HYDROCHLORIC ACID

STORAGE & SAFETY

BY
H S SEHGAL
 HYDROCHLORIC ACID
Known as
• Muriatic acid,
• Hydrochloric acid
• Mineral acid
• Known for its corrosive properties and general
effectiveness across applications.
Obsolete historical names
• Chlorohydric acid,
• Hydronium chloride,
• Spirits of salt.
• Chemical formula for hydrochloric acid, HCl
 HCL PROPERTIES
HCl Physical & Chemical Properties
WT% Molarity PH Boiling Point Freezing Point

10% 3 MOL/L -0.5 103°C 217°F -18°C 0.4°F

20% 6 MOL/L -0.8 108°C 226°F -59°C -74°F

30% 9.5 MOL/L -1.0 90°C 194°F -52°C -62°F

32% 10 MOL/L -1.0 84°C 183°F -43°C -45°F

34% 11 MOL/L -1.0 71°C 160°F -36°C -33°F

36% 11.5 MOL/L -1.1 61°C 142°F -30°C -22°F

38% 12.5 MOL/L -1.1 48°C 118°F -26°C -15°F

ACID REACTIVITY
 Hydrochloric Acid Density in g/cm3

-5°C / 0°C / 10°C / 20°C / 40°C / 60°C / 80°C / 100°C /

WT%
23°F 32°F 50°F 68°F 104°F 140°F 176°F 212°F

4% 1.0213 1.0213 1.0202 1.0181 1.0116 1.0026 0.9919 0.9791

10% 1.0536 1.0528 1.0504 1.0474 1.0400 1.0310 1.0206 1.0090

20% 1.1087 1.1067 1.1025 1.0980 1.0888 1.0790 1.0685 1.0574

30% 1.1648 1.1613 1.1553 1.1493 1.1376 1.1260 1.1149 1.1030

32% 1.1593

34% 1.1691

36% 1.1789
 Hydrochloric Acid Vapor Pressure in KPA*
0°C / 10°C / 20°C / 30°C / 40°C / 60°C / 80°C / 90°C / 100°C /
WT%
32°F 50°F 68°F 86°F 104°F 140°F 176°F 194°F 212°F
2.39E- 9.19E- 3.20E- 1.03E- 3.07E- 2.19E- 1.27E- 2.79E- 6.13E-
4%
06 06 05 04 04 03 02 02 02
5.60E- 1.79E- 5.27E- 1.48E- 3.76E- 2.09E- 9.73E-
10% 0.1973 0.3866
05 04 03 03 03 02 02
4.25E- 1.12E- 2.73E- 6.39E-
20% 0.1413 0.5865 2.079 3.746 6.532
03 02 02 02

