NH MY HA CHT BIN HA

I. TNG QUAN V NH MY: Nh my ha cht Bin Ha c thnh lp nm 1962, vo thi im ny nh my c tn gi l VICACO do mt s Hoa kiu gp vn xy dng.Nm 1975, nh my c t di quyn qun l ca Nh nc.Nm 1976, nh my chnh thc quc hu ha v ly tn l Nh My Ha Cht Bin Ha, trc thuc Cng ty TNHH mt thnh vin Ha cht C bn Min Nam. Nh my lun ch trng vic thay i cng ngh to ra sn phm c cht lng cao, chi ph thp. V th cc dy chuyn sn xut ca nh my ang p dng u l cng ngh tin tin nht trong cng ngh sn xut xt clo ca th gii. Nh my cn p dng cc h thng ISO 9001: 2000, IEC 17025: 2005, ISO 14001: 2004 trong qu trnh kinh doanh v sn xut nhm em n khch tong sn phm v dch v c cht lng cao v tt nht. Cng sut: acid HCl: 60 tn/ngy, clo lng: 24 tn/ngy, xt: 15000 tn xt/nm (ngy nay: 30000 tn/nm).

II. SN PHM: STT 1 Sn phm Natri hydroxit 32%. Tn ch tiu NaOH NaCl Na2CO3 Fe2O3 NaClO3 Natri hydroxit 45% NaOH NaCl Mc ch tiu 3133% 0,004% 0,3% 0,0004% 0,002%

Phng php sn xut; CTHH - in phn mng trao i ion. - CTHH: NaOH

Cng dng - Cht ty ra, x l nc. - Cng ngh thc phm, giy, lc du. - Sn xut ha cht: silicat natri, Al(OH)3, cht tr lng PVA

45 1% 0,015%

Na2CO3 Fe2O3 NaClO3 Acid clohydric k thut 2 HCl Fe Clo SO42As Pb Clo lng Cl2

0,5% 0,002% 0,005%

3133% 0,0005% 0,002% 0,001% 0,0001% 0,0005% 99,5%

- Tng hp kh Cl2 v H2. - CTHH: HCl

- Cng ngh thc phm. - Tng hp hu c v ha du. - M in. - Sn xut cc sn phm gc Clo

- in phn dung dch mui NaCl. - CTHH: Cl2

- X l nc. - Sn xut cc sn phm gc Clo: HCl, PVC, cao su, thuc tr su.

3

Natri silicat k thut loi M1 4 Natri silicat k thut loi R1 5 Natri hybocloric (javen)

Na2O SiO2 SiO2/Na2O Na2O SiO2 SiO2/Na2O

10% 26%

CTHH: Na2O.nSiO2

- Sn xut bt git, m phm - Cng ngh gm s, dt, giy

2,3 2,7

13% 20%

- Ph gia b tong.

1,5 1,7 Clo hu hiu Xt d (quy ra 100 g/l, 120 g/l. 20 g/l,

- c sn xut t xt lng v clo kh. - CTHH: NaOCl

- X l nc. - Cht ty trong cng ngh giy, dt

NaOH)

25 g/l.

Polyalumin 6

Al2O3

17% 23% 40%

CTHH: Aln(OH)mCl3n-m

- X l nc sinh hot, nc thi cng nghip giy, du kh.

um cloride - ClPVC Kim d pH dd 1%

3,84,5

III. NGUYN LIU: Nguyn liu chnh ca nh my l mui, a s c nhp t n . Nhu cu ca nh my l khong 50000 tn/nm. Ct s dng cho nh my l ct bin c cung cp t Bnh Thun, dng lm nguyn liu sn xut keo silicat. Ngoi ra cn cc nguyn liu ph nh:

Barium chloride (BaCl2). Sulfuric acid (H2SO4)

