DESALINATION AND BROMINE RECOVERY AND SALT EXTRACTION
[EIRI/EDPR/4555] J.C.: 2772XL
INTRODUCTION
Seawater desalination is a process in which salt and other constituents are removed to produce pure water. Approximately 75 million people worldwide rely on desalination and that number is expected to grow as freshwater resources are stressed by population growth and millions more move to coastal cities with inadequate freshwater resources. Desalination is most widely used in arid regions; more than half of the world’s desalination capacity (volume) is located in the Middle East and North Africa. Seawater accounts for over 50% of desalination source water worldwide. However, as of 2005 in the United States, only 7% of desalination plants used seawater. Brackish waters made up the majority of source waters for desalination, with most of the remainder consisting of river waters and wastewaters.
Two streams of water result from desalination: (1) a pure product water and (2) a high-concentration waste stream or brine. The principal desalination methods fall into two categories: thermal processes and membrane processes. Thermal treatment uses heat to evaporate the water, leaving behind the dissolved salts, or waste stream, and separating it from pure water. Membrane processes use reverse osmosis and high pressure to force saltwater through very fine, porous filters that retain the salts, leaving pure water on one side of the membrane and the waste stream on the other side. Since a great majority of earth’s water is found in the seas and oceans, desalination creates an opportunity for coastal communities to access virtually unlimited freshwater sources. In addition, desalination techniques can be used to purify brackish water in areas with seawater intrusion. In light of climate change adaptation, this is also a crucial resource for areas where existing freshwater resources can no longer support local populations or be rehabilitated to meet the freshwater demands.
Thermal desalination processes generally use heat to evaporate water, leaving dissolved constituents behind. The water vapour is then condensed and collected as product water. Distillation is the simplest of these thermal processes and the energy efficiency of this simple process has been greatly improved. The most common thermal desalination process today is multi-stage flash (MSF) distillation; in 2005, MSF was reported to account for 36% of desalination worldwide. MSF improves on the energy efficiency of simple distillation by utilizing a series of low-pressure chambers, recycling waste heat and, in some cases, can be operated at even greater efficiency by utilising the waste heat from an adjacent power plant. Multiple-effect Evaporation (MEE) (also known as multiple-effect distillation) is another thermal process that utilizes low-pressure chambers; it is possible to achieve much greater efficiency in MEE than in MSF. However, MEE is not as popular because early designs were plagued by mineral scaling. Newer designs have reduced mineral scaling and MEE is gaining in popularity. For smaller operations with volume needs around 3000 m3/day, vapour compression distillation (VCD) can be an appropriate thermal distillation option. VCD is a technically simple, reliable and efficient process that is popular for resorts, industries and work sites where adequate freshwater is unavailable.
The other prominent bromine producing countries are Germany and France.
Bromine, a heavy, mobile, reddish-brown liquid with an interesting irritating odour, is the only non-metallic element that is a liquid at normal temperature. It is a diatomic molecule with the chemical formula Br2
The bromine available for extraction occurs as bromide in the ocean, in salt lakes and in brine or saline deposits left by evaporation of such waters by solar heat. Sea bitterns, the left over concentrated solution after the crystallizing out of salt from the sea water, are very rich in bromine and offer a good raw material for the manufacture of bromine. Bromine is extracted from seawater.
COST ESTIMATION
Plant Capacity 1000 Kg./Day
Land & Building (10,000 sq.mt.) Rs. 1.59 Cr
Plant & Machinery Rs. 2.33 Cr
Working Capital for 1 Month Rs. 2.31 Cr
Total Capital Investment including 3 months working capital Rs. 10.70 Cr
Rate of Return 54%
Break Even Point 64%
CONTENTS
INTRODUCTION
SOURCE AND SAFETY OF BROMINE
SAFETY FIRST
MARKET OVERVIEW OF SALT
PRODUCTION OF SALT IN PAST FEW YEARS
GROWTH OF CHLOR-ALKALI INDUSTRY OF INDIA
PROPERTIES OF SALT
SALT IS A CHEMICAL COMPOUND WITH THE FOLLOWING PROPERTIES:
POTASSIUM IODIDE
PROPERTIES OF BROMINE
METHOD OF DESALINATION
THERE ARE THREE METHODS OF DESALINATION:
EVAPORATION:
REVERSE OSMOSIS:
ELECTRODIALYSIS:
METHOD OF COMMON SALT FROM SEA WATER
SEQUENCES IN SEA WATER DESALINATION
TECHNICAL DESCRIPTION1: REVERSE OSMOSIS (RO)
1: PRE-TREATMENT:
2: PRESSURIZATION:
3: SEPARATION:
4: STABILIZATION:
MANUFACTURING PROCESS OF SALT FROM SEAWATER
DETAILS OF SALT PURIFICATION PROCESS
TABLE.1 - CONCENTRATIONS OF SOME IONS FOUND IN SEAWATER
THE PRODUCTION OF SOLAR SALT
THE PRODUCTION OF VACUUM SALT
FURTHER PROCESSING
PROCESS FLOW DIAGRAM FOR SALT RECOVERY FROM SEA WATER
PRODUCTION METHODS OF SALT
SOLAR EVAPORATION METHOD
VACUUM PAN SALT PRODUCTION
SALT PRODUCTION FROM BRINE
SALT PRODUCTION BY SOLAR EVAPORATION OF SEA WATER
BRINE EVAPORATORS AND SALT PRODUCTION
EVAPORATED SALT PRODUCTION
CRYSTALLISING EVAPORATORS:-
VACUUM DRIERS
1. DRUM DRIER
2. VACUUM ROTARY DRIER
USES AND APPLICATION OF BROMINE
NATURAL SOURCES FOR BROMINE ARE CHLORIDE SOURCES SUCH AS
INDUSTRIAL SOURCES FOR BROMINE RECOVERY ARE
MARKET OVERVIEW OF BROMINE
MAJOR BROMINE MANUFACTURING COUNTRIES
INCREASING DEMAND FOR FLAME RETARDANTS
MAJOR PLAYERS
RAW MATERIAL SECTION
MATERIALS OF CONSTRUCTION FOR CHLORINE HANDLING:-
B.I.S. SPECIFICATIONS
SCOPE:-
REQUIREMENTS:-
TABLE - 1: REQUIREMENTS FOR BROMINE, TECHNICAL
PACKING & MARKETING:-
PACKING:-
MARKING:-
SAMPLING:-
ANALYSIS OF BROMINE, TECHNICAL
CALCULATION:
WHERE,
DETERMINATION OF BROMINE:-
THE SOLUTION SHALL BE STANDARDIZED BEFORE USE.
