Document ppKZXDQvyyV2a8v1wvm8MwDD7

DOW CHEMICAL U.S.A August 9, 197; LOUISIANA DIVISION PLAQUEMINE. LOUISIANA 70704 004 389-8000 K. L. Bowlin Building 2511 cc: L. D. Adcock C. A. Barrios II. Ii. Christensen J. Coates 2306 1601 2503 4601 G. R. Durham ~ 2511 G. Liu - 2509 M. Oubre - 1701 R. J. Rouse - 4601 llC.l PURIFICATION, C0S0RB PROCESS Bast'd on the available information supplied by Richard Durham, very preliminary design flow sheets, equipment sizing and capital cost estimates have been made for this process. The feed, containing 0.3% C2H;> by volume as ail impurity, and 50 ppm ] 120 is first dried to 1 ppm R?0, the C2H2 Is then absorbed on the Cosorb. No data was available, for the C2H2 remaining in the purified The dryer is designed on a 200 hour cycle, 27.. final water loading. The absorbers are on a 43 hour cycle, 70% efficiency. Disposal of the desorbed C2H2 ( ~ 2000 lb/day) is a problem. A burner and scrubber were added to the design, again, without enough data for proper design. The utilities requirements were estimated at an average of 600 lb/hour nitrogen, 100 lb/hour steam and 150,000 Btu/hour fuel. Since the process is not continuous, the demand varies during the cycle with peaks of 300% the average. This is only a rough estimate. CADE - an operating unit op the dow chemical company CONFIDFNTTAl DO 007217 R. L. Bowlin -2- August 9, 1977 The catalyst cost was taken as the cost of the raw materials only. The total cost is $370,000 (this alone is more than the equipment cost for the HgCla process). The catalyst preparation plant or catalyst handling and disposal facilities are not included at this time. The complexity of this system led us to estimate just the absorber first. The equipment cost is $650,000. The capital cost estimate was $3.0M. Material of construction is carbon steel although monel probably will be necessary for the dryer section. Prices were taken from the Dow Estimating Guide. Numerous assumptions were necessary to supplement the incomplete data. The list of assumptions may not be regarded as a complete one as a number of assumptions were made as process flow sheets were generated. The cost of the catalyst preparation plant was not estimated because 1) data was even more scarce than for the absorption plant, 2) the absorption plant compares unfavorably to the HgCl2 process. Difficulties in operation of this system, both HC1 purification and and catalyst preparation, are anticipated due to the requirements for inert atmosphere, complete dryness and the non-continuous nature of the process. Attached is a breakdown for the design and cost in each case includingi A) Assumptions B) Process Conditions 0) Flow Sheets D) Equipment Sizing and Drilling E) Capital Cost Estimate ft* Carlos M. Moreno*'^ Research and Development Attachments jmd cONFTdfnttal DO 007218 ASSUMPTIONS 1. Inlet CaHa concentration is 0.3% by volume. Inlet H20 concentration is 50 ppm. 2. Dryer final loading: 2% by weight maintaining less tham 1 ppm Ha0. Dryer dimensions: L/D 2 for a pressure drop of ~ 10 psi. 3. Absorber efficiency is 60%. C2H2 exit concentration not specified. Assumed given by equilibrium conditions, and satisfactory for our purposes at 1 min residence time. L/D = 1.6 for a pressure drop of ~ 10 psi. 4. C2H2 disposal not defined. Burner and scrubber added and estimated from existing units. 5. Residual CaH2 concentration in absorber after regeneration not defined. 