INTERNSHIP REPORT
SITARA CHEMICAL INDUSTRIES LIMITED, FAISALABAD
Submitted By: Noman Ejaz
Internee No: 50630
Department of Chemical
Engineering,
Comsats University, Lahore
Training Period
(20 June 2016 18 July 2016)
(Duration: 4 weeks)
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I
Internship Report on Caustic
Soda Plant at
Sitara Chemical Industries
Limited, Faisalabad
Table of Contents
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Acknowledgements.............................................................................................................................5
Introduction.........................................................................................................................................6
Health Safety & Environment (HSE)..............................................................................................6
International Organization and Standardization (ISO.....................................................................6
Primary Brine......................................................................................................................................8
i)Brine Saturation............................................................................................................................8
ii)Brine Purification.........................................................................................................................9
iii)Brine Filtration..........................................................................................................................10
Process Flow Diagram of Primary Brine..................................................................................12
Secondary Brine................................................................................................................................13
Nature of Ion Exchange Resin......................................................................................................13
Regeneration of the Resin Bed......................................................................................................14
Process Flow Diagram of Secondary Brine..............................................................................16
Cell Room..........................................................................................................................................17
Electrolyzer...................................................................................................................................17
Process Description:......................................................................................................................18
Process Flow Diagram of Cell Room........................................................................................21
Dechlorination...................................................................................................................................22
Process Description.......................................................................................................................22
i) Vacuum Striping.....................................................................................................................22
ii)Sodium Sulfite Treatment......................................................................................................23
iii)Activated Carbon..................................................................................................................23
Evaporation Unit...............................................................................................................................24
Process Description.......................................................................................................................24
Caustic Solidification Plant (CSP)....................................................................................................26
Process description........................................................................................................................26
Block Diagram of Caustic Solidification Plant.........................................................................28
SWOT Analysis.................................................................................................................................29
Conclusion.........................................................................................................................................30
Bibliography......................................................................................................................................31
Executive Summary
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The report is sub-divided into many sections according to those which were allocated to me by the
Management. Each section then comprises of sub-divisions. I first worked on the flow diagrams of
each section to understand the basic process which takes place then we went to the theory.
The major work which takes place in the plant is basically the increasing of concentration of the
caustic soda. This is done by the help of electrolysis of brine solution coming from the purification
sections. During the electrolysis the brine, NaCl, breaks up into Na + and Cl- ions and the partially
permeable membrane allows only sodium ions to pass through and attach to the OH - ions in the
other compartment hence raising the concentration of the caustic soda solution.
The other important part of the plant is the purification section where the raw salt solution is
saturated by the addition of depleted brine, which is unused after electrolysis, and the purification
of this brine solution via different methods of settling, filtration and ion-exchange.
The other major part is the de-chlorination unit for the de-chlorination of depleted brine coming
from the electrolyzer. It is first removed from chlorine then sent to the brine saturation area.
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Acknowledgements
I am very thankful to Mr. Muhammad Imtiaz (Production Manager Area-I) Mr. Zeeshan (Shift
Engineer), Mr. Muhammad Imran (HR Manager), Mr. Faheem Ahmed (Senior Manager ISO) for
their kindness and complete guidance throughout our training period and Sitara Chemical
Industries Limited for providing me such a marvelous and informative professional training
program.
Last but not least I offer my humble heartfelt gratitude and deepest affections to my great Mother,
respected Father and My Teachers who inspired me for higher ideals of life, supported morally
throughout my studies, and always prayed for success in the pursuits of my life
And at the end, special thanks to all plant operators for their help and cooperation.
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Introduction
SCIL was incorporated in 1981 and began producing caustic soda in 1985, initially at a rate of 30
metric tons Caustic a day. The plants capacity was gradually increased over years to current level
of 545 metric tons a day. In addition, various by-product facilities have been added and expanded
from time to time to cope with growing demand. Company entered into Textile Spinning Business
in 1995. Its specialty chemicals and export division was established in 2001 and agriculture
chemicals division in 2003.
