHAPTER 1.......................................................................................21

INTRODUCTION .............................................................................21

INTRODUCTION OF FORMIC ACID ................................... 21

1.1 General ................................................................................... 21

1.2 History.................................................................................... 21
1.3 Chemical Structure ................................................................ 22
1.4 Properties of Formic Acid ..................................................... 22
1.4.1 Physical properties ................................................................. 22
1.4.2 Chemical properties ............................................................... 23
1.5 Uses of Formic Acid .............................................................. 23
1.6 Health Hazards....................................................................... 24
1.7 First Aid Measures................................................................. 24
1.8 Material Data Safety Sheet ………………………………..25

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CHAPTER 2.................................................................................. 2526

SELECTION OF PROCESS ...........................................................26

2.1 Introduction ........................................................................ 26

2.1.1 Types of process technology ........................................ 26
2.1.1.1 Oxidation of hydrocarbons. ................................. 26
2.1.1.2 Hydrolysis of formamide. .................................... 26
2.1.1.3 Preparation of free formic acid from formats. ..... 28
2.1.1.4 Hydrolysis of Methyl Formate. ........................... 28
2.2 Selection of process ............................................................ 29
2.3 Chemistry of process .......................................................... 29
2.3.1 Main Reaction .............................................................. 29
2.3.2 Side Reaction ................................................................ 30
2.3.3 Effect of H2O ................................................................ 30
2.4 Properties of Product and Raw materials. ........................ 30
2.4.1 Feed gas ........................................................................ 30
2.4.2 Methanol ...................................................................... 30
2.4.3 Potassium Methoxide ................................................... 30
2.4.4 Methyl Formate (Intermediate product):..................... 31
2.4.5 Specifications of product .............................................. 31
2.5 Utilities specifications ........................................................ 31
2.5.1 Steam ............................................................................ 31
2.5.2 Cooling Water: ............................................................. 31
2.5.3 Liquid Ammonia .......................................................... 32
2.5.4 Nitrogen ........................................................................ 32
2.5.5 Electricity .................................................................... 32
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 2.6 Process Description For MF ............................................... 34
2.6.1 Methanol Drying Unit .................................................. 34
2.6.2 Methyl Formate Synthesis ............................................ 34
2.6.3 Methyl Formate Separation .......................................... 36
2.6.4 Salt Removal ................................................................ 36
2.6.5 Methyl Formate Intermediate Storage ......................... 37
2.7 Process Description For FA ............................................... 37
2.7.1 Hydrolysis Pre-mixing Tank(D-5050): ........................ 37
2.7.2 Hydrolysis Reactor (R- 5060): ..................................... 37
2.7.3 First Formic Acid Column(T-5060): ........................... 38
2.7.4 Recycle Column(T-5040M1): ...................................... 38
2.7.5 Second Formic Acid Column(T-5070A/5070) ............ 39
CHAPTER 3.......................................................................................41

3. MATERIAL BALANCE……………………………… 41

3.1 Formic Acid Section ..................................................................... 41

3.1.1 Material Balance of T5070/A .................................................... 41
3.1.2 Material Balance for T-5060/X .................................................. 41
3.1.3 Material Balance of Hydrolysis Reactor (R-5055) .................... 42
3.2 Methyl Formate Section ............................................................... 43
3.2.1 Material Balance for T-5030/X (MF Column) .......................... 43
3.2.2 Component Material Balance ..................................................... 43
3.2.3 Material Balance of MF Reactor (R-5020/X/R) ........................ 44
3.3 Salt Formation Reaction ................................................................ 45
CHAPTER 4………………………………………………………..47

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 4. ENERGY BALANCE 48

4.1 Introduction ................................................................................... 48

4.2 Energy balance around Methyl Formate Reactor ......................... 49
CHAPTER 5.......................................................................................50

UTILITIES .............................................................................................

5.1 COOLING WATER SYSTEM (COLLING TOWER) 51

5.1.1 Functioning of Cooling Tower: .......................................... 51

5.1.2 General Terms Used in Cooling Water Systems ............... 51

5.1.2.1 Acidity………………………………………………...51
5.1.2.2 Alkalinity ........................................................................ 52
5.1.2.3 Hold up capacity of the system ...................................... 52
5.1.2.4 Blow down ..................................................................... 52
5.1.2.5 Make up Water: .............................................................. 52
5.1.2.6 Drift ................................................................................ 52
5.1.2.7 System Losses ................................................................ 52
5.1.2.8 Evaporation Losses ........................................................ 52
5.1.2.9 Cycle of Concentration .................................................. 53
5.1.3 Typical Problems in Cooling Tower: ................................ 53
5.1.3.1 Scaling ............................................................................ 53
5.1.3.2 Corrosion ........................................................................ 53
5.1.3.3 Microbiology .................................................................. 53
5.1.3.4 Bacteria ........................................................................... 54

5.1.4 Disadvantages due to above problems in Cooling Water

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Systems ……………………………………….54
5.1.5 Cooling Tower System for Formic acid Plant ................... 54
5.2 CHILLING WATER SYSTEM 56

Chilling water System for Formic acid Plant ................... 56

CHAPTER 6.......................................................................................57

Detailed Description of Equipment .................................................58

6.1 List of equipments along with their description ............... 58

CHAPTER 7.......................................................................................60

Designing of Equipment....................................................................60

7.1 Introduction.................................................................................. 61
7.2 Design of Minor Equipment ...................................................... 61
7.2.1 Storage Tank............................................................................ 61
7.2.2 Knockout Drum....................................................................... 66
7.3 Designing of Major equipment .................................................. 70
7.3.1 Process Design......................................................................... 71
1. Actual Number of Trays .............................................................. 74
7.3.2 Mechanical Design ................................................................. 75
1. Height of the column ................................................................... 75
2. Torispherical head........................................................................ 79
3. Elliptical Head ............................................................................. 79
4. Nozzle Design.............................................................................. 80
5. Flange Design ............................................................................. 81
6.Hub design ................................................................................... 82
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7.Bolt Design .................................................................................. 82
8.Skirt support................................................................................. 84
CHAPTER 8.......................................................................................87

Pumps, Piping, Fittings and Control Valve ....................................87

8.1 Introduction ............................................................................ 88

8.2 Various types of pumps available ........................................... 88

8.3 Pipe and fittings ..................................................................... 91

8.4 Control Valve …………………………………….………93

CHAPTER 9.......................................................................................98

Safety, Health and Environment .....................................................98

9.1 Introduction ............................................................................. 99

9.2 Safety measures to be taken by Industry................................ 99

9.3 Safety Equipment ..................................................................100

9.4 All the auxiliary equipment related to safety: ...................... 104

9.5 Hazop of the plant .................................................................108

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9.6 Various pollution control measures taken by the industry….111

CHAPTER 10...................................................................................116

Plant Locations and Layout ...........................................................116

10.1 Introduction .........................................................................117

10.2 Plant Location .....................................................................117

10.3 Plant Layout …………………………………………… 121

CHAPTER 11...................................................................................124

COST ESTIMATION .....................................................................124

11.1 Introduction………………………………………………125
11.1.1 Total capital investment………………………………..125
11.1.2 Fixed capital investment……………………………….125
11.1.3 Working capital……………………………………… 126

11.1.4 Purchased equipment cost .............................................1256

11.1 Direct cost………………………………………………..126

11.2 Indirect cost .......................................................................1267

11.3 Total production cost ........................................................1278

11.3.2 Direct production cost………………………….............127

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 11.3.2 Fixed charges…………………………………………128

11.3.3 General expenses………………………………………128

11.4 Profitability………………………………………….....129

11.5 Conclusion...........................................................................131
CHAPTER 12...................................................................................132

CONCLUSION ................................................................................134

References ........................................................................................134

LIST OF FIGURES
Figure No. Figure
1.1 Physical Structure of FA
2.1 Process Flow Diagram
3.1 Block Diagram with Material
Balance
5.1 Induced Draft Cooling Tower
7.1 T-5030R Design
7.2 Equilibrium and operating line of
Distillation
8.1 Color Codes of Pipelines
8.2 Control Valve Arrangement
9.1 Classification of Fire
9.2 Types of Extinguishers
10.1 GNFC Layout

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LIST OF TABLES

Table no. Table

1.1 Formic Acid

1.2 Physical properties Formic Acid
2.1 Feed Gas Composition
2.2 Methanol Composition
2.3 Potassium Methoxide Composition
2.4 Methyl Formate Composition
2.5 Specification of Product
2.6 steam specification
2.7 cooling water specification
2.8 Liquid Ammonia specification
2.9 Nitrogen specification
2.10 Electricity specification
4.1 Energy balance for methyl Formate reactor
7.1 Storage Vessel Thickness
7.2 Summary table of Storage Vessel
7.3 Summary Table of Knockout Drum
7.4 Equilibrium Data
7.5 Summary table for Distillation tower design
8.1 List of Pump that used in Formic acid Plant
11.1 Direct cost
11.2 Indirect Cost
11.3 Direct Production Cost

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11.4 Fixed Charges
11.5 General Expenses
11.6 Summary table for cost estimation

ABBREVIATIONS
NTP Normal Temperature & Pressure
FA Formic Acid
MF Methyl Formate
MEG Mono Ethyl Glycol
BL Battery Limit
ppm Parts per million
HP Steam High Pressure Steam
LP Steam Low Pressure Steam
MP Steam Medium Pressure Steam
TFE Thin Film Evaporator

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NOMENCLATURE
Notation Parameter Unit

CP Specific heat capacity kJ/kg K

L Latent heat of kJ/kg

vaporization
m Mass flow rate kg/hour

Q Heat load kJ

D Diameter m

A Area m2
P Pressure kPa

u Viscosity kg/m s

T Temperature K

Th Thickness mm

CA Corrosion allowance mm

p Density kg/m3
V Volume kL

NRE Reynolds number

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 CHAPTER 1
INTRODUCTION

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 1. Introduction of Formic Acid
1.1 General

• Formic acid, systematically named methanolic acid, is the simplest

carboxylic acid. The chemical formula is HCOOH or HCO2H. It is an
important intermediate in chemical synthesis and occurs naturally, most
notably in some ants.

• The word “formic” comes from the Latin word for ant, Formica, referring to
its early isolation by the distillation of ant bodies. Esters, salts, and the anion
derived from formic acid are called formats.[6]

1.2 History

• Some alchemists and naturalists were aware that ant hills give off an acidic
vapor as early as the 15th century. The first person to describe the isolation of
this substance (by the distillation of large numbers of ants) was the English
naturalist John Ray, in 1671. Ants secrete the formic acid for attack and
defense purposes. Formic acid was first synthesized from hydrocyanic acid by
the French chemist Joseph Gay-Lussac. In 1855, another French chemist,
Marcellin Berthelot, developed a synthesis from carbon monoxide similar to
the process used today.

• Formic acid was long considered a chemical compound of only minor

interest in the chemical industry. In the late 1960s, however, significant
quantities became available as a byproduct of acetic acid production. It now
finds increasing use as a preservative and antibacterial in livestock feed. .[6]

Table 1.1 Formic Acid

IUPAC name Formic acid

Other names Methanoic acid

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 Chemical Name Carbonous acid;
Formic acid;
Hydrogen carboxylic acid;
Hydroxy(oxo)methane;
Metacarbonoic acid;
Oxocarbinic acid;
Oxo Methanol

1.3 Chemical Structure

Figure 1.1: Chemical Structure of FA

1.4 Properties of Formic Acid

• It is miscible with water and soluble in hydrocarbons to some extent. It

consists of hydrogen bonded dimers rather than individual molecules in
hydrocarbons and in vapor phase. In the gas phase, this hydrogen-bonding
results in deviations from the ideal gas law. Liquid and solid formic acid
consists of an effectively endless network of hydrogen-bonded formic acid
molecules.

1.4.1 Physical properties: -

Table 1.2: Physical Properties of Formic Acid

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 Molecular formula HCOOH, CH2O2

Molar mass 46.0254 g/mole

Appearance Colorless, fuming liquid

Density 1.22 g/ml

Melting point 8.4°C

Boiling point 100.8 °C

Viscosity 1.57 cp at 268°C

1.4.2 Chemical properties: -

• It is a bi-functional compound. Formic acid shares most of the chemical
properties of other carboxylic acids in its ability to participate in addition
reactions with alkenes. Formic acid and alkenes readily react to form
formate esters. It shares some of the reducing properties of aldehydes,
reducing the solution of gold, silver and platinum to the metal. .[6]

1.5 Uses of Formic Acid

• Used as a coagulant for obtaining rubber from latex.

• As an auxiliary for delining and pickling of flur, fixing of dyes in the

leather industry and in processing in the textile industry.

• As an intermediate in manufacturing of basic drugs, plant protection

agents, pesticides, vulcanization accelerators, antioxidants and cleaning
agents.

• Used in preservation of silage and grams.

• Used in electroplating and as a solvent as well. Explosive Limit of Formic Acid:

18-57%

• Threshold Limit Value: 5ppm.

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 1.6 Health Hazards

• Inhalation: May cause respiratory tract irritation, burns, coughing,

frothy sputum, difficulty in breathing, fatigue and pulmonary edema.
May cause nausea.

• Eye contact: EXTREMELY IRRITATING AND CORROSIVE. Contact

may cause conjunctivitis, redness, pain, blurred vision, corneal
destruction and permanent injury. Exposure to vapors of fumes may cause
irritation.

• Skin contact: EXTREMELY IRRITATING AND CORROSIVE.

Contact may cause reddening, itching, inflammation, burns, blistering,
and tissue damage.

• Ingestion: SLIGHTLY TOXIC. CORROSIVE. May cause burning pain

of the mouth, throat and abdomen and coughing.

• Chronic effects exposure: Chronic exposure by inhalation may produce

erosion of the teeth and jaw necrosis.

1.7 First Aid Measures

• Inhalation: Remove exposed person from source of exposure. If not breathing,

ensure open airway and institute cardiopulmonary resuscitation (CPR). If
breathing is difficult, administer oxygen if available. Keep the personnel
warm and at rest. Get immediate medical attention.

• Eye contact: flush with a large amount of water for 15 minutes. Eyelids should
be held away from the eyeballs to ensure thorough rinsing.

• Skin contact: wash the affected area with soap and water. Remove
contaminated clothing immediately.

• Ingestion: Do not induce vomiting. If the victim is conscious, give water or

milk to dilute stomach contents.

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 CHAPTER 2
SELECTION OF PROCESS

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 Selection of Process
2.1 Introduction

In this Chapter, I have discussed various processes for formic acid production, selection
of one process, utilities specification and process flow diagram of formic acid plant.

2.1.1 Types of process technology

Formic acid is produced as a byproduct while manufacturing other chemicals,

especially acetic acid. To meet the present demand various methods applied for the
production of Formic Acid are as follows….

2.1.1.1 Oxidation of hydrocarbons.

Formic acid is a byproduct in the production of acetic acid which is formed

by liquid-phase oxidation of butane or naphtha. For many years, oxidation
of hydrocarbons was the most important method of producing acetic acid.
This reaction is carried out preferably in stirred containers and provides the
heat for the distillation of formic acid. A hot slurry consisting ammonium
sulfate and formic acid flows out of the stirred container into a rotary kiln
where the residual formic acid is distilled so that dry, pure ammonium sulfate
is produced at the kiln end. The yield of formic acid exceeds 90 %. The
economic efficiency of this process is determined by the commercial value
of ammonium sulfate. Hydrochloric acid, nitric acid, or phosphoric acid can
also be used to hydrolyze formamide.

o Limitation:
Over the past decade, the preferred process in the establishment of new acetic
acid plants has been the carbonylation of methanol, which is expected to
remain the preferred method in the future. As a result, use of this method is
declining.

