A Report on Industrial Training

Department of Biotechnology and Chemical Engineering

Batch 2021-2025

Manipal University Jaipur

Industry: DCM Shriram Industries Ltd. Kota, Rajasthan

Process Department of Chlor-Alkali Group (CAG)

Name: Swayam Ghosh

Registration No.: 219101002

Duration: 03/06/2024 to 03/07/2024

Date of Submission: 28/11/2024

 Preface

Industrial Training refers to work experience that is relevant to professional development

prior to graduation. Industrial training is an essential component in the development of
practical and professional skills required of an engineer and an aid to prospective
employment.

Industrial Training Objectives:

 To expose students to engineering experience and knowledge which is required in

industry, which cannot be taught in the lecture rooms.
 To apply the engineering knowledge taught in the lecture rooms in real industrial
situations.
 To use the experience gained from the Industrial Training in discussions held in the
lecture rooms.
 To gain experience in writing reports in engineering works/projects.
 To expose the students to future employers.
 With all the experience and knowledge acquired, it is hoped that the students would
be able to choose appropriate work upon graduation.

This report was prepared to present the various functions and structures of the departments at
the DCM Shriram Industries Ltd., Kota.

Last but not the least, I would like to say that by this vocational training we tried to imbibe all
the important aspects that an industry requires for befitting its work. I’d once again thank
everyone that helped us in this endeavour.

i
 Acknowledgement

I wish to thank Mr. P.S. Rathore (Plant Head, CAG) & Dr. Abhishek Sharma (Faculty,
Manipal University Jaipur) for providing me this valuable opportunity to pursue practical
training at DCM Shriram Industries Limited, Kota.

I would also like to thank Mr. Ashok Gupta (HR, CAG), Mr. Deepesh Mittal (CAG) &
Mr. Ketan Khandekar (Trainer, CAG) for their support and guidance.

I would also like to thank Ms. Rinkey (HR) for her valuable initial guidance.

I am also indebted to all those who are directly and/or indirectly involved in making this
training session a success and who have given me the chance to develop my project in detail.

This training session, as a whole, was a great learning experience for me due to everyone
involved and I hope this valuable experience would help me to frame my career further.

ii
CERTIFICATE OF INTERNSHIP

iii
Table of Contents
Introduction 1
Asahi Kasei Membrane Technology 1
Reactions Involved 3
Assignments 4
Assignment 1 4
Assignment 2 5
Assignment 3 9
Assignment 4 12
Brine House Unit 13
Primary Purification 13
Secondary Purification 14
Cell House Unit 17
Electrolysis 17
PFD 18
Operation Conditions 20
Hydrogen Gas Treatment 22
Dechlorination 23
Chlorine Gas Treatment 24
Sulfuric Acid Treatment 27
Flaker Plant 28
PFD 28
Design Basis 29
Operating Modes 30
Specifications 31
Summary and Conclusion 34
Annotations 35
Safety Measures 36
References 37
Introduction: The Chlor-Alkali Processing Plant for the production of Caustic Soda at the DCM
Shriram Ltd. Kota, performs the functions of purification of brine, electrolysis using electrolysers, and
hence primarily the production of Caustic Soda and Chlorine gas & Hydrogen gas as the gaseous by-
products, which are purposed for various other products.

The Chlor-Alkali Group (CAG) at DCM Shriram Kota, utilizes the Asahi Kasei Membrane Process
for Electrolysis to obtain the desired product of caustic soda.

The Asahi Kasei membrane process for electrolysis is notable for several key features:

 Filter-Press Structure: This design facilitates on-site maintenance by allowing individual

membrane replacements to be completed within one shift from shutdown to start-up. This
process requires no special skills, which enhances operational efficiency and reduces
downtime.

 Metal Subheaders: The process employs titanium subheaders for the anolyte and nickel
subheaders for the catholyte. These materials are chosen for their resistance to corrosion in
their respective electrolytic environments, ensuring durability and longevity.

 Electrolyser Grounding: This feature enhances operator safety by ensuring that the
electrolyser is properly grounded, reducing the risk of electrical hazards.

 Rigid Structure: The rigid design of the electrolyser supports pressurized operation. This
eliminates the need for a chlorine fan and minimizes the necessary piping, thereby reducing
potential points of failure and maintenance requirements.

 No Polarization Technology: The zero-gap system utilized in this process operates without
polarization, which improves efficiency and performance by reducing the voltage required for
electrolysis.

1
 

Figure: The Asahi Kasei Membrane Technology.

These features collectively contribute to a more efficient, safe, and maintainable electrolysis process,
making the Asahi Kasei membrane process a robust choice for industrial applications.

The Asahi Kasei technology offers its customers the following benefits:

 Energy Saving:
o Zero-gap design
o Original anodes/cathodes and membranes

 Easy Maintenance:
o Hydraulic press-quick membrane replacement on site.
o Maintenance free metal (Ti, Ni) headers.
o Quick load and temperature change is applicable.

 Safety and Robustness:

o Polarization rectifier is not required (∑ technology).
o Robust cell design – pressurized operation is applicable.

2
Reactions involved: Asahi Kasei Chlor-Alkali Process

1 −¿¿

At Anode: Cl−¿→ 2 Cl +e
2 ¿

−¿ →Na ¿
At Cathode: 2 Na+ ¿+ e ¿

1 1
Total Reaction: NaCl+ H 2 O→ NaOH + Cl 2+ H
2 2 2

Figure: The Asahi Kasei Membrane Process for Electrolysis.

3
 Assignments

Assignment 1:

Q. For the production of 1 ton of Caustic Soda (NaOH), calculate how much NaCl & H2O is required
during electrolysis. Also find how much chlorine gas and hydrogen gas evolved?

Relevant data:

 Reactions Involved:

1 1
NaCl+ H 2 O→ NaOH + Cl 2+ H 2
2 2

 Molecular Weights:
NaCl: 58.5 kg/kmol, H2O: 18 kg/kmol,
NaOH: 40 kg/kmol, Cl2: 71 kg/kmol,
H2: 2 kg/kmol

Solution:

For production of 1 ton NaOH = 1000 kg NaOH

1000 kg NaOH
=25 kmol NaOH ¿ be produced
i.e., kg
40
kmol

From stoichiometry, 1 kmol NaOH requires → 1 kmol NaCl

⸫ 25 kmol NaCl is needed;

kg
i.e., 25 kmol NaCl ×58.5 =1462.5 kg NaCl isrequired .
kmol

Similarly, from stoichiometry, 1 kmol NaOH requires → 1 kmol H2O

⸫ 25 kmol H2O is needed;

kg
i.e., 25 kmol H 2 O× 18 =450 kg H 2 O is required .
kmol

25 kg
Thus, Cl2 gas evolved: kmol Cl2 ×71 =887.5 kg Cl 2 is evolved .
2 kmol

25 kg
Similarly, for H2 gas evolved: kmol H 2 ×2 =25 kg H 2 is evolved .
2 kmol

4
Ans. 1462.5 kg of NaCl and 450 kg of H2O is required for the electrolysis process where,
887.5 kg of Cl2 and 25 kg of H2 gas evolves, for the production of 1 ton of Caustic Soda.

