internship icl report - zeeshan ul haq

7/30/2019 Internship ICL Report - Zeeshan Ul Haq

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Students, ou=Administrator,

[email protected], c=PK

Date: 2011.06.12 15:18:56 +05'00'


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ACKNOWLEDGEMENT

The special thank goes to my helpful supervisor, Mr. Sheikh Khurshid. The

supervision and support that he gave truly help the progression and

smoothness of the internship program. The cooperation is much indeed

appreciated.

MygratefulthanksalsogotobothMr.AsmatNawazKhattak (MHR)andMr.

Rashid.Abigcontributionandhardworkedfrombothofyouduringthefour

weekisverygreatindeed.Besides,thisinternshipprogrammakesmerealized

thevalueofworkingtogetherasateamandasanewexperience inworking

environment,whichchallengesuseveryminute.Notforget,greatappreciation

gototherestofICLstaffthathelpmefromtimetotimeduringtheinternship.

Great

deals

appreciated

go

to

the

contribution

of

my

facultyInstitue

of

ChemicalEngineering&Technology(ICET).Iamalsowouldliketothankfulthe

DirectorofICET,Prof.Dr.SyedZahoorulHassanRizviandallthestaffinthe

ICETofficethatpatientinhelpinguscompletethisprogram.NotforgettoMr.

Ayyaz Ahmad Muhammadfor the smoothes and cooperation during the

visited.

Lastbutnot least Iwould liketothankmy friendsespeciallythosewhowork

togetherasinterneesatICL.

Special thanks also to Mr. Talha Trainee Engineer at ICL that have

encouraged,supportandhelpusincompletingthisprogramsuccessfully.

Z e e s h a n u l H a q , S a b i r G h a z i , I C E T , P U 3|P a g e
http://pu.edu.pk/faculty/descriptions.asp?faculty=25032http://pu.edu.pk/faculty/descriptions.asp?faculty=25032http://pu.edu.pk/faculty/descriptions.asp?faculty=25032http://pu.edu.pk/faculty/descriptions.asp?faculty=25032http://pu.edu.pk/faculty/descriptions.asp?faculty=25032http://pu.edu.pk/faculty/descriptions.asp?faculty=25032http://pu.edu.pk/faculty/descriptions.asp?faculty=25032http://pu.edu.pk/faculty/descriptions.asp?faculty=25032http://pu.edu.pk/faculty/descriptions.asp?faculty=25032


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TableofContents

IndustryProfile

Page: 05History

Mission

Vision

BoardofDirectors

Capacity&Expansions

Products

QualityPolicy

EnvironmentalPolicy

International

Standards

SourceofRawMaterial Page: 12

PrimaryRawMaterials

SecondaryRawMaterials

EnergyResources

Equipments Page: 15

MeasuringEquipments

SafetyEquipments

ControllingEquipments

Pumps:

HeatExchangers

Process Page: 19

CausticSoda(NaOH)

1. BrinePurificationforI.E.M 2. BrinePurificationforD.S.A 3. I.E.MCellRoom 4. D.S.ACellRooms

LiquidChlorine(Cl2)

HydrochloricAcid(HCl)

Applications Page: 38

CausticSoda:

LiquidChlorine:

HydrochloricAcid:

SodiumHypochlorite:

ZincSulphate:

Shaffaf(BleachingEarth)

Summary Page: 41

Conclusions Page: 42

Recommendations Page: 42

Downloaded From : http://www.ICETStudentS.com


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IndustryProfile

Z e e s h a n u l H a q , S a b i r G h a z i , I C E T , P U 5|P a g eDownloaded From : http://www.ICETStudentS.com


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IndustryProfile

Ittehad Chemicals Limited (ICL) is the pioneer and one of the largest

manufacturers of industrial chemicals in Pakistan. It produces Caustic Soda, Liquid

Chlorine,

Hydrochloric

Acid,

Sodium

Hypochlorite,

Bleaching

Earth

(Shaffaf),

ChlorinatedParaffin,SulphuricAcid80%,ZincSulphate,andBariumSulphate.ICLhas

strategicallydiversifieditsproductportfolioinordertocaterforthedemandofthe

mark

History

Thefactoryisstrategicallylocatedonthe19th/20thKilometerofGTRoadand

spread over an area of 106 acres. Under the Economic Reforms Order, United

Chemicals was nationalized in 1971 along with other industriesof the country and

renamed as Ittehad Chemicals. It was initially managed by the Board of Industrial

Management and thereafter the Federal Chemicals & Ceramics Corporation Ltd

undertheMinistryofProduction,Govt.ofPakistan.

Ittehad Chemicals Limited (ICL) was established in 1962 under the name of

UnitedChemicalsbyaprivateentrepreneur.ICLwascommissionedintheyear1964

withaninstalledcapacityof40MT/dayofCausticSoda.Theinitialplantwassetup

byM/SOronzioDenoraofItaly.

