HAZOP Report for

200 TPD CAUSTIC SODA PLANT EXPANDABLE TO 250 TPD 250 MTPD EVAPORATION PLANT

340 TPD NaOH CONCENTRATION/PRILLING PLANT 170 MTPD CHLORINATED PARAFFIN WAX PLANT

CAUSTIC SODA PLANT- UTILITY

Prepared For:

KLJ Organic-Qatar, WLL

Project Location:

Mesaieed Industrial City

Prepared By:

Velosi Certification LLC

23 June 2014

2

DOCUMENT HISTORY

S. No. Document

Identification

Revision Comments / Nature of Changes

No Date

2 HAZOP/KLJQ/13-14/01 01 23 June

2014

Incorporation of re-HAZOP of the Chlorine

System and the HCl and Caustic Storage

Nodes

1 HAZOP/KLJQ/13-14/01 00 18 March,

2014

Preparation of Original Document based

on HAZOP Sittings from 17th February to

6th March 2014

Revision Prepared By Reviewed By Approved By

00 Shanmuga Prasad. K

Technical Scribe H L Patel

HAZOP Chairman,

01 Michael Snakard

Re-HAZOP Chairman Michael Snakard

Re-HAZOP Chairman

3

LIMITATIONS

VELOSI Certification LLC (Applus VELOSI) has prepared this report for the sole use of KLJ Organics Qatar in accordance with the agreement under which our services were performed. No other warranty, expressed or implied, is made as to the professional advice included in this report or any other services provided by us. This report may not be relied upon by any other party without the prior and express written agreement of Applus VELOSI.

Unless otherwise stated in this report, the assessments made assume that the sites and facilities will be used for their current intended purpose without significant change. The conclusions and recommendations contained in this report are based upon information provided by others and upon the assumption that all relevant information has been provided by those parties from whom it has been requested. Information obtained from third parties has not been independently verified by Applus VELOSI, unless otherwise stated in the report.

Where inspections have been carried out, these have been restricted to a level of detail required to achieve the stated objectives of the services. The results of any measurements taken may vary spatially or with time.

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LIST OF ABBREVIATIONS

AKCC : Asahi Kasei Chemicals Corporation

API : American Petroleum Institute

BCPL : Bertrams Chemical Plant Limited

CPW : Chlorinated Paraffin Wax

DAH : Density Alarm High

DAL : Density Alarm Low

DIT : Density Transmitter

DCS : Distributed Control System

DP : Design Pressure

FI : Flow Indicator

FAL : Flow Alarm Low

FALL : Flow Alarm Low Low

FAH : Flow Alarm High

FAHH : Flow Alarm High High

FCV : Flow Control Valve

gpl : Grams per liter

HAZOP : Hazard & Operability Study

HSE : Health Safety & Environment

KLJQ : KLJ Organic- Qatar W.L.L

LAH : Level Alarm High

LAHH : Level Alarm High High

LAL : Level Alarm Low

LALL : Level Alarm Low Low

LCV : Level Control Valve

5

LG : Level Gauge

LI : Level indicator

LT : Level Transmitter

NRV : Non Return Valve

PAH : Pressure Alarm High

PAHH : Pressure Alarm High High

PAL : Pressure Alarm Low

PALL : Pressure Alarm Low Low

PCV : Pressure Control Valve

PDI : Pressure Differential Indicator

PDAH : Pressure Differential Alarm High

PI : Pressure indicator

PG : Pressure Gauge

PSV : Pressure Safety Valve

PT : Pressure Transmitter

SIL : Simon India Limited

SOP : Standard Operating Procedures

TAH : Temperature Alarm High

TAHH : Temperature Alarm High High

TAL : Temperature Alarm Low

TALL : Temperature Alarm Low Low

TCV : Temperature Control Valve

TI : Temperature indicator

6

CONTENTS

EXECUTIVE SUMMARY ........................................................................................................................... 8

CHAPTER 1 ............................................................................................................................................... 13

1.0 PREFACE ............................................................................................................................................ 14

1.1 INTRODUCTION ...................................................................................................................................... 14

1.2 DESCRIPTION OF THE FACILITY ..................................................................................................... 15

1.3 OBJECTIVE OF THE STUDY ................................................................................................................ 42

1.4 SCOPE OF THE STUDY .......................................................................................................................... 42

1.5 ACKNOWLEDGEMENTS ....................................................................................................................... 43

1.6 DISCLAIMER ............................................................................................................................................. 43

CHAPTER 2 ............................................................................................................................................... 44

2.0 METHODOLOGY ............................................................................................................................... 45

CHAPTER 3 ............................................................................................................................................... 48

3.0 ELEMENTS OF THE STUDY ........................................................................................................... 49

3.1 TYPICAL NODES OF THE STUDY ..................................................................................................... 49

3.2 HAZOP WORKSHEETS ...................................................................................... 53

CHAPTER 4 ............................................................................................................................................... 54

4. LIST OF RECOMMENDATIONS .................................................................................................... 55

CHAPTER 5 ............................................................................................................................................... 60

5. SUMMARY OF THE STUDY ........................................................................................................... 61

Appendix 1 HAZOP WORKSHEETS ............................................................................................ 68

Appendix 2 - LIST OF DRAWINGS WITH NODE MARKINGS ............................................... 200

Appendix 3 - LIST OF ATTENDEES ............................................................................................. 207

7

LIST OF FIGURES

Figure 1: Outline of Primary Brine Purification Section .............................................................................. 16

Figure 2: Outline of Secondary Brine Purification Section .......................................................................... 18

Figure 3: Outline of Brine Filter ................................................................................................................... 19

Figure 4: Outline of Merry-Go-Round system ............................................................................................ 20

Figure 5: Reaction of the Electrolyzer cell .................................................................................................. 22

Figure 6: Process flow around the Electrolyzer .......................................................................................... 22

Figure 7: Structure of the Electrolyzer ........................................................................................................ 25

Figure 8: Structure of the cell ..................................................................................................................... 26

Figure 9: Outline of the De-chlorination section ........................................................................................ 28

Figure 10: Over View of the Cl2 gas washing and drying section ................................................................ 29

Figure 11: Over view of the Cl2 gas compression and liquefaction section ................................................ 31

Figure 12:Over view of the H2 gas washing section ................................................................................... 32

Figure 13:Over view of Chlorine gas absorption section ............................................................................ 33

8

EXECUTIVE SUMMARY

This report presents the results of the initial Hazard and Operability (HAZOP) study carried out by Applus VELOSIs subcontractor CGC Converse Technologies for KLJ Organic- Qatar W.L.Ls greenfield plant in Mesaieed Industrial City, Doha, Qatar and the subsequent re-HAZOP of key nodes completed in May 2014 in the KLJ Offices in Doha, Qatar.

The initial HAZOP study session was started from 17th February 2014 and was completed by 6th March 2014.The venues for the sittings were at KLJ House, New Delhi and Simon India Limited, New Delhi.

The study was done for the following facilities within the KLJ Organic Qatar the plant.

A. 200 TPD CAUSTIC SODA PLANT EXPANDABLE TO 250 TPD. B. 250 MTPD EVAPORATION PLANT. C. 340 TPD NaOH CONCENTRATION/PRILLING PLANT. D. 170 MTPD CHLORINATED PARAFFIN WAX. E. CAUSTIC PLANT UTILITY.

During the week of May 18th, Mr. Mike Snakard lead a subsequent re-HAZOP of the chlorine, HCl storage and the Caustic storage Nodes with KLJ project and engineering team members in order to study these high risk nodes in more detail. Specifically, nodes reHAZOPed included the following:

A. 200 TPD CAUSTIC SODA PLANT EXPANDABLE TO 250 TPD: o Node 15: Chlorine Gas cooling and Drying System o Node 16: Spent Sulphuric Acid Dechlorination System o Node 17: Chlorine Compression and Liquefication o Node 18: Liquid Chlorine Process Tanks and Vapourisation o Node 19: Liquid Chlorine Vapourisation o Node 22: HCl Storage and Distribution

B. 250 MTPD EVAPORATION PLANT: o Node 6: Caustic Storage & Distribution

Each of the areas listed above were studied in the HAZOP reviews and the proposed

recommendations within each area are given below:

A. 200 TPD CAUSTIC SODA PLANT EXPANDABLE TO 250 TPD

1. Operating procedures to be updated to state that brine should not be fed to electrolyzers unless optimum temperature and the ion exchange efficiency are achieved. Procedures to reference the Temperature Indicator to be used to confirm the optimum temperature and operating procedures to state what the optimum temperature range is, as per the SOP given by the Basic Licensor.

2. Update the cause & Effect diagrams such that Steam valve TV-286 is closed on actuation of interlock I-285A.

3. LIZAL-550A/B tag number to be shown in the P&ID.

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4. Install manual isolation valves upstream and downstream of ZV-550 A/B and evaluate whether or not a bypass valve is also warranted.

5. Provide Nitrogen purging line between ZV-550 A/B and upstream isolation valve. 6. NRV to be provided in the nitrogen purging line to chlorine vaporizer, downstream of

isolation valve. 7. Both vaporizer outlet lines to be connected, with isolation valves, to the hypo header

upstream of the header isolation valves. 8. Add LALL-750 A/B to the existing level control loop on the Hypo Storage Tanks. On Low Low

Alarm, LALL-750 A/B to shut off Hypo Storage Tank pumps. 9. Remove Low Low alarm (LALL) on the Hypo Storage Tank Level switch such that LAL-750 is

the only Low Level Alarm shown. 10. Neutralizer pit High and Low pH alarms to be shown in the P&ID. 11. Show high and high high level alarms (LAH/HH-1053) on LGO tanks. LAHH-1053 to trip the

tanker unloading pump on activation. 12. Install Low-Low H2 / Cl2 differential pressure ESD on the Electrolyzer outlet and High-High Cl2

pressure ESD on the Electrolyzer Cl2 outlet piping. ESD to shut power to the rectifier to stop Chlorine production.

