1|Page

Approval
This is to endorse that three students of Chemical Engineering Dept. of Z.H. Sikder University
of Science & Technology have completed their industrial project report on “Tasnim Chemical
Complex Ltd.” heading Industrial
“Project on Chloro-Alkali process units of Tasnim Chemical Complex Ltd.”

The report is about to the partial fulfillment of the requirements for the degree of B.Sc in
Chemical Engineering Dept.

Their involvement was much appreciated and I wish for their stunning future.

Supervisor
Dr. Md. Amran Hossain
Lecturer & Co-Ordinator,
Dept. of Chemical Engineering
Z.H. Sikder University of Science and Technology .

Co-Supervisor
Hossain Mohammad Zakir

Lecturer,Dept. of Chemical Engineering,ZHSUST

 2|Page

Abstract
This paper is on a 15 days long project carried out from 3 december 2018 to 18 december 2018 for the
accomplishment of the course ChE- 431 which is programmed for the industrial attachment as a curriculum of
the Department of Chemical engineering of Z.H. Sikder
University of Science and Technology. The project was carried out at the Tasnim Chemical Complex Ltd.
whose valued collaboration is highly appreciated. Tasnim Chemical Complex Ltd. is one of the renowned
chlor-alkali Industries in Bangladesh that is completely integrated in producing caustic soda and also
bleaching, NaOCl (clotech B), Cl2 as by products.

The topics covered, as team work, in this project were as follows: Feasibility survey, Plant layout, Process
description, Material Balance, Energy Balance, cost estimation, piping and instrumentation diagram, HAZOP
study,, etc. The program had been finally completed successfully by the kind cooperation of many people.

Acknowledgement

I am grateful for the contributions from many individuals leading towards the successful completion of our
program, especially those who gave the time to share their thoughtful criticisms & suggestions to improve it. I
am deeply owing a favor to them for their personal encouragement and professional assistance.

First, I would like to thank Tasnim Chemical Complex Ltd. to give us the opportunity to do the project work in
their industry. I convey my respectful gratitude to our Teacher and Project Supervisors, Department of
Chemical Engineering and, Z.H. SikderUniversity of Science and Technology, for his valued co-operation in
making this project paper.

It is a great pleasure for us to acknowledge our Program Coach Md. Masudur Rahman, Process In charge,
Tasnim Chemical Complex Ltd. for his assistance and co-operation given to us throughout all the working
time. Without his heartiest interest and support, it would be quite impossible for us to carry out our project
work in such an industry and to complete this report with its full richness in information.
 3|Page

I also want to say with great thanks to Md. Rokan for the massive support of giving approach to the industry an
also for whole contribution.

Special thanks to Md sohel and Md. Abu Bakar, production engineers, for their constant support and heartiest
effort to help us make this program come to a success.

I also like to thank all the personnel of Tasnim Chemical Complex Ltd. for their kind cooperation, throughout
the period of the project work, with their sharing of the various engineering principles and techniques in the
theoretical and practical grounds that made me realize and understand the real complexity of manufacturing
processes and how to face them from the field of Chemical Engineering.
 4|Page

Contents:
Serial No: Table of Contents Page No:

1 Review of TCCL 5-6

2 Feasibility Studies 6

3 Process Description 7-18

4 Process Diagram 19-22

5 Material Balance 23-30

6 Energy Balance 30-34

7 Cost Estimation 35-39

8 Industrial Safety 39-44

9 Plant Layout 44-50

10 Hazop Analysis 51-54

11 Conclusion 55

12 Reference 55-58
 5|Page

Review of Tasnim Chemical Complex Ltd.

In this modern age of competition, Chemical Engineers need to operate a Chemical plant in
such way that it can compete in this business environment ensuring product quality.

Tasnim Chemical Complex Ltd. (TCCL) is a sister concern of MEGHNA group. In the
beginning of 21st Century, TCCL starts its journey as the first private sector Chlor-Alkali
Industry in Bangladesh. The industry is located on newtown, sonargaon,narayanganj .
Significantly related to all the hopes and expectations of the new century, TCCL has energized
the vision to open new horizon for industrial development in the country. The project site was a
20 feet deep low-lying land from the road level that has been filled and developed suitably for
TCCL plant. It has incorporated most advanced state of the art technologies, machineries and
equipments.

Tasnim Chemical Complex Ltd. believes in management excellence with commitment,

honesty, sincerity, dedication and efficiency. With its well-educated, trained and skilled
workforce, harmonious working atmosphere, good productivity record and strong
environmental commitment, Tasnim Chemical Complex Ltd.
enjoys a good standing with government and local public.

Some key points of Tasnim Chemical Complex Ltd.:

Company : Tasnim Chemical Complex Ltd. was established in 1987 .

Plant location : Newtown,Sonargaon,Narayanganj.

Plant occupied area :

Plant type : Chlor-alkali

industry.
Plant capacity :
 6|Page

FEASIBILITY SURVEY
Feasibility survey is the pre-pivotal task to establish a plant profitably. Some key factors are
necessary to analyze for the feasibility survey of a plant. For Tasnim Chemical Complex
Limited, the important key factors are listed bellow:

 Availability of raw materials: Raw material collection is one of the most predominant
task. TCCL collects their raw materials from our neighbour country India. Though raw
materials also available in Bangladesh it is collected from India because of higher
quality than Bangladesh & river way transportation cost makes it attractive.
 Availability of labour: Expert labours are available & there accomodation is also feasible
by easy transportation cost as TCCL situated at Dhaka area.
 Power: As our government can not provide electricity at low cost, So TCCL produce
their electricity as they need. They 14.5 MW power generation capacity to fulfil their
need. They use natural gas to produce electricity .
 TCCL uses surface water for their utility. Water is collected from meghna river & deep
tubewel. So they can manage their necessary amount of water easily.
 Transportation cost: Their transportation cost lower enough because of their industry
situated at Narayanganj. Buyer can easily collect product produced by TCCL.
 Another important thing is that disposal treatment. After treatment they can easily
through it to the river. They have good treatment system for their both effuent and
disposal.