Health Safety & Environment (HSE)
SCIL is a very much responsible organization. It cares greatly for the environment as well
satisfaction of its customers. For this reason, they have adapted almost all national and
international quality and environment safety policies. Sitara has Occupational Health and Safety
Assessment Specification (OHSAS).
OHSAS 18001:2007
International Organization and Standardization (ISO)
QUALITY POLICY:
Sitara Chemical Industries Ltd .is committed to remain alert and advance, to continuously grow as
a Quality Symbol for its products and in meeting industrial and consumer requirements, through
training, team work, and procedures, on time, every time.
ENVIRONMENTAL POLICY:
Sitara Chemical Industries Ltd. is committed to continual improvement of its Environmental
Management System (EMS) by adoption of appropriate pollution prevention measures and
complying with all relevant training, team work and procedures as implemented from time to time.
In actual words, SCIL has well developed and recognized Quality Management Systems and
Environmental Management Systems as well as SCIL has following certifications in QMS and
EMS from Society General Surveillance (SGS) under the authority of United Kingdom
Accreditation Service (UKAS).
ISO 9001:2008
ISO 14001:2004
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The Production Cycle of NaOH goes through the following steps:
Primary Brine Section
This section involves saturation of brine solution, its purification by settling after treatment with
certain reagents and primary filtration by pressure filters.
Secondary Brine Section
In this section, brine coming from primary brine section is filtered by resins to remove any
remaining impurities which may cause damage to membranes of the electrolyzer.
De-Chlorination Unit
Here de-chlorination and other preliminary treatments of depleted brine coming from cell room are
carried out before sending it to primary brine section.
Evaporation Unit
Caustic soda obtained from cell room has a concentration of 32 % w/w. in evaporation unit; this
concentration is raised to 50%.
Caustic Solidification Plant (CSP)
In this section, caustic soda from evaporation unit is concentrated up to 98.5% and solidified for
packing in bags and drums.
Primary Brine
Primary brine has 3 sections:
Brine saturation
Brine purification
Brine filtration
Explanation:
i)Brine Saturation
Saturators
Brine saturation is done by adding rock salt to the depleted brine which is being fed from the
electrolyzer to the bottom of saturator. There are five feeding pipes called nozzle which distribute
the brine in the saturator. Before saturation the concentration of brine is (180-210) g/l and after
saturation it reaches to (290-310) g/l. The flow rate of depleted brine is approximately (80-85)
m3/h. Make-up water is also add as requirement. The raw salt impurities such as calcium and
magnesium salt are carried in depleted brine. The temperature of depleted brine is about 70 0C.
Concentrated brine is then fed to the settling pits 30% and 70% to CaCL2 pit for removal of CO2.
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Average composition of rock salt:
NaCl = 97%w/w min
K+ = 0.17%w/w max
Mg+ = 0.20% w/w max
Ca++ = 0.60% w/w max
SO4-- = 1.50% w/w max
Al= 0.20 ppm max
Fe= 1.00 ppm max
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Settling pits:
Concentrated brine from the saturator is fed to the settling pits. Settling pits removes aluminates,
silica and dust by sedimentation.
Calcium chloride and common pits:
Brine from saturator contains about (13-14) g/l SO4, therefore brine is treated with CaCl2. Salt
contents are reduced to (3-4) g/l. There are three CaCl2 pits each having volume 700 m3. CaCl2
from CO2 plant is fed to CaCl2 pits. CaCl2 range here is (3500-4000) ppm. Sulfur reduces by this
reaction.
Na2SO4 + CaCl2 CaSO4 + 2NaCl
This CaCl2 control the sulfate level up to 7-8 g/l. A circulation mechanism is also available from
common pit to settling pit for controlling conc. of sulfate of brine.
ii)Brine Purification
Sulfates removal in calcium chloride pits and in reactor.
Calcium and magnesium are removed in reactors.
