Professional Documents
Culture Documents
CHAPTER IV
WASTE TREATMENT
4.1
Introduction
Waste is general problem in a chemical plant and is global problem in a
developing country. The waste whether is in solid, liquid, gases or mixture form must
not exceed levels at which they will harm the environment. Normally, a plant takes the
raw materials to produce, through stages of processing steps, one or more products for
sale with purpose to generate income. It is impossible to convert 100% of the raw
materials into saleable products, and there is always some waste or residual. This
follows the second thermodynamics law, which states that, there is no process which can
achieve 100% efficiency. Therefore, waste treatment plays the role to protect the
environment from the wastes from the industries.
Waste treatment is an essential process in order to decrease and minimize the
environment pollution, especially for those contain toxic components. It is responsibility
to treat the waste to an acceptable form or level before discharge, as direct discharge of
the unwanted material into the ecosystem will bring about detrimental effects. Waste
treatment is an economic burden to a process plant since it does not bring any economic
advantage to the company participated. However, the implication of waste treatment
Waste Treatment 4 -2
plant becomes important with regards to environmental pollution. Thus, waste treatment
is important in order to contribute to a safe environment.
As far as the environment pollution is concerned, the chemical waste either in the
form of solid, liquid or gases must be treated before being discharge to sewage, drain or
atmosphere. The quality of discharge should comply with The Environment Quality
(Sewage and Industrial Effluents) Regulations 1979 and Environmental Quality (Clean
Air) Regulation 1978. Under these regulations, the factory owner or waste generator
must ensure the waste generated is handle and disposal off appropriately to prevent
environmental pollution. Disposal of hazardous waste on-site or governed by
Department of Environment, Malaysia (DOE) regulations on scheduled waste. The
Quality of discharge should comply with the Environmental Quality (Scheduled
Wastes) Regulations 1989. The requirements are:
a) Under the regulations, 107 categories of wastes have been classified as scheduled
wastes.
b) Scheduled wastes can be stored, recovered and treated within the premises of a
waste generator.
c) Waste generators shall also keep an up-to-date inventory of scheduled wastes
generated, treated and disposed off.
d) In the case of transporting the waste from the waste generator to the treatment
and disposal facilities, shall be monitored until it reaches the approved
destination.
The details of the regualtions and standards which concerned with the production of
hydrogen plant is enclosed in Appendix E.
Waste Treatment 4 -3
4.2.1
Waste Management
Waste treatment management should follow some of the steps as below:
Waste Treatment 4 -4
i. Facilities Planning
Facilities plan are documents established to analyze the technical economic,
environmental and financial factor necessary to select a cost effective waste
management plan. The scope of the facilities plan includes:
a. Problems defining
b. Identifying design year needed (usually 20 years).
c. Defining, developing and analyzing alternative treatment and disposal systems.
d. Selecting a plan
e. Outlining an implementation plan including arrangements and a schedule for
design and construction
ii. Design
There are many steps of designing need to be adhered in order to design an
optimum waste treatment plant. Conceptual design is used to finalize the preliminary
design criteria. Here, principal engineering decisions are made, equipment is selected
and the layout of the plan. It is also advisable to have topographic surveys.
In preliminary design, the site plan is finalized, equipments are defined,
alternative mechanical equipment and piping arrangement are made as well as support
systems and utility requirements are determined. At this stage, a preliminary cost
estimate can be made and be absorbed into project budget.
iii. Special Studies
Here, the pilot plant testing of equipments or processes are made. It is important
that these investigations be completed before the final design starts in order to eliminate
uncertainties and costly redesign.
Waste Treatment 4 -5
Waste Treatment 4 -6
1) Providing, operating and maintaining a treatment plant that consistently meets its
performance requirements.