2.1.1.2 Hydrolysis of formamide.

The production of formic acid by hydrolysis of formamide played an important role in

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 past. In 1972, about one-third of the world production was obtained by this
process. Formic acid is produced this way in a three-stage process. In the first
stage, methanol is carbonylated to yield methyl formate:

CO + CH3 OH → HCOOCH3 Δ𝐻
R
0
= −29 kJ/mol ---------- (4.1)

• In the second stage, formamide is produced by ammonolysis of ethyl formate

HCOOCH3 + NH3 → HCONH2 + CH3OH Δ𝐻

R
0
= −72 kJ/mol ---------- (4.2)

• In the third stage, sulfuric acid is used to hydrolyze formamide to formic acid and
ammonium sulfate:

HCONH2 + 1/2H2SO4 + H2O → HCOOH + 0.5(NH4)2 + SO4 Δ𝐻R0 = −48 kJ/mol

(4.3)

Methanol is carbonylated as in the first stage of the processes already described Conversion to
formamide is usually carried out at 0.4 − 0.6MPa and 80 − 100 ∘C; methanol is distilled and
recycled to the methyl Formate stage (see → Formamides). Formamide is hydrolyzed
continuously in the third stage by using 68 − 74% sulfuric acid at temperatures between 85 ∘C
and the boiling point of formic acid. This reaction is carried out preferably in stirred containers
and provides the heat for the distillation of formic acid. A hot slurry consisting essentially of
ammonium sulfate and formic acid flows out of the stirred container into a rotary kiln where
the residual formic acid is distilled so that dry, pure ammonium sulfate is produced at the kiln
end. The yield of formic acid exceeds 90 %. The economic efficiency of this process is
determined by the commercial value of ammonium sulfate. Hydrochloric acid, nitric acid, or
phosphoric acid can also be used to hydrolyze formamide.

o Limitation:
The consumption of ammonia and sulfuric acid, along with the unavoidable production of
ammonium sulfate has made this process economically inferior.

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2.1.1.3 Preparation of free formic acid from formats.

This method involves formation of the free acid from its salts. Sodium
Formate andcalcium Formate.
Carbon monoxide reacts with alkaline compounds, even in aqueous solution,
to yield the corresponding formats:

𝐶𝑂 + 𝑁𝑎𝑂𝐻 → 𝐻𝐶𝑂𝑂𝑁𝑎 ---------- (4.4)

Carbon monoxide is mixed counter currently with aqueous sodium hydroxide, for
example, in a tower reactor at 1.5 – 1.8 MPa and 180 ∘C. Sodium Formate crystallizes
and reacts with strong mineral acids, (e.g., concentrated sulfuric acid) at normal
pressure in a cooled, stirred reactor at 35 ∘C.

2HCOONa + H2SO4 → 2HCOOH + Na2SO4--------- (4.5)

The reaction mixture is separated, for example, in a thin-film evaporator at normal pressure and
100 – 120 ∘C, to produce formic acid and dry sodium sulfate. The suggestion has been made
that reaction with sulfuric acid be carried out in two stages. In this case, the first stage takes
place in vacuo in a horizontal tubular reactor with rotating internals, and some of the formic
acid is evaporated at the same time. In the second stage, the remaining formic acid is
evaporated, also in vacuo, at 30 – 60 ∘C in a smaller tubular reactor. Norsk Hydro describes the
production of formic acid from calcium Formate by reaction with nitric acid. The calcium
nitrate produced may be used, for example, as a fertilizer.

o Limitation:
Production of formic acid is not economically viable because one equivalent of a
low-value inorganic salt (e.g., sodium sulfate), is produced per mole of formic acid

2.1.1.4 Hydrolysis of Methyl Formate.:

In this method, methanol and carbon monoxide are combined in the presence of a
strong base, sodium or potassium methoxide, acting as a catalyst. The reaction results

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in the formation of formic acid derivative methyl Formate, as per the chemical
equation:

CH3OH + CO → HCOOCH3 ---------- (4.6)

In industry, this reaction is performed in the liquid phase at elevated pressure. Typical reaction
conditions are 80°C and 40 atm. Hydrolysis of the methyl format produces formic acid
according to the reaction:

HCOOCH3 + H2O → HCOOH + CH3OH ----------- (4.7)

2.2 Selection of process

Selection of a process is the most vital step for setting up an industry. It is the building
block for any chemical industry. It also forms the bases for the selection of the
equipment, plant layout, equipment layout and also the cost of the final product.

GNFC is using Kemira technology to produce aqueous formic acid by reaction of

carbon monoxide and methanol. The main advantage of this process is that both raw
materials are easily available in plant as they are one of the products of GNFC itself.

2.3 Chemistry of process

2.3.1 Main Reaction:

1. Carbonylation
CH3OH + CO → HCOOCH3 ΔH= -10942 kcal/kgmol -----------(4.8)

2. Hydrolysis
HCOOCH3 + H2O → HCOOH + CH3OH ΔH= 9048 kcal/kgmol ---------- (4.9)

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2.3.2 Side Reaction

HCOOCH3 + KOCH3 → HCOOK + CH3O-CH3 ---------- (4.10)

2.3.3 Effect of H2O

CH3OK + H2O → CH3OH + KOH + CH3OH → HCOOK ----------- (4.11)

2.4 Properties of Product and Raw materials.

2.4.1 Feed gas:

Table 2.1: Feed Gas Composition

Composition
CH4 25% vol.
CO 50% vol.
N2/Ar/H2 25% vol.
Temperature: 5 to 15°C and Pressure: 1.1 bar

2.4.2 Methanol:

Table 2.2: Methanol Composition

Composition
CH3OH 99.9% vol.
200ppm W max.
H2O

2.4.3 Potassium Methoxide:

Table 2.3: Potassium Methoxide Composition

Composition
KOCH3 30% W
CH3OH 70% W

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 2.4.4 Methyl Formate (Intermediate product):

Table 2.4: Methyl Formate Composition

Composition
HCOOCH3 97% W
CH3O 3% W

2.4.5 Specifications of product:

Table 2.5: Specification of Product

Composition of Formic Acid

HCOOH 85% minimum
Heavy metals 20ppm

2.5 Utilities specifications

2.5.1 Steam:

Table 2.6: steam specification

MP-II steam 15bar a, 200 °C

LP steam 4.5bar a, 155°C

2.5.2 Cooling Water:

Table 2.7: cooling water specification

Supply Temperature -15 °C Maximum

Return Temperature -10 °C Maximum

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 Supply Pressure 6 bar
Return Pressure 2.5 bar a, Minimum
M.E.G. Content 45% wt. Minimum

2.5.3 Liquid Ammonia:

Table 2.8: Liquid Ammonia specification

Supply Temperature 24 °C
Supply Pressure 17 bar
Operating Temperature 20 °C
Operating Pressure 1.9 bar

2.5.4 Nitrogen:

Table 2.9: Nitrogen specification

Pressure 3.5 bar

O2 Content 10 ppm vol. Maximum
Dew Point -75 °C

2.5.5 Electricity:
Table 2.10: Electricity specification

For
3.3KV Supply from Ammonia
Compressor
Substation (50Hz, AC/3 Phase)

For others
440V Supply from Formic Acid Substation (50Hz,
AC/3 Phase)
110V, 50 Hz, AC/1Pha for DIDC through UPS

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Figure 2.1 Process Flow Diagram

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 2.6 Process Description For MF

CH3OH + CO → HCOOCH3 ΔH= -10942 kcal/kgmol ---------

2.6.1 Methanol Drying Unit:

Methanol obtained from the recycle column, T-5040 M1, by Distillation contains some
amount of water which is stored in the raw Methanol tank D-5004. The make-up
methanol received from the methanol-2 plant also contains some water. And because
water traces in the reactor R-5020 might cause salt formation as a result of the reaction
between water, methanol and catalyst that in turn slows down the main reaction. Hence,
Methanol in the raw methanol tank is subjected to drying in the column T-5040.

Methanol Drying Column (T-5040):

Operating Pressure – 1 bar; Temperature – top: 90℃, Bottom: 120 ℃

Type of Column – Valve tray column

In column, dry methanol is obtained as a distillate and rarely pure water is obtained as
bottom product. Reboiler (E-5044) is heated with LP steam. the methanol vapor from top
condenses in C.W. Condenser and condensate is collected in reflux drum(D-5040).The
purity of methanol in reflux drum is 99.99%.The part of methanol from reflux drum is
taken as reflux through pump( P-5040) and remaining is taken as product methanol to
dry methanol storage tank(D-5018), which is further lead its way to the reactor. Water
Obtained as the bottom product is sent to the acid section Dump Tank D-5086.

2.6.2 Methyl Formate Synthesis

Methyl Formate Reactor (R- 5020/ 5020 X): Reactor Pressure – 42 bar; Temperature -
85℃
Feed Gas Inlet:
The supply pressure of feed gas that contains CO is around 1.1 bar which is raised to
around 40-45 bar before reaction in the fed gas compressor (C/5021 A/B). The feed gas

35 | P a g e
stream introduction to the reactor, in which CARBONYLATION takes place, is done
with the help of a gas distributor. The gas distributor is located below the liquid level in
the reactor and is perforated so as to obtain:

a. A large contact area between gas and liquid

b. Relatively a small pressure drops
c. Reduced clogging because of salt deposits

Liquid Inlet:

The Dry Methanol from the tank D-5018 is pumped to the suction of vertical centrifugal
pump(P-5033/33X). In the same way the catalyst Potassium Methoxide from the storage
tank(D-5022), is also fed to the suction of the vertical centrifugal pump (P-5033/33X).
The liquid mixture from the pump (P-5033/33X) is now feed to the MF reactor (R-
5020/5020X).

The liquid ejectors provided at the top of rector produce jets of the liquid reactant. The
finely distributed gas on rising in the liquid meets the surface (being hit with high speed)
and experience an effective contact with the jets which result in an efficient mixing in the
reactor. To circulate the liquid constantly from the bottom of the reactor to the liquid
ejectors, placed at the top of the reactor, a circulating pump(P-5023/23X) is used. Now,
CO from the feed gas dissolves in the liquid in the reactor and reacts with methanol at
temperature of around 85 ℃ and 42 bar pressure. The reaction taking place is an
exothermic one hence the thermal energy generated is removed from the system with the
help of a cooler (E-5026/26X) which is located in the liquid recirculation loop itself. The
reactor is provided with a demisting mesh to prevent the liquid carry over in the form of
droplets from the reactor. There might be present some impurities in the system that
produces salts with catalyst thus to prevent the deposition of these salts on the heat
exchanger surfaces, the reactor liquid is subjected to a high circulation rate. This also
maintains a low temperature difference on the process side. The reactor off gases, that is,
unreacted CO+N2, Argon, H2 contains a small amount of MF and MeOH, most part of
these are returned to the reactor with the help of condensers and the uncondensed or de-
pressurized off gases are sent to Ammonia Plant or Flare. A side stream forms the liquid
recirculation loop is fed to the Methyl Formate column for separation.

36 | P a g e
 2.6.3 Methyl Formate Separation:

Methyl Formate Separation Column (T-5030 Old, T-5030 New)

Operating Pressure – 2 bar; Temperature -top: 55℃ , Bottom :89℃
Type of Column – valve tray

The feed to the MF separation column (T-5030/30X) is taken as the side stream from the
liquid recirculation stream in the reactor which is de-Pressurized with the help of a feed
valve. It contains MeOH, MF, catalyst and salts, dissolved CO, N2, H2 and Ar. Low
pressure steam is used in the re-boiler (E-5034/34X) and the condenser E-5036 uses
cooling water.
The separation results in the distillate content as 97% MF which is further fed to the MF
intermediate storage tank (D-5048). From the condenser MF containing gases are
withdrawn and are passed through the condenser(E-5036/36X) off-gas chillers (E-
5037/37X and 5038), where most of MF is condensed and sent to the MF intermediate
storage tank. The non-condensable gases are led to the flare through the knock out drum
(D-5039). The bottom contains Methanol and a small amount of catalyst, dissolved salts
and little amount of MF which is pumped backed to the MF reactor with the help of a
high-pressure pump (P-5033/33X).

2.6.4 Salt Removal:

10-12% salt concentration must be maintained in the system. Thus, to prevent salt
deposits on each transfer surfaces, plates, pipes and trays the salt is removed
continuously. From the Methyl Formate column a side stream is fed to the Thin Film
Evaporator which is also known as spent catalyst removal unit.

Thin Film Evaporator(E-5089/89X)

It consists of an evaporator with steam jacket and a continuously rotating centrally
mounted scrapper. Salts are removed by concentrating the liquid as a result of evaporation
and collected in an open drum. The methanol & Methyl Formate vapors are taken out from
the top and are condensed in a chiller (E-5082), collected in the drum (D-5080/80X) and
pumped backed to the MF Separation Tower.

37 | P a g e
 2.6.5 Methyl Formate Intermediate Storage:

MF intermediate storage tank(D-5048/5048A)

It receives Methyl Formate from the MF Separation Column T-5030/30X via D-

5030/30X) and from the recycle column (T-5040M1 via D-5040M1). As MF is highly
volatile the pressure in the storage tanks is kept constant with the help of a condenser (E-
5047) to avoid the loss of vapors. A part of MF is sent to the hydrolysis premixing tank
D-5050 with the help of a pump (P-5049 A,B,C,D) and the rest is either directly sent to
the MF filling section for sale or is redirected to the recycle column (T-5040 M1) if
desired purity is not achieved. [

2.7 Process Description For FA

HCOOCH3 + H2O → HCOOH + CH3OH ΔH= 9048 kcal/kgmol

2.7.1 Hydrolysis Pre-mixing Tank(D-5050):

MF to be reacted with water is sent to the hydrolysis pre-mixing tank (T-5050) is
maintained at atmospheric pressure with the help of a condenser E-5052 at the top to
avoid vapor losses. A part of the total water being used for hydrolysis is from the
condensate tank (D-5095) and the DM Water. The rest of the water is recirculated from
the top of the 2nd Formic Acid column. The raw material flow to the tank is adjusted
with the help of ratio controller such that MF/H2O ratio is maintained at 57:43.

2.7.2 Hydrolysis Reactor (R- 5060):

Reactor Pressure – 16 bar; Temperature – 130 ℃

Type of reactor– Plug Flow Reactor

The hydrolysis feed pressure of about 16 bar is attained with the help of a pump P-5051
and temperature of around 130 ℃ is acquired by a preheater P-5053. The hydrolysis

38 | P a g e
reactor is a plug flow one & hence residence time plays an important role and a steam
jacket with a continuous circulation of MP steam is provided so as to carry out
endothermic reaction. The conversion in this reactor is around 17% and the Formic Acid
here produced acts as a catalyst, hence an autocatalytic reaction. The product FA from
the reactor also contains some amount of unreacted H2O and the reaction product
Methanol and is sent to the separation tower.

