ACKNOWLEDGEMENT

Itaket hisoppor t
unit
ytoexpressmygr ati
tudeto
Dr.M. P.RajeshHeadoft hedepartment,Depar t
ment
ofChemi cal engineeri
ng,SRM inst
ituteofscience
andt echnology ,andDr.S.
Sam David,Research
Assi stantProf essorChemicaldepartment ,
whogav e
ust heper mi ssiontoundergoindustrialt
raini
ng

Iwouldli
ket othanktheMR.
Oli
chandran;
Planthead
Clar
iantchemical
s,SI
PCOT;
Cuddal
oreforgivi
ngus
theopportuni
tytodoimpl
antt
rai
ning.

IthankMr.
Mut husamy (
HR)Humanr esour
ce
manager,
Clar
iantchemi cal
sforhel
pingustocarr
y
outthei
mplanttraini
nginaneffect
ivemanner.

Iexpressmysincer
ethankst oall
techni
cians,
uni
t
operator
s,shi
fti
ncharges,
andareaengineerswho
gavetheguidancethr
ought heenti
reperi
od.
  Tabl
eofcont
ent
1.Companypr
ofi
l
e
2.Pr
oduct
sov
erv
iew
3.Chl
orani
lpl
ant
4.Bl
uepl
ant
5.Ut
il
it
ies
a)Demi
ner
ali
zeduni
t
b)Boi
l
ers
c)Cool
i
ngt
ower
s
6.Wast
ewat
ert
reat
mentpl
ant
7.Ef
fl
uentt
reat
mentcont
rol
syst
em
8.Qual
i
tycont
rol
labequi
pment
s
 PRODUCTS:
I
NTERMEDI ATESANDPI GMENTSFOR
Paints
Plasti
cs
Inks
Cosmet ics
Detergents
Viscoseandl atex
Automobi l
esandcoi lcoat
ings
Laserprint
ings
Noni mpactpr i
nti
ngsandmanymore…
1.
1.Aboutt
heCompany

 Clari
antisaglobal
lyl
eadi
ngcompanyinspeci
alt
y
Chemical
shavi
ngitsheadquar
ter
sinMutt
enz,
Swit
zerl
and.

 Therearefourcorebusi
nessar
eas
 1.CareChemical
s
 2.Catal
yst
s
 3.Natur
alResourcesand
 4.Plast
icscoati
ngs.

 Clar
ianti
srepr
esent
edbymor
ethan110Group
companiesandemploy
sar
ound20000peopl
eglobal
l
y.

 Cl
ari
antChemi cals(I
ndi
a)Limit
ed(CCIL)i
sapartof
gl
obalClari
antgroup.CCILisnowIndi
a'sl
eadi
ng
manufactur
erandsupplierofPigment
sandthei
r
i
nter
medi at
es.

Iti
scommi t
tedforenvi
ronmental
pr ot
ect
ionasadr i
vefor
growt
handcontribut
estov al
uecreati
onwi t
hinnov
ati
ve
andsustai
nabl
esoluti
onsforcust
omer sfrom many
i
ndustr
ies.
 CCILacti
v i
ti
esaredesignedt omeetv eryspeci
ficneeds
withasmuchpr ecisi
onaspossi ble.Att hesamet ime,
CCILresearchanddev elopmentisfocusedonaddr essi
ng
thekeytrendsfordevelopingandpr oducingpigment sand
i
ntermediatesf
orpaints, pl
asti
cs,i
nks, cosmetics,
deter
gentsandspecial appli
cati
onsl i
kev i
scose, l
atexetc.
Theproductrangesincludehigh-performancepi gment sto
meettheexactingdemandsoft heaut omot i
ve,coil
coati
ngindustr
ies.

 Pri
nti
ngpigmentsaresuppl
i
edtotheprint
ingi
nkindustry
and,i
ncr
easingl
y,f
ornonimpactpr
int
ing,i
nkjetandlaser
pri
nti
ng.
WASTEWATERTREATMENTPLANT
 Theeffl
uentf
rom chl
orani
lpl
antandbluepl
ant.
The
eff
luent
sarehydr
ochlori
caci
dandsulphuri
caci
d.

 Thust
heef
fl
uent
sar
eaci
dici
nnat
ure.

Inordert
omaketheeffl
uentneutr
alinnat
urewear e
addi
ngHYDRATEDLI ME(basicinnatur
e).
Theeffl
uents
aremixedwit
hhydrat
edli
meusingflashmixer.
ThepH
maintai
nedherei
s5-6.

 Theniti
ssentt
othi
ckeneri
smadeusi
ngRCC.I
ts
capaci
tyi
s260m^3.

