COLLEGE OF ENGINEERING

CENTRAL PHILIPPINE UNIVERSITY

Jaro, Iloilo City, Philippines
Tel No: 63 (33) 3291971 loc 1084

Design of a Table Salt Processing Plant

A Design Proposal

Presented to

The Faculty of the Chemical Engineering

Central Philippine University

Iloilo City

In Partial Fulfillment

of the Requirements for the Degree of

BACHELOR OF SCIENCE IN CHEMICAL ENGINEERING

By

Biso, Cedric Fritz P.

Chan, Liezl June U.

Dalisay, Lira Jane C.

Go, Gilead Mave O.

Son, Morella Niña Q.

October 2019
 Chapter I

Introduction

Background of the Study

Historically, salt was a prestigious commodity. Prior to industrialization, it was extremely

expensive and labor-intensive to harvest the mass quantities of salt necessary for food

preservation and seasoning. Salt was also used to clean food since bacteria and viruses cannot

live in a salt environment. This made salt an extremely valuable commodity. Entire economies

were based on salt production and trade. Though no longer presently a valuable commodity in

the monetary sense, salt is still valuable in the sense of being crucial to human health. Common

salt (sodium chloride) is 40% sodium and 60% chloride. An average adult consumes about 7 kg

(15 lb.) per year (Chemistry LibreTexts, 2019).

Salt can be found deposited in Earth’s layers in rock salt deposits. These deposits formed

when the water in the oceans that covered Earth many millions of years ago evaporated. The salt

was then covered by various types of rocks.

Salt plays a crucial role in maintaining human health. It is the main source of sodium and

chloride ions in the human diet. Sodium is essential for nerve and muscle function and is

involved in the regulation of fluids in the body. Sodium also plays a role in the body’s control of

blood pressure and volume. Although sodium is essential, people who consume too much

sodium may have hypertension or high blood pressure, a condition that can lead to serious

illnesses such as heart disease, kidney disease, and stroke.

Chloride ions serve as important electrolytes by regulating blood pH and pressure.

Electrolytes are compounds, often salts, which dissociate into their ionic components in solvents

like water. Chloride is also a crucial component in the production of stomach acid (HCl).
Humans excrete salt when sweating and must replenish these lost sodium and chloride ions

through their diet (from https://manoa.hawaii.edu).

Salt production is one of the oldest chemical practices performed by man. Although salt

is produced naturally when seawater evaporates, the process can easily be reproduced to create a

higher yield. There are two main sources of salt. It is harvested directly either from sea water or

natural brine, or from rock salt deposits formed by the evaporation of earlier seas that left a layer

of rock salt, otherwise known as halite. There are three types of salt extraction: solar evaporation,

rock salt mining and vacuum evaporation. Each one involves specific technology and

manufacturers select the most appropriate technique depending upon the particular topographic

and socio-economic conditions in their area of operation. Some salt is still produced using

ancient methods, but new, faster, and less expensive methods have been developed. Depending

on the source of the salt and the technique used to create it, the end product will have different

flavors and textures.

The worldwide production of salt is more than 200 million tons. As per the available

statistics, the salt industry is dominated by five nations. These are China, the US, India, Canada

and Germany. The salt industry located in Germany, Australia, Mexico, Chile, Brazil and the

United Kingdom also produces a massive amount of salt annually. The top salt exporters are the

Netherlands, Canada and Germany while the top salt importers are the United States, China and

Japan (Sheth, 2017). The Philippines, being an archipelago is also abundant with the

geographical means to harvest salt and Occidental Mindoro accounts for 40% of the Philippines’

salt production.

This project aims to design an efficient and economical table salt manufacturing plant.
 Chapter II

Concept Stage

Market Analysis

Industrial Salt Market

The industrial salt market was valued at USD 12.70 Billion in 2016 and is projected to

reach USD 14.93 Billion by 2022, at a CAGR of 2.8% from 2017 to 2022. The growth of the

chlor-alkali industry is driving the growth of the industrial salt market in the chemical processing

application. The growing use of industrial salt in de-icing and water treatment applications is

also fueling the growth of the market across the globe.

The rock salt segment of the industrial salt market is projected to witness a higher growth

during the forecast period. The growth of this segment of the market can be attributed to the

availability of large reserves of salt in salt mines. Rock salt is also commonly referred as halite.

Rock salt generally comprises of sodium chloride with impurities such as gypsum (CaSO4) and

sylvite (KCl). Rock salt deposits are found buried underground in arid regions, such as dry lake

beds, inland marginal seas, enclosed bays, and estuaries. These rock salts are mined either by

conventional mining, continuous mining equipment, or solution mining processes. Rock salt are

cheaper as compared to natural brine salt, due to the challenges in the evaporation process of

brine salt.

Based on manufacturing process, the conventional mining process segment of the

industrial salt market is projected to witness the highest growth during the forecast period. The

large availability of rock salt deposits and landscape of these mines favoring the mining process

is expected to drive the conventional mining process segment of the industrial salt market.
 Figure 1. U.S. Industrial Salts Market Revenue

Global salt consumption is forecast to grow 1.9 percent annually through 2020 to 335

million metric tons, valued at $14.1 billion. Steady gains in the Asia/Pacific and Africa/Mideast

regions, as well as in North America, will support market increases.

The average price for salt across the world is forecast to rise 2.0 percent per year to $42

per metric ton in 2020, rebounding from a low 2015 base. A strong dollar and a collapse in

commodity prices put downward pressure on dollar-denominated salt prices across the globe in

2014 and 2015. Through 2020, however, a more stable commodities market and increases in

global demand in volume terms will boost gains.

Rock Salt Market

Rock salt is another name for the mineral halite which is commonly known as sodium

chloride and has a chemical formula NaCl. It is formed by the evaporation of salty water from

large water bodies such as inland marginal seas, enclosed bays and estuaries in semi-arid regions

where it is found in enormous deposits.

 Rock salt is majorly used by chemical industries. It is often used both as residentially and

municipally for managing ice, because it has lower freezing point than pure water. It is also used

extensively in cooking as a flavor enhancer.

Figure 2. Rock Salt Market Share by Region

North America stood at the second largest market for rock salt in terms of revenue in

2016. The region’s market has been strengthened by robust sales of deicing salt in U.S. and

Canada.

Figure 3. Producer Price Index by Commodity for Chemicals and Allied Products: Rock Salt
Salt Brine Market

Brine fluid is a solution obtained when a salt usually sodium chloride is saturated in some

amount of water. Brine contains a very high salt content, which prevents the growth of bacteria

and thus help preserve the food items. The type of brine solution may vary with the variation in

the mixing proportions of salt with water. Brine fluids are typically formulated with inorganic

salts. These fluids are specifically manufactured to control formation pressure as well as reduce

damage in the reservoir.

The Global Brine Fluids market has witnessed rapid growth in recent years and this trend

is estimated to continue in coming years as well. Brine fluid is basically a solution of salt and

water. It is used as a preservative for food products through the process of brining. Brine

contains a very high salt content which prevents the growth of bacteria and thus help preserve the

food items. It also has industrial applications in medical and oil and gas industry.

The global brine fluids market is witnessing growth owing to the increasing consumption

in the regions of North America and Asia-Pacific. Manufacturers are investing heavily in

expansions and mergers & acquisitions in order to enhance their market share and revenue as

well as to fulfill the increasing demand for brine in various end-use applications. North America

leads the global brine fluids market with a market share of 50% in 2014.

Almost 85% of the total brine demand was from the oil and gas application in 2014. The

medical industry is seen as the fastest-growing end-use segment in coming years owing to the

increasing demand for medical services globally. The drivers of the global brine fluids industry

are extensive drilling activities, increasing demand for conventional and non-conventional

natural resources, and rising demand from other end-use markets.

 Along with the market estimates, competitive landscape of the brine fluids market has

been discussed in detail in the report. It also covers the profiles of leading players of this industry

with their recent developments and other strategic industry activities. Currently, the global

market is served by Israel Chemicals Limited (Israel), Albemarle Corporation (U.S.), Chemtura

Corporation (U.S.), Jordan Bromine Company (Jordan), Dow Chemicals (U.S.), Halliburton

(U.S.), M-I SWACO (U.S.), Hindustan Salts Ltd. (India), Tata Chemicals Ltd. (India), and Tetra

Technologies (Texas).

Table Salt Market

The global salt market size will grow by 31 million metric ton during 2018-2022. This

report offers an analysis of the market based on the type (rock salt, brine, solar salt and others)

and application (chemical processing, road de-icing, food processing and others). The salt market

research report further presents an in-depth insight on the growth prospects of the market across

the Americas, APAC and EMEA. The report analyzes the market’s competitive landscape and

offers information on several companies including Akzo Nobel, Cargill, Compass Minerals,

INEOS, K+S and Solvay.

Figure 4. Global Salt Market 2018-2022

 Revenue for the Table Salt Production industry slightly contracted over the five years to

2019, as consumers have become more health conscious and have reduced their sodium intake.

Over the five years to 2019, industry revenue decreased at an annualized rate of 0.1% to $497.8

million, including a 1.1% increase in 2019. Despite consumers steering away from sodium, table

salt remains a staple of the Western diet, which has helped support industry revenue during the

five-year period. The vast majority of table salt produced in the United States is used in the

production of processed foods sold in grocery stores and restaurants. The remainder is used by

households for preparing meals and as a table seasoning.

Competitive Analysis

The table salt production industry operates with a high level of market share

concentration. This is due to expanded product line offerings and production capacity levels for

the industry's major players which served to expand the scale of production with which the

company operates.

