OPERATING OF DRY HYDROGEN CHLORIDE GAS GENERATION UNIT

1.0    PURPOSE:
    
        To describe a  standard operating procedure (SOP) for operating of dry hydrogen chloride gas generation unit
    
2.0    SCOPE:
    
        The SOP describes in detail the method of operating of dry hydrogen chloride gas generation unit
    
3.0    RESPONSIBILITY:
    
    The responsibility of maintaining of operating of dry hydrogen chloride gas generation unit as per the SOP lies with the staff of rank not lower than operator of production department.
    
    The responsibility of preparing, reviewing and approving the SOP lies with the Executive (Production), Head of Production and Head of QAD respectively.
    
4.0    METHOD:
    
4.1    While starting check and fill level of HCl tank 72 half full and charge 5 L. of sulphuric acid into glass trap.
    
4.2    Circulate chilled water and brine to condenser I & II and ensure outlets are free from obstructions which create overflow of chilled water or brine respectively.
    
4.3    Open vent valve of the system. Care should be taken to see that valve is completely open which not in case can create pressurization and leakages.
    
4.4    Apply steam to re-boiler and when boiling starts raise the pressure to around 1.5 kg/cm2 (maximum) and keep it steady.
    
4.5    Start feeding HCl  to  pre-heater  slowly  at  a  rate  of  75 Kgs./hour and apply steam at around 0.5 Kg./cm2.
    
4.6    Open bottom effluent valve of re-boiler to spent HCl storage tank 73 to maintain steady level
    
4.7    Gradually raise the flow of HCl to 95–100 Kgs/hr. for a gas flow of 15–17.5 Kgs/hr.
    
4.8    Maintaining steam pressures on pre-heater & re-boiler constantly at 0.5 Kgs/cm2  &   1.5 Kgs/cm2 respectively, open the valve to the reactor through trap & close vent on system slowly.
    
5.0    SHUT DOWN:
    
5.1    Stop HCl feed and steam to re-boiler & pre-heater.
    
5.2    Open the vent valve of system & close valve to the reactor.
    
5.3    Stop chilled water and brine circulation for condensers I & II.
    
6.0    PRECAUTIONS:
    
6.1    Whenever unit is restarted, first drain off water in steam  line, allow  line to get hot before passing steam to boiler,  to  avoid hammering in glass coil.
    
6.2    Ensure steady operating conditions and ensure no build up of back pressure  from reactor to HCl gas generation unit. If HCl gas flow drops, while  steam  pressure & HCl feed rate are steady, system pressure will build up.  
    
6.3    Stop  the unit and restart after removing the restriction. Open vent valve and check the sparger  pipe for any choke.
    
6.4    Ensure ample flow of chilled water and Brine to condensers.
    
6.5    Attend to leaks immediately to avoid corrosion. Grease all bolts and provide with p.p. caps.
    
6.6    Steam pressure must be steady within ? 0.05 kg/cm2g.
    
    
    

Production, hydrogen chloride, generation