SALT, BROMINE AND POTASSIUM CHLORIDE

[EIRI/EDPR/4076] J.C.: 2213XL

INTRODUCTION

Salt was the name originally given to the residue left by evaporation of sea water.
Afterwards the name was employed to include all substances held in solution in
sea water. Chemists ultimately extended the name to cover all combinations of an
acid and a base. Sodium chloride (Nacl) now called common salt, is an example of
the simplest type of chemical salt.

Sodium chloride, common salt, is essential to human life. Our bodies contain up
to 450 grams of salt and we need to take in a few grams each week to stay
healthy. The value of salt can be seen in the way Roman soldiers used to be paid
in salt, leading to the phrase "worth his salt" and our word "salary". The growth of
industry has increased the demand for salt, both for direct use and as a raw
material for producing other chemicals.

Throughout the world the main sources of salt are sea water, lake water and rock
salt deposits. Salt is recovered from the sea and lakes by evaporation. Rock salt
may be mined like coal, or recovered by drilling wells into the salt bed, forcing
down pure water and pumping up the saturated brine which forms.

It is a deep red fuming liquid, member of the halogen elements as Group VII of the
periodic table that is liquid at ordinary temperature and pressure. Rare element
bromine is found in, nature dispersed throughout the earth crust only in
compounds such as soluble and insoluble bromides. The chief commercial source
of bromine is ocean water from which the element is extracted by means of
chemical replacement (oxidation) by more active chlorine. Bromine has
traditionally been manufactured as a byproduct from saline mother liquors
(bitterns) left after the crystallization of the main salt products.

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The properties of bromine are significantly different from those of fluorine and
chlorine. Discovered in the early 19th century, in the form of its salts (bromides)
in the bitterns remaining after evaporating sea water and extracting the sodium
chloride, it was obtained latter from stassfurt, Germany, as a byproduct in the
production of potassium salts and from other deposits and salt lakes.

Its main use was originally for bromides in medicine still a minor use. Bromine
first because of industrial importance with the development of modern
photographic process, in which the light sensitive material is an emulsion of
minute particles of silver bromide (together with silver chloride or iodide or both)
in gelatin.

For a time, the expanding world automobile industry. Threatened a scarcity of

bromine, obtained from brines, which contained about 0.5% bromine. To meet the
demand, it was necessary to turn to sea water which contains about 70 ppm
bromine.

The chief sources of bromine are sea water, brines and betters and the natural
deposits of potassium salts. In these, it is present in very small quantities in the
combined state. Sea-water contains, 66 parts per million (0.0066%) of bromine
and in 1933, the DOW Chemical Co., (U.S.A.) developed a process for its recovery.
Large quantities of bromine are now being produced both from the sea and from
the salt & lakes. The U.S.A. is now the world largest producer and used the entire
output for the manufacture of ethylene bromine.

The other prominent bromine producing countries are Germany and France.

Bromine, a heavy, mobile, reddish-brown liquid with an interesting irritating

odour, is the only non-metallic element that is a liquid at normal temperature. It
is a diatomic molecule with the chemical formula Br2

The bromine available for extraction occurs as bromide in the ocean, in salt lakes
and in brine or saline deposits left by evaporation of such waters by solar heat.
Sea bitterns, the left over concentrated solution after the crystallizing out of salt
from the sea water, are very rich in bromine and offer a good raw material for the
manufacture of bromine. Bromine is extracted from seawater.

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Potassium Chloride occurs naturally as Sylvite. However in general potassium
compounds are recorded as valuable article of commerce.

Potassium chloride has a wide field of application viz. source of potassium salts,
plant nutrient, salt substitute, and lab reagent, food additive, in slow release
tablets and in other pharmaceutical preparations.

Potassium chloride finds its application as fire extinguishing agent. However

potassium chloride as fire-extinguishing agent was originally developed as a
protein - foam compatible agent with class B capabilities and is about as effective
as potassium bicarbonate. It can ce somewhat corrosive and has a specialized use
in air-crash fires where corrosion is not normally a problem.

Potassium chloride as in the case of Potassium bicarbonate and multipurpose

agents is ground prior to processing As fre-extinguishing agent it is rated as a
class B.C. agent by UL and ULC and at one time was listed as foam compatible.

