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Home My WebLink AboutENGINEERING80Z-011(p ALLIED NEW TECHNOLOGIES, Inc. 3901 N.W. 115 Avenue Miami, Florida, 33178 Attention: Mr. Jim Palmer, President Remo W. Gritz 1214 Resaca Place Pittsburgh, PA 15212 Subject: Professional Engineer rmflO December 28, 2009 .1% 3 RAG FE8 11 �010 s Pub1tcC untY+��'� lu°je functional review ac 'approval Ref: 1. P&ID Documents ALU-341 -P-PD 2. PROCESS DESCRIPTION ror ALLIED TECHNOLOGY INC. 3. List of critical or important functions Dear Mr. Palmer, I am in receipt of 51 P&ID's of R independently reviewed to determ INC. plant. For purposes of this r system, as provided by the P&ID' More than- 59 system functions ha indentified in Reference 3, see att, the piping, instruments and comp( conclude "The piping, instrument: review can functionally perform a ALLIED NEW TECHNOLOGY ] 'e enced 1, see attached list. These documents were i system functionality for the ALLIED NEW TECHNOLOGY r ew "system functionality" is defined as the ability of the to perform the intended functions as described by Reference 2. been identified by reviewing Reference 2. These functions are ,hed list. The P&ID's in Reference 1 were reviewed to insure Lents can perform the functions as described in Reference 2. I can and components depicted on the system PI&D provided for intended and described in PROCESS DESCRIPTION for Td" » Notwithstanding my statement there are some sections in reference 2 that should be revised to better describe the functions as intend-,! by the P&ID's. This however, would not change the results of the review. Ve ruly Yours, G1/ _/Oy Remo W. Gritz PMP #1275439 PE #66989, Florida cc: Alberto Gonzalez 10691 North Kendall Drive Suite 303 B; Miami, Florida, 33176; Ph: (305) 412 9828; Fax: (305) 412 0287; usa@conveays.com 1 Engineering Diagrams for Allied New Technology Inc. 1. INDEX, ALU-3414-P-PID, Rev 2a 2. LEGENDS & SYMBOLS, ALU-3414- -PID-OOA, Rev 2 3. LEGENDS & SYMBOLS, ALU-3414 -PID-OOB, Rev 2 4. BRINE SATURATION - Unit 11, AL-3414-P-PID-11, Rev 2a 5. NaHSO3 Storage - Unit 14, ALU-341 -P-PID-14, Rev 2a 6. BRINE FILTRATION - Unit 15, ALU 3414-P-PID-15, Rev 2a 7. FILTERED BRINE FEED SYSTEM - nit 15. ALU-3414-P-PID-15B, Rev 2a 8. FILTER AID - Unit 15, ALU-3414-P- ID-15C, Rev 2a 9. SECONDARY TREATMENT -Unit 6, ALU-3414-P-PID-16A, Rev 2a 10. SECONDARY TREATMENT - Unit 6, ALU-3414-P-PID-16B, Rev 2a 11. PURE BRINE 1 -Unit 17, ALU-3414 -PID-17A, Rev 2a 12. PURE BRINE 2 - Unit 17, ALU-3414 P-PID-17B, Rev 2a 13. BRINE DECHLORINATION -Unit 1 , ALU-3414-P-PID-18A, Rev 2a 14. BRINE DECHLORINATION - Unit 1 , ALU-3414-P-PID-18B, Rev 2a 15. LEAN BRINE - Unit 19, ALU-3414- -PID-19, Rev 2a 16. CELL ROOM - Unit 21, ALU-3414-P PID-21A, Rev 2a 17. ELECTROLYZER 1 - Unit 21, ALU- 414-P-PID-21B, Rev 2a 18. ELECTROLYZER 2 - Unit 21, ALU- 414-P-PID-21C, Rev 2a 19. AC/DC CONVERTION - Unit 22, A U-3414-P-PID-22A, Rev 2a 20. AC/DC CONVERTION - Unit 22, -3414-P-PID-22B, Rev 2a U 21. CATHOLYTE CIRCULATION - U t 24, ALU-3414-P-PID-24A, Rev 2a 22. CATHOLYTE CIRCULATION - U t 24, ALU-3414-P-PID-24B, Rev 2a 23. HYDROGEN SYSTEM - Unit 31, A U-3414-P-PID-31A, Rev 2a 24. HYDROGEN SYSTEM - Unit 31, A U-3414-P-PID-3 I B, Rev 2a 25. CHLORINE COOLING - Unit 41, A U-3414-P-PID-41A, Rev 2a 26. CHLORINE COOLING - Unit 41, A U-3414-P-PID-41B, Rev 2a 27. NaOH 50% STORAGE - Unit 51, U-3414-P-PID-51, Rev 2a 28. HYPOCHLORITE SYSTEM - Unit 1, ALU-3414-P-PID-61A, Rev 2a 29. HYPOCHLORITE SYSTEM - Unit 1, ALU-3414-P-PID-61B, Rev 2a 30. HYPOCHLORITE SYSTEM - Unit 1, ALU-3414-P-PID-61C, Rev 2a 31. HYPOCHLORITE SYSTEM - Unit 1, ALU-3414-P-PID-61D, Rev 2a 32. HYPOCHLORITE STORAGE, AL-3414-P-PID-62A, Rev 2a 33. HYPOCHLORITE TANK FARM, ALU-3414-P-PID-62B, Rev 2a 34. HYPOCHLORITE LOADING, AL 13414-P-PID-62C, Rev 2a 35. DEMINERALIZED WATER -Unit 71, ALU-3414-P-PID-71A, Rev 2a 36. DEMINERALIZED WATER - Uni 71, ALU-3414-P-PID-71B, Rev 2a 37. COOLING WATER - Unit 72, AL-3414-P-PID-72A, Rev 2a 38. COOLING WATER - Unit 72, AL-3414-P-PID-72B, Rev 2a 39. HOT WATER - Unit 73, ALU-341 -P-PID-73, Rev 2a 40. COMPRESSED AIR - Unit 74, ALV-3414-P-PID-74A, Rev 2a 41. COMPRESSED AIR - Unit 74, ALU-3414-P-PID-74B, Rev 2a 42. SOFT WATER - Unit 75, ALU-341�4-P-PID-75, Rev 2a 43. RAW WATER - Unit 76, ALU-3414-P-PID-76, Rev 2a Engineering Diagrams 44. INDUSTRIAL GASES - Unit 77, ALI 45. CHILLED WATER - Unit 78, ALU-3, 46. HC1 ACID STORAGE - Unit 82, ALL 47. EFFLUENTS SYSTEM - Unit 91, AL 48. EFFLUENTS SYSTEM - Unit 91, AL 49. EFFLUENTS SYSTEM - Unit 91, AL 50. EFFLUENTS SYSTEM - Unit 91, AL 51. EFFLUENTS SYSTEM - Unit 91, AL Allied New Technology Inc. 3414-P-PID-77, Rev 2a .4-P-PID-78, Rev 2a 3414-P-PID-82, Rev 2a -3414-P-PID-91A, Rev 2a -3414-P-PID-91 B, Rev 2a 3414-P-PID-91 C, Rev 2a -3414-P-PID-91D, Rev 2a -3414-P-PID-91E, Rev 2a CONVE, & AVM' Inc.. ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 PROCESS DESCRIPTION Reference 2 rn used for Functional Review i� C.QNVE & AV,S Inc, ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 Objective PROCESS DESCRIPTION Page 2 of 24 The main objective of this document is to des 'be all the process steps necessary to produce high quality sodium hypochlorite, suitable for PURCHASERS b e i0h use. Redundant equipment are included in all process sections of the facility in order to ensure continuous ands fe operation 24 hours a day, 350 days per year. The plant is designed With adequate storage volume between each ection of the plant to facilitate easy maintenance (within 4 — 6 hours) without interrupting the operation of the plant i whole. The turn down production capacity shall be 70%. This document describes the basic chemistryconnections between equipment items, and process features of the main plant areas. Equipment connectivity a d process control philosophy are illustrated in the Process Flow Diagrams (PFD' s), ALU-3414-P-PD-REV 0. General Raw materials for sodium hypochlorite produ sodium hypochlorite shall be produced under Both sodium hydroxide solution and chlorine together in a separate reactor to produce so, stored. The Hypochlorite. Plant integrates process are • Area 100: Brine saturation and Filtr. • Area 100: Secondary Brine Purificati • Area 100: Brine Dechlorination, • Area 200: Brine Conditioning and Ce • Area 200: Electrolysis, • Area 600: Hypochlorite Generation, • Area 600: Final Chlorine Absorption, • Area 600/800: Chemical Supply, • Area 700: Cooling, Chilled and Hot V • Area 700: Compressed Air & N2 Uni • Area 700: Water Systems, • Area 900: Effluent Treatment, are salt, water and electrical energy. High quality and concentrated nuous mode. Both, diluted sodium hydroxide solution and chlorine gas react hypochlorite (hypo or bleach). No chlorine gas is intermediately illustrated in following process flow diagrams: n, PFD # ALU-3414-P-PD-01 PFD # ALU-3414-P-PD-02 PFD # ALU-3414-P-PD-03 ilyte Circulation PFD # ALU-3414-P-PD-04 PFD # ALU-3414-P-PD-05A /-05B PFb # ALU-3414-P-PD-06 PFD # ALU-3414-P-PD-07 PFD # ALU-3414-P-PD-08 er, Agitation Air PFD # ALU-3414-P-PD-09 PFD # ALU-3414-P-PD-10 PFD # ALU-3414-P-PD-11 PFD # ALU-3414-P-PD-12 To make the brine suitable to feed the memt cane cells, the brine must be very pure, free of suspended solids, and with lowest achievable levels of calcium, r iagnesium, strontium and sulfate. Salt and water consumed in the electrolysis process is added to the brine loc p. The brine loop is a closed circuit passing continuously through the cells. The brine treatment consists of the full wing process steps which have been designed to handle High Purity Salt with the following composition: NaCl 99.8900% SO4 0.0480% Sr 0.0003% Ca 0.0050% Mg 0.0030% Ins 0.0374% H2O 0.0163% C0NV/ E & AVS' Inc.. ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 • Brine Saturation • Brine Filtration • Secondary Brine Purification • Brine Dechlorination PROCESS DESCRIPTION Page 3 of 24 The use of other salt quality (with higher content of impurities) is possible. In that case additional process steps and equipment as brine precipitation (precipitationjof Ca, Mg and SO4) must be incorporated in the plant in order to ensure the brine quality requirements for the el ctrolysis process. Brine Saturation and Filtration, PFD # ALU-$414-P-PD-01 The saturation section comprises two (one pl 's one stand by) underground salt dissolving pits. Each comprises two sections, one section is the salt dissolving pitwhere salt is dumped from trucks or a shovel loader. Depleted brine from dechlorination and pH adjustment proces (pH value = 8) flows upwards through the salt bed and overflows into the second section of the saturator, which s�rves as a buffer pit for raw brine. Each brine dissolving section is designed to be filled up with salt within regular intervals of 12 h. The brine concentration is monitored by regular density measurements and adjusted to values between 300-305 gpl NaCl. Density adjustment is done by recycling a part stream of lean brine and mixing with salt rated brine. Demineralized water is added upstream to the lean brine stream to balance the water consumption in the electrolysis cells. The level of the raw brine pit is automatically controlled be level control loop LCA 101 and L -1101 Saturated brine is transferred with pump P-11 mode between service and cleaning. The filte A body feed of pre -coat (micro cellulose) susl AB. This body feed will ensure that the insole brine shall be less than 0.1 NTU. The flow ral 1501 A and —B. As the filter inlet pressure in frequency driven motors for Raw Brine Puml inlet service pressure to the filters, indicated tl At the beginning of each filter cycle, a pre - from the salt are retained on the filters and filters. Operation of the filter press is on sei The filtrated brine flows into the Filtrated Secondary Brine Purification - PFD # 1 A/B to the filter presses, F-1501 AB. Both filters operate in alternate have the function to filter out any insolubles (clay) from the raw brine. :nsion is continuously added by means of the body feed pump P-1504 des are completely filtrated out by the filter press. Turbidity of the exit through the filters is flow controlled by means of flow control loop FC- eases during service, the flow rate will be controlled through variable P-1101 AB. The end of the filtration cycle is indicated by maximum ough PT-1502 A/B. suspension is pumped to the filter using the pump P-1503. Insolubles discharged on a regular basis into roll off containers located below the Aomatic basis. Tank T 1501. 4-P-PD-02 and -04 Filtrated Brine from Tank T-1501 is pumped by means of Filtrated Brine Pump 1501AB through the Catholyte Heat Recuperator E-2402 and is fed into the secondary brine purification system. The brine is thereby heated up to around 180OF with hot catholyte taken from the cath lyte circulation system. Higher brine temperatures are desirable as the ion exchange (IX) resin has more capacity at igher temperatures. To increase further the capacity of IX resin the pH value of the brine is increased from 8 to a value of 9.5 by means of automated addition of 50% NaOH to the suction side of filtrated brine pumps P-1501 A/B. This is made with pH value control loop AC-1501 and control valve AV- 1501. 1 The flow rate of brine through the Ion Exchange system is automatically controlled by means of flow rate control loop FC-1601. To guarantee continuous destruction of any iesidual free Cl2 in brine, the filtrated brine is first passed through the activated carbon filter C-1601 before entering Ion Exchange Columns C-1602 A/B/C. To purpose of the secondary brine purificati ,n system is to reduce the total hardness in filtrated brine composed by 3 GONVE & AVS, Inc. ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 PROCESS DESCRIPTION Page 4 of 24 Ca, Mg and Sr from an initial total content of abut 10,000 ppb down to levels below 20 ppb. This process is achieved by means of strong cation exchange. The catiopic resin is content in three ion exchange columns C-1602A, -B and — C. The three columns shall operate under the "Merry go Round" system, that means, two fresh regenerated columns in series under service and a third one under regeneration, i.e.: A—B/C B—C/A C—A/B The unit is over designed to allow extended The regeneration of the resin is performed N automatically mixing 18% HCI and 50% NaOH The following reaction takes place: Operation: Regeneration Conversion The regeneration process is performed The alkaline effluent of the system will be cc system. The acidic effluent shall be sent to 9103 AB. The regeneration is performed by by by by periods above 48 hours between regeneration steps: 7% HCI and 4% NaOH. The dilution of the regenerants is made i demineralized water. R-2Na + Ca++ = R=Ca + 2 Na+ R=Ca + 2 HCI = R=2H + CaC12 R=2H + 2 NaOH = R-2Na + 2H2O which is governed by an individual PLC, located in the field. ad, neutralized in effluent tanks T-9102 AB and recycled to the brine battery limits effluent system after treatment in the effluent tanks T- wang steps: Reg. Step 1 Water circulation emin. Water Down -flow To T-9102 A/B 2 Back washing emin. Water Up -flow To T-9102 A/B 3 Regeneration % HCI Down -flow Effluent to be Purged 4 Water Circulation emin. Water Down -flow Effluent to be Purged 5 Conversion % NaOH Up -flow To T-9102 A/B 6 Water Circulation emin. Water Up -flow To T-9102 A/B 7 Brine Circulation 91trated Brine Down -flow To T-9102 A/B Total time needed for each regeneration cyclo is about 6 h. Analysis of hardness in brine in the ppb range must be also performed twice a shift in the lab by colorimetric analysis using a HACH type analyzer. Ultra pure brine is stored in two Pure Bn a Tanks, T-1701 A/B. The total storage buffer time of both tanks is maximum 3.5 hours. Before feeding the pure brine into each ele rolyzer, the pure brine is transferred to Brine Heat Exchangers E-1701 A/B where brine is heated up or cooled do% in according to the process conditions of each electrolyzer. This will be performed in an automated manner by mea�s of temperature control loops TC-1701 A and B controlling either the flow rate of hot or cooling water to the heat e, changers. Brine Dechlorination and Chlorate destruction - PFD # ALU-3414-P-PD-03 Dechlorination is performed in the anolyte exiting the cells, as well as to remove the entire chlorine from the brine to render it suitable for the subsequent process steps. The chlorine saturated depleted brine (anolyte) coming from the 4 CON,VE & AV$ ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 cells flows by gravity sequentially into both stripped out from the acidified anolyte using bearing air/water vapor stream exiting both I stream coming form cooling and sent to Hypo PROCESS DESCRIPTION Page 5 of 24 irination Tanks T-1801A and —B. Most of the chlorine gas is i air until a residual content of about 10 ppm Cl2.. The chlorine nation Tanks T-1801 A/B is mixed with the production chlorine Reactors C-6101 A and B. The acidification of the anolyte from a pH value 3.5 -4 down to a pH value =2 is necessary for the purpose of reducing Cl2 solubility and allowing easy chlorine release by means of air desorption. The dechlorinated or lean brine flows by gravity into the Lean Brine Tank T-1901 which serves as a storage buffer and receiver tank for different brine effluents to be recovered. An automatic pH adjustment to a value of 8. is made in two steps by means of automated controlled addition of 50% NaOH delivered by Pump P-5101 AB. I the first step the pH value is increased from 2 up to 4-5 at the exit of the T 1801 B. A further increase of pH value to� 8 - 8.5 is performed by adding 50% NaOH at the suction side of Lean Brine Pumps P-1901 A/B. A final dechlorination step is considered by means of S02 addition, which is mixed to the neutralized brine throggh ejector J-1802. This step is automatically co 'trolled by means of REDOX measurement with ORP meter AT-1903 and will ensure no presence of chlorine in the depleted brine before saturation. Excess of S02 is convenient until a ORP value of 150 mV is reached. The chemical reaction of Cl2 reduction can be epresented as S02 + Cl2 + 4NaOH = Na2SO4 + 2NaCl + 2H2O. Neutralized brine from T-1901 is pumped to th brine saturators with Lean Brine Pumps P-1901 A/B. Sodium Chlorate is further generated as a se ndary reaction during the electrolysis process. To keep the chlorate level in feed brine to the cells < 10 g NaC10 /I, chlorate is continuously destroyed in Chlorate Destruction Tank T- 1803 by means of reaction NaC103 + 6 HCl = NaCl + 3 C12 + 3 H2O A small anolyte stream is treated in the rea or with HCI, which decomposes the chlorate into Cl2 and NaCl. The chlorine gas is recovered and send together th the stripped out Cl2 the hypochlorite columns. The reaction takes place at temperatures > 170 deg F and HCI ntent between 1 -2 %. A small HCl 18% stream is added automati Ily by means of jet pump J-1801 to the chlorate reactor T-1803. The excess HCI not reacted with the chlorate overflows as acidified brine and mixes with the anolyte stream before entering T-1801 A. This quantity is sufficient to acidify the anolyte for dechlorination. The Acidified Brine Pump P- 1803 AB circulates the acidified brine through Ejector J-1801 and maintain the mixing in T 1803. The ejector sucks the necessary 18% HCI stream controlled by H meter AC-1802 and Flowmeter FC-1802. Electrolysis, PFD # ALU-3414-P-PD-04, -05A and -05B NOTE: THE INEOS' s OPERATION, MAINTENANCE AND LABORATORY MANUALS ARE PART OF THE DOCUMENTATION NEEDED FOR PLANT OPERATION AND ARE NOT INCLUDED IN THIS PROCESS DESCRIPTION. Two (2) BiChlorTm INEOS bipolar membrart�I electrolyzers are considered, which are designed with the following characteristics: Initial Cell Room o a N C ! . Curren Circuit Expected Rectifier Circuit Power Consumpti Capacity a e Z 2 ° Density KAW Current kA Cell Voltage V, Voltage, V on kWh/mt STPD Cl2 Z o m SOL I Design SOL /Design SOL I EOUMax SOL /Max NaOH w Z W (Note 1) 5 x og ON= no w am 0 - unr i MOT fausavy"W jav no yo, I.W., qvy 0, ho,wv put, IV Mwyyn r a WOE 5I Otto to! IN I W) Lyyv%r And pit", vMV0 ;"v -0pno gmay, h- %oo Hq 6 low '0 S&KAM al: a L 0 00 0 0 0 Mp"a own Woo old 10 Hunk NAN YM6 % 1 11 AWY w M: 0 MWA A. APYNA 'K, 0 c man MOO 9NM MOWN to ?I SOM W somqPQ on 0 'ps b Am UNk, ZOO to Reveywy. od PmN 10 no q No 0"4 ate."vp CLA Q Mov Moo= 6'rof gru N 1", on? 0 ARM MW MnKa sh AnA A vFw= va?"k a i st ;mob naawn ymonve a to hKownp qd ?, 0:001 n MO.' 00; 1 " 00 E 100 MK 1 a MOO:', lymbn No wav"Wou ANAV M n v MY No= QH won 0 rb 011 1 v1nKvWQM 0 n "w�� 'MA 0A on F My.