Nitrogen

Abstract

Liquefaction of air and subsequent rectification of the liquid air is the basis of the Linde-
frankl’s procession which this project is based .Prof Linde is credited today with the first man
producing liquid nitrogen on a commercial scale. This thesis report is a design of a nitrogen
plant of capacity 432 tones /day, along with nitrogen this plant also produces oxygen of very
high purity. In it a complete design of a distillation column , 1-2 shell and tube condenser and
a adsorption column has been done.
The Linde Frankl’s process is the most important process for the commercial production of
nitrogen in this process in which the air stream is divided in two, one is cooled by J-T effect
and the other by incoming pure nitrogen which is the most striking thing about this process
and which makes it more economical .
Finally a safety and preventions have been dealt with along with brief overview of plant
layout and locations of the plant.

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SR PAGE
NO. TITLE NO.
INTRODUCTION 1
1 1.1 PROPERTIES 1
1.2 INDUSTRIAL APPLICATIONS 2
2 LITERATURE SURVEY 5
PROCESS SELECTION AND PROCESS DESCRIPTION 7
3.1 AIR PROPERTIES 7
3.2 AIR SEPARATION TECHNOLOGIES 7
3 3.3 PROCESS SELECTION- CRYOGENICS AIR SEPARATION 9
3.4 PROCESS DESCRIPTION 12
3.5 PROCESS VARIABLES 15
3.6 THERMODYNAMICS OF THE PROCESS 17
MASS AND ENERGY BALANCE 19
4.1 OVERALL MASS BALANCE 20
4 4.2 AIR COMPRESSOR 21
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4.3 MASS AND ENERGY BALANCE FOR REFRIGERTION

CYCLE 22
4.4 MASS AND ENERGY BALANCE FOR COMPRESSION
CYCLE 27
EQUIPMENT DESIGN 30
5 5.1 DOUBLE BISTILLATION COLUMN 30
5.2 CONDENSOR DESIGN 50
5.3 ADSORPTION COLUMN 63
6 PROCESS CONTROLL AND INSTRUMENTATION 73
6.1 P & I DIAGRAM FOR COLUMN 74
SAFETY AND ENVIRONMENT 76
7 7.1 SAFETY 76
7.2 ENVIRONMENTAL IMPACT ANALYSIS 81
PLANT LOCATION AND PLANT LAYOUT 83
8 8.1 PLANT LOCATION 83
8.2 PLANT LAYOUT 86
COST ESTIMATION 88
9.1 CALCULATION OF FIXED CAPITAL INVESTMENT 89
9 9.2 CALCULATIONOF TOTAL CAPITAL INVESTMENT 93
9.3 CALCULATION OF THE PRODUCTION COST 94
9.4 CALCULATION OF PROFIT 100
APPENDIX 101
10 I PROPERTY ESTIMATION 101
2.MSDS OF NITROGEN 103
11 REFERENCES 108

LIST OF FIGURES:

SR PAGE
NO. TITLE NO.
3.1 AIR COMPOSITION 7
3.2 AIR SEPRETION SCHEME 8
3.3 SELECTION DIAGRAM FOR N2 PRODUCTION 9
3.4 T-S DIAGRAM FOR CLAUDE PROCESS 12
3.5 T-S DIAGRAM FOR LINDEFRANKL PROCESS 13
3.6 PROCESS FLOW SHEET 14
5.1 AIR DISTILLATION DOUBLE COLUMN 30
5.2 LOWER DISTILLATION COLUMN 31
5.3 EQUILIBRIUM DIAGRAM 34

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5.4 MCCABE AND THIELE DIAGRAM 34

5.5 CONDENSER 51
5.6 GRAPH OF EFFLUENT CONCENTRATION VS TIME 64
5.7 GRAPH OF (1-y/yo) Vs (w-wa)/wa) 66
6.1 P AND I DIAGRAM OF DOUBLE COLUMN 74
8.1 PLANT LAYOUT OF NITROGE COMPLEX 81

LIST OF TABLES:

PAGE
TABLE NO. TITLE NO.
1 PURCHASED EQUIPMENT COST 89
2 RAW MATERIAL COST 94
3 TOTAL ANNUAL FIXED CHARGES 98
4 TOTAL MANUFACTURING COST 98
5 TOTAL GENERAL EXPENSES 100
B PROPERTY ESTIMATION 102

CHAPTER 1 INTRODUCTION

.1 INTRODUCTION [2]:

Nitrogen is formally considered to have been discovered by Scottish physician Daniel

Rutherford in 1772, who called it noxious air or fixed air. The fact that there was constituent
of air that does not support combustion was clear to Rutherford. The English word nitrogen
(1794) entered the language from the French nitrogène, coined in 1790 by French
chemist Jean-Antoine Chaptal (1756–1832), from the Greek "nitron" (sodium carbonate) and
the French gène (producing). The gas had been found in nitric acid. Chaptal's meaning was
that nitrogen gas is the essential part of nitric acid, in turn formed from saltpetre (potassium
nitrate), and then known as nitre.[3] This word in the more ancient world originally

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described sodium salts that did not contain nitrate, and is a cognate of natron.

Nitrogen is a common element in the universe, estimated at about seventh in total abundance
in our galaxy and the Solar System. It is synthesised by fusion of carbon and
hydrogen in supernovas. Due to the volatility of elemental nitrogen and its common
compounds with hydrogen and oxygen, nitrogen is far less common on the rocky planets of
the inner Solar System, and it is a relatively rare element on Earth as a whole. However, as
on Earth, nitrogen and its compounds occur commonly as gases in the atmospheres of planets
and moons that have atmospheres.
Nitrogen is a chemical element with symbol N and atomic number 7. Elemental nitrogen is a
colorless, odorless, tasteless, and mostly inert diatomic gas at standard conditions,
constituting 78.09% by volume of Earth's atmosphere.

1.2 PROPERTIES
1. NITROGEN IN SOLID STATE: It is a hard, pale blue, doubly refracting crystalline
solid.
Molecular weight : 28.0134 g/mol
Melting point : -210 °C
Latent heat of fusion (1,013 bar, at triple point) : 25.73 kJ/kg
2. NITROGEN IN LIQUID STATE: It is a pale steel blue, transparent and very mobile
liquid
Liquid density (1.013 bar at boiling point) : 808.607 kg/m3
Liquid/gas equivalent (1.013 bar and 15 °C ) : 691 vol/vol
Boiling point (1.013 bar) : -195.9 °C
Latent heat of vaporization (1.013 bar at boiling point) : 198.38 kJ/kg
1. NITROGEN IN GASEOUS STATE: It is a colorless, odorless, tasteless, diatomic
gas, a volume of it slightly heavier than equal volume of air.
Gas density (1.013 bar at boiling point) : 4.614 kg/m3
Gas density (1.013 bar and 15 °C ) : 1.185 kg/m3
Compressibility Factor (Z) (1.013 bar and 15 °C ) : 0.9997
Specific gravity (air = 1) (1.013 bar and 21 °C ) : 0.967
Specific volume (1.013 bar and 21 °C ) : 0.862 m3/kg

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Heat capacity at constant pressure (Cp) (1.013 bar and 25 °C ) : 0.029 kJ/(mol.K)
Heat capacity at constant volume (Cv) (1.013 bar and 25 °C) : 0.02 kJ/(mol.K)
Ratio of specific heats (Gamma:Cp/Cv) (1.013 bar and 25 °C (77 °F)) : 1.403846
Viscosity (1.013 bar and 0 °C ) : 0.0001657 Poise
Thermal conductivity (1.013 bar and 0 °C ) : 24 mW/(m.K)
Critical point Triple Point:
Critical temperature : -147 °C Temperature : -210.1°C
Critical pressure : 33.999 bar Pressure : 0.125 bar
Critical density : 314.03 kg/m3

[10]
1.3 INDUSTRIAL APPLICATIONS : Following are the applications of Nitrogen in
various industries.
1. Chemicals Industries:
 Nitrogen can be used for blanketing
 Storage for protecting raw materials or finished products in liquid form from the
formation of peroxides and/or gum, and from contamination by oxygenated
components.
 Regeneration of purification beds (alumina and molecular sieve).
 Preparation of catalysts and transportation of polymer powders
 Medium for the exhaust of emitted heat in fluid bed reactors
 Temperature Control in reactors.
2. Pharmaceuticals Industries:
Nitrogen is used for inerting, cryo-grinding, lyophilisation, drying, liquid phase
transfer of products or synthesis intermediates, cryo-condensation of waste gases and
low temperature storage.
3. Food and Beverage
Liquid nitrogen: N2 is the most used cryogenic fluid, to chill, freeze or store food
products.
Gaseous nitrogen: N2 is very commonly used in contact with foodstuffs to avoid
oxidation or micro-organism growth by inerting of liquids. Modified Atmosphere
Packaging (MAP) preserves and protects foods (pure nitrogen or mixed with CO2).

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4. Glass, Cement and Lime Industries:

Nitrogen is used as an inert gas especially to create, in combination with hydrogen, a
reductive atmosphere over the tin bath in the float glass process.
5. Healthcare :
Low-temperature preservation of living tissues and cells
6. Laboratories & analysis :
Nitrogen is used as a carrier gas in gas chromatography for various industrial and
hospital analyses and quality control. Nitrogen is the balance gas of the calibration
gas mixtures for environmental monitoring systems and industrial hygiene gas
mixtures. Nitrogen is largely used as purge, dryer or blanket gas for analyzers or
chemical reactors (under gaseous state or at low temperature liquid state).
7. Welding, Cutting & Coating
Heat treatment of various metals. Nitrogen is a component of the special mixtures
used in CO2lasers.
8. Oil and Gas
Quality protection of products and facilities (blanketing)

9. Electronics
Nitrogen is used as carrier gas for overall protection against impurities and oxidation
in semiconductor and soldering processes. In its cold and liquid form, N 2 is used as a
cooling medium in the environmental testing of electronic devices.
10. Automotive & transportation
Gas Assisted Injection Molding requires pressures between 10 bar (145 psi) and 200
bar (2900 psi) and a nitrogen content of between 98.0 % and 99.9 %.Tires filling with
nitrogen increases their lifetime and therefore decrease the recycling or treatment of
this waste.
Other industries
Pneumatic transportation of powdered flammable materials (charcoal).
●●●

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CHAPTER 2 LITERATURE SURVEY:

Nitrogen is a chemical element with symbol N and atomic number 7. Elemental nitrogen is a
colorless, odorless, tasteless, and mostly inert diatomic gas at standard conditions,
constituting 78.09% by volume of Earth's atmosphere. Nitrogen is formally considered to have
been discovered by Scottish physician Daniel Rutherford in 1772,

Nitrogen gas is an industrial gas produced by the fractional distillation of liquid air, or by
mechanical means using gaseous air (i.e., pressurized reverse osmosis membrane or Pressure
swing adsorption). Commercial nitrogen is often a byproduct of air-processing for industrial
concentration of oxygen for steelmaking and other purposes. When supplied compressed in
cylinders it is often called OFN (oxygen-free nitrogen).[5]

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In a chemical laboratory it is prepared by treating an aqueous solution of ammonium

chloride with sodium nitrite.[6]
NH4Cl (aq) + NaNO2 (aq) → N2 (g) + NaCl (aq) + 2 H2O (l)

Small amounts of impurities NO and HNO 3 are also formed in this reaction. The impurities
can be removed by passing the gas through aqueous sulfuric acid containing potassium
dichromate.[6] Very pure nitrogen can be prepared by the thermal decomposition of barium
azide or sodium azide.[7]
2 NaN3 → 2 Na + 3 N2
Now coming to the modern process, which is the liquefaction of air and subsequent
rectification of the liquid air. Which will be the main concern in this report; few
pioneers who were responsible in the gradual development are Noothmore, who was the first
to produce chlorine in its liquid form in 1806, Faraday who succeeded in liquefying many
gases by the application of pressure. But still gases such as H 2, O2, and N2 for many years
resisted all attempts to liquefy them and were therefore called permanent gases.Investigations
in 1863by Andrew revealed that gases could not be liquefied however great the pressure
applied, until the temperature of the gas is below a certain limit, this temperature is called
‘critical temperature’. Further in this field two French scientists Pictat and Caillete in 1877
actually succeeded in liquefying first nitrogen and then many other gases.
Pictat merely elaborated the Faraday tube experiment using high pressure and low temp gas
already liquefied as the refrigerant, while Caillete on the other hand obtained this
refrigerating effect by suddenly expanding a gas under high pressure
Rest was for Deval, Linde and Hampson in 1844 to adopt Cailletet’s method to a practical
continuous process and prof.Linde is credited today with the first man producing liquid
nitrogen on a commercial scale.
The components presented in air (Nitrogen, Oxygen, Argon etc.) are very often
applied components in chemical technology. Large quantities of high‐purity air products are
used in several industries, including the steel, chemical, semiconductor, aeronautical,
refining, food processing, and medical industries. Distillation of air is currently the most
commonly used technique for production of pure oxygen, nitrogen and Argon on an
industrial scale. Much has been written concerning the design of air separation processes and
certainly the world wide patent activity for flow sheet and equipment innovation continues.

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Advanced control has been practiced in the air separation business for decades.
●●●

CHAPTER 3 PROCESS SELECTION AND PROCESS

DESCRIPTION
Separation of air by various methods in to its constituent gases is currently the most
commonly used technique for production of pure oxygen, nitrogen and Argon on an
industrial scale.
3.1 AIR PROPERTIES:
Air is a mixture of gases, consisting primarily of nitrogen (78 %), oxygen (21 %) and the
inert gas argon (0.9 %). The remaining 0.1 % is made up mostly of carbon dioxide and the
inert gases neon, helium, krypton and xenon.

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Figure 3.1: Air composition

Air can be separated into its components by means of distillation in special units. Air is
usually modeled as a uniform gas with properties averaged from the individual components.

3.2 AIR SEPARATION TECHNOLOGIES:

Air separation plants are designed to generate oxygen, and argon from air through the
process of compression, cooling, liquefaction and distillation of air. Air is separated for
production of oxygen, nitrogen, argon and ‐ in some special cases ‐ other rare gases (krypton,
xenon, helium, neon) through cryogenic rectification of air. The products can be produced in
gaseous form for pipeline supply or as cryogenic liquid for storage and distribution by truck.
One of the largest producers of air separation plants is Lined Company. It has built approx.
2,800 cryogenic air separation plants in more than 80 countries (Source:http://tn‐sanso‐
plant.com/en/air.html [4]) and has the leading market position for air separation plants.

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Figure 3.2: Air separation Scheme

Air can be separated into its components by means of distillation in special units. So‐called
air fractionating plants employ a thermal process known as cryogenic rectification to separate
the individual components from one another in order to produce high‐purity nitrogen, oxygen
and argon in liquid and gaseous form. Different type of air separation technologies was
developed:
 Cryogenic Air separation
 Membrane Air separation
 Separation by adsorption
 Other
Different technologies are applicable for different requirement on amount and purity of the
products. Figure (2.3) shows the Oxygen production process selection grid. A similar graph
describing the ranges for which the different nitrogen processes are applicable can be seen in
Fig. (2.3)

Figure3.3: Selection Diagram for N2 production process (2008) [11]

3.3 PROCESS SELECTION - CRYOGENIC AIR SEPARATION [12]:

Cryogenic air separation process is one of the most popular air separation process, used
frequently in medium to large scale plants. It is the most preferred technology for producing
nitrogen, oxygen, and argon as gases and/ or liquid products and supposed to be the most cost
effective technology for high production rate plants. In today's market scenario, all liquefied

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industrial gas production plants make use of cryogenic technology to produce liquid
products. There are different variations arising from differences in user requirements in the
cryogenic air separation cycles to produce industrial gas products. The cycle of processing
depends on:
 How many products are required (whether simply oxygen or nitrogen, both oxygen
and nitrogen, or nitrogen, oxygen and argon).
 Required purities of the products.
 Gaseous product delivery pressures.
 Lastly whether the products need to be stored in Liquid form.
In the cryogenic gas processing, various equipment is used like the distillation columns, heat
exchangers, cold interconnecting piping etc. which operate at very low temperatures and
hence must be well insulated. These items are located inside sealed "cold boxes". Cold boxes
are tall structures with either round or rectangular cross section.

Basic steps of cryogenic air separation:

1. First Step: The first step in any cryogenic air separation plant is filtering and
compressing air. After filtration the compressed air is cooled to reach approximately
ambient temperature by passing through air‐cooled or water‐cooled heat exchangers.
In some cases it is cooled in a mechanical refrigeration system to a much lower
temperature. This leads to a better impurity removal, and also minimizing power
consumption, causing less variation in plant performance due to changes in
atmospheric temperature seasonally. After each stage of cooling and compression,
condensed water is removed from the air.
2. Second Step: The second step is removing the remaining carbon dioxide and water
vapor, which must always be removed to satisfy product quality specifications. They
are to be removed before the air enters the distillation portion of the plant. The
portion is that where the very low temperature can make the water and carbon dioxide
to freeze which can be deposited on the surfaces within the process equipment. There
are two basic methods to get rid of water vapor and carbon dioxide ‐ molecular sieve
units and reversing exchangers.

