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1.4.2 Process description
Ferric chloride can be manufactured according to <strong>the</strong> following five major process routes:
1.4.2.1 Ferric chloride solution (scrap iron + chlorine)
1.
Reactions:
Fe + 2 FeCl3 3 FeCl2
2. 3 FeCl2 + 3/2 Cl2 (g) 3 FeCl3
The scrap iron is added to a dissolving tank with a solution of ferric chloride and converted into
a ferrous chloride solution.
In <strong>the</strong> second step, <strong>the</strong> ferrous chloride solution is oxidised in a chlorination tower using Cl2 (g).
The product is divided, about 2/3 is recycled to <strong>the</strong> first stage, and about 1/3 is withdrawn as a
final FeCl3 product.
A process flow diagram illustrating <strong>the</strong> production of FeCl3 based on scrap iron and chlorine is
given in Figure 1.6 below:
2/3 FeCl 3 (recycled)
Cl 2 (g)
Water Scrap iron
REACTOR
FILTRATION
(Ferrous Chloride (FeCl 2 ))
CHLORINATION
1/3 Ferric Chloride (FeCl 3 )
Sludge
Figure 1.6: Process diagram - production of FeCl3 based on scrap iron and chlorine
[CEFIC-INCOPA, 2004 #112]
1.4.2.2 Ferric chloride solution (scrap iron + hydrochloric acid + chlorine)
Reactions:
1. Fe + 2HCl FeCl2 + H2
2. FeCl2 + ½ Cl2 (g) FeCl3
FeCl2 is produced by <strong>the</strong> reaction of scrap iron with hydrochloric acid at a temperature of
>80 °C, hydrogen being released to <strong>the</strong> atmosphere.
This solution is also converted into ferric chloride by using Cl2 (g) in a chlorination tower.
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