Hafiz

hhjjjl Husnain Akhtar

2014-CH-335
Sitara Chemical Industry Limited, a unit of Sitara group founded by Haji Abdul Gafoor(late) and
Haji Abdul Bashir Ahmed, was established in 1981.
SCIL, began producing soda in 1985, initially at a rate of 30MT per day. The plant’s production
capacity was gradually increased over the years to current level of 400MT per day. SCH
produces “Caustic Soda, liquid chlorine and allied products” at a chemical complex, situated at
32Km Faisalabad Sheikhupura road, Faisalabad.
Sitara chemical industry limited is being headed by the honorable “Mian Muhammad Adrees”
as a Chief Executive Officer. SCH believes in demonstrating its abilities to consistently provide
products that meet industrial and consumer requirements.
SCI being the largest producer of chlor-alkali products in Pakistan is a reference in employing
the world’s largest technology at all times.
SCIL is committed to continual improvement of its environmental management system(EMS) by
adoption of appropriate pollution prevention measures and complying with all relevant
environmental legislation/regulations through training, team work and produces as
implemented from time to time.

 Caustic Soda Solid

 Caustic Soda Liquid (50%)
 Caustic Soda Liquid(33%)
 Caustic Soda Flakes
 Bleaching Powder (Commercial)
 Bleaching Powder(industrial)
 Sodium Hypochlorite
 Hydrochloric Acid
 Liquid Chlorine
 Ammonium Chloride
 Hydrated Lime

SCIL is committed to continual improvement of its environmental management system(EMS) by

adoption of appropriate pollution prevention measures and complying adoption of appropriate
pollution prevention measures and complying with all relevant environmental legislation
through training , team work and procedures as implemented from time to time.
There are over one thousand and highly qualified employees in all categories which include
Senior Management, Middle Management, Technical Manpower and allied contractor’s labor
workforce.

SCIL marketing policy aims at bringing about both qualitative and quantitative improvement in
all the prevailing function, related directly to the customer benefit and satisfaction.

We have to maintain a major market share in Caustic Soda range sales, particularly , the bi-
products by providing best possible product quality and services to the customer being catered
directly through dealers network. This helps in having an enhanced interaction and
communication with the customers
 Process

 Rock Salt
 Demi Water
 Chemicals (Na2CO3, BaCO3, Flocculent)
 HCl Acid
 Process Water

The saturated brine is treated by means of appropriate chemicals to perform a primary

brine purification in order to precipitate most of the raw salt contained impurities. The
main impurities normally contained in saturated brine that must be removed because they
can affect membrane performances, are the following.

o Sulphates, which are precipitated as barium sulphate by reaction with barium carbonate.
SO4-- + BaCO3 ------------> BaSO4 + CO3--
o Calcium, which is precipitated as calcium carbonate by reaction with sodium carbonate.
Ca++ + Na2CO3 ------------> CaCO3 + 2Na+
o Magnesium, which is precipitated as magnesium hydroxide by reaction with caustic soda.
Mg++ + 2NaOH ------------> Mg(OH)2 + 2Na+
o Strontium, which is precipitated mainly as strontium carbonate.
Sr++ + CO3 ------------> SrCO3

The saturated brine from the Brine Storage Pit is pumped to the reactors A and B
connected in series.
Here chemicals are added in order to precipitate the impurities; barium carbonate is added
in the first reactor, while light soda ash is added in the second reactor.
About 8% w/w barium carbonate suspension is prepared with water in stirred tank and
fed to the reactor by dosing pump. The flow rate is adjusted by means of the flow meter.
About 8% w/w light soda ash solution is prepared with dilute brine in stirred tank. Barium
carbonate added in the first reactor precipitates barium sulphate giving simultaneously
sodium carbonate.Precipitation is completed in the second reactor by adding light soda ash
solution.
Barium carbonate should be dosed on the basis of the sulphates which are really present in
the brine and introduced with the raw salt, in order to bring down sodium sulphate
concentration in the brine feeding electrolysers 7-8 gpl.
Carbonate and caustic soda shall be dozed so to react with all the calcium and magnesium
introduced with the raw salt and also have an excess of both the reagents respectively of
about 0.3-0.6 gl and 0.1-0.3 g/L. the operating target should be near upper levels.
Measurement of said excess shall control the addition of soda ash and caustic soda.