2.7.3 First Formic Acid Column(T-5060):

Operating Pressure – 1.2 -1.3 bar; Temperature – top: 125℃ , bottom: 128 ℃
Type of Column – Packed column
Packing Material – GRPP (glass reinforced polypropylene) SLVK-2

The feed to the T-5060 column is the outlet of the hydrolysis reactor which is at 11 bar g
pressure. A pressure reduction valve is provided on the feed tray so as to minimize the
backward reaction in between Formic Acid and Methanol. The pressure is maintained in
the column with the help of cooling water flow to the condenser and to the condenser(E-
5066). The desired boil up rate is regulated by the steam flow to the recoiled. In this
column, separation of Methyl Formate and Methanol from Water and Formic Acid takes
place. The distillate thus obtained contains Methyl Formate and Methanol which are fed
back to the recycle column (T-5040 M1) with the help of a pump( P-5061). The off gases
are cooled with the use of chilled water in chiller(E-5067) to prevent any loss of MF and
MeOH through them. The desired boil-up rate is maintained by regulating steam flow to
the reboiler(E-5065&E-5064) The bottom product contain Formic Acid and Water which
is fed to the second Formic Acid column (T-5070) with the help of pump(P-5063).

2.7.4 Recycle Column(T-5040M1):

Operating Pressure – 1.3 bar; Temperature – Top: 53℃ , bottom: 90 ℃

Type of column – Valve tray column

The feed to the Recycle Column, T-5040M1, is the distillate from the 1st Formic Acid
Column, i.e., MF & MeOH. It might contain some amount of inert that enables the

39 | P a g e
condensation in one stage only. The distillate contains MF which is collected in D- 5041M1 and
further directed to MF Intermediate Storage Tanks D5048/5048A. Almost pure MeOH is obtained
in the bottoms, which is led through a cooler(E-5042M1) to the raw methanol plant or acetic acid
plant or can be fed to the raw MeOH tank with the help of pump(P-5043). However, in normal
practice bottom product is transferred to D- 5004/02 with tower pressure to save electricity, were
P-5043 is kept off. Track logic of LIC-5040M1 is provided to prevent mixing of methanol and MF
when temperature reaches below 85℃.

2.7.5 Second Formic Acid Column(T-5070A/5070)

Operating pressure – 3.2 bar; Temperature – top: 145℃, bottom: 157 ℃
Type of column((T-5070A) – sieve tray column; MOC of shell and tray – ZirconiumType of
column(T-5070) – packed column; packings - GRPP (glass reinforced polypropylene) SLVK-2

The feed to this separation tower T-5070 is the bottom product of 1st FA column that contains FA
and water. FA and water form an azeotropic mixture and hence require a high pressure for
separation by distillation. Thus, a pressure of around 3.2 bars is maintained. In the distillate 3% FA
23 wt. is obtained and the bottom product contains 85% FA by wt. At bottom, FA might decompose
to release CO which can’t be condensed in condenser(E-5067A) and then sent to the flare.
continuous purge of inert like CO is maintained with PICA-5076/A for stabilized operation of T-
5070A.The reboiler is heatedwith MPII steam in E-5074A.MPII steam pressure is let down from 16
bar to 9 bar withPICA-4477/A. The streams from the reflux drum (D-5068) and distillate are fed
back tothe hydrolysis premixing tank (D-5050) and column(T-5070), respectively, with the helpof a
pump (P-5069). The latent heat of the column vapor is utilized in the heat recovery reboiler of the
1st FA column.

40 | P a g e
 CHAPTER 3
MATERIAL BALANCE

41 | P a g e
3. Material Balance

3.1 Formic Acid Section

• Assume: Production of 85% formic acid is 80 MTPD.

• Product contains: 85% FA. And 15% H2O.
• Final Product: 3333.33 kg/hr. = Bottom product of T-5070.
So, Formic Acid = 2833.33 kg/hrs.
Water = 499.995 kg/hrs.

3.1.1 Material Balance of T5070/A (Second Formic Acid Column)

• Top product composition = 97% H2O And 3% FA.

• Bottom product composition = 85% FA. And 15% H2O.
• Feed composition = Composition of bottom product of T-5060.
= 28% FA. And 72% H2O.
i. Component material balance for FA. = F×0.28 = T×0.03 + B×0.85
∴ 0.28F = 0.03T + 2833.33 ------- (1)
ii. Component material balance for H2O = F×0.72 = T×0.97 + B×0.15
∴ 0.72F = 0.97T + 499.995 ------- (2)
By Solving equation (1) & (2)

Material Balance of T-5070/A

T 7599.9656 kg/hr
F 10933.317 kg/hr
B 3333.33 kg/hr

3.1.2 Material Balance for T-5060/X (First Formic Acid Column)

• Top product composition = 60% MF, 28% MeOH and 12% H2O.
• Bottom product composition = 28% FA. And 72% H2O.
• Feed composition = Composition of Outlet of R-5055.
= 28.5% MF, 42.5% H2O, 13% MeOH and 17% FA.
42 | P a g e
i. Component material balance for FA. = F×0.17 = B×0.28
= 0.28×10933.317

Material Balance of T-5060/X

T 7074.49 kg/hr
F 18007.816 kg/hr
B 10933.317 kg/hr

3.1.3 Material Balance of Hydrolysis Reactor (R-5055)

• R-5055 Outlet = Inlet of T-5060

• R-5055 Outlet = 18007.816 kg/hr
• Outlet composition = 28.5% MF, 13% MeOH, 42.5% H2O and 17% FA
Formic acid formed = 3016.328 kg/hr

• Hydrolysis reaction:
HCOOCH3 + H2O → HCOOH + CH3OH ΔH= 9048 kcal/kmol ---------- (1)
Now, stoichiometric balance
1 mol HCOOH formed by 1 mol HCOOCH3
∴ 46 kg/hr HCOOH formed by 60 kg/hr HCOOCH3
∴ 301.328 kg/hr → (?)

MF Reacted 3993.036 kg/hr

MF Unreacted 5132.227 kg/hr
MF Fed 9125.26 kg/hr

1 mol HCOOH formed by 1 mol of H2O

∴ 46 kg/hr HCOOH formed by 10 kg/hr H2O
∴ 301.328 kg/hr → (?)

H2O Reacted 1197.1 kg/hr

H2O Unreacted 7653.32 kg/hr
H2O Fed 8851.2319 kg/hr

43 | P a g e
 • FA formed = 3061.328 kg/hr
• MeOH formed = 2341.016 kg/hr

Input 17976.49 kg/hr

Output 18187.892 kg/hr

INPUT ≈ OUTPUT ≈ 18000 kg/hr

• As Input of Hydrolysis reactor is outlet of premixing tank so separate inlet for

premixing tank as follows:
i. DM Water = 8851.2319 kg/hr
ii. Methyl Formate = 9125.26 kg/hr

3.2 Methyl Formate Section

• As Intermediate storage tank output is equal to input of Premixing tank

• Intermediate storage tank D-5048 flow rate is 9125.26 kg/hr
• But Intermediate storage tank contains 96% MF & 4% MeOH
∴ Input flowrate = Output flowrate = 9505.47916 kg/hr

3.2.1 Material Balance for T-5030/X (MF Column)

• Top product = Intermediate storage tank input

Composition: T = 9505.97 kg/hr, 96% MF, 4% MeOH
• Bottom product composition: 1% MF, 13% Salt, 84% MeOH and 1%
Catalyst.
• Feed composition: 15.5% MF, 72% MeOH, 5% Catalyst and 12% Salt
Because, Feed of T-5030 = Outlet of R-5020

3.2.2 Component Material Balance

For MF
0.155F = 0.96F + 0.02B
0.155F = 9125 kg/hr + 0.02B ----- (1)
44 | P a g e
 For MeOH
0.72F = 0.04T + 0.84B
0.72F = 380.219 + 0.84B ----- (2)
By solving equation (1) and (2)

T-5030
B 56228.44 kg/hr
F 65733.92 kg/hr
T 9505.47 kg/hr

3.2.3 Material Balance of MF Reactor (R-5020/X/R)

• Feed of T-5030 is outlet of R-5020 so Outlet of R5020 = 65733.9264 kg/Hr

Component mass flow rate

MF 10188.75 kg/hr
MeOH 47328.42 kg/hr
Catalyst 3286.696 kg/hr
Salt 7888.07158 kg/hr

• Reaction:

CH3OH + CO → HCOOCH3 ΔH= -10942 kcal/kgmol---------- (5.2)

Now, stoichiometric balance
1 mol HCOOCH3 formed by 1 mol CH3OH
∴ 60 kg/hr HCOOCH3 formed by 32 kg/hr CH3OH
∴ 10188.7576 kg/hr → (?)

MeOH Reacted 5434.004 kg/hr

MeOH Fed 52762.431 kg/hr

45 | P a g e
 1 mol HCOOCH3 formed by 1 mol of CO
∴ 60 kg/hr HCOOH formed by 28 kg/hr CO
∴ 10188.75 kg/hr → (?)

As conversion of CO is 0.2

CO Reacted 4754.7535 kg/hr

CO Fed 21612.54 kg/hr

CO Fed = 771.87 kmol/hr

Feed gas composition

CO 50% vol.
N2 + Ar + H2 25% vol.
CH4 25% vol.

Total feed gas = 1543.7411 kmol/hr

= 175987.629 kg/hr

Return gas = 171232.875 kg/hr

3.3 Salt Formation Reaction

KOCH3 + H2O → KOH + CH3OH --------- (3.3)

KOH + CH3COOH → HCOOK + CH3OH ---------- (3.4)

• As outlet stream has 12% salt

• Salt mass flow rate = 7888.0715 kg/hr
Now, stoichiometric balance on second reaction
1 mol HCOOK formed by 1 mol KOH
∴ 84 kg/hr HCOOK formed by 56 kg/hr KOH
∴ 7888.0715 kg/hr → (?)

46 | P a g e
 KOH 5258.71 kg/hr

Now, stoichiometric balance on first reaction

1 mol KOH formed by 1 mol KOCH3
∴ 56 kg/hr KOH formed by 70 kg/hr. KOCH3
∴ 5258.71 kg/hr → (?)

KOCH3 Reacted 6573.38 kg/hr

KOCH3 Unreacted 3286.696 kg/hr
KOCH3 Fed 9860.0855 kg/hr

Input 23861.19 kg/hr

Output 23696.80 kg/hr

INPUT ≈ OUTPUT ≈ 23800 kg/hr

Figure 3.1: Block Diagram with Material Balance

47 | P a g e
 CHAPTER 4
ENERGY BALANCE

48 | P a g e
4. Energy Balance

4.1 Introduction

This chapter contains the energy balance across Methyl Formate reactor,
The whole Energy Balance is done on Basis of 80 MTPD 85 wt.% Formic Acid Production

4.1.1 Energy balance around Methyl Formate Reactor

∆𝐻𝑅𝑒𝑎𝑐𝑡𝑖𝑜𝑛 = ∆𝐻𝑃𝑟𝑜𝑑𝑢𝑐𝑡 − ∆𝐻𝑅𝑒𝑎𝑐𝑡𝑎𝑛𝑡 ---------- (1)

∆𝐻 = 𝑚𝐶𝑝∆𝑇
∆𝐻𝑅𝑒𝑎𝑐𝑡𝑎𝑛𝑡 = ∆𝐻𝑓𝑒𝑒𝑑 𝑔𝑎𝑠 + ∆𝐻𝑚𝑒𝑡ℎ𝑎𝑛𝑜𝑙 + ∆𝐻𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 ----------------(2)

∆𝐻𝑅𝑒𝑎𝑐𝑡𝑎𝑛𝑡 = 175981.129×1.04× (353-298) + 52762.431×2.62× (313-298) +

9860.0855×2.62× (311-298)
= 3571.353 MJ/hr

∆𝐻𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = ∆𝐻𝑓𝑒𝑒𝑑 𝑔𝑎𝑠 + ∆𝐻𝑚𝑒𝑡ℎ𝑎𝑛𝑜𝑙 + ∆𝐻𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 + ∆𝐻𝑚𝑒𝑡ℎ𝑦𝑙 𝑓𝑜𝑟𝑚𝑎𝑡𝑒 ------------------ (3)

∆𝐻𝑝𝑟𝑜𝑑𝑢𝑐𝑡 =171232.875×1.37× (358-298) + 47328.42×2.62×(358-298) +

3286.696×2.62× (358-298) + 10188.75×2.94× (358-298)
= 3044.74 MJ/hr

∆𝐻𝑅𝑒𝑎𝑐𝑡𝑖𝑜𝑛 = ∆𝐻𝑃𝑟𝑜𝑑𝑢𝑐𝑡 − ∆𝐻𝑅𝑒𝑎𝑐𝑡𝑎𝑛𝑡 ---------- (4)

∆𝐻𝑅𝑒𝑎𝑐𝑡𝑖𝑜𝑛 = 526.613 𝑀𝐽/ℎ

49 | P a g e
 Table 4.1 Energy balance for methyl Formate reactor
Inlet Feed Gas Dry Methyl Formate Catalyst Total
Methanol

Mass 175987.69 52762. - 9860.0855

flow(kg/h) 431
phase V L L
Temperature 80 40 38
(℃)
Sp. Heat 1.04 2.62 2.62
(KJ/kg) [4]

Heat flow 1464.21 2073.5 33.583 3571.3

(MJ/h) 6 53
Outlet
Mass 171232.875 47328. 10188.75 3286.69
flow(kg/h) 42
phase V L L L
Temperature 85 85 85 85
(℃)
Sp. Heat [4] 1.37 2.62 2.53 2.94
(KJ/kg)
Heat flow 1407.53 32.59 1546.65 57.97 3044.7
(MJ/h) 4

50 | P a g e
CHAPTER 5
UTILITIES

51 | P a g e
 5.1 Cooling Water System (Cooling Tower)

Cooling Tower is a familiar sight in all industries. A tower through which water is
circulated to remove the heat generated from various heats generating operations and the
hot water comes back to the Cooling Tower. This water is cooled in the Cooling Tower
collected in the Sump and recirculated, the cycle continues. This is basic definition of
Cooling Tower.

There are three types of Cooling Towers:

• Natural Draft: Natural re-circulation of air-cools the hot water
• Forced Draft: Using a fan, air is forced in the cooling tower
Induced Draft: Air is sucked through the water shower using a fan. [3]

5.1.1 Functioning of Cooling Tower:

Water is lost through the Cooling Tower by evaporation during the process of heat exchange.
Fresh water is added to the cooling tower to make up the losses. Evaporated water leaving
along with air is pure water. While incoming water contains Dissolved Solids and Suspended
matters, etc. Therefore, there is always a concentration of Dissolved Solids in the
recirculating Cooling Water due to evaporation. This Solids build up in recirculating water
should not exceed certain limits else deposition in Heat Exchanger may take place. Inorder
to remove such Dissolved Solids, part of water removed periodically or continuously is
known as Blow down (Bleed Off).

Make up water (M) = Water lost by evaporation (E) + Blow down (B) + Drift loss
(D).

5.1.2 General Terms Used in Cooling Water Systems:

5.1.2.1 Acidity:

Presence of acid in water, pH of water less than 7.

52 | P a g e
5.1.2.2 Alkalinity:

Presence of alkali in water, pH of water is more than 7.