Reactor A (5020-A) (CSTR):
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Brine coming from common pits is supplied to a reactor (R-5020) having volume 50m3. BaCO 3 is
injected in this reactor for further removal of sulfates.
Na2SO4 + BaCO3 BaSO4 + Na2CO3
Brine is fed into settler A.
Settler-A:
Product from reactor A is fed into center of settler having an area of 1800 m3 in order to remove
suspended particles. Nalco is added for this purpose. Agitator is present for proper mixing and
sludge is regularly removed from the bottom.
Function of agitator:
Agitator in purifier serves three purpose:
To keep solid from suspension.
Proper dispersion of reagent into brine.
To make easier the agglomeration of small particles into larger ones.
Overflow brine from settler A gets entered into reactor-B for removal of calcium and magnesium
from solution.
Reactor B: (5020-B):
Brine from reactor A to settler A and then fed into tank 515 having volume 15m3. Brine from tank
is fed into reactor B. Na2CO3 and NaOH is also added into it for the removal of calcium and
magnesium, Na2CO3 removes calcium and NaOH removes magnesium Brine is then fed at the
center of settler B.
Na2CO3 + CaCl2 CaCO3 + 2NaCl
NaOH +MgCl2 Mg (OH)2 + 2NaCl
Settler-B:
Area of the settler B is 2630m3 sludge removes from bottom at every 02 hrs. Nalco solution with
RO water is added which act as coagulant to remove suspended solids from solution. Brine is
transfered to storage tank 5060 A/B having volume 75 m3.
iii)Brine Filtration
Filters:
Brine is fed into pressure filters to remove suspended solids (6 filters A, B, C, D, E&F) and then
pumped to guard filters for further removal of suspended solids. Then brine enters into the heat
exchanger to increase its temperature to (60-70) o C.
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Regeneration of pressure filters:
When inlet pressure of brine reaches to 3 bar it indicates that filters need to regenerated. Firstly, we
isolate the filters from brine circuit but it is filled with brine before regeneration. Level of tank is
checked from over flow to assure the level of filter. Then Arbocel insulation is fed across the filter
for pre-coating of leaf of polypropylene. Arbocel solution is prepared from solution which is fed
from leaf filter to the tank. Arbocel is injected on weight basis (A-D) filters each needs 17.5 kg of
arbocel for pre coating. On the other hand, E& F filters are provided with 13-kg when pressure
reaches to 1 bar it means filter is regenerated and ready for the service.
Specification:
When brine transferred from primary to secondary brine following ranges should be maintained.
SO4 7-8 g/l
Mg 1.0-2.4 ppm
Ca 2.0-5.0 ppm
PH 10-11
Turbidity 1
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Process Flow Diagram of Primary Brine
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Secondary Brine
Before feeding brine to electolyzers it is passed through ion exchange resin towers C-5040 A/B/C
placed in series in order to absorb Ca++, Mg++ and Sr++ contained in brine.
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Nature of Ion Exchange Resin
Ion exchange resins are based on solid insoluble polymers supplied in the form of beads, which
have fixed active ionic groups. Mobile ions of opposite charge can be exchanged reversibly and
stoichiometrically for ions of the same charge present in the solution.
++ ++
The resin being used TP-260 has Na+ ions as mobile ions and exchange with Ca &Mg present
++ ++
in the brine. When most of the Na+ has been exchanged with Ca &Mg , the bed is exhausted
and needs to be regenerated. The exhausted column is taken out of the stream and the other two
are remained in [Link]-260 has weak acidic chelating amino methyl phosphonic acid
groups which form stable complexes with a number of transition metals and main group element.
TP-260:
TP-260 is Amino methyl phosphonic acid.
It has very high selectivity for metal ions so that Ca, Mg can be reduced to below 30 ppb.
It is weakly acidic.
