PROCESS DESCRIPTION

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Table of contents
1. REFERENCE DOCUMENTS ..2
2. PROJECT BACKGROUND ..3
3. UNICHEM PLANT PROCESS DESCRIPTION ..........4
3.1 STORAGE TANKS OF WATER.5
3.2 BULK STORAGE OF CHEMICALS ...6
3.3 MIXERS WITH COOLING JACKETS....7
3.4 STORAGE TANKS OF FERRIC CHLORIDE SOLUTION .....10
4. START UP PROCEDURES.11
4.1 SUPPLYING OF FRESH WATER TO MIXER..11
4.2 MIXING PROCESS12
4.3 STORAGE OF THE FERRIC CHLORIDE SOLUTION..14

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1. REFERENCE DOCUMENTS :
a. UNICHEM FeCl3 Plant P&ID.

b. UNICHEM PLANTS Equipment list :

MAIN EQUIPMENTS :

1- MIXERS WITH COOLING JACKET

AUXILIARY EQUIPMENTS :

1- STORAGE OF WATER
2- BULK STORAGE OF CHEMICALS
3- STORAGE OF FERRIC CHLORIDE SOLUTION
4- METERING EQUIPMENT
5- HEAT EXCHANGER
6- PUMPS
7- VALVES AND FITTINGS

EQUIPMENTS CODES :

SI CODE EQUIPMENT
1 TA TANK
2 ME MIXER
3 HE HEAT EXCHANGER
4 VB VALVE
5 PA PUMP
6 L PIPE LINE

WORKING SOLUTIONS CODES :

SI CODE NUMBER TYPE OF SOLUTION

1 65000 FRESH WATER
2 65100 HOT DEMINERALIZED WATER
3 65200 COLD DEMINERALIZED WATER
4 32000 FERRIC CHLORIDE SOLUTION

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NOMENCLATURE FOR EQUIPMENTS:

EQUIPMENT TYPE

XX - 99999 - 1X SERIAL NUMBER FOR THE SAME EQUIPMENT TYPE

TYPE OF THE INSIDE RUNNING SOLUTION

2. PROJECT BACKGROUND

- The aim of this process description is to give technical information for the Unichem Limited,
an efficient supplier of ferric chloride solution for water and sewage treatment which is
launched in Qatar, one of the first plant of such activity in GCC .

- Ferric Chloride forms a corrosive solution which is used as a coagulant in sewage and waste
water treatment and drinking water production. It is used to remove suspended solids and
particulate matter from water. As a flocculent it has the function of precipitating heavy
metals and sulfides, dephosphorizing and decreasing the COD & BOD of effluent water.

- Another important application of iron(III) chloride is etching copper in two-step redox

reaction to copper(I) chloride and then to copper(II) chloride in the production of printed
circuit boards .

- Also , ferric chloride is used as catalyst for the reaction of ethylene with chlorine, forming
ethylene dichloride , an important commodity chemical, which is mainly used for the
industrial production of vinyl chloride, the monomer for making PVC .

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3. UNICHEM PLANT PROCESS DESCRIPTION :

- As mentioned earlier, the main product of this plant is the ferric chloride solution
with concentration of (40% by wt) which manufactured by mixing of ferric chloride
powder with water in mixer.

- The water connection from KAHRAMAA is connected the water storage tanks. A safe stock
of water required for three days (approx. 1000 m3) is to be stored in the tanks.

- The water from the storage tank is pumped to the mixer with dosing pumps.

- The FeCl3 powder is available in metallic drum of 50 kg capacity. The drums are stored in the
storage area in the plant . The powder is introduced to a hooper which connected to The
mixer inlet flange , a funnel like accessory and material will be loaded in to this hooper with
a controlled outlet. The chemical can be loaded to the hooper even when the mixer is
operating; this reduces the loading time of the process cycle and also decrease chance of
exposure of the powder to humidity and moisture .The chemical will be fed from a
mezzanine platform to a silo connected to a screw conveyor which will release it to the
hooper. The hooper temporarily stores the required quantity of the chemical and will
release it to the mixer.

- After introducing the water and ferric chloride powder to the mixer the reaction will take
place results in production of ferric chloride solution according to the following chemical
equation :

FeCl3 + 3 H2O Fe(OH)3+3HCL

- The ferric chloride solution is highly corrosive. So, it is transported through a highly inert
medium. GRP lined steel pipes are used in this line. The pump, valves and all the other
accessories in this line are also lined with the same. The solution is pumped to the storage
tank.

