TCCA-TAR CATALYTIC
CRACKER A
TCCB-TAR CATALYTIC
CRACKER B
Type: Fluidized bed
with cyclone filters
Type: Fixed bed with
guard bed
Catalyst: Calcined,
nickel treated
olivine
Catalyst: Calcined
dolomite
Figure 3.5: Tar removal Unit
Process Flow Diagram with Stream Information:
Figure 3.6 Overall Unit Ops Material Balance (will be updated)
2. Material and Energy Balance:
A) Pre-treatment of Biomass:
Switchgrass will be prepared by chopping and drying since it is one of the most effective technologies for
the preparation of switchgrass. This method provides low total energy consumption and low production
cost. The overall approach for switchgrass preparation is shown in figure 1. The preparation process
cosists of five steps: (1) establishment of switchgrass on cultivated land, (2) maintenance of switchgrass
fileds, (3) harvesting for loose hauling and chopping, (4) drying the swithcgrass in oven at 140°F for 48
hours and the chopping it, and (5) transporting the chooped switchgrass to the process plant.
SEEDS
HERBICIDES
LIME
ESTABLISMENT OF SWITCHGRASS ON
CULTIVATED LAND
MAINTENANCE OF SWITCHGRASS
FIELDS
HAVERSTING FOR LOOSE HAULING &
CHOPPING
DRYING AND CHOPPING
TRANSPORTING CHOPPED
SWITCHGRASS
Figure 1: Overall approach for switchgrass preparation
- SIZE OF SWITCHGRASS PARTICLE
The average particle size of the chopped switchgrass was found to be ½ inch in length what would be
appropriate to be feed into the grasifier.
- ENERGY REQUIREMENTS
The preparation of switchgrass requires energy inputs in most of the stages of the process as
exemplified in figure 2.
Soil Preparation
Seeding
Fertilizer/Lime/
Herbicide
Application
Fertilizer/Lime/
Herbicide
Fertilizer/Lime/
Herbicide
Production
Transportation
Growth
Harvest
Transport to
Process Plant
Energy Input
Figure 2: Energy pathways for switchgrass
The total energy required for the entire preparation process of switchgrass was found to be 829.23
Btu/lb of switchgrass. Table following table shows a summary of the energy consumption at every single
stage of the switchgrass preparation process.
SWITCHGRASS PREPARATION STAGE
ENERGY CONSUMPTION
(Btu/lb switchgrass)
Establishment
2.0875
(Cultivated Fields)
Growth
10.9596
Harvest
26.8878
(Loose hauling and chopping)
Transport
383.95
(Loose, chopped)
Emission & Energy Consumption from
fertilizers
200.12
Emission & Energy Consumption from
agriculture lime
2.56
Emission and & Energy Consumption
from all chemicals
202.67
Total Energy Consumption = 829.23 Btu/lb
- ECONOMIC ANALYSIS OF SWITCHGRASS PREPARATION
The total cost budget for switchgrass preparation includes the establishment, growth, harvest and
transportation of switchgrass. It is important to mention that machines, fuel, and energy requirements
for all farm operations were taken into consideration for the cost analysis. Using as a basis a studied
model which followed the same pretreatment approach and which has very similar characteristics as the
model presented in this paper, the price per ton switchgrass can be estimated to be the same. Both
models are bases on switchgrass from Alabama. A reasonable comparison of the two models is shown
below to demonstrate that the price estimation is valid.
Model from Literature
 HHV=16,694 kJ/kg or 7177.1
Btu/lb
 Switchgrass yield = 10 tons/year
 Stand life = 10 years
 Transportation distance = 50
miles
Present Model
 HHV = 7689 Btu/lb
 Switchgrass yield = 11.5
tons/year (Mass Balance Basis)
 Stand life = 10 years
 Transportation distance = 50
miles (Design Basis)
 Total cost = $ 41/ ton switchgrass
B) Gasifier information:
1. Gasifier Material Balance:
The material balance begins with an elemental balance on the switchgrass. Excel sheets used to
carry out the material and energy balance of the gasifier are presented in Appendix 2. A basis of
133,333 acres per year is used for calucation, which, at 11.5 tons switchgrass/acre in Alabama4, equals
3.07E9 Btu/year. Table 1a below presents the composition of switchgrass and a balance on the feed at
10% moisture.
Table 1a: Switchgrass Feed Balance
Mass %5
lb/yr
C
48.8% 1.50E+09
H
6.4% 1.97E+08
O
36.3% 1.11E+09
N
0.7% 2.21E+07
S
0.0% 6.13E+05
Ash
7.8% 2.39E+08
Moisture
3.41E+08
Total
100.0% 3.41E+09
lbmol/yr
1.25E+08
1.95E+08
6.95E+07
1.58E+06
1.91E+04
1.89E+07
4.10E+08
The switchgrass is fed along with a steam feed for gasification. Literature references have steam feeds
of 0.4 lb/lb dry biomass6, which yields 1.23E9 lb/year in our process. The switchgrass also contains ash,
the composition of which is shown in Table 1b below.
Table 1b: Ash Comp.
Ash
lb/year
SiO2
1.36E+08
Al2O3
1.91E+06
Fe2O3
8.83E+05
MgO
1.14E+07
CaO
2.64E+07
Na2O
7.16E+05
K2O
2.16E+07
P2O5
1.31E+07
Other
2.56E+07
The ash is considered inert and is parsed to the combustor in the char.
To balance the material entering the gasifier, a carbon conversion rate is needed, as is the
composition of the syngas from the Silvagas process. A pilot plant presents carbon conversion
percentages with respect to time in Figure 1b below.
Figure 1b: Carbon Conversion % of Silvagas process3
The composition of the syngas is presented in Table 1c below, along with the results of a carbon balance
at 60% carbon conversion. A ratio of CO to H2O of 25 to 40 is used for the steam in the syngas.6 Tar
enters the syngas as 16g/m3.1 Modeling the syngas as an ideal gas allows the mass of tar to be found.
Modeling the tar as C10H8 allows a molar calculation of the tar, which is required for an accurate
volume estimate.
Table 1c: Composition and Balance of Syngas
Mol %
lbmol/yr
lb/yr
CO2
12.2%
1.09E+07 4.79E+08
CO
44.4%
3.96E+07 1.11E+09
H2
22.0%
1.96E+07 3.96E+07
CH4
15.6%
1.39E+07 2.23E+08
C2H4
5.1%
4.55E+06 1.28E+08
C2H6
0.7%
6.24E+05 1.88E+07
H2O
6.31E+07 1.14E+09
Tar
1.07E+06 1.38E+08
Total
100.0%
1.53E+08 3.27E+09
Other components of the syngas will include sulfur and nitrogen compounds. Several
assumptions are made to balance these components. No SOx or NOx compounds are formed. 8.3% of
the sulfur is sent to the char, and the rest forms 90% H2S and 10% COS. 6.6% of the nitrogen is sent to
the char, and the rest forms 25% NH3, 10% HCN, and 65% N2. All chlorine forms HCl. Using these
assumptions, the compositions of other components in the syngas are found and presented in Table 1d.
Table 1d. Other
Compounds
H2S
COS
NH3
HCN
N2
HCl
Total
lbmol/yr
1.58E+04
1.75E+03
3.68E+05
1.47E+05
4.79E+05
3.36E+04
1.04E+06
lb/yr
5.38E+05
2.11E+04
6.27E+06
3.98E+06
1.34E+07
1.23E+06
2.54E+07
Once the entire composition of the syngas is found, the remaining elements are parsed to the
char. This char is fed to the combustor, where the combustion of C, H, and S, heats the circulating sand.
The gaseous products of this combustion comprise the flue gas, the composition of which is presented
in Table 1e below.
Table 1e: Combustion Products
lbmol/year
CO2
3.89E+07
N2
4.79E+04
NO2
8.32E+03
H2O
5.82E+07
SO2
1.59E+03
Total
9.72E+07
Parsing the inert ash to an ash tray and sending the feed air to the flue gas completes the mass
balance. A summary of the feed streams and product streams is shown below.
Feeds:
Air Introduced
lbmol/year 2.95E+08
lb/year
8.50E+09
Switchgrass Feed
lb/year
3.41E+09
Steam Feed
lb/year
lbmol/year
1.23E+09
6.81E+07
lbmol/year
2.32E+08
1.04E+07
5.82E+07
3.89E+07
7.86E+03
1.59E+03
3.40E+08
lb/year
6.50E+09
3.33E+08
1.05E+09
1.71E+09
2.36E+05
1.02E+05
9.60E+09
Products:
SynGas
CO2
CO
H2
CH4
C2H4
C2H6
H2S
COS
NH3
HCN
N2
HCl
H2O
Tar
Total
lbmol/year
1.09E+07
3.96E+07
1.96E+07
1.39E+07
4.55E+06
6.24E+05
1.58E+04
1.75E+03
3.68E+05
1.47E+05
4.79E+05
3.36E+04
6.31E+07
1.07E+06
1.54E+08
Mol %
7.05E+00
2.56E+01
1.27E+01
9.01E+00
2.95E+00
4.04E-01
1.02E-02
1.14E-03
2.38E-01
9.53E-02
3.10E-01
2.18E-02
4.09E+01
6.96E-01
1.00E+02
lb/year
4.79E+08
1.11E+09
3.96E+07
2.23E+08
1.28E+08
1.88E+07
5.38E+05
5.09E+04
6.27E+06
3.98E+06
1.34E+07
1.23E+06
1.14E+09
1.38E+08
3.30E+09
Flue Gas
N2
O2
H2O
CO2
NO2
SO2
Total
2. Gasifier Energy Balance:
The gasifier’s energy balance is carried out by balancing the enthalpies of feed and product
streams. The heat of formation plus the sensible heat of each stream is calculated, and the product and
feed streams have to be equal in Btu/year. The switchgrass heat of formation is found as the HHV of the
fuel minus the HHV of the elements comprising the fuel. The sensible heat of the switchgrass is found
from a heat capacity of 0.358 Btu/lboF. The enthalpies of all other streams are found using heats of
formation and Antoine Coefficients for heat capacities from literature. As beginning temperatures,
literature values, of 500 oF for the steam, 220 oF for the switchgrass, 500 oF for the air feed, 1900 oF for
the flue gas, and 1500 oF for the syngas.10,1 The temperatures of the syngas and flue gas are the
temperatures of the gasifier and combustor, respectively.
The temperatures of all streams, the carbon conversion %, the air feed rate, and the steam feed
rate are all manipulated to achieve an energy balance. The results of that balance are summarized
below.
Switchgrass Feed
T (oF)
220
Btu/year -1.1E+13
Steam Feed
T (oF)
700
Btu/year
-6.73E+12
Air Feed
T (oF)
Btu/year
500
8.62E+11
Syngas Out
T (oF)
1454
Btu/year -9.1E+12
Flue Gas Out
T (oF)
1770
Btu/year
-7.88E+12
Ash Out
T (oF)
Btu/year
1770
-1.50E+10
With a heat loss of 1%, the energy in equals the energy out. The rate of sand circulation is found based
on the energy of combustion of the carbon, hydrogen, and sulfur in the char. With a heat capacity of
0.378 Btu/lboF, the circulating rate is 1.13E11 lb/year, or 37 lb/lb dry biomass.
In depth calculations and an illustrated summary of all streams are present in Appendix 2. All
reported values lead to a complete material and energy balance, and the entire excel sheet can be
manipulated by changing the basis—if a different mass rate is desired—and by manually seeking an
energy balance if necessary. The sand circulation rate is found solely by an energy balance, but is
comparable to a value of 36 lb/lb dry biomass found in literature for a similar process9. Though the
process is modeled off of processes in literature, the final energy balance is based on thermodynamic
quantities. The temperatures end up close to those found in literature1,3,6,9 based on fundamental work
in the mass balance, but independent of the temperatures presented in those references. While an
energy balance is carried out over the entire system, an unexplored balance exists over the gasifier. The
heat of all the endothermic reactions in the gasification should equal the heat provided by the sand. As
there were several variables capable of being changed to close the energy balance, this would hone the
balance in on a single carbon conversion rate and should be explored.
C) Chemical Reactor Information:
1. Chemical Reactor Material/Energy balances:
The approach used in our model of alcohol synthesis is the Langmuir-Hinshelwood kinetic approach
that can be found in many classic kinetic books [2]. Based on the following equations a mechanism is
formed.
The rate equations derived from these reactions are found in many textbooks and are as follows.
Where
And
In addition to these rate equations we must have a differential equation that describes the water gas
shift reaction.
According to Larson [2], kwgs can be set to 10000 kmol/hr/kgcat/atm^2 and the water gas shift reaction
will quickly come to equilibrium. The parameters were calculated experimentally by Gunturu [1]. The
table below lists them with their units.