Mechanical agitators are provided in the purifiers in order to disperse the reagents in to
the brine, to keep the formed solids in suspension and also to make easier the
agglomeration of the small solid particles in larger ones. The agglomeration process is done
by adding flocculants named NULCO in order to make smaller fines in bigger particle.

The insoluble compounds formed following the reactions reported above are removed
from brine first by settling. To promote the settling of the solids, a flocculating agent
(accofloc) is added to the brine in settler B.
he brine over flowing from the second purifier is mixed with flocculating agent prepared in
separate tank and injected by means of metering pump.
Tests must be done, taking brine sample directly on site, to adjust flocculent concentration
in order to obtain the best performance. It should be noted that some substances which are
flocculants can also act as flotation agents if they are added in large amounts.
A concentration of 1-2 ppm in brine is normally effective. he sludge from the settler is
discharged discontinuously to the sludge pits A/B. The discharge is automatically operated
by opening the on-off drain valve placed at the bottom of the clarifier and allowing the
sludge to flow until clear brine is observed in the discharge line. The time of valve open is
settle by timer.

Brine filters are required to remove the suspended solids overflowing with the brine from
the settler/clarifier. The plant is provided with five flowing gravity sand filters operating in
parallel. The filter design consists of a multilayered sand filtering bed and one upper layer
of anthracite coal.Clarified brine coming from settler is distributed by gravity to the battery
of sand filters through individual hand control valves.
the brine percolates the filtering bed from the top, leaving the filter from the bottom
through the flow indicator. Filtered brine is collected in Secondary Brine Filter Feed Tank.
Each filter is provided with high and very high alarms, it must be excluded from service for
cleaning.
In case of very high alarm, the filter is automatically cut out of service, by closing the
relevant inlet and outlet valves. The backwashing is performed first by means of air
scrubbing and then by filtered brine coming from primary filters.

The filters operation and the cleaning system is performed from a local control panel
where all manual operations, controls and alarm signalizations are placed. The operation of
each filter is made by five remote controlled on-off valves (HV) operated by a selector
switch and by a set of push buttons associated to the cleaning sequences of the filters and
placed on the aforementioned panel. Backwashing brine and sludge from filters are sent by
gravity to the sludge pit.
The filtered brine collected in the Filtered Brine Storage Tank is pumped either to existing
Mercury Plant under flow control or to Secondary Brine Filtration Section for treating the
flow required to the New Membrane Plant.


 Caustic
 Soda ash
 OH-
 CO3
 Turbidity
 Ca++
 Mg++
 Pump pressure flow
 pH(6-9)
 NaCl concentration
 Temperature
 Level of brine
  Filter aid
 Pit flow rate and level
 Sulphate SO4-
 Tanks level

The Secondary Brine Filtration (or brine polishing filters) are vertical tubular backwash
filters that utilize a cellulose fibre precoat to achieve the required level of filtration.
Primary brine typically contains < 10 ppm suspended solids (mostly CaCO3 and Mg(OH)2).
The secondary brine filters reduce the concentration to < 1 ppm suspended solids with
particle size < 0.5 micron. This level of filtration is required to protect the ion exchange
system from suspended solids which would otherwise plug the column.
The secondary brine filters are tubular backwash filter vessels with tubes suspended
vertically from a tube sheet. The conical shaped bottom facilitates the backwash by
directing the filtered solids cake to the dump (drain) connection during the backwash. The
dished top serves as a reservoir of filtered brine which is used to backwash the filter. The
filtered vessels are constructed of rubber lined steel to minimise contamination of the
brine with metal impurities. The filter tubes are constructed of CPVC with a polypropylene
sleeve and are covered with a seamless polypropylene sock type covering. All other
internal hardware (fasteners etc.) is constructed of titanium or plastic to minimise metals
contamination of the brine. Gaskets are constructed of EPDM.
Incoming brine enters the filter through the bottom conical section and is evenly
distributed throughout the filter chamber. Filtration is from the outside of the tubes to the
inside. As the brine passes through the cake and tubes, suspended solids are deposited on
the outside diameter of the tubes. The collection of these suspended solids forms a cake
layer on the tubes. The formation of this cake layer results in increased pressure drop and
eventually necessitates backwashing of the filtered brine. Filtered brine flows up through
the inside diameter of the tubes and enters the top head of the filter through the openings
in the tube sheet. Filtered brine is then discharged from the top head through the main
filtered brine outlet nozzle.
The top dome of filter serves as a reservoir of filtered brine which is used to backwash the
filter. The design of the vessel is such that a small amount of air is trapped in the top dome
during the filtration cycle. This trapped air provides the motive force for the backwashing
action during the cleaning cycle. At the end of the filtration cycle, the main filtered brine
outlet valve is closed. Incoming brine causes the fluid level in the dome to rise, compressing
the air cap until the pressure equals brine feed pump dead head pressure. The main brine
inlet valve is then closed, trapping the pressure within the filter vessel. A quick opening
drain (dump) valve at the bottom of the filter is then opened, causing the pressure within
the vessel to release with nearly explosive force. In turn, the filter socks expand slightly,
cracking the filter cake along the entire length of the tube. Filtered brine is then forced
backward through the tubes, carrying the accumulated solids and backwash liquid to blow
down waste tank in a matter of seconds. Typically, blow down waste is sent to a filter press
to separate the solid matter from the liquid. Solids from the filter press are typically sent off
site for disposal, usually by landfills.
The secondary brine filtration system consists of two filters arranged in parallel. One in
operation and the other is stand-by. Two filters are required because they are operated
batch wise. The filters are operated with a constant flow rate of brine. During the filtration
process a filter cake forms on the filter tubes. The formation of this cake layer results in
increased pressure drop and eventually necessitates back washing of the filter at some pre-
determined maximum allowable pressure drop (typically 2.1-2.5 kg/cm2). The filter is then
taken offline, back washed and then placed in stand-by mode. The other (stand-by) filter is
pre-coated and then put into service before the other filter is taken offline so that the flow
of the brine to the ion exchange system is not disrupted.
The control system of the filters normally includes the following;
1. A flow control valve which maintains a constant brine flow rate by compensating
for the increased pressure drop resulting from the cake formation and
2. A pressure drop switch to indicate when the filter is ready for back wash.