&MUSL a' Alums ST 01 'A SO 10 10M AKA WAYWAM .. a v an W& an ; Awn? 0 ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 . PROCESS DESCRIPTION Page 6 of 24 119 2 120 5.04 / 5.5 14.62 / 16 3.05 / 3.28 / 3.6 398 / 475 2130 119 2 130 4.66 / 5.5 13.5 / 16 3.00 / 3.23 / 3.6 398 / 475 2095 + Each electrolyzer structure will be de igned for a minimum number of 120 and a maximum number of 134 cells or modules. • Each electrolyzer will be connected to one single electrical DC - circuit fed by one rectifier transformer unit. • Note 1) Power consumption determ ned on electrolyzer terminals operating with 32% NaOH and 900C temperature in cells. • Start of Life (SOL) Current Efficiency:196% / End of Life (EOL) CE 93% after 4 years operation. 2 Rectifier Transformer Units Imax=16 kA U= 0 - 475 V N U) :3 j O O 7 O O 2 + g + N N V G L a Q. tL tL Definitions The terms used to describe the BiChlorElectrolyzer are defined in this section. Each BiChlor Electrolyzer is made upjof a number of Nestpak modules connected up electrically in series. These Nestpak modules are physically bontained in frames, and the collection of Nestpak modules in one frame is referred to as a 'pack'. The active area of a single membrane io a Nestpak module is 2.895 m2. The Bichlor is designed for the future. 4 is hydraulically capable of taking fluids and operating at 8 KA/m2. In the Ineos research facilities they have taken the electrolyzer up to 9KA/m2. However current membrane D;-o C,0NVE & AXIS Inc. ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 development only guarantees up to 6 K The Bichlor can be operated at modest a pressure of 185 mbar. Exit Flexibles Support Rail Fixed End Feed Flexibles Cathode Electrode Assembly (Nickel) PROCESS DESCRIPTION Page 7 of 24 2 and we feel the optimum at the moment is 5 KA/m2 operation. crating pressures of up to 120-150 mbar but can be designed also for r, Ion Exchange Membrane ChlorinL Header / Figure 2 Design of the module concept: Gaskets �s'��'�rrrrr rr(f :r.rr�r.rrA�r.��; rr� rrr.rrrr.5�rr,c' :r.r�r��r�r' - .frr`rff�,,, Feed Caustic Header Anode Electrode Assembly (Titanium) Copper Electrical Connections Feed Caustic Sliding End T� Hydrogen Header Cell Gas (Hydrogen) Product Caustic Feed Brine Cell Gas (Chlorine) Feed Brine Depleted Brine Header Each module in the Bichlor is sealed in ividually by a perimeter flange. This means that the cell is not a filter press design and so when it is opened up it is not necessary to hold back the other modules to prevent the membranes falling out, which can occur n other technologies. The End plates only provide sufficient pressure to maintain the mechanical electrical connection between modules. A module comprises the anode and oath de half shells or pans housing the electrodes, the membrane, and the flange and sealing system. The anod1 is made from titanium whereas the cathode is made from nickel. Membrane is lightly held between anode and cathode mesh using sprung electrical distributors or'spiders' Bichlor is easy to operate featuring: Transparent feed and outlet hoses enabl checking of flows and liquor quality. The individual cell elements of an elect olyzer are suspended in a steel frame where they are lightly pressed together for electrical contact. Large sealing forces are not required in the single element concept, as each element is a separate, stand alone el lysis cell. 7 CONVE & AVS� Inc. ALLIED NEW TECWNOLOY INC. ALU-3414-P-PD-REV0.0 The big advantage of a modular design is hours with forced cooling present. A replacement module can be prepared when required. PROCESS DESCRIPTION Page 8 of 24 down time can be minimized. A module can be replaced in just 4 the workshop outside of the cell room and simply swapped over The area above the electrolyzer is clear'of piping or bus bars, simplifying access and removing the risk of leakage and associated corrosion problem on the electrolyzers. C 1 0 UVE 4: AV,5;1n-Q. ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 PROCESS DESCRIPTION N estpak i� CONV/ E &AVS; Inc.. ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 Figure 4 Cellroorn Crane for Nestpak Modules PROCESS DESCRIPTION Page 10 of 24 It is essential that a cellroom crane is pr' vided to lift the assembled Nestpak modules from the assembly area into the fixed BiChlor Electrolyzer frames The crane, and any associated lifting b am, should be set up such that, when lifting a module, the distance between the top of the lifted module and Xhe top of the Electrolyzer is at least 1.6 meters. Uniform feed distribution The offtakes from the Bichlor are tran parent and the flow pattern is designed for a slug flow into the exit header. There is a gas space occurring between the fluids in the headers and the fluids coming from the cell. This provides a natural break in the fluid path to prevent stray currents occurring. The brine and caustic are fed first through an inner tube along the full length of the module and then comes back on itself into an outer tube where t ere are small feed holes to give an even feed. The reason for the two tube system is to increase the path taken by the feed fluids, thus increasing the resistance of the fluids and minimizing the potential for stray currents. 10 i� CONVE, & AVIS- Inc. ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 mm0mm mmmom°mm0mm Inlet ® 1-I - -- Figure 5 PROCESS DESCRIPTION Page 11 of 24 The Bichlor uses a baffle in the anode I compartment to ensure efficient brine mixing. This is crucial for long membrane lifetime as poor brine distribution can lead to blistering and pinholing of the membrane. This baffle produces a natural circulafloo by making use of the gas lift effect which gives a circulation of brine across the membrane of something like 00 times the feed rate. 11 �-'QQNVEA- AXIS;.InC:. ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REVO.0 Figure 6 Outlet Header design A crucial design feature of the Bichlor allows chlorine and hydrogen gas to c outlet. This design means there is no other technologies. A fully wetted met electrolyzer performance. PROCESS DESCRIPTION Page 12 of 24 Membrane Baffle Anode Spider Anode Mesh the headers, which run across the entire length of the module. This :ngage directly from the top of each cell and be removed at the side s space at the top of the membrane, which is a weakness in several rane with no gas space exposure will increase the lifetime and overall The membrane is kept fully wetted since the liquor level in the electrolyzer is maintained above the top of the membrane at all times. The gas comes easily off the top of the cell and there is no resultant gas space. Gas spaces usually occur because the gas evolving is not adequately removed from the cell compartment and results in a pressure drop which gives rise to a gas space forming, as the gas can't escape quickly enough. Current Distribution To achieve low voltage operation the ct the maximum the amount of Nickel ( b poorer conductor). In addition the elec legs to distribute the current easily on spaced across the mesh, to ensure ti current distribution. it is passed from one module to the next through a design that allows conductor) carrying current and minimizes the amount of titanium ( it connection include connectors called sPFDers which use sprung anode and cathode mesh. The sPFDers are designed to be evenly are no short paths for the current to take and this ensures even 12 CONVE. &. A- /S Inc. ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 Membrane Figure 7 The gasket technology The gasket technology used has been module is perfect with no creep, embi bolting system with elastically deforme through the cathode header and scr assembled and fully tested elements (s Cell room brine and catholyte PROCESS DESCRIPTION Page 13 of 24 Anode Cathode Pan Pan Mesh Mesh Membrane roven over many years of operation. The seal around the edge of the lement or ageing due to PTFE gaskets, using a steel spring washer steel washers for stable long term compressive forces. The bolt goes is into the anode header. This enables long term storage of pre - also paragraph below for replacement of elements). The feed rates of electrolytes to the cells are automatically set by flowmeters. Since the feed lines to, and the discharge lines from, the cells are at different electric potentials, stray currents are prevented by liquid current resistors (PTFE-hoses) foreseen in the feed and product lines. Pure brine (approx. 