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Chemical plant engineering in Singapore

Are you looking for chemical plant engineering services in Singapore? Synopsis Chemitech a chemical solutions company provides chemical plant engineering services.

Chemical plant engineering pre-sales services

It provides a professional and comprehensive guide for your chemical plant engineering. Concerning the international and local market demands, they would guide you in choosing the right product category. They will help in choosing the right technologies, processes, and equipment to be used according to the production demands and your investment scale.  They assure you that they can provide the most flexible investment solution according to your need and the actual state of your company operations.

Synopsis Chemitech would prepare a conceptual design which would outline the new chemical plant projects. With the blueprint that they prepare, they would carry out feasibility tests which cover how profitable the business is. These feasibility studies would be conducted regularly in several stages of the project, which allows you to know which steps can enable you to yield high profitability.

With abundant achievements in plant construction in various fields, they will take the initial stage of the feasibility study as their starting point and also commence with a market survey. From the survey, they will check the production process and investigate the optimum configuration for process utility equipment, calculate the equipment and operating cost, and produce an optimized and highly economical proposal that will consider the whole plant life cycle.

Chemical plant engineering on-sale services

Synopsis Chemitech conducts two types of engineering, one is Basic Input Engineering and Detailed Engineering. Basic Input Engineering will be conducted after the conceptual design and feasibility study. Before starting engineering procurement and construction (EPC), various studies would be conducted to take note of the technical issues and estimate a rough cost for investment. This work would be done with EPC contractors.

Detailed engineering would involve the procurement of materials. In this phase, the project aspects would be evaluated further such as implementing a description of the product through 3D drawings and detailing the specifications. Synopsis Chemitech would also prepare the document involving the project requirements including the simulation and design of a complete whole chemical plant system.

If you are interested in their services, visit their website for more information about their chemical plant engineering and contact them today to work with the best professionals to design and engineer the most optimal chemical plant(s) for your business.

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Chemical plant design companies

When looking for chemical plant designs, it refers to the overall design of a manufacturing facility, where it needs to go through various stage of planning and designing and many other tasks before the whole chemical plant are ready for its intended use. You would need to consider factors like safety, environmental constraints, site location, or if the plant is an expansion to the company’s existing plants, operations and many more factors while you are planning the design.

If it is a chemical plant that is extending the existing functionality of the operations, then the technical work would be easier compared to creating one that is new. Designing and constructing a new plant would require many tests runs to be implemented to see if the plant design is reliable, its feasibility and if it can function properly. For this, a small chemical plant can be built (according to the planned design) just for performing the test runs. The testing plant, which is also the pilot plant would be monitored and performed simulations to see how it functions. After several simulations and testing the data collected from the pilot plant’s operations, it can be used for constructing a scaled-up version of the same plant with more capacity and the right proportions to perform as intended.

A chemical plant design company

A chemical plant design involves so many factors as discussed earlier, many companies have to research extensively on the design while also handling the complex construction needs according to their own specific requirements and needs. So, if you are opting to get designing services from a chemical plant design company, ensure that they can provide the exact and precise design that your company wanted and also a design that is optimal and functions properly.

A chemical plant design company like Synopsis Chemitech provides a professional and comprehensive guide for your chemical plant engineering which would guide you in choosing the right product category that is required for you. They would also guide you in choosing the right technologies process and equipment according to your requirements, production demands and investment scales. For them to provide a flexible investment solution for you, you would need to accompany them to the location site, introduce the production process and explain any issues you may be facing from the production process.

For more information about their chemical plant design services, contact Synopsis Chemitech today, or visit their website for more detailed information on the processes they take to plan and implement the most suitable chemical plant for your company.

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What is the Chlor Alkali plant?

Chlor Alkali is for manufacturing chemicals such as chlorine, hydrogen, sodium, and sodium hydroxide also a caustic solution. Among the three chemicals produced, Chlorine is the primary chemical and is used widely.

In the year of 2006, 84% of the world’s capacity for chlorine was produced electrolytically using the diaphragm and membrane cells. Chlorine is produced when electrolysis is performed on a sodium chloride solution which is often called brine. This process is used commonly for producing chlorine and caustic soda. Synopsis Chemitech a chemical solutions company provides innovative Chlor Alkali manufacturing solutions by building various Chlor Alkali plants that not only produce chlorine, and caustic solutions but also developed a process to produce potassium hydroxide.

