Hydrochloric Acid

HCl · 36.46 g/mol

HCl

Fundamental acid for metal processing and chemical synthesis

Molecular Weight

36.46 g/mol

State

Gas

Catalyst

None (Burner)

Reactor

Graphite or brick-lined

Hydrochloric Acid molecular structure — 2D structure

Olefinverbund Integration

Inputs

**Hydrogen** (Feedstock), Chlorine

→

Product

Hydrochloric Acid

→

Outputs

Vinyl Chloride, Methyl Chloride, Epichlorohydrin, Ferric Chloride

Chemistry & Engineering

Reaction	`H₂ + Cl₂ → 2HCl`
Thermodynamics	Highly exothermic combustion
Catalyst	None (Burner)
Reactor class	Graphite or brick-lined combustion chamber
Note	Often recovered as byproduct from chlorination reactions (e.g. isocyanates).

Applications

Metal pickling and cleaning
pH control and neutralization
PVC production (via VCM)
Ore processing and extraction

Extraterrestrial Production Pattern

Byproduct of chlor-alkali electrolysis
Reaction of NaCl + H₂SO₄ (Mannheim process)
Direct synthesis: H₂ + Cl₂ combustion
Absorption in water for aqueous HCl

Reaction Diagram

H2 + Cl2 -> 2HCl

Unit Operations

Process steps following chemical engineering unit operation principles

#	Operation	Description
1	H₂/Cl₂ Feed	Meter H₂ and Cl₂ to burner
2	Combustion	Burn H₂ + Cl₂ in graphite burner
3	Absorption	Absorb HCl gas in water (falling film)
4	Concentration	Absorb to 30-37% concentration
5	Cooling	Cool acid to storage temperature
6	Storage	Store in rubber-lined or plastic tanks

S88 Batch Control Model

ISA-88 BatchML schema — simplified for educational purposes

<?xml version="1.0" encoding="UTF-8"?>
<!-- ISA-88 Batch Control Model for Hydrochloric Acid -->
<!-- Educational schema - simplified for demonstration -->
<BatchML xmlns="http://www.wbf.org/xml/B2MML-V0600">
  
  <ProcessCell ID="HCL_SYNTHESIS_CELL">
    <Description>Process cell for Hydrochloric Acid production</Description>
    
    <Unit ID="HCL_SYNTHESIS">
      <Description>Main synthesis unit</Description>
      
      <!-- Equipment Modules -->
      <EquipmentModule ID="FLOW_METERS">
        <Description>Flow Meters</Description>
      </EquipmentModule>
      <EquipmentModule ID="BURNER">
        <Description>Burner</Description>
      </EquipmentModule>
      <EquipmentModule ID="ABSORBER">
        <Description>Absorber</Description>
      </EquipmentModule>
      <EquipmentModule ID="COOLER">
        <Description>Cooler</Description>
      </EquipmentModule>
      <EquipmentModule ID="COOLER_2">
        <Description>Cooler 2</Description>
      </EquipmentModule>
      <EquipmentModule ID="STORAGE">
        <Description>Storage</Description>
      </EquipmentModule>
    </Unit>
  </ProcessCell>
  
  <MasterRecipe ID="HCL_SYNTHESIS_RECIPE">
    <Description>Master recipe for Hydrochloric Acid</Description>
    <ProductID>HYDROCHLORIC_ACID</ProductID>
    
    <UnitProcedure ID="HCL_SYNTHESIS_UP">
      <Description>Unit procedure for synthesis</Description>
      
      <Operation ID="OP_01">
        <Description>Operation 1</Description>
        <Phase ID="FEED">
          <Description>Feed phase</Description>
          <PhaseLogic>
            <Step ID="STEP_1"><Action>Initialize</Action></Step>
            <Step ID="STEP_2"><Action>Execute</Action></Step>
            <Step ID="STEP_3"><Action>Complete</Action></Step>
          </PhaseLogic>
        </Phase>
      </Operation>
      
      <Operation ID="OP_02">
        <Description>Operation 2</Description>
        <Phase ID="COMBUST">
          <Description>Combust phase</Description>
          <PhaseLogic>
            <Step ID="STEP_1"><Action>Initialize</Action></Step>
            <Step ID="STEP_2"><Action>Execute</Action></Step>
            <Step ID="STEP_3"><Action>Complete</Action></Step>
          </PhaseLogic>
        </Phase>
      </Operation>
      
      <Operation ID="OP_03">
        <Description>Operation 3</Description>
        <Phase ID="ABSORB">
          <Description>Absorb phase</Description>
          <PhaseLogic>
            <Step ID="STEP_1"><Action>Initialize</Action></Step>
            <Step ID="STEP_2"><Action>Execute</Action></Step>
            <Step ID="STEP_3"><Action>Complete</Action></Step>
          </PhaseLogic>
        </Phase>
      </Operation>
      
      <Operation ID="OP_04">
        <Description>Operation 4</Description>
        <Phase ID="CONCENTRATE">
          <Description>Concentrate phase</Description>
          <PhaseLogic>
            <Step ID="STEP_1"><Action>Initialize</Action></Step>
            <Step ID="STEP_2"><Action>Execute</Action></Step>
            <Step ID="STEP_3"><Action>Complete</Action></Step>
          </PhaseLogic>
        </Phase>
      </Operation>
      
      <Operation ID="OP_05">
        <Description>Operation 5</Description>
        <Phase ID="COOL">
          <Description>Cool phase</Description>
          <PhaseLogic>
            <Step ID="STEP_1"><Action>Initialize</Action></Step>
            <Step ID="STEP_2"><Action>Execute</Action></Step>
            <Step ID="STEP_3"><Action>Complete</Action></Step>
          </PhaseLogic>
        </Phase>
      </Operation>
      
      <Operation ID="OP_06">
        <Description>Operation 6</Description>
        <Phase ID="STORE">
          <Description>Store phase</Description>
          <PhaseLogic>
            <Step ID="STEP_1"><Action>Initialize</Action></Step>
            <Step ID="STEP_2"><Action>Execute</Action></Step>
            <Step ID="STEP_3"><Action>Complete</Action></Step>
          </PhaseLogic>
        </Phase>
      </Operation>
    </UnitProcedure>
  </MasterRecipe>
  
</BatchML>

Process CellPhysical grouping of all production equipment

UnitMajor equipment performing the synthesis

Equipment ModulesIndividual devices: reactors, columns, absorbers

PhasesLowest control level: REACT, SEPARATE, PURIFY

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