IV. DY CHUYN CNG NGH: 4.1. S cng ngh chung:

S cp

Th cp

IN GII

Nc mui ngho

NaOH

Cl2

H2

Keo Natrisilicat

Javel

Ha Lng

Acid

4.2. Cng on ha tan v tinh ch s cp: 4.2.1. Dy chuyn sn xut

Nc b sung Dd NaCl 20 22% Ha tan Mui nguyn liu

Dd BaCl2 10- 12 %

Tch SO42-

Dd Na2CO3 8 10%

Tch Mg2+ v Ca2+

Dd NaOH 32%

Bn lng kt ta

Cht tr lng

Dd NaCl 30 32%

QUA TH CP

4.2.2. Thuyt minh qui trnh Mui nguyn liu c cp vo bn ha tan DS501A/B v c iu chnh cp t ng lun duy tr mc mui n nh trong bn ha tan. Nc mui ngho (200 220 g/l) t cng on x l nc mui ngho cng vi nc b sung c cp vo DS501A/B qua h thng ng phn phi nhng chm trong ct mui. Nc mui i t di ln trn thit b ha tan t nng 300 320 g/l v chy trn qua bn cha trung gian T501.Nc mui bo ha t T501 c bm ln lt qua hai thit b phn ng R501, R502.

Dung dch BaCl2 (120 180 g/l) c pha ti D520 c cp vo bn phn ng th nht R501, kt ta tp cht SO-. Lng BaCl2 cp vo c duy tr hm lng NaSO d cn li trong nc mui t 68g/l. Dung dch Na2CO3 (0,3 0,4 g/l) pha ch ti D521 v dung dch NaOH 32% t h thng iu dng xt c cp vo R502 kt ta cc tp cht Ca, Mg di dng Mg(OH)2, CaCO3. Lng Na2CO3 v NaOH cp vo c duy tr hm lng Na2CO3 v NaOH d trong nc mui khong 0,15 0,2 g/l. Nc mui cha cc kt ta tp cht chy trn qua cc bn lng nc mui TH501. T y, nc mui lng chy trn vo D504 ri c bm qua th cp, cn cn bn a qua D503 ch x l. 4.2.3. Cc thit b chnh 4.2.3.1. Bng ti Mui c vn chuyn trn bng chuyn vo DS501 nh motor AGS501. Khi lng mui trong DS501 t mt mc nht nh th motor t ng b ngt. 4.2.3.2. Bn ha tan DS501, DS502 DS501 v DS502 dng ha tan mui bi cc dng nc thy cc, nc mui ngho, nc mui thu hi v tch mt phn tp cht c hc c trong nc mui bo ha.Chng hot ng lun phin, cc dng lng c a vo b phn phn phi, i t di ln, ha tan mui.Nc mui bo ha (pH = 6 9, C = 300 320 g/l) qua li lc theo ng chy trn v bn cha T501. 4.2.3.3. Bn lng TH5010 C tc dng loi b cc kt ta (BaSO, CaCO, Mg(OH) ) to thnh trong qu trnh dng nc mui i qua cc thit b phn ng R501, R502. Dng nc mui c trn vi cht tr lng dn vo ng trung tm t trn xung ri i vng ln, theo ng ng chy trn v D506. Cc ht kt ta kt dnh li, ri xung pha y, theo ng ng dn v D503. ng c quay cnh co phn tn u kt ta, trnh lm nght ng ng.

4.3. Tinh ch th cp nc mui 4.3.1. Dy chuyn sn xut NaCl 30 32%

Lc

Cn bn HCl 32%

Na2SO3 10%

Kh Clo t do iu chnh pH (1011)

Gia nhit (6070C)

Trao i ion

Hiu chnh nhit

HCl 32%

iu chnh pH (25)

NaCl 30 32% tinh khit

QUA IN GII

4.3.2. Thuyt minh quy trnh

Nc mui tinh ch t D504 c bm P504 a n cc ct lc F557 A/B/C. y l ct lc s dng lp than Anthracit. Nc mui i t trn xung di, cn khng tan c lp than Anthracit ny gi li. Nc mui sau khi ra khi ct lc c a qua thit b trug ha DM507, ti y cp axit HCl 32% vo trung ha nc mui, v cp Na2SO3 vo kh Cl2 t do Sau khi ra khi DM507, pH = 10 11 v c cha bn cha nc mui lc D507. T bn cha D507 c bm P507 a qua thit b gia nhit E504, gia nhit nc mui ln 60 70oC. Mc ch ca vic trung ha v gia nhit ny nhm tng hiu sut lm vic ca nha trao i ion. Nc mui sau C504A/B c a n h thng nc mui cp. Ti y nc mui c cha trong bn D516 v mc bn ny c duy tr n nh mc cha 80% m bo cung cp n nh lng nc mui cho bnh in phn. 4.3.3. Cc thit b chnh 4.3.3.1. Thit b lc F557A/B/C Dng loi b cc tp cht c hc c trong nc mui theo nguyn l lc trng lc.Cc ct lc lm bng thp, bn trong cha cc khi than antraxit, chiu cao khi than khong 3m, cc ht mn trn, cc ht th di nhm lm tng hiu qu lc do ht nh c b mt ring ln hn. Cc ct hot ng song song.Dng nc mui vo t nh thp, khi i qua khi than di tc dng ca trng lc, cn b gi li, nc sau lc c a v bn D507. 4.3.3.2. B trn DM507 C chc nng kh Cl2 t do c trong nc mui t s cp bng Na2SO3 (t D531) v iu chnh pH v khong 10 11 bng HCl (t D518). Na2SO3 + Cl2 + H2O HCl + NaOH Na2SO4 + 2HCl NaCl + H2O