During the state enterprise period its production capacity was raised by

another 90 tons/day during the year 198485. The factory was ultimately

denationalized in 1995 by the Privatization Commission Govt. of Pakistan. It was

acquiredbytheChemiGroupofIndustries,aKarachibaseddynamicentrepreneurial

group. The new management immediately undertook the task of refurbishing the

factory,itsinfrastructure,andupdatingitsproductionlinetoimproveefficiencyand

capacity.

Shortly after the takeover, the plant capacity was soon raised to over 200

tons/day. TheenvironmentalfriendlyIonExchangeMembranePlantwasaddedtothe production line in the year 2003 with a capacity of 163 tons/day. This was

shortlyenhancedto240tons/daywiththeadditionofmore IEMElectrolyzers.The

new technology is not only environment friendly but also powerconscious.

However, due to its subtle and urbane nature, it requires an uninterrupted power

supply for troublefree operations. Accordingly, the company established its own

stateoftheartPowerPlantof30MWcapacityintheyear2005.


Witharichandillustrioushistory,ICListhefoundingcompanyinPakistanfor

theChloro

alkali

industry.

It

has

paved

the

way

for

other

organizations

competing

in



8/44

the local market. With a growing interest for ICL products in the international

market,theorganizationhasmadethenecessaryarrangements(andwillcontinueto

dosointhefuture)tocaterforthegrowingdemand.

Mission

We work for our customers to provide a trusted and reliable source of

chemical products. Hence, through constant innovation and research we pride

ourselves on our unrelentless drive to continuously addvalue to our stakeholders,

employees, and customers. We strive for sustainable growth in harmony with our

environmentandsupplierstofosteracordialandmutualrelationship.

Vision

Tobethefirstchoiceofpreferencebycustomerslookingforpremiumquality

chemicalproducts.Weaspiretobeatrendsetterinourindustryandalwayslookto

thefuturewithcourageandacommitmenttoexcellenceinallourpractices.

BoardofDirectors

The board acknowledges its responsibility for the overall strategy, management,

identification and solutions for risks and challenges, sustained business prosperity

and

safeguarding

the

rights

of

shareholders.

It

endorses

the

best

practices

of

the

Code of Corporate Governance as an effective tool in discharging these duties in

additiontoenhancingthetimelines,accuracy,comprehensivenessandtransparency

offinancialandnonfinancialinformationthroughaccountabilityandintegrity.


Mr.MuhammadSiddiqueKhatri Chairman&ChiefExecutive

Mr.AbdulSattarKhatri Director

Mr.AbdulGhafoorKhatri Director

Mr.MansoorAhmedKhatri Director

Ms.FarhanaAbdulSattar Director

Mr.FawadYousuf Director

Ms.NoorulHuda Director



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Capacity&Expansions

IttehadChemicalsLimited ispublicly listedchemicalmanufacturingcompany

inPakistan.Thecompanywascommissionedin1964asUnitedChemicalsandstarted

production

with

an

initial

installed

capasity

of

60

MT/day

of

caustic

soda

and

54

MT/dayofchlorine.Risingdemandfacilitatedthefirstexpension,carriedoutin1969,

whichincreasedcapacityto90MT/dayofcausticsodaand81MT/dayofchlorine.

Atthesametime,UnitedChemicalwasnationalizedbyPakistanGovernment,

renamed IttehadChemicalsandputunderthecontroloftheFederalChemicaland

Ceramics Corporation Limited(FPCCL). Anthercompany, Insecticide Ltd, was

nationalized and renamed IttehadPesticites Ltd. in 1973. Later the two companies

were merged to form Ittehad Chemicals was futher increased to 150 MT/day of

causticsoda

and

135

MT/day

of

chorine.

Later,through

another

expension

Products

CausticSoda(Liquid/Solid/Flakes)

CausticSoda,alsoknownasSodiumHydroxide,formsastrongalkalinesolution

whendissolvedinwater.ICLproducesCausticSodaintheformofflakes,solid,

liquid(31%

and

50%

concentration).

In

solid

form,

it

is

hygroscopic

and

as

such

readilyabsorbswaterfromtheair.Hence,itisstoredinairtightcontainers.

CausticSodaLiquidismanufacturedcommerciallybytheelectrolysisofbrinein

electrolytic cells, where 31% membrane grade and 50% Rayon grade Caustic

Sodaliquidisproduced.

ItisproducedbyevaporationofliquidCausticSodasolutiontotheanhydrous

state,

and

subsequent

conversion

to

either

a

Solid

or

a

Flakes

form.

SodiumHypochlorite


Sodium Hypochlorite is used for a wide range of applications where its

powerfuldisinfectionandoxidationpropertiesareutilizedtodelivertechnical

and commercial advantage. It is manufactured by passing gaseous chlorine

throughawellcooledsolutionofdiluteCausticSoda.



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LiquidChlorine

Chlorine isthesinglematerialonwhichproductionofotherchemicalsmostly

depends. It is used in 60% of all Commercial Chemistry, 85% of all

Pharmaceutical Chemistry and 95% of all yield enhancing or agrochemical

chemistry.