5.1.2.3 Hold up capacity of the system:

It is an amount of water contained in basin and sump of cooling tower + water

contained in piping and equipment.

5.1.2.4 Blow down:

Since pure water is evaporated out of the system, the dissolved and the suspended
solids are concentrated in the circulating water. Beyond certain limit, these solids
will cause massive scale and corrosion. In order to balance this, a certain amount of
water is removed from the system by blow down.

5.1.2.5 Make up Water:

This is the water, which is to be added to replace the water lost by evaporation, blow
down, drift and leakages.

5.1.2.6 Drift:

Some water droplets escape along with the evaporation. A usual drift loss in
conventional cooling towers is in the range of about 0.05 – 1 % of the recirculation
rate.

5.1.2.7 System Losses:

Circulating water is lost in the plant through pumps, valves or leakages through
flanges, etc.

5.1.2.8 Evaporation Losses:

The water lost to the atmosphere in the cooling process is evaporation. The rate of
evaporation depends upon the temperature differential and the circulation rate. It
amounts to about 0.1% of the circulation rate for each 10 of temperature drop.

53 | P a g e
 5.1.2.9 Cycle of Concentration:

Due to evaporation of water in Cooling tower the impurities get concentrated in

recirculating water. Number of times the impurities get concentrated in recirculating
water is known as Cycle of Concentration.

5.1.3 Typical Problems in Cooling Tower:

5.1.3.1 Scaling:

The salt like calcium carbonate, calcium sulfate and calcium phosphate in the cooling
water has reverse solubility, i.e. at high temperature their solubility decreases. This
causes precipitation and scaling in heat exchange. Cooling water is heated in the heat
exchangers where temporary hardness salts decompose and form scales. Cooling water
is concentrated in the system due to evaporation in tower. Due to concentration, sparingly
soluble salts like calcium sulphate tend to precipitate out and form scales. Thus scale of
calcium carbonate, calcium sulphate and calcium phosphate are often found in the heat
exchanger.

5.1.3.2 Corrosion:

Cooling water is corrosive to mild steel, copper, etc. due to higher TDS. More are the
dissolved salts in water more are the corrosiveness. Also various galvanic cells are formed
in the heat exchangers due to differential metal, combination, concentration, temperature,
velocities and stress strain on metal. Corrosion is generally observed all over the cooling
system. But it is more near welding, joints and under the deposition.

5.1.3.3 Microbiology:

Cooling water is ideal medium for microbiological growth. It provides optimum

temperature; oxygen, nutrient and sufficient surface area for growth. Algae, bacteria and
fungus are commonly found in cooling system. If not controlled in time, microbiological
growth can be Plugged heat exchanger and causes corrosion and reduce cooling tower
efficiency.

54 | P a g e
5.1.3.4 Bacteria:

Bacteria are mainly of two types aerobic and anaerobic. Aerobatic secrets certain
enzymes, which form sticky masses, called as slime. Slime can form on heat transfer
equipment as well as on complete pipelines. Slime attracts other suspended particles in
water to form deposits, which is generally called biofouling. [1]

5.1.4 Disadvantages due to above problems in Cooling Water Systems:

1. Problems of scale, deposition, fouling leads to maintenance cost for frequent

cleaning of heat exchanger etc.
2. Corrosion can damage heat transfer equipment and thereby leads to replacement
cost.
3. Frequent unscheduled forced shutdown for cleaning heat exchangers, lines etc.
causes’ production loss.
4. Scale, deposition, corrosion and fouling in cooling water system forced to run the
system at lower cycle of concentration. Hence water consumption is huge.
5. Energy consumption is more e.g. pumping cost

5.1.5 Cooling Tower System for Formic acid Plant:

To accomplish the cooling water supply to the coolers, four C.W. pumps P-5072A/B/C/D
are provided each with a capacity of 400 m3/hr. and for Revamp section two C.W. pumps
P-5072E/F. The draft is induced with the help of three fans. Cooling water circulation flow
is 1200 m3/hr. and CW make-up line is provided from the ammonia plant.

A provision of level switches is also there for low level and high-level alarms. A by- pass
isolation valve is provided from supply header to return header which is Butterfly Valve.
There is a level controller for controlling cooling tower basin level. For maintaining
proper analysis of dosing chemicals, a formulation tank is provided on the sump.
Additionally, a side stream filter has been provided to maintain turbidity of circulating
C.W. A chlorination system is provided to keep a check on low chlorination rate. For
maintaining pH of C.W. H2SO4 is added. [1]

55 | P a g e
Figure 5.1: Induced Draft Cooling Tower

56 | P a g e
5.2 Chilling Water System

Chilling water System for Formic acid Plant:

Chilled Water system is required for refrigeration purpose. To reduce the MF and
MeOH losses in the off-gases from the R-5020/20X/20R, T-5030/30X, T-5060/60X
etc. gases are cooled to below -10oC, this is achieved by using chilled water
circulation. MEG (Mono Ethylene Glycol) is used to bring down the freezing
temperature of water. Chilled Water is cooled down from -15oC to -10oC in E-
5006/6X using Ammonia liquid, which is supplied at 17 bar pressure and is
recovered in form of ammonia vapors at 1.9 bar a pressure. A closed loop system is
designed with a bypass valve provision.

When the Chilled Water system pressure goes down a pump P-5025 is used to
make up Chilled Water in the system from D-5024, where a proper concentration
of MEG solution is prepared and made up in a closed loop system by P-5025. P-
5077 A/B is used to boost up the pressure and return MEG solution back to pump
suction.

57 | P a g e
 CHAPTER 6
DETAILED DESCRIPTION OF
EQUIPMENT

58 | P a g e
Introduction:
From chapter 3, material balance, we came to know the total number of unit operations and unit
processes required for the production of formic acid of the said capacity. Based on the capacity
selected the following section will discuss on the capacity of all the equipment used along with MOC
used for the fabrication of same.

LIST OF ALL MAJOR AND MINOR EQUIPMENTS:

Serial Name of Number of Capacity MOC

no. Equipment Equipment (m3)

1. Cooling Water System 4 1800

2. Chilled Water system 2 SS-304
3. Acid Distillation Column 2 Zirconium
4. FA Storage Tank 4 500 SS-316
5. MF Storage Tank 2 350 Carbon
steel
6. Methanol Storage Tank 3 250 Carbon
steel
7. Reactor Vessel 3 15 SS-316
8. Reciprocating Compressor 2 Carbon
Steel

59 | P a g e
 9. Knockout Drum 3 1.5 SS-304
10. MF-Methanol Distillation 5 Zirconium
11. T-5060/T-5060X 2 Zirconium
12. Pumps

NOTE: All above mentioned information about each equipment is taken from Equipment data Sheet
available in Formic Acid plant.

Conclusion: Numerous equipment are involved in construction of any chemical plant. After
selection of any process, it is inevitable to decide the equipment necessary to accomplish the process.
Suitable material of construction (MOC) is decided based on the fluid to be handled, considering
their behavior in nature, properties, corrosion, fouling and reactivity with the material of equipment.
The MOC should be selected on the basis of its ability to withstand such conditions and work
efficiently without obtaining damage. By concluding this chapter, we are in position to design
equipment.

60 | P a g e
 CHAPTER 7
DESIGNING OF EQUIPMENT

61 | P a g e
7.1 Introduction:

In this chapter, Process design of storage tank, Knockout Drum is described as minor equipment
design and process as well as mechanical design of (T-5030) Distillation column is described as
major equipment design.

7.2 Design of Minor Equipment:

7.2.1 Storage Tank:

There are 4 storage tanks of Formic Acid is available in Formic Acid plant. Each of
have capacity of 500 MT. Due to safety purpose, storage tank is not fully filling with
FA. All the storage tanks are interaction type tanks. So, we can equalize tanks. After
that Formic Acid is sent for selling.

Storage Tank for Formic Acid:

• MOC: SS-316
• Maximum Allowable Stress: 20000 psi = 1406.13 kg/cm2
• ƍMOC: 7800 kg/m3
• ƍWNA: 1156 kg/m3
• Superimposed Load: 125 kg/m2
• Capacity of storage tank = 500 MT

= 500*103 kg

= 500000

1156

= 432.52 m3

62 | P a g e
 We have to take 20% extra volume.

∴ Total volume = 1.2*432.52 = 519.03 m3

So, using Volume We will get radius, Diameter, Height.

V = 𝜋𝑟2h
V = 𝜋𝑟3
519.03 = V = 𝜋𝑟3
Assumed,
r=4m & d=8m
h = 10.32 m

Diameter of the tank = 8 m

Height of tank = 10.32 m

V = 𝜋r2h
= 𝜋*(42) *10.32
= 518.9 m3

Corrosion Allowance = 1.5 mm

Young Modulus for SS-316 = 1.9*1011 pa
J = 0.85
Plate Size = 2 m * 2 m

P = 𝜌*(H – 0.3) *100 + P’

P = 1156*10-6 *(10.32 – 0.3) *100 + 0
P = 1.17 kg/cm2

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 Thickness of shell:

𝑝𝑑
t= +c
2𝑓𝑗

(1.17) *(800)
t=
(2*1406.13*0.85)

t = 5.26 mm + 0.15 cm
t = 5.41 mm or 6 mm

For course of 2 m, 6 mm thickness

H = 10.32 – 2 = 8.32 m

Table 7.1 Storage Vessel Thickness

H(m) P (kg/cm2) t (mm) H’ (m)

10.32 1.17 8 8.32
8.32 0.92 6 6.32
6.32 0.69 6 4.32
4.32 0.46 6 2.32
2.32 0.23 6 0.32

Bottom Design,

Diameter of bottom,

Db = [ di + 2t + 2 ×65 ]
1000

64 | P a g e
 = [ 8+ 2*(10*10-3) + 2∗65]
1000

Db = 8.142 m
di = 8.0 m, di < 12 m
tb= 6 mm

Roof Design,
tan θ = 1/5
θ = tan-1 (1/5)
θ = 11.31°
P = Pressure based on class of vessel + Superimposed Load
P = 625 + 125
P = 750 kg/m2

Thickness of Roof,

tr = di √p
si𝑛θ 0.204 E

tr = 17.80 mm

tr = 20 mm

Load,

w = 𝜋D2P
4

w = 𝜋 (8)2 * (7356.61)
4
65 | P a g e
w = 369783.5509 N

Compressive Stress,

T1 = 𝑝𝑑
4∗𝑠𝑖𝑛 θ

T1 = 7356.61 * 8.0
4* sin (11.31)

T1 = 75022.55 N/m

Tensile Stress,
T3 = T1cosθ
T3 = 75022.55*cos (11.31)
T3 = 73565.645 N/m
2fA = T3D
A = T3D
2f
A = P*D*cosθ × D
4sinθ 2f

A = 369783.5509 * cot (11.31)

2*𝜋* 6.892 * 10000000

A = 8.98*10 -4 m2

A = 898.036 mm2

A' = Ac + As + Ar

Ac = Area of curb member

If D < 10,

66 | P a g e
Then Ac = 65*6

Ac = 390 mm2

As = Area of shell effective

As = 1.5 * 5* √9142 ∗ 5
As = 1603.5 mm2
Ar = Area of roof effective
Ar = 1041.82 mm2
A' = 390 + 1603.5 + 1041.82
A' = 3035.32 mm2
A'> A So, Self-supported roof is there. Conical roof is not required.

Table 7.2 Summary table of Storage Vessel

Capacity (m3) 519.03

Height (m) 10.32
Diameter (m) 8
Bottom plate diameter (m) 8.142
Bottom plate thickness (mm) 6
Thickness of roof (mm) 20
Type of roof Self-supported roof

7.2.2 Knockout Drum:

• Pressure = 6.5 bar or 6.51 *10 5 N/m2

• MOC: Mild Steel
• Maximum Allowable Stress: 60MPa = 60N/mm2
• Operating Pressure = 10% Extra Of given Pressure
= 1.1 * 0.65 N/mm2
= 0.715 N/mm2

67 | P a g e
 Volume of Knockout Drum is 1.5 m3
So, Assumed radius r = 0.781 m
D = 1.562 m
H = 0.781 m

Thickness of Shell:
ts = Pd
2fJ - P
ts = (0.715 * 1562)
(2*60*0.85) – 0.715
ts = 11.02 mm + 1.5 mm

ts = 12.52 mm, but standard thickness is 14 mm.

Designing of Top and Bottom head of tank or drum:

• Torispherical Head:
Rc = 1562 mm
Rk = 0.06 * Rc
= 93.72 mm

Cs = (1/4) *(3+(1562/93.72))
= 1.7706

68 | P a g e
 Thickness of Head:
Th = P * Rc *Cs
2*F *J
Th = 0.715 * 1562 * 1.7706
2 * 60 * 0.85
Th = 20.88 mm + 1.5 mm
Th = 22.38 mm
Standard Thickness is 25mm

• Elliptical Head:

Th = P* D
(2*F*J) – 0.2 P

Th = 0.715 * 1562
(2*60*0.85) – (0.2 * 0.715)

Th = 10.96 mm + 1.5 mm
Th = 12.46 mm

Standard Thickness is 14 mm

69 | P a g e
Process Design:
Density of Vapor: 0.05843 lb/ft3 (CO density at 85˚c is 0.96 kg/m3)
Density of liquid: 54.498 lb/ft3
(density average of MF and methanol at 30˚c will be 872.98 kg/m3)
uv = 0.000315 centipoise
dp = 500 um = 1.64 * 10-3 ft

To determine dropout velocity, drag coefficient is determined

C(Re)2 = (0.95 * 108) * (0.05843*1.64*10-3*(54.498-0.05843)

(0.000315)2
C(Re)2 = 1.48 * 108
Using graph, we got the value of C =0.5
Dropout Velocity (ud)
ud = 1.15 * √ (32.2*1.64*10-3*(54.498-0.05843)
(0.05843*0.5)
ud = 11.407 ft/sec
so, using given calculation, we get that the dropout velocity of knockout drum will be 11.407
ft/sec.

70 | P a g e
 Table 7.3 Summary Table of Knockout Drum

Capacity (m3) 1.5

Height (m) 0.781

Diameter (m) 1.562

Thickness of Shell (mm) 14

Thickness of Torispherical head 25

(mm)
Thickness of Elliptical head (mm) 14

7.3 Designing of Major equipment: [T-5030R Distillation Column)

In FA plant the distillation tower present is made of Zirconium and containing sieve type trays.
First of all, mixture of methanol and Methyl Formate enters from the Feed section of the
column. It passes through perforations of sieve trays. In fact, from the bottom, reboiler is there
which enters Methanol. In mixture, separation takes place using simple distillation process. In
the operation, Methyl Formate having lower boiling point than Methanol separates out and
removes from the top section of the Tower. Actually, 41 sieve trays are in Distillation column.
cooling water and chilled water is used to maintain temperature.

