SaadJutt

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Table of Content:
Primary Brine
 Rock salt
 Saturator
 Settling pit
 CaCl2 pit
 Common pit
 Reactor A
 Settler A
 Reactor B
 Settler B
 Storage Tank D-5060
 Leaf Filter
 Storage Tank D-5070
 Heat Exchanger
Secondary Brine
 Resin Tower
 Working Principle
 Material of Construction
 Regeneration of Resin
 Storage Tank .
Electrolysis Chamber
 Header Tank
 Heat Exchanger
 Electrolysis membrane
 Storage Tank
Dechlorination Chamber
 Vacuum Dechlorination
 Chemical Treatment
 Activated Carbon

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Evaporator
 Storage Tank (32% NaOH)
 Evaporator EV-201
 Shell And Tube Heat Exchanger E- 202 & E-203
 Shell And Tube Heat Exchanger E-204 & E-205
 Steam Ejector
 Condenser
 Steam tank collector
 Shell And Tube Heat Exchanger E-206
 Tank (50% NaOH)
CSP
Furnace
ETP
Laboratory
Valves

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Process of Primary Brine:
In Primary Brine, we remove the impurities present in brine. The whole Process is
discussed as below
Rock Salt:
The Rock Salt contains not only pure NaCl but also contain many impurities.
Composition of Rock Salt:
Sodium Chloride (NaCl 97% w/w
Calcium (Ca+2
0.21% w/w
Magnesium (Mg+2
) 0.06% w/w
Sulphate (SO4-2
) 0.09% w/w
Potassium (K+
) 1.7ppm
Strontium (Sr+
) 1 ppm
Silicon dioxide (SiO2) 5 ppm
Aluminum (Al) 0.2 ppm
Iron (Fe+2
) 1 ppm
Manganese (Mn) 0.5 ppm
Nickel (Ni) 0.05 ppm
Iodide (I-
) 0.5 ppm
Fluoride (F-
) 1 ppm
Chromium (Cr), Molybdenum (Mo) 0.5 ppm
Insoluble 0.69%
Moisture 0.97% w/w
Saturator:
The first section of primary brine is saturator where two unit are present (in which
one is stand by) .In Saturator, we added rock salt, water and depleted brine.
Depleted brine coming from the dechlorination section enters the saturator through
5 nozzles .Water is added through the pipe and salt is added to the top of the
saturator.
Slaps:
To prevent the Nozzles of the depleted brine Slaps are inserting in the saturator (So
that the salt is not directly strike the nozzles).
STAINER:
Stainer is present in the saturator which is used to remove the insoluble impurities
(paper,Raper etc).
Purpose:
The Purpose of saturator is to increase the concentration of brine. The depleted
brine (coming from the dechlorination section) concentration is 190-210g/L and
saturator increases its concentration up to 290-310g/L which is required.

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Dimensions
Saturator DS-510
 Length = 8m
 Width = 6m
 height = 6.5m
 Volume = 312m3
Specifications:
 Depleted Brine Flow rate = 100m3/
 Depleted Brine PH = 7-8.5
 No of Nozzles = 5
 MOC of Nozzles = FRP coated PVC .
. 1) FRP Is stand for Fiber Reinforced plastic
2) PVC is stand for Polyvinyl Chloride
 Distance between Nozzles = 5ft
 Make up water type = Raw Water
 Length of Nozzles = 5m
 Diameter of Nozzles = 4inch
 Hole dia of Nozzles = 18 mm
 Holes in strainer = 365
Parameters:
 Concentration of
Saturate Brine = 290-310 g/L
 Temperature = 700
C
Outlet:
The outlet of saturator is enter in to pits
1) Settling pit
2) Calcium Chloride Pit

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Settling pits:
The brine is added in to the settling pit. There are two settling pits (In which one is
stand by).The impurities is settle down due to the effect of gravity and there settling
time is approximately 18 hours. After that it is (brine) is going to the common pit and
the impurities are remaining in the settling pit. When the impurities fulfilled in the
settling pit, then we clean the settling pit and use the settling Pit B.
Calcium Chloride (CaCl2) Pits:
The other line of saturator is going to the calcium Chloride pit.
There are three pits
1st
pit contain brine.
2nd
pit contain CaCl2..
3rd
pit is stand by.
Purpose:
The purpose of Calcium Chloride pit is remove the sulfates impurities present in
brine.
Process:
The sulphate range in Brine is 13 -14 g/L. When we add CaCl2 (in excess 3-4 g/L) in
brine the concentration of sulphate s is reduced (8-9 g/L.).In Calcium chloride pit we
added Calcium Chloride which is coming from the ETP(effluent treatment
plant)which is used to remove the sulfates .The impurities is settle down due to the
effect of gravity . When the impurities fulfilled in the Calcium Chloride pit, then we
clean the Calcium Chloride A and use the Calcium Chloride Pit B. Then brine is going
to the common pit through Centrifugal pump A and B in which one pump is stand by.
Reaction as Follow
CaCl2 + Na2SO4 → CaSO4 + 2NaCl
Common pit:
The brine is entering in to the Common pit through both Settling pit and Calcium
Chloride pit. Then Brine is moved through Centrifugal pump and enters in to the
reactor A and some quantity of the brine is recycled in to the saturator through
recycle valve.
Reactor A:
After the brine enters in to the reactor A, then we add Barium Carbonate (BaCO3)
through Barium Carbonate tank. The reaction is occur between Barium Carbonate
(BaCO3) and brine to produce Barium Sulphate (BaSO4) and Sodium Carbonate
(Na2CO3) . Barium Sulphate is impurities and sodium Carbonate act as a Catalyst and
totally sulphate are removed.

