PROFESSIONAL TRAINING
PRESENTATION
BY – JASHANPREET KAUR
16001005011 TRAINING AT
4TH YEAR SIEL CHEMICALS
CHEMICAL ENGINEERING
ABOUT THE COMPANY
Siel ltd. Emerged as an independent entity in 1989 . It was set up by Shriram and
present chairman of the company is Sidharth Shriram, grandson of Shriram. It
started with a textile mill in Delhi and grew one of the largest private organisation
in the country. It is one of the biggest private sector currently manufacturing units
for textiles, sugar, chemicals etc.
Siel chemical complex (scc) is one of the leading chlor alkali manufacturer in north
India. The products are Hcl, caustic soda, stable bleaching powder.
VARIOUS PLANT SITES OF SIEL CHEMICALS :-
1. BRINE HOUSE
2. CELL HOUSE
3. CHLORINE HOUSE
4. EVAPORATOR HOUSE
5. FLAKING UNIT
6. SBP PLANT
PLANT ABOUT WHICH WE ARE GOING IN DETAIL
PRIMARY BRINE SECTION
SALT SOURCES:-
Sea salt comes from Malia & Gandhidham (Gujarat). Mode of transportation is by
Trains and trucks.
SALT STORAGE:-
The salt is stored in three large silos.
BRINE PREPARATION:-
1. SALT HOOPER
It consist of two portion one rectangular & other is trapezoidal.
2. SATURATOR
There are 3 saturators. The salt is fed into tank from the hopper. The temp.
Is around 60 deg celsius. Salt and return brine mixed in counter current
pattern and the process is endothermic. Salt is passed to strainer.
3. STRAINER
There is one strainer. Saturated brine overflows moves to the strainer for
removal of dust or poly bags waste. Strainer is cleaned periodically.
PROCESS DESCRIPTION:-
The overflow of the strainer is dosed with BaCO3 before the reactor A, then the
overflow goes to reactor B before which it is dosed with NaCO3. Then it is dosed with
NaOH and the overflow goes to strainer where flocculent (Magnafloc 661) is dosed.
Naco3 Naoh flocculent
BaCO3 dosing dosing
dozing
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Brine Clarifier
from
saturator Strainer
Reactor A Reactor B
CHEMICAL TREATMENT OF IMPURITIES:-
In the dosing house there are 6 tanks. Two for barium carbonate solution, two
for soda ash solution, one for caustic soda solution, one for flocculants solution.
1. SULPHATE REMOVAL SYSTEM BY BARIUM CARBONATE:-
In general 5 % concentration of barium carbonate solution is used. Otherwise
concentration is depends upon sulphate level in the brine.
Reaction occurring in the reactor: -
Na2SO4+ BaCO3 BaSO4 (ppt) + Na2CO3
2. CALCIUM REMOVAL SYSTEM:-
Soda ash is used to remove the Calcium from the brine. The concentration of
soda ash is kept around 7 % generally. But its concentration is depends upon
the concentration of Calcium in the brine.
CaCl2 + Na2CO3 CaCO3 (ppt) + 2NaCl
3. MAGNESIUM REMOVAL SYSTEM:-
Caustic soda is added to remove the magnesium ions from the brine solution.
The concentration of caustic soda is kept around 10-15 % in [Link] is
dozed at the outlet of reactor because its flocks formed are so light that agitator
in the reactor can easily break it.
MgCl2 + 2NaoH Mg (OH) 2(ppt) + 2NaCl
FLOCCULANT:-
Flocculant’s solution is prepared in brine. The concentration of flocculants is kept
around 0.003%. It is added to enhance the settling effect of particles.
CLARIFIER:-
The brine now come into the clarifier. There is a provision for the agitation in the
clarifier by cone scraper at very slow speed, so that all ppt can settle down and
the clear brine comes out from the clarifier as an overflow product to clarified
brine tank and underflow to vacuum drum filter through ODS pumps.
OLIVER DIAPHRAGM SLUDGE PUMP (ODS):-
There are 3 ODS pumps (2+1 standby) attached to clarifier for the removal of
sludge. It contains diaphragm, which expands, and contracts for the passage of
sludge through the pump. It also contains 2 non-return valves in suction and
discharge line. It is air driven diaphragm pump.
SLUDGE RECYCLE SYSTEM:-
When the sludge is thin, it is recycle through the ODS pump to the saturator
outlet to enhance seeding effect in clarifier.
