final project synopsis 1 (2)

S.S.J.C.O.E Mfg of Liquid Bromine

Acknowledgement

We experience great pleasure in presenting the project report

entitled “Manufacturing of Liquid Bromine.

With the profound feelings of immense gratitude we express our

whole hearted thanks to our guide Prof. Ananya Dey for her

valuable support and guidance throughout the process without

which it would have been impossible.

We would like to thank our principle Dr. J. W. Bakal and HOD

Mrs. Leelamani for their never ending encouragement, moral

support and patience during the preparation of our project.

We therefore sincerely thank the company Excel Industries Ltd. for

guiding us in our project.

We also sincerely acknowledge our sense of gratitude to the

Chemical Engineering Department, Shivajirao S. Jondhale

College of Engineering who has extended their support and

outmost co-operation for our project.

We also thank all those who have directly or indirectly contribute

for making this report.

Mr. Shyam Yadav


Mr. Paresh Agarwal.

Mr. Anil Jain.


INTRODUCTION


INTRODUCTION

The project is about the production of Liquid Bromine in our chosen liquid brome

producing company.

This project contains all the details about the plant of hazardous chemicals both

reactant & product included in this project. It will give an idea about how actually a

hazardous chemical is handled and what are the preventing measures has to be followed.

Our main aim for selecting this project is to study all the information which is

covered by our syllabus and to remember the factors to start an industry and to design of

all the apparatus & utilities.


PRODUCT HISTORY


PRODUCT HISTORY

Bromine was discovered by two scientists working independently. In the Autumn of 1825,

student Karl Lowig took a bottle of a reddish liquid with an unpleasant smell to the

Laboratory of Medicine and Chemistry of Prof. L. Gemlin, at the University of

Heidelberg. Lowig told Gemlin that the liquid, of mineral origin, resulted from the

treatment with gaseous chlorine, thus explaining the red colour. The substance responsible

for that red colour was extracted with the help of ether, giving origin to a pink liquid later

known as bromine.

Almost simultaneously, Antoine Balard, who was working in a pharmacy school in

Montpellier, isolated a substance with the same properties of the liquid obtained by

Lowig. At first he thought that it was a chlorine or iodine compound. As he could not

isolate the compound, he suggested to have found a new chemical element. Balard

suggested the name "muride", from the Latin word "muria" for brine.

The French Academy of Science, in turn, proposed the name "brome" from the Greek

word bromos meaning stench to indicate its strong irritating odour.

Bromine occurs in the hydrosphere mainly as soluble bromide salts. Its con-centration

ranges from 65 mg/L in seawater up to 6.5 g/L in the southern basin of the Dead Sea. In

1826, Antoine-Jerome Balard in France published the discovery of bromine, which was

isolated by chlorinating seawater bitterns and distilling out bromine. Bromine had been

prepared earlier by Joss and Liebig but neither of them recognized it as an element.

Around 1840 bromine wasused in photography. The first mineral to contain bromine was

apparently silver bromide, discovered in 1941 by Berthier. Its first medical use was in

1857 when bromides were used for the treatment of epilepsy. The first commercial

bromine production from salt brines was in 1846 at Freeport, Pennsylvania. In

1858,potash was discovered in the Stassfurt salt deposits in Germany and bromine was a

by-product from the potash production. Herbert Dow invented the ‘‘blowing out’’ process

for Midland (Michigan) brines in 1889. The antiknock properties of tetraethyllead,


(CH3CH2)4Pb, were discovered in 1921 and soon after ethylene dibromide, C2H4Br2,

was found to aid the removal of leadfrom combustion chambers.

At one time, 80% of all bromine was used to produce ethylene dibromide.

Bromine was first commercially extracted from sea-water in 1934, using the Dow process.

The richest source of Br in the world is found in the Dead Sea brines, which contain up to

12 g/L of Br. Its commercial exploitation by DSBG started in 1957. In the 1950s, bromine

was discovered in south Arkansas brines, the only significant source of bromine in the

United States, with a bromine content of 2–5 g/L.

The biggest single bromine plant was erected by the Dead Sea in Israel, and is operated by

the Dead Sea Bromine Group (DSBG)


PHYSICAL

&CHEMICAL

PROPERTIES


Properties of Bromine

Physical properties:-

Molecular formula – Br

Atomic number – 35

Solubility in water – Slightly souluble

Solubility in organic solvents - highly soluble.

Molar mass – 79.901 g/mol

Appearance – Reddish Brown Liquid

Density – 3.1028 g/cm3

Melting point - -7.2°C (265.8 K)

Boiling point – 58.8 °C (332 K)

Critical Point – 588 K, 10.34 MPa

Heat of fusion - 10.571 KJ·mol−1

Heat of vaporization - 29.96 kJ·mol−1

Molar heat capacity - 75.69 J·mol−1·K−1

Chemical properties:-

Being less reactive than chlorine but more reactive than iodine, bromine reacts vigorously

with metals, especially in the presence of water, to give bromide salts. It is also reactive

toward most organic compounds, especially upon illumination, conditions that favour the

dissociation of the diatomic molecule into bromine radicals:

Br2 → 2 Br·


It bonds easily with many elements and has a strong bleaching action.

Bromine is slightly soluble in water, but it is highly soluble in organic solvents such

as carbon disulfide, carbon tetrachloride, aliphatic alcohols, and acetic acid.


Properties of Chlorine

General

Chlorine has a characteristic penetrating and irritating odour. The gas is greenish

yellow in colour and the liquid is clear amber.

Atomic and Molecular Properties:

Atomic Symbol ........... Cl2

Atomic Weight ........... 35.453

Atomic Number .......... 17

Molecular Weight ....... 70.906

Chemical Properties:

Flammability - Gas or liquid, is non-explosive and non-flammable. It is an oxidizer

and is capable of supporting combustion. Many organic chemicals react readily with

chlorine, sometimes violently.

Valence - Chlorine usually forms compounds with a valence of -1 but it can combine with

a valence of +1, +3, +4, +5 or +7.

Reactions With Water - Chlorine is only slightly soluble in water. (0.3 to 0.7 percent)

Reactions With Metals - At ordinary temperatures dry chlorine, gas or liquid, reacts with

aluminium, arsenic, gold, mercury, selenium,

tellurium, tin, and titanium. Carbon steel ignites near 251°C.

Reactions With Organic Compounds - Chlorine reacts with many organic compounds.

Some reactions can be extremely violent or explosive.

Physical Properties:-


The following properties are for pure chlorine. “Standard conditions”- At 32°F (O°C) and

an absolute pressure of 14.696 psi (101.325 kPa).

Boiling Point (Liquefying Point) = -29.15°F (-33.97°C)

Density- Gas at Standard Conditions = 0.2006 lb/ft3 (3.213 kg/m3)

Saturated Gas = At 32°F (O°C), 0.7632 lb/ft3 (12.23 Kg/m3)

Saturated Liquid = 91.56 lb/ft3 (1467 kg/m3) at 32°F (0°C);

Latent Heat of Vaporization = 123.9 Btu/lb (288.1 kJ/kg)

Melting Point - Freezing Point = -149.76°F (-100.98°C)

Solubility in Water = 6.93 lbs/100 gals. (60°F and 14.696 psi)

Specific Gravity = Gas- 2.485 (air);

Liquid, 1.467 0/4°C (water)

Vapour Pressure = 53.51 psi (368.9 kPa) at 32°F (0°C);

112.95 psi (778.8 kPa) at 77°F (25°C).