30% 0.319 0.697 1.413 2.799 5.252 16.53 45.32 72.25 112.64

32% 0.759 1.573 3.133 5.932 10.79 31.73 83.04 129.30

34% 1.746 3.519 6.732 12.26 21.46 59.99

36% 3.866 7.518 14.06 25.06 42.92 114.64

38% 8.398 15.59 27.99 47.98 79.71

*1 KPA = 7.5018 MM HG = 0.009869 ATM

 ACID REACTIVITY
• 10% hydrochloric acid density 1.048 g/cm3
• Density is near water.
• Density low even as concentrations increase.
• Freezing point increases up to 20% then start reducing
with rise in concentration .
• 20% Conc= -74°F
• 30% Conc = -62°F
• 38% Conc = -15°F
• Boiling point at 20% HCl ---226°F
• Decreasing quickly at 30% HCl --- 194°F
• For 38% boiling point is ---- 118°F
• Between 30% and 38%, boiling point drops from 194
degrees F to 118 oF
• Indicate volatility of HCl with concentration.
• As solution warms, acid volatilize and form toxic, gaseous
hydrogen chloride above the solution surface.
 HCL STABILITY & INSTABILITY
• Stable molecule.
• Last indefinitely without denaturing, decomposing,
or losing its strength and chemical properties
when stored by itself.
• The greatest source of decreasing solution-
strength is through volatilization, as with fuming
HCl or conditions that favorable stimulate vapor
production (i.e. increased temperatures, decreased
pressures).
• Sensitive to the effects of ultraviolet energy,
• Sun’s heat-contribution is a storage concern due to
the increased potential for HCl gas formation.
 HCL INCOMPATIBILITIES
• Stored away from direct sunlight, heat sources.
• React exothermically (generating heat) with organic/inorganic bases, with
carbonates and hydrogen carbonates to yield carbon dioxide,
• Metals generate flammable hydrogen gas,- iron, tin, aluminum, zinc,
calcium magnesium, and the alkali metals.
• Toxic or flammable gases with borides, carbides, phosphides, and sulfides.
• Violent reactions with acetic anhydride, ammonium hydroxide, calcium
phosphide, sodium hydroxide, 2-aminoethanol, ethylenediamine,
perchloric acid, chlorosulfonic acid, propylene oxide, silver
perchlorate/carbon tetrachloride, calcium carbide, rubidium carbide, vinyl
acetate, magnesium boride, and mercury(II) sulfate.
• HCl Mixing with concentrated sulfuric acid generate HCl vapors.
• Process to “dry” hydrochloric acid to yield anhydrous HCl.
• Corrosive to construction metals -carbon and stainless steels, aluminum,
copper, nickel, and bronze.
• Contact avoided, and the listed metals not used for HCl storage or other
such applications.
 HYDROCHLORIC ACID STORAGE
Points for storage, tank materials, temperature,
storage life, and requirements:
• XLPE tanks recommended
• HDPE, LDPE, FRP, rubber-lined steel, and
polypropylene tanks successfully store HCl.
• Total fluid capacity affect recommended storage
tanks.
• Tanks made to 1.9 specific gravity.
• PVC fittings, Hastelloy bolts, and Viton® gaskets
are recommended.
• Hydrochloric acid vapors are corrosive and
hazardous, as well as a regulated emission.
 Material Resistance Chart
Material HCl ≤ 20% HCl 20% - 37%