Potassium chloride also is used as water correcting agent Water used in the
brewing industry is often corrected to a uniform mineral salt content that
corresponds to water known to give the most satisfactory final product. A wide
variety of salts are used for this purpose including potassium chloride & others.

Also Potassium chloride finds its application in secondary batteries viz. lithium.
Iron sulphide battery utilizers a molten salt eutectic of lithium chloride, potassium
chloride at a temperature of you 400-500oC as electrolyte.

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 CONTENTS

INTRODUCTION
USES & APPLICATION OF POTASSIUM CHLORIDE
IT IS USED AS:-
USE OF POTASSIUM CHLORIDE IN SLOW-RELEASE TABLES IN
HARMACEUTICAL PREPARATIONS
USE OF POTASSIUM CHLORIDE AS INORGANIC NUTRIENT FOR CANDIDA
UTILIUS
PROPERTIES & CHARACTERISTICS OF POTASSIUM CHLORIDE
GRADES
B.I.S. SPECIFICATIONS
MARKET OVERVIEW OF SALT
PRODUCTION OF SALT IN PAST FEW YEARS
GROWTH OF CHLOR-ALKALI INDUSTRY OF INDIA
DEMAND, HOWEVER, EXPECTED TO SEE MORE ROBUST GROWTH
EXPORT OF SALT FROM INDIA
INDIA'S SALT EXPORT (IN TONES)
EXPORT OF SALT FROM GUJARAT
MARKET OVERVIEW OF POTASSIUM CHLORIDE
PROPERTIES OF SALT
POTASSIUM IODIDE
SOURCE AND SAFETY OF BROMINE
USE OF BROMINE
SOURCES OF BROMINE
SAFETY FIRST
MANUFACTURING BROMINE
OXIDATION OF BROMIDE IONS TO FORM BROMINE
BROMINE VAPOUR REMOVAL
PRODUCTION OF HYDROGEN BROMIDE
OXIDATION OF HYDROGEN BROMIDE TO BROMINE
HOW A HAZARDOUS CHEMICAL LIKE BROMINE IS HANDLED
PROPERTIES OF BROMINE
SALT PRODUCTION AND PROCESSING
SOLAR EVAPORATION METHOD
ROCK SALT MINING METHOD
VACUUM EVAPORATION METHOD
MANUFACTURING PROCESS OF SALT FROM SEAWATER
DETAILS OF SALT PURIFICATION PROCESS
TABLE.1 - CONCENTRATIONS OF SOME IONS FOUND IN SEAWATER

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THE PRODUCTION OF SOLAR SALT
THE PRODUCTION OF VACUUM SALT
FURTHER PROCESSING
PROCESS FLOW DIAGRAM FOR SALT RECOVERY FROM SEA WATER
BRINE EVAPORATORS AND SALT PRODUCTION
EVAPORATED SALT PRODUCTION
CRYSTALLISING EVAPORATORS:-
VACUUM DRIERS
1. DRUM DRIER
2. VACUUM ROTARY DRIER
USES AND APPLICATION OF BROMINE
SOURCES OF BROMINE
SOURCES OF BROMINE
MARKET OVERVIEW OF BROMINE
MAJOR BROMINE MANUFACTURING COUNTRIES
INCREASING DEMAND FOR FLAME RETARDANTS
CHINA TO DOMINATE THE ASIA-PACIFIC MARKET
MAJOR PLAYERS
RAW MATERIAL SECTION
MATERIALS OF CONSTRUCTION FOR CHLORINE HANDLING:-
B.I.S. SPECIFICATIONS
SCOPE:-
REQUIREMENTS:-
TABLE - 1: REQUIREMENTS FOR BROMINE, TECHNICAL
PACKING & MARKETING:-
PACKING:-
MARKING:-
SAMPLING:-
ANALYSIS OF BROMINE, TECHNICAL
CALCULATION:
WHERE,
DETERMINATION OF BROMINE:-
THE SOLUTION SHALL BE STANDARDIZED BEFORE USE.
PROCEDURE:-
WHERE:
DETERMINATION OF CHLORINE:-
PROCEDURE:-
CALCULATION:-
WHERE,
DETERMINATION OF NON-VOLATILE MATTER:-
CALCULATION:-
WHERE,
TEST FOR IODINE:-
ZINC DUST:-

