Shroff S. R.

Rotary Institute of Chemical Technology

Principal Supporter & Sponsor-United Phosphorus Ltd. (UPL)/ Shroff family
Managed by Ankleshwar Rotary Education Society
Approved by AICTE, New Delhi, Govt. of Gujarat & GTU Affiliated

A Report on Summer Industrial Training (SIT) at GACL, Dahej

Prepared as a part of the requirements for the gained knowledge at GACL, Dahej

B.E. Semester - VI

(Branch:- Chemical Engineering)

Submitted by:-

Sr. No. Name En. No.

1 Jadav Harsh H. 160990105013
2 Patel Ujval K. 160990105040
3 Shah Bhavya D. 160990105048

Academic year 2019-20

1
 CERTIFICATE

This is to certify that dissention entitled “Vocational Training at GACL,

Dahej” has been carried out by Jadav Harsh H. , Patel Ujval K. and Shah
Bhavya D. under the valuable guidance of human resource team of above
industry in fulfillment of the degree of Bachelor of Engineering in Chemical
Engineering (6th Sem.) of Gujarat Technological University, Ahmedabad
during the academic year 2019-20.

Date:- 30/06/2019

_____________ ______________________
Concerned A.J. Sharma
Training officer Chief Manager (HR & A)

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 ACKNOWLEDGMENT

 This training report is prepared not only by solo effort. A great deal of effort
and time has been devoted in preparing this training report. This report would
not been possible without the co-ordination from all the quarters. Many
employees are involved directly orindirectly.
 I express my sincere gratitude to our Head of Dept. as well as Training
Coordinator (Chemical) who allowed me to visit this plant for training in
GACL,Dahej.
 We convey special thanks to:-
 Mr. Anjan Kundu
 Mr. Nilesh Jethwa
 Mr. M.Y. Patel
 All other Foremen, Operator & Apprentice who helped us.

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 PREFACE

“Practice Makes Man Perfect”

 Everybody is familiar with this famous quote and it is definitely applicable in every
field, especially for all the technical students. Theory of any subject is important but
without its practical knowledge, it is incomplete knowledge. Both practical and
theoretical knowledge are like two sides of coin which have its own importance. A
technical student cannot become a perfect engineer or technician without practical
understanding of that particular branch. Hence, this training provides a golden
opportunity for all the technical students.

 This report consists of various operations and unit process of The Caustic Soda Plant
of GACL, Dahej. The production process and plant equipments, their M.O.C are
explained in the better way by their respective flow sheets.

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 INDEX

Sr. No Content No.

1 About GACL 6
2 Products of GACL 8
3 Plant layout & Location 9
4 Product detail
1 Caustic Soda lye 11
2 Caustic Soda flakes 11
3 Caustic Soda prills 12
5 Properties of Caustic Soda 14
6 Various process of manufacturing of Caustic Soda
1 Lime soda process 17
2 Electrolytic process 17
7 Selection of process 19
8 Process Description
1 Storage of raw material 21
2 Primary brine purification 22
3 Secondary brine purification 25
9 Standard procedure for cl2 bottling 31
10 C.C.U. 33
11 Equipments Details 37
12 Utilities 41
13 Waste water treatment 45
14 Block diagram 46
15 Material balance 47
16 Reference 49

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 ABOUT GACL

 One of the most prestigious, giant amongst (Indian Chemical Companies)

GUJARAT ALKALIES & CHEMICALS LIMITED (GACL) has been a name to
reckon with chemical industry in India.
 GACL was incorporated on 29th March 1973with a modest capacity of just 37,475
TPA Caustic Soda and now GACL has become the largest Caustic Soda producer
plant. From the humble beginning, the company's turnover has grown to over Rs.
1100 crore. GACL the largest producer of chloral-alkali in the country is the top
performing PSU's of Gujarat.
 GACL has attained accelerated growth rate of 128% fiscal year 2004-2005 and
outperformed its competitors in the chlor-alkali sector.
 The Dahej complex of GACL enable it to produce over 770 tones of Caustic Soda per
day.
 GACL's commitment towards sustainable development and adopting environment
friendly production and disposal practices has been awarded with prestigious
certifications like ISO 14001:-2015 for Environment systems and the ISO 18001:-
2007 for occupational health and safety and Management Systems.
 Both the complexes also have ISO 9001:-2015 certificate for excellence in Quality
Management System and the ICWAI award for Excellent Cost management. Backed
by the support from Chief Minister, Shri. Vijaybhai Rupani and the Govt. of Gujarat,
the company management has laid strong emphasis on cultural transformation of
PSU's which has propelled GACL's growth in every sphere making it one of the most
progressive PSUs of Gujarat.
 Some factors of this GACL(DAHEJ, Complex) are follow:-

 GACL GENERATE ITSELF POWER FOR PLANT:-

 With capacity of 100% which is much higher than an industry average

77%, GACL has a diversified basket of 24 products. The company is
major player of Chloromethane, Hydrogen Peroxide, Potash Group,
Phosphoric Acid and Sodium Cyanide.
 GACL's major thrust has been on the effectively utilizing the
membrane cell technology which has reduced the energy consumption
considerably. Besides this, GACL also operates a co-generation power
plant at its Dahej complex.

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  This gives GACL an added advantage of bringing down the cost of
production. Moreover consistent energy conservation efforts made by
GACL have made it a proud recipient of the prestigious National
Energy Conservation Award 2004-2005 which was presented by his
Excellency Dr. A.P.J. Abdul Kalam, the former president of India on
14th December 2005.

 ON A SAFE GROUND:-
 Rigorous safety protocols employed by GACL have gifted the company
with many years of accident free working. The company has won the
Green Tech Silver Safety Award for its Dahej unit also the IS 18001
certificate for occupational health and safety. The SHE (Safety, Health
and clean Environment) Policy at GACL trains employees to never ever
compromise with their safety and that of the environment.

 SOCIETY IS OUR RESPONSIBILITY:-

 GACL has partnered the Govt of Gujarat implementing Jyoti Gram
Yojna thereby empowering a number of villages with 24 hours power
supply and has actively participated in girl child education programs in
the state Further, GACL contributes to the rural development by
creating infrastructure, encouraging self employment, education,
sports, and cultural activities. The company co- promotes SVADES
(Society of Village Development in petrochemical area) and thereby
contributing better standard of living in the area. The PSU has always
been a front runner in providing relief at the time of natural calamities
like earthquake and floods.

 FUTURE WISE:-
 GACL's process driven working, proficient management policies
management policies and sensitive approach towards the
environment depict bright future, not only for the company, its
employees and stakeholders but also for Gujarat and its people.