13. Install Low-Low pressure ESD on the Chlorine Compressor discharge line. ESD to shutdown rectifier to stop Chlorine production and close ESDVs.

14. Install High-High Cl2 pressure and Low-Low Pressure ESD on the Liquefier sniff line. ESD to shut power to the rectifier to stop Chlorine production and close ESDVs.

15. Install High-High pressure ESD on the Chlorine Compressor discharge line. ESD to shutdown rectifier to stop Chlorine production and close ESDVs.

16. Install High-High pressure ESD on the Chlorine Compressor suction line to prevent back flow of Chlorine from compressor discharge to compressor suction. ESD to shutdown rectifier to stop Chlorine production and close ESDVs.

17. Personnel training to include training on the plant PTW system and on the hazards of the process, including hazards associated with: HCl, Cl2, H2, and H2SO4.

18. Install ESD isolation block valves on the inlet and outlet of the Liquid Chlorine tanks such that activation of the chlorine gas detectors, ESDVs on the tank inlet and out let are closed.

19. Consider increasing the number of chlorine gas detectors in the chlorine storage area and interlock detectors such that on activation detectors shutdown the plant.

20. Install ESD isolation block valves on the inlet and outlet of the Liquid Chlorine tanks such that activation of the chlorine gas detectors, ESDVs on the tank inlet and outlet are closed. These ESDVs to act as liquid chlorine isolation in the event of an emergency plant shutdown.

21. Install ESD isolation block valves on the inlet of the Liquid Chlorine tanks such that on High-High level in the tank ESDVs on the tank inlet are closed.

22. RD-550A/B and PSV-550 A/B to be sized for the maximum chlorine vaporization rate due to steam valve (LV-551 A/B) wide open (maximum CV of the steam valve to be considered).

23. Install double block and bleed on the inlet and outlet of the vaporizers such that positive isolation can be achieved when taking one vaporizer out of service while the other vaporizer is in service.

24. Install ESD isolation block valve on the outlet of the Chlorine Vaporizer such that on Low-Low downstream pressure the ESDV is closed. ESDV to be located as far downstream from the vaporizer as possible but still inside the building.

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25. KLJ to develop safe handling and storage procedures for the handling and storage of HCl. Procedures to address valve line up, PPE requirements and identify the potential hazards of the process.

B. 250 MTPD EVAPORATION PLANT

1. In the P&ID 82113-02-130-A1-3A title should be renamed as "2nd Stage Evaporation". 2. Licensor to consider moving TIC-7105 from the cooling water line to the Condensate line so

that the temperature control loop directly controls condensate temperature by sensing condensate temperature and modulating cooling water temperature.

3. Update P&ID to show correct exchanger representation and the number of passes for C-7101.

4. Add an NRV on the discharge of pumps (P-7101 A/B and P-7103 A/B). (4 NRVs, in total) 5. KLJ to develop safe handling and storage procedures for the handling and storage of CS-50

and CS-32. Procedures to address valve line up, PPE requirements, maintenance, tanker offloading and shall identify the potential hazards of the process.

6. Confirm tank vents for D-330 A/B and D-380 are sized for maximum pump out rate of the CS-50 & CS-32 storage tanks (assuming two pumps running).

C. 340 TPD NaOH CONCENTRATION/PRILLING PLANT

1. P&IDs to be updated to show the number of passes and partition for cooler E-401. 2. Interlock to be provided to stop M-301 conveyor. 3. Tag number for Z-311 outlet diverter gate XV-441 3 to be changed HV-4413 4. SOP to be developed for the safe isolation of steam valves around D-201 during normal

operation. 5. Consider changing automatic fill control LCV-8601 to manual control. If operation is changed

to a manual fill, level alarms are still required as shown. 6. OEM to confirm start up Interlock function that requires Pressure Alarm Low (PAL-8507) be

cleared prior to proceeding to the next step during start up. 7. Tags F-824A/B indication of blowers should be provided in the P&ID. 8. LAH-8201 not required, consider deleting alarm 9. TCV-8201 to be shown on motor of the damper (MP-302) in the P&ID. 10. Add an NRV on the discharge of pumps (P-302A/B) (2 NRVs. In total)

D. 170 MTPD CHLORINATED PARAFFIN WAX

1. Downstream isolation valves to be provided for HCl Absorber outlet flow rotameters (SG-413A-F).

2. Downstream isolation valves to be provided for HCl Absorber outlet flow rotameters (SG-414A-E).

3. Downstream isolation valves to be provided for HCl Absorber outlet flow rotameters (SG-415A/B).

4. Add process water makeup line to D-530. Evaluate whether make up flow to D-530 is to be manual or automatic.

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5. Add upstream and downstream isolation valves on Packed Tower Rotameters (FI-530D and FI-531).

6. Add High High alarm to LIA-535 B on D-535B. 7. PSV-501C set pressure to be shown in the P&ID. 8. Water seal to be provided to avoid excess pressurization in the tank D-535 A,B. 9. SOP to require the presence of an operator during CPW transfer operations. 10. CP Storage Tanks inlet line from IFT's pumps P-602/603 AB also to be shown in P&ID. 11. Instead of MS+Epoxy painted, CP Storage Tank information to read: MS+FRP coated. 12. CP Storage Tanks to be provided with alarm for fixed quantity filling from FIQ. 13. PumpP-901 A/B/C to be provided with a pump tripped alarm. 14. pH analyzer to be provided in the cooling water return header. 15. Cooling tower chemical dosing to be shown on P&IDs. 16. Pump discharge pressure transmitter to be provided on P-902 A/B/C. 17. Cooling tower fan trip alarm to be provided. 18. PSV-920 set pressure to be shown in the P&ID. 19. PSV-920 upstream isolation valve should be provided. 20. PSV-930 upstream isolation valve should be provided. 21. PSV-930 set pressure to be shown in the P&ID.

E. CAUSTIC PLANT UTILITY.

1. Add Low Low alarm (LALL) to LT-2000 on Chilled Water Tank (D-1020). 2. Add Low Flow Alarm (FAL) to FI-2000 in chilled water common discharge line of P-1020

A/B/C. 3. Add Low Low alarm (LALL) to LT-3000 on De-mineralized (DM) Water Tank (D-1031). 4. Add Low Flow Alarm (FAL) to FI-3000 in common discharge line of P-1030 A/B. 5. Add Low Low alarm (LALL) to LT-9000 on Drinking Water Tank (D-1090). 6. Change local pressure gauges (PI-9000A/B) in the discharge lines of P-1090A/B to Pressure

Transmitters with indication in the DCS or add a pressure transmitter (with indication in the DCS) in the common chiller water header.

7. PAH to be provided on the instrument air discharge line of PRV-7000 8. Low Pressure Alarm (PAL) to PT -1000 to be provided on the Cooling Water Supply Header. 9. Low Flow Alarm (FAL) to be provided on the Cooling Water Supply Header. 10. Add High Temperature alarm (TAH) to TI in Cooling Water return header. 11. PAH to be provided on the nitrogen discharge line of PRV-6001 12. PAH to be provided on the padding air discharge line of PRV-2100 13. PAH to be provided on the plant air discharge line of PRV-8000 14. Add Low Low alarm (LALL) to LT-4001 on Process Water Tank for pump seal (D-1041). 15. Add Low Pressure Alarm to pressure transmitter on seal water pump discharge header with

PAL to facilitate auto start of the standby pump. 16. Conventional de-super heater for water mixing in the steam header to produce LP Steam to

be shown in the P&ID. 17. NRV to be installed in both of the MP Steam supply headers (to be checked during package

discussion) 18. LALL to be provided to trip the Cooling Water Supply pumps for the Rectiformer.

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Please refer the worksheets for the node wise recommendations. (Click this link for the worksheets)

The summary of the HAZOP study done is as shown in the following table

NODE DEVIATION CAUSES CONSEQUENCES

SAFE GUARDS

RECOMMANDATIONS

CAUSTIC PROCESS

29 172 267 293 386 25

EVAPORATION 7 33 78 125 143 6

PRILLING 17 57 97 146 177 10

CPW 20 78 132 144 189 21

CAUSTIC UTILITIES

13 40 75 84 104 18

TOTAL 86 380 649 792 999 80

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CHAPTER 1 INTRODUCTION

14

1.0 PREFACE

1.1 INTRODUCTION

M/s. KLJ Organic Qatar W.L.L requires the services of Applus VELOSI to carry out the HAZOP Study

for their following facilities in the plant,

A. 200 TPD CAUSTIC SODA PLANT EXPANDABLE TO 250 TPD. B. 250 MTPD EVAPORATION PLANT. C. 340 TPD NaOH CONCENTRATION/PRILLING PLANT. D. 170 MTPD CHLORINATED PARAFFIN WAX. E. CAUSTIC PLANT- UTILITY.

Accordingly HAZOP sittings were done at two venues, KLJ House, New Delhi and Simon India Limited, New Delhi. The study was held from 17th February 2014 to 6th March 2014. Prilling & Evaporation plant design representative from Bertrams chemical plants Ltd and Kilburn Engineering Ltd, Caustic process expert from AKCC, Japan, Caustic process and utilities detailed engineering representatives from SIMON India limited, CPW plant design representatives from KSJ Techno services Pvt. Ltd, CPW process expert form KLJ Organic and the client KLJQ representatives took part in the respective study sessions. A re-HAZOP of the chlorine system, HCl storage and the Caustic storage nodes was done during the week of 18th May 2014 with KLJ project and engineering team members in order to study these high risk nodes in more detail. Specifically, nodes reHAZOPed included the following:

A. 200 TPD CAUSTIC SODA PLANT EXPANDABLE TO 250 TPD:

Node 15: Chlorine Gas cooling and Drying System

Node 16: Spent Sulphuric Acid Dechlorination System

Node 17: Chlorine Compression and Liquefication

Node 18: Liquid Chlorine Process Tanks and Vapourisation

Node 19: Liquid Chlorine Vapourisation

Node 22: HCl Storage and Distribution B. 250 MTPD EVAPORATION PLANT:

Node 6: Caustic Storage & Distribution

Several utilities packages drawing were not available from vendors; hence the available controls for the different packages were checked for the HAZOP. For the liquid chlorine handling during emergencies, two tonner posts are provided for draining of liquid chlorine from the system. (Extra tonners are also kept to replace filled tonners if required).Three surge tanks are also provided for surge purpose to handle liquid chlorine. One will be inline; one is standby and the other one for emergency situations.