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Reaction as follow
BaCO3 + Na2SO4 → Na2CO3 + BaSO4
Settler A:
The solution enter in to a settler A in which we add Nalco (which act as a
flocculent).Nalco is help to settle down the impurities of Barium Sulphate and the
brine is present in upper portion of settler A. The Barium sulphate is drain in to the
recovery pit and brine is going to the level tank. The Volume of Reactor is 50m3
.
Reactor B:
The brine is move from level tank to reactor B through centrifugal pump A and B (in
which one pump is standing by). We add Caustic Soda (from BMR 2) and Soda ash
(From Soda ash tank) in Reactor B.
Caustic Soda (NaOH):
Caustic Soda is used to remove the impurities of Magnesium present in Brine. The
reaction is occur between Caustic Soda (NaOH) and Magnesium Chloride (MgCl2) to
produce Magnesium Hydroxide (Mg (OH) 2) and Sodium Chloride (NaCl).
The reaction is occur in Reactor B as follow
MgCl2 + 2NaOH → Mg (OH) 2 + 2NaCl
Soda Ash (Na2CO3):
Soda Ash is used to remove the impurities of Calcium present in Brine. The reaction
is occur between Soda Ash and Calcium Chloride to produce Calcium Carbonate and
Salt (NaCl).
The reaction is occur in Reactor B as follow
CaCl2 + Na2CO3 → CaCO3 + 2NaCl
Settler B:
The solution is move from Reactor B in to a settler B in which we add Nalco(which
act as a flocculent).Nalco is help to settle down the impurities of Magnesium
Hydroxide and Calcium Carbonate and the brine is present in upper portion of settler
B.The Magnesium Hydroxide and Calcium Carbonate is drain in to the recovery Pit
and brine is going to the Storage tank D-5060 A & B.
Storage tank D-5060:
The Brine is store in storage tank D-5060 which is coming from Settler B and move
towards the Leaf Filter through Centrifugal pump A and B in which one pump is
stand by.

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Leaf Filter:
The Brine is entering the Leaf Filter and there is common inlet of all filters.
The filter outlet consists of three lines.
One line is going to the precoated tank (in which we add Arbo Cell) and recycle to
leaf through centrifugal pump A& B (where one pump is stand by).
Second line is going to guard filter and the outlet of guard filter moved towards
storage tank D-5070.
Third line is recycled to the tank D-5060.
 There are 6 Leaf Filter in which 4 leaf Filter contains 13 Leaf and 2 leaf Filter
Contain 17 leaf. The leaf is made of Teflon.
STORAGE TANK D- 5070:
The brine is stored in D-5070 tank which is coming from the guard filter. The brine is
move towards the plate and frame Heat Exchanger through Centrifugal Pump.
Heat Exchanger:
The Heat Exchanger is used in this process is plate 8and frame Heat Exchanger. The
brine is enter in to plate heat exchanger which is coming from the Storage Tank D-
5070.After passing the Heat Exchanger the brine outlet temperature is reaches 50 to
60o
C at 3bar pressure and the impurities(Ca,Mg) present in brine remaining only 6 -8
ppm.
Plate Heat Exchanger:
A plate heat exchanger is a type of heat exchanger that uses metal plates to
transfer heat between two fluids. This has a major advantage over a conventional
heat exchanger in that the fluids are exposed to a much larger surface area because
the fluids are spread out over the plates. This facilitates the transfer of heat, and
greatly increases the speed of the temperature change. Plate heat exchangers are
now common and very small brazed versions are used in the hot-water sections of
millions of combination boilers. The high heat transfer efficiency for such a small
physical size has increased the domestic hot water (DHW) flow rate of combination
boilers. The small plate heat exchanger has made a great impact in domestic heating
and hot-water. Larger commercial versions use gaskets between the plates, whereas
smaller versions tend to be brazed.
The concept behind a heat exchanger is the use of pipes or other containment
vessels to heat or cool one fluid by transferring heat between it and another fluid. In
most cases, the exchanger consists of a coiled pipe containing one fluid that passes
through a chamber containing another fluid. The walls of the pipe are usually made
of metal or another substance with a high thermal conductivity, to facilitate the
interchange, whereas the outer casing of the larger chamber is made of a plastic or;
8coated with thermal insulation, to discourage heat from escaping from the

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exchanger.
The plate heat exchanger (PHE) is a specialized design well suited to transferring
heat between medium- and low-pressure fluids. Welded, semi-welded and brazed
heat exchangers are used for heat exchange between high-pressure fluids or where a
more compact product is required. In place of a pipe passing through a chamber,
there are instead two alternating chambers, usually thin in depth, separated at their
largest surface by a corrugated metal plate. The plates used in a plate and frame
heat exchanger are obtained by one piece pressing of metal plates. Stainless steel is
a commonly used metal for the plates because of its ability to withstand high
temperatures, its strength, and its corrosion resistance.
The plates are often spaced by rubber sealing gaskets which are cemented into a
section around the edge of the plates. The plates are pressed to form troughs at
right angles to the direction of flow of the liquid which runs through the channels in
the heat exchanger. These troughs are arranged so that they interlink with the other
plates which forms the channel with gaps of 1.3–1.5 mm between the plates. The
plates are compressed together in a rigid frame to form an arrangement of parallel
flow channels with alternating hot and cold fluids. The plates produce an extremely
large surface area, which allows for the fastest possible transfer. Making each
chamber thin ensures that the majority of the volume of the liquid contacts the
plate, again aiding exchange. The troughs also create and maintain a turbulent flow
in the liquid to maximize heat transfer in the exchanger. A high degree of turbulence
can be obtained at low flow rates and high heat transfer coefficient can then be
achieved.