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3. Third Step: The third step in the cryogenic air separation is the transfer of additional
heat against product and waste gas so as to bring the air feed to cryogenic
temperature. The cooling is usually done in brazed aluminum heat exchangers. They
let the heat exchange between the incoming air feed and cold product and waste gas
streams leave the air separation process. The very cold temperatures required for
distillation of cryogenic Products are formed by a refrigeration process comprising
expansion of one or more elevated pressure process streams.
4. Fourth Step: This step involves the use of distillation columns to separate the air into
desired products. For example, the distillation system for oxygen has both "high" and
"low" pressure columns. Nitrogen plants can have one or two column. While oxygen
leaves from the bottom of the distillation column, nitrogen leaves from the top. Argon
has a boiling point similar to that of oxygen and it stays with oxygen. If however high
purity oxygen is needed, it is necessary that at an intermediate point argon must be
removed from the distillation system. Impure oxygen produced in the higher pressure
distillation column is further purified in the lower pressure column.

This process mainly comprises of two steps. One is the liquefaction & then the separation of
liquid air into nitrogen & nitrogen. Since the process mainly requires low temp., refrigeration
is necessary. Different cycles are in use to have required refrigerating effect.
For the separation also different types of columns are in use like simple, compound &
double. Taking into consideration the two stages various combinations were proposed.
1. Heylandt liquid nitrogen process
2. Le rought process
3. Kellogg low pressure process
4. Claude process
5. Linde frankl process
Out of the above processes the Claude process and Linde frankl process are really important
processes for the manufacture of nitrogen.
Briefly giving an overview of these two processes.
CLAUDE PROCESS:
This process is characterized by the double expansion engine. After passing through the
preliminary heat exchanger, at 60 atm pressures, part of the air traverses the liquefier from
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top to bottom & is admitted to the base of the dephlagmetar after expanded to 4 atm. The
reset is expanded like wise to 4 atm, in the first stage of the expansion engine, after which it
is again separated into two portions. One is added to the partially liquid air behind the valve,
the other is warmed by passing up the upper part of the liquefier, & is then expanded to 1
atm.In the second stage of the engine, the expanded air there upon mixes with the cold
nitrogen vapor emerging from the top of the column & returns through the lower part of the
liquefier & through the preliminary heat exchanger. The nitrogen in this air is wasted. The
refrigerant between the tubes of the dephlagmator is liquid nitrogen from the column, part of
which is withdrawn through tube.

Fig 3.4 t-s Diagram for Claude process.

3.4 PROCESS DESCRIPTION LINDE-FRANKL PROCESS:

This is the most important process for the commercial production of nitrogen in this process
at first air is filtered & compressed to 6.8 atm in turbo compressor CC 1. During the
compression cooling is done to maintain the temp to 35 -40 0C.After compression the air is
divided into two streams. One is 65% stream & the other is 35%, now the larger stream is
then passed through after cooler C 1 and heat exchanger HE1 where it is cooled to -150 0C to -
1700C by the incoming pure nitrogen & waste nitrogen streams produced from rectification
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columns. The smaller stream is passed through reciprocating compressor CC 2 to increase the
pressure to about 200atm.Here the air temp is maintained at 4-8 0C by intermediate cooling
between stages using cold water obtained by ammonia refrigeration. Then the air goes
through high pressure heat exchanger HE 2 where the temp of air is brought down to about-
120 -1400C. Now the air undergoes expansion to about 6.5 atm in the expansion engine EE1
The temperature of air is brought down to -170 to-1740Cby Joule Thompson effect. Now the
air will be in liquid state & mixes with the larger stream & changes the whole air stream into
saturated liquid state.
This saturation liquid is fed to Linde rectification column DD1. This column may be single,
double or compound depending on requirement. the liquid product coming out will have a
purity of about 99.4 -99.99%.This liquid is partially vaporized in condenser, to liquefy the
nitrogen vapor & the rest may be taken as liquid product or it may be obtained in gaseous
state if it is used for cooling of incoming air, the other products that obtained are pure
nitrogen of purity above 98% & waste nitrogen product of purity of about 92-96%.These
cold streams are utilized for cooling air, this process is most economical for tonnage nitrogen
plants &most widely used in the world.

Fig 3.5 T-S diagram for the process

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The stream from the lower column is passed to the column DD2.The streams from the
column is passed through heat exchanger 4 HE4 for the heat recovery. These cold streams are
used for refrigeration of inlet feed air.

Fig 3.6. Process Flow sheet of Linde frankl process

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3.6 PROCESS VARIABLES:

1. Initial temperature: The initial or the entrance temp for air is an independent
variable. Although it varies from 10 to 500C depending on the weather conditions and
the type of after cooler, for most cases, it is assumed as 27-300C.
2. Initial pressure: This is an important variable; it is independent in the case of liquid
nitrogen process. The lowest allowable value of pressure is controlled by the
saturation temp. Of air or nitrogen, this must be higher than the boiling point of
nitrogen at column pressure. In a double column, the air pressure must be such that
the nitrogen will condense at the temp of boiling point of nitrogen in order to produce
reflux. This will be in the 4-6.5atm range, depending on the pressure in the lower
pressure column, and on the necessary temperature difference in the condenser boiler.
3. Temperature approaches: An analysis of the process shows that it is necessary to
establish the minimum temp approaches for heat exchangers. For the exchange of
sensible heat, the minimum approach has to be 3-50C
4. Temperature level of refrigerants: vapor liquid refrigerants may be used at almost
any temp level down to liquid air temperature provided the right material is chosen.
The following is a list of common refrigerants’ with the temp to which they can cool
air.
Refrigerant temperature (0K)

 Sulphur dioxide 263

 Methyl chloride 249
 F_12 244
 Ammonia 240
 Propane 231

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 Ethane 184
 Ethylene 169
 Methane 111
 Nitrogen 77

5. Intake temperature to expander: this variable has the flexibility of being at almost
any value between the room temp and one close to that of air liquefaction, without
appreciable effect on the efficiency of expander. It is so chosen that the exhaust is
saturated vapor.
6. Purity of product gases: this is fixed at some value less than 100%,with due regard
to certain limitation that may set a definite upper limit with a single column, the
product nitrogen purity cannot exceed 93%.in case of producing liquid nitrogen, the
available refrigeration may set a still lower limit.
7. Heat leak: this is one of the most difficult variables to be selected since it depends on
factors which cannot readily be evaluated in advance. For e.g. the size of the plant is
of at most importance. Although the leak on an hourly basis increases when expressed
the basis increases as plant size increases when expressed the basis of a unit of air
treated or nitrogen produced, it decreases and in large plants, is almost negligible.
8. Energy requirement: once the various quantities, temp, pressure are established the
work done by the compressors and expanders, and hence the energy requirements can
be easily calculated.
9. Sizes of equipment units: The thermodynamic analysis plays an important role in
this variable, since it deals with the driving forces in the heat exchangers and in
distillation columns. The type of column chosen also plays a big role in the operation
of the unit. There are 3 types of columns that can be used for rectification namely
simple, double and compound. Simple consists of only an exhausting column and
liquid feed to it consists only the reflux. It has an adv of simplicity and economy of
distribution and construction, but the disadvantage is that it suits only moderate yield
of nitrogen since nitrogen leaving the column can never be enriched beyond 93%.The
compound column has both exhausting and enriching sections, but it must be
provided with a source of refrigeration at a very low temp, ie below the B.P.of

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nitrogen at the operating pressure of the column. The double column has two
rectification columns operated at two different pressures, so chosen that the nitrogen
at high pressure column condenses at a temperature above the boiling point of
nitrogen of low pressure column. Usually the pressure in the high pressure column is
6-7 atm and in the other is 1.5-2 atm. This has the adv of high yield without auxiliary
refrigeration, but it is expensive and complicated to manufacture. But on the tonnage
scale, double column is preferred of high yield and high purity.

3.6 THERMODYNAMICS OF THE PROCESS:

The computation of absolute minimum work required for air separation and nitrogen
liquefaction with the case is possible. It known that this work is given as:
W=H-T0.S
In air separation is zero if one neglects the enthalpy of mixing. The valve of S may be shown
that the enthalpy change accompanying the mixing of pure nitrogen and pure nitrogen to
yield one mole of a mixture of x mole fraction of O2 is
S = RX lnX +R (1-X) ln (1-X)
A similar expr may be written for a mix of mole fraction Y
So the entropy of M1 moles of air relative to pure O2 andN2 is
0.21Rln0.21+0.79ln0.79
Accordingly if M1 moles of air to be separated into M2 moles of O 2 rich gas of composition
X2 mole fraction O2 and M3 moles of nitrogen lean gas of X 3 mole fraction of O2 ,the overall
entropy change will be,
S = R [ M2 { (2X2 lnX2 )+(1-X2) ln (1-X2) } + M3{ (X3 lnX3 )+(1- X3 )ln(1-X3 ) }]
-RM1 {0.21ln0.21+0.79ln0.79}
This expression when multiplied by ambient temp., usually taken as 303K yields the
theoretical minimum energy requirement.
Now the material balance equations are:
M1=M2+M3
0.21M1=X3 M3+X3 M3
Defining M2 and M3 for chosen values of M1, X2 and X2.
Prior to the selection of the process it should be emphasized that there are so many adjustable

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variables involved, it is very difficult to put all on a comparable basis. Usually on the
smallest scale, the most important economic factors are capital and labor charges.
Thermodynamic efficiency and hence power charges for compression are of less
consequence. Charges for material such as compressor oil, chemicals for air purification are
small in relation to the other costs. The labor charges also decreases when the scale increases
and in this cases the capital costs and power costs dominate. When the plant produce a liquid
product, as in this case the power requirement to provide necessary refrigeration is
considerably increased and thermodynamic efficiency is of much importance.
The essential requirement on a general scale is a cheap and simple plant, easy to operate for
which a thermodynamic efficiency is not needed. But if the liquid is produced on a large
scale, the thermodynamic efficiency becomes important.
As the purpose of this project is to design large scale nitrogen product plant the only process
that seems economical is the LINDE FRANKL PROCESS.
As the most important adv here is the high purity of nitrogen (99.5) %, although the work of
liquefaction of air is about 3.5kwh/gallon which is relatively higher than other process. Also
the outgoing streams from the rectification column are used effectively in supplying the
required refrigeration for cooling the incoming air.
In view of all the above cited advantages the process for this project is LINDE FRANKL.

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CHAPTER 4 MASS AND ENERGY BALANCE:

MASS BALANCE:
Before any significant design procedure is carried out, the most important part to be
considered is the material balance. Material balances are the basis of process design. A
material balance taken over complete process will determine the quantities of raw materials
required and products produced. Balances over individual process set the process stream
flows and compositions. Material balance involves calculation of the product formed at the
end of the process and also the loss of the product occurred inherently in the process. Various
assumptions have to be made while carrying material balance, which are clearly stated where
used .The general conservation equation for any process can be written as:
Material out = material in + generation – consumption + accumulation
For a steady state process the accumulation term is zero. If a chemical reaction is taking
place a particular chemical species may be formed or consumed. But if there is no chemical
reaction, the steady state balance reduces to,
Material out = Material in
A balance equation can be written for each separately identifiable species present, elements,
and compounds and for total material.
ENERGY BALANCE:
The first law of the thermodynamics says that energy is conserved in the process.Energy is
converted from one form to another. It can neither be generated nor destroyed.
Energy out = Energy in

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 Nitrogen

4.1 OVERALL BALANCE:

CAPACITY of the unit is, 205 T/day of gaseous oxygen of 99.95 % purity. And 10 t/day of
liquid nitrogen of 99.97% purity.
So total oxygen production = 215 T/day
= (215*1000) / (24*32)
= 281.25 kmol / hr
At standard temperature and pressure, 1kmole occupies 22.4m3
Nitrogen produced in volumetric units = 281.25*22.4
= 6300Nm3/hr
Standard analysis of air:
Component volume%
Nitrogen 78.030
Oxygen 20.990
Argon 0.9400
Hydrogen 0.0100
Helium 0.0003
Krypton 0.00011
Xenon 0.00009
Carbon dioxide 0.03-0.06
Moisture 0.02-0.05
Quantity of intake air:
Capacity of the unit = 6300m3/hr of oxygen
Volume % of oxygen in the air = 21%
Quantity of air needed = 6300/0.21
= 30000m3/hr
Assuming about 15% less of air due to removal of moisture, CO2 and from possible leaks.
The quantity needed = 30000+30000 *.15

24
 Nitrogen

=34500m3/hr
= 34500*0.44509
=1535.5605 Kmol/hr

Material Balance for Nitrogen:

Moles of Nitrogen: Total moles of air – Total moles of oxygen produced

= 1535.5605 – 281.25
= 1254.6126 Kmol/hr
Total Capacity of gaseous nitrogen of 99.95%
= (1255.6126 * 14*24) /1000
= 421.8853 t / day
Total Capacity of nitrogen = 421.8883 + 10
= 431.8853 t /day
EQUIPMENT WISE MASS AND ENERGY BALANCE:
Atmospheric conditions :
Temperature =300C, relative humidity =60%
Now the air passes through elements of the system

4.2 COMPRESSOR CC 1:
AIR INLET OUTLET UNIT
TEMP 30 38 C
PRESSURE 1 6.8 ATM
ENTHALPY 3701.84 3766.23 Kcal/kmol
TOTAL ENTHALPY 5684399.3 5783274 kcal/hr

 Enthalpy of air at 1 atm and 300C = 3704.18 kcal/kmol.

 Enthalpy of air at 6.8 atm and380C = 3766.23 kcal/kmol
 Moles of air entering compressor = 34500Nm3=1535.56 kmol/hr
 Enthalpy of air entering compressor = 1535.56 * 3701 kcal/hr
=5701515.3kcal/hr

25
 Nitrogen

 Enthalpy of air leaving the compressor = 1535.56 * 3766.23

=5800672.1kcal/hr.
So change in enthalpy of air = 5800672.1-5701515.3
= 99156.8kcal/hr
Now the air is split into two streams one is 65% and the other is 35%. Larger stream
passes through refrigeration cycle and the smaller stream passes through compression
cycle and then expanded in expansion engine.

4.3 MASS AND ENERGY BALANCE FOR REFRIGERATION CYCLE:

65% stream is routed to refrigeration cycle
Amount of air passing = 1535.56*0.65
= 998.114325 K mol /hr
First air stream passes through water cooler
4.3.1 WATER COOLER C1:
MASS BALANCE:
INLET OUTLET UNIT
TEMP 38 8 C
PRESSURE 6.8 6.5 ATM
REL. HUMI 60 100 %
VAP PRESS 49.692 8.045 mm Hg
PARTIAL PR. 29.8152 8.045 mm Hg
MOLES OF AIR 998.1143 995.539 kmol/hr
DRY AIR 994.534 994.534 kmol/hr
MOLES OF WATER 3.581972 1.00693 kmol/hr

So partial pressure of water at 380 C =.6*49.692

=29.82cm of Hg
Total pressure is 760*6.8 = 5168 mmHg
Now ,
P = (H1 *Pt)/ (Mw/Ma+H1) from Perry’s handbook eq 15.6
Where

26
 Nitrogen

P = partial pressure in mm Hg
Pt = total pressure in mm Hg
Mw = molecular weight of water = 18
Ma = molecular weight of air =29
H1 = molal absolute humidity in kg moles of water vapor / kg moles of dry air
Substituting the values in the formula, we get
H1 = 3.6*10-3 kmol of water vapor / kmol of dry air
Let us assume air coming out from the cooler is saturated
So final humidity = 100%
Vapor pressure of water at 80 0C =8.045 mm Hg.
Final partial pressure of water = 8.045 mm of Hg
Total pressure = 6.5 *760 =4940 mm of Hg
Using the same equation, we get
H2 = 1*10-4 kmol of water vapor /kmol of dry air
Let the amount of dry air be M kg moles
Now M +.0036M = 998.11
M = (998.1/1.0036)
M =994.539 kmol of dry air
So amount of water contained =994.534(.0036-.000968)
=2.575 kmol /hr
 Moles of air coming out of cooler
= 998.114 - 2.575
= 995.539 kmol / hr
 Hence water at the inlet
= H1 * M
= 0.0036 * 994.539
=3.581972kmol/hr
 Water at Outlet in air
= 0.0001 * 994.534
= 1.00693 kmol / hr

27
 Nitrogen

ENERGY BALANCE:
AIR INLET OUTLET UNIT
TEMP 38 8 c
PRESSURE 6.8 6.5 atm
ENTHALPY 3766.23 3573.09 Kcal/kmol
995.5392
MOLES OF AIR 998.114325 9 kmol/hr
3557151.
TOTAL ENTHALPY 3759128.11 5 kcal/hr

 Enthalpy of entering air = 3766.23 kcal/kmol

 Enthalpy of outgoing air
 Enthalpy of entering air
 Enthalpy of leaving air
 Change in enthalpy of air
= 3573.09 kcal/kmol
= 998.114 * 3766.23
=3759128.114kcal/hr
= 995.542 * 3573.09
=3557151.47kcal/hr
=3759128.114 – 3557151.47 kcal/hr
= 201976.642 Kcal/hr

4.3.2 HEAT EXCHANGER HE1:

Air entering in a heat exchanger = 994.534 kmol/ hr
Volume % of CO2 in air = 0.045%
Moles of CO2 present in air entering = 998.492*0.045/100
= 0.4493 kmol/hr
Amount of dry air leaving heat = 994.534 - 0.4493
Exchanger = 994.08601 kmol /hr
This is cooled to -1680 C by circulating pure nitrogen and waste nitrogen streams coming

28
 Nitrogen

from distillation column.