Table2: certain parameters used in rate analysis
Parameter
Am, Ae, Ap, Ah
Em, Ee, Ep, Eh
nm, ne, np, nh
K1
K2
K3
Ke
Kp
Kh
Kz
Tcp
Pcpi
Methanol
14.6233
143.472
3
7.64E-09
0.6785
0.9987
Ethanol
3.0518
24.986
1
Propanol
0.2148
89.3328
1
Hydrocabons
Units
9.3856
mol/hr/kgcat
95.416
KJ/mol
1
0.7367
0.6086
1.2472
0.8359
46.7*(xi)
598
46.7*(xi)
46.7*(xi)
46.7*(xi)
Kelvin
atm
Tcp and Pcpi are the temperature and partial pressure at the center point experiment. The center
point experiment describes the basis for calculation of the above Parameters.
Table 3:Fractional-Factorial Experimental Design
Excerpt from Gunturu [1] lists experiments performed around center point condition located in last row.
These experiments were used to formulate values for the parameters of the rate equations relative to the
center point conditions.
Once the parameters and rate equations are obtained, the gross rate equations are easily transformed
into differential equations that can be solved with numerical software such as Polymath used in this
example. The net rates are obtained as follows.
With initial conditions:
These differential equations and their initial conditions are put into Polymath and the final program can
be seen in the Appendixes. The best results were achieved with approximately 1.1 kg of catalyst
resulting in a CO conversion of 74%.
Flow rate vs. Mass Catalyst used
25000
20000
lb/hr
15000
Methanol
10000
Ethanol
Propanol
5000
0
0
200
400
600
800
1000
1200
1400
g catalyst
Figure 1: shows the flow rate of products at the reactor exit versus the grams of catalyst
used
The outcome is a flow rate of approximately 21,643 lb/hr of ethanol from the mixed alcohol reactor.
The products are sent to the fractionation process where the alcohols are separated. A recycle stream
thus far has demonstrated no tremendous effect on the results. Table 4 lists the reactor inputs and
outputs in lb/hr. The mass in and mass out are listed to demonstrate balance of mass.
Table 4: Material balance information on reactor.
Table 4
IN
METHANOL
ETHANOL
PROPANOL
CH4
CO2
CO
H2
H2O
N2
C2H6
Balance
lb/hr
lb/hr
lb/hr
lb/hr
lb/hr
lb/hr
lb/hr
lb/hr
lb/hr
lb/hr
RECYCLE
0
4599
0
13576
0
1870
154795
5319944
2838
6000803
986217
6989251
82923
533877
1100
2611
9283
211958
18194
265412
20599251
OUT
34604
184448
73448
5562501
6358644
7295930
556738
64269
221241
283606
20599252
As shown in Table 5, the kinetic model demonstrated a need for 8250 Mg of catalyst. With a
flow rate of 389 MMscf/hr at standard conditions the volume of the reactor was determined to be
57,200 cubic feet.
The Energy balance on the reactor demonstrated that 328,000 lb per hour of water at 85.6
degrees Fahrenheit satisfies the heat duty associated with keeping the stream isothermal. The water
demand for ethanol at this level is approximately 1.5 gal/gal EtOH.
Table 5: Alcohol Synthesis Summary
After Reactor
Syngas from Conditioning
lbmol/hr
Recycled from Fractionation
lbmol/hr
996791
Total
lbmol/hr
1083671
Purge stream
lbmol/hr
86880
Rel wt Distribution
Methanol
(%)
12%
Ethanol
(%)
63%
Propanol
(%)
25%
Butanol +
(%)
<1%
Coolant flow rate
lb/hr
Coolant inlet
temperature
⁰F
85.6
566
42616
Conditioned Syngas H2:CO ratio
1.17
Recycled Gas H2:CO Ratio
1.06
At Reactor Inlet
3.28E+05
At Reactor Exit
Temperature
⁰F
Pressure
psia
H2:CO ratio
566
Temperature
⁰F
999
Pressure
psia
1.07
CO2
(mol %)
13.7%
989
CO2
(mol %)
12.6%
Methane
(mol %)
32.9%
Methane
(mol %)
31.5%
H2O
(wt %)
0.31%
H2O
(wt %)
0.02%
Inlet Molar Flow
MMscf/hr
Catalyst Mass
Mg
8250
389
Space Velocity (GHSV)
hr^-1
6800
Reactor Volume
ft^3
57200
Overall water
demand
production of
ethanol
production of all
alcohols
gal/gal etoh
1.54
gal/gal etoh
0.96
D) Alcohol Fractionation
The product stream exiting the reactor undergoes a series of separations to purify the ethanol and
propanol products. The process involves a high-pressure gas-liquid separator and six distillation
columns. Each unit is modeled in Aspen Plus with the NRTL property method. Below is a flow sheet for
this process and tables of component flow rates, temperatures, pressures, and enthalpies of each
stream.
3-BOT
3-TOP
4-BOT
4-TOP
0.77
0.74
0.01
0
0
0
0
948.54
0
0
0
1750.08
927.52
3678.43
1.41
0
0
0
0
42.63
0
0
0
0
PROPANOL WATER2
0
0
2.4
0
1184.22
0
0
0
0
0
0
0
0
0
6.06
2415
0
0
0
0
0
0
0
0
METHANOL
ETHANOL
PROPANOL
CH4
CO2
CO
H2
H2O
N2
C2H6
BENZENE
ETHYL-01
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
0
2.41
1184.2
0
0
0
0
2421.22
0
0
0
0
928.29
3679.17
1.43
0
0
0
0
991.11
0
0
0
0
Mole Flow
Mass Flow
Volume Flow
Temperature
Pressure
LBMOL/HR
LB/HR
CUFT/HR
F
PSI
3607.83
114895.6
2433.25
263.84
59
5600
2700.15
4650
217181.3 125772.7 200034.7
4997.16
2047.4
4448.79
240.41
299.38
192.48
59
25
25
6-TOP
7-BOT
METHANOL
ETHANOL
PROPANOL
CH4
CO2
CO
H2
H2O
N2
C2H6
BENZENE
ETHYL-01
Mole Flow
Mass Flow
Volume Flow
Temperature
Pressure
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LB/HR
CUFT/HR
F
PSI
WATER
MAKEUP
918.37
0
0.77
0
105.64
0
0.74
0
0
0
0.01
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0.98
0.06
948.48
0.06
0
0
0
0
0
0
0
0
0
0
0
0
0
1750.07
0.02
1750.07
1025
1750.13 950.02 1750.13
34311.24 108625 17147.71 108625
737.73 1834.73 299.29 1649.85
149.94
386.74
211.3
201.43
14.7
14.7
14.7
20
1192.68
71386.7
1574.87
204.33
14.7
ETHGREC
0
0
0
0
0
0
0
0
0
0
0
0.02
0.02
1.08
0.02
201
40
2415
43506.9
760.6
215.43
14.7
FROMREA
1083.71
3999.67
1219.18
347539
144714.1
261392.9
276821.6
3569.23
7919.16
6757.91
0
0
1055016
20605680
11895640
570
980
ETHANOL
9.15
3572.79
1.41
0
0
0
0
41.65
0
0
0
0
3625
165723.4
3614.93
172.84
14.7
FEED-12
1083.71
3999.67
1219.18
347539
144714.1
261392.9
276821.6
3569.23
7919.16
6757.91
0
0
1055016
20605680
6053341
70
980
GAS-1
METHANOL
ETHANOL
PROPANOL
CH4
CO2
CO
H2
H2O
N2
C2H6
BENZENE
ETHYL-01
Mole Flow
Mass Flow
Volume Flow
Temperature
Pressure
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LBMOL/HR
LB/HR
CUFT/HR
F
PSI
PROD-1
PROD-2
PURGE-1
PURGE-2
RECYCL2
150.6
933.11
928.29
6.17
4.82
918.37
307.97
3691.71 3681.59
12.63
10.12
105.64
32.48
1186.7
1185.63
1.33
1.07
0
346597.5
941.5
0
14210.5
941.5
0
142415.7 2298.34
0
5839.05 2298.34
0
261111.8
281.04
0
10705.58 281.04
0
276803.4
18.25
0
11348.94
18.25
0
151.59
3417.64 3412.33
6.22
5.31
0.98
7911.28
7.88
0
324.36
7.88
0
6595.24
162.66
0
270.4
162.66
0
0
0
0
0
0
0
0
0
0
0
0
0
1042078 12938.83 9207.83 42725.18
3731
1025
20143550 462132.3 332076.9 825885.6 130055.3 34311.24
6044160 9181.17 7948.04 247810.6 163189.1 770479.7
70
70
303.35
70
70.18
570
980
980
130
980
130
14.7
The outflow from the reactor is first cooled (CONDENSE) to 70 oF. The high pressure gas-liquid
separator (SEP-1) separates most of the volatile components, including CH4, CO, CO2, H2, and N2. A small
fraction of ethanol is lost to the vapor stream (GAS-1), while most of the H2O, methanol, ethanol, and
propanol comprise the bottom liquid stream (PROD-1). The separator is at the high pressure and
temperature, 980 psi and 570 oF, of the reactor. The gas product stream of this stage is recycled back
into the reactor to react more of the CO (RECYCLE). The reactor data in excel is iteratively solved along
with the beginning stage of the Aspen separation until convergence is achieved. 4.1% of the recycle gas
is purged (PURGE-1). The water-alcohol mixture is purified further with a distillation column at reduced
pressure (SEP-2). The 5 stages of this column separate out the remaining volatile components of the
reactor products (PURGE-2). SEP-2 is at 130 psi.
The final seven distillation columns purify the product (PROD-2) into streams of propanol,
ethanol, water, and a final stream of methanol mixed with ethanol (RECYCL-2), which is also recycled
back to the reactor. The third distillation column (SEP-3) separates a mixture of water and propanol (3BOT) from the water, methanol, and ethanol (3-TOP). The bottoms product of this column is further
distilled (SEP-5) into product streams of propanol and water. To dry the methanol, water, and ethanol,
extractive distillation with ethylene glycol is used to break water’s azeotrope with ethanol (SEP-4). 1750
lbmol/hr of ethylene glycol (ETHG-REC) is recycled through two columns comprising an extractive
distillation system. Water is removed from the top of SEP-7 while a small amount of ethylene glycol is
added to make-up for the solvent lost in the water stream (MAKE-UP). Finally, methanol and ethanol
RECYCLE
144.43
295.34
31.15
332387
136576.7
250406.2
265454.4
145.37
7586.92
6324.84
0
0
999352.4
19317670
5796350
70
980
are separated (SEP-6) at a high reflux ratio. The ethanol product (ETHANOL) is purer than the required
max vol% of water and methanol at 1% and .5% respectively. The methanol stream (RECYCL-2), which
contains about 10% ethanol, is recycled back to the reactor. The table below summarizes operating
values for each column.
SEP-
Stages
Reflux
L/D
Feed Stages
2
7
0 1 (PROD-1)
3
64
4 12 (PROD-2)
4
39
0.7 35 (3-TOP); 8 (MAKE-UP);
5
10
3 4 (PROPANL)
6
20
25 8 (4-TOP)
7
10
0.8 5 (4-BOT)
Note: Excel Data sheets attached
8 (ETHG-REC)
3. Data Sheets:
See attached data sheets
4. Calculations:
See attached data sheets from excel
5. Economic Evaluation factored from Equipment Costs:
a) Operating Cost/Capital Cost:
Operating Cost:
Operating cost consists of fixed and variable cost.
 Variable Cost of Production
Variable cost of production includes all costs regarding the plant operation and it is determined by
calculating the following costs.
1. Raw materials –feedstock (switchgrass)
$ 40/ton switchgrass
2. Utilities – includes electricity, air, steam, and cooling water.
Utility pricing for a US gulf coast plant (see table 1 )
3. Consumables – solvents and catalyst used in the reactor.
Ethylene glycol, $ 0.65/lb according to ICIS- Pricing Chemical Price Reports
MoS2 catalyst, $ 5.25/lb taken from the NREL report
4. Effluent disposal – the cost of treatment of waste streams
Waste water treatment, $6/1,000 gal
Solid wastes to landfills (ash), $ 50/ton
 Fixed Cost of Production
Fixed cost of production are costs regardless of the plant operation. These are costs that cannot be
reduced and include the following:
1. Operating Labor:
Number of operator per shift * Number of Shifts* $ /year
For the present project, the number of operators was assumed the following for the complex:
a. Two field operators for the feed preparation (switchgrass grinding / drying
section)
b. One field operator for the Gasifier / CO2 removal section
c. One field operator for the Alcohol Synthesis / Fractionation section
d. One board operator for the entire complex.
The number of shits was taken to be 3 and the annual salary was $ 50,000.00
2.
3.
4.
5.
6.
Supervision – 25% of operating labor
Direct Overhead – 45% of operating labor and supervision
Maintenance- 3% of the plant cost (ISBL investment)
Overhead Expenses- 65% of labor and maintenance
Capital Expenses – 10% of working capital
Working Capital:
Working capital is the money required to start up the plant and run it until it starts earning income. It
includes the following:
1.
