Mentor: Bill Keesom, Jacobs Engineering Improved Nitric Acid Production via Cobalt Oxide Catalysis for use in Ammonia- based Fertilizers Team Foxtrot Thomas Calabrese Cory Listner Hakan Somuncu David Sonna Kelly Zenger 4/24/2012 University of Illinois at Chicago – Department of Chemical Engineering
135
Embed
Improved Nitric Acid Production via Cobalt Oxide …che397-nitric-acid.wikispaces.com/file/view/CHE397_Team... · Web viewImproved Nitric Acid Production via Cobalt Oxide University
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Mentor: Bill Keesom, Jacobs Engineering
Improved Nitric Acid Production via Cobalt Oxide Catalysis for use in Ammonia-based Fertilizers
Team Foxtrot
Thomas Calabrese
Cory Listner
Hakan Somuncu
David Sonna
Kelly Zenger
4/24/2012
University of Illinois at Chicago – Department of Chemical Engineering
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
TABLE OF CONTENTS
I. Executive Summary 3II. Introduction 4III. Description of Process 6IV. Process Control 12V. Environmental Concerns 13VI. Economics 17VII. Competing Processes 19VIII.
Recommendations 22
IX. Appendices 23 Design Basis 24 Block Flow Diagram 25 Process Flow Diagram 27 Material Balance 28 Energy Balance 35 Physical Properties of Process Components 47 Annotated Equipment List 51 Economic Evaluation 58 Utilities 66 Conceptual Control Scheme 68 General Arrangement – Major Equipment Layout 71 Distribution and End-Use Issues Review 73 Constraints Review 74 Applicable Standards and Safety Review 79 Project Communications 86 Special Thanks 86 Information Sources and References 87
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 2
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
EXECUTIVE SUMMARY
In order to produce the ammonia-based fertilizer, several intermediate processes are
required; nitric acid formation is one such process. The raw materials used to produce nitric acid
include 572 TPD of ammonia, provided to the plant from the upstream ammonia team, and air
that will be taken from the atmosphere. The plant will produce 3,289 TPD of a 63% weight nitric
acid solution. 2,571.2 TPD will be provided to the downstream ammonium nitrate team while the
rest is sold to the open market. 1,843 TPD of high quality steam (1,250 psi and 970°F) is
generated in the process and will be provided to the combined heat and power team in exchange
for electricity.
Ammonia is converted in a catalytic reactor to nitrogen monoxide and is further oxidized
to nitrogen dioxide as the hot gases cool before being absorbed to produce the nitric acid
product. With the continuing rise in precious metal costs, platinum-rhodium catalysts are
becoming less economically viable as a catalyst for ammonia oxidation. The platinum-rhodium
catalyst requires frequent replacement and loss is prevalent at the high reaction temperature. A
relatively new catalyst that has been developed, making use of cobalt oxide, provides the same
conversion benefits of platinum-rhodium, while being vastly cheaper and inhibits the formation
of nitrous oxide, an environmental concern. The energy provided by the highly exothermic
reactions will be recovered through an efficient heat exchanger network which will allow steam
generation and preheating of tail gas for expansion to drive the plant compressors. Through
economic analysis the net-present-value was determined to be $984 million over the 20 year
plant life, with a rate of return of 12 years. Based on the plant economics, and the overall success
of the fertilizer plant, it is recommended to move into stage-gate 2.
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 3
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
INTRODUCTION
In order to make ammonium nitrate from natural gas several steps must be taken. Our
process is going to concentrate on the production of 3,829 tons per day of nitric acid from
ammonia which will be the feedstock for the ammonium nitrate process. The production of nitric
acid from ammonia undergoes the following process: Nitric oxide is produced by the reaction of
ammonia with oxygen over cobalt oxide catalyst, which is then oxidized to NO2. The NO2 is then
reacted with water in an absorption column to produce a nitric acid solution. Of the 3,289 tons
per day produced, 2571.2 tons will be supplied to the Ammonium Nitrate process while the rest
is sold on the open market. Ammonia is supplied by the ammonia plant at 571.5 tons per day.
Demand for nitric acid increased by 6.5% a year from 2002 to 2007. More recently the
demand increase has fallen to 3% per year and is expected to do so through 2018, however
because of federal rulings for ethanol components in gasoline the demand is not expected to drop
significantly. Prices between 2002 and 2007 went from a low of $145/short ton to a high of
$290/short ton; 42° Baume (67%), bulk, free on board (FOB). The majority (76%) of nitric acid
is used in the production of ammonium nitrate and the majority of the remaining 24% is used in
explosives manufacture. The strong growth for the mature product has been due to the increased
corn prices from ethanol production and also an increase in wheat prices. In addition, natural gas
prices have dropped significantly and look to stay at a low price for the foreseeable future.
The location of the plant will be in the Northwest corner of North Dakota in the Bakken
Formation of the Williston Basin. The Bakken Formation has an estimated undiscovered volume
of 1.85 trillion cubic feet of natural gas. The benefits of this site include a feed source of natural
gas and located in the agriculturally predominant Midwest. The location will have access to rail,
road, with Interstate 94 within three hours for truck transportation, and via pipeline to the little
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 4
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
used upper Missouri River or the Great Lakes for transportation. Since this is part of an
integrated process for the production of ammonium nitrate fertilizers and the only one of its kind
in the upper Midwest, the plant will have an ideal location to end users.
Currently, the majority of nitric acid production in the United States is produced by using
the Ostwald Process, which uses a platinum-rhodium catalyst under a single high-pressure. The
process employed will be based on a new cobalt oxide catalyst that has shown to increase yields.
Older plants were built to use a single pressure process to produce nitric acid, however because
the absorption processes favor a higher pressure, new plants use a combination of low and higher
pressure processes to increase yield. By manufacturing nitric acid using newer technologies; this
plant can increase production efficiency and therefore higher overall yield of nitric acid at a
lower cost while decreasing emissions.