Total Amount of pure nitrogen is 361.61 kmol / hr. It splits into 2 streams one passes through
this heat exchanger and other through high pressure heat exchanger in the compression cycle
Let the amount of pure nitrogen stream passing this exchanger is M kg.
Amount of waste nitrogen is 892.69 kmol /hr.
Table shows the inlet and outlet conditions of air, pure nitrogen, waste nitrogen, carbon
dioxide, moisture.
Conditions and enthalpy of streams: from enthalpy chart.
Stream Flow rate Temp0 C Pressure (atm) Enthalpy(kcal/kg)
Kmol/hr
Dry air Inlet 994.534 8 6.5 3573.09
Outlet 994.08601 -168 6.5 2092.35
Pure N2 Inlet - M -178 1.5 1500
Outlet - M 4 1.5 2750
Waste N2 Inlet – 892.69 -172 1.5 1510
Outlet – 892.69 6 1.5 2800

CO2 Inlet - 0.4493 8 6.5 28691.52kcal/hr

Outlet - nil Soli at -56.6 6.5
Moisture Inlet – 1.00693 8 6.5 1667.483kcal /hr
Outlet - nil Solidifies at - 4 6.5

Calculations:
Heat given up by dry air = 994.534 (3573.09-2092.35)
=1472646 kcal/hr
Heat given up by CO2 :
CO2 at first cools from 8 to -56.6 0 C and then solidifies
Specific heat Cp is 10.34 +0.0027T-195500/T in kcal/kmol K
T is absolute temp in k
 Sensible Heat lost by CO2 on cooling to -56.6 from 8 C
T1=298 k = inlet temperature
T2=216.4 k= outlet temperature
29
 Nitrogen

T1
∫ M CpdT
T2

= 27794.73 Kcal/hr
 Heat of sublimation of CO2 = 1993.83 kcal/kg mole
 Heat lost by CO2 on freezing = 0.4498*1993.83 kcal/hr
= 896.83 kcal / hr
 Total heat lost by CO2 = 27794.73 +896.83
= 28691.56 kcal/hr
WATER:
Heat lost by water molecule by
Cooling to -4 = 1.006 *18(8-(-4))
= 217.4972 kcal /hr
 Heat lost by water molecule on freezing
=1.006 *80*18
= 1449.985kcal/hr
Latent heat of condensation = 80 kcal/hr
So total heat lost by water = 217.4972 +1449.985
=1667.483kcal /hr
 Heat gained by water nitrogen stream
=892.67 (2800-1500)
= 1151750.7 kcal /hr
 Heat gained by pure nitrogen
= M (2750-1510)
= 1240M
1151750.7+1240M = 1476264.4+28691.56+1667.483
1204M = 318822.81
M = 281.0036 kg moles/hr
The amount of pure nitrogen passing through heat exchanger = 281.0036 kmol/hr
Amount of pure nitrogen routed to compression cycle = 361.61 – 281.0036

30
 Nitrogen

=80.606 kmol / hr

4.4 MASS AND ENERGY BALANCE FOR COMPRESSION CYCLE:

Amount of air passing = 34500*.35
=1207/22.4
=539.063kmol/hr
4.4.1 COMPRESSOR CC2:
INLET OUTLET UNIT
TEMP 38 8 C
PRESSURE 6.5 200 atm
ENTHALPY 3766.23 3251.119 Kcal/kmol
TOTAL ENTHALPY 2024145.908 1747301.5 kcal/hr

 Before compression, air is at 6.5 atm and 38 0C

 And after it is at 200 atm & 6 0C
 Enthalpy of inlet air = 3766.23 kcal/kmol
 Enthalpy of outlet air = 3251.119 kcal/kmol
So net enthalpy of entrance = 3766.23*539.063 kcal/hr
= 2024145.2kcal/hr
And for exit air net enthalpy =539.063*3251.119 kcal/hr
= 174730.15 Kcal/hr
Assuming no condensation of water vapor
The net change in enthalpy of air = 2024145.2 - 174730.15
=276844.437 Kcal / hr
4.4.1 CO2 ADSORBER : Used to remove CO2 and moisture from the air stream.
 Volume % of CO2 in air = 0.0454%
 Moles of CO2 present = 0.045*539.063/100

31
 Nitrogen

=0.2426 kmol/hr
Water Balance:
 From the earlier calculations, molar humidity of air H1 = 3.6*10-3
If G is the amount of dry air in kg mole/hr then G +.0036G=539.063
So G=538.478 kg moles/hr
Moisture present 539.063-538.478 = 0.535kmol/hr
4.4.2 HIGH PRESSURE HEAT EXCHANGER HE 2:
No change in mass. Now heat balance, from enthalpy chart in Perry’s
handbook

STREAM CONDITIONS INLET OUTLET UNIT

PURE TEMP -178 4 C

NITROGEN PRESS 1.5 1.5 atm
ENTHALPY 1500 2750 Kcal/kmol

MOLES 80.606306 80.60631 kcal/hr

TEMP -178.2 2 C
OXYGEN PRESS 30 30 atm
ENTHALPY 2161.6 3328.64 Kcal/kmol

MOLES 267.86 267.86 kcal/hr

TEMP 6 -150 C
PRESS 200 200 atm
2481.997
AIR ENTHALPY 3251.119 9 Kcal/kmol
MOLES 537.44618 537.4462 kcal/hr

 Heat taken by pure nitrogen stream= 80.606(2750-1500)

= 100757.8827kcal/hr
 Heat taken up by oxygen stream = 267.86 (3328.64-2161.6)

32
 Nitrogen

= 312603.33kcal/hr
 Heat lost by air in High press HE = 538.478(3251.119-H)
 Heat lost by air = Heat gained by N2 + Heat gained by O2
Hence, 538.478(3251.119-H) = 100757.8827 +312603.33
H = 2481.9979 Kcal / hr
Now the corresponding temp of air is -1500 C
So the air entering the expansion engine is at 200 atm and -150 0 C. Here air is expanded to
6.5 atm the temp. Of air after compression is -174 0 C(liquid state).Now both the air streams
are mixed. And finally the temp is at -172 0 C and will be in saturated liquid state and fed to
lower distillation column.

 The set up of nitrogen plant consists of two Linde column:

Upper column (1.5 atm)
Lower column (6.5atm)
The equilibrium data is as follows for lower column.

TABLE A FOR EQUILIBRIUM DATA OF AIR

Temp. 0 C Liquid composition Vapor composition
X% Y%
-160.9 0 0
-163.0 2.5 6.5
-165.0 17 32.5
-167.0 27 48.5
-168.0 32.5 50
-170.0 45 68
-172.0 60 79.5
-174.0 79 90
-175.0 89 95
-176.0 100 100

33
 Nitrogen

●●●

CHAPTER 5 EQUIPMENT DESIGN

5.1 DOUBLE DISTILLATION COLUMN:

In an air separation unit for separating air by cryogenic process, thereby recovering oxygen,
nitrogen and Argon, column of duplex type rectification tower is used. The air is fed into the
lower column with higher pressure. Liquid nitrogen is introduced into the upper column as a
reflux from lower column and a oxygen rich stream from the bottom of the lower column is
fed to the bottom of the higher column. Distillate from the upper column is practically pure
Nitrogen, bottom of this column in Oxygen and Argon reached stream is removed from the
middle part of the upper column

Figure 5.1: Air Distillation Double Column

34
 Nitrogen

1‐ Liquid oxygen and air 2‐ Bottom column

3‐ condenser – reboiler 4 –upper column
5 – Stages 6‐ Liquid nitrogen packet
7‐ valve 8‐ pipes

Distillation column combined from bottom column (2), condenser and reboiler (3) and upper
column (4). Bottom column work under 5.5‐ 6.5 at pressure and its allocation for preliminary
distillation of air in to nitrogen and mixed of oxygen and air that has 60 – 65% nitrogen and
35 – 40 % oxygen. In upper column that works at 1.3 – 1.4 at for finally distillation of mixed
oxygen and air in to nitrogen and oxygen . The produced Nitrogen, Oxygen and Argon purity
is: Mol fraction of oxygen 98.7%, mol fraction of nitrogen 99.0%, mol fraction of
Argon99.5%.
5.1.1 PROCESS DESIGN OF A DISTILLATION COLUMN:
V1 L2 (REFLUX TO THE UPPER
COLUMN)

L1 REFLUX TO LOWER COLUMN

SIDE STREAM S
FEED (AIR) F

W- OXYGEN RICH STREAM TO

UPPER COLUMN

Figure 5.2: LOWER DISTILLATION COLUMN

35
 Nitrogen

Typical distillation column with reflux and reboiler

 For mass balance, total air entering the column =998.114 + 537.446
F =1535.55 kmol / hr
 From an overall balance of Linde column kg moles of nitrogen coming out
= 6300/22.4
=281.25 kmol / hr

 So amount of waste nitrogen issuing out col = 1535.55-(361.61+281.25)

=892.69 kmol / hr

 Let the liquid to vapor ratio at the top of both columns to be 0 .58
So L1’/V1’=L2’/V2’=.58
Suffix 1 for LOWER column
Now V2’=361.61 kmol / hr
L2’= 0.58 * 361.61
=209.734 kmol / hr
This L2’ comes out of condenser in vapor state and fed at the top of upper column as
liquid after passing through expansion valve.
Hence overall balance at the top of the lower column gives,
0.58V1’+209.734 = V1’
0.42V1’ = 209.734
V1’ = 499.366 kmol / hr
 The amount L1’ refluxed to the lower column after condensation occurs in the
condenser = 0.58 * 499.366
L1’ = 289.632 kg moles/hr
 F = amount of feed =1535.55 kmol/hr
 W = bottom product from lower which is refluxed back to the top column ( rich liq)
 S = side stream from lower column, which is refluxed back to top column (impure
liquid)
 Xf = mole fraction of N2 in feed = .79
36
 Nitrogen

 Xw = mole fraction of N2 in rich liquid =.65

 Xs = mole fraction of N2 in IPL=.96
 X1 = mole fraction of N2 in top product = .9999
Now, from overall& component balance
F = W + S + L2 (1)
Component Balance on Nitrogen,
FXF = WXw +SXs + X1L2 (2)
From (1) 1535.55 = W + S +209.734
W +S = 1325.816

From (2) (1535.55 *.079) = (W*.65) + (S*.96) + (209.734*0.9999) (4)

1003.3714 = 0.65W + 0 .96S
Multiplying (3) by .65
0.65W +0.65S = 0.65 * 1325.816 (5)
Subtracting 5 from 4
141.591= S (0.96-0.65)
S=456.746 kmol / hr
From 3
W = 1325.816-456.746
= 869.07kmol/hr
Also calculating for middle section of the column
L1’/V1’ = .58 = L1’’/V1’’
L1’’/V1’’ = (456.746-289.633)/499.366
L1’’/V1’’ = .335 slope for side stream
The stream S is taken out as liquid
Hence amount of liquid flowing to the stripping section,
= 456.746 – 289.663 + 1535.55
= 1702.633 kmol / hr
V1’ = V1’’=V1’’’
Similarly calculating slope for the exhausting section,
L1’’’/V1’’’ = (1535.55+167.112)/499.366
37
 Nitrogen

L1’’’/V1’’’ = 3.4 slope of stripping line.

Using the equilibrium composition data at 6.5 atm, the curve is drawn from XL1=.9999 the
operating line is drawn with L1’/V1’=0.58
The side stream being taken out is impure liquid of 96% of N2
For this point from which the operating line of slope L1’’/V1’’ = 0.335 is drawn will be
Xs1 = [(456.746*.96) + (209.734*0.9999)]/456.746+209.734
= 0.978
These 2 operating lines are seen to be intersecting at X =0.96
Now the operating line for exhausting section is drawn from Xw =0.65 with slope
L1’’’/V1’’’ =3.4

Figure 5.3: Equilibrium diagram

38
 Nitrogen

Figure 5.4: McCabe & Thiele graph

Plate efficiency

Where µ is the average molal viscosity of the feed in cp

 µ Of liquid O2 = 0.19 Cp
 µ Of liquid N2 =0.24 Cp
 Avg molal µ of feed = .79*.24 +.21*.19
= 0 .2295 Cp
= 0 .6127
So actual no. of plates = 17.3/.6127= 27.249
So no. of plates = 28
 From graph, feed enters the 15th plate.
 Actual plate at which feed enters = 15/.6127 = 23.952 = 24
 Feed enters on 24th plate
 From graph, side stream is taken out from 5th plate
Actual plate from which side stream is taken out
= 5/0.6127

39
 Nitrogen

=8.16 = 9th plate

 Height of column :
 No. of plates =28
 Plate spacing = 12”
 Spacing at top & bottom = 12”each
 Spacing for feed = 12”
 Total height = ( 28+2)*12
= 360”
Height H = 9.146 m is the height of the column

COLUMN DIAMETER:
FLV top = (L/V)*(v/L) ^0.5 = 0.58 * (7.564/721.565)^0.5
= 0.0593835
FLV bot = (L/V)*(v/L) ^0.5 = 3.4 * (6.693/805.6)^0.5
= 0.3099
Take tray spacing as 0.5 m
From Figure 11.27(Coulson & Richardson's Chemical Engineering - Volume VI)
Base K1 = 0.070
Top K1 = 0.065
Base Uf = 0.059 *((805.6-6.693)/805.6)) ^0.5
= 0.07082 m/s
Top Uf = 0.065 * ((721.565 – 7.564) / (721.565)) ^0.5
= 0.064658 m/s
Design for 80 per cent flooding at maximum flow rate
Base Uf = 0.80*0.07082
= 0.05612 m/s
Top Uf = 0.8*0.064658
= 0.051726 m/s
Vapor volumetric flow-rate is constant through out the column.
Top = (499.366 * 14) / (3600*14*7.564)
=0.25674 m3/s
40
 Nitrogen

Area required
Top area = 0.2567/0.051726
Area (A) = 4.96338 m2
As first trial take down comer area as 12 per cent of total.
 Down comer area =0.12 * 4.96338
= 0.59560 m2
 Coss sectional area = 4.96338 – 0.59560
= 4.3677 m2
 Column diameter = ((4.366 * 4)/3.14)) ^ 0.5
Dc = 2.358 m

FOR TOP AND BOTTOM

Liquid flow pattern
Max liq. Flow rate = (289.332 * 14/3600 * 721.56) = 0.00156 m3/sec
The plate diameter is outside the range of Figure, but it is clear that a single pass plate can be
used.
PROVISIONAL PLATE DESIGN:
 Column diameter Dc = 2.358 m
 Column area Ac = 4.3677 m2
 Downcomer area Ad = 0.12 x 4.3677
= 0.59560 m2, at 12 per cent
 Net area An = Ac - Ad
= 4.3677 – 0.59560
An = 3.772 m2
 Active area Aa =Ac - 2Ad
= 4.3677 – 2*0.5960
Aa = 3.176 m2
Hole area Ah take 10 per cent Aa as first trial = 0.10*3.176 = 0.31762 m2
41
 Nitrogen

Weir length (from Figure 11.31, Coulson & Richardson's Chemical Engineering - Volume
VI)
 lw = 0.76 x Dc = 0.76*2.358
= 1.816 m
 Take weir height 50 mm
 Hole diameter 5 mm
 Plate thickness 5 mm
CHECK WEEPING TOP
Max liq. Rate = 289.6323 * 14/3600 = 1.1263 kg/s
Min liq. Rate at 70% turndown = 0.70 * 1.126 = 0.78844 kg/s
Max how = 750 *(1.1263 / (721.56 * 1.816)) ^ (2/3)
= 6.8115 mm liquid
Min how = 750*(0.7884/ (721.56 * 1.816))^(2/3)= 5.372 mm liq

At min rate, hw + how = 6.8115+5.372 =10.184 mm liq

From fig.11.30 (Coulson & Richardson's Chemical Engineering - Volume VI)
K2 =27
Umin = (27-0.9*(25.4-dh))/ (v^0.5)
= (27-0.9*(25.4-5)) * 0.1 /7.54^0.5
= 0.4123 m/s
Actual vapor velocity = 0.2564*0.7/0.31176
= 0.56761m/s
So, minimum operating rate will be well above weep point.