Secondary Brine Specification:
The brine feeding to the resin tower has following typical specifications
NaCl 290-310 g/L
Na2SO4 7-8 g/L
NaClO3 15 g/L
Ca++ 2-5 ppm
Mg++ 1-2 ppm
Sr++ 1 ppm
Temperature 60-70 0C
PH 9-10
The resin bed in the tower stayed on a grid plate. The spargers are fitted on this plate. The purified
brine from tank D-5070 is fed in the tower through P-5070A/B at a flow rate of 105-110 m 3/hr. As
the towers are connected in series, so the brine is fed in the first tower in the series and ultra-
purified brine is collected from the discharge of the third column.
Regeneration of the Resin Bed
The chemical nature of the resin functional group is suitable to form complex compounds with a lot
of metal ions.
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The resin at the beginning of the operating cycle is in the sodic form. During the operation it fixes
Ca++& Mg++ to which it has a high affinity, and releases Na+.
When the resin is exhausted, means when it has absorb max. Ca& Mg ions, it must be reconverted
in the sodic form. This process is referred to as resin regeneration.
The regeneration process requires a sequence of different operations. The most significant of which
are a treatment with diluted HCl which displaces the metal ions previously fixed by the resin
functional groups followed by a treatment with diluted NaOH solution which makes the resin to
change form the acidic form to the sodic form i-e H+ replaced with Na+
Steps involve in the Regeneration Process
1. Brine drainage (half empty)
2. Washing with demi water
3. Counter washing with demi water
4. Drainage
5. Washing with 4% HCl solution
6. Drainage
7. Washing with demi water
8. Drainage
9. Counter washing with 5% NaOH solution
10. Drainage
11. Washing with demi water
12. Drainage
13. Water replacement with brine
14. Filling with brine
After regeneration resetting is done almost in 60 minutes and brine is circulated between
resin towers and brine tanks [Link] circulation of brine remains on till the required
results of Ca &Mg are achieved. Then the column is taken in operation and placed in the last
in series.
Chemical Reaction:
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Chemical reactions involved in secondary purification and regeneration of resin towers are as given
below.
Brine Purification
Na2 (Resin) + Ca++ Ca (Resin) + 2 Na+
Na2 (Resin) + Mg++ Mg (Resin) + 2 Na+
Resin Regeneration
Ca (Resin) + 2HCl H2 (Resin) + Ca++ (Washing by HCl)
Mg (Resin) + 2HCl H2 (Resin) + Mg++ (Washing by HCl)
H2 (Resin) + 2NaOH Na2 (Resin) + 2H2O (Washing by NaOH)
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Process Flow Diagram of Secondary Brine
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Cell Room
Electrolysis
Electrolysis is the Phenomenon of decomposition of an electrolyte by passing electric current
through its solution.
The process of electrolysis is carried out in the presence of
A liquid containing mobile ions an electrolyte
An external source of direct electric current
Two solid rods or plates known as electrodes
Electrolyzer
The equipment used to carry the process of electrolysis is called electrolyzer.
The cell room comprises of three electrolyzers A/B/C placed in parallel.
Each electrolyzer has capacity of 164 elements. At present electrolyzer A has 162,
electrolyzer B has 161 and electrolyzer C has 163 elements.
Each element acts as an electrolyzer individually. Each element consists of anode and
cathode compartments separated by a membrane.
Anodic side is made of titanium while cathodic side is made of nickel.
The ion exchange membrane is clamped between the half shells with interposed PTFE
(Poly Tetra Fluoro Ethylene) gaskets.
Cathodic side of the membrane can prevent migration of OH-. The flow of Cl- across the
membrane is negligible, because electric field across the membrane opposes the chloride
ions transport.
The raw material feeding to the anolyte side electrolyzer is brine. The aqueous solution in
this compartment is called anolyte. The membrane separates the anolyte from the catholyte
compartment.
32% caustic soda from catholyte tank plus Demineralized water to make a 29-30% caustic
solution to use in electrolysis process.
Sodium hydroxide is formed by the combination of hydroxyl ions and sodium ions, which
migrate through the membrane to the cathode.