Products manufactured with chlorine as a raw material include Water

Treatment Chemicals, Plastic, Detergents, Pharmaceuticals, Disinfectants and

Agricultural Chemicals.Chlorine isalso used directly inwater tomake it safe

fordrinkingbychlorination.

Chlorineis

obtained

by

passing

an

electric

current

through

asolution

of

brine

toproduceCausticSoda,ChlorineandHydrogen.

Hydrochloricacid

HydrochloricacidissecondonlytoSulphuricAcidinitsnumerousanddiverse

usesinmanufacturingindustryandsyntheticchemistry.

HydrochloricacidisasolutionoftheGasHydrogenChloride(HCL)inwater.

TheHydrogenChlorideGasisderivedfromtheburningofChlorineand

Hydrogen.

Shaffaf(BleachingEarth)

Ittehad Chemicals Limited is the pioneer in introducing the Acid Thermal

Activated Bleaching Earth, in Pakistan. ICL, through the efforts of its

competenttechnical

professionals

and

continuous

research,

have

succeeded

in

developing Acid Activated Earth from the indigenous rawmaterial, which

isstrongly competing with the imported Bleaching Earths available in the

Market

ZincSulphate


Zinc Sulphate Monohydrate is free flowing white powdery material, which is

highlysolubleinwater.



11/44

BariumSulphate

Barium Sulphate prismatic crystal as amorphous powder, hardly soluble in

water,ethanol,andacid,andeasilyformslumpsindryair.

QualityPolicy

Ittehadchemicalslimitediscommittedto

a) Producecausticsoda,chlorineandalliedproductinaccordancewith: The defined quality , specification and the budgeted target of

production&

Improvethequalityofitsproductsthroughtheutilizationofadvancedtechnologies.

b) Review the quality management system for its effectiveness and continualimprovementthroughinternalaudits

c) Achieve quality objectives with continuous training , review and improveprocess

condition

through

research

and

development

where

needed

d) Attend to customers complains on priority with maximum emphasis oncustomerscareandsatisfaction.

e) Ensure that the quality policy is communicated and understand within theorganizationandreviewedforcontinuingsuitability.

EnvironmentalPolicy

Ittehadchemicalslimitediscommittedtoproducecausticsoda,chlorineand

alliedproductskeepinginviewallaspectoftheirenvironmentalimpact

Intheregardtheyshall


a) Continually seek opportunities to improve our environmental aspects andundertake effective measures to present pollution , keep the factory/ work

areaandoursurroundingenvironmentneatandcleaninallrespects.



12/44

b) Fulfillourcommitmenttocomplywithapplicableenvironmentallaws,ensureadopting of all safety measures during requirements as work and meeting

customerrequirementsasfaraspossible.

c) Establishandreviewtheenvironmentalobjectives&target inallareasofouractivitiesatdefinedintervals.

d) Ensure that the environmental policy is implemented communicated to allconcernedpersonsworkingforandonbehalfoftheorganizationand isalso

availabletothepublic.

InternationalStandards:

ICLiscertifiedfromtwointernationalstandardsfromInternationalStandardOrganization(ISO).

Whichare:

1. ISO-9001ISO9001:2000specifies requirements foraqualitymanagement system

whereanorganization

1.

needs

to

demonstrate

its

ability

to

consistently

provide

product

that

meets

customerandapplicableregulatoryrequirements,and

2. aimstoenhancecustomersatisfactionthroughtheeffectiveapplicationofthe system, including processes for continual improvement of the system

and the assurance of conformity to customer and applicable regulatory

requirements.

2. ISO-14001


The

ISO

14000

is

a

family

of

internationally

recognized

standards

for

environmental management systems that is applicable to any business or

organization, regardless of size, location or income. These standards are

developedbythe InternationalOrganization forStandardization (ISO),which

hasrepresentationfromcommitteesallovertheworld.TheISO14000family

includesmostnotablytheISO14001standard,whichrepresentsthecoreset

of standards used by organizations for designing and implementing an

effectiveenvironmentalmanagementsystem.Otherstandardsincludedinthis

series are ISO 14004, which gives additional guidelines for a good

environmental management system, andmore specialized standardsdealing

withspecific

aspects

of

environmental

management.



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SourceofRaw

Materials



14/44

SourceofRawMaterial

Primary

Raw

Materials

Water

Ittehadchemicalslimitedhastheirowntubewellsandelectricmotorsto

obtainwaterfromearthformakeupwaterwhichhavelistedinprocessing.For

example

Leakagefrompipelines Entrainment Evaporation Drainofcondensedsteam Drainofimpuritieswhichcontainwater.Etc.

SodiumChloride(NaCl)

Sodiumchloride(NaCl) isthemajorrawmaterialfortheproductionofcaustic

sodawhichisthemainproductofIttehadChemicalsLimited.

