Detailed Project Report on hydrochloric acid production

HYDROCHLORIC ACID PRODUCTION

[CODE NO.4190] 

Hydrochloric acid, also known as muriatic acid, is an aqueous solution of hydrogen chloride gas. At room temperature, it is a colorless gas, which forms white fumes of hydrochloric acid upon contact with atmospheric humidity. Hydrochloric acid is a strong inorganic acid widely used chemical. The largest end uses for hydrochloric acid are steel pickling, oil well acidizing, food manufacturing, producing calcium chloride, and ore processing.

Formula: HCl

Molar mass: 36.46 g/mol

Appearance: Colourless, transparent liquid

 It is a simple diatomic molecule consisting of a hydrogen atom and a chlorine atom connected with a covalent single bond. Since the chlorine atom is much more electronegative than the hydrogen atom, the covalent bond between the atoms is polar.

When dissolved in water, toxic hydrogen chloride gas will completely dissociate into its constituent ions to form hydrochloric acid. Aqueous HCl has water-like fluidity, color and appearance unless impurities such as iron (III) chloride are present that cause the solution to turn slightly yellow. Hydrochloric acid has a sharp, pungent, quickly-irritating odor that increases in potency and hazard with rising solution concentrations.

Traditional HCl concentrations are manufactured within the 31.5% to 38% weight/weight (wt%) range. Lower strength solutions are produced through dilution. Concentrated grades are considered 35-38 wt% HCl and are considered fuming hydrochloric acid due to the release of HCl gas from the solution. Higher concentrations are chemically possible but the properties of HCl make handling and long-term storage of these concentrations difficult due to necessary physical requirements, the generated fumes, and likelihood of evaporative loss. The pH of an HCl solution will be low, even for dilute mixtures, with a pH around zero or below to be expected for pure, concentrated solutions.

Molecularly, hydrochloric acid is an inorganic acid solution of the anhydrous gas dissolved in water. Upon dissolution, HCl reacts with water molecules to produce a mixture of hydronium ions, H3O+, and chloride ions, Cl-. The following equation demonstrates the reaction:

H2O(l) + HCl(g) ⇄ H3O+ (aq) + Cl-(aq)

The above reaction establishes an equilibrium but chemical properties and reactivity significantly favor production of the hydronium and chloride ions. The equilibrium shifts more to the production of HCl gas with increasing hydrochloric acid concentrations, (and also heat), eventually leading to fuming hydrochloric acid concentration strengths due to evolving gas vapors. Fumes from HCl solutions are HCl gas and are considered noxious and potentially corrosive.

Aqueous hydrochloric acid is used in recovery of semiprecious metals from used catalysts, as a catalyst in synthesis, use in catalyst regeneration, pH control, regeneration of ion exchange resins used in wastewater treatment and electric utilities, neutralization of alkaline products or waste materials, and in brine acidification for use in the production of chlorine and caustic soda. The pharmaceutical industry consumes hydrochloric acid as a catalyst in synthesis, for pH control, for deionization of water and as a reduction agent (e.g., in the production of ascorbic acid and Para- aminobenzoic acid).

Numerous other uses of hydrochloric acid include the manufacture of dyes and pigments; the removal of sludge and scale from industrial equipment; the de-liming, tanning and dying of hides by the leather industry; manufacture of permanent wave lotion; the carbonizing of wool; use as a bleaching and dyeing assistant in the textile industry; and the purification of sand and clay.

Hydrochloric acid is a solution of hydrogen chloride gas in water.  Hydrogen chloride gas is found in the volcame gases.  The order designation, muriatic acid, proposed by Lavoisier in 1789, was based on the term muriate, inclicating  the  presence of chloride is an inagam'c compound. Thus, it is also know as muriat'c  acid. The archaic designation is still used in US industry to refer to the commercial farm.  Similarly, the arbitrary specific gravity scall devised in the eighteenth century by the Franch chemist Baune is still used to characterize the commercial grades of the acid. The Twaddell density scale which approximates the concentration, is also less commonly used. The relationship of the varius density units of the concentration of the three standard commercial grades of hydrochloric acid is shown in Table 1.