4.3.3.3. Thit b trao i nhit E504 Gia nhit dng nc mui n 60 70C, to iu kin cho ct C504 hot ng tt. L thit b trao i nhit dng tm, dng hi v dng lng di chuyn ngc chiu cho dng. Nhit hi: 100 120C. 4.3.3.4. Ct trao i ion C504A, C504B C chc nng tch Ca+ v Mg+ n 20ppb bng phng php ha l s dng nha trao i ion loi cationit RCOOH, (trng thi lm vic l RCOONa), 1,4m nha/ct.Hai ct C504A v C504B hot ng ni tip ( 2 ct nha khng bo ha cng lc). 4.3.3.5. Cm thit b E516, DM516, D516 Nc mui tinh khit sau C504 qua E516 thc hin trao i nhit vi dng hi nc (ty nhit mui yu cu ca bnh in phn m y s lm lnh hoc gia nhit),ri n DM516 thc hin qu trnh khuy trn v thm HCl nhm axit ha dng nc mui v iu chnh pH thch hp vi tng ch in phn (thng chy my pH 2 5).Sau khi t c nhit v pH yu cu, mui s c cha trong D516 theo ng ng vo bnh in phn. 4.3.3.6. Cc thit b ph-

D507 cha nc mui bo ha cp, ti sinh C504 v v sinh F557. D515 cha nc v khong, HCl, NaOH sau khi ti sinh C504, sau c bm v s cp. J513, J514: nc v khong c ht vo h thng, cun theo dng ha cht (NaOH 32% D513 hoc HCl 30% D514) t pha long trong ng ng nc khi vo ct C504.

-

4.4. Cng on in gii 4.4.1. Dy chuyn sn xut

NaCl 30 32%

Nc v khong

BNH IN PHN

Tch kh anod

Tch kh catod

Nc mui ngho

Cl2

H2

NaOH 32%

4.4.2. Thuyt minh quy trnh Cc dng vo bnh in phn bao gm: Nc mui bo ho 295 - 300g/l NaCl ( t = 60 80oC, pH = 2 - 5 ) theo cc ng phn phi lng pha anod vo cc ngn anod. Nc v khong c cp vo pha long NaOH hon lu, theo cc ng phn phi lng pha catod cp vo cc ngn catod. Di tc dng ca dng in mt chiu s xy ra s in phn:in phn dd

2NaCl + 2H2O

Mng ngn

2NaOH + H2 + Cl2

Sn phm catod gm H2 v NaOH, sau khi vo b tch kh catod s c chia thnh 2 dng:-

Kh H2 thot ln trn, a vo thp C2101 ra NaOH ri chuyn v kt cha G2101, lm nguyn liu sn xut HCl. Ngoi ra, trn ng dn kh cn c thit b thy phong DH2101 x p t ng khi p xut H2 > 200 mmH2O.

-

Dung dch NaOH ( 32 0,5% ): chy trn qua b ngt dng v ly lm

thnh phm, c li c tun hon tr li catodlyte. Sn phm anod gm Cl2 v nc mui ngho, sau khi vo b tch kh anod s c chia thnh 2 dng:-

Kh Cl2 thot ln trn s theo ng ng v khu sn xut HCl v Clo lng. Tng t, c 2 thit b thy phong DH601 v DH602 n nh p xut.