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Section of Secondary Brine:

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Secondary Brine:
The Secondary Brine is used to purify the brine and convert the impurities (Ca, Mg) 6
-8 ppm to less than 30 ppb.
Unit of Secondary Brine:
A) Three Resin Tower
B) Storage Tank D-5160
Resin Tower:
The brine is stored in storage tank D-5070 and move towards the plate and frame
Heat Exchanger through Centrifugal Pump and enter in to the resin tower with
valves 50 and 54 (in which 54 valve is resetting valve).There are three Resin tower (C-
504 A,B,C)which is present in series. The brine is pass one resin tower to another but
there common inlet is same. After the resin tower it enter into a storage tank D-5160
Working principle:
In resin tower, resin (a crossed linked polymer) is present which is playing a main
role to purify the brine. Bed of spurges is also present in resin tower which contain
120 holes. The diameter of resin is 0.5mm and diameter of spurges is 0.2mm. THE
diameter of resin is greater than the spurge’s diameter so that it cannot pass
through the holes of spurges. Resin is present on the spurges’ in the form of bead.
When we showering the brine into the resin tower, resin absorb impurities (Ca and
Mg) .This process is occur in all three resin tower. And reach the concentration of
impurities (Ca, Mg) less than 20- 30 ppb.
Material of construction
Resin:
Cross linked polymer called resin.
Naturally occurring Resin:
Resin are found in nature in hydrocarbon secretion form. In some countries, people
are still making resin from tree secretion.
Chemically Nature of resin:
The chemically nature of resin is that the ion exchange is positively charged the ion
exchange is cation and if negatively charge then it is anionic
Resin Capacity:
The maximum Capacity measure the total number of exchangeable ions per unit

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mass or volume of resin. It capacity depend upon degree of cross linkage in
polymeric structure.
Process capacity in SCIL (Sitara Chemical Industry Limited):
In our process, resin capacity strongly depends upon the PH, TEMPERATURE OF
Saturated brine and concentration.
Basic Type of resin:
i. Strongly acid (To remove the cations)
ii. Strongly Base (To remove the anions)
iii. Weakly Acid
iv. Weakly Base
Resin used in SCIL (Sitara Chemical Industry Limited):
In resin tower, the resin is made up of Amino methyl phosphonic acid or lewatit
mono plus TP-260 and there is a cross linkage between styrene and divinyl benzene.
The main purpose is removal of magnesium and Calcium.
Lewatit® Mono plus TP 260:
Lewatit® MonoPlus TP 260 is a weekly acidic, macro-porous cation exchange resin
with ch-elating amino methyl phosphonic acid groups for the selective removal of
transition heavy metals and alkaline earth cations. The monodisperse beads are
mechanically and osmotic-ally superior stable. The optimized kinetics lead to an
increased operating capacity compared to ion exchange resins with heterodisperse
bead size distribution. Divalent cations are removed from neutralized waters in the
following order: Uranium (UO22+ Lead > Copper > Zinc > Nickel > Cadmium > Cobalt
> Magnesium > Strontium > Barium >>> Sodium. Adsorption of trivalent cations
takes place, but desorption may be difficult. For instance iron (III) can only be
desorbed by uneconomically high amounts of specific acid dosage.
It is suitable for use in:
 Secondary purification of brine feed to chloralkali membrane cells (traces of
alkaline earth ions are removed after their normal precipitation by
carbonates in the pH-range 8-11) at absence of iron (III) ions and in case of
low demand on Sr and Ba removal.
 uranium removal from crude phosphoric acid
 titanium removal from recycled battery acid
 antimony (Sb) and tungsten (Bi) removal from copper containing electrolytes
 aluminum removal from urea solutions
 fluoride removal with aluminum doped Lewatit®MonoPlus TP 260
 lead and strontium removal from BF4- containing waste water out of PCB
production
 removal of iron (II), nickel and zinc from 5 % gluconate containing metal
working liquid

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In brine purification the operating capacity of Lewatit® MonoPlus TP 260 depends
on the pH-value of the brine. At pH 10 it is approx. threefold of that achieved at pH
7. At pH 10 and calcium content of 5 ppm, a capacity up to 15 g
Ca/l Lewatit® MonoPlus TP 260 (volume of resin in Di-sodium form) is obtained. At a
service flow rate of 20-30 BV/h, the residual calcium concentration is well below 20
PPb. Greater security can be achieved by operating two units of equal size in
series. Lewatit® MonoPlus TP 260 has to be condition with caustic soda solution
after every regeneration cycle/before every exhaustion cycle. After the conditioning
it is in the di-sodium-form and ready to use for the final polishing of chloral alkali
brine feed.
The special properties of this product can only be fully utilized if the
technology and process used correspond to the current state-of-the- art and the
operating conditions are adapted to the individual requirements.
Regeneration of resin:
The efficiency of resin is low (more than 20 -30 ppb calcium and magnesium is
present after the process in resin tower) then it is necessary to regenerate the resin.
Process:
 Washing through Demi water
 Addition of HCl
 Back washing with NaOH
Washing through Demi water:
The first step is to regeneration is to washed the resin through demi water.We add
demi water at the top of resin tower and washed the whole resin tower. In this we
drain 50% water but 50% remain so that resin remains wet. If we not wet the resin it
causes degradation of resin.
Addition of HCl:
After washing through demi water, we add HCl at the top of resin tower. The HCl
remove the impurities of Ca and Mg.
Back washing with NaOH:
Before back washing with NaOH ,we again wash through demi water after the
process with HCl .If we not wash then neutralization reaction occur between HCl and
NaOH and produce salt and water. After washing with demi water, we add NaOH at
the bottom of the resin tower .The NaOH regenerate the resin and make it efficient,
so that it removes the maximum impurities.
Overall Reaction:
1) R-Na +CaCO3 → R-Ca + NaCaCO3
or
. R-Na + Mg (OH) 2 → R-Mg + 2NaOH
2) R-Ca + 2HCl → R-H2 + CaCl2

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3) R-H2 NaOH → R-Na + H2O
Storage tank:
The outlets of resin tower enter in to the storage tank D-5160 and store in it.

