CHEMICAL PROCESS INDUSTRIES - I ChE 506 10/Che/16 : Bipin Sharma 10/Che/17 : Vishal Rao 10/Che/18 : Annoy Roy 10/Che/19 : Riki Mandol 10/Che/20 : Koustav Ghosh 10/Che/22 : Md Dilshad 10/Che/23 : Pradeep Singh 10/Che/24 : Ravi Prakash Shiromani .Presented by: DEPT. OF CHEMICAL ENGG. Equipment & materials of construction in manufacturing of HCl . It is a highly corrosive.Hydrochloric acid(HCl) Industrial Name:-Muriatic acid Hydrochloric acid is a clear. colorless solution of hydrogen chloride (HCl) in water. strong mineral acid . brass or aluminum. stainless steel. • No wetted parts should contain any metals such as carbon steel. Teflon. rubber. • Metering pumps and other equipment that comes in contact with concentrated solutions of Hydrochloric Acid (Muriatic Acid)must also be constructed of acid resistant materials such as PVC. HDPE and/or rubber are the materials of choice for storage tanks. PVC. ceramic and Hastolly C.Material of construction: • FRP. . Kynar. fluorocarbon or acid resistant rubber lined pipe. polyethylene. Saran. ValvesThe valves must be made of acid resistant material (Teflon. Flexible pipingFlexible hose lined with acid resistant rubber. FRP. PVC. CPVC.Material of construction: Rigid pipingSchedule flanged poly vinyl chloride(PVC). used for rigid piping. . cross linked polyethylene or fluorocarbon lining is used. ceramic or graphite). Quarter turn PVC flanged ball bulb are widely used. FRP. PTFE or Kynar . . Viton fluoroelastomer. Level controlLevel control system should be protected with a diaphragm made of Viton. Teflon or Tantalum. EPR.Material of construction: GasketThe gasket are made of Teflon. Equipment in HCl plant: HCl can be produced in 3 major processes: 1. Reacting salt & sulfuric acid 3. Combustion of Chlorine & Hydrogen . Chlorination process 2. Furnace to roast Salt & 76% Sulfuric acid. . 2. Coke tower to separate suspension from HCl. Cooler. 3. Cooler absorber to separate HCl from highly corrosive mixture of HCl and water. HCl is a by product in chlorination of hydrocarbons.Chlorination: 1. Reacting salt & Sulfuric acid: 1. . 2. Burner for supplying heat & a flame arrestor to prevent flame to reach the pure hydrogen. Karbate cooler for cooling the produced gas.Synthesis: 1. Water jacketed combustion chamber for burning of chlorine. 4. Cooler absorber & tail gas scrubber for making the acid from HCl gas. 3. Comparison of Solvay & modified Solvay process . The raw materials reqd. . for the process includes sodium chloride. which makes use of the fact that sodium bicarbonate is less soluble in cold water than sodium chloride. limestone and gaseous ammonia.SOLVAY PROCESS OUTLINE: Sodium carbonate (soda ash) is commercially prepared by the Solvay process. Chemical interrelations of the Solvay process . Flow chart of solvay process: . Advantages of Solvay process: • • • • • Can use low-grade brine Less electric power Less corrosion problems No co-products to dispose of Does not require ammonia plant investment Disadvantages of Solvay process: • Higher salt consumption • Higher investment in ammonia recovery unit verses crystallization units for ammonium chloride • Waste disposal of calcium chloride brine stream • More steam consumption • Higher capacity plant for economic break-even operation • With current fertilizer shortage. all of the ammonium chloride will be used as a mixed chemical fertilizer ingredient. so co-product disposal no problem. . Instead of treating the remaining Calcium Chloride solution with lime.Modified Solvay process: This process was developed by Chinese chemist Hou Debeng. Here calcium chloride is replaced by ammonium chloride ( NH4Cl). . causing the ammonia chloride to be removed by filtration. The ammonium chloride is then recycled to be reused in the production of sodium carbonate. Carbon Dioxide and Ammonia is added to the solution until the solution is saturated at 40oC then cooled to 10oC. • Eliminates the need for waste beds and other disposal methods to take place. which can be recycled to be reused in the process. as the by-products can be used in other productions. • Requires existing machinery to be replaced or modified. • Much more economical and environmentally friendly than both the Le Blanc and the original Solvay processes. it is more economically beneficial for Solvay plants to use Hou's Process in their plants. • As ammonium chloride is more useful than calcium chloride. . refined and used as a fertilizer. Disadvantages of modified Solvay process: • More expensive than the Solvay Process.Advantages of modified Solvay process : • Replaces calcium chloride as a by-product with the ammonium chloride. Ammonium It can and calcium sulfide Calcium . reactions take place at around 300oC. Other o o required is 300 C. Water can be keep machine parts cool. Coal oxides at 1000oC. most of it needs to be disposed of. cooled and re-used. It can be recycled to re-use ammonia. however this is reused so loss is minimal.relatively useless. chloride . highest temperature Lower than Solvay Process. Water can be keep machine parts cool. . however this is reused so loss is minimal Ammonia gas (toxic).Comparison between the two processes:Solvay Process Modified Solvay Process Blanc Process Solvay Process By-products Modified Solvay Process useful in the production of fertilisers. cooled and re-used. Water can be keep machine parts cool. cooled and re-used. highest temperature Lower than Solvay Process. however this is reused so loss is minimal. Other reactions take temperature required is 300 C. Water Use Water Use Large amounts of water are neededof to water Large are amounts of water are Large requiredamounts to Larger amounts of water are needed to to Large amounts needed to of water are required keep machine parts cool. however other reactions take places at about room temperature. Hydrogen chloride gas (highly acidic). Cannot be reused. however this is reused so loss is minimal Ammonia gas (toxic). Water can be keep machine parts cool. Heat is released and absorbed into water By-products Calcium chloride . Water can be cooled and re-used. the production of fertilisers.very useful in Hydrogen chloride gas of it needs to be disposed chloride of. highest Very high. place at +40oC. highest o place at +40 C.relatively useless. Energy Consumption Relatively low. most Ammonium chloride .very be recycled to re-use ammonia. Thermal Pollution Thermal Pollution Air Pollution Heat is released and absorbed into water Heat is released and absorbed into water Heat is released and absorbed into water Heat is released and absorbed into water Ammonia gas (toxic). however other reactions take places at about room temperature. required is 300oC. Relatively low. must be stored. Air Pollution Energy Consumption Ammonia gas (toxic). cooled and re-used. Other reactions take temperature required is 300oC. Dryden . Class notes. Wikipedia.Reference Shreve’s Chemical Process Industries by George T. Austin. Outlines of Chemical Technology .