Chlorine gas, usually called cell gas, is formed at the anode while Hydrogen gas and
sodium hydroxide are formed at the cathode.
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Process Description:
Ultra-pure brine is stored in tank (D-51600) and pumped (via P-51600A/B) into overhead feed
brine tank (06D0010). Brine enters in the overhead tank from the top and over flows by gravity
from the top side back in D-5160. The outlet is from the bottom of the tank and leads to cell room
by gravity. The brine is heated before entering into cell room through heat exchanger (06E0010) to
raise its temperature up to 65-75oC. It is a plate type heat exchanger. Heat exchanger is provided
with steam as well as cooling water connections. There is also a stand by heat exchanger
(06E0020) which is either used to fill a single electrolyzer or in case of emergency. In the cell room
main feed brine line has three connections to feed each of the three electrolyzers. These supply
lines are underneath of each electrolyzer. Brine is fed in the anodic compartment of each cell.
32% NaOH is stored in the storage tank (31D0020). Its temperature is about 80-85oC. It is cooled
(in 31E001) before transferred in overhead tank (31D0010). A temperature of 70-75oC is usually
required to feed in cells. Catholyte enters into catholyte overhead tank (31D0010) from the top and
over flows from top side. Outlet is from the bottom and leads to cell room by gravity.
Electrical Supply Circuit:
11KV power is supplied from grid station. It is passed through transformer to step it down to 440 V.
Then it is passed through rectifiers to convert it into DC which is then supplied to electrolyzers via
bus bars and flexibles. There are 2 bus bars and 9 flexibles associated with each electrolyzer.
Reactions:
Following reactions takes place in the cells
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Sodium chloride and water are dissociated in the brine solution according to the equations
NaCl Na+ + Cl-
H2O H+ + OH-
The principal anode reaction involves the oxidation of the anion Cl- to produce chlorine gas
2Cl- Cl2 + 2e-
The primary cathode reaction is the reduction of the cation H+ to produce hydrogen gas
2H+ + 2e- H2
The sodium cation Na+ then combines with the OH- ions to form third overall product NaOH
Na+ + OH- NaOH
The overall cell reaction is:
2NaCl + 2H2O 2NaOH + Cl2 + H2
Side Reactions
The predominant side reactions in the anodic compartment of the cell are
4OH- O2 + 2H2O + 4e-
2OH- + Cl2 ClO- + Cl- + H2O
6ClO- + 3H2O 2ClO3- + 4Cl- + 3/2O2 + 6H+ + 6e-
3ClO- ClO3- + 2Cl-
Products Handling:
31.5-32.5% caustic soda is produced in cathodic compartment of the cell and is collected in the
catholyte header along with hydrogen gas. It leaves the catholyte header by gravity in the main
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caustic soda header and passes through hydrogen gas separator (31F0020). Then it is stored in the
catholyte storage tank (31D0020) to maintain its level about 50% for circulation through the cells.
The excess caustic is transferred in the caustic buffer tank (D20000) from where it is fed to
evaporators for increasing concentration. It is also transferred to storage tanks as such 32% caustic
soda as finished product.
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Process Flow Diagram of Cell Room
Dechlorination
Introduction
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Depleted brine from electrolyzer usually contains 0.3 g/lit dissolved chlorine at a pH of about 3.5-
4.0 and 1.0 g/lit as available chlorine in the form of hypochlorite ions. Depleted brine also carries
3000-4000 ppm of free chlorine.
The process of removal of chlorine from the depleted brine is termed as Dechlorination.
Chlorine must be removed from brine because of the following reasons:
The removal of impurities in the primary brine purification becomes difficult.
In the presence of high contents of chlorine, the impurities in the rock salt are more easily
dissolved during brine saturation.
Chlorine oxidizes ion exchange resins, hence increasing its consumption.
It decreases the sodium chloride solubility resulting in decreased efficiency.
Chlorates have a strong oxidizing effect which is more evident at high concentrations.
The third parameter affecting chlorates removal is pH. A low pH less than 2.0 is favorable.