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 PRODUCTS OF GACL

Caustic Soda Lye (32%) Caustic Soda Prills (98%) Methyl Chloride
Dilute sulphuric acid Caustic Soda Flakes (98%) Hydrogen Peroxide
Liquid Chlorine Sodium Hypochlorite Calcium Chloride
Hydrochloric acid Sodium Cyanide Carbon Tetrachloride
Caustic Potash Lye Sodium Ferrocyanide Hydrogen Peroxide
Caustic Potash Flakes Potassium Carbonate Compressed Hydrogen Gas
Chloroform Phosphoric Acid Aluminum Chloride

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 PLANT LAYOUT & LOCATION

GACL site for caustic plant is located at dahej village, approx. 50 km away from
Bharuch, adjacent to national highway no. 8. Other meteorological data associated with
plant site are as follow:-

A)Height above sea level:- 19.2m

I. Dry bulb temp (max):- 46°C
II. Dry bulb temp (Min):- 5°C

B) Pressure
I. max :- 101.23 kpa
II. Min:- 99.52kpa
III. Avg:- 100.6kpa

C)Relative Humidity:- 80%

D) Rainfall intensity:- 65mm/hr

I. Wind max velocity:- 62 km/hr
II. Wind direction:- North-East

E) General Climate:- Hot& Humid

Following reasons have been assigned for the selection of GACL plant site selection:-

1) Raw Material Availability:-

For caustic soda main raw material used is salt, which is require in
large quantity during process. Around 1.6 tons of raw salt is required for
production of 1 ton of NaOH. The sources are available nearly to the plant.

2) Market:-
This is most important factor to be considered during selection of
location because if market if market is not available nearly to the plant then
some problems arise during selling of product.

3) Waste Disposal:-
Sludge contains CaCO3 CaSO4, BaSO4 & carbon particles from brine
plant. Wash water contains graphite particles, traces of acid percentage
alkalies, etc, a proper effluent system should therefore be planned to take
care of above waste problems.

9
4) Weather:-
Particular attention should be given towards severe climate condition
such as hurricane & floods.

5) Labour Supply:-
Availability of low cost skilled, semi-skilled, & unskilled labor is to
be considered in final selection of plant. In the industry developed area,
adequate labour supply of all type will be available.

6) Site characteristics:-
The characteristics of land at proposed site should be examined
carefully. The cost of land is important as well as building cost; additional
space should be available for future expansion.

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 PRODUCT DETAIL(CAUSTIC SODA PLANT)

 CAUSTIC SODA LYE

 Caustic Soda Lye is manufactured by UHDE, Germany's membrane cell
technology.
 Mercury free process

1. APPLICATION
 Manufacturing of:-
 Dyes and Pharmaceuticals
 Rayon
 Pulp and Paper
 Aluminium Metal
 Sodium Salts
 Petroleum Products
 Rubber Chemicals
 Processing of Vegetable Oils
 Acid Neutralization

2. ADVANTAGES
 GACL guarantees minimum 47.0% purity of NaOH Caustic Soda Lye is
stable even at high temperatures. QCD is equipped with most modern
instruments to analyze special tests also on request.

3. CAPACITY
 770 Tonnes/day at Dahej Complex.

 CAUSTIC SODA (Flakes)

 Caustic Soda Lye is manufactured by Membrane Cell Technology of UHDE,
Switzerland Germany and Caustic Soda Flakes manufactured by Technology
of Bertram
 High purity Caustic Soda.
 Free flowing white deliquescent pieces.

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1. APPLICATION

Manufacturing of:-
 Dyes and Pharmaceuticals
 Rayon
 Pulp and Paper
 Aluminum Metal
 Sodium Salts
 Petroleum Products
 Rubber Chemicals
 Processing of Vegetable Oil.
 Acid Neutralization

2. ADVANTAGES
 Dissolves gradually in water.
 Easy to handle.
 QCD is equipped with most modern instruments to analyze special tests also
on request.

3. CAPACITY
 400 Tonnes/day at Dahej

 CAUSTIC SODA PRILLS

 Caustic Soda Lye is manufactured by Membrane Cell Technology of UHDE,

Germany and Caustic Soda Prills manufactured by Technology of Bertram
Switzerland.
 Ultra High purity Caustic Soda. Free flowing milky white granules.
Specially packed under completely diy and air conditioned climate.
 Automatic weighing, heat sealing and stitching dehumidified environment
gives a long lasting lump titee storage

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1. APPLICATION
 Manufacturing of
 Dyes and Pharmaceuticals
 Rayon
 Pulp and Paper
 Aluminum Metal
 Sodium Salts
 Petroleum Products
 Rubber Chemicals
 Processing of Vegetable Oil.
 Acid Neutralization

2. ADVANTAGES
 Dissolves readily and more easily in water/saves dissolution time.
 Highest purity Prills gives higher yield/ productivity.
 QCD is equipped with most modern instruments to analyze special tests also on
request.

3. CAPACITY
 100 Tonnes/day at Dahej

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PROPERTIES OF CAUSTIC SODA

PHYSICAL PROPERTIES:-
 Caustic soda is also known as sodium hydroxide, caustic, and lye.
 Anhydrous (100%, solid) sodium hydroxide has a chemical formula of
NaOH and a molecular weight of 40.00

1. Physical state and appearance:- Solid (Deliquescent solid)

2. Odor:- Odorless
3. Taste:- Not available
4. Molecular Weight:- 40 g/mole
5. Color:- White.
6. PH (1% soln/water):- 13.5 [Basic]
7. Boiling Point:- 1388°C (2530.4°F @ 100% NaOH)
8. Melting Point:- 323°C (613.4°F @ 100% NaOH)
9. Critical temperature:- Not available
10. Specific Gravity:- 2.13 (Water 1)
11. Vapor Pressure:- 1.5 mmHg & 68°F (0.20 kPa & @ 20C)
12. Vapor Density:- Not available
13. Volatility:- Not available.
14. Odor Threshold:- Not available.
15. Water/Oil Dist. Coeff.:- Not available.
16. Iconicity (in Water):- Not available
17. Solubility:- Easily soluble in cold water.
18. Freezing point:- 25°F (-4°C @ 5% NaOH)
14°F (-10°C @ 10% NaOH)
34°F (1°C @ 30% NaOH)
53.6°F (12°C @ 50% NaOH)

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CHEMICAL PROPERTIES:-
 Chemical formula:- NaOH
 Aqueous solution of caustic soda is highly basic and is very useful in reaction with
weakly acidic materials.
 Sodium hydroxide will neither burn nor support combustion, although in its
reaction with atmosphere metals such as aluminum, tin, & zinc. hydrogen gas
generated which may form an explosive material.

1) REACTION WITH
Electrolysis:-
In the laboratory, with careful control of conditions, sodium metal can be
isolated from the electrolysis of the molten monohydrate in a low temperature
version of the Castner process, according to the following reaction.
4 NaOH + H₂O(l) →4 Na(l)+ O₂(g) + 6 H₂O(g)
With acids:-
 Sodium hydroxide reacts with protic acids to give water and the
corresponding salts. For example, with hydrochloric acid, sodium chloride is
formed:-
NaOH(aq) + HCl(aq) →NaCl(aq) + H2O(aq)
 In general such neutralization reactions are represented by one simple net
ionic equation:-
OH ⁻ (aq) + H ⁻(aq) → H2O(l)
 This type of reaction with a strong acid releases heat, and hence is referred to
as exothermic. Such acid-base reactions can also be used for titrations.
However, sodium hydroxide is not used as a primary standard because it is
hygroscopic and absorbs carbon dioxide from air
 Sodium hydroxide reacts readily with carboxylic acids to form their salts and
is even a strong enough base to form salts with phenols. It is not, however,
strong enough to quantitatively produce enolates from carbonyl compounds or
deprotonate amines; this would require a superbase.