They get the sodium chloride (NaCl) from KhewraandJehlam. They get this

hugetransportationbytrucksandthemostimportanttrains

SecondaryRawMaterials

BariumCarbonate CausticSoda HydrochloricAcid Flocculent SulphuricAcid



15/44

EnergyResources

Electricity

ICL

is

producing

22MW

electricity

by

burning

Natural

Gas

in

the

boiler,

which generate Steam, to run turbines. Generators are attached which

generateelectricity.

Steam

After generating electricity remaining steam is used in industry for

different

purposes.

For

example,

in

Heat

exchangers,

evaporators

and

primaryheatingofbrinesolution.



16/44

Equipments



17/44

Equipments

MeasuringEquipments

OrificePlate

ICL is using the orifice plate for fluid flow measurement, with digital

pressure difference measuring meter. They measure the flow of liquid

streams.

Thermocouple

Thermocouples are used for temperature measurement after different

operation intheplant.Theymeasurethetemperatureofdepletedbrine,

chlorinegas,causticsodaproductetc.

Acid-BaseTitration

After taking the sample of caustic soda, acid base titration is used in in

laboratoriesto

determine

the

concentration

of

the

product.

GlassTube

Glasstubesare installed todetermine the levelofthe tank.Forexample

causticstoragetank,ionexchangestoragetankandwaterstoragetanks.

Safety

Equipments

Helmet

Forsafetypurposes,Safetyhelmetsareprovidedtoavoidanyaccident.

GasMask

In industry chlorine gas leakage is very common. This gas is

poisonous,thatswhygasmaskareprovidedtoavoidtheinhalingofgas.



18/44

Gloves

Gloves are commonly used while controlling the valves of hot

stream,likesteampipesandheatedcausticsolutionpipelines.

Earplug

Coolingtowers,Boilers,turbinesandpumpscausesomuchnoise.To

minimizethenoiseearplugsareused.

Glasses

Inmechanicalworkshopsandonplantmaintenancewhereweldinghasto

bedone,glassesareprovidedtoprotecteyesfromsparks

SafetyShoes

In the leakage and maintenance areas operators and works must have

safetyshoes.

Extinguisher

In case of fire,extinguishers and waterpipelines are used for firemen to

controlfire.

ControllingEquipments

Globevalve

GlobevalvesaremostlyusedinICLforthrottlingpurposes.Inletandoutlet

ofcontainersandreactorsaremostlycontrolledbyglobevalves

Gatevalve

Atthe inletandoutletofflowpipestherearegatevalveswhichareused

forcompleteopenorcompleteclosetheflowintheindustry.

NonReturningvalve


They are used to stop backward flow of a stream passing through the

pipeline.



19/44


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Process



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Process

CausticSoda(NaOH)

ProcessofCausticSodaisdividedinfollowingplants:

5. BrinePurificationforI.E.M6. BrinePurificationforD.S.A7. I.E.MCellRoom8. D.S.ACellRooms1.BrinePurificationforI.E.M

I.E.Mbrineunitprovidesfeedofbrinesolutiontoionexchangemembrane

cellroom.Thebrinesolutionfeedmustbeultrapure.Theidealconcentration

ofbrineis280g/l.FollowingarethemaincomponentsofI.E.Mbrineunit.

1. Saturator2. Purifier3. Settler4. PrimaryandSecondaryFilters5. IonExchangeUnit

1.SaturatorSaturatorconsistof largestorageofrocksalt.Attherocksalt,depletedand

dechlorinatedbrine,alsocalledanoliteisshoweredinordertoconcentrateit.

Theanoliteatatemperatureof6570oC.Thebrinesolutionisstoredin3pits

fromwhere

it

is

sent

to

first

purifier.

2.PurifierSolutionofbariumcarbonateinwhichsomequantityofhydrochloricacidhas

beenadded,isintroducedintofirstpurifier.Capacityoffirstpurifieris70m3.


Excess carbonates are maintained in the solution to insure removal of

sulphate ions. (0.20.4% excess in brine feed to DSA cell room and 0.40.5%

excessinbrinefeedtoI.E.Mcellroom).Sludgeformedisperiodicallyremove

frombottomofthefirstpurifier.



22/44

Overflow from firstpurifiergoes tosecondpurifierwherecausticsolution is

addedintoit.

From purifier the brine is transferred to settler prior to the introduction of

brineinto

the

settler,

aflocculent

named

Accofloq

is

added.

Purifier

is

made

ofmildsteelandlinedwithfiberglass.

3.SettlerSettlerhascapacityof1000m

3,brineoverflows fromsettlerafter settling.A

scraper isalso installed inthecenter,nearthebottomofthesettlertopush

thesludgesettled,towardsthebottomofthetankwhereanautomaticgate

valveopensfor15sec.Afterevery15minutes.Fromsettler,thebrinemoves

toastorage

tank.

Settler

is

made

of

mild

steel

and

coated

with

atype

of

resin

whichiscorrosionresistant.

4.PrimaryandSecondaryFiltersFromsettler,thebrinemovestoaseriesoffilterswhere5differentlayersof

pebbles are used to filter the brine solution. The layer at the top is of

anthraciteandremaininglayerareofpebbleswhossizeincreasesfromtopto

bottom.