2) Managing operations and maintenance costs within the required performance
level
3) Maintaining equipment to ensure proper operation and service
4) Training operating personnel
One of the principal tools used for plant startup, operation and maintenance is the
operations and maintenance manual. The purpose of this manual is to provide treatment
system personnel with the proper understanding of recommended operating techniques
and procedures, and the references necessary to efficiently operate and maintain their
facilities [Burton and Tchobanoglous, 1991]
Waste Treatment 4 -7
Improving process technology and equipment that alter the primary sources
of waste generation.
ii)
iii)
iv)
v)
easiest to recognize and implement. However, there are important economic limits to
recycling and often other waste reduction opportunities offer greater benefits.
In spite of concerns about product quality, improvements in process technology
and equipment appear to be a viable means of waste minimization. Such improvements
are important because often an entire waste stream can be eliminated. This method
depends on the type of industry. Mature industries that use continuous process are likely
to have fewer opportunities for changes in the process technology but they may still
have waste minimization opportunitie.
Waste Treatment 4 -8
4.4.1
are stream 5, 24, 34, 37 and 42. These waste streams are from five different sources as
shown in Figure 4.2.
Stream 3
Stream 22
Stream 32
Stream 35
Stream 40
Flash, F-3
Flash, F-19
Flash, F-27
Flash, F-29
Membrane
Separator S-32
Stream 5
Stream 24
Stream 34
Stream 37
Stream 42
Liquid Waste
water
Waste water
Vapor Waste
Vapor Waste
Vapor Waste
Waste Treatment 4 -9
discharged from flash, F-3 and from flash, F-19. The liquid streams discharged contain
various types of chemical compound including methane, ethane, propane, isobutane, nbutane, isopentane, n-pentane, n-haxene, hydrogen, carbon monoxide, carbon dioxide,
nitrogen, and water. These chemical compounds must be treated and ensured to comply
with the Malaysia Environmental Quality Act 1979 before discharged into environment.
The vapor streams are stream 34, stream 37 and stream 42. These streams are from flash,
F-27, flash, F-29 and membrane separator, S-32. These vapor form of waste streams do
contained various types of hydrocarbon and chemical compounds which are mentioned
just now in the liquid waste streams.
For the waste treatment in this Hydrogen Production Plant, the liquid form waste
streams will be treated separately with the vapor form waste streams. The waste
treatment method for these two different types of streams will be discussed in section
4.4.3 and 4.4.4. The waste streams composition will be further described in next section.
4.4.2
To consider from the economic aspect, either the waste can be recover and sell as
product or not
2.
To consider the waste properties aspect, either it can be discharged directly ti the
environment or need to treat it before discharged to environment.
3.
Stream 5
Stream 24
Stream 34
Kgmol/hr
Kgmol/hr
kgmol/hr
104.3663
75.5910
33.9750
9.2250
10.5750
4.2750
2.9250
6.0750
40.0388
28.9995
13.0341
3.5391
4.0570
1.6401
1.1221
2.3306
6.0556
2.9987E-03
2.1226E-06
1.4910E-09
1.3666E-10
3.8623E-14
3.2054E-15
8.8723E-21
3.4063
7.1585E-05
1.0701E-08
2.5322E-12
1.5452E-13
1.4943E-17
8.8517E-19
6.2484E-25
32.7337
4.8665E-03
5.0098E-07
7.3402E-11
3.6700E-12
1.8432E-16
8.9590E-18
2.4885E-24
