Waste Stream Composition Quantity
Plant Source Mol. Molecul Composi
Formula Name ar tion (wt Kg/hr.
Weight %)
C2HF5 R125 120 50% 13
R-134a Vent-1 C2H3F3 R 143a 84 30% 7.8
C2H2F4 R 134a 102 20% 5.2
CHF3 R23 70 13% 2.5
R-32 Vent-1 CH3Cl Methyl Ch 50.5 8% 1.5
CH2F2 R 32 52 79% 15
C2HF4Cl R124 136.5 64% 25
Vent-1 C2F4Cl2 R114 171 22% 8.5
R-125 C2H2F3Cl R133a 118.5 14% 6
C2ClF5 R-115 154.5 100% 5
Vent-2
C2HF5 R-125 120 Traces
CHF3 R23 70 99% 20.6
CH2F2 R 32 52 0.3% 0.07
R-22 Vent-1
C2H3F3 R 143a 84 0.3% 0.07
CHClF2 R-22 86.5 0.3% 0.07
CHF3 R23 70 10.0% 4.1
Fpone Vent-1 CH2F2 R 32 52 25.0% 10.3
CO Carbon M 28 65.0% 26.8
P-3613a Vent-1 CF3CCl3 187.5 100% 150
Total 301.528
Quantity
Total
Kg/hr
26
19
39.5
20.8
41.2
150
302
Waste Stream Compostion Quantity
Sourc Molecul Composi
Plant Comp.
e Mol. Formula Name ar tion (wt Kg/hr.
Weight %)
Residue-
1 124 100% 2.1
C4H6F2O2
P6 C3H4F2O2 110 70% 2.3
Residue- C4H6F2O2 124 25% 0.8
2
HF 20 5% 0.2
P7 Residue-1 C4H5F3O2 142 100% 1.5
C8H5F3O 174 13% 3.4
Residue- C8H4F3ClO 209 11% 2.9
1
P28 C8H3F3Cl2O 243 76% 20.0
Residue- C8H5F3O 174 20% 0.9
2 C16H8F6O3 362 80% 3.7
C6H7F3O2 168 50% 3.1
Residue-1
C10H8F6O3 290 50% 3.1
P34
C13H16F3O4N1 307 50% 21.4
Residue-2
C8H10 106 50% 21.4
C7H3F4Br 243 30% 3.8
SS-02 Residue- C7H4F4 164 5% 0.6
1 C7H3F4Br 243 5% 0.6
C7H2F4Br2 322 60% 7.5
C4H6N2S3 178 6% 0.6
SS-41 Residue- C4H3F3N2S2 200 42% 3.8
1
C3H4N2S3 164 52% 4.7
Total 108.3
Quantity
Total
Kg/hr
2.1
3.3
1.5
26.3
4.6
6.1
42.8
12.5
9.1
108
Carbon Hydrogen Fluorine Oxygen
1 SUB MERGED GASEOUS 55.19662 2.225122 129.493 15.30286
2 SUB MERGED LIQUID WASTE 54.68826 4.447315 21.2391 9.736916
109.885 6.67244 150.732 25.0398
A 18.30734 0.738017 42.94959 5.075575
B 50.49701 4.106477 19.61136 8.990689
Analysis
Carbon 18.30734 %
Hydrogen 0.738017 %
Nitrogen 0.00 %
Sulphur 0 %
Oxygen 5.075575 % 24.12
%
%
HCV= [35000*C+143000*(H-O/8)+9160*S]/100
LCV= HCV-9*H/100*2460
HCV = 6556 1566 Kcal/kg
NCV = 6392 1527 Kcal/kg
Chlorine Bromine Sulphur Nitrogen
99.28238 0 0 0 301.5 301.5
6.332688 5.163484 4.287463 2.404766 108.3 108.3
105.615 5.16348 4.28746 2.40477
32.92948 0 0 0 100
5.847358 4.76776 3.958876 2.220467 100
Analysis
Carbon 50.49701 %
Hydrogen 4.106477 %
Nitrogen 2.22 %
Sulphur 3.958876 %
Oxygen 8.990689 % 69.77
%
%
HCV= [35000*C+143000*(H-O/8)+9160*S]/100
LCV= HCV-9*H/100*2460
HCV = 22302 5326 Kcal/kg
NCV = 21393 5109 Kcal/kg
Date: 5/11/2019
DESIGN STEPS
TOTAL TYPES OF WASTES :
P.C.C
VENT GAS
Mass to be fed in to the PCC = 300 kg/hr
Calorific value :
HCV= [35000*C+143000*(H-O/8)+9160*S]/100
