SGL PT Brochure Systems HCL Syntheses
SGL PT Brochure Systems HCL Syntheses
SGL PT Brochure Systems HCL Syntheses
Process Technology
Broad Base
E SiC
reduces the weight of airplanes, cars and sports equipment. E reactive metals
E steel
E engineering
E project management
Carbon substitutes other materials and contributes to a
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reduction in CO2 emissions.
E commissioning
Powered by our Broad Base of competencies, products and services, we offer Best Solutions to
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The long-standing loyalty of our customers proves that we keep our promises – on-time,
on-spec, on-budget.
E Efficiency Tailor made, innovative solutions and an integrated approach on chemistry, materials,
technology and design, ensure outstanding efficiency and improved customer value:
higher yields, lower operating cost, lower service and maintenance cost, longer service
intervals and less downtimes, and the extended product lifetime sum up to significant
lower total cost of ownership and to a higher return on investment for our customers.
E Sustainability In all industries that deal with resource- and energy- consuming processes sustainability
is of crucial importance. Based on innovative solutions, more than 60 % of our sales
contribute to the saving of resources and energy and to the reduction of greenhouse
gases.
Contents
3
DIABON® Synthesis Plants –
the Combination of Know-How and Experience
4
DIABON synthesis plants supplied by SGL Group
demonstrate their capability in operation through
their unquestioned advantages:
씰 Oxygen-containing chlorine can be combusted Production of 120 t/d of 100 % HCl with two synthesis plants,
type 91-800, supplied with chlorine from one of
in our synthesis plants without affecting the the first large-membrane plants (in operation since 1980)
service life of the burner or the combustion
chamber.
씰 The combustion heat of hydrogen and chlorine
씰 Synthesis plants in DIABON graphite are also in HCl synthesis can be partially recovered in
used for the production of dry HCl gas. the form of steam or hot water.
Anhydrous HCl gas of 99.9 % purity can be
manufactured in our desorption units made of Synthesis plants in DIABON graphite
DIABON graphite and LICUFLON® steel/PTFE. fully meet these criteria, proven by our
more than 450 supplied plants all over
the world.
5
Synthesis Process
– a Straight-Through Process
The starting substances for the synthesis are hydro-
gen and chlorine. Hydrogen and chlorine are fed
into a burner at controlled rates. The burner consists
of two concentric tubes with chlorine flowing through
the inner tube and hydrogen through the outer an-
nulus. Above the burner, the gases are ignited to
produce hydrogen chloride gas. A hydrogen flow
of at least 5% stoichiometric excess is recommended Complete
to ensure that a complete synthesis takes place. combustion of
Cl2 and H2 in
synthesis burner
to produce HCl
The hydrogen chloride gas, at a temperature of less than 1 ppm free chlorine. By adjusting the ab-
2000 to 2500°C, flows from the combustion sorption water (weak acid) supply rate, the desired
chamber into an integrated isothermal falling-film HCl concentration can be obtained. The product acid
absorber. The HCl gas is then absorbed by water flows by gravity into a tank at atmospheric pressure.
or weak acid. The absorber is either co-current or The considerable heat generated in the synthesis
counter-current depending on the type of synthesis process must be removed, normally by cooling water.
unit. The combustion heat is 0.7 kWh per kg of HCl
The hydrochloric acid is normally produced with (100 %) and the heat of absorption in water is 0.5
kWh per kg of HCl (100 %).
Flow sheet Nearly one half of the generated
heat can be recovered as steam
or hot water.
Flow sheet of a series 81 hydrogen chloride synthesis unit made of DIABON® graphite
6
Reliability and Safety
at Low Operating Cost
씰 State-of-the-art design of the synthesis units and 씰 Flame failure monitors which automatically
tailor-made engineering of instrumentation, piping shut off the hydrogen and chlorine supplies by
and steel structure for optimal performance. rapid-closure valves if the flame is extinguished.
씰 Total operational safety to ensure safe 씰 Automatic shutdown of hydrogen and chlorine
processing of chlorine and hydrogen. in the event of pressure failure.
씰 Our expertise allows us to supply cost- effective 씰 Automatic purging of the system with nitrogen
plants. before any startup and shutdown.
씰 Reliable operation. Our units have uptimes 씰 Incorporation of a flame trap to prevent back
higher than 99.9 %. flashing into the pipeline.