The secondary brine filters are pre-coated with a cellulose fibre material prior to being put
into service. Using a pre-coat improves the achievable level of filtration, allowing particles
as small as 0.5 micron to be removed from the brine stream. The pre-coat is applied by
circulating a brine solution containing the pre-coat material through the filter until a
uniform layer of pre-coat is applied. The pre-coat mix tank is used for mixing pre-coat
material and brine. The tank is an open top FRP vessel with a hinged lid. An agitator is
provided to ensure a homogenous mixture. Pre-coat material in fibre form is manually
dumped into the top of the tank. The amount (kgs) of pre-coat material required depends
on the filtration area (m2). During the pre-coat cycle, brine from the pre-coat mix tank is
recycled through the filter. The brine turns from milky white to nearly clear as the pre-coat
material forms a thin cake layer on the filter tubes. Visual observation of the filter tubes
through the sight glass is used to confirm that the pre-coat has been applied uniformly.
If the brine feed stream contains a large percentage of fine (small) or slimy solids, then the
pressure drop across the filter may rise rapidly, giving short cycle times. This is often the
case when the brine has a poor Ca to Mg ratio (less than 2:1). Slimy and very fine solids
form a dense, impermeable cake very quickly, which plugs the pre-coat layer and filter
media. Practical filtration of such solids requires that the porosity of the cake be increased
to permit passage of the brine. This can be accomplished by adding body feed to the brine
just upstream of the filters. Eltech’s basic engineering design includes the provision for
continuous addition of body feed. Included are the body feed tank, body feed tank agitator
and body feed metering pumps.
The Secondary Brine Filtration (or brine polishing filters) are vertical tubular backwash
filters that utilize a cellulose fibre precoat to achieve the required level of filtration.
Primary brine typically contains < 10 ppm suspended solids (mostly CaCO3and Mg(OH)2).
The secondary brine filters reduce the concentration to < 1 ppm suspended solids with
particle size < 0.5 micron. This level of filtration is required to protect the ion exchange
system from suspended solids which would otherwise plug the column.
The secondary brine filters are tubular backwash filter vessels with tubes suspended
vertically from a tube sheet. The conical shaped bottom facilitates the backwash by
directing the filtered solids cake to the dump (drain) connection during the backwash. The
dished top serves as a reservoir of filtered brine which is used to backwash the filter. The
filtered vessels are constructed of rubber lined steel to minimise contamination of the
brine with metal impurities. The filter tubes are constructed of CPVC with a polypropylene
sleeve and are covered with a seamless polypropylene sock type covering. All other
internal hardware (fasteners etc.) is constructed of titanium or plastic to minimise metals
contamination of the brine. Gaskets are constructed of EPDM.
Incoming brine enters the filter through the bottom conical section and is evenly
distributed throughout the filter chamber. Filtration is from the outside of the tubes to the
inside. As the brine passes through the cake and tubes, suspended solids are deposited on
the outside diameter of the tubes. The collection of these suspended solids forms a cake
layer on the tubes. The formation of this cake layer results in increased pressure drop and
eventually necessitates backwashing of the filtered brine. Filtered brine flows up through
the inside diameter of the tubes and enters the top head of the filter through the openings
in the tube sheet. Filtered brine is then discharged from the top head through the main
filtered brine outlet nozzle.
The top dome of filter serves as a reservoir of filtered brine which is used to backwash the
filter. The design of the vessel is such that a small amount of air is trapped in the top dome
during the filtration cycle. This trapped air provides the motive force for the backwashing
action during the cleaning cycle. At the end of the filtration cycle, the main filtered brine
outlet valve is closed. Incoming brine causes the fluid level in the dome to rise, compressing
the air cap until the pressure equals brine feed pump dead head pressure. The main brine
inlet valve is then closed, trapping the pressure within the filter vessel. A quick opening
drain (dump) valve at the bottom of the filter is then opened, causing the pressure within
the vessel to release with nearly explosive force. In turn, the filter socks expand slightly,
cracking the filter cake along the entire length of the tube. Filtered brine is then forced
backward through the tubes, carrying the accumulated solids and backwash liquid to blow
down waste tank in a matter of seconds. Typically, blow down waste is sent to a filter press
to separate the solid matter from the liquid. Solids from the filter press are typically sent off
site for disposal, usually by landfills.
The secondary brine filtration system consists of two filters arranged in parallel. One in
operation and the other is stand-by. Two filters are required because they are operated
batch wise. The filters are operated with a constant flow rate of brine. During the filtration
process a filter cake forms on the filter tubes. The formation of this cake layer results in
increased pressure drop and eventually necessitates back washing of the filter at some pre-
determined maximum allowable pressure drop (typically 2.1-2.5 kg/cm2). The filter is then
taken offline, back washed and then placed in stand-by mode. The other (stand-by) filter is
pre-coated and then put into service before the other filter is taken offline so that the flow
of the brine to the ion exchange system is not disrupted.
The control system of the filters normally includes the following;
1. A flow control valve which maintains a constant brine flow rate by compensating
for the increased pressure drop resulting from the cake formation and
2. A pressure drop switch to indicate when the filter is ready for back wash.