LCV= HCV-9*H/100*2460
Waste composition : % Kg/hr
Organic 100 300
Moisture 0 0
Inorganics 0 0
300
Calorific Value 1500 kcal/kg
temperature T2 1100 °C
T1 30 °C
A/W Ratio 2.03 1.35
Consider (37% excess air) 2.74
Combustion air reqiured 821 kg/hr
D.G 805 kg/hr
Moist (Say 2 %) 16 kg/hr
Heat required for waste =
1 by organics m*0.6*(T2-T1)
195810.00 kcal/hr
2 by inorganics m*0.3*(T2-T1)
0.00 kcal/hr
3 by moisture m*{70+540+0.5(T2-100)}
0.00 kcal/hr
4 heat by Combustible air = Air * 0.28 *(T2-T1)
245955.41 kcal/hr
TOTAL HEAT REQUIRED = 1+2+3+4= 441765 kcal/hr
0.441765405 MKcal/hr
Heat Released by Organics = 450000 kcal/hr
AQUEOUS WASTE :
Total Mass flowrate = 108 Kg/hr
Mass flowrate to PCC = 108 Kg/hr
Waste composition : % Kg/hr
Organic 100 108
Moisture 0 0
Inorganics 0 0
108
Calorific Value = 5190 kcal/kg
A/W (50% extra) 7.01 10.00 1.43
Air Required = 1080 kg/hr 0
D.G.= 1058 kg/hr
Moist.= 22 kg/hr
Temperature T1 30 °C
T2 1100 °C
Heat and Mass Balance :
Heat absorbed by Aqueous waste =
1 by organics m*[0.6*(150-T1)+160+0.3(T2-150)]
55836 kcal/hr
2 by inorganics m*0.3*(T2-T1)
0 kcal/hr
3 by moisture m*{70+540+0.5*(T2-100)}
0 kcal/hr
4 heat by Combustible Air *0.28*(T2-T1)
air 323568 kcal/hr
Heat absorded by Aqueous waste = 379404 kcal/hr
Heat released by Aqueous waste = 560520 kcal/hr
Assume 0 kcal/hr
Total Heat absorbed in PCC = 821169 Kcal/Hr
Total Heat absorbed = 821169 Kcal/hr
Total Heat released in PCC = 1010520 Kcal/hr
Total Heat released (5% Radiation loss) = 959994 Kcal/hr
Net heat Available (Released - Absorbed) = 138825 kcal/hr
Fuel Required (F.O.) = CV = 9650 -30.47 Kg /hr , A/F = 13.04
-30 kg/hr 17.00
1.30
Combustion Air Required = -518 kg/hr
D.G. -508 kg/hr
Moist -10 kg/hr
Cooling Air Required = 463 kg/hr 17.00
#DIV/0!
Cooling Air Required = 463 kg/hr
D.G. 454 kg/hr
Moist 9 kg/hr
Cooling Water Required = 125 kg/kr
Mass out With Cooling Air = 2753 D.G = 2725
Moist = 28
Thermal capacity of Chamber = 0.8836 Mkcal/hr 0.9084
Mkcal/hr
Mass out With Water Cooling =
Mass out = 2424 D.G = 2271
Moist = 153
Thermal capacity of Chamber = 0.7780 Mkcal/hr 0.7998
Mkcal/hr
Volume in chamber
Inlet Temp 1100 C
D.G. 2271 kg/hr
141 kg/kr
Moist 0 kg/hr
406.4
EVAPORATIVE COOLER
Total Gas = 2424 kg/hr
Dry gas 2271 kg/hr
moisture 153 kg/hr ENTHALPY in kcal/kg
TEMP air MOIST
inlet temp 1100 °C 75 17.73 626.8
outlet temp 30 °C 100 23.765 640.228
200 48.14 692.9
Enthalpy @ t1 900 °C 250 60.525 719.34
D.G 290.02 Kcal/hr 300 73.048 746.11
MOIST 1153.17 Kcal/hr 400 98.4268 800.9361
600 151.4507 916.5375
