Internship OCL

INTERN SHIP REPORT
PREPARED BY HAFIZ MUHAMMAD AMIR SULTAN
1. INTRODUCTION
OCL is a Chemical Company. The core business of company is manufacturing and
marketing of Soda Ash and Sodium Bicarbonate. OCL is the second largest producer of Soda Ash
and Sodium Bicarbonate in Pakistan. OCL is part of Olympia group of companies each owned by
a member of the Monnoo family. The industrial group has been a success in Pakistan for more
than 40 years. It has started commercial production in 2000 with approximately 120 Tons/day
and now OCL has reached a production capacity of 450 tons/day of Soda Ash and 150 tons/day
of Sodium Bicarbonate annually. OCL is a Public Limited Company that employees 1200 people.
It has a distribution network spread throughout Pakistan. The majority of OCL customers are
glass, paper, soap and detergent manufactures. They are also exporting to UAE, South Africa,
India, Sri Lanka and Bangladesh.
1.1 Products:
Light Soda Ash:
Light soda ash is a white, odorless, uniform product, free from dirt and
other foreign matter.
Usage:
Sodium Silicate
Soaps Detergents
Paper Industry
Laundry
Chemical Industries
Textiles
Dense Soda Ash:
Dense soda ash is a white, odorless and uniform product, free from dirt
and other foreign matter.
Usage:
Glass Industry
Bottles, Jars, Sheets
Hollow Glass
Glass Balls
1
INTERN SHIP REPORT
Sodium Bicarbonate:
Sodium bicarbonate is a white solid that is crystalline but often appears as a fine
powder. It has a slight alkaline taste resembling that of sodium carbonate.
Usage:
Pharmaceuticals
Backing and Confectionary
Beverages
Tannery
Fire Extinguishers
1.2 Mission of Company:
The mission of OCL is:

A Company built on sound financial footings that achieve excellent operating results
through efficiency and cost control.
A Company that consistently benefits its stakeholders through enhanced quality and
profitability.
A Company that achieves a high level of customer care service by providing quality
products and positive feedback.
A Company that provides excellent working environment to its employees that assists in
enhancing their strengths and abilities create cultures that foster motivation and
promote individual growth.
A Company that contributes towards a good corporate citizenship and sets highest
standards in serving the society.
1.3 Quality Policy:
Olympia Chemicals Ltd aims to produce high quality soda ash at a competitive price. They
are committed to the following principles:
Understanding and meeting the customer requirements.
Compliance to legal and regulatory requirements.
Training and development of their employees.
Providing safe and healthy environment.
Continual improvement of quality management.
2
INTERN SHIP REPORT
1.4 Highlights:
This report is prepared by the observation and judgment of the respective internee.
Most of the information is obtained by questioning with operators working at different
sections of the industry.
Some of the technical information is added by engineers.
The information gathered is about different equipment like pumps, valves, kiln, cooling
tower, compressors, reactors, absorber, distiller, towers, filters etc.
The internee experienced that each operator gives the best of his knowledge, which
became much helpful.
With the help of this internship program my level of communication and confidence is
enhanced, mostly with my seniors.
1.5 Executive Summary:

This report gives a brief presentation by the student of Sharif College Of
Engineering and Technology (SCET affiliated with UET Lahore). The report contains general
information about specific areas of Olympia Chemicals Ltd (OCL), current issues, problems there
solutions, process, manufacturing products, and there applications. The report also contains
explanation of different equipments like, pumps, valves, filters, furnaces, reactors and much
more.
The data collected is based on interviews and questioning with the operators
and engineers at different sections of OCL. During this course of time I became much familiar
with the industrial environment and gain knowledge and information about different processes
and equipments. The data in this report is compiled by the respective internee with the help of
internet and questioning with the operators.
The areas that are covered in this report include:
Kiln section
Compressor section
Brine section
Refined soda Ash plant
Sodium bicarbonate plant
All these areas are briefly described. The report also contains current issues of
OCL, some problems highlighted along with their recommendations and their benefits. At the
end of this report final conclusion is specified.
3
INTERN SHIP REPORT
2. KILN SECTION
2.1 Objective of Plant:
The main objective of the kiln plant is to produce CO2 & CaO. To produce CO2
& CaO Coke with CaCO3 is burnt in kiln. The resulting products CO2 & CaO used in further
production of soda ash.
CaCO3 CO2 + CaO
CO2 use for the production of soda ash & CaO use to make calcium hydro-oxide or milk of lime
Ca(OH)2. This milk of lime (MOL) further use to recover ammonia which is also use in the
production process of soda ash.
Raw Materials:
Raw materials uses in kiln plant are:
1. Lime stone (CaCO3)

The standard size use in kiln plant of lime stone is 4-5 inches. Contents in lime stone are
CaCO3, MgSO4 & siliceous matter.
2. Coke
The standard size for coke to use in kiln plant is 1.25-2.5 inches. It has a calorific value of
about 1300 BTU/lb. it contains 8-9% moisture. It is use to generate CO2 & high
temperature for calcination of CaCO3.
2.2 Kiln Operation

Kiln Feeding System:
There are total three kilns. Two kilns are in operation one is standby. Raw
materials are charged from storage place to kiln top hopper by trolley. Trolley is attached to
skip hoist by a steel rope. Skip hoist is driven by a motor. The quantity of raw materials per
trolley is as follows:
Total weight of lime stone & coke per trolley = 890-913kg
Weight of lime stone per trolley = 830-850kg
Weight of coke per trolley = 60-63kg

4
INTERN SHIP REPORT
Raw materials are charged from top kiln hopper to kiln by hannon flask through combined
feeder. The quantity of raw materials per charge as follows:
Total weight of lime stone & coke per charge = 1350kg
Weight of lime stone per charge = 1250kg
Weight of coke per charge = 100kg
The level of feed is timely checked by rod. The outer distance of rod is known as burden height.
Calcination of CaCO3:
Two force draft fans and two induced draft fans are installed for each kiln.
When the kiln is full of raw material fire is ignited in kiln. As coke catches fire it starts burning
and temperature of kiln starts rising. The force draft fan is continuously running to provide
oxygen for burning of coke. As temperature rises in kiln three zones are maintained as follows:
Preheating zone 450-600c

Calcining zone 800-1100c
Cooling zone 100c
Preheating zone is maintained at top of the kiln; calcining zone is maintained

in middle and at the bottom of the kiln cooling zone is maintained. Temperature variations are
controlled by regulating speed of force draft fans and induce draft fans, by coke/lime stone
ratio and by drawing of burnt lime. As temperature in the middle zone or calcining zone reaches
to about 830c the calcination of lime stone (CaCO3) starts, by calcination of lime stone
following reaction takes place:
CaCO3 CO2 + CaO
By this reaction Calcium oxide (Cao) or burnt lime is discharged from the bottom of the kiln
through plate feeder and air lock on the plate conveyer. By bucket elevator this burnt lime is
discharged to burnt lime hopper.
Carbon dioxide gas (CO2) sucked from the top of the kiln by compressor
through scrubber, cooler and electro static precipitator. These equipments are installed for the
removal of dust and impurities from gas as well as for the cooling of gas.
Scrubber:
The entering temperature of CO2 gas is about 200c in scrubber. In scrubber

gas is passed from top to bottom also water is showering through nozzles from the top of the
5
INTERN SHIP REPORT
scrubber. By showering of water on gas the dust particles in gas mixed with water and this
water is drain out from the bottom of the scrubber. By showering of water the gas temperature
also down to about 100c, then gas is sent to cooler.
Cooler:
After cleaning in scrubber gas is passed through cooler. In cooler there are
rashing rings of ceramic material. Water is showering from the top of the cooler and gas is
passing through from the bottom of the cooler. By rashing rings the contact time between gas
and water is increased and by increasing this contact time gas is cool down in short time. The
leaving temperature of gas is about 30-32c, after cooler gas is entered in electrostatic
precipitator (ESP).
Electro Static Precipitator:
When gas is cooled down to 30-32c it enters in electro static precipitator. In

ESP 62KVA electrostatic charge is produced through 85 corona wires and diameter of this wire
is 3mm. This is called corona effect. At the end of each wire there is weight of about 0.5kg is
hanging by which the wires hanging still. Through positive and negative charge the remaining
dust particles attracts to these wires and removes from the gas. As the gas sucked by
compressor so after cleaning & cooling gas is sent to compressor section. The cleaning of ESPs
takes place after every 8hrs.
Specification of kiln:
Height of kiln 75ft

Diameter of kiln 12ft
Kiln top hopper capacity 550-600ton
Capacity of kiln 120ton
Insulation of kiln Refectory bricks
Refectory bricks made of Aluminum oxide & silica
Thickness of refectory bricks 2ft
Height of refectory bricks in kiln 65ft
6
INTERN SHIP REPORT
Operating parameters of kiln:
Sr. # Parameters Ranges

1. Pre heating zone/Top zone 450-600c
2. Calcining zone/Middle zone 800-1100c (preferably 830-950c)
3. Cooling zone/Bottom zone 100c
4. Kiln top pressure 0.02-0.05KPa
5. Force draft fan pressure 0-7KPa
6. Force draft fan flow rate 9000m3/hr
7. Kiln pull Adjust according to compressor pull
8. Compressor pull Adjust according to requirements
9. Burden height 1-2ft (out)
10. Hannon flask rotation time 2min & 55sec
11. Top hopper level
12. Kiln gas exit temperature 200c (preferably 120-150c )
13. Gas exit from cooler 30-32c
14. CO2 produce in kiln 35%
15. O2 produce in kiln 3% (excess)
16. Exit temperature of CaO 45-55c
2.3 Slacking Of CaO:

Burnt lime is discharged to plate conveyer by plate feeder and air lock. Bucket
elevator discharge this burnt lime into burnt lime hopper. Burnt stone is fed to the lime slacker.
There are total three slacker two of them are in working and one is standby. Water in hot
water storage tank is heated up to 70-80c by injecting steam which is coming from boiler. To
fulfill the requirements of hot water so the hot water is also supplied from combined building
through ammonia cooler.
Hot water is fed to slacker along with burnt stone and flow of water is adjusted
in such a way to get MOL of required strength. To separate out grit from MOL, the MOL flows
through a trough into a rotary sieve. Then it is sent to continuous stirred tank and from there it
is supplied to distiller and brine purification plant.
7
INTERN SHIP REPORT
Specification of slacker:
Length of slacker # 1,2 11.5m

Diameter of slacker # 1,2 1m
(at front)
Diameter of slacker # 1,2 1.8m
(at back)
Capacity of slacker # 1,2 120ton\day
Length of slacker # 3 16m
Diameter of slacker # 3 1m
(at front)
Diameter of slacker # 3 1.8m
(at back)
Capacity of slacker # 3 350ton\day
Operating parameters of slacker:

1. Entering temperature of CaO 45-55c
2. Hot water temperature 70-80c
3. Mesh size of rotary sieve # 1 3mesh
4. Mesh size of rotary sieve #2 10mesh
5. MOL at sieve shoot 120-124tt
6. MOL tank 140-150tt
7. MOL for brine purification plant 50-60tt
8. Slacker RPM 3-4RPM
8
INTERN SHIP REPORT
2.4 Troubleshooting at kiln:

Sr # Troubles Reasons Action
1. Increasing of gas Improper Maximum
Temperature discharging of charging &
kiln. discharging.
F.D fan pressure Decrease top
more then pressure.
required. Control kiln
Decrease burden pull if excess
height. then range.
Discharge plate Decrease F.D
feeder chock. fan pressure
according to
requirements.
2. Kiln top temperature F.D fan pressure Reduced F.D
Increase increase. fan pressure.
3. Kiln top temperature Draw increase. Proper
decrease discharging.
4. Kiln middle Clinker Use coke
temperature increase formation. within desire
Coke -is in excess limits.
quantity. By proper
Improper draw. discharging.
Adding fresh
feed.
5. Kiln middle Coke is in less Use coke
temperature decrease quantity. within desire
Draw increase. limits.
F.D fan pressure By proper
decrease. discharging.
Increase F.D
fan pressure.
6. Bottom temperature Too much lime is Proper
increase discharge, the discharging &
burning zone controlling the
moved down. right height.
Clinker formation Adjust the
in the kiln. coke %age.
Lime is over Reduce the F.D
burnt. fan pressure.
9
INTERN SHIP REPORT
7. Gas %age reduce Improper coke Adjust the

ratio. coke ratio.
8. Top pressure increase Less compressor Increase the
pull. compressor
F.D pressure is pull.
very high. Start I.D fan.
Scrubbing system Increase F.D
partially fan pressure.
blockage.
9. Top pressure decrease High compressor Decrease the
pull. compressor
F.D fan pressure pull.
is too low. Stop the I.D
Error in top fan.
pressure gauge. Increase F.D
Vent rate is too fan pressure.
high. Put on flapper
Flapper plates plates in a
are open. right way.
Check the
pressure
gauge.
10. O2 contents in kiln gas Air quantity is too Decrease the
are high high. air input.
There is partial Distribute the
burning in kiln. raw material
The pressure at properly.
top is negative Keep small
Top feeding positive
flapper plates are pressure at
open. top.
Top feeding
flapper plates
to be closed.
10
INTERN SHIP REPORT
3. COMPRESSORS
Compressors are an important part of the process industries. Compressors
increase the pressure of gases and vapors so they can be used in applications that require
higher pressures. For example, they can be used in a wide variety of applications like
compressing gases such as carbon dioxide, nitrogen, and light hydrocarbons, or providing the
compressed air required operating instruments or equipment.
The two most common compressor types are positive displacement and
dynamic. Positive displacement compressors use pistons, lobes, screws, or vanes to reduce a
fixed volume of gas through compression and deliver a constant volume. Dynamic compressors
use impellers or blades to accelerate a gas and then convert that velocity into pressure.
Dynamic compressors are more commonly used than positive displacement compressors
because they are less expensive, more efficient, have a larger capacity, and require less
maintenance.
All compressors require a drive mechanism such as an electric motor or turbine
to operate, and all are rated according to their discharge capacity and flow rate. Most
compressors require auxiliary components for cooling, lubrication, filtering, instrumentation,
and control. Some compressors require a gearbox between the driver and compressor to
increase the speed of the compressor.
3.1 Compressor Basics:
The principle of operation of a compressor is the same as that for a pump. The
compressor driver supplies kinetic energy that the compressor converts to pressure energy.
Some energy is wasted because of fluid friction; this turns kinetic energy to heat energy. Like all
other machines, compressors efficiency is always less than 100%.
Effects of Pressure on a Gas:
The main difference between liquids and gases is that:

Liquids are incompressible pressure has almost no effect on a liquids volume.
Gases are compressible pressure has a great effect on the volume of a gas.
There is a law that describes how a change of pressure changes the volume of a gas. It is called
Boyles Law and it says something very simple: as long as the temperature of the gas does not
change, increasing the pressure on a gas always decreases its volume. This is probably obvious:
a gas is squashed by pressure.
11
INTERN SHIP REPORT
If double the pressure, the volume is halved.