5
Assignment 2:

Q. 1. To remove impurities in the brine, ‘chemical dosing’ of Barium Carbonate (BaCO 3) and Soda
Ash/Sodium Carbonate (Na2CO3) are used. Apply mass balance to calculate how much BaCO3 and
Na2CO3 would be required for purification of brine if assuming 1 ton of salt containing impurities
enters as feed. Calculate how much make-up NaOH would be required for treating MgCl 2. Also,
calculate purity of this batch of salt and hence the actual amount of NaCl entering as feed.

Q.2. Why is H2 gas not liquified after treatment in the DCM Shriram Plant? Give reasons as to why H 2
gas is packed in smaller cylinders as compared to other gases.

Relevant Data:

 Salt Composition:

CaCl2: 695 ppm, MgCl2: 452 ppm,

Na2SO4: 0.29%, Na2CO3: 0.1%,

Moisture (H2O): 3%

 Reactions Involved:
MgCl2 + 2NaOH → Mg(OH)2 + 2NaCl
CaCl2 + Na2CO3 → CaCO3 + 2NaCl
Na2SO4 + BaCO3 → Ba(SO4) + Na2CO3
 Molecular Weights:
MgCl2: 95.2 kg/kmol, CaCl2: 111 kg/kmol
NaOH: 40 kg/kmol, Na2SO4: 142.042 kg/kmol
BaCO3: 197 kg/kmol, NaCl: 58.5 kg/kmol,
Na2CO3: 106 kg/kmol
 Excess Concentration:
BaCO3: 350 ppm excess, NaOH : 300 ppm excess
 Assume 95% reaction completion for each.

Solution:

For Q.1: Given: 1 ton of impure salt enters as feed: 1 ton = 1000 kg

To find feed salt concentration:

i. CaCl2: 695 ppm = 0.0695%;

0.0695
i.e., × 1000 kg=0.695 kg CaCl 2 present as impurity
100

6
 0.695 kg
=0.006261 kmol Ca Cl2 present as impurity
kg
111
kmol

ii. MgCl2: 452 ppm = 0.0452%;

0.0452
i.e., ×1000 kg=0.452 kg Mg Cl2 present as impurity
100
0.452 kg
=0.004547 kmol Mg Cl 2 present as impurity
kg
95.2
kmol

iii. Na2SO4: 0.29%,

0.29
i.e., ×1000 kg=2.9 kg Na2 SO 4 present as impurity
100
2.9 kg
=0.0207 kmol Na2 SO4 present as impurity
kg
140.042
kmol

iv. Na2CO3: 0.1%,

0.1
i.e., ×1000 kg=1 kg Na2 CO 3 present
100
1 kg
=0.00943 kmol Na2 CO 3 present
kg
106
kmol

v. Moisture (H2O): 3%
3
i.e., ×1000 kg=30 kg H 2 O present
100
30 kg
=1.606 kmol H 2 O present
kg
18
kmol

i.e. At inlet: MgCl2 = 0.004547 kmol, CaCl2 = 0.006261 kmol, Na2SO4 = 0.0207 kmol, Na2CO3 =
0.00943 kmol, Moisture (H2O) = 1.606 kmol

Now, we observe from reaction stoichiometry:

i. 1 kmol CaCl2 requires → 1 kmol Na2CO3

i.e. Na2CO3 required = 0.006261 kmol

7
 kg
⸫ Amount of Na2CO3 required = 0.006261 kmol × 106 =0.6636 kg
kmol
Since 95% completion, ⸫ for complete conversion required Na2CO3:
(0.95 × 0.6636) + 0.6636 = 1.294 kg Na2CO3 is required.

ii. 1 kmol Na2SO4 requires → 1 kmol BaCO3

i.e. BaCO3 required = 0.0207 kmol
kg
⸫ Amount of BaCO3 required = 0.0207 kmol ×197 =4.0779 kg
kmol
Since 95% completion, ⸫ for complete conversion required BaCO3:
(0.95 × 4.0779) + 4.0779 = 9.1058 kg BaCO3 is required.
Also,
1 kmol Na2SO4 produces → 1 kmol Na2CO3
i.e. Na2CO3 produced = 0.0207 kmol × 0.95 (95% conversion)
kg
⸫ Amount of Na2CO3 produced = 0.0207 kmol ×0.95 ×106 =2.08449 kg
kmol
Also, Na2CO3 present in feed = 0.00943 kmol ¿ 1 kg Na2 CO 3
⸫ Overall, Na2CO3 Balance:
2.08449 kg ( produced )−0.6636 kg ( required for CaCl 2 ) +1 kg ( present∈ feed )=1.79049 kg Na2 CO 3 r

iii. For make-up NaOH

1 kmol MgCl2 requires → 2 kmol NaOH
i.e. NaOH required = 2 × 0.004547 kmol = 0.009094 kmol
kg
⸫ Amount of NaOH required = 0.009094 kmol × 40 =0.36376 kg
kmol
Since 95% completion, ⸫ for complete conversion required BaCO3:
(0.95 × 0.36376 ) + 0.36376 = 0.709332 kg NaOH is required.

iv. Amount of NaCl entering thus,

1000 kg Salt Feed – 0.695 kg CaCl2 – 0.452 kg MgCl2 – 2.9 kg Na2SO4 – 1 kg Na2CO3 –
30 kg Moisture (H2O)
= 964.953 kg NaCl
964.953 kg NaCl
⸫ Salt Purity: × 100=96.4953 %
1000 kg feed

v. Since we need to have excess concentrations of Hydroxide and Carbonate ions:

a. For BaCO3: 350 ppm excess, i.e., 0.0350% excess of 9.1058 kg

8
  9.10615 kg BaCO3 is required.
b. For NaOH: 300 ppm excess, i.e., 0.0300% excess of 0.709332 kg
 0.70954 kg NaOH is required.

Ans: For Q.1: (a) For chemical dosing of 1 ton salt following are the requirements:

Soda Ash/ Sodium Carbonate (Na2CO3): 1.79049 kg Na2CO3 remains as excess.

Barium Carbonate (BaCO3): 9.10615 kg is required.

Caustic Soda/ Sodium Hydroxide (NaOH): 0.70954 kg is required.

(b) Amount of NaCl entering: 964.953 kg;

Purity of salt (NaCl percentage): 96.4953 %

For Q.2: (a) To liquefy H2 gas, it must be brought to its critical pressure and then cooled down to
temperatures below 33 oK (-240.15 oC), which will take up additional cost for the operation; rather,
the gas is treated and used as fuel in the Flaker plant unit because of its exceptionally high calorific
value (120 MJ/kg).