15
 With acidic oxides:--
 Sodium hydroxide also reacts with acidic oxides, such as sulfur dioxide, Such
reactions are often used to "scrub" harmful acidic gases (like S@ and HS)
produced in the burning of coal and thus prevent their release into the
atmosphere For example,
NaOH+CO2 → Na2CO3+H20
With metals and oxides:--
 Sodium hydroxide slowly reacts with glass to form sodium silicate, so glass
joints and stopcocks exposed to NaOH have a tendency to "freeze"
 Flasks and glass-lined chemical reactors are damaged by long exposure to hot
sodium hydroxide, and the glass becomes frosted. Sodium hydroxide does not
attack iron since iron does not have amphoteric properties (ie, it only
dissolves in acid, not base). A few transition metals, however, may react
vigorously with sodium hydroxide.

2Al + 2NaOH + 2H₂O₂ → NaAlO2+ 3H2

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VARIOUS PROCESS OF MANUFACTURING OF CAUSTIC SODA

 In older times, caustic soda was produced by Caustic Xing Process of lime or
electrolysis of commercial salt, but today, it is obtained by electrolysis process.
 Various processes are as described as under

 LIME SODA PROCESS

 Lime soda is no longer used for production of caustic soda on large scale but
is still employed by Industry. In this process, when milk of lime is added to
sodium carbonate solution, sodium hydroxide is obtained and calcium
carbonate being only slightly soluble separates out as mud This calcium
carbonate is burnt to obtain lime which is recycled.
Na₂CO₃ + Ca(OH)₂ → 2 NaOH +CaCO3.
 In this process, impure or less purity of NaOH is obtained

 ELECTROLYTIC PROCESS:-
 This process has an advantage that the production obtained is very pure and
hydrogen and chlorine are obtained as valuable by-products.
 When electric current is passed through water, Na+ ions combined with OH--
ions to give NaOH. The Cations on the other end are directed towards where
they use one electron each and are liberated as chlorine molecule as chlorine
gas as follows.
NaCl→ Na⁺ + Cl⁻
2H20 + 2e⁻→ H2+ 20H⁻
Na⁺ +OH⁻→NaOH
Cl⁻ → Cl + e⁻
Cl + Cl → Cl2
 If NaOH and Cl2 so produced are allowed to come in contact, they will react
again and the whole labour will be wasted.

2NaOH + Cl2→2NaCl + NaOCI+ 2H20

 The concentration of cell should be such that the NaOH and Cl 2 once
produced should not be allowed to come in contact with each other. This is
accomplished by anode The cathode by diaphragm or a membrane or by use
of mercury or by use of mercury as in Kellner-Castner cell.

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A. DIAPHRAGM CELL:-
 Here, a diaphragm made of Asbestos fiber is used to separate anode from
cathode Anode made of graphite and cathode is of CI The diaphragm elogs
after some interval and so must be replaced at regular intervals. In this cell
fairly impure brine may be used and it can produce 10-12% caustic soda.

CELL REACTION:-
Anode:- Cl + e⁻→⅟₂ Cl₂
Cathode:- Na⁺ + H₂0 + e⁻→ Na⁺ +OH⁻ + ⅟₂Cl₂
Overall:- NaCl + H₂0→ NaOH + ⅟₂H₂ + ⅟₂Cl₂

B. MEMBRANE CELL:-
 This use semi permeable membrane to separate anode and cathode membrane
is made up of perfluorosulfonic acid polymer. This cell uses more concentrated
brine and produce more concentrated product. It produces 50% NaOH

CELL REACTON:-
Anode:- Cl + e⁻→ ⅟₂ Cl2
Cathode:- Na⁺ + H20 + e⁻→ Na⁺ +OH⁻ + ⅟₂Cl2
Overall:- NaCl + H20→ NaOH + ⅟₂H2 + ⅟₂Cl2

C. MERCURY CELL
 In this above cell, the anode and cathode are stationary and cathode is flowing
around in pool of mercury. The electrolysis produces a sodium/mercury
(amalgam) which is not decomposed in a separate vessel according to
following reaction
2NaOH + 2H20→ 2NaOH + H2 +Hg
 It uses saturated solution if NaCl and produces 70% solution of caustic soda.

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 SELECTION OF PROCESS:-

INTRODUCTION
 Caustic Soda is base chemical with wide uses. It is mainly used in aluminum,
paper, textile and edible oil industries. Chlorine and hydrogen are its main
byproducts

ELECTROLYSIS:-

 Caustic soda is produced by electrolysis of sodium chloride solution. There are

two conventional process viz Diaphragm and Mercury process .
 In diaphragm process, Asbestos diaphragm is used. In view of low
concentration and high level of impurities, this process is not favored.
Therefore, mercury amalgam process where mercury is moving cathode,
became prominent due to high conc. Caustic, it could produce and also the
overall power consumption being low compared to diaphragm process. But the
biggest problem is booming large with to the mercury is its disposal of sludge
and emission in atmosphere.

ION EXCHANGE:-
 In ion exchange dell process cation exchange membrane is used as a separator
between anode compartments. A cation exchange permits and caustic soda and
hydrogen gas are formed at cathode department. There are two versions of
membrane cells viz
 Monopolar
 Bipolar
 The difference in these versions is mainly in current distributions. The process
proved to be not only pollution free but can also produce caustic soda
consuming 30% less power than other process.

OTHER ADVANTAGES OF MEMBRANE CELL PROCESS:-

1) REDUCED ENERGY CONSUMPTION:-

 Through utilization of perflourocarbonic membrane suitable for production
of 30-35% NaOH so there is considerable reduction in energy required for
evaporation of water to obtain 50% NaOH solution

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2) LOWER INVESTMENT:-
 Due to simplicity of electrolysis cell-and fewer requirements for
electrolysers.

3) EASE OF OPERATION
4) HIGH OPERATIONAL FLEXIBIITY
5) POWER OPERATION COST:--
 Due to high life expectancy for electrolysers and minimum 2 years of service
of membrane and also due to fewer personal requirement for cell operation
and maintenance.
6) HIGHER PRODUCT PURITY:-
 <100 ppm NaCl with 32% NaOH and practically no H2 gas.
7) NO ENVIRONMENT POLLUTION:-
 Due to high Hg or asbestos or any substances.

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 PROCESS DESCRIPTION

 The system consists of following sections for purification of brine:-

A. Salt storage,
B. Brine treatment

 Primary brine purification:-

 Brine clarification
 Brine saturation
 Brine filtration
 Brine polishing
 Secondary brine purification:-
 Ion exchange
 Chlorate destruction
 Anolyte dechloration

A. Storage of raw material

1. SALT STORAGE AND HANDLING:-

 Raw salt obtained from different source have impurities like Ca Mg SO2,
etc. of very high level. This salt is washed and this washed salt from
washing unit is fed to bucket elevators. Then this bucket elevators feed
salt to a common hopper located over brine saturators. In this unit, the
salt is reduced to a common uniform particle size in a roll crusher and
then fed to elutriator and then slurry is pumped to hydro extraction.
 The impurities from salt are recovered by circulating brine counter
current through a centrifugal to separate filtrate to collect washed salt.
 The washed salt is transferred to salt handling system and charged to
saturator via. conveyor and elevator. The brine in circulation goes to
settle pond which has six compartments. The solids in water gets settled
in this pit.

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 2. RAW MATERIALS:-

 Formerly Na2CO3, and NaOH were used for removing salt impurities
like Ca2+ Mg2+ SO42- but now company has installed its own separate
sulphate removing system (SRS) for removal of sulphate as BaCO3 is
very costly and this has helped a lot in economy Also, the company uses
98% H2SO4 for purpose of drying of Cl2.

