Final Report Production of SHMP
Final Report Production of SHMP
PROJECT REPORT
ON
BACHELOR OF ENGINEERING
IN
CHEMICAL ENGINEERING
SUBMITTED BY
HRISHIKESH YADAV
PRATHAMESH KATKAR
AMOD PADGE
Certificate
Examiner 1
Examiner 2
ACKNOWLEDGEMENT
I would like to express sincere gratitude and special thanks to Prof. M T Sose, Department of Chemical
Engineering, Datta Meghe College of Engineering, Navi Mumbai, for his invaluable guidance and
encouragement throughout the work.
Our special thanks to Dr.S.D.Sawarkar, Principal, Datta Meghe College of Engineering, Navi Mumbai,
and Dr.Mrs.K.S.Deshmukh, Head of Chemical Department, Datta Meghe College of Engineering, Navi
Mumbai, for their encouragement.
I would also like to thank Department of Chemical Engineering for providing the required facilities for the
work.
ABSTRACT
The main purpose of this project is to conduct a comprehensive study that
would lead ultimately to an integrated design, in a chemical engineering point of view, of a plant that
produces Sodium Hexametaphosphate(SHMP) with a production capacity specified in advance. This
study will take into consideration aspects including the plant's process unit design, process flow
diagrams, cost estimations, operation parameters, equipment sizing, construction materials and
environment/safety precautions. This project requires the theoretical and practical application of mass
transfer, heat transfer, fluid dynamics, unit operations, reaction kinetics and process control. There are
several tasks that are crucial to the completion of the project outlines including mass and energy
balances, Hysys simulation of the Process Flow Diagrams, design of the reactor, design of heat
exchangers, design of the crystallizer, energy optimization, economic analysis and hazard analysis.
The desired reaction is endothermic with a overall yield of 90-92%. The project's
target is to design a plant with a capacity of 100 kg SHMP/hr. This plant is to include three major units;
a reactor, an crystallizer, an filter, mixing tanks. Also it includes pumps, rotary dryer, and condenser.
All are to be designed and operated according to this production capacity.
List of Figures –
List of Tables -
Table 2.1 Parameters For Selection of Process
Table 5.2 Excel Sheet of Fix Capital Investment For Manufacturing of SHMP
1. Introduction ............................................................................................1
a) Introduction
e) Selection of Process
f) Conclusion
3. Thermodynamic Feasibility............................................................... 12
a) ∆G of formation of components.
b) ∆G of overall reaction.
4. Plant Utility......................................................................................... 14
a) Reactor P&ID
b) P&ID of Condenser
c) Plant Layout
5. Costing .......................................................................................... 18
7. Results… ...................................................................................... 27
8. Conclusion ................................................................................... 28
9. References ................................................................................... 29
1. Introduction
Sodium hexametaphosphate (SHMP) is a hexamer of sodium orthophosphate which contains six
repeating phosphate units. It is a kind of sodium metaphosphate polymers. It is also known as
"polyvinylidene sodium," "sodium multiple metaphosphate", "sodium metaphosphate vitreous body",
and "Graham salt". It was first prepared in 1963 by german chemist “Erich Thilo” and Ulrich Schulke.
It is a colorless transparent glass-like solid or white powder with greater solubility but low dissolving
rate in water. Its aqueous solution exhibits acidic property. Its complex of divalent metal ion is
relatively more stable than the complexes of mono-valent metal ion. It can easily be hydrolyzed to
orthophosphate in warm water, acid or alkali solution. Hexametaphosphate has a relative strong
hygroscopicity with being sticky after absorbing moisture. For certain metal ions (e.g., calcium,
magnesium, etc.), it has the ability to form soluble complexes, and thus being able to being used for
demineralizing water. It can also from precipitate with lead and silver ions with precipitate being re-
dissolved in excess amount of sodium hexametaphosphate solution to form a complex salt. Its barium
salt can also form complexes with the sodium hexametaphosphate.
Toxicity
Adult 0~70 mg/kg (in terms of phosphorus); LD50:4g/kg (rat, oral). According to the provision of the
GB2760-86, it is allowed for being applied to canned food, fruit juice drinks, dairy products, soy milk
as quality improver; the maximum usage amount is 1.0 g/kg. When being used as composite phospha
te, calculated as the total phosphate, the canned meat products shall not exceed 1.0 g/kg; for condensa
tion of milk, it shall not exceed 0.50 g/kg.
Uses-
1. It can be used as a food quality improver in food industry, pH adjusting agent, metal ion chelating
agents, dispersants, extenders, etc. It can be used as a kind of common analytical reagents, water and
also used for photofinishing and printing.