Also to avoid any chlorine gas spillage in the environment, chlorine absorption system is provided. A duct is also installed to avoid chlorine gas to atmosphere from the plant with flexible hoses during maintenance. The report is based on the discussions held during HAZOP Sitting.

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1.2 DESCRIPTION OF THE FACILITY

CAUSTIC PROCESS

The ion exchange membrane chlor-alkali process consists of following section;

A. Primary brine purification section B. Secondary brine purification section C. Electrolysis section D. De-chlorination section E. Cl2 gas washing and drying section F. Cl2 gas compression and liquefaction section G. H2 gas washing section H. Cl2absorptionsection I. Caustic soda section J. Hydrochloric acid synthesis section K. Operation of the CA Plant

Production rate of this plant is NaOH 200 ton/day as 100%.

In the future, Production rate of this plant will be NaOH 250 ton/day as 100%.

A. Primary Brine Purification Section

1. Over View

Brine of 305 g/l concentration is prepared with dissolving raw salt into the return brine (depleted brine) from Electrolyzer. The brine is required to meet the restrictive specification. This specification is achieved by Primary Brine Purification section and Secondary Brine Purification section. In Primary Brine Purification section, Brine is purified with chemicals in order to precipitate the impurities of raw salt, especially Ca2+ and Mg2+ as S.S. This section consists of a Reactor, a Retention Tank and Clarifier as shown fig.1.

16

Figure 1: Outline of Primary Brine Purification Section

2. Process Flow

In Salt Saturator, the saturated brine is adjusted by raw salt and return brine from Return brine tank. After the Salt Saturator, a part of the return brine is fed to adopt 305g/l concentration. If concentration is over 305 g/l, the salt can be crystallized in the line. That will be occurred the close of the line. Saturated Brine from Salt Saturator is fed to a Reactor, and then a Retention Tank to make suspended solid from the impurities, i.e. Ca2+ and Mg2+, by chemical dosing. After the retention tank, the brine is fed to the Clarifier to precipitate the S.S. 3. Description of the Equipment

Salt Handling

Raw salt is transported to storage area by salt conveyor. Raw salt is put into Salt hopper and sent to Salt saturator (D-010A/B) by Salt Conveyor. Salt Saturator

Two Salt Saturators (D-010A/B) are installed. One is online and the other is standby or maintenance. Raw salt is fed to the Salt Saturators by Salt Conveyer. The return brine from De-chlorination section is fed from bottom of salt saturator and is saturated through the salt bed. The saturated raw brine overflows into Reactor(R-020) by gravity flow. Insoluble of raw brine is accumulating at the bottom of the Salt Saturator, and then, insoluble is discharged periodically after changing to standby one. 4. Reactor and Retention Tank

In the Brine Precipitation, chemical dosage, reaction and sedimentation is proceeded in order to remove impurities from the saturated raw brine. Chemicals, such as sodium carbonate and caustic

Clarified Brine TankClarifierRetentiontank

SlurryNa2CO3

Reactor

NaOHTo mud filter

Salt Saturator

Salt

Return Brine

Clarified Brine TankClarifierRetentiontank

SlurryNa2CO3

Reactor

NaOHTo mud filter

Salt Saturator

Salt

Return Brine

17

soda, along with re-circulated suspended solid from Brine Clarifier are mixed with the saturated brine and are fed to Reactor(R-020).In the Reactor, Brine PH is adopted around pH=ten (10) which is appropriate condition to precipitate the Magnesium and Calcium. Magnesium, Calcium and other multivalent cations in the raw brine react with those chemicals and are changed into suspended solids as following reaction. Concentration can be achieved; Magnesium is under 1 mg/l. and Calcium is under 10mg/l.

-Sodium Carbonate reacts with Calcium ion (Ca2+).

Ca2+ + Na2CO3 CaCO3 + 2Na+

-Caustic soda reacts with Magnesium ion (Mg2+).

Mg2+ + 2NaOH Mg (OH)2 +2Na+

After the Reactor, the raw brine flows into the Retention tank(R-020) to finish above reactions. Before the raw brine flows into clarifier, the flocculant will be fed into the raw brine to make large particle for the precipitation.

5. Brine Clarifier

In the Brine Clarifier (T-030), the suspended solids are removed by precipitation less than 10ppm. From Clarifier, the brine overflows to Clarified Brine Tank (D-040) and stored. Some part of sludge from bottom of the Clarifier is fed in front of the Reactor and the remaining is fed to Mud filter Unit (U-092). In the Mud filter, the sludge is filtrated into solid and liquid, and liquid is recovered to brine circuit. B. Secondary Brine Purification Section 1. Over View

Secondary Brine Purification Section for further purification by removal of S.S, Ca2+ and Mg2+.

Secondary Brine must meet the following specifications.

NaCl : 305 5 g/l Temp. : 60 C pH : 10.0- 11.0 Ca2+& Mg2+ : Max. 0.02ppm I : Max. 0.2 ppm SO42- : Max. 5 g/l SiO2 : max. 5 ppm

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Ba : Max.0.1ppm Al : Max. 0.1 ppm Fe : Max. 0.05ppm Hg : Max. 0.1 ppm S.S. : Max. 0.5 mg/l Ni : Max. 0.01ppm Br : Max. 30ppm NaClO3 : Max. 10 g/1 TOC : Max. 10ppm Free C12 : none

The Secondary Purification section consists of Brine Filters and Ion Exchange Resin Columns as shown fig.2.

Figure 2: Outline of Secondary Brine Purification Section

2. Process Flow

The saturated brine stored in the Clarified Brine Tank is sent to the Brine filter to remove the S.S. The filtrated brine after Brine filter is fed to a Filtrated Brine tank. The brine from the filtrated tank is sent to ion exchange column to remove the Ca2+ and Mg2+. This purified brine is stored in a Purified Brine Tank.

3. Description of the Equipment

a. Brine Filtration

Three Brine Filters (F-140A/B) are installed. One Brine Filters are operated in parallel as shown Fig.3. The other brine filter is washed and Pre-coating. And then that is on standby condition.

Ion exchange columnBrine filter

Clarifier

Ion exchange columnBrine filter

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Figure 3: Outline of Brine Filter

The Brine Filters (F-140A/B) are pre-coat type ceramic filters. Alpha-cellulose is used as filter aids and filter elements are pre-coated by prior to the filtration. A concentration of the alpha-cellulose is 0.5 wt%. The alpha-cellulose is also used as the filter aids for the "body feed" method to reduce the consumption of the filter aids. The alpha-cellulose mixed with brine in the body feed tank is continuously supplied to the brine line. The concentration of the alpha-cellulose in body tank is 0.5 wt%.

Suspended solid (S.S.) in the filtered brine shall be reduced less than 1 mg/liter by this filtration. The brine through the Brine Filter is stored in the Filtrated Brine Tank (D-150) as filtrated brine.

Pre-coating of Standby Brine Filter

The flow rate of the brine to the Brine Filters (F-140A/B)are controlled by flow controller, and operations of the unit such as switching procedure, backwashing procedure and pre-coating procedure are carried out automatically by PLC or DCS.

The brine filter switches over at any case of the following:

1. Operation time reaches a set value. The normal operation time is 48 hours. This switching is normal.

2. The pressure drop through filter elements reaches a higher set level. The set value is 2.0 kg/cm2.

3. Switching button is pushed.

The brine filter cut off is back washed with compressed air and filtered brine. Trapped suspended solids are discharged with alpha-celluloses to the Filter Slurry Pit (PT-145). The slurry in the Filter Slurry Pit is sent to the Brine Mud Filter (U-092) in the Primary Brine Treatment and most of the brine in the slurry is recovered and fed back to the return brine tank. The cake made in the mud filter is handled as industrial waste products. b. Ion Exchange Column

Brine filter Filtrated Brine TankPre-coat Tank Body Feed Tank

ClarifiedBrine

20

The filtrated brine stored in filtrated brine tank is sent to the Ion Exchange Resin Column (T-160A/B/C), where multivalent cations, especially Ca2+ and Mg2+, harmful to the ion exchange membranes are removed to a certain extent that cannot be achieved by conventional chemical treatment. Three Ion Exchange Resin Columns are installed and are used one after another. Two columns are on-line in series, and the other column is off-line for resin regeneration. The regeneration cycle is every 24 hours for this 3 (2+1) columns system as shown fig.4. The system is called a merry-go-round system shown as in the below figure. Regeneration Process of the Resin

The Ion Exchange Column unit operation and the regeneration process are carried out by a sequencer on PLC or DCS.

Figure 4: Outline of Merry-Go-Round system

The regeneration operation with hydrochloric acid and caustic soda as summarized below:

Step-1: Washing with de-mineralized water

Step-2: Back washing with de-mineralized water

Step-3: HCl regeneration

Step-4: Washing with de-mineralized water

Step-5: Caustic Soda regeneration

Step-6: Washing with de-mineralized water

Step-7: Replacement of water with the brine

Small parts of the ion exchange resin are broken during operation and regeneration.

As these broken resin particles cause increasing pressure drop of Ion Exchange Resin Column, so the resin bed is periodically backwashed with de-mineralized water in order to remove these broken resin particles from the column.