B. PRIMARY BRINE PURIFICATION

BRINE SATURATION:-
 Normally saturator is charged with salt with two way diverters from
bucket elevators discharge. Lean brine of almost 230 GPL NaCl is fed to
saturator where it is entered at the bottom of tank through a submerged
pipe from the top to get out as an overflow. For controlling brine content
up to 310 GPL NaCl, a valve is used for controlling the DM water inlet.
DM water is also added to lean brine because to make up the water loss
due to water migration to catholyte pH of lean brine should be less than
9 so as to avoid the dissolution of silica.

 The impurities like Ca & Mg are removed as a precipitate of CaCO3 and

Mg OH 2 in precipitation tank. Naco3 and NaOH solutions in
precalculated quantities based on salt quantity are prepared in separate
tanks and then 10% solution of Na2CO3 and NaOH in 1st & 2nd ppt.
tanks respectively are added.

 Following reaction occur in ppt. tank-1:-

Na₂CO₃ + Ca(OH)₂ → 2NaOH +CaCO₃
 CaCO3 is removed as sludge in clarifier NaOH formed in this reaction
react with Mg⁺
2NaOH + MgCl₂→ Mg(OH)₂ + 2 NaCl
 As the brine temp. is below 60°C approx. 400 mg/1 & 200 mg/I NaOH excess is to be
maintained in crude brine. The crude brine containing CaCO3 and Mg OH 2 ppts.
Flow to clarifier feed well by gravity. The precipitation tanks are connected with
agitation air blower to facilitate keeping the precipitates in suspension. Precipitation
tanks are made of mild steel with rubber lining inside.

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CHEMICAL PREPARATION:-

 The 10% solution of Na2CO3 is prepared separately either in brine or

DM water. The feeding is done by reciprocating pump and measured by
rotameters Chemicals from bags are charged manually to hopper of tank.
Chemical tank are connected with agitation air blower to facilitate
agitation of solution.

BRINE CLARIFICATION:-

 The crude brine containing the precipitates flows by gravity to feed well
of clarifier. The clarifier is having capacity of 4600m3. In clarifier, more
than 90% of the solids settle at the bottom draw off and pumped to
decanter with help of hose pump. This consists of a large clarifier. Rake
arm s provided in clarifier for better settling which can rotate at 4 RPM.
 The pure rine from clarifier overflows into clarified brine tank For Better
settling of solids the flocculation agent Maga flocs is added to brine.
This helps in formation of large flies which is out of very fine ppts. pit.
Brine from Rit is recovered back to system The discharge of clarifier is
passed to the clarifier sludge
 The sludge from pit is passed to the decanter to recover brine from
sludge coming out of clarifier. The filtrate contains 90001200 ppm solids.
It is recovered back into brine circuit. Solid cake is discharged out of
scrolls in decanter and contains about 50% moisture. It is collected in
trolleys and discharged.

BRINE FILTRATION:-

 Brine from clarifier still contains approx. 50 ppm of suspended solids.

The removal of these suspended solids is done in Anthracite filter. Brine
filtration unit consists of 6 Anthracite filter, 5 in operation and 1 under
wash. The filter filled with Anthracite of 3 particle sizes.
 The top layer consists of fine particles and is acting as filter
media. the size of fine particles in top layer is 0.6 to 1.6 mm &
thickness of layer is 1000 mm.
 The lower two layer consists of fine particles 7 meant for
supporting the top layer. The size of fine particles in two layers is
1.5 to 2.5 mm thickness of layer is 150 mm.
 The complete bed rests on a perforated plate.
23
  The filter nozzles prevent passing of any anthracite into the
filtrate.

WORKING OF ANTHRACITE FILTER:-

 Brine enters the filter from the top by means of pump pressure.
 Brine is forced through the filters and the solids are retained on the top
of the filter bed.
 The filters passed through the nozzles to the lower part of the filter
housing and there to the filtered brine tank to remove the sludge
collected over the filter media, periodic backwashing the filter is
necessary.
 Backwashing is done for 4 hours after 24 hours working which is done
by purified polished brine.
 Exact frequency of backwashing depends on quality of clarified brine.
 If a filter is allowed to operate too long between two consequence back
washers, the cake build up may be too high which means the resistance
to flow will be too high. In such case small amount of brine through the
filter.
 The filtered brine containing approx. 2-3 ppm suspended solids flows to
filtered brine tank.

BRINE POLISNING:-

 The purpose of polishing unit i to remove the final traces of suspended

solids from the vine, to remove all dissolved impurities in ion exchanger
 The polishing unit consists of 4 identical filters 3 are in line and 1 in the
washing.
 These filters are cloth filters, which contain PP filter bed suspended on a
frame.
 Inside a rubber lined rectangular vessel.

WORKING OF POLISHED FILTER

 By means of pump pressure, the brine is forced thorough beds and the
solids are retained on the outer surface.
 The discharged channel is provided in the upper part of the filters
 The filter brine is discharged via this channel to the polished brine tank.
 Due to the retention of solids on the precoat over the beds a filter cake
builds upon the precoat over outer surface of the beds.
24
  The pressure drop across the filter increase with increasing filter cake.
 Normally one filter is backwashed after 48 hours.

PRECOATING

 To achieve good filtration and to avoid plugging of microscopic pores of

filter beds by very fine suspended solids a precoat is applied on the
outside of such candle before filtration is started.
 For this purpose a precoat suspension of a-cellulose is prepared in
precoat tank.
 The solution is agitated by air agitation precoat is applied on the surface
at the RP cloth
 From the polished brine tank the brine is pumped to Cl2 recuprator where
the brine is heated by hot Cl2 from cell and the through the brine
recuprator where it is further heated to 70°C before it goes to ion
exchange column in the plate type heat Exchanger.

C. SECONDARY BRINE TREATMENT:-

 In secondary brine treatment plant treatment followed as below

 Brine purification by ion exchange,
 Cell house,
 Chlorine drying,
 Hydrogen drying,
 Chlorate destruction,
 Free chlorine removal
 Sulphate removal system.

Brine purification by ion exchange:-

 Brine coming from the polished brine tank 05 D02 through polished
brine pump 05 P05 a/b discharge enter to Cl₂ recuprator where brine get
heat from the chlorine gas coming from the cell house and temperature
of outlet is near by 65ᵒC
 Outlet of chlorine recuprator enter to brine recuprator where heat gain
from lean brine and brine temperature rise to 75ᵒC
 This brine enter to ion exchange column which have capacity of 980 ppb.
It content rasine bed which attract the cation
 Ion exchange column 06 C01 A/B can operate in series, also get
regenerate in following stages
25
  Isolation, brine displacement backwash, acid injection, acid
displacement NaOH injection, NaOH displacement, water displacement
and operation
 O/L of ion exchange column sent to pure brine tank which is content <20
ppb impurities.
 Pure brine is sent to pure brine over head tank through pure brine pump
via heat exchanger which is increase temperature to 88 C.
 From the overhead tank brine sent to cell house.

CELL HOUSE
ELECTROLYSIS PROCESS:-

 Simultaneously Production of chlorine, caustic soda solution & hydrogen

from aqueous solution of alkaline chlorine by application of direct
current commonly know as "electrolysis of alkaline" has been widely
adopted in chemical industry.