In secondary filters, 140 tubes of CPVC are installed, sleeves and a sock is

mountedoverit.Alphacellulose isfilled intothefilterowetthesockwith it

and subsequently drained before the purifier start operation. And then the

brineispassedthroughthetubes.Impuritiesstickwithalphacelluloseandare

washedlaterduringregeneration.Fromsecondaryfilters,brineispumpedto

feedtankforionexchangeunit.

5.IonExchangeUnitFromsecondaryfilters,brineistransferredtoionexchangeunit,whereanion

exchange resin of general formula RNa2 is used to completely remove all

impuritiesoutofit.ThepurifiedbrineisthensenttoI.E.Mcellroom.



23/44

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24/44

2.BrinePurificationforD.S.ADSA brine unit provides brine to DSA cell rooms. The purity level of brine

solutionrequiredhereisnotthatmushhighasthatforI.E.Mcellroom.Thats

whylesser

purifiers

is

installed

into

this

unit.

Another

distinguishing

feature

of

theunitisthatbrineisdechlorinatedinthisunitasopposetoI.E.Mbrineunit

where dechlorinated brine is received from cell room. The unit consist of

followingsubunits.

1. DeChlorinationUnit2. Saturator3. Purifier4. Settler5. SandFilters

1.De-ChlorinationUnitDepletedbrinefromDSAcellroom isreceived inatankmarkedas2D10.The

pH of incoming brine is 4. Here hydrochloric acid is injected into the tank

whichreleaseschlorinethroughcommon ioneffect.AndpH isreducedto2,

dueto

the

acid

injected.

From2D10,brinesolution istransferredtoAirStripperswhereair isbubbled

through brine to dechlorinate it. Chlorine released here along with air is

called as lean chlorine. Lean chlorine is sent to chlorine compressors. To

improve the pH of brine solution, caustic solution is injected in line, before

introductiontothetanksmarkedas2D13Aand2D13B.ThepHincreasesto89.

The dechlorinated brine is sent to saturator in dechlorination unit, the

chlorinecontents

in

brine

solution

is

reduced

to

7.1

ppm.

2.Saturator


Dechlorinatedanolite isshoweredonrocksaltandsaturatedbrine isstored

inpits,whichalsoactsasasettlerforsomeimpuritiesofrocksalt.Frompits,

saturatedbrineistransferredtopurifiers.



25/44

3.PurifierInprimarypurifiers,brineistreatedwithbariumcarbonatesolutioninwhich

some quantity of hydrochloric acid has been added. Sludge settled in

periodically

removed

from

bottom

of

the

purifier.

From

primary

purifiers,

brine overflow is sent to secondary purifier. Where solution of caustic and

accofloqaremixedinitandfurtherpurificationiscarriedout.

4.SettlerThecapacityofthesettler is2300m

3.Remainingdetailsofsettlerarealmost

similarasmentionedpreviouslyfor I.E.Mbrineunit.Overflowfromsettler is

transferredtoatankmarkedas2D5.Fromthistank,brine issenttoprimary

filters.

5.SandFilters


ThearrangementofpebblesissameasdiscussedasI.E.Mbrineunit.Hereto

layer to the top is of sand. After filtration, the brine is sent o a temporary

storagemarkedas2D6.

Priortotheintroductionofthebrineintheoverheadtank,HydrochloricAcid

isinjected

inline

which

reduces

the

pH

of

brine

from

11

12

to

4.5

5.5.

From

overheadtankbrineflowstotheD.S.Acellroomsunderactionofgravity.



26/44



27/44

3.I.E.MCellRoomIonExchangeMembranetechnologyisthelatesttechnologyoftheproduction

of caustic soda. The technology uses semipermeable membranes. The cells

havebeen

imported

from

USA.

Ion Exchange membrane technology is safer than mercury cells. In Ittehad

ChemicalsLimited,wehavetotal40cellsinI.E.Mcellrooms.

Theunitcanbedividedintoflowingsubunits.

1. BrineFeedunit2. CausticUnit3.

I.E.M

unit

4. DechlorinationUnit5. EvaporationBriefdiscussionoftheabovementionedsubunitsareasfollows

1.BrineFeedunitUltraPurebrinefromI.E.MbrineunitisreceivedinUPbrinetank,whichisat

ground level.Fromhere,brine istransferredto2overheadtanks. Incaseof

overflowof

the

overhead

tanks

brine

is

transferred

to

UP

brine

tank

number

1.Andifitalsooverflows,thenbrineissenttoUPbrinetanknumber2.From

overheadtanks,thebrineisfedtothecellsinthecellroom.

2.CausticUnit


Theimportantandtheonlymajorcomponentofcausticunitiscaustic

circulationtank(C.C.T.)productfromthecellroom(i.e.31%causticsolution)

isreceivedinthisC.C.T.Atthesametime,incasefmalfunctioningofanycell,

thedrainedcausticisalsotransferredtothistank.

