A VOCATIONAL TRAINING

REPORT ON PRODUCTION
OF MAHCL AT

DEEPAK NITRITE LIMITED,NANDESARI

➢ PREPARED BY :

PATEL KRUNAL GIRISHBHAI

PREFACE :
Theory of any subject is important but without it practical
knowledge it becomes useless for technical students.A
technical student cannot be perfect engineer or technologist
without practical understanding of the scenario of the
branch.
Hence,this provides a golden opportunity for all the
students.
The principle objective of the training report is to get details
about the operation process & operation condition which are
carried out in the industries and more about the equipment
used in the chemical industries.Thus it is important for every
peson to be exposed to training in some kind of an industry
or other to enhance one’s knowledge.
In the context, our college SGI, UDAIPUR has arranged an
industrial training programme.

ACKNOWLEDGEMENT

➢ This training report is prepared not only by a solo

effort .A great deal of effort and time has been involved
in preparing this seminar report. Many people are
involved in it directly or indirectly. During the course of
 my project work I have been guided by many without
whom project may not have seen the light of the day.
➢ It is my sincere desire to express thanks for their
guidance and support.
I would like to take this opportunity to thank

● Mr. N.C.Chauhan
● Mr. C.C.Patel
● Mr. Ramkrishna Thadaka
● Mr. Ravi Menon

CONTENTS
✓PREFACE
✓ACKNOWLEDGEMENT
✓INDEX SR.NO
TITLE
1. INTRODUCTION TO INDUSTRY
 INTRODUCTION TO PRODUCT &
RAW MATERIALS
1. RAW MATERIALS & UTILITIES
SECTION
2. PROCESS AVAILABILITY
3. PROCESS DESCRIPTION
4. PROCESS MAJOR EQUIPMENT
5. UTILITIES
6. FIRE & SAFETY
7. LOCATION OF PLANT
8. VARIOUS POLICY OF DNL.

➢ INTRODUCTION TO THE INDUSTRY

➢DEEPAK NITRITE AT A GLANCE

➢ DNL has drawn on the world’s leading

technologist and systems for its various
production of cuitination of enterprise and
initiative,resourceful and resolve,technology at
DNL common vision for continous growth.
➢ DNL has always shown a dedication to standerds
of production and environment safeguard,
qualified research acumen, and 100% capacity
utilization for more than two decades.

➢ To be a technology driven,environmentally
responsible joint sector company
manufacture,commodity and specially chemicals
and fine chemicals highest standerds of
operational execellence and innovation for
creating sustainable for all stakeholders.

➢ MISSION STATEMENT

➢ Have a firm commitment to

quality,environment,health and safety.

➢ Enrich human resource and promote

teamwork,innovativeness and integrity.

➢ Achieve sustainable economic growth based on

corporate excellence driven by ethical business
practices,professionalism,dynamism and social
responsibility.

➢ FIRST STEP :
➢ In 1970 , the group commenced journey with the
institution of Deepak nitrite.

➢ In 1983, Expanded with Deepak Fertilizers,which

became india’s first producer of Ammonia.

➢ In 2007, Established Deepak Novochem and mfg.

basic building blocks.

➢ In 2013, the group achieved a turnover of 700

million $.

➢ PRODUCT PORTFOLIO

➢ BULK INTERMEDIATES :

SNI,SNA,ONT,PNT,MNT,OT,PT,MCB,DCB,SN
I liq,OA ,KNA, SS,3 NITRO
XYLENE,PNC,2,3XLD,MT,NSA,PC,PNA,OPDA

FINE & SPECIALITY CHEMICALS :

3,4 XLD, O-
CUMIDINE,MXLD,ONC,MAHCL,DASDA,PNT
SA,MMDPA,Ethoxy Amine Base.
OPTICAL BRIGHTENING AGENT :
DSP LIQUID,DWP LIQUID,MST,MST
LIQUID,BBU,2B CONC,2B POWDER, 2BA
POWDER,2B HC,ABP LIQUID,BAM 350%.

➢ KEY RECOGNITIONS :

➢ Sir P.C. Ray Award,for being the best

chemical industrial unit in india.