71 | P a g e
7.3.1 Process Design:

72 | P a g e
Gs = G1*(1-Y1)

= 1.113*(1-0.194)

Gs = 0.931Kmol/s

Table 7.4 Equilibrium data

X Y

0.1 0.035

0.2 0.066

0.3 0.092

0.4 0.118

0.5 0.141

0.6 0.162

0.7 0.1862

0.8 0.1976

0.9 0.2077

1.0 0.2285

73 | P a g e
So, we have to find Lmin (Minimum flowrate),

By putting Y1 (0.193) in equilibrium data, we get

Xmax (0.79) Lmin/Gs = (Y1 – Y ) / (Xmax – X2)

0.194 - 0.000194 * 0.931

Lmin =
0.79−0

Lmin = 0.228 Kmol/s

Let’s take, L = 1.7* Lmin

L = 1.7*0.228

Ls = L = 0.3876 Kmol/s

(Ls/Gs) = (Y1 – Y2) / (X1 – X2)

(0.3876/0.931) = (0.194 – 1.94*10-4) / (X1 – 0)

X1 = 0.465

74 | P a g e
 Y 0.25

0.2

1
0.15

2 Equilibruim line

0.1 Operating line

0.05

0.2 0.4 0.6 0.8 1.2

Figure 7.2 Equilibrium and operating line of Distillation (Source: MS Excel)

1. Actual Number of Trays:

m = 0.373

A = (Ls)/(m*Gs) = (0.3876/ (0.373*0.931))

= 1.1661

According to kremser equation,

N = Log (Y1−mX2) *(1 -) +) / Log(A)

Y2−mX2

By putting all the values in the above equation, we get number of trays,

75 | P a g e
N = Log (169.514)
Log (1.1661)

N = 2.229
0.0667

N = 33.4
Here, tray efficiency is 80%
Actual number of Trays = 33.4/0.8
Actual number of sieve trays = 42

7.3.2 Mechanical Design:

1. Height of the column:

Internal Pressure = 10.8 bar

Design Pressure = 1.1 * 10.8 bar = 11.88 bar

Thickness of insulation =80 mm

MOC = SS-304

F.O.S. = 2.5

Maximum allowable stress = 40000 psi

Tensile strength of this MOC = 100000 psi

E = 190 GPa

Corrosion Allowance = 2 mm

Joint efficiency Factor = 0.85

Top disengaging space =1 m

Weight of attachments (pipes, ladders platform) = 750 N/m

76 | P a g e
Wind velocity Vw = 2.5 m/s

Density of liquid = 1156 Kg/m3.

Density of MOC = 8000 Kg/m3

Density Of insulation = 5640 Kg/m3

Inside Diameter = 2.46 m

Column Shell Thickness:

ts = P*D / (2fJ – P)

ts = 1203741*2.46 / ((2*220608000*0.85) – 1203741)

ts = 4 mm + C.A.

ts = 4 + 2

ts = 6 mm

Axial Stress due to pressure:

fap= PD/4(t - c)

= 1203741*2.46 / 4*(6 - 2) *10-3

fap = 88991847.5 N/m2 .............1

Now, Do = Di + 2t

Do = 2.476 m

Stresses due to load:

Due to weight of shell:

Fdx =Weight of Shell/ cross section of shell

= (∏/4) *(D0 2 -D 2)*ƿ*H/ ((∏/4)*(D0 2 -D 2 ))

Fdx = 77008.5 H N/m2 .............2

77 | P a g e
Due to Weight of Insulation:

Fdins= (∏*Dins*ƿins*tins*H)/ (∏*Dm*(t-C))

Dm = (Do+ Di)/2 = 2468 mm

Dins = Do + 2*tins

= 2476 + 2(80) = 2636 mm

Fdx = (2636 * 80 * 5640 * H) / (2468 * 20)

Fdx = 122952H N/m2 .............3

Due to weight of liquid & tray:

Bulk weight of packing = 237 Kg/m3.

ρliq = 1156 kg/m3

Fdw packing = (H)* (Π/4*234) * Di2

Fdw packing = 36490.4773H Pa ............ 4

Fliq = (∏*Di*Di*H*9.81 /4) / (∏* Dm*(ts -C))

Fliq = 298288.633H N/m2............. 5

Due to attachments:

Attachment Weight = 800 N/m

Fdatt = Wt. of attachments * H / (∏*Dm*(ts-C))

= 800*H / (3.14*2483*20*0.0001)

Fdatt = 15298.975H N/m2 ............6

Now,

Total Stress = (77008.5 + 122952 + 15298.975 + 36490.4773 + 298288.633) *H

Fdh= 1455490.452H N/m2

78 | P a g e
Also, dead weight of top tower should be added for bottom column.

Its value is 641094.137H N/m2

Total Fdh= 1191600.85H N/m2

Stresses due to wind load:

Wind velocity = 2.5 m/s.

Fwind= 1.4* Pw* H2 / П*Do*(t-c)

Pw = 0.05(3.6*2.52)

= 1.125 N/m2

Fwind = 1.4*1.125*H2 / Π*2504*20*0.0001

Fwind = 10.0873H2 N/m2 ............ 7

FAllowable = 187516800 Pa............ 8

Now, we have

AH2+ BH + C = D

A = 10.0872

B = 1191600.85

C = 88991847.5

D = 187516800

On solving the equation,

10.0872H2 + 1969039.055H + 88991847.5 = 187516800

H = 52.234 m

Hence, Height of the column is 52.234 m.

79 | P a g e
2. Torispherical head: (bottom head)

Rc = ID – 6 inch

= 2.46 -0.1524

= 2.3076 m

Rk = 10% of ID =0.246 m

Cs=0.25*(3+(Rc/Rk)0.5)

=0.25*(3+(2.3076/0.246)0.5)

=0.87

Thickness (t) = [(P*Rc*Cs)/(2*f*J)] + CA

= 4.65 + 2

= 6.65 mm

Available market thickness is 8 mm.

3. Elliptical Head: (Top head)

t = (PDV)/ (2fJ-0.6P ) Where , V = 0.5(2 + k^2)

= (10.74*105 *2.46)/ ((2*275*10^6*0.85)-0.6(10.74*105))

= 5.65 mm + 2 mm

= 7.75 mm

Available market thickness is 8 mm.

80 | P a g e
4. Nozzle Design:

Manhole = 1000 mm

P = 10.74 x 105 Pa

di= 1000 mm

f = 275 MPa

tr = p*di/(2fj-p) + CA

= 2.29 + 2

= 4.29 mm

But, Minimum available thickness in market is 5mm.

So, Thickness of nozzle = 5 m

A = (dn + 2C) *tr

= 0.007311 m2

As = (d +2C) *(ts – tr-C)

= 0.00072 m2

An = Ao + Ai

Ao = 2Ho (tn – trn-C)

= 2*54.888*(5-2.235)

= 7.70*10-5 m2

Ai = 0

An = 7.70*10-5 m2

Ar = A – (As + An)

= 0.0065 m2

81 | P a g e
Hence, Compensation Required.

Ar = (Drpo - Drpi) tp

= [2(dn +2C)-( dn +2 tn) ] tp

tp= 2 mm

5. Flange Design:

Data:

• Design Pressure: 10.74 x 105 Pa

• Maximum allowable Stress at design temp: 275 MPa

• (fb)b = 79.05 x 106 Pa

• (fb)a = 89.45 x 106 Pa

• Nmin =0.1

• Gasket Factor m =2.75

• Y = 2551000 N/m2

(Go/Gi) = √251.60

250.4
= 1.024
G0 – Gi = 2*Nmin.

1.024*Gi – Gi = 2*0.1

Gi = 0.809 m

Go = 0.829 m

N = (Go - Gi)/2

Here, raised type gasket

82 | P a g e
 bo = N/2 = 5 mm,

bo< 6.3mm, b=bo

G = (Go + Gi)/2

=1.02158 m

6. Hub design:

go = (Do- Di)/2

= 0.005 m

g1 = 0.007075 m

h = 0.0075 m

7. Bolt Design:

Db = 0.01905 m

Arb = 0.0002850 m2

Fa = 89456340.76 N/m2

Fb = 79059002.9 N/m2

G = 1.02158 m

Y = 25510000 N/m2

b = 0.005 m

• Wm2=3.14*G*b*Y

= 413774.57 N

• Wm1 = (3.14/4) *G2*p + 2*3.14*G*m*p

= 995737.8753 N

83 | P a g e
• Am1 = Wm1 /fb

= 0.01259 m2

• Am2 = Wm2 /fa

= 0.00462 m2

• Amax = (3.14/4) *d 2 *n

N = 16.228 bolts

N = 20 bolts

• Bolt Circle Diameter

C1 = Dfi + 2(g1 + R) = 1.0858 m

R= (G- Do)/2 + 10 + db/2

= 0.0308 m

• Bolt spacing: 3.14*C/n

= 170.55 mm

There are 5 more nozzles on the absorption column.

1. Water inlet (Dia.- 0.1 m)

2. Water outlet (Dia. - 0.1 m)

3. NO2 inlet (Dia. - 0.2 m)

4. NO2 outlet (Dia. - 0.2 m)

5. Condensate discharge (Dia. - 0.2 m)

Calculation for these nozzles is attached as an excel sheet in Appendix 2.

84 | P a g e
 8. Skirt support:

Diameter Of vessel: 2.46 m

Height of vessel: 52 m

Weight of vessel + attachments: 200000 N

Diameter of skirt: 3000 mm

Height of skirt: 4.8 m

Wind pressure: 1285 N/m2

Allowable strength of concrete: 35 kgf/cm2

(a) Dead weight due to vessel + attachments:

Fd = 200000/(Π*2460*tsk)

Fd = 212.5/tsk N/mm2

(b) Wind load stress:

Mw = Plw*(h1/2) + K*P*h2*d0*(h1 + h2/2)

=K*P*h1*dr*(h1/2)+K*P*h2*d0*(h1 + h2/2)

= 0.7*10.74*105 *20*3*(20/2) + 0.7*10.74*105 *(52 + 4.8 – 200)*3*(20+ 14.9)

Mw = 3646.194 N m

Fw = (4*Mw)/(Π*d0 2 *Lsk)

= 473.36/tsk N/mm2

(c) Stress due to seismic load:

Fsb = (4*C*W*H)/(3*Π*do2 *Lsk)

= (4*0.08*200000*36.8*1000)/(3*Π*30002 *Lsk)

85 | P a g e
 = 399.3/tsk N/mm2

Since, Fw > Fs , so go ahead with Fw.

Now, two total stresses.

(I) Maximum tensile stress:

Ft(max) = 473.36/tsk – 212.5/tsk

= 261.3/tsk

Ft(max) = 140 N/mm2

tsk = 3 mm

(II) Maximum Compressive stress:

fc(max) = 473.36/tsk + 212.5/tsk

= 686.3/tsk

fc(max) = (Y*P)/3 = 66.6 N/mm2

tsk = 10.3 mm

So, go ahead with 12 mm support thickness.

86 | P a g e
 Table 7.5 Summary table for Distillation tower design

Minimum water flow rate (Kmol/s) 0.228

Actual water flow rate (Kmol/s) 0.3876
Theoretical number of sieve trays 33
Actual number of sieve trays 42
Shell thickness (mm) 6
Height of column (m) 52.234
Bottom head thickness (mm) 8
Top head thickness (mm) 8
Thickness of nozzle (mm) 5
Ring pad thickness (mm) 2
Thickness of flange (mm) 30
Outside diameter of flange (m) 1.124
Skirt support thickness (mm) 10.3

87 | P a g e
 CHAPTER 8

PUMPS, PIPING, FITTINGS, AND

CONTROL VALVE

88 | P a g e
8.1 Introduction:

In this chapter, there is a list of different pumps and control valves used in the FA plant.
It also consists piping color code system and control loops of FA plant.

8.2 Pump:
In an Industry, the equipment’s are needed to be connected for transportation of fluid or
chemicals. Therefore, pipelines are required to connect this equipment. Also, the
chemicals are required to flow through specific rate to maintain the flowrate through
this equipment. Hence, pumps are used for this purpose.

Various Type of Pumps

A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by
mechanical action. Pumps can be classified into thr.ee major groups according to the
method they use to move the fluid: direct lift, displacement, and gravity pumps,
reciprocating pumps and centrifugal pumps. There are two types of pumps used in the
company and are very common in almost every industry.

i. Reciprocating pump
ii. Centrifugal pump

Reciprocating pump:
A reciprocating pump is a class of positive-displacement pumps which includes the
piston pump, plunger pump and diaphragm pump. It is often used where a relatively
small quantity of liquid is to be handled and where delivery pressure is quite large. In
reciprocating pumps, the chamber in which the liquid is trapped, is a stationary cylinder
that contains the piston or plunger.

89 | P a g e
• Uses of Reciprocating pump:
1) The lubricating pump is a reciprocating pump and it supplies the lubrication oil to the
main engine.
2) Main bilge suction pump is also a reciprocating pump.
3) For ballast they are sometimes used.

• Advantages of Reciprocating pump:

1) Gives high pressure at outlet.
2) Gives high suction lift.
3) Priming is not required in this pump.
4) They are used for air also

• Disadvantages of Reciprocating pump:

1) High wear and tear, so requires a lot maintenance.
2) The flow is not uniform, so we have to fit a bottle at both ends.
3) The flow is very less and cannot be used for high flow operations.
4) More heavy and bulky in shape.
5) Initial cost is much more in this pump. [7]

Centrifugal pump:
Centrifugal pumps are a sub-class of dynamic axis symmetric work-absorbing turbo
machinery.
Centrifugal pumps are used to transport fluids by the conversion of rotational kinetic
energy to the hydrodynamic energy of the fluid flow.

• Advantages of centrifugal pump:

1) As there is no drive seal so there is no leakage in pump.
2) It can pump hazardous liquids.
3) There are very less frictional losses.
4) There in almost no noise.
90 | P a g e
5) Pump has almost 100 % efficiency
6) Centrifugal pump has minimum wear with respect to others.
7) There is a gap between pump chamber and motor, so there is no heat transfer
between them.
8) Because of the gap between pump chamber and motor, water cannot enter into motor.
9) Centrifugal pump uses magnetic coupling which breakup on high load eliminating
the risk of damaging the motor.

• Disadvantages of centrifugal pump:

1) Because of the magnetic resistance there is some energy losses.
2) Unexpected heavy load may cause the coupling to slip.

List of Pump that used in Formic acid Plant

Table 8.1: List of Pump that used in Formic acid Plant

PUMP NO. USED FOR
CENTRIFUGAL PUMP
P-5005 Raw Methanol feeding (To T-5040M2)
P-5006 Dry Methanol feeding (To P-5033 suction)
P-5040 Reflux drum outlet feeding (Of T-5040M2)
P-5023 Recirculation (In R-5020)
P-5030 Reflux drum outlet feeding (Of T-5030)
P-5049 MF Feeding (To D-5050)
P-5051 MF+ WATER Feeding (To R-5055)
P-5061 Reflux drum outlet feeding (Of T-5060)
P-5063 FA + WATER Feeding (From T-5060 bottom to T-
5070)
P-5069 Reflux drum outlet feeding (Of T-5070)
P-5040M1 Reflux drum outlet feeding (Of T-5040M1)

91 | P a g e
 P-5091 FA transportation (To D-5093)
P-5093 FA transportation (To IP Filling)
RECIPROCATING PUMP
P-5003 Catalyst Dosing (To P-5033 Suction) (Metering Pump)
P-5011 As Mechanical Seal (For P-5023)
P-5010 As Mechanical Seal (For P-5033)
VERTICAL HIGH-SPEED INTERNAL GEAR PUMP
P-5033 Feeding of Methanol, Catalyst and Recycle from MF
column (To R- 5020)

8.3 Piping:
In Plant piping material is selected on the base of bellow criteria:
• Material specification
• Chemical composition
• Mechanical properties
• Brittle facture toughness
• Carbon equivalent
• Inspection time
• Easy to repairing
• Welding procedure
Mainly SS 316 pipes are used to avoid corrosion and for a longer life.