-

Dung dch nc mui ngho ( 220 10g/l NaCl, pH = 4 0,5 ): mt phn tun hon tr li anodlyte tip tc qu trnh in gii, cn li a i x l.

4.4.3. Cc thit b chnh 4.4.3.1. Bnh in phn Cu to gm 35 chi tit lng cc trung gian ( mt l anod, mt l catod ) v 36 mng cation (Mc). H thng tun hon cho php cp dung dch vo mi ngn c s v phn ly sn phm.Cc ngn ca bnh c mc ni tip. Anod l cc mng bng Titan, c 240 ming vt hnh cn, hn vi cy st dn in, b anod to ngn cha dung dch. Catod c cu to tng t, gm mng Niken v 2 lp li Niken. Mng trao i cation dng vi Teflon c bn c hc cao, chu c axit m c cng nh cc cht oxy ho v cc cht kh mnh.Cu trc mng c 2 lp: pha tip xc vi anod v catodlyte c ion nh v dng COO (axit yu), pha tip xc vi anod v anodlyte c ion nh v dng SO3 (axit mnh). 4.4.3.2. B phn tch kh (anod hay catod) Thu nhn hn hp kh - lng t cc ngn in gii v c th tch tch ring 2 pha.Mc lng c gi nh 1 l chy trn

4.4.3.3. Thp ra H2, C2102 L thp m c vt liu m bng s. Kh H2 mang theo hi nc, xt,... i t di ln qua cc lp s, nc thu cc i t trn xung s ngng t phn

hi. Kh H2 ra khi thp c lm kh s c a v kt cha G2101. 4.4.3.4. Thit b thu phong Khi p sut H2 > 130mmH2O, kh s theo ng ng dn vo DH2101, y mc nc trong ng xung, ng thi nc trong bnh dng ln, trn ra ngoi qua c ngng. Nu p xut H2 qu cao, kh s c x b ra ngoi theo ng thng p kh quyn. 4.4.3.5. H thng tun hon Nh hiu ng thot kh, mt lu lng ng k dng lu cht 2 pha (lng v kh) c tun hon trong h thng m khng cn bm ph tr. H thng tun hon trong in gii c thit k cho lng nc mui ngho tun hon ln hn gp 10 ln lng nc mui cp v lng nc NaOH tun hon vi lu lng ln hn gp 100 ln lng nc v khong cp vo. 4.4.3.6. H thng kh N2 Kh N2 s c bm vo bnh tch kh catod khi h thng ngng hot mg tm thi. Kh N2 bm vo nhm to p dng cho h thng, ngn O2 xm nhp vo gy n. Ngoi ra, kh N2 cn c p nh k vo bnh cha NaOH trung gian nhm p kh H2 ra khi dung dch mt cch hon ton.

4.5. Cng on ho lng clo 4.5.1. Dy chuyn cng ngh Nguyn l ho lng Clo: h nhit v tng p sut.

Kh Cl2

Lm lnh, tch nc

H2SO4

Sy kh

H2SO4

Nn

Tch H2SO4

Ha lng

Kh khng ngng

Sn xut javen

Clo lng

4.5.2. Thuyt minh quy trnh Kh Clo thu c sau in gii c dn theo ng ng qua cc thit b E801, ME01 v E801 lm lnh v tch 1 phn hi nc.Sau khi qua E801, kh Clo s c sy kh C805 bng axt Sunfuric m c trc khi a v bm K805 nn ln p sut cao. Phn axt ln trong dng kh Clo qua bm K805 s c tch ra thit b D805 v F805. Dng axt tch ra cng vi phn axt t K805 c bm P804

y qua cc thit b lm lnh E804, E805 trc khi a ln C804 v C805 ri thi v bn cha D803. Dng kh Clo sau khi c tch axt s c ngng t E809 bng Freon 22 ri a sang bn cha. 4.5.3. Thit b chnh 4.5.3.1.Thit b sy kh Clo C804 v C805: Dng tch trit phn hi nc cn ln trong kh Clo.C cu to dng thp hp thu vi vt liu m vng Rasching. 4.5.3.2.H thng lm lnh: C tc dng ngng t kh Clo bng Freon 22.Gm thit b bay hi E809 v thit b ngng t E807. 4.6. Sn xut axt HCl 4.6.1. Dy chuyn cng ngh Nc v khong

Hp thu kh tha

Cl2 t: to > 100oC H2 4.6.2. Thuyt minh quy trnh Dng kh H2 v Cl2 sau in gii c a vo bung t ca thp axt. H2 chy trong Cl2 to ra HCl: H2 + Cl2to

Hp thu chnh

HCl 32%

2HCl

Hn hp (HCl v H2 d) s c hp thu bng nc v khong. Phn kh HCl cha hp thu s c a vo bung hp thu kh tha.