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This backwashing is automatically conducted with water as a step in the regeneration procedure.

At backwashing (Step2), the brine running out from the top of the column is introduced to Resin Catcher.

Regarding the effluent at regeneration of ion exchange resin, the acid effluent (at step3 and 4) and the alkaline effluent (at step 5 and 6) are discharged as waste. This effluent of the acid effluent (at step3 and 4) is sent to after treatment section: outside B/L. the alkaline effluent (at step 5 and 6) is corrected to Ion Exchange Waste Water Tank (D-162) once, and then, sent to D-080. At that time PH in D-080 should be cared. The other effluent (at step 1, 2 and 7) is sent to PT-145 after that is sent to Mud filter (F-090) and then is recovered into Return Brine Tank (D-080).

The brine thus obtained ensures the stable operation of the ion exchange membrane cell. The brine is stored in the purified Brine Tank (D-170) as pure brine.D-170 has capacity for preceding the stop procedure even if Ion Exchange Resin Column (T-160A/B/C) stops by any reason.

C. Electrolysis Section 1. Over View

The electrolysis section is the heart of chlor-alkali plant. Electrolysis Unit is composed of Electrolyzer section, Anolyte and Catholyte Circulation Facilities. In future, Electrolyzers are expanded from two (2) to three (3).

The electrolysis process consists of two (2) Electrolyzes and their associated equipment. One Electrolyzer has 200 cells. Each cell consists of an Anolyte compartment and a Catholyte compartment. The reaction inside the cell is as shown Fig.5.

Cl2is generated in the Anolyte compartment.

2NaCl Cl2+ 2Na+ + 2e-

NaOH and H2are generated in the Catholyte compartment.

2H2O + 2Na+ + 2e- H2 + 2NaOH

22

Figure 5: Reaction of the Electrolyzer cell

2. Process Flow

Figure 6: Process flow around the Electrolyzer

Schematic Flow for anolyte/catholyte circulation is as shown above.

Anolyte Part

The purified brine is supplied to anolyte inlet sub-header of each Electrolyzer from purified brine tank.

(1) NaCl Na+

+Cl-

(2) 2Cl- Cl2 +2e-

(3)2H2O+2e- H2 +2OH

-

(4)Na++2OH- NaOH

NaCl H2O

H2

NaOH

Cl2Anode Cathode

OH-

(1) NaCl Na+

+Cl-

(2) 2Cl- Cl2 +2e-

(3)2H2O+2e- H2 +2OH

-

(4)Na++2OH- NaOH

NaCl H2O

H2

NaOH

Cl2

OH-

Na(1) NaCl Na

++Cl

-

(2) 2Cl- Cl2 +2e-

(3)2H2O+2e- H2 +2OH

-

(4)Na++2OH- NaOH

NaCl H2O

H2

NaOH

Cl2Anode Cathode

OH-

(1) NaCl Na+

+Cl-

(2) 2Cl- Cl2 +2e-

(3)2H2O+2e- H2 +2OH

-

(4)Na++2OH- NaOH

NaCl H2O

H2

NaOH

Cl2

OH-

NaNa

De-chlorination

section

Feed Brine

HCl

Depleted Brine

Tank

Depleted Brine Pump Caustic Soda Pump

Caustic Soda

Tank

Product

NaOH

D.M Water

Cl2 H2

Return Brine

De-chlorination

section

Feed Brine

HCl

Depleted Brine

Tank

Depleted Brine Pump Caustic Soda Pump

Caustic Soda

Tank

Product

NaOH

D.M Water

Cl2 H2

Return Brine

23

The purified brine is then electrolyzed in the anolyte compartments, while chlorine gas is generated and sodium chloride concentration is decreased. Chlorine gas and depleted brine mixture is discharged through flexible hoses into the outlet sub-header, where it is collected. The mixture is then sent to Anolyte Separator, where it is separated into gas and solution.

Chlorine gas separated in each Separator is collected into main chlorine gas pipe and sent to chlorine gas treatment section. Chlorine gas pressure is controlled by a pressure controller installed on the main chlorine gas line. End of the sub-header, Brine PH is measured by PH meter to detect the abnormal situation, i.e. membrane is torn. Outlet brine PH has to be monitored to operate the Electrolyzer safety.

The depleted brine is discharged from the Anolyte Separator and collected into Depleted Brine Tank (D-240). Depleted brine collected in the Depleted Brine Tank is fed to next section by Depleted Brine Pump (P-244A/B) and a part of the depleted brine is returned to the feed purified brine line by a flow controller to prevent the corrosion of Anolyte sub-header. The amount of outgoing depleted brine is controlled by a level controller of the Depleted Brine Tank.

A density meter is also installed in order to measure the concentration of the depleted brine.

Catholyte Circulation Part

Catholyte is fed to the inlet sub-header of the Electrolyzer from caustic soda tank, and then supplied to each catholyte compartment through flexible hose which connects the header with each cell compartment. In order to keep caustic soda concentration of catholyte at the designated value, de-mineralized water is fed to catholyte inlet main header. The flow rate of the de-mineralized water is controlled by a flow controller. This controller is cascade-controlled by DC-electric current.

Catholyte Cooler (E-223) is installed on catholyte feeding line to control catholyte temperature by a temperature controller, by detecting the outlet temperature of the catholyte. The amount of catholyte fed into the Electrolyzer is monitored by a flow meter.

By electrolysis, hydrogen gas and caustic soda are produced in the catholyte compartments. Hydrogen gas and catholyte mixture is discharged from the cells through flexible hoses into the outlet header, where it is collected. The mixture is sent to Catholyte Separator where it is separated into gas and solution.

Hydrogen gas separated in each Catholyte Separator is collected into main hydrogen gas pipe and sent to hydrogen gas treatment section. Hydrogen gas pressure is controlled by a pressure controller equipped on the main hydrogen gas line. This is cascade-controlled by a chlorine gas pressure controller in order to keep the pressure difference between hydrogen and chlorine gas at the designated value. The catholyte is discharged from the Catholyte Separator and collected into the Caustic Soda Tank (D-250) as product.

The amount of product caustic soda sent to the next section by the Caustic Soda Pump (P-254A/B) is controlled by a level controller of the Caustic Soda Tank and measured by flow totalizers.

24

A small amount of catholyte is sent to a density meter by the Caustic Soda Pump in order to measure concentration of return catholyte.

3. Description of the Equipment

Electrolyzer

The electrolysis process consists of eight (2) Electrolyzers and their associated equipment. In the future, three Electrolyzers will run.

Two (2) Electrolyzers accommodates 200 cells and are designed to produce 200 ton/day NaOH (Caustic Soda) as 100 % at the current density of Normal 5.6KA/m2. And the electrolyzers can be operated at maximum 5.3 KA/m2. When electrolyzers are expanded to three electrolyzers, caustic soda is produced 250 ton/day NaOH as 100% in the future.

Specifications of Electrolyzer and Cell are summarized as follows:

Capacity (Caustic Soda) : 200 ton/day Type of Electrolyzer : Bipolar

ACILYZER-ML 32Double Rear Head No. of Electrolyzer : 3 (0ne is for the future) No. of cells per Electrolyzer : 200 Size of each cell : 1.2m x 2.4m Effective Area : 2.7m2

25

One Electrolyzer is composed of the following parts:

198 bipolar cell frames and 4 terminal cell frames with anodes and/or

cathodes

200 ion exchange membranes

A press unit to press mounted cell-units

Inlet sub-headers for feeding anolyte and catholyte

Anolyte and catholyte outlet sub-headers for collecting electrolysis

Products

200 x 2 flexible hoses for connecting cell-units with sub-headers

2 hydraulic manifold blocks which control oil pressure to hydraulic

cylinders each Electrolyzer.

Electrical cables are connected to the terminal cell frames mounted on both ends of the Electrolyzer. Electrolysis current supply is adjusted from the control room.

The anolyte compartment is made of titanium to give resistance against chlorine. The catholyte compartment is made of nickel pan and nickel ribs. Ribs on which the anode and the cathode are welded are fixed on each side of pan by welding. Each compartment has two nozzles for inlet and outlet of electrolyte, and there is the gas and liquid separator at the top of cell.

Structure of cell is shown in the following fig8

Figure 7: Structure of the Electrolyzer

26

Note:

Case of the Electrolyzer Shut down (C-DCDS)

After shut down the Electrolyzer (cutting off electricity), should keep circulation electrolyte and open the C-DCDS as following procedure to protect zero gap cathode.

STEP 1) During 2 minutes after S/D of main rectifier C-DCDS open immediately. Anolyte flow rate: 250 liter/Hr per Cell Catholyte Flow rate: 300 liter/hr per Cell STEP 2) From 2 minutes to 52 minutes after S/D of main rectifier

Step 2 total 50 minutes Anolyte flow rate: 250 liter/hr per Cell Catholyte flow rate: 0 liter/hr per Cell STEP 3) 52 minutes after S/D of main rectifier

(Preparation for next start-up) Anolyte flow rate: 250 56 liter/hr per Cell Catholyte flow rate: 0 300 liter/Hr per Cell

Anolyte and Catholyte circulation shall be kept with the above flow rate (STEP 3) until next start-up. And if S/D time of Electrolyzer will be continued more than 8 hours, the electrolyte of anolyte and catholyte will be drain out from Electrolyzer.

Figure 8: Structure of the cell

27

If S/D will be finished and Electrolyzer will be re-started up within 8 hours, circulation of anolyte and catholyte will be kept. The following equipment should be supplied emergency power to keep electrolyte circulation even if black out is occurred.

C-DCDS and control box should be connected to UPS same as DCS.

Purified Brine Pump (P-174A/B)

Depleted Brine Pump (P-244A/B)

Caustic Soda Pump (P-254A/B)

De-chlorination Pump (P-284A/B)

Instrument Air Compressor

DCS

Chlorine Absorber Circulation Pump and Blower

Hydraulic pump

De-mineralized Water Pump

When the Electrolyzer is disassembled or is shut down, electrolytes, both anolyte and catholyte must be drained from Electrolyzer. Before draining electrolytes, both chlorine and hydrogen gas must be purged from Electrolyzer.