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Line color codes:

Figure 8.1: Color Codes of Pipelines

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8.4 Control valves:
Process plants consist of hundreds, or even thousands, of control loops all networked
together to produce a product to be offered for sale. Each of these control loops is
designed to keep some important process variable such as pressure, flow, level,
temperature, etc. within a required operating range to ensure the quality of the end
product. Each of these loops receives and internally creates disturbances that
detrimentally affect the process variable, and interaction from other loops in the
network provides disturbances that influence the process variable.

To reduce the effect of these load disturbances, sensors and transmitters collect
information about the process variable and its relationship to some desired set point. A
controller then processes this information and decides what must be done to get the
process variable back to where it should be after a load disturbance occurs. When all the
measuring, comparing, and calculating are done, some type of final control element
must implement the strategy selected by the controller.

Principles of Operation:
The most common final control element in the process control industries is the control
valve. The control valve manipulates a flowing fluid, such as gas, steam, water, or
chemical compounds, to compensate for the load disturbance and keep the regulated
process variable as close as possible to the desired set point.

Any control loop usually consists of a sensor of the process condition, a transmitter and
a controller that compares the “process variable” received from the transmitter with the
“set point,” i.e., the desired process condition. The controller, in turn, sends a corrective
signal to the “final control element,” the last part of the loop and the “muscle” of the
process control system.

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While the sensors of the process variables are the eyes, the controller the brain, then the
final control element is the hands of the control loop. This makes it the most important,
sometimes the least understood, part of an automatic control system. This comes about,
in part, due to our strong attachment to electronic systems and computers causing some
neglect in the proper understanding and proper use of the all-important hardware.

Globe valves are normally used for control, and their ends are usually flanged for ease
of maintenance. Depending on their type of supply, the disk is moved by a hydraulic,
pneumatic, electrical or mechanical actuator. The valve modulates flow through the
movement of a valve plug in relation to the port(s) located within the valve body. The
valve plug is attached to a valve stem, which, in turn, is connected to the actuator.

Control Valve Arrangement:

The image below shows how a control valve can be used to control the rate of flow in a
line. The "controller" receives the pressure signals, and compares them with pressure
drop for the desired flow and if the actual flow is different, adjusts the control valve to
increase or decrease the flow.

Comparable arrangements can be devised to control any of numerous process variables.

Temperature, pressure, level, and flow rate are the most common controlled variables.

Figure 8.2 Control valve Arrangement

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Components of Control Valve
Control valves have basically three interactive components:
1) A valve body subassembly (either with a reciprocating or rotating stem),
2) An actuating device (usually a spring diaphragm type),
3) A valve positioner (an instrument that converts an electronic control signal from a
controller, or computer, into an air signal to control the position of the control valve
stem), and an air set or regulator to supply air pressure to the positioner.

Types of Valve Body

Many types of valve bodies are available to achieve specific flow regulation behavior.
The following description addresses the main valve bodies used in the process
industries; key features of each body type are presented after the descriptions in Table.

Globe Valve:
The name "globe" refers to the external shape of the valve, not the internal flow area. A
typical globe valve has a stem that is adjusted linearly (up and down) to change the
position of the plug. As the plug changes, the area for flow between the plug and seat
(opening) changes. Many different seats and plug designs are available to achieve
desired relationships between the stem position and flow rate; see the discussion on
valve characteristics below. The standard plug must oppose the pressure drop across the
valve, which is acceptable for small pressure drops. For large pressure drops, a balanced
globe valve is used to enable a valve with a small force to open and close the plug.

Ball valve:
The restriction for this body is a solid ball that has some part of the ball removed to
provide an adjustable area for flow. The ball is rotated to influence the amount of flow.
The example ball valve displayed through the link below has a tunnel through the ball,
and the ball is rotated to adjust the fraction of the tunnel opening available for flow.
Other types of ball valves have different sections removed from the ball to give desired

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properties.

Butterfly valve:
The butterfly valve provides a damper that is rotated to adjust the resistance to flow.
This vale provides a small pressure drop for gas flows.

Diaphragm valve:
The diaphragm valve has one surface which is deformed by the force from the valve
stem to vary the resistance to flow.

Gate valve:
These valves have a flat barrier that is adjusted to influence the area for flow. These
bodies are used primarily for hand-operated valves and valves automated for emergency
shutoff.

Advantages and Disadvantages of different types of valves

Valve Body Advantages Disadvantages

globe (unbalanced)
-large range -unbalanced
forces
-good shutoff
-high pressure loss
globe (balanced)
-high capacity
-poor shutoff
-large range
-high pressure loss
-balanced forces
ball
-high capacity -moderate pressure
drop applications
-tight shutoff
-tends to plug (except
segmented ball)

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butterfly
-high torque

-large dead band

-high capacity
-affects flow through
-low pressure limited range (i.e.
loss
0-60%)
-slurry applications
-tight shutoff requires
special seat material
diaphragm
-slurry -short diaphragm life
applications
-limited pressure and
-corrosion resistant temperature
materials
-small range
gate -tight shutoff -used only with clean
fluids

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 CHAPTER 9
SAFETY, HEALTH AND
ENVIRONMENT

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9. Fire & Safety

9.1 Introduction to Industrial Safety

• Safety is becoming very important with every management as it

has come to play a very vital role in the modern development.
• Long time ago, accidents were considered as an act of God and
Nature. Scientific minded people have analyzed accidents and
develop a separate engineering branch for accident prevention.
This analysis was required due to:
1. Rising trend of accidents

2. Increased use of machinery

3. Increased material handling

4. Lack of safety standard

5. Lack of training

6. Better reporting of accidents [1]

Safety

● Safe use of man, material and machine by safe system method of work is
to achieve zero accidents which results in higher productivity.

Accident

● An accident is unplanned and unexpected events which interfere or

interrupts the planned process of work and results in personal injury.

Accident Factors

1. A personal accident injury occurs as a result of an accident

2. An accident due to unsafe act and/or unsafe
condition 3. Unsafe act/unsafe

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 3. condition exists due to fault of persons
4. Fault of persons are due to negligence

Thus, if we can remove fault of persons, we can prevent 98% accidents.

9.3 List of Safety Equipment

Respiratory personal protective equipment:

• Self-contained breathing apparatus sets of 30 minutes and 10 min

• continuous airline masks.
• Trolley mounted self-contained breathing apparatus set 2.5 hours
• Canister gas mask.
• Dust mask/cloth mask. (Air purifying respirator)

Non-respiratory personal protective equipment:

• Helmet

• Ear muff and ear plugs

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• Goggles

• Face shield

Hand gloves

Aprons

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 Safety Shoes

• Suits

• Safety Harness

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Warning instruments:

Oxygen, carbon dioxide, chlorine, ammonia indicator with

replaceable sensors. Explosive meters for measuring explosive
range.
Fire fly instrument for confined space entry.

1.1.2 Gas leakage protection installation:

Safety Showers
Manual water sprinklers
Communication systems

Principles of Fire Extinguishing

Fire may be extinguished by withdrawing of flammable contents,

interrupting flammable flow, isolating fuel from air, heat removal
to below reaction temperature or by dispersal.
In the event of fire on electrical mains or apparatus, the affected
part shall be immediately isolated from its source of supply of
electrical energy.
Carbon tetrachloride extinguishers and Carbon dioxide
extinguishers are intended mostly for use on electrical fires and
may be used on energized electrical equipment without danger to
operator provides. They are properly maintaining no moisture.
It is dangerous to throw a stream of water, a wet blanket or a stream
from an ordinary soda acid or foam type fire extinguishers on line
main apparatus. When found necessary to use them, have all
neighboring mains or apparatus made dead.
In case of fire, it is the duty of the operating personnel to protect
life and property and to extinguish the fire as quickly as possible.
The greatest cause of fire is welding which may be required during
plant operation. It should be a stringent rule of the plant that no
welding without permission of the supervisor.
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Classification of Fire:

Figure 9.1: Classification of Fire

9.4 All the auxiliary equipment related to safety:

• Safety Valves
• Rupture Disk
• Pressure Relief valves
➢ For fire fighting
• Fire and Safety department
• Water hydrant system
• CO2 extinguishers
• Fire tender
• Fire detectors
• Fire alarm
➢ For tank safety
• Sprinkler system
• Dyke wall around tank

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• Breather valve & safety valves
• Foam system

Types of Fire Extinguishers

Figure 9.2: Types of Extinguishers

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Emergency Preparedness

Definition:

a. Emergency is defined as any situation which presents a threat to

safety of persons or property.
b. Emergency (in industry) can be defined as one or more
emergencies, which can: Affect one or several plants.
c. Cause serious injury to the person Result in extensive damage to the proper

Types of Emergencies

• Fire
• Explosion or blast
• Heavy leakage/spillage of chemicals
• Toxic or flammable gas leakage

Level of emergency

Level of emergency can be classified in three categories

Level I: The emergency which is containable within some plant

premises.
Level II: The emergency which is containable the factory
premises.
Level III: Likelihood of cloud formation of toxic and/or flammable
gases and drilling of such cloud affecting to the general public.

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 Emergency Siren Tone

i. Fire: Whaling sound for five minutes (one-minute sound and thirty seconds
break)
ii. Gas Leak: Whaling sound for seven minutes (one minute on and one minute
off)
iii. Tremors / Earthquake: Whaling sound for two minutes thirty
second (one- minute sound and thirty seconds break)
iv. All Clear: Continuous sound for three minutes.

Testing: Every Monday at 11:00 O’clock (Continuous sound for two minute)

Assembly points location

Bagging plant building
Hazardous chemical plant open area
Nitro phosphate bagging plant building
Coal handling building.

9.5 Hazop of the plant

HAZOP is a systematic and structured technique commonly used in identifying

potential hazards and/or problems with plant operability, recognizing consequences
arising from various causes and providing recommendations for safety improvements in
design and operations.

HAZOP for Distillation column

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Parameter Guide Deviation Possible Consequence Action
word Cause
Flow NO No flow• Pipe blockages• Column dry out • Install low level
• Control valve • Possible alarm
shut dangerous • Check
• Valves fail concentration maintenance
• Tube leakages • No operation procedure and
and blocking schedule
• Pump failure • Make bypass
• Emergency plant
shut down
LESS Less flow• Pipe blockages• Column dry out • Install low level
• Control valve • Changes in alarm
shut product quality • Check
• Valves fail maintenance
• Tube leakages procedure and
and blocking schedule
• Pump failure • Make bypass
• Emergency plant
shut down
MORE More • Control valve • Flooding in the • Install high level
flow is fully opened column alarm
• Increase • Changes in • Install control
pumping product quality • Check
capacity • Temperature maintenance
• Control valve decrease procedure and
failure • Rise in bottom schedule

Level HIGH High • Output • Over pressure • Install high level

level blockages reflux drum alarm
• Condensed liquid • Check
flow back to
maintenance
distillation
procedure and
schedule

LOW Low level • Pipe partial • Level decrease in • Install low level
clogged and the level alarm
leakage • The valve closed • Check
• Back flow of maintenance
material
procedure and
schedule
• Install valve

109 | P a g e
 9.6 Various pollution control measures taken by the industry:

9.6.1 Effluent Treatment Plant:

• Extraction

The water from the hydration reaction is condensed and separated in the
product decanter. From there it is pumped to the course water tank from
where a part is taken to the reactor as temperature moderator. The rest of
the water is about 3 % aniline.
By extracting this water with nitrobenzene in two steps the aniline is almost
completely
recovered. The composition after extraction is around 100 ppm aniline
and about 0.4 %NB. The extractors are operated in counter current and
the mixing device is a static mixer producing a good contact between
water and NB. The feed rate of NB and water is flow controlled and the
interface in the extractor is level controlled. A portion of both liquid
phases from each extractor can be recycled back to the static mixer
feed point of that stage to maintain a high liquid velocity through the
mixer.

• Precipitation of Nitro phenols

The second wash step for nitrobenzene is made with alkali in order to
remove the minerals acid remaining from the first wash step and more
important to remove the oxidation product, nitro phenols. In alkali the
nitro phenols are easily soluble and gives strongly red colored solution.
The nitro phenols are poisonous to bacterial growth and should be
removed as far as possible before biological treatment of the wastewater.
By acidifying the alkaline wash water, the nitro phenols are precipitated,
as the solubility in acidic water is very low.

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 The separation of nitrobenzene from the alkaline water is sometimes
difficult but at acidic conditions all emulsion is broken and a good
separation is obtained. By mixing the acidic first wash water the second
alkaline the nitro phenols will be separated from the water phase.

An extraction with NB keeps a constant low level of nitro phenols in the

wastewater from the NB plant. The settling of the remaining nitro
phenols is rather slow and the volume for this settling tank should be
quite big to about 5060 cubic meters. The separated organic phase should
be sent for burning in the incinerator unless the quantity of NB is very
high.
In that case the organic could be returned to the NB washing.

• Treatment of wastewater in the WWT. Unit

Stripping

The combined WW from NB – washing, after precipitation and the WW

from aniline hydrogenation after extraction are send to the stripper.
About 80 -90 % of the aniline. NB and 60 benzenes are stripped off. The
inorganic and organic salts will not be stripped offend will follow to the
biological treatment. The bottom from the stripper will be as follows.

Biological treatment

There are two basic processes for biological treatment of organic waste,
aerobic and anaerobic waste. In WW with very high organic content the
anaerobic process is possible but in this case with relatively low BOD the
efficiency of aerobic process is more. The speed of an aerobic oxidation
process cannot be greatly altered by providing large population of micro-
organisms I the form of a sludge and by giving the micro-organisms
111 | P a g e
optimal condition as an oxygen, temperature and nutrient it is possible to
achieve a rapid rate of removal of organic matter from the solution. The
large microbial surface permits initial absorption of colloidal and soluble
organic together with synthesis of new cells so that after a relatively short
time the liquid phase contains little residual organic matter. The absorbed
maturities oxidized to the normal aerobic and product CO2 and H2. There
are two types of aerobic treatment units. Biological filter / bacteria bed
Activated sludge.

The biological filter is the oldest form of biological treatment unit

consisting of basically of a bed of stone. Today some synthetic material
on which a rotating distributor doses the effluent. Liquid trickles through
the bed where microorganisms grow on the surface and the oxidation is
limited to the supply of oxygen normally by natural ventilation. Some
modification as forced ventilation alternating double filters; recirculation
and rotating disc filters are tested in order to increase the efficiency.

The supply of air can be made by compressed air diffusers at the bottom
of a tank or by aeration mixing devices on the surface. Sufficient air must
be transferred to the liquid to maintain DO (dissolved oxygen) of 1-2 mg
and the mixing must keep the sludge in good contact with the liquid. If
the sludge is settled rapidly, it becomes anaerobic.