1.0276
1.5278E-04
1.5728E-08
2.3044E-12
1.1522E-13
5.7865E-18
2.8126E-19
7.8125E-26
13.2750
5.0928
160.5587
17.7986
1270.5926
39.8892
0.3804
0.1459
1.6535E-01
7.3765E-02
8.8695E-01
2.7845E-02
0.0000
0.0000
1.2666
3.7202E-01
6.6594
2.0907E-01
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
134.4826
176.5199
0.0000
78.3479
1.3224E-03
0.0000
660.2488
1.5163E-03
1214.1773
20.7280
4.7602E-05
38.1181
Stream 37
Stream 42
kgmol/hr
kgmol/hr
6.5732E-01
1.0317E-03
2.6341E-07
5.7104E-11
1.0616E-01
1.6662E-04
4.2544E-08
9.2228E-12
252.0880
2.3065E-07
7.2057E-17
1.5896E-24
50.9436
4.6612E-08
1.4562E-17
3.2125E-25
N-Butane
Iso-Pentane
N-Pentane
Hexane
Carbon dioxide
Nitrogen
Carbon Monoxide
Hydrogen
Water
Methanol
4.4.3
3.0033E-12
1.5832E-16
7.3842E-18
1.7206E-24
25.4119
2.2596E-02
2.6275E-01
17.3269
5.2755E-04
575.4725
4.8506E-13
2.5570E-17
1.1926E-18
2.7790E-25
4.1043
3.6495E-03
4.2436E-02
2.7985
8.5205E-05
92.9447
2.7592E-27
2.5560E-35
7.6811E-38
3.5642E-49
182.2484
5.2634
24.1234
23.5536
9.4519E-38
7.5605
5.5761E-28
5.1654E-36
1.5522E-38
7.2029E-50
36.8300
1.0637
4.8750
4.7599
1.9101E-38
1.5279
Wastewater Treatment
There are two wastewater streams, Stream 5 and Stream 24 in Hydrogen
Production Plant. These two streams will be flowed in a mixer and a stream consist of
two phase will occured due to the combination of two different conditions of the
streams. The separation process need to be done with the stream before treatment using
flash. The vapor stream is flowed to the vapor stream waste treatment plant for treatment
while the liquid stream will be treated in the wastewater treatment plant.
The activated sludge process derieves its name from the biological mass formed
when air is continuously injected into the wastewater. In this process, microorganisms
are mixed thoroughly with organics under conditions that simulate their growth through
use of the organics as food. As the microorganisms grow and are mixed by agitation of
the air, the individual organisms clump together (flocculate) to form an active mass of
microbes (biological floc) called activated sludge.
Process Description of Wastewater Treatment Plant
Stream 5 Mixer
W1
Stream 24
Tank 1
Influent
Q, Xo
Valve
X, S
Q + Qr
Aeration
tank
Effluent
Xe, Se
Q3
Pump 3
Qu, Xu
Pump 2
Pump 1
Oxygen is fed
to the tank
Waste Activated
Sludge (WAS)
Qw, Xw, Sw
Qr, Xr
Figure 4.3: Process Flow sheet of Wastewater Treatment Plant
The process involved in wastewater treatment plant is biological treatment with
activated sludge system. Stream 5 and Stream 24 is fed into a mixer and came out with
Stream W1 which consist of two phase: vapor and liquid. Stream W1 is then fed into a
flash to separate the two phase. Vapor phase stream, V1 is then flowed to the vapor waste
treatment plant while liquid phase stream, Q is stored in a waste water tank and treated
in wastewater treatment plant. Q is fed into an aeration tank, where air from atmosphere
is bubbled into the tank or the mechanical surface aerator is used to saturate the
wastewater with oxygen. Microorganisms exist in the aeration tank to digest the wastes
that contains hydrocarbons: methane, ethane, propane, butane, pentane hexane,
methanol, nitrogen and so on. The general equation describing the reaction can be
written as below:
Table 4.2 shows the summary of the composition of the waste water streams. The
composition of the streams after the flash is calculated in mass balance in Appendix E.