Chlorine gas is purged to a Cl2 gas Absorber by air, and also hydrogen gas is purged to vent stack by N2.

Anolyte and catholyte remaining in the Electrolyzer is blown down to Anolyte Blow down Tank (D-260) and to Catholyte Blow Down Tank (D-270) respectively. After then, the inside of the Electrolyzer must be washed with de-mineralized water.

Recovered anolyte in the Anolyte Blow down Tank is sent out to De-chlorination Tower (T-280) by Anolyte Blow Down Pump (P-264).

Recovered catholyte in the Catholyte Blow Down Tank is sent out by using Catholyte Blow Down Pump (P-274).

When inside of the Electrolyzer is washed, anolyte and catholyte compartments are filled with de-mineralized water. This washed water in anolyte compartment is drained to Anolyte Blow Down tank. This washed water in catholyte compartment is drained to Wash water tank.

After finishing of maintenance work and before start of Electrolyzer, both compartments of the Electrolyzer, inlet and outlet sub-headers must be filled with purified brine and caustic soda, respectively.

28

D. De-chlorination

1. Over View

The depleted brine from the electrolysis section is saturated with chlorine as shown in the equilibrium equation below.

Cl2 + H2O ---- HOCl + H+ +Cl2

HClO ---- H+ + ClO

The dissolved chlorine gas is firstly removed by stripping at proper pH and vacuumed conditions in De-chlorination Tank. This section consists of the de-chlorination tower, de-chlorination tower cooler and vacuum pump as shown fig.9.

Figure 9: Outline of the De-chlorination section

2. Process Flow

The depleted brine is pumped to the De-chlorination Tower (T-280) by Depleted Brine Pump, where the pressure is kept vacuum by vacuum pump. Before the De-chlorination tower, the depleted brine is arranged at PH=1.5 to change the chlorine formation, from HOCl to Cl2. The dissolved chlorine is stripped together with water vapor in the vacuum condition. It is cooled in De-chlorination Tower Cooler (E-281). The water vapor is condensed there and the non-condensed chlorine gas is sucked by the ejector and recovered into the Chlorine Gas Header.

Then there still remains a small amount of free chlorine in brine. Free chlorine cause a damage of the filter elements against the Brine Filters and a deterioration of ion exchange resin. To kill the chlorine, Sodium Sulfite should be added to completely.

Cl2 + 2NaOH ----> NaOCl + NaCl + H2O

Return Brine Tank

Stripped Cl2 gas

De-chlorination tower

HCl

NaOH

Depleted brine

Na2SO3

Chlorine water

Vaccum pump

29

Na2SO3+ NaClO---->Na2SO4+ NaCl

Then, the brine is sent to Primary Brine Purification section via the Return Brine Tank.

E. Cl2Gas Cooling and Drying Section

1. Over View

In this section, the water vapor is removed of the wet-chlorine gas from Electrolyzer to make the dry chlorine gas.

The chlorine treatment section has No.1 Washing tower, No.2 Cl2 gas cooler, a mist separator, and No.1 to 3 Cl2 drying towers as shown fig.10.

Figure 10: Over View of the Cl2 gas washing and drying section

2. Process Flow

Chlorine Gas Cooling

The chlorine gas from Electrolyzers contains the saturated water vapor. So, the wet chlorine gas is cooled through No.1 Cl2 gas washing tower (T-410) and No.2 Cl2 gas cooler (E-420). Cooling water is used for No.1 Cl2 Gas washing tower and chilled water is used for the No.2 Cl2 Gas Cooler. The outlet temperature of No.2 Cl2 Gas Cooler is controlled by chilled water to avoid over-cooled less than 10C. After passing through the No. 1 Mist Separator (F-424) where water mist is separated, the chlorine gas is fed to Chlorine drying tower. The condensed water from Cl2 gas cooling section is sent to the Chlorine Gas Seal Pot (SP-401).

Chlorine Gas Drying

No.1 Cl2Washing

Tower

No.2 Cl2Gas Cooler

No. 1 mist

separator

No.1 Cl2Gas Drying

Tower

Cl2 gas from

electrolyzer

No. 2 Mist

Separator

Cl2 gas

compressor

No.2 Cl2Gas Drying

Tower

No.3 Cl2Gas Drying

Tower

30

The cooled chlorine gas is dried in the three series of Cl2 Gas Drying Towers with the circulating sulfuric acid. Chlorine gas from Electrolyzer is fed to No.1 Cl2 gas drying tower through No.2 tower to No.3 tower.98% sulfuric acid is fed to the No.3 Cl2 Gas Drying Tower (T-450) through a flow controller. Sulfuric acid flow rate to the No.3 Cl2Gas Drying Tower is cascade-controlled by concentration of sulfuric acid discharging from No.1 Cl2 Gas Drying Tower (T-430). The supply of sulfuric acid to No.2 and No.1 Cl2 Gas Drying Tower is conducted by the level control valve from No.3 and No.2 Cl2 Gas Drying Tower respectively. The level of sulfuric acid in the No. 1 Cl2 Gas Drying Tower is controlled by a level controller. And the concentration of sulfuric acid circulating in the No. 1 Cl2 Gas Drying Tower is continuously monitored by a density meter. The target of sulfuric acid concentration in the No. 1 Cl2 Gas Drying Tower is around 70%. Each Cl2 Gas Drying Tower has its own Coolers (E-433, E-443 and E-453) to cool the circulating sulfuric acid with chilled water. And the sulfuric acid is circulated with Tower Pump (P-434A/B, P-444A/B and P-454B/S) respectively. After then, the dried chlorine gas is fed to the Compression section through No.2 Mist Separator (F-464A/B) where sulfuric acid mist is separated. 98% sulfuric acid is stored to 98% Sulfuric Acid Storage Tank (D-470) and feed to No.3 Drying tower by 98% Sulfuric Acid Storage Pump (P-474). Diluted sulfuric acid containing chlorine is sent to H2SO4 Aeration Tower (T-490) to strip dissolved chlorine by air from Aeration Tower Blower (C-491A/B). After that it is sent to 70% Sulfuric Acid Storage Tank by Aeration Tower Pump (P-496A/B). F. Cl2 Gas Compression and Liquefaction Section

1. Over View

In this section, Dry chlorine from the Cl2 Drying tower is compressed and liquefied. This section has a Cl2 compressor, a Cl2liquefactor as shown fig.11.

31

Figure 11: Over view of the Cl2 gas compression and liquefaction section

2. Process Flow

Cl2 Gas Compression

Dried chlorine gas is compressed at (3.5 kg/cm2G) with the chlorine compressor (C-510). The compressed chlorine gas is sent to Liquefaction section.

Liquefaction

Discharged Cl2 Gas from Compression System is sent to Cl2 Gas Liquefaction System for liquefaction. In the liquid chlorine tank, high pressure Cl2 gas is cooled (-10 degree). The Cooling medium use R-230. There are three liquid chlorine Tanks. Normally, two liquid chlorine tanks are used and one tank is stand-by for emergency situation. The gas is from the liquid chlorine tank is condensed in the Cl2 Gas Liquefier (U-520).

G. H2 gas Washing Section

1. Over View

In this section, the wet hydrogen gas from Electrolyzers contains the saturated water vapor and a little amount of caustic soda Hume. So, the wet hydrogen gas is cooled through H2 scrubber as shown fig.12. This section consists of the H2 gas scrubber and Mist separator.

Dry Chlorine gas

Chlorine

compressor

Chlorine

liquefier

Liquid Chlorine

Liquid Chlorine

Tank

Dry Chlorine gas

Chlorine

compressor

Chlorine

liquefier

Liquid Chlorine

Liquid Chlorine

Tank

32

Figure 12:Over view of the H2 gas washing section

Wet hydrogen gas from the Electrolysis contains the saturated water vapor and a small amount of NaOH Hume. So, the wet hydrogen gas is sent to H2 Gas Scrubber (T-610). In the H2 Gas Scrubber, condensed water is circulated as cooling and washing medium with H2 Gas Scrubber pump (P-614A/B). For cooling, the circulated water is cooled with H2 Gas Scrubber Cooler (E-613). The cooled hydrogen gas is sent to the H2 Gas Mist Separator (F-624) to remove mist in the cooled hydrogen gas. After passing through the H2 Gas Mist Separator (F-624) where water mist is separated, the hydrogen gas is sent to next section.

H. Chlorine Absorption Section

1. Over View

The Chlorine gas which is not used for product chlorine gas is sent to a Cl2 gas absorber to absorb the chlorine gas as shown fig.13. Cl2 gas Absorber is very important equipment, so when the Electrolyzer is running, absorber has to work continuously to absorb the leakage of the chlorine gas any time. During normal operation, Cl2 off gas from Electrolysis section, Cl2 drying section and Cl2 liquefaction section is absorbed. During the start-up operation and shut-down operation, Cl2 gas is also purged to Cl2 Gas Absorber. Further, at an emergency stop, Cl2 gas will be absorbed in Cl2 Gas Absorber, too. This section consists of the Cl2 gas absorber, Cl2 gas absorber tank and pump, Cl2 gas absorber blower and NaOH head tank.

H2 gas

H2 gas

scrubber

Mist separator

33

Figure 13:Over view of Chlorine gas absorption section

2. Process flow

In case chlorine gas cannot be sent to main line of chlorine gas, i.e. Plant shut down, chlorine

gas leak from plant, chlorine gas is sent to a Cl2 gas absorber. The Cl2gas absorber is vacuumed by blower.

The Cl2 gas is absorbed in Cl2 Gas Absorber with (18%) caustic soda solution that is diluted with De-mineralized water from the (32%) caustic soda intermediate tank. In the tower, Cl2 will change into Sodium Hypochlorite (NaClO) with Caustic Soda (NaOH) as following reaction.

