Case Study: Advanced HCL and Chlorine Scrubbing System for Pigment Manufacturing

 

Client Overview:

SCIL, a prominent player in the pigment manufacturing industry, faced critical challenges with Hydrochloric Acid (HCL) and chlorine fumes emitted during their manufacturing processes. The existing scrubbing system was inefficient in effectively extracting and scrubbing these pollutants, leading to environmental compliance issues. Moreover, the material of construction of the scrubber and internal components was not suitable to withstand the corrosive nature of the pollutants, posing durability and performance concerns.

Challenges:

  1. Inefficient Pollution Control: The existing scrubbing system failed to achieve the required efficiency in capturing and scrubbing HCL and chlorine fumes, resulting in environmental compliance challenges.
  2. Material Suitability: The chosen materials for the scrubber and internals were not corrosion-resistant, leading to frequent maintenance issues and compromised operational reliability.
  3. Byproduct Utilization: Inefficient pollutant removal hindered the potential for valuable byproduct generation, such as Sodium hypochlorite, which could have added significant operational and environmental benefits.

Solution:

SCIL partnered with Caramet Technologies Pvt Ltd to address these challenges by designing, manufacturing, installing, and commissioning an advanced negative pressure series of Packed Bed Scrubbing System tailored specifically for their pigment manufacturing operations.

Implementation Process:

  1. Comprehensive Assessment: Caramet Technologies conducted an extensive assessment of SCIL’ manufacturing processes and emission control requirements. This included analyzing the characteristics of HCL and chlorine fumes and identifying optimal locations for pollutant capture and extraction.
  2. System Design and Engineering: Based on the assessment, Caramet Technologies engineered a customized solution featuring:
    • Advanced Packed Bed Scrubbing Technology: Utilizing negative pressure to enhance pollutant capture efficiency and minimize emissions.
    • Suitable Material Selection: High-quality, corrosion-resistant materials such as FRP (Fiberglass Reinforced Plastic) and Polyplast such as CPVC and special alloys were chosen for scrubber construction and internal components to ensure long-term durability and reliability.
    • Optimized Pump and Blower Specifications: Precision-engineered pumps and blowers were selected to meet the specific flow rate and pressure requirements, ensuring efficient liquid circulation and airflow within the scrubbing system.
  3. Installation and Commissioning: Caramet Technologies managed the installation process with meticulous attention to detail and safety protocols. The system was commissioned with rigorous testing to verify performance and compliance with stringent environmental regulations.

Results:

  1. Effective Pollution Control: The advanced Packed Bed Scrubbing System successfully captured and scrubbed HCL and chlorine fumes, significantly reducing emissions both within the manufacturing area and at the chimney outlet.
    • Initial Chlorine Load: 155 kilograms per hour (kg/hr).
    • Achieved Outlet Emissions for Chlorine: Below 10 parts per million (ppm).
  1. Enhanced Durability and Reliability: The use of corrosion-resistant materials and robust internal components improved the scrubber’s durability, reducing maintenance downtime and operational disruptions.
  2. Byproduct Generation: Efficient removal of pollutants enabled SCIL to produce Sodium hypochlorite as a valuable byproduct. This not only added to their product portfolio but also enhanced sustainability and resource utilization.
    • Achieved up to 14% Sodium Hypochlorite as a byproduct in scrubbing liquid.

Conclusion:

By partnering with Caramet Technologies and implementing the advanced Packed Bed Scrubbing System, SCIL successfully addressed their emission control challenges in pigment manufacturing. The solution not only achieved effective pollution control and regulatory compliance but also enhanced operational efficiency and sustainability through byproduct utilization. This case study highlights Caramet Technologies’ expertise in delivering tailored environmental solutions that meet complex industrial requirements and drive positive environmental impact.

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