IttehadC ChemicalsL Limite ed

Inte ernsh hipRe eport t

June2 2010July y2010
2010 10/22/2

Ins stitut teofC mical Chem Engineerin Tech ogy E ng& hnolo

versit tyof The Punjab Univ

ICET Students

Digitally signed by ICET Students DN: cn=ICET Students, o=ICET Students, ou=Administrator, email=admin@icetstudents.com, c=PK Date: 2011.06.12 15:18:56 +05'00'
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ZeeshanulHaq,SabirGhazi,ICET,PU

In nternshipR Report
June2 2010July y2010

Subm mittedBy y:

Name: Enrollment: Course:

Zee eshanulHa aq E08 8CE29 B.S Sc.Chemic calEngg. farj jadulhaq@ @yahoo.co om 032 21416863 30 14 C,Wahda atColony,Lahore,P Pakistan.

EmailAd ddress: Contact tNo#:

PostalA Address:

Name: Enrollment: Course:

Sab birGhazi E08 8CE17 B.S Sc.Chemic calEngg. sab bir_ghazi@ @yahoo.co om 033 34978805 54 14 C,Wahda atColony,Lahore,P Pakistan.

EmailAd ddress: Contact tNo#:

PostalA Address:

Subm mittedTo:
InternshipIncharge e Dr.AyyazMuhamm mad Instituteo ofChemic calEnginee ering&Te echnology y, University yofThePunjab,Lah hore.
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 2|P a g e

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 thevalue ofworkingtogetherasateamandas anewexperienceinworking environment,whichchallengesuseveryminute.Notforget,greatappreciation gototherestofICLstaffthathelpmefromtimetotimeduringtheinternship. Great deals appreciated go to the contribution of my faculty Institue of ChemicalEngineering&Technology(ICET).Iamalsowouldliketothankfulthe DirectorofICET,Prof.Dr.SyedZahoorulHassanRizviandallthestaffinthe ICETofficethatpatientinhelpinguscompletethisprogram.NotforgettoMr. Ayyaz Ahmad Muhammadfor the smoothes and cooperation during the visited. LastbutnotleastIwouldliketothankmyfriendsespeciallythosewhowork togetherasinterneesatICL. Special thanks also to Mr. Talha Trainee Engineer at ICL that have encouraged,supportandhelpusincompletingthisprogramsuccessfully.
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TableofContents

IndustryProfile History Mission Vision BoardofDirectors Capacity&Expansions Products QualityPolicy EnvironmentalPolicy InternationalStandards SourceofRawMaterial PrimaryRawMaterials SecondaryRawMaterials EnergyResources Equipments MeasuringEquipments SafetyEquipments ControllingEquipments Pumps: HeatExchangers Process CausticSoda(NaOH) 1. BrinePurificationforI.E.M 2. BrinePurificationforD.S.A 3. I.E.MCellRoom 4. D.S.ACellRooms LiquidChlorine(Cl2) HydrochloricAcid(HCl) Applications CausticSoda: LiquidChlorine: HydrochloricAcid: SodiumHypochlorite: ZincSulphate: Shaffaf(BleachingEarth) Summary Conclusions Recommendations
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IndustryProfile

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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 industries of 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.TheenvironmentalfriendlyIonExchangeMembranePlantwasaddedto the production line in the year 2003 with a capacity of 163 tons/day. This was shortlyenhancedto240tons/daywiththeadditionofmoreIEMElectrolyzers.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 theChloroalkaliindustry.Ithaspavedthewayforotherorganizationscompetingin
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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 Mr.AbdulSattarKhatri Mr.AbdulGhafoorKhatri Mr.MansoorAhmedKhatri Ms.FarhanaAbdulSattar Mr.FawadYousuf Ms.NoorulHuda

Chairman&ChiefExecutive Director Director Director Director Director Director

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Capacity&Expansions
IttehadChemicalsLimitedispubliclylistedchemicalmanufacturingcompany 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 Ittehad Chemicals and putunder thecontrol of the Federal Chemicaland 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 causticsodaand135MT/dayofchorine.Later,throughanotherexpension

Products
CausticSoda(Liquid/Solid/Flakes)
CausticSoda,alsoknownasSodiumHydroxide,formsastrongalkalinesolution whendissolvedinwater.ICLproducesCausticSodaintheformofflakes,solid, liquid(31%and50%concentration).Insolidform,itishygroscopicandassuch readilyabsorbswaterfromtheair.Hence,itisstoredinairtightcontainers. CausticSodaLiquidismanufacturedcommerciallybytheelectrolysisofbrinein electrolytic cells, where 31% membrane grade and 50% Rayon grade Caustic Sodaliquidisproduced. ItisproducedbyevaporationofliquidCausticSodasolutiontotheanhydrous state,andsubsequentconversiontoeitheraSolidoraFlakesform.