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Cellulone Compartment (Electrolysis):
In this section, OUR MAIN PRODUCT Caustic(NaOH) is produce whose concentrated
percentage is 32%.Along with Caustic many side products are also produce such as
Hydrogen( H2),Chlorine(Cl2),Hypo-chloride (HOCl)and depleted brine.
Unit Involve in Cellulone Compartment:
 Header Tank(brine)
 Header Tank (NaOH)
 Plate and Frame heat exchanger
 Electrolysis Membrane
 Storage Tank
Process:
Header Tank (Brine) :
The Brine is move towards the header tank through a centrifugal pump A and B (in
which one pump is stand by) coming from storage tank D-5160.After entering in to
header tank ,there are two further line. One line is coming back to the storage tank
and other line pass through heat exchanger.
Header Tank (NaOH):
The NaOH is entering in to the NaOH HEADER TANK WHOSE PERCENTAGE IS 32%
.We reduce this percentage (29.7%) with the help of water. Then this 29.7 percent
caustic enter in to heat exchanger.
Heat exchanger:
We pass both brine and Caustic in to heat exchanger to gain optimum temperature
and pass it to electrolyzer.
Electrolyzer:
An apparatus in which electrolysis is carried out, consisting of one or many
electrolytic cells. An electrolyzer is a vessel (or system of vessels) filled with an
electrolyte, in which electrodes (cathode and anode) have been placed;
the cathode is connected to the negative pole of the direct current source and the
anode is connected to the positive pole.
There are two compartments Anode and Cathode Compartment.
Process:
The ion-exchange membrane method, have been used for producing caustic soda,
chlorine and hydrogen by electrolyzing sodium chloride solution (in the electrolysis

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soda industry). The principle of the electrolysis of sodium chloride solution in this
method is explained in the following. In the ion-exchange membrane method,
sodium chloride solution is divided in the anodic and cathode sides by an ion-
exchange membrane made of special resin. The ion-exchange membrane used in this
method has a specific characteristic of allowing only cations (positively-charged ions)
to pass through it while not allowing anions (negatively-charged ions) to do so.
Chlorine, caustic soda and hydrogen are produced by electrolyzing sodium chloride
solution with the electricity applied to the solution through the electric terminals
while sodium chloride solution and water are supplied to the cathodic and anodic
chambers, respectively, in the ion-exchange membrane method. As the cathodic
chamber is filled with sodium chloride solution, there are sodium ions (Na+) and
chloride ions (Cl-) in the chamber. When electricity is applied to the solution,
movement of the ions will occur. Since Na+ ions are cations, they will move from the
cathodic chamber, through the membrane and into the anodic chamber, while Cl-
ions will remain in the cathodic chamber, since they are anions. Then, they will move
to the anode, release electrons and become chlorine gas (Cl2) on the anode.
Meanwhile, part of water supplied into the anodic chamber has been broken down
to hydrogen ions (H+) and hydroxide ions (OH-). When electricity is applied to the
solution, hydrogen ions will move to the cathode, acquire electrons on the cathode
and become hydrogen gas (H2). Meanwhile, the hydroxide ions will move toward the
anodic chamber. However, their movement will be blocked by the ion-exchange
membrane and they will remain in the anodic chamber with the sodium ions which
have moved from cathodic chamber. As a consequence, there will be a solution of
caustic soda (NaOH) generated in the cathodic chamber
Outlet of Anode Compartment:
Depleted Brine, HOCl and free Cl2 are generated in to the anode compartment.
Outlet of Cathode Compartment:
Caustic and H2 is produced in the cathode compartment.
Storage Tank:
Then solution of NaOH (32% concentrated) is store in the storage tank and it is send
to the evaporator.
Caustic Soda:
Caustic soda is an alkali salt which is also called Lye. It is the common name of
sodium hydroxide. This name is given due to the corrosive nature of this salt on
animal and plant tissues. It has a wide range of applications. The chemical formula of
sodium hydroxide is NaOH.

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Properties of Sodium Hydroxide:
 It is a white solid which has a melting point of 591K
 It is a stable compound
 NaOH is bitter in taste and has a soapy feel to it
 It is highly soluble in water and moderately soluble in alcohol.
 Sodium hydroxide is strongly alkaline in nature.
Uses of Sodium Hydroxide:
 It is used as a cleansing agent and in the manufacturing of washing soda.
 Sodium hydroxide is also used as a reagent in the laboratories.
 It is used in the preparation of soda lime.

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Section of Dechlorination Chamber:

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Brine Dechlorination:
Removal of Chlorine from depleted brine is called brine dechlorination. Depleted
brine contain 0.3g/l dissolved Cl2 at 3.5-4 PH and 1g/l of HOCl (Hypochlorite ions)
Why Chlorine is Necessary to remove?
It is necessary to remove the Chlorine because
 In primary purification, removal of impurities is very difficult due to presence of
O Cl-
ion.This ion is produce in the anode compartment (reacti;8on occur
between Cl2 and OH) due to following reaction.
Cl2 + OH-
→ OCl-
+ H2O + Cl-
 When Cl2 Content is high then it is easier dissociation of impurities from the salt
during the saturation step.
 Its oxidize ion exchange resin and increase its Consumption
The Cl2 which is essentially removed is available Chlorine.
Dechlorination Step:
Dechlorination accomplished in to three steps
1. Vacuum Dechlorination
2. By Chemical(Na2SO3) Treatment
3. Activated Carbon Absorption
Vacuum Dechlorination:
In this process storage tank emit two line, 75% depleted brine enter in to Vacuum
Separator and 25% depleted brine enter in to DM5050 tank where HCl is added
DM-5050:
In DM-5050 tank 25%depleted brine and HCl is added and the common ion effect is
occur. When brine enter PH is 3-4 and when is come out through this its PH IS
REDUCE 1.5-2.5
At anode Compartment:
H2O + Cl2 ↔ HOCl + HCl
When we add HCl, the Common ion effect is occur and the process is become one
side reaction
HOCl + HCl ← H2O + Cl2
The free Chlorine is passing through Hypochlorite Chamber.