How their Chlor Alkali manufacturing process is done:

There are three types of electrolytic cells to produce chlorine.  The similarity between these three types is that the chlorine gas is prevented from mixing with sodium hydroxide to ensure the purity of both chemicals.

They use diaphragm cells which are permeable and made of asbestos and are used for separating the anode and cathode compartments. When brine (a nearly concentrated sodium chloride solution) enters the anode compartment it flows through the diaphragm to flow into the cathode compartment.

As it does so, the chloride ions (Cl-) in the anode section would be oxidized to form chlorine gas, while the hydrogen ions are pulled at the cathode by water molecules present in the sodium chloride solution (NaCl) to form the hydroxyl anions and hydrogen gas.

Lastly, sodium ions (Na+) that are in the solution and the hydroxyl ions produced at the cathode would make up the components of sodium hydroxide (NaOH) which is also the caustic soda.

With a similar process, they have managed to produce potassium hydroxide with their own Chlor Alkali process. They assure that their potassium Hydroxide solution is an extremely versatile cleaning agent, where they are able to switch to the new technology for both the traditional Chlor Alkali process and membrane electrolysers.

For more information about their Chlor Alkali plant and manufacturing processes visit Synopsis Chemitech’s website for more information and learn about other innovative chemical solutions it provides.

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What is the Ethylenediaminetetraacetic acid plant?

Ethylenediaminetetraacetic acid is a chelating agent and is commonly used for directly treating metal poisoning as they bind the toxic metal ions more strongly than the vulnerable components of a living organism. The acid removes bleaching from ferric, cupric, and manganic ions. It is a white and water-soluble solid that is used for binding iron and calcium ions. The ions that are bound would form a hexadentate chelating agent. The acid, ETDA in short is also produced in different forms of salt such as disodium EDTA, sodium calcium edetate and tetrasodium EDTA.

What is Ethylenediaminetetraacetic acid used for:

Pulp and paper industries: The acid is used in the pulp and paper industry where it can be used for machine pulp bleaching, chemical pulp, de-inking, etc.

Water systems: it is also used in treating water systems such as boiler and cooling water systems, evaporators, and heat-exchanging systems.

Cleaning agent properties: it can be used for reducing the water hardness of laundry products, can be used for cleaning buildings, disinfectant agents, food processing system cleaning, car cleaning agent, sanitisers etc.

Medical purposes: treating lead poisoning, anaemia treatment, anti-biotics, eye care products, mineral supplements, etc.

Synopsis Chemitech’ s Ethylenediaminetetraacetic acid plant:

Synopsis Chemitech a chemical solutions company produces this acid with different kinds of advanced technologies developed by them. They promise that each technology gives its own advantages. The technologies include Chloroacetic Acid Method, Hydrocyanic Acid Method, Hydroxy acetonitrile Method, and Sodium Cyanide Method.

Each one of them has its advantages and disadvantages, thus Synopsis Chemitech recommends one of the technical methods for the EDTA plant as the best of the four methods. It is the use of the Hydroxy acetonitrile method. This method has been modified by them which improved the method’s cleaning process for producing the Ethylenediaminetetraacetic acid. Through their optimized process, it has significantly reduced material consumption. This helped in solving the problem of their by-product sodium sulfate recycling process thus giving the impression of having a “zero emissions” design and a clean production of the acid. They also assure that their production rate of raw materials and power consumption is better than others.

If you are interested in Synopsis Chemitech’s Ethylenediaminetetraacetic acid plant solutions, contact them now and discover other innovative chemical solutions it provides.

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All about electrolyser refurbishment

Refurbishment in electrolyser refurbishment is to recoat, rebuild or replace a compartment which would be dependent on the state of the anodes and electrolysers. Symptoms that would require refurbishment include low current output, damaged standoffs leaking seals or having damaged mounting threads.

Synopsis Chemitech is a chemical solutions company which offers many innovative chemical solutions. It provides electrolyser refurbishment services for membrane electrolysers. The refurbishment is mainly for the production of chlorine, caustic soda, potassium hydroxide and hydrogen. So, their electrolyser refurbishment coating technology would be able to cater to all kinds of membrane electrolysers including both anodes and cathodes. They assure that they can refurbish any kind of old electrolyser and can make it perform almost the same as a new electrolyser.

Synopsis Chemitech’s electrolyser refurbishment services also provide the option for clients to be able to customize their electrolyser and they would do it for them with precision and best quality.