Dung dch HCl thnh phm c cha D604A. Ngoi ra cn c ejector dng hi cao p to chn khng cho ton thp, nh dng kh chuyn ng t di ln trn. 4.6.3. Thit b chnh 4.6.3.1.Bung t: L thit b trao i nhit kiu v o dng nc gii nhit, v ngoi lm bng thp khng g, thn trong bng than chu nhit, chu axt, pha di l bec t bng thch anh, Cl2 i bn trong, H2 i bn ngoi.Trc khi khi ng phi thng kh N2 ui ht H2 trong bung t m bo an ton chy n. 4.6.3.2. Bung hp thu chnh: Kh HCl t bung t ln s vo cc ng than thc hin qu trnh hp thu mng, dng nc hp thu i t trn xung, dung dich HCl (31,5 32,5%) theo ng ly sn phm ra ngoi. 4.6.3.3. Bung hp thu kh tha: L thit b dng mm chp, c 6 mm v 6 ng chy chuyn, c chc nng hp thu kh HCl cn st li 4.6.3.4. Thit b Ejector: C chc nng to p chn khng cho ton thp dng kh HCl i t di ln. S dng hi cao p 2,5 4kg/cm2

NaOH 32%

Ct 4.7. Quy trnh sn xut silicat phn ng nguy L Ra, sng n liu 4.7.1. Quy trnh sn xut Keo Silicat

Sn phm th

Lng

Ty keo

Lc

Cn

4.7.2. Thuyt minh quy trnh Nguyn liu ct sau khi c ra v sng loi b tp cht v bn s c phi trn vi dung dch NaOH trong thit b phn ng vi t l c tnh ton thch hp. Hn hp ny c gia nhit sao cho p sut trong l t 10 kg/cm2 th ngng gia nhit, phn ng gia NaOH v SiO2 s lm cho p sut trong l tip tc tng ln 11 13 kg/cm2. Khi p sut gim xung cn 10 kg/cm2 th thc hin vic gia nhit p trong p sut trong l phn ng ln 12 kg/cm2 trong khong 30 60. Phn ng gi NaOH v SiO2 xy ra sau mt thi gian p sut trong l gim xung cn 3 kg/cm2 th tin hnh x liu. Keo silicat sau khi c x s qua khu lng, lc v ty keo ri em i kim tra trc khi a v bn thnh phm.

V. X L NC THI: 5.1. X l nc thi:

X l v p dng h thng qun l mi trng theo tiu chun ISO 14001: 2004. Cc loi cn b rn sau cc qu trnh lc phn xng sn xut s cp v xng sn xut silicat c a vo my lc p phn lng c ti x dng cn phn rn c giao cho cc n v x l cht thi. Cn cc loi cht thi khc: rc sinh hot, rc ha hc c phn loi ring bit v cng c giao cho cc n v x l cht thi mang i. Nc thi c a ti b cha, x l t tiu chun nc thi loi A ri mi thi ra sng. Kh thi ti cc thp hp th c thi ra ngoi vi nng cho php. 5.2. V sinh cng nghip Hng ngy, cng nhn vn hnh (CNVH) phi dn dp v sinh khu vc h cha nc thi sch s, vt cn rc ni trn b mt nc thi. nh k 3 thng/ln bm bn t h lng D1404A/B v khu vc p lc v thc hin cng vic p lc. Nc thi sau khi lc c a v h thng x l nc thi, cn bn p kh c giao cho cng ty dch v Mi trng th Bin Ha x l. i vi h cha nc thi D1405A/B khi pht hin cn lng b ht theo ng bm hoc 3 thng/ln CNVH phi thc hin v sinh, bm bn nc thi trc khi cha nc thi x l, phn cn bn thu c sau qu trnh v sinh c a qua khu vc p lc thc hin qu trnh p lc chung vi cn bn h lng nc thi.