(b) Storing hydrogen gas in racks of containers allows for high-pressure storage (200 to 300 barg) and
high density (20 to 30 kg/m³). These racks, also known as tube trailers, are primarily designed for
transportation. However, using them for large-scale storage presents challenges, including a large
ground footprint and the risk of domino effects between racks. To mitigate these risks, safeguards
such as firewalls and adequate separation distances must be implemented to protect against thermal
and overpressure events.

9
Assignment 3:

Q. Taking into account relevant data from Assignment 1, calculate the actual amount of salt that is
required for the production of 1 Ton of Caustic Soda using the same batch of salt as used in
Assignment 2 and hence; calculate the actual amount of Soda Ash, Barium Carbonate and Caustic
Soda that is required for chemical dosing.

 Relevant Data: Salt Composition:

CaCl2: 695 ppm, MgCl2: 452 ppm,

Na2SO4: 0.29%, Na2CO3: 0.1%,

Moisture (H2O): 3%

 Reactions Involved:
NaCl + H2O → NaOH + 0.5 Cl2 + 0.5 H2
MgCl2 + 2NaOH → Mg(OH)2 + 2NaCl
CaCl2 + Na2CO3 → CaCO3 + 2NaCl
Na2SO4 + BaCO3 → Ba(SO4) + Na2CO3
 Molecular Weights:
MgCl2: 95.2 kg/kmol, CaCl2: 111 kg/kmol
NaOH: 40 kg/kmol, Na2SO4: 142.042 kg/kmol
BaCO3: 197 kg/kmol, NaCl: 58.5 kg/kmol,
Na2CO3: 106 kg/kmol
 Excess Concentration:
BaCO3: 350 ppm excess, NaOH : 300 ppm excess
 Assume 95% reaction completion for each.

Solution:

We know, from Assignment 2, purity of salt (NaCl percentage) = 96.49 %.

And, from Assignment 1, amount of NaCl required for production of 1 ton NaOH = 1462.5 kg NaCl.

⸫ 96.49 % of x=1462.5 kg NaCl; where x = the total amount of salt required.

i.e., x = 1515.701 kg of total Salt is required.

Now following similar steps as before in Assignment 2;

10
To find feed salt concentration:

i. CaCl2: 695 ppm = 0.0695%;

0.0695
i.e., × 1515.701kg=1.053 kg Ca Cl 2 present as impurity
100
1.053 kg
=0.009486 kmol CaCl 2 present as impurity
kg
111
kmol

ii. MgCl2: 452 ppm = 0.0452%;

0.0452
i.e., ×1515.701 kg=0.685 kg Mg Cl2 present as impurity
100
0.685 kg
=0.00719 kmol Mg Cl 2 present as impurity
kg
95.2
kmol

iii. Na2SO4: 0.29%,

0.29
i.e., ×1515.701 kg=4.395 kg Na2 SO 4 present as impurity
100
4.395 kg
=0.0309 kmol Na2 SO 4 present as impurity
kg
140.042
kmol

iv. Na2CO3: 0.1%,

0.1
i.e., ×1515.701 kg=1.5157 kg Na2 CO3 present
100
1.5157 kg
=0.0142 kmol Na2 CO3 present
kg
106
kmol

v. Moisture (H2O): 3%
3
i.e., ×1515.701 kg=45.47 kg H 2 O present
100
45.47 kg
=2.526 kmol H 2 O present
kg
18
kmol

i.e. At inlet: MgCl2 = 0.00697 kmol, CaCl2 = 0.00922 kmol, Na2SO4 = 0.03043 kmol,
Na2CO3 = 0.01386 kmol.

11
Now, from reaction stoichiometry:

i. 1 kmol CaCl2 requires → 1 kmol Na2CO3

i.e. Na2CO3 required = 0.009486 kmol
kg
⸫ Amount of Na2CO3 required = 0.009486 kmol ×106 =1.005516 kg
kmol
Since 95% completion, ⸫ for complete conversion required Na2CO3:
(0.95 × 1.005516 ) +1.005516 = 1.9607562 kg Na2CO3 is required.
ii. 1 kmol Na2SO4 requires → 1 kmol BaCO3
i.e. BaCO3 required = 0.0309 kmol
kg
⸫ Amount of BaCO3 required = 0.0309 kmol × 197 =6.0873 kg
kmol
Since 95% completion, ⸫ for complete conversion required Na2CO3:
(0.95 × 6.0873 ) +6.0873 = 11.870 kg BaCO3 is required.
Also,
1 kmol Na2SO4 produces → 1 kmol Na2CO3
i.e. Na2CO3 produced = 0.0309 kmol
kg
⸫ Amount of Na2CO3 produced = 0.0309 kmol × 0.95 ×106 =3.1163kg
kmol
Also, Na2CO3 present in feed = 0.01386 kmol ¿ 1.5157 kg Na2 CO3
⸫ Overall, Na2CO3 Balance:
3.1163 kg ( produced )−1.9607562 kg ( required for CaCl 2 ) +1.5157 kg ( present∈ feed )=2.66 kg Na2 C

iii. For make-up NaOH

1 kmol MgCl2 requires → 2 kmol NaOH
i.e. NaOH required = 2 × 0.00719 kmol = 0.01438 kmol
kg
⸫ Amount of NaOH required = 0.00697 kmol ×40 =0.5752 kg
kmol

vi. Since we need to have excess concentrations of Hydroxide and Carbonate ions:
a. For BaCO3: 350 ppm excess, i.e., 0.0350% excess of 11.870 kg
 11.8741 kg BaCO3 is required.
b. For NaOH: 300 ppm excess, i.e., 0.0300% excess of 1.12164 kg
 1.121976 kg NaOH is required.

Ans: (a) For the production of 1 ton of Caustic Soda (NaOH), 1515.701 kg of Salt feed is required out

of which 1462.5 kg is NaCl.

12
(b) For chemical dosing of 1515.701 kg salt following are the requirements:

Soda Ash/ Sodium Carbonate (Na2CO3): 2.66 kg Na2CO3 remains as excess.

Barium Carbonate (BaCO3): 11.8741 kg is required.

Caustic Soda/ Sodium Hydroxide (NaOH): 1.121976 kg is required.

