1

Approval
This is to endorse that three students of Chemical Engineering & Polymer Science
Dept. of Shahjalal University of Science & Technology have completed their
industrial project report on Global Heavy Chemicals Ltd. heading Industrial
Project on Chloro-Alkali process units of Global Heavy Chemicals Ltd.

The report is about to the partial fulfillment of the requirements for the degree
of B.Sc in Chemical Engineering & Polymer Science Dept.
Their involvement was much appreciated and I wish for their stunning future.
Name of the student

Registration no.

Md. Sumon Ali

2006332028

Ahmad-Ur Rob

2006332011

HM Bakhtiar Akib

2007332028

Supervisor

Sreejon Das, Lecturer, CEPS

Shahjalal University of Science and Technology
Sylhet.

Abstract

This paper is on a 20 days long project carried out from 7 March 2012 to 27 March 2102 for the
accomplishment of the course CEP- 431 which is programmed for the industrial attachment as
a curriculum of the Department of Chemical Engineering and Polymer Science of Shahjalal
University of Science and Technology. The project was carried out at the Global Heavy
Chemicals Ltd. whose valued collaboration is highly appreciated. Global Heavy Chemicals Ltd. is
one of the renowned chlor-alkali Industries in Bangladesh that is completely integrated in
producing caustic soda and also bleaching, NaOCl (clotech B), Cl2 as by products.

The topics covered, as team work, in this project were as follows: Feasibility survey, Plant
layout, Process description, Material Balance, Energy Balance, Economic analysis by
breakthrough curve, Equipment Design, Control Systems,, etc. The program had been finally
completed successfully by the kind cooperation of many people.

Acknowledgement

I am grateful for the contributions from many individuals leading towards the successful
completion of our program, especially those who gave the time to share their thoughtful
criticisms & suggestions to improve it. I am deeply owing a favor to them for their personal
encouragement and professional assistance.
First, I would like to thank Global Heavy Chemicals Ltd. to give us the opportunity to do the
project work in their industry. I convey my respectful gratitude to our Teacher and Project
Supervisors, Department of Chemical Engineering and Polymer Science, Shahjalal University of
Science and Technology, for his valued co-operation in making this project paper.
It is a great pleasure for us to acknowledge our Program Coach Md. Masudur Rahman, Process
In charge, Global Heavy Chemicals Ltd. for his assistance and co-operation given to us
throughout all the working time. Without his heartiest interest and support, it would be quite
impossible for us to carry out our project work in such an industry and to complete this report
with its full richness in information.
I also want to say with great thanks to Mr. Jahangir Alom Mukul for the massive support of
giving approach to the industry an also for whole contribution.
Special thanks to Mahmudul Hasan and Bidyut Sarker, production engineers, for their constant
support and heartiest effort to help us make this program come to a success.
I also like to thank all the personnel of Global Heavy Chemicals Ltd. for their kind cooperation,
throughout the period of the project work, with their sharing of the various engineering
principles and techniques in the theoretical and practical grounds that made me realize and
understand the real complexity of manufacturing processes and how to face them from the field
of Chemical Engineering.

Author
25th July, 2012

Contents
1. Review of GHCL
2. Feasibility Studies
3. Process Description
4. Process Diagram
5. Material Balance
6. Sludge Calculation
7. Energy Balance
8. Equipment Design
9. Economic Evaluation
10. Industrial Safety
11. Plant Layout
12. Hazop Analysis
13. Reference

5
6
8
21
26
32
34
39
44
48
54
60
65

Review of Global Heavy Chemicals Ltd.

In this modern age of competition, Chemical Engineers need to operate a Chemical
plant in such way that it can compete in this business environment ensuring
product quality.
Global Heavy Chemicals Ltd. (GHCL) is a sister concern of OPSONIN group. In
the beginning of 21st Century, GHCL starts its journey as the first private sector
Chlor-Alkali Industry in Bangladesh. The industry is located on the southern part
of Dhaka district in Hasnabad union under Keranigonj Thana. Significantly related
to all the hopes and expectations of the new century, GHCL has energized the
vision to open new horizon for industrial development in the country. The project
site was a 20 feet deep low-lying land from the road level that has been filled and
developed suitably for GHCL plant. It has incorporated most advanced state of the
art technologies, machineries and equipments.
Global Heavy Chemicals Ltd. believes in management excellence with
commitment, honesty, sincerity, dedication and efficiency. With its well-educated,
trained and skilled workforce, harmonious working atmosphere, good productivity
record and strong environmental commitment, Global Heavy Chemicals Ltd.
enjoys a good standing with government and local public.
Some key points of Global Heavy Chemicals Ltd.:
Company

: Global Heavy Chemicals Ltd. was incorporated on the 19

September 2000, Bangladesh.

th

Plant location

: Hasnabad union under Keranigonj Thana which is on the

southern part of Dhaka district.

Plant occupied area : 8.5 acres.

Plant type

: Chlor-alkali industry.

Plant capacity

: 70 TPD

FEASIBILITY SURVEY

Feasibility survey is the pre-pivotal task to establish a plant profitably. Some key
factors are necessary to analyze for the feasibility survey of a plant. For Global
Heavy Chemicals Limited, the important key factors are listed bellow:
Availability of raw materials: Raw material collection is one of the most predominant task. GHCL collects their raw materials from our neighbour
country India. Though raw materials also available in Bangladesh it is
collected from India because of higher quality than Bangladesh & river way
transportation cost makes it attractive.
Availability of labour: Expert labours are available & there accomodation is
also feasible by easy transportation cost as GHCL situated at Dhaka area.
Power: As our government can not provide electricity at low cost, So GHCL
produce their electricity as they need. They 14.5 MW power generation
capacity to fulfil their need. They use natural gas to produce electricity
which collected from Titas Gasfield at low cost. They have also Disel
power generation system.
GHCL uses surface water for their utility. Water is collected from river
Burigonga and deep tubewel. So they can manage their necessary amount
of water easily.
Transportation cost: Their transportation cost lower enough because of their
industry situated at Dhaka. Buyer can easily collect product produced by
GHCL.
Another important thing is that disposal treatment. After treatment they can
easily through it to the river. They have good treatment system for their both
effuent and disposal.
So above discussion proved that GHCL is quiet feasible both economically &
environmentally.