In 2013, China accounted for over one-quarter of the global salt market, more than any

other single country, producing 68,517,465 tons of salt annually. In the following years, China

continued to represent the leading salt market, while India is projected to rank as the world's

fastest growing salt consumer and ranks third in the global salt production with an estimated

production of 27,006,626 tons. Huge chlor-alkali sectors in China and India primarily drive salt

consumption, supported by solid regional demand for PVC and other downstream products.

Massive population sizes in both countries, combined with ongoing advances in the nations' food

and beverage industries, boosted salt demand in their respective food processing markets. North

America stands as the second largest regional salt market, behind Asia/ Pacific, bolstered by
strong sales of deicing salt in the US and Canada with an estimated production 44,312,914 tons

annually. The US has plenty of salt reserves and deposits in underwater domes and other places,

while 28 companies have the mandate to operate the 67 salt plants in 16 states, including Kansas,

Utah, Louisiana, Ohio, Michigan, and New York. Large food and beverage industries in the

region further propel salt consumption. In Western Europe, Germany, the region's largest

producer of chlor-alkali chemicals, will continue to rank as the leading salt market through 2018.

As stated in the market analysis, there has been an increase in the possible applications of

salt. Aside from it being a staple in cuisines around the world, it is currently used by chemical

industries and as a deicing agent.

In this study, the vacuum evaporation method will be used. With this method, the product

obtained is of a higher purity and it can be used with rock salt or brine as raw material.

Therefore, constraints such as location and raw materials used are less likely to be encounter in

the processing and design.

Design Alternatives

Rock Salt

Rock salt (also known as halite) is present in the rocky under layers of the Earth's surface

and can be extracted through deep-shaft mining. These large deposits of salt are the result of

ancient underground waterways that have long since dried up.

Rock salt is extracted through dynamite, similar in fashion to the mining of any other

mineral. Once it is brought to the Earth's surface, it is crushed and used for industrial and other

non-food purposes. This type of salt contains many minerals and other impurities.
Salt Brines

While the ocean is a natural salt brine, hydraulic mining (or solution mining) of salt

involves pumping water below the earth's surface to dissolve salt deposits and create a salt brine.

This brine is then pumped to the surface and evaporated to create salt. The salty brine may be

treated prior to evaporation to reduce mineral content, yielding a nearly pure sodium chloride

crystal. This method is inexpensive, has a high yield, and produces a very clean salt. Most table

salt is produced with this method.

Salt Production Processes

A. Vacuum Evaporation Method

Another method of salt production is the evaporation of salt brine by steam heat in large

commercial evaporators, called vacuum pans. This method yields a very high purity salt, fine in

texture, and principally used in those applications requiring the highest quality salt.

The first part of the operation is known as solution mining. Wells are drilled from several

hundred to 1,000 feet apart into the salt deposit. These wells are connected via lateral drilling, a

recently developed technology. Once the wells are connected, the solution mining operation

begins: water is pumped down one well, the salt below is dissolved, and the resulting brine is

forced to the surface through the other well. It is then piped into large tanks for storage.

Next, the brine is pumped into vacuum pans. These are huge closed vessels under

vacuum about three stories high. They are normally arranged in a series of three, four or five,

with each one in the line under greater vacuum than the preceding one. This series of vacuum

pans operates on a very simple principle: Whenever pressure is lowered, the temperature at

which water will boil is also lowered. For instance, under normal air pressure at sea level, water
boils at 212°F. But at ten thousand feet above sea level, where air pressure is much less, water

boils at 194°F. Vacuum pans may operate at as low as 100°F.

In the vacuum pan process, steam is fed to the first pan. This causes the brine in the pan

to boil. The steam from the boiling brine is then used to heat the brine in the second pan. The

pressure in the second pan is lower, allowing the steam made by the boiling in the first pan to

boil the brine in the second pan. The pressure is reduced still further in each succeeding pan.

This allows the steam made by the boiling brine in the previous pan to boil the brine in the next

pan. While the boiling operation could be done with just one pan, several pans in a row produce

more salt per pound of steam, thus allowing greater energy efficiency.

The main impurities in natural brine are calcium, magnesium and sulphate. In open pans

these produce a thick scale on the pan bottom which, with fine pans, must be removed weekly

when the mother liquor from the week’s salt making is run to waste and replaced with fresh

brine. With a vacuum plant it is necessary to remove the scale forming impurities from the brine

in a purification process. Calcium is precipitated as carbonate and magnesium as hydroxide. In

some processes the sulphate can be reduced as barium sulphate but usually the evaporator is

operated in such a way that the sulphate level in the mother liquor is not allowed to build up to a

concentration that would permit the crystallization of hydrated sodium sulphate with the salt.

In the early days of the vacuum process it was necessary to discharge the mother liquor

and any build-up of solid impurities in the vessels by “boiling out” which was done every few

days. This reduced the time for salt making and, furthermore, led to a considerable discharge of

brine to the adjacent canal or river. With modern plants, improved methods of brine purification

and evaporator operation have enabled the plant to operate for as much as six months between

boil-out and to operate with minimal loss of brine to the environment.

B. Solar Evaporation Method

This is the oldest method of salt production. It has been used since salt crystals were first

noticed in trapped pools of sea water. Its use is practical only in warm climates where the

evaporation rate exceeds the precipitation rate, either annually or for extended periods, and

ideally, where there are steady prevailing winds. Solar salt production is, typically, the capturing

of salt water in shallow ponds where the sun evaporates most of the water. The concentrated

brine precipitates the salt which is then gathered by mechanical harvesting machines. Any

impurities that may be present in the brine are drained off and discarded prior to harvesting.

Usually two types of ponds are used. First is the concentrating pond, where the salty

water from the ocean or salt lake is concentrated. The second is called the crystallizing pond,

where the salt is actually produced.

Crystallizing ponds range from to 40 to 200 acres with a foot-thick floor of salt resulting

from years of depositions. During the salt-making season of four to five months, brine flows

continuously through these ponds. This is a saturated brine solution, containing as much salt as it

can hold, so pure salt crystallizes out of the solution as the water evaporates. Natural chemical

impurities are returned to the salt water source.

There are three systems of evaporating the sea water and/ or brine.

• Single - Pond System

Though production cost will be lower, quality of salt is very much reduced, and the

production rate is also limited. Impounding of sea water in all the ponds and after evaporation

scrapping of salt from all the ponds - a batch wise process – reduced the production cost.

However, complete evaporation in the same pond results in the crystallization of all the salts

present in sea water/ brine which makes NaCl impure.

• Double - pond system

The second system, in the process of salt recovery from sea water was made with the

division of the evaporation basin into two: the first basin, usually called nurse pond, was used for

the production of NaCl-saturated brine, which was fed into the second basin, usually called

crystallizer. Thus, it was made possible to achieve continuous salt production (crystallization)

and to eliminate those seawater salts, with less solubility than NaCl (i.e. CaCO3 and CaSO4),

since these crystallize in the first basin and remain there.

• Multi - pond system

The third and most decisive system concerned was the division of the nurse pond into

several interconnected basins. With this design, sea water enters the first basin and, as it flows

through successive ponds and evaporates in the sun, its concentration increases. This production

method ensures greater control over the concentrations and quantities of the brines fed through

the system, thus resulting in the unobstructed production of much better quality and quantity of

the salt. Nursing ponds cover around 90% (to concentrate brine 2.6 from 3.5 to 26°Be) of the

total area of the saltern and create a complete, living ecosystem.

This production method is still used nowadays for the recovery of salt from sea water,

although there have been improvements and variations, allowing for the production of some

hundred to a few million tons of salt, depending on the size of the area in use (Korovessis and

Lekkas, 1994). These three stages (reservoirs, condensers and crystallizers) constitute the basic

steps towards improving the salt manufacturing technology.

C. Rock Salt Mining Method

The second oldest method of producing salt is the underground mining. This is probably

the most dramatic method of gathering salt. Large machines travel through vast cave-like

passageways performing various operations.

Salt mines are among the safest of mines. They are also the most comfortable to work in.

While mine temperature varies with depth, the average temperature remains about 70° F year-

round.

Salt may appear in veins, as does coal. Veins are the original bedded salt deposits. Salt

also may be found in domes, which were formed when Earth pressures forced salt up through

cracks in the bedrock from depths as great as 30,000 or 40,000 feet; they resemble plugs of

almost-circular shape a few hundred yards to a mile across. Some domes occur close to the

surface. Both domes and veins are mined in a similar way. Most domes in North America are

located in the south from Alabama to Texas with many out under water in the Gulf of Mexico.

To enter a salt mine, miners go down a shaft from the Earth’s surface to the salt bed.

There are two shafts in each Morton mine – one for personnel and one to lower materials and

equipment into the mine, as well as to hoist the mined rock salt to the surface. The shafts also are

used to deliver a constant supply of fresh air to the miners while they work hundreds to

thousands of feet below the surface. Most mine shafts are lined with a concrete wall called a

shaft liner.

Salt is mined by the room and pillar method. It is removed in a checkerboard pattern to

leave permanent, solid salt pillars for mine roof support. Usually 45 to 65 percent of the salt is

removed. The room height may average 18 feet in a bedded deposit to 100 feet in a dome mine.
Normally, the first operation is undercutting. Large machines cut a slot 10 or more feet in depth

across the bottom of a solid salt wall. This leaves a smooth floor for picking up the salt after

blasting.

Next, small holes are drilled into the salt wall to a depth of 10 or more feet and

explosives are loaded into the drilled holes. After the work shift, the explosives are set off

electrically. Several hundred to several thousand tons of rock salt are blasted and fall onto the

mine floor.

Equipment is used to load and haul the salt to machines that crush and feed the salt onto a

conveyor belt. The lumps are conveyed to a series of stations for crushing and additional sizing

of the lumps. The salt is then placed in a storage bin to await hoisting to the surface.