So above discussion proved that TCCL is quiet feasible both economically & environmentally.
 7|Page

PROCESS DESCRIPTION
TCCL is mainly a chloro-alkali industry.Its main products are caustic Soda(NaOH), Sodium
Hypochlorite(NaOCl), Clorine Gas(Cl2), hydrogen(H2), Bleaching(Ca(OCl)Cl). TCCL uses membrane cell
technology. Sodium hydroxide is produced (along with chlorine and hydrogen) via the Chloro-
alkali process. This involves the electrolysis of an aqueous solution of sodium chloride. The
sodium hydroxide builds up at the cathode, where water is reduced to hydrogen gas and
hydroxide ion:

Electrochemical and chemical reactions occurring in diaphragm and membrane cells

[1] 2Cl- ==> Cl2+ 2e- (anodic reaction)

[2] 2H2O + 2e- ==> 2OH- + H2 (cathodic reaction)

[3] 2Cl- + 2H2O ==> Cl2 + H2 + 2OH- (overall ionic reaction)

[4] 2NaCl + 2H2O ==> Cl2 +2NaOH + H2 (overall reaction)

 8|Page

Fig: Overall Process.

In the process, three products are produced. It is vital that these are not allowed to mix. Thus, a
requirement of a commercial cell for the electrolysis of brine is that it separates the three
products effectively. Electrolysis in a simple vessel (described as a ‘one-pot’ vessel) leads to
the reaction of chlorine with sodium hydroxide to give unwanted sodium hypochlorite
(NaClO), sodium chlorate (NaClO3) and oxygen by the following reactions:

Cl2 + OH- → Cl- + HOCl

HOCl → H+ + OCl-
2HOCl + OCl- → ClO3- + 2Cl- + 2H+
4OH- → O2 + 2H2O + 4e-
 9|Page

The main process units of TCCL are listed bellow:

I. 14.6 MW power plant including diesel generator & boiler house.

II. 2500 MT water storage tank including two-pump house & cooling tower.
III. Bi-polar membrane cell house including rectifier, rectifier transformer, DCS control
room,
IV. Anolyte & Catholyte tank, de-chlorination building as well as quality control
department.
V. Utility building including DM plant, Nitrogen plant, absorption chillers & compressors.
This block has got HCl synthesis building including storage tank and delivery platform.
VI. Primary & Secondary brine purification area including Salt Saturator,
Reactor, Chemical-dosing Tanks, Main Clarifier, Anthracite Filter, Candle Filter, Polished
Brine Tank, Ion-Exchange Resin Column and Purified Brine Storage Tank.
VII. Chlorine Drying & Compression Building including Bottling area as well as four large
storage tank and delivery platform.
VIII. Caustic Evaporation and Flaking Building including bagging and storage facility.
IX. Hydrogen gas Compression and bottling building.
X. Automatic Effluent treatment plant for industrial water treatment.

Process Procedure : TCCL works on the following step by step process. The main task of this industry is to purify the
raw salt into two steps
 10 | P a g e

 Primary purification

 secondary purification

So total process procedure given sequencially:

Raw Material:

The main raw material for this project the solid salt which is further processed to produce
caustic soda.

In this plant salts are imported from the neighboring country India. Because the composition of
the salt comes from India is better from the local salt and also have less impurities than the
local salt. We can say this by testing the composition.

Raw salt composition:

Composition Percentage
Ca2+ 0.227%
Mg2+ 0.049%
SO42- 0.645%
Total Iron 13.2 ppm
NaCl 95.43%
Moisture 3.649%

Salt Saturator:

For melting the solid salt, in the salt saturator there is a continuous process of pumping of
return brine solution at about 75°c from the return brine tank which is executed from the cell
and is not converted to the caustic soda.
 11 | P a g e

After melting raw salt in the salt saturator the solution is passed through a plate filter to remove
the floating substance and impurities that come from the salt feeding. Then the solution is fed
to the dosing unit.

Impurities or the mud which come from the salt decompose at the bottom of the salt saturator
and decrease the efficiency of the salt saturator. For this reason after 3-4 months the salt
saturator is washed to make it clean.

Dosing:

From analysis of the raw salt the dissolved impurities are the Ca 2+ , Mg2+ ,SO42- and the mud
that can be said. To remove these impurities chemical dosing is required. BaCl 2 is used to
removed the S . C is used to remove Ca2+ and also NaOH for the Mg2+.

After the dosing of these chemical the salt solution is send to the reactor for the proper mixing.

In a chloro-alkali plant mainly five different dosing are performed and these are as follows:

1. Soda Ash(Na2CO3) dosing

2. Barium Chloride(BaCl2) dosing
3. Sodium Sulphide(Na2SO3) dosing
4. Caustic Soda(NaOH) dosing
5. Flocculants dosing Chemical dosing:

Ca2+ in raw materials = (6385.774*0.227) Kg /100 hr

= 14.49 kg/hr

For removing Ca2+ Na2CO3 needed:

CaCl2 + Na2CO3 = CaCO3 + 2NaCl

Na2CO3 needed = (106*14.49)kg /111 hr

= 13.83 kg/hr
 12 | P a g e

Amount of Mg = (6385.774*0.049) kg / 100 hr

= 3.129 kg/hr

NaOH needed for removing Mg2+:

MgCl2 + 2NaOH = 2NaCl + Mg(OH)2

NaOH needed = (80*3.129)kg / 95 hr

= 2.634 kg/hr

Amount of SO = (6385.774*0.645)kg /100 hr

= 41.18 kg/hr

BaCl2 needed for removing SO42-:

Na2SO4 + BaCl2 = 2NaCl + BaSO4

BaCl2 needed = (208*41.18)kg /142 hr

= 60.32 kg/hr

Procedure of making Dosing:

1. Barium Chloride (BaCl2): Desired concentration- 0.15% by weight Required

composition:

1. 475 kg BaCl2
2. 2000-2500 Liter H2O
3. 500 kg HCl Chemical Reaction:
BaCO3 + HCl = BaCl2 + CO2 + H2O
 13 | P a g e

In this reaction ph of HCl is 3.5 to 4 where p h should be maintained at level 6.This is done by
adding 10 to 12 kg excess NaOH.

