-- --:-,------~

DESIGN OF A PLANT TO PRODUCE 15000 TONNES PER

ANNUM OF HYDROCHLORIC ACID

BY

EMUZE, ANDREW IGHODALO (2003/14981 EH)

DEPARTMENT OF CHEMICAL ENGINEERING, FEDARAL UNIVERSITY OF TECHNOLOGY, MINNA

NOVEMBER, 2008

ii

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DESIGN OF A PLANT TO PRODUCE 15000 TONNES PER

ANNUM OF HYDROCHLORIC ACID

BY

EMUZE, ANDREW IGBODALO

(2003/1 4981 EH)

A PROJECT SUBMITTED TO THE DEPARTMENT OF CHEMICAL

ENGINEERING, FEDERAL UNIVERSITY OF TECHNOWGY, MINNA

IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE

AWARD OF B.ENG (CHEMICAL)

NOVEMBER, 2008

DECLARATION

I, EMUZE, ANDREW GIHODALO (2003/14981EH), declare that this project work is

my work, and to the best of my knowledge has never been submitted elsewhere before now.

Signature Date

iii

CERTIFICATION

This is to certify that this project work was carried out by Emuze, Andrew Ighodalo with

registration number 2003/14981 , and that it was supervi~ examined and approved for the

partial fulfillment for the award of Bachelor's Degree in Chemical Engineering, Federal

university of Technology, Minna.

Engr. M. Auta

(project Supervisor)

Dr. M.O. Edoga

(Head of Department)

External Examiner

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n -11- 2-00,??

Date

Date

Date

I DEDICATION

This project work is dedicated to God Almighty for his love, care, protection and

provision for me and my family throughout our time on earth. This project is also dedicated to

.~ my ever-loving parents, Mr. and Mrs. 8.0. Emuze, for being there for me at all times. May God !

... continue to bless you, and grant your heart desires. Amen

.

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ACKNOWLEDGEMENT

I overwhelmingly acknowledge and thank God Almighty, the Alpha and Omega,

Beginning and the End for his wlquantifiable love, care, guidance, provision, mercies and favour

:. granted to me since I was born till date. You enabled the beginning and end of this pursuit, there

is none like You.

.

Great thanks and appreciation to my supervisor, Engr. Auta .M. whom without your

constructive criticism, guidance, and moral support tIus project, would not have been a success.

I also acknowledge the Dean of the School of Engineering and Engineering Technology,

Prof. J.A. Odigure. I say a big tIlank you for your moral and academic advices, may God

continue to bless you. Amen.

My sincere gratitude also goes to my Head of Deprutment, Dr. M.O. Edoga. Thank you

for all your moral and academic advice, your principles have added beauty to my life .

I greatly tIlrulk Prof. K. R. Olufade. You have been a fatl1er to me in tIlis school,

and I pray God blesses you with your heart desires, long life, and excellent health. I can't thank

you enough.

I also greatly appreciate my lecturers; Dr. D. Aloko, Engineer Muktar, Engineer

Mrulasseh, Engineer Galadima, and indeed the entire staff (teaching ruld non-teaching) of

Chemical Engineering department. May God reward you greatly.

I say a big tIlank you to Pastor Emmenuel Ohere of Transfonl1ation Chapel, may God

continue to uplift you, strengthen you, and continue to grow your knowledge. A big thank you to

the entire Living Faith Church family in Minna, may God bless you all. I also appreciate Pastor

ltuah Ighodalo and the entire family of R.C.C.G-ChristChurch Parish, for your love, prayers, and

messages, May God bless you aU abundantly. Amen

My thanks cannot be enough for my loving parents, Mr. and Mrs. S.O. Emuze, words

C8l1 't tell how much I love you, and appreciate all your efforts. You are the best parent rulyone

could have, and I thank. God I'm your son. May God continually bless and keep you. Amen.

vi

Great thanks to my brothers and sisters; Anthony, Arnold, and Alero, you have made me who I

am today. I thank God we're family, and pray God bless you abundantly. Thanks also to my

youngest aunt Adesuwa, may God bless you.

Big thanks to my cousins; Tuoyo, Mone, Dolapo, Temilola, and others, may God be with

you. My sincere gratitude also goes to aunties and uncles, and also to Mr. and Mrs. Odunuga for

your kindness, may God always guide you. I also appreciate my big bros, Mr. Funso Akin­

Amuwa, you are a brother indeed, and may God bless you abwuiantly. My sincere appreciation

to the Mr. and Mrs. Akinbo, and the entire Akinbo family, you were my parents in Minna, and I

would never forget you and your kindness. May God be with you all always. I also say a big

thank you to Mr. Akande Hassan, and Mr. Tunde and your family, you would always be

remembered. May God bless you all.