Types of electrolyser refurbishment services and their benefits:

Modification of cathode by zero gap technology

This technology is suitable for refurbishing electrolyzers and upgrading them to the next generation. It enables protection from mechanical injuries for the membrane using the elastic mesh which also improves the distribution of the DC Current. The refurbishment uses nickel materials which increases the life of the electrodes significantly. Their advanced coating technology improves cathode coating performance.

Oxygen electrode

The oxygen electrodes that are made by Synopsis Chemitech are mostly used in electrolytic metallurgy and the electroplating industry. This electrode provides good stability for electrochemical and chemical properties that are in the operation. Also provides a good electric catalytic activity. So overall this electrode reduced operating costs while also improving equipment performance and increasing the production capacity.

Chlorate special electrode

Synopsis Chemitech provides refurbishment services for various types of chlorate electrodes or even makes a new batch of it. they provide an anodic coating for chlorate production using a new process. The new process they use enhances the electrolytic efficiency thus reducing the oxygen from the production process and also reducing the operational cost of the chlorate plant.

For more information about their refurbishment services, visit Synopsis Chemitech’ s website and learn about the amazing new processes and technologies they use to provide various refurbishment services and other chemical solutions.

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Calcium Hypochlorite manufacturing plant

Calcium hypochlorite which is also can be used as a bleaching powder is a highly efficient bleaching agent that contains chlorine. The main element in this chemical is calcium chloride, sodium chloride and calcium hydroxide and many more. The amount of activated chlorine in calcium hypochlorite is 70% giving it good stability thus being convenient for handling, transporting and storing this solution.

What is Calcium hypochlorite used for?

Calcium hypochlorite can be used as an efficient disinfectant, bactericide and oxidant and is commonly used in chemical, military, and health sectors. It can also be used for sterilizing and disinfecting your homes, drinking water and during epidemic situations. It can also be used for bleaching cotton textiles and cloth, pulp, silk, fibers, and other things as well.

Calcium hypochlorite manufacturing plant solution

Synopsis Chemitech a chemical solutions company built a Calcium hypochlorite manufacturing plant. Their Calcium hypochlorite solutions have met the local standards and requirements, also being able to sell their product to countries like North America, South America, and Europe.

Their manufacturing plant produces Calcium hypochlorite using an advanced technology called “Sodium Process” technology with a 70% concentration.

In the traditional method, which is called the “Calcium process” a hydrated lime would be made into a slurry such that the lime would be able to react directly to the chlorine gas. The reacted components would be separated through crystallization, and after drying the resulting solid would-be calcium carbonate.

The calcium chloride that is in the reactant would not be converted fully, thus the contents of the calcium chloride product would be much higher, and chlorine concentration would be no more than 65%. With the high concentration of calcium chloride present, it would have a strong hygroscopicity and would not be stable. Thus, it would not be convenient or suitable for long-term storage and transportation.

However, with the advanced process “Sodium process” developed by Synopsis Chemitech, the concentration would be at 70% unlike the 65% of the traditional. This method allowed their product to be ideal for storing long-term and for transportation.

If you are interested in their Calcium hypochlorite solution, visit their website to learn more about their solution produced using their advanced process and be inspired by the various other innovative chemical solutions that they can provide.

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All about the Trichloroisocyanuric acid plant

Trichloroisocyanuric acid is an organic compound having the chemical formula of (C3CLN303). This acid is commonly used for disinfection in various places such as drinking water, industrial circulating water, swimming pools, restaurants, hotels and many more places. The solution is more efficient compared to sodium hypochlorite and is ranked as the highest graded acid for disinfection in the industry.

How the acid is used in various things:

Trichloroisocyanuric acid has a strong oxide reaction with substances like fungi, bacteria, and spores and thus would be able to remove these substances efficiently and effectively. Other than cleaning the surfaces it is also safe and convenient to be used for disinfecting edible items such as dairy products, rice deed treatment, fruit preservation, egg disinfection, and controlling for fish diseases. It is also used for other purposes than disinfecting such as fibre bleaching, preventing wool from shrinking, chemical bleaching, wood mildew, paper bleaching, rubber chlorination and many more.

Characteristics of Trichloroisocyanuric acid

The acid would look a little dry and white in colour. It can be in the form of hygroscopic crystalline powder or tablets. It would be made up of approximately 90% chlorine and thus would emit a mild chlorine-like odour. The acid would decompose at 225 Celsius degrees. It can be moderately toxic if it is ingested and direct contact with skin and eyes can cause irritation.