ELECTROLYSIS OF CELL:-

 Some chemical reaction can be made to be occur via. ionic mechanism

by the application of energy to an electrical cell
 Central to the application of any cell is occurrence of ionic reaction
which produces or consumes electrons of isolated phases on the cell.
These phase are called electrodes must be good conductors. The
electrical circuit therefore the cell is completed by electrolysis which
support change transfer by ionic conductin. The electrodes at which an
electron consuming reaction is…

H₂O+ e⁻→⅟₂ H₂+OH⁻

 The direction of electron flow in external circuit is always from anode to

cathode.

PRINCIPLE OF MEMBRANE CELL:-

 The ion exchange membrane is the heart of the membrane cell system. It
acts as partition between the anode & cathode compartment of the cell.
 The efficiency of membrane as a separation device between anode 7
cathode compartment defines the current efficiency of the cell.
 The chemical composition of the membrane based on the fluorocarbon
matrices, defines the range at caustic concentration at which an optimum
26
 performance is given. Membrane is available to produce caustic
concentration up to 33% NaOH with optimum performance & a
minimum 3 years experience are routinely adopted from an economical
stand point
 The ion exchange membrane is impermeable for liquid & gas..It is
actively permeable for actions & passes of OH ions back into anode
compartment if blocked thus allowing a high current efficiency.
 The membrane effectively allows the passage of Na ions only & prevents
the diffusion of anions from the anode compartment to the cathode
compartment, thereby making it possible to obtain NaOH of a very high
purity.
 One faraday of electricity produces an equivalent of Cl₂ in anode
compartment & one equivalent of H₂ equivalent of NaOH in cathode
compartment
 In the actual practice, alkaline feed brine i.e. without addition of HO⁻ is
supplied to cell anions at cathode to form O₂ . In that case one faraday of
electricity will produce less one equivalent of Cl in the anode. This is
because a small amount of electricity is consumed by discharge of OH⁻
 Cl2 gas contains 1.5% volume O₂. In practice it is not possible to avoid
Cl2 generation at anode.
 A small amount part of Cl₂ generated in anode compartment is
transferred to hypo & chlorate anions.
 When anolytes from the cells is acidified, the cell with the equivalent
amount of HCl. The transformed amount of Cl₂ is recovered back.

CHEMICAL & ELECTROCHEMICAL REACTION:-

A.GROSS REACTION:-

 The gross reaction for formation of chlorine, caustic & hydrogen from
NaCl solution can be expressed as follows:-
 Anode:- Cl + e⁻→⅟₂ Cl₂
 Cathode:- Na⁺ + H₂0 + e⁻→ Na⁺ + OH⁻ + ⅟₂ Cl₂
 Overall:- NaCl + H₂0 →NaOH + ⅟₂ H₂ + ⅟₂ Cl₂

27
CELL DESIGN AND FUNCTIONS:-

 More then 140 elements of the electrolysis are suspended in a steel

frame/From current transmission, the individual elements of electrolysis
are divided into 4 groups First 3 of 34 elements each & last of 32
elements.
 The piping is located underneath the cell.
 Titanium is used for anode & nickel is used for cathode.
 The ion exchange membrane is clamped between the half-cells with
interpolated gaskets.
 The half-cells are bolted together by the flange. The current is conducted
from the cell to cell by means of contact strips.
 The brine & catholyte are admitted at the bottoms of the cell. White
anolyte and catholyte are likewise discharged downward via longinternal
stand pipes where the electrolyte overflow to maintain the level in the
cell
 Each element is sealed at the flanges by bottling & insulated to preclude
current transmission. The contacts required for current transmission is
located outside the electrolytes.

MEMBRANE HANDLING & TREATMENT:-

 The membrane must not be punctured, folded crimped or creased before

to use. The membrane should be pretreated to minimize the risk of
mishandling & it should be rolled on the shipping core for transport,
rather than carried by hand supplied.
 Unrolling the membrane for shipping core directly into pretreatment tank.
 Spray-misting membrane for the shipping once the sheet has been
removed from shipping tank.
 Maintaining work environment humidity level above 50% (measure at
25°C).
 Before mounting the membrane it should be soaked for 12hr. in solution
of mg/lit of NaOH. The solution must not contain more than a pm total
hardness.
Mount the wet membrane & keep it wet a water spray The electrolyzer
unit until start up.

28
CHLORINE DRYING:-
 Chlorine gas coming from cell house is content moisture that must
be removed for that chlorine drying followed below procedure.
 Chlorine pass through chlorine recuprator, chlorine cooler and
cooler chiller where moisture removed due to condensation attained
by indirect contact of polished brine, cooling water and chilled
water.
 After that it passes through wet chlorine filter where moisture as
well as impurities is filtrate through candle filter.
 O/L of wet chlorine filter gets dry in drying tower by 98% H2SO4
from top of the tower. Drying tower content arrangement of packing
of poll ring and try tower.
 There is also circulation system of 78% H2SO4 to center of column
via chiller to maintain drying tower temperature as well as 78%
H2SO4 concentration which is sent to liquid dispatch.
 Dry chlorine from drying tower is then pass through dry chlorine
filter and sent to PGW compressor section.

Hydrogen drying:-
 Hydrogen coming from cell house content moisture which is
removed by hydrogen cooler and hydrogen chiller by cooling water
and chilled water.
 Gas and moisture get separated in hydrogen separator and sent to
hydrogen blower and hydrogen compressor section.

CHLORATE DESTRUCTION:-
 Main reaction at anode is ⅟₂ Cl₂ → Cl + e⁻
 But some chlorine is partially dissolve in water form hypochlorus
acid which is dissociate and form chlorate
Cl₂+ H₂0 → HOCI
HOCL→OCl + H
2HOCI →ClO₃ + 2H + 2Cl₂
29
  This chlorate can be destructed by high temperature and low pH
because it is depend on concentration of Cl ion, partial pressure of
chlorine and pH of solution.
 For that anolyte from cell is collected in anolyte tank which is
connected by vacuum tank with dip.
 Anolyte material transfer to chlorate destruction tank by pump, this
tank material is heated in steam heater through acidify pump.
 Heater discharge circulated to anolyte tank by HCI dosing which is
controlled by redox meter
 Destructed chlorine from vacuum tank as well as chlorate
destruction tank is entered to chlorine recuprator inlet
 Moisture in chlorine is removed by chiller and moisture separator.
One trapping provided for hypo section also.
 Brine of anolyte section is transfer to saturator via chlorine removal
and sulphate removal section through lean brine pump.
 Main reaction for destruction of chlorate is….
NaClO₃ + 6 HCl→ NaCl + 3 C1₂ + 3 H₂O

FREE CHLORINE REMOVAL & SULPHATE REMOVAL SYSTEM:-

 Lean brine still content trace of chlorine which is removed by
addition of sodium bisulphate and to control acidity or pH also
added NaOH.
 This formed impurities in form fsulphate is removed by sulphate
removal system.
 Lean brine is collected in dean brine tank is pumped to two heat
exchanger which is heat exchange through SRS brine and cooling
water.
 O/L of heat exchanger is entered to activated carbon filter contain
activated carbon bed to removed free chlorine and to filter brine.
There is HCl and NaOH trapping to control pH.
 This brine pass through guard filter and enter to SRS feed tank from
where is pass through SRS system to remove sulphate through
membrane at high pressure.
 Rejected brine is sent to PAP plat where this impurity is removed
by addition of CaCl₂.