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
Chlorineisthesinglematerialonwhichproductionofotherchemicalsmostly 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 is also used directly in water to make it safe fordrinkingbychlorination. Chlorineisobtainedbypassinganelectriccurrentthroughasolutionofbrine 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 competenttechnicalprofessionalsandcontinuousresearch,havesucceededin 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.
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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& Improvethequalityofitsproductsthroughtheutilizationofadvanced technologies. b) Review the quality management system for its effectiveness and continual improvementthroughinternalaudits c) Achieve quality objectives with continuous training , review and improve processconditionthroughresearchanddevelopmentwhereneeded d) Attend to customers complains on priority with maximum emphasis on customerscareandsatisfaction. e) Ensure that the quality policy is communicated and understand within the organizationandreviewedforcontinuingsuitability.

EnvironmentalPolicy
Ittehadchemicalslimitediscommittedtoproducecausticsoda,chlorineand alliedproductskeepinginviewallaspectoftheirenvironmentalimpact Intheregardtheyshall a) Continually seek opportunities to improve our environmental aspects and undertake effective measures to present pollution , keep the factory/ work areaandoursurroundingenvironmentneatandcleaninallrespects.
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b) Fulfillourcommitmenttocomplywithapplicableenvironmentallaws,ensure adopting of all safety measures during requirements as work and meeting customerrequirementsasfaraspossible. c) Establishandreviewtheenvironmentalobjectives&targetinallareasofour activitiesatdefinedintervals. d) Ensure that the environmental policy is implemented communicated to all concernedpersonsworkingforandonbehalfoftheorganizationandisalso availabletothepublic.

InternationalStandards:
ICLiscertifiedfromtwointernationalstandardsfromInternationalStandardOrganization(ISO). Whichare:

1.

ISO9001

ISO 9001:2000 specifies requirements for a quality management system whereanorganization 1. needstodemonstrateitsabilitytoconsistentlyprovideproductthatmeets customerandapplicableregulatoryrequirements,and 2. aimstoenhancecustomersatisfactionthroughtheeffectiveapplicationof the system, including processes for continual improvement of the system and the assurance of conformity to customer and applicable regulatory requirements.

2. ISO14001
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 developedby the International Organization for Standardization (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, and more specialized standards dealing withspecificaspectsofenvironmentalmanagement.
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SourceofRaw Materials
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SourceofRawMaterial

PrimaryRawMaterials
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

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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.
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Equipments

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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 operationintheplant.Theymeasurethetemperatureofdepletedbrine, chlorinegas,causticsodaproductetc.

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

GlassTube
Glass tubes are installed to determine the level of the tank. For example causticstoragetank,ionexchangestoragetankandwaterstoragetanks.

SafetyEquipments
Helmet
Forsafetypurposes,Safetyhelmetsareprovidedtoavoidanyaccident.

GasMask
In industry chlorine gas leakage is very common. This gas is poisonous,thatswhygasmaskareprovidedtoavoidtheinhalingofgas.
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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 water pipelines are used for firemen to controlfire.

ControllingEquipments
Globevalve
GlobevalvesaremostlyusedinICLforthrottlingpurposes.Inletandoutlet ofcontainersandreactorsaremostlycontrolledbyglobevalves

Gatevalve
Attheinletandoutletofflowpipestherearegatevalveswhichareused forcompleteopenorcompleteclosetheflowintheindustry.

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

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MechanicalSteamtrap
Like all other steam traps these are also used to drain the condensed steaminsteampipelines.

Pumps:
CentrifugalPump:
Almost all pumps used for the transport of liquid streams are centrifugal pumps.

AirBlowers:
Airblowersareusedinairstrippersforblowingairthroughthedepleted brinesolutiontoremovechlorine.

HeatExchangers
Boiler
Shell and tube type Boilers are used to generate steam by the help of Naturalgas.Whicharealsousedforgeneratingelectricity.

BlastFurnace
Hydrogen and chlorine are burned in blast furnace to attain maximum temperature.Verticaltypeblastfurnaceisusedwhichislinedbybricks.

PlateTypeHeatExchanger
For evaporation of 30% caustic soda to achieve 50 % caustic soda plate typeheatexchangersareused.

ShellandTubeheatExchanger
Unit1 is completely consisting of shell and tube type heat exchangers. WhileinUnit2thesearealsousedforpreheatingpurposes.