Process Description
De-chlorination is carried out in three successive steps:
By Vacuum Stripping
By Sodium Sulfite treatment
With Activated Carbon
Depleted brine coming from the electrolyzers is stored in storage tank (07D001), from here the
brine is pumped. The discharge of the pump is divided into two streams, one leads to vacuum
stripper C-5010 and second leads to acid mixing drum (DM-5050).
i) Vacuum Striping
Brine containing absorbed chlorine enters from the upper part of the packed tower C-5010 where
vacuum is generated by means of steam ejector. Normally 75% material goes to C-5010 and 25 %
in DM-5050 for decomposition of chlorates. In DM-5050, 33% HCl is added to lower down its pH
almost zero, after acidification the brine flows down by gravity into the reactor R-5050 where it is
mixed with chlorinated steam coming from the vacuum stripper (C-5010). In R-5050 at low pH and
high temperature, chlorates are decomposed, producing free chlorine which is vented in the
chlorine sniff line. The over flow of R-5050 entered in the acidification pot and lower the pH of the
depleted brine ranging (1.5-2.0).
NaClO3 + 6HCl NaCl + 3Cl2 + 3H2O
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The wet chlorine stripped from the brine leaves the tower and is cooled in the heat exchanger (E-
5010). The condensed chlorinated water is returned in the depleted brine tank while the chlorinated
steam is sent to reactor (R-5050). The brine flows down by gravity in the dechlorinated brine tank
(D-5020). The tank is vented to chlorine sniff line.
ii)Sodium Sulfite Treatment
Sodium sulfite solution is prepared in the tank by absorbing of SO 2 in sodium carbonate solution
and sent in D-5300 by means of pump P-5250A/B. Sulphur dioxide is prepared by burning sulfur
mud in the sulfur furnace which is sucked through an absorber by a suction fan. The gas is entered
from the bottom of the absorber and left from the top. The sodium carbonate solution is fed from
the upper side of the absorber and flows down back to the same tank. When the solution is ready it
is transferred in tank (5250A).
During chlorates decomposition following reaction takes place
Na2SO3 + Cl2 + H2O Na2SO4 + 2HCl
iii)Activated Carbon
After treatment with sodium sulfite(Na2SO3), brine is passed through an activated carbon bed in
tower C-5020. Care must be taken that the carbon should work with acidic brine pH less than 2 and
chlorine less than 50ppm. High chlorine contents in brine feeding the tower causes to violent
reaction with the carbon, relatively high pH in the feed brine to tower causes carbon degradation in
the form of fine particles which can plug the tower. The pH is raised up to (6.0-9.0) before it is
transferred in primary brine section.
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Evaporation Unit
Evaporator
An evaporator is used to evaporate a volatile solvent, usually water, from a solution. An evaporator
is essentially a heat exchanger in which a liquid is boiled to give a vapor. It may be possible to
make use of the steam thus produced for further heating in another following evaporator called
Multi-effect. Its purpose is to concentrate non-volatile solutes such as organic compounds,
inorganic salts, acids or bases. It is a unit operation that is used extensively in processing foods,
chemicals, pharmaceuticals, fruit juices, dairy products, paper and pulp, and both malt and grain
beverages.
Plant Introduction
The plant is designed for continuous concentration of Caustic Soda 31-32% to 50%. The
concentration is improved by evaporation in a triple effect counter flow falling film evaporator. The
plant consists of three falling film evaporators. At first there was only one unit of capacity
120mt/day, with the passage of time capacity of caustic soda plant was enhanced so another
evaporation unit of capacity 250 MT/day was designed to meet industrial and consumers needs.
Falling film evaporator is a tube bundle heat exchanger with a separator at the bottom. In the
separator vapors and thick liquor are separated. The feed liquor is uniformly distributed in the tubes
by a distribution device, thus the liquid moves down forming a thin film along inside wall of the
tube. That is why it is called a falling film evaporator.