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 5
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
DESCRIPTION OF PROCESS
General Process:
Among the different processes for nitric acid (HNO3) production the Ostwald Process in
addition to a dual-pressured system were selected for the design of the plant. The Ostwald
Process employs three major process steps for the production of nitric acid. Ammonia (NH3)
must be first oxidized to form nitrogen monoxide (NO). After ammonia oxidation, nitrogen
monoxide must be oxidized to nitrogen dioxide (NO2). The final step is absorption of nitrogen
dioxide with water (H2O) to form nitric acid. The following three chemical reactions are the
major reactions that occur in the process; oxidation of ammonia, oxidation of nitrogen monoxide,
and absorption with water (Ullman’s).
4 NH3 (g) + 5 O2 (g) → 4 NO (g) + 6 H2O (l)
2 NO (g) + O2 (g) → 2 NO2 (g)
4 NO2 (g) + O2 (g) + 2 H2O (l) → 4 HNO3 (aq)
The first reaction, oxidation of ammonia, has two undesired side reactions that take place.
The first is conversion of ammonia to nitrogen gas (N2). This particular product is of no real
concern as nitrogen is inert and a harmless gas. The second, however, leads to the formation of
nitrous oxide (N2O), more commonly known as laughing gas. As stated previously, the cobalt
oxide catalyst helps inhibit the conversion to these unwanted products. After ammonia oxidation
occurs, the temperature of the process gas exceeds 1600°F and must be cooled to form nitrogen
dioxide. A heat exchanger network allows concurrent cooling of process gases, steam generation,
and tail gas preheating. The network employs the use of a waste heat boiler, steam superheater,
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 6
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
shell-and-tube heat exchangers, and condensers to achieve this goal. As the process gas cools
nitrogen dioxide will readily dimerize to unwanted nitrogen tetroxide (N2O4).
After cooling, the process gas is sent to an absorption column to allow nitrogen dioxide to
be absorbed with water to produce nitric acid. An adequate amount of make-up water is used to
ensure that the product requirements of 63% acid by weight are met.
Detailed Process:
The following detailed process overview will reference the process flow diagram that can
be found in the appropriate appendix section. The process begins by taking vaporous ammonia
from the back-end ammonia team at 250°F and filtering it to rid it of any particulate that may
have accumulated during transportation to the plant. Air taken from the outside at approximately
60°F is pressurized to 72.5 psia, the desired pressure for ammonia oxidation. The compressor
used is two-stage in order to reduce the chances of equipment failure due to a hot exit gas
temperature. Due to compression the air is preheated to 480°F. The air stream is split into a
primary reactant stream that will be mixed with ammonia and a secondary air stream that will be
sent to the bleacher column to strip nitrogen tetroxide out of the nitric acid formed at the
absorption stage. The primary air stream contacts the ammonia vapor reducing the overall
temperature to 420°F. An adequate amount of air contacts the ammonia to maintain a 9:1 ratio of
air to ammonia. This ratio must be met in order to prevent the ammonia from igniting.
The air-ammonia mixture is sent to the catalytic reactor to pass over the cobalt oxide bed.
The conversion of ammonia to nitrogen monoxide is highly exothermic and increases the
temperature of the gas to 1634°F. An attached waste heat boiler and steam superheater system
allow pressurized water at the saturation point to be preheated to 970°F. The generated steam is
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 7
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
sold to the combined heat and power design team in return for electricity. After the steam
generation phase the product gases are cooled to 824°F. No nitrogen dioxide has been formed at
this point.
Following steam generation, the process gas passes over a series of five heat exchangers.
The first heat exchanger reduces the process gas from 824°F to 748°F in addition to preheating
the tail gas of the absorption column from 125°F to 312°F. The second heat exchanger cools the
process gas to 536°F while preheating boiler feed water from 250°F to just below its saturation
point. The third heat exchanger further cools the process gas to 428°F and nitrogen monoxide
begins to convert to nitrogen dioxide and nitrogen tetroxide. The tail gas is further preheated to
478°F at this point. The fourth and fifth heat exchangers cool the process gas 356°F and 230°F
respectively against water.
After the series of heat exchangers the first condenser is met. Further conversion of
nitrogen monoxide to nitrogen dioxide and nitrogen tetroxide occurs. The condenser allows the
formation of a very weak nitric acid solution that is pumped to the appropriate tray of the
absorption column. At this point the process gas is compressed a second time to 145 psia with
the NOx laden gases of the bleacher column. As a result of compression, the process gas is heated
to 508°F. Another heat exchanger and condenser are employed to cool the process gas to 257°F
and 197°F respectively while further converting nitrogen monoxide to nitrogen dioxide. A
second weak acid stream is formed as is sent to an acid mixer to be mixed with acid formed at
the absorption column.
At the absorption column nitrogen dioxide is combined with water to form nitric acid.
The acid leaves the column at 198°F and is then combined with the acid stream from the second
condenser raising the overall temperature to 222°F. The acid stream is sent to a bleacher column
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 8
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
to strip out dissolved nitrogen tetroxide enabling the 63% by weight acid solution to be achieved.
Before being sent to the bleacher the stream is cooled to 127°F. The final product is sent to the
ammonium nitrate team at 123°F and 144 psia.
The tail gas of the column primarily consists of nitrogen and oxygen with trace amounts
of nitrogen monoxide, nitrogen dioxide, nitrogen tetroxide, and nitrous oxide. These NOx gases
are environmental concerns and their contents are checked against the Environmental Protection
Agency’s (EPA) parts per million (ppm) regulations in order to ensure that they do not surpass
the limit. The tail gas is first preheated against the secondary air stream from the air compressor
and as a result is heated to 125°F. It is further preheated against the process gas leaving the
ammonia burner as described above. The hot tail gas is expanded from 145 psia to atmospheric
pressure which results in the gas being cooled to 60°F and enough power generation to power the
second compressor entirely.
Catalyst:
In the Ostwald process, ammonia oxidation occurs over a catalyst. Traditionally, a 90%
platinum and 10% rhodium based gauze is placed inside the bed and ammonia and air are reacted
over the gauze.