The secondary brine filters are pre-coated with a cellulose fibre material prior to being put
into service. Using a pre-coat improves the achievable level of filtration, allowing particles
as small as 0.5 micron to be removed from the brine stream. The pre-coat is applied by
circulating a brine solution containing the pre-coat material through the filter until a
uniform layer of pre-coat is applied. The pre-coat mix tank is used for mixing pre-coat
material and brine. The tank is an open top FRP vessel with a hinged lid. An agitator is
provided to ensure a homogenous mixture. Pre-coat material in fibre form is manually
dumped into the top of the tank. The amount (kgs) of pre-coat material required depends
on the filtration area (m2). During the pre-coat cycle, brine from the pre-coat mix tank is
recycled through the filter. The brine turns from milky white to nearly clear as the pre-coat
material forms a thin cake layer on the filter tubes. Visual observation of the filter tubes
through the sight glass is used to confirm that the pre-coat has been applied uniformly.
If the brine feed stream contains a large percentage of fine (small) or slimy solids, then the
pressure drop across the filter may rise rapidly, giving short cycle times. This is often the
case when the brine has a poor Ca to Mg ratio (less than 2:1). Slimy and very fine solids
form a dense, impermeable cake very quickly, which plugs the pre-coat layer and filter
media. Practical filtration of such solids requires that the porosity of the cake be increased
to permit passage of the brine. This can be accomplished by adding body feed to the brine
just upstream of the filters. Eltech’s basic engineering design includes the provision for
continuous addition of body feed. Included are the body feed tank, body feed tank agitator
and body feed metering pumps.

The brine feeding to the resin tower as following typical specifications.



Brine is drained by gravity upto 300mm abive the level of the resin, so to keep the resin
wholly wet and it is discharged into effluents tank.