304 SS Not Recommended / Severe Not Recommended / Severe

316 SS Not Recommended / Severe Not Recommended / Severe

ABS Plastic Excellent / None Excellent / None

CPVC Excellent / None Excellent / None

PVC Excellent / None Good / Minor

XLPE Excellent / None Excellent / None

HDPE Excellent / None Excellent / None

LDPE Excellent / None Good / Minor

Polypropylene Good / Minor Fair / Moderate

Nylon Not Recommended / Severe Not Recommended / Severe

Neoprene Fair / Moderate Good / Minor

 Material Resistance Chart
PVDF (Kynar) Excellent / None Excellent / None

Viton Excellent / None Excellent / None

Hastelloy-C Excellent / None Good / Minor

Teflon Excellent / None Excellent / None

Fluorocarbon (FKM) Excellent / None Excellent / None

EPDM Excellent / None Fair / Moderate

Aluminum Not Recommended / Severe Not Recommended / Severe

Brass Not Recommended / Severe Not Recommended / Severe

Copper Not Recommended / Severe Not Recommended / Severe

Natural Rubber Excellent / None Excellent / None

Titanium Not Recommended / Severe Not Recommended / Severe

 HYDROCHLORIC ACID STORAGE
• Airtight man ways and connections.
• Employ fume scrubbers and/or vents for HCl vapor
mitigation.
• Thermoplastics or FRP are material choices.
• Secondary containment measures for bulk quantities
due to its chemical hazards.
• Engineering standards contain 110% of total HCl tank
system volume in the event of a release.
• Storage away from heat sources, direct sunlight, and
incompatible materials due to the potential for
evolving vapors and hazardous reactions.
• HCl inherently stable without degradation.
• Freezing is not a general concern.
 STORAGE TANKS
• Engineered to withstand the pressure-stress
generated by evolving HCl vapors and the back
pressure of the scrubber, whether in long-term
storage, in product transfer, or in product refilling.
• Tank vents at least double the tank inlet diameter.
• HCl fumes mitigation-efforts incorporated into
successful HCl storage tank systems.
• Density of hydrochloric acid is around that of water,
making it generally lighter than other common
industrial chemicals.
• Even though the density is low, storage tank specific
gravity ratings of at least 1.9 are still recommended
due to the hazards and vapor pressures of muriatic
acid.
 POLYETHYLENE TANKS
• Made of cross-linked polyethylene (XLPE), high-density
polyethylene (HDPE), and low-density polyethylene (LDPE)
Three forms of poly tanks
• Poly tank HCl storage, up to 12,500 gallons .
• Multiple tanks need for exceeding 12,500 gallons.
• 1.9 specific gravity rating,
• PVC fittings,
• Viton® gaskets,
• Hastelloy bolts.
• Polyethylene tanks- cost-effective service longevity.
• Outdoor storage in poly tanks- UV-stabilizing resins
recommended to resist the damaging effects of sunlight .
• Polyethylene tanks never exceed 100oF .
 FRP TANKS
• FRP tanks have high strength-to-weight ratios with
potentially long life cycles and low maintenance costs.
• FRP tanks fabricated and lined with a corrosion resistant
barrier.
• The selected tank resin is important.
• It must be chemically resistant to hydrochloric acid and
mechanically durable against the increased pressure-stress
that can arise from HCl vapors or during product transfer.
• FRP tank effectiveness is dependent upon proper
construction with an HCl-resistant resin and corrosion
barrier.
• Routine tank inspection and maintenance, such as re-
lamination of the corrosion-barrier, is also important.
• Polypropylene or PVC are additionally effective material
choices for FRP linings in hydrochloric acid storage.
 RUBBER-LINED STEEL TANKS
• Expensive than the other listed tanks.
• Steel tanks of 15,000 gallons or more due to the increased
structural integrity of the metal.
• Steel is susceptible to the corrosive activities of HCl.
• Corrosive activity between acid and metal generate
hydrogen gas.
• HCl-resistant interior lining is required to prevent corrosion.
• Integrity of this protective layer must be maintained.
• The Chlorine Institute recommends natural gum rubber for
hydrochloric acid steel storage tanks.
• Constructed of ASTM-283 Grade C steel or equivalent,
• Rubber-lining to withstand a maximum temperature of
160°F
• 3/16 inch thickness.
 POLYPROPYLENE HCL TANKS
• Are among the least effective in HCl storage when
compared to the storage options presented above,
but are still more resistant to muriatic acid than
other, non-mentioned storage solutions.
• Lose their chemical resistance when HCl
concentrations approach and exceed 20%.
• Best reserved for smaller quantities (5 – 45
gallons)
• Dilute hydrochloric acid solutions.
 Venting Hydrochloric Acid Tanks
• All hydrochloric acid storage tanks properly vented to avoid
exceeding the pressure or vacuum rating of the tank.
• Exceeding the design limits of the tank lead to possible
failure of the tank.
• A pressure/vacuum relief device in place in addition to the
tank vent
Internal Tank Pressure/Vacuum
• Increase in pressure occurs when filling the tank.
• As acid is transferred into the tank, the pressure tends to
increase unless the vent system has the capability to relieve
the pressure.
• When liquid is withdrawn from the tank, an equal volume of
outside air must enter the tank through a vent system or a
partial vacuum will be created inside the tank which could
result in cracking or collapse of the tank.
 Venting Hydrochloric Acid Tanks
• When acid is unloaded by air pressure from a tank car
or trailer, a properly designed vent is extremely
important because of the sudden surge of air through
the hose at the end of the unloading.
• The vent system must be designed to handle this air
surge condition.
• In order to provide guidance on storage tank vent
requirements, a calculated air flow rate could be 1350
SCFM at the completion of a typical unloading
operation.
• This calculation was based upon a 2” unloading hose