3.It can be used as a detergent, preservative, cement hardening accelerator, fiber dyeing and cleaning
agents; it can also used for medicine, food, petroleum, printing and dyeing, tanning, and paper industry.
4. It can be used as texturizing agent; emulsifiers; stabilizer; chelating agent. The mixture is mainly
used for ham, sausage, surimi such as the tissue improver for water retention, tendering and meat
softening. It can also be used for prevention of crystallization of canned crab as well as dissolving
agent of pectin.
5. It can be used as the water softening agent of boiler water and industrial water (including water for
the production of dyes, water for the production of titanium dioxide, water for printing and dyeing,
and slurry mixing, water for cleaning color copy of the film, as well as chemical industrial water and
the water for the medicines, reagents production, etc.) as well as the water treatment agent for the
industrial cooling water; it can also be used as a corrosion inhibitor, flotation agent, dispersant agent,
high temperature binding agent, dyeing auxiliaries, metal surface treatment, rust inhibitors, detergent
additives and also cement hardening accelerator.
6. Coated paper production can use it as pulp dispersants in order to improve the penetration capability.
In addition, it can also be apply to the washing utensils and chemical fiber in order to remove iron ions
of the pulp.
7. In the oil industry, it can be used for the antirust of the drilling pipe and adjusting the slurry viscosity
upon the control of oil
drilling.It can be used as the quality improver with various effects of increasing the complex metal
ions of food, pH, ionic strength, thereby improving the adhesive capability as well as the water holding
abilityof food.
China provides that it can be applied to the dairy products, poultry products, ice cream, instant noodles
and meat with the maximum permitted amount being 5.0 g/kg; the maximal permitted usage amount
in canned food, fruit juice (flavored) drinks and vegetable protein drink is 1.0g/kg. It can be used as
a food quality improver in food industry and applied to canned food, fruit juice drinks,dairy products,
and soy milk.
8. It can be used as Ph adjusting agent, metal ion chelate agent, adhesive and bulking agents. When being
applied to beans and canned fruits and vegetables, it can be stabilize the natural pigment and protect
the food color and lustre; when being used in canned meat, it can be used for preventing the
emulsification of the fat and maintaining its uniform texture; when being applied to meat, it can be
used to increase the water holding capacity and prevent the deterioration of fat in the meat. It can also
help to clarify the wine when being supplied to beer and further prevent turbidity.
9. It also has applications in fabric dyeing, tanning, paper, color film, soil analysis, radiation
chemistry and analytical chemistry and other departments
It can be used as a food quality improver in food industry and applied to canned food, fruit juice drinks,
dairy products, and soy milk.
10. It can be used as Ph adjusting agent, metal ion chelate agent, adhesive and bulking agents. When
being applied to beans and canned fruits and vegetables, it can be stabilize the natural pigment and
protect the food color and lustre; when being used in canned meat, it can be used for preventing the
emulsification of the fat and maintaining its uniform texture; when being applied to meat, it can be
used to increase the water holding capacity and prevent the deterioration of fat in the meat. It can also
help to clarify the wine when being supplied to beer and further prevent turbidity.
11. It also has applications in fabric dyeing, tanning, paper, color film, soil analysis, radiation
chemistry and analytical chemistry and other departments
Current Global Production
➢ The SHMP production mainly concentrates in China. Each year, China exports about 50000
MT SHMP to the world. USA is a net importer of SHMP.
➢ Other than China; USA, India, Germany, Czech Republic, Indonesia are major Producers.
➢ The global SHMP market in 2020 values at 569.8 million USD and expected to reach 692.9
million USD in 2026 with growth rate of CAGR 2.8% during 2021-2026.
➢ The major manufacturers are Aditya Birla Chemicals, Prayon, ICL, Xingfa Group, Sundia,
Northwest Chemical, Mexichem, TKI, Recochem, Innophos, Chengxing Group, Chuandong
Chemical, Blue Sword Chemical, Mianyang Aostar, Sino-Phos Jinshi, Norwest Chemical,
WeifaHuabo, Nandian Chemical, Huaxing Chemical, Kindia May, Tianjia Chemical, Tianrun
Chemical, Zhenhua Industry.
Why it is important ?
1. Since Indo-China Trade war in 2020 and US-China trade war in 2019, US already imposes
anti-dumping duty on SHMP from china to end its monopoly. US is also looking for new
manufacturers.
2. Now India has great opportunity for global exports of SHMP with less costly raw material,
cheap labour and government incentives.
2. Literature survey
Equipments :- Neutralization Kettle, Filter, Dryer, Quartz Crucible, Rotary Dryer , Pulverizer.
Reactions:-
Process Description :-
It is the neutralization reaction followed by meltpolymerization at high temperature and rapid cooling.
