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Presentation on Flaking Plant Siel Chemical Complex Issues Related Problems

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Presentation on Flaking Plant Siel Chemical Complex Issues Related Problems

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    1. Presentation on Flaking Plant (Siel Chemical Complex) Issues & Related Problems

    3. Siel Chemical Complex, Rajpura, (A unit of Siel Limited. ) One of the oldest business house of India (Formerly DCM Chemical Works) Turn over Rs. 200 Crore of the unit Integrated Chemical complex, manufacturing wide range of chemicals State- of – the - art technology to produce Caustic soda, Bleaching powder and Chlorine Unparalleled standard of commitment to quality and customer satisfaction Presence in international markets

    4. Products Manufactured

    5. Caustic Soda Lye 82500 TPA Caustic Soda Flakes 33000 TPA Chlorine 73095 TPA Hydrogen 2062 TPA HCl 66000 TPA Sodium Hypochlorite 23100 TPA Stable Bleaching Powder 18000 TPA Production Capacity of Siel Chemical Complex

    7. Flakes Production Year 2008 Jan’08 2141 Feb’08 949 Mar’08 1079 Apr’08 672 May’08 394 Jun’08 706 Jul’08 594 Aug’08 - Sep’08 526 Oct’08 953 Nov’08 156 Dec’08 1189

    9. PROCESS DESCRIPTION OF 100 TPD FLAKING PLANT Bertrams makeBertrams make

    12. The 33% cell liquor is produced in Inos chloro make monopolar membrane continuous process. The concentration of 33% cell liquor is increased to 47.5% by vacuum evaporation method. This 47.5% concentrated caustic soda acts as input raw material for flaking plant.

    13. The concentration of 47.5% caustic soda lye is increased to 99% by falling film evaporation method. The hot 99% liquid caustic is converted to solid flakes by cooling & forming a layer over the rolling flaker drum & subsequent cutting the layer to form flakes by sharp edged blade.

    14. PROCESS DESCRIPTION OF 100TPD FLAKING PLANT The evaporation of water from 47.5% lye to convert it in to 99% takes place in two stages ie at Pre-concentrator & at Final concentrator. The working of Pre-concentrator & Final concentrator is explained as given below.

    15. The concentration of 47.5% lye is increased to 61% in this unit. The unit is kept under vacuum (680mmof Hg). 47.5% lye enters the unit from the top & the hot vapours (from Final concentrator) from the bottom, due to counter current flow heat is exchanged which removes the moisture there by increasing the concentration from 47.5% to 61%.

    17. Sugar Solution In order to prevent corrosion of the Nickel equipment, a 5% sugar solution is daily produced in sugar dissolving tank & fed continuously to the 61% caustic soda flow by means of dosing pump.

    18. Heat Transfer Salt System The high temperature heat transfer salt system consists of a salt heater with a combustion air pre-heater, to heat the molten salt (Eutectic mixture of 53% KNO3, 40% NaNO2 & 7% NaNO3) which is circulated through the system by a salt pump mounted on salt tank.

    20. Final Concentrator 61% caustic from Pre-concentrator enters the final concentrator tube (8 in number) from the top. The caustic is then made to flow uniformly through out the surface of the tube by the help of propeller. The heat carrying salt at 400*C enters from the bottom of this tubes in the shell side & due to counter flow the heat of salt takes away

    21. Final Concentrator The water from 61% caustic & the concentration increases to 99%.The hot water vapor thus liberated in this unit is sent to Pre-concentrator as mentioned above.

    23. Major Problem Faced

    24. Flaker Drum Leakage The flaker drum leakage is chronic problem. The leakage is normally arrested by means of welding, but the crack developed does not get rectified completely. The water seeping through this leaky part causes formation of lump of caustic, which further causes chocking of hopper.

    25. Frequent Damage of Blade It has been observed that the blade gets deformed after approximate production 500-600T.

    26. Oil & Air Ratio The performance of Eurotherm Controller for setting oil & air ratio is not satisfactory .

    27. SPM Level The SPM level runs on higher side showing improper burning of fuel. Atomization is done with steam but still the burning found not up to the mark.

    28. Melting Point Of Salt The Melting point of salt increases despite nitrogen blanket being maintained at a pressure of 3.5 kg / cm2.

    29. Final Concentrator Tubes It has been observed that the average life of Final concentrator tube is 4to5 years. It has been observed that the average life of Final concentrator tube is 4to5 years.

    30. THANK YOU

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