Lastly,my profound gratitude goes to my friends Ige Saheed, Kamal, Mahmood, Ramat,

Bola, Yewande, Tobosun, Paul and others in queens, may God be with you all. I can't say

enough thank you to Tolu (Ori-Tee), Bisola, (MSA), Oyinlola, Grace, Busayo, and Bunmi, you

were my family in Milma, and I'm going to miss you big rune. I thank God I meet you guys, and

hope we meet even in another generation. Big thanks to Mr. and Mrs. B. Agusiobo

(MOLISA'08), your house was my presidential lodge in Abuja, may God bless you greatly. I

can't forget to say thank you to my great peeps; Chinedu, Micheal, Dotun, Ayo Alabi, Ayo

Akinsola, and Wole (Abuja), you guys have a pennanent place in my heart. May God bless and

keep you. Amen. I greatly appreciate Dare, thanks for your calls, messages, prayers and

encouragement. You are dear to me, may God bless you greatly.

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ABSTRACT

The production of hydrochloric acid using propylene and chlorine as raw materials has

been investigated in this work. The product properties studied were used to design a plant to

produce 15000 tonnes of hydrochloric acid per annum, with great consideration to safety,

quality, economy and technology.

The production process is showed in the process flow diagram, and consists of unit

processes involving heating chlorine and propylene to reaction temperator of 350QC, chlorination

of propylene, cooling of reactor product, separation of dicbloro propylene from the reactor

product, reactive absorption of to produce more HCI and finally, separation of excess propylene

for recyclene.

The economic analysis was used using carried out using a plant efficiency of 90% and

300hours operating days, and assuming 8ooohours per annum. The plant was found to be of

great economy, having pay-back period of9 months, and rate of return of 134.274%.

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TABLE OF CONTENTS

Cover Page

Title page

Declaration

Certification

Dedication

Acknowledgemen.t

Abstract

Table of content

CHAPTER ONE

2.0 Introduction

2.1 Historical Background

2.1.1 General propeliies of Hydrochloric Acid

2.1.2 Chemical properties of Hydrogen Chloride and

Hydrochloric Acid

2.2.1 Hydrochloric Acid Emissions

2.3.0 Alternative Process Description Routes

2.3.1 The manufacture of Hydrochloric Acid by Thermal or Synthetic

Process

2.3.2 Hydrochloric Acid manufacture from By-Product of Organic

Chlorination

2.3.3 Manufacture of Hydrochloric Acid from the Reaction between

Sodiwn Chloride with Sulphuric Acid or Hydrogen. Sulphate

2.4. Selection of Best Alternative Production Route

2.4.1 By-Product Process

2.4.2 Synthetic Process

2.4.3 Hargreaves Process

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111

IV

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VI

VIll

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3

4

5

5

5

5

6

7

8

8

8

8

2.4.4 Salt Sulphuric Process 8

2.5 Yield and Conversion 9

2.6 Number of Equipments 9

2.6.1 Salt Sulphuric process 9

2.6.2 Hargreaves Process 10

2.6.3 Synthetic Process 10

2.7 By-Product Process 10

2.8 ProcessFlexibility 11

2.9 Application of Hydrochloric Acid 11

2.9.1 Ends Uses of Hydrochloric Acid 12

2.10 Design Process 12

2.11 Assumptions used in the project Work 12

2.12 Technical Matters of Importance 13

2.20 Process Description of Selected Technology 13

CHAPTER THREE

3.0 Material Balance Across Units 15

CHAPTER FOUR

4.0 Energy Balance 23

CHAPTER FIVE

5.0 Process Flow Diagram 32

CHAPTER SIX

6.0 Equipment Design and Optimization of Separator (2) 33

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CHAPTER SEVEN

7.0 Safety and Quality Control 37

7.1 Insight into Safety 37

7.1.2 Some Safety Measures 38

7.2 Quality Control 39

CHAPTER EIGHT

8.0 Process Control and Instnunentation 40

8.1 Process Control 40

8.1.2 Control of Flowrate 40

8.1.3 Control of Temperature 41

8.1.4 Control of Pressure 42

8.2 Process Instrwnentation 42

8.2.1 Objectives of Instrumentation 42

8.2.2 Instrwnentation Equipments 43

CHAPTER NINE

9.0 Environmental Acceptability 47

CHAPTER TEN

10.0 Start-Up and Shut-Down Procedure 49

10.1 Start-Up and Shut-Down Procedure for the Hydrochloric-

Acid plant 49

10.1.2 Strut-Up of the Separator 50

10.1.3 Start-Up of the Heater 50

10.1.4 Start -Up of the Reactor 50

10.1.5 Start-Up of the Absorber 50

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10.2 Hydrochloric Acid Plant Shut-Down 51

10.2.1 Routine Hydrochloric Acid plant Shut-Down 51

10.2.2 Emergency Shut-Down of the Hydrochloric Acid Plant 52

10.3 Start-Up after Emergency Shut-Down 52

CHAPTER ELEVEN

11.0 Plant Location and Layout

11.1 Plant Location

11.2 Diagram of Plant Layout

CHAPTER TWELVE

12.0 Economic Analysis

CHAPTER THIRTEEN

l3.0 Recommendation to the Industrialists

REFERENCES

APPENDIX

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