2.
3.
4.
5.
6.
Value of raw material inventory
Value of product and by-product inventory
Cash on hand
Accounts receivable
Accounts payable
Spare parts inventory
Working capital is also usually estimated as a percent of the fixed capital cost. For the present process,
the working capital was estimated as 30% of the fixed capital since this is the common percentage used
for multiple product process.
Table 1: Variable Cost of Production
RAW MATERIAL COSTS
Raw Materials
Switchgrass
Units
Unit/yr
Price $/unit
Price $MM/yr
Mlb
20,738,731.59
18.144
376.28
Total Raw Materials (RM)
By-Products & Waste Streams
Flue Gas
Ash
Quench water, ammonia
Gas out of Amine Stripper
CO2
H2S
Water out of Fractionation
376.28
Units
Unit/yr
Price $/unit
Price $MM/yr
Mlb
Mlb
Mlb
760,457.28
18,787.92
309,479.06
22.68
0.72
0.42610
0.22251
Mlb
Mlb
Mlb
64,600.85
46.65
10,275.08
0.72
0.00739
Total Waste Streams (BP)
0.65600
UTILITIES
Electric
HP Steam
MP Steam
LP Steam
Air
Boiler Feed
Condensate
Cooling Water
Fuel Fire
Units
Unit/hr
Price $/unit
Price $MM/yr
kwhr
Mlb
Mlb
Mlb
851.76
0.00
0.00
0.10
14.38
11.95
10.57
107.39
0.00
0.00
Mlb
Mlb
Mlb
Mlb
MMBtu
5,902.35
0.00
0.00
3,229.68
0.00
0.0023
1.84
1.29
11.08
9.19
0.12
0.00
0.00
3.58E-02
0.00
Total Utilities (UTS)
107.55
CONSUMABLES
Catalyst
Ethylene Glycol
Units
Unit/yr
Price $/unit
Price $MM/yr
kg
Mlb
8,250,000.00
2,279.10
11.55
650.00
95.29
1.48
Total Consumables (CONS)
96.77
$ MM/yr
Variable Cost of Production
(VCOP = RM - BP + CONS + UTS)
579.937
Table 2: Fixed Operating Cost
FIXED OPERATING
COSTS
$MM/yr
Labor
5-Operators per shif
position
3-Number of shif
positions
Operating Labor
Supervision
Direct Ovhd.
Total Labor
50,000
25%
45%
$/yr each
of Operating Labor
of Labor & Superv.
0.750
0.188
0.422
1.359
3%
of ISBL Investment
6.690
Maintenance
Overhead Expense
65%
of Labor & Maint.
5.232
Capital Expenses
10%
of Working Capital
11.239
Fixed Cost of
Production
(FCOP)
24.521
Types of Cost
percentage
ISBL Capital Cost
$MM
650.00
OSBL Capital Cost
40% f ISBL
260.00
Ingineering Costs
10% of ISBL & OSBL Cost
91.00
Contingency
10% ISBL & OSBL Cost
91.00
Total Fixed Capital Cost
Working Capital
1092.00
30% of Fixed Capital
327.60
Product analysis:
The amount of revenue we will be making per year from Ethanol and Propanol are shown below. We will
be selling these two products; whereas, the methanol and other products will be recycled back to the
reactor.
Product
Ethanol
Propanol
**needs to be evaluated
Prices
$1.58/gal
**
Yearly product price
$273,906,195
**
b) Equipment Installed Costs
This is a very basic cost analysis done in accordance to the NREL report on ethanol production to
get an idea of how much the installed equipment cost would be. As it is seen from the installed
cost in 2009, the cost is lesser than the base equipment cost and this is because the base
production rate is higher than our production rate. These analyses will be recalculated before
our final plant analysis meeting.
Table 5.1: Rough Cost Analysis:
Base Year Scaled-up Base Size New Size Base Cost New Cost
Index, 2005 Index, 2009
Year
(BPD)
(BPD)
(approx.)
(approx.)
2005
2009
15000
10000
475
600
Base cost in
2005 ($)
Installed cost
in 2009 ($)
$ 137,228,869
$ 135,909,047
Chemical Engineering Cost Index:
𝑵𝒆𝒘 𝑺𝒊𝒛𝒆 𝟎.𝟔
𝑵𝒆𝒘 𝑪𝒐𝒔𝒕 = 𝑩𝒂𝒔𝒆 𝑪𝒐𝒔𝒕 (𝑩𝒂𝒔𝒆 𝑺𝒊𝒛𝒆)
𝑵𝒆𝒘 𝒄𝒐𝒔𝒕 𝑰𝒏𝒅𝒆𝒙
(𝑩𝒂𝒔𝒆 𝑪𝒐𝒔𝒕 𝑰𝒏𝒅𝒆𝒙)
(Eqn 5.1)
Figure 5.1: Chemical Engineering Plant cost Index
c) Equipment Cost Analysis/ Material of Construction:
The Equipment sizing has been evaluated for the equipments listed in tables shown below. The cost of
these equipments has been scaled-up in accordance with NREL report. The material of construction of
various components has been evaluated depending on the pressure, temperature and chemicals in
contact of the equipment.
Table 5.2: Construction of Materials:
Item Description
Operating Pressure (PSI)
Operating Temperature
(°C)
Gasifier
23
1770
Combustor
23
1454
cyclone 1
cyclone 2
cyclone 3
cyclone 4
reactor compressor
initial compressor
Waste Heat Boiler
23
23
23
23
1770
1454
1770
23
510
Mixed Alcohol Reactor
1000
570
Amine Stripper
1020
CO2/H2S absorber
15
Shredder/Hopper
23
HP Gas/liquid Seperator
LP Gas/Liquid Seperator
Gas/Water Seprator
Conveyor/ Dryer
23
Ash Container
23
TCCA-Tar catalytic Cracker A
23
TCCB-Tar catalytic Cracker B
23
pumps
Amine HX
HeatX2, Steam Superheater
Amine Condensor In/out
condensor After initial
compressor
Fractionation Units
See attached Icarus report
Note: the information will be updated.
570
120
220
1454
1454
Construction of Material
CS+1/16’’CA (shell), 4’’ refractory, or
Hastelloy B-3 or C-22 alloy
CS+1/16’’CA (shell), 4’’ refractory, or
Hastelloy B-3 or C-22 alloy
1-1/4'' Cr- 1/2'' Mo + 1/8'' CA
1-1/4'' Cr- 1/2'' Mo + 1/8'' CA
1-1/4'' Cr- 1/2'' Mo + 1/8'' CA
1-1/4'' Cr- 1/2'' Mo + 1/8'' CA
A285C
A285C
SS316 (shell), Incoloy (tubes)
CS+CA (shell), or Incoloy 800H (Shell),Haynes
556 (tubes)
SS316
SS316
CS
SS316
SS316
SS316
CS
SS316
CS+CA (shell)
CS+CA (shell)
---SS316orSS304CS/A214
SS316orSS304CS/A214
SS316orSS304CS/A214
SS316orSS304CS/A214
See attached Icarus report
SS304, Shells- A515, trays-A285C
Table 5.3: Material Information and cost of material:
Material
CS
CA
Hastelloy B-3 alloy
Material Information
No minimum content of Cr, Co, Ni, Mo, Ti, W, V, Zr needed, but increased Carbon content and alloying elements
can give better tensile properties.
General purpose material
Lower corrosion rates than some of the other alloys in the presence of HCL, SO2. Basically there will be less or
almost no corrosion attack over a period of time.
Hastelloy C-22 alloy
Similar to Hastelloy B, Lower corrosion rates than some of the other alloys in the presence of HCL, SO2. Basically
there will be less or almost no corrosion attack over a period of time.
SS316
High resistance to corrosion from chlorine and sulfides. Higher creep strength than ss304 due to higher Ni
content. General purpose steel.
SS304
CS/A214
Incoloy 800H
General purpose material
General purpose material
High strength and resist oxidation, carburization, and other high temperature chemical exposures. Optimum
creep and rupture properties is seen. Chromium in the alloy imparts resistance to oxidation and corrosion. High
percentage of Ni maintains austenitic structure, so that the alloy is ductile. The Fe content provides resistance
to internal oxidation.
Haynes 556
Fe-Ni-Cr-Co alloy that combines resistance to sulfidizing, carburizing, and chlorine bearing environments at high
temperatures. Has good oxidation resistance, increases high temperature strength.
A285C
A515
General purpose material
Usually used for high/ambient pressure, temperature vessels
Alcohol Reactor Costing Analysis:
Alcohol Reactor Cost
Total out (lbmol/hr) Base, NREL Model
Total out (lbmol/hr) At the moment
Total out (lbmol/hr) New After Recycle
Estimated Alcohol Reactor Cost, $MM, NREL Model
Scale-up Cost - At the moment without recycle
Scaled-up Cost New After Recycle
Ethanol product with no recycle (lbmol/hr)
Ethanol product with recycle (lbmol/hr)
Additional Ethanol Product (lbmol/hr)
Additional Ethanol Product (gal/hr)
Hours of operation per year
Cost of ethanol $/ gal
Additionla Ethanol Product Value if recycle used
Ethanol Product Value w/o recycle
Simple Payback w/o Add'l Utilities- w/o recycle
Simple Payback w/o Add'l Utilities-w/ recycle
Data
285,128 lbmol/hr
225661.69 lbmol/hr
20605700 lbmol/hr
$3,218,633.00
$3,533,294.86
$61,016,433.97
528 lbmol/hr
3625 lbmol/hr
3097 lbmol/hr
21669.8 gal/hr
8000 hr
$1.58
$273,906,195
$6,673,920
0.05
0.21
Information
Size-1795 Cu.ft
Size-57200 Cu.ft
20,612,585- whole unit area, NREL
w/o a recycle stream to Alcohol Reactor
with a recycle stream to Alcohol Reactor
w/o a recycle stream to Alcohol Reactor
with a recycle stream to Alcohol Reactor
The Alcohol reactor size was calculated based on the GHSV. As it seen from alcohol reactor costing analysis table, the size of the reactor is
increased due to recycling of unnecessary products to achieve a desired product yield of Ethanol to meet our design basis; furthermore, the
reactor feed is also increased. The cost of the reactor after recycling is about $61,016,433.97 and it is based on equation 5.1. As it is seen from
the reactor payback period based on ethanol product value per year, conclusion has been made to keep the recycling of the unnecessary
products. Various other components equipment cost has been calculated based on NREL data and it is shown in table below.