4 NH3 (g) + 5 O2 (g) → 4 NO (g) + 6 H2O
Low pressures cause low NO yields, while high space velocities and high temperatures
give way to large catalyst losses. At $3-4 per short ton of nitric acid produced platinum losses
accrue for a large amount of the operating cost in the oxidation reactor (Joy Industries). Catalyst
entrapments are used downstream from the reactor to recollect the platinum that is washed out of
the bed. Platinum based reactors are operated from 1490-1724˚F and achieve a 93-96%
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 9
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
conversion to NO. Offsite storage is required for extra platinum gauzes, which must be changed
out every 3-4 months. Changing the catalyst charges requires a full plant shutdown.
Additionally, every 3-4 weeks the plant must also be shut down in order to remove rhodium
oxide deposits.
Alternatively, a cobalt oxide based catalyst may be used for the ammonia oxidation. Ali
Nadir Caglayan has developed a cobalt oxide based catalyst for use in ammonia oxidation in
nitric acid plants. This catalyst is available through the Catalyst Development Corporation and
Joy Indsturies. Currently a cobalt oxide catalyst is being used in several plants, including Incitec
Pivot’s girdler plant on Kooragang Island, Australia and Simplot Canada’s nitric acid plant in
Brandon, Manatoba.
The operating cost for the catalyst is $0.50-0.75 per short ton of nitric acid produced.
Cobalt oxide is stronger and more durable, keeping it from degrading at high temperatures and
washing away at high space velocities. A 95-98% NO conversion rate can be achieved while
operating at approximately 1550˚F. This lower operating temperature equates to less stress on
the heat exchangers. The higher conversion rate of NO means there is less N2O produced,
resulting in lower green house gas emissions for the plant. The plant may also be operated at a
lower pressure without compromising NO yield, meaning a lower pressure drop and, therefore, a
higher lifespan of the plant.
The cobalt catalyst has a lifespan of approximately a year, in which a smaller volume of
catalyst must be added to the bed. The plant does not need to be shutdown during this process,
and after approximately 6-9 years, the entire catalyst must be changed out. Because the plant
doesn’t need to be shutdown and cooled off repeatedly, there won’t be equipment failure due to
thermal cycling. There is also no rhodium oxide buildup or need for a catalyst entrapment or
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 10
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
offsite storage for extra catalyst. Table 3 summarizes the comparison between the two catalyst
options.
Table 3: Catalyst Comparison
Platinum-Rhodium Cobalt Oxide (Co3O4)
Cost ($/short ton of HNO3
produced)$3 - $4 $0.50 - $0.75
Lifespan 3-4 months 12 months
Downtime 4 hours to replace gauze at end of lifespan
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 29
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
Sample Calculations:
Material BalanceBasis: 100 lbmol NH3
*NOTE: Each value will be scaled up to illustrate actual flow rates and will be indicated with green
*NOTE: Values differ from figures generated in Aspen as some side reactions were ignored for hand calculations and aspects of the process were changed as the semester progressed.
Actual NH3 Supplied to Plant: 581 TPD (68,920 lbmol), Aspen: 571.5 TPD
Air Supplied to ReactorAssume 11% v/v mixture of ammonia and air to be below lower explosive limit
Air supplied=100 lbmol N H 3
0.11=909.09 lbmol Air=8,955TPD
O2 supplied=( 909.09 lbmol Air )× 0.21=190.91 lbmol O2=2,086 TPD
N2 supplied= (909.09lbmol Air )× 0.79=718.18 lbmol N 2=6,879 TPD
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 30
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
Reactor Balance
NO Produced∈[ 1 ]=100 lbmol N H3×( 4 lbmol NO4 lbmol N H 3 )× 0.980=98.00lbmol NO=1,004 TPD
N 2 Produced ∈[2 ]=100 lbmol N H3 ×( 2lbmol N2
4 lbmol N H3)×0.019=0.95 lbmol N2=9TPD
N2 O Produced∈ [ 1 ]=100 lbmol N H 3×( 2 lbmol N 2O4 lbmol N H3
Heat Recovery: Steam Superheater, Waste-heat Boiler, Heat Exchangers, CondenserAssumption: 100% of NO converted to NO2 before condenser inlet, ignore dimerizationAssumption: 100% of water vapor condenses at condenserAssumption: 45% w/w solution of nitric acid and water is formed at condenser
N O2 Produced=98.00 lbmol NO×( 2lbmol N O2
2lbmol NO )=98.00 lbmol N O2=1,539 TPD
Total H 2 OCondensed=150.00 lbmol H2O=923TPD
H 2O Required ¿ Produce 100lbmol HN O3=100 lbmol HN O3×( 1 lbmol H 2 O2lbmol HN O3
)=50lbmol H 2O
Mass of 100lbmol HN O3=100 lbmol HN O3×( 63.01lb HN O3
1lbmol HN O3)=6 ,301 lb HN O3
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 32
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
Water Required¿ Dilute¿45 % ww
=( 6 ,301 lb HN O3
0.45 )−6 ,301lb HN O3=7,701 lb H2O
TotalWater for Dilution=7,701+(50 lbmol H 2 O×18.02 lb H2 O1 lbmol H 2 O )=8,602 lb H2 O
HN O3 Formed=100 lbmol HN O3×( 150 lbmol H 2 O477.48 lbmol H 2O )=31.41lbmol HN O3=675 TPD
Cold Stream: Vaporize boiler feedwater and superheat to 970°F
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 41
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
m= qC p ∆T +∆ H vap+∆ H superheat
m=[ 1.76 ∙ 108 Btuhr
(0.58 Btulb ∙F ) (567.4−550 F )+970 Btu
lb+(1481−1184 Btu
lb ) ]× 24 hrday
2000 lbton
=1,681 TPD=1,843TPD
Sizing:
q=UA ∆ T LM
∆ T LM=¿¿¿
∆ T LM=(1634−970℉ )−(824−550℉ )
ln (1634−970℉)(824−550℉)
=440.60
A=1.96 ∙ 108 Btu
hr
(203 Btuft2 ∙ hr ∙℉ )(440.60)
=2,194 ft2
Sample Pump Calculation:
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 42
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
HP= Q ∆ P1714 ϵ
HP=(156,083 lb
hr )(15 psi)
(58.62 lbft3 )(0.1337 ft3
gal )(60 minhr ) (1714 )(0.75)
=3.87 HP
Storage Tank Sizing
Specifications: Product at 120°F and density of 1.3398 kg/L (Handymath). 3 days worth of storage with a tank capacity of 70% (tank is 70% full) 4 tanks each with a diameter of 55 ft.