Trichloroisocyanuric acid plant solution

Synopsis Chemitech a chemical solutions company has built a Trichloroisocyanuric acid plant to create and produce the acid. Their acid solution has satisfied multiple customers and has also been exported to countries such as North America, South America, and Europe with meeting their local standards.

The technology that they have used in the Trichloroisocyanuric acid plant follows an advanced continuous chlorination process called the “Multistage Countercurrent Type” which consumes low amounts of chlorine gas at less than 0.97 tons per ton of the acid.

The advanced process was developed by Synopsis Chemitech and aims to mitigate the deficiencies experienced in using the “Two Stage Countercurrent Type” process of the continuous chlorination system. The main advantage of this advanced process is that it replaces the reaction system in stage 1 which consists of the water injector, circulation pump and chlorination reactor that is in the “Two Stage Countercurrent Process” by the multistage dynamic absorption equipment.

Sounds interesting? Visit Synopsis Chemitech’s website for more information about the processes involved in their advanced process of producing Trichloroisocyanuric acid. Contact them now if you are interested in their product and discover other varieties of chemical solutions Synopsis Chemitech provides.

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The Caustic soda plant

The caustic soda is created using the Chlor Alkali process. Though in this process, Chlorine is also produced. It is also known as the Chlor Alkali plant which produces Chlorine and caustic soda using the electrolytic method using the diaphragm and membrane cells.

The diaphragm cells are permeable and made of asbestos. It is used for separating the anode and cathode compartments. When the nearly concentrated sodium chloride solution enters the anode compartment it flows through the diaphragm to flow into the cathode compartment.

In this process, the chloride ions (Cl-) in the anode section get oxidized to form chlorine gas, while the hydrogen ions are pulled at the cathode by water molecules present in the sodium chloride solution (NaCl) to form the hydroxyl anions and hydrogen gas.

After which the sodium ions (Na+) that are also present in the solution and the hydroxyl ions produced at the cathode would be combined later to produce sodium hydroxide (NaOH), which is also known as the caustic soda.

Synopsis Chemitech the chemical solutions company has used this method to produce Chlorine and caustic soda. However, they have also created a newer version of the Chlor Alkali that has been modified to produce Potassium hydroxide solutions as well. To get more information about their Chlor Alkali process and other chemical solutions, visit Synopsis Chemitech website.

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Cyanuric acid plant

Cyanuric acid is a structural analogue of melamine and is an FDA-accepted component that is of feed-grade biuret and a ruminant feed additive. This chemical is also found in the swimming pool which is used with chlorine as dichloroisocyanurates water disinfecting as Cyanuric acid is also used for making the chlorine last longer as it can break down in sunlight exposure. 

The acid is considered an industrially useful chemical, where this white, odourless solid finds use as a component of bleaches, disinfectants, and herbicides.

Synopsis Chemitech a chemical solutions company developed a new continuous process for Cyanuric acid plant using a “Continuous Phase Method” and is said to be a more advanced method compared to the traditional “Tunnel Kiln Method”. 

The Continuous Solid Phase Method is also known as the Continuous production by external circulation method.

The basic process of the technology is something like this:

Urea Re-granulation > Condensation > Crushing > Refining

The material, Urea will be the main raw material used in the Cyanuric acid plant. The core factor that contributes to their continuous technology by external circulation method is by making the complex formation of Urea to Cyanuric acid in the condensation process.

Some Benefits of using their new technology:

Reduce the sublimation of Urea significantly during the heating and condensation process, to reduce the loss of urea.

They have good stability of the ammonia gas output

The Urea consumption they use is only 1.65 tons per ton of Cyanuric acid with their continuous technology, compared to the traditional method of Tunnel Kiln method which uses about 1.75 tons.

If you are interested in their technology, visit Synopsis Chemitech and find more details about their Cyanuric acid plant and their other innovative chemical solutions.

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What is the Chlor Alkali process?

 The Chlor Alkali process is done for manufacturing chemicals such as chlorine, hydrogen, sodium, and sodium hydroxide which is a caustic solution. However, of these three chemicals produced, Chlorine is the primary chemical and is used for a range of industrial uses.