CHECK WEEPING BOTTOM:

Max liq. Rate = 1697.845*14/3600
= 6.602 kg/s
Min liq. Rate at 70% turndown = 0.70*7.2
= 4.622 kg/s
Max how = 750 *(6.602/(805.6*1.815))^(2/3)
= 23.159 mm liq
42
 Nitrogen

Min how = 750*(4.622/ (805.6*1.815))^(2/3)

= 16.2113 mm liq
At min rate, hw + how = 16.2113 + 50 = 66.2113 mm liq
From fig.11.30 (Coulson & Richardson's Chemical Engineering - Volume VI)
K2 = 29
Umin = (29-0.9*(25.4-dh))/ (6.93^0.5)
= (29-0.9*(25.4-5))*0.1/6.93^0.5
= 0.5067 m/s < actual velocity
So, minimum operating rate will be well above weep point.
PLATE PRESSURE DROP TOP
Dry plate drop
Maximum vapour velocity through holes
Uh = 0.2564/0.31172 = 0.6203 m/s
From Figure 11.34, for plate thickness/hole dia. = 1, and
At/Ap = Af/Aa = 0.1,
C0 = 0.84
hd = 51*((Uh/ Co) ^2)*(v/L)
= 51*((0.4123/0.84) ^2)*(7.564/721.564)
= 0.128814 mm liq
Residual head
hr = (12.5*10^3) /721.54 = 17.323 mm liq
ht = hd + (hw + how) + hr = 0.12184+ (50+5.133)+17.323
= 72.8239 mm liq

PLATE PRESSURE DROP BOTTOM

Dry plate drop
Maximum vapour velocity through holes
Uh = 0.2564/0.31172 = 0.6203 m/s
From Figure 11.34, for plate thickness/hole dia. = 1, and
At/Ap = Af/Aa = 0.1,
C0 = 0.84

43
 Nitrogen

hd = 51*((Uh/ Co) ^2)*(v/L)

= 51*((0.506/0.84) ^2)*(6.93/805.6)
= 0.159663 mm liq
Residual head
hr = (12.5*10^3) / 805.6 = 15.523 mm liq
ht = hd + (hw + how) + hr = 0.159663+ (50+16.2113)+15.523
= 81.89 mm liq
DOWNCOMER LIQUID BACK UP TOP :
Downcomer pressure loss
Take hap = hw — 10 = 40 mm.
Area under apron, Aap = 1.254*40*10^-3 = 0.05 m2.
As this is less than Ad =0.2556 m2 use Aap to calculate hdc
hdc = 166*(1.1263/(721.54*0.05))^2 = 0.1617mm

Back-up in downcomer,
hb = (hw + how)+ ht + hdc = (50+5.133)+72.893+0.167 = 129.79 mm
= 0.130 m

0.130 < (1/2)*(plat spacing + weir height) so tray spacing is acceptable.

Check residence time
tr = (Ad * hb *L )/ Lwd = (0.05 * 0.130 * 721.54)/1.1236
= 4.172sec > 3 sec satisfactory.
DOWN COMER LIQUID BACK UP BOTTOM:
Downcomer pressure loss
Take hap = hw — 10 = 40 mm.
Area under apron, Aap = 1.254*40*10^-3 = 0.05 m2.
As this is less than Ad =0.2556 m2 use Aap to calculate hdc
hdc = 166*(6.62/(805.6*0.05))^2
= 4.48mm
Back-up in down comer,
hb = (hw + how)+ ht + hdc = (50+16.2133)+81.89+4.48 = 152.583 mm

44
 Nitrogen

= 0.153 m
0.153 < (1/2)*(plat spacing + weir height) so tray spacing is acceptable.
Check residence time
tr = (Ad * hb *L )/ Lwd = (0.05 * 0.153 * 805.6)/6.6206
= 3.5sec > 3 sec satisfactory

CHECK ENTRAINMENT:
Uv = Vol flowrate / net area =0.2564 / 3.7112 = 0.05206 m/s
Percent flooding = (0.05206 /0.64658 )*100 = 79.89%
FLV= 0.060 from fig. 11.29 (Coulson & Richardson's Chemical Engineering - Volume VI)
=0.070 well below 0.1.
As the per cent flooding is well below the design figure of 85, the column diameter could be
reduced, but this would increase the pressure drop.

TRIAL LAYOUT:
Use cartridge-type construction. Allow 50 mm unperforated strip round plate edge; 50 mm
wide calming zones.

PERFORATED AREA:
From Figure 11.32 (Coulson & Richardson's Chemical Engineering - Volume VI)
at lw/Dc = 0.76
c = 99°
45
 Nitrogen

angle subtended at plate edge by unperforated strip == 180 — 99 = 81°

Mean length, unperforated edge strips = (2.358 - 50 x 10^-3) x 81/18
= 3.263 m
 area of unperforated edge strips = 50 x 10^-3 x 3.263
= 0.163118 m2
 Mean length of calming zone = (1.816 - 50 x 10^-3) sin (99/2)
= 1.22 m
 Area of calming zone = 2(50 x 10^-3)*(1.816- (2*50*10^-3))
= 0.171629 m2
 Total area for perforations, Ap = 3.176 - 0.16381 - 0.171629
= 2.842 m2
 Ah/Ap = 0.3176/2.842 = 0.1117
From Figure 11.33(Coulson & Richardson's Chemical Engineering - Volume VI) lp/dh =
2.75, satisfactory, within 2.5 to 4.0.
NUMBER OF HOLES:
Area of holes = *(5*10^-3)/4 = 1.963*10^-5 m2
No. of holes = 0.3176/1.963*10^-5
= 16186.33 say 17000 holes

5.1.2 MECHANICAL DESIGN OF DISTILLATION COLUMN

Material for shell is Carbon Steel

THICKNESS OF SHELL
Thickness of shell = ts ts =
[p D / 2f J – p] + c
Where,
Inner Diameter of vessel = Di = 2.366 m
Working Pressure = 6.58 *105 N/m2
Design Pressure = p = 1.05 * 6.58 x105 N/ m2
= 6.9 x 105
Permissible Stress = 118 *106 N/m2
46
 Nitrogen

J= Joint Efficiency = 0.85

Corrosion allowance =2mm
Hence,
ts =10.2mm
We take thickness as 10.2mm(Including corrosion allowance)
So outer diameter of shell Do = 2.366 m + 2 x 0.0102 m = 2.386 m
Axial Stress Due to Pressure
Axial stress due to pressure = fap
fAP = P* Di / 4* ( tS – c )
= 1.05*6.58*105*2.366/4*(10.2-2)
= 49.837*106 N/m2

Stress due to Dead Load:

a) Compressive Stress due to weight of shell up to a distance X
Do = Di + 2 ts
=2.36 + 2*10.2*10-3 = 2.386 m
Density of Shell material = ρs = 7700 kg /m3
fds = π/4 ( Do2 – Di2 )ρs X] / π /4 ( Do2 – Di 2 )
=7.7*103* X N/m2

b) Compressive stress due to weight of insulation at height

Insulator used is asbestos
Thickness of insulation = tins =100mm
Diameter of insulation = Dins
Density of insulation =575 kg / m3(from bhattacharya)
Mean diameter of vessel = Dm = (2.366+2.386)/2 =2.376
For large diameter column
Dins = Do
Fdins = π* Dins tins *ρ ins *X/ π Dm ( ts – c )

47
 Nitrogen

= (100*10-3*575*2.386)*X/(8.2*10-3*2.376)
= 7.04*103 X N /m2

c) Compressive stress due to liquid in column up to height X

Density of liquid = ρl = 900 kg/m3
Number of trays = n=(X-1/0.30)+1) = ((10X-7)/3))
fdliq = [ ( π /4 ) * Di2 * ρ l *((10X-7)/3))*0.05 ]/ π Dm ( ts – c
= 3240*((10X-7)/3)) N/m2
d) Compressive stress due to attachment
 Tray weight is 1 Kn/m2
 Head weight
 Ladder

i. Weight of TRAY : ( π /4 ) * Di2 *1000 *((10X-7)/3))

=4394(10X-7/3) N
ii. Head weight (approximately) = 35000 N
iii. Weight of Ladder = 1600 X N ----------------(4)
Total compressive stress due to attachments fd is given by
fd(attachments) = ( Tray weight + Head weight + Ladder ) / [ π Di ( ts – c ) ]
= (16246.67X + 45252.67)/( π*2.36*8.2*10-3) N
= 266776.19 X +743065.18 N
Stress due to Wind:
Stress due to wind is given by
fwx = M w / Z
Where,
Bendnig Moment = Mw = (0.7* pw* Do* X2)/2
Z = (π /4) *Do2 *( ts –c )
Pressure due to wind = pw = 0.05 x vw 2
Considering velocity of wind be 100Mph (assumed)

48
 Nitrogen

Vw =44.7m/s
pw = 1197 N /m2( from table)
fwx = 1.4* pw *X2 /π Do ( ts – c)
= 27.46*103*X2
To determine the value of X
ft max = 118 *106 N/m2
ftmax = fwx + fap – fdx
118 * 106 (0.85) = (27.46*103X2 +49.837*106) – (266776.19 X +743065.18)
X = 48.3139 m >>9.04 m

DESIGN OF GASKET AND BOLT SIZE

Gasket material is Asbestos Gasket factor=m=2
Minimum design seating stress = Ya= 11.2 N / mm2
Basic gasket seating width bo = N/2
bo = 10 mm / 2 = 5mm
Effective gasket seating width b = 2.5 (bo)1/2
= 6.25 mm
Inner diameter = Di = 2.866 m
Outer diameter = Do = 2.366m + 2 x 8 x 10 –3
Flange inner diameter =Dfi = 3.01 m
Flange outer diameter = Dfo = 3.05 m
Mean diameter = G = (Dfi + Dfo) /2
= 3.03m
Under atmospheric conditions, the bolt load due to gasket reaction is given by
Wm1 = π b G Ya
=π*6.25*103*3.03*68.25*106N
= 4006.73*103 N

49
 Nitrogen

Design pressure = P = 6.503*105*1.10 (10% of allowance is given)

= 6.9* 105 N/m2
After the internal pressure is applied, the gasket which is compressed earlier, is released to
some extent and the bolt load is given by
Wm2 =π(2b) G * m * P + (π/4)G2 *P
= [π*2*6.25*10-3*3.05*2 + π*(3.05)2]6.825*105 =
=49.70*105 N
Bolt used is hot rolled carbon steel
fa is permissible tensile stress in bolts under atmospheric condition f b
is permissible tensile stress in bolts under operating condition
fa=58.7 x106 N/m2
fb = 54.5 x 10 6 N /m2 Am is the area of bolt
Am1= Wm1 / fa

Am2 = Wm2 / fb
Am1= 4006*103/58.7*106
= 0.0682 m2
Am2 = 0.0899 m2
Number of bolts = mean diameter /bo x 2.5
=244 bolts
To determine the size of bolts, the larger of above two areas should be considered
Diameter of bolts = [(Am2 /Number of bolts) x (4/π)]1/2
= [(0.0899/244)*(4/π)]1/2 = 2.166 cm

FLANGE THICKNESS
Thickness of flange tf= [G√(p/K f) ] + c
Where,
K=1/[ 0.3 + ( 1.5 Wm hG)/H x G]
Hydrostatic end force = H = (π /4) G2 P
=(π/4)*(3.05)2*6.8*105

50
 Nitrogen

=4.8*106 N
hG is radial distance from gasket load reaction to bolt circle,
hG = ( B – G )/ 2
= 3.11-3.05/2 = 0.03m
B = outside diameter of gasket + 2 x diameter of bolt +12mm =
3.08 +2*0.90*10-2 +12*10-3
= 3.11 m
Wm = 90*105 N
K= 1/(0.3+(1.5*90*105*0.03/4.8*106*3.05))
K= 3.05
Hence the thickness of flange = 60 mm

HEAD DESIGN: FLANGED & SHALLOW

Material stainless steel
Permissible stress = f= 130 N/mm2
Design pressure = p = 6.9 x 10 5 N/m2
Stress identification factor W is given by
W = (¼) [3 + ( Rc/R1)1/2]
Crown Radius = Rc= 2.366m
Knuckle radius = R1 = 0.142 m
So,
Stress identification factor W is 1.6
Thickness of head =
th = (p x Rc W)/(2f) th= 10 mm
So , we can take thickness of head as that of thickness of shell

NOZZLE THICKNESS
Material Cu
Considering diameter of nozzle = Dn =0.5 m

51
 Nitrogen

Thickness of nozzle =tn

Material is Stainless steel ( 0.5 cr 18 Ni 11 Mo 3)
Permissible stress =130 *106 N/m2
J=0.85
tn=P*Dn /(2 f x J-P)
tn = 1.6 mm
No corrosion allowance , since the material is stainless steel.
We can use thickness of 3mm

SUPPORT FOR COLUMN:

Material used is structural steel ( IS 800) Skirt support is used.
Inner Diameter of the vessel = Di =2.366 m
Outer Diameter of the vessel = Do =2.38 m
Height of the vessel = H = 9.146 m Density
of carbon steel = ρs = 7700 kg/m3 Density of
water = ρl =900 kg /m3
Total weight = Weight of vessel + Weight of Attachments (liquid + tray weight+ headladder
=(π/4) ( Do2 – Di2) * H ρs * 9.81 + (π /4) Di2 * H * ρL * 0.8*9.81 + (π /4) Di2 *
weight of each tray(1000)*no. of trays + 35000N + 1600 * H
=5.055*105 N
Diameter of Skirt is 2.366 m
Considering the height of Skirt is 4m
Wind Pressure is 1197N/m2
Stress due to Dead Weight
Thickness of the skirt support is tsk
Stress due to dead load

52
 Nitrogen

fd = Total Weight /π Ds tsk

= 5.055*105/π*2.366* tsk N/m2
=6.8*104/tsk N/m2

Due to wind load

The forces due to wind load acting on the lower and upper parts of the vessels are determined
as
plw = k p1 h1 Do (for Height less then 20m) for
Height less then 20m
Where K is coefficient depending on the shape factor.
k=0.7 for cylindrical surface
P is wind pressure for the vessel.
P1 = 700 N /m2 { 40-100 Kg/m2}

H=9.142 m
plw = k P1 h1 Do
= 10598.
Bending moment due to wind at the base of the vessel is determined by
Mw = Plw*H/2
=48446.595 N- m
fwb = 4 x Mw / πDo tsk
=4*48446.595 /π*2.366*tsk
=26084.2804/tsk

Stress due to Seismic Load

Load F= CW
W is total Weight of vessel
C is Seismic Coefficient
C=0.08
fsb = ( 2/3)[ CWH/π Rok2 tsk]
Where,

53
 Nitrogen

Rok is radius of skirt =3.32*104/tskN

Maximum Compressive Stress
fcmax = ( fwb or fsb ) + fdb
= (3.32*10^4 + 6.8*10^4)
= (101200 / tsk ) N /m2
Yield point = 200 N / mm2
1/3) Yield point ≥ fcpermissible
= 66.6 N/mm2
tsk= (101200/66)
=32 mm

5.2 CONDENSER DESIGN:

Basic Theory
The fundamental equations for heat transfer across a surface are given by:

Where w is tube side flow and W is shell side flow and CPt is specific heat fr tube side and
CPs is for shell side

In design, a correction factor is applied to the LMTD to allow for the departure from true
countercurrent flow
to determine the true temperature difference.
ΔTm = Ft ΔTm
The correction factor is a function of the fluid temperatures and the number of tube and shell
passes and is correlated as a function of two dimensionless temperature ratios

54
 Nitrogen

The overall heat transfer coefficient U is the sum of several individual resistances as follows

Continuing with our problem .Nitrogen vapors enter counter currently through the tubes of
the condenser, where it meets the liquid oxygen coming out on the bottom product of the top
column. for this purpose, a 1-2 shell and tube condenser is chosen. It is a vertical type
condenser.