If halve the pressure, the volume doubles.
Normally, pressure also has an effect on the temperature of a gas. As pressure of a gas
increases its temperature also increases. To give the exact relationship between pressure and
volume described by Boyles Lawdoubling pressure halves volumethe gas must kept cool to
stop its temperature increasing.
3.2 Types of compressors:
Compressors
Positive displacement compressor Dynamic compressor
Reciprocating compressor Rotary compressor Centrifugal compressor Axial compressor
Piston
Lobe Vane Screw
3.3 Positive Displacement Compressors:

Positive displacement compressors are devices that may use screws, sliding
vanes, lobes, gears, or a piston to deliver a set volume of gas with each stroke. Positive
displacement compressors work by trapping a set amount of gas and forcing it into a smaller
volume. The two main types of displacement compressors are reciprocating and rotary, with
reciprocating being the most commonly used. Here in Olympia Chemical Industries
reciprocating & screw type compressors are used.
Reciprocating compressor:
The term reciprocating refers to the back-and-forth movement of the

compression device (a piston or other device is positioned in a cylinder). Reciprocating
12
INTERN SHIP REPORT
compressors use the inward stroke of a piston to draw (intake) gas into a chamber and then use
an outward stroke to positively displace (discharge) the gas.
In a reciprocating compressor, a piston receives force from a power medium
(e.g., a drive shaft) and then transfers that power to the gas being compressed. In a piston type
reciprocating compressor, the gas is trapped between the piston and the cylinder head and
then compressed. The cylinder is the cylindrical chamber in which a piston compresses gas and
from which gas is expelled.
In theory, reciprocating compressors are more efficient than centrifugal
compressors. They are also cheaper to purchase and install than a centrifugal compressor.
However, problems with pulsation and mechanical reliability cause these compressors to be
less desirable than centrifugal compressors for most industrial applications.
Working principal of Reciprocating compressor:
In piston-type reciprocating compressors, the pistons connect to a crankshaft

that converts the rotational motion of a driver to the reciprocating motion of the piston. The
pistons motion pulls gas into a cylinder from the suction line, and then displaces it from the
cylinder through the discharge line. Check valves (compression valves) on the suction and
discharge allow the flow of the gas in one direction only.
Piston-type compressors can be single or double-acting. Double-acting
compressors trap the gas during the suction stroke on one side of the piston, while compressing
the gas on the discharge side of the piston at the same time.
Two stage reciprocating compressor:

CO2 coming from kiln has a concentration of 38-40% and the gas coming from
calciner has a concentration of 88-90%. Gas coming from kiln has a small amount of moisture,
to remove these water vapors gas is passes through coconut bed separator where water vapors
removes from the gas, after passing through coconut bed separator the gas sent to
compressors through cyclone to remove remaining water vapors.
Two stage reciprocating compressor means two single stage reciprocating
compressor in series, with the discharge of first compressor (1 st stage) feeding to the suction of
the compressor (2nd stage).
The 1st compressor increases the pressure of the gas & then the 2 nd compressor
increases the pressure even further.
For example 1st stage compressor - 1.0 bar inlet pressure

2.0 bar outlet pressure
13
INTERN SHIP REPORT
2nd stage compressor - 2.0 bar inlet pressure

5.0 bar outlet pressure
When the gas is compressed it becomes hot. Hot compressed gas could cause a compressor to
overheat, & overheating can damage a compressor.
In two stage compressor, the compressed gas from stage 1 must be cooled
before it enters in 2nd stage. To cool the gas, an inter cooler is installed between the first &
second stage. The inter cooler is a heat exchange, normally shell & tube type & as the gas
passes through the tubes it is cooled by water flowing around the shell.
When the gas pressure increased in the second stage, this also increases the
temperature of the gas. This high temperature can damage the downstream equipments so the
gas is cooled in cold gas tower. In cold gas tower gas is passes from bottom to top through
rashing rings & water is showering from the top of the cooler through nozzles. These rings
increase the contact time between gas and water. The temperature of gas is down then it
passes through cyclone to remove water vapors in gas.
Now the gas is sent to carbonating tower. The kiln gas is used as top gas as its
concentration is low & calciner gas is used as bottom gas as its concentration is high. Also kiln
gas is used as cleaning gas.
Operation safeties of reciprocating compressor:
Operator must read & understand the service manual carefully.

Before start-up, strictly inspect whether each piping & facility connection are fixed.
Check oil level.
Supply cooling water to each cooling piping & check whether there is any leakage.
Safety devices must be test.
Check all valves.
Start main motor to check if there is any problem.
After completing operation, start-up carried at on site also at control room depending
on actual situation. Compressor may be started if everything is okay.
Before starting up compressor the vent valve and suction valve should be open.
Open cooling water supply valve and discharge valve.
Now start compressor & check when the torque load is stable.
When torque load is stable slowly close down the vent valve as well as slowly open the
gas discharge valve.
Regulating the water injecting quantity.
Regulating the gas filling pressure.
14
INTERN SHIP REPORT
In normal operation after completing 1st pressure rise, pressure may gradually increases
to specified value.
When pressure reaches to specified value fully close the vent valve.
When compressor shut down; all pressure must be relieved by opening the vent valve &
closing the inlet valve & discharge valve.
Upon compressor is shut down power should be off.
Reciprocating Compressor Data:
There are total 9 reciprocating compressors. There data as below:
Sr. Suction Discharge Motor Motor Compressor Flow capacity

# capacity (Kw) RPM RPM (m3/min)
1. Kiln Cleaning 95 975 --- 20

2. Kiln + calciner Top + bottom 200 742 556 42
3. Kiln Cleaning + top 135 728 516 28
+ cleaning
9. Kiln + calciner Cleaning + 200 742 556 42
bottom
Reciprocating Compressor (Technical Data):
Suction temperature 10-38c:

Suction pressure -0.0096MPa
Discharge temperature 180c:
Discharge pressure 0.14-.016MPa
Lubricant 68 turbo oil
Oil temperature 70c:
Oil pressure 0.15MPa
Consumption of cooling water 10ton/hr
Compressed gas temp. after cold gas tower 30c:
15
INTERN SHIP REPORT
3.4 Rotary Compressor:

Rotary compressors move gases by rotating a set of screws, lobes, or vanes. As
these screws, lobes, or vanes rotate, gas is drawn into the compressor by negative pressure on
one side and forced out of the compressor (discharged) through positive pressure on the other.
Rotary compressors do not require a constant suction pressure to produce discharge pressure.
Working principle of Rotary Screw Compressor:

The rotary type screw compressor is the type of positive displacement
compressor. Its working principles are the same as pistons compressor. It has three steps
including gas inlet, gas compression & gas outlet. So it also features pulsation while gas is
discharged. However, due to high speed & more quantity of lobes, so gas outlet pulsation is
very small. Gas flow is regarded as steady. Due to action of synchronous gear & bearing, it
makes sure that smaller clearance between male and female rotor occur at compressor running
so that there is no friction & available for sealing in compression & increasing gas pressure. In
this case, the unit reaches to lower gas leakage loss & mechanical loss & obtain high efficiency.
Screw compressor:
CO2 coming from kiln has a concentration of 38-40% and the gas coming from
calciner has a concentration of 88-90%. Gas coming from kiln has a small amount of moisture,
to remove these water vapors gas is passes through coconut bed separator where water vapors
removes from the gas, after passing through coconut bed separator the gas sent to
compressors through cyclone to remove remaining water vapors.
Most screw compressors have two meshing helical screw rotors. They may be
single flow, with gas entering at one end and leaving from the other, or double-flow, with gas
entering at both ends and leaving at the centre. These are the same arrangements as for screw
pumps.
Gas is compressed as it is screwed along the lengths of the rotors and force out
of the discharge. Wet screw compressors are lubricated by oil sprayed into the gas as it enters.
These can operate without synchronizing gears. One of the screw rotors then becomes an idler
and is turned by the drive rotor. If the gas must be oil-free, non-lubricated dry compressors are
used. These need synchronizing gears to avoid metal-to-metal contact between the screws.
16
INTERN SHIP REPORT
After compression gas is sent to cold gas tower to cool down and then through
cyclone it is sent to carbonating tower.
Lubrication System of Screw Compressor:
Normally, when gases are compressed, the bearings and seals become hotter.
Some of the heat is transmitted to the seals and bearings. This heat is removed by cooling the
lubricants. Lubrication systems circulate and cool sealing and lubricating oils. In some
applications, the sealing and lubricating oils are the same. The oil piping system of screw
compressor is as below:
Lube oil Motor, gear box, Lubeoiloilinjection

Each Oil return Lube oil
oil distributer point of compressor pipe unit
Emergency tank
Oil is circulated to lubricate all parts of screw compressor. After passing through all parts of
compressor oil is recycled back to oil storage tank, by passing through shell and tube heat
exchanger (in shell there is oil and in tubes there is cold water) to cool down the temperature
of oil and it is filtered to remove impurities.
The compressor adopts high quality E-46 turbine oil, which features better anti
rust and anti-oxidation and higher anti-halogenations. Moreover, lubricant must be clean and
no moisture is permitted in lubricant. Also turbine oil features longer life generally oil
replacement once every two to three years.
17
INTERN SHIP REPORT
Alarms or Tripping Values of Different tags of screw compressor:
Sr. Different 630KW 1400KW

# Tags Alarm Tripping Alarm Tripping
1. Radial Bearing 65c: 70c: 75c: 80c:
2. Thrust bearing 65c: 70c: 75c: 80c:
3. Gear Box 85c: 95c: 85c:
95c:
4. Discharge pressure 0.39MPa 0.43MPa 0.39MPa 0.41MPa
5. Oil pressure 0.18MPa 0.15MPa 0.18MPa 0.15MPa
6. Discharge temp. 90c: 100c: 105c:
110c:
7. Vibration 1.5ge 2.5ge 0.150mm 0.200mm
Operation safeties of screw compressor:
Operator must read & understand the service manual carefully.

Before start-up, strictly inspect whether each piping & facility connection are fixed.
Oil piping is cleaned by circulated oil supplied by oil console.
Supply cooling water to each cooling piping & check whether there is any leakage.
Safety devices must be test.
Open small cover on gear box & check whether there is non-balance & no friction shock.
Start main motor to check if there is any problem.
After completing operation, start-up carried at on site also at control room depending
on actual situation. Compressor may be started if everything is okay.
Start oil pump.
After permitting compressor start-up lamp is lighted, compressor should be started
immediately because more liquid in compressor it will have difficulty in start-up. Before
start-up firstly open valve located before liquid supplement mouth.
If everything is okay. At that moment pass-by valve and outlet stop valve are fully open.
If pressure rise begins from start-up conditions, start compressor.
Slowly close pass-by valve and outlet valve to increase discharge pressure.
Regulating the water injecting quantity at pressure rise and control discharge
temperature no larger then 90c:.
Regulating the gas filling pressure to 50-85% of discharge pressure to avoid oil/water
mixing. After compressor running to desire working pressure, it is run for 4hrs
continuously and make a record on running one/half hr.
Test relief valve on piping on-site.
18
INTERN SHIP REPORT
In normal operation after completing 1st pressure rise, pressure may gradually increases
to specified value.
When compressor shut down; all pressure must be relieved by opening the by-pass loop
& relief valve & closing the inlet valve & discharge valve.
If compressor is shut down for a long time, drain off all cooling liquid in housing & cooler
fill N2 gas in piping to prevent6 the unit rust.
Upon compressor is shut down power should be off.
Main Technical Data of Screw Compressors:
There are two screw compressors of 1400KW power and 630KW power. There
technical data as below:
Sr # Parameters 1400KW 630KW
3
1. Flow rate of gas(at 290m /hr 120m3/hr
suction)
2. Pressure capacity 3.8bar 3.8bar
3. Compressor speed 2703r/min 4900r/min
4. Motor power 1400KW 630KW
5. Motor speed 1485r/min 2977r/min
:
6. Suction temperature of 10-38c 10-38c:
gas
7. Suction pressure of gas -19 to -20kPa -201kPa
:
8. Discharge temperature 100c 80c:
9. Discharge pressure 0.29-0.38MPa 0.34-0.38MPa
19
INTERN SHIP REPORT
4. WATER TREATMENT
In Olympia chemicals water is coming from canal. It has two types of impurities. Those are:
1. Suspended impurities
2. Dissolved impurities
To remove these types of impurities water treatment has to be done. To remove these
impurities there are two treatments:
1. Physical treatment
2. Chemical treatment
Physical treatment is for suspended particles or impurities and chemical treatment is done to
remove dissolved impurities.
1. Physical treatment
I. Screening
II. Sedimentation
III. Filtration
2. Chemical treatment
I. Coagulation
II. Flocculation
4.1 Physical & Chemical Treatment of Water:

1. Screening:
Screening is the process to remove impurities from water of large size such as
large size stones, shopping bags, wood pieces & other organic material. Screening is done by
places screen or sieve or strainer at suction of each pump, so that these large size impurities
can never chock the pump.
2. Coagulation:
As large size impurities remove by screening & some impurities which have large
molecular weight settles down at reservoir. But some impurities which do not settle down &
suspended in water are removed by coagulation process. There are attractive & repellent forces
between these particles, when the attractive & repellent forces between the particles are of
same amount then particles do not settle down & suspended in water. To remove these
particles a chemical aluminum sulfate (Al2SO4) or it is named as alum is added in water, by
addition of this chemical the attractive & repulsive force between the particles break. So the
particles with negative charge attract towards aluminum ions & the particles having positive
charge attracts towards sulfate ions, by the attraction of these particles they made coagulates
20
INTERN SHIP REPORT
and settle down. The settling time given to a reservoir is about 1-2days. The amount of adding
aluminum sulfate in water is according to requirements. Other chemicals that can be added
instead of aluminum sulfate are: potassium sulfate, ferric chloride, aluminum-potassium salts
etc.
3. Flocculation:
The particle which does not remove by coagulation can be removed by
flocculation. In this process the chemical flocculent is added in clean water tank having a
capacity of 1m3, and then the doze of this solution is added in water having impurities in it. By
the addition of this chemical solution the suspended particles stick with each other & make
flocks of large molecular size. These large size flocks and remaining impurities remove by
sedimentation process.
4. Sedimentation:
Sedimentation takes place on sand bed filter. Sand bed filter is made of four
layer bed. Top layer of sand bed filter is of silica sand, second layer is of gravel stones having
size of about 2-4mm, and third layer is of also gravel stones with a size of 4-8mm & the fourth
layer is of porous bricks. Water passes through these layers and the flocks and the remaining
impurities settles down on these layers. The capacity of sand filters is about 1290m3. The
settling time given to sand filter is about 1-2hrs in winter & 2-3hrs in summer. Water after
passing through sand bed filter sent to multimedia filters for filtration.
5. Filtration:
Filtration is the process by which the particles having very low molecular weight
can b removed. The process of filtration is takes place in multimedia filters. In multimedia filters
there are also layers of different materials as in sand bed filter. In multimedia filters the top
layer is of thickness of 400mm of anthracite, second layer is of quartz sand having size of about
0.8-1mm & thickness of this layer in fitter is about 600mm. the third or last layer is of gravel
stones of size of 2-4mm & the thickness of this layer is about 200mm. Nozzles are fitted at the
beneath of multimedia filters.
Water from sand bed filter is entering in multimedia filter from top and
discharge from bottom through those nozzles. Those nozzles can bear a pressure of about 6bar.
When water passes through these layers very small particles settles on these layers and clean
water pass through and sent to use in process.
21
INTERN SHIP REPORT
4.2 Water Softening:

Raw water is taken into a tank called catalyzer where it is heated up to 40c:-60c: by
the help of steam.
Milk of lime Ca(OH)2 is added into this heated water which reacts & helps to remove
Mg+2 ions.
Heavier particles from precipitates formed in catalyzer are also removed along with
lime grit from the bottom of catalyzer.
Heated water with addition of lime over flows to a tank called settler where almost all
fine particles settle down & form sludge. This drained from bottom of settler once in a
shift & in way clear water is obtained.
After removing Mg hardness, the treated water is taken into a cat-ion exchanger
through coke filter.
In coke filter solid impurities are removed.
In cat-ion exchanger, water is free from Ca & Mg ions & is called soft water which is
stored in a tank.
From storage tank that soft water is pumped & supplied to combined building & soft
water tank in pump house.
Standby ion exchanger is put on duty whenever any Ca hardness appear in soft water.
The exhausted cat-ion exchanger is regenerated with brine.
22
INTERN SHIP REPORT
5. COOLING TOWERS
Cooled water is needed for, for example, air conditioners, manufacturing processes or power
generation. A cooling tower is equipment used to reduce the temperature of a water stream by
extracting heat from water and emitting it to the atmosphere. Cooling towers make use of
evaporation whereby some of the water is evaporated into a moving air stream and
subsequently discharged into the atmosphere. As a result, the remainder of the water is cooled
down significantly. Cooling towers are able to lower the water temperatures more than devices
that use only air to reject heat, like the radiator in a car, and are therefore more cost-effective
and energy efficient.
5.1 Types of Cooling Towers:

Cooling towers
Natural draft cooling tower Mechanical draft cooling tower
Cross flow Counter flow Induced draft cooling tower Force draft cooling tower
Cross flow counter flow
There are total 14 induced draft cooling towers in Olympia chemicals, and in 14 cooling towers
10 cooling towers are counter flow induced draft cooling tower and 4 are cross flow induced
draft cooling towers.
Working Principal of cooling towers:
The basic principle of the cooling tower operation is that of evaporative

condensation and exchange of sensible heat. The air and water mixture releases latent heat of
vaporization which has a cooling effect on water by turning a certain amount of liquid into its
gaseous state thereby releasing the latent heat of vaporization.
This is more effectively demonstrated by wetting the back of your hand with
water and blowing on it. This effect is what happens inside the cooling tower. The air stream
releases latent heat of vaporization thereby dropping the temperature of the water on your
skin. The liquid changing to its vaporous state consumes heat which is taken from the water
remaining, thus lowering its temperature.
23
INTERN SHIP REPORT
There is a penalty involved, and that is loss of water which goes up to the cooling
tower and is discharged into the atmosphere as hot moist vapor. Under normal operating
conditions, this amounts to approximately 1.2% for each 10 :F cooling range.
Sensible heat that changes temperature is also responsible for part of the
cooling towers operation. When water is warmer that the air, there is a tendency for the air to
cool the water. The air then gets hotter as it gains the sensible heat of the water and the water
is cooled as its sensible heat is transferred to the air.
Approximately 25% of the sensible heat transfer occurs in the tower while the
balance of the 75% cooling is due to the evaporative effect of latent heat of vaporization.
5.2 Induced Draft Cooling Towers:

Induced draft towers have an air discharge velocity of from 3 to 4 times higher
than their air entrance velocity, with the entrance velocity approximating that of a 5 mph wind.
Therefore, there is little or no tendency for a reduced pressure zone to be created at the air
inlets by the action of the fan alone. The potential for recirculation on an induced draft tower is
not self-initiating and, therefore, can be more easily quantified purely on the basis of ambient
wind conditions. Location of the fan within the warm air stream provides excellent protection
against the formation of ice on the mechanical components. Widespread acceptance of induced
draft towers is evidenced by their existence on installations as small as 15gpm and as large as
700,000gpm.
I. Counter flow induce draft cooling tower:

In counter flow towers shown in fig. below air moves vertically upward through
the fill, counter to the downward fall of water. Because of the need for extended intake and
discharge plenums; the use of high-pressure spray systems; and the typically higher air pressure
losses, some of the smaller counter flow towers are physically higher; require more pump head;
and utilize more fan power than their cross flow counterparts. In larger counter flow towers,
however, the use of low pressure, gravity-related distribution systems, plus the availability of
generous intake areas and plenum spaces for air management, is tending to equalize, or even
reverse, this situation. The enclosed nature of a counter flow tower also restricts exposure of
the water to direct sunlight, thereby retarding the growth of algae.
24
INTERN SHIP REPORT
II. Cross flow induce draft cooling tower:
Cross flow towers shown in below fig. have a fill configuration through which the
air flows horizontally, across the downward fall of water. Water to be cooled is delivered to hot
water inlet basins located atop the fill areas, and is distributed to the fill by gravity through
metering orifices in the floor of those basins. This obviates the need for a pressure-spray
distribution system, and places the resultant gravity system in full view for ease of
maintenance. By the proper utilization of flow control valves, routine cleaning and maintenance
of a cross flow towers distribution system can be accomplished sectionally, while the tower
continues to operate.
25
INTERN SHIP REPORT
Cooling towers Efficiency:
The efficiency of cooling towers can be determined by the following formula:

Efficiency = *100
Where;
Range = Return water temperature - cooling water temperature

Approach = cooling water temperature wet bulb temperature
5.3 Cooling water treatment:

After cooling from cooling towers water is stored in open pond or basin. From
these basins water is pumped to use in process. As water is in contact with air in basin & also in
cooling towers it contains bacteria, fungi & also becomes corrosive. So to remove all these
impurities cooling water treatment should be carried out as follows:
pH of water should be between 7.5-8. If pH of water increases it can cause scaling & if
its pH decreases it can cause corrosion. So to control the pH of water doze of sulfuric
acid is added in water.
For anti-corrosion & anti-scaling tri-sodium phosphate is used.
For anti-bacteria and anti-fungi biocides are used.
To make water odorless a dozing of sodium or calcium hypochlorite is added in water.
The dozing of these chemicals is according to the requirements. The sample of water is taken by
lab and after analysis the dozing of these chemicals are decided, that how much chemical
dozing is suitable for cooling water treatment.
26
INTERN SHIP REPORT
6. CHILLERS
6.1 Absorption Chillers:

The two stage absorption refrigeration cycle uses water as refrigerant and
lithium bromide (LiBr) as absorbent. It is strong affinity these two substances have for each
other that makes the cycle work. The entire process occurs in hermetic vessel in an almost
complete vacuum.
The below diagram shows indicates the complete chilling cycle. The absorption
chilling cycle is continuous. The process is described below:
Absorption chiller
1. Solution pump/ Heat exchanger:

A dilute solution of lithium bromide and water descends from the absorber to
the solution pump. This flow of dilute solution is split into two streams and pumped through
heat exchangers to the first stage generator or high pressure generator and to the second stage
generator or low pressure generator. The exclusive two-way split of solution flow virtually
eliminates the possibility of crystallization by allowing the unit to operate at much lower
solution concentration and temperature then series flow system.
1. High pressure generator:
A heat source heats dilute lithium bromide coming from the solution pump. This
produces a hot refrigerant vapor which is sent to low pressure generator, leaving a
concentrated solution this is returned to heat exchanger.
27
INTERN SHIP REPORT
2. Low pressure generator:

The energy source for the production of refrigerant vapor in the low pressure
generator is the hot refrigerant vapors produced by the high pressure generator. The
refrigerant vapor produce in low pressure generator is increased by 40% at no additional fuel
expense.
This additional refrigerant vapor is produced when dilute solution from the heat
exchanger is heated by refrigerant vapor from the high pressure generator. The additional
result is returned to the heat exchanger. The refrigerant vapor from the high pressure
generator condenses into liquid giving up its heat, and continues to condenser.
3. Condenser:
Refrigerant from two sources:
I. Liquid resulting from the condensing of vapor produced in the high
pressure generator.
II. Vapor produced by the low pressure generator.
So the refrigerant from these two sources enters in condenser. As the liquid
refrigerant enters low pressure of condenser it flashes to vapors. The two sources of refrigerant
vapors combine and condense to liquid as they are cooled by the condenser water. The liquid
flows down to evaporator.
4. Evaporator:
Liquid from the condenser passing through metering valve and flows down to
the refrigerant pump where it pumped to the top of evaporator. Here, the liquid is sprayed out
as a fine mist over the evaporator tubes. Due to the extreme vacuum in evaporator, some of
the refrigerant liquid vaporizes creating the refrigerant effect. (This vacuum is created by
hygroscopic action the strong affinity lithium bromide has for water in the absorber directly
to the right.)
The refrigerant effect cools the returning system chilled water in the evaporator
tubes. The refrigerant liquid/vapor picks up the heat of returning chilled water and cools it. The
chilled water is then supplied back to the system.
5. Absorber:
As the refrigerant liquid/vapor flows to the absorber from the evaporator, a
concentrated solution coming from the heat exchanger is sprayed out into the flow of
descending refrigerant. The hygroscopic action between lithium bromide and water and the
related changes in concentration and temperature result in the creation of an extreme
vacuum in the evaporator directly above. The dissolving of lithium bromide in water gives off
heat, which is removing by condenser water entering from the cooling tower. The resultant
28
INTERN SHIP REPORT
dilute lithium bromide solution collects in the bottom of the absorber where it flows down to
solution pump or heat exchanger.
The chilling cycle is now completed and begins again at step 1. Now this chilling
water is used in PHE to cool down the cooling tower water in summer.
Parameters of Absorption Chiller:
Parameters of absorption chiller are as below:

Temperatures
1. Cooled water (PHE) inlet 24-30c
2. Cooled water (PHE) outlet 22-27c
3. Chilled water inlet 12-15c
4. Chilled water outlet 11-12c
5. Steam temperature 150-165c
6. Absorber cooling water 25-30c
inlet
7. Absorber cooling water 30-35c
outlet
8. Solution from H.P 130-135c
generator
9. Solution from L.P 90-100c
generator
10. Strong solution spray 85-95c
11. Condensation 40-50c
12. Evaporation 8-10c
13. De-crystallization 50-60c
14. Steam condensate 95-105c
Pressures
15. Steam 0.5-0.6Mpa
16. Chilled water inlet 0.9-1.2bar
17. Chilled water outlet 0.75-0.9bar
18. Absorber cooling water 2.7-2.9bar
inlet
19. Absorber cooling water 1.6-1.9bar
outlet
20. High pressure generator 128kpa
21. Auto purging unit 1.5-1.7kpa
22. Measured concentration Up to 56%
29
INTERN SHIP REPORT
7. BRINE SECTION
7.1 Brine Manufacturing:
Rock salt is coming from salt mines and is stored in 4 salt basins. Each basin contains 2
parts.
Raw water and washing water from three layer settler is sprayed on basin # 1 by
centrifugal pump.
That raw water after spraying on basin # 1 pickup crude brine concentration about 30%
of the final concentration from where it flows into holding tank # 1.
A part of crude brine from holding tank # 1 is re-circulated to maintain the
concentration about 30% and again it is circulated and rest is sprayed on basin # 2.
From basin # 2 the crude brine of about 60% concentration flows into holding tank # 2
from where again above process is repeated.
Similar process is repeated on basin # 3 and finely on basin # 4.
The final crude brine is taken into holding tank # 4, this crude brine is of required
concentration i.e. 104-105tt.
When the crude brine is manufactured of prescribed concentration then it is pump to
brine purification plant.
7.2 Brine Purification:

Crude brine coming from holding tank # 4 directly into labyrinth trough. Milk of
lime coming from kiln section is added in this trough. Milk of lime is added to remove Mg
hardness. The reactions taking place in labyrinth trough is as below:
MgSO4 + Ca (OH)2 Mg(OH)2 + CaSO4

MgCl2 + Ca (OH) 2 Mg (OH) 2 + CaCl2
Through this trough this solution flows down to mixing reactors .there are 3 mixing reactors, in
first mixing reactor the solution of sodium carbonate (Na2CO3) is added. The solution of sodium
carbonate is added to remove Ca hardness. The solution of sodium carbonate make in purified
brine to reduce the loss of chlorides from brine. Reaction takes place in CSTR are:
CaSO4 + Na2CO3 Na2SO4 + CaCO3

CaCl2 + Na2CO3 2NaCl + CaCO3
After these mixing reactor 1 and 2, the solution flows down to mixing reactor # 3. In mixing
reactor # 3 flocculent is added. By adding this flocculent the light particles sticks with it and
30
INTERN SHIP REPORT
make heavy particles or flocks. Then this solution moves to brine settler. In brine settler there is
scrapper type agitator which does not allow the slurry and flocks to settle in one place, above
this scrapper a bed of honey comb fins through this fin the flocks does not move upward thats
why only purified brine overflows from this settler and store in purified brine reservoir.
The slurry from the bottom of settler is taken out into the slurry tank and
from this tank the slurry tank is pumped to three layer washing slurry tank. In three layers
washing slurry tank, there are three portions and each portion contains a scrapper type
agitator. The slurry from slurry tank enters in this tank from bottom also water is mixed with
this slurry to dissolve remaining chlorides in the slurry. Then this chloride containing water is
discharged from the top of the tank to salt dissolving basin and the remaining slurry discharged
from the bottom.
Capacity of tanks:
Sr. # Tanks Capacity of tanks

1. Na2CO3 solution tank (main) 17m3
2. Na2CO3 solution tank (at brine purification plant) 6m3
3. Milk of lime tank 9m3
4. Mixing reactor # 1 17m3
7. Brine settler # 1,2,3 250m3 each
8. Capacity of three layer washing slurry tank # 1,2 320m3 each
9. Capacity of refined brine reservoir # 1,2,3 60m3 each
Tests for brine:
Sr. # Test for crude brine