Various Components Costing:
Gasifier Unit
Sizes
Information
Data
Total out (lbmol/hr) Base
217827
Total out (lbmol/hr) previous cost
Total out (lbmol/hr) New
Total out (lbmol/hr) New
412201.39
3132730.564
2287717.715
Estimated Rotary Biomass Cost, $MM
Scale-up Cost previous
Scale-up Cost New
Scale-up Cost New
Size at the moment
Information
$6,458,119.00
$11,960,857.85
$51,016,202.18
$53,364,617.44
dia 20ft x 28 ft
tan-tan height
Scaled up size
Combustor Unit
NREL Data
Flow-rate at the moment
To achieve 10KBPD basis, 7.6 scaled up
with a recycle stream to Alcohol Reactor, 5.555 scaled up
NREL Data
At the moment cost
To achieve 10KBPD basis, 7.6 scaled up
with a recycle stream to Alcohol Reactor, 5.555 scaled up
At the moment, 10KBPD design basis
IF RECYCLED, TO MEET THE 10Kbpd design basis
Data
Information
Total out (lbmol/hr) Base
464459
NREL Data
Total out (lbmol/hr) previous cost
29647.3
Flow-rate at the moment
Total out (lbmol/hr) New
225319.48
Total out (lbmol/hr) New
164542.515
To achieve 10KBPD basis, 7.6 scaled up
with a recycle stream to Alcohol Reactor, 5.555 scaled up
Estimated Rotary Biomass Cost, $MM
$6,458,119.00
NREL Data
Scale-up Cost previous
Scale-up Cost New
Scale-up Cost New
$1,565,259.48
$6,676,243.06
$6,983,568.78
At the moment cost
To achieve 10KBPD basis, 7.6 scaled up
with a recycle stream to Alcohol Reactor, 5.555 scaled up
Size at the moment
dia 24ft x 30 ft
tan-tan height
At the moment, 10KBPD design basis
Scaled up size
IF RECYCLED, TO MEET THE 10Kbpd design basis
TCCA Unit
Data
Total out (lbmol/hr) Base
Total out (lbmol/hr) previous cost
Total out (lbmol/hr) New
Total out (lbmol/hr) New
379930
412201.39
3132730.564
2287717.715
Estimated Rotary Biomass Cost, $MM
Scale-up Cost previous
Scale-up Cost New
Scale-up Cost New
Size at the moment
$4,335,112.00
$5,750,445.36
$24,527,160.76
$25,656,213.03
dia 12ft x 24 ft
tan-tan height
Scaled up size
TCCB Unit
379930
412201.39
3132730.564
2287717.715
Estimated Rotary Biomass Cost, $MM
$4,335,112.00
$5,750,445.36
$24,527,160.76
$25,656,213.03
dia 6ft x 30 ft tan-
NREL Data
Flow-rate at the moment
To achieve 10KBPD basis, 7.6 scaled up
with a recycle stream to Alcohol Reactor, 5.555 scaled up
NREL Data
At the moment cost
To achieve 10KBPD basis, 7.6 scaled up
with a recycle stream to Alcohol Reactor, 5.555 scaled up
At the moment, 10KBPD design basis
IF RECYCLED, TO MEET THE 10Kbpd design basis
Information
Data
Total out (lbmol/hr) Base
Total out (lbmol/hr) previous cost
Total out (lbmol/hr) New
Total out (lbmol/hr) New
Scale-up Cost previous
Scale-up Cost New
Scale-up Cost New
Size at the moment
Information
NREL Data
Flow-rate at the moment
To achieve 10KBPD basis, 7.6 scaled up
with a recycle stream to Alcohol Reactor, 5.555 scaled up
NREL Data
At the moment cost
To achieve 10KBPD basis, 7.6 scaled up
with a recycle stream to Alcohol Reactor, 5.555 scaled up
At the moment, 10KBPD design basis
tan height
Scaled up size
Waste Heat Boiler Unit
IF RECYCLED, TO MEET THE 10Kbpd design basis
Data
Total out (lbmol/hr) Base
Total out (lbmol/hr) previous cost
Total out (lbmol/hr) New
Total out (lbmol/hr) New
379930
412201.39
3132730.564
2287717.715
Estimated Rotary Biomass Cost, $MM
Scale-up Cost previous
Scale-up Cost New
Scale-up Cost New
Size at the moment
Scaled up size
CO2/H2S Absorber with Amine
Removal Unit
Total out (lbmol/hr) Base
Total out (lbmol/hr) previous cost
Total out (lbmol/hr) New
Total out (lbmol/hr) New
Information
$4,500,000.00
$5,969,166.23
$25,460,062.72
$26,632,059.01
Data
NREL Data
Flow-rate at the moment
To achieve 10KBPD basis, 7.6 scaled up
with a recycle stream to Alcohol Reactor, 5.555 scaled up
NREL Data
At the moment cost
To achieve 10KBPD basis, 7.6 scaled up
with a recycle stream to Alcohol Reactor, 5.555 scaled up
At the moment, 10KBPD design basis
IF RECYCLED, TO MEET THE 10Kbpd design basis
Information
332608
326338.22
2480170.472
1811177.121
NREL Data
Flow-rate at the moment
To achieve 10KBPD basis, 7.6 scaled up
with a recycle stream to Alcohol Reactor, 5.555 scaled up
Estimated Rotary Biomass Cost, $MM
$12,147,805.00
NREL Data
Scale-up Cost previous
Scale-up Cost New
Scale-up Cost New
Size at the moment
Scaled up size
$15,170,384.99
$64,705,678.94
$67,684,258.24
At the moment cost
To achieve 10KBPD basis, 7.6 scaled up
with a recycle stream to Alcohol Reactor, 5.555 scaled up
At the moment, 10KBPD design basis
IF RECYCLED, TO MEET THE 10Kbpd design basis
Rotary biomass drier
Total out (lbmol/hr) Base
Total out (lbmol/hr) previous cost
Total out (lbmol/hr) New
Total out (lbmol/hr) New
Estimated Rotary Biomass Cost, $MM
Data
Information
266512
425924.86
3237028.936
2363882.973
$22,297,527.00
NREL Data
Flow-rate at the moment
To achieve 10KBPD basis, 7.6 scaled up
with a recycle stream to Alcohol Reactor, 5.555 scaled up
NREL Data
Scale-up Cost previous
Scale-up Cost New
$37,315,053.77
$159,158,511.17
At the moment cost
To achieve 10KBPD basis, 7.6 scaled up
Scale-up Cost New
Size at the moment
Scaled up size
$166,485,012.55
with a recycle stream to Alcohol Reactor, 5.555 scaled up
At the moment, 10KBPD design basis
IF RECYCLED, TO MEET THE 10Kbpd design basis
Pumps/Compressors equipment sizing:
PRELIMINARY EQUIPMENT DATA
Compressors and Drivers
Customer:
Location:
Unit:
Item Number
Service
Type
(Reciprocating, Centrifugal, Axial,
Other)
Total Number of Machines
Number of Machines Running
Number of Casings (Centrifugal &
Axial)
Number of Stages (Reciprocating)
Rated Capacity, 106 scfd (Each
Machine)
Inlet Capacity acfm (Each
Machine)
Suction Temperature, °F
Suction Pressure, psia
Design
Engineer:
Project Number:
Date:
Positive
displacement
Positive
displacement
Positive
displacement
Positive
displacement
Positive
displacement
1
1
1
1
1
1
1
1
1
1
3
3
3
3
3
235
40
200
60
193
95
201
170
200
420
Discharge Pressure, psia
Gas Molecular Weight
mol % Hydrogen in Gas
'k' Value of Gas
Corrosive Material (H20, HCL,
H2S, Other)
Estimated BHP, (Each Machine)
Speed Limits ft/min, rpm
(Reciprocating)
Driver Type (Motor, Turbine,
Other)
Electric Power, Volts/Phase/Hz
65
18.221
0.392
100
18.221
0.392
175
14.74877
0.445
425
14.74877
0.445
1005
14.74877
0.445
H2S,H2O
H2S,H2O
H2O
H2O
H2O
7555.11732
7555.11732
8112.58424
13054.5612
12032.7188
Noncondensing
Non-condensing
Noncondensing
Noncondensing
Noncondensing
Motor (Single Speed, VFD)
Turbine (Condensing or NonCondensing)
Steam: Inlet Press, psig
Outlet Press, psig (NonCondensing)
Gear Required (yes/no)
Remarks:
d) Fractionation Cost Evaluation:
Fractionation Units Icarus Sizing/Costing report:
RECYCL-2
6-TOP
RECYCLE
HEA TER
SEP-6
ETH-GLY 1
GAS-1
FEED-1
PURGE-1
SPLIT-1
6-BOT
4-TOP
PURGE-2
SEP-4
COND-1
7-TOP
SEP-1
FEED-12
3-TOP
4-BOT
SEP-2
SEP-7
HEA TER-2
ETH-GLY
PROD-1
7-BOT
SEP-3
PROD-2
3-BOT
Fractionation Units
Equipment Costs
(USD)
Vessel Diameter
(Feet)
Vessel Tangent-toTangent Height (Feet)
SEP 1-TOWER
32900
7.5
23
SEP 2-TOWER
437300
21.5
24
SEP 3-TOWER
1525400
20
1.36
SEP 4-TOWER
399200
12.5
86
SEP 6-TOWER
867100
27.5
48
SEP 7-TOWER
75000
7
28
Note: see attached Fractionation Icarus report.
6. Utilities:
The utilities usage is evaluated in section 5 of the report.
7. Conceptual Control Scheme:
8. General Arrangement-Major Equipment Layout:
Shown below is a general layout of the plant. The plant layout is analyzed according to the sizes
of the plants components.
O1
O2
O3
EG1
E1
E2
E3
P1
S1
T4
E4
E5
E6
P2
Exchangers
OSBL
OSBL
Flare
Waste
heat
Boiler
CO2
Removal
Fractionation
Tar cleanup
Feedstock
processing
Reactors
Utilities
Compressor shed
T3
T2
Road
T1
Waste treatment
Gasifier and
combuster
OSBL
S1
S2
S3
Control
Building
S4
Knockout
FEEDSTOCK STORAGE
S6
S7
S8
Road
S5
Road
Road
E1-E6: Ethanol product storage
EG1: Benzene
S1-S6: Switchgrass storage
P1-P2: Propanol storage
S1: Ammonium Sulfate
T1-T4: Water treatment
O1-O3: Off-spec
TANK STORAGE
TANK
CAPACITY(GAL)
DIMENSIONS(FT)
E1
1,153,824.00
70 dia x 40'1" height
E2
1,153,824.00
70 dia x 40'1" height
E3
1,153,824.00
70 dia x 40'1" height
E4
1,153,824.00
70 dia x 40'1" height
E5
1,153,824.00
70 dia x 40'1" height
E6
1,153,824.00
70 dia x 40'1" height
P2
1,153,825.00
71 dia x 40'1" height
P3
1,153,826.00
72 dia x 40'1" height
O1
200,161.00
30 dia x 37'10" height
O2
200,161.00
30 dia x 37'10" height
O3
200,161.00
30 dia x 37'10" height
B1
46,788.00
21 dia x 18'1" height
S1
46,789.00
22 dia x 18'1" height
All storage tanks by API standards.
Reference: Walas, Stanley; Chemical Process Equipment
9. Distribution and End Issues Review:
10. Constraints Review:
a. Feedstock Definition:
b. Conversion technology Description
Gasifier:
The Silvagas process was chosen as a model for the gasifier. It is a dual fluidized bed system comprised
of a gasifier, combustor, and two cyclones. Figure 1a below illustrates this process.
Figure 1a: The Silvagas Process3
The biomass is fed into the gasifier to be gasified with steam. Hot sand from the combustor is separated
from the combustor’s flue gas, and it provides the heat for the endothermic gasification reactions.
Some of the carbon from the biomass is gasified into the syngas, creating the useful product.
Unconverted biomass is separated from the syngas and fed to the combustor along with the cooled
sand. The unconverted elements from the gasifier comprise the char, which is combusted with air in the
combustor. This combustion heats the sand to complete the cycle.1
The Silvagas process has several advantages. It is designed for biomass gasification, and it is
adaptable to forest waste, agricultural waste, municipal solid waste, and energy crops. It has short
residence times with high throughputs of 3000lb/hr-ft2. It is also adaptable to wide ranges of moisture
levels in the biomass feed. Finally, no pure oxygen is required with steam gasification.2
Chemical Reactor:
Synthesis of ethanol from syngas
The catalyst that was chosen for the synthesis of ethanol from syngas is a modified FischerTropsch catalyst specifically molybdenum disulfide bases promoted with alkali metals and cobalt
(Co/MoS2). The catalyst was selected based on important characteristics. First of all, this catalyst has an
ability to produce linear alcohols rather than branched alcohols. The production of linear alcohols is
attributed to the presence of promoted on this catalyst. Promoters help to switch the reaction from the
production of hydrocarbons to the production of linear alcohols. Another important aspect of this
catalyst is its tolerance to sulfur; it can resist sulfur concentrations up to 100ppm. This quality helps to
reduce the gas cleanup cost. It is important also to mention that a H2S stream must be added to
maintain the catalyst activity. The catalyst must be sulfided constantly. Also, this type of catalyst has
methanol decomposition functionality which means that methanol in the feed is not detrimental to the
reaction and so methanol can be recycle to increase the selectivity of ethanol production. This catalyst
poses a potential for higher ethanol selectivity, a high catalytic activity of 13.5% conversion of CO, and
an ethanol yield of 25,900 lb/hr after adding the methanol recycle.
Synthesis of n-butanol from bimolecular ethanol condensation
For the synthesis of n-butanol from ethanol, the most appropriate catalyst is the gamma
alumina supported nickel specifically the 8%Ni/Al2O3 catalyst. This catalyst is prepared by adding gamma
alumina to a solution of Ni(NO3)2·6H2O, then it is dried 150 °C and finally, pretreated with hydrogen at
500°C for 4hours. The most important characteristics of the type of catalyst are the low reaction
temperature of just 200°C, the high selectivity to n-butanol of 64.3% which means that the byproducts
have low percent selectivity as shown in table 1, the high catalytic activity that corresponds to 19.1%
conversion of ethanol, and the n-butanol yield of 12.3%.
Table 1 The catalytic performances of different catalysts over ethanol condensation reactions
AD
BD
EA
BO
Others
Sel. (%)
Sel. (%)
Sel. (%)
Sel. (%)
Sel. (%)
5.8
3.8
3.1
64.3
23.0
Catalyts
8%Ni/γ-Al2O3
a)Reaction conditions: temp: 200° C; LHSV: 0.67 h-1 b) AD: Acetaldehyde; BD: Butaldehyde; EA: Ethanyl
acetate; BO: n-butanol c) Others: 2-Ethylbutanol, n-hexanol, ethyl ether, n-butyl ether etc.
c. Separation technology Description:
There is no specific separation technology being used at the moment. The Separation of alcohols
were done in aspen/icarus.
d. Product Description:
Product Costing are shown in table below:
e. Location Sensitivity Analysis:
The plant will be located in Alabama according to switch grass analysis. According to the
design basis, the plant site will be located about 50 miles from the switch grass
production site to reduce the transportation costs.
Distance: 2750 ft.
Elev. 186 ft.
266 acres
Wind dir. NNW
Elev. 212 ft.