➢ Certificate of merit at the ‘ENVIROTECH

93’ for sustainable development for adopting
environment friendly practices.

➢ NATIONAL SAFETY COUNCIL AWARD

for meritious performance in industrial
safety.

➢ Business world FICCI CSR AWARD 2011-

12.
 ➢ HAS & MPP-2 PLANT
RAW MATERIALS :
CAUSTIC SODA LYE ( NaOH)
SODIUM NITRATE ( NaNO2)
SULPHUR DIOXIDE (SO2)
RO WATER
DI-METHYL SULPHATE

CHARACTERISTICS OF RAW MATERIALS :

CAUSTIC SODA LYE

OTHER NAME : SODIUM HYDROXIDE

CHEMICAL FORMULA: NaOH
MOLAR MASS : 39.9971 (gm/mol)
Odor: odorless
Density : 2.13 gm/cm^3
Melting point: 318 ˚C
Boiling point : 1388 ˚C
Solubility : soluble in Glycerol
Insoluble in ether.
Vapor pressure : <2.4 Kpa

SODIUM NITRATE

OTHER NAME : SODIUM SALT,NITROUS ACID

MOLAR MASS : 84.9947 GM/MOL
APPEARANCE : WHITE POWDER
ODOR: SWEET
DENSITY : 2.257 gm/cm^3
MELTING POINT : 308 ˚C
BOILING POINT : 388 ˚C
SOLUBILITY: SOLUBLE IN ALCOHOL
INSOLUBLE IN ACETONE
VISCOCITY :2.85 cP
HAZARD : OXIDANT,IRRITANT
FLASH POINT :NON-FLAMMABLE
USES: FOOD PRESERVATIVES,DYE MFG.

➢ SULPHUR DIOXIDE
CHEMICAL FORMULA : SO2
OTHER NAME : SULPHURUS ANHYDRIDE
 APPEARANCE : COLORLESS
MOLAR WEIGHT : 64.1 gm/mol
Threshold limit value : 2 ppm
FLASH POINT : NON- FLAMMABLE
HAZARD : TOXIC & CORROSIVE

➢ Di-METHYL SULPHATE
APPEARANCE : COLORLESS
ODOR: SWEETISH SLIGHTLY
SOLUBLITY : SOLUBLE IN WATER @ 30˚C
PH : ACIDIC
HAZARD : OXIDIZER,CORROSIVE
 PROCESS LAYOUT OF
PRODUCTION OF MAHCL