The active sludge process consists of two parts. The mixed aerated Porte
and the sludge settling part from which the sludge part is returned to the
aerated part and partly dewatered for disposal. Apart oxygen the
microorganisms also need phosphorus and nitrogen in the relation P-N-
BOD, 1-3-100. In the case of organic material difficult to oxidize the
microorganism need an organic nutrient to feed on example: Ethanol,
methanol, acetone or some other simple hydrocarbon. For the WW
112 | P a g e
 coming from the NB-AN plants after the stripper and eventual WW from
other productions the activated sludge process is recommended. The
design and dimensions can be made on the basic data given in the process
but it will not be sufficient to meet the concentration accepted by the
Indian government.

The aerated volume should give a retention time of minimum 24 hours. The sludge
for disposal must be de watered and before that some method for improving the
dewatering characteristics can be employed like thickening, chemical coagulants,
heat treatment. Dewatering can be done in number of ways like drying beds;
vacuums filters, pressure filtration and centrifugation are the most common.

Activated carbon treatment:

Some organic compounds like microorganisms are not able to oxidize

completely. In such case a filtration through activated carbon is a very
efficient way of reducing difficult impurities. Both powdered and
granulated carbon can be used. The former is cheaper but cannot be
recovered like the granulated type. This recovery is however quite
complicated.
As an indication of the demand of carbon a consumption 5 Kg carbon
per 1 Kg dissolved organic material can be estimated.

Incinerator:

From the purification of the aniline a tar product is coming as bottom from the purge
recovery column. It contains aniline and some high boiling impurities form the stripper in
113 | P a g e
the WWT. An organic phase is separated containing mainly NB. There is also organic
waste coming from the precipitation of the alkalis wash water in NB plant. All these
organic wastes in liquid from should be burned in an incinerator. The incinerator
consists of a burner, which can operate on the liquid waste of alternative on fuel gas. A
burning chamber with ceramic thermal insulation and a stack.

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 CHAPTER 10

PLANT LOCATION AND PLANT

LAYOUT

115 | P a g e
10.1 Introduction:
Present chapter comprises of various factors affecting the plant location and plant layout.
The Layout of FORMC ACID PLANT is also shown.

10.1 Plant Location:

Plant location is however one of the most important part of final planning. Selection
of suitable location of the plant is very important because success of the plant is
based on this point.
The geographic allocation of the final plant can have a strong influence on the
success of an industrial venture. Much care must be exercised in choosing the plant
site, and many different factors must be considered. Primarily, the plant should be
located where the minimum cost of production and distribution can be obtained, but
other factors, such as room for expansion and general living conditions, are also
important.
An approximate idea as to the plant location should be obtained before a design
project reach detailed-estimate stage, and firm location should be established upon
completion of the detailed- estimate design. The choice of the final site should first
be based on a complete survey of the advantage sand disadvantages of various
geographical area and, ultimately ,on the advantage sand disadvantages of available
real estate.
The following factors should be considered in choosing a plant site:

• Raw materials

• Markets

• Power and fuel

• Climate

116 | P a g e
 • Transportation facilities

• Water supply

• Waste disposal

• Labor supply

• Taxation and legal restrictions

• Site characteristics

• Flood and fire protection

• Community factors

The factors that must be evaluated in a plant-location study indicate the need for a
vast amount of information, both quantitative (statistical) and qualitative.

Raw materials:

The source of raw materials is one of the most important factors influencing the
selection of a plant site. This is particularly true if large volumes of raw materials are
consumed, because location near the raw-materials source permits considerable
reduction in transportation and storage charges. Attention should be given to the
purchased price of the raw materials, distance from the source of supply, freight or
transportation expenses, reliability of supply, purity of the available raw materials,
and storage requirements.

Market:

The location of market so intermediate distribution centers affects the cost of product
distribution and the time required for shipping. Proximity to the major markets is an
important consideration in the selection of a plant site, because the buyer usually
117 | P a g e
finds it advantageous to purchase from nearby sources. It should be noted that
markets are needed for byproducts as well as for the major final products.
Power and fuel:

Power and steam requirements are high in most industrial plants, and fuel is
ordinarily required to supply the utilities. Consequently, power and fuel can be
combined as one major factor in the choice of a plant using electrolytic processes are
often located near large hydroelectric installations. If the plant requires large
quantities of coal or oil, location near a source of fuel supply may be essential for
economic operation. The local cost of power can help determine whether power
should be purchased or self-generated.

Climate:

If the plant is located in a cold climate, costs may be increase by the necessity for
construction of protective shelters around the process equipment, and special cooling
towers or air-conditioning equipment may be required if the prevailing temperature
are high. Excessive humidity or extremes of hot or cold weather can have a serious
effect on the economic operation of a plant and these factors should be examined
when picking a plant site.
Transportation facilities:

Water, rail roads and highways are the common means of transportation used by
industrial concerns. The kind and number of products and raw materials determine
the most suitable type of transportation facilities. In any case, careful attention should
be given to local freight rates and existing railroad lines. The proximity to rail road
center sand possibility of canal, river, lake, or ocean transport must be considered. If
possible, the plant site should have access to all three types of transportation and
certainly, at least two types should be available. Effective transportation facilities for
the plant workers are necessary.
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Water supply:

The process industries use large quantities of water for cooling, washing, steam
generation and raw material. The plant therefore must be located where a dependable
supply of water is available.
The temperature, mineral content, silt or sand content, bacteriological content and
cost for supply and purification treatment must so be considered when choosing a
water supply.

Waste disposal:

In recent years, many legal restrictions have been placed on the methods for
disposing of waste materials from the process industries. The site selected for a plant
should have adequate capacity and facilities for correct waste disposal. Even though
a given has no restrictions on pollution, it should not be assumed that this condition
will continue to exist. Waste disposal can be accomplished by water, land, or air
dispersal. In choosing a plant site, the permissible tolerance levels for the various
methods of waste disposal should be considered and attention should be given to
potential requirements for additional waste- treatment facilities.

Labor supply:

The type and supply of labor available in the vicinity of a proposed plant site must
be examined. Consideration should be given to prevailing pay rates, restrictions to
number of hours worked per week, competing industries that can cause dissatisfaction
or high turnover rates among the workers, racial problems and variations in the skill
and intelligence of the workers.

119 | P a g e
 Taxation and legal restrictions:

State and local tax rate so property, income, unemployment insurance and similar
items vary from one location to another. Similarly, local regulations on zoning,
building codes, nuisance aspects and transportation facilities can have a major
influence on the final choice of a plant site.

10.3 Plant Layout:

10.3.1 General:
➢ Layout of FA plant will be determined on the basis of several factors such a

safety, increased production, better utilization of labor, and shorter

manufacturing time. All contributing to lower the cost of production of Formic
Acid. For optimization among all these factors, following principles have been
adopted.

10.3.2 Detailed about factors affecting plant layout

Equipment layout

➢ FA plant is divided in different sections. The equipment in FA plant is at different

floor, this will enable not only in saving in floor space area, but also each and every
equipment will have easier accessibility for replacement or maintenance.
➢ There is ample space around plant for initial construction and maintenance.

Plant layout
➢ Enough attention has been given in allotting space on each section to take care to
future expansion or modification of plant capacity. Plant in its present condition is
120 | P a g e
 capable of providing space for replacement of equipment with higher capacity.

Utilities servicing
➢ The distribution of air, cooling water, steam and power is quite flexible in the plant.
There is one distribution cooling water headed and one common receive cooling
water from all of the heat exchangers of the plant
Building
➢ The building will have approximate 25ft wide road on every side of plant, thus
allowing any truck to reach plant location for replacement or dismantling of any
equipment.
➢ The control room is near to the FA plant.
Roads
➢ The building will have approximate 25ft wide road on every sides of plant, thus
allowing any truck to reach plant location for replacement or dismantling of any
equipment.

Safety
➢ Safety related all the equipment and safety alarms are provided at all the critical pointsin the
plant.

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13. Roads and railroads

Figure 10.1 GNFC layout

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 CHAPTER 11
COST ESTIMATION

123 | P a g e
11.1 Introduction
Cost estimation is done to calculate the total cost of the plant including fixed costs, direct production
costs for raw materials, labour, maintenance, power, and utilities along with costs for plant and
administrative overhead, distribution of the final products, and other miscellaneous items.
As soon as the final process-design stage is completed, it becomes possible to make accurate cost
estimations because detailed equipment specifications and definite plant-facility information are
available. Direct price quotations based on detailed specifications can then be obtained from various
manufacturers.

11.1.1 Total capital investment

Before an industrial plant can be put into operation, a large sum of money must be supplied to
purchase and install the necessary machinery and equipment. Land and service facilities must be
obtained, and the plant must be erected complete with all piping, controls, and services. In addition,
it is necessary to have money available for the payment of expenses involved in the plant operation.
The capital needed to supply the necessary manufacturing and plant facilities is called the fixed
capital investment, while that necessary for the operation of the plant is termed the working capital.
The sum of the fixed-capital investment and the working capital is known as the total capital
investment. The fixed-capital portion may be further subdivided into manufacturing capital
investment and nonmanufacturing capital investment.

11.1.2 Fixed capital investment

Manufacturing fixed-capital investment represents the capital necessary for the installed process
equipment with all auxiliaries that are needed for complete process operation. Fixed capital
investment can be finding out by summing direct & indirect cost.

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11.1.3 Working capital
The working capital for an industrial plant consists of the total amount of money invested in,
Raw materials and supplies carried in stock.
Finished products in stock and semi-finished products in the process of being manufactured.
Accounts receivable.
Cash kept on hand for monthly payment of operating expenses, such as salaries, wages, and raw-
material purchases.
Accounts payable.
Taxes payable.

11.1.4 Purchased equipment cost

= Purchased equipment cost is estimated to be 500 cr.

Table 11.1 Direct cost

percentage of
No. Item purchased equipment Total cost in Cr.
cost
1 equipment - 500
2 installation cost 15 75
instrumentation &
3 20 100
control
4 piping 35 175
5 electrical installation 10 50
6 service facilities 22 110
land & yard
7 9 45
improvement
8 building 15 75
total direct cost in
1130
INR

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 11.2 Indirect cost
Table 11.2 Indirect cost
percentage of
No. Item purchased equipment Total cost in Cr.
cost

engineering &
1 15 75
supervision

2 construction 16 80

3 contractor fees 5 25

4 contingency 10 50

total indirect cost 230

Fixed capital investment = direct cost + indirect cost

= INR 1360 Cr.
Working capital investment = 15 % of FCI
= INR 204 Cr.
Total capital investment = (fixed + working) capital investment
= INR 1564 Cr.

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 11.3 Total production cost
Total production Cost = Manufacturing Cost + General Expenses

Manufacturing Cost = Direct Production Cost + Fixed Charges + Plant Overhead Costs

11.3.2 Direct production cost

Table 11.3 Direct Production Cost
item percentage of purchased equipment cost total cost in Cr.
equipment - 500
installation cost 15 75
instrumentation & control 20 100
piping 35 175
electrical installation 10 50
service facilities 22 110
land & yard improvement 9 45
building 15 75
total direct cost in INR 1130

Where, X = Total Production Cost (TPC)

OL = Operating labor
FCI = Fixed capital investment

Now Equipment Cost = 500 cr

Salvage Value = 250 cr
Life of Plant = 25 Years

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By Straight Line Method,
Depreciation= (Initial investment – Salvage Value)/Life of Plant
= (548.8-75)/25
= 10 Cr PA
11.3.2 Fixed charges
Table 11.4 Fixed Charges
particulars basis chosen cost (Cr. INR)
depreciation 10
interest 10 % of TCI 156.4
local taxes 4 % of FCI 54.4
insurance 1 % of FCI 13.6
total 234.4

11.3.3 General expenses

Table 11.5 General Expenses
particulars basis chosen cost (Cr INR)
administrative cost 10 % of OL 0.01*X
distribution & marketing cost 12 % of TPC 0.12*X
R&D 4 % of TPC 0.04*X
total 0.17*X

Plant Overhead Expenses = 60% of (Maintenance & Repair + OL)

= 0.06*X + 40.8
Manufacturing Cost = Direct Production Cost + Fixed Charges + Plant Overhead Expenses
= 1089.4 + 0.28 * X
Total Production Cost = Manufacturing Cost + General Expanses
X = 1089.4+ 0.28 * X + 0.17 *X
128 | P a g e
Total Production Cost (X) = 1980.72 Cr PA
11.1 Profitability
Selling price of H2 = 500 Rs/kg
Production rate = 66471428.57 kg/yr

Annual income from sales = 3323.57 Cr PA

Gross profit = Sales - TPC = 1342.84 Cr PA
Assume Tax = 18% of gross profit = 241.71 Cr PA, Surcharge = 3% of Tax = 7.25 Cr PA
Net profit = Gross profit – Tax – Surcharge - Depreciation
= 1083.88 Cr PA
Rate of return before income taxes = (Gross profit/TCI) x 100
= 85.85 %
Rate of return after income taxes = (Net profit /TCI) x 100
= 69.3 %
Turnover ratio = Total Income/ FCI
= 2.44
Payback period = FCI / NP
= 1.25 years
Fixed Charges + General Expenses + Plant Overhead
Breakeven Point =
(𝑆𝑒𝑙𝑙𝑖𝑛𝑔 𝑃𝑟𝑖𝑐𝑒 𝑝𝑒𝑟 𝑘𝑔 − 𝑀𝑎𝑛𝑢𝑓𝑎𝑐𝑡𝑢𝑟𝑖𝑛𝑔 𝐶𝑜𝑠𝑡 𝑝𝑒𝑟 𝑘𝑔)

(TPC – (Fixed Charges + General Expenses + Plant Overhead))

Where, Manufacturing Cost =
annual Production Capacity

General expenses = 0.17*X = 336.72 Cr PA

Plant overhead expenses = 159.64 Cr PA
Production capacity = 70714285.71 kg/yr

129 | P a g e
Manufacturing cost = 176 Rs/kg
Breakeven point = 22607716.86 kg/year
Breakeven capacity = 32 %
Table 11.6 Summary table for cost estimation
Sr no. particulars value (in crores)
1 total purchased equipment cost 500.00
2 direct cost 1130.00
3 indirect cost 230.00
4 Total Fixed Capital (FCI) 1360.00
5 Working Capital (Wc) 204.00
6 Total Capital Investment (TCI) 1564.00
7 Total Raw Material Cost 3643.70
8 Depreciation (d) 10.00
9 Fixed Charges 234.40
10 General Expenses 336.72
11 Plant Overhead Cost 159.64
12 Total production Cost 1980.73
13 Total Annual Income 3323.57
14 Gross Profit 1342.84
15 Tax + Surcharge 248.96
16 Net Profit 1083.88
17 Rate of Return after income tax 69.30 %
18 Payback Period 1.25 year
19 Turn-over Ratio 2.44
20 Break-even Point 22607716.86 kg/year
21 Break-even Capacity 31.97 %

130 | P a g e
 11.5 Conclusion
In this Chapter we calculated cost of plant. All calculations are based on percentage of purchased
equipment cost method. We also performed profitability analysis of the plant. From that we conclude
that average 1083.88 Cr rupees net profit is obtained by running of the plant. Also, we calculated
direct cost, indirect cost, depreciation, local taxes, plant overhead cost, insurance policy,
manufacturing cost, general expenses, etc.