ρ=(1.3398 kgL )(2.204 lb
kg )( 1 L0.304 ft3 )=83.64 lb
ft3
mTOT=(3 days )( 3,289 tonsday )=(9,867 tons )( 2,000lbs
1ton )=19,734,000 lbs
V∏ ¿=(19,734,000 lbs )( 1
83.64 lbft3 )=235,939 ft3 product ¿
V TOT=235,939 ft3
0.70=337,057 ft3 total
V TANK=337,057 ft3
4=84,264 ft3 per tank
A=π (55 ft2
)2
=2,376 ft2
H=84,264 ft3
2,376 ft2 =35.5 ft
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 43
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
Purpose: Transfer nitric acid from absorption column to mixerFlow [lb/hr] Flow [GPM] Density [lb/ft3] ΔP [psi] Eff. HP
255,690 390 73.04 10 0.75 3.39
Table 30: Pump 6 SpecificationsPump 6 (SS304L)
Purpose: Transfer nitric acid solution to bleacher columnFlow [lb/hr] Flow [GPM] Density [lb/ft3] ΔP [psi] Eff. HP
381,448 699 68.05 25 0.75 13.59
Table 31: Pump 7 SpecificationsPump 7 (SS304L)
Purpose: Transfer nitric acid product to storage tankFlow [lb/hr] Flow [GPM] Density [lb/ft3] ΔP [psi] Eff. HP
274,120 447 76.45 20 0.75 6.95
Table 32: Storage Tank 1 SpecificationsStorage Tank 1
Purpose: Store nitric acid product (tank farm can hold 3 days worth of product)Volume [ft3] Diameter [ft] Height [ft] Capacity [%] Density [lb/ft3] Material
84,264 55 35.5 70 83.64 SS304L
Table 33: Storage Tank 2 SpecificationsStorage Tank 2
Purpose: Store nitric acid product (tank farm can hold 3 days worth of product)Volume [ft3] Diameter [ft] Height [ft] Capacity [%] Density [lb/ft3] Material
84,264 55 35.5 70 83.64 SS304L
Table 34: Storage Tank 3 SpecificationsStorage Tank 3
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 57
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
Purpose: Store nitric acid product (tank farm can hold 3 days worth of product)Volume [ft3] Diameter [ft] Height [ft] Capacity [%] Density [lb/ft3] Material
84,264 55 35.5 70 83.64 SS304L
Table 35: Storage Tank 4 SpecificationsStorage Tank 4
Purpose: Store nitric acid product (tank farm can hold 3 days worth of product)Volume [ft3] Diameter [ft] Height [ft] Capacity [%] Density [lb/ft3] Material
84,264 55 35.5 70 83.64 SS304L
ECONOMIC EVALUATION
Table 36: Materials CostsMaterials
Material Requirement Base Cost Total Cost [per year]Air 10,344 TPD $0.00/ton $0.00Ammonia Vapor 571.5 TPD $350/ton $73,009,125Nitric Acid* (SOLD) 2,571.2 TPD $220/ton $206,467,360
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 58
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
Nitric Acid** (SOLD) 717.8 TPD $300/ton $78,599,100Steam (SOLD) 1,843 TPD $20/ton $13,451,491Cobalt Oxide Catalyst - $0.50/ton acid $476,454TOTAL + $225,032,372/year *Sold to Ammonium Nitrate, **Sold to Open Market
Utility Requirement Base Cost Total CostCooling Water 169,739 TPD $0.05/kgal $745,185/yearBoiler Feed Water 1842.67 TPD $3.50/kgal $161,793/yearProcess Water 607.1 TPD $0.75/kgal $53,305/yearElectricity 30,000 kWh $0.025/kWh $6,570,000/yearSewage - - Installed CostSteam Start-up/Misc. Use - Est. $2,000,000/yearNatural Gas Heating - Est. $5,000/yearTOTAL -$9,535,283/year
Table 41: Yearly ProfitYearly Profit
Item CostRaw Materials +$225,032,372Operating Costs -$2,900,000Utilities -$9,535,283TOTAL Est. Profit: $213,000,000/year
Table 42: Overall Plant EconomicsNPV $983,871,359
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 60
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
IRR 23.98%Interest Rate 8.00%Inflation Rate 3.00%Payback Period for Plant 7 years
Table 43: Net-Present Value / Internal Rate of Return Calculation (Years 0-4)Income Statement for Team FoxtrotYear 0 1 2 3 4
500,000,000 Total Revenues vs. Total ExpensesTotal...
Years
USD
($)
Figure 10: Total Revenues vs. Expenses
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 66
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
UTILITIES
A summarized table with all utility cost and requirement information can be found in the
economic evaluation section of the report.
Cooling Water
Cooling water is received from the combined heat and power group at 80 psia and 80°F.
The nitric acid plant requires 169,739 TPD of cooling water used in the heat exchanger network
and condensers for process gas cooling. All of the cooling water used is returned to CHP at
100°F.
Boiler Feed Water
Boiler feed water is received from the combined heat and power group at 1,350 psia and
250°F. 1,843 TPD of boiler feed water are required. The boiler feed water is used in the process
to both cool down the process gas and eventually be converted to 1,250 psia steam at 970°F to be
sold back to the combined heat and power team. They will then use this steam to power a steam
turbine to generate electricity for the fertilizer complex.
