1.

Prepare the process flow diagram and the complete list of major equipment required for

starting up the Hydrochloric acid production plant to meet the annual demand with major

equipment specification.

Hydrochloric acid is an extremely corrosive substance. It is an acidic environment damage

mechanism and it is a big problem for the people who operate refining and chemical process

units. Normally, all the manufacturing materials and equipment are chosen to resist

hydrochloric acid corrosion. The manufacturers of this equipment usually know where and how

much hydrochloric acid will be present in the process of manufacturing. However, there could

be a problem when the PH of hydrochloric acid is low and it passes where it was not expected,

this may cause HCL corrosion (The Chlorine Institute, 2001).

In the process of refining, hydrochloric acid corrosion is caused by dew point formation in the

overhead of distillation towers. Most of the materials used in the manufacturing of HCL contain

organic salts. These salts are main cause of dew point corrosion. Although effective desalting

methods can remove majority of these salts, chloride salts are difficult to remove and they

usually end up in the overhead pipes, accumulators and exchanger vessels inform of a water

solution. HCL can be generally and highly localized depending on the dew formation point, the

occurrence of hydrodynamic effects a where the low PH solutions accumulate.

Hydrochloric acid can also occur in various mixing points in process streams. At these points

chloride contaminated streams mix with low temperatures and they mix with wet process

streams causing corrosion at the point of mixture. Another source of HCL corrosion happens in
the cat reforming units. It happens when chloride is removed from the catalyst and then it

travels downstream in recycled hydrogen streams. To prevent HCL corrosion, one should have

the knowledge of the location of low PH solutions and taking precautions. These precautions

include choosing corrosion resistant equipment and installing wash water systems. It is also

advisable to monitor the PH of the water systems. The manufactures should also be careful and

ensure that the following metals do not come into contact with these metals; carbon steel,

stainless steel, nickel, bronze, brass, copper and aluminum.

 List of equipment used in production of hydrochloric acid

Pipes

All the pipes used in Hydrochloric acid are supposed to be properly supported. When selecting

the pipes, the manufacturer is should consider the coldest ambient temperature that may be

experienced in the production process. Lined steel is most preferred in piping systems for HCL.

This is because it is considered to be the most structurally rigid metal and there are low chances

of being affected by physical abuse (The Chlorine Institute, 2001). Also, lined steel systems do

not require gaskets at flanged connections. The liner usually acts as gasket material. The

common lining materials used in HCL production pipes are polytetrafluoroethylene (PTFE),

polypropylene (PP), and polyvinylidene fluoride (PVDF). The Pipes are typically carbon steel

manufactured to ASTM F-1545 specifications.

FRP (Fiberglass Reinforced Plastic) piping systems used in the manufacture of hydrochloric acid

are usually made up of resins such as epoxy based vinyl and polyesters which are chemically

resistant. They are structurally fitted with glasses made of fiber during the process of molding.

The coating material used in FRP piping systems should also be put into consideration. The pipes

should be coated with ultraviolet light resistant barriers to extend the life of the pipes. Other

pipes used are the thermoplastic piping systems. They consist of materials such as

perfluoroalkoxy(PFA), chlorinated polyvinyl chloride (CPVC), polyvinyl chloride(PVC) and

polyvinylidene fluoride (PVDF). Thermosplastic piping systems are weak compared to FRP and

lined steel systems, therefore, they are used for tank vents and other areas which to not require

structurally strong pipes. Dual laminate piping systems can also be used in the Hydrochloric acid
plants. They are have a thermoplastic lining that is over wrapped with FRP on the outside. These

pipes ensure that there is no internal corrosion and they are also strong on the outside.

Horses

Manufacturing of Hydrochloric acid requires acid resistance horses. They are mainly use for

sucking and discharging hydrochloric acid. Viton, natural rubber, hypalon, and neoprene butyl

rubber are the materials used in making these horses. They usually offer good chemical

resistance to HCL and this means that there is minimal or less corrosion.

Pumps

Manufacturing of HCL requires lined steel and composite pumps. These pumps are usually made

from the following elements; PP (polypropylene), PVDF (polyvinylidene fluoride), FRP

(fiberglass reinforced plastic), PFA (perfluoroalkoxy) and ETFE (ethylene tetrafluoroethylene).