 Byusi
ngf
il
terpr
ess,t
hesl
udgewhi
chi
sgy
psum i
staken
out
.

I
tissenttoequali
zat
ionbiologyt
ankwhosecapacityi
s
600m^3theyar
edesignedt oprov
ideconsi
stenti
nfl
uent
fl
owtodownst r
eam processesbyret
aini
nghighfl
ow
fl
uct
uati
ons.
  Duetothi
s,i
tpr
event
sf r
om becomi
ngsept
icandt
o
maint
ainsol
i
dsinsuspensi
on.

 Nexti
tissenttoaerat
iontankI&I
Iwhosecapaci
tyi
s
675m^3.Nexti
tissenttosecondar
yclar
if
ierI
&II

 Andfi
nall
yt hetr
eatedwaterissentt
oBAYOFBENGAL.
Andthefurthert
reatedwateri
ssentfort
heuseof
i
ndustr
yitself
.

TheSchemeofEf
fl
uentTr
eat
ment
Plant
 Theexi
sti
ngwastewat
ertr
eat
mentpl
antwasdesi
gned
andimplement
edin1999tomeetapeakv
olumeof1800
m3/day
.

 Fi
gureshowsaschemat
icr
epr
esent
ati
onoft
heexi
sti
ng
tr
eat
mentscheme.

 Thecombinedef
fluent
sfr
om al
lpr
ocessplant
sand
uti
l
iti
esar
erecei
vedinanequal
i
zati
ontank.

 Theequali
zedef
fl
uentisf
urt
hersubj
ectedtocl
ari
-
fl
ocul
ati
onandcoll
ect
ioninahol
dingtank.

 Simil
artoanyconventi
onalbiol
ogicaltr
eatmentuni
ts,
two
paral
lelext
endedaerat
iont
anksar einplacetoremove
CODandBODf rom t
hewast ewater.Thesecondar
y
cl
arif
ieroutl
eti
scoll
ectedi
nacol lecti
ontankfor
 homogeni
zati
onandmoni
tor
ingbef
oredi
schar
gingi
nto
mari
neoutf
all
.

 Onli
neeffl
uentmoni
tor
ingsyst
em isinpl
acet omoni t
or
fl
ow,pH,TSS,COD,BODandCraspert heCPCBand
TNPCB( Tamil
nadupol
lut
ionboar
dandcont rol)gui
deli
nes.
Theonli
neeffl
uentmonit
ori
ngdataisconnectedto
TNPCBandCPCBser ver.
 CHLORANI
LPLANT(
YELLOW PI
GMENT)

I
NTRODUCTIONABOUTCHLORANI
L
1.I
tisaqui
none.

2.Mol
ecul
arf
ormul
aC6Cl
4O2

3.Mol
ecul
arwei
ght
:245.
864g/
mol

4.Al
soknownast
etr
achl
oro1,
4-benzoqui
none.

5.I
tisapl
anarmol
ecul
eandami
l
doxi
dant
.

6.I
UPACname:
2,3,
5,
6-Tet
rachl
orocy
clohexa-
2,5-
diene-
1,4-
di
one.

7.Appear
ance:
yel
l
owsol
i
d

8.Mel
ti
ngpoi
nt:
2956t
o296degr
eeCel
sius.

 USESOFCHLORANI
L:

 Asoxi
dizi
ngagent

 Fungi
ci
dei
nseedt
reat
ment
,fol
i
arappl
i
cat
ion

 Vul
cani
zi
ngagent

 Asananal
yti
calreagentfordeter
minati
onofmany
chemi
cal
s(pcp,
ephedr i
ne,pencil
l
in,
piper
azi
ne)

 Dy
eint
ermedi
ate

 Dehy
drogenat
ionagent

 Usedasachemi
cal
int
ermedi
atef
ort
hesy
nthesi
sof
 dir
ectbl
ue106,
108,
109andpi
gmentv
iol
et23,
37;
sul
phur
red7.

I
NDUSTRYUSES

I
nter
medi
ates

Rawmateri
alsr
equi
red:
 Hcl

 Cl
2

 Monochl
oral
benzene

 Hy
droqui
none

Ut
il
it
iesr
equi
red:
 H20

 Ai
r

 St
eam

 N2

Amountofut
il
it
iesr
equi
red:

 St
eam-5.
0tons

 El
ect
ri
cit
y-975KwH/
ton

 RawH20-
70m^
3/t
on

 Ai
r- 8.
8Kwh/
ton
Equi
pmentsused:
 React
orvessel
s

 Pur
if
icat
ionv
essel

 Pr
essur
efi
l
ter

 Di
sti
l
lat
ioncol
umn

 Scr
ubber

 Rot
aryandv
acuum dr
yer

 Lumpbr
eaker

 Si
l
os

 Pul
ver
izer

 Bl
ender
s

Uni
toper
ati
on:

 Mi
xi
ng

 Pul
ver
izat
ion

 Fi
l
trat
ion

 Di
sti
l
lat
ion

Uni
tpr
ocess:

 Pur
if
icat
ion

 Scr
ubbi
ng
2.
3Pr
oducti
onpr ocessofInter
mediates
 Hydr
oquinonei smixedwithHClintheglassl
inereact
or
(
GL)alongwi thcat
alystandanti
foamingagents.