It is said that in the year 2006, 84% of the world’s capacity for chlorine was produced electrolytically using the diaphragm and membrane cells. Chlorine is produced when doing electrolysis on a sodium chloride solution which is often called brine. This process is widely used for producing chlorine and caustic soda.

How the Chlor Alkali process is done:

The diaphragm cell:

There are three types of electrolytic cells to produce chlorine.  In the three types, the similarity is that the chlorine gas is prevented from mixing with sodium hydroxide to ensure the purity of both chemicals.

The diaphragm cells are permeable and made of asbestos and are used for separating the anode and cathode compartments. When brine (a nearly concentrated sodium chloride solution NaCl) enters the anode compartment it flows through the diaphragm to flow into the cathode compartment.

As it does so, the chloride ions (Cl-) in the anode section would be oxidized to form chlorine gas, while the hydrogen ions are pulled at the cathode by water molecules present in the sodium chloride solution (NaCl) to form the hydroxyl anions and hydrogen gas.

Lastly, sodium ions (Na+) that are in the solution and the hydroxyl ions produced at the cathode would make up the components of sodium hydroxide (NaOH) which is also the caustic soda.

Synopsis Chemitech the chemical solutions company created a newer version of the Chlor Alkali process that can cater to produce Potassium hydroxide solutions as well. For more information about their Chlor Alkali process, visit their website at https://synopsischemitech.com.

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EPC & Turnkey: What is the Difference?

An EPC is a construction project that is detailed out to the letter of the contract. The contractor (company) will provide all labor, materials, equipment, and other expenses for the project through one agreement in exchange for a fixed price. A turnkey project has a set scope of work including design services and team members that are agreed upon in advance with the customer.

 What is EPC?

“Engineering, Procurement, and Construction” EPC is a particular form of contracting arrangement used in some industries where the EPC Contractor is made responsible for all the activities from design, procurement, construction to commissioning and handover of the project to the End-User or Owner.

The engineering and construction contractor will carry out the detailed engineering design of the project, procure all the equipment and materials necessary, and then construct to deliver a functioning facility or asset to their clients.

 What is a Turnkey Project?

One of the unique modes of carrying out international business is a turnkey project. The turnkey projects mean a contract under which a firm agrees to fully design, construct and equip a manufacturing/ business/ service facility and turn the project over to the purchaser when it is ready for operation for remuneration.

The term turnkey project describes a project in which the supplier or provider is responsible to the client for the total result of the project and presents it to the client finished and ready to use.

 Difference between EPC and Turnkey Contracts

In an EPC contract, the project company will do some basic engineering before handing over the project to the contractor. But in a turnkey contract, the owner would specify certain technical aspects of the project. And then, the turnkey contractor will have all the project controls till the completion of the contract.

In Turnkey, contractor is responsible to perform construction and commissioning, start-up and take over the plant to employer, but in EPC, it may be the responsibility of other third person to do the commissioning and start-up.

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All About Plant Commissioning

What Is Plant Commissioning, exactly?

Plant commissioning is a vital step near the end of a plant’s construction, its purpose is to hand over a safe, efficient, and operation-ready facility to the owner. It is the planned coordination and execution of the final stages of construction and the beginning of production.

A detailed, systematic commissioning plan can reduce the overall time between completion of construction and the start of facility operations and verify that the equipment and systems installed to meet the design intent.

 Stages of Commissioning Process

There are eight stages of the plant commissioning process, which include preparation, design, pre-construction, construction, commissioning of services, pre-handover, initial occupation, post occupancy care.

It is known that a building’s actual energy use in the first year is up to 25% higher than estimated during the design stage and this is attributed to poor commissioning and handover.  Successfully conducting all the stages above and starting the plant commissioning process as early as possible ensures cost-effective project completion whilst enabling the building occupants to maximise equipment use long after the constriction process is complete.  

 Creating a Roadmap

Successful commissioning starts with a commissioning plan, which establishes a framework for how commissioning will be handled and managed on a project. Serving as a project roadmap, it identifies all parties involved, their roles and responsibilities, and the documentation required.

Planning begins with a solid schedule and process systemization. For instance, in a chemical plant, process systemization involves a commissioning process engineer taking the project’s piping and instrumentation diagrams (P&IDs) and identifying sub-systems that can be broken out and prioritized based on a logical sequence of events to start up the facility. The commissioning engineer will then work with the contractor to prioritize construction completion to meet this systemized startup sequence. This allows the contractor to refocus construction efforts in a way that permits an overlap of plant startup activities with construction, minimizing the overall time required to commission and start up the facility.