25 feet long; maximum pressure in the tank car or
trailer of 30 PSIG; unloading into a storage tank 8
½feet high; and with a vertical tank vent line not
exceeding 3 feet in length.
 Venting Hydrochloric Acid Tanks
Vent Systems
• Keep the tank at or near atmospheric pressure and within
the tank design parameters.
• Acid tanks vent into fume scrubber systems to absorb all
acid vapors.
• 2 basic venting systems used most commonly:
(1) vent through a fume scrubber open to the atmosphere;
(2) completely closed system not open to the atmosphere
• Both the fume scrubber and closed systems eliminate acid
vapor emission to the atmosphere.
• The closed system must use a pump only for unloading and
transferring acid and utilizes return vapor lines, i.e., from
the storage tank to the tank trailer or tank car while
unloading.
• This system contain a pressure/vacuum relief device also
connected to a scrubber in case of pressure release
 Vent Design
• Vent designs based upon
• Starting with the pressure/vacuum rating
• Liquid flow rates;
• Maximum air flow rates for air unloading;
• Transfer line size,
• Length and configuration;
• Tank pressure/vacuum rating.
Critical in sizing vent lines.
• a) A tank designed for +25” Water Column requires a
3” diameter vent
• b) A tank designed for +10” Water Column requires a
4” diameter vent
• c) A tank designed for +1” Water Column requires a
5” diameter vent
 Recirculating Scrubber
• Consists of a pump, lines, eductor, scrubber tank, and
sparger.
• Fume eductor draws acid vapors from the storage
tank.
• The acid vapors are then absorbed by water being
recirculated through the eductor.
• The solution in the scrubber tank gradually builds
strength up to a maximum of 15% HCl.
• Weak acid solution removed at this point for use or
sent to an appropriate hazardous waste treatment
site.
• Recharged with fresh water.
• No acid is lost and the fumes from the hydrochloric
acid are contained by the system.
 Packed Column Scrubber
• Water is fed into the top of a packed column
• Acid vapors from the storage tank are fed into the
bottom.
• Acid vapors are removed from the air by scrubbing
them with the countercurrent flow of water.
• Air then vents out of the top of the scrubber
• Weak acid flows into a suitable chemical waste
handling system
 SECONDARY CONTAINMENT
• Maintain satisfactory secondary containment
• Corrosion-resistant containment basins, sumps, and
double-walled tanks as secondary containment.
• Concrete containment dikes with acid-resistant
coatings are another common choice.
• Hydrochloric acid attack un-lined concrete.
• Secondary containment minimum 110% of total
volume for a tank system.
• Local regulatory statutes and codes requirements for
secondary containment systems.
• Designed and maintained according to local regulating
law codes
 FUME MITIGATION
• Non-mitigated HCl vapors cause health effects and
corroding sensitive materials.
• Service-ways-lines made of HCl-resistant material
• Corrosive HCl gas is a main concern.
• Strong HCl solutions have high vapor pressures.
• Absorbs heat from its environment or from sunlight.
• Increased temperatures cause increased amounts of gas
leaving the solution.
• HCl vapor released to the atmosphere reacts with water
vapor to produce an HCl acid mist.
• Situation exacerbated when a solution is heated to near
boiling.
• Production of HCl gas cause hazardous vapor buildup when
stored incorrectly or in a sealed container.
• Fume vents and/or fume scrubbers are necessary for safe
storage, handling, and transfer.
 FUME MITIGATION
• Transporting or transferring of acid to a storage tank, a
fume scrubber or other means of fume/pressure dissipation
is needed to mitigate the increased pressure arising from
displacing saturated vapor spaces.
• Without proper mitigation, the pressure increase can lead
to fitting or tank failure.
• Airtight man ways maintained on bulk storage tanks.
• Vapors will develop at ambient temperatures and the rate of
produced gases will increase as temperatures and HCl
concentrations rise,
• Venting system must remain intact and functioning properly
or a venting schedule performed regularly.
• Entering the tank for any reason—even post-use, visibly-
empty tanks—is not recommended due to the toxic,
corrosive dangers of muriatic acid and its vapors.
• Tanks completely drained as required to minimize or
eliminate the need for entering and/or cleaning the tank.
FUME SCRUBBERS
 CHEMICAL SCRUBBERS
• Basic venting of chemical tank systems includes
vent pipes of sufficient diameter that are open to
the general atmosphere.
• Venting for inert, non-volatile chemicals, chemicals
that generate non-noxious, non-corrosive, or non-
regulated fumes, or for applications that do not
generate fumes above regulatory permit limits
 TYPES OF FUME SCRUBBERS
WET SCRUBBERS
• Driving the generated gaseous stream through a
scrubbing solution prior to its atmospheric discharge.
• Vapors dissolves in the scrubbing media and/or
dilutes the amount of fumes
• Reaching the external vent pipe.
• Water is used scrubber solution.
• Sodium hydroxide, NaOH, alkaline material utilized in
wet scrubber systems.
• Scrubbing medium will be exhausted from use.
• Inexpensive scrubbing solutions is advised
• Proper, regular scrubber inspection and maintenance
schedules followed.
 DRY SCRUBBERS
Dry scrubbers
• Remove the acidic gases resulting from combustion
processes.
• Operate due to a dry, gas-absorbing material
• Evolving fumes absorbed and neutralized.
• Known as physical adsorption systems.
• Activated carbon is dry adsorbent material.
• Medium used too exhausted.
• Proper maintenance and medium replacement
schedules followed.
Horizontal and vertical scrubber systems
• Defines the direction of system airflow and their
constructional directions
 FUME SCRUBBER MATERIALS
Fume scrubbers and scrubber tanks MOC
• PVC,
• CPVC,
• polypropylene,
• fiberglass/FRP