Detailed Project Report on bromine recovery plant

BROMINE RECOVERY PLANT

[code no.4209]  

It is a deep red fuming liquid, member of the halogen elements as Group VII of the periodic table that is liquid at ordinary temperature and pressure. A rare element bromine is found in, nature dispersed throughout the earth crust only in compounds such as soluble and insoluble bromides. The chief commercial source of bromine is ocean water from which the element is extracted by means of chemical replacement (oxidation) by more active chlorine. Bromine has traditionally been manufactured as a byproduct from saline mother liquors (bitterns) left after the crystallization of the main salt products.

The properties of bromine are significantly different from those of fluorine and chlorine. Discovered in the early 19th century, in the form of its salts (bromides) in the bitterns remaining after evaporating sea water and extracting the sodium chloride, it was obtained latter from stassfurt, Germany, as a byproduct in the production of potassium salts and from other deposits and salt lakes.

Its main use was originally for bromides in medicine still a minor use. Bromine first because of industrial  importance with the development of modern photographic process, in which the light sensitive material is an emulsion of minute particles of silver bromide (together with silver chloride or iodide or both) in gelatin.

For a time, the expanding world automobile industry. Threatened a scarcity of bromine, obtained from brines, which contained about 0.5% bromine. To meet the demand, it was necessary to turn to sea water which contains about 70 ppm bromine.

The chief sources of bromine are sea water, brines and betters and the natural deposits of potassium salts. In these, it is present in very small quantities in the combined state. Sea-water contains, 66 parts per million (0.0066 %) of bromine and in 1933, the DOW Chemical Co., (U.S.A.) developed a process for its recovery. Large quantities of bromine are now being produced both from the sea and from the salt & lakes. The U.S.A. is now the world largest producer and used the entire output for the manufacture of ethylene bromine.

The other prominent bromine producing countries are Germany and France.

Bromine, a heavy, mobile, reddish-brown liquid with an interesting irritating odour, is the only non-metallic element that is a liquid at normal temperature. It is a diatomic molecule with the chemical formula.

The bromine available for extraction occurs as bromide in the ocean, in salt lakes and in brine or saline deposits left by evaporation of such waters by solar heat. Sea bitterns, the left over concentrated solution after the crystallizing out of salt from the sea water, are very rich in bromine and offer a good raw material for the manufacture of bromine. Bromine is extracted from seawater.

USES, SOURCE AND SAFETY OF BROMINE

Use of Bromine

Bromine is widely used in the chemical and pharmaceutical industries. Major applications are brominated organic components used as

• Flame retardants (e.g. polybrominated biphenyls)

• Pesticide (e.g. methyl bromide)

• Reactive intermediates in organic synthesis and pharmaceutical ingredients

Sources of Bromine

Natural sources for bromine are chloride sources such as natural salt stocks and seawater where bromides are accompanying the chlorides.  Industrial sources for bromine recovery are quench waters of waste incinerators (coming from the flame retardants) and effluents of industrial bromination processes.

The reactions to form the a.m. chemicals may generate hydrogen bromide as a by-product:

R-H+Br2 => R-Br+HBr

In this case no more than half of the bromine added ends up in the product, the rest being released as hydrogen bromide gas and as dissolved bromides (often rejected in washing solutions).  Since bromine is an expensive, widely used raw material, recovery is usually a viable option.

Safety First

Bromine is highly corrosive, toxic, and causes serious chemical burns. 3 ppm in the air is considered immediately dangerous to life and health. Therefore, it is vitally important to take the highest safety precautions when working with bromine. 

Accordingly, plants processing bromine have to be made of highly corrosion and diffusion resistant, robust materials. QVF borosilicate glass 3.3 and glass-lined steel are ideal materials for their construction. All measures are taken to avoid any bromine leakage; the equipment fulfills ASME requirements for pressure and tightness of flange connections.  For extra safety measures, the vent systems are equipped with bromine scrubbers.