The above ground processing of the rock salt consists of screening the mined salt into

various marketable sizes by sorting through mechanically operated screens. When separated,

each size is conveyed to its individual storage bin to await packaging for shipment or to be

loaded as bulk salt into railroad cars, trucks, river barges or lake boats for shipment to customers.

There are two techniques in mining rock salt:

• Cut and Blast Mining

In “cut and blast mining” a slot is cut at the base of the rock face using a machine called

an undercutter, with a jib carrying a series of tungsten-carbide picks. This is the “cut” part of the

process.

The face is then drilled with a series of carefully sited holes, using an electro-hydraulic

rotary drill. The holes are charged with explosives and detonated, yielding about 1,200 tons of

broken rock salt. This is the “blast” part of the process.

 The rock blasted from the face is then crushed into pieces about the size of a football and

then carried on a conveyor belt to the main crusher. This breaks the rock down into smaller

pieces, passing through a sieve to ensure that it has reached the correct size for use in road de-

icing. The salt is then hoisted to the surface in skips.

• Continuous Mining

Continuous mining produces smaller lumps of rock than the cut and blast technique. A

boring machine, similar to a pneumatic drill used in digging up roads, is used. It has a rotating

head, carrying tungsten-carbide tips, which bores into the salt. The lumps are then taken directly

to a crushing and screening plant, without the need to be crushed by a feeder-breaker first.

Constraints and Trade Offs

Salt Production Advantages Disadvantages

Methods
1. Vacuum Typically, high-purity films can be There is poor surface coverage
Evaporation deposited from a source material when it comes to line of sight
Method with high purity. The source of the unless the fixture is properly
material that is going to be working in conjunction with the
vaporized onto the substrate can be movement. Also, this affects the
a solid in any shape or form. The thickness of the film on complex
versatility of this method trumps surfaces. Because of the lack of
other deposition processes. Also, movement and sight, unevenness
when deposition is not desired, and inaccurate deposition may
masks are utilized to define the occur. The usage rate of the
areas on the substrate for control source material is often times low.
purposes. Out of all of the physical Depending on this usage rate,
vapor deposition processes, this high radiant heat loads can occur
option is ultimately the cheapest within the deposition system. This
and can still provide sufficient thin will affect the substrate’s film
film vacuum coating. quality and overall appearance.
2. Solar Solar saltworks are most efficient  Efficiency Problems
Evaporation converters of solar energy into an Although solar ponds are simple
Method inorganic commodity. Conversion to construct, they are costly in
rate of solar radiation into removal terms of energy efficiency. The
of water vapor from the brine takes maximum theoretical efficiency of
place with 45% efficiency. Solar a solar pond is 17 percent,
salt requires only a fraction of man- assuming that the hottest saltwater
made energy compared with salt has a temperature of 80 degrees
produced by solution mining and Celsius (176 degrees Fahrenheit)
thermal evaporation. Advanced and the coolest water is 20
technologies for biological degrees Celsius (68 degrees
management, crystallization, Fahrenheit). Compare this to a
harvesting techniques and salt power plant that can generate heat
processing, allow production of reaching 800 degrees Celsius
solar salt 99.94% pure, which is (1,472 degrees Fahrenheit) -- the
comparable with purity of vacuum power plant has an efficiency of
salt. Proper biological management 73 percent. This means that the
of solar saltworks leads to brine solar pond is significantly less
containing less organics. Organic heat-efficient than the power
compounds in brine adversely plant.
influence the crystal growth habit,  Maintenance
which results in inclusions of To make use of the stored thermal
impurities inside the salt crystals. energy in a solar pool, the hot
saltwater at the bottom of the pool
must be pumped out. This
depletes the amount of water in
the pool, so new saltwater must be
added to the pool regularly.
Furthermore, salt crystals, which
can accumulate in the water, must
be removed to prevent buildup.
 Land Area
Solar ponds require a significant
amount of land to function
properly. Like solar panel arrays,
the ability of solar ponds to
capture energy is related to their
surface area. If this land could be
used for other, more efficient
energy sources, a solar pond
might be a wasted investment --
one pond in Israel took up
 210,000 square meters for an
electrical output of 5 megawatts.
3. Rock Salt In the most cases solution mining If the geological and tectonical
Mining has a very high economic efficiency conditions are very difficult, the
Method because: solution mining is not usable.
 The investment costs are
low.
The drilling of the bore
holes are running costs
 Demand of manpower is
low
 Solution mining can also use
by difficult hydrogeological
conditions.
The first step of the potash
mill (hot leaching) is in the
underground.
 There are no costs for this
equipment.
 Residue and high
concentrated brine stays in
the cavern, therefore there
environmental burdens are
low.

Salt Production
Advantages Disadvantages
Raw Materials
1. Rock Salt • Less energy expended for • Costly to obtain from salt
purification. domes.
• Large deposits of rock salt from • Causes environmental
around the world. problems from drilling and
mining.
• Possible conflicts with the
communities within the
vicinity.
2. Brine • Large deposits of brine since it can • Contains many impurities.
be found in oceans. • Uses more energy in the
• Impurities are commercially valuable purification process.
as the salt itself.

Process Flow Diagram

Vacuum Evaporation Process

Chapter III
 Mass and Energy Balance

Salt Production Process

Evaporator Balance

Vo, To, Po, Ho, V1, T1, P1, Hv1, V2, T2, P2, Hv2,
ho hv1 hv2 V3, T3

F1, xF, TF L1, xL F2, xF, TF L2, xL F3, xF, TF L3, xL

D1 D2 D3

The plant will use parallel feed triple effect evaporators to concentrate the brine. Since
the location of the plant is in the Philippines, the feed is assumed to have a temperature of 30℃
since the temperature of the brine source will be affected by the temperature of the environment
(average Philippine temperature is between 26-29℃ according to
https://www1.pagasa.dost.gov.ph). It is desired for the evaporating system to produce a total of
151 tons per day of wet solids (salt) with concentration of 60% solids.
SYMBOL MEANING VALUE REFERENCE
F1 Mass flowrate 1,200 Calculations
of feed (brine) T/day
entering the 1st
effect
evaporator
F2 Mass flowrate 1028.5714 Calculations
of feed (brine) T/day
entering the 2nd
effect
evaporator
F3 Mass flowrate 874.2857 Calculations
of feed (brine) T/day
entering the 3rd
effect
evaporator
xF Concentration 0.035 https://sensorex.com/blog/2016/05/04/brine-
of feed concentration-measurement/
TF Temperature of 30℃ https://www1.pagasa.dost.gov.ph
brine feed
L1 Mass flowrate 70 T/day Desired value
of product (wet
solids) exiting
the 1st effect
evaporator
L2 Mass flowrate 60 T/day Desired Value
of product (wet
solids) exiting
the 2nd effect
evaporator
L3 Mass flowrate 51 T/day Desired value
of product (wet
solids) exiting
the 3rd effect
evaporator
xL Concentration 0.6 Based on the process from
of wet solids http://www.beneteccn.com/epc-services/vacuum
-salt-plant-manufacturer-supplier/
Vo Mass flowrate 1,359.3869 Calculations
of steam T/day
entering the 1st
effect
evaporator
V1 Mass flowrate 1,130 Calculations
of steam exiting T/day
the 1st effect
 evaporator and
entering the 2nd
effect
V2 Mass flowrate 968.5714 Calculations
of steam exiting T/day
the 2nd effect
evaporator and
entering the 3rd
effect
V3 Mass flowrate 823.2857 Calculations
of steam exiting T/day
the 3rd effect
evaporator and
entering the
condensers
Po Steam pressure 20 psi https://www.saltassociation.co.uk/education/salt-
entering 1st history/salt-the-chemical-revolution/vacuum-
effect process/
evaporator
P1 Steam pressure 15 psi Assumed based on
entering 2nd https://www.saltassociation.co.uk/education/salt-
effect history/salt-the-chemical-revolution/vacuum-
evaporator process/
P2 Steam pressure 27.3455 psi Table 2-305 at 118.1881℃ temperature, Perry’s
entering 3rd Chemical Engineers’ Handbook, 8th ed
effect
evaporator
To Temperature of 126℃ https://www.saltassociation.co.uk/education/salt-
steam entering history/salt-the-chemical-revolution/vacuum-
the 1st effect process/
evaporator
T1 Temperature of 121℃ Table 2-305 at 15 psi pressure, Perry’s Chemical
steam entering Engineers’ Handbook, 8th ed
the 2nd effect
evaporator
T2 Temperature of 118.1881 Calculations
steam entering ℃
the 3rd effect
evaporator
T3 Temperature of 109.9337 Calculations
steam exiting ℃
the 3rd effect
evaporator
Ho(vapor) Enthalpies of 2727.5171 Table 2-305 at 20 psi pressure and 126℃,
steam entering kJ/kg Perry’s Chemical Engineers’ Handbook, 8th ed
ho(liquid) the 1st effect 528.5942
kJ/kg

Hv1(vapor) Enthalpy of 2678.0908 Table 2-305 at 15 psi pressure, Perry’s Chemical

steam entering kJ/kg Engineers’ Handbook, 8th ed
the 2nd effect
hv1(liquid) 421.4043
kj/kg

Hv2(vapor) Enthalpy of 2705.5365 Table 2-305 at 27.3455 psi pressure, Perry’s

steam entering kJ.kg Chemical Engineers’ Handbook, 8th ed
the 3rd effect
hv2 (liquid) 496.5492
kJ/kg

CF Specific heat of 4.011 https://www.engineeringtoolbox.com/sea-water-

feed (brine) kJ/kg-K properties-d_840.html
λ of water Heat of 40.65 https://bio.libretexts.org
vaporization of kJ/mol
water
Dryer Balance
Y3 = Y2
q2
Air
V’, Y1 V’, Y2 V’, Y3
T2 RH
RH
q1 T3
T1

Ws Ws
XF Xprod
TF Tprod

The brine or wet solids from each evaporator containing approximately sixty percent
(60%) solids at 30oC will be subjected to drying under constant drying conditions. The process
will result to a product (dry solids) with minimal to no moisture, leaving the drier at 40oC.