305 gA NaCI) ente anodes. The anode and cathode comf The membrane only allows individual chamber (about 3-4 moles H2O / mole the anode compartments where chlorine is generated at the titanium tment is isolated by a membrane which is hydraulically impermeable. fusion of Na+-ions and a certain quantity of water into the cathode i+). A two-phase mixture of chlorine and anolyte is discharged via the 13 QQNV E & AVSs MICR. ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 PROCESS DESCRIPTION Page 14 of 24 installed overflow pipe into the anolyte header where chlorine gas is separated from the anolyte. The brine leaving the cells is depleted to approximately 200 gN NaCl. The chlorine generated leaves the cells t 188-194 OF saturated with water vapor and is sent to a Chlorine Cooler. Hydrogen and OH —ions are generated atl the cathodes. This electrochemical reaction and the dilution of the circulating catholyte stream requires wat r which is partly supplied by the above mentioned H2O transport phenomenon through the membrane a d partly added as demineralised water. The two phase mixture comprising 32 % caustic and hydrogen fl ws from the catholyte compartment via the over flow pipe into the catholyte header where the hydrogen gas o separated from the catholyte. The produced hydrogen exits the cells at Due to secondary electrochemical react! both anode and'cathode decreases to chlorate and oxygen. The catholyte flows to the catholyte tank. a product to storage or for down stream t Chlorine Depleted BI W OF saturated with water vapor and is sent to the H2 Stack. and OH- diffusion through the membrane, the current efficiency on rox. 96 % of the theoretical value. These reactions mainly form the catholyte tank one part of the catholyte stream is pumped as g and to various internal plant consumers. OH- Backmigration drops CE to <100% "3I` - 2e = C12 r. IH - - 4e-- 02 ♦. OH- ide Rea ion) 2Na+ + H2O) NaCI = Brine F W Figure 9 The remaining catholyte is cooled and i + 2Na+ Hydrogen Catholyte 32% NaOH 1 2Na+ +20H- =2W i 1 Ja+ +(H20)* 2H2O + 2er =20H- - Perfluorated Cation Exchange Membrane Caustic Feed Demin Water with demineralised water before recycling back to the electrolyzer. 14 00KVE. &,, AVS. Inc;:. ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 PROCESS DESCRIPTION Page 15 of 24 The electrolyzer includes several controls and interlocking devices to protect the cells against up -sets. The rectifier trips at high cell voltage, low brine nd caustic flows to the electrolyzer. The flow rate of the brine and caustic will be set manually for the electrolyzer on flowmeters and monitored and alarmed by flow switches. In case of a vgry low flow rate signal the rectifier will be disconnected. Too high catholyte temperature will be alarmed and isconnect the rectifier when reaching an upper limit. The electrolyzer temperature is adjuste during operation to minimize energy consumption. Cell voltage increases about 10 mV per OF of catholyte temperature at cell outlet. Maximum recommended cell temperature is 194°Fand min. 167 OF. In order to main ain high operating cell temperature in the range between 176-194°F brine feed and / or catholyte feed mus be heated or cooled according to the actual electrolyzer power consumption. Heating or cooling of caustic ed is provided through a Catholyte Heat Exchanger. Feed Brine Composition for BiChloirm Calcium plus magnesium <0.02 mg/kg Strontium <0.4 mg/kg Soluble Silica <5.0 mg/kg Aluminium <0.1 mg/kg Manganese <0.05 mg/kg Lead <0.05 mg/kg Iron <0.15 mg/kg Nickel <0.01 mg/kg Mercury <0.5 mg/kg Barium <0.5 mg/kg Sodium Sulphate <8.0 g/I >5.0 gA Total Iodine <0.2 mg/kg Copper <0.05 mg/kg Silver <0.05 mg/kg Zinc <0.05 mg/kg Bromide <150 mg/kg Fluoride <1.0 mg/kg Organics in feed brine can affect the perf rmance of membrane technology. The effects are dependent on the type and quantity of the organic present. If organics are present in the feed brine then the client should consult with IEL so that influence of the organics on the membrane warranties and guarantees can be assessed. Exit Brine from BiChlorTm Electrolyser Sodium chlorate Fluoride <20 g/I <1.0 mg/kg The pH -value of the anolyte from the cells ip continuously monitored and alarmed as required, for suitable cell operation by means of AElr-2101A/B analyzerj Normal pH value of anolyte is 3.5- 4.5. Steady Operating Conditions Feed brine concentration (NaCI) Exit brine concentration (NaCI) Feed Sodium hydroxide concentratioi Exit Sodium hydroxide concentration Feed Sodium chloride pH (at 73. OF) Exit Sodium chloride temperature Exit Sodium hydroxide temperature 290-305 gA 190-230 gA 28-32% w/w 31-33% w/w <11.6 176-194 OF 188-194 OF 15 3_)o Q_ONVE & AV,$ I,nc, ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 H2/Cl2 differential pressure Hydrogen maximum pressure Hydrogen minimum pressure Exit Sodium chloride Cell pressure control: PROCESS DESCRIPTION 10-20 mbar 185 mbarg 0 mbarg pH 2-11 Page 16 of 24 Maintaining a constant pressure difference between the cathode and anode compartment is essential for safe operation of the cells. The hydrogen pressure is always kept approximately 20 mbar higher than the chlorine pressure. This ensures that the membrane only touches the anode and is kept in this defined state. Electrolyzer pressure control valves and Seal Pots, T-i4102 (Chlorine seal pot) and T-3101 A (Hydrogen seal pot) on H2 lines and Cl2 lines are provided to take care of this. In case the pressure of chlorine or hydroge6 increases excessively several safety measures will react: • automatic valves to the waste ga dechlorination / H2 stack; • over -pressure seal pot also to the waste gas dechlorination / H2 stack. Cell Workshop A cell workshop meets the requirements for the assembly and disassembly of the cells and for all manipulations necessary in the cell room. Pre-treatment of new membranes. The membranes are shipped fully conductive i.. in the sodium form as received. Prior to mounting the membranes in the cell elements, a pre-treatment is necessary o fully expand the membrane and to prevent undesirable wrinkles. Replacement of modules. An exchange of nestpack modules in the electr lyzer may be necessary due to • scheduled exchange of membra as, • scheduled recoating of electrode , • unexpected problems of a module like high voltage, leakage, etc.. Then, the following procedure applies to exchange elements in an operating electrolyzer. This electrolyzer has to be cut-off from the current circuit. Subsequently, a electrolyzer is cooled down to approx. 113'F. Prior to taking out a single element, the eledrolyzer is drained. Then, the relevant contact pressure springs and individual flange connections to the feed and c ischarge lines are loosened and the concerned element is taken out, transported to the neighboring cell workshop, and exchanged by a pre -assembled spare element. Eventually, the electrolyzer is refilled with brine and caustic c f approx. 122°F and after heating up, the electrolyzer can be again energized. The overall downtime of an electrolyzer to exc ange an element - including cooling down and heating up - amounts to approx. 5-8 hours. Two men are required for the mechanical work. The essential advantage of the modular con pt is that the exchange of one Nestpack in an electrolyzer does not affect the remaining Nestpacks. Since pre -assembled single Nestpacks can be stored for several months the BiChlor concept minimizes electrolyzer downtime during maintenance work. Thus, we �trongly recommend that a small number of assembled Nestpacks are kept in store. Catholyte Circulation - PFD # ALU-34 16 0- QNVE & AV$ Inc, ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 PROCESS DESCRIPTION Page 17 of 24 Catholyte is continuously circulated through t e cells with Catholyte Pumps P-2401AB passing Catholyte Heat Exchanger E-2401 and Heat Recuperator E-240 and returning to the Catholyte Tank T-2401. 