13
Assignment 4:

(i) Using Faraday’s Law, calculate how much electrical energy is required to produce 1 Ton
of NaOH for the DCM Shriram Ltd. Kota Plant operating at a capacity of electric current at
99kA, electrical power of 47.7 MW and production capacity of 546 TPD.
(ii) Obtain information from DCS of the Cell House Unit and compare actual power usage to
the one calculated theoretically and find their efficiency.
(i) Solution: Assuming current flow of 1kA in a single element of
electrolyser;
Using Faraday’s Law: W =zit
E
Where, z = ; E = Equivalent weight (of NaOH = 40)
96500 C
i.e., Weight deposition on one cell in one hour:
40
W= ×1000 A ×3600 s=1492.2 g=1.4922 kg
96500 c
i.e., in 150 elements: 223.83kg of NaOH is being deposited.
Therefore for 1 Ton of NaOH:

' 223.83
Current Required (1 Ton), I = =4.4676 kA /Ton
1000
or Power Required (1Ton), P' =444.4 V × 4.7676 kA=1.9854 MW /Ton

(ii) From our visit at the DCS of the Cell House Unit of DCM Shriram Ltd. Kota,

We obtained,

(a) Power of Unit R230A = 2.086 MW

1.9854
i.e. Efficiency, ε R 230 D = × 100=95.17 %
2.086

(b) Power of Unit R230B = 2.086 MW

1.9854
i.e. Efficiency, ε R 230 E = ×100=95.17 %
2.098

(c) Power of Unit R230C = 2.068 MW

1.9854
i.e. Efficiency, ε R 230 E = ×100=96.00 %
2.068

(d) Power of Unit R230D = 2.053 MW

1.9854
i.e. Efficiency, ε R 230 E = ×100=96.70 %
2.053

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15
SECTION I. Brine House/Chlor-Alkali Plant: The Treatment of Brine:

The salt/brine solution before it can be utilized, needs to be free from impurities; hence the need of the
Brine House Unit. The Brine House unit performs all the necessary steps needed such that both the
fresh brine and the depleted brine once electrolysis has taken place is fit for use and re-use.

The Brine House Unit not only performs the treatment of brine but also the treatment of Hydrogen gas
and in the production of HCl (hydrochloric acid) and the bottling of hydrogen. It also takes part in the
separation of chlorine gas which is itself then transferred to different plants based on its requirement.

The following is an interpreted BFD of the Brine House/Chlor-Alkali Plant:

Figure: Overall BFD of the Brine House/Chlor-Alkali Plant.

 Brine Purification:
o I.1.Primary Purification of Brine: The first step of purification partakes in the
removal and monitoring of in-appropriate components such as Barium Carbonate
(BaCO3), Sodium Carbonate (Na2CO3), Caustic Soda (NaOH) from the saturated
brine solution.
The saturated brine solution comprising of BaCO3 and Na2CO3 is first sent to the
‘Barium Tank’ via a pump, where the NaOH rate is controlled by the pH in the tank.
Following conditions are to be maintained in the tank:
Dissolved (calcium) Ca: Less than 10mg/L
Dissolved (sulfate) SO4: Less than 2g/L
pH: 10-11
The brine-slurry mixture is sent to reactor and agitator, wherefrom raw brine
containing Ca, Mg (magnesium), multi-cation and sulfate ions, is sent to the
Retention Tank. The remaining is flocculant.

16
 The flocculant in the flocculant tank is a 500ppm solution and is sent to the brine
clarifier unit where, slurry at the bottom is sent to reactor via a pump. The slurry is
kept at 80-120g/L concentration (monitored) and sent to brine slurry tank via a timer
valve.
The now clarified brine is sent to the secondary brine purification unit.
Reactions involved in chemical dosing:
CaCl2 + Na2CO3 → CaCO3 + 2NaCl
CaSO4 + BaCO3 → Ba(SO4) + 2CaCO3

o I.2. Secondary Purification of Brine: The secondary brine purification consists of

anthracite filters, brine filters and Ion-Exchange Membranes. Before the brine
solution can be sent to the Ion-Exchange Resin unit it has to meet the following
criteria which will be attained in the secondary purification step:

NaCl →305 ± 5 g / L
Temperature →≈. 60 ℃
pH → 10.5−11
++¿→ max 10 ppm¿
Ca
++¿→ max 1 ppm¿
Mg
Na2 SO 4 as sulfate →max 7.5 g /L
NaCl O3 → max 10 g/ L
Iodine → max 0.1 ppm
Strontium → max 0.1 ppm
Barium→ max 0.1 ppm
Iron →max 0.1 ppm
Aluminium →max 0.1 ppm
Silica → max 5 ppm
Free C12 →−¿
Suspended Solids (S . S)→max 10 ppm

o Anthracite Filter: First the brine passes through the Anthracite Filter which filters
the S.S with anthracite. The anthracite filters are installed in parallel and operated
together. The pressure drop in the anthracite filter increases due to the trapped
material inside and is then backwashed with anthracite brine.

17
o Brine Filter: There are three brine filter present. Two of the filters are ‘on-line’ and
work simultaneously in parallel and the third is ‘off-lined’ for backwashing and
standby. The Two ‘on-line’ filters are pre-coated with α-Cellulose (aqueous slurry).
The anthracite brine alongside the α-Cellulose is mixed in the Body Feed Tank
wherefrom, the slurry is then sent to the brine filter where the S.S are trapped on the
α-Cellulose, and then sent to Filtrated Brine Tank.
When filtrate’s’ pressure difference becomes greater than 2 kg/cm 2 or when the
designated time has passed, the filter is switched to stand-by brine filter & then off-
lined filter is backwashed with filtrated brine with the use of pumps and compressed
air.

o Ion-Exchange Resin (I-E) Unit: The filtrated brine is sent into the Ion-Exchange
Resin (I-E) Unit. The I-E Unit is comprised of three I-E units, two connected ‘on-
line’ in series and one is ‘off-lined’ for the regeneration process.
After every 24-hours, The Primary Column is cut-off for resin regeneration, the
Secondary Column is switched as Primary, and the Stand-by Column is ‘on-lined’ as
the Secondary Column.
The resins in the (now) ‘off-lined’ column, mainly comprised of multivalent cations,
are regenerated with Hydrochloric Acid (HCl) and Caustic Soda (NaOH), at every
24-hour cycle.
At the outlet line of each I-E Column, sampling line to an ‘on-line’ analyser is
connected for monitoring the calcium (less than 20 ppb) and magnesium (less the
20 ppb) content in the brine.
The I-E Resin used is similar to a Cation Exchange Resin here, Na + ions are replaced
by metal ions (divalent cation) in brine.
The small resin particles cause pressure drop across the I-E bed which, must be
periodically backwashed with De-Mineralised Water (D.M Water) before
regeneration, and this is done automatically.

The Regeneration Process (using HCl and NaOH):

i. Wash with D.M Water.

ii. Backwash with D.M Water.
iii. Use of HCl for regeneration.
iv. Wash with D.M Water.
v. Use of NaOH for regeneration.
vi. Wash with D.M Water.
vii. Replacement of water with brine.

18
The resin used is a chelating resin of the ‘Styrene-Divinyl benzene copolymer with
amino phosphoric acid group’ and the has the chemical structure
RCH2NHCH2PO3Na2 :

Figure: The resin used in Ion-Exchange Resin Unit.

The following reaction takes place to form the resin chelate:

2 RCH2NHCH2PO3Na2 + Ca++ → -(RCH2NHCH2PO3)2CaNa2 + 2Na+

Figure: The Resin Chelate formed.