CoolingTower
InICLsixforcedcirculationtypecoolingtowersareinstalled.
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Process

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Process
CausticSoda(NaOH)
ProcessofCausticSodaisdividedinfollowingplants: 5. 6. 7. 8. BrinePurificationforI.E.M BrinePurificationforD.S.A I.E.MCellRoom D.S.ACellRooms

1. BrinePurificationforI.E.M
I.E.Mbrineunitprovidesfeedofbrinesolutiontoionexchangemembrane cellroom.Thebrinesolutionfeedmustbeultrapure.Theidealconcentration ofbrineis280g/l.FollowingarethemaincomponentsofI.E.Mbrineunit. 1. 2. 3. 4. 5. Saturator Purifier Settler PrimaryandSecondaryFilters IonExchangeUnit

1. Saturator
Saturator consist oflarge storage of rocksalt.Attherock salt, depleted and dechlorinatedbrine,alsocalledanoliteisshoweredinordertoconcentrateit. Theanoliteatatemperatureof6570oC.Thebrinesolutionisstoredin3pits fromwhereitissenttofirstpurifier.

2. Purifier
Solutionofbariumcarbonateinwhichsomequantityofhydrochloricacidhas 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.
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Overflow from first purifier goes to second purifier where caustic solution is addedintoit. From purifier the brine is transferred to settler prior to the introduction of brineintothesettler,aflocculentnamedAccofloqisadded.Purifierismade ofmildsteelandlinedwithfiberglass.

3. Settler
Settler has capacity of 1000m3, brine overflows from settler after settling. A scraperisalsoinstalledinthecenter,nearthebottomofthesettlertopush thesludgesettled,towardsthebottomofthetankwhereanautomaticgate valveopensfor15sec.Afterevery15minutes.Fromsettler,thebrinemoves toastoragetank.Settlerismadeofmildsteelandcoatedwithatypeofresin whichiscorrosionresistant.

4. PrimaryandSecondaryFilters
Fromsettler,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.Alphacelluloseisfilledintothefilterowetthesockwithit and subsequently drained before the purifier start operation. And then the brineispassedthroughthetubes.Impuritiesstickwithalphacelluloseandare washedlaterduringregeneration.Fromsecondaryfilters,brineispumpedto feedtankforionexchangeunit.

5. IonExchangeUnit
Fromsecondaryfilters,brineistransferredtoionexchangeunit,whereanion exchange resin of general formula RNa2 is used to completely remove all impuritiesoutofit.ThepurifiedbrineisthensenttoI.E.Mcellroom.

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2. BrinePurificationforD.S.A
DSA brine unit provides brine to DSA cell rooms. The purity level of brine solutionrequiredhereisnotthatmushhighasthatforI.E.Mcellroom.Thats whylesserpurifiersisinstalledintothisunit.Anotherdistinguishingfeatureof theunitisthatbrineisdechlorinatedinthisunitasopposetoI.E.Mbrineunit where dechlorinated brine is received from cell room. The unit consist of followingsubunits. 1. 2. 3. 4. 5. DeChlorinationUnit Saturator Purifier Settler SandFilters

1. DeChlorinationUnit
DepletedbrinefromDSAcellroomisreceivedinatankmarkedas2D10.The pH of incoming brine is 4. Here hydrochloric acid is injected into the tank whichreleaseschlorinethroughcommonioneffect.AndpHisreducedto2, duetotheacidinjected. From2D10,brinesolutionistransferredtoAirStripperswhereairisbubbled 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 chlorinecontentsinbrinesolutionisreducedto7.1ppm.

2. Saturator
Dechlorinatedanoliteisshoweredonrocksaltandsaturatedbrineisstored inpits,whichalsoactsasasettlerforsomeimpuritiesofrocksalt.Frompits, saturatedbrineistransferredtopurifiers.
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3. Purifier
Inprimarypurifiers,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. Settler
Thecapacityofthesettleris2300m3.Remainingdetailsofsettlerarealmost similarasmentionedpreviouslyforI.E.Mbrineunit.Overflowfromsettleris transferredtoatankmarkedas2D5.Fromthistank,brineissenttoprimary 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 is injected inline which reduces the pH of brine from 1112 to 4.55.5. From overheadtankbrineflowstotheD.S.Acellroomsunderactionofgravity.