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Chemical Plant Operation: Who is responsible for it

A chemical plant is an industrial process plant that manufactures (or otherwise processes) chemicals, usually on a large scale. The general objective of a chemical plant is to create new material wealth via the chemical or biological transformation and or separation of materials. Chemical plants use specialized equipment, units, and technology in the chemical manufacturing process. Chemical plant operators are responsible for operating the chemical plant, ensuring that all chemical manufacturing processes run smoothly.

 What is a chemical plant operator?

Chemical plant operators work with and maintain plant equipment and hazardous chemicals under strict safety guidelines. They monitor plant equipment using flowmeters, panel lights and other indicators. In cases of emergency, they shut down the system under the direction of supervisors. A large part of this job involves inspecting equipment and tanks to ensure they are in good working condition.

 What do chemical plant operators do?

-Patrols and inspects equipment to ensure proper operation and sets operating controls on equipment.

-Controls the preparation, measuring and feeding of raw material and processing agents

-Analyses samples and readings and records test data.

-Controls records of production, quantities transferred and details of blending and pumping operations.

-Checks equipment for malfunctions and arranges maintenance.

-Controls equipment that performs continuous and batch processes to process chemicals.

 Employment Opportunities for a Chemical Plant Operator

Chemical plant operators are employed in industries that produce pharmaceuticals, petrochemicals, plastics, paint, explosives, industrial gases, fertilisers and cosmetics, as well as in industries that process minerals and treat waste materials. Employment opportunities depend on the profitability of these sectors, the price and quantity of similar chemicals imported from overseas, advancements in technology and government controls restricting the nature of by-products.

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Worldwide Caustic Soda Production

Approximately 99.5% of caustic soda worldwide is produced through the traditional chlor-alkali process which simultaneously generates chlorine and hydrogen gas. The wider spectrum of caustic production technologies includes the chlor-alkali membrane process, the chlor-alkali diaphragm process, bipolar membrane electrodialysis (EDBM), and direct electrosynthesis (DE). Both of the chlor-alkali processes produce H2 and Cl2 in addition to NaOH, while EDBM and DE produce HCl in addition to NaOH. Based on these underlying reactions, all of the methods can produce the same maximum amount of NaOH per kg of 7% w/w NaCl brine.

 Chlor-Alkali Process

Usually, the process is conducted on a brine (an aqueous solution of NaCl), in which case NaOH, hydrogen, and chlorine result. When using calcium chloride or potassium chloride, the products contain calcium or potassium instead of sodium. Related processes are known that use molten NaCl to give chlorine and sodium metal or condensed hydrogen chloride to give hydrogen and chlorine.

The process has a high energy consumption, for example around 2,500 kWh (9,000 MJ) of electricity per tonne of sodium hydroxide produced. Because the process yields equivalent amounts of chlorine and sodium hydroxide (two moles of sodium hydroxide per mole of chlorine), it is necessary to find a use for these products in the same proportion. For every mole of chlorine produced, one mole of hydrogen is produced. Much of this hydrogen is used to produce hydrochloric acid, ammonia, and hydrogen peroxide, or is burned for power and/or steam production.

 Challenges of the Chlor-Alkali Process

A critical parameter in the chlor-alkali process is determining the purity of the feed brine. In the membrane cell production process caustic soda and trace level, alkaline earth metals are analysed for cation analysis. To ensure production efficiencies, the sum of calcium and magnesium must be less than 20 ppb in 30% sodium chloride (NaCI).

The produced gases (Cl2 and H2) have their unique challenges. Cl2 and H2 can contain moisture after the production process and lead to corrosion issues during storage and transportation.

Monitoring the formation of contaminants and byproducts during salt electrolysis enables purity objectives to be achieved efficiently and safely. The formation of nitrogen trichloride during the production of high-grade chlorine is a key example. When its concentrations exceed 20,000 ppm, the compound becomes explosive.

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All About Membrane Electrolyser

What is an electrolyser?

An electrolyser is a system that uses electricity to break water into hydrogen and oxygen in a process called electrolysis.

 How does an electrolyser work in membrane electrolysis?