2. Soda Ash (Na2CO3):

Desired concentration-0.14%

Required composition:

1. Soda Ash (Na2CO3)

2. 1400 liter H2O
3. Flocculent:

Required composition:

1. 500 gm floccal
2. 1000 liter H2O Chemical Reaction:

500gm floccal+1000L H2O

Main function of flocculent is to hold up the moisture.

4. Sodium Sulphide(Na2SO3):

Desired concentration- 7% by weight.

Required composition:

1. 100L Na2SO3
2. 200L H2O
 14 | P a g e

Reactor:

Reactor which is used here mainly a CSTR. In this reactor the following reaction occurs:
Na2SO4 + BaCl2 → NaCl + BaSO4 ↓

Na2CO3 + Ca2+ → CaCO3 ↓ + 2 Na+

2NaOH + Mg2+ → Mg (OH)2 ↓

After complete mixing of the brine and dosing solution a flocculent named Megna floc is added
to the solution. Then the solution is send to the clarifier for the removing the precipitate of the
solution and also increasing the turbidity of the solution.

In reactor concentration range of brine is 295-305 gpl and is continuously monitored by a

Hydrometer. Reactor temperature is 60-65oc and is continuously monitored by a Thermometer.

Clarifier:

In the clarifier the mud, precipitated produced by the chemical dosing which are carried by the
saturated brine solution is precipitated in the bottom of the clarifier. From the bottom of the
clarifier the thick mud solution of the saturated brine is pumped to the decanter and mud is
separated and collected for disposal as waste product. The brine solution driven from the
clarifier is stored in clarified brine tank and then sends to anthracite filter for further removal of
flock particles.

Anthracite filter:

Filter medium of the anthracite filter is mainly the anthracite. In anthracite filter solid-solid
adsorption occurred. Three types of carbon: large, small and medium lies in the anthracite
filter. When the brine solution is passed through the fine anthracite filter medium the flock
particles cannot pass through the medium and get trapped in the anthracite medium. Then the
solution is stored in the anthracite filter tank to make the process continuous.

Candle filter:
 15 | P a g e

Candle filter is a special type of filter in which the filter medium is activated carbon and the
filter coated with the alpha cellulose. This alpha cellulose blocks the micro level particles from
the brine solution. To maintain the layer of the alpha cellulose which is externally exerted in
the upper surface of the activated carbon filter 1-2 atm pressure is maintain continuously. If the
pressure drops, there will no more alpha cellulose layer upon the activated carbon filter. To
maintain the efficiency the of the filter aid, alpha cellulose is continuously added in the candle
filter. Brine solution is feed at the bottom of the filter and mud free solution is out at the top of
the filter. After filtering in the candle filter the turbidity becomes -3 or -4 and brine solution is
3 to 4 times transparent than water.

Regeneration:

The candle of the alpha cellulose is washed away by using the back flow of the air. The new
alpha cellulose is added from the pre-coat tank.

Ion Exchanger:

Multivalent ions are exchange with the Iminodiacetic acid of ion exchange resin in the ion-
exchanger. But sodium is mono-valent ion so it is not exchanged with this resin. Na ion is
replaced by Ca2+ and Mg2+. The resin used in ion-exchanger passed only Na+ and as it is a
cation exchanger so Na+ and Cl- entered into cell house. The Iminodiacetic acid formula is as
follows:

Regeneration of ion-exchange resin:

Resin can work very well till its efficiency is high or moderate. But when concentration of Ca 2+
is less than 10 ppm and concentration of Mg2+ is 2-3 ppb the bed is needed to regenerate. The
regeneration process is as follows:

Wash-1:

At first the resin bed is washed away by demineralized water at constant flow 1600 L/h and it
continue 1 hour as all ash and dust will washed.
 16 | P a g e

Back wash:

Back wash is done by DM water at a flow rate of 1.6m3/h over 30 minute. DM water supplied
at the bottom of the tower and resin was circulate with the tower. Water flow is maintained at a
constant rate so that resin does not overflow. After ensuring that all brine washed away back
wash was completed.

HCl regeneration:

18% concentrated HCl is then supplied in the at 600L/h flow rate over 30 to 50 minutes. By
adding DM water at rate 1000L/h, 5% concentrated HCl made up. When the p h of HCl
becomes 1 HCl supply will stop. During HCl regeneration Na of Iminodiacetic acid was
replaced by Cl2 and the media become acidic.

Wash-2:

To remove the acidic media again DM water supplied at a flow rate 1600L/h over 1 hour.
Consequently all Cl2 will replace by H+ ion of water.

NaOH regeneration:

Now 32% NaOH passed through the bed at a rate 200L/h with DM water of rate 1400L/h over
40 to 50 minutes. As a result COOH of iminodiacitic acid will converted to COONa and resin
regeneration will completed.

Wash-3:

Again the bed will washed away by DM water at a flow rate of 1600L/h over 1 hour to
maintain the ph 10. If ph 10 is obtained water supply should stopped.

Brine filler:
 17 | P a g e

Now the resin bed will fill up by 30% NaCl at 1.8m3/h flow rate over 1 hour.

Brine feed:

At last feed brine is feed in the ion-exchange column as the bed is fully regenerated and ready
to use with 100% efficiency.

Cell House:

Membrane technology is the unique Single Element, which comprises an anode half shell, a
cathode half shell and an individual sealing system with external flanges. The Single Elements
are suspended in a frame and are pressed against each other by a clamping device to form a
"Bipolar stack”. Each Single
Element can be replaced quickly and easily. The elements are assembled in the Electrolyzer
workshop, where tightness tests are also carried out.
 18 | P a g e

Figure : Cell House

Important Feature of this Membrane

 Perfluro Sulphonate Polymer act as a anode coating.

 Perfluro Carboxylate Polymer act as a cathode coating.
 High caustic flow is maintained as coating could not attach with the membrane body.
 Hence chlorine is a heavy gas so it pulled from separator by a compressor.
 This membrane is only permeable to Na+ ion.
 19 | P a g e

DIAGRAMS

Figure: Block Diagram for Process

 20 | P a g e

Fig: P & I Diagram Caustic Soda & Clorine Unit

 21 | P a g e

Fig: Block Diagram for cpw unit

 22 | P a g e

Fig: Block Diagram for Flaking Unit

 23 | P a g e

Material Balance

Material balance for production 30% NaOH from 28% NaoH on the basis of 50 ton
production per day.