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Common ion effect:
In Common ion effect, in the solution of an electrolyte in water, there exist
equilibrium between the ions and the unionized molecules to which the law of Mass
Action is applied.
According to this law:
AB → A+
+B-
K = [A] [B]/ [AB]
The main purpose of Common ion effect is decomposition of weak electrolyte stop
by addition of strong electrolyte
HOCl → OH+
+ Cl-
By addition of strong electrolyte
HCl → H+
+ Cl-
Then it become
OH+
+ Cl -
→ OHCl
R-5050:
Then the depleted brine pass the decomposer where NaClO3 react with 6 moles of
HCl and form Sodium Chloride, Free chlorine, water, ClO2 at high temperature .The
PH in this place is nil.
NaClO3 + 6HCL → NaCl + 3Cl2 +3H20
After the Decomposer, brine coming back in to storage tank (07-D001)
Vacuum Separator (5010):
The 75 % brine enters in to Vacuum separator in which Chlorine is remove by apply
the Application of Henry Law (provide low pressure and high temperature so that Cl2
gas is dissoluble from the depleted brine. This pressure is reducing with the help of
steam injector. Actually, the brine move in to the cooling tank coming from the
Vacuum separator and enter in to the decomposer and one line of depleted brine
enter in to the storage tank D-5020
Henry Law:
According to this law
“At constant temperature, the amount of given gas that dissolves in a given type and
volume of liquid is directly proportional to partial pressure of that gas in equilibrium
with that liquid “
Or
“Solubility of gas is directly proportion to the partial pressure of that gas”

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Chemical Treatment:
In depleted brine, the chlorine is further removed by chemical means. The Chemical
used is Sodium sulphate .Sodium Sulphate reacts with free Chlorine and remove it by
the formation of Sodium Sulphide and HCl.
Cl2 + Na2SO3 + H2O → Na2SO4 + HCl
After treated depleted brine with Sodium sulphate, it enters in to the line of storage
tank D-5020 AND moves towards Carbon tower through Centrifugal pimp.
Formation of Na2SO3:
We form Sodium sulphate itself. The formation process is as follow;
 First heat the sulphur mud in sulphur furnace and produce SO2 gas.
 There is a Caustic Soda tank present in above section.
NaOH its move downward and SO2 gas upward with the help of blower and the
reaction start which cause formation of Na2SO3 which is a surface phenomenon
2NaOH + SO2 → Na2SO3 +H2O
Activated Carbon:
Before enter the depleted brine; it is necessary to check Chlorine Concentration is
less than 50 ppm. If Cl2 present in excess form then it cause degradation in Carbon
tower or decrease carbon beads
The depleted brine enter in Activated Carbon, de-chlorination mechanism with
Activated Carbon involve is a chemical reaction (it is a misconception that Activated
Carbon remove Chlorine from absorption).The Activated Carbon surface being
oxidized by Cl2, HOCl, OCl-
The reactions are following
C + HOCl → CO+
+ H+
+ Cl-
C + OCl-
→ CO+
+ Cl-
CO+ is oxidized site of Activated Carbon. These reactions occur very quickly .Pressure
drop across Carbon tower is 3 bars.
After these process, depleted brine enter in to saturator brine through Nozzles
(before enter in to primary brine, we increase its ph by addition of NaOH).

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EVAPORATER:
It is used to increase the concentration of solute in a solution and reduce the solvent
concentration.
Main Component of Evaporator:
 Storage Tank (32% NaOH)
 Shell And Tube Heat Exchanger E- 202 & E-203
 Shell And Tube Heat Exchanger E-204 & E-205
 Steam Ejector
 Condenser
 Steam tank collector
 Shell And Tube Heat Exchanger E-206
 Tank (50% NaOH)
PROCESS:
Storage Tank (32% NaOH):
It is storage tank of 32% NaOH is stored and send to the evaporator EV-201.
Evaporator EV- 201:
It is backward falling film evaporator. In which 32% NaOH is added in the tube of
evaporator and heating is provided in the shell side that vapors coming from the
evaporator EV-202 and temperature is about 87 o
C.The concentration of NaOH is
reached 37%. Then NaOH is moved down through span (It is separated NaOH and
steam).Then NaOH is send to heat exchanger through the centrifugal pump A&B.
Shell and Tube Heat Exchanger E- 202 & E-203:
It is two heat exchanger (E-202 & E-203). The NaOH is added shell of heat exchanger
E-202 and NaOH is added in tube heat exchanger E-203. Then both heat exchanger
outlet is mixed and to evaporator EV-202. In the tube side of heat exchanger E-202
NaOH 50% is added that is coming from evaporator E-202 .The shell side of heat

25
exchanger E-203 steam is added that is coming the heat exchanger E-205. Then
steam is send to boiler.