The medium that will be used for drying is air, taken from the atmosphere at ambient
conditions based on the Philippine recorded data. The air will be preheated to 60oC in a heater
and then fed to the drier. There will be an increase in humidity in the medium from 75% to 80%
due to the transfer of moisture from the wet solids (brine). It will then be released to the
environment with a temperature of 40oC. These parameters are constant with all the heater and
drier assigned to each evaporator.
For first effect
SYMBOL MEANING VALUE REFERENCE
Y1 0.0383
Humidity Calculations
Y2 0.0149
Y3 0.0149
RH (final) 80% Average relative humidity in the
RH Relative Humidity 75% Philippines
(initial) (bagong.pagasa.dost.gov.ph)
Ws Wet Solids 70 T/day Calculations
XF Concentration of 0.6 solids/H2O
Calculations
feed 0.6667 H2O/kgDS
Xprod Concentration of 1 solids/H2O
Calculations
product 0 H2O/kgDS
V’ Mass flow rate of T d.a.
1196.6410 Calculations
dry air day
T1 Temperature of air 40 C
o
Desired value
(leaving the drier)
T2 Temperature of air 60oC
Optimal drying temperature for salt
(entering the drier)
T3 Temperature of air 25oC
Based on ambient conditions in the
(entering the
Philippines
heater)
TF Temperature of 30oC
https://www1.pagasa.dost.gov.ph
feed
Tprod Temperature of 40oC
Desired value
product
CpDS Specific Heat of 0.88 kJ/kg DS Relationship between salinity and
dry solids specific heat ( nexusstem.co.uk)
CpH2O Specific Heat of 4.1868 kJ/kg Table 2-305, Perry’s ChE Handbook,
dry solids 8th edition
q1 Heat required by 498.2749 kW
Calculations
heater
q2 Heat required by 513.3198 kW
Calculations
dryer

For Second Effect

SYMBOL MEANING VALUE REFERENCE
Y1 Humidity 0.0383 Calculations
Y2 0.0149
Y3 0.0149
RH (final) 80% Average relative humidity in the
RH Relative Humidity 75% Philippines
(initial) (bagong.pagasa.dost.gov.ph)
Ws Wet Solids 60 T/day Calculations
XF Concentration of 0.6 solids/H2O
Calculations
feed 0.6667 H2O/kgDS
Xprod Concentration of 1 solids/H2O
Calculations
product 0 H2O/kgDS
V’ Mass flow rate of T d.a.
1025.6923 Calculations
dry air day
T1 Temperature of air 40 C
o
Desired value
(leaving the drier)
T2 Temperature of air 60oC
Optimal drying temperature for salt
(entering the drier)
T3 Temperature of air 25oC
Based on ambient conditions in the
(entering the
Philippines
heater)
TF Temperature of 30oC
https://www1.pagasa.dost.gov.ph
feed
Tprod Temperature of 40oC
Desired value
product
CpDS Specific Heat of 0.88 kJ/kg DS Relationship between salinity and
dry solids specific heat ( nexusstem.co.uk)
CpH2O Specific Heat of 4.1868 kJ/kg Table 2-305, Perry’s ChE Handbook,
dry solids 8th edition
q1 Heat required by 427.0928 kW
Calculations
heater
q2 Heat required by 439.9984 kW
Calculations
dryer
For Third Effect
SYMBOL MEANING VALUE REFERENCE
Y1 0.0383
Humidity Calculations
Y2 0.0149
Y3 0.0149
RH (final) 80% Average relative humidity in the
RH Relative Humidity 75% Philippines
(initial) (bagong.pagasa.dost.gov.ph)
Ws Wet Solids 51 T/day Calculations
XF Concentration of 0.6 solids/H2O
Calculations
feed 0.6667 H2O/kgDS
Xprod Concentration of 1 solids/H2O
Calculations
product 0 H2O/kgDS
V’ Mass flow rate of T d .a .
871.8385 Calculations
dry air day
T1 Temperature of air 40oC
Desired value
(leaving the drier)
T2 Temperature of air 60oC
Optimal drying temperature for salt
(entering the drier)
T3 Temperature of air 25oC
Based on ambient conditions in the
(entering the
Philippines
heater)
TF Temperature of 30oC
https://www1.pagasa.dost.gov.ph
feed
Tprod Temperature of 40oC
Desired value
product
CpDS Specific Heat of 0.88 kJ/kg DS Relationship between salinity and
dry solids specific heat ( nexusstem.co.uk)
CpH2O Specific Heat of 4.1868 kJ/kg Table 2-305, Perry’s ChE Handbook,
dry solids 8th edition
q1 Heat required by 363.0289 kW
Calculations
heater
q2 Heat required by 373.9902 kW
Calculations
dryer
Condenser Balance

QT1

Tm1

F1 TS1
TF1
TTSS
QT2

Tm2
F2 TS2
TF2

QT3

Tm3
F3 TS3
TF3

Three condensers will be used to cool down, condense, and further cool the condensed
liquid from the exiting steam of each evaporator prior to discharge. The cooling medium will be
water at 25oC and cool the steam from 109.9337℃ to 80℃ .

For condenser 1:

SYMBOL MEANING VALUE REFERENCE

F1 Mass flow rate of tons Evaporator calculations
274.4286
day
feed (steam)
TF1 Temperature of the 109.9337℃ Evaporator calculations
feed (steam)
Ts1 Temperature of 80℃ Appendix A: Condensate NOD,
condensed water Phase 1
leaving the (https:/www.epa.gov)
condenser
Tm1 Temperature of 25℃ Water Quality Guidelines and
cooling water Effluent Standards and Its
 Implementation in the Philippines
((https://www.wepa-db.net)
Tc1 Temperature of 100℃
saturated steam as it
condenses to
saturated liquid
QT1 Total heat leaving kJ Calculations
-648.5556 x 106
day
the condenser
Qcond Heat of condensation cal Latent Heat of
-540
g
Vaporization/Condensation
(https://link.springer.com/
referenceworkentry/
10.1007%2F978-90-481-2642-
2_327)
Qvap Heat of vaporization cal Latent Heat of
540
g
Vaporization/Condensation
(https://link.springer.com/
referenceworkentry/
10.1007%2F978-90-481-2642-
2_327)
Q1 Heat released as kJ Calculations
-5.4794 x 106
day
temperature of
saturated steam
decreases
Q2 Heat released during kJ Calculations
-620.1010 x 106
day
condensation
Q3 Heat released as kJ Calculations
-22.9752 x 106
day
temperature of
saturated liquid
decreases
CpH2O Specific heat of kJ Perry’s Chemical Engineering
4.186
kg−K
water Handbook 8th Edition
(Table 2-305)
Cpsteam Specific heat of kJ Perry’s Chemical Engineering
2.01
kg−K
steam Handbook 8th Edition
(Table 2-305)
ṁ1 Mass of cooling tons Calculations
117.375 4.186
hr
water entering the
condenser

For condenser 2:

SYMBOL MEANING VALUE REFERENCE

F2 Mass flow rate of tons Evaporator calculations
274.4286
day
feed (steam)
TF2 Temperature of the 109.9337℃ Evaporator calculations
feed (steam)
Ts2 Temperature of 80℃ Appendix A: Condensate NOD,
condensed water Phase 1
leaving the (https:/www.epa.gov)
condenser
Tm2 Temperature of 25℃ Water Quality Guidelines and
cooling water Effluent Standards and Its
Implementation in the Philippines
((https://www.wepa-db.net)
Tc2 Temperature of 100℃
saturated steam as it
condenses to
saturated liquid
QT2 Total heat leaving kJ Calculations
-648.5556 x 106
day
the condenser
Qcond Heat of condensation cal Latent Heat of
-540
g
Vaporization/Condensation
(https://link.springer.com/
referenceworkentry/
10.1007%2F978-90-481-2642-
2_327)
Qvap Heat of vaporization cal Latent Heat of
540
g
Vaporization/Condensation
(https://link.springer.com/
referenceworkentry/
10.1007%2F978-90-481-2642-
2_327)
Q1 Heat released as kJ Calculations
-5.4794 x 106
day
temperature of
saturated steam
decreases
Q2 Heat released during kJ Calculations
-620.1010 x 106
day
condensation
Q3 Heat released as kJ Calculations
-22.9752 x 106
day
temperature of
saturated liquid
decreases
CpH2O Specific heat of kJ Perry’s Chemical Engineering
4.186
kg−K
water Handbook 8th Edition
(Table 2-305)
Cpsteam Specific heat of kJ Perry’s Chemical Engineering
2.01
kg−K
steam Handbook 8th Edition
(Table 2-305)
ṁ2 Mass of cooling tons Calculations
117.375 4.186
hr
water entering the
condenser
For condenser 3:

SYMBOL MEANING VALUE REFERENCE

F3 Mass flow rate of tons Evaporator calculations
274.4286
day
feed (steam)
TF3 Temperature of the 109.9337℃ Evaporator calculations
feed (steam)
Ts3 Temperature of 80℃ Appendix A: Condensate NOD,
condensed water Phase 1
leaving the (https:/www.epa.gov)
condenser
Tm3 Temperature of 25℃ Water Quality Guidelines and
cooling water Effluent Standards and Its
Implementation in the Philippines
((https://www.wepa-db.net)
Tc3 Temperature of 100℃
saturated steam as it
condenses to
saturated liquid
QT3 Total heat leaving kJ Calculations
-648.5556 x 106
day
the condenser
Qcond Heat of condensation cal Latent Heat of
-540
g
Vaporization/Condensation
(https://link.springer.com/
referenceworkentry/
10.1007%2F978-90-481-2642-
2_327)
Qvap Heat of vaporization cal Latent Heat of
540
g
Vaporization/Condensation
(https://link.springer.com/
 referenceworkentry/
10.1007%2F978-90-481-2642-
2_327)
Q1 Heat released as kJ Calculations
-5.4794 x 106
day
temperature of
saturated steam
decreases
Q2 Heat released during kJ Calculations
-620.1010 x 106
day
condensation
Q3 Heat released as kJ Calculations
-22.9752 x 106
day
temperature of
saturated liquid
decreases
CpH2O Specific heat of kJ Perry’s Chemical Engineering
4.186
kg−K
water Handbook 8th Edition
(Table 2-305)
Cpsteam Specific heat of kJ Perry’s Chemical Engineering
2.01
kg−K
steam Handbook 8th Edition
(Table 2-305)
ṁ3 Mass of cooling tons Calculations
117.375 4.186
hr
water entering the
condenser
Brine Feed Pump Balance

, BHP

P2
u2
D2
P1 T2
u1
D1
T1

Three pumps will be used to supply the feed (brine) to each evaporator. Initial and final
temperatures will remain constant, only having a change in pressure and fluid velocity.

For 1st effect:

SYMBOL MEANING VALUE REFERENCE

P1 Inlet pressure 1 atm Atmospheric pressure
u1 Inlet velocity 0 Velocity at bottom of a pond
D1 Inlet diameter of 24 in Desired value
pump
T1 Inlet temperature 30℃ https://www1.pagasa.dost.gov.ph
P2 Outlet pressure 0.1 atm Desired value
u2 Outlet velocity m Calculations
0.0462
s
D2 Outlet diameter of 24 in Desired value
pump
T2 Outlet temperature 30℃ Desired value
ṁ Mass flow rate of tons Evaporator calculations
1200
day
brine
h Height of pump from 10 ft Desired value
 evaporator
ρ Density of brine kg Average density of seawater
1029
m3 (https://www.windows2universe.org)
∆P Change in pressure -0.9 atm Calculations
2
∆ (u ) Change in velocity 2.13444 x 10-3 Calculations
m2
s2
∆ Ep Change in potential m2 Calculations
29. 8982 2
energy s
Ẇ Work produced by 815. 5853 W Calculations
the pump
Q Heat 0 Assuming adiabatic operation
BHP Break horse power 60 HP Calculations

For 2nd effect:

SYMBOL MEANING VALUE REFERENCE

P1 Inlet pressure 1 atm Atmospheric pressure
u1 Inlet velocity 0 Velocity at bottom of a pond
D1 Inlet diameter of 24 in Desired value
pump
T1 Inlet temperature 30℃ https://www1.pagasa.dost.gov.ph
P2 Outlet pressure 0.1 atm Desired value
u2 Outlet velocity m Calculations
0.0396
s
D2 Outlet diameter of 24 in Desired value
pump
T2 Outlet temperature 30℃ Desired value
ṁ Mass flow rate of tons Evaporator calculations
1028.5714
day
brine
h Height of pump from 10 ft Desired value
 evaporator
ρ Density of brine kg Average density of seawater
1029
m3 (https://www.windows2universe.org)
∆P Change in pressure -0.9 atm Calculations
2
∆ (u ) Change in velocity m
2
Calculations
1.5682 x 10 2
-3
s
∆ Ep Change in potential m2 Calculations
29. 8982
energy s2
Ẇ Work produced by 699.1198 W Calculations
the pump
Q Heat 0 Assuming adiabatic operation
BHP Break horse power 50 HP Calculations

For 3rd effect:

SYMBOL MEANING VALUE REFERENCE

P1 Inlet pressure 1 atm Atmospheric pressure
u1 Inlet velocity 0 Velocity at bottom of a pond
D1 Inlet diameter of 24 in Desired value
pump
T1 Inlet temperature 30℃ https://www1.pagasa.dost.gov.ph
P2 Outlet pressure 0.1 atm Desired value
u2 Outlet velocity m Calculations
0.0337
s
D2 Outlet diameter of 24 in Desired value
pump
T2 Outlet temperature 30℃ Desired value
ṁ Mass flow rate of tons Evaporator calculations
874.2857
day
brine
h Height of pump from 10 ft Desired value
evaporator
 ρ Density of brine kg Average density of seawater
1029
m3 (https://www.windows2universe.org)
∆P Change in pressure -0.9 atm Calculations
2
∆ (u ) Change in velocity m
2
Calculations
1.1357 x 10-3
s2
∆ Ep Change in potential m2 Calculations
29. 8982
energy s2
Ẇ Work produced by 594.2411 W Calculations
the pump
Q Heat 0 Assuming adiabatic operation
BHP Break horse power 50 HP Calculations

Cooling Water Pump Balance

 Pumps 1,2, and 3 used the same inlet and outlet parameters

, BHP

P2
u2
D2
P1 T2
u1
D1
T1

Three pumps will be used for each of the three condensers. Initial and final temperatures
will remain constant, only having a change in pressure and fluid velocity. All three pumps will
have the same mass and energy balance due to having the same feed flow rate.
 SYMBOL MEANING VALUE REFERENCE
P1 Inlet pressure 1 atm Atmospheric pressure
u1 Inlet velocity 0 Velocity at bottom of
a pond
D1 Inlet diameter of pump 8 in Desired value
P2 Outlet pressure 0.5 atm Desired value
u2 Outlet velocity m Calculations
0.0462
s
D2 Outlet diameter of pump 6 in Desired value
ṁ Mass flow rate of water tons Calculations
274.4286
day
ρ Density of water kg Density of water at
1000
m3 4°C
∆P Change in pressure -0.5 atm Calculations
∆ (u2 ) Change in velocity m2 Calculations
3.1948
s2
∆ Ep Change in potential energy 0 Calculations
Ẇ Work produced by the pump -1547.6369 W Calculations
Q Heat 0 Assuming adiabatic
operation
BHP Break horse power 105 HP Calculations
Compressor Balance

ρ1

T1

P1

ṁ ρ@20◦C
Ẇ
V1

ρ2

T2

P2

ṁ

V2

SYMBOL MEANING VALUE REFERENCE

ρ1 Initial density 1.184 kg/m3 Perry’s Chemical
Engineering Handbook
8th Edition
T1, T2 Initial temperature 25◦C Desired value
P1 Initial Pressure 1 atm Atmospheric pressure
ṁ Mass flow rate 1196.6410 tons DA/day Calculations
ρ@20◦C Density 1.2041 kg/m3 Calculations
ρ2 Final density 1.776 kg/m3 Perry’s Chemical
Engineering Handbook
8th Edition
P2 Final pressure 1.5 atm Desired value
V2 Final velocity 106.8778 m/s Calculations
V1 Initial velocity 0 Desired value
Ẇ Work produced by 887.5454 hP Calculations
compressor
 Chapter IV

Equipment Design

Long Tube Vertical Evaporators

Long tube vertical or rising film evaporators are used due to its low residence

time compared to other evaporator designs. This is crucial because it allows the usage of the

evaporator in higher operating temperatures and gives assurance of high quality products.
Additional advantage is the availability of the option to operate the evaporator as a continuous

process which is overall more energy and time efficient than batch processing operations.

Stainless steel is used in the construction of the evaporator due to its resistance to corrosion and

increased efficiency in heat transfer at a lower cost.

Material Stainless Steel 304

SPECIFICATIONS
SYMBOL MEANING VALUE
A Heating surface area required 1286 m2
L Tube length 6.4024 m

Di Inside diameter 0.0492506 m

Do Outside diameter 0.060325 m

a Surface area of each tube 1.2134 m

2

NT Number of tubes required at 10% 1060 tubes

overdesign
PT Triangular tube pitch 0.0754 m
ATt Total area occupied by tubes 2. 6095 m2

AA Actual area required with a factor of 0.9 2.8994 m

2

AD Downcomer area 1.5148 m2

dD Downcomer diameter 1.3888 m

ATev Total area of tube sheet in evaporator 4.4142 m2

dT Tube sheet diameter 2.3707 m

tt Tube thickness 0.0564 mm
Conical head at bottom and top cone 120°
angle
ts Sheet thickness 9 mm
Rd Downcomer radius 1.3
 d dr Drum diameter 5.2926 m
h dr Drum height 9.4828 m
tD Drum thickness 1.0973 mm
Gp Shell ID 5.2926 m
tt s Tube sheet thickness 8.74 cm

Rotary Drum Dryer

 Rotary dryers are less sensitive to particle size. It can accept the highest flue gases of any

tupe of dryer and has a low maintenance cost compared to other dryers. It also has the greatest

capacity of any type of dryer. Brass can withstand high temperatures and is highly resistant to

corrosion thus it is a suitable material to be used for salt slurries.

Material Brass C37

SPECIFICATIONS
SYMBOL MEANING VALUE
A Area 11.1343 m2
D Shell Diameter 3.7652 m ≈ 4 m
L Length 24 m

Single Pass Shell and Tube Heat Exchanger

 Single pass shell and tube heat exchanger are used since power plants use single pass

straight tube heat exchangers as their surface condensers. This makes construction much simpler.

Brass is recommended for the construction of heat exchangers for the service below 200°C and

at the same time, this material is cost effective.