Basis: 200 MT
 24 | P a g e

Per day production of the plant is 200 MT.

So capacity of the plant = 200 MT NaOH/day

200 × 1000 kg 1 k mol NaoH

24 hr 40 kg NaoH

=208.33 k mol / hr

208.33 k mol 40 kg NaoH

hr 1 k mol

=8333.2 kg / hr

Basic reaction that takes place in the electrolyzer

2 NaCl + H2O = 2NaOH + H2 + Cl2

NaCl +1/2 H2O = NaOH + 1/2 H2 + 1/2Cl2

So equivalent amount of NaCl is needed for production of equivalent Caustic Soda (NaOH).
We could write

1 kmol/h NaOH ≡ 1 kmol/h NaCl

208.33 kmol/h NaOH ≡ 208.33 kmol/h NaCl

NaClin = 300 gpl

= 300 g/L

300g 1k mol Nacl 1000 L 1 kg

L 58.5 kg Nacl 1 m3 1000 gm

 25 | P a g e

= 5.12 kmol/m3

NaClout = 220 gpl

= 220 g/l

220 1kmol Nacl 1000 L 1kg

[[{{{{{

L 58.5kg Nacl 1m3 1000 g

= 3.76 kmol/m3 soln

Amount of NaCl Consumption in the electrolyzer

NaClconsumption= NaClin - NaClout

=(5.12 - 3.76) kmol/m3 soln

= 1.379 kmol/m3 soln

Flow rate of brine in the anode side :

208.33 kmol m3

hr 1.379 kmol

= 151.073 m 3/hr

Material balance at Anode side

Nacl in Nacl out

 26 | P a g e

773.49 kmol/hr 568.03 kmol/hr

Nacl in = 151.073 m3/hr x 5.12 kmol/m3

= 773.49 kmol/hr

= 30939.6 kg/hr

Nacl out= 151.073 m3/hr x 3.76 km/m3

= 568.03 kmol/ hr

= 22721.2 kg/hr

Production of Chlorine

2Nacl + 2 H2O = 2 NaOH + Cl2 + H2

We know, NaCl + H2O = NaOH + 1/2 H2 + 1/2Cl2

Cl2 produced = ½ x 208.33 kmol/hr

= 104.165 kmol/hr

= 4166.5 kg/hr

Flow rate at Cathod side

Density of 28% NaOH at 600C , ρ = 1.284* 103 kg/m3 soln

NaOHin :
 27 | P a g e

1.284 × 10^3 kg 0.28 kg NaOH 1 kmol

m3 1 kg Solution 40 kg NaOH

= 8.989 k mol / m3

Density of 32% NaOH at 850C , ρ = 1.326* 103 kg/m3 soln

NaOHout :

1.326 × 103 kg 0.32 kg NaoH 1 kmol

m3 1 kg solution 40 kg NaoH

= 10.608 kmol/m3 soln

NaOHproduced = NaOHout − NaOHin

= 10.608 – 8.988

= 1.62 kmol/m3 soln

Flow rate at Cathod side :

208.33 k mol m3
hr 1.62 k mol

= 128.5 m3/hr

Material balance at Cathode side:

NaoHin NaoHout

1154.95 kmol/hr 1363.28 k mol / hr

 28 | P a g e

NaOHin = 8.988 (kmol/m3 soln) × 128.5 (m3/hr)

= 1154.95 kmol/hr = 46198 kg/hr

NaOHout = NaOHin + NaOHproduced

= (1154.95 + 208.33) k mol/hr

= 1363.28 k mol / hr

= 54531.2 kg / hr

H2Oin H2Oout

1847.92 k mol / hr 2120.66 k mol / hr

H2Oin = 46198 kg/hr × 0.72

=33262.56 kg/hr

=1847.92 k mol/hr

H2Oout = 54531.32 × 0.70

= 38171.84 kg/hr

= 2120.66 k mol/h
 29 | P a g e

Hydrogen (H2) produced = ½ × NaOHout

= ½ × 1363.28 k mol / hr

= 681.64 k mol/h

= 1363.28 kg/hr

NaCl needed = (30214.8 – 18129.6) kg/h

= 12084.8 kg/hr

So raw salt needed:

12084.8 kg 100

hr 95.43

=12663.523 kg/hr

Flow rate at both Anode & Cathode side is shown below-

Name Flowrate (m3/h) Kmol/hr Kg/hr

NaCl 773.49 30939.6

Anode in H2O 50915 106470

NaCl 151.073 568.03 22721.2

Anode out H2O 50915 106470

Cl2 104.165 4166.6

NaOH 1154.95 46198

 30 | P a g e

Cathode in H2O 1847.92 33262.56

NaOH 128.5 1363.28 54531.2

Cathode out H2O 2120.66 38171.84

H2 681.64 1363.28

Energy Balance

Table 1: Specific Heat Constant

Specific Heat Constant

Component a b *10-2 c*10-5 d *10-7
NH3(gas) 8.4017 0.70601 0.10567 −0.01598
NH3( liquid) 4.6356 - - -
CO2 (gas) 6.393 1.01 − 0.3405 -
Urea 38.43 4.98 0.705 −8.61
Water 7.88 0.32 −4.833
Carbamate 2.596 - - -
Biuret 183.8 - - -

Energy balance for NaCl:

ΔĤin ΔHout
 31 | P a g e

-223847040 kj/hr -138223410 kj/hr

Energy Balance in inlet section:

60

ΔĤNaCl = ΔHf + ∫ Cp dT
25

kJ
= (-411+ 0) mol
kJ
= -411 mol
kJ mol
ΔĤNaCl = -411 mol * 544640 hr
kJ
= -223847040 hr

Energy Balance in outlet section:

85

ΔĤNaCl = ΔHf + ∫ Cp dT
25

kJ
= (-411 + 0) mol
kJ
= -411 mol
kJ mol
ΔHNaCl = -411 mol * 336310 hr
kJ
= -138223410 hr

Energy balance for H2O:

ΔĤin ΔHout

9718915297 kj/hr 17504406050 kj/hr

Energy Balance in inlet section:

 32 | P a g e

60

ΔĤin = ΔHf + ∫ Cp dT
25
60

= -285.84 +∫ 75.4 dT
25

= -285.84 + [75.4 T]
= -285.84 + 75.4(60-25)
= -285.84 + 2639
kJ
= 2353.14 mol
kJ mol
ΔH(H2Oin) = 2353.14 mol * 4130190 h
kJ
= 9718915297 hr

Energy Balance in outlet section:

85

ΔĤH2O = ΔHf + ∫ Cp dT
25
85

= -285.84 + ∫ 75.4 T
25

kJ
= -285.84 + 75.4[85-25] mol
kJ
= (-285.84 + 4524) mol
kJ
= 4238.16 mol
kJ mol kJ
ΔHH2O = 4238.16 mol *4130190 hr = 17504406050 hr

Energy balance for NaOH:

ΔHin ΔHout

-590354992 kj/hr -688920390 kj/hr

 33 | P a g e

Energy Balance in inlet section:

60

ΔĤ(NaOHin) = ΔHf + ∫ Cp dT
25

kJ
= (-469.4 + 0) mol
kJ
= -469.4 mol
kJ mol
ΔH(NaOHin) = -469.4 mol * 1257680 hr
kJ
= -590354992 hr

Energy Balance in outlet section:

85

ΔĤNaOH = ΔHf + ∫ Cp dT
25

kJ
= (-469.9 + 0) mol
kJ
= -469.9 mol
kJ mol
ΔHNaOH = -469.9 mol * 1466100 hr
kJ
= -688920390 hr

Energy balance for Cl2:

85

ΔĤ(Cl2out) = ΔHf + ∫ Cp dT
25
(33.60 + 1.367*10-2 T-1.607*10-5 T2 +6.473*10-9 T3)dT
=0+
kJ
= 2058 mol
kJ mol
ΔHCl2 = 2058 mol * 104165 hr
kJ
= 214371570 hr
Energy balance for H2:
85

ΔĤH2 = ΔHf + ∫ Cp dT
25
 34 | P a g e

85

= 0 + ∫ Cp dT
25

kJ
= 1731.3 mol
kJ mol
ΔHH2 = 1731.3 mol * 733050 hr
kJ
= 1269129465 hr
Total ΔHin = ΔHNaCl + ΔHH2O + ΔHNaOH
kJ kJ kJ
= -223847040 hr +9718915297 hr -590354992 hr
kJ
= 8904713265 hr

Total ΔHout = ΔHNaCl + ΔHCl2 + ΔHNaOH + ΔHH2 + ΔHH2O

kJ
= (-138223410 + 214371570 -688920390 + 1269129465 + 17504406050) hr
kJ
= 18160763290 hr

Overall Energy Balance:

Total ΔHout - Total ΔHin
kJ
= (18160763290 – 8904713265) hr
kJ
= 9256050020 hr

Energy Balance At a Galance:

Name Inlet Outlet

Nacl -223847040 kj/hr -138223410 kj/hr
NaoH -590354992 kj/hr -688920390 kj/hr
H2O 9718915297 kj/hr 17504406050 kj/hr
Cl2 - 214371570 kj/hr
 35 | P a g e

H2 - 1269129465 kj/hr

Cost Estimation

Table 5.1: Typical percentages of fixed-capital investment values for direct and indirect cost

Component Range of FCI (%)

Direct costs
Purchased equipment 18-43%
Purchased equipment installation 5-10%
Instrumentation & controls (installed) 4-12%
Piping (installed) 3-15%
Electrical system (installed) 3-10%
Buildings (including services) 3-16%
Yard improvements 3-6%
Service facilities (installed) 7-25%
Land 2-5%
Indirect costs
Engineering & supervision 3-17%
Construction expenses 3-20%
Legal expenses 2-5%
Contractor’s fee 1-4%
Contingency 3-17%

Table 5.2 : Summary of purchased equipment cost for the Caustic Soda plant
 36 | P a g e

Equipment Type Purchased Cost(TK)

Conveying system 985580

Saturator 583000
Reactor (CSTR) 532000
Clarifier 324000
Carbon Filter 9867010
Ion Exchange Resin Column 946464
Pumps 547480
Boiler 110000
Heat exchangers and Condensers 430600
Storage Tank 105800
Stripper 4400053
Ion Exchange Membrane 7606500
9700000
5200000
600000

Total 3,45,52,487

4.3 Estimation of Total Product Cost

Section Percentage (%) Amount (TK)

Variable production cost    

Raw materials 9% 450,000
Operating labor 2% 100,000
Operating supervision 0.50% 25,000
     
Utilities 10% 500,000
 
Electricity 9% 45,000
Fuel 5% 25,000
Refrigeration 2% 10,000
Steam 5% 25,000
Waste treatment &
27% 135,000
disposal
Water, process 25% 125,000
Water, cooling 27% 135,000
     
Maintenance and repairs 6% 300,000
 37 | P a g e

Operating supplies 2% 100,000

Laboratory charges 3% 150,000
Royalties (if not on
2% 100,000
lump-sum basis)
Catalysts and solvents 2% 100,000

Subtotal: 1,825,000

Fixed charges    
     
Depreciation 3% 150,000
Taxes(property) 1% 50,000
Financing (interest) 2% 100,000
Insurance 2% 100,000
Rent 3% 150,000
     

Subtotal 550,000

Plant overhead costs    

     
Medical    
Safety and protection 2% 100,000
General plant overhead 3% 150,000
Payroll overhead 1% 50,000
Packaging 0.50% 25,000
Restaurant 1% 50,000
Recreation 1% 50,000
Salvage 1% 50,000
Control laboratories 2% 100,000
Plant superintendence 2% 100,000
Storage facilities 1% 50,000
     
     
Subtotal: 725,000

Manufacturing cost = Total of variable production cost + Total of fixed charges + Total
of plant overhead costs
 38 | P a g e

Total= 1825000+55000+725000

Total= 3,100,000
     
Administrative expenses    
     
Executive salaries 7% 350,000
Clerical wages 1% 50,000
Engineering 4% 200,000
Legal costs 1% 50,000
Office maintenance 1% 50,000
Communications 2% 100,000
     
Subtotal: 800,000
     
Distribution and
   
marketing expenses
     
Sales offices 3% 150000
Sales personnel expenses 2% 100000
Shipping 3% 150000
Advertising 6% 300000
Technical sales service 1% 50000
     
     

Subtotal: 750,000

Research and
7% 350000
development (R&D)

General expenses = Total of administrative expenses + Total distribution and

marketing expenses + R&D

= 800000 + 750000 + 350000

 39 | P a g e

= 1900000 TK

 
 

Total product cost = Manufacturing costs + General expenses

= 3100000 + 1900000

= 50,00000 TK

SAFETY

Industrial Safety:

Industrial safety is the term consists of some precautionary measures that are
observed by people at the time of performing a job inside the factory with the help
of some machine or equipment design in such manner that can check the accident to
be happened with ultimate view to achieve the possible higher productivity.