Distance: 4211 ft.
Possible location for plant: N32 16’39” Outside Montgomery Alabama
f.
ESH/OSHA/EPA Law Compliance:
Safety analysis of the plant has been done in order to meet the EPA/NIOSH/ESH
regulations. See attached safety sheets for the specific safety requirements on chemical
regulations.
g. Laws of Physics Appliance:
h. Turndown Ratio:
11. Applicable Standards:
12. Design Basis:
A. 10,000 BPD Gasoline Equivalent – Energy Content:
B. Environmental Review:
C. Specifications to meet Fuel Standards:
D. Clear Statement of Feedstock:
E. Engineering Design Standards:
13. Project Communications File:
Teleconference #9: Thursday 3:30 pm, 2nd April 2009:
Teleconference #8: Thursday 3:30 pm, 26th March 2009:
Due to spring break, we have continued to work on the roles from last conference call.
Teleconference #7: Thursday 3:30 pm, 19th March 2009:
Teleconference #6: Thursday 3:30 pm, 12th March 2009:
Attendance:
Adam Kanyuh, Dave Myers, Tim O., Haseeb Q., Greg D., Tim B., Catalina M.
Agenda:
Discussed about the presentation made on Tuesday and what necessary changes needs to be
made in order to move forward.
For next week
Work on more sizing, capital cost, and operating cost, plant layout, and process control scheme
Teleconference #5: Thursday 3:30 pm, 5th March 2009:
Attendance:
Adam Kanyuh, Dave Myers, Tim O., Haseeb Q., Greg D., Tim B., Catalina M.
Agenda:
Teleconference #4: Thursday 3:30 pm, 26th February 2009:
Attendance:
Adam Kanyuh, Dave Myers, Tim O., Haseeb Q., Greg D., Tim B., Catalina M.
Agenda:
Discuss future roles
Review Problems:
Aspen Flow sheets
Chemical Reactor material and energy analysis
Recycle stream analysis
Alcohol synthesis, fractionation analysis
Equipment sizing
Stick to Block Flow diagram when explaining MB and EB. (Bigger overall picture)
Equipment sizing
Construction of materials for the main components of the plant
Icarus costing Estimates
Combine the whole process sheet (close loop analysis, no loose ends to process sheet)
Debate on Ethanol vs Butanol
- Market analysis of ethanol and butanol
- If stopped at ethanol, then what are we going to do with it.
Advisor- is going to provide us with equipment sizing information and costing info. and going to
ask professor perl about what is really needed when it comes to costing the plant.
Tim Bannon
-Chemical reactor completion, alcohol synthesis fractionation unit and link up of processes
Greg Discosola
-update on tar removal and CO2 removal unit and link up of processes
Haseeb Quadri
-Construction of materials for the main components and costing of these equipments
Tim O’brien
-More detail look into MB and EB and link up of processes
Catalina
Biomass pre-treatment details
Teleconference #3: Monday 4:00 pm, 9th February 2009:
Attendance
Adam Kanyuh, Tim O'Brien, Greg Dicosola, Haseeb Quadri, Tim Bannon
-Agenda
Discuss upcoming presentation, progress
-Review Problems
Catalyst- what have we determined. Moly sulfide based. Sulfer (How much can we tolerate?).
Catalyst we chose tolerates sulfer within range (50-100ppm)
Location- Setting up in Alabama because best switchgrass is available.
Waste Streams- Need to determine where all of them are going. Options for Sulfer- Bubble
through caustic gas, Amine absorber, DEA or MEA
Amine Absorber- Could handle CO2 and H2S
Handling Tar- Absorb or catalytically absorb. Make sure tar stays in gas phase. Waste heat
boiler is where it will come out.
Oil Absorber? (Polisher)- For NOx, H2S. Might be able to get rid of it if we handle tar removal
and CO2 removal. Problems (Should probably remove)
Mass Balance- -complete general one for around plant. E.G. How much syn gas is going in and
what is coming out. Complete mass and energy balances as much as possible. C O2 S N2 in C
O2 S N2 out
Alcohol Synthesis- -type of catalyst does water gas shift itself -add enough heat to just do water
gas shift -take a look at methane coking. Make back end smaller, remove CO2 initially - Catalina
and Tim B look into how much Methanol and Ethanol will come out of mixed alcohol reactor.
Rough cost Estimate- -Look into sizing. All we can really do right now is look into prices of
products and feedstocks.
-Roles and Responsibilities
No Change
Teleconference #2: Friday 3:00pm 30th January 2009:
Attendance
Adam Kanyuh, Dan Rusinak, David Meyers, Catalina Mogollon, Tim O’Brien, Greg Dicosola
-Agenda
Feedback on presentation. Assign goals and responsibilities for next week.
-Review Problems
Decided on mix of alcohols as product - avoid costs of distillation, have market, can still leave
open to butanol.
Gasification techniques - Packer engineering (Peter Schubert presentation); also Taylor
gasification (will be sent through e-mail).
Mass Balance- Work from catalyst type and gasifier to find rates between other steps. Consider
economics of heat streams, energy coming out of process, electricity generation. What is done
with every stream?
Design Basis- where are we building plant? Determine economic escalation factors, units of
measure. How will we price product? Set up economic values up front. Also, have assumptions
of yields, etc., and impact on environment.
-Roles and Responsibilities
Tim O. - Gasification - decide on gasifier
Catalina - Catalyst - research catalyst
Greg D. - PFD
Group - work on mass balance around system - work outside-in
-Other Ideas
N/A
Monday 26 January 2009 Meeting after classAttendance
Tim B, Tim O, Haseeb, Catalina, Greg
-Agenda
Assign duties for power point presentation due 27 January 2009. Assign initial research
responsibilities.
-Review Problems
Each group member will have one slide they are responsible for and will forward said slide to
Catalina NLT 2200 hrs 26 January 2009.
Each group member was assigned an area of initial research responsibility to begin gathering
necessary data.
-Action Items
N/A
-Roles and Responsibilities
Research
Tim B -> Alcohol Synthesis
Tim O -> Gasifier
Catalina -> Alcohol Synthesis
Greg -> Clean up
Haseeb -> CO2 Removal
-Other Ideas
N/A
Teleconference #1: Friday 3:00pm 23rd January 2009:
-Attendance
Adam Kanyuh, David Myers, Tim O'Brien, Greg Dicosola, Tim Bannon
-Agenda:
Narrow in on Design Project in preparation of Tuesday's presentation
-Review Problems:
Tentative project is to design process for gasification of feedstock for production of butanol or
possibly methanol.
Advantages of Butanol
-can be used in existing pipelines
-no need to modify internal combustion engines
-nearly drop in replacement for gasoline (110,000 Btu/gal)
Disadvantages of Butanol
-possible need of many fractionators leading to complicated project
Advantages of Methanol
-simpler process
-can be sold for further processing
Disadvantages of Methanol
-may not meet project guidelines
Feedstock Suggestions
-municipal solid wastes or switchgrass
-Action Items:
Tentative process is gasification of switchgrass to produce methanol
-Roles and Responsibilities:
Tim B. Project Wiki, Help with Project outline
Tim O. Research feedstocks
Greg Block flow diagram
Catalina Research feedstocks
Haseeb Project Outline
-Other Ideas:
Narrowing project to encompass only gasifier. Black box around gasifier.
14. Information Sources and References:
General References:
1. http://en.wikipedia.org/wiki/Switch_grass, Wikipedia
2. http://uicchemegroupa.wikispaces.com/file/view/switchgrass.pdf, Mark Leser, Revised
Methodology for Developing Model Switchgrass Compositions.
3. http://bioenergy.ornl.gov/papers/misc/switgrs.html, Biofuels from Switchgrass: Greener Energy
Pasture, Oak Ridge National Laboratory.
5 a Gasifier Technology References
. Higman, C., van der Burgt, M., “Gasification.” 2003, Elsevier Science
2. Silvagas Corporation, www.silvagas.com
3. Paisley, M.A., Overend, R.P., “The Silvagas Process from Future Energy Resources—A
Commercialization Success.” 2002.
4. Bioenergy Feedstock Development Program. “Biofuels from Switchgrass: Greener Energy
Pastures.” Oak Ridge National Laboratory.
5. Laser, M., “Switchgrass Composition Methods.” Memo: 2004
6. Philips, S., Aden, A., Jechura, J., Dayton, D., “Thermochemical Ethanol via Indirect Gasification
and Mixed Alcohol Synthesis of Lignocellulosic Biomass.” NREL: 2007
7. Basu, P., “Combustion and Gasification in Fluidized Beds.” Taylor and Francis Group: 2006
8. Kaliyan, Morey, “Strategies to Improve the Durability of Switchgrass Briquettes.” ASAE: 2007
9. Bain, R.L., “Material and Energy Balances for Methanol from Biomass Using Biomass Gasifiers.”
NREL: 1992
10. Smith, J.M., Van Ness, H.C., Abbott, M.M., “Introduction to Chemical Engineering
Thermodynamics.” 7th Ed. McGraw-Hill: 2005
5 b Alcohol Synthesis Technology References:
[1] Gunturu, A.; et.al. ”A Kinetic Model for the Synthesis of High-Molecular-Weight
Alcohols over
a Sulfided Co-K-Mo/C Catalyst.” Ind. Eng. Chem. Res. Vol. 37, 1998. pp. 2107 – 2115.
[2] Larson, E.D., Consonni, S., Katofsky, R.E., Iisa, K. Frederick, J., “A Cost-Benefit
Assessment of
Gasification-Based Biorefining in the Kraft Pulp and Paper Industry, Volume 2, Detailed
Biorefinery Design and Performance Simulation”, Final Report under contract DE-FC26-
04NT42260 with the U.S. Department of Energy and with cost-sharing by the American
Forest
and Paper Association, December 2006.
[3] A. Aden, P. Spath, B. Atherton, NREL Milestone Completion Report “The Potential of
thermochemical Ethanol Via Mixed Alcohols Production”, (2005).
International Chemical Safety Cards
ICSC: 0021
CARBON DIOXIDE
Carbonic acid gas
Carbonic anhydride
CO2
Molecular mass: 44.0
(cylinder)
ICSC # 0021
CAS # 124-38-9
RTECS # FF6400000
UN #
1013
October 10, 2006 Validated
TYPES OF
HAZARD/
EXPOSURE
ACUTE HAZARDS/
SYMPTOMS
PREVENTION
Not combustible.
In case of fire in the
surroundings: use appropriate
extinguishing media.
Containers may burst in the
heat of a fire!
In case of fire: keep cylinder
cool by spraying with water.
Combat fire from a sheltered
position.
Dizziness. Headache. Elevated Ventilation.
blood pressure, increased
Fresh air, rest. Artificial
respiration may be needed.
FIRE
EXPLOSION
FIRST AID/
FIRE FIGHTING
EXPOSURE
•INHALATION
heart rate. Suffocation.
Unconsciousness.
•SKIN
Refer for medical attention.
ON CONTACT WITH LIQUID:
FROSTBITE.
Cold-insulating gloves.
Protective clothing.
ON FROSTBITE: rinse with
plenty of water, do NOT
remove clothes. Refer for
medical attention.
On contact with liquid:
frostbite.
Safety goggles or face shield .
First rinse with plenty of water
for several minutes (remove
contact lenses if easily
possible), then take to a
doctor.
•EYES
•INGESTION
SPILLAGE DISPOSAL
STORAGE
Personal protection: self-contained
breathing apparatus. Ventilation.
NEVER direct water jet on liquid.
Fireproof if in building. Cool.
Ventilation along the floor.
PACKAGING & LABELLING
UN Hazard Class: 2.2
Signal: Warning
Cylinder
May be harmful if inhaled
Contains refrigerated gas; may
cause cryogenic burns or injury
SEE IMPORTANT INFORMATION ON BACK
Prepared in the context of cooperation between the International Programme on Chemical Safety & the
Commission of the European Communities (C) IPCS CEC 1994. No modifications to the International
version have been made except to add the OSHA PELs, NIOSH RELs and NIOSH IDLH values.
ICSC: 0021
International Chemical Safety Cards
ICSC: 0021
CARBON DIOXIDE
I
M
P
PHYSICAL STATE; APPEARANCE:
ODOURLESS, COLOURLESS
COMPRESSED LIQUEFIED GAS.
ROUTES OF EXPOSURE:
The substance can be absorbed into the
body by inhalation.
PHYSICAL DANGERS:
The gas is heavier than air and may
INHALATION RISK:
On loss of containment this liquid
O
R
T
accumulate in low ceiling spaces causing
deficiency of oxygen. Build up of static
electricity can occur at fast flow rates
and may ignite any explosive mixtures
present. Free-flowing liquid condenses
to form extremely cold dry ice.
A
N
T
D
A
T
A
PHYSICAL
PROPERTIES
CHEMICAL DANGERS:
The substance decomposes on heating
above 2000°C producing toxic carbon
monoxide.
evaporates very quickly causing
supersaturation of the air with serious
risk of suffocation when in confined
areas.