55
 Nitrogen

Figure5.5 Condenser

5.2.1 PROCESS DESIGN:

Enthalpy of N2 vapor at 96.5K is 238.35 J/gm=1595.16 cal/kmol
=1595.16 Kcal/kmol.
Enthalpy of N2 vapor at 94.8 K is1592.05 cal/kmol
Enthalpy of N2 liquid at 94.8K is 443.52 cal/kg mol
So total enthalpy change of stream
(499.367*1595.16) (209.734*1592.02+289.633*443.52) =1399009.42KJ/hr
LMTD calculations:

56
 Nitrogen

fig.6
Tha is inlet temp of nitrogen vapor = -176.50 C
Thb is outlet temp of nitrogen = -178.20 C
Tca is inlet oxygen liquid =-179.50 C
Tcb is outlet oxygen vapour =-178.20 C
∆Tl = 1.491
Taking overall heat transfer coefficient as 100 Btu/hrft 2F0=567W/m2 0
C
Now Q = UA∆Tl
From this A comes around 460 m2
Let N is the no. of tubes so total heat transfer area =N*π*D* L
Where D is tube OD
And L is the length
We are choosing 1 inch OD. and 14 BWG cu tubes of 20 inch length and calculating the no.
of tubes obtained is 2360
Also taking a triangular pitch of 1.25 inch that ,nearest no of tubes found from TEMA
regulations is 2362 and shell dia as 1.67 meters
Now the corrected area becomes 460.5m2
So using this value of heat transfer area the U becomes 560.6W/m2 0C
Inside and outside coefficient calculations:
Nitrogen in tube side
Flow area for the given tube is 3.52cm2

57
 Nitrogen

Gas mass velocity = 499.367*28/(3.52*2362/10000*2)=33634.52kg/m2hr

Density of nitrogen =802.6kg/m3
So velocity = .01155 m/sec
So Nre = 822
Condensate loading per linear foot is G’ = W/DNπ
= 88.955 kg /m hr
From graph in kern we get the value of hi = 240 btu/hr ft2 0 F
Also ho = hi*id/od= 22.16 btu/hr ft2 0F
Nitrogen on shell side
Density = 1140 kg/m3
Thermal conductivity =k= 0.07 btu/ft.hr.0 F
Here flow area = As = ID*C’*B/144pt
C’ is clearance taken as 0.25 inch B = baffle spacing = 1 inch i.d. =66 inch Pt =1.25 inch so
As = 1.1 ft2 =11.84m2
Gas mass velocity Gs = W/As = 1535.55*32/11.84=4150.135kg/m2 hr
From this NRE can be calculated by DeGs/µ
We get it as 72824
Now from the graph of jH Vs Nre
jH =175
now ho = jHk/De*(cµ/k)^-1/3
solving ho = 223.61 btu/hr ft2F
=1267.8w/m2 0C
Clean overall coefficient
Uc=hio*ho/(hio+ho)=598.865 w/m2 0C
Dirt factor :
Rd = Uc-Ud/(Uc*Ud)
= 0.0000952m2 0C/w
PRESSURE DROP:
Shell side
No. of crosses = N+1 =8 so no. of baffles =8-1 = 7
For Nre 72824

58
 Nitrogen

Friction factor =0001.4 (graph)

Sp gravity of nitrogen = .00624
Ds= inside diameter in ft and n is the no. of tube passes
So Ps=fGs 2Ds(N+1)/(5.22*10^10De*S)
So Ps =1.522psi
For tube side:
Pt= fGt 2Ln/(5.22*10^10*DS) ,psi
= 0.155*10^-3 psi
Return losses: Pr = 4nV2/2Sg
= 2.2 *10 ^-4 psi
So PT = Pt+Pr = 3.75*10 ^-4
DESIGN SUMMARY:
 No. of tubes =2362
 Shell ID = 66 inch
 Clean overall H.T.C. = Uc =598.865 w/m2 0C
 Design overall = 560.6W/m2 0C
 Dirt factor Rd = 0.0000952m2 0C/w
 Pressure drop for tube side = 0.000375 psi
 Pressure drop for shell side = 1.522 psi

5.2.2 MECHANICAL DESIGN OF SHELL AND TUBE HEAT EXCHANGER

Carbon Steel (Corrosion allowance 3 mm)
SHELL SIDE
Number of shell=1
Number of pass =2
Fluids in shell are Oxygen
Nitrogen Design pressure =1.5 x10 5 N /m2 =0.1575N/mm2
Temperature of inlet = -179.5 C
Temperature of outlet = -178.2 C

59
 Nitrogen

Permissible Stress for carbon steel (f)= 95N/mm 2

Segmental baffle cut with tie rods and spacers
TUBE SIDE
Tube and sheet material --------- Stainless steel
No. of tubes = 2362
Outside Diameter =25.4mm
Thickness of a tube =14BWG
Length of tube = 3.05 M
Pitch triang pitch = 1.25inch
Fluid = Nitrogen
Working pressure =6.5atm
=0.65N/mm2
Design pressure =0.6825 N/mm2
Inlet temperature = -176.50C
Outlet temperature = -178.20C
SHELL SIDE DIAMETER
Shell Diameter = 1676 mm
Shell thickness
ts= pd/2fj +p
where j=85%
=0.1575*1676/(2*95*0.85+0.1)
=1.6244mm
From IS-4503 Table (4) gives a minimum thickness of 6.3 including corrosion allowance Use
10.0 mm thickness.
HEAD THICKNESS
Consider Shallow dished and torespherical head
th=P*Rc*W/ (2*f*j)
Where j=0.85
Rc = Crown radius
W =stress intensification factor
RK = knuckle radius

60
 Nitrogen

RK = 6% Rc
W =1/4*(3+ (RC/RK) 1/2) = 1.77
th = 0.1575*1676 * 1.77/2*95
=2.4590 mm
Use thickness same as for shell , i.e. 10mm including corrosion allowance.
TIE RODS AND SPACERS
Tie Rods and Spacers shall be provided to retain all cross baffles and tube support heater
accurately.
Diameter of rod=15mm
No. of the rod =6mm
Following is from bhattacharya
FLANGES
Design Pressure =0.1575MN/m2
Flange material =IS:2004 ------1962
class2 Bolting Steel = 5% Cr Mo Steel
Gasket material = Asbestos composition
Shell diameter =1676mm
Shell thickness =10mm
Outside diameter = 1686mm
Allowable stress of flange material =100MN/m2
Allowable stress for bolting material =138 MN/m2

dO / di =(y-Pm)/( y-pm)
where
m =gasket factor
y = min design seating stress MN/m2assuming gasket thickness of 1.6mm
y =25.5
m= 2.75…………… from IS 2825-1969
do/di = [(25.5-0.1575*2.75)/(25.5-0.1575(2.75 +1)]1/2
do/di =1.002
Let dI of the gasket equal to 1696mm , 10mm greater than Shell dia
61
 Nitrogen

Therefore
do =1.002*di
=1.002*1696
=1699.4mm
Minimum gasket width =do –di /2 = (1699.4-1696)*10-3/2
=0.0034m =3.4mm
Taking Gasket width = 0.012m
Diameter of location of gasket load reaction is
G = di +N
= 1.696 +0.010
=1.706 m
Estimation of bolt loads
Load due to design pressure
H= ∏*G2*P/4
=∏ (1.706)2*0.1575/4
=0.359 MN
Load to keep joint tight under operation
HP=∏*G*(2*b)*m*p
= ∏*(1.707)2*2*5*10-3*2.75*0.1575
=0.0396 MN

Total operating load :

W d = H + HP
=0.359 + 0.0396
=0.3986 MN
Load to seat gasket under bolting up condition
Wg =∏*G*b*y
=∏*1.706*0.005*25.5
= 0.6829 MN
Also Wg > Wd

62
 Nitrogen

Therefore
Controlling load =0.6829MN
Minimum bolting area =Am = Wg/Sg
= 0.6829/138
=4.94*10-3 m2
Sg =138 from bhattacharya pg no.10
Calculation for optimum boltsize Let
us choose Bolt as M 18X12 Min no.
Of bolts = 44
Also
R=0.027 We have
G1= B + 2(g1+R) G1
= 1.686 + 2[g1 +R]
g1 = go/0.707 =1.415go for weld leg
G1 = 1.686 +2 (1.415*10*10-3 +0.027)
G1 = 1.7683
Using 75 mm bolt spacing C1 = 44*0.075/∏
=1.05m
From the above calculation the minimum bolt circle is 1.424 m when M18 Bolt 44
bolts of 18 mm diameter on 1.424 m bolt circle are specified.

Bolt circle diameter =1.42 m

A = C + Bolt diameter +0.02
= 1.42 +0.018 + 0.02
= 1.458m
= 1.46m
Check of gasket width =Ab*Sg/∏*G*N
=44*138*1.54*10-3/∏*1.706*0.01
=29.89
also 29.89<2*y

63
 Nitrogen

Flange moment computation

W0 = W1 + W2+ W3
W1 = ∏ *B2*P/4
Hydrostatic end force on area inside of flange .
W1 = ∏*(1.686)2*0.1575/4
= 0.351 MN
W2 =H- W1
= 0.359 – 0.351
=0.008 MN
WS = Wo – H =HP=gasketload
= 0.0396MN
Mo = W1a1 + W2a2 + W3a3
Where Mo = Total Flange moment
a1 = C – B/2 =1.42 –1.0187/2 =0.17
a3 = C1 –C1/2 = 1.424 –1.107/2 =0.1585
a2 = a1 + a3/2 = 0.164m
Mo = 0.351 *0.17 + 0.008*0.164 +0.0396*0.164
=0.0678 MN-m
For bolting up condition
Mg = Wa3
W = Am + Ab/2* Sg
Ab = 44*1.54*10-4 m2
Sg = 138 MN/m2
Am = 3.19*10-3 m2
Am +Ab/2 =4.983*10-3 m2
W = 0.687
Mg = 0.108
Mg > Mo.Hence moment under operating condition Mg is controlling
Therefore Mg = M
Calculation of flange thickness
t2 = M*Cf*Y/B*ST = M*Cf*Y/B*Sfo

64
 Nitrogen

where
k= A/B =1.46/1.087 =1.34
Assuming Cf = 1
Y = 6 from graph
t2 = 0.108*1*6/1.087*100
t = 0.0792 m
Actual bolt spacing
BS = ∏*C/n = ∏*1.42/44 = 0.101
Bolt correction factor
Cf = (BS/2*d + t)1/2
Cf = [(0.101)/ (2*0.018 +0.101)]1/2
Cf = (0.737)1/2 = 0.858
Actual Bolt thickness = (C) 1/2 *t
= 0.93* 0.0792
= 0.0796 = 73.66 mm = 75mm
Tube Sheet Thickness
tts = f*G*(0.25*P/f)1/2
tts = 1*1.107* (0.25*0.11/95)1/2 = 0.0188m
tts = 18.83 +3 = 22 mm (Includes corrosion allowance )

Channel and Channel cover

Th = GC*(K*P/f)
= 1.107*(0.3*0.11/95)1/2
= 0.0206 m = 22mm (includes corrosion allowance)
NOZZLE THICKNESS
Material used is carbon steel
Considering diameter of nozzle to be 0.5m
Permissible stress = f = 95 x 10 6 N/ m2
Corrosion allowance = 3mm

65
 Nitrogen

tn = p Dn/ (2f J –p )]+c

=4.66 mm
SADDLE SUPPORT:
Material- low carbon steel
Diameter = 1676 mm
Length of the shell, L = 3.05 m
Knuckle radius = 6% of diameter
= 100.56 mm
Total depth of head

=
H = 290.205 mm
Weight of vessel & contents, W = 12000 kg.
Distance of saddle center line from shell end,
A = 0.5 x R = 419 mm
Longitudianl bending moments:

Q = Load carried by each symmetrical support

= 20619.42 Kg

66
 Nitrogen

M1 = 4054.16 kg m
M2 = 7154.13 kg m
Stresses in shell at the saddle
1. At the topmost fibre of the cross section.

t= thickness of the shell =10 mm

f1 = 18.38 kg / cm2
2. At the bottom most fibre of the cross – section

f2 = 18.38 kg/cm2
Stresses are well within the permissible values.
Stresses in the shell at mid – span: The stress at the span is ,

F3 = 32.44 kg /cm2

Axial stress is the shell due to internal pressure:

fp = 285.30 Kg / cm2
Total stress = 285.30 + 32.44
= 317.745 kg/cm2
Stresses are well within the permissible values.

67
 Nitrogen

5.3ADSORPTION COLUMN:

Adsorption is the adhesion of atoms, ions, or molecules from a gas, liquid, or dissolved solid
to a surface.[1] This process creates a film of the adsorbate on the surface of the adsorbent.
This process differs from absorption, in which a fluid (the absorbate) permeates or
is dissolved by a liquid or solid (the absorbent).[2] Note that adsorption is a surface-based
process while absorption involves the whole volume of the material. The term sorption
encompasses both processes, while desorption is the reverse of adsorption. It is a surface
phenomenon.
Design of a column for adsorption starts with laboratory testing to establish the breakthrough
curve. At time intervals, the effluent from a column is sampled. Time zero is when the
solution is applied to the column.At first, the adsorbent (usually activated carbon) is fresh
with all its adsorption sites. Essentially none of the material to be removed escapes from the
column. As time passes, some of the adsorption sites are used up, and concentration in the
effluent rises.The shape of the graph may vary considerably for different situations. Usually
there is a long time before the effluent concentration rises sharply and then levels off. If all
the sites were occupied, we would expect the inlet concentration and the outlet
concentrations to become the same.

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 Nitrogen

Figure 5.6 Graph of effluent concentration vs time.

Note the lines in blue. The breakthrough concentration is determined by the process
specifications. This is the allowable concentration. If a pollutant is being removed, the
breakthrough concentration might be the government regulation for what your plant can
discharge. For a commercial product where the column is removing color, the break through
concentration is determined by your specification for product quality. The point is that
breakthrough concentration is not some fundamental number but depends on how you decide
to operate your process.The exhaustion concentration also depends on process
considerations. If there are not enough workers on the night shift, the column may have to be
removed in time for regeneration by the day shift so that it can ready in time the next day to
become the t rail column. Note that the column could still adsorb some more material.
However, you get little benefit by running for a longer time. You pay for labor, for
electricity, for plant costs, etc. When the benefits are not worth the costs, the column is
considered exhausted.

CO2 Removal
H20

Air

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 Nitrogen

MOLAL FLOWRATE OF AIR = 537.446 kmol/h

Mass flow rate of air GS = 537.446 * 29 /3600 =4.329 kg / sec
Humidity of air at inlet Y0 = 0.0036 kg H2O/ kg dry air
Humidity of air at outlet when = 0.0024 kg H2O/ kg dry air (assumed)
bed is exhausted Ye
Humidity of air at outet at break =0.0001 kg H2O/ kg dry air (assumed)
through time Yb
Y Y' 1/(Y-Y') dy/(Y-Y') (w-wa/wa) Y/Y0 (1-Y/Y0) X(Y=0.0025X
0.027777
Yb 0.0001 0.00003 14285.7 0 0.000 8 0.97222 0.004
0.055555
0.0002 0.00007 7692.31 1.1 0.118 6 0.94444 0.008
0.111111
0.0004 0.00016 4166.67 2.219 0.238 1 0.88889 0.016
0.166666
0.0006 0.00027 3030.3 2.93 0.315 7 0.83333 0.024
0.222222
0.0008 0.00041 2564.1 3.487 0.375 2 0.77778 0.032
0.277777
0.001 0.00057 2325.58 3.976 0.427 8 0.72222 0.04
0.333333
0.0012 0.00077 2298.85 4.438 0.477 3 0.66667 0.048
0.388888
0.0014 0.001 2469.14 4.915 0.528 9 0.61111 0.056
0.444444
0.0016 0.00123 2702.7 5.432 0.584 4 0.55556 0.064
0.0018 0.00148 3125 6.015 0.646 0.5 0.5 0.072
0.555555
0.002 0.00175 4000 6.728 0.723 6 0.44444 0.08
0.0022 0.00203 5882.35 7.716 0.829 0.611111 0.38889 0.088

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 Nitrogen

1
0.666666
Ye 0.0024 0.0023 10000 9.304 1.000 7 0.33333 0.096
Table 1: Equilibrium data
The table shows the equilibrium data. Data is used in designing of the adsorption column.
Equilibrium relationship is obtained from Treybal.
Y=0.0025X
Assuming unit cross sectional area of the tower.
Hence, diameter of the column
D = (1*4/3.14) ^ 0.5
D = 1.12m2
Adsorbent used is silica gel.
At breakthrough point the fractional ability of the adsorbent to adsorb is
f=

Figure 5.7 Graph of (1-Y/Y0) VS (w-wa/wa)

From the graph area under the curve will give f,

Area under the curve = Number of squares * X axis scale * Y axis scale
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 Nitrogen

= 175 * 0.1 *0.04

= 0.7
F=0.7
From the table the area under the curve dy/(y-y') corresponding to Y=Ye=0.0024 is 9.304
NtoG = 9.304

Extrapolating the equilibrium data

At Y0 = 0.0036,
X = 0.152 Kg water/kg adsorbent
Ss = Amount of the adsorbent used
= 0.0036 *4.32/0.152
=0.10254 kg adsorbent
Slope of the equilibrium curve: m=0.0185
mGs/ Ss = (0.0185 * 4326/0.10254)
= 0.7811
Kyap =70.749
Ksap = 0.965
(From treybal)
HtG = Gs/Kyap = 0.061193 m

Hts = Ss/Ksap = 0.10625 m

HtoG = HtG +mGs/Ss Hts
= 0.061193 + (0.7811 * 0.1062)
=0.1442 m
Za = NtoG * HtoG
Za = Height of adsorption zone
= 9.304 * 0.1442
=1.342 m

Degree of saturation at break point D = 0.9 (assumed)

D = (Z- f *Za/Za)

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 Nitrogen

Substituting D we get,
Height of bed Z = 2.1465158 m3 adsorbent/m2 of cross section
Bed density = 690 kg / m3 from Perry
The mass of the adsorbent = 2.1456 * 690
=1330.84 kg / m2
M =1330.84 kg
At 90% of equilibrium with air the gel contains = 0.90 * M *X
= 0.90 * 1330.84 * 0.152
=192.173 kg H2O/m2 cross section
The air introduces with water = 0.0036 * 4.329
= 0.015585 kg H2O/m2 s
Break point occurs at =192.173/0.015585
= 12330.638 sec
Break point =3.425 hrs
Break point occurs after 3.425 hrs after introducing air in an adsorber.
Total height = Height of bed + Disengaging space
H = 2.146 + 2*(0.5)
H = 3.146 m
THICKNESS OF SHELL
Thickness of shell =
ts = [p D / 2f J – p] + c
Where,
Inner Diameter of vessel = Di = 1.12 m
Working Pressure = 6.58 *105 N/m2
Design Pressure = p = 1.05 * 6.58 x105 N/ m2
= 6.9 x 105
Permissible Stress = 118 *106 N/m2
J= Joint Efficiency = 0.85
Corrosion allowance =2mm
Hence, ts =5.640mm
Support Design:

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 Nitrogen

Bracket or lug support is designed.

