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As a leading manufacturer based in Tianjin, China, Tianjin ZhuoLiNeng (ZLN) Technology Co., Ltd specializes in the design and production of high-performance chemical processing equipment. Our Hydrochloric Acid Synthesis Unit with Skid Mounted Plug-Play Configuration and Integrated PLC represents a breakthrough in modular HCl production technology. This unit is engineered to deliver exceptional operational efficiency, safety, and ease of installation—all in a compact, pre-assembled package that minimizes on-site work and accelerates time to production.
With over a decade of experience in the chemical equipment industry, ZLN has supplied HCl synthesis solutions to markets across North America, South America, Europe, Africa, and Asia. Our skid-mounted plug-and-play design eliminates the need for complex field assembly, while the integrated PLC control system ensures precise process automation and real-time monitoring. Whether you are expanding an existing plant or building a new facility, this unit offers a reliable, cost-effective path to high-purity hydrochloric acid synthesis.
Below, we provide a comprehensive overview of the unit’s features, technical specifications, advantages, and the trust factors that make ZLN your ideal partner.
Key Features & Technical Specifications
Skid Mounted Design: All components (burner, absorption tower, heat exchanger, pumps, piping, and control panel) are pre-assembled on a single structural steel skid. This reduces installation time by up to 70% and eliminates the need for extensive civil works.
Plug-and-Play Configuration: The unit arrives with pre-wired electrical systems, pre-piped connections, and factory-tested subsystems. Simply connect utilities (hydrogen, chlorine, cooling water, power) and start production within days.
Integrated PLC Control System: A Siemens or equivalent PLC with a color touch-screen HMI provides full automation of the synthesis process. Operators can monitor temperature, pressure, flow rates, acid concentration, and safety interlocks in real time. Advanced alarm and shutdown logic ensures safe operation under all conditions.
High Efficiency Absorption: Utilizes a multi-stage falling film absorber or packed tower (depending on capacity) to achieve HCl absorption efficiency >99.5%. The unit can produce hydrochloric acid with concentrations ranging from 30% to 37% (or higher upon request).
Corrosion-Resistant Materials: All wetted parts are made from high-grade graphite, PTFE, or titanium, ensuring long service life even under harsh operating conditions. The burner is constructed from graphite or silicon carbide, with a quartz or glass-lined combustion chamber for optimal heat resistance.
Compact Footprint: The skid dimensions are optimized for containerized shipping and fit into standard 20ft or 40ft containers, making it ideal for remote locations or limited space facilities.
Safety Features: Includes automatic flame monitoring, hydrogen/chlorine flow ratio control, emergency shutdown (ESD), pressure relief valves, and leak detection sensors. The system complies with international safety standards (IEC, ATEX optional).
Energy Efficiency: The integrated heat recovery system captures waste heat from the synthesis reaction to preheat feed gases or generate steam, reducing overall energy consumption by up to 15%.
Remote Monitoring & Data Logging: The PLC can be connected to your plant’s DCS or SCADA system via Modbus TCP/IP. Historical data logging enables performance analysis and predictive maintenance.
Customizable Options: Available in capacities from 0.5 t/d to 50 t/d (as 100% HCl basis). Additional options include automatic acid concentration adjustment, integrated storage tanks, and fume scrubbing systems.
Technical Parameters (Typical for a 5 t/d Unit)
| Parameter | Value |
|---|---|
| Production Capacity (100% HCl) | 5 t/d (customizable) |
| Product Acid Concentration | 30% – 37% (adjustable) |
| Raw Material Consumption (per ton HCl) | H₂: 28 kg; Cl₂: 970 kg (approx.) |
| Cooling Water Requirement | ~30 m³/h at 25°C |
| Skid Dimensions (L×W×H) | 6.0 m × 2.4 m × 3.0 m (approx.) |
| Electrical Power Supply | 380V / 50Hz, 3-phase (or as requested) |
| Control System | Siemens S7-1200 PLC + 7" HMI |
| Material of Construction (wetted parts) | Graphite / PTFE / Titanium |
| Safety Standards | IEC 61508, ATEX (optional) |
Advantages for Your Business
Rapid Deployment: The plug-and-play skid allows you to start HCl production within 1–2 weeks of delivery, compared to 3–6 months for field-erected systems. This means faster return on investment.