Process Water
Process water is received from the combined heat and power group at 114 psia and 80°F.
607 TPD of process water are required. The process water is used as make-up water in the
absorption column. The absorption column is responsible for converting nitrogen dioxide into
the nitric acid product.
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 67
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
Electricity
Electricity is received from the combined heat and power group. The major use of
electricity comes from the air compressor at a whopping 17 MW. The remainder of the
electricity is used for pumps, lighting, controllers, and other general areas. For estimation
purposes the plant assumes a usage of 30 MW per day with the majority used by the air
compressor.
Steam
Steam is not used in the plant, but rather generated and sold to the combined heat and
power team. The 1,843 TPD of boiler feed water is turned into 1,250 psia and 970°F steam.
Upon plant startup steam will most likely need to be used to bring the ammonia burner up to
temperature. A second option is burning hydrogen or some other gas.
Sewage
Sewage systems will need to be installed within the plant.
Natural Gas
Natural gas is received by the gas purification team. Natural gas is not used in the
process, but it would be required for heating offices and other buildings for the staff.
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 68
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
CONCEPTUAL CONTROL SCHEME
Figure 11: Control Scheme for Ammonia Oxidation
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 69
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
Figure 12: Control Scheme for Nitrogen Monoxide Oxidation
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 70
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
Figure 13: Control Scheme for Absorption
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 71
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
GENERAL PLANT LAYOUT
Figure 14: General Plant Layout
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 72
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
The plant was laid out with the idea of safety and ease of access in mind. The plant
offices and parking lot are located away from the process block with a road as a barrier. The
prevailing wind in the figure above blows towards the south. Within the process block,
equipment was laid out based on the location of the pipe rack in order to minimize piping costs
while remaining safe. The compressor shack is located in the southwest corner of the process
block and is accessible by two roads for ease of maintenance. Within the compressor shack are
the two process compressors as well as the tail gas expander. The three pieces of equipment are
placed in a sheltered environment in order to minimize sound and protect them from the
elements. Along the northeastern edge of the pipe rack the ammonia oxidizer reactor with
attached waste heat boiler, steam drum, and steam superheater can be found. The pieces of
equipment are located near each other to maximize heat recovery for steam generation and
minimize piping costs as the boiler feed water and steam are at 1250 psi.
The northwestern edge of the pipe rack contains the air and ammonia filters as well as the
static mixer. The southern edge of the pipe rack houses many of the process heat exchangers that
are used for boiler feed water and tail gas preheating. Each of the heat exchangers has a tube-
pulling area in order to pull bundles should maintenance on the unit be required. The condensers
and their respective pumps are located near each other to minimize piping costs as a very weak
acid is produced at this point. The brown line that surrounds the acid mixer, absorption column,
and bleacher column represents a dike. The dike is used in case of catastrophic failure of the
absorption column. The dike will ensure that the acid does not spill into the rest of the process
block. The pumps within column area are near the columns in order to minimize costs. The
material for this stronger acid is much more expensive than other parts of the plant. The
southeast corner of the process block contains the nitric acid storage area which contains surge
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 73
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
tanks and product holding tanks. Should the plant need to be shutdown, additional nitric acid will
be ready. The loading zone allows for products to be shipped to the market or the ammonium
nitrate plant by tanker, rail, or pipeline.
DISTRIBUTION AND END-USE ISSUES REVIEW
The hot steam output from the nitric acid production process will be sent to the combined
heat and power plant, and the bulk of the 63 weight % nitric acid solution produced will be sent
to the urea plant. Both will delivered using simple piping.
The nitric acid not required by the urea plant will be sold at market value outside of the
plant. Contacts should be made with companies that will have a use for the product now or in the
future, when the plant is operational. Nitric acid has a relatively low price per weight, which will
probably make long-distance transport and handling economically infeasible. Due to this, most
sales are expected to be to nearby firms.
The nitric acid for sale will be stored upon production in a vertical cylindrical tank with a
fixed roof. It will be transported by truck, so the tank will be located near the periphery of the
overall plant near road access. The storage tank will be fitted with proper couplings and hoses.
To prevent damage from a truck leaving the loading area with the hose attached, a breakaway
hose coupling should be used. The loading area will be the area of the plant with the highest risk
of dangerous leakage due to the potential for operator error. Operators of the loading area must
be thoroughly trained and follow strict protocols and checklists. There should also be careful
maintenance of the hoses to anticipate and prevent corrosive failure.
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 74
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
CONSTRAINTS REVIEW
Feedstock Definition
This process will utilize natural gas from hydraulic fracturing of shale in the Bakken
Formation of the Williston Basin in North Dakota. This natural gas will be sweetened in the gas
purification unit and sent to the Ammonia Plant where the natural gas will be converted to
99.98% pure ammonia vapor. The ammonia plant will deliver 571.5 tons of ammonia vapor per
day to the nitric acid plant. The ammonia vapor will be filtered and mixed with 9100 tons per
day of filtered air and sent to the ammonia burner.
Conversion Technology
The ammonia-air mixture is sent to the ammonia burner where by utilizing a cobalt-oxide
catalyst will be converted to nitric oxide (NO). Because this is an exothermic process, there is a
tremendous amount of heat produced. The heat that is generated will produce high pressure
steam which will be sent to the Combined Heat and Power Group for electricity generation.
Nitric oxide will then be converted primarily to nitrogen dioxide as it cools down through a
series of heat exchangers and condensers. However, there is a small amount of weak nitric acid
produced. The weak nitric acid is removed from the system and introduced to the absorption
column higher up than the nitrogen dioxide. The nitrogen dioxide is then compressed and sent to
the absorption column where it runs through a series of sieve trays counter currently to water.
During the absorption process, nitrogen dioxide and water undergo a chemical reaction that
again, generates heat. The acid is drawn out at different stages, cooled, and sent back to the
column to continue the process. The acid that eventually leaves the column is approximately
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 75
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
63% by weight nitric acid. At this point the nitric acid is known as “red acid” and must be
purified by the bleacher column.