30
 STANDARD PROCEDURE FOR Cl2 BOTTLING:-

EMPTY CHLORINE TUNNEL UNLOADING AND CHECKING:-

 If weight is beyond 650 kg then we put it separately and the rest
under physical conditions particularly external surface value
condition, spindle, plug, etc.
 These tunnels are put under hypo for removing the chlorine gas or
other gases (sniping).
 After sniping the empty tunnel we open both valve and checked.
 Plug is opened and inside of the tunnel is checked with help of bulb.
 After checking everything tunnel is fit for filling
 The empty tunnels which are for hydro test is sent to hydro testing
area as per gas cylinder rules act.

FILLING PROCEDURE:-
 Each balance for tunnel filing should be calibrated in each shift by
instrument and process person with standard weight tunnel.
 Filling operator should ensure that tunnel is fit for filling If he
founds anything abnormal then he should immediately stop filling.
 In each tunnel 900kg liquid chlorine is to be filled by operator in no
case net weight of tunnel should exceed 905 kg.
 After filling the tunnel both valves should be properly closed with
valve key and after closing valve operator has to check leakage with
ammonia torch.
 After disconnecting the joint tunnel has to be lifted with help of
hoist.
 An operator has to check weight on hanging balance put up on each
hoist.
 Weight indicated by hanging balance and weight scale should be
equal.
 Operator has to write tunnel number, gross number, tare weight, net
weight, filling starting time and stopping time, balance number and
calibration report in filling point.

31
  During tunnel filling operator has to check surface temp. of chlorine
tunnel if temp is increasing then tunnel is to be sent for hypo and
next hydro test.
 Lead washes should be removed from valve after completion of
tunnel filling.
 In case of chlorine leakage while leaching while filling immediately
filling pipeline isolation valve is to be closed and emergency blower
is to be started of suck chlorine dispersed in ATM also foreman and
shift incharge has to be informed. Operators should know how to
attend chlorine leakage during filling with the help of safety
equipments like breathing apparatus, on line air mass etc.

CHLORINE BOTTLING HANDLING:-

 Filling chlorine tunnels are to be approved by QCD with respect to
net weight chlorine leakage.
 Only those chlorine filled tunnels are to be offered for dispatch
which is filled for at least 24 hours before dispatch.
 After QCD approval each and every tunnel should be fit with stud.
 Tunnel should be painted properly if not they should be dispatched.
 While loading the filled chlorine tunnel in truck, operator has to see
weight in hanging balance put on crane.
 Dispatch operator has to see chlorine leakage in each tunnel also
tunnel physical condition should be checked.
 Dispatch operator has to report tunnel number, weight of hanging
balance and tunnel physical condition in dispatch.

32
 CAUSTIC CONCENTRATION UNIT:-

 The concentration of caustic soda obtained either from reaction of

soda ash and line from the electrolytic decomposition of brine
present certain distinct problems
a) Caustic have high elevation in boiling point which causes a
large loss of availabletemp.dif.in multiple effect evaporators.
b) The conc. Solutions are highly viscous reducing sharply the heat
transfer rate in natural circulation evaporators.
c) Caustic have detrimental effects on steel, causing caustic
embrittlement.
d) Caustic solution may require the removal of large quantities of
salt as solution becomes concentrated.
 In order to avoid caustic embrittlement of steel, solid nickel tubes
are used along with nickel clad plate-steel bodies Auxiliary
equipment which comes in contact with caustic solution is also
nickel clad.
 Due to costliness of nickel as a material of construction however it's
important to design this class of equipment for as small heating
surface as possible. Since the liquid film heat-transfer coefficient is
a function of velocity of caustic solution thought the tubes; a high
velocity must be established in order to obtain a large transfer
coefficient in tubes
 The concentration of caustic coming out of cell house is 32%,
which is the concentration in caustic concentration unit.

CCU CAN BE DIVIDED INTO FOLLOWING UNIT:-

A. Caustic Evaporation Unit,
B. Caustic Concentration Unit,
C. Caustic Flaking & Pilling Unit.

A. CAUSTIC EVAPORATION UNIT:-

 These units consist of 3 evaporators placed in series

33
  These evaporators are falling film type evaporator in which caustic
is evaporated by means of steam.
 Caustic (32-33%) coming from the cell house is stored into the
intermediate tank & then fed to the 1st evaporator.
 Caustic is fed to the tube side which falls as a film inside the tube.
 This caustic film is heated by means of steam on shell side.
 The concentration of caustic after 1st stage is 36%.
 This 36% concentrated caustic is fed to the 2nd evaporator.
 After 3rd evaporator the concentration is increased to 49%
 In 3rd evaporator the press. Is maintained at 10 bars while 1 st & 2nd
evaporators are operated under vacuum.
 The temp. of 1st evaporator is 65 °C. The hot steam is entered in the
3rd evaporator 2nd & the 1st is operated under vacuum. This type is
called as backward flow evaporator.
 This caustic lye after 3rd evaporator unit is 49% is stored as lye
product.
 For the mfg. the flake or pills this caustic lye is used as a raw
material.

FEED:-
NaOH :- min. 32% by wt
Na₂CO₃:- max.500 ppm
NaCl:- approx. 50ppm
NaClO3:- approx. 10ppm
Temp.:- 75 °C & press. 3 bar

PRODUCT:-
NaOH :- 49%
Pressure:- 4.7-5.3 bar
Temp. Approx.:- 45-85 °C

B.CAUSTIC PRECONCENTRATION UNIT:-

34
 The plant is developed for concentration of caustic from 49%-99%. The plant
is divided into following parts:-
A. Caustic preconcentration;
B. Caustic concentration;
C. Heat transfer salt system.
 The feed caustic 49% is fed to preconcentration by pump which is heated by
vapour. The preconcentrator concentrates the caustic upto 58%. It is then fed
via 58% NaOH pumps to final pumps to final concentrator and becomes
98.7-99% NaoH.
 In order to prevent corrosion of nickel equipment a 10% sugar solution is
collected in sugar dissolving tank & conveyed by sugar meter in pump.
 The high temp. Heat transfer salt system consists of a salt burner with
combustion air preheater to heat the molten salt above 400 °C. Which is
circulated through the system.
consist by a salt pump. The automatically operating furnace, natural
gas or hydrogen gas burner unit is mounted in vertical (position on
the top of the salt heater.

HEAT TRANSFER SALT (MOLTEN SALT):--

 KNO3 :-53%
 NaNO2:- 40%
 NaNO3 :-7%

C. CAUSTIC FLACKING UNIT

 Caustic melt flows through final concentration into the dipping vat
of flaker.
 The principle of flake is based on rotating water cooled cylinder
dipped 10-20 mm in to a vat which is constantly added with a
product
 The film of 8-13mm thickness, which forms on the upper surface of
cooling cylinder, crystallize and cooling is done to a temp. about
55-60 °C during rotation of cylinders.

35
  The NaOH layer is scarped off from the cylinder by scraping knives
During the scrapping of the layer on the cooling surface breaks into
flakes.
 For cooling purpose of product water is used. This cooling water
tangentially sprayed into inner surface of the cooling cylinder by
means of nozzle.
 The flakes are cooled with a closed casing thus avoiding the caustic
dust which forms during scrapping of NaOH film. The flakes are
the packed in airtight bags thought the bagging device.
D.CAUSTIC PRILLING UNIT:-

 The plant is developed for the concentration of NaOH 97.8%-99.2%.