Moreoverhydrogengasformedduringelectrolysisisalsopassedthroughthis

tankbeforesendinghydrochloricacidfurnaces.FromC.C.Tapartofcaustic

solution(31%,89oC)issenttostoragetanks.Whileapartofcausticiscooled

to84oC.Anddeionizerwaterisaddedintoittoreduceitconcentrationto28%

andthenfedtocellsinthecellroom.Iftemperatureofcausticsolutiondrops

below84oC,thencausticsolutioncanbeheatedtoincreaseitstemperatureto

avoidany

production

losses.



28/44

3.I.E.MunitThecellsarenotonlythemostimportantbutalsothemostcomponentofcell

rooms.

Construction:

Acellconsistsoffollowingparts.

1. BulkHeads2. BulkHeadInsulators3. InterCellsSpacers4. CurrentDistributers5. Membranes6. ElectrodePlates


EachCathodeismadeofNickelandeachanodeismadeoftitanium.Current

distributorsaremadeofcopperswithmeshofnickelstickingoverit.

Electrodes are activated with coating of noble metals to minimize voltage

drop. Life of electrodes depends on chlorine formed. Greater the chlorine

lesserwillbethelife.

Working/ChemicalReactions:

Brine is injected from bottom right side of the cells and caustic (28%) is

injected from bottom left sideof the tank. Whileproduct i.e. 31% caustic is

recoveredfromtoprightsideofthetankandhydrogenisalsorecoveredfrom

thesameside.Whiledepletedbrine,alsocalledanoliteisrecoveredfromtop

leftsideofthecellandchlorineisalsorecoveredfromthesameside.

Drainlineareprovidedatbottomsidewhileoverflowlinesareprovidedattop

sideofthetank,bothbrineandcaustic.

Sodium ionstraveltowardsthecathodethroughsemipermeablemembrane

andarereducedtosodiummetal.Chlorideionstraveltowardsanodeandare

oxidized to form chlorine gas. Sodium ions are absorbed by the membrane

andtransferredtoothersidewhenmoreionsapproachit.

Hencechlorineiscollectedfromanodesandhydrogenandcausticofrequired

concentrationi.e.31%iscollectedatcathode.



29/44

Each cell consumes approximately 9 volts. From the power plant 13KV are

receivedandsteppeddownto370volts.

AssemblingandDisassemblingofcell:

For

the

process

disassembling

to

start

the

cell

is

taken

out

of

circuit

by

attachingajumperinparalleltothecelltoavoidanydisturbanceinoperation

ofothercells.Cellisthedrainedtoemptyitfrombrineandcausticsolutionis

sent to caustic circulation tank. A part of drain line is transparent to make

visible the flow of draining liquid from the cell. Than the cell is brought to

ground level where it is washed and then cell rotation frmae is used to

changeitspositionfromhorizontaltoverticalinordertodisassembleit.Both

side rods and nuts of top bulk head are removed. After removing the bulk

headinsulator,

the

whole

assembly

is

disassembled.

All

the

components

are

washedandcheckedforanyleakageusingpressurizeairframe.

Theassemblingprocessisthereverseoperationofdisassemblingoperation.

Purgingoperation:

Airisusedforpurgingofhydrogenfromthewholesystemorthecellwhen

theyaretakenoutofthecircuit.Nitrogenisusedonlywhenchlorineis

required

to

be

taken

out

of

the

whole

system.



30/44

4.De-chlorinationUnitDepletedbrineissenttodepletedbrinetankatgroundlevel,fromwhereitis

pumpedtoanoverheaddechlorinationtower.Thetowerisrandomlypacked

withrashing

rings.

Brine

enters

from

the

top

and

both

de

chlorinated

brine

as

well as chlorine is removed from bottom of the tower from two outlets at

samelevel.

The chlorine is sent to heat exchanger at higher level where it temperature

reduces from 89oC to approximately 50

oC. This chlorine is pumped with the

helpofliquidringtyperotarycompressorandpassedthroughdepletedbrine

tankandfinallysenttohydrochloricacidfurnaces.Theliquidusedtolubricate

pump isalsosenttodepletedbrinetank.Thedechlorinatedbrine issentto

chlorinatedbrine

tank,

from

where

it

is

sent

to

saturators

of

I.E.M.

brine

unit.

5.EvaporationFromI.E.M.Cellroomweobtaincausticsodaatconcentrationof31%whichis

not the demand of customers. So to achieve 50% concentration multiple

effectheatexchangersareusedforevaporation. In ICLthere istwounitsfor

evaporation Unit1 contain Plate & Shell type heat exchanger while Unit2

only contain Shell Type heat exchangers. Feed is PreHeated by utilizing the

leavingstream(50%causticSoda),beforeenteringtomainheatexchangers.

Unit1 id forward feed heat exchangers and Unit2 is backward feed heat

exchangers.



31/44



32/44

4.D.S.ACellRoomsNortherncellroomhasthirtytwomercurycellsalsocalledasDenorasCell.In

additionto

main

electrolytic

cell,

the

cell

room

has

following

components.