PROCESS DESCRIPTION

GHCL is mainly a chloro-alkali industry.Its main products are caustic Soda(NaOH), Sodium
Hypochlorite(NaOCl), Clorine Gas(Cl2), hydrogen(H2), Bleaching(Ca(OCl)Cl). GHCL uses
membrane cell technology. Sodium hydroxide is produced (along with chlorine and

hydrogen) via the Chloro-alkali process. This involves the electrolysis of an

aqueous solution of sodium chloride. The sodium hydroxide builds up at the
cathode, where water is reduced to hydrogen gas and hydroxide ion:
Electrochemical and chemical reactions occurring in diaphragm and membrane
cells
[1]

2Cl- ==> Cl2+ 2e-

(anodic reaction)

[2]

2H2O + 2e- ==> 2OH- + H2

[3]

2Cl- + 2H2O ==> Cl2 + H2 + 2OH-

[4]

2NaCl + 2H2O ==> Cl2 +2NaOH + H2 (overall reaction)

(cathodic reaction)
(overall ionic reaction)

10

Fig: Overall Process.

In the process, three products are produced. It is vital that these are not allowed to
mix. Thus, a requirement of a commercial cell for the electrolysis of brine is that it
separates the three products effectively. Electrolysis in a simple vessel (described
as a one-pot vessel) leads to the reaction of chlorine with sodium hydroxide to
give unwanted sodium hypochlorite (NaClO), sodium chlorate (NaClO3) and
oxygen by the following reactions:
Cl2 + OH- Cl- + HOCl
HOCl H+ + OCl-

2HOCl + OCl- ClO3 + 2Cl- + 2H+

4OH- O2 + 2H2O + 4e-

11

The main process units of GHCL are listed bellow:

I.
II.
III.
IV.
V.

VI.

VII.
VIII.
IX.
X.
XI.

14.6 MW power plant including diesel generator & boiler house.

2500 MT water storage tank including two-pump house & cooling tower.
Bi-polar membrane cell house including rectifier, rectifier transformer, DCS
control room,
Anolyte & Catholyte tank, de-chlorination building as well as quality control
department.
Utility building including DM plant, Nitrogen plant, absorption chillers &
compressors. This block has got HCl synthesis building including storage
tank and delivery platform.
Primary & Secondary brine purification area including Salt Saturator,
Reactor, Chemical-dosing Tanks, Main Clarifier, Anthracite Filter, Candle
Filter, Polished Brine Tank, Ion-Exchange Resin Column and Purified Brine
Storage Tank.
Automatic Salt Washer unit including separate storage area for raw &
washed salt, conveyers, small clarifier etc.
Chlorine Drying & Compression Building including Bottling area as well as
four large storage tank and delivery platform.
Caustic Evaporation and Flaking Building including bagging and storage
facility.
Hydrogen gas Compression and bottling building.
Automatic Effluent treatment plant for industrial water treatment.

12

Process Procedure : GHCL works on the following step by step process. The main task of this industry is
to purify the raw salt into two steps

Primary purification
secondary purification

So total process procedure given sequencially:

Raw Material:
The main raw material for this project the solid salt which is further processed to
produce caustic soda.
In this plant salts are imported from the neighboring country India. Because the
composition of the salt comes from India is better from the local salt and also have
less impurities than the local salt. We can say this by testing the composition.

Raw salt composition:

Composition
Ca2+
Mg2+
SO42Total Iron
NaCl
Moisture

Percentage
0.227%
0.049%
0.645%
13.2 ppm
95.43%
3.649%

Salt Saturator:
For melting the solid salt, in the salt saturator there is a continuous process of
pumping of return brine solution at about 75c from the return brine tank which is
executed from the cell and is not converted to the caustic soda.

13

After melting raw salt in the salt saturator the solution is passed through a plate
filter to remove the floating substance and impurities that come from the salt
feeding. Then the solution is fed to the dosing unit.
Impurities or the mud which come from the salt decompose at the bottom of the
salt saturator and decrease the efficiency of the salt saturator. For this reason after
3-4 months the salt saturator is washed to make it clean.
Dosing:
From analysis of the raw salt the dissolved impurities are the Ca2+ , Mg2+ ,SO42and the mud that can be said. To remove these impurities chemical dosing is
required. BaCl2 is used to removed the S
.
C is used to remove Ca2+ and
also NaOH for the Mg2+.
After the dosing of these chemical the salt solution is send to the reactor for the
proper mixing.
In a chloro-alkali plant mainly five different dosing are performed and these are as
follows:
1.
2.
3.
4.
5.

Soda Ash(Na2CO3) dosing

Barium Chloride(BaCl2) dosing
Sodium Sulphide(Na2SO3) dosing
Caustic Soda(NaOH) dosing
Flocculants dosing

Chemical dosing:
.

Ca2+ in raw materials =

= 14.49 kg/hr
For removing Ca2+ Na2CO3 needed:
CaCl2 + Na2CO3 = CaCO3 + 2NaCl
Na2CO3 needed =

= 13.83 kg/hr

14

Amount of

Mg2+ =

= 3.129 kg/hr
NaOH needed for removing Mg2+:
MgCl2 + 2NaOH = 2NaCl + Mg(OH)2
NaOH needed =

= 2.634 kg/hr
.

Amount of SO42- =

= 41.18 kg/hr
BaCl2 needed for removing SO42-:
Na2SO4 + BaCl2 = 2NaCl + BaSO4
BaCl2 needed =

= 60.32 kg/hr
Procedure of making Dosing:
1. Barium Chloride (BaCl2):
Desired concentration- 0.15% by weight
Required composition:
1. 475 kg BaCl2
2. 2000-2500 Liter H2O
3. 500 kg HCl
Chemical Reaction:

15

BaCO3 + HCl = BaCl2 + CO2 + H2O

In this reaction ph of HCl is 3.5 to 4 where ph should be maintained at level 6.This
is done by adding 10 to 12 kg excess NaOH.
2. Soda Ash (Na2CO3):
Desired concentration-0.14%
Required composition:
1. Soda Ash (Na2CO3)
2. 1400 liter H2O
3. Flocculent:
Required composition:
1. 500 gm floccal
2. 1000 liter H2O
Chemical Reaction:
500gm floccal+1000L H2O
Main function of flocculent is to hold up the moisture.
4. Sodium Sulphide(Na2SO3):
Desired concentration- 7% by weight.
Required composition:
1. 100L Na2SO3
2. 200L H2O

Reactor:
Reactor which is used here mainly a CSTR. In this reactor the following reaction
occurs:

16

Na2SO4 + BaCl2 NaCl + BaSO4

Na2CO3 + Ca2+ CaCO3 + 2 Na+
2NaOH + Mg2+ Mg (OH)2
After complete mixing of the brine and dosing solution a flocculent named Megna
floc is added to the solution. Then the solution is send to the clarifier for the
removing the precipitate of the solution and also increasing the turbidity of the
solution.
In reactor concentration range of brine is 295-305 gpl and is continuously
monitored by a Hydrometer. Reactor temperature is 60-65oc and is continuously
monitored by a Thermometer.