 The NaOH is concentrated to 97.8% by flash evaporators. The 97.8% NaOH is
pumped by submerge caustic melt pump to head tank located on the top level of
the system.
 From head tank, the caustic melt flows by gravity into the rotating basket of pilling
tower. The amount of holes in spray basket designed such that at a spray basket &
clog them.
 This requires periodical cleaning of spray basket with water.
 The caustic droplets are falling from spray basket to bottom in direct contact with
ambient air.
 The pills are cooled down that much they solidify in lower part of prill tower &
later on transported via. Prill duct to prill cooler.

PRILLS PRODUCT HANDLING:--

 In the prill cooler the pills are cooled down to a baggage product by
transporting it through the water cooled rotating cylinder and through bucket
elevators the pills are transported to vibratating screen. In this screen product
is eliminated & collected in shell. Those off space product are dissolved in
dissolving tank. The marketable product is led to pills silo.
 To prevent it from picking up moisture from ambient atm., screen to prill
hopper is blanketed with dry air.

36
 EQUIPMENT DETAILS

BRINE SATURATORS
 NOs:- 3
 Capacity:- 150m3
 MOC :- C.S.R.L.(Carbon Steel Rubber Lined)
 Diameter :- 5.5m
 Height :- 6.5m
 Medium:- Brine (NaCl solution)
 Temp. :- 85 °C

 The brine saturator is a cylindrical tank with conical bottom. The lean brine
coming from cell house is introduced at bottom part of tank through a
submerged pipe line & the overflow goes to purification.

BRINE PRECIPITATION TANK

 No.:- 3
 Capacity:- 110m3
 M.O.C:- C.S.R.L. (carbon steel rubber lined)
 Diameter :- 42m
 Height:- 8.6m
 Medium :- Brine (NaCl solution)
 Temp. :- 85 °C

 Precipitation are also same in appropriate as the brine saturator from outside.
Inside these tanks there is provision for air agitation & by gravity flow the
brine travels in forward direction from downward.

37
BRINE CLARIFIER
 NOs.:- 2
 Capacity:- 4600m3
 M.O.C.:- C.S. epoxy painted
 Diameter:- 35m
 Height:- 4.26m

 Clarifier is a huge suspended tank in which the brine containing suspended

particles is introduced at the centre through a well clarified brine is recovered
through overflow. The thick sludge-is coming out from the bottom. It also
contains a slow speed rotating. This moves at the rate of 4 RPM.

ROTARY VACUUM DRUM FILTER(RVDF)

 NOs.:- 2
 M.O.C:- Special Alloy
 Medium:- Brine (NaCl solution
 Flow rate:- 9m3/hr

 The equipment is mainly used for separating the solution from the sludge. It
contains a filter cloth which is covering the bottom. The drum is vacuumized
from inside to suck the moisture & the filtrate cake is scraped with the help
of doctor's knife.

ANTHRACITE FILTER
 NOs.:- 11
 Capacity:- 110m3
 М.О.С.:- C.S.R.L.(Carbon Steel Rubber Lined)
 Dia:- 4.2m
 Height:- 8.6m
 Medium:- Brine (NaCl solution)

38
  It is a simple cylindrical tank with 3 beds of anthracite coal particles with
decreasing the particle size from top to bottom.

BRINE POLISHING FILTER

 NOs.:- 8
 Flow rate:- 75m3/hr
 Working Temp.:- 85 C
 Working press.:- 6bar

 These filters are cloth filter, which contains PP filter beds suspended on a
frame, inside a rubber lined rectangular vessel.

 ION-EXCHANGE COLUMN

 NOs.:- 5
 Capacity:- 220m3
 Media:- Chelating cation-exchange resin
 Dia.:- 3.2m
 Height:- 3.3m
 Medium:- Brine (NaCl solution)

 It is a simple cylindrical tank with inlet at top & outlet at the bottom. It
contains a bed of sodium zeolite for ion-exchange.

CHLORINE DRYING TOWER

 NOs.:- 3
 M.O.C.:- C.S.
 Media:- 98% H₂SO₄

 Inside tower Demişter trays vs packing

 It is a long cylindrical column with demister on the top, trays in the middle &
packing at the bottom. Chlorine flow from the bottom to the top & SO4 is
39
 counter currently contacted with it.H₂SO₄ is used as a media for drying as it
absorbs the moisture from wet chlorine.
 The concentration ofH₂SO₄ decrease here from 98% to78%. There is a
provision for recirculation of 78%H₂SO₄.

HCI REACTION TANK

 It is a long cylindrical furnace with top fire provision and divided into three
main operation i.e. reaction, absorption & heat exchange. It is connected to
vacuum pump to bottom. Also rupture disc is provided for safety purpose.
Inside the tower is made of graphite & chlorine sparger is made ceramic &
hydrogen tube is made up of quartz. There is provision for providing spark to
hydrogen during starting up the frame. DM water sprayed to absorb HCl in
the product foam.
 Cooling water is used providing for cooling & the tail gas goes to scrubber.

DUST SCRUBBERS

 It is equipment for dust control of the air coming out of pilling tower. It is
simple gas-liquid conta equipment with PP packing. DM water & outlet goes
to dissolving tank & the exhaust air goes to stacking.

EVAPORATORS
 These are triple effect falling film type evaporators with forward feed &
steam as a heating media in counter motion. The tubes are made up of nickel
through NaOH passes & shell made up of carbon steel.

PRILLS COOLER
 It is a cylindrical vessel mounted horizontally. The pills are cooled with
water passing through tubes. The cooler is floating to help the pills inside the
cylinder due to which bills move ahead.

40
 UTILITIES
 The basic utilities used in the caustic soda plant are as under.
 Process Water, Fire Water, Drinking Water,
 Cooling Water System,
 Demineralized Water,
 Chilled Water System
 Instrument Air, Plant Air & Nitrogen Air,
 Chlorine Unloading Air System,
 Steam

PROCESS WATER
 Process water from captive power plant is piped through to NaOH plant with
200 NB main header Branching to 150 NB headers for cooling tower make
up & 80 NB header for consumers in caustic soda plant.

DRINKING WATER
 The water from over head from PAP after passing through filter & CS ionizer
is used for drinking water Drinking water have capacity of 10 cubic meter.

FIRE-FIGHTING WATER
 The fire fighting water system for caustic soda plant is designed based on 270
m3/hr of fire water required.
 This water will be supplied from power plant at 8.2 kg/hr pressure.

COOLING WATER SYSTEM

 The cooling water system consist of induced draft cross flow cooling tower
with two different pressure level of circulation with set of pumps no. 1,
emergency cooling water pump, side stream filtration unit & chemical dosing
system.
 Also there are tank providing for the addition of 98% H2SO4 &Na2SO4
 One set of pumps are provided for cooling water to all process coolers at high
pressure such pump is designed for 370 m3/hr are provided for following unit.
41
  The cooling water return from all compressors is joined directly to high
pressure cooling water return to header The cooling water return header is
taken to individual cell basin & the suction chamber.
 Screens are provided for removal of large size Substance Each cell provided
with fan. The cooling tower basin is provided with a level indicating
controller to supply make up water based on level in the pump.
 A part of stream cooling water basin
 The gravity filter is designed for a flow rate of 100 m3/hr with inlet solid of
50 ppm & outlet turbidity of 3.5 ppm
 As the filter bed collects dirt during the filtration, the pressure drop goes up
& backwash flow starts & washes the filter bed at 460 m3/hr for period of 3
minute.

