Project Nebula

BASIC ENGINEERING

CONCEPT NOTES FOR

SCRUBBER SYSTEM

P90-UL83-01-001 0 01/12/2019 Nikhil Ajinkya Shrivardhan

Document No Rev Date Prepared by Checked by Issued by

F/NPT/CCP/WI-025 Rev No. 00 Effective date: 01/04/2014 Page 1 of 6

 Project Nebula
1.0 Introduction
Aim

• To design the scrubber system to convert the gaseous by-product of Sunbeat/Galhueshield and EHT
synthesis process to valuable and saleable products.
• To design the process to convert HCl gas into HCl solution of purity of 30% HCl and having SO2 content of
less than 0.1%
• To design the process to convert the SO 2 gas to sodium bisulfite solution having NaCl conc. of less than 50
PPM
• The concentration of SO2 in the vent gas shall be less than 5 mg/Nm3 and of HCl shall be less than 5 mg/Nm3
• Scrubber will be designed for 300kg/hr TC addition.

Background:

Sunbeat and Galhueshield process has first step chlorination where PMCA reacts with Thionyl Chloride which
generates HCl and SO2 gases.
In EHT process, HCl gas generate during alkylation.

Preparation of RB650 (Chlorination reaction-Sunbeat)

• The scrubber system needs to be designed to convert the gaseous byproducts to valuable and saleable product.
• This scrubber will be designed as per Titlee scrubber.

2.0 Philosophy

F/NPT/CCP/WI-025 Rev No. 00 Effective date: 01/04/2014 Page 2 of 6

 Project Nebula
Philosophy

• The gaseous by-products are scrubbed in the absorption column where the gas is first scrubbed with water
to remove the HCl gas from the gaseous stream.
• The HCl gas gets absorbed in the water to form the aqueous solution of HCl. There will be total five packed
columns available for HCl system.
• There will be total five HCl scrubber in which four will be used in sunbeat/Galhueshield process and other one
will be used for EHT process.
• This HCl system will be designed to make 30% aqueous solution of HCl which will be having dissolved SO 2
in the range of 4-7%.
• Further the SO2 free HCl solutions will be prepared using stripping column. At the outlet of this stripper column
we will be getting 30% HCl with less than 0.1% SO2 content.
• The gas stream after passing through the first set of absorption column will be passes through a second set
of absorption column where the gases will be scrubbed with Caustic solution
• There will be total two packed columns for SO2 system.
• SO2 reacts with sodium hydroxide to form sodium sulfite
𝑆𝑂2 + 2 𝑁𝑎𝑂𝐻 → 𝑁𝑎2 𝑆𝑂3 + 𝐻2 𝑂
• Sodium sulfite reacts with SO2 and water to form sodium bisulfite
𝑁𝑎2 𝑆𝑂3 + 𝑆𝑂2 + 𝐻2 𝑂 → 2 𝑁𝑎𝐻𝑆𝑂3

• The system will be designed to make 30% aqueous solution of sodium bisulfite which will be having NaCl
concentration of less than 50 PPM
• This SBS solution will be used either in SIT or sold in market.
• The vent from the scrubber system will have SO2 concentration of less than 5 mg/Nm3 and HCl concentration
of less than 5 mg/Nm3

Equipment List and Sizing:

Equipment Tag No. Location Diameter(mm Capacity MOC

)
HCl Scrubber 1 95C1.G Ground floor 400 PPFRP
HCl Holding Tank 1 95V1.G Ground floor 1200 2 kl PPFRP
HCl Pump 1 95P1.G Ground floor - 3 m3/hr PFA
Heat Exchanger for 95C1.G 95E1.G Ground floor - Graphite

HCl Scrubber 2 95C2.G Ground floor 400 PPFRP

HCl Holding tank 2 95V2.G Ground floor 1200 2 kl PPFRP
HCl Pump 2 95P2.G Ground floor - 3 m3/hr
Heat Exchanger for 95C2.G 95E2.G Ground floor - Graphite

HCl Scrubber 3 95C3.G Ground floor 400 PPFRP

HCl Holding tank 3 95V3.G Ground floor 1200 2 kl PPFRP
HCl Pump 3 95P3.G Ground floor - 3 m3/hr
Heat Exchanger for 95C3.G 95E3.G Ground floor - Graphite

