Hydrochloric Acid Production from Sodium Chloride and Sulfur
Hydrochloric Acid Production Costs Report | Issue D | Q4 2024
| Report Details |
| 15 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 15 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
Feasibility analysis of a typical Hargreaves process for Hydrochloric Acid production from sodium chloride and sulfur in the USA. In this process, first sulfur is subjected to an oxidation reaction producing sulfur dioxide. Sulfur dioxide and sodium chloride are then heated up to the point in which they start a spontaneous and exothermic reaction that produces hydrogen chloride, which is subsequently absorbed in water to produce Hydrochloric Acid as the final product. Sodium sulfate is generated as a by-product.
The report provides a comprehensive study of Hydrochloric Acid production and related Hydrochloric Acid production cost, covering three key aspects: a complete description of the Hydrochloric Acid production process examined; an in-depth analysis of the related Hydrochloric Acid plant capital cost (Capex); and an evaluation of the respective Hydrochloric Acid plant operating costs (Opex).
The Hydrochloric Acid production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Hydrochloric Acid plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Hydrochloric Acid plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Overview
Products
Hydrochloric Acid. Hydrogen Chloride (a.k.a. HCl, Hydrochloric Acid, Muriatic Acid) is a hydrogen halide and one of the most important basic industrial chemicals. It is a colorless gas, which forms white fumes upon contact with atmospheric water. Due to the high electronegativity of the chlorine atom, this molecule has a large dipole moment and is very soluble in water and other polar solvents. Its solutions with water receive the name "Hydrochloric Acid", a strong acid with corrosive properties. Production of Hydrogen Chloride follows the chlor-alkali electrolytic process, where brine is electrolyzed producing chlorine gas and hydrogen gas. These gases are then combined in the presence of UV light, resulting in HCl.
Sodium Sulfate. Sodium sulfate is an inorganic compound used in detergents, paper manufacturing, and glass production. It acts as a filler in powdered detergents and as a fining agent to remove air bubbles from molten glass. Sodium sulfate is obtained from natural deposits or as a byproduct of chemical processes, and it is stored as a white crystalline solid. Additionally, it serves in textile dyeing to promote even color distribution on fibers.
Raw Materials
Sodium Chloride. Sodium chloride (NaCl) is the salt naturally occurring in sea water. Sodium chloride (as aqueous solution, i.e., brine or solid) is widely used in the chemical industry as a feedstock for the production of chlorine, sodium hydroxide, and other sodium-based compounds through electrolysis.
Sulfur. Sulfur is an abundant, multivalent non-metal of great importance in the chemical industry. It is a key raw material, mainly used in the form of Sulfuric Acid and sulfur dioxide. In its elemental form, sulfur is used in the production of carbon disulfide, rubber, pesticides, pharmaceuticals, and cosmetics. Elemental sulfur can be produced from a variety of sources, and through a number of different techniques. It is frequently obtained as by-product from petroleum refining, natural gas processing and coking plants, for instance.
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Hydrochloric Acid production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Hydrochloric Acid process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Hydrochloric Acid production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Hydrochloric Acid plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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