61% caustic from Pre-concentrator enters the fina

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Presentation on Flaking Plant (Siel Chemical
Complex)Issues Related Problems
Presented By RAKTIM PALIT
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Siel Chemical Complex, Rajpura (Pb), (A unit of
Siel Limited. )
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Siel Chemical Complex, Rajpura, (A unit of Siel
Limited. )

• One of the oldest business house of India
  (Formerly DCM Chemical Works)
• Turn over Rs. 200 Crore of the unit
• Integrated Chemical complex, manufacturing wide
  range of chemicals
• State- of the - art technology to produce
  Caustic soda, Bleaching powder and Chlorine
• Unparalleled standard of commitment to quality
  and customer satisfaction
• Presence in international markets

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Products Manufactured

• Caustic Soda lye
• Caustic Soda flakes
• Liquid Chlorine
• Hydrochloric Acid
• Bleaching Powder
• Hydrogen
• Sodium Hypochlorite

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Production Capacity of Siel Chemical Complex

• Caustic Soda Lye 82500 TPA
• Caustic Soda Flakes 33000 TPA
• Chlorine 73095 TPA
• Hydrogen 2062 TPA
• HCl 66000 TPA
• Sodium Hypochlorite 23100 TPA
• Stable Bleaching Powder 18000 TPA

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Process Flow Diagram Of Plant
SODIUM HYPO CHLORITE
WAD
PLANT
RETURN BRINE
BRINE
SNIFF GAS
DECHLORINATION
SALT
CPW
PLANT
CHLORINE COOLING
CHLORINE
LIQUID CHLORINE
CHLORINE
PRIMARY
DRYING AND
STORAGE
BRINE
BOTTLING AND
AND SECONDARY
LIQIFICATION
COMPRESSION
SATURATION
DISPATCH
BRINE PURIFICATION
HYDROGEN
HCl
STORAGE
DM Water
HCl
PLANT
COOLING
DISPATCH
HCL
Plant
SCRUBBING AND
COMPRESSION
HYDROGEN GAS
TO BOILER
CHLORINE GAS
RAW WATER
47.5 CAUSTIC
E
CAUSTIC LYE
Cl
-
H

VAPORATOR
SODA DISPATCH
STORAGE
HOUSE

-
Na
OH
33 CAUSTIC LYE
FEED BRINE
CAUSTIC SODA
FLAKING PLANT
RECYCLE
FLAKES
DM WATER
CAUSTIC LYE/
STORAGE
28 CAUSTIC
MEMBRANE
SODA
SODIUM HYPO
CHLORITE
STABLE BLEACHING
LIME STONE
HYDRATED
CALCINATION
POWDER
CHLORINATION
PLUS FURNACE
AND
LIME
OIL
HYDRATION
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Flakes Production Year 2008

• Jan08 2141
• Feb08 949
• Mar08 1079
• Apr08 672
• May08 394
• Jun08 706
• Jul08 594
• Aug08 -
• Sep08 526
• Oct08 953
• Nov08 156
• Dec08 1189

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PROCESS DESCRIPTION OF 100 TPD FLAKING PLANT
Bertram make
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PROCESS DESCRIPTION OF 100TPD FLAKING PLANT

• The 33 cell liquor is produced in Inos chloro
  make monopolar membrane continuous process. The
  concentration of 33 cell liquor is increased to
  47.5 by vacuum evaporation method. This 47.5
  concentrated caustic soda acts as input raw
  material for flaking plant.

Cont
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PROCESS DESCRIPTION OF 100TPD FLAKING PLANT

• The concentration of 47.5 caustic soda lye is
  increased to 99 by falling film evaporation
  method. The hot 99 liquid caustic is converted
  to solid flakes by cooling forming a layer over
  the rolling flaker drum subsequent cutting the
  layer to form flakes by sharp edged blade.

Cont
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PROCESS DESCRIPTION OF 100TPD FLAKING PLANT

• The evaporation of water from 47.5 lye to
  convert it in to 99 takes place in two stages ie
  at Pre-concentrator at Final concentrator. The
  working of Pre-concentrator Final concentrator
  is explained as given below.

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Preconcentrator

• The concentration of 47.5 lye is increased to
  61 in this unit. The unit is kept under vacuum
  (680mmof Hg). 47.5 lye enters the unit from the
  top the hot vapours (from Final concentrator)
  from the bottom, due to counter current flow heat
  is exchanged which removes the moisture there by
  increasing the concentration from 47.5 to 61.

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Sugar Solution

• In order to prevent corrosion of the Nickel
  equipment, a 5 sugar solution is daily produced
  in sugar dissolving tank fed continuously to
  the 61 caustic soda flow by means of dosing pump.

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Heat Transfer Salt System

• The high temperature heat transfer salt system
  consists of a salt heater with a combustion air
  pre-heater, to heat the molten salt (Eutectic
  mixture of 53 KNO3, 40 NaNO2 7 NaNO3) which
  is circulated through the system by a salt pump
  mounted on salt tank.

SALT
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Final Concentrator

• 61 caustic from Pre-concentrator enters the
  final concentrator tube (8 in number) from the
  top. The caustic is then made to flow uniformly
  through out the surface of the tube by the help
  of propeller. The heat carrying salt at 400C
  enters from the bottom of this tubes in the shell
  side due to counter flow the heat of salt
  takes away

Cont
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Final Concentrator

• The water from 61 caustic the concentration
  increases to 99.The hot water vapor thus
  liberated in this unit is sent to
  Pre-concentrator as mentioned above.

Technical
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Major Problem Faced
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Flaker Drum Leakage

• The flaker drum leakage is chronic problem.
  The leakage is normally arrested by means of
  welding, but the crack developed does not get
  rectified completely. The water seeping through
  this leaky part causes formation of lump of
  caustic, which further causes chocking of hopper.

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Frequent Damage of Blade

• It has been observed that the blade gets
  deformed after approximate production 500-600T.

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Oil Air Ratio

• The performance of Eurotherm Controller for
  setting oil air ratio is not satisfactory .

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SPM Level

• The SPM level runs on higher side showing
  improper burning of fuel. Atomization is done
  with steam but still the burning found not up to
  the mark.

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Melting Point Of Salt

• The Melting point of salt increases despite
  nitrogen blanket being maintained at a pressure
  of 3.5 kg / cm2.

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Final Concentrator Tubes
It has been observed that the average life of
Final concentrator tube is around 4 to 5 years.
Technical know how for ways means of increasing
the life of tubes.
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THANK YOU