Clarifier:
In the clarifier the mud, precipitated produced by the chemical dosing which are
carried by the saturated brine solution is precipitated in the bottom of the clarifier.
From the bottom of the clarifier the thick mud solution of the saturated brine is
pumped to the decanter and mud is separated and collected for disposal as waste
product. The brine solution driven from the clarifier is stored in clarified brine tank
and then sends to anthracite filter for further removal of flock particles.
Anthracite filter:
Filter medium of the anthracite filter is mainly the anthracite. In anthracite filter
solid-solid adsorption occurred. Three types of carbon: large, small and medium
lies in the anthracite filter. When the brine solution is passed through the fine
anthracite filter medium the flock particles cannot pass through the medium and
get trapped in the anthracite medium. Then the solution is stored in the anthracite
filter tank to make the process continuous.
Candle filter:
Candle filter is a special type of filter in which the filter medium is activated
carbon and the filter coated with the alpha cellulose. This alpha cellulose blocks
the micro level particles from the brine solution. To maintain the layer of the alpha
cellulose which is externally exerted in the upper surface of the activated carbon
filter 1-2 atm pressure is maintain continuously. If the pressure drops, there will no

17

more alpha cellulose layer upon the activated carbon filter. To maintain the
efficiency the of the filter aid, alpha cellulose is continuously added in the candle
filter. Brine solution is feed at the bottom of the filter and mud free solution is out
at the top of the filter. After filtering in the candle filter the turbidity becomes -3 or
-4 and brine solution is 3 to 4 times transparent than water.
Regeneration:
The candle of the alpha cellulose is washed away by using the back flow of the air.
The new alpha cellulose is added from the pre-coat tank.
Ion Exchanger:
Multivalent ions are exchange with the Iminodiacetic acid of ion exchange resin in
the ion-exchanger. But sodium is mono-valent ion so it is not exchanged with this
resin. Na ion is replaced by Ca2+ and Mg2+. The resin used in ion-exchanger passed
only Na+ and as it is a cation exchanger so Na+ and Cl- entered into cell house. The
Iminodiacetic acid formula is as follows:

Regeneration of ion-exchange resin:

Resin can work very well till its efficiency is high or moderate. But when
concentration of Ca2+ is less than 10 ppm and concentration of Mg2+ is 2-3 ppb the
bed is needed to regenerate. The regeneration process is as follows:
Wash-1:
At first the resin bed is washed away by demineralized water at constant flow 1600
L/h and it continue 1 hour as all ash and dust will washed.
Back wash:
Back wash is done by DM water at a flow rate of 1.6m3/h over 30 minute. DM
water supplied at the bottom of the tower and resin was circulate with the tower.
Water flow is maintained at a constant rate so that resin does not overflow. After
ensuring that all brine washed away back wash was completed.

18

HCl regeneration:
18% concentrated HCl is then supplied in the at 600L/h flow rate over 30 to 50
minutes. By adding DM water at rate 1000L/h, 5% concentrated HCl made up.
When the ph of HCl becomes 1 HCl supply will stop. During HCl regeneration Na
of Iminodiacetic acid was replaced by Cl2 and the media become acidic.
Wash-2:
To remove the acidic media again DM water supplied at a flow rate 1600L/h over
1 hour. Consequently all Cl2 will replace by H+ ion of water.
NaOH regeneration:
Now 32% NaOH passed through the bed at a rate 200L/h with DM water of rate
1400L/h over 40 to 50 minutes. As a result COOH of iminodiacitic acid will
converted to COONa and resin regeneration will completed.
Wash-3:
Again the bed will washed away by DM water at a flow rate of 1600L/h over 1
hour to maintain the ph 10. If ph 10 is obtained water supply should stopped.
Brine filler:
Now the resin bed will fill up by 30% NaCl at 1.8m3/h flow rate over 1 hour.
Brine feed:
At last feed brine is feed in the ion-exchange column as the bed is fully regenerated
and ready to use with 100% efficiency.

19

Cell House:
Membrane technology is the unique Single Element, which comprises an anode
half shell, a cathode half shell and an individual sealing system with external
flanges. The Single Elements are suspended in a frame and are pressed against
each other by a clamping device to form a "Bipolar stack. Each Single
Element can be replaced quickly and easily. The elements are assembled in the
Electrolyzer workshop, where tightness tests are also carried out.

Figure : Cell House

20

Important Feature of this Membrane

Perfluro Sulphonate Polymer act as a anode coating.
Perfluro Carboxylate Polymer act as a cathode coating.
High caustic flow is maintained as coating could not attach with the
membrane body.
Hence chlorine is a heavy gas so it pulled from separator by a compressor.
This membrane is only permeable to Na+ ion.

21

DIAGRAMS

22

23

Figure: Block Diagram for Process

24

Fig: P & I Diagram Caustic Soda & Clorine Unit

25

Fig: Block Diagram for cpw unit

26

Fig: Block Diagram for Flaking Unit

27

Material Balance

28

Material balance for production 30% NaOH from 28% NaoH on the
basis of 50 ton production per day.

Basis: 50 MT

Per day production of the plant is 50 MT.