COST ESTIMATION

Plant Capacity                                    35 MT/Day

Land & Building (8500 sq.mt.)  US$ 8.86 Lac

Plant & Machinery                               US$ 1.87 Lac

Working Capital for 1 Month              US$ 9.24 Lac

Total Capital Investment                     US$ 21.05 Lac

Rate of Return                                        52%

Break Even Point                                   47%

• INTRODUCTION
• DENSITY AND CONCENTRATION OF COMMERCIAL GRADES OF 
• HYDROCHLORIC ACID
• USES & APPLICATION
• PICKLING OF STEEL
• PRODUCTION OF ORGANIC COMPOUNDS
• PRODUCTION OF INORGANIC COMPOUNDS
• REGENERATION OF ION EXCHANGERS
• OIL WELL ACIDIZING
• FOOD
• OTHER FOOD USES
• PRODUCTION OF CALCIUM CHLORIDE
• ORE PROCESSING
• OTHER
• CHLORINE AND SODIUM HYDROXIDE END USES
• INDUSTRIAL USES OF HYDROCHLORIC ACID
• SPECIFICATION
• HYDROCHLORIC ACID EQUIVALENT PROPERTIES
• PROPERTIES & CHARACTERISTICS
• PHYSICAL AND CHEMICAL PROPERTIES
• REGULATORY INFORMATION
• NORTH AMERICAN REGULATORY INFORMATION
• OTHER REGULATORY INFORMATION
• PRODUCT CERTIFICATIONS AND LISTINGS
• CORROSIVITY
• REACTIVITY
• B.I.S. SPECIFICATION
• 1.   SCOPE
• 2.   GRADES
• 3.   REQUIREMENTS
• PACKING AND MARKING
• 4.1  PACKING
• 4.2  MARKING
• TABLE 1 REQUIREMENTS FOR HYDROCHLORIC ACID
• CORRELATION TABLE FOR RELATIVE DENSITY AND PERCENT BY MASS
• OF HYDROCHLORIC ACID
• 1. SCOPE
• 2. PROPERTIES OF HYDROCHLORIC ACID
• 3. HAZARDS ASSOCIATED WITH HYDROCHLORIC ACID
• 4. STORAGE
• 5. PREVENTIVE MEASURES
• 6. TANK CLEANING AND REPAIRS
• MARKET POSITION
• CHLOR-ALKALI INDUSTRY
• CHLORATE INDUSTRY
• GLOBAL HYDROCHLORIC ACID MARKET (2016-2023) (USD MILLION)
• INCREASING DEMAND FOR PICKLING IN THE STEEL INDUSTRY
• ASIA-PACIFIC REGION DOMINATED THE HYDROCHLORIC ACID 
• MARKET GLOBALLY
• CHINA IS ESTIMATED TO CONTRACT TO SOME EXTENT AND IS EXPECTED 
• TO WITNESS RECOVERY IN 2021
• INDUSTRIAL MARKET
• STRUCTURE AND REACTIONS
• PHYSICAL PROPERTIES
• MELTING TEMPERATURE AS A FUNCTION OF HCL CONCENTRATION IN WATER
• MANUFACTURE OF HYDROGEN CHLORIDE
• SYNTHESIS OF HYDROCHLORIC ACID
• PROCESS DESCRIPTION
• PREPARATION OF BRINE AND PRIMARY PURIFICATION
• FIG. HYDROCHLORIC ACID PROCESS DIAGRAM
• SECONDARY BRINE PURIFICATIONS
• ELECTROLYSIS
• ANODE SIDE REACTION
• CATHODE SIDE REACTION
• HYDROCHLORIC ACID PRODUCTION
• DESIGN FEATURES OF HCL SYNTHESIS FURNACE
• CHEMICAL ANALYSES
• CHLOR/ALKALI MANUFACTURING PROCESS
• FIG:- SCHEMATIC OF A MERCURY CELL & SCHEMATIC OF A DIAPHRAGM CELL
• MERCURY CELLS
• DIAPHRAGM CELLS
• SCHEMATIC OF A MEMBRANE CELL
• MEMBRANE CELLS
• MONOPOLAR OR BIPOLAR CONFIGURATION
• CHLORINE PROCESSING
• HYDROGEN PROCESSING
• CAUSTIC SODA PROCESSING
• BRINE PROCESSING
• SODIUM HYPOCHLORITE MANUFACTURING PROCESS
• CHLOR/ALKALI MANUFACTURING PROCESS
• COMPARISON OF CELL TECHNOLOGIES
• SODIUM HYPOCHLORITE/CHLORATE MANUFACTURING PROCESS
• PROCESS FLOW SHEETS
• DIAPHRAGM CELL PROCESS FLOW SHEET
• MEMBRANE CELL PROCESS FLOW SHEET
• ABSORPTION TOWER
• FLOW SHEET DIAGRAM OF MANUFACTURE OF HYDROCHLORIC ACID  
• FROM COMMON SALT
• OTHER MANUFACTURING PROCESSES OF HYDROCHLORIC ACID FROM 
• CHLORINE AND HYDROGEN
• FLOW SHEET OF MANUFACTURE OF HYDROCHLORIC ACID FROM 
• CHLORINE AND HYDROGEN
• HARGREAVES PROCESS
• HERE THE PREDOMINANT REACTIONS IS
• BY PRODUCT HYDROCHLORIC ACID
• MANUFACTURE OF HYDROCHLORIC ACID FROM SODIUM CHLORIDE 
• AND SULPHURIC ACID
• HANDLING, PACKAGING AND FIRE HAZARDS OF HYDROCHLORIC ACID
• SAFE HANDLING AND STORAGE
• PACKAGING AND SHIPPING
• FIRE AND EXPLOSION HAZARDS
• HEALTH & ENVIRONMENTAL EFFECT OF HYDROCHLORIC ACID
• ENVIRONMENTAL EFFECTS
• EXPOSURE POTENTIAL
• SUPPLIERS OF PLANT AND MACHINERY
• PUMPS
• PIPING
• P.E.P
• VALVES
• GASKETS
• GAUGES
• SCRUBBERS
• SUPPLIERS OF RAW MATERIALS
• MACHINERY PHOTOGRAPHS
• RAW MATERIAL PHOTOGRAPHS
• NACL
• H2SO4
• CL2
• NA2SO4
• PRODUCT PHOTOGRAPHS

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)