DHARANGADHARA

DHARANGADHARA CHEMICAL
CHEMICAL WORKS
WORKS (DCW)
(DCW) LTD.,
LTD.,

“ MANUFACTURING OF CAUSTIC SODA BY CHLOR ALKALI

PROCESS ”
DCW LIMITED SAHAPURAM, TUTICORIN

Submitted by
ABINESH S (16CHR002)

8/5/19
 INTRODUCTION

 M/s. DCW Limited herein called as DCW operates a Chemical Complex at

Sahupuram, Thiruchendur Taluk, Thoothukudi District with multi - locational and
multi - product facilities.
 The products from this complex range from Industrial Grade Salt, Caustic Soda,
Liquid Chlorine, Hydrochloric Acid, Trichloro Ethylene, Synthetic Rutile
(Beneficiated Ilmenite), Ferric Chloride, Yellow Iron Oxide, PVC Resin.
 As this is a process plant, it has both power and steam requirements and this is met
through Coal based Cogen Power Plant & Oil based Captive Power Plant. DCW
established their Caustic Soda Plant in the year 1958 and the present capacity of
Caustic Soda is 1,00,000 TPA using Membrane Cell Process.
12.07.19
 The chlor-Alkali Industry in DCW produces four main chemicals such as,
The chlor-Alkali Industry in India forms an Important component in Basic
chemicals industry, comprising around 74% of basic chemicals production.The
chlor-Alkali Industry in DCW produces four main chemicals such as,
 Caustic Soda
 Chlorine

 Tri Chloro ethylene

 Hydro Chloric Acid ( HCL)

At Sahupuram, the Plant is designed and engineered by UIL, Mumbai with the
technology from Thyssen Krupp, Germany. The Rated Capacity of the Plant is
to produce 283.0 MT of Caustic Soda /Day when operated at 80.0 kA load with
6 Electrolysers in line.

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 RAW MATERIAL
The three main raw material for the chlor-Alkali products are;
Apart from these we also need Sulphuric Acid (H2SO4), Acytlene gas, etc
to meet the process requirements.
S.No Raw Material Source

1) Salt Salt Pans of DCW

2) Power Coal Thermal Power Plant

of DCW

3) Water Local Sources

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 Chlor-Alkali Plant in the Industry functions as follows:
POLISH AND ION
EXCHANGE MEMBRANE
Brine Filtration ELECTROLYSIS
FILTER Cl2

Na2Co3
BaSo4
NaOH

H2

Triple effect evaporator

NaOH 32%

Heater
30⁰C

32-36 %
36-41%

48.5% Liquid

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 Process Description:
 Common Salt which is the basic raw material is conveyed by trucks to the
Saturation Pit where it is mixed with depleted Brine returned from Electrolysers.
 The Brine solution is concentrated in the Saturation Pit.
 The concentrated Brine is overflowing to the Pumping Tank through strainers and
pumped to the 2 Nos. Precipitation Tank placed in series.
 Treatment Chemicals like Caustic Soda, Soda Ash and Barium Carbonate are added
to the System for the removing impurities like Magnesium, Calcium, and Sulphate
present in the salt.
 This Brine, with dozing of Treatment Chemicals as salted above is continuously
over flowing to Brine Clarifier for settling of impurities, Calcium as Calcium
Carbonate, Magnesium as Magnesium Hydroxide and Sulphate as Barium Sulphate.