 Themixtur
etemperatur
eisr
aisedt
odesi
red
temper
atureusi
ngsteam.

 ThenChlori
neandwaterar
eaddedbymai
ntai
ningt
he
requi
redtemper
atur
e.

 Theacidi
tyischeckedaft
eraddi
ti
onofrequi
red
quant
it
yofwat er.Basedonaci
dit
ytheChlor
ineaddi
ti
on
i
sdetermined.

 Oncetheacidi
tyi
sreachedt
other
equir
edl
evel
,
degassi
ngiscarr
iedouti
ncr
easei
ntemper
atur
eto
complet
ethereacti
on.

 Theventof
fgasesistr
eatedinacaust
icscr
ubbert
o
absor
b/neutr
ali
zeanyfugit
iveemi
ssi
onsofun-r
eact
ed
HClvapor
.

 Thereact
edmixt
urei
scool
edandf
il
ter
ed.Thef
il
tr
atei
s
col
lect
edasSpentHCl
.

 Thewetcakei
swashedt
il
lneut
ral
pH.

 Thewetcakei
sfurt
herpur
if
iedinasepar
ateSSv
essel
usi
ngMCBsolventbydi
sti
l
lati
on.

 Agai
ntheslurr
yisf
il
ter
edandt hesol
venti
scol
l
ect
ed
forr
euse.Thewetcakeisdr
iedandmill
ed.
  Thebl
endedpr
oducti
spackedf
inal
l
y.

RawMat eri
alRequi
rementf
orInter
medi
atesManuf
act
uri
ng
RawMat eri
al Kg/day
Hydrochl
ori
cacid(33%) 9021
Hydroqui
none 1836
Chl
orine 8274
Fer
ri
cChl or
ide 9
Hostapur 31
NaOH 8009
MCB 339
QUALI
TYCONTROLLABORATORY

 Gaschr
omat
ogr
aphy

 Hpl
i
qui
dchr
omat
ogr
aphy

 Or
gani
cel
ement
alanal
yzer

 Par
ti
cl
esi
zeanal
yzer

ORGANI
CELEMENTALANALYZER
PARTI
CLESI
ZEANALYZER
GASCHROMATOGRAPHY

HPLC
(
I)Ma
I nuf
act
uri
ngPr
ocessBl
uePi
gment
s

 Thepigmentmanuf
acturi
ngprocessinv
olvesacid&sol
vent
swell
i
ngfoll
owedbyfi
l
t r
ati
on,
drying,
mi l
l
ing,bl
endi
ngand
packi
ng.

 Theprocessinv
olv
esswel
l
ingofCr
udeBlueinsul
fur
icaci
d
andsubsequentdr
owni
ngthemassinwater
.

 Latertheslurryisfil
ter
ed,washedforf
reeofacid.Thewet
cakethent reatedwithCausti
clyeandaddit
ivestogiv
e
desir
edproduct .Thi
sslur
ryisagai
nfil
ter
ed,washedfreeof
sal
tandal kaline.

 Thewetcakei
sdriedinSpinfl
ashdry
erort
raydr
yer
sand
l
atermi
ll
ed,bl
endedforfi
nalpacki
ng.

 WhenCrudebl
uei
str
eat
edinsol
ventandgi
vensimil
ar
tr
eat
mentasabove,
togetadi
ff
erentpr edbet
oductcal
l a
bl
ue.

 CrudeBlue+H2SO4+H2O-
--
--
--
--
--
--
-Bl
uePi
gment+Spent
Sulphur
icAci
d

 Rawmat er
ialssuchasCr udeBlue,Sul
phuricaci
d( 98%),
Capryli
cacid,CausticLye, Addi
tiv
e,MEK/ I
BA, Hydr
ochlori
c
aci
d( 33%) ,Hydroquinone,Chlori
ne,Ferr
icChlor
ide,
Hostapur,arebeingsour cedthroughlocalandimpor t
suppli
er.