So capacity of the plant = 50 MT NaOH/day
=

kmol/hr

=52.083 kmol/hr
= 2083.32 kg/hr

29

Basic reaction that takes place in the electrolyzer

2 NaCl + H2O = 2NaOH + H2 + Cl2
NaCl +1/2 H2O = NaOH + 1/2 H2 + 1/2Cl2
So equivalent amount of NaCl is needed for production of equivalent Caustic Soda
(NaOH). We could write
1 kmol/h NaOH 1 kmol/h NaCl
52.083 kmol/h NaOH 52.083 kmol/h NaCl
NaClin = 300 gpl = 300 g/l = 5.12 kmol/m3 soln
NaClout = 220 gpl = 220 g/l = 3.76 kmol/m3 soln
Amount of NaCl Consumption in the electrolyzer
NaClconsumption= NaClin - NaClout
=(5.12-3.76) kmol/m3 soln
= 1.379 kmol/m3 soln
Flow rate of brine in the anode side =

.
.

/
/

= 37.91 m3/h
Material balance at Anode side
NaClin = 37.76 (m3/h)* 5.12 kmol/m3 soln
= 193 kmol/h
= 11309.805 kg/h
NaClout = 37.76 (m3/h)* 3.76 kmol/m3 soln

30

= 141.247 kmol/h
= 8262.9495 kg/h
H2Oin =
H2Oout =
Production of Chlorine
We know,

NaCl +1/2 H2O = NaOH + 1/2 H2 + 1/2Cl2

Cl2 produced = * 52.083 kmol/h

= 26.046 kmol/h
= 1478.75 kg/h
Flow rate at Cathod side
Density of 28% NaOH at 600C , = 1.284* 103 kg/m3 soln
NaOHin=

= 8.988 kmol/m3 soln

Density of 30% NaOH at 850C , = 1.296* 103 kg/m3 soln
NaOHout=

= 9.7263 kmol/m3 soln

NaOHproduced = NaOHout NaOHin
= 9.7263 8.988
= 0.7383 kmol/m3 soln
Flow rate at Cathod side =

31

= 73.253 m3/hr
Material balance at Cathode side:
NaOHin = 8.988 (kmol/m3 soln)*73.253 (m3/hr)
= 658.39 kmol/h
= 26335.6 kg/h
NaOHout = NaOHin + NaOHproduced
= 658.39 + 52.083
= 28418.92 kg/h
= 710.473 kmol/h
H2Oin = 26335.6 * .72 =18961.632 kg/h =1053.424 kmol/h
H2Oout = 28418.92 *0.70 = 19893.244 kg/h = 1105.1802 kmol/h

Hydrogen (H2) produced = * NaOHout

= *710.473
=355.2365 kmol/h
= 710.473 kg/h
NaCl needed = (11309.805 8262.9495) kg/h
= 3046.85 kg/h
So for production of 50 MT NaOH, amount of Raw salt needed =

.
.

= 3192.71 kg/h
& for production of 1 kg NaOH, amount of Raw salt needed =

.
.

kg

= 1.5325 kg raw salt

32

& amount of NaCl needed =

.
.

kg =1.46 kg NaCl

Flow rate at both Anode & Cathode side is shown belowFlowrate (m3/h)

Anode in

Kmol/hr

Kg/hr

NaCl

193.37

11309.805

H2O

1478.75

26617.5

141.247

8262.9495

H2O

1478.75

26617.5

Cl2

26.0415

1848.94

NaOH

658.39

26335.6

18961.632

1053.424

28418.92

710.473

19893.244

1105.1802

710.473

355.2365

NaCl
Anode out

Cathode in

H2O
NaOH

Cathode out

37.76

H2O
H2

73.253

33

Sludge Calculation
From our material balance we found that 2083.32 kg NaOH is produced from
3192.75 kg raw material (raw salt).
So 1 kg NaOH is produced from
= (3192.752083.31) kg raw salt
= 1.5325 kg raw salt
And we found from material balance that 1 kg NaOH is produced from 1.46 kg
NaCl . Thus 1 kg raw salt produced some sludge due to unnecessary other
component in raw salt. The amount of raw salt produced net amount sludge is
found as
Sludge (kg) = (1.53251.46) kg
= 0.0725 kg
The composition of raw salt is given bellow:
Ca2+
Mg2+
SO42Total Iron
NaCl
Moisture

0.227%
0.049%
0.645%
13.2 ppm
95.43%
3.649%

Sludge is produced by the following chemical reactions:

For Ca2+ removing we add NaCO3 which show the following reaction
CaCl2 + Na2CO3 = CaCO3 + 2NaCl

34

So Ca2+ is present in 1.5325 kg raw salt

= (1.5325 0.00227) kg
=0.00347 kg
For Mg2+ removing the chemical reaction is as follow
MgCl2 + 2NaOH = 2NaCl + Mg(OH)2
So Mg2+ is present in raw salt = (1.5325 0.00049) kg
=0.0075 kg
For SO42+ is present in 1.5325 kg raw salt= ( 1.5325 0.00645) kg
= 0.00988 kg
Moisture is present in 1.5325 kg raw salt = ( 1.5325 0.03469 ) kg
=0.0531 kg
Iron is present in 1.5325 kg raw salt = (1.5325 13.2 10-6)
=0.00002022 kg
Others component is present in 1.5325 kg raw salt = (1.5325 0.0053) kg
= 0.00812 kg
So total sludge is produced from 1.5325 kg raw salt = 0.0725 kg
Our plant supervisor gave us the plant capacity is 50 ton per day.
50 ton = (50 1000) kg = 50000 kg per day.
From above calculation we find 1 kg NaOH is produced when the amount of
sludge is 0.0725 kg. So total sludge produced = (50000 0.0725) kg = 3625 kg
So we can take a decision that Global Heavy Chemicals Ltd. Produce 3625 kg
sludge per day.