-1
1. For Cl 103-104tt
+2
2. For Mg <2tt
+2
3. For Ca <1tt
Test for mix brine
4. For OH-1 0.08-0.10tt
-2
5. For CO3 0.12-0.18tt
Test for refined brine
-1
6. For Cl 102-105tt
7. For Mg+2 <5ppm
+2
8. For Ca <10ppm
9. Hardness 50ppm
31
INTERN SHIP REPORT
8. REFINED SODA BICARBONATE PLANT
8.1 Manufacturing Process of RSB:

Refined soda bicarbonate or sodium bicarbonate is produced by the following chemical
reaction:
Na2CO3 + H2O + CO2 2NaHCO3
1. Soda solution tank:

To start the manufacturing of sodium bicarbonate the first batch of sodium
carbonate solution is made. For making the saturated solution of soda solution a tank dissolver
provided with a stirrer is used. The tank is filled with about 8m3 of soft water and sodium
carbonate is fed to about 238g/l, also mixing is takes place by agitator.
2. Filtration:
After smooth mixing this solution pumped to candle filter or tube filter, candle
filters consist of candle type tubes which are fitted in four section and total number of tubes
are 220-250. Solution enters from the bottom side of the filters and filter cake retain outside of
the tube and filtrate over flows through each discharge line in each section. After filtration, this
solution flows by gravity in soda solution storage tank.
3. Carbonating tower:
Now this solution is pumped to bicarbonate towers from top, also dozing of
food grade CaCl2 solution is pumped in tower with soda solution as anti caking agent, and CO2
gas, generally kiln gas coming from compressor, passed through bottom of the towers. The
packing in towers is consisting of mushroom plates or passettes plates; by these plates the
contact between soda solution and CO2 gas is increased. CO2 gas converts in bubbles by these
plates and high reaction rate is achieved. The mixture obtains, after reaction between soda and
CO2 gas, flows down to magma distributor.
4. Centrifuges:
The mixture or magma in magma distributor sent to centrifuges. The un-reacted
gas through cyclone sent to mono carbonating tower. The crystals in magma are filtered and
dry by these centrifuges. These centrifuges consist of filter cloth which rotate at a speed of
1550rpm, and by this rotation centrifugal force is produced and by this action crystals are
separated from the mother liquor through filter cloth. This mother liquor is stored in mother
liquor tank. The crystals which contain 5-6% moisture sent to air flow dryer by vibrating
conveyer.
32
INTERN SHIP REPORT
5. Air flow dryer:

In air flow dryer hot air is coming from force draft fan through heater. The heater
contains 8-10 set of tubes and each set contains 29tubes. Steam passes from these tubes and
these tubes become hot and when air from force draft fan passes through these tubes it
become hot. This hot air flow from bottom to top in air flow dryer, the soda bicarbonate when
enters in air flow dryer the moisture content removes by the contact with hot air.
6. Vortex separator & hop pocket dust remover:
The dry sodium bicarbonate flows to vortex separator, where light and heavy
crystals are separated in hop pocket dust remover. Hop pocket dust remover consist of 5 filter
section and vacuum is created by induced fan in one section at a time. When vacuum is created
the light crystals stick with filter bags and when vacuum released crystals separate from filter
and filled in bags. The heavy crystals from vortex separator flows into hopper and packed in
25kg packing bags. Food grade CaCO3 is added as anti caking agent in final packed bags of about
3kg/bag.
The again process is repeated by making the batch of soda solution in 8m 3 of
mother liquor and 2m3 of soft water also the light crystals are added with sodium carbonate.
Parameters of refined sodium bicarbonate plant:

Flow rates
1. Soda solution flow rate Up to 7.5m3/hr
2. CO2 gas flow rate Up to 1000m3/hr
Temperatures
3. Soda solution dissolving tank 60-70c:
4. Mother liquor 65-70c:
5. Washing liquor 30-40c:
6. Soda solution storage tank 60-65c:
7. Tower top temp. 65-70c:
8. Tower middle temp. 70-75c:
9. Tower draw temp. 60-70c:
10. Main steam temp. 170c:
11. Heater outlet 120c:
12. Dryer end temp. 60-70c:
33
INTERN SHIP REPORT
Pressures
13. Tower bottom 150-170kpa
14. Top gas/waste gas 30-40kpa
15. CO2 main pressure >240kpa
16. Hot air pressure >2kpa
8.2 Troubleshooting at filters:

Sr. # Troubles Reason Action
1. Filter rate decreasing. Filter tube resistance is big. Cleaning filter.
2. Soda solution conc. Raw water inlet valve open. Shutting down or changing
decreasing. raw water valve.
3. Soda solution Filter tube breakage or Opening the cover &
cloudiness after separation. checking filter tube.
filtering.
8.3 Troubleshooting at bicarbonate tower:
Sr. # Troubles Reasons Actions

1. The pressure in the Serious scar in the upper Blowing steam in the
tower is low & level is middle of tower. middle of tower or
high. cleaning.
2. The flow rate of The pressure in tower is Increasing the pressure of
discharge liquor tube low. tube.
is decreasing. The liquor outlet tube is Blowing steam.
stopped up.
3. The outlet liquor has a Low tower pressure. Adjusting operation.
little crystals & Low gas content in middle Index is controlled in the
conversion is low & section. normal range.
high Na2CO3 content. Low liquor concentration.
Excessive liquor &
temperature deviating
index.
8.4 Troubleshooting at centrifuge:

1. High moisture content Carbonated crystals are Contact with carbonating
of NaHCO3 fine. section about crystals
34
INTERN SHIP REPORT
Feed or wash water valve improvement.

leak. Close or replace valve.
Filter cloth is blocked up. Wash the equipment.
2. Filtrate contains Filter cloth is worn. Mend or replace filter
crystals. cloth.
3. Vibration of Feed is not uniform or load Adjust feed flow.
centrifuge. is over high. Mend or replace filter
Filter cloth is worn. cloth.
Machine has failure. Shut down & repair.
4. High temperature of Oil passage has failure. Shut down machine &
main bearing. Bearing has failure. repair.
8.5 Equipment specification used at RSB:
Sr. # Equipment detail Power Speed Load Flow

(KW) (rpm) (Amp.) (m3/hr)
Conveyers
1. Light ash conveyer 5.5 1415 3.9 -
2. Vibrating conveyer 1.5 1000 0.78 -
3. Packing screw 3 22 0.7 -
conveyer
Pumps & fans
1. Soda dissolving 4 2900 4.5 25
pump
2. Soda solution pump 7.5 2900 5.6 25
3. Washing liquor 7.5 2900 5.2 25
pump
4. Mother liquor pump 4 2900 3.8 25
5. Force draft fan 30 2900 28 9802
6. Induce draft fan 22 1450 22 11267
Tanks agitator
1. Soda dissolving tank 5.5 38 7.4 -
2. Magma distributor 4 65 3.5 -
Other
1. Centrifuge filter 65 1550 - -
35
INTERN SHIP REPORT
Capacity of tanks at RSB:
Sr. # Tanks Capacity

1. Soda dissolving tank # 1,2 12m3 each
2. Filter # 1,2,3,4 2.5-3m3 each
3. Soda solution tank 28m3
4. Bi-carbonating tower # 1,2,3 15.7m3
5. Magma tank 6-7m3
6. Centrifuge filter 100lit
7. Mother liquor tank 28m3
8. Washing liquor tank 28m3
8.6 Analyses involved in process of RSB:

1. Total alkalinity (T.A):
Weight 4gm of sample in conical flask and dissolve it in de-mineralize water. Add few drops of
methyl orange indicator and titrate it against 1N HCl.
T.A% = reading 2.1
2. Sodium chloride (NaCl):

Weight 2gm sample in titration flask, add some distilled water then add 10-15ml 4N HNO3. Add
few drops iron indicator.
Fix 0.05N KSCN and 0.05N AgNO3 solution level in burette and note initial
readings. Titrate first with KSCN just to produce brick red color. Now titrate 0.05N AgNO3
solution until white color is obtained, then add 0.05N AgNO3 about 3ml in excess and note the
total volume (V1) of AgNO3.
Now titrate back with 0.05N KSCN solution till brick red color appears and note
total KSCN volume (V2).
NaCl % = (V1 V2) 0.14625
3. Fe2O3:
Weigh accurately 1gm sample in conical flask. Dissolve in about 20ml demin water and then
acidify with 6N HCl. Add 0.3gm of ammonium per-sulfate and boil. Transfer this solution into
Nesseler cylinder and add 5ml KSCN solution and make up the volume up to 50ml. To another
Nesseler cylinder add 5ml of 6N HCl + 0.3gm ammonium per-sulfate + 5ml KSCN solution.
Compare the color of solution in both cylinders by adding standard iron solution (0.1mg/ml) in
36
INTERN SHIP REPORT
blank drop by drop with the help of 1ml graduate pipette. The intensity of the color in test
sample should not exceed that in standard solution.
Fe2O3 % = reading / 100
4. Loss on drying (LOD):

Weight about 10gm sample in a known weighed china disk, dry it in oven for two hrs. Cool it in
desicator to ambient temperature before weighing. After 10-20min reweigh and note the final
weight.
LOD % =
( )
=
5. Conversion:
Take 5ml sample in conical flask. Add 2-3 drops of phenolphthalein indicator in it. The pink color
will appear, titrate it with 1N HCl till colorless. Note the reading as V 1. Now add 2-3 drops of
methyl orange as indicator in it. Titrate it with 1N HCl till red color appears. Note the reading as
V 2.
Conversion % = 100
6. pH:
Take 250ml washed and cleaned glass beaker take 1gm of sample in it and dissolve completely
in 100ml of distilled water. Check the pH of the solution with the help of pH meter.
7. Sieving:
Sieving % = weight of sample retained on +100 mesh size
= weight of sample retained on +200 mesh size
= weight of sample retained on -200 mesh size
8. Moisture:
Take 20gm sample on watch glass. Transfer to beaker with a little water and dissolve the
sample. Transfer the above in 500ml measuring flask and make up the volume. Pipette out
10ml of volume into a titration flask. Add 3 drops of methyl orange indicator. Titrate against
N/10 HCl until pink color is obtained. Note the volume of N/10 HCl used as V.
Moisture % = 100 - (V 2.0125)
37
INTERN SHIP REPORT
Tests at RSB plant:
Sr. # Tests Range

1. Soda liquor (TA) 50tt
2. Magma (conversion) 50tt
3. Tower exit gasses CO2 30%
4. Tower exit gasses O2 5%
5. Sodium bicarbonate centrifuge 10%
moisture
Sodium bicarbonate specifications:
Sr. # Tests Ranges

1. Total alkalinity 99%
2. pH 8-8.5
3. Chlorides (Cl-) 0.05%
4. Fe2O3 0.005%
5. Material retained on +100 mesh sieve = 14mm 10%
6. Material retained on +200 mesh sieve = 0.07mm 40%
7. Material retained on -200 mesh sieve = 0.07mm 95%
8. Loss on drying 0.5%
38
INTERN SHIP REPORT
9. SODA ASH PLANT

9.1 Absorption section:
The main objective of this section to absorb ammonia in brine to form
ammoniated brine, because CO2 is more soluble in ammoniated brine rather than brine
solution. The Absorber section consists of Absorber, Mono-carbonating Tower, Carbonating gas
Washer/old washer, and tower waste gas washer/new washer and vent gas washer/mini
washer. These towers are used to recover ammonia gas present in different vent gas towers.
The following reactions take place in the Absorber section.
NaCl + H2O + NH3 NH4OH + NaCl
2NH4OH+NaCl+CO2 (NH4)2CO3+NaCl+H2O
Carbonating Gas Washer:
Refined brine from brine section enters in carbonating gas washer/ old washer at
the top; also gasses from mono carbonating tower enter in old washer through bottom. The
reason to pass these gasses through refined brine is to recover ammonia from these gasses and
to produce weak ammoniated brine. Old washer consists of bubble caps packing. There are
total 8 bubble caps for good mixing of brine and ammonia gas. Then this weak ammoniated
brine is stored in weak ammoniated brine tank.
Tower Waste Gas Washer:
Refined brine from brine section enters in tower waste gas washer/new washer
from the top, and here also gasses from mono carbonating tower enter in the new washer from
the bottom. The reason is the same to recover ammonia from these gasses and to produce
weak ammoniated brine; also this week ammoniated brine is stored in weak ammoniated brine
tank. New washer also consists of 8 bubble caps for good absorption of ammonia in brine.
Vent gas Washer:
Purified brine from brine section enters in vent gas washer/ mini washer.
Vacuum is applied to mini washer and through this vacuum un-absorbed ammonia from
absorber sucked in mini washer through the bottom. Refined brine enters in tower from top
and ammonia gas enters through bottom so this ammonia absorbed in brine solution to
produce weak ammoniated brine. Also ammonia gas vapors from hot ammoniated brine tank
39
INTERN SHIP REPORT
also enter in this tower for absorption. Mini washer consists of 4 bubble caps to achieve
complete absorption. Also this weak ammoniated brine flows into weak ammoniated brine tank
by gravity.
Absorber:
` Weak ammoniated brine from weak ammoniated brine tank is pumped to

absorber through weak ammoniated brine PHE to decrease its temperature as the absorption
process in absorber is highly exothermic.
Ammonia gas from distiller enters in absorber through ammonia coolers. There
are 5 ammonia coolers. Each cooler consists of 12 cooling boxes. These cooling boxes are shell
and tube type heat exchangers. Each cooling box consists of 104 tubes. In tubes there is cold
water and shell having ammonia gas. Each cooler divided into two or three portion by cooling
water inlet and outlet. As gas travelled from bottom to top its temperature decreases. This
cooled gas now enters in absorber from bottom.
Absorber consists of two main portions; one portion is cooling portion and one is
absorption portion. Cooling section consists of cooling boxes same as shell and tube type heat
exchanger. Each cooling box has 215 tubes with water in it and gas in shell. Absorption section
consists of 7 bubble caps for good absorption. The absorber is treated under vacuum. Also
liquid ammonia is pumped in the absorber to maintain the concentration of ammonia in
ammoniated brine. The liquid ammonia is added in absorber from the center of absorber.
Ammonia enters in absorber from bottom and weak ammoniated brine is enter in absorber
from top side and absorption takes place in the absorber. The absorption process is described
by following reaction:
NaCl + H2O + NH3 NH4OH + NaCl
As the reaction is highly exothermic so the ammoniated brine produce has a very high
temperature. This hot ammoniated brine is stored in hot ammoniated brine tank. The un-
absorbed ammonia gas is sent to mini washer. As mini washer is under vacuum so by the
suction of vacuum gas travelled to mini washer and by this vacuum the absorber is also under
vacuum.
Specifications of absorber as follows:
Height of absorber 30m

Internal diameter of absorber 1.6m
Volume of absorber 60.288m3
Number of cooling boxes 8
Number of tubes in cooling boxes 214 tubes in each box
40
INTERN SHIP REPORT
Type of packing Bubble caps