26
Evaporator EV- 202:
evaporator that is coming heat exchanger E-202 & E-203.The heating is provided in
the shell side that vapors coming from the evaporator EV-203 and temperature is
about 113 C.The concentration of NaOH is reached 41%. Then NaOH is moved down
through span (It is separated NaOH and steam ).Then NaOH is send to heat
exchanger(E-204 & E-205) through the centrifugal pump A&B.
Shell and Tube Heat Exchanger E- 204 & E-205:
It is two heat exchanger (E-204 & E-205). The NaOH is added shell of heat exchanger
E-204 and NaOH is added in tube heat exchanger E-205. Than both heat exchanger
(E-204 & E-205) outlet are mixed and send to evaporator. In the tube side of heat
exchanger E-204 NaOH 50% is added that is coming from evaporator E-203 .The shell
side of heat exchanger E-205 steam is added that is coming the steam collector tank
TK-202.
Evaporator EV- 203:
evaporator that is coming heat exchanger E-204 & E-205.The heating is provided in
the shell side by steam that is coming from steam ejector and temperature is about
174 C.The concentration of NaOH is reached 50%. Then NaOH is moved down
through span (It is separated NaOH and steam ).Then NaOH is send to heat
exchanger E-204 in the tube side and steam is sent to heat exchanger E-205 that is
coming from steam collector tank.
Steam Collector Tank:
It is used to store the steam that is coming from upward portion of evaporator EV-
203 and collected in tank.
Shell and Tube Heat Exchanger E-206:
The NaOH is send to the tube of heat exchanger and cooling water is provided in the
shell of heat exchanger. The NaOH 50% is cooled down because tank is made by mild
steel and it cannot bear high temperature that is why it is necessary to cooled the
NaOH which is required.
Storage tank (50% NaOH):
The NaOH of 50% concentration is stored in the tank. The tank is made by mild steel

27
CAUSTIC Soda pearls (CSP):
CSP:
This plant is used to increase the concentration of 50% NaOH to 99% concentration
of NaOH.
NaOH Storage tank:
It is moved through the centrifugal pump and sugar is added in pipe line of nickel
because caustic soda is reacted with nickel so sugar is added in the pipe line and
send in preconcentrater.
Preconcentrater:
The preconcentrater in which caustic soda of 50% concentration is in tube side and
heating is provided in shell side by using the vapors of final concentrater and send to
the condenser and NaOH concentration reached 70% and to the final concentrater.
Condenser:
The condenser in which is entered that is coming from the preconcentrater and
condensed it. To suck the vapors we used the steam ejector which creates the
vacuum. The vapor is entered in the tube side and cooling water is provided in shell
side. The vapors are condensed and store in the storage tank.
Burner Tank:
This tank is used to heat the salt. The salt is entered in the internally coiled and
heating is provided in the shell side. When salt is heated it sent to the final
concentrator.
Final concentrator:
The caustic soda of 70% concentration is entered in the tube and heated salt is
entered in shell side. The temperature is rises and the concentration of NaOH is
reached 99%. The salt again send to the salt tank, the vapors NaOH is send to
condenser and caustic soda of 99% concentration is send to the flanker tank.
Flanker Drum:
The caustic soda 99% concentration is added in the flanker tank. The flanker tank in
a drum is rotated and temperature is 418o
C. The caustic soda is content with drum
caustic soda flakes are form due to high temperature of and compression. The flakes
of caustic soda are stored.
.

29
Furnace:
It is an enclosed structure in which material can be heated to very high temperature. The word
furnace derives from Latin word fornax, which means oven. So, furnace is a device used for
high-temperature heating.
Furnace process in SCIL (Production of HCl)
In the furnace, HCl is produce. The Cl2 is added in the upper part of furnace which is coming
from the storage tank of Chlorine and hydrogen is also added in to the furnace which is coming
from the hydrogen tank. The H 2 and Cl2 react and produce HCL and pass through Hollow black
and then heat exchanger enter in to the HC and after maintain temperature, it enter in to a
storage tank and tail gases is move upward in to the tank in which gain 7% Cl2 we regain and
enter in to the furnace and remain unwanted gases pass out from the chimney.
Reaction:
The reaction is very exothermic in which release a lot of heat.
The reaction is occur between Chlorine and H2 to produce HCl and reach the temperature of
furnace 2300to 2500o
C
H2 + Cl2 → 2HCl (exothermic reaction)
Cooling jacket:
To maintain the temperature of Hydrogen Chloride we put a jacket insulator in which cooling
water is present which inlet temperature is 30o
C The water is circulate in to the shell side of
furnace and pass it horizontal side of tubes. The HCl present in vertically tubes and water move
horizontally, It can maintain the temperature of HCL by absorb heat and pass out at outlet line
whose temperature is 35C and HCl temperature reach up to 35 and enter in to HCl storage tank
Tail gases:
The unwanted gases and also some amount of Chlorine which is remain unrelated move
upward in to the striper or separator in which water is showering and 7% HCl is produce which
is come back in to the furnace and unwanted gases come out from the chimneys.

30
Parameters OF furnace:
H901 H2 Cl2 H20 l/h Acid tempo
C Conc%
A 55 65 1600 46 34
B 55 65 1700 48 32
C 90 60 1200 46 26
D 45 65 1600 49 33.6
F 85 80 3400 38 34.7
G 25 90 3000 40 33
H 41 90 3000 35 34
J 46 95 38000 40 34.6
Cooling water Flows and pressure:
a)
Cooling #3 2.0 bar
Cooling #4 1.7 bar
F 290 m3
/hr
G 306 m3
/hr
H 110/112 m3
/hr
J 156/159 m3
/hr
b)
Type of Cooling Tower enter in to the furnace Capacity ton /day
A Force cooling tower 25
B Force cooling tower 25
C Force cooling tower 25
D Force cooling tower 25
F Force cooling tower 50
G Force cooling tower 50
H Induce cooling tower 50
I Induce cooling tower 50
J Induce cooling tower 50

31
Liquefaction:
Liquefaction:
Liquefaction is a process that generates a liquid from a solid or a gas.
. Or
That generates a non-liquid phase which behaves in accordance with fluid dynamics. It occurs
both naturally and artificially.
Commercial Application:
A "major commercial application of liquefaction is the liquefaction of air to allow separation of
the constituents, such as oxygen, nitrogen, and the noble gases.
Liquefaction of gases:
The process of condensing a gas to liquid is sometimes referred to as liquefaction of gases.
Process:
The processes are used for scientific, industrial and commercial purposes. Many gases can be
put into a liquid state at normal atmospheric pressure by simple cooling; a few, such as carbon
dioxide, require pressurization as well. Liquefaction is used for analyzing the fundamental
properties of gas molecules (inter molecular forces), or for the storage of gases, for example:
LPG, and in refrigeration and air conditioning. There the gas is liquefied in the condenser, where
the heat of vaporization is released, and evaporated in the evaporator, where the heat of
vaporization is absorbed. Ammonia was the first such refrigerant, and is still in widespread use
in industrial refrigeration, but it has largely been replaced by compounds derived from
petroleum and halogens in residential and commercial applications.
Process in SCIL:
We convert the vapors of Chlorine in to liquid chlorine.
Unit of liquefaction:
 Tower
 Compressor
 Demister
 Liquefier condenser