Importance of Safety:

The ultimate aim of safety is the complete prevention of personal injury, loss of
life and destruction of properties. Effective plant safety and fire protection are
essential for every phase of operation and maintenance of equipment &
machines. Calculated risks must be reduced as far as possible. Equipment &
individual items must be examined time to time for normal service and also
emergency demands. Some major principles and practice of plant safety are
 40 | P a g e

mentioned below. For safe plant operation, detailed safety instructions must
always be established. All buildings, workshops, installation, machinery and
equipment must be furnished and maintains so as to protect the workers against
accidents and professional diseases. The instructions issued by the plant
management for safe operation and for the conduct of personnel must be
followed strictly.

Responsibility of safety:

The safety is of a preventive nature; the aim is to stop the risks and
unsatisfactory conditions and their incorporation into better working
conditions. This requires contributions from and above all, co-operation
between both employees and employer.

General Safety Rules:

The Bangladesh government established a general safety rule for industry called
“Safety in the Factory Rules, 1979”. Every industrial personnel is to observe the
following general safety rules:

• Use appropriate personal protective apparel and equipment for the operation.

• Use alert to unsafe conditions and reactions. Call attention to hazards so the corrections can
be made immediately.

• Use laboratory equipment only for its designed purpose.

• Know the location of emergency equipment in your area. Read and become familiar with
emergency response procedures.

• Label all chemicals clearly and correctly.

 41 | P a g e

• Avoid destructing or startling any co-worker in the laboratory. Practical jokes or any
horseplay cannot be tolerated at any time in the laboratory.

• Access to exits, emergency equipment, controls and such must never be blocked. Stairways
and hallways must not be used as storage areas even temporarily.

• Laboratory equipment must be inspected regularly and serviced accordingly to

manufacturer’s suggested schedule.

Safety Sign:

For the concern of the company’s personnel safety, different safety signs are used such as:

• Prohibition Sign
Example: No smoking, Pedestrians prohibited, No drinking water etc.

• Warning Sign

Example: Risk of electrical shock, Laser beam, Risk of explosion, Risk of fire, Toxic hazard.

• Mandatory Sign
 42 | P a g e

Example: Eye protection, Hand, head and foot protection, Hearing and respiratory
protection etc.

• Safe Condition Sign

Example: First aid, Indication of direction.

Safety equipments: The following equipments are used for safety consideration

Fig: Head protection gear Fig: Face protection equipment

 43 | P a g e

Fig: Hand protection equipment Fig: Leg protection equipment

Fig: Flame retardant cloth

 44 | P a g e

Fig: high visibility wear

PLANT LAYOUT
The laying out of a plant is still an art rather than a science. Plant Layout is the
physical arrangement of equipment and facilities within a Plant. The Plant Layout
can be indicated on a floor plan showing the distances between different features of
the plant. Optimizing the Layout of a Plant can improve productivity, safety and
quality of Products. Unnecessary efforts of materials handling can be avoided when
the Plant Layout is optimized. It involves the placing of equipment so that the
following are minimized:

(1) Damage to persons and property in case of a tire or explosion;

 45 | P a g e

(2) Maintenance costs;

(3) The number of people required to operate the plant;

(4) Other operating costs;

(5) Construction costs;

(6) The cost of the planned future revision or expansion.

All of these goals cannot be met. For example, to reduce potential losses in case of
fire, the plant should be spread out, but this would also result in higher pumping
costs, and might increase manpower needs. The engineer must decide within the
guidelines set by his company which of the aforementioned items are most
important.
The first thing that should be done is to determine the direction of the prevailing
wind. This can be done by consulting Weather Bureau records. In Bangladesh the
prevailing winds are often from the north to south in the summer. Wind direction
will determine the general location of many things. All equipment that may spill
flammable materials should be located on the downwind side. Then if a spill occurs
the prevailing winds are not apt to carry any vapors over the plant, where they could
be ignited by an open flame or a hot surface.
For a similar reason the powerhouse, boilers, water pumping, and air supply
facilities should be located 250 ft (75 m) from the rest of the plant, and on the
upwind side. This is to minimize the possibility that these facilities will be damaged
in case of a major spill. This is especially important for the first two items, where
there are usually open flames.
Every precaution should be taken to prevent the disruption of utilities, since this
could mean the failure of pumps, agitators, and instrumentation. For this reason, it
may also be wise to separate the boilers and furnaces from the other utilities. Then,
should the fired equipment explode, the other utilities will not be damaged.
Other facilities that are generally placed upwind of operating units are plant offices,
mechanical shops, and central laboratories. All of these involve a number of people
who need to be protected. Also shops and laboratories frequently produce sparks
and flames that would ignite flammable gases. Laboratories that are used primarily
for quality control are sometimes located in the production area.
 46 | P a g e

A list of items that should be placed downwind of the processing facilities is given below
Items That Should Be Located Upwind of the Plant
 Plant offices