Separation Technology
As stated above, during the conversion of nitric oxide to nitrogen dioxide, a small amount
of weak nitric acid is produced. Before introduction to the absorption column, the weak acid and
nitrogen dioxide must be separated. This is accomplished with the condensers. As the vapor
stream passes through the first condenser, weak nitric acid separates from the vapor stream and is
pumped to the absorption column at a higher stage. In addition, as the vapor cools even further it
is sent to a compressor and second condenser. The very weak (2-3% by weight) nitric acid
separated by the second condenser is used as make-up in nitric acid purification in the bleacher
column. The acid mixture stream is sent to the bleacher column to remove impurities. The
bleacher column consists of a stripping section and a reboiler. The acid stream is run counter
current to an air stream. The air stream absorbs impurities such as nitrogen dioxide and
dinitrogen tetraoxide from the acid mixture and is sent to the compressor.
Product Description
2289 tons per day of 63% by weight purified nitric acid leaves the bleacher column. From
here the nitric acid either enters storage or is sent directly to the ammonium nitrate group. It
should be noted that any nitric acid sent to storage should be used as quickly as possible if color
is important because as the acid sits, the acid can “yellow due to the separation of NOX. The
ammonium nitrate group will convert nitric acid, ammonia, and urea into either ammonium
nitrate or urea ammonium nitrate to be used as fertilizer for crop production.
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 76
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
Location Sensitivity Analysis
The nitric acid plant will be located in the Bakken Shale Deposit of the Williston Basin in
Northwestern North Dakota. The Bakken Shale Deposit lies in a relatively non-geologically
active zone, and therefore earthquakes are rare. The largest earthquake on record occurred on
July 8, 1968 and was magnitude 4.4. Should accidental release of nitric acid or vapors from the
process occur, the damage should be insignificant. The only concern would be nitric acid leakage
to the Missouri river. The effect of an accidental spill will be minimized by proper containment
and neutralization, training, and communication with the local officials. This plant has been
designed to keep emissions from the tail gas low by use of an economizer. The area of
Northwestern North Dakota is sparsely populated with the largest community being Williston
with a population of just over 13,000 residents. Any accidental spill should not adversely affect
the community there, but safety protocols have been put into practice to avoid such releases.
ESH Law Compliance
This plant’s emissions are under the USEPA regulations for air contaminants. The state
of North Dakota does not have its own EPA regulations and as such only the USEPA standards
apply. The only major pollutant is NO2, the EPA maximum allowable emissions is 53 parts per
billion. The nitric acid plant produces over 5000 parts per billion, however because the plant
utilizes tail gas treatment to power a turbine at the end of the process, the emissions fall below
EPA standards. The EPA does not currently regulate NO2 emissions, however, design has been
that there may be regulations of NO2 in the future and when regulations are implemented this
plant will be well below the limit.
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 77
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
Employee safety is of the utmost importance in this plant. Plant process controls are
installed in order to prevent any catastrophic accidents from occurring. The largest source of
danger is in the ammonia oxidation process. The ammonia to air ratio has to be held at under
14% in order to prevent an explosion hazard. The nitric acid plant will run at a ratio of under
11% as well as having controls to prevent higher concentrations from occurring. The plant is
designed to alarm workers to a dangerous condition first and if it is not alleviated the process
will in effect shut itself down. Workers are to be trained in all aspects of safety in regards to
nitric acid production with repeat training occurring at least annually. Should an emergency
arise, teams of first responders trained in that situation will respond immediately, while clear
communication to local emergency officials ensures the situation will be contained quickly. In
addition, weekly safety meetings with the supervisors are to be performed. Each department is to
conduct its own safety review on a monthly or sooner basis. Safety teams and the safety
committee headed by the EHS director will conduct routine safety audits to ensure the plant is in
compliance with any and all regulations.
Laws of Physics Compliance
None of the laws of thermodynamics are shown to be broken. There is no decrease in
entropy at any point. Oxidation of ammonia produces nitric oxide and heat employs the first and
second laws of thermodynamics. The heat generates steam which powers a turbine for electricity
employs the first law. Nitric oxide is oxidized in a series of heat exchangers that lowers the
temperature of the system proving the zeroth, first and second laws. Condensers separate the
streams proving the second law. Compressors add work to the system once again proving the
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 78
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
first and second laws to be in effect. Turbines utilize gas expansion to provide work proving the
first and second laws.
Turndown Ratio
If for some reason, the production of nitric acid needs to be slowed down the plant has
the ability to achieve a turndown ratio of 2-3:1. The main reasoning for this is the minimum
vapor velocity on the trays in the absorption column. However, if there is a complete stoppage of
production in one of the downstream processes, surge tanks will be utilized. For emergency
purposes of the downstream processes being down for a week, four 250,000 gallon storage tanks
made from 304L stainless steel will be utilized. Each tank will have a dike that will contain the
one and one half times the contents of the tank in case of a leak. In addition, there will be four
more storage tanks storage for transportation. These tanks can also be used for emergency
storage if needed.
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 79
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
APPLICABLE STANDARDS / SAFETY REVIEW
The safety of employees and the public are of utmost concern for a chemical production
plant. Economic and logistical concerns as detailed in this report drive the design and
construction of the plant, but safe use is the number one goal of such an operation. There are
numerous important safety precautions to be taken. Some are to be considered during equipment
design and plant layout, some will be regular actions to take during operation, and some others
are to be performed during an emergency. The following is an outline of safety matters that are
relevant to the production of nitric acid.
Environmental
A great concern for the process at hand is a catastrophic equipment failure (Perry). A
likely cause for this is a situation of thermal runaway. The two highly exothermic reactions in the
Ostwald process make unchecked heating a serious problem with severe consequences. Process
controls have been prepared to carefully monitor and regulate these reactions, and cease them
immediately if need be. They also keep the ratio of ammonia to air below a safe level. The
catalytic reactor, absorption column, bleacher, heat exchangers, and various pipes and fittings
have been designed to withstand fluctuations in operation conditions within a reasonable margin.