32
Tower:
The vapors of Chlorine enter in to a tower where H2SO4 is present. In this tower, sulfuric acid
(H2SO4) is present, use to remove the moisture present in Chlorine.
Compressor:
After this tower they move towards the compressor where vapor of Chlorine is converted in to
liquid at Pressure 1-1.5 BAR .In this also sulfuric acid is present which is used to remove the
moisture.
There are four compressors whose capacity is as follow
Compressor Capacity
A 18 ton
B 18ton
C 18 ton
D 33 ton
Demister:
After compressor they move towards the demister where moisture is remove and enter in to
two more demister whose inlet and outlet is same (also purpose to remove moisture) and enter
one final demister where almost moisture are remove present in Chlorine.
Why we remove moisture?
We remove moisture because if they enter in to a liquefier condenser, they cause scaling. To
remove the scaling it is necessary to remove all moisture then enter in to a liquefier
Liquefier Condenser:
After the demister it enters in to liquefier condenser, where all chlorine is liquefy.
It consist of shell and tube (270 -300 tubes).In this all Chlorine is liquefy. To maintain the
temperature of Chlorine we add a refrigerating agent Freon.
Process:
The process is that we add Freon in a shell and Chlorine in to a tube. The Freon contains whole
heat from the chlorine and converts in to vapors and chlorine become liquefies. After
liquification,liquid chlorine enter in to a chlorine storage tank(TK301 A,B,C,D) and vapors of
Freon go to the process of liquefy so that it may use again
Production Capacity of liquid Cl2:
Approximately, 12 to 14ton Chlorine is produce per shift

33
How to liquefy the Freon?
To liquefy it, first enter in to a compressor then enter in to a instanstage cooler and then it pass
through the compressor where it discharge and then enter in to a oil separator where oil
separator (to remove oil from the Freon) remain downward and Freon remain upward and
enter in to a three separate condenser and enter in to the main condenser where all Freon are
liquefy and use again in a liquefy Condenser.
Parameters
Pressure of Compressor suction =0.3-0.6 bar
Pressure of Compressor discharge =13-16 bar
Pressure of Instanstage Cooler = 2.3 bar
Expand point =-30 to -33o
C

35
Effluence Treatment Plant:
The second name of this plant is waste water treatment plant.
This plant is used to treatment the effluence material and increase the PH. The HCL is a
effluence and we needed to drain the HCL then it is increased
Process:
Calcium Chloride Pit:
There are three calcium chloride pits in which HCL is added and CaCO3 is react with CaCO3 the
reached its PH is about is 6-9.
The following reaction is occur
HCL + CaCO3 → CaCl2 +CO2
Then CaCl2 is added in Ca (OH) 2 pits
Calcium hydroxide tank:
In this tank Ca and water is added and formed the calcium hydroxide and calcium hydroxide is
added in calcium hydroxide pits.
Calcium hydroxide pits:
There are two calcium hydroxide pits in which one is stand by. The calcium chloride inter the
calcium hydroxide pits it increases the PH of calcium chloride up to 11- 13 . Then it is drained

36
Laboratory: Functioning of equipment and Sampling
. Technique.

37
Laboratory:
In the laboratory, we take different samples and different techniques are used
There are many equipment present in the laboratory such as
 Conductivity meter
 PH-meter
 Spectrometer
 Turbidity meter
 Titration Flask
PH Meter:
This meter is used to check ph of solution. THIS Meter is placed in the discharge of effluence
material to check the ph.
A pH meter is a scientific instrument that measures the hydrogen-ion activity in water-based
solutions, indicating its acidity or alkalinity expressed as pH. The pH meter measures the
difference in electrical potential between a pH electrode and a reference electrode, and so the
pH meter is sometimes referred to as a "potentiometric pH meter". The difference in electrical
potential relates to the acidity or pH of the solution. The pH meter is used in many applications
ranging from laboratory experimentation to quality control
Conductivity meter:
This meter is used to determine the conductivity of solution and also determine the TDS of the
solution.
Spectrophotometer:
Spectrophotometer is a method to measure how much a chemical substance absorbs light by
measuring the intensity of light as a beam of light passes through sample solution. The basic
principle is that each compound absorbs or transmits light over a certain range of wavelength.
This measurement can also be used to measure the amount of a known chemical substance.
Spectrophotometer is one of the most useful methods of quantitative analysis in various fields
such as chemistry, physics, biochemistry, material and chemical engineering and clinical
applications.
Turbidity meter:

38
Turbidity meters are used to quickly measure the turbidity (or cloudiness) of water, caused by
suspended solid particles.
What is Turbidity?
Turbidity is the cloudy or opaque appearance of water caused by suspended solid particles. It is
often used as a general water quality indicator, particularly for clean water such as drinking
water.
How do turbidity meters work?
Electronic turbidity meters work by measuring the amount of light which is scattered at 90° by
the suspended particles.
Turbidity meter setup
However, this scattering does vary slightly with the size of the particles .Large particles may be
more prone to scatter light at smaller angles, while small particles will allow light to scatter at
larger angles; particle size scatter.
This is why some meters state “ratio” and “non-ratio” in their specifications – they use a range
of detectors to compensate for differences in the particle size.
Sampling Techniques:
Sampling of sodium hypo:
In the sample of sodium hypo, we determine the concentration of sodium hypo
In this sampling we determine the
 Free Alkali
 Available Chlorine
Procedure
 Take 2 ml sample of sodium hypo with the help of dipper and enter in to a conical flask
 Add demi water in a conical flask
Then add peroxide in to the flask to remove the Chlorine
a) Titration with HCl(for free Alkali)
 After adding peroxide, Titrate it with HCl.
 Add 0.1N HCl in the titration flask and titrate it with sodium hypo including peroxide.
 Add phenolphthalein indicator in the conical flask, color is dark pink.
 Add slowly HCl in to the flask and note the end point. The end point is colorless solution.
 When end point achieve note the volume of HCl.
 After it find the concentration of Sodium hypo by applying formula.