The Resin Chelate then reacts:

(RCH2NHCH2PO3)2CaNa2 + 4HCl → 2RCH2NHCH2PO3H2 + CaCl2 + 2NaCl

The regeneration of resin by NaOH:

RCH2NHCH2PO3H2 + 2NaOH →RCH2NHCH2PO3Na2 + 2H2O

19
SECTION II. CELL HOUSE UNIT

Figure: The Electrolysis Unit.

 Electrolysis: The electrolysis process mainly has two electrolysers along with their
associated equipment.
Each electrolyser has the following components:
 1 Hydraulic press unit.
 184 Bipolar Cells.
 2 Anode & 2 Cathode Terminal Cells.
 2 Inlet & 2 Outlet subheader for supplying & collecting
anolyte & catholyte products.
 186 Sheets of I-E membrane are set in one electrolyser by
pressing them between cells together with cell gaskets.
 186 x 4 Flexible hoses for connecting each cell with
subheader.

Figure: Schematic of the Electrolyser.

20
If electrolyser is shut down for more than 8 hours then, both, anolyte and catholyte must be
drained from the electrolyser.

o Each Bipolar Cell is separated into two compartments by a partition wall:

Electrolyser

Anolyte Catholyte
Compartment Compartment

o The PFD consisting of three sections an Anolyte Circulation section, a Catholyte

Circulation section and an Electrolysis section:

Figure: PFD of electrolysis section.

o Anolyte Compartment: Purified brine (flow rate is cascade-controlled by a DC

electric current) is sent to the anolyte inlet subheader of each electrolyser through
brine head tank via a pump; and then sent to each anolyte compartment through
hoses that are connect subheader with all anolyte compartments.
During the electrolysis process, OH- ions move from catholyte to anolyte. HCl is
continuously supplied to neutralize migrated OH- anion. The flowrate of HCl is
continuously monitored and the pump for HCl is shut off as soon as DC electrolyser
is shut off.
When pure brine is electrolysed Cl2 gas is generated as the concentration of NaCl
decreases (depleted brine); the mixture discharges through the base and into the
outlet subheader whereon it is separated into gas and depleted brine.

21
 Cl2 gas is fed to main Chlorine Gas Header and fed to Chlorine Gas Treatment
section.
Depleted brine is fed to the tank and introduced to main header to protect Titanium
piping from corrosion. A small amount of the depleted brine is fed to the analyser
through cooler.

 Concentration of Anolyte: Using Ion-exchange membrane during

electrolysis the transport number of Na+ (sodium) ions in the membrane is
much greater than compared to that in anolyte; therefore, the Na +
concentration on and near the surface of the membrane is lower than that in
the bulk anolyte. Thus, the necessary amount of Na+ ions must be supplied
by diffusion.
When the anolyte concentration drops, the Na+ ions concentration on and
near the surface membrane becomes negligible; and if it becomes too low
(below critical level), the operating voltage increases significantly, the
purity of chlorine decreases, and this will in-turn cause blisters to generate
on the membrane due to the electrolysis of water itself.
Also, if the anolyte concentration increases too much, the operating voltage
also increases significantly and causes membrane shrinkage. Thus, it is
necessary to keep the anolyte concentration within the specified range.

o Catholyte Compartment: Catholyte (flow rate is cascade-controlled by a DC electric

current) is fed to subheader of each electrolyser through the caustic soda head tank,
and into the catholyte compartment through inlet hoses. For some specific
concentration, demineralised water (flow rate is cascade-controlled by a DC electric
current) is also fed at inlet.
A cooler is also installed in between to cool the catholyte.
During electrolysis, a mixture of H2 gas along with NaOH (Caustic Soda) is
produced.
H2 gas is fed to Hydrogen Gas Header and then to Hydrogen Gas Treatment section.
The pressure of H2 gas is controlled by Cl2 gas pressure controller to keep the same
pressure difference between H2 gas and Cl2 gas.
The excess caustic soda is sent to the next section of 32% concentration product
under level control.
Most of the catholyte from electrolyser is recycled back to catholyte compartment.

22
  Concentration of Catholyte: If the concentration of catholyte goes over 34%
the operating cell voltage increase significantly.
The membrane’s efficiency is optimum at 32%.

o Cl2 gas is purged to the Chlorine Gas Absorber and H2 gas is purged to Vent Stack
by N2 (Nitrogen) gas.

Use
Demineralised
Electrolyser to water in Anolyte
be washed Use dilute
NaOH in
Electrolytes Catholyte
after draining
Using Purified
Brine in Anolyte
To restart
after washing
Using NaOH in
catholyte

o Effect of Temperature on electrolyser: As temperature increases the electrical

resistance of electrolyte and membrane. The lowest optimal cell voltage occurs at
approximately 90ºC, hence the catholyte has to be cooled by a cooler.

o Effect of Pressure on electrolyser: As operating pressure increases in electrolyser,

the gas volume decreases in the electrolyte and the cell.

o Control Range: Acidity in return brine range: 0.001 – 0.005 N. If the acidity at inlet
exceeds 0.15 N then, auxiliary anodes on anolyte inlet nozzles are damaged and
distressed also; water blisters are generated within the membrane due to protonation
of membrane.

o Membrane Leakage Test: Before the electrolyser can be start up, it needs to be
checked for potential leakages because:
 If Cl2 or H2 gas concentrations are in excess; H2 gas can cause explosions in
electrolyser.
 Anode can be damaged due to NaOH passing through membrane pinholes
into anode which could be due to excess anode coating and anode substrate
corrosion or, mechanical damage due to corrosion or, short service life.

23
  Cathode can be damage by Cl2 gas passing through membrane pinholes into
cathode which could be due to cathode corrosion/ coating damage or, short
life of cathode.
 If NaOH concentration is high (if off-spec).
 Cell gasket corrosion due to Hypochlorite attack which can cause electrolyte
to leak.

o Safety Measures:
i. The rectifiers shutdown automatically when there’s:
 Abnormal electrolysis voltage distribution of electrolyser.
 Different gas pressure of electrolyser.
 DC high current of electrolyser in rectifier.
 Low flow rate of brine or caustic soda.
 Opening of purified brine valve.
ii. Each electrolyser shuts down when:
 HCl feed is shut.
 Brine feed valve is switched to purified brine valve.
iii. All electrolysers shut down when:
 Both chlorine and hydrogen gas compressors are shut down.
 Depleted brine feed valve to purified brine main header is
closed.
 Demineralised water to catholyte main header is closed.
 N2 gas purge valve to caustic soda tank is opened.
iv. Equipments such as the hydraulic oil pumps for electrolyser pressure;
pumps for the purified brine, depleted brine, caustic soda,
dechlorination tower and more; the DCS (distributive controller
systems), and various other equipments, are connected to emergency
power.

24
SECTION III. Hydrogen Gas Treatment Plant: The H2 gas treatment plant consists of two
sections: Hydrogen Gas Washing & Cooling Section and Hydrogen Gas Compression Section.

