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Module 4
Lecture: 19 Hydrochloric acid
Dr. N. K. Patel
MANUFACTURE
HCl is manufactured by various methods as follows
1.
2.
3.
4.
5.
Synthesis from hydrogen and chlorine
From salt and sulfuric acid
As by-product from chemical processes
From incineration of waste organics
Hydrochloric acid solutions
1. Synthesis from Hydrogen and Chlorine
There is large demand in the market for water white acid. Such acid is
obtained by synthetic method, and most of the plants are based on this process.
Raw materials
Basis: 1000kg of Hydrochloric acid (98% yield)
Hydrogen
= 28.21kg
Chlorine
= 999.21kg
Sources of raw material
Both hydrogen and chlorine can be obtained during electrolysis of brine for
manufacturing of NaOH as described in Module: 3, Lecture: 13.
Also, hydrogen can be synthesized from any one methods of following which
are described in detail in Module: 2, Lecture: 4.
1.
2.
3.
4.
Lane process or iron steam process
Steam hydrocarbon process
Liquefaction of coal gas and coke oven gas
Bosch process or water gas-steam process
Reaction
H2 + Cl2
2 HCl
H = - 43.9kcals
Manufacture
Block diagram of manufacturing process
Diagram with process equipment
Animation
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Module 4
Lecture: 19 Hydrochloric acid
Dr. N. K. Patel
Dilute acid or water
added under control
Combustion
chamber
Cold water
inlet
Exhaust
fan
Hydrogen
burning
in chlorine
Exit for
exhaust
gas
Water
outlet
Chlorine
Hydrogen
Hydrochloric
acid
storage tank
Figure: Manufacturing of Hydrochloric acid from hydrogen and chlorine combustion
The plant consists of combustion chamber of structural carbon or lined with
silica bricks provided with cooling device which may consist even of cold-water
circulation in the shell. To ensure all the chlorine reacts with hydrogen, exces
s of 10%
hydrogen compare to chlorine is charged from the bottom of combustion chamber.
Also, care should be taken that the combustion chamber and length of ducting
which leads the gas to absorber should be sufficiently specious, otherwise
hydrochloric acid will contain free chlorine. The burning of hydrogen is started
by
igniting the burner with an external air-hydrogen torch. Dry chlorine is passed
into the
combustion chamber, where hydrogen burns in an atmosphere of chlorine to
produce HCl. The exothermic nature of the direct combination of both gases (H2
and Cl2) is such as to raise the temperature of the reagents, and the reaction
products to a point where they are incandescent. The reaction is carried out at
24000C with greenish flame. The gases are always kept above dew point to avoid
corrosion. The combustion chamber is then cooled externally by water and gas tig
ht
lid is fitted at the top of the reactor which suddenly opens to allow the gases
to
escape in case of emergency. Hydrochloric acid gas is cooled absorbed in water
or dilute HCl solution by passing through cooler and absorber through the
connecting pipe. The strength of acid produced is generally 32-33 %. The heat of
absorption of HCl in water is removed by spray of cold water outside the absorbe
r.
The solution of HCl flows into a storage tank.
Anhydrous hydrogen chloride
Hot gases originating from combustion chamber are passing over anhydrous
CaCl2 or washing them with 98% sulfuric acid and then cooled and compressed to
60atm pressure. The cooled and compressed gas having 99.9% purity is filled in s
teel
cylinders.
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Module 4
Lecture: 19 Hydrochloric acid
Dr. N. K. Patel
In another process, absorb the combustion gas into water and distilled it to
36% concentration of HCl. If one is to obtain 97% HCl at the top of the column.
The
35% acid is cooled to -120C and aqueous liquid containing 50% HCl is left to
condense, while residual gases, when they have been de nebulized as compressed
to 60atm are of purity exceeding 99.5%.
Thermodynamics and kinetics
H2 + Cl2
2HCl
H = - 44kcal
Above exothermic reaction is much favoured by both by large evolution of
energy and the product gas leaving the chamber, thereby circumventing the fact
that equilibrium would otherwise be attained. The very fact that equilibrium is
not
established also precludes the large increase in temperature from having a negat
ive
effect on the yield of highly exothermic reaction.
On account of the existence of large energy barrier to the reaction, mixture
of molecular H2 and Cl2 is stable at ambient temperatures and in absence of
suitable wavelengths. Photons with frequencies which are able to furnishing the
activation energy can be produced by creating an electrical spark in a mixture o
f
molecular H2 and Cl2 or by first burning mixture of H2 with air and then gradual
ly
replacing air with chlorine.