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3. I.E.MCellRoom
IonExchangeMembranetechnologyisthelatesttechnologyoftheproduction of caustic soda. The technology uses semipermeable membranes. The cells havebeenimportedfromUSA. Ion Exchange membrane technology is safer than mercury cells. In Ittehad ChemicalsLimited,wehavetotal40cellsinI.E.Mcellrooms. Theunitcanbedividedintoflowingsubunits. 1. 2. 3. 4. 5. BrineFeedunit CausticUnit I.E.Munit DechlorinationUnit Evaporation

Briefdiscussionoftheabovementionedsubunitsareasfollows

1. BrineFeedunit
UltraPurebrinefromI.E.MbrineunitisreceivedinUPbrinetank,whichisat groundlevel.Fromhere,brineistransferredto2overheadtanks.Incaseof overflowoftheoverheadtanksbrineistransferredtoUPbrinetanknumber 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 avoidanyproductionlosses.
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3. I.E.Munit
Thecellsarenotonlythemostimportantbutalsothemostcomponentofcell rooms.

Construction:
Acellconsistsoffollowingparts. 1. 2. 3. 4. 5. 6. BulkHeads BulkHeadInsulators InterCellsSpacers CurrentDistributers Membranes 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 side of the tank. While product i.e. 31% caustic is recoveredfromtoprightsideofthetankandhydrogenisalsorecoveredfrom thesameside.Whiledepletedbrine,alsocalledanoliteisrecoveredfromtop leftsideofthecellandchlorineisalsorecoveredfromthesameside. Drainlineareprovidedatbottomsidewhileoverflowlinesareprovidedattop sideofthetank,bothbrineandcaustic. Sodiumionstraveltowardsthecathodethroughsemipermeablemembrane andarereducedtosodiummetal.Chlorideionstraveltowardsanodeandare oxidized to form chlorine gas. Sodium ions are absorbed by the membrane andtransferredtoothersidewhenmoreionsapproachit. Hencechlorineiscollectedfromanodesandhydrogenandcausticofrequired concentrationi.e.31%iscollectedatcathode.
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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 head insulator, the whole assembly is disassembled. All the components are washedandcheckedforanyleakageusingpressurizeairframe. Theassemblingprocessisthereverseoperationofdisassemblingoperation.

Purgingoperation:
Airisusedforpurgingofhydrogenfromthewholesystemorthecellwhen theyaretakenoutofthecircuit.Nitrogenisusedonlywhenchlorineis requiredtobetakenoutofthewholesystem.

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4. DechlorinationUnit
Depletedbrineissenttodepletedbrinetankatgroundlevel,fromwhereitis pumpedtoanoverheaddechlorinationtower.Thetowerisrandomlypacked withrashingrings.Brineentersfromthetopandbothdechlorinatedbrineas 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 50oC. This chlorine is pumped with the helpofliquidringtyperotarycompressorandpassedthroughdepletedbrine tankandfinallysenttohydrochloricacidfurnaces.Theliquidusedtolubricate pumpisalsosenttodepletedbrinetank.Thedechlorinatedbrineissentto chlorinatedbrinetank,fromwhereitissenttosaturatorsofI.E.M.brineunit.

5. Evaporation
FromI.E.M.Cellroomweobtaincausticsodaatconcentrationof31%whichis not the demand of customers. So to achieve 50% concentration multiple effectheatexchangersareusedforevaporation.InICLthereistwounitsfor 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.
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4. D.S.ACellRooms
NortherncellroomhasthirtytwomercurycellsalsocalledasDenorasCell.In additiontomainelectrolyticcell,thecellroomhasfollowingcomponents. 1. Decomposer 2. CirculationTray

ProcessDetail
Brineisintroducedataconcentrationof295300g/literandatemperatureof 62oC at a flow rate of 45m3/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 from decomposer is transferred to mercury recirculation tray.Waterformsupperlayerinmercuryrecirculationtraytoavoidanyvapor formation.Thenmercuryisrecycledtothecells. Sometimescaustic(30%)isdirectlyintroducedintodecomposertoincreaseits concentrationof260265g/literandatemperatureof85oC.

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LiquidChlorine(Cl2)
Chlorinefromdechlorinatedunitsisboughttochlorinewasherwheresulphuricacid is showered from the top to neutralize any caustic presence and to absorb the moisture.Chlorine isthen passed throughdemisters to removeany entrained salts comingfromcellrooms.Chlorineisthensenttocentrifugalcompressorsfromwhere gas is sent to discharge separator which is also act as separator for acid. 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.
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HydrochloricAcid(HCl)
Hydrochloric acid Plant utilizes the gases produced as the byproducts of I.E.M. cell room, northern cell room and southern cell room. These gases are hydrogen and chlorine.Therearetotaltwelvefurnaces.Thefurnacesmaybetopfiredorbottom firedandmaybeoperatingunderpressureorundersuction. Themajorcomponentsofthefurnaceare: 1. 2. 3. 4. 5. 6. Chamber JointPiece PreCooler Absorber TailTower Scrubber