32% NaOH Storage Tank T-2402 is available t hold up the complete volume of both electrolyzers in case of first filling or draining during maintenance. Caustic is nsferred with P-2402 to the electrolyzer. Both pumps P-2401 AB are considered critica for electrolyzer operation. If the operating pump fails, the stand by pump will be automatically switched in. Both pu ps are also connected to the Emergency Power Generator. Part of the heat generated in the process is tran ferred to the filtrated brine by means of Catholyte Heat Recuperator E-2402. Catholyte Heat Exchanger E-2401 serves to eat up or cool down the catholyte stream according to operation requirements. In order to maintain the recomm nded operating cell temperature between 180-190 OF the brine feed and / or catholyte feed streams must be heat d up or cooled down according to the operating load. This will be performed in an automated manner by means of temperature control loops TC-2405 A and B controlling either the flow rate of hot or cooling water to the heat ex angers. The density or concentration is continuously onitored as required by cell operation with density / mass flow meter DE/FE- 2416. Total caustic production exiting t e cells can be measured with the same instrument. Demineralized water is added in automated mode for caustic make-up as required, according to current load by means of controller FC-2407 and control valve DV 2407. The tank level of Catholyte Tanks T-2401 amid T 2402 is maintained constant by control loop LC-2401 and control valve LV-2401. The 32% NaOH production st earn is sent to a caustic dilution station and hypochlorite production v 1 column. Hydrogen and Chlorine Processing - PFD # U-3414-P-PD-05A and -05B Independent Headers for each Chlorine and H drogen with corresponding independent pressure control systems are considered for each single electrolyzer. That l means each electrolyzer can be operated completely independently from each other. The electrolyzers will be operated at nearly aFof 'ospheric pressure. The produced hydrogen exits the cells at 180-190 OF saturated with water vapor at a pressur 0.44 psig (30 mbar g). The chlorine exits the cell at the same temperature but at 0.22 psig (15 mbar g), maiaining a differential pressure between H2 and Cl2 of about 0.22 psi. The differential pressure value measured be en H2 and Cl2 cell headers is automatically controlled by means of two control loops PDC-2101A and PDC-210 for electrolyzer A and PDC-2101 B and PDC-2102 E for electrolyzer B maintaining a constant value at 0.22 psi. Each pressure differential control loop is provided with two control valves, PV-2101 A and PV-2102 A for electrolyzer and PV 2101 B and PV 2102 B for electrolyzer B. The second valve assures smooth cell operation at low load ors art up operation. Each electrolyzer is additionally protected agdinst too high pressure on either H2 and Cl2 headers by means of water pressure seals. Each electrolyzer has one H� safety seal T-3101 A and B, as well as one Cl2 safety seal T-4101A and B which limits the pressure to about 0.66 ipsig on H2 and 0.44 psig on Cl2. The hydrogen is vented to atmosphere throu The chlorine generated in each electrolyzer independent Chlorine Coolers E-4101 A/B vi by two independent pressure control loops and PV 2104 A for electrolyzer A and PV smooth start up and low load operations. a stack. Ives the cells at 180-190 OF saturated with water vapor and sent to two ire it is cooled to about 140°F. The chlorine cell pressure is controlled :-2103 A and B. Each control loop has two control valves PV 2103 A 03 B and PV 2104 B for electrolyzer B. The second valves are for 17 CO:N;UE.: &, AVS, lie.. ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 PROCESS DESCRIPTION Page 18 of 24 Subsequently both Chlorine gas streams are li `ixed with the C12/Air stream coming from the brine dechlorinators. Both C12/Air streams are sent subsequently to both Hypochlorite reactor columns C-6101A and C-6101B. Nitrogen purge to the H2 electrolyzer headers and air purge to the Cl2 electrolyzer headers are initiated after any shut down, during shut down and prior to any start up of the electrolyzer. Thereby availability of continuous N2 supply is fundamental. Chlorine Absorption, PFD # ALU-3414-P-PD-0,6 and -07 The system has been designed to operate 'th two independent hypochlorite generation units, each of them connected to one electrolyzer. These units are designed to produce high quality sodium hypochlorite in continuous mode between a concentration range from 1 up to 180 gpl active C12 and excess caustic between 1.5 — 10 gpl NaOH. The concentration of the hypochlorite i dependent of the concentration of the caustic feed to the reaction towers which is adjusted as needed in automated form. Two pH value control loops on each unit will control the excess caustic in automated mode. Sodium Hypochlorite is continuously generated in the Hypochlorite Reactor C-6101 A and C-6101 B by absorbing with diluted caustic soda all the chlorine as w II as chlorinated air from brine dechlorination produced in the plant. Chlorine gas enters the packed columns at he bottom section. Fresh caustic and hypochlorite is continuously circulated to the tower entering at the top and flowing into the tower downwards in countercurrent with the chlorine gas being absorbed. Both units operate in parallel mode and are connected in series with the Final Absorption Column, C-6102 through the exit waste gas lines from each reactor. 'his column operates as a scavenger to guarantee a virtual zero C12 emission to atmosphere of the waste gas, even in the worst case scenario, i.e. circulation failure in one or the two of the main units. Maximum Cl2 emission in efflueInt gas shall be less than 0.1 ppm. One pair of hypochlorite circulating pumps per unit, P-6101 A/B and P-6101 C/D, are provided for high circulation rates and low operating temperature in the Ever to ensure the lowest decomposition rates. Both pumps will be in operation on each circuit when cooling wa�er temperatures are at the highest level. At lower cooling water temperatures only one pump may be in operation. Hypochlorite will be continuously circulated through towers C-6101 A and B passing Hypochlorite Suction Tanks T- 6101 A and B and Hypochlorite Coolers E-6101 A and B. These plates heat exchangers, will maintain the hypochlorite within the reactor at temperatures less than 100 OF by means of cooling water circulation ensuring maximum reaction efficiencies. The level in Hypochlorite Suction Tanks will Ike maintained by means of level control loops LC-6101 A and B with control valves LV-6101 A and B. The produced hypochlorite will be sent to the storage tanks passing the Hypochlorite Chiller E-6103. The purpose of the chiller is to reduce the temperature of the produced hypochlorite down to 68 deg F prior to be sent to the storage tanks, ensur g thereby minimum decomposition rate. The caustic feed stream necessary for the H�pochlorite Reactors will be provided by Hypochlorite Circulation Pump P-6102 A/B. These pumps take diluted caus>ic soda (15-20% NaOH) from the sump of the Final Absorption Column C-6102. The stream will be controlled by coFresponding redundant pH -controllers AC-6104 A/B and AC-6104 C/D and control valves AV 6104 A and -B maintaining the required pH -value of the product at about 11.5 -12. The pH value of the exit hypochlorite stream will gpvem the amount of excess NaOH concentration. This value can be adjusted between 1.5 -10 gpl NaOH. Diluted caustic is continuously produced by mixing streams of soft water from Soft Water Pump P-7501 A/B, catholyte from the Catholyte Pump P-2401AB and 50°/ NaOH make-up stream from P-5101 A/B. All streams are automatically controlled. The soft water stream is controlled by density control loop DC-6103 and the 50%NaOH stream is controlled by level controller LC-6102. The diluted caustic necessary for the C12 absorption is continuously circulated through Final Absorption Column, C-6102. Waste gas exhausters K-6101A / B are provided to ensure suction in the chlorine system. The suction pressure is automatically controlled by means of pressure control loop PC-6101. The 18 00NVEA-VS Inc,. ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 All Hypochlorite Circulation pumps as well as W Hypochlorite Circulation pumps are considered i stand by pump will be automatically switched in. Chemical Supply, PFD # ALU-3414-P-PD-08 The caustic storage area comprises the PROCESS DESCRIPTION Page 19 of 24 Gas Exhauster are connected to the emergency power system. d for the plant operation. If one of the operating pumps fails, the Storage Tank T 5101. 50% NaOH is received by an underground double walled pipe and discharged into 50% NaOH Storage Tank T 5101. 50% NaOH pump P-5101 A or B supplies the pl nt with caustic soda. An air operated diaphragm pump, P-5102 is in tailed within the caustic containment area. In case of any spills, the liquid will be pumped using the pump to the effiu nts tanks T-9102A/B. Hydrochloric acid will be stored at 18% HCI co centration in order to avoid acid fuming out of the storage tank T 8201. Commercial 32% HCI is received by an nderground double walled pipe and mixed with demineralized water for dilution down to 18% in ejector J=8201. The ilution is automatically controlled by means of a conductivity control loop AC-8103. The supply of 18 % HCI from the Storage Tank -8201 will be by gravity through a trench pipeline. The HCI tank is installed in a containment area iI order to avoid potential contamination by this hazardous chemical. An air -operated diaphragm pump P-8202 is installed inthe acid effluent sump to discharge any acid spill into the effluents treatment tanks (1 T9102 AB) Water Systems, PFD # ALU-3414-P-PD-11 Raw water (City Water) from B.L. is received i tank l T7601 and from here it will be distributed by pump P-7602 A/B to the different water stations within the facility. 