Membrane electrolysis is a process whereby both electrode reactions, i.e., the cathodic reduction as well as the anodic oxidation, are linked to the transport and transfer of charged ions. In membrane electrolysis, the electrode reaction is essential to the actual separation process. The purpose of the membrane is to separate the anode loop (anolyte) from the cathode loop (catholyte) by a fluid, to avoid unwanted secondary reactions, to combine the electrode reaction with a separation step or to isolate separately the products formed on the electrode. In water electrolysis, such products may be in a gaseous form such as oxygen and hydrogen as well as the acids (H+) and bases (OH-) formed on the electrode or the combination of gaseous chlorine and caustic soda solution and hydrogen as in sodium chloride electrolysis.

 Proton Exchange Membrane (PEM) Electrolysers

PEM electrolysers use a Proton Exchange Membrane which uses a solid polymer electrolyte.

When current is applied to the cell stack, the water splits into hydrogen and oxygen and the hydrogen protons pass through the membrane to form H2 gas on the cathode side.

 Why is hydrogen such a good option for clean energy?

Hydrogen can act as an energy storage medium to address these grid challenges, allowing renewable power to be more easily used outside the electric power grid. Hydrogen is a stable way to store and transport renewable electricity efficiently over long periods. That way, renewable electricity generated by wind and solar that isn’t being used right away can be used another time or in another place. Hydrogen’s potential for storing and transporting energy makes it a key enabler of a global transition to renewable energy.

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Nitrogen Fertiliser Production Process

Mineral fertilizers play a central role to achieve the yield and returns expected by farmers and required by a growing world population. But where does mineral fertilizer actually come from? Under which conditions is it produced? Is production sustainable?

 As the economic pressure on farmers rises, improving returns becomes a vital necessity. Optimizing farm inputs is a way to cut costs while controlling returns. One of the most important farming inputs is mineral fertilizer. It originates from various sources throughout the world and can be of variable quality.

 Producing Nitrogen Fertiliser

In a modern plant, nitrogen fertilizer is produced from natural gas. In several transformation steps, natural gas, essentially methane, is upgraded by combination with nitrogen from the air to form nitrogen fertilizer. 80% of the gas is used as feed­stock for fertilizer while 20% is used for heating the process and producing electricity.

 Following Davy’s discovery, chemists began trying to develop electrosynthesis procedures to produce ammonia on a large scale. And with an understanding of the biological nitrogen-fixing process, chemists have been trying to develop metal catalysts that mimic enzymes. But researchers haven’t quite figured out how to make these approaches work efficiently on a large enough scale to be practical.

 For that, we have the Haber-Bosch chemical synthesis process. This brute-force industrial method employs a metal catalyst to couple H2 with N2 at high temperature and pressure to prepare NH3. Much of the NH3 is then converted to nitric acid by the Ostwald process to make the fertilizer ammonium nitrate.

 The Haber-Bosch-Ostwald pathway requires a substantial industrial infrastructure that consumes massive amounts of energy and creates great volumes of carbon dioxide and other pollutants. Researchers have therefore sought out environmentally friendlier and more sustainable approaches to producing ammonia, ranging from thermal solar reactors to engineered plants that make their own ammonia.

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How to Write a Plant Operation Manual

Plant Operation Manual is a guide for all the engineers who is involved in successfully operating the plant. It is a responsibility of a process engineer working in Process Design field to bring out the better manual which helps the operating team in startup, shutdown, troubleshooting and optimization of the plant. Here is guidance for preparing a better chemical plant operating manual.

 The task of writing plant manual categorized into two. One is for new plants and the other is for plants that already running. For old plants there are already established systems and procedures and for the modifications or revamps additional information has to be added, which is a simple task. But writing the operating manual for new chemical plant is a challenging task though already similar plants are running around the world. Let us will see how to write operation manual for new plants here.

 The real challenge lies in writing a new operating manual and that is where the experience of the process engineer comes into force.

 Following input documents are required during preparation of Chemical Plant Operating Manual:

a. Basis of Design – Process Description

b. Process & Utility Flow Diagrams (PFDs and UFDs)

c. Piping & Instrument Diagrams (P&ID’s)

d. Detailed process description from "Technology Licensor" for proprietary processes if applicable

e. Operating and Maintenance manuals of vendor equipment and packages (e.g. Instrument Air Package, Compressor Systems, Pumps, Water Treatment Plants, Fired Heaters etc.)

f. Function logic narrative provided by Instrumentation

g. Safety

h. Flow diagrams

i. Appendix