1. Chamber
The chamber has circular hollow cylindrical sections or elements of graphite which are fixed in a mild steel shell. It is also provided with a cooling tower chest.Atthetop,thereisacrownforequaldistributionofwaterinallside. Below the crown is a burst made of graphite. It lifts to some extent after whichitwillburst. Hydrogenandchlorinearefedinthesamemannerasincaseofthefurnace 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. JointPiece
Jointpieceismadeofgraphite.Itisjointbetweenchamberandprecooler.It is also cooled by cooling tower which is also distributed with the help of a rectangularcrownasopposedtothechamberinwhichwaterwasdistributed bycircularcrown.
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3. PreCooler
Precoolerhas109graphitetubesandreceivesgasatatemperatureof250 300oCandexititatatemperaturelowenoughtoallowitsabsorptioninfeed water.

4. Absorber
Absorber 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. TailTower
Tail 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. Scrubber
Unabsorbedgasesfromtailtowerarefedtoscrubber.Scrubberisalsorashing ringpacked sectionwhere industrialwater isshowered at differentlevels to maximize the absorption of gases. The weak acid formed is drained. Unabsorbedgasesfromscrubberareexhaustedtoatmospherewiththehelp ofanexhaust.

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Applications

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Applications

CausticSoda:

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

LiquidChlorine:

Waterdisinfectionandtreatment Paperandboard Coolingtowers Productionofplastic,suchasPVC Pharmaceuticalsformulation AgroChemicalproduction(insecticides,herbicides&fungicides) Productionofchlorinatedsolvent,hydrocarbonsandderivatives.

HydrochloricAcid:

Textiles Steelandgalvanizingindustry Metalpickling Gelatin Dyestuffs Pharmaceuticals Syntheticrubber MetalChloridesmanufacturing PVC

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SodiumHypochlorite:

Bleaching(widelyusedinpaper,carpetwashing,andtextileindustry) Formulateddisinfectants Potableandwastewatertreatment Swimmingpoolwatertreatment Processandcoolingtowertreatment Odourcontrol Chemical intermediates in agriculture, pharmaceutical, printing and metal processingindustries

ZincSulphate:

Agriculture: added to fertilizers as trace nutrient and animal feed to correct dietarydeficiencies. Chemical:asasourceofZincforthemanufacturingofotherZincchemicals. Textile:ViscoseRayon.

Shaffaf(BleachingEarth)
SHAFFAF (Acid Activated Bleaching Earth) has excellent bleaching properties and helpsinachievingthedesiredcolorvaluesatconsiderablereducedproductioncosts. Forthebleachingof:

Edible/cookingoil/vegetableoil. Lubricatingoil Mineraloil Fatinsoapmanufacturing

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Summary
Ittehad Chemicals Limited (ICL) is the pioneer and one of the largest manufacturers of industrial chemicals in Pakistan. The company was commissioned in1964asUnitedChemicalsandstartedproductionwithaninitialinstalledcapacity of60MT/dayofcausticsodaand54MT/dayofchlorine.Risingdemandfacilitated 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. ForDSAcellroomthedepletedbrineisshoweredonrocksaltafterchlorine 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.thepurificationprocessisthesameasDSAwithlittledifference 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 separatorfromwhereitgoestothechlorinefilters.Afterfilteringthechlorinegasli liquefiedinaliquefierinwhichFreongasisthecoolingmedium.

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Conclusions
During student life internship program have its own great importance. Theoretical conceptsaresometimesnotrealizedtillwedoitspracticals.IndustrialInternshipis like a piratical of our entire engineering theoretical base. In points our conclusions are: Manyconceptsareclearedwhichwastheoreticallynotrealized. Dealingwithothersinindustryandrealizingtheenvironmentofindustry. Maintaintimebymakingschedules. Punctualityandworkresponsibility. Teamworkandworkingwithotherfieldengineers. Successfullycompletingassignmentswhicharegiventous.

Recommendations
During four weeks of internship we face some problems. So asan internee we can onlyrecommendfollowingpoints Process flow sheets should be provided on the plant for visitors for quick guide. Thechlorinepipelineshavetobechangedandtominimizetheleakageofthis poisonousgas. Pipelineswithpropercolourhavetobepaintedtodistinguishthemwiththe fluidflowthroughit. Flowmeasuringdevicesshouldbeinstalledonfluidflowpipelines. Minimizetheliquidaswellasgasleakagebyproperrenovation.

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END
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