internship icl report - zeeshan ul haq
TRANSCRIPT
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
1/44
Itte
IntJune2
10/22/
hadC
rns010Jul
010
hemi
ipR2010
calsL
por
imite
d
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
2/44
Z e e s
a n u l H a q , S a b i
E
G h a z i ,
Inngin
Uni
I C E T , P
titueeri
ersi
U
eof
g&
yof
heTec
The
1
ical
nol
Punj
|P a g e
gy
ab
ICET StudentsDigitally signed by ICET Students
DN: cn=ICET Students, o=ICET
Students, ou=Administrator,
[email protected], c=PK
Date: 2011.06.12 15:18:56 +05'00'
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
3/44
Z e e s
Sub
Sub
a n u l H a
ittedBy
Name:
Enrollm
Course:
EmailAContact
Postal
Name:
Enrollm
Course:
EmailAContact
Postal
ittedTo
q , S a b i
I
:
ent:
ddress:
No#:ddress:
ent:
ddress:
No#:ddress:
:
G h a z i ,
tern
June
Ze
E0
B.S
far
03
14
Sa
E0
B.S
sa
03
14
Internshi
Dr.Ayyaz
Institute
Universit
I C E T , P
ship010Jul
shanulH
CE29
c.Chemi
adulhaq
141686
C,Wahd
irGhaziCE
17
c.Chemi
ir_ghazi
497880
C,Wahd
pInchargMuham
fChemi
of
The
P
U
epo2010
q
alEngg.
yahoo.c
0
tColony,
alEngg.
yahoo.c
4
tColony,
ead
alEngine
unjab,La
rt
m
Lahore,
m
Lahore,
ring&T
ore.
2
akistan.
akistan.
chnolog
|P a g e
,
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
4/44
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 -
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
5/44
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 4|P a g e
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
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
6/44
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
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
7/44
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.
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 6|P a g e
Witharichandillustrioushistory,ICListhefoundingcompanyinPakistanfor
theChloro
alkali
industry.
It
has
paved
the
way
for
other
organizations
competing
in
Downloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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.
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 7|P a g e
Mr.MuhammadSiddiqueKhatri Chairman&ChiefExecutive
Mr.AbdulSattarKhatri Director
Mr.AbdulGhafoorKhatri Director
Mr.MansoorAhmedKhatri Director
Ms.FarhanaAbdulSattar Director
Mr.FawadYousuf Director
Ms.NoorulHuda Director
Downloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
9/44
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
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 8|P a g e
Sodium Hypochlorite is used for a wide range of applications where its
powerfuldisinfectionandoxidationpropertiesareutilizedtodelivertechnical
and commercial advantage. It is manufactured by passing gaseous chlorine
throughawellcooledsolutionofdiluteCausticSoda.
Downloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
10/44
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
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 9|P a g e
Zinc Sulphate Monohydrate is free flowing white powdery material, which is
highlysolubleinwater.
Downloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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
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 10|P a g e
a) Continually seek opportunities to improve our environmental aspects andundertake effective measures to present pollution , keep the factory/ work
areaandoursurroundingenvironmentneatandcleaninallrespects.
Downloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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
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 11|P a g e
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.
Downloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
13/44
SourceofRaw
Materials
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 12|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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
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 13|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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.
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 14|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
16/44
Equipments
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 15|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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.
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 16|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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
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 17|P a g e
They are used to stop backward flow of a stream passing through the
pipeline.
Downloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
19/44
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
20/44
Process
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 19|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
21/44
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.
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 20|P a g e
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.
Downloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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.
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 21|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
23/44
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 22|P a g eZ 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 22|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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
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 23|P a g e
Dechlorinatedanolite isshoweredonrocksaltandsaturatedbrine isstored
inpits,whichalsoactsasasettlerforsomeimpuritiesofrocksalt.Frompits,
saturatedbrineistransferredtopurifiers.
Downloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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
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 24|P a g e
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.
Downloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
26/44
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 25|P a g eZ 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 25|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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
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 26|P a g e
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.
Downloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
28/44
3.I.E.MunitThecellsarenotonlythemostimportantbutalsothemostcomponentofcell
rooms.
Construction:
Acellconsistsoffollowingparts.
1. BulkHeads2. BulkHeadInsulators3. InterCellsSpacers4. CurrentDistributers5. Membranes6. ElectrodePlates
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 27|P a g e
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.
Downloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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.
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 28|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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.
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 29|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
31/44
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 30|P a g eZ 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 30|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
32/44
4.D.S.ACellRoomsNortherncellroomhasthirtytwomercurycellsalsocalledasDenorasCell.In
additionto
main
electrolytic
cell,
the
cell
room
has
following
components.
1. Decomposer2. CirculationTray
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 31|P a g e
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.
Downloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
33/44
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 32|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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.
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 33|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
35/44
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 34|P a g eZ 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 34|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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.
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 35|P a g e
2.JointPieceJointpieceismadeofgraphite.Itisjointbetweenchamberandprecooler.It
is also cooled by cooling tower which is also distributed with the help of a
rectangularcrownasopposedtothechamberinwhichwaterwasdistributed
bycircularcrown.
Downloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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.
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 36|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
38/44
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 37|P a g eZ 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 37|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
39/44
Applications
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 38|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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
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 39|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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
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 40|P a g eDownloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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.
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 41|P a g e
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.
Downloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
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.
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 42|P a g e
Minimizetheliquidaswellasgasleakagebyproperrenovation.
Downloaded From : http://www.ICETStudentS.com
-
7/30/2019 Internship ICL Report - Zeeshan Ul Haq
44/44
END