Viscosity - Sat. Gas = 0.0125 cP (0.0125 mPa·s) at 32°F (0°C);

Liquid = 0.3863 cP (0.3863 mPa·s) at 32°F (0°C)

Chlorine, liquefied under a pressure of 8 bar at room temp. The liquid column size is ca.

0.3×3 cm.


Properties of HBr


Molecular formula – HBr

Solubility in water – Slightly soluble



Appearance – Colourless


Melting point – -86.9°C (186.1 K)

Boiling point – -66.8 °C (206 K)

Vapour Pressure – 2.308 MPa (at 21 °C)

Critical Point – 363.15 K, 85.52 bar

Refractive Index – 1.325

Specific heat capacity – 350.7 mJ·g−1·K−1


Properties of NaBr


Molecular formula – NaBr

Appearance – White powder


Density – 3.21 g/cm3(anhydrous)

2.18 g/cm3(dihydrate)

Melting point – 747 °C (anhydrous)

36 °C (dihydrate)

Boiling point – 1396 °C


Solubility in water – Miscible

Solubility in organic solvents – highly soluble.

Refractive index – 1.6459

Std enthalpy of formation – -369 kJ.mol-1

Std molar entropy – 84 J.mol-1.K-1

Flash Point – 800 °C


Properties of H2SO4


Molecular formula – H2SO4

Appearance – Colourless

Molar mass – 98 g/mol


Melting point – 10°C (283.15 K)

Boiling point – 337 °C (610 K)


Solubility in water – Miscible


Std enthalpy of formation – -814 kJ.mol-1

Std molar entropy – 157 J.mol-1.K-1


APPLICATIONS/ USES


Uses/Applications of Bromine

In its liquid form, bromine is reddish-brown in colour. Its vapours give off a pungent

smell and are reddish in colour. It was found that bromine is more soluble in carbon

disulfide and solvents, like methanol and acetic acid than in the water. It needs only one

electron to complete an octet of electron in its outermost shell. This enables it to take part

in various chemical reactions and act as a strong oxidizing agent.

In Fire Retardant Chemicals

One of the important bromine applications is in manufacturing brominated flame

retardants. These are used as chemical flame retardants in the plastic industry and in

products, such as cables, connectors, plastic covers. Bromine's flame retardant property is

also employed to make products, like carpets, upholstery, paints and kitchen appliances

safe. It is also used in the clothing and furniture industries, to prevent the products from

catching fire. In the electronics industries, especially in computers, it is used to make

fireproof printed circuit boards. Polybrominated diphenyl ether, polybrominated biphenyl,

decabromodiphenyl ether, hexabromocyclododecane, tetrabromobisphenol are of flame

retardant.

As a Disinfectant

Bromine is a bleaching agent, and is used to disinfect water in cooling towers and the

swimming pools. In this case, bromine test strips are used to detect phenols and

unsaturated double bond compounds as well as alkalinity, pH and hardness of water. In

hospitals and commercial industries and homes, it is manly used as a sanitizer and a

germicide to neutralize bacteria, algae and fungi. It is also employed as a sanitizer, in

areas where there is less or no chances of it coming in contact with food. Bromine is also

preferred for disinfection of industrial water.


In Water Purification Compounds

Bromine can be found in products that are used in water purification systems.

Tralomethrin is one such product used to purify drinking water. The amount of bromine

present in water should not be more than 100mg/decilitre, which is its lowest toxic level.

In Pesticides

Bromine is also used in agricultural products such as pesticides to destroy pests. It is most

preferred to get rid of pests which targets crops, such as potatoes, tomatoes, etc. Methyl

bromide, is a compound that acts as a fumigate. It is used to protect stored grains and

other produces by destroying pests.

In Photography Film

The most well-known use of bromine is in making photographic films. Silver bromide is

light-sensitive and is used to manufacture photography plates. Its microscopic particles

when exposed to light undergo a change as a result of chemical reaction. This property of

silver bromide is responsible for the production of the image, when the photographic film

is exposed to light when you click the shutter. Potassium bromide is used in photography,

to prevent undesired reduction of silver, which causes fogging in a photograph.

IN medicines

Bromine has been used as a drug, for a long time, in one or the other form. Primarily,

chemical compounds derived from it are used as oral sedatives, to treat epilepsy and as

diuretics. It is well-known for its central nervous system depressive role in bromide

poisoning. In the past, as late as the start of 20th century, potassium bromide was used as a

sedative.


In Dyes

It was in 1909, when a German chemist Paul Friedlander found that the Tyrian purple

(red-purple to deep purple) contains bromine. In this form, it was known to man for

hundreds of years. Tyrian purple dye is nothing but a chemical 6,6'-dibromoindigo.

Another such dye used is tetra butyl ammonium bromide. These have many other

applications in the textile industry.

Other Uses

Salts of bromine formed with calcium, sodium, and zinc are water-soluble. The dense

solution thus, formed is used as a drilling fluid while drilling boreholes.

Ethidium bromide or EtBr is used as a DNA stainer, in the process of gel electrophoresis.

Normally this chemical, under ultraviolet light, gives out orange-glow which intensifies, if

EtBr binds with a DNA.

Bromine is employed to reduce mercury pollution that the coal consuming power plants

cause. Activated carbon and coal treated with bromine, does the trick.

5-bromouracil, is used as an artificial mutagen which helps scientists in forcing the genetic

materials, such as, DNA to change the bromides of the alkali and alkaline earth elements

find usage in pharmacy because of their sedative actions, in photography for preparing

silver bromide emulsions, and in the industrial drying of air as desiccants.

Zinc–bromine storage batteries (qv) are under development as load-levelling devices in

electric utilities.

Photovoltaic batteries have been made of sele n ium o r bo ron doped w i th

b romine .

Bromine and its salts are known to recover gold and other precious metals

from their ores.


SELECTION OF

PROCESS


SELECTION OF PROCESS

The two primary stripping vapours are steam and air. Steam is used when the

concentration of bromine in brine is>1000 ppm. The advantage is that bromine can be

condensed directly from the steam. Air is used, when seawater is the source of bromine

because very large volumes of stripping gas are needed and steam would be too expensive.

When air is used the bromine needs to be trapped in an alkaline or reducing solution to

concentrate it.

Blowing-out Process

Blowing-out process, used when the source of bromine is sea water, air is used instead of

steam to strip bromine from solution. At the pH of seawater, the liberated bromine

hydrolyzes to hypobromous acid and bromide. Bromide traps bromine as the tribromide

ion and little bromine is released. Before stripping, enough sulphuric acid is added to the

seawater to reduce the pH to 3–3.5. The exiting air containing bromine is absorbed in a

sodium carbonate solution.

3 Na2CO3 + 3 Br2 → 5 NaBr + NaBrO3+3 CO2

When the alkalinity of the absorbing solution becomes low it is moved to

storage. Acidifying the absorbing solution with sulphuric acid reconstitutes

the bromine that can then be steamed out.