1. Decomposer2. CirculationTray


ProcessDetail

Brineisintroducedataconcentrationof295300g/literandatemperatureof

62o

C

at

a

flow

rate

of

45m

3

/h

for

every

cell.

Mercury

is

introduced

from

mercury circulation tray. Sodium mercury amalgam is taken out from the

opposite side and sent to decomposer. Feed water is introduced into the

decomposer. Caustic solution is sent to main caustic storage tanks after

passingthroughafilterhavingporoustubesofgraphite.

Thehydrogenformedispassedthroughhydrogencoolerandthensenttothe

furnaces

for

production

of

hydrochloric

acid.

In

S.C.R.

separate

hydrogen

coolerhavebeenprovidedforindividualcellswhileinN.C.R.alargehydrogen

coolerhavebeenprovidedwhichcoolsthehydrogencollectedfromthewhole

cellroom.Chlorinereleasedisalsosenttothefurnacesafterwashingitwith

water.

Mercury recovered fromdecomposer is transferred to mercury recirculation

tray.Waterformsupperlayerinmercuryrecirculationtraytoavoidanyvapor

formation.Thenmercuryisrecycledtothecells.

Sometimescaustic(30%)isdirectlyintroducedintodecomposertoincreaseits

concentrationof260265g/literandatemperatureof85oC.



33/44



34/44

LiquidChlorine(Cl2)

Chlorinefromdechlorinatedunitsisboughttochlorinewasherwheresulphuricacid

is showered from the top to neutralize any caustic presence and to absorb the

moisture.Chlorine isthenpassedthroughdemisterstoremoveanyentrainedsalts

comingfromcellrooms.Chlorineisthensenttocentrifugalcompressorsfromwhere

gas issent todischargeseparatorwhich isalsoactasseparator foracid.Sulphuric

acidisbeingusedhereisactingasalubricantaswellasmoistureabsorbent.

ChlorineisthensenttofiltersfromwhereitissenttoliquefierwhereliquidFreonis

usedtoliquefyit.GasifiedFreonisreceivedinreceiverwherenecessaryadjustments

of different parameters is done and the sent to Freon condenser where water is

showeredoverit.Fromcondenser,FreonistransferredtocompressorswhereFreon

isliquefiedandrecycledtochlorineliquefier.Whileliquidchlorineissenttostorage

tanks.



35/44



36/44

HydrochloricAcid(HCl)

Hydrochloric acid Plant utilizes the gasesproduced as the byproducts of I.E.M. cell

room, northern cell room and southern cell room. These gases are hydrogen and

chlorine.There

are

total

twelve

furnaces.

The

furnaces

may

be

top

fired

or

bottom

firedandmaybeoperatingunderpressureorundersuction.

Themajorcomponentsofthefurnaceare:

1. Chamber2. JointPiece3. PreCooler4. Absorber5. TailTower6. Scrubber

1.ChamberThechamberhascircularhollow cylindricalsectionsorelementsofgraphite

whichare fixed inamildsteelshell. It isalsoprovidedwith acooling tower

chest.At

the

top,

there

is

acrown

for

equal

distribution

of

water

in

all

side.

Below the crown is a burst made of graphite. It lifts to some extent after

whichitwillburst.

Hydrogenandchlorinearefed inthesamemanneras incaseofthefurnace

which is bottom fired under pressure. Temperature of the flame is 1800oC.

Cooling water is showered with the help of the crown which equally

distributes it in all sides and is finally collected at the bottom and sent to

watercoolingunit.


2.JointPieceJointpieceismadeofgraphite.Itisjointbetweenchamberandprecooler.It

is also cooled by cooling tower which is also distributed with the help of a

rectangularcrownasopposedtothechamberinwhichwaterwasdistributed

bycircularcrown.



37/44

3.PreCoolerPrecoolerhas109graphitetubesandreceivesgasatatemperatureof250

300oCandexititatatemperaturelowenoughtoallowitsabsorptioninfeed

water.

4.AbsorberAbsorber is also a vertical column having shell and tube arrangement

consisting of 77 tubes of graphite in which gas and weak acid flow co

currently.Concentratedacidissenttostoragetankswhileunabsorberdgases

alsoleavesfrombottomandaresenttotailtower.

5.TailTowerTail tower is ceramic made rashing ring packed column where unabsorbed

gases are coming from bottom and feed water is showered from the top.

Weakacidformedissenttoabsorberforfurtherconcentration.

6.ScrubberUnabsorbedgasesfromtailtowerarefedtoscrubber.Scrubberisalsorashing

ring

packed

section

where

industrial

water

is

showered

at

different

levels

to

maximize the absorption of gases. The weak acid formed is drained.

Unabsorbedgasesfromscrubberareexhaustedtoatmospherewiththehelp

ofanexhaust.