Table 4.2: Composition wastewater for streams
Component
Methane
Ethane
Propane
Iso-Butane
N-Butane
Iso-Pentane
N-Pentane
Hexane
Carbon dioxide
Nitrogen
Carbon Monoxide
Hydrogen
Water
Methanol
Stream 5
(kmol/hr)
104.3663
75.5910
33.9750
9.2250
10.5750
4.2750
2.9250
6.0750
13.2750
0.3804
0.0000
0.0000
0.0000
0.0000
Stream 24
(kmol/hr)
6.0556
2.9987E-03
2.1226E-06
1.4910E-09
1.3666E-10
3.8623E-14
3.2054E-15
8.8723E-21
160.5587
1.6535E-01
1.2666
134.4826
176.5199
0.0000
Stream W1
(kmol/hr)
110.4219
75.5940
33.9750
9.2250
10.5750
4.2750
2.9250
6.0750
173.8337
0.5458
1.2666
134.4826
176.5199
0.0000
Stream V1
(kmol/hr)
110.3722
75.0045
32.9196
8.4910
9.4132
3.2291
2.0412
2.4798
173.6341
0.5454
1.2655
134.4162
17.6520
0.0000
Stream Q
(kmol/hr)
0.0496
0.5894
1.0554
0.7340
1.1618
1.0459
0.8838
3.5952
0.1996
0.0003
0.0011
0.0664
158.8679
0.0000
X0
Va
Ks
Kd
Qw
Xe
Xr
At steady state, the mass balance equation for food (soluble BOD5) may be written:
Food in
Influent
Food
Consumed
Food in
Effluent
Food in
WAS
1
Kd
0.025-0.075
D
1
2-10
D
m
Y
Mg VSS/mg BOD5
0.4-0.8
Typical
60
0.06
5
0.6
Table 4.3 shows the typical values of the microbial growth constants for domestic
wastewater which is going to used at the calculation for the sizing of the activated sludge
system.
i)
S = 20 mg/L
S
K S (1 K d c )
c ( m K d ) 1
20
60 * (1 0.06 c )
c (5 0.06) 1
= 0.84 day
c (Y )( S o S )
(1 K d c )
3000
0.84(0.6)(1000 20)
(1 0.06 0.84)
= 0.1638 day
= 3.9315 hr
= Q
Va
ii)
10 6
mg/L
SVI
10 6
200
= 5000 mg/L
Volume of sludge wasted daily, Qw
Qw
=
=
VA X
c X r
11.7117 m 3 3000mg
L
0.84day
L
5000 mg
= 8.3655 m3/day
Return Sludge flow rate, Qr
=
=
QX Qw X r (Q Qw ) X e
Xr X
(71.4936)(3000) (8.3655)(5000) (71.4936 8.3655)(20)
5000 3000
= 85.6954m/day
(Check this result using Figure 5-23 [Davis and Cornwell, 1998], showed it is a valid
result.)
157.189m 3 / day
33m / day
= 4.7633 m
Diameter of the tank
4.7633 m
= D/4
= 2.4627 m
= 2.5 m
From the Table 5-12 [Davis and Cornwell, 1998], we select side water depth
(SWD) of 3.4m
Now we must check the solids loading. (1mg/L=1g/m)
SL
3000 g 0.0018m 3
4
3
s
m
( 2.5 2 )m 2
21.6 g
10 3 kg 86400 s
g
day
19.6350 sm 2
= 95.0466 kg/d.m
From Figure 5-27 [Davis and Cornwell, 1998], we find that for an SVI = 200, we
have the maximum allowable solids loading of 150 kg/d.m.
The weir loading for a single weir located at the periphery
WL
0.0018 86400
2 .5
= 19.8014 m/d.m
From literature [Davis and Cornwell, 1998], the GLUMRB has set
maximum recommended weir loadings for secondary settling tank at 125 to 250
m/d.m. The WL calculated is below the maximum value, therefore the result is
acceptable.
iv) Summary for Costing Wastewater Treatment Equipment
Cost (RM)
RM 246579.05
RM 222,657.59
RM 30,000.00
RM 80,000.00
RM 27, 397.00
RM 30,773.15
RM 26,352.30
RM 27,889.85
RM 663,759.09
Utilities
RM 28276.01/year
RM 73.58 / year
RM 135.01/ year
RM 54.24/ year
RM 28,538.84/year
Nitrogen
Carbon Monoxide
Hydrogen
Water
Total
0.159688305
1.277293109
186.7950638
5975.103343
6190.981535
From Table 4.5, we can see that the components of the recycled stream are more
or less the same with the waste stream in waste water treatment plant. The only different
is that 96.5% of the composition is consisted of water. Therefore, the same treatment
system activated sludge system is used for the recycled water treatment. In order to
save cost for this production hydrogen plant, the wastewater treatment plant will be used
as the recycled water treatment plant instead of another water treatment plant is built.