Diameter of tower = 1.12 m
Height of tower = 3.14 m
Clearance from vessel bottom to foundation – 1.0m
Wind pressure – 128.5 kg/m2
Number of brackets – 4
Diameter of anchor bolt circle – 1.9 m (Db)
Height of bracket from foundation = 1.8 m
Permissible stresses for structural steel
(IS-800) tension – 1400 Kg/cm2
Compression – 1233 kg/cm2
Binding – 1575 Kg/cm2
Permissible bearing pressure for concrete – 35 Kg/cm2
Weight of the vessel with contents = 10000 Kg.
Maximum compressive load:
Wind pressure, Pw = kp h Do.
k-Coefficient depending on the shape factor= 0.7
Pw=0.7x128.5x3.44x1.72
= 532.2 Kg.
Maximum total compressive load in the support is
P=+
H – Height of the vessel above the foundation
F – Vessel clearance from foundation to vessel bottom.
W – Maximum weight of the vessel
n = number of brackets
P= +
P = 3463.5 Kg.

Bracket:
(a)Base plate: Suitable base plate size, a = 140 mm

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 Nitrogen

B = 150 mm
Average pressure on the plate,
Pav = P/(aB)
Pav=(3463)/(14x15) = 16.5 Kg/cm2
Maximum stress in a rectangular plate subjected to a pressure Pav and fixed at the edges
is given by
f = 0.7 Pav *
= 1290/T2
F= 1575 /Kg cm 2
T1 = 8.7 mm
Use a 9 mm thick plate
(b) Web plate.
Bending moment of each plate =

For f = 1575, T2 = 7 mm
Column support for bracket:
It is proposed to use a channel section as column.
The size chosen is ISMC 150.

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 Nitrogen

Size – 150 x 75
Area of cross section – 20 .88 cm2
Modulus of section – 19.4 cm3
Radius of gyration , r– 2.21 cm
Weight – 16.4 Kg/m
Height from foundation, l=1.8m
Equivalent length for fixed ends le=1/2
= 0.9 m

Slenderness ratio=
For the load acting accentric on a short column, the maximum combined bending and
direct stress is given by,

w = Load on column
A – Area of cross section
E – Eccentricity
Z – Modulus of section of cross – section
N – Number of columns

Base plate for column:

Size of the column 150 x 75
It is assumed that the base plate extends 25 mm on either side of channel
Side B – 0.8 x 75 + 2 x 20=100mm

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 Nitrogen

Side C – 0.95 x 150 + 2 x 20 = 182.5 mm

Bearing pressure, Pb = (3463/4) x (1/10x18.25)= 4.74 Kg/cm2
This is less than the permissible bearing pressure for concrete.

For f = 1575 Kg/cm2

t = 2.33 mm
It is usual to select a plate 4 to 6 mm thick.

CONCLUSION AND DISCUSSION

On the basis of above calculations, I propose an nitrogen plant with a capacity of 205 T/day
with the above design specifications. This plant can be actually called as an nitrogen cum
nitrogen plant as it is producing pure nitrogen along side the nitrogen.
Apart from equipment design there are certain other factors which have to kept in mind
before designing and finally establishing a plant., like location analysis and a plant layout .

CHAPTER 6 PROCESS CONTROLAND INSTRUMENTATION

Process control is such an important topic in the design of increasingly complex chemical

77
 Nitrogen

plants. Instruments which can monitor the important process variables during plant operation
must be specified. These instruments must be capable of measuring the variables and should
have an acceptable accuracy and repeatability of measurement, usually the latter attribute is
more important than the former on chemical plant measurements. The instruments may be
used for manual measurements or included in automatic control loops. Automatic alarms
may also be required to indicate deviations outside acceptable limits. If possible, direct
measurement of the process variable should be made, however it is often easier to measure a
dependent variable, e.g. temperature measured as an indication of composition for distillation
column top product.
The specification of a control scheme and the associated instrumentation for a chemical plant
should satisfy several main objectives. First, the plant should operate at all times in a safe
manner. Dangerous situations should be detected as early as possible and appropriate action
initiated, also the process variables should be maintained within safe operating limits.
Second, the plant should operate at the lowest cost of production. Finally, the production rate
and the product quality must be maintained within specified operating limits.
The P & ID is used to prepare the preliminary instrumentation and control scheme. Control
loops are identified for level, flow, pressure and temperature controls to ensure steady plant
operation. The first steps in the design of a good control system are to define which variables
need to be measured and which need to be controlled. To specify pressure, temperature, flow
and level controllers on all units at different locations, and to assume that the measurements
will provide the basis for adequate control is unrealistic.It is necessary to specify:
(a) The variables that need to be measured;
(b) The location of these measurements;
(c) The variables that need to be controlled;
(d) How the desired control can be achieved.
The process and instrumentation (P&I) diagram provides a graphical representation of the
control configuration for the process. The P&I diagrams illustrate the measurement devices
that provide inputs to the control strategy, the actuators that will implement the results of the
control calculations, and the function blocks that provide the control
logic.

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 Nitrogen

Figure 6.1 P&I diagram of the double column

Distillation columns have four or more closed loops—increasing with the number of product
streams and their specifications—all of which interact with each other to some extent.
Because of this interaction, there are many possible ways to pair manipulated and controlled

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 Nitrogen

variables through controllers and other mathematical functions with widely differing degrees
of effectiveness. Columns also differ from each other, so that no single rule of configuring
control loops can be applied successfully to all.
Here in distillation at cryogenics , temperature and pressure are the most important
parameters. The minute disturbance in the temperature and pressure may change the purity of
products.The temperature controller (TC) in the loop are used to control the temperatures of
the top and bottom column for steady state operation of the column.The manipulated variable
to control the temperature of both upper and lower column is the flowrate of liquid oxygen to
the condenser and flowrate of liquid nitrogen to lower column from the condenser. The flow
rate controllers will give signal to the valves (main controlling element).The valve opening
will be adjusted to contol the flow and thereby controlling the temperature. Pressure is
controlled by manipulating the heat-transfer surface in the condenser through flooding. If the
condenser should become overloaded, pressure will rise above set point, but this has no
significant effect on the other control loops.The PC is placed in the vapor line of nitrogen to
ensure high pressure in the lower column.
Hence contol system of each equipment of process is necessary and important part of the
designing.A good Process control system of the process will give most economic and stable
performance of the plant .

●●●

CHAPTER 7 SAFETY AND ENVIRONMENT

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 Nitrogen

7.1 SAFETY:
In recent years there has been an increased emphasis on process safety. Process safety differs
from the traditional approach to accident prevention in a number of ways
• There is more concern with accidents that arise out of the technology.
• There is more emphasis on foreseeing hazards and taking action before accidents occur.
There is more emphasis on a systematic rather than a trial-and error approach, particularly
on systematic methods of identifying hazards and of estimating the probability that they will
occur, and their consequences.
• There is concern with accidents that cause damage to plants and loss of profit but do not
injure anyone, as well as those that do cause injury.
• Traditional practices and standards are looked at more critically
Process safety can be applied in any industry, but the term and the approach have been
particularly widely used in the process industries, where it usually means the same as loss
prevention.
Two studies are suggested: one at the conceptual or business analysis stage when the process
is being chosen, and another at the flowsheet stage. For the latter, the usual hazard and
operability (HAZOP) study questions may be suitable but with one difference. Having
specified the detailed design , the Hazard and Operability Study (HAZOP) can now be
performed. This study is used to determine the process control requirements and also to gain
an appreciation of the difficulties that may occur during operation of plant. The HAZOP
study comprises a detailed examination of each of the streams flowing into and out of the
various equipments. All significant aspects of deviation for each of these streams are then
considered under ‘Key Word’ headings. The HAZOP approach used here follows that
suggested by the Institute for the Prevention of Accidents in their HAZOP publication. The
HAZOP study was instrumental in determining the need for an adequate alarm system on
each of the specified controllers.

Liquid Nitrogen Use Guidelines

Liquid nitrogen is inert, colorless, odorless, non corrosive, nonflammable, and extremely

81
 Nitrogen

cold. Nitrogen makes up the major portion of the atmosphere (78% by volume). Nitrogen is
inert and will not support combustion; however, it is not life supporting. When nitrogen is
converted toliquid form it becomes a cryogenic liquid. Cryogenic liquids are liquefied gases
that have a normal boiling point below -150oC (-238oF).Liquid nitrogen has a boiling point of
-195.8oC (-320.5oF). All cryogenic liquids produce large amounts of gas when they vaporize.
HEALTH EFFECTS:
Extensive tissue damage or burns can result from exposure to liquid nitrogen or cold nitrogen
vapors. Being odorless, colorless, tasteless, and nonirritating, nitrogen has no warning
properties. Humans possess no senses that can detect the presence of nitrogen. Although
nitrogen is nontoxic and inert, it can act as a simple asphyxiant by displacing oxygen in air to
levels below that required to support life. Inhalation of nitrogen in excessive amounts can
cause dizziness, nausea, vomiting, loss of consciousness, and death. Death may result from
errors in judgment, confusion, or loss of consciousness that prevents self-rescue. At low
oxygen concentration, unconsciousness and death may occur in seconds and without
warning. Personnel including rescue workers should not enter areas where the oxygen
concentration is below 19.5%, unless provided with a self-contained breathing apparatus or
air-line respirator.
Containers
Liquid nitrogen is stored, shipped, and handled in several types of containers, depending
upon the quantity required by the user. The types of containers in use are the dewar,
cryogenic liquid cylinder, and cryogenic storage tank.
Cryogenic Liquid Cylinders
Cryogenic liquid cylinders are insulated, vacuum-jacketed pressure vessels. They come
equipped with safety relief valves and rupture discs to protect the cylinders from pressure
build up. These containers operate at pressures up to 350 psig and have capacities between 80
and 450 liters of liquid.
Cryogenic Storage Tanks
Tanks may be spherical or cylindrical in shape. They are mounted in fixed locations as
Stationary vessels. Tanks are designed to ASME specifications for the pressures and
temperatures involved. Use only suitable vessels for the handling and/or transport of
cryogenic liquids. Do not store liquid nitrogen in any container with a tight fitting lid; a loose

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 Nitrogen

fitting lid helps preventing air and moisture from entering the container and at the same time
allows pressure to escape.
7.1.2Safety Considerations
Cold contact burns
Liquid or low-temperature gas from any of the specified cryogenic substances will produce
effects on the skin similar to a burn. The extremely low temperature of the liquid can cause
severe frostbite or eye damage upon contact. Symptoms of frostbite include change in skin
color to white or grayish yellow and the pain after contact with liquid nitrogen may quickly
subside. Items in contact with liquid nitrogen become extremely cold. Touching these items
may result in torn flesh.
Asphyxiation
Liquid nitrogen gas released in a confined space can displace sufficient oxygen to make the
atmosphere incapable of sustaining life and cause asphyxiation without warning. Degrees of
asphyxia will occur when the oxygen content of the working environment is less than 20.9%
by volume. Effects from oxygen deficiency become noticeable at levels below ~ 18% and
sudden death may occur at ~ 6% oxygen content by volume. This decrease in oxygen content
can be caused by a failure/leak of the cryogenic vessel or transfer line and subsequent
vaporization of the cryogen.
Explosion – Pressure
Heat flux into the cryogen from the environment will vaporize the liquid and potentially
cause pressure buildup in cryogenic containment vessels and transfer lines. On vaporization
liquid nitrogen expands by a factor of 696; one liter of liquid nitrogen becomes 24.6 cubic
feet of nitrogen gas. Adequate pressure relief must be provided to all parts of a system to
permit this routine out gassing and prevent explosion.
Explosions – Chemical
Cryogenic fluids with a boiling point below that of liquid oxygen are able to condense
oxygen from the atmosphere. Repeated replenishment of the system can thereby cause
oxygen to accumulate as an unwanted contaminant. Similar oxygen enrichment may occur
where condensed air accumulates on the exterior of cryogenic piping. Violent reactions, e.g.
rapid combustions or explosion, may occur if the materials which make contact with the
oxygen are combustible.

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 Nitrogen

Buildings
Because of the large expansion ratio of liquid to gas (1:696), it is important to provide
adequate ventilation in areas using liquid nitrogen. A minimum of six air changes per hour is
required in these areas.
Oxygen level monitoring should be provided for areas where oxygen displacement may
occur. OSHA has established 19.5% oxygen concentration as the minimum for working
without supplied air.
7.1.3 Storage and Handling
Store and use liquid nitrogen containers with adequate ventilation. Do not store containers in
confined areas or in areas unprotected from the extremes of weather. Cryogenic containers
are equipped with pressure relief devices designed to control the internal pressure. Under
normal condition these containers will periodically vent product. Do not plug, remove or
tamper with any pressure relief device.
Cryogenic containers must be stored, handled, and transported in the upright position. When
moving never tip, slide, or roll containers on their side. Use a suitable hand truck for moving
smaller containers. Move larger container by pushing, not pulling. Use freight elevators
whenever possible to transport liquid nitrogen. Do not ride in the elevator with the liquid
nitrogen. Make arrangements for someone to send the elevator to a receiving person waiting
on the desired floor. Avoid mechanical and thermal shock. Never leave the vessel unattended
while transferring liquid nitrogen. Ensure that the delivery of the liquid nitrogen is directly
below the mouth of the receiving vessel. Always fill warm dewars slowly to reduce
temperature shock effects and to minimize splashing. Do not fill cylinders and dewars to
more than 80% of capacity. Never allow any unprotected part of the body to come in contact
with uninsulated pipes or equipment containing cryogenic product. The extreme cold will
cause flesh to stick fast and potentially tear on withdrawal.
If there is any difficulty in operating the container valve or container connections discontinue
use and contact the vendor.
Do not remove or interchange connections. Use only the properly assigned connections. Do
not use adapters. Use only transfer lines and equipment designed for use with cryogenic
liquids. Some elastomer sand metals, such as carbon steel, may become brittle at extremely
low temperatures and may easily fracture. These materials must be avoided in cryogenic

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 Nitrogen

service.
On gas withdrawal systems use check valves or other protective apparatus to prevent reverse
flow in the containers. On liquid systems pressure relief devices must be used in lines where
there is the potential to trap liquid between valves. It is recommended that all vents be piped
to the exterior of the building.
Liquid containers should not be left open to the atmosphere for extended periods. Keep all
valves closed and outlet caps in place when not in use. If restriction results from freezing
moisture or foreign material present in openings and vents contact the vendor for
instructions. Restrictions and blockages may result in dangerous over-pressurization. Do not
attempt to remove the restriction without proper instructions. If possible move the cylinder to
a remote location.
7.1.4Personal Protective Equipment (PPE)
Personnel must be thoroughly familiar with properties and safety considerations before being
allowed to handle liquid nitrogen and/or its associated equipment.
Eyes are most sensitive to the extreme cold of liquid nitrogen and its vapors. The
recommended personal protective equipment when handling or using liquid nitrogen is a full
face shield over safety glasses/goggles; loose-fitting thermal insulated gloves; and long-
sleeved shirts and pants without cuffs. In addition, safety shoes are recommended for those
involved with the handling of liquid nitrogen containers.
First Aid
In the event a person is injured by liquid nitrogen, the following first aid treatment should be
given pending the care of a physician ONLY if there is no risk to you.
For skin contact with cryogenic liquid nitrogen, remove any clothing that may restrict
circulationto the frozen area. Do not rub frozen parts, as tissue damage may result. People
with frostbitten feet should not walk on them. As soon as practical place the affected area in a
warm water bath that has a temperature not in excess of 105oF (40oC). Never use dry heat.
Frozen tissue is painless and appears waxy with a possible yellow color. It will become
swollen, painful, and prone to infection when thawed. If the frozen part of the body has been
thawed, cover the area with a dry sterile dressing with a large bulky protective covering,
pending medical care. In case of massive exposure, remove clothing while showering the
victim with warm water. Do not use hot water. Call a physician immediately. If the eyes are