 Central laboratories

 Mechanical and other shops

 Office building

 Cafeteria

 Storehouse

 Medical building

 Change house

 Fire station

 Boiler house

 Electrical powerhouse

 Electrical Substation

 Water treatment plant

 Cooling tower

 Air compressors

 Parking lot

 Main water pumps

 Warehouses that contain nonhazardous,

 Non explosive, and

 Non flammable materials

 Fired heaters
 47 | P a g e

 All ignition sources

Items That Should Be Located

Downwind of the Plant
 Equipment that may spill inflammable materials

 Blow down tanks

 Burning flares  Settling ponds Storage Facilities

Tank farms and warehouses that contain nonhazardous, nonflammable, and non
explosive materials should be located upwind of the plant. Those that do not fit this
category should not be located downwind of the plant, where they could be damaged
and possibly destroyed by a major spill in the processing area. Nor should they be
located upwind of the plant where, if they spilled some of their contents, the
processing area might be damaged. They should be located at least 250 ft (75m) to
the side of any processing area.2 Some authorities suggest this should be 500 ft.
The same reasoning applies to hazardous shipping and receiving areas.
Sometimes storage tanks are located on a hill, in order to allow the gravity
feeding of tank cars. Care must be taken under these circumstances to see that any
slop over cannot flow into the processing, utilities, or service areas in case of a
tank fire.
Spacing of Items
The OSHA has standards for hazardous materials that give the minimum distances
between containers and the distance between these items and the property line,
public roads, and buildings. These depend on the characteristics of the material, the
type and size of the container, whether the tank is above ground or buried, and what
type of protection is provided. Specific details are provided for compressed gas
equipment containing acetylene-air, hydrogen-oxygen, and nitrous oxide, as well as
liquefied petroleum gases. They also prohibit the storage and location of vessels
containing flammable and combustible materials inside buildings, unless special
precautions are taken.
Processing Area
 48 | P a g e

There are two ways of laying out a processing area. The grouped layout places all
similar pieces of equipment adjacent. This provides for ease of operation and
switching from one unit to another. For instance, if there are 10 batch reactors,
these would all be placed in the same general area, and could be watched by a
minimum of operators; if they were spread out over a wide area, more operators
might be needed. This type of scheme is best for large plants. The flow line layout
uses the train or line system, which locates all the equipment in the order in which
it occurs on the flow sheet. This minimizes the length of transfer lines and,
therefore, reduces the energy needed to transport materials. This system is used
extensively in the pharmaceutical industry, where each batch of a drug that is
produced must be kept separate from all other batches. In other industries it is used
mainly for small-volume products. Often, instead of using the grouped or flow line
layout exclusively, a combination that best suits the specific situation is used.
Elevation
If there is no special reason for elevating equipment, it should be placed on the
ground level. The superstructure to support an elevated piece of equipment is
expensive. It can also be a hazard should there be an earthquake, fire, or explosion.
Then it might collapse and destroy the equipment it is supporting as well as that
nearby. Some pieces of equipment will be elevated to simplify the plant operations.
An example of this is the gravity feed of reactors from elevated tanks. This
eliminates the need for some materials-handling equipment. Other pieces may have
to be elevated to enable the system to operate. A steam jet ejector with an inter
condenser that is used to produce a vacuum must be located above a 34 ft (10 m)
barometric leg. Condensate receivers and holding tanks frequently must be located
high enough to provide an adequate net positive suction head (NPSH) for the pump
below. For many pumps an NPSH of at least 14 ft (4.2 m)
Hz0 is desirable. Others can operate when the NPSH is only 6 ft (2 m) H2O.
The third reason for elevating equipment is safety. In making explosive materials,
such as TNT, the reactor is located above a large tank of water. Then if the mixture
in the reactor gets too hot and is in danger of exploding, a quick-opening valve
below the reactor is opened and the whole batch is dumped into the water. An
emergency water tank may need to be elevated so that, in case of a power failure,
cooling water to the plant will continue to flow, and there will be water available
should a tire occur. Sometimes this tank is located on a nearby hill. An elevation
 49 | P a g e

plan should be drawn to scale showing the vertical relationships of all elevated
equipment. These drawings, as well as the plot plan, are usually sketched by the
engineer and then redrawn to scale by a draftsman.
Maintenance
Maintenance costs are very large in the chemical industry. In some cases the cost of
maintenance exceeds the company’s profit.
Construction and Building
Proper placing of equipment can result in large savings during the construction of the
plant. For instance, large columns that are field-erected should be located at one end
of the site so that they can be built, welded, and tested without interfering with the
construction of the rest of the plant.
Buildings
Included with the layout of the plant is the decision as to what types of buildings
are to be constructed, and the size of each. When laying out buildings, a standard
size bay (area in which there is no structural supports) is 20 ft x 20 ft (6m x 6m).
Under normal conditions a 20 ft (6 m) span does not need any center supports. The
extension of the bay in one direction can be done inexpensively. This only
increases the amount of steel in the long girders, and requires stronger supports.
Lavatories, change rooms, cafeterias, and medical facilities are all located inside
buildings. The minimum size of these facilities is dictated by OSHA. It depends on
the number of men employed. Research laboratories and office buildings are
usually not included in the preliminary cost estimate. However, if they are
contemplated their location should be indicated on the plot plan.
Processing Buildings
Quality control laboratories are a necessary part of any plant, and must be included
in all cost estimates. Adequate space must be provided in them for performing all
tests, and for cleaning and storing laboratory sampling and testing containers. The
processing units of most large chemical plants today are not located inside
buildings. This is true as far north as Michigan. The only equipment enclosed in
buildings is that which must be protected from the weather, or batch equipment that
requires constant attention from operators. Much of the batch equipment used
today does not fit this category. It is highly automated and does not need to be
enclosed. When buildings are used, the ceilings generally vary from 14 to 20 ft (4
 50 | P a g e