They will be fitted with relief valves to prevent dangerous over-pressurization. With or without
thermal runaway, equipment will fail if it is sufficiently degraded (European Fertilizer
Manufacturers' Association). It will be important to ensure that the equipment is of quality
construction, and proper materials have already been selected for each of the components to
prevent corrosion. Corrosion is important to consider because of the chemicals used in the plant.
Equipment must be tested regularly for corrosion and replaced if need be.
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 80
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
The total failure of a key piece of equipment will result in the release of some or all of its
contents. The plant designer must take the small chance of this occurrence seriously and
adequately prepare for the plant and employees to withstand such an event. For the components
handling gases, failure will lead to the release of dangerously hot gases. It will be important for
plant personnel to be immediately made aware of the failure and evacuate the area downwind
from the failed equipment (Towler). The absorption column and adjacent piping will contain a
liquid solution of highly reactive nitric acid, and the release of a large amount of heated nitric
acid from this section is the greatest safety concern in the entire plant. Once again, plant
personnel should be alerted, and the layout of the area should allow for immediate evacuation to
avoid contact with liquid and vapor release. A large amount of liquid, when spilled, has the
potential to travel far along the ground. Bunding should be used in this area to contain a spill
within this section of the plant, which will defend personnel as well as other equipment from
damage and harm. A thick foundation of concrete may be necessary as well to prevent
contamination of groundwater. Nitric acid itself has low flammability, but it it is still a fire
hazard. Its reactions involve exothermic oxidation, which can produce flammable vapors and
enough heat to ignite them. Equipment and support structures within reach of the ground in the
area of the absorption column should be coated with a material that can withstand fire and
insulate from high heat.
In the case of any large failure, it is vital for the public and plant employees to be
prepared. Evacuations and other emergency procedures should be planned and reviewed with
employees before the possibility of a spill. Contacts should be previously established with nearby
chemical cleanup specialists. Proper Personal Protective Equipment (PPE) should be acquired
and kept on-hand for work that must be performed immediately in the area of a spill. The PPE
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 81
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
required to handle a dangerous spill would be a hazardous materials suit, including protective
clothing and a breathing apparatus.
The Environmental Protection Agency details the work that must be done by a Local
Emergency Planning Committee (LEPC) (EPA). These committees are established to protect the
safety of the public near the plant, and it is especially relevant in emergency preparations. Its
tenets, as detailed by the EPA, are as follows:
“Write emergency plans to protect the public from chemical accidents;
Establish procedures to warn and, if necessary, evacuate the public in case of an
emergency;
Provide citizens and local governments with information about hazardous chemicals and
accidental releases of chemicals in their communities; and
Assist in the preparation of public reports on annual release of toxic chemicals into the
air, water, and soil.”
The light release of chemicals is a hazard for employees as well. It can be caused by an error
by a plant operator, such as leaving a sample point open, or spilling material while loading or
unloading. It can also be caused by leaks from degraded or improperly fitted equipment. Liquid-
handling areas of the plant should have ground formations to contain and direct the flow of
hazardous liquids to storage containers. Neutralization of small quantities of the nitric acid
solution can be done by slowly adding a weak base or a third-party product to the spill. Some
neutralization materials, equipment, and training for doing so should be prepared in the plant
beforehand.
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 82
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
Indeed, a more in-depth study of plant risks is necessary. The Occupational Safety and
Health Administration (OSHA) requires a formal process hazard assessment for the plant. A
failure-mode effect analysis, which is a discussion panel with experts in aspects of the plant, is
also recommended to ensure that all potential hazards are fully considered.
Occupational Health & Safety
The long-term well-being of plant personnel is vital to consider. OSHA in the United States
regulates this facet of plant operation, and the following are many of the things that must be
minded while constructing and operating the plant.
The dilute presence of airborne chemicals is a hazard requiring constant management
(Wells). This presence must be kept within acceptable levels by containing leaks, using proper
ventilation around work areas, and by engineering controls. OSHA allows for certain levels of
airborne chemicals, and the permitted concentrations are as follows. The terms used are defined,
followed by the concentration limits accepted by OSHA for key chemicals in the process.
PEL: Permissible Exposure Limit.
TWA: Time-Weighted Average. Defined by OSHA as "… the employee's average
airborne exposure in any 8-hour work shift of a 40-hour work week which shall not be
exceeded."
STEL: Short Term Exposure Limit.
IDLH: Immediately Dangerous to Life or Health.
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 83
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
Table 48: OSHA Chemical Exposure Limits (from OSHA online)
Material PEL, TWA [ppm] STEL [ppm] IDLH [ppm]NH3 25 35 300HNO3 2 4 25NO 25 - -NO2 5 - -
Another risk to be managed is that of noise. OSHA allows for a 90 decibel PEL, and it
will be imperative to maintain that for the sake of employees' ear health. There are several ways
for one to keep noise exposure within acceptable levels. They include using machinery which is
inherently low-noise, keeping bearings lubricated, erecting sound barriers, and limiting time
which personnel spend near sources of noise. If the plant exceeds a level of 85 decibels, it will be
required that an employee Hearing Conservation Program be enacted. OSHA also regulates noise
pollution of the area surrounding the plant, but that is a lesser concern due to its remote location.
There are numerous OSHA regulations regarding working spaces. There will be
numerous heated vessels and pipes throughout the plant which are burn risks. There is a zone
defined as seven feet from the ground or floor and within 15 inches of stairs and ladders which
much be protected from contact with employees. Hot components within this area must be
sufficiently insulated or guarded. Moving parts should also have guards around them. Platforms
should have guard rails, be wide enough, and have non-slip surfaces. The work area should also
be well-lit and have plenty of emergency exits.
The following is a list of components used in the process and their associated risks.Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 84
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
“Assessment of Undiscovered Oil Resources in the Devonian-Mississippian Bakken Formation, Williston Basin Province, Montana and North Dakota, 2008.” United States Geological Survey.