1 he main users for the raw water (city potable water) are: • Safety showers • Demineralized Water Units • Soft Water Units • Water stations The Demineralized Water System consists of Itwo units, U-7101 A/B, each having 100% capacity. Both units are designed for 12 hours operation cycle each. a regeneration time is about 3 hours. During regeneration mode of one unit the other enters automatically in rvice, granting herby continuous supply of water. This unit is over designed (about 40%) on the basis that, for an , reason, recoverable effluents cannot be recycled to the brine system. The regeneration of the cationic IX Column is performed with 18% HCI diluted with raw water. The effluent of this cationic resin is sent to the waste water, effluen sump T-9101. The regeneration of the anionic resin is done with 50% NaOH diluted with demineralized water. The ffiuent of during this regeneration is send to the Soft Water Tank T- 7501. In this way the amount of total effluents pent to B.L. is reduced and excess NaOH contained in this effluent is recovered by sending the soft water stream tolthe hypochlorite production. The quality of the hypochlorite will not be measurablly affected by this procedure. II The required output quality of the Conductivity Iron water is as follows: <5 x 10'6 ohmscrri' <20 ppb w/w 19 CONVE & AV$ Inc; ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 Si02 Demineralized water will be collected in the C consumers with Demineralized Water Pump P-71 The Soft Water Unit U-7501 A/B consist of two water. The unit is over designed by 30%. The other enters automatically in service, granting sent to the waste water effluent sump T-9101. The required output quality of the soft water is as Hardness as Ca Soft water will be collected in the Soft Water Pump P-7501 A/B. A part stream of the soft the Soft Water tank. Cooling Water, Chilled Water, Hot Water and PROCESS DESCRIPTION Page 20 of 24 <50ppb w/w Water Tank T-7101 and distributed to the different A/13. ins with cationic resin which retains hardness (Ca+Mg) from raw ;ration time is about 1 hour. During regeneration of one unit the continuous supply of water. The effluent of this cationic resin is <0.5 ppm T-7501 and distributed to the different consumers with Soft Water is sent as make up water to the cooling towers prior to enter into Air PFD # ALU-3414-P-PD- 09 Cooling water will be generated with two or th ' e factory -assembled, induced draft, crossflow cooling towers, U- 7201A/B/C with vertical air discharge. Soft wateywill be used for the raw water. Two cooling water pumps P-7201 A/B/C will be used for water circulation. A "pick p" self cleaning filters , F-7201 A/B are installed at the discharge of the pumps in order to protect the plate heat exchangers against clogging. The Hot Water Boiler Unit, U-7801, consists firetube designed to burn natural gas. The burr The air -gas mixture is ignited as it exits each 1 and small in diameter. The flame from each immersed in liquid. There is a separate tube 1 These small diameter flames bum in the first heating surface in the single pass boiler — 50 percentage of radiant heating surface, the I throughout the multiple tubes virtually elimii boilers. an immersion fired hot water boiler with horizontal, single pass, assembly delivers premixed air and gas through multiple nozzles. ne retaining nozzle at high velocity. The resulting flames are long these nozzles is directed into a 2" O.D. tube that is completely each flame with the same amount of heat going into each tube. If of the tube lengths. Therefore, the "fire shines " on half of the of the total heating surface is radiant heating surface. The high r heat input into each tube, and the even distribution of heat e thermal stress problems that are common in multiple pass The hot water unit includes in addition one Hot Water Expansion Tank, T-7801 and two Hot Water Circulation Pumps P-7801 AB. Consumers of hot water t a temperature of 195 deg F are the Brine Heat Exchanger E- 1701 A/B and Catholyte Heat Exchangers E-2401 A/B. During normal operation the hot water unit is not in operation. Heat will be required during start up and low load operation in order to maintain minimum temperature of 170 deg F in the electrolyzers. The Chilled Water Unit U-7801 serves the Hyp 9 chlorite Chiller E-6103 with cold water at 68 deg F (20 deg C). The unit is packaged water-cooled liquid chiller, whin is factory wired, piped, and charged with HFC-134a. The compressor is a semi -hermetic twin screw design with refrigerant gas cooled motor and integral oil filter and discharge gas muffler. Complete thermal and electrical protection is provided. The water-cooled condenser is mechanically cleanable shell -and -tube type witt removable heads and is tested and stamped in accordance with ASME Code for a refrigerant working side pressure of 235 psig (1620 kPa) and a minimum water side pressure of 300 psig (2068 kPa). Each refrigerant circuit includes oil separator, filter drier, moisture indicating sight glass, e) (including temperatures, pressures and % k control based on leaving chilled water temper pump(s) and chiller. side pressure relief device, liquid and discharge line shutoff valve, on valve. Microprocessor control includes keypad, system status 1) and the alarm conditions. Automatic circuit leadllag. Capacity with return water temperature sensing. 7-day time scheduling of 20 C NVE &, AXIS Inr. ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 PROCESS DESCRIPTION Page 21 of 24 The chilled water is a closed circuit. The chilled B water pumps P-7801 Arecirculate the water from Chilled Water Tank T-7801 passing Hypochlorite Chiller E-6101 and back to the water chiller. The Agitation Air Compressor Unit, U-7403, p�ovides moist compressed air at 14 psig for agitation purposes of the plant It is a complete system, fully assembled with a ring compressor, a motor, service liquid lines, accessories, and separator tank. Special cooling liquids are n¢t required to cool the compression process. The continuous introduction of small quantities of fresh cooling water as service liquid is all that is required. The water is separated from the air in an integrated se arator. The water exits the separator and is recycled to the cooling tower. Compressed Air and Nitrogen unit, PFD # AL-3414-P-PD-10 The Compressed Air Unit U-7401 A/B sup lies compressed air for field instruments and process area. The compressor consists of a lubricated rotary scr w compressor with oil filter and dryer. Dry compressed air will be supplied at 150 psig. The unit integrates two compressed air tanks, T-7401 which supplies instrument air at 100 psig and T-7402 which supplies process air at 72 psi . Further quality of is • Dew Point 140 F • Oil content <35 mg/ft The Nitrogen Unit supplies N2 for hydrogen li a purge in the electrolyzer area. It consists of a cryogenic tank with evaporator and guarantees long term supply of 2 during shut down periods. Effluent Treatment, PFD # ALU-3414-P-PD-12 _ Process effluents from this plant are classmed a$ recoverable and non recoverable to the process. Recoverable effluents are those which can be recycled to the process without affecting performance or product quality of the plant. The sources of recoverable Ofluents are: • Liquid effluents from the regeneration) of the brine Ion Exchanger Columns C-1602 AB/C, discontinuous stream every 2 days, containing mainly demineralized water, brine and caustic soda at pH > 9. • Mechanical Pump Seal water retu n from centrifugal pumps, continuous flow, containing mainly demineralized water at pH = 6-8. They are collected in Recovered Effluent Ta ks T,9102 A/B and treated with HCI or NaOH for neutralization. Agitation with compressed air from Agitation r compressor Unit U-7403 in each tank is for uniform mixing. The addition 18% HCI is, made through Ejector J- 102 and of 50% NaOH by means of pump P-5101 A/B. The pH adjustment is automatically controlled through t e control loop AT -9102 and control valves AV 9102A and-S. The neutralized water effluent is transferred wi Effluent Pump P-9102 A/B to Lean Brine Tank T-1901. The flow rate of the effluent sent to the brine system is monit red with flow meter FT-9102. Other recoverable effluent stream Is from An! n Resin regeneration of the demineralized water unit. This effluent consist mainly of demineralized water, low con ntration of salt of anions retained by the anionic resin and NaOH at low concentration. This stream is send to the S it Water Tank T-7501 for further use in hypochlorite production. Non recoverable effluents are those which cannot be recycled to the process without affecting the performance of the plant or product quality. These sources are: • Liquid effluents from the regeneration of the brine Ion Exchanger Columns C-1602 A/B/C, discontinuous stream every 2 days, containing mainl demineralized water, Ca, Mg and Sr salts and HCI at pH < 3. These are send to the Waste Effluent Tanks -9103 AB. a • Liquid effluents from the regeneration of Cationic Columns of the Demineralized Water Unit, discontinuous stream every 12 hours, containing m inly water, salt from Ca, Mg and other cations removed by the resin from the raw water and HCl at pH < 3. These are send to the Waste Effluent Tanks T-9103 AB. 21 C.Q NV E & AVS I nip,. ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 • Liquid effluents from the regeneration every 12 hours, containing mainly wate brine at pH = 7 - 8. These are send to tl • Continuous brine purge stream from bri SO4-. These are send to the Waste Eft • Wash water from the process area wit 9101. • Eventual overflows from water or brine main trench and from there to the Wa, Pit is sized according to the worst case the process area. • Eventual effluents from contained area! o Acid containments area under 1804 o Caustic containments area ur 2104 o Hypochlorite containments an Effluent Pump P-6103 o Hypochlorite containments are Effluent Pump P-6203 o Acid containments area surrc 8202 o Caustic containments area ur 5102 These eventual effluents are tray driven diaphragm pumps to the Waste effluents collected in the Waste Effluent 9101 AB to the tanks l -9103 A/B for neutralizati PROCESS DESCRIPTION Page 22 of 24 if Cationic Columns of the Soft Water Unit, discontinuous stream salt from Ca and Mg removed by the resin from the raw water and Waste Effluent Tanks T-9103 A/B. e circuit in order to maintain the sulphate level in brine at max. 5 gpl ent Tanks T-9103 A/B. unknown composition. These are sent to the Waste Effluent Pit T- iks to the floor. These will flow by gravity on the sloped floor to the Effluent Pit T-9101. The the volume of trench and Waste Effluent enario, i.e. capable to collect the content of the major sized tank in brine dechlorination unit, ACA 001 with Acid Effluent Pump P- the electrolyzers, CCA-002 with Caustic Effluent Pump P- surrounding hypochlorite production, HCA-003 with Hypochlorite surrounding hypochlorite storage area, HCA-004 with Hypochlorite 18% HCI Tank-8201, ACA-005 with Acid Effluent Pump P- the electrolyzers, CCA-006 with Caustic Effluent Pump P- in a controlled manner from the containment areas with a.m. air Effluent Tanks T-9103 A/B. T-9101 are transferred with Waste Effluent Sump Pump P- Waste Effluents are treated with HCI or NaOH Ifor neutralization. Agitation with compressed air from Agitation Air compressor Unit U-7403 in each tank is for uniform mixing. The addition 18% HCI is made through Ejector J-9103 and of 50% NaOH by means of pump P-5101 A/B. The pH adjustment is automatically controlled through the control loop AT -9103 and control valves AV-9103 A anc.-B. Eventual hypochlorite content in effluents must be destroyed with sodium bisulfite or any other equivalent reducing agent. A redox meter, AT-9104 monitors the O P value of the effluent. Any possible Cl2 release from the treatment tanks is being sent to the Waste Gas Absorption IColumn C-6102. Effluent streams from Cooling Water Towers U-, A/B and from Raw Water Activated Carbon Fifte 11 AB/C, Back Wash water from the Cooling Water Filters F-7201 F-7601 A/B/C/D/E shall be sent to the rainwater sewer. 22 C.O.N-VE & AMS-, I.nc; ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 Safety Philosophy and Emergency Systems The safety philosophy is composed of the • Inherently safe process design • Strategically placed instrumentation and • Safety interlocks • Physical and mechanical safety devices • Emergency systems The plant is designed with inherent safety in chlorine area monitoring, strategic control valve PROCESS DESCRIPTION Page 23 of 24 elements: training including critical process systems, emergency trip systems, positions and emergency power systems. Instrumentation is provided at key locations in th ' process to enable operators to monitor critical plant parameters. A thorough process training program (with qualifica:ion testing) ensures that operators have the knowledge to use this process information to avoid unsafe operating co ditions. The safety and interlock system continuously m nitors all critical operating parameters and takes corrective action before hazardous conditions can develop. Typica interlock actions are the shut down of pumps, fans and other plant equipment; the opening or closing of control va es; and initiation of process purge streams. Before the interlock action takes place, an alarm will sound on the C CS warning the operator that the process parameter has deviated from the normal operating range. Safety devices such as liquid seals and dikes pi containment walls and sumps are designed to a, Safety Showers Safety showers are located at strategic location flashing lights and remote indication in the DCS, Fire Protection e backup if the process develops a hazardous condition. Dike or mixing of incompatible chemicals. wt the Plants. The safety showers are equipped with local on use of the shower. Portable fire extinguishers will be provided in tho plant. CO2 extinguishers will be provided in the control room and MCC room. In addition a firewater ring line is pr vided. A Firewater Pump P-7602 and fire water Jockey Pump, P- 7603 delivers firewater to the firewater stations and to the Sprinkler Systems in the buildings. Chlorine and Hydrogen Monitoring The alkaline effluents will be collected -I a piping collection system within the trench located under the walkway of the modules. This pipe collection system is connected to a tank T-6101 located at the end of the main trench. From the sump, alkaline effluents are transferred to one of the effluent neutralization tanks T- 9102 A/B. The pH -value of the effluents is adjusted to 6 — 8 by addition of caustic and acid and mixed with aid of compressed air. Treated effluents are re -cycled to the brine treatment system with Effluent Pumps P-9102. Hazardous gas monitors are located at strategic locations throughout the Plant: • Two Cl2 monitors in the cell room area, AT-4105 and AT-4106 • One monitor at the Hypochlorite Exhaus Fan waste air exit AT-6110 • Two H2 monitors in the cell room area, T-3105 and AT-3106 Critical Process Panel Critical instruments are hard wired to a separat( emergency e.g. loss of main electrical power or C • Brine purge for Sulfate control; • Brine from Ion Exchange Column • Water from DI Water System, U These instruments provided continuing operation during an C-1602 AB/C )1 AB and 23 CONVE &AV$ Inc., ALLIED NEW TECHNOLOY INC. ALU-3414-P-PD-REV0.0 • Accidental spills and floor wash i • Laboratory no hazardous waste Plant Operation Manpower Requirements Besides the factory technical (including mainten we consider that the plant will require the followir -1 shift operator in the control room and 1 opera - 1 shift operator in the field Personnel to handle raw materials, products and PROCESS DESCRIPTION Page 24 of 24 ice and safety) and administrative management and organization, operating staff: in the lab transport and handling are not being considered. 24 Important or Critical Functio�s Identified in Process Description 1. The saturation section comprises tw (one plus one stand by) underground salt dissolving pits. 2. Saturated brine is transferred with pump P-1101 A/B to the filter presses, F-1501 A/B. 3. A body feed of pre -coat (micro cell ose) suspension is continuously added by means of the body feed pump P-1504 A/B. 4. The flow rate through the filters is fl w controlled by means of flow control loop FC-1501 A and B. 5. The end of the filtration cycle is indicated by maximum inlet service pressure to the filters, indicated through PT-1502 AB. 6. At the beginning of each filter cycle, a pre -coat suspension is pumped to the filter using the pump P-1503. 7. Filtrated Brine from Tank T-1501 is pumped by means of Filtrated Brine Pump 1501AB through the Catholyte Heat Recuper for E-2402 and is fed into the secondary brine purification system. 8. Automated addition of 50% NaOH to the suction side of filtrated brine pumps P-1501 AB 9. Filtrated brine is first passed throu L the activated carbon filter C-1601 before entering Ion Exchange Columns C-1602 AB/C. 10. Ultra pure brine is stored in two Pure Brine Tanks, T-1701 AB. 11. Before feeding the pure brine into ach electrolyzer, the pure brine is transferred to Brine Heat Exchangers E-1701 AB where brine is heated up or cooled down according to the process conditions of each electrolyz r. 12. The chlorine saturated depleted brine (acolyte) coming from the cells flows by gravity sequentially into both Dechlorinatio Tanks T-1801A and B. 13. Most of the chlorine gas is stripped oat from the acidified acolyte using agitation air until a residual content of about 10 ppm C12. 14. The chlorine bearing air/water vapor stream exiting both Dechlorination Tanks T-1801 AB is mixed with the production chlorine stream coming from cooling and sent to Hypochlorite Reactors C-6101 A and B. 15. The dechlorinated or lean brine flow by gravity into the Lean Brine Tank T-1901 16. An automatic pH adjustment to a v ue of 8.5 is made in two steps by means of automated controlled addition of 50% NaOH delivered by Pump P-5101 AB. In the first step the pH value is increased from 2 up to 4-5 at the exit of the T-1801B. A further increase of pH. value to 8 - - 8.5 is performed by adding 5 % NaOH at the suction side of Lean Brine Pumps P- 1901 AB. 17. A final dechlorination step is considered by means of S02 addition, which is mixed to the neutralized brine through ejector J-IgO2. Important or Critical Function s Identified in Process Description 18. Neutralized brine from T-1901 is p ped to the brine saturators with Lean Brine Pumps P- 1901 A/B. 19. A small HCl 18% stream is added automatically by means of jet pump J-1861 to the chlorate reactor T-1803. 