Material Balance

Capacity of plant= 250MTPD=10416.66kg/hr

NaOH For 250 MTPD of NaOH = (250 × 1000)/(24 × 40) = 260.1𝑘𝑚𝑜𝑙𝑒/ℎ𝑟

Membrane efficiency to convert NaOH is 97% then NaCl needed=260/0.97 = 268.47 𝑘𝑚𝑜𝑙𝑒/ℎ𝑟 =
15705.54 kg/hr

The rock salt taken from Khewra location is 98.30% pure

Rock salt required = (15705.54 kg/hr)/0.9830 = 15977.15 𝑘𝑔/ℎ𝑟

Assumptions:

 Steady state process

 1hr operation

Saturator:

Saturator

Componen %Mass Composition

t in Feed
(A)
NaCl 98.3
Moisture 0.11
Water 0.4
Ca+2 0.3
Mg+2 0.12
So4-2 0.28
K+ 0.046

Demin Water = 40195.4834 kg/hr (B)

Component % Mass composition

in Product Out
 (C)
NaCl 28.154
Moisture 0.0313
Ca+2 0.113
Mg+2 0.085
SO4-2 0.076

A+B=C

15977.15+B=C

Component Material Balance on NaCl= 0.09380*15977.15= 0.28*C

After solving above equation:

C=56106.673

B=40195.48

A=15977.15

Summary:

MASS
INPUT
Component % Mass Mass Fraction Amount in Kg
s Composition In
NaCl 98.3 0.983 15705.53845
Moisture 0.11 0.0011 17.574865
Water 0.4 0.004 63.9086
Ca+2 0.3 0.003 47.93145
Mg+2 0.12 0.0012 19.17258
SO4-2 0.28 0.0028 44.73602
K+ 0.046 0.00046 7.349489

MASS
OUT
Component % Mass Mass Fraction Amount in Kg
s Composition In
NaCl 28.15424934 0.0281542493 15729
Moisture 0.031332772 0.000313328 17.574865
Water 0.113937352 0.001139374 63.9086
Ca+2 0.85453014 0.00085453 47.93145
Mg+2 0.034181206 0.000341812 97.17258
SO4-2 0.079756146 0.000797561 44.73602
K+ 0.013102795 0.000131028 7.349489
Water 71.51592947 0.715159295 40114
Checking Water Balance

Water in 40195.48347 = Water out 40195.48

Total Mass In 56091.15

Total Mass Out 56091

Purification of Brine:

The chemical required to remove impurities

 NaOH solution for chlorides of Mg

 Na2CO3 for chlorides of Ca
 BaCO3 for sulphates

Stoichiometric requirement:

 MgCl2 + NaOH Mg(OH)2 + NaCl

The amount of MgCl2 in Brine is 19.17 kg/hr so NaOH requirement =19.17 80/95 = 16.58kg/hr

Mg(OH)2 =19.17 58/95 = 11.7 kg/hr

NaCl =19.17 (2 × 58.5)/95 = 23.60 kg/hr

 2KCl + Na2CO3 K2CO2 + 2NaCl

Na2 CO3 requirement =7.34 106/149 = 5.22 kg/hr

K2CO3 requirement =7.34 138/149 = 6.88 kg/hr

NaCl requirement =7.34 117/149 = 5.27 kg/hr

Treatment Tank 1

BaCO3 and Na2CO3are added to neutralize impurities regarding SO 4 -2 and Ca +2.

TANK 1
 Component in (C) % Mass composition
In
NaCl 28.154
Moisture 0.0313
Ca+2 0.113
Mg+2 0.085
SO4-2 0.034
Water 0.076

Component in % Mass composition Out

Product (D)
NaCl 28.1828418
Moisture 71.4837919
BaSO4 0.07679147
K2CO3 0.15459662
Mg(OH2) 0.05564625
Mg+2 0.1223542
CaCO3 0.04309659

Summary:

MASS
INPUT
Components % Mass Amount in Kg
Composition In
NaCl 28.15424934 15729
Moisture 0.031332772 17.57487
Water 0.113937352 97.9086
Ca+2 0.085453014 47.93145
Mg+2 0.034181206 19.7258
SO4-2 0.079756146 44.73602
K+ 0.013102795 7.349489

MASS OUT
% Mass Amount in Kg
Composition In
NaCl 28.18284178 15847.27
Moisture 71.48379188 40195.84 Total Mass out in(C+Chemicals)= 56230.27kg
Water 0.076791467 43.18
Ca+2 0.154596624 86.93 Total Mass out (D)= 56230kg
+2
Mg 0.055646248 31.29
SO4-2 0.012235417 6.88 Treatment Tank 2
K+ 0.034096585 19.17258
Here impurities regarding SO4-2 is neutralizes