Figure: Interpreted BFD of Hydrogen Gas treatment section.

Treatment of H2 gas is necessary as, H2 gas is a light, well diffusive, well penetrable and highly
inflammable gas. It is an easy to explode gas when it comes into contact with Oxygen (O 2). A
[H2:O2:::1:2] mixture ratio is termed as ‘detonation gas’ and has the property of violent detonation. H 2
gas is also a reducing substance and reacts with metal-oxides, unsaturated hydrocarbons and halogens
easily hence, it is also important to use proper piping and vessels.

H2 gas from the electrolyser section contains saturated water vapours and a little amount of caustic
soda (NaOH) as entrainment and is hence sent to the Hydrogen Gas Scrubber Column.

The Hydrogen Gas Scrubber Column (packing column type) washes and cools the H2 gas by
condensed water that is itself cooled by the Scrubber Cooler to approximately 44ºC which, causes the
impurities to be removed.

The H2 gas from the scrubber column is then sent to the Hydrogen Demister Column where H 2 gas
and mist are thus separated. The obtained H2 gas is then sent to the Hydrochloric Acid (HCl)
Synthesis Plant under normal conditions.

In case of startup or emergency shutdown, H2 gas is led to Hydrogen Seal Pot which, is a safety
device to avoid excess pressure and firing and, the automatic block valve is thus closed, if not then it
is sent to vent line to the atmosphere.

25
SECTION IV. Dechlorination: The depleted brine from electrolysis section is saturated with
chlorine (Cl2), about 700-800 mg/L of Cl2 is contained and needs to be removed as it causes air
pollution in brine, increases unit consumption of sulfate used for dichlorination and the α-cellulose
brine filters in I-E unit are damaged.

The following reaction takes place:

−¿ ¿
+¿+Cl ¿
Cl 2+ H 2 O ↔ HClO + H
−¿ ¿
+¿+ClO ¿
HClO ↔ H

Depleted brine from the Electrolysis unit has its pH adjusted to 1.5-1.8 by HCl where Cl 2 gas is
stripped and then sent to the top of Dechlorination Tower where the brine flows down.

Dechlorination Tower is operated under vacuum with Dechlorination Tower Ejector to strip Cl 2 gas.
Water entrainment in Cl2 gas is condensed and trapped by Chlorination Tower Cooler. The remaining
uncondensed Cl2 gas is then sent to Chlorine Gas Absorber through the ejector.

After dechlorination, the pH is adjusted to 9-10 by NaOH and Na2SO3 and then sent to salt saturator
along with process water for chemical dechlorination. The following reaction takes place:

Na2 S O3 + NaClO → Na2 S O4 + NaCl

 Key principles:
 Target Control level of impurity:
Mg: Less than 1 mg/L
Ca: Less than 10 mg/L
SO4: Less than 7.5 g/L
pH: 10-11
 Reactions Involved:
MgCl2 + 2NaOH → Mg(OH)2 + 2NaCl
CaCl2 + Na2CO3 → CaCO3 + 2NaCl
CaSO4 + BaCO3 → Ba(SO4) + 2CaCO3

26
SECTION V. Chlorine Gas Treatment Plant: The chlorine gas treatment comprises of two
sections: Cooling Section and Chlorine Gas Drying Section.

Figure: BFD of the Chlorine Gas treatment section.

The Cl2 gas from electrolyser contains saturated water vapours and a small amount of brine as
entrainment and is sent to Chlorine Gas Washing Tower (packing column type; direct contact with
counter current flow with chilled water) where Cl2 gas along with some brine and impurities are
cooled to approximately 22-23ºC. The brine and impurities are thus removed to condensed water.

The Cl2 gas from washing tower is sent to Chlorine Gas Cooling Tower (shell and tube type) to be
further cooled to nearly 9-10ºC by chilling using freon gas and separated with chlorinated water and
then sent to Drying Tower.

Cooling of the gas is important because it is observed that as the temperature decreases the moisture
content decreases, hence decreasing the amount of acid required in the drying tower.

 The cooling water required for the cooling of the chlorine gas (from the brine house unit) is
cooled using three VAMs (Vapor Absorber Machine).
o The VAM operates on the Vapor Absorption Cycle concept using a mix of 63%
Lithium-Bromide (LiBr) solution to chill the cooling water that is to be used, due to
its high water affinity.
o The cooling water enters into the system at 12 oC. Under near-vacuum conditions of
a pressure of 6 mm of Hg, the refrigerant (here, chilled DM water) reaches its
boiling point at approximately 4 oC and hence it acts as a “heat source” for chilling
the cooling water from 12 oC to 8 oC.
o The chilled vapours evaporating from this heat transfer procedure are thus absorbed
by the 63% LiBr solution diluting it to 55% LiBr solution.

27
 Figure: Vapor Absorption Cycle.
 The working mechanism of the VAM:
o Heat Exchange and Pumping: Lithium Bromide (LiBr) from the absorber is pumped
through a heat exchanger to the generator, forming a reservoir.
o Heating in Generator: Hot steam heats the LiBr-water mixture in the generator, causing
water to boil and form vapor, which is then collected in the condenser.
o LiBr Circulation: Concentrated LiBr particles return through the heat exchanger,
transferring heat to the weak solution line, then cooling down and being sprayed back into
the absorber.
o Condensation: Water vapor in the condenser contacts cooling pipes (cooled by water from
a cooling tower), condensing into liquid water.
o Evaporation and Cooling: Condensed water flows into the evaporator, where low pressure
(6 mm Hg) causes it to flash evaporate, cooling to around 4°C.
o Chilled Water Loop: Chilled water (entering at 12°C) circulates in the evaporator,
transferring heat to the thin film of water on pipe surfaces, which evaporates and removes
heat, cooling the water to 8°C.
o Heat Collection: The chilled water, now cooled to 8°C, is pumped around to collect heat
from the process (chlorine gas cooling) and returns to the absorber to restart the cycle.
o Evaporation Loop: Water that doesn't evaporate initially is recirculated and sprayed again
until it fully evaporates.
o Water Collection and Absorption: Evaporated water cools and collects in the evaporator
chamber, where it is absorbed by the strong LiBr solution.
o Vacuum Creation: The strong attraction between water and LiBr creates the vacuum in
the chamber.

28
 o Heat Removal: The cooling tower water loop removes the heat generated by the
absorption process and from the chilled water loop.
o Condensation of Residuals: Cooling tower water condenses any remaining water vapor or
LiBr particles back into liquid.
o LiBr-Water Mixture: The LiBr-water mixture collects at the bottom of the absorber and is
pumped back to the generator, completing the cycle.

 Key Points:
o LiBr solution circulates through generator, absorber, and heat exchangers.
o Heat from steam drives the boiling and condensation cycle.
o Low pressure in the evaporator enables effective cooling.
o Chilled water loop facilitates heat transfer without mixing with process water.
o Recirculation: Ensures all water is evaporated.
o Strong LiBr Absorption: Drives vacuum creation.
o Cooling Tower Loop: Removes excess heat and condenses residuals.
o Continuous Cycle: LiBr-water mixture is recycled back to the generator.