Catalyst Development Corporation. 2003. Tulsa, Oklahoma, USA. <www.cobaltoxide.com>.
Coker, A. Ludwig’s Applied Process Design for Chemical and Petrochemical Plants: Volume 2: Distillation, Packed Towers, Petroleum Fractionation, Gas Processing and Dehydration. Burlington MA: Gulf Professional Publishing. 2007. Print
Counce, Robert and Joseph Perona. “Gaseous Nitrogen Oxide Absorption in a Sieve-Plate Column.” Industrial and Engineering Chemical Fundamentals. July 1980. Print.
EPA. Available and Emerging Technologies for Reducing Greenhouse Gas Emissions from the Nitric Acid Production Industry. U.S. Environmental Protection Agency. 2010. <http://www.epa.gov/nsr/ghgdocs/nitricacid.pdf>.
Environmental Protection Agency. “Emergency Planning and Community Right-to-Know Act Overview.” Accessed April 5th, 2012. <http://www.epa.gov/oem/content/lawsregs/epcraover.htm>
European Fertilizer Manufacturers' Association. “Best Available Techniques for Pollution Prevention and Control in the European Fertilizer Industry”, booklet 2 of 8, 2000. <http://www.efma.org/documents/file/bat/BAT%20Production%20of%20Nitric%20Acid.pdf>
Glushchenko, V. and E. Kirichuk, “Mathematical Model of Absorption Columns for the Production of Nitric Acid”. International Chemical Engineering. 1982. Print
H.E. Eduljee. “Design of Sieve Tray Type Distillation Plates.“ British Chemical Engineering. 1958. Print
Handbook, 6th Edition, New York: McGraw-Hill 1984 Print
JOY Industries. The Complete Heat Transfer and Process Company. 1998.
Keesom, Bill. Personal Interview. 27 Mar. 2012
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 88
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
Kniel, G. E., Delmarco, K. and Petrie, J. G. (1996), Life cycle assessment applied to process design: Environmental and economic analysis and optimization of a nitric acid plant. Environ. Prog., 15: 221–228. doi: 10.1002/ep.670150410 <http://blowers.chee.arizona.edu/ChEE455-555/papers/Paper4.pdf>
Koch-Glitsch Column Sizing Program
Miller, D. “Mass Transfer in Nitric Acid Absorption.” AIChE Journal. Aug. 1987. Print.
“Nitric Acid.” Wikipedia. Wikimedia Foundation, Inc.,Valenciano et al. 16 Apr. 2012.“North Dakota Earthquake History.” Earthquake Information Bulletin, Volume 7, Number 6.,
United States Geological Survey., von Hake, Carl., Dec. 1975.
OSHA. “Safety and Health Topics: Ammonia.” Accessed April 1st, 2012. <http://www.osha.gov/dts/chemicalsampling/data/CH_218300.html>
OSHA. “Safety and Health Topics: Nitric Acid.” Accessed April 1st, 2012. <http://www.osha.gov/dts/chemicalsampling/data/CH_256600.html>
OSHA. “Safety and Health Topics: Nitric Oxide.” Accessed April 1st, 2012. <http://www.osha.gov/dts/chemicalsampling/data/CH_256600.html>
OSHA. “Safety and Health Topics: Nitrogen Dioxide.” Accessed April 1st, 2012. <http://www.osha.gov/dts/chemicalsampling/data/CH_257400.html>
Parkinson, Richard. UOP. Where Does It Go? An Introduction to the Placement of Process Equipment. 2009.
Perry, R.H. and Green, D.W. Perry's Chemical Engineers' Handbook. 7th Edition. McGraw-Hill Professional, 1997.
Peters, Max and Klaus Timmerhaus. Plant Design and Economics for Chemical Engineers. New York: McGraw-Hill, Inc., 1991. Print.
R.H. Perry and D. Green (Eds), Perry’s Chemical Engineers’
Ray, Martin and David Johnston. Chemical Engineering Design Project: A Case Study Approach. New York: Gordon Breach Science Publishers. 1989. Print.
Richard M. Pollastro. et al. 2008. Web. 23 Apr. 2012.
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 89
Improved Nitric Acid Production via Cobalt Oxide University of Illinois at ChicagoCatalysis for use in Ammonia-Based Fertilizers
Smith, J. and H. Van Ness. Introduction to Chemical Engineering Thermodynamics. New York: McGraw-Hill, Inc., 1987. Print
Suchak, N., K. Jethani, and J. Joshi. “Modelling and Simulation of NOX Absorption in Pilot-Scale Packed Columns.” AIChE Journal. Mar. 1991. Print
Suchak, N. and J. Joshi. Simulation and Optimization of NOX “Absorption System in Nitric Acid Manufacture.” AIChE Journal.June 1994. Print.
Taylor, Guy, Thomas Chilton, and Stanley Handforth. “Manufacture of Nitric Acid by the Oxidation of Ammonia.” Industrial and Engineering Chemistry.Aug. 1931. Print.
Towler, Gavin and Sinnott, Ray. Chemical Engineering Design. Butterworth-Heinemann, 2008.
“U.S. Natural Gas Wellhead Price” US Energy Information Administration. n.a. Web. Jan. 2012.
Ullman’s Encyclopedia of Industrial Chemistry. Volume A17. VCH.
Wells, G.L. Safety in Process Plant Design. John Wiley & Sons, 1980.
“Williston Basin.” Wikipedia, The Free Encyclopedia. Wikimedia Foundation, Inc. 10 Apr. 2012. Accessed 12 Apr. 2012. <http://en.wikipedia.org/wiki/Williston_Basin>.
“Williston (city), North Dakota.” State & County QuickFacts, United States Census Bureau, n.a. Web. 31-Jan-2012
Senior Design II – CHE 397 Team Foxtrot Spring 2012Calabrese, Listner, Somuncu, Sonna, Zenger Page: 90