NaBrO3 +5NaBr +3 H2SO4→3 Br2 + 3 Na2SO4+ 3 H2O

An alternative absorbing solution uses sulphur dioxide.

Br2 + SO2 +2 H2O →2 HBr + H2SO4

The bromine is recovered by oxidizing the bromide with chlorine and steaming it out of

solution. Treatment with sulphuric acid and fractional distillation are the main methods

used to purify bromine. It is especially important to reduce the water content to<30ppm to

prevent corrosion of metal transportation and storage containers.


PROCESS DESCRIPTION


FLOWSHEET


Mfg of Liquid Bromine (in brief) :-

Liquid bromine is produced from organic waste (acidic & alkaline) obtained from

pharmaceutical & fertilizer industries. NaBr obtained from waste is first acidified and then

treated with HBr and Cl2 gas to get gaseous bromine which when condensed in a

condenser gives Liquid Bromine.

Overall Reaction:-

NaBr + H2SO4 → HBr + Na2So4

HBr + Cl2 → HCl + Br2

Manufacturing Process:-

Raw Materials:-

Organic waste containing NaBr or HBr in significant quantity is obtained from fertilizer

and pharmaceutical industries.

Chlorine gas is used in substitution reaction to get liquid bromine.

Steam is used as heating medium as well as carrier gas.

Process: -

Reactor 1: -

Organic waste containing 10% to 25% concentration of NaBr is acidified in reactor 1. Due

to the corrosive nature of reactants reactor has to be glass lined. H2SO4 is added as a

acidifying medium. Acid used is of 98% conc. Steam of 1kg/hr mass flow rate is used to

attain reaction temperature of 110 oC and a pressure of 1kg/mm2.

Reaction taking place in the reactor is given by

NaBr + H2SO4 → HBr + Na2So4


Since the reaction temperature is maintained at 110 oC all the organics having boiling

point less than that of water along with water and HBr get seperated and are sent to

condenser where hot vapours get condensed.

Filtration: -

The condensed liquid obtained is a mixture of HBr, water, & low boiling organics. Here

organics are undesired product therefore it needs to be removed.

Thus the liquid mixture is passed over a filter cloth in a filtration unit which acts under

vacuum. Here all the organics are removed from the mixture & HBr of approx. 30% conc.

is obtained. HBr obtained is pumped in reactor 2 for substitution reaction.

Reactor 2: -

Reactor 2 is made up of glass and is 6 m tall. Rasching rings are used as packing so as to

increase liquid gas contact time. Reaction temperature is 80 oC.

Liquid HBr is allowed to pass from the top and steam and Cl2 gas is passed through

bottom. Here, steam performs dual jobs firstly, of a heating medium & secondly, as a

carrier gas. The reaction taking place in the reactor is given by

HBr + Cl2 → HCl + Br2

HCl obtained is of 10% concentration which is of no significant use. It can either be

concentrated to 25% for sale or can be neutralised and discharged as an effluent. Br2

vapours along with unreacted Cl2 gas & H2O is condensed in a condenser & sent to a

distillation unit for further separation.

Distillation Unit: -

Distillation unit is also made up of glass & is also 6 m tall. Packing used is rasching rings

and temperature is maintained 80oC.

The liquid mixture obtained from condenser is allowed to be heated using steam. Cl2 gas

having least boiling point in the mixture evolves first & is recycled back to reactor 2.

Around 62 to 65oC Br2 starts to evolve which is sent to the condenser where its


temperature is reduced below boiling point. Liquid bromine obtained is then stored in

amber coloured bottles. Water obtained from the bottom of distillation column and is

recycled for further use.


INSTRUMENTATION &

PROCESS CONTROL


INSTRUMENTATION AND PROCESS CONTROL

In any chemical industry quality has become the most important specification. This can be

achieved by proper instrumentation “Precise process control is a reward to Production”.

The measurement of the level of various energies and the control of the energy, which can

take place, is called instrumentation.

Instrumentation and process control are necessary in a plant for the following reasons:

1. Quality Control

2. Recording of certain variables (Viz. Temperature, Pressure, Viscosity, and pH) for

future analysis

3. To eliminate human errors while operating or running a plant

4. Safety of plant and efficient control

5. For controlling pollution free better control of plant emissions to meet more

stringent regulations

Since, in a chemical plant, the reactions are taking place in the reactor or column which

cannot be analyzed from outside and hence we have to rely on the reading indicated by

instruments and hence their reliability is to be accurately examined.

But only instrumentation cannot serve our purpose because instruments only indicated the

values of various parameters like pressure, temperature, level etc. And also, mere

indication is of no use. Sometimes there may be deflections in parameters and we have to

control it. So some systems are provided with these instruments and are termed as

“Process Control”.

In instrumentation and process control temperature, pressure, flow and level are the four

main variables, which are to be controlled for plant safety and from economic point of

view.

A well planned instrumentation and process control scheme leads to the following

advantages.


1. Saving of labour.

2. Saving of service consumption.

3. Controlled speed of operation.

4. Accuracy

5. Continuous recording of process variables.

Instrumentation and process control does not mean automatic control of parameters.

Instrumentation also makes the use of local indicator. Local temperature and pressure

indicators are used to control the temperature and pressure indicators are used to control

the temperature and pressure manually in the emergency e.g. when there is power failure

at such time automatic controllers cannot work. Local indicators are installed with

equipments such as reactors, distillation columns, pumps, reboilers, heat exchangers etc.

Valves are installed at inlet and outlet with all the units of POCl3 plant to control the inlet

outlet flow rates of the process and utility lines.

INSTRUMENTATION FOR SPECIFIC EQUIPMENTS:-

Distillation Column: -

Distillation column should be provided with feed flow controllers by using flow-recording

controllers.

At the top of the distillation column a pressure relief valve is installed to release the excess

pressure and maintain the inside pressure.

Condenser & Preheater: -

Condenser and Preheater are installed as heat exchanging equipments. In both the units

utility inlet valves are controlled by process outlet temperature by means of a control loop.

Reboilers: -

At the bottom of the distillation column reboilers is placed. In reboilers steam flow is

controlled by process temperature level indicator controller is used with reboilers to

control the level of the process fluid in the reboilers.


Pump: -

For transporting the process liquid positive suction centrifugal pump are used. Before a

pump a strainer is used to remove the solid particles or impurities. A nonreturnable valve

is also installed at the pump outlet.

Reactor: -

Flow:

Being a batch plant, the production capacity is fixed & hence the flow rate of raw material

plays an important role. Flow indicators & Controllers along with flow measuring devices

such as Rotameter have to be installed flow lines

Temperature:

The reaction taking place inside the reactor is endothermic and temperature is to be

maintained at 110˚C, which requires perfect process control to have higher conversion

hence for temperature measurement RTD or Thermocouple is satisfactorily used. The

temperature is sensed by the measuring unit & when it approaches 112˚C or 114˚C the

temperature is controlled to 110˚C. By altering the flow rate of chilled water flowing into

the internal coils which is a manipulated variable.

Level: -

Shaft & float type indicators are economically used as a level measuring devices


MATERIAL BALANCE


MATERIAL BALANCE FOR REACTOR 1

Chemical reaction:-

2NaBr + H2SO4 → Na2SO4 + 2HBr

Required data:-

Chemicals Molecular weight

H2SO4 98

NaBr 103

HBr 81

Basis: 1000 kg solution of 10% NaBr and 10% organics.

i.e. 1000 kg of solution contains → 100 kg of NaBr, 100 kg of organics and 800 kg of

water.