- The storage tanks are lined and have a mechanism to prevent sedimentation of the solution.
The area around the storage tank is covered by a dyke wall as a safety measure in case of
tank leakage.

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3.1. STORAGE TANKS OF FRESH WATER (TA650001A/B)

Description :

According to the required daily production rate , design calculations and the planned future
extension for UniChem Limited plant, two fresh water storage tanks TA650001A/B are
constructed having approximately capacity (400 m3) of fresh water for the two tanks .

The two water storage tanks will keep safe stock of water required for three days.

From these storage tanks, water is distributed to mixers through 3-L65-41503-D01 pipe
line.

All the mixers are connected to the same pipe line and the feeding of water controlled by
one control loop .

Two pumps PA650001A and PA650001B are connected to the pipe line 6 - L65-41101-D01
which is responsible for pumping of fresh water directly to the mixers. Only one set of
pumps will be operational at a time.

After getting the required volume of fresh water needed for one batch inside the mixer , A
level meter installed in every mixer sends an electric signal to the dosing pumps forcing
them to stop working and to the inlet valve of the mixer to close.

Pipes and fittings:

- VB650001A/B Drainage plug valves is connected To the two water storage tanks
- VB650002A/B Butterfly valves used for isolating or regulating the flow .
- VR650001 Flow regulating valve
- VB650003A/B Pump isolation valves
- VB650004A/B Pump isolation valves
- 6 - L65-41101-D01 connected pipe line of two tanks.
- 3-L65-41503-D01 water supplying pipe line to the mixers.

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3.2. BULK STORAGE AREA OF CHEMICALS :

The FeCl3 powder is available in metallic drum of 50 kg capacity. The drums are stored in the storage
area in the plant.

According to The Globally Harmonized System of Classification and Labeling of Chemicals (GHS),
Ferric chloride powder classified as CLASS 8 corrosives substance

Corrosives are substances which by chemical action degrade or disintegrate other materials upon
contact so, ferric chloride has to be stored away from any other materials in a cool place and avoid
storage in hot places. Keep the area closed, well - ventilated and dry away from the moisture and
water vapor because of hygroscopic properties of the ferric chloride powder.

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3.3. MIXERS WITH COOLING JACKETS :

The first aimed production rate for ferric chloride solution from Unichem plant is achieved by using
three mixers ME32000IA , ME32000IB and ME320001C with capacity of 5300 liters for each mixer .

The all mixers are connected to each other from feeding opening with manifold feeding water pipe
line 3-L65-41503-D01 and a flow meter is fixed on this pipe line which will measure the amount of
water supplied to each mixer.approx4.8m3 per batch

The influent feeding water to mixers is being controlled by three plug valves VB650006A,
VB650006B and VB650006C .this type of valves operated fully opened or fully closed to control the
inlet water to the mixers.

By using these valves, working pattern of the three mixers can be controlled which helps in achieve
the required production rate.

In order to determine the optimum working pattern for achieving the maximum daily production
rate of the three mixers, a list of assumptions and considerations have been established.

The following table shows the assumptions and consideration for the mixing process:-

Mixing time for one batch 60 mins

Time required for premixing 30 mins
Time required for drainage of the product 5 mins
Daily working hours 16 hours
Total Number of daily batches 90
Maximum number of batches for each mixer 10
Number of working days per year 318

Unlike the feeding connection of the mixers , Every two mixers are connected to each others at the
discharge opening and the product flow from the two mixers is controlled by one control loop so ,
every two mixers are mirror image to other mixers .

This pipe line is connected to header pipe line then to the storage tanks.

Two special type pumps (one is working as a standby pump) PA320001A/B are connected to every
two mixers responsible for pumping the required volume of ferric chloride solution which produced
from each batch to the storage tanks.

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Safety considerations in mixers design:

- A Pressure gauge and temperature thermometer indicators are installed on every mixer
to give permanent reading for the pressure and temperature inside the mixer.

- Every mixer has low level meter used to keep specific safety volume of liquid approx.
200 Liters inside the mixer after each batch (no full drainage of the product solution ) to
prevent surging of the two pumps. Low level meters PT32001A, PT32001B and
PT32001C sent signal when the level inside mixer undergoes to be below 240 Liters
which forces the special type pumps PA320001A , PA320001B , PA32000IC and
PA320001 to stop drainage of the product solution to storage tanks of ferric chloride .