2NaOH + Cl2 -->NaClO + NaCl + H2O

After Cl2 gas absorber, Caustic soda is sent to Cl2 gas absorber tank. Caustic soda is circulating until concentration of remaining caustic soda is above 3wt%. If caustic soda concentration becomes fewer than 3 wt%, the Cl2 gas absorber tank is switched to other one to continue the caustic soda circulation. Caustic soda which is held in the switched off Cl2 gas absorber tank is sent to the Hypo production section.

NaOH head tank is prepared for blackout.

I. Caustic Soda Section Caustic Soda Evaporation Unit is to produce 50 wt% caustic soda.

Hypo tower

Cl2 gas Absorber

NaOH Head Tank

Cl2 Gas Absorber Tank

34

The 32wt% caustic soda is storage in the caustic soda Tank (D-330). And then caustic soda is sent to Caustic soda Evaporation unit.

J. Hydrochloric acid synthesis

Dry chlorine gas and hydrogen gas is sent to the Hydrochloric Synthesis Main Tower (U-800) to Synthesize HCl. Chlorine gas and hydrogen gas react into hydrochloric acid gas.

The hydrochloric acid gas is absorbed by de-mineralized water.

Cl2 + H2 2HCl

Dry chlorine gas and hydrogen gas are supplied to bottom by controlling the flow rate to react into HCl gas in HCl Synthesis Main Tower(R-810). The HCl gas is absorbed by de-mineralized water. De-mineralized water is sent through the HCL Synthesis Tails Tower to the HCL Synthesis Unit.

HCl (32wt %) is synthesized in the HCl Synthesis Unit and is discharged from bottom of HCl Synthesis Main Tower(R-810) to the HCl Receiver tank (D-810).

K. Operation of the CA Plant

Safety Devices

To ensure the safety of the Plant, electrolysis power for the Electrolyzer is automatically shut down under the following conditions. (Typical conditions)

All Electrolyzer Shut Down

Abnormal differential pressure in Cl2 and H2 Gas Header

Abnormal high level of Depleted Brine Tank or Caustic Soda Tank

Excess pressure of chlorine or hydrogen gases

Emergency stop switch push on

Stoppage of utilities supplies (instrument air pressure, instrument power electricity)

Stoppage of chlorine gas compressor

Each Electrolyzer Shut Down

Abnormal electrolysis voltage distribution in Electrolyzers

DC over current of Electrolyzer

Grounding of Electrolyzer Low flow rate of feed of Anolyte and Catholyte

Abnormal Gas pressure difference at outlet of Each Electrolyzer.

Emergency Power

Emergency power source is connected to the following pumps.

C-DCDS and control box should be connected to UPS same as DCS.

Purified Brine Pump (P-174A/B)

Depleted Brine Pump (P-244A/B)

Caustic Soda Pump (P-254A/B)

35

De-chlorination Pump (P-284A/B)

Instrument Air Compressor

DCS

Chlorine Absorber Circulation Pump and Blower

Hydraulic pump

De-mineralized Water Pump

EVAPORATION PROCESS DESCRIPTION

(Values in brackets are referring to Mode B)

Mode A describes the evaporation unit in respect to only evaporation unit is in operation. Mode B describes the evaporation unit in respect to evaporation and concentration plant is in operation. The 32% membrane cell NaOH liquor at 80C is fed to the first stage evaporator, a falling film evaporator EV-1101 operating on product side under vacuum. During a single pass through the evaporator, the caustic solution is concentrated to approx. 39% (43%).

The generated vapors are fed via duct D-1101 to the surface condenser C-7101, where they are indirectly condensed by cooling water. Inert gases are extracted by vacuum pump (P-7102 A/B). The 39% (43%) caustic solution is discharged from the bottom part of the first effect evaporator by means of a pump P-1101 A/B and is passed through either gasketed plate type heat exchanger HE-1511 or Becorex type heat exchanger HE-1551. On passing these heat exchangers, the NaOH solution is warmed up.

During a single pass through the second stage evaporator, a falling film evaporator EV-1301, operating on product side under pressure, the caustic solution is concentrated to 50% wt. The vapors generated hereby are used to heat the first stage evaporator EV-1101. In mode B additional vapors coming from concentration plant are used to heat the first stage evaporator. The falling film evaporator EV-1301 is heated by live steam at 8.0 bar (g).

The steam condensate is collected in the steam condensate tank T-1301 and is then being used to partially preheat the intermediate NaOH solution. It leaves the plant at a temperature of approx. 80C (88C). The 50% NaOH solution is discharged from the bottom part of EV-1301 by means of a pump P-1301 A/B and is passed through the heat exchangers HE-1511. In Mode B it is then led to the concentration plant. In mode A it is led to a water cooled plate type heat exchanger HE-1531, where the product is cooled down to 45C by cooling water.

The vapor condensate coming from EV-1101 is collected in the condensate tank T-7101. The total quantity of condensed vapors is collected in a tank T-7101 and is discharged by the extraction pumps P-7101 A/B for further use in other sections of the process plant (e.g. for dilution system or preparation of sugar solution in prilling plant).Part of the process condensates being used as seal water for the pump mechanical seals or sent to de-superheating unit in duct Z-102 where the superheated vapors coming from concentration plant are cooled

36

down to saturation temperature. To ensure liquid level in condensate tank an additional de-mineralized water line is connected to the condensate tank T-7101.

Control and Instrumentation

The plant is/shall be equipped with a control system enabling a fully automatic operation of the unit by controlling the important process parameters, such as temperatures, feed rate and liquid levels & monitoring the critical parameters with pre-alarms and interlocks for personal safety and material protection

No separate local control panel is required for the operation and control of the unit and all the signals shall be sent to the DCS where supervision of the operation is made.

Description of control philosophy

The plant capacity is controlled by measuring the product flow from the unit. The level of the separators is controlled and kept constant in order to ensure the barometric sealing and also to avoid dry operation of the caustic transfer pumps.

The level of the vapor condensate tank is controlled and kept constant to insure that the condensate lines coming from the surface condenser is always barometrically immersed. The level of the steam condensate tank is controlled to avoid any possible steam by-pass. It primary functions as a steam trap and secondly keeps the condensate between tank and control valve under pressure, thus using the steam condensate to preheat the caustic pre-concentrated solution.

Concentration of product is controlled by measurement of the boiling point in the evaporator EV-1301 achieved by measurement of the pressure in the separator of the falling film evaporator EV-1301 and by the boiling temperature of the product in EV-1301. The product concentration is then controlled and kept constant by changing the steam pressure which is done by means of steam control valve. The flow rate to each evaporator is controlled and an automatic recirculation is provided to permanently insure a sufficient wetting of the tubes even when running the plant at low turndown ratio.

PRILLING - PROCESS DESCRIPTION

The caustic dehydration line consists of the following sub-units: A. Concentration first stage (E-101), second stage (E-102A/B) B. Molten salt unit (unit 200) C. The caustic prilling line consists of the following sub-units: D. Prilling unit E. Dilution unit A. CONCENTRATION UNIT

Concentration Unit The caustic concentration units consist of the following components:

37

A vapor heated pre-concentrator (E-101)

Two molten salt heated concentrators (E-102 A/B)

Two diverting devices (B-101 A/B)

Auxiliary system such as vacuum system, sugar preparation, filtration, etc. The 50% wt caustic soda solution is fed from battery limit (from evaporation plant and/or from storage tank) via a double filter unit to falling film evaporator E-101,operating on product side under vacuum. During a single pass through this evaporator the caustic liquor is concentrated from 50% up to approx. 58%. The generated vapors are led to a water cooled mixing condenser (G-101), where they are condensed by cooling water. Inert are extracted by a vacuum pump (J-101 A/B). The excess vapors are either used to preheat the caustic in evaporation plant or are condensed in the mixing condenser G-102 by cooling water. The resulting vapor condensate coming from the condensers (G-101 and G-102), the condensate ex the falling film evaporator (E-101), the water ex vacuum pumps (J-101 A/B and P-7102 A/B) are collected in tank (D-601). From there it flows (by gravity) to battery limits. The 58% caustic solution is discharged from evaporator (E-101) by means of a pump (P-102 A/B) and is then split to feed to specially designed falling film concentrators (E-102 A/B). In order to protect the final concentrators from heavy corrosion by concentrated caustic soda, sugar in form of aqueous solution is added to the 50% NaOH solution. The sugar solution at approx. 5-10% is prepared alternatively in dissolving tank (D-101 A/B) and dosed to the process by means of a pump (P-104 A/B). To prepare the sugar solution, condensate is fed from the evaporation plant. During a single pass through concentrators the NaOH solution is dehydrated from 58% up to 98%. The concentrators (E-102 A/B) operate on product side under atmospheric pressure. They are heated with molten salt. The generated vapors are used to heat the falling film evaporator (E-101). By gravity the caustic melt is fed from the final concentrators to the diverting devices (B-101 A/B) where caustic melt can be led to either melt tank (D-103) or to dilution tank (D-401). The process is controlled by instruments to ensure fully automatic operation.