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TEST FOR SULPHATES:-
PROCEDURE:-
SAMPLING OF BROMINE, TECHNICAL
NUMBER OF CONTAINERS TO BE DRAWN FOR SAMPLING
MANUFACTURING PROCESS OF BROMINE
BROMINE GENERATION
BROMINE SEPARATION
PURIFICAION AND DRYING
PROCESS FLOW DIAGRAM
BROMINE RECOVERY PLANT
BROMINE CAN BE RECOVERED FROM TWO SOURCES
A) STEAMING OUT PROCESS (HOT PROCESS)
B) AIR BLOWING PROCESS (COLD PROCESS)
BROMINE PROCESSES
PRODUCTION OF BROMINE
PROCESSING DETAILS OF BROMINE RECOVERY
PROCESS FLOW DIAGRAM
PROCESS IN DETAILS OF BROMINE PRODUCTION
THE BROMINE-GENERATING STEP
EXPLAIN.
RESIDUAL ORGANIC MATTER FOUND IN DEAD SEA WATER
SIDE-REACTIONS OCCURRING IN THE REACTION TOWER
1. CONDENSATION
2. SEPARATION
3. PURIFICATION
MANUFACTURE OF LIQUID BROMINE
PROCESS
THE FOUR PRINCIPAL STEPS IN BROMINE PRODUCTION ARE
STEAMING OUT PROCESS:-
DOW PROCESS:-
LIQUID BROMINE FROM SEA WATER
SAFETY IN BROMINE PLANT
SAFE HANDLING OF BROMINE LEAKAGE
SAFE STORAGE OF BROMINE
SAFE TRANSPORTATION OF BROMINE
THE BROMINE STORAGE TANK SIGN IS AS FOLLOWS:
PRODUCTION PROCESS OF BROMINE FROM BRINE
BROMINE-GENERATING STEP
BROMINE SEPARATION STEPS
1. CONDENSATION
2. SEPARATION
3. PURIFICATION AND DRYING
EXTRACTION OF BROMINE FROM SEA WATER
OXIDATION OF BROMIDE IONS TO BROMINE

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OXIDATION OF BROMIDE TO BROMINE
REMOVAL OF BROMINE VAPOUR
PRODUCTION OF BROMINE TO HYDROBROMIC ACID
OXIDATION OF HYDROBROMIC ACID TO BROMINE
DETAILS OF EXTRACTION BROMINE FROM SEA WATER
FROM SEA WATER
RAW MATERIAL
BLOCK DIAGRAM FOR MANUFACTURING PROCESS
REACTION
PROCESS DIVIDES IN THREE STEPS
AIR POLLUTANT EMISSIONS & THEIR CONTROL
MANUFACTURING PROCESS OF POTASSIUM CHLORIDE FROM SEA
WATER OR BRINE
RAW MATERIALS:
1. SYLVINITE (OR) BRINE
1. CRYSTALLIZATION PROCESS:
2. FLOTATION PROCESS:
BLOCK DIAGRAM FOR THE MGCL2 RECOVERY PROCESS.
BRINE CONCENTRATOR
ADDRESSES OF RAW MATERIALS SUPPLIERS
ADDRESSES OF PLANT & MACHINERY SUPPLIERS
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF HEAT EXCHANGER
SUPPLIERS OF CONDENSER
SUPPLIERS OF DISTILLATION COLUMN
SUPPLIERS OF STORAGE VESSEL (STORAGE TANKS)
SUPPLIERS OF LABORATORY EQUIPMENTS
SUPPLIERS OF D.G. SETS
SUPPLIERS OF BOILERS
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS
GOVT. LICENSE DETAILS FOR LIQUID BROMINE PLANT

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APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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 COST ESTIMATION

Plant Capacity 59 MT/Day

Land & Building (1 Acre) Rs. 3.76 Cr
Plant & Machinery Rs. 11.70 Cr
Working Capital for 2 Months Rs. 13.23 Cr
Total Capital Investment Rs. 29.35 Cr
Rate of Return 45%
Break Even Point 42%

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