Enthalpy @ t2 30 °C 700 178.6064 960.0029
D.G 54.33 Kcal/hr 800 206.0226 991.2487
MOIST 706.12 Kcal/hr 900 233.7183 1022.492
1000 261.7603 1086.95
Amount of Water Evaporated 893 Kg/hr 1100 290.0246 1153.168
10% Total Dissloved Salts 89 Kg/hr 1150 304.5091 1187.163
1200 318.9124 1221.185
1155 982
VENTURI SCRUBBER 115 HUMIDITY
1039
Total = 3463 kg/hr TEMP HUMIDITY kgmoist/kg gas
Dry gas 2271 kg/hr 15 0.0106
moisture 1192 kg/hr 70 0.2782
75 0.3851
inlet temp T1 30 C 80 0.5511
outlet temp T2 75 C 85 0.8352
90 1.414
enthalpy @ t1 30 C 95 3.173
D.G 54.33 Kcal/hr 99 18.73
MOIST 706.12 Kcal/hr 30 0.0273
60 0.153
enthalpy @ t2 75 C 65 0.2051
D.G 17.73 Kcal/hr
MOIST 626.8 Kcal/hr
Water Evaporated 298 kg/hr
-90
@ venturi outlet
average mol. Wt. 23.35 kg
-128.71
density of gas@ 0.818 kg/m³
outlet temp 0.0510 lb/ft³
Vol flow rate 4600 m³/hr 1.27764 m³/sec
162412 ft³/hr
Velocity of gas @ throat 70 m/s assumed
229.66 ft/s
c/s area of throat 0.0183 m² For v = 65 Dia = 355
0.1965 ft² for v = 75 Dia = 330
diameter 0.1524 m
length 0.4572 m
Pr. Drop 250 mm WC assume
9.843 inch WC
L 9.4474 gal/1000ft³gas
Water circulated 1534.37 gal/hr
5.808 M³/hr Extra 20% = 7.0 M³/hr
26 m3/hr
@ venturi Outlet 3761 kg/hr
Dry gas 2271 kg/hr 23.3481
moisture 1490 kg/hr 0.8176 4599.50
Moisture Holding Capacity @ 75 C 875 kg/Kg of moist, as the humidity @ 75°C 0.3851
For the Dry Air kg moist/Kg DG
Amount of water being condensed = 615 kg/hr
NO CONDENSATION OCCURS
Mass out 3145 kg/hr
Dry gas out 2271 kg/hr 72.20%
moisture out 875 kg/hr 27.80%
I D FAN
Inlet Temp 75 C
D.G. 2271 kg/hr
Moist 875 kg/hr
Total 3145 kg/hr
Mol Wt 24.79 kg
Density 0.868 kg/m³
Vol Flow 3624 m³/hr
30% Extra 4711 m³/hr
4711 m³/hr
Power Required for this System
Assume Pr.drop = 1200 mm of water column; Efficiency 0.65
Power = 32.21 HP OR 24 KW
Taking 20% loss = 39 HP 29 KW
kgmoist/kg gas
mm
mm
kg moist/Kg DG
Total mass = 2424 Kg/hr @ 1100 deg C
Dry gas = 2271 Kg/hr
Moist = 153 Kg/hr
Avg Mole wt.= 27.92 kg
Gas Density.= 0.2478 kg/m3
Vol.flow rate.= 9779 m3/hr
Thermal capacity of MCC = = 0.7998 Mkcal/hr.
799806.12 kcal/hr
FOR CIRCULAR CHAMBER
Assume: Thermal intensity of Combustion chamber = 100000 kcal/hrm3
Volume of chamber = Thermal capacity/Thermal intensity
= 8.00 m3 = ∏* r2 * h
Dimension: Radius = 0.683 m
Diameter = 1.365 m 2850 mm
Length (L/ D) = 4 5.462 m Actual volume =
And the above dimensiones are can be corss checked for the sufficient
residence time (Minimum 2 sec) in the chamber
Residence time Rt = 2.94 (ok,as the Rt more than 2 sec.)