B. MOLTEN SALT HEATING UNIT

The molten transfer salt unit consists of the following components:

- A salt tank (D-201) with immersion salt pump (P-201)

- A forced flow salt heater (H-201) with a burner (H-202) built on top, designed for combustion of LDO (Light diesel oil) and/or Hydrogen

- A combustion air pre-heater (E-201) and flue gas stack

38

The heat required for the concentration of caustic soda from 58% up to 98% NaOH is transferred by molten salt. The heat transfer salt is circulated by a pump (P-201) from the molten salt tank (D-201) through a LDO and/or Hydrogen fired forced flow heater (H-201), where it is warmed up to approx. 430C. The heat produced in the burner is transferred to the molten salt by radiation (in the inner part of heater) and convection (in the outer part of the heater). Coming off the heater, the salt circulates to the lower collectors of the final concentrators (E-102 A/B) and is evenly distributed to the individual concentrator elements. In the concentrator elements, the salt flows counter current from the caustic. The cooled down molten salt is then transferred by gravity from the final concentrator outlet (E-102 A/B) down to the molten salt tank (D-201). A combustion air blower (F-201) feeds the burner (H-202), designed to burn LDO and/or Hydrogen and for operation with pre-heated combustion air. Combustion air has been warmed up in the combustion air pre-heater (E-201) by the flue gases. The flue gases then are vented through the stack (Z-206/207) into the atmosphere. In the flue gas an oxygen measurement will be installed to ensure an optimal combustion of fuel. Steam tracing with high pressure steam is provided to pre-heat the complete salt circuit. The salt tank itself is located at the lowest point of the plant in order for the salt to freely flow back into the tank in case of shut-down. The salt tank is blanketed with nitrogen to prevent decomposition of the molten salt by atmospheric oxygen. C. PRILLING UNIT

From the above mentioned diverting devices (B-101 A/B) the caustic melt flows by gravity to the caustic melt tank D-103 for prilling operation. The caustic melt pump (P-103 A/B) pumps the melt up to the top of the prill tower, via an electrically traced caustic melt line. The level in caustic melt tank is controlled by the speed control of the caustic melt pump (P-103 A/B). From top of the prill tower the caustic melt flows by gravity to the rotating basket of the prill spraying device X-301A/B in which caustic melt is transformed into droplets which are cooled and crystallized by ambient air during free fall through the prilling tower T-301. Nickel residues carried along with the caustic melt can deposit in the holes of the spray basket and clog them. This entails periodical cleaning (depending on mode of operation of the plant) of the spraying system. Therefore, to avoid interruption of production during cleaning, two spraying devices with the same capacity have been foreseen, of which one is in operation while the other spray basket is cleaned and heated up to operating temperature in the spray basket heater H-301 A/B. Changing spraying device can therefore be done very quickly. Connecting piece and spray baskets are blanketed with nitrogen. Via ring collector in the lower part of the prill tower, the cooling air is extracted by exhaust air fan F-302 through an air scrubber G-301 where NaOH dust carried along is washed out. Cleaned air is then discharged to atmosphere. The NaOH containing wash water is continuously led via overflow to wash water tank D-302.

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The exhaust air quantity is controlled in function with a constant air temperature in the prill tower, this to avoid moisture pick up of the prills. The solidified prills are collected in the conical lower part of the prill tower and are transported via vibrating conveyor M-301 to the water cooled rotating prill cooler E-301. The prills leaving the cooler are fed via vibrating conveyor M-302 and bucket elevator M-303 to either big bag station or to FFS machines. If prills are fed to FFS machines they pass a vibrating screening machine L-301, where over-sized particles are separated from the marketable product and collected separately. The marketable prills are led via the prill diverting flap to the prill storage section, consisting of two silos T-302 A/B. The whole prill conveying system is closed dust tight. To prevent the prills from picking up moisture from the ambient air, the whole system, from weighing stations to prill hopper is blanketed with dry air. To prevent the hot prills from baking to the inner surface of the hopper or at least to reduce it to a minimum, the hopper is heated electrically. However, the prill tower in particular the hopper must be washed out periodically in the following steps: The wash water from the wash water tank D-302 is pumped by the wash water pump P-301 A/B to the tower cleaning device X-303 on top of the tower. With this device which consists of a hose, drum and a spray nozzle, first the bottom part of the tower (hopper), afterwards the tower wall is washed out. The NaOH/Na2CO3 containing wash water flows back into the wash water tank D-302 via hopper outlet nozzle. As a last step, the tower is subject to a final cleaning with cooling water. The wash water content (approx. 30% NaOH/Na2CO3 solution) is then fed back to BL for neutralizing. The prill cooler E-301 has to be periodically washed out and cleaned. D. CAUSTIC DISSOLVING PART

It is unavoidable that the caustic melt produced during start-up of the concentration unit, caustic melt will be contaminated by nickel and nickel oxide. This quality of caustic melt must not be processed into prills as the Nickel oxide particles would clog the small holes of the spray basket. It is therefore proposed to dissolve this off-spec caustic melt in the dilution tank D-401 into an approx. 50% wt NaOH solution. Make-up water to achieve this concentration can be taken from process condensate. Via a loop consisting of the pump P-401A/B and the cooling water cooled heat exchanger E-401 temperature is controlled to be constant since dilution of NaOH results in excess heat. Off spec material can also be fed to dilution tank via rotary valve (RV-401) on top of the tank. The caustic circulation pump P-401 A/B circulates the content of the tank and send the contaminated 50% NaOH solution out of BL.

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CHLORINATED PARAFFIN WAX- PROCESS DESCRIPTION

1. PARAFFIN UNLOADING AND STORAGE

Paraffin received in road tankers is unloaded by HNP unloading pumps and stored in HNP storage tanks. HNP is filtered through cartridge filters while storing in the tanks. A number of tanks are installed for storing variety of paraffin in different storage tanks.

2. PARAFFIN HEATING AND TRANSFER TO REACTORS

Raw Paraffin is fed to reactors through HNP heat exchangers so as to raise the temperature of HNP before feeding to reactors. Three reactors can be fed at a time. Charging time for HNP per reactor shall be approximately 45 minutes.

Hot Paraffin is passed through Filter for eliminating any suspended impurities. Metallic impurities (suspended particles) are specially avoided as they impart a strong color to the product during chlorination. HNP is charged to Glass lined reactors through flow transmitter and integrator. An on-off valve is installed in the line, which shall automatically cut off the supply, once integrator reads the required reading.

CT 1010 shall be added for reaction startup, if required.

3. CHLORINATION

Before starting chlorine supply to reactors, absorption water flow to the HCl scrubber and caustic soda circulation in scrubber is started. Chlorination is started with the chlorine supplied from the main plant at 3.0 Kgs/cm2 g pressure at atmospheric temperature. Flow of chlorine is continuously measured by flow transmitter installed in the line. Initially the chlorine bubbling from the sparger remains suspended in the paraffin without any actual reaction taking place until saturation occurs.

This is characterized by a slight drop in the reactor temperature. After the saturation point is reached, reaction takes place with a rapid rise of temperature.

This reaction is exothermic

C n H 2n+2 + mCl2------(C n H 2n+2-m) Clm +mHCl + Heat

To maintain the temperature of the mass in the reactor, cooling water is circulated in the jacket of the reactor. Cooling water is also circulated through a pipe type cooler installed in the reactor from the bottom side for better heat transfer. Control valve is installed in the cooling water line. However if the temperature goes out of control even on full opening of the control valve, chlorine flow rate is reduced to maintain the desired temperature.

DF 2020 shall be added as and when required during chlorination.

Once the desired gravity of the product is achieved, chlorination is stopped, dry air at a pressure of 3 Kgs/cm2g and atmospheric temperature is passed through the reactor at a rate of 150 Kgs/hr to make the product free from any entrained chlorine &HCl gas.

41

During the reaction, HCl gas is generated as a byproduct. This HCl gas along with the mist of paraffin & traces of chlorine leaves the reactor from the top and is passed through a series of vessels to arrest the paraffin mist.

These vessels are named as DE vessels and one set consists of 3 numbers of DE vessels. One such set shall cater to six numbers of reactors and so in total 6 sets of DE vessels are installed.

The first two of these DE vessels are filled with CPW up to 50% level. When the HCl gas passes through these vessels, Paraffin mist is arrested in the CPW and continuously overflows to a specified vessel. Once the color of CPW in DE Vessels changes, the material is replaced with the fresh one.

4. PRODUCT TRANSFER

Once the degasification of the product is over in reactor (done for about 1 -2 hrs), product is transferred to Intermediate finishing tanks (IFT) for further treatment and degasification with air. About seven gear pumps have been installed for the purpose of transferring CPW from reactors to IFTs.

Each IFT has got 4 compartments of 10 m3 capacity each. One batch is transferred in one such compartment. Stabilizer is added in these IFTs. Dry air is also again passed for about 3-4 hours to ensure complete removal of chlorine/HCl gas from the product. Required quantities of Additives e.g. Stabilizer, SL 3030 shall be added if required. Finally the product from these IFTs is transferred to storage tanks.

5. HCL PRODUCTION

The HCl gas from the DE vessels is fed to HCL absorbers. HCl absorbers have been considered in three stages in series i.e. Primary, Secondary & Tertiary. For primary absorption six nos. of absorbers are installed in parallel. Three nos. of absorbers are with two numbers of circulation tank. Once the HCl concentration is achieved in one tank, changeover is given. Product HCL is transferred to storage tanks. HCl absorbers are falling film block type graphite heat exchangers and heat of absorption is removed by circulating cooling water in absorber .The HCl produced from primary HCl absorber is degassed for removal of free chlorine and then is transferred in main storage tank. Required quantity of SS 4040 shall be added.

For Secondary absorption five numbers of absorbers are installed in parallel with two numbers of circulation tank. Change over is given when HCL is required to transfer in primary absorber circulation tanks.

For Tertiary absorption two numbers of absorbers are installed in parallel with one no of circulation tank. Change over is given when HCL is required to transfer in primary absorber circulation tanks or secondary absorber circulation tanks.

6. OFF GASES SCRUBBING

The gas from tertiary absorber, the off gases from the Reactors and IFTs at the time of degasification & the gases from vent of absorber circulation tanks, storage tanks & HCL filling

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station are sent to packed tower, where process water is circulated to absorb HCL in gas. One no. tank is installed for circulation. Low concentrated HCL is transferred to absorber circulation tanks.