 Thefi
nalproductswill
bemar ket
edi nl
ocalandexpor
t.
Chemical
slikesulphur
icaci
d,hydrochl
ori
carebeingused
 i
nt heprocesseswhi
charehazardous.
 Howev er,
in-
buil
tsaf
etyf
eatur
esoft heplantwoul
dbe
madeadequat einor
dertoavoi
dhazar dousevent
s
causingdamage.

RawMat
eri
alRequi
rementf
orBl
uePi
gmentManuf
act
uri
ng

RawMat er
ial Kg/day
CrudeBlue 8711
Sulphuri
cacid(98%)31477
Capryli
cacid 345
CausticLye 438
Additi
ve 532
MEK/ I
BA 141
UTI
LITI
ESI
NTHEPLANT………………………

1.
De-
miner
ali
zed wat
eruni
t

(
Ionexchangesy
stems)
(Dei
oni
zedwat
er)

I
tistheprocessofr
emov i
ngminer
alsal
tsfr
om
waterbyusingthei
onexchangepr
ocess.
Deionizat
ionproducesahighpuri
tywat
ert
hati
s
generall
ysimil
artodist
il
ledwater
.

Adv
ant
agesoft
hispr
ocess:
Qui
ck
Noscal
efor
mat
ion

CATI
ONSf
ormedar
e

Cal
cium
Magnesi
um
Sodi
um
 Pot
assi
um
ANI
ONS
Chl
ori
de
Bi
car
bonat
e
Ni
tr
ate
Car
bonat
e

CATI
ONI
CBED
I
thasHclr
esi
nswhi
chr
epl
acesHi
nNa,
Ca,
Mgions.

Ani
oni
cbed
I
thascausti
c,whi
chr
epl
acesSo4,
Cl,
CO3i
ons
t
oOH^ -
ions.

Act
ivat
edcar
bonf
il
ter
I
tremovestheodor
,col
orandchl
ori
nei
n
t
hewater.

Dual
medi
afi
l
ter
I
tremov
est hesandandsuspendedsol
i
ds
i
nthest
art
ingstageoftheprocess.
Mi
xedbed
I
tist
omai
ntai
npH.
Pol
i
sht
hewat
ert
ohi
gherl
evel
pur
it
ies.

 BOI
LERSI
NTHEPLANT
Descript
ionDetail
s
1Capaci tyofBoil
er 8TPH 6TPH–
Standby
2Fuel Used Bi
o-br
iquet
tes Fur
nace
Oil
3Make I
AEC,
Bombay I
AEC,
Madr as
4Ty pe HMT,
Fir
etube HMT,
Fir
e
tubeBoiler
5Maxi mum wor ki
ngPr
essur
e 11.
5Kg/
cm2
11.5Kg/cm2
 Cool
ingTower
sint
hepl
ant
 Coolingisrequiredforpr ocessheatexchanger s,
equipmentseal cool i
ng,chill
er,
ai rcompr essors.
 Twocool i
ngtower sar ei
noper ationt ocatertot hecooling
needsi ntheplant.
 Rawwat erisusedf ormake- upappl i
cati
onsint hecooling
towers.Aircooledsy stemsar eusedf oraircondi t
ioni
ng
appli
cations.
I ndi
vidualcooli
ngt ower sareav ailabl
ef or860KVA
and1050KVADGset s,whichar eoper atedonst and-by
mode.

 Det
ail
soft
heexi
sti
ngcool
i
ngt
ower
sar
epr
esent
edher
e
 under
:

Cooli
ngt owerfori ntermedi
atepr
oduct
smanuf
act
uri
ngsect
ion
Locati
on: Wat erPl ant
Type: FanlessNat ural
draf
tFRPTower
TonsofRef ri
ger ation:600TR
Pressure:3Kg/ cm2
CycleofConcent rati
on:5

Cooli
ngt owerf ortheBl uePigment
smanufact
uri
ngsect
ion
Locati
on: Bluepl antBackside
Type: FanlessNat uraldraf
tFRPTower
TonsofRef rigeration: 600TR
Pressure:2.5Kg/ cm2
CycleofConcent rati
on: 5
OUTCOMESOFTRAI
NING:
 Learnttheuni
toperat
ionsanduni
tpr
ocessesandt
he
condit
ionsfordoi
ngthat.

 Learntaboutt
heutil
i
ties(
cool
ingt
ower
s,DM pl
antand
Boil
ers)i
nadet ai
l
edmanner .

CONCLUSI
ON:

 Thisi
ndustr
ial
visi
tgavemet heknowledgeofspeci
alt
y
chemical
sandtheintermedi
ateswhicharet
heraw
mater
ialsf
ormanyi ndust
ri
es.