38/44



39/44

Applications



40/44

Applications

CausticSoda:

Textilefinishingprocess Soap,detergentandcleaners Paperandpulp Oilandgasprocessing Rayonindustry Vegetableoilandghee Agriculturalindustry(Fertilizer) Pharmaceuticals

Beveragesanddairies Mineralwaterandsewagetreatment

LiquidChlorine:

Waterdisinfectionandtreatment Paperandboard Coolingtowers Production

of

plastic,

such

as

PVC

Pharmaceuticalsformulation AgroChemicalproduction(insecticides,herbicides&fungicides) Productionofchlorinatedsolvent,hydrocarbonsandderivatives.

HydrochloricAcid:

Textiles Steelandgalvanizingindustry

Metal

pickling

Gelatin Dyestuffs Pharmaceuticals Syntheticrubber MetalChloridesmanufacturing PVC



41/44

SodiumHypochlorite:

Bleaching(widelyusedinpaper,carpetwashing,andtextileindustry) Formulateddisinfectants Potable

and

waste

water

treatment

Swimmingpoolwatertreatment Processandcoolingtowertreatment Odourcontrol Chemical intermediates in agriculture, pharmaceutical, printing and metal

processingindustries

ZincSulphate:

Agriculture: added to fertilizers as trace nutrient and animal feed to correctdietarydeficiencies.

Chemical:asasourceofZincforthemanufacturingofotherZincchemicals. Textile:ViscoseRayon.

Shaffaf

(Bleaching

Earth)

SHAFFAF (Acid Activated Bleaching Earth) has excellent bleaching properties and

helpsinachievingthedesiredcolorvaluesatconsiderablereducedproductioncosts.

Forthebleachingof:

Edible/cookingoil/vegetableoil. Lubricatingoil Mineraloil Fatinsoapmanufacturing



42/44

SummaryIttehad Chemicals Limited (ICL) is the pioneer and one of the largest

manufacturersof industrialchemicals inPakistan.Thecompanywascommissioned

in1964

as

United

Chemicals

and

started

production

with

an

initial

installed

capacity

of60MT/dayofcausticsodaand54MT/dayofchlorine.Risingdemand facilitated

the first expansion, carried out in 1969, which increased capacity to 90 MT/day of

causticsodaand81MT/dayofchlorine.

Causticsodaisthemainproduct.Mostlytheyfocusontheproductionofthis

product. Liquid Chlorine, Hydrochloric Acid, Sodium Hypochlorite, Bleaching Earth

(Shaffaf), Chlorinated Paraffin, Sulphuric Acid 80%, Zinc Sulphate, and Barium

SulphatearetheotherproductsofICL.

Thedefinedquality,specification,attendtocustomerscomplain,Reviewthe

qualitymanagementsystemforitseffectivenessandcontinualimprovementthrough

internal audits and the budgeted target of production are main objectives of their

qualitypolicy.

Water and sodium chlorite are the primary raw materials while barium

chloride,caustic,sulfuricacidandflocculentarethesecondaryrawmaterials.

ForDSA

cell

room

the

depleted

brine

is

showered

on

rock

salt

after

chlorine

removel.Fromwhereinsendtothepits,thenithaspumpedtothepurifierswhere

barium carbonate,caustic and flocculent is added Then it send to the brine settler

fromwhereitpumpedtothebrinefilters.AfterfiltrationfinialitgoestotheDSAcell

roomfromwheretheelectrolysishasbeendone.

For I.E.M cell room the depleted brine is send to the showering without

removingchlorine .thepurificationprocess isthesameasDSAwith littledifference

ofsecondaryfiltersandionexchangers.

I.E.Mcellsproduce3033%causticsolutionwhichisconcentratedupto50%

afterevaporation.


Chlorine gas produces from cell rooms after cooling is washed with sulfuric

acidshoweringinthechlorinewashers,fromwhereitissenttothedemister.From

demister it goes to the suction separator then compressor and then discharge

separatorfromwhere itgoestothechlorinefilters.Afterfilteringthechlorinegas li

liquefiedinaliquefierinwhichFreongasisthecoolingmedium.



43/44

Conclusions

During student life internship program have its own great importance. Theoretical

conceptsare

sometimes

not

realized

till

we

do

its

practicals.

Industrial

Internship

is

like apiraticalofourentireengineering theoreticalbase. Inpointsourconclusions

are:

Manyconceptsareclearedwhichwastheoreticallynotrealized. Dealingwithothersinindustryandrealizingtheenvironmentofindustry. Maintaintimebymakingschedules. Punctualityandworkresponsibility. Teamworkandworkingwithotherfieldengineers. Successfullycompletingassignmentswhicharegiventous.

Recommendations

During fourweeksof internshipwe facesomeproblems.Soasan interneewecan

onlyrecommendfollowingpoints

Process flow sheets should be provided on the plant for visitors for quickguide.

Thechlorinepipelineshavetobechangedandtominimizetheleakageofthispoisonousgas.

Pipe lineswithpropercolourhavetobepaintedtodistinguishthemwiththefluidflowthroughit.

Flowmeasuringdevicesshouldbeinstalledonfluidflowpipelines.


Minimizetheliquidaswellasgasleakagebyproperrenovation.



44/44

END

internship icl report - zeeshan ul haq

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