HCl Scrubber 4 95C4.G Ground floor 400 PPFRP

HCl Holding tank 4 95V4.G Ground floor 1200 2 kl PPFRP
HCl Pump 4 95P4.G Ground floor - 3 m3/hr

SO2 Stripper 95C7.G Ground floor 250 PPHFRP

Stripper Holding tank 95V7.G Ground floor 1200 2 kl PPHFRP
Stripper Circulation Pump 95P7.G Ground floor - 2 m3/hr
Heat Exchanger for 95C7.G 95E7.G Ground floor - Graphite

SO2 Scrubber 1 95C5.G Ground floor 500 PPFRP

F/NPT/CCP/WI-025 Rev No. 00 Effective date: 01/04/2014 Page 3 of 6

 Project Nebula
SBS Holding tank 1 95V5.G Ground floor 1200 2 Kl PPFRP
SBS Pump 1 95P5.J Ground floor - 3 m3/hr
Heat Exchanger for 96C5.G 95E5.G Ground floor - Titanium

SO2 Scrubber 2 95C6.G Ground floor 500 PPFRP

SBS Holding tank 2 95V6.G Ground floor 1200 2 kl PPFRP
SBS Pump 2 95P6.G Ground floor - 3 m3/hr FEP Lined
Heat Exchanger for 95C6.G 95E6.G Ground floor - -

SBS storage Tank Ground floor 1800 11.54 kl PPFRP

HCl storage Tank Ground floor 1800 11.54 kl PPFRP

HCl and SBS Production (in kgs):

Generation/batch(30%) Monthly Production Annual Production

HCl SBS Batches/month HCl SBS HCl SBS
Sun beat 306.72 873.94 4 1226.88 3492 14722.56 41904
EHT 216 19 4104 49248
Total Annual Production 63970 41904

Civil requirement:

• HCl and SBS storage tanks are in scrubber area only but will be separated by a brick wall coated with epoxy or
acid tiling, high enough to hold the 110% capacity of tank volume.
• Scrubber systems will be fully enclosed by a dike wall.
• There will be operation or maintenance platform provided in scrubber area.
• Complete structure will MS coated with FRP.
• Caustic will be handled in drums

Piping:

• For HCl+SO2 gases and HCl & SBS solution PPH-FRP/PPRC/MSTL or equivalent pipes and fittings will be used.
High temperature line will be provided of MSTL MOC.
• Piping network in between scrubbers will be kept as simple as possible.
• All chilled water consumption points will have Y strainer at inlet.
• All pump suction will be provided with Y strainer.
• Both Cooling water and chiller water lines are provided to some heat exchangers. First temperature will be brought
down by cooling water then by chilled water in series.

Instrumentation:

• Transfer of HCl/SBS solution from one column to another and to storage tank will be kept manual.
• Mass flow meter will be provided for soft water.
• level indicator will be given to each column and tank for safety point of view.
• Pressure indicator will be provided to gaseous feed and stripper gas outlet to monitor vacuum required on suction
side of ejector.
• Manual valves will be used until unless control is really necessary.
• All pump discharge will have pressure gauge and NRV.
• pH transmitters will be installed in SO2 scrubbers to maintain a pH of 4-5 in SBS column and above 9 in caustic
scrubber column.
• temperature sensor will be considering.
• DCS feed back will be provided for the following:
o Run/Trip, Start/Stop feedback of all pumps to be evaluated.
o SBS and caustic column pH indicator

F/NPT/CCP/WI-025 Rev No. 00 Effective date: 01/04/2014 Page 4 of 6

 Project Nebula
o Mass flow meter

Safety:

• The HCl, SO2, SBS solution and HCl solution will be handled in the closed loop which will avoid the direct
contact of these material with human
• Gas detection instruments for the detection of leaks of HCl and SO2 will be installed at the required places.
• Body and Eye washer will be provided in scrubber area.

3.0 Layout (Approx.)

F/NPT/CCP/WI-025 Rev No. 00 Effective date: 01/04/2014 Page 5 of 6
 Project Nebula

F/NPT/CCP/WI-025 Rev No. 00 Effective date: 01/04/2014 Page 6 of 6