35

Energy Balance

36

ENRGY BALANCE ON CELL HOUSE:

Inflow energy balance:
NaCl,in = Hf +
= (-411+ 0)
= -411
HNaCl,in = -44

* 193.37

= -79475070
H2O,in = Hf +
= -285.84 + 75.4[75-25]
=3484.16
HH2O in = 1222.16

* 20440.382

= 24981417265.12

37

(NaOH in) = Hf +
= (-469.4 + 0)
= -469.4

H(NaOH in) = -469.4

* 658.39

= -309048266
Total enthalpy at inlet
Hin = HNaCl + HH2O + HNaOH
= -79475070

+ 24981417265.12

= 24582893929.12
Outflow energy balance:
NaCl,out = Hf +
= (-411 + 0)
= -411
HNaCl, out = -411

* 141.247

= -58052517
Cl2 out = Hf +

- 309048266

38

= 0 + (33.60 + 1.367 10
10

)dT
= 1712.04

HCl2,out= 26.0415

* 1712.04

= 44584089.66
H2O,out = Hf +
= -285.84 +

75.4

= -285.84 + 75.4[75-25]
= 3484.16
HH2O,out = 21371.994

* 3484.16

= 74463446615.04
H2,out = Hf +
= 0 +
= 1442.75
HH2,out= 1442.75

* 710.473

= 1025612020.75
NaOH,out = Hf +

1.607 10

+ 6.473

39

= (-469.9 + 0)
= -469.9
HNaOH,out= -469.9
= -13354050508
Total Hout = HNaCl + HCl2 + HNaOH+ HH2 + HH2O
= -5802517

+ 44584089.66

+ 74463446615.04

-13354050508

1025612020.75
= 62100000000
=6.21*108

Overall Energy Balance:

Total Hout - Total Hin
= 37538695780
So, Reaction occurring in electrolyzer are exothermic.

40

Equipment Design
Plate & Frame Heat Exchanger Design

Cold water, 55C

30% brine, 25C

20% brine, 55C

Hot water, 95C

At average temperature the fluid properties for each stream are listed belowPerrys Chemical Engineering Handbook.
Property

Brine at 450C

Water at 82.50C

41

Heat capacity, Cp (J/kg K)

Thermal conductivity,( kW/mK)
Viscosity, v (Pa.S)
Density, (kg/m3)

3320
0.470
1.4 * 10-3
1.2 * 103

Mass flow rate of brine

=

= 14.75 kg/s
The total heat transfer rate is
q= (mCpT)c
= 14.75 * 3320 * (70 - 20)
= 2448500 W
The mass flow rate of water is,
mh = q/(CpT)h
=

= 23.31 kg/s
Lets assume
Thickness of a plate, xw=7mm=0.007 m
Length of a wall, L=1m
Width of a plate, W=0.5 m
Spacing between the plate, b=0.005 m
The mean hydraulic diameter, De=2b=2*0.005=0.01m

4200
0.670
3.45*10-4
970

42

Log mean temperature difference

LMTD=
Where

= hot fluid temperature difference

= cold fluid temperature difference

Hence LMTD (Tm)=

=

) (
(
(

)
)
)

= 34.76
For single pass counter flow plate type heat exchanger, F=1
As the Plate is constructed by mild stainless steel,
Thermal conductivity, kw=45.7 J/ms .K
The heat transfer surface area of the exchanger in terms of plate, n
A= (n-1)LW=(n-1)*1*0.5
= 0.5(n-1)m2
The flow area for each stream with
S= Wb =

flow passage is given by,

* 0.5 *0.005

= 2.5*10-3n m2
Velocity of water, Vh=

=
Velocity of brine, Vc=

.
.

m/s
.

43

m/s

Reynolds no. for hot fluid, Rh=

.

.
.

=
Reynolds no. for cold fluid, Rh=
=

Prandlt number for hot fluid, Prh= (

)h
.

= 2.16

Prandlt number for cold fluid, Prc= (

)c
.

= 9.88

Heat transfer coefficient of hot fluid(water)

*(Reh)0.8*(Pr)0.33

hh= 0.023*
= 0.023*
=

*(

)0.8 * 2.160.33

.
.

Heat transfer coefficient of cold fluid(brine)

*(Rec)0.8*(Pr)0.33

hc= 0.023*
= 0.023*

.
.

*(

)0.8 * 9.880.33

44
.

Overall heat transfer coefficient= U

We know,
=

+
.

.
.

= 1.0945 10

+ 1.53 10

= 1.53 10 (n0.8+.715)

Minimum Number of Transfer Unit for cold stream with a minimum mCp is define
as,
NTUmin=

. (

( .
.

(
.

)(
)

)
)(

= 0.925

0.0766( 1)= 0.925(n0.8+1)

. 0.0828n + 1.083 = 0
n = 67423

45

Economics Analysis Using Breakthrough

Curve

46

Total equipment cost { Pump (maximum pressure 42 psi) + Plate type heat
exchanger + Reactors + Saturators + Clarifier + Tank + Membrane for cell house}
= 21*10 TK
Direct Cost = (Equipment Cost + Piping + Instrument and controlled installed +
Electrical Cost + Equipment maintenance) = 21* 10 (1+0.4+0.7+0.2+0.1)
= 50.4*10 tk.
Investment which are not directly involved with material and labor of actual
installation or complete facility.
Indirect cost are cost of engineering & designing, contactors fee, contingency
equals 20106 tk.
So fixed capital investment = 70.56106 tk.
Assume working capital investment is approximately 20% of fixed capital. Thus
working capital is therefore 14.11106 tk.
So total capital investment = fixed capital + working capital.
=84.67106 tk.
Sales value = (70320100075) tk.
= 168106 tk.
We take unit production = production of 36 days
=(3670) ton = 2520 ton
We know that breakeven point can be found by the following equation

47

BEP =
=

= 7702.957
We also found from breakeven curve breakeven unit is 45.9
The value of BEP unit in ton = (45.92520) ton
=

days

=1652.4 days
= 4.52 y

Determination of product price based on Break Even Point

Variable cost/unit
Fixed cost
Price/unit
BEP unit
Break Even Point

14.11
7056
168.00
45.9
7702.957

48

45000
40000
35000
30000
$

25000
20000
15000
10000
5000
0
0

50

100

150

200

250

Unit sales
Fixed Cost

Total Cost

Revenue

Fig: Breakeven curve

Unit
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85

Fixed
Variable Total
Cost
Cost
Cost
7056
0
7056
7056
70.55 7126.55
7056
141.1
7197.1
7056
211.65 7267.65
7056
282.2
7338.2
7056
352.75 7408.75
7056
423.3
7479.3
7056
493.85 7549.85
7056
564.4
7620.4
7056
634.95 7690.95
7056
705.5
7761.5
7056
776.05 7832.05
7056
846.6
7902.6
7056
917.15 7973.15
7056
987.7
8043.7
7056 1058.25 8114.25
7056
1128.8
8184.8
7056 1199.35 8255.35

Revenue Profit
0 -7056.0
840 -6286.6
1680 -5517.1
2520 -4747.7
3360 -3978.2
4200 -3208.8
5040 -2439.3
5880 -1669.9
6720
-900.4
7560
-131.0
8400
638.5
9240
1408.0
10080
2177.4
10920
2946.9
11760
3716.3
12600
4485.8
13440
5255.2
14280
6024.7

49

Fig: Breakeven sequential data

SAFETY

50

Industrial Safety:
Industrial safety is the term consists of some precautionary measures that are observed by people
at the time of performing a job inside the factory with the help of some machine or equipment
design in such manner that can check the accident to be happened with ultimate view to achieve
the possible higher productivity.