100 kg NaBr → 971 mol of NaBr

From the stoichiometry of the reaction,

971 mol of NaBr → 485.5 mol of H2SO4

Amount of 98% H2SO4 required for 100 kg of NaBr

= (485.5 × 98)/.98

=48.55 kg

Similarly,

971 mol of NaBr → 485.5 mol of Na2SO4 and 971 mol of HBr

Amount of Na2SO4 formed = 485.5 × 142

= 68.94 kg.


Amount of HBr formed = 971 × 81

=78.651kg.

From top we get 20% HBr solution.

Wt. of HBr solution = 78.651/.2

= 393.255 kg

Wt. of water in HBr solution = 393.255 – 78.651

= 314.6 kg

At bottom, we obtain

Wt. of organics + water = (Wt. of feed solution + Wt. of H2SO4 – Wt. of

HBr solution)

= (1000 kg + 48.55 kg – 393.255 kg )

= 655.295 kg


MATERIAL BALANCE FOR REACTOR 2

Chemical reaction:

2HBr + Cl2 → 2HCl + Br2

Basis: - 1kmole of product POCl3

Compound Molecular Weight

Br2 80

HCl 36.5

HBr 81

Chlorine 35.5

From the stoichiometry of the reaction,

971 mol of HBr → 485.5 mol of Cl2

971 mol of HBr → 78.65 kg/hr of HBr

Amount of Cl2 required for 78.65 kg of HBr

= (485.5 × 71)

=34.47 kg

Similarly,

971 mol of HBr → 485.5 mol of Br2 and 971 mol of HCl

Amount of Br2 formed = 485.5 × 80


= 38.84 kg.

Amount of HCl formed = 971 × 36.5

=35.44 kg/hr

At bottom, we obtain

Wt. of 12% HCl = 35.44/.12

= 295.33 kg/hr

Wt. of water in HCl solution = 295.33 – 35.44

= 259.9 kg/hr

For reaction, we provide

Cl2 flowrate = 50kg/hr

Steam flowrate = 16kg/hr

At top, we obtain

Wt. of Cl2 = 50 – 34.47

= 15.53 kg/hr

Wt of Br2 = 38.84

Wt. of steam = ( Wt.of water in HBr solution + steam feed – Wt. of

water in HCl solution)

= ( 314.6 + 16 - 259.9)

= 70.7 kg/hr


MATERIAL BALANCE FOR DISTILLATION

Feed contains 38.84 kg of Br2 and 70.7 kg of water.

i.e. .41% of Br2 and 59% of water

At top,

Wt. of 98% Br = 38.84/.98

= 39.63 kg

Wt. of water = 39.63 – 38.84

= .8 kg

Wt of water at bottom= 70.7 - .8

= 69.9 kg


ENERGY BALANCE FOR REACTOR 1

Reaction 1

2NaBr + H2SO4 → Na2SO4 + 2HBr

Chemicals Standard heat of reaction

(KJ/mol)

Heat Capacity

(cal mol-1K-1)

H2SO4 -814 25

NaBr -361 11.74 + .00233T

HBr -36.4 6.8 + .000084T

Na2SO4 -1387.1 32.8

Total heat of reaction at standard temperature

ΔHR 0 = ∑ΔHo PRODUCTS - ∑ΔHoREACTANTS

= [ 2(-36.4) + (-1387.1) ] - [ 2(-361) + (-184) ]

= 76.1 KJ/mol

= 18200 cal/mol

Total heat of reaction at operating temperature i.e. at 383 K

ΔHR383 = ΔHR 0 + ∫ ΔCp dt

= 18200 + ( 2.08T + .00298T2/2]383298

= 18200 - ( 176.8 + 86.248 )

= 17936.952 cal/mol of H2SO4

= 8708413 cal

Steam required is given by


ΔHR383 = mass of steam * Latent heat of vaporisation

ΔHR383 = m * λ

8708413 = m 540

m = 16 kg/hr of steam

ENERGY BALANCE FOR REACTOR 2

Reaction 2

2HBr + Cl2 → 2HCl + Br2

Chemicals Standard heat of reaction

(KJ/mol)

Heat Capacity

(cal mol-1K-1)

HCl -72.31 6.7 + .00084T

Cl2 0 8.28 + .00056T

HBr -66.36 6.8 + .000084T

Br2 30.91 9

Total heat of reaction at standard temperature

ΔHR 0 = ∑ΔHo PRODUCTS - ∑ΔHoREACTANTS

= [ 2(-72.31) + (30.91) ] - [ 2(-66.36) + 0 ]

= 18.41 KJ/mol

= 4400 cal/mol

Total heat of reaction at operating temperature i.e. at 353 K


ΔHR353 = ΔHR 0 + ∫ ΔCp dt

= 4400 + ( .54T + .000056T2/2]353298

= 18200 + ( 29.7 - 10 )

= 4419.7 cal/mol of Cl2

= 2145910 cal

Steam required is given by

ΔHR353 = mass of steam * Latent heat of vaporisation

ΔHR353 = m * λ

2145910 = m 540

m = 3.97 kg/hr of steam

ENERGY BALANCE FOR DISTILLATION TOWER

Balance on Bromine, bromine loss at bottom is neglected.

38.84 = D .98


ENERGY BALANCE for POCl3

HR (333K) = - 279.5kJ/mole

Total heat of reaction at (333K) Reaction temperature

=No. of moles of POCl3 × (279.5) kJ/mole

No. of moles of POCl3 = (6281.54kg/ batch)/157.5

= 39.883 × 103 gm mole

HR (333K) = 39.883 × 103 × (279.5) kJ/mole

= -11.147 × 103 kJ/mole

HR (333K) = Q = Heat evolved = Heat absorbed

During reaction by cold water

Q = mW CpW T

Where mw = Mass flow rate of chilled water

Cpw = Specific heat of water

T = (Inlet temperature – Outlet temperature)

-11,147.17 × 103 = mw × 4.182 × (25-35)

mw = 266.551 × 18 kg/batch

mw = 4797.92 kg/batch


Mass flow rate of water required = 599.74 kg/ hr.


THERMODYNAMIC

FEASIBILITY


THERMODYNAMIC FEASIBILITY FOR POCL3

Thermodynamics Feasibility is of great importance in chemical process. The following

points can state its importance:-

1) Because of thermodynamic calculation of equilibrium constant “k” from free

energy of reacting material is possible. Thus for reaction with only the equilibrium

constant known, the expected maximum attainable conversation so obtained will

be maximum one for given reaction. This calculation is nothing but

thermodynamic feasibility.

2) Thermodynamic gives the heat liberated or absorbed during the reaction and hence

the nature of reaction i.e., endothermic or exothermic

Reaction: - PCl3 + ½O2 → POCl3

Due to non availability of thermodynamic data, from the literature the practical

value of heat of formation of compounds is accepted from “Langes Handbook”.