One no. scrubber is considered for the air coming from HCL de-chlorination tanks. Gas from packed tower is sent most of the time to local waste air scrubbing system; however provision has been kept to send it to main plant waste air scrubbing system, if required. In local scrubbing system dilute caustic soda is circulated to arrest the chlorine gas from the off gases before leaving this to the atmosphere.

Two towers are considered in series first tower having two tanks one in circulation & another for product transfer. Second tower has one tank for circulation via over head tank which is considered as a safety tank in case of power failure. One cooler has been considered with both towers to remove the heat of chlorine absorption.

1.3 OBJECTIVE OF THE STUDY

To identify the hazard and operability problems and to reduce the probability and consequences of an incident in the storage and dispatch facilities that would have a detrimental impact to the personnel, plant, properties and environment.

1.4 SCOPE OF THE STUDY

The scope of HAZOP study is to identify the hazard and operability problems and to reduce the probability and consequences of an incident in the station facilities included under the scope of this report for Qatar Petroleum that would have a detrimental impact to the personnel plant, properties and environment or any operability problem.

The HAZOP study is conducted to examine the overall process design, searching for operating deviations and process interactions that can lead to any safety hazard(s), environmental risk or operability problem, which include:

Review of the design and operation of process facility and their engineering requirements

Safety and Occupational Health Hazards to personnel

Damage to equipment/asset/environment

Operability/maintainability problems

Plant non-availability/limitation and lack of product quality

Environmental emissions

To identify all possible causes of deviations from normal operation that could lead to any safety hazard, environmental risk or operability problem

Identification of hazards, possible causes and consequences and suggest recommendations for necessary changes/ alterations

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Critical examination of the process and the engineering intentions to assess the hazard potential or mal-operation or mal- function of individual items of equipment and the consequential effects on the facility as a whole.

1.5 ACKNOWLEDGEMENTS

Applus VELOSI gratefully acknowledges the co-operation received from the management of KLJQ, particularly who has attended the HAZOP session and provided their contribution in the discussion. Applus VELOSI in particular would like to thank Mr. P P Soni, Mr. Umesh Chandra Tiwari and their team for their active support for successful completion of the study.

1.6 DISCLAIMER

The advice rendered by Applus VELOSI is in the nature of guidelines based on good engineering practices and generally accepted safety procedures and Applus VELOSI does not accept any liability for the same. The priorities of suggestions shown in the report are advisory in nature and not binding on the parties involved viz. Applus VELOSI and KLJQ.

44

CHAPTER 2 METHODOLOGY

45

2.0 METHODOLOGY

A HAZOP study is a formal systematic procedure used to review the design and operation of a potentially hazardous process facility. It is used to identify deviations from normal safe operation, which could lead, to hazards or operability problems, and to define any actions necessary to deal with these. The study is performed by a team of people who are familiar with the plant design and operation, working under the guidance of a leader who is experienced in use of the HAZOP method. The method involves several repetitive steps (Reference is invited to Figure 2.1 on next page)

1. Identify a section of plant on the P&I diagram. 2. Define the design intent and normal operation conditions of the section. 3. Identify a deviation from design intent or operating conditions by applying a system of

guidewords. 4. Identify possible causes for, and consequences of, the deviation. A deviation can be

considered meaningful if it has credible cause and can result in harmful consequences. 5. For a meaningful deviation, decide what action, if any is necessary. 6. Record the discussion and action.

Step 3 to 6 is repeated until all the guidewords have been exhausted and the team is satisfied that all meaningful deviations have been considered. The team then goes back to step 1 and repeats the procedure for the all the pipelines. In the HAZOP method, the guidewords are systematically applied to a segment of process equipment in order to promote discussion on possible deviations from the design intention. The guidewords represent deviations to the design intent and their use leads to systematic highlighting of hazards and operability problems.

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Figure 2.1: HAZOP study procedure

No

No

No

STOP

Yes

Yes

Yes

Yes

START

Explain overall design

Is deviation credible?

Select a node

Identify whether any of the elements can

be usefully sub-divided into characteristics

Select an element (and

Characteristic if any)

Select a guide word

Apply the guide word to the

selected elements (and to each of its

characteristics as relevant) to obtain a

specific deviation

Identify relevant elements

Examine and agree design intent

Have all interpretation of the

guide word and elements/

characteristics combinations been

applied?

Have all the guide words applied

to selected element?

Have all the elements been

confirmed?

Have all nodes been examined?

Investigate causes, consequences and

protection or indication & document

Assess severity, likelihood and assign

Risk Rank for each consequence and

provide recommendation.

recommendation.

Ye

s

N

o

No

47

The HAZOP study was based on the P&I diagrams for the sections to be covered by study as per the details made available to the HAZOP team.

HAZOP Recording:

Two methods of recording of a HAZOP study can be employed:

1. Complete - in which details of all discussion points are noted. 2. By Exception - in which only those deviations that require action are recorded.

Recording of this study is 'complete recording' wherein all discussions of significance were recorded. The recording was done using a software tool PHA-Pro' developed by 'Dyadem, Canada. The use of software enabled the on-line recording of the team discussion. The discussion from the study is recorded on log sheets. Information is recorded in columns on the log sheets as follows:

Guideword

Parameter

Deviation

Causes

Consequences

Safeguards

Recommendations

These HAZOP Log sheets are attached as Appendix 1.

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CHAPTER 3 ELEMENTS OF THE STUDY

49

3.0 ELEMENTS OF THE STUDY

3.1 TYPICAL NODES OF THE STUDY

CAUSTIC PROCESS

Nodes Type Equipment ID Comment

1. Salt handling, salt dissolving & chemical dosing

Saturator Z-015, D-010A/B

2. Brine Clarification and filtration Clarifier and filter T-030, P-034A/B, P-044A/B, F-140 A/B

3. Slurry Handling Vessels and

pipelines Package unit.

4. Secondary Brine Purification Filters P-154 A/B, E-153

5. Brine ultra purification Tank and pumps P-174 A/B I-174 interlock tag to be

removed from the P&ID.

6. Brine Electrolyzer Electrolyzer R-230A/B/C

7. Brine Electrolysis Electrolyzer R-230A/B/C, D-210, 220 A/B/C

8. Anolyte System Separator and

pumps

D-240, P-244 A/B LV-240 should be failed to open instead of fail to close.

9. Catholyte System Separator D-250, P-254 A/B

10. Anolyte Blow down System Blow down System

This section is operated only during shutdown and collected material will be processed in a planned manner.

11. Catholyte Blow down System Blow down System

This section is operated only during shutdown and collected material will be processed in a planned manner.

12. Brine Dechlorination Separator T-280, E-264, 284,083, P-284, 289, 084, 294 A/B.

13. 32% Caustic Soda distribution system Distribution unit P-314 A/B, E-313

14. Chlorate Decomposition system D-286, E-286

15. Chlorine Gas cooling and Drying System Cooling and

moisture removal

T-410,430,440, E-420, E-413, 433,443, 453, P-404, 414, 434, 444, 454

16. Spent Sulphuric Acid Dechlorination System

Separator T-490, P-494 A/B

17. Chlorine Compression and Liquefaction Compressor and

Condenser

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Nodes Type Equipment ID Comment

18. Liquid Chlorine Process Tanks and Vaporization

Chemical intermediate

Storage

D-540 A/B/C, P-544 A/B

19. Liquid Chlorine Vaporization Vaporizer E-550 A/B, D-554

20. Hydrogen Gas Washing and Distribution Washing and

Distribution unit T-610, E-613, SP-601, 602, F-624, P-614 A/B

21. HCl Synthesis Reactor Package unit.

22. HCl Storage and Distribution Storage Area and Distribution unit

P-834, 844 A/B

23. Sulphuric Acid Storage and Distribution Storage Area and Distribution unit

P-474, 484 A/B

24. Chlorine Absorption Absorber T-710, 730, E-713, 733, 743, P-724, 731, 744 A/B

25. Hypo Storage and Dispatch Storage Area and Distribution unit

P-754 A/B

26. Neutralization Pit Storage Area PT-900, P-904

27. Liquid chlorine handling during emergency.

Storage Area

28. LGO storage and distribution. Storage Area D-105 A/B, P-1052 A/B, 1053

29. Steam condensate collection and distribution system.

Utility Package unit. Detail

P&ID to be provided by vendor.

EVAPORATION

Nodes Type Equipment ID Comment

1. 1st stage evaporation Evaporator E-1101, P-1101 A/B,

2. 2nd Stage Evaporation Evaporator E-1301, T-1301, P-1301 A/B,

3. Heat Exchange Heat Exchanger HE-1511, 1531, 1551

4. Condensation & Vacuum Condenser T-7101, C-7101, P-7101, 7103, 7102 A/B,

C-7101 - temperature control to be confirmed

5. Steam, condensate and cooling water system.

Utility C-8251, P-8251, 8252, 8252 A/B.

6. Caustic Storage & Distribution Storage and distribution

P-334, 344, 384 A/B, HE-334

7. Utility Distribution Utility Package units.

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PRILLING

Nodes Type Equipment ID Comment

1. Caustic Filtration &Vapor Heated pre-concentrator

Evaporator F-101 A/B, E-101, P-102 A/B,

2. Final Concentrator Evaporator E-102 A/B, B-101 A/B,

3. Prilling Prilling system

D-103, 1. Purpose of TI-3203 is not confirmed. 2. Some nozzles are marked with hold. - Why?

4. Caustic Dilution Tank D-401, E-401,

5. Prill Handling Material handling M-301, 302,303, 304,305, X-301 A/B, E-301, T-302 A/B

6. Prill Tower Cleaning Cleaning system

7. Salt Heating Heat exchanger D-201, P-201

8. Furnace Firing Furnace and

burners H-201, E-201, F-20,P-8601, 8602 A/B, T-8601,

9. Vapor Condensing & Vacuum Utility G-101, 102, D-601, J-101 A/B

10. Steam distribution System Utility

11. Nitrogen distribution Utility D-802

12. Air Drying Pac