The same treatment plant will be used alternately for both wastewater treatment and
recycled water treatment. Figure 4.4 shows the layout of water treatment plant.
Figure 4.4: Recycled Water Treatment System
Tank 1
Waste water
stream
Valve 1
Tank 2
Recycled water
stream
Valve 2
Activated Sludge
System (same as
illustrated in Figure 4.3)
Water
(Output)
Waste Activated
Sludge (WAS)
From Figure 4.4, both waste water stream and recycled water stream is treated in
single activated sludge system. But the treatment for waste water and recycled water is
carried out alternately where valves are used to control the flow rate of the waste water
stream and recycled water stream. Once the Valve 1 is open for the waste water stream
treatment, the Valve 2 will be closed to prevent the flow in of the recycled water stream.
Tank 2 is installed with the purpose to accumulate the continuously recycled stream
from the flash. After the waste water treatment is done, Valve 1 will close and Valve 2
will open and the recycled water stream will flow into the water treatment system. The
function of Tank 1 is to accumulate the continuously wastewater stream from the main
plant while the recycled water is being treated. The activated sludge system is the same
as described in section 8.4.3.1 and will not be described further in this section.
With this system applied, the cost for setting up another water treatment plant
will be saved. There is only one extra equipment installed for this treatment system
which is the Tank 2. The cost for this tank is shown in Table 4.6 and detail calculation is
shown in Appendix E. For certain period which is long enough, the whole recycled
water will be purged from the recycling system and the fresh water is replaced to prevent
the accumulation of contaminates in the recycled stream.
Table 4.6: Cost for equipment needed in recycled water treatment
Equipment
Tank 2
Cost
RM 185,932.33
treated. Use of chemicals for phosphorus removal can add another 1.0 percent. The
sludge withdrawn from the treatment processes are still largely water, as much as 97
percent [Davis and Cornwell, 1998].
Sludge treatment processes are concern with the removal of the large amount if
water from the solid residues. In this section, the basic processes for sludge treatment are
introduced and described briefly. The basic processes are:
a)
b)
c)
Conditioning: Treating the sludge with chemicals or heat so that the water can be
readily separated.
d)
e)
Basically, the land disposal is divided into three categories: land spreading,
landfilling and dedicated land disposal. The brief description of these three categories is
explained.
Land Spreading
Land spreading is the practice of applying WWTP residuals for the purposes of
recovering nutrients, water or reclaiming despoiled land such as strip mine soils. In
contrast to other land disposal techniques, land spreading is land-use intensive. The
application rates of this method are governed by the character of the soil and the ability
of the crops or forests on which the sludge is spread to accommodate it.
Landfilling
Sludge landfill can be defined as the planned burial of wastewater solids,
including processed sludge, screenings, grit and ash, as a designated site. The solids are
placed into a prepared site or excavated trench and covered with a layer of soil. The soil
cover must be deeper than the depth of the plow zone (about 0.20 to 0.25 m). For the
most part, landfilling of screenings, grit and ash is accomplished with methods similar to
those used for sludge landfilling.
Dedicated Land Disposal (DLD)
Dedicated land disposal means the application of heavy sludge loadings to some
finite land area that has limited public access and has been set aside or dedicated for all
time to the disposal of the wastewater sludge. Dedicated land disposal does not mean inplace utilization. No crops may be grown. Dedicated sites typically receive liquid
sludge. While application of dewatered sludge is possible but not common. In addition,
disposal of dewatered sludge in landfill is generally more cost-effective.
4.4.4
are Stream 34, Stream 37 and Stream 42. With an extra one vapor waste stream from the
separation unit (flash drum) of the wastewater treatment plant, there are total 4 vapor
waste streams which are to be treated in the waste gas treatment.