Now heat of formation at 298K or 25°C

Sr. No. Chemicals Specific heat

Cal/mol°k (25°C to

60°C)

Heat of formation

Kcal/mol K

1. PCl3 23.44 -76.4

2. Oxygen 7.016 0

3. POCl3 33.17 -142.7

∆H°R (298°K) = H°f (Product) - H°f (Reactants)

= (-142.7) - (-76.4 + 0)

= -66.3 kcal/mol Heat of reaction.


We know that,

∆G = ∆H°R - T∆S -------- (1)

∆G = - R T ln K -------- (2)

Since our reaction is liquid

S≈O

Therefore Equation (1) becomes

∆G = ∆H°R -------- (3)

Now from equation (2) & (3)

∆G = - R T ln k -------- (4)

Where

R = Universal gas constant = 1.987 cal/g mole

T = 298k

K = Equilibrium constant

∆H°R = Heat of reaction at 298 k

From equation (4)

-66.3×103 = - (1.987) × (298) × ln kp1

kp1 = 40.24 ×1048

∆H°R at reaction temperature i.e. 333 k

∆H°R (333k) = ∆H°R (298k) + ΔCp 298 ∫333 dT -------- (A)

ΔCp in range of 298K to 333K


ΔCp = [Cp (product) - Cp (reactant)]

= [33.17 – 23.44+ (0.5×1.016)]

= 6.222 cal/mole.K

From equation (A)

∆H°R (333k) = -66.3 + 6.22 (333 – 298)

∆H°R (333k) = -66.53 kcal/mole

= -279.3kJ/mole

ΔS = 0.308 kcal/mole K

Now, to find the ‘k’ at 333K, we use relation….

lnk1⁄k2 = ∆H°R (298°k) ⁄ R [1/T1 – 1/T2]

ln (4.24 ×1048 / k2 ) = (-66.3/1.927) [(1/333)-(1/298)]

k2 = 3.28 × 1043

As the value of ‘k2’(at 333K) is very high i.e. equal to infinity.

So conversion is also high ( consider about 90 to 95% ).


REACTOR DESIGN


PLANT UTILITIES


In manufacturing of liquid bromine, three main utilities are involved. They are as follows:

Cooling water: –

Cooling water is used in condenser and cooling water tower. In condenser it is used to

absorb heat so as to convert gaseous mixture of HBr, H2O, from reactor 1 to liquid state

and condense Br gas coming out of distillation column to obtain liquid bromine.

Steam: –

It is used in reactor 1 and distillation column as a heating medium. In reactor 2 it is used

as heating medium and carrier gas to carry Cl2 gas.

Electricity: –

It is the common utility used in every plant to run electric motor, controllers, different

equipments and instruments.

Vacuum: –

It is used in filtration to separate impurities from mixture coming out from reactor 1.


MAINTENANCE


MAINTENANCE

The world “Maintain” literally means, “to cause to Continue”. In a plant this means that

physical plant assets (machinery and equipment) continue to fulfill their intended function.

Maintenance is necessary so as to keep the machines, equipment etc. running at their

maximum operating efficiency. Thus smooth production with minimum breakdown is

achieved. Maintenance creates so far working condition in the plant and also help to

reduce the total working cost of the plant.

Maintenance of the equipment in the Liquid Bromine plant is done as follows:-

Centrifugal Pump:-

1. The Suction and discharge pipes of the Centrifugal Pump should be cleaned by

flushing water.

2. Bearing should be lubricated.

3. If the shaft sleeves are worn out they should be replaced.

4. If the impeller is damaged it should be repaired or replaced. Run out of the shaft

should be prevented.

5. Alignment of the pump should be checked.

6. Power / voltage given should be measured.

Valves:-

1. Valves, which may be pneumatic, hydraulic etc, are used to stop completely or

regulate flow.

2. The Valve should be flushed with water to remove the rust, scale and dirt, which

may be present under the disc and washer between the threads and other place.

3. The threads and seating surface should be cleaned with brush. If needed the seats

and disc should be replaced.

4. All rotating and sliding parts must be lubricated.


Piping:-

1. All the pipes are initially cleaned by mild acid and then by then by a neutralizing

agent followed by flushing with clean water. Pipe threads should be cleaned with

wire brush.

2. Leakage from the piping must be permanently stopped.

3. Pipes and pipe joints which have been attacked by corrosion should be replaced

immediately.

Process Control Instruments:

1. All process Control Instruments including indicators, controller, sensor, actuators

etc should be checked for their proper working.

2. Their calibrations should be checked with the master instruments. Any faulty

instruments should be replaced by new one or recalibrated.

Reactors:-

1. Initially all the material presents it inside the reactor must be drained off in a safe

point of discharge. If any undesirable gases are present it should be vented to the

stripping section.

2. The reactor is then thoroughly flushed with hot or cold water it should be seen that

the reactor contains no traces of PCl3 & POCl3.

3. Reactor consist “Rapture Disc”, which is worked at the time of emergency i.e.

when the pressure developed inside the reactor goes to tolerance level. The person

entering the reactor should be properly examining it, after every month. He should

be checking its proper sound condition.


4. The person entering the reactor should be wear his safety uniform & should carry

the “safety permit” with him. Before he enter the reactor he should be see that it is

sufficiently ventilated as well as illuminated.

5. The jobs to be performed by this worker also include cleaning the alignment of the

shaft.


HANDLING AND

STORAGE


HANDLING, SHIPPING & STORAGE

Liquid Bromine is classified by the ICC as a corrosive liquid, and DOT corrosive material

label is required by law, on individual containers. Glass lined and PTFE lined steel

equipment is frequently in reactors.

An exhaustive survey and awareness of safety hazards are among the basic and primary

conditions for the safe handling of materials at all stages, including: production, storage,

transportation and use.

Consequences of Exposure

Liquid bromine produces a mild cooling sensation on first contact with the

skin, which is followed by a sensation of heat. If bromine is not removed immediately by

flooding with water, the skin becomes red and finally brown, resulting in a deep burn that

heals slowly. Contact with concentrated vapour can also cause burns and blisters. For

very small areas of contact in the laboratory, a 10% solution of sodium thiosulfate in water

can neutralize bromine and such a solution should be available when working with

bromine.

Bromine is especially hazardous to the tissues of the eyes where severely painful and

destructive burns may result from contact with either liquid or concentrated vapour.

Ingestion causes severe burns to the gastrointestinal tract.

Detection of Bromine Vapour

Bromine vapour in air can be monitored by using an oxidant monitor instrument that

sounds an alarm when a certain level is reached. An oxidant monitor operates on an

amperometric principle. The bromine oxidizes potassium iodide in solution, producing an

electrical output by depolarizing one sensor electrode.


Protective Equipment

Totally enclosed systems should be used for processes involving bromine. For handling

bromine in the laboratory, the minimum safety equipment should include chemical

goggles, rubber gloves, laboratory coat, and fume hood. For handling bro-mine in a plant,

safety equipment should include hard hat, goggles, neoprene full coverage slicker,

neoprene rubber gloves, and neoprene boots. For escaping from an area where a bromine

release has occurred, a full face respirator with an organic vapor–acid gas canister is

desirable. For emergency work in an area with bromine concentrations>0.1ppm, a self-

contained breathing apparatus can be used until the air supply gets low.

Safe production of bromine

In bromine production, as in any other production process in which bromine is involved

strict safety rules have to be observed11, based on a thorough understanding of the

hazards inherent in each of the processes, raw materials, intermediate products and

products.

