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Contents
Overview of Chlor Alkali Industry in India Introduction of Chlor Alkali Plant (RIL(DMD)) Process Description Process Control
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Ref: AMAI
No. of Industry
Total Chlor Alkali Plants in india 34 Total Production Capacity 29.11 Lacs MTPA as on 31.03.2008
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Reliance Industries Ltd, Dahej G A C L, (Vadodara, Dahej) GRASIM, Nagda DCM (Kota, Jhagadia) UPL Unit -5, Jhagadia Indian Rayon, Veeraval Punjab Alkalies & Chemicals Limited, Nangal Chemfab Alkalies, Pondicheri TATA Chemicals Ltd, Mithapur
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Membrane Cell Process Mercury Cell Process Diaphragm Cell Process Other
No. of Industry
25 20 15 10 5 0
Technology
Mercury
Membrane
Diaphragm
Capacity Expansion
Date of Capacity Expansion 10th Nov 2004 Process Licensor: UHDE, Gmbh Engg. Contractor: Uhde India Limited
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Electrolysers Chlorine, Hydrogen & Air Compressor Rectiformers Refrigeration units ( Ammonia Compression & VAR) Centrifuges, clarifier, filters Caustic Evaporation Unit (CEU) Caustic Concentration Unit (CCU) Prilling tower
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10
Awards Won
11
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Daily
494 MT
Monthly
Yearly
:
:
15170 MT
164524 MT
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Manpower
: : : : :
130 50 80 70 60
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PROCESS DESCRIPTION
Products
By Products
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Major raw material is industrial grade salt. It is sourced from salt suppliers from the local areas such as
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UTILITIES
Cooling Water Chilled water DM Water Filter Water MP Steam LP Steam LP Condensate Plant Air Instrument Air Nitrogen Power
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Chemical Consumption
Barium Carbonate Sodium Carbonate Sodium Hydroxide Sodium By Sulphite Alfa Cellulose Flocculent Sugar 25 % HCl 98 % Sulphuric Acid
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Process Overview
98% H2SO4
Salt chemicals
Primary Brine
Secondary Brine
Cl2 Treatment
HCl Unit
CHLORINE CAUSTIC
H2 Unit G CELL
HCL
HYPO
HOUSE
Waste Air Dechlorination
Utilities
Anolyte Dechlorination
Catholyte system
SOLID WASTE
LIQUID WASTE SCRUBBED NON TOXIC GAS
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Salt Handling & Storage Brine Saturation Brine Precipitation Brine Clarification Brine Filtration Brine Polishing Secondary Brine Purification Pure Brine Heat Conditioning Chlorate Destruction Unit Anolyte Dechlorination Catholyte Section
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Cell House
Electrolysers
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Chlorine System
Chlorine Cooling Chlorine Drying Chlorine Compression Chlorine Liquefaction Chlorine Evaporation Chlorine Storage
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Hydrogen System
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Other Units
HCl Synthesis Unit Waste Air dechlorination Unit Vapour Absorption Refrigeration Unit Ammonia Compression Refrigeration System
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PROCESS CONTROL
DCS by Tata Honeywell, TDC 3000 PC-PLC by Tata Honeywell Siemens PLC for burner Siemens PLC for chlorine compressor Allen Bradley PLC for Rectiformers
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ENERGY CONSERVATION
Membrane cell technology Heat recovery interchangers VAR Captive use of Hydrogen Partial bypassing of chlorine liquefier
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ENVIRONMENT MANAGEMENT
Environmental Consideration
Operating philosophy is to keep minimum Cl2 inventory. only i.e. Approximately 50 MT. SLF for solid waste. Neutralizations and circulation facilities in effluent pit. Two PH analysers are also present. Chlorine Detectors
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Wastes Management
Waste Generated Brine Sludge Waste Disposal Option Secured & Simple Landfill Cell
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Liquid Effluent Neutralization Pit at Plant & CETP Waste & Used Oil Incineration Oily & Cotton Waste Incineration Gaseous Waste Chlorine HYPO Stack HCl HCL Stack Molten Salt Molten Salt Furnace Stack 6/8/2013 Hydrogen Hydrogen Stack
SAFETY
Caustic (32%,48%,98.5% solid) Chlorine 98% Sulphuric Acid 78% Sulphuric Acid 30% HCL Ammonia Sodium Hypochlorite Hot Brine
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Hydrogen Ammonia Molten Salt Dowtherm Oil Lubrication oils and Diesel Plastic Piping Electric Short Circuit
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Trips / Interlocks by DCS for process plant. HCl furnace interlocks are hardwired. Cl2 compressor interlocks are hardwired. N2 purging in molten salt furnace stack. N2 purging in HCl furnace - after tripping.
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Process design for safe startup, operation and S/D. Remote Control operation for chlorine supply to VCM. Specific measures taken to avoid explosion in cell house between hydrogen & chlorine. On line analyser provided for hydrogen in chlorine sniff gas. N2 purging system whenever electrolyser is cutout. implemented for avoiding popping. This was based on M/s UHDE recommendation.
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Fire water network provided in the entire plant. Fire and smoke detection alarm system. Cl2 detectors in plant area (26 nos). H2 detectors in cell house, H2 area. Safety showers provided at various locations. Breathing air line provided in critical Cl2 areas. Cl2 safety valve vents connected to WAD
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Suitable MOC used for corrosive services: Cell house : Pans - Titanium /Nickel Suitable plastic metallurgy for wet chlorine / caustic services. For dry chlorine service - LTCS/ Carbon steel. PVC - FRP piping for H2SO4 service. PVDF for chlorate destruction. Ti/Ni / Haste alloy-C for exchanger. Safety valves with rupture disc with failure indication in DCS in chlorine service after compressor. Pumps are double mechanical seal in caustic ,Hypo and H2SO4 service.
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5 bullets with always one bullet kept as spare. Alternate measuring devices for level. Automatic closure of liquid chlorine inlet at high level. Remote operated on/off valves. Bellow seal valves in chlorine service. Double safety valves along with rupture disks to prevent high pressure.
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Three stage scrubbing. Dumping of caustic from overhead tank incase of fast temperature increase. Dosing based on redox. UPSV to prevent higher vacuum. Remote operated auto standby system. Emergency power supply includes DG set.
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COST ECONOMICS
Cost of Production
Sr. No. Description 1 2 3 Raw Material By Product (Credit) Catalyst & Chemicals Amount (Rs / MT) 603 236 403
4
5
Utilities
Consumables Total
3942
396 5109
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End Users
Viscose Manufacture Pulp and paper industries Soaps and detergents Chemical industry Nitrite and Nitrate Manufacture Alumina Industry RIL market share is 10%.
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Thank you
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