Importance of Safety:
The ultimate aim of safety is the complete prevention of personal injury, loss of life and
destruction of properties. Effective plant safety and fire protection are essential for every phase
of operation and maintenance of equipment & machines. Calculated risks must be reduced as
far as possible. Equipment & individual items must be examined time to time for normal service
and also emergency demands. Some major principles and practice of plant safety are
mentioned below. For safe plant operation, detailed safety instructions must always be
established. All buildings, workshops, installation, machinery and equipment must be furnished
and maintains so as to protect the workers against accidents and professional diseases. The
instructions issued by the plant management for safe operation and for the conduct of
personnel must be followed strictly.

51

Responsibility of safety:
The safety is of a preventive nature; the aim is to stop the risks and unsatisfactory conditions
and their incorporation into better working conditions. This requires contributions from and
above all, co-operation between both employees and employer.

General Safety Rules:

The Bangladesh government established a general safety rule for industry called Safety in the
Factory Rules, 1979. Every industrial personnel is to observe the following general safety
rules:

Use appropriate personal protective apparel and equipment for the operation.

Use alert to unsafe conditions and reactions. Call attention to hazards so the corrections can
be made immediately.

Use laboratory equipment only for its designed purpose.

Know the location of emergency equipment in your area. Read and become familiar with
emergency response procedures.

Label all chemicals clearly and correctly.

Avoid destructing or startling any co-worker in the laboratory. Practical jokes or any
horseplay cannot be tolerated at any time in the laboratory.

Access to exits, emergency equipment, controls and such must never be blocked. Stairways
and hallways must not be used as storage areas even temporarily.

Laboratory equipment must be inspected regularly and serviced accordingly to

manufacturers suggested schedule.

Safety Sign:
For the concern of the companys personnel safety, different safety signs are used such as:

Prohibition Sign
Example: No smoking, Pedestrians prohibited, No drinking water etc.

52

Warning Sign
Example: Risk of electrical shock, Laser beam, Risk of explosion, Risk of fire, Toxic hazard.

Mandatory Sign
Example: Eye protection, Hand, head and foot protection, Hearing and respiratory protection
etc.

Safe Condition Sign

Example: First aid, Indication of direction.

Safety equipments: The following equipments are used for safety consideration

53

Fig: Head protection gear

Fig: Hand protection equipment

Fig: Face protection equipment

Fig: Leg protection equipment

54

Fig: Flame retardant cloth

Fig: high visibility wear

55

PLANT LAYOUT

56

The laying out of a plant is still an art rather than a science. Plant Layout is the physical
arrangement of equipment and facilities within a Plant. The Plant Layout can be indicated on a
floor plan showing the distances between different features of the plant. Optimizing the Layout
of a Plant can improve productivity, safety and quality of Products. Unnecessary efforts of
materials handling can be avoided when the Plant Layout is optimized. It involves the placing of
equipment so that the following are minimized:
(1) Damage to persons and property in case of a tire or explosion;
(2) Maintenance costs;
(3) The number of people required to operate the plant;
(4) Other operating costs;
(5) Construction costs;
(6) The cost of the planned future revision or expansion.
All of these goals cannot be met. For example, to reduce potential losses in case of fire, the plant
should be spread out, but this would also result in higher pumping costs, and might increase
manpower needs. The engineer must decide within the guidelines set by his company which of
the aforementioned items are most important.
The first thing that should be done is to determine the direction of the prevailing wind. This can
be done by consulting Weather Bureau records. In Bangladesh the prevailing winds are often
from the north to south in the summer. Wind direction will determine the general location of
many things. All equipment that may spill flammable materials should be located on the
downwind side. Then if a spill occurs the prevailing winds are not apt to carry any vapors over
the plant, where they could be ignited by an open flame or a hot surface.
For a similar reason the powerhouse, boilers, water pumping, and air supply facilities should be
located 250 ft (75 m) from the rest of the plant, and on the upwind side. This is to minimize the
possibility that these facilities will be damaged in case of a major spill. This is especially
important for the first two items, where there are usually open flames.
Every precaution should be taken to prevent the disruption of utilities, since this could mean the
failure of pumps, agitators, and instrumentation. For this reason, it may also be wise to separate
the boilers and furnaces from the other utilities. Then, should the fired equipment explode, the
other utilities will not be damaged.
Other facilities that are generally placed upwind of operating units are plant offices, mechanical
shops, and central laboratories. All of these involve a number of people who need to be
protected. Also shops and laboratories frequently produce sparks and flames that would ignite
flammable gases. Laboratories that are used primarily for quality control are sometimes located

57

in the production area.