7
Design of Our Synthesis Units
State of the Art
8
Simple and reliable control and monitoring on the first platform
9
Synthesis Unit
Series 81
Dimensions
Type Output
t/d* d [mm] h 1 [mm] h 2 [mm] weight [kg**]
81-160 2.0 273 7200 2700 800
* Nominal output, based on 100 % HCl gas | **Operating weight; dimensions given in the table are not binding
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Synthesis Unit
Series 91
Dimensions
Type Output Synthesis unit Scrubber
t/d* d [mm] h 1 [mm] weight** h 2 [mm] weight** h 3 [mm] a [mm] h 4 [mm]
91-250 4 342 8000 1300 3300 80 3300 1050 11300
91-310 8 427 8100 2200 3300 130 3900 1200 12000
91-410 15 542 9100 2800 3450 190 4600 1200 13700
91-500 22 647 9500 3700 3500 250 5100 1350 14600
91-660 36 826 11800 6300 3600 400 5800 1350 16000
91-800 55 1000 12800 9600 4550 700 6700 1700 18000
91-970 75 1252 16100 17000 4640 1000 9500 1700 21000
91-1200 115 1480 17900 24000 4700 1350 10600 2000 23000
91-1440 155 1780 19700 36000 5200 1750 12600 2200 25000
* Nominal output, based on 100 % HCl gas | **Operating weight (in kg); dimensions given in the table are not binding
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Advantageous Details
of a Flawless Design
Tailor-made solutions under any process conditions Protection against overpressure: DIABON® graphite safety
disc at the top of the hydrogen chloride synthesis unit, well
outside the control zone
씰 Operation of the plant at ground level chimney between combustion chamber and safety
The burner, and therefore all feed gas lines control disc guarantees a controlled pressure release in case
and safety systems, are arranged at the bottom. of excess pressure. Fumes are released at the very top
This allows easy and safe control, monitoring, of the plant, far away from the operator’s working
operation and maintenance at ground level. The area. Splashing acid is completely avoided.
design guarantees regular and reliable inspection
of the plant by the operation staff. 씰 Gas traps
At the highest point of every available design of
씰 Plant without rotating parts synthesis units, unburned hydrogen and inerts can
SGL Group plants do not need acid recycle and accumulate. Only SGL Group designs its synthesis
product pumps due to their design and the elevated units so that this hydrogen is continuously vented
acid product outlet. Therefore, the added capital through the scrubber to avoid hazardous situations.
and maintenance costs of additional equipment
such as tanks and pumps are obsolete. 씰 Nitrogen flushing
Purging with nitrogen is carried out from the bottom
씰 Safety disc to the top of the synthesis unit. Unburned feed gas
HCl synthesis units require an excess pressure safety mixtures are removed automatically and completely
device. Therefore, a DIABON safety disc is located after shutdown, ignition failure or planned shut-
at the top of the synthesis unit. A specifically designed down. This guarantees a safe restart of the unit.
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씰 Safety interlock system 씰 Burner flushing
The safety interlock system will safely shut down the The arrangement of the burner at the bottom also
plant in case of any failure, e.g. feed gas pressures, allows the installation of a flushing system. The bur-
flame failure, cooling water flow, absorption wa- ner can be flushed in operation (without stoppage)
ter flow and safety disc monitoring. to remove salt incrustations which are drained sep-
arately.
씰 Automatic ignition and control
The automatic ignition system, together with the auto- 씰 High-quality hydrochloric acid product
matic control of the H2 /Cl2 / absorption water ratio Condensate is formed in every cooled combustion
guarantees trouble-free operation under any ope- chamber, independently of up- or downward firing.
rating conditions. The unique SGL Group design allows this con-
densate to be drained off separately from the acid
씰 Flame arrestor product, thus improving product quality.
Flame arrestors for vertical installation in the hydro-
gen feed gas line prevents the flame from flashing 씰 Highest payback due to heat recovery
back into the main pipeline and the pipeline to the The combustion of H2 and Cl2 to give HCl is a strong-
pilot burner. SGL Group supplies a specifically ly exothermic process that releases 0.7 kWh for each
developed flame arrestor suitable for HCl synthesis kg of hydrogen chloride produced. This energy can
units. Only this kind of flame arrestor is in accor- be partially recovered in the form of steam (all pres-
dance with the European Directive 94/9/EC and the sure levels achievable) or hot water. Depending on
European Standards EN 1127-1 and EN 12784. plant size and energy a payback time of only 1- 3
years can be achieved for the heat recovery system.
씰 High-performance burner
SGL Carbon’s proprietary burner Flow sheet
is capable of burning the chlorine
with only 5 % excess of hydrogen.
However, depending on the on-
site conditions, e.g. the perfor-
mance of the instrumentation, it
might be necessary to increase
the excess to 10 %.
Flow sheet of a series 91 hydrogen chloride synthesis unit with steam generation system
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Quality Management
and After Sales Service
14
Process Technology
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15
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The data contained herein represent the current state of our product knowledge and are intended to provide general information on our products
and their application spectra. In view of the variety and large number of application possibilities, these data should be regarded merely as general
information that gives no guarantee of any specific properties and/or suitability of those products for any particular application. Consequently,
when ordering a product, please contact us for specific information on the properties required for the application concerned. On request, our
technical service will supply a profile of characteristics for your specific application requirements without delay.
Process Technology
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