PROCEDURE:-
WHERE:
WHERE
DETERMINATION OF CHLORINE:-
PROCEDURE:-
CALCULATION:-
WHERE,
DETERMINATION OF NON-VOLATILE MATTER:-
PROCEDURE:-
CALCULATION:-
WHERE,
TEST FOR IODINE:-
ZINC DUST:-
TEST FOR SULPHATES:-
PROCEDURE:-
SAMPLING OF BROMINE TECHNICAL
NUMBER OF CONTAINERS TO BE DRAWN FOR SAMPLING
EXTRACTION TECHNIQUE OF BROMINE
THE TECHNIQUES OF EXTRACTION BROMINE
A. STEAMING-OUT AND AIR BLOW-OUT TECHNIQUE
B. ION EXCHANGE RESIN ADSORPTION
C. MEMBRANE PROCESS
1). GAS MEMBRANE PROCESS
2). EMULSION MEMBRANE PROCESS
D. HIGH GRAVITY AIR STRIPPING TECHNIQUE
A) STEAMING OUT PROCESS (HOT PROCESS)
B) AIR BLOWING PROCESS (COLD PROCESS)
PRODUCTION OF BROMINE
BLOCK SCHEME A - BROMINE PRODUCTION
DEBROMINATION
BLOCK SCHEME B - DEBROMINATION
EXTRACTION OF BROMINE FROM SEA WATER
OXIDATION OF BROMIDE TO BROMINE
REMOVAL OF BROMINE WATER
REDUCTION OF BROMINE TO HYDROBROMIC ACID
OXIDATION OF HYDROBROMIC ACID TO BROMINE
PRE TREATMENT FOR EXTRACTION BROMINE
FIGURE: ACID PROCESS BROMINE PROCESS
ETP PROCESS
DETAILS OF ETP PROCESS IN LIQUID BROMINE MANUFACTURE
PROCESS FLOW DIAGRAM
STAGES IN BROMINE MANUFACTURE
THE MANUFACTURING PROCESS OF BROMINE INVOLVES FOUR MAIN STAGES:
OXIDATION OF BROMIDE IONS TO FORM BROMINE
BROMINE VAPOUR REMOVAL
PRODUCTION OF HYDROGEN BROMIDE
OXIDATION OF HYDROGEN BROMIDE TO BROMINE
HOW A HAZARDOUS CHEMICAL LIKE BROMINE IS HANDLED
DETAILS OF LIQUID BROMINE MANUFACTURE
PROCESS
THE FOUR PRINCIPAL STEPS IN BROMINE PRODUCTION ARE
STEAMING OUT PROCESS:-
DOW PROCESS:-
SAFETY IN BROMINE PLANT
SAFE HANDLING OF BROMINE LEAKAGE
SAFE STORAGE OF BROMINE
SAFE TRANSPORTATION OF BROMINE
THE BROMINE STORAGE TANK SIGN IS AS FOLLOWS:
TECHNICAL DETAILS OF BROMINE MANUFACTURE
FROM SEA WATER
RAW MATERIAL
BLOCK DIAGRAM FOR MANUFACTURING PROCESS
REACTION
PROCESS DIVIDES IN THREE STEPS
AIR POLLUTANT EMISSIONS & THEIR CONTROL
PROCESS OF EXTRACTING POTASSIUM CHLORIDE FROM SEA WATER TECHNOLOGYOF RAW MATERIAL WATER TREATMENT FOR EXTRACTING BROMINE
FIGURE: ACID PROCESS BROMINE PROCESS
ADDRESSES OF RAW MATERIALS SUPPLIERS
ADDRESSES OF PLANT & MACHINERY SUPPLIERS
MACHINERY SUPPLIERS OF SALT FARMING
SUPPLIERS OF EFFLUENT TREATMENT PLANT
SUPPLIERS OF HEAT EXCHANGER
SUPPLIERS OF CONDENSER
SUPPLIERS OF DISTILLATION COLUMN
SUPPLIERS OF STORAGE VESSEL (STORAGE TANKS)
SUPPLIERS OF LABORATORY EQUIPMENTS
SUPPLIERS OF D.G. SETS
SUPPLIERS OF BOILERS
SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS
GOVT. LICENSE DETAILS FOR LIQUID BROMINE PLANT
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