6. Dryer and absorber regeneration requirements for heat and nitrogen estimated from average values. 7. Material of construction is carbon steel. 8. No special site preparation necessary. 9. Prices as per Dow Estimating Guide. 10. Price of catalyst as cost of raw materials only. 11. Catalyst preparation, handling facilities and disposal not considered. CONFTDFNTIAl DO 007219 PROCESS CONDITIONS Location: Vinyl Plant Feed Conditions: 0.5M lb/day at 220 pslg, 14F, 0.3% C2Hj by volume, 50 ppm H20 Product Conditions: ~ 200 pslg temperature varies with cycle C2Ha content, not defined, assumed given by equili brium conditions Dryer Cycle: 200 hours, 26 sec residence time, 2% final loading Absorber Cycle: 48 hours, 1.2 min residence time Equipment Cost' Dryers and Absorbers Compressors Exchangers Scrubber and Burner Analyzers Catalysts AW 300 Zeolon Cosorb Solution Catalyst Preparation 234,000 173,000 93,000 150,000 30,000 23,400 265,650 80,277 -0- Utilities: Nitrogen 600 lb/hour 30 lb Steam 100 Ib/hour Fuel 150,000 Btu/hour 650,000 30,000 369,327 1,059,327 confident^ DO 007220 EQUIPMENT D 401 A-B Dryers A 401 A-B-C Absorber C 401 Compressor Motor Gear Box C 402 Compressor Motor Gear Box H 401 Heater H 402 Heater E 401 Cooler Motor E 402 Cooler Motor S 401 Scrubber System B 401 Burner System 240 psia 93 cu ft packed vol 4'D x 12'L Carbon Steel 240 psia 643 cu ft packed vol 8'D x 16'L Carbon Steel 160 psia 400F inlet 180 psia 400F outlet 700 cu ft/min inlet TEFC 200 hp 160 psia 200F inlet 180 psia 200F outlet 3400 cu ft/min TEFC 800 hp Gas fired, 240 psia 625 sq ft Carbon Steel 400F 240 psia 200F 625 sq ft Carbon Steel 180 psia 400F 750 sq ft Carbon Steel 150 hp TEFC ISO psia 200F 2500 sq ft Carbon Steel 100 hp TEFC 36,000 198,000 35,000 7,000 8,000 85,000 18,000 20,000 10,000 8,000 20,000 4,500 38,000 3,000 50,000 100,000 CONFTDFNTTAI DO 0072?! * ..... c * . . NEWTON'S FACTORED METHOD DATEi 0777 PRODUCTION RATEi 20888,0 LB/HR OR 156,660 MM LB/YR AT 100.0 % CA cc ITEM ( PLANT EQUIPMENT c FOUNDATIONS -------- STRUCTURES-----------------------------------------------------( EQUIPMENT ERECTION -------- PIPING-------------------------------------------------------------INSULATION c PAINTING FIRE PROTECTION -------- SAFETY EQUIPMENT------------------------------------------ c INSTRUMENTATION ELEC 1 h i UAL OTHER SPECIAL COSTS (. TOTAT~INSTALTAT10N~COSTS COST <M*> 650.0 -- . y39/tZ*2} 97,5 487 5 73*1 32 * 5 6*5 o,5 95*0 34 * 5 0.0 ' y6y. 8 BASE-COST "= 'EQUIPMENT" T'l'NSTALLATION 161978 SALES (AXES 36 * / c FREIGHT COSTS L'UN 1 KAC 1 OR' 8 FEe 10.4 ------------- 290*9--------- TOTAL TAX r FREIGHTt 8 FEES 358.1 1r ...... - f C \ TOTAL CONTRACT COST ENGINEERING CONI IGeNCIES TOTAL ENGINEERING 8 CONTIGENCIES PROCESS UNIT INSTALLED COSTS 197,8 2Vo * 7 -- * i?* 494.5 BUILDINGS 8 FURNISHINGS 0.0 5ITE--PREPARATION 20,0 4=r~ SHIPPING FACILITIES(RAIL SPURS INCL) 0.0 STORAGE TANKS "(NOT INCL "A'BA'UEJ> : OTO UTILITY SUPPLY FACILITIES 0.0 COOLING TOWtK AND"WAiEFT SUPPLY 07IT WASTE DISPOSAL OTHER"FACILITIES~NUI 0.0 1NULD ABUVE-------------------- 370>0------- 1977.9 2472.4 TOTAT-AITPTTTONAL FACILII1ES--------------------------------390T0 ENGINEERING 8 CONTIGENCIES 97*5 ----------------- rUTAL COST ADDII1UNAL FAClLlllES------- ------------- 487.5-- TOTAr^PCANT-CUST CUNS' IRCLTI TU'N~ESCSEATTON TOTAL PROJECT COST ~ CURRENT - 2757T9 s4 * 0 ./ --2993.y ^:_______________________________________________ ____________ ' ~ ' ( C0^TOENTTa[ DO 0077??