The initiation, propagation and termination of the chain reactions are as
follows
Initiation
Cl2 + h
Propagation
Cl + H2
H + Cl2
Termination
Cl + Cl
H + H
H + Cl
2Cl
HCl + H+
HCl + Cl
Cl2 + heat
H2 + heat
HCl +heat
A large amo nt of heat is developed both from chain propagation reactions
and from chain termination processes, the contin ed renewal of the chain
propagators by thermal ro te is ens red over the long term. In brief reaction
between hydrogen and oxygen to prod ce hydrogen chloride is a chain reaction
with a high q ant m yield.
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Mod le 4
Lect re: 19 Hydrochloric acid
Dr. N. K. Patel
Engineering aspect
The comb stion chamber and d cting to absorber sho ld be s fficiently
specio s for avoiding wall effect. From physicochemical point of view if the wal
ls of
reactor in which chain reactions takes place by their varying nat re, developmen
t,
shape and orientation as to affect the chain carriers is called wall effect. In
the
present case wall tends to interr pt the process by promoting the chain breaking
reaction (termination reactions). Physico chemically, chain terminators act as a
third
body in a system which already consists of the reactant bodies.
2. The SaltS lf ric acid process
The reaction between NaCl and s lf ric acid occ rs in two endothermic
stages.
Raw materials
Basis: 1000kg Hydrochloric acid
Sodi m Chloride
= 3206kg
S lf ric acid
= 2688kg
So rces of raw material
Sodi m chloride can be obtained from sea water, salt lake and s b soil
water as described in Mod le: 3, Lect re: 8.
S lf ric acid can be obtained by contact process as described in Mod le: 4,
Lect re: 18
Reaction
NaCl + H2SO4
NaCl + NaHSO4
NaHSO4 + HCl
Na2SO4 + HCl
Man fact re
Block diagram of man fact ring process
Diagram with process eq ipment
Animation
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Mod le 4
Lect re: 19 Hydrochloric acid
Dr. N. K. Patel
Off
gases H2O
Salt
Cooler
H2O
Reactor
Na2SO4
F el
H2SO4
Cooler
Absorber
Scr bber
H2SO4
HCl
Storage
Fig re: Man fact ring of Hydrochloric acid from salt and s lf ric acid
Salt (NaCl) and s lf ric acid are charged to the f rnace. It is desirable to
keep one of the components in the reaction mixt re in a liq id form in both step
s.
The first step is carried o t at the lower temperat re compare to second step. E
ven
so, for liq efaction of NaHSO4, which is req ired to carry o t in second step, m
aterial
is heated p to 4000C. Sodi m s lfate in form of sl dge is collected from the bo
ttom
of the f rnace. The prod ct and nconverted s lf ric acid is sent to f rther
processing in which recovery of s lf ric acid and nitric acid in cooling tower a
nd
absorber respectively.
3. As by-prod ct from chemical processes
Over 90% of the hydrogen chloride prod ced as a by-prod ct from vario s
chemical processes. The cr de HCl generated in these processes is generally
contaminated with imp rities s ch as nreacted chlorine, organics, chlorinated
organic and entrained catalyst particles. A wide variety of techniq es are
employed to treat these HCl streams to obtain either anhydro s HCl or hydrochlor
ic
acid. Some of the processes in which HCl is prod ced as by-prod ct is the
man fact re of chloro orohydrocarbons, man fact re of aliphatic and aromatic
hydrocarbons, prod ction of high s rface area silica, and the man fact re of
phosphoric acid and esters of phosphoric acid.
4. From incineration of waste organics
Environmental reg lations regarding the disposal of chlorine-containing
organic wastes have motivated the development of technologies for b rning or
paralyzing the waste organics and recovering the chlorine val es as hydrogen
Mod le 4
Lect re: 19 Hydrochloric acid
Dr. N. K. Patel
5. From hydrochloric acid sol tions
Gaseo s hydrogen chloride is obtained by partially stripping concentrated
HCl acid sing an absorberdesorber system. The stripper is operated at a press re
of 100200kPa (12atm) for improved recovery of HCl. The overhead vapors
consisting of 97% HCl and 3% H2O is cooled to remove most of the water as
concentrated HCl, and the resid al water vapor is removed by drying the gas with
s lf ric acid.
PROPERTIES
Mod le 4
Lect re: 19 Hydrochloric acid
Dr. N. K. Patel
It is also sed in medicine and as laboratory reagent.
Aq a regia sed for dissolving metal
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