 The Refrigeration cycle of freon gas:

The drying tower is a packed column tower comprised of ‘telleretts rings’ as packing material and
uses sulfuric acid for drying.

 The need to dry Chlorine gas (free from moisture) arises from the fact that moist Cl 2 gas when
cooled down to low temperatures (8-10 oC) may form chlorite (ClO2-)(crystalline solid) which
can cause the choking in the pipelines hence, greatly increasing operational and maintenance
cost.

In the Drying Tower, Cl2 gas is dried using 98% concentration Sulfuric Acid (H2SO4) {optimum
concentration of 70%} in liquid form. The dried Cl2 gas is sent to Chlorine Gas Compression System

29
and then to the Mist Separator where, H2SO4 returns to Chlorine Gas Compression System; the Cl2 gas
is sent to the Chlorine Gas Liquefier.

 Treatment of discharged H2SO4: The used H2SO4 is sent to vacuum tower to strip Cl2 gas in
the H2SO4 acid. Stripped Cl2 gas is sent to Chlorine Absorber through the top of the Sulfuric
Acid Aeration Tower.

Since, Chlorine gas is being produced in excess during the production of Caustic Soda and also since
Chlorine gas cannot be vented out into the atmosphere, it needs to be put to use. Chlorine has multiple
uses and thus it is used for production of HCl, sent the Fenesta Plant adjacent to the Chlor-Alkali
Plant for the production of PVC and various such products, compressed to bottle into drums and lastly
for the production of Standard Bleaching Powder (SBP) in the SBP Plant as a part of the Chlorine
Plant.

30
SECTION VI. FLAKER PLANT

Introduction: The caustic soda produced from the cell house is at 32% wt. and needs to be
concentrated for the end user/ buyer. This is achieved through the various operations in the flaker
plant by the use of heat exchangers, burners, evaporators and various equipments associated with
them.

The end user/ buyer of the final product is Bertmans Chemical Plant LTD. and therefore the plant
design is optimized to their need at 200 MTPD Caustic Soda evaporation/ 200 MTPD Concentration.

Figure: BFD of the Flaker Plant.

31
Figure: (Interpreted) Overall PFD of the Flaker Plant.

32
 Design Basis of the Flaker Plant:

 General Description:
o The plant is designed and implemented with the most advanced of technology.
o The plant is suitable to produce exports of caustic soda flakes or liquid NaOH
solution of 48% from a 31% NaOH Solution generated in Ion Exchange Membrane
cells.
o The plant is optimised for low energy consumption, and the design is proven and
also safe in operation.

 Evaporation Unit:
o First Stage: Falling film evaporator using the vapours of the second stage film
evaporator, while the first stage evaporator is working under vacuum.
o Second Stage: Falling film evaporator heated by live steam of medium pressure.
o Collecting Tanks for condensator.
o Surface condenser for the vapour.

 Concentration Unit:
o Heat Transfer Salt (Molten Salt/ HT Salt) is heated in a falling film concentrator,
consisting of individual concentrator elements of special design operating at
atmospheric pressure.
o High efficiency Heat Transfer Salt (HT Salt) system is heated by the combustion of
H2 and/or Fuel Oil.
o Distributing Device.
o Special design flaking machines to process highly concentrated caustic soda melt
into flakes at low temperatures.
o Semi-automatic bagging scale to fill hygroscopic (moisture absorbing) NaOH flakes
into open type bags.
o Instrumentation and control systems are designed to operate the process plant
automatically.

33
 Mode A (Evaporation Mode B (Concentration Mode C (Evaporation,
Technical Data Only) and Flaking) Concentration & Flaking)
Binding Evaporation Unit (31-48%):
Technical Data Concentration & Flaking 100 MTPD;
(For NaOH Evaporation Unit (31- Unit (31-98.5%): 200 Concentration Unit (48-
100%) Production Capacity 48%): 200 MTPD MTPD 98.5%): 100 MTPD
Operating Recommended
Flexibility (for Minimum Operating 100 - 130 MTPD (Lye);
NaOH 100%) Capacity 80 - 200 MTPD 140 - 200 MTPD 70 - 100 MTPD (Flakes)
Consumption Evaporation: 550 Concentration/Flaking:
Figures MTPD 200 MTPD -
Cooling Water
(35 – 43 oC) 51 m3/T 112 m3/T -
Electricity
(independent of Approximately 3.6 - approximately 34.8 - 36
plant capacity) 4.2 kWh/T kWh/T -
If Continuous (process):
Steam 1050 kg/T;
(11 bar(g) | If Discontinuous
saturated) 735 kg/T (tracing): 48-60 kg/T -
Heating Energy (H2) - 55600 kCal/T [220 m3/T] -
Sugar - 0.1 - 0.2 kg/T -

 Operating Modes: The plant has three modes of operation to either perform Evaporation only
(Mode A) or, Concentration & Flaking (Mode B) or, Evaporation-Concentration & Flaking
(Mode C):

Table: Mode respective technical data analysis of the flaker plant.

34
  Stream Specifications:

Stream Name/Type Feed Solution Product Solution Flakes

Exit Membrane cell At the outlet of Caustic
Source At Bagging scale (as is basis)
electrolyser Soda cooler

Composition (filtered,
Basis Composition Composition 98.5% total solids
quality: 10 µm)
NaOH 31% wt. 48% wt. 98.2% wt. nom.
NaCl 60 ppm wt. max 93 ppm wt. max 112.5 ppm wt. nom.
NaClO3 19 ppm wt. max 30 ppm wt. max -
Na2CO3 400 ppm wt. - 2252 ppm wt. nom.
Na2SO4 - 0.047% wt. -
Fe 0.5 ppm wt. max - 3 ppm wt. nom.
Ni - - 4 ppm wt. nom.
o o o
Temperature 80 C 50 C max 60 C max (at bagging scale)
Pressure at entrance 4 bar(g) at 4 bar(g) at
-
battery limit level 0 m level 0 m
Bulk Density - - 0.7 – 0.9 ton/m3
Thickness - - 0.8 – 1.2 mm

Table: Specifications of the important streams/product(s).

 Specifications of Utilities for Concentration Unit:

(i) Sugar: Food grade quality, white, granulated and sulphur free.
(ii) Heat Transfer Salt: An eutectic mixture of 53% wt Potassium Nitrate (KNO 3), 40%
wt Sodium Nitrite (NaNO2) and, 7% wt Sodium Nitrate (NaNO3).
 Behaviour:
 Under normal conditions, can be used for several years.
 Oxidation of NaNO2 to NaNO3 occurs in presence of atmospheric
oxygen causing successive rise of point of crystallisation. This can be
prevented by blanketing the salt tank with Nitrogen (N2).
 In case HT Salt is overheated for a longer period of time (faulty
operation), the component NaNO2 may thermally decompose to
Na2O, O2 and N2.
 Advantages:

35
  Has excellent heat transfer properties.
 Pressure-less operation for up to 500 oC.
 Non-corrosive in nature.
 Disadvantages:
 Has high crystallisation point. To avert this, system can be pre-heated
efficiently.