39
Calculation:
N=Normality of HCl =0.1N
Eq= equalent weight of NaOH = 40
V=Volume of HCl used. = 3.9m3
Formula used:
Concentration of sodium hypo=V*N*m/2
=3.9*0.1*40/2
=7.8
b) Titration with Sodium thiosulphate (Na2S2O3) :
 Add potassium iodide(10ml) as a reagent, and acetic acid(10ml) in a 2ml sample
of Sodium hypo, Color of conical flask is red orange
 Add sodium sulphate in the titration flask.
 add drop wise in to the conical flask until the end point is reach( colorless)
 Determine the concentration of a Chlorine by apply formula
Calculation:
Volume of sodium sulphateNa2S2O3 = 38.2
Normality of Na 2 S2O3. =0.282
Molecular weight of Cl2= 71
Formula used:
Concentration of Chlorine = Eq *N*V/2
=71*38.2*0.282/2
= 10.0114
2)
Determine the presence of Chlorine present in depleted brine
Procedure:
 Take a sample of depleted brine
 Add a solution of starch
 Shake it well
.If the color of brine change in to black then it shows that chlorine is present
.But if the color is not change then chlorine is not present.

40
3)
Determine the turbidity of demi water
Procedure:
 Take 10 ml of demi water in a sample bottle.
 Place the sample bottle in a turbidity meter
 Turbidity meter show the turbidity presence in demi water
Result:
The turbidity of water is 2.

41
Valves (Butterfly Valve, Tube Valve, Diaphagram Valve, globe valve,
Sleeve Valve)

42
VALVES USED IN SCIL (Sitara Chemical Industry Limited):
Some valves are described as follow:
 Butterfly Valve
 Diaphragm Valves
 Ball Valves
 Sleeve Valve
 Globe Valve:
Butterfly Valve:
A butterfly valve is a shut-off valve with a relatively simple construction. In closed position, the
disc blocks the valve bore while in open position, the disc is turned to allow flow. A quarter turn
takes the valve from fully open to fully closed position, or opposite, and thus the butterfly valve
allows for quick opening and closure.
Application:
Butterfly valves can be used for a broad range of applications within water supply, wastewater
treatment, fire protection and gas supply, in the chemical and oil industries, in fuel handling
systems, power generation etc. Some of the advantages for this type of valve are the simple
construction not taking up too much space, and the light weight and lower cost compared to
other valve designs.
Diaphragm Valves:
Diaphragm valves are used on shut-off and throttling service for liquids, slurries and
vacuum/gas.
The seal is achieved by a flexible membrane, usually elastomeric, and possibly reinforced with a
metal part. The membrane is tensed by the effect of a stem/compressor with lineal movement
until contact is made against the seal of the body.
Suitability:
The operating parts of the diaphragm valve are isolated from the flow. This makes this valve
suitable for viscous flows and also hazardous, abrasive and corrosive flows as its sealing system
avoids any contamination towards or from the environment.
Avaibility:
Diaphragm valves are available in a wide variety of metals, solid plastics, plastic, rubber and
glass linings. They are well suited to the handling of multiple chemical applications both clear

43
fluids as well as slurries.
Application:
The diaphragm valve has an extended use for applications at low pressures and slurry fluid
where most other kinds of valves corrode or become obstructer.
Ball Valves:
A ball valve is a shut-off valve that controls the flow of a liquid or gas by means of a rotary ball
having a bore. By rotating the ball a quarter turn (90 degrees) around its axis, the medium can
flow through or is blocked. They are characterized by a long service life and provide a reliable
sealing over the life span, even when the valve is not in use for a long time. As a result, they are
more popular as a shut-off valves then for example the gate valve. Moreover, they are more
resistant against contaminated media than most other types of valves. In special versions, ball
valves are also used as a control valve. This application is less common due to the relatively
limited accuracy of controlling the flow rate in comparison with other types of control valves.
However, the ball valve also offers some advantages here. For example, the valve still ensures a
reliable sealing, even in the case of dirty media.
Sleeve Valve:
A sleeve valve is a device typically used in a water supply or distribution system when there is a
need to reduce high pressure or throttle flow. The sleeve valve consists of a cylindrical gate
(tube) which slides over an inner sleeve. The inner sleeve consists of a series of nozzles
specifically sized and arranged to provide a solution to cavitations issues frequently
encountered in throttling applications with other valve types. Because of its design, it minimizes
cavitation. Cavitations that does occur in severe throttling conditions is directed from the valve
down to center of the valve or pipe so that no erosion damage to the piping can take place.
Globe Valve:
A globe valve, different from ball valve, is a type of valve used for regulating flow in a pipeline,
consisting of a movable disk-type element and a stationary ring seat in a generally spherical
body.
Globe valves are named for their spherical body shape with the two halves of the body being
separated by an internal baffle. This has an opening that forms a seat onto which a movable
plug can be screwed in to close (or shut) the valve. The plug is also called a disc or disk. In globe
valves, the plug is connected to a stem which is operated by screw action using a hand wheel in
manual valves. Typically, automated globe valves use smooth stems rather than threaded and
are opened and closed by an actuator assembly.

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