SO2 GAS
SS REACTOR FOR HADS CONTINOUS
RECTOR FOR HADS LIQ
SNI
17 TO18%
+CSL

3.5+0.2 PH
8 TO 12˚C
CSL SS REACTOR FOR ALK.HADS

TEMP 10 TO 30˚C
ALK HADS LIQ
DMS
METHYLATION AT MPP-2
TEMP 70 TO 72˚C
 CSL

MADS LIQ
STORAGE TANK
TEMP 40 TO 50˚C

MPP-1
H2SO4 HYDROLYSIS OF MADS LIQ
TEMP 100 TO 110 ˚C
ALKALINE AND ACIDIC REACTOR

ALK & ACID WATER

CSL NEUTRALISATION AND MABASE
DISTILLATION PH=8.3 TO 8.5
TEMP 89 TO 106˚C

RESIDUE TO
SODIUM SULPHATE RECOVERY

MABASE RECOVERY IN DILUTE HCL TEMP 15 TO 25˚C

MAHCL CONC. TO 30% (MSGLR)
UNDER VACUUM TEMP 60 TO 65 ˚C

TO STORAGE TANK TEMP 30 TO 45˚C

PROCESS DESCRIPTON
➢ HAS PLANT
PREPARATION OF PREMIX :
➢ NOTE DOWN LEVEL OF ST-006 ON MLI
@ 60TO70 CMS
➢ COOLING WATER INLET & OUTLET
VALVES ARE OPEN IN ST-006. COOLING
WATER PRESSURE 1.5 KG/CM^2
➢ CHARGE 7200 LITERS RO WATER FROM
ST-016 TO ST-006.
➢ 1.8 MT NANO2 IN ST-006.
➢ CHARGE CSLYE IN ST-006.
➢ AGITATE PREMIX FOR 2 TO 3 HOURS.
➢ CS LYE = 11.2 TO 12.0 %
➢ SNI = 18.5 TO 19.5 %
➢ TRANSFER THIS PREMIX TO ST-010 BY
PUMP XPS-006.
➢ TRANSFER IT TO THEN IN REACTOR-
003/001.
➢ START SO2 VAPORISER FROM TONNER
AND TRANSFER IT TO REACTOR-003/001
THROUGH FLOW METER 40 TO 50 M^3/HRS.
➢ INITIAL REACTOR PH IS 13 IT WILL
REDUCE GRADUALLY.
➢ PH=3.5+_0.2
➢ TEMPERATURE= 10TO12 ˚C
➢ OVERFLOW ITS HADS IN REACTOR-
007/ST-002 BY PUMP XPR-007(A/B)
➢ TRANSFER THIS TO MPP-2.
➢ MPP-II PLANT
➢ HADS LIQ =12 TO 13.8% (W/W)
➢ DMS =99% (W/W)
➢ CSL=47 TO 49 % (W/W)
➢ RECEIVE CSL IN ST-007 TO XDT-019
THROUGH XPS-007.
➢ DMS IN XST-009.
➢ TAKE ALK HADS TO XDT-020
➢ TO XAT-001/002/003 OR XRT-015/022.
➢ RAISE TEMP OF REACTOR TO 65˚.BY
APPLYING STEAM IN STEAM JACKET.
➢ CONTROL STEAM THROUGH STEAM
CONTROL VALVE.
➢ REACTOR TEMPERATURE REACH 70˚C
START DMS ADDITION AT SLOW RATE
FROM XDT-002/006 TILL MAX 72˚C.
➢ ADDITION OF DMS & CSL IN LOT 1.5 HOURS.
➢ GIVE REACTON TIME TO 4 HOURS.
➢ AFTER COMPLETE OF REACTION TIME AND
THIRD LOT OF CSL,COOL REACTOR MASS
UPTO 40 TO 60˚C.
➢ DUMPING MADS LIQ TO XST-048/005 BY
GRAVITY FORCE.
➢ AS PER REQUIREMENT OF MPP-I TRANSFER
IT TO XST-007/042 THROUGH PUMP XPS-
048/005 FOR MFG OF MAHCL.

MPP-I PLANT MFG OF

LIQUID MAHCL.
➢ RECEIVED MADS FROM MPP-II PLANT
IN STORAGE TANK.
➢ CHARGE IT TO RESPECTED REACTOR-
001/002/003/006/010/013/014/019.
➢ AFTER APPROVAL FROM Q.C
DEPARTMENT TAKE IT INTO REACTOR.
➢ APPLY STEAM IN STEAM JACKETED
REACTOR UPTO 100˚C.
➢ PRIMARY HEAT EXCHANGER FILLED
WITH COOLING WATER & SECONDARY
H.E FILLED WITH CHILLED WATER .
➢ START ALKALINE WATER RECOVERY
IN EFFLUENT TANK .
➢ MAX. ALK DISTILLATION TEMP =110˚C.
➢ CONC. H2SO4 FROM XST-008 TO DOZING
TANK XDT-012 THROUGH XPS-008.
➢ COOL REACTION MASS TO 55 TO 60˚C
ADD H2SO4 AT SLOW RATE FROM
DOZING TANK TO REACTOR.
➢ DRAIN COOLING WATER FROM
REACTOR JACKET & APPLY STEAM IN
JACKET TILL TOTAL REFLUX
CONDITION FOR 1 HOUR & START
ACIDIC RECOVERY OF 800 LITERS.
➢ MAX TEMPERATURE IS 110˚C.
➢ TRANSFER ACIDIC WATER TO XST-
066/045/005.
➢ AFTER ACIDIC RECOVERY , COOL
MASS UPTO 40-45˚C.
➢ TRANSFER CS LYE FROM STORAGE TO
XST-029 TO DOZING TANK XDT-010/011
BY XPS-029.
➢ TRIPPING POINT OF PUMP IS 120 CMS.
➢ START CS LYE ADDITION TO REACTOR
AT TEMP LESS THAN 65˚C.
➢ ADJUST PH 8 TO 9 BY CS LYE ADDITION
APPROX 1050 LITERS.
➢ TRANSFER HCL FOR CRUDE MAHCL.
➢ FOR HCL USE MSGLR REACTOR FOR
MABASE RECOVERY MAX TEMP FOR
DISTILLATION OF MABASE =105 ˚C.
➢ TRANSFER MOTHER LIQ TO MPP-2.
FLOW CHART FOR MFG OF LIQUID MAHCL
XRT-
MADS LIQ 001/002/003/006/010/011/0 NAOH
13/014/019/020/021