A list of items that should be placed downwind of the processing facilities is given below
Items That Should Be Located Upwind of the Plant
Plant offices
Central laboratories
Mechanical and other shops
Office building
Cafeteria
Storehouse
Medical building
Change house
Fire station
Boiler house
Electrical powerhouse
Electrical Substation
Water treatment plant
Cooling tower
Air compressors
Parking lot
Main water pumps
Warehouses that contain nonhazardous,
Non explosive, and
Non flammable materials
Fired heaters
All ignition sources

Items That Should Be Located Downwind

of the Plant
Equipment that may spill inflammable materials
Blow down tanks
Burning flares
Settling ponds

58

Storage Facilities
Tank farms and warehouses that contain nonhazardous, nonflammable, and non explosive
materials should be located upwind of the plant. Those that do not fit this category should not be
located downwind of the plant, where they could be damaged and possibly destroyed by a major
spill in the processing area. Nor should they be located upwind of the plant where, if they spilled
some of their contents, the processing area might be damaged. They should be located at least
250 ft (75m) to the side of any processing area.2 Some authorities suggest this should be 500 ft.
The same reasoning applies to hazardous shipping and receiving areas.
Sometimes storage tanks are located on a hill, in order to allow the gravity feeding of tank cars.
Care must be taken under these circumstances to see that any slop over cannot flow into the
processing, utilities, or service areas in case of a tank fire.
Spacing of Items
The OSHA has standards for hazardous materials that give the minimum distances between
containers and the distance between these items and the property line, public roads, and
buildings. These depend on the characteristics of the material, the type and size of the container,
whether the tank is above ground or buried, and what type of protection is provided. Specific
details are provided for compressed gas equipment containing acetylene-air, hydrogen-oxygen,
and nitrous oxide, as well as liquefied petroleum gases. They also prohibit the storage and
location of vessels containing flammable and combustible materials inside buildings, unless
special precautions are taken.
Processing Area
There are two ways of laying out a processing area. The grouped layout places all similar pieces
of equipment adjacent. This provides for ease of operation and switching from one unit to
another. For instance, if there are 10 batch reactors, these would all be placed in the same general
area, and could be watched by a minimum of operators; if they were spread out over a wide area,
more operators might be needed. This type of scheme is best for large plants. The flow line
layout uses the train or line system, which locates all the equipment in the order in which it
occurs on the flow sheet. This minimizes the length of transfer lines and, therefore, reduces the
energy needed to transport materials. This system is used extensively in the pharmaceutical
industry, where each batch of a drug that is produced must be kept separate from all other
batches. In other industries it is used mainly for small-volume products. Often, instead of using
the grouped or flow line layout exclusively, a combination that best suits the specific situation is
used.
Elevation
If there is no special reason for elevating equipment, it should be placed on the ground level. The
superstructure to support an elevated piece of equipment is expensive. It can also be a hazard
should there be an earthquake, fire, or explosion. Then it might collapse and destroy the
equipment it is supporting as well as that nearby. Some pieces of equipment will be elevated to
simplify the plant operations. An example of this is the gravity feed of reactors from elevated

59

tanks. This eliminates the need for some materials-handling equipment. Other pieces may have
to be elevated to enable the system to operate. A steam jet ejector with an inter condenser that is
used to produce a vacuum must be located above a 34 ft (10 m) barometric leg. Condensate
receivers and holding tanks frequently must be located high enough to provide an adequate net
positive suction head (NPSH) for the pump below. For many pumps an NPSH of at least 14 ft
(4.2 m)
Hz0 is desirable. Others can operate when the NPSH is only 6 ft (2 m) H2O.
The third reason for elevating equipment is safety. In making explosive materials, such as TNT,
the reactor is located above a large tank of water. Then if the mixture in the reactor gets too hot
and is in danger of exploding, a quick-opening valve below the reactor is opened and the whole
batch is dumped into the water. An emergency water tank may need to be elevated so that, in
case of a power failure, cooling water to the plant will continue to flow, and there will be water
available should a tire occur. Sometimes this tank is located on a nearby hill. An elevation plan
should be drawn to scale showing the vertical relationships of all elevated equipment. These
drawings, as well as the plot plan, are usually sketched by the engineer and then redrawn to scale
by a draftsman.
Maintenance
Maintenance costs are very large in the chemical industry. In some cases the cost of maintenance
exceeds the companys profit.
Construction and Building
Proper placing of equipment can result in large savings during the construction of the plant. For
instance, large columns that are field-erected should be located at one end of the site so that they
can be built, welded, and tested without interfering with the construction of the rest of the plant.
Buildings
Included with the layout of the plant is the decision as to what types of buildings are to be
constructed, and the size of each. When laying out buildings, a standard size bay (area in which
there is no structural supports) is 20 ft x 20 ft (6m x 6m). Under normal conditions a 20 ft (6 m)
span does not need any center supports. The extension of the bay in one direction can be done
inexpensively. This only increases the amount of steel in the long girders, and requires stronger
supports. Lavatories, change rooms, cafeterias, and medical facilities are all located inside
buildings. The minimum size of these facilities is dictated by OSHA. It depends on the number
of men employed. Research laboratories and office buildings are usually not included in the
preliminary cost estimate. However, if they are contemplated their location should be indicated
on the plot plan.
Processing Buildings
Quality control laboratories are a necessary part of any plant, and must be included in all cost
estimates. Adequate space must be provided in them for performing all tests, and for cleaning
and storing laboratory sampling and testing containers. The processing units of most large
chemical plants today are not located inside buildings. This is true as far north as Michigan. The
only equipment enclosed in buildings is that which must be protected from the weather, or batch

60

equipment that requires constant attention from operators. Much of the batch equipment used
today does not fit this category. It is highly automated and does not need to be enclosed. When
buildings are used, the ceilings generally vary from 14 to 20 ft (4 to 6 m). Space must be allowed
above process vessels for piping and for access to valves. One rule of thumb is to make the
floortofloor heights 8- 10 ft (approximately 3m) higher than the sides of a dished-head vertical tank.6
Packaging equipment generally must be in an enclosed building, and is often located at one end
of the warehouse. If the material being packaged is hazardous, either this operation will be
performed in a separate building, or a firewall will separate it from any processing or storage
areas
Warehouse:
The engineer must decide whether warehouses should be at ground level or at dock level. The
latter facilitates loading trains and trucks, but costs 1520% more than one placed on the ground.
It is usually difficult to justify the added expense of a dock-high warehouse. To size the amount
of space needed for a warehouse, it must be determined how much is to be stored in what size
containers. The container sizes that will be used are obtained from the scope. Liquids are
generally stored in bulk containers. No more than a weeks supply of liquid stored in drums
should be planned. Solids, on the other hand, are frequently stored in smaller containers or in a
pile on the ground.
Control Rooms
The control center(s) and the electrical switching room are always located in an enclosed
building. It is important that both of these services be maintained so that the plant can be shut
down in an orderly manner in the case of an emergency. Therefore these buildings must be built
so that should an external explosion occur the room will not collapse and destroy the control
center and switching center. To avoid this, either the structure must have 3-4 ft (l-l.2 m) thick
walls, or the roof must be supported independently of the walls. The Humble Oil and Refining
Co. has specified that the building withstand a 400 psf (2,000 kg / m2) external explosive force.
To keep any flammable or explosive vapors from entering the building, it is frequently slightly
pressurized. This prevents the possibility of an internal explosion.