The soda solution was subjected to neutralization reaction with phosphoric acid solution at 80-1000C
for 2 hours which results in monosodium orthophosphate solution;which then concentrated by
evaporation, cooling, filtering and dewatering into dryer at 110-130°C with moisture content of 0.1-0.2
%. Then it is fed to into silica crucible and heated gradually towards 630-650°C to remove all water
resulting in molten sodium hexametaphosphate. Then the chilling shock is applied to sodium
hexametaphosphate by Rotary Dryerwhich brought down temp. from 650 to 80°C. Then it is crystallised
and send to pulverizer for Sizingand further for packaging.
Pulverizer.
Reactions:-
Equipments :- Neutralization Kettle, Filter, Dryer, Quartz Crucible, Rotary Dryer , Pulverizer.
Reactions:-
Selection of Process:-
This is the table below for selection of process. The selection is based uponthe following parameters such
as Temperature, Pressure, Mole Ratio, Catalyst, Polymerization Degree, P2O5 content, By-product,
Moisture content and Conversion.
In conclusion of Literature Survey, we conclude that Process No.2 which is Sodium Chloride Method
is best for production of Sodium Hexametaphosphate.
Because,
It is simple process with less equipments and short production flow, convenient operation and easy
realization of industrialized production.
The starting material NaCl is cheap and easy to get as compared to starting material of other process
which more costly.
Then the phosphoric acid which is expensive raw material is required less amount in this process than
other two processes.
With low polymerization degree and high conversion rate this is the best method for production of
Sodium Hexametaphosphate.
3.Thermodynamic Feasibility
∆G of formation of components.
In order to calculate the ∆G of reaction we will need the ∆G of formation of all
compounds i.e. all reactants and products. These are the the ∆G of formation of all compounds in the
reaction in the table below
We calculated all these values from “Carl Yaws Chemical Engineering Handbook” and “CRC
Handbook of Chemistry and Physics”.
Here, we have calculated gibbs free energy of overall reaction which is -168 kJ/mol which is
less than -50kJ/mol. So, the reaction is feasible.
4. Plant utility
In our process we need four utilities i.e. cold water, dry air, steam and electricity.
We need steam for NaCl saturator, dry air for Rotary Dryer, Cold water for condenser and electricity
to almost all equipments but primarily for mixing tanks, reactor, pump and pulverizer.
At the bottom you can see all utility outlets from plant.
1. Reactor P&ID -
We have developed P&ID for reactor and condenser ; two main equipments.
Here in reactor P&ID you can see on the left side, to maintain constant temperature in
reactor we control heating fluid flow rate using flow controller and temperature controller.
On the right side, we can see we control inlet of feed and outlet of by-product HCL using
flow controller.
Add the bottom we control flow rate of product for constant reactor volume using level
controller.
In this P&ID of condenser, for steady temperature of HCl outlet we control cooling water
flow rate by flow indicator and flow controller along with temperature transmitter and
temperature controller for HCl outlet.
Here you can see plant area with future expansion area, warehouse, STP, utilities, cooling water,
maintenance area, lab area, fire station, administrative building along with parking area, Canteen,
General Assembly area, emergency water supply, etc.
We put utilities near plant area to reduce piping cost and ease on operatability.
Direct Production cost is addition of Plant overhead cost , Power and utilities cost and
Direct labour cost. So,
By profit formula,
258620.44 = 2160*X
X = Rs.119.7316852
Table 5.1 Excel Sheet for TPC and Selling Price for Manufacturing of SHMP
After that we calculate all other cost like piping and instrumentation cost, electrical, building
cost, Services, Yard Improvement, Direct plant cost, engineering and Procurement, other expenses
contingency, etc. with appropriate formulae from Timmerhaus book.
You can see all the calculations with proper formulae done in below excel sheet.
Table 5.2 Excel Sheet of Fixed Capital Investment for Manufacturing of SHMP
3. Break-even Point –
continuous process)
Annual Sales = 800000 kg/yr ......... (8000hrs*100kg)
= (136798*8000/800000*24)
= Rs. 57/kg
n = 646718.9 kg/year
So, our production capacity which is 100 kg/hr is already above break even point.
(before taxes)
1. SHMP by NaCl method is better than other two because of high P2O5
content, low temp.,easy operation and value added by product.
Reaults of costing –
1. Equipment design and sizing of CSTR with spiral baffle jacket and Condenser which is
floating head type SATHE
2. We have developed PFD, ULD, P&ID and Plant Layout diagram in Autocad.
Conclusion of Costing –
3. Chen M., Zhang W., and Yu Y., 2008. Method of producing sodium
hexametaphosphateby sodium chloride method, CN101462711A.