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Acid Regeneration Plant


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Arp Training manual

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  • ‘Tiaano’ for Hydrochloric Acid in Steel Processing

    HCL Heating for Pickling:

     TANTALUM Serpentine Immersion Coils.

     TANTALUM Grid Heat Immersion Coils.

     TANTALUM U-Shaped Immersion Coils.

     TANTALUM Shell & Tube Heat Exchanger.

     Tantalum Fasteners.

    Acid Regeneration in Pickling for recovery & reuse of HCL:

     Ti-Pd. (Titanium Gr.7) Venturi.

     Ti-Pd. (Titanium Gr.7) Blowers.

     Ti-Pd. (Titanium Gr.7) Impellers.

     Ti-Pd. (titanium Gr.7) Fasteners.

     Ti-Pd. (Titanium Gr.7) Acid Lance.

     Ti-Pd. (Titanium Gr.7) Coloumn Pipes.

     Ti-Pd. (Titanium Gr.7) Diffuser Pipe bends.

     Ti-Pd. (Titanium Gr.7) Sleeved EPDM Bellows.
    HCL (Hydrochloric Acid) Heating in Pickling process:

    Tiaano design, manufacturing & supplying TANTALUM Heat Exchanger Immersion Coils for Hydrochloric Acid heating in pickling bath, they are...

     TANTALUM Serpentine Immersion Coils

     TANTALUM Grid Heat Immersion Coils

     TANTALUM U-Shaped Immersion Coils


     Complete / Superior Corrosion resistance.

     Better / High heat transfer characteristics than non-metallic elements.

     Higher steam pressure capabilities than traditional PTFE coils – reduce required surface area.

     Cost competitive with PTFE Heaters / Heat exchanger coils.

     Retrofittable into existing equipment footprint.

     Indirect heating eliminates pickle liquor dilution.

     No spare parts to keep in inventory.

     Elimination of down time due to equipment failure

    Tiaano design, manufacturing & supplying TANTALUM Shell & Tube Heat Exchanger for Hydrochloric Acid heating in pickling bath.


     Cost Competitive with Carbon Block Heat Exchangers.

     Complete / Superior Corrosion resistance.

     Better / High heat transfer characteristics than non-metallic elements.

     Higher steam pressure capabilities than traditional PTFE coils – reduce required surface area.

     Seam welded metal design eliminates breakage during handling, Installation & Operation.

     Easily retrofittable into existing equipment footprint.

     Elimination of HCL acid leakages into steam condensate.

     No spare parts to keep in inventory.

     Elimination of down time due to equipment failure.
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Acid Regeneration Plant