EFFECTS OF SHORT-TERM EXPOSURE:
Rapid evaporation of the liquid may
cause frostbite. Inhalation of at high
levels may cause unconsciousness.
Suffocation.
EFFECTS OF LONG-TERM OR REPEATED
OCCUPATIONAL EXPOSURE LIMITS:
EXPOSURE:
TLV: 5000 ppm as TWA; 30000 ppm as The substance may have effects on the
STEL; (ACGIH 2006).
metabolism.
MAK: 5000 ppm, 9100 mg/m³;
Peak limitation category: II(2);
(DFG 2006).
OSHA PEL†: TWA 5000 ppm (9000
mg/m3)
NIOSH REL: TWA 5000 ppm (9000
mg/m3) ST 30,000 ppm (54,000 mg/m3)
NIOSH IDLH: 40,000 ppm See: 124389
Sublimation point: -79°C
Solubility in water, ml/100 ml at 20°C: 88
Vapour pressure, kPa at 20°C: 5720
Relative vapour density (air = 1): 1.5
Octanol/water partition coefficient as log
Pow: 0.83
ENVIRONMENTAL
DATA
NOTES
Carbon dioxide is given off by many fermentation processes (wine, beer, etc.) and is a major component of flue
gas. High concentrations in the air cause a deficiency of oxygen with the risk of unconsciousness or death. Check
oxygen content before entering area. No odour warning if toxic concentrations are present. Turn leaking cylinder
with the leak up to prevent escape of gas in liquid state. Other UN classification numbers for transport are: UN
1845 carbon dioxide, solid (Dry ice); UN 2187 carbon dioxide refrigerated liquid.
Transport Emergency Card: TEC (R)-20S1013 or 20G2A
ADDITIONAL INFORMATION
ICSC: 0021
CARBON DIOXIDE
(C) IPCS, CEC, 1994
Neither NIOSH, the CEC or the IPCS nor any person acting on behalf of NIOSH, the CEC or the
IPCS is responsible for the use which might be made of this information. This card contains the
collective views of the IPCS Peer Review Committee and may not reflect in all cases all the
IMPORTANT
detailed requirements included in national legislation on the subject. The user should verify
LEGAL NOTICE:
compliance of the cards with the relevant legislation in the country of use. The only
modifications made to produce the U.S. version is inclusion of the OSHA PELs, NIOSH RELs and
NIOSH IDLH values.
International Chemical Safety Cards
ICSC: 0807
TRIDYMITE
Crystalline silica, tridymite
Crystalline silicon dioxide, tridymite
SiO2
Molecular mass: 60.1
ICSC # 0807
CAS # 15468-32-3
RTECS # VV7335000
September 10, 1997 Validated
TYPES OF
HAZARD/
EXPOSURE
ACUTE HAZARDS/
SYMPTOMS
Not combustible.
FIRE
EXPLOSION
PREVENTION
FIRST AID/
FIRE FIGHTING
In case of fire in the
surroundings: all extinguishing
agents allowed.
PREVENT DISPERSION OF
DUST!
EXPOSURE
•INHALATION
Cough.
Local exhaust or breathing
protection.
•SKIN
Safety goggles, or eye
protection in combination with
breathing protection.
•EYES
•INGESTION
SPILLAGE DISPOSAL
STORAGE
PACKAGING &
LABELLING
Sweep spilled substance into
containers; if appropriate, moisten
first to prevent dusting. Wash away
remainder with plenty of water.
(Extra personal protection: P3 filter
respirator for toxic particles).
SEE IMPORTANT INFORMATION ON BACK
Prepared in the context of cooperation between the International Programme on Chemical Safety & the
Commission of the European Communities (C) IPCS CEC 1994. No modifications to the International
version have been made except to add the OSHA PELs, NIOSH RELs and NIOSH IDLH values.
ICSC: 0807
International Chemical Safety Cards
ICSC: 0807
TRIDYMITE
I
M
PHYSICAL STATE;
APPEARANCE:
COLOURLESS OR WHITE
CRYSTALS
P
PHYSICAL DANGERS:
O
R
T
A
N
T
D
A
CHEMICAL DANGERS:
Reacts with strong oxidants causing
fire and explosion hazard.
OCCUPATIONAL EXPOSURE
LIMITS:
TLV: 0.05 mg/m³ (respirable dust)
(ACGIH 1997).
MAK:
Carcinogen category: I
(DFG 2005).
ROUTES OF EXPOSURE:
The substance can be absorbed into
the body by inhalation.
INHALATION RISK:
Evaporation at 20°C is negligible; a
harmful concentration of airborne
particles can, however, be reached
quickly when dispersed.
EFFECTS OF SHORT-TERM
EXPOSURE:
EFFECTS OF LONG-TERM OR
REPEATED EXPOSURE:
The substance may have effects on
the lungs , resulting in fibrosis
(silicosis). This substance is possibly
carcinogenic to humans.
T
A
Boiling point: 2230°C
Melting point: 1703°C
PHYSICAL
PROPERTIES
Relative density (water = 1): 2.3
Solubility in water: none
ENVIRONMENTAL
DATA
NOTES
Depending on the degree of exposure, periodic medical examination is indicated.
ADDITIONAL INFORMATION
ICSC: 0807
TRIDYMITE
(C) IPCS, CEC, 1994
IMPORTANT
LEGAL
NOTICE:
Neither NIOSH, the CEC or the IPCS nor any person acting on behalf of NIOSH, the CEC
or the IPCS is responsible for the use which might be made of this information. This card
contains the collective views of the IPCS Peer Review Committee and may not reflect in all
cases all the detailed requirements included in national legislation on the subject. The user
should verify compliance of the cards with the relevant legislation in the country of use. The
only modifications made to produce the U.S. version is inclusion of the OSHA PELs,
NIOSH RELs and NIOSH IDLH values.
International Chemical Safety Cards
ICSC: 0351
ALUMINIUM OXIDE
alpha-Aluminum oxide
Alumina
Aluminum trioxide
Al2O3
Molecular mass: 101.9
ICSC # 0351
CAS # 1344-28-1
RTECS # BD1200000
February 10, 2000 Validated
TYPES OF
HAZARD/
EXPOSURE
ACUTE HAZARDS/
SYMPTOMS
PREVENTION
Not combustible.
FIRST AID/
FIRE FIGHTING
In case of fire in the
surroundings: all extinguishing
agents allowed.
FIRE
EXPLOSION
PREVENT DISPERSION OF
DUST!
EXPOSURE
•INHALATION
Cough.
•SKIN
Redness.
Local exhaust or breathing
protection.
Fresh air, rest.
Protective gloves.
Rinse and then wash skin with
water and soap.
•EYES
Safety goggles, or eye
First rinse with plenty of water
protection in combination with for several minutes (remove
breathing protection.
contact lenses if easily
possible), then take to a doctor.
•INGESTION
Do not eat, drink, or smoke
during work.
SPILLAGE DISPOSAL
STORAGE
Rinse mouth.
PACKAGING &
LABELLING
Sweep spilled substance into
containers; if appropriate, moisten
first to prevent dusting. Wash away
remainder with plenty of water.
(Extra personal protection: P1 filter
respirator for inert particles).
SEE IMPORTANT INFORMATION ON BACK
ICSC: 0351
Prepared in the context of cooperation between the International Programme on Chemical Safety & the
Commission of the European Communities (C) IPCS CEC 1994. No modifications to the International
version have been made except to add the OSHA PELs, NIOSH RELs and NIOSH IDLH values.
International Chemical Safety Cards
ICSC: 0351
ALUMINIUM OXIDE
I
M
PHYSICAL STATE;
APPEARANCE:
WHITE POWDER.
ROUTES OF EXPOSURE:
The substance can be absorbed into
the body by inhalation of its aerosol.
P
PHYSICAL DANGERS:
INHALATION RISK:
Evaporation at 20°C is negligible; a
harmful concentration of airborne
particles can, however, be reached
quickly.
O
CHEMICAL DANGERS:
R
T
OCCUPATIONAL EXPOSURE
LIMITS:
TLV: 10 mg/m³ (as TWA) A4, for
particulate matter containing no
asbestos and < 1% crystalline silica
(ACGIH 2000).
MAK: 1.5 mg/m³ (Respirable
fraction) 4 mg/m³ (Inhalable
fraction)
Pregnancy risk group: D
(DFG 2006).
OSHA PEL†: TWA 15 mg/m3 (total)
TWA 5 mg/m3 (resp)
NIOSH REL: See Appendix D
NIOSH IDLH: N.D. See: IDLH
INDEX
A
N
T
D
A
T
A
EFFECTS OF SHORT-TERM
EXPOSURE:
Inhalation of high concentrations of
dusts of this substance may cause
eyes and upper respiratory tract
irritation.
EFFECTS OF LONG-TERM OR
REPEATED EXPOSURE:
The substance may have effects on
the central nervous system .
Boiling point: 3000°C
Melting point: 2054°C
Density: 3.97
g/cm³
PHYSICAL
PROPERTIES
Solubility in water:
none
ENVIRONMENTAL
DATA
NOTES
There is a different and hard crystalline form of aluminium oxide which occurs abundantly in nature under the
name corundum (CAS 1302-74-5). Other melting points: 2015°C (approx.) (corundum). Occurs also as the
minerals: bauxite, bayerite, boehmite, diaspore, gibbsite. Card has been partly updated in October 2006. See
section Occupational Exposure Limits.
ADDITIONAL INFORMATION
ICSC: 0351
ALUMINIUM OXIDE
(C) IPCS, CEC, 1994
IMPORTANT
LEGAL
NOTICE:
Neither NIOSH, the CEC or the IPCS nor any person acting on behalf of NIOSH, the CEC
or the IPCS is responsible for the use which might be made of this information. This card
contains the collective views of the IPCS Peer Review Committee and may not reflect in all
cases all the detailed requirements included in national legislation on the subject. The user
should verify compliance of the cards with the relevant legislation in the country of use. The
only modifications made to produce the U.S. version is inclusion of the OSHA PELs,
NIOSH RELs and NIOSH IDLH values.
International Chemical Safety Cards
FERRIC OXIDE
ICSC: 1577
Anhydrous ferric oxide
Iron (III) oxide
Diiron trioxide
Iron trioxide
Ferric sesquioxide
Fe2O3
Molecular mass: 159.7
ICSC # 1577
CAS # 1309-37-1
RTECS # NO7400000
UN #
See Notes
October 28, 2004 Validated
TYPES OF
HAZARD/
EXPOSURE
ACUTE HAZARDS/
SYMPTOMS
PREVENTION
Not combustible.
FIRST AID/
FIRE FIGHTING
In case of fire in the
surroundings: use appropriate
extinguishing media.
FIRE
EXPLOSION
EXPOSURE
•INHALATION Cough.
Avoid inhalation of dust .
Fresh air, rest.
Safety goggles.
First rinse with plenty of water
for several minutes (remove
contact lenses if easily
possible), then take to a doctor.
•SKIN
Redness.
•EYES
Do not eat, drink, or smoke
during work.
•INGESTION
SPILLAGE DISPOSAL
STORAGE
PACKAGING &
LABELLING
Personal protection: P1 filter
respirator for inert particles. Sweep
spilled substance into covered
containers.
SEE IMPORTANT INFORMATION ON BACK
ICSC: 1577
Prepared in the context of cooperation between the International Programme on Chemical Safety & the
Commission of the European Communities (C) IPCS CEC 1994. No modifications to the International
version have been made except to add the OSHA PELs, NIOSH RELs and NIOSH IDLH values.
International Chemical Safety Cards
ICSC: 1577
FERRIC OXIDE
I
PHYSICAL STATE;
APPEARANCE:
REDDISH BROWNTO BLACK
CRYSTALS OR POWDER
M
P
PHYSICAL DANGERS:
O
R
CHEMICAL DANGERS:
Reacts with carbon monoxide
causing explosion hazard.
T
A
OCCUPATIONAL EXPOSURE
LIMITS:
TLV: (as Fe) 5 mg/m³ as TWA; A4;
(ACGIH 2004).
MAK: (as the respirable fraction of
the aerosol) 1.5 mg/m³; (DFG 2004).
OSHA PEL†: TWA 15 mg/m3 (total)
TWA 5 mg/m3 (resp)
NIOSH REL: See Appendix D
NIOSH IDLH: N.D. See: 1309371
N
T
D
A
ROUTES OF EXPOSURE:
INHALATION RISK:
A nuisance-causing concentration of
airborne particles can be reached
quickly when dispersed, especially if
powdered.
EFFECTS OF SHORT-TERM
EXPOSURE:
May cause mechanical irritation.
EFFECTS OF LONG-TERM OR
REPEATED EXPOSURE:
Lungs may be affected by repeated
or prolonged exposure to dust
particles , resulting in siderosis, a
benign condition.