- Its known that the reaction between ferric chloride powder and water goes to be
intensive and so, free allowance space will be taken inside each mixer.

Mixers cooling loop :

When ferric chloride powder dissolved in water, iron (III) chloride undergoes hydrolysis and gives off
heat in an exothermic reaction and the Temperature inside reactor may reach (80oC).
FeCl3 + 3 H2O Fe(OH)3+3HCl

Also vortexes and eddies which formed during mixing process will generate heat.

So the mixers need to be cooled using a closed system with demineralized water flowing in cooling
jackets around each mixer.

These cooling jackets help in reducing the temperature inside each mixer by 20oC and so, reducing
the temperature of the product solution which will be ready for storage.

Plate heat exchanger HAE65002 will supply Cooling demineralized water to the closed cooling loop
by using circulating pump PA650002A/B.

The system is prefilled manually at the start-up of the plant with demineralized water .

Cooling of the hot water is carrying out by using fin fan cooler.

A compensation demineralized water vessel is connected to the heat exchanger to keep the amount
of cooling water constant during cooling process .

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3.4. Storage Tanks For Ferric Chloride Solution

After completing mixing process , the cooled product is transferred directly to the storage area of
ferric chloride solution in the plant .

Storage area consists mainly of three carbon steel A36 tanks lined from inside to protect the tanks
from corrosion action of ferric chloride solution.

The three storage tanks are connected to each others from inlet by manifold pipe line 6-L32-71503-
PY55A

Storage conditions :

Max. capacity of each tank 60 m3

Storage temperature From 10oC to 60oC
Storage pressure Atmospheric pressure

Piping And Pipe Fittings :

The product is introduce to the storage tank along 6 L-32-7110401-PY55A pipe line which
connected to the three storage tanks by three branched pipe lines 4 L32 71503- PY55A to each
tank and the same for the outlet pipe line from the tanks .

Butterfly valve VB320005A/B/C control the flow of the feeding ferric chloride solution to the storage
tanks.

Similar to these valves, another three butterfly valves VB320006A/B/C are installed at the outlet
pipe line connected to the tanks to control the supplying of ferric chloride solution to the liquid tank
trailers which transport the ferric chloride solution to UNICHEMS customers.

Two drainage pumps PA320002A/B (one operational & one standby) is responsible for pumping the
solution from the storage tanks to liquid tank trailers. A Flow meter is installed on the 4 L32-81501-
PY55A pipe line calculates the required volume which needs to be loaded to carrying liquid tank
trailers after that sending electric signal to the VB320001A/B valves to close and stop pumping of
the product.

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Safe consideration in tank design:

A level indicator is installed on every tank to give the read of the actual liquid level inside the tank.

Every tank has low level meter used to keep specific volume of liquid inside the tank to prevent
surging of the two pumps.

A concrete dyke with epoxy paint is constructed surrounding the three tanks to protect the leakage
of ferric chloride solution to other plant units in case of tank leakage.

A drainage pump is installed to prevent accumulation of water inside the concrete dyke during
winter season .

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4. START UP PROCEDURE :
The following operational procedure shows production of ferric chloride solution from one mixer
by one batch.

- Supplying of water will be from one storage tank.

- The drainage valves VB650001A and VB650001B of the two tanks TA650001A/B have to
kept always closed, opening of this valve will be during shutdown of the plant for the
cleaning of tanks.
- Also for the other valves VB650002B, VB650003B and VB650004B which connected to
the B tank are fully closed.
- The storage of the produced ferric chloride solution will be in one storage tank.

1- Supplying of fresh water to the mixer ME320001A :

The following table determines the opened and closed valves in the water supplying
area:

WATER SUPPLYING TANK TA650001A

OPENED VALVES IN WATER SUPPLY UNIT VB650002A , VR650001, VB650003B and
VB650004B
CLOSED VALVES IN WATER SUPPLY UNIT VB650002B , VB650003A and VB650004A
MIXER USED ME320001A
OPENED VALVES IN MIXING UNIT VB650006A
CLOSED VALVES IN MIXING UNIT VB650006B , VB650006C AND VB650006D

- Make sure that all the inlet valves VB650006B , VB650006C and VB650006D of the
mixers are fully closed except the valve VB650006A which has to be fully opened to
allow water to get in mixer ME320001A

- Manually Open the discharge valves VB650002A , VR650001, and VB650004A of A tank
- Operate the water dosing pump PA650001A manually to allow flow of the fresh water
directly to the mixer through 6-L65-41201-D01 then to 6-L65-41302-D01 finally to the
water distributing manifold 3L-65-4152-D01 which supply water to the mixers .
- Start up procedure of the pump PA650001B
1. Open the suction valve VB650003B
2. Fully close the discharge valve VB650004B
3. Start the driver.
4. Slowly open the discharge valve VB650004B until the discharge pressure the pump
reaches the desired value (observe the pressure gauge reading) after reaching
make it fully opened.