Resin washing with demineralized water has the purpose of removing the brine trapped in
the resin bed. Brine must be removed co0mpletely because the chlrone possibly present in
the brine could decompose during the acid washing and give free chlorine which oxidizes
the resin with an increase in resin consumption. The washing lasts 60 minutes with a
flowrate of about 20m^3/ hr.

The resin is back washed with demineralized water at different flowrates in order to
expand the bed in the established percentage. Back washing achieves different purposes:

 Removes fine particles of resin which have been formed due to chemical
degradation or mechanical wear and the insoluble solids filtered out by the resin
bed. Fines removal is necessary because they increase the pressure drop across the
resin bed.
Back washing allows the fines to flow out from the top of tower by expanding the
resin bed. The back washing provides also to classify the resin bed and remove the
channels formed during operation.
 Presence of channels in the resin bed reduces contact time b/w brine and resin
there by decreasing the actual absorption capacity of the resin. After the back
washing resin bed must be let to rest for some minutes in order to allow the
packing to settle.

In this phase the real regeneration of the resin occurs, the metal ions fixed by the resin are
displaced and the resin is converted into its acid form. 4% HCl acid is fed to the top of the
tower. The conversion of the resin to its acidic form produces a contraction of the resin
volume. Therefore the downward direction of the flow allows the settling of the resin and
promotes the contact b/w the acid and particles avoiding the formation of channels.
The pH of effluents leaving the tower at the end of the plates should be less than 2.
Normally 50 minutes washing with a flow rate of about 24m^3/ hr are enough for the
scope.
Washing water is fed to the top and is discharged through the same siphon as the acid. This
siphon permits to always maintain the resin covered by liquid thus avoiding the package of
the resin resuting from a whole draining.
Washing with water reduces the consumption of caustic soda which must be used in the
following regeneration phase and avoids possible damage of resin particles due to heat
evolved in the reaction b/w acid and caustic soda . the washing lasts 40 minutes with a flow
rate of 20m^3/hr.

During the alkaline washing the resin is converted from the acid form to the soda form. 5%
caustic soda solution is fed to the bottom of the tower and is discharged from the top of the
tower.
The pH of effluents leaving the tower at the end of the phase should be greater than 12.
Normally 90 minutes washing with a flowrate of aboit 16m^3/hr are enough for scope. The
caustic soda is displaced by means of demineralized water. The flow is downward in order
to classify the resin which has increased its volume. Washing water is fed to the top of the
tower and discharged from the bottom through the siphon . the washing lasts 30 minutes
with a flowrate of about 20m^3/hr. the resin bed is allowed to rest 15 minutes and to
settle.

At the end of the regeneration filtered concentration brine coming from the tank through a
pump at a flowrate of 30m^3/hr is sent to the resin tower in order to displace
demineralized water trapped into resin bed . the effluents are discharged for 15 minutes to
tank. Then the tower is completely filled with brine in about 15 minutes.

When the tower is full , the resin bed must be reset. This operation is performed by
sending the same filtered brine in tank .resetting flow rate is maintained at 80m^3/hr for
60 minutes.

R-Na+ + Ca/Mg → R-Ca/Mg + Na

R-Na/Mg + HCl → R-H+ + Ca/MgCl
R-H+ + NaOH → Ra-Na + H2O
 DECHLORINATION

“The process of removal of chlorine from the depleted brine is termed as Dechlorination”.

The chlorine is produced as a byproduct in the cells for the production of caustic soda. Few
amount of unabsorbed chlorine in the depleted is easily separated in the separator where
residence time is provided whereas the absorbed chlorine is separated in the process of
dechlorination. The purpose of dechlorination is to achieve pure depleted brine and to get
more chlorine to make it useable.

Depleted brine from electrolyzer usually contains 0.3g/L dissolved chlorine at a pH of

about 3.5-4 and 1 g/L as available chlorine in the form of hypochlorite ions. Depleted brine
also carries 2000-2500 ppm of free chlorine.

Removal of chlorine is necessary because of following reasons:

 The removal of impurities in the primary brine purification becomes difficult

 In the presence of high contents of chlorine the impurities in the rock salt are more
easily dissolved during brine saturation.
 Chlorine oxidizes ion exchange resins hence increases its concentration.

Chlorates are formed in the anodic compartment of the cell of electrolyzer via chemical or
electrochemical reactions.

High temperature is also favors the chlorates removal, a temperature of 85-90oC is

recommended.

The third parameter affecting chlorates removal is pH. A low pH less than 2 is favorable.