131 | P a g e
CHAPTER 12

CONCLUSION

132 | P a g e
 After completing this two-month industrial training at GNFC Limited, I came to conclude that
such type of training connects theoretical aspects of technical knowledge and how that is
implemented in practical world. Also, this training helped me a lot in terms of technical aspects
along with social wellbeing. I got an opportunity to understand the practical functioning of various
equipment with their basic design and application along with running, I also tried to observe
important aspects of industrial management, discipline and safety precautions. What I studied here is
some general information about products, diagrams, mass balance, energy balance, functioning of
major and minor process equipment, safety rules, utilities and cost estimation of the plant. Finally, I
would like to say that this two-month endeavor helped me a lot.

133 | P a g e
References
Books
(1) M.V. Joshi, Mahajan V.V. Process equipment design, McMillan India Ltd. 1999
(2) Richardson J.F., Coulson J.M., and Sinnott R.K. Chemical engineering
(3) Robert H. Perry handbook of chemical technology McGraw Hill international edition,
Singapore s1998
(4) Process Engineering and Design, Thakore S.B. and Bhatt B.I. Stoichiometry, 5th edition
(5) Plant Design and Economics for Chemical Engineers, Peters Max S. and Timmerhaus Klaus D
(6) Chemical Process Safety, Daniel A. Crowl and Joseph F. Louvar, 3rd edition
(7) Software used: Microsoft office Word 2019, Microsoft Excel 2019.

134 | P a g e
1|Page
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2
Fire 2
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Pe rs o n a l
Pro t e c t io n

Material Safety Data Sheet

Formic acid, 85% MSDS

Section 1: Chemical Product and Company Identification

Product Name: Formic acid, 85%

TSCA: TSCA 8(b) inventory: Formic acid; Water
CI#: Not applicable.
Synonym: Formic Acid, 85%
Chemical Name: Not applicable.
Chemical Formula: HCOOH

Section 2: Composition and Information on Ingredients

Composition:

Name CAS # % by Weight

Formic acid 64-18-6 85
Water 7732-18-5 15

Toxicological Data on Ingredients: Formic acid: ORAL (LD50): Acute: 700 mg/kg [Mouse]. 1100 mg/kg [Rat]. 4000 mg/kg
[Dog]. VAPOR (LC50): Acute: 6200 mg/m 0.25 hours [Mouse].

Section 3: Hazards Identification

Potential Acute Health Effects:

Very hazardous in case of skin contact (irritant), of eye contact (irritant, corrosive), of ingestion, . Hazardous in case of skin
contact (corrosive, permeator). Slightly hazardous in case of inhalation (lung sensitizer). Non-corrosive for lungs. Liquid or
spray mist may produce tissue damage particularly on mucous membranes of eyes, mouth and respiratory tract. Skin contact
may produce burns. Inhalation of the spray mist may produce severe irritation of respiratory tract, characterized by coughing,
choking, or shortness of breath. Inflammation of the eye is characterized by redness, watering, and itching. Skin inflammation
is characterized by itching, scaling, reddening, or, occasionally, blistering.
Potential Chronic Health Effects:
Slightly hazardous in case of skin contact (sensitizer). CARCINOGENIC EFFECTS: Not available. MUTAGENIC EFFECTS:
Mutagenic for mammalian somatic cells. [Formic acid]. Mutagenic for bacteria and/or yeast. [Formic acid]. TERATOGENIC
EFFECTS: Not available. DEVELOPMENTAL TOXICITY: Not available. The substance may be toxic to kidneys, liver, upper

p. 1
respiratory tract, skin, eyes, central nervous system (CNS). Repeated or prolonged exposure to the substance can produce
target organs damage. Repeated or prolonged contact with spray mist may produce chronic eye irritation and severe skin
irritation. Repeated or prolonged exposure to spray mist may produce respiratory tract irritation leading to frequent attacks of
bronchial infection.

Section 4: First Aid Measures

Eye Contact:
Check for and remove any contact lenses. In case of contact, immediately flush eyes with plenty of water for at least 15
minutes. Cold water may be used. Get medical attention immediately.
Skin Contact:
In case of contact, immediately flush skin with plenty of water for at least 15 minutes while removing contaminated clothing
and shoes. Cover the irritated skin with an emollient. Cold water may be used.Wash clothing before reuse. Thoroughly clean
shoes before reuse. Get medical attention immediately.
Serious Skin Contact:
Wash with a disinfectant soap and cover the contaminated skin with an anti-bacterial cream. Seek immediate medical
attention.
Inhalation:
If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Get medical
attention immediately.
Serious Inhalation:
Evacuate the victim to a safe area as soon as possible. Loosen tight clothing such as a collar, tie, belt or waistband. If
breathing is difficult, administer oxygen. If the victim is not breathing, perform mouth-to-mouth resuscitation. WARNING: It may
be hazardous to the person providing aid to give mouth-to-mouth resuscitation when the inhaled material is toxic, infectious or
corrosive. Seek medical attention.
Ingestion:
Do NOT induce vomiting unless directed to do so by medical personnel. Never give anything by mouth to an unconscious
person. If large quantities of this material are swallowed, call a physician immediately. Loosen tight clothing such as a collar,
tie, belt or waistband.
Serious Ingestion: Not available.

Section 5: Fire and Explosion Data

Flammability of the Product: Combustible.

Auto-Ignition Temperature: The lowest known value is 539°C (1002.2°F) (Formic acid).
Flash Points: The lowest known value is OPEN CUP: 69°C (156.2°F). (Formic acid)
Flammable Limits: The greatest known range is LOWER: 18% UPPER: 57% (Formic acid)
Products of Combustion: These products are carbon oxides (CO, CO2).
Fire Hazards in Presence of Various Substances:
Flammable in presence of open flames and sparks, of heat. Slightly flammable to flammable in presence of metals. Non-
flammable in presence of shocks, of oxidizing materials, of reducing materials, of combustible materials, of organic materials,
of acids, of alkalis, of moisture.
Explosion Hazards in Presence of Various Substances:
Explosive in presence of oxidizing materials. Slightly explosive in presence of organic materials, of metals. Non-explosive in
presence of open flames and sparks, of shocks.
Fire Fighting Media and Instructions:
SMALL FIRE: Use DRY chemical powder. LARGE FIRE: Use water spray, fog or foam. Do not use water jet.
Special Remarks on Fire Hazards:

p. 2
Decomposes more rapidly under fire conditions, forming carbon monoxide. Aluminum reduces formic acid (itself a reductant)
with incandescence. (Formic acid)
Special Remarks on Explosion Hazards:
Formic acid forms explosive reactions with the following: Furfuryl alcohol, Hydrogen Peroxide + organic matter; Nitromethane,
P2O5, Thallic nitrate trihydrate +vanillin, and oxidizing agents Explosive decompositon of Formic Acid on clean nickel. (Formic
acid)

Section 6: Accidental Release Measures

Small Spill:
Dilute with water and mop up, or absorb with an inert dry material and place in an appropriate waste disposal container. If
necessary: Neutralize the residue with a dilute solution of sodium carbonate.
Large Spill:
Combustible material. Corrosive liquid. Keep away from heat. Keep away from sources of ignition. Stop leak if without risk.
Absorb with DRY earth, sand or other non-combustible material. Do not get water inside container. Do not touch spilled
material. Use water spray curtain to divert vapor drift. Prevent entry into sewers, basements or confined areas; dike if needed.
Call for assistance on disposal. Neutralize the residue with a dilute solution of sodium carbonate. Be careful that the product is
not present at a concentration level above TLV. Check TLV on the MSDS and with local authorities.

Section 7: Handling and Storage

Precautions:
Keep locked up.. Keep container dry. Keep away from heat. Keep away from sources of ignition. Ground all equipment
containing material. Do not ingest. Do not breathe gas/fumes/ vapor/spray. Never add water to this product. In case of
insufficient ventilation, wear suitable respiratory equipment. If ingested, seek medical advice immediately and show the
container or the label. Avoid contact with skin and eyes. Keep away from incompatibles such as oxidizing agents, organic
materials, acids, alkalis.
Storage:
Keep container in a cool, well-ventilated area. Keep container tightly closed and sealed until ready for use. Avoid all possible
sources of ignition (spark or flame).

Section 8: Exposure Controls/Personal Protection

Engineering Controls:
Provide exhaust ventilation or other engineering controls to keep the airborne concentrations of vapors below their respective
threshold limit value. Ensure that eyewash stations and safety showers are proximal to the work-station location.
Personal Protection:
Face shield. Full suit. Vapor respirator. Be sure to use an approved/certified respirator or equivalent. Gloves. Boots.
Personal Protection in Case of a Large Spill:
Splash goggles. Full suit. Vapor respirator. Boots. Gloves. A self contained breathing apparatus should be used to avoid
inhalation of the product. Suggested protective clothing might not be sufficient; consult a specialist BEFORE handling this
product.
Exposure Limits:
Formic acid TWA: 5 STEL: 10 (ppm) from ACGIH (TLV) [United States] [1999] TWA: 9 (mg/m3) from NIOSH TWA: 5 (ppm)
from NIOSH TWA: 9 (mg/m3) from OSHA (PEL) [United States] TWA: 5 (ppm) from OSHA (PEL) [United States] TWA: 5
(ppm) [United Kingdom (UK)] TWA: 9.3 (mg/m3) [United Kingdom (UK)]3 Consult local authorities for acceptable exposure
limits.

Section 9: Physical and Chemical Properties

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Physical state and appearance: Liquid.
Odor: Pungent. Penetrating. Benzaldehyde-like
Taste: Sour
Molecular Weight: Not applicable.
Color: Clear Colorless.
pH (1% soln/water): Acidic.
Boiling Point: The lowest known value is 100°C (212°F) (Water). Weighted average: 100.67°C (213.2°F)
Melting Point: May start to solidify at 8.4°C (47.1°F) based on data for: Formic acid.
Critical Temperature: Not available.
Specific Gravity: Weighted average: 1.21 (Water = 1)
Vapor Pressure: The highest known value is 4.7 kPa (@ 20°C) (Formic acid). Weighted average: 4.6 kPa (@ 20°C)
Vapor Density: The highest known value is 1.59 (Air = 1) (Formic acid). Weighted average: 1.55 (Air = 1)
Volatility: Not available.
Odor Threshold: The highest known value is 0.625 ppm (Formic acid)
Water/Oil Dist. Coeff.: Not available.
Ionicity (in Water): Not available.
Dispersion Properties: See solubility in water, diethyl ether, acetone.
Solubility:
Easily soluble in acetone. Soluble in cold water, hot water, diethyl ether.

Section 10: Stability and Reactivity Data

Stability: The product is stable.

Instability Temperature: Not available.
Conditions of Instability: Heat, ignition sources, incompatible materials
Incompatibility with various substances:
Highly reactive with oxidizing agents. Reactive with organic materials, metals, acids, alkalis.
Corrosivity:
Highly corrosive in presence of copper. Corrosive in presence of stainless steel(304). Non-corrosive in presence of glass, of
aluminum, of stainless steel(316).
Special Remarks on Reactivity:
Formic acid is a strong reducing agent. Decomposes slowly during storage! Vent Container At Least Monthly. Formic acid
may react with alkalies and oxidizing materials such as peroxides, nitric acid, and chromic acid. It is also incompatible with
concentrated Sulfluric Acid, Nitromethane, finely powdered metals, permanganates, strong bases, oxidizing agents. (Formic
acid)
Special Remarks on Corrosivity: Corrosive to metals
Polymerization: Will not occur.

Section 11: Toxicological Information

Routes of Entry: Absorbed through skin. Dermal contact. Eye contact. Inhalation. Ingestion.

p. 4
Toxicity to Animals: Acute oral toxicity (LD50): 729 mg/kg (Mouse) (Calculated value for the mixture).
Chronic Effects on Humans:
MUTAGENIC EFFECTS: Mutagenic for mammalian somatic cells. [Formic acid]. Mutagenic for bacteria and/or yeast. [Formic
acid]. May cause damage to the following organs: kidneys, liver, upper respiratory tract, skin, eyes, central nervous system
(CNS).
Other Toxic Effects on Humans:
Extremely hazardous in case of inhalation (lung corrosive). Very hazardous in case of skin contact (irritant), of eye contact
(corrosive), of ingestion, . Hazardous in case of skin contact (corrosive, permeator).
Special Remarks on Toxicity to Animals: Not available.
Special Remarks on Chronic Effects on Humans: May affect genetic material (mutagenic)
Special Remarks on other Toxic Effects on Humans:
Acute Potential Health Effects: Skin: Corrosive. Causes skin irritation and burns . Absorbed through the skin. May cause
erythema and blistering. Eyes: Corrosive. Causes eye irritation and burns. Lachrymator. May cause corneal edema, ulceration
and scaring. Vapors may cause itching, burning and swelling of the eyes. Inhalation: Affects respiration and causes respiratory
tract irritation and burns. Vapors may afect behavior (brain) and sense organs and cause dizziness, and nausea. May
also affect the urinary system and liver Ingestion: May be harmful if swallowed. Causes digestive tract irritation and burns
with abdominal pain, vomiting, and possible death. May product corrosive ulceration and bleeding, and necrosis of the
gastrointestinal tract. May also affect the cardiovascular system, urinary system, blood, behavior, and metabolism. Chronic
Potential Health Effects: Prolonged or repeated skin contact may cause dermatitis. Mah cause liver and kidney damage.
Effects may be delayed. Laboratory experiments have resulted in mutagenic effects.

Section 12: Ecological Information

Ecotoxicity: Not available.

BOD5 and COD: Not available.
Products of Biodegradation:
Possibly hazardous short term degradation products are not likely. However, long term degradation products may arise.
Toxicity of the Products of Biodegradation: The products of degradation are less toxic than the product itself.
Special Remarks on the Products of Biodegradation: Not available.

Section 13: Disposal Considerations

Waste Disposal:
Waste must be disposed of in accordance with federal, state and local environmental control regulations.

Section 14: Transport Information

DOT Classification: Class 8: Corrosive material

Identification: : Formic acid (Formic acid) UNNA: 1779 PG: II
Special Provisions for Transport: Not available.

Section 15: Other Regulatory Information

Federal and State Regulations:

New York release reporting list: Formic acid Rhode Island RTK hazardous substances: Formic acid Pennsylvania RTK: Formic
acid Florida: Formic acid Minnesota: Formic acid Massachusetts RTK: Formic acid New Jersey: Formic acid TSCA 8(b)

p. 5
inventory: Formic acid; Water SARA 313 toxic chemical notification and release reporting: Formic acid CERCLA: Hazardous
substances.: Formic acid: 5000 lbs. (2268 kg);
Other Regulations: OSHA: Hazardous by definition of Hazard Communication Standard (29 CFR 1910.1200).
Other Classifications:
WHMIS (Canada):
CLASS B-3: Combustible liquid with a flash point between 37.8°C (100°F) and 93.3°C (200°F). CLASS E: Corrosive liquid.
DSCL (EEC):
HMIS (U.S.A.):
Health Hazard: 3
Fire Hazard: 2
Reactivity: 0
Personal Protection:
National Fire Protection Association (U.S.A.):
Health: 3
Flammability: 2
Reactivity: 0
Specific hazard:
Protective Equipment:
Gloves. Full suit. Vapor respirator. Be sure to use an approved/certified respirator or equivalent. Wear appropriate respirator
when ventilation is inadequate. Face shield.

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