8/5/19 ….continued
 The settled impurity as sludge is continuously withdrawn as underflow of the
Clarifier and the clear Brine overflows to the Clarified Brine Tank. This Clarifier
Brine is taken to series of two filtration and IEC purification step for conditioning
before it is fed to the Electrolysers for Caustic Soda Production.
 In the electrolyser the process, membrane cell technology is used
  Saturated brine is passed into the first chamber of the cell where the chloride
ions are oxidised at the anode, losing electrons to become chlorine gas
2Cl− → Cl2 + 2e−
 At the cathode, positive hydrogen ions pulled from water molecules are
reduced by the electrons provided by the electrolytic current, to hydrogen gas,
releasing hydroxide ions into the solution
2H2O + 2e− → H2 + 2OH−
 The ion-permeable ion exchange membrane at the center of the cell allows the
sodium ions (Na+) to pass to the second chamber where they react with the
hydroxide ions to produce caustic soda (NaOH) of 32% lye .The overall
reaction for the electrolysis of brine is thus:
2NaCl + 2H2O → Cl2 + H2 + 2NaOH
 A membrane cell is used to prevent the reaction between the chlorine and
hydroxide ions.
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  Each Electrolyser consists of 103 Elements. Each Element consists of Anode and
Cathode in between Membrane is placed through which Sodium Ion migrating from
Anode Compartments to Cathode Compartments.
 The Chlorine & Hydrogen is cooled and chilled and used for producing
Hydrochloric Acid.
 Remaining Chlorine is liquefied and stored in Liquid Chlorine Plant. Remaining
Hydrogen is used as fuel in Ilmenite Plant.
 The 32% Lye is concentrated in Caustic Evaporation Unit to get 48% concentration
and marketed. For Concentrating 32.0% Caustic soda Lye into 48.50% Caustic soda
Triple-effect Falling Film Evaporator supplied by Betrams.
 By using the steam in evaporator 32.0% lye is concentrated to 48.0% lye. This
48.5% Caustic soda lye converted into 98.0% as flakes and or solids as per the
customer requirements.

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  The Solid Caustic Soda is obtained by evaporating the water content in Caustic soda
lye using Salt Heating Unit where the Molten Salt is used as Heating Media for
evaporation, which in turn is heated in Furnace oil fired Heater.
 The Molten Caustic Soda obtained from Salt Heating Unit is partly filled in drums
as Fused Solid and partly for making Flakes with the use of Flaker which is
Rotating Drum fitted with knives to get Caustic Soda Flakes for sales which are
packed in HDPE bags

APPLICATIONS OF CAUSTIC SODA & TRICHLORO ETHYLENE

Caustic Soda Trichloroethylene

 Used as a solvent, a refrigerant and
 Paper and pulp in dry cleaning fluid
 Dye  Main use of trichloroethylene is as
 Soap and detergents an industrial degreaser to remove
 Inorganic chemicals
grease from metals.
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8/5/19
 PART – A
PROJECT TITLE
ON

EFFICIENT CONVERSION OF POST CONSUMED PET WASTES INTO

VALUE ADDED PRODUCTS”

PROJECT MEMBERS:
1. R.GOKULAPRIYA(16CHR027)
2. S.ABINESH(16CHR002)
3. R.ABDULKHADER (16CHL113)

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 OBJECTIVES OF THE PROJECT

PET is an polymer product of Ethylene glycol (EG) and Terephthalic acid,

where it derives from petroleum products, since it is an example for excellent
type of thermoplastics, Since it has various industrial applications like
packaging of food, automobile parts and drinking water bottles.

Plastic recycling is very important for at least two main reasons

 First, to reduce the increasing volumes of plastic wastes and
 Second, to generate value added materials.

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 MAJOR APPLICATIONS OF WASTE PET

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 METHODOLOGY
Chemical recycling process is employed here in which the PET undergoes
depolymerization, by which the polyethylene terephthalate is converted into
its monomer. The alkaline hydrolysis type of reaction is used for the
depolymerisation process, reaction, where the main raw material of PET

i.e. TPA (Terephthalic acid) is recovered as the product as an outcome.

Alkaline hydrolysis method is the efficient method for this process, as it does
not give out any type of toxic chemicals during the reaction.

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 PURPOSE OF OUR PROJECT
CURRENT SCENERIO OF RECYCLING
Currently, Mechanical compression of the waste is employed and remelted to
produce polystyrene and low graded plastic bottles.

OUR PROJECT AIM:

Though the waste is recycled into different technique, the petroleum product at
the end of the day goes to earth soil after its usage. It affect the environment in a
crucial manner in later stage.

The recycled product of Terephthalic acid (TPA) is further converted chemically by

various reactions, then it can be used as a additives for various products to increase
the physical, thermal and chemical properties of that product.

It is also used as an additive product for cement, highway asphalt tar and due to its
high plasticity and thermal property, it can be used for adhesives and paint industry.

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 GOAL OF OUR PROJECT

 Direct esterification of the obtained TPA and 2-ethyl-1-hexanol will

yield the product of dioctyl terephthalate or DOTP. This compound can
increase the mechanical properties and flammability of specimens.
 Further research will be done after the depolymerization process to
find the efficient way to dispose the TPA depolymerized from PET, in
an economical and eco friendly manner.

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 REUSE, RECYCLE FOR BETTER FUTURE…..!

8/5/19