Fuel: ( F.O.) 3.5 % sulphur
Fuel Reqirement for startup ( to rise to 850 deg C) the MCC
Fuel is needed per m2 of chamber to raise to 850 deg C = 1.5
RK inside surface area = 26.36 m2
Therefore, fuel needed = 39.54 Litre
Dimension: Radius = 0.750 m
Diameter = 1.500 m 2850
7.993 m³ Length (L/ D) = 3 4.500 m Actual volume =
And the above dimensiones are can be corss checked for the sufficient
residence time (Minimum 2 sec) in the chamber
Residence time Rt = 2.93 (ok,as the Rt more than 2 sec.)
lpm2
mm
Actual volume = 7.948 m³
73.55 Kpa
61.29 kpa
9.8 kpa
49.03 kpa
H + Cl ---------->
1 35.5
HCl + NaOH ---------->
36.5 40
1 1.096
Feed Rate = 0
Cl generated after decomposition =
Therefore, HCl generated = 108.59
CAUSTIC SCRUBBING FOR HBr
H + Br ---------->
1 79.9
HCl + NaOH ---------->
79.9 40
1 0.501
Feed Rate = 0
Br generated after decomposition =
Therefore, HBr generated = 5.23
CAUSTIC SCRUBBING FOR HF
H + F ---------->
1 19
HF + NaOH ---------->
20 40
1 2.000
Feed Rate = 0
F generated after decomposition =
Therefore, HF generated = 158.67
HCl 108.59
HBr 5.23
HF 158.67
HCl
36.5
NaCl + H2O
58.5 18
1.603 0.493
Kg/Hr
105.62 Kg/Hr
kg/hr
HBr
80.9
NaBr + H2O
102.9 18
1.288 0.225
Kg/Hr
5.16 Kg/Hr
kg/hr
HF
20
NaF + H2O
43 18
2.150 0.900
Kg/Hr
150.73 Kg/Hr
kg/hr
BLOWER :1
0.25 barg 2600 Nm^3/hr
BLOWER :2
0.98 barg 1.25 barg 2600 Nm^3/hr
ACID SCRUBBING
Fuel consumed for start up 157.61 lit/hr
Fuel Consumed kg/hr (max either of fuel used for start up Or Continuous)
Sulphur (assumed) = 3.5 % 40 FROM FLUE
Therefore total Sulphur content = 45.52 kg/hr max Sulphur is considered.
S + O2 ------------> SO2
32 32 64 kg/hr
SO2 generated == 91.03 kg/hr
O2 required == 45.52 kg/hr
Air required == 216.74 kg/hr
CAUSTIC SCRUBBING FOR SO2
SO2 + 0.5 O2 + 2NaOH ----------> Na2SO4 +
64 80 142
NaOH required 113.79 kg/hr
Salt formation 227.58 kg/hr
CAUSTIC SCRUBBING FOR HCl
CH3Cl + 1.5 O2 ----------> CO2 + H2O + Cl
50.5 48 44 18 35.5
1 0.950 0.871 0.356 0.703
H + Cl ----------> HCl
1 35.5 36.5
HCl + NaOH ----------> NaCl + H2O
36.5 40 58.5 18
1 1.096 1.603 0.493
Feed Rate = 0 Kg/Hr
Cl generated after decomposition = 504.00 Kg/Hr
Therefore, HCl generated = 97.73 kg/hr
NaOH required 107.10 kg/hr
Salt formation 156.64 kg/hr
CAUSTIC SCRUBBING FOR HBr
H + Br ----------> HBr
1 79.9 80.9
HCl + NaOH ----------> NaBr + H2O
79.9 40 102.9 18
1 0.501 1.288 0.225
Feed Rate = 0 Kg/Hr
Br generated after decomposition = 40.00 Kg/Hr
Therefore, HBr generated = 4.71 kg/hr
NaOH required 2.36 kg/hr
Salt formation 6.06 kg/hr
CAUSTIC SCRUBBING FOR HF
H + F ----------> HF
1 19 20
HF + NaOH ----------> NaF + H2O
20 40 43 18
1 2.000 2.150 0.900
Feed Rate = 40 Kg/Hr
F generated after decomposition = 40.00 Kg/Hr
Therefore, HF generated = 14.28 kg/hr
NaOH required 28.56 kg/hr
Salt formation 30.70 kg/hr
Total NaOH req 251.81 kg/hr Caustic lye
Total Salt formation 420.98 kg/hr
To maintain a TDS level ( 10 % )
10% = 4209.81 kg/hr
Water is to be recirculated = 28561 kg/hr 27
(for Packed Bed)
Total mass to be circulated = 29191 kg/hr
(Caustic + Water)
So the Conc of caustic in RC Tank = 1.44218 % per hr
Conc of caustic in RC Tank = 28.844 % 20 hrs per day
Bleed off of RC Tank = 0.693 Days
p Or Continuous)
FROM FLUE
max Sulphur is considered.
H2O
18
629.52 40%
kg/hr
m3/hr
20 hrs per day