  1. 1. CRM Complex Acid Regeneration Plant Training Manual0
  2. 2. INTRODUCTIONThe Regeneration of the used Pickling Acid The hydrochloric acid used in the pickling process is thermally treated in the regeneration plant for the purpose of recovery and reuse in the pickling process.Roughly, the plant is divided into the following sections;• The rector in which the iron chloride is transformed into iron oxide and gaseous HCl• The cyclone, incl. dust recirculation• The venturi, in which the hot gases are cooled down from approximately 850’C to100’C during this process the pickling acid is strongly concentrated due toevaporation of water• The separator in which the waste gases coming from the venturi liquid• The absorber in which the hydrochloric acid is recovered by absorption of thegaseous HCl in water• The fan F-V-31 with the fume stake which sucks of the gases developed in the reactor and keeps the entire system below atmospheric pressure. The residual inert gases are led through the fume stake into the atmosphere• The venture F25 with separator B26 in which a final treatment of the waste gas isachieved. 1
  3. 3. LINE DIAGRAM K11 Nomenclature Nomenclature K11 A4 A4 K38 B26 F5 F5 F25 K38 F3 B26 F25 F3 C1 C2 K8 K8 B7 B7 V31 V31 C1 C2 C1,C2 –Reactor V31 –Exhaust fan V31 - Exhaust fan C1,C2 - Reactor F3 –Cyclone K38 –Control valve valve F3 -Cyclone separator K38 - Control A4 –Gas duct F25 –Venturi scrubber V30 A4 –Venturi F5 - Gas duct F25 - Venturi scrubber B26 –Scrubber F5 - Venturi B26 - Scrubber B7-Separator B7- Separator K11-Chimney K11- Chimney K8 - Absorber K8 -Absorber V30 -Combustion Blower Blower V30 - Combustion 2
  4. 4. BASIC PROCESS The oxides which result from the oxidation with oxygen while the material is being hot rolled are an obstacle to the subsequent treatment and must be eliminated. In this case the oxides are eliminated by pickling with a solution of hydrochloric acid. The oxides arising during the oxidation process are transformed by the effects of HCl into FeCl2. Reaction Equation The chemical reaction during the pickling process can be illustrated with the following reaction equation: Fe2O3 + 6HCl = 2FeCl3 + 3H2O FeO + 2HCl = FeCl2 + H2O 2FeCl3 + H2 = 2FeCl2 + 2HCl 3
  5. 5. LINE SPECIFICATIONS Specifications Rinse water to Absorber 80- 90 C Rinse water to Absorber -5 to-10 mbar -150 to-180 mbar -150 to-180 mbar 800- 850 C -5 to-10 mbar 100- 105 850- 870 C 50 mbar 50 mbar C -80 to-90mbar -80 to-90 mbar 400- 750 C 870- 890 C 1440 g/lit Acid to Reactor Oxide bed Scrubbercirculation Scrubber circulation oooooooooooo oooooooooooo Regenerated Acid Regenerated Acid Venturi Circulation Whirl Air Whirl Air Natural Gas Natural Gas 4
  6. 6. TECHNICAL SPECIFICATIONS • Waste Acid input : 4000 Ltr/hr • Oxide Production : 700 Kg/hr • Regenerated Acid Production : 5000 Ltr/hr • Exhaust Fan V31 : 19000 M3/hr • Air Blower V30 : 6000 M3/hr • Venturi Circulation Pumps P32/P33 : 90 M3/hr • Scrubber Circulation Pumps P34/P35 : 30 M3/hr 5
  7. 7. PROCESS DESCRIPTION Plant consists of following main equipments: • Reactor with cyclone separator • Venturi F5 • Absorption Tower • Fan V31 • Venturi F25 6
  8. 8. THE REACTOR AND THE CYCLONE SEPERATOR Oxide Oxide HCL Fumes HCL Fumes 870- 890 C Oxide bed oooooooooooo oooooooooooo oooooooooooo oooooooooooo oo oooooo oooooooo By By product product Fe2O3 Fe2O3 7
  9. 9. THE REACTOR AND THE CYCLONE SEPERATOR The fluidized bed in the reactor consists of particles of iron oxide in turbulent state by the combustion gas. In to this fluidized bed, the concentrated venturi liquid is pumped through a titanium lance. As a result of high temperature about 850 C the FeCl2 splits up into Fe2O3 and Hcl. Thus the reverse of pickling reaction takes place in the reactor. 2FeCl2 + 2H2O +1/2 O2 ------- Fe2O3 + 4Hcl About 95% of this reaction takes place on the surfaces of the oxide particles present, and only approx. 5% in the gas phase in between the grains. 8