The following precautions should be taken:

- All the production systems should be hermetically sealed.

- All outputs of the system should be treated appropriately (products,

by products, exhaust fumes, sewage and solid waste) to prevent

compromising safety and endangering the environment.

- Appropriate steps must be taken to prevent emission of toxic gases.

- All parts of the installation must be constructed from bromine-

resistant materials.


Safe handling of bromine leakage

If an accident occurs and there is a bromine leakage, it is important to deal with the

leakage immediately in such a way as to limit the harm done to people and the

environment as much as possible. We saw how bromine is neutralized in the laboratory.

Different considerations may be put forward for the establishment of suitable industrial

bromine-neutralizing methods, adapted to large-scale processes. The use of larger

quantities of material requires that serious thought be given to such questions as: - Ease of

handling - Availability of neutralizing agents - Costs - Reaction enthalpy.

Safe storage of bromine

Safe storage of materials is an important issue, which over the years has itself become a

special expertise. Storage rules and methods must comply with the particular properties of

each material, its reactions with other materials and the different hazards involved. The

properties of bromine also have an important bearing on its storage: - The volatility of

bromine dictates the need to store it in a place protected from external damage. - Its

oxidizing capacity dictates the need to avoid contact with reducing agents, organic

compounds and combustible materials. - Its highly corrosive action in the presence of

water dictates the need to store it in a dry place and to build storage tanks with suitable

resistant coating. - Its ability to form light-induced free radicals requires storage in a

dark place. - In addition there are other requirements, such as: protection against static

electricity, etc.

Safe transportation of bromine

Accidents in which toxic materials are involved, and plants producing such materials,

quickly make headlines and are widely publicized. Usually these accidents are caused by

carelessness, negligence or human error. Many accidents during transportation of

hazardous materials occur as a result of speeding. These accidents could have been

prevented if everybody involved in the transportation of materials in general, and

hazardous materials in particular, had obeyed the rules that apply to them.


Transportation of hazardous materials requires particular expertise and bromine is no

exception. International and local transportation of bromine is subject to international

control and regulations on transportation of hazardous materials.

Bromine is transported in liquid form, but its volatility and toxicity demand that it be

transported in the safest possible way, with complete sealing of the transporters and

precautions against the danger of bromine leakage to the air.

Safe use of bromine

Bromine is used for many purposes in research and industry. All safety rules observed

during the production, storage and transportation of bromine must also be obeyed during

its handling and use. Every customer who uses large amounts of bromine must have an

unloading station. The bromine is unloaded while connected to the isotank or the

container of the absorption tower to prevent bromine vapours escaping into the air.

Emptying of the isotank is monitored by weighing or by watching through a glass

window. When all the bromine is removed, the colour of the windows changes from

brownish-red to a light hue. At any such unloading station suitable neutralizing materials

and protective equipment must be available.


Section 1

Chemical Product and Company Identification

Product Name : Liquid Bromine

Catalog Codes : SLB4777

CAS# : 7726-95-6

RTECS : EF9100000

TSCA : TSCA 8(b) inventory: Bromine

CI# : Not available.

Synonym :

Chemical Name : Bromine

Chemical Formula : Br2

Contact Information : Sciencelab.com, Inc.14025 Smith Rd.

Houston, Texas 77396 US Sales: 1-800-901-7247

International Sales: 1-281-441-4400

Section 2

Composition and Information on Ingredients

Name CAS # % by Weight

Bromine 7726-95-6 100

Toxicological Data on Ingredients: Bromine: ORAL (LD50): Acute: 3100 mg/kg [Mouse]. 4160 mg/kg [Rabbit]. 2600 mg/kg [Rat].


Section 3

Hazards Identification

Potential Acute Health Effects : Very hazardous in case of skin

Contact (irritant), of eye contact

(irritant), of ingestion, of inhalation.

CARCINOGENIC EFFECTS : Not available.

MUTAGENIC EFFECTS : Not available.

TERATOGENIC EFFECTS : Classified.POSSIBLE for human.

DEVELOPMENTAL TOXICITY : Not available. Repeated or prolonged

exposure is not known to aggravate

medical condition.

Section 4

First Aid Measures

Eye Contact:

Check for and remove any contact lenses. In case of contact , immediately flush eyes with

plenty of water for atleast 15 minutes. Get medical attention immediately.

Skin Contact:

In case of contact, immediately flush skin with plenty of water. Cover the irritated skin

with an emollient. Remove contaminated clothing and shoes. Wash clothing before reuse.

Thoroughly clean shoes before reuse. Get medical attention.


Serious Skin Contact:

Wash with a disinfectant soap and cover the contaminated skin with an anti-bacterial

cream. Seek immediate medical attention.

Inhalation:

If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is

difficult, give oxygen. Get medical attention.

Serious Inhalation:

Evacuate the victim to a safe area as soon as possible. Loosen tight clothing such as a

collar, tie, belt or waistband. If breathing is difficult, administer oxygen. If the victim is

not breathing, perform mouth-to-mouth resuscitation.

WARNING: It may be hazardous to the person providing aid to give mouth-to-mouth

resuscitation when the inhaled material is toxic, infectious or corrosive. Seek immediate

medical attention.

Ingestion:

Do NOT induce vomiting unless directed to do so by medical personnel. Never give

anything by mouth to an unconscious person. If large quantities of this material are

swallowed, call a physician immediately. Loosen tight clothing such as a collar, tie, belt or

waistband.

Serious Ingestion : Not available.

Section 5:

Fire and Explosion Data

Flammability of the Product : Nonflammable


Auto-Ignition Temperature : Not applicable

Flash Points : Not applicable

Flammable Limits : Not applicable

Products of Combustion : Not available

Fire Hazards in Presence

of Various Substances : Flammable in presence of combustible

materials of reducing materials of organic

material of aluminium.

Explosion Hazards in Presence

of Various Substances : Risks of explosion of product in presence

of mechanical impact : not available.

Risks of explosions of the product in

Presence of static discharge: not available.

Fire fighting Media and instructions : Not applicable

Special Remarks on Fire Hazards: Flammable in the form of liquid or vapour by

spontaneous chemical reaction with reducing

materials. May cause fire in contact with

wood, sawdust, cotton, straw, etc.

Special Remarks on Explosion Hazards : Reacts explosively with Acetylene,

Acrylonitrile, Ammonia, Dimethyl Formaldehyde, Ethyl

Phosphine, H2, Ni, Nitrogen Triiodide, O3, O2, P, K, Ag, Na.


Section 6:

Accidental Release Measures

Small Spill:

Absorb with an inert material and put the spilled material in an appropriate waste disposal.

Large Spill:

Corrosive liquid. Poisonous liquid. Stop leak if without risk. Absorb with DRY earth, sand

or other non-combustible material. Do not get water inside container. Do not touch spilled

material. Use water spray curtain to divert vapour drift. Use water spray to reduce

vapours. Prevent entry into sewers, basements or confined areas; dike if needed. Call for

assistance on disposal. Be careful that the product is not present at a concentration level

above TLV. Check TLV on the MSDS and with local authorities.

Section 7:

Handling and Storage

Precautions:

Keep locked up. Keep container dry. Do not ingest. Do not breathe gas/fumes/

vapour/spray. Never add water to this product. In case of insufficient ventilation, wear

suitable respiratory equipment. If ingested, seek medical advice immediately and show the

container or the label. Avoid contact with skin and eyes. Keep away from incompatibles

such as reducing agents, combustible materials, organic materials

Storage:

Keep container tightly closed. Keep container in a cool, well-ventilated area.

Section 8:

Exposure Controls/Personal Protection

Engineering Controls:


Provide exhaust ventilation or other engineering controls to keep the airborne

concentrations of vapours below their respective threshold limit value. Ensure that

eyewash stations and safety showers are proximal to the work-station location.

Personal Protection:

Face shield, Full suit, Vapour respirator. Be sure to use an approved/certified respirator or

equivalent, Gloves, Boots.

Personal Protection in Case of a Large Spill:

Splash goggles, Full suit, Vapour respirator. Boots, Gloves. A self contained breathing

apparatus should be used to avoid inhalation of the product. Suggested protective clothing

might not be sufficient; consult a specialist BEFORE handling this product.

Exposure Limits:

TWA: 0.66 STEL: 1.3 (mg/m3) from ACGIH (TLV) [United States] TWA: 0.1 STEL: 0.2

(ppm) from ACGIH (TLV) [United States] TWA: 0.1 from OSHA (PEL) [United States]

TWA: 0.7 (mg/m3) from OSHA (PEL) [United States] TWA: 0.66 STEL: 2 (mg/m3)

[United Kingdom (UK)] TWA: 1 STEL: 0.3 (ppm) [United Kingdom (UK)] Consult local

authorities for acceptable exposure limits..

Section 9:

Physical and Chemical Properties

Physical state and appearance : Liquid

Odor : Pungent (Suffocating)

Taste : Not available.

Molecular Weight : 159.808 g/mole

Colour : Reddish Brown

pH (1% soln/water) : Not available.


Boiling Point : 58.78 oC

Melting Point : -7.25 oC.

Critical Temperature : 315 oC.

Specific Gravity : 3.11

Vapor Pressure : 23.3 kPa.

Vapor Density : 7.1 (Air)

Volatility : Not available.

Odor Threshold : 0.05 ppm.

Water/Oil Dist. Coeff. : Not available.

Ionicity (in Water) : Not available.

Dispersion Properties : See solubility in water, diethyl ether

Solubility: Easily soluble in diethyl ether. Very

slightly soluble in cold water. Freely

soluble in alcohol, chloroform, carbon

disulfide, carbon tetrachloride,

concentrated hydrochloric acid, and

aqueous solution of bromides.

Section 10:

Stability and Reactivity Data

Stability : The product is stable.

Instability Temperature : Not available.

Conditions of Instability : Incompatible materials.


Incompatibility with various

Substances : Not available.

Corrosivity : Extremely corrosive in presence of

aluminum, of zinc, of stainless steel(304), of

stainless steel(316). Highly corrosive in presence of

copper. Non-corrosive in presence of glass

Special Remarks on Reactivity :Incompatible with organic compounds containing

active hydrogen atoms adjacent to the carbonyl

group (aldehydes, ketones, carboxylic acids).

Special Remarks on Corrosivity : Corrodes iron, stainless steel and copper.

Severe corrosive effect on bronze

Polymerization : Will not occur.

Section 11:

Toxicological Information

Routes of Entry : Inhalation, Ingestion.Dermal contact.

Toxicity to Animals : Acute oral toxicity (LD50): 1271 mg/kg

[Rat].

TERATOGENIC EFFECTS : Classified POSSIBLE for human.

Other Toxic Effects on Humans : Slightly hazardous in case of skin contact

(irritant), of ingestion, of inhalation.

Special Remarks on Toxicity to Animals : Not available.


Special Remarks on Chronic Effects on Humans:

Not available.

Special Remarks on other Toxic Effects on Humans:

Acute Potential Health Effects: Skin: Contact with liquid is corrosive and causes

ulceration and skin burns. In milder cases, it might cause skin rash, pustles, measle-like

erruptions, furuncles, and cold and clammy skin with cyanosis or pale color. Eyes: It is a

lacrymator and causes eye irritation, eyelid inflammation at low concentration. At higher

concentrations it may cause blepharospasm, photophobia, conjunctivitis, and burns.

Inhalation: Inhalation of smaller amounts may cause severe irritation of the respiratory

tract with coughing, chest tightness, shortness of breath, and nosebleed. Inhalation of

larger amounts may cause pulmonary edema, chemical pneumonitis, bronchospasm,

pneumomidiastinum, glottal spasm, glottal edema, inflammatory lesions in the mucous

membranes, inflammed tongue and palate, chemical burns of the lungs, asthmatic

bronchitis, and severe choking. Death may occur due to circulatory collapse, asphyxiation

from edema of the glottis, aspiration pneumonia, or pulmonary edema. It may also affect

behavior/central nervous system and gastrointestinal tract, cardiovascular system, thyroid,

Symptoms may include dizziness, headache, fatigue, disturbances of sleep and sexual

function, feeling of opression, vertigo, anxiety, depression, muscle incoordination,

emotional instabililty, delirium, stupor, vomiting, diarrhea, abdominal pain, tachycardia,

hypotension. Ingestion: May cause severe and permanent damage to the digestive tract. It

may cause gastrointestinal tract burns, burning pain of the mouth and esphagous, corrosive

gastroenteritis with vomiting, abdominal pain, diarrhea, and possible bloody feces. It may

cause kidney damage (hemmorrhagic nephritis with oliguria or anuria, and liver damage,

brownish discoloration of lips, tongue and mucous membranes It may also affect the

cardiovascular system (tachycardia, hypotension, and cyanosis and behavior/central

nervous system (symptoms similar to inhalation) Chronic Potential Health Effects:

Inhalationand Ingestion: Prolonged or repeated exposure may affect respiration and


endocrine system (thyroid), metabolism, behavior/central nervous system, and

cardiovascular system, and cause kidney and liver damage. Effects may be delayed.

Section 12:

Ecological Information

Ecotoxicity : Not available.

BOD5 and COD : Not available.

Products of Biodegradation : Possibly hazardous short term degradation

products are not likely. However,

long term degradation products may arise.

Toxicity of the Products

of Biodegradation : The products of degradation are less toxic

than the product itself.

Special Remarks on the Products

of Biodegradation : Not available.

Section 13:

Disposal Considerations

Waste Disposal:

Waste must be disposed of in accordance with federal, state and local environmental

control regulations.


Section 14:

Transport Information

DOT Classification :Class 8: Corrosive material CLASS 6.1:

Poisonous material

Identification : Bromine UNNA: 1744 PG: I.

Special Provisions for Transport : Poison-inhalation hazard, Zone A

Section 15:

Other Regulatory Information

Federal and State Regulations:

Connecticut hazardous material survey.: Bromine Illinois toxic substances disclosure to

employee act: Bromine Illinois chemical safety act: Bromine New York release reporting

list: Bromine Rhode Island RTK hazardous substances: Bromine Pennsylvania RTK:

Bromine Minnesota: Bromine Massachusetts RTK: Bromine Massachusetts spill list:

Bromine New Jersey: Bromine New Jersey spill list: Bromine Louisiana RTK reporting

list: Bromine California Director's list of Hazardous Substances: Bromine TSCA 8(b)

inventory: Bromine SARA 302/304/311/312 extremely hazardous substances: Bromine

SARA 313 toxic chemical notification and release reporting: Bromine.

Other Regulations:

OSHA: Hazardous by definition of Hazard Communication Standard (29 CFR

1910.1200). EINECS: This product is on the European Inventory of Existing Commercial

Chemical Substances.


Other Classifications:

WHMIS (Canada):

CLASS D-1A: Material causing immediate and serious toxic effects (VERY TOXIC).

CLASS E: Corrosive liquid.

DSCL (EEC):

R26- Very toxic by inhalation. R35- Causes severe burns. R50- Very toxic to aquatic

organisms. S1/2- Keep locked up and out of the reach of children. S7/9- Keep container

tightly closed and in a well-ventilated place. S26- In case of contact with eyes, rinse

immediately with plenty of water and seek medical advice. S45- In case of accident or if

you feel unwell, seek medical advice immediately (show the label where possible). S61-

Avoid release to the environment. Refer to special instructions/Safety data sheets

HMIS (U.S.A.)

Health Hazard : 3

Fire Hazard : 0

Reactivity : 0

National Fire Protection Association (U.S.A.)

Health : 3

Flammability : 0

Reactivity : 0

Specific hazard:

Protective Equipment: Gloves. Lab coat. Vapour respirator. Be sure to use an

approved/certified respirator or equivalent. Safety glasses.


Section 16:

Other Information

References : Not available.

Other Special Considerations : Not available.

Created : 10/11/2005 1:06 PM

Last Updated : 06/09/2012 12:00 PM

MARKET SURVEY


Bromine Production by area in 2008

China

Japan

USA

Isreal

JordanUSA 36%

Isreal 27%

Jordan 14% China 19%

Japan 3%

fig 2 from Isreal Chemicals ltd.


Bromine Consumption in 2008

China30%

U.S.A19%Europe

13%

Japan7%

India6%

Others25%

fig.3from Israel chemicals ltd.


Bromine demand by applications

Flame Retardants 48%

Drilling Fluids 10%

Others 30%

Fu-mi-

gates 3%

Water Treatment 4% Industrial

Uses 5%

fig.4from Israelchemicals ltd.


SITE SELECTION


SITE SELECTION

Selected Site Badlapur

The location of the plant has a very significant effect on the profitability of a project and

the scope for future expansion. The following are the factors which were examined for our

site selection.

Raw Material supply

This is one of the most important aspect to be examined to finalize a site. The availability

of raw materials for NaBr & HBr at the above selected site is discussed below.

A) NaBr: NaBr is obtained from pharmaceutical and fertilizer industry as an effluent.

These industries are situated in the nearby area so obtaining raw material is a very easy

task.

B) Chlorine in quantitative terms chlorine is the largest required raw material. Chlorine is

obtained from nearby plants in the MIDC region

C) Steam is easily available from boilers.

Location with respect of marketing area

Liquid Bromine is chiefly used in pharmaceutical indistries in manufacturing of

plastisicers as additive I hydraulic fluids, in lubricants amongst others. The badlapur

region and the Mumbai Ahmadabad industrial belt offer a very good potential market for

the product. Therefore the site is well located with respect to marketing area.

Transport facility.

Therefore transport facility is easily available for raw materials, products and equipments.

The proximity to railways also plays an important role in selecting this site.


Availability of labour

The labour for plant construction and operation is readily available locally and cheaply.

Also due to its proximity to education center like Mumbai and being an already developed

industrial area it attracts semi skilled plant operators and managers from neighbors states

Availability of Utilities

The site is located near chikhaloli dam thus; water and power are supplied at reasonable

rates. Also the availability of fuel is no problem due to excellent facilities.

Availability of suitable land

Badlapur being an industrial zone, acquiring land is not difficult. The land soil has a good

bearing capacity and not terrain.

Local community consideration

The proposed plant would be acceptable to the local community since it is a chemical

zone. Also the plant is solely located away from the residential area. Adequate schools,

banks, housing, recreational and cultural faculties are available for the plant employees

near the site. Also there are no significant inter community tension.

Climate

The region experiences moderate to hot climate throughout the year and seasonal rainfall.

It is not prone to high winds or earthquakes.

Political and strategic consideration

There are no restrictions on development of industry at the location as it is allocated for

industrial development.

Besides the above factors communication, industrial infrastructure, medical and fire

fighting services are well established.


Thus the above actors will give a strategic advantage to a liquid Bromine plant located at

the recommended site.


PROJECT COST

ESTIMATION


PROJECT COST ESTIMATION

The cost of the individual equipment is calculated on the basis of the Weight of the

equipment and the material of construction required for the particular equipment. The cost

is rounded up to the higher Value depending upon the complexity of the equipment.

The basic purchase of equipment used in the plant is calculated.

Equipment Cost Rs. Lakhs

Demister Tank 4.0

POCl3 Reactor with Jacket and 2.0

Agitators

Condenser 8.0

Distillation Tower 5.0

Disaster Vessel 1.0

Noah Scrubber 0.8

Packed Tower along with Packing 1.2

Silica Gel Column 2.0

Storage of PCl3 & POCl3 2.0

Liquid O2 storage 8.0

Pump (4) 3.2

A = 35.20


INSTALLATION

Piping 8,80,000

Insulation 70,000ll

Utilities 7,04,000

Electrical 5,28,000

Instruments 3,52,000

Effluent treatment plant 5,28,000

B = 3,06,24,000

MAN POWER EMPLOYED

Manager 3,25,000

Plant Superintendent 1,95,000

Engineer × 2 3,90,000

Skilled workers × 10 3,90,000

Office staff × 8 2,60,000

Transportation × 4 6,24,000

C = 2,18,40,000

Total Cost = A + B + C = Rs.5,39,84,000


ENVIRONMENTAL

CONSIDERATIONS


ENVIRONMENTAL DATA

CONCLUSION


CONCLUSION

After completing this project, we have concluded that this project gives all that knowledge

for establishing a plant of such hazardous chemicals.

The complete project is arranged by taking consideration of properties, safety, precaution,

prevention method & various manufacturing method. This project gives brief idea about

behavior of such hazardous chemical.

Project itself describes importance of such chemical because not only these both

chemicals are very dangerous but also very importance especially for pharmaceutical

products. Therefore, such projects are guideline for future aspects.


BIBLIOGRAPHY &

REFERENCES


BIBLIOGRAPHY

Sr.

No.

Name of book Author

1. Perry’s chemical engineering

Handbook.

Robert.H.Perry, Don Green

2. Material Handbook. Brady & Clauser

3. Safety management. Greemaldi, Simonds.

4. Chemical process & Equipment

design .

K.A.Gavhane.

5. Chemical Reaction Engineering. K.A.Gavhane.

6. Encyclopedia of Chemical Engg. Kirk Othmer.

7. Piping Handbook. Nayyar

8. Industrial Gases. Downie

9. Property of gases & liquids. Reid, Prausnitz, Paling

final project synopsis 1 (2)

Documents

production of liquid

discovery of bromine

project report

reddish liquid

pink liquid

chosen liquid brome

antoine balard

valuable support