Process Description
The Caustic is fed to the first evaporator Ev-201 by a pump at the discharge of Caustic buffer tank
(D-2000). On product side the first evaporator is operated under a vacuum. The caustic leaves the
first evaporator effect Ev-201 at a concentration of 36-37%.
The first evaporator is heated with vapors formed in the second evaporator Ev-202. The shell of
the evaporator Ev-201 is also under vacuum about 250-270 mmHg. The condensate of the Ev-201
collected in the same tank. The vapors of Ev-201 are condensed in pan E-201. The cooling water is
fed in the shell and the vapors are condensed in the tubes. The condensate is collected in the tank
[Link] vacuum in Ev-201 is produced through steam ejectors.
After the Ev-201, pump 201A/B pumped the caustic soda to the second evaporator Ev-202 via heat
exchangers E-202 & E-203. The discharge of the pump P- 201 is divided into two streams; one
admitted to the shell of E-202 and second is admitted in the tubes of the E-203. These two streams
rejoined before entering the Ev-202. This evaporator effect is heated with the vapors from Ev-203
the pressure in the shell of EV-202 is (1.9-2.0) bar. The caustic soda enters Ev-202 at conc. range
36-37%, and temp. range110 -115oC and leaves at conc. 42-43% and [Link] caustic
soda is fed to the third evaporator Ev-203 through pump via heat exchangers E-204 & E-205. The
Page | 24
condensate is collected in condensate tank TK-202 and then transferred in TK-201 from where it is
transferred in D-5150B.
The discharge of pump P-202 is again divided into two streams; one admitted to the shell of E-204
and second is admitted in the tubes of the E-205. These two streams rejoined before entering the
Ev-203. This evaporator effect is heated with the steam at a pressure of about 14 bars. The vapors
produced here are used to heat the second evaporator and the condensate is collected in the tank
[Link] caustic leaves this evaporator at 50% conc. at temp. of 175-185oC.
Now it is to be cooled before storage. For this purpose, it is first passed through tube side of E-204.
Here its temp. is reduced to 155-160 oC. Then it is pumped via P-203 through the tube side of the
E-202 and E-206, the final temp is about 55-65 oC. The condensate of the evaporator Ev-203 also
bears a sufficient amount of heat, which is recovered by passing it through the shells of E-205 & E-
[Link] steam condensate at a temp about 97-98oC is returned to boiler section.
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Caustic Solidification Plant (CSP)
Introduction:
Caustic solidification plant is designed in order to concentrate 50 % caustic soda to 97-98% caustic
soda in solid form. For this purpose a single effect tube bundle falling film evaporator is used as
pre-concentrator. 50% NaOH is concentrated up to 60% NaOH using vapors produced in the final
concentrator for heating in this equipment. In the final concentrator the concentration is improved
up to 97-98% using outside heating media. Due to increasing demand of the solidified caustic soda
three CSP units are designed on same pattern named as CSP-I , CSP-II and CSP-III. Another plant
named as CSP-IV is under construction yet.
Process description
Pre-concentrator:
50% caustic soda stored in caustic buffer tank is pumped to feed into pre-concentrator. There are
temperature and pressure gauges to indicate the feed temperature and pressure respectively. Pre-
concentrator is heated with vapors formed in final concentrator. The pre-concentrator is designed as
tube bundle falling film evaporator. Above the tubes there are vertical slits through which caustic
soda feed flows evenly into the tubes and form an unbroken film along the inner wall of the tube.
The pre-concentrator works at 0.93 bar vacuum on the product side. This vacuum is created in the
system by steam ejector. A two stage ejector, 14 bar steam, is used for this purpose. The vapors
produced in the pre-concentrator are removed by steam ejector and are condensed in a condenser.
Vapors are introduced in the shell side of the condenser while cooling water is introduced in the
tubes.
Vapors condensed in the condenser are collected in the condensate tank. The condensate of the pre-
concentrator also goes into condensate tank by gravity. This condensate is also used for sugar
solution preparation and for heating the salt of 60% caustic pump A/B.