  10. 10. THE REACTOR AND THE CYCLONE SEPERATOR While the iron oxide reacting on the surface of the oxide particles, they form fine oxide dust which is carried out of the reactor with combustion gasses in the cyclone this dust is recovered and lead back to the reactor by means of dust return pipe. This formed iron oxide is discontinuously drawn off from the reactor as Byproduct. Due to this the amount of the material and thus the height of the whirling bed is kept constant. 9
  11. 11. THE VENTURI F5 • The hot reaction gasses drawn out of the Rinse water Rinse water reactor at a temperature of 850 C are cooled in the venturi to approx 100 C. 850 C F5 • This cooling is achieved by the evaporation of Evaporation Evaporation water out of the venturi liquid, also the fine dust 100 C passing the cyclone also washed out by means of venturi circulation. K8 Hcl gas Hcl gas B7 Density 1440 g/l • The venturi liquid needed for cooling is taken Density 1250 g/l from Separator B7 by means of pumps Regn Acid Regn Acid P32,P33. as a result of evaporation the venturi liquid becomes very concentrated. P32 • Adding rinse water sets density of 1440 g/lit in P33 the venturi circulation system. 10
  12. 12. THE VENTURI F5 • Adding rinse water sets density of 148 Kg/CM3 in the venturi circulation system. • A split system is taken out of this Venturi circulation system and conveyed to reactor C1. • The waste stacked in the storage station is pumped by means of pumps into receiver vessel B15. This receiver vessel communicates with the separator B7. Any reduction in the level of the separator as a result of the consumption of Venturi liquid in reactor C1 in thus automatically equalized by the addition of waste acid. • Any excess waste conveyed to receiver vessel B15 flows back into the appropriate waste acid storage tank. 11
  13. 13. ABSORBER K8• The hydrochloric acid present in the waste gas stream is scrubbed out in absorber K8.• To accomplish this, the upper part of the absorber is impinged with city water which then flows through the absorber from top to bottom countercurrent to the flow of gas.• In doing so, the hydrochloric acid carried in the gas flow is washed out.• Then the recycled regenerated acid flows from the bottom-most of the absorber into the acid storage station. 12
  14. 14. THE EXHAUST FAN V31 The waste gas out of the absorber K8 are drawn Off by the exhaust fan V31 and blown K11 K11 out to the Venturi F25, To avoid build up on the titanium Impeller. Water is continuously sprayed over it. K38 K38 B26 B26 F25 F25 V31 V31 P34 P35 13
  15. 15. THE VENTURI F25 & OXIDE COOLINGTABLE & VERTICAL OXIDE CONVEYOR • After the fan V31 the waste gases reach the venture F25 in which the waste gases are mixed with water and thus the remaining HCl is removed out of the waste gases. Oxide Cooling Table V50 • Hot oxide is drained and cooled with cooling Table having water cooled jackets and VFD motors to remove the oxide generated in the reactor. Vertical oxide conveyor • Cooled oxide from V50 is transported to oxide storage bin by vertical spiral conveyor driven by two unbalanced motors. From oxide bin cooled oxide is safely filled in dumper and sent for recycling. 14
  16. 16. THE TANK FARM & SUMP From ARP From ARP To ARP RW WPL RA Regn Acid Regn Acid RA TO PKL 1 1 RA TO PKL 10KL 10KL 10KL To ARP Regn Acid Pkl 1 Pkl 1 Pkl 1 Regn Acid 85 kl kl 85 Pkl85 kl 1 85 kl Regenerated Acid pkl 2 Regenerated Acid pkl 2 150 kl 150 kl RA TO PKL 2 RA TO PKL 2 Rinse water Waste pickle Waste pickle Waste pickle Waste pickle Waste pickle Acid 2 Acid 1 Pkl 1 & 2 Acid 3 Waste pickle Rinse water Acid 3 Acid 2 Acid 1 150 kl 150 kl kl 150 150kl 150 kl 150 kl Acid 1 & 2 150 kl 150 kl WPL From PKL 2 RW TO PKL 2 WPL From PKL 1 WPL From PKL 2 WPL From PKL 1 RW From PKL 2 15
  17. 17. THE TANK FARM & SUMP • ARP reserves the total capacity of 950 kl in its tank farm, which consists of 160 kl Rinse water, 460 kl Waste pickle Acid and 330 kl Regenerated acid. • The tank farm is safely designed and located at -2 mtr level and having safe Drainage system to meet Environmental and safety requirements. • Waste water from ARP and Tank farm are collected in the sump pit and is pumped to Effluent Treatment plant safely. 16
  18. 18. Thank you Compiled by : RAJIV ARORA