desalination and bromine recovery and salt extraction (1000 kg/day)

DESALINATION AND BROMINE RECOVERY AND SALT EXTRACTION

[EIRI/EDPR/4555] J.C.: 2772XL 

INTRODUCTION

Seawater desalination is a process in which salt and other constituents are removed to produce pure water. Approximately 75 million people worldwide rely on desalination and that number is expected to grow as freshwater resources are stressed by population growth and millions more move to coastal cities with inadequate freshwater resources. Desalination is most widely used in arid regions; more than half of the world’s desalination capacity (volume) is located in the Middle East and North Africa. Seawater accounts for over 50% of desalination source water worldwide. However, as of 2005 in the United States, only 7% of desalination plants used seawater. Brackish waters made up the majority of source waters for desalination, with most of the remainder consisting of river waters and wastewaters.

Two streams of water result from desalination: (1) a pure product water and (2) a high-concentration waste stream or brine. The principal desalination methods fall into two categories: thermal processes and membrane processes. Thermal treatment uses heat to evaporate the water, leaving behind the dissolved salts, or waste stream, and separating it from pure water. Membrane processes use reverse osmosis and high pressure to force saltwater through very fine, porous filters that retain the salts, leaving pure water on one side of the membrane and the waste stream on the other side. Since a great majority of earth’s water is found in the seas and oceans, desalination creates an opportunity for coastal communities to access virtually unlimited freshwater sources. In addition, desalination techniques can be used to purify brackish water in areas with seawater intrusion. In light of climate change adaptation, this is also a crucial resource for areas where existing freshwater resources can no longer support local populations or be rehabilitated to meet the freshwater demands.

Thermal desalination processes generally use heat to evaporate water, leaving dissolved constituents behind. The water vapour is then condensed and collected as product water. Distillation is the simplest of these thermal processes and the energy efficiency of this simple process has been greatly improved. The most common thermal desalination process today is multi-stage flash (MSF) distillation; in 2005, MSF was reported to account for 36% of desalination worldwide. MSF improves on the energy efficiency of simple distillation by utilizing a series of low-pressure chambers, recycling waste heat and, in some cases, can be operated at even greater efficiency by utilising the waste heat from an adjacent power plant. Multiple-effect Evaporation (MEE) (also known as multiple-effect distillation) is another thermal process that utilizes low-pressure chambers; it is possible to achieve much greater efficiency in MEE than in MSF. However, MEE is not as popular because early designs were plagued by mineral scaling. Newer designs have reduced mineral scaling and MEE is gaining in popularity. For smaller operations with volume needs around 3000 m3/day, vapour compression distillation (VCD) can be an appropriate thermal distillation option. VCD is a technically simple, reliable and efficient process that is popular for resorts, industries and work sites where adequate freshwater is unavailable.

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 Br2

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.

COST ESTIMATION

Plant Capacity            1000 Kg./Day  

Land & Building (10,000 sq.mt.)    Rs. 1.59 Cr    

Plant & Machinery                    Rs. 2.33 Cr 

Working Capital for 1 Month    Rs. 2.31 Cr 

Total Capital Investment including 3 months working capital          Rs. 10.70 Cr 

Rate of Return                          54%

Break Even Point                      64%

CONTENTS

INTRODUCTION

SOURCE AND SAFETY OF BROMINE

SAFETY FIRST

MARKET OVERVIEW OF SALT

PRODUCTION OF SALT IN PAST FEW YEARS

GROWTH OF CHLOR-ALKALI INDUSTRY OF INDIA

PROPERTIES OF SALT

SALT IS A CHEMICAL COMPOUND WITH THE FOLLOWING PROPERTIES:

POTASSIUM IODIDE

PROPERTIES OF BROMINE

METHOD OF DESALINATION

THERE ARE THREE METHODS OF DESALINATION:

EVAPORATION:

REVERSE OSMOSIS:

ELECTRODIALYSIS:

METHOD OF COMMON SALT FROM SEA WATER

SEQUENCES IN SEA WATER DESALINATION

TECHNICAL DESCRIPTION1: REVERSE OSMOSIS (RO)

1: PRE-TREATMENT:

2: PRESSURIZATION:

3: SEPARATION:

4: STABILIZATION:

MANUFACTURING PROCESS OF SALT FROM SEAWATER

DETAILS OF SALT PURIFICATION PROCESS

TABLE.1 - CONCENTRATIONS OF SOME IONS FOUND IN SEAWATER

THE PRODUCTION OF SOLAR SALT

THE PRODUCTION OF VACUUM SALT

FURTHER PROCESSING

PROCESS FLOW DIAGRAM FOR SALT RECOVERY FROM SEA WATER

PRODUCTION METHODS OF SALT

SOLAR EVAPORATION METHOD

VACUUM PAN SALT PRODUCTION

SALT PRODUCTION FROM BRINE

SALT PRODUCTION BY SOLAR EVAPORATION OF SEA WATER

BRINE EVAPORATORS AND SALT PRODUCTION

EVAPORATED SALT PRODUCTION

CRYSTALLISING EVAPORATORS:-

VACUUM DRIERS

1. DRUM DRIER

2. VACUUM ROTARY DRIER

USES AND APPLICATION OF BROMINE

NATURAL SOURCES FOR BROMINE ARE CHLORIDE SOURCES SUCH AS

INDUSTRIAL SOURCES FOR BROMINE RECOVERY ARE

MARKET OVERVIEW OF BROMINE

MAJOR BROMINE MANUFACTURING COUNTRIES

INCREASING DEMAND FOR FLAME RETARDANTS

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

CALCULATION:

WHERE,

DETERMINATION OF BROMINE:-

THE SOLUTION SHALL BE STANDARDIZED BEFORE USE.

PROCEDURE:-

WHERE:

WHERE

DETERMINATION OF CHLORINE:-

PROCEDURE:-

CALCULATION:-

WHERE,

DETERMINATION OF NON-VOLATILE MATTER:-

PROCEDURE:-

CALCULATION:-

WHERE,

TEST FOR IODINE:-

ZINC DUST:-

TEST FOR SULPHATES:-

PROCEDURE:-

SAMPLING OF BROMINE TECHNICAL

NUMBER OF CONTAINERS TO BE DRAWN FOR SAMPLING

EXTRACTION TECHNIQUE OF BROMINE

THE TECHNIQUES OF EXTRACTION BROMINE

A. STEAMING-OUT AND AIR BLOW-OUT TECHNIQUE

B. ION EXCHANGE RESIN ADSORPTION

C. MEMBRANE PROCESS

1). GAS MEMBRANE PROCESS

2). EMULSION MEMBRANE PROCESS

D. HIGH GRAVITY AIR STRIPPING TECHNIQUE

A) STEAMING OUT PROCESS (HOT PROCESS)

B) AIR BLOWING PROCESS (COLD PROCESS)

PRODUCTION OF BROMINE

BLOCK SCHEME A - BROMINE PRODUCTION

DEBROMINATION

BLOCK SCHEME B - DEBROMINATION

EXTRACTION OF BROMINE FROM SEA WATER

OXIDATION OF BROMIDE TO BROMINE

REMOVAL OF BROMINE WATER

REDUCTION OF BROMINE TO HYDROBROMIC ACID

OXIDATION OF HYDROBROMIC ACID TO BROMINE

PRE TREATMENT FOR EXTRACTION BROMINE

FIGURE: ACID PROCESS BROMINE PROCESS

ETP PROCESS

DETAILS OF ETP PROCESS IN LIQUID BROMINE MANUFACTURE

PROCESS FLOW DIAGRAM

STAGES IN BROMINE MANUFACTURE

THE MANUFACTURING PROCESS OF BROMINE INVOLVES FOUR MAIN STAGES:

OXIDATION OF BROMIDE IONS TO FORM BROMINE

BROMINE VAPOUR REMOVAL

PRODUCTION OF HYDROGEN BROMIDE

OXIDATION OF HYDROGEN BROMIDE TO BROMINE

HOW A HAZARDOUS CHEMICAL LIKE BROMINE IS HANDLED

DETAILS OF LIQUID BROMINE MANUFACTURE

PROCESS

THE FOUR PRINCIPAL STEPS IN BROMINE PRODUCTION ARE

STEAMING OUT PROCESS:-

DOW PROCESS:-

SAFETY IN BROMINE PLANT

SAFE HANDLING OF BROMINE LEAKAGE

SAFE STORAGE OF BROMINE

SAFE TRANSPORTATION OF BROMINE

THE BROMINE STORAGE TANK SIGN IS AS FOLLOWS:

TECHNICAL DETAILS OF BROMINE MANUFACTURE

FROM SEA WATER

RAW MATERIAL

BLOCK DIAGRAM FOR MANUFACTURING PROCESS

REACTION

PROCESS DIVIDES IN THREE STEPS

AIR POLLUTANT EMISSIONS & THEIR CONTROL

PROCESS OF EXTRACTING POTASSIUM CHLORIDE FROM SEA WATER TECHNOLOGYOF RAW MATERIAL WATER TREATMENT FOR EXTRACTING BROMINE

FIGURE: ACID PROCESS BROMINE PROCESS

ADDRESSES OF RAW MATERIALS SUPPLIERS

ADDRESSES OF PLANT & MACHINERY SUPPLIERS

MACHINERY SUPPLIERS OF SALT FARMING

SUPPLIERS OF EFFLUENT TREATMENT PLANT

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 EFFLUENT 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)