COST ESTIMATION

Plant Capacity                                   6 MT/Day

Land & Building (8000 sq.mt.)  Rs. 4.04 Cr

Plant & Machinery                               Rs. 3.50 Cr

Working Capital for 1 Month       Rs. 2.59 Cr

Total Capital Investment                    Rs. 10.45 Cr

Rate of Return                                       44%

Break Even Point                                    50%

• INTRODUCTION
  
• USES, SOURCE AND SAFETY OF BROMINE
• USE OF BROMINE
• SOURCES OF BROMINE
• SAFETY FIRST
• ORIGIN OF BROMINE
• PROPERTIES
• USES & APPLICATION
• SOURCES OF BROMINE
• SOURCES OF BROMINE
• MARKET OVERVIEW OF BROMINE
• MAJOR BROMINE MANUFACTURING COUNTRIES
• INCREASING DEMAND FOR FLAME RETARDANTS
• CHINA TO DOMINATE THE ASIA-PACIFIC MARKET
• MAJOR PLAYERS
• RAW MATERIAL SECTION
• MATERIALS OF CONSTRUCTION FOR CHLORINE HANDLING:-
• B.I.S. SPECIFICATIONS
• SCOPE:-
• REQUIREMENTS:-
• TABLE - 1: REQUIREMENTS FOR BROMINE, TECHNICAL
• PACKING & MARKETING:-
• PACKING:-
• MARKING:-
• SAMPLING:-
• ANALYSIS OF BROMINE, TECHNICAL
• DETERMINATION OF BROMINE:-
• PROCEDURE:-
• DETERMINATION OF CHLORINE:-
• PROCEDURE:-
• DETERMINATION OF NON-VOLATILE MATTER:-
• TEST FOR IODINE:-
• ZINC DUST:-
• TEST FOR SULPHATES:-
• PROCEDURE:-
• SAMPLING OF BROMINE, TECHNICAL
• NUMBER OF CONTAINERS TO BE DRAWN FOR SAMPLING
• LOCATION OF THE PLANT
• HEALTH & SAFETY FACTORS
• MANUFACTURING PROCESS OF BROMINE
• BROMINE GENERATION
• BROMINE SEPARATION
• PURIFICAION AND DRYING
• PROCESS FLOW DIAGRAM
• BROMINE RECOVERY PLANT
• BROMINE CAN BE RECOVERED FROM TWO SOURCES
• A) STEAMING OUT PROCESS (HOT PROCESS)
• B) AIR BLOWING PROCESS (COLD PROCESS)
• BROMINE PROCESSES
• PRODUCTION OF BROMINE
• PROCESSING DETAILS OF BROMINE RECOVERY
• PROCESS FLOW DIAGRAM
• INDUSTRIAL PRODUCTION OF BROMINE
• THE BROMINE-GENERATING STEP
• RESIDUAL ORGANIC MATTER FOUND IN DEAD SEA WATER
• SIDE-REACTIONS OCCURRING IN THE REACTION TOWER
• BROMINE SEPARATION STEPS
• 1. CONDENSATION
• 2. SEPARATION
• 3. PURIFICATION
• MANUFACTURE OF LIQUID BROMINE
• PROCESS
• THE FOUR PRINCIPAL STEPS IN BROMINE PRODUCTION ARE
• STEAMING OUT PROCESS:-
• DOW PROCESS:-
• CONSTRUCTION MATERIAL OF BROMINE PLANT
• SAFE HANDLING OF BROMINE LEAKAGE
• SAFE STORAGE OF BROMINE
• STORAGE AND TRANSPORTTATION HAZARDS OF BROMINE
• HAZARDS OF BROMINE
• • A CORROSIVE SUBSTANCE:
• • TOXIC:
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF HEAT EXCHANGER
• SUPPLIERS OF CONDENSER
• SUPPLIERS OF DISTILLATION COLUMN
• SUPPLIERS OF STORAGE VESSEL (STORAGE TANKS)
• SUPPLIERS OF LABORATORY EQUIPMENTS
• SUPPLIERS OF D.G. SETS
• SUPPLIERS OF BOILERS
• SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
• SUPPLIERS OF INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS
• GOVT. LICENSE DETAILS FOR LIQUID BROMINE PLANT

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)