Material Brass C37

SPECIFICATIONS
SYMBOL MEANING VALUE
A Heat Transfer Area 85.5454 m2
nt No. of tubes 380 tubes
De Equivalent diameter for the tube side 92.6804 m
Db Bundle diameter 1.4292 m
Ds Diameter of shell 1.5 m
as tube side cross flow area 0.0254 m2
De Equivalent diameter for the shell side 0.0478 m

Pumps and Compressors

EQUIPMENT LOCATION CAPACITY

Centrifugal Pump Brine Feed to 1st Effect 60 HP
Centrifugal Pump Brine Feed to 2nd Effect 50 HP
Centrifugal Pump Brine Feed to 3rd Effect 50 HP
Centrifugal Pump Cooling Water Feed to 1st Condenser 105 HP
Centrifugal Pump Cooling Water Feed to 2nd Condenser 105 HP
Centrifugal Pump Cooling Water Feed to 3rd Condenser 105 HP
Compressor Heater Feed 900 HP
 Chapter V

Analysis of Cost Estimation

Estimation of Capital Investment Cost

The following equipment base prices were taken as the average selling prices from online

sources based on the specifications provided in Chapter IV. The total purchased equipment cost

was estimated to be ₱15,670,000.00.

PURCHASED EQUIPMENT Qty. Price Total

Long Tube Vertical Evaporator 3 ₱1,300,000.00 ₱3,900,000.00
Rotary Drum Dryer 3 ₱520,000.00 ₱1,560,000.00
Single Pass Shell and Tube HE 3 ₱520,000.00 ₱1,560,000.00
Centrifugal Pump 50HP 2 ₱300,000.00 ₱600,000.00
Centrifugal Pump 60HP 1 ₱430,000.00 ₱430,000.00
Centrifugal Pump 105HP 1 ₱520,000.00 ₱520,000.00
Compressor 900 HP 3 ₱1,500,000.00 ₱4,500,000.00
Boiler 1 ₱2,600,000.00 ₱2,600,000.00
Subtotal: ₱15,670,000.00

The base prices of the direct cost were based on the total purchased equipment cost and

multiplied to the factor introduced in Plant Design and Economics for Chemical Engineers 5th

Ed. to compute for a total direct cost of ₱37,038,181.82.

DIRECT COSTS Factor Basis Total

Purchased Equipment 0.3 ₱52,233,333.33 ₱15,670,000.00
Installation, including insulation and 0.3 ₱15,670,000.00 ₱4,701,000.00
painting
Instrumentation and controls, installed 0.15 ₱15,670,000.00 ₱2,350,500.00
Piping, installed 0.1 ₱15,670,000.00 ₱1,567,000.00
Electrical, installed 0.1 ₱15,670,000.00 ₱1,567,000.00
Buildings, process, and auxiliary 0.2536363 ₱15,670,000.00 ₱3,974,481.82
6
Service facilities and yard improvement 0.4 ₱15,670,000.00 ₱6,268,000.00
Land 0.06 ₱15,670,000.00 ₱940,200.00
 Subtotal: ₱37,038,181.82

The base prices of the indirect cost were based on the total direct cost and total fixed

capital investment multiplied to the factor introduced in Plant Design and Economics for

Chemical Engineers 5th Ed. to compute for a total direct cost of ₱15,195,151.52.

INDIRECT COSTS Factor Basis Total

Engineering and supervision 0.1 ₱37,038,181.82 ₱3,703,818.18
Legal expenses 0.02 ₱52,233,333.33 ₱1,044,666.67
Construction expense and contractor's fee 0.1 ₱52,233,333.33 ₱5,223,333.33
Contingency 0.1 ₱52,233,333.33 ₱5,223,333.33
Subtotal: ₱15,195,151.52

The fixed capital investment was taken as the sum of direct and indirect costs incurred

and estimated to be a total of ₱52,233,333.33.

FIXED CAPITAL INVESTMENT Total

Direct Costs ₱37,038,181.82
Indirect Costs ₱15,195,151.52
Subtotal: ₱52,233,333.33

The total capital investment was taken as the sum of fixed capital investment and

working capital. The working capital was approximated using the total capital investment as a

basis multiplied to a factor introduced in Plant Design and Economics for Chemical Engineers 5th

Ed. to compute for a total capital investment of ₱61,450,980.39.

TOTAL CAPITAL INVESTMENT Factor Basis Total

Fixed Capital Investment ₱52,233,333.33
Working Capital 0.15 ₱61,450,980.39 ₱9,217,647.06
Subtotal: ₱61,450,980.39
Estimation of Total Product Cost

The base prices used to compute for total product cost were based on total product cost

and fixed capital investment multiplied to a factor introduced in Plant Design and Economics for

Chemical Engineers 5th Ed. to compute for direct production costs of ₱46,539,900.00.

Direct Production Costs Factor Basis Total

Raw materials 0.2 ₱70,515,000.00 ₱14,103,000.00
Operating labor 0.1 ₱70,515,000.00 ₱7,051,500.00
Operating supervision 0.1 ₱70,515,000.00 ₱7,051,500.00
Utilities 0.1 ₱70,515,000.00 ₱7,051,500.00
Maintenance and repairs 0.06 ₱52,233,333.33 ₱3,134,000.00
Operating supplies 0.0075 ₱52,233,333.33 ₱391,750.00
Laboratory Charges 0.1 ₱70,515,000.00 ₱7,051,500.00
Patents and royalties 0.01 ₱70,515,000.00 ₱705,150.00
Subtotal: ₱46,539,900.00

The base prices used to compute for total product cost were based on total capital

investment and fixed capital investment multiplied to a factor introduced in Plant Design and

Economics for Chemical Engineers 5th Ed. to compute for total fixed charge of ₱8,128,735.69.

FIXED CHARGES Factor Basis Total

Taxes (property) 0.025 ₱52,233,333.33 ₱1,305,833.33
Financing (interest) 0.05 ₱61,450,980.39 ₱3,072,549.02
Insurance 0.07 ₱52,233,333.33 ₱3,656,333.33
Rent 0.1 ₱940,200.00 ₱94,020.00
Subtotal: ₱8,128,735.69
 The total manufacturing cost was taken as the sum of direct production costs, fixed

charges and plant overhead cost. The plant overhead cost was approximated using the total

product cost as a basis multiplied to a factor introduced in Plant Design and Economics for

Chemical Engineers 5th Ed. to compute for a total capital investment of ₱61,720,135.69

MANUFACTURING COST Factor Basis Total

Direct Production Costs ₱46,539,900.00
Fixed Charges ₱8,128,735.69
Plant Overhead Cost 0.1 ₱70,515,000.00 ₱7,051,500.00
Subtotal: ₱61,720,135.69

The base prices used to compute for general expenses were based on total product cost

multiplied to a factor introduced in Plant Design and Economics for Chemical Engineers 5th Ed.

to compute for total general expenses of ₱8,794,864.31.

GENERAL EXPENSES Factor Basis Total

Administrative Costs 0.02 ₱70,515,000.00 ₱1,410,300.00
0.0547233
Distribution And Marketing Costs 1 ₱70,515,000.00 ₱3,858,814.31
Research And Development Costs 0.05 ₱70,515,000.00 ₱3,525,750.00
Subtotal: ₱8,794,864.31

The total product cost was taken as the sum of manufacturing cost and general expenses

incurred and estimated to be a total of ₱70,515,000.00.

TOTAL PRODUCT COST Total

Manufacturing Cost ₱61,720,135.69
General Expenses ₱8,794,864.31
Subtotal: ₱70,515,000.00
 Based on calculations from Chapter III, the plant is predicted to have a production rate of

181 tons per day and from this, the total income per day can be calculated by multiplying it to the

average selling price of ₱14,500.00 per ton of salt. Total income per day is estimated to be

₱2,624,500.00 and an annual income of ₱682,370,000.00 with 260 working days per year. Gross

earnings are calculated from the difference of total income and total product cost to yield

₱550,404,019.61 per year and ₱2,116,938.54 per day.

INCOME SUMMARY Total

Production Rate (Tons/Day) 181.00
Selling Price (Per Ton) ₱14,500.00
Total Income (Per Day) ₱2,624,500.00
Total Income (Per Year) ₱682,370,000.00
Gross Earnings (Per Year) ₱550,404,019.61
Gross Earnings (Per Day) ₱2,116,938.54

Based on the cost estimation of the proposed salt production plant, the plant is predicted

to provide enough profit to compensate the expenses incurred during start-up and operation.

Therefore, on account of cost analysis, the design of the proposed salt production plant can be

considered feasible.
 Chapter VI

General Design Considerations

Health and Safety Hazards

Majority of workers employed in the salt industry are unskilled and poorly educated and

employed through contractor on temporary basis. A major share of accidents is due to bad work

practice and human error and hence can be avoided. Apart from accidents, workers in the salt

industry suffer from health problems arising out of work environment/ work conditions

(Industrial Safety and Hazard Management in Salt Industry, 2019).

Sources of Exposure

Studies have established that a large number of salt workers are exposed to salt and

facing occupational health problems like prevalence of ophthalmic symptoms, dermatological

symptoms, headache, giddiness, breathlessness, muscular and joint pains. The ophthalmic

problems were most common, probably due to irritation by direct sunlight and its glare caused by

salt crystals to brine as well as irritation, traumatic ulcers, dermatitis, muscular and joint pains.

Headache and giddiness were other more common symptoms to salt workers (Durairaj &

Murugan, 2019).

This salt processing plant will also expose workers to heat from substances and

equipment and potentially harmful machines.