Depleted brine leaving the electrolyzers flow into the acidification tank where it is mixed
with acidifie stream of brine from reactor R-5050. Then it is collected in depleted brine
storage tank from here the brine is pumped and the discharge of the pump is divided into
two streams one leads to vaccum stripper and second leads to acid mixing drum. Normally
75% material goes to stripper and 25% in the reactor for the decomposition of chlorates. In
acidification tank 33% HCl is added to lower down its pH almost zero. After acidification
the brine flows down by gravity into the reactor where it is mixed with chlorinated steam
coming from the vaccum stripper. In reactor at low pH and high temperature, Chlorates are
decomposed producing free chlorine which is vented in the chlorine sniff line. The over
flow of R-5050 entered in the acidification pot and lower the pH of the depleted brine
ranging 1.5-2.0.

NaClO3 + 6HCl NaCl + 3Cl2 + 3H2O

Brine containing absorbed chlorine enters from the upper part of the packed tower where
vaccum is generated by means of steam ejector. The wet chlorine stripped from the brine
leaves the tower and is cooled in the heat exchanger. The condensed chlorinated water is
returned in the depleted brine tank.


Sodium sulphite is added to the depleted brine leaving the tank D-5020. Sodium sulphite
solution is prepared in the tank by absorbing SO2 in sodium carbonate solution. The
sodium carbonate solution is fed from the upper side of the absorber and flows down back
to the same tank.


After treatment with sodium sulphite, brine is passed through an activated carbon bed in
tower. Carbon must work with acidic brine of pH less than 2 and chlorine less than 50ppm.
High chlorine contents in the brine feeding the tower causes to violet the reaction with the
carbon, relatively high pH in the feed brine to tower causes the carbon degradation in the
form of particles which can plug the tower. The brine passing out of the tower is made
alkaline by addition of dilute caustic effluent from tank. The pH is raised upto 6- 9 before it
is transferred in the primary brine section.
 EVAPORATION

The caustic produced in the cells is of 32% that concentration is raised to 50% in the
evaporation system. It’’s a complete economizing system consists of three evaporators
backward feed operation(Falling film).
A triple effect evaporator is used for concentrating the 32% caustic to 50% caustic. The
32% caustic is stored in the tank 201.
Evaporation is carried out in first evaporator by using steam as heating medium which is
falling film type evaporator having steam in the shell side. The temperature of steam is
about 1900C and pressure is about 14 bar. The steam condensate are stored in the tank 203
and are further used in the heat exchangers 205 and 203 and finally sent to theboiler.
Heating media in the second evaporator are the condensate formed in the last evaporator
and heating media in the first evaporator are the condensate of second evaporator. A
vaccum is created in order to lower the boiling points caustic.
The condensates leaving the first evaporator are cooled by using cooling water which
helps to achieve vaccum and these condensates are stored in a tank from where they are
sent to the dechlorination.
 Evaporation Unit

Cooling Water In

Cooling Water out

EV.203
EV.201
TK-201

EV.202
TK.203

206
203
205

205 205

202
205 50%
Caustic
205
204 205
204 205 205

205

CW

Production
line
 FURNACES
The chlorine and hydrogen produced as the byproduct in the caustic production is use to
produce the HCl. Both the hydrogen and chlorine is combusted in the furnaces at about
25000 C. Chlorine and hydrogen gases are produced together with caustic in the
electrolyzers. These gases are transferred in the furnaces for synthesis of hydrochloric acid.
Following reactions takes place:

H2 + Cl2 2HCl

During the reaction a lot of heat is generated and temperature inside the furnace is about
2500-3000. In top fired furnaces HCl gas produced in furnace is absorbed in weak acid. As a
lot of heat is generated during HCl synthesis, plenty of cooling water is circulated in the
exchanger block to cool down HCl gas as well as acid produced and also to improve
absorption.

Unabsorbed gas termed as tail gas is separated from the acid is passed through the
absorber and absorbed in the water thus producing weak acid of 4-8% concentration
which is fed to the furnace and 34-35% HCl is produced. Chlorine is introduced into the
inner tube while hydrogen in the outer. The tubes have cuts which allow both the gases to
form a mixture. Initially combustion is carried out with the help of oxygen and when the
flame is stabilized oxygen is replaced with chlorine. The temperature inside the furnace is
very high near about 25000C. The furnaces contain a weir, hollow blocks and exchanger
blocks which cool the HCl gas produced. Cooling water is introduced from bottom and
removed from top.