CHEMICAL DOSING
 To maintain the quality of the circulating cooling water is important to
reduce the corrosion in the heat exchanger, to avoid scale formation on tube
& to effectively stop the growth of algae & other biological.

D.M.WATER
 D.M.water is used in the caustic soda plant for cooling steam generation etc.
purposes. DM water is prepared in DM water plant by ion-exchange method.
The raw water is coming zanor GIDC which is surface water.

PRETREATMENT
 The water coming from zanor GIDC is quiet pure which does not need any
pretreatment. The raw water contains turbidity is nearly 850 NTU.

AERATION
 The raw water contains micro-organisms, which is anaerobic type. Thus we
are adding O2 by reaction method. Aeration tank is an open tank consisting
of agitator. The water is fed at the bottom of the tank Due to oxygen in the
atmosphere it will dissolve in the water & this micro-organism is recovered.
Now water is fed to the clarifier for clarification purpose.

CLARIFICATION

42
  The clarification tank is having capacity of 4500m3 water from aeration tank
contains suspended solids which do not settle due to gravitational force thus
we are adding flocculating agent such as ALUM, CATAFLOR,
MAGNAFLOC. The flocculating agent accumulates the solid particles &
settle down at the bottom. The overflow & settled solids are drain off After
clarification the turbidity of the water decrease to 20 NTU. The clear liquid
will go for the filtration purpose.

FILTRATION
 Mainly two filters are used in our plant.
 Dual media filter:-- In this filter water coming from clarifier containing 20
NTU turbidity. We are decreasing it to <5 NTU. The top layer of sand, the
middle one contains layer of anthracite & the bottom one contains gravel for
support

ACTIVATED CARBON FILTER

 In this ACF the order, color, organic matter are removed. In this filter
turbidity decrease up to <0.1 NTU.

REFRIGERATION UNIT FOR CHILLED WATER SYSTEM

 This system consists of a package unit, water tank; pump which pumps the
water ro chilled water gets cooled from 13.6 °C to 10.C Freon -11°C is used
as a chiller in refrigeration unit.

INSTRUMEN AIR. PLANT & NITROGEN SYSTEM

 Compressed air from compressor unit at approx. 7 bar is supplied partly to
plant as plant air to air & partly to air drying unit both these are plant air
reaction.

CHLORINE UNLOADING AIR SYSTEM

43
  Compressed air from compressor unit at approx. 13 bar is to fed to the plant
through air receiving tank. Required pressure for chlorine unloading will be
maintained by valve located on air supply lines. Non return valve is provided
on air compressors through main utility system.

STEAM
 Boiler unit at 15 TPD suitable for either natural gas or fuel oil is tapped from
fuel oil day tank of PAP boiler.
 Initially steam was supposed to be supplied from this boiler
 After commissioning of power plant, there is provision to use steam from
power plant as well as boiler.
 Steam at 13 kg/cm3 is fed to the PAR The better limit pressure of steam to
PAP is 5.5 kg/cm?.
 Low pressure steam is required by heat exchanger in brine &catholyte
system of approx 2 kg/cm. Low pressure steam is derived from high pressure
steam by pressure controlled system.
 This steam is superheated by spring DM water directly into stem line by
spray nozzle.
 After pressure reduction & desuperheating condensate will be removed in
steam desuperheater & LP steam will be supplied to LP consumer in brine &
to chlorate distribution unit.

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 WASTE & WATER TREATMENT

 Mainly water used in caustic plant at rate of 2150 MT/ Day NaoH i.e. 5.23
m3 water used per ton of NaOH produced.
 Now the liquid effluent produced is 781 m3/day.
 The process is continues so no batch wise production is there. There is no
separate energy meter installed as very small amount of effluent is produced.
 A separate flow meter is installed which indicate the flow rate of treated
effluent directly going into the sea via pipeline.

METHOD OF TREATMENT

 The effluent produced from NaOH plant mainly contains wash water & cleaning
water from safety showers & leakage
 It mainly contains caustic & has pH which is basic by nature.
 So generally it is neutralized by HCL solution up to pH 7 & then disposed to the
lagoon.
 If more amount of acidity is there in the effluent then it is send to ETP.
 Basically this ETP contains 2 reactors in which effluent is treated with milk of
lime, then pH is maintained from 7-8 & the liquid is sent to the lagoon & sea by
pipeline.
 The treated effluent is introduced in such a way that the marine life is not disturbed.
It is introduced 4 km inside the sea.
 The solids from the clarifier go to the gravity decanter from where the recovered
liquid is recycled.
 The Solids are dumped into a pit & covered with 2-3 mm thick PVC sheet for
around 10 years during which they are decomposed & become harmless for
environment.

45
 D.M. WATER
Block diagram
Salt Lean Brine
310 GPL Brine 10% Na2CO3

10% NaOH

Precipitation
tank

Flocculent

Saturator
Mixing tank

Clarifier Brine

Anthracite

filter Clarifier

Sludge

celleous

Anthracite Brine Pre coating

Police Brine

Skibbler filter

28 % NaOH Ion-
-ve +ve Exchanger

310 GPL Brine

32%
NaOH &
H2
210 GPL Brine & Cl2 46
 MATERIAL BALANCE

Saturator:-

 Input:- 1134 ton Salt + 206.65 ton lean brine (220 GPL)
 Output:- 1340.65 ton brine (310GPL)
 Flow rate of output brine:- 180.19 m3/hr

Precipitation tank:-
 Input:- 10% NaOH (0.15m3/hr), 10% Na2CO3 (0.108m3/hr)
 Flow rate of input brine:- 180.19 m3/hr
 Flow rate of output brine:- 180.44 m3/hr

Mixing tank:-
Neglect the flow of flocculants in mixing tank
 Flow rate of input brine:- 180.44 m3/hr
 Flow rate of output brine + Flocculants :- 180.44 m3/hr

Flow rate of input and output is nearly same in Clarifier, Anthracite filter,

Skibbler filter, pre coating and ion-exchanger.

47
Cell house:-
Power consumption in cell house
Faraday’s second law of electrolysis states that, when the same quantity of
electricity is passed through several electrolytes, the mass of the substances
deposited are proportional to their respective chemical equivalent or equivalent
weight. (Faraday cons. = 96487c/mol)
1unit(kAh) = 3.6*106 (Amp*sec.)

1 faraday = 1 gm eq. substance

3.6*106 = ?

Amount of Substance = 3.6*106*(1 gm eq.)/96487

Produce

Cl2= 3.6*106*(35.5)/96487 = 1322.8 gm

H2= 3.6*106*(1)/96487 = 37.6 gm
NaOH = 3.6*106*(40)/96487 = 1492.3 gm

Consume

NaCl = 3.6*106*(58.45)/96487 = 3180.6 gm

Transfer

Na+ = 3.6*106*(23)/96487 = 818.14 gm

48
 REFERENCE

 Outlines of Chemical Technology, M Gopala Rao, Marshall Sittig.(Dryden’s)

 Library of GACL, DAHEJ Complex.
 Encyclopedia of Chemical Engineering.

49