T
A
Melting point: 1565°C
Density: 5.24
g/cm³
PHYSICAL
PROPERTIES
Solubility in water:
none
ENVIRONMENTAL
DATA
NOTES
There is a UN number associated with ferric oxide but this relates to iron oxide, spent, or iron sponge, spent
obtained from coal gas purification which is spontaneously combustible.
ADDITIONAL INFORMATION
ICSC: 1577
FERRIC OXIDE
(C) IPCS, CEC, 1994
IMPORTANT
LEGAL
NOTICE:
Neither NIOSH, the CEC or the IPCS nor any person acting on behalf of NIOSH, the CEC
or the IPCS is responsible for the use which might be made of this information. This card
contains the collective views of the IPCS Peer Review Committee and may not reflect in all
cases all the detailed requirements included in national legislation on the subject. The user
should verify compliance of the cards with the relevant legislation in the country of use. The
only modifications made to produce the U.S. version is inclusion of the OSHA PELs,
NIOSH RELs and NIOSH IDLH values.
International Chemical Safety Cards
ICSC: 0504
MAGNESIUM OXIDE
Calcined brucite
Calcined magnesia
Magnesia
MgO
Molecular mass: 40.3
ICSC # 0504
CAS # 1309-48-4
RTECS # OM3850000
September 04, 1997 Validated
TYPES OF
HAZARD/
EXPOSURE
ACUTE HAZARDS/
SYMPTOMS
Not combustible.
FIRE
PREVENTION
NO contact with halogens or
strong acids.
FIRST AID/
FIRE FIGHTING
In case of fire in the
surroundings: all extinguishing
agents allowed.
EXPLOSION
PREVENT DISPERSION OF
DUST!
EXPOSURE
•INHALATION
Cough. See Notes.
Fresh air, rest.
Remove contaminated clothes.
Rinse skin with plenty of water
or shower.
•SKIN
Redness. Pain.
•EYES
Local exhaust or breathing
protection.
Safety goggles, or eye
First rinse with plenty of water
protection in combination with for several minutes (remove
breathing protection.
contact lenses if easily
possible), then take to a doctor.
•INGESTION
Diarrhoea.
Do not eat, drink, or smoke
during work.
SPILLAGE DISPOSAL
STORAGE
Sweep spilled substance into
containers; if appropriate, moisten
first to prevent dusting. Wash away
remainder with plenty of water
(extra personal protection: P1 filter
respirator for inert particles).
Rinse mouth. Refer for
medical attention.
PACKAGING &
LABELLING
Separated from strong acids,
halogens. Dry.
SEE IMPORTANT INFORMATION ON BACK
ICSC: 0504
Prepared in the context of cooperation between the International Programme on Chemical Safety & the
Commission of the European Communities (C) IPCS CEC 1994. No modifications to the International
version have been made except to add the OSHA PELs, NIOSH RELs and NIOSH IDLH values.
International Chemical Safety Cards
ICSC: 0504
MAGNESIUM OXIDE
I
PHYSICAL STATE;
APPEARANCE:
HYGROSCOPIC, FINE, WHITE
POWDER.
ROUTES OF EXPOSURE:
The substance can be absorbed into
the body by inhalation of its aerosol
or fume and by ingestion.
PHYSICAL DANGERS:
INHALATION RISK:
Evaporation at 20°C is negligible; a
nuisance-causing concentration of
airborne particles can, however, be
reached quickly when dispersed.
M
P
O
R
T
A
N
T
D
A
T
A
CHEMICAL DANGERS:
Reacts violently with halogens and
strong acids.
OCCUPATIONAL EXPOSURE
LIMITS:
TLV: 10 mg/m³
(Inhalable fraction)
A4 (not classifiable as a human
carcinogen); (ACGIH 2006).
MAK: 1.5 mg/m³ (Respirable
fraction); 4 mg/m³ (Inhalable
fraction).
As magnesium oxide fume :
IIb (not established but data is
available) (DFG 2006).
OSHA PEL†: TWA 15 mg/m3
NIOSH REL: See Appendix D
NIOSH IDLH: 750 mg/m3 See:
1309484
EFFECTS OF SHORT-TERM
EXPOSURE:
The substance irritates the eyes and
the nose. Inhalation of fume may
cause metal fever.
EFFECTS OF LONG-TERM OR
REPEATED EXPOSURE:
Boiling point: 3600°C
Melting point: 2800°C
PHYSICAL
PROPERTIES
Relative density (water = 1): 3.6
Solubility in water: poor
ENVIRONMENTAL
DATA
NOTES
Headache, cough, sweating, nausea and fever may be caused by exposure to freshly formed fumes. The symptoms
of metal fume fever do not become manifest until 4-12 hours after exposure. Magcal, Maglite, Magox, Akro-Mag,
Animag, Granmag, Magchem 100, Marmag are trade names.
Card has been partially updated in July 2007: see Occupational Exposure Limits.
ADDITIONAL INFORMATION
ICSC: 0504
MAGNESIUM OXIDE
(C) IPCS, CEC, 1994
IMPORTANT
LEGAL
NOTICE:
Neither NIOSH, the CEC or the IPCS nor any person acting on behalf of NIOSH, the CEC
or the IPCS is responsible for the use which might be made of this information. This card
contains the collective views of the IPCS Peer Review Committee and may not reflect in all
cases all the detailed requirements included in national legislation on the subject. The user
should verify compliance of the cards with the relevant legislation in the country of use. The
only modifications made to produce the U.S. version is inclusion of the OSHA PELs,
NIOSH RELs and NIOSH IDLH values.
International Chemical Safety Cards
ICSC: 0409
CALCIUM OXIDE
Lime
Burnt lime
Quicklime
CaO
Molecular mass: 56.1
ICSC # 0409
CAS # 1305-78-8
RTECS # EW3100000
UN #
1910
September 04, 1997 Validated
TYPES OF
HAZARD/
EXPOSURE
ACUTE HAZARDS/
SYMPTOMS
FIRST AID/
FIRE FIGHTING
PREVENTION
Not combustible.
In case of fire in the
surroundings: all extinguishing
agents allowed except water.
FIRE
EXPLOSION
PREVENT DISPERSION OF
DUST! STRICT HYGIENE!
EXPOSURE
Burning sensation. Cough.
•INHALATION Shortness of breath. Sore
throat.
Local exhaust or breathing
protection.
Dry skin. Redness. Skin burns. Protective gloves. Protective
Burning sensation. Pain.
clothing.
•SKIN
Fresh air, rest. Refer for
medical attention.
Remove contaminated clothes.
Rinse skin with plenty of water
or shower. Refer for medical
attention.
•EYES
Redness. Pain. Blurred vision. Safety goggles or eye
First rinse with plenty of water
Severe deep burns.
protection in combination with for several minutes (remove
breathing protection.
contact lenses if easily
possible), then take to a doctor.
•INGESTION
Burning sensation. Abdominal Do not eat, drink, or smoke
pain. Abdominal cramps.
during work.
Vomiting. Diarrhoea.
SPILLAGE DISPOSAL
Rinse mouth. Do NOT induce
vomiting. Give nothing to
drink. Refer for medical
attention.
PACKAGING &
LABELLING
STORAGE
Sweep spilled substance into dry
Separated from strong acids,
containers. Personal protection: P2
organics water food and feedstuffs .
filter respirator for harmful particles. Dry.
Do not transport with food and
feedstuffs.
UN Hazard Class: 8
UN Packing Group: III
SEE IMPORTANT INFORMATION ON BACK
ICSC: 0409
Prepared in the context of cooperation between the International Programme on Chemical Safety & the
Commission of the European Communities (C) IPCS CEC 1994. No modifications to the International
version have been made except to add the OSHA PELs, NIOSH RELs and NIOSH IDLH values.
International Chemical Safety Cards
CALCIUM OXIDE
I
M
ICSC: 0409
PHYSICAL STATE;
APPEARANCE:
HYGROSCOPIC WHITE
CRYSTALLINE POWDER.
ROUTES OF EXPOSURE:
The substance can be absorbed into the
body by inhalation of its aerosol and by
ingestion.
PHYSICAL DANGERS:
INHALATION RISK:
Evaporation at 20°C is negligible; a
P
O
R
CHEMICAL DANGERS:
The solution in water is a medium
strong base. Reacts with water
generating sufficient heat to ignite
combustible materials. Reacts violently
with acids , halogens , metals .
T
A
N
T
OCCUPATIONAL EXPOSURE
LIMITS:
TLV: 2 mg/m³ as TWA; (ACGIH
2004).
MAK: IIb (not established but data is
available); (DFG 2004).
OSHA PEL: TWA 5 mg/m3
NIOSH REL: TWA 2 mg/m3
NIOSH IDLH: 25 mg/m3 See: 1305788
D
A
T
A
Boiling point: 2850°C
Melting point: 2570°C
Relative density (water = 1): 3.3-3.4
PHYSICAL
PROPERTIES
harmful concentration of airborne
particles can, however, be reached
quickly when dispersed.
EFFECTS OF SHORT-TERM
EXPOSURE:
The substance is corrosive to the eyes,
the skin and the respiratory tract. The
effects may be delayed. Medical
observation is indicated.
EFFECTS OF LONG-TERM OR
REPEATED EXPOSURE:
Repeated or prolonged contact with
skin may cause dermatitis. Lungs may
be affected by repeated or prolonged
exposure to dust particles. The
substance may cause ulceration and
perforation of the nasal septum.
Solubility in water:
reaction
ENVIRONMENTAL
DATA
NOTES
Reacts violently with fire extinguishing agents such as water. Clumps of calcium oxide formed by reaction with
moisture and proteins in the eye are difficult to remove by irrigation. Manual removal by a physician is necessary.
NEVER pour water into this substance; when dissolving or diluting always add it slowly to the water. Card has
been partly updated in October 2005. See sections Occupational Exposure Limits, Emergency Response.
ADDITIONAL INFORMATION
ICSC: 0409
CALCIUM OXIDE
(C) IPCS, CEC, 1994
IMPORTANT
LEGAL
NOTICE:
Neither NIOSH, the CEC or the IPCS nor any person acting on behalf of NIOSH, the CEC
or the IPCS is responsible for the use which might be made of this information. This card
contains the collective views of the IPCS Peer Review Committee and may not reflect in all
cases all the detailed requirements included in national legislation on the subject. The user
should verify compliance of the cards with the relevant legislation in the country of use. The
only modifications made to produce the U.S. version is inclusion of the OSHA PELs,
NIOSH RELs and NIOSH IDLH values.
International Chemical Safety Cards
SODIUM OXIDE
ICSC: 1653
Sodium monoxide
Disodium oxide
Disodium monoxide
Na2O
Molecular mass: 62.0
ICSC # 1653
CAS # 1313-59-3
UN #
1825
October 11, 2006 Validated
TYPES OF
HAZARD/
EXPOSURE
ACUTE HAZARDS/
SYMPTOMS
FIRE
Not combustible but enhances
combustion of other
substances.
PREVENTION
FIRST AID/
FIRE FIGHTING
NO water. Dry powder, dry
sand.
EXPLOSION
AVOID ALL CONTACT!
IN ALL CASES CONSULT A
PREVENT DISPERSION OF DOCTOR!
DUST!
EXPOSURE
Sore throat. Cough. Burning
Local exhaust. Breathing
sensation. Laboured breathing. protection.
•INHALATION Shortness of breath.
•SKIN
Redness. Pain. Serious skin
burns.
Protective gloves. Protective
clothing.
Redness. Pain. Burns
Face shield, or or eye
Rinse with plenty of water
protection in combination with (remove contact lenses if
breathing protection if powder. easily possible). Refer
immediately for medical
attention.
•EYES
•INGESTION
Fresh air, rest. Half-upright
position. Artificial respiration
may be needed. Refer
immediately for medical
attention.
Sore throat. Burning sensation Do not eat, drink, or smoke
in the throat and chest. Shock during work.
or collapse.
SPILLAGE DISPOSAL
STORAGE
Remove contaminated clothes.
Rinse skin with plenty of water
or shower. Refer immediately
for medical attention.
Rinse mouth. Do NOT induce
vomiting. Refer immediately
for medical attention.
PACKAGING &
LABELLING
Personal protection: chemical
protection suit including selfcontained breathing apparatus.
Sweep spilled substance into dry
covered plastic containers. Wash
away remainder with plenty of
water.
Separated from strong acids, food
and feedstuffs. Dry.
Do not transport with food and
feedstuffs.
UN Hazard Class: 8
UN Packing Group: II
Signal: Danger
Corr
Causes severe skin burns and eye
damage
SEE IMPORTANT INFORMATION ON BACK
Prepared in the context of cooperation between the International Programme on Chemical Safety & the
Commission of the European Communities (C) IPCS CEC 1994. No modifications to the International
version have been made except to add the OSHA PELs, NIOSH RELs and NIOSH IDLH values.