(iii) Dual Fuel Burner:

100% H2

Fuel To be Used

Pre-defined Mixture of LDO + H2

(iv) Semi-Automatic Bagging Scales: Produced flakes are fed by gravity through vertical
flake chute to the feeding vibrating conveyor of semi-automatic bagging sack
controlled by mechanical weighing system filling into 25-50 kg open bags.
o Scrubbing System of Bagging Scale:
 To keep operating area free of NaOH dust, NaOH dust is
sucked off at the bagging port. The dust particles are led
through an electric suck off tube to a washing system
consisting of a process water filled scrubber and exhaust air
fan.
 Due to under pressure in scrubbing system, contaminated air
with NaOH dust is sucked through the liquid level in the dust
scrubber which dissolves the dust in the water, hence
purifying the air.
 To avert high NaOH concentration in liquid of scrubber, a
partial flow of process water is constantly fed to the
scrubber. The surplus quantity flows via overflow into the
wastewater system. Purified air leaves scrubber via exhaust
air fan into the atmosphere.

36
(v) Types of steam systems used:
o Medium Press Steam System: from battery limit and is used during
start up period to start heat transfer salt circulation as well as
continuous heating of:
 Tracing molten salt valves stuffing boxes.
 Heating the salt tank during start up.
 Tracing the molten salt piping system during startup.
 Tracing the concentration elements of the falling film
concentrator (evaporator) during start up.
o Low Pressure Steam System: from battery limit and used for:
 Blanketing of nickel (Ni) made concentrator equipment
during shutdown period.
 Blanketing of distribution device during shutdown period.
 Cleaning/Flushing pipes and equipment.

37
 Summary:

During my summer industrial training at the Chlor-Alkali Plant at DCM Shriram Industries
Limited, Kota, Rajasthan, I gained valuable insights into the production of Caustic Soda using the
industry-leading Asahi Kasei Membrane technology. The plant boasts an impressive production
rate of 545-550 tons per day. Throughout the training, we were introduced to various chemical
engineering operations, including heat transfer, mass transfer, process control, mechanical and
chemical filtration methods, safety protocols, gas absorption, drying and cooling, refrigeration
cycles, and scrubbing.

We explored different types of equipment used in the plant, such as reactors, agitators, and
clarifiers in the brine house unit, along with anthracite filters, brine filters, and the Asahi Kasei
Ion Exchange Membrane column for secondary filtration. In the electrolysis-cell house unit, we
observed multiple electrolyser units and associated equipment like level gauges and transformers.
The chlorine gas treatment section included dechlorination towers, vacuum towers, cooling
towers, and chilling towers. Additionally, we learned about pre-heaters, burners, condensers, and
conveyor belts in the flaker plant.

Commonly used equipment throughout the plant included various types of pipes, pumps, valves
(timer valves, pneumatic valves), compressors, level gauges (pressure and temperature gauges),
and sampling points for quality control. The plant's operations were managed by both on-site
workers and control room operators using advanced Distributed Control Systems (DCS) in each
plant unit, with the main DCS located in the Cell House unit.

 Conclusion:

My summer industrial training at the Chlor-Alkali Plant at DCM Shriram Industries Limited was
an enriching experience that provided me with comprehensive knowledge of the plant's operations
and the chemical engineering principles involved. The exposure to cutting-edge technologies and
various industrial processes has significantly enhanced my understanding of the Chlor-Alkali
industry. I am grateful to DCM Shriram for this opportunity, which has equipped me with
practical skills and insights that will be invaluable in my future career.

38
39
 Annotations

 CAG: Chlor Alkali Group

 ∑: Sigma
 Ti: Titanium
 Ni: Nickel
 Cl2: Chlorine
 H2: Hydrogen
 Na: Sodium
 HCl: Hydrochloric Acid
 H2O: Water
 NaCl: Sodium Chloride/ Salt/ Brine
 NaOH: Sodium Hydroxide/ Caustic Soda
 N2: Nitrogen
 Mg: Magnesium
 Na2CO3: Sodium Carbonate/ Soda Ash
 BaCO3: Barium Carbonate
 MgCl2: Magnesium Chloride
 CaCl2: Calcium Chloride
 Na2SO4: Sodium Sulphate
 Mg(OH)2: Magnesium Hydroxide
 CaSO4: Calcium Sulphate
 NaClO3: Sodium Chlorate
 BaSO4: Barium Sulphate
 S.S.: Suspended Solids
 I-E: Ion Exchange
 ppm: parts per million
 ppb: parts per billion
 DM Water: Demineralised Water
 PFD: Process Flow Diagram
 BFD: Block Flow Diagram
 VAM: Vapor Absorption Machine
 SBP: Standard Bleaching Powder
 HT Salt: Heat Transfer Salt

40
 Safety Measures:
Safety is a major concern at the DCM Shriram CAG Plant and many steps for the steps are actively
put in place to keep both, the work environment and the environment as a whole safe and as much
pollution free as possible.
Key safety measures include:
 Workplace Safety:
o Mandatory application of safety boots
o Mandatory application of safety glasses.
o Mandatory application of colour coded safety helmets for different departments and
designations.
o Mandatory use of PPE kits wherever and whenever necessary.
o Use of safety videos and safety training for people new to the facility.
o Use of safety interlocks: If a system fails, it will automatically and safely shut down
to stop further processing hence, stopping any further harm to both life and property.

 Environmental Safety:
o The entire facility is covered by trees and green vegetation to help in offsetting the
plant’s carbon footprint.
o The DCM Shriram CAG plant also emphasises on the treatment of the gaseous side
products such as Cl2 and H2 gas to further control environmental pollution.
o The facility also employs a waste water treatment plant to recycle and reuse industrial
water.

41
 References

 The Asahi Kasei/ Chlor-Alkali manual provided at the DCM Shriram Industries Ltd., Kota’s
CAG DCS.
 Donald R. Coughanowr, Steven E LeBlanc, “Process System Analysis and Control”, McGraw
Hill education, 3rd Edition.
 Don W. Green, Marylee Z. Southard, “Perry’s Chemical Engineer’s Handbook”, McGraw
Hill education, 9th Edition.
 Asahi Kasei Membrane Process Chlor-Alkali Electrolysis, Membrane Process Chlor-Alkali
Electrolysis | Asahi Kasei Corporation (asahi-kasei.co.jp)
 Heating value of hydrogen » SFC Energy AG
 How to Liquefy Hydrogen | Sciencing
 Absorption Chiller, How it works - The Engineering Mindset

42