85
 Nitrogen

exposed to the extreme cold of the liquid nitrogen or its vapors, immediately warm the
frostbite area with warm water not exceeding 105 oF (40oC) and seek immediate medical
attention.
7.2 Environmental Impact Analysis

This topic needs to be considered at an early stage in the design, in relation to the site
considerations, and reassessed during the detailed design stage . The effect of the operation
of the chemical plant upon the environment and the population must be considered during
the feasibility study and during subsequent design stages. The formal environmental impact
analysis (EIA) has two parts, these relate to:
(a) The treatment of unwanted chemicals (by-products) and the concentrations of liquid
discharges and gaseous emissions during normal operation;
(b) The handling of a major chemical accident, including all chemicals within the plant and
any subsequent reaction products, and containment and clean up.
The environmental impact analysis is specific to the plant under consideration, the
comments/suggestions made here are of a general The concentrations of all chemicals to be
discharged, including gaseous emissions, must be determined and measures taken to ensure
that these levels conform to allowable legislative standards. The cost of clean-up can be high,
e.g. scrubbing systems, filters, etc., and may affect the economic analysis of the plant
operation . It is prudent to ensure that not only are present emission standards observed, but
also that the plant could conform to any subsequent legislative reductions in these emission
levels (while still operating economically). The effects of all emissions on the environment,
and upon company employees and the population must be assessed..Noise levels from the
plant need to be considered, and finally its aesthetic acceptability.
The second part of the environmental impact analysis (EIA) relates to the effects of a major
accident or spill within the plant. The safety aspects of an explosive gas discharge (for
example) should be considered in stored within the plant, prevailing wind direction, location
of plant personnel and the general public, access to the plant and to particular high-risk areas.
There is a large amount of information available concerning chemical discharges,
environmental protection, clean-up and the applicable legislation. The Environmental
Protection Agency in the USA has produced a prodigious number of reports concerning a
wide range of chemical plants. Much of the available information is specific to particular
86
 Nitrogen

chemicals and process routes, however so much information has been published that locating
a relevant source is usually the main problem. Most countries now require a company to file
an environmental impact assessment with any proposal for a new chemical plant. This
document is usually open to public scrutiny and can be a source of much useful information.
Copies of the relevant legislation are readily available and advice can be obtained from
appropriate government departments conjunction with the loss prevention studies for the
plant . However, proposals for containment, clean-up, and discharge of major chemical spills
should be part of the EIA report. Any proposals should ensure the safety of personnel,
minimize the discharge and its effect on the environment, and preserve the integrity of the
plant..
●●●

CHAPTER 8 PLANT LOCATION & LAYOUT:

Introduction
A suitable site must be found for a new project, and the site and equipment layout planned.

87
 Nitrogen

Provision must be made for the ancillary buildings and services needed for plant operation;
and for the environmentally acceptable disposal of effluent.
9.1 PLANT LOCATION AND SITE
The location of the plant can have a crucial effect on the profitability of a project, and the
scope for future expansion. Many factors must be considered when selecting a suitable site,
and only a brief review of the principle factors are given below. The principle factors to
consider are:

1. Location, with respect to the marketing area.

2. Raw material supply.
3. Transport facility.
4. Availability of labour.
5. Availability of utilities: water, fuel, power.
6. Availability of suitable land.
7. Environmental impact and effluent disposal.
8. Local community considerations.
9. Climate.
10. Political and strategic considerations.

8.1.1 Marketing area

For materials that are produced in bulk quantities; such as Isoamyl Alcohol where the cost of
the product per tonne is relatively low and the cost of transport a significant fraction of the
sales price, the plant should be located close to the primary market. This consideration will
be less important for low volume production, high-priced products; Pharmaceuticals.
In an international market, there may be an advantage to be gained by locating the plant
within an area with preferential tariff agreements;

8.1.2 Raw Materials

The availability and price of suitable raw materials will often determine the site location.
Plants producing bulk chemicals are best located close to the source of the major raw
material; where this is also close to the marketing area.

88
 Nitrogen

8.1.3 Transport
The transport of materials and products to and from the plant will be an overriding
consideration in site selection. If practicable, a site should be selected that is close to at least
two major forms of transport: road, rail, waterway (canal or river), or a sea port. Road
transport is being increasingly used, and is suitable for long- distance transport of bulk
chemicals. Air transport is convenient and efficient for the movement personnel and essential
equipment and supplies, and the proximity of the site to a major air port should be
considered.
8.1.4 Availability of labour
Labor will be needed for construction of the plant and its operation. Skilled construction
workers will usually be brought in from outside the site area, but there should be an adequate
pool of unskilled labour availability locally; and labour suitable for training to operate the
plant. Skilled tradesmen will be needed for plant maintenance. Local trade union customs
and restrictive practices will have to be considered when assessing the availability and
suitability of the local labour for recruitment and training.
8.1.5 Utilities (Services)
Chemical processes invariably require large quantities of water for cooling and general
process use, and the plant must be located near a source of water of suitable quality. Process
water may be drawn from a river, from wells, or purchased from a local authority.
At some sites, the cooling water required can be taken from a river or lake, or from the sea; at
other locations cooling towers will be needed.
Electrical power will be needed at all sites. Electrochemical processes that require large
quantities of power; need to be located close to a cheap source of power.A competitively
priced fuel must be available on site for steam and power generation.

8.1.6 Environmental impact and effluent disposal

All industrial processes produce waste products, and full consideration must be given to the
difficulties and cost of their disposal. The disposal of toxic and harmful effluents will be
covered by local regulations, and the appropriate authorities must be consulted during the
initial site survey to determine he standards that must be met.

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 Nitrogen

An environmental impact assessment should be made for each new project or major
modification or addition or an existing process.
8.1.7 Local community considerations
The proposed plant must be fit in with and be acceptable to the local community. Full
consideration must be given to the safe location of the plant so that it does not impose a
significant additional risk to the community.
On a new site, the local community must be able to provide adequate facilities for the plant
personnel: schools, banks, housing, and recreational and cultural facilities.
8.1.8 Land (site considerations)
Sufficient suitable land must be available for the proposed plant and for future expansion.
The land should ideally be flat, well drained and have suitable load-bearing characteristics. A
full site evaluation would be made to determine the need for piling or other special
foundations.
8.1.9 Climate
Adverse climatic conditions at a site will increase costs. Abnormally low temperatures will
require the provision of additional insulation and special heating for equipment and pipe
runs. Stronger structures will be needed at locations subject to high winds
(cyclone/hurricane) or earthquakes.
8.1.10 Political and strategic considerations
Capital grants, tax concessions, and other inducements are often given by governments to
direct new investment to preferred locations; such as areas of high unemployment. The
overriding of such grants can be the overriding considerations in site selection.

8.2. PLANT LAYOUT:

The efficiency of production depends on how well the various machines; production facilities
and amenities are located in a plant. An ideal plant layout should provide the optimum
relationship among the output, floor area and manufacturing process. An efficient plant
layout is one that aims at achieving various objectives like efficient utilization of available

90
 Nitrogen

floor space, minimizes cost, allows flexibility of operation, provides for employees
convenience, improves productivity etc. The entrepreneurs must possess the expertise to lay
down a proper layout for new or existing plants. It differs from one plant to another. But
basic principles to be followed are more or less same.Plant layout is applicable to all types of
industries or plants. At the end, the layout should be conducive to health and safety of
employees. It should ensure free and efficient flow of men and materials. Future expansion
and diversification may also be considered while planning factory layout.
Following figure shows the plant layout of the nitrogen plant.

91
 Nitrogen

Figure 8.1: Plant Layout of the nitrogen complex.

92
 Nitrogen

CHAPTER 9 COST ESTIMATION

Cost estimation mainly consists of three parts:

1. TOTAL CAPITAL INVESTMENT

2. TOTAL PRODUCTION COST
3. PROFITABILITY
TOTAL CAPITAL INVESTMENT:
A. FIXED CAPITAL INVESTMENT
B. WORKING CAPITAL(10% OF FCI)
INDIRECT COST
1. Purchased equipment
2. Purchased equip. installation
3. Instrumentation & control
4. Piping & installation
5. Electrical installation
6. Building installation
7. Yard improvement
8. Service facilities
9. Land
DIRECT COST
1. Engineering and supervision
2. Construction expenses
3. Contractor’s fees
4. Contingency

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 Nitrogen

Sr. Quantit
No. Equipment Name y Price in USD.
1 Compressor 2 4326600.00
2 Heat exchagers 3 883800.00
3 Distillation column 1 5181300.00
4 Distillation column 2 5516800.00
5 Adsorption tower 2 901400.00
6 Film type heat exch. 2 749400.00
7 Condensers 1 572400.00
8 Reflux Pump 2 104400.00

Table 1 Purchased equipment cost

Total Cost of Purchased Equipment = 18,236,100.00 USD
989,855,508.00 Rs.
All the equipments cost are taken from the internet
http://www.matche.com/EquipCost/index.htm
Now, 1$ = 52 Indian Rupees
9.1 CALCULATION OF FIXED CAPITAL INVESTMENT (FCI):
For calculating fixed capital investment we have to calculate
(A) Direct Cost
(B) Indirect Cost
A. CALCULATION OF DIRECT COST:
1. PURCHASED EQUIPMENT COST:
The cost of purchased equipment is the basis for estimating fixed capital investment.
The most accurate method for determining purchased equipment cost is to obtain
quotation from fabricators or suppliers.The second best method is to obtain cost values from
the file of past purchased record.
From above the total purchased equipment cost is found to be Rs.989,855,508.00 ---------(A)
The total purchased equipment cost is always 15 to 40% of fixed capital investment.
For our convenience we take it as 22% of fixed capital investment.
As we know purchased equipment cost we can calculate estimated fixed capital investment.
Therefore
Estimated fixed capital investment = 0.22 x 989,855,508.00

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 Nitrogen

= Rs. 989,855,508.00

2. PURCHASED EQUIPMENT INSTALLATION:

The installation of equipment involves cost for labour, foundation, support, platform,
construction expense & other factors directly related to the erection of purchased equipment.
Purchased equipment installation is always 25% of purchased equipment cost
For our convenience we take it as 23 % of purchased equipment cost
Therefore,
Cost of purchased equipment installation = 0.23 x 989,855,508.00

= Rs 227,666,766.84

3. INSTRUMENTATION & CONTROL:

Instrument costs, installation cost constitute the major portion of capital investment required
for instrumentation. Total instrumentation cost depends on the amount of controller
required.This cost is always 2-8% of purchased equipment cost
For our convenience we take it as 6% purchased equipment cost
Therefore,
Cost of instrumentation & control = 0.06 x 989,855,508.00
= Rs. 1,094,166.00 ---------------(C)
4. PIPING:
The cost of piping covers labor, valve, fitting, pipe, support & other item involved in
erection of all piping used in the process.
This cost is always 3-20% of purchased equipment cost
But For our convenience we take it as 3% of purchased equipment cost
Therefore,
Cost of piping = 0.03 x 989,855,508.00
= Rs. 547,083.00 ---------------- (D)

5. BUILDING INSTALLATION:
The cost for building including services consists of expense for labor, material & supply
involved in the erection of all building connected with the plant. In this cost of plumbing,
heating, lighting, ventilation & similar services are included.
95
 Nitrogen

This cost is always 3-18 % of purchased equipment cost

But For our convenience we take it as 17% of purchased equipment cost
Therefore,
Cost of building installation = 0.17 x 989,855,508.00
= Rs. 3,100,137.00 ----------- (E)

6. YARD IMPROVEMENT:
Cost of fencing, grading, roads, sidewalk, railroad siding, landscaping & similar item
constitute the portion of yard improvement.
This cost is always 2-5 % of purchased equipment cost
For our convenience we take it as 3% of purchased equipment cost
Therefore,
Cost of yard improvement = 0.03 x 989,855,508.00
= Rs 547,083.00 ------------ (F)

7. SERVICE FACILITIES:
Utilities for supplying steam, water, power, compressed air & fuel lies in the service
facilities. Waste disposal, fire protection & miscellaneous service item such as first aid &
cafeteria equipment are included in this.
This cost is always 8-20 % of purchased equipment cost
But For our convenience we take it as 9% of purchased equipment cost
Therefore,
Cost of service facility = 0.09 x 989,855,508.00
= Rs. 1,641,249.00------------- (G)

8. LAND:

The cost of land & the accompanying surveys & fees depends on the location of property &
may vary by cost factor.
This cost is always 1-2 % of purchased equipment cost
For our convenience we take it as 2% of fixed capital investment.
Therefore,

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Cost of land = 0.02 x 989,855,508.00 = Rs. 364,722.00 ---------------- (H)

Now,

Direct Cost = (A) + (B) + (C) + (D) + (E) + (F) + (G) + (H)
= Rs. 1,225,546,158.84 ------------------------- (A#)

B. CALCULATION OF INDIRECT COST:

1. ENGINEERING &SUPERVISION:
The cost of construction design & engineering, drafting, purchasing, accounting,construction
& cost engineering, travel, reproductions are included in this cost. This cost is always 4-21
% of Total direct cost For our convenience we take it as 8% of Total direct cost
Therefore,
Engineering & supervision cost = 0.08 x 1,225,546,158.84

= Rs 134,810,077.47-------- (A)
2. CONSTRUCTION EXPENSE:
This includes temporary construction & operation, construction tool & rental office,home
office at construction site etc.
This cost is always 4-16 % of Total direct cost.
For our convenience we take it as 7% of Total direct cost
Therefore,
Construction expense = 0.07 x 1,225,546,158.84

= Rs. 98,043,692.7 ----------- (B)

3. CONTRACTOR’S FEES:
The contractor’s fee varies for different situation but it is always 2-6 % of Total direct cost.
For our convenience we take it as 5% of Total direct cost.
Therefore,
Contractor’s fees = 0.05 x 1,225,546,158.84

= Rs. 61,277,307.9 ------------ (C)

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 Nitrogen

4. CONTINGENCIES:
A contingency factor is usually included in an estimate of capital investment to compensate
for unpredictable events such as storms, floods, strikes, price change, small design change
etc.
This is always 5-15 % of Total direct cost. For our convenience we take it as 7% of Total
direct cost Therefore,
Contingencies = 0.07 x 1,225,546,158.84
= Rs 85,788,231.12 --------------- (D)

Now,
Total indirect cost = (A) + (B) +(C) + (D)
= Rs. 379,919,309.24------------------ (B#)

Therefore,
Fixed Capital Investment = Direct Cost + Indirect Cost
= (A#) + (B#)
= Rs 1,605,465,468.08

9.2 CALCULATION OF TOTAL CAPITAL INVESTMENT (TCI):

TCI = FCI + WORKING CAPITAL ---------- (1#)
Working Capital is 15% of TCI.
Total Capital investment = 1,605,465,468.08 /0.85

= Rs 1,888,782,903.62

Therefore,
Working capital =0.15 x 1,888,782,903.62

= Rs 283,317,435.54

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 Nitrogen

9.3 CALCULATION OF TOTAL PRODUCT COST:

RAW MATERIAL COST FOR 431.22 TPD of NITROGEN production

Total working days in a year = 300 days
Plant is running in three shifts i.e. 24 hrs per day
Capacity of the plant per year= 135,003,464.96 m3/ day

CALCULATION OF DIRECT PRODUCT COST:

RAW MATERIAL COST:
Sr.
No. Description Quantity per annum Unit
1 Atm Air 302,220,000.00 m3 per annum
2 Silica Gel 388.00 kg/27836N2
3 Carbon tetra chloride 4,364.96 kg/27836N2
4 Recycled water 43,649.63 kg/27836N3

Total annual cost in

Cost per unit USD. Norm of consmp.
0.01 164,045,016.00 -
0.50 10,530.23 0.08
0.90 213,237.19 0.90
0.50 1,184,651.04 9.00

Table 2:Raw Material Cost

The amount of raw material which must be supplied per unit time can be determined from
process material balance & from that we can find raw material cost required per annum.
The raw material cost for our product is Rs 165,453,434.46---------- (a)

2. OPERATING LABOR COST:

In general, operating labour cost is divided into skilled & unskilled labour.
It is most commonly 10 -50% of raw material cost.
For our convenience we take it as 15% of raw material cost.
Therefore,

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 Nitrogen

Operating labour cost = 0.15 x 165,453,434.46

= Rs 24,818,015.17 --------- (b)

3. OPERATING SUPERVISION
It is most commonly 10 -50% of operating labour
For our convenience we take it as 15% of operating labour
Therefore,
Operating labour cost = 0.15 x 24,818,015.17
= Rs. 3,722,702.28--------- (c)

4. UTILITIES:
The cost for utilities such as steam, electricity, process & cooling water, compressed
air varies depending on the amount of consumption.
As a rough approximation it is always 10-20% of total product cost.
For our convenience we take it as 10% of total product cost.
Therefore,
Utility cost = Rs 400000.00------------ (d)

5. MAINTENANCE & REPAIRS:

A considerable amount of expense is necessary for maintenance & repair if a plant is to be
kept in efficient operating condition.
As a rough approximation this is always 3% of Purchased Equipment Cost
Therefore,
Maintenance & repair cost = 0.03 x 989,855,508.00

= Rs. 29,695,665.24------- (e)

6. OPERATING SUPPLIES:
In any manufacturing operation, many miscellaneous supplies are needed to keep the
process functioning efficiently & it is not included in the raw material cost.
It is always 15% of maintenance & repair cost.