There are different types of pumps. For instance there is the centrifugal pumps and they

commonly used in pumping of HCL. Centrifugal pumps with a magnetic driver do not require any

seal. This eliminates any possibility that they will leak through the seal. If using pumps that

require a seal, a double mechanical seal is most preferred. For the operators’ safety and

protection, the gland area of the pump must be well sealed. The pumps which are used for

transferring HCL should be set to ensure that they will signal when they are running dry. This will

stop the operation. To prevent damage in the dead-heading, a minimum flow recycle line is

used.

A suction lift is a material that is used in loading and offloading tank trailers and tank cars with

top outlets. In this application, self-priming centrifugal pumps are most preferred. However, if

you want to use standard centrifugal pumps, then priming will be required. Diaphragm and any
 other positive displacement pumps do not have to be primed to be used in pumping HCL.

However, if they are used, the diaphragm rupture will release fumes which can worsen the

situation because of the compressed air in the pumps.

Valves

Valve lining depends on the type of valve that is used in manufacture of hydrochloric acid. There

are various resistant polymers which are considered the most suitable for valve lining. These

include PTFE (polytetrafluoroethylene), PP (polypropylene) , PFA (perfluoroalkoxy) and PVDF

(polyvinylidene fluoride). The composite body ball valves have balls, bodies and are usually

made of fiberglass reinforced epoxy resin.

Gaskets

The materials preferred for gaskets are ethylene-propylene rubber, Teflon envelope, Hycar

rubber and vinyl materials.

Pressure Gauges

To ensure their effectiveness, they should be protected from direct contact with hydrochloric

acid.

2. Based on the purchased equipment cost, prepare a study estimate of the Hydrochloric

Acid plant (with an accuracy of ± 30 percent) and determine the total capital investment

(TCI) required to establish the plant.

Estimation of fixed capital investment

 Items Amount (oman rial)

1. Total delivered equipment cost (tanks, pumps, valves, gaskets) 1250000

2. Installation of equipment (foundations, platforms) 500000

3. Piping, 'wiring, instruments, 400000

4. Engineering and contractors fees 520000

5. Contingencies . 300000

6 Total erected equipment costs 2970000

7: Land and building costs . 80000

8. Estimated fixed capital investment 3000000

3. Estimated the total production cost (TPC) per kg of Hydrochloric acid.

Estimated total production cost per of hydrochloric acid

Raw materials UOM Qty Total

Sulphuric acid (98%) Tons 2000

Sodium chloride (NaCl) Tons 2000

Packaging materials for HCL Tons 3000

Packing materials for sodium sulphate Tons 1000

Total

Utilities

Electricity 4000
Water 2000

Furnace oil 1000

Gas 3000

Total 10000

Labor and supervision

27 Operators, $4.00/hr 2000

18 Helpers, $3.40/hr 1000

3 Laboratory technicians, $3.50/hr 500

3 Foremen, $34.00/day 1000

1 superintendent $48.00/day 500

Total 5000

4. Determine the Rate of Return (ROR) of the project. Comment on whether this RoR is
justifiable to undertake the project.

Rate of return = ((Current value - original value) / original value) x 100

Current value = 3,000,000

Original value = 2,970,000

 = (3,000,000 – 2,970,000)/2,970,000

= 0.01 * 100

= 1.01

The rate of return for the project is 1.01.

The rate is positive and it indicates that the project will make returns in future. The rate of

return is used to measure and evaluate whether the project is viable and whether it is worth

undertaking or rather investing in the project. JAMAL should invest in the hydraulic acid

production project.

5. Prepare a complete project feasibility report, which contains all of the above information in

the form of a standard feasibility report format.

Hydraulic acid is highly corrosive. It is used for several applications. Therefore, production of

hydraulic acid is a lucrative business. The processing firm for the hydraulic acid production

requires a few procedures, which include determining and accessing the manufacturing

materials and equipment. These materials are chosen to resist hydrochloric acid corrosion. The

manufacturers of this equipment usually know where and how much hydrochloric acid will be

present in the process of manufacturing. However, there could be a problem when the PH of

hydrochloric acid is low and it passes where it was not expected, this may cause HCL corrosion.

There is also a process of refining the hydrochloric acid. In the process, corrosion is caused by

dew point formation in the overhead of distillation towers. Most of the materials used in the

manufacturing of HCL contain organic salts. These salts are main cause of dew point corrosion.

The list of equipment used in the production process of preparing hydraulic acid production are

basically pipes, pumps, horses, gaskets, valves, among other equipment. From the above

information, the business has a positive rate of return of 1.01. JAMAL chemicals should invest in

the business.
 References
The Chlorine Institute (2001). Hydrochloric Acid Storage and Piping Systems, Pamphlet 163,