ICSC: 1653
International Chemical Safety Cards
ICSC: 1653
SODIUM OXIDE
I
M
PHYSICAL STATE;
APPEARANCE:
WHITE LUMPS OR POWDER
ROUTES OF EXPOSURE:
Serious local effects by all routes of
exposure.
P
PHYSICAL DANGERS:
INHALATION RISK:
A harmful concentration of airborne
particles can be reached quickly when
dispersed, especially if powdered
O
R
T
A
N
CHEMICAL DANGERS:
The solution in water is a strong base, it
reacts violently with acid and is
corrosive. Reacts violently with water,
producing sodium hydroxide. The
substance decomposes on heating
(>400°C), producing sodium peroxide
and sodium. Attacks many metals in the
presence of water.
T
D
OCCUPATIONAL EXPOSURE
LIMITS:
TLV not established.
MAK not established.
EFFECTS OF SHORT-TERM
EXPOSURE:
The substance is corrosive to the eyes,
the skin and the respiratory tract.
Corrosive on ingestion. Inhalation of
aerosol may cause lung oedema (see
Notes). Medical observation is
indicated.
EFFECTS OF LONG-TERM OR
REPEATED EXPOSURE:
A
T
A
PHYSICAL
PROPERTIES
Melting point: 1275°C (sublimes)
Density: 2.3
g/cm³
Solubility in water:
reaction
ENVIRONMENTAL
DATA
NOTES
Reacts violently with fire extinguishing agents such as water. The symptoms of lung oedema often do not become
manifest until a few hours have passed and they are aggravated by physical effort. Rest and medical observation
are therefore essential. Immediate administration of an appropriate inhalation therapy by a doctor or a person
authorized by him/her, should be considered. See ICSC 0360 Sodium hydroxide.
Transport Emergency Card: TEC (R)-80GC6-II+III
ADDITIONAL INFORMATION
ICSC: 1653
SODIUM OXIDE
(C) IPCS, CEC, 1994
IMPORTANT
LEGAL
NOTICE:
Neither NIOSH, the CEC or the IPCS nor any person acting on behalf of NIOSH, the CEC
or the IPCS is responsible for the use which might be made of this information. This card
contains the collective views of the IPCS Peer Review Committee and may not reflect in all
cases all the detailed requirements included in national legislation on the subject. The user
should verify compliance of the cards with the relevant legislation in the country of use. The
only modifications made to produce the U.S. version is inclusion of the OSHA PELs,
NIOSH RELs and NIOSH IDLH values.
International Chemical Safety Cards
ICSC: 0769
POTASSIUM OXIDE
Potassium monoxide
Dipotassium oxide
K2O
Molecular mass: 94.2
ICSC # 0769
CAS # 12136-45-7
UN #
2033
October 11, 2006 Validated
TYPES OF
HAZARD/
EXPOSURE
FIRE
ACUTE HAZARDS/
SYMPTOMS
Not combustible.
PREVENTION
FIRST AID/
FIRE FIGHTING
Powder, carbon dioxide. NO
hydrous agents
EXPLOSION
EXPOSURE
PREVENT DISPERSION OF IN ALL CASES CONSULT A
DUST! AVOID ALL
CONTACT!
DOCTOR!
Sore throat. Cough. Burning
Local exhaust. Breathing
sensation. Laboured breathing. protection.
•INHALATION Shortness of breath.
•SKIN
Redness. Pain. Serious skin
burns.
Protective gloves. Protective
clothing.
Redness. Pain. Burns logy of
the Eyes
Face shield and eye protection Rinse with plenty of water
in combination with breathing (remove contact lenses if
protection.
easily possible). Refer
immediately for medical
attention.
•EYES
•INGESTION
Fresh air, rest. Half-upright
position. Artificial respiration
may be needed. Refer
immediately for medical
attention.
Sore throat. Burning sensation Do not eat, drink, or smoke
in the throat and chest. Shock during work.
or collapse.
SPILLAGE DISPOSAL
Personal protection: chemical
protection suit including selfcontained breathing apparatus.
Sweep spilled substance into dry
covered plastic containers. Wash
away remainder with plenty of
water.
Remove contaminated clothes.
Rinse skin with plenty of water
or shower. Refer immediately
for medical attention.
Rinse mouth. Do NOT induce
vomiting. Refer immediately
for medical attention.
PACKAGING &
LABELLING
STORAGE
Separated from strong acids, food
and feedstuffs. Dry.
Airtight. Do not transport with food
and feedstuffs.
UN Hazard Class: 8
UN Packing Group: II
Signal: Danger
Corr
Causes severe skin burns and eye
damage
SEE IMPORTANT INFORMATION ON BACK
ICSC: 0769
Prepared in the context of cooperation between the International Programme on Chemical Safety & the
Commission of the European Communities (C) IPCS CEC 1994. No modifications to the International
version have been made except to add the OSHA PELs, NIOSH RELs and NIOSH IDLH values.
International Chemical Safety Cards
ICSC: 0769
POTASSIUM OXIDE
I
M
PHYSICAL STATE;
APPEARANCE:
GREY, HYGROSCOPIC,
CRYSTALLINE POWDER.
P
PHYSICAL DANGERS:
O
R
T
ROUTES OF EXPOSURE:
Serious local effects by all routes of
exposure.
INHALATION RISK:
A harmful concentration of airborne
particles can be reached quickly when
dispersed
CHEMICAL DANGERS:
The solution in water is a strong base, it EFFECTS OF SHORT-TERM
reacts violently with acid and is
EXPOSURE:
corrosive. Reacts violently with water
producing potassium hydroxide.
Attacks many metals in presence of
water.
A
N
T
OCCUPATIONAL EXPOSURE
LIMITS:
TLV not established.
MAK not established.
D
The substance is corrosive to the eyes,
the skin and the respiratory tract.
Corrosive on ingestion. Inhalation of
aerosol may cause lung oedema (see
Notes). Medical observation is
indicated.
EFFECTS OF LONG-TERM OR
REPEATED EXPOSURE:
A
T
A
Melting point (decomposes): 350°C
Density: 2.3
g/cm³
PHYSICAL
PROPERTIES
Solubility in water: reaction
ENVIRONMENTAL
DATA
NOTES
Reacts violently with fire extinguishing agents such as water. The symptoms of lung oedema often do not become
manifest until a few hours have passed and they are aggravated by physical effort. Rest and medical observation
are therefore essential. Immediate administration of an appropriate inhalation therapy by a doctor or a person
authorized by him/her, should be considered. See Potassium hydroxide ICSC 0357.
Transport Emergency Card: TEC (R)-80GC6-II+III
ADDITIONAL INFORMATION
ICSC: 0769
POTASSIUM OXIDE
(C) IPCS, CEC, 1994
IMPORTANT
LEGAL
NOTICE:
Neither NIOSH, the CEC or the IPCS nor any person acting on behalf of NIOSH, the CEC
or the IPCS is responsible for the use which might be made of this information. This card
contains the collective views of the IPCS Peer Review Committee and may not reflect in all
cases all the detailed requirements included in national legislation on the subject. The user
should verify compliance of the cards with the relevant legislation in the country of use. The
only modifications made to produce the U.S. version is inclusion of the OSHA PELs,
NIOSH RELs and NIOSH IDLH values.
International Chemical Safety Cards
PHOSPHORUS PENTOXIDE
ICSC: 0545
Diphosphorus pentoxide
Phosphoric anhydride
Phosphorus pentaoxide
P2O5
Molecular mass: 141.9
ICSC # 0545
CAS # 1314-56-3
RTECS # TH3945000
UN #
1807
EC #
015-010-00-0
September 04, 1997 Validated
TYPES OF
HAZARD/
EXPOSURE
FIRE
ACUTE HAZARDS/
SYMPTOMS
PREVENTION
Not combustible but enhances NO contact with water and
combustion of other
combustibles.
substances. Many reactions
may cause fire or explosion.
Gives off irritating or toxic
fumes (or gases) in a fire.
FIRST AID/
FIRE FIGHTING
Powder. Carbon dioxide. Dry
sand. NO hydrous agents.
EXPLOSION
PREVENT DISPERSION OF IN ALL CASES CONSULT A
DUST! AVOID ALL
DOCTOR!
CONTACT!
EXPOSURE
Sore throat. Cough. Burning
Local exhaust or breathing
sensation. Shortness of breath. protection.
•INHALATION
Symptoms may be delayed
(see Notes).
Pain. Blisters. Skin burns.
Protective gloves. Protective
clothing.
Pain. Redness. Severe deep
burns.
Face shield or eye protection First rinse with plenty of water
in combination with breathing for several minutes (remove
protection.
contact lenses if easily
possible), then take to a doctor.
Abdominal cramps. Burning
sensation. Diarrhoea. Sore
Do not eat, drink, or smoke
during work.
•SKIN
•EYES
•INGESTION
Fresh air, rest. Half-upright
position. Artificial respiration
may be needed. Refer for
medical attention.
Remove contaminated clothes.
Rinse skin with plenty of water
or shower. Refer for medical
attention. Wear protective
gloves when administering
first aid.
Do NOT induce vomiting.
Rest. Refer for medical
throat. Vomiting.
SPILLAGE DISPOSAL
attention.
PACKAGING &
LABELLING
STORAGE
Sweep spilled substance into
containers. Cautiously neutralize
remainder with soda ash or calcium
carbonate. Wash away remainder
with plenty of water. Personal
protection: chemical protection suit
including self-contained breathing
apparatus.
Separated from combustible and
reducing substances, strong oxidants,
strong bases, food and feedstuffs ,
water . Dry.
Airtight. Do not transport with food
and feedstuffs.
C symbol
R: 35
S: 1/2-22-26-45
UN Hazard Class: 8
UN Packing Group: II
SEE IMPORTANT INFORMATION ON BACK
ICSC: 0545
Prepared in the context of cooperation between the International Programme on Chemical Safety & the
Commission of the European Communities (C) IPCS CEC 1994. No modifications to the International
version have been made except to add the OSHA PELs, NIOSH RELs and NIOSH IDLH values.
International Chemical Safety Cards
ICSC: 0545
PHOSPHORUS PENTOXIDE
M
PHYSICAL STATE;
APPEARANCE:
HYGROSCOPIC , WHITE
CRYSTALS OR POWDER.
P
PHYSICAL DANGERS:
I
O
R
T
A
N
T
D
A
T
ROUTES OF EXPOSURE:
The substance can be absorbed into the
body by inhalation of its aerosol and by
ingestion.
INHALATION RISK:
Evaporation at 20°C is negligible; a
harmful concentration of airborne
particles can, however, be reached
CHEMICAL DANGERS:
The solution in water is a strong acid, it quickly when dispersed.
reacts violently with bases and is
corrosive. Reacts violently with
EFFECTS OF SHORT-TERM
perchloric acid causing fire and
EXPOSURE:
explosion hazard. Reacts violently with The substance is very corrosive to the
water to produce phosphoric acid.
eyes, the skin and the respiratory tract.
Attacks many metals in presence of
Corrosive on ingestion. Inhalation of
water.
dust of this substance may cause lung
oedema (see Notes). The effects may be
delayed. Medical observation is
OCCUPATIONAL EXPOSURE
indicated.
LIMITS:
TLV not established.
MAK: (Inhalable fraction) 2 mg/m³;
EFFECTS OF LONG-TERM OR
Peak limitation category: I(2);
REPEATED EXPOSURE:
Pregnancy risk group: C;
(DFG 2005).
EU OEL: 1 mg/m³ as TWA (EU 2006).
A
PHYSICAL
Sublimation point: 360°C
Solubility in water:
PROPERTIES
Melting point: 340°C
Relative density (water = 1): 2.4
reaction
ENVIRONMENTAL
DATA
NOTES
Reacts violently with fire extinguishing agents such as water. The symptoms of lung oedema often do not become
manifest until a few hours have passed and they are aggravated by physical effort. Rest and medical observation is
therefore essential. Immediate administration of an appropriate inhalation therapy by a doctor or a person
authorized by him/her, should be considered. NEVER pour water into this substance; when dissolving or diluting
always add it slowly to the water. Card has been partly updated in October 2005 & 2006. See sections:
Occupational Exposure Limits, Emergency Response.
Transport Emergency Card: TEC (R)-80GC2-II+III
NFPA Code: H2; F0; R2;
ADDITIONAL INFORMATION
ICSC: 0545
PHOSPHORUS PENTOXIDE
(C) IPCS, CEC, 1994
IMPORTANT
LEGAL
NOTICE:
Neither NIOSH, the CEC or the IPCS nor any person acting on behalf of NIOSH, the CEC
or the IPCS is responsible for the use which might be made of this information. This card
contains the collective views of the IPCS Peer Review Committee and may not reflect in all
cases all the detailed requirements included in national legislation on the subject. The user
should verify compliance of the cards with the relevant legislation in the country of use. The
only modifications made to produce the U.S. version is inclusion of the OSHA PELs,
NIOSH RELs and NIOSH IDLH values.