100
 Nitrogen

Therefore,
Operating supplies cost = 0.15 x 29,695,665.24
= Rs. 4,454,349.79----------- (f)

7. LABORATORY CHARGES:
The cost of laboratory test for control of operation & for product quality is covered in
this cost.
For quick estimates, this is always 2-10% of operating labour cost.
For our convenience we take it as 2% of operating labour cost.
Therefore,
Laboratory charges = 0.2 x 24,818,015.17

= Rs. 4,963,603.03-------- (g)

8. PATENTS & ROYALTIES:

Many manufacturing processes are covered by patents & it may be necessary to pay a
set amount for patent right or royalty based on the amount of material produced.
For rough approximation this is 0-6% of total product cost.
For our convenience we take it as 0% of total product cost.
Therefore,
Patent & royalty cost = Rs. 0.00---------- (h)
Therefore,
Direct product cost = (a) + (b) + (c) + (d) + (e) + (f) + (g) + (h)
= Rs. 233,507,769.96------------------ (C#)

B. CALCULATION OF FIXED CHARGES:

1.DEPRECIATION:
Equipment, building & other material object comprising a manufacturing plant require an
initial investment which must be written off as a manufacturing expense. This is called as
depreciation.

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 Nitrogen

This is always 10% of fixed capital investment.

Therefore, Depreciation = 0.1 ×1,605,465,468.08

= Rs. 16,054,654.68 ---------- (h)

2. LOCAL TAXES:
The magnitude of local property taxes depends on the particular locality of the plant &
regional laws.
This is always 1-4% of fixed capital investment.
For our convenience we take it as 1% of fixed capital investment.
Therefore,
Local taxes = 0.01 * 1,605,465,468.08
= Rs. 16,054,654.68 --------- (i)

3. INSURANCE:
Insurance rate depends on the type of process being carried out in the manufacturing
operation & on the extent of available protection facilities.
It is always 1% of fixed capital investment.
Therefore,
Insurance = 0.01 x 1,605,465,468.08
= Rs. 16,054,654.68 ----------- (j)
4. Annual cost of Depreciation for buildings is taken as 3% of the Initial Cost of
buildings
Annual cost of depreciation = 0.03 x 3,100,137.00

= Rs 93,004.11----------- (k)

5. Annual cost of Depreciation for Instrumentation & Controls, piping, Electrical

equipment and Materials is assumed as 5% of FCI
Annual cost of depreciation = 0.05 x 1,605,465,468.08

= Rs 80,273,273.40---------- (l)

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Therefore
Fixed charges = (h) + (i) + (l)

Table 3 Total Annual Fixed Charges

S.
No. Description Total Annual cost in Rs.
1.00 Depreciation 96,420,932.19
2.00 Taxes 16,054,654.68
3.00 Insurance 16,054,654.68
4.00 Rent 0.00

Total fixed charges = 128,530,241.56 --------- (D#)

CALCULATION OF PLANT OVERHEAD COST:

The expenditure required for routine plant services are included in plant overhead cost.
This is always 30- 50% of total expense of operating labour cost, supervision and
maintenance
For our convenience we take it as a 30% of cost of operating labour, supervision and
maintenance.
Therefore,

Plant overhead cost = Rs 17,470,914.81----------- (E#)

Manufacturing cost = (C#) + (D#) + (E#)

Total Manufacturing Costs (M)

S. Total Annual cost in

No. Description Rs.
1 Direct Production Cost 233,507,769.96
2 Fixed Charges 128,530,241.56
3 Plant Overhead Cost 17,470,914.81

Table 4 Manufacturing Cost

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Total Manufacturing costs = Rs. 379,508,926.32 -------- (F#)

D. CALCULATION OF GENERAL EXPENSES:

1. ADMINISTRATIVE COST:
The expenses connected with top management or administrative activities are necessary to
include if economic analysis is to be done.
This is always 20-30% of total expense of operating labor cost.
So we take it as 10% of operating labor cost.
Therefore,
Administrative cost = 0.10* 24,818,015.1

= Rs 2,481,801.52 ---------- (k)

2. DISTRIBUTION & MARKETING COST:

Distribution & marketing cost vary widely for different types of plant depending on the type
of material being produced, plant location & lay out etc.
For rough approximation this is 2-20% of total product cost.
For our convenience we take it as 50% of total product cost.
Therefore,
Distribution & marketing cost = 0.50 *233,507,769

= Rs 116,753,884.98---------- (l)

3. RESEARCH AND DEVELOPMENT:

This includes salaries & wages for all personnel directly connected with this type of work.
In chemical industry this cost amount is about 2% of total product cost.
Therefore,
Research & development cost = 0.02 * 233,507,769

= Rs. 4,670,155.40-------- (m)

4. INTEREST:
Interest is considered to be compensation paid for the use of borrowed capital.
For rough approximation this is 0-10% of total product cost.

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For our convenience we take it as 0% of total product cost.

Therefore, Interest = Rs 0.00----- (n)
Therefore,
General expenses = (k) + (l) + (m) + (n)

Total General Expenses

S.
No. Description Total Annual cost in Rs.

1 Administrative Expenses 2,481,801.52

2 Distribution and Marketing Expenses 116,753,884.98

3 Research and Development 4,670,155.40

4 Financing (interest) 0.00

Table 5 General expenses Cost

Total General Expenses = Rs. 123,905,841.90------- (G#)

Therefore,
Total product cost = Manufacturing cost + General expenses
= (F#) + (G#)
= Rs. 503,414,768.22 --------- (H#).

9.4 CALCULATION OF PROFIT:

Nitrogen production/ day = 431.885 TPD
= 135,003,464.96 m3 N2
Selling price of Nitrogen = Rs. 26.5/m3
Annual Revenue through sales at 75% capacity = 0.75*26.5*135003464.96

= 2,683,193,866.08--------- (I#)

Now,

Gross profit = total sales income – total product cost

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 Nitrogen

= (I#) – (H#)
= 2,683,193,866.08 - 503,414,768.22

= Rs. 2,179,779,097.86---------------- (J#)

Now, total income tax is equal to 35%

Therefore,
Total income tax = 0.35 x Gross profit
= 0.35 x 2,179,779,097.86

= Rs 762922684-------------- (K#)

Net profit = Gross profit – Income tax

= (J#) – (K#)
= Rs 1438654205Now,Pay Back Period = Total Investment / ( Net Profit +
Depreciation )Where Total Investment = Fixed Capital Investment

Pay Back Period =1,605,465,468.08 /( 1438654205+96,420,932.19)

= 1.05 years

Rate of Return = (Net Profit / Total Investment) x 100

= (1438654205 / 1,605,465,468.08) x 100

= 89.60 %

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APPENDIX
PROPERTY ESTIMATION:

Stream Feed1 Top Bottom

Stage 14 1 28
Pressure (N/m2) 650000 200000 650000
Vapour fraction (-) 1 1 0
Temperature (K) 105 83.686 104.821
Enthalpy (J/kmol) 5624000 6248000 11000000
Entropy (J/kmol/K) 41261.1 42611.3 92166.4

Mole flows (kmol/s)

Nitrogen 120 0.390691 119.609
Nitrogen 379 300.729 78.2712

Total molar flow 499 301.12 197.88

Mole fractions (-)

Nitrogen 0.240481 0.001297 0.604452
Nitrogen 0.759519 0.998703 0.395548

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 Nitrogen

He a l t h
0
F i re
0
Re a c t i v i t y
0
P e rs o n a l
A

MATERIAL SAFETY DATA SHEET

1.CHEMICAL PRODUCT AND COMPANY IDENTIFICATION

MATHESON TRI-GAS, INC. EMERGENCY CONTACT:

959 ROUTE 46 EAST CHEMTREC 1-800-424-9300
PARSIPPANY, NEW JERSEY NEW JERSEY
07054-0624 INFORMATION CONTACT:
973-257-1100
SUBSTANCE: NITROGEN, COMPRESSED GAS
TRADE NAMES/SYNONYMS:
MTG MSDS 67; DIATOMIC NITROGEN; DINITROGEN; NITROGEN; NITROGEN-14;
NITROGEN GAS;
UN 1066; N2; MAT16625; RTECS QW9700000
CHEMICAL FAMILY: inorganic, gas
CREATION DATE: Jan 24 1989
REVISION DATE: Jun 16 2005

108
 Nitrogen

2. COMPOSITION, INFORMATION ON INGREDIENTS

 COMPONENT: NITROGEN, COMPRESSED GAS
 CAS NUMBER: 7727-37-9
 PERCENTAGE: 100
3. HAZARDS IDENTIFICATION
 NFPA RATINGS (SCALE 0-4): HEALTH=1 FIRE=0 REACTIVITY=0
 EMERGENCY OVERVIEW:
 COLOR: colorless
 PHYSICAL FORM: gas
 ODOR: odorless
 MAJOR HEALTH HAZARDS: difficulty breathing
 PHYSICAL HAZARDS: Containers may rupture or explode if exposed to heat.
 POTENTIAL HEALTH EFFECTS:
 INHALATION:
 SHORT TERM EXPOSURE: nausea, vomiting, difficulty breathing, headache,
drowsiness, dizziness,tingling sensation, loss of coordination, convulsions, coma
 LONG TERM EXPOSURE: no information is available
 SKIN CONTACT:
 SHORT TERM EXPOSURE: no information on significant adverse effects
 LONG TERM EXPOSURE: no information on significant adverse effects
 EYE CONTACT:
 SHORT TERM EXPOSURE: irritation
 LONG TERM EXPOSURE: no information on significant adverse effects
 INGESTION:
 SHORT TERM EXPOSURE: ingestion of a gas is unlikely
 LONG TERM EXPOSURE: ingestion of a gas is unlikely
4. FIRST AID MEASURES
 INHALATION: If adverse effects occur, remove to uncontaminated area. Give
artificial respiration if not breathing. If breathing is difficult, oxygen should be
administered by qualified personnel. Get immediate medical attention.
 SKIN CONTACT: Wash exposed skin with soap and water.

109
 Nitrogen

 EYE CONTACT: Flush eyes with plenty of water.

 INGESTION: If a large amount is swallowed, get medical attention.
 NOTE TO PHYSICIAN: For inhalation, consider oxygen.
5. FIRE FIGHTING MEASURES
 FIRE AND EXPLOSION HAZARDS: Negligible fire hazard. Pressurized
containers may rupture or explode if exposed to sufficient heat.
 EXTINGUISHING MEDIA: carbon dioxide, regular dry chemical
 Large fires: Use regular foam or flood with fine water spray.
 FIRE FIGHTING: Move container from fire area if it can be done without risk.
Cool containers with water spray until well after the fire is out. Stay away from the
ends of tanks. Withdraw immediately in case of rising sound from venting safety
device or any discoloration of tanks due to fire. For tank, rail car or tank truck,
evacuation radius: 800 meters (1/2 mile). Use extinguishing agents appropriate for
surrounding fire. Cool containers with water spray until well after the fire is out.
Apply water from a protected location or from a safe distance. Do not get water
directly on material. Reduce vapors with water spray. Avoid inhalation of material or
combustion by-products. Stay upwind and keep out of low areas. Consider downwind
evacuation if material is leaking.
6. ACCIDENTAL RELEASE MEASURES
 OCCUPATIONAL RELEASE:Stop leak if possible without personal risk. Keep
unnecessary people away, isolate hazard area and deny entry. Stay upwind and keep
out of low areas.
7. HANDLING AND STORAGE
 STORAGE: Store and handle in accordance with all current regulations and
standards. Subject to storage regulations: U.S. OSHA 29 CFR 1910.101. Keep
separated from incompatible substances.
8. EXPOSURE CONTROLS, PERSONAL PROTECTION
 EXPOSURE LIMITS: NITROGEN, COMPRESSED GAS:
 NITROGEN:ACGIH (simple asphyxiant)
 VENTILATION: Provide local exhaust ventilation system. Ensure compliance with
applicable exposure limits.

110
 Nitrogen

 EYE PROTECTION: Eye protection not required, but recommended.

 CLOTHING: Protective clothing is not required.
 GLOVES: Protective gloves are not required.
 RESPIRATOR: Under conditions of frequent use or heavy exposure, respiratory
protection may be needed. Respiratory protection is ranked in order from minimum to
maximum. Consider warning properties before use.
 For Unknown Concentrations or Immediately Dangerous to Life or Health -
 Any supplied-air respirator with full facepiece and operated in a pressure-demand or
other positive-pressure mode in combination with a separate escape supply.
 Any self-contained breathing apparatus with a full face piece.

10. PHYSICAL AND CHEMICAL PROPERTIES

 PHYSICAL STATE: gas
 COLOR: colorless
 ODOR: odorless
 TASTE: tasteless
 MOLECULAR WEIGHT: 28.0134
 MOLECULAR FORMULA: N2
 BOILING POINT: -321 F (-196 C)
 FREEZING POINT: -346 F (-210 C)
 VAPOR PRESSURE: 760 mmHg @ -196 C
 VAPOR DENSITY (air=1): 0.967
 SPECIFIC GRAVITY: Not applicable
 DENSITY: 1.2506 g/L
 WATER SOLUBILITY: 1.6% @ 20 C
 PH: Not applicable
 VOLATILITY: 100%
 ODOR THRESHOLD: Not available
 EVAPORATION RATE: Not applicable
 VISCOSITY: 0.01787 cP @ 27 C
 COEFFICIENT OF WATER/OIL DISTRIBUTION: Not applicable

111
 Nitrogen

 SOLVENT SOLUBILITY:
 Soluble: liquid ammonia
 Slightly Soluble: alcohol
10. STABILITY AND REACTIVITY
 REACTIVITY: Stable at normal temperatures and pressure.
 CONDITIONS TO AVOID: Protect from physical damage and heat. Containers
may rupture or explode if Exposed to heat.
 INCOMPATIBILITIES: metals, oxidizing materials
 HAZARDOUS DECOMPOSITION: Thermal decomposition products: oxides of
nitrogen
 POLYMERIZATION: Will not polymerize.
11. TOXICOLOGICAL INFORMATION
Not available
12. ECOLOGICAL INFORMATION
Not available
The information above is believed to be accurate and represents the best information currently available to us.
However, we make no warranty of merchantability or any other warranty, express or implied, with respect to
such information, and we assume no liability resulting from its use. Users should make their own investigations
to determine the suitability of the information for their particular purposes. In no event shall ScienceLab.com
be liable for any claims, losses, or damages of any third party or for lost profits or any special, indirect,
incidental, consequential or exemplary damages, howsoever arising, even if ScienceLab.com has been advised
of the possibility of such damages

●●●

112
 Nitrogen

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 Perry, R.H., and Green, D.W., (Eds), Perry’s Chemical Engineers’ Handbook, 6th
Edn, McGraw-Hill Book Co., New York (1984)
 BE. Kirk and D.F. Othmer (Eds), Encyclopedia of Chemical Technology,
3rdEdn,Volume 15, pp.853-871, Wiley-Interscience, New York (1981).
 Basic Theoretical Physics ,Springer new York ,part 4 ,pages 313-325
 Cryogenic Engineering, Springer new York ,part 1,pages 3-27 and 146-160
 US Patent 4072023 - Air-rectification process and apparatus
 Chemical and Petroleum Engineering journal, Air separation in plants with an
external source of refrigeration ,,volume 4 ,pages 825-829
 American Chemical society journal , some aspects of gas separation at low
temperatures by W. H. Granville
 Air liquefaction: distillation encyclopedia of separation science, 2007, pages 1895-
1910, science direct R. Agrawal, D.M. herron Cryogenic Process Engineering
Encyclopedia of Physical Science and Technology, 2004,Pages13-36Klaus D.
Timmerhaus Journal of Chemical and Petroleum Engineering, University of Tehran,
Vol. 45, No.1, June 201
 Peters, M.S., and Timmerhaus, K.D., Plant Design and Economics for
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 Site Designed and Maintained by Industrialgasplants.com , 24/11/2010
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