Final concentrator:
60% caustic soda obtained from pre concentrator is pumped into final concentrator. The final
concentrator is basically consisting of 10 individual concentrator tubes and the vapor separator. Salt
is used as a heating media in final concentrator. The feed liquor is uniformly distributed to each
concentrator element. It flows evenly with the inner wall of the tubes from top to bottom. Vapors
produced in final concentrator leave the separator from the top and are used to heat the pre
concentrator. The molten caustic soda leaves the separator through its lower part and is directed by
the distributing device to the flaker and/or drum filling device.
The heating medium is a mixture of following salts in a particular composition.
KNO3 53%
Page | 26
KNO2 40%
NaNO3 7%
Sucrose system:
All the equipment and piping in contact with caustic melt is made of pure nickel
are low carbon nickel because of corrosive resistant of nickel. Oxygen acts corrosively, particularly
when combines with high temperature and form nickel oxide which would contaminate the product
i.e. caustic melt, so it is very important to prevent the penetration of atmospheric oxygen into the
equipment. For this purpose system is blanketed with nitrogen or steam. In addition by adding 0.15
Kg sugar solution into the system just after the feeding valve to pre concentrator, the nickel pickup
of the caustic soda melt is reduced to 2 ppm approximately.
5% aqueous solution of sugar is prepared by using food grade sugar in the water/vapor condensate
in the sugar tanks and dosed into the caustic system by pumping via sugar pump at a rate of 3 - 5
lit/hr. Flow rate of sugar dose is very important, low flow may cause increasing nickel ppm and
excessive flow may leads to blackish particles in the caustic melt.
Flaker:
The flaker consists of a rotating drum/cylinder which dips in the vat containing caustic melt. The
cylinder is cooled to 60-55oC by showering cooling water on its inner walls thus a thin film of
caustic melt is formed over the drum surface which is scrapped by a sharp blade/scrapper. The
flakes thus formed are directly made to fall into the duct which conveys them to the filling hopper
where it is provided with an automated weighing and then filling in bags lined with polyethylene
bags which is tied with cable ties and then stacked inserting tag cards in the stitching.
Dust collector:
For purpose of operational safety and to facilitate the operator working at filling station, a dust
collection system is provided. The system consists of a suction fan .It sucks dry air from the flaker,
passed through the duct, weighing system and also from the bags. The suction pipe is dipped into a
water tank where the caustic soda is precipitated in water in seal pot when its concentration is about
5 to 10%, it is replaced by another water filling.
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Block Diagram of Caustic Solidification Plant
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SWOT Analysis
SWOT analysis is a tool for auditing an organization and its environment. It is the first stage of Strategic
planning and helps managers to focus on key issues. SWOT stands for strengths, weaknesses, opportunities, and
threats. Strengths and weaknesses are internal factors. Opportunities and threats are external factors.
Strength:
Largest Manufacture Caustic Soda
Largest Shareholder
Plant Infrastructure
Advance Technology
Strong Management
Strong Brand name
Financially sound
Weaknesses:
Relying on Permanent Customers
Lack of Operations in Abroad
Need considerable market to sustain
Opportunities:
Increase Production Capacity
Increase Product Line
Take advantage of Geographic position
Provide online customer service ordering system
Threats:
Energy Crises
Economic Environment
Competitors
Threat of stakeholders
Unstable law & Order Situation
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Conclusion
In review this internship has been an excellent and rewarding experience. I have been able to meet
and network with so many people that I am sure will be able to help me with opportunities in the
future. One main thing that I have learned through this internship is time management skills as well
as self-motivation. I came up with various proposals and ideas that the company is still looking
into using .I will continue to work hard in my position and hope to continue to learn about the
industry and meet new people. This was an excellent experience and I hope that other internee got
as much out of it as I did.
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Bibliography
[Link]
Annual Report SCIL Ltd
[Link]/[Link]
Company Magazine
Operating Manual
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