XST-007/042 H2SO4

ALK &ACIDIC RECOVERY

MABASE HCL
NUTCH FILTER

XRT-004/008

ML TO XST-010 012/009/021/02
DMW
3
HAS PLANT

XST-
044/023/074

CRUDE
MAHCL

XRT-005/016
CRUDE MAHCL

XRT-005/016

CONC. UNDER

VACUUM

CONDENSATE

(XST-055/018/015) XST-032/033

MAHCL LIQUID

IBCFILLING
Unit operations are carried out in mfg of solid
MAHCL :
➢ Vacu
um distillation
➢ Evap
oration
➢ Dryi
ng

✓
Vacuum distillation & evaporation are
carried out for the increasing the
concentration of the liquid MAHCL from
30% to 60%.
✓ After
that it is sent to the centrifuge for forming
of MAHCL cake contain 60% MAHCL in
solid form.
✓ In
centrifuge cake is cut and sent to the
ROTARY VACUUM DRYER.
 ✓ In
ROTARY VACUUM DRYER moisture
of MAHCL cake is dried and sent for
quality checking.
✓ After
approval it sent to packing.

Chemical reaction carried out in

whole process of mfg MAHCL

2 NaOH + 2 NaNO3 + 4 SO2 10 to 12˚c

2 HON(SO3Na)2
HADS
2 HON(SO3Na)2 + 2 NaOH 10 to 20˚c

HADS CSLYE EXOTHERMIC REACTION

2 NaON(SO3Na)2 + 2 H2O
 ALK. HADS

2 NaON(SO3Na)2 + 2(CH3)2SO4

2 CH3NaSO4 ( sodium methyl sulphate)

+ 2CH3ON(SO3Na)2
Methoxy HADS
2CH3ON(SO3Na)2 + 4 H2O (CH3NH2)2H2SO4
Methoxyamine sulphate

Methoxy HADS + H2SO4 + 2 NaSO4

(CH3NH2)2H2SO4 + 2 NaOH 2 CH3ONH2

MABASE +
NaSO4 + 2 H2O
2 CH3ONH2 + 2 HCL 2 CH3ONH2
HCL
MAHCL

WHAT WE OBSERVED DURING TRAINING

PERIOD THAT COULD IMPROVE DEEPAK
NITRITE LIMITED PRODUCT & UTILITIES
AND INCREASE PROFIT OF DNL :

➢ INCREASING CONCENTRATION OF MAHCL

FROM 60% TO FURTHER MORE.
 INCREASING PURITY OF MAHCL IN SOLID
FORM.

➢ REMOVAL OF IODINE FROM BRINE.

TO REDUCE IODINE CONTENT FROM SALT FOR

OPTIMUM PRODUCTION & REDUCTION IN
POWERLOSS.

➢ CHOCKING OF DMS INLET LINE IN REACTOR

AT MPP-2 PLANT.

INCREASING FLOWRATE OF DMS IN REACTOR.

BECAUSE OF EVAPORATION IN REACTORE
PLUGGING OF INLET LINE IS COMMON.
TO OVERCOME THIS INLET LINE SHOULD BE
ATTACHED TO REACTOR I N TANGENTAIL
WHICH ALLOW TO AVOID CHOCKING OF INLET
PIPE OF DMS.