20. The Acidified Brine Pump P-1803 circulates the acidified brine through Ejector J-1801 and maintains the mixing in T-1803. 21. The ejector sucks the necessary 18 o HCl stream controlled by pH meter AC-1802 and Flow meter FC-1802. 22. BiChlorTm Electrolyser process (pac aged units from supplier) 23. Catholyte is continuously circulate, through the cells with Catholyte Pumps P-2401AB passing Catholyte Heat Exchanger E 2401 and Heat Recuperator E-2402 and returning to the Catholyte Tank T-2401. 24.32% NaOH Storage Tank T-2402 is vailable to hold up the complete volume of both electrolyzes in case of first filling or draining during maintenance. Caustic is transferred with P-2402 to the electrolyzer 25. Both pumps P-2401 AB are consi ered critical for electrolyzer operation. If the. operating pump fails, the stand by pump wi 1 be automatically switched in. Both pumps are also connected to the Emergency Power enerator. 26. Catholyte Heat Exchanger E-2401 s rves to heat up or cool down the Catholyte stream according to operation requirements 27. Demineralized water is added in automated mode for caustic make-up as required, according to current load by means of controll r FC-2407 and control valve DV-2407 28. The tank level of Catholyte Tanks T-2401 and T-2402 is maintained constant by control loop LC-2401 and control valve L -2401. The 32% NaOH production stream is sent to a caustic dilution station and hypochl rite production column. 29. Each electrolyzer is additionally p otected against too high pressure on either H2 or C12 headers by means of water pressure eals. Each electrolyzer has one H2 safety seal T-3101 A and B, as well as one C12 safety se T-4101A and B which limits the pressure to about 0.66 psig on H2 and 0.44 psig on C12. 30. The hydrogen is vented to atmosphere through a stack. 31. The chlorine generated in each electrolyzes leaves the cells at 180-190 °F (Temperature cannot be verged by MID r�view) saturated with water vapor and sent to two independent Chlorine Coolers E-4101 AB where it is cooled to about 140°F. The chlorine cell pressure is controlled by two independent pressure control loops PC-2103 A and B. Each control loop has two control vlIalves. PV-2103 A and PV-2104 A for electrolyzer A and PV-2103 B and PV-2104 B for elec iolyzer B. The second valves are for smooth start up and - low load operations. Important or Critical Functions Identified in Process Description 32. Subsequently both Chlorine gas stre s are mixed with the C12/Air stream coming from the brine dechlorinators. Both C12/Air streams are sent subsequently to both Hypochlorite reactor columns C-6101A and C-610 1 B. 33. Nitrogen purge to the H2 electrolyz r headers and air purge to the C12 electrolyzer headers are initiated after any shut down,, during shut down and prior to any start up of the electrolyzer. 34. Sodium Hypochlorite is continuously generated in the Hypochlorite Reactor C-6101 A and C-6101 B by absorbing with diluted austic soda all the chlorine as well as chlorinated air from brine dechlorination produced ' i the plant. Chlorine gas enters the packed columns at the bottom section. 35. Both units operate in parallel mode mid are connected in series with the Final Absorption Column, C-6102 through the exit w to gas lines from each reactor. 36. One pair of hypochlorite circulatiId pumps per unit, P-6161 A/B and P-6101 C/D, are provided for high circulation rates low operating temperature in the tower to ensure the lowest decomposition rates. 37. Hypochlorite will be continuously culated through towers C-6101 A and B passing Hypochlorite Suction Tanks T-6101 and Band Hypochlorite Coolers E-6101 A and B. 38. The level in Hypochlorite Suction Tz mks will be maintained by means of level control loops LC-6101 A and B with control valves LV-6101 A and B. 39. The caustic feed stream necessary for the Hypochlorite Reactors will be provided by Hypochlorite Circulation Pump P-61 2 A/B. 40. Diluted caustic is, continuously produced by mixing streams of soft water from Soft Water Pump P-7501 AB, Catholyte from the Catholyte Pump P-2401A/B and 50% NaOH make- up stream from P-5101 AB. All streams are automatically controlled 41.50% NaOH is received by an underground double walled pipe and discharged into 50% NaOH Storage Tank T-5101. 50% NaOH pump P-5101 A or B supplies the plant with caustic soda. 42. Commercial 32% HCl is received by an underground double walled pipe and mixed with Demineralized water for dilution down to 18% in ejector J-8201. 43. The supply of 18 % HCl from the Storage Tank T-8201 will be by gravity through a trench pipeline. 44. An air -operated diaphragm pump P- 202 is installed in the acid effluent sump to discharge any acid spill into the effluents treatment tanks (T-9102 AB) 45. Raw water (City Water) from B.L. is received in tank T-7601 and from here it will be distributed by pump P-7602 AB to different water stations within the facility. 46. The Demineralized Water System cIl nsists of two units, U-7101 AB, each having 100% capacity Important or Critical Functions Identified in Process Description 47. Demineralized water will be colle ted in the Demineralized Water Tank T-7101 and distributed to the different consumers with Demineralized Water Pump P-7101 A/B. 48. The Soft Water Unit U-7501 A/B consisting of two 'columns with cationic resin which retains hardness (Ca+Mg) from raw ater. The unit;is over designed by 30%. 49. Soft water will be collected in the S ft Water Tank T-7501 and distributed to the different consumers with Soft Water Pump P4 501 A/B. 50. Cooling water will be generated wit two or three factory -assembled, induced draft, cross flow cooling towers, U-7201A/B/C mith vertical air.discharge. 51. The Hot Water Boiler Unit, U-7801 consists of an immersion fired hot water boiler with horizontal, single pass, fire tube des' ed to burn natural gas. 52. The hot water unit includes in additi n one Hot Water Expansion Tank, T-7801 and two Hot Water Circulation Pumps P-7801 53. The Chilled Water Unit U-7801 serves the Hypochlorite Chiller E-6103 with cold water at 68 deg F (20 deg Q. 54. The Agitation Air Compressor Unit, U-7403, provides moist compressed air at 14 psig for agitation purposes of the plant. 55. The Compressed Air Unit U-7401 supplies compressed air for field instruments and process area. 56. Recoverable effluents: They are col ected in Recovered Effluent Tanks T-9102 A/B and treated with HCl or NaOH for neutralization. 57. Agitation with compressed air from gitation Air compressor Unit U-7403 in each tank is for uniform mixing. 58. The addition 18% HCI is made throu I Ejector J-9102 and of 50% NaOH by means of pump P-5101 AB. The pH adjustment is utomatically controlled through the control loop AT - 9102 and control valves AV-9102A d-B. 59. Non recoverable effluents send to the Waste Effluent Tanks T-9103 A/B. a. Liquid effluents from the regen ration of the brine Ion Exchanger Columns C-1602 A/B/C, discontinuous stream every 2 days, containing mainly Demineralized water, Ca, Mg and Sr salts and HCl at pH < 3. b. Liquid effluents from the regeneration of Cationic Columns of the Demineralized Water Unit, discontinuous stream every 12 hours, containing mainly water, salt from Ca, Mg and other cations removed by the esin from the raw water and HCl at pH < 3. Unit 71 c. Liquid effluents from the regen ation of Cationic Columns of the Soft Water Unit, discontinuous stream every 12 hours, containing mainly water, salt from Ca and Mg removed by the resin from the ra water and brine at pH = 7 - 8. d. Continuous brine purge stream from brine circuit in order to maintain the sulphate level in brine at max. 5 gpl SOC.' e. Wash water from the process area with unknown composition. Important or Critical f. Eventual overflows from water o: the sloped floor to the main trenc according to the worst case scena tank in the process area. Unit 19 g. Acid containments area underneal h. Caustic containments area under. Pump P-2104 i. Hypochlorite containments area Hypochlorite Effluent Pump P-61 j. Hypochlorite containments area s k. Acid containments area surround Pump P-8202 1. Caustic containments area under. Pump P-5102 Identified in Process Description brine tanks to the floor. These will flow by gravity on . The volume of trench and Waste Effluent Pit is sized D, i.e. capable to collect the content of the major sized brine dechlorination unit, ath the electrolyzer, CCA-002 with Caustic Effluent ing hypochlorite production, HCA-003 with unding hypochlorite storage area, Unit 61 18% HCl Tank-8201, ACA-005 with Acid Effluent the electrolyzer, CCA-006 with Caustic Effluent