Incineration or combustion is most common ways to treat the gaseous waste. It
is deemed the most appropriate disposal method for these gaseous wastes [Kroschwitz,
1985] since the organic compounds in these streams can rapidly oxidized at high
temperature. The latter differs from the former in that is it involves recovery of energy in
the form of heat generated from the process. Decision to either operate the unit as an
incinerator or combustor weighs heavily on economic scale, with unprofitable energy
recovery not uncommon due to the high capacity and operating costs of auxiliary
equipment. Flare or incinerator, from a different view point is used to minimize the
emission of toxic and dangerous substances as it is designed to push the reaction as close
as possible to completion, leaving a minimum of unburned compounds [Peavy et al,
1985].
Where other components are present in the gas such as sulfur or halogen, scrubber will
usually be required.
Flares
Flares being a low cost means disposal of relatively large amounts of gas
containing combustible components, they are suited to processes, which are not
continuous. Continuous gas generation often lends itself towards heat recovery. Flares
handle process upset and emergency gas releases that the base load system is not
designed to recover. Heat recovery, almost by definition, is not possible with a flare.
Two types of flares are currently in use, namely the ground level and elevated or
tower flares. Ground flares can be used where there is sufficient space around the flare to
provide for safety of personnel and equipment. The tower flare is more preferred choice
where space is limited as it keeps the flame above the level of surrounding equipment
and personnel, as well as to promote the dilution of its products of combustion into the
air. Temperature developed in flare system normally ranges from 1100-1370C
[Brunner,1984].
Catalytic Incineration
Catalytic incineration is another method available when combustible materials in
the waste gas are too low to make direct-flame incineration feasible. It is normally used
to destroy waste at low concentrations, less than 25 % of the lower explosive limits
[Brunner,1984].
Thermal Incineration
Thermal incinerator is used when the concentration of combustible materials is
too low to make direct-flame. It is widely used as an air pollution control technique
whereby organic vapors are oxidized at high temperatures.
The most important variables to be considered in the design of this system are
the combustion temperature and residence time since they determine the incinerators
destruction efficiency (DE). Thermal incinerator can achieve a wide range of destruction
efficiency.
The waste is preheated, often by the use of a heat exchanger utilizing heat
produced by the thermal incinerator itself. The preheated gas is directed into a
combustion zone equipped with a burner supplied with fuel. The temperature of
operation depends upon the nature of the pollutants in the waste gas. A thermal
incinerator requires a strict design for safe and efficient operation.
Thermal incinerator, as complex as its name sounds, requires stringently careful
design for provide safe, efficient operation. The three Ts of combustion (time,
temperature, turbulence) and oxygen level must be carefully monitored to prevent the
production of PIC (products of incomplete combustion). Ideally, the relatively clean
stream of hot air produced is used as heat source for other operations within the
industrial plant and offers the potential to be further incorporated into the Heat
Exchanger Network (HEN) for maximum recovery of heat.
Emission Source
Dilution Air
Combustion Air
Supplementary
Fuel
Thermal
Incinerator
Stack
Heat
Exchanger
Scrubber
4.4.4.2 Scrubber
Packed scrubber generally is arranged in one of the four ways based in which the
liquid is contacted with the gas stream. Concurrent flow scrubbers make up two of these
classifications; in both cases the liquid and gas flow in the same direction.
In a horizontal concurrent scrubber, the gas velocity carries scrubbing liquid
into the packed bed and the device actually operates as a wetted entrainment separator.
Normally, superficial gas velocity is limited to a maximum of 9.6 ft/s due to liquid reentrainment at higher velocities. Packed bed thickness is restricted because the
allowable gas velocity limits the depth of liquid penetration into the tower packing.
A vertical concurrent scrubber can operate at very high velocities so that
pressure drops from 1 inch H2O/ft to as high as 3 inch H2O/ft are common. There is no
flooding limit of the packing because the liquid holdup in the packed bed decreases as
the gas rate increases. Contact time between gas and liquid is a function of bed depth as
well as the gas velocity. Absorption driving forces are reduced because the exit gas is in
contact with the highest concentration of contaminant in the liquid phase. The exit gas
phase may contain substantial liquid entrainment that must be removed before this gas
is discharged into the atmosphere.
The third class of scrubber is called cross flow. This device contacts a
horizontally flowing gas stream with a vertically descending liquid flow. Thus, cross
sectional area for gas flow is different flow the area for liquid flow. Liquid flow rates as
low as 2.6 gal/min per 1000 ft3/min of gas may be possible with this arrangement rather
than a minimum liquid rate of 4.2 gal/min per 1000 ft3/min when the gas flow area is
the same as the liquid flow area [Geankoplis, 1993].
Mass transfer driving forces are intermediate between vertical concurrent
scrubbers and counter current scrubbers. If the absorbed solute obeys Henrys law in the
liquid phase, the mass transfer driving force will limit solute removal efficiency to
about 90 % for typical chemical fumes assuming scrubbing water flow is limited.
However, if the absorption of solute is followed by a rapid chemical reaction in the
liquid phase so that there is no appreciable vapor pressure of solute above the solution,
the mass transfer driving force will be the same as for a countercurrent scrubber.
The most widely used type of scrubber operates with gas and liquid in
countercurrent flow as the liquid flows vertically downward under the influence of
gravity. Maximum gas flow rate is limited by liquid entrainment or by pressure drop.
Packed bed depth as well as gas velocity controls contact time between the gas and the
liquid phases. Mass transfer driving forces are maximized because the exit gas stream
contacts the entering liquid, which contains a minimum or zero solute concentration.
The pressure drop through the tower packing is very important because the cost
of power to move the gas stream through the scrubber may be the largest operating cost
factor. Most tower packing manufacturers can provide experimental pressure drop data
specific to the air/water system. Countercurrent scrubbers generally have these
characteristics [Geankoplis, 1993]:
i. Designed to operate at a pressure drop between 0.25 inch H2O/ft and 0.60 inch
H2O/ft of packed depth.
ii.
Air velocity normally between 5.5 ft/s and 8.0 ft/s if modern, high capacity
plastic tower packing is used.
iii.
iv.
Thus, the countercurrent scrubber is chosen to remove the sulfur present in the
gas flow from the incinerator. The decision to choose a countercurrent scrubber is
because of the inlet gas concentration is at 190C and 101.325 kPa.
4.4.4.3 Chimney
Several types of chimney (referred to as stack by some industry) are used to
discharge incinerator flue gases into the ambient atmosphere. Stub or short chimney are
usually fabricated of steel and extend a minimum distance upward from the discharge of
an induced draft fan. These are constructed either of unlined or refractory-lined steel
plate, or entirely of refractory and structural brick. Tall stacks are constructed of the
same material as short stacks and are used to provide a greater pressure difference
driving force (draft) than that resulting from the shorter stacks and to obtain more
effective dispersion of the flue gas effluent into the atmosphere.
Some chemical and utility application use metal stacks that are made of a double
wall with an air space between the metal sheets. This double wall provides an insulating
air pocket to prevent condensation on the inside of the chimney and thus avoid corrosion
of the metal.
An important factor in handling acid gases in a chimney involves maintaining a
high internal temperature. This often retards the detrimental effect on the masonry
without the necessity for other precautions. If the flue gases are such that high
temperatures alone are not sufficient, it may be necessary to protect the main walls by
using an independent lining for the full height of the stack, and with a 3-4 inch air space
between the lining and the main walls. The independent lining must be built of
impervious brick with a low content and acid-proof mortar; very thin joints should be
used. The mortar should be carefully chosen for its resistance not only to the particular
acid involved, but to moisture as well. In addition, the top of the chimney should be
protected by a cap covering both the lining and main walls and made of material not
affected by the flue gas. While room should be allowed for expansion, fumes and
moisture must be not allowed to penetrate under the cap.