61

HAZOP STUDY

62

The hazard and operability study, commonly referred to as the HAZOP study is a
systematic approach for identifying all plant or equipment hazards and operability
problems. In this technique all segment are carefully examined and all possible
deviation from normal operating conditions are identified.
Hazard assessment is vital tool in loss prevention throughout the life of a facility.
A through hazard and risk assessment of a new facility is essential during the final
design stage.
A hazard assessment during the prestart-up period should be a final check rather
than an initial assessment.
The major hazard usually include toxicity, fire, and explosions, however thermal
radiation, nose, asphyxiation and various environmental concerns also need to
be considered.
Hazard in chlor-alkali industry:
1. Chlorine Hazard:
Hazards associated with breathing of Chlorine:
Chlorine is a severe nose, throat and upper respiratory tract irritant. People exposed
to chlorine, even for short periods of time, can develop a tolerance to its odour and
irritating properties. Concentrations of 1 to 2 ppm produce significant irritation and
coughing, minor difficulty breathing and headache. Concentrations of 1 to 4 ppm
are considered unbearable. Severe respiratory tract damage including bronchitis
and pulmonary edema (a potentially fatal accumulation of fluid in the lungs) has
been observed after even relatively low, brief exposures (estimates range from 15
to 60 ppm). . However, long-term respiratory system and lung disorders have been
observed following severe short-term exposures to chlorine.
Reactive Airways Dysfunction Syndrome
permanently reduced lung function
Hazard associated when Chlorine comes into contact with skin:
Direct contact with the liquefied gas escaping from its pressurized cylinder
can cause frostbite. Symptoms of mild frostbite include numbness, prickling
and itching in the affected area. The skin may become waxy white or yellow.

63

Blistering, tissue death and gangrene may also develop in severe cases. In
addition, the airborne gas may irritate and burn the skin

Hazard associated when Chlorine hurt eyes:

Chlorine gas is a severe eye irritant. Stinging, a burning sensation, rapid blinking,
redness and watering of the eyes have been observed at concentrations of 1 ppm
and higher.
Health effects to exposure of Chlorine:
INHALATION: Despite design limitations, the small number of human
population studies conducted have not shown significant respiratory system
effects in workers with long-term, low-level (typically less than 1 ppm)
chlorine exposure and 1.42 ppm (0.15 ppm average) for an average
exposure. Chlorine workers reported a higher incidence of tooth decay
(based on medical history.
First Aid Measures :
Inhalation:
Remove to fresh air. Get medical attention for any breathing difficulty.
Ingestion:
If large amounts were swallowed, give water to drink and get medical
advice.
Skin Contact:
Wash exposed area with soap and water. Get medical advice if irritation
develops.
Eye Contact:
Immediately flush eyes with plenty of water for at least 15 minutes, lifting

64

upper and lower eyelids occasionally. Get medical attention if irritation

persists.
Bleaching Hazard:
o

Chlorine bleach contains chlorine, a toxic gas, combined with sodium

and oxygen as sodium hypochlorite. Hazards arise when the chlorine
is released from this bond. The U.S. Food and Drug Administration
reports that chlorine bleach is also a common food tampering
adulterant.

Gastrointestinal Damage
Excluding deliberate beverage tampering, accidental ingestion is relatively
unlikely because this strong-smelling, caustic liquid induces the gag reflex.
However, when it is swallowed, bleach causes corrosive damage to the
throat and stomach linings. At domestic concentrations, severe tissue
damage or systemic poisoning are unlikely. Both toxicity levels and
causticity are more hazardous in industrial-strength bleach products.
Skin Damage
Undiluted bleach is corrosive. Even domestic bleach damages skin tissues
and removes essential fats. During extended contact, small amounts of toxic
chlorine may enter the body through the skin. Industrial bleach carries a
much greater corrosive hazard, and protective clothing and eye protection
are required.
Lung Damage
It is relatively easy accidentally to mix bleach, used in cleaning, with
other cleaning products--for example in the toilet, sink or drain. Mixing
bleach with ammonia is particularly hazardous, releasing chlorine gas,
ammonia gas and chloramines.
These gases are caustic and irritating, and inhalation damages the
lungs and nasal passages. Exposure to high concentrations of
ammonia gas for longer than 15 to 30 minutes can lead to irreversible

65

damage, even death. Because chlorine gas is water-soluble, it forms

hydrochloric or hypochlorous acid upon meeting moisture in the
mucus membranes, eyes and mouth. In the lungs, acid damage results
in pulmonary edema (release of fluid into the tissues), causing
breathing difficulties.Chloramines cause similar breathing difficulties
and irritation to the eyes, nose, throat and skin. These are the
compounds that cause irritation in swimming pools.

Explosion
More likely to occur in an industrial than a domestic setting, ammonia
mixed with bleach in higher proportion may form nitrogen trichloride or
hydrazine, both of which are explosive. Exposure to hydrazine causes
burning pain in the eyes, nose and throat, head.

66

References:
1.

Kern D. Q. (1950) Process Heat Transfer, McGraw-Hill.

2.

Pletcher D., Walsh F. C. (1990) Industrial Electrochemistry. 2nd ed.

3.

Perry R. H (1997) Chemical Engineering Handbook. 7th ed., McGraw-Hill.

4.

Peters M. S., Timmerhaus K. D., West R. E. (2003) Plant Design & Economics for Chemical
Engineers. 5th ed., McGraw-Hill, New York.

5.

Coulson J. M., Richardson, J. F. (1998) Chemical Engg. Vol.6, 3rd ed.

6.

Fogler H. S. (2007) Elements of Chemical Reaction Engineering. 4th ed., Dorling Kindersley
(India) Pvt. Ltd.

7.

Douglas J. M. (1988) Conceptual design of chemical processes, McGraw-Hill.

8.

Website: www.opsoglobal.com