Reduced Capital Expenditure: No need for expensive on-site construction, heavy cranes, or extensive piping. The unit is fully assembled and tested at our factory, saving you time and labor costs.
Operational Simplicity: The integrated PLC automates the entire process from ignition to acid storage. Minimal operator training is required; the intuitive HMI guides the user through all steps.
Consistent Product Quality: Advanced control algorithms maintain stable combustion and absorption conditions, ensuring that the acid concentration varies by less than ±0.5% throughout the production run.
Low Maintenance: Corrosion-resistant materials and robust design mean fewer breakdowns and longer intervals between maintenance. The PLC also provides diagnostic alerts for predictive maintenance.
Environmental Compliance: The closed-loop system minimizes fugitive emissions. The optional tail gas scrubber ensures that any unabsorbed HCl is neutralized before venting, meeting local environmental regulations.
Our HCl synthesis units are currently operating in over 20 countries, including demanding environments in the Middle East, Southeast Asia, and South America. Customers report consistent performance, high uptime, and significant cost savings compared to conventional designs.
Frequently Asked Questions (FAQ)
Q: What is the typical delivery time for a skid-mounted HCl synthesis unit?
A: Standard delivery time is 8–12 weeks from order confirmation, depending on capacity and customization. Rush orders can be arranged with shorter lead times.Q: What are the utility requirements to operate the unit?
A: You need a supply of hydrogen and chlorine gas (at certain purity and pressure), cooling water, and electrical power. Specific requirements are detailed in the technical proposal.Q: Can the unit produce acid with concentration higher than 37%?
A: Yes, we can design the absorption system to produce up to 40% HCl by using additional cooling stages or azeotropic distillation. Please contact us for your specific requirement.Q: Is the PLC system compatible with our existing DCS?
A: Yes, the PLC supports Modbus TCP/IP, Profinet, and other common protocols. We can also integrate OPC UA for seamless communication with your supervisory system.Q: What kind of after-sales support does ZLN provide?
A: We offer remote commissioning assistance, on-site training (optional), a 12-month warranty, and a spare parts package. Our technical team is available 24/7 for emergency support.Q: Do you provide certificates of compliance with international standards?
A: Yes, our factory is certified. We can also provide material certificates, pressure test reports, and CE/ATEX certification if required (at additional cost).Q: Can the unit be expanded in the future if my production needs increase?
A: The skid design is modular. We can add a second absorption tower or parallel burner module to increase capacity. The PLC can be upgraded to handle additional I/O points.Q: What safety measures are in place if there is a power failure?
A: The system includes an uninterruptible power supply (UPS) for the PLC, spring-return valves that fail-safe to close, and an emergency shutdown button. The burner automatically extinguishes and purges with nitrogen if power is lost.
At Tianjin ZhuoLiNeng (ZLN) Technology Co., Ltd, we are committed to delivering excellence. Our certified manufacturing facility in Tianjin, China, employs advanced production techniques and rigorous quality control. We have successfully supplied HCl synthesis units to clients in North America, South America, Eastern Europe, Southeast Asia, Africa, Oceania, the Middle East, and many other regions. Our port of shipment is Tianjin, one of the world’s busiest ports, ensuring efficient logistics and timely delivery.
We invite you to experience the ZLN difference. Our team of experienced engineers can customize a solution that perfectly matches your production targets, space constraints, and budget. Whether you need a small-scale unit for laboratory use or a large industrial plant, we have the expertise to deliver.
Contact us today for a detailed quotation and technical proposal. Let ZLN be your trusted partner in hydrochloric acid synthesis.
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