Stream 34
(kmol/hr)
32.7337
4.8665E-03
5.0098E-07
7.3402E-11
3.6700E-12
1.8432E-16
8.9590E-18
2.4885E-24
1270.5926
8.8695E-01
6.6594
660.2488
1.5163E-03
1214.1773
Stream 37
(kmol/hr)
6.5732E-01
1.0317E-03
2.6341E-07
5.7104E-11
3.0033E-12
1.5832E-16
7.3842E-18
1.7206E-24
25.4119
2.2596E-02
2.6275E-01
17.3269
5.2755E-04
575.4725
Stream 42
(kmol/hr)
252.0880
2.3065E-07
7.2057E-17
1.5896E-24
2.7592E-27
2.5560E-35
7.6811E-38
3.5642E-49
182.2484
5.2634
24.1234
23.5536
9.4519E-38
7.5605
Stream V1
(kmol/hr)
110.3722
75.0045
32.9196
8.4910
9.4132
3.2291
2.0412
2.4798
173.6341
0.5454
1.2655
134.4162
17.6520
0.0000
To Chimney
Cooling Water
Stream V1
Stream V2
Stream 34
Stream V3
Stream V4
Stream 37
Heat
Exchanger
Stream 42
Mixer
Incinerator
Steam
CH4
+ 2 O2
CO2 + 2 H2O
2.
C2H6
+ 3.5 O2
2 CO2 + 3 H2O
3.
C3H8
+ 5 O2
3 CO2 + 4 H2O
4.
C4H10 + 6.5 O2
4 CO2 + 5 H2O
5.
C5H12 + 8 O2
5 CO2 + 6 H2O
6.
C6H14 + 9.5 O2
6 CO2 + 7 H2O
7.
CO
+ 0.5 O2
8.
H2
+ 0.5 O2
9.
CH3OH
+ 1.5O2
CO2
H2O
CO2 + 2 H2O
pollution to the environment (atmosphere). The effluent stream (Stream V4) is flowed
through a chimney before releasing to atmosphere.
Stream V2
395.8512
75.0104
32.9196
8.4910
9.4132
3.2291
2.0412
2.4798
1651.8870
6.7183
32.3111
835.5455
17.6540
1797.2103
0.0000
4870.7618
Stream V3
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
4208.8863
18755.0970
0.0000
0.0000
5734.5335
0.0000
453.0678
29151.5846
Stream V4
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
4208.8863
18755.0970
0.0000
0.0000
5734.5335
0.0000
453.0678
29151.5846
Incinerator
1.5377E+12
Heat Exchanger
3.7120E+11
Table 4.9 shows the heat duty of two major equipments in the waste vapor
treatment plant. From the energy balance, the incinerator heat duty is 1.5377E+12J/hr
and the heat exchanger duty is 3.7120E+11J/hr. The detail calculation is shown in
Appendix E.
The detail calculations for equipment sizing are shown in the Appendix E. The
following tables are the summary of each equipment.
1. Mixer
Temperature (C)
Pressure (atm)
49.957
0.1
Volume (m3)
3586.4450
Diameter (m)
5.6974
2. Catalytic Incinerator
Temperature (C)
580
Pressure (atm)
Diameter (m)
13.1356
Length (m)
3.048
3. Heat exchanger
Area (m2)
992.6497 m2
30
260
8
4. Chimney
Temperature (C)
30
Pressure (atm)
Height (m)
58.0638
Diameter (m)
1.2
The detail calculation of the equipment and utility costing are shown in
Appendix E respectively. The following tables (Table 4.10 and Table 4.11) show the
summary of the each equipment and utility cost.
Cost
Mixer
RM 2,465,790.48
Catalytic incinerator
RM 3,928,039.57
Heat exchanger
RM 591,780.96
Chimney
RM 769,315.25
Total
RM 7,754,926.25
Reduction (%)
100
100
100
100
100
100
100
100
100
100
100
From the summary result above, all the organic wastes are completely oxidized
in incinerator. The heat of recovery system in this waste treatment plant generates
7,249.8584 kmol/hr steam at T = 260C and pressure = 8 bar. The detail calculation is
shown in Appendix E.