VACCUM DRUM FLITER:-
The slurry from the clarifier reaches VDF through ODS pump. There are
2(1+1 standby) drums. . The vacuum is applied for filtration. The vacuum is
produced by vacuum pump by circulation of water. The silencer is attached
to reduce the sound of vacuum pump. If the sludge is thin in size, it is
recycled back to clarifier to enhance the seeding` effect of sludge particles.
CLARIFIER BRINE TANK:-
The overflow brine from the clarifier moves to the clarifier brine tank
from where it is moves for further purification.
REMOVAL OF INSOLUABLE FROM BRINE AFTER CHEMICAL TREATMENT:
ANTHRACITE FILTER:-
There are 4 anthracite filters in parallel . Each filter has four layers of
anthracite coal, which are supported by hubs. Size of coal particle increase as
we move down. From the anthracite filter, the filtrate passes to the filtered
brine tank.
FILTERED BRINE TANK:-
The brine from anthracite filter is stored in filtered brine tank. It is using as a
storage tank as well as to backwash the anthracite filter.
SECONDARY BRINE PURIFICATION:-
BRINE FILTRATION:-
Large size impurities are removed from clarifier and anthracite filter; the
remaining impurities are removed through Durco filter and Ion exchange column.
DURCO FILTER:-
The Durco filter consist of 26 leaves of polypropylene, which having a coating of
Alpha cellulose The leaves are precoated with a alpha cellulose prepared in recoat
tank, in the form a aqueous slurry, and supplied to the filter from recoat pump.
When the filtration pressure difference of the operating Durco filter has increased
up to 1.5 kg/cm2 or after 72 hours, the Durco filter is switched to another Durco
filter and then off- lined filter is washed with demineralised water.
The whole brine solution is passed to the ion exchange column.
ION EXCHANGE COLUMN:-
Calcium and Magnesium ion or other multivalent cations in the brine are very
much harmful to the membrane electrolysis process.
Generally, these multivalent cations can be removed, to some extent, by chemical
treatment and sedimentation in the primary purification. For stable operation of
the membrane process, however, brine purification by ion –exchange resin is
required as secondary purification. This purified brine is then fed to the electrolysis
for manufacturing of Caustic Soda, Chlorine and Hydrogen.
EVAPORATOR HOUSE
Caustic soda is one of the most important products of Chlor-Alkali industry. The
Caustic soda is sold in the market in the form of caustic soda lye(47.5-48%
concentration) and in the form of caustic soda flakes. Caustic soda flakes is easy to
transport. The evaporator house and flaking section consists of:-
1. Evaporator House.
2. Caustic soda storage tank.
3. Pre concentrator.
4. Salt Heater.
5. Final Concentrator
6. Cooling & flaking unit.
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INTRODUCTION OF EVAPORATOR HOUSE:-
The caustic soda (33%) comes from the Cell House comes to the Evaporator house
to increase the concentration. The Evaporator house consists of
-Three affect evaporator.
-Flash tank.
-Barometric condenser.
-Pre-heater.
Caustic soda is concentrated by using steam. There is backward feed arrangement.
The feed is enter in the 3rd effect while the steam is enter in the 1st effect.
Barometric condenser is connected to the 3rd effect evaporator. There is external
type heating arrangement in the evaporator. The condensate comes for the 1st and
2nd evaporator is used to pre heat the feed. Final concentrated product is fed to the
flash drum. The final concentration of caustic soda is 47.5%-48%. Is sent to flaking
section.
CAUSTIC STORAGE TANK:-
There are three storage tank of 33% caustic soda and three for the 47.5%
concentrated caustic soda.
PRE-CONCENTRATOR:-
In the pre-concentrator the 47.5% caustic soda is concentrated up to 61% by using
steam as the eating medium. The 61% concentrated solution is send to the final
concentrator.
SALT HEATER:-
Salt heater is the assembly in which the salt is melted in a furnace which is fired
by furnace oil. The mixture of salt is melted at the higher temperature around 500
0C.
FINAL CONCENTRATOR:-
Final concentrator is used to concentrate the 61% caustic into 99.9 % caustic soda
by using the melted salt mixture. The Final concentrator is jacketed type vessel
which is provided with agitator in the middle of the vessel. The inner side the
caustic soda is fed into the vessel thin film wise where the melted salt mixture is
fed into the annulus of the vessel. Where the caustic soda is concentrated in
desired level. This is fed into the flash tank. Then it is send to the flakers.
FLAKING:-
The concentrated caustic soda is kept in tank on which the drum is half dipped
into it. The drum is filled with chilled water inside the drum. Due to this there is a
formation of thin layered on the outer side of the drum, which is scrapped out by
knife provided in the drum this scrapped flakes is send to the packing section,
where the packing of Caustic Soda flakes is done.