to 6 m). Space must be allowed above process vessels for piping and for access to
valves. One rule of thumb is to make the floorto-
floor heights 8- 10 ft (approximately 3m) higher than the sides of a dished-head
vertical tank.6 Packaging equipment generally must be in an enclosed building, and
is often located at one end of the warehouse. If the material being packaged is
hazardous, either this operation will be performed in a separate building, or a
firewall will separate it from any processing or storage areas
Warehouse:
The engineer must decide whether warehouses should be at ground level or at dock
level. The latter facilitates loading trains and trucks, but costs 1520% more than
one placed on the ground. It is usually difficult to justify the added expense of a
dock-high warehouse. To size the amount of space needed for a warehouse, it must
be determined how much is to be stored in what size containers. The container
sizes that will be used are obtained from the scope. Liquids are generally stored in
bulk containers. No more than a week’s supply of liquid stored in drums should be
planned. Solids, on the other hand, are frequently stored in smaller containers or in
a pile on the ground.
Control Rooms
The control center(s) and the electrical switching room are always located in an
enclosed building. It is important that both of these services be maintained so that
the plant can be shut down in an orderly manner in the case of an emergency.
Therefore these buildings must be built so that should an external explosion occur
the room will not collapse and destroy the control center and switching center. To
avoid this, either the structure must have 3-4 ft (l-l.2 m) thick walls, or the roof
must be supported independently of the walls. The Humble Oil and Refining Co.
has specified that the building withstand a 400 psf (2,000 kg / m2) external
explosive force. To keep any flammable or explosive vapors from entering the
building, it is frequently slightly pressurized. This prevents the possibility of an
internal explosion.
Chapter 5

HAZOP Analysis
 51 | P a g e

A hazard and operability study (HAZOP) is a structured and systematic examination of

a complex planned or existing process or operation in order to identify and evaluate
problems that may represent risks to personnel or equipment. The intention of
performing a HAZOP is to review the design to pick up design and engineering issues
that may otherwise not have been found. The technique is based on breaking the
overall complex design of the process into a number of simpler sections called 'nodes'
which are then individually reviewed. It is carried out by a suitably experienced multi-
disciplinary team (HAZOP) during a series of meetings. The HAZOP technique is
qualitative, and aims to stimulate the imagination of participants to identify potential
hazards and operability problems. Structure and direction are given to the review
process by applying standardized guide-word prompts to the review of each node. The
relevant international standard [1] calls for team members to display 'intuition and good
judgment' and for the meetings to be held in 'a climate of positive thinking and frank
discussion'.
The HAZOP technique was initially developed in the 1960s to analyze major chemical
process systems but has since been extended to other areas, including mining
operations and other types of process systems and other complex systems such
as nuclear power plant operation and software development. It is also used as the
basis for reviewing Batch processes and operating procedures.
The method is applied to complex 'processes' for which sufficient design information is
available, and not likely to change significantly. This range of data should be explicitly
identified and taken as the ‘design intent’ basis for the HAZOP study. For example, a
prudent designer will have allowed for foreseeable variations within the process
creating a larger design envelope than just the basic requirements and the HAZOP will
be looking at ways in which this might not be sufficient.
For processes plant, the nodes are chosen so that for each a meaningful design
intent can be specified and they are commonly indicated on piping and instrumentation
diagram (P&IDs) and process flow diagram (PFD). The extent of each node should be
appropriate to the complexity of the system and the magnitude of the hazards it might
pose. However, it will also need to balance between "too large and complex" (fewer
nodes, but the team members may not be able to consider issues within the whole
 52 | P a g e

node at once) and "too small and simple" (many trivial and repetitive nodes, each of
which has to be reviewed independently and documented).

HAZOP
Table No:- 01
Parameter/Guid More Less None Reverse As well Part of Other then
e Word as
Flow Corrosion Undesired
of PVC. ion can be
High No No No High mixed
with
brine.
Pressure Ion GPL will
High No No No High exchanger be
resin will reduced.
destroiate.
Temperature Low PVC Explosion.
No No No Low installation
will
destroiate.
Level No Corrosion Brine can
High No No High of pipeline not pass
properly.
Time Too Too Operating GPL will
long No No No long cost will be
be high. reduced.

Table no:- 02
Ref./Paramete Deviation Cause Consequenc Safeguards Action
r e
Brine can Corrosion, Flow can be Manually flow
Flow High Flow pass damage of controlled by can be
 53 | P a g e

properly. pipeline. automatic controlled.

control loop.
Firstly we
trying to find
Desired Corrosion, Pressure can out the
ion can be product may be controlled problem,
Pressure High removed be damaged. by automatic Secondly we
Pressure in short control loop. called the
time maintenance
officer to
solve the
problem.
Ion Explosion, Temperature
Temperature Low exchanger corrosion Automatic can be reduced
temperatur resin can can not control loop. manually.
e not occur
destroiate.
Pvc Corrosion, Level can be
High installation undesired Automatic reduced
Level level can not ion can not control loop. manually.
occur. reduced
properly.
Increased Friendly
GPL can Operating section of environment
Time Too long not cost will be manufacturin can be created
reduced. high. g process. between
engineer and
administration.

Braine Section

Nacl and water can be mixed to produced Braine

1.Flow
2. Temperature
 54 | P a g e

1. High Flow
2. Low Temperature

1. Braine can pass properly

2. Ion exchanger resin can not destroiate

1. Damage of pipeline
2. Corrosion, explosion can’t occur

1. Automatic control loop

2. Automatic control loop

1. Manually control
2. Manually control

Stage is complete
Fig:- Flow diagram for the HAZOP analysis of section or stage of an operation

Conclusion:
The Textiles and Dyeing sector in Bangladesh are playing the major role in the economy. It is a
booming sector of Bangladesh and it require a huge amount of chemicals including Sodium
hydroxide. The total requirement of caustic soda per Annual about 80,000 ton. And ASM
Chemical Industries Limited produces 20,000 ton per annum. So there is a good opportunity to
set up this kind of Industry since it is the only industry in private sector.
 55 | P a g e

It is one of the modern factory in Bangladesh which is operated by DCS system which is used
only in four industries in Bangladesh including it. It is equipped with latest technology,
machineries and facilities. This factory maintains an effective administration, securities and
good labour management. So every year this factory fulfils the estimate production capacity.

From this I have received a good concept on the latest technology of chemical process in this
selective field. Besides that I can mentioned some machineries like Clarifier, Evaporator,
Boiler, Ion Exchange column which I have only the theoretical knowledge before.

In this report, I have tried my best to cover up all aspects of this plant including process
chemistry and operation, utilities, environmental pollution, safety aspects, economics etc.

Finally, the visit was an event of great success and sufficient significance from the both
academic and professional view point. I hope the concerning authority will realize the prime
importance of such type of industrial visit will take adequate steps to make it more effective in
the years to come.

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