Number of bubble caps 7
Material of absorber Cast iron
Mono Carbonating Tower:
From hot Ammoniated tank the ammoniated brine pumped to mono

carbonating tower through PHE .It enters from the top of MCT and the vent gases from
carbonating section and bicarb section enter to the bottom of MCT. In MCT we have rashing
rings that provide large surface area to increase the absorption of the carbon dioxide in the
Ammoniated brine solution. From bottom the solution is re-circulated to the top of MCT to
increase the absorption. Than this solution is pumped to the Re-ammoniater to add Ammonia.
This Ammoniated brine then forward to the cold ammoniated brine tank and vent gases
forward to carbonating gas washer/old washer and tower waste gas washer/new washer where
refined brine is showered from top and we use bubble caps for better absorption. The reaction
takes place in mono carbonating tower is as follow:
2NH4OH+NaCl+CO2 (NH4)2CO3+NaCl+H2O
Operating parameters:
Flow rates (m3/hr)
1. Fresh brine (old washer) 20-50
2. Fresh brine (new washer) 20-50
3. Fresh brine (mini washer) 2-10
4. Weak ammoniated brine (absorber) 30-100
5. Liquid ammonia 50-200
Temperatures(c)
1. Fresh brine 20-40
2. Weak ammoniated brine PHE in 38-40
3. Weak ammoniated brine PHE out 32-34
4. Hot ammoniated brine (absorber outlet) 65-66
5. Return water (lower) 30-50
6. Return water (upper) 30-50
7. Ammonia gas cooler # 1,2,3,4 64-66
8. Gas inlet in absorber 64-66
41
INTERN SHIP REPORT
9. Outlet gas to washer 30-40

10. Hot ammoniated brine PHE in 65-66
11. Hot ammoniated brine PHE out 35-38
Pressures(kpa)
1. Absorber middle 5-12
2. Absorber top 5-10
3. Gas inlet 5-12
4. Washer outlet 5-20
9.2 Trouble Shooting at Absorption Section:
Sr. # Trouble Reason Actions

1. Low FNH3 concentration High inlet Drop the outlet
in ammoniated brine temperature of temperature of
ammonia absorber ammonia gas cooler
More feed rate of Check and adjust the
weak ammoniated feed rate of weak
brine ammoniated brine.
Fluctuation of Contact with this
distillation rate of distillation post or
concentration of regulate the feed rate
mother liquor of weak ammoniated
brine
2. High temperature of hot High gas inlet Drop the gas inlet
ammoniated brine temperature temperature
High liquid inlet Drop the liquid inlet
temperature of each temperature of each
zone zone
Less circulation rate Increase the
circulation rate
3. Low vacuum of storage Balancing pipe of Supply steam to blow
tank storage tank blocked it open
4. High liquid outlet Small quantity of Increase the quantity
temperature of cooler cooling water of cooling water
Cooler Scrubbing Replace or pickle the
cooler
5. Low S content of Low concentration of Increase the quantity
ammoniated brine Na2S solution of Na2S solution
42
INTERN SHIP REPORT
Na2S solution added Clean the sulfur

too small or sulfur feeding pipe or
feeding pipe block increase the input of
Na2S solution
6. Vent lines of tank area Formation of scale Proper steaming to all
and absorber section due to ammonia required parts to be
block due to scale carbonate presence done
formation
9.3 Analyses Involved in Absorption Section:

1. Free ammonia (NH3):
Take 10ml sample into 250ml volumetric flask and dilute it up to mark. Take 5ml from this
sample into titration flask; add 1-2 drops of methyl orange indicator and titrate it by 0.1N H2SO4
solution until the solution changes from yellow to orange color. Volume of consumed titrant
will be recorded and preserved this solution for chlorides test.
FNH3 (tt) =10 V
2. NaCl:
Add 2-3 drops of potassium chromate indicator in above preserved solution and titrate it 0.05N
AgNO3 solution until the solution appears brick red color. Note the volume of AgNO 3 used.
TCl-1 (tt) = V 5
3. Sulfide (S-2):
Take 25ml sample into titration flask already containing 50ml distilled water. Add 5 drops of
sodium nitro perusside indicator, purplish red color will appear. Then titrate it 0.025N
potassium ferric-cyanide until purplish red color will disappear and yellow color appears. Note
the volume of titrant consumed.
S-2 (tt) = V 0.02
4. Carbonates (CO3-2):
Take 1ml sample into the reaction bottle of apparatus used for determining of CO 2. Put 5-30ml
CO2 6N H2SO4 solution into the rubber tube inside the reaction bottle. Air tight the bottle with
cork. Equalize the water level in leveling bottle and eudiometer burette & note the initial
reading of water level in burette. Then shake the reaction bottle properly. When liquid level
stops dropping in eudiometer burette then again take the final reading making the levels equal
as above. Note the both reading as V.
43
INTERN SHIP REPORT
CO2 (tt) = V
Tests for absorption section:
Sr. # Tests Ranges

1. Hot ammoniated brine free NH3 100 ~101tt
2. S-2 in H.A.B 0.01tt
3. T Cl-1 84 ~ 87tt
4. Cold ammoniated brine free NH3 101 ~103tt
5. Re-Ammoniator free NH3 101 ~103tt
6. CO3 - in M.C.T 20tt
7. Ratio of Free NH3 / T Cl-1 1.13 ~ 1.17tt
9.4 Carbonation of Ammoniated Brine:

Carbonation section is the heart section of soda ash plant. In this section CO2
made treated with ammoniated brine to produce sodium bicarbonate which on calcinations
gives light soda ash.
Seven carbonating towers are provided to give the desire production of soda
ash. Three large towers are of 140-150 tons/day and four small towers are of 60-70 tons/day.
While as we concern about the towers operation two small towers or on large tower is
subjected to cleaning operation while remaining towers work on making condition. Towers
consist of passette plates at upper section and at the bottom there are cooling boxes as the
reaction is highly exothermic.
Cleaning operation:
The product ammonia brine from absorption section enters into the top of a
carbonating tower which is acting as a cleaning tower, at the same time as the cleaning gas
containing 40% CO2 kiln gas form compression section come in to the washing tower from the
bottom. Ammoniated brine and the gas will counter contact. It can clean the scabs of the tower
and have a pre-carbonation. The solution from the bottom ring is called cleaning liquor.
Through the pipe below the cleaning tower, the cleaning liquor enters into the cleaning liquor
tank, and by cleaning liquor pump it will be transferred to the top of another carbonating tower
which shall act as a soda ash producing tower. In the cleaning tower it is generally considered
that the following reaction takes place:
44
INTERN SHIP REPORT
2NH3(aq) + CO2(gas) (NH4)2CO3(aq)
The vent gas from the tower will be discharged from the top of the tower into
cyclone where the gas is separated from traces of liquor then this gas discharged to mono
carbonating tower, and the liquor or condensate from cyclone discharged to cleaning liquor
tank. Cleaning of tower is takes place after 94hrs and it will remain for 24hrs in cleaning
operation.
Making operation:
The cleaning liquor from cleaning liquor tank is pumped to carbonating tower from the top
after passing through PHE and strainer. CO2 gas after compression is introduced in the tower
from top and bottom. The top gas containing 40% CO2 is kiln gas and the bottom gas containing
88-92% CO2 is calciner gas. The top gas introduce in middle part of tower located near top of
the cooling boxes. Ratio of gas introduced in tower is about 45% from the bottom and 55%
from top.
As tower consist of pessette plates for better reaction between pre-carbonated brine or
cleaning liquor, the plates also regulates the flow of liquor and gas. The reaction between CO2
gas and pre-carbonated brine is highly exothermic so the crystals made are very weak at the
top of tower. At the bottom of the tower there are cooling boxes to maintain the temperature
of reaction also necessary for the crystallization. The cooling boxes are shell and tube heat
exchanger type where water in tubes and liquor in shell. As the liquor flows down in the tower
the size of crystals become very fine, and according to the requirement. The formation of good
crystals in tower depends upon:
High concentration of ammonia and NaCl in the cold ammoniated brine with a
proper ratio between the two titer.
Rich CO2 gas properly cooled.
High reaction temperature at a point about two-third of the height of tower
above the base.
Gradual cooling from the point down ending with thorough cooling with as much
cooling water as possible as the draw point reached.
As CO2 make contact with cleaning liquor following reaction take place:
H2O + CO2 H2CO3
NH4OH + H2CO3 NH4HCO3 + H2O
NH4HCO3 + NaCl NaHCO3 + NH4Cl
45
INTERN SHIP REPORT
NH4OH + H2CO3 (NH4)2 CO3 + H2O NH4HCO3 + NH4OH
The vent gas from the tower will be discharged from the top of the tower into
cyclone where the gas is separated from traces of liquor then this gas discharged to mono
carbonating tower, and the liquor or condensate from cyclone discharged to cleaning liquor
tank. The magma from the bottom of the tower flows by gravity into magma distributor from
where it flows down for filtration.
Specifications of towers:
Sr. # Specifications Small towers Large towers

1. No. of towers 4 3
2. Length of tower 24m 27m
3. Diameter of tower 1.5m 2.5m
4. No. of pessette plates 34 36
5. No. of cooling boxes 9 9
6. No. of tubes in cooling boxes 104 214
7. Production capacity 60-70ton/day 140-150ton/day
8. Material of tower Cast iron Cast iron
Operating parameters of towers:

Flow rates (m3/hr)
1. Flow rate of liquor (for small tower) 10-12
2. Flow rate of liquor (for large tower) 32-34
3. Flow rate of gas at bottom (for small tower) 700-850
4. Flow rate of gas at bottom (for large tower) 1700-1950
5. Flow rate of gas at top (for small tower) 900-1100
6. Flow rate of gas at top (for large tower) 2200-2600
Temperatures (c)
7. Top temperature (in cleaning) 36-37
8. Middle temperature (in cleaning) 36-37
9. Draw temperature (in cleaning) 36-37
10. Top temperature (in making) 55-56
11. Middle temperature (in making) 64-65
12. Draw temperature (in making) 28-29
13. Cold ammoniated brine temp. (at PHE inlet) 40-42
14. Cold ammoniated brine temp. (at PHE outlet) 36-38
15. Cleaning liquor temp. (at PHE inlet) 40-42
16. Cleaning liquor temp. (at PHE outlet) 36.5-38
17. Middle gas header temperature 32-35
46
INTERN SHIP REPORT
18. Bottom gas header temperature 32-34

19. Cooling water temperature 25-26
20. Chiller water temperature 22-24
Pressures
21. Tower pressure 280-285 Kpa
22. Middle gas pressure 2.7-2.8 bar
23. Bottom gas pressure Up to 3bar
24. Cleaning gas pressure 2.7-2.8bar
25. Cold ammoniated brine pressure 3bar
26. Waste gas pressure 36-42Kpa
27. Cooling water header pressure 236-238Kpa
Conductivity(s/cm)
28. Conductivity of return cooling water 650-750
9.5 Troubleshooting at Carbonation Section:

1. Blockage or scaling Incomplete cleaning of Steaming and complete
middle part of carbonating tower and proper cleaning of
carbonating tower Input quantity of top gas tower during next
too high and draw rate of cleaning cycle.
tower is comparatively less Decrease top gas flow and
causing the carbonation increase draw rate to
reaction move upward. reduce temperature of
Velocity of sodium upper part or change the
bicarbonate discharge is tower ahead of schedule.
too low. Increase tower draw rate.
2. Blockage in the bottom Incomplete cleaning Steam bottom entry gas

part of the carbonation during cleaning cycle and inlet and magma draw
tower bottom gas flow high scaling or sodium thoroughly. Completely
decreases or completely bicarbonate is and thoroughly clean the
stops entering. accumulated in the tower during nest
bottom of the tower. cleaning cycle.
Ratio of ammonia to NaCl Control ammonia brine Cl
in ammoniated brine is too and NH3
high. Control cooling water to
Cooling is too rapid; the cooling boxes to increase
temperature of outgoing temperature or steam
magma is too low. inside through draw.
47
INTERN SHIP REPORT
Bottom gas flow too high Decrease bottom gas. If

and discharge rate low or too much gas. If too much
bicarbonate accumulated gas comes out with the
in the bottom part. drawn magma then
thoroughly steam inside
the tower. In extremes
cases change tower ahead
of schedule.
3. Draw pipe of Draw pipe steaming Thoroughly steam draw
carbonation tower is routine was not carried pipe and inside tower
blocked out. through draw neck.
The temperature of outlet Increase tower draw
magma is too low, the temperature
crystal is too fine. Thoroughly steam draws
Sodium bicarbonate line inside the tower
accumulated at the draw.
bottom.
4. Cooling water pressure Check the cooling water of Contact the absorber
is too high P.H.E of absorber section. section for adjustment of
Extra pump in service of cooling water.
cooling water. Contact the cooling water
Temperature of the section to adjust the
system become below cooling water pressure.
range, Rapid Cooling. Cooling Become too rapid,
check the cooling water to
making tower.
5. Weak crystals Gases increase. Reduce gases ratio. (top gas
Gases temperature reduces. less as compared to Bottom
Ammonia Brine gas)
concentration less. Increase gases
Sharp cooling. temperature.
Maintain test of
ammoniated brine.
Gradually increase water
flow. (avoid sharp cooling)
6. Gas line chock Back flow of liquor By steaming
7. Top pressure increase M.C.T level increase Maintain the M.C.T level by
adjusting the circulation
48
INTERN SHIP REPORT
9.6 Analyses Involved in Carbonation Section:

1. Free ammonia (F NH3):
Take 10ml sample from the inlet of magma distributor into 250ml volumetric flask and dilute it
up to mark. Take 5ml from this sample into titration flask; add 1-2 drops of methyl orange
indicator and titrate it by 0.1N H2SO4 solution until the solution changes from yellow to orange
color. Volume of consumed titrant will be recorded and preserved this solution for chlorides
test.
FNH3 (tt) =10 V
2. Combined ammonia (C NH3):

Take 25ml from above 250ml volume into titration flask, add 25ml of 0.1N NaOH from burette
into the flask and heat it till there is no smell of ammonia.
After cooling to room temperature, add 1-2drops methyl orange indicator and titrate by 0.1N
H2SO4 titrant until the solution changes from yellow to orange color. Note the volume V of
titrant used.
C NH3 (tt) = (25 - V) 4
3. Total chlorides (T Cl-1):