Exposure Evaluation

Although ingestion is not thought to produce harmful effects, Sodium chloride may still

be damaging to the health of the individual following ingestion, especially where pre-existing

organ damage is evident. In an occupational setting however, ingestion of insignificant quantities

is not thought to be cause for concern. There are also evidences to suggest that this material can

cause eye irritation and damage in some people and the material can produce health damage if it

enters through wounds, lesions, and abrasions. Persons with impaired respiratory function,

airway diseases and conditions such as emphysema or chronic bronchitis, may incur further

disability if excessive concentrations of particulate are inhaled. It is not normally a hazard when

inhaled but there is some evidence to suggest that this material can irritate the throat and lungs of

some persons.

Control of Exposure Hazards

The following precautions should be taken when working with the chemical to ensure

that one is steering clear of any potential dangers:

1. Work area should have sufficient exhaust ventilation. Regularly vacuum dust to minimize

the potential of air-borne exposure.

2. Avoid eye contact and wear eye protection if/when eye contact is likely to occur.

3. Avoid skin contact and wear protective clothing and gloves.

If exposure does occur:

1) Eye Contact

Remove contact lenses, if necessary. Rinse immediately with plenty of water for at least five

minutes. Seek medical attention if irritation occurs and persists.

2) Skin Contact

Remove contaminated clothing and wash affected area with plenty of soap and water. Seek

medical attention if the skin becomes irritated or a rash develops.

3) Inhalation

Remove the person from exposure and bring into fresh air. Seek medical attention if the exposed

individual has any difficulty breathing.

4) Ingestion

Do not induce vomiting. If person is conscious, rinse mouth with plenty of water and give

several glasses of water to drink. Seek medical attention if adverse symptoms occur.

In the event of a sodium chloride spill, the area should be vacuum or wet-swept. Dry

sweeping or other methods that will raise dust should be avoided and the area should be cleaned

with water and detergent.

Fire and Explosion Hazards

In the industrial setting, there are many hazards – more importantly fires, explosions and

toxic releases. Fires occur most frequently in industries and are the first major hazard in chemical

or process industries. Industrial fires are highly hazardous and dangerous, and accidents lead to

the loss of lives and major damage to infrastructure. (Industrial Fire and Explosion Hazards,

2018)

Here are some of the major fires and explosions that can occur inside the plant:

1) Jet fires

Jet fires, or ejected flames, occur when there is an ejection of flammable liquid from a

vessel, pipe or pipe flange. Jet flames scenarios are highly dangerous and jet fires can go up to 50

meters or more. Jet fires dissipate thermal radiation away from the flame’s visible boundaries

and the energy transmitted could be hazardous to both life and property.

2) Pool fires

A pool fire, defined as “a pool of flammable liquid burning with a stationary diffusion

flame or the combustion of material evaporating from a layer of liquid at the base of fire”, occurs

when a flammable liquid spills and is ignited on the ground. A pool fire is dangerous because

wind can extend the base of the flame and cause flame drag.

Some incidents describe a pool fire taking place in a storage tank or bund. In both cases,

the boundary of the pool is clearly defined and the shape of the pool may be circular or
rectangular. Other types of pool fire occur after a liquid is discharged on the ground, the shape

and depth of the pool being determined by the local contours.

3) Flash fires

Flash fires, or vapor cloud fires, are defined as “the combustion of a flammable vapor and

air mixture in which flame passes through the mixture, at less than sonic velocity (speed of

sound in the medium), such that negligible over pressure is generated”. A flash fire occurs when

a vapor cloud forms from a leak and is ignited. Release of flammable vapor from a process plant

followed by ignition is common. In a flash fire, the gas burns and may cause a sudden depletion

of oxygen.

4) Vapor Cloud Explosion (VCE)

The explosion resulting from the ignition of a cloud of flammable vapor, gas, or mist in

which flame speeds accelerate to sufficiently high velocities to produce significant overpressure.

5) Boiling Liquid Expanding Vapor Explosion (BLEVE)

BLEVE is a vapor explosion which may result from a catastrophic failure of a tank

structure, which was containing cargo liquid above the boiling point at nominal atmospheric

pressure.

The cargo in the tanks of gas carrier is partially liquid and partially vapors in normal

condition. However, when the tank structure collapses, the vapor tries to escape or leak through

the opening, resulting in a decrease in the pressure inside the tank. These drastic lowering of

pressure inside the cargo tank results in rapid boiling of liquid and increase in vapour formation.
Personnel Safety

In order for the plant to produce the desired product successfully, personnel/workers must

also work effectively and safely securing the equipment and the process as a whole. There are

some threats to the safety of the personnel working in the plant. One of the most common is the

eye problem in the salt industry which is caused by intense reflectance of the sun light from

water surface and salt. Contact with salt laden water causes different type of skin lesions

amongst the workers. According to medical practitioners and skin specialists, other skin ailments

commonly occurring amongst the workers of the salt industry are:

a) Fungal infection in the feet

b) Allergic contact dermatitis

c) Photo-dermatitis

d) Toxin metanosis

e) Fungal infection in different parts of the body due to moist air.

Other hazards that endanger worker’s health and well-being in the salt industry are:

a) Sharp edged crystals in the salt farm

b) Electricity

c) Contact with machine parts

d) Air pollution

e) Leakage of acids and aggressive chemicals

f) Light (both excessive light as well as poor light)

g) Heat

h) Manual carrying of load

i) Poor house keeping

 j) Fire

k) Poor living conditions

l) Shift work

In work situation where exposure to hazard cannot be avoid the worker needs to use

personal protection equipment for his safety. Equipment required to be used in the salt industry

include safety helmets, eye goggles, hand gloves, safety shoes disposal filter mask, breathing

equipment, body clothing and waist support belts.

Awareness amongst the workers of the salt industry should be increased regarding

different hazards of the work place and action required to be taken for safe working. Hazard

awareness education has to be given at the time of inducting the worker for job. Workers should

also be educated regarding the necessity of using personal protection equipment, its proper

usage, upkeep and maintenance.

Safety Regulations

The salt units have to comply with a number of statutes. Factories Act as amended by

Factories (Amendment) Act 1987 lays down aspects relating to licensing and registration of

factories, inspecting authorities under the Act, health, safety, welfare, working hours of the

workers, employment of adults and young children, annual leave and penalties. Workmen

compensation Act, 1923 provides for payment of compensation to the worker or his dependents

in the event of an accident taking place. Other laws covering the welfare of the workers include

ESIC Act, Employees Provident Fund and miscellaneous provisions Act, Maternity Benefit Act,

Payment of Gratuity Act, Contract labour (Regulation and abolition) Act, Industrial Dispute Act,
Payment of Bonus Act. The purpose of all such acts is to ensure safe work place for the

workmen, social justice and social security to the worker and his family.

Management of the salt units should organize awareness and orientation programs for all

new workers. It must ensure periodic testing of existing protective equipment and get the same

serviced for smooth functioning with the help of protective equipment manufacturers.

To avoid the problem of manual lifting of heavy loads, mechanical means of material

movement must be introduced wherever possible. In situation where it is not feasible to have

mechanization, action must be taken to explore the possibility of redesigning the workplace so as

to minimize worker fatigue and posture problem. For workers who are required to undertake

manual lifting work, waist support belt must be provided.

Management options like permit system tag out/ lockout system, planned maintenance

should be adopted to minimize human errors and unsafe work practices. Fixed guard or

interlocking guards or Trip Devices must be installed with various machines that are used in the

salt units to minimize incidents of accidents due to contact with moving machine parts.

Medical health surveillance must also be adopted. The medical check must be carried out

at the time of induction of worker and at regular intervals. The records of such medical checks

should be properly kept. Machine layout should be planned considering safety aspects, providing

access for maintenance, waste removal etc. Further, housekeeping should be good- allowing

sufficient space for material & worker movement without any obstruction.
Loss Prevention

HAZOP Study

Type of Hazard Preventive Measures

Accident  Falls caused by slips, particularly  Use shoes with non-slip
Hazards on floors made slippery as a result soles
of extensive use of water and
liquids
 Falls from elevated places  Use shoes with non-slip
throughout inspection of soles
equipment or taking samples for
analysis
 Capture of fingers and other parts  Use suitable clothing
of body between various parts of according to the nature of
equipment work including PPE
 Burns and scorches caused by  Use suitable clothing
contact with red hot surfaces, hot according to the nature of
water and leaking steam work including PPE
 Electric shock and lethal  Install warning signs and
electrocution due to defective warning marks regarding
electrical equipment high voltage
 Verify, by periodical
inspections, that all
electrical appliances
correspond to the relevant
electrical safety rules
 Hazard of explosion or implosion  Check periodically the
due to extreme pressures or condition of the pressure
damage to a sealed device gauges and the other
indicators
 Accidental exposure to toxic  Use suitable clothing
 substances released in an outburst according to the nature of
from the evaporator work including PPE
 Fire hazard due to release of gases  Install effective exhaust
during evaporation , or of ventilation and air
particulate matter released during conditioning, to prevent air
the cleaning of evaporator as well contamination and heat
as the other equipment stress; use PPE
 Injury of eyes and other parts of  Use suitable clothing
the body caused by splashes of according to the nature of
the liquid that is used for work including PPE
evaporation, from defective pipes
Physical  Exposure to excessive heat and  Install effective exhaust
Hazards high humidity, due to wide use of ventilation and air
steam, may cause fatigue and conditioning, to prevent air
thermal exhaustion contamination and heat
stress; use PPE
 Exposure to high noise levels  Use specific personal
protective equipment (PPE)
for the ears
Chemical  Exposure to toxic gases released  Install effective exhaust
Hazards throughout the process ventilation and air
conditioning, to prevent air
contamination and heat
stress; use PPE
 Maintain high level of
personal hygiene
 Exposure to dust that contains  Install effective exhaust
various metals and other toxic ventilation and air
substances, while cleaning the conditioning, to prevent air
equipment, may cause irritation of contamination and heat
the respiratory tract and the eyes
 stress; use PPE
 Maintain high level of
personal hygiene
 Exposure to heavy metals during  Install effective exhaust
evaporation ventilation and air
conditioning, to prevent air
contamination and heat
stress; use PPE
 Maintain high level of
personal hygiene
 Exposure to volatile organic  Install effective exhaust
substances in various processes ventilation and air
conditioning, to prevent air
contamination and heat
stress; use PPE
 Maintain high level of
personal hygiene
Biological  Damage to the environment, due
Hazards to release of acid vapors to the
atmosphere
 Solution may contain harmful
microorganisms
Ergonomic,  Exposure to unpleasant odors  Install effective exhaust
Psychosocial, produced throughout the ventilation and air
and production process conditioning, to prevent air
Organizational contamination and heat
factors stress; use PPE
 Maintain high level of
personal hygiene
 Musculoskeletal disorders as a  Plan the workstation
according to ergonomic
 result of prolonged action requirements, with
appropriate consideration of
human factors such as the
height and personal
characteristics of the
worker.

Environmental Protection

Environmental Regulations

The plant should abide by the major environmental laws:

a) The REPUBLIC ACT 9003 ECOLOGICAL SOLID WASTE MANAGEMENT ACT

OF 2000

The law aims to adopt a systematic, comprehensive and ecological solid waste

management program that shall ensure the protection of public health and environment. The law

ensures proper segregation, collection, storage, treatment and disposal of solid waste through the

formulation and adaptation of best eco-waste products.

b) REPUBLIC ACT 9275 PHILIPPINE CLEAN WATER ACT OF 2004

The law aims to protect the country's water bodies from pollution from land-based

sources (industries and commercial establishments, agriculture and community/household

activities). It provides for comprehensive and integrated strategy to prevent and minimize

pollution through a multi-sectoral and participatory approach involving all the stakeholders.
 c) REPUBLIC ACT 8749 PHILIPPINE CLEAN AIR ACT OF 1999

The law aims to achieve and maintain clean air that meets the National Air Quality

guideline values for criteria pollutants, throughout the Philippines, while minimizing the possible

associated impacts to the economy.

d) REPUBLIC ACT 6969 TOXIC SUBSTANCES, HAZARDOUS AND NUCLEAR

WASTE CONTROL ACT OF 1990

The law aims to regulate restrict or prohibit the importation, manufacture, processing,

sale, distribution, use and disposal of chemical substances and mixtures the present unreasonable

risk to human health. It likewise prohibits the entry, even in transit, of hazardous and nuclear

wastes and their disposal into the Philippine territorial limits for whatever purpose; and to

provide advancement and facilitate research and studies on toxic chemicals.

e) PRESIDENTIAL DECREE 1586 ENVIRONMENTAL IMPACT STATEMENT

(EIS) STATEMENT OF 1978

The Environment Impact Assessment System was formally established in 1978 with the

enactment of Presidential Decree no. 1586 to facilitate the attainment and maintenance of

rational and orderly balance between socio-economic development and environmental

protection. EIA is a planning and management tool that will help government, decision makers,

the proponents and the affected community address the negative consequences or risks on the

environment. The process assures implementation of environment-friendly projects.

Development of a Pollution Control System

 Pollution control system is widely understood as Only-Air pollution system but it also

covers water pollution control, noise pollution control, soil pollution control, and thermal

pollution control. This system helps in reducing or preventing polluting particle of hazardous

particles to get directly into the environment system.

Air Pollution Abatement

Air pollution produce inside the plant will be eliminated using a technology that will

purify the air and also taking proper measures that will reduce it and its effects in the

environment. Air pollution abatement controls the quality of the air at surface level everywhere,

especially in the industrial sites. The main feature consists of monitoring and abating pollutants

like particulate matter (PM) emissions and the control of gaseous emissions. Processes that are

typically employed to reduce these particulate emissions are using settling chambers, cyclone

collectors, impingers, wet scrubbers, electrostatic precipitators, and filtration devices.

The air stream is directed through a settling chamber, which is relatively long and has a

large cross-section, causing the velocity of the air stream to be greatly decreased and allowing

sufficient time for the settling of solid particles. For wet scrubbers, they control particulate

emissions by wetting the particles in order to enhance their removal from air stream. In filtration,

the most commonly used device is a baghouse which consists of fabric bags through which the

air stream is directed. Particles become trapped in the fiber mesh on the fabric bags, as well as

the filter cake which is subsequently formed

Water Pollution Abatement

 Brine waste is the major cause of water pollution in salt industry. It has high

concentration of salts such as sodium chloride. These streams of waste can be some of the most

challenging to treat or discharge because their composition and purification requirements can be

rather dynamic and complex. Brine waste was produced as a by-product such as the cooling

tower and boiler effluent. This waste can be either recycled for use in the facility’s process or

treated for disposal. It is known to reduce thermal conductivity so they are reused as a cooling

agent for steel heat exchangers. In treating brine waste for reuse, it can be pre-treated with

coagulants, polymers, additives, and pH adjustment to settle out many of the larger

contaminants. It can then be treated with specialty chelating resins that target specific metals for

removal without being exhausted by sodium. The technologies and methods of purification

and/or separation vary greatly depending on the quality of the brine waste and the brine

composition. (What is Brine Waste, and how it can be treated for Reuse or Disposal, 2018)

Solid Waste Disposal

Solid waste produced by the process if non-toxic, could be used as an additive for soil

remediation. However, because of its salt content, it has no use and can be disposed to a licensed

landfill, also based on its classification EPA guidelines.

Thermal Pollution Control

Adequate and reliable technologies exist for the control of thermal pollution. Two of

them are the cooling ponds and cooling towers.

A cooling pond is a pond or lake especially constructed to provide a source of cooling

water and a closed sink to which to return it after use. It must be sufficiently large that
evaporation and other heat transfer to the air from its surface can keep the average water

temperature low enough to provide a continuous source of cooling tower. The pond outlet is

usually located as far as possible from the hot water return to maximize the time allowed for

cooling.

A cooling tower allows for the efficient contact of ambient air with heated water,

resulting in the rapid cooling of the water without returning it to its source, or before it is

returned to its source. When a cooling tower is used, it is possible to use the same water for plant

cooling again and again, by adding small fractions of fresh water to make up for evaporation

losses.

Noise Control

A noise source such as rough-running equipment could be made quieter by tuning it up or

treating it. A barrier could be placed between them and the receiver (which is much likely the

worker inside the plant), such that the sound waves cannot propagate to the receiver. Or, the

receiver can be treated by using ear plugs or headsets. Workers subjected to noise will have an

annual audiogram. If there is a shift in their hearing threshold relative to their baseline audiogram

of an average of 10 dB or more in the 2000, 3000, and 4000 Hz frequency levels, in either ear,

the worker must be retested within 30 days. OSHA has established permissible noise exposure

limits to help avoid the standard threshold shifts in working. (Industrial Noise Control-

Occupational Health and Safety, 2007) Substitution of the noisy equipment for quieter ones is

also a good alternative to protect the workers from exposure to noise. Other options can also be:

a) enclosing the noisy equipment with a sound-absorbing material b) avoiding metal to metal

contact by using plastic bumpers c) undertaking regular maintenance on equipment.

Plant Location and Layout

The salt processing plant will be built in Occidental Mindoro in the Philippines.

Occidental Mindoro, along with the province of Cavite, were the biggest suppliers of salt in the

country in 1990 (Verdey & Abilay, 2017). Mindoro is surrounded by the sea which makes it

ideal for the salt processing plant since the raw material will be taken from the sea. Also, DOST

is presently planning to enhance the salt industry in Occidental Mindoro (Verdey & Abilay,

2017). It has many ports connecting to the various regions of the Philippines so there is greater

access and more opportunities for potential buyers since the location is easily accessible.

Occidental Mindoro is not highly urbanized, with only 83 inhabitants per square kilometer

according to the 2015 census so cost of labor is also low and since the place is not densely

populated, there will be less negative impact (less complaints from the community from noise,

odor, etc) compared to densely populated areas. Also, since the area is not as highly urbanized,

there is greater availability of manpower for the plant.

Photo taken from https://www.philatlas.com/luzon/mimaropa/occidental-mindoro.html

 After obtaining the specifications of the equipment and giving spaces between each

equipment and spaces for piping, instruments, and other possible additions, the area of the

process house having two floors was estimated to be 2000 square meters. Adding the warehouse,

other buildings and facilities, the wastewater pond, and other possible additions, the whole plant

was estimated to cover 4 hectares of area near the sea. Roads will be built between buildings

inside the plant for the people and for shipping vehicles to the main road. The main source of

waste in this plant is water from the different processes. The condensed steam will be recycled

back to the boiler. No chemicals are used in the process so the wastewater from other sources

will be discharged into a pond.

The layout of the plant will likely be:

1st Floor of the Process House

2nd Floor of the Process House

Layout of the whole plant

Plant Operation and Control

The salt processing plant will be operated 260 whole days per year and 60 days per year

will be used for maintenance. Temperature and pressure sensors and level control devices will be

installed in the equipment to monitor and control the values. The product will be stored in the

warehouse before shipping and no storage for raw materials is required since the brine will be

collected immediately from the sea. Water for the boiler, the offices and other facilities will be

taken from underground and electricity for the plant will be provided by the boiler. Pipes will be

used to transport the materials during the process and conveyor belts will be used to transport the

final product to the warehouse where it will be packaged and shipped.

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