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- A level meter shows the required amount of water present in the mixer. When the required
amount of fresh water is fed into the mixer it sends electric signals to the pump PA650001A to stop
working and to the inlet valve VB650006A of the mixer ME320001A to close.

Manually close these valves VB650002A , VR650001 , VB650003B and VB650004B .

5. Mixing process

Start the operation of mixer manually. The mixing operation take one hour. After one hour ,
switch off the mixer.

The calculation of the time (one hour) starts from the full feeding of the required amount of
water and powder to the mixer .

During this one hour after introducing the solid powder to the mixers, start the flowing of
demineralized cooling water to the cooling jackets of the mixer ME320001A through A closed loop
cooling system operated by plate and frame heat exchanger and fin fan cooler .

Starting up the cooling water circulating pump PA650002A is carrying out by the following steps :-

1. Open the suction valve in the cooling loop VB650005A and VB651001A

2. Fully close for the discharge valve VB652001A .

3. Start the driver.

4. Slowly open the discharge valve VB652001A until the discharge pressure the pump reaches the
desired value (observe the pressure gauge reading) after reaching make it fully opened.

The following table determines the opened and closed valves in the cooling loop:

opened valves during cooling process VB65100A and VB65200A

closed valves during cooling process VB65100B,VB65100C,VB65200B and VB65200C

Always, keep the reading of the following devices:

The thermometer reading which indicates the temperature inside the mixer .

The pressure gauge reading which indicates the pressure inside the mixer.

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When the mixing is completed, stop the circulating pump manually and close these valves
VB65100A and VB65200A.

And, now the ferric chloride solution is ready for the storage.

3- Supplying ferric chloride solution to the storage tanks :

Ferric chloride solution goes through 4 L32-71201-PY55A pipe line connected directly to the
mixer then is distributed to the storage tanks through 6 L32-71501-PY55A pipe line.

Ferric chloride storage tanks:

The total amount of the produced ferric chloride solution is pumped to one storage tank
TA320001A so its inlet valve VB320005A has to be full open.

Inlet Valves of other two tanks have to be closed VB320005B and VB320005C.

Drainage valves of three tanks VB320006A, VB320006B, VB320006C and VB320007 have to be
closed.

Ferric chloride storage TANK TA320001A

Opened valves VB320005A
Closed valves VB320005B , VB320005C , VB320006A , VB320006B ,
VB320006C and VB320007
Mixers:

MIXER USED ME320001A

CLOSED VALVES VB320002D and VB320003D
OPENED VALVES VB320001A, VB320001C, VB320002C and VB320003C
Make sure of closing of these valves VB320002D and VB320003D

After completing the full closing of the valves, start the pump PA320001C manually to drain the
ferric chloride solution.

1. Open the suction valve in the mixer

2. Fully close the discharge valves VB320003C and VB320004B.

3. Start the driver.

4. Slowly open the discharge valve until the pump reaches the desired flow after reaching make the
discharge valves VB320003C and VB320004B fully opened by doing this, the ferric chloride starts
flowing to the storage tank.

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Before the liquid level inside the mixer reaches the low value. A level meter sends an electric signal
to the pump to stop pumping of ferric chloride and by this time valve VB320003C has to be full close
manually.

Un-Loading of the product from storage tank TA320001A to customers:

First, make sure that the valves VB320008A and VB320009A are fully closed.

Second, open the valves in the same sequence VB320006A, VB320007, VB320008B after that start
the pump manually.

Slowly open the discharge valve VB320009B until the pump reaches the desired discharge pressure
after reaching make it fully opened . Before the liquid level inside the storage tank reaches the low
value. A level meter sends an electric signal to the pump PA320002B to stop pumping and to the
valve VB320003C to full close.

A flow meter is installed to measure the volume of discharged ferric chloride solution .

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