Take already preserved solution from (1) and add 2-3 drops of potassium chromate indicator
and titrate it with 0.05N AgNO3 until the solution appears brick red color.
T Cl-1 (tt) = volume of AgNO3 used 5
Take 1ml sample from cleaning liquor into the reaction bottle of apparatus used for
determining of CO2. Put 5-30ml CO2 6N H2SO4 solution into the rubber tube inside the reaction
bottle. Air tight the bottle with cork. Equalize the water level in leveling bottle and eudiometer
burette & note the initial reading of water level in burette. Then shake the reaction bottle
properly. When liquid level stops dropping in eudiometer burette then again take the final
reading making the levels equal as above. Note the both reading as V.
CO2 (tt) = V
-2
5. Sulfide (S ):
Take 25ml sample from cleaning liquor into titration flask already containing 50ml distilled
water. Add 5 drops of sodium nitro-prusside indicator, purplish red color will appear. Then
titrate it 0.025N potassium ferric-cyanide until purplish red color will disappear and yellow color
appears. Note the volume of titrant consumed.
49
INTERN SHIP REPORT
S-2 (tt) = V 0.02
6. Total Ammonia (T NH3):

Take 10ml sample from cleaning liquor in a conical flask and neutralized against N/10 HCl using
methyl orange as indicator. 5-10ml of 1:3 formaldehyde (neutral) is added and titrated against
N/10 NaOH using phenolphthalein as indicator.
T NH3 (tt) = reading of N/10 NaOH 0.2
Tests for carbonation section:
Sr. # Tests Ranges

Making Cleaning
(magma, liquor
tower draw)
1. F NH3 15tt -
2. T NH3 - 80tt
3. C NH3 55tt 2tt
4. T Cl-1 85tt 70tt
5. CO2 - 20tt
6. S-2 - 0.10-0.1
9.7 Rotary Vacuum Drum Filter:

The removal of solid particles from a fluid by passing the fluid through a filtering
medium on which solids are deposited is said to be filters. Solid liquid separation is the
separation of two phases, solid and liquid, from a suspension. The technology for carrying out
this process is often referred to as `Mechanical Separation' because the separation is
accomplished by purely physical means.
Working principle of rotary vacuum drum filter:

Negative pressure is made inside the filter by action of vacuum pump to form
double side pressure different of filtering medium (filter gauze), and liquid in suspension is
taken out, solid particles are lifted up on filter gauze, so that solid and liquid are separated. At
the same time, solid granules are washed and absorbed dry, which make the content of salt and
water to the required value.
50
INTERN SHIP REPORT
Working of rotary vacuum drum filter:

Magma flows down from magma distributer to soda filter. As vacuum applied
the solid particles or sodium bicarbonate crystals lifted up on filter gauze with the help of
vacuum. As the cake reaches to washing zone the cake is washed by soft water to make the
content of salt and water to required value. After washing there are two drum rollers which
press down the cake to remove moisture from the cake. When the some moisture content
removes there is knife to cut down the cake, at that point there is a blow back pressure on filter
drum to remove the small crystals stuck in the filter sieves. Size of crystals achieved is 0.80-
0.85s. So this process repeats and sodium bicarbonate crystals are separated from ammonium
chloride. The crystals are sent for calcinations process to gat soda ash from it.
By the applied vacuum ammonium chloride with some gasses such as CO2, NH3 etc remove
from the bottom of filter and enter in vacuum separator. This separator is just like a cyclone
separator with a bubble cap at the bottom. The gasses are separates from ammonium chloride
solution. This mother liquor is flows down to cold mother liquor tank. Whereas the gasses are
lifted up to filter vent gas washer. This washer has a packing of bubble caps, there are 9 bubble
caps. Soft water showers from the upper middle side and gasses are lifted up in washer through
bottom by vacuum. The soft water absorbs ammonia gas which then flows down by gravity to
hot mother liquor tank. The other gasses are vented through vacuum engine.
Results of control analysis of filter bicarbonate:
1. Yield 53.52%
2. NaCl 0.36%
3. NH3 0.92%
51
INTERN SHIP REPORT
Filters specifications:
Sr. # Specifications Filter # 1 & 2 Filter # 3 Filter # 4

1. Design pressure - -0.1Mpa -0.1Mpa
2. Design temperature - 50c 50c
3. Working temperature - 80c 30c
4. Vacuum -47 to -54 Kpa 400mmHg 400mmHg
5. Capacity 120 ton/day 170ton/day 250-300ton/day
6. Drum size 1800 900 2250 930 2250 1150
7. Drum speed 1.1-2.7rpm 1.1-3.6rpm 1.1-3.4rpm
8. Agitator speed - 33.7rpm 25rpm
9. Output frequency - 0.1-400Hz 0.1-50Hz
10. Main motor power 5-15KW 7.5KW 7.5KW
11. Agitator motor power 0.12KW 4KW 4KW
12. Filtration area 5.02m2 6.5m2 8m2
13. Upper filter gauze mesh size 200mesh 200mesh 200mesh
14. Lower filter gauze mesh size 18mesh 18mesh 18mesh
Operating parameters of filters:

3
Flow rates (m /hr)
1. Magma flow rate 104-105
2. Wash water flow rate 13-15

Temperatures (c )
3. Magma temperature 28-30
4. Wash water temperature 35-40
Pressures
5. Blow back pressure (R.F # 1,2) 20-22Kpa
6. Blow back pressure (R.F # 3,4) 10-12Kpa
7. Vacuum -40 to -50Kpa
52
INTERN SHIP REPORT
Tests of filtration section:
Sr. # Tests Ranges

Wash water
1. F NH3 70tt
2. NaCl 0.6%
Crude Bicarb
3. Moisture 22%
4. NaCl 0.6%
Filter vent washer
5. F NH3 30tt
Calciner gas scrubber
6. F NH3 100tt
53
INTERN SHIP REPORT
9.8 Distillation Section:

The distillation section consists of prelimers and distillers. The following
reactions take place in the distillation section.
Ca (HO)2 + 2NH4Cl CaCl2 + 2NH3 + 2H2O
Free ammonia such as NH4HCO3, (NH4)2CO3 and (NH4)2S etc. that is all the ammonia compounds
are readily decomposable and volatilized by steam.
Fixed ammonia such as NH4Cl and (NH4)2SO4 these compounds required lime to recover
ammonia from them. There are 5 distillers and for each distiller there are 2 prelimers. Each
distiller consists of two sections (1) is heater portion and (2) is distiller portion. Heater portion
consist of rashing rings and at the top there is bubble cap. Distiller portion consist of 12 bubble
caps between these portions there is gas compartment where is also a bubble cap. Heater
portion made of cast iron material and distiller portion made of milled steel. Prelimers contains
agitator for the reaction of lime with mother liquor.
Ammonia Recovery Process:
The cold mother liquor from the cold mother liquor tank becomes hot mother
liquor when it is use in mother liquor scrubber to scrub CO2 gas coming from calciner. By this
scrubbing the temperature of CO2 decreases and mother liquor increases then this hot mother
liquor will flow automatically in to the hot mother liquor tank, then be transferred into the top
ring of the preheating section in the ammonia distillers through the warm mother liquor pump,
then it will have matter and heat exchange with the rising gas of the distillation section, most of
the CO2 in it can be distilled. The preheated mother liquor from the bottom of preheating
section will flow into the bottom of the prelimer.
The lime milk from the lime section flows into the lime milk distributor, the
surplus lime milk return to the lime section from the top. After being measured, the milk flows
into the prelimer. The mother liquor and lime milk will be mixed in the prelimer. Most of the
fixed ammonia can be transferred into free ammonia. The gas discharged from the prelimer will
enter into the hollow ring on the top of the distillation section, the mixture overflows to the
first plate on the top of distillation section, and the sandy liquor from the tapered bottom of
prelimer will enter into the third plate on the top of distillation section.
In the distillation section the mixture goes through the plate from top to bottom,
and counter contact the low pressure steam, the decomposed ammonia in the liquor will be
distilled out, that makes the content of ammonia in the waste liquor less than the fixed part.
Then the liquor will enter into the discharge blow off and be flashed to the normal pressure, at
last it flows automatically outside the battery limit.
54
INTERN SHIP REPORT
The gas from preheating section enters into the ammonia gas cooler having
being cooled by the circulating water, will be transferred into the ammonia absorber, and the
condensate will flow automatically into the warm mother liquor tank. The circulating water will
enter into the ammonia gas cooler in two flows. The return water of the higher part will back to
the circulating water system, the return water of the lower part will be transferred separately
to brine section for slurry washing, lime section for lime slaking and the distillation section for
Na2S dissolving, the rest should return to the circulating water system.
To lighten corrosion on the internal walls of the towers and the pipes, also to
warrant the quality of the soda ash product, a specific quantity of Na 2S solution will be added in
the warm mother liquor.
The ammoniated water in the mixed water pool will be transferred in to
preheating section of the ammonia distillers through the mixed water pump; there the
ammonia contained in it can be recovered.
Reactions in heater section are:
NH3 (aq) NH3 (g)
NH4HCO3 NH3 + CO2 + H2O
(NH4)2CO3 2NH3 + CO2 + H2O
(NH4)2S 2NH3 + H2S
Reactions in lime still or distiller section are:
Ca (HO)2 + 2NH4Cl CaCl2 + 2NH3 + 2H2O
Na2CO3 + Ca(OH)2 2NaOH + CaCO3
CO2 + Ca(OH)2 CaCO3 + H2O
2NH4Cl + + Ca(OH)2 CaCl2 + 2NH3 + 2H2O
(NH4)2SO4 + Ca(OH)2 CaSO4 + 2NH3 + 2H2O
CaCO3 + 2NH4Cl CaCl2 + 2NH3 + CO2 + H2O
Parameters of Distillation section:

Flow rates (m3/hr)
1. Ammonium chloride Max. up to 40
2. Milk of lime According to test
Temperatures (c)
3. Heater bottom 98-99
4. Distiller middle temp. 98-99
5. Distiller top temp. 88-90
6. Prelimer temp. 95-96
7. Discharge blow off temp. 100
55
INTERN SHIP REPORT
8. Hot mother liquor temp. Up to70

9. Exhaust steam temp. 150-160
Pressures (Kpa)
10. Distiller top pressure 12-14
11. Distiller middle pressure 15-17
12. Distiller bottom pressure 40-50
13. Bleed off gas pressure 15-17
14. Steam pressure 140-150
9.9 Trouble shooting at distillation section:

1. Temperature of mother Steam flow to distiller is Decrease the steam
liquor leaving heater
high. flow.
section is high
Flow of mother liquor to Increase the quantity of
heater is less. mother liquor.
Gas holding in the upper Adjust and balance the
part of distiller flow of mother liquor
and steam to break
holding of liquor.
2. Temperature of mother Flow of mother liquor is Increase the flow of
liquor leaving heater
high. mother liquor.
section is low
Steam flow to distiller is Increase steam flow to
low. distiller.
Gas holding in the lower Balance the flow of
part of distiller section. mother liquor and
Temperature of mother steam to break liquor
liquor is too low. holding.
Increase mother liquor
flow or increase steam
56
INTERN SHIP REPORT
flow to distiller.
3. Middle pressure of Blockage in the upper part Decrease mother liquor
distiller is high
of distiller section. flow rate or arrange for
Gas holding in the upper the cleaning of the
part of distiller section. distiller.
Blockage / partial blockage Adjust and balance
in the gas riser of the mother liquor and
distiller section steam flow to break
holding of gas / liquor.
Arrange for checking /
cleaning of gas riser.
4. Bottom pressure of Blockage due to scaling in Decrease mother liquor
distiller is high. the distiller. flow rate or arrange for
Very high distillation rate. the cleaning of distiller.
Gas holding in upper part Decrease the distillation
of distiller section. rate of mother liquor.
Bottom level of distiller is Adjust and balance
high. steam and liquor to
Top pressure of distiller is break holding.
increase Reduce mother liquor
flow or arrange for
cleaning of DBO outlet
valve and pipelines.
Arrange to remove scale
at the steam inlet of
distiller
5. Bottom pressure of Vacuum at ammonia Contact absorber
57
INTERN SHIP REPORT
distiller is low absorber is too high. operator to adjust the

Distillation rate of mother vacuum.
liquor is too low. Increase / balance
distillation range.
6. Ammonia in Distiller Addition of milk of lime is Increase milk of lime
blow off liquor is high. not enough. flow.
Steam to distillers is not Increase steam flow.
enough and temperature Adjust mother liquor
of preheated mother flow
liquor is low. Balance the flow of
Flow of mother liquor is steam and mother liquor
excessive. to break liquor holding.
Arrange to clear gas
riser if there is any
problem.
7. CaO concentration in Quantity of milk of lime is Reduce milk of lime
distiller flow off is high. excessive. flow.
Concentration of milk of Milk of lime quantity
lime is high. should be increased.
Concentration if mother Milk of lime quantity
liquor is low or its flow is should be increased.
less
8. CaO concentration in Milk of lime flow is less or Increase milk of lime
distiller blow off is low. its concentration is low. flow.
Concentration of mother Increase quantity of milk
liquor is increased. of lime.
Temperature of heater Raise the temperature
58
INTERN SHIP REPORT
section is low / CO2 of mother liquor leaving

content in heater section heater section.
is high.
9.10 Analyses Involved in Ammonia Recovery Process:

1. Active calcium oxide (A CaO):
Take 300ml sample from prelimer and stir it with glass rod so that the whole sample should be
mixed uniformly and then take 5ml sample from this in titration flask. Add some distilled water
and 2-5 drops of phenolphthalein indicator. Titrate it with 1N HCl solution until red color of
solution fades three times which is the end point. Note the volume V of HCl consumed.
A CaO (tt) = 4 V
1. Total Ammonia (T NH3):
Take 10ml sample from distiller waste outlet pipe in a conical flask and neutralized against N/10
HCl using methyl orange as indicator. 5-10ml of 1:3 formaldehyde (neutral) is added and
titrated against N/10 NaOH using phenolphthalein as indicator.
T NH3 (tt) = reading of N/10 NaOH 0.2
2. Active calcium oxide (A CaO):

Take 50ml sample from distiller blow off which has been shaken to uniformity. Add some
distilled water heat it until there is no ammonia smell. Cool it, add 2-3 drops of phenolphthalein
indicator and titrate it with 1N HCl titrant, shaking vigorously during titration until solution
changes into white and that is end point, note volume V of HCl noted.
A CaO (tt) = V 0.4
Take 1ml sample from heater portion into the reaction bottle of apparatus used for
determining of CO2. Put 5-30ml CO2 6N H2SO4 solution into the rubber tube inside the reaction
bottle. Air tight the bottle with cork. Equalize the water level in leveling bottle and eudiometer
burette & note the initial reading of water level in burette. Then shake the reaction bottle
properly. When liquid level stops dropping in eudiometer burette then again take the final
reading making the levels equal as above. Note the both reading as V.
59
INTERN SHIP REPORT
CO2 (tt) = V
Tests for Distiller Section:
Sr. # Tests Ranges

