Project Synopsis
Perform a conceptual process design (FEL-0) feasibility study for the production of titanium oxychloride (TiOCl2) using non-traditional methods for a pigment and dye manufacturer.
Project Summary
Process Engineering Associates, LLC (PROCESS) was contracted by the client, a pigment and dye manufacturer, to perform a conceptual process design (FEL-0) study for the production of titanium oxychloride (TiOCl2). PROCESS used information provided by the client, along with literature available on the open web, to better understand the chemistry of the TiOCl2 process. Through this study PROCESS was able to recommend the client produce a weaker grade of TiOCl2 that eliminates HCl co-production and the need for an additional scrubber.
PROCESS modeled the continuous TiOCl2 process using both CHEMCAD and OLI Flowsheet. PROCESS evaluated proposed reaction conditions for the new process to minimize HCl off-gassing while simultaneously avoiding TiO2 precipitation. Process Flow Diagrams (PFDs) were developed along with a heat and material balance to present the model results to the client.
After the heat and material balance was developed, equipment lists, utility summaries, and a general equipment arrangement (plot plan) were developed. These deliverables were then used to develop a rough order of magnitude (ROM) installed capital cost estimate and an operating cost estimate for the new process. Capital cost estimates were developed in Aspen Capital Cost Estimator (Icarus). Due to a favorable capital cost estimate, PROCESS also provided a cost estimate for a scaled-up unit over 100% larger than the original design capacity. PROCESS also performed studies to determine the cost of various additional equipment such as additional tankage, a TiOCl2 truck loading rack, and to determine piping material of construction changes.
PROCESS also provided the client with an opinion of applicability of the EPA Clean Air Act (Title V) and OSHA PSM regulations to the new TiOCl2 production unit. Finally, PROCESS provided the client with a Process Design Risk Assessment that provided recommendations for additional studies required for future design phases. Specifically, PROCESS recommended pilot plant testing be performed to verify the heat and vapor generation of TiOCl2 process before commencing further engineering and design.
Industry Type
- Pigment and Dye Production
Utilized Skills
- Technical literature search
- FEL-0 feasibility study
- Process design risk assessment
- CAPEX estimation.