Tank 2
Feed=56230.21kg/hr

E=Caustic 16.58kg/hr

Summary:

MASS
INPUT
Components % Mass Amount in Kg
Composition In
NaCl 28.18284178 15847.27
Water 71.48379188 40195.48
CaCO3 0.076791467 43.18
BaSO4 0.154596624 86.93
MgCO3 0.055646248 31.29
K2CO3 0.012235417 6.88
Mg+2 0.034096585 19.17258

MASS Out
Components % Mass Amount in Kg
Composition out
NaCl 28.21672 15870.87
Moisture 71.4633 40195.48
Water
CaCO3 0.076769 43.18
BaSO4 0.154552 86.93
MgCO3 0.05563 31.29
K2CO3 0.012232 6.88
 Mg(OH)2 0.020801 11.7

Total Mass In (D+E) = 56246.79 kg/hr

Total Mass Out (F)= 56246.33 kg/hr

Clarifier:

For the simplification assuming all impurities are removed in clarifier in sludge and pure brine goes to the
membrane cell

Clarifier

Feed from treatment tank 2=F=56246.33 Kg/hr

Sludge= 179.98 kg/hr

G=Purified brine to electrolytic cell= 56066.35 kg/hr

NaCl= 15870.87 kg/hr

H2O= 40195.48 kg/hr

Gernalized Material Balance on Membrane Cell:

56066.35 kg/hr is feed of electrolytic cell and starts operation %age conversion of electrolytic cell is
assumed to be 97%.

NaOH =1056.23kg/hr

Cl2= 9342.11 kg/hr

H2= 263.4 kg/hr

NaCl=476.1261 kg/hr

H2O=35461 kg/hr
Saturated Brine Feed= 56066.35 kg/hr

NaCl= 15870.87 kg/hr

H2O= 40195.8 kg/hr

Depleted Brine= 476.1261 kg/hr

H2 Formed=263.3 kg/hr

Water out= water in –water consumed

40195.8-4734= 3546.8 kg/hr

Cl2 produced= 0.5 *263= 131.5 kmol/hr=9342.11 kg/hr

H2 produced= 0.5 * 2*263=263kmol/hr=263.4 kg/hr

Total Mass in (G)=56066.35 kg/hr

Total Mass out (H)= 56069.76 kg/hr

Material Balance on Operational Membrane Cell:

From Faraday’s Law of electrolysis

 1F = 1 mole NaOH

40g NaOH=96500C

1gm NaOH= 96500/40

250MTPD= 96500/40 × 25 × 1000 × 1000 = 6.01 × 1011𝐶

We know that

Q = I× t

I= Q/t= 6.01 * 1011C/24*3600= 6980KA

Area of a cell = 2.9 m2 = 2.9 * (100 cm)2 = 29000 cm2

Current density = 0.4 A/cm2

Total Current needed for one cell= 0.4A/cm 2*29000cm2=11600A

So total cells needed for 250MT NaOH plant= 6980.613/11.6=601 Cells

If current efficiency is assumed to be 97%= 97*11.6/1000*10 6=0.3989 ton/day

Actual number of cells= 627 cells are required for the production of 250MTPD at a current efficiency of
97%.

H2O=100%
Material Balance on Evaporator:
N=275215.8 kg/hr

FEED From CELL 1091801kg/hr

M = 816585.4 kg/hr
NaOH= 334800 kg/hr= 30.6%
NaOH=41%
H2O= 757001.2kg/hr= 69.3%
H2O = 59%

Overall Balance L= M+N

1091801 = M+N

For Water balance 0.69L=0.41M+ N

Solving equations simultaneously

N= 275215.8 kg/hr
 M= 816585 kg/hr

Total Mass In = 1091801 kg/hr Total Mass out = 275215.8+818585 = 1091800.8 kkg/hr.

Evaporator 2:

O=146985.4 kg/hr

Water=100%

M=816585.4 kg/hr P=669600 kg/hr

NaOH=41% Evaporator 2 NaOH=50%

H2O = 59% H2O = 50%

Overall Balance

M= O+P

816585.4 = O+P

For Water balance

0.59M=0.50O+ P

Solving equations simultaneously

O = 146985.4 kg/hr

P = 669600 kg/hr

Total mass In = 816585.4

Total mass Out = 816585.4

Cl2 Dryer : H2SO4as a dehydrating agent:

S= 132.89
Q= 7.90 k mol/hr kmol/hr

H2O = 0.02 Cl2 = 0.999

H 2SO 4 = 0.98 H2O = 0.001

Mass IN = Mass OUT

10296kg/hr = 10296 kghr