1. A CaO (in prelimer) 100tt
2. T NH3 10tt
3. A CaO (in DBO) 8tt
4. Carbonates 2.5tt
9.11 Calcination Section:

Calcination is defined as the thermal decomposition of a compound at a
temperature below the melting point of the product material by applying heat to the material.
In soda ash production industry it is mainly referred to the thermal decomposition of sodium bi
carbonate (NaHCO3) in to sodium carbonate (Na2CO3).
Calcination is carried out in furnaces or reactors of various designs including
shaft furnaces, rotary kilns, and multiple hearth furnaces and fluidized bed reactor. The device
used in soda ash production for the calcination of sodium bi carbonate into sodium carbonate is
called calciner. There are mainly two types of calciners.
1. Directly heated calciner
2. Indirectly heated calciner
Indirect heating means that the product does not come in contact directly with the heating
medium used like in the calciner bicarbonate is heated by using steam which is contained in the
steam tubes. Indirectly heated calciner is the one commonly used in the soda ash production
plants.
The basic function of calciner is to decompose Sodium bicarbonate to remove carbon dioxide.
For this purpose, there are three indirect heated steam calciners which are functioning
effectively to meet desire process requirements.
2NaHCO3 Na2CO3 + CO2 + H2O
There is one indirect heated steam calciner for the production of dense ash. The Calcinations
section consists of calciner, M.L scrubber, Gas Condenser and Gas scrubber.
60
INTERN SHIP REPORT
Light soda ash calciner:
Main shell of the steam calciner is of cylindrical shape. Heating tubes are located
inside the calciner shell. These tubes are located in the inner surface of the calciner shell
horizontally. Three vanes are present on the outer periphery of the shell. Three vanes travel
parallel to each other horizontally along the calciner shell. Two vanes are used for returning of
the soda ash and one for the final product. Operating valves are provided for opening and
closing of each vane. Inspection windows are provided on each vane. Temperature gauges are
also provided to check the temperature of the material. Shell is insulated with rock wool and G.I
sheets. Calciner shell can be divided into two zones: one is heating zone and the other is mixing
zone. Mixing zone is present near the head side of calciner shell, while heating zone starts just
after the mixing zone.
Sodium bicarbonate enters the calciners from rotary vacuum filters through belt
conveyer. Medium pressure steam is also injected from other end. Calciner has three valves 2
for circulation and 1 for discharge. From discharge point dry light soda ash goes to packing hall
through screw conveyers. Some of its portion is also added to hydrator and bicarb section.
Some amount of light soda goes to soda liquor tank for brine purification section.
CO2 gas from the top of the Calciner goes to cyclone separator to remove the
soda ash particles; from here it goes to the mother liquor scrubber in which cold mother liquor
is showered from top. This mother liquor dissolves ammonia gas and goes to the hot mother
liquor tank. The soda ash particles again introduced into calciner through screw conveyer.
CO2 gas then goes to the condenser where heat is removed from CO 2 with the
help of cold water. The condenser consist of cooling boxes; these boxes are shell and tube type
heat exchangers with water in tubes and gas in shell. From the bottom of condenser gas and
also condensate goes to the calciner gas scrubber here we showered soft water. This CO2 gas
from the top of the scrubber sends to the compressor hall and the wash water from the bottom
of scrubber pump to wash water tank through PHE.
Dense soda ash calciner:
From Light ash bucket elevator some of the light ash is transferred to light soda
ash silo. From light ash silo feed enters into hydrator where water is also making treated. From
hydrator dust particles and evolved gases enter in the bottom of waste gas scrubber while solid
material enters to the one side of Calciner. Medium pressure steam is also injected from other
end. Calciner has four valves 2 for circulation and 2 for discharge. From discharge point dry light
soda ash goes to packing hall through screw conveyers. Product from dense ash Calciner
discharge from the other side of Calciner. This product is taken over conveyor and leads to the
dense ash bucket elevator. From there it transferes to packing hall through screw conveyers.
61
INTERN SHIP REPORT
Dust particle and some evolved gases including water vapors discharge from
feed side and taken at the bottom of waste gas scrubber, where water is showered from top to
remove solid waste particles. After that waste gases are vent in atmosphere.
From dense ash bucket elevator DA is transferred to the bottom of fluidized bed
cooler in which high pressure air from F.D fans is introduced to cool and purify the product. Air
taking along with it dust particle, which is passed through cyclone separator to recover DA
particles. And then air enters into tail gas scrubber in which soft water is showered from top to
clean the air. From this scrubber air is vent out by means of I.D fans. In tail gas scrubber water is
re-circulated and store in dense ash water tank outside of the combined building.
Steam & condensate system:
The medium pressure steam enters in to the calciners. For calciner # 2 steam is coming
from boiler and for calciner # 3, 4 turbine waste steam is used. From calciners the condense
steam goes to the condensate tank. In condensate tank pressure is maintained by injecting
medium pressure steam. When its volume reaches to 45% the control valve opens and
condensate goes to the flash tank. In flash tank pressure is reduced to separate steam from
condensate, the condensate is send to the boiler. In flash vessel when level increases from 50%
control valve open and steam goes to the distiller, bicarbonate and chiller sections, this steam is
called as exhaust steam.
Calciner Specifications:
Sr. # Specifications Light ash calciners Dense ash calciner

1. Length of calciner 20m 17m
2. Diameter of calciner 2m 1.8m
3. No. of steam tubes 54 21
4. Diameter of steam tubes 3inches 3inches
5. Rpm of main motor 6.14 6.14
6. Rpm of auxiliary motor 0.33 0.33
7. Rom of calciner 6.14 6.14
8. Volume of calciner 62.8m3 43.24m3
9. Capacity of calciner 150ton/day each 90ton/day
62
INTERN SHIP REPORT
Parameters of Light Soda ash calciner:

Flow rate (ton/hr)
1. Main steam flow ( for calciner # 3,4) 13-15
2. Main steam flow (for calciner # 2) 8-10
Temperatures (c)
3. Calciner gas outlet temp. 125-130
4. Separator inlet gas temp. 120-125
5. Condenser gas outlet temp. 35-40
6. Scrubber gas outlet temp. 30-35
7. Mother liquor scrubber inlet temp. 28-30
8. Mother liquor scrubber outlet temp. 78-82
9. Soda ash temp. (at return outlet 1) 200
10. Soda ash temp. (at return outlet 2) 200
11. Soda ash temp. (at product outlet) 190-200
12. Soda ash discharge temp. 170-180
13. Soda ash temp. after cooling for packing 80-90
Pressures (Kpa)
14. Main steam pressure Up to 30kg/cm2
15. Mother liquor head pressure (for M.L scrubber # 2) 0.8-0.9
18. Inlet to separator pull -0.06 to -0.08
19. Inlet to M.L scrubber pull -0.08 to -1.0
20. Inlet to calciner gas scrubber pull -2.0 to -3.0
Tank levels
21. Condensate tank level 40-50%
22. Flash vessel tank 50-60%
63
INTERN SHIP REPORT
9.14 Troubleshooting at Calciner Section:

1. Too low gas Bicarb feed is too high Reduce the bicarb feed.
temperature Moisture is too high in Reduce the moisture at
bicarb feed. filter.
Dust separator is scaled up. De-scaled the cyclone
Thermocouple scaled up separator.
De-scaled the
thermocouple
2. Discharge temperature Bed level of Calciner is high. Reduce the feed & increase
is too low. Bed level of Calciner is low. the discharge.
Discharge hopper is scaled Control the product valve
up. & increase circulation
Steam pressure reduce (Return Vane)
De-scaled the discharge
hopper.
Increase steam pressure
3. Pull becomes low Mother liquor scrubber Adjust the mother liquor
level increase. flow.
Calciner gas scrubber level Adjust the Calciner gas
too high. scrubber.
CO2 control valve scaled Reduce the bicarb feed &
up. wash the control valve.
CO2 inlet line to mother De-scaled the CO2 line to
liquor scrubber scaled up mother liquor scrubber.
4. Inlet calciner gas Improper M.L showering. Adjust the mother liquor
temperature to Improper showering at flow.
scrubber is high main CO2 line. Adjust the flow at CO2 line.
Insufficient pressure of Adjust the cooling water
cooling water. pressure.
5. Return temperature of Bed level is high. Reduce the feed & increase
calciner dropped. Bed level is low. the discharge.
Steam pressure reduce Reduce the feed &
increase the circulation.
64
INTERN SHIP REPORT
Maintain or increase steam

pressure
6. Thrower trip Scaling Problem De- scale the thrower
7. Too high gas Bicarb feed is too low Increase bicarb feed
temperature Due to chute pack De- scale chute
Due to thrower trip De- scale thrower
8. Condenser outlet M.L level high in M.L.S Adjust the mother liquor
temperature high scrubber level
9. Product Conveyor Trip Due to overload Avoid excess Product in
Product conveyor vane one conveyor
touch with Product Routine maintainace of
conveyor base (supporting product conveyor
hanger break down)
9.15 Analyses For Light Soda Ash & Dense Soda Ash:
Analyses for light and dense soda ash are same. Sample is collected from calciner discharge and
from packing hall. Analyses are given below:
1. Total alkalinity (T.A):
Weight 2.65gm of sample in conical flask and dissolve it in de-mineralize water. Add few drops
of methyl orange indicator and titrate it against 1N HCl.
T.A% = reading 2
2. Sodium chloride (NaCl):

Weight 2gm sample in titration flask, add some distilled water then add 10-15ml 4N HNO3. Add
few drops iron indicator.
Fix 0.05N KSCN and 0.05N AgNO3 solution level in burette and note initial readings. Titrate first
with KSCN just to produce brick red color. Now titrate 0.05N AgNO3 solution until white color is
obtained, then add 0.05N AgNO3 about 3ml in excess and note the total volume (V1) of AgNO3.
Now titrate back with 0.05N KSCN solution till brick red color appears and note total KSCN
volume (V2).
NaCl % = (V1 V2) 0.14625
3. Sodium sulfate (Na2SO4):
Take 10gm sample in 500ml beaker. Dissolve in 100ml demin water and add 6N HCl till acidic
using methyl orange indicator. Filter through Whatmann filter paper # 41. Wash till free of
chloride. Boil filtrate for 5min and add 10ml 10% BaCl2 solution. Cool and allow settling for 4hrs.
65
INTERN SHIP REPORT
Filter through Whatmann filter paper # 42, wash till free of chloride, dry and ignite in a weighed
crucible then weigh BaSO4.
Na2SO4 (%) = weight of BaSO4 6.085
4. Fe2O3:
Weigh accurately 1gm sample in conical flask. Dissolve in about 20ml demin water and then
acidify with 6N HCl. Add 0.3gm of ammonium per-sulfate and boil. Transfer this solution into
Nesseler cylinder and add 5ml KSCN solution and make up the volume up to 50ml. To another
Nesseler cylinder add 5ml of 6N HCl + 0.3gm ammonium per-sulfate + 5ml KSCN solution.
Compare the color of solution in both cylinders by adding standard iron solution (0.1mg/ml) in
blank drop by drop with the help of 1ml graduate pipette. The intensity of the color in test
sample should not exceed that in standard solution.
Fe2O3 % = reading / 100

5. Water insoluble matter:
Weigh 10gm sample and dissolve in 150ml demin water in a 500ml beaker. Boil and filter
through a dried and weighed Whatmann filter paper # 40, wash with demin water till free of
chloride, dry and weight.
Insoluble (%) = difference of weight 10
6. Apparent density:
Weight 30gm sample and transfer in a 100ml measuring cylinder. Set the material slowly by
rolling the cylinder and note down the volume of sample.
Apparent density (gm/l) = 30000 / volume noted
7. Pouring density:
Fill the density meter vessel (0.5lit) using freely dropping system of density meter. Remove the
excess soda ash from vessel by spatulas and weigh the filled vessel (W1) and also weigh the
empty vessel (W2).
Pouring density (gm/l) = (W1 W2) 2
66
INTERN SHIP REPORT
Specifications of Light soda ash & dense soda ash:
Sr. # Tests Light soda ash Dens soda ash

1. Total alkalinity 98% 98%
2. NaCl 0.85% 0.85%
3. Na2SO4 0.08% 0.08%
4. Fe2O3 0.007% 0.007%
5. Water insoluble mater 0.15% 0.15%
6. Bulk density 450-600gm/l 950-1200gm/l
67
INTERN SHIP REPORT
10. Major Equipments Used in OCL

Some of the equipments are listed below that are used in almost every industry and also in
OCL.
10.1 Centrifugal Pump:
A centrifugal pump is a rotodynamic

pump that uses a rotating impeller to increase the
velocity of a fluid. Centrifugal pumps are commonly
used to move liquids through a piping system. The
fluid enters the pump impeller along or near to the
rotating axis and is accelerated by the impeller,
flowing radially outward into a diffuser or volute
chamber, from where it exits into the downstream
piping system. Centrifugal pumps are used for large
discharge through smaller heads.
A centrifugal pump works by the conversion of the rotational kinetic energy,
typically from an electric motor or turbine, to an increased static fluid pressure. This action is
described by Bernoulli's principle. The rotation of the pump impeller imparts kinetic energy to
the fluid as it is drawn in from the impeller eye (centre) and is forced outward through the
impeller vanes to the periphery. As the fluid exits the impeller, the fluid kinetic energy (velocity)
is then converted to (static) pressure due to the change in area the fluid experiences in the
volute section. Typically the volute shape of the pump casing (increasing in volume), or the
diffuser vanes (which serve to slow the fluid, converting to kinetic energy in to flow work) are
responsible for the energy conversion. The energy conversion results in an increased pressure
on the downstream side of the pump, causing flow.
10.2 Valves:
Globe valve:
A Globe valve is a type of valve used for regulating
flow in a pipeline, consisting of a movable disk-type element and a
stationary ring seat in a generally spherical body. Globe Valves are
named for their spherical body shape with the two halves of the
68
INTERN SHIP REPORT
body being separated by an internal baffle. This has an opening that forms a seat onto which a
movable plug can be screwed in to close (or shut) the valve. The plug is also called a disc or disk.
In globe valves, the plug is connected to a stem which is operated by screw action in manual
valves. Typically, automated valves use sliding stems. Automated globe valves have a smooth
stem rather than threaded and are opened and closed by an actuator assembly. When a globe
valve is manually operated, the stem is turned by a hand wheel
Although globe valves in the past had the spherical bodies which gave them their
name, many modern globe valves do not have much of a spherical shape. However, the term
globe valve is still often used for valves that have such an internal mechanism. In plumbing,
valves with such a mechanism are also often called stop valves since they don't have the global
appearance, but the term stop valve may refer to valves which are used to stop flow even when
they have other mechanisms or designs.
Globe valves are used for applications requiring throttling and frequent operation. For
example, globe valves or valves with a similar mechanism may be used as sampling valves,
which are normally shut except when liquid samples are being taken. Since the baffle restricts
flow, they're not recommended where full, unobstructed flow is required.
Gate valve:
A Gate Valve, or Sluice Valve, as it is
sometimes known, is a valve that opens by lifting a round or
rectangular gate/wedge out of the path of the fluid. The
distinct feature of a gate valve is the sealing surfaces
between the gate and seats are planar. The gate faces can
form a wedge shape or they can be parallel. Gate valves are
sometimes used for regulating flow, but many are not suited
for that purpose, having been designed to be fully opened or
closed. When fully open, the typical gate valve has no obstruction in the flow path, resulting in
very low friction loss.
Gate valves are characterized as having either a rising or a non-rising stem. Rising
stems provide a visual indication of valve position. Non-rising stems are used where vertical
space is limited or underground.
Bonnets provide leak proof closure for the valve body. Gate valves may have a
screw-in, union, or bolted bonnet. Screw-in bonnet is the simplest, offering a durable, pressure-
tight seal. Union bonnet is suitable for applications requiring frequent inspection and cleaning.
It also gives the body added strength. Bolted bonnet is used for larger valves and higher
pressure applications.
69
INTERN SHIP REPORT
Plug coke valve:

Plug valves are valves with cylindrical or conically tapered "plugs" which can be
rotated inside the valve body to control flow through the valve. The plugs in plug valves have
one or more hollow passageways going sideways through
the plug, so that fluid can flow through the plug when the
valve is open. Plug valves are simple and often economical.
When the plug is conically tapered, the
stem/handle is typically attached to the larger diameter end
of the plug. Plug valves usually do not have bonnets but
often have the end of the plug with the handle exposed or
mostly exposed to the outside. In such cases, there is usually
not much of a stem. The stem and handle often come in one piece, often a simple,
approximately L-shaped handle attached to the end of the plug. The other end of the plug is
often exposed to the outside of the valve too, but with a mechanism that retains the plug in the
body.
The simplest and most common general type of plug valve is a 2-port valve with
two positions: open to allow flow, and shut (closed) to stop flow. Ports are openings in the
valve body through which fluid can enter or leave. The plug in this kind of valve has one
passageway going through it. The ports are typically at opposite ends of the body; therefore,
the plug is rotated a fourth of a full turn to change from open to shut positions. This makes this
kind of plug valve a quarter-turn valve. There is often a mechanism limiting motion of the
handle to a quarter turn, but not in glass stopcocks.
Butterfly valve:
A butterfly valve is a valve which can be used for isolating or regulating flow. The
closing mechanism takes the form of a disk. Operation is similar to that of a ball valve, which
allows for quick shut off. Butterfly valves are generally favored because they are lower in cost
to other valve designs as well as being lighter in weight, meaning less support is required. The
disc is positioned in the center of the pipe, passing through the disc is a rod connected to an
actuator on the outside of the valve. Rotating the actuator
turns the disc either parallel or perpendicular to the flow.
Unlike a ball valve, the disc is always present within the flow,
therefore a pressure drop is always induced in the flow,
regardless of valve position.
A butterfly valve is from a family of valves called
quarter-turn valves. The "butterfly" is a metal disc mounted on
70
INTERN SHIP REPORT
a rod. When the valve is closed, the disc is turned so that it completely blocks off the
passageway. When the valve is fully open, the disc is rotated a quarter turn so that it allows an
almost unrestricted passage of the fluid. The valve may also be opened incrementally to
throttle flow.
There are different kinds of butterfly valves, each adapted for different pressures
and different usage. The resilient butterfly valve, which uses the flexibility of rubber, has the
lowest pressure rating. The high performance butterfly valve, used in slightly higher-pressure
systems, features a slight offset in the way the disc is positioned, which increases the valve's
sealing ability and decreases its tendency to wear. The valve best suited for high-pressure
systems is the triple offset butterfly valve, which makes use of a metal seat and is therefore
able to withstand a greater amount of pressure.
10.3 Plate heat Exchanger:

A plate heat exchanger is a type of heat
exchanger that uses metal plates to transfer heat
between two fluids. This has a major advantage over a
conventional heat exchanger in that the fluids are
exposed to a much larger surface area because the fluids
spread out over the plates. This facilitates the transfer of
heat, and greatly increases the speed of the temperature
change. Plate heat exchangers are now common and
very small brazed versions are used in the hot-water
sections of millions of combination boilers. The high heat
transfer efficiency for such a small physical size has
increased the domestic hot water (DHW) flow rate of combination boilers. The small plate heat
exchanger has made a great impact in domestic heating and hot-water. Larger commercial
versions use gaskets between the plates, smaller version tend to be brazed.
The plate heat exchanger (PHE) is a specialized design well suited to transferring
heat between medium- and low-pressure fluids. Welded, semi-welded and brazed heat
exchangers are used for heat exchange between high-pressure fluids or where a more compact
product is required. In place of a pipe passing through a chamber, there are instead two
alternating chambers, usually thin in depth, separated at their largest surface by a corrugated
metal plate. The plates used in a plate and frame heat exchanger are obtained by one piece
pressing of metal plates. Stainless steel is a commonly used metal for the plates because of its
ability to withstand high temperatures, its strength, and its corrosion resistance. The plates are
71
INTERN SHIP REPORT
often spaced by rubber sealing gaskets which are cemented into a section around the edge of
the plates. The plates are pressed to form troughs at right angles to the direction of flow of the
liquid which runs through the channels in the heat exchanger. These troughs are arranged so
that they interlink with the other plates which forms the channel with gaps of 1.31.5 mm
between the plates.
The plates produce an extremely large surface area, which allows for the fastest
possible transfer. Making each chamber thin ensures that the majority of the volume of the
liquid contacts the plate, again aiding exchange. The troughs also create and maintain a
turbulent flow in the liquid to maximize heat transfer in the exchanger. A high degree of
turbulence can be obtained at low flow rates and high heat transfer coefficient can then be
achieved.
10.4 Temperature Sensors:

Thermocouple:
Thermocouple; an electrical device that responds to a difference in temperature

by producing an electric current. Thermocouples are used as measuring instruments and as
control devices. Thermocouples are simple and rugged, can be used over a wide range of
temperatures (from -200 C. to 1,600 C.), and permit great precision. For these reasons
thermocouples are used to measure temperatures inside furnaces and jet engines and in
laboratory experiments
The thermocouple is based on the Seebeck effect, named after its discoverer,
Thomas J. Seebeck. In its simplest form, the thermocouple consists of two wires of dissimilar
metals or alloys joined at their ends, with a potentiometer (or a voltmeter) connected in one
side of the circuit. The thermocouple using wires of iron and constantan (an alloy of 60 per cent
copper and 40 per cent nickel).
The measuring junction is placed in the environment whose temperature is to be
measured. For precision work, the reference junction is kept at a fixed, known temperature (for
example, by being placed in an ice bath). If great precision is not required, the reference
junction may be left at room temperature, which is known only approximately. The potential
difference between the two junctions, as shown by the potentiometer or voltmeter, is used to
find the temperature of the heated junction, usually from a table in a handbook.
72
INTERN SHIP REPORT
Resistance thermometer:
Resistance thermometers, also called resistance temperature detectors (RTDs),

are sensors used to measure temperature by correlating the resistance of the RTD element with
temperature. Most RTD elements consist of a length of fine coiled wire wrapped around a
ceramic or glass core. The element is usually quite fragile, so it is often placed inside a sheathed
probe to protect it. The RTD element is made from a pure material, platinum, nickel or copper.
The material has a predictable change in resistance as the temperature changes; it is this
predictable change that is used to determine temperature.
They are slowly replacing the use of thermocouples in many industrial
applications below 600 C, due to higher accuracy and repeatability.
10.5 Pressure Sensors:

Manometer:
Manometer, as shown in fig. an

instrument used to measure the pressure of a fluid,
such as a gas or vapor. It is typically used with fluids
under relatively low pressure in a closed container.
Scientists use manometers to obtain precise
measurements of the pressure of gases in laboratory
experiments. In medicine, a type of manometer
called a sphygmomanometer is used to obtain blood-
pressure readings.
The simplest manometer is a U-shaped glass tube partially filled with a liquid,
usually mercury. One end of the U-tube is open to the fluid in a closed container; the other end
is open to the atmosphere. The difference between the height of the column of mercury or oil
in the two sides of the tube corresponds to the difference between the pressure of the fluid in
the container and the atmospheric pressure.
Pressure transmitter:
Pressure transmitters are commonly used for industrial processes and they are
used to gauge the pressure and control the operation of industrial equipment. Pressure
transmitters can sense physical variables such as pressure and flow-rate. This can be brought
into existence due to the differential measurements.
A pressure transmitter contains a pressure sensor that can process fluids and
calculate an output. This output will be the answer to pressure applied on it by the fluid. The
73
INTERN SHIP REPORT
pressure difference between two process pressures is measured by a differential pressure

transmitter. A differential pressure transmitter requires two connections to the process fluid.
This type of pressure transmitter measures the gage or absolute pressure of a processing fluid.
It needs a single union with the process fluid chamber. This differential pressure transmitter
comprises of a main body that has an internal enclosure. This internal enclosure contains a
measurement chamber which can hold a pressure transducer. Differential pressure sensors are
mainly used to measure small pressure differences over an absolute pressure range.
74
INTERN SHIP REPORT
11. HEALTH AND SAFETY

Exposure to soda ash is ordinarily not hazardous but soda ash dust may produce
temporary irritation of the nose and throat. Although some become familiar to working in this
dust and suffer relatively little discomfort, others are allergic to alkaline materials and develop
a condition of dermatitis. Tests have shown that dermal effects due to soda ash range from a
transient reddening and inflammation to mild burns to abraded skin areas. The skin irritations
experienced by workmen exposed to soda ash dust in hot weather are usually more severe
because soda ash is likely to dissolve in perspiration.
Soda ash is corrosive to the eyes. It produces severe corneal, iridal, and
conjunctival effects (tissue destruction). Soda ash is harmful if ingested and may be corrosive to
the lining of the stomach. A private communication has indicated that the acute oral LD50 on
for soda ash is 2.8 g/kg.
Potential Health Effects of Soda ash:
Eye: Contact with eyes may cause severe irritation, and possible eye burns.
First aid: Immediately flush eyes with plenty of water for at least 15 minutes, occasionally lifting
the upper and lower lids. Get medical aid immediately
Skin: Contact with skin causes irritation and possible burns, especially if the skin is wet or moist.
First aid: Get medical aid. Flush skin with plenty of soap and water for at least 15 minutes while
removing contaminated clothing and shoes.
Ingestion: May cause irritation of the digestive tract.

First aid: Do not induce vomiting. If victim is conscious and alert, give 2- 4cupfuls of milk or
water. Never give anything by mouth to an unconscious person. Get medical aid immediately.
Inhalation: May cause irritation of the respiratory tract with burning pain in the nose and
throat, coughing, wheezing, shortness of breath and pulmonary edema.
First aid: Remove from exposure to fresh air immediately. If not breathing, give artificial
respiration. If breathing is difficult, give oxygen. Get medical aid if cough or other symptoms
appear.
Chronic: Prolonged or repeated inhalation may cause nosebleeds, nasal congestion, erosion of
the teeth, perforation of the nasal septum, chest pain and bronchitis.
75
INTERN SHIP REPORT
12. Suggestions for Improvement

Following are some suggestions for the betterment and improvement of the industry.
The pipe lines and equipment installed should have a daily routine checkup.
The equipment should be replaced immediately before it becomes hazardous to its
surroundings.
The equipment used in the process area should not run above its maximum stress limit.
During handling of corrosive fluids appropriate precautions should be taken, including
wearing rubber or PVC gloves, protective eye goggles, and chemical-resistant clothing.
Leakages should be fixed properly to avoid corrosion of equipments.
Class Conflict should be avoided and equality between labor and engineers should be
maintained.
Equal facilities should be given to every person working in the industry.
12.1 Conclusion:
During these 06 weeks, the student concluded that OCL being the 2nd largest soda ash
industry has maintained its level in the competitive industries. There are some problems which
every industry has to face in daily routine.
I find OCL a better place for gaining experience and knowledge for especially fresh
bachelors and would like to recommend every new student to gain experience from OCL. At last
I like to thank the management of OCL for being so cooperative and giving a chance to the
student of SCET to be among the competitive students.
76

Internship OCL

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Internship OCL

Hochgeladen von

Copyright:

Verfügbare Formate

INTERN SHIP REPORT

PREPARED BY HAFIZ MUHAMMAD AMIR SULTAN

Dense Soda Ash:

1.2 Mission of Company:

The mission of OCL is:

1.3 Quality Policy:

1.5 Executive Summary:

The areas that are covered in this report include:

CaCO3 CO2 + CaO

Raw materials uses in kiln plant are:

1. Lime stone (CaCO3)

2.2 Kiln Operation

Total weight of lime stone & coke per trolley = 890-913kg

Weight of lime stone per trolley = 830-850kg

Weight of coke per trolley = 60-63kg

Total weight of lime stone & coke per charge = 1350kg

Weight of lime stone per charge = 1250kg

Weight of coke per charge = 100kg

Preheating zone 450-600c

Preheating zone is maintained at top of the kiln; calcining zone is maintained

CaCO3 CO2 + CaO

The entering temperature of CO2 gas is about 200c in scrubber. In scrubber

Electro Static Precipitator:

When gas is cooled down to 30-32c it enters in electro static precipitator. In

Height of kiln 75ft

Operating parameters of kiln:

Sr. # Parameters Ranges

2.3 Slacking Of CaO:

Length of slacker # 1,2 11.5m

Operating parameters of slacker:

Sr. # Parameters Ranges

2.4 Troubleshooting at kiln:

7. Gas %age reduce Improper coke Adjust the

3.1 Compressor Basics:

Effects of Pressure on a Gas:

The main difference between liquids and gases is that:

If double the pressure, the volume is halved.

3.2 Types of compressors:

Positive displacement compressor Dynamic compressor

Reciprocating compressor Rotary compressor Centrifugal compressor Axial compressor

Lobe Vane Screw

3.3 Positive Displacement Compressors:

The term reciprocating refers to the back-and-forth movement of the

Working principal of Reciprocating compressor:

In piston-type reciprocating compressors, the pistons connect to a crankshaft

Two stage reciprocating compressor:

For example 1st stage compressor - 1.0 bar inlet pressure

2nd stage compressor - 2.0 bar inlet pressure

Operation safeties of reciprocating compressor:

Operator must read & understand the service manual carefully.

Reciprocating Compressor Data:

There are total 9 reciprocating compressors. There data as below:

Sr. Suction Discharge Motor Motor Compressor Flow capacity

1. Kiln Cleaning 95 975 --- 20

Reciprocating Compressor (Technical Data):

Suction temperature 10-38c:

3.4 Rotary Compressor:

Working principle of Rotary Screw Compressor:

Lubrication System of Screw Compressor:

Lube oil Motor, gear box, Lubeoiloilinjection

Alarms or Tripping Values of Different tags of screw compressor:

Sr. Different 630KW 1400KW

Operator must read & understand the service manual carefully.

Main Technical Data of Screw Compressors: